Kawasaki Ninja 250R & GPX250R Classic Twin-Model 1987 Service & Repair Guide (P/N 99924-1109-51)

Need factory data for the 1988 EX250-F2? This 248-page PDF contains Kawasaki’s Ninja250R / GPX250R Motorcycle Service Manual Supplement, First Edition dated October 2, 1987, P/N 99924-1109-51. The 1987 date is the publication date; the model-application table identifies 1988 motorcycles. Fitment begins with frame JKAEXMF1□JA000001 for US/Canada models and EX250F-000001 for Europe/General models. The square represents a check digit that varies by motorcycle. Regional material also addresses California evaporative-emission equipment and separate electrical layouts for US/Canada and UK/Australia models.

Publication Scope and Base-Manual Requirement

Kawasaki identifies this document as a model-specific supplement, not a stand-alone replacement for the full base manual. It must be used with the Ninja 250R (GPZ 250R) base service manual, P/N 99924-1066-01, for carry-over procedures marked as base-manual content. This publication supplies the EX250-F2 specifications, component layouts, routing information, model-specific repair coverage, regional differences, and diagnostic data needed alongside that volume. Technicians, independent shops, and experienced owners planning a complete engine or chassis repair should account for both publications.

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, isolate electrical power where specified, relieve pressure, and follow the manual’s warnings before beginning shop work.

Critical Specifications

• Engine and fuel system: 248 cc, liquid-cooled DOHC two-cylinder engine with a 62.0 × 41.2 mm bore and stroke, 12.4:1 compression ratio, and twin Keihin CVK30 carburetors. The supplement specifies 0.10 mm intake and 0.13 mm exhaust valve clearance, 1,300 ±100 rpm idle speed, 17 mm float height, and a usable cylinder-compression range of 980–1,500 kPa. Standard, California, and high-altitude carburetor data are separated to prevent incorrect jetting or emissions-system setup.

• Cooling and lubrication: Covers coolant draining, filling and air bleeding, cooling-system pressure testing, radiator and cap checks, thermostat testing, water-pump repair, and fan-switch and temperature-sensor inspection. Oil quantities are distinguished as 1.5 L without filter removal, 1.6 L with the filter removed, and 1.9 L total capacity. The oil-pressure relief valve opens at 430–590 kPa, while running pressure must exceed 343 kPa at 4,000 rpm with the oil at 90°C.

• Clutch, crankshaft, and transmission: Clutch lever free play is 2–3 mm, friction-plate thickness is 2.9–3.1 mm with a 2.8 mm service limit, and standard plate warp is under 0.2 mm. Internal engine coverage includes crankcase splitting, crankshaft and connecting-rod inspection, Plastigage oil-clearance checks, color-coded bearing-insert selection, balancer timing, starter-clutch repair, drive and output shafts, shift drum, shift forks, gear backlash, gear dogs, and ball and needle bearings.

• Chassis and final drive: Front-fork data calls for SAE 10W-20 oil, 288 ±2.5 mL per completely dry leg or approximately 230 mL during an oil change, with the level set 205 ±2 mm below the top of the fully compressed inner tube without the spring. Rear-shock preload is non-adjustable. The manual also gives Uni-Trak, swingarm, tie-rod, rocker-arm, steering-head, wheel-bearing, tire, and wheel-balance repair data. Drive-chain slack is 35–40 mm, and the endless EK520 MV-O chain is checked by a 20-link wear measurement.

• Brakes and electrical systems: Brake coverage includes caliper and master-cylinder repair, pad and disc inspection, fluid replacement, line bleeding, and hose replacement. Pad lining is 4.35 mm standard with a 1 mm service limit. Electrical chapters cover charging-system output, regulator/rectifier testing, pickup and ignition coils, IC igniter diagnosis, starter-motor repair, lighting, cooling-fan circuits, gauges, switches, relays, diodes, and the junction box. Reference values include 100–150 Ω pickup-coil resistance and 14.0–15.0 V regulator/rectifier output.

Repair Procedures, Special Tools, and Shop Visuals

Factory procedures include carburetor synchronization and fuel-level setting, cylinder-head and valve-seat repair, camshaft timing, piston and ring service, clutch removal and inspection, oil-pressure testing, engine removal and installation, crankcase assembly, transmission inspection, fork disassembly and resealing, Uni-Trak needle-bearing service, steering adjustment, wheel and tire service, brake bleeding, and charging/ignition fault diagnosis. The appendix adds symptom-based troubleshooting for no-start, poor running, overheating, shifting faults, abnormal engine or drivetrain noise, oil-pressure warnings, unstable handling, and weak braking.

Named Kawasaki tools include Vacuum Gauge 57001-1198, Valve Adjuster 57001-1220, Oil Pressure Gauge 57001-164 with Adapter 57001-1188, Clutch Hub Holder 57001-303, Stem Nut Wrench 57001-1100, and Kawasaki Hand Tester 57001-983. Particularly useful visuals include the Engine Oil Flow Chart, Camshaft Chain Timing diagram, Cylinder Head Bolts Tightening Order, Valve Seat Repair flowchart, Evaporative Emission Control System layout, and full EX250-F2 Wiring Diagrams for US/Canada and UK/Australia models.

Several repair cautions are specific to this engine. The camshaft caps are machined with the cylinder head and must return to their marked positions; mixing them can damage the cam journals or head. Liquid gasket applied outside the indicated crankcase areas can obstruct an oil passage and cause engine seizure. The alternator rotor must not be struck during removal because impact can separate its internal magnets or reduce their magnetism.