Manual Coverage
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Systems Covered
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Engine:
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Engine disassembly, assembly, lubrication, cooling, fuel system, ignition system, starting system, exhaust system, emissions control.
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Transmission:
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Clutch operation, gear shifting mechanism, transmission disassembly and assembly, oil specifications.
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Drivetrain:
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Shaft drive system, differential, wheel hub assembly, bearing specifications.
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Suspension:
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Front and rear suspension systems, shock absorbers, linkages, adjustments, overhaul procedures.
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Brakes:
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Hydraulic brake system, caliper overhaul, brake pad replacement, bleeding procedures, disc specifications.
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Electrical:
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Wiring diagrams, charging system, lighting system, ignition system components, electrical troubleshooting, diagnostic codes.
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Chassis Frame:
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Frame inspection, steering system, handle bar assembly, foot peg mounting.
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Bodywork Trim:
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Body panel removal and installation, seat assembly, fender mounting, decal application.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, lubrication points, valve clearance adjustments.
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Troubleshooting:
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Diagnostic charts, symptom-based troubleshooting, common problem resolution.
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Repair:
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Component overhaul, part replacement, assembly and disassembly procedures for all major systems.
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Diagnostics:
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Fault code interpretation, electrical system testing, mechanical component testing.
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Specifications:
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Torque specifications, tolerances, clearances, fluid capacities, electrical resistance values.
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Technical Depth
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Depth Level:
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Comprehensive; covers from basic maintenance to full engine and transmission rebuilds.
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Diagnostic Capability:
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Advanced diagnostic procedures and troubleshooting for all electronic and mechanical systems.
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, SOHC, 4-valve, liquid-cooled, single-cylinder
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Engine Displacement:
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686cc
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Bore X Stroke:
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100.0 mm x 85.5 mm
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Compression Ratio:
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9.2:1
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Fuel Delivery:
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Mikuni 44mm throttle body, EFI (Electronic Fuel Injection)
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Ignition:
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TCI (Transistor Controlled Ignition)
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Performance
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Horsepower Estimated:
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Approx. 45-50 HP (at crankshaft, varies by region/tuning)
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Torque Estimated:
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Approx. 45-50 lb-ft (at crankshaft, varies by region/tuning)
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Fuel System
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Fuel Type:
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Unleaded gasoline (91 octane or higher recommended)
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Fuel Tank Capacity:
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3.7 US gal (14 L)
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Cooling System
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Cooling Method:
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Liquid-cooled
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Coolant Type:
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Yamaha All-Weather Water-Cooled Engine Antifreeze (or equivalent ethylene glycol-based)
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 1000 km or 6 months, whichever comes first.
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Air Filter Cleaning:
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Every 500 km or 3 months, or more frequently in dusty conditions.
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Spark Plug Inspection:
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Every 2000 km or 12 months.
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Valve Clearance Adjustment:
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Every 4000 km or 24 months.
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Fluid Specifications
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Engine Oil Specification:
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Yamalube 4 (API SG, SAE 20W-40) or equivalent JASO MA certified 4-stroke motorcycle oil.
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Engine Oil Capacity:
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2.00 US qt (1.90 L) without filter change, 2.10 US qt (2.00 L) with filter change.
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Brake Fluid Type:
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DOT 3 or DOT 4 hydraulic brake fluid.
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Known Issues
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Common Wear Items:
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Clutch plates, brake pads, wheel bearings, tie rod ends, suspension bushings due to high-performance use.
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Efi System Notes:
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The EFI system generally provides reliable operation but requires proper maintenance; manual details troubleshooting specific to EFI.
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Engine Performance Notes:
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Regular cleaning of the throttle body and proper spark plug maintenance are crucial for optimal EFI performance.
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