Kawasaki KLX250S 2009-2010 WSM Service Manual Repair

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Basic Information Identification Make: Kawasaki Model: KLX250S Year: 2009-2010 Codes Product Code Identifier: KLX250S_2009_2010_WSM_PDF Generation Model Generation: Second Generation KLX250S (2008-2010) Introduction Market Position Segment: Dual-sport motorcycle, lightweight off-road capable...

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Mots clés: 2009 2010 Kawasaki KLX250S Misc Motorcycle Motorcycles

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Description

Basic Information
Identification
Make:	Kawasaki
Model:	KLX250S
Year:	2009-2010
Codes
Product Code Identifier:	KLX250S_2009_2010_WSM_PDF
Generation
Model Generation:	Second Generation KLX250S (2008-2010)

Introduction
Market Position
Segment:	Dual-sport motorcycle, lightweight off-road capable machine.
Competitive Analysis
Key Competitors:	Suzuki DR-Z400S, Honda CRF250L (later models), Yamaha WR250R.
Key Features
Performance Bias:	Balanced performance for both on-road commuting and off-road trail riding.
Reliability:	Known for Kawasaki's robust engineering and long-term durability.
Customization Potential:	Popular platform for modification and enhancement.

Manual Details
Coverage Areas
Language:	English
Format:	PDF Download
Page Count
Estimated Page Count:	Over 400 pages (typical for full WSM)
Manual Type
Manual Type:	Workshop Service Manual (WSM)

Manual Coverage
Systems Covered
Engine Mechanical:	Complete engine disassembly, assembly, inspection, and repair procedures.
Fuel System:	Fuel injection system (EFI) components, troubleshooting, and calibration.
Ignition System:	Ignition coil, CDI unit, spark plug testing, and troubleshooting.
Cooling System:	Radiator, fan, water pump, thermostat, and coolant specifications.
Transmission Drivetrain:	Clutch operation, gearbox inspection, disassembly, and assembly.
Suspension:	Front fork (USD) and rear monoshock adjustment, servicing, and rebuilds.
Brakes:	Front and rear brake system inspection, fluid replacement, caliper overhaul, and bleeding procedures.
Electrical System:	Wiring diagrams, component testing, battery, charging system, lighting, and starter system.
Chassis Frame:	Frame inspection, steering head bearing service, and alignment.
Bodywork Trim:	Fairing removal, installation, and component replacement.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning.
Troubleshooting:	Diagnostic flowcharts for common starting, running, and electrical issues.
Engine Rebuild:	Detailed steps for cylinder head, piston, crankshaft, and valve servicing.
Suspension Rebuild:	Fork seal replacement, oil changes, and shock absorber servicing.
Electrical Diagnostics:	Component testing, voltage drop tests, and wiring harness troubleshooting.
Wheel Tire Service:	Tire mounting/dismounting, wheel balancing, and spoke tensioning.
Technical Depth
Diagnostic Capabilities:	Advanced diagnostic procedures, including ECU reading (if applicable via interface).
Repair Scope:	Comprehensive repair instructions for all major and minor components.
Specifications Data:	Includes torque values, clearances, fluid capacities, and diagnostic parameters.

Manual Specifications
File Format
File Type:	PDF
Searchable Text:	Yes (typically, for professionally scanned manuals)
Print Quality:	Professional quality, high-resolution scans.
Binding Type
Binding Type:	N/A (Digital Download)
Paper Type
Paper Type:	N/A (Digital Download)

Engine Specifications
Primary Engine
Engine Type:	Four-stroke, DOHC, liquid-cooled, single-cylinder
Displacement:	249 cc (249 cm³)
Bore X Stroke:	72.0 x 61.2 mm
Compression Ratio:	11.0:1
Performance
Horsepower Output:	Approx. 20.3 kW (27.2 hp) @ 8,000 rpm (varies by region and tune)
Torque Output:	Approx. 23.5 Nm (17.3 lb-ft) @ 7,000 rpm (varies by region and tune)
Fuel System
Fuel Delivery:	Digital Fuel Injection (DFI) with dual 34mm throttle bodies
Fuel Type:	Unleaded gasoline, minimum 87 octane (AKI)
Fuel Tank Capacity:	11.0 L (2.9 US gal)

Transmission
Standard
Transmission Type:	Constant mesh, 6-speed
Clutch Type:	Wet, multi-disc, manual operation
Features
Final Drive:	Sealed chain drive

Dimensions
Exterior
Overall Length:	2,225 mm (87.6 in)
Overall Width:	850 mm (33.5 in)
Overall Height:	1,205 mm (47.4 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:	Approx. 132 kg (291 lbs)
Front Suspension Travel:	280 mm (11.0 in)
Rear Suspension Travel:	250 mm (9.8 in)

Safety Features
Ratings
Safety Standards:	Motorcycle safety regulations of the region of sale.
Active Features
Braking System:	Front: 250mm petal disc with 2-piston caliper; Rear: 240mm petal disc with 1-piston caliper. Optional ABS available in some markets.
Passive Features
Lighting:	Halogen headlight, LED taillight and brake light.

Technology Features
Infotainment
Display Type:	Digital LCD instrument cluster.
Instrumentation:	Speedometer, tachometer, odometer, trip meters, fuel gauge, clock, indicator lights.
Driver Assistance
ABS Availability:	Optional Anti-lock Braking System (ABS) available on some trims/markets.
Connectivity
Diagnostic Interface:	On-board diagnostics (OBD) through specific connectors for service tools (detailed in manual).

Maintenance
Service Intervals
Engine Oil Change:	Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement:	Replace at every oil change.
Air Filter Cleaning:	Every 6,000 km (3,700 miles) or annually.
Spark Plug Check:	Inspect every 6,000 km (3,700 miles); replace as needed.
Chain Lubrication Adjustment:	Every 1,000 km (600 miles) or after washing/riding in rain.
Fluid Specifications
Engine Oil Type:	SAE 10W-40 API SG or SH, or JASO MA certified.
Engine Oil Capacity:	1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.
Coolant Type:	High-quality ethylene glycol based antifreeze coolant, mixed 50/50 with distilled water.
Brake Fluid Type:	DOT 4 brake fluid.
Known Issues
Carburetor Vibration Risk:	Some early models of the previous generation had potential vibration issues with the carburetor; the fuel-injected model addresses this.
Fuel Pump Reliability:	While generally reliable, fuel pump issues can occur over time, especially with contaminated fuel. The manual details testing procedures.
Suspension Seal Leaks:	Like many off-road oriented bikes, front fork seals can wear and leak over extended use or aggressive riding. The manual provides detailed replacement instructions.

Vehicle History
Brand Heritage
Kawasaki Legacy:	Kawasaki has a long history in motorcycle manufacturing, known for performance and reliability, particularly in off-road and dual-sport segments with its KLR and KLX lines.
Model Evolution
Klx Lineage:	The KLX250S is part of a lineage of Kawasaki dual-sport motorcycles, evolving from earlier models to incorporate modern technology like fuel injection and improved suspension.
Production
Manufacturing Origin:	Primarily manufactured in Japan.

Awards & Recognition
Recognitions
Segment Performance Awards:	Frequently cited in reviews for its balance of usability and off-road capability in its class.