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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete overhaul, disassembly, inspection, assembly, and troubleshooting for engine components.
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Engine Management:
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Ignition system, fuel injection system, emissions control, ECU diagnosis and repair.
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Transmission Drivetrain:
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Clutch system, gearbox operation, internal components, maintenance, and repair.
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Suspension Steering:
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Front and rear suspension systems, steering components, geometry, and alignment procedures.
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Brakes:
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Brake system components (master cylinder, calipers, discs), hydraulic system, bleeding procedures, troubleshooting.
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Electrical System:
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Wiring diagrams, battery, charging system, lighting, starter, ignition switch, sensors, actuators, and troubleshooting.
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Fuel System:
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Fuel tank, fuel pump, fuel filter, injectors, pressure regulation.
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Cooling System:
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Radiator, coolant, thermostat, water pump, fan operation.
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Exhaust System:
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Exhaust manifold, catalytic converter, muffler, lambda sensors.
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Body Chassis:
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Frame, body panels, seat mounting, subframes, and related hardware.
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Wheels Tires:
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Wheel specifications, tire fitment, balancing, and inflation.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement.
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Troubleshooting:
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Systematic diagnostic procedures for common and uncommon faults.
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Repair Procedures:
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Step-by-step instructions for component removal, replacement, and reassembly.
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Diagnostic Procedures:
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Guidance on interpreting diagnostic trouble codes (DTCs) and using diagnostic tools.
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Engine Rebuild:
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Detailed instructions for complete engine disassembly and rebuild, including torque specifications.
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Suspension Geometry Adjustment:
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Procedures for setting and adjusting steering and suspension alignment.
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Electrical Component Testing:
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Methods for testing starters, alternators, ignition coils, and sensors.
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Technical Depth
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Diagnostic Capabilities:
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Advanced diagnostics including component testing, circuit analysis, and system interpretation.
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Repair Scope:
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Comprehensive repair coverage from minor adjustments to major component overhauls.
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Special Tools:
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Identification and usage instructions for specialized tools required for specific repairs.
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Torque Specifications:
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Detailed torque values for critical fasteners across all systems.
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Schematics Diagrams:
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Inclusion of detailed electrical schematics and mechanical diagrams.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Refer to manual for specific intervals based on usage (e.g., operating hours or mileage).
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Air Filter Cleaning:
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Frequent cleaning recommended, especially in dusty conditions. Refer to manual.
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Chain Lubrication Adjustment:
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Regularly inspect and adjust chain tension and lubricate. Refer to manual.
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Spark Plug Replacement:
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Refer to manual for recommended replacement intervals.
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Fluid Specifications
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Engine Oil Type:
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Refer to manual for specific API service classification, viscosity grade (e.g., SAE 10W-40 or 15W-50), and manufacturer specifications.
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Engine Oil Capacity:
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Refer to manual for exact oil capacity with and without filter change.
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Coolant Type:
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Ethylene glycol-based antifreeze mixture. Refer to manual for exact ratio and type.
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Brake Fluid Type:
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DOT 4 recommended. Refer to manual for specific DOT classification.
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Known Issues
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Typical Wear Items:
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Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals are common wear items on competition bikes.
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Electrical Connections:
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Ensuring clean and tight electrical connections is crucial for reliable operation, especially in off-road environments.
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Air Filter Sealing:
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Proper sealing of the air filter is vital to prevent dirt ingress into the engine.
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