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Bajaj Legend

1. Mount the engine on support stand Remove fan cover and cowling A Screws for removal of cowling Remove rear brake drum by following method Straighten bent edges of split pin and pull it out with the help of plier Remove the cap Remove castle nut and washer 2 A GX mS 9 A Castle nut for removal of Rear brake drum Removal of Rear brake drum back plate Hold the brake shoes with a clean cloth to protect the linings from grease and dirt Lift the outer portion of brake shoes turn them upward and remove them Remove the springs to separate the two shoes Remove back plate by removing 3 screws with spring washers Remove 2 O rings amp gasket on c case cover A Screws for Removal of back plate CYLINDER HEAD REMOVAL Take out spark plug cap and spark plug Remove cam chain tensioner by removing 2 bolts fitted on cylinder block Remove intake manifold by removing 3 bolts fitted on cylinder head Remove OHC cover by removing 2 flanged bolts Remove both the caps of valves by using 24 mm spanner Rotate magneto assembly and ensure piston is at TDC and both tappets are free Remove 2 flanged bolts fixing timing chain sprocket on camshaft Slide out timing chain from sprocket and take out sprocket Remove4nutsand2bolts mounting cylinder head on crankcase alongwith 4 special washers Remove cylinder head Take
2. Remove both LH and RH bonnets Drain Engine oil completely by removing drain plug Drain Plug B Nut for rear brake cable Nut for gear shifter assly Disconnect lower ends of rear brake amp clutch cable Remove gear shifter cover and release lower ends of gear cables by unscrewing screw terminals Remove H T Coil by removing 2 screws on crankcase side Disconnect magneto harness coupler from main harness Disconnectchoke and throttle cable from carburettor Disconnect duct from carburettor Disconnect carburettor from intake manifold Disconnect fuel pipe and sensing pipe Remove silencer by removing 2 nuts at the exhaust port of cylinder block and 1 bolt on crankcase arm Remove bolt fixing lower end of rear shock absorber to the engine Hold engine carefully and then remove the bolt fixing crankcase arm with engine mounting link on chassis Hold engine carefully amp remove the bolt fixing c case arm with engine mounting link on chassis 23 Take out the engine carefully from the chassis Take out rear wheel and mount the engine on support stand P No 37 1030 01 m Sya 110255 2688 KETAN CO XO R B Choke cable D Intake manifold A Throttle cable C Screw for Duct qu 55 A Nut for silencer B Nut for mounting engine on link ENGINE DISMANTLING
3. Kick Shaft Assembly Fix circlip for the gear kick on kick shaft and assemble washer on it Assemble gear kick on kick shaft Put one washer on gear kick amp fix circlip on it Assemble ratchet gear on the serrations of kick shaft in such a way that the dot mark punched on the beginning of serrations on kick shaft matches with the dot mark on the ratchet gear Fix coil spring on shaft and put cup kick shaft Fix circlip over the cup kick shaft Assemble kick return spring on the shaft in such a way that hook on inner diameter of spring is located in hole on kick shaft Put nylon spring guide on the kick shaft and fix circlip Cylinder Head Assembly Smear slight amount of grease on valve Pushinletvalve intothe valve guide from combustion chamber side Put spring seat valve spring and valve spring retainer from the other side The loose coil ends of the spring should be facing downwards Use the valve spring compressor to press down the valve spring retainer Install the collets and slowly remove the spring compressor Ensure that the collets are seated properly holding the retainer down Repeat same procedure for exhaust valve Assemble cam shaft Assemble both rocker arms amp then respective pins Fixlocking plate for camshaft and inlet rocker arm pin with the help of screw pan cross Clutch Assembly wheel clutch and assemble plate friction and plate clutch alternatively on it starting wit
4. Improper earthing Switch defective Loose or improper connections L T coil loose connection or short open Horn not working Horn defective Connections loose Switch defective Horn coil defective Brake light remains Sticky switch Vehicle not starting not getting off Ignition ON OFF switch not working For effective overhaul and optimum performance Get fully familiarised with dismantling assembly procedures as given in this manual Always use genuine Bajaj Spares for replacement Use special tools developed for disassembling and assembly procedures XX ua auto Ii
5. Service SAIO VENE MODEL NO 00300728 NOTICE All information contained in this manual is based on the latest product information at the time of publication Bajaj Auto Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible All procedures and specifications subject to change without prior notice The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to product manufactured previously Contact your authorised bajaj dealer for the latest information on product improvements incorporated after this manual was issued DOC NO 36 02 0147 FOREWORD We have pleasure in presenting this Service Manual for Bajaj LEGEND This manual is designed by bajaj auto ltd primarily for use by authorised bajaj dealers and their qualified mechanics However it contains enough details and basic information to make it useful to the vehicle owner who desires to carry out his own basic maintenance and repair work Since a certain basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily the adjustments maintenance and repairs should be carried out only by qualified mechanic If proper adjustment can not be obtained by following the procedures in this manua
6. This manual is intended for use by experienced mechanics and is not intended for use by the general public Therefore please refer to the appropriate Owner s Manual for warnings applicable to this scooter Mechanical repair can be hazardous and is very dangerous if you are inexperienced or unknowledgeable We strongly urge you to never undertake repair operations with which you are not completely familiar The repair operations described in this book must be carried out exactly as described in order to ensure that the scooter is returned to safe condition after you have worked on it Failure to observe this warning can lead to a dangerous condition which could lead to an upset accident serious injury or even death INDEX Page No Identification Data Technical Specification General Information Periodic Maintenance Chart Check and Adjustments during and 1st 2nd 3rd 4th amp 5th Servicing Scheduled Maintenance General Precautions Dismantling assembly Tightening Torques Special Tools Engine Exploded View Dismantling and Assembly Engine Service Data Engine Dismantling and Assembly Chassis Service Data Chassis Electricals Electrical Wiring Diagram Trouble Shooting Guide IDENTIFICATION DATA The chassis and engine serial numbers are used to register the vehicles They are the only means of identifying your particul
7. Keep the vehicle off the stand facing a wall Inflate both front and rear tyres to specified inflation pressure There should be sufficient darkness Keep the vehicle at a distance of 5 meter 16 4 ft from a wall as shown in figure SCREEN HV 1M 3 28 FT VEHICLE OFF THE STAND 5M 16 4 FT Start the vehicle Switch ON the Headlight high beam and then lower beam Check the beam pattern on the wall For correct pattern of High beam amp low beam a screw is provided below Head lamp assly Loose this screw before carrying out adjustment Pressing Head light assly at the top shifts the pattern up and pressing Head light assly at the bottom shifts the pattern down The High beam pattern should be as shown in figure and it should be 1 meter 3 28 ft above the ground The Low beam pattern should be set 5 cm below the HV point as shown in the figure 1M 3 28FT 2M 6 56 FT Low Beam pattern 2M 6 56 FT Hi Beam pattern Screw for head lamp adjustment STEERING Steering play If the steering is too tight it will be difficult to turn the handlebar quickly the vehicle may pullto one side and the steering stem bearings may become damaged If the steering is too loose the handlebar will vibrate and the vehicle will be unstable and difficult to steer in a straight line Inspection Raise the front wheel off th
8. ON position Q Press the Start Button with accelerator in completely closed position Once the engine warms up release choke lever to OFF position When engine is warm While starting warm engine open the accelerator 1 8th to 1 4th and press the Start Button NEVER REV UP THE ENGINE TO HIGHER RPMs IMMEDIATELY AFTER STARTING OR IN NEUTRAL GEAR If the engine is raved to higher RPMs immedi ately after starting it may lead to severe engine damages as lubricating oil take some time to reach all th components Moving from Stand still position Pull the clutch lever and twist the gear control tube upwards in one smooth motion to put the vehicle in 1 gear Release clutch gradually and simultaneously open the throttle gradually to move away from stand still position Don t run vehicle with clutch lever partially depressed or don t slip the clutch to overtake or to climb a gradient This will damage the clutch Downshifting of gears i e Shifting from 4 to 34 to 2 to 1 gear Reduce the speed of the vehicle Depress the clutch lever completely and twist the gear lever upwards and release the clutch lever gradually and increase throttle For further ease of gear shifting slightly open the throttle momentarily while depressing the clutch lever and then twist the gear lever upwards Do not tilt the vehicle towards spare wheel side Engine oil may drain out from the crankcase breather tube and hence there will be a drop
9. Remove guide chain tension by removing the special bolt Take out timing chain Remove oil pump assembly by removing 3 screws Take out dowel pin and two O rings carefully and store them alongwith oil pump Take out screw pan cross and take out oil tube alongwith oil seal Take out baffle by removing 2 screws SPLITING OF CRANKCASE HALVES Take out oil strainer cap bolt alongwith oil strainer mesh Removal of oil strainer Loosen all the 10 nuts fixing crankcase clutch and magneto side together Remove the nuts and take out bolts plain amp spring washers and store them properly o ol 5Y f 20 TS Crankcase joining nuts Gently tap the crankcase magneto side with the help of nylon mallet and take out Remove crankshaft assembly alongwith float control rubber ring Take out mainshaft assembly Remove intermediate shaft by tapping gently from crankcase cover side 2 4 Sy Spliting of crankcase halves B Mainshaft assly C Intermediate shaft assly DISMANTLING OF SUB ASSEMBLIES Crankcase Magneto Side Remove D bolt and nut alongwith plain amp spring washer for kick starter lever Tapthe kick shaft assembly lightly to take it out from crankcase Remove O ring from
10. check and adjust Front rear brake inspection adjustment Overhaul Check battery electrolyte level Apply petroleum jelly on battery terminals Lubricate Front and rear brake levers Control cables gear shifter Brake cam shafts After Speedo pinion gears cable Stand pivot washing Front fork bearing races balls the vehicle Wheel bearings Front suspension Refer Page No 15 Indicates operation to be performed Indicates lubrication by SAE 20W40 of API SC CC grade oil Indicates lubrication by Lithium calcium soap base grease be cleaned more frequently in dusty area Must be performed to maintain emissions warranty CHECK amp ADJUSTMENTS TO BE CARRIED OUT DURING 1st 2nd 3rd 4th amp 5th SERVICING dd Wash and clean the vehicle on receipt Check and correct tyre inflation pressure including that of spare wheel Check all nuts and bolts for tightness especially handle bar bolt engine foundation bolt shock absorber nuts and wheel nuts etc Check Engine oil level and top up if necessary Flush and refill Engine oil Remove and clean air cleaner filter element Clean spark plug adjust the gap and refit Clean the carburettor adjust idling speed Check amp adjust valve clearance Carry out lubrication as per lubrication cha
11. dry the vehicle and carry out the lubrication WARNING Washing your scooter will allowthe brakes to become wet with the same effect as riding on a wet road Whenever the brakes become wet always dry them by gently applying the brakes repeatedly until the heat causes the brakes to dry and full brake function is restored Failure to follow this procedure can lead to loss of brake effectiveness and a serious accident PERIODIC MAINTENANCE Periodic maintenance in accordance with the periodic maintenance chart of a vehicle is most important to prolongits life trouble free running and ensure your safety while driving LUBRICATION To reduce the friction between two moving parts lubricate them periodically Insufficient lubrication will cause rapid wear damaging the parts prematurely Lubricate everytime after washing the vehicle and whenever the vehicle is operated under wet rainy conditions Before lubricating clean off any rusty parts and wipe off old grease oilor dirt Afew drops of oil are effective to keep bolts and nuts away from rusting and sticking This makes removal easier Please refer lubrication chart for details of lubrication ENGINE OIL Check engine oil level daily For proper functioning of cylinder block piston crankshaft tappets clutch and transmission the oil should be maintained at an appropriate level Oil level inspection Place the vehicle on centre stand on a level ground Clean the surf
12. Clutch Side Press ball bearing for intermediate shaft 0 AN Fitment of bearing Assemble of oil pump Assemble 2 O rings for oil pump on the crankcase Assemble hallow dowel pin Assemble oil pump with the help of 3 screws and check freeness of oil pump gear Assemble baffle with the help of 2 screws Assemble rubber bush on the steel tube and press this assembly into the hole on crankcase Fix the tube with the help of a screw Fit oil drain plug alongwith washer Assemble adjuster for clutch cable Crankcase Magneto Side Assemble needle roller bearing with the help of special tool P No 37 1005 04 Q Press magneto side oil seal with the help of special tool P No 37 1030 61 Inner driver 20 Assemble guide kick with help of 2 screws 31 Fitment of oil seal Assemble O ring inside the hole for kick shaft Assemble kick shaft assembly amp intermediate shaft assembly at a time in their respective positions in crankcase Ss E 1 Ke 012427 lt D OZ LED 20 cae E T Kick shaft amp intermediate shaft assembly Rotate kick shaft amp lock the ratchet gear below guide kick Place the kick return spring on kick shaft in such a way that one end should be in the hole provided on kick shaft Place Nylon
13. DOO A CQ N TIGHTENING TORQUES PART NAME NUTS FOR Crankcase to Crankcase Qty 5 Gear shifter housing Qty 2 Cylinder Head Qty 4 Crankshaft clutch side Gear primary spur Crankshaft magneto side Rotor nut Silencer to Cylinder head Crankcase to Crankcase Qty 2 Kick lever BOLTS FOR Cylinder head to Cylinder Block Qty 2 Silencer to Crankcase Qty 1 Cam shaft sprocket Cam chain tensioner adjuster Manifold to Cylinder head Chain tensioner body Cover to Crankcase Oil drain bolt SCREWS FOR Stator plate Screw for oil tube assly Stopper plate Cylinder head Gear shifter cover Guide kick Qty 2 GENERAL Spark plug Cap Cylinder head Oil plug 16 TORQUE Kgm TS 1 5 to 1 8 RTT 1 3 to 1 5 2 0 to 2 2 9 0 to 9 5 5 5 to 6 0 9 0 to 9 5 0 8 to 1 0 5 0 to 5 5 1 3 to 1 5 PO 2 0 to 2 5 VES 1 3 to 1 5 2 0 to 2 5 0 9 to 1 1 ee 3 0 to 3 5 1 1 to 1 3 xx de a 0 8 to 1 0 0 6 to 0 8 MEN 0 6 to 0 8 1 3 to 1 5 2 6 to 3 0 0 6 to 0 8 0 3 to 0 4 VEM 0 6 to 0 8 0 6 to 0 8 0 6 to 0 8 2 5 to 3 0 0 8 to 1 0 2 6 to 3 0 TIGHTENING TORQUES CHASSIS PART NAME TORQUE Kgm NUTS FOR Front shock absorber 3 0 to 3 5 Fuel cock assly on Fuel tank nennen enne 3 0 Engine link mounting on chassis 3 0 to 4 0 Engin
14. O rings small bushes and using suitable punch from bearing driver set P No 371030 61 remove big bushes Ce Removal of Big bushes a of Antidive kink ANTIDIVE LINK ASSEMBLY Assemble L type grease nipple at one end of link and other type of grease nipple at other end of link as shown in sketch Assemble grease nipple P No 35 1710 33 on this hole Assemble grease nipple P No 23 1613 05 on this hole Link assly Press big bushes using suitable punch from bearing driver set P No 37103061 and then assemble small bushes O rings and cup washers on link FRONT BRAKE PANEL ASSEMBLY Using suitable punch from bearing driver set P No 37 1030 61 punch Needle roller bearings into Front Brake panel Apply grease to Needle roller bearings Using suitable punch from bearing driver set punch Grease seal into Front brake panel Assembly of Grease seal Assemble Grease nipple on Front brake panel Insert Front brake Actuating shaft assly into Front brake panel Assemble O ring amp Indicator into Actuating shaft and fit Actuating lever into Actuating shaft by Bolt amp Nut Assembly of Actuating lever a Facing paint mark upward assemble Front brake shoe into Front brake panel Fit spring lock This is done to have proper positioning of Leading and Trailing Brake shoe Assemble Speedometer pi
15. a chance to workup into all engine parts The table given below shows the maximum permissible speed during running Distance Max vehicle speed in in miles gears mph Ist IInd IVth 0 1200 10 20 30 40 STARTING Kick start Turn the Ignition switch to ON position Confirm that the vehicle is in neutral gear turn indica tor switch is OFF and supplementary engine stop switch in RUN position How to operate kick Move the kick slowly Ensure that ratchet is engaged then kick When engine is cold Use CHOKE only for cold starting Do not open throttle Pull the choke lever and operate kick for starting Release the Choke lever to OFF position immediately once the engine starts When engine is warm Do not open throttle while kick starting If the engine fails to start with 2 3 kicks slightly open the throttle not more than 1 4 th turn before kicking STARTING With Self Start Turn the Ignition switch to ON position Confirm that the vehicle is in neutral gear otherwise engine will not start Neutral switch is fitted on gear shifter assly for this purpose as a safety feature Confirm that the turn indicator switch is OFF and supplementary engine stop switch in RUN position Q Press the Start Button to start the engine Release start button as soon as engine starts When engine is cold Pull the choke lever in
16. bar movement changes the idling speed the accelerator cable may be improperly adjusted damaged or improperly routed Rectify any of these conditions before riding Do not attempt to compensate for faults in other systems by adjusting the idle speed Normal idling speed 1200 150 rpm JE SS A Idling adjustment screw C Increase speed B Decrease speed D Air screw REMOVAL OF WHEELS For removal of wheels in case of puncture or Tire rotation follow the procedure given below Front wheel Rotate wheel cover cap in anticlockwise direction and take out Pull wheel cover Remove 5 nuts 3 special amp 2 regular and take out front wheel assly After mounting wheel check the sequence of 5 mounting nuts Front wheel nuts Rear wheel Remove LH cover Remove spare wheel Rotate wheel cover cap in anticlockwise direction and take out Pull wheel cover Tilt the vehicle on engine side Remove 5 nuts 3 special amp 2 regular and take out front wheel assly After mounting wheel check the sequence of 5 mounting nuts Rear wheel nuts Inspection window Installation Install the rear wheel on brake drum studs Install the plain and spring washers Install the nuts andtighten them securely Tightening torque 2 to 2 5 kg m BRAKES Brakes should always be maintained in perfect condition for safety Brake drum wear brake lining wear and brake cab
17. bulb follow the procedure given below Remove 2 screws on Handle bar rear cover holding Handle bar front cover Handle bar cover Rear mounting screws Remove one screw provided on H Bar front cover just below H Light adjustment screw Carefully disengage the locking lugs of handle bar front cover by prying with the help of a small screw driver Disconnect Head Lamp harness coupler Take out Handle bar front cover with head lamp assly Slide bellow from head lamp bulb holder Head light bulb holder Remove bulb holder amp replace bulb Brake Tail light rear blinkers bulb replacement For replacing Tail stop bulb or rear blinkers bulb remove 2 screws for lens take out lens amp replace bulb EEE Removal of screws for lens Front blinker bulb replacement Remove 2 mounting screws for nose grill and take out nose grill Remove 2 mounting screws for blinker and take out blinker assly Take out holder amp replace the bulb HEAD LIGHT BEAM ALIGNMENT The headlight beam can be adjusted vertically and horizontally If adjusted too low neither low nor high beam will illuminate the road adequately If adjusted too high the high beam will fail to illuminate the road
18. gasket leak cylinder head loose Cylinder block piston worn out Worn out piston rings sticky rings Valve seatimproper valve bent carbon accumulation on seating surface INCORRECT RUNNING Lack of Power Spark plug loose Cylinder head gasket leak cylinder head loose Cylinder block piston worn out Worn out piston rings sticky rings Valve seatimproper valve bent carbon accumulation on seating surface 62 00000005 0000000000 Fuel air mixture improper Pilot jet clogged Incorrect position of needle jet Carburettor holder loose Inlet manifold bolt loose Insulator O rings cut or insulator loose Air filter clogged or dry i e oil not applied Fuel supply insufficient from fuel valve excess fuel supply Lack of power at high speed Spark plug gap incorrect H T Coil defective Clutch slippage Main jet clogged or of wrong size Choke stuck open Adulterated fuel Compression weak Insufficient fuel supply from fuel cock Clogged air filter KNOCKING TRICS not working properly i e Ignition timing not returning to 16 BTDC FROM 30 BTDC Excessive carbon build up on piston top Incorrect carburettor setting Adulterated fuel Wrong heat range spark plug CLUTCH SLIPPAGE No clutch lever play Friction plates worn out burnt Steel plates warped or worn out Clutch spring weak Hub clutch unevenly worn out Clutch release mechanism faulty Plunger protruding above crank
19. ifthe accelerator grip has no play control of carburettor throttle valve will be difficult If theinner cable is overstretched idling rpm will be too high and cause improper ignition timing ACCELERATOR PLAY ADJUSTMENT Q Checkthe accelerator play by lightly turningthe grip back and forth Accelerator play can be adjusted by cable adjuster a provided on carburettor Loosen the adjuster lock nut and turn the adjuster until specified free play is obtained Retighten lock nut after adjustment is over ACCELERATOR GRIP PLAY 4 5 MM Adjusters A on Carburettor CAUTION Always maintain correctaccelerator play It is very important for vehicles fitted with TRICS as the ignition timing is regulated by throttle opening IDLING SPEED ADJUSTMENT Whenever the idling adjustment is disturbed follow the procedure given below for setting proper engine idling Open seat lock amp lift the seat Remove engine Start engine amp drive it for atleast 5 kms or warm the engine till the oil temp reaches 80 C Then set the engine idling r p m by rotating the idle adjustment screw clockwise or anticlockwise with the help of a screw driver For the precise adjustment of idling speed use of tachometer is recommended Openandclose the throttle a few times to make sure that the idling speed does not change Readjust if necessary With the engine idling turn the handle bar to either side If the handle
20. in oil level in the crankcase Accidently if the vehicles falls down on spare wheel side ensure correct oil level after lifting and placing the ve hicle on stand Braking For stopping the vehicle smoothly and safely first close the accelerator and then apply front and rear brake simultaneously Using only the front or rear brake is dangerous and cause skidding and loss of control Anticipate your stop well in advance for avoiding sudden braking which may be dangerous Stopping the engine Q Close the throttle Forstopping the engine turn the keyto OFF position of ignition switch Supplementary engine stop switch on RH control Switch can also be used to stop the engine when ignition switch is not to be put off Parking Always prefer to park the vehicle on level ground and on the centre stand Lock the steering cum ignition lock DAILY SAFETY CHECKS Check the following items each day before you ride These checks hardly require any time and habitual performance of these checks will help to ensure a safe reliable ride If any irregularities are found during these checks referto the maintenance chapter or contact an authorised bajaj dealer for the action required to return your vehicle to a safe operating condition Fuel Enough fuel for the planned distance of travel amp check leakage if any Electrical Operation of switches lighting of head tail brake lamp horn sound battery electrolyt
21. in the Hydrometer to eye level and read the gradua tions on the float scale bordering on the lower meniscus i e curved down portion of electrolyte surface as shown in the figure Specific gravity of fully charged Battery at 27 C Room Temperature 1 28 to 1 24 in Tropical climate 1 27 to 1 28 in Cold climate Hydrometer Read here 271 Checking battery specific gravity After charging is over fit the filling caps Wash acid spillage with water Dry the battery Ensure terminals are clean Install the battery on vehicle as described below BATTERY INSTALLATION a Ensure that in all six cells the level of electrolyte is near the maximum level mark b To clean amp dry the surface wipe the top of the battery with a clean cloth Install the battery on its rubber seat Fasten the battery firmly with the band Connect cables to the positive and negative terminals properly Reverse connections will damage the charging system permanently since the DC Regulator may get damaged due to excessive current in the reverse direction d Always connect the negative earthing terminal last e Clean the battery terminals and cable connections Smear them with petroleum jelly to avoid corrosion NEVER USE ORDINARY GREASE f Route the battery exhaust tube properly Do not fold or crimp as it may cause explosion of the battery g Check that the battery cables connections are firm
22. kick shaft from crankcase Take out needle roller bearing for main shaft by using special tool P No 37 1003 02 Removal of needle roller bearing Q Take out oil seal for crankshaft magneto side Removal of crankshaft magneto side oil seal Take out guide kick by removing 2 screws Crankcase Clutch Side Remove ball bearing from crankcase clutch side Removal of ball bearing Crankcase Cover Clutch cover Remove circlip for mainshaft bearing by using circlip plier Remove ball bearing for mainshaftby using extractor P No 37 10BA 56 Remove oil seal for mainshaft 28 Remove the plunger Remove the spring for clutch spindle assembly Take out clutch spindle assembly alongwith internal lever and plain washer Remove O ring Main Shaft Mainshaft assly dismantling Push the cup slightly towards the gear wheels Press both the springs for gear selector against the gear selector with the help of a thin plate or hacksaw blade and lift out the cup from mainshaft Take out 2 springs amp balls carefully Take out circlip alongwith shoulder ring Take out gear wheels one by one Take out shoulder washer and circlip Remove stem after unlocking the lock washer NOTE STEM HAS LEFT HAND THREADING Take out gear selector Remove cross from mainshaft Intermediate Shaft Assembly Remove
23. on cam brake and attachthe other end of spring to crankcase magneto side Prefix O ring on oil strainer nylon mesh Assemble oil strainer on the crank case by holding the lug provided onthe strainer body with the help of a nose plier Assembly of oil strainer Note If the oil strainer is fitted in the reverse way i e lugonthe strainer body goes inside thenthere will not be any oil supply to oil pump Assemble O ring on the cap strainer Assemble the cap strainer along with O ring on the crankcase Assemble rear brake drum on mainshaft Assemble washer and castle nut on mainshaft Tighten the castle nut Fit the cap on castle nut and Fitment of rear brake drum on mainshaft Assemble 2 dowels on crankcase One on clutch side and the other on magneto side block sitting area Assemble gasket for cylinder block Assemble piston assembly on connecting rod with piston pin Assemble circlips on both sides of piston pin Apply slight amount of oil on piston skirt and rings Positioning of rings on piston should be as follows Topring Opening facing towards exhaust side 2ndring Opening facing towards inlet side Oilexpander Opening facing towards inlet side Top oil rail 30 left of exhaust side Bottom oil rail 30 right of exhaust side NOTE Keep Top marking on top and 2nd ring on upper side Keep IN marking on piston top towards intake side Clean cylinder
24. out lower guide chain slack from cylinder block A Bolts for cam chain tensioner assly B Bolts for intake manifold assly A Cap for valve B Bolts for timing chain sprocket C Nuts for cylinder head D Bolts for cylinder head CYLINDER BLOCK PISTON REMOVAL Take out cylinder head as explained above Remove the cylinder head gasket and dowel pins Pry up the cylinder with a suitable tool to free the cylinder from crankcase Lift the cylinder off and guide the cam chain through the tunnel in the cylinder Take out cylinder along with oil seal from piston Removal of cylinder head Remove one of the piston pin snap rings Push out the piston pin and remove the piston Removal of piston assly MAGNETO ASSEMBLY DISMANTLING Remove 4 bolts mounting fan on rotor A Fan mounting bolts 25 Remove rotor nut by holding rotor with the help of rotor holder 37 1030 54 Removal of nut for magneto rotor Remove nut alongwith spring washer By using rotor puller 37 1030 34 take out rotor I 7G 5 24 Removal of magneto rotor Take outstator plate assembly by removing screws 22 L m wi E CN a 7 A Stator plate assly mounting screws GEAR SHIFTER REMOVAL Remove2nuts mounting gea
25. soon fail again Make sure all connectors in the circuit are clean and tight andexamine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system operation Measure coil and winding resistance when the partis at room temperature Colour codes Black Brown Green Grey Blue Light Green Orange Red White Yellow Black Yellow Red White Blue White White Green Yellow Red Black White White Red Red Black Red Yellow THROTTLE REGULATED CONTROL SYSTEM TRICS IGNITION In TRICS Ignition timing varies as per throttle opening Below half throttle ignition timing changes from 16 to 30 in proportion to engine rpm Refer graph IGNITION TIMING 0 1000 2000 3000 4000 RPM IGNITION TIMING BELOW HALF THROTTLE After half throttle ignition timing changes to 16 irrespective of engine rpm Refer graph 2 2 2 e O 2 o IGNITION TIMING AFTER HALF THROTTLE Details of modifications in various parts are as under A Throttle sensor Throttle sensor is provided in Handle bar A signal is passed to C D 1 Unit with the help of this sensor as per position of throttle B Gas control link Gas control link is modified CHECKING PROCEDURES B FRONT amp REAR BRAKE SWITCHES Disconnect the two terminals of the front or rear brake switch and connect an ohmmeter between the two terminals A CONTROL SWITCHES setting iton x 10 ohms range W
26. volume 0 50 litres Initial charging duration 8 12 hrs Initial charging current 0 9 to 1 0A INITIAL CHARGING PROCEDURE 1 Pull of the short plastic tube on the exhaust vent outlet and replace it with the long open tube provided with battery 2 Do not crimp or bend the exhaust tube This is a safety device to remove fumes Blockage of this tube is liable to cause an explosion 3 Fill each cell with dilute sulfuric acid of the correct specific gravity 1 24 at room temp for use above 10 C and 1 28 at room temp for use below 10 C 4 Allow the battery after filling to stand for half an hour 5 Keep vent plugs open Connect battery to charger P No 37 20 3102 and charge at 0 9 6 Charge continuously for 8 to 12 hours taking specific gravity readings every hour Fully charged condition is indicated when all cells are gassing freely and evenly and show no rise in specific gravity over 3 successive readings 7 After charging push vent plugs firmly into place and wash off acid spillage with water and dry the battery CHECKING THE SPECIFIC GRAVITY The charge condition of the individual cell can be checked by measuring specific gravity of electrolyte in that cell The specific gravity of electrolyte can be checked by using Hydrometer having small diameter spout Such a Hydrometer is available in Spare Part Dept or can be directly procured from market For measuring the specific gravity bring the electrolyte
27. 2 027 mm 44 00 46 00 mm 31 50 33 50 mm 1 25 kg cm 18 PSI 1 75 kg cm 25 PSI 2 50 kg cm 36 PSI 3 0 5 0 mm 3 0 5 0 mm 10 0 15 0 mm ELECTRICALS MAINTENANCE amp CHECKING GENERAL PRECAUTIONS There are some important precautions to be taken while servicing electrical system Please follow them Donotreversethebattery lead connections This will burn out the diodes in the electrical parts Always check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damage to electrical parts do not dis connect the battery leads or any other electrical connections when the ignition switch is on or the engine is running Do notuse a meter illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the meter or gauge panel could be warped by excessive heat radiated from the bulb Take care not to short the leads that are directly connected to the battery positive terminal to the chassis ground Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will
28. 9 04 Removal of Needle roller bearing Remove the Circlip locking ball bearing from Front brake drum Tap out ball bearing with the help of suitable punch FRONT BRAKE DRUM ASSEMBLY Fit the ball bearing on Front brake drum by using suitable outer driver from bearing driver set P No While fitting Speedometer gear and Spacer on Front brake drum use Special Tool Outer driver P No 37 1519 04 Metallic portion of Speedometer should face downward while assembling This tool consists of three parts i e a punch a socket head screw and a locating plug Assembling of Speedometer gear and Spacer FRONT BRAKE PANEL DISMANTLING Remove bolt connecting the antidive link with front brake panel 213 UN We 2 Assembling of Ball bearing Fit Circlip locking ball bearing Use suitable punch from bearing driver set for fitting Needle roller bearing in Front brake drum assembly Assembling of Needle roller bearing 44 Removal of Antidive link a Remove spring lock and then remove brake shoe Remove actuating lever along with indicator and 0 ring by removing bolt and nut Remove actuating shaft Remove needle roller bearing by using suitable punch from bearing driver set P No 371030 61 DISMANTLING OF ANTIDIVE LINK AFTER REMOVING FROM FRONT BRAKE PANEL Remove grease nipples Remove
29. ESSURE 12 1 kg cm VALVES Tappet clearance In amp Exh engine cold 0 08 0 12 mm 0 003 to 0 005 Valve Inlet head thickness 0 7 0 15mm Valve Exhaust head thickness 1 0 0 15 mm Valve Inlet stem diameter 5 45 5 51 mm Valve Exhaust stem diameter 5 45 5 48 mm Valve Exhaust guide inside diameter 5 520 5 532 mm Valve spring free length 37 5 mm CAM amp ROCKER Rocker arm inside diameter 10 015 mm Rocker shaft diameter 9 975 9 990 mm Cam height Inlet 30 81 mm Cam height Exhaust 30 44 mm CAMSHAFT CHAIN LENGTH 20 Links 127 00 127 48 mm 36 SERVICE DATA ENGINE SR NO DESCRIPTION STANDARD REMARK CYLINDER PISTON GROUPING Cylinder bore 57 000 57 015 mm Piston diameter 56 979 56 995 mm Measure at 7 mm from bottom Cylinder Piston clearance 0 010 0 029 mm Use Cylinder amp Piston of same group PISTON RING Piston ring groove thickness a Top ring 1 0 mm b Second ring 1 0 mm c Oil 2 0 mm Piston ring thickness a Top ring 1 0 mm b Second ring 1 0 mm Piston ring end gap a Top ring 0 2 0 45 mm b Second ring 0 2 0 45 mm Piston ring gap position Top ring Towards Exhaust side Second ring Towards Inlet side Top oil rail 30 left of Exhaust side Oil expander Towards Inlet side Bottom oil rail 30 right of Exhaust side CRANKSHAFTRUNOUT 0 02 mm CONNECTING ROD BIG END PLAY Axial 0 15 0 35 mm CLUTCH ASSLY Friction plate thickness 3 1 3 3 mm Pr
30. LINDI a HIHOLIAS IOMINOO IAVIS AZI 4WvlavaH Var Var AUN C HD WOLVOIQNI LOTIA NYAL WALAN TANA aax aniano MOSN3S TILLONHL HOLIMS TOULNOD SOIML WSLSAS 1OHLNOO dQ31V 109338 31LLOHH L 1415 54195 HLIM QN393 1 INVHOVIC ONISIM 60 TROUBLE SHOOTING GUIDE This is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the trouble shooting for some of the more common difficulties For details of Electrical Component Checking please refer Electricals Maintenance amp Checking STARTING TROUBLE e o 09 o o 0o o 2 EEEE No fuel supply No Fuel in fuel tank Clogged fuel filter in fuel cock Vacuum line disconnected Leakage from vacuum side of Fuel cock Fuel cock fitment not at 45 angle with respectto fuel tank centre line Flooding Float valve stuck Worn out Fuel cock diaphragm damaged remains open Tank cap air vent obstructed No Spark Weak spark Spark plug dirty broken maladjusted Spark plug cap short Pulser coil short Charging coil short open CDI unit defective Wiring short open Ignition switch short Rotor Key broken Compression Low Spark plug loose Cylinder head
31. NG FOR STARTER MOTOR COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION Starter Motor not A Ensure that the battery is fully working charged Check Specific gravity of electrolyte in each cell It should be as specified Fuse 10 to be intact All terminal screws nuts at the starter motor Earthing point on the engine battery starter relay and the neutral switch should be clean and tightened adequately Ignition switch must be in ON position and engine kill switch in run position Start button pressed Check for 12 V D C supply at the 1 1 No response indicates that 12 V D C starter motor terminal S4 with a supply is not available at the starter motor voltmeter VM D C Range 25V S M terminal S The starter circuit needs to be checked Refer clause 1 2 below If the V M indicates 12V D C supply at the S M Terminal S then the S M is faulty To cross check connect battery VE terminal B1 directly to the S M VE terminal S with a 6 mm cable If the S M does not respond then it should be replaced If the S M is checked as per 2 1 Ifthe click noise is present it indicates that 1 1 1 and no supply is available the relay is operating butthere is no output at the S terminal then cover fromthe Relay Checkfor 12VD C supply the following steps between the input R1 of the Relay and Hear for click noise of the starter chassis ground Startbutton not pressed relay while pressing starter butto
32. ace area around the oil filler opening Unscrew the dipstick from oil filler opening hole and wipe it dry Put the dip stick on oil filler opening take out the dip stick and observe the oil level on it There are two marks engraved on it If the level is below the lower level mark top up with the appropriate quantity of recommended oil up to upper level mark If the oil level is too high i e above the upper level mark drain some oil from drain hole A Oil filler hole C Upper level B Oil level gauge D Lower level Oil replacement If the oil is used for a longer duration its lubricating performance deteriorates So it is necessary to replace the oil in accordance with periodic maintenance chart For replacing the oil follow the procedure given below Run the vehicle for few minutes Place the vehicle on main stand Let the oil settle Remove the oil drain bolt with its aluminium washer Also take out dip stick Let the oil drain completely Tighten the drain bolt with new aluminium washer securely Tightening torque 2 6 3 0 kg m By using afunnel pour the recommended oil from the oil filler opening hole or open Inlettappet cover amp pour oil Fit back the dip stick and tighten it securely Ensure that there is no oil leakage Do not use inferior grade of oil as a replacement for the recommended oil otherwise it will lead towards engine troubles Oil capacity 1100 ml For ne
33. adjuster back or forth as follows Turning the adjusting nut in clockwise direction increases the play at the brake pedal Turningthe adjusting nut out anticlockwise direction reduces the play at the brake pedal After adjustment check the wheel for free rotation and for braking effectiveness Rear brake shoe liner wear can be checked through the inspection window on rear brake drum after unscrewing the plug If the brake remain ineffective despite above adjustments check brake shoes brake drum amp brake cable Rear Brake pedal Play 10 to 15 mm Pm E E 22 Rear brake adjusting nut TIRES For better road holding and longer tire life always maintain correct air pressure Overinflation will cause bumpy ride andfaster wear ofthetire atthe centre Under inflation will cause poor steering and faster wear at the sides Recommended Tire Pressure 1 25 Kg cm 18 PSI Solo 1 75 Kg cm 25 PSI With Pillion 2 50 Kg cm 36 PSI Tire wear damage Worn out tire is unsafe Replace the tyre when the tread depth reaches to less than 3 mm Tire tread depth Measure the tire tread depth by using the depth gauge If tread pattern is not visible replace the tire Also replace the tire when the tire tread depth is found to be less than the service limit Standard Service limit 5 to 6 mm 3 mm Tire rotation To even outtread wear itis
34. air cleaner insufficient high tension voltage continuous slow speed driving Clean the spark plug preferably in a sand blasting device and thoroughly clean off abrasive material left on it Measure the gap between the electrodes with the wire type thickness gauge adjust the gap if incorrect by bending the outer electrode carefully The gap at the electrode for optimum performance is 0 6 to 0 7 mm Connect the lead to spark plug ground the plug and check the current jumping across the plug electrode The bright blue spark should jump across the electrodes Replace the spark plug in case of following conditions 2 Cracked insulator 4 Shorted plug While installing back the spark plug check for 1 The condition of sealing washer 2 Cleanliness of contact surfaces of spark plug seat and cylinder head seat 1 Excessive electrode wear 3 Chipped off insulator When installing the plug first screw it in with finger and then use the spanner for the final tightening only This will prevent chances of stripping of the cylinder head threads Recommended Spark Plugs Champion PL 7 YC SparkPlug Cap Resisiance Plug Cap Resistance m gap 0 6 to 0 7 mm Spark Plug gap 0 o P Exceessoill Plug gap AIR FILTER Bigger PU foam air filter is provided for better breathing If the air filter is clogged intake air flow will be restricted which results in low engine power increase in fuel consump
35. alves are in closed position by checking freeness of tappets Settappet clearance on intake valve with the help of feeler gauge and tappet tightening tool Lock the tappet locking nut after setting tappet clearance to 0 8 to 1 2 mm Repeatthe same procedure for exhaust valve keeping tappet clearance 0 8 to 1 2 mm Rotate rotor anticlockwise 3 4 times and check again the tappet clearance by feeler gauge after aligning markings as stated above Fix O ringonmanifoldandassembleiton crankcase alongwith insulator Fix 3 flanged bolts Assemble O ring on camshaft cover and fix it on cylinder head Align the holes of cover with cylinder head and fix two flanged bolts Assemble O ring on cap for intake and exhaust valves Fix the caps on respective position on cylinder head and tighten it to the torque of 0 5to 0 9 kg m Prefix spark plug by handandtightenittothe torque 2 5 to 3 kg m 35 Assemble fan cover and cowling into the slots of each other Fix the fan cover and cowling screws Assemble H T Coil alongwith its bracket on crankcase magneto side with the help of two screws SERVICE DATA ENGINE SR NO DESCRIPTION STANDARD REMARK CARBURETTOR Make amp Type Keihin PB20 Main jet 108 Main air jet 90 Pilot jet 42 Jet needle OB 4 Jet needle clip position 3 from top Float height 10 7mm Air screw setting 2 25 0 25 turns From fully closed position CYLINDER HEAD Cylinder head warp 0 03 mm COMPRESSION PR
36. and cables do not rub against any metal components je eK Electrolyte level inspection A Battery B Upper level C Lower level BATTERY MAINTENANCE For the optimum performance and longer battery life the maintenance of battery is important The condition of the battery should be checked at least once in a month as follows a Always keep the battery clean and dry b Visually inspect the surface of the battery container If there are any signs of cracking or electrolyte leakage from battery replace the battery Battery electrolyte level inspection The electrolyte level inside all the six cells should be checked fort nightly and topped up if necessary as per procedure given below i Remove LH side cover Remove battery holding band Remove battery after removing cables Check whether the electrolyte level of each cell is between the upper and lower level lines If the level is low in any of the cells then top up with dis tilled water as follows Remove the battery from vehicle Remove filling caps fill distilled water until electrolyte level in each cell reaches upper level NEVER ADD ACID OR ORDINARY TAP WATER FOR TOPPING UP SINCE THIS WILL SHORTEN BATTERY LIFE ALWAYS KEEP THE EXHAUST TUBE FREE FROM OBSTRUCTIONS NON USE MAINTENANCE When the vehicle is likely to remain off road for a longer time say more than a month then non use mainte
37. ar vehicle from the other of the same model and type These serial numbers may be needed by your dealer when ordering the parts In the event of theft the investigating authorities will require both these numbers in addition to the model type and any special features of your vehicle that can help identification Serial numbers with prefix 28 C and 28 E are stamped on chassis and engine of the vehicle in the position indicated in the figures below Engine number Chassis number The chassis and engine numbers serial numbers are used by the factory to identify your particular vehicle Always quote these numbers when ordering parts or when making inquiry with regard to service operations The vehicle is identified by the Department of Motor Vehicles in your state by the Vehicle Identification Number It is a crime in all states to alter any of these numbers Location of VIN Number I 022809082AD72233 f o VIN Number VIN Number ENGINE amp TRANSM Type No of oylinders Bore Stroke Engine displacement 9 00 HP 6 71 kw at 6000 rpm 1 15 kgf m at 4000 rpm Maximum net power Maximum net torque TECHNICAL SPECIFICATIONS SSION Four stroke Forced Air cooled One 57 00 mm 57 00 mm 145 45 Compression Pressure 12 1 kg cm Compression Ratio Idling speed Ignition system Fuel Carburettor Spark Plug Spark plug gap Lubrication Starting Clutch T
38. arness branch for brake switch from the hole on chassis near brake pedal mounting Insert tail lamp wiring harness through diaphragm hole Routethe harness along LH side of diaphragm and take it out from hole on rear end of chassis Take out harness branch for regulator and CDI unit through hole on LH side of chassis Take out harness branch for stator from hole on RH side of chassis Align hook with chassis holes and fix it with 2 Nos of screws alongwith plain spring washers and nuts Insert control cables i e Accelerator cable Gear cables and choke cables from upper terminal in proper position Fix cap for upper terminal Assemble handle for Engine bonnet and LH bonnet with spring plain washer and nylock nut on LH and n RH side chassis ooo 46 SERVICE DATA CHASSIS WHEEL RIM RUN OUT Axial Radial BRAKE DRUM INSIDE DIAMETER Front Rear BRAKE SHOE LINING THICKNESS Front Rear BRAKE ACTUATING SHAFT DIAMETER Front Rear BRAKE ACTUATING SHAFT HOLE DIAMETER Front Rear BRAKE SHOE SPRING FREE LENGTH Front Rear TIRE PRESSURE Front Rear Without pillion Rear With pillion FREE PLAY Clutch lever play Front brake lever play Rear brake pedal play 47 SR NO DESCRIPTION STANDARD REMARK Service limit Service limit 150 16mm 130 16mm Service limit 151 00 mm Service limit 131 00 mm Service limit Service limit 12 925 12 968 mm 11 957 11 984mm 13 043 mm 1
39. ase Assemble guide chain slack side with the help of a special bolt and two plain washers on either side of guide chain 10 Assembly of guide chain slack side Put the spring inside the hole on crankshaft Assemble parallel pin in the through hole provided on the crankshaft arm Assemble key parallel on the crankshaft key way and fix primary spur gear on it Prefix the special nut on the crankshaft Hold the primary spur gear with the help of special tool P No 37 1028 17 and tighten the special nut to 9 to 9 5 kgm torque Assemble timing chain on crankshaft sprocket Assemble the plunger in such a way that it fits into the parallel pin fitted in the crankshaft arm Assemble the spacer collar and clutch assembly on intermediate shaft Hold the hub clutch with the help of a special tool P No 37 1031 52 and tighten the nut to the torque of 9 to 9 5 kgm O AT PN gs Fitment of clutch assly 33 Assemble springs on the hub clutch amp plate the holding plate on it Assemble bolts on the holding plate and tighten it in criss cross pattern Assemble collar amp bearing on holding plate Assemble 2 dowels on crankcase clutch side Fix gasket for clutch cover Assemble clutch cover on crankcase clutch side Prefix 6 flanged bolts on clutch cover Also prefix 4 nuts alongwi
40. block and apply oil on liner bore and assemble iton piston Take outtiming chain from the tunnel provided on the crankcase Check free rotation of timing chain and motion of piston Assemble guide chain through tunnel provided onthe cylinder block into the crankcase Assembly of cylinder block Assemble Head gasket Assemble bush oil seal on cylinder block face for oil carrying stud Position of bush oil seal on cylinder head Puttiming chain through tunnel on cylinder head and hold on holder camshaft on cam shaft Fix cylinder head with the help of special copper plated washers and dome cap nut Apply torque of 2 0 to 2 2 Kg m to dome cap nuts Assemble two flanged bolts on cylinder head joining cylinder head and cylinder block with crankcase Assemble chain on timing sprocket and fix it with the help of two bolts Keep piston at TDC position with the help of rotor and marking provided on crankcase magneto side Check that the marking on timing chain sprocket matches with marking provided on cylinder head Assembly of cylinder head Position chain tensioner assembly into the bore provided on cylinder block and fix it with the help of 2 flanged bolts Release the tensioner bolt by 1 thread and tighten it again Align rotor marking with crankcase marking Check that marking on timing chain sprocket matches with marking on cylinder head Also check that both the v
41. bowl if fuel is left in for a longer time the fuel will break and could clog the carburettor Remove the spark plug and put several drops of 2T oil into the cylinder Kick the engine over slowly a few times to coat the cylinder wall with oil and install back the spark plug Set the vehicle on a box or a stand so that both the wheels are raised off the ground Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or brake shoes Lubricate the control cables Cover the entire vehicle neatly Make sure that the storage area is well ventilated and free from any source of flames or spark Remove battery from vehicle Maintain electrolyte level at Upper Level Ensure that battery is fully charged Charge the battery once in a month Keep the battery away from rain dew moisture amp direct sunlight Store battery in cool amp dry place GENERAL PRECAUTIONS Dismantling assembly Before Servicing Before starting to service a vehicle careful reading of the applicable section is recommended to eliminate unnecessary work Photographs diagrams notes cautions warnings and detailed descriptions have been included wherever necessary Nevertheless even a detailed account has limitations a certain amount of basic knowledge is also required for successful work Especially note the following 1 Dirt Before removal and disassembly clean the vehicle Any dirt entering the engine
42. cables by unscrewing screw terminals Disconnect magneto harness coupler from main harness Also remove body earthing screw on fan cover amp remove earthing cable Disconnect choke andthrottle cable from carburettor Disconnect duct from carburettor Disconnect carburettor from intake manifold Disconnect fuel pipe and sensing pipe Remove bolt fixing lower end of rear shock absorber to the engine Hold engine carefully amp remove the bolt fixing c case arm with engine mounting link on chassis Take out the engine carefully from the chassis CHASSIS ASSEMBLY Assemble various grommets on chassis in respective holes i e grommets for petrol pipes tail lamp control cables etc Fix plug for bonnet on LH and RH side of chassis Insert 2 bolts alongwith plain washer from front side of shield in the holes for L box Fit plain washer spring washer and on each bolt and tighten it Pre fit shield beading on shield on the shield by light hammering by rubber mallet Press fit the beading by using special tool Insert 4 bolts for stand mounting and Position stand on chassis and insert stand clip LH and RH on the bolts Prefix 4 nuts spring washers and tighten them Assemble hook plate on chassis and assemble stand spring Insert wiring harness into the chassis from front side Near steering hsg side Take out the harness branches for LH and RH control switches head lamp and instrument panel from the cavity of the chassis Take out h
43. case cover surface Engine oil level low GEAR SHIFTING NOT PROPER Q Clutch notdisengaging properly Clutch Gear cable play improper Gear shifter stem worn out Cross worn out Gear shifter slider jam KICK SLIP Clutch plates burnt Gear kick and ratchet kick teeth chipped off Spring for gear kick weak Guide kick broken loose STEERING COLUMN Becomes tight Bearing races pitted Balls pitted Race fitment improper Excessive play Bearing races not fitted properly or lock ring nut loose e eo0 7 POORBRAKING Control pedal or lever play not adjusted properly Q Brake shoes lining worn out or oily Brake drums scratched INEFFICIENCY OF FRONT SUSPENSION Noisy Front Shock Absorber upper lower mounting loose Front Shock Absorber weak Riding instability Play between front brake drum and axle excessive Hub pin or roller bearings worn out Front shock absorber weak or hard Excessive clearance between engine foundation arm and engine link assly 000 INEFFICIENCY OF REAR SUSPENSION 1 Noisy Spring weak or broken Top bracket rubber block for rear shock absorber loose or broken 63 ELECTRICAL Fuel Gauge not working Tank unit defective loose contact at resistor coil Fuel meter in instrument panel defective No supply to tank unit e o o Bulb fusing Regulator defective Bulb holder short Loose contact in holder Bulbs do not light Bulb fused
44. clip for removing Front brake panel Tiltthe scooter on one side and take out the steering a Circlip b Washer column carefully from the bottom side Give suitable support below floor board of chassis Remove front shock absorber upper mounting Using puller P No 37180103 remove lower bear bracket by removing 2 nuts ing race from fork Remove top bearing race by special tool P No 37180506 Remove the front mudguard by removing two bolts Removal of Upper bracket a for Fr shock absorber Remove front shock absorber lower end bolt and Removal of Front mudguard then take out front shock absorber Remove grease nipple provided at cross tube of steering column FRONT BRAKE DRUM DISMANTLING Remove speedometer gear and spacer from front brake drum by using Extractor P No 37151905 which is to be used along with 37100114 Removal of Front shock absorber lower bolt a Remove hub pin locking plate bolt and lock plate Remove hub pin alongwith shoulder washer and take out front hub Using hook spanner P No 37180101 unscrew lock nut and upper bearing race Take care to hold steering column to avoid it from falling down Remove upper and lower steering ball cage Removal of Speedometer gear 43 Remove the needle roller bearing from the Brake drum by using Extractor P No 371703 05 without its cup but with the tool P No 37181
45. ct your hands with gloves or a piece of thick cloth when lifting the engine or turning it over 14 6 High Flash point Solvent A high flash point solvent is recommended to reduce fire danger Always follow manufacturer and container directions regarding the use of any solvent 7 Gasket O ring Do not reuse a gasket or O ring once it has been in service The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks 8 Press A part installed using a press or driver such as a wheel bearing should first be coated with oil on its outer or inner circumference so that it will go into place smoothly 9 Ball Bearing When installing a ball bearing the bearing race which is affected by friction should be pushed by a suitable driver This prevents severe stress on the balls and races and prevents races and balls from being dented Press a ball bearing until it stops at the stop in the hole or on the shaft IO Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals When pressing in a seal which has manufacturer s marks press itin with the marks facing out Seals should be pressed into place using a suitable driver which contacts evenly with the side of seal until the face of the seal is even with the end of the hole Seal Guide A seal guide is required for certain oil or grease sea
46. de out outlet of air filter from the hole on chassis and take out Air Filter box REMOVAL OF STEERING LOCK Remove T nose Remove screw for ignition switch and take out ignition switch Remove screw for lock cam Ensure that key is either in ON or OFF position and remove lock cam with nose plier Otherwise lock cam will not come Removal of Antidive cover a Screws b Antidive cover Remove front brake drum nylock nut and take out front brake drum a 29 m b a Screw for ignition switch b Screw forlock cam Removal of Front brake drum a Nylock nut b Front brake drum Press the lug of lock and pull the lock barrel assly with key Ensure that spring plate will not fall down Remove snap pin and then remove bolt connecting link of steering column REMOVAL amp DISMANTLING OF STEERING COLUMN Remove handle bar covers and handle bar as explained Disconnect speedo cable and front brake cable Removal of Speedo cable amp Front brake cable Removal of Snap pin a for Antidive link a Speedometer cable b Front brake cable Remove front wheel Remove mudguard side cover screws and take out antidive cover 42 Remove circlip holding front brake panel on front axle and then remove front brake panel Q b Removal of Lock plate a Removal of Cir
47. e ground From the straight forward position of the handle bar slowly push the handlebar to either side ifthe handle bar to turn by the action of gravity and continues moving until its stopper on L H and R H side the steering is not too tight Ifthe handle bar does not begin to turn by the action of gravity the steering is too tight necessitating adjustment Squat in front ofthe vehicle and grasp the lower ends of the front fork Push and pull the fork end back and forth ifthe play is felt the steering is loose necessitating adjustment Adjustment Remove handle bar covers Loosen Handle bar bolt amp lift up slightly Loosen the upper lock ring nut f the steering is too tight loosen the lock nut a fraction of turn if the steering is too loose tighten the locknut a fraction of turn Tighten the upper lock ring nutto a specified torque Check the steering again If the steering is still tight orlooserepeatthe adjustment Ifthe proper condition cannot be obtained inspite of correct adjustment inspect the steering parts Install handle bar covers OIL STRAINER CLEANING Oil strainer is situated in side the bolt as shown in fig Remove the bolt and take out oil strainer Clean it with petrol Apply air jet to dry oil strainer and assembled back Oil strainer should be cleaned in accordance with periodic maintenance chart i e at every 3000 miles Oil strainer b
48. e level and battery condition Brakes Front and rear brake effectiveness lever play Tires Inflation pressure cracks cuts and foreign material embedded intread FUEL SAVING TIPS Awell maintained vehicle can contribute alotto the saving of petrol Following are a few simple tips for keeping your vehicle healthy and your pocket wealthy Good riding habits Ride smoothly and steadily at an optimum driving speed of 18 to 25 mph Don t waste petrol by stop and go riding and by sudden starts and stops Q void harsh braking Do not brake unless it is very essential anticipate your stops turns well in advance and slow down by deceleration Choose a proper route to ride especially in peak hours Don overload the vehicle above the specified pay load Use the accelerator judiciously Think of the accelerator barrel as fuel cock The more you will turn it the more petrol will be consumed For better fuel economy change the gear as given below Change 1 to 2 gear at 6 mph Change 2 to 3 gear at 12 mph Change 3 to 4 gear at 18 mph Drive at 18 to 30 mph in 4 gear Cut off the engine if you want to stop more than for two minutes Remember idling costs fuel Vehicle condition Check all fuel lines and connections whenever your vehicle smells of petrol Never fill the petrol right up to the filler cap Always maintain the recommended tyre pressure and check it every we
49. e mounting on link 3 5 to 4 0 Pivot securing wheel hub 5 0 to 5 5 Wheel assly on brake drum Qty 5 2 0 to 2 7 BOLTS FOR Handle bar mounting 3 2 to 3 8 Rear shock absorber to engine 2 0 to 2 3 0 25 to 0 3 0 4 to 0 5 STEERING Upper bearing race 0 6 to 0 7 Ring nut 5 0 to 6 0 17 SPECIAL TOOLS The special tools recommended for carrying out repairs overhauls are illustrated below These tools are designed to facilitate quick and safe repairs Use of these special tools is recommended to carry out repairs efficiently and for avoiding costly mistakes such as damages to parts injuries etc The following list contains for each tool the description tool application and an illustrative sketch 1 37 0030 01 Engine support stand 4 37 1014 10 Extractor for input shaft bearing For supporting engine crankcase while assembly To be used for removing input shaft bearing from dismantling crankcase clutch side 2 37 1003 02 Extracter 5 37 1014 13 Inner driver Extractor for needle bearing in crankcase magneto To be used with holder and outer bearing driver for side installing front brake drum bearing 3 37 1005 04 Bearing Driver 6 37 1014 14 Inner driver PSU KRKK Driver for fitting needle bearing in crankcase magneto To be used with holder amp outer bearing driver for side installing input shaft bearing
50. e wire coming from DC Regulator and meter ve lead to Red wire coming from battery ve terminal ll DC load viz Brake lights and Side indicator bulbs to be switched OFF Startthe Engine Set the Engine RPM at 3500 RPM Measure Battery charging current It should be 1 0 to 3 0 amps i e current must flow into the Battery Red White Red 20ADC 1 0 to 3 0A Stopthe Engine Disconnectthe meter and reconnect the fuse As a further check set meter range at 25 V DC Connect ve lead of meterto ve terminals of Battery and ve terminal of meter to ve terminal of Battery Ensure that all lights are off Start the Engine As the RPM of engine increases voltage will also increase Measure the Battery terminal voltage at 3500 RPM owed Reading Range 25VDC Battery Battery 14 7 1 V Note Use fully charged Battery specific gravity of electrolyte z 1 24 H TURN SIGNAL RELAY Remove the flasher unit which is to be checked and connect it to another vehicle whose flasher unit and side indicators are working properly Checkthatthe terminals are connected correctly Startthe vehicle and put ON the indicator switch and see if the flasher unit functions or not If flasher unit works properly then there may be some problem with the switch or regulator or with the wiring of the vehicle whose flasher unit is being checked Also check flash rate No of flashes min If flash rate is not withi
51. eat Disconnect seat lock cable from seat lock amp seat lock mechanism Remove 2 bolts mounting the seat lock mechanism and bracket seat lock alongwith plain amp spring washers Take out seat lock mechanism and bracket seat lock Remove screw mounting cable seat lock alongwith spring washer and take out cable REMOVAL OF CARRIER PLATE After Removal of seat lock mechanism Remove 3 bolts mounting carrier plate on chassis Remove 2nuts mounting carrier plate on Grab handle alongwith plain amp spring washers Take out carrier plate ees Removal of carrier plate a Bolts for mounting carrier plate b Nuts for mounting carrier plate on grab handle REMOVAL OF PETROL TANK a Removal of petrol tank from chassis Removal of seat hinge with dual seat amp carrier plate with seat lock Disconnect coupler joining fuel gauge tank unit with main wiring harness Liftthe fuel tank and remove vaccum pipe amp fuel pipe alongwith clips from fuel cock assly Take out fuel tank with fuel cock assly amp gasket Carrier Bag Seat hinge Removal of petrol tank b Dismantling of petrol tank Remove all the fuel from the tank Remove 4 special bolts for mounting fuel gauge tank unit and take it out carefully without damaging float and float lever alongwith rubber gasket Loosenthetwo mounting bolts and take out fuel cock assly from bottom of the ta
52. ek Under inflated tyres increases rolling resistance and thus costs both fuel and tyre life Ensure that the brakes are not dragging binding Forkeeping the engine healthy Inspect and clean the spark plug adjust the gap Clean the air filter Service carburettor and adjust idling speed If there is a power loss then contact an authorised bajaj dealer and get the vehicle properly tuned UUW Regular maintenance will save fuel and money assuring you trouble free enjoyable and safe riding The maintenance and adjustments outlined in this section are easily carried out and must be done in accordance with the periodic maintenance chartto keep the vehicle in good running condition The initial maintenance is vitally important and must not be neglected PERIODIC MAINTENANCE CHART WHICHEVER COMES FIRST 2 ODOMETER READING 3 MILES Servicing Engine oil Replacement EVERY 3000 Oil strainer cleaning EVERY 3000 MILES Air filter element cleaning 3000 MILES Spark plug Cleaning gap setting Replace 6000 MILES Carburettor cleaning overhaul Fuel line Fuel Filter element cleaning Fuel Filter replacement if required 6000 MILES Check amp adjust valve clearance Control cables adjustment Tightening nuts bolts fasteners Month Check functioning of allelectrical components Day Head lamp alignments check amp adjust Tire rotation 6000 MILES Tire pressure Week Steering column
53. essure plate thickness 1 25 mm Clutch spring free length 25 5 0 3 mm 37 DISMANTLING AND ASSEMBLY CHASSIS REMOVAL OF T NOSE A Removal of T Nose assly from chassis Open Luggage box door Remove 2 square grommets on the side walls of the Luggage box and 2 round grommets on the front face of luggage box Remove 2 screws each from both side attaching Nose with chassis from square holes provided on the both side walls of Luggage box Remove 1screweach fromthe round holes provided on the front face of Luggage box Remove 2 screws provided on the top of Luggage box Take out T Nose after disconnecting horn deeper flasher and AC DC Unit cables Mounting screws for T Nose B Dismantling of T Nose assly Remove 2 screws mounting Grill on T Nose Remove 2 screws mounting LH blinker and slide out blinker assly from nose Similarly dismantle RH blinker Remove 4 bolts for Beeper Flasher mounting bracket and horn Take out horn Remove 2 screws for beeper and separate it from bracket Dismantling of T Nose REMOVAL OF LUGGAGE BOX Open Luggage box door Remove 2 screws provided on the topmost portion of Luggage box Remove 2 Nuts from the door opening Remove 2 screws provided on the lowermost portion of Luggage box and take ou
54. g gear but the engine is notcranked A whining noise is heard Starter continues to run after the switch is released STEPS FOR CHECKING 1 4 Neutral switch checking a b c d e f 9 a b Discharged battery Defective battery Relay drop high Loose or oxidized battery terminals corroded or loose defective earth connections Brushes wornout and not making proper contact with commutator Dirty oily or badly burnt commutator Bush worn out Armature defective Pinion movement sticky Heavily burred pinion or ring gear Drive slip Sticky push button switch Sticky relay Bush in pinion seized on shaft Pinion Ring gear fouled or damaged 59 CAUSE AND CORRECTIVE ACTION 1 4 1 Adjust continuity range on a multimeter Connectthe multimeter across the neutral switch with one probe on the switch terminal black wire and the other probe on the gear shifter If continuity is not observed then it indicates that the neutral switch may be faulty Take the following steps 1 4 2 Remove the neutral switch from the Gear shifter housing Check whether there is any oil layer on the plunger of the switch Clean it and again check for continuity If there is no continuity then the neutral switch is faulty Replace the same 1 4 3 If continuity is observed then check whether the plunger of the switch has got compressed and as such is not making contact with the Gear Shifter In that case al
55. gest on the mainshaft in such a way that the larger collar should be facing towards stem side or lesser collar should be facing towards threaded end of mainshaft Assemble 2 gearwheel 2 largest on the mainshaft in such a way that the larger collar is facing towards 1st gear wheel Assemble gear wheel on to the mainshaftin such away thatthe larger collaris facing towards 2nd gear wheel Assemble 4 gear wheel such away thatthe larger collar is facing towards 3 gear wheel Then assemble shoulder washer and fix circlip Put one steel ball into each of two holes provided on the mainshaft after smearing slight amount of grease on it Assemble spring on each ball Compress boththe springs with the help ofthin plates or hacksaw blade and assemble the cup on the springs The cup should be assembled in such a way that lower diameter of cup should befacingtowards gear wheels Clutch Cover Assembly Q Press first oil seal then bearing amp fix circlip for mainshaft from the outer side of clutch cover Assemble adjuster with nut for Rear brake cable Assemble O ring into the bore for clutch lever Assemble spring amp plain washer on clutch lever spindle Smearlightcoatof grease on clutch lever spindle and assemble it into the clutch cover alongwith internal lever Lock the spring on the clutch cover lug Apply some grease on plunger and assemble it on the internal lever Crankcase
56. guide spring between kick shaft amp spring Assemble circlip to lock the guide spring Assemble other end of kick return spring into the crankcase lug Assemble kick lever on the kick shaft ENGINE ASSEMBLY Take crankcase magneto side subassembly Assemble the rubberised damper ring around the crankshaft bearing seat area in crankcase magneto side Damper ring for crankshaft Assemble the crankshaft assembly into the bearing seat of crankcase Note Crankshaft assembly is slide loose fit in crankcase If the crankshaft bearing is getting tight in crankcase slightly heat the bearing seat by heater Assembly of crankshaft Assemble the main shaft assembly in the needle roller bearing by meshing it with intermediate shaft gears Assembly of mainshaft Assemble 2 no of dowels on crankcase Assemble the centre gasket on to the crankcase Assemble crankcase clutch side on magneto side taking studs as guide Crankcase assly Assemble D bolts alongwith plain amp spring washers and nuts Also assemble plain spring washers and nuts on the crankcase studs Tighten all the nuts in a criss cross pattern to the torque of 1 5 to 1 8 kgm N 2 0 lt I NP Nuts for crankc
57. h a friction plate Insert Hub clutch into the subassembly described above by matching teeth of Hub clutch and mate clutch Then place the above described subassembly into Housing complete clutch C C 3 friction plate C3 A v 5699 28 10 1184 Sequence of clutch plate assly Intermediate Shaft Assembly Assemble cluster gear on intermediate shaft in such a way that small gear of the cluster gear faces towards threaded end of the shaft Then assemble 4th driver gear wheel Assemble kick driven gear Then press bearing on the intermediate shaft Intermediate Shaft Assembly 30 Main shaft Assembly First assemble circlip on the main shaft towards threaded end of mainshaft Put shoulder washer on the circlip Hold mainshaft vertical and slide cross into the slots of mainshaft Position the cross in the slots where a circular groove is provided and rotate cross by 90 Check that the projection provided at the centre of cross is facing upwards Assemble gear selector inside main shaft Matchthe projection on the cross with the slot of gear selector Checkthatthe grooves provided on Gear selector are facing towards the holes provided on mainshaft for fixing spring loaded balls Assemble washer on the gear selector Tighten the stem on the cross CAUTION STEM HAS LEFT HAND THREADING Assemble 1 gearwheel lar
58. hen the switch is pressed Control switch LH the ohmmeter should show infinity oo and when switch M is released the ohmmeter should show 0 ohms a Dipper Switch When Head light is ON If not showing above readings replace brake switch Violet Red Switch pressed CO x10 lt ohms Blue Switch released 0 ohms C STEERING CUM IGNITION SWITCH Position Connect the ve meter lead to Red cable and ve meter lead to Black cable Check continuity 0 ohms as given below ON Pressed Switch position Black Ignition OFF Control switch RH steering lock a Side Indicator Switch Ignition OFF steering unlock Green White Grey Red Blue White N To measure the H T Coil resistance onthe vehicle remove the spark plug cap from spark plug lead and test as per LH table Take both reading i e primary and secondary with respect to ground Ignition ON steering unlock b Start Button Primarywinding 0 9to 1 1 ohms Secondarywinding x1kohms 6 5to7 5Kohms E COILS ON STATOR PLATE ASSLY Use the Hand Tester 37 1030 63 for checking the resistance across the coils 1 Lighting Coil First connect the ve meter lead to Green cable and ve meter lead to Black earth The resistance value should be as tabulated below x1 ohms 0 5 to 0 8 ohms 49 2 Charging Coil First connect the ve meter lead to Violet cable and ve meter lead to Black earth The resistance value sh
59. in crankcase clutch side amp needle bearings in front brake drum 7 37 1028 32 Spur gear holder 11 37 1030 61 Tool for holding primary gear while removing nut Inner Driver 20 used with Bearing Driver set for installing main shaft bearing amp magneto side oil seal 8 37 1030 34 Rotor puller Inner Driver 25 used with Bearing Driver set for installing main shaft oil seal 12 37 1031 07 amp 37 1031 08 Valve spring compressor assembly with adopter For pulling magneto rotor from crankshaft 9 37 1030 48 Bearing puller Used for taking out inlet amp exhaust valves by compressing valve spring in cylinder head 13 37 1031 52 Clutch holder Bearing puller for extracting bearing from input shaft 10 37 1030 54 Magneto rotor holder Used for hold the clutch housing stationary while loosening amp tightening the clutch hub nut For holding the magneto rotor stationary while loosening or tightening the rotor nut 14 37 1031 53 Valve adjusting screw driver Ps XK Used for holding screw while adjusting valve clearance 15 37 1519 03 Bearing driver To be used with bearing driver set 37 1030 61 for assembling needle roller bearing in front brake drum 16 37 1519 04 Driver For assembling speedometer gear amp spacer in front wheel bra
60. intact 1 3 5 Check for 12V DC supply between Red White wire in the coupler for Ignition Switch and chassis ground If the meter does not show supply then cable from fuse to the Ignition switch coupler may be open To cross check check for continuity between Red White wire in switch coupler and point F2 If 12V DC is indicated on the meter check for 12V DC supply between the Red wire in the Ignition switch coupler and chassis ground If there is no supply then the Ignition switch is faulty Replace the same 1 3 6 If the Voltmeter indicate 12V DC supply then ensure proper fitment of the 3 pole natural coupler below the T nose If both are OK then check for proper functioning of the start button as follows 1 3 7 Remove the 2 screws of the L H control switch Check for 12 V D C supply between the soldered Terminal red wire and chassis ground Starter button not pressed The V M should indicate 12V D C supply if the above clauses 1 3 4 and 1 3 5 are OK 1 3 8 Keeping the start button pressed check for the 12 V D C supply between the red yellow and chassis ground If the V M does not indicate supply then it implies that the start button is faulty Replace the same 58 COMPLAINT Armature fails to rotate or rotates slowly and the starter does not crank the engine though pinion has engaged with ring gear Armature rotates but pinionfails to engage Armature rotates pinion engages with the rin
61. ire and other lead of meter to horn terminal from which Orange wire is removed Start the engine and set it at 3500 rpm Press the Horn button Measure the Current at 3500 rpm Range Connection Reading 20A DC Horn Terminal 1 5 A max L SPARK PLUG CAP RESISTIVE Remove H T cable from Spark plug cap Connect ve lead of meter to Spark plug cap where H T cable is connected and ve lead of meter inside cap where spark plug is fitted Measure the resistance across the spark plug cap Range Reading Where Where 4 0 to 6 5 ohms H T cable Spark plug ohms is connected is fitted 51 M C D I UNIT With TRICS METER METER NEGATIVE VE LEAD CONNECTION RANGE X10 w 1 3 4 6 7 8 9 x 40 60 x x x 0 250 400 w 40 60 w x x x x 250 400 w METER 40 6014 250 400 40 60w 4 VE LEAD CONNECTION 40 0 52 CHECKING PROCEDURE FOR SELF STARTER On vehicles with button start a 12V motor is used to crank the engine instead of a kick when button is pressed The starter motor draws it current from a 12V 9 AH battery through a relay solenoid switch The solenoid switch relay is energized by pressing starter button Vehicle should be in neutral gear When the relay gets energized it connects battery to starter motor The supply of current to starter bu
62. ke drum 17 37 1519 05 Adopter For removing speedometer gear amp spacer from front wheel brake drum To be used with 37 1001 14 20 18 37 1801 06 Bearing races assembly tool To be used for installing the upper and lower bearing race on chassis tube 19 37 1805 08 Bearing driver for fork assembly 0 025249 To be used for fitting lower bearing race on front fork tube 20 37 1819 03 Bearing driver Tool for assembling needle roller bearings in steering column To be used alongwith 37 1014 14 21 37 1819 04 Bearing extracter Tool for removing needle roller bearings from steering column 22 37 10BA 56 Bearing extractor Toremove main shaft ball bearing from crankcase cover 23 37 1030 79 Crankshaft alignment fixture To be used for mounting crankshaft while checking its run out 24 67 7505 51 Compression Tester To be used for checking compression pressure in the cylinder 25 37 1030 63 Hand tester For checking electrical components Refer Electrical Maintenance 26 69 7505 26 amp 69 7505 28 Torque wrenches To be used for tightening fasteners to specified torque 27 37 2031 02 Battery charger 12T6 12V For charging battery 28 67 1691 69 Hydrometer For checking specific gravity of electrolyte 21 IN3931 dO Q3GO ldX3 22 ENGINE DISMANTLING REMOVAL OF ENGINE FROM VEHICLE
63. l find out the cause and correct as necessary In order to perform the work efficiently and to avoid costly mistakes the mechanic should read the text thoroughly familiarising himself with the procedures before starting work and then do the work carefully in a clean area Wherever special tool or equipment is specified make sure that same are used Precision measurements can only be made if proper instruments are used and the use of substitute tools may adversely affect safe operation of the vehicle The safety precaution and special instructions have been printed in bold type to draw your attention These instructions indicates points of particular interest for more efficient convenient and safe operation It is essential that you do not neglect these instructions while carrying out repairs so as to avoid any personnel injury and damage to or destruction of equipments and vehicle As the technique of repair maintenance procedure develops and as the manufacturing process changes it is likely that this Service Station Manual will be subject to modifications as necessary The manual is therefore to be taken valid for operation on the date of its print For subsequent modifications and informations always refer to Service Information Circulars This manual has been divided into various sections for convenience of presenting the contents in a useful manner Please refer to the detailed Index for locating the section information you want WARNING
64. l wires are either single colour or two colour and with only a few exceptions must be connected to wires of the same colour On any of the two colour wires there is a greater amount of one colour and a lesser amount of a second colour so a two colour wire is identified by first the primary colour and then the secondary colour For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colours were reversed to make red the main colour Name of Wire Color Wire cross section Wire strands Yellow red Yellow 15 16 17 18 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed These replacement parts will be damaged or lost their original function once removed Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Colour change Deterioration Seizure Service Data Numbers of service data in this text have following meanings Standards Showdimensions or performances which brand new parts or systems have Service limits Indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts ENGINE N
65. le stretch causes the brakes to go out of adjustment This increases the free play at the brake lever and reduces the braking efficiency FRONT BRAKE ADJUSTMENT Check the front brake lever play If it is more or less than the standard adjust the front brake The adjusting nut for front brake is located on front brake inner cable at the end Depending upon the adjustment required turn the adjuster back or forth as follows Turning the adjusting nut in clockwise direction increases the play at the brake lever Turningthe adjusting nut out anticlockwise direction reduces the play at the brake lever After adjustment check the wheel for free rotation and for braking effectiveness If the brake remain ineffective despite above adjustments check brake shoes brake drum amp brake cable WARNING Never permit the operation of a scooter with abrake cable in anything but absolutely perfect condition Any wearing or fraying of the cable can lead to ineffective brakes which can lead to loss of control an upset or a serious accident with subsequent serious injury or even death Front Brake Lever Play 3toSmm Front brake adjuster REARBRAKE ADJUSTMENT Check the rear brake pedal play as shown in figure If it is more or less than the standard adjust the rear brake The adjusting nut for rear brake is located on rear brake inner cable at the end Depending upon the adjustment required turn the
66. ls during installation to avoid damage to the seal lips Before a shaft passes through a seal apply alittle oil preferably high temperature grease on the lips to reduce rubber to metal friction 11 12 Circlip Retaining Ring Replace any circlips and retaining rings that were removed with new ones as removal weakens and deforms them When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more 13 Cotter Pin Replace any cotter pins that were removed with new ones as removal deforms and breaks them 14 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film During assembly oil or grease whichever is more suitable should be applied to any rubbing surface which has lost its lubricative film Old grease and dirty oil should be cleaned off Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles Don t use just any oil or grease Some oils and greasesin particular should be used only in certain applications and may be harmful if used in an application for which they are not intended This manual makes reference to molybdenum disulfide grease MoS in the assembly of certain engine and chassis parts Always check manufacturer recommendations before using such special lubricants 15 Electrical Wires All the electrica
67. n If the supply is present then the cover the following steps Refer 1 2 1 amp 1 2 2 if click noise comes 1 2 2 Checkfor 12V DC supply between R2 and Refer 1 3 if click noise does not Ground If the supply is present Check come for voltage drop between R1 amp R2 If the dropis morethan 2V startbutton pressed then relay is faulty replace the same To cross check refer 1 1 3 If starter motor is ok check continuity of wire from relay to starter motor 57 COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION 1 3 Relay operation not present click 1 3 1 Check for 12 V D C supply at the Relay noise of Relay operation not heard coil terminals Soldered points C1 and C2 Ref circuit diagram If the supply is indicated on the V M thenthe Starter Relay isfaulty Replace the same 1 3 2 Ifthe 12 V D C supply is not indicated on the then check the supply between point C1 andchassis ground If supply is indicated on the V M then it indicates that the point C2 is not getting grounded properly through the neutral switch Refer clause 1 4 below 1 3 3 If the doesn t show 12 V D C supply between C1 and chassis ground then it indicates that the battery supply is not reaching the relay coil terminal C1 To cross check connect the battery ve B1 to C1 directly by a1 Sq mm cable If the S M responds then check for the control circuit as follows 1 3 4 Ensure the 10 A fuse in the fuse holder is
68. n the specified limit i e 90 30 flashes min replace it as it is faulty If right or left signal gets ON check that the blinker bulbs are Ok FUEL LEVEL GAUGE TANK UNIT For knowing the quantity of fuel inside the fuel tank at a glance fuel gauge is provided on an instrument panel The fuel gauge works on the principle of variable resistance The fuel gauge works on A C supply The fuel gauge consists of a float for level sensing a senderforsendingthe signal andthe gauge for converting the signals from sender into the movement of needle Checking of Fuel Tank Unit Tank float White Black Fuel Full Highest position ohms Meterx10ohms Vis Black Fuel Empty 10310117 Lowestposition ohms J DC Voltage Measurement Connect velead of meterto Orange wire and ve lead of meter to Orange Brown wire from AC DC unit Startthe engine and set it at 3500 rpm Pressthe Horn button Measure the DC Voltage at 3500 rpm Connection Reading Meter Meter ve 25V DC Orange Orange Brown 9 to13 V K DC HORN 1 Tuning of DC Horn Check the Horn sound If itis weak or feeble loose the check nut provided at the back of Horn With the help of screw driver rotate the screw till the horn sound is good After proper tune up hold the screw amp lock the checknut 2 DC Current Measurement Remove the Orange wire from Horn amp connectone lead of meter to Orange w
69. nance should be carried out as follows otherwise the battery may get sulphated and permanently damaged a b Remove the battery from vehicle Maintain electrolyte at UPPER LEVEL During off service period battery should be charged once a month d Keep the battery fully charged e Store the battery in cool dry place f Keep the battery away from rain dew moisture and direct sunlight wa wa BATTERY SULPHATION A sulphated battery is one which has been left standing in a discharged condition or undercharged to the point where abnormal lead sulphate has formed on the plates Sulphated cells looks like white crystal like sugar Where this happens the chemical reactions within the battery are affected and results in loss of capacity Mostly the causes of sulphation are as under a Undercharging b Standing in a partially or completely discharged condition for long time c Low electrolyte level if electrolyte level is permitted to fall below the top of the battery plates then the 56 exposed surfaces will harden and will become sulphated Adding acid if acid is added to a cell in which sulphation exists the condition will be aggravated High specific gravity if specific gravity is higher than the recommended value then sulphation may occur f High temperature high temperature accelerates sulphation particularly of an idle partially discharged battery Voltage of the sulphated ba
70. necessary to change the face of tire and to rotate it position wise every 10000 kms Change the face of the tire in relation with the wheel rim and inflate tire to the specified pressure The good tire should be kept at the rear which is a driving wheel CONTROL CABLES Due to continuous operation of cables by the brake levers and throttle the inner cables are subjected to wear and tear Cable maintenance is primarily concerned with preventing deterioration due to rust and weather as well as providing proper lubrication for free movement of inner cables inthe outer casing For checking any ofthe control cables follow the procedure given below Disconnect the inner cable Check free movement of the cable within its casing If movement is obstructed check for fraying or kinking of cable strands If such damage is noticed replace the inner cable or cable assembly as necessary To lubricate cable hold it in vertical position Apply necessary oil to uppermost end of cable and move the inner cable to and fro Leave itin vertical position until the oil flows down to the lower end Allow excess oil to drain and reinstall the cable Note Friction free cables do not require lubrication BULB REPLACEMENT When exchanging the bulbs always replace the bulbs with that of the specified type and rating This is important to preventthe electrical lighting circuit from malfunctioning Head light bulb replacement For replacing head light
71. nion alongwith support into Front brake panel with screw O ring should be fixed on support Screw for speedometer holder Refitting of Needle roller bearing 45 Assembly of Speedometer holder Assemble Front brake cable adjuster into Front brake panel Assemble Brake links on Actuating lever by Split pin Assemble antidive link end having L type grease nipple on brake panel by bolt alongwith flexible washer It should be assembled such that it should have easy access while greasing Assembly of Brake links a DISMANTLING OF FRONT SHOCK ABSORBER Remove two nuts c holding Front shock absorber upper mounting bracket Remove the Shock pads amp Pad locators Remove nut holding spring and then remove front suspension spring FRONT SHOCK ABSORBER ASSEMBLY Assemble front suspension spring on front shock absorber such that its lower pitch side face down wards and then tighten the nut Assemble shock pads amp pad locators on front shock absorber and then tighten with the nuts cc Assembly of Front shock absorber REMOVAL OF ENGINE FROM VEHICLE Put the vehicle on the stand open seat lock amp lift seat and remove both LH and RH bonnets Drain Engine oil completely by removing drain plug Disconnect lower ends of rear brake amp clutch cable Remove gear shifter cover and release lower ends of gear
72. nk REMOVAL OF GRAB HANDLE A Removal of grab handle from chassis Open seat lock and lift the seat Release seat lock cable Remove 2 nuts of plate grab handle located inner side chassis below tail lamp Remove 2 nuts attaching grab handle with carrier plate Take out grab handle assly B Dismantling of grab handle Remove 2 screws for tail lamp lens Remove tail lamp amp rear side indicator lens Remove 2 screws of bottom piece grab handle Remove 2 screws of reflex reflector 41 a Screws for lens b Screws for bottom piece c Screws for reflex reflector Remove 2 screws of tail light reflector and take out tail light reflector Remove clip for seat lock with barrel and take out seat lock with barrel a Screws for reflector b Clip for seat lock SPARE WHEEL BRACKET REMOVAL Take out LH bonnet Remove spare Wheel cover amp spare wheel Remove screw pan cross mounting voltage regulator onspare wheelbracketand disconnectthe terminals Remove 4 bolts take out footrest Remove 5 bolts mounting sp wheel bracket on chassis and take out spare wheel bracket a Bolts for removal of spare wheel REMOVAL OF AIR FILTER BOX Remove spare wheel Take out Air Filter element Remove Dual seat hinge carrier plate Take out fuel tank Remove flange bolts of Air filter from engine bonnet side Sli
73. ol pulley and take out gas control pulley Pull out gas control tube Remove spring clip holding gear control link and take out gear control link Remove plain and special washer Pull out gear control tube assly Take out silent bushes from handle bar LH and RH tubes with the help of a suitable tube or L tommy REMOVAL OF TAIL PIECE ASSLY Remove 3 screw pan cross self tapping alongwith plain washer for fixing rear number plate a Screws for rear number plate Remove 3 screws mounting tail piece on chassis alongwith plain washer spring washer and nut a Screws for tail piece REMOVAL OF DUAL SEAT a Removal of dual seat from chassis Unlock seat lock with key and lift the seat Disconnect fuel gauge coupler Remove 3 bolts mounting the seat hinge on chassis alongwith spring washers Remove the clip holding harness from fuel gauge tank unit Q Take out seat assly with hinge b Dismantling of dual seat Remove2nuts mounting the hinge bracket on seat alongwith spring washers Remove split pin plain washer and remove pin holding hinge bracket with seat hinge 40 Remove2nuts mounting hookforseatlock alongwith spring washers PR Removal of dual seat a Bolts for seat hinge b Split Coupler REMOVAL OF SEAT LOCK MECHANISM a Removal of seat lock mechanism from carrier plate assly Unlock seat lock with key and lift the s
74. olt BATTERY MAINTENANCE For checking topping up electrolyte level Remove LH bonnet Remove rubber strap holding battery and slide out battery slightly for easy topping up Remove battery filler cap amp fill distilled water until the electrolyte level in each cell reaches the upper level line CAUTION Add only distilled water to the battery Do notuse ordinary water for topping up it will shorten life of battery Apply petroleum jelly to the terminals amp assembled back battery on the vehicle 2 e 2 fea Ve Location of battery LUBRICATION OF FRONT SUSPENSION The locations of Grease nipples and recommended intervals for lubrication of Front suspension by grease HP multipurpose or equivalent are as under Antidive link bushes amp O rings Y Lubricate at Every 2000 miles Needle roller bearings of Front brake panel Lubricate at Every 4000 miles Bushes amp O rings of Antidive link amp hub pin Lubricate at Every 2000 miles NON USE MAINTENANCE Non use maintenance is necessary if a vehicle remains off roadfor a longer duration The correct and careful non use maintenance carried out before storing the vehicle will preventthe vehicle from rusting and from such other non operational damages like fire hazards Clean the entire vehicle thoroughly Empty the fuel from the fuel tank and carburettor float
75. or other parts will work as an abrasive and shorten the life of the vehicle For the same reason before installing a new part clean off any dust or metal filings 2 Tightening Sequence Generally when installing a part with several bolts nuts or screws they should all be started in their holes and tightened to a snug fit Then tighten them evenly in a cross pattern This is to avoid distortion of the part and or causing gas or oil leakage Conversely when loosening the bolts nuts or screws first loosen all of them by about a quarter of turn and then remove them Where there is a tightening sequence indication in this Service Manual the bolts nuts or screws must be tightened in the order and method indicated 3 Torque The torque values given in this Service Manual should always be adhered to Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removal of screws held by a locking agent in order to avoid damaging the screw heads 4 5 Edges Watch for sharp edges especially during major engine disassembly and assembly Prote
76. ould be as tabulated below Canned Meter ve Meter ve x10ohms Violet 245t02950hms 3 Pulser Coil First connect the ve meter lead to Grey cable and ve meter lead to Black earth The resistance value should be as tabulated below x10ohms 108to1320hms 4 Battery Charging Coil First connect the ve meter lead to Orange cable and ve meter lead to Blue Red The resistance value should be as tabulated below Meter ve Meter ve xi0ohms Yellow Yellow Red 0 65t00 950hms 5 Insulation Check ForLighting Horn Battery Charging coils amp Charging coils To check whether coil is body short Note Disconnect wire connectedto earthfor lighting amp charging coil before conducting insulation check Core Eitherone 200Kohms ofterminal Reading x1K ohms Removevarnish fromcoretohave propercontact F DC VOLTAGE REGULATOR DC Voltage Measurement Connect ve lead of meter to ve terminal of Battery and ve terminal of meter to ve terminal of Battery Ensure that all lights are off Start the Engine set it at 3500 RPM Measure the Battery terminal voltage LOAD METER READING AT 4500 RPM OFF DC 25 14 7 1 Note Use fully charged Battery specific gravity of electrolyte z 1 24 50 G BATTERY CHARGING SYSTEM Q Ensure that battery is fully charged Set meter range at 20 A DC Remove fuse amp connect meter ve lead to other terminal of fuse i e Red Whit
77. r Twist grip type on left hand of handle bar Lever operated on left side of handle bar Lever operated on right side of handle bar Pedal operated by right foot 12 Volts DC 12V 9Ah 35 35 W 5 10W 10W 12V DC 1825 mm 71 85 685 mm 26 97 1275 mm 50 20 1150 mm 45 28 805 mm 31 69 115 kg 253 Ibs 256 kg 564 Ibs 90 km h 55 mph with 68 kg 150 Ibs single rider payload 25 0 max All dimensions are under unladen condition Above information is subject to change for the latest information please contact Service dept GENERAL INFORMATION RUNNING IN Inthe process of manufacturing the best possible materials are used and all machined parts are finished to a very high degree of accuracy But it is still necessary to allow the moving parts to break in before subjecting the engine to maximum stresses The future performance and reliability of the engine depends upon the care and restraint exercised during its early life The general running in rules are Always keep to the specified running in speed Do not ride the vehicle at high speed Donotrace the engine Do notrun the engine under constant speed for prolonged period please vary the speed for better bedding in of the mating parts Donotstart moving or race the engine immediately after starting Run the engine fora few minutes at idle speed to give the oil
78. r shifter on crankcase Engage 4th gear amp pull out gear shifter complete Nuts for gear shifter assly REMOVAL OF CLUTCH COVER C CASE COVER Loosen 6 flanged bolts and remove them Remove 4 nuts alongwith plain and spring washers A Bolts B Nuts for mounting clutch cover Take out clutch cover by tapping the cover gently using Nylon mallet Remove two dowel pins Remove plunger oil from the crankshaft Remove clutch release bearing amp bearing seat Remove the 6 bolts of clutch and take out 6 springs alongwith holder plate Removal of plunger A B Bolts for holder 26 Hold the wheel clutch with the help of clutch holder 37 1031 52 Remove clutch hub nut NOTE HUB NUT HAS LEFT HAND THREADING Clutch holder Remove housing complete clutch alongwith wheel clutch Store housing complete clutch collar spacer carefully Hold primary spur gear with the help of special tool 37 1028 17 and remove the special nut Take out primary spur gear alongwith the key Take out parallel pin and spring from the crankshaft NOTE Removal of special nut for primary spur gear is required only if primary gear or crankshaft is to be replaced A Bolt for guide chain C Screws for oil tube B Screws for oil pump D Screws for baffle
79. ransmission Overall gear ratios First gear Second gear Third gear Fourth gear Primary gear ratio CHASSIS AND BODY Monocoque construction Frame type Suspension Front Rear Brake type Front amp Rear Brake size Front Rear Tires Front Rear Tire pressure FRONT REAR without pillion REAR with pillion Fuel tank capacity 17 33 10 81 9 3 1 1200 150 rpm C D I 87 octane petrol Keihin PB 20 Champion PL 7 YC 0 6 to 0 7 mm Wet sump forced lubrication Kick start Electric start Wet multidisc type 4 speed constant mesh 7 96 6 11 2 75 Leading link Anti dive variable rate coil spring amp double acting shock absorber Variable rate coil spring amp double acting shock absorber Mechanical expanding shoe friction type 150 mm dia 5 91 130 mm dia 5 12 3 50 X 10 4 P R 3 50 X 10 4 P R 1 25 kg cm 18 Psi 1 75 kg cm 25 Psi 2 50 kg cm 36 Psi 1 32 Gal 5 litres CONTROLS Steering Accelerator Gears Clutch Brakes Front Rear ELECTRICALS System Battery Headlamp Tail stop lamp Side indicator lamp Horn DIMENSIONS Length Width Wheel base Height Saddle height WEIGHTS Curb weight Max total weight including driver PERFORMANCE Maximum speed Climbing ability NOTES Handle bar Twist grip type on right hand of handle ba
80. rt Check steering cum ignition lock amp other lock for proper operation Check for smooth operation of choke lever andaccelerator Check front amp rear brakes for efficient working Check and adjust steering Check all lights horn switches speedometer for satisfactory working Initial charging of battery Install amp apply Petroleum Jelly on Terminals Check battery electrolyte level amp apply petroleum jelly on terminals Test drive the vehicle Repair for any other defects seen or observed during test drive Clean the vehicle before delivery SCHEDULED MAINTENANCE Fit back the dipstick and tighten it securely CLEANING The vehicle must be cleaned periodically by using pressurised water Before cleaning the vehicle cover the important parts like ignition switch silencer ignition unit coil starter motor by plastic bags Don t apply the jet of water directly towards electrical parts such as switches ignition unit coils etc otherwise they may get damaged Brushing with parafin and wiping dry with clean rag is advisable for external cleaning of the engine All painted surfaces should be washed with water Do not use kerosene or detergent soap on painted surfaces as it damages the paint and turns it dull If necessary blow with compresseddry air the head lamp reflector clean or wipe off dust with a very soft feather brush After washing
81. so replace the switch Substitute with a fully charged battery If the starter now cranks the engine then the battery must be attended to Repair Replace relay Clean the terminal and smear petroleum jelly Tighten all connections Replace brushes if found to be wornout Remove dirt or oil commutator is burnt replace armature Replace bush bearing Replace armature Lubricate pinion and shaft helix with light oil Deburr by filing and clean up Remove the starter from the vehicle and replace drive assly test and refit the starter Tap on bush button switch to release if not disconnect battery Disconnect battery repair or replace relay Remove the starter from the vehicle and replace bush Clean thoroughly deburring pinion amp ring gear by filing UV6 ATI AWALLVS A MOLVOIGNI FAIS iP dWVIdOLS IVL T imas HOLIMS IVALNIN wOLvIND aa LINA ES 7100 LH lt 1025 uu N 7 4 L ovuonivis ASSV OLANDVIN IVANINN NINOI 4 Gragsv ra ASSV 5 music run aan us1an09 Wane 440 122 9 HOLIAS NOL
82. switches b Screw for instrument panel DISMANTLING OF HANDLE BAR COVER FRONT Remove 2 spring clip nuts from cover Remove 2 screws for mounting Head lamp mounting brackets Screw In the Head lamp beam adjustment screw and take it out from the inner side of cover Remove 3 lock washers of fairing carefully and take out fairing 39 Dismantling of Handle bar cover front a Screw for mounting head lamp b Lock washer for fairing REMOVAL OF HANDLE BAR A Removal of handle bar from steering column Remove Handle bar front cover and rear cover Disconnect front brake cable from wheel end Take out front brake cable from RH lever Disconnect both Gear cables from gear shifter end and also disconnect them from Gear control link Disconnect throttle amp Choke cable from carburettor end and from Gas control link Disconnect front brake switch connections Disconnect sensor connections Remove handle bar mounting bolt Handle bar mounting bolt Lift handle bar from steering column Disconnect Gear cables and Throttle cable by slipping nylock provided on cable outers from handle bar body and take out Handle Bar b Dismantling of handle bar Remove 3 spring nuts on cover mounting brackets Remove 2 screws to take out sensor assly from handle bar Take out 2 bolts alongwith spring washer for mounting cover mounting bracket Remove both handgrips Remove spring clip holding gas contr
83. t Luggage box assembly 1 WN Mounting screws Luggage box REMOVAL OF HANDLE BAR COVERS Remove 2 screws on handle bar rear cover holding handle bar front cover Remove one screw provided on handle bar front cover just below Head Light adjustment screw A Screw on front cover Carefully disengage the locking lugs of handle bar front cover by prying with the help of a small screw driver Take out Handle bar front cover Disconnect Head lamp harness coupler and remove handle bar front cover Remove both mirror by removing packing and hex Socket bolts Disconnect L H and R H Switch couplers near steering column lower mounting race Remove 2 screws mounting Handle bar rear cover on handle bar from front side Remove 1 screw mounting handle bar rear cover from back side Remove speedometer cable connection and harness connection Take out Handle bar rear cover DISMANTLING OF HANDLE BAR COVER REAR Remove 2 spring clip nuts from cover Remove 2 screws for mounting LH switch on cover and take out LH switch from the window provided on cover Remove 2 screws for mounting RH switch on cover and take out RH switch from the window provided on cover Remove 5 screws alongwith plain washer for mounting instrument panel and take out instrument panel Dismantling of Handle bar cover rear a Screw for
84. th plain amp spring washers on the studs Tighten the flanged bolts amp nuts in a criss cross pattern to the torque of 1 3 to 1 5 kgm Bolts amp nuts for mounting clutch cover Assemble stator assembly on crankcase magneto side by using 3 nos of screw pan cross spring washers amp plain washers Fix the grommet of the stator harness on crankcase magneto side Assemble woodruff key on the crankshaft Assemble rotor on the crankshaft Prefix the flanged nut alongwith spring washer Hold the rotor by using special tool 37 1030 54 and tighten the flange nut to 5 5 to 6 kgm KO Fitment of magneto rotor Fix the fan on magneto rotor Pull out the gear shifter stem and engage the cross in 4th gear Assemble gear shifter gasket on crankcase magneto side Engage lever of gear shifter in stem and taking studs as guide assemble the gear shifter Prefix nut plain washer amp spring washer and tighten them Assemble larger O ring for back plate and also assemble 2 nos of smaller rubber gaskets on crankcase Assemble back plate and fix 3 screws alongwith spring washer Assemble cam brake and O ring on the crankcase Assemble rear brake lever along with rear brake links on cam brake Fixthe rear brake lever on cam brake with the help of flanged bolt Assemble brake shoes alongwith spring on the cam brake and pivot pins Assemble cam brake return spring
85. the bearing from the shaft by using special tool P No 37 1030 48 12 02 L A 3 LN Removal of bearing Remove kick driven gear Remove 4th driver gear Remove cluster gear Clutch Dismantling Take out hub clutch Take out plate friction and plate clutch one by one Clutch dismantling Cylinder Head Remove stopper plate by removing screw Take out inlet rocker arm shaft by using a bolt Take out exhaust rocker arm shaft by nose plier Removal of rocker arm shaft Take out both the rocker arms Take out camshaft Using valve spring compressor and adaptor press down the valve spring retainer Remove the collets Removal of valve 29 Loosen valve spring compressor and take out valve spring retainer valve spring and spring seat Push out one valve Repeat same procedure for the other valve Kick Shaft Dismantling Remove circlip holding the spring guide Remove spring guide by nose plier Remove spring by taking it out from the hole provided on the kick shaft Remove the circlip alongwith the washer Take out gear kick alongwith washer on other side of gear Remove circlip and take out ratchet gear Remove spring coil and cup kick shaft Remove circlip Kick Shaft Dismantling ENGINE ASSEMBLY REASSEMBLING OF SUB ASSEMBLIES
86. tion amp spark plug fouling Air filter removal Open seat lock amp lift the seat Remove LH bonnet Remove spare wheel Pull Cover air filter slot from slot provided on chassis for inserting air filter assly Take out air filter assly carefully from slot Remove air filter element Removal of air filter Air filter cleaning Soak the element for about 1 2 minute in high flash point stoddard solvent or equivalent Squeeze the element blow the air so that it dries Dip the element in 20 W 40 oil Soak the element for about 1 2 minute Squeeze the element hard manually so that excess oil is removed Assemble the air filter assly insert it inside slot Fix the Cover air filter slot on chassis DO NOT USE PETROL ORLOWFLASHPOINTSOLVENT FOR CLEANING THIS MAY CAUSE BACK FIRE Air filter element should be cleaned as per periodic maintenance chart If vehicle is operating in dusty roads areathe element should be checked and cleaned more frequently Wash Squeeze Out Cil And Dry Squeeze Out Excess oil ACCELERATOR GRIP The accelerator grip controls the movementof carburettor throttle valve and ignition timing For TRICS If the accelerator grip has excessive play due to cable stretch it will cause a delay in carburettor response especially at low engine rpm and cause improper ignition timing Also throttle valve will not open completely in full throttle condition On the other hand
87. ttery Cells of the sulphated battery will show low specific gravity Follow the procedure given below i Check voltage before charging ii Charge for 2 hours iii Check voltage every one hour If voltage increases then continue charging But if voltage does not increase the discontinue charging otherwise battery charger will get permanently damaged 5 I If battery is not badly sulphated i e voltage more than 9 volts then battery can be revived by special treatment In such case it is advisable to give sulphated battery to battery specialists for necessary special treatment HOW TO DETERMINE CONDITION OF BATTERY Specific gravity check Whether battery is fully charged or partially charged it will always show same no load voltage of 12 volts or more unless battery cells are damaged due to sulphation etc But specific gravity of the fully charged battery and partially charged battery will be different Fully charged battery will show specific gravity of 1 240 in tropical climate and 1 28 in cold climate while partially charged battery will show less specific gravity Therefore specific gravity check is very important to know condition of the battery SAFETY Never bring the naked flame or spark such as a candle lighted cigarette etc near the battery especially during or shortly after charge Battery charging room should be well ventilated NOTE These are general guidelines TROUBLE SHOOTI
88. tton is routed through ignition switch Hence the motor will run only when the ignition switch is ON A battery charging coil on stator plate supplies A C charging current to regulator It converts it into D C and charges the battery continuously when engine is running A 10 Amp fuse is provided for safety IGNITION SWITCH NEUTRAL SWITCH BLACK WHITE COUPLER NATURAL RED WHITE E I Y o 3 m RED YELLOW 3 POLE COUPLER NATURAL BELOW T NOSE COUPLER NATURAL Thus with ignition switch in ON position vehicle in neutral gear the current flows through relay when starter button is pressed Starter motor is energised which engages the pinion to ring gear on flywheel and the starting shock is absorbed by spring Upon engaging the ring gear rotates with magneto rotor and engine starts Once the engine starts ring gear rpm becomes more than the pinion and pinion is forced back to its rest position STARTER MOTOR FUSE 10 Amps RED WHITE GROUND ON CRANKCASE LN AT FAN COVER STARTER RELAY CIRCUIT DIAGRAM FOR CHECKING OF STARTER MOTOR OPERATION ON LEGEND SELF START VEHICLE 54 BATTERY TECHNICAL SPECIFICATION Make voltage amp type Exide 12V MX 9 B Capacity 9 AH Specific gravity of electrolyte 1 24 for use above for initial filling of new battery 10 Specific gravity of electrolyte 1 28 for use below for initial filling of new battery 10 Electrolyte
89. wly assembled engine 1000 ml For drain amp refill Recommended oil SAE 20 W40 of API SC SF grade Replace oil after every 5000 kms 3000 miles e x S N SA Drain bolt SPARK PLUG The condition of the spark plug indicates how the engine is operating A defective spark plug will lead to difficult starting and poor performance Engine heat and combustion chamber deposits will cause any spark plug to slowly break down and erode over a period of use The sparkplug should be removed periodically and inspected for electrode gap and the colour at the tips at regular intervals as specified in periodic maintenance chart If the engine is operating correctly and the machine is being ridden properly the colour at the electrode tip will be greyish yellow to light brown The centre electrode will not have pitting and the side electrode will have constant thickness The combustion chamber residues left on the tip gives an indication of engine performance as follows Greyish yellow to light brown Correct running of engine Spark plug is perfectly matched for optimum engine performance Shining black or wet carbon deposits Presence of oil in fuel Burnt white pearly deposits of metallic enamel beads Overheated engine too lean air fuel mixture spark plug not fully tight use of hotter plug Dull black velvety carbon deposits Too rich fuel air mixture electrode gap too wide plug too cold clogged

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