Segment:
Dual-sport / Adventure Motorcycle
Target Audience:
Riders seeking off-road capability combined with on-road comfort and practicality.
Key Competitors 2010:
BMW G 650 GS Sertão, Honda XR650L, Kawasaki KLR650, Suzuki DR650SE.
Engine Configuration:
Single-cylinder, 4-stroke, SOHC
Suspension Type:
WP high-quality adjustable suspension front and rear.
Braking System:
High-performance Brembo brakes.
Off Road Bias:
True off-road prowess with long-travel suspension and rugged construction.
Engine Mechanical:
Full engine disassembly, assembly, inspection, and repair procedures for all internal components.
Engine Management:
Fuel injection system (Keihin EFI), ignition system, emissions control, ECU diagnostics and troubleshooting.
Transmission:
Clutch operation, gear shifting mechanisms, gearbox disassembly, assembly, and inspection.
Fuel System:
Fuel pump, fuel filter, fuel lines, fuel tank, injector cleaning and testing.
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat, and associated plumbing.
Exhaust System:
Exhaust pipes, catalytic converter, mufflers, exhaust leak testing, and component replacement.
Suspension Front:
WP Upside-Down (USD) forks, fork seal replacement, oil level and viscosity, damping adjustments, fork spring replacement.
Suspension Rear:
WP Monoshock absorber, linkage system, shock absorber service, spring preload adjustment, rebound and compression damping.
Brakes Front:
Brembo hydraulic disc brakes, brake caliper service, pad replacement, rotor inspection, bleeding procedures.
Brakes Rear:
Brembo hydraulic disc brakes, brake caliper service, pad replacement, rotor inspection, bleeding procedures.
Wheels Tires:
Spoke wheel maintenance, rim inspection, tire mounting and balancing, recommended tire pressures.
Electrical System:
Battery service, charging system (alternator, regulator/rectifier), starter motor, lighting system, fuses, relays.
Wiring Diagrams:
Detailed color-coded wiring diagrams for all electrical circuits and components.
Frame Bodywork:
Chassis inspection, frame integrity, body panel removal and installation, seat, fuel tank, fairings.
Controls:
Throttle control, clutch lever, brake levers, handlebar setup, footpegs.
Tools Equipment:
Special tools required for specific repair and maintenance procedures.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, error code interpretation (if applicable).
Engine Rebuild:
Complete step-by-step instructions for engine overhaul, including piston, cylinder, crankshaft, and valve train work.
Suspension Overhaul:
Detailed procedures for rebuilding front forks and rear shock absorbers.
Brake System Service:
Complete brake bleeding, caliper and master cylinder service, ABS system troubleshooting (if applicable).
Electrical Diagnostics:
Troubleshooting electrical faults, testing components, wiring harness repair.
Bodywork Repair:
Panel removal/installation, minor cosmetic repairs.
Depth Level:
Comprehensive Rebuild to Advanced Diagnostics
Detail Level:
Detailed torque specifications, clearances, and component tolerances.
Oil Change Interval:
Every 5,000 km or annually, whichever comes first.
Oil Filter Replacement:
With every oil change.
Air Filter Cleaning:
Every 5,000 km or as needed based on conditions.
Spark Plug Inspection:
Every 10,000 km.
Valve Clearance Check:
Every 10,000 km.
Coolant Type:
KTM Antifreeze or equivalent water-glycol mixture (50/50).
Fork Oil Viscosity:
KTM Fork Oil SAE 5 (or equivalent).
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals are typical wear items on high-mileage or heavily used dual-sports.
Efi Calibration:
Occasional EFI adjustments or sensor checks might be required depending on operating conditions.
