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General| Engine Type | Single cylinder, 4-stroke |
|---|---|
| Compression Ratio | 12.8:1 |
| Transmission | 6-speed |
| Final Drive | 13:50 |
| Clutch | Wet Multi-Disc Clutch, Hydraulically Operated |
| Cooling | Liquid Cooled |
| Ignition | Kokusan digital DC-CDI |
| Lubrication | Pressure lubrication with 2 oil pumps |
Instructions for updating and managing the repair manual content.
Overview of the repair manual's scope and usage guidelines.
Form for providing feedback and reporting errors in the manual.
Procedure for removing air from the motorcycle's cooling system.
Steps for replacing the engine oil filter and related components.
Diagram and explanation of the engine's oil circulation system.
Process for removing air from the hydraulic clutch system.
Instructions for adjusting the throttle cable free play and operation.
Listing and illustration of specialized tools required for engine work.
Step-by-step guide to safely removing the engine from the motorcycle frame.
Step-by-step guide for reinstalling the engine into the motorcycle frame.
Initial steps and checks before disassembling the engine.
Procedure to set the engine's crankshaft to Top Dead Center.
Detailed steps for removing the camshafts from the cylinder head.
Process for removing the cylinder head and piston assembly.
Steps to remove the engine's clutch cover.
Procedure for taking apart the motorcycle's clutch assembly.
Steps to remove the engine's chain drive and primary gear components.
Procedure for disassembling the motorcycle's gear shifting mechanism.
Steps to remove the engine's internal oil pumps.
Process for splitting engine cases and removing crankshaft/shafts.
Detailed procedures for servicing the left engine casing and its components.
Detailed procedures for servicing the right engine casing and its components.
Checking and servicing the engine's bypass valve.
Servicing the clutch cover and related seals.
Inspection, measurement, and servicing of the crankshaft.
Method for measuring crankshaft web dimensions.
Procedures for servicing crankshaft bearings.
Checking and adjusting the crankshaft's axial clearance.
Inspection and measurement of the engine cylinder.
Process for measuring piston and cylinder for correct fit.
Inspection and replacement criteria for the engine piston.
Measuring the end gap of piston rings.
Inspecting the engine oil pumps for wear and damage.
Servicing and maintenance of the engine's oil lubrication system.
Procedures for servicing camshaft bearings.
Inspection and servicing of the engine camshafts.
Servicing the automatic decompression mechanism.
Inspection and servicing of camshaft bearing bridges.
Servicing and correct installation of the timing chain tensioner.
Inspection of timing chain, gears, and tensioning components.
Servicing procedures for the engine cylinder head.
Inspection and servicing of the clutch components.
Servicing the kickstarter mechanism.
Steps for pre-assembling the kickstarter shaft.
Servicing and inspection of the gear shift mechanism.
Steps for pre-assembling the shift shaft.
General checks for transmission wear and parts.
Procedure for assembling the main transmission shaft.
Procedure for assembling the counter transmission shaft.
Procedure for installing shafts and assembling engine casing halves.
Installing the engine's oil pump assembly.
Reinstalling the gear shift mechanism into the engine.
Installing the primary drive gear and timing chain.
Reassembling and installing the clutch assembly.
Installing the clutch cover with a new gasket.
Reinstalling the piston and cylinder head assembly.
Installing the engine camshafts.
Installing the timing chain tensioner.
Measuring and adjusting valve clearances after assembly.
Final steps for completing the engine assembly.
Information and testing procedures for the CDI unit.
Testing the ignition coil resistance for proper function.
General information and troubleshooting for the ignition system.
Testing stator and pulse generator resistance values.
Steps for removing and installing the ignition stator.
Location and replacement of the main electrical fuse.
Procedure to test the starter motor's operation.
Testing the start relay continuity and function.
Steps for removing and reinstalling the motorcycle battery.
Guidelines and precautions for charging the motorcycle battery.
Measuring the charging system voltage output.
Method for checking battery drain or current loss.
Information on selectable engine performance curves.
Using a peak voltage adapter to measure static ignition values.
Using a peak voltage adapter to measure static generator values.
Procedures for removing and reinstalling the carburetor.
Step-by-step guide to disassembling the carburetor.
Inspection of choke and hot start slide mechanisms.
Checking the accelerator pump diaphragm and bores.
Inspecting the jet needle for wear or bending.
Checking the float needle valve and seat for cleanliness.
Inspecting the throttle valve and its rollers for wear.
Reassembly procedures for the motorcycle carburetor.
Calibrating the throttle position sensor for correct idle speed.
Testing the throttle valve sensor resistance and operation.
Steps for removing and installing the throttle valve sensor.
Adjusting the carburetor for correct engine idling speed.
Measuring and adjusting the carburetor's float height.
Diagnosis and remedies for an engine that won't crank via electric starter.
Troubleshooting steps when the engine cranks but fails to start.
Diagnosis and remedies for starting issues using the kickstarter.
Troubleshooting steps for an engine that idles poorly or not at all.
Diagnosing and fixing issues where the engine won't accelerate.
Identifying causes for reduced engine performance.
Troubleshooting engine stalling or sputtering related to the carburetor.
Diagnosing and resolving engine overheating issues.
Identifying and addressing excessive engine oil consumption.
Troubleshooting a discharged battery, likely due to charging system issues.
Technical data for 250 SX-F engines from 2005-2007.
Chassis specifications for 250 SX-F models 2005-2006.
Specifications for critical component clearances and wear limits.
Torque specifications for engine and chassis fasteners.
Specific torque values for engine assembly fasteners.
Specific torque values for chassis assembly fasteners.
Maintenance schedule for 2005 model year motorcycles.
Maintenance schedule for 2006 model year motorcycles.
Maintenance schedule for 2007 model year motorcycles.
Maintenance schedule for 2008 model year motorcycles.
Recommended maintenance tasks requiring specialized workshop services.
Specialized maintenance for racing use performed by authorized workshops.
Wiring diagrams for 2005 model year motorcycles.
Wiring diagrams for 2006 model year motorcycles.
Wiring diagrams for 2007 model year motorcycles.
Wiring diagrams for 2008 model year motorcycles.
Key to identifying cable colors used in wiring diagrams.
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