This manual covers the dual-sport motorcycles produced for the 2009 through 2012 model years. The platform is celebrated for its versatile nature, adeptly handling both urban commuting and light off-road exploration. Key features include a liquid-cooled, four-stroke engine, robust upside-down front forks, and adjustable rear suspension, all contributing to its nimble handling and reliable performance. The legacy of engineering excellence is evident in the motorcycle's balanced power delivery and durable construction, making it a favored choice for riders seeking an accessible and capable dual-sport machine. This comprehensive workshop service and repair manual provides essential information for maintaining and repairing your motorcycle series. Within its approximately 500+ pages, you will find detailed procedures for engine disassembly and assembly, fuel system maintenance, ignition system troubleshooting, transmission and clutch servicing, suspension overhauls, brake system repairs, and electrical system diagnostics. The manual also includes routine maintenance tasks, special tool requirements, exploded views, wiring diagrams, and troubleshooting guides, ensuring that owners, mechanics, and technicians have the resources needed to keep their motorcycles in optimal condition. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250 Sub Models: KLX250S, KLX250SF Model Years Covered: 2009, 2010, 2011, 2012 Vehicle Type: Dual-Sport Motorcycle 👋 Introduction Market Position Segment: Lightweight dual-sport motorcycle, appealing to riders seeking versatility for on-road and light off-road use. Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 (contemporaneous models). Key Features Versatility: Adaptable for commuting, trail riding, and light adventure touring. Engine Type: Fuel-injected, liquid-cooled, four-stroke engine (for most of the covered period, though earlier models may have been carbureted, this manual specifically covers FI for later years or models). Suspension: Upside-down (USD) front forks and adjustable rear suspension for capable off-road performance. Target Audience Rider Profile: New riders, commuters, and experienced riders looking for a nimble and reliable dual-sport machine. 📋 Manual Details Coverage Areas Primary Coverage: Complete workshop service and repair for Kawasaki KLX250, KLX250S, and KLX250SF models Page Count Estimated Page Count: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed engine disassembly, assembly, tuning, and troubleshooting (e.g., cylinder head, piston, crankshaft, valve train, lubrication system) Fuel System: Carburetor (mention specific type if known, e.g., Keihin CVK) maintenance, cleaning, adjustment, and troubleshooting; fuel pump and filter for SF models. Ignition System: CDI unit, ignition coils, spark plugs, timing adjustments, and troubleshooting. Transmission Clutch: Clutch operation, maintenance, replacement; transmission gear inspection, disassembly, assembly, and troubleshooting. Frame Suspension Steering: Front fork (e.g., USD forks) overhaul, oil changes, seal replacement; rear shock absorber adjustment and rebuild; steering head bearing maintenance; swingarm and linkage servicing. Brakes: Front and rear brake system inspection, pad replacement, caliper service, master cylinder overhaul, bleeding procedures, hydraulic lines. Wheels Tires: Tire pressure, wear inspection, replacement, wheel bearing maintenance, spoke tension adjustment. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starting system, instrumentation, and fuses. Cooling System: Radiator, cooling fan operation, coolant replacement, hose inspection. Exhaust System: Exhaust pipe and muffler inspection, heat shield servicing. Bodywork Fittings: Fairings, fenders, seat, fuel tank removal and installation, graphics. Procedures Included Maintenance Tasks: Routine inspections, oil changes, filter replacements, chain adjustment, lubrication points, brake fluid flushes, coolant flushes, spark plug checks. Repair Tasks: Engine internal repairs, transmission overhauls, suspension rebuilds, brake system repairs, electrical component replacement and troubleshooting. Troubleshooting: Diagnostic procedures for common and uncommon issues, including electrical faults, starting problems, running issues, and performance concerns. Special Tools: Identification and usage of specialized tools required for specific repair and maintenance procedures. Technical Depth Diagnostic Capabilities: Comprehensive diagnostic charts and flow diagrams for identifying and resolving mechanical and electrical problems. Rebuild Procedures: Detailed step-by-step instructions for complete engine and major component rebuilds, including torque specifications and clearances. Diagrams Illustrations: Exploded views, schematics, and detailed illustrations to guide disassembly, assembly, and component identification. Wiring Schematics: Complete and color-coded wiring diagrams for all electrical systems, facilitating troubleshooting and repair. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Searchable text content for quick information retrieval. Print Quality Printability: Printable pages for offline reference. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, 4 valves per cylinder, single-cylinder Displacement: 249 cc (249 cm³) Bore X Stroke: 72.0 x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 20-25 HP (peak, varies by specific model tune and regulations) Torque: Approx. 19-21 Nm (peak, varies by specific model tune and regulations) Fuel System Fuel Delivery: Fuel Injection (EFI) for most 2009+ models, potentially Keihin CVK carburetor on earlier or specific variants not explicitly detailed in the product name. Fuel Type: Unleaded gasoline Lubrication Oil Type: Kawasaki recommends KAWASAKI HIGH PERFORMANCE SEMISYNTHETIC MOTOR OIL SAE 10W-40 or API SG, SF, SE, SG, SH, SJ or SL classification. Oil Capacity: Approx. 1.5...