Segment:
Entry-level sportbike, lightweight sport-tourer, beginner motorcycle.
Key Competitors Era:
Honda CBR250R, Yamaha YZF-R25 (later models), Suzuki GS500F (larger displacement but similar market positioning).
Model Highlights:
Nimble handling, fuel efficiency, approachable power, reliability, cost-effectiveness for new riders.
Manual Value Proposition:
Enables owners to perform routine maintenance, diagnose issues, and complete repairs, saving money and extending the motorcycle's lifespan.
Engine Systems:
Engine overhaul, fuel injection, ignition, cooling, lubrication, carburetor (if applicable to specific sub-models), starting system, charging system.
Drivetrain Systems:
Clutch, transmission, gearbox, final drive (chain and sprockets).
Chassis Systems:
Frame, suspension (front forks, rear shock absorber), steering, wheels, tires, braking system (front and rear discs, calipers, master cylinders), exhaust system.
Electrical Systems:
Wiring diagrams, lighting system, instrumentation, battery, starter motor, alternator, ignition system, ECU, sensors, relays, fuses.
Bodywork And Plastics:
Fairings, seat, fuel tank, handlebars, body panel removal and installation, cosmetic repairs.
Maintenance Procedures:
Oil changes, filter replacements, chain adjustment and lubrication, brake fluid flush, coolant replacement, spark plug inspection and replacement, air filter cleaning/replacement, valve clearance adjustment.
Diagnostic Procedures:
Troubleshooting guides for common problems, symptom-based diagnostics, error code interpretation (if applicable).
Repair Procedures:
Engine disassembly and reassembly, transmission overhaul, brake caliper rebuild, fork seal replacement, electrical component testing and replacement.
Technical Specifications Data:
Torque specifications for all fasteners, engine timings, fluid capacities, electrical system resistance values, performance data.
Depth Of Coverage:
Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics and troubleshooting.
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin.
Bore X Stroke:
55.0 x 54.5 mm
Compression Ratio:
12.4:1
Horsepower Est Peak:
30-34 hp @ 10,500 rpm (approx.)
Torque Est Peak:
16-18 lb-ft @ 8,000 rpm (approx.)
Fuel Delivery:
Digital Fuel Injection (DFI) with dual throttle valves.
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON+MON)/2
Ignition System:
TCBI (Transistor Controlled Ignition) with digital advance.
Safety Certification:
Meets relevant DOT/ECE standards for street-legal motorcycles (typical for production).
Braking System:
Dual hydraulic disc brakes (front and rear). ABS was generally not a standard feature on this model, check specific market variants.
Tire Specifications:
Front: 110/70-17, Rear: 130/70-17 (typical fitment).
Lighting:
Halogen headlamp, LED taillight, standard incandescent turn signals.
Frame Construction:
High-tensile steel diamond frame.
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance Features:
N/A (None)
Connectivity Options:
N/A (None)
Dashboard Features:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, neutral indicator, high beam indicator.
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 Inspection:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA certified.
Engine Oil Capacity:
1.5 L (1.6 US qt) without filter change, 1.6 L (1.7 US qt) with filter change.
Coolant Type:
Ethylene glycol based, permanent type antifreeze, 50/50 mix with distilled water.
Fork Oil Type:
SAE 10W (consult manual for exact type and quantity per leg).
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates, fork seals (depending on mileage and maintenance).
Fuel Injection Notes:
While generally reliable, occasional injector cleaning or sensor checks might be needed on high-mileage units.
Electrical Gremlins:
Less common, but faulty regulators or stator issues can occur with age and mileage. Wiring harness integrity is key.
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries Motorcycle & Engine division, renowned for performance and sportbikes.
Ex250 Lineage:
The EX250 platform has a long history dating back to the 1980s, evolving from carbureted models to the fuel-injected EX250K generation covered by this manual.
Manufacturing Origin:
Typically manufactured in Thailand or Japan, depending on the market and specific model year.
Typical Awards Segment:
Frequently cited in 'best beginner sportbike' lists for its accessibility and value.
Owner Satisfaction Trend:
Generally high due to reliability and low running costs.
Emission Standards:
Meets applicable emissions standards for its production years (e.g., EPA, Euro).
