|
Introduction
|
|
Market Position
|
|
Category:
|
Entry-level to mid-range dual-sport motorcycle, popular for trail riding, light off-roading, and commuting.
|
|
Target Audience:
|
Beginner riders, recreational off-road enthusiasts, commuters seeking a versatile and reliable machine.
|
|
Competitive Analysis
|
|
Competitors:
|
Honda CRF250L, Kawasaki KLX250S, Suzuki DR-Z250.
|
|
Key Features
|
|
Features:
|
Robust air-cooled engine, durable chassis, long-travel suspension, capable off-road performance with street-legal amenities.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine:
|
Detailed disassembly, assembly, inspection, and adjustment procedures for the 249cc air-cooled, four-stroke, SOHC engine.
|
|
Fuel System:
|
Carburetor (likely Mikuni BS30 or similar) tuning, cleaning, and overhaul; fuel tank and petcock service.
|
|
Ignition System:
|
CDI ignition timing, spark plug specifications, troubleshooting.
|
|
Transmission:
|
5-speed constant mesh transmission service, clutch operation and adjustment, lubrication.
|
|
Drivetrain:
|
Chain and sprocket inspection and replacement, rear wheel hub and bearing service.
|
|
Suspension:
|
Front fork (telescopic) overhaul, oil level and specification; rear shock absorber adjustment and replacement; linkage system inspection.
|
|
Brakes:
|
Front and rear disc brake system service, hydraulic fluid specifications, caliper overhaul, pad replacement, bleeding procedures.
|
|
Electrical System:
|
Wiring diagrams, battery specifications, charging system (stator, regulator/rectifier), lighting, starter motor, and instrumentation.
|
|
Cooling System:
|
Air-cooled engine, focus on fin cleaning and airflow.
|
|
Frame And Bodywork:
|
Frame inspection, subframe, body panel removal and installation, seat, fuel tank, and fender service.
|
|
Procedures Included
|
|
Maintenance:
|
Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment, brake checks, bolt torquing.
|
|
Troubleshooting:
|
Systematic diagnostics for common running issues, electrical faults, and mechanical problems with flowcharts and symptom-based guides.
|
|
Repair:
|
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
|
|
Engine Rebuild:
|
Complete engine overhaul procedures, including piston, cylinder, crankshaft, and valve train service.
|
|
Suspension Rebuild:
|
Front fork seal replacement, rear shock absorber service, linkage bearing lubrication/replacement.
|
|
Electrical Diagnostics:
|
Wiring diagrams, component testing, and fault finding for the electrical system.
|
|
Brake Service:
|
Fluid replacement, bleeding, caliper and master cylinder overhaul, pad and rotor replacement.
|
|
Technical Depth
|
|
Depth:
|
Comprehensive, covering basic maintenance to full engine and component rebuilds, suitable for professional mechanics and advanced DIY enthusiasts.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Type:
|
249cc, Air-cooled, Four-stroke, SOHC, 2-valve
|
|
Bore X Stroke:
|
73.0 mm x 57.3 mm (typical for this class)
|
|
Compression Ratio:
|
9.5:1 or similar
|
|
Carburetor:
|
Mikuni BS30 (likely) or similar Constant Velocity carburetor
|
|
Ignition:
|
CDI (Capacitor Discharge Ignition)
|
|
Performance
|
|
Horsepower:
|
Approx. 20-22 HP (at crankshaft)
|
|
Torque:
|
Approx. 14-16 lb-ft (at crankshaft)
|
|
Fuel System
|
|
Fuel Type:
|
Unleaded gasoline (Octane rating as per manual)
|
|
Fluid Capacity
|
|
Engine Oil Capacity:
|
Approx. 1.6 L (with oil filter change)
|
|
Maintenance
|
|
Service Intervals
|
|
Engine Oil Change:
|
Every 3,000 km (1,800 miles) or 6 months.
|
|
Oil Filter Replacement:
|
Every 6,000 km (3,600 miles) or 12 months (concurrent with oil change).
|
|
Air Filter Cleaning:
|
Every 1,000 km (600 miles) or 6 months (more frequently if used in dusty conditions).
|
|
Spark Plug Inspection:
|
Every 6,000 km (3,600 miles).
|
|
Valve Clearance Check:
|
Every 12,000 km (7,200 miles).
|
|
Fluid Specifications
|
|
Engine Oil Grade:
|
SAE 20W-40 or SAE 10W-30 (API SG or higher).
|
|
Brake Fluid Type:
|
DOT 4 Hydraulic Brake Fluid.
|
|
Fork Oil Grade:
|
Yamaha Fork Oil G10 (or equivalent SAE 10W fork oil).
|
|
Known Issues
|
|
Common Wear Items:
|
Clutch plates, brake pads, chain and sprockets, front fork seals, wheel bearings, swingarm bearings.
|
|
Common Issues
|
|
Carburetor Fouling:
|
Can occur with infrequent use or poor fuel quality, requiring cleaning and adjustment.
|
|
Suspension Seals:
|
Front fork seals can weep over time due to riding conditions and age.
|
|
Electrical Connections:
|
Corrosion or loose connections, particularly in exposed areas, can lead to intermittent electrical issues.
|
