This manual covers the KLX250S and KLX250SF models from the second generation, produced between 2009 and 2014. These versatile dual-sport motorcycles are engineered for riders seeking capability in both on-road and off-road environments, offering a balance of performance and reliability. Key features include a modern fuel injection system for improved efficiency and response, and long-travel suspension designed for various terrains. The KLX250S, chassis code LX250V, and the KLX250SF, chassis code LX250W, represent a strong legacy in the dual-sport segment, providing dependable performance for adventure and everyday riding. This comprehensive workshop service repair manual in English provides detailed instructions for the maintenance, troubleshooting, and repair of your KLX250S/SF. It covers all major systems, including engine overhaul, transmission, chassis components, and electrical systems, along with specific procedures for regular maintenance, adjustments, and diagnostics. With detailed diagrams and step-by-step guidance, this manual is an essential resource for owners and technicians to ensure the optimal performance, longevity, and safe operation of their motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S / KLX250SF Model Variant: KLX250 Generation Generation Identifier: Second Generation (KLX250S/SF) Codes Chassis Codes: KLX250S: LX250V, KLX250SF: LX250W 👋 Introduction Market Position Segment: Dual-sport motorcycle Target Audience: Riders seeking a capable off-road and on-road versatile motorcycle for adventure and commuting. Competitive Analysis Key Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 Key Features Versatility: Designed for both on-road legal use and off-road trail riding. Fuel Injection: Modern fuel injection system for improved throttle response, fuel efficiency, and emissions. Suspension: Long-travel suspension for off-road capability, adjustable for rider preference. 📋 Manual Details Coverage Areas Covered Years: 2009, 2010, 2011, 2012, 2013, 2014 Page Count Estimated Page Count: Approx. 400-600 pages (typical for complete workshop manuals) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, assembly, disassembly, lubrication, cooling, ignition, fuel injection, emissions control. Transmission: Clutch operation, gearbox overhaul, gear shift mechanism, final drive (chain). Chassis: Frame, suspension (front fork, rear shock absorber), steering system, wheels, tires, braking system (front and rear). Electrical: Wiring diagrams, lighting system, starting system, charging system (alternator, battery), ignition system, fuel injection control, instrumentation, sensors. Bodywork: Body panels, seat, fuel tank, fenders, fairings, exhaust system. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, brake pad inspection and replacement. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics. Repair: Detailed step-by-step repair instructions for all major components and systems. Rebuilds: Complete engine and transmission rebuild procedures, including torque specifications and clearances. Adjustments: Carburetor (if applicable to specific market models, though FI is standard for this era), clutch, throttle, suspension settings. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and chassis overhauls. Diagnostic Capabilities: Includes diagnostic procedures, error code interpretation (if applicable to FI system), and specific troubleshooting trees. Component Level Detail: Provides detailed diagrams and specifications for individual components and sub-assemblies. 📊 Manual Specifications File Format PDF Quality: High-resolution scans or digital creation, ensuring clarity of text and diagrams. Searchability: Likely text-searchable PDF for quick information retrieval. Print Quality Printable: Designed to be printable, allowing for physical copies in a workshop environment. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder, liquid-cooled Displacement: 249 cc Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 22-24 HP (at crank, depending on market and tuning) Torque: Approx. 14-16 lb-ft (at crank, depending on market and tuning) Fuel System Fuel Delivery: Fuel Injection (DFI) Ignition: Digital CDI Carburetor Type: Not applicable (Fuel injected models) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-disc, cable operated Optional Optional Transmission: N/A Features Final Drive: Sealed chain, 14T front sprocket, 42T rear sprocket (typical). 📐 Dimensions Exterior Length: Approx. 2,235 mm (88.0 in) Width: Approx. 805 mm (31.7 in) Height: Approx. 1,165 mm (45.9 in) Wheelbase: Approx. 1,430 mm (56.3 in) Ground Clearance: Approx. 255 mm (10.0 in) Seat Height: Approx. 865 mm (34.1 in) Weights Curb Weight: Approx. 131 kg (289 lbs) - KLX250S Fuel Capacity: 7.7 L (2.0 US gal) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is primarily based on rider skill and design features). Active Features Brakes: Front: 250mm petal disc with dual-piston caliper; Rear: 240mm petal disc with single-piston caliper. ABS available on some models/markets. Lighting: Halogen headlight, LED taillight. Passive Features Frame Construction: Semi-double cradle, high-tensile steel. Tires: Tubeless or tube-type, typically dual-sport tread pattern. 💡 Technology Features Infotainment Infotainment System: Not applicable (Basic motorcycle instrumentation). Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on some models/markets for enhanced braking safety. Connectivity Connectivity Features: Not applicable. Instrumentation Dashboard Type: Digital LCD with analog tachometer. Included Displays: Speedometer, tachometer,...