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Manual Coverage
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Systems Covered
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Engine:
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Complete overhaul, tuning, lubrication, cooling system, fuel system (carburetion), exhaust system, engine internals (pistons, rings, valves, camshafts, crankshaft, connecting rods), engine mounting.
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Transmission:
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Gearbox disassembly and assembly, clutch operation and adjustment, gear shift mechanism, transmission lubrication.
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Chassis And Suspension:
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Front fork (oil change, seal replacement, spring rates), rear shock absorber (adjustment, replacement), swingarm, bearings, linkages, steering head bearings.
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Brakes:
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Front and rear brake system, caliper overhaul, disc inspection and replacement, brake fluid flush and bleeding, master cylinder, brake lines.
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Electrical System:
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Wiring diagrams, ignition system, charging system (stator, regulator/rectifier), battery, lighting, starter motor, instrumentation, fuses, relays, ECU (if applicable).
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Fuel System:
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Carburetor identification, removal, disassembly, cleaning, adjustment, jetting, fuel tank, fuel pump (if applicable), fuel lines.
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Cooling System:
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Radiator, cooling fan, thermostat, coolant hoses, coolant type and capacity.
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Bodywork And Trim:
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Fairing removal and installation, body panel fasteners, seat removal, tank cover, emblems.
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Procedures Included
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Maintenance:
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Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, brake checks, fluid level checks, spark plug replacement, air filter cleaning/replacement.
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Troubleshooting:
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Diagnostic charts for common problems, identifying symptoms and causes, fault finding procedures.
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Repair:
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Step-by-step instructions for component disassembly, repair, and reassembly. Detailed procedures for engine rebuilds, carburetor tuning, suspension overhauls, electrical system diagnostics and repairs.
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Technical Specifications:
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Detailed torque specifications for all fasteners, measurement specifications (clearances, tolerances), engine timing, valve clearances.
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Diagrams And Illustrations:
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Exploded views of components, detailed assembly diagrams, wiring schematics, pictorial guides for procedures.
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Technical Depth
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Depth:
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Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and suspension overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.
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Engine Specifications
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Primary Engine
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Engine Type:
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Liquid-cooled, four-stroke, DOHC, inline-four cylinder
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Displacement:
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599 cc
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Bore X Stroke:
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61.0 mm x 50.9 mm
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Compression Ratio:
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12.2:1
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Performance
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Horsepower:
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Approx. 95 hp (70 kW) @ 12,000 rpm (claimed)
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Torque:
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Approx. 62 Nm (6.3 kgf-m, 45.7 lb-ft) @ 10,000 rpm (claimed)
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Fuel System
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Fuel Delivery:
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Four Mikuni CV carburetors (likely BSW26 or similar)
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Fuel Type:
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Unleaded gasoline, minimum 91 octane (RON+MON)/2
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Lubrication
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Oil Type:
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API SG, JASO MA or equivalent motorcycle-specific 4-stroke engine oil
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Oil Capacity:
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Approx. 3.5 liters (3.7 US qt) with filter change
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Cooling System
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Coolant Type:
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Ethylene glycol based coolant with demineralized water (50:50 mix recommended)
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Ignition System
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Ignition Type:
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Digital TCI (Transistor Controlled Ignition)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 5,000 - 6,000 km (3,000 - 3,700 miles) or 6 months, whichever comes first.
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Air Filter Cleaning:
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Every 10,000 km (6,000 miles)
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Spark Plug Replacement:
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Every 20,000 km (12,000 miles)
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Valve Clearance Check:
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Every 30,000 km (18,000 miles)
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Fluid Specifications
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Fork Oil:
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Yamaha Suspension Fluid 10W or equivalent (capacity and level specified in manual)
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Brake Fluid:
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DOT 4
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Coolant:
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50% Ethylene Glycol, 50% Demineralized Water
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Known Issues
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Common Wear Items:
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Chain and sprockets, brake pads, tires, fork seals due to mileage and usage. Carburetor synchronization may require periodic adjustment.
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Electrical Gremlins:
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Occasional issues with regulator/rectifier or stator windings, particularly on higher mileage units. Check wiring connections for corrosion.
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Carburetor Tuning:
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Carburetors can sometimes become slightly out of sync or suffer from gumming if the bike sits for extended periods without fuel stabilizer. Manual provides detailed tuning procedures.
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