Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Transmission, Clutch, Drivetrain, Frame, Suspension, Steering, Brakes, Electrical System, Lighting, Bodywork, Troubleshooting, Maintenance, Specifications, Wiring Diagrams
Type:
Workshop Service Manual / Repair Manual
Engine Mechanical:
Detailed breakdown, assembly, inspection, and repair procedures for the 249cc liquid-cooled, four-stroke engine.
Fuel System:
Carburetor (Keihin CVK34) disassembly, cleaning, adjustment, and troubleshooting; fuel pump and filter inspection.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing checks, troubleshooting ignition faults.
Cooling System:
Radiator, coolant, fan operation, thermostat, hoses, and pump inspection and maintenance.
Transmission Drivetrain:
Six-speed transmission inspection, maintenance, and repair; clutch operation, adjustment, and component replacement; chain and sprockets maintenance.
Frame Suspension Steering:
Frame inspection, front fork (telescopic) disassembly, adjustment, and repair; rear shock absorber inspection and adjustment; swingarm and linkage maintenance; steering system bearing inspection and adjustment.
Brakes:
Front and rear disc brake systems, caliper inspection and overhaul, brake pad replacement, master cylinder and slave cylinder maintenance, brake fluid specifications and bleeding procedures.
Electrical System:
Battery maintenance, charging system (alternator, regulator/rectifier), starter motor operation, fuse box layout, and component testing.
Lighting Indicators:
Headlight, taillight, brake light, turn signals, and instrument panel bulb specifications and replacement.
Bodywork:
Panel removal and installation, seat, fuel tank, fenders, and fairing maintenance.
Maintenance:
Detailed routine maintenance procedures, including oil changes, filter replacements, chain adjustment, brake checks, and fluid level checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, with symptom-based fault finding guides.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly, covering major systems.
Engine Rebuild:
Comprehensive guide for engine overhaul, including piston, ring, valve, and crankshaft specifications and procedures.
Electrical Diagnostics:
Methods for testing electrical components, wiring continuity, and diagnosing electrical faults using multimeter readings.
Suspension Adjustment:
Guidance on adjusting front and rear suspension for optimal performance and rider preference.
Brake System Maintenance:
Detailed instructions for brake bleeding, pad replacement, and caliper servicing.
Depth:
Comprehensive, covering everything from basic owner maintenance to advanced engine and transmission overhauls and electrical diagnostics.
Type:
Liquid-cooled, four-stroke, DOHC, four-valve single-cylinder
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Horsepower:
Approx. 22-24 HP (Varies by market and tune)
Torque:
Approx. 16-18 lb-ft (Varies by market and tune)
Carburetor:
Keihin CVK34 with accelerator pump
Fuel Tank Capacity:
3.7 gallons (14 L)
Oil Type:
API SG, SF or higher, SAE 10W-40, JASO MA certified motorcycle oil
Oil Capacity With Filter Change:
1.6 US qt (1.5 L)
Safety Features:
Disc brakes front and rear, sturdy frame construction, compliant suspension.
Braking System:
Hydraulic disc brakes front and rear
Front Brake Rotor Diameter:
250 mm (9.8 in)
Rear Brake Rotor Diameter:
240 mm (9.4 in)
Lighting:
Halogen headlight, LED taillight, incandescent turn signals
Initial Service:
First service typically around 600 miles (1000 km) - includes oil change, filter inspection, chain adjustment, and general inspection.
Regular Oil Change:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 3,700 miles (6,000 km) or more frequently in dusty conditions.
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Valve Clearance Check:
Every 7,500 miles (12,000 km)
Engine Oil Capacity:
1.6 US qt (1.5 L) with filter change
Coolant Type:
Kawasaki All Season Motorcycle Coolant or equivalent (50/50 mixture of distilled water and ethylene glycol)
Brake Fluid Type:
DOT 3 or DOT 4
Chain Lube Type:
High-quality motorcycle chain lubricant
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires, and air filter are common wear items that require regular inspection and replacement.
Carburetor Cleaning:
Occasional cleaning of the carburetor may be necessary, especially if the bike sits for extended periods, to prevent fuel-related issues.
Electrical Connections:
Ensure all electrical connectors are clean and secure to prevent intermittent faults, especially on older models.
Heritage:
Kawasaki has a long-standing reputation for producing durable and performance-oriented motorcycles, particularly in the off-road and dual-sport segments.
Klx Lineage:
The KLX series has evolved over decades, with models ranging from smaller displacement dirt bikes to the versatile dual-sport offerings like the KLX250.
Production Period Klx250:
The KLX250 platform has been in production for many years, with the VA designation representing a specific iteration for the 2010 model year, often reflecting minor updates or regional specifications.
