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• 2004 Kawasaki Ninja 250 Repair Manual
• 2004 Kawasaki Ninja 250r Repair Manual

. Ninja 250R Motorcycle Service Manual. Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © 2007 Kawasaki Heavy Industries, Ltd. First Edition (1): Nov. 15, 2007 (M). LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current.

EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof. (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. venient operation. Use proper tools and genuine Kawasaki Mo-.

torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.

GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing.Model Identification. General Specifications.Unit Conversion Table.1-11. 1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Replacement Parts Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled. 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit.

Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation.

Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. GENERAL INFORMATION 1-7 Model Identification EX250J8F Left Side View (United States and Canada) EX250J8F Right Side View (United States and Canada) Frame Number Engine Number. 1-8 GENERAL INFORMATION General Specifications Items EX250J8F Dimensions Overall Length 2 085 mm (82.1 in.) Overall Width 715 mm (28.1 in.) Overall Height 1 110 mm (43.7 in.) Wheelbase 1 400 mm (55.1 in.) Road Clearance 130 mm (5.1 in.) Seat Height 775 mm (30.5 in.) Dry Mass. GENERAL INFORMATION 1-9 General Specifications Items EX250J8F Lubrication System Forced ubrication (wet sump) Engine Oil: Grade API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE10W-40 Capacity 1.7 L (1.80 US qt) Drive Train Primary Reduction System: Type Gear Reduction Tatio. 1-10 GENERAL INFORMATION General Specifications Items EX250J8F Brake Type: Front Single disc Rear Single disc Electrical Equipment Battery 12 V 6 Ah Headlight: Type Semi-sealed beam Bulb: High 12 V 55 W + 55 W (quartz-halogen) 12 V 55 W (quartz-halogen) Tail/brake Light 12 V 5/21 W Alternator. GENERAL INFORMATION 1-11 Unit Conversion Table Prefixes for Units: Units of Length: × 0.6214 mile Prefix Symbol Power × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque: micro µ.

PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart.Torque and Locking Agent. 2-11 Special Tools. 2-13 Periodic Maintenance Procedures.2-14 Fuel System. 2-14 Air Cleaner Element Cleaning.

2-14 Air Cleaner Element Installation.2-15 Throttle Control System Inspection. 2-2 PERIODIC MAINTENANCE Rocker Arm Operation Inspection.2-35 Tie-Rod Operation Inspection. 2-35 Swingarm Pivot Lubrication.2-36 Steering System.2-36 Steering Play Inspection.2-36 Steering Play Adjustment.2-36 Steering Stem Bearing Lubrication. 2-37 Electrical System.

2-37 Lights and Switches Operation Inspection. PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. Periodic Inspection FREQUENCY Whichever. ODOMETER READING comes ×. Spss version 20 manual. 2-4 PERIODIC MAINTENANCE Periodic Maintenance Chart FREQUENCY Whichever. ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page INSPECTION Every (0.6) (4) (7.5) (12) (15) (20) (24) Drive chain slack - inspect # Every 1 000 km (600 mile) 2-29.

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart Periodic Replacement Parts FREQUENCY Whichever. ODOMETER READING comes × 1 000 km first (× 1 000 mile) Page CHANGE/REPLACE ITEM Every (0.6) (7.5) (15) (24) (30) Air cleaner element # 2 years 2-44. 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Use a torque wrench to tighten bolts and nuts to their specified torque values. If too little torque is applied, the bolts and nuts could loosen and fall out.

If too much torque is applied, the threads could be sheared off. PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Chain Tensioner Mounting Bolts 87 inlb Camshaft Cap Bolts 106 inlb Camshaft Cap Bolts 106 inlb Cylinder Head Bolt (M6) 106 inlb MO, S Cylinder Head Bolts (M8) 24.5 MO, S Water Passage Plugs.

2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Crankcase Bolts 8 (L = 73) MO, S Starter Motor Clutch Bolts 34.3 Connecting Rod Big End Cap Nuts 27.5 Shift Drum Bearing Holder Bolt 104 inlb Shift Drum Pin Plate Bolt 80 inlb Neutral Switch. PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener Remarks Nm kgfm ftlb Rocker Arm Pivot Nut Tie-Rod Nuts Rear Shock Absorber Mounting Nuts Swingarm Pivot Nut 10.0 Steering Steering Stem Nut 43 inlb Handlebar Holder Mounting Bolts Steering Stem Head Bolt Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Frame. 2-10 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – Idle Speed 1 300 ±50 r/min (rpm) – – – Carburetor Synchroniza- Less than 2.7 kpa (2 cmHg) difference –.

2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes Brake Fluid: Grade DOT4 – – – Brake Pad Lining 4.5 mm (0.18 in.) 1 mm (0.04 in.) Thickness: Brake Light Timing: – – – Front Pulled ON Rear ON after 10 mm (0.39 in.) of pedal travel Electrical System Type CR8E, U24ESR-N. PERIODIC MAINTENANCE 2-13 Special Tools Steering Stem Nut Wrench: Filler Cap Driver: Vacuum Gauge KEK-55-5:. 2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Air Cleaner Element Cleaning. Remove: Right Side Cover (see Side Cover Removal in the Frame chapter) Air Cleaner Cap Bolts A Air Cleaner Cap B.

2004 Kawasaki Ninja 250 Repair Manual

Pull out the air cleaner element A. PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures WARNING Clean the element in a well-ventilated area, and make sure that there are no sparks or flame any- where near the working area. Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. 2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Loosen the locknut A, and screw accelerator cable ad- juster B in completely so as to give the throttle grip plenty of play.

Turn the accelerator cable adjuster until 2 ∼ 3 mm (0.08 ∼ 0.12 in.) of throttle grip play is obtained. PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Choke Operation Inspection. Remove: Front Seat (see Front Seat Removal in the Frame chap- ter) Fuel Tank (see Fuel Tank Removal) Side Covers (see Side Cover Removal in the Frame chapter) Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal).

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Start the engine and let it idle to measure the carburetor intake vacuum. If the intake vacuum difference between the two cylinders exceeds the limit, adjust the synchronization. Engine Vacuum Synchronization Less than 2.7 kPa (2 cmHg) difference between both cylinders. PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Fuel Hose Inspection (fuel leak, damage, installation condition) ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance. However, if the motorcycle is not properly handled, the high pressure in- side the fuel line can cause fuel to leak A or the hose to burst.

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Check the liquid/vapor separator as follows. ○ Remove: Left Lower Fairing (see Lower Fairing Removal in the Frame chapter) ○ Disconnect the hoses from the separator, and remove the separator B from the motorcycle left side. PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Radiator Hose Damage and Installation Condition Inspection ○ The high pressure inside the radiator hose and pipe can cause coolant to leak A or the hose to burst if the line is not properly maintained. 2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Start the engine and run it at idle speed. Plug A the vacuum switch valve hose end with your fin- ger and feel vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for leak. PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures. Using the thickness gauge A, measure the valve clear- ance between cam and valve lifter. Valve Clearance Standard: Exhaust 0.22 ∼ 0.29 mm (0.0087 ∼ 0.0114 in.) 0.15 ∼ 0.24 mm (0.0059 ∼ 0.0094 in.) Inlet ○.

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures. Clean the shim to remove any dust or oil.

Measure the thickness of the removed shim A. Select a new shim thickness calculation as follows. A + b – c = d a Present Shim Thickness b Measured Valve Clearance c Specified Valve Clearance (Mean Value = 0.255 mm. PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Adjustment Shims Thickness Part Number Mark 2.50 2.55 2.60 2.65 2.675 2.70 2.725 2.75 2.775 2.80 2.825 2.85 2.875 2.90 2.925 2.95. 2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection. Pull the clutch lever just enough to take up the free play A. Measure the gap between the lever and the lever holder.

2004 Kawasaki Ninja 250r Repair Manual

If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures Wheels/Tires Air Pressure Inspection. Remove the air valve cap. Measure the tire air pressure with an air pressure gauge A when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).