Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of engine components.
Fuel System:
Carburetor (Mikuni VM28 type is common for this era, though specific model may vary), fuel tank, fuel lines, filters.
Ignition System:
CDI, spark plug, stator, wiring.
Cooling System:
Radiator, coolant hoses, fan (if applicable), thermostat.
Exhaust System:
Muffler, exhaust pipes, gaskets.
Transmission:
Gearbox internals, clutch operation and adjustment, gear shift mechanism.
Suspension Front:
Upside-down telescopic forks, internal components, seals, fluid replacement, adjustments.
Suspension Rear:
Monoshock absorber, linkage system, adjustment procedures, rebuild.
Braking System Front:
Hydraulic disc brake caliper, master cylinder, brake lines, pad replacement, rotor specifications.
Braking System Rear:
Hydraulic disc brake caliper, master cylinder, brake lines, pad replacement, rotor specifications.
Wheels Tires:
Spoke wheel maintenance, hub bearings, tire pressure, recommended tire sizes.
Electrical System:
Wiring diagrams, lighting, battery maintenance, charging system, fuses, switches.
Frame Chassis:
Frame inspection, steering head bearings, swingarm maintenance.
Bodywork Plastics:
Fairing removal and installation, seat, fuel tank cover.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication, air filter cleaning.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling major and minor components.
Adjustments:
Carburetor tuning, clutch and brake lever adjustments, suspension settings.
Rebuilds:
Engine top-end and bottom-end rebuilds, carburetor rebuilds, suspension fork and shock rebuilds.
Torque Specifications:
Detailed torque values for all critical fasteners.
Depth Of Information:
Comprehensive, covering all aspects from basic checks to complete overhauls.
Diagrams Illustrations:
Detailed pictorial diagrams, exploded views, and photographs.
Special Tools:
Identification and usage instructions for specialized service tools.
Service Data:
Precise specifications, tolerances, and wear limits.
Engine Type:
Single-cylinder, 2-stroke, liquid-cooled
Displacement:
Approximately 249cc (exact bore and stroke would be detailed in the manual)
Bore X Stroke:
Refer to manual for exact specifications.
Compression Ratio:
Refer to manual for exact specifications.
Horsepower:
Estimated around 40-45 HP, depending on tuning and specific model variant.
Torque:
Refer to manual for precise figures and delivery curve.
Fuel Delivery:
Carburetor (likely Mikuni VM28 or similar 28mm constant-velocity carburetor).
Fuel Type:
Unleaded gasoline (Octane rating specified in manual).
Oil Mixture:
Premix or Autolube system (specific details in manual).
Engine Oil Type:
Specific 2-stroke engine oil, viscosity and brand recommendations in manual.
Transmission Oil Type:
Specific gearbox oil, viscosity and brand recommendations in manual (e.g., SAE 75W/90 or 10W/40 for wet clutches).
Length:
Refer to manual for precise dimensions.
Width:
Refer to manual for precise dimensions.
Height:
Refer to manual for precise dimensions.
Dry Weight:
Typically around 105-110 kg (231-243 lbs) for this class of enduro bike.
Wet Weight:
Refer to manual for accurate specification with fluids.
Fuel Capacity:
Approximately 8-10 Liters (2.1-2.6 Gallons), confirm in manual.
Wheelbase:
Refer to manual for precise dimensions.
Ground Clearance:
Refer to manual for precise dimensions.
Engine Oil Change Interval:
Typically every 10-15 hours of riding for aggressive use, or as specified in the periodic maintenance chart within the manual.
Air Filter Cleaning Interval:
Frequent cleaning recommended, especially in dusty conditions, check after every few rides as per manual.
Spark Plug Maintenance:
Inspection and cleaning/replacement at regular intervals (e.g., every 50-100 hours or as per manual).
Chain Lubrication Adjustment:
Lubricate every 300-500 km or as needed based on conditions; check and adjust tension regularly.
Valve Clearance Check:
Not applicable for 2-stroke engines.
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed with distilled water in a 50/50 ratio. Specific capacity in manual.
Common Issues:
Potential for carburetor jetting issues in varying altitudes/temperatures, standard 2-stroke wear on piston/rings over extended high-hour usage, clutch wear. Manual provides diagnostic steps for these.
Suspension Seal Wear:
Fork seal leaks are common on off-road bikes; the manual details replacement procedures.
