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Kawasaki Ninja 250R 2008 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 250R Year: 2008 Generation Generation Identifier: EX250-J8F Codes Vin Code: JKAEX250A 👋 Introduction Market Position Positioning: The Kawasaki Ninja 250R (EX250) is...
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Kawasaki Ninja 250R 2008 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Ninja 250R
Year:
2008
Generation
Generation Identifier:
EX250-J8F
Codes
Vin Code:
JKAEX250A
👋 Introduction
Market Position
Positioning:
The Kawasaki Ninja 250R (EX250) is a popular entry-level sportbike, known for its agility, fuel efficiency, and affordability. It serves as a gateway into sportbike riding for many enthusiasts.
Competitive Analysis
Competitors:
Competes with other lightweight sportbikes such as the Honda CBR250R, Yamaha YZF-R25, and Suzuki GS500F (in certain markets).
Key Features
Sportbike Appeal:
Full fairing, sporty riding position, and performance characteristics that mimic larger Ninja models.
Accessibility:
Beginner-friendly power delivery and manageable weight make it accessible for new riders.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair, maintenance, diagnostics, and disassembly/assembly procedures for the 2008 Kawasaki Ninja 250R.
Secondary Coverage:
Includes adjustments, checks, and specifications.
Page Count
Estimated Pages:
300-400
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Full disassembly, assembly, inspection, and repair of the 250cc parallel-twin engine, including valve clearance, timing, lubrication system, and cooling.
Fuel System:
Carburetor tuning and adjustment, fuel pump operation, fuel tank and lines.
Ignition System:
CDI system, spark plugs, ignition timing checks.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, chain maintenance and adjustment, final drive.
Chassis Frame:
Frame inspection, fork disassembly and assembly, rear suspension adjustment and service, steering head bearing maintenance.
Brakes:
Front and rear brake system overhaul, fluid replacement, caliper inspection, master cylinder service, pad replacement.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter system, charging system, fuses.
Bodywork Fittings:
Fairing removal and installation, seat, fuel tank removal, body panel care.
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacement, chain lubrication, brake fluid flush, coolant replacement.
Troubleshooting:
Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical issues.
Repair:
Detailed step-by-step instructions for component repair and replacement.
Disassembly Assembly:
Comprehensive guides for dismantling and reassembling all major motorcycle systems.
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch and throttle cable adjustment, suspension settings.
Technical Depth
Depth:
Complete factory-level repair information suitable for professional mechanics and advanced DIY enthusiasts, covering everything from basic maintenance to full engine rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick access to specific information.
Print Quality
Print Readability:
Designed for clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, parallel-twin
Displacement:
249 cc (15.2 cu in)
Bore X Stroke:
55.0 x 52.4 mm
Compression Ratio:
11.6:1
Valve Train:
DOHC, 8 valves (2 per cylinder)
Performance
Horsepower Est:
Approx. 30-34 HP @ 10,500 RPM (crank)
Torque Est:
Approx. 17-19 lb-ft @ 8,000 RPM (crank)
Fuel System
Fuel Delivery:
Two Keihin CVK34 carburetors
Fuel Tank Capacity:
18 L (4.8 US gal)
Lubrication
Oil Type Spec:
SAE 10W-40 API SG, SF, or SH (check manual for exact specification)
Cooling System
Coolant Type:
Ethylene glycol-based antifreeze solution (50/50 mix with distilled water)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-disc
Features
Final Drive:
Sealed chain, 520
Gear Ratios:
Refer to manual for specific gear ratios.
📐 Dimensions
Exterior
Overall Length:
2,005 mm (78.9 in)
Overall Width:
760 mm (29.9 in)
Overall Height:
1,075 mm (42.3 in)
Wheelbase:
1,400 mm (55.1 in)
Ground Clearance:
155 mm (6.1 in)
Weights
Curb Weight:
170 kg (375 lbs)
Dry Weight:
151 kg (333 lbs)
Load Capacity:
Refer to manual for rider and luggage limits.
🛡️ Safety Features
Ratings
Safety Standards:
Meets or exceeds applicable safety standards for motorcycles in its class.
Active Features
Braking System Front:
290 mm petal disc, dual piston caliper
Braking System Rear:
220 mm petal disc, dual piston caliper
Suspension Front:
37 mm telescopic fork
Suspension Rear:
Uni-Trak with adjustable preload
Passive Features
Lighting:
Halogen headlight, LED taillight
Tires Front:
110/70-17 M/C 54H
Tires Rear:
130/70-17 M/C 62H
Wheel Type:
Cast alloy wheels
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic sportbike, no infotainment system)
Driver Assistance
Rider Aids:
None (e.g., no ABS or traction control offered on this model year)
🔧 Maintenance
Service Intervals
First Service:
Typically around 600 miles (1,000 km) for the initial break-in service (oil change, filter check, chain adjustment, valve clearance check).
Regular Maintenance:
Oil and filter change every 3,000-4,000 miles (5,000-6,000 km). Chain adjustment and lubrication every 500-700 miles (800-1,100 km). Air filter cleaning/replacement every 6,000-8,000 miles (10,000-13,000 km). Valve clearance checks every 7,500-15,000 miles (12,000-24,000 km) depending on usage and conditions (refer to manual).
Fluid Specifications
Engine Oil Capacity:
Approx. 1.6 L (1.7 US qt) with filter change; 1.4 L (1.5 US qt) without filter change.
Brake Fluid:
DOT 4 (refer to manual for exact specification and type)
Coolant Capacity:
Approx. 1.1 L (1.2 US qt)
Known Issues
Carburetor Issues:
Carburetors can sometimes require cleaning or synchronization, especially if the bike has sat for extended periods or has had fuel quality issues.
Cam Chain Tensioner:
While not overly common, the automatic cam chain tensioner can occasionally fail or require manual adjustment/replacement in higher mileage units.
Clutch Wear:
Normal wear and tear on clutch plates is expected with regular use, requiring adjustment or replacement over time.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki Heavy Industries has a long history of producing motorcycles, known for their performance and innovation, particularly in the sportbike segment with the Ninja line.
Model Evolution
Ninja 250 Lineage:
The Ninja 250R has been a staple in Kawasaki's lineup for decades, undergoing continuous evolution. The 2008 model represents a significant update from previous generations, often referred to as the 'Ninja 250R' designation in many markets.
Production
Manufacturing Location:
Typically manufactured in Thailand or Japan.
Production Years:
The EX250 platform that includes the 2008 model has seen production from the early 2000s up to the redesign that introduced the Ninja 300.
🏆 Awards & Recognition
Recognitions
Award History:
Frequently praised in motorcycle publications as an excellent beginner sportbike for its balance of performance, handling, and affordability. Specific awards may vary by region and publication.
Ratings
Reliability Rating:
Generally considered reliable with proper maintenance.
Certifications
Certification Standards:
Meets all required emissions and safety certifications for its model year.
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