Engine System:
Detailed disassembly, assembly, inspection, and repair of the 150+ hp, 998cc inline-four engine, including valve clearance, camshafts, crankshaft, pistons, cylinders, lubrication system, cooling system, fuel injection system, ignition system, and exhaust system.
Fuel System:
Comprehensive coverage of the fuel pump, fuel injectors, throttle body, fuel pressure regulator, fuel filter, and fuel tank servicing.
Ignition System:
Ignition coil testing, spark plug specifications, ECU control, and timing adjustments.
Cooling System:
Radiator, water pump, thermostat, cooling fan operation, coolant types, and flushing procedures.
Lubrication System:
Oil pump, oil filter specifications and replacement intervals, oil type and capacity, lubrication points.
Transmission System:
Clutch operation, gearbox disassembly and reassembly, gear inspection, shift mechanism, transmission fluid type and capacity.
Chassis And Suspension:
Front fork (upside-down telescopic) disassembly, adjustment (compression, rebound, preload), and servicing. Rear shock absorber (monoshock) inspection and adjustment. Swingarm, linkage, and bearing maintenance.
Braking System:
Front dual hydraulic disc brakes (radial-mount calipers) and rear single hydraulic disc brake. Brake pad replacement, caliper servicing, brake fluid type (DOT 4) and bleeding procedures, master cylinder inspection.
Electrical System:
Wiring diagrams, battery specifications and maintenance, charging system (stator, rectifier/regulator), starter motor, lighting (headlight, taillight, signals), fuses, relays, ignition switch, instruments and indicators.
Instrumentation And Controls:
Dashboard layout, meter functions, switchgear operation, throttle control, clutch lever adjustment.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank mounting, fenders, and related components.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain lubrication and adjustment, brake pad inspection, coolant level checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable via ECU), electrical system diagnosis.
Engine Rebuild:
Complete step-by-step instructions for engine disassembly, component measurement, part replacement, and reassembly to factory specifications.
Suspension Setup:
Guidance on adjusting suspension for different riding conditions, including fork and shock settings.
Electrical Diagnostics:
Testing of sensors, actuators, wiring harnesses, and ECU for electrical faults.
Brake System Service:
Detailed procedures for brake caliper overhaul, master cylinder replacement, and brake line maintenance.
Fuel System Cleaning:
Procedures for cleaning fuel injectors and throttle bodies.
Wheel And Tire Service:
Wheel bearing replacement, tire mounting/dismounting, and balancing.
Diagnostic Capabilities:
Advanced diagnostics, including torque specifications for all fasteners, alignment procedures, and electronic system checks.
Rebuild Instructions:
Full rebuild procedures for major mechanical components like the engine and transmission.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Torque Specifications:
Precise torque values for all critical fasteners, essential for ensuring component integrity and safety.
Schematics And Diagrams:
Detailed wiring diagrams, exploded views of assemblies, and system schematics.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, 5-valve, inline-four cylinder
Bore X Stroke:
74.0 mm x 58.0 mm
Compression Ratio:
11.5:1
Fuel Induction:
Fuel Injection with Mikuni 45mm throttle bodies (x2), YCC-T (Yamaha Chip Controlled Throttle)
Ignition:
TCI (Transistor Controlled Ignition) with Digital Advance
Horsepower Estimate:
Approx. 150-155 hp @ 10,000 rpm (at crankshaft, varies by market)
Torque Estimate:
Approx. 80-82 lb-ft @ 7,500 rpm (at crankshaft, varies by market)
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON + MON)/2 (AKI)
Fuel Tank Capacity:
18 Liters (4.8 US gallons)
Oil Change Interval:
Every 6,000 miles (10,000 km) or 1 year, whichever comes first.
Air Filter Check Interval:
Every 6,000 miles (10,000 km).
Spark Plug Inspection Interval:
Every 12,000 miles (20,000 km).
Valve Clearance Check Interval:
Every 26,600 miles (42,000 km).
Engine Oil Specification:
Yamalube 4 (or equivalent SAE 10W-40 API SG or higher, JASO Standard).
Coolant Specification:
Yamaha All-Weather Water Cooled Engine Coolant (50% solution of ethylene glycol) or equivalent.
Brake Fluid Specification:
DOT 4
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, tires, fork seals, wheel bearings.
Potential Performance Issues:
Minor throttle response smoothing required on early models via ECU reflash, occasional thermostat issues.
