Vento Phantom R4i Service Maintenance Manual Download

Page: 1 / 88

VENTO MOTORCYCLES

Rev no.01/ page 1of 84

VENTO MOTORCYCLES

Motorcycle division

Doc.Title :SERVICE MANUAL Phantom R4i
Doc.no(Model code):VS-01-A-4-A

Brand Name :VENTO

Revision Number : 01

Date of release :26.01.2004

Page :1 of 84

PAGE

DESCRIPTION

PAGE

DESCRIPTION

GENERAL
INFORMATION

Left crankcase Accessories

Model
identification

Crank case installation

Break in
procedures

Transmission case installation

Precautions &
General
instructions

Movable drive face

Specifications

Valve clearance adjustment procedure

PERIODIC
MAINTENANCE

Compression Test

Storage battery

AIR FUEL SYSTEM

Spark plug

Carburetor Tuning

Air cleaner

CHASSIS

Special tools list 58

Front Wheel assembly

Specified torque
values

Front fork assembly

ENGINE

Hydraulic Brake Disc System

Gear Ratio

ELECTRICAL

Engine disassembly
& Assembly

TROUBLE SHOOTING

Camshaft holder
assembly

Engine

Piston
installation

Carburetor

Left crankcase
cover installation 80

Electrical

Right crank case
cover Accessories

Battery

Right crank case
Accessories

Brakes

Revision Number

Date of Issue

Revision Number Date of Issue

26.01.2004

Design and Development Dept.

Summary of Contents for Phantom R4i

Page 1: ...ance adjustment procedure 12 PERIODIC MAINTENANCE 46 Compression Test 13 Storage battery 47 AIR FUEL SYSTEM 15 Spark plug 56 Carburetor Tuning 16 Air cleaner 57 CHASSIS 17 Special tools list 58 Front Wheel assembly 20 Specified torque values 61 Front fork assembly 21 ENGINE 63 Hydraulic Brake Disc System 24 Gear Ratio 68 ELECTRICAL 25 Engine disassembly Assembly 77 TROUBLE SHOOTING 29 Camshaft hol...

Page 2: ...VENTO MOTORCYCLES Rev no 01 page 2of 84 Phantom R4i Service Maintenance Manual ...

Page 3: ...wing features such as V belt drive automatic transmission Fan air cooling system CDI Ignition system Auto Ignition system Alarm System Remote start system Illustrations in this manual are used to show the Basic principles of operation and work procedures This manual contains an introductory description on VENTO Phantom R4i scooter and procedures for Inspection Service and overhaul of its main Comp...

Page 4: ...L COPYING It is the policy of Vento Motorcycles to actively protect its copyrights and trademarks Legal action will be taken against anyone who unlawfully copies the cover or contents of this manual This includes all forms of unauthorised copying including digital mechanical and electronic in any form Illegal copying will also be reported to the appropriate statutory authorities CONTENTS ...

Page 5: ... NUBER AND ENGINE NUMBER are designed especially for registration your scooter and for spare parts order FUEL AND ENGINE OIL RECOMMENDATION Be sure to use specified fuel and engine oil Some specifications are as follows FUEL Gasoline should be Unleaded the octane number must be 85 95 or more ENGINE OIL For engine lubrication use specified high quality SAE10W 40 or SAE 10W 50 engine oil GEAR OIL Us...

Page 6: ...ty of the engine depends on the care and restraint during its early life General requirements are as follows Limit break in speed At the first 1000 Kms 630 miles mileage use throttle opening less than 1 2 Up to 1600 Kms 1000 miles mileage use throttle opening less than 3 4 Upon reaching an odometer reading of 1600 Kms 1000 miles you can operate the motorcycle to full throttle operation Do not main...

Page 7: ... always ensure that it is completely seated in its groove and securely fitted o Do not use self locking nuts a few times over o If parts replacement is necessary replace the parts with VENTO Genuine parts or their equivalent o When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstall in proper order and orientation o Always use special tools wh...

Page 8: ...rade Lubricating system Oil pump style Air cleaner Cylinder pressure Inlet port open Close Exhaust open Close Tappet Clearance Inlet valve Exhaust valve Idle speed Max Torque Max Output power Starting system Dry weight of engine 4 Stroke Air Cooled Single Cylinder 52 4X57 8 124 6 cc 10 3 1 Two Valve 0 9L SAE10W 40 or SAE 10W 50 Pressure splash type lubrication Rotor type 10 0 2 0Kg Cm 2 30 BTDC 30...

Page 9: ...g gap Fuse Horn Battery CDI 13º BTDC 1400RPM 28º BTDC 4000 RPM 114W 4000RPM C7HSA 0 6 0 7mm 8A 100dB 12V 6Ah YUASA YTX7A BS LIGHT Headlight high beam Low beam Taillight brake light Turning signal light Head light Indicator Turn Signal Indicator High beam indicator Alarm indicator light 12V 18W 18W 2 12V 15W 5W 12V 10W 2 Front Rear 12V 3 W 2 12V 1 7WX2 12V 1 7WX2 LED ...

Page 10: ...tem Primary gear reduction Gear ratio First Second Max speed Dry shoe Automatic CVT 10 86 2 64 2 8 42 15 3 077 40 13 85 5km h CARBURETOR Model code Piston Dia Main jet Slow running jet Idle speed air adjusting screw Float height Jet needle position from top PD24J 24mm 191 19 Inside1 2 1 2 1 rounds 15 1mm 3 rd Groove ...

Page 11: ...eel specification Rear wheel specification Tire pressure front Tire pressure rear Front brake Rear brake Fuel tank capacity Engine Oil capacity Liquid pressure type compressibility 130 mm Liquid pressure type compressibility 75mm 130 60 13 130 60 13 32 PSI 32 PSI Disc Type Drum Type 6 0 Liter 1 0 Liter ...

Page 12: ...VENTO MOTORCYCLES Rev no 01 page 12of 84 CHAPTER 2 PERIODIC MAINTENANCE AND SERVICE Periodic maintenance and service schedule Storage Battery Spark Plug Air Cleaner Special Tools Specified Torque Values ...

Page 13: ... 18000 24000 Interval Months 2 12 24 36 48 Storage battery I I I I I Cylinder head nut and exhaust pipe bolt T T T T T Cylinder head and cylinder C C C C Spark plug C R C R Air cleaner Inspect Clean every 3000 Kms 1890 miles Replace every 12000 Kms 1750 Miles Idle speed rpm I I I I I Throttle cable play I I I I I Oil pump I I I I I Gear oil I R R I I I I I Fuel line Replace every 4 years Brake I I...

Page 14: ... then remove the battery from the battery box Disconnect Negative terminal Cable first then Positive terminal Cable of Battery Measure the voltage between the ve and ve terminal of Battery charge the Battery if the voltage is below the specified limit Inspect at initially 1000Kms 630 miles 2 months and every 6000 Kms 3780 miles 12 months ...

Page 15: ...k to see the carbon deposit on the Spark Plug If the carbon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointed end Check to see the worn out or burnt condition of the electrodes If it is extremely worn or burnt replace the plug and also replace the plug if it has a broken insulator damaged thread etc Thickness gauge Spark plug gap 0 6 0 7 mm 0 024 0 0...

Page 16: ...the washed element By pressing it between the palms of both hands do not twist or wring the air cleaner element or it will develop tears Immerse cleaned filter element in CCI or CCI Super oil and Squeeze the oil out of the element leaving it slightly wet with oil Fit the element to the Air cleaner case properly Install Air cleaner in the reverse order of removal CAUTION Before and during the clean...

Page 17: ... 2 3 4 5 6 7 8 9 10 T01 T02 T03 T04 T05 T06 T07 T08 T09 T10 T SHAPE TAPPET ADJUSTING TOOL GUIDE CYLINDER TOOLS 8 10 12 13 TOOL FOR FLY WHEEL DISASSEMBLY TOOLS TO DISASSEMBLE VALVE SPRING DISASSEMBLING TOOLS FOR OIL DRAINAGE COMPRESSION PRESSURE GAUGE DISASSEMBLING TOOL FOR PISTON PIN SPARK PLUG SOCKET ELECTRIC TOOL FOR OPENING OF FLY WHEEL BOLT CULTCH CLAMP ...

Page 18: ...VENTO MOTORCYCLES Rev no 01 page 18of 84 1 2 3 4 ...

Page 19: ...VENTO MOTORCYCLES Rev no 01 page 19of 84 7 8 9 10 SPECIFIED TORQUE VALUES IT IS IMPORTANT FOR THE COMPONENTS FASTENERS TO BE TIGHTEED AS PER SPECIFIED TORQUE NO NA ME QTY TORQUE ...

Page 20: ...e cover Oil filter cover cap Nut for oil pump Nut for oil pump sprocket Nut for oil pump Nut for oil pump cover Screw for starting clutch Screw for super starting clutch outside Bolt for right crankcase Double head bolt for left and right crankcase Fixing bolt for self start motor Bolt for left crankcase cover and wiring harness Tapping screw for ventilating guide board of left crankcase cover Nut...

Page 21: ...Engine 4 18Фx3 5 1 Oil Level gauge Engine 5 30 5Фx3 1 Filter spring cap Engine 6 40 7Фx1 9 2 Driven wheel disc Engine 7 27Фx2 1 Inlet seat Engine S NO Size mm Qty Description Location 1 20x32x6 1 Output shaft gearbox cover Engine 2 27x42x7 1 Output shaft left crankcase Engine 3 20x29x6 1 Crank left crankcase Engine 4 19 8x30x5 1 Crank right cover Engine S NO Code Qty Description Location 1 6203 1 ...

Page 22: ...eft Crank case Engine 6 6301 1 Output shaft left Crank case Engine 7 TM SCD4ASSCS12 1 Left crank left Crank case Engine 8 TM SCD4ASSCS12 1 Right crank right Crank case Engine 8 K28x33x14 1 Crank pin crank connecting big end Engine 9 K28x32x17 1 Clutch hub clutch gear Engine 10 6902NSE28 x15x7 1 Driven disc output shaft Engine 11 HK20 x29x18RS 1 Driven disc output shaft Engine 12 6002 2 Camshaft Ho...

Page 23: ...ket Type Qty Location 1 Cylinder head cover Anti Oil Asbestos Rubber 1 Engine 2 Cylinder head Steel 1 Engine 3 Cylinder body Anti Oil Asbestos Rubber 1 Engine 4 Crankcase Anti Oil Asbestos Rubber 1 Engine 5 Right crankcase cover Anti Oil Asbestos Rubber 1 Engine 6 Left crankcase cover Anti Oil Asbestos Rubber 1 Engine 7 Chain adjuster Anti Oil Asbestos Rubber 1 Engine ...

Page 24: ... 40 NO GEAR No teeth POSITION 1 Kick starter gear 38 Engine 2 Kick starter transition small gear 13 Engine 3 Kick starter transition big gear 49 Engine 4 Crank kick starter driven gear 20 Engine 5 Starting motor drive gear 9 Engine 6 Electric starter transition gear 49 17 Engine 7 Clutch gear 60 Engine No Sprocket wheel No teeth POSITION 1 Right crank oil pump driver sprocket wheel 18 Engine 2 Oil...

Page 25: ...he side of kick starter gear and transition gear with mark is towards left cover 5 Chain guide groove should be towards chain and column rod of chain guide part is not higher than the surface of cylinder 6 White piston ring is the first one black piston ring is the second one groove of 1st and 3rd ring towards exhaust port groove of ring 2 and ring 4 are towards inlet port the side with English le...

Page 26: ... pin Piston piston pin circlip Spring clip piston pin piston cylinder gasket dowel pin Cooling Fan flywheel Stator coil cylinder cover gasket dowel pin Right crankcase cover oil filter oil gauge Cam camshaft holder Right crankcase outside Chain adjustor cylinder head cover Start motor left and right crankcase crank Left crankcase outside assy Gearbox Left crankcase cover gasket dowel pin Left cran...

Page 27: ...y CYLINDER HEAD ASSEM BLY Screw 6 Bolt 7 Fan cover assy 8 Cover 9 Cooling pipe 5 Screw 10 Bolt 1 Top cowling Bottom cowling Top cowling Seal gasket 2 Bottom cowling seal gasket 3 Coil clip 12 Cover 13 Specified torque value Fan cover screw 6 2NM Fan cover bolt 7 11NM Guide fan cover screw 10 2NM Guide fan cover bolt 1 11NM ...

Page 28: ... shaft holder assy Cam shaft holder assy cam shaft fixer assy Cam shaft assay and cam shaft holder assy Cylinder head assy Right against mark T on magneto rotor and correct timing mark on sprocket keep timing marking on the same level as joint surface of cylinder head Valve lock clip valve spring holder Inlet exhaust valve spring Use special tool T04 Timing chain tensioner adjust Inlet valve exhau...

Page 29: ...KER 4 ATMOLYSIS SHAFT AND LEFT BEARING 13 STOPPER BOARD 5 ATMOLYSIS SHAFT SPROCKET ASSY 11 AXIS 6 AND BUSH 7 ATMOLYSIS SHAFT ASSY MASS 8 AND SPRING 9 ATMOLYSIS SHAFT SUPPORTER 10 CAM SHAF HOLDER 10 AXES 6 BUSH 7 MASS 8 AND SPING 9 CAM SHAFT ASSY STOPPER BOARD 5 CAM SHAFT SPROCKET11 ROCKER 4 AND GASKET 3 CAM SHAFT RIGHT BEARING 12 CAM SHAFT LEFT BEARING ROCKER SHAFT 2 AUTO REDUCTOR OUTSIDE CIRCLE 1...

Page 30: ...VENTO MOTORCYCLES Rev no 01 page 30of 84 PISTON INSTALLATION ...

Page 31: ...e first ring is white ring and the second ring is black one The sides of the first ring and the second one with English Letters are up Letter IN is towards inlet port and the first ring is dead against oil ring slice Never make mistake in positioning the first ring and the second ring Keep exhaust port the second ring oil ring slice The gap of spring clip is 80º 100º against the gap of groove ...

Page 32: ... ventilation board respectively of 4 tapping screws with specified torque 3 6N M and tighten the board plate with same tool then respectively cover tapping screw head 2 When installing left crankcase cover tap it to its proper position with wooden hammer or plastic hammer not with metal hammer to avoid damaging the face of crankcase crankcase cover 3 Brake cable clip 1 main stand stopper holder 2 ...

Page 33: ...earance between flywheel trigger and pickup Oil filter screw cap 24 O ring 23 Spring 22 Filter assy 21 Oil gauge 6 Seal 5 Other bolts Right crankcase end cover 3 Gasket 1 Screw 12 Fan assy 13 Nut 14 Gasket 15 Flywheel 16 Screw 11 Pickup assy 10 Bolt 7 Cable holder 4 Specified Torque Value Nut 14 50N M Magnet motor bolt 17 7N M Fan bolt 12 11N M Trigger screw 11 6N M Oil filter screw cap 24 57N M O...

Page 34: ... pump sprocket end cover 8 Start clutch complete 3 Nut 9 Half round plate 4 Oil pump chain 10 Oil pump sprocket wheel 11 Bolt 12 Special Screw 13 screw 14 Oil pump cover 15 Rotor 16 Pin 17 Oil pump cover 18 Specified Torque value 1 Clutch locknut 35 40N M 2 Oil pump fixing bolt 10 12 N M 3 Sprocket wheel locknut 10 12 N M 4 Sprocket wheel end cover bolt 8 10 N M 5 Pump cover fixing screw 3 5 N M ...

Page 35: ...nd kick start gear assy Assemble with little grease keep arrow mark on transmission gear dead against crankshaft align kick start gear dead against marking point on transmission gear carefully pull kick start shaft spring to correct position with special tool be careful that spring doesn t turn back position starting spring correctly and tighten the nut with specified torque 10 12NM When installin...

Page 36: ... bearing with some little oil and then vertically put the oil into bearing hole assemble timing chain with crankshaft gear check crankshaft connecting rod should be rotate freely and feel that axial clearance exists for connecting rod big end It is permitted to disassemble or assemble left and right crankcase with wooden hammer or plastic hammer but never with metal hammer otherwise crankcase will...

Page 37: ...ATION The installation sequence is just reverse of the removal NOTE Check Correct position of each bearing the mark of bearing should be outside and its rotation should be freely without any obstruction During assembly of oil seal should be apply little oil don t damage the oil seal Various gears should be positioned properly and should be turn freely To assemble 6 Bolts first of all pre fasten pi...

Page 38: ...cle 5 ball bearing 14 limiter 22 pin shaft 23 Compression spring 5 rear transmission main disc 11 driving board bottom holder 24 ASSEMBLY The assembly sequence is just reverse of removal NOTE When reinstalling clutch driving board assy be sure to use new limiter and pin shaft and ensure stable connection When installing ball bearing and roller needle bearing use some lubrication to ensure free tur...

Page 39: ... it Daub shaft end with proper lubrication to install bush 6 Be sure to install pin proper tightly TRANSMISSION GEAR SHAFT ASSEMBLY REMOVAL Transition gear shaft assy Fixing pin 6 Adjustment gasket 4 Transition gear assy 3 including 5 Tension spring 2 Transition gear shaft 1 Clip 5 Installation The installation sequence is the reverse of removal Notice Before installing transition gear install cli...

Page 40: ...ushion gaskets into 8 Bush 2 should be slide freely REMOVAL Face fixed drive 1 Bush 2 Plate Drive 8 Cushion gasket 9 Roller 7 Washer 3 Bush 4 Washer 6 Face movable drive 5 INSTALLATION Face movable drive 5 Washer 6 Steel bush 4 Washer 3 Roller 7 Cushion gasket 9 Plate Drive 8 Bush 2 Face fixed drive 1 ...

Page 41: ...6 3 Clutch hub 4 Pin 5 Rolling pole 6 spring bush 7 and spring 8 Clutch outside circle rubber 9 Spring seat 10 Clutch side circle 11 Installation The installation sequence is just reverse of removal NOTE Should not be loose clutch side cover screw M6 and spring seat after installation Clutch gear should turn only one direction ...

Page 42: ... 2 Crank 11 Driving disc Driven disc 6 Clutch 7 Gearbox input axes 10 From kick start Kicking start shaft Kicking start axes 5 Start gear Transition little gear Transition big gear Crank start driven gear Crank 11 X Reduction Ratio Y Primary Reduction Ratio 15 42 Z Secondary Reduction Ratio 13 40 ...

Page 43: ... Seals combustion chamber ANTI WEAR Improves the life of moving components The type of lubrication used in the engine of motorcycle is known as wet sump splash Pressure feed lubrication ENGINE OIL CIRCULATION Oil pump assembled in right crankcase sucks oil through main gears on right crankshaft Oil in crankcase is filtered through the oil filter core of left crankcase and then flows across oil pum...

Page 44: ...VENTO MOTORCYCLES Rev no 01 page 44of 84 LUBRICATION DIAGRAM Rocker arm Camshaft assy Crank assy Oil pump assy Filter assy ...

Page 45: ...heel to the same line with the mark on right crankcase cover Ensure timing mark of cam sprocket in the same line with joint surface of cylinder head cover Check the clearance of Inlet valve and Exhaust valve Inlet valve 0 03 0 05mm Exhaust valve 0 05 0 06mm If clearance is not at the specified limit then adjust Tappet clearance to the specified limit COMPRESSION TEST ...

Page 46: ...ine again Remove spark plug and put few drops of engine oil inside the combustion chamber Connect Compression gauge repeat above said procedure as explained in STEP 1 If the Compression pressure reading increases then check for following a Worn out cylinder b Worn out piston piston rings c Scoring Seizure of cylinder piston d Piston ring jammed in groove If the Compression pressure does not increa...

Page 47: ...de Exhaust 0 035 0 057mm Inner Spring 32 8mm Spring free length Outer Spring 35 55mm A B Inner diameter of cylinder Bore 52 400 52 405mm 52 405 52 410 mm Diameter of piston 52 370 52 375mm 52 375 52 380mm Cylinder piston Clearance between piston and cylinder 0 025 0 035mm 0 025 0 035mm Piston pin OD 15 002 15 005mm 15 005 15 008mm Piston pin Piston pin ID 14 997 15 000mm 15 000 15 003mm The first ...

Page 48: ...ge 48of 84 CHAPTER 4 AIR FUEL SYSTEM Carburetor specification FUEL CONSUMPTION CURVE Type Model Piston dia Main jet Slow jet Mixture screw Needle position Float height CV PD24J 24mm 191 19 1 5 0 5 turnout 3rd groove from top 15 1mm ...

Page 49: ...VENTO MOTORCYCLES Rev no 01 page 49of 84 ...

Page 50: ... mixes with clean air in right proportion in the carburetor and then air fuel mixture is supplied to the combustion chamber of the engine In engine this air fuel mixture is controlled by the intake valve and camshaft rocker arm mechanism AIR FUEL FLOW CHART AIR FUEL Atmosphere Fuel tank Air cleaner assy Strainer fuel cock Filters Sedimentation bowl Flame Trap Filter Venturi Inlet Floater Chamber D...

Page 51: ...R CIRCUITS Starting 7 8 1 The Phantom R4i Scooter has 6 main circuits Idling speed 10 12 1 1 Fuel Intake circuit Slow speed 12 14 1 2 Choke circuit Medium speed 15 17 1 3 Idling speed circuit High speed 13 15 1 4 Slow speed circuit 5 Medium speed circuit 6 High speed circuit ...

Page 52: ...E CIRCUIT Choke is provided for easy starting since it requires rich mixture Hence choke knob is being operated from the carburetor Due to this an air stopper Butterfly valve comes on the way to the venturi Air filter side of the carburetor thus reducing the amount of air being mixed with fuel Excessive fuel is being sucked from the slow jet and less quantity of air enters from the choke valve and...

Page 53: ...acceleration Air fuel mixture is being supplied by slow jet and also from main jet This is due to partial opening of throttle valve lifts needle jet upwards Hence some quantity of air fuel mixture coming out from main jet diffuser also mixes along with slow jet mixture to increase the mixture quantity as required by engine 5 MEDIUM SPEED CIRCUIT Economy speed range Further acceleration the air fue...

Page 54: ...upplied due to higher velocity Hence pressure drops at the opening of throttle jet needle Where as more fuel is sucked from the main jet due to tapperness of jet needle A jet holder is provided to the main jet to avoid fuel flow strain turbulence effect in the float chamber created during the very high speed to diffuser As shown in the figure ...

Page 55: ... screws Pull out the float arm pin to remove the float Remove the main jet along with jet holder and needle Remove the slow jet Now clean all the carburetor components and apply compressed dry air in all passages galleries NOTE Don t remove clip from the jet needle groove Ensure that float and float valve is being removed before carrying out any other jobs on carburetor So that these components wi...

Page 56: ...kwise slowly till engine RPM increases to the peak highest speed position while setting Now stop adjusting air screw Maximum recommended air screw opening position 1 turns out 5 Readjust Idling speed to 1400 100 RPM by the throttle stop screw ensure that exhaust emission Carbon Monoxide CO 1 5 to 2 0 6 After adjusting Idling speed check for its stability flat spot missing if any by accelerating fe...

Page 57: ...bsorber 2 22 29N m Handlebar 1 Fixing bolt for handlebar and supporting under connecting board 1 37 44N m Frame 1 Fixing bolt for frame and engine bracket 2 37 44N m 2 Fixing bolt for frame and rear absorber 2 37 44N m Rear wheel rear absorber 1 Rear wheel locknut 1 100 130Nm 2 Fixing bolt for left rear absorber and engine 1 22 29N m 3 Fixing bolt for right rear absorber and muffler connecting boa...

Page 58: ...ng 8 Tire 1 Rim assy Rim 4 Front wheel bush 5 Bearing 9 valve 3 valve cap 2 Speedometer gear 11 Gear set oil seal 10 gear seat 12 Assembly Speedometer gear 11 Gear seat oil seal 10 gear seat 12 Rim 4 front wheel middle bush 5 bearing 9 valve 3 valve cap 2 Tire 1 Rim assy Front wheel seal ring 8 Front wheel assy front wheel left bush 7 gear seat assy front wheel centre bolt 6 locknut 13 ...

Page 59: ...7 Anti dust assembling board 8 Bolt M6X35 6 Rear braking rocker arm 9 Seal ring 13 Rear brake camshaft 5 Rear rim 12 Valve 3 valve cap 2 Assembly Rear rim 12 Valve 3 valve cap 2 Rear brake camshaft 5 Seal ring 13 Rear brake rocker arm 9 Bolt M6X35 6 Anti dust assembling board 8 Anti dust cover 7 Brake tension spring 10 Brake shoe pulling spring 4 Brake shoe assy 11 Tire 1 Rear rim Rear wheel assy ...

Page 60: ...pe bush 6 Bolt M8X35 10 bolt M8X55 9 Nut M16X1 5 7 Outside orientation bush 8 Muffler connecting board 3 Inner orientation bush 14 Assembly Inner orientation bush 14 Muffler connecting board 3 Outside orientation bush 8 Nut M16X1 5 7 Bolt M8X35 10 bolt M8X55 9 Exhaust pipe bush 6 Exhaust pipe assy 1 Special nut 5 Bolt M8X125 2 bolt M8X40 4 Flat gasket φ8 11 spring gasketφ8 12 nut M8 13 ...

Page 61: ... ball 4 Under connecting support assy 7 Taper roller bearing 6 Upper steel bowl holder 5 Under steel bowl holder 11 Frame assy 12 Assembly Frame assy 12 Under steel bowl holder 11 Upper steel bowl holder 5 Taper roller bearing 6 Under connecting support assy 7 Upper steel ball assy 4 Upper steel bowl 3 Anti dust spring assy 2 Special locknut 1 Front left absorber assy 9 front right absorber assy 8...

Page 62: ...g 11 Oil seal assy 12 Aluminum outer tube 13 Buffer prick 9 Assembly Install piston ring into piston lever Install buffer spring into piston lever Install above assy into inner tube assy Cover piston lever with buffer prick bush Install above accessories into aluminum outer tube Tighten screw gasket Fixing torque is 20 Nm Oil seal assy Oil seal stopper ring Anti dust ring assy Add oil for absorber...

Page 63: ...VENTO MOTORCYCLES Rev no 01 page 63of 84 ...

Page 64: ...master cylinder The pressurized brake fluid gets transferred to the caliper through the brake hose As the brake lever released the piston return spring forces the piston to return to its original position As the brake fluid from the caliper returns slowly a negative pressure is being created between the secondary and primary brake seals This causes the collapse of the primary brake seal which in t...

Page 65: ... no 01 page 65of 84 1 Oil cap 5 Clip ring 9 Tension spring 2 Oil gasket 6 Bowl 10 Outlet oil hole 3 Inlet oil hole 7 Stopper 11 Supplement hole 4 Stopper anti dust cover 8 Bowl 12 Master cylinder MASTER CYLINDER ASSY Fig 6 ...

Page 66: ...VENTO MOTORCYCLES Rev no 01 page 66of 84 DISC BRAKE CALIPER ASSY ...

Page 67: ...VENTO MOTORCYCLES Rev no 01 page 67of 84 OVERHAULING PROCEDURE OF DISC BRAKE ...

Page 68: ...piston assy Assemble the master cylinder parts in reverse order of disassembly sequence NOTE Apply brake fluid on master cylinder piston seals then insert into the master cylinder body OVERHAULING OF DISC BRAKE CALIPER 1 Disconnect the brake hose from caliper and collect the brake fluid and plug the hole 2 Loosen the mounting bolts of caliper assay and take out 3 Disassemble bolt braking caliper a...

Page 69: ...nce of front absorber spring 130MM Disc brake system Description STANDARD Specified disc brake oil DOT3 or DOT4 The thickness of the brake shoe 6MM The thickness of brake plate 4MM Description STANDARD Driver 32 PSI Tire air pressure Driver and passenger 32 PSI The free play of brake lever 20MM Diameter of rear brake hub 130MM The thickness of the rear brake pad kit 4 mm ...

Page 70: ...nted on crank case RHcover CDI unit charging and pick up coil are used for ignition purpose Lighting coil battery charging coil wire connections goes to Regulator cum Rectifier for lighting battery charging purpose Magneto wire color code various coil resistance values are as follows S NO COIL DESCRIPTION RESISTANCE VALUE WIRE COLOR CODE 1 CHARGING COIL 300 500 Ω Red and black 2 PICK UP COIL 200 2...

Page 71: ...specific gravity less than 1 220 then change the battery OPEN CIRCUIT During the charging of battery does not pickup the charge In any of the above case replace the battery RECOMDED BATTERY LOAD TESTER MAKE ELAK MODEL BCT7 CAUTION During Inspection if the battery on the vehicle is found defective before replacing with a new battery it is important to check the battery charging circuit BATTERY CHAR...

Page 72: ...echeck NOTE 2 AMMETER Series connection inline with positive battery wire to measure DC Amp VOLTMETER Parallel connection between positive negative terminal of the battery to measure DC Volts Electrical starting power flow chart Circuit process Storage battery Fuse Main switch Alarm System Stop switch Start switch Start relay Start motor Connect ground magnet motor ...

Page 73: ...wise replace H T coil Check secondary coil resistance between H T cable and earth wire it should be 7 5 1K ohms in total includes 5 0 K ohms series resistance of the suppressor cap otherwise replace H T coil 5 PICK UP COIL Check for its resistance value across blue white and green white wire it should be 150 to 300 ohms at 20 otherwise replace pick up coil Remove spark plug then connect a L E D of...

Page 74: ...g light at ignition mark on the magneto fly wheel As shown in figure During idling speed Ignition mark F align with I mark of timing inspection hole i e 13º before TDC 1400 RPM See Tachometer During Acceleration II FULL ADVANCE index mark align with I mark of timing inspection hole i e 28º before TDC 4000 RPM If the ignition timing is not correct replace CDI and then check with new one ...

Page 75: ...e assembly sequence is the reverse of disassembly INDICATOR BULB Remove Indicator Remove and replace bulb 12V10 W SPEEDOMETER DISASSEMBLY Remove front cover of handlebar Remove connector of headlight Take out flasher from its retainer and remove connector Remove fixing screw Front board back board Remove rotating meter and the core of odometer Replace bulb including high beam turning signal light ...

Page 76: ...VENTO MOTORCYCLES Rev no 01 page 76of 84 ...

Page 77: ...1 240 Below 1 220 Charging current 0 6 Amp Battery Charging time 8 12 hours Capacity 114W at 5000rpm Battery charger Battery charging coil resistance at 20 68 f Between Black and Black White wiring Less than 2 Ohms Lamp cable Yellow and Green White Less than 2 Ohms VOLTAGE REGULATOR OUTPUT Regulated voltage for lighting circuit 14 5Volt Rectified DC voltage for battery charging 11 5 Volt Rectified...

Page 78: ...arging of battery 5 After warming up the engine open timing whole inspection cap then check oil splash for lubrication 6 Check correct tyre pressure if required 7 Check spark plug gap adjust if required and refit properly 8 Check proper functioning of all electrical electronic system and control switches 9 Check proper functioning of accelerator cable and choke 10 Check and adjust Idling speed if ...

Page 79: ...ck turn signals for proper functioning Check tire pressure 2 25Kg cm2 32PSI Check torque of engine mounting bolts Check throttle grip free play 2 4mm Ensure to install first fully charged battery then start the motorcycle Check proper fitment of Spark plug Suppressor cap Check and adjust Idling Speed 1400 100 Check tire pressure 2 25Kg cm2 32PSI Check engine oil level Check brake oil level ...

Page 80: ...high tension cord 5 Defective ignition switch No fuel reaching to the carburetor 1 Clogged hole in the fuel tank cap 2 Clogged or defective fuel cock 3 Defective carburetor float valve 4 Clogged fuel hose or defective vacuum hose Replace Repair or replace Repair or replace Repair or replace Retighten Replace or rebore See electrical section Replace Replace Clean Replace Replace Replace Clean or re...

Page 81: ...lines 3 Worn or damaged bearing of drive shaft or rear axle shaft Replace Replace Replace Replace Replace Adjust Replace Replace Replace Replace Replace Replace repair Replace Replace Replace Replace Replace Slipping clutch 1 Worn or damaged clutch shoes 2 Worn clutch housing 3 Weakened clutch shoe springs 4 Worn or slipping drive belt Replace Replace Replace Replace Engine idles poorly 1 Excessiv...

Page 82: ...es 4 Weakened valve springs 5 Worn piston rings or cylinder 6 Worn Valves or stems 7 Worn oil rings side rails Check with Oil level gauge drain excessive oil Check Replace Check Replace Replace Replace Replace Replace Engine lacks power 1 Excessively worn cylinder or piston rings 2 Sticky piston ring in grooves 3 Compression leaks from valves gaskets 4 Spark plug gaps incorrect 5 Clogged air clean...

Page 83: ...t jet pilot air jet are clogged or loose 2 Air leaking from carburetor s joint vacuum pipe joint or starter 3 Pilot outlet is clogged 4 Starter plunger is not fully close Check and clean Check and replace Check and clean Check and replace Complaint Symptom and possible causes Remedy Medium or high speed trouble 1 Main jet or main air jet is clogged 2 Needle jet is clogged 3 Fuel level is improperl...

Page 84: ...park plug electrodes overheat or burn 1 Spark plug too hot 2 Overheated the engines 3 Loose spark plugs 4 Too lean mixture 5 Not enough engine lubricating oil Replace with specified cold plugs Tune up Retighten Adjust carburetor Check oil pump Magneto does not charge the battery 1 Open or short in lead wires or loose lead connections 2 Shorted grounded or open magneto coil 3 Shorted or open regula...

Page 85: ... or replace BATTERY Complaint Symptom and possible causes Remedy Battery runs down quickly 1 The charging system is not correct 2 Cell plates have lost much of their active material as a result of over charging 3 A short circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte 4 Battery is too old Check the magneto and regulator rec...

Page 86: ...ssure in tires Adjust Replace Replace Adjust tire pressure Wobbly handlebars 1 Loss of balance between right and left front suspension 2 Distorted front axle or crooked tire 3 Distorted front fork Replace Replace Repair or replace Wobbly front wheel 1 Distorted wheel rim 2 Worn front wheel bearings 3 Defective or incorrect tire 4 Loose axle nut 5 Loose nuts on the rear shock absorber 6 Worn engine...

Page 87: ...unting bushing 3 Loose bolts on shock absorber Retighten Replace Retighten BRAKES Complaint Symptom and possible causes Remedy Insufficient brake power 1 Leakage of brake fluid from hydraulic system 2 Worn pads 3 Oil adhesion on engaging surface of pads 4 Worn disc 5 Air entered into hydraulic system 6 Worn shoe 7 Friction surfaces of shoes are dirty with oil 8 Excessively worn drum 9 Too much bra...

Page 88: ...ce Replace Replace brake fluid Disassemble and clean master cylinder Repair surface with sandpaper Tighten to specified torque Replace Excessive brake lever stroke 1 Air entered into hydraulic system 2 Insufficient brake fluid 3 Improper quality of brake fluid 4 Worn brake cam lever 5 Excessively worn shoes and or drum Bleed air Replenish fluid to specified level bleed air Replace with specified f...

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