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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete disassembly and reassembly of the 125cc Rotax engine, including cylinder, piston, crankshaft, connecting rod, bearings, seals, and gaskets.
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Fuel System:
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Carburetor adjustment and overhaul (likely Dell'Orto or similar), fuel lines, fuel pump, fuel filter.
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Ignition System:
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CDI ignition system, spark plug specifications, ignition timing, troubleshooting ignition faults.
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Cooling System:
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Radiator, coolant flow, water pump, thermostat, fan operation, coolant specifications, bleeding procedures.
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Transmission Drivetrain:
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Automatic transmission (likely CVT - Continuously Variable Transmission), clutch operation, variator, torque converter, drive belt inspection and replacement, final drive.
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Electrical System:
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Wiring diagrams, battery specifications, charging system (alternator/stator), starter motor, lighting, horn, switches, fuses, troubleshooting electrical circuits.
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Chassis Frame:
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Frame inspection, welding points, steering head bearings, center stand, side stand.
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Suspension Front:
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Front fork overhaul, oil specifications, seal replacement, spring rates, damping adjustments.
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Suspension Rear:
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Rear shock absorber specifications, adjustment, linkage lubrication, swingarm bearings.
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Brakes Front:
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Front brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications.
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Brakes Rear:
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Rear brake caliper service, brake pad replacement, master cylinder overhaul, brake fluid specifications (DOT 4), bleeding procedures, rotor specifications.
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Wheels Tires:
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Wheel bearing inspection and replacement, tire pressure specifications, recommended tire sizes.
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Bodywork Fairings:
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Panel removal and installation, fairing repair, seat removal, storage compartment access.
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Procedures Included
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Routine Maintenance:
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Oil change intervals and specifications, air filter cleaning/replacement, spark plug replacement, chain/belt adjustment, brake adjustments.
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Engine Rebuild:
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Detailed step-by-step instructions for full engine disassembly, inspection, component replacement (piston, rings, bearings, seals), and reassembly with torque specifications.
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Carburetor Overhaul:
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Complete carburetor disassembly, cleaning, reassembly, jetting adjustments, and idle speed settings.
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Brake System Service:
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Bleeding the brake system, replacing brake pads and rotors, servicing brake calipers and master cylinders.
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Suspension Fork Rebuild:
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Front fork oil change, seal replacement, and general overhaul procedures.
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Electrical Troubleshooting:
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Diagnosis of common electrical issues using wiring diagrams and multimeter testing.
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Troubleshooting Guides:
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Diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical problems.
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Technical Depth
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Depth Level:
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Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.
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Engine Specifications
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Primary Engine
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Engine Type:
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2-stroke, liquid-cooled, single-cylinder, Rotax
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Displacement:
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124.8 cc (125cc class)
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Bore X Stroke:
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Approximately 54 mm x 54.5 mm (typical for this engine) - specific data may vary, check manual.
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Compression Ratio:
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Likely around 7.0:1 to 8.0:1 (for 2-stroke) - specific data in manual.
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Performance
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Horsepower Output:
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Approx. 14-15 HP at 7,500-8,500 RPM (estimated, performance tuning can vary)
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Torque Output:
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Approx. 1.3-1.4 kgf-m at 7,000-7,500 RPM (estimated)
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Fuel System
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Carburetor Model:
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Likely Dell'Orto PHVB 26 or similar
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Fuel Delivery:
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Carburetor
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Fuel Type:
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Unleaded gasoline (RON 95 or higher recommended)
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Oil Mixing:
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Automatic oil injection system
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Lubrication
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Engine Oil Type:
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2-stroke specific engine oil (e.g., Motul 510, Castrol Power 1 TTS) - specific viscosity (e.g., SAE 7.5W-30) and API rating (e.g., API TC, JASO FD) in manual.
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Transmission Oil Type:
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Gear oil (e.g., SAE 80W-90) - specific capacity and API GL-4 rating in manual.
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 3,000-4,000 km or annually. Specific interval in manual.
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Air Filter Cleaning:
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Every 2,000-3,000 km or as needed based on operating conditions. Replacement recommended every 6,000-8,000 km.
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Spark Plug Replacement:
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Every 5,000-6,000 km. Specific plug type (e.g., NGK CR7E or similar) in manual.
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Drive Belt Inspection:
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Inspect every 5,000 km, replace as needed (typically around 10,000-15,000 km depending on usage).
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Brake Fluid Flush:
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Every 2 years or as per manual recommendation. Use DOT 4 brake fluid.
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Fluid Specifications
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Coolant Type:
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Ethylene glycol-based coolant with anti-corrosion additives. Mixing ratio 50/50 with distilled water recommended. Specific brand/type in manual.
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Known Issues
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Common Problems:
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Wear on CVT components (variator rollers, clutch shoes), carburetor tuning issues, potential for 2-stroke engine wear if not maintained properly, electrical connections can corrode.
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