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Manual Coverage
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Systems Covered
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Engine:
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Engine disassembly, assembly, repair, diagnostics, internal components (pistons, rings, valves, camshaft, crankshaft), timing
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Cooling System:
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Radiator, coolant, fan, hoses, water pump (if applicable)
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Carburetion:
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Carburetor inspection, cleaning, adjustment, overhaul, fuel delivery system
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Drive Train:
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Transmission (gears, shafts, bearings), clutch, final drive, driveshafts, differentials (if applicable)
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Chassis:
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Frame, suspension (front and rear), steering, wheels, brakes (hydraulic and mechanical components), body panels, seats
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Electrical:
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Ignition system, charging system (stator, regulator/rectifier), lighting, starting system, battery, wiring diagrams, switches, sensors
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Procedures Included
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Maintenance:
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Regular servicing, lubrication, fluid changes, filter replacements, adjustments
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Diagnostics:
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Troubleshooting guides, symptom-based diagnostics, fault finding procedures
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Repair:
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Detailed step-by-step instructions for component repair, overhaul, and replacement
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Rebuild:
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Engine rebuild, transmission rebuild, carburetor overhaul
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Restoration:
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Guidance for restoring components to original specifications
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Technical Depth
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Depth:
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In-depth technical information suitable for professional repair and extensive DIY projects.
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Detail Level:
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Detailed illustrations, exploded views, torque specifications, clearances, and diagnostic flowcharts.
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Engine Specifications
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Primary Engine
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Engine Type:
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Single-cylinder, 4-stroke
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Displacement:
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196cc (approximate, based on '200' model designation)
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Bore X Stroke:
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Typically around 66mm x 57mm (specifics to be confirmed in manual)
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Cooling Method:
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Air-cooled
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Performance
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Horsepower:
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Estimated 12-15 HP (typical for this class of ATV in that era)
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Torque:
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Not explicitly stated, but designed for low-end grunt for off-road use.
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Fuel System
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Fuel Delivery:
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Carburetor
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Carburetor Model:
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Likely a Mikuni VM or similar model (specifics in manual)
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Ignition
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Ignition Type:
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CDI (Capacitor Discharge Ignition)
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Engine Components
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Valvetrain:
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SOHC (Single Overhead Camshaft)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 1000 km or annually (refer to manual for exact recommendation)
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Air Filter Cleaning:
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Regular inspection and cleaning, especially in dusty conditions (frequency in manual)
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Spark Plug Replacement:
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Recommended at specific intervals or based on condition (refer to manual)
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Fluid Specifications
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Engine Oil Type:
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Yamalube or API SG/SH SAE 10W-40 or 20W-40 (specific recommendation in manual)
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Engine Oil Capacity:
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Approximately 1.5 - 2.0 liters (with filter change) - confirm in manual
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid (confirm in manual)
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Known Issues
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Common Wear Items:
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Carburetor clogging due to fuel quality or sitting, electrical connections, brake component wear, suspension bushings.
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Tuning Considerations:
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Carburetor jetting adjustments may be needed for altitude or modifications.
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