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2008-2012 Kawasaki Ninja 250R Service Repair Manual
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🏷️ Basic Information Identification Make: Kawasaki Model: Ninja 250R Model Code: EX250K Year: 2008-2012 Generation Generation Designation: Second Generation (EX250J/EX250K) Introduction Year: 2008 Key Updates For Generation: All-new chassis, fuel...
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🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Ninja 250R
Model Code:
EX250K
Year:
2008-2012
Generation
Generation Designation:
Second Generation (EX250J/EX250K)
Introduction Year:
2008
Key Updates For Generation:
All-new chassis, fuel injection, revised bodywork, improved suspension.
Codes
Chassis Code Prefix:
EX250K
👋 Introduction
Market Position
Market Segment:
Entry-level sportbike, beginner motorcycle.
Target Audience:
New riders, budget-conscious enthusiasts, commuters, track day participants.
Competitive Analysis
Key Competitors:
Honda CBR250R, Yamaha YZF-R25 (later models), Suzuki GS500F (larger displacement but similar role).
Competitive Advantages:
Reliability, affordability, ease of use, good fuel economy, strong aftermarket support.
Key Features
Design Philosophy:
Compact, lightweight, sporty styling with accessible performance.
Performance Characteristics:
Nimble handling, forgiving power delivery, excellent for learning and urban riding.
User Friendliness:
Low seat height, manageable weight, user-friendly controls contribute to its beginner-friendly reputation.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service and Repair
Additional Coverage:
Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams
Page Count
Approximate Page Count:
300-400 pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of engine components (cylinder head, pistons, crankshaft, camshafts, valves, etc.).
Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, pressure regulator, fuel tank, fuel lines.
Cooling System:
Radiator, fan, thermostat, coolant lines, water pump.
Ignition System:
Ignition coils, spark plugs, ECU control, timing.
Transmission:
Clutch (wet multi-plate), gearbox internals, shift mechanism, lubrication.
Chassis And Frame:
Frame inspection, alignment, removal and installation of frame components.
Suspension Front:
Telescopic fork service, oil replacement, seal replacement, spring inspection.
Brakes Front:
Hydraulic disc brake system, caliper service, pad replacement, rotor inspection, hydraulic fluid flush.
Wheels And Tires:
Tire inspection and replacement, wheel bearing service, rim specifications.
Electrical System:
Battery, charging system (alternator/stator), starter motor, lighting, horn, ignition switch.
Wiring Diagrams:
Detailed color wiring schematics for all electrical circuits.
Bodywork And Trim:
Fairings, seat, fuel tank, fenders, instrument panel, removal and installation procedures.
Suspension Rear
Suspension Rear:
Monoshock absorber, linkage system, swingarm, bearing maintenance.
Brakes Rear
Brakes Rear:
Hydraulic disc brake system, caliper service, pad replacement, rotor inspection, hydraulic fluid flush.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, brake checks, tire pressure, coolant checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul.
Engine Rebuild:
Full engine rebuild instructions, including torque specifications and tolerances.
Carburetor Service:
N/A for this model (fuel injected)
Fuel Injection Diagnosis:
Diagnostic trouble codes (DTCs), sensor testing, injector testing.
Suspension Tuning:
Fork oil weight and level adjustments, shock preload adjustment.
Brake Bleeding:
Procedures for bleeding both front and rear brake systems.
Electrical Troubleshooting:
Circuit testing, component testing, diagnostic flowcharts.
Technical Depth
Depth Level:
Comprehensive: Covers everything from basic rider maintenance to full engine and transmission rebuilds, including electrical system diagnostics.
Diagnostic Capabilities:
Detailed diagnostic procedures for EFI system, electrical faults, and mechanical issues.
Specification Detail:
Includes detailed torque specifications, clearances, fluid capacities, resistance values, and other critical technical data.
📊 Manual Specifications
File Format
Digital File Type:
PDF (Portable Document Format)
Searchable Text:
Yes (typically, if professionally scanned and indexed)
Printable:
Yes (designed for printing specific sections or the entire manual)
Image Quality:
High-resolution scans of original diagrams, illustrations, and photographs.
Print Quality
Print Quality Description:
N/A (Digital PDF format, printing quality depends on user's printer).
Binding Type
Binding Type Description:
N/A (Digital PDF format, no physical binding).
Paper Type
Paper Type Description:
N/A (Digital PDF format, no physical paper).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, parallel-twin.
Displacement:
249 cc (249 cubic centimeters).
Bore X Stroke:
55.0 x 52.4 mm.
Compression Ratio:
11.0:1.
Valve Train:
DOHC, 4 valves per cylinder.
Performance
Horsepower Approx:
30-34 HP (at crankshaft, depending on region/tuning).
Torque Approx:
17-19 lb-ft (at crankshaft, depending on region/tuning).
Redline Rpm Approx:
10,500 RPM.
Fuel System
Fuel Delivery:
Fuel Injection (DFI) with dual throttle valves.
Fuel Type Required:
Unleaded gasoline, minimum 87 octane (RON+MON)/2.
Fuel Tank Capacity:
18 Liters (4.8 US gal).
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh.
Clutch Type:
Wet multi-plate.
Optional
Optional Transmission:
N/A (Always manual 6-speed).
Features
Final Drive:
RK Chain, 106 links, 520 pitch.
Gear Ratios:
1st: 2.750 (33/12), 2nd: 1.944 (35/18), 3rd: 1.560 (39/20), 4th: 1.333 (32/24), 5th: 1.160 (29/25), 6th: 1.000 (28/28).
📐 Dimensions
Exterior
Overall Length:
2005 mm (78.9 in).
Overall Width:
750 mm (29.5 in).
Overall 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 Approx:
168-170 kg (370-375 lbs) depending on configuration.
Front Tire Size:
110/70-17 M/C 54H.
Rear Tire Size:
130/70-17 M/C 62H.
Wheel Type:
Cast aluminum alloy wheels.
Wheelbase Type:
Steel diamond frame.
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not subject to the same crash ratings as cars).
Active Features
Braking System:
Dual hydraulic disc brakes (front and rear).
ABS Availability:
Optional (ABS available on some models/markets).
Passive Features
Lighting:
Halogen headlight, LED tail light.
Frame Construction:
High-tensile steel frame designed for rigidity and responsiveness.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No infotainment system on this model).
Instrumentation:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, clock.
Driver Assistance
Driver Assistance Features:
ABS (Anti-lock Braking System) optional on select models.
Connectivity
Connectivity Features:
N/A.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 miles (6,000 km) or 6 months.
Oil Filter Change Interval:
Every 8,000 miles (12,000 km) or 12 months (or with every oil change).
Air Filter Cleaning:
Every 4,000 miles (6,000 km).
Spark Plug Replacement:
Every 7,500 miles (12,000 km).
Chain Lubrication:
Every 500 miles (800 km) or after washing/rain.
Chain Adjustment:
Check every 4,000 miles (6,000 km).
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA or MA2.
Engine Oil Capacity:
1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.
Coolant Type:
Permanent type antifreeze (ethylene glycol based) mixed with distilled water, 50/50 ratio.
Brake Fluid Type:
DOT 4.
Fork Oil Type:
SAE 10W (check manual for exact specification as variations may exist).
Known Issues
Common Wear Items:
Clutch plates, brake pads, tires, chain and sprockets.
Potential Issues:
Occasional issues with the starter relay, some owners report vibration at higher RPMs. Early models might have had minor EFI calibration quirks, generally resolved with firmware updates or proper diagnosis.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycle Division:
Kawasaki Heavy Industries' Motorcycle and Engine division has a long history of innovation and performance since its inception.
Model Evolution
Ninja 250 Lineage:
The Ninja 250 series has been a popular entry-level sportbike globally for decades, evolving through several generations to meet changing market demands and emissions standards.
Predecessor:
The 2008-2012 model replaced the previous generation (EX250E/F/G) which featured carbureted engines.
Successor:
The 2013 model saw a significant redesign and displacement increase to 300cc (Ninja 300).
Production
Manufacturing Locations:
Primarily produced in Thailand and Japan.
🏆 Awards & Recognition
Recognitions
Award History:
Consistently praised for its value, reliability, and beginner-friendliness by motorcycle publications and riders.
Ratings
Rider Reviews:
Generally high ratings for ease of use, fuel efficiency, and low running costs.
Certifications
Certification:
Meets all relevant emissions and safety standards for its respective model years and markets.