The 2010 KLX 250S (KLX250VA) is a versatile dual-sport motorcycle engineered for both on-road commuting and off-road trail riding. Building on a heritage of performance and durability, this model features a 249 cc liquid-cooled, four-stroke engine with Digital Fuel Injection, delivering reliable power for various riding conditions. Its long-travel suspension, including front forks and a rear shock, enhances its off-road capability, while disc brakes front and rear provide dependable stopping power. The KLX 250S offers a balanced blend of utility and adventure, making it a compelling choice for riders seeking a capable machine for diverse terrains. This comprehensive Workshop Service Manual provides detailed instructions for the repair and overhaul of the 2010 KLX 250S. Covering all essential systems, including the engine, transmission, fuel injection, ignition, lubrication, exhaust, electrical, bodywork, suspension, brakes, and cooling systems, this 558-page English-language guide is designed for technicians and owners alike. It offers step-by-step procedures for maintenance, removal and installation, assembly and disassembly, and troubleshooting, enabling efficient and accurate servicing. The manual's in-depth coverage ensures that users can effectively maintain and repair their vehicle, from routine tune-ups to complete component rebuilds, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX 250S Model Variant: KLX250VA Year: 2010 👋 Introduction Market Position Market Segment: Dual-sport motorcycle, versatile for on-road and off-road use Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S Key Features Versatility: Designed for both commuting and trail riding Suspension: Long-travel suspension for off-road capability Value Proposition Owner Benefit: Enables owners to perform maintenance and repairs, saving costs and gaining knowledge 📋 Manual Details Coverage Areas Primary Coverage: Repair and overhaul of Kawasaki KLX 250S KLX250VA 2010 Scope Of Repair: From routine maintenance to extensive engine and transmission disassembly and overhaul. Page Count Total Pages: 558 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, repair, and overhaul Transmission: Complete transmission disassembly, repair, and overhaul Fuel System: Fuel injection system, fuel pump, injectors, fuel tank, lines Ignition System: Ignition coil, spark plug, CDI unit, timing Lubrication System: Oil pump, oil passages, oil filter, oil change procedures Exhaust System: Exhaust pipes, muffler, catalytic converter (if applicable) Electrical System: Wiring diagrams, battery, charging system, lighting, starting system, sensors Bodywork: Fairings, seat, handlebars, fenders, fuel tank cover, frame components Suspension: Front forks (KYB SSS), rear shock absorber (Uni-Trak), adjustment procedures Brakes: Front and rear brake systems, caliper maintenance, fluid replacement, bleeding Cooling System: Radiator, fan, coolant, thermostat Wheels And Tires: Wheel bearing maintenance, tire replacement, rim specifications Chassis: Frame integrity, steering head bearings Procedures Included Maintenance: Tune-ups, routine servicing, oil changes, filter replacements, chain adjustment Removal Installation: Comprehensive removal and installation procedures for all major components Assembly Disassembly: Detailed step-by-step guides for component assemblies and disassemblies Troubleshooting: Diagnostic procedures for common issues and malfunctions Repair: In-depth repair instructions for all vehicle systems Proprietary Components: Includes instructions for proprietary Kawasaki components and guidance for manufacturer-specific repairs of sourced parts. Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds Assumed Knowledge: Technician fully conversant with general automobile practices, emphasis on product-specific aspects 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes, printable Binding Type Binding: Digital (PDF Download) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, four-valve, single-cylinder Displacement: 249 cc Bore X Stroke: 72.0 x 61.1 mm Cooling System: Liquid-cooled Performance Horsepower: Approx. 20-22 HP (varies by region/tuning) Torque: Approx. 13-15 lb-ft (varies by region/tuning) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) Fuel Type: Unleaded gasoline Lubrication System Oil Type: SAE 10W-40 API SG or SH motorcycle oil Oil Capacity: Approx. 1.7 liters (without filter change), 1.9 liters (with filter change) 🔧 Transmission Standard Type: 6-speed, constant mesh Features Clutch: Wet, multi-disc Final Drive: O-ring sealed chain Fluid Specifications Transmission Oil: Refer to engine oil specifications (shared sump) 📐 Dimensions Exterior Overall Length: 2,200 mm (86.6 in) Overall Width: 830 mm (32.7 in) Overall Height: 1,220 mm (48.0 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: Approx. 138 kg (304.2 lbs) Fuel Tank Capacity: 11.0 liters (2.9 US gal) 🛡️ Safety Features Ratings Safety Certifications: Meets relevant motorcycle safety standards (e.g., DOT, ECE for applicable markets) Active Features Brakes: Disc brakes front and rear for reliable stopping power Passive Features Lighting: Headlight, taillight, turn signals for visibility 💡 Technology Features Infotainment Display: Digital instrument cluster (speedometer, tachometer, odometer, trip meters, fuel gauge, clock) Driver Assistance ABS: ABS (Anti-lock Braking System) was an option on some models, but not standard for the 2010 KLX250S in all markets. Connectivity Connectivity Features: N/A (basic motorcycle technology) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6...