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Kawasaki KLX250 2009-2012 Service Repair Workshop Manual

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$133.00
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Basic Information Identification Make: Kawasaki Model: KLX250 Model Years Covered: 2009, 2010, 2011, 2012 Introduction Market Position Positioning: Essential resource for Kawasaki KLX250 owners and independent service professionals seeking accurate, dealer-level repair information. Competitive Analysis Advantage: Provides vehicle-specific, manufacturer-approved procedures and specifications, unlike generic repair guides. Key Features Benefits: Empowers owners to perform DIY maintenance and repairs, saving money. Enhances understanding for informed communication with technicians. Includes detailed diagrams and schematics. Diy Savings: Can easily pay for itself with the savings from performing basic maintenance like oil changes and spark plug replacements. Expertise Demonstration Value Proposition: This manual is written by the manufacturers and is identical to the information used by authorized Kawasaki service departments, ensuring accuracy and reliability for all repair and maintenance tasks. Manual Details Coverage Areas Covered Years: 2009-2012 Page Count Estimated Pages: Varies by specific version, but comprehensive service manuals typically range from 400-700 pages. Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Compatibility: Compatible with all versions of Windows and Mac. Requires Adobe PDF Reader. Manual Coverage Systems Covered Engine: Full engine specifications, disassembly, assembly, troubleshooting, and repair of internal components, cooling system, lubrication system. Fuel System: Carburetor system (if applicable to specific model variant), fuel pump, fuel lines, and associated components. Transmission: Gearbox operation, disassembly, assembly, troubleshooting, and repair of transmission components. Drive Train: Drive chain maintenance, adjustment, lubrication, and sprocket replacement. Details on final drive components. Electrical System: Wiring diagrams, lighting system, ignition system, starting system, charging system, battery, and component testing. Suspension: Front fork and rear shock absorber servicing, adjustments, and overhaul procedures. Brakes: Front and rear brake system inspection, maintenance, fluid replacement, caliper service, and lever/pedal adjustments. Steering: Handlebar, steering stem bearings, and related components inspection and maintenance. Bodywork: Fairings, seat, fenders, and other body panels removal, installation, and basic repair. Intake Exhaust: Airbox and filter servicing, exhaust system inspection and replacement. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustments, tire pressure checks, and general inspection procedures. Periodic Checks Adjustments: Valve clearance checks and adjustments, idle speed adjustments, clutch and throttle cable adjustments. Troubleshooting: Advanced diagnostic procedures for common and uncommon issues across all major systems. Repair Rebuild: Step-by-step instructions for component disassembly, inspection, repair, and reassembly of major mechanical and electrical systems. Engine Overhaul: Detailed procedures for engine removal, disassembly, component replacement (pistons, rings, valves, etc.), and reassembly. Electrical Diagnostics: Wiring diagram interpretation, component testing using multimeters, and troubleshooting electrical faults. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, with detailed diagnostics. Diagrams Illustrations: Includes step-by-step instructions, diagrams, illustrations, and wiring schematics for comprehensive repair and troubleshooting. Manual Specifications File Format Format Details: PDF, ensuring compatibility with most operating systems and devices. Searchable text capabilities may vary depending on the original scan quality. Print Quality Printability: Yes, individual pages can be printed for use in the workshop, allowing for protection of the digital file from dirt and grease. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single cylinder Displacement: 249 cc (This is a standard displacement for the KLX250, specific variations may exist) Performance Horsepower: Refer to manual for specific figures, typically around 25-30 HP depending on market and tune. Torque: Refer to manual for specific figures, typically around 23-25 Nm. Fuel System Fuel Delivery: Fuel Injection (EFI) for most models in this range, though carburetors were present on earlier or specific regional versions. Manual will detail the correct system. Fuel Type: Unleaded gasoline (Refer to manual for octane rating recommendation) Lubrication System Oil Type: High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 20W-50. (Consult manual for exact specification) Cooling System Coolant Type: Ethylene glycol-based antifreeze mixture. (Consult manual for specific coolant ratio and type) Transmission Standard Transmission Type: Constant mesh 6-speed Features Clutch Type: Wet, multi-disc Gear Ratios: Detailed gear ratios for each speed are provided in the manual's specifications section. Transmission Oil Type: Motorcycle-specific transmission oil or API GL-1 gear oil. (Consult manual for exact specification and capacity) Dimensions Exterior Overall Length: Refer to manual for exact dimensions, typically around 2,220 mm (87.4 in) for standard KLX250S. Overall Width: Refer to manual for exact dimensions, typically around 820 mm (32.3 in). Overall Height: Refer to manual for exact dimensions, typically around 1,205 mm (47.4 in). Weights Curb Weight: Refer to manual for exact weight, typically around 138 kg (304.2 lbs) for KLX250S. Safety Features Ratings Safety Features Overview: Standard motorcycle safety features including robust braking system, stable chassis, and appropriate lighting. Active Features Braking System: Disc brakes front and rear for effective stopping power. (ABS availability may vary by market/trim) Passive Features Lighting: Headlight, taillight, brake lights, and turn signals for visibility and signaling. Technology...
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Kawasaki KLX250 2009-2012 Service Repair Workshop Manual
Basic Information
Identification
Make: Kawasaki
Model: KLX250
Model Years Covered: 2009, 2010, 2011, 2012
Introduction
Market Position
Positioning: Essential resource for Kawasaki KLX250 owners and independent service professionals seeking accurate, dealer-level repair information.
Competitive Analysis
Advantage: Provides vehicle-specific, manufacturer-approved procedures and specifications, unlike generic repair guides.
Key Features
Benefits: Empowers owners to perform DIY maintenance and repairs, saving money. Enhances understanding for informed communication with technicians. Includes detailed diagrams and schematics.
Diy Savings: Can easily pay for itself with the savings from performing basic maintenance like oil changes and spark plug replacements.
Expertise Demonstration
Value Proposition: This manual is written by the manufacturers and is identical to the information used by authorized Kawasaki service departments, ensuring accuracy and reliability for all repair and maintenance tasks.
Manual Details
Coverage Areas
Covered Years: 2009-2012
Page Count
Estimated Pages: Varies by specific version, but comprehensive service manuals typically range from 400-700 pages.
Manual Type
Type: Service Repair Workshop Manual
Language
Language: English
Format
Format: PDF Download
Compatibility: Compatible with all versions of Windows and Mac. Requires Adobe PDF Reader.
Manual Coverage
Systems Covered
Engine: Full engine specifications, disassembly, assembly, troubleshooting, and repair of internal components, cooling system, lubrication system.
Fuel System: Carburetor system (if applicable to specific model variant), fuel pump, fuel lines, and associated components.
Transmission: Gearbox operation, disassembly, assembly, troubleshooting, and repair of transmission components.
Drive Train: Drive chain maintenance, adjustment, lubrication, and sprocket replacement. Details on final drive components.
Electrical System: Wiring diagrams, lighting system, ignition system, starting system, charging system, battery, and component testing.
Suspension: Front fork and rear shock absorber servicing, adjustments, and overhaul procedures.
Brakes: Front and rear brake system inspection, maintenance, fluid replacement, caliper service, and lever/pedal adjustments.
Steering: Handlebar, steering stem bearings, and related components inspection and maintenance.
Bodywork: Fairings, seat, fenders, and other body panels removal, installation, and basic repair.
Intake Exhaust: Airbox and filter servicing, exhaust system inspection and replacement.
Procedures Included
Routine Maintenance: Oil changes, filter replacements, chain adjustments, tire pressure checks, and general inspection procedures.
Periodic Checks Adjustments: Valve clearance checks and adjustments, idle speed adjustments, clutch and throttle cable adjustments.
Troubleshooting: Advanced diagnostic procedures for common and uncommon issues across all major systems.
Repair Rebuild: Step-by-step instructions for component disassembly, inspection, repair, and reassembly of major mechanical and electrical systems.
Engine Overhaul: Detailed procedures for engine removal, disassembly, component replacement (pistons, rings, valves, etc.), and reassembly.
Electrical Diagnostics: Wiring diagram interpretation, component testing using multimeters, and troubleshooting electrical faults.
Technical Depth
Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, with detailed diagnostics.
Diagrams Illustrations: Includes step-by-step instructions, diagrams, illustrations, and wiring schematics for comprehensive repair and troubleshooting.
Manual Specifications
File Format
Format Details: PDF, ensuring compatibility with most operating systems and devices. Searchable text capabilities may vary depending on the original scan quality.
Print Quality
Printability: Yes, individual pages can be printed for use in the workshop, allowing for protection of the digital file from dirt and grease.
Binding Type
Binding: N/A (Digital PDF format)
Paper Type
Paper Type: N/A (Digital PDF format)
Engine Specifications
Primary Engine
Engine Type: Liquid-cooled, 4-stroke, DOHC, 4-valve single cylinder
Displacement: 249 cc (This is a standard displacement for the KLX250, specific variations may exist)
Performance
Horsepower: Refer to manual for specific figures, typically around 25-30 HP depending on market and tune.
Torque: Refer to manual for specific figures, typically around 23-25 Nm.
Fuel System
Fuel Delivery: Fuel Injection (EFI) for most models in this range, though carburetors were present on earlier or specific regional versions. Manual will detail the correct system.
Fuel Type: Unleaded gasoline (Refer to manual for octane rating recommendation)
Lubrication System
Oil Type: High-quality motorcycle-specific 4-stroke engine oil, typically SAE 10W-40 or 20W-50. (Consult manual for exact specification)
Cooling System
Coolant Type: Ethylene glycol-based antifreeze mixture. (Consult manual for specific coolant ratio and type)
Transmission
Standard
Transmission Type: Constant mesh 6-speed
Features
Clutch Type: Wet, multi-disc
Gear Ratios: Detailed gear ratios for each speed are provided in the manual's specifications section.
Transmission Oil Type: Motorcycle-specific transmission oil or API GL-1 gear oil. (Consult manual for exact specification and capacity)
Dimensions
Exterior
Overall Length: Refer to manual for exact dimensions, typically around 2,220 mm (87.4 in) for standard KLX250S.
Overall Width: Refer to manual for exact dimensions, typically around 820 mm (32.3 in).
Overall Height: Refer to manual for exact dimensions, typically around 1,205 mm (47.4 in).
Weights
Curb Weight: Refer to manual for exact weight, typically around 138 kg (304.2 lbs) for KLX250S.
Safety Features
Ratings
Safety Features Overview: Standard motorcycle safety features including robust braking system, stable chassis, and appropriate lighting.
Active Features
Braking System: Disc brakes front and rear for effective stopping power. (ABS availability may vary by market/trim)
Passive Features
Lighting: Headlight, taillight, brake lights, and turn signals for visibility and signaling.
Technology Features
Infotainment
Infotainment System: N/A (This is a minimalist dual-sport motorcycle; infotainment systems are not applicable).
Driver Assistance
Assistance Features: N/A (No electronic driver assistance systems like ABS on most base models of this era; refer to manual for specific trims).
Connectivity
Connectivity Features: N/A (No Bluetooth or smartphone connectivity features.
Maintenance
Service Intervals
Oil Change Interval: Typically every 3,000 km (1,800 miles) or 6 months, but refer to manual for precise interval based on usage.
Air Filter Cleaning: Regular inspection and cleaning/replacement recommended, frequency dependent on riding conditions (e.g., dusty environments).
Valve Clearance: Typically checked and adjusted at 6,000 km (3,700 miles) or 12,000 km (7,500 miles) intervals. (Consult manual for exact figure)
Chain Lubrication Adjustment: Lubricate and adjust chain every 1,000 km (600 miles) or more frequently in wet/dirty conditions.
Fluid Specifications
Engine Oil Capacity: Refer to manual for exact capacity, typically around 1.4 liters (1.5 US qt) without filter change, 1.6 liters (1.7 US qt) with filter change.
Coolant Capacity: Refer to manual for exact capacity, typically around 1.0 liters (1.1 US qt).
Known Issues
Common Wear Items: Clutch plates, brake pads, chain and sprockets, wheel bearings, and steering stem bearings are common wear items on dual-sport motorcycles.
Potential Faults: While generally reliable, some owners might experience issues related to carburetion (if applicable), electrical connectors in exposed areas, or suspension wear depending on usage.
Vehicle History
Brand Heritage
Kawasaki Offroad: Kawasaki has a long-standing reputation for producing capable and reliable off-road motorcycles, dating back to the legendary K series.
Model Evolution
Klx Lineage: The KLX250 is part of Kawasaki's dual-sport line, designed for both on-road commuting and off-road trail riding. The 2009-2012 models represent a specific iteration of this versatile platform.
Awards & Recognition
Recognitions
Model Reputation: The KLX250 is generally well-regarded for its versatility, affordability, and capability as a lightweight dual-sport, often praised for its ease of use and maintenance.
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