Manual Coverage
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Systems Covered
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Engine:
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Complete overhaul, tuning, carburetor service (Bing), ignition system, lubrication system, cooling system (air-cooled).
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Transmission:
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5-speed gearbox overhaul, clutch service, drive shaft, final drive unit.
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Chassis Suspension:
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Front forks (BMW Telelever/Mono-lever variations may require supplemental data), rear swingarm, shock absorbers, steering head bearing.
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Brakes:
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Front disc brake system (including caliper rebuild, hydraulic lines), rear drum brake system.
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Electrical System:
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Wiring diagrams, alternator, starter motor, battery, lighting system, instrumentation.
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Fuel System:
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Fuel tank, fuel lines, petcock, carburetor tuning and rebuilding.
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Bodywork Frame:
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Frame inspection, body panel removal and installation, seat, fuel tank mounting.
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Procedures Included
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Maintenance Procedures:
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Regular servicing, oil changes, filter replacements, spark plug service, valve adjustments, carburetor synchronization.
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Repair Procedures:
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Engine rebuilds, transmission overhauls, brake caliper servicing, fork seal replacement, electrical component repair.
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Troubleshooting:
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Diagnostic flowcharts for common issues, ignition problems, fuel delivery issues, starting problems.
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Torque Specifications:
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Detailed torque values for all critical fasteners.
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Technical Depth
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Depth:
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Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed electrical system diagnostics.
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Engine Specifications
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Primary Engine
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Engine Type:
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Air-cooled, four-stroke, boxer-twin engine
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Bore R80:
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82 mm
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Stroke R80:
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74.5 mm
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Displacement R80:
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797.5 cc
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Bore R90:
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90 mm
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Stroke R90:
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70.6 mm
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Displacement R90:
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897.8 cc
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Bore R100:
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94 mm
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Stroke R100:
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70.6 mm
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Displacement R100:
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999.2 cc
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Performance
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Horsepower R80:
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50 hp @ 6200 rpm (approx.)
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Torque R80:
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57 Nm @ 4800 rpm (approx.)
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Horsepower R90:
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65 hp @ 7000 rpm (approx.)
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Torque R90:
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70 Nm @ 5500 rpm (approx.)
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Horsepower R100:
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65 hp @ 7000 rpm (approx.)
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Torque R100:
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74 Nm @ 6000 rpm (approx.)
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Fuel System
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Carburetors:
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Dual Bing carburetors (e.g., 32/36mm for R80, 40mm for R90/R100)
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Fuel Type:
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Unleaded gasoline (87 octane or higher recommended for modern fuels)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000-5,000 miles (approx., check manual for specific guidance)
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Valve Adjustment Interval:
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Every 6,000-10,000 miles (approx., check manual for specific guidance)
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Spark Plug Replacement:
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Every 6,000-12,000 miles (approx., check manual for specific guidance)
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Fluid Specifications
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Engine Oil Spec:
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SAE 20W-50 or SAE 10W-40 motorcycle-specific oil (check manual for temperature recommendations)
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Brake Fluid Spec:
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DOT 3 or DOT 4 hydraulic brake fluid
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Final Drive Fluid Spec:
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SAE 90 hypoid gear oil (GL-4)
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Known Issues
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Common Issues:
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Carburetor synchronization drift, ignition coil failure, worn output shaft seal, clutch pushrod seal leaks, starter motor brushes, steering head bearing adjustment.
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Preventative Maintenance:
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Regular valve adjustments, proper carburetor tuning, keeping electrical connections clean, regular inspection of seals.
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