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.