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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, valve timing, lubrication system, cooling system, oil pump, engine specifications.
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Fuel System:
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Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, fuel tank, evaporative emission control (EVAP).
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Ignition System:
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Ignition coils, spark plugs, ECU control, timing.
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Electrical System:
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Wiring diagrams, battery, charging system (stator, rectifier/regulator), starter motor, lighting, fuses, relays, ECUs, sensors.
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Transmission:
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Clutch operation, gearbox assembly, gear selection, shift drum, shift forks, transmission oil specifications.
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Chassis Suspension:
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Front fork (USD) disassembly, assembly, oil levels, damping adjustments, rear shock absorber, linkage, swingarm.
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Brakes:
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Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications, bleeding procedures, ABS system (if applicable).
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Wheels Tires:
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Wheel specifications, tire sizes, pressures, bearing maintenance, wheel balancing.
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Bodywork Fittings:
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Fairings, seat removal, fuel tank removal, handlebars, instrument cluster, lighting components.
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Diagnostics Troubleshooting:
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Fault code identification, diagnostic procedures, common problems and solutions, symptom-based troubleshooting.
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Procedures Included
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Routine Maintenance:
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Oil and filter changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake fluid flush.
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Engine Rebuild:
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Complete engine overhaul, piston ring replacement, valve seat grinding, crankshaft bearing replacement, seal replacement.
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Suspension Service:
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Front fork seal replacement, fork oil change, rear shock absorber servicing, linkage bearing maintenance.
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Electrical Diagnostics:
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Wiring harness testing, sensor testing, starter system troubleshooting, charging system analysis.
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Brake System Service:
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Brake pad replacement, caliper servicing, master cylinder overhaul, brake line replacement, hydraulic system bleeding.
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Troubleshooting Guides:
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Step-by-step guides for diagnosing and resolving common issues like starting problems, misfires, electrical faults.
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Specifications And Tolerances:
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Detailed torque specifications, clearance measurements, engine tolerances, fluid capacities.
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Technical Depth
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Depth:
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Comprehensive, covering from basic maintenance to advanced engine and electrical system diagnostics and repair. Suitable for professional technicians and experienced DIY mechanics.
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Maintenance
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Service Intervals
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Oil And Filter Change:
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Every 6,000 miles (10,000 km) or 6 months, whichever comes first.
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Spark Plug Inspection:
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Every 18,000 miles (30,000 km).
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Valve Clearance Check:
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Every 26,600 miles (42,800 km) or 48 months.
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Air Filter Cleaning:
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Every 6,000 miles (10,000 km) or 6 months (more frequently in dusty conditions).
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Drive Chain Lubrication:
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Every 600 miles (1,000 km) or after washing/rain, adjust as needed.
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Fluid Specifications
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Engine Oil Capacity:
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With oil filter change: 3.40 L; Without oil filter change: 3.20 L; Dry engine: 3.70 L.
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Coolant Capacity:
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Approx. 2.00 L (including reservoir).
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Brake Fluid Type:
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DOT 4
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Known Issues
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Throttle Response Early Models:
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Some early models experienced slightly abrupt throttle response. The manual provides procedures for potential ECU re-mapping or adjustments to mitigate this.
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Clutch Lever Feel:
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Assist & Slipper clutch provides light feel, but adjustments and maintenance are crucial for optimal performance.
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Suspension Tuning:
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While offering good adjustability, fine-tuning the suspension for specific riding styles or loads is a common area for owners, well-covered in the manual.
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