1) Engine and Performance 2) Dimensions 3) Chassis 4) Electrical wiring diagram 5) Ignition 6) Torque values 7) Wear limits 8) Bearing and seal sizes |
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Engine | Air cooled 2-stroke twin |
Bore and stroke | 54mm x 54mm (2.1 x 2.1 in.) |
Displacement | 247cc (15.1 cu in.) |
Compression ratio | 7.3 : 1 |
Carburettors | Mikuni VM 24 SH (x2) |
Carburettor float level | 0.98 inch (25.0mm) |
Carburettor idle mixture screw | Screw out approx 1.75 turns |
Maximum power | 29bhp @ 7500rpm |
Maximum speed | 100mph |
Acceleration | Standing 1/4 mile in 15.1s |
Braking distance | 39.4 foot @ 30mph |
Maximum torque | 20.3 ft-lb @ 7000rpm |
Maximum rev limit | 8000rpm |
Gearbox | 6-speed constant mesh |
Overall top gear ratio | 6.171 : 1 |
mph/revs in 6th | 100mph/8800rpm |
Clutch | Wet, 12 plate |
Length | 76.8 inch (1.95m) |
Width | 30.1 inch (0.765m) |
Height | 40.6inch (1.02m) |
Wheelbase | 50.4 inch (1.28m) |
Ground clearance | 6.5 inch (0.165m) |
Dry weight | 297lb (135kg) |
Steering angle | 45° |
Caster | 63° |
Trail | 3.3 inch |
Turning radius | 78.7 inch |
Steering damper | Friction plate |
Front brake type | Twin leading shoe drum |
Rear Brake type | Single leading shoe drum |
Front suspension | hydraulically damped telescopic fork |
Fork leg oil capacity | 200cc per leg |
Rear suspension | hydraulically damped swinging arm |
Fuel tank capacity | 3.1 gallon (3.7 US gal) 14 litre |
Oil tank capacity | 2.3qt. |
Tyre sizes / pressures - front - back |
2.75 x 18in / 22psi 3.00 x 18in / 26psi |
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Ignition timing | 27° (3.63mm) before TDC |
Spark plugs | NGK B-77 HC |
Spark plug gap | 0.024 inch (0.6mm) |
Contact breaker points gap | 0.012-0.016 inch (0.3-0.4mm) |
Condensor (capacitor) capacity | 0.20-0.28 µFarad |
Condensor insulation resistance | Greater than 10 MegaOhm |
Ignition coil resistance | Between + and - terminals should be 1-2 Ohms |
Ignition coil resistance | Primary to secondary coil resistance is 5k to 11k Ohms |
Cylinder head bolts | 14 ft/lb |
Engine pinion nut | 31 ft/lb |
Clutch sleeve nut | 24 ft/lb |
Final drive sprocket nut | 36 ft/lb |
Rotor bolt | 14 ft/lb |
Fork yoke bolts | 58 ft/lb |
Handlebar bracket bolts | 11 ft/lb |
Rear suspension unit nuts | 18 ft/lb |
Swing arm pivot nut | 33 ft/lb |
Front and rear wheel spindle | 31 ft/lb |
Ring Gap 0.004 inch | Wear limit max 0.04 inch |
Clutch plate thickness 0.118 inch | Minimum 0.110 inch |
Clutch spring length 1.87 inch | Minimum length 1.79 inch |
Primary gear/primary pinion backlash | Measure with solder squashed in gap - 0.006inch max |
Connecting rod side to side motion | (not end float) max 0.118 at top of rod |
Gear fork/gear groove clearance | Maximum value 0.032 inch |
Front wheel | 6202 Z 6002-Z |
Rear wheel | 6303 Z 6203 Z |
Sprocket casing | 6205 Z |
Gearbox output shaft | 6304 NS-1 (KOYO) or 6304 1NX (NSK) |
Clutch shaft bearing | 6304 NS-1 (KOYO) or 6304 1NX (NSK) |
Steering head bearings | 48mm x 32mm |
Rear sprocket oil seal | 52mm x 30mm x 8mm |
Front sprocket oil seal | 52mm x 25mm x 7mm |
Kickstart oil seal | 30mm x 16mm x 8mm |
Front fork seals | 46mm x 34mm x 11mm |
N.B. The data above is true to the best of my Knowledge, but I can accept no liability for any mistakes.
Please send me any corrections or other information that you know of. Does anyone out there have copies of original service sheets?