Engine:
Complete engine tear-down and rebuild, including cylinder head, crankshaft, conrod, piston, camshaft, valves, ignition system, starting system, charging system (stator, rectifier).
Fuel System:
Carburetor (including jetting, pilot jet, main jet, mixture screw, idle speed), fuel pump, fuel tank, fuel lines, fuel injection (if applicable, though typically carb'd for this model).
Drivetrain:
Drive train components, including primary reduction gear, transmission, clutch, drive shaft, kickstart mechanism.
Suspension:
Front forks, rear suspension (swingarm, strut), wheel bearings, linkage.
Brakes:
Brake system components, including rotors, pads, calipers, brake lines, hydraulic system, parking brake.
Electrical:
Wiring diagrams, lighting system (headlights, taillights), switches, battery, fuses, magneto, starter motor, electronic components.
Bodywork:
Plastic components, fenders, seat, handlebars, body panels, plastics.
Lubrication System:
Details on engine oil circulation, lubrication points, and oil capacity.
Exhaust System:
Information on muffler, exhaust pipes, and related components.
Cooling System:
Details on air cooling system operation and any associated components.
Steering System:
Components like steering stem, handlebars, and related linkage.
Body Panels And Plastics:
Instructions for removal, installation, and care of plastic bodywork and fenders.
Maintenance:
Regular maintenance schedules, fluid changes (engine oil, coolant), filter replacements, lubrication points, tire pressure checks.
Troubleshooting:
Diagnosing and resolving common issues, error code interpretation (if applicable), no spark troubleshooting, starting problems.
Repair:
Step-by-step instructions for complete tear-down, rebuild, and repair of all major components.
Installation:
Procedures for installing replacement parts and accessories.
Torque Specifications:
Includes critical torque specifications for engine, chassis, and drivetrain fasteners, essential for proper assembly and safety.
Part Diagrams:
Includes detailed part diagrams with exploded views for easy identification of components during disassembly and reassembly.
Valve Adjustment:
Step-by-step instructions for checking and adjusting valve clearance (valve lash).
Clutch Adjustment And Replacement:
Procedures for clutch adjustment, inspection, and replacement of clutch components.
Wheel And Tire Maintenance:
Information on tire pressure, inspection, and wheel removal/installation.
Frame And Chassis Inspection:
Guidance on inspecting the frame and chassis for damage or wear.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine overhaul and advanced diagnostics.
Diagnostic Tools Required:
Standard mechanic's tools, torque wrench, feeler gauges, multimeter. Manual may recommend specific tools for certain procedures.
Engine Type:
Four-stroke, SOHC
Bore X Stroke:
66.0 mm x 57.0 mm (typical for this displacement, to be confirmed by manual)
Compression Ratio:
9.5:1 (typical, to be confirmed by manual)
Horsepower:
Approx. 15-17 HP (estimated, actual figures vary)
Torque:
Not explicitly stated, but designed for low-end torque for trail riding.
Carburetor Type:
Mikuni VM series (likely 26mm or similar), specific model detailed in manual.
Fuel Type:
Unleaded gasoline
Fuel Capacity:
Approx. 2.5 gallons (9.5 liters), specific to be confirmed by manual.
Ignition System:
CDI (Capacitor Discharge Ignition)
Cooling Method:
Air-cooled
Length:
Approx. 73 inches (1855 mm) (typical, to be confirmed by manual)
Width:
Approx. 40 inches (1015 mm) (typical, to be confirmed by manual)
Height:
Approx. 42 inches (1065 mm) (typical, to be confirmed by manual)
Dry Weight:
Approx. 397 lbs (180 kg) (typical, to be confirmed by manual)
Ground Clearance:
Approx. 5.5 inches (140 mm) (typical, to be confirmed by manual)
Front Tire Size:
AT22 x 7-10 (typical, to be confirmed by manual)
Rear Tire Size:
AT22 x 10-10 (typical, to be confirmed by manual)
Wheel Bolt Pattern:
Not applicable (hub-mounted wheels)
Engine Oil Change:
Recommended every 1,000 km (600 miles) or 6 months; refer to manual for precise intervals and specific oil type.
Air Filter Cleaning:
Check and clean at recommended intervals, typically every 1,000 km (600 miles) or more frequently in dusty conditions.
Spark Plug Replacement:
Inspect and clean/gap at recommended intervals, replace as needed (refer to manual for part number and gap).
Engine Oil Type:
Yamalube 4W or equivalent SAE 10W-30 or 10W-40 API SE or SF (refer to manual for exact viscosity and API classification).
Engine Oil Capacity:
Approx. 1.6 liters (1.7 US qt) with oil filter change (refer to manual for exact capacity).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specification).
Carburetor Issues:
Common issues can include clogged jets, worn floats, or deteriorating gaskets due to fuel contamination or age. Manual provides detailed cleaning and adjustment procedures.
Electrical Reliability:
Older wiring harnesses can degrade, leading to intermittent electrical problems. Stator output can also diminish over time. The manual's wiring diagrams are crucial for diagnostics.
Suspension Wear:
Bushings and seals in the forks and rear shock can wear out, leading to a less responsive ride. Manual details replacement procedures.
Cvt Belt Wear:
The CVT belt is a wear item and requires periodic inspection and replacement to prevent slippage and power loss. Manual specifies inspection intervals and replacement procedures.
