1986-2002 Kawasaki Ninja 250R, GPZ 250R, ZZ-R250 Factory Service Manual and Supplement (P/N C4256-90954)

• 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 Part Number C4256-90954, First Edition (3) dated March 3, 1989.
• Contains 16 distinct chapters and 278 total pages of technical documentation.
• Features 111 detailed exploded-view diagrams to support accurate part identification and repair planning.
• Includes precise torque specification tables for major fasteners across the cooling, engine, clutch, and chassis systems.
• Provides the primary documentation for early EX250-E generation bikes, detailing unique CA-spec and Australian-spec trim differences.

Component and System Documentation

This factory literature organizes information through a highly logical progression. It starts with general identification, maintenance intervals, and standard torque requirements for major frame and engine fasteners. Following the basics, dedicated chapters offer exhaustive data on the liquid-cooled fuel and cooling systems. You will find complete component layouts for the Keihin CVK32 carburetors. Engine-specific sections cover the top end, lubrication circuits, and transmission assemblies. Mechanics get clear assembly notes alongside strict wear limits for internal parts, which is crucial reference material before beginning any major repair job.

Engine, Clutch, and Cooling Reference Data

Accurate factory specifications streamline the workflow in any busy garage. The cooling system relief pressure is documented at 93–123 kPa (14–18 psi). In the cylinder head specification table, intake valve clearance is tightly defined at 0.08–0.13 mm. Cylinder compression for the 248 mL engine must fall within the usable range of 961–1,471 kPa. When inspecting the drivetrain, clutch friction plate thickness is specified at 2.9–3.1 mm, with a hard service limit of 2.8 mm. Always prioritize personal safety and observe standard workshop precautions when handling heavy components, high-pressure fluids, or live electrical circuits.