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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Engine assembly, disassembly, inspection, troubleshooting, valve clearance adjustment, piston/cylinder inspection, crankshaft/connecting rod inspection, oil pump operation.
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Fuel System:
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Carburetor (or fuel injection if applicable for the specific model year) disassembly, cleaning, adjustment, fuel pump, fuel filter, fuel tank inspection and cleaning.
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Ignition System:
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CDI unit, ignition coil, spark plug inspection and replacement, timing inspection.
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Transmission Drivetrain:
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Automatic transmission (CVT) operation, belt inspection and replacement, clutch inspection and adjustment, final drive inspection.
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Cooling System:
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Radiator, coolant, hoses, fan operation, thermostat inspection and replacement.
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Electrical System:
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Battery inspection, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, turn signals), horn, wiring diagrams, fuse box, component testing.
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Brakes System:
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Brake fluid replacement, brake pad inspection and replacement, brake caliper overhaul, brake hose inspection, disc inspection, parking brake adjustment (if applicable).
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Suspension Steering:
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Front fork disassembly, inspection, oil replacement, seal replacement. Rear shock absorber inspection and replacement. Steering head bearing inspection and adjustment. Swingarm bearing inspection.
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Chassis Frame:
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Frame inspection, engine mounting inspection, body panel removal and installation, seat removal, luggage compartment access.
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Wheels Tires:
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Tire inspection, pressure check, wheel bearing inspection and replacement, valve stem replacement.
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Procedures Included
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Routine Maintenance:
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Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain/belt adjustment (if applicable), lubrication points.
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Troubleshooting Diagnostics:
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Step-by-step diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical diagnostic flowcharts.
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Major Repairs:
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Engine rebuild procedures, transmission overhauls, suspension component replacements, electrical system component diagnosis and repair.
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Component Replacement:
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Detailed instructions for replacing specific parts such as brake levers, mirrors, lighting components, seat, body panels, exhaust system.
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Adjustments:
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Carburetor idle and mixture adjustment, throttle cable adjustment, brake lever free play adjustment, parking brake adjustment.
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Wiring Diagrams:
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Includes detailed wiring diagrams essential for electrical troubleshooting and repair.
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Torque Specifications:
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Provides crucial torque values for all critical fasteners, ensuring correct assembly and preventing damage.
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Technical Depth
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Depth Level:
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Comprehensive (covering basic maintenance to full engine rebuilds and electrical diagnostics).
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Diagnostic Tools:
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While not explicitly stated, dealership-level manuals typically include specifications for essential diagnostic tools and test procedures (e.g., multimeter usage for electrical testing).
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Specification Tables:
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Contains comprehensive specification tables for all components, including wear limits, clearances, and operational parameters.
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Engine Specifications
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Primary Engine
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Engine Type:
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Four-stroke, liquid-cooled, SOHC, 4-valve.
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Engine Displacement:
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249.5 cc (referencing typical Majesty 250 variants, confirmation for 2006 model specifically is based on common specifications).
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Bore X Stroke:
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70.0 mm x 64.8 mm (typical for 250cc class, specific value to be confirmed by manual).
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Compression Ratio:
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10.2:1 (typical for this engine class, to be confirmed by manual).
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Performance
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Horsepower:
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Approximately 20-22 hp @ 7,500 rpm (typical for this displacement and type, exact figure in manual).
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Torque:
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Approximately 2.0-2.2 kgf-m (14.5-16.0 lb-ft) @ 5,500 rpm (typical, exact figure in manual).
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Fuel System
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Fuel Delivery:
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Mikuni CV carburetor (likely model BSR40 or similar for the 250cc, exact model in manual) or potentially electronic fuel injection depending on exact market/variant.
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Fuel Type:
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Unleaded gasoline.
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Lubrication
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Oil Type:
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Yamalube 4 (or equivalent API SG, JASO MA certified 10W-40 or 20W-50, manual to specify exact viscosity).
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Oil Capacity:
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Approx. 1.5-1.7 liters with filter change (manual to provide precise capacity).
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 4,000 km or 4 months (typical, manual to provide exact interval and recommended oil).
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Air Filter Cleaning:
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Every 8,000 km (typical, manual to provide exact interval).
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Spark Plug Replacement:
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Every 12,000 km or 12 months (typical, manual to specify spark plug type and gap).
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Brake Fluid Change:
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Every 2 years or 24,000 km (typical, manual to specify fluid type DOT 4).
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Cvt Belt Inspection:
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Every 20,000 km (typical, manual to provide inspection procedure and replacement interval).
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Fluid Specifications
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Coolant Type:
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Permanent type antifreeze coolant, manual to specify Yamaha's recommendation or equivalent.
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Brake Fluid Spec:
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DOT 4 (Manual to confirm)
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Known Issues
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Common Wear Items:
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CVT belt wear, brake pad wear, suspension wear, occasional carburetor jetting issues (if applicable).
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Electrical Gremlins:
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Less common, but potential for connector corrosion or faulty regulator/rectifier over time; manual provides diagnostic steps.
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