2) Dimensions
3) Chassis
4) Electrical
wiring diagram 5) Ignition
6) Torque values
7) Wear limits
8) Bearing and seal sizes
| 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?
