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Kawasaki KLX250SA 2010 Workshop Service Repair Manual PDF Download
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Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 Motorcycle Type: Dual-Sport / Off-Road Generation Generation Code: KLX250 (SF/S/D-Tracker) Introduction Market Position Segment: Lightweight dual-sport motorcycle, popular for trail riding,...
Type: Motorcycles
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| Basic Information | |
| Identification | |
| Make: | Kawasaki |
| Model: | KLX250SA |
| Year: | 2010 |
| Motorcycle Type: | Dual-Sport / Off-Road |
| Generation | |
| Generation Code: | KLX250 (SF/S/D-Tracker) |
| Introduction | |
| Market Position | |
| Segment: | Lightweight dual-sport motorcycle, popular for trail riding, commuting, and light off-road use |
| Competitive Analysis | |
| Competitors: | Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 |
| Key Features | |
| Versatility: | Capable on both pavement and unpaved roads, offering a balance of performance and usability |
| Reliability: | Known for its robust engine and durable construction, common in Kawasaki's off-road lineage |
| Maneuverability: | Lightweight chassis and manageable power delivery contribute to excellent handling |
| Manual Details | |
| Coverage Areas | |
| Coverage Scope: | Complete Factory Service Repair |
| Page Count | |
| Estimated Page Count: | Hundreds of pages (exact count not specified, but implied to be comprehensive) |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Full disassembly, assembly, tuning, troubleshooting, specifications |
| Fuel System: | Carburetor (CVK34), fuel pump, fuel lines, fuel tank maintenance and repair |
| Ignition System: | CDI, spark plug, ignition coils, timing |
| Cooling System: | Liquid cooling system, radiator, fan, coolant specifications |
| Transmission: | Clutch, gearbox, shift drum, internal components, lubrication, troubleshooting |
| Drivetrain: | Chain drive, sprockets, maintenance and replacement procedures |
| Chassis Frame: | Frame inspection, alignment, related components |
| Suspension Front: | Telescopic front fork, damping adjustment, oil change, seal replacement, troubleshooting |
| Suspension Rear: | Uni-Trak rear suspension, shock absorber, linkage components, adjustment, maintenance |
| Brakes Front: | Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications |
| Brakes Rear: | Hydraulic disc brake, caliper, master cylinder, brake pads, fluid, bleeding, rotor specifications |
| Wheels Tires: | Wheel bearing maintenance, spoke tension, tire pressure, specifications |
| Electrical System: | Battery, charging system (stator, regulator/rectifier), lighting, starting system, wiring diagrams |
| Instrumentation: | Speedometer, tachometer, indicator lights, troubleshooting |
| Bodywork Trim: | Fairings, fenders, seat, fuel tank cover, decals, removal and installation |
| Exhaust System: | Muffler, head pipe, gaskets, inspection and repair |
| Troubleshooting: | Comprehensive diagnostic guides for all major systems, fault finding charts |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication |
| Repair: | Component disassembly, assembly, replacement, and adjustment for all major systems |
| Rebuild: | Detailed instructions for engine rebuilds, carburetor overhauls, and suspension rebuilds |
| Diagnostics: | Systematic troubleshooting steps and diagnostic flowcharts |
| Specifications: | Torque values, clearances, fluid capacities, electrical specifications, measurements |
| Wiring Diagrams: | Complete and detailed electrical system schematics |
| Technical Depth | |
| Depth: | Factory-level technical detail for professional mechanics and advanced DIY enthusiasts |
| Detail Level: | Includes step-by-step procedures, exploded diagrams, and troubleshooting charts |
| Manual Specifications | |
| File Format | |
| Format Details: | Searchable PDF, allowing easy navigation and printing of specific pages or the entire manual |
| Print Quality | |
| Quality: | High-resolution scans, ensuring clarity of text and diagrams |
| Binding Type | |
| Binding: | N/A (Digital PDF Download) |
| Paper Type | |
| Paper: | N/A (Digital PDF Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, DOHC, 4-valve, Single-cylinder |
| Displacement: | 249 cc (250cc class) |
| Bore X Stroke: | 72.0 mm x 61.2 mm (typical for this generation) |
| Compression Ratio: | 11.0:1 (typical) |
| Performance | |
| Horsepower: | Approximately 22-24 HP @ 7,500 RPM (Estimate based on model year and configuration) |
| Torque: | Approximately 16-18 lb-ft @ 6,500 RPM (Estimate based on model year and configuration) |
| Fuel System | |
| Carburetor: | Keihin CVK34 with Accelerator Pump |
| Fuel Capacity: | Approx. 2.5 - 3.0 gallons (7.7 - 11.0 Liters) depending on sub-model |
| Lubrication | |
| Oil Capacity With Filter: | Approx. 1.6 - 1.8 Liters (Consult manual for exact specification) |
| Engine Oil Type: | API SG or SH, SAE 10W-40 motorcycle specific oil (Consult manual for exact specification) |
| Transmission | |
| Standard | |
| Transmission Type: | 6-speed constant mesh |
| Optional | |
| Optional Transmission: | N/A |
| Features | |
| Clutch Type: | Wet, multi-disc |
| Final Drive: | Sealed chain |
| Dimensions | |
| Exterior | |
| Length: | Approx. 85.2 inches (2165 mm) (Varies slightly by sub-model) |
| Width: | Approx. 33.5 inches (850 mm) (Varies slightly by sub-model) |
| Height: | Approx. 45.7 inches (1160 mm) (Varies slightly by sub-model) |
| Wheelbase: | Approx. 56.7 inches (1440 mm) |
| Ground Clearance: | Approx. 11.0 inches (280 mm) |
| Weights | |
| Curb Weight: | Approx. 291 lbs (132 kg) (Varies slightly by sub-model) |
| Gross Vehicle Weight Rating: | Not explicitly specified, but typically around 350-400 lbs |
| Front Tire Size: | 80/100-21 M/C 51P (Typical for KLX250S) |
| Rear Tire Size: | 100/100-18 M/C 59P (Typical for KLX250S) |
| Wheel Bolt Pattern: | N/A (Spoked wheels with axle nuts) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | N/A (Motorcycles are not typically rated by organizations like NHTSA or IIHS) |
| Active Features | |
| Braking System: | Disc brakes front and rear, hydraulic actuation |
| ABS: | Not available on this model |
| Passive Features | |
| Lighting: | Halogen headlight, LED tail light, incandescent turn signals |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (Motorcycle, basic instrumentation only) |
| Driver Assistance | |
| Rider Aids: | N/A (No electronic rider aids like traction control or ABS) |
| Connectivity | |
| Connectivity Features: | N/A |
| Engine Technology | |
| Fuel Injection Vs Carburetion: | Utilizes a carburetor (CVK34), which is detailed thoroughly in the manual for maintenance and troubleshooting. |
| Engine Cooling: | Liquid-cooled, a more advanced system than many air-cooled counterparts, improving performance and reliability. The manual covers its maintenance. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 3,000 km or 3 months, whichever comes first (Consult manual for exact interval and conditions) |
| Air Filter Cleaning Interval: | Every 6,000 km or as needed in dusty conditions (Consult manual for exact interval) |
| Spark Plug Replacement Interval: | Every 12,000 km or as needed (Consult manual for exact interval) |
| Chain Maintenance Interval: | Lubricate and adjust chain every 1,000 km or as needed (Consult manual for exact interval) |
| Fluid Specifications | |
| Brake Fluid: | DOT 3 or DOT 4 (Consult manual for exact specification) |
| Coolant: | Kawasaki's Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water) (Consult manual for exact specification) |
| Fork Oil Type: | SAE 0W-20 or 10W (Consult manual for exact specification and volume) |
| Known Issues | |
| Carburetor Performance: | Some users report lean conditions or flat spots, often addressed by rejetting or tuning the CVK34 carburetor, which the manual will detail. |
| Suspension Softness: | Stock suspension can be considered soft for aggressive off-road use, but the manual provides adjustment and rebuild procedures. |
| Cooling System Efficiency: | Proper coolant level and fan operation are critical, especially during sustained low-speed off-road riding. The manual covers checks and maintenance. |
| Vehicle History | |
| Brand Heritage | |
| Kawasaki Off Road: | Kawasaki has a long and successful history in off-road motorcycling, including motocross and enduro racing, which informs the design of the KLX line. |
| Model Evolution | |
| Klx Lineage: | The KLX250 has evolved over several generations, with the 2010 model representing a refinement of the design that emphasizes usability and off-road capability. |
| Sf Vs S: | The KLX250SA designation often refers to the standard 'S' model (dual-sport), while 'SF' models may feature different wheel configurations (e.g., 17-inch wheels for street). The manual likely covers variants of the KLX250. |
| Production | |
| Manufacturing Location: | Primarily manufactured in Thailand for global markets. |
| Awards & Recognition | |
| Recognitions | |
| Motorcycle Awards: | While specific awards for the 2010 KLX250SA might not be widely publicized, the KLX lineage consistently receives positive reviews for its all-around capabilities and value in the dual-sport segment. |
| Ratings | |
| Owner Satisfaction: | Generally high owner satisfaction for its segment, valued for its durability and ease of maintenance. |