This manual covers the KLX250, a versatile dual-sport motorcycle offered in KLX250S and KLX250SF (D-Tracker) variants, specifically for the 2009 through 2012 model years. Built upon extensive off-road heritage, the KLX250 features a liquid-cooled, 4-stroke, 249 cc engine with fuel injection, delivering approximately 24-27 horsepower. Its robust engineering ensures reliability, making it suitable for both on-road commuting and off-road adventures. Notable features include a 6-speed transmission, hydraulic disc brakes on both wheels, and an optional ABS system on certain models. The digital LCD instrument cluster provides essential riding information, complementing the motorcycle's practical design. This comprehensive factory service repair manual, presented in English, provides detailed guidance for owners and technicians. It covers all essential aspects of the KLX250, including in-depth maintenance procedures for scheduled servicing, fluid changes, and component replacements, as well as step-by-step repair instructions for complete disassembly and reassembly of all major systems. The manual also offers troubleshooting guides for diagnosing and resolving common and uncommon issues. With hundreds of pages and numerous photos and illustrations, this manual is an invaluable resource for maintaining the KLX250's performance and longevity, offering a cost-effective alternative to professional servicing. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Model Variant: KLX250S / KLX250SF (D-Tracker) Generation Generation Code: KLX250 (Gen 2) Codes Chassis Code Early: KLX250V 👋 Introduction Market Position Target Audience: Do-it-yourselfers and experienced mechanics Competitive Analysis Advantage Over Print: Less expensive, more convenient, searchable, printable on demand Key Features Content Detail: Hundreds of pages with hundreds of photos and illustrations, step-by-step instructions Value Proposition: Inexpensive way to keep vehicle working properly, saves money on mechanic fees Convenience: Speed download, no expiry dates, access from multiple devices 📋 Manual Details Coverage Areas Years Covered: 2009, 2010, 2011, 2012 Page Count Estimated Pages: Hundreds (Specific count not provided, but implies extensive detail) Manual Type Type: Complete Official Full Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: General Information, Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission Chassis: Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Frame Electrical: Electrical System Appendices: Appendix (Likely includes specifications, wiring diagrams, troubleshooting charts) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, general upkeep Repair: Step-by-step instructions for disassembly and reassembly of all major components Troubleshooting: Diagnostic procedures for common and uncommon issues Technical Depth Depth: Complete disassembly of the machine, hundreds of photos and illustrations for detailed guidance 📊 Manual Specifications File Format Compatibility: All Versions of Windows AND Mac Accessibility: Accessible via Adobe PDF Reader and Web Browser on PC/Mobile Devices Print Quality Printability: Yes, individual pages or entire manual can be printed Binding Type Binding Type: Digital (PDF) - No physical binding Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single Displacement: 249 cc Bore X Stroke: 72.0 x 61.1 mm Compression Ratio: 11.0:1 Performance Horsepower: Approximately 24-27 HP (Varies by market and tuning) Torque: Approximately 17-18 lb-ft (Varies by market and tuning) Fuel System Fuel Delivery: Fuel Injection (EFI) Fuel Type: Unleaded gasoline Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Transmission: N/A Features Clutch Type: Wet, multi-disc, manual 📐 Dimensions Exterior Overall Length: Approx. 2,235 mm (88.0 in) Overall Width: Approx. 800 mm (31.5 in) Overall Height: Approx. 1,165 mm (45.9 in) Wheelbase: Approx. 1,430 mm (56.3 in) Weights Curb Weight: Approx. 137 kg (302 lbs) Fuel Capacity: Approx. 7.7 L (2.0 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle - specific crash ratings not applicable in the same way as cars) Active Features Braking System Front: Hydraulic disc Braking System Rear: Hydraulic disc ABS: Optional on some models/markets (e.g., KLX250SF often featured ABS) Passive Features Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Instrument Cluster: Digital LCD instrument cluster (Speedometer, Tachometer, Odometer, Trip Meter, Clock, Fuel Gauge, Coolant Temperature Warning) Driver Assistance ABS Availability: Optional ABS on certain models/markets Connectivity Connectivity Features: N/A (Motorcycle of this era does not feature modern connectivity) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-6,000 km (1,800-3,700 miles) or 6-12 months, refer to manual for precise intervals based on usage. Air Filter Cleaning: Recommended to check and clean every 3,000-6,000 km (1,800-3,700 miles) or as needed based on riding conditions. Spark Plug Replacement: Typically every 12,000-18,000 km (7,500-11,000 miles). Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil Engine Oil Capacity: Approx. 1.6 L (1.7 US qt) without filter change; Approx. 1.8 L (1.9 US qt) with filter change. Coolant Type: High-quality ethylene glycol-based coolant (50/50 mix with distilled water) Known Issues Common Wear Items: Chain and sprockets, brake pads, tires, clutch plates (with high mileage/aggressive use), fork seals. Potential Reliability: Generally considered a reliable platform,...