Engine:
Complete engine overhaul, including disassembly, assembly, inspection, and adjustment of all internal components (pistons, rings, connecting rods, crankshaft, valves, camshafts, timing chain, etc.).
Fuel System:
Carburetor servicing and adjustment (including jetting, float levels, and synchronization), fuel pump operation, fuel tank, fuel lines.
Ignition System:
CDI system, spark plugs, ignition coils, timing, troubleshooting.
Cooling System:
Radiator, cooling fan, coolant, thermostat, water pump.
Exhaust System:
Muffler, exhaust pipes, gaskets, mounting hardware.
Transmission:
Gearbox removal, disassembly, assembly, inspection of gears, bearings, shift drum, and forks. Clutch operation and adjustment.
Drivetrain:
Final drive chain and sprockets maintenance, adjustment, and replacement. Rear wheel hub assembly.
Suspension:
Front fork (telescopic) servicing, oil changes, seal replacement, spring inspection. Rear shock absorber servicing and adjustment.
Brakes:
Front and rear brake systems (hydraulic disc brakes), caliper servicing, pad replacement, brake fluid bleeding, master cylinder inspection, rotor condition checks.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure, tire wear inspection.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), lighting system, starter motor, switches, fuses, relays.
Frame Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank mounting, controls, handlebars.
Maintenance:
Routine maintenance, lubrication points, fluid changes, filter replacements, chain adjustment, brake adjustments.
Troubleshooting:
Diagnostic procedures for common problems, symptom analysis, fault finding charts.
Repair:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Installation:
Procedures for removing and installing various vehicle components and systems.
Cleaning:
Cleaning procedures for specific components (e.g., carburetors, fuel system).
Lubrication Points:
Detailed diagrams showing all lubrication points for the engine, chassis, and moving parts.
Specifications Lists:
Comprehensive lists of service specifications, including tightening torques, wear limits, and measurement data.
Diagnostic Information:
Information on diagnosing common issues and electrical troubleshooting.
Depth:
Comprehensive (from basic maintenance to complete engine and component rebuilds).
Detail Level:
Detailed step-by-step procedures with pictorial diagrams, exploded views, and clear explanations.
Special Tools:
Identification and usage instructions for required special service tools.
Specifications:
Precise technical data, including torque values, clearance specifications, wear limits, fluid capacities, and adjustment settings.
Diagrams:
Includes exploded diagrams, sectional drawings, and detailed illustrations of components and procedures.
Engine Type:
4-stroke, Liquid-cooled, DOHC, Inline-four
Displacement:
749 cc (45.7 cu. in.)
Bore X Stroke:
73.0 x 44.7 mm (2.87 x 1.76 in.)
Horsepower Approx:
Approximately 95-100 HP at the crank (varies by specific model year and tuning)
Torque Approx:
Approximately 50-53 lb-ft at the crank (varies by specific model year and tuning)
Carburetors:
Four Keihin CVKD34 carburetors
Fuel Capacity:
Approximately 4.5 - 5.3 US gallons (17 - 20 liters)
Cooling Type:
Liquid-cooled
Oil Type Spec:
Refer to manual for specific SAE viscosity grade (e.g., 10W-40) and JASO MA specification for wet clutches.
Valvetrain:
DOHC, 4 valves per cylinder
Oil Change Interval:
Refer to manual; typically every 3,000-5,000 miles (5,000-8,000 km) or annually.
Spark Plug Replacement:
Refer to manual; typically every 8,000-15,000 miles (13,000-24,000 km).
Chain Lubrication Adjustment:
Frequent checks and lubrication recommended, usually every 500 miles (800 km) and adjustment as needed.
Engine Oil Grade:
SAE 10W-40 (recommended, verify with manual for specific conditions)
Brake Fluid Type:
DOT 3 or DOT 4 (verify with manual)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (typically a 50/50 mix with distilled water).
Cam Chain Tensioner:
Some models may develop a noisy cam chain tensioner over time, requiring replacement.
Carburetor Synchronization:
Carburetors may require periodic synchronization for smooth running and optimal performance.
Stator Output:
Aging stators can lead to charging system issues; testing is crucial.
Fork Seals:
Like many motorcycles of this era, fork seal leaks are a common maintenance item.
