Engine Mechanical:
Engine assembly, disassembly, internal components (pistons, rings, crankshaft, connecting rods, valves, camshafts), cylinder head, lubrication system, cooling system.
Fuel System:
Fuel injection system, throttle body, fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines.
Ignition System:
Ignition coil, spark plug, CDI unit, timing.
Electrical System:
Wiring diagrams, battery, charging system, starter motor, lighting, sensors, ECU (Engine Control Unit).
Transmission:
Clutch assembly, gearbox, shift mechanism, internal transmission components, lubrication.
Suspension:
Front forks (KYB SSS, Speed Sensitive System), rear shock absorber (KYB, linkage system), adjustments, maintenance, rebuild procedures.
Brakes:
Front and rear brake systems, calipers, master cylinders, brake pads, brake discs, hydraulic lines, bleeding procedures.
Chassis And Frame:
Frame structure, subframe, swingarm, steering system, bearings, alignment.
Bodywork And Plastics:
Fairings, seat, fuel tank cover, fenders, removal and installation procedures.
Wheels And Tires:
Wheel installation, spoke tension, tire selection, pressure, mounting.
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication, general inspection.
Troubleshooting:
Diagnostic procedures for common problems, fault finding, error codes (if applicable).
Engine Repair:
Complete engine overhaul, component replacement, seal replacement, gasket replacement.
Transmission Repair:
Clutch adjustment and replacement, gear inspection and repair, shift drum and fork procedures.
Suspension Service:
Fork oil change and level adjustment, seal replacement, shock absorber service, spring preload adjustment.
Brake Service:
Brake pad replacement, caliper overhaul, master cylinder rebuild, hydraulic system bleeding.
Electrical Diagnostics:
Wiring harness inspection, sensor testing, troubleshooting electrical faults.
Fuel System Service:
Injector cleaning, throttle body cleaning, fuel pressure testing.
Depth:
Professional-level, suitable for mechanics and technicians. Covers complete rebuilds and advanced diagnostics.
Documentation Style:
Step-by-step instructions, detailed exploded diagrams, high-quality pictures.
Engine Oil Change:
Every 10-15 hours of riding, or more frequently for competitive use (refer to manual for specific recommendations).
Air Filter Cleaning:
After every few rides, or more often in dusty conditions.
Spark Plug Inspection:
As per manual, typically around 20-30 hours of use.
Chain Lubrication And Adjustment:
Regularly, at least every 500 km or before long rides.
Engine Oil Type:
SAE 10W-40, API SG, SH, SJ, SL or JASO MA/MA2. Specific recommended brands and specifications are in the manual.
Fork Oil Type:
KYB Suspension Fluid 01 or equivalent (specified viscosity, e.g., SAE 5W)
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol-based) with distilled water (50:50 mix recommended).
Clutch Wear:
Standard wear and tear on clutch plates, especially under aggressive riding.
Fuel Injector Clogging:
Can occur with contaminated fuel, requiring cleaning or replacement.
Suspension Seals:
Fork seal leaks can occur with heavy use, requiring seal replacement.
Maintenance Schedule Detail
Schedule Detail:
The manual provides detailed mileage/hour-based maintenance schedules for all major components.
