Segment:
Entry-level sportbike, beginner-friendly motorcycle.
Target Audience:
New riders, commuting, sport riding enthusiasts seeking an affordable and reliable machine.
Competitors:
Honda CBR250R, Suzuki GS500F (older models), Yamaha R3 (later models), Ninja 300 (later models).
Agility:
Lightweight chassis and nimble handling.
Affordability:
Accessible purchase price and low running costs.
Reliability:
Proven Kawasaki engineering known for durability.
Years Covered:
2008, 2009, 2010, 2011, 2012
Specific Models Covered:
EX250J (North America), EX250JFA (specific markets)
Estimated Pages:
Approximately 500+
Type:
Service Repair Manual
Format:
PDF (Portable Document Format)
Print Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type:
Not Applicable (Digital Download)
Paper Type:
Not Applicable (Digital Download)
Engine:
Complete engine overhaul, disassembly, assembly, lubrication, cooling system, fuel system (carburetor specifications, adjustment), ignition system, exhaust system, emissions controls.
Transmission:
Gearbox removal and installation, internal components, clutch operation, shift mechanism.
Chassis:
Frame inspection and repair, front fork overhaul, rear suspension system, steering system.
Brakes:
Front and rear brake system inspection, service, hydraulic system bleeding, pad replacement, caliper service.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, battery), lighting system (headlight, taillight, turn signals), ignition system components, instrument panel, sensors.
Fuel System:
Carburetor identification, disassembly, cleaning, reassembly, adjustment, fuel tank and lines.
Cooling System:
Radiator, fan, thermostat, coolant specifications, bleeding procedures.
Bodywork And Trim:
Fairing removal and installation, seat, tank cover, fenders.
Maintenance:
Oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid checks, coolant checks, air filter cleaning/replacement.
Troubleshooting:
Diagnostic charts for common starting problems, running issues, electrical faults, and performance anomalies.
Repair:
Detailed step-by-step instructions for component removal, installation, and repair across all systems.
Rebuilds:
Engine top-end and bottom-end rebuild procedures, carburetor rebuilds.
Adjustments:
Valve clearance adjustment, idle speed adjustment, carburetor synchronization (if applicable), clutch and throttle cable adjustments.
Depth:
Comprehensive (from basic maintenance to complete engine teardowns and electrical system diagnostics).
Engine Type:
4-stroke, DOHC, 8-valve, parallel-twin
Displacement:
249 cc (249.8cc)
Bore X Stroke:
55.0 x 52.4 mm
Compression Ratio:
11.0:1
Cooling System:
Liquid-cooled
Horsepower:
Approx. 30-34 PS (22-25 kW) @ 10,500 rpm (market dependent)
Torque:
Approx. 20-22 Nm (15-16 lb-ft) @ 8,000 rpm (market dependent)
Fuel Delivery:
Carburetor (Dual Keihin CVK32)
Fuel Type:
Unleaded gasoline, 91 octane (or higher) recommended
Ignition System:
Digital CDI
Oil Type:
SAE 10W-40 API SG or SH
Oil Capacity:
1.7 L (1.8 US qt) with filter change
Crash Test Ratings:
Not typically rated by consumer safety organizations like NHTSA/IIHS for motorcycles.
Braking System:
Front: Single 290mm petal disc with 2-piston caliper. Rear: Single 220mm petal disc with 2-piston caliper. (Some models may have optional ABS, but uncommon for this generation EX250).
Lighting:
Halogen headlight, LED taillight.
Frame Construction:
High-tensile steel diamond frame.
Tires Front:
110/70-17 M/C 54H
Tires Rear:
130/70-17 M/C 62H
Display:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, clock.
Lighting Technology:
Halogen headlight, LED taillight for better visibility and reduced power draw.
ABS:
Anti-lock Braking System (ABS) was not standard or widely available on the 2008-2012 EX250 Ninja in most markets.
Connectivity Features:
None (This era of motorcycle predates widespread connectivity features like Bluetooth or smartphone integration).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 18,000 km (11,000 miles).
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Coolant Change:
Every 24,000 km (15,000 miles) or 2 years.
Engine Oil Viscosity:
SAE 10W-40
Coolant Type:
Kawasaki Long Life Coolant (50/50 mix of ethylene glycol and distilled water) or equivalent.
Chain Lube:
High-quality motorcycle chain lubricant.
Carburetor Cleaning:
Carburetors can become gummed up if the bike sits for extended periods with fuel in them, requiring cleaning and synchronization.
Regulator Rectifier:
While generally reliable, the regulator/rectifier can be a point of failure in some older bikes, impacting battery charging.
Stator Output:
Check stator output as per manual specifications if charging issues are suspected.
Chain Wear:
Regular lubrication and adjustment are crucial to prevent premature chain and sprocket wear.
Heritage:
Kawasaki Heavy Industries has a long history in motorcycle manufacturing, known for performance and sportbikes.
Predecessor:
GPZ250R, EX250-F (Gen 1 & 2 Ninja 250).
Generation Update:
The 2008-2012 models represent the third generation (EX250J), featuring a significant styling update, improved aerodynamics, and revised suspension compared to the previous generation.
Key Design Changes:
Introduction of fuel injection in some markets (though the manual likely covers carbureted models), sharper styling mimicking larger Ninja sportbikes, improved fairing design.
Manufacturing Location:
Thailand (primary for global markets)
Production Years:
2008-2012 (for this specific generation covered by the manual)
