Motorcycle Segment:
Middleweight sport-touring motorcycle, known for its versatility, upright riding position, and parallel-twin engine.
Key Competitors:
Yamaha FZ6, Suzuki Bandit 650, Honda NC700X (later models), Kawasaki ER-6f (faired version).
Vehicle Strengths:
Comfortable ergonomics, tractable engine, nimble handling, practical for commuting and touring.
Target Audience:
DIY motorcycle owners, independent repair shops, technicians seeking factory-level repair data.
Unique Selling Points:
Comprehensive factory data, lifetime access, multi-device compatibility, printable format.
Engine:
Complete diagnosis, repair, overhaul, tuning, specifications, and troubleshooting for the 649cc parallel-twin engine.
Fuel System:
Fuel injection system (EFI) components, sensors, actuators, fuel pump, injectors, throttle body, and diagnostics.
Ignition System:
Ignition coils, spark plugs, ECU control, timing, and troubleshooting.
Transmission:
Clutch operation, gearbox components, shifting mechanisms, lubrication, and repair procedures.
Drivetrain:
Final drive chain and sprockets maintenance, inspection, and replacement.
Cooling System:
Radiator, cooling fan, coolant, hoses, thermostat, and maintenance procedures.
Exhaust System:
Exhaust pipes, mufflers, catalytic converter, and inspection.
Suspension Front:
Front forks (telescopic, cartridge type), oil levels, seals, spring rates, damping adjustments, and rebuilding.
Suspension Rear:
Monoshock rear suspension, linkage system, adjustable pre-load and rebound damping, and maintenance.
Brakes Front:
Dual disc front brakes, calipers, brake pads, master cylinder, fluid, lines, and bleeding procedures.
Brakes Rear:
Single disc rear brake, caliper, brake pad, master cylinder, fluid, lines, and bleeding procedures.
Wheels Tires:
Wheel bearings, tire pressures, tire replacement, wheel balancing.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting, horn, fuses, relays, and wiring diagrams.
Instrumentation:
Instrument cluster (speedometer, tachometer, warning lights), sensors, and troubleshooting.
Bodywork Chassis:
Frame inspection, fairings, seats, fuel tank, body panels, mounting hardware, and removal/installation.
Steering:
Handlebars, steering stem, bearings, and troubleshooting.
Routine Maintenance:
Oil changes, filter replacement, chain lubrication and adjustment, tire pressure checks, brake fluid checks, coolant checks, spark plug inspection/replacement, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems, including fault codes (if applicable to the era).
Engine Rebuild:
Complete internal engine repair, including piston, ring, valve, camshaft, and crankshaft procedures.
Suspension Servicing:
Fork seal replacement, fork oil change and level adjustment, rear shock service.
Brake System Overhaul:
Brake caliper rebuild, master cylinder replacement, brake line replacement, brake bleeding.
Electrical Diagnostics:
Wiring harness checks, component testing, charging system troubleshooting.
Bodywork Repair:
Panel removal and installation, fairing repair and mounting.
Diagnostic Capability:
Advanced diagnostics with detailed step-by-step troubleshooting guides for electrical and mechanical issues.
Repair Scope:
Comprehensive repair procedures from minor adjustments to complete engine and component rebuilds.
Diagrams Illustrations:
Hundreds of detailed photos and exploded diagrams for clear visualization of procedures and parts.
Technical Specifications:
Inclusion of all necessary torque values, clearances, fluid capacities, and electrical specifications.
Oil Change Interval:
Every 6,000 km (3,700 mi) or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Every 12,000 km (7,500 mi) or 12 months.
Chain Maintenance Interval:
Lubricate and check tension every 1,000 km (600 mi).
Air Filter Cleaning Interval:
Inspect every 6,000 km (3,700 mi), clean or replace as needed.
Spark Plug Replacement Interval:
Inspect every 12,000 km (7,500 mi), replace as needed.
Coolant Flush Interval:
Every 24,000 km (15,000 mi) or 24 months.
Brake Fluid Replacement Interval:
Every 24 months, regardless of mileage.
Coolant Type:
Ethylene glycol based, permanent type anti-freeze coolant (50% solution).
Brake Fluid Type:
DOT 4 (or DOT 3 as minimum, check manual for exact specification).
Common Wear Items:
Chain and sprockets, brake pads, tires, fork seals (due to suspension travel).
Potential Engine Quirks:
While generally reliable, occasional fuel injection sensor issues or minor vibrations at certain RPMs are not uncommon in this engine configuration.
