LML Star Deluxe 4S Owner'S Manual Download Page 43

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Maintenance by Authorised Service Dealer

PERIODICAL MAINTENANCE TO BE CARRIED OUT BY AN AUTHORISED LML ASSISTANCE CENTRE

Preventive Maintenance:

To obtain the best performance from your STAR 4 STROKE it is important to carry out periodical mainte-
nance on your vehicle. The following table gives the suggested action for different items of maintenance and
their periodicity.

Code of suggested action is:

NR.

Item

Check or main-

tenance

jobs

0 Km

Pre-

deliv-

ery

500

3000

6000

9000

1200

0 Km

1500

0 Km

1800

0 Km

2100

0 Km

2400

0 Km

2700

0 Km

3000

0 Km

Engine Oil

Filling

Replacement

Check level every 1000 Km and top up if required.

Replace every 3000 Km or every 1 year.

Engine Oil

Filter

Replacement

Replace every 3000 Km or every 1 year.

Engine Oil

Filter

Screen

Clean

Summary of Contents for Star Deluxe 4S

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Page 2: ...Redefining mobility worldwide ÑÉÒÛÎŽÍ ÓßÒËßÔ ÑÉÒÛÎŽÍ ÓßÒËßÔ i ÕÒÑÉ ÇÑËÎ ÍÌßÎ ÜÛÔËÈÛ ìÍ i ØÑÉ ÌÑ ÑÐÛÎßÌÛ ÇÑËÎ ÍÌßÎ ÜÛÔËÈÛ ìÍ i ÝßÎÛ ßÒÜ Óß ÒÌÛÒßÒÝÛ ÑÚ ÇÑËÎ ÍÌßÎ ÜÛÔËÈÛ ìÍ ...

Page 3: ...NT INFORMATION 1 Name Address Licence No 2 YOUR DEALER Name Address Tel No 3 YOUR VEHICLE Model LML STAR DELUXE 4 STROKE Colour Engine No Chassis No Key No Date of purchase Date of Registration Registration No ...

Page 4: ...ride It is equipped with a powerful 125 150cc four stroke engine that unleashes a phenomenal power Apart from offering an excellent performance and a comfortable ride the Star will make everybody envious thanks to its breathtaking design and its original colours that nobody can ignore This owner s manual has been specially designed to help you understand your scooter better It is important to read...

Page 5: ...ol Functions 18 Locking System 18 Switches 21 Clutch 22 Gear 23 Brakes 24 Fuel supply 24 DESCRIPTION PAGE NO Operating the vehicle 26 Running in Instructions 29 Care and Maintenance 30 Cowls 30 Changing the tyres 31 Engine oil 33 Spark plug cleaning 34 Battery 34 Air Cleaner 37 Cleaning Polishing 38 Maintenance while not in use 38 Recommended Lubricants 39 Maintenance by LML authorised Technical A...

Page 6: ...ce in kilometres can therefore vary on the basis of the road conditions the intensity of traffic and driving habits and conditions as well as the respect for the periodical mainte nance intervals Tips to stretch each litre of petrol even longer 1 1 Change gears as per the required speed Try to maintain the speed of 35 45 kms hr to give you the best mileage 1 2 Use clutch brakes and full throttle o...

Page 7: ...rful DC horn and indicators with a buzzer enable you to negotiate busy and noisy traffic conditions In addition the head light retains its intensity even at low speed that makes for safer night driving Some tips for even safer driving 2 1 Always use a helmet while driving 2 2 Make yourself familiar with the driving signs and regulations 2 3 Drive at a speed at which you are in com plete control of...

Page 8: ...y to the extent you are in complete control of the scooter 3 2 Use its maximum power only when you need to 4 An enjoyable ride that only the STAR 4 STROKE knows how to give Your scooter has been designed so as to enable you to sit in a correct posture to avoid strain Its com fortable and long seat double acting suspen sion and strong shock absorbers better with stand uneven road conditions to give...

Page 9: ...umber is stamped inside the glove compartment on upper chassis as shown in Fig 1 The engine number is stamped on the crank case Fig 2 Every STAR 4 STROKE has a spare set of keys An identification number is punched on metallic tag which is provided alongwith the key ring Fig 3 Please keep your duplicate key carefully along with the metallic tag Fig 3 Fig 2 Fig 1 ...

Page 10: ...lencer 8 Kick starter 9 Rear brake pedal 10 Front direction indicator right side 11 Horn 12 5 spoke wheel hub 13 Glove compartment 14 Fuel cock lever 15 Choke control knob 16 LH side cowl 17 Front direction indicator left side 18 Spare wheel 19 Driver s foot platform 20 Rear turn indicator LH side 21 Rear mudguard 22 Tail light ...

Page 11: ...symbol 7 Fork cover 8 LML nameplate 9 Grill 10 Crest 11 Central stand 12 Rear view mirror 13 Clutch lever 14 Glove compartment lock 15 Ignition cum steering lock 16 Instrument panel 17 Accelerator twistgrip 18 Front brake lever 19 Gearchange twistgrip 20 Indicator switch 21 Light switch starter and horn buttons Fig 6 Fig 7 ...

Page 12: ...ever located on the left hand side of the handlebar and is adjustable 1 5 Gear Box Four speed forward drive with constant mesh gears immersed in oil bath are operated by the twist grip on the left hand side of the handlebar which func tions in conjunction with the clutch control lever 1 6 Cooling Forced air provided by a cen trifugal fan 1 7 Mechanical starter With kick starter pedal located on th...

Page 13: ...ubular structure A pressed steel sheet shell covers the tubular structure 3 2 Handlebar Light alloy casting with head lamp instrument panel and indicator lights All transmission cables are con cealed therein 3 3 Steering column and suspension The steering column is pivoted on the front wheel swinging hub Front and rear sus pensions are provided with helical spring hydraulic dampers 3 4 Rear view m...

Page 14: ...r brake drum brake with expanding brake shoes activated by a foot pedal on the right side of the foot platform 4 3 Front brake disc brake activated by a manual lever positioned on the right side of the handlebars 5 TOOL KIT Tool kit in a pouch containing Box Spanner with lever Double sided screw driver 2 Double ended spanners Fig 8 ...

Page 15: ...level as per the marks provided on the level gauge dipstick as shown in the figure for de tails of checking see page no 33 Note ATake care that Engine Oil level is always maintained between the up per and lower level mark on the oil level gauge dipstick Running en gine with insufficient oil may cause serious engine damage Fig 9 Fig 10 Upper level Lower level ...

Page 16: ...is operated by a 12 volt 9 Ah battery A PRD relay prevention of restarting device is provided to avoid use of the self starter when the engine is running A declutch switch has been provided to prevent starting of scooter when the clutch is engaged An 8 Amp fuse on spare wheel bracket Fig 12 13 is provided to avoid any damage due to short circuiting in auto start system A powerful 12 volt 96 watt m...

Page 17: ...14 Parts Specifications ...

Page 18: ...1 Maximum power 5 84 0 25 kW at 6 000 rpm 200 rpm 6 75 0 25 kW at 6 250 rpm 200 rpm Maximum torque 9 15 Nm at 5 000 rpm 11 54 Nm at 3 500 rpm Fuel feed system KEHIN PB Ø 18 carburettor Fuel 95 octane petrol Fuel tap three way Open ON Closed OFF Reserve RES Spark plug RG4HC Champion C8EH9 NGK UHR3CC Bosch Clutch Multiplate oilbath type Starter Electronic CDI Starter Electric with kick start pedal G...

Page 19: ...ect shock absorber with helical spring Front rear wheels Assembled pressed sheet steel unit Front rear tyres 3 50 10 Front brake Disc brake in stainless steel Ø 200 mm Rear brake Drum brake Ø 150 mm Frame Pressed sheet steel with rear tubular framed structure covered by a sheet steel shell assembly Weight 121 kgs Maximum load capacity 275 kgs 2 persons with 10 kgs of luggage Controls Steering Hand...

Page 20: ...Volt 96 Watt Head lamp 12 Volt 35 35 Watt Tail light bulb 12 Volt 5 Watt Stop light bulb 12 Volt 10 Watt Speedolight bulb 12 Volt 1 2 Watt x 2 Turn signal light bulb 12 Volt 10 Watt Tell tale lamp 12 Volt 1 2 Watt x 4 Horn 12 Volt DC Horn fitted with AC to DC convertor Battery 12 Volt 9 Ah Fuse 8 Amp ...

Page 21: ...ng lock cum ignition switch Locking the Handlebar First turn the han dlebar to the extreme left and then turn the key anti clockwise to lock position Pull out the key after locking Fig 14 Un locking the Handlebar Insert the key in ignition switch and turn it clockwise to unlock the handlebar To switch on the igni tion turn the key further clockwise to ON position Fig 15 Fig 14 Fig 15 ...

Page 22: ...press the lid turn the key clockwise and then take out the key Fig 16 17 1 3 Seat Lock Dual Seat Insert the key ro tate it clockwise till the end then take it out Push the lock with thumb Fig 18 and lift the saddle from the back Fig 19 Place the saddle in its normal position press it down To lock the saddle follow the above proce dure in reverse order Fig 19 Fig 18 Fig 17 Fig 16 ...

Page 23: ...gned instrument panel which con tains the following 1 Fuel Gauge 2 Fuel level indicator needle 3 Head light low beam indicator 4 LH turn signal indicator 5 Speed indicator needle 6 Odometer 7 RH Turn signal indicator 8 Head light high beam indicator Fig 20 ...

Page 24: ...low beam l Headlight is switched off if 1 is pressed at top end High and low beam positions are indi cated on the instrument panel 2 1 2 Instrument Panel lights and tail lights Press bottom end of 1 for light Press top end of 1 to switch off light 2 1 3 Stop Light Becomes operative when foot brake pedal or hand brake lever is pressed 2 1 4 Horn Press button 3 2 1 5 Press the starter button 4 to el...

Page 25: ...d for turning right Left right turn indicators are shown on the instrument panel 3 CLUTCH AND GEARCHANGE CONTROLS Located on the left hand side of the handlebar consisting of clutch lever for engaging the clutch and the gear twist for changing gears 3 1 Clutch lever Press the clutch lever to wards the handlebar to disengage the clutch Fig 23 Fig 23 Fig 22 ...

Page 26: ...ow 1 Upto 10 Kms hour 0 Neutral 2 10 20 kms hour 3 20 35 kms hour 4 35 kms hour above To change gear press clutch lever and turn the twist grip Fig 24 to the required position 4 ACCELERATOR CONTROL Located on the right hand side of the handlebar It is a twist grip For increasing acceleration rotate the twist grip towards yourself Do the reverse for decreasing acceleration Fig 25 Fig 24 Fig 25 ...

Page 27: ... distance in which the scooter can be brought to a halt will depend on the speed at which the vehicle is travel ling and the user s driving habits Fig 26 5 2 Hand Brake Operates on the front wheel Press hand brake lever towards the twist grip Fig 27 6 FUEL SUPPLY 6 1 The fuel tank is located under the seat Fig 28 and is accessible only when the seat is unlocked and lifted For filling in petrol uns...

Page 28: ...e in the instrument panel for indicating the quantity of fuel in the tank 6 3 Choke control knob Fig 30 Located below the fuel cock To be used for start ing the engine when it is cold Pull the choke knob out wards for operation Pull out the choke control knob to operate it It must be pushed back in when the engine has warmed up Caution If the choke control knob is pulled out and remains out this w...

Page 29: ...orrect play in the clutch lever Fig 23 and make sure that it operates properly 1 3 Check that the brake pedal play is cor rectly adjusted 1 4 Check that the accelerator control func tions correctly and the play is within nor mal limits A Open fuel cock B Switch ON ignition C Put gear in neutral position D Pull out the choke control knob only when the engine is cold E Position the accelerator contr...

Page 30: ...normally press the choke knob back to its normal position Caution i Do not use electric starter for more than 5 seconds at a time Release the push button start switch for approximately ten seconds before pressing it again If the engine fails to start after repeated attempts hold the throttle 1 8 1 4 open and push the button start switch ii Before using the electric starter button ensure that the c...

Page 31: ...l and position it on the next upper or lower gear 3 6 Use indicator switch button for turning and use horn whenever required 4 APPLICATION OF BRAKES 4 1 Turn the accelerator twistgrip back to zero 4 2 Press the clutch lever and change the gear to the neutral position 4 3 Use foot pedal brake and hand brake simultaneously for the most efficient brak ing ...

Page 32: ...rload the engine 1 Keep to the following speed limits 1st Gear 0 to 10 kms hr 2nd Gear 10 to 20 kms hr 3rd Gear 20 to 35 kms hr 4th Gear 35 kms hr and above 2 Avoid running the scooter on full accelerator throttle for long periods Vary the speed from time to time 3 Do not drive with half partially engaged clutch This will not only damage the clutch but will also cause overheating of the engine 4 A...

Page 33: ...heel The levers for opening the cowls are placed under the seat To remove the cowls 1 1 Lift the seat as explained on page 19 1 2 Turn the cowl opening levers outwards Fig 32 1 3 Hold the body fairing with both hands and remove the cover in an upwards and backwards movement and remove it Fig 33 34 1 4 Pull out the cowl by disengaging its rear end Fig 35 1 5 Refit the cowl by following above proce ...

Page 34: ...of Front Wheel 2 2 1 Put the vehicle on its central stand 2 2 2 Remove the five nuts that fix the wheel to the wheel hub using the box spanner from the tool kit Fig 37 While loosen ing the nuts hold the wheel with one hand 2 2 3 Remove the spring washers and take out the wheel from the brake drum 2 2 4 For refitting follow the above procedure in reverse order 2 3 Changing of Rear Wheel 2 3 1 Put t...

Page 35: ...ouching the ground at right an gle 2 3 7 Bring the vehicle in first gear and hold the wheel with one hand Remove the five nuts securing the wheel to the brake drum by using the box spanner Fig 38 2 3 8 Remove the spring washers and take out the wheel from the brake drum 2 3 9 For refitting follow the above procedure in reverse order Precaution 1 Tighten all wheel securing nuts alternately and prog...

Page 36: ... the face of the tyre in relation to the wheel rim after every 6000 kms Follow the sequence for tyre rotation as explained in fig 39 3 CHECKING ENGINE OIL LEVEL AND CLEANING SPARK PLUG 3 1 Park the vehicle on level surface 3 1 1 Remove the right hand side cowl as di rected on page 30 3 2 Checking oil level 3 2 1 For checking the oil level unscrew disp stick as shown in fig 40 3 2 2 Clean dipstick ...

Page 37: ... box spanner unscrew the spark plug Fig 43 3 3 5 Clean out any excessive carbon deposit 3 3 6 Refix the spark plug back to its position 3 3 7 Refit the cowl If you have a feeler gauge you can check the gap between the electrodes in the spark plug This gap should be 0 7 0 8 mm fig 41 To adjust the gap again it is better to go to an authorised LML assistance centre 4 BATTERY CHECKING Battery require...

Page 38: ...lacing fus 4 2 Removal and refitting the battery 4 2 1 Turn the ignition key to off position 4 2 2 Remove the left hand side cowl as ex plained on page 30 4 2 3 Remove the screw securing ground cable black connected to the negative bat tery terminal by using the end of the screw driver from your tool kit Fig 45 4 2 4 Similarly follow the procedure for remov ing the red cable connected to the posi ...

Page 39: ...s routed properly through its clamp 4 3 6 Fix the Positive terminal first and then the Negative terminal 4 3 7 Make sure the battery cable does not touch any metallic surface during fitment 4 3 8 Apply grease around the terminals to pre vent corrosion 4 3 9 Ensure Protection cap provided on bat tery harness is fixed properly on positive terminal of battery Caution Always ensure that the bleeder tu...

Page 40: ...battery away from rain dew high moisture and direct sunlight 4 4 5 The battery should be charged once a month when the vehicle is not in use For initial charging the battery must be charged at least for 7 hours Always go to the authorised LML assis tance centre for battery maintenance and charging the battery 5 AIR CLEANER Air cleaner is fitted below the fuel tank and requires cleaning during each...

Page 41: ...R VEHICLE WHEN NOT IN USE FOR LONG PERIODS If you are not going to use your vehicle for more than two months then you should store it properly as per the following ad vices 7 1 With the help of a pipe syphon out the petrol from the fuel tank 7 2 Start the engine for some time and ex haust the petrol in the carburettor 7 3 Remove the spark plug as explained on page 34 and put a few drops of Engine ...

Page 42: ...39 Recommended Lubricants Recommended quantity of oil to be filled in Engine is 850 ml ...

Page 43: ...ggested action for different items of maintenance and their periodicity Code of suggested action is NR Item Check or main tenance jobs 0 Km Pre deliv ery 500 Km 3000 Km 6000 Km 9000 Km 1200 0 Km 1500 0 Km 1800 0 Km 2100 0 Km 2400 0 Km 2700 0 Km 3000 0 Km 1 Engine Oil Filling R Replacement S Check level every 1000 Km and top up if required Replace every 3000 Km or every 1 year 2 Engine Oil Filter R...

Page 44: ...Spark Plug Check Replacement C C C C S C C C S C C 5 Air Filter and its elements Clean Lubricate P P P S P P P S P P 6 Fuel Circuit Pipes Check Replacement C C C C C S C C C S C C 7 Fuel Filter Check Replacement C C S C S C S C S C S 8 Check Emission Level Check Adjust C C C C C C C C C C C 9 Valves Clearence Check Adjust C C C C C C 10 Nut Fixing Head Cylinder Check Tightened C C C C C C C C C C ...

Page 45: ... Tensioner Check Replacement C C S C C 12 Chain Guide Check Replacement C C C C C 13 Electrical System Check C C C C C C C C C C C C 14 Battery Check C C C C C C C C C C C C 15 Front Brake System Check Replacement C C C C C C C C C C C C Replace brake oil every 12000 Km or every 2 years 16 Rear Brake System Check Adjust Replacement C C C C C C C C C C C C 17 Clutch Lever Play Check Adjust C C C C ...

Page 46: ... 3000 0 Km 18 Accelera tor Com mand Check Adjust C C C C C C C C C C C C 19 Steering Column Rings Check Adjust C C C C C C C C C C C C 20 Security Tightened Nuts Bolts and Screw Check Tightened C C C C C C C C C C C C 21 Central Stand Check C C C C C C C C C C C C 22 Oil Pump Function ing Check C C C C C C C C C C C C 23 Clean Crank Case Breather Tube Check Clean C C C C C C C C C C C C ...

Page 47: ...y 500 Km 3000 Km 6000 Km 9000 Km 1200 0 Km 1500 0 Km 1800 0 Km 2100 0 Km 2400 0 Km 2700 0 Km 3000 0 Km 24 Rear Front Damper Check C C C C C C C C C C C C 25 Wheels Tires Check Replaceme nt C C C C C C C C C C C C Tyre rotation every 6000 Km C Check Adjust P Clean Lubricate S Replacement R Filling ...

Page 48: ...on Monoxide CO level in exhaust gases Following are some tips to control CO level in ex haust gases 1 Use only recommended spark plug 2 Clean the air filter and replace if required 3 Clean and adjust carburettor properly Adjust the air mixture screw to to 1 threads anti clockwise from fully to closed position and thereafter set idling screw 1000 to 1300 RPM 4 Check the compression pressure and ens...

Page 49: ......

Page 50: ...e hex bolts Fig 47 of mounting bracket secondary air system B Disconnect tube to Air cleaner box X intake manifold Y by removal of spring clips C Disconnect tube Z to Silencer by removal of hose clamp D For cleaning blow air through pipe X Y Z E Check tubes for leakage replace if necessary Bolt Fig 47 Fig 48 ...

Page 51: ...bed and illustrated herein remaining unaltered LML Limited reserves the right to carry out at any moment without being obliged to bring this booklet up to date modifications to the machine its parts or accessories that the company deems to be convenient for improvement purposes or of what may be required for manufacturing or commercial purposes ...

Page 52: ...Redefining mobility worldwide C 10 Panki Industrial Estate Site ll Kanpur 208022 INDIA 91 512 2691381 6660300 91 512 2691391 6660301 lmlknp lml india com ...

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