Engine Mechanical:
Complete overhaul, including cylinder head, valve train, pistons, connecting rods, crankshaft, lubrication system.
Engine Fuel System:
Carburetor tuning, cleaning, rebuilding, fuel pump, fuel lines, fuel filter replacement.
Engine Ignition System:
Ignition timing, spark plugs, coils, CDI unit, wiring.
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, flushing procedures.
Exhaust System:
Exhaust pipes, mufflers, gaskets, inspection and replacement.
Transmission:
Gearbox disassembly, assembly, gear inspection, shift mechanism, clutch operation and adjustment.
Clutch System:
Clutch operation, hydraulic system (if applicable), cable adjustment, clutch plate replacement.
Chassis Frame:
Frame inspection, alignment checks, swingarm bearings, steering head bearings.
Suspension Front:
Front fork disassembly, fork seal replacement, oil levels and types, spring replacement, damping adjustments.
Suspension Rear:
Monoshock or twin shock absorber inspection, linkage lubrication, spring pre-load adjustment.
Brakes Front:
Brake caliper overhaul, piston seals, pad replacement, disc inspection and replacement, master cylinder service.
Brakes Rear:
Brake caliper/drum inspection, pad/shoe replacement, disc/drum condition, master cylinder service.
Wheels Tires:
Wheel bearing inspection and replacement, rim runout checks, tire pressure and wear analysis, wheel balancing.
Electrical System:
Wiring diagrams, charging system (stator, rectifier/regulator), starting system (starter motor, solenoid), battery maintenance.
Lighting System:
Headlight, taillight, brake lights, turn signals, instrument panel illumination, bulb replacement.
Controls:
Throttle control, clutch lever, brake lever, gear shift lever, handlebar and grip replacement.
Bodywork Fairings:
Fairing removal and installation, mounting points, cosmetic repairs, decal application.
Instrumentation:
Speedometer, tachometer, fuel gauge, warning lights, sensor diagnostics.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake adjustments, fluid level checks, lubrication points.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, fault finding charts.
Repair Procedures:
Step-by-step instructions for all major component repairs and replacements.
Rebuild Procedures:
Detailed instructions for engine, transmission, and carburetor rebuilds.
Electrical Diagnostics:
Testing circuits, diagnosing component failures, utilizing wiring diagrams.
Wiring Diagrams:
Comprehensive, detailed wiring diagrams for all electrical systems.
Depth Of Coverage:
Expert Level (Suitable for professional technicians and experienced DIY mechanics)
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical testing and mechanical adjustments.
Special Tools:
Identification of necessary special tools for specific procedures.
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000-10,000 km (3,600-6,000 miles).
Spark Plug Replacement:
Every 10,000-15,000 km (6,000-9,000 miles).
Chain Lubrication Adjustment:
Every 500-1,000 km (300-600 miles) and after washing/rain.
Engine Oil Type:
SAE 10W-40 or 10W-50, API SG or higher (refer to manual for exact specification and capacity).
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 recommended (check manual for exact specification).
Fork Oil Type Viscosity:
Typically SAE 10W or 15W, specified volume per fork leg.
Carburetor Issues:
Carburetors can become gummed up if the bike sits for extended periods, leading to rough idling and poor throttle response. Synchronisation is critical.
Electrical Gremlins:
Aging wiring, corrosion in connectors, and failing rectifier/regulators can cause charging issues or intermittent electrical problems.
Suspension Wear:
Fork seals and bushings can wear over time, leading to leaks and degraded damping. Rear shock absorbers can lose their damping effectiveness.
Cam Chain Tensioner:
Some models may have a less robust cam chain tensioner that can become noisy or fail, requiring replacement.