Table of Contents

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1. Intended use & cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Initial assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Pre-ride checks & initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Basic operation & control functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
engine starting & stopping, engine break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5. Control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
brake lever, brake pedal, throttle, bar & lever positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1. Description - diagram of motorcycle components & controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Machine ID & date of manufacture information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Cable & hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Fuel & oil requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Definition of units & conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. Notes & warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2. Maintenance & lubrication schedule chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3. Maintenance preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4. Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5. Air cleaner service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6. Transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
7. Seat removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
8. Fuel tank & gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
9. Front & rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
10. Expansion pipe & muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
11. Control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
12. Plastic care & cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
13. Footpegs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
14. Hoses-vent, fuel, coolant & overflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
15. Reed valve & intake boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
16.1 Engine top end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
inspection & repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
16.2 Crankcase & transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
waterpump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
17. Clutch & kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3 shoe clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2 shoe clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
18. Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
adjustments, disassembly & cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
19. Suspension & chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
wheels & spokes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
front suspension, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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Summary of Contents for Polini X1R

  • Page 1: Table Of Contents

    Page 1 page I. OPERATING INSTRUCTIONS 1. Intended use & cautions ..............3 2.
  • Page 2 Page 2 fork service ................33 rear suspension, adjusting .
  • Page 3: Operating Instructions

    1. Intended use Thank you for purchasing your Polini motorcycle. With proper care and maintenance, your Polini will last for many years and pro- vide unparalleled performance. ALWAYS wear a helmet and other safety gear, respect the environment & local laws, and ride within your abilities.
  • Page 4 Page 4 Begin by cutting the plastic zip tie straps securing the front and rear calipers to their mounting brackets. Install front fender using 4 phillips head screws M6x16 and 4 washers M6x18x1. Install the front wheel next. Spread brake pads enough to accept rotor, then align front wheel with axle holes in forks.
  • Page 5: Pre-Ride Checks & Initial Startup

    Page 5 with masking tape, and notice where any curves and creas- es might occur. The curves and areas where the plastic tapers in 2 directions will be the most difficult areas to apply. When you’ve determined the best fit, tape one edge of the decal securely in place, and remove the tape from the opposite edge.
  • Page 6: Control Adjustment

    Page 6 Break in - The initial startup and running of the engine is crucial for long life and full power potential. Always warm engine for a few minutes before riding motorcycle. Do not idle for extended periods - note that water pump does not circulate when rear wheel is not turning.
  • Page 7: Specifications

    Page 7 idle screw choke choke knob idle fuel metering screw screw fuel metering screw Fuel valve - Off position Idle, fuel metering screw - X1 Choke knob - X1 lift & ⁄ turn to engage choke 2. Specifications Length - X1: 50˝ X3: XX X5: XX Width - X1: 24 ⁄...
  • Page 8: Machine Id & Date Of Manufacture Information

    Page 8 3. Chassis number, production year leave some slack in throttle cable Model & year Chassis number Cable, hose & wiring routing 4. Cable & hose routing Route cables, hoses and wires as per photos II.9 and II.10. Be sure seal cable ends with tape and leave some slack in throttle cable near carburetor.
  • Page 9: Definition Of Units/Conversions

    Page 9 6. Definition of units/conversions 1˝ = 25.4mm 1mm = .0394˝ 1cm = 10mm 1cc = 1 mL = .0338 oz. (fluid) 1 oz. (fluid) = 29.565 mL 1 oz. (weight) = 28.35 grams 1 gram = .035 oz. (weight) 1 liter = 1.057 quarts = 2.114 pints = 4.228 cups 1Nm = .102 m/kg 1m/kg = 9.804 Nm...
  • Page 10: Maintenance, Adjustments, Service Procedures

    Page 10 III. MAINTENANCE, ADJUSTMENTS & SERVICE PROCEDURES 1. Notes & warnings Use caution when working on or around motorcycle. Note that exhaust, engine, cooling system and brake parts may be extremely hot after operation. Be very cautious of moving parts, especially the chain and sprockets which can draw clothing, hair and fingers into sprockets, chain guard or chassis causing severe injury.
  • Page 11: Coolant

    Page 11 4. Coolant Filling cooling system - When engine is cool, unscrew radiator cap slowly to release any pressure safely. Do not open when warm or hot! Fill the radiator until liquid reaches opening. Wait a few minutes for the coolant to reach all the internal cavities, top off coolant as needed.
  • Page 12: Seat Removal

    Page 12 7. Seat removal To remove seat, loosen large screw at rear of seat using a coin, or a wide, flat screwdriver. When screw is loose, lift up slightly on rear of seat and slide seat to rear to remove. To install seat, note slot underneath seat at front.
  • Page 13: Expansion Pipe & Muffler

    10. Expansion pipe & silencer, repacking The exhaust system on your Polini needs regular service to properly quiet the bike and maintain peak power. The silencer uses fiberglass packing to reduce sound. If the packing becomes saturated with oil, or burnt and fragmented the exhaust gases will be much more turbulent in the silencer which will noticeably reduce power output as well as making the bike much louder.
  • Page 14: Control Cables

    Page 14 insert packing into endcap Inserting inner tube and packing into outer body. Repacking silencer - To service silencer, remove right side panel/number plate. Remove bolt and clamp securing silencer to frame using a 6mm allen wrench. Twist and pull silencer off pipe. Remove three bolts at front of muffler using a 4mm allen wrench.
  • Page 15: Reed Valve & Intake Boot

    Page 15 and the swingarm. The radiator overflow tube runs down the front left frame rail. Make sure the transmission vent line is properly secured and pointing to the rear of the bike so it does not tend to gather water. If the line is removed from the vent fit- ting, make sure to always replace it.
  • Page 16 Page 16 lubricate hose with soapy water Remove exhaust extension using 5mm allen wrench. Rotate pipe outward and ease rear portion of pipe through frame. Note position of front wheel. Remove radiator cap & drain coolant using bleed screw Hang radiator to side using rubber o-ring Move radiators to side - remove hose clamp (by prying end of clamp with flat-bladed screwdriv- er) and hose attached to cylinder head.
  • Page 17: Inspection & Repair

    Page 17 Remove cylinder - Lift cylinder straight up on studs. Rock cylin- der to loosen as required - DO NOT pry between cylinder and cases. When cylinder nears top frame rail, angle cylinder rearward to match angle of top frame rail. Using care not to scratch inside of cylinder on studs, slide cylinder forward about 1 inch, then remove cylinder from right side.
  • Page 18: Reassembly

    Page 18 If new rings and/or piston does not seem to restore the normal amount of power and the usual starting and running still suffers, then bring the motor to a machine shop for a thorough inspection using precision measuring tools. This detailed inspection follows below.
  • Page 19: Crankcase & Transmission

    Page 19 Cylinder - Coat both sides of the base gasket with a thin coat of RTV silicone sealer, especially around the water passages. Install the base gasket onto the base of the cylinder and line it up with the casting. Slide the cylinder into position over the cylinder studs, then lower it onto the studs.
  • Page 20: Crankshaft

    Page 20 Use 6mm allen wrench to turn forcing screw and begin to separate cases. See photo III-23. Turn forcing screw a little at a time. If it seems to require a lot of effort, check to make sure all the case bolts have been removed. Do not use screwdriver to pry cases apart! The transmission gears will not be able to sep- arate during this process, so the countershaft will have to pull through the left case as the cases separate.
  • Page 21: Waterpump

    Page 21 properly in place and install 11 case bolts. med. long short bolts Bolts can be gradually tightened in a criss bolts bolts cross pattern to bring cases fully together. Tighten case bolts to 10 ft/lbs. Using a brass hammer, tap gently on both ends of crankshaft to help center crankshaft in cases.
  • Page 22: Clutch & Kickstarter

    Page 22 pulling the gear off the shaft. A disposable spring retainer is used to hold the waterpump shaft assembly into transmission case. Being careful not to damage waterpump shaft, use a screwdriver to pry the retaining ring out of the engine case. It will be necessary to bend or break the retaining ring to remove it.
  • Page 23 Page 23 components as it will damage shoe linings and springs. Install clutch puller. Make sure 3 puller bolts go into clutch hub evenly and as far as possible so they don’t pull the threads out of the hub. To reduce damage to end of crankshaft, put a penny between puller screw and end of crankshaft to help protect it.
  • Page 24 Page 24 Spring installed length Photo of kickstarter mechanism and spring. 2-shoe clutch assembly. Note 2 dowels in case. Adjust springs from 19 - 21mm. Different thickness flat washers ranging from .030˝ to .070˝ are available from Action Racing. Thicker washers will raise the engagement RPM, thinner washers will lower it.
  • Page 25: Shoe Clutch

    Page 25 Two shoe clutch - Refer to three shoe clutch section for removal and replacement of 2 shoe clutch. The engagement RPM of the two shoe clutch New style Old style can be adjusted by loosening or tightening the two nuts on the clutch assem- bly.
  • Page 26: Carburetor

    This is probably the most difficult aspect of working on your Polini, but in time will be one of the most rewarding. Mastery of jet- ting will enable your rider to always have the best tuned bike, which might be just enough for an advantage at that next start or high speed straightaway.
  • Page 27: Testing

    Page 27 Fuel mixture - Reducing the amount of oil in the fuel will cause a richer condition, but engine damage may result if not enough oil is used. (less oil, more fuel = richer jetting) The opposite is also true, more oil will tend to cause a lean condition. Humidity - The more moisture in the air, the less air available.
  • Page 28: Adjustments, Disassembly & Cleaning

    Page 28 code when it is as lean as safely possible. When you have the bike running well, try leaning out 2.46 0.60 the needle position and main jet a little at a time, keeping close tabs on the condition of 2.46 0.60 the spark plug at WOT.
  • Page 29 Page 29 slide lines up with stud inside carburetor body. Make sure top cover gasket is in place and the top cover is in the proper direction. Do not force slide into carburetor. Install two top cover screws. An optional metal slide is available. See photo III-48. Float - To service jets and float assembly, remove slide as above.
  • Page 30: Assembly

    Page 30 Cleaning - If carburetor needs cleaning, remove choke assembly and fuel metering screw. Make sure all the parts come out with the fuel metering screw, including the spring and the tiny metal washer and o-ring. Use carburetor cleaner and/or compressed air to flush out all air and fuel jets and passages.
  • Page 31: Wheels & Spokes

    Page 31 make sure the tire is squeezed together and in the center portion of the wheel so the tire has enough slack to mount. Slide a tire iron under the tire far enough to catch the rim, then push the tire iron up and outward just over 90° to mount that section of tire. Continue using 2 tire irons alternately until the tire is mounted.
  • Page 32: Front Suspension, Adjusting

    Front suspension The Polini uses a conventional hydraulic fork for the front suspension. It can be adjusted by changing the oil volume, oil weight, fork height and spring preload. The standard setting is 160cc of 10wt fork oil for the X1 model, and 180cc for the X3 & X5 models. Lighter riders can try a 7wt oil or mix a 5 and 10wt oil to reduce dampening force.
  • Page 33: Fork Service

    Page 33 measurement again with the rider on the bike. The difference between the measure- ments is the fork sag. Add shim washers under the fork caps if the fork sag is too great, switch to a softer spring if there is too little sag. If the front tire seems to skitter and wash out in bumpy corners, consider using a lighter weight oil to reduce damp- ening forces.
  • Page 34: Rear Suspension, Adjusting

    Page 34 Assembly - Lubricate fork seal lips and inside of fork slider with fork oil. Insert the seal by hand, then use the proper size seal driver or a large socket (shown) to drive seal gently into housing. See photo III- 59.
  • Page 35 Page 35 being turned fully clockwise. (A click is approximately ⁄ turn) See photo III.62. The compression circuit determines the rear wheels resistance to moving quickly upwards, such as when hitting a high speed bump or landing from a jump. Stiffer compression settings will help resist bottoming.
  • Page 36: Shock & Swingarm Removal

    Page 36 Proper maintenance will greatly prolong the life of the shock. The entire shock should be frequently lubricated with WD40, espe- cially the shock shaft. Always spray shock after washing bike. Frequent cleaning and regreasing of the top and bottom bearings will greatly prolong their life.
  • Page 37: Grip Replacement

    Page 37 To grease bearings, remove adjusting nut and remove the steering stem from the chassis from the bottom. Clean the bearings thoroughly and inspect for missing bearings, damage to the bearing cage or ball bearings. See photo III-67. Clean and inspect the ball races on the chassis, the steering stem, and on the steering stem adjusting nut assembly.
  • Page 38: Ignition Timing

    Page 38 Remove the sparkplug (careful, it will still be hot!) and closely examine the insulator of the plug. The insulator is the ceramic portion of the plug just behind the metal tip in the center of the plug. If the insulator is white and appears glazed, the bike is probably too lean.
  • Page 39: Coil & Ignition Assembly

    Page 39 Coil & ignition assembly - The coil and ignition assembly are a one piece unit and have no serviceable parts. One two conductor lead is connected to the stator assembly for power and timing signal. One lead goes to ground through the kill switch to stop the motor.
  • Page 40: Sprockets & Gearing

    Page 40 Chain replacement - Most replacement chains will be longer than needed and will have to be trimmed to size. Remove the old chain by removing the master link. The master link will have a U shaped spring clip holding the chain’s side plate on.
  • Page 41: Chain Roller & Wear Pads

    Page 41 22. Cleaning & storage Before extended periods of storage, observe the following precautions: Clean and dry motorcycle thoroughly. Completely drain fuel tank and carburetor. Spray a little oil into spark plug hole and kick engine over a few times. Change transmission oil.
  • Page 42: Special Tools, Supplies & Chemicals

    CV boot clamp pliers (for hose clamps) inductive tachometer, Northern Hydraulics #160596 (to check clutch engagement rpm) Polini parts book 097.0064 (contains exploded parts diagrams & part numbers) main case splitter tool 144.695.001 (needed to split main cases) clutch puller set (2 & 3 shoe & flywheel) 99029 (this tool is the most useful puller for the price) flywheel puller 144.695.002...
  • Page 43: Troubleshooting Guide

    Page 43 IV. TROUBLE SHOOTING GUIDE Motorcycle won’t start - check for: Spark at plug - if weak or no spark, check coil ground, disconnect kill switch, and check ohm readings for coil & stator. Fouled spark plug - replace, adjust jetting as needed. Fuel flow to carburetor - if no flow from hose, make sure there is gas in tank and fuel valve is on.
  • Page 44: Tips & Tricks

    Page 44 2. tips & tricks Clean the air filter. Change the oil. Clean the clutch. Clean the air filter. Change the oil. Clean the clutch. Repeat... Zip tie carburetor & plug boots! Disposable rubber or nitrile gloves will make messy and dirty tasks a lot less objectionable (like cleaning air filters...) Use tape to seal both ends of throttle cable to boots.
  • Page 45: Www Info, Support Forum, Manufacturers Links

    This manual is ©copyrighted, 2001, by Action Racing and can not be copied or distributed electronically or in print, in whole or in part, except with the permission of Action Racing. The only exception is that owners of Polini motorcycles may make copies for their own use.
  • Page 46: Index

    Page 46 VII. INDEX accessories ....... .42, 43 pads ........13 air filter .

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