Kawasaki Ninja 250R 2008-2012 Factory Service Repair Manual

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Typ: Motorcycle

Anbieter:

Art.-Nr: 96380

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

Produktvarianten

Beschreibung

The Ninja 250R (model code EX250J) represents the second generation of this popular lightweight sportbike, produced from 2008 to 2012. Designed with an emphasis on affordable performance, sporty styling, and user-friendliness, it appeals to entry-level sportbike enthusiasts, daily commuters, and novice riders. Its full fairing design enhances aerodynamics and rider protection, while the accessible riding position ensures comfort during everyday use. Powered by a 249 cc liquid-cooled, parallel-twin engine, the Ninja 250R delivers a balanced blend of power and efficiency, supported by a 6-speed transmission and a robust high-tensile steel perimeter frame. This Service Repair Manual provides comprehensive guidance for the maintenance, repair, and troubleshooting of the Ninja 250R (EX250J) models from 2008 to 2012. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, cooling, brakes, suspension, and electrical components. The manual includes scheduled maintenance guidelines, diagnostic troubleshooting charts, repair procedures, technical specifications, and accurate wiring diagrams. Its thorough coverage is designed to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle to factory standards.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 250R

Model Code:

EX250J

Generation:

2nd Generation (2008-2012)

👋 Introduction

Market Position

Target Audience:

Entry-level sportbike enthusiasts, commuting riders, and DIY motorcycle mechanics.

Segment:

Lightweight sportbike / Supersport

Competitive Analysis

Key Competitors:

Honda CBR250R, Yamaha YZF-R25 (where applicable), Suzuki GSX250R.

Key Features Of Vehicle

Design Philosophy:

Affordable performance, sporty styling, and ease of use for new riders.

Aerodynamics:

Full fairing design for improved aerodynamics and rider protection from wind.

Ergonomics:

Sport-oriented but generally accessible riding position suitable for everyday use.

📋 Manual Details

Coverage Areas

Years Covered:

2008, 2009, 2010, 2011, 2012

Model Variants:

All Ninja 250R models (EX250J)

Page Count

Estimated Pages:

Approximately 500-600 pages (typical for factory service manuals of this era)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, disassembly, assembly, inspection, and adjustment of all engine components.

Engine Fuel System:

Carburetor inspection, cleaning, adjustment, and overhaul; fuel pump, fuel filter replacement.

Engine Ignition System:

Spark plug inspection and replacement, ignition coil testing, CDI unit diagnostics.

Transmission:

Clutch operation, inspection, and adjustment; gearbox disassembly and assembly, gearshift mechanism.

Cooling System:

Radiator, fan, coolant hoses, thermostat inspection and replacement; coolant bleeding procedures.

Exhaust System:

Exhaust pipe, muffler inspection and replacement.

Frame And Suspension:

Front fork disassembly, service, and adjustment; rear shock absorber replacement; frame inspection.

Brakes System:

Front and rear brake caliper service, brake pad replacement, hydraulic system bleeding, master cylinder overhaul.

Wheel And Tires:

Tire inspection and replacement, wheel bearing service, rim runout checks.

Electrical System:

Wiring diagrams, battery testing and maintenance, charging system (alternator, rectifier/regulator), starter motor, lighting system.

Controls And Instruments:

Throttle grip, clutch lever, brake lever adjustment; speedometer, tachometer, indicator lights.

Bodywork And Fairings:

Removal and installation of fairings, seat, fuel tank, fenders.

Procedures Included

Scheduled Maintenance:

Detailed procedures for oil changes, filter replacements, chain adjustment, spark plug checks, and other routine service items.

Troubleshooting:

Diagnostic charts and step-by-step procedures for identifying and resolving common mechanical and electrical issues.

Repair Procedures:

Comprehensive instructions for disassembling, repairing, and reassembling all major vehicle components.

Technical Data And Specifications:

Torque values, clearances, fluid capacities, electrical specifications, and measurement data for all components.

Wiring Diagrams:

Detailed, factory-accurate wiring diagrams for all electrical systems, including lighting, ignition, and charging.

Special Tools:

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

Technical Depth

Depth:

Complete factory-level diagnostic, repair, and overhaul information. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Digital Quality:

High-resolution scans of original factory documents, ensuring clear text and diagrams.

Searchability:

Likely text-searchable PDF, allowing quick access to specific information.

Print Quality

Print Readability:

Designed for clarity when printed, with legible diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

249 cc (249 cm³)

Bore X Stroke:

62.0 x 41.2 mm

Compression Ratio:

11.6:1

Valve Train:

DOHC, 8 valves (4 per cylinder)

Performance

Horsepower Peak:

Approximately 30.5 HP @ 10,500 rpm (claimed)

Torque Peak:

Approximately 17.5 lb-ft @ 8,000 rpm (claimed)

Fuel System

Fuel Delivery:

Keihin CVK34 carburetors (dual)

Fuel Tank Capacity:

18.0 L (4.8 US gal)

Ignition

Ignition System:

Digital CDI

Cooling System

Cooling Method:

Liquid-cooled

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch:

Wet, multi-disc

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Length:

2,000 mm (78.7 in)

Width:

750 mm (29.5 in)

Height:

1,100 mm (43.3 in)

Wheelbase:

1,370 mm (53.9 in)

Ground Clearance:

155 mm (6.1 in)

Weights

Curb Weight:

Approximately 170 kg (375 lbs)

Seat Height:

780 mm (30.7 in)

Front Tire:

110/70-17 M/C 54H

Rear Tire:

130/70-17 M/C 62H

Front Brake:

290 mm petal disc, dual-piston caliper

Rear Brake:

220 mm petal disc, dual-piston caliper

Front Suspension:

41 mm telescopic fork, 130 mm (5.1 in) travel

Rear Suspension:

Uni-Trak with 5-way adjustable preload, 131 mm (5.2 in) travel

🛡️ Safety Features

Ratings

Safety Features Overall:

ABS was an optional feature on some models/markets, but not standard on all. Disc brakes front and rear offer good stopping power.

Active Features

ABS Availability:

Optional (depending on market and specific model variant)

Passive Features

Frame Type:

High-tensile steel perimeter frame

Lighting:

Halogen headlamp, LED tail lamp.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meters, clock, and indicator lights.

Driver Assistance

ABS System:

Available as an option on select models, providing enhanced braking stability.

Connectivity

Connectivity Features:

N/A (No advanced connectivity features like Bluetooth or smartphone integration on this model).

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Oil Filter Change Interval:

At every oil change (6,000 km / 3,700 miles).

Spark Plug Inspection:

Every 6,000 km (3,700 miles).

Valve Clearance Check:

Every 12,000 km (7,500 miles) or 12 months.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km (600 miles) or as needed.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or SH. Recommended: Kawasaki Genuine Motorcycle Oil (or equivalent).

Engine Oil Capacity:

1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.

Coolant Type:

Permanent type antifreeze coolant (50% solution with distilled water). Recommended: Kawasaki Genuine Coolant or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4.

Fork Oil Type:

SAE 10W.

Known Issues

Common Wear Items:

Clutch plates, brake pads, fork seals, and chain/sprockets are common wear items due to the bike's performance-oriented nature.

Carburetor Tuning:

Carburetors may require periodic cleaning and adjustment, especially if the bike is not regularly ridden or maintained.

Charging System:

Rare instances of rectifier/regulator failure have been reported on some units.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long-standing reputation for performance motorcycles across various segments.

Model Evolution

Ninja Lineage:

The Ninja 250R (or EX250) has been a cornerstone of Kawasaki's entry-level sportbike offerings for decades, evolving significantly in technology and styling.

2Nd Gen Introduction:

The 2008 model year marked a significant redesign, featuring new styling inspired by the larger Ninja ZX models, updated chassis, and improved ergonomics.

Production

Manufacturing Locations:

Primarily manufactured in Thailand.

🏆 Awards & Recognition

Recognitions

Market Reputation:

Consistently praised for its value, reliability, and sporty handling, making it a popular choice for new riders and commuters.