Lesson 1Wheels, tyres, and braking systems (rims, hubs, disc rotors, calipers, pads)This section covers wheel assemblies, tyre selection, and braking hardware in detail. You will learn how rims, hubs, rotors, calipers, and pads are specified, inspected, stored, and prepared for safe installation during assembly.
Rim and hub types, sizes, and specificationsDisc rotor dimensions, offset, and mountingCaliper designs, mounting styles, and hardwareBrake pad compounds, wear limits, and codingTyre sizing, load ratings, and speed indexesWheel, tyre, and brake storage and labellingLesson 2Electrical system components (battery, wiring harness, ECU, ignition, lighting, fuses)This section details the electrical system, from power supply to lighting. You will learn how the battery, harness, ECU, ignition, and protection devices are specified, labelled, and organised for assembly and diagnosis in the workshop.
Battery types, ratings, and mounting hardwareMain wiring harness branches and connectorsECU location, mounting, and part numberingIgnition coils, plugs, and high-tension leadsLighting units, bulbs, and connector standardsFuses, relays, and circuit protection layoutLesson 3Overview of 250cc street motorcycle architectureThis section provides a system-level view of a 250cc street motorcycle. You will learn how major assemblies connect, how weight and packaging are balanced, and how parts diagrams represent the complete architecture for better understanding.
Major assemblies and system group breakdownFrame, engine, and suspension layout overviewIntake, exhaust, and fuel routing on chassisElectrical harness routing and component zonesControl ergonomics and rider triangle basicsReading OEM exploded views and part treesLesson 4Fuel and intake systems (fuel tank, fuel lines, petcock, injectors/carburettor)This section details fuel storage and delivery components. You will learn how tanks, lines, valves, pumps, and injectors or carburettors are specified, protected from contamination, and organised for safe assembly in the workshop.
Fuel tank construction, caps, and ventingFuel petcock, pump, and filter arrangementsFuel line diameters, materials, and routingInjectors, rails, and pressure regulator partsCarburettor bodies, jets, and float assembliesIntake boots, airbox, and clamp orientationLesson 5Bodywork and finishing parts (fairings, seat, mounting fasteners, decals)This section focuses on body panels, seat units, and cosmetic parts. You will learn how fairings, covers, fasteners, and decals are catalogued, protected from damage, and matched by colour and finish codes for proper assembly.
Front and side fairing panel identificationTail section, cowl, and seat base componentsBodywork mounting clips, screws, and grommetsPaint, colour, and graphic code referencesWindscreens, mirrors, and trim accessoriesPackaging and scratch prevention for panelsLesson 6Controls and rider interface (handlebar, grips, throttle, clutch/brake levers, foot controls)This section covers all rider control components and interfaces. You will learn how handlebars, levers, pedals, and cables are specified, adjusted, and inventoried to ensure consistent ergonomics and safe operation during rides.
Handlebar dimensions, rise, and clamp sizesGrips, bar ends, and vibration control partsThrottle tube, cables, and housing assembliesFront brake and clutch lever types and pivotsFootpegs, pedals, and linkage arrangementsControl adjustment ranges and reference pointsLesson 7Chassis and frame components (subframe, mounting points, fasteners)This section explains the main frame, subframe, and structural brackets. You will learn how mounting points, gussets, and fasteners are identified, protected, and organised to maintain alignment and structural integrity in assembly.
Main frame materials and construction typesSubframe designs, load paths, and supportsEngine and suspension mounting point locationsFrame brackets, tabs, and accessory mountsChassis fastener grades, coatings, and torqueFrame identification numbers and corrosion careLesson 8Engine and drivetrain components (engine assembly, gearbox, clutch, chain/sprockets)This section covers engine, gearbox, clutch, and final drive parts. You will learn how assemblies are broken into subcomponents, how chains and sprockets are specified, and how to inventory wear and replacement items effectively.
Engine assembly groups and major subassembliesGearbox shafts, gears, and selector componentsClutch basket, hub, plates, and actuation partsFront and rear sprocket specs and tooth countsDrive chain pitch, length, and master link typesDrivetrain wear inspection and replacement setsLesson 9Suspension and steering components (front fork, rear shock, triple clamps, steering bearings)This section explains suspension and steering hardware. You will learn how forks, shocks, triple clamps, and bearings are identified, stored, and prepared so that geometry, preload, and damping functions remain correct during use.
Front fork types, tube diameters, and travelRear shock units, linkages, and mounting pointsTriple clamp offsets, stem lengths, and pinchSteering head bearings, races, and sealsSwingarm construction and pivot hardwareSuspension labelling, pairs, and orientation