Vehicle Segment:
Dual-sport / Off-road motorcycle
Target Audience:
Riders seeking versatile on-road/off-road capability, enthusiasts, mechanics
Key Competitors 1996:
Honda XR250L, Yamaha XT225, Suzuki DR250SE
Vehicle Attributes:
Lightweight chassis, tractable engine, capable suspension for off-road use, road legal
Manual Value Proposition:
Empowers owners and technicians with complete diagnostic and repair knowledge for maintaining optimal performance and longevity.
Engine:
Complete overhaul, tuning, troubleshooting, specifications
Fuel System:
Carburetor (Keihin CVK34) diagnosis, cleaning, adjustment, jetting
Ignition System:
CDI, spark plug, timing, troubleshooting
Cooling System:
Liquid cooling, radiator, hoses, pump, coolant specifications
Exhaust System:
Header pipe, muffler, gasket replacement
Transmission:
Clutch operation, gearbox disassembly, reassembly, lubrication
Drivetrain:
Chain drive maintenance, sprocket replacement, lubrication
Suspension Front:
Fork disassembly, oil change, seal replacement, spring specifications
Suspension Rear:
Monoshock (Uni-Trak) adjustment, overhaul, linkage maintenance
Brakes Front:
Hydraulic disc, caliper service, pad replacement, fluid flush
Brakes Rear:
Hydraulic disc, caliper service, pad replacement, fluid flush
Wheels Tires:
Spoke maintenance, rim alignment, tire changing, pressure
Electrical System:
Wiring diagrams, battery service, lighting, charging system
Frame Chassis:
Inspection, lubrication points, bolt torque specifications
Bodywork Plastics:
Fairing removal, seat, tank, fender maintenance
Scheduled Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication
Troubleshooting:
Diagnostic flowcharts for common problems, electrical and mechanical issues
Engine Rebuild:
Piston, cylinder, valve, crankshaft, and camshaft service
Carburetor Tuning:
Idle speed, air/fuel mixture, jetting adjustments for altitude and modifications
Suspension Adjustment:
Sag settings, rebound, compression adjustments
Brake Bleeding:
Complete hydraulic brake system bleeding procedure
Wiring Diagram Analysis:
Component identification, circuit tracing
Torque Specifications:
All critical fasteners and components
Part Numbers:
References for key service parts
Depth:
Comprehensive, from basic maintenance to complete engine and chassis overhaul
Diagnostic Level:
Advanced diagnostic procedures and troubleshooting guides
Repair Procedures:
Detailed step-by-step repair instructions with illustrations
Engine Oil Change:
Every 3,000 km (1,800 miles) or 6 months
Oil Filter Change:
Every 6,000 km (3,600 miles) or 12 months
Spark Plug Inspection:
Every 3,000 km (1,800 miles)
Air Filter Cleaning:
Every 1,500 km (900 miles), or more frequently in dusty conditions
Chain Lubrication Adjustment:
Every 1,000 km (600 miles)
Engine Oil Type:
SAE 10W-40 API SG or higher motorcycle oil
Engine Oil Capacity:
1.6 L (1.7 US qt) without filter change, 1.8 L (1.9 US qt) with filter change
Coolant Type:
Ethylene glycol based coolant, 50% solution with distilled water
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Wear:
Potential for wear in the CV diaphragm or needle jet over high mileage, affecting fuel delivery.
Suspension Seals:
Fork seal leaks can occur with age and off-road use, requiring timely replacement.
Cam Chain Tensioner:
Some models may benefit from manual cam chain tensioner adjustment or replacement for optimal timing and noise reduction.
Exhaust Gaskets:
Exhaust header pipe gaskets can degrade, leading to leaks if not replaced during service.
