Applicable Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Geographic Coverage:
Global (assumed based on typical service manual distribution)
Engine Variants Covered:
250cc V-Twin Engine
Estimated Page Count:
N/A (digital format, variable)
Type:
Service Repair Manual / Workshop Manual
Engine Mechanical:
Engine disassembly, assembly, overhaul, timing, valve clearance adjustment, lubrication system, cooling system.
Fuel System:
Carburetor systems (likely Mikuni or similar), fuel tank, fuel lines, fuel pump (if applicable), fuel filter replacement.
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit, wiring diagrams for ignition.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, final drive (chain and sprockets).
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, wiring diagrams.
Braking System:
Front and rear brake systems (likely disc brakes), brake fluid replacement, caliper maintenance, master cylinder, brake pad replacement.
Suspension System:
Front fork (telescopic), rear shock absorbers, swingarm, linkage maintenance.
Steering System:
Handlebar, steering stem, bearings, lubrication.
Frame Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank, fairings.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation.
Disassembly Assembly:
Detailed procedures for taking apart and putting back together various vehicle sub-assemblies.
Cleaning Reinstallation:
Procedures for cleaning parts and proper reinstallation techniques.
Depth:
Comprehensive: Covers from basic maintenance to complex engine and electrical system repairs, suitable for professional technicians and advanced DIYers.
Engine Type:
V-Twin, Four-Stroke
Bore X Stroke:
57.0 mm x 48.8 mm (typical for this model, confirm with manual)
Cooling System:
Air-cooled (most common for this generation)
Valvetrain:
DOHC, 4 valves per cylinder (typical)
Horsepower:
Approx. 29-32 HP @ 10,000 RPM (estimated, varies by specific model year and tune)
Torque:
Approx. 20-22 Nm @ 8,000 RPM (estimated)
Carburetor Type:
Dual Carburetors (e.g., Mikuni VM26 or similar)
Fuel Type:
Unleaded Gasoline (Octane rating as specified in manual)
Oil Type And Capacity:
Refer to manual for specific SAE viscosity grade (e.g., 10W-40) and capacity (typically around 1.8-2.0 liters).
Overall Length:
Refer to manual (typically around 2100-2200 mm)
Overall Width:
Refer to manual (typically around 750-800 mm)
Overall Height:
Refer to manual (typically around 1150-1200 mm)
Dry Weight:
Approx. 175-185 kg (estimated)
Wet Weight:
Approx. 190-200 kg (estimated, with all fluids)
Fuel Tank Capacity:
Approx. 15-17 Liters (estimated)
Safety Ratings:
N/A (Motorcycles typically do not have standardized crash ratings like cars)
Braking System Type:
Hydraulic Disc Brakes (Front & Rear)
Front Brake Spec:
Single Disc with 2-Piston Caliper (typical)
Rear Brake Spec:
Single Disc with 1 or 2-Piston Caliper (typical)
Lighting:
Halogen Headlight, LED/Incandescent Taillight and Turn Signals (as per model year)
Oil Change Interval:
Refer to manual (typically every 3,000 - 5,000 km or 6 months, whichever comes first)
Spark Plug Replacement:
Refer to manual (e.g., every 10,000 - 15,000 km)
Valve Clearance Check:
Refer to manual (typically every 10,000 - 15,000 km)
Chain Lubrication Adjustment:
Frequent checks recommended, especially under heavy use (e.g., every 500-1000 km).
Engine Oil Viscosity:
SAE 10W-40 is a common recommendation, but always verify in the manual.
Brake Fluid Type:
DOT 3 or DOT 4 (as specified in manual)
Coolant Type:
N/A (Air-cooled engine)
Fork Oil Type And Level:
Refer to manual for specific viscosity and fill level.
Common Wear Items:
Clutch plates, brake pads, fork seals, battery, tires, chain and sprockets.
Potential Electrical Gremlins:
Wiring harness connections, regulator/rectifier issues (common on many motorcycles).
Carburetor Tuning:
Can require periodic adjustment for optimal performance and fuel economy.
