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General| Engine Type | 249cc liquid-cooled single-cylinder four-stroke |
|---|---|
| Bore and Stroke | 78.0mm x 52.2mm |
| Compression Ratio | 12.5:1 |
| Ignition | CD with electronic advance |
| Transmission | 5-speed |
| Final Drive | #520 chain; 13T/51T |
| Rear Suspension | Pro-Link Showa single shock with spring preload, 17-position rebound damping adjustability, and compression damping adjustment separated into low-speed (13 positions) and high-speed (3.5 turns); 12.4 inches travel |
| Front Brake | Single 240mm disc with twin-piston caliper |
| Rear Brake | Single 240mm disc |
| Front Tire | 80/100-21 |
| Rear Tire | 100/100-18 |
| Wheelbase | 58.3 inches |
| Seat Height | 37.7 inches |
| Fuel Capacity | 1.9 gallons |
| Induction | Keihin 37mm flat-slide carburetor |
| Front Suspension | 47mm inverted Showa cartridge fork with 16-position rebound and 16-position compression damping adjustability; 12.4 inches travel |
Standard torque specifications for various fasteners.
Torque specifications for engine and frame mounting points.
Scheduled maintenance intervals and tasks for 2004-2006 models.
Scheduled maintenance intervals and tasks for models after 2006.
Procedures for checking and changing engine oil and filter.
Procedures for checking and changing transmission oil.
Inspection, adjustment, cleaning, lubrication, and replacement of the drive chain.
Inspection and filling procedures for brake fluid.
Checking and adjusting clutch lever free play.
Disassembly, inspection, and assembly of the oil pump.
Procedures for adjusting idle mixture and idle speed.
Procedure for removing the carburetor from the engine.
Disassembly procedures for carburetor components.
Procedure for adjusting the pilot screw for optimal idle.
Preparation and procedure for replacing coolant.
Inspection, removal, and installation of the water pump.
Step-by-step procedure for removing the engine from the motorcycle.
Step-by-step procedure for installing the engine into the motorcycle.
Procedure for removing the camshaft and rocker arm assembly.
Disassembly procedures for the cylinder head.
Inspection procedures for the cylinder head.
Assembly procedures for the cylinder head.
Procedure for installing the cylinder head.
Procedure for removing the cylinder.
Procedure for removing the piston and piston pin.
Inspection procedures for cylinder bore, taper, and piston.
Inspection procedures for piston and piston rings.
Procedure for installing piston rings into the piston.
Procedure for installing the cylinder.
Procedures for removing and installing the right crankcase cover.
Procedures for removing, inspecting, and installing the clutch assembly.
Procedures for removing, inspecting, and assembling the kickstarter.
Procedures for removing, inspecting, and assembling the starter clutch.
Procedures for removing, inspecting, and installing the gearshift linkage.
Procedure for removing the left crankcase cover.
Procedures for removing and installing the stator.
Procedures for removing and installing the flywheel.
Torque specifications for crankcase and related bolts.
Procedure for separating the crankcase halves.
Disassembly procedures for the transmission.
Procedure for removing the crankshaft.
Procedures for replacing crankcase bearings and oil seals.
Procedure for installing the crankshaft.
Procedure for assembling the crankcase halves.
Procedures for removing and installing the front wheel.
Procedures for removing and installing the front fork.
Disassembly procedures for the fork outer tube and slider.
Disassembly procedures for the fork damper.
Procedures for refilling and assembling the fork damper.
Procedures for removing and installing the handlebar.
Procedures for removing and installing the steering stem.
Procedures for removing and installing the rear wheel.
Assembly procedures for the rear wheel hub.
Procedures for removing and installing the shock absorber.
Procedure for replacing the shock absorber bladder.
Disassembly procedures for the shock absorber damper.
Disassembly procedures for the damper rod.
Procedures for replacing swingarm and shock link bearings.
Procedures for replacing brake fluid and bleeding the system.
Procedure for filling and bleeding the hydraulic brake system.
Procedures for removing, disassembling, and inspecting the starter motor.
Torque specifications for mounting screws.
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