Manual Coverage
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Systems Covered
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Engine:
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Complete engine overhaul, disassembly, assembly, and component specifications.
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Fuel Supply System:
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Carburetor systems, fuel pump, fuel lines, and related components.
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Cooling System:
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Radiator, coolant flow, thermostat, water pump, and associated plumbing.
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Electrical System:
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Wiring diagrams, ignition system, lighting, battery, charging system, starter motor, and controls.
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Chassis Parts:
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Frame, suspension (front and rear), wheels, brakes, steering, and bodywork.
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General Information:
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Vehicle identification, safety precautions, torque specifications, general maintenance philosophy.
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Service And Setting Up:
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Initial setup procedures, routine maintenance checks, and adjustments.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, spark plug service, chain adjustment.
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Repair:
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Step-by-step instructions for disassembly, repair, and reassembly of all major components.
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Troubleshooting:
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Diagnostic procedures for identifying and resolving common and uncommon issues.
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Component Replacement:
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Detailed guides for replacing wear items and malfunctioning parts.
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Technical Depth
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Depth:
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Complete rebuild procedures, including detailed torque specifications, clearances, and assembly sequences.
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Illustrations:
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Hundreds of photos and illustrations to guide repair procedures.
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Engine Specifications
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Primary Engine
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Engine Type:
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Single-cylinder, four-stroke.
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Displacement:
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652 cc (Cubic Centimeters).
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Bore X Stroke:
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Typically around 100 mm x 82.6 mm (Exact figures to be confirmed within the manual).
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Valve Train:
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SOHC (Single Overhead Camshaft), 4 valves.
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Cooling Method:
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Liquid-cooled.
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Performance
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Horsepower Approx:
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Around 48-50 HP at the crankshaft (Exact figures to be confirmed within the manual).
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Torque Approx:
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Around 58-60 Nm at the crankshaft (Exact figures to be confirmed within the manual).
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Fuel System
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Fuel Delivery:
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Carburetor(s) (likely a single Mikuni or similar).
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Fuel Type:
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Unleaded gasoline.
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Fuel Tank Capacity:
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Approximately 16-18 liters (Exact figures to be confirmed within the manual).
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically 5,000-7,500 km or annually (Exact interval to be confirmed in manual).
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Chain Maintenance Interval:
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Regular cleaning and lubrication recommended every 500-1,000 km or after riding in wet/dirty conditions.
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Major Service Interval:
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Often around 10,000-15,000 km, involving valve checks, etc. (Specific intervals detailed in manual).
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Fluid Specifications
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Engine Oil Type:
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API SG/SH/SJ or ACEA A2/A3, Viscosity SAE 10W-40 or 15W-50 (Specific Aprilia recommendations to be confirmed in manual).
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Coolant Type:
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Ethylene glycol-based antifreeze coolant (e.g., Motul Motocool, Castrol Radicool SF) mixed with distilled water (50/50 ratio). (Specific Aprilia spec in manual).
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Brake Fluid Type:
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DOT 4 (Specific Aprilia recommendations to be confirmed in manual).
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Known Issues
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Common Wear Items:
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Clutch plates, fork seals, wheel bearings, rear shock absorber (especially if not regularly maintained).
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Electrical Concerns:
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Occasional issues with rectifier, stator, or wiring harness connections due to age and vibration (Manual will provide diagnostic procedures).
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Fuel System Issues:
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Carburetor clogging if fuel is left in for extended periods, or due to poor fuel quality. (Manual provides cleaning and tuning guides).
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