Manual Coverage
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Systems Covered
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Engine:
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Complete engine disassembly, assembly, inspection, troubleshooting, and repair of all internal components.
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Fuel System:
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Carburetor (if applicable for TE 125 model), fuel pump, fuel lines, fuel tank, and associated components.
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Ignition System:
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CDI unit, ignition coils, spark plugs, wiring diagrams related to ignition.
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Cooling System:
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Radiator, hoses, thermostat, water pump, coolant specifications and procedures.
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Transmission:
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Clutch operation, gearbox disassembly and assembly, gear inspection, shift mechanism, lubrication requirements.
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Chassis Frame:
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Frame inspection, alignment, welding repairs (if applicable), subframe details.
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Suspension Front:
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Front fork (telescopic) disassembly, assembly, oil change, seal replacement, spring specifications, adjustments.
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Suspension Rear:
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Monoshock rear suspension, linkage inspection, shock absorber service, spring preload adjustments.
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Brakes Front:
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Brake caliper service, master cylinder overhaul, brake pad replacement, rotor inspection, hydraulic fluid specifications.
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Brakes Rear:
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Rear brake caliper service, master cylinder overhaul, brake pad replacement, rotor inspection, hydraulic fluid specifications.
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Wheels Tires:
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Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing, spoke tension (if applicable).
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Electrical System:
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Battery, starter motor, lighting system (headlight, taillight, indicators), horn, wiring diagrams, fuse specifications.
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Exhaust System:
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Exhaust pipe, muffler inspection and replacement, exhaust gasket specifications.
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Controls:
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Handlebar controls, throttle, clutch lever, brake lever service, cable adjustments.
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Bodywork Plastics:
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Fairing, fender, seat, tank cover removal and installation, cosmetic repair guidelines.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, chain adjustments, lubrication points, tire pressure checks.
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Troubleshooting Diagnostics:
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Step-by-step diagnostic procedures for common performance issues, electrical faults, and mechanical problems.
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Engine Rebuild:
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Detailed procedures for engine disassembly, component inspection (piston, rings, valves, crankshaft), reassembly, and break-in procedures.
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Suspension Service:
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Fork oil replacement, seal replacement, shock absorber service, and linkage lubrication.
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Brake System Service:
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Bleeding the hydraulic system, caliper overhaul, master cylinder rebuild, and pad/rotor replacement.
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Electrical Component Testing:
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Testing of battery voltage, charging system output, ignition coil resistance, and other electrical components.
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Wiring Diagrams:
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Comprehensive electrical schematics for all circuits.
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Special Tool Usage:
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Identification and recommended usage of specialized tools required for specific repair procedures.
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Technical Depth
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Diagnostic Capabilities:
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Advanced diagnostics, including specific measurements, tolerances, and troubleshooting trees.
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Repair Instructions:
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Detailed, step-by-step instructions with torque specifications, clearances, and critical assembly information.
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Component Tolerances:
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Precise specifications for wear limits, clearances, and critical component dimensions.
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Schematics:
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Includes detailed electrical and mechanical schematics for clarity.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Typically 1,000-1,500 km or annually, refer to manual for precise interval and conditions.
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Air Filter Cleaning:
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Frequent checks, cleaning/replacement based on riding conditions (e.g., every 500 km or as needed in dusty environments).
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Chain Lubrication Adjustment:
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Regularly, ideally every 500 km or after riding in wet conditions. Adjustment as needed to maintain proper slack.
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Fluid Specifications
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Engine Oil Type:
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Semi-synthetic or fully synthetic 10W-40 motorcycle oil (Specific API classification and JASO standard to be confirmed in manual).
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Coolant Type:
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Ethylene glycol-based antifreeze/coolant mixture, typically a 50/50 mix with distilled water. Manual will specify exact type and capacity.
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Brake Fluid Type:
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DOT 4 hydraulic brake fluid.
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Fork Oil Type:
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Specific viscosity grade (e.g., SAE 5W or 10W) and quantity per leg. Manual will detail.
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Known Issues
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Common Wear Items:
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Chain and sprockets, brake pads, fork seals, air filter, clutch plates (depending on usage).
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Potential Electrical Gremlins:
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As with many motorcycles of this era, ensure all electrical connections are clean and secure to prevent intermittent issues. Manual's wiring diagrams are crucial here.
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