Engine Mechanical:
Complete overhaul, cylinder head, valve clearance, piston, connecting rods, crankshaft, oil pump, lubrication system.
Fuel System:
Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank, fuel lines.
Ignition System:
Ignition coils, spark plugs, ECU ignition control, wiring diagrams.
Transmission:
Clutch (dry clutch operation), gearbox, gear shift mechanism, final drive (chain and sprockets), transmission fluid specifications.
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting (headlight, taillight, indicators), horn, starter solenoid, ignition switch.
Chassis And Frame:
Frame inspection, steering head bearings, swingarm, rear suspension linkage, general chassis maintenance.
Suspension Front:
Front fork (Marzocchi 50mm USD on EVO, Ohlins on EVO SP), fork seals, oil levels and type, spring preload, compression and rebound damping adjustments.
Suspension Rear:
Monoshock ( Sachs on EVO, Ohlins on EVO SP), shock absorber servicing, spring preload, damping adjustments, linkage lubrication.
Brakes Front:
Brembo radial monobloc calipers, brake discs, brake master cylinder, brake lines, brake fluid specifications, bleeding procedures.
Brakes Rear:
Brembo caliper, brake disc, master cylinder, brake lines, fluid specifications, bleeding.
ABS System:
Bosch ABS system components (modulator, wheel speed sensors), diagnostic procedures for ABS faults (for ABS models).
Wheels And Tires:
Tire pressure, wheel bearing inspection, tire replacement, wheel balancing, recommended tire sizes and types.
Bodywork And Trim:
Fairings, seat removal, fuel tank removal, fenders, minor body panel repairs and replacement.
Instrumentation And Controls:
Dashboard assembly, switches, levers, cable adjustments (throttle, clutch).
Cooling System:
Oil cooler system, oil filter replacement, oil level checking and top-up procedures.
Diagnostic Troubleshooting:
Fault code interpretation, diagnostic procedures for common issues, testing electrical components.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake fluid flush.
Engine Overhaul:
Complete disassembly, inspection, reassembly of the Desmodromic L-Twin engine.
Suspension Service:
Front fork seal replacement, rear shock absorber service, linkage bearing maintenance.
Brake System Service:
Brake pad replacement, caliper service, master cylinder replacement, brake bleeding.
Electrical Component Testing:
Testing ignition coils, starter motor, alternator, battery health.
Desmodromic Valve Adjustment:
Detailed instructions for setting the Desmodromic valve clearance.
Clutch Replacement:
Service of the dry clutch, including friction and steel plate replacement.
Troubleshooting Guides:
Step-by-step guides for diagnosing and resolving common mechanical and electrical faults.
Torque Specifications:
All critical torque values for engine, chassis, and suspension fasteners.
Depth Level:
Comprehensive Workshop Level
Detail Level:
Includes detailed diagrams, exploded views, troubleshooting charts, and step-by-step repair instructions.
Oil Change Interval:
Every 12,000 km (7,500 miles) or 12 months
Desmo Service Interval:
Every 24,000 km (15,000 miles)
Valve Clearance Check:
Every 24,000 km (15,000 miles)
Air Filter Cleaning:
Every 12,000 km (7,500 miles)
Engine Oil Spec:
See engine_specs section (SAE 15W-50 Synthetic)
Fork Oil Spec:
SAE 5W (Marzocchi forks) or specific Ohlins fluid
Coolant Type:
N/A (Oil-cooled engine)
Common Wear Items:
Clutch plates (dry clutch), chain and sprockets, front fork seals, rear shock absorber bushings.
Electrical Gremlins:
Occasional issues with battery charging system components or ignition switch connections (refer to manual for diagnostics).
Desmodromic Maintenance Importance:
Crucial to adhere to Desmo service intervals to maintain engine performance and prevent valve train damage.