Target Audience:
Kawasaki KLX250 owners, independent motorcycle repair shops, and DIY mechanics seeking detailed service information.
Value Proposition:
Provides OEM-level repair information at a fraction of the cost of official dealer manuals, enabling significant cost savings on maintenance and repairs.
Completeness:
100% complete and intact, ensuring no critical information is missing for effective servicing.
Ease Of Use:
User-friendly PDF format with clear language and sequential procedures for easy understanding and application.
Accessibility:
Instant download feature provides immediate access to critical repair data.
Coverage Scope:
Comprehensive repair and service information for the Kawasaki KLX250
Section Coverage:
General Information, Diagnosis, Testing, Adjustments, Removal, Installation, Disassembly, Assembly, Troubleshooting, Specifications, Torque Values, Wear Limits, Maintenance
Type:
Workshop Service Manual
Delivery Method:
Instant Download
Engine:
Engine disassembly, assembly, inspection, adjustments, overhaul, lubrication system, cooling system, fuel system (including fuel injection system diagnostics), ignition system, exhaust system.
Transmission:
Clutch operation and adjustment, gearbox disassembly, assembly, inspection, lubrication, shift mechanism.
Chassis:
Frame inspection, front fork (suspension) disassembly, assembly, servicing, rear suspension (shock absorber and linkage) servicing, steering system maintenance, wheel and tire servicing, brake system (front and rear) overhaul, adjustment, bleeding, hydraulic system.
Electrical:
Battery maintenance, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system (headlight, taillight, turn signals), ignition system troubleshooting, wiring diagrams, instrument panel, sensors, ECU diagnostics.
Bodywork:
Body panel removal and installation, seat servicing, fuel tank maintenance, fairing and plastics repair and fitting.
Maintenance Procedures:
Routine maintenance, periodic service checks, oil changes, filter replacements, chain adjustment, brake pad inspection/replacement, spark plug checks, valve clearance adjustments.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Troubleshooting:
Diagnostic procedures for common problems, fault finding trees, symptom-based troubleshooting.
Special Tools:
Identification and usage instructions for specialized Kawasaki service tools required for specific repair operations.
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete engine and transmission rebuilds.
Illustrations:
Detailed exploded diagrams, line drawings, and photographs to guide repair procedures.
Data Accuracy:
Includes precise specifications, tolerances, torque values, and fluid types based on factory data.
Readability:
High-resolution PDF ensuring clear text and legible diagrams.
Printable:
Yes, all pages are printable for on-the-job use.
Software Requirement:
Adobe Reader or compatible PDF viewer.
Binding:
Digital (PDF Download)
Paper Type:
N/A (Digital Format)
Operating Systems:
Compatible with Windows, Mac, and Linux operating systems.
Engine Type:
Four-stroke, DOHC, four-valve, single-cylinder
Displacement:
249 cc (249 cm³)
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Cooling System:
Liquid-cooled
Horsepower Estimated:
Approximately 30-32 hp (figures vary by market and specific tuning)
Torque Estimated:
Approximately 18-20 lb-ft (figures vary by market and specific tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Valvetrain:
DOHC, 4 valves per cylinder
Overall Length:
Approximately 2,120 mm (83.5 in)
Overall Width:
Approximately 800 mm (31.5 in)
Overall Height:
Approximately 1,150 mm (45.3 in)
Wheelbase:
Approximately 1,420 mm (55.9 in)
Ground Clearance:
Approximately 255 mm (10.0 in)
Curb Weight:
Approximately 132 kg (291 lbs)
Fuel Tank Capacity:
11 Liters (2.9 US gal)
Safety Standards:
Meets or exceeds relevant motorcycle safety standards for its production years.
Braking System:
Disc brakes front and rear. Optional ABS available on some models/markets, though not explicitly stated for all 2009-2012 base models.
Suspension:
Adjustable front forks and rear shock absorber for optimized handling and stability.
Lighting:
Halogen headlight, LED taillight, turn signals.
Instrument Cluster:
Digital LCD instrument cluster including speedometer, tachometer, odometer, trip meters, fuel gauge, clock, and indicator lights.
ABS Availability:
ABS was an optional feature on some models during these years. The manual will detail ABS system components and diagnostics if equipped.
ECU Diagnostics:
The EFI system includes an ECU that can be diagnosed using Kawasaki's diagnostic tools, information for which is likely detailed in the manual.
Oil Change Interval:
Recommended every 3,000-6,000 km (1,800-3,700 miles) or 6 months, depending on riding conditions (refer to manual for specific recommendation).
Valve Adjustment Interval:
Recommended every 10,000-12,000 km (6,200-7,500 miles) (refer to manual for specific recommendation).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment recommended (e.g., every 500-1000 km).
Engine Oil Type:
JASO MA certified 4-stroke motorcycle oil, SAE 10W-40 recommended (check manual for precise specification).
Coolant Type:
High-quality ethylene glycol-based coolant with antifreeze and anti-corrosion properties (refer to manual for specific type and mixture ratio).
Common Wear Items:
Clutch plates, brake pads, tires, chain and sprockets are common wear items that require periodic inspection and replacement.
Potential Issues:
Some owners have reported potential issues with fuel pump longevity, starter solenoid reliability, and occasional minor electrical gremlins. Proper maintenance and adherence to manual procedures mitigate these risks.
Kawasaki Legacy:
Kawasaki has a long and respected history in motorcycle manufacturing, known for performance and innovation across various segments, including off-road and dual-sport motorcycles.
Klx Lineage:
The KLX250 model has evolved over the years, with updates often focusing on engine performance, fuel injection systems, suspension improvements, and emissions compliance. The 2009-2012 models represent a significant iteration, incorporating fuel injection for improved efficiency and performance.
Manufacturing Location:
Primarily manufactured in Japan.
