The 2010 KLX250SA is a versatile dual-sport motorcycle, engineered for both on-road legality and off-road capability. This lightweight machine features a liquid-cooled, four-stroke engine, known for its reliable performance and adaptability across various terrains. With its robust suspension system and street-legal lighting, the KLX250SA is designed to handle commuting, trail riding, and adventure touring, embodying a legacy of producing durable and capable motorcycles. This comprehensive workshop repair service manual provides detailed information essential for the maintenance and repair of the 2010 KLX250SA. It covers all models, engines, and transmissions, offering in-depth guidance on routine maintenance, engine mechanicals, fuel and ignition systems, cooling, transmission, suspension, brakes, electrical systems, and chassis components. The manual includes step-by-step repair procedures, troubleshooting guides, diagnostic charts, and technical data tables, equipping owners and technicians with the knowledge needed to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Kawasaki Model: KLX250SA Year: 2010 Codes Internal Model Code: KLX250SA 👋 Introduction Market Position Segment: Dual-sport / Off-road motorcycle Target Audience: Owners, mechanics, and enthusiasts seeking detailed repair and maintenance information for the 2010 Kawasaki KLX250SA. Competitive Analysis Key Competitors Segment: Honda CRF250L, Yamaha WR250R, Suzuki DR-Z250 Key Features Klx250Sa Model Description: A versatile and lightweight dual-sport motorcycle, known for its off-road capability and street-legal compliance. Features a liquid-cooled, four-stroke engine and a capable suspension system. 📋 Manual Details Coverage Areas All Models Engines Trims Transmissions: Yes Page Count Estimated Pages: Estimated 300-500 pages (typical for this type of manual) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, torque specifications, cylinder head, piston, crankshaft, connecting rod, valves, camshafts, timing. Fuel System: Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, lines. Ignition System: Ignition coils, spark plugs, CDI unit, crankshaft position sensor, ignition timing. Cooling System: Radiator, cooling fan, water pump, thermostat, coolant hoses, coolant type. Exhaust System: Exhaust pipes, muffler, catalytic converter, O2 sensors. Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, gear ratios, shift mechanism, final drive (chain and sprockets), lubrication. Suspension Front: Front fork (upside-down), fork oil type and level, seals, bushings, spring rates, adjustments. Suspension Rear: Rear shock absorber, linkage system, swingarm, bearings, adjustments. Brakes Front: Brake caliper, master cylinder, brake pads, brake disc, brake fluid type and bleeding procedure. Brakes Rear: Rear brake caliper, master cylinder, brake pads, brake disc, brake fluid type and bleeding procedure. Wheels Tires: Wheel bearing inspection and replacement, tire pressure specifications, tire size recommendations, spoke tensioning. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays. Instrumentation Controls: Dashboard, speedometer, tachometer, indicator lights, handlebar controls, throttle operation. Chassis Frame: Frame inspection, steering head bearings, swingarm pivot. Bodywork Plastics: Fairings, fenders, fuel tank cover, seat removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, air filter cleaning/replacement, spark plug checks, brake pad inspection. Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues, error code explanations (if applicable). Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul of major systems. Diagnostic Charts: Flowcharts and tables to help identify and resolve problems. Technical Data Tables: Torque specifications, fluid capacities, clearances, electrical resistances, diagnostic values. Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to complete engine rebuilds and system diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically text-searchable PDF for quick information retrieval. Print Quality Print Readability: Designed for clear printing of diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, DOHC, four-valve single cylinder Displacement: 249 cc (15.2 cu in) Bore X Stroke: 72.0 x 61.2 mm (2.83 x 2.41 in) Compression Ratio: 11.0:1 Performance Horsepower: Approx. 22-24 HP (at crankshaft, actual may vary) Torque: Approx. 15-17 lb-ft (at crankshaft, actual may vary) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) with Keihin 34mm throttle body Fuel Type: Unleaded gasoline, 87 octane or higher Lubrication Oil Type: SAE 10W-40 API SG or SH with JASO MA certification Oil Capacity With Filter: 1.7 L (1.8 US qt) Oil Capacity Without Filter: 1.5 L (1.6 US qt) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh, return shift Features Clutch Type: Wet, multi-disc, cable operated Final Drive: Sealed chain, RK520KXO, 14T front sprocket, 50T rear sprocket 📐 Dimensions Exterior Length: 2,180 mm (85.8 in) Width: 820 mm (32.3 in) Height: 1,190 mm (46.9 in) Wheelbase: 1,430 mm (56.3 in) Ground Clearance: 255 mm (10.0 in) Seat Height: 865 mm (34.1 in) Weights Curb Weight: 136 kg (299.8 lbs) Fuel Capacity: 7.7 L (2.0 US gal) Front Tire Size: 80/100-21M/C 51P Rear Tire Size: 100/100-18M/C 59P Wheel Bolt Pattern: N/A (Spoked wheels, hub-mounted) 🛡️ Safety...