Segment:
Dual-sport / Adventure Motorcycle
Target Market:
Motorcyclists seeking a capable off-road and on-road touring machine
Key Competitors:
Honda Transalp, Yamaha Tenere, Suzuki DR-Z, BMW GS series (though often larger displacement)
Design Philosophy:
Robustness, versatility, capable off-road performance with touring comfort
Distinctive Features:
Italian design influence, often featuring distinctive styling and handling characteristics
Primary Coverage:
Repair, maintenance, adjustments, disassembly, assembly, checks
Target Audience:
Mechanics and DIY persons
Estimated Page Count:
Varies (typical for this era, often 200-400 pages)
Type:
Service and Repair Manual
Language:
English (assumed based on common practice for this market)
Format:
Printed (typical for factory manuals of this era, digital formats may exist)
Engine:
Detailed disassembly, assembly, troubleshooting, tuning, specifications
Fuel System:
Carburetor(s) (likely Dell'Orto or similar), fuel pump, fuel lines, fuel tank maintenance and repair
Ignition System:
Ignition coil, spark plugs, CDI unit, timing adjustments
Transmission:
Gearbox disassembly, assembly, inspection, oil change procedures, clutch operation
Suspension:
Front forks (likely Marzocchi or similar), rear shock absorber(s), linkage, preload adjustments, seal replacement
Brakes:
Front and rear brake systems (likely disc brakes), caliper overhaul, pad replacement, bleeding procedures, master cylinder
Electrical System:
Wiring diagrams, lighting, battery, charging system (alternator/stator), starter motor, fuses, relays
Cooling System:
Air cooling (typical for this model)
Exhaust System:
Muffler and header pipe inspection and replacement
Wheels And Tires:
Tire pressure, wheel bearing inspection, spoke tensioning (if applicable), rim maintenance
Frame And Bodywork:
Chassis inspection, fairing removal and installation, seat, fuel tank mounting
Controls:
Throttle cable adjustment, clutch cable adjustment, brake lever adjustment, shifter linkage
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, lubrication points
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts
Repair:
Step-by-step instructions for component repair and replacement
Disassembly Assembly:
Complete guide to taking apart and reassembling major and minor components
Adjustments:
Carburetor synchronization, ignition timing, clutch and brake free play
Depth:
Comprehensive, covering routine maintenance to full engine and transmission rebuilds
Digital Format:
PDF (potential for scanned or transcribed format)
Print Quality:
High-resolution images and clear text (typical for factory originals)
Binding:
Stapled or perfect bound (for printed versions)
Paper Type:
Durable, often coated paper to withstand shop use
Configuration:
Single-cylinder, four-stroke
Displacement:
478 cc (approximate, actual may vary slightly based on bore/stroke) - '500' in model name often denotes approximate cubic capacity.
Bore X Stroke:
Data not explicitly provided, but typical for this displacement range.
Compression Ratio:
Data not explicitly provided, but typically around 9-10:1 for this era.
Cooling System:
Air-cooled
Horsepower:
Estimated 30-35 HP (actual figures often vary by market and tuning)
Torque:
Estimated 30-35 Nm (actual figures often vary by market and tuning)
Carburetion:
Single carburetor, likely Dell'Orto PHM 38 or similar.
Fuel Type:
Unleaded gasoline (petrol)
Length:
Data not explicitly provided, typical for dual-sport of this era.
Width:
Data not explicitly provided, typical for dual-sport of this era.
Height:
Data not explicitly provided, typical for dual-sport of this era.
Dry Weight:
Approx. 160-170 kg (unladen)
Wet Weight:
Approx. 180-190 kg (with fluids)
Fuel Capacity:
Approx. 16-20 Liters
Crash Safety:
N/A for motorcycles of this era; focus on rider protection and vehicle handling.
Braking System:
Disc brakes front and rear (typically single disc front, single disc rear)
Lighting:
Headlight, taillight, brake light, turn signals
Chassis Design:
Steel frame for durability and handling
Handguards:
Often fitted as standard or common aftermarket addition for protection.
Oil Change:
Every 3,000 - 5,000 km (or annually)
Air Filter:
Inspect every 3,000 km, clean/replace as needed
Spark Plug:
Replace every 6,000 - 10,000 km
Chain Lubrication Adjustment:
Every 1,000 km or after riding in wet conditions
Engine Oil Type:
SAE 10W-40 or 20W-50 Motorcycle-specific (API SG or higher recommended)
Engine Oil Capacity:
Approx. 1.5 - 2.0 Liters (check dipstick/sight glass)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific recommendation)
Transmission Oil Type:
SAE 80W-90 Gear Oil
Electrical Connections:
Corrosion in connectors, grounding issues due to age
Carburetor Performance:
Gumming of jets if fuel is left standing, need for periodic cleaning and adjustment
Suspension Seals:
Fork seal leaks, rear shock absorber wear
Exhaust Leaks:
Gasket failures at header pipe to engine connection
