Segment:
Lightweight Dual-Sport / Enduro motorcycle, popular for trail riding, commuting, and light off-road use.
Key Competitors:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S.
Vehicle Purpose:
Versatile on-road and off-road capabilities, known for its nimble handling and reliable performance.
Manual Value Proposition:
Provides detailed technical guidance for owners and technicians to maintain and repair the KLX250SA, ensuring optimal performance and longevity.
Systems Covered:
Engine, Fuel System, Ignition System, Starting System, Charging System, Transmission, Clutch, Drivetrain, Suspension, Brakes, Wheels, Tires, Frame, Bodywork, Electrical System, Cooling System, Exhaust System, Lubrication System, Troubleshooting, Maintenance
Estimated Page Count:
Comprehensive (exact count not specified but implied to be extensive for a full service manual)
Manual Type:
Service Repair Workshop Manual
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures for the KLX250SA's 250cc liquid-cooled engine.
Fuel System Diagnosis:
Detailed information on the fuel injection system, including injector testing, fuel pump operation, and sensor diagnostics.
Ignition System Components:
Covers ignition timing, spark plug specifications, CDI unit testing, and troubleshooting ignition system faults.
Electrical Schematics:
Includes complete wiring diagrams for all electrical components, aiding in troubleshooting and repair of lighting, starting, and charging circuits.
Suspension Adjustment:
Guidance on front fork and rear shock absorber adjustments, maintenance, and internal component repair.
Braking System Service:
Detailed procedures for brake pad replacement, caliper service, master cylinder overhaul, and bleeding the hydraulic system.
Cooling System Maintenance:
Instructions for coolant replacement, radiator service, fan operation, and leak detection.
Drivetrain Inspection:
Covers chain and sprocket inspection, replacement, and adjustment, as well as rear hub and bearing service.
Frame And Bodywork:
Procedures for fairing removal, installation, and repair, as well as frame inspection for damage.
Routine Maintenance:
Oil changes, filter replacements, air filter cleaning, chain lubrication, and general inspection procedures.
Troubleshooting Guide:
Systematic diagnostic flowcharts and procedures for identifying and resolving common operational issues.
Engine Rebuilding:
Detailed steps for piston removal, cylinder honing, valve adjustment, and camshaft replacement.
Electrical Troubleshooting:
Guidance on diagnosing issues with the battery, starter motor, alternator, and lighting circuits.
Suspension Servicing:
Instructions for fork seal replacement, oil changes, and rear shock servicing.
Brake System Repair:
Complete procedures for bleeding brakes, replacing brake fluid, and servicing brake calipers and master cylinders.
Carburetor Adjustment:
While the 2010 KLX250SA is fuel-injected, early models or variations might have carburetors. If applicable, this would cover jetting and idle adjustments.
Tire And Wheel Service:
Instructions for tire removal and installation, wheel balancing, and spoke tensioning.
Depth:
Comprehensive: Covers everything from basic maintenance checks and adjustments to complete engine and component overhauls and advanced troubleshooting.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve single cylinder
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
72.0 x 61.3 mm (2.83 x 2.41 in.)
Compression Ratio:
11.0:1
Horsepower:
Approximately 22-24 HP (at crankshaft, depending on region/tuning)
Torque:
Approximately 15-17 lb-ft (at crankshaft, depending on region/tuning)
Fuel Delivery:
Digital Fuel Injection (DFI) with Keihin 34mm throttle body
Fuel Type:
Unleaded gasoline, 87 octane or higher
Oil Type:
SAE 10W-40 API SG or SH JASO MA
Oil Capacity With Filter:
1.7 L (1.8 US qt)
Oil Filter Part Number:
Kawasaki OEM 16097-0004 (example, verify for specific model year)
Dashboard:
Digital LCD instrument cluster featuring speedometer, tachometer, fuel gauge, clock, trip meters, and indicator lights.
ABS:
Anti-lock Braking System (ABS) was not standard on the 2010 KLX250SA model, though some later iterations or regional variants might have offered it. Manual would specify if applicable.
Connectivity Features:
N/A (Motorcycle of this era typically does not feature advanced connectivity like Bluetooth or smartphone integration).
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) or 6 months.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or 12 months.
Engine Oil Spec:
SAE 10W-40 API SG or SH JASO MA
Coolant Type:
High-quality ethylene glycol based coolant, 50% mixture with distilled water.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, and tires due to dual-sport usage.
Potential Quirks:
Some users report a relatively stiff suspension from the factory, which is adjustable. Engine may feel a bit strained at sustained high speeds compared to larger displacement bikes.
