2006r Service data.pdf

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SERVICE DATA
4 STROKE
ENGINE TOP END
ITEM
Cam height
IN.
EX.
Camshaft journal clearance
Camshaft journal diameter
Camshaft journal inside diameter
Camshaft journal runout
Cylinder compression
STANDARD
34.642 – 34.758
(1.3639 – 1.3684)
33.941 – 34.057
(1.3363 – 1.3408)
0.020 – 0.062
(0.0008 – 0.0024)
21.959 – 21.980
(0.8645 – 0.8654)
22.000 – 22.021
(0.8661 – 0.8670)
TIR 0.02 (0.0008) or less
Usable range
431 – 706 kPa
(4.4 – 7.2 kgf/cm
2
, 62.5 – 102 psi)
@ 5 kicks
—
0.10 – 0.15
IN.
(0.0039 – 0.0059)
0.17 – 0.22
EX.
(0.0067 – 0.0087)
TIR 0.01 (0.0004) or less
IN.
EX.
Valve guide inside diameter
Valve/valve guide clearance
(Wobble method)
IN. & EX.
IN.
EX.
Valve seat cutting angle
Valve seat surface outside
diameter
4.475 – 4.490
(0.1762 – 0.1768)
4.455 – 4.470
(0.1754 – 0.1760)
4.500 – 4.512
(0.1772 – 0.1776)
0.03 – 0.10
(0.0012 – 0.0039)
0.08 – 0.16
(0.0031 – 0.0063)
45°, 32°, 60°
30.62 – 30.82
(1.2055 – 1.2134)
24.62 – 24.82
(0.9693 – 0.9772)
0.50 – 1.0
(0.0197 – 0.0394)
37.88 (1.4913)
Date: July 25, 2005
Model: RM-Z250K6
Unit: mm (in)
LIMIT
34.54
(1.3598)
33.84
(1.3322)
0.15
(0.0059)
21.93
(0.8634)
22.08
(0.8693)
TIR 0.1
(0.0039)
—
Cylinder head warp
Valve clearance
0.05 (0.0020)
—
—
TIR 0.05
(0.0020)
4.46
(0.1756)
4.44
(0.1748)
4.57
(0.1779)
0.26
(0.0102)
0.32
(0.0126)
—
—
—
—
37.0 (1.4567)
Valve stem bend
Valve stem diameter
IN.
EX.
Valve seat surface width
Valve spring free length
IN. & EX.
TIR: Total Indicator Readings
Model: RM-Z250K6
1/6
E-03, 19, 24, 28
ITEM
Cylinder inside diameter
Piston diameter
Piston/cylinder clearance
Piston ring/ring groove clearance
Piston ring groove width
Piston ring thickness
Piston ring end gap
Top
Top
Top
Top
Oil
Piston pin diameter
Piston pin hole diameter
Connecting rod small end inside
diameter
STANDARD
77.000 – 77.012
(3.0315 – 3.0320)
76.955 – 96.970
(3.0297 – 3.0303)
0.030 – 0.057
(0.0012 – 0.0022)
0.04 – 0.08
(0.0016 – 0.0031)
0.83 – 0.85
(0.0327 – 0.0335)
0.77 – 0.79
(0.0303 – 0.0311)
0.15 – 0.25
(0.0059 – 0.0098)
0.20 – 0.70
(0.0079 – 0.0276)
15.992 – 15.997
(0.6296 – 0.6298)
16.004 – 16.010
(0.6301 – 0.6303)
16.010 – 16.018
(0.6303 – 0.6306)
LIMIT
77.06
(3.0339)
76.82
(3.0244)
—
0.18
(0.0071)
0.93
(0.0366)
0.70
(0.0276)
0.55
(0.0217)
1.0
(0.0394)
15.96
(0.628)
16.07
(0.633)
16.05
(0.632)
Unit: mm (in)
CRANKSHAFT/TRANSMISSION
ITEM
Connecting rod big end radial
clearance
Connecting rod big end side
clearance
Crankshaft runout
Shift fork ear thickness
Gear shift fork groove width
Shift fork guide pin diameter
Shift drum groove width
STANDARD
0.002 – 0.014
(0.00008 – 0.0006)
0.25 – 0.35
(0.0098 – 0.0138)
TIR 0.03 (0.012) or less
4.9 – 5.0
(0.1929 – 0.1969)
5.05 – 5.15
(0.1988 – 0.2028)
5.9 – 6.0
(0.2323 – 0.2362)
6.05 – 6.20
(0.2382 – 0.2441)
LIMIT
0.06
(0.0024)
0.55
(0.0217)
TIR 0.08
(0.0031)
4.8
(0.1890)
5.25
(0.2070)
5.8
(0.2283)
6.3
(0.2480)
Model: RM-Z250K6
2/6
E-03, 19, 24, 28
CLUTCH
ITEM
Clutch lever free play
Friction plate thickness
Steel plate thickness
Friction plate warp
Steel plate warp
Clutch spring free length
Friction plate/clutch housing
clearance
STANDARD
2.0 – 3.0
(0.08 – 0.12)
2.72 – 2.88
(0.107 – 0.113)
1.5 – 1.7
(0.059 – 0.067)
0.15 (0.0059) or less
0.2 (0.0079) or less
46.8 (1.843)
0.04 – 0.55
(0.0016 – 0.0217)
Unit: mm (in)
LIMIT
—
2.62
(0.1031)
1.4
(0.055)
0.3 (0.0118)
0.3 (0.0118)
44.9 (1.768)
0.9
(0.035)
Unit: mm (in)
STANDARD
Type
DAIDO: D.I.D 520DMA2
Links
114 links
317.5 – 318.2
20-link length
(12.50 – 12.53)
52 – 58
(2.05 – 2.28)
55.48 – 55.68 (2.184 – 2.192) /13T
232.62 – 233.12 (9.158 – 9.178) /48T
Under 0.4 (0.016)
LIMIT
—
—
323
(12.72)
—
54.8 (2.157)
232.1 (9.138)
0.5 (0.020)
Unit: mm (in)
STANDARD
KEIHIN FCR37
#68
#60
#178
#1.5
0BEKS
3rd groove from the top
#40
#100
1 and 3/4 turns out
6.5 ± 1
(0.256 ± 0.039)
8±1
(0.315 ± 0.039)
FINAL DRIVE
ITEM
Drive chain
Drive chain slack
Engline sprocket diameter
Rear sprocket diameter
Rear sprocket warp
FUEL SYSTEM
ITEM
Carburetor type
Starter jet
Leak jet
Main jet
Throttle valve cutaway
Jet needle
Jet needle clip position
Slow jet
Slow air jet
Pilot air screw
Servise fuel level (above the bot-
tom edge of the carburetor body)
Float height
Model: RM-Z250K6
3/6
E-03, 19, 24, 28
COOLING SYSTEM
ITEM
Coolant type
Coolant color
Coolant mixing ratio
Coolant total amount
Radiator cap relief pressure
STANDARD
Permanent type anti-freeze for aluminum engines and radiators
Green
Soft water 50%, anti-freeze 50%
1.2 L (1.27 US qt)
93 – 123 kPa
(0.95 – 1.25 kgf/cm
2
, 13 – 18 psi)
ELECTRICAL SYSTEM
)
ITEM
Crankshaft sensor resistance
Magneto output voltage
(Reading @ 4 000 r/min)
STANDARD
80 – 120
Ω
(Tester range)
250 V AC
(Tester range)
50 V AC
(Tester range)
×1
Ω
(Tester range)
×1
Ω
59 V or more
16 V or more
27.2 – 40.8
Ω
1.76 – 2.64
Ω
NOTE
+:
B/R –
-:
R/W
+:
Y –
-:
Y
+:
B/R –
-:
R/W
+:
Y –
-:
Y
Magneto coil resistance
Ignition timing (Disconnect the
throttle sensor lead)
Ignition coil
8° BTDC @ 2 000 r/min
3 needle arcing
distance
Secondary
winding
resistance
Primary
winding
resistance
type
gap
7 mm (0.26 in) or more
0.28 – 0.34
Ω
(@ 20 °C)
7.65 – 10.35 kΩ (@ 20 °C)
NGK CR8EB
0.7 – 0.8 mm
(0.026 – 0.031 in)
176 V or above
Around 5 V
Spark plug
Throttle sensor ignition coil primary
peak voltage
Throttle sensor input voltage
Output voltage
When the
throttle valve
completely
closed
When the
throttle fully
opened
0.58 – 0.78 V
3.5 – 3.7 V
Model: RM-Z250K6
4/6
E-03, 19, 24, 28
BRAKES
ITEM
Brake lever free play
Brake fluid type
Brake pad lining thickness
Brake disc thickness
STANDARD
Adjustable (to suit rider)
DOT 3 or DOT 4
DOT 4
3.8 (0.150)
6.4 (0.252)
2.85 – 3.15
(0.112 – 0.124)
3.85 – 4.15
(0.152 – 0.163)
Not more than 0.25 (0.098)
Unit: mm (in)
LIMIT
—
—
—
1 (0.04)
1 (0.04)
2.5
(0.10)
3.5
(0.14)
0.3 (0.01)
Front
Rear
Front
Rear
Front
Rear
Brake disc runout
Front &
Rear
WHEELS/TIRES
ITEM
Wheel rim runout
Axle runout (/100 mm)
Tire air pressure
Front tire
STANDARD
Axial &
Radial
Front &
Rear
Front &
Rear
Size
Type
Rear tire
Size
Type
1.0 (0.039) or less
0.1 (0.004)
100 kPa
(1.0 kgf/cm
2
, 14 psi)
80/100-21 51M
BRIDGESTONE M401, Tube
M201, Tube (EU)
100/90-19 57M
BRIDGESTONE M402, Tube
M202, Tube (EU)
Unit: mm (in)
LIMIT
2 (0.08)
0.2 (0.008)
—
—
—
—
—
EU: European Model
SUSPENSIONS
ITEM
Front fork air pressure
Front fork rebound damping
adjustment
(From the seated position; adjuster
turned fully clockwise)
Front fork compression damping
adjustment
(From the seated position; adjuster
turned fully clockwise)
Front fork oil viscosity
Front fork oil capacity
STANDARD
Atmospheric pressure
11 clicks counterclockwise
12 clicks counterclockwise (EU)
Unit: mm (in)
LIMIT
—
(Adjustable
range)
16 clicks
(Adjustable
range)
16 clicks
—
10 clicks counterclockwise
11 clicks counterclockwise (EU)
KAYABA 01 or SAE 5W CORRESPOND
575 ± 4 ml
(19.44 ± 0.14 US oz)
568 ± 4 ml (EU)
(19.20 ± 0.14 US oz)
—
Model: RM-Z250K6
5/6
E-03, 19, 24, 28

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