EX250 parts diagrams

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These diagrams are the same as the ones on buykawasaki.com and the Ron Ayers parts fiche, but they're easier to use. (Of the two, Ron Ayers is usually easier to use than Kawasaki.)

The purpose of these diagrams is to let you see how everything goes together, and to get a lead on the part # that you might need. In all reality, Ron Ayers is a better place to look up part #s, as there is only part of the part # here; you'll need to look at Ron Ayers and get the second half.

Here's a short lesson on how Kawasaki part #s work. The first half tells what kind of part it is. The part after the dash (-) is the specific # for that bike. Let's take a typical replacement part: the clutch cable. You look on the 'cables' picture and see that it's #54011. Then look to the side, where all the numbers are listed (we don't have that bit) and see the extended #, 54011-1295. The EX500 for the same year is 54011-1340, and the ZX600 is 54011-1293.

Note that these images are for an EX250F8 (1994) model. This was the year before Kawasaki changed to CDI ignition, so some of the electronics drawings are not the same as on newer bikes.

Names used are from the Ron Ayers fiche, in ALL CAPS. Further explanation is (in parentheses). They are in alphabetical order, more or less. We hope that these diagrams will make it easier for you to figure out what goes where, and to put your cycle back together more efficiently.

1. AIR CLEANER (airbox) 2. CABLES 3. CARBURETOR PARTS 4. CARBURETOR

Airbox.jpg Cables.jpg Carb assy 1.jpg Carb assy 2.jpg

1. LABELS (caution stickers) 2. STAND(S) 3. RADIATOR (cooling system) 4. CAMSHAFT(S)/TENSIONER

Caution sticker locs.jpg Center side stands.jpg Cooling system.jpg Eng camshaft assy.jpg

1. CRANKCASE BOLT PATTERN 2. CRANKCASE 3. CLUTCH 4. CRANKSHAFT

Eng case assy 1.jpg Eng case assy 2.jpg Eng clutch assy.jpg Eng crankshaft rod assy.jpg

1. CYLINDER/PISTON(S) 2. GENERATOR 3. CYLINDER HEAD 4. ENGINE COVER(S)

Eng cylinder piston assy.jpg Eng electric magneto.jpg Eng head assy.jpg Eng side covers.jpg

1. TRANSMISSION 2. VALVE(S) 3. CYLINDER HEAD COVER 4. MUFFLER(S)

Eng trans assy.jpg Eng valve assy.jpg Eng valve cover assy.jpg Exhaust assy.jpg

1. FOOTRESTS 2. FRONT FORK 3. FRAME FITTINGS 4. ELECTRO BRACKET (frame brackets)

Footpegs.jpg Fork triples assy.jpg Frame.jpg Frame brackets.jpg

1. FRAME (steering head) 2. FRONT BRAKE 3. FRONT MASTER CYLINDER 4. FRONT WHEEL

Frame steering head.jpg Fr brake caliper.jpg Fr brake upper.jpg Fr wheel assy.jpg

1. FUEL EVAPORATIVE SYSTEM (CA emissions) 2. FUEL TANK 3. HANDLEBAR 4. HEADLIGHT(S)

Gas fuel calif emiss.jpg Gas tank fuel assy.jpg Handlebar perch control.jpg Headlight.jpg

1. IGNITION SYSTEM 2. IGNITION SWITCH/LOCKS/REFLECTORS 3. OIL PUMP/OIL FILTER 4. BRAKE PEDAL/TORQUE LINK

Ignition sys.jpg Keyed and misc.jpg Oil filter pump assy.jpg Rr brake asstd.jpg

1. REAR MASTER CYLINDER 2. REAR BRAKE 3. REAR WHEEL/CHAIN 4. SEAT

Rr brake assy 1.jpg Rr brake assy 2.jpg Rr wheel assy.jpg Seat assy.jpg

1. GEAR CHANGE MECHANISM 2. GEAR CHANGE DRUM/SHIFT FORK(S) 3. SUSPENSION/SHOCK ABSORBER 4. STARTER MOTOR

Shift trans assy 1.jpg Shift trans assy 2.jpg Shock linkage.jpg Starter assy.jpg

1. SWINGARM 2. TAILLIGHT(S) 3. TURN SIGNALS 4. WIRING DIAGRAM (see here)

Swingarm assy.jpg Taillight.jpg Turn signals.jpg Wiring harness.jpg