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Kawasaki · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

EL 250

Library entry covers 1988-2001

35 factory 56 guideline

Published source

Kawasaki Werkstatthandbuch (EL 250 B), Stand November 1988, Inspektionstabelle pp.1-8 to 1-9 (ManualsLib.de 949946)

Factory workshop manual. Covers Kawasaki EL 250 B workshop manual, November 1988 (cover prints EL 250 B, the factory model code); later variants in the 1988-2001 row may differ.

91 items for a 1992 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

1992 Kawasaki EL 250

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 300 km

1 item

Drive chain (lubricate)

Final drive

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 300 km.

Every 800 km

1 item

Drive chain slack (check)

Final drive

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 800 km.

Every 1,600 km or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,600 km or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 1 month

2 items

Battery electrolyte level (check)

Ignition and electrics

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km. Or every month.
Brake fluid level (check)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km. Or every month.

Every 5,000 km or 12 months

13 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline
Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km

12 items

Engine vacuum synchronization (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km.
Evaporative emission system (check, California model)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).
General lubrication

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).
Idle speed (adjust)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km.
Spark plug (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).
Spark plug (clean)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).
Drive chain wear (check)

Final drive

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).
Steering (check)

Front end

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km.
Brake light switch (check)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km.
Brake pad or shoe wear (check)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. From 10,000 km every 5,000 km.
Brake play (check)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 5,000 km.
Tire wear (check)

Wheels and tires

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 5,000 km (5,000 to 30,000 km).

Every 6,500 km or 12 months

3 items

Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 9,500 km or 12 months

8 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Synchronize carburetors

Fuel and air

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km or 12 months

2 items

Engine oil (change)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km). Or every year.
Radiator hoses and connections (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km). Or every year.

Every 10,000 km

7 items

Nuts, bolts and fasteners (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km).
Oil filter (replace)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km).
Throttle grip play (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km).
Valve clearance (check)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000 km, then every 10,000 km (10,000, 20,000, 30,000 km).
Air filter (clean)

Fuel and air

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 1,000, 10,000 and 30,000 km.
Fuel system (check)

Fuel and air

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 10,000 km.
Swingarm bearings (lubricate)

Rear suspension and frame

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 10,000 km.

Every 13,000 km or 2 years

2 items

Check valve clearances (shim adjusted)

Engine

Guideline
Replace spark plugs

Engine

Guideline

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 19,500 km or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 20,000 km

1 item

Air filter element (replace)

Fuel and air

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Replace after 5 cleanings (at 20,000 km).

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 30,000 km

1 item

Fork oil (change)

Front end

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. At 30,000 km.

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

10 items

Coolant (change)

Engine

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Master cylinder primary cup and dust seal (replace)

Primary and gearbox

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Steering head bearings (lubricate)

Front end

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake caliper piston seal (replace)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Brake camshaft (lubricate)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Brake fluid (change)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 2 years.
Replace brake fluid

Brakes

Guideline

Every 4 years

5 items

Fuel hose (replace)

Fuel and air

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 4 years.
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Brake hoses (replace)

Brakes

Factory

Factory: Inspektionstabelle (Kawasaki Werkstatthandbuch EL 250 B, Stand November 1988, German, printed pp.1-8 and 1-9, translated; odometer columns 1,000, 5,000, 10,000, 15,000, 20,000, 25,000 and 30,000 km, plus time periods whichever comes first; at higher readings repeat the same periods). Items marked * renew, top up, adjust or tighten if necessary. Every 4 years.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.