Engine Mechanical:
Full disassembly, assembly, inspection, and repair of the engine and its sub-components.
Fuel System:
Carburetor (model specific), fuel pump (if applicable), fuel lines, and tank servicing.
Ignition System:
CDI, spark plugs, ignition coils, and related wiring.
Cooling System:
Radiator, fan, coolant circulation, and related components (for liquid-cooled variants, though this model is air-cooled, the manual likely covers related heat dissipation).
Exhaust System:
Muffler, exhaust pipes, and mounting.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, chain drive, sprockets, and lubrication.
Chassis Frame:
Frame inspection, alignment, and repair procedures.
Suspension Front:
Front fork assembly, oil seals, springs, damping adjustments, and steering head bearings.
Suspension Rear:
Monoshock or twin-shock absorber (depending on specific EX250-H2 variant), swingarm, and linkage maintenance.
Braking System:
Front and rear brake systems (disc or drum), master cylinders, calipers, brake pads, fluid, and bleeding procedures.
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator), lighting, horn, starter motor, and fuses.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure, and mounting/dismounting.
Bodywork Trim:
Fairings, fuel tank cover, seat, and other cosmetic components.
Routine Maintenance:
Oil changes, filter replacements, chain adjustments, lubrication, and general inspection.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling major components and sub-assemblies.
Adjustments:
Carburetor synchronization, valve clearance adjustment, brake lever adjustment, clutch adjustment, and suspension settings.
Rebuilds:
Detailed procedures for overhauling engine components, carburetors, and brake systems.
Special Tool Usage:
Identification and application of specialized tools required for specific repair tasks.
Technical Depth:
Comprehensive, covering from basic adjustments to full engine and component rebuilds.
Diagnostic Information:
Included for effective troubleshooting.
Service Data:
Precise specifications, tolerances, and wear limits are provided.
Illustrations:
Detailed pictorial diagrams, exploded views, and photographs.
Engine Type:
4-stroke, parallel-twin, DOHC, 2 valves per cylinder
Displacement:
249 cc (249 cubic centimeters)
Bore X Stroke:
55.0 mm x 52.4 mm
Cooling System:
Air-cooled
Horsepower Est:
Approx. 30-35 HP (at crank), depending on specific market tuning.
Torque Est:
Approx. 18-20 Nm (at crank)
Carburetion:
Twin Keihin carburetors (e.g., CVK30 or similar)
Fuel Type:
Unleaded gasoline
Oil Type Recommendation:
Kawasaki recommends API SE, SF, SG or SH, JASO MA certified oil. Viscosity typically 10W-40 or 20W-50 depending on ambient temperature.
Oil Capacity W Filter:
Approximately 2.2 - 2.5 Liters (refer to manual for exact specification)
Oil Filter Part Number Example:
K&N KN-111, Hiflofiltro HF111 or equivalent OEM equivalent (e.g., 16097-1001).
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first (refer to manual for precise interval).
Chain Lubrication Interval:
Every 500-1,000 km (300-600 miles) or after riding in wet conditions.
Valve Clearance Check:
Typically every 10,000-12,000 km (6,000-7,500 miles) (refer to manual for exact interval).
Air Filter Cleaning Replacement:
Inspection at every oil change, cleaning/replacement as needed based on conditions, typically every 10,000-20,000 km.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Common Issues:
Carburetor synchronization drift, aging fuel lines, wear on suspension bushings, potential for stator failure over time.
Preventative Maintenance Emphasis:
The manual stresses the importance of adhering to scheduled maintenance to ensure reliability and prevent costly repairs.
