Kawasaki KLX250 D-TRACKER X 2009-2012 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 D-TRACKER X Applicable Years: 2009, 2010, 2011, 2012 Product Type: Workshop Service Repair Manual Codes Engine Codes: Likely J300-type 4-stroke, SOHC, 2 valves (specific code not provided but typical for KLX250) 👋 Introduction Market Position Market Segment: Dual-purpose, off-road and street-legal motorcycle, popular in supermoto and light trail riding segments. Competitive Analysis Competitors: Yamaha WR250X, Honda CRF250L/M (though KLX is often positioned as more performance-oriented in its segment). Key Features Key Features: Lightweight chassis, capable suspension, fuel-injected engine, versatile for both on-road and light off-road use. 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair information for Kawasaki KLX250 D-TRACKER X (2009-2012) Page Count Estimated Page Count: N/A (PDF format, but comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF Specifications Print Quality: Fully printable, allowing for use in workshop environments. Zoom Functionality: YES, allowing for detailed examination of illustrations and diagrams. Delivery Method: Instant Download Software Requirements: Adobe PDF Reader & WinZip Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed coverage of engine disassembly, inspection, assembly, and troubleshooting. Engine Electrical: Includes wiring diagrams, ignition system, starting system, and charging system. Emission Control: Information pertaining to emissions control systems and their maintenance. Fuel System: Covers fuel injection system, fuel pump, injectors, and related components. Suspension: Front fork and rear shock absorber maintenance, adjustment, and repair. Clutch System: Clutch operation, inspection, adjustment, and replacement. Manual Transaxle: Gearbox operation, inspection, and repair procedures. Driveshaft Axle: Details on final drive and related components (if applicable, likely chain drive). Steering System: Handlebar, steering stem, and bearing maintenance and adjustment. Brake System: Front and rear brake caliper, master cylinder, lines, and disc maintenance and bleeding. Body Interior Exterior: Body panel removal, installation, and cosmetic repairs. Body Electrical: Lighting, indicators, horn, and instrument cluster electrical components. Restraint System: Information related to rider safety, though typically not extensive in motorcycle manuals beyond basic chassis integrity. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes. Troubleshooting: Diagnostic procedures for common issues, electrical fault finding, and engine performance problems. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Wiring Schematics: Detailed wiring diagrams for electrical system diagnosis and repair. Technical Depth Depth Of Coverage: Comprehensive, covering routine maintenance to full engine rebuilds and electrical system diagnosis. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High Resolution, suitable for printing Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single-cylinder Displacement: 249.1 cc Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 28-30 HP (at crank, varies by region/tuning) Torque: Approx. 22-24 Nm (at crank, varies by region/tuning) Fuel System Fuel Delivery: Fuel Injection, Keihin Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Fuel Tank Capacity: 7.7 Liters (2.0 US gal) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet, multi-disc, manual Optional Optional Transmission: N/A Features Final Drive: Sealed O-ring chain, 14T front sprocket, 42T rear sprocket (typical) 📐 Dimensions Exterior Length: Approx. 2,115 mm (83.3 in) Width: Approx. 830 mm (32.7 in) Height: Approx. 1,105 mm (43.5 in) Wheelbase: Approx. 1,430 mm (56.3 in) Ground Clearance: Approx. 255 mm (10.0 in) Weights Curb Weight: Approx. 138 kg (304.2 lbs) Seat Height: Approx. 865 mm (34.1 in) 🛡️ Safety Features Ratings Braking System Type: Hydraulic disc brakes front and rear Active Features ABS: Not typically standard on this model/year, check specific regional variants. Passive Features Lighting: Halogen headlight, LED taillight (typical) 💡 Technology Features Infotainment Instrument Cluster: Digital LCD instrument cluster displaying speed, RPM, odometer, trip meter, clock, fuel gauge, and indicator lights. Driver Assistance ABS Availability: ABS was an optional feature on some later KLX models, but not standard for the 2009-2012 D-TRACKER X in many markets. Connectivity Connectivity Features: N/A (Motorcycle of this era does not typically feature advanced connectivity). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km or 6 months, consult manual for exact figures. Spark Plug Replacement: Typically every 10,000-15,000 km, consult manual. Air Filter Cleaning: Regular inspection and cleaning/replacement based on riding conditions (e.g., every 2,000-4,000 km). Fluid Specifications Engine Oil Type: SAE 10W-40, API SG or higher, JASO MA compliant motorcycle oil. Engine Oil Capacity: Approx. 1.6 L (without filter change), 1.8 L (with filter change). Coolant Type: Ethylene glycol based coolant, 50/50 mix with distilled water. Brake Fluid Type: DOT 4 Known Issues Common Issues: Potential for occasional stalling in older models if not properly maintained; carburetor adjustment/cleaning might be needed on non-FI models; chain wear; general wear and tear on suspension and brakes due to its dual-purpose nature. 📚 Vehicle History Brand Heritage...
Approx. 28-30 HP (at crank, varies by region/tuning)
Torque:
Approx. 22-24 Nm (at crank, varies by region/tuning)
Fuel System
Fuel Delivery:
Fuel Injection, Keihin
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Fuel Tank Capacity:
7.7 Liters (2.0 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc, manual
Optional
Optional Transmission:
N/A
Features
Final Drive:
Sealed O-ring chain, 14T front sprocket, 42T rear sprocket (typical)
📐 Dimensions
Exterior
Length:
Approx. 2,115 mm (83.3 in)
Width:
Approx. 830 mm (32.7 in)
Height:
Approx. 1,105 mm (43.5 in)
Wheelbase:
Approx. 1,430 mm (56.3 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Weights
Curb Weight:
Approx. 138 kg (304.2 lbs)
Seat Height:
Approx. 865 mm (34.1 in)
🛡️ Safety Features
Ratings
Braking System Type:
Hydraulic disc brakes front and rear
Active Features
ABS:
Not typically standard on this model/year, check specific regional variants.
Passive Features
Lighting:
Halogen headlight, LED taillight (typical)
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD instrument cluster displaying speed, RPM, odometer, trip meter, clock, fuel gauge, and indicator lights.
Driver Assistance
ABS Availability:
ABS was an optional feature on some later KLX models, but not standard for the 2009-2012 D-TRACKER X in many markets.
Connectivity
Connectivity Features:
N/A (Motorcycle of this era does not typically feature advanced connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, consult manual for exact figures.
Spark Plug Replacement:
Typically every 10,000-15,000 km, consult manual.
Air Filter Cleaning:
Regular inspection and cleaning/replacement based on riding conditions (e.g., every 2,000-4,000 km).
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA compliant motorcycle oil.
Engine Oil Capacity:
Approx. 1.6 L (without filter change), 1.8 L (with filter change).
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4
Known Issues
Common Issues:
Potential for occasional stalling in older models if not properly maintained; carburetor adjustment/cleaning might be needed on non-FI models; chain wear; general wear and tear on suspension and brakes due to its dual-purpose nature.
📚 Vehicle History
Brand Heritage
Kawasaki Heritage:
Kawasaki has a long history in motorcycle manufacturing, known for performance and reliability, particularly in off-road and sportbike segments.
Model Evolution
Klx Lineage:
The KLX series represents Kawasaki's lineage of dual-purpose and off-road motorcycles, evolving over decades with technological advancements.
Production
Production Region:
Primarily Japan (Kawasaki Heavy Industries)
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
While specific awards for this exact model year are not prominently documented, the KLX series is generally recognized for its reliability, performance, and value in the dual-sport/supermoto segment.
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