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Kawasaki KLX250 S SF 2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S / KLX250SF Year: 2009 Codes Chassis Code: KLX250V (for S variant), KLX250X (for SF variant) Engine Code: LX250J 👋 Introduction Market Position Vehicle Segment: Dual-sport / Off-road motorcycle Target Audience: Enthusiasts and owners seeking comprehensive maintenance and repair guidance Competitive Analysis Manual Value Proposition: Provides factory-level diagnostic and repair information, equivalent to what professional Kawasaki technicians use Key Features Manual Advantage: Authoritative and accurate information directly from the manufacturer Content Accuracy: Original workshop manual content ensures high accuracy and completeness 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, and maintenance for Kawasaki KLX250S and KLX250SF models Secondary Coverage: Diagnostic procedures, electrical system troubleshooting, wiring diagrams Page Count Page Count: 452 Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF Compatibility Operating Systems: All Versions of Windows & Mac Requirements Software Requirements: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly/disassembly, cylinder head, piston, crankshaft, valve train, lubrication, cooling, fuel system, ignition system Chassis Systems: Frame, front suspension (forks), rear suspension (shock absorber, linkage), steering, wheels, tires Braking System: Front and rear brake systems (disc brakes), hydraulic components, service and bleeding procedures Electrical System: Ignition system, lighting system, starting system, charging system, battery, wiring diagrams, troubleshooting electrical faults Bodywork And Trim: Fairings, fenders, seat, fuel tank, body panel removal and installation Power Supply: Battery, charging system, starter motor, electrical components Engine From Vehicle: Procedures for removing and reinstalling the engine from the chassis. Chassis Chas: Includes frame inspection, steering head bearing service, and general chassis components. Procedures Included Maintenance Procedures: Routine maintenance checks, oil changes, filter replacements, chain adjustment, brake pad inspection, fluid level checks, pre-delivery inspection Repair Procedures: Engine rebuilds, suspension overhaul, brake system repairs, electrical component replacement, carburetor servicing Troubleshooting Procedures: Systematic diagnostic steps for common and uncommon problems, fault codes, electrical troubleshooting charts Special Tools: Details on specialized tools required for specific repair and maintenance tasks. Pre Delivery: Information relevant to the initial setup and inspection of a new motorcycle before customer delivery. Technical Depth Diagnostic Capability: Comprehensive diagnostic information used by professional technicians Repair Detail Level: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and installation Diagrams And Illustrations: Hundreds of diagrams, schematics, and illustrations for clarity and precision 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within PDF for quick information retrieval Print Quality Print Readability: Designed for clarity and ease of reading when printed Binding Type Binding Type: Digital (PDF) - No physical binding Paper Type Paper Type: Not Applicable (Digital File) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single cylinder Displacement: 249 cc (249 cubic centimeters) Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower Estimated: Approximately 28-30 HP (specific dyno results may vary) Torque Estimated: Approximately 17-18 lb-ft (specific dyno results may vary) Fuel System Fuel Delivery: Carburetor (specific model varies by region, e.g., Keihin CVK34) Lubrication Oil Type Specification: API SG, SF or SE service classification, SAE 10W-40 viscosity recommended (refer to manual for precise specification) Oil Capacity With Filter: 1.7 L (1.8 US qt) Cooling System Cooling Method: Liquid-cooled Coolant Type: High-quality ethylene glycol based antifreeze coolant (refer to manual for specific type and mixture ratio) 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed Clutch Type: Wet, multiple-disc Features Final Drive: Sealed O-ring chain 📐 Dimensions Exterior Overall Length: KLX250S: 2,130 mm (83.9 in); KLX250SF: 2,115 mm (83.3 in) Overall Width: KLX250S: 805 mm (31.7 in); KLX250SF: 800 mm (31.5 in) Overall Height: KLX250S: 1,230 mm (48.4 in); KLX250SF: 1,170 mm (46.1 in) Wheelbase: KLX250S: 1,430 mm (56.3 in); KLX250SF: 1,415 mm (55.7 in) Weights Curb Weight: KLX250S: 135 kg (297.6 lbs); KLX250SF: 136 kg (300 lbs) Weight Distribution: Refer to manual for specific front/rear weight bias 🛡️ Safety Features Ratings Safety Certifications: EPA, CARB (model dependent) Active Features Braking System Type: Disc brakes front and rear (KLX250SF features larger front brake rotor) Suspension Type: Long-travel suspension designed for varied terrain Passive Features Lighting: Headlight, taillight, brake lights, turn signals 💡 Technology Features Infotainment Dashboard Display: Digital LCD instrument cluster with speedometer, tachometer, odometer, trip meter, clock, and indicator lights. Driver Assistance ABS: ABS was not standard on the 2009 KLX250S/SF models. Connectivity Connectivity Features: No advanced electronic connectivity features. 🔧 Maintenance Service Intervals Engine Oil Change: Every 2,000-3,000 km (1,250-1,875 miles) or 6 months, whichever comes first (refer to manual for exact interval) Air Filter Cleaning: Every 1,000-2,000 km (625-1,250 miles) or as needed depending on riding conditions Spark Plug Inspection: Every 3,000-5,000 km (1,875-3,125 miles) Chain Lubrication And Adjustment: Every 500-1,000 km (310-625 miles) and before long rides Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 brake fluid (refer to manual for precise specification)...
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Kawasaki KLX250 S SF 2009 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250S / KLX250SF
Year:
2009
Codes
Chassis Code:
KLX250V (for S variant), KLX250X (for SF variant)
Engine Code:
LX250J
👋 Introduction
Market Position
Vehicle Segment:
Dual-sport / Off-road motorcycle
Target Audience:
Enthusiasts and owners seeking comprehensive maintenance and repair guidance
Competitive Analysis
Manual Value Proposition:
Provides factory-level diagnostic and repair information, equivalent to what professional Kawasaki technicians use
Key Features
Manual Advantage:
Authoritative and accurate information directly from the manufacturer
Content Accuracy:
Original workshop manual content ensures high accuracy and completeness
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete service, repair, and maintenance for Kawasaki KLX250S and KLX250SF models
Secondary Coverage:
Diagnostic procedures, electrical system troubleshooting, wiring diagrams
Page Count
Page Count:
452
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
File Format:
PDF
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software Requirements:
Adobe PDF Reader
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine assembly/disassembly, cylinder head, piston, crankshaft, valve train, lubrication, cooling, fuel system, ignition system
Chassis Systems:
Frame, front suspension (forks), rear suspension (shock absorber, linkage), steering, wheels, tires
Braking System:
Front and rear brake systems (disc brakes), hydraulic components, service and bleeding procedures
Electrical System:
Ignition system, lighting system, starting system, charging system, battery, wiring diagrams, troubleshooting electrical faults
Bodywork And Trim:
Fairings, fenders, seat, fuel tank, body panel removal and installation
Power Supply:
Battery, charging system, starter motor, electrical components
Engine From Vehicle:
Procedures for removing and reinstalling the engine from the chassis.
Chassis Chas:
Includes frame inspection, steering head bearing service, and general chassis components.
Procedures Included
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, brake pad inspection, fluid level checks, pre-delivery inspection
Repair Procedures:
Engine rebuilds, suspension overhaul, brake system repairs, electrical component replacement, carburetor servicing
Troubleshooting Procedures:
Systematic diagnostic steps for common and uncommon problems, fault codes, electrical troubleshooting charts
Special Tools:
Details on specialized tools required for specific repair and maintenance tasks.
Pre Delivery:
Information relevant to the initial setup and inspection of a new motorcycle before customer delivery.
Technical Depth
Diagnostic Capability:
Comprehensive diagnostic information used by professional technicians
Repair Detail Level:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and installation
Diagrams And Illustrations:
Hundreds of diagrams, schematics, and illustrations for clarity and precision
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text within PDF for quick information retrieval
Print Quality
Print Readability:
Designed for clarity and ease of reading when printed
Binding Type
Binding Type:
Digital (PDF) - No physical binding
Paper Type
Paper Type:
Not Applicable (Digital File)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve single cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
72.0 x 61.2 mm
Compression Ratio:
11.0:1
Performance
Horsepower Estimated:
Approximately 28-30 HP (specific dyno results may vary)
Torque Estimated:
Approximately 17-18 lb-ft (specific dyno results may vary)
Fuel System
Fuel Delivery:
Carburetor (specific model varies by region, e.g., Keihin CVK34)
Lubrication
Oil Type Specification:
API SG, SF or SE service classification, SAE 10W-40 viscosity recommended (refer to manual for precise specification)
Oil Capacity With Filter:
1.7 L (1.8 US qt)
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
High-quality ethylene glycol based antifreeze coolant (refer to manual for specific type and mixture ratio)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed
Clutch Type:
Wet, multiple-disc
Features
Final Drive:
Sealed O-ring chain
📐 Dimensions
Exterior
Overall Length:
KLX250S: 2,130 mm (83.9 in); KLX250SF: 2,115 mm (83.3 in)
Overall Width:
KLX250S: 805 mm (31.7 in); KLX250SF: 800 mm (31.5 in)
Overall Height:
KLX250S: 1,230 mm (48.4 in); KLX250SF: 1,170 mm (46.1 in)
Wheelbase:
KLX250S: 1,430 mm (56.3 in); KLX250SF: 1,415 mm (55.7 in)
Weights
Curb Weight:
KLX250S: 135 kg (297.6 lbs); KLX250SF: 136 kg (300 lbs)
Weight Distribution:
Refer to manual for specific front/rear weight bias
🛡️ Safety Features
Ratings
Safety Certifications:
EPA, CARB (model dependent)
Active Features
Braking System Type:
Disc brakes front and rear (KLX250SF features larger front brake rotor)
Suspension Type:
Long-travel suspension designed for varied terrain
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals
💡 Technology Features
Infotainment
Dashboard Display:
Digital LCD instrument cluster with speedometer, tachometer, odometer, trip meter, clock, and indicator lights.
Driver Assistance
ABS:
ABS was not standard on the 2009 KLX250S/SF models.
Connectivity
Connectivity Features:
No advanced electronic connectivity features.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 2,000-3,000 km (1,250-1,875 miles) or 6 months, whichever comes first (refer to manual for exact interval)
Air Filter Cleaning:
Every 1,000-2,000 km (625-1,250 miles) or as needed depending on riding conditions
Spark Plug Inspection:
Every 3,000-5,000 km (1,875-3,125 miles)
Chain Lubrication And Adjustment:
Every 500-1,000 km (310-625 miles) and before long rides
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for precise specification)
Fork Oil Type:
Kawasaki KHL15-10 or equivalent (e.g., 10W fork oil) - 570 ml per leg (refer to manual for exact type and quantity)
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals due to off-road use.
Carburetor Tuning:
May require occasional carburetor tuning or cleaning for optimal performance, especially with aftermarket exhaust or airbox modifications.
Starter Solenoid:
Some users have reported occasional issues with the starter solenoid on higher mileage units, though this is not a widespread widespread problem.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing reliable and capable off-road and dual-sport motorcycles.
Model Evolution
Klx Lineage:
The KLX designation has been used by Kawasaki for decades to represent their range of off-road and dual-sport bikes, evolving from smaller displacement models to more capable machines.
2009 Klx250 Variants:
The 2009 model year introduced the KLX250S (dirt-biased dual-sport) and the KLX250SF (supermoto variant with street-focused tires and suspension) to cater to different riding preferences.
Production
Manufacturing Location:
Likely manufactured in Japan or Thailand (specific location may vary by region)
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The KLX250 series is generally well-regarded in the dual-sport community for its balance of on-road usability and off-road capability.
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