Engine Mechanics:
Complete disassembly, inspection, assembly, tuning, troubleshooting of engine components (cylinder, piston, crankshaft, valves, camshaft).
Fuel System:
Carburetor (VM17) specifications, adjustment, cleaning, fuel pump, fuel tank, fuel lines.
Ignition System:
CDI ignition system, spark plug selection and gap, timing checks, coil specifications.
Cooling System:
Air cooling system, airflow management.
Transmission And Drivetrain:
Automatic centrifugal clutch, V-belt drive system, variator unit, final drive gear inspection and maintenance.
Chassis And Frame:
Frame inspection, handlebar, steering system disassembly and adjustment, center stand, side stand.
Suspension System:
Front fork overhaul, rear shock absorber replacement, swingarm inspection.
Braking System:
Front drum brake specifications, adjustment, rear drum brake specifications, adjustment, brake cable maintenance.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), lighting system (headlight, taillight, indicators), starter system, horn.
Bodywork And Trim:
Fairing removal and installation, seat, luggage rack, floorboard, plastics and trim piece procedures.
Preventative Maintenance:
Oil change intervals, filter replacement, spark plug service, air filter cleaning/replacement, brake adjustment, V-belt inspection.
Troubleshooting:
Diagnostic charts for common starting issues, poor performance, unusual noises, and electrical faults.
Engine Rebuild:
Step-by-step instructions for complete engine overhaul, including piston ring replacement, valve seat grinding, and crankshaft bearing checks.
Carburetor Rebuild:
Detailed instructions for carburetor disassembly, cleaning, jet replacement, and float bowl adjustment.
Electrical Diagnostics:
Testing voltage, resistance, and continuity for all electrical circuits, including starter motor, alternator, and lighting.
Suspension Overhaul:
Front fork oil replacement, seal replacement, rear shock absorber removal and installation.
Brake System Repair:
Drum brake shoe replacement, brake linkage adjustment, cable lubrication.
Bodywork Repair:
Panel removal, fastener identification, and reassembly procedures.
Depth:
Comprehensive (from basic maintenance to complete engine and electrical system overhaul).
Diagnostic Tools:
Details on using multimeters, feeler gauges, torque wrenches, and specialized Yamaha tools.
Torque Specifications:
Includes precise torque values for critical fasteners across all systems.
Clearances:
Specifications for valve clearances, piston ring gap, and other critical component clearances.
Engine Oil Change:
Every 3,000 km (1,800 mi) or 6 months, whichever comes first.
Air Filter Check:
Inspect every 3,000 km (1,800 mi), clean or replace as needed.
Spark Plug Service:
Inspect and clean every 3,000 km (1,800 mi), replace at 10,000 km (6,000 mi).
V Belt Inspection:
Inspect every 6,000 km (3,600 mi) for wear and damage, replace as needed.
Brake Adjustment:
Inspect and adjust every 3,000 km (1,800 mi).
Engine Oil Spec:
Yamalube 4-stroke motorcycle oil (API SG, JASO MA) SAE 10W-40 or SAE 20W-40.
Carburetor Clogging:
Common in older scooters with infrequent use or poor fuel quality; requires thorough cleaning.
Variator Wear:
V-belt and variator roller wear can lead to reduced acceleration and top speed, requiring replacement.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can cause intermittent electrical faults.
