Manual Details
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Coverage Areas
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Systems Covered:
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Engine, Transmission, Chassis, Electrical System, Bodywork, Suspension, Braking System, Cooling System, Fuel System, Exhaust System, Lubrication System, Ignition System, Starting System, Lighting System, Instruments, Controls, Body Panels, Seat, Fairings, Wheels, Tires, Frame.
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Page Count
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Estimated Pages:
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200-300
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Manual Type
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Type:
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Parts Catalog / Parts List
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Language
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Language:
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English (likely, typical for European market parts lists)
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Format
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Format:
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Printed Booklet / PDF (digital formats are common for parts lists)
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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Cylinder head, piston, crankshaft, connecting rod, valves, camshaft (if applicable), timing system, oil pump.
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Fuel System:
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Carburetor (likely for 2003 models), fuel pump, fuel lines, fuel filter, fuel tank.
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Cooling System:
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Radiator, water pump, coolant hoses, thermostat, fan.
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Ignition System:
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Spark plug, ignition coil, CDI unit, wiring.
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Exhaust System:
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Exhaust pipe, muffler, gaskets, clamps.
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Transmission Drive:
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V-belt, variator, clutch, torque converter, drive pulleys, driven pulleys, gearbox components (if applicable for scooter).
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Suspension Front:
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Front forks, steering bearings, front axle, brake caliper mounting.
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Suspension Rear
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Rear Suspension:
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Shock absorber(s), swingarm, rear axle, engine mounting.
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Braking System Front
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Front Brakes:
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Brake disc, brake pads, brake caliper, master cylinder, brake lever, brake line, brake fluid reservoir.
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Braking System Rear
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Rear Brakes:
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Brake disc/drum, brake pads/shoes, brake caliper/drum assembly, rear brake lever, brake line, brake fluid reservoir.
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Electrical System
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Lighting:
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Headlight bulbs, taillight bulbs, turn signal bulbs, indicator lights, wiring harnesses for lighting.
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Instruments Controls:
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Speedometer, tachometer, fuel gauge, indicator lights, switches, levers, throttle grip, handlebar assembly.
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Starting Charging:
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Starter motor, battery, starter relay, ignition switch, stator, rectifier/regulator.
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Bodywork Chassis
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Frame Structure:
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Main frame, subframe, engine mounting points, steering head assembly.
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Panels Fairings:
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Front fairing, side panels, leg shields, seat, rear cowl, storage compartment, mudguards.
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Wheels Tires:
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Wheel rims, spokes (if applicable), wheel bearings, tire sizes, valve stems.
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Procedures Included
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Parts Identification:
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Detailed diagrams with exploded views and part numbers for all components.
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Assembly Disassembly:
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Illustrations showing how parts fit together, essential for ordering correct components.
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Interchangeability:
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Identification of superseded or interchangeable parts.
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Technical Depth
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Depth:
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Comprehensive listing of all original manufacturer parts, including fasteners, seals, and small components.
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Maintenance
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Service Intervals
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Oil Change Frequency:
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Every 3,000-5,000 km or annually, depending on usage and oil type.
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V Belt Inspection:
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Every 5,000-10,000 km for inspection and potential replacement.
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Spark Plug Replacement:
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Every 5,000-10,000 km, or as per specific spark plug manufacturer recommendation.
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Fluid Specifications
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Engine Oil Type:
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Semi-synthetic or fully synthetic 2-stroke oil, specific API/JASO rating required (e.g., JASO FD/FC).
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Transmission Oil Type:
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Specific gear oil for automatic transmissions, e.g., SAE 80W-90 or equivalent.
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Coolant Type:
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Ethylene glycol-based antifreeze, diluted with distilled water (typically 50/50 mix).
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Brake Fluid Type:
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DOT 4 brake fluid is common.
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Known Issues
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Common Wear Items:
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V-belt, clutch shoes, brake pads, suspension bushings, variator rollers, spark plugs, air filter.
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Potential Electrical Faults:
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Wiring harness issues, faulty rectifier/regulator, ignition coil problems.
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Engine Specific Concerns:
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Carbon build-up in 2-stroke engines, potential for oil leaks, cooling system leaks if not maintained.
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