MORIWAKI MD250H User manual

MORIWAKI MD250H
SERVICE MANUAL

GENERAL INFORMATION
Refueling
Remove the tank cover.
PRINT EDITION 2.1
1-1
Remove the fuel tank cap.
Fuel tank capacity: 7.0 liter
Fuel: Unleaded high-octane gasoline
Be sure to install the fuel tank cap and breather tube before ride.
Coolant
MD250H uses water for its engine cooling system.
Remove the radiator cap and fill the radiator with coolant water up to
the filler neck.
Coolant: Tap water (soft water) or drinking water
The “DANGER” label on the top of the radiator cap indicates
potential danger.
Be sure to bleed any air trapped in the coolant system after refilling
the coolant. Remaining air may cause the engine over heating.
Air bleeding procedure:
1．Remove the radiator cap and fill the radiator with coolant slowly
up to the filler neck.
2．Loosen the drain bolt and release any trapped air.
3．Hold the handle bars and lean the bike left to right for a few times
to release air. If the coolant level drops, add more coolant.
4．Repeat above procedure until the coolant level doesn’t drop.
5．Reinstall the radiator cap and fasten it securely.
Gasoline is explosive. It can cause you to be burned or
seriously hurt due to explosion.
When you handle gasoline;
・ Engine must be stopped. The work area must be free form
flames, sparks or heat source.
・ Work in a well ventilated area.
・ If you spill gasoline, wipe and remove it immediately.
WARNING
Removing the radiator cap while the engine is hot can allow the
coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing
the radiator cap.
Notice
The radiator cap has a double-lock fasten system.
Be sure to fasten the radiator cap completely, otherwise the system will
not hold the required pressure and cause coolant leakage and serious
troubles.
(1) Fuel tank cap
DENGER
DANGER
(
1
)
Radiator ca
p
(1)
(
1
)
Drain bolt
(
1
)
Radiator hose

GENERAL INFORMATION
(1)
(2)
6．Remove the radiator cap and start the engine when it is cold.
Check the coolant flow at the filler neck (coolant will not flow if
there is trapped air in the system). Stop the engine and re-check
the coolant level. Add more coolant if necessary, then reinstall
the radiator cap.
Drain any coolant in the catch tank before ride.
Drain coolant from the cooling system after finish riding to avoid
troubles in the system such as corrosion or clogging.
Riding
(
1
)
Main switch
(
2
)
Starter button
Starting
Check the coolant level before start the engine. (→1-1)
Cold start:
1. Switch the main switch to “RUN”.
Tachometer and water temp. indicator start operating
(Power ON)
Tachometer: Indicator goes all the way and back to the minimum
value; 3000rpm and the back light turns on.
Water temp. indicator: Start indicating the coolant temperature.
2. Turn the fuel valve to “ON”.
3. Open and close the throttle 2 to 3 times in quick motion. (1) Fuel valve
4. Push the starter button to start the engine.
(1)
(2)
Warm start:
Follow the “Cold start” procedure above except #3 and start the engine.
Stopping
1. Shift the transmission into neutral.
2. Turn the fuel valve to “OFF”.
3. Push the engine stop button when the engine rev drops and keep
until the engine stops completely.
4. Switch the main switch to “OFF”.
Leaving the fuel valve “ON” may cause starting difficulty especially
when the carburetor overflow the gasoline. (1) Throttle grip (2) Engine stop button
(1)
(2)
Engine warm up
Do not run the engine at high rev idle for too long during the warming
up.
1. Start the engine, then open the throttle instantaneously while
obtaining 5,000rpm～6,000rpm until the coolant temperature
rises to 40～50℃.
2. Then, open the throttle further in same instantaneous motion up
to 8,000rpm until the temperature rises to 70℃, and stop the
engine.
3. To stop the engine, close the throttle and push the engine stop
button until the engine stops.
(1) Tachometer (2) Water temp indicator
PRINT EDITION 2.1
1-2

GENERAL INFORMATION
PRINT EDITION 2.1
1-3
Break-in ride
First break-in ride
Keep the engine rev constant at the specified rpm during break-in ride. Shift speed up and down below the specified rpm. Use
relatively high gears and observe function of each part. Use 4 to 5 speed gears when riding through straight section of circuit tracks.
Up to 7,000rpm…………… about 50km (approx. 30min)
Up to 8,000rpm‥………… about 15km
Up to 9,000rpm…………… about 15km
Up to 10,000rpm ………… about 15km
Total: approx. 1hr or 95km
After parts change
・ Perform same amount of break-in ride as first break-in when cylinder or crankshaft is replaced: approx. 1hr (95km)
・ In case of replacement of engine parts such as piston, piston rings and gears:
Up to 7,000rpm………… about 20km
Up to8,000rpm………… about 10km
Up to 9,000rpm………… about 10km
Up to 10,000rpm……… about 10km
Total: approx. 30min or 50km
・ Replace the transmission oil（⇒3-6）after break-in rides. Check the contamination and foreign substances in used oil.

GENERAL INFORMATION
(1) Lock nut (2) Adjuster
(A) Increase the free play (B) Decrease the free play
Operation system
Clutch
Check the clutch lever free play at the lever end.
Free play: 10 – 20mm
Minor adjustments can be made at the cable end adjuster on the
lever.
・ Turning the cable end adjuster in direction A will increase free
play
・ Turning the cable end adjuster in direction B will decrease free
play.
Major adjustments can be made with the in-line cable adjuster
located behind the starter motor.
・ Turning the adjuster in direction C will increase free play
・ Turning the adjuster in direction D will decrease free play
Start the engine and check the clutch for disengaging or slips.
(1) Lock nut (2) Adjuster
(C) Increase the free play (D) Decrease the free play
Throttle grip
Throttle grip free play
Check the free play at the throttle grip flange.
Free play: 3mm
Minor adjustments are made with the throttle grip side adjuster.
・ Turning the adjuster in direction A will increase free play
・ Turning the adjuster in direction B will decrease free play
Tighten the lock nut after adjustment.
Check the throttle grip for its operation. (1) Lock nut (2) Adjuster
(A) Increase free play (B) Decrease free play
(
1
)
Arrow mark
(
2
)
Ali
g
nment mark
(
3
)
Ad
j
uste
r
Front brake lever adjustment
The brake lever position can be adjusted by adjuster.
Adjust the brake lever to appropriate position by using the arrow and
alignment marks as reference.
PRINT EDITION 2.1
1-4

GENERAL INFORMATION
Brake pedal height
Adjust the brake pedal to the desired height by loosening the lock nut
and turning the push rod.
Apply grease to the brake pedal axle at every ride.
(1) Lock nut (2) Adjuster
(A) Pedal goes higher (B) Pedal goes lower
Gear shift linkage
(1)
(2)
(1)
The change pedal height can be adjusted by changing the length of the
change rod.
Loosen the lock nuts at both ends and turn the change rod to adjust
the change pedal height. Measure the distance between 2 pillow b
as a reference to the pedal height.
alls
Change rod adjustable length (between the pillow balls)
minimum length: 311mm
maximumlength:332mm
One of 2 ends of the change rod had reverse threads.
Shift pattern: 1 up 4 down
(
1
)
Lock nut
(
2
)
Chan
g
e rod
1 UP 4 DOWN
(1) Change arm (2) Change rod
(3) Change pedal
PRINT EDITION 2.1
1-5

GENERAL INFORMATION
Steering damper
The steering damper damping force can be adjusted by its adjuster.
The damping force is adjusted in 7steps. The damping force increases
as turning the adjuster clockwise and obtain the maximum damping
force at the turning end.
The damping force decrease as turning the adjuster counter-clockwise.
Standard setting: Minimum damping force (1) Steering damper (2) Adjuster
(A) Increase damping force (B) Decrease damping force
CAUTION
Do not start the steering damper setting from its maximum
damping force position. It will cause problem in handling of the
motorcycle.
Always start the steering damper setting from its minimum
damping force position.
Note
・Do not turn the adjuster to clockwise further than its turning
end. It will break the stopper in the steering damper and
cause damping force adjustment malfunction.
・Be sure to install the steering damper within the tolerance of 2
spherical bearings movement. Inappropriate installation will
create unnecessary stress on the piston rod and disturb
steering movement.
・Do not damage the sliding surface of the piston rod. Score
marks or hitting marks cause damper oil leaks.
・Make sure that the steering damper is not fully stretched at
both steering ends. Also check the steering damper for
interference with the frame or other parts of the motorcycle.
・Do not disassemble the steering damper unit
・Make sure to use the thick washers (2.3mm) between the frame
and spherical bearing, and bottom bridge and spherical
bearing, then tighten the bolts.
(
1
)
Washers
(
2.3mm
)
(
2
)
S
p
herical bearin
g
s
PRINT EDITION 2.1
1-6

SERVICE INFORMATION
Service specification
Unit: mm
ITEM STANDARD SERVICE LIMIT
Recommended transmission oil HONDA Ultra-G1 (4-stroke
motorcycle oil)
LUBRICATION
SYSTEM
SPECIFICATIONS Recommended engine oil HONDA Ultra-G1 (4-stroke
motorcycle oil)
Venturi diameter 40
Carburetor identification number FCR12C A
Float level 6.0
Main jet #160
Slow jet #42
Jet needle NCYR
Pilot screw initial opening 1-1/4 turns out
FUEL SYSEM
SPECIFICATIONS
Jet needle clip position(Standard) 4th groove from top
Coolant Tap water (soft water) or
drinking waterCOOLING SYSEM
SPECIFICATIONS
Radiator cap relief pressure 1.1－1.4kgf/c ㎡
Clutch spring free length 38.8 38.0
Clutch disc thickness 2.92-3.08 2.85
CLUTCH
SPECIFICATION
Clutch plate warpage －0.10
Cylinder compression 392kPa(0.95-1.25kgf/c ㎡)－
Cylinder head warpage －0.05
ＩＮ 35.580-35.660 35.44Camshaft Cam lobe height
ＥＸ 25.081-25.161 24.98
Valve lifter O.D. 22.478-22.493 22.47Valve lifter
Valve lifter bore I.D. 22.510-22.526 22.54
ＩＮ 0.12±0.3 －Valve clearance
ＥＸ 0.28±0.3 －
ＩＮ 4.975-4.990 －Valve stem O.D.
ＥＸ 4.965-4.980 4.955
Valve guide I.D. ＩＮ/ＥＸ 5.000-5.012 5.052
ＩＮ 0.010-0.037 －Stem-to-guide
clearance ＥＸ 0.020-0.047 －
ＩＮ 14.8-15.0 －Valve guide projection
above cylinder head ＥＸ 19.9-20.1 －
Valve and
valve guide
Valve seat width ＩＮ/ＥＸ 0.90-1.10 1.7
ＩＮ 39.47 38.5Valve
spring
Valve spring free
length ＥＸ 43.07 42.1
Rocker arm I.D. 12.016-12.034 12.07
Rocker arm shaft O.D. 11.977-11.985 11.93
CYLINDER
HEAD/VALVE
SPECIFICATION
Rocker
arm
Rocker arm-to-shaft clearance 0.031-0.057 0.11
Warpage －0.05Cylinder
I.D. 78.00-78.015 78.025
Circularity / Cylindricity －0.010
O.D. (7mm from the bottom of skirt) 77.970-77.980 77.940
Piston
Cylinder-to-piston clearance 0.020-0.045 0.085
Piston pin bore I.D. 16.002-16.008 16.03
Piston pin O.D. 15.994-16.000 15.98
Piston pin
Piston-to-piston pin clearance 0.002-0.014 0.04
Top ring 0.15-0.25 0.39Piston ring end
gap Oil ring 0.20-0.70 0.90
Piston ring
Piston ring-to ring groove
clearance (Top)
0.065-0.100 0.08
Connecting rod small end I.D. 16.016-16.038 16.04
CYLINDER/PISTON
SPECIFICATIONS
Connecting rod-to-piston pin clearance 0.016-0.044 0.06
PRINT EDITION 2.1
2-1

SERVICE INFORMATION
ITEM STANDARD SERVICE LIMIT
FRONT 1.8kgf/c ㎡－Cold tire pressure
REAR 1.9kgf/c ㎡－
Axle runout －0.5ｍｍ
Radical －0.3ｍｍWheel rim runout
Axial －0.3ｍｍ
Drive chain slack 20ｍｍ±2ｍｍ －
WHEEL/TIRE
SPECIFICATION
Drive chain slider thickness －2.0ｍｍ
Fork tube runout －0.20ｍｍ
Fork oil (type) HONDA Ultra Cushion Oil
Special (SAE5W), SHOWA
SS05 or equivalent
－
R L
(Std) 111ｍｍ 106ｍｍ －
(Upper) 92ｍｍ 87ｍｍ －
Fork oil level
(Lower) 152ｍｍ 147ｍｍ －
(Std) 233ｃ㎥ －
(Upper) 257ｃ㎥ －
Fluid capacity
(Lower) 210ｃ㎥ －
Compression damping adjuster standard position 10 clicks out from full in －
FRONT
SUSPENSION
SPECIFICATION
Rebound damping adjuster standard position 6 clicks out from full in －
Damper gas pressure 10.0-13.0kgf/c ㎡－
Damper rod compressed force (at 10mm compressed) 15.4-20.0kgf －
Spring installed length 147ｍｍ －
Compression damping adjuster standard position 6 clicks out from full in －
REAR
SUSPENSION
SPECIFICATION
Rebound damping adjuster standard position 10 clicks out from full in －
Brake fluid ＤＯＴ４ －
Brake disk thickness 4.0ｍｍ 3.5ｍｍ
Brake disc runout －0.3ｍｍ
Master cylinder I.D. 12.700-12.743ｍｍ 12.755ｍｍ
Front
Master piston O.D. 12.657-12.684ｍｍ 12.650ｍｍ
Brake disk thickness 4.0ｍｍ 3.5ｍｍ
Brake disc runout －0.3ｍｍ
Master cylinder I.D. 12.700-12.743ｍｍ 12.755ｍｍ
Master piston O.D. 12.657-12.684ｍｍ 12.650ｍｍ
Caliper cylinder I.D. 27.000-27.005ｍｍ 27.06ｍｍ
HYDRAULIC
BRAKE
SPECIFICATION
Rear
Caliper piston I.D. 26.900-26.950ｍｍ 26.85ｍｍ
PRINT EDITION 2.1
2-2