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Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, tuning, diagnostics, component inspection, torque specifications
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Fuel System:
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Fuel injection system (EFI), fuel pump, injectors, fuel lines, throttle body, fuel pressure testing
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Ignition System:
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Ignition coils, spark plugs, ECU (engine control unit) diagnostics, timing
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Transmission:
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Clutch operation, gear shifting mechanisms, gearbox disassembly and reassembly, lubrication
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Electrical System:
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Wiring diagrams, starter motor, alternator, battery, lighting, sensors, ECU troubleshooting, fuses and relays
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Brakes:
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Brake system maintenance, bleeding, caliper overhaul, master cylinder, brake lines, ABS (if applicable)
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Suspension:
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Front fork service, rear shock absorber, linkage maintenance, spring rates, damping adjustments
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Cooling System:
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Radiator, coolant, fan, thermostat, hoses, pressure testing
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Exhaust System:
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Exhaust pipes, muffler, catalytic converter inspection and replacement
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Chassis And Frame:
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Frame inspection, swingarm, steering head bearings, wheel bearings
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Bodywork:
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Fairings, seat removal, panel replacement, body component diagnostics
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Procedures Included
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Maintenance:
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Routine maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes, coolant flushes
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Troubleshooting:
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Diagnostic procedures for common and uncommon faults, error code interpretation, symptom-based troubleshooting guides
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Repair:
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Step-by-step instructions for component replacement, overhaul, and repair of all major systems
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Disassembly Reassembly:
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Detailed instructions for dismantling and reassembling components and major assemblies
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Diagnostics:
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Wiring diagrams, diagnostic charts, testing procedures for electrical and mechanical components
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Technical Depth
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Depth:
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Comprehensive, covering basic maintenance to advanced engine and electrical diagnostics and repairs
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Visual Aids:
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Hundreds of detailed photos and exploded diagrams
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Engine Specifications
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Primary Engine
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Engine Type:
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Single-cylinder, four-stroke
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Engine Displacement:
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652 cc (cc for cubic centimeters)
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Bore X Stroke:
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100 mm x 83 mm (typical for this engine family)
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Engine Management:
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Electronic Fuel Injection (EFI) with Motronic engine control
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Performance
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Horsepower:
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Approximately 53 hp @ 7,000 rpm (indicative for the engine, may vary by specific model variant and market)
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Torque:
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Approximately 60 Nm (or 44 lb-ft) @ 5,250 rpm (indicative)
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Fuel System
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Fuel Delivery:
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Bosch Motronic electronic fuel injection (EFI)
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Fuel Type:
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Unleaded gasoline, minimum 91 octane (RON + MON)/2 = 87 AKI
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 10,000 km (6,000 miles) or annually, whichever comes first (refer to manual for exact specs)
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Air Filter Replacement:
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Inspect every 10,000 km (6,000 miles), replace as needed or per manual schedule
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Spark Plug Replacement:
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Typically replaced every 20,000 km (12,000 miles) or as per manual
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Fluid Specifications
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Engine Oil Type:
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SAE 5W-40 synthetic motorcycle oil meeting BMW specifications (e.g., API SG/SH or JASO MA)
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Engine Oil Capacity:
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Approximately 2.2 liters (2.3 US quarts) with filter change (verify in manual)
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Coolant Type:
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Ethylene glycol-based coolant mixture (e.g., BMW Advanced Antifreeze) mixed 50/50 with distilled water
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Brake Fluid Type:
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DOT 4 brake fluid
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Known Issues
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Common Wear Items:
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Clutch wear, chain and sprockets, brake pads, fork seals, occasional electrical connector issues
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Engine Quirks:
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Some models may experience vibration at certain RPMs; proper maintenance of the single-cylinder engine is key.
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