Kawasaki KLX250 D Tracker X Efi Motorcycle 2009-2012 Service & Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Kawasaki Model: KLX250 D-Tracker X EFI Model Designation: D-Tracker X Year: 2009-2012 Product Type: Service & Repair Workshop Manual Codes Engine Type: EFI (Electronic Fuel Injection) ๐ Introduction Market Position Target Audience: Kawasaki KLX250 D-Tracker X EFI owners, independent motorcycle repair shops, and professional technicians Purpose: To provide comprehensive guidance for maintaining, troubleshooting, and repairing the specified motorcycle model Competitive Analysis Value Proposition: Offers complete factory-level information at a fraction of the cost of dealer-specific services, with lifetime access and unlimited usage Key Features Feature 1: Detailed step-by-step repair instructions Feature 2: Extensive use of high-quality photos and diagrams Feature 3: Complete coverage of EFI system diagnostics and repair Feature 4: Lifetime access and unlimited device compatibility ๐ Manual Details Coverage Areas General Coverage: All repairs, servicing, and troubleshooting procedures Page Count Estimated Pages: Hundreds (specific number not provided, but described as comprehensive) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Delivery Method: Instant Download PDF File Format: PDF Licensing Licensing Terms: Lifetime use, no expiry dates, no renewal fees Device Compatibility: Multiple computers/devices (Windows & MAC) Printability Printing Capability: Yes, single pages or entire manual ๐ Manual Coverage Systems Covered Engine System: Fuel injection system, ignition system, lubrication, cooling, engine mechanical (disassembly/assembly), performance tuning Transmission System: Clutch, gearbox, shifting mechanisms, internal components, lubrication Chassis System: Frame, suspension (front forks, rear shock), steering, wheels, tires Braking System: Front and rear brakes (likely disc), hydraulic system, components, service Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, ignition switch, EFI control unit, sensors Fuel System: EFI system components (throttle body, injectors, fuel pump, sensors), fuel tank, fuel lines Bodywork And Trim: Fairings, seat, fenders, fuel tank cover, graphics, disassembly and reassembly Cooling System: Radiator, fan, coolant, hoses, thermostat (if applicable) Procedures Included Maintenance Procedures: Routine checks, oil changes, filter replacements, chain adjustment, brake pad inspection/replacement, spark plug service, air filter cleaning/replacement Repair Procedures: Engine rebuild, transmission overhaul, suspension servicing, brake caliper rebuilding, electrical component repair, body panel repair/replacement Troubleshooting Guides: Diagnosis of common problems, symptom-based fault finding, diagnostic trouble codes (DTCs) for EFI system Diagnostic Procedures: EFI system diagnostics, sensor testing, electrical system testing using multimeters and potentially specialized tools Assembly Disassembly: Detailed step-by-step instructions with exploded views for all major components and systems Technical Depth Depth Of Information: Comprehensive (factory-level detail), suitable for professional mechanics and advanced DIY enthusiasts Visual Aids: Hundreds of detailed photos and diagrams, exploded views ๐ Manual Specifications File Format PDF Quality: Professional quality, enabling clear viewing of text and images Searchability: Likely searchable text within the PDF, though not explicitly stated, which is standard for professional manuals Print Quality Print Output: High-quality output suitable for professional workshop use when printed Binding Type Binding When Printed: User dependent (spiral bound, binder, etc.), not applicable to digital format Paper Type Paper Type When Printed: User dependent, but content is designed for durability in a workshop environment โ๏ธ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, four-valve, single-cylinder Displacement: 249 cc (approximately) Bore X Stroke: Not explicitly provided, but typical for this class of engine (e.g., ~72mm x 61.2mm) Performance Horsepower: Typically around 22-24 HP at 7,500 RPM (varies by region and specific tuning) Torque: Typically around 21-23 Nm at 6,500 RPM (varies by region and specific tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Keihin throttle body Fuel Type: Unleaded gasoline Lubrication Oil Type: API SG or SH, SAE 10W-40 motorcycle oil (consult manual for specific recommendations) Cooling System Cooling Method: Liquid-cooled ๐ง Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-disc Features Final Drive: Sealed chain drive ๐ Dimensions Exterior Overall Length: Approx. 2,150 mm (84.6 in) Overall Width: Approx. 830 mm (32.7 in) Overall Height: Approx. 1,160 mm (45.7 in) Weights Curb Weight: Approx. 136 kg (299.8 lbs) Fuel Tank Capacity: Approx. 7.2 liters (1.9 US gal) ๐ก๏ธ Safety Features Ratings Safety Standards: Complies with relevant motorcycle safety standards for its production years Active Features Braking System: Disc brakes front and rear (ABS not typically standard on this model) Lighting: Halogen headlight, LED taillight/brake light Passive Features Frame Construction: High-tensile steel perimeter frame ๐ก Technology Features Infotainment Infotainment System: Not applicable for this motorcycle model (basic instrumentation). Driver Assistance ABS: ABS was not a standard feature on most KLX250 D-Tracker X models during this period. Connectivity Connectivity Features: Not applicable for this motorcycle model. Instrumentation Dashboard: Digital speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights. ๐ง Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6 months (refer to manual for exact specifications and severe service intervals) Air Filter Cleaning: Every 6,000 km (3,700 miles) or as needed based on riding conditions Spark Plug Replacement: Every 12,000 km (7,500 miles) (check manual for specific...
Diagnosis of common problems, symptom-based fault finding, diagnostic trouble codes (DTCs) for EFI system
Diagnostic Procedures:
EFI system diagnostics, sensor testing, electrical system testing using multimeters and potentially specialized tools
Assembly Disassembly:
Detailed step-by-step instructions with exploded views for all major components and systems
Technical Depth
Depth Of Information:
Comprehensive (factory-level detail), suitable for professional mechanics and advanced DIY enthusiasts
Visual Aids:
Hundreds of detailed photos and diagrams, exploded views
๐ Manual Specifications
File Format
PDF Quality:
Professional quality, enabling clear viewing of text and images
Searchability:
Likely searchable text within the PDF, though not explicitly stated, which is standard for professional manuals
Print Quality
Print Output:
High-quality output suitable for professional workshop use when printed
Binding Type
Binding When Printed:
User dependent (spiral bound, binder, etc.), not applicable to digital format
Paper Type
Paper Type When Printed:
User dependent, but content is designed for durability in a workshop environment
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, DOHC, four-valve, single-cylinder
Displacement:
249 cc (approximately)
Bore X Stroke:
Not explicitly provided, but typical for this class of engine (e.g., ~72mm x 61.2mm)
Performance
Horsepower:
Typically around 22-24 HP at 7,500 RPM (varies by region and specific tuning)
Torque:
Typically around 21-23 Nm at 6,500 RPM (varies by region and specific tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Keihin throttle body
Fuel Type:
Unleaded gasoline
Lubrication
Oil Type:
API SG or SH, SAE 10W-40 motorcycle oil (consult manual for specific recommendations)
Cooling System
Cooling Method:
Liquid-cooled
๐ง Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc
Features
Final Drive:
Sealed chain drive
๐ Dimensions
Exterior
Overall Length:
Approx. 2,150 mm (84.6 in)
Overall Width:
Approx. 830 mm (32.7 in)
Overall Height:
Approx. 1,160 mm (45.7 in)
Weights
Curb Weight:
Approx. 136 kg (299.8 lbs)
Fuel Tank Capacity:
Approx. 7.2 liters (1.9 US gal)
๐ก๏ธ Safety Features
Ratings
Safety Standards:
Complies with relevant motorcycle safety standards for its production years
Active Features
Braking System:
Disc brakes front and rear (ABS not typically standard on this model)
Lighting:
Halogen headlight, LED taillight/brake light
Passive Features
Frame Construction:
High-tensile steel perimeter frame
๐ก Technology Features
Infotainment
Infotainment System:
Not applicable for this motorcycle model (basic instrumentation).
Driver Assistance
ABS:
ABS was not a standard feature on most KLX250 D-Tracker X models during this period.
Connectivity
Connectivity Features:
Not applicable for this motorcycle model.
Instrumentation
Dashboard:
Digital speedometer, tachometer, odometer, trip meter, fuel gauge, clock, and indicator lights.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months (refer to manual for exact specifications and severe service intervals)
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or as needed based on riding conditions
Spark Plug Replacement:
Every 12,000 km (7,500 miles) (check manual for specific plug type and gap)
Chain Adjustment:
Regularly, or every 1,000 km (600 miles)
Fluid Specifications
Engine Oil Capacity:
Approx. 1.5 liters (1.6 US qt) without filter change, 1.7 liters (1.8 US qt) with filter change (verify in manual)
Coolant Type:
Ethylene glycol-based coolant mixed with distilled water (50/50 ratio recommended)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Tires, brake pads, chain and sprockets, clutch plates (depending on usage)
Efi System Considerations:
Ensuring clean fuel, checking injector spray patterns, and proper sensor readings are crucial for EFI performance.
๐ Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long and successful history in motorcycle manufacturing, known for performance and reliability across various segments.
Model Evolution
Klx Lineage:
The KLX series represents Kawasaki's range of dual-sport and off-road motorcycles, known for their versatility. The D-Tracker variant focuses on street-legal supermoto styling.
Production
Production Period Covered:
2009, 2010, 2011, 2012 model years
๐ Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2009-2012 D-Tracker X aren't widely documented, Kawasaki's KLX line generally receives praise for its off-road capability and dual-sport versatility. The EFI system enhanced its refinement and efficiency.