Engine Mechanical:
Engine disassembly, assembly, inspection, overhaul, cylinder heads, pistons, rings, crankshaft, connecting rods, valve train.
Engine Fuel System:
Carburetor (Mikuni BST40), fuel pump, fuel lines, fuel tank, fuel filter.
Ignition System:
Ignition timing, spark plugs, ignition coils, electronic control unit (ECU), wiring diagrams.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable), mounting hardware.
Transmission Drivetrain:
Clutch operation, transmission disassembly and assembly, gear selection, final drive (belt drive system).
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, wiring harness.
Chassis Frame:
Frame inspection, steering head bearing maintenance, swingarm, pivot bearings.
Suspension Front:
Front forks (telescopic), oil seals, springs, damper rods, adjustments.
Brakes Front:
Brake caliper, brake disc, master cylinder, brake lines, brake fluid, bleeding procedures.
Wheels Tires:
Wheel bearing maintenance, tire inspection and replacement, tire pressures.
Bodywork Cosmetics:
Fairings, fuel tank cover, seat removal and installation, fenders, minor body panel repair.
Controls Instruments:
Handlebars, grips, levers, throttle control, brake levers, dashboard indicators, switches.
Suspension Rear:
Rear shock absorber, spring preload adjustment, damping adjustments, linkage system (if applicable).
Brakes Rear:
Brake caliper, brake disc, master cylinder, brake lines, brake fluid, bleeding procedures.
Maintenance Procedures:
Routine inspections, oil changes, filter replacements, chain/belt adjustment, brake fluid flush, spark plug replacement.
Troubleshooting Diagnostics:
Systematic diagnosis of common and uncommon problems, fault finding charts, symptom-based troubleshooting.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, repair, assembly, and installation.
Adjustment Procedures:
Carburetor adjustments, clutch free play, throttle cable free play, suspension adjustments.
Special Tool Usage:
Identification and usage instructions for required special service tools.
Depth Of Coverage:
Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and chassis component repairs.
Engine Type:
Air-cooled, 45-degree V-twin, 4-stroke
Bore X Stroke:
3.50 in x 3.13 in (88.9 mm x 79.5 mm)
Valve Train:
OHV (Pushrod), 2 valves per cylinder
Horsepower Estimated:
Approximately 75-80 HP @ 6000 RPM (manufacturer claims may vary)
Torque Estimated:
Approximately 70-75 ft-lbs @ 4500 RPM (manufacturer claims may vary)
Fuel Delivery:
Mikuni BST40 flat-slide carburetor
Fuel Tank Capacity:
3.7 U.S. gallons (14 liters)
Oil Type Specification:
Refer to manual for specific viscosity (e.g., SAE 20W-50, or Harley-Davidson recommended oils).
Oil Capacity:
Approximately 2.5-3.0 U.S. quarts (2.4-2.8 liters) with filter change.
Oil Change Interval:
Typically every 3,000-5,000 miles or annually, refer to manual for precise recommendations.
Belt Tension Check:
Regularly check and adjust belt tension per manual specifications.
Spark Plug Replacement:
Refer to manual for mileage or time-based replacement intervals.
Brake Fluid Type:
DOT 4 recommended (refer to manual for exact specification).
Primary Chain Case Oil:
Specific Buell or Harley-Davidson primary case lubricant (refer to manual).
Common Wear Items:
Belt drive wear, fork seal leaks, voltage regulator failures, carburetor adjustments can be sensitive.
Potential Electrical Gremlins:
Can occur with age and mileage, especially wiring harness connections and grounds.
Special Tools Importance:
Crucial for accurate adjustments and repairs, particularly for belt tension and wheel bearings.
