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General| Fuel System | Carburetor |
|---|---|
| Cooling | Air-cooled |
| Transmission | Automatic CVT |
| Rear Brake | Drum |
| Tires Front | 100/80-10 |
| Tires Rear | 120/70-10 |
| Length | 1, 700 mm |
| Width | 680 mm |
| Seat Height | 765 mm |
| Engine Type | 4-stroke, single cylinder |
| Front Brake | Disc |
| Max Torque | 6.5 Nm @ 5, 500 rpm |
General safety and maintenance rules for vehicle operations.
Details on vehicle prefixes and identification numbers.
Specifications for vehicle weight, width, length, wheelbase, and height.
Technical specifications of the engine, including bore, stroke, and capacity.
Description of the transmission system with variator and clutch.
Components and specifications of the vehicle's electrical system.
Details on chassis type, front and rear suspension.
Specifications for front and rear brake systems.
Detailed specifications of the Keihin CVK 20 carburettor.
Specific torque values for various assembly components.
Clearances for cylinder and piston assembly.
Dimensions and quantities for piston sealing rings.
Axial clearance specifications for crankshaft and connecting rod.
Procedure for measuring piston protrusion and compression ratio.
Table of recommended lubricants and products.
Specific tools for various repair and maintenance operations.
Essential tools for general maintenance and repair tasks.
Scheduled maintenance tasks based on mileage intervals.
Procedure for disassembling, washing, and checking the carburettor.
Procedure to check and adjust spark advance using a stroboscopic gun.
Procedure for checking, adjusting, and replacing the spark plug.
Procedure for checking and replacing rear hub oil.
Procedure for cleaning and replacing the air filter.
Information on engine oil usage, consumption, and replacement.
Procedure for changing the engine oil and cleaning the mesh filter.
Procedure for checking and aligning ignition timing.
Procedure for checking and adjusting valve clearance.
Procedure for adjusting headlight beam position.
Procedure for checking and adjusting CO levels in exhaust.
Possible causes and operations for excessive fuel consumption.
Troubleshooting for clutch malfunctions and irregular functioning.
Causes and solutions for low engine compression.
Common causes and corrective actions for poor engine performance.
Common issues and solutions for difficulty starting the engine.
Causes and solutions for high oil consumption and smoky exhaust.
Causes and solutions for insufficient engine lubrication pressure.
Troubleshooting for rear brake lever, clutch, braking efficiency, and overheating.
Troubleshooting for battery, turn indicators, and other electrical malfunctions.
Troubleshooting for steering clearance and suspension noise.
Key for understanding the electrical diagram components.
Details on the vehicle's ignition system.
Diagrams and key for headlights and automatic starter.
Procedures for battery recharging and starting the vehicle.
Diagrams and key for level indicators and enable signals.
Diagram and key for the vehicle's turn signal lights.
Procedures for checking ignition system components like stator and pick-up.
Procedure to check voltage regulator for malfunctions.
Test procedures to check the electrical starter motor.
Information about the electrical system fuse.
Procedure for using a sealed battery for the first time.
Maintenance procedures for dry-charge batteries.
Procedure for removing the exhaust assembly.
Steps for removing the engine from the vehicle chassis.
Procedures related to the automatic transmission.
Procedure for removing the driven pulley shaft bearing.
Procedure for removing the driven pulley assembly.
Procedure for inspecting the clutch drum diameter and eccentricity.
Procedure for removing the clutch assembly.
Procedure for inspecting the driven fixed half-pulley and its bearings.
Procedure for inspecting the driven sliding half-pulley and its bushing.
Procedure for inspecting the clutch spring length and thickness.
Procedure for refitting the clutch assembly.
Procedure for checking the drive belt condition and width.
Procedure for checking the driving pulley's bushing, rings, and rollers.
Procedure for refitting the driving pulley assembly and belt.
Procedure for removing the hub cover and intermediate gear.
Procedure for removing wheel axle bearings.
Procedure for inspecting the hub shaft for wear or distortion.
Procedure for refitting the wheel axle bearing.
Procedure for removing and refitting the cooling hood.
Procedure for removing the stator and its wiring.
Procedure for refitting the stator and flywheel.
Procedure for removing the starter motor.
Procedure for removing the flywheel magneto.
Inspection of flywheel magnets, splines, and stator components.
Procedure for removing the rocker-arms cover.
Procedure for removing the timing system drive components.
Procedure for removing the cylinder head.
Procedure for removing the valves.
Procedure for removing the cylinder and piston assembly.
Procedure for inspecting the piston and piston rings.
Procedure for inspecting the cylinder's inner diameter and surface.
Procedure for inspecting piston rings and their clearances.
Procedure for selecting the correct base gasket thickness.
Procedure for refitting the cylinder and tightening head nuts.
Procedure for inspecting timing system components like guide shoes.
Procedure for inspecting valve guides for wear.
Procedure for inspecting valve stem diameter and clearance.
Procedure for inspecting the camshaft and bearings.
Procedure for refitting the head and timing system components.
Procedure for splitting the crankcase halves.
Procedures for removing and refitting crankshaft oil seals.
Procedures for removing and inspecting the oil pump.
Procedure for emptying and cleaning the fuel tank and cock.
Procedure for detaching the carburettor from the engine.
Procedure for checking the carburettor float level.
Procedure for inspecting the automatic choke device.
Procedure for adjusting engine idle speed and CO levels.
Procedure for removing and refitting the front wheel.
Procedure for overhauling the front wheel hub.
Procedures for removing and refitting the handlebar.
Procedure for overhauling the front fork.
Procedures for refitting and removing steering column components.
Procedure for removing the rear wheel.
Procedures for removing and refitting shock absorbers.
Procedure for replacing the centre stand.
Procedure for removing, overhauling, and reassembling the front brake caliper.
Explanation of the floating caliper's functioning principle.
Procedure for refitting the brake caliper and bleeding the system.
Procedure for removing and refitting the front brake disc.
Procedure for removing, checking, and refitting front brake pads.
Procedure for filling and bleeding the front brake system.
Procedure for removing and refitting the front brake pump.
Procedure for removing and refitting rear drum brake shoes.
Procedure for removing the ignition key-switch in the 'off' position.
Procedure for removing the ignition key-switch in the 'lock' position.
Procedure for removing the footrest assembly.
Procedure for removing and disassembling the air filter housing.
Procedure for removing the rear mudguard.
Procedure for removing the helmet compartment.
Procedure for removing the fuel tank.
Checkpoints for appearance, paintwork, and plastic fitting.
Inspection of critical tightening torques and safety locks.
Checks for the vehicle's electrical system components.
Checking of hydraulic brake fluid, hub oil, and engine oil levels.
Procedures for conducting a road test.
Static controls after the test ride.
Checks for functional operation of various vehicle systems.
Repair times for engine removal, refitting, and oil change.
Repair time for engine crankcase replacement.
Repair times for crankshaft and related components.
Repair times for cylinder-piston assembly replacement and inspection.
Repair times for cylinder head gasket, valves, and head replacement.
Repair times for valve clearance adjustment and camshaft replacement.
Repair times for driven pulley, clutch, and bell housing.
Repair times for oil pump components and chain.
Repair times for variator, half-pulley, driving pulley, and drive belt.
Repair times for transmission cover and related parts.
Repair times for starter motor, sprocket wheel, lever, and kick starter.
Repair times for stator, flywheel, oil filter, and cooling fan.
Repair times for intake manifold, air cleaner fitting, choke, and carburettor.
Repair times for muffler and exhaust emissions adjustment.
Repair times for air filter and air filter box replacement/cleaning.
Repair times for stand, stand bolt, and frame replacement.
Repair times for front shield components and footrest.
Repair times for rear shield components like trunk levers and glove box.
Repair times for central cover components like fairing and luggage rack.
Repair times for front and rear mudguard replacement.
Repair times for fuel tank cap, float, hose, valve, and breather.
Repair time for rear shock absorber removal and refitting.
Repair times for steering column components and adjustment.
Repair times for handlebar cover components and odometer glass.
Repair times for handlebar components like mirrors, levers, grips, and throttle control.
Repair times for engine/frame swinging arm fitting and replacement.
Repair times for saddle and passenger handgrip replacement.
Repair times for front and rear turn indicators and bulbs.
Repair times for front wheel axle, bearings, tyre, and brake disc.
Repair times for rear wheel tyre, rim, and brake pads/shoes.
Repair times for electrical system, voltage regulator, and control unit.
Repair times for lights switch, horn button, starter button, and lock series.
Repair times for odometer and brake transmissions.
Repair times for front brake hose, pads, caliper, and fluid system.
Repair times for steering column components and front suspension.
Repair times for helmet compartment and battery cover.
Repair times for gear reduction unit, wheel axle, and gear box oil.
Repair times for secondary air connection, filter, housing, and reed.
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