Engine Mechanical:
Complete overhaul, disassembly, assembly, inspection, and adjustment of all internal engine components including cylinder head, valves, pistons, crankshaft, camshafts, and lubrication system.
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, fuel lines, and evaporative emission control system (EVAP).
Ignition System:
Ignition coils, spark plugs, ECU (Engine Control Unit) and associated wiring.
Cooling System:
Radiator, cooling fan, water pump, thermostat, coolant hoses, and fluid capacities.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and O2 sensors.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, transmission disassembly and assembly, final drive (chain and sprockets).
Chassis Frame:
Frame inspection, steering head bearing service, swingarm inspection and lubrication.
Suspension Front:
Front fork assembly, oil seals, springs, damping adjustments, and related components.
Suspension Rear:
Rear shock absorber, linkage components, and adjustment procedures.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and wheel removal/installation.
Brakes Front:
Brake calipers, brake discs, master cylinder, brake fluid, bleeding procedures, and pad replacement.
Brakes Rear:
Rear brake caliper, brake disc, master cylinder, brake fluid, bleeding procedures, and pad replacement.
Electrical System Charging:
Stator, regulator/rectifier, battery maintenance, and charging system testing.
Electrical System Lighting:
Headlight, taillight, brake light, turn signals, and license plate light bulb replacement.
Electrical System Instrumentation:
Speedometer, tachometer, warning lights, and instrument cluster diagnostics.
Electrical System Starting:
Starter motor, starter relay, and battery testing.
Bodywork Fairings:
Removal and installation of fairings, seat, fuel tank cover, and other cosmetic components.
Troubleshooting:
Comprehensive diagnostic procedures for various systems, including engine performance, electrical faults, and starting issues.
Periodic Maintenance:
Oil and filter changes, spark plug replacement, chain adjustment and lubrication, brake fluid replacement, coolant replacement, air filter cleaning/replacement.
Disassembly Assembly:
Detailed step-by-step instructions for removing and reinstalling all major components and sub-assemblies.
Adjustments:
Clutch cable free play, throttle cable free play, idle speed adjustment, suspension preload and damping adjustments.
Inspections:
Visual inspections of all critical components, checks for wear and damage, and functional tests.
Cleaning:
Instructions for cleaning specific components like the air filter and fuel injectors.
Lubrication:
Specifications for lubricants and greases for various points, including chain, cables, and pivot points.
Special Tool Usage:
Identification and illustration of special tools required for specific repair and maintenance procedures.
Depth:
Comprehensive workshop level, covering routine maintenance to complete engine and chassis rebuilds. Includes detailed specifications and diagnostic information.
Illustrations:
Detailed pictorial diagrams, exploded views, drawings, and photos to guide through procedures.
Torque Specifications:
Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.
Wear Limits:
Specifications for allowable wear limits on various engine and chassis components.
Service Data:
Essential service data including fluid capacities, electrical specifications, and general maintenance parameters.
Precautions Notes:
Special notes, important points, precautions, and safety warnings for each procedure.
Engine Oil Filter Change:
Every 6,000 km or 6 months, whichever comes first.
Air Filter Inspection Cleaning:
Every 6,000 km.
Spark Plug Replacement:
Every 18,000 km.
Brake Fluid Replacement:
Every 2 years or as needed.
Coolant Replacement:
Every 2 years or 24,000 km.
Chain Lubrication Adjustment:
Every 1,000 km or as needed (check slack).
Engine Oil:
Yamaha Yamalube 10W-40 API SG or higher, JASO MA.
Coolant:
High-quality permanent type antifreeze, mixture of 50% ethylene glycol and 50% distilled water.
Throttle Response:
Some riders reported slightly abrupt throttle response, which can be mitigated by ECU remapping or throttle tamers, detailed in manual diagnostics.
Suspension Tuning:
While competent, the stock suspension may benefit from adjustments for heavier riders or aggressive riding, with adjustment procedures outlined in the manual.
Clutch Feel:
Minor complaints about clutch feel; cable adjustment and lubrication are key, with specific instructions provided.