CONTENTS

GENERAL INFORMATION				1
	Introduction				Expendable supplies
	Service hints				Safety hints
        Tools


CHAPTER ONE
ENGINE DISASSEMBLY				4
	Cylinder and piston			Engine case separation
	Magneto side components			Transmission components
        Primary drive components		Crankshaft and bearings


CHAPTER TWO
ENGINE REPAIR					18
	Crankshaft                              Cylinder and piston
	Transmission inspection			Cylinder liner
	Transmission shimming


CHAPTER THREE
ENGINE REASSEMBLY				49
	Crankshaft alignment			Top end installation
	Engine case reassembly			Magneto components
	Primary side components


CHAPTER FOUR
CARBURETOR					68
	Double needle models			Adjustment and tuning
	Single needle models


CHAPTER FIVE
ELECTRICAL SYSTEM				83
	Ignition testing			Headlight
	Pioneer charging circuit check		Wiring diagram


CHAPTER SIX
FRONT SUSPENSION AND STEERING			96
	Fork oil				Steering
	Fork servicing


CHAPTER SEVEN
FRAME, SWINGING ARM, AND REAR SUSPENSION	112

	Frame					Shock absorbers
        Swinging arm


CHAPTER EIGHT
WHEELS, BRAKES, AND HUBS			122

	Wheel service				Hub service
	Brakes


CHAPTER NINE
TROUBLESHOOTING				129
	Operating requirements			Engine noises
	Starting difficulties			Piston seizure
	Poor idling				Excessive vibration
	Misfiring				Clutch slip
	Flat spots				Poor handling
	Power loss				Brake problems
	Overheating				Lighting problems
	Backfiring


SPECIFICATIONS					133

	250 Stiletto MX				250 Plonker
	250 Stiletto T.T.			175 Stiletto
	250 Pioneer				175 Pioneer


INDEX						139