The KLX250S, produced for the 2009 and 2010 model years, is a versatile dual-sport motorcycle engineered for riders seeking balanced performance both on and off the pavement. Built with a legacy of robust and performance-oriented machines, this model offers agile handling and a lightweight design, making it suitable for enthusiasts, off-road adventurers, and commuters who value adaptability. Its liquid-cooled, four-stroke, 249 cc engine, paired with a 6-speed manual transmission, provides reliable power for a wide range of riding conditions, distinguishing it in its segment. This comprehensive service repair manual is designed to be an indispensable resource for maintaining and repairing your KLX250S. Covering all essential systems including the engine, transmission, chassis, brakes, and electrical components, it provides detailed procedures for scheduled maintenance, troubleshooting common issues, and complete repair or rebuild processes. With extensive technical specifications, torque values, fluid requirements, and clear, high-resolution illustrations and diagrams, this manual empowers owners, mechanics, and technicians to ensure the optimal performance, reliability, and longevity of their vehicle. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250S Year: 2009-2010 Codes Engine Code: KLX250SE (example, specific code would be in manual) 👋 Introduction Market Position Segment: Dual-sport motorcycle Target Audience: Enthusiast riders, off-road adventurers, commuters seeking versatility. Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z400S. Key Features Design Philosophy: Balanced performance for both on-road and off-road use, lightweight and agile handling. 📋 Manual Details Coverage Areas Vehicle Models Covered: Kawasaki KLX250S (2009, 2010) Page Count Estimated Page Count: 400-600 pages (typical for full service manual) Manual Type Manual Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel system, ignition system, starting system, exhaust system, emissions control. Transmission: Clutch, gearbox, internal components, lubrication, adjustment procedures. Chassis: Frame, suspension (front forks, rear shock), steering system, wheels, hubs, spokes, tires. Brakes: Front and rear brake systems (hydraulic disc), brake fluid, caliper service, master cylinder, bleeding procedures. Electrical: Battery, charging system (alternator/stator), ignition system, lighting system, instrument cluster, wiring diagrams, troubleshooting. Bodywork: Fairings, body panels, seat, fuel tank, fenders, graphics, fasteners. Procedures Included Maintenance: Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Rebuild: Detailed procedures for engine and transmission component rebuilds. Technical Depth Diagnostics: Advanced diagnostic procedures, electrical system troubleshooting with wiring diagrams. Specifications: Comprehensive torque specifications, clearances, tolerances, fluid capacities, electrical specifications. Illustrations: Detailed diagrams, exploded views, and photographic illustrations for clarity. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution, suitable for printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single cylinder Displacement: 249 cc (249 cm³) Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approximately 20-23 HP (varies by specific market tuning) Torque: Approximately 13-15 lb-ft (varies by specific market tuning) Fuel System Fuel Delivery: Fuel Injection (Digital EFI) Fuel Type: Unleaded gasoline Fuel Capacity: Approximately 2.1 US gallons (7.9 Liters) 🔧 Transmission Standard Transmission Type: 6-speed manual Optional Transmission Options: N/A Features Clutch Type: Wet multi-disc Final Drive: Sealed chain drive 📐 Dimensions Exterior Length: Approximately 86.8 inches (2205 mm) Width: Approximately 32.5 inches (825 mm) Height: Approximately 49.4 inches (1255 mm) Wheelbase: Approximately 56.7 inches (1440 mm) Weights Dry Weight: Approximately 258 lbs (117 kg) Curb Weight: Approximately 286.6 lbs (130 kg) Ground Clearance: Approximately 11.8 inches (300 mm) Seat Height: Approximately 34.7 inches (880 mm) 🛡️ Safety Features Ratings Safety Certifications: DOT, EPA, CARB (market dependent) Active Features Braking System: Disc brakes front and rear Passive Features Lighting: Halogen headlamp, LED taillight 💡 Technology Features Infotainment Instrument Cluster: Digital LCD display with speedometer, tachometer, odometer, trip meters, clock, fuel gauge, and indicator lights. Driver Assistance ABS: N/A (Anti-lock Braking System not standard on this model) Connectivity Connectivity Features: N/A (Basic motorcycle electronics) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles or 6 months (typical, refer to manual for exact) Valve Clearance Check Interval: Every 6,000 miles or 12 months (typical, refer to manual for exact) Air Filter Cleaning Interval: Every 2,000 miles or 4 months (typical, refer to manual for exact) Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher, JASO MA certified Engine Oil Capacity: Approximately 1.7 US quarts (1.6 Liters) with filter change (refer to manual for exact) Brake Fluid Type: DOT 4 Coolant Type: Permanent type coolant (ethylene glycol based), 50/50 mix with distilled water Known Issues Common Wear Items: Chain and sprockets, brake pads, tires, clutch plates, fork seals. Potential Engine Considerations: Maintaining proper valve clearance is crucial for optimal performance and longevity. Fuel injection system cleanliness. 📚...