Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, assembly, disassembly, tuning, performance modifications, internal components (pistons, crankshaft, valves, camshafts), lubrication system, cooling system.
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Fuel System:
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Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), carburetor specifications (if applicable to specific sub-models), fuel tank, fuel lines, emissions control system.
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Transmission:
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5-speed manual transmission with reverse, clutch operation, gear shifting mechanism, transmission disassembly and assembly, lubrication, performance upgrades.
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Drivetrain:
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Shaft drive system, rear differential, CV joints, wheel hub assemblies, chain drive maintenance (if applicable), sprocket replacement.
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Suspension:
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Front and rear suspension systems, shock absorbers, springs, A-arms, linkages, adjustments, tuning for different terrains, replacement procedures, bearing services.
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Brakes:
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Hydraulic disc brakes (front and rear), brake calipers, brake pads, brake fluid specifications, bleeding procedures, master cylinder, brake lines, parking brake system.
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Electrical System:
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Wiring diagrams, ignition system (CDI, spark plug specifications), starting system (starter motor, battery), charging system (stator, rectifier/regulator), lighting system (headlights, taillights, indicators), sensors, ECU (Engine Control Unit) diagnostics.
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Cooling System:
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Radiator, cooling fan, coolant specifications, coolant flow, water pump, thermostat, flushing and refilling procedures.
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Frame And Bodywork:
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Chassis inspection, frame straightening, plastic panel removal and installation, seat, handlebars, footpegs, bodywork repair and replacement.
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Wheels And Tires:
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Tire size specifications, inflation pressures, wheel bearing maintenance, lug nut torque specifications, tire replacement.
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Procedures Included
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Maintenance:
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Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, battery maintenance, brake inspection, coolant checks, general lubrication.
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Troubleshooting:
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Systematic diagnostic procedures for common and uncommon problems, fault finding charts, error code interpretation (if applicable).
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Repair:
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Detailed step-by-step instructions for component removal, installation, and repair for all major systems.
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Disassembly And Assembly:
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Complete instructions for taking apart and reassembling all major components and sub-assemblies.
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Torque Specifications:
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All critical fastener torque values for engine, chassis, suspension, and drivetrain components.
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Technical Depth
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Depth:
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Comprehensive, covering from basic routine maintenance to complete engine rebuilds and advanced diagnostics.
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