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Manual Details
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Coverage Areas
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Primary Coverage:
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Comprehensive Service and Repair
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Engine Coverage:
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Engine disassembly, assembly, tuning, and diagnostics
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Drivetrain Coverage:
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Transmission, drive shafts, differential (if applicable)
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Electrical Coverage:
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Ignition system, charging system, lighting, wiring diagrams
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Chassis Coverage:
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Frame, suspension, steering, brakes
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Bodywork Coverage:
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Body panel removal and installation, seat, fenders
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Troubleshooting Coverage:
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Diagnostic procedures for common issues
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Page Count
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Estimated Pages:
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Refer to actual document for precise count, likely 300+ pages based on description
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Manual Type
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Type:
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Factory Service Repair Manual
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Language
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Language:
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English
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, valve adjustments, piston/cylinder work, crankshaft, carburetor tuning and rebuilding
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Transmission:
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Gearbox inspection, clutch adjustment/replacement, chain drive maintenance
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Brakes:
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Brake system inspection, pad/shoe replacement, hydraulic system bleeding
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Electrical:
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Starting system, battery, alternator, CDI ignition, lighting circuits, wiring harness schematics
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Fuel System:
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Fuel tank, fuel lines, carburetor (Mikuni likely), fuel filter
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Cooling System:
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Air-cooled engine; emphasis on airflow and cooling fins
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Exhaust System:
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Muffler and header pipe inspection and replacement
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Suspension:
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Front and rear suspension inspection, shock absorber adjustment/replacement, linkage lubrication
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Steering:
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Handlebar, steering stem, tie rods, wheel alignment
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Procedures Included
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Maintenance:
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Regular maintenance checks, lubrication points, filter changes, spark plug replacement
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Repair:
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Detailed step-by-step instructions for component repair and replacement
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Diagnostics:
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Troubleshooting guides for common performance issues, starting problems, and electrical faults
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Adjustments:
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Carburetor jetting and idle speed, throttle cable, clutch cable, brake adjustments
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Disassembly Assembly:
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Complete vehicle and component breakdown and reassembly procedures
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Technical Depth
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Depth:
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Full workshop level, suitable for advanced DIY mechanics and professional technicians
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Diagnostics Focus:
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Includes detailed diagnostic flowcharts and symptom-based troubleshooting
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Specifications Detail:
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Provides critical torque values, clearances, and dimensional data for all major components
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, SOHC, Air-Cooled
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Displacement:
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196 cc (likely, based on '200' designation)
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Bore X Stroke:
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Specific dimensions would be detailed in the manual
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Compression Ratio:
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Specific ratio would be detailed in the manual
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Valve Train:
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SOHC (Single Overhead Camshaft), 2 valves per cylinder (likely)
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Performance
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Horsepower:
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Approx. 14-16 HP (estimated, actual figures in manual)
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Torque:
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Specific torque figures would be detailed in the manual
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Fuel System
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Carburetor Model:
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Likely Mikuni VM series (e.g., VM26 or similar)
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Fuel Type:
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Unleaded gasoline
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Fuel Capacity:
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Specific tank capacity would be detailed in the manual
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Ignition
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Ignition System:
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CDI (Capacitor Discharge Ignition)
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Spark Plug Type:
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Specific spark plug type and gap would be detailed in the manual (e.g., NGK)
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Dimensions
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Exterior
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Length:
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Specific dimensions in manual
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Width:
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Specific dimensions in manual
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Height:
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Specific dimensions in manual
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Weights
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Dry Weight:
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Approx. 400-450 lbs (estimated, actual figures in manual)
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Gross Vehicle Weight Rating:
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Specific GVWR in manual
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Wheels Tires
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Front Tire Size:
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Specific size in manual (e.g., AT22x8-10)
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Rear Tire Size:
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Specific size in manual (e.g., AT22x10-10)
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Wheel Bolt Pattern:
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Specific pattern would be detailed in the manual
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Maintenance
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Service Intervals
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Oil Change Interval:
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Refer to manual for specific mileage/time intervals, typically every 1000 miles or annually.
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Air Filter Cleaning:
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Regular inspection and cleaning/replacement based on operating conditions.
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Spark Plug Replacement:
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Refer to manual, typically every 1000-3000 miles or as needed based on inspection.
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Fluid Specifications
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Engine Oil Type:
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Yamalube or equivalent motorcycle/ATV specific 4-stroke oil, e.g., SAE 10W-30 or 20W-40 (verify in manual).
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Engine Oil Capacity:
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Specific capacity in manual (e.g., approx. 1.5 - 1.8 liters).
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Transmission Fluid:
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Engine oil is typically used for the transmission in this model (verify in manual).
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Brake Fluid:
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DOT 3 or DOT 4 brake fluid (if hydraulic brakes are equipped, verify in manual).
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Known Issues
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Carburetor Fouling:
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Common in older ATVs due to fuel degradation or lack of use; requires cleaning and tuning.
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Electrical Connections:
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Corrosion or loose connections in wiring harness can lead to intermittent issues.
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Suspension Wear:
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Bushings and bearings can wear over time, affecting handling.
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