Segment:
Enduro/Off-Road Motorcycle
Competitors:
KTM EXC, Yamaha WR, Honda CR, Suzuki RM
Vehicle Type:
Two-stroke, liquid-cooled Enduro motorcycle
Manual Purpose:
To provide comprehensive guidance for maintenance, repair, and troubleshooting
Engine:
Engine disassembly, assembly, troubleshooting, tuning, component overhaul
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank
Ignition System:
Ignition coil, spark plug, CDI unit, timing
Cooling System:
Radiator, hoses, thermostat, coolant specifications
Transmission:
Gearbox disassembly, assembly, inspection, fluid specifications
Clutch:
Clutch operation, adjustment, replacement (friction plates, pressure plates)
Suspension:
Front forks (Öhlins or WP depending on spec), rear shock absorber, linkages, seals, oil levels, valving
Brakes:
Hydraulic brake systems (front and rear), caliper service, master cylinder, brake fluid specifications, bleeding procedures
Electrical System:
Wiring diagrams, lighting, battery, charging system, starter, switches, fuses
Exhaust System:
Exhaust pipe and silencer maintenance
Wheels And Tires:
Wheel bearing service, tire pressure, rim specifications
Frame And Bodywork:
Chassis inspection, seat, plastics, decals
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Component Overhaul:
Detailed step-by-step instructions for rebuilding major components
Specifications And Tolerances:
Torque values, clearances, measurements for all serviceable parts
Adjustment Procedures:
Carburetor jetting, ignition timing, clutch, brake lever adjustments
Depth:
Mechanic-level detail, suitable for in-depth repairs and diagnostics
Engine Type:
Two-stroke, liquid-cooled
Bore X Stroke:
72.0 mm x 85.0 mm (typical for this era/displacement)
Compression Ratio:
Approx. 8.0:1 to 9.0:1 (typical for off-road two-strokes)
Horsepower:
Approx. 40-45 HP (estimated, varies with tuning and specific model year)
Torque:
Not readily specified, but characteristic of strong mid-range power for off-road use
Carburetor Model:
Mikuni VM38SS or similar 38mm flat-slide carburetor (common for this model)
Fuel Type:
Unleaded gasoline with appropriate two-stroke oil pre-mix (ratio specified in manual)
Premix Oil:
High-quality synthetic or mineral two-stroke oil (specific grades recommended in manual)
Oil Change:
Every 10-15 hours of riding, or as specified by manual (typical for 2-strokes)
Air Filter Cleaning:
After every few rides or as needed depending on conditions
Spark Plug Check:
Regularly, before extended rides
Engine Oil Premix:
Refer to manual for specific API service classification and viscosity grade (e.g., SAE 2T)
Transmission Oil:
Refer to manual for specific grade (e.g., SAE 80W/90 or ATF)
Coolant:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water
Brake Fluid:
DOT 3 or DOT 4 (refer to manual for exact specification)
Two Stroke Specific:
Piston ring wear, cylinder scoring, crank seal leaks, carburetor jetting sensitivity, exhaust port carbon buildup
Suspension Wear:
Fork seal leaks, rear shock absorber degradation over time
Electrical Gremlins:
Corroded connections, failing ignition components (common in off-road environments)
