Kawasaki KLX250VA 2010 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250VA Year: 2010 Product Type: Service Repair Workshop Manual Codes Model Code Identifier: KLX250VA 👋 Introduction Market Position Vehicle Segment: Dual-sport / Off-road motorcycle. Target Audience: Enthusiasts and owners seeking detailed technical information for maintenance, repair, and performance tuning of their 2010 KLX250VA. Competitive Analysis Competitors 2010: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (though DR-Z is a slightly older platform). Key Features Klx250Va Heritage: Known for its off-road capability, reliable engine, and suitability for both trails and light street use. Manual Value Proposition: Provides professional-level repair and maintenance guidance, empowering owners to perform tasks themselves, saving on labor costs and ensuring proper upkeep. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, maintenance, and troubleshooting for the 2010 Kawasaki KLX250VA. Page Count Estimated Page Count: Refer to product listing for exact count; typically 300-500 pages for this type of manual. Manual Type Manual Classification: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, and repair; piston, rings, cylinder, crankshaft, camshaft, valves, timing. Fuel System: Carburetor (if applicable), fuel injection system (if applicable), fuel pump, fuel lines, filters, fuel tank. Ignition System: CDI unit, ignition coil, spark plug, wiring diagrams. Cooling System: Radiator, fan, hoses, coolant, water pump. Exhaust System: Muffler, exhaust pipes, catalytic converter (if applicable). Transmission Drivetrain: Clutch operation, gear shifting mechanism, internal transmission components, drive chain, sprockets. Chassis Frame: Frame inspection, straightening, welding procedures, sub-frame. Suspension Front: Front fork assembly, seals, oil, springs, adjustments, steering head bearings. Suspension Rear: Rear shock absorber, linkage system (if applicable), swingarm, bushings, bearings. Braking System: Front and rear brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures. Wheels Tires: Wheel bearings, rim inspection, tire mounting, balancing. Electrical System: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, horn, instrumentation. Wiring Diagrams: Detailed electrical wiring diagrams for all systems. Bodywork Fittings: Fairings, seat, handlebars, controls, plastics, body panels, fasteners. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, inspections, lubrication points. Routine Service: Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement. Disassembly Assembly: Step-by-step instructions for dismantling and reassembling major vehicle components. Troubleshooting: Diagnostic procedures for identifying and resolving common and uncommon problems. Component Testing: Procedures for testing the functionality and performance of various components. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for critical fasteners across all systems. Technical Depth Depth Level: Comprehensive, covering everything from basic checks to full engine rebuilds and electrical diagnostics. Diagnostic Capability: Advanced diagnostic information, fault codes (if applicable), and troubleshooting flowcharts. Rebuild Guidance: Detailed instructions and specifications for rebuilding engine, transmission, and suspension components. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Typically fully searchable text within the PDF for quick information retrieval. Print Quality Resolution: High resolution, suitable for clear printing of diagrams and text. Binding Type Binding Method: Not applicable (Digital PDF Download) Paper Type Paper Quality: Not applicable (Digital PDF Download) ⚙️ 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 Compression Ratio: 11.0:1 Performance Horsepower Estimated: Approximately 22-24 HP at 7,000-7,500 RPM (depending on market and specific tuning). Torque Estimated: Approximately 17-19 lb-ft at 6,000-6,500 RPM. Fuel System Fuel Delivery: Keihin CVK34 carburetor (standard on many global models; North American models may have FI variants). Fuel Type: Unleaded gasoline, minimum 87 octane. Lubrication Oil Type Specification: SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil. Oil Capacity With Filter: 1.7 Liters (approx. 1.8 US qt). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, return type. Final Drive: O-ring sealed chain drive. Features Clutch Type: Wet, multiple disc. Transmission Oil Specification: Same as engine oil: SAE 10W-40 API SG or higher, JASO MA certified. 📐 Dimensions Exterior Overall Length: Approx. 2180 mm (85.8 in) Overall Width: Approx. 800 mm (31.5 in) Overall Height: Approx. 1195 mm (47.0 in) Wheelbase: Approx. 1430 mm (56.3 in) Ground Clearance: Approx. 255 mm (10.0 in) Seat Height: Approx. 865 mm (34.1 in) Weights Curb Weight: Approx. 135 kg (298 lbs) Fuel Tank Capacity: 11 Liters (2.9 US gal) 🛡️ Safety Features Ratings Crash Safety Rating: Not applicable for this motorcycle type; safety relies on rider skill and adherence to safe operating practices. Active Features Braking System Type: Disc brakes front and rear. Tire Specification Front: 80/100-21 51P (Tube Type) Tire Specification Rear: 110/100-18 64P (Tube Type) Passive Features Lighting System: Halogen headlight, LED taillight, incandescent turn signals. 💡 Technology Features Infotainment Infotainment System: Not applicable (basic motorcycle instrumentation). Driver Assistance ABS Availability: ABS was not standard or widely available on the 2010 KLX250VA model;...
Enthusiasts and owners seeking detailed technical information for maintenance, repair, and performance tuning of their 2010 KLX250VA.
Competitive Analysis
Competitors 2010:
Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (though DR-Z is a slightly older platform).
Key Features
Klx250Va Heritage:
Known for its off-road capability, reliable engine, and suitability for both trails and light street use.
Manual Value Proposition:
Provides professional-level repair and maintenance guidance, empowering owners to perform tasks themselves, saving on labor costs and ensuring proper upkeep.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete service, repair, maintenance, and troubleshooting for the 2010 Kawasaki KLX250VA.
Page Count
Estimated Page Count:
Refer to product listing for exact count; typically 300-500 pages for this type of manual.
Approximately 22-24 HP at 7,000-7,500 RPM (depending on market and specific tuning).
Torque Estimated:
Approximately 17-19 lb-ft at 6,000-6,500 RPM.
Fuel System
Fuel Delivery:
Keihin CVK34 carburetor (standard on many global models; North American models may have FI variants).
Fuel Type:
Unleaded gasoline, minimum 87 octane.
Lubrication
Oil Type Specification:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Oil Capacity With Filter:
1.7 Liters (approx. 1.8 US qt).
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh, return type.
Final Drive:
O-ring sealed chain drive.
Features
Clutch Type:
Wet, multiple disc.
Transmission Oil Specification:
Same as engine oil: SAE 10W-40 API SG or higher, JASO MA certified.
📐 Dimensions
Exterior
Overall Length:
Approx. 2180 mm (85.8 in)
Overall Width:
Approx. 800 mm (31.5 in)
Overall Height:
Approx. 1195 mm (47.0 in)
Wheelbase:
Approx. 1430 mm (56.3 in)
Ground Clearance:
Approx. 255 mm (10.0 in)
Seat Height:
Approx. 865 mm (34.1 in)
Weights
Curb Weight:
Approx. 135 kg (298 lbs)
Fuel Tank Capacity:
11 Liters (2.9 US gal)
🛡️ Safety Features
Ratings
Crash Safety Rating:
Not applicable for this motorcycle type; safety relies on rider skill and adherence to safe operating practices.
Active Features
Braking System Type:
Disc brakes front and rear.
Tire Specification Front:
80/100-21 51P (Tube Type)
Tire Specification Rear:
110/100-18 64P (Tube Type)
Passive Features
Lighting System:
Halogen headlight, LED taillight, incandescent turn signals.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable (basic motorcycle instrumentation).
Driver Assistance
ABS Availability:
ABS was not standard or widely available on the 2010 KLX250VA model; check specific market variations.
Connectivity
Connectivity Features:
Not applicable.
Instrumentation
Dashboard Layout:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, indicator lights (neutral, turn signals, high beam, oil pressure).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months, or at every oil change if indicated by manual.
Air Filter Cleaning:
Every 1,000 km (600 miles) or as needed in dusty conditions.
Spark Plug Inspection:
Every 3,000 km (1,800 miles).
Chain Lubrication Adjustment:
Every 500 km (300 miles) or after washing/rain.
Fluid Specifications
Coolant Type:
Permanent type ethylene glycol based coolant, pre-mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4.
Fork Oil Type Viscosity:
SAE 10W (refer to manual for exact quantity and level).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, steering head bearings.
Potential Issues 2010:
Carburetor jetting can sometimes be lean depending on altitude and modifications; occasional fuel pump issues (if FI equipped); stator failure on higher mileage units.
Maintenance Clarity
Manual Maintenance Detail:
The manual provides clear diagrams and step-by-step instructions for all scheduled maintenance tasks, ensuring correct procedures are followed.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries has a long-standing history in motorcycle manufacturing, known for performance and innovation in various segments, including off-road and dual-sport.
Model Evolution
Klx Lineage:
The KLX series has been a staple for Kawasaki's off-road and dual-sport offerings, evolving over decades to meet changing rider demands and emissions standards. The KLX250 has seen various iterations, with the 2010 model representing a mature and capable iteration of the 250cc dual-sport platform.
Production
Manufacturing Location:
Typically manufactured in Japan or Thailand by Kawasaki Heavy Industries.
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
While specific awards for the 2010 KLX250VA may not be widely documented, the KLX line is generally recognized for its versatility and reliability in the dual-sport category by motorcycle publications and riders.
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