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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete disassembly, inspection, repair, and reassembly of engine components, including cylinder head, pistons, crankshaft, connecting rods, valve train, oil pump, and lubrication system.
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Fuel System:
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Carburetor removal, cleaning, synchronization, jetting, float level adjustment, fuel pump operation, fuel filter replacement.
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Cooling System:
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Radiator, cooling fan, thermostat, water pump, coolant circulation, bleeding procedures.
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Ignition System:
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CDI unit, ignition coils, spark plugs, timing checks, wiring diagrams.
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Transmission And Drivetrain:
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Clutch operation, gearbox disassembly and reassembly, gear shift mechanism, chain drive maintenance, sprocket replacement.
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Brakes:
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Front and rear brake caliper overhaul, master cylinder service, brake fluid replacement, bleeding procedures, pad and disc inspection and replacement.
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Suspension:
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Front telescopic forks (fork seal replacement, oil level and type, spring inspection), rear monoshock absorber (preload adjustment, damping settings, rebuild procedures), linkage maintenance.
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Electrical System:
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Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting systems, instrument cluster, fuses, relays.
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Chassis And Frame:
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Frame inspection, steering head bearing service, swingarm maintenance, wheel bearing replacement, general disassembly and reassembly of body panels and subframes.
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Exhaust System:
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Exhaust pipe and muffler inspection, gasket replacement, exhaust valve operation (if applicable).
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Procedures Included
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Routine Maintenance:
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Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment and lubrication, brake inspection, tire pressure checks.
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Troubleshooting:
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Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical fault finding.
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Repair Procedures:
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Detailed step-by-step instructions for component removal, overhaul, and installation for all major systems.
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Engine Rebuild:
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Comprehensive guide for full engine disassembly, inspection of wear limits, component replacement, and reassembly with torque specifications.
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Carburetor Tuning:
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Detailed guidance on synchronizing carburetors, adjusting idle speed, and understanding jetting for optimal performance.
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Electrical Diagnostics:
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Wiring diagrams, component testing procedures, and fault finding techniques for the electrical system.
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Technical Depth
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Depth Level:
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Professional Workshop Level
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Information Type:
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Detailed step-by-step instructions, exploded diagrams, technical specifications, torque values, clearances, troubleshooting flowcharts.
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Engine Specifications
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Primary Engine
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Engine Type:
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Liquid-cooled, 4-stroke, DOHC, inline-four cylinder
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Displacement:
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599 cc (cubic centimeters)
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Bore X Stroke:
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62.0 mm x 49.6 mm
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Compression Ratio:
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11.5:1
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Performance
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Horsepower:
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Approx. 95 hp (70 kW) @ 11,500 rpm (claimed)
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Torque:
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Approx. 60 Nm (44 lb-ft) @ 9,000 rpm (claimed)
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Fuel System
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Fuel Delivery:
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Four Mikuni BSR32 CV carburetors
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Fuel Type:
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Unleaded gasoline, 95 RON recommended
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Lubrication
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Oil Type:
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Yamalube 4 (or equivalent) SAE 10W-40 API SG or higher
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Oil Capacity W Filter:
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3.4 Liters (3.6 US qt)
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Ignition
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Ignition System:
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TCBI (Transistor Controlled Ignition)
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Engine Codes
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Engine Variant Codes:
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RJ02 (1998-2001), RJ04 (2002-2003)
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Maintenance
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Service Intervals
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Oil Filter Change:
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Every 6,000 km (3,700 mi) or 6 months.
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Air Filter Cleaning:
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Every 6,000 km (3,700 mi).
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Spark Plug Replacement:
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Every 12,000 km (7,500 mi).
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Valve Clearance Check:
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Every 12,000 km (7,500 mi).
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Brake Fluid Replacement:
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Every 24,000 km (15,000 mi) or 2 years.
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Coolant Replacement:
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Every 24,000 km (15,000 mi) or 2 years.
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Fluid Specifications
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Engine Oil Spec:
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SAE 10W-40, API SG or higher (Yamalube 4 recommended)
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Coolant Type:
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Yamaha's genuine coolant or an equivalent mixture of ethylene glycol and distilled water (50:50).
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Brake Fluid Type:
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DOT 4
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Fork Oil Type:
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Yamaha Fork Oil 10W or equivalent
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Fluid Capacities
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Engine Oil Capacity:
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3.4 L (3.6 US qt) with filter change
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Coolant Capacity:
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2.2 L (2.3 US qt)
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Fork Oil Capacity:
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495 ml (16.7 US fl oz) per fork leg
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Known Issues
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Common Wear Items:
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Clutch plates, brake pads, chain and sprockets, fork seals, steering head bearings.
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Carburetor Synchronization:
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Can drift over time, requiring periodic synchronization for smooth running and fuel efficiency.
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Stator Failure:
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While generally reliable, stator output can degrade over extended mileage, affecting charging system performance.
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Regulator Rectifier:
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Can sometimes be a weak point, especially under heavy electrical load or in hot conditions.
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Cam Chain Tensioner:
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May require manual adjustment or replacement if a rattling noise develops.
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