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MORIWAKI MD250H Service Manual

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MORIWAKI MD250H
SERVICE MANUAL

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  • Page 1 MORIWAKI MD250H SERVICE MANUAL...

  • Page 3: General Information

    Fuel: Unleaded high-octane gasoline Be sure to install the fuel tank cap and breather tube before ride. Coolant MD250H uses water for its engine cooling system. Remove the radiator cap and fill the radiator with coolant water up to the filler neck.
  • Page 4 GENERAL INFORMATION 6． Remove the radiator cap and start the engine when it is cold. Check the coolant flow at the filler neck (coolant will not flow if there is trapped air in the system). Stop the engine and re-check the coolant level.
  • Page 5 GENERAL INFORMATION Break-in ride First break-in ride Keep the engine rev constant at the specified rpm during break-in ride. Shift speed up and down below the specified rpm. Use relatively high gears and observe function of each part. Use 4 to 5 speed gears when riding through straight section of circuit tracks. Up to 7,000rpm……………...
  • Page 6 GENERAL INFORMATION Operation system Clutch Check the clutch lever free play at the lever end. Free play: 10 – 20mm Minor adjustments can be made at the cable end adjuster on the lever. Turning the cable end adjuster in direction A will increase free ・...
  • Page 7 GENERAL INFORMATION Brake pedal height Adjust the brake pedal to the desired height by loosening the lock nut and turning the push rod. Apply grease to the brake pedal axle at every ride. (1) Lock nut (2) Adjuster (A) Pedal goes higher (B) Pedal goes lower Gear shift linkage The change pedal height can be adjusted by changing the length of the change rod.
  • Page 8 GENERAL INFORMATION Steering damper The steering damper damping force can be adjusted by its adjuster. The damping force is adjusted in 7steps. The damping force increases as turning the adjuster clockwise and obtain the maximum damping force at the turning end. The damping force decrease as turning the adjuster counter-clockwise.

  • Page 9: Service Information

    SERVICE INFORMATION Service specification Unit: mm ITEM STANDARD SERVICE LIMIT HONDA Ultra-G1 (4-stroke LUBRICATION Recommended transmission oil motorcycle oil) SYSTEM HONDA Ultra-G1 (4-stroke Recommended engine oil SPECIFICATIONS motorcycle oil) FUEL SYSEM Venturi diameter SPECIFICATIONS Carburetor identification number FCR12C A Float level Main jet #160 Slow jet...

  • Page 10: Specification

    SERVICE INFORMATION ITEM STANDARD SERVICE LIMIT WHEEL/TIRE Cold tire pressure FRONT 1.8kgf/c ㎡ － SPECIFICATION REAR 1.9kgf/c ㎡ － Axle runout 0.5ｍｍ － Wheel rim runout Radical 0.3ｍｍ － Axial 0.3ｍｍ － Drive chain slack 20ｍｍ±2ｍｍ － Drive chain slider thickness 2.0ｍｍ...

  • Page 11: Tightening Torque Values

    SERVICE INFORMATION Tightening torque values Engine THREAD TORQUE ITEM DIA.(mm) N･m(kgf･m) REMARKS Engine oil drain bolt 16 (1.6) Apply engine oil ８ １ Transmission oil drain bolt 16 (1.6) Apply engine oil ８ １ Timing hole cap 6.0 (0.6) Apply grease １４...
  • Page 12 SERVICE INFORMATION FRAME THREAD TORQUE ITEM DIA.(mm) N･m(kgf･m) REMARKS Engine mounting bolt (1 crankcase bolt) 41.2(4.2) Apply grease Steering thread 6(0.6) Apply oil Steering stem bolt 59(6.0) Apply grease Top / bottom bridge pinch bolt 23(2.3) Axle nut 69(7.0) Apply grease Axle holder bolt 22(2.2) Fork bolt...

  • Page 13: Lubrication & Seal Points

    SERVICE INFORMATION LUBRICATION & SEAL POINTS ENGINE ITEM LOCATION MATERIAL Camshaft Cam lobe, journal Molybdenum oil solution Rocker arm Shaft, slipper surface (mixture of the engine oil and Valve stem Valve guide sliding surface, stem end molybdenum grease with the ratio Valve lifter Outer surface 1：1)
  • Page 14 Master cylinder pivot sliding area / piston contact area Silicone grease Rear brake caliper pin bolt Rear brake caliper piston seal Silencer joint area Heat resistant sealing agent (ME30) MORIWAKI Drive chain slider screw threads Locking agent Steering thread Honda Ultra U Handle grip / Throttle pipe...

  • Page 15: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE Perform maintenance operation according to following chart to obtain performance of your MD250H. The maintenance schedule may differ depending on condition of use. Machines subjected to severe use require more frequent servicing. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. L: Lubricate FREQUENCY 　　　　　...

  • Page 16: Post-Ride Inspection

    ・Parts replacement schedule is based upon sprint race conditions and therefore, it is reference for your use. Machines subjected to severe use require more frequent replacement operation. MORIWAKI ENGINERRING is not responsible for lifetime of any periodic replacement parts or consumables.

  • Page 17: Engine Oil / Oil Filter

    MAINTENANCE Engine oil / Oil filter Oil level inspection C A U T I O N ・Support the machine upright on a level surface when you perform oil level inspection or adding oil. ・Be aware that the engine and the transmission have individual lubrication systems.
  • Page 18 MAINTENANCE Engine oil / Oil filter change Note It is easier to drain the engine oil when it is warm. Start the engine and let it idle for 3 minutes. Stop the engine and support the machine upright on a level surface. Remove the oil filler cap / level gauge.
  • Page 19 MAINTENANCE Apply grease to the filter side of the spring end, then install the spring into the new oil filter. Spring Oil filter Install the oil filter assembly. C A U T I O N “OUT SIDE” mark O-ring Be sure to install the oil filter with the “OUTSIDE” mark facing out Apply engine oil to a new O-ring and install it to the oil filter cover.

  • Page 20: Transmission Oil

    MAINTENANCE Transmission oil Transmission oil level inspection C A U T I O N ・Support the machine upright on a level surface when you perform oil level inspection or adding oil. ・Be aware that the transmission and engine have individual lubrication systems. Start the engine and let it idle for 3 minutes.

  • Page 21: Oil Catch Tank

    MAINTENANCE Oil catch tank Oil catch tank is build-in to the left hand side of the main frame. Insert the breather tube of the crankcase to the carburetor box attachment. Remove the drain bolt to drain any oil left in the oil catch tank before ride.

  • Page 22: Spark Plug

    MAINTENANCE Coolant overflow catch tank Coolant overflow catch tank is attached on right hand side of the main frame with tei-wraps. Make sure to put an end of the overflow tube into the catch tank. Drain any coolant in the catch tank by taking it off from the frame before ride.
  • Page 23 MAINTENANCE Clutch Check the smooth operation of the clutch lever. Apply grease to the pivot bolt and the clutch cable if necessary. Inspect the clutch cable for damage. (1) Clutch lever Fuel tank / Fuel strainer D A N G E R DENGER Gasoline is explosive.
  • Page 24 MAINTENANCE Thermometer Cover a part of radiator front with packing tape in case the water temperature gets too low during running Appropriate temperature: 70－80℃ “888” will comes on for 3sec on the water temperature indicator when you turn on the main switch to “RUN”, then it will start indicating actual water temperature.

  • Page 25: Drive Chain Slack Adjustment

    MAINTENANCE Drive chain slack adjustment Loosen the rear axle nut. Turn the drive chain adjust bolt and adjust the chain slack. Turn the adjust bolt counter-clockwise to reduce the amount of chain slack C A U T I O N Improper drive chain slack will lose not only the engine power but also the motorcycle running performance.

  • Page 26: Drive Chain Slider

    MAINTENANCE Handle is straight. Equalize the [a] and [a’] appearance Drive chain slider Inspection Check the chain slider for wear or damage. Replace with new one if 2mm or more wear is noticed. When you install a new drive chain slider, apply locking agent to the screw and tighten it.

  • Page 27: Brake Fluid

    MAINTENANCE Driven sprocket change Remove the rear wheel. Remove the driven sprocket collar, driven sprocket and washer. Reverse sequence to install the driven sprocket. ※It may require shim adjustment at installation. Adjust the drive chain slack. Check the alignment of the wheels. (1) Driven sprocket (2) Sprocket washer Advice ・Make sure to check the driven sprocket nut tightening...

  • Page 28: Brake Pads

    MAINTENANCE Brake pads Visually check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Use genuine HRC brake pads. (1) Brake pads Brake system Brake lever position adjustment. （⇒1-4） Brake pedal height adjustment.

  • Page 29: Wheels, Tires

    MAINTENANCE Handle bar / Head pipe bearings Handle bar Check the handle bars for bend, crack and damage. Confirm that the handle bars are on appropriate position. Handle bar position: Touching the fork top bridge bottom Make sure that the flange bolts of handle holder and fork top bridge are securely tightened.

  • Page 30: Front Suspension

    MAINTENANCE Front suspension 1. Inspect slide pipes and oil seals for dirt. 2. Check the entire assembly for signs of fork oil leaks. Replace the oil seals with new ones before ride in case oil leak is detected. 3. Check the action of the forks by operating the front brake and compressing the front suspension several times.

  • Page 31: Rear Suspension

    MAINTENANCE Rear Suspension The swing arm is operated with a single suspension unit with a reservoir chamber which contains oil and nitrogen gas. The rear suspension is adjustable. Suitable settings for different condition can be obtained by performing following adjustment procedure.
  • Page 32 MAINTENANCE Wire-lock Be sure to wire-lock the transmission oil drain bolt, oil filler cap, oil filter cover bolt , engine oil drain bolt, oil catch tank drain bolt and brake caliper bolt before ride. Put a wire through the hole of bolt head and twist the wire with the wire-twister.
  • Page 33 MAINTENANCE (1) Engine oil filler cap / Level gauge (1) Engine oil drain bolt (2) Oil filter cover bolt (1) Transmission oil filler cap (1) Transmission oil drain bolt (1) Water pump cover bolt (1) Oil catch tank drain bolt (2) Transmission oil check bolt (1) Brake caliper bolt PRINT EDITION 2.1...

  • Page 34: Engine Maintenance

    ENGINE MAINTENANCE Carburetor removal DENGER D A N G E R Gasoline is flammable and explosive. Work area must be free from flames or sparks. Perform this operation in a well Bolt ventilated area. Vaporized gasoline can cause an explosion. Adjusting bolts Remove the following parts;...
  • Page 35 ENGINE MAINTENANCE Remove the bolts, wire clamp, top cover and O-ring. Bolts Wire clamp O-ring Top cover Remove the jet needle / holder assembly. Needle holder Jet needle Remove the needle clip from the jet needle, then remove Jet needle the collar, spring and needle holder.
  • Page 36 ENGINE MAINTENANCE Remove the throttle valve plate and roller from the throttle Throttle valve valve. Check the throttle valve, throttle valve plate for wear or damage, and replace them if necessary. They must be replaced as a Throttle valve assembly. Valve plate Roller SE valve / Throttle position sensor...
  • Page 37 ENGINE MAINTENANCE Remove the screw and throttle stop screw stay. Throttle stop screw stay Screws Remove the 4 screws, hose guides, float chamber and O-ring. Float chamber Hose guide O-ring Pull out the push rod while holding the push rod link lever. Push rod Adjusting screw C A U T I O N...
  • Page 38 ENGINE MAINTENANCE Inspect the following parts; Float valve － Float for damage, and replace it with new one if necessary. － Float valve and valve seat for scores, scratches, clogging or damage, and clean of replace them if necessary － Tip of the float valve where it contacts the valve seat for wear, and replace it if necessary.
  • Page 39 ENGINE MAINTENANCE Set plate Remove the socket bolts and set plate. Socket bolt Blow open all carburetor body openings with compressed air. Carburetor assembly Throttle position sensor Install the throttle position sensor by aligning its tabs with the float side of the shaft as shown. Apply locking agent to the torx screw threads and tighten it by fingers.

  • Page 40: Float Level Inspection

    ENGINE MAINTENANCE Pilot screw Baffle plate Install the O-ring, washer, spring and pilot screw. Slow jet Main jet C A U T I O N Install the pilot screw and return it to its original position as noted during removal. Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat.
  • Page 41 ENGINE MAINTENANCE Install the push rod while holding the push rod link lever. Link lever Push rod Bypass jet Install the accelerator pump bypass jet into the float chamber and tighten to the specified torque. Torque: 0.3 N･ｍ (0.03 kgf･ｍ) Install a new O-ring to the float chamber.
  • Page 42 ENGINE MAINTENANCE O-rings Install the diaphragm, spring, new O-ring and accelerator pump cover, and tighten the screws to the specified torque. Torque: 2.1 N･m (0.2 kgf･ｍ) Spring Diaphragm SE valve Install the SE valve and tighten the lock nut to the specified torque.
  • Page 43 ENGINE MAINTENANCE Install the jet needle through the needle holde r, sp ring and collar. Needle holder Install the needle clop to the jet needle groove. Spring Standard clip position: 4th position from the top. Clip Collar Jet needle Install the jet needle holder into the throttle valve and Needle holder tighten it to the specified torque.

  • Page 44: Carburetor Installation

    ENGINE MAINTENANCE Adjusting bolt Bolt Carburetor installation Connect the throttle cables to the throttle drum. Install the throttle cable to the cable holder and tighten the lock nut. Install the throttle drum cover and bolt and tighten it to the specified torque.
  • Page 45 ENGINE MAINTENANCE Engine removal Remove the following parts; － Cowl assembly － Fuel tank － Battery terminal (－disconnect the terminals) － Radiator hose － Muffler assembly － Seat rail assembly － Carburetor － Carburetor box － Shift guide plate － Gear change arm －...
  • Page 46 ENGINE MAINTENANCE Engine installation Apply grease to the threads of the swing arm adjust bolt. Install the swing arm adjust bolt to the frame. Do not tighten the swing arm adjust bolt yet. The tip of the swing arm adjust bolt should not come out from inner side of the frame to avoid having it interfering with the swing arm.

  • Page 47: Component Location

    CYLINDER HEAD/VALVES COMPONENT LOCATION PRINT EDITION 2.1 4-14...

  • Page 48: Service Information

    CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL ･ This section covers service of the camshaft, cylinder head and valves. These services can be done with the engine installed in the frame. ･ During disassembly, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. ･...
  • Page 49 CYLINDER HEAD/VALVES TOOLS Valuve guide driver，5.0ｍｍ Vaive spring compuressor Valve spring compressor attach-ment 07942-MA60000 07757-0010000 07JME-KY20100 Valuve guide remer，5.0mm Valuve seat cutter，33mm(45°IN) Valuve seat cutter，27.5mm(45°EX) 07984-MA60001 07780-0010800 07780-0010200 Flat cutter，33mm(32°IN) Interior cutter，37.5mm(60°IN) Flat cutter，28mm(32°EX) 07780-0014100 07780-00129-00 07780-0012100 Interion cutter，30mm(60°EX) Cutter holder，5.0mm Tappet hole protector 07780-0014000 07780-0010400...

  • Page 50: Troubleshooting

    CYLINDER HEAD/VALVES TROUBLESHOOTING ･ Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing top-end noise with a sounding rod or stethoscope. ･ If the performance is poor at low speeds, check for white smoke in the crankcase breather hose. If the hose is smoky, check for a seized piston ring. Compression too low, hard starting or poor performance at low speed ･...

  • Page 51: Cylinder Compression Test

    CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Remove the fuel tank. Warm up the engine. Stop the engine and remove the spark plug . Connect a compression gauge. TOOL: Compression gauge attachment 07RMJ-MY50100 Open the throttle all the way and crank the engine Make sure the with the starter motor until the gauge reading stops compression...

  • Page 52: Camshaft/Rocker Arm Removal

    CYLINDER HEAD/VALVES Remove the plug hole seal. CAMSHAFT/ROCKER ARM REMOVAL Remove the cylinder head cover. The decompressor cam will be disassembled later, loosen the stopper plate bolt, but do not remove it yet. Remove the crankshaft hole cap and O-ring Turn the crankshaft clockwise to align the punch mark on the primary drive gear with the index mark on the right crankcase cover.
  • Page 53 CYLINDER HEAD/VALVES Remove the cam chain tensioner lifter bolt and sealing washer. Turn the cam chain tensioner lifter shaft clockwise If a special tool is fully and secure it with the special tool. not available, refer to the next step to make an alternative TOOL: tool.

  • Page 54: Rocker Arm

    CYLINDER HEAD/VALVES Remove the valve lifters from the cylinder head. ･ Shims may stick to the inside of the valve lifters. Do not allow the shims to fall into the left crankcase. ･ Mark the valve lifters to ensure correct reassembly in their original locations.
  • Page 55 CYLINDER HEAD/VALVES DISASSEMBLY Remove the bolt, stopper plate, decompressor weight, spring and bearing. INSPECTION If the camshaft Inspect the camshaft contact surface of the rocker contact surface of the rocker arm is arm for wear or damage. damaged or Inspect the rocker arm oil passage for clog.
  • Page 56 CYLINDER HEAD/VALVES Check the decompressor weight for bend or damage. Check the decompressor weight cam area for wear or damage. Temporarily install the spring and decompressor weight into the camshaft. Check the decompressor cam spring for damage or fatigue. Check the smooth operation of the decompressor system, and replace if necessary.

  • Page 57: Cylinder Head Removal

    CYLINDER HEAD/VALVES ASSEMBLY Install the bearing with its ring groove facing out side. Apply oil to the decompressor weight sliding area. Install the spring and decompressor weight into the camshaft. Align the spring end and decompressor cam as shown. Clean the decompressor cam stopper plate bolt threads and apply a locking agent.
  • Page 58 CYLINDER HEAD/VALVES Remove the cylinder head mounting bolts. Loosen the cylinder mounting bolt. Be careful not to let Loosen the cylinder head nuts in a crisscross pattern in two or three the nuts and steps. washers fall into the Remove the nuts, washers and cylinder head. left crankcase.

  • Page 59: Cam Chain Tensioner/Cam Chain Guide

    CYLINDER HEAD/VALVES CAM CHAIN TENSIONER/CAM CHAIN GUIDE REMOVAL Remove the following: - Cylinder head - Left crankcase cover - Flywheel Remove the cam chain guide Remove the bolt, collar, washer and cam chain tensioner INSPECTION Inspect the cam chain tensioner and cam chain guide for excessive wear or damage, replace if necessary.

  • Page 60: Cylinder Head Disassembly

    CYLINDER HEAD/VALVES INSTALLATION Clean the cam chain tensioner bolt threads and apply a locking agent. Install the washer, cam chain tensioner, collar and bolt. Tighten the bolt to the specified torque. TORQUE: 12 N･m (1.2 kgf･m, 9 lbf･ft) Install the cam chain guide by aligning the guide end with the groove in the crankcase and the tab with the groove in the cylinder.

  • Page 61: Cylinder Head Inspection

    CYLINDER HEAD/VALVES An equivalent tool can easily be made from a plastic 35 mm (1.4 in) film container as shown. Remove the valve spring cotters using the special tools. To prevent loss of tension, do not compress the valve springs more than TOOLS: necessary to...

  • Page 62: Valve Spring

    CYLINDER HEAD/VALVES Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) Check the valve lifter bore for scoring, scratches or damage. Measure each valve lifter bore I.D. SERVICE LIMIT: 22.54 mm (0.887 in) VALVE SPRING Check the valve springs for fatigue or damage.

  • Page 63: Valve Guide Replacement

    CYLINDER HEAD/VALVES Ream the valve guide to remove any carbon buildup before measuring the guide. Insert the reamer from the combustion chamber side of the cylinder head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 5.0 mm 07984-MA60001 Measure and record each valve guide I.D.

  • Page 64: Valve Seat Inspection/Refacing

    CYLINDER HEAD/VALVES While the cylinder head is still heated, drive new valve guides into the cylinder head from the top of the cylinder head (camshaft and rocker arm side). Remove the guides from the freezer. Drive in the guides until the marks are parallel with the cylinder head.

  • Page 65: Valve Seat Refacing

    CYLINDER HEAD/VALVES Inspect the valve seat face for: ･ Uneven seat width: - Replace the valve and reface the valve seat. ･ Damaged face: - Replace the valve and reface the valve seat. The valves ･ Contact area (too high or too low) cannot be - Reface the valve seat.
  • Page 66 CYLINDER HEAD/VALVES Reface Use a 45° seat cutter, remove any roughness or the seat irregularities from the seat. with a ° cutter TOOLS: whenever 07780-0010800 Seat cutter, 33 mm (IN) a valve guide is 07780-0010200 Seat cutter, 27.5 mm (EX) 07781-0010400 Cutter holder, 5.0 mm Use a 32°...

  • Page 67: Cylinder Head Assembly

    CYLINDER HEAD/VALVES INTAKE SIDE: After refacing, wash the cylinder head and valve. Do not clean the intake valves with sand papers. C A U T I O N ･Do not lap the intake valves. They are titamium and have a thin oxide coating.
  • Page 68 CYLINDER HEAD/VALVES Blow out all oil passages in the cylinder head with compressed air. Install the spring seat and new stem seal. Lubricate the valve stem and stem end sliding surface with molybdenum oil solution. Insert the valve into the guide while turning it slowly to avoid damage to the stem seal.

  • Page 69: Cylinder Head Installation

    CYLINDER HEAD/VALVES Tap the valve stems gently with two plastic hammers Support the cylinder head so as shown to seat the cotters firmly. the valve heads do not contact anything that may damage them. Install the insulator aligning its groove with the lug on the cylinder head.
  • Page 70 CYLINDER HEAD/VALVES Install the cylinder head onto the cylinder. Apply oil to the cylinder head nut threads and seating surface. Install the washers and cylinder head nuts. Tighten the nuts in a crisscross pattern in two or Be careful not three steps to the specified torque.

  • Page 71: Camshaft/Rocker Arm Installation

    CYLINDER HEAD/VALVES CAMSHAFT/ROCKER ARM INSTALLATION ROCKER ARM Apply molybdenum oil solution to the rocker arm bore and slipper surfaces. Install the rocker arm and rocker arm shaft while aligning the camshaft holder bolt holes with the rocker arm shaft holes. Check that the O-ring is in good condition, and replace if necessary.
  • Page 72 CYLINDER HEAD/VALVES Turn the crankshaft clockwise to align the punch mark with the index mark on the right crankcase cover. Make sure the piston is at T.D.C. (Top Dead Center). Do not get Apply molybdenum oil solution to the cam lobes. molybdenum oil Install the cam chain onto the cam sprocket, then solution on the...
  • Page 73 CYLINDER HEAD/VALVES Install the camshaft holders in their proper position Be careful not to let the by aligning the camshaft bearing groove with the set rings fall set ring. into the Apply oil to the camshaft holder bolt threads and seating surface.

  • Page 74: Cylinder Head Cover Installation

    CYLINDER HEAD/VALVES Check that the O-ring is in good condition, replace if necessary. Apply transmission oil to the O-ring and install it onto crankshaft hole cap. Apply grease to the crankshaft hole cap threads. Install the crankshaft hole cap and tighten it to the specified torque.
  • Page 75 CYLINDER HEAD/VALVES Install the cylinder head cover and tighten the bolts to the specified torque. TORQUE: 10 N･m (1.0 kgf･m, 7 lbf･ft) Connect the cylinder head breather hose. Install the direct ignition coil. Install the fuel tank . PRINT EDITION 2.1 4-42...

  • Page 76: Component Location

    CYLINDER/PISTON COMPONENT LOCATION 4-43 PRINT EDITION 2.1...
  • Page 77 CYLINDER/PISTON SERVICE INFORMATION GENERAL ･ This section covers maintenance of the cylinder and piston. These procedures can be done with the engine installed in the frame. ･ Before disassembly, clean the engine thoroughly to prevent dirt from entering it. ･ Be careful not to damage the mating surfaces when removing the cylinder. For example, do not use a screwdriver to pry the cylinder. ･...

  • Page 78: Cylinder Removal

    CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head. Remove the bolts, cam chain tensioner lifter and gasket. Remove the mounting bolt and cylinder. Prevent the cam Remove the dowel pins and gasket. chain from falling into the crankcase. PISTON REMOVAL Place a clean Remove the piston pin clips with pliers.
  • Page 79 CYLINDER/PISTON Spread the piston rings and remove them by lifting Piston rings up at a point just opposite the gap. are easily broken; take care not to damage them during removal. CYLINDER/PISTON INSPECTION CYLINDER Inspect the cylinder bore for wear or damage. Measure the cylinder I.D.
  • Page 80 CYLINDER/PISTON PISTON/PISTON RING INSPECTION Remove the carbon deposits from the piston head Clean carbon deposits and piston ring grooves. from the ring Inspect the piston for damage, and the ring grooves grooves with a for wear. ring that will be discarded, never use a wire brush;...

  • Page 81: Connecting Rod Inspection

    CYLINDER/PISTON Insert each piston ring into the cylinder and measure Push the ring into the the ring end gap. cylinder with the top of the piston to be SERVICE LIMITS: sure the ring Top: 0.39 mm (0.015 in) is squarely in Oil (side rail): 0.90 mm (0.035 in) the cylinder.

  • Page 82: Piston Ring

    CYLINDER/PISTON PISTON RING Clean the piston ring grooves thoroughly. Apply oil to the piston rings and install them onto Install the the piston. top ring with ･Do not damage the piston ring by spreading the the marked side facing ends too far. ･Be careful not to damage the piston during piston ring installation.

  • Page 83: Cylinder Installation

    CYLINDER/PISTON CYLINDER INSTALLATION Install the dowel pins. Install a new cylinder base gasket on the crankcase. Coat the cylinder bore, piston and piston rings with Avoid piston ring damage during oil and install the cylinder while compressing the installation. piston rings. Install the cylinder mounting bolt.

  • Page 84: Clutch /Starter Clutch/Gearshift Linkage

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 4-51 PRINT EDITION 2.1...

  • Page 85: Specifications

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL ･ This section covers service of the clutch, starter clutch, and gearshift linkage. All service can be done with the engine installed in the frame. ･ Transmission oil viscosity and level have an effect on clutch disengagement. Oil additives also affect clutch performance and are not recommended.
  • Page 86 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Hard to shift ・Improper clutch operation ・Improper oil viscosity ・Bent shift fork claw ・Bent shift fork shaft ・Incorrect clutch adjustment ・Loose guide plate bolt ・Damaged shift drum center and pin Transmission jumps out of gear ・Worn or damaged shift drum stopper arm ・Weak or broken shift drum stopper arm return spring ・Loose guide plate bolt...

  • Page 87: Right Crankcase Cover

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the coolant. Drain the transmission oil. -Loosen the hose band screw and disconnect the radiator hose from the water pump cover. RADIATOR HOSE Loosen the right crankcase cover bolts in a crisscross pattern in two or three steps.

  • Page 88: Installation

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install a new O-ring onto the by-pass pipe. Install the by-pass pipe into the crankcase Install the dowel pins and a new gasket Make sure that the plain washer is installed onto the water pump shaft. Install the right crankcase cover while engaging the water pump driven gear with the water pump drive gear.
  • Page 89 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Connect the radiator hose to the water pump cover and tighten the hose band screw securely. Install the following: Fill the cooling system with the recommended coolant and bleed the air. Fill the transmission with the recommended transmission oil.
  • Page 90 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Remove the friction spring and spring seat. Bend the tabs of the lock washer away from the lock nut. Remove the clutch center lock nut using the special tool. TOOL: Clutch center holder 07724-0050001 or 07724-0050002 Remove the lock washer and thrust washer Remove the clutch center.
  • Page 91 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Disconnect the clutch cable from the clutch lifter lever. Remove the clutch lifter lever from the left crankcase. INSPECTION CLUTCH SPRING Measure the clutch spring free length. Clutch springs should be SERVICE LIMIT: 38.0 mm (1.50 in) replaced as a set if one or more is less...

  • Page 92: Clutch Center

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE FRICTION SPRING/SPRING SEAT Check the friction spring and spring seat for deformation, warpage or damage, and replace if necessary. ･ A damaged or warped spring seat will cause the friction spring to be pressed unevenly. ･ A damaged friction spring also causes the weak contact between the discs and plates or uneven disc/plate contact.

  • Page 93: Clutch Lifter

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE CLUTCH Check the clutch outer for nicks, indentations or abnormal wear made by the clutch discs. Check the serrated teeth of the primary driven gear for wear or damage. NEEDLE BEARING/CLUTCH Check the needle bearing for wear or damage. Check the mainshaft for wear or damage at the sliding surface of the clutch outer guide.
  • Page 94 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION Connect the clutch cable end to the clutch lifter lever. Install the clutch lifter lever into the left crankcase. Apply molybdenum oil solution to the clutch outer guide sliding surface. Apply transmission oil to the needle bearings. Install the clutch outer guide and needle bearings onto the mainshaft.
  • Page 95 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Apply transmission oil to the clutch outer sliding surface. Install the clutch outer and thrust washer. Install the clutch center onto the mainshaft. Install the thrust washer. Install a new lock washer by aligning its groove with the clutch center rib.
  • Page 96 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Coat the clutch plates and discs with clean transmission oil. Install the spring seat and friction spring as shown. Install the clutch disc B (large I.D. disc). Stack the clutch plates and disc A alternately. Apply transmission oil to the clutch lifter assembly and clutch lifter rod contact surface.
  • Page 97 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Install and tighten the cover bolts in a crisscross pattern in two or three steps. TORQUE: 10 N･m (1.0 kgf･m, 7 lbf･ft) Install the brake pedal. Adjust the clutch lever free play . Fill the engine with the recommended transmission oil Start the engine and check for oil leaks.
  • Page 98 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Check the kickstarter idle gear for wear or damage. Measure the kickstarter idle gear I.D. SERVICE LIMIT: 17.06 mm (0.672 in) Measure the countershaft O.D. at the idle gear sliding surface. SERVICE LIMIT: 16.97 mm (0.668 in) ASSEMBLY PRINT EDITION 2.1 4-65...
  • Page 99 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Apply molybdenum oil solution to the kickstarter spindle spline and gear rolling area. Install the thrust washer into the kickstarter spindle. Install the pinion gear and thrust washer. Install the snap ring in the groove of the spindle Set the sharp edge of the snap ring...
  • Page 100 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the ratchet spring. Apply transmission oil to the kickstarter spindle journal. Install the kickstarter assembly to the crankcase and rotate the spindle counterclockwise until the ratchet Be sure the tab is clear of the stopper plate. ratchet spring does not fall off the spindle...

  • Page 101: Starter Clutch

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE STARTER CLUTCH REMOVAL Remove the following: - Right crankcase cover (page 4-54) - Clutch (page 4-56) Hold the starter clutch using the special tool and loosen the water pump drive gear nut. TOOL: Universal holder 07725-0030000 Remove the nut, washer, water pump drive gear and collar.
  • Page 102 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE DISASSEMBLY/INSPECTION Check that the starter driven gear turns clockwise smoothly and does not turn counterclockwise. Remove the driven gear and needle bearing from starter clutch outer. Remove the snap ring and one-way clutch from the clutch outer. Check the needle bearing for abnormal wear or damage.
  • Page 103 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Check the one-way clutch sprag for abnormal wear or damage. Check the starter clutch outer inner surface for wear or damage. Remove the snap rings, washers, starter reduction gear and idle gear. Check the starter reduction gear and idle gear for wear or damage.
  • Page 104 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE ASSEMBLY Apply molybdenum oil solution to the starter gear holder sliding surfaces. Install the starter reduction gear, idle gear, washers and snap rings. Apply transmission oil to the one-way clutch and starter clutch outer sliding surface. Install the one-way clutch into the starter clutch outer with the white paint facing out.
  • Page 105 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Install the starter gear holder assembly and socket bolt. Tighten the bolts to the specified torque. TORQUE: 22 N･m (2.2 kgf･m, 16 Ibf･ft) Install the starter clutch while aligning its wide cutout in the splines with the punch mark on the mainshaft.

  • Page 106: Gearshift Linkage

    CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Install the collar onto the balancer shaft. Install the water pump drive gear while aligning its wide cut-out in the splines with the punch mark on the balancer shaft. Apply transmission oil to the water pump drive gear nut threads and seating surface.
  • Page 107 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Remove the shifter collar. Remove the bolts, guide plate and drum shifter Do not let the ratchet pawls as an assembly. fall when removing the guide plate and drum shifter. Remove the shift drum center pin and shift drum center.
  • Page 108 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE RATCHET PAWL Remove the following: - Guide plate - Drum shifter - Ratchet pawls - Plungers - Springs Clean the ratchet pawls, plungers, springs and drum shifter with clean transmission oil. Check each part for wear or damage. Assemble the drum shifter, springs, plungers and ratchet pawls in the guide plate as shown.
  • Page 109 CLUTCH /STARTER CLUTCH/GEARSHIFT LINKAGE Set the drum center in a position other than neutral. While holding the ratchet pawls in place in the guide plate and drum shifter, install the drum shifter assembly by aligning the hole of the drum shifter with the shift drum center pin, and guide plate "UP"...

  • Page 110: Component Location

    ALTERNATOR COMPONENT LOCATION 4-77 PRINT EDITION 2.1...
  • Page 111 ALTERNATOR SERVICE INFORMATION GENERAL ･ This section covers the removal and installation of the alternator stator and flywheel. These services can be done with the engine installed in the frame. ･ Refer to inspection for the alternator stator TORQUE VALUES Flywheel nut 64 N･m (6.5 kgf･m, 47 lbf･ft) Apply engine oil to the threads and...

  • Page 112: Left Crankcase Cover Removal

    ALTERNATOR LEFT CRANKCASE COVER REMOVAL Remove the following: - Fuel tank - Left engine guard - Gearshift pedal Drain the engine oil. Remove the wire band. Disconnect the alternator 4P (Black) connector and ignition pulse generator 2P (Black) connector. Loosen the bolts in a crisscross pattern in two or three steps.
  • Page 113 ALTERNATOR STATOR REMOVAL Remove the left crankcase cover. Remove the bolts and wire clamp. Remove the ignition pulse generator and grommet from the left crankcase cover. Remove the screws and stator. INSTALLATION Place the stator/ignition pulse generator into the left crankcase cover.
  • Page 114 ALTERNATOR Remove the flywheel using the special tools. TOOLS: Flywheel puller 07933-1480000 Flywheel puller adaptor 070MG-KSE0100 Remove the woodruff key. INSTALLATION Install the woodruff key into the groove in the crank shaft. Clean the crankshaft and flywheel tapered areas. Install the flywheel to the crankshaft by aligning the groove in the flywheel with the woodruff key.

  • Page 115: Left Crankcase Cover Installation

    ALTERNATOR LEFT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket Install the left crankcase cover and bolts. Tighten the left crankcase cover bolts in a crisscross pattern in two or three steps. Connect the ignition pulse generator 2P (Black) connector and alternator 4P (Black) connector.
  • Page 116 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER COMPONENT LOCATION PRINT EDITION 2.1 4-83...
  • Page 117 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SERVICE INFORMATION GENERAL ･ This section covers service of the crankcase, crankshaft, transmission and balancer. ･ The crankcase halves must be separated to service the crankshaft and transmission. To service these parts, the engine must be removed from the frame. The following parts must be removed before separating the crankcase, - Engine - Starter motor...
  • Page 118 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER TORQUE VALUES 20N･m(2.0kgf･m, 15lbf･ft) Apply locking agent to the threads Right crankshaft bearing set plate torx (ThreeBond2430, 1373N or equivalent screw high strength locking agent). Countershaft bearing set plate screw 10 N･m (1.0 kgf･m, 7 lbf･ft) Apply locking agent to the threads. Shift drum bearing set plate bolt 10 N･m (1.0 kgf･m, 7 lbf･ft) Apply locking agent to the threads.

  • Page 119: Transmission Jumps Out Of Gear

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER TROUBLESHOOTING Excessive noise ･ Worn crankshaft main journal bearings ･ Worn or damaged connecting rod bearings ･ Worn connecting rod small end ･ Worn balancer bearings ･ Improper balancer installation ･ Worn, seized or chipped transmission gear ･ Worn or damaged transmission bearing Transmission jumps out of gear ･...
  • Page 120 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER BALANCER GEAR/BALANCER REMOVAL Remove the following: - Right crankcase cover - Clutch - Starter clutch - Flywheel Remove the balancer drive and driven gears. Remove the balancer shaft from the crankcase. INSPECTION Check the balancer shaft for wear, damage or excessive scratches.

  • Page 121: Crankcase Separation

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the balancer drive gear while aligning its wide cut-out in the splines with the punch mark on the crankshaft. Install the balancer driven gear while aligning its wide cut-out in the splines with the punch mark on the balancer shaft. Align the punch mark of the driven gear with the punch mark of the drive gear by turning the balancer shaft.
  • Page 122 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Remove the bolt, collar, washer and cam chain tensioner. Remove the bolt and cam chain stopper plate. Remove the cam chain from the timing sprocket. Remove the transmission oil drain bolt and sealing washer. Loosen the crankcase bolts in a crisscross pattern in two or three steps.

  • Page 123: Transmission Disassembly

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Check the orifice for damage or clogging. Do not remove the crankcase Blow open passage in the orifice with compressed orifice unless it is air. necessary to replace with a new one. TRANSMISSION DISASSEMBLY Separate the crankcase halves. Temporarily install the right crankcase. Place the right crankcase facing down and separate the right and left crankcase halves.
  • Page 124 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER INSPECTION Check the gear dogs, dog holders and teeth for damage or excessive wear. Measure the I.D. of each gear. SERVICE LIMITS:M4, M5: 23.07 mm (0.908 in) 20.07 mm (0.790 in) 27.07 mm (1.066 in) 25.07 mm (0.987 in) BUSHING Check the bushings for damage or excessive wear.

  • Page 125: Shift Fork

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SHIFT FORK Check the shift fork shaft for abnormal wear or deformation. Measure the shift fork shaft O.D. SERVICE LIMITS: Center: 10.97 mm (0.432 in) Right and left: 11.95 mm (0.470 in) SHIFT DRUM Inspect the shift drum for scoring, scratches or evidence of insufficient lubrication.

  • Page 126: Crankshaft Removal

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER CRANKSHAFT REMOVAL REMOVAL Separate the crankcase. Remove the transmission. Remove the crankshaft from the right crankcase. INSPECTION Place the crankshaft on a stand or V-blocks. Set the dial indicator on the crankshaft journals. Rotate the crankshaft two revolutions (720°) and read the runout.

  • Page 127: Crankshaft Bearing

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER CRANKCASE BEARING REPLACEMENT CRANKCASE BEARING/OIL SEAL LOCATION CRANKSHAFT BEARING Remove the torx screws and right crankcase bearing set plates. Remove the crankshaft oil seals and bearings from both crankcase halves. PRINT EDITION 2.1 4-94...
  • Page 128 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Drive new crankshaft bearings into both crankcase Drive in the halves using the special tools. new bearing squarely with the marking side facing TOOLS: toward the Left crankshaft bearing: inside of the Driver 07749-0010000 crankcase. Attachment 52 × 55 mm 07746-0010400 Right crankshaft bearing: Driver...
  • Page 129 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER TRANSMISSION/BALANCER/SHIFT DRUM BEARINGS LEFT CRANKCASE Remove the countershaft oil seal and balancer shaft oil seal. Remove the screws and countershaft bearing set plates. Remove the snap ring from the left crankcase. Remove the countershaft bearing out of the crankcase. Remove the mainshaft bearing, balancer shaft bearing using the special tools as shown.
  • Page 130 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Drive new bearings into the left crankcase Drive in the new bearings using the special tools. squarely with the marking TOOLS: side facing toward the Countershaft bearing: inside of the Driver 07749-0010000 crankcase. Attachment 52 × 55 mm 07746-0010400 Pilot 22 mm 07746-0041000 Mainshaft bearing:...

  • Page 131: Remover Weight

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Apply grease to the countershaft and balancer shaft oil seal lips. Install the oil seals to the crankcase until it is flush with the crankcase surface. RIGHT Remove the socket bolts and set plates. Remove the countershaft bearing, mainshaft bearing and shift drum bearing. Remove the bolts and set plates.

  • Page 132: Crankshaft Installation

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Drive in new bearings into the right crankcase using Drive in the new bearings the special tools. squarely with the marked TOOLS: side facing toward the Shift drum bearing: inside of the 07749-0010000 Driver crankcase. 07746-0010300 Attachment, 42 x 47 mm 07746-0040600 Pilot 25 mm Mainshaft bearing:...

  • Page 133: Transmission Assembly

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER TRANSMISSION ASSEMBLY Coat the spline area, rolling and sliding area of each gear with molybdenum oil solution. Apply transmission oil to the teeth of each gear. Assemble the mainshaft and countershaft. MAINSHAFT: PRINT EDITION 2.1 4-100...

  • Page 134: Installation

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER INSTALLATION ･ Check the gear movement and rotation on the shaft. ･ Install the washers and snap rings with the chamfered edge facing the thrust load side. ･ Do not reuse worn snap rings which could easily spin in the grooves.

  • Page 135: Crankcase Assembly

    CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER CRANKCASE ASSEMBLY If the crankcase orifice was removed, install a new crankcase orifice to the left crankcase and tighten it to the specified torque. TORQUE: 2.1 N･m (0.2 kgf･m, 1.5 lbf･ft) Temporarily install the left crankcase. Place the left crankcase facing down and separate the left and right crankcase halves.
  • Page 136 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the crankcase bolts and breather hose stay. Apply transmissi Install the transmission oil drain bolt with a new on oil to sealing washer and tighten it to the specified the drain torque. bolt threads. TORQUE: 16 N･m (1.6 kgf･m, 12 lbf･ft) Tighten the crankcase bolts in a crisscross pattern in two or three progressive steps.
  • Page 137 CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER Install the crankcase bolts and breather hose stay. Apply transmissi Install the transmission oil drain bolt with a new on oil to sealing washer and tighten it to the specified the drain torque. bolt threads. TORQUE: 16 N･m (1.6 kgf･m, 12 lbf･ft) Tighten the crankcase bolts in a crisscross pattern in two or three progressive steps.

  • Page 138: Chassis Maintenance

    CHASSIS MAINTENANCE Front wheel Removal Remove the axle nut. Loosen the axle holder bolts. Hold the motorcycle upright and raise the front wheel off the ground by placing the work st nd or equivalent Remove the axle and front wheel. Note Do not operate the brake lever after removing the front wheel.

  • Page 139: Wheel Balance

    CHASSIS MAINTENANCE Inspection Wheel rim Check the rim runout by placing the wheel on a truing stand. Spin the wheel slowly by hand, and read the runout using a dial indicator. Advice Casted wheels are not repairable. Replace the wheel with new one in case of damage or excessive runout.
  • Page 140 CHASSIS MAINTENANCE Installation Clean the clamping surface of the axle and axle holders. Install the front wheel between the fork legs. Be careful not to damage the brake pads with the disc. Apply a thin layer of grease to the front axle and insert the axle from the left side.
  • Page 141 CHASSIS MAINTENANCE Fork Removal Remove the front wheel Remove the bolts and front fender. Remove the front brake caliper. Loosen the handlebar holder bolts. Loosen the top bridge pinch bolts. When disassembling the fork, make sure to loosen the top bridge pinch bolts before loosen the fork bolts.
  • Page 142 CHASSIS MAINTENANCE Push the fork spring seat stopper down and put a 17mm wrench into the slit of the rebound adjuster. Hold the rebound adjuster and remove the fork bolt from damper rod. Remove the following parts; － Fork damper －...
  • Page 143 CHASSIS MAINTENANCE Inspection Advice ・Do not disassemble the fork damper. Do not loosen or remove the rebound adjuster nut or adjuster from the damper rod. ・Always check the slider sliding surface for score marks and scratches when replacing the oil seal due to oil leaks. (1) Fork damper (2) Centering plate (3) Slider (1) Stopper ring...
  • Page 144 CHASSIS MAINTENANCE (1) Rebound adjuster lock nut Bush / Backup ring Check the sliding surface of the bushing for wear or scratches. Remove any metal powder from the slider and guide bushings with a nylon brush and fork oil. If copper appears on the surface or excessive scratch is found, replace the bushing.
  • Page 145 CHASSIS MAINTENANCE Fork slider Check the slider for score marks, scratches and excessive or abnormal wear Set the slider on V-blocks and measure the runout. Actual runout is 1/2 of the total indicator reading. Service limit: 0.2mm Replace if the measurement exceeds the service limit. Assembly ・Before assembly, wash all parts with a high flash point or non-flammable solvent and remove all dirt.
  • Page 146 CHASSIS MAINTENANCE (1) Stopping ring Always hold both outer tube and axle holder (slider) together. If you hold only the outer tube, the slider goes down due to gravity and damages bushing and oil seals, or cause oil leaks. Attach the fork set collar above the axle holder. Gently bring down the outer tube until it sits on the fork set collar.
  • Page 147 CHASSIS MAINTENANCE Set the axle holder in a vise with a piece of wood or soft jaws to avoid damage. (Do not over-tighten the vise.) Tighten the socket bolt to the specified torque. Torque: 34N・m(3.5kgf・ｍ) In case the fork damper moves with the socket bolt, install the fork spring and fork bolt temporary to hold the fork damper.
  • Page 148 CHASSIS MAINTENANCE Install the fork spring with its identification mark facing upward. Install the following parts; － Joint plate － Spring collar － Spring seat stopper (1) Fork spring (2) Joint plate (3) Spring collar (4) Spring seat stopper Install a new O-ring into the fork bolt. Push down the spring seat stopper while holding the damper rod, and install the fork bolt onto the damper rod.
  • Page 149 CHASSIS MAINTENANCE Coat a new O-ring with the recommended fork oil and install the pre-load adjuster into the fork bolt. Hold the fork bolt and tighten the pre-load adjuster. Install the stopping ring. (1) New O-ring (2) Pre-load adjuster Installation Insert the fork leg into the bottom bridge, handlebar and top bridge.
  • Page 150 CHASSIS MAINTENANCE Install the front fender and tighten the bolts. Install the brake caliper and tighten the bolts. Install the front wheel. (1) Front fender (2) Brake caliper Handlebar Removal Remove the screws and throttle housing cover. Remove the throttle housing. Disconnect the throttle cables from the throttle pipe.

  • Page 151: Steering Stem

    CHASSIS MAINTENANCE (1) Screws (2) Clutch lever bracket Remove the steering stem bolt. Loosen the top bridge pinch bolts and remove the top bridge. Loosen the handlebar pinch bolt and remove the handlebar. Torque: Handlebar pinch bolt: 23N・m(2.3kgf・ｍ) Top bridge pinch bolt: 23N・m(2.3kgf・ｍ) Steering stem bolt: 59N・m(6.0kgf・ｍ) (1) Steering stem bolt (2) Top bridge pinch bolt...
  • Page 152 CHASSIS MAINTENANCE Remove the following parts; (1) Dust seal (2) Upper bearing (3) Steering stem (4) Lower bearing (1) Dust seal (2) Upper bearing (3) Steering stem (4) Lower bearing Bearing outer race replacement ・Always replace the bearings and races as a set. ・Check around the steering head pipe for damages from crashing.
  • Page 153 CHASSIS MAINTENANCE Install a new lower outer race and special tools as shown. Hold the installer shaft (1) with a wrench and turn the installer nut (2) slowly until the groove of installer attachment (4) aligns with the steering head pipe lower surface.
  • Page 154 CHASSIS MAINTENANCE Installation Pack the upper and lower bearings, outer races and dust seals with grease. Install the steering stem into the head pipe. Install the upper bearing and dust seal. (1) Lower bearing (2) Steering stem (3) New upper bearing (4) New dust seal Install the steering stem as follows;...
  • Page 155 CHASSIS MAINTENANCE 5. Move the steering stem 15 degrees to left and right several times (about 5 times) to seat the bearings. 6. Retighten the adjusting nut by fingers. 7. Repeat 4～6 operation a few times until the adjusting nut doesn’t move by fingers.

  • Page 156: Rear Wheel

    CHASSIS MAINTENANCE Rear Wheel Removal Raise the rear wheel off the ground by lacing the maintenance stand. Loosen the axle nut. Hold the axle and remove the axle nut. Remove the axle and washer. Remove the drive chain from the driven sprocket and remove the rear wheel.

  • Page 157: Rear Cushion

    CHASSIS MAINTENANCE Installation Place the rear wheel into the swing arm. Be careful not to damage the brake pads with the disc. Apply a thin coat of grease to the axle. Install the washer and axle from the left side. Install the washer and axle nut.
  • Page 158 CHASSIS MAINTENANCE Damper Check the damper for oil leaks. If any oil leaks are found, replace the damper. Expand the damper fully and mark at 10mm below the damper bottom. Place the damper on the scale and read the weight. Compress the damper with hydraulic press until the bottom of the damper reaches the marking.
  • Page 159 CHASSIS MAINTENANCE Install one of the stopping rings. Push-in the spherical bearing until its hits the stopping ring using the special tool. Tool Spherical bearing driver 07946-KA30200 (1) Spherical bearing driver (2) Stopping ring (3) Spherical bearing Install the other stopping ring to the upper joint. Install the collars.

  • Page 160: Cushion Linkage

    CHASSIS MAINTENANCE Turn the adjuster to adjust the spring pre-load. Hold the adjuster and tighten the lock nut. Torque: 49N・m(5.0kgf・ｍ） (1) Rebound adjuster (1) Pre-load (2) Adjuster Installation (3) Lock nut Set the rear cushion into the frame. Insert the lower mounting bolt from the left hand side of the motorcycle.

  • Page 161: Bearing Replacement

    CHASSIS MAINTENANCE Bearing replacement Remove the pivot collar and dust seals スイングアームピボットナットを取り外す。 Remove the needle bearings using special tools and a hydraulic スイングアームピボットロックナットをゆるめる。 press. Tool: Needle bearing driver 07946-MJ00000 － Driver shaft 07946-MJ00100 － Driver head 07946-MJ00200 Pack new needle bearings with grease. Press the new needle bearings with the special tools.
  • Page 162 CHASSIS MAINTENANCE (1) Lock nut wrench この時、ジャッキ等でエンジンを支持しておくこと。 Turn the swing arm pivot bolt and loosen the adjusting bolt. Remove the pivot bolt and swing arm. ※Make sure to hold the engine at it position by placing a jack underneath. (1) Pivot bolt (2) Adjusting bolt Disassembly Remove the screws and drive chain slider.
  • Page 163 CHASSIS MAINTENANCE (5) (6) (1) Pivot collar “B” (2) L. Dust seals (3) Needle bearing (4) L.Distance collar (5) R.Distance collar (6) Snapring (7) L.Pivot bearing(20x37x9mm) (8) R. Dust seal (9) Dust seal(17x24x5mm) (10) Needle bearing(17x24x17mm) (A) A bearing put in to a bottom. (10) Assembly Securely install the circlip into the groove of the swing arm.
  • Page 164 CHASSIS MAINTENANCE Installation Apply grease to the threads of swing arm adjusting bolt. Install the swing arm adjusting bolt to the frame. The tip of the swing arm adjust bolt should not come out from inner side of the frame to avoid having it interfering with the swing arm (1) Adjusting bolt Install the swing arm onto the frame.

  • Page 165: Brake Pad Replacement

    ・HONDA RS125R brake system is used in MD250H, however, never use the cast iron disc (45120-NX4-004, ‘96model) in combination with the stainless steel disc pads (45105-NX4-770, ’97-98model).
  • Page 166 CHASSIS MAINTENANCE Use neutral or less aggressive cleaning solution to protect piston seal when cleaning the inside of the caliper. Advice Do not allow cleaning fluid or gasoline to get on the piston seal. It will lose the brake performance. Always use neutral cleaning solution to clean the caliper pistons.
  • Page 167 CHASSIS MAINTENANCE Push the caliper pistons all the way in with old pads to allow installation of new brake pads. Check the brake fluid level in the V-tube. Remove the pad pin, brake pads and pad spring. W A R N I N G Check the brake fluid level in the V-tube as this operation causes the fluid level to rise.

  • Page 168: Front Brake Caliper

    CHASSIS MAINTENANCE Front brake caliper Removal Drain the front brake hydraulic system. Place a clean tray under the caliper. Spilled brake fluid will damage painted surface, plastic and rubber parts. Be careful not to spill the fluid on those parts. Remove the following parts;...
  • Page 169 CHASSIS MAINTENANCE Disassembly / Assembly Torque: 13N･m (1.3kgf･m) Apply locking Torque: 7N･m (0.7kgf･m) Apply silicon grease agent Apply locking agent (2)(3)Apply brake fluid (4)Apply silicon grease Apply silicon grease (7)Torque: 23N･m (2.3kgf･m) (1) Caliper bracket (2) Caliper piston (3) Piston seal Torque: 1N･m (0.15kgf･m) (4) Dust seal (5) Brake pads...

  • Page 170: Front Master Cylinder

    CHASSIS MAINTENANCE Installation Install the caliper/bracket assembly onto the caliper bracket collar. Install the washer with its sagging side facing inside. Securely install the circlinp into the groove of the bracket collar. Install the torque rod to the bracket and tighten the bolt/nut. (1) Bracket collar (2) Caliper bracket assembly (3) Washer (4) Circlip (5) Torque rod Install the brake hose eyelet and new sealing washers.
  • Page 171 CHASSIS MAINTENANCE Disassembly / Assembly (1) Boot (2) Circlip (3) Master piston (4) Primary cup (5) Secondary cup (6) Spring (7) Circlip (8) O-ring (9) Reservoir joint Brake lever assembly procedure. 1. Install the joint pin with arrow mark pointing at the lever. 2.

  • Page 172: Rear Master Cylinder

    CHASSIS MAINTENANCE Installation Assembly the master cylinder to the handlebar and install them with “UP” mark on the master cylinder holder facing up. Install the holder bolts. Install the brake lever and adjust its angle. Tighten the upper holder bolt first, then the lower bolt. Install the brake hose eyelet with new sealing washers.
  • Page 173 CHASSIS MAINTENANCE Disassembly / Assembly (1) Push rod joint assembly (2) Circlip (3) Master piston (4) Primary cup (5) Secondary cup (6) Spring (7) Reservoir joint (8) O-ring Installation Install the master cylinder to the bracket and tighten the bolts. Install the brake hose eyelet and new sealing washers.
  • Page 174 CHASSIS MAINTENANCE Install the brake pedal joint to the brake pedal. Install the joint bolt and nut, and tighten them. Fix the V-tube to the frame with a tie wrap. Fill and bleed the rear brake hydraulic system. (1) Joint bolt / nut (2) V-tube (3) Tie wrap PRINT EDITION 2.1 5-37...

  • Page 175: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM PRINT EDITION 2.1...

  • Page 176: Machine Setting

    MACHINE SETTING Carburetor setting table Reference setting for various temperature range. Carburetor setting (Standard) M/J: Main jet S/J: Slow jet Main Jet ＃160 J/N: Jet needle Slow jet ＃42 P/S: Pilot screw initial opening N/C: Jet needle clip position Jet needle NCYR Jet needle clip position 4th groove from top...

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