Kawasaki Ninja 250R Motorcycle. Service Manual (2007) - page 5
APPENDIX 17-1
Appendix
Table of Contents
Cable, Wire, and Hose Routing
17-2
Troubleshooting Guide
17-40
17
17-2 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-3
Cable, Wire, and Hose Routing
1. Right Switch Housing Leads
2. Ignition Switch Leads
3. Left Switch Housing Leads
4. Choke Cable
5. Guide
6. Guide
7. Guide
8. Speedometer Cable
9. Throttle Cable (Accelerator)
10. Throttle Cable (Decelerator)
11. Brake Hose
12. Throttle Cables
13. Guide
14. Guide
15. Left Switch Housing Leads
16. Right Switch Housing Leads
17-4 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-5
Cable, Wire, and Hose Routing
1. Choke Cable
2. Clutch Cable
3. Left Switch Housing Leads
4. Meter Leads Connectors
5. Band
6. Guide
7. Band
8. Headlight Leads Connectors
9. Guide
10. Speedometer Cable
11. Guide
12. Starter Locknut Switch Lead
17-6 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-7
Cable, Wire, and Hose Routing
1. Throttle Cables
2. Guide
3. Radiator Fan Leads Connectors
4. Clamp
5. Right Switch Housing Leads
6. Water Temperature Switch
7. #2 Ignition Coil
8. Clutch Cable
9. Front Right Turn Signal Light Connector
10. #2 Ignition Coil
11. Water Temperature Switch
12. Main Harness
13. Guide
14. Front Left Turn Signal Light Connector
15. Bracket
16. Bracket
17. Ignition Switch Leads Connector
17-8 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-9
Cable, Wire, and Hose Routing
1. Left Switch Housing Leads
2. Clutch Cable
3. Clamp
4. Left Switching Housing Leads Connector
5. Guide
6. Front Left Turn Signal Light Connector
7. Guide
8. #1 Ignition Coil
9. Oil Pressure Switch Connector
10. Radiator Fan Switch
11. Radiator/Rectifier
12. Guide
13. Choke Cable
14. Horn
15. Guide
16. Guide
17. Coolant Reserver Tank Breather Hose
18. Guide
19. Fuel Tank Tank Breather Hose
20. Fuel Tank Tank Breather Hose
21. Guide
22. Guide
17-10 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-11
Cable, Wire, and Hose Routing
1. Alternator Leads
2. Crankshaft Sensor Leads
3. Brackets
4. Engine Ground Lead
5. Clutch Cable
6. Guide
17-12 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-13
Cable, Wire, and Hose Routing
1. Neutral Switch Connector
2. Clamp
3. Sidestand Switch Connector
4. Sidestand Switch Leads
5. Clamp
6. Sidestand Switch
17-14 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-15
Cable, Wire, and Hose Routing
1. Rear Left Turn Signal Light Connector
2. Rear Right Turn Signal Light Connector
3. IC Igniter
4. Fuse Box
5. Headlight Circuit Relay
6. Starter Circuit Relay
7. Diodes
8. Starter Relay
9. Fuel Level Sensor Connector
10. Clamp
11. Alternator Connector
12. Crankshaft Connector
13. Clamp
14. Battery (+) Cable
15. Starter Relay
16. Starter Motor Cable
17. Battery (-) Cable
18. Rear Brake Switch
19. Clamp
20. Rear Brake Switch Connector
17-16 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-17
Cable, Wire, and Hose Routing
1. Rear Left Turn Signal Light Connector
2. Rear Right Turn Signal Light Connector
3. Brake/Tail Light Connector
4. License Plate Light Connector
5. Clamps
6. Clamp
7. Rear Left Turn Signal Light Connector
8. Rear Right Turn Signal Light Connector
9. License Plate Light Connector
10. Turn Signal Relay
11. Bracket
17-18 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-19
Cable, Wire, and Hose Routing
1. Headlight (High) Connector
2. Headlight (Low) Connector
3. Bands
4. Horn Connector
5. Meter Connector
6. Diode Connector
7. Regulator/Rectifier Connector
8. Ignition Coil Connector
9. Radiator Fan Switch Connector
10. Oil Pressure Switch Connector
11. Left Switch Housing Connectors
12. Front Turn Signal Light Connector
13. Neutral Switch Connector
14. Sidestand Switch Connector
15. Bands
16. Starter Relay
17. Fuse Box
18. Turn Signal Relay
19. Clamp
20. Choke Cable
17-20 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-21
Cable, Wire, and Hose Routing
1. License Plate Light Connector
2. Tail/Brake Light Connector
3. IC Igniter Connector
4. Rear Right Turn Signal Light Connector
5. Rear Left Turn Signal Light Connector
6. Brake Light Switch Connector
7. Starter Relay Connector
8. Headlight Circuit Relay
9. Diode
10. Diode
11. Battery (-) Cable
12. Alternator Connector
13. Crankshaft Sensor Connector
14. Front Turn Signal Light Connector
15. Fuel Level Sensor Connector
16. Ignition Switch Connector
17. Frame Ground Terminal
18. Radiator Fan Switch Connector
19. Ignition Coil Connector
20. Right Switch Housing Connector
21. Radiator Fan Connector
22. Bands
17-22 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-23
Cable, Wire, and Hose Routing
1. Thermostat
2. Radiator Cap
3. Install the hose so that its white mark side faces the radiator.
4. Radiator
5. Clamp Screw
6. 45°
7. Cylinder Head
8. 45° ∼ 55°
9. Align the white mark on the hose with the projection mark on the fitting.
10. Install the hose so that its end cover the white mark on the pipe.
11. Cylinder
12. Install the hose so that its white mark side faces the pipe.
17-24 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-25
Cable, Wire, and Hose Routing
1. Run the reserver tank vent hose into the guide (2 places).
2. Reserver Tank Vent Hose
3. Bracket
4. Run the clutch cable and over flow hose into the hole of the reserver tank.
5. Clutch Cable
6. Radiator Overflow Hose
7. Radiator Cap
8. Coolant Reserver Tank
9. Clamp
10. Hose Curve Side
11. Run the only reserver tank vent hose into the bracket guide.
17-26 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-27
Cable, Wire, and Hose Routing
1. Air Suction Valve Cover
2. Vaccum Switch Valve
3. Carburetor
4. Install the vaccum switch valve hose so that its white mark faces the air cleaner box.
5. Air Cleaner Box
6. Install the vaccum valve switch fitting so that its white mark side faces the air suction valve hose.
7. This side is closed.
8. Air Suction Valve Hose
17-28 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-29
Cable, Wire, and Hose Routing
1. Air Cleaner Box
2. Battery
3. Run the carburetor vent hose between the air cleaner box and battery.
4. Fuel Hose
5. Run the fuel hose inside of the frame.
17-30 APPENDIX
Cable, Wire, and Hose Routing
APPENDIX 17-31
Cable, Wire, and Hose Routing
1. Front Master Cylinder
2. Front Brake Hse
3. Bracket
4. Clamp
5. Front Brake Caliper
6. Rear Brake Resevvoir
7. Rear Brake Caliper
8. Clamp
9. Rear Master Cylinder
17-32 APPENDIX
Cable, Wire, and Hose Routing
California Model (EX250J8)
APPENDIX 17-33
Cable, Wire, and Hose Routing
1. Install the clamps as shown, noting their clip direction.
2. Vaccum Switch Valve
3. Fitting
4. To Air Cleaner Box
5. To Carburetor
6. Regulator/Rectifier
7. Bracket
8. Canister
9. Align the hole on the separator with the white mark on the hose.
10. Align the hole on the separator with the hose direction.
11. Run the hoses through the guide of the bracket.
12. To Air Suction Valve Cover.
17-34 APPENDIX
Cable, Wire, and Hose Routing
California Model (EX250J9 ∼ JC)
APPENDIX 17-35
Cable, Wire, and Hose Routing
1. Install the clamps as shown, noting their clip direction.
2. Vaccum Switch Valve
3. Fitting
4. To Air Cleaner Box
5. To Carburetor
6. Regulator/Rectifier
7. Bracket
8. Canister
9. Align the hole on the separator with the white mark on the hose.
10. Align the hole on the separator with the hose direction.
11. Run the hoses through the guide of the bracket.
12. To Air Suction Valve Cover.
13. Run the hose through the clamp as shown.
14. Run the hose through the clamp.
15. Drain Hose.
17-36 APPENDIX
Cable, Wire, and Hose Routing
California Model
APPENDIX 17-37
Cable, Wire, and Hose Routing
1. Fuel Tank
2. Blue Mark
3. Red Mark
4. Hose (Blue)
5. Hose (Red)
6. Separator
7. Hose (White)
8. Hose (Green)
9. Hose (Blue)
10. Canister
11. EX250J8
17-38 APPENDIX
Cable, Wire, and Hose Routing
Australia Model
APPENDIX 17-39
Cable, Wire, and Hose Routing
1. Filter Body
2. Clamps
3. Cooling Hose
4. Water Pipe
5. Carburetor
6. Coolant Valve Assmbly
7. Damper
8. Run the cooling hose inside of the water pipe.
17-40 APPENDIX
Troubleshooting Guide
NOTE
Crankshaft sensor trouble
○This is not an exhaustive list, giving every
Ignition coil trouble
possible cause for each problem listed. It
Ignition or engine stop switch shorted
is meant simply as a rough guide to assist
Wiring shorted or open
the troubleshooting for some of the more
Main fuse blown
common difficulties.
Compression Low:
Spark plug loose
Engine Doesn’t Start, Starting
Cylinder head not sufficiently tightened
Difficulty:
down
Starter motor not rotating:
No valve clearance
Starter lockout switch or neutral switch trou-
Cylinder, piston worn
ble
Piston ring bad (worn, weak, broken, or
Starter motor trouble
sticking)
Battery voltage low
Piston ring/groove clearance excessive
Starter relays not contacting or operating
Cylinder head gasket damaged
Starter button not contacting
Cylinder head warped
Wiring open or shorted
Valve spring broken or weak
Ignition switch trouble
Valve not seating properly (valve bent,
Engine stop switch trouble
worn, or carbon accumulation on the
Main fuse blown
seating surface)
Starter motor rotating but engine doesn’t
Fuel/air mixture incorrect:
turn over:
Pilot screw or idle adjusting screw malad-
Starter motor clutch trouble
justed
Engine won’t turn over:
Pilot jet or air bleed hole clogged
Valve seizure
Air cleaner clogged, poorly sealed, element
Valve lifter seizure
missing
Cylinder, piston seizure
Starter jet clogged
Crankshaft seizure
Connecting rod small end seizure
Poor Running at Low Speed:
Connecting rod big end seizure
Spark weak:
Transmission gear or bearing seizure
Battery voltage low
Camshaft seizure
Spark plug dirty, broken, or maladjusted
Starter idle gear seizure
Spark plug cap or high tension wiring trou-
No fuel flow:
ble
No fuel in fuel tank
Spark plug cap shorted or not in good con-
Fuel tap vacuum hose clogged
tact
Fuel tank air vent obstructed
Spark plug incorrect
Fuel tap clogged
IC igniter trouble
Fuel line clogged
Crankshaft sensor trouble
Float valve clogged
Ignition coil trouble
Engine flooded:
Fuel/air mixture incorrect:
Fuel level in carburetor float bowl too high
Pilot screw maladjusted
Float valve worn or stuck open
Pilot jet, or air passage clogged
Starting technique faulty (When flooded,
Air bleed pipe bleed holes clogged
crank the engine with the throttle fully
Pilot passage clogged
opened to allow more air to reach the
Air cleaner clogged, poorly sealed, or ele-
engine.)
ment missing
No spark; spark weak:
Choke plunger stuck open
Battery voltage low
Fuel level in carburetor float bowl too high
Spark plug dirty, broken, or maladjusted
or too low
Spark plug cap or high tension wiring trou-
Fuel tank air vent obstructed
ble
Carburetor holder loose
Spark plug cap not in good contact
Air cleaner duct loose
Spark plug incorrect
Compression low:
IC igniter trouble
Spark plug loose
Neutral, starter lockout, or sidestand switch
Cylinder head not sufficiently tightened
trouble
down
APPENDIX 17-41
Troubleshooting Guide
No valve clearance
Cylinder head warped
Cylinder, piston worn
Valve spring broken or weak
Piston ring bad (worn, weak, broken, or
Valve not seating properly (valve bent,
sticking)
worn, or carbon accumulation on the
Piston ring/groove clearance excessive
seating surface.)
Cylinder head warped
Knocking:
Cylinder head gasket damaged
Carbon built up in combustion chamber
Valve spring broken or weak
Fuel poor quality or incorrect
Valve not seating properly (valve bent,
Spark plug incorrect
worn, or carbon accumulation on the
IC igniter trouble
seating surface)
Miscellaneous:
Other:
Throttle valve won’t fully open
IC igniter trouble
Vacuum piston doesn’t slide smoothly
Carburetor not synchronizing
Brake dragging
Vacuum piston doesn’t slide smoothly
Clutch slipping
Engine oil viscosity too high
Overheating
Drive train trouble
Engine oil level too high
Brake dragging
Engine oil viscosity too high
Drive train trouble
Poor Running or No Power at High
Speed:
Overheating:
Firing incorrect:
Firing incorrect:
Spark plug dirty, broken, or maladjusted
Spark plug dirty, broken, or maladjusted
Spark plug cap shorted or not in good con-
Spark plug incorrect
tact
IC Igniter trouble
Spark plug incorrect
Fuel/air mixture incorrect:
IC igniter trouble
Main jet clogged or wrong size
Crankshaft sensor trouble
Fuel level in carburetor float bowl too low
Ignition coil trouble
Carburetor holder loose
Fuel/air mixture incorrect:
Air cleaner poorly sealed, or missing
Choke plunger stuck open
Air cleaner duct poorly sealed
Main jet clogged or wrong size
Air cleaner clogged
Jet needle or needle jet worn
Compression high:
Air jet clogged
Carbon built up in combustion chamber
Fuel level in carburetor float bowl too high
Engine load faulty:
or too low
Clutch slipping
Bleed holes of needle jet holder or needle
Engine oil level too high
jet clogged
Engine oil viscosity too high
Air cleaner clogged, poorly sealed, or miss-
Drive train trouble
ing
Brake dragging
Air cleaner duct poorly sealed
Lubrication inadequate:
Water or foreign matter in fuel
Engine oil level too low
Fuel to carburetor insufficient
Engine oil poor quality or incorrect
Fuel tank air vent obstructed
Coolant incorrect:
Carburetor holder loose
Coolant level too low
Fuel tap clogged
Coolant deteriorated
Fuel line clogged
Cooling system component incorrect:
Compression low:
Radiator fin damaged
Spark plug loose
Thermostat trouble
Cylinder head not sufficiently tightened
Radiator cap trouble
down
Radiator fan switch trouble
No valve clearance
Fan relay trouble
Cylinder, piston worn
Fan motor broken
Piston ring bad (worn, weak, broken, or
Fan blade damaged
sticking)
Water pump not turning
Piston ring/groove clearance excessive
Water pump impeller damaged
Cylinder head gasket damaged
17-42 APPENDIX
Troubleshooting Guide
Over Cooling:
Abnormal Engine Noise:
Cooling system component incorrect:
Knocking:
Radiator fan switch trouble
IC igniter trouble
Thermostat trouble
Carbon built up in combustion chamber
Gauge incorrect:
Fuel poor quality or incorrect
Water temperature gauge broken
Spark plug incorrect
Water temperature sensor broken
Overheating
Piston slap:
Clutch Operation Faulty:
Cylinder/piston clearance excessive
Clutch slipping:
Cylinder, piston worn
Friction plate worn or warped
Connecting rod bent
Steel plate worn or warped
Piston pin, piston pin hole worn
Clutch inner cable trouble
Valve noise:
No clutch lever play
Valve clearance incorrect
Clutch spring broken or weak
Valve spring broken or weak
Clutch release mechanism trouble
Camshaft bearing worn
Clutch hub or housing unevenly worn
Other noise:
Clutch not disengaging properly:
Connecting rod small end clearance exces-
Clutch plate warped or too rough
sive
Clutch spring compression uneven
Connecting rod big end clearance exces-
Engine oil deteriorated
sive
Engine oil viscosity too high
Piston ring worn, broken, or stuck
Engine oil level too high
Piston seizure, damage
Clutch housing frozen on drive shaft
Piston ring groove worn
Clutch release mechanism trouble
Piston ring/groove clearance excessive
Clutch hub spline damaged
Cylinder head gasket leaking
Clutch friction plate installed wrong
Exhaust pipe leaking at cylinder head con-
Clutch lever play excessive
nection
Clutch hub nut loose
Crankshaft runout excessive
Engine mounts loose
Gear Shifting Faulty:
Crankshaft bearing worn
Doesn’t go into gear; shift pedal doesn’t
Camshaft chain tensioner trouble
return:
Camshaft chain, sprocket, guide worn
Clutch not disengaging
Alternator rotor loose
Shift fork bent or seized
Primary gear worn or broken
Gear stuck on the shaft
Shift return spring weak or broken
Abnormal Drive Train Noise:
Shift return spring pin loose
Clutch noise:
Pawl spring broken
Weak or damaged damper
Shift mechanism arm broken
Clutch housing/friction plate clearance ex-
Shift pawl broken
cessive
Jumps out of gear:
Clutch housing gear worn
Shift fork ear worn
Transmission noise:
Gear groove worn
Bearings worn
Gear dogs and/or dog holes worn
Transmission gears worn or chipped
Shift drum groove worn
Metal chips jammed in gear teeth
Neutral positioning pin spring weak or bro-
Engine oil insufficient
ken
Drive line noise:
Shift fork guide pin worn
Drive chain adjusted improperly
Drive shaft, output shaft, and/or gear
Drive chain worn
splines worn
Rear and/or engine sprocket worn
Overshifts:
Chain lubrication insufficient
Neutral positioning lever spring weak or
Rear wheel misaligned
broken
Pawl spring broken
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
APPENDIX 17-43
Troubleshooting Guide
Spring weak or broken
Handlebar shakes or excessively vibrates:
Rear shock absorber noise:
Tire worn
Shock absorber damaged
Swingarm pivot bearings worn
Disc brake noise:
Rim warped, or not balanced
Pad installed incorrectly
Wheel bearing worn
Pad surface glazed
Handlebar clamp bolts loose
Disc warped
Steering stem head nut loose
Caliper trouble
Front/rear axle runout too large
Other noise:
Handlebar pulls to one side:
Bracket, nut, bolt, etc.
not properly
Frame bent
mounted or tightened
Wheel misalignment
Swingarm bent or twisted
Oil Pressure Warning Light Goes On:
Steering maladjusted
Engine oil pump damaged
Front fork bent
Engine oil screen clogged
Right and left front fork oil level uneven
Engine oil level too low
Shock absorption unsatisfactory:
Engine oil viscosity too low
(Too hard)
Camshaft bearing worn
Front fork oil excessive
Crankshaft bearings worn
Front fork oil viscosity too high
Oil pressure switch damaged
Rear shock absorber adjustment too hard
Wiring faulty
Tire air pressure too high
Relief valve stuck open
Front fork bent
O-ring at the oil passage in the crankcase
(Too soft)
damaged
Front fork oil insufficient and/or leaking
Engine oil filter clogged
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Exhaust Smokes Excessively:
Rear shock absorber oil leaking
White smoke:
Rear shock absorber adjustment too soft
Piston oil ring worn
Tire air pressure too low
Cylinder worn
Valve oil seal damaged
Brake Doesn’t Hold:
Valve guide worn
Air in the brake line
Engine oil level too high
Pad or disc worn
Black smoke:
Brake fluid leakage
Air cleaner clogged
Disc warped
Main jet too large or fallen off
Contaminated pad
Choke plunger stuck open
Brake fluid deteriorated
Fuel level in carburetor float bowl too high
Primary or secondary cup damaged
Brown smoke:
Master cylinder scratched inside
Main jet too small
Fuel level in carburetor float bowl too low
Battery Trouble:
Air cleaner duct loose
Battery discharged:
Air cleaner poorly sealed or missing
Battery faulty (e.g., plates sulphated,
shorted through sedimentation, elec-
Handling and/or Stability
trolyte insufficient)
Unsatisfactory:
Battery cables making poor contact
Handlebar hard to turn:
Load excessive (e.g., bulb of excessive
Cable routing incorrect
wattage)
Hose routing incorrect
Ignition switch trouble
Wiring routing incorrect
Alternator trouble
Steering stem locknut too tight
Wiring faulty
Steering stem bearing damaged
Regulator/rectifier trouble
Steering stem bearing lubrication inade-
Battery overcharged:
quate
Regulator/rectifier trouble
Steering stem bent
Battery faulty
Tire air pressure too low
MODEL APPLICATION
Year
Model
Beginning Frame No.
2008
EX250J8
JKAEXMJ1□8DA00001
2009
EX250J9
JKAEXMJ1□9DA17355
2010
EX250JA
JKAEXMJ1□ADA49773
2011
EX250JB
JKAEXMJ1□BDA71588
2012
EX250JC
JKAEXMJ1□CDA96621
□:This digit in the frame number changes from one machine to another.
Part No.99924-1391-05
Printed in Japan