Engine Mechanical:
Comprehensive coverage of internal engine components, disassembly, assembly, inspection, and repair.
Fuel System:
Carburetor tuning, cleaning, overhaul, fuel pump, fuel lines, and filter servicing.
Ignition System:
CDI unit, spark plug, ignition coil, timing checks, and troubleshooting.
Lubrication System:
Oil pump, oil filter, oil passages, and oil change procedures.
Cooling System:
Liquid-cooled system, radiator, hoses, water pump, thermostat, and coolant specifications.
Transmission Drivetrain:
Clutch operation, gearbox disassembly/assembly, gear inspection, chain drive, and sprocket maintenance.
Chassis Frame:
Frame inspection, steering head bearing service, swingarm maintenance, and suspension adjustment.
Front Suspension:
Front fork disassembly, seal replacement, oil type and level, spring rates, and damping adjustments.
Rear Suspension:
Monoshock absorber service, linkage lubrication, spring preload adjustment, and rebound damping.
Braking System:
Front and rear brake caliper overhaul, pad replacement, disc inspection, hydraulic system bleeding, and fluid specifications.
Electrical System:
Wiring diagrams, battery maintenance, lighting system, horn, starter motor, charging system (stator/regulator/rectifier).
Wheels Tires:
Spoke wheel maintenance, rim inspection, tire pressure recommendations, and wheel bearing service.
Bodywork Fittings:
Fairing removal/installation, seat, fuel tank, fenders, and other external components.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning, and lubrication points.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and braking issues, with symptom-based solutions.
Engine Rebuild:
Complete procedures for engine disassembly, component inspection (pistons, rings, valves, crankshaft), reassembly, and critical torque specifications.
Suspension Overhaul:
Detailed steps for fork seal replacement, shock absorber service, and linkage bearing replacement.
Carburetor Rebuilding:
Step-by-step guide for carburetor disassembly, cleaning, jet replacement, and adjustment.
Electrical Diagnostics:
Troubleshooting electrical circuits using multimeter readings and wiring diagrams.
Wheel Service:
Spoke tightening, wheel bearing replacement, and wheel balancing procedures.
Depth:
Comprehensive; suitable for both novice and experienced mechanics. Covers routine maintenance to complete engine and chassis overhauls.
Diagnostic Capabilities:
Detailed diagnostic charts and flowcharts for identifying and resolving mechanical and electrical faults.
Special Tools:
Lists and descriptions of essential special tools required for specific repair procedures.
Oil Change Interval:
Typically every 4,000-6,000 km (2,500-3,700 miles) or 6 months, whichever comes first (refer to manual for exact spec).
Spark Plug Replacement:
Inspect every 4,000 km (2,500 miles), replace as needed.
Air Filter Cleaning:
Clean every 2,000-4,000 km (1,200-2,500 miles), depending on riding conditions.
Valve Adjustment:
Typically every 8,000-12,000 km (5,000-7,500 miles).
Engine Oil Type:
SAE 10W-40 API SG or higher, JASO MA compliant motorcycle oil.
Coolant Type:
Permanent type anti-freeze coolant (ethylene glycol based), typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, brake pads, chain and sprockets, fork seals, and wheel bearings are typical wear items.
Engine Carburetor:
Carburetor can become gummed up if not used regularly; requires periodic cleaning and adjustment.
Electrical Components:
Older electrical components, like regulator/rectifier or stator, can be prone to failure over time and mileage.
