Engine:
Complete engine disassembly, assembly, tuning, and diagnostics
Fuel System:
Carburetor overhaul (likely Keihin CVK), fuel pump, fuel lines, and tank service
Ignition System:
Ignition coil, spark plugs, timing, ECU diagnostics
Cooling System:
Radiator, fan, coolant flow, thermostat service
Transmission:
Gearbox, clutch operation, lubrication, and servicing
Chassis:
Frame inspection, alignment, and reinforcement points
Suspension Front:
Fork disassembly, seal replacement, oil levels, spring rates, damping adjustments
Suspension Rear:
Monoshock absorber, linkage system, adjustment procedures
Brakes Front:
Caliper service, pad replacement, disc inspection, hydraulic system bleeding
Brakes Rear:
Caliper service, pad replacement, disc inspection, hydraulic system bleeding
Electrical System:
Wiring diagrams, component testing, battery, charging system, lighting, starter motor
Bodywork And Fairings:
Removal, installation, repair of plastic components and trim
Wheels And Tires:
Wheel bearing replacement, tire mounting, balancing
Controls:
Throttle cables, clutch cable, brake levers, foot controls
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points
Troubleshooting:
Diagnostic charts and fault finding procedures for common issues
Engine Rebuild:
Piston ring replacement, valve lapping, gasket renewal, bearing checks
Carburetor Tuning:
Synchronization, jetting adjustments, idle speed settings
Electrical Diagnosis:
Testing of starter, alternator, ignition, lights using multimeters and oscilloscopes
Suspension Rebuild:
Fork seal replacement, damper rod service, rear shock refurbishment
Brake System Overhaul:
Master cylinder rebuild, caliper piston service, brake line replacement
Torque Specifications:
Detailed torque settings for all critical fasteners
Special Tools:
Identification and usage of specialized tools required for certain procedures
Depth:
In-depth, covering everything from basic maintenance to full engine and component overhauls
Diagnostic Capability:
Advanced diagnostics with specific fault codes and troubleshooting flowcharts
Visual Aids:
Step-by-step instructions accompanied by clear photographic illustrations
Oil Change:
Every 4,000 miles or 6 months
Spark Plug Check:
Every 8,000 miles
Valve Clearance Check:
Every 16,000 miles
Engine Oil:
SAE 10W-40 API SG or higher (Synthetic recommended)
Coolant:
Ethylene Glycol based coolant (50/50 mix with distilled water)
Fork Oil:
Approx. 15W viscosity, 430-440 ml per fork leg
Carburetor Sync:
Can drift out of sync, requiring periodic adjustment
Stator Output:
Potential for stator failure leading to charging issues
Cam Chain Tensioner:
May require inspection or replacement to prevent rattling
