1979–1982 Kawasaki Z250/KZ305 Service & Repair Manual (P/N 99924-1019-04)

• Covers engine removal and crankcase splitting, cylinder head disassembly, camshaft chain timing, and intake and exhaust valve clearance verification.
• Keihin CV32 carburetor service includes removal, internal disassembly, diaphragm and choke checks, fuel-level adjustment, and synchronization.
• Transmission overhauls and clutch repair cover shaft and gear assemblies, shift mechanisms, friction plates, and springs. Chain-drive maintenance includes drive chain slack adjustment and sprocket wear checks.
• Brake procedures address caliper and master-cylinder rebuilding, hydraulic bleeding, and front drum brake shoe synchronization.
• Chassis sections cover fork disassembly and oil-seal replacement, steering bearings, wheel balancing, and rim and spoke service.
• Electrical tests cover the alternator, regulator/rectifier, ignition coils and contact breakers, plus starter relay and motor checks.

This 312-page PDF reproduces Kawasaki’s Z250/KZ305 Motorcycle Service Manual, P/N 99924-1019-04, Fourth Edition, dated September 30, 1981. It was written primarily for motorcycle mechanics in an equipped shop, with basic maintenance and repair information for owners who already understand mechanical work, tools, and workshop procedures.

Model Coverage and Factory Supplements

Model identification pages and a chart listing starting frame numbers help identify the correct version. The volume combines the 1979 base manual with 11 model supplements. The supplements are intended for use with the base chapters and applicable earlier revisions.

Model-Specific Systems and Maintenance

The covered engines are air-cooled SOHC twins: 248 cc for the Z250 and 306 cc for the KZ305, paired with six-speed transmissions. Z250-A models use front and rear disc brakes; Z250-B models use front and rear drums. KZ305 models combine a front disc with a rear drum.

The 1982 KZ305-B1 and D1 belt-drive sections add belt replacement, pulley inspection, alignment, and tension testing. The 1980 supplements cover bolt-type rocker shafts; later revisions track carburetor calibration changes.

The 1981 Z250-A3/B2 supplements distinguish their automatic camshaft chain tensioner from the earlier manually adjusted unit. The 1982 chapters cover a revised right-side clutch release, while the Z250-A4 adds an air-adjustable front fork with pressure checks and service procedures.

The automatic tensioner section warns that retightening a partly loosened unit can damage the tensioner and chain. Assembly notes for the cylinder head cover warn of tachometer gear damage if the pinion remains in the cover during installation.

Engine Repair and Fuel-System Diagnosis

Disassembly flowcharts outline access to assemblies with the engine installed or removed. Engine repair coverage extends to compression testing, cylinder boring and honing, valve-guide replacement, and valve-seat cutting and lapping.

Inspection data address camshaft journals, connecting-rod clearances, and crankshaft runout. The crankshaft section distinguishes replaceable end bearings from inner bearings that require replacement with the crankshaft assembly.

The fuel chapters explain the starter, pilot, main, and float systems and compare rich- and lean-running symptoms. The 1982 U.S. KZ305 material adds high-altitude carburetor adjustments.

Specifications, Tools, and Electrical Reference

Factory tables provide tightening torques and locking-agent requirements, fluid capacities, service limits, adjustment data, and electrical test values. Tool references include the updated vacuum gauge 57001-1152, belt tension gauge 57001-1155, and fork air-pressure gauge 52005-1003.

The Camshaft Chain Timing drawing, Engine Oil Flow Chart, and exploded Shift Drum, Drive Shaft, Output Shaft view support internal engine work. Ignition Circuit and Starter Motor Circuit schematics accompany wiring diagrams for European and general-export Z250 models and U.S./Canadian KZ305 models. The 1982 European Z250 wiring diagram excludes West German models.

A symptom-based troubleshooting guide covers hard starting, poor running, clutch faults, and shifting problems. Electrical diagnosis appears in the individual component sections.

Always cross-reference the factory specifications for your model and follow the manual’s precautions for brake-lining dust, fuel handling, and electrical isolation.