1986-2002 Kawasaki Ninja 250R, GPZ 250R, ZZ-R250 Motorcycle Service Manual and Supplement

Inside the 1986–2002 Kawasaki Ninja 250R and GPZ 250R Service Manual

• This 1986–2002 Kawasaki Ninja 250R and GPZ 250R service manual covers the EX250-E1 and EX250-E2 liquid-cooled, 248 mL twin-cylinder motorcycle variants.
• Original OEM publication, First Edition (3) dated March 3, 1989.
• Contains 16 distinct chapters and 278 total pages of technical documentation.
• Features 111 detailed exploded-view diagrams covering systems from engine top end to electrical schematics.
• Includes precise torque specification tables for major fasteners across the cooling, engine, clutch, and chassis systems.
• Indexed PDF search covers every chapter and appendix.
• Accessible from your device as soon as the order is placed.
• This 1989 first edition provides the primary documentation for the early EX250-E generation bikes, including the unique CA-spec and Australian-spec trim differences.

Component and System Documentation

The 1986–2002 Kawasaki Ninja 250R manual organizes information through a logical progression, starting with general information and technical specifications. The initial section details identification, maintenance intervals, and torque requirements for major frame and engine fasteners. Following chapters dedicate exhaustive segments to the liquid-cooled fuel and cooling systems, documenting component removal and setup for the Keihin CVK32 carburetors. Engine-specific data covers the top end, lubrication circuits, and internal transmission components, providing clear assembly notes and wear limits for internal components like the clutch friction plates.

Engine, Clutch, and Cooling Reference Data

The 1986–2002 Kawasaki Ninja 250R cooling system relief pressure is documented at 93–123 kPa (14–18 psi). Valve clearance for the intake is listed at 0.08–0.13 mm in the cylinder head specification table. Cylinder compression for the 248 mL engine is defined within a usable range of 961–1,471 kPa. Clutch friction plate thickness is specified at 2.9–3.1 mm, with a service limit of 2.8 mm. This official Kawasaki factory publication serves as the primary technical reference for the 1986–2002 Kawasaki Ninja 250R and GPZ 250R motorcycle series, documenting assembly, system specifications, and performance data for the EX250-E1 and E2 builds. Reference only — always consult a certified technician before performing service on this equipment.