Engine Mechanical:
Complete engine overhaul, cylinder head, pistons, crankshaft, camshaft, valve timing, lubrication system, cooling system.
Fuel System:
Carburetor (Mikuni VM or similar), fuel pump, fuel tank, fuel lines, filtration.
Ignition System:
CDI ignition, spark plugs, coils, wiring, timing.
Exhaust System:
Exhaust pipes, muffler, heat shields.
Transmission Drivetrain:
Clutch operation, gearbox, gear selection, final drive, chain adjustment, sprockets.
Suspension Front:
Telescopic forks, oil seals, springs, damping adjustment (if applicable), steering head bearings.
Suspension Rear:
Monoshock absorber, linkage system, swingarm, wheel bearings.
Brakes Front:
Hydraulic disc brake system, caliper, master cylinder, brake pads, brake lines, bleeding procedure.
Brakes Rear:
Hydraulic disc brake system, caliper, master cylinder, brake pads, brake lines, bleeding procedure.
Wheels Tires:
Spoked wheels, rim maintenance, spoke tension, tire types and pressures.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams.
Chassis Frame:
Frame inspection, bodywork, seat, fuel tank mounting.
Controls:
Throttle, clutch lever, brake lever, handlebar controls, foot controls.
Troubleshooting:
Diagnosis of common problems, symptom-based troubleshooting guides.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, brake fluid checks.
Engine Repairs:
Top-end rebuilds, bottom-end repairs, valve adjustments, gasket replacements.
Carburetor Service:
Disassembly, cleaning, adjustment, synchronization (if applicable).
Suspension Service:
Fork seal replacement, shock absorber service, linkage bearing maintenance.
Brake System Service:
Pad replacement, caliper overhaul, master cylinder service, line replacement, bleeding.
Electrical Diagnostics:
Wiring harness tracing, component testing, starter troubleshooting, charging system diagnosis.
Wheel Tire Service:
Spoke tightening, wheel balancing, tire mounting/dismounting.
Depth:
Comprehensive from basic maintenance to full engine and chassis overhauls, including diagnostics and troubleshooting.
Diagnostic Capability:
Detailed symptom-based troubleshooting and diagnostic procedures.
Rebuild Instructions:
Step-by-step instructions for major component rebuilds.
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for specific recommendations)
Air Filter Service:
Every 6,000 km, clean/replace as needed
Spark Plug Replacement:
Every 12,000 km (check and gap more frequently)
Valve Clearance Check:
Every 6,000 km or annually
Engine Oil Type:
SAE 10W-40 motorcycle oil, API SG or higher, JASO MA certified.
Engine Oil Capacity:
Approx. 1.9 Liters with filter change
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid
Fork Oil Type:
SAE 10W fork oil
Fork Oil Quantity:
Approx. 480 ml per fork leg
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets.
Potential Electrical Issues:
Regulator/rectifier failure, stator coil degradation (due to heat). Wiring harness connections can corrode.
Carburetor Quirks:
Can be sensitive to vacuum leaks, requires periodic cleaning and adjustment for optimal performance, especially with ethanol fuels.