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Kawasaki KLX250 D-TRACKER X 2009-2012 Service Manual

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Basic Information Identification Make: Kawasaki Model: KLX250 D-TRACKER X Model Variant: D-TRACKER X Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves Codes Model Years Covered: 2009, 2010, 2011, 2012 Introduction Market Position Positioning: Essential resource for owners and mechanics seeking to maintain, repair, and troubleshoot the Kawasaki KLX250 D-TRACKER X models. Competitive Analysis Value Proposition: Provides comprehensive, factory-level information at a fraction of the cost of dealership service or printed manuals. Enables DIY maintenance, saving on labor costs. Key Features Instructional Format: Detailed substeps, notes, cautions, warnings, numbered instructions, and bold figure numbers enhance clarity and safety. Visual Aids: Hundreds of photos, illustrations, drawings, and enlarged insets for detailed part examination and procedural guidance. Navigational Aids: Numbered table of contents for quick information retrieval. Digital Advantages: Immediate access via download, no shipping costs or delays, ability to print specific sections as needed. Manual Details Coverage Areas Primary Coverage: Complete factory service and repair for Kawasaki KLX250 D-TRACKER X Specific Styles Covered: All styles Page Count Estimated Page Count: Hundreds of pages (specific count not provided, but indicated as comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Manual Coverage Systems Covered Engine System: Comprehensive engine disassembly, assembly, inspection, and repair for all engine components. Fuel System: Detailed procedures for fuel injection system, fuel pump, injectors, and related components. Cooling System: Radiator, fan, coolant flow, thermostat, and associated parts. Exhaust System: Muffler, catalytic converter (if applicable), and exhaust pipe maintenance and replacement. Transmission System: Clutch operation, gearbox disassembly, assembly, inspection, and lubrication specifications. Chassis System: Frame, swingarm, suspension components (forks, rear shock), steering system. Braking System: Front and rear brake calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures. Electrical System: Ignition system, lighting, battery, charging system (stator, regulator/rectifier), starter motor, and complete wiring diagrams. Wheel And Tire System: Wheel bearings, spoke tensioning (if applicable), tire removal and installation, and rim specifications. Bodywork And Fittings: Fairings, seat, fuel tank, fenders, and other external components. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain maintenance, spark plug replacement, brake fluid changes. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, including electrical fault finding. Repair: Step-by-step instructions for complete disassembly, component repair, and reassembly of all major systems. Rebuilds: Detailed instructions for engine, transmission, and suspension component rebuilds. Adjustments: Carburetor (if applicable), clutch, throttle, and suspension adjustments. Technical Depth Depth: Complete factory level detail, suitable for both novice DIY mechanics and experienced professionals. Covers full disassembly to component level. Diagnostic Capabilities: Extensive troubleshooting guides and detailed wiring diagrams facilitate accurate diagnosis of electrical and mechanical faults. Manual Specifications File Format Format: PDF Compatibility: Compatible with all PC-based Windows operating systems and Mac. Print Quality Printability: Printable without restriction; users can print specific pages or the entire manual. Binding Type Binding: Digital Download (PDF) - implies no physical binding. Paper Type Paper Type: Not applicable (digital format). Delivery Delivery Method: Instant download link provided on checkout page after payment. Requirements Software Requirement: Adobe PDF Reader Engine Specifications Primary Engine Engine Displacement: 249 cc (Approximate, as per typical KLX250 specifications) Bore X Stroke: 72.0 x 61.2 mm (Typical for KLX250, refer to manual for exact spec) Compression Ratio: 11.0:1 (Typical for KLX250, refer to manual for exact spec) Performance Horsepower: Approximately 30-33 PS (Refer to manual for specific dyno-tested figures for the covered years) Torque: Approximately 21-23 Nm (Refer to manual for specific figures for the covered years) Fuel System Fuel Delivery: Fuel Injection (EFI) - Specific details on injector types and pressure will be in the manual. Fuel Type: Unleaded gasoline, minimum octane rating to be specified in the manual. Ignition System Ignition Type: Digital CDI, electronic advance Lubrication System Oil Type: JASO MA certified motorcycle oil, viscosity grade specified in manual (e.g., 10W-40). Transmission Standard Type: 6-speed constant mesh Clutch Type: Wet, multi-disc Features Gear Ratios: Specific gear ratios for each of the 6 speeds will be detailed in the manual. Final Drive: Sealed chain drive Fluid Specifications Transmission Oil Type: Refer to manual for specific transmission oil grade and capacity (typically shared with engine oil for wet clutch systems). Dimensions Exterior Overall Length: Approximately 2,175 mm (Refer to manual for exact specification) Overall Width: Approximately 800 mm (Refer to manual for exact specification) Overall Height: Approximately 1,170 mm (Refer to manual for exact specification) Wheelbase: Approximately 1,425 mm (Refer to manual for exact specification) Weights Dry Weight: Approximately 131 kg (Refer to manual for exact specification) Curb Weight: Typically around 138 kg (Refer to manual for exact specification) Fuel Tank Capacity: Approximately 7.7 Liters (Refer to manual for exact specification) Safety Features Ratings Safety Standards: Compliance with applicable national and international motorcycle safety standards of the era will be implicitly covered in repair and specification sections. Active Features Braking System Type: Dual hydraulic disc...
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Kawasaki KLX250 D-TRACKER X 2009-2012 Service Manual
Basic Information
Identification
Make: Kawasaki
Model: KLX250 D-TRACKER X
Model Variant: D-TRACKER X
Engine Type: Four-stroke, single-cylinder, DOHC, 4 valves
Codes
Model Years Covered: 2009, 2010, 2011, 2012
Introduction
Market Position
Positioning: Essential resource for owners and mechanics seeking to maintain, repair, and troubleshoot the Kawasaki KLX250 D-TRACKER X models.
Competitive Analysis
Value Proposition: Provides comprehensive, factory-level information at a fraction of the cost of dealership service or printed manuals. Enables DIY maintenance, saving on labor costs.
Key Features
Instructional Format: Detailed substeps, notes, cautions, warnings, numbered instructions, and bold figure numbers enhance clarity and safety.
Visual Aids: Hundreds of photos, illustrations, drawings, and enlarged insets for detailed part examination and procedural guidance.
Navigational Aids: Numbered table of contents for quick information retrieval.
Digital Advantages: Immediate access via download, no shipping costs or delays, ability to print specific sections as needed.
Manual Details
Coverage Areas
Primary Coverage: Complete factory service and repair for Kawasaki KLX250 D-TRACKER X
Specific Styles Covered: All styles
Page Count
Estimated Page Count: Hundreds of pages (specific count not provided, but indicated as comprehensive)
Manual Type
Type: Workshop Service Repair Manual
Language
Language: English
Format
File Format: PDF
Manual Coverage
Systems Covered
Engine System: Comprehensive engine disassembly, assembly, inspection, and repair for all engine components.
Fuel System: Detailed procedures for fuel injection system, fuel pump, injectors, and related components.
Cooling System: Radiator, fan, coolant flow, thermostat, and associated parts.
Exhaust System: Muffler, catalytic converter (if applicable), and exhaust pipe maintenance and replacement.
Transmission System: Clutch operation, gearbox disassembly, assembly, inspection, and lubrication specifications.
Chassis System: Frame, swingarm, suspension components (forks, rear shock), steering system.
Braking System: Front and rear brake calipers, master cylinders, brake lines, pads, rotors, and bleeding procedures.
Electrical System: Ignition system, lighting, battery, charging system (stator, regulator/rectifier), starter motor, and complete wiring diagrams.
Wheel And Tire System: Wheel bearings, spoke tensioning (if applicable), tire removal and installation, and rim specifications.
Bodywork And Fittings: Fairings, seat, fuel tank, fenders, and other external components.
Procedures Included
Maintenance: Routine checks, oil changes, filter replacements, chain maintenance, spark plug replacement, brake fluid changes.
Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, including electrical fault finding.
Repair: Step-by-step instructions for complete disassembly, component repair, and reassembly of all major systems.
Rebuilds: Detailed instructions for engine, transmission, and suspension component rebuilds.
Adjustments: Carburetor (if applicable), clutch, throttle, and suspension adjustments.
Technical Depth
Depth: Complete factory level detail, suitable for both novice DIY mechanics and experienced professionals. Covers full disassembly to component level.
Diagnostic Capabilities: Extensive troubleshooting guides and detailed wiring diagrams facilitate accurate diagnosis of electrical and mechanical faults.
Manual Specifications
File Format
Format: PDF
Compatibility: Compatible with all PC-based Windows operating systems and Mac.
Print Quality
Printability: Printable without restriction; users can print specific pages or the entire manual.
Binding Type
Binding: Digital Download (PDF) - implies no physical binding.
Paper Type
Paper Type: Not applicable (digital format).
Delivery
Delivery Method: Instant download link provided on checkout page after payment.
Requirements
Software Requirement: Adobe PDF Reader
Engine Specifications
Primary Engine
Engine Displacement: 249 cc (Approximate, as per typical KLX250 specifications)
Bore X Stroke: 72.0 x 61.2 mm (Typical for KLX250, refer to manual for exact spec)
Compression Ratio: 11.0:1 (Typical for KLX250, refer to manual for exact spec)
Performance
Horsepower: Approximately 30-33 PS (Refer to manual for specific dyno-tested figures for the covered years)
Torque: Approximately 21-23 Nm (Refer to manual for specific figures for the covered years)
Fuel System
Fuel Delivery: Fuel Injection (EFI) - Specific details on injector types and pressure will be in the manual.
Fuel Type: Unleaded gasoline, minimum octane rating to be specified in the manual.
Ignition System
Ignition Type: Digital CDI, electronic advance
Lubrication System
Oil Type: JASO MA certified motorcycle oil, viscosity grade specified in manual (e.g., 10W-40).
Transmission
Standard
Type: 6-speed constant mesh
Clutch Type: Wet, multi-disc
Features
Gear Ratios: Specific gear ratios for each of the 6 speeds will be detailed in the manual.
Final Drive: Sealed chain drive
Fluid Specifications
Transmission Oil Type: Refer to manual for specific transmission oil grade and capacity (typically shared with engine oil for wet clutch systems).
Dimensions
Exterior
Overall Length: Approximately 2,175 mm (Refer to manual for exact specification)
Overall Width: Approximately 800 mm (Refer to manual for exact specification)
Overall Height: Approximately 1,170 mm (Refer to manual for exact specification)
Wheelbase: Approximately 1,425 mm (Refer to manual for exact specification)
Weights
Dry Weight: Approximately 131 kg (Refer to manual for exact specification)
Curb Weight: Typically around 138 kg (Refer to manual for exact specification)
Fuel Tank Capacity: Approximately 7.7 Liters (Refer to manual for exact specification)
Safety Features
Ratings
Safety Standards: Compliance with applicable national and international motorcycle safety standards of the era will be implicitly covered in repair and specification sections.
Active Features
Braking System Type: Dual hydraulic disc brakes, front and rear.
Passive Features
Lighting: Headlight, taillight, brake lights, turn signals; specifications for bulbs and operation covered.
Technology Features
Infotainment
Instrumentation: Digital speedometer, tachometer, odometer, trip meters, clock, and indicator lights. Manual details calibration and troubleshooting.
Driver Assistance
ABS: ABS was not standard or commonly available on the D-TRACKER X models of this era; refer to manual for specific model variations.
Connectivity
Connectivity Features: None in the modern sense; focuses on the motorcycle's mechanical and electrical systems.
Maintenance
Service Intervals
Oil Change Interval: Typically every 6,000 km or 12 months (Refer to manual for exact recommendation based on usage).
Air Filter Cleaning: Recommended at 6,000 km intervals, or more frequently in dusty conditions.
Spark Plug Replacement: Typically recommended at 12,000 km intervals, but inspection at 6,000 km is advised.
Fluid Specifications
Brake Fluid Type: DOT 4 (Refer to manual for confirmation and specific fluid properties).
Coolant Type: Permanent type antifreeze coolant, mixture ratio specified in manual (e.g., 50/50 water/coolant).
Known Issues
Common Wear Items: Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals (typical for this class of motorcycle).
Electrical Considerations: Checking electrical connections for corrosion and ensuring battery health are key maintenance points, covered comprehensively in the manual.
Vehicle History
Brand Heritage
Kawasaki Legacy: Kawasaki is renowned for its performance-oriented motorcycles, including a long lineage of dual-sport and off-road models.
Model Evolution
Klx Lineage: The KLX series has a history of versatile motorcycles, blending off-road capability with on-road usability. The D-TRACKER X is a supermoto variant.
Production
Production Period: The KLX250 platform has been in production for many years, with the D-TRACKER X variant specifically targeting markets that favor supermoto styling and performance.
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