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Kawasaki Z250 KZ305 1979-1982 Workshop Service Repair Manual

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The Kawasaki Z250 KZ305, produced from 1979 to 1982, represents a significant entry in the sport motorcycle segment, offering a blend of performance and reliability. This model, powered by an...
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Type: Motorcycle
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Sku: 144397
Kawasaki Z250 KZ305 1979-1982 Workshop Service Repair Manual
The Kawasaki Z250 KZ305, produced from 1979 to 1982, represents a significant entry in the sport motorcycle segment, offering a blend of performance and reliability. This model, powered by an air-cooled, 4-stroke, parallel-twin engine displacing 305cc, features a DOHC valve train and typically produces around 27-30 horsepower. Known for its robust engineering and accessible performance, the Z250 KZ305 was designed for riders seeking an engaging and dependable machine. Its semi-double cradle steel frame and straightforward mechanicals contributed to its reputation for durability and ease of maintenance, making it a popular choice for both commuting and recreational riding during its production era. This comprehensive workshop service repair manual provides in-depth coverage for the Kawasaki Z250 KZ305 across its production years. It details essential maintenance procedures, including oil changes, filter replacements, and chain adjustments, alongside thorough troubleshooting guides for common and complex issues. The manual covers all major systems, from engine overhaul and fuel system service to electrical diagnostics, brakes, suspension, and drivetrain. With hundreds of pages featuring detailed illustrations and step-by-step instructions, this English-language resource is an invaluable tool for Kawasaki Z250 KZ305 owners, independent mechanics, and DIY enthusiasts aiming to maintain, repair, and optimize their motorcycles.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Z250 KZ305
Model Years:
1979, 1980, 1981, 1982
Codes
Chassis Code Common:
KZ305
👋 Introduction
Market Position
Target Audience:
Kawasaki Z250 KZ305 owners, independent mechanics, DIY enthusiasts
Competitive Analysis
Value Proposition:
Cost-effective alternative to expensive dealer service, comprehensive DIY resource
Key Features
Content Detail:
Official factory specifications, hundreds of pages, detailed illustrations
Usability:
Searchable PDF, printable, easy navigation with numbered table of contents
📋 Manual Details
Coverage Areas
Covered Regions:
Global (factory specifications)
Page Count
Estimated Pages:
Hundreds (actual count not specified, but described as comprehensive)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnosis, tuning, internal components
Fuel System:
Carburetor(s) service and adjustment, fuel lines, fuel pump
Ignition System:
Ignition timing, points, coil, spark plugs, troubleshooting
Transmission:
Clutch, gearbox operation, internal components, maintenance
Drivetrain:
Final drive, chain, sprockets
Brakes:
Front and rear brake systems, hydraulic components, adjustment
Suspension:
Front forks, rear shock absorbers, linkage, servicing
Electrical System:
Wiring diagrams, lighting, charging system, starting system, troubleshooting
Frame And Bodywork:
Chassis, body panels, seat, fenders, mounting hardware
Wheels And Tires:
Tire sizes, pressures, wheel maintenance
Controls:
Throttle, clutch, brake levers, footpegs
Exhaust System:
Mufflers, pipes, mounting
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacement, chain adjustment
Troubleshooting:
Diagnostic procedures for common and complex issues
Repair:
Step-by-step repair instructions for all major components
Disassembly Assembly:
Complete disassembly and reassembly procedures
Engine Rebuild:
Detailed instructions for engine overhaul
Electrical Diagnosis:
Fault finding and repair of electrical circuits
Technical Depth
Depth:
Comprehensive (Do-it-yourself to experienced mechanic)
Detail Level:
Hundreds of photos, illustrations, and detailed sub-steps
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows and Mac operating systems
Print Quality
Printability:
Printable without restriction (entire manual or selected pages)
Binding Type
Delivery Method:
Digital Download
Physical Format Analogy:
Printable to create a physical bound manual
Paper Type
Digital Media Compatibility:
Can be burned to CD-ROM
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, DOHC, Parallel-Twin
Displacement:
305cc (often referred to as Z250, but model code KZ305 indicates displacement)
Bore X Stroke:
Typically around 53.0 x 56.0 mm (confirm with specific manual data)
Compression Ratio:
Typically around 9.2:1 (confirm with specific manual data)
Performance
Horsepower Output:
Approx. 27-30 HP (estimate based on era and displacement)
Torque Output:
Approx. 18-20 lb-ft (estimate based on era and displacement)
Fuel System
Carburetion:
Twin Mikuni VM or similar constant-velocity carburetors (e.g., VM26SS)
Fuel Capacity:
Typically around 13-14 liters (3.4-3.7 US gal)
Engine Components
Valve Train:
DOHC (Double Overhead Camshaft), 2 valves per cylinder
Cooling System:
Air-cooled
🔧 Transmission
Standard
Type:
6-speed constant mesh, foot-operated
Features
Clutch Type:
Wet, multi-plate, cable-actuated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase:
Approx. 1385 mm (54.5 inches)
Overall Length:
Approx. 2110 mm (83.1 inches)
Weights
Dry Weight:
Approx. 160-170 kg (353-375 lbs)
🛡️ Safety Features
Active Features
Braking System:
Front: Disc brake; Rear: Drum brake
Passive Features
Frame Type:
Semi-double cradle steel frame
💡 Technology Features
Infotainment
Features:
Basic analog instrumentation (speedometer, tachometer, fuel gauge, indicator lights)
Driver Assistance
Features:
None (pre-dates modern electronic rider aids)
Connectivity
Features:
None
🔧 Maintenance
Service Intervals
Oil Change:
Every 2,000-3,000 km or 6 months (refer to manual for precise intervals)
Spark Plug Service:
Inspect every 3,000 km, replace as needed
Chain Adjustment:
Check and adjust every 1,000 km or as needed
Fluid Specifications
Engine Oil Type:
API SE, SF, SG or JASO MA rated motorcycle oil, SAE 10W-40 or 20W-50 recommended
Engine Oil Capacity:
Approx. 2.0 - 2.5 liters with filter change (confirm with manual)
Brake Fluid Type:
DOT 3 or DOT 4 (confirm with manual)
Known Issues
Common Wear Items:
Carburetor diaphragms, clutch plates, fork seals, cam chain tensioner
Electrical Corrosion:
Corrosion in connectors and wiring due to age and exposure
Carburetor Tuning:
Requires periodic synchronization and cleaning for optimal performance
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries, Motorcycle & Engine Company
Model Evolution
Segment:
Sport motorcycle, entry-level performance
Production
Production Period:
1979-1982
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Historical Impact:
Part of Kawasaki's successful Z series, known for reliability and performance in its class
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