Kawasaki EX250 EX250-J Workshop Service Repair Manual
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This workshop service repair manual covers the Kawasaki EX250-J, commonly known as the Ninja 250R. This model represents a significant iteration in Kawasaki's long-standing tradition of producing reliable and performance-oriented...
This workshop service repair manual covers the Kawasaki EX250-J, commonly known as the Ninja 250R. This model represents a significant iteration in Kawasaki's long-standing tradition of producing reliable and performance-oriented motorcycles, particularly within the popular Ninja sportbike lineage. Engineered for accessible performance and rider control, the Ninja 250R has earned a reputation as an excellent entry-level sportbike, celebrated for its mechanical simplicity and dependability. This manual is designed to support owners, DIY mechanics, and professional technicians in maintaining and repairing all EX250-J variants globally.
This comprehensive English-language manual provides factory-level information across a wide range of systems, including the powertrain, chassis, and complete electrical system, featuring detailed wiring diagrams. It outlines scheduled maintenance procedures, fluid changes, filter replacements, and offers in-depth guidance for disassembly, assembly, and reinstallation of all major components. Furthermore, it includes diagnostic procedures for common issues and detailed troubleshooting steps. With hundreds of pages of diagrams, critical specifications, and step-by-step instructions, this manual is an essential resource for ensuring the optimal performance and longevity of your Kawasaki Ninja 250R.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
EX250-J
Common Name:
Ninja 250R
Chassis Code:
EX250-J
Codes
Engine Code:
EX250J
👋 Introduction
Market Position
Target Audience:
Kawasaki EX250-J owners, DIY mechanics, professional repair shops
Competitive Analysis
Manual Advantage:
Comprehensive, factory-level information, digitally accessible for convenience and cleanliness
Key Features
Content Source:
Original Kawasaki Workshop Manual, used by local service/repair shops
Information Access:
Hundreds of pages of diagrams and detailed information, click-of-a-mouse access
Disassembly, Assembly, Reinstallation of all major components
Troubleshooting:
Diagnostic procedures for common issues, electrical troubleshooting
Technical Depth
Level Of Detail:
Professional Technician Level, including detailed substeps, critical specifications, and illustrations
Diagnostic Capabilities:
Comprehensive diagnostics for all systems
Rebuild Procedures:
Detailed procedures for engine and transmission rebuilds
📊 Manual Specifications
File Format
PDF Quality:
High Resolution, Searchable (implied by PDF format and professional nature)
Print Quality
Printable:
Full Printable
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
All Versions of Windows & Mac
Requirements
Software:
Adobe PDF Reader & WinZip
⚙️ Engine Specifications
Primary Engine
Engine Type:
Parallel-Twin, Four-stroke
Displacement:
249 cc
Bore X Stroke:
55.0 mm x 52.4 mm (Typical for this generation)
Compression Ratio:
11.7:1 (Typical for this generation)
Performance
Horsepower:
Approx. 30-32 HP @ 10,500 RPM (Varies slightly by market/year)
Torque:
Approx. 15-16 lb-ft @ 8,000 RPM (Varies slightly by market/year)
Fuel System
Fuel Delivery:
Carbureted (Dual Keihin CVK34 typically)
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
18 Liters (4.8 US gal) (Typical for this generation)
Cooling System
Cooling Method:
Liquid-Cooled
🔧 Transmission
Standard
Transmission Type:
Constant Mesh, 6-speed
Clutch Type:
Wet, multiple-disc
Features
Gear Ratios:
Detailed in manual (specific ratios vary by model year)
Final Drive:
Sealed Chain
📐 Dimensions
Exterior
Length:
Approx. 2,000 mm (78.7 in) (Varies slightly)
Width:
Approx. 715 mm (28.1 in) (Varies slightly)
Height:
Approx. 1,095 mm (43.1 in) (Varies slightly)
Weights
Dry Weight:
Approx. 151 kg (333 lbs) (Varies slightly)
Curb Weight:
Approx. 161 kg (355 lbs) (Varies slightly)
🛡️ Safety Features
Ratings
Safety Features:
Primary safety features are mechanical: reliable brakes, stable chassis, effective lighting system. No electronic rider aids typical of modern motorcycles.
Active Features
Braking System:
Front: Single Disc, Rear: Disc (ABS typically optional or absent on earlier EX250-J models)
Passive Features
Lighting:
Halogen Headlight, LED Taillight (model year dependent)
💡 Technology Features
Infotainment
Instrument Cluster:
Analog Tachometer, Digital Speedometer, Odometer, Trip Meters, Fuel Gauge, Neutral Indicator Light
Driver Assistance
Rider Aids:
None typical for this model year, emphasis is on mechanical simplicity and rider control.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Recommended every 3,000-6,000 miles or 6 months (refer to manual for exact specification)
Spark Plug Replacement:
Typically every 10,000-15,000 miles
Valve Clearance Check:
Recommended every 10,000-15,000 miles
Fluid Specifications
Engine Oil Type:
API SG, SH, SJ, or higher, SAE 10W-40 (refer to manual for specific viscosity and API classification)
Engine Oil Capacity:
Approx. 1.8 - 2.1 Liters with filter change (refer to manual)
Coolant Type:
Kawasaki Full-time Dope or equivalent (Ethylene Glycol based antifreeze)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Clutch wear, chain and sprockets wear, brake pad wear, fork seal leaks
Carburetor Issues:
Can become gummed up if not run regularly or properly stored, leading to rough running or starting problems.
Electrical Issues:
Older models might experience regulator/rectifier failures or stator issues, though less common on the EX250-J compared to some earlier models.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long history of producing reliable and performance-oriented motorcycles, with the Ninja line being a cornerstone.
Model Evolution
Ex250 Lineage:
The EX250 platform has been a popular entry-level sportbike for decades, consistently evolving to meet market demands and emissions regulations. The EX250-J represents a specific iteration within this lineage.
Production
Manufacturing Country:
Japan (and other global locations depending on model year)
🏆 Awards & Recognition
Recognitions
Model Reputation:
The Kawasaki Ninja 250 series has consistently been lauded as an excellent beginner sportbike, offering accessible performance and reliability.
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