MOTORCYCLE SERVICE MANUAL

MODEL COVERED:

EX250 Ninja 250R (1988-2012)

This Kawasaki Ninja Manual is 424 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications Specs

CHAPTER TWO / TROUBLESHOOTING
Starting the engine / Engine spark test / Engine performance / Electrical testing / Starting system / Engine noise / Motorcycle noise / Engine lubrication / Engine leakdown test / Clutch / Gear shift linkage and transmission / Brakes / Steering and handling / Brake troubleshooting Specs

CHAPTER THREE / LUBRICATION, MAINTENANCE and TUNE-UP
Tune-up / Air filter / Engine oil and filter / Idle speed adjustment / Spark plugs / Battery / Compression test / Ignition timing inspection / Brake system / Clutch / Cooling system / Fuel hose inspection / Emission control systems / Throttle cables / Choke cable / Carburetor synchronization / Tires and wheels / Valve clearance / Lights and horn inspection / Sidestand switch and ignition cut-off system / Steering head bearing inspection / Front suspension inspection / Front fork oil change / Rear suspension inspection / Swing arm bearing lubrication / Drive chain / Speedometer cable / Fasteners / Specifications Specs

CHAPTER FOUR / ENGINE TOP END (1988-2007 MODELS)
Exhaust system / Cylinder head cover / Camshafts / Rocker arms / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications Specs

CHAPTER FIVE / ENGINE TOP END (2008-ON MODELS)
Exhaust system / Air suction valve / Cylinder head cover / Camshafts / Valve lifters and shims / Cylinder head / Valves / Cam chain tensioner / Cylinder / Piston and piston rings / Specifications Specs

CHAPTER SIX / ENGINE LOWER END
Engine / Left crankcase cover / Starter idler gear / Flywheel (alternator rotor) and starter clutch / Right crankcase cover / Cam chain tensioner (1988-2007 models) / Camshaft chain and guides / (1988-2007 models) / Oil pump / Oil pressure relief valve / Crankcase oil screen / Oil pipes / Crankcase / Crankshaft / Connecting rods / Balancer shaft / Crankcase breather / Engine break-in / Specifications Specs

CHAPTER SEVEN / CLUTCH AND EXTERNAL GEARSHIFT MECHANISM
Clutch / Shift linkage / External gearshift linkage / Primary drive gear / Clutch cable replacement / Specifications Specs

CHAPTER EIGHT / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM
Transmission / Shift drum and forks / Specifications Specs

CHAPTER NINE / FUEL AND EMISSION CONTROL SYSTEMS
Carburetor / Throttle cables / Choke cable / Air box / Fuel tank / Fuel valve / Fuel level sensor (2008-on models) / Clean air system (2008-on models) / Evaporative emissions control system (California models only) / Specifications Specs

CHAPTER TEN / ELECTRICAL SYSTEM (1988-2007 MODELS)
Electrical component replacement / Continuity testing guidelines / Electrical connectors / Negative battery terminal / Battery / Charging system / Stator / Flywheel and starter clutch / Regulator/rectifier / Starting system / Starter / Starter relay / Starter circuit relay / Ignition system / Fan system / Coolant temperature gauge and sensor / Meter unit / Lighting system / Turn signal relay / Switches / Junction box and fuses / Wiring diagrams / Specifications Specs

CHAPTER ELEVEN / ELECTRICAL SYSTEM (2008-ON MODELS)
Negative battery terminal / Battery / Charging system / Stator / Flywheel and starter clutch / Regulator/rectifier / Starting system / Starter / Starter relay / Starter circuit relay / Ignition system / Fan system / Meter unit / Fuel level system / Lighting system / Turn signal relay / Coolant temperature switch / Switches / Diodes / Fuses / Wiring diagrams / Specifications Specs

CHAPTER TWELVE / COOLING SYSTEM
Safety precautions / Radiator and fan / Thermostat / Thermostat housing / Coolant temperature sensor/switch / Water pump / Coolant reservoir / Specifications

CHAPTER THIRTEEN / WHEELS, TIRES AND DRIVE CHAIN
Front wheel and speedometer drive unit / Rear wheel / Front and rear hubs / Wheel balance / Tire repairs / Tire changing / Drive chain / Drive sprocket guard / Sprockets / Specifications Specs

CHAPTER FOURTEEN / FRONT SUSPENSION AND STEERING
Handlebars / Front fork / Steering stem and head / Steering head bearing races / Steering play inspection and adjustment / Specifications Specs

CHAPTER FIFTEEN / REAR SUSPENSION (1988-2007 MODELS)
Rear end support / Shock absorber / Shock absorber linkage / Swing arm / Specifications Specs

CHAPTER SIXTEEN / REAR SUSPENSION (2008-ON MODELS)
Rear end support / Shock absorber / Shock absorber linkage / Swing arm / Shock absorber adjustment / Specifications Specs

CHAPTER SEVENTEEN / BRAKES (1988-2007 MODELS)
Brake fluid selection / Brake service / Brake pads / Front brake caliper / Front brake master cylinder / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake system draining / Brake system bleeding / Brake disc / Specifications Specs

CHAPTER EIGHTEEN / BRAKES (2008-ON MODELS)
Brake fluid selection / Brake service / Front brake pads / Front brake caliper / Front master cylinder / Rear brake pads / Rear brake caliper / Rear master cylinder / Rear brake pedal / Brake system draining / Brake system bleeding / Brake disc / Specifications Specs

CHAPTER NINETEEN / BODY (1988-2007 MODELS)
Seat / Side covers / Lower fairing / Upper fairing / Upper fairing bracket / Front fender / Rear fender / Tail cover / Side mirrors

CHAPTER TWENTY / BODY (2008-ON MODELS)
Retaining clips / Front seat / Rear seat / Side covers / Lower fairing / Radiator fairing / Windshield / Upper fairing / Upper cover / Upper fairing bracket / Front fender / Front fender bracket / Rear fender / Side mirrors

Index

Color Wiring Diagrams