Segment:
High-performance Supermoto motorcycle, aimed at both competitive use and enthusiast riders.
Target Audience:
DIY mechanics, professional motorcycle technicians, and owners seeking in-depth knowledge for maintenance and repair.
Competitors:
KTM EXC, Yamaha WR450F, Honda CRF450X (in their respective supermoto conversions/variants).
Ease Of Use:
Designed for clarity with exploded views, diagrams, and step-by-step instructions for simplified repairs.
Comprehensiveness:
Covers all aspects of the motorcycle's systems, from basic maintenance to major overhauls.
Accessibility:
Instant PDF download provides immediate access to critical repair information.
Engine Overhaul:
Complete engine teardown, inspection, and reassembly procedures for all internal components.
Fuel System:
Carburetor (Mikuni VM series) tuning, cleaning, rebuilding, and adjustment.
Ignition System:
CDI unit, ignition coil, spark plug specifications, and troubleshooting.
Cooling System:
Radiator maintenance, fan operation, coolant type, and leak detection.
Exhaust System:
Muffler and header pipe inspection and replacement.
Transmission:
Gearbox disassembly, inspection, lubrication, and reassembly.
Clutch System:
Clutch operation, adjustment, plate replacement, and fluid specifications.
Suspension Front:
Fork maintenance, seal replacement, oil levels and type, compression and rebound adjustments.
Suspension Rear:
Shock absorber servicing, linkage maintenance, spring preload, and damping adjustments.
Braking System Front:
Caliper overhaul, pad replacement, disc inspection, and hydraulic system bleeding.
Braking System Rear:
Caliper overhaul, pad replacement, disc inspection, and hydraulic system bleeding.
Wheels Tires:
Spoke tensioning, rim maintenance, tire pressure specifications, and installation.
Electrical System:
Wiring diagrams, component testing, battery maintenance, lighting, and horn operation.
Frame Chassis:
Frame inspection for cracks or damage, steering head bearing service.
Bodywork Plastics:
Fairing and plastic component removal, installation, and repair.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication points.
Troubleshooting Guides:
Systematic diagnostic procedures for common performance issues.
Repair Instructions:
Detailed, step-by-step instructions for all major repair tasks.
Adjustment Procedures:
Carburetor, clutch, brakes, suspension, and chain adjustments.
Rebuilding Kits:
Guidance for using rebuild kits for carburetor, forks, and brake calipers.
Assembly Disassembly:
Clear instructions for component removal and reinstallation with torque specifications.
Detail Level:
Comprehensive, from basic rider maintenance to full engine and chassis rebuilds.
Diagnostic Tools:
Information on necessary tools and techniques for diagnosis.
Illustrations Diagrams:
Abundant exploded views, wiring diagrams, and step-by-step illustrations.
Technical Specifications:
Detailed torque values, clearances, fluid capacities, and electrical parameters.
Compatibility:
PC & Mac compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)
Searchability:
Likely searchable text due to PDF format.
Resolution:
High resolution for clear text and images.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Estimated Pages:
Likely 300-500 pages (typical for comprehensive workshop manuals).
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
Approximately 449cc (specific bore/stroke to be detailed in manual)
Bore X Stroke:
To be confirmed in manual (e.g., 95mm x 63.4mm for similar era engines)
Compression Ratio:
Likely around 12.0:1 or higher (to be confirmed in manual)
Valve Train:
DOHC, 4 valves
Horsepower:
Estimated 50-55 HP at peak RPM (to be confirmed in manual)
Torque:
Estimated 45-50 Nm at peak RPM (to be confirmed in manual)
Fuel Delivery:
Carburetor (likely Mikuni VM38 or similar)
Fuel Type:
Unleaded gasoline, minimum 91 octane
Fuel Tank Capacity:
Approximately 7.5 - 9.5 liters (to be confirmed in manual)
Transmission Type:
5-speed manual
Clutch Type:
Wet, multi-plate, hydraulic actuation
Gear Ratios:
Specific gear ratios for each speed to be detailed in the manual.
Final Drive:
O-ring sealed chain, 520 pitch (standard for this type of bike)
Transmission Oil Type:
Motorcycle-specific transmission oil, e.g., SAE 10W-40 or 15W-50 (refer to manual for exact specification).
Transmission Oil Capacity:
Approximately 0.8 - 1.2 liters (to be confirmed in manual)
Oil Change Interval:
Every 50-100 hours of riding or annually (refer to manual for specific recommendation based on usage).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).
Chain Lubrication Adjustment:
Lubricate every 300-500 km; adjust slack as needed based on rider preference and wear.
Fork Oil Change:
Recommended every 1-2 years or 100-200 hours of heavy use.
Engine Oil:
High-quality synthetic motorcycle engine oil, e.g., Motul 300V, Castrol Power 1, SAE 10W-40 or 15W-50 (verify with manual).
Coolant:
Mixture of distilled water and antifreeze/coolant (e.g., ethylene glycol based) with corrosion inhibitors. 50/50 mix is typical.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid (refer to manual for exact type).
Fork Oil:
Specific suspension fork oil with a designated viscosity grade (e.g., 5W, 10W, 15W, as specified in manual).
Carburetor Tuning:
Can be sensitive to altitude and temperature changes; requires periodic adjustment.
Valve Clearances:
Require periodic checking and adjustment, typically every 100-200 hours.
Cooling System Leaks:
Hoses and seals can degrade over time; regular inspection is advised.
Clutch Discs:
Wear can accelerate with aggressive riding; replacement is a common maintenance item.
