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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. Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance.

To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction. 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. Lubri- cation kawqsaki 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.

Kawasaki Ninja 250R Service Manual

Overall Width mm Overall Height 1 mm Wheelbase 1 mm Road Clearance mm 5. Seat Height mm Type Semi-sealed beam Bulb: Torque and Locking Agent The initial maintenance is vitally important and must not be neglected. Letters used in the “Remarks” column mean: Apply a non-permanent locking agent. Apply molybdenum disulfide grease oil solution.

Front Up to kg lb load: Throttle Sensor Setting Adapter: If the throttle grip free play can not be adjusted with the adjuster, use the adjusters in the lower ends of the throttle cables. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged.


If the clearance is out of the specified range, use the additional shim. Swelling or high spots indicate inter- nal damage, requiring tire replacement. Apply the oil to the O-rings so that the O-rings will be coated with oil. If there is any irregularity, replace the drive chain. If the brake fluid leaked from any position, inspect or re- place the problem part. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [C].

If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak see Rear Shock Absorber Oil Leak Inspection. Lubricate with Rust Inhibitor. Also, check to see that each cotter pin is in place and in good condition. When the fuel hose is disconnected, fuel spills out from the hose and the pipe because of residual pressure. Open the bleed valve [A]. Apply the brake and hold it [B].

Standard Spark Plug Type: Battery 12 V 8 Ah 3. Inlet Air Pressure Sensor 5. Air Switching Valve 6. Water Temperature Sensor 7. Joint Connector 2 4. Kawasaki Diagnostic System Connector 5. Battery 12 V 8 Ah 8. Fuel Level Warning Indicator Light: Ground for Fuel System: Ground for Ignition System: Type Two barrel type Bore 28 mm 1.

Throttle Body Vacuum Kawasaki Bond Silicone Sealant: Do not use any other battery except for a 12 V sealed battery as a power source.

ninja service manual .pdf – BARF – Bay Area Riders Forum

Remove the fuel tank see Fuel Tank Removal and check the fuel hose [A]. After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing. Sealant – Kawasaki Bond Silicone Sealant: A fully charged battery is a must for conducting accurate tests of the DFI system.


If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it.

1986-2007 Kawasaki Ninja EX250 Online Motorcycle Service Manual

Connect the connectors securely. Year of initial registration: Environment when problem occurred. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties in DFI system.

Fuel line clogged Inspect and repair see 25r 3. Inlet air pressure sensor trouble Inspect see chapter 3. Inlet air temperature sensor trouble Inspect see chapter 3. Spark plug dirty, broken or gap maladjusted Inspect and replace see chapter 2.

Stick coil trouble Inspect see chapter Stick coil shorted or not in good contact Inspect or Reinstall see chapter Air dervice valve trouble Inspect and replace see chapter 5. Never drop the throttle body assy especially on a hard surface. Special Tool – Hand Tester: Such a shock to the sensor can damage it. Standard Atmospheric Pressure Absolute Pv: Throttle Full Open UR: Water-proof Joint 2 3.

Inlet Air Pressure Sensor 4. Water-proof Joint 1 http: Water-proof Joint 1 3. Inlet Air Temperature Sensor http: Water-proof Joint 2 4. Water-proof Joint 3 3. Water-proof Joint 1 4. Joint Connector 2 7. Service Code 51 Stick Coil 2: Engine Stop Amnual 2.

Stick Coil 1, 2 3. Water-proof Joint 3 4.

Joint Connector 2 6. Battery 12 V 8 Ah 7. Joint Connector 2 3. Battery 12 V manua Ah 4. Main Fuse 30 A 6. Joint Connector 1 7. Subthrottle Valve Actuator http: So, the heater itself can not be removed. FI Indicator Light Circuit 1. Joint Connector 2 5. Other- wise, the motorcycle cannot clear the regulation. If the connector is clogged with mud or dust, blow it off with compressed air.

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