Kawasaki Ninja 250R 2008-2012 Workshop Service Manual

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Type: Motorcycle

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Sku: 57619

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

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Description

The Kawasaki Ninja 250R (model code EX250K) is a popular entry-level sportbike, produced for the 2008 through 2012 model years. Renowned for its accessible performance and Kawasaki's legacy of engineering quality, this motorcycle offers a balanced riding experience suitable for both new riders and daily commuting. Its liquid-cooled, 4-stroke, DOHC parallel-twin engine, displacing 249 cc, delivers approximately 30-34 horsepower, providing a responsive and engaging ride. The Ninja 250R features a high-tensile steel backbone frame for rigidity and dual hydraulic disc brakes for reliable stopping power, embodying a blend of practicality and sporty design. This comprehensive workshop service manual provides essential information for maintaining and repairing the Kawasaki Ninja 250R (EX250K) from 2008-2012. Covering a wide array of systems including the engine, transmission, chassis, and electrical components, it details everything from routine maintenance procedures like oil changes and spark plug replacement to in-depth engine overhauls and carburetor tuning. The manual also includes troubleshooting guides, disassembly and assembly instructions, and specific technical data, making it an invaluable resource for owners, DIY enthusiasts, and professional mechanics alike. With 520 pages of detailed guidance, this English-language manual is designed for easy navigation and practical application.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Ninja 250R

Model Code:

EX250K

Product Name:

Kawasaki Ninja 250R 2008-2012 Workshop Service Manual PDF Download

👋 Introduction

Market Position

Target Audience:

Motorcycle owners, DIY enthusiasts, independent repair shops, and professional mechanics.

Competitive Analysis

Value Proposition:

Provides essential repair and maintenance information for a popular entry-level sportbike, enabling cost savings and extended vehicle lifespan.

Key Features

Instant Download:

Immediate access to the manual upon purchase, eliminating shipping delays and costs.

Digital Format:

Convenient PDF format accessible on various devices (computers, tablets, smartphones).

📋 Manual Details

Coverage Areas

Years Covered:

2008, 2009, 2010, 2011, 2012

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, including disassembly, inspection, assembly, valve clearance adjustment, lubrication system, cooling system, fuel system, ignition system, emission control.

Transmission System:

Clutch operation, gearbox inspection and repair, shift mechanism, lubrication.

Chassis System:

Frame inspection, suspension (front forks and rear shock absorber), steering system, wheels, tires, brakes (front and rear hydraulic disc brakes), final drive (chain).

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system (ECU, ignition coils), lighting (headlight, taillight, turn signals), instrumentation, starting system, horn, fuses, relays.

Fuel System:

Carburetor (dual Keihin CVK34) service, fuel pump, fuel tank, fuel lines.

Cooling System:

Radiator, cooling fan, coolant, hoses, water pump.

Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable).

Bodywork And Trim:

Fairing removal and installation, seat, fuel tank cover, fenders, mirrors, handlebars.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid checks, tire pressure checks, coolant level checks.

Troubleshooting Guides:

Diagnostic procedures for common problems, electrical system diagnostics, engine performance issues, starting difficulties.

Disassembly And Assembly:

Step-by-step instructions for removing and reinstalling major components and sub-assemblies.

Engine Rebuild:

Detailed procedures for engine disassembly, component inspection, piston/ring replacement, cylinder honing, valve seat grinding, crankshaft and connecting rod checks.

Brake System Repair:

Brake pad replacement, caliper servicing, brake line replacement, bleeding the brake system.

Suspension Service:

Front fork oil change and seal replacement, rear shock absorber inspection and adjustment.

Electrical Component Testing:

Testing ignition coils, stator, regulator/rectifier, starter motor, battery.

Carburetor Tuning:

Carburetor synchronization, idle speed adjustment, mixture control.

Technical Depth

Depth Of Coverage:

Comprehensive coverage from basic maintenance and routine servicing to complete engine overhaul and advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Print Quality

Resolution:

High-resolution scans ensuring clarity of text and diagrams.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Searchability

Search Functionality:

Searchable text within the PDF document allows for quick information retrieval.

Printability

Printable:

Yes, the PDF is designed to be printable for workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

249 cc (15.2 cu. in.)

Bore X Stroke:

62.0 x 41.2 mm (2.44 x 1.62 in.)

Compression Ratio:

11.6:1

Performance

Horsepower:

Approximately 30-34 hp (depending on region and specific tuning)

Torque:

Approximately 17-18 lb-ft

Fuel System

Fuel Delivery:

Dual Keihin CVK34 carburetors

Fuel Tank Capacity:

18 L (4.8 US gal)

Lubrication

Oil Type:

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

Oil Capacity With Filter Change:

1.6 L (1.7 US qt)

Cooling System

Coolant Type:

Ethylene glycol based coolant with distilled water (50/50 mixture)

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Clutch Type:

Wet, multiple disc

Features

Gear Ratios:

Specific ratios detailed within the manual, enabling precise engine performance at various speeds.

Final Drive:

Sealed chain (520)

Transmission Oil Type:

API GL-4, SAE 80W-90 (Specific Kawasaki recommendation may vary)

📐 Dimensions

Exterior

Length:

2005 mm (78.9 in.)

Width:

750 mm (29.5 in.)

Height:

1100 mm (43.3 in.)

Wheelbase:

1370 mm (53.9 in.)

Ground Clearance:

155 mm (6.1 in.)

Seat Height:

780 mm (30.7 in.)

Weights

Curb Weight:

Approximately 169 kg (373 lbs)

Front Tire Size:

110/70-17 M/C 54H

Rear Tire Size:

130/70-17 M/C 62H

Front Brake Type:

Single hydraulic disc

Rear Brake Type:

Single hydraulic disc

Wheel Bolt Pattern:

Not applicable (cast wheels)

🛡️ Safety Features

Ratings

Safety Features:

ABS was an optional feature on some international models but generally not standard on the 250R in many markets.

Active Features

Braking System:

Dual hydraulic disc brakes provide effective stopping power.

Passive Features

Frame Construction:

High-tensile steel backbone frame designed for rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment Features:

Basic analog tachometer and digital speedometer, fuel gauge, odometer, trip meter, clock.

Driver Assistance

ABS Availability:

Optional on select models/regions.

Connectivity

Connectivity Features:

Not applicable for this model year.

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

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

Air Filter Cleaning Interval:

Every 6,000 km (3,700 mi) or as needed based on operating conditions.

Spark Plug Replacement Interval:

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

Valve Clearance Check Interval:

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

Brake Fluid Change Interval:

Every 24,000 km (15,000 mi) or 24 months.

Fluid Specifications

Front Fork Oil Type:

Kawasaki Fork Oil G10 or equivalent (e.g., Showa SS-10)

Front Fork Oil Level:

105 mm (4.1 in.)

Coolant Capacity:

1.3 L (1.4 US qt)

Known Issues

Common Wear Items:

Chain and sprockets, brake pads, tires, clutch plates (with high mileage).

Potential Performance Issues:

Carburetor synchronization drift, minor electrical gremlins (frequently addressed in this manual).

Technical Specs

Spark Plug Type:

NGK CR9E or DENSO U27ESR-N

Spark Plug Gap:

0.7 - 0.8 mm (0.028 - 0.031 in.)

Idle Speed:

1300 ± 100 rpm

Chain Slack:

10-20 mm (0.39-0.79 in.)

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki has a long-standing reputation for producing reliable and performance-oriented motorcycles, with the Ninja line being a cornerstone of their sportbike offerings.

Model Evolution

Ninja Lineage:

The Ninja 250R (also known as the EX250) has been a popular entry-level sportbike for decades, evolving through various iterations to offer modern styling and performance while remaining accessible to new riders.

Production

Manufacturing Origin:

Primarily manufactured in Thailand and Japan.

Release Years:

The 2008 model year marked a significant redesign from previous generations.

🏆 Awards & Recognition

Recognitions

Market Acclaim:

Consistently praised as a reliable and forgiving entry-level sportbike, making it a popular choice for new riders and commuters.