Segment:
Sportbike / Lightweight Naked Bike
Target Audience:
Enthusiasts seeking performance and handling in a user-friendly package
Competitors 1995:
Kawasaki ER-5, Suzuki GS500, Honda CB500
Engine Type:
Single-cylinder, 4-stroke, SOHC
Design Philosophy:
Lightweight, agile, user-friendly sportbike with a focus on accessible performance
Primary Coverage:
Complete service, repair, and maintenance
Secondary Coverage:
Troubleshooting, diagnostics, specifications
Estimated Page Count:
Approximately 300-400 pages (typical for this era/type of manual)
Type:
Service Workshop Manual
Format:
Digital (likely PDF), Print
Engine:
Disassembly, assembly, tuning, lubrication, cooling system, fuel system (carburetor), exhaust system
Transmission:
Clutch operation, gearbox disassembly and assembly, gearshift mechanism
Chassis:
Frame inspection, swingarm, rear suspension, front fork assembly, steering bearings
Brakes:
Front and rear brake system inspection, overhaul, fluid replacement, hydraulic lines
Electrical System:
Ignition system, lighting system, charging system, battery, wiring diagrams, starter motor
Fuel System:
Carburetor identification, settings, maintenance, fuel tank, fuel lines
Wheels And Tires:
Tire pressure, wheel bearing maintenance, spoke tensioning
Maintenance:
Oil change intervals, filter replacements, spark plug checks, chain adjustment, lubrication points
Repair:
Engine rebuild procedures, carburetor overhaul, suspension component replacement, brake caliper service
Troubleshooting:
Diagnostic charts for common performance issues, electrical faults, starting problems
Diagnostics:
Checking ignition timing, carburetor synchronization, electrical system resistance values
Engine Tuning:
Carburetor jetting adjustments, idle speed settings, ignition timing verification
Suspension Adjustment:
Front fork preload and damping (if adjustable), rear shock spring preload adjustment
Depth:
Comprehensive from basic adjustments to complete engine and gearbox overhauls
Detail Level:
Detailed step-by-step instructions with torque specifications and component clearances
Wiring Diagrams:
Detailed color-coded wiring schematics for all electrical components
Torque Specifications:
Comprehensive torque values for all fasteners, crucial for engine and chassis integrity
Completeness:
This is a comprehensive workshop manual, not a condensed version. It covers all major service and repair aspects.
Digital Format:
PDF (Searchable, Printable)
Print Quality:
High-resolution scans, clear diagrams
Binding:
N/A (for digital), Typically spiral or perfect bound for print
Paper Type:
N/A (for digital), High-quality, durable paper for print versions
Engine Type:
Single-cylinder, 4-stroke, DOHC, 5 valves per cylinder
Displacement:
660 cc (660 cubic centimeters)
Bore X Stroke:
100.0 mm x 85.0 mm (approximate, refer to manual for exact)
Compression Ratio:
9.2:1 (typical, refer to manual for exact)
Horsepower:
Approx. 45-50 HP @ 6,000 RPM (varies by market/tune, refer to manual)
Torque:
Approx. 5.5 - 6.0 kg-m @ 4,500 RPM (refer to manual)
Carburetor Type:
Mikuni VM34SS (or similar, refer to manual for exact model and jetting)
Fuel Tank Capacity:
Approx. 15 Liters (refer to manual for exact)
Length:
Approx. 2065 mm (refer to manual for exact)
Width:
Approx. 760 mm (refer to manual for exact)
Height:
Approx. 1100 mm (refer to manual for exact)
Dry Weight:
Approx. 154 kg (refer to manual for exact)
Wet Weight:
Approx. 169 kg (fully fueled, refer to manual for exact)
Oil Change Interval:
Every 3,000 km or 6 months (refer to manual for exact)
Spark Plug Inspection:
Every 6,000 km (refer to manual for exact replacement)
Valve Clearance Check:
Every 12,000 km (refer to manual for exact adjustment)
Engine Oil Type:
Yamalube 4 (or equivalent API SG/SH, SAE 10W-40, JASO MA)
Coolant Type:
Ethylene glycol-based antifreeze with deionized water (50/50 mix)
Common Wear Items:
Clutch plates, fork seals, wheel bearings, carburetor diaphragms
Carburetor Performance:
Potential for jetting issues or wear over time affecting idle and low-speed performance
Electrical Connections:
Corrosion on connectors, especially around the battery and headlight, can cause intermittent issues
