Covered Systems:
Engine, Fuel System, Lubrication System, Exhaust System, Transmission, Clutch, Suspension, Brakes, Electrical System, Ignition System, Lights, Meters, Switches, Body Panels, Steering System, Wheel Assembly
Estimated Pages:
Refer to file size and typical manual density for estimation, likely several hundred pages.
Type:
Workshop Service Repair Manual
Engine Mechanical:
Detailed breakdown and assembly of all internal engine components including crankshaft, piston, cylinder, cylinder head, valves, camshaft, and timing.
Fuel System:
Carburetor identification, adjustment, disassembly, cleaning, and reassembly. Fuel tank, lines, and filter service.
Lubrication System:
Oil pump operation, oil filter replacement, oil change procedures, and oil passage cleaning.
Cooling System:
Air-cooling system principles, inspection, and cleaning of fins.
Exhaust System:
Muffler and exhaust pipe removal, installation, and inspection.
Transmission And Drivetrain:
Gearshift linkage adjustment, transmission gear inspection, bearing checks, and clutch operation.
Clutch:
Clutch lever, cable adjustment, clutch plate inspection and replacement, and clutch cover gasket service.
Wheels And Tires:
Wheel bearing inspection and lubrication, spoke tensioning, tire pressure checks, and tire replacement procedures.
Suspension:
Front fork inspection, service, and seal replacement. Rear shock absorber inspection and linkage maintenance.
Steering:
Steering bearing inspection, lubrication, and adjustment. Handlebar and control lever service.
Braking System:
Hydraulic brake system bleeding, pad inspection and replacement, caliper service, and lever/pedal adjustment.
Electrical System:
Battery inspection and maintenance, charging system (alternator) testing, and ignition system troubleshooting.
Ignition System:
Spark plug inspection and replacement, ignition timing checks, and CDI unit testing (if applicable).
Lighting And Indicators:
Headlight, taillight, brake light, and meter illumination bulb replacement and inspection.
Bodywork And Chassis:
Removal and installation of body panels, fenders, seat, and fuel tank.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, tire pressure checks, brake adjustments.
Engine Rebuilding:
Complete engine disassembly, inspection of wear limits, component replacement (pistons, rings, valves, bearings), and reassembly.
Troubleshooting:
Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical systems.
Suspension Service:
Front fork oil change, seal replacement, and rear shock absorber checks.
Brake Service:
Bleeding hydraulic systems, caliper maintenance, pad replacement, and hose inspection.
Electrical Diagnostics:
Wiring diagram interpretation, component testing (ignition coil, stator, rectifier/regulator), and fault finding.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls.
Diagnostic Focus:
Detailed troubleshooting guides with specific symptoms and corrective actions.
Repair Focus:
Step-by-step instructions with clear diagrams for component removal, repair, and installation.
Configuration:
149 cc, Single-cylinder, 4-stroke
Cooling System:
Air-cooled
Valve Train:
SOHC (Single Overhead Camshaft)
Bore X Stroke:
Typically around 57.3 mm x 57.8 mm (exact for specific model year should be verified within manual).
Compression Ratio:
Typically around 9.5:1 (exact for specific model year should be verified within manual).
Horsepower:
Approx. 12-14 HP (at ~8,000 RPM, subject to model year and tuning).
Torque:
Approx. 12-13 Nm (at ~6,000 RPM, subject to model year and tuning).
Carburetor Type:
Keihin (e.g., PE26) or similar CV-type carburetor.
Fuel Type:
Unleaded gasoline (typically 87 octane or higher).
Oil Type:
SAE 10W-30 API SG or higher motorcycle-specific 4-stroke engine oil.
Oil Capacity:
Approx. 1.6 Liters (with filter change, subject to model year).
Oil Change Interval:
Every 1000 km or 6 months (refer to manual for specific recommendations).
Air Filter Cleaning:
Every 10-20 hours of operation or as needed based on conditions.
Spark Plug Replacement:
Every 6000 km or annually.
Valve Clearance Check:
Every 6000 km or annually.
Engine Oil:
SAE 10W-30 API SG or higher motorcycle 4-stroke oil.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (for hydraulic systems).
Chain Lube:
Specific motorcycle chain lubricant.
Carburetor Clogging:
Can occur with infrequent use or poor fuel quality, requiring cleaning.
Suspension Seals:
Front fork seal leaks can develop with hard use.
Clutch Adjustment:
Cable stretching may require periodic adjustment.
