06 ninja 250 service manual

For information on how to get a service or owners manual, follow this link: Ninja Rider's bookshelf. There is only one Service Manual for the models. It was written in , when the EX was introduced.

Despite the fact that the bike went through a major redesign in , and has remained more or less the same since, there is no separate manual for the ' bikes. This is what the Supplement is for.

Cam Height Standard: This will warp the cylinder head. Exhaust 0. Inlet Service Limit: Exhaust This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair.

Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. If the seat width is within the specified range, lap the valve to the seat as described below. The rings should fit perfectly parallel to groove surfaces. If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low. Wait until the muffler cool down. Special Tool and Sealant Clutch Lever and Cable Clutch Lever Free Play Inspection Clutch Lever Free Play Adjustment Clutch Cable Removal Clutch Cable Installation Clutch Cable Lubrication Clutch Lever Free Play — — — Clutch 2.

Friction Plate Thickness 2. Friction and Steel Plate Warp 0. Clutch Spring Free Length Torque - Clutch Spring Bolts: 8. Engine Oil Flow Chart Special Tools and Sealant Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Replacement Bypass Valve Disassembly Bypass Valve Assembly Engine Removal Engine Installation A: After installation, set the projection in the hole.

When inserting the front engine mounting bolt, use the suitable stand under the engine to lift it. Starter Motor Clutch Assembly.. Balancer Removal Crankshaft Main Bearing Insert Thickness: 1.

CAUTION If the crankshaft, bearing inserts, or crankcase halves are replaced with new ones, select the bear- ing inserts and check clearance with a plastigage press gauge before assembling engine to be sure the correct bearing inserts are installed.

If the measurement exceeds the service limit, replace the crankshaft. If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings [A] on the balancer shaft, make new marks on Balancer Shaft Journal Diameter Marks None: If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.

Circlip, 29 mm 1. Ball Bearing 2. Circlip Drive Shaft 3. Thrust Washer, 30 mm 1. Inside Diameter: Nut Washer 4. Toothed Washer, 30 mm 1. If the thickness of a shift fork ear is less than the service limit, the shift fork must be replaced.

Radial TIR 0. TIR 0. Wheel Balance 10 g 0. Page 30 g 1. An imbalance of less than 10 grams 0. Page Tire Repair Also, permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire. For these reasons, Kawasaki does not recommend temporary exter- nal repair. Only appropriate permanent internal repairs are recommended. Repair methods may vary slightly from make to make.

If any bear- ings are removed, they will need to be replaced with new ones. HO: Apply heavy oil. Turn the bearing around by hand a few times to make sure the grease is distributed uniformly inside the bearing.

If they show any damage, replace the dust seals with new ones. Replace the caliper if the cylinder and piston are badly scores or rusty. Removing the rear brake pad is the same as for the front brake pad. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Pump the brake lever until it becomes hard, and apply the brake and hold it [A].

Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Holding the inner tube by hand in a vertical position, pull down the outer tube several times to pull out the inner tube.

If there is visible damage, replace the sleeve with a new one. G: Apply grease. If there is any damage to the frame, replace it. If the frame is bent, dented, cracked, or warped, replace it. Meter Unit 2. Ignition Switch 3. Starter Lockout Switch 4. Air Switching Valve 5. Stick Coils 6. Spark Plugs 7. Starter Relay 8. ECU Turn Signal Relay Fuse Box Learn and ob- serve all the rules below. This will burn out the diodes on the electrical parts.

If any wiring is poor, replace the damaged wiring. These names must be the same. Page Newly activated sealed batteries require an initial charge.

Standard Charge: 0. When properly installed, the strip of the caps will be level with the top of the battery. Forcibly prying off the seal cap to add water is very dangerous. Never do that.

Battery Terminal Voltage Standard: Page Charging System Apply silicone sealant to the crankshaft sensor lead grom- met and crankcase halves mating surface [A] on the front and rear sides of the cover mount. Striking the rotor can cause the magnets to lose their magnetism.

Alternator 2. Frame Ground 4. Main Fuse 30 A 5. Joint Connector 1 6. Thank you. I am a subscriber to the Cyclepedia Ninja online repair manual — thank you for this wonderful resource, keep up the good work.

Thank you for the online Kawasaki EX manual. I followed the instructions and the new starter is installed and working perfectly. I am very satisfied with this service and I saved BIG money buying a used part and doing the repair myself. Cyclepedia is a great service. The pictures and directions are simple and accurate.

Love your Ninja online manual service. Yours is very good, has excellent pictures, and handy torque specs and hints. The hyperlinked topics relevant to a repair are great. Being on line is very handy too. No worries about dragging a paper book from home to work or to a friends.

The price was half of a paper factory manual, a great value. Keep up the good work. Super product. The Cyclepedia Ninja manual is simple and quick to use. The instructions seem clear and logical. Name: J. Emmett Turner. Originally Posted by FrugalNinja Copyright law is pretty explicit on this.

A manual or any other document is an independent work product and fully subject to copyright laws. A manufacturer or dealer may elect to give you a copy of a document with your purchase if they so choose, but even then the transfer of the document in no way implies any transfer of publication or duplication rights other than what may be covered under fair use doctrines.

And most assuredly, owning a document in one format does not give any rights of ownership in other formats. For instance, say you own a physical book, then download an E-book version from someone other than the authorized publisher or distributor. That's a violation of copyright and the copy you have is pirated, even if it was a copy of the original legitimate E-book version and even though you own a version of the book already.

I hang with several authors and these kinds of discussions come up quite frequently. August 5th, , PM Alex. Mike - I'm not sure that you're reading this situation correctly. The OP has a company that produces service manuals. They are not from Kawasaki. Just like Haynes, Chilton, or any other separate company. To my knowledge, none of those folks are required to pay royalties to anyone for publishing books on a topic, but they likely do have to get permission from Kawasaki at some point to use their name and trademarks in print.

I have no reason to believe that this online company does or does not get the same assurances from Kawasaki that the other manual creators do, I just don't know and neither does anyone else. What we can be sure of is that their opinion is correct, that freely copied copyrighted service manuals, produced by Kawasaki, are by the letter and spirit of the law, illegal.

There have been any number of questions about this on online forums and even enthusiast magazines for years. What it comes down to is it's highly unlikely any manufacturer would make a stink about some sharing of those manuals from time to time, as the profit center is the bike, and not trying to make huge margins on manuals afterwards. And more manuals mean more people working on their bikes anyway. But it's still not a great idea for us to rub Kawi's or any other manufacturer's noses in it, because if push came to shove they would have a right to enforce copyright as they see fit.

That's the reason that these electronic manuals aren't traded openly on sites like this. August 5th, , PM FrugalNinja Originally Posted by CZroe. Except that it very well may be considered "Fair Use. The format argument is irrelevant. For example, you can scan and make a PDF yourself, as long as you don't sell it. That is inarguably fair use and exercising First Sale Doctrine and your right to a backup. The Home Recording Act of America makes it legal to share audio recording your don't own the copyright to as long as you don't profit, and similar "fair use" considerations may apply to other copyrighted works.

Why is audio considered so different? August 5th, , PM CZroe. It's called the RIAA brother, and their billions in the pockets of our senators. Making a copy of a CD or songs thereof for personal use would be considered fair use.

AFAIK scanning a printed document into an electronic format, though in itself probably not considered infringement, is almost always only done as a means to illegally distribute bootleg copies of the work, and as such is merely one possibly legal step in a series of illegal ones.

I know for a fact that my author friends routinely win copyright infringement actions against people creating and distributing unauthorized electronic versions of their printed works. Sounds like you need to pursue a test case. Turn yourself in for bootlegging written works and then you'll have standing to pursue the case all the way up to the Supreme Court.