Kawasaki Ninja 250R 2008-2012 Service Repair Manual

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This manual covers the Ninja 250R (model code EX250J) from the second generation, produced between 2008 and 2012. Positioned as an entry-level sportbike, the Ninja 250R is renowned for its...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 92875

Stichworte: 2008 2009 2010 2011 2012 Kawasaki Misc Motorcycle Motorcycles Ninja 250R

Produktvarianten

Beschreibung

This manual covers the Ninja 250R (model code EX250J) from the second generation, produced between 2008 and 2012. Positioned as an entry-level sportbike, the Ninja 250R is renowned for its agile handling, sporty aesthetics, and accessible performance, making it an ideal choice for new riders and urban commuters. Built upon a legacy of performance and reliability, this model offers a blend of everyday usability and spirited riding dynamics, competing in a segment known for its affordability and engaging riding experience. This comprehensive service repair manual in English provides detailed information for the maintenance, repair, and troubleshooting of your Ninja 250R. It covers all major systems, including the engine, fuel system, transmission, electrical system, brakes, suspension, and chassis. Within its approximately 400-600 pages, you will find step-by-step procedures for disassembly and assembly, diagnostic charts, torque specifications, wiring diagrams, and special tool requirements. This resource is designed to assist owners and technicians in keeping the motorcycle in optimal condition, ensuring its longevity and performance.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 250R

Model Code:

EX250J

Generation

Generation:

Second Generation (2008-2012)

👋 Introduction

Market Position

Market Niche:

The Kawasaki Ninja 250R (EX250J) occupies the entry-level sportbike segment, appealing to new riders, commuters, and those seeking an affordable, nimble, and fuel-efficient motorcycle with sporty styling.

Competitive Analysis

Competitors:

Key competitors during its production run included the Honda CBR250R, Yamaha YZF-R25 (in some markets), Suzuki GSX250R (later models), and other similar displacement sportbikes.

Key Features

Design Philosophy:

Designed for agility, ease of use, and affordability, combining sporty aesthetics with practical performance for everyday riding and spirited canyon carving.

📋 Manual Details

Coverage Areas

Covered Years:

2008, 2009, 2010, 2011, 2012

Market Segment:

Sportbike, Entry-level Sportbike

Page Count

Estimated Page Count:

Approximately 400-600 pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

File Format Details:

Searchable PDF, allowing for quick access to specific information. Likely contains high-resolution diagrams and schematics.

Printability:

Printable pages, enabling users to create physical copies of sections or the entire manual for workshop use.

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, including top-end (cylinder head, valves, cams) and bottom-end (crankshaft, connecting rods, pistons) assembly, timing, lubrication system, cooling system.

Fuel System:

Carburetor (or fuel injection for specific markets if applicable to this generation, though typically carbureted), fuel pump, fuel lines, fuel tank, vacuum lines, fuel filter replacement.

Transmission:

Clutch assembly, gear shifting mechanism, transmission gears, lubrication, troubleshooting transmission issues.

Electrical System:

Ignition system (CDI, spark plugs, coils), starting system (starter motor, battery), charging system (alternator, regulator/rectifier), lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays, diagnostic codes.

Brakes:

Front and rear brake system maintenance, caliper service, master cylinder overhaul, brake pad replacement, brake fluid flush and bleeding, troubleshooting brake performance.

Suspension:

Front fork (telescopic) service, oil seals, spring replacement, rear shock absorber maintenance, linkage system inspection and lubrication.

Chassis Frame:

Frame inspection, steering head bearing service, swingarm removal and maintenance, wheel bearing replacement.

Bodywork:

Fairing removal and installation, body panel repair, seat maintenance, graphics and decals.

Exhaust System:

Exhaust pipe and muffler maintenance, gasket replacement, leak detection.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid replacement, coolant replacement, valve clearance checks.

Troubleshooting:

Diagnostic charts for common problems (e.g., starting issues, poor performance, electrical faults), step-by-step troubleshooting guides.

Repair:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems.

Diagnostics:

Procedures for identifying and diagnosing malfunctions, including electrical system testing with multimeters, engine compression testing, and carburetor synchronization.

Assembly Disassembly:

Detailed step-by-step instructions for disassembling and reassembling every major component and sub-system of the motorcycle.

Torque Specifications:

Comprehensive list of torque values for all critical fasteners, ensuring proper assembly and preventing component damage.

Technical Depth

Depth:

Comprehensive: Covers everything from basic user maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and service limits.

Diagnostic Codes:

Inclusion of any diagnostic trouble codes (DTCs) if the motorcycle is equipped with an ECU capable of reporting them, along with procedures to read and clear them.

Wiring Diagrams:

Full electrical system wiring diagrams, color-coded and clearly labeled, facilitating diagnosis and repair of electrical issues.

Special Tools:

Identification and usage instructions for any specialized tools required for specific maintenance or repair procedures.

📊 Manual Specifications

File Format

File Type:

Digital Document (PDF)

Print Quality

Image Resolution:

High resolution, suitable for clear viewing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format, printable on standard paper)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, parallel-twin

Displacement:

249 cc (250cc class)

Bore X Stroke:

62.0 mm x 41.2 mm (typical for this generation)

Compression Ratio:

11.6:1 (typical)

Performance

Horsepower:

Approximately 30-34 HP @ 11,000 RPM (varies slightly by market and tune)

Torque:

Approximately 16-18 lb-ft @ 9,500 RPM (varies slightly by market and tune)

Fuel System

Fuel Delivery:

Carburetor (dual Keihin CVK34 or similar, depending on market)

Fuel Capacity:

18 Liters (4.8 US gal)

Lubrication System

Oil Type:

SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil

Oil Capacity:

1.7 Liters (1.8 US qt) with filter change

Cooling System

Coolant Type:

Permanent type anti-freeze coolant, 50/50 mixture with distilled water

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh, sequential manual

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2010 mm (79.1 in)

Overall Width:

Approx. 710 mm (28.0 in)

Overall Height:

Approx. 1110 mm (43.7 in)

Wheelbase:

Approx. 1370 mm (53.9 in)

Ground Clearance:

Approx. 160 mm (6.3 in)

Seat Height:

Approx. 780 mm (30.7 in)

Weights

Curb Weight:

Approx. 170 kg (375 lbs)

Gross Vehicle Weight Rating:

Not typically specified for motorcycles, but max load capacity is relevant.

🛡️ Safety Features

Ratings

Crash Test Ratings:

Motorcycles are not typically rated by consumer safety organizations like NHTSA or IIHS in the same way as cars.

Active Features

Braking System:

Standard: Hydraulic disc front, drum rear (some markets may offer optional ABS or dual disc front).

Passive Features

Lighting:

Halogen headlight, LED taillight, bright turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, clock, fuel gauge, indicator lights. Modern digital displays were not standard.

Driver Assistance

ABS Availability:

ABS was typically an optional feature on some models/markets, not standard across all units.

Connectivity

Connectivity Features:

None (no Bluetooth, smartphone integration, etc. typical for this era).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6,000 km (3,700 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

First check at 10,600 km (6,600 miles), then every 12,000 km (7,500 miles).

Brake Fluid Replacement:

Every 24 months or as needed based on condition.

Fluid Specifications

Engine Oil Specification:

SAE 10W-40, API SG or higher, JASO MA

Brake Fluid Specification:

DOT 4

Coolant Specification:

Ethylene glycol-based, 50/50 mix with distilled water

Known Issues

Common Wear Items:

Brake pads, tires, chain and sprockets, clutch plates, fork seals. Carburetor synchronization may be needed over time.

Electrical Component Longevity:

Regulator/rectifier can be a point of failure on some Kawasaki models, though not excessively common on this specific generation.

Carburetor Issues:

Gumming or clogging of carburetors if fuel sits for extended periods without stabilizers, leading to rough idling or starting issues.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long and storied history in motorcycle manufacturing, known for performance, innovation, and iconic sportbikes across various displacements.

Model Evolution

Ninja 250 Lineage:

The Ninja 250R has been a staple in Kawasaki's lineup for decades, evolving from earlier generations to meet modern standards while maintaining its accessible performance and sportbike appeal. The 2008-2012 generation represented a significant styling and chassis update.

Production

Manufacturing Location:

Primarily manufactured in Thailand, with components sourced globally.