Engine Mechanical:
Complete overhaul, disassembly, assembly, inspection, and repair of all engine components (crankshaft, pistons, cylinders, valves, timing, etc.)
Fuel System:
Fuel injection system, fuel pump, injectors, sensors, ECU control, fuel tank, lines, and filters.
Ignition System:
Ignition coils, spark plugs, ECU control, timing.
Cooling System:
Radiator, coolant pump, hoses, thermostat, fan operation, coolant specifications.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, final drive (shaft drive), gearbox internal inspection and repair, lubrication.
Electrical System:
Battery, charging system (alternator/stator), starting system, lighting, horn, wiring diagrams, fuse box, ECU, sensors, relays.
Chassis Frame:
Frame inspection, alignment, modifications.
Suspension Front:
Front forks (telescopic, upside-down), internal components, oil specifications, adjustment, rebuild procedures.
Suspension Rear:
Rear shock absorber, linkage (if applicable), adjustment, rebuild procedures.
Braking System:
Front and rear brakes (discs, calipers, master cylinders), brake fluid specifications, bleeding procedures, pad replacement, disc inspection.
Steering System:
Handlebar, steering stem, bearings, lubrication, adjustments.
Wheels Tires:
Wheel bearing inspection, tire pressures, wheel removal/installation, balancing.
Bodywork Fairings:
Removal and installation of all body panels, fairings, seat, fuel tank cover, etc.
Lighting Instruments:
Headlight, taillight, turn signals, instrument cluster, dashboard functions.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain/belt adjustment (if applicable, VMAX is shaft drive), brake fluid flush, coolant flush, lubrication points.
Troubleshooting:
Diagnostic charts, common problems and solutions, fault codes (if applicable for this era).
Component Overhaul:
Detailed step-by-step instructions for rebuilding engine, transmission, forks, shock absorbers, brake calipers.
Electrical Diagnostics:
Troubleshooting electrical issues using wiring diagrams, testing components, identifying shorts/opens.
Suspension Tuning:
Fork oil level and viscosity recommendations, sag adjustment, rebound and compression damping adjustments.
Wheel Tire Service:
Wheel bearing replacement, tire mounting/dismounting (though often done by specialists).
Bodywork Repair:
Removal, installation, and minor repair of body panels.
Safety Checks:
Inspection of critical safety components like brakes, steering, tires.
Depth:
Comprehensive factory-level detail covering everything from basic maintenance to full engine and transmission rebuilds, including all specifications and tolerances.
Diagnostic Capability:
High. Provides detailed troubleshooting guides and schematics for diagnosing complex issues.
Specifications And Tolerances:
Includes detailed torque specifications, clearances, fluid capacities, and wear limits for all major components.
First Service:
1000 km (600 miles) or 6 months, whichever comes first.
Subsequent Services:
Every 6000 km (4000 miles) or 12 months.
Engine Oil:
Yamalube 4 (or API SG, SF or SH) SAE 10W-40 or 20W-50. Check manual for specific viscosity based on climate.
Engine Oil Capacity:
3.20 L (3.38 US qt) without filter change; 3.40 L (3.59 US qt) with filter change.
Coolant:
High-quality ethylene glycol-based antifreeze mixed with distilled water (50:50 ratio).
Final Drive Oil:
Yamaha Genuine Gear Oil 80W-90 or equivalent.
Common Wear Items:
Tires, brake pads, clutch plates (depending on riding style), spark plugs.
Potential Electrical:
Occasional reports of minor electrical gremlins if not properly maintained, but generally reliable.
Performance Tuning Considerations:
While potent stock, aggressive tuning may require careful ECU remapping and potentially exhaust/intake modifications.