Kawasaki Ninja 250R & GPX250R 1987 Service Manual Supplement (P/N 99924-1109-51)

Need factory data for the 1988 EX250-F2? This Kawasaki Ninja 250R / GPX250R Service Manual Supplement is the First Edition dated October 2, 1987, P/N 99924-1109-51. It supplies model-specific repair information and must be used with the Ninja 250R (GPZ 250R) base service manual, P/N 99924-1066-01, for complete service procedures.

PDF Access and Wiring Detail

Search, navigation and diagrams: PDF text search and embedded bookmarks are not available. Small wiring labels require zooming. Some component names along the left edge of the UK/Australia wiring diagram are clipped.

One printable English-language PDF contains 248 pages, including 15 blank pages, eight cover/front-matter pages, and the model-application back cover.

Twin-Cylinder Repair and Electrical Diagnosis

These coverage highlights sample the workshop content. Additional topics include fairing removal and speedometer gear-housing service.

• Fuel and emissions: Carburetor synchronization, fuel-level adjustment, carburetor disassembly and inspection, throttle and choke cables, and California evaporative-emission equipment.

• Cooling and lubrication: Coolant filling and bleeding, pressure testing, radiator-cap and thermostat checks, water-pump replacement, oil-pump service, and oil-pressure diagnosis.

• Engine top end: Cylinder-head and valve-seat repair, camshaft timing, chain-tensioner service, compression testing, valve adjustment, and piston-ring inspection.

• Clutch and internal drivetrain: Clutch removal and inspection, crankcase splitting, crankshaft and connecting-rod checks, bearing-insert selection, balancer timing, and transmission repair.

• Suspension and final drive: Fork disassembly and resealing, Uni-Trak linkage service, swingarm inspection, steering adjustment, chain replacement, and wheel and tire service.

• Hydraulic brakes: Caliper and master-cylinder repair, pad and disc inspection, fluid replacement, brake-line bleeding, and hose replacement.

• Electrical troubleshooting: Charging and ignition tests, IC igniter diagnosis, starter-motor repair, junction-box checks, and regional EX250-F2 wiring diagrams.

Kawasaki wrote this manual primarily for trained mechanics in equipped shops; owners performing basic maintenance and repair need mechanical knowledge, proper tools, and familiarity with workshop procedures.

Fuel-System Setup and Cooling Diagnosis

Standard, California, and US high-altitude carburetor specifications are separated. Together with synchronization and fuel-level checks, these distinctions help match the setup to the motorcycle before diagnosing poor running.

The California section covers the liquid/vapor separator, canister, hose routing, and separator operation test. The Evaporative Emission Control System layout identifies the connections between these components.

Cooling coverage distinguishes external leakage from possible internal leakage and includes radiator, thermostat, fan-switch, and temperature-sensor checks. Water-pump instructions cover impeller inspection and replacement of the pump unit.

Engine Assembly and Internal Inspection

Step-by-step procedures address engine removal and installation, cylinder-head disassembly, camshaft installation, and crankcase assembly. The Camshaft Chain Timing diagram, Cylinder Head Bolts Tightening Order, and Valve Seat Repair flowchart support these jobs.

Bearing and transmission work: Plastigage checks and color-coded insert-selection tables cover crankshaft, connecting-rod, and balancer bearings. Transmission material extends to drive and output shafts, shift drums, shift forks, gear backlash, gear dogs, and ball and needle bearings.

Camshaft-cap location matters because the caps are machined with the head; incorrect placement can cause seizure. The crankcase assembly section also warns that misplaced liquid gasket can block oil passages and cause engine seizure.

The Engine Oil Flow Chart supports lubrication diagnosis, with separate checks for relief-valve operation and running oil pressure.

Forks, Uni-Trak and Brake Service

Fork specifications distinguish completely dry filling from an oil change and define the oil-level measurement condition. Rear-shock spring preload is non-adjustable.

Uni-Trak coverage separates swingarm needle-bearing service from tie-rod and rocker-arm bushing inspection and lubrication. Final-drive instructions address the endless EK520 MV-O chain, chain wear measurement, sprockets, and the rear-wheel coupling.

Wheel-bearing replacement, wheel balancing, steering-head service, and brake hydraulic repairs are documented alongside component inspection criteria.

Circuit Testing and Workshop Tools

Electrical material covers alternator output, regulator/rectifier tests, pickup and ignition coils, starter components, lighting, cooling fans, gauges, switches, relays, and diodes. The IC Igniter Troubleshooting chart links test results to further diagnosis.

Separate EX250-F2 wiring diagrams cover US/Canada and UK/Australia configurations. Junction-box circuit drawings and connector-terminal references support fault tracing.

Specified equipment: Fuel-system work uses Vacuum Gauge 57001-1198; valve adjustment uses Valve Adjuster 57001-1220. Other listed tools include Oil Pressure Gauge 57001-164 with Adapter 57001-1188, Clutch Hub Holder 57001-305, and Stem Nut Wrench 57001-1100.

IC igniter resistance testing specifies Kawasaki Hand Tester 57001-983. The electrical chapter explains tester-related damage risks and warns that striking the alternator rotor can reduce magnet strength.

The appendix adds symptom-based troubleshooting for starting, running, overheating, shifting, abnormal noise, oil-pressure warnings, handling, and braking faults.

Fuel-system work, hydraulic brake repair, pressurized cooling-system tests, high-voltage ignition checks, engine lifting, and disposal of the nitrogen-charged rear shock carry real hazards. Support the motorcycle securely and follow the manual’s warnings before beginning shop work.

Clutch Wear and Pickup-Coil Specification Samples

Clutch friction plates have a standard thickness of 2.9–3.1 mm and a 2.8 mm service limit. These values accompany inspection procedures for wear, damage, and plate distortion.

The EX250-F2 pickup-coil resistance specification is 100–150 Ω. The ignition section pairs this measurement with a separate check for insulation to ground.