Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete engine disassembly, assembly, inspection, and repair of all internal components (pistons, rings, connecting rods, crankshaft, cylinder head, valves, camshafts, timing system).
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Fuel System:
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Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, throttle body, fuel lines, fuel tank, evaporative emission control system.
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Ignition System:
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Ignition coil, spark plug, crankshaft position sensor, CDI unit, wiring diagrams for ignition.
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Cooling System:
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Radiator, water pump, thermostat, coolant hoses, fan operation, coolant type and capacity.
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Exhaust System:
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Exhaust manifold, catalytic converter, muffler, oxygen sensors, lambda sensors.
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Transmission:
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CVT (Continuously Variable Transmission) system: variator, torque driver, drive belt, driven pulley, clutch, gears, lubrication, and overhaul procedures.
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Brakes:
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Front and rear hydraulic brake systems, brake calipers, master cylinders, brake fluid type, bleeding procedures, brake pad replacement, rotor inspection and replacement.
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Suspension:
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Front telescopic fork: oil type, level, seal replacement, fork leg disassembly. Rear shock absorber and swingarm: lubrication, adjustment, replacement.
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Steering:
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Handlebar assembly, steering stem, bearings, lubrication, adjustment, and replacement.
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Electrical System:
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Battery, starter motor, alternator, lighting system (headlight, taillight, indicators), horn, fuses, relays, wiring harnesses, fault finding with wiring diagrams.
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Chassis And Bodywork:
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Frame inspection, fairing removal and installation, seat, storage compartments, footrests, body panel torque specifications.
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Diagnostic Troubleshooting:
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Detailed diagnostic flowcharts and procedures for identifying and resolving common and uncommon issues across all systems.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements (oil, air), spark plug replacement, coolant checks and changes, brake fluid flushes, chain/belt inspection and adjustment (if applicable, though likely shaft/CVT). Detailed service intervals.
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Component Disassembly Reassembly:
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Step-by-step instructions for removing, disassembling, inspecting, repairing, and reassembling major and minor components.
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Troubleshooting Guides:
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System-specific troubleshooting charts to diagnose problems efficiently, including symptom-based diagnosis.
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Torque Specifications:
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Precise torque values for all critical fasteners throughout the vehicle, ensuring proper assembly and preventing damage.
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Electrical Diagnostics:
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In-depth electrical troubleshooting, including use of multimeters, interpretation of wiring diagrams, and testing of sensors and actuators.
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Rebuild Procedures:
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Detailed instructions for complete engine rebuilds, transmission overhauls, and suspension component overhauls.
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Technical Depth
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Depth Level:
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Comprehensive: Covers everything from basic owner maintenance to full professional-level repair and diagnostics.
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Diagnostic Capability:
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Advanced: Includes information on ECU (Engine Control Unit) diagnostics and potential fault codes (OBD if applicable).
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Maintenance
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Service Intervals
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First Service:
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1,000 km or 6 months
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Subsequent Service Intervals:
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Every 6,000 km or 12 months (includes engine oil and filter change)
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Major Service Intervals:
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Includes CVT belt check/replacement, valve clearance check, spark plug replacement at prescribed intervals (e.g., 12,000 km or 24,000 km).
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Fluid Specifications
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Engine Oil Grade:
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SAE 5W-40 Synthetic (API SG/SH/SJ/SL, JASO MA)
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Brake Fluid Type:
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DOT 4
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Coolant Type:
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Ethylene glycol based antifreeze with corrosion inhibitors (e.g., Aprilia Coolant or equivalent).
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Known Issues
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Common Wear Items:
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CVT belt wear, variator rollers, starter motor brushes, voltage regulator, rear shock absorber seals.
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Potential Problems:
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Fuel injector clogging (use quality fuel), thermostat sticking, occasional electrical connector issues.
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Maintenance Parts
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Oil Filter Part Number:
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e.g., AP8102220, HF183 (K&N), KN-183 (K&N)
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Air Filter Part Number:
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e.g., AP257862
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Spark Plug Part Number:
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e.g., NGK CR9EB
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