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Quick Reference Guide
This Quick Reference Guide will
assist you in finding the information
you're looking for.
A Table of Contents is included after
the Foreword.
SAFETY INFORMATION
GENERAL INFORMATION
HOW TO RIDE THE MOTORCYCLE
MAINTENANCE AND ADJUSTMENT
APPENDIX
MAINTENANCE RECORD
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Table of Contents

   Summary of Contents for Kawasaki Ninja 250l

  • Page 1 SAFETY INFORMATION Quick Reference Guide GENERAL INFORMATION This Quick Reference Guide will HOW TO RIDE THE MOTORCYCLE assist you in finding the information you’re looking for. MAINTENANCE AND ADJUSTMENT APPENDIX MAINTENANCE RECORD A Table of Contents is included after the Foreword.
  • Page 2 NOTICE Whenever you see the symbols shown below, heed their instructions! NOTICE is used to address prac- Always follow safe operating and main- tices not related to personal in- tenance practices. jury. DANGER NOTE DANGER indicates a hazardous ○ This note symbol indicates points of situation which, if not avoided, particular interest for more efficient will result in death or serious in-...
  • Page 3 NOTICE THIS PRODUCT BEEN MANUFACTURED FOR USE IN A REASONABLE AND PRUDENT MANNER BY A QUALIFIED OP- ERATOR AND AS A VEHICLE ONLY.
  • Page 4 Foreword Congratulations on your purchase of a new Kawasaki motorcycle. Your new mo- torcycle is the product of Kawasaki’s advanced engineering, exhaustive testing, and continuous striving for superior reliability, safety and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of your motorcycle’s controls, its fea-...
  • Page 5 However, there may be minor differences between the actual product and illustra- tions and text in this manual. All products are subject to change without prior notice or obligation. KAWASAKI HEAVY INDUSTRIES, LTD. Motorcycle & Engine Company © 2012 Kawasaki Heavy Industries, Ltd. Aug. 2012. (1)
  • Page 6 (Australian model only) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) 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;...
  • Page 7: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ....GENERAL INFORMATION....20 Read Owner’s Manual ..... Specifications ........20 Training ..........Serial Number Locations....25 Daily Safety Checks and Periodic Location of Labels ......26 Maintenance ......... Location of Parts ......35 Loading and Accessories Meter Instruments ......
  • Page 8 Helmet Hooks........61 Throttle Control System ....98 Tying Hooks ........62 Idle Speed ........100 Tool Kit Compartment....... 62 Clutch ..........101 Event Data Recorder......63 Drive Chain ........103 HOW TO RIDE THE MOTORCYCLE . 64 Brakes ..........108 Break-In ...........
  • Page 9: Safety Information

    WARNING Training Failure to perform these checks Kawasaki strongly recommends that or to correct a problem before all operators of this vehicle complete a operation may result in serious suitable motorcycle rider training pro- damage or an accident. Always...
  • Page 10: Loading And Accessories Information

    Before you ride the Kawasaki dealer as soon as possible. motorcycle, make sure it is not overloaded and that you have followed these instructions.
  • Page 11: Passenger

    Kawasaki Parts and Accessories oughly familiar with motorcycle op- have been specially designed for eration. The passenger can affect use on Kawasaki motorcycles. We control of the motorcycle by im- strongly recommend that all parts proper positioning during cornering and accessories you add to your and sudden movements.
  • Page 12: Baggage And Luggage

    SAFETY INFORMATION 4. Do not carry passengers unless will not move around while you are passenger footpegs are installed. riding. Recheck baggage security Instruct any passenger before riding as often as possible (not while the to keep his or her feet on the pas- motorcycle is in motion) and adjust senger footpegs and hold on to the as necessary.
  • Page 13: Other Load

    Kawasaki does not manu- 2. Weight attached to the handlebar or facture sidecars or trailers for mo- front fork will increase the mass of...
  • Page 14: Safe Operation

    Do not run the engine in en- ent. Have your motorcycle thoroughly closed areas. Operate only in a checked at a Kawasaki dealer as soon well-ventilated area. as possible. Safe Operation The following should be carefully ob- served for safe and effective vehicle operation.
  • Page 15: Fueling

    SAFETY INFORMATION Fueling Protective Gear and Clothing Helmet WARNING Kawasaki strongly recommends both Gasoline is extremely flammable the operator and passenger wear a hel- and can be explosive under cer- met even if this is not a legal require- tain conditions. To prevent fire ment.
  • Page 16: Safe Riding Techniques

    SAFETY INFORMATION Gloves Safe Riding Techniques Wear gloves which have suitable protection for your hands, especially against abrasion. Keep Hands on Handlebars Clothing When riding always keep both hands Wear protective clothing. on the handlebars and both feet on the Wear bright, highly visible clothing footpegs.
  • Page 17 SAFETY INFORMATION Accelerate and Brake Smoothly throttle so that the engine can act as an In general your actions should be auxiliary brake. Use the front and rear smooth as sudden acceleration, brak- brakes for primary braking. ing or turning may cause loss of control, Riding in Wet Conditions especially when riding in wet conditions Rely more on the throttle to control...
  • Page 18: Additional Considerations For High Speed Operation

    SAFETY INFORMATION fuel consumption but also for long ve- Additional Considerations for hicle life and quieter operation. High Speed Operation Riding on Rough Roads Exercise caution, slow down, and grip the fuel tank with the knees for WARNING better stability. Handling characteristics of a Acceleration motorcycle at high speeds may...
  • Page 19: Electrical Equipment

    SAFETY INFORMATION Engine Oil see that they are correctly adjusted and functioning properly. To avoid engine seizure and resulting loss of control, make sure that the oil Steering level is at the upper level line. Looseness in the steering can cause Coolant loss of control.
  • Page 20: General Information

    GENERAL INFORMATION GENERAL INFORMATION Specifications PERFORMANCE Maximum (AU, SEA, TH) 23.0 kW (31 PS) @11 000 r/min (rpm) Horsepower (ID, MY, PH) 23.5 kW (32 PS) @11 000 r/min (rpm) Maximum Torque (AU, SEA, TH) 21.0 N·m (2.1 kgf·m, 15 ft·lb) @8 500 r/min (rpm) (ID, MY, PH) 21.0 N·m (2.1 kgf·m, 15 ft·lb) @10 000 r/min (rpm) Minimum Turning Radius...
  • Page 21 GENERAL INFORMATION Road Clearance 140 mm (5.51 in.) Curb Mass (EX250L) 172 kg (379 lb) (EX250M) 174 kg (384 lb) ENGINE Type DOHC, 2-cylinder, 4-stroke, liquid-cooled Displacement 249 cm³ (15.2 cu in.) Bore × Stroke 62.0 × 41.2 mm (2.44 × 1.62 in.) Compression Ratio 11.3 : 1 Starting System...
  • Page 22 GENERAL INFORMATION Lubrication System Forced lubrication (wet sump) Engine Oil: Type API SG, SH, SJ, SL, or SM with JASO MA, MA1 or Viscosity SAE 10W-40 Capacity 2.4 L (2.5 US qt) Coolant Capacity 1.5 L (1.6 US qt) TRANSMISSION Transmission Type 6-speed, return shift Wet, multi disc...
  • Page 23 GENERAL INFORMATION 1.789 (34/19) 1.409 (31/22) 1.160 (29/25) 1.000 (27/27) 0.893 (25/28) FRAME Castor 27° Trail 93 mm (3.7 in.) Tire Size: Front 110/70-17M/C 54S Rear 140/70-17M/C 66S Rim Size: Front J17M/C × MT2.75 Rear J17M/C × MT4.00 Fuel Tank Capacity 17 L (4.5 US gal) Brake Fluid: Front...
  • Page 24 GENERAL INFORMATION Headlight: High Beam 12 V 55 W + 55 W Low Beam 12 V 55 W Tail/Brake Light 12 V 5/21 W AU: Australia model SEA: Southeast Asia model TH: Thailand model ID: Indonesia model MY: Malaysia model PH: Philippines model Specifications are subject to change without notice, and may not apply to every country.
  • Page 25: Serial Number Locations

    GENERAL INFORMATION Serial Number Locations The engine and frame serial numbers are used to register the motorcycle. They are the only means of identifying your particular machine from others of the same model type. These serial numbers may be needed by your dealer when ordering parts.
  • Page 26: Location Of Labels

    Therefore, it is very important that all warning labels be on your vehicle in the locations shown. If any label is missing, damaged, or worn, get a replacement from your Kawasaki dealer and install it in the correct posi- tion. NOTE ○...
  • Page 27 GENERAL INFORMATION 2. Brake Fluid (Rear) 3. Battery Poison/Danger 4. Rear Shock Absorber Warning...
  • Page 28 GENERAL INFORMATION 5. Radiator Cap Danger 6. Important Drive Chain Information 7. Tire and Load Data 8. Daily Safety Checks...
  • Page 29 GENERAL INFORMATION *9. Stationary Noise Test Information **10. Vehicle Emission Control Information ***11. Fuel Level ****12. Unleaded Gasoline *****12. Helmet Wearing ***13. Vacuum Hose Routing Diagram *: Only on Australia model **: Only on Philippines model ***: Only on Australia and Southeast Asia model ****: Only on Southeast Asia model *****: Only on Thailand model...
  • Page 30 GENERAL INFORMATION...
  • Page 31 GENERAL INFORMATION...
  • Page 32 GENERAL INFORMATION 9) only on Australia model 10) only on Philippines model...
  • Page 33 GENERAL INFORMATION 11) only on Australia and Southeast 12) only on Thailand model Asia model 12) only on Southeast Asia model...
  • Page 34 GENERAL INFORMATION 13) only on Australia and Southeast Asia model...
  • Page 35: Location Of Parts

    GENERAL INFORMATION Location of Parts 1. Rear View Mirrors 6. Front Brake Lever 2. Clutch Lever 7. Throttle Grip 3. Starter Lockout Switch 8. Left Handlebar Switches 4. Meter Instruments 9. Ignition Switch/Steering Lock 5. Brake Fluid Reservoir (Front) 10. Right Handlebar Switches...
  • Page 36 GENERAL INFORMATION 1. Headlight 11. Radiator 2. Turn Signal Light 12. Side Stand Switch (Other than 3. Spark Plugs Indonesia model) 4. Fuel Tank 13. Shift Pedal 5. Idle Adjusting Screw 14. Side Stand 6. Battery and Fuse Box 15. Swingarm 7.
  • Page 37 GENERAL INFORMATION 1. Muffler 8. Fuel Tank Cap 2. Tail/Brake Light 9. Coolant Reserve Tank 3. Passenger’s Seat 10. Brake Discs 4. Brake Fluid Reservoir (Rear) 11. Brake Calipers 5. Rider’s Seat 12. Rear Brake Light Switch 6. Air Cleaner 13.
  • Page 38: Meter Instruments

    GENERAL INFORMATION Meter Instruments A. Green Neutral Indicator Light B. Red Battery Charging System Warning Indicator Light C. Red Oil Pressure Warning Indicator Light D. Red Coolant Temperature Warning Indicator Light E. Yellow Engine Warning Indicator Light F. Yellow ABS Indicator Light (Only on ABS model) G.
  • Page 39: Tachometer

    If the tachometer does Engine r/min (rpm) should not not operate correctly, have it checked be allowed to enter the red zone; by an authorized Kawasaki dealer. operation in the red zone will overstress the engine and may cause serious engine damage.
  • Page 40: Multifunction Meter

    GENERAL INFORMATION Multifunction Meter A. Economical Riding Indicator B. Speedometer C. Clock D. Multifunction Display - Odometer - Trip meter A - Trip meter B E. Fuel Gauge When the ignition switch is turned on, all LCD segments are displayed with opening display functions for few seconds, then the multifunction meter turns to operational mode.
  • Page 41 GENERAL INFORMATION Speedometer NOTE ○ The speedometer shows the speed Do not operate the motorcycle with of the vehicle in digital values. wrong unit (mph or km/h) of the speedometer. Unit Setting The unit setting in the meter instru- To change the meter display unit in ment can be changed according to lo- the meter instrument as follows: •...
  • Page 42 GENERAL INFORMATION NOTE NOTE ○ ○ For safety, do not operate the instru- The data is maintained even if the ment buttons while riding the motor- battery is disconnected. ○ cycle. When the figures come to 999999, ○ The multifunction display is dis- they are stopped and locked.
  • Page 43 GENERAL INFORMATION • • Push the right button and hold it in. Push the right button for more than • After two seconds, the figure display two seconds. Both the hour and turns to 0.0, and then starts counting minute displays start blinking. when the vehicle is operated.
  • Page 44 GENERAL INFORMATION ○ When the battery is disconnected, the clock is reset to 1:00 and starts working again when the battery is connected. • Economical Riding Indicator Push the right button. Both the hour When the operator is driving the mo- and minute displays start blinking torcycle for optimum fuel-efficiency, the again.
  • Page 45 GENERAL INFORMATION WARNING the fuel gauge checked by an autho- rized Kawasaki dealer. Failing to properly observe the As the fuel level in the tank goes road ahead increases the chance down, the segments disappear one by of an accident resulting in se- one from F (full) to E (empty).
  • Page 46: Indicator Lights

    Have the wiring inspected shortly after the motorcycle starts mov- by an authorized Kawasaki dealer im- ing. If the ABS is normal, it stays off. If mediately. something is wrong with the ABS, this NOTE light goes on and stays on.
  • Page 47: Warning Indicator Light

    V or higher than 16 V. Green Turn Signal Indicator Light If this light goes on, have the battery : When the turn signal switch is checked by an authorized Kawasaki pushed to the left or right, the cor- dealer. responding turn signal indicator light...
  • Page 48 This light also goes on or blinking down, then have the cooling system whenever the troubles occur in digital checked by an authorized Kawasaki fuel injection (DFI) system. dealer. The blinking of this light indicates the condition that the engine cannot be started.
  • Page 49: Keys

    Blank keys are available at your Kawasaki dealers. Ask your dealer to make any additional spare keys you may need, using your original key as a master.
  • Page 50 GENERAL INFORMATION ○ If you leave the key in the “ON” po- Engine off. Electrical circuits sition on for a long time, the battery off. may become totally discharged. Engine on. All electrical equipment can be used. Steering locked. Engine off. LOCK Electrical circuits off.
  • Page 51: Right Handlebar Switches

    GENERAL INFORMATION Right Handlebar Switches The engine stop switch is for emer- gency use. If required, move the switch to the position. NOTE ○ Although the engine stop switch stops the engine, it does not turn off all the electrical circuits. Ordinarily, the ignition switch should be used to stop the engine.
  • Page 52: Left Handlebar Switches

    GENERAL INFORMATION Left Handlebar Switches High beam..( Low beam..( Turn Signal Switch When the turn signal switch is turned to the left ( ) or right ( ), the corresponding turn signals blink on and off. To stop blinking, push the switch in. Horn Button When the horn button is pushed, the horn sounds.
  • Page 53: Fuel Tank Cap

    ○ Do not push on the key to close the Fuel Requirements cap, or the cap cannot be locked. Your Kawasaki engine is designed to use only unleaded gasoline with a minimum octane rating shown below.
  • Page 54 NOTICE Never use gasoline with an octane rat- ing lower than the minimum specified If engine “knocking” or “ping- by Kawasaki to prevent severe engine ing” occurs, use a different damage. brand of gasoline of a higher The octane rating of a gasoline is a octane rating.
  • Page 55 GENERAL INFORMATION Fuel Type and Octane Rating (For Australia, Philippines Thailand Specification) (Except for Australia, Philippines Use clean, fresh unleaded gasoline and Thailand Specifications) with an ethanol volume content not Use clean, fresh unleaded gasoline more than 10% and an octane rating with an octane rating equal to or higher equal to or higher than that shown in than that shown in the table.
  • Page 56: Filling The Tank

    GENERAL INFORMATION NOTICE Do not use any fuel that con- tains more ethanol or other oxy- genates than specified for E10 fuel* in this vehicle. Damage to the engine and fuel system, or engine starting and/or per- formance problems may result from the use of improper fuel.
  • Page 57 GENERAL INFORMATION NOTICE WARNING Gasoline is extremely flammable Australia, Southeast Asia and and can be explosive under cer- Thailand models only: tain conditions, creating the po- Never fill the tank so the fuel tential for serious burns. Turn level rises into the filler neck. If the ignition switch off.
  • Page 58: Side Stand

    GENERAL INFORMATION Side Stand NOTE ○ Other than Indonesia model, the mo- The motorcycle is equipped with the torcycle is equipped with a side stand side stand. switch. This switch is designed so that the engine does not start if the transmission is in gear and the side stand is down.
  • Page 59 GENERAL INFORMATION A. Ignition Key A. Projection B. Seat Lock B. Slots C. Passenger’s Seat C. Tabs D. Insert Passenger’s Seat Installation • Push down the front part of the pas- Install the passanger’s seat in the re- senger’s seat until the lock clicks. verse order of removal.
  • Page 60 GENERAL INFORMATION • Pull the left and right side covers to the outside for detaching the projec- tions. A. Bolt and Collar (Left Side) B. Rider’s Seat C. Pull Up and Rear Rider’s Seat Installation A. Side Cover (Left Side) Install the rider’s seat in the reverse B.
  • Page 61: Helmet Hooks

    GENERAL INFORMATION Helmet Hooks Helmets can be secured to the motor- cycle using the helmet hooks. The hel- met hooks are located under the pas- senger’s seat. WARNING Riding with helmets attached to the hooks could cause an ac- cident by distracting the oper- A.
  • Page 62: Tying Hooks

    GENERAL INFORMATION A. Helmet Hooks A. Tying Hooks Tying Hooks Tool Kit Compartment When tying up light loads to the seat, The tool kit compartment is located use the tying hooks located in front of under the passenger’s seat. the rear turn signal lights and rear of the The kit contains tools that can be rear footpegs.
  • Page 63: Event Data Recorder

    Event Data Recorder the EDR. Kawasaki does not access the EDR information without obtaining This vehicle is equipped at the fac- consent, unless pursuant to court order tory with an event data recorder (EDR).
  • Page 64: How To Ride The Motorcycle

    HOW TO RIDE THE MOTORCYCLE HOW TO RIDE THE MOTORCYCLE Break-In Distance Maximum engine traveled speed The first 1 600 km (1 000 mi) that the 0 ∼ 800 km motorcycle is ridden is designated as 4 000 r/min (rpm) (0 ∼...
  • Page 65: Starting The Engine

    A. Engine Stop Switch that the owner has the initial mainte- B. Starter Button nance service performed by an autho- • Turn the ignition key to “ON” position. rized Kawasaki dealer. • Make sure the transmission is in neu- tral.
  • Page 66 HOW TO RIDE THE MOTORCYCLE if the engine cannot be started. Af- ter righting the motorcycle, first turn the ignition key to “OFF” position and then back to “ON” position before starting the engine. • Without holding the throttle grip, push the starter button to start the engine.
  • Page 67: Jump Starting

    HOW TO RIDE THE MOTORCYCLE NOTICE designed so that the engine does not start if the transmission is in gear and Do not let the engine idle longer the side stand is down. However, the than five minutes, or engine engine can be started if the clutch overheating and damage may lever is pulled and the side stand is...
  • Page 68 HOW TO RIDE THE MOTORCYCLE • DANGER Remove the side covers and the rider’s seat. Battery acid generates hydro- • Remove the battery cover. Refer to gen gas which is flammable and the Battery section in the MAINTE- explosive under certain con- NANCE AND ADJUSTMENT chap- ditions.
  • Page 69 HOW TO RIDE THE MOTORCYCLE DANGER Batteries contain sulfuric acid that can cause burns and pro- duce hydrogen gas which is highly explosive. Do not make this last connection at the fuel system or battery. Take care not to touch the positive and nega- tive cables together, and do not lean over the battery when mak- A.
  • Page 70: Moving Off

    HOW TO RIDE THE MOTORCYCLE NOTICE Moving Off • Do not operate the starter con- Check that the side stand is up. • tinuously for more than 5 sec- Pull in the clutch lever. • onds or the starter will overheat Shift into 1st gear.
  • Page 71: Shifting Gears

    HOW TO RIDE THE MOTORCYCLE NOTE WARNING ○ Other than Indonesia model, the mo- Downshifting to a lower gear at torcycle is equipped with a side stand high speed causes engine rpm switch. This switch is designed so to increase excessively, poten- that the engine does not start if the tially damaging the engine and transmission is in gear and the side...
  • Page 72: Braking

    HOW TO RIDE THE MOTORCYCLE • standing still. The transmission will Even in motorcycles equipped with shift only into neutral. ABS, braking during cornering may cause wheel slip. When turning a corner, it is better to limit braking to Braking the light application of both brakes •...
  • Page 73: Anti-lock Brake System (abs)

    HOW TO RIDE THE MOTORCYCLE prevent wheel lock-up and allows sta- ble steering control while stopping. Brake control function is identical to that of a conventional motorcycle. The brake lever is used for the front brake and the brake pedal for the rear brake. Although the ABS provides stability while stopping by preventing wheel lock-up, remember the following char-...
  • Page 74 HOW TO RIDE THE MOTORCYCLE distance of a motorcycle with ABS WARNING may be longer than that of an equiv- ABS cannot protect the rider alent motorcycle without ABS. Use from all possible hazards and special caution in such areas. is not a substitute for safe rid- •...
  • Page 75: Yellow Abs Indicator Light

    ABS. You should have the ABS approx. 10 km/h (6 mph) or above. checked by an authorized Kawasaki ABS indicator light goes off by this dealer. operation, but if it remains lit, you •...
  • Page 76: Stopping The Engine

    • Close the throttle completely. an Emergency • Shift the transmission into neutral. • Your Kawasaki Motorcycle has been Turn the ignition key to “OFF” posi- designed and manufactured to pro- tion. • vide you optimum safety and conve- Support the motorcycle on a firm, nience.
  • Page 77: Parking

    HOW TO RIDE THE MOTORCYCLE Improper maintenance can create a used, turn off the ignition switch after dangerous situation known as throt- stopping the motorcycle. tle failure. Two of the most common Parking causes of throttle failure are: 1. An improperly serviced or clogged air cleaner may allow dirt and dust WARNING to enter the throttle body and stick...
  • Page 78 HOW TO RIDE THE MOTORCYCLE • WARNING If parking inside a garage or other structure, be sure it is well ventilated The engine and exhaust system and the motorcycle is not close to get extremely hot during normal any source of flame or sparks; this operation and can cause serious includes any appliance with a pilot burns.
  • Page 79: Maintenance And Adjustment

    Please note that Kawasaki cannot assume any responsibility for damage result- ing from incorrect or improper adjustment made by the owner.
  • Page 80 The cooling fan spins at high speed and can cause serious injuries. Keep your hands and clothing away from the cooling fan blades at all times. NOTE ○ If a torque wrench is not available, the maintenance items which require a specific torque value should be serviced by an authorized Kawasaki dealer.
  • Page 81: Daily Safety Checks

    MAINTENANCE AND ADJUSTMENT Daily Safety Checks Check the following items each day before you ride. The time required is minimal, and habitual performance of these checks will help ensure you a safe, reliable ride. If any irregularities are found during these checks, refer to the MAINTENANCE AND ADJUSTMENT chapter or see your dealer for the action required to return the motorcycle to a safe operating condition.
  • Page 82 MAINTENANCE AND ADJUSTMENT Operation Page Lubricate if dry Bolts, nuts and fasteners – Check for loose and/or missing bolts, nuts and fasteners Steering – Action smooth but not loose from lock to lock – No binding of control cables Brakes Brake pad wear Brake fluid level –...
  • Page 83 MAINTENANCE AND ADJUSTMENT Operation Page Coolant – No coolant leakage Coolant level between level lines (when engine is cold) Electrical equipment – All lights (head, tail/brake, turn signal, warning/indicator) and horn work Engine stop switch – Stops engine Side stand –...
  • Page 84: Periodic Maintenance

    MAINTENANCE AND ADJUSTMENT Periodic Maintenance *A: Service at number of years shown or indicated odometer reading intervals, whichever comes first. *B: For higher odometer readings, repeat at the frequency interval established here. *C: Service more frequently when operating in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping.
  • Page 85 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) Air cleaner element (*C) Idle speed Throttle control system (play, smooth return, no drag) – Engine vacuum synchronization –...
  • Page 86 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) : every 36 000 km – Coolant, water hoses and O-rings (22 500 mile) – Valve clearance –...
  • Page 87 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) : every 1 000 km Drive chain slack (*C) (600 mile) – Drive chain wear (*C) – Drive chain guide wear –...
  • Page 88 MAINTENANCE AND ADJUSTMENT Odometer Reading (*B) × 1 000 km (× 1 000 mile) year (*A) Page Items (0.6) (3.8) (7.6) (11.4) (15.2) – Suspension system – Lubrication of rear suspension – Steering play – Steering stem bearings – Electrical system –...
  • Page 89: Engine Oil

    MAINTENANCE AND ADJUSTMENT Engine Oil Oil Level Inspection • If the engine is cold, start the engine and run it for several minutes at idle speed. • Stop the engine, then wait several minutes until the oil settles. NOTICE A. Oil Level Inspection Window Racing the engine before the oil B.
  • Page 90 MAINTENANCE AND ADJUSTMENT Oil and/or Oil Filter Change • The oil change and oil filter replace- ment should be done by an autho- rized Kawasaki dealer. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods A.
  • Page 91 MAINTENANCE AND ADJUSTMENT NOTE ○ Do not add any chemical additive to the oil. Oils fulfilling the above re- quirements are fully formulated and provide adequate lubrication for both the engine and the clutch. Engine Oil Capacity Capacity: 2.0 L (2.1 US qt) [when filter is not removed] A.
  • Page 92: Coolant

    MAINTENANCE AND ADJUSTMENT A. F (Full) Level Line Coolant B. L (Low) Level Line C. Reserve Tank Coolant Level Inspection NOTE • Position the motorcycle so that it is ○ Check the level when the engine is perpendicular to the ground. •...
  • Page 93 If coolant must be added of- ten, or the reserve tank com- pletely runs dry, there is proba- bly leakage in the system. Have the cooling system inspected by your authorized Kawasaki dealer. • Install the reserve tank cap. A. Reserve Tank Cap...
  • Page 94: Air Cleaner

    MAINTENANCE AND ADJUSTMENT NOTICE Coolant Requirement If hard water is used in the sys- WARNING tem, it causes scale accumula- Coolant containing corrosion in- tion in the water passages, and hibitors for alminum engines considerably reduces the effi- and radiators include harm- ciency of the cooling system.
  • Page 95 MAINTENANCE AND ADJUSTMENT A. Air Cleaner Element Cap A. Element B. Mounting Screws • Remove the element from the frame. • Pull out the air cleaner element from the air cleaner housing.
  • Page 96 MAINTENANCE AND ADJUSTMENT WARNING If dirt or dust is allowed to pass through into the throttle body assembly, the throttle may be- come stuck, possibly causing accident. Be sure to keep the dust from entering during clean- ing. NOTICE A. Element B.
  • Page 97 MAINTENANCE AND ADJUSTMENT WARNING Element Cleaning • Clean the element in a bath of a high Gasoline and low flash-point sol- flash-point solvent. vents are extremely flammable • Squeeze it dry in a clean towel. Do and may explode, causing se- not wring the element or blow it dry;...
  • Page 98: Throttle Control System

    • If the throttle grip does not return properly, have the throttle control system checked by an authorized Kawasaki dealer.
  • Page 99 MAINTENANCE AND ADJUSTMENT • Check the throttle grip free play by Throttle Grip Free Play Adjustment • turning back and forth. Loosen the locknut at the throttle grip, and turn the adjuster until the proper amount of throttle grip play is obtained.
  • Page 100: Idle Speed

    MAINTENANCE AND ADJUSTMENT Idle Speed be done by an authorized Kawasaki dealer. • With the engine idling, turn the han- Idle Speed Adjustment • dlebar to each side. If handlebar Start the engine, and warm it up thor- movement changes the idle speed, oughly.
  • Page 101: Clutch

    If handlebar ularity, have the clutch cable checked movement changes the idle speed, by an authorized Kawasaki dealer. the throttle cables may be improperly • Check the clutch lever play as adjusted or incorrectly routed, or they shown.
  • Page 102 MAINTENANCE AND ADJUSTMENT WARNING Too much cable play can pre- vent clutch disengagement and cause an accident resulting in serious injury or death. When adjusting the clutch or replac- ing the cable, be sure the up- per end of the clutch outer cable is fully seated in its fitting, or it could slip into place later, creat- A.
  • Page 103: Drive Chain

    MAINTENANCE AND ADJUSTMENT Drive Chain Drive Chain Lubrication Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed chains to prevent deterioration of chain seals. If the chain is especially dirty, clean it using a cleaner for sealed chains fol- lowing the instructions supplied by the...
  • Page 104 MAINTENANCE AND ADJUSTMENT chain midway between the engine sprocket and rear wheel sprocket. • Wipe off any lubricant that gets on the tire surface. A. Chain Slack Drive Chain Slack Inspection • • Set the motorcycle up on its side If the drive chain is too tight or too stand.
  • Page 105 MAINTENANCE AND ADJUSTMENT • If the chain is too loose, turn in the left Drive Chain Slack Adjustment • Loosen the left and right chain ad- and right chain adjusting nuts evenly. • juster locknuts. If the chain is too tight, turn out the •...
  • Page 106 Tightening Torque Axle Nut: 98 N·m (10 kgf·m, 72 ft·lb) NOTE ○ Wheel alignment also NOTE checked using the straightedge or ○ If a torque wrench is not available, string method. this item should be serviced by an authorized Kawasaki dealer.
  • Page 107 MAINTENANCE AND ADJUSTMENT • Rotate the wheel, measure the chain the cotter pin hole in the axle shaft, slack again at the tightest position, tighten the nut clockwise up to the and readjust if necessary. next alignment. • ○ It should be within 30 degrees. Install a new cotter pin through the ○...
  • Page 108: Brakes

    Brake Fluid Level Inspection when applying the brakes, have the • With the front brake fluid reservoir brake system checked by an autho- held horizontal, the brake fluid level rized Kawasaki dealer immediately. must be above the lower level line.
  • Page 109 In this case, have lower level lines. the brake system inspected by an au- thorized Kawasaki dealer. Brake Pad Wear Inspection Inspect the brakes for wear. For each front and rear disc brake caliper, if the...
  • Page 110 MAINTENANCE AND ADJUSTMENT thickness of either pad lining is less than below table, replace both pads in the caliper as a set. Pad replace- ment should be done by an authorized Kawasaki dealer. Lining Thickness Service Limit EX250L EX250M 1.5 mm (0.06 1.0 mm (0.04...
  • Page 111: Brake Light Switches

    MAINTENANCE AND ADJUSTMENT • If it does not, ask your authorized Kawasaki dealer to inspect the front brake light switch. • Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after the proper pedal travel.
  • Page 112: Suspension System

    MAINTENANCE AND ADJUSTMENT NOTICE Brake Pedal Travel 10 mm (0.4 in.) To avoid damaging the electrical connections inside the switch, be sure that the switch body Brake Light Switch Adjustment • does not turn during adjustment. To adjust the rear brake light switch, move the switch up or down by turn- ing the adjusting nut.
  • Page 113 MAINTENANCE AND ADJUSTMENT A. Chain Cover A. Bolts B. Bolts • Turn the adjuster counterclockwise to increase spring preload and stiffen the suspension. • Turn the adjuster clockwise to de- crease preload and soften the sus- pension.
  • Page 114 MAINTENANCE AND ADJUSTMENT A. Spring Preload Adjuster B. Wrench • Install the chain cover in the reverse order of removal.
  • Page 115: Setting Table

    MAINTENANCE AND ADJUSTMENT Setting Table Rear Shock Absorber Spring Preload Setting Hardest setting Softest setting limit Standard limit Adjuster Position ←→ Spring Action Weak Strong ←→ Setting Soft Hard ←→ Load Light Heavy ←→ Road Good ←→ Speed High...
  • Page 116: Wheels

    MAINTENANCE AND ADJUSTMENT Wheels Tire Pressure Inspection • Remove the air valve cap. • Check the tire pressure often, using an accurate gauge. • Make sure to install the air valve cap securely. NOTE ○ Measure the tire pressure when the A.
  • Page 117 MAINTENANCE AND ADJUSTMENT So it is false economy and unsafe to Minimum Tread Depth use the tires until they are bald. — Front 1 mm (0.04 in.) Tire Wear Inspection Under 130 km/h • 2 mm (0.08 in.) Measure the depth of the tread with (80 mph) Rear a depth gauge, and replace any tire...
  • Page 118 MAINTENANCE AND ADJUSTMENT WARNING Tires that have been punctured and repaired do not have the same capabilities as undam- aged tires and can suddenly fail, causing an accident resulting in serious injury or death. Re- place damaged tires as soon as possible.
  • Page 119 MAINTENANCE AND ADJUSTMENT ○ When operating on public roadways, WARNING keep maximum speed under traffic Mixing tire brands and types can law limits. adversely affect handling and cause an accident resulting in Standard Tire (Tubeless) injury or death. Always use the Make, Type: same manufacturer’s tires on IRC, ROAD WINNER RX-01F...
  • Page 120: Battery

    The battery installed in this motorcy- charged using an appropriate charger cle is a sealed type, so it is not nec- (check with your Kawasaki dealer). essary to check the battery electrolyte If you will not be using the motorcy- level or add distilled water.
  • Page 121 If the above chargers are not avail- away from the battery. Wear eye able, use equivalent one. protection when working with a For more details, ask your Kawasaki battery. In the event of battery dealer. acid contact with skin, eyes, or...
  • Page 122 MAINTENANCE AND ADJUSTMENT Seats section in the GENERAL IN- FORMATION chapter. • Unscrew the cover screw and pull up the battery cover with the relay assy. A. (+) Terminal B. (–) Terminal • Take the battery out of the case. •...
  • Page 123 MAINTENANCE AND ADJUSTMENT NOTICE Installing the (–) cable to the (+) terminal of the battery or the (+) cable to the (–) terminal of the battery can seriously damage the electrical system. • Put a light coat of grease on the ter- minals to prevent corrosion.
  • Page 124: Headlight

    C. Battery Cover Headlight A. Horizontal Adjuster B. Vertical Adjuster Headlight aiming should be done by an authorized Kawasaki dearer. Vertical Adjustment The headlight beam is adjustable ver- Horizontal Adjustment tically. If adjusted too low, neither low The headlight beam is adjustable nor high beam will illuminate the road horizontally.
  • Page 125: Fuses

    MAINTENANCE AND ADJUSTMENT the high beam will fail to illuminate the road close ahead, and the low beam will blind oncoming drivers. • Turn the vertical adjuster in or out to adjust the headlight vertically. NOTE ○ On high beam, the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated.
  • Page 126 MAINTENANCE AND ADJUSTMENT system. Have the motorcycle checked WARNING by an authorized Kawasaki dealer. Substituting fuses can cause The main fuse removal should be wiring to overheat, catch fire done by an authorized Kawasaki and/or fail. Do not use any sub- dealer.
  • Page 127: General Lubrication

    Clutch Lever (K) Throttle Inner Cable Upper Ends • Front Brake Lever • Rear Brake Pedal (K): Should be serviced by an authorized Kawasaki dealer. Lubricate the following cables with a pressure cable luber NOTE • (K) Clutch Inner Cable ○...
  • Page 128: Cleaning Your Motorcycle

    Frequent and proper care of your and increase the risk of fire. Kawasaki motorcycle will enhance When operating the vehicle in its appearance, optimize overall per- conditions that allow debris or formance, and extend its useful life.
  • Page 129: Washing Your Motorcycle

    MAINTENANCE AND ADJUSTMENT • • Be sure the engine and exhaust are Avoid spraying water in delicate cool before washing. areas such as in air intakes, fuel sys- • Avoid applying degreaser to seals, tem, brake components, electrical components, muffler outlet, and fuel brake pads, and tires.
  • Page 130 MAINTENANCE AND ADJUSTMENT detergent can damage parts of your immediately wash your motorcycle motorcycle). with cold water. Do not use warm • Use a soft cloth to dry your motorcy- water as it accelerates the chemical reaction of the salt. After drying, cle.
  • Page 131 Do not obstruct or deflect air- • If any doubt, consult an authorized flow through the radiator by Kawasaki dealer. installing unauthorized acces- sories in front of the radiator or Windshield and Other Plastic behind the cooling fan. Inter-...
  • Page 132 MAINTENANCE AND ADJUSTMENT NOTICE should be washed with a mild neu- tral detergent and finished with a spray Plastic parts may deteriorate polish. Aluminum wheels, both painted and break if they come in con- and unpainted can be cleaned with tact with chemical substances special non-acid based wheel spray or household cleaning products...
  • Page 133 MAINTENANCE AND ADJUSTMENT WARNING Rubber protectants can be slip- pery and, if used on the tread area, cause loss of traction re- sulting in accident causing in- jury or death. Do not apply rub- ber protectant to any tread area.
  • Page 134: Appendix

    APPENDIX APPENDIX Storage Preparation for Storage • Clean the entire vehicle thoroughly. • Run the engine for about five minutes to warm the oil, shut it off, and drain the engine oil. WARNING Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recy- cling.
  • Page 135 APPENDIX WARNING Gasoline is extremely flammable and can be explosive under certain con- ditions, creating the potential for serious burns. Turn the ignition key off. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Gasoline is a toxic substance.
  • Page 136 APPENDIX • Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes. • Lubricate the drive chain and all the cables. • Remove the battery, and store it where it will not be exposed to direct sunlight, moisture, or freezing temperatures.
  • Page 137: Troubleshooting Guide

    APPENDIX Troubleshooting Guide Engine Does Not Start Starter Motor Won’t Turn • Engine stop switch off • Transmission not in neutral • Fuse blown • Battery leads do not make good electrical contact with battery terminals • Battery discharged Engine Cranks, But Won’t Start •...
  • Page 138: Owner Satisfaction

    Battery discharged Owner Satisfaction (For Products Sold in Australia Only) Your satisfaction is important to your authorized Kawasaki dealer and to Kawasaki Motors Pty., Ltd. If you have a problem concerning warranty or service, please take the following action: Contact the owner and/or service manager of your authorized Kawasaki dealer.
  • Page 139 Also, all warranty and service matters are handled and resolved through the authorized Kawasaki dealer network. If you are unsatisfied after working with your Kawasaki dealer and feel you still require further assistance, WRITE to the address below. Please be certain to pro-...
  • Page 140: Environmental Protection

    Con- sult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire vehicle at the...
  • Page 141: Maintenance Record

    MAINTENANCE RECORD MAINTENANCE RECORD Owner Name..................Address ....................Phone Number ................... Engine Number .................. Vehicle Number.................. Key Code .................... Selling Dealer Name ................Phone Number ................... Warranty Start Date ................Note: Keep this information and a spare key in a secure location. Odometer Date Maintenance Performed...
  • Page 142 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 143 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 144 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 145 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...
  • Page 146 MAINTENANCE RECORD Odometer Date Maintenance Performed Dealer Name Dealer Address Reading...

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Ninja ex250lNinja ex250m

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