This manual provides comprehensive service and repair information for the KLX250S, covering model years 2009 and 2010. The KLX250S is a versatile dual-sport motorcycle designed to excel in both on-road commuting and off-road trail riding. It features a robust 249 cc liquid-cooled, four-stroke engine with Electronic Fuel Injection (EFI) for enhanced throttle response and efficiency, paired with a reliable 6-speed transmission. Its long-travel, adjustable suspension and dual-sport tires contribute to its balanced performance across various terrains, making it a capable and well-regarded option in its segment. The purpose of this factory service repair manual is to equip owners, mechanics, and technicians with the detailed knowledge necessary for the proper maintenance and repair of the KLX250S. This extensive English-language guide, spanning over 500 pages, covers all major systems, including the engine, fuel system, transmission, electrical system, suspension, brakes, chassis, and bodywork. It offers step-by-step procedures for routine maintenance, in-depth troubleshooting, component overhaul, torque specifications, and includes essential wiring diagrams and diagnostic information for the engine management system, ensuring the vehicle remains in optimal condition. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Year: 2009-2010 Product Type: Factory Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Dual-sport motorcycle, targeting riders for both on-road commuting and off-road trail use. Competitive Analysis Key Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250. Key Features Vehicle Purpose: Versatile platform offering a balance of street-legal capability and off-road prowess. Efi System: Electronic Fuel Injection (EFI) for improved throttle response, fuel efficiency, and emissions control. Suspension Type: Long-travel, adjustable suspension (front and rear) for off-road capability. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service and repair information for the Kawasaki KLX250S (2009-2010 models). Specific Models Covered: Kawasaki KLX250S (Model Years 2009, 2010) Page Count Estimated Pages: Over 500 pages (typical for a factory service manual of this era and scope) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF, likely) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, internal components, lubrication system, cooling system. Fuel System: Fuel injection system (EFI) operation, components, troubleshooting, cleaning, adjustments. Transmission: Clutch operation, gearbox inspection, gear shift mechanism, lubrication. Electrical System: Ignition system, lighting, charging system, starter system, wiring diagrams, fault diagnosis. Suspension: Front fork (USD) disassembly, assembly, oil levels, seals, rear shock absorber adjustment and overhaul. Brakes: Front and rear brake system inspection, pad replacement, caliper service, fluid bleeding, master cylinder service. Chassis And Bodywork: Frame inspection, body panel removal and installation, seat, handlebars, footpegs. Wheels And Tires: Wheel bearing inspection, spoke tensioning, tire replacement, balancing. Exhaust System: Exhaust pipe and muffler inspection, clamp tightening, catalytic converter information (if applicable). Cooling System: Radiator service, coolant type and capacity, fan operation, thermostat. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues across all major vehicle systems. Repair And Overhaul: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly. Torque Specifications: Precise torque values for all critical fasteners and components. Wiring Diagrams: Comprehensive electrical system wiring schematics for accurate diagnosis and repair. Engine Management System: Diagnosis and troubleshooting of EFI system faults, sensor testing (TPS, MAP, IAT, O2), ECU reset procedures. Chassis Alignment: Inspection and correction of frame and steering head alignment. Wheel Bearing Service: Removal, cleaning, greasing, and installation of wheel bearings. Battery And Charging System Checks: Testing of battery voltage, alternator output, and regulator/rectifier function. Emission Controls: Information on emission-related components and their function. Technical Depth Depth Of Information: Factory-level detail, suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Image Resolution: High resolution for clear diagrams and illustrations. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, single-cylinder Displacement: 249 cc Bore X Stroke: 72.0 x 61.2 mm Cooling System: Liquid-cooled Performance Horsepower: Approx. 23-27 HP (varies slightly by year and regional tuning) Torque: Approx. 16-18 lb-ft (varies slightly) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with dual 34mm throttle bodies Fuel Type: Unleaded gasoline, 87 octane minimum Ignition Ignition System: Digital CDI with electric start Lubrication Oil Type: SAE 10W-40 API SG or higher motorcycle oil Oil Capacity: 1.5 L (1.6 US qt) without filter change, 1.7 L (1.8 US qt) with filter change 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed Features Clutch Type: Wet, multi-disc Final Drive: Sealed chain 📐 Dimensions Exterior Overall Length: 2,230 mm (87.8 in) Overall Width: 810 mm (31.9 in) Overall Height: 1,190 mm (46.9 in) Wheelbase: 1,430 mm (56.3 in) Ground Clearance: 255 mm (10.0 in) Seat Height: 865 mm (34.1 in) Weights Curb Weight: Approximately 138 kg (304.2 lbs) Fuel Tank Capacity: 11 L (2.9 US gal) 🛡️ Safety Features Ratings Safety Certifications: DOT/ECE...