Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, valve clearance adjustment, piston/ring/cylinder inspection, crankshaft/connecting rod checks.
Fuel System:
Carburetor (FCR) inspection, cleaning, adjustment, synchronization; fuel pump, fuel filter, fuel tank maintenance.
Ignition System:
CDI unit, spark plugs, ignition timing, ignition coil inspection.
Transmission And Drivetrain:
Clutch inspection, operation, adjustment; gearbox disassembly, assembly, inspection, gear engagement; final drive maintenance (chain and sprockets), lubrication.
Cooling System:
Radiator, hoses, thermostat, water pump inspection and replacement, coolant specifications and bleeding procedures.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Brakes System:
Hydraulic brake systems (front and rear), caliper service, master cylinder service, brake pad replacement, brake fluid specifications, bleeding procedures, disc inspection.
Suspension System:
Front forks (telescopic), rear shock absorber service, spring preload adjustment, fork oil specifications, seal replacement, linkage inspection.
Steering System:
Handlebar removal/installation, steering head bearing inspection, adjustment, and replacement.
Electrical System:
Wiring diagrams, battery inspection and maintenance, charging system (alternator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, horn, instrument panel functions and troubleshooting.
Frame And Bodywork:
Chassis inspection, frame integrity checks, body panel removal/installation, seat, fuel tank, fairings, fenders.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, tire wear inspection, wheel balancing.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake fluid changes, coolant checks.
Troubleshooting:
Diagnostic charts for common issues (engine starting problems, performance issues, electrical faults).
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair.
Specific Tasks:
Carburetor synchronization, valve clearance adjustment, steering head bearing adjustment, fork seal replacement.
Depth:
Expert-level detail for professional mechanics and advanced DIY enthusiasts, covering complete disassembly and reassembly of all major components.
Transmission Type:
Constant mesh 5-speed
Clutch Type:
Wet, multi-plate, diaphragm spring
Final Drive:
O-ring sealed chain, 530 pitch
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st: 2.55, 2nd: 1.87, 3rd: 1.46, 4th: 1.21, 5th: 1.04)
Transmission Oil Type:
Yamaha Motorcycle Gear Oil or equivalent API GL-4, SAE 10W-30
Transmission Oil Capacity:
3.2 Liters (3.4 US qt) with filter change
Engine Oil Change:
Every 6,000 km (3,750 miles) or 6 months, whichever comes first.
Oil Filter Change:
At every engine oil change.
Air Filter Inspection:
Every 6,000 km (3,750 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Valve Clearance Check:
Every 18,000 km (11,250 miles).
Brake Fluid Change:
Every 2 years or as needed.
Coolant Change:
Every 2 years or 24,000 km (15,000 miles).
Engine Oil Specification:
Yamaha Genuine Yamalube 4S or equivalent SAE 10W-40 API SG or higher, JASO MA.
Engine Oil Capacity:
3.4 Liters (3.6 US qt) without filter change, 3.8 Liters (4.0 US qt) with filter change.
Coolant Type:
Yamaha Genuine Yamalube Coolant or equivalent ethylene glycol-based antifreeze (50% mix with distilled water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Fork Oil Type:
SAE 10W fork oil (230cc per fork leg).
Common Wear Items:
Clutch plates, fork seals, steering head bearings, rear shock absorber bushings.
Carburetor Tuning:
Carburetors can require periodic synchronization and cleaning due to their age and usage.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues if not maintained.