Installation Instructions for Motorcycle Crankcase Covers and Cylinder Gasket Kit Set

Compatible Models:

• 250R (93-96)
• 250 (94-95)
• 250ES (94-97)
• 250SR (93-97)

Tools Required:

1. Socket Wrench Set - For removing and installing screws and bolts.
2. Torque Wrench - To ensure bolts are tightened to the manufacturer's specifications.
3. Screwdriver Set - For tasks requiring flathead or Phillips head screws.
4. Scraper Tool - To remove old gaskets and ensure a clean surface.
5. Cleaning Supplies - Rags and degreaser for cleaning the crankcase and surrounding areas.
6. Sealant (if necessary) - To enhance the seal between components.
7. Gloves - To protect your hands and maintain cleanliness.
8. Safety Goggles - To protect your eyes during installation.

Installation Steps:

1. Preparation:

   • Ensure the motorcycle is parked on a flat surface and allowed to cool down completely.
   • Disconnect the negative terminal of the battery to avoid electrical issues during installation.

2. Removal of Existing Components:

   • Using the socket wrench and appropriate sockets, remove the crankcase cover and old gaskets carefully.
   • Utilize the scraper tool to remove remnants of the old gasket, ensuring the surface is clean and free from debris.

3. Cleaning:

   • Thoroughly clean the mating surfaces on the crankcase and cylinder using cleaning supplies.

4. Installation of New Gaskets:

   • Place the new gaskets from the kit onto the cleaned surfaces, ensuring proper alignment with the holes.
   • If instructed, apply sealant as per the manufacturer's guidelines to enhance gasket sealing.

5. Reassembly:

   • Reattach the crankcase cover, ensuring all gaskets are in their proper place.
   • Use the socket wrench to tighten all bolts and screws uniformly. Follow the recommended torque specifications with the torque wrench to prevent over-tightening.

6. Final Steps:

   • Reconnect the battery terminal.
   • Start the motorcycle and check for any leaks or irregular sounds.
   • Allow the engine to run for a few minutes, then recheck all bolts to ensure everything is secure.

Note:
Always refer to your motorcycle's service manual for specific instructions related to your model. If you encounter any issues during installation, consult a professional mechanic for assistance.