Category:
High-performance off-road motorcycle, specifically an enduro competition machine with dual-sport capability.
Target Audience:
Enthusiast riders, competitive off-road racers, and individuals seeking a robust and capable adventure/trail bike.
Competitors 2008:
Yamaha WR450F, Honda CRF450X, Husqvarna TE450, Beta RR450.
Engine Type:
Liquid-cooled, SOHC, four-stroke single-cylinder.
Suspension Provider:
WP Suspension (known for high-quality performance components).
Frame Material:
Chromium-molybdenum steel trellis frame.
Offroad Focus:
Designed with a strong emphasis on off-road performance, with street-legal features for dual-sport use.
Engine:
Complete engine overhaul, including top-end, bottom-end, valve adjustments, timing, lubrication system.
Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting, fuel pump (if applicable), fuel lines.
Ignition System:
CDI unit, spark plug, ignition coil, wiring diagrams.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, chain and sprocket maintenance, oil change procedures.
Cooling System:
Radiator, coolant, fan operation, bleeding procedures.
Exhaust System:
Muffler, header pipe maintenance, de-carbonizing.
Suspension Front:
WP USD (Upside-Down) forks: disassembly, seal replacement, oil change, damping adjustments, spring preload.
Suspension Rear:
WP PDS (Progressive Damping System) or Monoshock: linkage maintenance, shock absorber disassembly, oil and gas charging, damping and rebound adjustments.
Brakes Front:
Brake caliper, master cylinder, brake pads, rotors, bleeding, fluid replacement.
Brakes Rear:
Brake caliper, master cylinder, brake pads, rotors, bleeding, fluid replacement.
Wheels Tires:
Spoke tensioning, wheel bearing replacement, tire fitting and balancing.
Electrical System:
Wiring harness inspection, battery maintenance, lighting, starter motor, stator, rectifier/regulator.
Frame Chassis:
Frame inspection, headstock bearing replacement, swingarm pivot maintenance.
Bodywork Plastics:
Fairing removal and installation, seat, fuel tank, fender maintenance.
Basic Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks.
Intermediate Repair:
Brake pad replacement, coolant flush, wheel bearing replacement, cable adjustments, clutch lever service.
Advanced Repair:
Engine top-end rebuild, piston and ring replacement, valve clearance adjustment, carburetor re-jetting, suspension fork service, shock absorber rebuild.
Troubleshooting:
Diagnostic charts for common problems (e.g., hard starting, poor performance, electrical issues).
Electrical Diagnostics:
Fault finding for charging system, ignition system, and lighting circuits.
Suspension Tuning:
Detailed instructions on adjusting damping and spring preload for various riding conditions.
Torque Specifications:
Detailed torque values for all critical fasteners.
Clearances Tolerances:
Specifications for valve clearances, piston-to-cylinder wall, bearing tolerances, etc.
Special Tools:
Identification of necessary special tools for specific repair procedures.
Wiring Diagrams:
Comprehensive electrical wiring schematics for the motorcycle.
Exploded Views:
Detailed exploded diagrams of all major components for easy identification and assembly.
Engine Type:
Liquid-cooled, four-stroke, single-cylinder, SOHC
Bore X Stroke:
97.0 mm x 60.8 mm
Compression Ratio:
11.9:1 (typical for this engine family)
Horsepower:
Approx. 50-55 HP (at crankshaft, estimated based on similar models)
Torque:
Approx. 45-48 Nm (at crankshaft, estimated)
Carburetor:
Keihin FCR-MX 39 (Flat-slide, Constant Velocity, Racing, Motocross type)
Fuel Type:
Unleaded gasoline, minimum 95 octane recommended
Oil Type:
Fully synthetic motorcycle-specific 4-stroke oil (e.g., Motorex Power Synt 4T 10W/50 or equivalent)
Oil Capacity:
Approx. 1.1 liters (dry fill) / 1.0 liters (with filter change)
Certification:
CE and EPA compliant for street use in applicable regions (e.g., USA).
Brakes:
Hydraulic disc brakes front and rear (e.g., Brembo calipers), providing strong stopping power.
Lighting:
Headlight, taillight, brake light, turn signals (for street legality).
Frame Design:
Robust trellis frame provides excellent rigidity and rider feedback.
Ergonomics:
Designed for an upright riding position, offering rider control and maneuverability.
Engine Oil Change:
Every 15-20 hours of riding or annually, whichever comes first (refer to manual for precise recommendations).
Oil Filter Replacement:
Every 2-3 oil changes or as per manual.
Air Filter Cleaning:
Frequent cleaning recommended for off-road use, especially in dusty conditions (e.g., every 5-10 hours).
Valve Adjustment:
Every 30-40 hours of riding or annually, crucial for maintaining performance and preventing damage.
Spark Plug Check:
Every 15-20 hours of riding.
Chain Adjustment Lubrication:
Every 500-1000 km or as needed, especially after washing or off-road riding.
Engine Oil:
SAE 10W/50, API SG or higher, JASO MA certified (e.g., Motorex Power Synt 4T 10W/50).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water. (e.g., Motul Motocool Expert).
Brake Fluid:
DOT 4 or DOT 5.1 (check specific manual for precise recommendation, typically DOT 4 is used).
Fork Oil:
WP recommend specific fork oil weights; commonly SAE 5W or 7.5W, but manual will specify exact type and volume per leg.
Clutch Actuation:
Occasional reports of clutch slave cylinder leaks, requiring seal replacement.
Carburetor Performance:
Can be sensitive to altitude and temperature changes; requires proper jetting for optimal performance.
Suspension Maintenance:
WP suspension requires regular servicing of seals and oil to maintain performance, especially under aggressive off-road use.
Cooling System Leaks:
Hose clamps and radiator integrity should be periodically checked for leaks.
