Engine Systems:
Engine overhaul, top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), cooling system (liquid-cooled for TE/TC models of this era), lubrication system, ignition system (CDI), fuel system (carburetor, fuel lines), exhaust system.
Transmission Drivetrain:
Gearbox internal components, clutch operation and service, shift mechanism, final drive (chain and sprockets), gearbox oil specifications and change intervals.
Suspension Steering:
Front fork service (oil change, seal replacement, internal components), rear shock absorber service (if applicable, damping adjustments, linkage lubrication), steering head bearing maintenance and adjustment, wheel bearing service.
Braking System:
Hydraulic brake system (master cylinders, calipers, brake lines, fluid type and bleeding), brake pad replacement, rotor inspection and maintenance, rear drum brake service (if applicable).
Electrical System:
Wiring diagrams, lighting system, starting system (kick-start primary, electric start on some variants), charging system (stator, regulator/rectifier), battery maintenance and specifications, fuses, switches, and instrumentation.
Fuel System Carburetion:
Detailed carburetor identification (e.g., Mikuni VM series common on these bikes), jetting specifications, float bowl adjustment, idle speed control, choke operation, fuel tank and petcock service.
Cooling System:
Radiator inspection and cleaning, coolant specifications and capacity, thermostat operation, water pump service.
Chassis Frame:
Frame inspection for damage, swingarm service (bearings, bushings), footpeg and control lever adjustments, seat removal and installation.
Bodywork Trim:
Fender removal and installation, fuel tank graphics and mounting, side panel removal, seat upholstery.
Routine Maintenance:
Oil and filter change procedures, air filter cleaning and replacement, spark plug inspection and replacement, chain adjustment and lubrication, cable lubrication.
Engine Overhaul:
Complete engine disassembly, inspection of internal components, piston ring replacement, valve lapping and seat grinding, gasket replacement, reassembly procedures with torque specifications.
Carburetor Rebuild:
Complete carburetor disassembly, cleaning of jets and passages, float level adjustment, needle and jet replacement, reassembly.
Suspension Service:
Front fork oil replacement, fork seal replacement, fork spring replacement, rear shock absorber service (where applicable).
Brake System Maintenance:
Brake fluid flush and bleed, brake pad replacement, caliper piston service, master cylinder seal replacement.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, testing of ignition components, charging system testing, starter system troubleshooting.
Troubleshooting Guides:
Problem identification and diagnostic charts for common issues related to starting, running, electricals, and transmission.
Torque Specifications:
Detailed torque values for critical fasteners throughout the motorcycle, ensuring proper assembly and preventing damage.
Diagnostic Capabilities:
Advanced diagnostic procedures for engine performance issues, electrical system faults, and suspension anomalies.
Repair Scope:
Comprehensive repair procedures ranging from basic adjustments to complete engine and transmission rebuilds.
Special Tools:
Identification of specific tools required for certain procedures, such as fork seal drivers, valve spring compressors, and specialized wrenches.
Specifications Data:
Detailed technical data including tolerances, clearances, fluid capacities, and electrical resistance values.
Engine Type:
Four-stroke, liquid-cooled (TE/TC models of this era)
Engine Displacement Te350:
Approximately 349 cc
Engine Displacement Te410:
Approximately 400 cc
Engine Displacement Te610:
Approximately 576 cc
Engine Displacement Tc610:
Approximately 576 cc
Bore X Stroke Te610 Tc610:
Example: 92.0 mm x 84.0 mm (typical for the 576cc variant)
Compression Ratio Te610 Tc610:
Example: 9.0:1 or 9.5:1 (typical for the era)
Horsepower Te610 Tc610:
Estimated 40-50 HP (varies by tuning and specific model variant)
Torque Te610 Tc610:
Estimated 35-45 Nm (varies by tuning and specific model variant)
Carburetor Type Te350 Te410:
Likely single Mikuni VM series (e.g., VM34 or VM36)
Carburetor Type Te610 Tc610:
Likely single Mikuni VM series (e.g., VM38 or VM40)
Fuel Type:
Unleaded gasoline, 91-98 octane (RON+MON)/2
Fuel Capacity:
Typically 8-10 liters (2.1-2.6 US gallons)
Engine Oil Change:
Every 1000-2000 km or 6-12 months (refer to manual for exact interval based on usage).
Air Filter Cleaning:
Every 500-1000 km or more frequently in dusty conditions.
Spark Plug Replacement:
Every 3000-5000 km or as per manual recommendations.
Chain Lubrication Adjustment:
Every 300-500 km, or as needed.
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle-specific 4-stroke oil (API SG or higher).
Cooling System Coolant:
Ethylene glycol-based antifreeze mixture, typically 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for specific recommendation).
Carburetor Clogging:
Common with older carbureted bikes, especially if fuel sits for extended periods. Requires periodic cleaning.
Worn Suspension Seals:
Front fork seals and rear shock seals can degrade over time, leading to oil leaks.
Electrical Connections:
Corrosion or looseness in electrical connectors can cause intermittent issues.
Clutch Cable Wear:
Clutch cables can stretch or fray, affecting clutch operation.
