Kawasaki KLX250S 2009-2010 All Service Manual Repair

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Model Years Covered: 2009, 2010 Codes Chassis Code: KLX250S Engine Code Prefix: LX250F 👋 Introduction Market Position Segment: Dual-sport/Off-road motorcycle Target Audience:...

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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 Covered:

2009, 2010

Codes

Chassis Code:

KLX250S

Engine Code Prefix:

LX250F

👋 Introduction

Market Position

Segment:

Dual-sport/Off-road motorcycle

Target Audience:

Enthusiast riders, DIY mechanics, and service technicians.

Competitive Analysis

Competitors:

Honda CRF250L (later model), Yamaha WR250R, Suzuki DR-Z250.

Klx250S Advantage:

Known for its user-friendly nature, capable off-road suspension, and reliable engine, making it a popular choice for trail riding and commuting.

Key Features

Design Philosophy:

Lightweight, agile, and versatile for both on-road and off-road use.

Engine Configuration:

Liquid-cooled, DOHC, four-valve, single-cylinder engine.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service, repair, and maintenance for Kawasaki KLX250S models 2009-2010.

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, troubleshooting, and repair of all internal and external components.

Fuel System:

Carburetor (Keihin CVK34) tuning, disassembly, cleaning, repair, and adjustment.

Ignition System:

CDI ignition system, spark plug specifications, troubleshooting, and testing.

Cooling System:

Radiator, fan, thermostat, coolant specifications, and bleeding procedures.

Lubrication System:

Oil pump, oil passages, oil filter specifications, and oil change procedures.

Transmission:

Clutch operation, gearbox disassembly, assembly, inspection, and maintenance.

Suspension Front:

Inverted telescopic fork service, oil levels, seal replacement, and adjustments.

Suspension Rear:

Uni-Trak rear suspension, shock absorber service, linkage maintenance, and adjustments.

Braking System:

Hydraulic disc brakes (front and rear), caliper service, master cylinder, fluid specifications, bleeding procedures, and pad replacement.

Electrical System:

Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery specifications, starter motor, and fuse box.

Frame And Bodywork:

Frame inspection, handlebars, seat, fuel tank, fenders, and all body panel removal/installation.

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire replacement, and pressure specifications.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement.

Troubleshooting Guides:

Diagnostic procedures for common and uncommon issues with detailed symptom-cause-remedy charts.

Engine Rebuild:

Complete procedures for cylinder head removal/installation, piston and ring replacement, crankshaft and connecting rod service.

Suspension Overhaul:

Detailed instructions for fork seal replacement, shock absorber servicing, and linkage bearing maintenance.

Carburetor Tuning:

Jetting adjustments, idle speed settings, pilot screw adjustments, and float bowl level checks.

Electrical Diagnostics:

Step-by-step testing of charging system, ignition system, lighting circuits, and starter system.

Brake System Maintenance:

Bleeding procedures, pad replacement, caliper piston service, and master cylinder rebuild.

Technical Depth

Depth:

Comprehensive from basic adjustments and fluid changes to complete engine and transmission overhauls.

Detail Level:

Highly detailed with exploded views, torque specifications, and special tool requirements.

📊 Manual Specifications

File Format

File Format:

Searchability:

Fully searchable text content for quick information retrieval.

Print Quality

Print Quality:

High-resolution scans of original factory manual pages.

Image Clarity:

Clear, legible diagrams and photographs.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, four-valve, single-cylinder

Displacement:

249 cc (250 cc class)

Bore X Stroke:

72.0 x 61.2 mm

Compression Ratio:

11.0:1

Cooling Method:

Liquid-cooled

Performance

Horsepower Est:

Approximately 20-24 hp @ 7000 rpm (varies with emissions equipment and region)

Torque Est:

Approximately 15-18 lb-ft @ 6000 rpm (varies with emissions equipment and region)

Fuel System

Fuel Delivery:

Carburetor: Keihin CVK34 with accelerator pump

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

2.4 US gallons (9.1 L)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed

Clutch Type:

Wet, multi-disc

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Detailed gear ratios available in manual (e.g., 1st: 2.643, 2nd: 1.933, 3rd: 1.556, 4th: 1.333, 5th: 1.150, 6th: 1.000)

Transmission Fluid:

Refer to manual for specific type and capacity (typically motorcycle-specific gearbox oil).

📐 Dimensions

Exterior

Length:

86.8 in (2205 mm)

Width:

32.1 in (815 mm)

Height:

49.8 in (1265 mm)

Wheelbase:

56.5 in (1435 mm)

Ground Clearance:

11.0 in (280 mm)

Seat Height:

34.8 in (885 mm)

Weights

Curb Weight Est:

286.6 lbs (130 kg)

Front Tire Size:

80/100-21M/C 51P

Rear Tire Size:

110/100-18M/C 64P

Wheel Type:

Spoked wheels

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety is assessed differently than automobiles; focus is on design, materials, and component quality covered in manual).

Active Features

Braking System Type:

Hydraulic disc brakes, front and rear.

Suspension Stability:

Inverted front fork and Uni-Trak rear suspension contribute to stable handling.

Passive Features

Lighting:

Halogen headlight, LED taillight, turn signals.

Ergonomics:

Designed for rider control and visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance Features:

N/A (Motorcycle design focuses on rider control and mechanical feedback).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (4,800 km) or 6 months, whichever comes first (refer to manual for exact specification).

Air Filter Cleaning:

Every 3,000 miles (4,800 km) or as needed based on riding conditions.

Spark Plug Check:

Every 7,500 miles (12,000 km).

Valve Clearance Check:

Every 15,000 miles (24,000 km).

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 10W-40 motorcycle oil (refer to manual for exact specification).

Engine Oil Capacity:

1.7 US qt (1.6 L) without filter change; 1.8 US qt (1.7 L) with filter change.

Coolant Type:

Permanent type antifreeze coolant mixed with demineralized water (50/50 ratio).

Brake Fluid Type:

DOT 4 (refer to manual for exact specification).

Fork Oil Type Viscosity:

Kawasaki KHL15-10W or equivalent SAE 10W (refer to manual for exact specification).

Fork Oil Level:

Refer to manual for exact measurement (typically measured from the top of the fork tube with spring removed and fork compressed).

Known Issues

Carburetor Icng:

Carburetor can sometimes be prone to clogging if fuel is left stagnant for extended periods; regular use and fuel stabilizer recommended.

Cam Chain Tensioner:

Some owners report the automatic cam chain tensioner can become noisy over time, potentially requiring manual adjustment or replacement. The manual will detail inspection and adjustment procedures.

Suspension Seals:

Like many motorcycles of this era, fork seal leaks can occur with heavy off-road use. The manual provides detailed instructions for seal replacement.

📚 Vehicle History

Brand Heritage

Kawasaki Motorcycles:

Kawasaki Heavy Industries has a long-standing reputation for producing reliable and performance-oriented motorcycles across various segments.

Model Evolution

Klx Lineage:

The KLX line has a history dating back decades, evolving from smaller displacement dirt bikes to more versatile dual-sport machines like the KLX250S.

Klx250S Design:

The 2009-2010 models represent a refinement of the KLX250 platform, often featuring updated styling and emissions compliance compared to earlier generations.

Production

Manufacturing Location:

Typically manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Often praised in reviews for its balance of off-road capability and on-road manners, making it a versatile package for its class.

Ratings

Durability Reputation:

Generally considered a durable and reliable motorcycle with proper maintenance, as detailed in this service manual.

Certifications

Emissions Compliance:

Models are designed to meet emissions standards for their respective markets for the specified years, with details on adjustments in the manual.