Manual Coverage
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Systems Covered
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Engine Mechanical:
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Engine teardown, assembly, cylinder head, piston, crankshaft, connecting rod, timing, valve adjustment.
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Fuel System:
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Carburetor (Dell'Orto PHBH 28 or similar), fuel pump, fuel lines, fuel tank, fuel filter.
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Ignition System:
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CDI ignition, spark plug specifications, ignition timing, stator, pickup coil.
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Exhaust System:
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Exhaust pipe, silencer, lambda sensor (if applicable), emissions control.
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Cooling System:
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Radiator, coolant, water pump, thermostat, hoses, fan.
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Transmission Clutch:
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Clutch operation, clutch plates, pressure plates, gearbox, gear shift mechanism, lubrication.
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Chassis Frame:
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Frame inspection, alignment, steering head bearings, swingarm, rear suspension linkages.
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Front Suspension:
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Telescopic forks, oil levels, seals, damping adjustments, fork springs, maintenance.
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Rear Suspension:
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Monoshock absorber, spring preload adjustment, damping settings, linkage bearings.
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Brakes Front:
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Brake calipers, brake discs, master cylinder, brake fluid specifications, bleeding procedures, pad replacement.
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Brakes Rear:
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Brake caliper, brake disc, master cylinder, brake fluid specifications, bleeding procedures, pad replacement.
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Wheels Tires:
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Wheel bearing maintenance, tire pressure, tire replacement, wheel balancing, spoke tension.
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Electrical System:
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Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams.
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Instrumentation:
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Speedometer, tachometer, fuel gauge (if applicable), indicator lights, sensor diagnostics.
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Bodywork:
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Fairings, seat, fuel tank cover, fenders, mounting points, cosmetic repairs.
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Procedures Included
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Scheduled Maintenance:
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Oil changes, filter replacement, spark plug checks, chain adjustment, lubrication points.
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Troubleshooting:
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Diagnostic flowcharts, common problems and solutions, electrical fault finding.
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Repair Procedures:
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Step-by-step instructions for component removal, installation, and repair.
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Overhaul Rebuild:
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Detailed procedures for engine, gearbox, and suspension component overhauls.
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Specifications Data:
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Torque values, clearances, fluid capacities, electrical resistance values.
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Technical Depth
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Depth:
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Professional-level workshop manual covering all aspects from basic maintenance to full engine rebuilds and advanced diagnostics.
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Engine Specifications
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Primary Engine
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Engine Type:
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Single-cylinder, 2-stroke, liquid-cooled
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Displacement:
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124.7 cc (cubic centimeters)
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Bore X Stroke:
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54 mm x 54.5 mm (typical for this model)
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Compression Ratio:
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Approx. 12.2:1 (typical for this model)
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Power Output:
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Approx. 15 hp (11 kW) at 9000 rpm (Europe, A1 license compliant) - higher in some markets.
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Torque:
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Approx. 12 Nm (8.8 lb-ft) at 8500 rpm (typical for this model)
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Performance
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Top Speed:
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Subject to rider skill, gearing, and local regulations; typically around 110-120 km/h (68-75 mph).
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Fuel System
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Carburetor:
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Dell'Orto PHBH 28 CD or similar, with automatic oil injection (separate from fuel tank).
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Fuel Type:
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Unleaded gasoline (min. 95 RON recommended)
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Oil Injection:
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Automatic 2-stroke oil mixing system.
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Maintenance
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Service Intervals
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Oil Change:
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Every 3,000-5,000 km or annually, engine oil and gearbox oil (refer to manual for specific grade and interval).
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Spark Plug Check:
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Every 3,000-5,000 km or annually. Replacement interval may vary based on plug type.
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Chain Maintenance:
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Clean and lubricate every 500-1000 km or after riding in wet conditions. Adjust tension as needed.
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Air Filter Cleaning:
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Inspect every 3,000-5,000 km, clean or replace as needed.
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Coolant Replacement:
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Typically every 2 years or as specified by the coolant manufacturer.
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Fluid Specifications
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Engine Oil Grade:
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SAE 10W-40 or 15W-50, API SG or higher (confirm with specific manual recommendations).
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Gearbox Oil Grade:
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SAE 75W-90 or 80W-90, API GL-4 or GL-5 (confirm with manual).
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Brake Fluid Type:
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DOT 4
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Coolant Type:
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Ethylene glycol-based coolant with anti-corrosion inhibitors (50/50 mix with distilled water).
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Known Issues
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Common Problems:
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Carburetor jetting sensitivity to altitude/temperature, potential for sticky power valve due to carbon buildup, wear on steering head bearings, fork seal leaks.
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