🏷️ Basic Information

Make:

Kawasaki

Model:

KLX250

Sub Models:

KLX250S, KLX250SF

Model Years Covered:

2009, 2010, 2011, 2012

Vehicle Type:

Dual-Sport Motorcycle

👋 Introduction

Segment:

Lightweight dual-sport motorcycle, appealing to riders seeking versatility for on-road and light off-road use.

Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (contemporaneous models).

Versatility:

Adaptable for commuting, trail riding, and light adventure touring.

Engine Type:

Fuel-injected, liquid-cooled, four-stroke engine (for most of the covered period, though earlier models may have been carbureted, this manual specifically covers FI for later years or models).

Suspension:

Upside-down (USD) front forks and adjustable rear suspension for capable off-road performance.

Rider Profile:

New riders, commuters, and experienced riders looking for a nimble and reliable dual-sport machine.

📋 Manual Details

Primary Coverage:

Complete workshop service and repair for Kawasaki KLX250, KLX250S, and KLX250SF models

Estimated Page Count:

500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Detailed engine disassembly, assembly, tuning, and troubleshooting (e.g., cylinder head, piston, crankshaft, valve train, lubrication system)

Fuel System:

Carburetor (mention specific type if known, e.g., Keihin CVK) maintenance, cleaning, adjustment, and troubleshooting; fuel pump and filter for SF models.

Ignition System:

CDI unit, ignition coils, spark plugs, timing adjustments, and troubleshooting.

Transmission Clutch:

Clutch operation, maintenance, replacement; transmission gear inspection, disassembly, assembly, and troubleshooting.

Frame Suspension Steering:

Front fork (e.g., USD forks) overhaul, oil changes, seal replacement; rear shock absorber adjustment and rebuild; steering head bearing maintenance; swingarm and linkage servicing.

Brakes:

Front and rear brake system inspection, pad replacement, caliper service, master cylinder overhaul, bleeding procedures, hydraulic lines.

Wheels Tires:

Tire pressure, wear inspection, replacement, wheel bearing maintenance, spoke tension adjustment.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starting system, instrumentation, and fuses.

Cooling System:

Radiator, cooling fan operation, coolant replacement, hose inspection.

Exhaust System:

Exhaust pipe and muffler inspection, heat shield servicing.

Bodywork Fittings:

Fairings, fenders, seat, fuel tank removal and installation, graphics.

Maintenance Tasks:

Routine inspections, oil changes, filter replacements, chain adjustment, lubrication points, brake fluid flushes, coolant flushes, spark plug checks.

Repair Tasks:

Engine internal repairs, transmission overhauls, suspension rebuilds, brake system repairs, electrical component replacement and troubleshooting.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, including electrical faults, starting problems, running issues, and performance concerns.

Special Tools:

Identification and usage of specialized tools required for specific repair and maintenance procedures.

Diagnostic Capabilities:

Comprehensive diagnostic charts and flow diagrams for identifying and resolving mechanical and electrical problems.

Rebuild Procedures:

Detailed step-by-step instructions for complete engine and major component rebuilds, including torque specifications and clearances.

Diagrams Illustrations:

Exploded views, schematics, and detailed illustrations to guide disassembly, assembly, and component identification.

Wiring Schematics:

Complete and color-coded wiring diagrams for all electrical systems, facilitating troubleshooting and repair.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for offline reference.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4 valves per cylinder, single-cylinder

Displacement:

249 cc (249 cm³)

Bore X Stroke:

72.0 x 61.2 mm

Compression Ratio:

11.0:1

Horsepower:

Approx. 20-25 HP (peak, varies by specific model tune and regulations)

Torque:

Approx. 19-21 Nm (peak, varies by specific model tune and regulations)

Fuel Delivery:

Fuel Injection (EFI) for most 2009+ models, potentially Keihin CVK carburetor on earlier or specific variants not explicitly detailed in the product name.

Fuel Type:

Unleaded gasoline

Oil Type:

Kawasaki recommends KAWASAKI HIGH PERFORMANCE SEMISYNTHETIC MOTOR OIL SAE 10W-40 or API SG, SF, SE, SG, SH, SJ or SL classification.

Oil Capacity:

Approx. 1.5 L (without filter change), 1.7 L (with filter change)

🔧 Transmission

Type:

6-speed constant mesh

Transmission Options:

N/A (single transmission option)

Clutch Type:

Wet, multiple disc

Final Drive:

Sealed chain drive

📐 Dimensions

Length:

Approx. 2,200 mm (varies slightly by model variant)

Width:

Approx. 820 mm (varies slightly by model variant)

Height:

Approx. 1,205 mm (varies slightly by model variant)

Wheelbase:

Approx. 1,430 mm

Ground Clearance:

Approx. 255 mm

Dry Weight:

Approx. 118 kg (varies slightly by model variant)

Curb Weight:

Approx. 132 kg (with all necessary operating fluids and a full tank of fuel)

Fuel Capacity:

Approx. 11 Liters (including reserve)

🛡️ Safety Features

Safety Certification:

Meets relevant DOT and EPA standards for road use.

Braking System:

Front: Single large-diameter petal disc; Rear: Single petal disc. ABS not standard on these models.

Lighting:

Halogen headlamp, LED tail light and brake light.

Chassis Design:

Strong perimeter frame and robust suspension components contributing to stability.

💡 Technology Features

Instrument Cluster:

Digital LCD instrument panel featuring speedometer, tachometer, odometer, trip meter, clock, and indicator lights.

ABS:

Anti-lock Braking System (ABS) was not standard equipment on all variants of the KLX250 during these model years. The manual will cover systems as equipped.

Connectivity Features:

N/A (Motorcycle of this era did not feature Bluetooth or advanced connectivity).

🔧 Maintenance

Oil Change Interval:

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

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Spark Plug Inspection:

Every 6,000 km (3,700 miles).

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet conditions.

Engine Oil:

SAE 10W-40 API SG, SF, SE, SG, SH, SJ or SL classification (e.g., KAWASAKI HIGH PERFORMANCE SEMISYNTHETIC MOTOR OIL).

Coolant:

Mixture of permanent antifreeze and distilled water (50:50 ratio). Use a high-quality ethylene glycol-based coolant.

Brake Fluid:

DOT 4

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, tires, fork seals.

Potential Tuning Points:

Carburetor jetting (if applicable), fuel mapping (if EFI), suspension setup for rider weight and terrain.

📚 Vehicle History

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments, including off-road and dual-sport.

Klx Lineage:

The KLX series has a history dating back to the early 1980s, evolving through various iterations to meet changing rider demands and emissions standards. The 250cc platform has consistently offered a balance of power and usability.

Manufacturing Origin:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Motorcycle Reviews:

Generally well-received by motorcycle publications for its balance of performance, reliability, and off-road capability within its class. Often praised for its ease of use and value proposition.