Engine Mechanical:
Engine disassembly, assembly, inspection, lubrication, timing, valve clearance adjustment, cylinder head, pistons, crankshaft, connecting rods, oil pump, oil cooler, water pump.
Fuel System:
Fuel injection system (FI), throttle body, fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, evaporative emission control (EVAP).
Ignition System:
Ignition coils, spark plugs, crankshaft position sensor, camshaft position sensor, ECU (Engine Control Unit) ignition control.
Cooling System:
Radiator, cooling fan, thermostat, water pump, coolant hoses, coolant specifications, coolant flow.
Exhaust System:
Exhaust pipes, catalytic converter, mufflers, exhaust valve (if applicable).
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, gear inspection, shift drum and forks, drive chain maintenance, final drive ratios.
Chassis Frame:
Frame inspection, alignment, subframe, swingarm removal and installation, bearing inspection and replacement.
Suspension Front:
Front forks, telescopic fork disassembly, assembly, oil type and level, spring rates, damping adjustments, steering head bearings.
Suspension Rear:
Rear shock absorber, linkage system, swingarm pivot bearings, preload and damping adjustments.
Brakes Front:
Brake calipers, brake discs, master cylinder, brake fluid specifications, bleeding procedure, pad replacement, hose inspection.
Brakes Rear:
Rear brake caliper, brake disc, master cylinder, brake fluid specifications, bleeding procedure, pad replacement, hose inspection.
Wheels Tires:
Wheel bearings, wheel removal and installation, tire pressures, tire wear inspection, wheel balancing.
Electrical System Charging:
Stator, alternator, rectifier/regulator, battery specifications, voltage checks.
Electrical System Starting:
Starter motor, starter solenoid, battery testing, starter circuit troubleshooting.
Lighting Signals:
Headlight, taillight, brake lights, turn signals, hazard lights, bulb specifications, wiring diagrams for lighting.
Instrumentation Controls:
Instrument cluster, speedometer, tachometer, fuel gauge, warning lights, handlebar controls, throttle grip, clutch lever.
Wiring Diagrams:
Comprehensive electrical schematic diagrams for all systems, including ECU, sensors, actuators, and lighting.
Bodywork Fairings:
Fairing removal and installation, seat removal, fuel tank removal, body panel fasteners, graphics.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code lookup (if applicable via diagnostic tool), symptom-based troubleshooting guides.
Preventative Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug replacement, brake fluid flush, coolant flush.
Disassembly Assembly:
Step-by-step instructions for component removal, inspection, service, and reinstallation.
Component Testing:
Procedures for testing electrical components (sensors, actuators, coils), mechanical components (clutch, gearbox), and fluid systems.
Calibration Adjustment:
Valve clearance adjustment, throttle position sensor (TPS) calibration, idle speed adjustment (if applicable).
Lubrication:
Specific points of lubrication, recommended lubricants, lubrication intervals.
Tightening Torques:
Detailed torque specifications for all critical fasteners and bolts.
Depth Level:
Comprehensive (covers everything from basic maintenance to full engine and gearbox rebuilds, including electrical diagnostics).
Diagnostic Capabilities:
Detailed diagnostic flowcharts, symptom analysis, and electrical troubleshooting guides.
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Every 12,000 km (7,500 miles) or 12 months.
Air Filter Cleaning Interval:
Every 6,000 km (3,700 miles); replace if damaged.
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles) or 12 months.
Chain Maintenance Interval:
Clean and lubricate every 1,000 km (600 miles) or after riding in the rain/wet conditions; adjust slack every 6,000 km (3,700 miles).
Brake Fluid Replacement Interval:
Every 12,000 km (7,500 miles) or 12 months.
Coolant Replacement Interval:
Every 24,000 km (15,000 miles) or 24 months.
Valve Clearance Check Interval:
Every 18,000 km (11,000 miles) or 18 months.
Engine Oil Specification:
Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher, JASO MA.
Brake Fluid Specification:
DOT 4.
Coolant Specification:
High-quality ethylene glycol-based coolant with demineralized water (50:50 mixture).
Fork Oil Type:
Yamaha Suspension Fluid 01 or equivalent SAE 5W (check manual for exact specification and level).
Common Wear Items:
Chain and sprockets, brake pads, tires, clutch plates (depending on usage).
Potential Electrical Gremlins:
Corrosion in connectors, particularly in the headlight and tail light circuits, can lead to intermittent issues. Battery charging system voltage checks are important.
Fuel System Notes:
While generally reliable, fuel injectors can become clogged with poor quality fuel; regular use of quality fuel and occasional injector cleaner is advisable.
