MotoService Log
No photo of this model in the library yet.

Have this bike? Send a photo or the manual's service chart

Thumpstar · Two-stroke single, premix, chain drive

TSN 250

Library entry covers 2024

51 factory 35 guideline

Published source

Thumpstar TSN 250 N2 Owner's Manual, 9 Service Schedule pp.27-28

Factory owner's handbook. Covers Thumpstar TSN 250 N2 Owner's Manual (ManualsLib 4646400), no year printed; hours-based service schedule.

86 items for a 2024 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
Single carburetor
Cooling
Liquid cooled
Primary drive
Gear or chain inside engine, shares engine oil
Gearbox oil
Separate gearbox oil
Clutch control
Hand lever, cable
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

2024 Thumpstar TSN 250

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: every 10 h

1 item
  • Lubricate drive chain
    Pre-ride / on the road
    Factory

    Manual: Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

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 fuel tap filter / sediment bowl
    Fuel and air
    Guideline
  • 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 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 6,500 km or 12 months

1 item
  • Inspect, clean and gap spark plugs
    Engine
    Guideline

Every 9,500 km or 12 months

5 items
  • Clean carburetor float bowl(s), check float level and jets
    Fuel and air
    Guideline

    Ethanol fuel varnishes old carbs quickly in storage.

  • 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

2 items
  • Replace air filter element
    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 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 10 h

36 items
  • Change engine oil
    Engine
    Factory

    Manual: Change the engine oil and oil filter, clean the oil screen. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check idle
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the antifreeze and coolant level
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the rim run-out
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the screws and nuts for tightness
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Final check: check the vehicle for safe operation and take a test ride
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Inspect coolant hoses and clamps
    Engine
    Factory

    Manual: Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Make the service entry in the Dealer.net and in the Service and Warranty Booklet
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Read out the error memory after the test ride using the diagnostics tool
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Read out the fault memory using the diagnostics tool
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Change the fuel screen
    Fuel and air
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the fuel pressure
    Fuel and air
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check throttle cable(s) free play and return
    Fuel and air
    Factory

    Manual: Check that the throttle cables are undamaged, routed without sharp bends, and set correctly. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Clean / inspect air filter
    Fuel and air
    Factory

    Manual: Clean the air filter and air filter box. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Clean battery terminals, check charge and strap
    Ignition and electrics
    Factory

    Manual: Check and charge the battery. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check/correct the fluid level of the hydraulic clutch
    Primary and gearbox
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the chain tension
    Final drive
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Inspect chain and sprockets for wear (measure stretch)
    Final drive
    Factory

    Manual: Check the chain, rear sprocket, engine sprocket, and chain guide. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check steering head bearing adjustment
    Front end
    Factory

    Manual: Check the steering head bearing play. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the frame and swingarm
    Rear suspension and frame
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the heim joints at the top of the shock absorber
    Rear suspension and frame
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Inspect rear shocks for leaks and damping
    Rear suspension and frame
    Factory

    Manual: Check the shock absorber linkage. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check brake pads and discs
    Brakes
    Factory

    Manual: Check the front brake linings. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the brake discs
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the free travel of the foot brake lever
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the free travel of the hand brake lever
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the front brake fluid level
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the rear brake fluid level
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the rear brake linings
    Brakes
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Inspect brake hoses; replace old rubber
    Brakes
    Factory

    Manual: Check the brake lines for damage and leakage. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check the spoke tension
    Wheels and tires
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the tire air pressure
    Wheels and tires
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the wheel hubs
    Wheels and tires
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Check wheel bearings for play
    Wheels and tires
    Factory

    Manual: Check the wheel bearing for play. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

  • Inspect tire tread, sidewalls and date codes
    Wheels and tires
    Factory

    Manual: Check the tire condition. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 10 h/after every race, every 20 h, every 30 h

  • Check the cables for damage and routing without sharp bends
    Controls and cables
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 10 h/after every race, every 20 h, every 30 h

Every 20 h

3 items
  • Change the glass fiber yarn filling of the main muffler
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 20 h

  • Adjust clutch free play, lubricate cable and lever pivot
    Primary and gearbox
    Factory

    Manual: Check the clutch. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 20 h

  • Grease swingarm pivot
    Rear suspension and frame
    Factory

    Manual: Check the swingarm bearing for play. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 20 h

Every 30 h

2 items
  • Change the cover seal and shaft seal rings of the water pump
    Engine
    Factory

    Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): every 30 h

  • Check and adjust valve clearances
    Engine
    Factory

    Manual: Check the valve clearance. Factory: 9.1 Required work p.27 (columns once after 1 operating hour, every 10 operating hours/after every race, every 20 operating hours, every 30 operating hours): once after 1 hour; every 30 h

Every 40 h

2 items
  • Change fork oil
    Front end
    Factory

    Manual: Service the fork. Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): once after 10 h, then every 40 h

  • Service the shock absorber
    Rear suspension and frame
    Factory

    Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): once after 20 h, then every 40 h

Every 50 h

1 item
  • Replace spark plugs
    Engine
    Factory

    Manual: Perform minor engine service including removing and installing engine (change spark plug and spark plug connector, change piston, check and measure cylinder, check cylinder head, check camshaft and cam lever, check timing assembly, change intake flange). Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): every 50 h and every 100 h

Every 100 h

2 items
  • Replace fuel filter
    Fuel and air
    Factory

    Manual: Change the fuel filter. Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): every 100 h

  • Perform major engine service including removing and installing engine (change valves, valve springs, valve spring seats and retainers, connecting rod, conrod bearing and crank pin; check transmission and shift mechanism, oil pressure regulator valve; change suction pump; check force pump and lubrication system; change timing chain, all engine bearings and freewheel)
    Final drive
    Factory

    Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): every 100 h

Every 12 months

4 items
  • Change the hydraulic clutch fluid
    Primary and gearbox
    Factory

    Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): annually

  • Grease the steering head bearing
    Front end
    Factory

    Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): annually

  • Change the rear brake fluid
    Brakes
    Factory

    Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): annually

  • Replace brake fluid
    Brakes
    Factory

    Manual: Change the front brake fluid. Factory: 9.2 Recommended work p.28 (columns once after 10 h, once after 20 h, every 40 h, every 50 h, every 100 h, annually): annually

Every 2 years

3 items
  • Replace coolant
    Engine
    Guideline
  • Inspect wiring, bullet connectors and ground points
    Ignition and electrics
    Guideline
  • Inspect frame, welds and lugs for cracks
    Rear suspension and frame
    Guideline

Every 4 years

2 items
  • Replace fuel lines
    Fuel and air
    Guideline

    Old rubber and modern ethanol fuel do not mix well.

  • 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

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.

Keep up with this schedule on your phone

Add the bike in the app and this chart loads itself, ready to log against and edit.

Coming soon to Google Play