The KLX250S, produced for the 2009-2010 model years, is a versatile dual-sport motorcycle designed to excel in both off-road and on-road environments. Built upon a reputation for robust engineering and reliability, this model offers a liquid-cooled, four-stroke, 249cc engine with DOHC and four valves, providing a balance of power and efficiency. Its long-travel, adjustable suspension system enhances its off-road capability, making it suitable for trail riding and light off-road adventures, while its street-legal features ensure it can also serve as a capable urban commuter. The KLX250S is recognized for its value and all-around performance in its competitive segment. This comprehensive Workshop Service Repair Manual provides complete service and repair information for the 2009-2010 KLX250S. It covers all major systems, including the engine, fuel system, ignition, cooling, transmission, suspension, brakes, and electrical systems, detailing everything from basic maintenance like oil changes and chain adjustments to complex procedures such as engine rebuilds and advanced diagnostics. The manual is designed to assist owners, mechanics, and technicians in maintaining, troubleshooting, and repairing the vehicle, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Year: 2009-2010 Codes Model Code: KLX250S 👋 Introduction Market Position Segment: Dual-sport motorcycle Target Audience: Off-road enthusiasts, light trail riders, urban commuters seeking versatility Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 Key Features Versatility: Capable both on-road and off-road Engine Type: Liquid-cooled, four-stroke, single-cylinder Suspension: Long-travel adjustable suspension for off-road capability 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Pages: Approx. 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Full engine disassembly, assembly, tuning, and diagnostics Fuel System: Carburetor (Keihin CVK34), fuel pump, fuel tank, lines Ignition System: CDI, spark plug, ignition timing Cooling System: Radiator, fan, coolant, water pump Transmission: Clutch, gearbox, gear shift mechanism, lubrication Suspension: Front forks (USD), rear shock absorber, linkage, adjustments Brakes: Front and rear disc brakes, hydraulic system, pad replacement, bleeding Electrical System: Wiring diagrams, battery, charging system, lighting, starter motor Chassis And Frame: Frame inspection, steering head bearings, swingarm Bodywork And Fittings: Fairings, seat, fuel tank, fenders, controls Procedures Included Maintenance: Oil change, filter replacement, chain adjustment, lubrication points Troubleshooting: Diagnostic charts for common problems, symptom analysis Repair: Step-by-step repair instructions for all major components Rebuilds: Complete engine and transmission rebuild procedures Adjustments: Carburetor tuning, valve clearance, suspension settings Technical Depth Depth: Comprehensive, suitable for professional mechanics and skilled DIY enthusiasts Diagnostic Level: Advanced diagnostics, including electrical testing and component analysis 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF Printability: Printable pages for easy workshop use Binding Type Type: N/A (Digital PDF Download) Paper Type Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single Displacement: 249 cc (250cc class) Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 25-28 HP (estimated, varies by region and tuning) Torque: Approx. 17-19 lb-ft (estimated) Fuel System Carburetor: Keihin CVK34 Fuel Capacity: 2.1 gal (7.9 L) 🔧 Transmission Standard Type: Constant-mesh, 6-speed Clutch: Wet, multi-disc Optional Type: N/A Features Gear Ratios: Refer to manual for specific ratios 📐 Dimensions Exterior Length: 85.2 in (2165 mm) Width: 32.5 in (825 mm) Height: 47.4 in (1205 mm) Wheelbase: 56.5 in (1435 mm) Ground Clearance: 11.6 in (295 mm) Weights Dry Weight: 262.4 lb (119 kg) Curb Weight: 280.0 lb (127 kg) (est.) Gvwr: N/A (Motorcycle) Payload Capacity: N/A (Motorcycle) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle) Active Features Brakes: Disc brakes (front and rear) for effective stopping power Lighting: Headlight, taillight, brake lights, turn signals for visibility Passive Features Chassis Design: Robust frame construction for stability Ergonomics: Comfortable rider positioning for control 💡 Technology Features Infotainment Features: N/A (Basic motorcycle instrumentation: speedometer, odometer, trip meter, neutral indicator, high beam indicator) Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles (4,800 km) or 6 months (refer to manual for specific recommendations) Air Filter Cleaning: Every 3,000 miles (4,800 km) or as needed based on conditions Chain Lubrication And Adjustment: Every 500 miles (800 km) or after washing/wet conditions Valve Clearance Check: Every 7,500 miles (12,000 km) Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or SH, JASO MA Engine Oil Capacity: 1.6 US qt (1.5 L) without filter change, 1.8 US qt (1.7 L) with filter change Coolant Type: High-quality ethylene glycol based coolant with distilled water (50/50 mix) Brake Fluid Type: DOT 4 Known Issues Common Problems: Potential for carburetor jetting adjustments for optimal performance in different altitudes/conditions, occasional cam chain tensioner noise, clutch lever play adjustment. Prevention: Adherence to scheduled maintenance, using correct fluids and parts, proper break-in procedures are key. 📚 Vehicle History Brand...