Engine Mechanical:
Engine disassembly, assembly, inspection, tuning, top-end rebuild, bottom-end rebuild, cylinder head, piston, connecting rod, crankshaft, seals, gaskets, lubrication system.
Fuel System:
Carburetor (Mikuni VM series typical), fuel lines, fuel tank, fuel filter, jetting specifications, float adjustment, cleaning and maintenance.
Ignition System:
CDI ignition, stator, coil, spark plug specifications, timing adjustment (if applicable), troubleshooting.
Cooling System:
Liquid cooling system (radiator, hoses, water pump, thermostat), coolant specifications, bleeding procedure.
Transmission:
Gearbox disassembly, assembly, inspection, lubrication, clutch (wet multi-plate), shift drum and forks, gear ratios, clutch lever and cable adjustment.
Suspension Front:
Telescopic front fork (Kayaba or similar), fork oil type and level, seal replacement, damping adjustments, spring rates, disassembly and assembly.
Suspension Rear:
Monoshock rear suspension (Monocross system), shock absorber service, spring preload adjustment, damping adjustment, linkage inspection and lubrication, bearing replacement.
Brakes Front:
Hydraulic disc brake system, caliper, master cylinder, brake lines, brake fluid specifications (DOT 4 typical), pad replacement, bleeding procedure, rotor inspection.
Brakes Rear:
Hydraulic disc brake system, caliper, master cylinder, brake lines, brake fluid specifications, pad replacement, bleeding procedure, rotor inspection.
Wheels And Tires:
Spoke wheel service, rim inspection, bearing replacement, tire size recommendations, inflation pressures, wheel balancing.
Electrical System:
Wiring diagrams, lighting, kill switch, fuses, basic troubleshooting of electrical components.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, fuel tank mounting, handlebars, footpegs.
Maintenance:
Regular service checks, oil changes, filter cleaning/replacement, chain adjustment and lubrication, bolt torque specifications, general upkeep.
Troubleshooting:
Diagnosis of common problems, step-by-step troubleshooting guides for various systems (engine, electrical, etc.).
Repair:
Detailed instructions for component removal, overhaul, and reassembly of all major systems.
Diagnostics:
Identification of faults, measurement of clearances, compression testing, electrical resistance checks.
Depth:
Comprehensive, covering routine maintenance to full engine and component rebuilds, including detailed diagrams and specifications.
Oil Change:
Every 15-20 hours of riding or as specified in the manual (transmission oil).
Air Filter:
Clean after every few rides, replace as needed.
Spark Plug:
Inspect and clean/replace every 20-30 hours of riding.
Top End Rebuild:
Typically every 50-75 hours of aggressive riding (piston, rings, gaskets).
Engine Oil Type:
2-stroke pre-mix oil (e.g., Yamalube 2-stroke oil).
Transmission Oil Type:
Yamalube 10W-40 API SG or equivalent.
Coolant Type:
Permanent type antifreeze/coolant (e.g., Yamalube Coolant).
Common Wear Items:
Clutch plates, piston rings, fork seals, chain and sprockets, swingarm bearings, steering head bearings.
Ypvs Maintenance:
YPVS system can accumulate carbon deposits, requiring periodic cleaning to ensure proper operation.
