Kawasaki KLX250VA 2010 Service Repair Workshop Manual
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The 2010 Kawasaki KLX250VA is a capable dual-sport motorcycle renowned for its versatility and robust engineering. Designed to excel in both off-road and light street riding conditions, this model builds upon Kawasaki's strong heritage in the dual-sport segment. It features a reliable four-stroke, liquid-cooled, 249 cc single-cylinder engine, known for its smooth power delivery and durability. The KLX250VA offers a comfortable riding position and ample ground clearance, making it suitable for tackling various terrains. Its intuitive handling and responsive suspension contribute to an enjoyable riding experience for enthusiasts and everyday riders alike. This comprehensive Service Repair Workshop Manual provides in-depth guidance for the maintenance, repair, and troubleshooting of the 2010 Kawasaki KLX250VA. Covering all essential systems, including the engine, fuel, ignition, cooling, exhaust, transmission, chassis, suspension, braking, and electrical systems, this manual offers detailed procedures. It includes routine service tasks, disassembly and assembly instructions, diagnostic flowcharts, component testing, and crucial torque specifications. The manual is designed to empower owners and technicians, ensuring the longevity and optimal performance of the vehicle through clear, step-by-step instructions and technical data. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250VA Year: 2010 Product Type: Service Repair Workshop Manual Codes Model Code Identifier: KLX250VA 👋 Introduction Market Position Vehicle Segment: Dual-sport / Off-road motorcycle. Target Audience: Enthusiasts and owners seeking detailed technical information for maintenance, repair, and performance tuning of their 2010 KLX250VA. Competitive Analysis Competitors 2010: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (though DR-Z is a slightly older platform). Key Features Klx250Va Heritage: Known for its off-road capability, reliable engine, and suitability for both trails and light street use. Manual Value Proposition: Provides professional-level repair and maintenance guidance, empowering owners to perform tasks themselves, saving on labor costs and ensuring proper upkeep. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, maintenance, and troubleshooting for the 2010 Kawasaki KLX250VA. Page Count Estimated Page Count: Refer to product listing for exact count; typically 300-500 pages for this type of manual. Manual Type Manual Classification: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, and repair; piston, rings, cylinder, crankshaft, camshaft, valves, timing. Fuel System: Carburetor (if applicable), fuel injection system (if applicable), fuel pump, fuel lines, filters, fuel tank. Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams. Cooling System: Radiator, fan, hoses, coolant, water pump. Exhaust System: Muffler, exhaust pipes, catalytic converter (if applicable). Transmission Drivetrain: Clutch operation, gear shifting mechanism, internal transmission components, drive chain, sprockets. Chassis Frame: Frame inspection, straightening, welding procedures, sub-frame. Suspension Front: Front fork assembly, seals, oil, springs, adjustments, steering head bearings. Suspension Rear: Rear shock absorber, linkage system (if applicable), swingarm, bushings, bearings. Braking System: Front and rear brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures. Wheels Tires: Wheel bearings, rim inspection, tire mounting, balancing. Electrical System: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, horn, instrumentation. Wiring Diagrams: Detailed electrical wiring diagrams for all systems. Bodywork Fittings: Fairings, seat, handlebars, controls, plastics, body panels, fasteners. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, inspections, lubrication points. Routine Service: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement. Disassembly Assembly: Step-by-step instructions for dismantling and reassembling major vehicle components. Troubleshooting: Diagnostic procedures for identifying and resolving common and uncommon problems. Component Testing: Procedures for testing the functionality and performance of various components. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for critical fasteners across all systems. Technical Depth Depth Level: Comprehensive, covering everything from basic checks to full engine rebuilds and electrical diagnostics. Diagnostic Capability: Advanced diagnostic information, fault codes (if applicable), and troubleshooting flowcharts. Rebuild Guidance: Detailed instructions and specifications for rebuilding engine, transmission, and suspension components. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Typically fully searchable text within the PDF for quick information retrieval. Print Quality Resolution: High resolution, suitable for clear printing of diagrams and text. Binding Type Binding Method: Not applicable (Digital PDF Download) Paper Type Paper Quality: Not applicable (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, single-cylinder. Displacement: 249 cc (Cubic Centimeters) Bore X Stroke: 72.0 mm x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower Estimated: Approximately 22-24 HP at 7,000-7,500 RPM (depending on market and specific tuning). Torque Estimated: Approximately 17-19 lb-ft at 6,000-6,500 RPM. Fuel System Fuel Delivery: Keihin CVK34 carburetor (standard on many global models; North American models may have FI variants). Fuel Type: Unleaded gasoline, minimum 87 octane. Lubrication Oil Type Specification: SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil. Oil Capacity With Filter: 1.7 Liters (approx. 1.8 US qt). 🔧 Transmission Standard Transmission Type: 6-speed constant...
The 2010 Kawasaki KLX250VA is a capable dual-sport motorcycle renowned for its versatility and robust engineering. Designed to excel in both off-road and light street riding conditions, this model builds upon Kawasaki's strong heritage in the dual-sport segment. It features a reliable four-stroke, liquid-cooled, 249 cc single-cylinder engine, known for its smooth power delivery and durability. The KLX250VA offers a comfortable riding position and ample ground clearance, making it suitable for tackling various terrains. Its intuitive handling and responsive suspension contribute to an enjoyable riding experience for enthusiasts and everyday riders alike.
This comprehensive Service Repair Workshop Manual provides in-depth guidance for the maintenance, repair, and troubleshooting of the 2010 Kawasaki KLX250VA. Covering all essential systems, including the engine, fuel, ignition, cooling, exhaust, transmission, chassis, suspension, braking, and electrical systems, this manual offers detailed procedures. It includes routine service tasks, disassembly and assembly instructions, diagnostic flowcharts, component testing, and crucial torque specifications. The manual is designed to empower owners and technicians, ensuring the longevity and optimal performance of the vehicle through clear, step-by-step instructions and technical data.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250VA
Year:
2010
Product Type:
Service Repair Workshop Manual
Codes
Model Code Identifier:
KLX250VA
👋 Introduction
Market Position
Vehicle Segment:
Dual-sport / Off-road motorcycle.
Target Audience:
Enthusiasts and owners seeking detailed technical information for maintenance, repair, and performance tuning of their 2010 KLX250VA.
Competitive Analysis
Competitors 2010:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (though DR-Z is a slightly older platform).
Key Features
Klx250Va Heritage:
Known for its off-road capability, reliable engine, and suitability for both trails and light street use.
Manual Value Proposition:
Provides professional-level repair and maintenance guidance, empowering owners to perform tasks themselves, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete service, repair, maintenance, and troubleshooting for the 2010 Kawasaki KLX250VA.
Page Count
Estimated Page Count:
Refer to product listing for exact count; typically 300-500 pages for this type of manual.
Approximately 22-24 HP at 7,000-7,500 RPM (depending on market and specific tuning).
Torque Estimated:
Approximately 17-19 lb-ft at 6,000-6,500 RPM.
Fuel System
Fuel Delivery:
Keihin CVK34 carburetor (standard on many global models; North American models may have FI variants).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Lubrication
Oil Type Specification:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Oil Capacity With Filter:
1.7 Liters (approx. 1.8 US qt).
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh, return type.
Final Drive:
O-ring sealed chain drive.
Features
Clutch Type:
Wet, multiple disc.
Transmission Oil Specification:
Same as engine oil: SAE 10W-40 API SG or higher, JASO MA certified.
📐 Dimensions
Exterior
Overall Length:
Approx. 2180 mm (85.8 in)
Overall Width:
Approx. 800 mm (31.5 in)
Overall Height:
Approx. 1195 mm (47.0 in)
Wheelbase:
Approx. 1430 mm (56.3 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Seat Height:
Approx. 865 mm (34.1 in)
Weights
Curb Weight:
Approx. 135 kg (298 lbs)
Fuel Tank Capacity:
11 Liters (2.9 US gal)
🛡️ Safety Features
Ratings
Crash Safety Rating:
Not applicable for this motorcycle type; safety relies on rider skill and adherence to safe operating practices.
Active Features
Braking System Type:
Disc brakes front and rear.
Tire Specification Front:
80/100-21 51P (Tube Type)
Tire Specification Rear:
110/100-18 64P (Tube Type)
Passive Features
Lighting System:
Halogen headlight, LED taillight, incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable (basic motorcycle instrumentation).
Driver Assistance
ABS Availability:
ABS was not standard or widely available on the 2010 KLX250VA model; check specific market variations.
Connectivity
Connectivity Features:
Not applicable.
Instrumentation
Dashboard Layout:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, indicator lights (neutral, turn signals, high beam, oil pressure).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months, or at every oil change if indicated by manual.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions.
Spark Plug Inspection:
Every 3,000 km (1,800 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) or after washing/rain.
Fluid Specifications
Coolant Type:
Permanent type ethylene glycol based coolant, pre-mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4.
Fork Oil Type Viscosity:
SAE 10W (refer to manual for exact quantity and level).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, steering head bearings.
Potential Issues 2010:
Carburetor jetting can sometimes be lean depending on altitude and modifications; occasional fuel pump issues (if FI equipped); stator failure on higher mileage units.
Maintenance Clarity
Manual Maintenance Detail:
The manual provides clear diagrams and step-by-step instructions for all scheduled maintenance tasks, ensuring correct procedures are followed.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long-standing history in motorcycle manufacturing, known for performance and innovation in various segments, including off-road and dual-sport.
Model Evolution
Klx Lineage:
The KLX series has been a staple for Kawasaki's off-road and dual-sport offerings, evolving over decades to meet changing rider demands and emissions standards. The KLX250 has seen various iterations, with the 2010 model representing a mature and capable iteration of the 250cc dual-sport platform.
Production
Manufacturing Location:
Typically manufactured in Japan or Thailand by Kawasaki Heavy Industries.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
While specific awards for the 2010 KLX250VA may not be widely documented, the KLX line is generally recognized for its versatility and reliability in the dual-sport category by motorcycle publications and riders.
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