HITLIS Quick Installation Guide | Step-by-Step Setup

HITLIS Quick Installation Guide | Step-by-Step Setup

Installing HITLIS on your YZ250 is a straightforward process that improves throttle response and eliminates power valve flutter. This guide provides a detailed step-by-step breakdown of the installation, from disassembly to final setup.

If you need more in-depth guidance, be sure to check out the Extended HITLIS Installation Guide, which offers additional details and troubleshooting tips for a seamless installation process.

Step 1: Preparing the Bike for Installation

  • Gather the required tools: sockets (6mm, 8mm, 10mm), wrenches (8mm, 12mm), Allen wrenches, pliers, and a hooked pick.
  • Drain the coolant and oil to prepare for disassembly.
  • Remove the seat, fuel tank, kick lever, and exhaust pipe for access.

Step 2: Disassembling the Power Valve System

  • Remove radiators, linkage covers, and PV box covers.
  • Take out the valve shaft screws and linkage components carefully.
  • Use a pick to remove the washers, springs, and pulleys inside the PV box.

Step 3: Setting Up the Governor with HITLIS

  • Replace the old thrust washers and springs with HITLIS components.
  • Adjust the preload settings for different riding conditions (0.8mm for desert setup, 0.9mm for woods setup).
  • Reassemble the governor linkage and gear alignment for precise movement.

Step 4: Installing the HITLIS System

  • Insert new pulleys, torsion springs, and washers onto the power valve shaft.
  • Ensure proper alignment of linkage arms and spring positioning.
  • Tighten all screws while maintaining silky smooth movement.

Step 5: Reassembly & Final Checks

  • Reinstall the side case, radiators, kick lever, and pipe.
  • Refill the coolant and oil to complete the process.
  • Verify that all power valves are moving freely before testing the bike.

With HITLIS installed, take your bike for a test ride. If needed, fine-tune the governor settings to adjust power delivery. 

 

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