Engine Mechanical:
Complete engine disassembly, inspection, repair, and reassembly. Includes piston, rings, cylinder, crankshaft, connecting rods, valve train, and seals.
Fuel System:
Carburetor (or fuel injection system depending on year/variant) diagnosis, cleaning, adjustment, and repair. Fuel pump, fuel lines, and filter servicing.
Ignition System:
Spark plugs, ignition coils, CDI unit, wiring, and troubleshooting. Timing verification.
Cooling System:
Radiator, coolant hoses, thermostat, water pump, and fan operation and maintenance. Coolant type and capacity.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable), and gasket replacement. Emission control system details.
Transmission Drivetrain:
Clutch operation, adjustment, and replacement. Gearbox disassembly, inspection, and reassembly. Chain drive and sprocket maintenance.
Suspension Front:
Front fork disassembly, seal replacement, oil level and viscosity, spring rates, and general inspection. Adjustment of damping (if applicable).
Suspension Rear:
Rear shock absorber service, linkage maintenance, swingarm pivot, and wheel bearing inspection. Adjustment of preload and damping (if applicable).
Brakes Front:
Brake caliper overhaul, brake pad replacement, brake fluid bleeding and replacement, master cylinder service, and rotor inspection. ABS system diagnosis (if equipped).
Brakes Rear:
Rear brake caliper service, pad replacement, fluid bleeding, master cylinder, and rotor inspection. ABS system diagnosis (if equipped).
Wheels Tires:
Wheel bearing inspection and replacement, spoke tensioning (if applicable), tire mounting and balancing, and recommended tire pressures.
Electrical System:
Battery maintenance, charging system (alternator/stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, and wiring diagrams.
Instrumentation Controls:
Speedometer, tachometer, odometer, warning lights, and switchgear (handlebar controls) servicing. Cable routing and adjustment.
Bodywork Frame:
Fairing, tank, seat, fenders, and chassis component inspection and repair. Frame integrity checks.
Troubleshooting:
Diagnostic charts and procedures for common and complex issues across all systems.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, brake pad inspection, tire pressure checks, coolant checks, and general lubrication.
Component Overhaul:
Complete teardown and rebuild procedures for major components like engine, gearbox, forks, and brake calipers.
Electrical Diagnostics:
Step-by-step troubleshooting for electrical faults using wiring diagrams and multimeter measurements.
Suspension Adjustment:
Guidance on adjusting suspension settings for different riding conditions and rider preferences.
Brake System Service:
Detailed instructions for bleeding brakes, replacing pads and fluid, and servicing master cylinders and calipers.
Fuel System Cleaning:
Procedures for cleaning and synchronizing carburetors or servicing fuel injection components.
Torque Specifications:
All critical torque values for fasteners and engine components presented clearly.
Depth:
Comprehensive from basic maintenance to full engine and chassis rebuilds. Includes detailed diagnostic procedures.
Visuals:
Includes pictures and part diagrams for clarity in repair and assembly processes.
Engine Type:
Single-cylinder, four-stroke.
Engine Displacement:
652 cc
Bore X Stroke:
100 mm x 83 mm (typical for Rotax 655-based engines)
Valve Train:
SOHC, 4 valves per cylinder, chain-driven.
Engine Cooling:
Liquid-cooled.
Engine Manufacturer:
Rotax (typically).
Horsepower Approximate:
Approximately 48-50 HP (depending on year and specific tuning).
Torque Approximate:
Approximately 60-62 Nm (depending on year).
Fuel Delivery:
Carbureted (e.g., Dell'Orto PHM 40) for earlier models, potentially fuel injection for later variants.
Fuel Type:
Unleaded Gasoline (91 RON or higher recommended).
Fuel Tank Capacity:
Approximately 14-16 liters (including reserve).
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually, whichever comes first.
Valve Check Interval:
Typically every 10,000 - 15,000 km.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km or after riding in wet conditions.
Engine Oil Type:
Semi-synthetic or fully synthetic SAE 10W-40 or 15W-50 motorcycle oil meeting API SG or higher, JASO MA standards.
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water, with corrosion inhibitors.
Fork Oil Type:
SAE 5W or 10W motorcycle fork oil (specific viscosity in manual).
Common Wear Items:
Clutch wear, swingarm pivot bearings, fork seals, voltage regulator/rectifier failure, and potential starting issues on older models.
Maintenance Tips:
Regularly check and maintain the charging system, inspect the fuel tank for corrosion (especially with ethanol fuels), and ensure proper cooling system maintenance.
