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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine overhaul, top-end and bottom-end components, cylinder, piston, rings, valves, camshaft, crankshaft, lubrication system, oil pump, oil filter, cooling system, radiator, fan, water pump.
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Transmission Drivetrain:
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Transmission inspection, repair, disassembly, assembly, gears, bearings, clutch operation, drive shafts, differential.
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Chassis Frame:
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Frame inspection, repair, alignment, body panel removal and installation, mounting points.
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Steering Suspension:
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Steering system components (handlebars, steering column, tie rods, ball joints), suspension components (shocks, springs, control arms), wheel alignment.
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Braking System:
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Brake caliper, brake pads, brake discs, brake lines, master cylinder, brake fluid, bleeding procedures, parking brake.
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Electrical System:
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Wiring diagrams, battery, charging system (alternator/stator), starter motor, ignition system, lighting (headlights, taillights, signals), switches, fuses, relays, sensors, ECU.
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Fuel System:
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Fuel tank, fuel pump, fuel filter, carburetor (or fuel injection system), fuel lines, fuel delivery.
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Seats Locks:
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Seat removal and installation, seat mechanism, lock cylinders, ignition switch, storage compartments.
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Lubrication:
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Lubrication points, recommended lubricants, oil change procedures, grease points.
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Procedures Included
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Maintenance Procedures:
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Regular service, oil changes, filter replacements, spark plug checks, fluid level checks and top-offs, brake pad inspection, chain adjustment (if applicable).
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Troubleshooting:
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Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting charts, fault code interpretation (if applicable).
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Repair Procedures:
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Step-by-step instructions for disassembly, cleaning, inspection, repair, and reassembly of all major components and systems.
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Technical Specifications:
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Torque specifications for fasteners, engine timing, valve clearances, fluid capacities, electrical resistance values, critical measurements.
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Technical Depth
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Depth:
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Comprehensive, covering routine maintenance, intermediate repairs, and advanced diagnostics and overhauls. Equivalent to dealership-level service information.
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, Single Cylinder (commonly Liquid-Cooled)
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Displacement:
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400cc - 425cc range (specific for 400 vs 425 variants)
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Bore X Stroke:
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Varies by specific 400/425 model, requires manual lookup for exact figures.
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Compression Ratio:
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Varies by specific model, requires manual lookup for exact figures.
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Performance
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Horsepower:
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Approximately 20-25 HP (estimated, varies by model and tuning).
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Torque:
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N/A (Specific figures require manual lookup).
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Fuel System
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Fuel Delivery:
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Carburetor (likely Keihin or similar), or potentially Electronic Fuel Injection (EFI) on later/higher spec models.
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Fuel Type:
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Unleaded Gasoline
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Fuel Tank Capacity:
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Typically around 12-15 liters (requires manual lookup for exact figures).
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Ignition
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Ignition System:
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CDI (Capacitor Discharge Ignition) or similar electronic ignition.
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Lubrication
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Oil Type Capacity:
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Requires specific SAE grade and capacity (e.g., SAE 10W-40, ~1.5-2.0 liters) as per manual.
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Cooling
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Cooling System:
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Liquid-cooled
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Coolant Type:
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Ethylene Glycol based antifreeze/coolant (specific mix ratio and type in manual).
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 100 hours or 6 months, whichever comes first (refer to manual for exact schedule).
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Air Filter Cleaning Replacement:
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Inspect every 3 months or 50 hours; clean/replace as needed (refer to manual).
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Spark Plug Check Replacement:
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Check at first service, replace per manual schedule or if fouled.
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Brake Fluid Flush:
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Recommend flushing every 12-24 months or as per manual.
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Fluid Specifications
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Engine Oil Specification:
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SAE 10W-40 API SG or higher (verify exact spec and quantity in manual).
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Coolant Specification:
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50/50 mix of ethylene glycol antifreeze and distilled water (verify type and ratio).
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Brake Fluid Specification:
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DOT 4 Hydraulic Brake Fluid (verify type).
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Known Issues
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Common Wear Items:
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Brake pads, tires, drive belts (CVT), suspension bushings, battery.
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Potential Electrical Issues:
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Wiring harness connections, stator output on older units (refer to manual for specific troubleshooting).
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Engine Starting Problems:
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Can be related to fuel delivery, spark, battery voltage, or compression (manual will detail diagnostic steps).
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