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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, piston, crankshaft, connecting rod, valves, timing, lubrication system, cooling system (radiator, fan), fuel injection system (throttle body, injectors, fuel pump, regulator).
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Electrical System:
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Ignition system, lighting, battery, starter motor, alternator, wiring diagrams, sensors (TPS, MAP, O2, coolant temp), ECU diagnostics.
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Drivetrain:
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Clutch operation and inspection, transmission gears and shafts, shifting mechanism, final drive (chain and sprockets).
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Suspension:
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Front fork (upside-down, telescopic hydraulic) service and adjustment, rear shock absorber service and adjustment, linkage system maintenance.
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Braking System:
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Front and rear hydraulic disc brake systems, caliper service, master cylinder maintenance, brake pad replacement, bleeding procedures.
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Fuel System:
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Fuel tank, fuel pump assembly, fuel filter, fuel lines, EFI components (injectors, regulator, throttle body).
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Exhaust System:
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Exhaust pipe, muffler, O2 sensor connection.
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Frame And Bodywork:
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Frame inspection, subframe, body panels, seat, handlebars, footpegs.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements (oil, air), chain adjustment, brake adjustments, tire pressure checks, spark plug service.
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Troubleshooting:
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Diagnostic procedures for common starting, running, and electrical issues, fault code interpretation.
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Engine Rebuild:
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Complete engine overhaul, piston and ring replacement, valve guide seals, gasket replacements, torque specifications for all internal components.
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Suspension Overhaul:
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Fork seal replacement, fork oil changes, shock absorber seal service.
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Electrical Diagnostics:
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Wiring harness inspection, sensor testing, ECU diagnostic procedures.
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Efi System Service:
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Throttle body cleaning, injector testing, fuel pressure testing.
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Wheel Bearing Service:
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Inspection and replacement of wheel bearings.
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Steering Head Bearing Service:
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Inspection and adjustment/replacement of steering head bearings.
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Technical Depth
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Depth:
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Comprehensive: Covers everything from basic owner maintenance to full workshop-level repairs, diagnostics, and component overhauls. Includes detailed exploded diagrams and specifications.
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Engine Specifications
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Primary Engine
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Type:
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Four-stroke, liquid-cooled, DOHC, 4-valve single-cylinder
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Displacement Te 250:
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249.4 cc (Bore x Stroke: 76 x 55 mm)
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Displacement Te 310:
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297.8 cc (Bore x Stroke: 83 x 55 mm)
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Performance
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Horsepower Te 250 Est:
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~35-40 HP (at crankshaft, estimated)
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Horsepower Te 310 Est:
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~40-45 HP (at crankshaft, estimated)
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Torque Te 250 Est:
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~26-28 Nm (at crankshaft, estimated)
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Torque Te 310 Est:
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~30-33 Nm (at crankshaft, estimated)
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Fuel System
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Induction:
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Electronic Fuel Injection (EFI) - Mikuni D45 (or similar)
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Fuel Type:
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Unleaded Gasoline (91 octane or higher recommended)
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Lubrication
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System:
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Wet sump with integrated oil cooler (typical)
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Cooling System
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Type:
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Liquid-cooled with radiator and electric fan
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 10-15 operating hours or annually (whichever comes first, typical for off-road use).
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Oil Filter Replacement:
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Every 20-30 operating hours or annually.
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Air Filter Cleaning:
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Every 5-10 operating hours, depending on conditions.
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Spark Plug Service:
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Every 20-30 operating hours.
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Valve Clearance Check:
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Every 30-40 operating hours.
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Chain And Sprockets Inspection:
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Regularly, lubricate every 5-10 operating hours.
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Fluid Specifications
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Engine Oil Type:
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Fully synthetic 4-stroke motorcycle oil, SAE 10W-50 (e.g., Motul 7100 10W-50, Castrol Power RS 10W-50, or equivalent). Always check manual for exact OEM specification.
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Engine Oil Capacity:
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Approximately 1.0 - 1.2 liters (check dipstick or fill plug level).
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Coolant Type:
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Ethylene Glycol based coolant, 50/50 mix with distilled water. (e.g., Yamalube Coolant, Motul M7 Motocool Expert).
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Brake Fluid Type:
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DOT 4 hydraulic brake fluid.
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Clutch Fluid Type:
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DOT 4 hydraulic fluid (if hydraulic clutch).
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Known Issues
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Common Wear Items:
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Clutch plates, chain and sprockets, wheel bearings, steering head bearings, suspension seals, cam chain.
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Potential Efi Quirks:
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Can be sensitive to battery voltage, occasional sensor faults (TPS, MAP), dirty injectors. Fuel pump longevity can vary.
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Cooling System Maintenance:
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Regular flushing of coolant and checking hoses for leaks is important to prevent overheating.
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