Kawasaki KLX250S 2009-2010 Repair Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Model Years: 2009, 2010 Product Type: Repair Service Manual Product Format: PDF Download Codes Kawasaki Model Code Klx250S 2009: KLX250SBF Kawasaki Model...

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类型: Motorcycle

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标签: 2009 2010 Kawasaki KLX250S Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250S

Model Years:

2009, 2010

Product Type:

Repair Service Manual

Product Format:

PDF Download

Codes

Kawasaki Model Code Klx250S 2009:

KLX250SBF

Kawasaki Model Code Klx250S 2010:

KLX250SDF

👋 Introduction

Market Position

Segment:

Dual-sport motorcycle, lightweight, off-road capable with street legality

Target Audience:

Beginner to intermediate riders, commuters, recreational trail riders

Competitive Analysis

Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250

Key Features

Versatility:

Adaptable for both on-road commuting and off-road trail riding

Engine Type:

Liquid-cooled, DOHC, four-stroke, single-cylinder with fuel injection

Suspension Setup:

Long-travel inverted front forks and adjustable rear monoshock for off-road capability

Manual Purpose

Purpose:

Provide detailed instructions for maintenance, repair, and troubleshooting, primarily for professional technicians but accessible to informed owners.

📋 Manual Details

Coverage Areas

Primary Coverage:

2009-2010 Kawasaki KLX250S

Secondary Coverage:

Related components and systems

Page Count

Estimated Pages:

Approximately 300-400 pages (typical for this model's service manual)

Manual Type

Type:

Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod), lubrication system, cooling system

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, fuel injectors, evaporative emission control system

Ignition System:

Ignition coil, spark plug, ECU control, sensors

Transmission:

Clutch system, gearbox (gear shifting, internal components), lubrication

Suspension:

Front fork (inversion, damping, seals), rear shock absorber, linkages, adjustments

Brakes:

Front and rear disc brake systems, calipers, master cylinders, brake lines, bleeding procedures, pad replacement

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter system, fuses, relays, ECU diagnostics

Chassis Body:

Frame, subframe, wheels, tires, handlebars, footpegs, body panels, seat, fuel tank removal/installation

Procedures Included

Maintenance:

Oil changes, filter replacements, chain maintenance, brake fluid changes, coolant checks, valve clearance checks

Troubleshooting:

Diagnostic procedures for common faults, error code interpretation (if applicable), symptom-based troubleshooting guides

Repair:

Component disassembly, assembly, and replacement procedures with torque specifications

Rebuilds:

Engine and transmission overhaul procedures

Adjustments:

Clutch lever, throttle cable, suspension settings, idle speed

Technical Depth

Depth:

Comprehensive, intended for professional technicians but accessible to skilled DIY mechanics with appropriate tools

Diagnostic Capabilities:

Includes diagnostic procedures and potential troubleshooting steps for EFI systems

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable for efficient information retrieval

Print Quality

Printability:

Designed for digital viewing and printing of specific pages/sections

Binding Type

Binding:

Not applicable (Digital PDF)

Paper Type

Paper:

Not applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve single

Displacement:

249 cc (249.7 cm3)

Bore X Stroke:

72.0 x 61.2 mm

Compression Ratio:

11.0:1

Fuel Delivery:

Digital Fuel Injection (DFI) with dual throttle valves

Performance

Horsepower Approx:

Approximately 20-23 HP (stock, varies by market and measurement)

Torque Approx:

Approximately 14-16 lb-ft (stock, varies by market and measurement)

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane or higher recommended

Fuel Tank Capacity:

2.1 US gallons (7.9 Liters)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh 6-speed return

Clutch Type:

Wet, multi-disc, cable-actuated

Features

Final Drive:

Sealed chain drive

Gear Ratios:

Specific ratios documented in the manual

Transmission Oil Type:

Kawasakilubricant SAE 10W-40 (or equivalent API SG, SE)

Transmission Oil Capacity:

Approximately 1.7 US quarts (1.6 Liters)

📐 Dimensions

Exterior

Overall Length:

Approx. 86.8 inches (2205 mm)

Overall Width:

Approx. 32.3 inches (820 mm)

Overall Height:

Approx. 49.4 inches (1255 mm)

Wheelbase:

Approx. 57.1 inches (1450 mm)

Ground Clearance:

Approx. 11.0 inches (280 mm)

Weights

Dry Weight:

Approx. 253.5 lbs (115 kg)

Curb Weight:

Approx. 282.2 lbs (128 kg)

Front Tire Size:

80/100-21 51P

Rear Tire Size:

100/100-18 59P

Wheel Type:

Spoked wheels

Wheelbase Type:

Standard motorcycle wheelbase

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable to motorcycles in the same way as cars; manual focuses on mechanical safety and operational integrity.

Active Features

Brakes Type:

Dual hydraulic disc brakes (front and rear)

ABS Availability:

Not available on standard KLX250S models for these years.

Passive Features

Lighting:

Halogen headlamp, LED tail light, turn signals

Frame Construction:

Semi-double cradle steel frame for durability and rigidity

💡 Technology Features

Infotainment

Infotainment System:

Not applicable; this is a minimalist dual-sport motorcycle with no integrated infotainment system.

Driver Assistance

Not equipped with ABS.

Digital Fuel Injection (EFI) with dual throttle valves for improved throttle response and fuel efficiency.

Connectivity

Connectivity Features:

Not applicable.

Instrumentation

Dashboard:

Digital LCD display for speedometer, odometer, trip meter, clock, and indicator lights. Analog tachometer.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 4,000 miles (6,000 km) or 6 months

Oil Filter Replacement:

Every 4,000 miles (6,000 km) or 6 months (concurrent with oil change)

Air Filter Cleaning:

Every 2,000 miles (3,000 km) or 12 months; replace as needed

Valve Clearance Check:

Every 8,000 miles (12,000 km) or 24 months

Brake Fluid Replacement:

Every 2 years (or as needed)

Fluid Specifications

Engine Oil Type:

Kawasaki Genuine Motorcycle Oil SAE 10W-40, API SG or higher, JASO MA approved

Engine Oil Capacity:

1.8 US quarts (1.7 Liters) upon disassembly, 1.6 US quarts (1.5 Liters) after draining and refilling

Coolant Type:

High-quality ethylene glycol-based antifreeze coolant (50% mixture with distilled water)

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Known Issues

Efi System:

Occasional reports of minor hesitation at certain throttle positions, often addressable with ECU reflash or sensor cleaning.

Suspension Seals:

As with many long-travel suspension systems, fork seal leaks can occur with heavy off-road use; regular inspection is advised.

Clutch Wear:

Normal wear and tear on clutch plates, particularly with frequent hard use or improper adjustment. Manual provides clutch inspection and replacement procedures.

Spark Plug Fouling:

Can occur with excessive short trips or improper fuel mixture; manual covers spark plug inspection and replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long history in motorcycle manufacturing, with a strong reputation for performance and innovation, particularly in off-road and dual-sport segments.

Model Evolution

Klx Lineage:

The KLX line has evolved from earlier dual-sport and off-road models, with the KLX250S representing a modern iteration focused on usability and updated technology.

Key Updates Pre 2009:

The KLX250S received significant updates prior to 2009, notably the adoption of fuel injection and an inverted front fork, differentiating it from earlier carbureted models.

Production

Manufacturing Location:

Primarily manufactured in Japan.

Sales Status:

The 2009-2010 models were part of a successful generation of the KLX250S, catering to riders seeking a capable and versatile dual-sport machine.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards are not readily documented, but the KLX250S has been consistently recognized for its balance of performance, reliability, and value in the dual-sport category.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its intended purpose, often cited for its ease of use and capability.