Kawasaki EX250 Ninja - Service Repair Manual - Wiring Diagrams - Owners Manual

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KAWASAKI EX250 NINJA - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for motorcycles Kawasaki EX250 Ninja.

 
CONTENTS:

- SERVICE MANUAL EX250J8F (2008)
- SERVICE MANUAL EX250K8F (2008)
- OWNERS MANUAL (2008)


INDEX SERVICE MANUAL  

General Information
- Before starting to perform an inspection service or carry out a
- Battery Ground
- Edges of Parts
- Solvent
- Cleaning vehicle before disassembly
- Arrangement and Cleaning of Removed Parts
- Storage of Removed Parts
- Inspection
- Replacement Parts
- Assembly Order
- Tightening Sequence
- Tightening Torque
- Force
- Gasket, O-ring
- Liquid Gasket, Non-permanent Locking Agent
- Press
- Ball Bearing and Needle Bearing
- Oil Seal, Grease Seal
- Circlips, Cotter Pins
- Lubrication
- Direction of Engine Rotation
- Electrical Wires
- Instrument
- EX250J8F Left Side View (United States and Canada)
- EX250J8F Right Side View (United States and Canada)
- Frame Number
- Engine Number
- Prefixes for Units:
- Units of Temperature:
Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- Use a torque wrench to tighten bolts and nuts to their specified
- Steering Stem Nut Wrench:
- Fuel System
- Air Cleaner Element Cleaning
- Air Cleaner Element Installation
- Torque -
- Throttle Control System Inspection
- Choke Operation Inspection
- Engine Vacuum Synchronization Inspection
- Special Tool -
- Idle Speed Inspection
- Idle Speed Adjustment
- Fuel Hose Inspection (fuel leak, damage, installation condition)
- Evaporative Emission Control System (California Model)
- Evaporative Emission Control System Inspection
- Cooling System
- Coolant Level Inspection
- Radiator Hose Damage and Installation Condition Inspection
- Coolant Filter Cleaning (Australia Model)
- Air Suction System
- Air Suction System Damage Inspection
- Engine Top End
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Clutch
- Clutch Operation Inspection
- Wheels/Tires
- Air Pressure Inspection
- Wheel/Tire Damage Inspection
- Tire Tread Wear, Abnormal Wear Inspection
- Wheel Bearing Damage Inspection
- Drive Train
- Drive Chain Lubrication Condition Inspection
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Wheel Alignment Inspection
- Drive Chain Wear Inspection
- Chain Guide Inspection
- Brake System
- Brake Fluid Leak (Brake Hose and Pipe) Inspection
- Brake Hose and Pipe Damage and Installation Condition Inspection
- Brake Operation Inspection
- Brake Fluid Level Inspection
- Brake Pad Wear Inspection
- Brake Light Switch Operation Inspection
- Suspensions
- Front Forks/Rear Shock Absorber Operation Inspection
- Front Fork Oil Leak Inspection
- Rear Shock Absorber Oil Leak Inspection
- Rocker Arm Operation Inspection
- Tie-Rod Operation Inspection
- Swingarm Pivot Lubrication
- Steering System
- Steering Play Inspection
- Steering Play Adjustment
- Steering Stem Bearing Lubrication
- Electrical System
- Lights and Switches Operation Inspection
- Headlight Aiming Inspection
- Sidestand Switch Operation Inspection
- Engine Stop Switch Operation Inspection
- Others
- Chassis Parts Lubrication
- Bolts, Nuts and Fasteners Tightness Inspection
- Replacement Parts
- Air Cleaner Element Replacement
- Fuel Hose Replacement
- Coolant Change
- Torque -
- Radiator Hose and O-ring Replacement
- Engine Oil Change
- Oil Filter Replacement
- Brake Hose and Pipe Replacement
- Brake Fluid Change
- Master Cylinder Rubber Parts Replacement
- Caliper Rubber Parts Replacement
- Spark Plug Replacement
Fuel System
- Fuel Level Gauge:
- Free Play Inspection
- Free Play Adjustment
- Throttle Cable Removal
- Throttle Cable Installation
- Throttle Cable Lubrication
- Free Play Inspection
- Free Play Adjustment
- Choke Cable Removal
- Choke Cable Installation
- Choke Cable Lubrication and Inspection
- Idle Speed Inspection
- Idle Speed Adjustment
- Engine Vacuum Synchronization Inspection
- Engine Vacuum Synchronization Adjustment
- Pilot Screw Adjustment
- Special Tool -
- Service Fuel Level Inspection
- Special Tool -
- Service Fuel Level Adjustment
- Fuel System Cleanliness Inspection
- Carburetor Removal
- Carburetor Installation
- Carburetor Separation
- Carburetor Joining
- Carburetor Disassembly
- Carburetor Assembly
- Carburetor Cleaning
- Carburetor Inspection
- Air Cleaner Element Removal
- Air Cleaner Element Installation
- Air Cleaner Housing Removal
- Air Cleaner Housing Installation
- Air Cleaner Housing Disassembly
- Air Cleaner Housing Assembly
- Oil Draining
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tap Removal
- Fuel Tap Installation
- Torque -
- Fuel Tank and Tap Cleaning
- Fuel Tap Inspection
- Fuel Tank and Cap Inspection
Cooling System
- Kawasaki Bond (Silicone Sealant):
- Permanent type antifreeze is used as a coolant to protect the co
- Coolant Deterioration Inspection
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Cooling System Flushing
- Pump Cover Removal
- Pump Cover Installation
- Torque -
- Water Pump Removal
- Water Pump Installation
- Pump Impeller Inspection
- Radiator and Radiator Fan Removal
- Radiator Inspection
- Radiator Cleaning
- Radiator Cap Inspection
- Radiator Filler Neck Inspection
- Thermostat Removal
- Thermostat Installation
- Thermostat Housing Removal
- Thermostat Housing Installation Note
- Thermostat Inspection
- Hose Installation
- Torque -
- Hose Inspection
- Radiator Fan Switch, Water Temperature Switch Removal
- Radiator Fan Switch, Water Temperature Switch Installation
- Sealant -
- Torque -
- Radiator Fan Switch, Water Temperature Switch Inspection
Engine Top End
- Exhaust System
- Compression Gauge, 20 kgf/cm :
- Vacuum Switch Valve Removal
- Vacuum Switch Valve Installation
- Vacuum Switch Valve Operation Test
- Vacuum Switch Valve Unit Test
- Special Tool -
- Air Suction Valve Removal
- Air Suction Valve Installation
- Torque -
- Air Suction Valve Inspection
- Clean Air System Hose Inspection
- Cylinder Head Cover Removal
- Cylinder Head Cover Installation
- Torque -
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Torque -
- Torque -
- Camshaft Removal
- Camshaft Installation
- Torque -
- Camshaft and Sprocket Assembly
- Torque -
- Camshaft and Camshaft Cap Wear Inspection
- Torque -
- Camshaft Runout Inspection
- Cam Wear Inspection
- Camshaft Chain Guide Wear Inspection
- Cylinder Compression Measurement
- Special Tool -
- Torque -
- Cylinder Head Removal
- Cylinder Head Installation
- Torque -
- Torque -
- Torque -
- Cylinder Head Warp Inspection
- Cylinder Head Cleaning
- Valve Clearance Inspection
- Valve Clearance Adjustment
- Valve Removal
- Special Tools -
- Valve Installation
- Valve Guide Removal
- Special Tool -
- Valve Guide Installation
- Special Tools -
- Special Tool -
- Valve-to-Guide Clearance Measurement (Wobble Method)
- Valve Seat Inspection
- Valve Seat Repair
- Special Tools -
- Seat Cutter Operation Cares
- Marks Stamped on the Cutter
- Operating Procedures
- Cylinder Removal
- Cylinder Installation
- Special Tool -
- Piston Removal
- Special Tool -
- Piston Installation
- Cylinder Wear Inspection
- Piston Wear Inspection
- Piston Ring, Piston Ring Groove Wear Insepction
- Piston Ring Groove Width Inspection
- Piston Ring Thickness Inspection
- Piston Ring End Gap Inspection
- Boring, Honing
- Carburetor Holder Installation
- Muffler Removal
- Muffler Installation
- Exhaust System Inspection
Clutch
- Clutch Holder:
- Clutch Lever Free Play Inspection
- Clutch Lever Free Play Adjustment
- Clutch Cable Removal
- Clutch Cable Lubrication
- Clutch Lever Removal
- Clutch Cover Removal
- Clutch Cover Installation Note
- Special Tool -
- Clutch Release Shaft Removal
- Clutch Release Shaft Installation
- Clutch Removal
- Special Tool -
- Clutch Installation
- Special Tool -
- Torque -
- Torque -
- Clutch Plate Wear and Damage Inspection
- Clutch Plate Warp Inspection
- Clutch Spring Free Length Inspection
- Clutch Housing Finger Damage Inspection
- Clutch Hub Spline Damage Inspection
Engine Lubrication System
- Outside Circlip Pliers:
- WARNING
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Replacement
- Bypass Valve Disassembly
- Bypass Valve Assembly
- Bypass Valve Cleaning and Inspection
- Oil Screen Cleaning and Inspection
- Oil Pressure Relief Valve Removal
- Oil Pressure Relief Valve Installation
- Torque -
- Oil Pressure Relief Valve Inspection
- Oil Pump Removal
- Oil Pump Installation
- Torque -
- Oil Pump Disassembly
- Special Tool -
- Oil Pump Assembly
- Oil Pump Inspection
- Oil Pressure Measurement
- Special Tools -
- Oil Pressure Switch Removal
- Oil Pressure Switch Installation
- Sealant -
- Torque -
- Torque -
Engine Removal/Installation
- Engine Removal
- Engine Installation
- Torque -
Crankshaft/Transmission
- Bearing Puller:
- Crankcase Splitting
- Crankcase Assembly
- Special Tool -
- Special Tool -
- Torque -
- Torque -
- Crankcase Exchange
- Crankshaft Removal
- Crankshaft Installation
- Connecting Rod Removal
- Connecting Rod Installation
- Torque -
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend Inspection
- Connecting Rod Twist Inspection
- Connecting Rod Big End Side Clearance Inspection
- Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
- Crankshaft Side Clearance Inspection
- Crankshaft Runout Inspection
- Crankshaft Main Bearing Insert/Journal Wear Inspection
- Starter Motor Clutch Removal/Installation
- Starter Motor Clutch Inspection
- Starter Motor Clutch Disassembly
- Starter Motor Clutch Assembly
- Torque -
- Balancer Removal
- Balancer Installation
- Balancer Shaft Bearing Insert/Journal Wear Inspection
- Torque -
- External Shift Mechanism Removal
- External Shift Mechanism Installation
- External Shift Mechanism Inspection
- Torque -
- Transmission Removal
- Transmission Installation
- Transmission Shaft Disassembly
- Special Tool -
- Special Tools -
- Transmission Shaft Assembly
- Shift Drum and Fork Removal
- Shift Drum and Fork Installation
- Torque -
- Torque -
- Shift Drum Disassembly
- Shift Drum Assembly
- Torque -
- Gear Backlash Inspection
- Shift Fork Bending Inspection
- Shift Fork/Gear Groove Wear Inspection
- Shift Fork Guide Pin/Drum Groove Wear Inspection
- Gear Dog and Gear Dog Hole Damage Inspection
- Ball and Needle Bearing Wear Inspection
Wheels/Tires
- Inside Circlip Pliers:
- Front Wheel Removal
- Front Wheel Installation
- Torque -
- Rear Wheel Removal
- Rear Wheel Installation
- Torque -
- Wheel Inspection
- Axle Inspection
- Balance Inspection
- Balance Adjustment
- Balance Weight Removal
- Balance Weight Installation
- Air Pressure Inspection/Adjustment
- Tire Inspection
- Tire Removal
- Special Tool -
- Special Tools -
- Tire Installation
- Tire Repair
- Hub Bearing Removal
- Special Tool -
- Special Tools -
- Hub Bearing Installation
- Special Tool -
- Special Tool -
- Special Tool -
- Hub Bearing Inspection
- Hub Bearing Lubrication
- Speedometer Gear Housing Disassembly
- Speedometer Gear Housing Assembly
- Speedometer Gear Housing Lubrication
Final Drive
- Bearing Driver Set:
- Drive Chain Slack Inspection
- Drive Chain Slack Adjustment
- Wheel Alignment Inspection/Adjustment
- Drive Chain Wear Inspection
- Drive Chain Lubrication
- Drive Chain Removal
- Drive Chain Installation
- Torque -
- Torque -
- Drive Chain Replacement
- Recommended Tool -
- Engine Sprocket Removal
- Engine Sprocket Installation
- Torque -
- Rear Sprocket Removal
- Rear Sprocket Installation
- Torque -
- Coupling Installation
- Coupling Bearing Removal
- Special Tool -
- Coupling Bearing Installation
- Special Tool -
- Special Tool -
- Coupling Bearing Inspection
- Coupling Bearing Lubrication
- Coupling Damper Inspection
- Grease Seal Inspection and Lubrication
- Sprocket Wear Inspection
- Rear Sprocket Warp Inspection
Brakes
- Inside Circlip Pliers:
- Brake Pedal Position Inspection
- Brake Pedal Position Adjustment
- Torque -
- Front Caliper Removal
- Rear Caliper Removal
- Caliper Installation
- Torque -
- Caliper Disassembly
- Caliper Assembly
- Caliper Fluid Seal Damage
- Rear Caliper Dust Boot and Friction Boot Damage
- Caliper Piston and Cylinder Damage Inspection
- Caliper Holder Shaft Wear
- Brake Pad Removal
- Brake Pad Installation
- Brake Pad Wear Inspection
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Torque -
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Torque -
- Torque -
- Rear Brake Reservoir Removal
- Rear Brake Reservoir Installation
- Front Master Cylinder Disassembly
- Rear Master Cylinder Disassembly
- Master Cylinder Assembly
- Master Cylinder Inspection
- Brake Disc Removal
- Brake Disc Installation
- Torque -
- Brake Disc Wear Inspection
- Brake Disc Warp Inspection
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Bleeding
- Torque -
- Torque -
- Brake Hose Removal/Installation
- Brake Hose Inspection
Suspension
- Inside Circlip Pliers:
- Front Fork Removal
- Front Fork Installation (each fork leg)
- Torque -
- Torque -
- Front Fork Oil Change
- Special Tool -
- Front Fork Disassembly
- Special Tools -
- Special Tool -
- Front Fork Assembly
- Special Tool -
- Special Tool -
- Special Tools -
- Torque -
- Inner Tube/Outer Tube Inspection
- Fork Spring Inspection
- Oil Seal/Dust Seal Inspection
- Spring Preload Adjustment
- Special Tool -
- Rear Shock Absorber Removal
- Special Tools -
- Rear Shock Absorber Installation
- Torque -
- Rear Shock Absorber Scrapping
- Swingarm Removal
- Special Tools -
- Swingarm Installation
- Torque -
- Swingarm Bearing Removal
- Special Tool -
- Special Tool -
- Swingarm Bearing Installation
- Special Tool -
- Swingarm Bearing, Sleeve Inspection
- Swingarm Lubrication
- Chain Guide Inspection
- Tie-rods Removal
- Special Tools -
- Tie-Rod Installation
- Torque -
- Rocker Arm Removal
- Special Tools -
- Rocker Arm Installation
- Torque -
- Tie-rod, Rocker Arm Bushing Inspection
- Tie-rod, Rocker Arm Sleeve Inspection
Steering
- Steering Stem Bearing Driver:
- Steering Inspection
- Steering Adjustment
- Steering Stem, Stem Bearing Removal
- Special Tool -
- Special Tool -
- Special Tools -
- Steering Stem, Stem Bearing Installation
- Special Tools -
- Special Tools -
- Special Tool -
- Torque -
- Torque -
- Stem Bearing Lubrication
- Grease Seal, Deterioration, Damage Inspection
- Steering Stem Warp Inspection
- Right Handlebar Holder Removal
- Right Handlebar Holder Installation
- Torque -
- Left Handlebar Holder Removal
- Left Handlebar Holder Installation Note
- Torque -
Frame
- Front Seat Removal
- Front Seat Installation
- Rear Seat Removal
- Rear Seat Installation
- Lower Fairing Removal
- Lower Fairing Installation
- Upper Fairing Removal
- Upper Fairing Installation
- Upper Cover Removal
- Upper Cover Installation
- Side Cover Removal
- Side Cover Installation
- Front Fender Removal
- Rear Fender Removal
- Rear Fender Installation
Electrical System
- Flywheel Holder:
- There are a number of important precautions that are musts when
- Wiring Inspection
- Special Tool -
- Battery Removal
- Battery Installation
- Battery Activation
- Precautions
- 1)
- 2)
- 3)
- 4)
- Interchange
- Charging Condition Inspection
- Refreshing Charge
- Alternator Cover Removal
- Alternator Cover Installation
- Sealant -
- Torque -
- Stater Coil Removal
- Stator Coil Installation
- Special Tool -
- Torque -
- Alternator Rotor Removal
- Special Tool -
- Special Tool -
- Alternator Rotor Installation
- Special Tool -
- Torque -
- Alternator Inspection
- Special Tool -
- Regulator/Rectifier Inspection
- Torque -
- Charging Voltage Inspection
- Special Tool -
- Charging System Circuit
- Ignition System Troubleshooting
- Crankshaft Sensor Removal
- Crankshaft Sensor Installation
- Special Tool -
- Crankshaft Sensor Inspection
- Special Tool -
- Crankshaft Sensor Peak Voltage Inspection
- Special Tool -
- Ignition Coil Removal
- Ignition Coil Installation
- Ignition Coil Inspection
- Special Tool -
- Special Tool -
- Ignition Coil Primary Peak Voltage
- Special Tool -
- Spark Plug Removal
- Spark Plug Installation
- Spark Plug Condition Inspection
- IC Igniter Inspection
- IC Igniter Operation Inspection
- Special Tool -
- Diodes Inspection
- Ignition System Circuit
- Starter Motor Removal
- Starter Motor Installation
- Starter Motor Disassembly
- Starter Motor Assembly
- Torque -
- Torque -
- Carbon Brush Inspection
- Commutator Inspection, Cleaning
- Armature Inspection
- Special Tool -
- Brush Lead Inspection
- Special Tool -
- Terminal Bolt Inspection
- Special Tool -
- Starter Relay Inspection
- Special Tool -
- Starter Circuit Relay Inspection
- Electrical Starter Circuit
- Headlight Beam Horizontal Adjustment
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- Tail/Brake Light Bulb Replacement
- Front Turn Signal Light Bulb Replacement
- Rear Turn Signal Light Bulb Replacement
- Turn Signal Relay Inspection
- Headlight Circuit Relay Inspection
- Headlight/Tail Light Circuit
- Turn Signal Light Circuit
- WARNING
- Fan System Circuit Inspection
- Fan Motor Inspection
- Radiator Fan Circuit
- Meter Unit Removal
- Meter Unit Disassembly
- Meter Unit Installation
- Indicator Light Replacement
- Tachometer Inspection
- Tachometer Circuit
- Water Temperature Warning System Inspection
- Water Temperature Warning System Circuit
- Brake Light Timing Inspection
- Brake Light Timing Adjustment
- Switch Inspection
- Special Tool -
- Fuel Gauge Circuit
- Radiator Fan Switch Inspection
- Water Temperature Switch Inspection
- Fuel Level Sensor Inspection
- 30 A Main Fuse Removal
- Fuse Removal
- Fuse Installation
- Fuse Inspection
Appendix
- California Model
- California Model
- Australia Model
- NOTE
- Engine Doesn't Start, Starting Difficulty:
- Starter motor not rotating:
- Starter motor rotating but engine doesn't turn over:
- Engine won't turn over:
- No fuel flow:
- Engine flooded:
- No spark; spark weak:
- Compression Low:
- Fuel/air mixture incorrect:
- Poor Running at Low Speed:
- Spark weak:
- Fuel/air mixture incorrect:
- Compression low:
- Other:
- Poor Running or No Power at High Speed:
- Firing incorrect:
- Fuel/air mixture incorrect:
- Compression low:
- Knocking:
- Miscellaneous:
- Overheating:
- Firing incorrect:
- Fuel/air mixture incorrect:
- Compression high:
- Engine load faulty:
- Lubrication inadequate:
- Coolant incorrect:
- Cooling system component incorrect:
- Over Cooling:
- Cooling system component incorrect:
- Gauge incorrect:
- Clutch Operation Faulty:
- Clutch slipping:
- Clutch not disengaging properly:
- Gear Shifting Faulty:
- Doesn't go into gear; shift pedal doesn't return:
- Jumps out of gear:
- Overshifts:
- Abnormal Engine Noise:
- Knocking:
- Piston slap:
- Valve noise:
- Other noise:
- Abnormal Drive Train Noise:
- Clutch noise:
- Transmission noise:
- Drive line noise:
- Abnormal Frame Noise:
- Front fork noise:
- Rear shock absorber noise:
- Disc brake noise:
- Other noise:
- Oil Pressure Warning Light Goes On:
- Exhaust Smokes Excessively:
- White smoke:
- Black smoke:
- Brown smoke:
- Handling and/or Stability Unsatisfactory:
- Handlebar hard to turn:
- Handlebar shakes or excessively vibrates:
- Handlebar pulls to one side:
- Shock absorption unsatisfactory:
- Brake Doesn't Hold:
- Battery Trouble:
- Battery discharged:
- Battery overcharged: