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Page 2: ...Tension b Maintenance Brakes a Rear BraK Adjustment b Rear Reservoir Fluid level c Rear Brake Pads d Front Reservoir Fluid Level e Front Brake Pads f Bleeding the Front and Rear Brakes Air Filter Engi...
Page 3: ...to the on position NOTE Cl ose to off position when not in use 7 Read the rest of this operators manual BREAK IN PERIOD A little bit of care in the way you treat your mqtorcycle during its initial ope...
Page 4: ...or Awtaftflf tU T lllixJ When selecting an oil to mix with your gas use a high qualttJ 2 cycle oil Mix the oil according to manufacturer recaamendattons on the container Rec011111ended Fuel Ratios 250...
Page 5: ...Remove the front wheel brake caliper assy and brake line guides and lay back at sfde of machine 4 Pull forks from machine invert and unscrew inner tube fork cap Remove preload spacer 1f fitted and fo...
Page 6: ...Wait till there are no more air bubbles in the on 13 The standard measurement of the oil level is when the damping rod is extended 12Qmn from the fork tube yet at the same time keeping the oil level f...
Page 7: ...ofter the tnftfal travel will lie Ste ftgure for freload measurement PRELOAD LENGTH 0 Inch Ollln 1 8 Inch i 1 4 Inch am FIGt RE FIGURE 2 EXAMPLE SPRING RATE FORK ACTION Ll6HT MEDIUM HEAVY If increased...
Page 8: ...re 4 This distance is the extended travel length Take the bike off the stand and sit on it in your normal riding positon Measure the new distance between the center of the axle to the center of the le...
Page 9: ...ngs to choose from Turn the knob counter clockwise until it stops at this position the compression dampening is set at the softest rate To increase compression dampening turn the adjustment knob clock...
Page 10: ...igure 6 This minimal slack requirement is due to the design characterist1c of the ATK chain torque eliminator CHAIN MAINTENANCE The drive chain should be checked cleaned and lubricated after every rid...
Page 11: ...so that it will not be applied unknowingly free Play adjustment between the Master cylinder piston and actuating rod should never be nonexistent 1 16 to 1 tin i tLr a1r UM l I_ _ _ _ _ s c t r Rear Br...
Page 12: ...ary to bleed the system in order to purge the air out Check the level of fluid in the reservoir and top up if required Remove the dust cap from the bleed screw Attach a rubber hose of internal diamete...
Page 13: ...rally onto the entire element and let soak for 10 minutes 5 RINSE OFF Rinse off the element with low pressure water Tap water is OK Always flush from the clean side to dirty side This removes the dirt...
Page 14: ...it to wann up briefly Remove the 6mm Allen head bolt from the bottom of engine and completely drain the oil NOTE Don t remove the 17nun bolt head kickstart spring retaining bolt The drain plug tip is...
Page 15: ...spection hole and rev the engine to 5000 RPM for a brief instant If the timing is correct the magneto cover mark and flywheel mark will align with each other If timing was incorrect remove magneto cov...
Page 16: ...AT 20 NEEDLE VALVE ASSBLY 21 PIN FLOAT ARM 22 RING NEEDLE VALVE 23 CAP FLOAT RETAINER 24 SCREW TOP COVER 25 THROTTLEVALVE 26 SPRJNG T V 27 HOSE VENT 28 SCREW FLOAT BOWL 29 HOSE OVER FLOW 30 FLOAT LEFT...
Page 17: ...14 0 005 0 18 DID 0 007 Increased perfonnance can be obtained by changing compression ratios on the 250 and 406 The chart below can be used as a guide to your fuel needs 250 Com2ression Ratio Fuel Re...
Page 18: ...er head nuts 8mm Cylinder head nuts lOnm Shock eye bolts Torque ft lb 30 6 8 65 75 65 75 15 20 25 30 65 75 60 70 68 78 40 50 16 18 26 26 30 35 The table below relating tightening torque to thread diar...
Page 19: ...5 50 Ignition Motoplat totoplat Carburetor Keihin Keihin Chain 520 520 Oil Capacity lqt lqt Afr Filter K N K N Weight 208 216 Steering Angle 27 27 Uheelbase 5711 57 Seat Height 37 37a Ground Clearance...
Page 20: ...250 Plastic Ring insertion jig clutch side Plastic Ring insertion jig mag side Pu11er assy Clutch hub locking tool old style Clutch hub locking tool new style Protection Cap Guide sleeve for oil seal...
