Kawasaki KLX250SA 2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 Motorcycle Type: Dual-Sport / Off-Road Generation Generation Code: KLX250 (SF/S/D-Tracker) 👋 Introduction Market Position Segment: Lightweight dual-sport motorcycle, popular for...

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标签: 2010 Kawasaki KLX250SA Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250SA

Year:

Motorcycle Type:

Dual-Sport / Off-Road

Generation

Generation Code:

KLX250 (SF/S/D-Tracker)

👋 Introduction

Market Position

Segment:

Lightweight dual-sport motorcycle, popular for trail riding, commuting, and light off-road use

Competitive Analysis

Competitors:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250

Key Features

Versatility:

Capable on both pavement and unpaved roads, offering a balance of performance and usability

Reliability:

Known for its robust engine and durable construction, common in Kawasaki's off-road lineage

Maneuverability:

Lightweight chassis and manageable power delivery contribute to excellent handling

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Factory Service Repair

Page Count

Estimated Page Count:

Hundreds of pages (exact count not specified, but implied to be comprehensive)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Full disassembly, assembly, tuning, troubleshooting, specifications

Fuel System:

Carburetor (CVK34), fuel pump, fuel lines, fuel tank maintenance and repair

Ignition System:

CDI, spark plug, ignition coils, timing

Cooling System:

Liquid cooling system, radiator, fan, coolant specifications

Transmission:

Clutch, gearbox, shift drum, internal components, lubrication, troubleshooting

Drivetrain:

Chain drive, sprockets, maintenance and replacement procedures

Chassis Frame:

Frame inspection, alignment, related components

Suspension Front:

Telescopic front fork, damping adjustment, oil change, seal replacement, troubleshooting

Suspension Rear:

Uni-Trak rear suspension, shock absorber, linkage components, adjustment, maintenance

Brakes Front:

Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications

Brakes Rear:

Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications

Wheels Tires:

Wheel bearing maintenance, spoke tension, tire pressure, specifications

Electrical System:

Battery, charging system (stator, regulator/rectifier), lighting, starting system, wiring diagrams

Instrumentation:

Speedometer, tachometer, indicator lights, troubleshooting

Bodywork Trim:

Fairings, fenders, seat, fuel tank cover, decals, removal and installation

Exhaust System:

Muffler, head pipe, gaskets, inspection and repair

Troubleshooting:

Comprehensive diagnostic guides for all major systems, fault finding charts

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication

Repair:

Component disassembly, assembly, replacement, and adjustment for all major systems

Rebuild:

Detailed instructions for engine rebuilds, carburetor overhauls, and suspension rebuilds

Diagnostics:

Systematic troubleshooting steps and diagnostic flowcharts

Specifications:

Torque values, clearances, fluid capacities, electrical specifications, measurements

Wiring Diagrams:

Complete and detailed electrical system schematics

Technical Depth

Depth:

Factory-level technical detail for professional mechanics and advanced DIY enthusiasts

Detail Level:

Includes step-by-step procedures, exploded diagrams, and troubleshooting charts

📊 Manual Specifications

File Format

Format Details:

Searchable PDF, allowing easy navigation and printing of specific pages or the entire manual

Print Quality

Quality:

High-resolution scans, ensuring clarity of text and diagrams

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, 4-valve, Single-cylinder

Displacement:

249 cc (250cc class)

Bore X Stroke:

72.0 mm x 61.2 mm (typical for this generation)

Compression Ratio:

11.0:1 (typical)

Performance

Horsepower:

Approximately 22-24 HP @ 7,500 RPM (Estimate based on model year and configuration)

Torque:

Approximately 16-18 lb-ft @ 6,500 RPM (Estimate based on model year and configuration)

Fuel System

Carburetor:

Keihin CVK34 with Accelerator Pump

Fuel Capacity:

Approx. 2.5 - 3.0 gallons (7.7 - 11.0 Liters) depending on sub-model

Lubrication

Oil Capacity With Filter:

Approx. 1.6 - 1.8 Liters (Consult manual for exact specification)

Engine Oil Type:

API SG or SH, SAE 10W-40 motorcycle specific oil (Consult manual for exact specification)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-disc

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

Approx. 85.2 inches (2165 mm) (Varies slightly by sub-model)

Width:

Approx. 33.5 inches (850 mm) (Varies slightly by sub-model)

Height:

Approx. 45.7 inches (1160 mm) (Varies slightly by sub-model)

Wheelbase:

Approx. 56.7 inches (1440 mm)

Ground Clearance:

Approx. 11.0 inches (280 mm)

Weights

Curb Weight:

Approx. 291 lbs (132 kg) (Varies slightly by sub-model)

Gross Vehicle Weight Rating:

Not explicitly specified, but typically around 350-400 lbs

Front Tire Size:

80/100-21 M/C 51P (Typical for KLX250S)

Rear Tire Size:

100/100-18 M/C 59P (Typical for KLX250S)

Wheel Bolt Pattern:

N/A (Spoked wheels with axle nuts)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS)

Active Features

Braking System:

Disc brakes front and rear, hydraulic actuation

Not available on this model

Passive Features

Lighting:

Halogen headlight, LED tail light, incandescent turn signals

💡 Technology Features

Infotainment

Infotainment System:

N/A (Motorcycle, basic instrumentation only)

Driver Assistance

Rider Aids:

N/A (No electronic rider aids like traction control or ABS)

Connectivity

Connectivity Features:

Engine Technology

Fuel Injection Vs Carburetion:

Utilizes a carburetor (CVK34), which is detailed thoroughly in the manual for maintenance and troubleshooting.

Engine Cooling:

Liquid-cooled, a more advanced system than many air-cooled counterparts, improving performance and reliability. The manual covers its maintenance.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 3 months, whichever comes first (Consult manual for exact interval and conditions)

Air Filter Cleaning Interval:

Every 6,000 km or as needed in dusty conditions (Consult manual for exact interval)

Spark Plug Replacement Interval:

Every 12,000 km or as needed (Consult manual for exact interval)

Chain Maintenance Interval:

Lubricate and adjust chain every 1,000 km or as needed (Consult manual for exact interval)

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (Consult manual for exact specification)

Coolant:

Kawasaki's Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water) (Consult manual for exact specification)

Fork Oil Type:

SAE 0W-20 or 10W (Consult manual for exact specification and volume)

Known Issues

Carburetor Performance:

Some users report lean conditions or flat spots, often addressed by rejetting or tuning the CVK34 carburetor, which the manual will detail.

Suspension Softness:

Stock suspension can be considered soft for aggressive off-road use, but the manual provides adjustment and rebuild procedures.

Cooling System Efficiency:

Proper coolant level and fan operation are critical, especially during sustained low-speed off-road riding. The manual covers checks and maintenance.

📚 Vehicle History

Brand Heritage

Kawasaki Off Road:

Kawasaki has a long and successful history in off-road motorcycling, including motocross and enduro racing, which informs the design of the KLX line.

Model Evolution

Klx Lineage:

The KLX250 has evolved over several generations, with the 2010 model representing a refinement of the design that emphasizes usability and off-road capability.

Sf Vs S:

The KLX250SA designation often refers to the standard 'S' model (dual-sport), while 'SF' models may feature different wheel configurations (e.g., 17-inch wheels for street). The manual likely covers variants of the KLX250.

Production

Manufacturing Location:

Primarily manufactured in Thailand for global markets.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the 2010 KLX250SA might not be widely publicized, the KLX lineage consistently receives positive reviews for its all-around capabilities and value in the dual-sport segment.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its segment, valued for its durability and ease of maintenance.