Engine Mechanical:
Complete disassembly, assembly, inspection, and repair of engine components (pistons, cylinders, crankshaft, camshaft, valve train, etc.).
Engine Cooling:
Radiator, coolant hoses, water pump, thermostat, and related components.
Fuel System:
Carburetor (likely Keihin CV type), fuel pump, fuel lines, fuel tank, and related adjustments/cleaning.
Ignition System:
CDI unit, ignition coil, spark plug, timing adjustments.
Transmission Gearbox:
Gearbox disassembly, assembly, inspection, lubrication, and shift mechanism.
Clutch:
Clutch operation, friction plates, steel plates, springs, and hydraulic actuation (if applicable).
Electrical System:
Wiring diagrams, lighting system, starter motor, battery, charging system (alternator/stator), fuses, relays.
Suspension Front:
Fork internal components, oil levels, seals, damping adjustments, spring preload.
Suspension Rear:
Monoshock absorber, linkage system, spring preload, damping adjustments, rear axle assembly.
Brakes Front:
Brake caliper, master cylinder, brake lines, brake disc, pad replacement, bleeding procedures.
Brakes Rear:
Brake caliper, master cylinder, brake lines, brake disc, pad replacement, bleeding procedures.
Wheels Tires:
Spoke tensioning, wheel bearings, tire mounting/removal, wheel balancing.
Frame Chassis:
Frame inspection, headstock bearings, swingarm bearings, general chassis integrity.
Bodywork:
Fairings, fenders, seat, fuel tank, exhaust system, control levers, and pedals.
Preventative Maintenance:
Regular servicing, fluid changes, filter replacements, chain adjustment, lubrication points.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding charts.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.
Adjustment Procedures:
Carburetor tuning, valve clearance adjustment, suspension settings, clutch and brake lever adjustments.
Torque Specifications:
Precise torque values for all critical fasteners, essential for safe and proper assembly.
Wiring Diagrams:
Detailed electrical schematics for easy diagnosis and repair of electrical faults.
Special Tools:
Identification and usage of specialized tools required for specific repair tasks.
Depth Of Coverage:
Comprehensive and detailed.
Engine Type:
Liquid-cooled, 4-stroke, single-cylinder
Displacement 400:
Approx. 398cc
Displacement 660:
Approx. 625cc
Bore X Stroke 400:
e.g., 84mm x 72mm (exact spec may vary, refer to manual)
Bore X Stroke 660:
e.g., 100mm x 80mm (exact spec may vary, refer to manual)
Compression Ratio:
e.g., 10.5:1 (approximate, consult manual for precise figures)
Horsepower 400:
Approx. 30-35 HP (at crankshaft, depending on tuning/market)
Horsepower 660:
Approx. 45-50 HP (at crankshaft, depending on tuning/market)
Torque:
Strong low-end torque profile.
Carburetor Model:
Keihin CV (Constant Velocity) Carburetor (e.g., 39mm or 41mm)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 8-12 liters (model dependent, e.g., 9.5L for Duke, larger for Adventure variants)
Oil Change Interval:
Typically every 3,000-5,000 km or annually.
Air Filter Cleaning:
As needed, or every 3,000-5,000 km.
Spark Plug Replacement:
Typically every 6,000-10,000 km.
Valve Clearance Check:
Initial check around 1,000 km, then every 6,000-10,000 km.
Engine Oil Type:
API SG/SH/SJ or higher, JASO MA certified, viscosity 10W-40 or 15W-50 (consult manual for exact specification).
Engine Oil Capacity:
Approx. 1.2 - 1.5 liters (dry fill, check manual).
Coolant Type:
Ethylene glycol-based antifreeze mixture (50/50 with distilled water).
Brake Fluid Type:
DOT 4 brake fluid.
Fork Oil Type:
Specific fork oil viscosity (e.g., SAE 5W or 10W) and quantity.
Oil Leaks:
Can occur at clutch cover, oil filter housing, or valve cover gaskets.
Cam Chain Tensioner:
Potential for wear or malfunction, leading to ticking noises.
Carburetor Performance:
Can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Starter Clutch:
Some models experienced issues with the starter clutch mechanism.
