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Essential preparatory steps and precautions before starting any service work.
Visual guides to identify the motorcycle's specific model designation.
Key technical specifications for the motorcycle, including dimensions and engine details.
Schedule of recommended maintenance tasks and intervals for optimal performance.
Explanation of the KIPS system's function, mechanism, and operation at different speeds.
Guidelines for fastener tightening torques and the use of non-permanent locking agents.
List of specialized tools and sealants required for service procedures.
Diagrams illustrating the correct routing for cables, wires, and hoses.
Diagram showing all fuel system components in an assembled view.
Technical specifications related to the fuel system.
Maintenance and adjustment of the throttle grip and cable assembly.
Detailed service procedures for the carburetor, including inspection and cleaning.
Instructions for removing, installing, and cleaning the air cleaner element.
Procedures for fuel tank removal, installation, and cleaning.
Steps for removing, installing, and inspecting the reed valve.
Diagram of engine top end components.
Technical specifications for engine top end parts.
Procedures for cylinder head removal, installation, and inspection.
Steps for cylinder and piston removal, installation, and wear inspection.
Service procedures for the KIPS exhaust valve system.
Maintenance for the exhaust system components.
Diagram showing all clutch assembly components.
Technical specifications related to the clutch system.
Inspection and adjustment of the clutch cable and lever free play.
Procedures for removing and installing the clutch cover.
Steps for removing and installing the right engine cover.
Detailed procedures for clutch removal, installation, and inspection of parts.
Maintenance and inspection of the external shift mechanism.
Service procedures for the primary gear.
Removal, assembly, and inspection of the kickstarter mechanism.
Diagram showing engine mounting and related components.
Technical specifications relevant to engine removal and installation.
Step-by-step guide for safely removing the engine from the motorcycle.
Procedures for correctly installing the engine back into the motorcycle.
Diagram showing all crankshaft and transmission components.
Technical specifications for the crankshaft and transmission.
Information on transmission oil level inspection and change procedures.
Detailed steps for splitting and assembling the crankcase halves.
Procedures for crankshaft and connecting rod removal, installation, and disassembly.
Service procedures for transmission shafts, gears, and forks.
Diagram of wheel and tire assembly components.
Technical specifications for wheels, tires, and related parts.
Procedures for front and rear wheel removal, installation, and rim inspection.
Information on tire air pressure, inspection, and replacement.
Steps for removing, installing, and inspecting hub bearings.
Maintenance procedures for the trip meter gear housing.
Diagram of final drive components including chain and sprockets.
Technical specifications for the drive chain and sprockets.
Procedures for drive chain slack inspection, adjustment, wear inspection, and lubrication.
Steps for sprocket removal, installation, wear, and warp inspection.
Diagram of the entire brake system components.
Technical specifications for brake levers, fluid, pads, discs, and hoses.
Adjustments and procedures for brake levers and pedals.
Recommendations, inspection, and change procedures for brake fluid.
Step-by-step guide to bleeding air from the brake lines.
Detailed removal, installation, and disassembly procedures for brake calipers.
Procedures for front and rear brake pad removal and installation, and inspection.
Service procedures for front and rear master cylinders, including disassembly.
Installation and inspection procedures for brake discs.
Removal, installation, and inspection of brake hoses.
Diagram of front fork and rear shock absorber components.
Technical specifications for suspension components.
Service procedures for front fork adjustment, oil change, and spring replacement.
Procedures for rear shock absorber adjustment, spring replacement, and disassembly.
Steps for swingarm removal, installation, and bearing service.
Maintenance procedures for tie-rods and rocker arms.
Diagram of steering system components, including handlebars and steering stem.
Technical specifications for steering system parts and special tools.
General inspection and adjustment procedures for the steering system.
Steps for removing the steering stem and its bearings.
Procedures for installing the steering stem and its bearings.
Routine maintenance for steering stem bearings, including lubrication and wear checks.
Diagram of the motorcycle frame and its main components.
Procedures for removing and installing the seat.
Diagram of various electrical system components.
Visual identification of key electrical components on the motorcycle.
Schematic diagram illustrating the motorcycle's electrical wiring connections.
Technical specifications for ignition, lighting, and regulator systems.
Details on ignition coil, spark plug, magneto, and CDI unit service.
Procedures for headlight, taillight, and regulator maintenance.
Steps for removing, installing, and inspecting the trip meter.
Common problems and potential causes for starting and running issues.
Guidelines for lubricating various motorcycle parts.
List of fasteners to check for tightness and proper torque application.
Table for converting between different measurement units.
Introduction to the 2002 model supplement.
Guidance on how to effectively use this supplement manual.
Overview of the 2002 model, including specifications and identification.
Detailed technical specifications specific to the 2002 model.
Service procedures for the crankshaft and transmission unique to the 2002 model.
Specific technical data for the 2002 model's crankshaft and transmission.
Details on transmission oil type, capacity, and change procedures for the 2002 model.
Step-by-step instructions for changing transmission oil on the 2002 model.
Introduction to the 2003 model supplement.
Guidance on how to effectively use this supplement manual.
Overview of the 2003 model, including specifications and identification.
Detailed technical specifications specific to the 2003 model.
Specifications and details for wheels and tires of the 2003 model.
Specific technical data for the 2003 model's wheels and tires.
Exploded view of the frame components for the 2003 model.
Diagram of the frame assembly for the 2003 model.
Essential preparatory steps and precautions before starting any service work.
Visual guides to identify the motorcycle's specific model designation.
Key technical specifications for the motorcycle, including dimensions and engine details.
Schedule of recommended maintenance tasks and intervals for optimal performance.
Explanation of the KIPS system's function, mechanism, and operation at different speeds.
Guidelines for fastener tightening torques and the use of non-permanent locking agents.
List of specialized tools and sealants required for service procedures.
Diagrams illustrating the correct routing for cables, wires, and hoses.
Diagram showing all fuel system components in an assembled view.
Technical specifications related to the fuel system.
Maintenance and adjustment of the throttle grip and cable assembly.
Detailed service procedures for the carburetor, including inspection and cleaning.
Instructions for removing, installing, and cleaning the air cleaner element.
Procedures for fuel tank removal, installation, and cleaning.
Steps for removing, installing, and inspecting the reed valve.
Diagram of engine top end components.
Technical specifications for engine top end parts.
Procedures for cylinder head removal, installation, and inspection.
Steps for cylinder and piston removal, installation, and wear inspection.
Service procedures for the KIPS exhaust valve system.
Maintenance for the exhaust system components.
Diagram showing all clutch assembly components.
Technical specifications related to the clutch system.
Inspection and adjustment of the clutch cable and lever free play.
Procedures for removing and installing the clutch cover.
Steps for removing and installing the right engine cover.
Detailed procedures for clutch removal, installation, and inspection of parts.
Maintenance and inspection of the external shift mechanism.
Service procedures for the primary gear.
Removal, assembly, and inspection of the kickstarter mechanism.
Diagram showing engine mounting and related components.
Technical specifications relevant to engine removal and installation.
Step-by-step guide for safely removing the engine from the motorcycle.
Procedures for correctly installing the engine back into the motorcycle.
Diagram showing all crankshaft and transmission components.
Technical specifications for the crankshaft and transmission.
Information on transmission oil level inspection and change procedures.
Detailed steps for splitting and assembling the crankcase halves.
Procedures for crankshaft and connecting rod removal, installation, and disassembly.
Service procedures for transmission shafts, gears, and forks.
Diagram of wheel and tire assembly components.
Technical specifications for wheels, tires, and related parts.
Procedures for front and rear wheel removal, installation, and rim inspection.
Information on tire air pressure, inspection, and replacement.
Steps for removing, installing, and inspecting hub bearings.
Maintenance procedures for the trip meter gear housing.
Diagram of final drive components including chain and sprockets.
Technical specifications for the drive chain and sprockets.
Procedures for drive chain slack inspection, adjustment, wear inspection, and lubrication.
Steps for sprocket removal, installation, wear, and warp inspection.
Diagram of the entire brake system components.
Technical specifications for brake levers, fluid, pads, discs, and hoses.
Adjustments and procedures for brake levers and pedals.
Recommendations, inspection, and change procedures for brake fluid.
Step-by-step guide to bleeding air from the brake lines.
Detailed removal, installation, and disassembly procedures for brake calipers.
Procedures for front and rear brake pad removal and installation, and inspection.
Service procedures for front and rear master cylinders, including disassembly.
Installation and inspection procedures for brake discs.
Removal, installation, and inspection of brake hoses.
Diagram of front fork and rear shock absorber components.
Technical specifications for suspension components.
Service procedures for front fork adjustment, oil change, and spring replacement.
Procedures for rear shock absorber adjustment, spring replacement, and disassembly.
Steps for swingarm removal, installation, and bearing service.
Maintenance procedures for tie-rods and rocker arms.
Diagram of steering system components, including handlebars and steering stem.
Technical specifications for steering system parts and special tools.
General inspection and adjustment procedures for the steering system.
Steps for removing the steering stem and its bearings.
Procedures for installing the steering stem and its bearings.
Routine maintenance for steering stem bearings, including lubrication and wear checks.
Diagram of the motorcycle frame and its main components.
Procedures for removing and installing the seat.
Diagram of various electrical system components.
Visual identification of key electrical components on the motorcycle.
Schematic diagram illustrating the motorcycle's electrical wiring connections.
Technical specifications for ignition, lighting, and regulator systems.
Details on ignition coil, spark plug, magneto, and CDI unit service.
Procedures for headlight, taillight, and regulator maintenance.
Steps for removing, installing, and inspecting the trip meter.
Common problems and potential causes for starting and running issues.
Guidelines for lubricating various motorcycle parts.
List of fasteners to check for tightness and proper torque application.
Table for converting between different measurement units.
Introduction to the 2002 model supplement.
Guidance on how to effectively use this supplement manual.
Overview of the 2002 model, including specifications and identification.
Detailed technical specifications specific to the 2002 model.
Service procedures for the crankshaft and transmission unique to the 2002 model.
Specific technical data for the 2002 model's crankshaft and transmission.
Details on transmission oil type, capacity, and change procedures for the 2002 model.
Step-by-step instructions for changing transmission oil on the 2002 model.
Introduction to the 2003 model supplement.
Guidance on how to effectively use this supplement manual.
Overview of the 2003 model, including specifications and identification.
Detailed technical specifications specific to the 2003 model.
Specifications and details for wheels and tires of the 2003 model.
Specific technical data for the 2003 model's wheels and tires.
Exploded view of the frame components for the 2003 model.
Diagram of the frame assembly for the 2003 model.
General| Displacement | 198 cc |
|---|---|
| Cooling System | Liquid-cooled |
| Bore x Stroke | 66.0 mm x 58.0 mm |
| Transmission | 6-speed |
| Front Brake | Single disc |
| Rear Brake | Single disc |
| Fuel System | Carburetor |
| Ignition | CDI |
| Final Drive | Chain |
| Engine Type | 2-stroke single |
| Front Suspension | Telescopic fork |
| Rear Suspension | Uni-Trak |
| Fuel Capacity | 11 liters |
| Wheelbase | 1435 mm |
