Manual Coverage
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Systems Covered
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Engine:
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Disassembly, assembly, inspection, repair, tuning of the 348cc air-cooled engine
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Fuel System:
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Carburetor (Mikuni BSR33) adjustment, cleaning, overhaul, fuel tank, fuel pump
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Cooling System:
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Air cooling system components and inspection
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Ignition System:
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CDI, ignition coil, spark plug, timing verification
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Exhaust System:
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Muffler, exhaust pipe inspection and replacement
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Transmission:
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Clutch operation, gear shifting mechanism, lubrication
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Drivetrain:
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Shaft drive system, universal joints, differential inspection and maintenance
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Suspension:
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Front and rear suspension systems, shocks, springs, A-arms, linkages
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Brakes:
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Front and rear drum brake systems, brake shoe inspection, adjustment, hydraulic system (if applicable)
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Steering:
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Handlebar assembly, steering stem, tie rods, steering knuckle inspection and repair
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Wheels Tires:
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Wheel bearing inspection, tire pressure, tire replacement
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Electrical System:
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Wiring diagrams, lighting, starting system, charging system (stator, regulator/rectifier), battery maintenance
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Frame Chassis:
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Frame inspection for damage, welding repairs, component mounting points
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Bodywork Plastics:
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Fender, body panels, seat, rack inspection and removal/installation
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Procedures Included
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Maintenance:
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Regular maintenance checks, lubrication points, fluid changes, filter replacements
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Troubleshooting:
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Diagnostic charts for common problems, symptom-based solutions
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Repair:
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Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly
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Adjustment:
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Carburetor idle and mixture, brake free play, clutch cable
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Disassembly Assembly:
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Complete breakdown and reassembly procedures for major components
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Torquing Specifications:
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Critical fastener torque values for engine, chassis, and suspension components
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Technical Depth
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Depth:
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In-depth, factory-level repair and diagnostic information suitable for professional mechanics and advanced DIY enthusiasts
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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, air-cooled, single-cylinder
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Displacement:
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348cc
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Bore X Stroke:
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83.0 mm x 64.5 mm
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Compression Ratio:
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8.2:1
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Ignition:
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CDI (Capacitor Discharge Ignition)
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Performance
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Horsepower:
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Estimated 20-22 HP (at crankshaft, manufacturer dependent)
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Torque:
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Estimated 20-22 lb-ft (at crankshaft, manufacturer dependent)
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Fuel System
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Carburetor Type:
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Mikuni BSR33, single, slide-type
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Fuel Capacity:
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Approximately 3.3 gallons (12.5 liters), including reserve
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Lubrication
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Oil Type:
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Yamalube 4 (or equivalent 10W-40 or 20W-40 API SG or higher, SE/SF may be acceptable based on manual)
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Oil Capacity:
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Approximately 1.7 Liters (1.8 US qt) without filter change, 1.9 Liters (2.0 US qt) with filter change
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Spark Plug
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Plug Type:
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NGK DPR7EA-9 (or equivalent)
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Gap:
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0.8 - 0.9 mm (0.031 - 0.035 in)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000 km (1,800 miles) or 6 months, whichever comes first (or as per manual recommendation)
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Air Filter Cleaning:
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Every 1,000 km (600 miles) or monthly, or as needed based on operating conditions
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Spark Plug Inspection:
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Every 2,000 km (1,200 miles) or annually
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Valve Clearance Check:
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Every 6,000 km (3,600 miles) or 2 years
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Fluid Specifications
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Engine Oil Spec:
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Yamalube 4 (or equivalent SAE 10W-40 or 20W-40 API SG or higher)
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Gear Oil Spec:
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Yamalube Gear Oil (or equivalent SAE 80 hypoid gear oil)
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Brake Fluid Spec:
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DOT 3 or DOT 4 brake fluid (ensure manual confirms for drum systems if any hydraulic components are present, usually for clutch/master cylinder if applicable)
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Known Issues
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Common Wear Items:
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Brake shoes, wheel bearings, drive shaft U-joints, carburetor needle valve
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Carburetor Fouling:
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Can occur with infrequent use or poor fuel quality, requiring cleaning and adjustment.
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Drivetrain Maintenance:
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Regular greasing of U-joints and inspection of driveshaft boots is crucial.
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