TIGHTENING TORQUES
Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)
Nuts-cylinder base M 10 35 Nm (25 ft.lb)
Flywheel collar nut M 12x1 60 Nm (44 ft.lb)
Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb)
Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb)
Crankcase and cover bolts M 6 8 Nm (6 ft.lb)
Swingarm pivot M 14 100 Nm (74 ft.lb)
Flat head screw release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)
Other screws M 6 10 Nm (7 ft.lb)
M 8 25 Nm (19 ft.lb)
M 10 45 Nm (33 ft.lb)
Piston fitting clearance 0.05 mm (250) 0.06 mm (300) 0.08 mm (380)
Piston ring end gap 0.3 –0.4 mm
Connecting rod bearing - radial clearance 0.021– 0.032 mm
Transmission shafts end float 0.1– 0.2 mm
Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm
TOLERANCES AND FITTING CLEARANCES
GASKET THICKNESSES
Crankcase 0.5 mm
Clutch cover 0.5 mm
Cylinder bottom gasket as required
Available cylinder bottom gaskets 0.2/0.4/0.5/0.75 mm
Cylinder-head gasket O-rings
250 SX
380 SX
TABLE 4
BASIC CARBURETOR SETTING
Keihin PWK 38 AG PJ
010300
172 (170,175)
48 (45,50)
85
NOZ E (NOZ F)
III
7
1,5
–
55
Keihin PWK 38 AG
070300
170 (168,172)
45 (48)
85
NOZ G (NOZ I/NOZ H)
III
6,5
1,5
–
–
250/300 EXC
throttled
Keihin PWK 38 AG
020300
175 (172,178,180)
35
85
R 1475 J
III
6,5
1,5
slide stop 34mm
–
300 EXC AUS
throttled
Keihin PWK 38 AG
060300
175 (172,178)
45 (48)
85
NOZ H (NOZ I)
III
6,5
1,5
slide stop 34mm
–
250 EXC AUS
throttled
Keihin PWK 38 AG
040300
178 (175,180)
45 (48)
85
NOZ G (NOZ H)
IV
6,5
1,5
slide stop 34mm
–
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Power jet jet
380 EXC
throttled
Keihin PWK 38 AG
080300
170 (168,172)
45 (48)
85
NOZ G (NOZ I/NOZ H)
III
6,5
1,5
slide stop 36mm
–
ENGLISH
40
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