1980 KZ250 service/repair manual

What is the difference between the two manuals?


Factory Service Manual Reprint

Factiry Service Manual

One is almost twice as the other. I am getting ready to tear down my KZ250 and rebuild it. The engine runs good, but has a good aweful noise to it. I thought it was the cam chain slopping around, but it looks good. I had a post from quite sometime ago on it, but cannot find it anymore. Thinking back, I think the sound started after my nephew took it for a 60 mile ride at around 50 - 60mph. I think during the ride, his tach cable came loose. I do not know if it has anything to do with it. I also noticed that the starter will sometime free spin and will not engage - it eventually does though. I am not able to pin-point if the noise is from the bottom or top. I have to say top. At any rate, trying to find a good manual and see if I can figure out what is going on. Perhaps the valves need adjusted.
I am also planning to clean up the carbs, polish up the engine, replace handle bars, lights, etc., put a new coat of paint and all that good stuff.

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It is a 1980 KZ250 LTD. I think it is a D2 - not sure though. I will have to check once I get home tonight.

FYI, I did put the year and model in subject line.

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Definitely find out what the last leters of the official model are.
If I recall, there is a 250 single, and a 250 twin. Obviously they would be quite different, so you'll want to make sure you have the right one. (They may not have been available at the same time 1980, or even in the same country.)

A reprint may be a pdf copy re-printed on someone's home computer.

You obviously want an original.

Mine is definitely a single. Does D1 or D2 refers single or twin? If so, then it should be D1.

I was amazed that the reprint is twice the cost. I will check out ebay as well.

+1 on an original FSM. I started with a downloaded copy but found pictures to be lacking. Found original FSM's on ebay for both of my KZ's.
On the owner info section of the Kawasaki website I was able to type my 1982's VIN in and found out it's a H3 not a H2 as DMV has it listed.

Scoured ebay and found a few with good price. But I am a bit confused....

This one says it is for a single. While this one says it is for 1980 only. Are the two the same? I shot a question to the seller, but thought I ask here as well. Since I only have the 1980 year bike, I rather have the manual with 1980 stuff only, assuming it will be in a bit more detail rather than craming the variances in different years into one manual.

If it's like my multi year FSM it would have same info as the single year. The other years would be as a supplements to the single year. Plus it may contain any changes the factory made on servicing the bike since the single year was printed.

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The number after the letter is just a sequence number referring to the year of production, not referring to any description of the bike. If 1980 was the D1, then likely 1981 was the D2.

In the U.S., in 1980 there was a KZ250 D1 single, and there's also mention of a KZ250G1 single, but I can't find any details on the G1.

Other parts of the world, in 1980, got a KZ250A1 twin standard, and a KZ250C1 single, which looks a little like a cross between a standard and an LTD.

This is according to some searches on google, kawasaki.com, and this site.

I think by the time the U.S. got these small twins, they had grown to 305cc, so wouldn't be KZ250's.

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Good Fortune!