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Kawasaki KLX 250 S 2009 Service Workshop Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Year: 2009 Codes Model Code Vin: JBKLX250T9F 👋 Introduction Market Position Category: Dual-Sport / Enduro Motorcycle Target Audience: Off-road enthusiasts, trail riders,...
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Type: Motorcycle
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Sku: 592232
Kawasaki KLX 250 S 2009 Service Workshop Repair ManualKawasaki KLX 250 S 2009 Service Workshop Repair ManualKawasaki KLX 250 S 2009 Service Workshop Repair ManualKawasaki KLX 250 S 2009 Service Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250S
Year:
2009
Codes
Model Code Vin:
JBKLX250T9F
👋 Introduction
Market Position
Category:
Dual-Sport / Enduro Motorcycle
Target Audience:
Off-road enthusiasts, trail riders, commuters seeking versatility
Competitive Analysis
Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250
Key Features
Versatility:
Capable of both on-road and off-road use
Engine Type:
Reliable, liquid-cooled four-stroke engine
Suspension:
Long-travel suspension for off-road capability
Handling:
Agile and responsive handling characteristics
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Workshop, Repair
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Top End (Cylinder Head, Valves, Camshaft), Bottom End (Crankshaft, Connecting Rods, Piston), Cooling System (Radiator, Hoses, Thermostat)
Fuel System:
Carburetor (Keihin CVK34), Fuel Pump, Fuel Lines, Fuel Tank
Ignition System:
CDI Unit, Ignition Coil, Spark Plug, Stator
Exhaust System:
Exhaust Pipes, Muffler, Catalytic Converter (if applicable)
Transmission Drivetrain:
Clutch (Wet Multi-Plate), Gearbox (5-Speed), Final Drive (Chain and Sprockets)
Suspension:
Front Fork (Inverted, Adjustable), Rear Shock Absorber (Adjustable Preload and Rebound), Swingarm
Brakes:
Front Disc Brake (Single Caliper), Rear Disc Brake (Single Caliper), Brake Lines, Master Cylinders, Fluid
Electrical System:
Battery, Charging System (Alternator), Lighting (Headlight, Taillight, Turn Signals), Starter Motor, Wiring Diagrams
Chassis Frame:
Frame Structure, Subframe, Body Panels, Seat
Wheels Tires:
Spoked Wheels, Hubs, Bearings, Tire Installation and Balancing
Procedures Included
Routine Maintenance:
Oil Change, Filter Replacement, Chain Adjustment and Lubrication, Air Filter Cleaning/Replacement, Spark Plug Inspection/Replacement, Brake Pad Inspection/Replacement, Coolant Flush
Troubleshooting:
Diagnostic Flowcharts for Common Issues (Starting Problems, Engine Performance, Electrical Faults)
Engine Rebuild:
Top-end Overhaul, Piston and Ring Replacement, Valve Clearance Adjustment, Gasket Replacement, Crankshaft Inspection
Transmission Service:
Clutch Adjustment and Replacement, Gearbox Disassembly and Reassembly, Shift Drum and Fork Inspection
Suspension Repair:
Fork Seal Replacement, Fork Oil Change, Shock Absorber Service
Brake System Service:
Brake Bleeding, Caliper Rebuild, Master Cylinder Rebuild, Rotor Replacement
Electrical Diagnostics:
Wiring Diagram Interpretation, Component Testing (Coil, CDI, Stator), Battery and Charging System Testing
Carburetor Overhaul:
Disassembly, Cleaning, Jetting, Float Level Adjustment, Reassembly
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine and chassis overhaul)
Diagnostic Capabilities:
Detailed troubleshooting guides with symptoms, causes, and remedies
Repair Procedures:
Step-by-step instructions with torque specifications and special tool requirements
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text content for quick information retrieval
Print Quality
Print Readability:
High-resolution digital scans for clear text and diagrams
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ 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:
Approximately 30-33 HP (Manufacturer specified variation possible)
Torque:
Approximately 17-19 lb-ft (Manufacturer specified variation possible)
Fuel System
Carburetor Type:
Keihin CVK34
Fuel Capacity:
2.0 US gal (7.6 L)
Fuel Type:
Unleaded gasoline, 87 octane (or higher)
🔧 Transmission
Standard
Transmission Type:
Constant-mesh, 5-speed
Clutch Type:
Wet, multi-plate
Features
Final Drive:
Sealed O-ring chain, 13/47T (example, verify for specific model)
Transmission Oil Type:
Kawasaki Genuine Gear Oil API GL-4 SAE 80W or equivalent
📐 Dimensions
Exterior
Length:
86.8 in (2205 mm)
Width:
32.1 in (815 mm)
Height:
46.3 in (1175 mm)
Wheelbase:
56.5 in (1435 mm)
Ground Clearance:
11.2 in (285 mm)
Weights
Curb Weight:
295.7 lbs (134.1 kg)
Dry Weight:
273.4 lbs (124.0 kg)
🛡️ Safety Features
Ratings
Crash Safety:
N/A (Motorcycle safety is assessed differently than cars)
Active Features
Brakes:
Disc brakes front and rear for reliable stopping power
Lighting:
Bright headlight, taillight, and turn signals for visibility
Passive Features
Frame Construction:
Robust perimeter frame for chassis rigidity
Ergonomics:
Designed for rider control and stability
💡 Technology Features
Infotainment
Infotainment System:
None (Basic analogue/digital instrument cluster)
Driver Assistance
ABS:
Not available on the 2009 KLX250S model.
Instrumentation
Gauge Cluster:
Analogue speedometer, digital tachometer, odometer, trip meters, fuel gauge, clock, indicator lights.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 miles (4,800 km) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 3,000 miles (4,800 km) or 6 months.
Air Filter Cleaning:
Every 2,000 miles (3,200 km), clean and re-oil. Replace as needed.
Spark Plug Inspection:
Every 3,000 miles (4,800 km). Replace as needed.
Chain Maintenance:
Inspect and lubricate every 500 miles (800 km). Adjust tension as needed.
Valve Clearance Check:
Every 7,500 miles (12,000 km) or 12 months.
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
1.5 L (1.6 US qt) without filter change; 1.7 L (1.8 US qt) with filter change.
Coolant Type:
High-quality ethylene glycol based coolant, pre-mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Carburetor Performance:
Some owners report lean running conditions or hesitation, often addressable with rejetting or proper carburetor cleaning/adjustment.
Suspension Softness:
Stock suspension can be considered a bit soft for aggressive off-road riding by some, upgradable with aftermarket components.
Clutch Feel:
Clutch lever pull can be slightly heavy for some riders.
Recommended Filters
Oil Filter Part Number:
Kawasaki 16099-003 (or aftermarket equivalents like HiFlofiltro HF111)
Air Filter Part Number:
Kawasaki 11013-0029 (or aftermarket equivalents like Twin Air 152219)
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries, Motorcycle & Engine Division
Model Evolution
Klx Lineage:
Part of Kawasaki's long-standing KLX series of off-road motorcycles, known for their versatility.
2009 Updates:
This generation of the KLX250S, introduced in the mid-2000s, featured fuel injection in some markets, but the 2009 S model typically retained a carburetor. It represented a significant update over previous KLX models with improved suspension and handling.
Production
Manufacturing Location:
Japan (Primary)
🏆 Awards & Recognition
Recognitions
Industry Awards:
N/A (Specific awards for this model year are not widely publicized; focus is on performance and reliability.)
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