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1988-2005 KAWASAKI GPX250 Service Repair Manual Supplement

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$16.99
The Kawasaki GPX250, also known as the Ninja 250 in certain markets, is a versatile motorcycle produced from 1988 to 2005. This model is recognized for its entry-level sportbike appeal,...
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Taper: Motorcycle
Distributeur:
Kawasaki
UGS: 128818
Mots clés: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 GPX Models GPX250 Kawasaki Motorcycle Motorcycles
1988-2005 KAWASAKI GPX250 Service Repair Manual Supplement
The Kawasaki GPX250, also known as the Ninja 250 in certain markets, is a versatile motorcycle produced from 1988 to 2005. This model is recognized for its entry-level sportbike appeal, offering a blend of manageable power, sporty styling, and efficient performance, making it an excellent choice for both new riders and those seeking a reliable commuter. Built with Kawasaki's reputation for engineering quality and reliability, the GPX250 provides an engaging riding experience characterized by its liquid-cooled, parallel-twin engine and agile chassis. Its design prioritizes affordability and ease of maintenance, contributing to its enduring popularity in the lightweight motorcycle segment. This Service Repair Manual Supplement provides comprehensive guidance for the Kawasaki GPX250 models (EX250-F through EX250-M) produced between 1988 and 2005. It covers essential maintenance procedures, detailed engine overhaul and repair, fuel and ignition system servicing, transmission, electrical systems, chassis, suspension, and braking systems. The manual includes troubleshooting guides, diagnostic procedures, and technical specifications to assist owners, mechanics, and technicians in maintaining and repairing the motorcycle effectively. Its scope ensures that users can confidently perform routine servicing, address common issues, and undertake more complex repairs, thereby preserving the motorcycle's performance and longevity.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
GPX250
Model Nickname:
Ninja 250 (for some markets)
Product Type:
Service Repair Manual Supplement
Codes
Production Years Covered:
1988-2005
👋 Introduction
Market Position
Market Segment:
Entry-level sportbike, lightweight commuter, beginner motorcycle.
Competitive Analysis
Competitors 1990S:
Honda CBR250RR, Yamaha FZR250R, Suzuki GSX-R250.
Key Features
Vehicle Appeal:
Affordable performance, manageable power, sporty styling, good fuel economy, ease of maintenance.
Manual Value Proposition
Manual Benefit:
Empowers owners to perform routine maintenance, diagnose issues, and undertake repairs, saving time and money compared to dealership service. Crucial for preserving the lifespan and performance of the motorcycle.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
Kawasaki GPX250R (EX250-F, EX250-G, EX250-H, EX250-J, EX250-K, EX250-L, EX250-M)
Page Count
Page Count:
Estimated 200-300 pages (typical for a supplement covering multiple years)
Manual Type
Manual Type:
Service Repair Manual Supplement
Language
Language:
English
Format
Format:
Digital (PDF) / Print (likely print-on-demand or scanned)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, top-end rebuild (cylinder head, valves, camshafts), bottom-end rebuild (crankshaft, connecting rods, pistons), cooling system (liquid-cooled), lubrication system (oil pump, oil passages).
Fuel System:
Carburetor tuning and rebuilding (typically twin Keihin CVK carburetors), fuel pump operation (if applicable), fuel tank and lines.
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit (Capacitor Discharge Ignition).
Transmission System:
Clutch operation and adjustment, gearbox inspection, gear shaft removal and installation, shift drum and fork mechanisms.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting circuits, starter motor circuit, instrument panel indicators.
Chassis And Suspension:
Front fork servicing (oil change, seal replacement), rear shock absorber adjustment and replacement, swingarm maintenance, steering head bearing service.
Braking System:
Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding, master cylinder inspection.
Bodywork And Fairings:
Fairing removal and installation, seat maintenance, fuel tank removal and installation, accessory mounting.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug inspection and replacement, air filter cleaning/replacement, coolant level checks, brake fluid checks.
Troubleshooting:
Diagnostic charts for common starting, running, and electrical issues, symptom-based fault finding.
Engine Repair:
Complete engine disassembly and reassembly procedures, piston ring replacement, valve clearance adjustment, timing chain replacement.
Carburetor Rebuild:
Detailed steps for cleaning, re-jetting, and synchronizing twin carburetors.
Suspension Servicing:
Front fork seal and bushing replacement, rear shock linkage lubrication.
Electrical Diagnostics:
Testing stator output, regulator/rectifier function, troubleshooting lighting and starting circuits.
Brake System Maintenance:
Brake pad replacement, caliper piston service, brake line bleeding procedures.
Technical Depth
Depth Of Coverage:
Comprehensive coverage for engine, transmission, chassis, electrical, and bodywork repairs. Includes detailed exploded views, torque specifications, and diagnostic procedures suitable for experienced home mechanics and professional technicians.
📊 Manual Specifications
File Format
Digital File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans for clarity of diagrams and text. (If printed, quality depends on reproduction).
Binding Type
Binding Type:
N/A (for digital) / Staple-bound, perfect bound, or coil-bound (if printed).
Paper Type
Paper Type:
N/A (for digital) / Glossy or matte paper stock (if printed).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin.
Displacement:
248 cc (approximately, varies slightly by generation/market code)
Bore X Stroke:
55.0 mm x 52.4 mm (typical for early models, check specific sub-model).
Compression Ratio:
11.0:1 (typical)
Performance
Horsepower:
Approximately 30-35 HP (varies by year and market restrictions).
Torque:
Approximately 20-23 Nm (varies by year and market restrictions).
Fuel System
Carburetion:
Twin Keihin CVK carburetors (e.g., CVK30 or similar).
Fuel Tank Capacity:
Approximately 13-16 Liters (varies by generation).
Lubrication
Oil Type:
API SE, SF, or SG classification, SAE 10W-40 motorcycle oil recommended. (Consult manual for specific viscosity based on temperature).
Oil Capacity:
Approximately 1.6-1.9 Liters with filter change. (Verify in manual).
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential.
Features
Clutch Type:
Wet multi-plate.
Final Drive:
Chain drive.
📐 Dimensions
Exterior
Length:
Approximately 2000 mm (varies by generation).
Width:
Approximately 700 mm (varies by generation).
Height:
Approximately 1100 mm (varies by generation).
Weights
Dry Weight:
Approximately 140-150 kg (varies by generation).
Wet Weight:
Approximately 155-165 kg (with fluids).
Wheels And Tires
Front Tire Size:
110/70-17 or 100/80-17 (typical, confirm in manual).
Rear Tire Size:
130/70-17 or 120/80-17 (typical, confirm in manual).
Wheel Base:
Approximately 1370-1390 mm (varies by generation).
🛡️ Safety Features
Ratings
Crash Test Ratings:
Not applicable to motorcycles in the same manner as automobiles. Focus is on rider safety features and handling characteristics.
Active Features
Braking System:
Hydraulic front disc brake, mechanical rear drum brake (early models) or hydraulic rear disc brake (later models).
Passive Features
Lighting:
Halogen headlight, taillight, turn signals.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable. Basic analog instrument cluster (speedometer, tachometer, fuel gauge, indicator lights).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was not a standard or widely available option during this period for the GPX250.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or 6 months, whichever comes first. (Consult manual for precise recommendations).
Chain Lubrication Inspection:
Every 500-1,000 km or after riding in wet conditions.
Spark Plug Check:
Every 6,000-10,000 km.
Valve Clearance Check:
Every 12,000-18,000 km.
Fluid Specifications
Coolant Type:
Permanent type anti-freeze coolant, mixture of 50% ethylene glycol and 50% distilled water. (Consult manual for specific Kawasaki coolant).
Brake Fluid:
DOT 3 or DOT 4 brake fluid. (Always use fresh fluid from a sealed container).
Known Issues
Carburetor Issues:
Clogged jets, diaphragm issues due to age and fuel quality, synchronization drift. Often requires thorough cleaning and rebuilding.
Electrical Issues:
Corroded connections, failing regulator/rectifier, worn stator windings over time. Symptoms include poor charging, intermittent electrical faults.
Suspension Wear:
Front fork seals may leak, and rear shock can lose damping effectiveness with age and mileage.
Cam Chain Tensioner:
Some models may exhibit cam chain rattle if the tensioner becomes worn or fails.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries, Ltd. is a renowned Japanese manufacturer with a long history in motorcycles, aerospace, and heavy industry, known for performance and innovation.
Model Evolution
Gpz250 To Gpx250:
The GPX250R evolved from earlier models like the GPZ250, inheriting its parallel-twin engine architecture and sportbike styling, with updates focusing on aerodynamics, chassis refinement, and minor engine enhancements over its production run.
Production
Manufacturing Locations:
Primarily Japan. Some models may have been assembled in other regions.
Sales Performance:
Consistently popular as an entry-level sportbike and a reliable commuter, contributing to Kawasaki's strong presence in the 250cc segment globally.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards are not widely documented for this model in the same way as cars, the GPX250 series was recognized for its value, performance, and reliability in the entry-level motorcycle market.
Ratings
Ownership Satisfaction:
Generally high ownership satisfaction due to its low running costs and dependability.
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