1988 - 2012
Kawasaki Ninja 250R Repair, Service & Maintenance Manual by CLYMER
The following Kawasaki
Ninja 250R models are
covered:
Every Clymer contains hundreds
of original photographs and illustrations developed from a complete disassembly
and assembly of the Motorcycle. This, in addition to extensive research, allows
Clymer to achieve an un-matched level of detail, accuracy & clarity.
The step-by-step instructions
and two column text with large print are user friendly, bold figure numbers make
it easy to quickly match instructions with illustrations and photos. Thumb
tabbed chapters, numbered table of contents and extensive index make it possible
to locate the desired section quickly.
This manual includes a Quick
Reference Data section with frequently used specifications and the typical Table
of Contents.
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
Models covered: EX250 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998
1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012