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Kawasaki KLX 250 S9 2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Model Code: KLX250S9 Year: 2009 👋 Introduction Market Position Segment: Dual-sport motorcycle Target Audience: Riders seeking a capable off-road and on-road versatile...
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Kawasaki KLX 250 S9 2009 Workshop Service Repair ManualKawasaki KLX 250 S9 2009 Workshop Service Repair ManualKawasaki KLX 250 S9 2009 Workshop Service Repair ManualKawasaki KLX 250 S9 2009 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250S
Model Code:
KLX250S9
Year:
2009
👋 Introduction
Market Position
Segment:
Dual-sport motorcycle
Target Audience:
Riders seeking a capable off-road and on-road versatile motorcycle
Competitive Analysis
Key Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S
Key Features
Versatility:
Designed for both trail riding and street legal commuting
Engine Character:
Torquey and user-friendly for its displacement class
Suspension Performance:
Adjustable front and rear suspension for varied terrain
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Workshop Service and Repair
Scope:
All mechanical, electrical, and cosmetic aspects of the KLX250S9
Page Count
Estimated Pages:
400+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of the 249cc liquid-cooled 4-stroke engine
Fuel System:
Carburetor system (Keihin CVK34), fuel pump, lines, and tank maintenance
Ignition System:
CDI system, spark plug specifications, timing
Transmission:
6-speed gearbox, clutch operation, maintenance, and overhaul
Suspension:
Front telescopic forks (inversion type), rear Uni-Trak linkage system, adjustment, and service
Brakes:
Front and rear hydraulic disc brakes, caliper service, pad replacement, fluid bleeding
Electrical System:
Wiring diagrams, lighting, battery, charging system, starter motor, switches
Frame And Bodywork:
Chassis inspection, panel removal/installation, seat, fuel tank, fairings
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, air filter cleaning
Troubleshooting:
Diagnostic guides for common starting, running, and electrical issues
Disassembly Reassembly:
Detailed step-by-step procedures for major component overhaul
Torque Specifications:
Precise torque values for all critical fasteners
Engine Rebuild:
Piston, ring, cylinder, valve train, crankshaft, and connecting rod service
Special Tools:
Identification and usage of specialized tools required for specific procedures
Technical Depth
Depth:
Comprehensive; suitable for experienced DIY mechanics and professional technicians
📊 Manual Specifications
File Format
Format Details:
Searchable PDF with high-resolution images and diagrams
Print Quality
Image Resolution:
High resolution for clear visibility of diagrams and text
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Displacement:
249 cc
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Performance
Horsepower:
Approx. 30 hp (Varies by region and emissions compliance)
Torque:
Approx. 18 lb-ft (Varies by region and emissions compliance)
Fuel System
Carburetor:
Keihin CVK34 with accelerator pump
Fuel Capacity:
2.0 US gal (7.7 L)
Lubrication
Oil Type:
SAE 10W-40 API SG or higher
Oil Capacity W Filter:
1.6 US qt (1.5 L)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch:
Wet multi-disc, cable-actuated
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
86.8 in (2205 mm)
Width:
32.1 in (815 mm)
Height:
47.4 in (1205 mm)
Wheelbase:
56.7 in (1440 mm)
Weights
Dry Weight:
262.4 lb (119 kg)
Curb Weight:
288.8 lb (131 kg) (Approx.)
Wheels
Front Wheel:
21M/C x 1.60 (Spoked)
Rear Wheel:
18M/C x 2.15 (Spoked)
Tires
Front Tire Size:
80/100-21M/C 51P
Rear Tire Size:
100/100-18M/C 59P
🛡️ Safety Features
Ratings
Crash Testing:
N/A (Motorcycle specific safety features and rider protection are primary focus)
Active Features
Braking:
Dual hydraulic disc brakes for effective stopping power
Passive Features
Lighting:
Halogen headlight, LED tail light, turn signals
Rider Protection
Ergonomics:
Upright riding position for better control and visibility
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, odometer, trip meter, clock, and indicator lights.
Driver Assistance
ABS:
Not equipped with ABS
Connectivity
Bluetooth:
Not equipped
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 miles (4,800 km) or 6 months
Oil Filter Replacement:
Every 6,000 miles (9,600 km) or 12 months
Air Filter Cleaning:
Every 1,500 miles (2,400 km) or as needed based on riding conditions
Chain Lubrication Adjustment:
Every 300 miles (500 km) or as needed
Valve Clearance Check:
Every 7,500 miles (12,000 km)
Fluid Specifications
Coolant Type:
Permanent antifreeze, ethylene glycol-based, with deionized water (50/50 mix)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Carburetor Tuning:
Can require periodic adjustment for optimal performance at altitude changes or after modifications.
Suspension Seals:
Like many motorcycles of this era, fork seal leaks can occur with age and heavy use; proactive inspection is recommended.
Charging System:
While generally robust, stator or regulator/rectifier issues can manifest over time, detailed testing procedures are in the manual.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company
Model Evolution
Klx Lineage:
The KLX series has a long history of dual-purpose motorcycles, evolving from earlier dual-sport models.
Klx250S Specifics:
The KLX250S model line was introduced to offer a more accessible and user-friendly dual-sport experience compared to its larger siblings.
Production
Production Period:
The KLX250S model was produced for a significant period, with the 2009 model representing a specific iteration in its development.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The KLX250S is generally well-regarded in reviews for its balance of performance, reliability, and affordability in the dual-sport segment.
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