1990-1996 Kawasaki ZZ-R250 Service & Repair Manual (P/N 99924-1129-54)
125 Pages • 28.82 MB • Instant, Printable PDF
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
Model 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
- Covers 1990–1996 Kawasaki ZZ-R250 motorcycle variants (EX250-H1 through EX250-H7) equipped 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
Technical Details and Data
This 125-page service manual supplement provides dedicated technical information for the EX250-H series, serving as the definitive resource alongside the base EX250E motorcycle documentation. It documents critical systems essential for professional workshop routines. Inside, technicians will find parameters for fuel-air induction via Keihin CVK30 carburetors, cooling system pressure, thermostatic switch behavior, and specific top-end overhaul tolerances. The documentation also covers the six-speed constant-mesh transmission, electrical wiring configurations, and Uni-trak rear suspension adjustments. Keep in mind that working on high-pressure cooling systems and electrical components carries inherent physical risks; always ensure the motorcycle is properly secured, cooled down, and disconnected from power sources before referencing these specifications during maintenance.
Factory Specification Preview
The manual records precise technical limits necessary for professional and DIY service, acting purely as a detailed data log rather than a step-by-step repair guide. For example, the engine top-end table specifies a piston ring end gap of 0.30–0.45 mm. The cooling system section lists a total coolant capacity of 1.0 liters. Additionally, the electrical reference chart documents a spark plug gap of 0.6–0.7 mm. This fourth edition incorporates all technical revisions that supersede earlier documentation from the 1990 launch, ensuring you have the exact OEM tolerances required to maintain the H-series model range properly.
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