The 2010 Kawasaki KLX250SA is a capable third-generation dual-sport motorcycle, engineered to offer a balanced blend of on-road usability and off-road prowess. This model is popular for its lightweight design, long-travel suspension, and reliable liquid-cooled, 249 cc single-cylinder engine, making it suitable for trail riding, commuting, and light adventure touring. Its engineering emphasizes durability and performance, ensuring a responsive and enjoyable riding experience across various terrains. This service repair manual provides comprehensive guidance for the maintenance and repair of your 2010 Kawasaki KLX250SA. It covers all essential systems, including the engine, transmission, fuel and ignition systems, cooling, exhaust, chassis, suspension, brakes, wheels, tires, and electrical components. Detailed procedures for routine maintenance, troubleshooting, component overhauls, and disassembly/reassembly are included, offering invaluable assistance to owners and technicians in keeping the motorcycle in optimal condition. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 Vehicle Type: Dual-Sport Motorcycle Generation Model Generation: Third Generation KLX250 Codes Chassis Code: KLX250SA 👋 Introduction Market Position Segment: Lightweight dual-sport motorcycle, popular for trail riding, commuting, and light adventure touring. Competitive Analysis Competitors: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250. Key Features Engine Type: Liquid-cooled, DOHC, four-valve, single-cylinder. Suspension Type: Long-travel, adjustable front forks and rear monoshock suspension. Design Philosophy: Balance of on-road manners and off-road capability. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Fuel System: Yes Ignition System: Yes Cooling System: Yes Exhaust System: Yes Chassis: Yes Suspension Front: Yes Suspension Rear: Yes Brakes Front: Yes Brakes Rear: Yes Wheels Tires: Yes Electrical System: Yes Lighting: Yes Instruments Controls: Yes Bodywork: Yes Troubleshooting: Yes Periodic Maintenance: Yes Wiring Diagrams: Yes Page Count Approximate Pages: Hundreds Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full overhaul, including piston, rings, cylinder, valve timing, and component inspection. Engine Management: EFI system diagnosis, sensor testing, injector service, and ECU troubleshooting. Transmission Drivetrain: Clutch inspection and adjustment, gear inspection, transmission disassembly and reassembly. Suspension Geometry: Front fork service (oil change, seal replacement, spring rates), rear shock absorber adjustment and service. Braking System: Brake pad replacement, caliper servicing, master cylinder maintenance, bleeding procedures. Electrical Schematics: Comprehensive wiring diagrams for all electrical components, including lighting, ignition, and accessories. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, tire pressure checks, spark plug replacement. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common issues, fault code interpretation (if applicable). Component Rebuild: Detailed instructions for rebuilding major components like the engine, carburetor/EFI, and suspension. Disassembly Reassembly: Exploded views and step-by-step guides for dismantling and reassembling the entire motorcycle. Adjustment Calibration: Carburetor tuning, throttle cable adjustment, clutch lever adjustment, suspension sag adjustment. Technical Depth Depth: Comprehensive, covering basic owner maintenance to full engine and chassis rebuilds. Diagnostic Level: Advanced diagnostics, including component testing and troubleshooting flowcharts. Repair Scope: Complete repair procedures for all mechanical and electrical systems. 📊 Manual Specifications File Format Format: PDF Searchable: Likely (standard for factory PDFs) Print Quality Printability: Designed for full or selective printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: Likely DOHC, 4-stroke, 4-valve single cylinder (specific code not provided in product info) Displacement: 249 cc Bore X Stroke: 72.0 mm x 61.2 mm Compression Ratio: 11.0:1 Performance Horsepower: Approx. 24-27 HP (stock, varies by market and tuning) Torque: Approx. 15-17 lb-ft (stock, varies by market and tuning) Fuel System Fuel Delivery: Fuel Injection (EFI), likely Keihin throttle body system. Fuel Type: Unleaded gasoline Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: Constant-mesh, 6-speed return Clutch Type: Wet, multi-disc Features Gear Ratios: Specific ratios detailed within the manual. Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2,165 mm (85.2 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1,180 mm (46.5 in) Wheelbase: Approx. 1,430 mm (56.3 in) Ground Clearance: Approx. 265 mm (10.4 in) Weights Curb Weight: Approx. 132 kg (291 lbs) Fuel Capacity: 11 Liters (2.9 US gal) 🛡️ Safety Features Ratings Safety Features: N/A (Motorcycle safety is primarily based on rider skill and machine condition, though ABS was introduced on later models). Active Features Braking System: Disc brakes front and rear. Passive Features Lighting: Headlight, tail light, brake lights, turn signals. 💡 Technology Features Infotainment Display Type: Digital LCD instrument cluster. Features Cluster: Speedometer, tachometer, odometer, trip meters, fuel gauge, clock, indicator lights. Driver Assistance ABS: Not typically equipped on the 2010 KLX250SA model; ABS was introduced on later iterations. Connectivity Connectivity Features: None (basic motorcycle electronics). 🔧 Maintenance Service Intervals Oil Change: Every 3,000 km or 6 months (refer to manual for specific recommendation). Spark Plug Check: Every 6,000 km or 12 months. Chain Maintenance: Lubrication and adjustment every 500-1,000 km. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher, JASO MA. Engine Oil Capacity:...