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Manual Coverage
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Systems Covered
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Engine Overhaul:
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Complete disassembly, inspection, repair, and reassembly procedures for the 125cc two-stroke engine.
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Cooling System:
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Radiator, hoses, thermostat, coolant specifications, bleeding procedures.
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Fuel System:
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Carburetor identification, adjustment, disassembly, cleaning, jetting, fuel pump (if applicable), fuel tank, fuel lines.
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Ignition System:
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CDI unit, spark plug specifications, ignition timing, stator, coil testing.
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Exhaust System:
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Exhaust pipe, silencer maintenance, packing replacement.
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Transmission And Drivetrain:
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Clutch assembly, gearbox disassembly/reassembly, gear inspection, chain and sprocket maintenance, lubrication.
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Suspension Front:
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Front fork disassembly, seal replacement, oil type and level, damping adjustments, spring preload.
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Suspension Rear:
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Monoshock absorber, linkage system, bearing maintenance, shock oil, gas pressure, spring adjustments.
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Braking System Front:
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Brake caliper, master cylinder, brake lines, brake pads, rotor inspection and replacement, fluid specifications, bleeding.
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Braking System Rear:
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Rear brake caliper, master cylinder, brake lines, brake pads, rotor inspection and replacement, fluid specifications, bleeding.
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Wheels And Tires:
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Wheel bearing maintenance, spoke tension, tire pressure recommendations, tire replacement.
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Electrical System:
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Wiring diagrams, lighting system, battery maintenance, fuse locations, switch operation.
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Frame And Bodywork:
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Frame inspection, subframe, plastic body panel removal/installation, seat, fuel tank mounting.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacement, chain lubrication, air filter cleaning/replacement, spark plug checks, brake checks.
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Troubleshooting:
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Diagnostic charts for common problems, symptoms, and solutions.
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Engine Repair:
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Piston and cylinder inspection/replacement, crankshaft and connecting rod service, valve clearance (if applicable, though unlikely for 125 2T), reed valve inspection.
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Suspension Rebuild:
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Detailed steps for fork seal replacement, shock absorber servicing.
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Electrical Diagnostics:
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Testing of charging system, ignition components, and lighting circuits.
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Clutch Adjustment And Service:
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Cable adjustment, clutch plate replacement.
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Carburetor Tuning:
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Jetting recommendations for different altitudes and conditions, idle speed adjustment.
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Technical Depth
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Diagnostic Information:
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Includes specifications for measurements, tolerances, and test procedures.
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Repair Procedures:
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Step-by-step instructions with diagrams for most mechanical and electrical repairs.
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Technical Specifications:
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Torque values, clearances, fluid capacities, electrical specifications.
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Parts Identification:
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Likely includes part numbers and exploded views for component identification (though not a dedicated parts catalog).
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Maintenance
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Service Intervals
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Oil Change Interval:
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Transmission oil: Recommended every 10-15 hours of riding or annually (verify in manual).
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Air Filter Cleaning:
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Recommended after every few rides, depending on conditions.
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Spark Plug Replacement:
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Check and clean every 10-15 hours, replace as needed (refer to manual for specific type).
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Chain And Sprocket Inspection:
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Check tension and wear before every ride; lubricate frequently.
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Fluid Specifications
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Coolant Type:
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Ethylene Glycol based coolant with corrosion inhibitors (specific type and mix ratio in manual).
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Brake Fluid Type:
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DOT 4 Hydraulic Brake Fluid (verify in manual).
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Known Issues
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Clutch Wear:
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Common in 125cc two-strokes with aggressive riding; clutch plates may require replacement sooner than expected.
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Carburetor Tuning Sensitivity:
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Two-stroke carburetors can be sensitive to altitude and temperature changes, requiring frequent jetting adjustments for optimal performance.
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Power Valve Maintenance:
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The exhaust power valve system requires regular cleaning and lubrication to prevent sticking and ensure proper operation.
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