Kawasaki Ninja 250R Service Manual

Kawasaki
Motorcycle
Table of Contents
  • GENERAL INFORMATION

    3
  • Emission control information

    7
  • How to use this manual

    9
  • General information

    12
  • Model identification

    17
  • General specifications

    18
  • Periodic Maintenance

    23
  • Periodic Maintenance Chart

    26
  • PERIODIC MAINTENANCE

    27
  • Torque and Locking Agent

    28
  • Fuel System

    33
  • Specifications

    34
  • Periodic Maintenance Procedures

    36
  • Air Cleaner Element Installation

    37
  • Choke Operation Inspection

    39
  • Idle Speed Inspection

    40
  • Fuel Hose Inspection (fuel leak, damage, installation condition)

    41
  • Cooling System

    42
  • Radiator Hose Damage and Installation Condition Inspection

    43
  • Engine Top End

    44
  • Valve Clearance Adjustment

    45
  • Clutch

    48
  • Wheels/Tires

    49
  • Wheel Bearing Damage Inspection

    50
  • Drive Train

    51
  • Drive Chain Slack Adjustment

    52
  • Wheel Alignment Inspection

    53
  • Chain Guide Inspection

    54
  • Brake Fluid Level Inspection

    55
  • Brake Light Switch Operation Inspection

    56
  • Front Fork Oil Leak Inspection

    57
  • Swingarm Pivot Lubrication

    58
  • Steering Stem Bearing Lubrication

    59
  • Headlight Aiming Inspection

    61
  • Sidestand Switch Operation Inspection

    62
  • Engine Stop Switch Operation Inspection

    63
  • Others

    64
  • Bolts, Nuts and Fasteners Tightness Inspection

    65
  • Replacement Parts

    66
  • Radiator Hose and O-ring Replacement

    68
  • Engine Oil Change

    69
  • Brake Hose and Pipe Replacement

    70
  • Master Cylinder Rubber Parts Replacement

    72
  • Caliper Rubber Parts Replacement

    73
  • Spark Plug Replacement

    74
  • Fuel System

    75
  • Exploded view

    77
  • Throttle grip and cables

    84
  • Choke cable

    85
  • Engine vacuum synchronization adjustment

    86
  • Fuel system cleanliness inspection

    89
  • Carburetor removal

    90
  • Carburetor installation

    91
  • Carburetor disassembly

    93
  • Carburetor cleaning

    94
  • Carburetor inspection

    95
  • Air cleaner

    97
  • Air cleaner housing installation

    98
  • Oil draining

    99
  • Fuel tank

    102
  • Cooling System

    103
  • Coolant flow chart

    108
  • Coolant deterioration inspection

    110
  • Cooling system flushing

    111
  • Water pump

    112
  • Radiator inspection

    115
  • Radiator filler neck inspection

    116
  • Thermostat removal

    117
  • Thermostat inspection

    118
  • Hoses and pipes

    119
  • Radiator fan switch, water temperature switch

    120
  • Engine Top End

    121
  • Exhaust system

    126
  • Special tools

    129
  • Clean air system

    131
  • Air suction valve inspection

    132
  • Cylinder head cover

    134
  • Camshaft chain tensioner

    135
  • Camshaft and sprocket assembly

    139
  • Camshaft runout inspection

    140
  • Cylinder head

    141
  • Cylinder head installation

    142
  • Cylinder head warp inspection

    143
  • Valve installation

    145
  • Valve seat inspection

    147
  • Cylinder installation

    152
  • Piston removal

    153
  • Cylinder wear inspection

    154
  • Piston ring thickness inspection

    155
  • Piston ring end gap inspection

    156
  • Carburetor holder

    157
  • Muffler removal

    158
  • Exhaust system inspection

    159
  • Clutch

    161
  • Special tool and sealant

    165
  • Clutch lever and cable

    166
  • Clutch cover

    167
  • Clutch removal

    168
  • Clutch plate wear and damage inspection

    170
  • Engine Lubrication System

    173
  • Engine lubrication system

    175
  • Engine oil and oil filter

    179
  • Bypass valve disassembly

    180
  • Oil pressure relief valve

    182
  • Oil pump

    183
  • Oil pressure measurement

    184
  • Oil pressure switch

    185
  • Crankshaft/Transmission

    193
  • Special tools and sealants

    201
  • Crankcase splitting

    202
  • Crankcase assembly

    203
  • Crankcase exchange

    205
  • Crankshaft and connecting rods

    206
  • Connecting rod removal

    207
  • Connecting rod bend inspection

    208
  • Wear inspection

    209
  • Crankshaft runout inspection

    211
  • Starter motor clutch

    213
  • Balancer removal

    214
  • Transmission removal

    217
  • Transmission installation

    218
  • Transmission shaft assembly

    219
  • Shift drum disassembly

    221
  • Gear backlash inspection

    222
  • Wheels/Tires

    225
  • Wheel inspection

    233
  • Balance inspection

    234
  • Tire inspection

    236
  • Tire installation

    237
  • Tire repair

    239
  • Hub bearing

    240
  • Hub bearing inspection

    241
  • Speedometer gear housing

    242
  • Final Drive

    245
  • Final drive

    247
  • Drive chain

    250
  • Drive chain installation

    251
  • Rear sprocket installation

    256
  • Coupling bearing installation

    257
  • Sprocket wear inspection

    258
  • Brakes

    259
  • Brake lever, brake pedal

    266
  • Caliper installation

    267
  • Caliper disassembly

    268
  • Caliper piston and cylinder damage inspection

    269
  • Brake pads

    270
  • Master cylinder

    271
  • Rear master cylinder removal

    272
  • Rear brake reservoir installation

    273
  • Master cylinder inspection

    274
  • Brake disc

    275
  • Brake fluid

    276
  • Brake hose

    279
  • Suspension

    281
  • Front fork

    287
  • Front fork oil change

    288
  • Front fork disassembly

    289
  • Front fork assembly

    290
  • Inner tube/outer tube inspection

    291
  • Rear shock absorber

    292
  • Rear shock absorber installation

    293
  • Swingarm removal

    294
  • Swingarm bearing removal

    295
  • Swingarm lubrication

    296
  • Tie-rod, rocker arm

    297
  • Steering stem

    304
  • Frame

    311
  • Front seat installation

    316
  • Lower fairing removal

    317
  • Upper fairing removal

    318
  • Upper fairing installation

    319
  • Side cover

    320
  • Rear fender installation

    322
  • Electrical System

    323
  • Parts location

    338
  • Electrical wiring

    341
  • Battery removal

    342
  • Charging condition inspection

    345
  • Refreshing charge

    346
  • Charging system

    347
  • Stator coil installation

    348
  • Alternator inspection

    349
  • Regulator/rectifier inspection

    350
  • Charging voltage inspection

    352
  • Ignition system

    355
  • Crankshaft sensor inspection

    356
  • Ignition coil installation

    357
  • Ignition coil primary peak voltage

    358
  • Spark plug installation

    359
  • Ic igniter inspection

    360
  • Electric starter system

    363
  • Starter motor disassembly

    364
  • Carbon brush inspection

    365
  • Armature inspection

    366
  • Starter system

    367
  • Starter circuit relay inspection

    368
  • Lighting system

    370
  • Headlight circuit relay inspection

    373
  • Radiator fan system

    377
  • Indicator light replacement

    379
  • Water temperature warning system inspection

    380
  • Radiator fan switch inspection

    383
  • Fuel level sensor inspection

    384
  • Fuse installation

    385
  • Troubleshooting guide

    424
  • Over cooling

    426
  • Exhaust smokes excessively

    427

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