Kawasaki KLX250S 2009-2010 Factory Service Repair Manual

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UGS: 92725

Mots clés: 2009 2010 Kawasaki KLX250S Misc Motorcycle Motorcycles

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Description

This manual provides comprehensive service and repair information for the KLX250S, covering model years 2009 and 2010. The KLX250S is a versatile dual-sport motorcycle designed to excel in both on-road commuting and off-road trail riding. It features a robust 249 cc liquid-cooled, four-stroke engine with Electronic Fuel Injection (EFI) for enhanced throttle response and efficiency, paired with a reliable 6-speed transmission. Its long-travel, adjustable suspension and dual-sport tires contribute to its balanced performance across various terrains, making it a capable and well-regarded option in its segment. The purpose of this factory service repair manual is to equip owners, mechanics, and technicians with the detailed knowledge necessary for the proper maintenance and repair of the KLX250S. This extensive English-language guide, spanning over 500 pages, covers all major systems, including the engine, fuel system, transmission, electrical system, suspension, brakes, chassis, and bodywork. It offers step-by-step procedures for routine maintenance, in-depth troubleshooting, component overhaul, torque specifications, and includes essential wiring diagrams and diagnostic information for the engine management system, ensuring the vehicle remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250S

Year:

2009-2010

Product Type:

Factory Service Repair Manual

👋 Introduction

Market Position

Vehicle Segment:

Dual-sport motorcycle, targeting riders for both on-road commuting and off-road trail use.

Competitive Analysis

Key Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250.

Key Features

Vehicle Purpose:

Versatile platform offering a balance of street-legal capability and off-road prowess.

Efi System:

Electronic Fuel Injection (EFI) for improved throttle response, fuel efficiency, and emissions control.

Suspension Type:

Long-travel, adjustable suspension (front and rear) for off-road capability.

📋 Manual Details

Coverage Areas

Overall Coverage:

Comprehensive service and repair information for the Kawasaki KLX250S (2009-2010 models).

Specific Models Covered:

Kawasaki KLX250S (Model Years 2009, 2010)

Page Count

Estimated Pages:

Over 500 pages (typical for a factory service manual of this era and scope)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF, likely)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, overhaul, internal components, lubrication system, cooling system.

Fuel System:

Fuel injection system (EFI) operation, components, troubleshooting, cleaning, adjustments.

Transmission:

Clutch operation, gearbox inspection, gear shift mechanism, lubrication.

Electrical System:

Ignition system, lighting, charging system, starter system, wiring diagrams, fault diagnosis.

Suspension:

Front fork (USD) disassembly, assembly, oil levels, seals, rear shock absorber adjustment and overhaul.

Brakes:

Front and rear brake system inspection, pad replacement, caliper service, fluid bleeding, master cylinder service.

Chassis And Bodywork:

Frame inspection, body panel removal and installation, seat, handlebars, footpegs.

Wheels And Tires:

Wheel bearing inspection, spoke tensioning, tire replacement, balancing.

Exhaust System:

Exhaust pipe and muffler inspection, clamp tightening, catalytic converter information (if applicable).

Cooling System:

Radiator service, coolant type and capacity, fan operation, thermostat.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues across all major vehicle systems.

Repair And Overhaul:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Wiring Diagrams:

Comprehensive electrical system wiring schematics for accurate diagnosis and repair.

Engine Management System:

Diagnosis and troubleshooting of EFI system faults, sensor testing (TPS, MAP, IAT, O2), ECU reset procedures.

Chassis Alignment:

Inspection and correction of frame and steering head alignment.

Wheel Bearing Service:

Removal, cleaning, greasing, and installation of wheel bearings.

Battery And Charging System Checks:

Testing of battery voltage, alternator output, and regulator/rectifier function.

Emission Controls:

Information on emission-related components and their function.

Technical Depth

Depth Of Information:

Factory-level detail, suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Image Resolution:

High resolution for clear diagrams and illustrations.

Binding Type

Physical Binding:

N/A (Digital Format)

Paper Type

Physical Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, single-cylinder

Displacement:

249 cc

Bore X Stroke:

72.0 x 61.2 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 23-27 HP (varies slightly by year and regional tuning)

Torque:

Approx. 16-18 lb-ft (varies slightly)

Fuel System

Fuel Delivery:

Digital Fuel Injection (DFI) with dual 34mm throttle bodies

Fuel Type:

Unleaded gasoline, 87 octane minimum

Ignition

Ignition System:

Digital CDI with electric start

Lubrication

Oil Type:

SAE 10W-40 API SG or higher motorcycle oil

Oil Capacity:

1.5 L (1.6 US qt) without filter change, 1.7 L (1.8 US qt) with filter change

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Overall Length:

2,230 mm (87.8 in)

Overall Width:

810 mm (31.9 in)

Overall Height:

1,190 mm (46.9 in)

Wheelbase:

1,430 mm (56.3 in)

Ground Clearance:

255 mm (10.0 in)

Seat Height:

865 mm (34.1 in)

Weights

Curb Weight:

Approximately 138 kg (304.2 lbs)

Fuel Tank Capacity:

11 L (2.9 US gal)

🛡️ Safety Features

Ratings

Safety Certifications:

DOT/ECE approved lighting and safety equipment for street legality.

Active Features

Braking System:

Front: 250mm petal disc with dual-piston caliper; Rear: 240mm petal disc with single-piston caliper.

Tire Type:

Dual-sport rated tires suitable for mixed terrain.

Passive Features

Lighting:

Halogen headlight, LED tail light, front and rear turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD instrument cluster including speedometer, tachometer, odometer, trip meters, clock, and indicator lights.

Driver Assistance

Not typically equipped with ABS as standard on these models.

Connectivity

Smartphone Integration:

N/A (Motorcycle technology of this era did not include this feature).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 12,000 km (7,500 miles) or 12 months.

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or 6 months; replacement as needed.

Spark Plug Replacement:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles).

Fluid Specifications

Coolant Type:

Kawasaki Super Coolant or equivalent (50/50 mix of ethylene glycol and distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Maintenance Items:

Chain adjustment and lubrication, checking tire pressures, inspecting brake pad wear, cleaning air filter.

Potential Reliability Points:

Early EFI systems could be sensitive to fuel quality; suspension seals may require periodic inspection.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for building reliable and performance-oriented motorcycles across various segments.

Model Evolution

Klx Lineage:

The KLX line has evolved over decades, with the KLX250S representing a modern iteration focused on dual-sport versatility and fuel injection.

Production

Manufacturing Location:

Japan (primary)

🏆 Awards & Recognition

Recognitions

Industry Perception:

Well-regarded for its blend of affordability, off-road capability, and usability as a daily rider.