1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual


SKU: R99924-1023-04 Category:


This 295 page, 1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1980-1983 KZ250 motorcycles. This rare book is out of print and only available as a high quality reproduction. If you are restoring or trying to keep one of these little bikes on the road this manual contains all the information you need to do it yourself.

This 1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual is designed primarily for use by Kawasaki motorcycle mechanics working in a properly equipped shop, although it contains enough detail and basic information to make it useful to the KZ250 owner who desires to carry out his own basic maintenance and repair work. Since a certain basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily; the adjustments, maintenance, and repair should be carried out only by qualified mechanics whenever the owner has insufficient experience, or has doubts as to his ability to do the work, so that the motorcycle can be operated safely. In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughly familiarizing himself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment is specified, makeshift tools or equipment should not be used. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation of the motorcycle. Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual Organization

This manual is divided into the following chapters:

(1) Adjustment The adjustment chapter gives the procedure for all adjustments which may become necessary periodically and which do not involve major disassembly.

(2) Disassembly This chapter shows the best method for the removal, disassembly, assembly, and installation which are necessary for maintenance and repair. Do not disassemble the component parts further than explained here. Since assembly and installation are usually the reverse of disassembly and removal, assembly and installation are not explained in detail in some cases. Instead, assembly notes and installation notes are provided to explain special points. In cases the removal procedures are apparent without explanation such as for the seat or side stand, no information is given.

(3) Maintenance The procedures for inspection and repair are described in detail in this chapter. An explanation on the structure and functioning of each of the major parts and assemblies, especially on one of new devices, is given to enable the mechanic to better understand what he is doing.

(4) Appendix The appendix in the back of this manual contains miscellaneous information, including a special tool list and a wiring diagram. (5) Supplement The maintenance and repair procedures, that are unique to later year units since the first publication of the Service Manual, are explained in this chapter per one year unit. Since the Service Manual is based on the first production units of KZ250-C, D, G, there may be minor discrepancies between some vehicles and the illustrations and text in this manual. Explanations on major changes and additions pertaining to later year units will be added in the end of the supplement by a new edition, as required.

1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual Vehicle Coverage

1983 Kawasaki Z250-W1 (UK)
1983 Kawasaki Z250-V1 (UK)
1983 Kawasaki Z250-R1 (UK)
1983 Kawasaki KZ250-W1 LTD
1983 Kawasaki KZ250-V1
1982 Kawasaki Z250-G3 (UK)
1982 Kawasaki Z250-C3 (UK)
1982 Kawasaki KZ250-M1
1982 Kawasaki KZ250-L1 CSR
1981 Kawasaki Z250-G2 (UK)
1981 Kawasaki Z250-D2 (UK)
1981 Kawasaki Z250-C2 (UK)
1981 Kawasaki KZ250-D2 CSR250
1980 Kawasaki Z250-C1 (UK)
1980 Kawasaki KZ250-D1 Ltd
1980 Kawasaki KZ Z250-G1 (UK)

1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual Table of Contents


Adjustment  of Engine and Chassis

Disassembly – Introduction
Engine (Installed)
Engine (Removed)

Maintenance & Theory




Index of Topics

1980-1983 Kawasaki KZ250 Motorcycle Repair Service Manual Topics Covered

Additional Considerations for Racing, Air Cleaner, Air Cleaner Element, Alternator, Alternator Rotor, Alternator Stator, Axle, Ball Bearing, Battery, Bearing, Engine, Steering Stem, Wheel, Brakes, Front, Rear, Brake Cable (Front), Brake Light, Brake Light Circuit, Brake Light Switch, Front, Rear, Breather (Oil), Bypass Valve, Cable, Clutch, Front Brake, Speedometer, Tachometer, Throttle, Camshaft, Camshaft Chain, Camshaft Chain Tensioner, Camshaft Sprocket, Capacitor, Carburetor, Chain, Camshaft, Drive, Starter Motor, Chain Guide (Camshaft), Chain Tensioner (Camshaft), Charging System, Circuit, Brake Light, Headlight, Starter Motor, Turn Signal, Clutch, Clutch (Starter motor), Clutch Cable, Clutch Release, Connecting Rod, Contact Breaker, Crankcase, Crankcase Split, Crankshaft, Cylinder Block, Cylinder Head, Drive Chain, Drive Shaft, Electric Starter System, Engine Lubrication, Engine Oil, Engine Oil Pump, Engine Performance Curves, Engine Perspective, Engine Removal, Engine Sprocket, External Shift Mechanism, Filter (Oil), Flow Chart, Disassembly-Chassis, Disassembly-Engine Installed, Disassembly-Engine Removed, Engine Removal, Front Brake, Front Brake Cable, Front Brake Light Switch, Front Fork, Front Hub, Front Wheel, Fuel System, Fuel Tank, Gear, Oil Pump Drive, Primary, General Lubrication, Grease Seals, Handlebar, Headlight, Headlight Circuit, Horn, Hub, Front, Rear, Ignition Coil, Ignition Switch, Ignition System, Ignition Timing, Indicator Lights, Introduction to Disassembly, Left Engine Cover, Lighting System, Light, Headlight, Indicator, Meter, Speedometer, Tachometer, Tail/Brake, Turn Signal, Lubrication (Chassis), Lubrication (Engine), Locking Agent Table, Meter Lights, Model Identification, Muffler, Needle Bearing, Neutral Switch, Oil Breather, Oil Filter, Oil Level, Oil Pump (Engine), Oil Pump Drive Gear, Oil Seals, Output Shaft, Overshift Limiter, Performance Curves, Engine, Running, Periodic Maintenance Chart, Pickup Coil Assembly, Piston, Piston Rings, Primary Gear, Rear Brake, Rear Brake Light Switch, Rear Hub, Rear Shock Absorbers, Rear Wheel, Rear Wheel Coupling, Rectifier, Regulator, Right Engine Cover, Rim, Rocker Arms, Inlet, Exhaust, Rocker Arm Shafts, Roller Bearing, Rotor (Alternator), Running Performance Curves, Shaft, Camshaft, Crankshaft, Drive, Output, Rocker Arm, Shift Drum, Shift Mechanism, Shift Mechanism (External), Shock Absorbers (Rear), Spark Plug, Special Tools, Specifications, Speedometer, Speedometer Cable, Speedometer Gear, Speedometer Light, Spokes, Sprockets, Camshaft, Engine, Rear, Starter Motor, Starter Motor, Starter Motor Chain, Starter Motor Circuit, Starter Motor Clutch, Starter (Alternator), Steering, Steering Stem, Steering Stem Bearing, Supplement, 1981 Model, 1982 Model, 1983 Model, Swing Arm, Switch, Brake Light, Front Brake Light, Ignition, Neutral, Rear Brake Light, Tachometer, Tachometer Cable, Tachometer Light, Tail Light, Tensioner (Camshaft Chain), Throttle Cable, Timing Advancer, Tires, Torque Table, Transmission, Tube, Turn Signal Assembly, Turn Signal Circuit, Trun Signal Light, Valves, Valve Clearance, Valve Guide, Valve Seat, Valve Springs, Wheels, Front, Rear, Wheel Balance, Wheel Bearings, Wheel Coupling, Wiring Diagram

Additional information

Weight 1.7 lbs
Dimensions 11 × 8.25 × 0.75 in

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