Kawasaki KLX250 D Tracker X Motorcycle 2009-2012 Service Repair Workshop Manual Pdf
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 D-Tracker X Year: 2009-2012 Product Type: Service Repair Workshop Manual Format: Digital Download (PDF) 👋 Introduction Market Position Target Audience: Kawasaki KLX250 D-Tracker X owners and independent motorcycle technicians. Competitive Analysis Value Proposition: Provides professional-level repair and maintenance information at a fraction of the cost of dealership-specific manuals or labor. Key Features Content Depth: Comprehensive coverage mirroring factory service manuals used by authorized Kawasaki technicians. Accessibility: Instant download, usable on any computer or smart device. 📋 Manual Details Coverage Areas Engine Servicing: Complete Transmission Servicing: Complete Electrical System: Complete Chassis Maintenance: Complete Suspension System: Complete Brake System: Complete Fuel System: Complete Cooling System: Complete Exhaust System: Complete Troubleshooting: Comprehensive Page Count Estimated Pages: Hundreds Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Type: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, inspection, repair, and reassembly of all engine components including cylinder, piston, crankshaft, camshaft, valves, and timing. Fuel Injection System: Component testing, diagnostics, cleaning, and calibration of fuel injectors, throttle body, fuel pump, and ECU. Ignition System: Inspection and testing of spark plugs, ignition coils, ECU ignition control, and related wiring. Transmission And Drivetrain: Clutch operation, gearbox inspection and repair, final drive chain and sprocket maintenance, and lubrication specifications. Suspension And Steering: Front fork (USD) disassembly, seal replacement, oil level and type specifications, rear shock absorber adjustment and maintenance, steering head bearing service. Braking System: Front and rear brake caliper overhaul, brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder inspection. Electrical System: Wiring diagrams, component testing for headlights, taillights, turn signals, starter motor, battery charging system, and instrument cluster. Cooling System: Radiator inspection, fan operation, coolant type and capacity, thermostat replacement, and bleeding the cooling system. Frame And Bodywork: Component removal and installation for fairings, seat, fuel tank, fenders, and chassis component torque specifications. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake fluid checks, tire pressure, and general inspection points. Engine Rebuilds: Step-by-step instructions for complete engine disassembly and reassembly, including torque values and clearances. Troubleshooting Guides: Diagnostic flowcharts and common problem identification for starting issues, running problems, electrical faults, and performance degradation. Suspension Tuning: Guidance on adjusting front and rear suspension for different riding conditions. Electrical Diagnostics: Testing sensors, actuators, and wiring harnesses using multimeters and diagnostic tools. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, fault code interpretation (if applicable), and component testing. Repair Complexity: Covers everything from simple bolt-on replacements to full engine and transmission overhauls. Illustrations And Diagrams: Hundreds of detailed photos and exploded diagrams for visual guidance. 📊 Manual Specifications File Format Compatibility: Windows & MAC compatible Print Quality Printable: Yes, single pages or the entire manual Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Licensing Usage Rights: Unlimited use on multiple devices, lifetime access ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single cylinder Displacement: 249 cc (249cm3) Performance Bore X Stroke: 72.0 x 61.1 mm Compression Ratio: 11.0:1 Horsepower Approximate: Approx. 22-24 HP (at crankshaft, depending on market tuning) Torque Approximate: Approx. 19-21 Nm (at crankshaft, depending on market tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 87 octane (91 RON) Ignition Ignition System: Digital CDI Lubrication Oil Capacity With Filter Change: 1.7 L (1.8 US qt) Recommended Oil Type: SAE 10W-40, API SG or higher, JASO MA or MA2 Cooling Cooling Method: Liquid-cooled Coolant Capacity: 1.0 L (1.1 US qt) Recommended Coolant: Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with distilled water (50:50 mix) 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed Clutch Type: Wet, multi-disc, cable operated Final Drive: Sealed chain Gear Ratios: (Refer to manual for specific ratios: 1st, 2nd, 3rd, 4th, 5th, 6th) Lubricant Transmission Oil Type: API GL-4 SAE 80W gear oil (typically shared with engine oil for wet clutch) 📐 Dimensions Exterior Overall Length: Approx. 2,140 mm (84.3 in) Overall Width: Approx. 830 mm (32.7 in) Overall Height: Approx. 1,165 mm (45.9 in) Wheelbase: Approx. 1,430 mm (56.3 in) Ground Clearance: Approx. 255 mm (10.0 in) Weights Curb Weight: Approx. 138 kg (304.2 lbs) Fuel Tank Capacity: 7.7 L (2.0 US gal) 🛡️ Safety Features Ratings Safety Features: Disc brakes front and rear for reliable stopping power. Active Features Braking System Front: 250 mm petal-style disc with dual-piston caliper Braking System Rear: 240 mm petal-style disc with dual-piston caliper Passive Features Lighting: Halogen headlight, LED taillight, LED turn signals. 💡 Technology Features Infotainment Instrument Cluster: Digital LCD instrument cluster displaying speedometer, tachometer, odometer, trip meters, clock, and fuel gauge. Driver Assistance ABS Availability: Anti-lock Braking System (ABS) was typically an optional feature or not available on this specific D-Tracker X model, refer to manual for confirmation. Connectivity Connectivity Features: N/A...
Kawasaki KLX250 D-Tracker X owners and independent motorcycle technicians.
Competitive Analysis
Value Proposition:
Provides professional-level repair and maintenance information at a fraction of the cost of dealership-specific manuals or labor.
Key Features
Content Depth:
Comprehensive coverage mirroring factory service manuals used by authorized Kawasaki technicians.
Accessibility:
Instant download, usable on any computer or smart device.
📋 Manual Details
Coverage Areas
Engine Servicing:
Complete
Transmission Servicing:
Complete
Electrical System:
Complete
Chassis Maintenance:
Complete
Suspension System:
Complete
Brake System:
Complete
Fuel System:
Complete
Cooling System:
Complete
Exhaust System:
Complete
Troubleshooting:
Comprehensive
Page Count
Estimated Pages:
Hundreds
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
File Type:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly of all engine components including cylinder, piston, crankshaft, camshaft, valves, and timing.
Fuel Injection System:
Component testing, diagnostics, cleaning, and calibration of fuel injectors, throttle body, fuel pump, and ECU.
Ignition System:
Inspection and testing of spark plugs, ignition coils, ECU ignition control, and related wiring.
Transmission And Drivetrain:
Clutch operation, gearbox inspection and repair, final drive chain and sprocket maintenance, and lubrication specifications.
Suspension And Steering:
Front fork (USD) disassembly, seal replacement, oil level and type specifications, rear shock absorber adjustment and maintenance, steering head bearing service.
Braking System:
Front and rear brake caliper overhaul, brake pad replacement, brake fluid specifications and bleeding procedures, master cylinder inspection.
Electrical System:
Wiring diagrams, component testing for headlights, taillights, turn signals, starter motor, battery charging system, and instrument cluster.
Cooling System:
Radiator inspection, fan operation, coolant type and capacity, thermostat replacement, and bleeding the cooling system.
Frame And Bodywork:
Component removal and installation for fairings, seat, fuel tank, fenders, and chassis component torque specifications.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake fluid checks, tire pressure, and general inspection points.
Engine Rebuilds:
Step-by-step instructions for complete engine disassembly and reassembly, including torque values and clearances.
Troubleshooting Guides:
Diagnostic flowcharts and common problem identification for starting issues, running problems, electrical faults, and performance degradation.
Suspension Tuning:
Guidance on adjusting front and rear suspension for different riding conditions.
Electrical Diagnostics:
Testing sensors, actuators, and wiring harnesses using multimeters and diagnostic tools.
Covers everything from simple bolt-on replacements to full engine and transmission overhauls.
Illustrations And Diagrams:
Hundreds of detailed photos and exploded diagrams for visual guidance.
📊 Manual Specifications
File Format
Compatibility:
Windows & MAC compatible
Print Quality
Printable:
Yes, single pages or the entire manual
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Licensing
Usage Rights:
Unlimited use on multiple devices, lifetime access
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Displacement:
249 cc (249cm3)
Performance
Bore X Stroke:
72.0 x 61.1 mm
Compression Ratio:
11.0:1
Horsepower Approximate:
Approx. 22-24 HP (at crankshaft, depending on market tuning)
Torque Approximate:
Approx. 19-21 Nm (at crankshaft, depending on market tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 87 octane (91 RON)
Ignition
Ignition System:
Digital CDI
Lubrication
Oil Capacity With Filter Change:
1.7 L (1.8 US qt)
Recommended Oil Type:
SAE 10W-40, API SG or higher, JASO MA or MA2
Cooling
Cooling Method:
Liquid-cooled
Coolant Capacity:
1.0 L (1.1 US qt)
Recommended Coolant:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with distilled water (50:50 mix)
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed
Clutch Type:
Wet, multi-disc, cable operated
Final Drive:
Sealed chain
Gear Ratios:
(Refer to manual for specific ratios: 1st, 2nd, 3rd, 4th, 5th, 6th)
Lubricant
Transmission Oil Type:
API GL-4 SAE 80W gear oil (typically shared with engine oil for wet clutch)
📐 Dimensions
Exterior
Overall Length:
Approx. 2,140 mm (84.3 in)
Overall Width:
Approx. 830 mm (32.7 in)
Overall Height:
Approx. 1,165 mm (45.9 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Weights
Curb Weight:
Approx. 138 kg (304.2 lbs)
Fuel Tank Capacity:
7.7 L (2.0 US gal)
🛡️ Safety Features
Ratings
Safety Features:
Disc brakes front and rear for reliable stopping power.
Active Features
Braking System Front:
250 mm petal-style disc with dual-piston caliper
Braking System Rear:
240 mm petal-style disc with dual-piston caliper
Passive Features
Lighting:
Halogen headlight, LED taillight, LED turn signals.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD instrument cluster displaying speedometer, tachometer, odometer, trip meters, clock, and fuel gauge.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was typically an optional feature or not available on this specific D-Tracker X model, refer to manual for confirmation.
Connectivity
Connectivity Features:
N/A (Basic motorcycle electronics, no integrated Bluetooth or smartphone connectivity).
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,000 km (1,864 miles) or 6 months, whichever comes first.
Oil Filter Change Interval:
Every 6,000 km (3,728 miles) or 12 months, or with every oil change.
Air Filter Cleaning Interval:
Every 3,000 km (1,864 miles) or 6 months.
Spark Plug Replacement Interval:
Every 6,000 km (3,728 miles) or 12 months.
Chain Adjustment Inspection:
Every 1,000 km (621 miles).
Fluid Specifications
Brake Fluid:
DOT 4
Fork Oil Type:
Showas fork oil SS-8 or equivalent (Refer to manual for specific viscosity and fill level)
Known Issues
Common Wear Items:
Clutch plates, brake pads, front fork seals, and chain/sprockets due to typical riding conditions.
Potential Electrical Gremlins:
While generally reliable, intermittent issues with wiring connectors or charging system components can occur with age and exposure.
Fuel System Maintenance:
Regular cleaning of the fuel filter and injector service is recommended to maintain optimal performance from the EFI system.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long history of producing durable and capable off-road and dual-sport motorcycles, with the KLX lineage being a prominent example of performance and versatility.
Model Evolution
Klx Lineage:
The KLX250 series evolved from earlier dual-sport models, with the D-Tracker variant specifically designed with Supermoto styling, featuring larger wheels and street-oriented tires for enhanced on-road agility.
Production
Manufacturing Period:
The KLX250 D-Tracker X was produced for the specific model years of 2009 through 2012, with variations in specifications potentially existing across global markets.
🏆 Awards & Recognition
Recognitions
Model Segment Awards:
While specific awards for the 2009-2012 KLX250 D-Tracker X are not widely documented, the KLX line generally receives accolades for its versatility and performance in the lightweight dual-sport and supermoto segments.