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            Manual Coverage
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            Systems Covered
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            Engine Mechanical:
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            Disassembly, inspection, assembly, torque specifications, valve timing, piston and cylinder details, crankshaft and connecting rod service.
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            Engine Fuel System:
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            Carburetor (Mikuni VM series) overhaul, adjustment, jetting, fuel pump, fuel filter, fuel tank and lines.
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            Engine Ignition System:
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            CDI ignition system, spark plug specifications, ignition timing, coil testing, stator and rotor inspection.
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            Engine Cooling System:
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            Air-cooled engine principles, oil cooler circuit, oil specifications and change intervals.
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            Transmission Gearbox:
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            Gearbox disassembly, inspection, clutch operation, shift mechanism, transmission fluid type and capacity.
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            Electrical System:
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            Wiring diagrams, component identification, battery maintenance, starter motor, alternator, lighting system, horn, switches, fuses.
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            Chassis Frame:
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            Frame inspection, headstock bearing service, general chassis integrity checks.
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            Suspension Front:
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            Telescopic fork service, seal replacement, oil type and level, spring rates, damping adjustments.
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            Suspension Rear:
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            Monoshock suspension system, linkage service, shock absorber overhaul, spring pre-load adjustment.
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            Brakes Front:
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            Disc brake system, caliper service, pad replacement, fluid type (DOT 3/4), bleeding procedure, master cylinder overhaul.
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            Brakes Rear:
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            Drum brake system, shoe replacement, adjustment, brake cable service.
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            Wheels Tires:
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            Wheel bearing service, spoke tensioning, tire pressure specifications, recommended tire sizes.
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            Bodywork Fairings:
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            Fairing removal and installation, seat service, fuel tank removal and installation, side cover access.
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            Procedures Included
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            Routine Maintenance:
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            Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement, brake adjustments.
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            Engine Rebuild:
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            Complete engine disassembly, component inspection, replacement of wear items (rings, gaskets, seals), reassembly with torque specifications.
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            Carburetor Tuning:
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            Detailed steps for cleaning, rebuilding, and synchronizing carburetors for optimal performance and fuel efficiency.
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            Suspension Servicing:
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            Fork seal replacement, fork oil change, rear shock absorber maintenance.
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            Brake Bleeding:
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            Step-by-step instructions for bleeding hydraulic brake systems.
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            Electrical Diagnostics:
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            Troubleshooting common electrical faults using wiring diagrams and multimeter testing.
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            Troubleshooting Common Issues:
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            Diagnosis and repair of starting problems, running issues, electrical gremlins, braking performance issues.
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            Technical Depth
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            Depth:
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            Comprehensive: Covers everything from basic rider maintenance to full engine and transmission overhauls.
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            Diagnostic Level:
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            Advanced diagnostic procedures and specifications for all major systems.
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            Specifications Detail:
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            Includes all essential torque values, clearances, fluid capacities, electrical resistance values, and timing data.
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            Maintenance
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            Service Intervals
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            Engine Oil Change:
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            Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.
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            Oil Filter Change:
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            Every engine oil change.
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            Spark Plug Check:
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            Every 6,000-10,000 km (3,700-6,200 miles).
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            Air Filter Cleaning:
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            Every 3,000-6,000 km (1,800-3,700 miles).
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            Chain Lubrication:
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            Every 500-1,000 km (300-600 miles) and after washing or riding in rain.
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            Brake Fluid Change:
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            Every 2 years.
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            Fluid Specifications
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            Engine Oil Type:
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            Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, or SG.
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            Engine Oil Capacity:
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            Approx. 1.8 Liters (1.9 US qt) without filter change; 2.0 Liters (2.1 US qt) with filter change.
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            Brake Fluid Type:
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            DOT 3 or DOT 4.
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            Fork Oil Type:
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            Yamaha Fork Oil 10W or equivalent.
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            Fork Oil Capacity:
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            Approx. 170 ml (5.7 US fl oz) per fork leg.
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            Known Issues
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            Carburetor Performance:
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            Mikuni VM carburetors can be sensitive to dirt and require regular cleaning and adjustment to maintain optimal running.
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            Electrical Connections:
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            Corrosion in electrical connectors, especially on older units, can lead to intermittent issues.
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            Fork Seals:
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            Like many bikes of this era, fork seals can degrade over time, leading to leaks.
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            Common Checks
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            Chain Tension:
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            Crucial for drivetrain longevity and rider safety; requires periodic adjustment.
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