The KLX250SA, a 2010 model year dual-sport motorcycle, is engineered for versatility, adeptly handling both on-road commuting and off-road exploration. Renowned for its reliable four-stroke, DOHC, single-cylinder engine, this model offers a balance of performance and durability. Its design caters to riders seeking a capable machine for diverse riding conditions, from city streets to challenging trails, embodying a heritage of producing robust and user-friendly motorcycles. This comprehensive workshop service manual provides essential information for the maintenance, diagnosis, and repair of your 2010 KLX250SA. It covers all major systems, including detailed procedures for engine disassembly and assembly, fuel and ignition systems, transmission, drivetrain, suspension, brakes, and electrical systems. The manual also includes crucial maintenance schedules, troubleshooting guides, technical specifications, and information on special tools, serving as an indispensable resource for owners and technicians to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 👋 Introduction Market Position Vehicle Category: Dual-sport motorcycle, known for its versatility on and off-road. Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S. Key Features Target Audience: Riders seeking a capable and reliable machine for commuting, trail riding, and light adventure touring. Manual Value Proposition: Essential resource for owners and technicians to maintain, diagnose, and repair the Kawasaki KLX250SA, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Page Count: 558 Format: PDF Download Language: English 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair of all internal and external components, including cylinder head, piston, crankshaft, camshaft, valves, timing system, and cooling system. Fuel System: Carburetor system diagnosis, cleaning, adjustment, and overhaul; fuel tank, fuel pump, and fuel lines maintenance and replacement. Ignition System: CDI unit, ignition coil, spark plug, and wiring checks, testing, and replacement. Transmission: Clutch operation, disassembly, assembly, inspection, and adjustment; gearbox internal inspection, lubrication, and repair. Drivetrain: Chain and sprocket inspection, adjustment, and replacement; rear wheel hub and bearing service. Suspension: Front fork (telescopic) disassembly, inspection, seal replacement, oil level and type specifications; rear shock absorber inspection and service. Brakes: Front and rear brake system diagnosis, pad replacement, caliper overhaul, master cylinder service, brake fluid type and bleeding procedures. Electrical System: Wiring diagrams for all circuits, battery testing and maintenance, charging system (stator, regulator/rectifier) testing, lighting system, instrumentation, and starter motor troubleshooting. Chassis And Bodywork: Frame inspection, handlebar, seat, fuel tank, fenders, and side cover removal and installation procedures. Wheels And Tires: Tire pressure recommendations, wheel bearing inspection and lubrication, spoke tension adjustment. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacement, chain lubrication, brake adjustments, and general inspection procedures. Troubleshooting: Comprehensive diagnostic charts and flowcharts for identifying and resolving common issues across all vehicle systems. Repair: Detailed step-by-step instructions for disassembling, repairing, and reassembling all major components and sub-assemblies. Specifications: Torque specifications for all fasteners, engine tolerances, fluid capacities, electrical component specifications, and measurement data. Special Tools: Identification of any special tools required for specific repair or maintenance procedures. Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine rebuilds and complex electrical diagnostics). 📊 Manual Specifications File Format File Type: PDF Searchable: Yes Printable: Yes Quality: High-resolution scans for clear text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder, liquid-cooled Displacement: 249 cc (15.2 cu in) Bore X Stroke: 72.0 x 61.1 mm (2.8 x 2.4 in) Compression Ratio: 11.0:1 Performance Horsepower: Approximately 22 hp @ 7,500 rpm (varies by region and tuning) Torque: Approximately 15 lb-ft @ 6,000 rpm (varies by region and tuning) Fuel System Carburetor: Keihin FCR32 (Flat CR - Constant Velocity Rectangular) with acceleration pump Fuel Tank Capacity: 2.4 US gal (9.1 L) Lubrication System Oil Type: API SG or SH, SAE 10W-40, JASO MA certified motorcycle oil Oil Capacity With Filter Change: 1.7 L (1.8 US qt) Cooling System Coolant Type: Permanent type anti-freeze, 50% solution in distilled water (Kawasaki Coolant recommended) Ignition System Spark Plug Type: NGK CR8E or equivalent Spark Plug Gap: 0.7 - 0.8 mm (0.028 - 0.031 in) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-disc Final Drive: Sealed chain (520) Features Clutch Fluid: DOT 3 or DOT 4 brake fluid 📐 Dimensions Exterior Overall Length: 2,150 mm (84.6 in) Overall Width: 830 mm (32.7 in) Overall Height: 1,205 mm (47.4 in) Wheelbase: 1,430 mm (56.3 in) Ground Clearance: 255 mm (10.0 in) Seat Height: 875 mm (34.4 in) Weights Curb Weight: 132 kg (291 lbs) Front Tire Size: 80/100-21 51P Rear Tire Size: 100/100-18 59P Wheel Bolt Pattern: N/A (Spoked wheels) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles typically not subject to standardized automotive crash testing like cars) Active Features Brakes: Disc brakes front and rear. (ABS not...