This manual covers the KLX 250 SA, a versatile dual-sport motorcycle produced in 2010. Building on a heritage of producing reliable and performance-oriented machines, the KLX line is recognized for its off-road capability and adaptability. This particular model features a liquid-cooled, four-stroke, 249cc single-cylinder engine with Digital Fuel Injection (DFI) and a 6-speed transmission, designed for both trail riding and general use. Its robust construction and thoughtful engineering ensure a dependable and enjoyable riding experience, whether for daily commuting or exploring more adventurous terrain. This comprehensive Workshop Service Manual provides detailed information for maintaining and repairing the KLX 250 SA 2010. It covers all major systems, including the engine, transmission, electrical system, chassis, and bodywork, with in-depth procedures for routine maintenance, troubleshooting, and complete overhauls. The manual is designed to assist mechanical technicians and experienced DIY enthusiasts by offering dealer-level information, special tool identification, and systematic diagnostic guides, ultimately enabling professional-quality service and ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX 250 SA Year: 2010 Model Variant: SA Codes Manual Product Code: KLX250SA2010 👋 Introduction Market Position Target Audience: Mechanical technicians, experienced DIY enthusiasts. Competitive Analysis Advantage: Provides dealer-level information and procedures, enabling professional quality service and cost savings for owners. Key Features Emphasis: Highlights special aspects of the KLX 250 SA 2010, safety warnings, cautions, and notes. Manual Purpose: To help owners get the best value from their Kawasaki KLX 250 SA 2010 and perform repairs knowledgeably. 📋 Manual Details Coverage Areas Primary Coverage: Kawasaki KLX 250 SA 2010 Page Count Total Pages: 558 Manual Type Type: Workshop Service Manual Language Language: English Format File Format: PDF Delivery Method: Fast and Free Electronic Delivery via Email. 📖 Manual Coverage Systems Covered Engine: Comprehensive engine repair, overhaul, tuning, lubrication, fuel system, ignition, exhaust. Transmission: Detailed procedures for transmission disassembly, assembly, and repair. Electrical System: Complete coverage of the electrical system, including wiring diagrams, component testing, and troubleshooting. Bodywork: Procedures for body panel removal and installation, adjustments, and general body maintenance. Chassis: Includes details on suspension, steering, brakes, wheels, and tires. Fuel System Details: Detailed component descriptions, calibration, troubleshooting, and cleaning of fuel injection system. Ignition System Details: Ignition timing, coil testing, sensor diagnostics, CDI unit troubleshooting. Lubrication System Details: Oil pump inspection, oil cooler (if applicable), oil filter replacement, lubrication circuit analysis. Exhaust System Details: Muffler removal/installation, catalytic converter (if applicable), exhaust pipe maintenance. Proprietary Components: Includes instructions for proprietary components, referencing manufacturer specifications for optimal understanding and performance. Engine And Transmission: Extensive coverage for engine and transmission disassembly and reassembly for in-depth repair. Procedures Included Maintenance: Routine maintenance, servicing, tune-ups. Repair: Diagnostic and repair procedures for all major components and systems. Overhaul: Detailed overhaul procedures for engine and transmission. Removal Installation: Step-by-step instructions for removal and installation of various components. Assembly Disassembly: Procedures for assembly and disassembly of all major assemblies. Troubleshooting: Systematic troubleshooting guides for common and uncommon faults, including electrical and mechanical issues. Technical Depth Depth: Advanced diagnostics, complete rebuilds, proprietary component repair, in-depth system analysis. Diagnostic Tools: References specialized Kawasaki tools (identified by part numbers) and standard automotive diagnostic practices. Special Tools: Lists and illustrates specific Kawasaki special tools required for certain adjustments and repairs, e.g., torque wrenches, measurement tools. Information Reliability: States that the manual provides the most reliable information. 📊 Manual Specifications File Format Quality: High-resolution PDF for clarity and readability. Print Quality Printability: Yes, fully printable. Binding Type Binding: Digital (PDF Download) - No physical binding. Paper Type Paper: Not applicable (Digital format). ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single cylinder Performance Displacement: 249cc Bore X Stroke: 72.0 x 61.2 mm (2.83 x 2.41 in) Compression Ratio: 11.0:1 Fuel System Type: Digital Fuel Injection (DFI) with two 34mm Keihin throttle bodies Ignition System: Digital CDI Lubrication System: Forced lubrication, wet sump 🔧 Transmission Standard Type: 6-speed, return shift Optional Optional Transmissions: N/A (Standard single transmission configuration) Features Clutch Type: Wet, manual clutch 📐 Dimensions Exterior Length: 2,175 mm (85.6 in) Width: 810 mm (31.9 in) 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 132 kg (291 lbs) Fuel Capacity: 7.7 L (2.0 US gal) 🛡️ Safety Features Ratings Crash Test Results: Not applicable for this type of motorcycle; manual emphasizes safety precautions during maintenance and operation. Active Features Braking System: Front: Semi-floating petal disc, dual-piston caliper. Rear: Petal disc, dual-piston caliper. (Manual details inspection and maintenance). Passive Features Lighting: Halogen headlamp, LED taillight. (Manual covers bulb replacement and electrical checks). 💡 Technology Features Infotainment Features: Basic instrumentation cluster (speedometer, tachometer, odometer, trip meter, fuel gauge, indicator lights). Driver Assistance Assistance Features: N/A (No electronic rider aids like ABS or traction control on...