Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of V-twin engines (450cc & 550cc), including cylinders, pistons, crankshaft, camshafts, valves, timing systems.
Fuel System:
Carburetor systems (Mikuni VM series or similar), fuel pump, fuel lines, fuel tank, and associated components.
Ignition System:
CDI ignition, spark plugs, ignition coils, stator, and wiring diagrams.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, and fan operation.
Exhaust System:
Exhaust headers, mufflers, and associated mounting hardware.
Transmission:
Clutch system (wet multi-plate), gearbox disassembly, inspection, and reassembly, including gear sets, shift drum, and shift forks.
Drivetrain:
Chain drive system, sprockets, and swingarm maintenance.
Suspension Front:
Upside-down telescopic forks (e.g., Marzocchi or Paioli), including disassembly, seal replacement, oil changes, and adjustment procedures.
Suspension Rear:
Monoshock rear suspension, including linkage maintenance, shock absorber inspection and service, and spring pre-load adjustments.
Brakes Front:
Dual hydraulic disc brakes, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures.
Brakes Rear:
Single hydraulic disc brake, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures.
Wheels Tires:
Wheel bearing service, tire removal and installation, and rim maintenance.
Electrical System:
Battery maintenance, starter motor, lighting system (headlight, taillight, turn signals), horn, and wiring diagrams for all circuits.
Frame Bodywork:
Frame inspection and repair, body panel removal and installation, seat, fuel tank, and fairing components.
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides, and fault finding.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug inspection, and general lubrication.
Engine Rebuild:
Complete engine teardown, component measurement, wear assessment, and reassembly with torque specifications.
Suspension Service:
Fork seal replacement, fork oil changes, shock absorber fluid replacement, and linkage bearing service.
Brake System Overhaul:
Complete brake caliper rebuilding, master cylinder servicing, and brake line replacement.
Electrical Diagnostics:
Wiring harness tracing, component testing (e.g., ignition coil resistance, stator output), and troubleshooting electrical faults.
Carburetor Tuning:
Adjustment of idle speed, mixture screws, and jetting recommendations for different conditions.
Depth:
Comprehensive, from basic maintenance to complete engine and component overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.
Engine Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. More frequent changes recommended for hard riding.
Air Filter Service:
Every 1,000-2,000 km (600-1,200 miles), or more often in dusty conditions.
Spark Plug Replacement:
Every 6,000-10,000 km (3,700-6,000 miles), check condition at oil changes.
Valve Clearance Check:
Every 10,000-15,000 km (6,000-9,000 miles) or as specified by the manual.
Fork Oil Change:
Every 1-2 years or 10,000-20,000 km (6,000-12,000 miles), or if performance degrades.
Engine Oil:
API SG/SH/SJ, JASO MA, SAE 10W-40 or 15W-50 (refer to manual for specific viscosity based on climate).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 synthetic brake fluid.
Clutch Fluid:
DOT 4 or DOT 5.1 synthetic brake fluid (check manual for exact specification).
Fork Oil:
Specific viscosity oil (e.g., Showa SS-08, Motul Fork Oil Expert 7.5W) as per manual; quantity specified per fork leg.
Common Complaints:
Potential for electrical gremlins, clutch slave cylinder leaks, starter motor issues, and occasional carburetor tuning sensitivities. Cam chain tensioner wear on high-mileage examples. Valve seat wear on earlier models.
Maintenance Recommendations:
Strict adherence to maintenance schedule, regular cleaning of air filter, and keeping electrical connections clean and protected are crucial for longevity.
