Systems Covered:
Engine (mechanical & electrical), Fuel System, Ignition System, Cooling System, Transmission (CVT), Chassis, Suspension (front & rear), Brakes (front & rear), Electrical System (lighting, starting, charging), Bodywork, Wheels & Tires, Maintenance, Troubleshooting, Diagnostics, Specifications
Estimated Page Count:
~200-250 pages (estimated based on typical workshop manuals for this class of vehicle)
Manual Type:
Workshop Repair Service Manual
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of engine components including cylinder, piston, crankshaft, connecting rod, valves, camshaft, timing system, oil pump.
Fuel System:
Carburetor (Teikei YG or similar) identification, adjustment, overhaul, fuel pump, fuel filter, fuel lines.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing, stator and pickup coil inspection.
Cooling System:
Radiator, fan, water pump, thermostat, coolant specifications, flushing and filling procedures.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) system, variator, torque converter, drive belt inspection and replacement, clutch operation, final drive unit.
Chassis Frame:
Frame inspection, steering head bearing maintenance, center stand and side stand.
Suspension Front:
Telescopic fork disassembly, inspection, oil change, seal replacement, spring specifications.
Suspension Rear:
Monoshock absorber adjustment and replacement, swingarm bearing inspection and lubrication.
Brakes Front:
Disc brake system, caliper overhaul, pad replacement, fluid flush, hose inspection, master cylinder.
Brakes Rear:
Disc brake system (likely), caliper overhaul, pad replacement, fluid flush, hose inspection, master cylinder.
Electrical System Charging:
Stator, rectifier/regulator, battery maintenance and testing.
Electrical System Starting:
Starter motor, starter solenoid, battery testing.
Electrical System Lighting:
Headlight, taillight, turn signals, brake light wiring and bulb replacement.
Bodywork Trim:
Fairing removal and installation, seat, storage compartment, paneling.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure, tire wear limits, rim specifications.
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, fluid level checks, filter replacements.
Troubleshooting Diagnostics:
Systematic diagnostic flowcharts for common problems (e.g., no start, poor performance, electrical faults).
Repair Rebuild:
Step-by-step instructions for component removal, repair, and reinstallation for all major systems.
Component Adjustment:
Carburetor adjustments, brake lever free play, throttle cable adjustment, suspension settings.
Wiring Diagrams:
Detailed electrical system wiring diagrams for all circuits.
Depth Level:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers detailed specifications, torque values, tolerances, and diagnostic procedures.
Engine Type 125:
Four-stroke, liquid-cooled, SOHC, 2-valve
Bore X Stroke 125:
52.0 mm x 51.8 mm (estimated)
Displacement 125:
124.9 cc
Compression Ratio 125:
10.0:1 (estimated)
Fuel System 125:
Carburetor (Teikei YG or similar), 30mm or 32mm diameter (estimated)
Engine Type 200:
Four-stroke, liquid-cooled, SOHC, 2-valve
Bore X Stroke 200:
62.0 mm x 51.8 mm (estimated)
Displacement 200:
197.9 cc
Compression Ratio 200:
10.0:1 (estimated)
Fuel System 200:
Carburetor (Teikei YG or similar), 32mm or 34mm diameter (estimated)
Max Power 125:
Approximately 12-14 HP @ 8500-9000 RPM (estimated)
Max Torque 125:
Approximately 10-11 Nm @ 7500-8000 RPM (estimated)
Max Power 200:
Approximately 16-18 HP @ 8000-8500 RPM (estimated)
Max Torque 200:
Approximately 15-17 Nm @ 7000-7500 RPM (estimated)
Oil Change Interval:
Every 3,000-4,000 km or annually (refer to manual for exact mileage)
Air Filter Replacement:
Every 6,000-8,000 km or as needed
Spark Plug Replacement:
Every 8,000-10,000 km
Brake Fluid Flush:
Every 2 years or as per manual recommendation
Coolant Flush:
Every 2-3 years or as per manual recommendation
Engine Oil Spec:
SAE 10W-40 API SG or higher (refer to manual for exact specification)
Engine Oil Capacity:
Approx. 1.3 - 1.5 Liters (with filter change)
Coolant Spec:
Ethylene glycol based antifreeze, 50% mixture with distilled water
Common Wear Items:
CVT drive belt, brake pads, tires, fork seals, battery.
Potential Electrical Issues:
Age-related issues with wiring loom connectors or rectifier/regulator may occur, though generally robust.
Carburetor Tuning:
Carburetor may require periodic cleaning and adjustment due to fuel quality variations.