Engine Overhaul:
Complete disassembly, inspection, and reassembly of the engine.
Fuel System:
Carburetor service, fuel pump, fuel lines, and fuel tank maintenance.
Cooling System:
Radiator, coolant, water pump, and thermostat service.
Ignition System:
CDI unit, spark plug, ignition coil, and wiring checks.
Transmission Clutch:
Clutch operation, clutch plates, transmission gears, shift mechanism, and lubrication.
Suspension Front:
Front fork service, oil levels, seals, springs, and damper adjustments.
Suspension Rear:
Monoshock absorber service, linkage, bearings, and adjustability.
Braking System Front:
Brake caliper service, master cylinder, brake pads, rotors, and fluid.
Braking System Rear:
Rear brake caliper service, master cylinder, brake pads, rotor, and fluid.
Electrical System:
Wiring diagrams, battery, lighting, starter motor, charging system, and fuses.
Frame Chassis:
Frame inspection, swingarm, steering head bearings, and wheel bearings.
Bodywork:
Fairing removal, plastics, seat, and fuel tank installation.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, and lubrication points.
Troubleshooting Diagnostics:
Step-by-step guides for identifying and resolving common problems.
Engine Rebuild Procedures:
Detailed instructions for engine disassembly, cleaning, part replacement, and reassembly.
Carburetor Tuning:
Adjustments for idle speed, jetting, and mixture for optimal performance.
Suspension Setup:
Sag adjustment, damping control, and oil weight recommendations.
Brake Bleeding:
Proper procedure for removing air from the hydraulic brake system.
Electrical Troubleshooting:
Using wiring diagrams to diagnose electrical faults.
Wheel Bearing Replacement:
Instructions for removing and installing wheel bearings.
Steering Head Service:
Inspection and replacement of steering head bearings.
Depth Level:
Comprehensive Workshop Manual
Detail Level:
Factory-level repair and maintenance procedures.
Specifications Accuracy:
Includes all critical torque specifications, clearances, and measurements.
Diagnostic Charts:
Detailed diagnostic flowcharts for common issues.
Special Tools:
Lists and descriptions of special tools required for specific repairs.
Engine Type:
Four-stroke, single-cylinder, DOHC, 4-valve
Bore X Stroke:
74.0 mm x 57.7 mm
Cooling Method:
Liquid-cooled
Horsepower Estimated:
Approximately 30-35 HP (stock, may vary)
Torque Estimated:
Approximately 20-23 Nm (stock, may vary)
Carburetor Type:
Mikuni VM34SS (or similar 34mm flat-slide carburetor)
Fuel Type:
Unleaded gasoline (Octane rating as specified in manual)
Ignition System:
Digital CDI
Oil Type:
Yamaha Genuine 4-Stroke Motor Oil or equivalent SAE 10W-30 or 20W-40 API SE, SF, SG
Oil Capacity W Filter:
1.00 L (1.05 US qt)
Oil Capacity Wo Filter:
0.90 L (0.95 US qt)
Engine Oil Change:
Every 1000 km or 6 months, whichever comes first (refer to manual for exact recommendations).
Air Filter Cleaning:
Inspect and clean every 1000 km or more frequently in dusty conditions.
Spark Plug Replacement:
Inspect every 1000 km, replace as needed (refer to manual for part number).
Chain Lubrication Adjustment:
Every 500 km or after riding in wet conditions.
Valve Clearance Check:
Every 1000 km or as specified by the manual.
Coolant Type:
High-quality ethylene glycol based coolant with demineralized water (50:50 mix).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, fork seals, wheel bearings, and chain/sprockets are common wear items for this model due to its off-road nature.
Carburetor Maintenance:
Periodic cleaning and tuning of the carburetor may be required for optimal performance, especially after prolonged storage.
Suspension Service:
Regular fork and shock service is crucial for maintaining ride quality and handling.
