Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete disassembly, inspection, overhaul, and reassembly of the K100 inline-four engine.
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Fuel System:
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Bosch L-Jetronic fuel injection system, injectors, fuel pump, pressure regulator, throttle bodies.
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Ignition System:
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Electronic ignition system, coils, spark plugs, timing.
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Cooling System:
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Liquid cooling system, radiator, water pump, thermostat, coolant hoses, fan.
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Transmission Drivetrain:
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5-speed manual transmission, clutch assembly, final drive, driveshaft, universal joints.
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Brake System:
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Front and rear disc brakes, hydraulic system, brake calipers, master cylinder, ABS (if equipped).
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Suspension System:
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Front telescopic forks (potentially with electronic adjustment on later models), rear monoshock suspension, swingarm, linkage.
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Electrical System:
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Wiring diagrams, battery, alternator, starter motor, lighting system, instrumentation, fuse box.
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Chassis Frame:
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Steel trellis frame, fairing removal and installation, body panels, seat.
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Wheels Tires:
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Wheel bearing replacement, tire mounting and balancing, rim specifications.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable, though K-series is shaft drive).
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Troubleshooting:
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Diagnostic procedures for common engine, electrical, and mechanical faults.
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Engine Rebuild:
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Detailed steps for engine overhaul, including piston replacement, ring installation, valve work, bearing replacement.
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Transmission Repair:
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Clutch adjustment and replacement, transmission gear inspection and replacement.
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Suspension Overhaul:
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Fork seal replacement, shock absorber inspection and replacement.
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Electrical Diagnostics:
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Fault finding using wiring diagrams, component testing.
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Brake System Service:
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Brake pad replacement, caliper service, bleeding the brake system.
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Technical Depth
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Depth Level:
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Comprehensive Workshop Level: Covers all aspects from basic maintenance to complete engine and transmission rebuilds.
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Diagnostic Coverage:
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Includes detailed diagnostic charts and troubleshooting trees for identifying and resolving issues.
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Specification Accuracy:
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Provides precise torque specifications, clearances, fluid capacities, and wear limits.
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Engine Specifications
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Primary Engine
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Engine Type:
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Four-stroke, transverse four-cylinder inline
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Displacement:
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1000cc (approx. 987cc)
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Bore X Stroke:
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67 mm x 70 mm
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Compression Ratio:
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10.2:1
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Valvetrain:
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SOHC, 2 valves per cylinder
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Cooling System:
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Liquid-cooled
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Performance
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Horsepower:
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Approx. 90 hp @ 8,000 rpm
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Torque:
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Approx. 9.2 kgm (90 Nm) @ 6,500 rpm
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Fuel System
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Fuel Injection System:
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Bosch L-Jetronic electronic fuel injection
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Fuel Type:
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Unleaded gasoline, 95 RON recommended
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Lubrication
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Oil Capacity:
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Approx. 4.5 liters (with filter change)
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Oil Specification:
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SAE 10W-40 API SG or equivalent
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 10,000 km or 1 year, whichever comes first.
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Filter Change Interval:
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With every oil change.
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Spark Plug Interval:
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Every 20,000 km or 2 years.
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Valve Clearance Check:
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Every 20,000 km or 2 years.
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Coolant Flush:
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Every 2 years.
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Fluid Specifications
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Engine Oil:
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SAE 10W-40 API SG or higher.
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Transmission Oil:
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API GL-5, SAE 75W-90.
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Brake Fluid:
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DOT 4.
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Coolant:
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BMW Advanced Coolant or equivalent (50% ethylene glycol and distilled water).
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Known Issues
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Fuel Injector Seals:
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Potential for degradation leading to fuel leaks or rough running.
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Charging System Issues:
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Voltage regulator or alternator failures can occur.
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Brake Line Aging:
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Rubber brake lines can degrade over time, requiring replacement.
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Fuel Pump Reliability:
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Early K-series fuel pumps can be a point of failure.
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Suspension Wear:
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Fork seals and rear shock absorbers may require service/replacement due to age.
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