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Key specifications for the BR-500, including dimensions, performance, and engine details.
Essential guidelines for safe operation, assembly, and handling of parts and fluids.
Specific torque values for engine and flywheel cover fasteners and nuts for proper assembly.
Explanation of throttle, brake, and starting procedures for vehicle operation.
Explanation of symbols and displays on the digital LCD speedometer for vehicle information.
Daily checks required before driving to ensure safety and prevent damage.
Explanation of gear shifting, parking, and differential lock controls for safe vehicle operation.
Recommended maintenance intervals for engine oil, filters, brakes, and other components.
Instructions for coolant level inspection, replacement, and system bleeding.
Step-by-step guide for replacing engine oil and oil filter, including torque values.
Information on idle speed control via EMS and checking throttle cable clearance.
Overview of the forced circulation cooling system, components, and airflow.
Steps for filling the cooling system with the correct coolant mixture and bleeding air.
Checks to perform before thermostat disassembly, including diagnostic tester use and visual inspection.
Identification of key electric parts like ECU, Fuel Pump, Ignition Coil, sensors, and controllers.
Details on battery type, precautions, recharging procedures, and removal.
Step-by-step instructions for safely removing the engine from the vehicle, including fluid drainage.
Steps to remove the transmission gearbox, including CV joints, muffler, and mounting bolts.
Steps for removing and replacing front wheels, emphasizing not to disassemble castle nuts.
Procedure for checking and adjusting front wheel toe-in alignment using tie rods.
Instructions for checking steering wheel operation, turn mechanism rubber, and tie-rod nuts.
Procedure for checking brake fluid level, filling, and bleeding air from calipers.
Steps for dismantling, inspecting, and installing front brake calipers and pads.
Steps for dismantling, inspecting, and installing rear brake calipers and pads.
Overview of the injection system, safety precautions, and troubleshooting basics.
Details about the integrated injection and ignition system, its parameters, and components.
Steps for troubleshooting EMS system failures, focusing on connections and components.
Description of the fuel feeding system, its components, and safety warnings.
Troubleshooting guide for the revolution sensor and its circuit, including resistance and continuity checks.
Troubleshooting the coolant temperature sensor and its circuit, including resistance and voltage measurements.
Guide to resetting the TPS for optimal carburetion and idle management.
Troubleshooting the stepper motor circuit, checking its steps, and diagnosing failures.
Information on lubricating, cleaning, and handling parts related to the final reduction assembly.
Instructions for removing bands, water pump cover, and draining engine oil.
Checks for O-ring condition, starter motor installation, and intermediate gear lubrication.
Identification of parts related to the driving shaft crankcase assembly.
Overview of the lubrication system, divided into high and low pressure sections.
Assembly operation drawing for pre-delivery inspection of the BR-500.
Detailed steps for the assembly procedure during pre-delivery inspection.
A checklist of essential checks to perform before delivering the kart to the customer.
Time chart for engine component repairs, listing job numbers, parts, and standard hours.
Time chart for chassis component repairs, listing codes, descriptions, and labor hours.
Reference table for quantities and torque values related to final reduction components.
General| Fuel Capacity | 6.5 liters |
|---|---|
| Front Brake | Disc |
| Rear Brake | Drum |
| Front Suspension | Telescopic Fork |
| Engine | 4-stroke |
| Transmission | CVT |
| Engine Type | Air-cooled, 4-stroke |
| Starting System | Electric |
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