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Kawasaki Ninja 250R EX250 2008-2012 WSM Service Manual

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The Ninja 250R EX250, specifically chassis code EX250K, represents a significant offering in the entry-level sportbike segment for the model years 2008 through 2012. Engineered with a focus on nimble handling, accessible power delivery, and sporty styling, this lightweight sportbike is designed to appeal to beginner riders, commuters, and budget-conscious enthusiasts. Its reliable four-stroke, DOHC, parallel-twin engine, with a displacement of 249 cc, provides an approximate horsepower of 30-32 HP, making it an approachable yet engaging machine. The Ninja 250R's engineering quality is a testament to a long-standing heritage in producing performance-oriented motorcycles. This comprehensive Workshop Service Manual (WSM) provides complete service and repair information for the Ninja 250R EX250 (EX250J/K) models from 2008 to 2012. It covers all essential areas, including routine maintenance, detailed component overhauls, troubleshooting procedures with diagnostic flowcharts, and essential technical specifications. The manual is designed to empower owners, mechanics, and technicians by offering step-by-step instructions for engine mechanicals, fuel systems, ignition, transmission, brakes, suspension, electrical systems, and frame/bodywork. With its high-resolution diagrams and searchable text in English, this manual is an indispensable resource for maintaining and repairing the motorcycle effectively, ensuring its longevity and optimal performance. 🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 250R EX250 Model Variant: EX250J/K Model Years Covered: 2008, 2009, 2010, 2011, 2012 Codes Chassis Code: EX250K (2008-2012) 👋 Introduction Market Position Segment: Entry-level Sportbike / Lightweight Sportbike Target Audience: Beginner riders, commuters, budget-conscious sportbike enthusiasts. Competitive Analysis Key Competitors: Yamaha YZF-R3 (later model), Honda CBR250R (later model), Ninja 300 (later model), Hyosung GT250. Key Features Design Philosophy: Nimble handling, accessible power delivery, fuel efficiency, sporty styling. Manual Value Proposition: Empowers owners to perform routine maintenance and repairs, saving on labor costs and extending the life of the motorcycle. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Specifications Page Count Estimated Page Count: 400-500 (typical for this model and manual type) Manual Type Manual Type: Workshop Service Manual (WSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, valves, crankshaft, pistons, lubrication system, cooling system (radiator, fan, thermostat), timing system. Fuel System: Carburetor systems (cleaning, adjustment, synchronization), fuel pump, fuel filter, fuel tank, fuel lines. Ignition System: Ignition timing, spark plugs, ignition coils, ECU (Engine Control Unit) identification and basic function. Transmission Drivetrain: Clutch operation, gearbox overhaul, shift mechanism, final drive (chain, sprockets). Braking System: Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, brake disc specifications. Suspension Steering: Front fork service (oil change, seal replacement), rear shock absorber replacement, steering head bearing adjustment, wheel bearing service. Electrical System: Battery, charging system (alternator, regulator/rectifier), starter motor, lighting circuits, wiring diagrams, fuses, relays, horn, instrument panel. Frame Bodywork: Frame inspection, body panel removal/installation, fairing components, seat, handlebars, footpegs. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks/replacement, chain adjustment, brake fluid changes, coolant checks. Troubleshooting: Step-by-step diagnostic flowcharts for common running issues, electrical faults, and mechanical problems. Component Overhaul: Detailed instructions for disassembling, inspecting, repairing, and reassembling major components like the engine, transmission, and suspension. Special Tools: Identification and usage of specific tools required for various maintenance and repair tasks. Technical Depth Depth Level: Comprehensive (covering everything from basic adjustments to full engine rebuilds). 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically, depending on the source scan quality) Print Quality Image Resolution: High resolution for clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, DOHC, parallel-twin Displacement: 249 cc (cubic centimeters) Bore X Stroke: 55.0 mm x 52.4 mm Compression Ratio: 11.7:1 Fuel Induction: Dual Keihin CVK34 carburetors Cooling System: Liquid-cooled Performance Horsepower: Approx. 30-32 HP (at crankshaft, varies slightly by region) Torque: Approx. 17-18 lb-ft (at crankshaft, varies slightly by region) Fuel System Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: 18.0 Liters (4.8 US gal) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch: Wet, multi-plate Features Final Drive: Sealed chain 📐 Dimensions Exterior Length: 2010 mm (79.1 in) Width: 710 mm (28.0 in) Height: 1110 mm (43.7 in) Wheelbase: 1370 mm (53.9 in) Ground Clearance: 155 mm (6.1 in) Seat Height: 780 mm (30.7 in) Weights Curb Weight: Approx. 170 kg (375 lbs) - may vary by spec Dry Weight: Approx. 155 kg (342 lbs) Front Tire Size: 110/70-17 M/C 54H Rear Tire Size: 130/70-17 M/C 62H Wheel Type: Alloy (typically 5-spoke) Wheelbase Type: 17 inch 🛡️ Safety Features Ratings ABS Availability: Optional (on select models/years, often market-dependent) Active Features Brakes: Hydraulic disc front and rear. The manual details maintenance and adjustment for optimal performance. Passive Features Frame Design: High-tensile steel backbone frame designed for rigidity and handling. 💡 Technology Features Infotainment Instrument...
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Kawasaki Ninja 250R EX250 2008-2012 WSM Service ManualKawasaki Ninja 250R EX250 2008-2012 WSM Service ManualKawasaki Ninja 250R EX250 2008-2012 WSM Service ManualKawasaki Ninja 250R EX250 2008-2012 WSM Service Manual
The Ninja 250R EX250, specifically chassis code EX250K, represents a significant offering in the entry-level sportbike segment for the model years 2008 through 2012. Engineered with a focus on nimble handling, accessible power delivery, and sporty styling, this lightweight sportbike is designed to appeal to beginner riders, commuters, and budget-conscious enthusiasts. Its reliable four-stroke, DOHC, parallel-twin engine, with a displacement of 249 cc, provides an approximate horsepower of 30-32 HP, making it an approachable yet engaging machine. The Ninja 250R's engineering quality is a testament to a long-standing heritage in producing performance-oriented motorcycles. This comprehensive Workshop Service Manual (WSM) provides complete service and repair information for the Ninja 250R EX250 (EX250J/K) models from 2008 to 2012. It covers all essential areas, including routine maintenance, detailed component overhauls, troubleshooting procedures with diagnostic flowcharts, and essential technical specifications. The manual is designed to empower owners, mechanics, and technicians by offering step-by-step instructions for engine mechanicals, fuel systems, ignition, transmission, brakes, suspension, electrical systems, and frame/bodywork. With its high-resolution diagrams and searchable text in English, this manual is an indispensable resource for maintaining and repairing the motorcycle effectively, ensuring its longevity and optimal performance.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Ninja 250R EX250
Model Variant:
EX250J/K
Model Years Covered:
2008, 2009, 2010, 2011, 2012
Codes
Chassis Code:
EX250K (2008-2012)
👋 Introduction
Market Position
Segment:
Entry-level Sportbike / Lightweight Sportbike
Target Audience:
Beginner riders, commuters, budget-conscious sportbike enthusiasts.
Competitive Analysis
Key Competitors:
Yamaha YZF-R3 (later model), Honda CBR250R (later model), Ninja 300 (later model), Hyosung GT250.
Key Features
Design Philosophy:
Nimble handling, accessible power delivery, fuel efficiency, sporty styling.
Manual Value Proposition:
Empowers owners to perform routine maintenance and repairs, saving on labor costs and extending the life of the motorcycle.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics, Specifications
Page Count
Estimated Page Count:
400-500 (typical for this model and manual type)
Manual Type
Manual Type:
Workshop Service Manual (WSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine removal/installation, cylinder head, valves, crankshaft, pistons, lubrication system, cooling system (radiator, fan, thermostat), timing system.
Fuel System:
Carburetor systems (cleaning, adjustment, synchronization), fuel pump, fuel filter, fuel tank, fuel lines.
Ignition System:
Ignition timing, spark plugs, ignition coils, ECU (Engine Control Unit) identification and basic function.
Transmission Drivetrain:
Clutch operation, gearbox overhaul, shift mechanism, final drive (chain, sprockets).
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures, brake disc specifications.
Suspension Steering:
Front fork service (oil change, seal replacement), rear shock absorber replacement, steering head bearing adjustment, wheel bearing service.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting circuits, wiring diagrams, fuses, relays, horn, instrument panel.
Frame Bodywork:
Frame inspection, body panel removal/installation, fairing components, seat, handlebars, footpegs.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks/replacement, chain adjustment, brake fluid changes, coolant checks.
Troubleshooting:
Step-by-step diagnostic flowcharts for common running issues, electrical faults, and mechanical problems.
Component Overhaul:
Detailed instructions for disassembling, inspecting, repairing, and reassembling major components like the engine, transmission, and suspension.
Special Tools:
Identification and usage of specific tools required for various maintenance and repair tasks.
Technical Depth
Depth Level:
Comprehensive (covering everything from basic adjustments to full engine rebuilds).
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes (typically, depending on the source scan quality)
Print Quality
Image Resolution:
High resolution for clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, DOHC, parallel-twin
Displacement:
249 cc (cubic centimeters)
Bore X Stroke:
55.0 mm x 52.4 mm
Compression Ratio:
11.7:1
Fuel Induction:
Dual Keihin CVK34 carburetors
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 30-32 HP (at crankshaft, varies slightly by region)
Torque:
Approx. 17-18 lb-ft (at crankshaft, varies slightly by region)
Fuel System
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
18.0 Liters (4.8 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch:
Wet, multi-plate
Features
Final Drive:
Sealed chain
📐 Dimensions
Exterior
Length:
2010 mm (79.1 in)
Width:
710 mm (28.0 in)
Height:
1110 mm (43.7 in)
Wheelbase:
1370 mm (53.9 in)
Ground Clearance:
155 mm (6.1 in)
Seat Height:
780 mm (30.7 in)
Weights
Curb Weight:
Approx. 170 kg (375 lbs) - may vary by spec
Dry Weight:
Approx. 155 kg (342 lbs)
Front Tire Size:
110/70-17 M/C 54H
Rear Tire Size:
130/70-17 M/C 62H
Wheel Type:
Alloy (typically 5-spoke)
Wheelbase Type:
17 inch
🛡️ Safety Features
Ratings
ABS Availability:
Optional (on select models/years, often market-dependent)
Active Features
Brakes:
Hydraulic disc front and rear. The manual details maintenance and adjustment for optimal performance.
Passive Features
Frame Design:
High-tensile steel backbone frame designed for rigidity and handling.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, clock, coolant temperature warning light, oil level warning light.
Driver Assistance
ABS:
Available as an option on some models, providing enhanced braking control.
Connectivity
Lighting:
Halogen headlamp, LED taillight.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Air Filter Inspection:
Every 6,000 km (3,700 mi)
Spark Plug Replacement:
Every 12,000 km (7,500 mi) or 12 months
Brake Fluid Change:
Every 2 years or as needed
Coolant Change:
Every 24,000 km (15,000 mi) or 2 years
Valve Clearance Check:
Every 24,000 km (15,000 mi)
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
Engine Oil Capacity:
1.6 Liters (1.7 US qt) without filter change; 1.8 Liters (1.9 US qt) with filter change.
Coolant Type:
Kawasaki Coolant 50% or equivalent ethylene glycol based antifreeze/coolant.
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Item:
Clutch plates can wear over time, especially with aggressive riding.
Carburetor Tuning:
Carburetors may require periodic cleaning and synchronization for optimal performance and fuel economy.
Electrical Component Reliability:
Regulator/rectifier can be a failure point on some older Kawasaki models, though generally reliable on this generation.
Suspension Performance:
Front forks can benefit from servicing (oil change and seal replacement) after significant mileage for maintained damping.
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries, Ltd.
Segment Focus:
Kawasaki has a long history of producing reliable and performance-oriented motorcycles across various segments.
Model Evolution
Predecessor:
Ninja 250 (EX250-F, EX250-G, EX250-J generations)
Successor:
Ninja 300 (EX300)
Production
Production Period Covered:
2008-2012
Manufacturing Locations:
Primarily Japan (e.g., Akashi)
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently a best-selling model in its displacement class, praised for its value and beginner-friendliness.
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