Category:
Adventure Touring / Dual-Sport Motorcycle
Target Audience:
Owners, DIY mechanics, professional motorcycle technicians
Competitors Era:
Honda Transalp, Suzuki DR650, Yamaha Tenere (contemporary competitors in the dual-sport segment)
Manual Strength:
Comprehensive coverage, detailed diagrams, step-by-step procedures, diagnostic information
Download Benefit:
Instant access, no shipping costs, immediate usability
Engine:
Complete overhaul, disassembly, assembly, troubleshooting, tuning, specifications
Fuel System:
Carburetor (Mikuni BS40), fuel pump, fuel tank, fuel lines, troubleshooting, cleaning, adjustment
Transmission:
Gearbox disassembly, assembly, inspection, lubrication, shifting mechanism
Clutch:
Clutch plate replacement, pressure plate, springs, operation, adjustment
Drivetrain:
Chain and sprocket inspection, adjustment, replacement, rear shock linkage lubrication
Suspension Front:
Fork disassembly, assembly, oil change, seal replacement, spring inspection, adjustments
Suspension Rear:
Monoshock (Uni-Trak) inspection, adjustment, linkage lubrication, bearing inspection
Brakes Front:
Hydraulic disc brake system, caliper, master cylinder, pad replacement, fluid flush, bleeding, rotor inspection
Brakes Rear:
Drum brake system, shoe inspection, adjustment, replacement
Electrical System:
Ignition system, charging system (stator, regulator/rectifier), battery, starter motor, lighting, wiring diagrams, troubleshooting
Cooling System:
Radiator, hoses, thermostat, fan operation, coolant specifications, bleeding
Frame And Bodywork:
Frame inspection, fairing removal/installation, seat, fuel tank mounting, fenders, luggage rack system
Maintenance:
Scheduled maintenance, oil changes, filter replacements, lubrication, adjustments
Troubleshooting:
Systematic fault diagnosis, common issues, diagnostic flowcharts
Repair:
Step-by-step instructions for component repair and replacement
Disassembly Assembly:
Complete breakdown and reassembly procedures for all major components
Adjustments:
Carburetor synchronization, valve clearance, chain tension, brake adjustments, clutch lever free play
Depth:
Comprehensive (from basic maintenance to full engine rebuilds)
Detail Level:
Detailed step-by-step procedures with explanatory text and diagrams
Illustrations:
Pictorial diagrams, exploded views, detailed drawings, and photos
Special Tools:
Identification and usage of specific service tools required for certain operations
Torque Specifications:
Comprehensive list of torque values for fasteners across all systems
Wear Limits:
Specifications for component wear limits to ensure proper function and longevity
Engine Type:
Four-stroke, single-cylinder, DOHC, 4 valves
Bore X Stroke:
100.0 x 83.0 mm
Horsepower Approx:
Approx. 46 HP @ 6,000 RPM (varied slightly by year/tuning)
Torque Approx:
Approx. 53 Nm @ 5,000 RPM
Carburetor:
Mikuni BS40 (Constant Velocity)
Fuel Delivery:
Mechanical Fuel Pump
Cooling Method:
Liquid-cooled (radiator and fan)
Ignition System:
Digital CDI with electronic advance
Lubrication System:
Forced lubrication (wet sump)
Oil Change Interval:
Refer to manual for specific mileage/time intervals, typically every 3,000-5,000 km (1,800-3,000 miles) or annually.
Valve Clearance Interval:
Refer to manual, usually at 6,000-12,000 km (3,700-7,500 miles) or as specified.
Chain Tension Check:
Regularly, e.g., every 1,000 km (600 miles) or as part of pre-ride checks.
Engine Oil Type:
API SG or higher, SAE 10W-40 or 20W-50 (refer to manual for ambient temperature recommendations)
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based) with sufficient water (50/50 mix recommended)
Brake Fluid Type:
DOT 3 or DOT 4
Common Wear Items:
Clutch plates, front fork seals, brake pads, rear shock bushings, carburetor diaphragms (age-related degradation).
Typical Problems:
Potential for valve seat recession (less common in later versions), carburetor issues if not maintained, electrical connections can corrode over time, countershaft seal leaks.
