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General| Transmission | 6-speed |
|---|---|
| Engine Type | Single-cylinder, 4-stroke |
| Ignition | Kokusan digital |
| Cooling System | Liquid Cooled |
| Starter | Electric |
| Bore x Stroke | 76 mm x 54.8 mm |
Procedure for draining and refilling the motorcycle's cooling system.
Steps to replace the engine's oil filter and add new oil.
Diagram and explanation of how engine oil circulates through the motorcycle.
Process to remove air from the hydraulic clutch system.
Instructions for setting the correct free play in the throttle cables.
List and illustrations of specialized tools required for engine work.
Step-by-step guide to safely remove the engine from the motorcycle frame.
Procedure for reinstalling the engine into the motorcycle frame.
Initial steps to clean and prepare the engine for disassembly.
How to position the engine's crankshaft for correct timing.
Detailed steps to remove the camshafts from the cylinder head.
Procedure for removing the cylinder head and piston assembly.
Steps to safely remove the motorcycle's clutch cover.
How to take apart the motorcycle's clutch assembly.
Steps to remove the engine's chain drive and primary gear components.
How to disassemble the motorcycle's gear shifting mechanism.
Procedure for removing the engine's oil pump assemblies.
Steps to split the engine cases and remove the crankshaft.
Procedures for inspecting and servicing the left engine casing half.
Procedures for inspecting and servicing the right engine casing half.
How to inspect and measure the engine's crankshaft for wear and runout.
Steps for measuring cylinder bore and piston for wear and clearance.
Checks and maintenance for the engine's oil lubrication system components.
Inspecting camshafts for wear, damage, and proper function.
Procedures for checking clutch components for wear and damage.
Inspecting and checking wear on shift forks, drum, and rails.
Steps for assembling the transmission's main and countershafts.
Guide to fitting shafts and closing the engine casings.
Steps for installing the engine's oil pump assemblies.
Procedure for assembling the gear shift mechanism.
Installing the primary gear and timing chain drive components.
Steps for correctly assembling the motorcycle's clutch.
Procedure for installing the clutch cover with a new gasket.
Steps for installing the piston into the cylinder and mounting the cylinder head.
How to install the camshafts into the cylinder head.
Procedure for installing the timing chain tensioner correctly.
How to measure and adjust valve clearances after assembly.
Final steps for assembling the engine components.
Procedures for checking the CDI unit and its connections.
How to test the ignition coil resistance values.
Guide to diagnosing ignition system faults.
Testing stator and pulse generator resistance values.
Location and check procedure for the motorcycle's main fuse.
How to test the starter motor's functionality.
Procedure for testing the start relay continuity.
Steps for removing and reinstalling the motorcycle battery.
Important precautions and steps for charging the battery.
How to measure the charging system's voltage output.
Procedure to identify parasitic current drain from the battery.
Information on ignition curves for engine performance tuning.
Using a peak voltage adapter to measure static ignition values.
Using a peak voltage adapter to measure static generator values.
Steps for removing and reinstalling the motorcycle's carburetor.
Detailed instructions for taking apart the carburetor components.
Inspecting the choke knob and hot start slide for proper operation.
How to check the accelerator pump diaphragm and bores.
Inspecting the jet needle for bending and wear.
Procedure to check the float needle valve seat for cleanliness.
Inspecting the throttle valve rollers and paddles for wear.
Steps for correctly reassembling the motorcycle's carburetor.
How to set the correct position of the throttle valve sensor.
Testing the resistance and function of the throttle valve sensor.
Steps for removing and reinstalling the throttle valve sensor.
Procedure for correctly setting the engine's idle speed.
How to measure and adjust the carburetor's float height.
Table listing common engine problems, their causes, and remedies.
Specifications for engine displacement, bore, stroke, and other engine parameters.
Specifications for frame, forks, brakes, and other chassis components.
Recommended settings for front fork compression and rebound.
Recommended settings for rear shock absorber.
Specific measurements for component clearances and wear limits.
List of all engine component screw and nut tightening torque specifications.
List of all chassis component screw and nut tightening torque specifications.
Maintenance intervals and tasks for the 2005 model year.
Maintenance intervals and tasks for the 2006 model year.
Maintenance intervals and tasks for the 2007 model year.
Maintenance intervals and tasks for the 2008 model year.
Electrical wiring schematic for 2005 models.
Electrical wiring schematic for 2006 models.
Electrical wiring schematic for 2007 models.
Electrical wiring schematic for 2008 models.
Key for understanding wire colors used in the diagrams.
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