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Manual Coverage
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Systems Covered
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Engine:
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Detailed engine disassembly, assembly, tuning, and troubleshooting including fuel system, ignition, lubrication, and cooling
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Transmission:
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Clutch, gearbox, shift mechanism, and lubrication system service
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Chassis:
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Frame, suspension (front fork and rear shock absorber), steering, and swingarm
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Brakes:
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Front and rear hydraulic brake systems, including caliper, master cylinder, and fluid service
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Electrical System:
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Wiring diagrams, lighting, ignition system, battery, charging system, and troubleshooting
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Fuel System:
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Carburetor (Keihin FCR40), fuel pump, fuel lines, and maintenance
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Cooling System:
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Radiator, fan, hoses, and coolant specifications
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Exhaust System:
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Muffler, header pipe inspection and maintenance
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Wheels And Tires:
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Wheel bearing service, tire pressure, and replacement
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Procedures Included
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Maintenance:
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Regular scheduled maintenance, oil changes, filter replacements, and lubrication points
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Troubleshooting:
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Diagnostic procedures for common problems, fault codes (if applicable), and systematic problem-solving
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Repair:
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Step-by-step instructions for component replacement, overhaul, and adjustment
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Rebuilds:
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Engine and transmission component rebuild procedures
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Specifications:
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Torque specifications, clearances, and measurements for all components
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Wiring Diagrams:
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Detailed electrical system schematics
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Technical Depth
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Depth:
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Comprehensive, covering basic maintenance to complete engine and chassis rebuilds
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, DOHC, liquid-cooled, single cylinder
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Displacement:
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449 cc (27.4 cu in)
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Bore X Stroke:
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96.0 x 62.1 mm (3.78 x 2.44 in)
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Compression Ratio:
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12.0:1 (typical)
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Performance
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Horsepower:
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Approx. 52 hp @ 8,500 rpm (specifications may vary slightly by year and tuning)
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Torque:
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Approx. 47 Nm (34.5 lb-ft) @ 6,500 rpm (specifications may vary slightly by year and tuning)
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Fuel System
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Carburetor:
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Keihin FCR40 (Flat CR) with Acceleration Pump
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Fuel Type:
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Unleaded gasoline (91 octane or higher recommended)
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Lubrication
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Oil Type:
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SAE 10W-40 API SG or higher motorcycle specific oil
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Oil Capacity:
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Approx. 1.2 L (1.3 US qt) with filter change
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Cooling System
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Coolant Type:
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High-quality ethylene glycol based coolant with distilled water (50:50 mix)
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Ignition
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Ignition System:
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Digital CDI
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 1,000 km (600 miles) or 6 months, whichever comes first, or more frequently under severe use.
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Air Filter Cleaning:
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Cleaned every 500 km (300 miles) or more often in dusty conditions.
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Spark Plug Replacement:
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Recommended every 6,000 km (3,700 miles) or as needed based on inspection.
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Valve Clearance Check:
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Every 6,000 km (3,700 miles) or 12 months.
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Fluid Specifications
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Brake Fluid:
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DOT 4
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Coolant Capacity:
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Approx. 1.1 L (1.2 US qt)
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Known Issues
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Common Wear Items:
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Clutch plates, chain and sprockets, fork seals, and wheel bearings are common wear items for this type of motorcycle.
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Carburetor Tuning:
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Keihin FCR carburetors may require occasional fine-tuning based on altitude, temperature, and modifications.
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Common Issues
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Engine Starting:
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Intermittent starting issues can sometimes be related to the starter clutch or battery condition, detailed in the manual.
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