Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly of engine components including cylinder, piston, rings, crankshaft, connecting rod, valve train, and timing.
Engine Fuel System:
Carburetor (model specific, e.g., Dell'Orto PHVA) tuning, cleaning, rebuilding, fuel pump operation, fuel filter replacement.
Engine Ignition System:
CDI unit, spark plug specifications, ignition timing, stator and rotor testing.
Cooling System:
Radiator, fan operation, coolant capacity, thermostat replacement, bleed procedures.
Transmission Clutch:
Automatic transmission (CVT) operation, belt inspection and replacement, variator maintenance, clutch shoe inspection.
Brakes Front:
Disc brake caliper service, pad replacement, hydraulic system bleeding, master cylinder inspection, rotor specifications.
Brakes Rear:
Disc brake caliper service, pad replacement, hydraulic system bleeding, master cylinder inspection, rotor specifications.
Suspension Front:
Telescopic fork overhaul, oil level and type, seal replacement, spring inspection.
Suspension Rear:
Monoshock absorber service, linkage lubrication, bush replacement, spring preload adjustment.
Electrical System Charging:
Stator output testing, regulator/rectifier function, battery testing and maintenance.
Electrical System Lighting:
Headlight, taillight, turn signal bulb replacement and wiring checks.
Electrical System Starting:
Starter motor service, solenoid function, wiring harness inspection.
Electrical System Instrumentation:
Speedometer, tachometer, fuel gauge, warning light diagnostics.
Frame Chassis:
Frame inspection for damage, headstock bearing service, swingarm bearing maintenance.
Bodywork Fairings:
Fairing panel removal, installation, and repair, seat removal, storage compartment access.
Wheels Tires:
Wheel bearing replacement, tire pressure recommendations, tire removal and installation.
Scheduled Maintenance:
Detailed steps for routine checks and services at specified intervals (e.g., oil changes, filter replacements, belt tension).
Troubleshooting Diagnostics:
Systematic approach to identifying and resolving common problems with diagnostic flowcharts and symptom-based solutions.
Engine Rebuild:
Comprehensive instructions for complete engine disassembly, part measurement, clearance checks, and reassembly for both 125cc and 200cc variants.
Transmission Overhaul:
Detailed guidance on CVT removal, inspection of drive belt, clutch assembly, and variator components.
Brake System Service:
Step-by-step instructions for brake pad replacement, caliper servicing, hydraulic line bleeding, and master cylinder rebuilding.
Fork Seal Replacement:
Detailed guide on front fork disassembly, oil replacement, and seal replacement for optimal suspension performance.
Electrical Component Testing:
Procedures for testing ignition coils, stator, regulator/rectifier, starter motor, and battery condition using multimeters.
Carburetor Cleaning And Adjustment:
In-depth instructions for carburetor disassembly, cleaning jets, float bowl adjustment, and idle speed/mixture settings.
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds, electrical diagnostics, and chassis component overhauls.
Diagnostic Information:
Includes specific fault codes (if applicable), diagnostic procedures, and expected values for electrical and mechanical components.
Torque Specifications:
Extensive listing of all critical torque values for fasteners across all major components (engine, chassis, brakes, suspension).
Clearances And Tolerances:
Precise specifications for engine component clearances (piston-to-cylinder, ring gap, bearing play) and other critical tolerances.
Wiring Diagrams:
Detailed electrical wiring schematics for all circuits, including lighting, ignition, starting, and instrumentation.
Engine Type 125:
Single-cylinder, four-stroke, liquid-cooled, OHC
Engine Type 200:
Single-cylinder, four-stroke, liquid-cooled, OHC
Bore X Stroke 125:
52.0 mm x 51.8 mm (approx.)
Bore X Stroke 200:
62.0 mm x 65.0 mm (approx.)
Displacement 125:
124.9 cc
Displacement 200:
197.9 cc
Horsepower 125:
Approx. 14-15 HP @ 9,000 RPM
Horsepower 200:
Approx. 17-18 HP @ 8,000 RPM
Torque 125:
Approx. 11-12 Nm @ 7,500 RPM
Torque 200:
Approx. 15-16 Nm @ 6,500 RPM
Carburetor Type:
Dell'Orto PHVA (specific model varies by market/engine)
Fuel Delivery:
Gravity feed with electric fuel pump (on some models/configurations)
Fuel Type:
Unleaded gasoline (min. 95 RON recommended)
Fuel Tank Capacity:
Approx. 13 Liters (including reserve)
Engine Oil Change Interval:
Every 3,000 - 5,000 km or annually, whichever comes first. (Refer to manual for specific type.)
Air Filter Cleaning Replacement:
Check every 5,000 km, clean or replace as needed.
Spark Plug Replacement:
Every 10,000 - 15,000 km (specific plug type and gap essential).
Cvt Belt Inspection Replacement:
Inspect every 10,000 km, replace typically between 15,000 - 20,000 km depending on wear.
Coolant Flush Replacement:
Every 2 years or 20,000 km.
Engine Oil Type:
API SG or higher, SAE 10W-40 synthetic or semi-synthetic motorcycle oil (confirm with manual for exact spec).
Engine Oil Capacity:
Approx. 1.0 - 1.2 Liters (with filter change).
Coolant Type:
Ethylene glycol based antifreeze coolant (50% mixture with distilled water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt, brake pads, fork seals, drive bearings.
Potential Electrical Issues:
Degradation of wiring insulation over time, regulator/rectifier failure, starter solenoid issues.
Engine Performance Degradation:
Can be caused by carburetor issues (clogging, incorrect adjustment), worn CVT components, or carbon buildup.