Kawasaki KLX250 D-TRACKER X 2009-2012 Service Repair Manual
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Basic Information Identification Make: Kawasaki Model: KLX250 D-TRACKER X Model Code: KLX250E (likely, based on year and model) Production Years: 2009, 2010, 2011, 2012 Vehicle Type: Dual-sport Motorcycle Introduction Market Position Target Audience: Kawasaki KLX250 D-TRACKER X owners (2009-2012), independent repair shops, DIY mechanics Value Proposition: Cost savings on maintenance and repairs, empowerment for owners to perform their own work, access to professional-grade information Competitive Analysis Competitor Manuals: Haynes, Clymer (often less detailed than factory service manuals) Key Features Authenticity: Exact same information used by authorized dealer service departments Comprehensiveness: Covers all major topics for repair and troubleshooting User Friendliness: Clear, concise text with diagrams and illustrations for ease of understanding Manual Details Coverage Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Printability: Yes (all pages) Digital Compatibility: PC, Mac, Phones, E-readers (e.g., Kindle) Software Requirements: Adobe PDF Reader Manual Coverage Systems Engine Service: Complete overhaul, disassembly, reassembly, inspection Fuel System: Carburetor (likely), fuel pump, fuel lines, fuel filter, fuel tank Cooling System: Radiator, coolant, fan, hoses, thermostat Transmission: Gearbox, clutch, internal components, inspection, repair Drive Train: Drive chain, sprockets (front and rear), adjustment, replacement Electrical System: Ignition, charging system, lighting, battery, starter motor, wiring diagrams Suspension: Front forks (USD), rear shock absorber, adjustment, rebuild, service Steering System: Handlebars, steering stem, bearings, fork yokes, adjustment, repair Braking System: Front and rear disc brakes, calipers, master cylinders, fluid replacement, bleeding Bodywork: Fairings, fenders, seat, fuel tank, plastics, disassembly, reassembly Intake And Exhaust: Airbox, carburetor intake, exhaust system, muffler, catalyst (if applicable) Procedures Routine Maintenance: Oil changes, filter replacements, chain lubrication, tire pressure checks Periodic Checks And Adjustments: Valve clearance, clutch, throttle cables, brake levers Troubleshooting: Diagnostic procedures for common and advanced issues Engine Removal And Installation: Step-by-step guide for engine R&I Wiring Schematics: Detailed electrical system diagrams for diagnosis and repair Technical Depth Diagnostic Procedures: Advanced troubleshooting techniques Repair Instructions: Step-by-step repair guides with diagrams and illustrations Specifications: Torque values, clearances, fluid capacities, electrical data Illustrations And Diagrams: Comprehensive visual aids for all procedures Manual Specifications File Details File Format: PDF Searchable Text: Likely, as standard for professional PDF manuals Page Count: Not specified in product info, but implied to be comprehensive (typical for service manuals range from 300-800+ pages) Production Quality Print Quality: High-resolution, suitable for printing Binding Type: N/A (Digital PDF) Paper Type: N/A (Digital PDF) Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve Single Cylinder Displacement: 249 cc Bore X Stroke: 72.0 x 61.1 mm Compression Ratio: 11.0:1 Performance Horsepower: Approximately 20-23 HP (varied slightly by market and tuning) Torque: Approximately 14-16 lb-ft (varied slightly by market and tuning) Fuel System Fuel Delivery: Fuel Injection (EFI) - Keihin throttle body (likely 34mm) Fuel Type: Unleaded gasoline Lubrication Oil Type: API SG or SH, SAE 10W-40 or 10W-50 (refer to manual for exact spec) Oil Capacity: Approximately 1.6 L (without filter change), 1.8 L (with filter change) - verify in manual Transmission Standard Type: 6-speed constant mesh Optional Type: N/A Features Clutch Type: Wet, multiple disc Transmission Oil Type: API GL-1 or GL-3, SAE 80 or 80W-90 (verify in manual) Transmission Oil Capacity: Approximately 0.7 L - verify in manual Dimensions Exterior Overall Length: Approximately 2,170 mm (verify in manual) Overall Width: Approximately 810 mm (verify in manual) Overall Height: Approximately 1,190 mm (verify in manual) Wheelbase: Approximately 1,430 mm (verify in manual) Weights Dry Weight: Approximately 130 kg (verify in manual) Curb Weight: Approximately 138 kg (verify in manual) Safety Features Ratings Crash Test Ratings: N/A (Motorcycle specific, not subject to automotive crash testing standards) Active Features Braking System: Front and rear disc brakes (dual piston front, single piston rear) Lighting: Halogen headlight, LED taillight and brake light Passive Features Frame Construction: Perimeter frame (high-tensile steel) Ergonomics: Designed for rider control and comfort during dual-sport riding Technology Features Infotainment Instrument Cluster: Digital LCD display with speedometer, tachometer, odometer, trip meter, clock, fuel gauge, and indicator lights. Driver Assistance ABS: Not typically equipped on this model, but some later iterations or regional variants might have offered it. The manual would specify if ABS is present. Connectivity Bluetooth Or Usb: N/A (This era of motorcycle does not feature modern connectivity options like Bluetooth or USB ports). Maintenance Service Intervals Engine Oil Change: Every 4,000 km or 6 months (refer to manual for precise intervals) Oil Filter Replacement: Every 8,000 km or 12 months, or with every oil change (refer to manual) Air Filter Cleaning/Replacement: Every 4,000 km (cleaning), 8,000 km (replacement) - depends on riding conditions Spark Plug Replacement: Every 8,000 - 16,000 km (refer to manual) Valve Clearance Check: Every 8,000 km or 12 months (refer to manual) Fluid Specifications Engine Oil: API SG or SH, SAE 10W-40 or 10W-50 (verify in manual) Transmission Oil: API GL-1 or GL-3, SAE 80 or 80W-90 (verify...
Diagnostic procedures for common and advanced issues
Engine Removal And Installation:
Step-by-step guide for engine R&I
Wiring Schematics:
Detailed electrical system diagrams for diagnosis and repair
Technical Depth
Diagnostic Procedures:
Advanced troubleshooting techniques
Repair Instructions:
Step-by-step repair guides with diagrams and illustrations
Specifications:
Torque values, clearances, fluid capacities, electrical data
Illustrations And Diagrams:
Comprehensive visual aids for all procedures
Manual Specifications
File Details
File Format:
PDF
Searchable Text:
Likely, as standard for professional PDF manuals
Page Count:
Not specified in product info, but implied to be comprehensive (typical for service manuals range from 300-800+ pages)
Production Quality
Print Quality:
High-resolution, suitable for printing
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 4-valve Single Cylinder
Displacement:
249 cc
Bore X Stroke:
72.0 x 61.1 mm
Compression Ratio:
11.0:1
Performance
Horsepower:
Approximately 20-23 HP (varied slightly by market and tuning)
Torque:
Approximately 14-16 lb-ft (varied slightly by market and tuning)
Fuel System
Fuel Delivery:
Fuel Injection (EFI) - Keihin throttle body (likely 34mm)
Fuel Type:
Unleaded gasoline
Lubrication
Oil Type:
API SG or SH, SAE 10W-40 or 10W-50 (refer to manual for exact spec)
Oil Capacity:
Approximately 1.6 L (without filter change), 1.8 L (with filter change) - verify in manual
Transmission
Standard
Type:
6-speed constant mesh
Optional
Type:
N/A
Features
Clutch Type:
Wet, multiple disc
Transmission Oil Type:
API GL-1 or GL-3, SAE 80 or 80W-90 (verify in manual)
Transmission Oil Capacity:
Approximately 0.7 L - verify in manual
Dimensions
Exterior
Overall Length:
Approximately 2,170 mm (verify in manual)
Overall Width:
Approximately 810 mm (verify in manual)
Overall Height:
Approximately 1,190 mm (verify in manual)
Wheelbase:
Approximately 1,430 mm (verify in manual)
Weights
Dry Weight:
Approximately 130 kg (verify in manual)
Curb Weight:
Approximately 138 kg (verify in manual)
Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle specific, not subject to automotive crash testing standards)
Active Features
Braking System:
Front and rear disc brakes (dual piston front, single piston rear)
Lighting:
Halogen headlight, LED taillight and brake light
Passive Features
Frame Construction:
Perimeter frame (high-tensile steel)
Ergonomics:
Designed for rider control and comfort during dual-sport riding
Technology Features
Infotainment
Instrument Cluster:
Digital LCD display with speedometer, tachometer, odometer, trip meter, clock, fuel gauge, and indicator lights.
Driver Assistance
ABS:
Not typically equipped on this model, but some later iterations or regional variants might have offered it. The manual would specify if ABS is present.
Connectivity
Bluetooth Or Usb:
N/A (This era of motorcycle does not feature modern connectivity options like Bluetooth or USB ports).
Maintenance
Service Intervals
Engine Oil Change:
Every 4,000 km or 6 months (refer to manual for precise intervals)
Oil Filter Replacement:
Every 8,000 km or 12 months, or with every oil change (refer to manual)
Air Filter Cleaning/Replacement:
Every 4,000 km (cleaning), 8,000 km (replacement) - depends on riding conditions
Spark Plug Replacement:
Every 8,000 - 16,000 km (refer to manual)
Valve Clearance Check:
Every 8,000 km or 12 months (refer to manual)
Fluid Specifications
Engine Oil:
API SG or SH, SAE 10W-40 or 10W-50 (verify in manual)
Transmission Oil:
API GL-1 or GL-3, SAE 80 or 80W-90 (verify in manual)
Brake Fluid:
DOT 4 (verify in manual)
Coolant:
Ethylene glycol-based coolant, 50% mixture with distilled water (verify in manual)
Known Issues
Common Problems:
While generally reliable, common issues can include occasional carburetor jetting issues (on pre-EFI models), clutch wear, and standard wear and tear on suspension and bearings. The EFI system on this model is generally robust.
Common Maintenance Tasks
Self Service Potential:
Oil changes, air filter maintenance, chain adjustment/lubrication, spark plug replacement, brake fluid flush are all readily serviceable by owners with basic tools and this manual.
Vehicle History
Brand Heritage
Kawasaki Motorcycle History:
Kawasaki Heavy Industries is a long-standing Japanese manufacturer with a rich history in motorcycle production, known for performance and innovation.
Model Evolution
Klx Lineage:
The KLX series has a history of dirt-oriented and dual-sport motorcycles. The KLX250 has seen various iterations and updates over the years, with this generation (2009-2012) representing a modern iteration with fuel injection and improved styling.
Production
Manufacturing Location:
Likely manufactured in Japan or Thailand (common for Kawasaki models).
Awards & Recognition
Recognitions
Model Awards:
Specific awards for the 2009-2012 KLX250 D-TRACKER X are not prominently documented, but the KLX line generally receives positive reviews for its versatility and off-road capability.