Kawasaki KLX250SA 2010 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 Codes Internal Model Code: KLX250SA 👋 Introduction Market Position Segment: Dual-sport / Off-road motorcycle Target Audience: Owners, mechanics, and enthusiasts...

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类型: Motorcycle

斯库: 76809

标签: 2010 Kawasaki KLX250SA Misc Motorcycle Motorcycles

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Description

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KLX250SA

Year:

Codes

Internal Model Code:

KLX250SA

👋 Introduction

Market Position

Segment:

Dual-sport / Off-road motorcycle

Target Audience:

Owners, mechanics, and enthusiasts seeking detailed repair and maintenance information for the 2010 Kawasaki KLX250SA.

Competitive Analysis

Key Competitors Segment:

Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250

Key Features

Klx250Sa Model Description:

A versatile and lightweight dual-sport motorcycle, known for its off-road capability and street-legal compliance. Features a liquid-cooled, four-stroke engine and a capable suspension system.

📋 Manual Details

Coverage Areas

All Models Engines Trims Transmissions:

Page Count

Estimated Pages:

Estimated 300-500 pages (typical for this type of manual)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, torque specifications, cylinder head, piston, crankshaft, connecting rod, valves, camshafts, timing.

Fuel System:

Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, lines.

Ignition System:

Ignition coils, spark plugs, CDI unit, crankshaft position sensor, ignition timing.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant hoses, coolant type.

Exhaust System:

Exhaust pipes, muffler, catalytic converter, O2 sensors.

Transmission Drivetrain:

Clutch operation, gearbox disassembly and assembly, gear ratios, shift mechanism, final drive (chain and sprockets), lubrication.

Suspension Front:

Front fork (upside-down), fork oil type and level, seals, bushings, spring rates, adjustments.

Suspension Rear:

Rear shock absorber, linkage system, swingarm, bearings, adjustments.

Brakes Front:

Brake caliper, master cylinder, brake pads, brake disc, brake fluid type and bleeding procedure.

Brakes Rear:

Rear brake caliper, master cylinder, brake pads, brake disc, brake fluid type and bleeding procedure.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure specifications, tire size recommendations, spoke tensioning.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays.

Instrumentation Controls:

Dashboard, speedometer, tachometer, indicator lights, handlebar controls, throttle operation.

Chassis Frame:

Frame inspection, steering head bearings, swingarm pivot.

Bodywork Plastics:

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

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, air filter cleaning/replacement, spark plug checks, brake pad inspection.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues, error code explanations (if applicable).

Repair Procedures:

Step-by-step instructions for component removal, installation, and overhaul of major systems.

Diagnostic Charts:

Flowcharts and tables to help identify and resolve problems.

Technical Data Tables:

Torque specifications, fluid capacities, clearances, electrical resistances, diagnostic values.

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to complete engine rebuilds and system diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically text-searchable PDF for quick information retrieval.

Print Quality

Print Readability:

Designed for clear printing of diagrams and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, four-stroke, DOHC, four-valve single cylinder

Displacement:

249 cc (15.2 cu in)

Bore X Stroke:

72.0 x 61.2 mm (2.83 x 2.41 in)

Compression Ratio:

11.0:1

Performance

Horsepower:

Approx. 22-24 HP (at crankshaft, actual may vary)

Torque:

Approx. 15-17 lb-ft (at crankshaft, actual may vary)

Fuel System

Fuel Delivery:

Digital Fuel Injection (DFI) with Keihin 34mm throttle body

Fuel Type:

Unleaded gasoline, 87 octane or higher

Lubrication

Oil Type:

SAE 10W-40 API SG or SH with JASO MA certification

Oil Capacity With Filter:

1.7 L (1.8 US qt)

Oil Capacity Without Filter:

1.5 L (1.6 US qt)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, return shift

Features

Clutch Type:

Wet, multi-disc, cable operated

Final Drive:

Sealed chain, RK520KXO, 14T front sprocket, 50T rear sprocket

📐 Dimensions

Exterior

Length:

2,180 mm (85.8 in)

Width:

820 mm (32.3 in)

Height:

1,190 mm (46.9 in)

Wheelbase:

1,430 mm (56.3 in)

Ground Clearance:

255 mm (10.0 in)

Seat Height:

865 mm (34.1 in)

Weights

Curb Weight:

136 kg (299.8 lbs)

Fuel Capacity:

7.7 L (2.0 US gal)

Front Tire Size:

80/100-21M/C 51P

Rear Tire Size:

100/100-18M/C 59P

Wheel Bolt Pattern:

N/A (Spoked wheels, hub-mounted)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle safety ratings typically not applicable in the same way as cars)

Active Features

Braking System:

Front: 250mm petal disc with dual-piston caliper; Rear: 240mm petal disc with dual-piston caliper.

Lighting:

Halogen headlight, LED taillight, standard turn signals.

Passive Features

Frame Construction:

High-tensile steel semi-double cradle frame for strength and rigidity.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Not standard on this model year KLX250SA

Connectivity

Connectivity Features:

Instrumentation

Dashboard Features:

Digital LCD display featuring speedometer, odometer, trip meter, clock, and indicator lights for turn signals, high beam, neutral, and low oil pressure.

🔧 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 Inspection Cleaning:

Every 1,000 miles (1,600 km) or 3 months; Clean/replace as needed

Spark Plug Check Replacement:

Inspect every 4,000 miles (6,000 km); Replace as needed, typically every 8,000-12,000 miles (12,000-20,000 km)

Chain Lubrication Adjustment:

Every 500 miles (800 km) or after washing/wet riding

Valve Clearance Inspection:

Every 15,000 miles (24,000 km)

Fluid Specifications

Brake Fluid:

DOT 4

Coolant Type:

High-quality ethylene glycol-based coolant with demineralized water (50/50 mix)

Fork Oil Type:

Kawasaki KSH10W-40 (or equivalent SAE 10W fork oil)

Fork Oil Level:

110 mm (4.3 in) from top of inner tube when fully compressed

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, tires, fork seals, wheel bearings are common wear items due to the nature of dual-sport riding.

Efi Specific Considerations:

Potential for clogged injectors if fuel quality is poor; regular fuel system cleaning recommended. Check for intake air leaks.

Suspension Care:

Regular fork seal checks and dust boot maintenance are crucial, especially with off-road use. Rear shock linkage bearings require periodic cleaning and greasing.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation in performance motorcycles, including a significant history in off-road and dual-sport segments with its KLX line.

Model Evolution

Klx Series Development:

The KLX250 line has evolved over decades, starting with carbureted models and progressing to fuel-injected versions like the 2010 model, offering improved performance and emissions.

Production

Manufacturing Location:

Japan (Primary, though specific plant may vary by year/region)

🏆 Awards & Recognition

Recognitions

Model Awards:

Kawasaki KLX models are generally well-regarded for their reliability and off-road prowess in their segment, often receiving positive reviews from riding publications.