🏷️ Basic Information Identification Make: Kawasaki Model: EX250-H2 Year: 1991 Model Designation: Ninja 250R Codes Internal Chassis Code: EX250-H2 👋 Introduction Market Position Target Audience: DIY enthusiasts and professional mechanics working on the 1991 Kawasaki EX250-H2. Key Features Key Features: Detailed procedures, extensive diagrams, troubleshooting guide, service data, and special tool references. Value Proposition: Enables efficient, accurate, and safe repair and maintenance, ensuring reliability and longevity of the vehicle. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive repair and maintenance for the 1991 Kawasaki EX250-H2. Page Count Page Count: 125 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, assembly, inspection, and repair of the engine and its sub-components. Fuel System: Carburetor (model specific), fuel pump (if applicable), fuel lines, and tank servicing. Ignition System: CDI, spark plugs, ignition coils, and related wiring. Cooling System: Radiator, fan, coolant circulation, and related components (for liquid-cooled variants, though this model is air-cooled, the manual likely covers related heat dissipation). Exhaust System: Muffler, exhaust pipes, and mounting. Transmission Drivetrain: Clutch operation, gear shifting mechanism, chain drive, sprockets, and lubrication. Chassis Frame: Frame inspection, alignment, and repair procedures. Suspension Front: Front fork assembly, oil seals, springs, damping adjustments, and steering head bearings. Suspension Rear: Monoshock or twin-shock absorber (depending on specific EX250-H2 variant), swingarm, and linkage maintenance. Braking System: Front and rear brake systems (disc or drum), master cylinders, calipers, brake pads, fluid, and bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator/stator), lighting, horn, starter motor, and fuses. Wheels Tires: Wheel bearing inspection and replacement, tire pressure, and mounting/dismounting. Bodywork Trim: Fairings, fuel tank cover, seat, and other cosmetic components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustments, lubrication, and general inspection. Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues. Disassembly Assembly: Step-by-step instructions for removing and reinstalling major components and sub-assemblies. Adjustments: Carburetor synchronization, valve clearance adjustment, brake lever adjustment, clutch adjustment, and suspension settings. Rebuilds: Detailed procedures for overhauling engine components, carburetors, and brake systems. Special Tool Usage: Identification and application of specialized tools required for specific repair tasks. Technical Depth Technical Depth: Comprehensive, covering from basic adjustments to full engine and component rebuilds. Diagnostic Information: Included for effective troubleshooting. Service Data: Precise specifications, tolerances, and wear limits are provided. Illustrations: Detailed pictorial diagrams, exploded views, and photographs. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable Page Quality: High-resolution scans, ensuring clarity of text and diagrams. Binding Type Binding Type: Digital (PDF) Paper Type Paper Type Equivalent: N/A (Digital) Compatibility Software Requirement: Adobe Reader Operating Systems: Windows, Mac, Linux OS ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, parallel-twin, DOHC, 2 valves per cylinder Displacement: 249 cc (249 cubic centimeters) Bore X Stroke: 55.0 mm x 52.4 mm Cooling System: Air-cooled Performance Horsepower Est: Approx. 30-35 HP (at crank), depending on specific market tuning. Torque Est: Approx. 18-20 Nm (at crank) Fuel System Carburetion: Twin Keihin carburetors (e.g., CVK30 or similar) Fuel Type: Unleaded gasoline Engine Oil Oil Type Recommendation: Kawasaki recommends API SE, SF, SG or SH, JASO MA certified oil. Viscosity typically 10W-40 or 20W-50 depending on ambient temperature. Oil Capacity W Filter: Approximately 2.2 - 2.5 Liters (refer to manual for exact specification) Oil Filter Part Number Example: K&N KN-111, Hiflofiltro HF111 or equivalent OEM equivalent (e.g., 16097-1001). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Final Drive: O-ring sealed chain Transmission Oil Transmission Oil Type: SAE 80W API GL-4 (commonly used, refer to manual for Kawasaki specified oil) Transmission Oil Capacity: Approximately 1.0 - 1.2 Liters (refer to manual for exact specification) 📐 Dimensions Weights Dry Weight: Approx. 146 kg (322 lbs) Wet Weight: Approx. 154 kg (340 lbs) Exterior Length Overall: Approx. 2000 mm (78.7 in) Width Overall: Approx. 740 mm (29.1 in) Height Overall: Approx. 1100 mm (43.3 in) Wheelbase: Approx. 1365 mm (53.7 in) Ground Clearance: Approx. 150 mm (5.9 in) Wheels Tires Front Tire Size: 110/80-17 M/C 57H Rear Tire Size: 130/70-17 M/C 62H Wheel Type: Spoked or Alloy (depending on market/trim) 🛡️ Safety Features Ratings Safety Rating: N/A (Motorcycle Safety is assessed differently than cars, focus is on design and operational safety) Active Features Active Safety Features: Responsive braking system, balanced chassis dynamics for stable handling. Passive Features Passive Safety Features: Frame integrity, rider protection through ergonomics. 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle, focus is on mechanical and electrical systems). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first (refer to manual for precise interval). Chain Lubrication Interval: Every 500-1,000 km (300-600 miles) or after riding in wet conditions. Valve Clearance Check: Typically every 10,000-12,000...