Segment:
Lightweight, performance-oriented off-road motorcycle, often used for trail riding, motocross, and dual-sport conversions.
Competitors:
Yamaha WR250F/R, Honda CRF250X/R, Suzuki RM-Z250, KTM 250 EXC/SX
Engine Type:
Liquid-cooled, four-stroke, single-cylinder engine offering a balance of power and usability.
Suspension Setup:
Long-travel, adjustable suspension (USD front forks, Monoshock rear) designed for off-road terrain.
Chassis Design:
Lightweight, durable frame and bodywork optimized for maneuverability and off-road durability.
Manual Benefit:
Empowers owners to perform all maintenance and repairs, saving significant costs and increasing self-sufficiency.
Covered Years:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Coverage Scope:
All Models/Engines/Trim/Transmissions Types
Format:
Downloadable (Digital)
File Type:
PDF (Portable Document Format)
Accessibility:
Accessible on PC, MAC, Tablets, Smartphones
Software Requirement:
Adobe Reader (Free Download)
Delivery Method:
Instant Email Delivery
Type:
Workshop Service Repair Manual
Estimated Page Count:
Varies by specific model year revision, typically 300+ pages for a comprehensive manual.
Engine Mechanical:
Top End, Bottom End, Piston, Rings, Cylinder, Crankshaft, Connecting Rod, Valves, Camshaft, Timing System
Fuel System:
Carburetor(s), Fuel Pump, Fuel Lines, Fuel Tank, Fuel Filter
Ignition System:
Ignition Coil, Spark Plug, CDI Unit, Stator, Flywheel
Cooling System:
Radiator, Hoses, Coolant, Thermostat (if applicable), Water Pump
Exhaust System:
Exhaust Pipe, Muffler, Heat Shields
Transmission Drivetrain:
Clutch, Gearbox, Shift Mechanism, Drive Chain, Sprockets
Suspension:
Front Fork (USD), Rear Shock Absorber, Linkage (if applicable), Swingarm
Brakes:
Front Disc Brakes, Rear Disc Brakes, Master Cylinders, Calipers, Brake Lines, Brake Pads
Wheels Tires:
Spoked Wheels, Hubs, Bearings, Tire Mounting/Removal
Electrical System:
Wiring Harness, Battery, Lighting (Headlight, Taillight, Signals), Horn, Switches
Controls:
Handlebars, Levers (Clutch, Brake), Throttle, Footpegs, Shifter Lever
Frame Chassis:
Frame, Subframe, Bodywork (Fenders, Side Panels, Seat)
Routine Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement
Troubleshooting:
Diagnosis of common problems, systematic fault finding
Engine Rebuild:
Complete engine disassembly, inspection, repair, and reassembly procedures
Suspension Service:
Fork Seal Replacement, Shock Rebuilding, Linkage Maintenance
Brake Service:
Brake Pad Replacement, Bleeding, Caliper Service
Electrical Diagnosis:
Wiring diagrams, component testing, troubleshooting electrical faults
Carburetor Overhaul:
Disassembly, cleaning, adjustment, and reassembly of the carburetor
Specifications Data:
Torque values, clearances, fluid capacities, component measurements
Special Tools:
Identification and usage of specialized tools required for specific repairs
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls.
Engine Type:
Four-stroke, SOHC, four-valve
Cooling System:
Liquid-cooled
Displacement:
292 cc (approximate)
Bore X Stroke:
Refer to specific model year in manual for exact figures (e.g., 78.0 x 61.2 mm)
Horsepower:
Refer to specific model year in manual (typically in the 25-30 HP range for this era).
Torque:
Refer to specific model year in manual (typically 18-22 lb-ft range).
Carburetor Type:
Keihin CVK (Constant Velocity Carburetor) - size varies by year (e.g., 36mm).
Fuel Tank Capacity:
Refer to specific model year (typically around 2.3 - 2.6 gallons).
Ignition:
Digital CDI (Capacitor Discharge Ignition)
Oil Type:
API SG, SF or SE, SAE 10W-40 motorcycle specific oil recommended. Refer to manual for exact specification.
Oil Capacity:
Refer to specific model year in manual (typically around 1.5 - 1.8 liters with filter change).
Engine Oil Change:
Recommended every 600 miles (1000 km) or 6 months, whichever comes first. More frequent changes recommended for hard riding.
Air Filter Cleaning:
Inspect and clean/replace every 10-15 hours of riding or as needed based on conditions. Crucial for engine longevity.
Spark Plug Check:
Inspect and clean/gap every 600 miles (1000 km) or as part of scheduled maintenance.
Chain Adjustment Lubrication:
Check and lubricate chain every 200-300 miles (300-500 km) and adjust tension as needed.
Engine Oil Specification:
API SG, SF or SE, SAE 10W-40 motorcycle specific oil. Check manual for exact viscosity based on ambient temperature.
Coolant Type:
Ethylene glycol-based permanent type antifreeze coolant (e.g., Honda Type 2 or equivalent) mixed with distilled water at a 50/50 ratio.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Carburetor Tuning:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment or jetting changes for optimal performance, especially if used in varying conditions.
Suspension Wear:
Fork seals and rear shock bushings/seals may require replacement over time due to the demanding nature of off-road riding.
Clutch Wear:
Clutch plates can wear down with aggressive use, particularly if ridden in boggy or sandy conditions.
Exhaust System:
Aftermarket exhausts are common for weight reduction and performance improvement.
Jet Kit:
Often installed with aftermarket exhausts and air filters to optimize fuel delivery.
