Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly procedures for all internal components.
Fuel System:
Carburetor tuning, cleaning, overhaul, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
Ignition timing, spark plug specifications, CDI unit testing, coil resistance values.
Cooling System:
Radiator, fan, thermostat, coolant flushing, leak testing, and component replacement.
Exhaust System:
Muffler, pipe inspection, gasket replacement, and emissions control components.
Transmission Drivetrain:
Clutch operation, gear inspection, shift mechanism, and lubrication requirements.
Suspension Front:
Fork disassembly, seal replacement, oil levels, spring rates, and damping adjustments.
Suspension Rear:
Shock absorber service, linkage lubrication, swingarm bearing inspection, and wheel bearing maintenance.
Braking System Front:
Brake caliper overhaul, pad replacement, hydraulic fluid bleeding, lever and master cylinder service.
Braking System Rear:
Brake drum inspection, shoe replacement, linkage lubrication, and pedal adjustment.
Wheels Tires:
Spoke tensioning, rim inspection, tire pressure recommendations, and wheel bearing replacement.
Electrical System Lighting:
Headlight, taillight, brake light, turn signal operation, bulb specifications, and wiring diagrams.
Electrical System Charging:
Stator output, rectifier/regulator testing, battery maintenance, and charging system diagnosis.
Electrical System Starting:
Starter motor testing, solenoid operation, and battery voltage checks.
Controls Cables:
Throttle cable adjustment, clutch cable lubrication and adjustment, and brake cable service.
Frame Chassis:
Frame inspection for damage, steering head bearing service, and general chassis integrity checks.
Bodywork Plastics:
Fairing removal and installation, fender inspection, seat mounting, and general body panel care.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake checks, and general inspection procedures.
Troubleshooting:
Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical issues.
Major Repairs:
Complete engine rebuilds, transmission overhauls, and suspension component replacements.
Component Rebuilds:
Detailed instructions for rebuilding carburetors, brake master cylinders, and suspension forks.
Electrical Diagnostics:
Wiring diagrams, component testing procedures, and troubleshooting for electrical faults.
Torque Specifications:
Precise torque values for all critical fasteners, nuts, and bolts.
Special Tool Requirements:
Identification and usage instructions for any specialized tools required for specific repairs.
Depth Level:
Comprehensive
Diagnostic Capabilities:
Detailed diagnostic procedures for identifying root causes of malfunctions.
Rebuild Instructions:
Step-by-step guides for complete engine and component overhauls.
Specifications Data:
Extensive listing of all critical measurements, tolerances, and performance data.
Oil Change Interval:
Refer to manual for specific mileage/time recommendations (typically 2000-3000 km or 6 months)
Air Filter Cleaning:
Regular checks and cleaning, especially after off-road use (refer to manual for intervals)
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment (refer to manual)
Spark Plug Replacement:
Refer to manual for recommended intervals
Engine Oil Type:
Yamaha recommends Yamalube 4 (or equivalent) SAE 10W-40, API SE or SF (refer to manual for precise specification)
Engine Oil Capacity:
Refer to manual for exact capacity with and without filter change
Coolant Type:
Ethylene glycol-based, permanent type antifreeze (50% solution with distilled water)
Brake Fluid Type:
DOT 4 brake fluid
Fork Oil Type:
Yamaha Fork Oil (or equivalent, specific viscosity in manual, e.g., 10W)
Common Wear Items:
Clutch plates, fork seals, wheel bearings, chain and sprockets, brake pads.
Carburetor Maintenance:
Periodic cleaning and jetting adjustments due to fuel quality or debris ingress.
Electrical Connections:
Corrosion or looseness in electrical connectors, especially in wet or dusty conditions.