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General guidelines and safety protocols for vehicle maintenance and operation.
Specifications detailing the vehicle's physical size, weight, and dimensions.
Technical specifications for the vehicle's engine, including type, bore, stroke, and displacement.
Details on the vehicle's gearbox and its operational specifications.
Information on fluid capacities for gearbox, oil tank, and fuel tank.
Overview of the vehicle's electrical system components and specifications.
Data regarding the chassis, suspension system, and frame construction.
Specifications for the front and rear braking systems, including disc and drum details.
Information on wheel sizes, tyre specifications, and recommended tyre pressures.
Detailed specifications for the carburettor, including jets and settings.
Recommended torque values for various fasteners and components during assembly.
Specifications for the crankcase, crankshaft, and connecting rod assembly clearances.
Specifications for gearbox shoulder dimensions and replacement procedures.
List of recommended lubricants and fluids for vehicle maintenance.
Tools for general maintenance and component removal/installation.
Tools for diagnosing system issues and performance.
Tools for specific vehicle systems and components.
Schedule of recommended maintenance tasks based on time or mileage intervals.
Procedures for disassembling, cleaning, and checking the carburettor.
Method for verifying and adjusting ignition timing using a timing light.
Instructions for inspecting, measuring gap, and replacing the spark plug.
Steps for removing, cleaning, and reinstalling the air filter.
Procedure for adjusting the vehicle's headlight beam for optimal visibility.
Instructions for checking, draining, and refilling the gearbox oil.
Key to symbols and color codes used in electrical diagrams.
Visual guide to the location of electrical components on the vehicle.
Conceptual diagram and explanation of the ignition system.
Electrical diagram and component list for the lighting system.
Procedures for battery charging and starter motor operation.
Explanation of safety switches and indicators for fuel and brake fluid levels.
Diagram and components for turn signals, brake lights, and horn system.
Identification of dashboard warning lights and gauges.
Detailed wiring diagram and component identification for the ignition circuit.
Procedure for inspecting and testing the stator for proper function.
Steps for testing the voltage regulator's performance and diagnosing faults.
Bench test procedures and specifications for the starter motor.
Information on fuse types, locations, and replacement precautions.
Instructions for the initial charging and setup of a dry-charge battery.
Steps for removing the exhaust system from the engine.
Detailed procedure for detaching and removing the entire engine from the vehicle frame.
Instructions for removing and reinstalling the flywheel cover and associated components.
Procedure for detaching and removing the stator from the engine.
Guidance on correctly positioning and reinstalling the stator for proper engine timing.
Steps for detaching and removing the starter motor assembly.
Procedure for removing the flywheel magneto using specialized tools.
Instructions for reinstalling the flywheel magneto, including lubrication.
Information on cylinder, piston, and timing system assembly and overhaul.
Guidance on inspecting the small end of the connecting rod and fitting roller cages.
Steps for reinstalling the cylinder, paying attention to piston orientation.
Procedures for splitting the crankcase and accessing the crankshaft.
Method for extracting the crankshaft from the crankcase using special tools.
Instructions for removing crankshaft bearings and retaining rings.
Procedures for heating and installing crankshaft bearings and sealing rings.
Explanation of the automatic fuel mixer system and its lubrication process.
Steps for removing and servicing the oil pump assembly.
Procedures related to the fuel system, including carburettor removal.
Instructions for reinstalling the carburettor, emphasizing seal replacement.
Procedure for removing and overhauling the manual gear shifter mechanism.
Detailed steps for separating the crankcase halves, including gear removal.
Instructions for refitting the trunnion onto the gear shifter shaft and related procedures.
Specification for axial play in the gear shaft and the tool for measurement.
Information on clutch removal and inspection of components.
Steps for removing the clutch assembly, including locknut and disc removal.
Procedures related to the front suspension system and its components.
Instructions for the removal and refitting of the handlebar.
Specific instructions for refitting the handlebar and associated parts.
Procedures for removing, overhauling, and refitting the steering column assembly.
Steps for removing and refitting the front shock absorber.
Details on the connection and service of the shock absorber and caliper bracket.
Procedure for removing the rear shock absorber and associated components.
Steps for overhauling the wheel hub and replacing sealing rings.
Procedures related to the rear suspension components, including wheel removal.
Instructions for removing and replacing rear shock absorbers.
Procedure for removing and refitting the vehicle's centre stand.
Instructions for removing, refitting, and bleeding the front brake caliper.
Procedures for removing, refitting, and inspecting the front brake disc.
Method for checking the brake disc for flatness and potential replacement.
Steps for removing, replacing, and refitting front brake pads.
Procedure for filling and bleeding the front brake system with new fluid.
Instructions for removing and refitting the front brake pump and bleeding the circuit.
Steps for removing the rear wheel and accessing the drum brake components.
Procedure for removing and refitting the rear brake pedal assembly.
Instructions for removing and refitting the vehicle's seat.
Procedure for removing the rear handlebar cover and accessing the dashboard.
Steps for removing and replacing headlight bulbs and adjusting the headlight.
Procedure for removing and replacing the ignition key-switch cylinder in the 'OFF' position.
Method for removing and replacing the ignition key-switch when keys are missing.
Instructions for replacing taillight bulbs and the entire taillight assembly.
Procedure for removing and refitting the fuel tank and related components.
Steps for removing and refitting the front mudguard.
Instructions for removing the top-case and glove-box assembly.
Procedure for removing the front central cover, horn, and grid.
Steps for removing the side cowlings using the release levers.
Checks for paint, plastic parts, damages, and overall cleanliness before delivery.
Verification of all critical torque settings as per specifications.
Pre-delivery checks for the battery, lights, horn, and dashboard illumination.
Verification of brake fluid, gearbox oil, and oil tank levels.
Comprehensive test drive to evaluate cold start, throttle, brakes, stability, and noises.
Final checks on tire pressure, locks, mirrors, and accessories.
Estimated time for engine removal, refitting, and oil replacement.
Time estimates for crankshaft and bearing replacement or overhaul.
Time estimates for cylinder/piston replacement, overhaul, and spark plug service.
Time estimates for starter motor, brushes, and kick-start lever service.
Time estimates for stator, flywheel, and pick-up replacement or overhaul.
Time estimates for carburettor replacement, overhaul, and adjustment.
Time estimates for fuel level sensor and fuel tank replacement/painting.
Time estimates for steering column bearing, support, and lock replacement/adjustment.
Time estimates for handlebar controls, grips, and brake pump service.
Time estimates for front wheel, tyre, rim replacement, and painting.
Time estimates for ECU/CDI replacement.
Time estimates for battery, voltage regulator, and compartment replacement.
Time estimates for clutch, throttle, and brake cable replacement/adjustment.
Estimated time for front shock absorber removal and refitting.
Time estimates for gearbox component replacement and overhaul.
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