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Manual Coverage
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Systems Covered
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Engine:
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Detailed diagnostics, disassembly, assembly, and tuning for 125cc and 200cc variants.
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Fuel System:
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Carburetor service, fuel pump operation, fuel lines, and tank maintenance.
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Ignition System:
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Spark plugs, ignition coil, CDI unit, wiring diagrams, and troubleshooting.
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Cooling System:
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Radiator, coolant, water pump, and fan operation (if applicable).
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Exhaust System:
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Muffler, catalytic converter (if applicable), and pipe inspection.
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Transmission:
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Automatic transmission (CVT) maintenance, belt replacement, roller weights, and clutch operation.
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Brakes:
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Hydraulic system, brake pads, discs, lines, bleeding procedures, and parking brake.
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Suspension:
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Front fork service (oil change, seal replacement), rear shock absorber adjustment and replacement.
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Steering:
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Handlebar assembly, steering head bearings, and alignment.
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Electrical System:
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Battery, charging system (stator, regulator/rectifier), starter motor, lighting, and fuses.
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Bodywork And Frame:
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Panel removal and installation, seat mechanism, safety cage structure, and fairings.
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Wheels And Tires:
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Tire pressure, rotation, and replacement. Wheel bearing maintenance.
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Procedures Included
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Preventative Maintenance:
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Oil changes, filter replacements, spark plug checks, chain/belt adjustments, brake fluid flushes.
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Troubleshooting:
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Systematic diagnostic steps for common and uncommon issues, symptom analysis.
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Engine Repair:
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Top-end rebuilds, piston and cylinder inspection, valve adjustments, gasket replacement.
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Transmission Service:
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CVT belt inspection/replacement, clutch servicing, variator maintenance.
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Brake Service:
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Pad replacement, caliper servicing, fluid bleeding, rotor inspection.
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Electrical Diagnostics:
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Wiring harness checks, component testing, charging system troubleshooting.
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Suspension Overhaul:
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Fork seal replacement, shock absorber rebuild/replacement.
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Technical Depth
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Depth:
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Comprehensive from basic maintenance to full engine and component overhaul and diagnostics.
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Diagnostic Charts:
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Includes detailed diagnostic flowcharts for various operational issues.
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Torque Specifications:
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All critical fasteners and components have specified torque values.
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Clearances And Tolerances:
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Engine component clearances (piston-to-cylinder, bearing clearances) and other critical tolerances.
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Maintenance
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Service Intervals
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Oil Change:
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Typically every 5,000-6,000 km or annually. (Refer to manual for exact specification).
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Air Filter:
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Inspect every 5,000 km, replace as needed.
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Spark Plug:
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Inspect every 10,000 km, replace as needed. (Specific plug type in manual).
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Brake Fluid Flush:
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Recommended every 2 years.
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Fluid Specifications
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Engine Oil Grade:
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Likely SAE 10W-40 or 15W-50 Synthetic/Semi-Synthetic Motorcycle Oil (API SG or higher). Check manual for exact BMW specification.
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Engine Oil Capacity:
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Approx. 1.0 - 1.2 liters (dry fill).
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Coolant Type:
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Ethylene Glycol based coolant (e.g., BMW approved coolant or equivalent).
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Brake Fluid Type:
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DOT 4.
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Transmission Fluid:
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CVT systems typically do not have a separate transmission fluid, but the CVT belt and variator require specific maintenance. Gearbox oil for final drive if applicable.
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Known Issues
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Electrical Connections:
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Corrosion in connectors can be an issue over time, especially with exposure to elements.
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Suspension Seals:
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Front fork seals can degrade and leak over time.
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Cv Belt Wear:
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CVT belts have a lifespan and require periodic inspection and replacement.
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