Engine Mechanical:
Engine assembly/disassembly, piston, rings, cylinder, cylinder head, valves, camshaft, crankshaft, lubrication system, cooling system (if applicable), timing components.
Fuel System:
Carburetor (Mikuni VM series common) or Fuel Injection (EFI) components, fuel pump, fuel filter, fuel lines, injectors, ECU (if applicable).
Ignition System:
Spark plug, ignition coil, CDI unit, stator, wiring diagrams.
Transmission Drivetrain:
Clutch operation and adjustment, gear shifting mechanism, transmission gears, bearings, seals, final drive (chain and sprockets maintenance).
Suspension:
Front forks (upside-down type common), rear shock absorber, linkage systems, fork oil replacement, seal replacement, spring rates, damping adjustments.
Brakes:
Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures, fluid specifications.
Electrical System:
Battery, starter motor, lighting system, wiring diagrams, fuses, relays, switchgear, instrument cluster, diagnostic connectors (if applicable).
Cooling System:
Radiator, coolant, water pump, hoses, thermostat (if liquid-cooled).
Exhaust System:
Exhaust pipe, muffler, heat shields, gasket replacement.
Chassis Frame:
Frame inspection, swingarm, steering head bearings, wheel bearings, axle maintenance.
Bodywork:
Fairings, plastics, seat, fuel tank removal and installation.
Preventative Maintenance:
Oil changes, filter replacements, chain adjustment, spoke tensioning, bolt torque checks, air filter cleaning/replacement.
Troubleshooting:
Diagnostic flowcharts for common problems, identification of symptoms and potential causes.
Engine Overhaul:
Complete engine rebuild procedures, including part replacement, clearances, and assembly sequences.
Suspension Servicing:
Fork seal replacement, fork oil and quantity specifications, rear shock absorber service.
Brake System Maintenance:
Brake pad replacement, caliper service, brake fluid flush and bleeding.
Electrical Diagnostics:
Wiring harness inspection, component testing, troubleshooting electrical faults using wiring diagrams.
Carburetor Rebuild Adjustment:
Disassembly, cleaning, reassembly, and adjustment of common carburetor models.
Efi System Diagnostics:
Basic diagnostics for fuel injection systems (if equipped), sensor checks.
Wheel Bearing Replacement:
Procedure for replacing front and rear wheel bearings.
Steering Head Bearing Service:
Inspection and replacement of steering head bearings.
Torque Specifications:
Critical torque values for fasteners throughout the motorcycle.
Depth Level:
Comprehensive (covers routine maintenance to major component overhaul and diagnostics).
Diagnostic Capabilities:
Includes troubleshooting guides and procedures for identifying and rectifying common issues.
Repair Scope:
Detailed step-by-step repair instructions for nearly all motorcycle systems.
Special Tools:
Likely lists specific tools required for certain procedures (e.g., piston ring compressor, flywheel puller).
Engine Type:
Four-stroke, liquid-cooled, single-cylinder
Displacement:
Approximately 249.5 cc (specific bore/stroke may vary slightly)
Bore X Stroke:
Likely around 76 mm x 55 mm (typical for this displacement and design)
Valve Train:
DOHC, 4 valves per cylinder
Horsepower:
Estimated 35-40 HP (peak, subject to tuning and market regulations)
Torque:
Estimated 20-25 lb-ft (peak)
Fuel Delivery:
Mikuni VM34SS carburetor (common for 2007-2008 models) or Keihin FCR carburetors depending on market variant. EFI was less common on this specific model at this time but possible for certain markets.
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended
Oil Type:
JASO MA certified 10W-40 or 15W-50 motorcycle specific 4-stroke engine oil
Oil Capacity:
Approximately 1.0-1.2 liters (including filter, check manual for exact specification)
Engine Oil Change:
Every 10-15 hours of riding or annually, whichever comes first. Check manual for precise interval.
Air Filter Cleaning:
After every few rides, especially in dusty conditions. Clean and re-oil every 10-20 hours.
Chain Lubrication Adjustment:
Lubricate every 500 km (300 miles) or more frequently in wet/dirty conditions. Adjust tension as per manual specifications.
Spark Plug Replacement:
Inspect every 100 hours, replace as needed (typically every 200-300 hours, check plug condition).
Fork Oil Type:
Likely a Motul Factory Line (e.g., 5W or 7.5W) or equivalent, check manual for specific viscosity and level.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, 50/50 mix with distilled water
Common Wear Items:
Clutch plates, fork seals, steering head bearings, wheel bearings, chain and sprockets, air filter sealing.
Carburetor Issues:
Carburetor jetting may require adjustment based on altitude and environmental conditions. Diaphragm wear can affect performance.
Electrical Quirks:
Older bikes can develop issues with aging wiring, connectors, and grounds, particularly in an off-road environment.
