Kawasaki KLX250S / KLX250SF Service Manual Repair 2009-2014 KLX250
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S / KLX250SF Model Variants: KLX250S (Dual Sport), KLX250SF (Supermoto) Applicable Years: 2009-2014 (KLX250S), 2009-2010 (KLX250SF) Codes Engine Codes: KLX250 (Specific engine code not provided in product info, but typically shared across variants) 👋 Introduction Market Position Target Audience: Owners, DIY mechanics, and professional technicians working on Kawasaki KLX250S and KLX250SF models. Product Category: Motorcycle Service Manuals Competitive Analysis Value Proposition: Provides comprehensive factory-level repair and maintenance information for a specific range of popular dual-sport and supermoto motorcycles, offering a cost-effective alternative to dealership service. Key Features Content Breadth: Covers virtually all aspects of the motorcycle from basic maintenance to complete engine rebuilds. Format Convenience: Instant digital download with searchability and printable capabilities enhances usability. 📋 Manual Details Coverage Areas Coverage Years: 2009, 2010, 2011 (implied for S variant), 2012, 2013, 2014 Models Covered: KLX250S (Dual Sport), KLX250SF (Supermoto) Page Count Page Count: 451 pages Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, top-end rebuild, piston, connecting rod, crankshaft, cylinder, valve clearance adjustment, cams, valves, spark plug, ignition system, fuel injection system (EFI/PGM-FI), fuel pump, fuel system, air intake, lubrication, cooling system, exhaust system. Transmission Drivetrain: Transmission overhaul, gears, clutches, primary reduction gear, drive train, clutch operation, gearbox. Chassis Suspension: Frame, suspension (front forks, rear shock/strut, linkage), steering system, wheels, tires, swingarm, triple clamps. Electrical Electronics: Electrical system, charging system, battery, starter motor, ignition coil, magneto, rectifier, switches, lights, fuse box, wiring diagrams (implied by 'no spark' troubleshooting). Braking Controls: Brake system (front and rear), brake pads, brake rotors, hydraulic systems, throttle cable, gearshift operation. Bodywork Plastics: Body panels, fenders, seats, fuel tank, general bodywork. Procedures Included General Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication, fluid checks, tire pressure, chain adjustment. Troubleshooting: Diagnostic procedures, 'no spark' issues, engine starting problems, error code diagnosis (implied), electrical troubleshooting, fuel system issues. Rebuilding Overhauling: Complete engine tear-down and rebuild, transmission rebuild, suspension overhaul, brake system overhaul. Adjustment Calibration: Carburetor mixture screw adjustment (if applicable to specific models, though EFI is prominent), idle speed adjustment, valve clearance adjustment, suspension adjustments. Installation Replacement: Part replacement procedures, installation instructions for major components. Technical Depth Depth Of Information: Comprehensive; covers complete tear-down and rebuild, including detailed diagrams and specifications. Visual Aids: Includes pictures and part diagrams. Specification Detail: Provides torque specifications, fluid types, and other critical technical data. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text Print Quality: Printable without restrictions Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Usage Features Navigation: Clickable chapters File Management: No restrictions on saving/burning to disc Support Replacement Policy: Free replacement if lost ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, four-valve, single-cylinder Displacement: 249 cc (249 cm³) Bore X Stroke: 72.0 x 61.2 mm (typical for this generation KLX250) Compression Ratio: 11.0:1 (typical for this generation KLX250) Cooling System: Liquid-cooled Performance Horsepower: Approximately 22-24 hp @ 8,000 rpm (varies by year/spec) Torque: Approximately 15-17 lb-ft @ 7,000 rpm (varies by year/spec) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin (specific model varies) Fuel Type: Unleaded gasoline Fuel Capacity: Typically around 2.0 - 2.5 gallons (7.7 - 9.5 liters), varies by specific model variant. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-disc Final Drive: O-ring sealed chain Features Gear Ratios: Detailed gear ratios are available within the manual's transmission section. Lubrication: Engine oil lubricates the transmission. 📐 Dimensions Exterior Length: Approx. 86.8 in (2,195 mm) for KLX250S, 86.0 in (2,185 mm) for KLX250SF (typical) Width: Approx. 32.1 in (815 mm) for KLX250S, 34.1 in (865 mm) for KLX250SF (typical) Height: Approx. 46.7 in (1,185 mm) for KLX250S, 46.7 in (1,185 mm) for KLX250SF (typical) Wheelbase: Approx. 56.7 in (1,440 mm) Ground Clearance: Approx. 11.2 in (285 mm) for KLX250S, 7.1 in (180 mm) for KLX250SF (typical) Weights Dry Weight: Approx. 267 lbs (121 kg) for KLX250S, 271 lbs (123 kg) for KLX250SF (typical) Curb Weight: Approx. 288.9 lbs (131 kg) for KLX250S (typical) 🛡️ Safety Features Ratings Safety Standards: Complies with applicable motorcycle safety regulations for its production era. Active Features Braking System: Disc brakes front and rear (standard). Lighting: Headlight, taillight, brake lights, turn signals (standard). Passive Features Frame Construction: High-tensile steel perimeter frame designed for stability and handling. 💡 Technology Features Infotainment Infotainment System: Basic analog/digital dashboard with speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment features. Driver Assistance ABS: ABS was not standard on all models during this period; some later or specific variants may have offered it as an option. Connectivity Connectivity Features: No built-in Bluetooth or smartphone connectivity. 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,700 miles (6,000...
KLX250 (Specific engine code not provided in product info, but typically shared across variants)
👋 Introduction
Market Position
Target Audience:
Owners, DIY mechanics, and professional technicians working on Kawasaki KLX250S and KLX250SF models.
Product Category:
Motorcycle Service Manuals
Competitive Analysis
Value Proposition:
Provides comprehensive factory-level repair and maintenance information for a specific range of popular dual-sport and supermoto motorcycles, offering a cost-effective alternative to dealership service.
Key Features
Content Breadth:
Covers virtually all aspects of the motorcycle from basic maintenance to complete engine rebuilds.
Format Convenience:
Instant digital download with searchability and printable capabilities enhances usability.
📋 Manual Details
Coverage Areas
Coverage Years:
2009, 2010, 2011 (implied for S variant), 2012, 2013, 2014
High-tensile steel perimeter frame designed for stability and handling.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog/digital dashboard with speedometer, tachometer, odometer, trip meter, and indicator lights. No advanced infotainment features.
Driver Assistance
ABS:
ABS was not standard on all models during this period; some later or specific variants may have offered it as an option.
Connectivity
Connectivity Features:
No built-in Bluetooth or smartphone connectivity.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months (refer to manual for exact specification).
Oil Filter Replacement:
Recommended at each oil change (refer to manual for part number).
Air Filter Cleaning:
Inspect every 3,700 miles (6,000 km); clean or replace as needed.
Valve Clearance Check:
Every 7,500 miles (12,000 km) or 12 months (refer to manual for exact specification).
Fluid Specifications
Engine Oil Type:
API SG, SH, SJ, SL or SMA, SAE 10W-40 (verify specific viscosity based on ambient temperature).
Coolant Type:
Permanent type coolant (antifreeze) mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 4 (verify specific requirement for consistency).
Known Issues
Common Wear Items:
Clutch wear, chain and sprockets, brake pads, suspension seals can be common wear items on dual-sport motorcycles depending on usage.
Potential Problems:
Some owners have reported occasional issues with the fuel pump or minor electrical connections in older models, which this manual would help diagnose.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing robust and capable off-road and dual-sport motorcycles, dating back to models like the KLR and KDX series.
Model Evolution
Klx Lineage:
The KLX250 lineage has evolved over many years, with the 250S and 250SF representing a modern iteration focused on versatility and trail-ability. The SF variant introduced a supermoto-specific setup for enhanced street performance.
Production
Manufacturing Origin:
Kawasaki motorcycles are typically manufactured in Japan, with some production potentially occurring in other international facilities depending on the specific model and year.
🏆 Awards & Recognition
Recognitions
Model Accolades:
The KLX250 series is generally well-regarded for its versatility and reliability in the dual-sport and lightweight adventure categories, often praised for its handling and off-road capability.
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