Segment:
Performance Off-Road Motorcycle (Enduro/Motocross)
Key Competitors:
KTM EXC/MXC, Yamaha YZ, Honda CR, Suzuki RM, Kawasaki KX.
Vehicle Platform:
Two-stroke, liquid-cooled (for CR), air-cooled (for WR), high-performance off-road chassis.
Engine:
Comprehensive engine overhaul, top-end, bottom-end, carburetor, ignition, cooling (air-cooled).
Transmission:
Gearbox disassembly, inspection, repair, lubrication, clutch service.
Chassis:
Frame, suspension (front forks, rear shock), steering, swingarm, bearings.
Brakes:
Hydraulic brake system (front and rear calipers, master cylinders, lines, bleeding).
Electrical:
Wiring diagrams, lighting system, ignition system troubleshooting, stator, CDI unit.
Fuel System:
Carburetor disassembly, cleaning, adjustment, fuel tank, petcock.
Exhaust:
Exhaust system components, pipe packing, spark arrestor.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain adjustment, air filter cleaning.
Troubleshooting:
Diagnostic flowcharts for common performance issues, starting problems, electrical faults.
Repair:
Detailed step-by-step repair instructions for all major components and systems.
Rebuilds:
Complete engine and transmission rebuild procedures, including torque specifications and tolerances.
Adjustments:
Carburetor jetting and mixture adjustments, clutch lever free play, chain slack.
Suspension Setup:
Basic suspension adjustments, fork oil level and type, rear shock adjustment.
Wheel Service:
Tire removal/installation, wheel balancing, spoke tensioning.
Bodywork Repair:
Fender removal/installation, seat, fuel tank, side panels, graphics.
Diagnostic Capability:
Advanced diagnostic procedures for identifying root causes of mechanical and electrical failures.
Rebuild Complexity:
Suitable for comprehensive engine and gearbox rebuilds, including piston, ring, crank, and bearing replacement.
Special Tools:
Lists and descriptions of specialized tools required for specific repair and maintenance tasks.
Torque Specifications:
Extensive list of critical torque values for engine, transmission, chassis, and fasteners.
Diagnostic Charts:
Detailed flowcharts for troubleshooting common starting, running, and electrical issues.
Engine Type:
Two-stroke, single-cylinder
Cooling System:
Air-cooled (WR250/360), Liquid-cooled (CR250)
Bore Stroke 250:
Approx. 68mm x 68.8mm
Bore Stroke 360:
Approx. 76mm x 79mm
Reed Valve System:
Standard
Horsepower Estimate 250:
Approx. 40-45 HP
Horsepower Estimate 360:
Approx. 45-50 HP
Carburetor Size 250:
Mikuni TMX38 or similar
Carburetor Size 360:
Mikuni TMX38 or similar
Fuel Type:
Premium Unleaded Gasoline
Ignition Type:
CDI (Capacitor Discharge Ignition)
Premix Ratio:
Typically 30:1 to 50:1 (refer to manual for specific recommendations)
Top End Rebuild:
Variable, dependent on usage; often recommended every 50-100 hours of hard riding.
Transmission Oil Change:
Every 15-20 hours or as specified in manual.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Engine Oil Type:
2-stroke premix oil (e.g., Motul 800, Castrol TTS, or equivalent).
Gearbox Oil Grade:
SAE 75W/90 or 80W/90 GL-3/GL-4 gear oil (specific recommendation in manual).
Coolant Type:
Ethylene Glycol based antifreeze with corrosion inhibitors (for CR models).
Clutch Wear:
Clutch plates can wear over time due to aggressive riding and improper adjustment.
Carburetor Tuning:
May require re-jetting due to altitude, temperature, or modifications.
Ignition Coil Failure:
CDI or ignition coil can fail, leading to no spark.
Power Valve Sticking:
Carbon buildup can cause the exhaust power valve to stick, affecting engine performance.
