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CABLE ROUTING DIAGRAMSPECEC240000CABLE ROUTING DIAGRAM1 Brake hose2 Clamp3 Cable4 Frame5 Radiator breather hose6 YPVS cable 1, 2 (right cylinder)7 Ignition coil lead8 Starter cable9 Solenoid valve lead0 Fuel hose¡ Clutch cable Fuel pump lead£ Throttle cable¢ Transmission oil breather hoseA Pass the brake hose through the hole in the inner fender.B Cut the clamp so that the protruding portion is less than 5 mm (0.20 in).C Install the clamp with its ends facing backward.D Position the cable from bottom to top in the following order.• Starter cable• Throttle cable• Solenoid valve lead2-13
CABLE ROUTING DIAGRAMSPEC1 Fuel pump lead2 Clamp3 Fuse holder4 Servomotor5 Front brake hose (right)6 YPVS cable 1, 2 (right cylinder)7 Clutch cableA Clamp the fuel hose and clutch cable. Position the upside ends of theclamp inside of the seat rail.B Clamp the radiator hose 3 and ignition coil lead.C Clamp the radiator hose 3 and YPVS cable (right cylinder).D Do not cut the end of the clamp.E Connect the left cylinder YPVS cables (silver cables) to the inner YPVSservomotor pulley and right cylinder YPVS cables (black cables) to theouter. The sleeved cables must be connected to the top side (open side)of the YPVS servomotor.F Align the end of the cover with that of the meter stay.G Be sure the brake hose is not twisted.2-14
Page 1 and 2: OWNER’S SERVICE MANUALTZ250N1/(N)
Page 3 and 4: EC020000INTRODUCTIONCongratulations
Page 5 and 6: EC040001IMPORTANT NOTICETHIS MACHIN
Page 7 and 8: EC050000TO THE NEW OWNERThis manual
Page 9 and 10: EC083000MANUAL FORMATAll of the pro
Page 11 and 12: MEMO
Page 13 and 14: EC0A0000CONTENTSCHAPTER 1GENERAL IN
Page 15 and 16: CHAPTER 7TUNINGENGINE . . . . . . .
Page 17 and 18: MACHINE IDENTIFICATIONGENINFO1EC120
Page 19 and 20: IMPORTANT INFORMATIONGENINFOEC13200
Page 21 and 22: SPECIAL TOOLSGENINFOEC140002SPECIAL
Page 23: CONTROL FUNCTIONSGENINFOEC150000CON
Page 26 and 27: CONTROL FUNCTIONSGENINFOEC15Y000IND
Page 28 and 29: CONTROL FUNCTIONSGENINFOEC15Q001DET
Page 30 and 31: INFORMATION BEFORE PRE-OPERATIONGEN
Page 32 and 33: STARTING AND BREAK-INGENINFOEC19303
Page 34 and 35: TORQUE-CHECK POINTSGENINFOEC1A0060T
Page 36 and 37: CLEANING AND STORAGEGENINFOEC1B0000
Page 38 and 39: GENERAL SPECIFICATIONSSPECEC200000S
Page 40 and 41: MAINTENANCE SPECIFICATIONSSPECEC212
Page 42 and 43: MAINTENANCE SPECIFICATIONSSPECPart
Page 46 and 47: MAINTENANCE SPECIFICATIONSSPEC∆
Page 52 and 53: CABLE ROUTING DIAGRAMSPEC1 Clamp2 T
Page 54 and 55: MAINTENANCE INTERVALSINSPADJEC30000
Page 56 and 57: MAINTENANCE INTERVALSINSPADJItemAft
Page 58 and 59: LOCKING WIRE INSTALLATION GUIDEINSP
Page 60 and 61: COOLING WATER REPLACEMENTINSPADJ3.
Page 62 and 63: COOLING SYSTEM INSPECTION/CLUTCH CA
Page 64 and 65: STARTER CABLE ADJUSTMENT4. Adjust:
Page 66 and 67: YPVS CLOSE SIDE CABLE ADJUSTMENT/YP
Page 68 and 69: PILOT AIR SCREW ADJUSTMENT4. Remove
Page 70 and 71: CHASSIS/BRAKE SYSTEM AIR BLEEDINGIN
Page 72 and 73: FRONT BRAKE PAD INSPECTION AND REPL
Page 74 and 75: REAR BRAKE PAD INSPECTION AND REPLA
Page 76 and 77: DRIVE CHAIN INSPECTIONINSPADJEC3690
Page 78 and 79: DRIVE CHAIN SLACK ADJUSTMENTINSPADJ
Page 80 and 81: FRONT FORK INSPECTION/FRONT FORK TO
Page 82 and 83: FRONT FORK SPRING PRELOAD ADJUSTMEN
Page 84 and 85: FRONT FORK COMPRESSION DAMPING FORC
Page 86 and 87: REAR SHOCK ABSORBER SPRING PRELOADA
Page 88 and 89: REAR SHOCK ABSORBER COMPRESSION DAM
Page 90 and 91: STEERING HEAD INSPECTION AND ADJUST
Page 92 and 93: WIRES, CABLES/COWLING INSTALLATION
Page 94 and 95: LUBRICATIONINSPADJEC36a023LUBRICATI
Page 96 and 97: IGNITION TIMING CHECKINSPADJEC37207
Page 98 and 99: RECHARGING BATTERYINSPADJEC376000RE
Page 100 and 101:
COWLING, INDUCTION GUIDE, SEAT AND
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EXHAUST PIPE AND SILENCERENGEC4S000
Page 104 and 105:
RADIATORENGEC456000HANDLING NOTEWDo
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CARBURETOR AND REED VALVEENGEC46000
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CARBURETOR AND REED VALVEENG4. Inst
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CYLINDER HEAD, CYLINDER AND PISTONE
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CLUTCHENGEC4A0000CLUTCHEC4A8000CLUT
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CLUTCHENGEC4A3000REMOVAL POINTSEC48
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CLUTCHENGEC4A5000ASSEMBLY AND INSTA
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CLUTCHENG9. Install:• Push rod 1
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PRIMARY DRIVEN GEAR, PRIMARY DRIVE
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Page 144 and 145:
SHIFT SHAFTENGEC4F3000REMOVAL POINT
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SHIFT SHAFTENG2. Install:• Plain
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SHIFT SHAFTENGEC4F5411Transmission
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WATER PUMPENGEC4G0000WATER PUMPT2 N
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WATER PUMPENGEC444400Oil seal1. Ins
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TRANSMISSION, SHIFT CAM AND SHIFT F
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Page 158 and 159:
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OIL PUMPENGEC4J4000INSPECTIONEC4J41
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OIL PUMPENG6. Install:• Oil pump
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CDI MAGNETOENGEC4L3000REMOVAL POINT
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ENGINE REMOVALENGEC4M0000ENGINE REM
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ENGINE REMOVALENGEC4M6000HANDLING N
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ENGINE REMOVALENG6. Install:• Eng
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CRANKCASE AND CRANKSHAFTENGT 11 Nm
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CRANKCASE AND CRANKSHAFTENG2. Inspe
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CRANKCASE AND CRANKSHAFTENG6. Insta
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FRONT WHEEL AND REAR WHEELCHASEC500
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FRONT WHEEL AND REAR WHEELCHAS7. Ti
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FRONT WHEEL AND REAR WHEELCHAS9. In
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FRONT BRAKE AND REAR BRAKECHASEC5A8
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FRONT BRAKE AND REAR BRAKECHASEC533
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FRONT BRAKE AND REAR BRAKECHAS2. In
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FRONT BRAKE AND REAR BRAKECHAS2. In
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FRONT FORKCHASEC550000FRONT FORKT 2
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FRONT FORKCHASEC556010HANDLING NOTE
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FRONT FORKCHASEC553322Damper rod1.
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FRONT FORKCHASEC555000ASSEMBLY AND
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FRONT FORKCHAS10.Install:• Stoppe
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FRONT FORKCHAS19.Install:• Fork s
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FRONT FORKCHAS26.Install:• Cap bo
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HANDLEBARCHASEC5B0000HANDLEBART 7 N
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HANDLEBARCHAS2. Install:• Throttl
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HANDLEBARCHAS11.Install:• Main sw
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STEERINGCHASEC560000STEERINGEC56800
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STEERINGCHASEC563000REMOVAL POINTSE
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STEERINGCHAS4. Install:• Under br
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STEERINGCHAS13.Adjust:• Front for
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SWINGARMCHASEC573000REMOVAL POINTSE
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SWINGARMCHAS4. Calculate:• Swinga
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SWINGARMCHAS4. Install:• Swingarm
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REAR SHOCK ABSORBERCHASEC580000REAR
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REAR SHOCK ABSORBERCHASEC583000REMO
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REAR SHOCK ABSORBERCHAS4. Tighten:
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IGNITION SYSTEMELECEC620000IGNITION
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IGNITION SYSTEMELECEC624000COUPLERS
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IGNITION SYSTEMELEC3. Inspect:• S
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CHARGING SYSTEMELECEC624000COUPLERS
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YPVS SYSTEMELECEC640000YPVS SYSTEME
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SOLENOID VALVE SYSTEMELECEC650001SO
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THERMO UNIT SYSTEMELECEC6A0000THERM
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FUEL PUMP SYSTEMELECEC670000FUEL PU
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FUEL PUMP SYSTEMELEC2. Inspect:•
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FUEL PUMP SYSTEMELEC3. Turn the fue
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SETTINGTUNThat is:• Higher temper
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SETTINGTUNIf the main jet is fully
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SETTINGTUNCCAUTION:If a change in c
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SETTINGTUNEC71Q021Carburetor settin
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SETTINGTUNNOTE:• Finish the break
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SETTINGTUN3rd gearGear ratioPart nu
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SETTINGTUNEC720000CHASSISEC72J001Ch
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SETTINGTUNEC72K014SettingsFor full
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SETTINGTUNEC71P011Selection of the
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SETTINGTUN HandlebarfluctuatingPoo
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SETTINGTUNEvent nameDateWeatherPlac
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