|
Manual Coverage
|
|
Systems Covered
|
|
Engine Mechanical:
|
Engine disassembly, assembly, troubleshooting, cylinder head, piston, crankshaft, connecting rod, valves, timing, lubrication system, cooling system
|
|
Fuel System:
|
Carburetor (Mikuni VM series or similar), fuel pump, fuel lines, fuel tank, fuel filter
|
|
Ignition System:
|
CDI, ignition coil, spark plug, stator, rotor, troubleshooting
|
|
Exhaust System:
|
Exhaust pipe, muffler, gasket replacement
|
|
Transmission Drivetrain:
|
Gearbox, clutch (wet multi-plate), shift mechanism, chain drive, sprockets, lubrication
|
|
Chassis Frame:
|
Frame construction, subframe, swingarm, bearings, bushings
|
|
Suspension Front:
|
Upside-down telescopic forks (e.g., WP Suspension), fork seals, oil change, internal components, adjustment
|
|
Suspension Rear:
|
Monoshock absorber (e.g., WP Suspension), linkage system, rear shock adjustment, rebuild
|
|
Brakes Front:
|
Hydraulic disc brake, brake caliper, master cylinder, brake pads, brake discs, fluid flush and bleed, troubleshooting
|
|
Brakes Rear:
|
Hydraulic disc brake, brake caliper, master cylinder, brake pads, brake discs, fluid flush and bleed, troubleshooting
|
|
Wheels Tires:
|
Wheel bearing replacement, spoke tensioning, tire mounting and balancing, recommended tire pressures
|
|
Electrical System:
|
Wiring diagrams, battery, starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays, troubleshooting
|
|
Controls Cables:
|
Throttle cable, clutch cable, brake cables, lever adjustment, replacement
|
|
Bodywork Fairings:
|
Panel removal and installation, graphics, seat, fuel tank cover
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil and filter changes, spark plug inspection/replacement, chain adjustment, air filter cleaning/replacement, brake inspection, tire pressure checks
|
|
Major Repairs:
|
Engine rebuild (top-end and bottom-end), transmission overhaul, clutch replacement, fork seal replacement, shock absorber rebuild
|
|
Troubleshooting:
|
Diagnostic procedures for common problems, electrical faults, engine running issues, starting problems
|
|
Component Disassembly Assembly:
|
Step-by-step instructions for removing, inspecting, servicing, and reinstalling major components
|
|
Tightening Torques:
|
Specific torque values for critical fasteners
|
|
Special Tools:
|
Identification and usage of specialized tools required for certain procedures
|
|
Technical Depth
|
|
Diagnostic Capabilities:
|
In-depth troubleshooting guides, symptom-based diagnostics
|
|
Rebuild Instructions:
|
Comprehensive guides for complete engine, transmission, and suspension rebuilds
|
|
Electrical Schematics:
|
Detailed wiring diagrams for all electrical systems
|
|
Component Specifications:
|
Detailed specifications for all serviceable parts, including clearances, tolerances, and wear limits
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Every 10-15 hours of riding or annually. Check manual for specific mileage/time.
|
|
Air Filter Cleaning:
|
Every 5-10 hours of riding, or more frequently in dusty conditions.
|
|
Spark Plug Inspection:
|
Every 15-20 hours of riding.
|
|
Chain Lubrication Adjustment:
|
Every 500-1000 km or as needed based on slack.
|
|
Fluid Specifications
|
|
Engine Oil Type 2Stroke:
|
High-quality synthetic 2-stroke oil, premixed or for oil injection system (specific formulation per manual).
|
|
Cooling System Coolant:
|
Ethylene glycol based coolant with anti-corrosion additives (e.g., Motorex Coolant M3.0 or equivalent). Typically 50/50 mix with distilled water.
|
|
Brake Fluid Type:
|
DOT 4 hydraulic brake fluid
|
|
Transmission Oil Type:
|
Specific motorcycle transmission oil (e.g., SAE 10W/40 or SAE 80W, check manual for exact viscosity and API rating).
|
|
Known Issues
|
|
Carburetor Tuning:
|
Sensitivity to altitude, temperature, and exhaust modifications requiring meticulous jetting adjustments.
|
|
Clutch Wear:
|
Clutch plates can wear prematurely with aggressive riding or improper adjustment.
|
|
Suspension Seals:
|
Fork seals can leak, especially on off-road oriented models, requiring periodic replacement.
|
|
Cooling System Maintenance:
|
Ensuring proper coolant levels and radiator cleanliness is vital to prevent overheating, especially for 2-stroke engines.
|
