The KLX250S, produced for the 2009 and 2010 model years, is a versatile dual-sport motorcycle designed for both on-road commuting and off-road trail riding. This lightweight machine features a liquid-cooled, DOHC, four-stroke, single-cylinder engine with Digital Fuel Injection (DFI) and dual throttle valves, delivering reliable performance. Its long-travel suspension, including inverted front forks and an adjustable rear monoshock, provides excellent off-road capability, while its semi-double cradle steel frame ensures durability. The KLX250S is known for its adaptability, making it a suitable choice for beginner to intermediate riders and those seeking a dependable machine for diverse riding conditions. This comprehensive repair service manual provides detailed instructions for the maintenance, repair, and troubleshooting of the 2009-2010 KLX250S. It covers all essential systems, including engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, and the electrical system. The manual includes maintenance procedures such as oil changes and valve clearance checks, as well as in-depth repair instructions with torque specifications and rebuild procedures for the engine and transmission. Additionally, it offers diagnostic guidance for common issues and technical specifications to assist professional technicians and skilled owners in maintaining the optimal performance and longevity of their KLX250S. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Model Years: 2009, 2010 Product Type: Repair Service Manual Product Format: PDF Download Codes Kawasaki Model Code Klx250S 2009: KLX250SBF Kawasaki Model Code Klx250S 2010: KLX250SDF 👋 Introduction Market Position Segment: Dual-sport motorcycle, lightweight, off-road capable with street legality Target Audience: Beginner to intermediate riders, commuters, recreational trail riders Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 Key Features Versatility: Adaptable for both on-road commuting and off-road trail riding Engine Type: Liquid-cooled, DOHC, four-stroke, single-cylinder with fuel injection Suspension Setup: Long-travel inverted front forks and adjustable rear monoshock for off-road capability Manual Purpose Purpose: Provide detailed instructions for maintenance, repair, and troubleshooting, primarily for professional technicians but accessible to informed owners. 📋 Manual Details Coverage Areas Primary Coverage: 2009-2010 Kawasaki KLX250S Secondary Coverage: Related components and systems Page Count Estimated Pages: Approximately 300-400 pages (typical for this model's service manual) Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Top end (cylinder, piston, valves), bottom end (crankshaft, connecting rod), lubrication system, cooling system Fuel System: Fuel injection system (EFI), throttle body, fuel pump, fuel injectors, evaporative emission control system Ignition System: Ignition coil, spark plug, ECU control, sensors Transmission: Clutch system, gearbox (gear shifting, internal components), lubrication Suspension: Front fork (inversion, damping, seals), rear shock absorber, linkages, adjustments Brakes: Front and rear disc brake systems, calipers, master cylinders, brake lines, bleeding procedures, pad replacement Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter system, fuses, relays, ECU diagnostics Chassis Body: Frame, subframe, wheels, tires, handlebars, footpegs, body panels, seat, fuel tank removal/installation Procedures Included Maintenance: Oil changes, filter replacements, chain maintenance, brake fluid changes, coolant checks, valve clearance checks Troubleshooting: Diagnostic procedures for common faults, error code interpretation (if applicable), symptom-based troubleshooting guides Repair: Component disassembly, assembly, and replacement procedures with torque specifications Rebuilds: Engine and transmission overhaul procedures Adjustments: Clutch lever, throttle cable, suspension settings, idle speed Technical Depth Depth: Comprehensive, intended for professional technicians but accessible to skilled DIY mechanics with appropriate tools Diagnostic Capabilities: Includes diagnostic procedures and potential troubleshooting steps for EFI systems 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval Print Quality Printability: Designed for digital viewing and printing of specific pages/sections Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single Displacement: 249 cc (249.7 cm3) Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Fuel Delivery: Digital Fuel Injection (DFI) with dual throttle valves Performance Horsepower Approx: Approximately 20-23 HP (stock, varies by market and measurement) Torque Approx: Approximately 14-16 lb-ft (stock, varies by market and measurement) Fuel System Fuel Type: Unleaded gasoline, 87 octane or higher recommended Fuel Tank Capacity: 2.1 US gallons (7.9 Liters) 🔧 Transmission Standard Transmission Type: Constant-mesh 6-speed return Clutch Type: Wet, multi-disc, cable-actuated Features Final Drive: Sealed chain drive Gear Ratios: Specific ratios documented in the manual Transmission Oil Type: Kawasakilubricant SAE 10W-40 (or equivalent API SG, SE) Transmission Oil Capacity: Approximately 1.7 US quarts (1.6 Liters) 📐 Dimensions Exterior Overall Length: Approx. 86.8 inches (2205 mm) Overall Width: Approx. 32.3 inches (820 mm) Overall Height: Approx. 49.4 inches (1255 mm) Wheelbase: Approx. 57.1 inches (1450 mm) Ground Clearance: Approx. 11.0 inches (280 mm) Weights Dry Weight: Approx. 253.5 lbs (115 kg) Curb Weight: Approx. 282.2 lbs (128 kg) Front Tire Size: 80/100-21 51P Rear Tire Size: 100/100-18 59P Wheel Type: Spoked wheels Wheelbase Type: Standard motorcycle wheelbase 🛡️ Safety Features Ratings Crash Test Results: Not...