H.62
TE 250 - 310 2012 I.E. / TE 250 - 310 2012 I.E. USA
TC 250 2012 - TC 250 2012 I.E. USA
TXC 250 - 310 2012 I.E. USA
TE 250-310
H11095
TXC 250-310
H11096
TC 250
H11097
ENGINE REASSEMBLY
Workshop Manual Ed. 12-2011
Installing the engine and assembling the motorcycle
Install the engine and any parts you had removed in the order given below.
- Place the engine in the chassis.
- Insert the swinging arm shaft from the right-hand side and tighten its nut
using a 22 mm wrench.
- Tighten the engine mounting bolts to the frame using a 12 mm wrench on
the left-hand side and a 10 mm wrench on the right-hand side.
- Install the drive chain (fit the master link clip by setting the closed side facing
the chain direction of rotation).
- Install the clutch control on the engine and tighten the fitting with an 8 mm
wrench. Add clutch fluid.
- On the left-hand side, use an 8 mm wrench to install the chain guide plate.
Fit the transmission sprocket cover and tighten its screws using a 6 mm
wrench.
- Fit the spark plug cap to the spark plug. Install the rubber hose on the right-
hand side of the cylinder head cover.
- Refit the oil sump guard if you had removed it.
- Refit the coolant hoses with their clamps.
- Refit the rear brake pedal with its bolt.
- Refit the side guards of the chassis.
- Refit the carburettor.
- Refit the exhaust system.
- Refit the fuel tank together with the scoops.
- Refit the fuel tank front retaining screw and hook up the scoops to the spoil
-
ers on the radiators.
- Refit the breather hose of the fuel tank plug on the steering stem. Refit the
hose running from fuel tank to carburettor.
- Refit the side panels with their retaining screws.
- Refit the saddle and secure it with its rear fixing.
NOTES
1) Unless otherwise specified, standard torque values for the different thread
sizes are as follows
M5x0.8 (5.6-6.2 Nm; 0.57-0.63 Kgm; 4.1-4.5 ft/lb)
M6x1 (7.6-8.4 Nm; 0.80-0.85 Kgm; 5.8-6.1 ft/lb)
M8x1.25 (24-26 Nm; 2.4-2.6 Kgm; 17.3-18.8 ft/lb)
2) For electrical connections, see relevant diagram included in Section M.
3) Bleed the clutch (see Section P).
4)
Pour the oil in the crankcase (for the characteristics and quantities, see Chapter
A)
5)
Pour the liquid in the RH radiator (for the characteristics and quantities, see
Chapter A)
6) Check that the kick start pedal moves freely.
7) Perform the necessary adjustments as outlined in Section D "Settings and
adjustments".