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Manual Details
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Coverage Areas
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Systems Covered:
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Engine, Transmission, Drivetrain, Chassis, Suspension, Brakes, Electrical System, Fuel System, Ignition System, Cooling System, Lubrication System, Bodywork, Controls, Troubleshooting, Maintenance, Specifications.
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Page Count
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Estimated Page Count:
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Approximately 200-300 pages (typical for this era and vehicle type)
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Manual Type
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Manual Type:
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Service Repair Workshop Manual
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Language
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Language:
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English
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Format
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Digital Format:
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PDF
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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Disassembly, inspection, repair, and reassembly of engine components including cylinder, piston, rings, crankshaft, connecting rod, camshaft, valves, timing system.
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Fuel System:
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Carburetor adjustment, cleaning, and repair; fuel tank, fuel lines, fuel filter maintenance.
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Ignition System:
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CDI unit, ignition coil, spark plug testing and replacement, stator and pickup coil inspection.
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Transmission Drivetrain:
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Gearbox inspection and repair, clutch operation and adjustment, drive chain maintenance and adjustment, differential (if applicable).
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Suspension Steering:
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Front fork disassembly, service, and adjustment; rear shock absorber service; steering system inspection and adjustment.
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Braking System:
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Brake pad replacement, caliper inspection and service, brake fluid replacement, brake cable adjustment, drum brake maintenance (if equipped).
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Electrical System:
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Wiring diagrams, lighting system, battery maintenance, starter motor, charging system (generator/alternator), fuses, switches.
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Chassis Bodywork:
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Frame inspection, body panel removal and installation, seat, fenders, handlebars, footpegs.
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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 lubrication and adjustment, brake adjustments, general inspection.
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Troubleshooting:
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Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical issues.
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Component Rebuild:
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Detailed instructions for engine top-end rebuild, carburetor overhaul, and brake caliper servicing.
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Adjustments:
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Valve clearance adjustment, carburetor idle speed and mixture adjustment, clutch and throttle cable adjustments.
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Technical Depth
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Depth Of Information:
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Comprehensive, covering everything from basic owner maintenance to full mechanical overhauls, including diagnostic procedures and specifications.
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, Air-cooled, SOHC
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Displacement 200:
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Approximately 195cc (for MOTO 4 200)
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Displacement 225:
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Approximately 223cc (for MOTO 4 225, likely derived from XT225 engine)
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Performance
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Bore X Stroke Typical:
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Variable depending on specific model variant (e.g., 66.0 mm x 57.0 mm for 225cc class)
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Fuel System
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Carburetor Type:
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Mikuni VM Series or similar constant velocity carburetor
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Fuel Grade:
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Unleaded gasoline, typically 87 octane or higher
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Maintenance
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Service Intervals
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Engine Oil Change:
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Every 1,000 km or 3 months, whichever comes first (typical recommendation)
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Air Filter Cleaning:
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Every 500 km or as needed based on operating conditions
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Spark Plug Replacement:
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Every 6,000 km or as needed
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Valve Clearance Check:
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Every 10,000 km or 1 year
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Fluid Specifications
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Engine Oil Type:
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Yamalube 4 (or equivalent SAE 10W-30 API SE, SF or SG)
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Engine Oil Capacity:
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Approximately 1.5 - 1.8 Liters (including filter, refer to manual for exact capacity)
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid
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Known Issues
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Common Wear Item:
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Carburetor jets can become clogged over time due to fuel varnish; brake components may require regular cleaning and adjustment.
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Electrical Component Longevity:
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Age-related degradation of wiring insulation and electrical connectors can occur; CDI units can be a point of failure.
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Suspension Wear:
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Front fork seals and rear shock absorbers can wear out, leading to leaks and reduced damping performance.
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