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Kawasaki KLX250VA 2010 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250VA Year: 2010 Codes Vin Prefix: 162 👋 Introduction Market Position Segment: Dual-sport motorcycle, targeting riders looking for on-road and off-road versatility. Target Audience: Enthusiasts and owners seeking to perform their own maintenance and repairs, enhancing the longevity and performance of their KLX250VA. Competitive Analysis Competitors: Competes with models like the Honda CRF250L, Yamaha WR250R, and Suzuki DR-Z250 from respective model years. Key Features Manual Advantage: Provides factory-level accuracy and detail, enabling correct procedures and preventing costly mistakes. Essential for maintaining optimal performance and safety. Vehicle Utility: The KLX250VA is a capable dual-sport motorcycle known for its agility and off-road prowess, while still being street-legal. 📋 Manual Details Coverage Areas Primary Coverage: Complete factory service and repair procedures for the 2010 Kawasaki KLX250VA. Geographic Scope: Global market specifications, reflecting typical international model variations. Page Count Estimated Pages: Hundreds (exact number not specified, but implies comprehensive coverage) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the KLX250VA engine (e.g., top end, bottom end, valve train, lubrication system). Fuel System: Carburetor system (maintenance, adjustment, overhaul), fuel tank, fuel pump, fuel lines. Ignition System: Ignition timing, CDI unit, spark plug, ignition coils, wiring diagrams related to ignition. Cooling System: Radiator, coolant, hoses, fan (if applicable), temperature sensor. Exhaust System: Muffler, exhaust pipes, heat shields, catalytic converter (if applicable). Transmission: Clutch operation, gear shifting mechanism, transmission disassembly and assembly, lubrication. Drivetrain: Chain drive system (adjustment, lubrication, replacement), sprockets. Suspension: Front fork (oil changes, seal replacement, internal components), rear shock absorber, linkage system. Brakes: Front and rear brake systems (disc brakes), brake pad replacement, caliper overhaul, bleeding procedure, master cylinder. Wheels And Tires: Wheel bearing inspection, tire pressure, tire replacement, rim maintenance. Steering: Handlebar, steering stem bearings (inspection, adjustment, replacement). Electrical System: Battery, charging system (generator/alternator), lighting (headlight, taillight, turn signals), horn, starter motor, wiring diagrams for all circuits. Chassis And Frame: Frame inspection, sub-frame, swingarm. Bodywork: Fairings, fuel tank cover, seat, fenders, plastics (removal, installation, repair). Procedures Included Maintenance: Regular scheduled maintenance, fluid changes, filter replacements, chain adjustments, brake checks, general inspections. Troubleshooting: Diagnostic procedures for common problems, fault finding based on symptoms, electrical troubleshooting using diagrams. Repair: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment. Overhaul: Complete engine and transmission overhaul procedures. Calibration: Carburetor synchronization and tuning, idle speed adjustment. Safety Checks: Brake system checks, steering integrity, tire condition. Technical Depth Depth: Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed internal component specifications and tolerances. Diagnostic Capability: Advanced diagnostic trees for electrical and mechanical issues. Rebuild Capability: Full engine and transmission rebuild capabilities. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text content (standard for quality PDFs). Print Quality Printability: Designed for printing, allowing users to print specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF, user prints and binds as needed) Paper Type Paper: N/A (Digital PDF, user selects paper type upon printing) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, DOHC, single-cylinder Displacement: 249 cc (Cubic Centimeters) Bore X Stroke: 72.0 mm x 61.2 mm (Millimeters) Compression Ratio: 11.0:1 (Eleven to One) Valve Train: DOHC (Double Overhead Camshaft), 4 valves per cylinder Performance Horsepower: Approximately 22-24 HP (Horsepower) at 7,000-7,500 RPM (Revolutions Per Minute) - exact figure may vary by market and tuning. Torque: Approximately 16-18 lb-ft (Pound-feet) at 6,000-7,000 RPM - exact figure may vary. Fuel System Carburetor: Keihin CVK34 (Constant Velocity Carburetor, 34mm bore) or similar specification. Fuel Type: Unleaded gasoline, minimum 87 octane (RON+MON)/2. Fuel Capacity: 2.1 US gallons (Approx. 7.9 Liters) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch: Wet, multi-plate Features Gear Ratios: Specific ratios detailed in the manual, crucial for performance tuning and diagnosis. Final Drive: O-ring sealed chain, 520 pitch 📐 Dimensions Exterior Length: Approximately 86.0 inches (2185 mm) Width: Approximately 33.1 inches (840 mm) Height: Approximately 46.9 inches (1190 mm) Wheelbase: Approximately 56.7 inches (1440 mm) Ground Clearance: Approximately 11.8 inches (300 mm) Weights Dry Weight: Approximately 262.4 lbs (119 kg) Curb Weight: Approximately 289 lbs (131 kg) - includes all necessary fluids and a full tank of fuel. Load Capacity: Not explicitly stated, but typical for this class, usually around 300-350 lbs combined rider and cargo. 🛡️ Safety Features Ratings Safety Standards: Compliant with applicable motorcycle safety regulations for its model year and target markets. Active Features Braking System: Hydraulic disc brakes front and rear for reliable stopping power. Lighting: Headlight, taillight, brake light, and turn signals for visibility. Passive Features Frame Construction: High-tensile steel perimeter frame providing rigidity and durability. 💡 Technology Features Infotainment Instrument Cluster: Digital LCD instrument panel including speedometer, tachometer, odometer, trip meter, clock, and indicator lights. Driver Assistance ABS: Not...
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Kawasaki KLX250VA 2010 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250VA
Year:
2010
Codes
Vin Prefix:
162
👋 Introduction
Market Position
Segment:
Dual-sport motorcycle, targeting riders looking for on-road and off-road versatility.
Target Audience:
Enthusiasts and owners seeking to perform their own maintenance and repairs, enhancing the longevity and performance of their KLX250VA.
Competitive Analysis
Competitors:
Competes with models like the Honda CRF250L, Yamaha WR250R, and Suzuki DR-Z250 from respective model years.
Key Features
Manual Advantage:
Provides factory-level accuracy and detail, enabling correct procedures and preventing costly mistakes. Essential for maintaining optimal performance and safety.
Vehicle Utility:
The KLX250VA is a capable dual-sport motorcycle known for its agility and off-road prowess, while still being street-legal.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete factory service and repair procedures for the 2010 Kawasaki KLX250VA.
Geographic Scope:
Global market specifications, reflecting typical international model variations.
Page Count
Estimated Pages:
Hundreds (exact number not specified, but implies comprehensive coverage)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed disassembly, assembly, inspection, and repair of the KLX250VA engine (e.g., top end, bottom end, valve train, lubrication system).
Fuel System:
Carburetor system (maintenance, adjustment, overhaul), fuel tank, fuel pump, fuel lines.
Ignition System:
Ignition timing, CDI unit, spark plug, ignition coils, wiring diagrams related to ignition.
Cooling System:
Radiator, coolant, hoses, fan (if applicable), temperature sensor.
Exhaust System:
Muffler, exhaust pipes, heat shields, catalytic converter (if applicable).
Transmission:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, lubrication.
Drivetrain:
Chain drive system (adjustment, lubrication, replacement), sprockets.
Suspension:
Front fork (oil changes, seal replacement, internal components), rear shock absorber, linkage system.
Brakes:
Front and rear brake systems (disc brakes), brake pad replacement, caliper overhaul, bleeding procedure, master cylinder.
Wheels And Tires:
Wheel bearing inspection, tire pressure, tire replacement, rim maintenance.
Steering:
Handlebar, steering stem bearings (inspection, adjustment, replacement).
Electrical System:
Battery, charging system (generator/alternator), lighting (headlight, taillight, turn signals), horn, starter motor, wiring diagrams for all circuits.
Chassis And Frame:
Frame inspection, sub-frame, swingarm.
Bodywork:
Fairings, fuel tank cover, seat, fenders, plastics (removal, installation, repair).
Procedures Included
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, chain adjustments, brake checks, general inspections.
Troubleshooting:
Diagnostic procedures for common problems, fault finding based on symptoms, electrical troubleshooting using diagrams.
Repair:
Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Overhaul:
Complete engine and transmission overhaul procedures.
Calibration:
Carburetor synchronization and tuning, idle speed adjustment.
Safety Checks:
Brake system checks, steering integrity, tire condition.
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers detailed internal component specifications and tolerances.
Diagnostic Capability:
Advanced diagnostic trees for electrical and mechanical issues.
Rebuild Capability:
Full engine and transmission rebuild capabilities.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text content (standard for quality PDFs).
Print Quality
Printability:
Designed for printing, allowing users to print specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital PDF, user prints and binds as needed)
Paper Type
Paper:
N/A (Digital PDF, user selects paper type upon printing)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, single-cylinder
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (Millimeters)
Compression Ratio:
11.0:1 (Eleven to One)
Valve Train:
DOHC (Double Overhead Camshaft), 4 valves per cylinder
Performance
Horsepower:
Approximately 22-24 HP (Horsepower) at 7,000-7,500 RPM (Revolutions Per Minute) - exact figure may vary by market and tuning.
Torque:
Approximately 16-18 lb-ft (Pound-feet) at 6,000-7,000 RPM - exact figure may vary.
Fuel System
Carburetor:
Keihin CVK34 (Constant Velocity Carburetor, 34mm bore) or similar specification.
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON+MON)/2.
Fuel Capacity:
2.1 US gallons (Approx. 7.9 Liters)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch:
Wet, multi-plate
Features
Gear Ratios:
Specific ratios detailed in the manual, crucial for performance tuning and diagnosis.
Final Drive:
O-ring sealed chain, 520 pitch
📐 Dimensions
Exterior
Length:
Approximately 86.0 inches (2185 mm)
Width:
Approximately 33.1 inches (840 mm)
Height:
Approximately 46.9 inches (1190 mm)
Wheelbase:
Approximately 56.7 inches (1440 mm)
Ground Clearance:
Approximately 11.8 inches (300 mm)
Weights
Dry Weight:
Approximately 262.4 lbs (119 kg)
Curb Weight:
Approximately 289 lbs (131 kg) - includes all necessary fluids and a full tank of fuel.
Load Capacity:
Not explicitly stated, but typical for this class, usually around 300-350 lbs combined rider and cargo.
🛡️ Safety Features
Ratings
Safety Standards:
Compliant with applicable motorcycle safety regulations for its model year and target markets.
Active Features
Braking System:
Hydraulic disc brakes front and rear for reliable stopping power.
Lighting:
Headlight, taillight, brake light, and turn signals for visibility.
Passive Features
Frame Construction:
High-tensile steel perimeter frame providing rigidity and durability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD instrument panel including speedometer, tachometer, odometer, trip meter, clock, and indicator lights.
Driver Assistance
ABS:
Not standard on the 2010 KLX250VA model.
Connectivity
Connectivity Features:
None (This is a utility-focused motorcycle, not equipped with modern digital connectivity features).
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 miles (4,800 km) or 6 months, whichever comes first (refer to manual for specific mileage/time intervals).
Air Filter Cleaning:
Every 3,000 miles (4,800 km) or as needed based on operating conditions (dusty environments require more frequent checks).
Spark Plug Replacement:
Refer to manual for specific interval, typically around 7,500-10,000 miles (12,000-16,000 km).
Valve Clearance Check:
Initial check at 600 miles (1,000 km), then every 3,000 miles (4,800 km) thereafter, or as specified.
Chain Maintenance:
Lubricate and adjust chain every 500 miles (800 km) or after riding in wet conditions.
Fluid Specifications
Engine Oil:
API SG, SH, SJ, SL or SM, SAE 10W-40. Kawasaki Genuine Oil or equivalent.
Engine Oil Capacity:
1.7 US qt (1.6 L) with filter change; 1.5 US qt (1.4 L) without filter change.
Coolant:
Permanent type ethylene-glycol based coolant, mixed with distilled water at a 50:50 ratio.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Chain and sprockets due to off-road use, clutch wear, front fork seals, carburetor jetting sensitivity to altitude/temperature.
Electrical Gremlins:
While generally reliable, issues can arise with grounding points or connectors, particularly in high-mileage or off-road used machines. Wiring diagrams in the manual are crucial for diagnosis.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for producing robust and performance-oriented motorcycles, including a strong lineage in off-road and dual-sport segments with the KLX series.
Model Evolution
Klx Lineage:
The KLX250 model has evolved over many years, with the VA designation typically referring to specific market or configuration variations within a given year. The 2010 model represents a mature iteration of this popular dual-sport platform.
Production
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other global locations depending on market.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The KLX250 series has historically received positive reviews for its off-road capability, reliability, and value in the dual-sport market.
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