Kawasaki KLX250 2010 Owner's manual

Motorcycle

Owner’s Manual

ENGLISH j

Whenever you see the symbols
shown below, heed their instructions!
Always followsafeoperating andmain­tenance practices.

DANGER

DANGER indicates a hazardous

situation which, if not avoided,

will result in death or serious in-

jury.

WARNING

WARNINGindicates a hazardous

situation which, if not avoided,

could result in death or serious

injury.

CAUTION

CAUTION indicates a hazardous
situation which, if not avoided,
could result in minor or moder­ate injury.

NOTICE

NOTICE is used to address prac­tices not related to personal in­jury.

NOTE

This note symbol indicates points of

○

particular interest for more e fficient
and convenient operation.

FOREWORD

Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo­torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing,
and continuous striving for superior reliability, safety and performance.

Please read this Owner ’s Manual carefully before riding so that you will be
thoroughly familiar with the proper operation of your motorcycle’s controls, its fea­tures, capabilities, and limitations. This manual offers many safe riding tips, but its
purpose is not to provide ins truction in all the techniques and skills required to ride
a motorcycle safely. Kawasaki strongly recommends that all operators of this vehi­cle enroll in a motorcycle rider training program to attain awareness of the mental
and physical requirements necessary for safe motorcycle operation.

To ensure a long, trouble-free life for your motorcycle, give it the proper care and
maintenance described in this manual. For those who would like more detailed in­formationon their Kawasaki Motorcycle, aService Manual is available for purchase
fromany authorized Kawasaki motorcycledealer. The ServiceManualcontains de­tailed disassembly and maintenance information. Those who plan to do their own
work should, of course, be competent mechanics and possess the special tools
described in the S ervice Manual.

Keep this Owner’s Manual aboard your motorcycle at all times so that you can
refer to it whenever you need information.

Thismanualshould be considered apermanentpartof the motorcycleandshould

remain with the motorcycle when it is sold.

All rights reserved. No part of this publication may be reproduced without our

prior written permission.

This publication includes the latest information available at the time of printing.
However, there may be minor differences between the actual product and illustra­tions and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

© 2010 Kawasaki Heavy Industries, Ltd. May 2010. (1).

TABLE OF CONTENTS

SPECIFICATIONS ............................... 8

LOCATION OF PARTS....................... 12

LOCATION OF LABELS..................... 15

LOADING INFORMATION.................. 18

GENERAL INFORMATION................. 21

Meter Instruments............................ 21

Meter Instruments:........................ 22

Tachometer Gauge:...................... 22

Speedometer :.............................. 22

Odometer/Trip Meter AB/Fuel

Warning Message (ODO/TRIP

AB): ........................................... 23

Indicator/Warning Light:................ 27

Warning/Indicator Lights:.............. 27

Key................................................... 29

Ignition Switch/Steering Lock........... 29

Right Handlebar Switches................ 31

Engine Stop Switch: ..................... 31

Starter Button: .............................. 31

Headlight Switch:.......................... 31

Left Handlebar Switches .................. 32

Dimmer Switch: ............................ 32

Turn Signal Switch:....................... 33

Horn Button: ................................. 33

Fuel Tank Cap.................................. 33

Fuel.................................................. 34

Fuel Requirements: ...................... 34

Filling the Tank:............................. 36

Stand................................................ 38

Helmet Hook.................................... 39

Tool Kit Bag/Tool Kit......................... 40

Seat.................................................. 40

BREAK-IN ........................................... 42

HOW TO RIDE THE MOTORCYCLE .44

Starting the Engine .......................... 44

Jump Starting................................... 46

Moving Off........................................ 49

Shifting Gears.................................. 50

Braking............................................. 51

Stopping the Engine......................... 52

Stopping the Motorcycle in an

Emergency ................................... 53

Parking............................................. 54

Catalytic Converter........................... 56

SAFE OPERATION............................. 58

Safe Riding Technique..................... 58

Daily Safety Checks......................... 61

Additional Considerations for Off

Road Operation............................ 64

MAINTENANCE AND ADJUSTMENT 65

Periodic Maintenance Chart............. 66

Engine Oil ........................................ 77

Cooling System................................ 83

Spark Plugs...................................... 87

Valve Clearance............................... 89

Kawasaki Clean Air System............. 89

Air Cleaner....................................... 90

Throttle Grip..................................... 96

Idle Speed........................................ 98

Clutch............................................... 99

Drive Chain ...................................... 102

Brakes.............................................. 109

Brake Light Switches........................ 113

Front Fork......................................... 115

Rear Shock Absorber....................... 117

Wheels............................................. 120

Battery.............................................. 124

Headlight Beam................................ 129

Fuses ............................................... 131

Cleaning Your Motorcycle ................ 132

STORAGE........................................... 136

ENVIRONMENTAL PROTECTION..... 139

LABEL INFORMATION ...................... 140

8 SPECIFICATIONS

SPECIFICATIONS

PERFORMANCE

Maximum Horsepower
Maximum Torque
Minimum Turning Radius

DIMENSIONS

Overall Length 2 200 mm (86.62 in.)
Overall Width 820 mm (32.28 in.)
Overall Height 1 205 mm (47.4 in.)
Wheelbase
Road Clearance 285 mm (11.22 in.)
CurbMass 138kg(304lb)

ENGINE

Type
Displacement
Bore x Stroke 72.0 × 61.2 mm (2.83 × 2.41 in.)

16 kW (22 PS) @7 500 r/min (rpm)

20.5 N·m (2.09 kg·m, 15.1 ft·lb) @7 000 r/min (rpm)

2.4 m (94.5 in.)

1 430 mm (56.30 in.)

DOHC, single-cylinder, 4-stroke, liquid-cooled
249cm³(15.2cuin.)

SPECIFICATIONS 9

Compression Ratio
Starting System

11.0 : 1

Electric starter
Fuel System FI (Fuel Injection)
Ignition System CDI
Ignition Timing

(Electronically advanced)

10° BTDC @1 300 r/min (rpm) ∼ 34° BTDC @11 000

r/min (rpm)
Spark Plugs NGK CR8E
Lubrication System Forced lubrication (wet sump)
Engine Oil

Type:
Viscosity:
Capacity:

API SG, SH, SJ, SL or SM with JASO MA, MA1 or MA2

SAE 10W-40

1.3 L (1.4 US qt)

Coolant Capacity 1.3 L (1.4 US qt)

TRANSMISSION

Transmission Type
Clutch Type

6-speed, return shift

Wet, multi disc
Driving System Chain drive

10 SPECIFICATIONS

Primary Reduction Ratio
Final Reduction Ratio
Overall Drive Ratio 8.000 (Top gear)
Gear Ratio

1st
2nd
3rd
4th
5th
6th

FRAME

Castor 26.5°
Trail
Tire Size:

Front 3.00-21 51P
Rear

2.800 (84/30)

3.000 (42/14)

3.000 (30/10)

2.000 (30/15)

1.500 (27/18)

1.250 (25/20)

1.050 (21/20)

0.952 (20/21)

105 mm (3.31 in.)

4.60-18 63P

SPECIFICATIONS 11

Rim Size:

Front 21 × 1.60
Rear

18 × 2.15
Fuel Tank Capacity 7.7 L (2.04 US gal)

ELECTRICAL EQUIPMENT

Battery 12V6Ah
Headlight

12 V 60/55 W
Tail/Brake Light 12 V 5/21 W

Specificationssubject tochangewithout notice, andmaynot apply to everycountry.

12 LOCATION OF PARTS

LOCATION OF PARTS

1. Clutch Lever

2. Meter Instruments

3. Brake Fluid Reservoir (Front)

4. Front Brake Lever

5. Left Handlebar Switches

6. Ignition Switch/Steering Lock

7. Right Handlebar Switches

8. Throttle Grip

LOCATION OF PARTS 13

9. Front Fork

10. Headlight

11. Turn Signal Light

12. Fuel Tank Cap

13. Fuel Tank

14. Rear Shock Absorber

15. Tool Kit Bag

16. Tool Kit

17. Helmet Hook

18. Brake Disc

19. Brake Caliper

20. Radiator

21. Horn

22. Shift Pedal

23. Side Stand

24. Side Stand Switch

25. Drive Chain

26. Coolant Reserve Tank

27. Battery

14 LOCATION OF PARTS

28. Tail/Brake Light

29. Muffler

30. Seat

31. Air Cleaner Element

32. Idle Adjusting Screw

33. Front Brake Light
Switch

34. Radiator Cap

35. Brake Flu id Reservoir
(Rear)

36. Rear Brake Light
Switch

37. Oil Level Gauge

38. Rear Brake Pedal

39. Speedometer Lead

LOCATION OF LABELS

1. Brake Fluid (Front)

2. Important Drive Chain Information

3. Tire and Load Data
(For further information of label,

refer to the “LABEL INFORMATION”
chapter.)

LOCATION OF LABELS 15

16 LOCATION OF LABELS

4. Brake Fluid (Rear)

5. Daily Safety Checks
(For further information of label,

refer to the “LABEL INFORMATION”
chapter.)

LOCATION OF LABELS 17

6. Unleaded Gasoline

7. Battery Poison/Danger
(For further information of label,

refer to the “LABEL INFORMATION”
chapter.)

18 LOADING INFORMATION

LOADING INFORMATION

WARNING

Incorrect loading, improper in­stallation or use of accessories,
or modification of your motorcy­clemay result in an unsaferiding
condition. Before you ride the
motorcycle,makesureitisnot
overloaded and that you have
followed these instructions.

With the exception of genuine
Kawasaki Parts and Accessories,
Kawasaki has no control over the
design or application of accessories.
In some cases, improper installation
or use of accessories, or motorcycle
modification, will void the motorcycle
warranty. In selecting andusing acces­sories, and in loading the motorcycle,

you are personally responsible for your
own safety and the safet y of other per­sons involved.

NOTE

Kawasaki Parts and Accessories

○

have been specially designed for
use on Kawasaki motorcycles. We
strongly recommend that all parts
and accessories you add to your
motorcycle be genuine Kawasaki
components.

Because a motorcycle is sensitive to
changes in weight and aerodynamic
forces, you must take extreme care
in carrying cargo, passengers and/or
in the fitting of additional accessories.
The following general guidelines have

LOADING INFORMATION 19

been prepared to assist you in making
your dete rminations.

1. Any passenger should be thor­oughly familiar with motorcycle op­eration. The passenger can affect
control of the motorcycle by im­proper positioning during cornering
and sudden movements. It is impor­tant that the passenger sit still while
the motorcycle is in motion and not
interfere with the operation of the
motorcycle. Do not carry animals
on your motorcycle.

2. You should instruct any passenger
before riding to keep his feet on the
passenger footpegs and hold on to
the operator or seat strap. Do not
carry a passenger unless he or she
is tall enough to reach the footpegs
and footpegs are provided.

3. All baggage should be carried as
low as possible to reduce the effect

on the motorcycle center of gravity.
Baggage weight should also be dis­tributed equally on both sides of the
motorcycle. Avoidcarryingbaggage
that extends beyond the rear of the
motorcycle.

4. Baggage should be securely at­tached. Makesure that the baggage
will not move around w hile you are
riding. Recheck baggage security
as often as possible (not while the
motorcycle is in motion) and adjust
as necessary.

5. Donot carry heavyor bulky itemson
a luggage rack. They are designed
for light items, and overloading can
affect handling due to changes in
weightdistributionand aerodynamic
forces.

6. Do not install accessories or carry
baggage that impairs the perfor­mance of the motorcycle. Make
sure that you have not adversely

20 LOADING INFORMATION

affected any lighting components,
road clearance, banking capability
(i.e., lean angle), control operation,
wheel travel, front fork movement,
or any other aspect of the motorcy­cle’s operation.

7. Weight attached to the handlebar or
front fork will increase the mass of
the steering assembly and can re­sult in an unsafe riding condition.

8. Fairings, windshields, backrests,
and other large items have the ca­pability of adversely affecting stabil­ity and handling of the motorcycle,
not only because of their weight, but
also due to the aerodynamic forces
acting on these surfaces while the
motorcycleisinoperation. Poorly
designed or installed items can re­sult in an unsafe riding condition.

9. This motorcycle was not intended
to be equipped with a sidecar or to

be used to tow any trailer or other
vehicle. Kawasaki does not manu­facture sidecars or trailers for mo­torcycles and cannot predict the ef­fects of such accessories on han­dling or stability, but can only warn
that the effects can be adverse and
that Kawasaki cannot assume re­sponsibility for the results of such
unintended use of the motorcycle.
Furthermore, any adverseeffects on
motorcycle components caused by
the use of such accessories will not
be remedied under warranty.

Maximum Load

Weight of rider, passenger, baggage,
and accessories must not exceed 181 kg
(399 lb).

Meter Instruments

A. MODE Button
B. RESET Button
C. Tachometer Gauge
D. Odometer/Trip Meter

AB/Fuel Warning Message
E. Speedo meter
F. Clock
G. Coolant Temperature

Warning Light
H. High Beam Indicator Light
I. Neutral Indicator Light
J. Turn Signal Indicator Light
K. Red Zone
L. FI (Fuel Injection)

Warning Light
M. Fuel Level Indicator Light

GENERAL INFORMATION 21

GENERAL INFORMATION

22 GENERAL INFORMATION

Meter Instruments:

The meter displays all segments for
a few seconds when the ignition key is
turned to “ON”. The tachometer mo­mentarily goes from the minimum to
the maximum, then goes back from the
maximum to the minimum reading to
check its operation. If any meter instru­ments or tachometer does not operate
or display correctly, have it checked by
an authorized Kawasaki dealer.

Tachometer Gauge:

The tachometer shows the engine
speed in revolutions per m inute (r/min,
rpm). On the right side of the tachome­terfaceisaportioncalledthe“red
zone”. Engine r/min (rpm) in the
red zone is above maximum recom­mended engine speed and is also
above the range for goodperformance.

NOTE

This motorcycle is equipped with the

○

engine speed limitter to prevent the
excesive high engine speed. When
operating this limitter, the segments
of the tachometer indicate the differ­ent engine speed and stops at about
5000 r/min (rpm) for the ignition con­trol, but this operation is not a failure.

NOTICE

Engine r/min (rpm) should not
be allowed to enter the red zone;
operationintheredzonewill
overstress the engine and may
cause serious engine damage.

Speedometer :

The speedometer shows the speed

of the vehicle in digital values.

GENERAL INFORMATION 23

Odometer/Trip Meter AB/Fuel

Warning Message (ODO/TRIP
AB):

This meter displays the odometer,
the trip meter AB, and the f uel warning
message.

The odometer and the trip meter AB
canbeshiftedpushingtheMODEbut­ton.

A. Odometer
B. Trip meter A
C. Trip meter B
D. MODE Button

NOTE

Do not shift the odometer/tr ip meter

○

while riding for safe operation.

Odometer -

The odometer shows the total dis­tance in kilometers or miles that the ve­hicle has been ridden. This meter can­not be reset.

NOTE

The data is maintained even if the

○

battery is disconnected.
When the figures come to 999999,

○

they are stopped and locked.

Trip Meters A/B -

The trip meter shows the distance in
kilometers or miles traveledsince it was
last reset to zero.

To reset the trip meter:

24 GENERAL INFORMATION

Push the MODE button to displaythe

•

trip meter A or B.
Push the RESET button and hold it

•

in.
After two second, the f igure display

•

turns to 0.0, and then starts counting
when the vehicle is operated. The
meter counts until it is next reset.

NOTE

The data is maintained by the back

○

-up power if the ignition key is turned
off.
When the trip meter reaches 999.9

○

(TRIP A) or 9999.9 (TRIP B) while
riding, the meter resets to 0.0 and
continues counting.
When the battery is disconnected,

○

the meter display resets to 0.0.

Mile/Km Display:

Mile/Km Display can alternate be­tween English and metric modes (mph
and km/h) in the meter unit. Make sure
that km/h or mph according to local
regulations is correctly displayed be­fore riding.

NOTE

Do not operate the vehicle with

○

the meter unit displaying in the
wrong unit (km/h or mph). Shift
the km/h·mph display in the meter
unit as follows.

Display the odometer.

•

Thekm/h·mph display shifts by push-

•

ing the RESET button while the
MODE button pushed in.

A. Km/h·Mph Display

The km/h/mph display shifts as fol-

•

lows.

GENERAL INFORMATION 25

A. Km/h
B. Mph
C.PushRESETButtonwithMODEButtonin

NOTE

The data is maintained even if the

○

battery is disconnected.

Clock:

To adjust hours and minutes:

Turn the ignition key to “ON”.

•

Push the RESET button for more

•

than two seconds. Both the hour and
minute displays start flashing.

26 GENERAL INFORMATION

Push the RESET button. The hour

•

display only flashes. Push the
MODE button to advance the hours.

Push the RESET button. The hour

•

display stops flashingand the minute
display starts flashing. Push the
MODE button to advance the min­utes.

Push the RESET button. Both the

•

hour and minute displays start flash­ing again.
Push the MODE button. The dis-

•

playsstopflashingandtheclock
starts working.

NOTE

Pushing the MODE button momen-

○

tarily advances the hour or minute
step by step. Pushing and hold­ing the button advances the hour or
minute continuously.
The clock works normally fro m the

○

back-up power while the ign ition
switch is turned off.

GENERAL INFORMATION 27

When the battery is disconnected,

○

the clock resets to 1:00 and starts
working again when the battery is
connected.

Indicator/Warning Light:
N : When the transmission is in neutral,

the neutral indicator light is lit.

: When the turn signal switch is
turned to left or right, the turn signal
indicator light flashes on and off.

: When the headlight is on high
beam, the high beam indicator light is
lit.

: The coolant temperature warning
light goes on when the ignition key
is turned to “ON” and goes off soon
after ensurin g that its circuit function
properly. The warning light also goes
on whenever the coolant temperature

rises too high when the motorcycle is
in operation. If it stays on, stop the
engine and check the coolant level in
the reserve tank after the engine cools
down.

NOTICE

Do not let the engine continue
running when the warning light
goes on. Prolonged engine op­eration will result in severe dam­age from overheating.

Warning/Indicator Lights:

: The fuel level warnin g indicator
light goes on and “FUEL” flashes in the
digital meter, whe n approximately 2.3
L(0.6 US gal) of usable fuel remains.
Refuel at the earliest opportunity when
thefuel level indicator light goes onand
“FUEL” flashes.

28 GENERAL INFORMATION

When vehicle stands with side stand,
warning message cannot show the
amount of fuel in the fuel tank exactly.
Stand upright the vehicle to check the
fuel level.

A. “Fuel Warning Message”

FI: The fuel inje ction (FI) indicator light

in the tachometer goes on when the ig­nitionkeyis turned to “ON”andgoes off
soon after ensuring that its circuit func­tions properly. The indicator light also
goes on whenever the troubles occur
in digital fuel injection system (DFI). If
the indicator light comes on, have the

DFI system checked by an authorized
Kawasaki dealer,
When the indicator light flashes, first
turn the ignition key to “OFF” and then
back to “ON”.