Engine:
Complete overhaul, diagnostics, component replacement (e.g., pistons, rings, valves, camshafts, timing components, oil pump)
Gearbox And Clutch:
Clutch operation, adjustment, replacement; gearbox disassembly, inspection, assembly, gear selection mechanisms
Cooling System:
Radiator, hoses, thermostat, water pump, coolant specifications, bleeding procedures
Fuel System:
Fuel pump, fuel injectors, fuel filter, fuel lines, throttle body, idle control system, fuel pressure testing
Braking System:
Front and rear brake components (calipers, pads, rotors, master cylinder, brake lines), hydraulic system, bleeding procedures
Suspension:
Front forks (oil change, seal replacement, internal components), rear shock absorber, linkage (if applicable), swingarm
Electrical System:
Battery, charging system (alternator/stator, rectifier/regulator), ignition system (spark plugs, coils), lighting (headlight, taillight, turn signals), starter motor, fuses, relays
Body And Fixtures:
Fairings, fenders, fuel tank removal/installation, seat, handlebars, controls, instrument panel, mirrors
Exhaust System:
Exhaust pipes, mufflers, gaskets, mounting hardware, emission controls (if applicable)
Wheels And Tyres:
Wheel bearing inspection and replacement, tire removal and installation, wheel balancing, tire pressure specifications
Wiring Diagrams:
Detailed electrical schematics for various circuits, component identification
Maintenance:
Regular servicing, lubrication points, fluid checks, filter replacements, adjustments
Technical Information And Specifications:
Torque values, clearances, engine tuning data, fluid types and capacities, dimensional data
Frame And Body:
Frame inspection, chassis components, mounting points, body panel alignment
Steering System:
Steering head bearing inspection and adjustment, handlebar mounting
Controls:
Throttle cables, clutch cable, brake levers, control levers adjustment and replacement
Lighting And Signaling:
Headlight aiming, bulb replacement, tail light assembly, turn signal operation, electrical connections
Ignition System:
Spark plug type and gap, ignition coil testing, CDI unit (if applicable) diagnostics
Diagnostic Procedures:
Troubleshooting guides for common symptoms and system failures
Repair Procedures:
Step-by-step instructions for component repair and replacement
Adjustment Procedures:
Carburetor/throttle body synchronization, clutch cable adjustment, brake lever adjustment
Disassembly And Assembly:
Detailed instructions for taking apart and reassembling major vehicle components
Torque Specifications:
Precise torque values for all critical fasteners
Troubleshooting Engine:
Starting issues, misfires, power loss, oil consumption diagnosis
Troubleshooting Electrical:
No power, charging system faults, lighting issues, starter motor problems
Depth:
Comprehensive (Covers all repair procedures used by professional mechanics)
Illustrations:
Highly detailed exploded pictures and diagrams
Rebuild Procedures:
Engine internal component rebuild, gearbox overhaul, suspension fork rebuild
Diagnostic Tools:
Manual assumes use of standard mechanic tools; specific diagnostic equipment not explicitly mentioned but implied for advanced diagnostics.
Oil Change Interval:
Typically every 3,000 - 5,000 km or 6 months (Refer to manual for exact intervals)
Air Filter Replacement:
Typically every 6,000 - 10,000 km or annually (Refer to manual for exact intervals)
Spark Plug Replacement:
Typically every 10,000 - 20,000 km (Refer to manual for exact intervals and type)
Engine Oil Type:
API SG/SH/SJ or higher, JASO MA Certified, SAE 10W-40 (Verify with manual for specific viscosity and API classification)
Engine Oil Capacity:
Approx. 2.2 - 2.5 Liters (with filter change, verify with manual)
Coolant Type:
Ethylene Glycol based, permanent type antifreeze (typically 50/50 mix with distilled water, verify with manual)
Brake Fluid Type:
DOT 4 (verify with manual)
Common Problems:
Occasional fuel system cleaning requirements, potential for regulator/rectifier failure (common on many bikes of this era), clutch adjustment needs.
Maintenance Focus:
Regular checks of belt tension, tire wear, and electrical connections are crucial.
