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9-5C
Flange bolts - cylinder-head M 8 35 Nm (25 ft.lb)
Nuts-cylinder base M 10 35 Nm (25 ft.lb)
Flywheel collar nut M 12x1 60 Nm (44 ft.lb)
Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb)
Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb)
Crankcase and cover bolts M 6 8 Nm (6 ft.lb)
Swingarm pivot M 14 100 Nm (74 ft.lb)
Flat head bolt release plate kickstarter M 6x16 Loctite 648 19 Nm (14 ft.lb)
Other bolts M 6 10 Nm (7 ft.lb)
M 8 25 Nm (19 ft.lb)
M 10 45 Nm (33 ft.lb)
Piston fitting clearance 0.05 mm (250) 0.06 mm (300) 0.08 mm (380)
Piston ring end gap 0.3–0.4 mm
Connecting rod bearing - radial clearance
0.021–0.032 mm
Transmission shafts end float 0.1–0.2 mm
Clutch springs - length Ø 2.5 new = 43 mm, minimum length = 42 mm
Crankcase 0.5 mm
Clutch cover 0.5 mm
Cylinder bottom gasket as required
Available cylinder bottom gaskets 0.2/0.4/0.5/0.7 mm
Cylinder-head gasket O-rings
250 SX
250 MXC, EXC
300 MXC, EXC
380 EGS
AUSTRALIA
380 SX, MXC, EXC
TABLE 4
Carburetor
Carburetor setting number
Main jet
Idling jet
Starting jet
Jet needle
Needle position from top
Throttle valve
Air adjustment screw open
Performance restrictor
Keihin PWK 38
090598
172(168,170,175)
45(48,50)
85
NOZ G(NOZ H,NOZ I)
II
6
1,5
–
Keihin PWK 38
100598
175(170,172,178)
45(42,48)
85
N85 C(N85 D)
III
6
1,5 Umdr.
–
250/300 EGS
AUSTRALIA
Keihin PWK 38
100598
175(170,172,178)
45(42,48)
85
N85 C(N85 D)
III
6
1,5 Umdr.
slide stop 31mm
Keihin PWK 38
070598
170(168,172,175)
48(45,50)
85
NOZ H(NOZ G,NOZ I)
II
6
1,5 Umdr.
–
Keihin PWK 38
060598
175(168,170,172)
45(48,50)
85
NOZ G(NOZ H,NOZ I)
II
6
1,5 Umdr.
slide stop 36mm
TOLERANCES AND FITTING CLEARANCES
BASIC CARBURETOR SETTING
TIGHTENING TORQUES
GASKET THICKNESSES