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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete engine disassembly, assembly, inspection, and repair procedures.
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Fuel System:
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Fuel injection system (EFI) components, troubleshooting, and calibration.
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Ignition System:
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Ignition coil, CDI unit, spark plug testing, and troubleshooting.
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Cooling System:
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Radiator, fan, water pump, thermostat, and coolant specifications.
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Transmission Drivetrain:
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Clutch operation, gearbox inspection, disassembly, and assembly.
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Suspension:
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Front fork (USD) and rear monoshock adjustment, servicing, and rebuilds.
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Brakes:
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Front and rear brake system inspection, fluid replacement, caliper overhaul, and bleeding procedures.
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Electrical System:
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Wiring diagrams, component testing, battery, charging system, lighting, and starter system.
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Chassis Frame:
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Frame inspection, steering head bearing service, and alignment.
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Bodywork Trim:
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Fairing removal, installation, and component replacement.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning.
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Troubleshooting:
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Diagnostic flowcharts for common starting, running, and electrical issues.
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Engine Rebuild:
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Detailed steps for cylinder head, piston, crankshaft, and valve servicing.
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Suspension Rebuild:
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Fork seal replacement, oil changes, and shock absorber servicing.
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Electrical Diagnostics:
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Component testing, voltage drop tests, and wiring harness troubleshooting.
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Wheel Tire Service:
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Tire mounting/dismounting, wheel balancing, and spoke tensioning.
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Technical Depth
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Diagnostic Capabilities:
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Advanced diagnostic procedures, including ECU reading (if applicable via interface).
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Repair Scope:
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Comprehensive repair instructions for all major and minor components.
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Specifications Data:
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Includes torque values, clearances, fluid capacities, and diagnostic parameters.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
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Oil Filter Replacement:
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Replace at every oil change.
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Air Filter Cleaning:
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Every 6,000 km (3,700 miles) or annually.
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Spark Plug Check:
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Inspect every 6,000 km (3,700 miles); replace as needed.
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Chain Lubrication Adjustment:
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Every 1,000 km (600 miles) or after washing/riding in rain.
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Fluid Specifications
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Engine Oil Type:
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SAE 10W-40 API SG or SH, or JASO MA certified.
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Engine Oil Capacity:
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1.7 L (1.8 US qt) without filter change; 1.9 L (2.0 US qt) with filter change.
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Coolant Type:
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High-quality ethylene glycol based antifreeze coolant, mixed 50/50 with distilled water.
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Brake Fluid Type:
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DOT 4 brake fluid.
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Known Issues
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Carburetor Vibration Risk:
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Some early models of the previous generation had potential vibration issues with the carburetor; the fuel-injected model addresses this.
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Fuel Pump Reliability:
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While generally reliable, fuel pump issues can occur over time, especially with contaminated fuel. The manual details testing procedures.
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Suspension Seal Leaks:
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Like many off-road oriented bikes, front fork seals can wear and leak over extended use or aggressive riding. The manual provides detailed replacement instructions.
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