1990-1996 Kawasaki ZZ-R250 Motorcycle Service Manual
For ZZ-R250 motorcycle models: diagnostics, service, and parts information for engine, chassis, electrical systems, and more. Part Number: 99924-1129-54.
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Sample pages from the 1990-1996 Kawasaki ZZ-R250 Motorcycle Service Manual manual
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Kawasaki Models Covered & Key Technical Specifications
Models: EX250-H1, EX250-H2, EX250-H3, EX250-H4, EX250-H5, EX250-H7
Sub-models / Variants: Australia Model (A), Austria Model (AS), Finland Model (F), Greece Model (G), Switzerland Model (S)
Trade Names: ZZ-R250
Build Years: 1990–1996
Serial Numbers: JKAEXMH1_LA000001 (1990), JKAEXMH1_MA008801 (1991), JKAEXMH1_NA025001 (1992), JKAEXMH1_RA050001 (1994), JKAEXMH1_TA060001 (1996)
Technical Data:
- Engine: 248 mL, 4-stroke, DOHC, 2-cylinder, liquid-cooled
- Transmission: 6-speed, constant mesh, return shift
- Fuel System: Keihin CVK30 carburetors
- Ignition Timing: From 10° BTDC @ 1200 r/min to 42° BTDC @ 4500 r/min
- Spark Plug: NGK CR8HSA or ND U24FSR-U
- Front Suspension: Telescopic fork, 125 mm travel
- Rear Suspension: Swingarm (Uni-trak), 110 mm travel
- Brakes: Single disc front and rear
- Alternator Output: 17 A @ 10,000 r/min (14 V)
Kawasaki Manual Features & Content Preview
Official Kawasaki ZZ-R250 Supplement
- Covers 1990–1996 Kawasaki ZZ-R250 motorcycle variants including the EX250-H1 through EX250-H7 models with liquid-cooled twin-cam parallel-twin engines
- Official OEM publication Part No. 99924-1129-54, Fourth Edition dated August 19, 1997
- Includes 16 chapters of factory-specified maintenance data, 40 exploded-view component illustrations, and 14 detailed technical specification tables for engine, chassis, and electrical systems
- Accessible from your device as soon as the order is placed
- Indexed PDF search covers every chapter and appendix
- Re-download the file any time, no expiration
- This fourth edition is the definitive service supplement for the EX250-H line, incorporating technical revisions that supersede earlier documentation released at the 1990 launch
Technical Scope and Data
This 125-page 1990–1996 Kawasaki ZZ-R250 service manual supplement provides dedicated technical information for the EX250-H series. It documents critical systems including fuel-air induction via Keihin CVK30 carburetors, cooling system pressure and thermostatic switch parameters, and specific engine top-end overhaul tolerances. The manual contains comprehensive data on the six-speed constant-mesh transmission, electrical system wiring configurations, and the Uni-trak rear suspension assembly adjustments.
Factory Specification Preview
The manual documents precise technical limits for professional service work. Piston ring end gap is specified at 0.30–0.45 mm in the engine top-end table. Coolant total amount is listed as 1.0 liters in the cooling system specifications section. Spark plug gap is documented at 0.6–0.7 mm in the electrical system reference chart. For those requiring deeper insight, this guide serves as a detailed reference for factory workshop documentation to be used alongside the base EX250E motorcycle service manual. Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. An official 125-page Kawasaki OEM service manual supplement covering the 1990–1996 ZZ-R250 (EX250-H), documenting engine, chassis, electrical, and fuel-system specifications for the H-series model range.
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