Engine Mechanical:
Engine assembly, disassembly, inspection, repair of all internal components (pistons, rings, crankshaft, connecting rods, camshafts, valves, timing chain).
Engine Fuel System:
Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), EFI system troubleshooting, ECU diagnosis.
Engine Cooling System:
Radiator, cooling fan, thermostat, water pump, coolant flow, diagnosis of overheating.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, O2 sensors, inspection and replacement.
Transmission:
Gearbox assembly, disassembly, inspection, repair, clutch operation, lubrication.
Chassis Frame:
Frame inspection, alignment, front frame neck service, rear subframe.
Suspension Front:
Front forks (telescopic, cartridge), springs, oil seals, fork leg disassembly, adjustment, maintenance.
Suspension Rear:
Rear shock absorber, linkage, swingarm, bearing inspection, adjustment, maintenance.
Brakes Front:
Brake calipers, master cylinders, brake lines, discs, pads, bleeding procedure, component inspection.
Brakes Rear:
Rear brake caliper, master cylinder, brake disc, pads, bleeding procedure, component inspection.
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting, balancing, recommended tire pressures.
Steering:
Handlebar, steering stem, head bearings, adjustment, lubrication, troubleshooting.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting (headlights, taillights, indicators), wiring diagrams.
Instrumentation:
Instrument cluster (speedometer, tachometer, LCD display), indicator lights, sensor diagnosis.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, minor body panel repair and alignment.
Lubrication Maintenance:
Engine oil change, oil filter replacement, chain lubrication and adjustment, fork oil replacement.
Routine Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, chain adjustments, spark plug replacements.
Engine Overhaul:
Complete engine disassembly, component inspection, reassembly, torque specifications for all fasteners.
Fuel System Repair:
Throttle body cleaning, injector testing, fuel pump replacement, fuel pressure checks.
Suspension Servicing:
Front fork seal replacement, fork oil level/pressure adjustment, rear shock absorber linkage service.
Brake System Service:
Brake fluid replacement, caliper overhaul, master cylinder rebuild, rotor inspection.
Electrical Troubleshooting:
Diagnosis of starting issues, charging system faults, lighting problems, using wiring diagrams.
Diagnostic Procedures:
Troubleshooting guides for common performance issues, error code interpretation (if applicable).
Special Tool Requirements:
Identification and usage of specialized tools required for specific repair procedures.
Depth:
Comprehensive Workshop Level (suitable for professional technicians and advanced DIY enthusiasts).
Detail Level:
Detailed step-by-step instructions, diagrams, specifications, and troubleshooting guides.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first.
Oil Filter Replacement:
Every 12,000 km (7,500 miles) or 24 months.
Air Filter Cleaning:
Every 6,000 km (3,700 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Chain Maintenance:
Inspect and lubricate every 1,000 km (600 miles) or after riding in rain. Adjust slack every 1,000 km (600 miles).
Coolant:
Suzuki Super Long Life Coolant or equivalent (50/50 mix of ethylene glycol and distilled water).
Fork Oil:
SAE 0W-20 or equivalent (check manual for precise grade and volume).
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings.
Electrical Gremlins:
Occasional issues with regulator/rectifier failure or stator coil degradation due to heat.
Fuel System Concerns:
Potential for injector fouling with poor fuel quality, though generally reliable.
