Category:
Off-Road Competition Motorcycle
Target Audience:
Motocross and Enduro riders, off-road enthusiasts
Competitors 2008:
KTM EXC series, Honda CRF-X, Kawasaki KX-F, Suzuki RM-Z
Engine Type:
High-performance liquid-cooled, four-stroke, DOHC, four-valve
Suspension System:
Industry-leading KYB Speed Sensitive System (SSS) forks and rear shock
Chassis Design:
Lightweight aluminum frame for agility and handling
Fueling:
Carbureted (Keihin FCR 37mm) for responsive power delivery
Engine:
Complete Engine Rebuild and Maintenance
Transmission:
Gearbox, Clutch, and Shifting Mechanism
Electrical:
Ignition System, Lighting, Charging System, Wiring Diagrams
Suspension:
Front Fork (KYB SSS), Rear Shock Absorber, Linkage System
Brakes:
Front and Rear Hydraulic Disc Brakes, Master Cylinders, Calipers, Lines
Fuel System:
Carburetor (Keihin FCR), Fuel Pump, Fuel Lines
Cooling System:
Radiator, Coolant Hoses, Water Pump
Frame And Bodywork:
Chassis, Seat, Fuel Tank, Fenders, Handlebars
Troubleshooting:
Diagnostic Charts and Symptom-Based Solutions
Maintenance:
Scheduled Maintenance, Lubrication Points
Technical Specifications:
Detailed Specs for all Components
Page Count:
Estimated 300-400 pages (typical for a full service manual)
Manual Type:
Service Repair Manual
Engine Assembly:
Full engine strip-down, inspection, and reassembly procedures
Cylinder Head:
Valve adjustment, camshaft removal/installation, de-carbonizing
Crankshaft And Piston:
Piston ring replacement, connecting rod checks, bearing clearances
Lubrication System:
Oil pump operation, oil filter replacement, oil passage cleaning
Ignition Timing:
Ignition system component testing, timing verification
Carburetor Tuning:
Jetting specifications, idle adjustment, float bowl level
Suspension Forks:
Fork oil change, seal replacement, spring rates, damping adjustments (KYB Speed Sensitive System)
Rear Shock:
Rebuilding, oil changes, seal replacements, adjustment procedures
Wheel Bearings:
Front and rear wheel bearing inspection and replacement
Steering Stem:
Steering head bearing adjustment and replacement
Throttle Control:
Cable adjustment, grip replacement
Clutch Operation:
Clutch cable adjustment, clutch plate inspection and replacement
Brake Fluid:
Brake fluid type, bleeding procedures, pad replacement
Wiring Diagrams:
Comprehensive electrical system schematics for troubleshooting
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks
Engine Overhaul:
Detailed instructions for full engine rebuilds
Suspension Setup:
Guidance on adjusting suspension for different riding conditions
Troubleshooting Diagnostics:
Step-by-step guides to identify and fix common and complex issues
Carburetor Cleaning And Rebuilding:
Complete disassembly and reassembly of the Keihin FCR carburetor
Brake System Maintenance:
Pad replacement, caliper service, bleeding procedures
Electrical Component Testing:
Testing ignition coils, stator, CDI unit, lighting circuits
Wheel And Tire Service:
Tire changes, wheel balancing, spoke tensioning
Radiator And Cooling System Flushing:
Coolant replacement and system bleeding
Depth:
Comprehensive; covers basic maintenance to complete engine and chassis rebuilds.
Diagnostic Capability:
Advanced diagnostic trees and troubleshooting guides
Rebuild Procedures:
Detailed instructions for all major component rebuilds, including engine and suspension
Torque Specifications:
Precise torque values for all fasteners
Clearance Measurements:
Specifications for valve clearances, piston ring gaps, bearing clearances
Engine Type:
Liquid-cooled, four-stroke, DOHC, four-valve, single cylinder
Bore X Stroke:
77.0 mm x 53.6 mm
Compression Ratio:
12.5:1
Horsepower:
Approx. 38-40 HP (at crankshaft, estimated)
Torque:
Approx. 19-20 lb-ft (at crankshaft, estimated)
Carburetor:
Keihin FCR41 (Flat CR) with Accelerator Pump
Fuel Tank Capacity:
2.1 gallons (8 liters)
Oil Capacity:
1.05 quarts (1.0 liter)
Ignition System:
Digital CDI with TCI (Transistor Controlled Ignition)
Engine Oil Change:
Every 10-15 hours of riding or annually, whichever comes first.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Valve Clearance Check:
Every 20-30 hours of riding, or as per manual recommendations.
Spark Plug Inspection:
Every 15-20 hours of riding.
Chain Lubrication And Adjustment:
Every 5-10 hours of riding.
Engine Oil:
Yamalube 4 (10W-40) or equivalent API SG or higher, JASO MA certified.
Coolant:
Permanent type anti-freeze coolant, 50/50 mixture with distilled water.
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Fork Oil:
Yamaha Suspension Fluid (or equivalent, e.g., Bel-Ray SAE 0W-20, Motul Fork Oil Expert 5W)
Common Wear Items:
Clutch plates, brake pads, wheel bearings, steering head bearings, suspension seals, piston rings.
Carburetor Issues:
Can be sensitive to jetting changes and require meticulous cleaning for optimal performance.
Suspension Maintenance:
KYB SSS forks are excellent but require regular oil and seal maintenance to prevent premature wear.
