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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, diagnosis, performance modifications.
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Transmission:
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Clutch, gearbox, shifting mechanisms, lubrication, troubleshooting.
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Fuel System:
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Carburetor (Keihin FCR40), fuel pump, fuel lines, tank, filters.
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Cooling System:
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Radiator, coolant, water pump, thermostat, hoses, fan operation.
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Ignition System:
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CDI unit, ignition coil, spark plug, wiring, timing.
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Exhaust System:
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Muffler, head pipes, catalytic converter (if applicable), heat shields.
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Frame And Bodywork:
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Frame structure, subframe, plastics, seat, fenders, graphics.
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Suspension:
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Front forks (USD, adjustable), rear shock absorber (adjustable), linkage, bearings, seals.
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Brakes:
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Front and rear disc brakes, master cylinders, calipers, lines, pads, fluid specifications, bleeding procedures.
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Wheels And Tires:
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Spoked wheels, rim sizes, spoke tension, tire pressure, tire replacement.
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Electrical System:
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Lighting, charging system (stator, regulator/rectifier), battery, fuses, wiring diagrams, switches, starter motor.
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Controls:
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Throttle, clutch lever, brake lever, shifter, footpegs, handlebars.
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Maintenance Procedures:
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Oil changes, filter replacements, chain adjustment, valve clearance checks, spark plug replacement.
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Troubleshooting:
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Diagnostic charts for common problems, fault finding, electrical issues.
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Procedures Included
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Disassembly Assembly:
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Complete step-by-step procedures for all major components and systems.
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Torque Specifications:
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Detailed torque values for all fasteners and critical components.
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Special Tools:
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Identification of required special tools for specific repair procedures.
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Technical Depth
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Depth:
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Comprehensive; covers routine maintenance to complete engine and transmission rebuilds, electrical diagnostics, and suspension tuning.
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Engine Specifications
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Primary Engine
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Engine Type:
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Liquid-cooled, four-stroke, DOHC, four-valve single
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Displacement:
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449 cc
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Bore X Stroke:
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92.0 x 68.3 mm
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Compression Ratio:
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11.0:1
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Performance
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Horsepower Approx:
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Approx. 50 HP (varies by region and tuning)
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Torque Approx:
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Approx. 40 Nm / 30 lb-ft (varies by region and tuning)
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Fuel System
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Carburetor:
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Keihin FCR40, flat-slide, semi-double throttle valve with accelerator pump.
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Fuel Type:
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Unleaded gasoline, minimum 90 octane.
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Lubrication
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Oil Type:
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SAE 10W-40 API SG or higher, JASO MA certified motorcycle oil.
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Oil Capacity:
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1.9 L (engine and clutch, without filter replacement); 2.0 L (engine and clutch, with filter replacement); 2.2 L (total engine lubrication).
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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 hours of use or every 6 months, whichever comes first.
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Oil Filter Replacement:
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At every oil change.
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Air Filter Cleaning:
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Every 5-10 hours of use, or more frequently in dusty conditions.
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Valve Clearance Check:
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Every 20-30 hours of use.
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Chain Adjustment:
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Regularly, check for slack and lubrication (e.g., every 5-10 hours).
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Spark Plug Replacement:
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Every 30-40 hours of use, or as needed based on inspection.
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Fluid Specifications
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Engine Oil Specification:
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SAE 10W-40 API SG or higher, JASO MA
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Brake Fluid Specification:
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DOT 3 or DOT 4 brake fluid (non-silicone based).
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Coolant Specification:
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Permanent type anti-freeze coolant mixed with distilled water (50/50 ratio).
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Known Issues
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Carburetor Tuning:
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Can require fine-tuning for different altitudes or modifications. Accelerator pump jetting is a common area for adjustment.
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Clutch Wear:
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In demanding use, clutch plates may require periodic inspection and replacement.
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Suspension Seals:
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Fork seal leaks can occur with hard use; regular maintenance is crucial.
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