Kawasaki Ninja 250R EX250 2008-2012 All Service Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 250R Model Code: EX250 Years Covered: 2008, 2009, 2010, 2011, 2012 Generation Generation: 2nd Generation (EX250-J) 👋 Introduction Market Position Market Segment: Entry-level sportbike, popular for beginners and commuter use. Competitive Analysis Key Competitors: Honda CBR250R, Suzuki GS500F, Yamaha YZF-R3 (later models). Key Features Bike Attributes: Lightweight, nimble handling, fuel-efficient, reliable parallel-twin engine, accessible ergonomics. Manual Value Proposition Diy Repair Benefit: Empowers owners to perform maintenance and repairs independently, saving costs and ensuring quality of work. Knowledge Acquisition: Provides in-depth understanding of the vehicle's intricacies, beneficial for both novice and experienced riders. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service and repair for all aspects of the Kawasaki Ninja 250R EX250 from 2008-2012. Page Count Page Count: Estimated 400-600 pages (typical for comprehensive service manuals) Manual Type Manual Type: Service Manual / Repair Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Full engine disassembly, assembly, inspection, tuning, and repair for the 249cc parallel-twin engine. Transmission Service Repair: Clutch operation, gearbox inspection, maintenance, and repair; torque specifications for all fasteners. Brake System: Front and rear brake system maintenance, caliper service, hydraulic fluid replacement, bleeding procedures, disc and pad inspection. Wiring Diagram: Detailed electrical wiring diagrams for all model variations, including lighting, ignition, starting, charging, and accessory circuits. Electrical System: Component testing, troubleshooting of electrical faults, battery service, alternator and starter motor procedures. Suspension: Front fork (telescopic) maintenance, oil changes, seal replacement, rear shock absorber service and adjustment. Steering: Handlebar, steering stem bearing inspection and maintenance, adjustment procedures. Cooling System: Radiator, fan, coolant, thermostat inspection, flushing and refilling procedures. Fuel Injection Fuel System: Fuel pump, injector service, throttle body cleaning, idle speed adjustment, fuel pressure testing. Emission System: Catalytic converter information, evaporative emission control system (EVAP) details. Engine Control System: ECU (Engine Control Unit) information, sensor identification and testing (e.g., TPS, MAP, IAT). Chassis Body: Frame inspection, fairing removal and installation, seat, fuel tank, and body panel service. Restraint System: N/A (Motorcycle - no typical automotive restraint systems like airbags or seatbelts). Axle: Front and rear axle inspection, lubrication, and installation procedures. Procedures Included General Maintenance: Regular checks, cleaning, lubrication, bolt torque checks, fluid level checks. Troubleshooting: Systematic diagnosis of common problems, fault finding guides, symptom-based troubleshooting. Periodic Lubrication: Detailed schedules and types of lubricants for all moving parts, chain maintenance. Disassembly Reassembly: Step-by-step instructions for component removal and installation, with torque specifications. Refurbish Renovate: Guidance on component restoration and cosmetic improvements. Technical Depth Depth Of Coverage: Complete mechanical and electrical repair, from basic maintenance to major component overhauls. Diagnostic Capabilities: Includes diagnostic procedures for electrical systems and engine performance issues. Diagrams Illustrations: Profusely illustrated with diagrams, exploded views, and clear photographs of components and procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, clear text and diagrams suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements Software Requirements: Adobe Acrobat Reader, WinZip (or equivalent decompression software). Platform Compatibility Platform Compatibility: Compatible with all Windows and Mac operating systems. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, DOHC, parallel-twin Displacement: 249 cc Bore X Stroke: 55.0 x 52.4 mm Compression Ratio: 12.4:1 Performance Horsepower Peak: Approx. 30.5 PS (22.4 kW) @ 10,500 rpm (varies slightly by market) Torque Peak: Approx. 22 Nm (16.2 lb-ft) @ 8,000 rpm (varies slightly by market) Fuel System Fuel Delivery: Digital Fuel Injection (DFI) Fuel Type: Unleaded gasoline, 87 octane or higher Lubrication Oil Type: API SG or SH, SAE 10W-40 motorcycle oil. Oil Capacity: 1.4 L (1.5 US qt) without filter change; 1.6 L (1.7 US qt) with filter change. 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch Type: Wet, multi-disc Features Final Drive: Sealed chain, 520 pitch Transmission Fluid: SAE 80W hypoid gear oil 📐 Dimensions Exterior Overall Length: 2005 mm (78.9 in) Overall Width: 715 mm (28.1 in) Overall Height: 1105 mm (43.5 in) Wheelbase: 1370 mm (53.9 in) Weights Dry Weight: Approx. 151 kg (333 lbs) Curb Weight: Approx. 168 kg (370 lbs) Fuel Tank Capacity: 18 L (4.8 US gal) 🛡️ Safety Features Ratings Safety Features: Linked-action ABS optional on some models/markets. Active Features Brakes Front: 290mm petal-disc, 2-piston caliper Brakes Rear: 220mm petal-disc, 2-piston caliper Passive Features Lighting: Dual halogen headlights, LED tail light 💡 Technology Features Infotainment Infotainment System: Basic analog tachometer and digital speedometer, LCD display for odometer, trip meters, clock. Driver Assistance ABS Availability: Optional ABS (Anti-lock Braking System) available on certain trims/markets. Connectivity Connectivity Features: N/A (Basic motorcycle electronics). 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 mi) or 6 months, whichever comes first. Air Filter Replacement: Inspect every 6,000 km (3,700 mi), clean/replace as needed. Replace...
1.4 L (1.5 US qt) without filter change; 1.6 L (1.7 US qt) with filter change.
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet, multi-disc
Features
Final Drive:
Sealed chain, 520 pitch
Transmission Fluid:
SAE 80W hypoid gear oil
📐 Dimensions
Exterior
Overall Length:
2005 mm (78.9 in)
Overall Width:
715 mm (28.1 in)
Overall Height:
1105 mm (43.5 in)
Wheelbase:
1370 mm (53.9 in)
Weights
Dry Weight:
Approx. 151 kg (333 lbs)
Curb Weight:
Approx. 168 kg (370 lbs)
Fuel Tank Capacity:
18 L (4.8 US gal)
🛡️ Safety Features
Ratings
Safety Features:
Linked-action ABS optional on some models/markets.
Active Features
Brakes Front:
290mm petal-disc, 2-piston caliper
Brakes Rear:
220mm petal-disc, 2-piston caliper
Passive Features
Lighting:
Dual halogen headlights, LED tail light
💡 Technology Features
Infotainment
Infotainment System:
Basic analog tachometer and digital speedometer, LCD display for odometer, trip meters, clock.
Driver Assistance
ABS Availability:
Optional ABS (Anti-lock Braking System) available on certain trims/markets.
Connectivity
Connectivity Features:
N/A (Basic motorcycle electronics).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Air Filter Replacement:
Inspect every 6,000 km (3,700 mi), clean/replace as needed. Replace every 12,000 km (7,500 mi).
Spark Plug Replacement:
Replace every 12,000 km (7,500 mi).
Valve Clearance Check:
Every 12,000 km (7,500 mi).
Fluid Specifications
Brake Fluid Type:
DOT 4
Coolant Type:
Kawasaki Genuine Coolant or equivalent high-quality ethylene glycol-based coolant (50/50 mix with distilled water).
Chain Lube:
High-quality motorcycle chain lubricant.
Known Issues
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates.
Potential Electrical Issues:
While generally reliable, occasional stator or rectifier failures can occur (covered in manual).
Engine Performance Notes:
Proper fuel injection cleaning and maintenance are key to sustained optimal performance.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries is a long-standing Japanese manufacturer known for its performance-oriented motorcycles.
Model Evolution
Ninja 250R Lineage:
The Ninja 250R has a history dating back to the 1980s, evolving into a refined and popular entry-level sportbike.
2Nd Gen Updates:
The 2008-2012 models received a significant styling update, a larger fairing, and a fuel-injected engine, setting it apart from earlier carbureted versions.
Production
Production Location:
Primarily manufactured in Thailand.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Consistently praised for its value, ease of use, and suitability for new riders.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to reliability and low running costs.
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