Kawasaki KLX250S / KLX250SF – 2009 Factory Service Manual (P/N 99924-1393-02)

Kawasaki factory service manual for the 2009 KLX250S (KLX250T9F) and KLX250SF (KLX250W9F), P/N 99924-1393-02.

Text Search, Chapter Bookmarks, and PDF Details

Search and diagram detail: Embedded OCR supports text searches, although some codes and diagram labels are misrecognized. PDF bookmarks link to all 17 chapters. Small wiring labels require zooming.

One printable, English-language PDF contains 452 pages: seven front-matter pages, 444 chapter pages, and one final Model Application page.

Engine Repair, Chassis Service, and Electrical Testing

These highlights are a selection of covered work, rather than a complete contents list. Additional topics include speed-sensor testing and meter-unit inspection.

• Engine repair: Engine removal, cylinder-head and piston service, valve-clearance adjustment, camshaft timing, crankcase splitting, and crankshaft inspection.

• Clutch and transmission: Clutch-pack inspection and adjustment, gearbox disassembly and reassembly, shift-mechanism inspection, balancer alignment, and starter-clutch/torque-limiter service.

• Fuel system: Step-by-step Keihin CVK34 carburetor overhaul, service-fuel-level checks, float-height adjustment, and California evaporative-emission-system inspection.

• Cooling and lubrication: Cooling-system pressure testing, thermostat inspection, water-pump seal replacement, oil-pump service, and oil-pressure measurement.

• Brakes and chassis: Step-by-step front-fork rebuilding and brake-line bleeding, plus caliper, master-cylinder, wheel-bearing, final-drive, and steering-stem service.

• Electrical diagnosis: Charging-system tests, ignition peak-voltage checks, starter-motor overhaul, safety-interlock testing, and model-specific wiring diagrams.

Written primarily for trained mechanics in a properly equipped shop, the manual also supports owners with basic mechanical knowledge performing basic maintenance and repair.

Valve Gear and Internal Engine Inspection

The Valve Clearance Adjustment Charts relate measured clearances to replacement shim sizes. Camshaft installation illustrations identify sprocket timing marks, while the General Information section defines crankshaft rotation relative to the output-side view.

The camshaft cap and cylinder head are machined together and must be replaced as a set. Transmission inspection covers shift-fork, drum-groove, and gear-dog wear, with illustrated shaft and gear assembly arrangements.

KACR diagnosis: The Kawasaki Automatic Compression Release section distinguishes compression-release failure during starting from unwanted release while running. Its spring and weight checks help assess hard starting or stalling alongside cylinder-compression testing. KACR coverage is inspection and replacement with the exhaust camshaft, rather than separate mechanism disassembly.

The Periodic Maintenance Chart organizes scheduled inspections and replacements. Annotated exploded views identify fastener torques, lubrication points, and locking-agent requirements for reassembly.

Carburetor and Market-Specific Emissions

Carburetor inspection extends to the vacuum piston, diaphragm, float valve, jets, and pilot screw. The cleaning cautions explain how compressed air applied to an assembled carburetor can crush the floats or damage the diaphragm.

California evaporative-emission coverage includes separator operation and canister inspection. The Exhaust System Identification chart distinguishes early and late KLX250S exhaust configurations and identifies the California codes listed above.

Fuel-system warnings address flammable cleaning liquids, ventilation, and ignition sources.

Cooling Leaks and Lubrication Checks

The Coolant Flow Chart shows the circulation path. Water-pump inspection connects leakage at the drain passage with mechanical-seal condition, while the lubrication section provides oil-pressure test conditions and oil-pump and relief-valve checks.

Suspension Settings and Chassis References

Separate KLX250T and KLX250W specifications cover fork oil, springs, damping settings, and steering geometry. Uni-Trak linkage service includes rocker-arm, tie-rod, and swingarm bearing inspection and replacement.

Rear-shock removal cautions explain how forcing a mounting bolt can damage the bolt, sleeve, or bearing. The procedure also addresses securing the motorcycle against falling.

Ignition Fault Tracing and Wiring References

The Ignition System Troubleshooting Flow Chart connects no-spark symptoms with component tests. Separate wiring diagrams distinguish the Australian KLX250T from the other KLX250T/KLX250W circuit, supported by the Charging System Circuit and Cable, Wire, and Hose Routing views.

Peak-voltage testing specifies the Hand Tester (57001-1394) and Peak Voltage Adapter (57001-1415), allowing users to identify the required diagnostic equipment before starting work.

Examples of Valve, Head-Bolt, and Coolant Specifications

Cold-engine valve-clearance standards are 0.10–0.19 mm for intake valves and 0.15–0.24 mm for exhaust valves, accompanied by shim-selection charts.

The M10 cylinder-head bolt specification has an initial stage of 15 N·m and a final stage of 46 N·m, with specified molybdenum-disulfide grease application and a prescribed tightening sequence.

Cooling specifications list a total coolant quantity of 1.3 L, including the radiator and engine with the reserve tank at its full mark.