Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, cylinder head, pistons, crankshaft, camshafts, valves, timing.
Engine Fuel System:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel lines, evaporative emission control (EVAP).
Engine Ignition System:
Ignition coils, spark plugs, ECU control, timing.
Engine Cooling System:
Oil cooler, oil circulation, oil filter replacement, oil specifications.
Transmission:
Clutch operation, gearbox disassembly and assembly, gear selection, lubrication, torque specifications.
Drivetrain:
Shaft drive system, final drive, universal joints, lubrication.
Brakes:
Brake system operation, hydraulic components, brake fluid specifications, bleeding procedures, pad and rotor replacement, ABS system (if equipped).
Suspension:
Front fork (telescopic) overhaul, rear shock absorber replacement, spring settings, oil levels, adjustment procedures.
Electrical System:
Battery specifications, charging system (alternator, regulator), starter motor, lighting system (headlight, taillight, turn signals), wiring diagrams, fuses, relays, ECU.
Bodywork And Frame:
Frame inspection, body panel removal and installation, seat, handlebars, fairings, luggage system (Montauk specific).
Wheels And Tires:
Tire specifications, pressure recommendations, wheel bearing maintenance, spoke tension (if applicable), rim specifications.
Scheduled Maintenance:
Routine inspections, oil changes, filter replacements, brake system checks, drive shaft lubrication, valve clearance adjustments.
Troubleshooting:
Diagnostic charts for common problems, symptom-based troubleshooting, fault code interpretation (if applicable).
Repair Procedures:
Step-by-step instructions for component removal, repair, and reinstallation of all major systems.
Diagnostics:
Electrical system diagnostics, fuel system testing, ignition system analysis.
Specifications And Tolerances:
All essential torque values, clearances, fluid capacities, and wear limits.
Depth:
Comprehensive, from basic checks to complete engine and transmission rebuilds.
Engine Type:
Air-cooled, four-stroke, horizontally opposed two-cylinder (Boxer) engine
Displacement:
1170 cc (71.4 cu in)
Bore X Stroke:
101 mm x 73 mm (3.98 in x 2.87 in)
Compression Ratio:
10.0:1
Power Output:
Approximately 61 hp (45 kW) at 5250 rpm
Torque Output:
Approximately 98 Nm (72 lb-ft) at 3000 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) with BMS-K
Fuel Type:
Unleaded premium (95 RON)
Engine Control Unit:
BMS-K
Oil Type:
SAE 20W-50, API SG/SH/SJ/SL or higher
Oil Capacity:
Approx. 4.0 liters (4.2 US qt) with filter change
Oil Change Interval:
Every 10,000 km (6,000 miles) or annually, whichever comes first.
Valve Adjustment Interval:
Every 20,000 km (12,000 miles)
Final Drive Oil Change:
Every 20,000 km (12,000 miles)
Transmission Oil Type:
SAE 75W-90, API GL-5
Final Drive Oil Type:
SAE 75W-90, API GL-5
Common Wear Items:
Clutch plates, wheel bearings, brake pads, fork seals, exhaust mufflers (corrosion).
Electrical Concerns:
Occasional issues with starter solenoids or charging systems, though generally reliable.
Engine Notes:
Boxer engines can be sensitive to oil level; ensure it's maintained within the correct range for optimal cooling and lubrication.
