Engine:
Complete engine disassembly, assembly, tuning, diagnostics, and repair for the 200cc two-stroke engine.
Fuel System:
Carburetor adjustment, cleaning, rebuilding, fuel pump and line service.
Ignition System:
Ignition timing, coil testing, spark plug specifications, CDI unit diagnostics.
Cooling System:
Radiator, hoses, thermostat, coolant specifications and maintenance.
Transmission:
Clutch operation, gearbox disassembly, assembly, gear inspection, and lubrication.
Suspension:
Front fork disassembly, seal replacement, oil levels, rear shock absorber service and adjustments.
Brakes:
Hydraulic brake system bleeding, pad replacement, caliper service, master cylinder inspection.
Electrical System:
Wiring diagrams, component testing, battery maintenance, lighting, stator and rectifier service.
Chassis And Frame:
Frame inspection, headstock bearing service, swingarm maintenance.
Exhaust System:
Muffler and pipe maintenance, gasket replacement.
Wheel And Tire:
Wheel bearing service, spoke tensioning, tire pressure recommendations, and wheel balancing.
Bodywork And Fairings:
Removal and installation procedures for plastic panels, seat, and fuel tank.
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, brake adjustments.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component overhaul and replacement.
Diagnostics:
Methods for identifying and resolving issues across all major vehicle systems.
Electrical Troubleshooting:
Detailed troubleshooting flowcharts for electrical faults.
Suspension Tuning:
Guidance on adjusting suspension settings for various terrain and riding styles.
Carburetor Rebuilding:
Step-by-step instructions for full carburetor overhaul and jetting changes.
Depth:
Detailed, from basic maintenance to complete engine and component rebuilds.
Torque Specifications:
Precise torque values for all critical fasteners and engine components.
Clearances:
Specifications for valve clearances (if applicable to 2-stroke port timing), piston ring gap, and other critical tolerances.
Engine Type:
2-stroke, single-cylinder
Bore X Stroke:
64 mm x 60 mm
Cooling Method:
Liquid-cooled
Power Output:
Approx. 30-35 HP (Varies by tune and specific model variant)
Torque Output:
Approx. 25-28 Nm (Varies by tune and specific model variant)
Spark Plug Type:
NGK BR8ES (or equivalent, check manual for precise fitment)
Compression Ratio:
Approx. 7.5:1
Fuel Delivery:
Keihin PWK 35 carburetor
Fuel Type:
Unleaded gasoline with 2-stroke oil mix (ratio specified in manual)
Fuel Tank Capacity:
Approx. 9-11 Liters (Varies slightly by model year/submodel)
Oil Change Interval:
Every 10-15 hours of use or annually, whichever comes first (refer to manual for exact specification).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (typically every 5-10 hours).
Spark Plug Replacement:
Every 20-30 hours of use or as per manual recommendations.
Chain And Sprocket Maintenance:
Regular cleaning, lubrication, and tension adjustment (check after every ride).
Engine Oil Type:
Fully synthetic 2-stroke premix oil, specific API/JASO rating detailed in manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, specific mixture ratio detailed in manual.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Transmission Fluid Type:
Specified ATF or dedicated manual transmission fluid (refer to manual for exact type and quantity).
Common Wear Items:
Piston rings, clutch plates, crank seals, suspension seals, and carburetor jets are common wear items for this era of two-stroke.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustments.
Cooling System Maintenance:
Regular flushing and refilling of the cooling system is crucial to prevent overheating.
