Covered Systems:
Engine, Transmission, Fuel System, Ignition System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Lubrication, Cooling, Troubleshooting, Maintenance, Repair, Disassembly, Assembly, Diagnostics
Estimated Pages:
Likely over 300 pages (typical for a complete factory service manual)
Type:
Factory Service / Repair / Workshop Manual
Format:
PDF (Digital Download)
Engine:
Detailed overhaul, component inspection, timing procedures, piston and cylinder service, crankshaft and connecting rod assembly, valve train (heads, cams, valves, springs, guides), oil pump and lubrication system, cooling system, carburetor and intake system, exhaust system (muffler, headers).
Transmission:
Clutch (pressure plate, clutch shoes, clutch case), gearbox disassembly and assembly, shift linkage, gear ratios, maintenance and inspection.
Fuel System:
Carburetor disassembly, cleaning, adjustment (air screw), fuel pump, fuel filter, fuel lines, fuel tank service.
Ignition System:
Spark plugs, spark plug wires, ignition timing, coil testing, sensors (oil pressure sensor), voltage testing.
Electrical System:
Wiring harnesses (engine harness, chassis harness), starter, alternator, battery, lighting (headlights, taillights, interior lights, turn signals, fog lights), switches, relays (headlight relay, starter relay, ignition relay), wiring diagrams.
Chassis And Suspension:
Frame, forks, rear shock absorber, swingarm, wheel bearings, axles, steering system, brake system (discs, pads, shoes, rotors, calipers, master cylinders, lines, hoses), tire rotation and replacement, wheel alignment.
Bodywork:
Fairings, body panels, seat, fuel tank, fenders, handlebars, dashboard, interior lighting, emblems, trim, door hinges, door panels, glovebox, center console.
Routine Maintenance:
Oil change, transmission fluid change, filter replacement (air filter, fuel filter), spark plug replacement, brake fluid change, coolant change, chain lubrication and adjustment, tire pressure checks.
Engine Repair:
Complete engine teardown and rebuild, piston ring replacement, head gasket replacement, valve adjustments, camshaft installation, crankshaft balancing, bearing replacement (main bearings, cam bearings), freeze plug replacement, gasket replacement.
Electrical Diagnostics:
Troubleshooting electrical faults, testing components with multimeters, tracing wiring issues using diagrams, sensor testing, relay function.
Brake System Service:
Brake pad replacement, brake shoe replacement, rotor replacement, caliper service, master cylinder overhaul, brake bleeding, brake line replacement.
Suspension And Steering:
Fork seal replacement, shock absorber replacement, wheel bearing service, steering head bearing adjustment, steering component inspection.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault finding trees, symptom-based troubleshooting.
Special Tools:
Identification and use of specialized tools required for specific procedures (e.g., rotor puller, torque wrenches).
Depth:
Complete factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic maintenance to full engine and chassis rebuilds.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled
Bore X Stroke:
Refer to Manual (Specifics depend on exact variant)
Compression Ratio:
Refer to Manual
Horsepower:
Approximately 45-50 HP (Varies by specific market and tuning)
Torque:
Approximately 55-60 Nm (Varies by specific market and tuning)
Carburetor:
Likely a Mikuni BST series carburetor (e.g., BST40) or similar Japanese brand
Fuel Delivery:
Carbureted, with a mechanical or electric fuel pump
Oil Capacity:
Refer to Manual (Typically around 2.5 - 3.0 liters)
Oil Type:
Refer to Manual (Likely SAE 10W-40 or 20W-50, JASO MA rated)
Cooling Type:
Liquid-cooled
Coolant Type:
Ethylene Glycol based antifreeze/coolant (Refer to Manual for specific mixture ratio and type)
Oil Change Interval:
Refer to Manual (Typically every 3,000-5,000 km or annually)
Valve Clearance Check:
Refer to Manual (Likely around 6,000-10,000 km intervals)
Spark Plug Replacement:
Refer to Manual (Typically every 10,000-15,000 km)
Common Problems:
Carburetor synchronization and adjustment, potential wear on valve guides or seats with high mileage, electrical connections can sometimes be a point of attention, stator or rectifier issues can occur on older models.
Preventative Maintenance:
Regular cleaning and lubrication of the chain, proper checking of tire wear and pressure, timely replacement of filters and fluids are crucial for longevity.
