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2009-2012 Kawasaki Klx250 D-tracker X Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 D-Tracker X Model Variant: D-Tracker X Years Covered: 2009, 2010, 2011, 2012 Codes Chassis Code: KLX250V (typical for this generation/market) 👋 Introduction Market Position Segment: Lightweight Supermoto / Dual-Sport Motorcycle Target Audience: Enthusiasts seeking reliable performance and the ability to perform comprehensive maintenance and repairs on their Kawasaki KLX250 D-Tracker X. Competitive Analysis Competitors: Honda CRF250M, Yamaha WR250X (in similar displacement/style categories) Key Features Vehicle Appeal: Agile handling, versatile on-road and light off-road capability, user-friendly maintenance Manual Value Proposition Cost Effectiveness: Inexpensive way to maintain vehicle working properly and avoid costly dealership repairs Completeness: 100% complete and intact, detailed illustrations and step-by-step instructions 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: Hundreds (typical for full factory service manuals) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, lubrication, cooling, fuel injection, ignition, emissions control Transmission: Clutch, gearbox, final drive, lubrication, troubleshooting Chassis: Frame, suspension (front forks, rear shock), steering system, wheels, tires Brakes: Front and rear disc brake systems, hydraulic components, bleeding procedures, pad replacement Electrical System: Battery, charging system, ignition system, lighting, instrumentation, wiring diagrams, troubleshooting Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body Bodywork And Plastics: Panel removal and installation, fairings, fenders, seat Cooling System: Radiator, fan, coolant, hoses Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake inspection Repair: Engine rebuild, transmission repair, suspension overhaul, electrical component replacement Troubleshooting: Diagnostic procedures for common and complex issues, fault code interpretation (if applicable) Disassembly And Assembly: Detailed step-by-step instructions for complete component disassembly and reassembly Technical Depth Depth: Factory-level detail for DIY enthusiasts and professional mechanics, covering complete disassembly and repair 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF for efficient information retrieval Print Quality Printability: All pages printable Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, four-valve, single-cylinder Displacement: 249 cc (249 cubic centimeters) Bore X Stroke: 72.0 x 61.2 mm (typical for this model, confirm with manual) Cooling System: Liquid-cooled Performance Horsepower Approx: ~20-22 HP (Varies by region/tuning, consult manual for exact spec) Torque Approx: ~18-20 Nm (Varies by region/tuning, consult manual for exact spec) Fuel System Fuel Delivery: Fuel injection (EFI) Fuel Type: Unleaded gasoline Ignition: Digital CDI Lubrication Oil Type: SAE 10W-40 motorcycle oil (API SG or higher, JASO MA recommended - confirm in manual) Oil Capacity With Filter: 1.6 L (1.7 US qt) (typical, confirm in manual) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, return type Clutch Type: Wet, multiple-disc, cable operated Features Final Drive: Sealed chain 📐 Dimensions Exterior Length Approx: 2,105 mm (82.9 in) (typical, confirm in manual) Width Approx: 840 mm (33.1 in) (typical, confirm in manual) Height Approx: 1,150 mm (45.3 in) (typical, confirm in manual) Wheelbase Approx: 1,430 mm (56.3 in) (typical, confirm in manual) Weights Curb Weight Approx: 138 kg (304.2 lbs) (typical, confirm in manual) Fuel Tank Capacity: 7.7 L (2.0 US gal) (typical, confirm in manual) 🛡️ Safety Features Ratings Safety Certification: Not typically crash-tested like cars; safety relates to handling, braking, and rider protection (manual covers safe operation). Active Features Braking System: Disc brakes front and rear for effective stopping power. Suspension: Capable suspension system contributing to stable handling. Passive Features Frame Construction: Rigid chassis designed for stability and responsive control. 💡 Technology Features Infotainment Display Type: Digital LCD instrument cluster Instrumentation Features: Speedometer, tachometer, odometer, trip meter, fuel gauge, clock, indicator lights. Driver Assistance ABS: ABS was an optional feature on some models, check specific vehicle configuration. Manual will detail its operation if equipped. Connectivity Connectivity Features: Not applicable (typical for this era of motorcycle, no advanced connectivity features). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-6,000 km (1,800-3,700 mi) or 6 months, whichever comes first (consult manual for precise intervals). Air Filter Cleaning: Inspect every 3,000 km (1,800 mi), clean or replace as needed. Spark Plug Replacement: Every 12,000-24,000 km (7,500-15,000 mi), or as recommended by the manual. Fluid Specifications Brake Fluid: DOT 4 (confirm in manual for specific recommendations) Coolant Type: High-quality ethylene glycol based coolant with distilled water (50/50 mix), or specified Kawasaki coolant (confirm in manual). Known Issues Common Wear Items: Clutch plates, brake pads, chain and sprockets, tires are common wear items. Suspension seals can also be a point of attention over time. Fuel Injection Cleaning: Periodic cleaning of the fuel injector and throttle body may be beneficial for maintaining optimal performance. 📚 Vehicle History Brand Heritage Kawasaki Motorcycles: Kawasaki Heavy Industries is a renowned manufacturer with a long history of producing high-performance motorcycles across various segments, including sportbikes, cruisers, and off-road/dual-sport models. Model Evolution...
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2009-2012 Kawasaki Klx250 D-tracker X Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
KLX250 D-Tracker X
Model Variant:
D-Tracker X
Years Covered:
2009, 2010, 2011, 2012
Codes
Chassis Code:
KLX250V (typical for this generation/market)
👋 Introduction
Market Position
Segment:
Lightweight Supermoto / Dual-Sport Motorcycle
Target Audience:
Enthusiasts seeking reliable performance and the ability to perform comprehensive maintenance and repairs on their Kawasaki KLX250 D-Tracker X.
Competitive Analysis
Competitors:
Honda CRF250M, Yamaha WR250X (in similar displacement/style categories)
Key Features
Vehicle Appeal:
Agile handling, versatile on-road and light off-road capability, user-friendly maintenance
Manual Value Proposition
Cost Effectiveness:
Inexpensive way to maintain vehicle working properly and avoid costly dealership repairs
Completeness:
100% complete and intact, detailed illustrations and step-by-step instructions
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Hundreds (typical for full factory service manuals)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, tuning, lubrication, cooling, fuel injection, ignition, emissions control
Transmission:
Clutch, gearbox, final drive, lubrication, troubleshooting
Chassis:
Frame, suspension (front forks, rear shock), steering system, wheels, tires
Brakes:
Front and rear disc brake systems, hydraulic components, bleeding procedures, pad replacement
Electrical System:
Battery, charging system, ignition system, lighting, instrumentation, wiring diagrams, troubleshooting
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body
Bodywork And Plastics:
Panel removal and installation, fairings, fenders, seat
Cooling System:
Radiator, fan, coolant, hoses
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake inspection
Repair:
Engine rebuild, transmission repair, suspension overhaul, electrical component replacement
Troubleshooting:
Diagnostic procedures for common and complex issues, fault code interpretation (if applicable)
Disassembly And Assembly:
Detailed step-by-step instructions for complete component disassembly and reassembly
Technical Depth
Depth:
Factory-level detail for DIY enthusiasts and professional mechanics, covering complete disassembly and repair
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text within the PDF for efficient information retrieval
Print Quality
Printability:
All pages printable
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper Quality:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, DOHC, four-valve, single-cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
72.0 x 61.2 mm (typical for this model, confirm with manual)
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
~20-22 HP (Varies by region/tuning, consult manual for exact spec)
Torque Approx:
~18-20 Nm (Varies by region/tuning, consult manual for exact spec)
Fuel System
Fuel Delivery:
Fuel injection (EFI)
Fuel Type:
Unleaded gasoline
Ignition:
Digital CDI
Lubrication
Oil Type:
SAE 10W-40 motorcycle oil (API SG or higher, JASO MA recommended - confirm in manual)
Oil Capacity With Filter:
1.6 L (1.7 US qt) (typical, confirm in manual)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh, return type
Clutch Type:
Wet, multiple-disc, cable operated
Features
Final Drive:
Sealed chain
📐 Dimensions
Exterior
Length Approx:
2,105 mm (82.9 in) (typical, confirm in manual)
Width Approx:
840 mm (33.1 in) (typical, confirm in manual)
Height Approx:
1,150 mm (45.3 in) (typical, confirm in manual)
Wheelbase Approx:
1,430 mm (56.3 in) (typical, confirm in manual)
Weights
Curb Weight Approx:
138 kg (304.2 lbs) (typical, confirm in manual)
Fuel Tank Capacity:
7.7 L (2.0 US gal) (typical, confirm in manual)
🛡️ Safety Features
Ratings
Safety Certification:
Not typically crash-tested like cars; safety relates to handling, braking, and rider protection (manual covers safe operation).
Active Features
Braking System:
Disc brakes front and rear for effective stopping power.
Suspension:
Capable suspension system contributing to stable handling.
Passive Features
Frame Construction:
Rigid chassis designed for stability and responsive control.
💡 Technology Features
Infotainment
Display Type:
Digital LCD instrument cluster
Instrumentation Features:
Speedometer, tachometer, odometer, trip meter, fuel gauge, clock, indicator lights.
Driver Assistance
ABS:
ABS was an optional feature on some models, check specific vehicle configuration. Manual will detail its operation if equipped.
Connectivity
Connectivity Features:
Not applicable (typical for this era of motorcycle, no advanced connectivity features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-6,000 km (1,800-3,700 mi) or 6 months, whichever comes first (consult manual for precise intervals).
Air Filter Cleaning:
Inspect every 3,000 km (1,800 mi), clean or replace as needed.
Spark Plug Replacement:
Every 12,000-24,000 km (7,500-15,000 mi), or as recommended by the manual.
Fluid Specifications
Brake Fluid:
DOT 4 (confirm in manual for specific recommendations)
Coolant Type:
High-quality ethylene glycol based coolant with distilled water (50/50 mix), or specified Kawasaki coolant (confirm in manual).
Known Issues
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires are common wear items. Suspension seals can also be a point of attention over time.
Fuel Injection Cleaning:
Periodic cleaning of the fuel injector and throttle body may be beneficial for maintaining optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries is a renowned manufacturer with a long history of producing high-performance motorcycles across various segments, including sportbikes, cruisers, and off-road/dual-sport models.
Model Evolution
Klx Lineage:
The KLX series represents Kawasaki's commitment to off-road and dual-sport motorcycles, known for their durability and versatility. The D-Tracker X variant specifically emphasizes the supermoto styling with street-oriented tires and suspension setup.
Production
Manufacturing Location:
Likely manufactured in Japan or other Kawasaki global facilities, specific location may vary by market (confirm in manual/vehicle details).
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
While specific awards for the 2009-2012 KLX250 D-Tracker X might not be widely publicized, the KLX line is generally recognized for its reliability and capability in the dual-sport and supermoto segments.
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