Manual Coverage
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Systems Covered
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Engine:
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Complete disassembly, assembly, inspection, troubleshooting, repair of all engine components.
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Fuel System:
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Fuel injection system, fuel pump, injectors, throttle body, fuel tank, lines, and filters.
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Cooling System:
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Radiator, fan, thermostat, water pump, coolant flow, hoses, and troubleshooting.
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Transmission Drive Train:
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CVT system, drive belt, variator, clutch, final drive gear unit, bearings, and seals.
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Electrical System:
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Ignition system, starting system, charging system (stator, regulator/rectifier), battery, lighting, horn, instrument cluster, sensors.
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Brakes:
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Hydraulic brake systems (front and rear), brake calipers, master cylinders, brake lines, brake pads, rotors, fluid replacement, bleeding procedures.
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Suspension Steering:
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Front telescopic forks (disassembly, seals, oil replacement), rear shock absorber, swingarm, bearings, steering head bearings.
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Chassis Frame:
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Frame inspection, welding integrity, body panel removal/installation, seat, storage compartment.
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Wheels Tires:
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Wheel bearings, tire inspection, replacement, mounting, balancing.
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Diagnostic Troubleshooting:
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Extensive troubleshooting charts, symptom-based diagnostics, error code interpretation (if applicable).
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Procedures Included
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Scheduled Maintenance:
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Oil changes, filter replacements, spark plug replacement, air filter service, brake fluid flush, coolant flush, drive belt inspection/replacement.
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Engine Repair:
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Piston, cylinder, crankshaft, valve adjustments, camshafts, gaskets, seals, lubrication system.
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Transmission Overhaul:
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CVT clutch assembly, variator assembly, drive belt replacement, gear oil change.
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Electrical Diagnostics:
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Wiring diagrams, component testing, charging system troubleshooting, ignition system fault finding.
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Brake System Service:
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Pad replacement, caliper service, master cylinder rebuild, brake line replacement, bleeding.
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Suspension Fork Rebuild:
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Front fork seal replacement, fork oil change, spring inspection.
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Bodywork Refinishing:
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Panel removal and installation, fairing repair, trim replacement.
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Troubleshooting Guides:
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Detailed step-by-step troubleshooting for common and uncommon issues.
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Technical Depth
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Depth Of Coverage:
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Factory-level repair and maintenance procedures, including complete disassembly and reassembly of all major components.
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Diagnostic Capabilities:
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Includes diagnostic procedures, component testing, and interpretation of diagnostic information.
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Specifications Data:
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Provides all critical torque specifications, clearances, fluid capacities, and wear limits.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Typically every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for precise interval).
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Air Filter Service:
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Inspect every 5,000 km, replace as needed.
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Spark Plug Replacement:
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Typically at 10,000-20,000 km (check manual for specific plug type and interval).
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Drive Belt Inspection:
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Inspect at 10,000 km, replace around 20,000 km or if wear is evident.
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Brake Fluid Flush:
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Every 2 years, or as per manual recommendation.
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Fluid Specifications
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Engine Oil Type:
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Yamalube (or equivalent API SG, JASO MA/MA2) SAE 10W-40 or 20W-50 (confirm viscosity based on ambient temperature from manual).
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Engine Oil Capacity:
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Approx. 1.6-1.8 Liters with filter change (refer to manual for exact capacity).
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Coolant Type:
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Yamaha's recommended permanent antifreeze coolant (ethylene glycol based).
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Brake Fluid Type:
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DOT 4 Hydraulic Brake Fluid.
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Final Drive Oil Type:
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Yamalube Gear Oil (or equivalent SAE 80 hypoid gear oil) (confirm capacity in manual).
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Known Issues
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Common Wear Items:
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Drive belt wear, variator/clutch wear, fork seal leaks, brake pad wear, suspension components.
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Potential Electrical Issues:
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Regulator/rectifier failure, battery issues due to age (standard for many vehicles of this era).
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