🏷️ Basic Information

Make:

Kawasaki

Model:

ZZR250

Model Code:

EX250-F

Generation Designation:

First Generation (J-model)

Chassis Code Range:

EX250F-000001 to EX250F-039999

Engine Code Range:

EX250FE000001 to EX250FE039999

👋 Introduction

Market Position:

The Kawasaki ZZR250 (EX250-F) was positioned as an entry-level sportbike, offering sporty styling and performance at an accessible price point, targeting younger riders or those seeking an economical daily commuter with a sporting character.

Competitive Analysis:

Competed directly with other 250cc class sportbikes of the era, such as the Honda CBR250RR (MC22), Yamaha FZR250R (3LN), and Suzuki GSX-R250 (GJ74A/GJ75A), offering a slightly different blend of performance, styling, and rider ergonomics.

Key Features:

Liquid-cooled parallel-twin engine, full fairing for aerodynamic efficiency, sport-tuned suspension, disc brakes front and rear, digital instrumentation (on some models/markets).

📋 Manual Details

Region Covered:

Global (primarily targeting markets where ZZR250 was officially sold, with potential applicability to similar model variants)

Page Count:

Approximately 400-500 pages (typical for comprehensive service manuals of this era)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered:

Engine (Top End, Bottom End, Cooling, Lubrication), Fuel System (Carburetor, Fuel Pump), Ignition System, Electrical System (Wiring Diagrams, Lighting, Starting, Charging), Clutch, Transmission, Drivetrain (Chain, Sprockets), Suspension (Front Forks, Rear Shock), Brakes (Front and Rear), Wheels and Tires, Frame, Bodywork, Troubleshooting, Specifications

Procedures Included:

Routine Maintenance, Engine Tune-up, Carburetor Adjustment and Rebuild, Valve Clearance Adjustment, Oil and Filter Change, Coolant Flush and Replacement, Brake Bleeding and Pad Replacement, Fork Seal Replacement, Shock Absorber Servicing, Electrical Component Testing, Troubleshooting Faults, Disassembly and Reassembly of major components, Torque Specifications for critical fasteners

Technical Depth:

Comprehensive, covering routine maintenance to complete engine and chassis overhauls. Includes diagnostic procedures and detailed repair instructions suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Yes (typically, if produced from a digitized original).

Print Quality:

High resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

4-stroke, Liquid-cooled, DOHC, Parallel-twin

Displacement:

249 cc

Bore X Stroke:

55.0 mm x 52.4 mm

Compression Ratio:

12.0:1

Horsepower:

Approximately 40-45 PS (29-33 kW) at 13,000 rpm (market dependent)

Torque:

Approximately 24-26 Nm (18-19 lb-ft) at 11,000 rpm (market dependent)

Carburetor Type:

Dual Keihin CVK32 carburetors

Fuel Tank Capacity:

17 Liters (approx.)

Ignition System Type:

Digital CDI

Lubrication Type:

Forced lubrication, wet sump

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet, multiple disc

Final Drive:

O-ring sealed chain

📐 Dimensions

Overall Length:

Approximately 2050 mm (80.7 in)

Overall Width:

Approximately 700 mm (27.6 in)

Overall Height:

Approximately 1135 mm (44.7 in)

Wheelbase:

Approximately 1400 mm (55.1 in)

Dry Weight:

Approximately 150-155 kg (331-342 lbs)

Curb Weight:

Approximately 170-175 kg (375-386 lbs)

Interior Dimensions:

N/A (Motorcycle)

Cargo Capacity:

N/A (Motorcycle, though some models may have provisions for small luggage racks)

🛡️ Safety Features

Safety Ratings:

N/A (Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP)

Active Safety Features:

Dual-piston front disc brake, single-piston rear disc brake, responsive suspension geometry.

Passive Safety Features:

Steel frame construction, full fairing for rider protection from elements and minor impacts.

💡 Technology Features

Infotainment Features:

N/A (Motorcycle of this era)

Driver Assistance Features:

N/A (Motorcycle of this era)

Connectivity Features:

N/A (Motorcycle of this era)

Instrumentation:

Analog speedometer and tachometer, fuel gauge, coolant temperature gauge, indicator lights (turn signals, oil pressure, high beam, neutral).

🔧 Maintenance

Oil Change Interval:

Every 3,000-4,000 km (1,800-2,500 miles) or 6 months, whichever comes first.

Valve Clearance Check Interval:

Every 10,000-12,000 km (6,000-7,500 miles).

Chain Lubrication Interval:

Every 800-1,000 km (500-600 miles) and after washing/rain.

Engine Oil Type:

API SG or higher, SAE 10W-40 or 20W-50 motorcycle specific oil.

Engine Oil Capacity:

1.7 Liters (approx.) without filter change, 1.9 Liters (approx.) with filter change.

Coolant Type:

Permanent type anti-freeze coolant (ethylene glycol based), mixed with distilled water (50/50 ratio).

Coolant Capacity:

Approximately 1.3 Liters (including reservoir)

Brake Fluid Type:

DOT 4

Known Issues:

Carburetor synchronization drift, potential for wear in the cam chain tensioner, occasional issues with the starter clutch, fork seal leaks, fuel tank corrosion (especially with ethanol-laced fuels if not managed properly).

Common Upgrades:

Upgraded exhaust systems for improved performance and sound, aftermarket air filters, braided stainless steel brake lines for enhanced braking feel.

📚 Vehicle History

Brand Heritage:

Kawasaki Heavy Industries has a long-standing reputation for building high-performance motorcycles across various categories, from sportbikes to cruisers and off-road machines, known for their engineering prowess and distinctive styling.

Model Evolution:

The ZZR250 (EX250-F) was part of Kawasaki's ZZR series, which aimed to offer sportbike aesthetics and performance. It succeeded earlier models like the GPZ250 and evolved into different iterations and markets. This specific generation (1990-1996) was a significant step in the 250cc sportbike segment.

Production Years:

1990-1996 (for the EX250-F model covered by this manual)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions:

N/A (Specific awards for this model are not widely documented, but it was a popular and well-regarded model in its class at the time of release.)

Performance Ratings:

Generally praised for its nimble handling, smooth engine operation, and competitive performance within the 250cc sportbike segment.

Certifications:

Compliant with emissions and safety standards of the respective markets it was sold in during the 1990-1996 production period.