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AIR CLEANER ELEMENT
CLEANING



Remove Rh side cover
assembly as per steps given
in point number-2.



Remove intake pipe by
removing 3 screws 20 mm
length.



Remove air cleaner
element for cleaning.

CLEAN THE ELEMENT BY AIR.
REPLACE IF DAMAGED

Reassembly in the reverse
order of removal and
disassembly.

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Summary of Contents for Renegade Commando

Page 1: ...SERVICE MANUAL BODY RENEGADE MOTORCYCLE 300 CC...

Page 2: ...RENEGADE COMMANDO RENEGADE SPORTS...

Page 3: ...VEHICLE MAJOR DIMENSIONS...

Page 4: ...VEHICLE IDENTIFICATION NUMBER VIN VIN number is punched on the Right Side of the Frame Generally on the Head Tube as shown in the Picture Yellow marked area...

Page 5: ...LOCATION OF IMPORTANT BODY PARTS 1 Storage box 2 Air cleaner 3 Tool box 4 Cushioned backrest 5 Rear fender assembly 6 Rear Wheel 7 Rear Brake panel 8 RH side cover 9 Fuel Tank 10 Chassis...

Page 6: ...TS 1 Radiator 2 Carburetor Throttle body 3 Battery 4 Rear sprocket Chain drive 5 Pillion hand hold 6 Main stand 7 Side stand 8 Front wheel Front fender 9 Front Hydraulic brake assembly 10 Handle bar a...

Page 7: ...D 41 MM SUSPENSION REAR TWIN HYDRAULIC WITH SPRING TWIN HYDRAULIC WITH SPRING VEHICLE DIMENSIONS KERB WEIGHT 172 Kg with 90 fuel oil 172 Kg with 90 fuel oil WHEELBASE 1545 MM 1545 MM WIDTH 780 MM 780...

Page 8: ...5 3 5 15 TYRE SIZE FRONT 110 90 16 TVS 110 70 17 TVS Tubeless TYRE SIZE REAR 140 90 15 TVS 140 90 15 TVS Tubeless TYRE TYPE TUBE TUBELESS BRAKES BRAKES FRONT DISC D 280 MM 2 Piston Caliper DISC D 280...

Page 9: ...Engine decoration covers LH RH side 5 Fuel tank 6 Air cleaner 7 Rear fender 8 Rear sprocket brake panel rear wheel 9 Rear swing arm 10 Front wheel 11 Front fender 12 Front fork 13 Steering stem 14 Re...

Page 10: ...1 REAR FRONT SEAT ASSEMBLY Remove rear seat Flange bolt M6 16 T wrench 10mm Remove front seat flange bolts M6 12 2 No s T wrench 10mm...

Page 11: ...COVER Remove Lower side cover RH by unlocking with key Remove rear side cover RH by pulling out side carefully Remove 3 pan head screws M6 16 to remove front side cover RH Reassembly in the reverse or...

Page 12: ...IDE COVERS LEFT SIDE COVER Remove rear side cover LH by pulling out side carefully Remove 3 screws to remove front side cover LH M6 16 No s Pan head Reassembly in the reverse order of removal and disa...

Page 13: ...4 ENGINE DECORATION COVER LH RH SIDE Remove LH RH side Engine decoration cover Allen screw M6 16 2 No s each side Allen key 4mm Reassembly in the reverse order of removal and disassembly...

Page 14: ...e Fuel tank rear side bolt M8 35 with plain washer T Wrench 12mm Remove rubber cushion Disconnect fuel gauge speedometer couplers GASOLINE IS HIGHLY FLAMMABLE AND EXPLOSIVE KEEP HEAT SPARK FLAME AWAY...

Page 15: ...EANER After removing Fuel tank as per procedure given Refer Point 5 AIR FILTER ASSY can be taken out Flange bolts M6 16 3 No s T wrench10mm Tightening torque 10 12 Nm Remove tool kit box by pulling it...

Page 16: ...ver assembly as per steps given in point number 2 Remove intake pipe by removing 3 screws 20 mm length Remove air cleaner element for cleaning CLEAN THE ELEMENT BY AIR REPLACE IF DAMAGED Reassembly in...

Page 17: ...st Allen bolt M8 16mm 2 No s with spring washer 2 each RH LH side Tool Allen key 6mm Loosen RL LH Rear Shock absorber upper mounting dome nut M10 T 18 Remove both side rear fender decoration plates Al...

Page 18: ...racket is mounted on main frame with the help of M6 16 4 bolts Reassembly in the reverse order of removal and disassembly ENSURE THAT REAR FENDER IS REMOVED WITHOUT ANY SCRATCHES ON IT DISCONNECT ALL...

Page 19: ...REAR BRAKE PANEL REAR WHEEL Remove rear brake cam nut CHECK THAT BRAKE CAM IS WORKING SMOOTHLY APPLY GREASE IF REQUIRED Remove Brake panel nut from position rod Remove Rear axle nut M with the help o...

Page 20: ...Remove rear axle from the wheel Remove Left bush rear sprocket Flange Rear wheel carefully from rear wheeling arm Check damper rear wheel for any damage Replace if found damaged...

Page 21: ...ut noisy Remove right bush rear wheel Panel rear brake carefully from rear wheel CLEAN HUB INNER SURFACE BRAKE LINEAR SURFACE BEFORE REFITTING REPLACE BRAKE SHOES IF FOUND WORN OUT OR HARD REPLACE HUB...

Page 22: ...CHECK THAT BEARING 6302 2RS REAR WHEEL Rh SIDE IS FITTED PROPERLY IN HUB Reassembly in the reverse order of removal and disassembly...

Page 23: ...9 REAR SWING ARM Remove Bolt nut of swing arm Bolt M14 279 1 5 mm Nut M14 Lock nut Tightening Torque 60 70 Nm...

Page 24: ...ower side 1 CHECK THAT BOTH SIDES DUST COVER CHAIN SLIDER ARE FITTED PROPERLY NOT IN DAMAGED CONDITION 2 CHECK THAT BOTH SIDE ARMS BUSH ARE IN GOOD CONDITION THERE SHOULD NOT BE ANY DAMAGE WERING 3 CH...

Page 25: ...Reassembly in the reverse order of removal and disassembly...

Page 26: ...WHEEL Remove Front nut from wheel RH side Nut M14 Ring spanner 20 22 Remove axle bolt M14 268 Tightening Torque 60 70 Nm While refitting front wheel check that speedometer sensor is properly fitted i...

Page 27: ...Remove Bush 28 15 22 OD ID T CHECK THAT DUST SEAL BEARING BOTH THE SIDES 6302 2RS ARE IN GOOD CONDITION REPLACE IF DAMAGED WORN OUT...

Page 28: ...If bearing is noisy worn out should be removed with the help of special tool Inside there is one spacer rubber washer to properly locate spacer...

Page 29: ...Fitment of both sides bearing with the help of special tool Replace the disc if worn out thickness is 4 2 mm To replace remove 6 Allen screws Allen Bolt M8 25...

Page 30: ...While tightening Apply Loctite 290 before tightening TORQUE 25 28 Nm...

Page 31: ...11 FRONT FENDER Remove bolts on each LH RH side Bolt M6 16 2 2 RH 2 LH side T Wrench 10 mm...

Page 32: ...an be removed from vehicle with or without front wheel Remove STEERING BOLT M14 30 CHROME TORQUE WHILE TIGHTENING 60 70 Nm Remove Head light decoration cover side top screws Side Allen screws M6 12 4...

Page 33: ...16 2 Allen key 4 mm Loosen UPPER TRIPLE CLAMP M10 30 2 No s both sides TIGHTENING TORQUE WHILE ASSEMBLING 30 35 Nm Remove STEERING STEM ASSY HEX BOLT M10 40 2 both sides TIGHTENING TORQUE WHILE ASSEMB...

Page 34: ...y carefully along with upper triple clamp without damaging any other part Remove upper lower rubber dust seals from shocker tube cover Remove both side covers Remove front brake caliper assembly Bolt...

Page 35: ...Remove complete Fork assembly from Steering stem Reassembly in the reverse order of removal and disassembly...

Page 36: ...13 STEERING STEM Remove Stem steering nut carefully Nut M25 Tightening torque while assembling 20 22 Nm...

Page 37: ...Remove dust proof cover Remove top upper cone Remove bearing cage Now remove complete Steering stem from Chassis Main pipe TAKE CARE OF STEM THREADING FOR ANY DAMAGE...

Page 38: ...1 2 FRONT SUSPENSION LEFT 41 MATT BLACK 1 3 OIL SEAL FRONT FORK 2 4 UPPER RUBBER FRONT SUSPENSION 41 47 17 2 5 FRONT SUSPENSION UPPER DECORATION COVER R MATT BLACK 1 5 FRONT SUSPENSION UPPER DECORATIO...

Page 39: ...T TURNING LIGHT BRACKET COVER 1 12 FRONT HEADLIGHT BRACKET MATT BALCK 1 13 STEERING STEM ASSY MATT BLACK 1 14 CLAMP FOR SPEED SENSER CABLE UP MATT BLACK 1 15 CLAMP FOR BRAKE TUBE UP MATT BLACK 1 16 ST...

Page 40: ...14 REAR BRAKE PEDAL No picture specifications 1 Hexagon Bolt M6 30 nut M6 2 washer 16 spring clip 14 3 Hexagon flange bolt M10 1 25 40 4 Hexagon flange bolt M10 1 25 20...

Page 41: ...BRAKE PLAY PEDAL POSITION ADJUSTMENT Maintain the Brake Pedal Height as per given specification Height from Front Footrest Rubber 65 70mm Height from the ground 350 355mm...

Page 42: ...15 RADIATOR Drain Complete coolant Loosen all the coolant hoses before dismounting Radiator No specifications 1 Hexagon flange bolt M6 16 2 Hexagon flange bolt M6 25 self lock nut M6...

Page 43: ...tands are smooth in function Check spring for proper fitment Apply Grease if hard in operation Central stand is tightened with 1 central stand axle L 130 2 washer 16 3 spring pin Side stand is tighten...

Page 44: ...cover Magneto Switch gear indication wires are disconnected from wiring harness Coolant is totally drained from engine radiator Radiator is removed from chassis Muffler silencer is removed from Engine...

Page 45: ...SUB FRAME ENGINE MOUNTING WITH CHASSIS...

Page 46: ...flange bolt M10 1 25 110 self lock nut M10 1 25 55 65 Nm 2 Allen Bolt M8 60 self lock nut M8 28 32 Nm 3 Hexagon flange bolt M8 60 self lock nut M8 28 32 Nm 4 M6 20 5 Allen Bolt M10 1 25 30 Hexagon nu...

Page 47: ...SERVICE MANUAL VER B170626...

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