Category:
Supersport Motorcycle
Target Audience:
Enthusiasts, track day riders, performance-oriented sportbike owners.
Era Competition:
Competed against machines like the Ducati 916, Honda RC45, and Kawasaki ZX-7R.
Chassis Design:
Race-derived Deltabox II frame, lightweight construction.
Engine Type:
Inline-four, liquid-cooled, DOHC.
Performance Focus:
Designed for track performance and high-speed stability.
Aerodynamics:
Full fairing designed for aerodynamic efficiency.
Major Systems:
Engine, Fuel System, Ignition System, Lubrication System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Chassis, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Wiring Harness, Lighting, Instruments, Bodywork, Frame, Wheels, Tires, Specifications, Troubleshooting, Maintenance
Type:
Owner's Service Manual / Repair Manual
Format:
Digital Download (PDF)
Engine Mechanical:
Detailed disassembly, inspection, and reassembly of cylinder head, valves, camshafts, crankshaft, connecting rods, pistons, and oil pump. Includes torque specifications and clearances.
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment (idle speed, mixture), jetting specifications, fuel pump operation, fuel tank, fuel lines.
Ignition System:
CDI unit, ignition coils, spark plugs, timing, troubleshooting ignition faults.
Lubrication System:
Oil pump operation, oil filter replacement, oil change intervals, oil capacity, oil specifications.
Cooling System:
Radiator, coolant, water pump, thermostat, hoses, bleed procedure, coolant specifications.
Exhaust System:
Muffler, exhaust pipes, inspection for leaks, gasket replacement.
Transmission Drivetrain:
Gearbox disassembly, inspection of gears, shift drum, shift forks, clutch operation, clutch plate replacement, clutch cable adjustment, final drive chain maintenance and adjustment.
Chassis Suspension:
Front fork (telescopic, upside-down) disassembly, seal replacement, oil type and level, rear shock absorber adjustment and replacement, swingarm bearings, steering head bearings.
Brakes:
Front and rear brake caliper overhaul, master cylinder inspection, brake pad replacement, brake fluid type and bleeding procedure, brake line inspection.
Electrical System:
Battery specifications, charging system (stator, rectifier/regulator), starter motor, lighting (headlight, taillight, turn signals), instrument panel, fuses, wiring diagrams, troubleshooting electrical faults.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, minor body panel repair.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid checks, coolant level checks, tire pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common performance issues, starting problems, electrical faults, and operational anomalies.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension fork rebuilds, brake system servicing, electrical component replacement.
Technical Specifications:
Detailed torque values, clearances, fluid capacities, electrical component resistance values, performance data.
Component Overhaul:
Complete instructions for dismantling, cleaning, inspecting, and reassembling key components.
Depth:
Comprehensive: Covers everything from basic owner checks to full engine and chassis rebuilds. Suitable for home mechanics and professional technicians alike.
Oil Change:
Every 6,000 km (3,700 miles) or annually, whichever comes first. (Refer to manual for exact intervals and conditions).
Air Filter:
Inspect every 6,000 km (3,700 miles), clean or replace as needed.
Spark Plugs:
Inspect every 12,000 km (7,500 miles), replace as needed. (Specific plug type and gap required).
Chain Maintenance:
Clean and lubricate every 1,000 km (600 miles) or after riding in wet conditions. Adjust slack as per manual specifications.
Engine Oil:
Yamalube 10W-40 or equivalent API SG, JASO MA. Capacity: 3.4 L (3.6 US qt) with filter change.
Coolant:
Permanent type anti-freeze coolant (ethylene glycol based) mixed with distilled water at a 50/50 ratio. Capacity: Approx. 2.0 L (2.1 US qt).
Brake Fluid:
DOT 4 hydraulic brake fluid.
Fork Oil:
Specific viscosity and quantity as per manual (e.g., Showa SS-02 or equivalent). Approx. 470 ml per fork leg.
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets are typical wear items requiring regular inspection and replacement.
Potential Faults:
Carburetor synchronization can drift over time, requiring adjustment. Electrical connections may need cleaning/dielectric grease for reliability.