Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of engine components (cylinder head, valves, piston, connecting rod, crankshaft, oil pump, etc.)
Fuel System:
Carburetor service, fuel delivery, fuel tank, fuel lines, fuel filter replacement and troubleshooting.
Ignition System:
Ignition coil testing, spark plug specifications, ECU (Engine Control Unit) and sensor diagnosis.
Transmission Clutch:
Clutch operation, adjustment, replacement; gearbox disassembly, inspection, and repair.
Drivetrain:
Drive shaft, universal joints, final drive assembly maintenance and repair.
Suspension Front:
Front fork disassembly, seals replacement, oil change, spring and damper inspection.
Suspension Rear:
Rear shock absorber inspection, adjustment, and replacement; swingarm and linkage maintenance.
Braking System Front:
Brake caliper overhaul, pad replacement, disc inspection, brake fluid bleeding, master cylinder service.
Braking System Rear:
Rear brake caliper overhaul, pad replacement, disc inspection, brake fluid bleeding, master cylinder service.
Electrical System Charging:
Stator, regulator/rectifier testing, battery maintenance and charging system diagnosis.
Electrical System Lighting:
Headlight, taillight, turn signals, and accessory lighting service and troubleshooting.
Electrical System Ignition Start:
Starter motor service, ignition switch, and related circuitry troubleshooting.
Electrical System Instruments Controls:
Speedometer, tachometer, gauges, switches, and control lever servicing.
Chassis Frame:
Frame inspection, steering head bearing service, and general chassis maintenance.
Bodywork Cosmetics:
Fender removal/installation, fuel tank servicing, seat mounting, and minor body panel adjustments.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, brake fluid flush, drive shaft lubrication.
Troubleshooting Diagnostics:
Systematic diagnostic flowcharts for common issues, electrical system troubleshooting, and performance problems.
Engine Rebuild:
Comprehensive step-by-step instructions for complete engine overhauls and component replacement.
Suspension Overhaul:
Detailed procedures for front fork and rear shock absorber rebuilds.
Brake System Repair:
Full repair procedures for calipers, master cylinders, and hydraulic lines.
Electrical Component Replacement:
Instructions for replacing common electrical parts like starter motor, stator, regulators, and switches.
Carburetor Tuning Rebuild:
Detailed guidance on cleaning, rebuilding, and adjusting carburetors for optimal performance.
Depth Level:
Comprehensive from basic maintenance to full engine and transmission rebuilds.
Diagnostic Information:
Inclusion of diagnostic codes (if applicable), electrical schematics, and troubleshooting tables.
Torque Specifications:
Precise torque values for all critical fasteners and engine components.
Clearances Tolerances:
Specific measurements for engine part clearances (piston-to-cylinder, valve lash, bearing clearances).
Engine Oil Change:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 10,000 km (6,000 miles).
Spark Plug Replacement:
Every 20,000 km (12,000 miles).
Brake Fluid Flush:
Every 2 years or 20,000 km (12,000 miles).
Drive Shaft Greasing:
Every 10,000 km (6,000 miles).
Engine Oil Type:
SAE 20W-40 API SG or higher (Yamalube 4 is recommended).
Engine Oil Capacity:
Approx. 4.2 Liters (4.4 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4.
Fork Oil Type:
Yamaha Suspension Fluid (or equivalent SAE 10W fork oil).
Fork Oil Capacity:
Approx. 596 ml (20.1 US fl oz) per fork leg.
Common Wear Items:
Clutch plates, brake pads, tires, and fork seals are common wear items.
Potential Issues:
Carburetor synchronization and occasional idle issues can arise with age and mileage. Drive shaft splines may require inspection and greasing to prevent wear.
