Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the engine, including cylinder, piston, connecting rod, crankshaft, valves, camshafts, and timing components.
Fuel System:
Carburetor tuning, cleaning, and overhaul (likely Keihin or Mikuni based on model year), fuel pump, fuel lines, and tank maintenance.
Ignition System:
Ignition coil testing, spark plug specifications, CDI unit diagnostics, and wiring schematics for the ignition system.
Cooling System:
Radiator, cooling fan, water pump, thermostat, and coolant hose inspection and replacement procedures.
Exhaust System:
Exhaust pipe and silencer inspection, repair, and repacking (if applicable for off-road use).
Transmission Drivetrain:
Gearbox disassembly, inspection, and repair; clutch operation, adjustment, and replacement; chain and sprocket wear assessment and replacement.
Suspension Front:
Fork disassembly, oil change, seal replacement, spring inspection, and adjustment procedures for WP USD forks.
Suspension Rear:
Monoshock absorber inspection, service, and adjustment; linkage system lubrication and bearing checks; swingarm maintenance.
Brakes Front:
Brake caliper overhaul, pad replacement, master cylinder service, brake line inspection, and bleeding procedures.
Brakes Rear:
Rear brake caliper overhaul, pad replacement, master cylinder service, brake line inspection, and bleeding procedures.
Wheels Hubs:
Spoke tension adjustment, rim inspection, hub bearing replacement, and tire mounting/dismounting.
Electrical System:
Wiring diagrams, lighting system maintenance, battery testing and replacement, starter motor checks, and general electrical troubleshooting.
Frame Chassis:
Frame inspection for damage, steering head bearing service, subframe checks, and footpeg mount inspections.
Bodywork:
Fairing removal and installation, seat maintenance, fender replacement, and graphics application/removal.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common starting issues, running problems, and system malfunctions.
Engine Rebuild:
Detailed instructions for full engine disassembly, component measurement, and reassembly for major overhauls.
Suspension Service:
Front fork oil change, seal replacement, and rear shock absorber servicing.
Brake System Repair:
Brake bleeding, pad and disc replacement, and caliper/master cylinder servicing.
Carburetor Overhaul:
Complete cleaning, adjustment, and jetting guidance for the stock carburetor.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams and component testing methods.
Depth:
Comprehensive; covers everything from basic maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values.
Engine Type:
Liquid-cooled, 2-stroke single-cylinder
Displacement:
194 cc (bore x stroke typically around 62.5 mm x 65 mm, but confirm specific model variant)
Compression Ratio:
Typically around 8.5:1 to 9.5:1 for a 2-stroke of this era, subject to specific tuning.
Carburetor:
Likely a Keihin PWK or Mikuni TM series, 38mm common for this class.
Horsepower Estimated:
Approx. 35-40 HP (at crank, typical for this engine size and class)
Torque Estimated:
Approx. 25-30 Nm (at crank, typical)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (e.g., 50:1 or 40:1 ratio depending on oil and usage).
Premix Ratio:
Refer to manual for specific recommendation (e.g., 1:40 or 1:50).
Engine Oil Change:
Refer to manual; typically every 15-20 hours of riding for rigorous off-road use, or annually.
Air Filter Cleaning:
Clean after every few rides, or more frequently in dusty conditions. Replace as needed.
Spark Plug Inspection:
Inspect every 20-30 hours of riding. Replace if fouled or worn.
Chain Lubrication:
Lubricate every ride, or every 300-500 km depending on conditions.
Chain Tension Adjustment:
Check and adjust every 500-1000 km or as needed.
Engine Oil Type:
Dedicated 2-stroke engine oil, JASO FD or higher specification. Refer to manual for specific brand/type.
Transmission Oil Type:
Motorex Gear Oil 10W/40 or equivalent SAE 80W/90 transmission oil (confirm specific viscosity from manual).
Fork Oil Type:
WP Suspension Fluid or equivalent, typically SAE 5W or 7.5W. Refer to manual for specific viscosity and quantity.
Coolant Type:
Distilled water with a high-quality anti-freeze/anti-corrosion additive (e.g., 50% mix).
Power Valve Sticking:
Common on 2-stroke engines of this era, the power valve can accumulate carbon and stick, affecting performance. Regular cleaning is recommended.
Clutch Wear:
Aggressive riding can lead to premature clutch wear. Regular inspection of plates and springs is advised.
Suspension Seal Leaks:
Fork and shock seal leaks can occur with hard use, requiring seal replacement.
