Kawasaki KLX250 D-TRACKER X 2009-2012 Full Service Repair Manual

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This manual covers the KLX250 D-TRACKER X, a versatile dual-sport motorcycle produced for the 2009, 2010, 2011, and 2012 model years. Known for its lightweight and agile design, the D-TRACKER...

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Mots clés: 2009 2010 2011 2012 D Tracker D-TRACKER X Kawasaki KLX250 Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the KLX250 D-TRACKER X, a versatile dual-sport motorcycle produced for the 2009, 2010, 2011, and 2012 model years. Known for its lightweight and agile design, the D-TRACKER X variant typically features supermoto styling, making it adept at both urban commuting and light trail riding. Building on a legacy of performance and innovation, this model offers a blend of off-road capability adapted for street use, positioning it as a capable competitor in its segment. This comprehensive English-language Full Service and Repair Manual provides detailed, step-by-step instructions for all aspects of maintenance, repair, and rebuilding for the KLX250 D-TRACKER X. It covers critical systems including the engine, transmission, electrical components, chassis, suspension, brakes, and fuel system, along with routine maintenance procedures and systematic troubleshooting guides. With extensive technical detail, precise specifications, and clear explanations, this manual serves as an indispensable resource for owners and technicians alike to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250 D-TRACKER X

Product Type:

Full Service Repair Manual

Codes

Applicable Years:

2009, 2010, 2011, 2012

👋 Introduction

Market Position

Segment:

Dual-sport motorcycle, known for its versatility on and off-road.

Competitive Analysis

Key Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S.

Key Features

Model Characteristics:

Lightweight, agile, capable of both commuting and light trail riding. D-TRACKER X variant typically features supermoto styling and tires.

📋 Manual Details

Coverage Areas

Geographic Coverage:

Global (covers models sold internationally)

Page Count

Estimated Page Count:

Extensive (specific page count not provided, but described as comprehensive)

Manual Type

Manual Classification:

Full Service and Repair Manual

Language

Language:

English

Format

Delivery Method:

Instant Download

File Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end rebuild, bottom-end assembly, lubrication system, cooling system, fuel injection system diagnostics and repair.

Transmission:

Clutch operation and adjustment, gearbox disassembly and reassembly, gear shift mechanism, transmission fluid specifications and change procedures.

Electrical:

Complete electrical system diagnosis, wiring diagrams, charging system, ignition system, lighting, starting system, instrument panel, ECU diagnostics, troubleshooting.

Chassis And Suspension:

Front fork service and repair, rear shock absorber maintenance, swingarm lubrication and inspection, steering system, wheel bearings, spoke tensioning.

Braking System:

Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, brake pad replacement, rotor inspection.

Fuel System:

Fuel tank removal and installation, fuel pump operation, fuel filter replacement, fuel injector cleaning and testing, throttle body servicing.

Exhaust System:

Exhaust pipe removal and installation, muffler inspection and repair, exhaust gasket replacement.

Bodywork And Trim:

Fairing removal and installation, seat assembly, fuel tank cover, fenders, decals, and other body panels.

Procedures Included

Maintenance:

Routine maintenance checks, oil and filter changes, chain adjustment and lubrication, air filter cleaning/replacement, spark plug replacement, valve clearance adjustment.

Troubleshooting:

Systematic troubleshooting guides for common and uncommon issues, diagnostic charts, electrical fault finding.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components, including component disassembly, inspection, repair, and reassembly.

Rebuilding:

Comprehensive instructions for rebuilding major assemblies such as the engine, gearbox, and suspension components.

Restoration:

Guidance for restoring the vehicle to its original specifications, including component identification and refurbishment techniques.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures, including ECU error code retrieval and interpretation (where applicable to the model's technology level).

Component Level Detail:

Detailed illustrations and exploded views for component identification, precise torque specifications, tolerances, and fitting instructions.

User Accessibility:

Caters to both professional technicians and experienced DIY mechanics due to its detailed, step-by-step format and clear explanations.

📊 Manual Specifications

File Format

Compatibility:

Compatible with all versions of Windows and Mac operating systems.

Print Quality

Printability:

Full printable; individual pages or the entire manual can be printed.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital PDF format)

Requirements

Software Requirements:

Adobe PDF Reader and WinRAR (for extracting compressed files, if applicable).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, single cylinder.

Displacement:

249 cc (for KLX250 base model; D-TRACKER X may share this).

Performance

Bore X Stroke:

72.0 x 61.2 mm (typical for KLX250 platform).

Compression Ratio:

11.0:1 (typical for KLX250 platform).

Fuel System

Fuel Delivery:

Fuel Injection (EFI) - Specific injector type and ECU mapping would be detailed in the manual.

Ignition:

Digital CDI (Capacitor Discharge Ignition).

Engine Management

Cooling Method:

Forced air and liquid cooling.

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh, return shift.

Optional

Clutch Type:

Wet, multi-disc, manual.

Features

Final Drive:

O-ring sealed chain, 14T front sprocket, 42T rear sprocket (typical, check manual for exact specs).

📐 Dimensions

Exterior

Length:

Approx. 2,165 mm (subject to variation, check manual).

Width:

Approx. 800 mm (subject to variation, check manual).

Height:

Approx. 1,150 mm (subject to variation, check manual).

Weights

Curb Weight:

Approx. 132 kg (subject to variation, check manual).

Fuel Capacity:

11 Liters (approx. 2.9 US gal).

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle safety ratings differ from automobiles; manual focuses on mechanical safety.)

Active Features

Braking System Type:

Disc brakes front and rear. Specifics on caliper piston count and rotor diameter will be in the manual.

Passive Features

Lighting System:

Halogen headlight, LED taillight and indicators (typical).

💡 Technology Features

Infotainment

Display Features:

Digital instrument cluster displaying speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and indicator lights.

Driver Assistance

ABS was an optional feature on some KLX250 models during this period; the manual will detail its operation and service if equipped.

Connectivity

ECU Functionality:

Engine Control Unit (ECU) manages fuel injection and ignition timing based on sensor inputs.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000 km or 6 months, whichever comes first (refer to manual for exact interval and oil type).

Valve Adjustment Interval:

Recommended every 12,000 km or 12 months (critical to verify in the manual).

Chain Maintenance:

Lubrication and tension check recommended every 1,000 km or after riding in wet conditions.

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ or SL, SAE 10W-40. Check manual for exact viscosity and quantity.

Coolant Type:

Permanent type antifreeze (ethylene glycol-based), 50% solution with distilled water. Check manual for specific Kawasaki coolant or equivalent.

Brake Fluid Type:

DOT 4. Always use fresh, sealed fluid.

Fork Oil Type:

Specific viscosity (e.g., 5W or 10W) and quantity per fork leg detailed in the manual.

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings, spark plugs.

Potential Problems:

Fuel injection system cleaning (due to age/usage), occasional carburetor issues (if earlier models were covered under similar manuals), suspension wear, chain adjustment frequency.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and innovation in various segments.

Model Evolution

Klx Series Development:

The KLX series has evolved over decades, with the KLX250 being a staple in the lightweight dual-sport and supermoto categories, known for its reliability and off-road prowess adapted for street use.

Production

Manufacturing Location:

Primarily manufactured in Japan (specific plant details not typically in a service manual).

🏆 Awards & Recognition

Recognitions

Model Accolades:

Specific awards for the 2009-2012 KLX250 D-TRACKER X are not widely publicized, but the KLX series is generally well-regarded for its class.