Segment:
Lightweight dual-sport/enduro motorcycle, popular for trail riding, off-road exploration, and light commuting.
Target Audience:
Enthusiast owners, mechanics, and restoration specialists looking for authoritative repair information.
Competitors Era:
Honda XR250L, Yamaha WR250, Suzuki DR250SE.
Engine Type:
Robust and reliable liquid-cooled 4-valve DOHC single-cylinder engine, known for its tractable power delivery.
Suspension:
Often featured advanced suspension components for its class, with adjustable front forks and a linkage-driven rear monoshock for capable off-road performance.
Versatility:
Designed as a true dual-sport, balancing off-road capability with street legality and moderate on-road comfort.
Repair Confidence:
Empowers owners to perform a wide range of maintenance and repairs, reducing reliance on external service providers.
Resale Value:
A well-maintained motorcycle with a documented service history (supported by this manual) can command a higher resale value.
Engine Overhaul:
Complete disassembly, inspection, repair, and reassembly of the engine. Includes cylinder head, piston, rings, crankshaft, connecting rod, valve train, timing chain, and lubrication system.
Fuel System:
Carburetor (model specific, likely Keihin), fuel pump, fuel lines, fuel tank maintenance, and troubleshooting.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, and coolant specifications.
Ignition System:
CDI unit, ignition coil, spark plug specifications, timing procedures, and troubleshooting.
Transmission:
Clutch operation, gearbox disassembly, inspection, repair, and lubrication. Includes gear ratios and shift mechanism.
Drivetrain:
Chain and sprockets maintenance, adjustment, and replacement. Rear wheel hub and drive bearing service.
Suspension Front:
Front forks (USD or conventional depending on specific sub-model), oil levels, seals, springs, damping adjustments, and rebuild procedures.
Suspension Rear:
Monoshock rear suspension, linkage system, shock absorber service, spring preload adjustment, and bearing maintenance.
Brakes Front:
Hydraulic disc brake system, caliper service, pad replacement, master cylinder, brake lines, fluid type, and bleeding procedures.
Brakes Rear:
Hydraulic disc brake system, caliper service, pad replacement, master cylinder, brake lines, fluid type, and bleeding procedures.
Wheels Tires:
Spoke wheel maintenance, rim care, tire mounting/removal, tube replacement, and balancing.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting (headlight, taillight, turn signals), horn, starter system, and fuse identification.
Chassis Frame:
Frame inspection, headstock bearings, swingarm pivot, and general chassis component service.
Bodywork Trim:
Fairings, fenders, seat, fuel tank cover, and other cosmetic component removal, installation, and care.
Routine Maintenance:
Oil changes, filter replacements, chain adjustments, air filter cleaning, spark plug checks, brake fluid flushes, and general inspection points.
Troubleshooting Diagnostics:
Step-by-step diagnostic flowcharts for common problems related to starting, running, electrical faults, and performance issues.
Engine Repair:
Detailed instructions for internal engine component repair, including decarbonization, gasket replacement, and part tolerance checks.
Carburetor Rebuild:
Complete carburetor disassembly, cleaning, jetting information, synchronization, and adjustment procedures.
Suspension Rebuild:
Fork seal replacement, damper rod service, shock absorber re-pressurization (if applicable to the era), and bushing replacement.
Brake System Service:
Hydraulic system bleeding, caliper piston service, master cylinder overhaul, and brake pad installation.
Electrical Component Testing:
Testing of ignition components, charging system output, and other electrical parts using a multimeter.
Wiring Diagram Interpretation:
Detailed, component-level wiring diagrams for troubleshooting electrical issues.
Torque Specifications:
Precise torque values for all critical fasteners throughout the motorcycle.
Special Tools:
Identification and usage of any specialized tools required for specific repair procedures.
Depth Level:
Comprehensive (from basic maintenance to full engine and chassis rebuilds).
Diagnostic Capability:
High - covers common failure points and provides systematic troubleshooting steps.
Repair Scope:
Encompasses all mechanical and electrical systems of the motorcycle.
Engine Type:
4-stroke, Liquid-cooled, DOHC, 4-valve, Single Cylinder
Bore X Stroke:
72.0 x 61.2 mm (typical for this generation)
Compression Ratio:
11.0:1 (typical)
Horsepower:
Approximately 27-30 HP @ 7500-8000 RPM (subject to tuning and specific market regulations)
Torque:
Approximately 20-22 lb-ft @ 6000-6500 RPM (subject to tuning and specific market regulations)
Fuel Delivery:
Carburetor (e.g., Keihin CVK34 or similar)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
SAE 10W-40 motorcycle oil, API SG or higher
Oil Capacity:
Approx. 1.6 - 1.8 Liters (with filter change)
Ignition System:
Digital CDI with electronic advance
Spark Plug:
NGK CR8E or equivalent (verify with manual)
Oil Change Interval:
Every 2,000-3,000 km (1,200-1,800 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 1,000-1,500 km (600-900 miles) or as needed based on riding conditions.
Spark Plug Check:
Every 3,000-4,000 km (1,800-2,500 miles).
Valve Clearance Check:
Every 6,000-8,000 km (3,700-5,000 miles) or every 12 months.
Brake Fluid Flush:
Every 12 months or 24 months, depending on conditions.
Engine Oil:
SAE 10W-40, API SG or higher, JASO MA certified.
Coolant:
Ethylene glycol based, 50/50 mixture with distilled water. Kawasaki Coolant Type 1 or equivalent.
Brake Fluid:
DOT 3 or DOT 4 (verify with manual).
Fork Oil:
Specific viscosity and amount detailed in manual (often 10W or 15W).
Carburetor Cleaning:
Carburetors can become gummed up with age and infrequent use, requiring cleaning and jetting.
Suspension Seals:
Fork seals are prone to wear and leakage, especially with off-road use, necessitating replacement.
Cam Chain Tensioner:
Some models may develop noise from the cam chain tensioner; manual provides inspection and adjustment procedures.
Exhaust Flange Gasket:
The exhaust header flange gasket can sometimes leak, requiring replacement.
