Manual Coverage
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Systems Covered
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Engine:
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Engine overhaul, tuning, lubrication, cooling system, fuel system (injection), exhaust system, ignition system.
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Transmission:
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Gearbox, clutch operation and adjustment, final drive (chain and sprockets).
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Brakes:
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Hydraulic system, ABS component testing and bleeding, pad and disc replacement, caliper service.
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Electrical:
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Wiring diagrams, starter system, charging system (alternator, regulator/rectifier), lighting, instrumentation, ECU diagnostics, sensor testing.
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Chassis:
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Frame, front suspension (forks, steering head bearings), rear suspension (monoshock, linkages), wheel bearings, swingarm.
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Bodywork:
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Fairing removal and installation, seat, fuel tank, fenders, mirrors.
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Procedures Included
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Maintenance:
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Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid flush, coolant flush.
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Troubleshooting:
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Diagnostic flowcharts for common performance issues, starting problems, electrical faults.
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Repair:
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Step-by-step instructions for component disassembly, repair, and reassembly of all major motorcycle systems.
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Specifications:
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Torque values, clearances, fluid capacities, electrical resistance readings, component tolerances.
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Technical Depth
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Depth:
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Comprehensive coverage suitable for professional technicians and advanced DIY enthusiasts, including engine rebuild procedures and complex electrical diagnostics.
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Engine Specifications
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Primary Engine
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Type:
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Liquid-cooled, DOHC, inline-three cylinder
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Bore X Stroke:
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79 x 67.2 mm
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Compression Ratio:
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11.2:1
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Performance
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Horsepower Est:
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Approx. 123 bhp (92 kW) @ 9,200 rpm
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Torque Est:
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Approx. 75 lb-ft (101 Nm) @ 7,500 rpm
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Fuel System
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Type:
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Sequential multi-point fuel injection with individual throttle bodies
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Fuel Type:
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Unleaded gasoline, minimum 95 RON
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Ignition System
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Type:
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Electronic, Distributorless (EDIS)
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Exhaust System
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Configuration:
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3-into-1 catalytic converter, silencer
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Safety Features
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Ratings
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ABS:
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Available as an option (Sprint ST ABS model).
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Active Features
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Brakes Front:
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Twin 320mm discs, 4-piston calipers ( Nissin or Tokico)
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Brakes Rear:
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Single 255mm disc, 2-piston caliper
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Suspension Front:
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43mm USD (Upside Down) forks, adjustable preload and rebound damping (e.g., Showa).
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Suspension Rear:
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Monoshock with adjustable preload and rebound damping (e.g., Showa).
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Passive Features
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Lighting:
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Dual Halogen headlights, LED taillight
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Maintenance
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Service Intervals
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Oil Change:
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Every 6,000 miles (10,000 km) or 12 months, whichever comes first.
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Air Filter Check:
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Check every 12,000 miles (20,000 km), replace as needed.
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Spark Plug Replacement:
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Replace every 12,000 miles (20,000 km).
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Coolant Flush:
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Every 24,000 miles (40,000 km).
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Brake Fluid Flush:
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Every 24,000 miles (40,000 km) or 24 months.
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Fluid Specifications
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Engine Oil:
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SAE 10W-40, API SG or higher, JASO MA certified (e.g., Castrol Power1 4T 10W-40).
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Engine Oil Capacity:
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3.4 Liters (3.6 US qt) with filter change.
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Coolant:
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Ethylene glycol based antifreeze, 50/50 mix with distilled water.
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Brake Fluid:
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DOT 4 hydraulic fluid.
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Clutch Fluid:
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DOT 4 hydraulic fluid (shared with brake system).
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Known Issues
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Common Problems:
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Potential for rectifier/regulator failure, stator winding issues, occasional fuel injector clogging, wear on steering head bearings.
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Rectifier Alternator:
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Upgrade kits are available to address potential failure of the original charging system components.
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Tire Sizes
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Front Tire:
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120/70 ZR17
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Rear Tire:
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180/55 ZR17
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