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Ossa · Two-stroke single, premix, chain drive

Explorer (248 cc)

Library entry covers 2016

88 factory 38 guideline

Published source

Ossa Explorer User Manual, Maintenance grid engine and cycle pp.32-33 (viewer p.17)

Factory owner's handbook. Covers Ossa Explorer user manual (ManualsLib 1047272), maintenance grid; an Explorer 2014 manual is also on ManualsLib and was not compared; hours, each use, each year.

126 items for a 2016 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke premix (oil in fuel)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, hydraulic
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

2016 Ossa Explorer (248 cc)

On the road: every 200 km

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: no interval set

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Secondary transmission (grease/lubricate). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash

Every 3,000 km or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 5,000 km or 12 months

6 items

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 5,000 km or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 9,500 km or 12 months

4 items

Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 19,500 km or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 5 h

1 item

Front/rear spokes (adjust)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: 5 hours

Every 15 h

1 item

Sparkplug (clean)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: 15 hours

Every 30 h

4 items

Reed block (check/inspect)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: 30 hours
Sparkplug (adjust)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: 30 hours
Transmission oil (check/inspect)

Primary and gearbox

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: 30 hours
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings (check/inspect). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: 30 hours

Every 60 h

5 items

Change engine oil

Engine

Factory

Manual: Transmission oil (replace/change). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: 60 hours
Cylinder (check/inspect)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: 60 hours
Piston and piston ring (check/inspect)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: 60 hours
Replace spark plugs

Engine

Factory

Manual: Sparkplug (replace/change). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: 60 hours
Change fork oil

Front end

Factory

Manual: Front suspension lubricant (replace/change). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: 60 hours

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

5 items

Cylinder (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: each year
Front suspension (check/inspect)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each year
Piston and piston ring (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: each year
Replace coolant

Engine

Factory

Manual: Refrigerant (coolant) (replace/change). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: each year
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear shock absorber (check/inspect). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each year

Every 2 years

6 items

Front suspension (replace/change)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: every 2 years
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Replace hydraulic clutch fluid

Primary and gearbox

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Rear shock absorber (replace/change)

Rear suspension and frame

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: every 2 years
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

69 items

Change / kick-start pedal (adjust)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Change / kick-start pedal (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Change / kick-start pedal (clean)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: when necessary
Change / kick-start pedal (grease/lubricate)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Change / kick-start pedal (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Chassis (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Chassis (clean) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Chassis (replace/change)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Crankcase protector (adjust)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: first use
Crankcase protector (clean) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Crankcase protector (replace/change)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Exhaust (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Exhaust (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Front suspension (adjust)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Inspect coolant hoses and clamps

Engine

Factory

Manual: Radiator tube and connections (check/inspect) (pre-ride check). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Sparkplug (check/inspect) (pre-ride check). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Muffler (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Protective stickers (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Protective stickers (replace/change)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Radiator tube and connections (adjust)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Reed block (adjust)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Reed block (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Refrigerant (coolant) (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Screw, nuts and fastenings (adjust)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Screw, nuts and fastenings (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Screw, nuts and fastenings (clean) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Screw, nuts and fastenings (replace/change)

Engine

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Wire and throttle grip (adjust)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Wire and throttle grip (check/inspect) (pre-ride check)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Wire and throttle grip (clean)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: when necessary
Wire and throttle grip (replace/change)

Engine

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Air filter (check/inspect) (pre-ride check)

Fuel and air

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Air filter (grease/lubricate)

Fuel and air

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Air filter (replace/change)

Fuel and air

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Wire and throttle grip (grease/lubricate). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (clean) (pre-ride check). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Fuel tank (check/inspect) (pre-ride check)

Fuel and air

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Fuel tank (clean) (pre-ride check)

Fuel and air

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Fuel tank (replace/change)

Fuel and air

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (check/inspect) (pre-ride check). Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Clutch (replace/change)

Primary and gearbox

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Clutch discs (replace/change)

Primary and gearbox

Factory

Factory: Maintenance grid, engine p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Secondary transmission (adjust)

Primary and gearbox

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Secondary transmission (check/inspect) (pre-ride check)

Primary and gearbox

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Secondary transmission (clean) (pre-ride check)

Primary and gearbox

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Secondary transmission (replace/change)

Primary and gearbox

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Check steering head bearing adjustment

Front end

Factory

Manual: Steering bearings (grease/lubricate). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Steering bearings (check/inspect) (pre-ride check)

Front end

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Steering bearings (replace/change)

Front end

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Swing arm and linkage arms (grease/lubricate). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Swing arm and linkage arms (check/inspect) (pre-ride check)

Rear suspension and frame

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Swing arm and linkage arms (clean) (pre-ride check)

Rear suspension and frame

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Swing arm and linkage arms (replace/change)

Rear suspension and frame

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Brake discs (adjust)

Brakes

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Brake discs (check/inspect) (pre-ride check)

Brakes

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Brake discs (replace/change)

Brakes

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Brakes (adjust)

Brakes

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): adjust: when necessary
Brakes (replace/change)

Brakes

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Check brake pads and discs

Brakes

Factory

Manual: Brakes (check/inspect) (pre-ride check). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Front/rear spokes (check/inspect) (pre-ride check)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Front/rear spokes (clean) (pre-ride check)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Front/rear spokes (replace/change)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Front/rear tire (check/inspect) (pre-ride check)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Front/rear tire (clean) (pre-ride check)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): clean: each use
Front/rear tire (replace/change)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires (check/inspect) (pre-ride check). Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): check/inspect: each use
Tires (replace/change)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged
Wheel bearings (grease/lubricate)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): grease/lubricate: each wash
Wheel bearings (replace/change)

Wheels and tires

Factory

Factory: Maintenance grid, cycle p.32-33 (columns check/inspect, adjust, replace/change, clean, grease/lubricate): replace/change: when damaged

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.