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...
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).
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.