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Service Manual

Classic 500 & 350

Содержание Classic 350 2009

Страница 1: ...Service Manual Classic 500 350 ...

Страница 2: ...INTRODUCTION SECTION ONE 01 ...

Страница 3: ...manual is correct at the time of going to print However Royal Enfield does not assume responsibility for any damage loss or injury caused to the vehicle or to the person carrying out repairs due to errors or omissions in this manual IMPORTANT NOTICE All images shown are only for reference to explain and may not be exactly the same on the motorcycle Technical specifications are subject to change wi...

Страница 4: ... wiring harness routing SECTION THREE 03 SERVICE DATA Service limits of components Periodical maintenance chart SECTION FOUR 04 ENGINE Engine Lubrication system Lubrication system Hydraulic Tappets RHVL Auto decompressor Electric starting system sprag mech Auto Chain Tensioner Assembly Engine breather System Inlet manifold Throttle body Blow up Charts SECTION FIVE 05 ENGINE DISMANTLING INSPECTION ...

Страница 5: ...aintenance Inspecton Checking procedure of electrical components Starter coil Pulsar coil Ignition coil Suppressor Cap Battery Horn Relay starter E Starter motor IC Flasher RR Unit Electrical parts Inspection Clutch switch Starter switch Do s and Dont s Complete Wiring diagram Classic 500 Complete Wiring diagram Classic 350 Trouble shooting Electricals SECTION ELEVEN 11 TROUBLE SHOOTING SAFETY DEF...

Страница 6: ...GENERAL SECTION TWO 02 ...

Страница 7: ...INJECTION SYSTEM FOUR STROKE CYCLE OPERATION SUCTION COMPRESSION POWER EXHAUST STROKE STROKE STROKE STROKE Inlet Valve Open Closed Closed Closed Exhaust Valve Closed Closed Closed Open Piston Movement TDC to BDC BDC to TDC TDC to BDC BDC to TDC Gas Flow Air Petrol Air Petrol Air petrol mix Exhaust gas mixture is mixture gets burns gas flows out drawn into compressed expands cylinder Piston is Few ...

Страница 8: ...he piston when the piston is at the topmost position TDC ENGINE The Engine converts Chemical energy availbale in petrol into heat energy then to mechanical energy for motion It is the powerplant of the vehicle where the power is generated for moving the vehicle BORE Bore is the inside diameter of the cyclinder block in which Piston moves up and down TDC TDC stands for Top Dead Center It is the top...

Страница 9: ...METRIC EFFICIENCY Volumetric efficiency is the ratio between the volume of air fuel mixture that actually enters the cylinder and Swept volume Volumetric Efficiency Volume of air fuel mixture inhaled during suction stroke Swept volume HORSE POWER HP OR PS HP Horse Power PS PFERDESTARKE is German unit of power Horse Power is the ability of the engine to do a certain amount of work in a given time O...

Страница 10: ... is the ratio between Brake horsepower and Indicated horse power Brake horsepower BHP Indicated Horse power IHP TORQUE Torque is a twisting or turning force or effort It is the product of a distance and force in circular motion In the picture shown the torque applied is the product of distance distance between the center of the bolt and point where force is acting and the amount of force applied W...

Страница 11: ...atio It is determined by number of teeth on the respective gears Gear Ratio No of teeth of Driven Gear No of teeth of Driving Gear In Fig 1 the Gear ratio is 20 10 2 1 In Fig 2 the Gear ratio is 20 20 1 1 Gear ratios multiply the engine torque to fulfil various demands for pulling the vehicle like More effort is required during initial move ment of the vehicle More effort is required to climb an e...

Страница 12: ...12 Engine oil tank capacity 2 75 litres 2 75 litres 13 Engine oil grade MOTUL 3000 4T Plus 15W50 MOTUL 3000 4T Plus 15W50 API SL JASO MA API SL JASO MA 14 Cooling Natural air flow Natural air flow B TRANSMISSION 1 Clutch Wet multiplate 7 Friction Plates Wetmultiplate 6FrictionPlates 6 Steel Plates 5 Steel Plates 2 Primary drive 3 8 Duplex chain sprocket 3 8 Duplex chain sprocket 3 Primary ratio 2 ...

Страница 13: ...internal expanding 153 mm internal expanding 8 Brake Oil Capacity 60 ml 60 ml 9 Brake Oil Grade DOT 3 or DOT 4 DOT 3 or DOT 4 10 Tyre size Front 90 90 18 51 P Front 3 25X19 4PR 6PR Rear 110 90 18 61 P Rear 110 90 18 61 P D TYRE PRESSURE 1 Solo Front 20 PSI 1 41 kg cm2 Front 20 PSI 1 41 kg cm2 Rear 30 PSI 2 11 kg cm2 Rear 30 PSI 2 11 kg cm2 2 With Pillion Front 22 PSI 1 55 kg cm2 Front 22 PSI 1 55 ...

Страница 14: ...urn Signal Tell Tale 12V 2W 12V 2W 13 Turn signal 12V 10W 12V 10W 14 Horn 12V DC 12V DC 15 Starter Motor 12V 0 9 KW 12V 0 7 KW F WEIGHTS 1 Kerb Weight 187 Kg 182 Kg 2 Max pay load 178 Kg 168 Kg G DIMENSIONS 1 Length 2160 mm 2160 mm 2 Width 800 mm 800 mm 3 Height 1050 mm 1050 mm 4 Wheel base 1370 20 mm 1370 20 mm 5 Ground clearance 135 mm 135 mm 6 Saddle height 800 mm 800 mm NOTE 1 Values given abo...

Страница 15: ...ype of Engine Swept Volume Type of Start Type of Transmission Type of Fuel Feed Dummy No Year of Manufacturing Month Manufacturing Production Sl No U 3 S 5 C O 9 A 00001 ENGINE NUMBER DETAILS The VIN is a 17 digit number punched on the right side steering head tube Manufacture s Code Type of Engine Swept Volume Type of Start Type of Transmission Type of Fuel Feed Dummy No Year of Manufacturing Mon...

Страница 16: ...utch plates 9 ST 25153 4 Extractor for gear box rocker Removal of rocker shaft spring top pivot pin pivot pin and camplate pivot pin 10 ST 25835 2 Front drive sprocket removing To remove FD sprocket on the sleeve tool gear 11 ST 25834 2 Front fork dismantling tool To hold pipe seat of front fork while dismantling main tube with bottom case fork end assy 12 ST 25114 4 Extractor for fork oil seal To...

Страница 17: ...l Tools Its Application Application To compress the valve spring for removal and fitting of valve ST 25123 1 Valve spring compressor Rotor tightening loosening Tool Application To hold magneto rotor while loosening of magneto nut ST 25612 4 ST 25128 2 Puller Magneto Rotor Extractor Application Removal of magneto rotor assy ...

Страница 18: ...or chain case outer Application To remove Crank case LH cover ST 25151 4 Application To hold Clutch housing sprag sprocket while dismantling tightening the Clutch Sprag Sprocket bolt Sprocket clutch tightening tool ST 25591 4 ST 25594 4 Clutch plate tightening tool Application To compress clutch springs while dismantling reassembling of clutch plates ...

Страница 19: ...ker pivot pin FD sprocket removing tool Application To remove front drive sprocket from Sleeve Gear ST 25835 2 Application To hold pipe seat of front fork while dismantling tightening of front fork main tube with bottom case fork end assy Front fork Dismantling tool ST 25834 2 ST 25114 4 Extractor for Fork oil seal Application To remove oil seal in front fork bottom case ...

Страница 20: ...or front fork oil seal Application Expanding the oil seal lip while inserting main tube into bottom case of front fork ST 25112 4 Application Alignment of Swing Arm while mounting tightening into chassis Gauge plate for tightening chain stay ST 25110 3 ST 25244 4 Application To adjust gas filled shock absorber spring load Special spanner adjuster ...

Страница 21: ...02 16 UNDER TANK AND SEAT TOP VIEW UNDER TANK LH VIEW CONTROL CABLES AND WIRING HARNESS ROUTING Control Cables Wiring Harness Routing UNDER TANK RH VIEW ...

Страница 22: ...02 17 HARNESS ROUTING STEERING RH MAGNETO WIRES ROUTING PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING General Vehicle Information ...

Страница 23: ...02 18 HORN WIRE ROUTING FUSE CARRIERS ARRANGE MENT CLASSIC 500 General Vehicle Information FUSE CARRIERS ARRANGE MENT CLASSIC 350 HANDLE BAR INSTRUMENT PANEL CABLE ROUTING ...

Страница 24: ...02 19 TAIL LAMP TRAFFICATOR WIRES ROUTING ECU MOUNTING CLASSIC 500 TCI UNIT MOUNTING CLASSIC 350 General Vehicle Information THROTTLE BODY MOUNTING ...

Страница 25: ...SERVICE DATA SECTION THREE 03 ...

Страница 26: ...e Limit Cylinder bore Cylinder bore Point of measurement 84 045 70 00 84 075 70 03 84 190 70 10 Classic 500 Classic 350 New Min New Max Service Limit 0 03 0 04 0 07 0 08 0 11 0 12 Classic 500 Classic 350 New Min New Max Service Limit 83 940 69 94 83 970 69 97 83 890 69 87 Classic 500 Classic 350 New Min New Max Service Limit 0 03 0 04 0 07 0 18 0 15 0 12 Classic 500 Classic 350 New Min New Max Ser...

Страница 27: ...ft Run out Small end bore inner diameter Service Limits of Components All units in mm unless specified Classic 500 Classic 350 Classic 500 Classic 350 New Min New Max Service Limit 0 20 0 20 0 70 0 70 0 90 0 90 Classic 500 Classic 350 New Min New Max Service Limit 0 20 0 20 0 55 0 55 0 65 0 65 Classic 500 Classic 350 New Min New Max Service Limit 20 007 20 007 20 016 20 016 20 046 20 046 Classic 5...

Страница 28: ...Service Limit 7 00 7 00 7 015 7 015 7 25 7 25 Classic 500 Classic 350 New Min New Max Service Limit 6 945 6 945 6 960 6 960 6 935 6 935 Classic 500 Classic 350 New Min New Max Service Limit 0 00 0 00 0 05 0 05 0 08 0 08 Classic 500 Classic 350 Connecting rod bend Valve stem OD Inlet Valve to guide inlet clearance Cylinder Head warpage Valve guide bore Valve stem OD Exhaust New Min New Max Service ...

Страница 29: ... Max Service Limit Classic 500 Classic 350 New Min New Max Service Limit 0 04 0 04 0 07 0 07 1 00 1 00 Classic 500 Classic 350 New Min New Max Service Limit Classic 500 Classic 350 Valve to guide Exhaust Clearance Hydraulic Tappet OD Valve Spring length 21 417 21 438 21 450 Hydraulic Tappet guide bore Push rod run out 0 00 0 02 0 05 0 012 0 051 0 060 Hydraulic tappet to guide clearance 21 387 21 4...

Страница 30: ...350 9 96 9 98 9 94 B A Location New Min New Max Service Limit Classic 500 Classic 350 X Y 17 99 23 95 18 00 23 97 17 97 23 93 X Y 17 99 23 95 18 00 23 97 17 97 23 93 Lay shaft Outer diameter Y X New Min New Max Service Limit Classic 500 Classic 350 New Min New Max Service Limit Classic 500 Classic 350 10 00 10 03 9 98 Selector fork inner diameter 3 90 3 95 3 88 Selector fork lug thikness 10 00 10 ...

Страница 31: ... New Max Service Limit Classic 500 Classic 350 Service Limits of Components All units in mm unless specified Lay shaft 1st gear inner diameter 12 98 13 00 12 96 64 5 65 5 60 0 2 95 3 05 2 60 64 5 65 5 60 0 2 95 3 05 2 60 24 00 24 03 24 06 24 00 24 03 24 06 24 00 24 03 24 06 24 00 24 03 24 06 18 03 18 06 18 09 Pivot cam plate outside diameter 12 98 13 00 12 96 Lay shaft 2nd gear inner diameter Clut...

Страница 32: ...t 0 00 0 05 0 10 Classic 500 Classic 350 New Min New Max Service Limit Classic 500 Classic 350 1 mm 2 mm 20 00 30 00 5 00 20 00 30 00 5 00 2 mm 4 mm 2 mm 4 mm 190 00 191 00 195 00 190 00 191 00 195 00 0 00 0 05 0 10 Service Limits of Components All units in mm unless specified Clutch steel plate Distortion Throttle cable free play 1 mm 2 mm Drive chain slackness Duplex Chain Length across 21 pins ...

Страница 33: ...Classic 350 New Min New Max Service Limit Classic 500 Classic 350 152 40 152 50 153 50 0 1 0 mm 2 00 mm 0 00 0 01 0 02 0 1 0 mm 2 00 mm 0 00 0 01 0 02 3 80 4 06 2 00 3 80 4 06 2 00 320 322 328 320 322 328 Service Limits of Components All units in mm unless specified 152 40 152 50 153 50 Brake drum rear Internal dia Sprocket GOOD REPLACE Sharp bend broken teeth Drive chain length across 21 pins Whe...

Страница 34: ...ax Service Limit 0 00 0 04 Classic 500 Classic 350 New Min New Max Service Limit Classic 500 Classic 350 25 31mm 12 64 mm 12 76 mm 1 2 6 4 m m 12 76 mm 25 46 mm 25 46 mm 538 544 527 538 544 527 0 00 0 04 Service Limits of Components All units in mm unless specified 25 31mm Caliper Piston Outer Diameter Main tube run out OD Front fork assembly spring length Master Cylinder piston OD Caliper Bore In...

Страница 35: ... 0 8 1 00 mm Service Limits of Components All units in mm unless specified Tyre tread Depth Spark Plug Gap Location New Min New Max Service Limit Classic 500 Classic 350 Bush after reaming I D Swing Arm bush spacer O D I D SPACER Spacer I D 18 9 19 0 19 5 18 7 18 8 18 5 Bush after reaming I D Spacer I D 18 9 19 0 19 5 18 7 18 8 18 5 ...

Страница 36: ... 9 9 9 1 Engine Oil R I R I R I R I R I R Check level at every 500 Kms or earlier as required 2 Engine oil filter element R R R R R R 3 Engine suction filter and Secondary drain magnetic plug C C C C C C 4 Spark plug 2nos C A C A C A C A C A R C A C A C A C A R 5 HT leads for crack I I I I I I I I I I I 6 Air filter element C C C C R C C C R C C 7 Carburettor Clean Inspect and Tune as required 8 F...

Страница 37: ...reverse order of dismantling SPARK PLUG CLEANING Disconnect suppressor cap and remove spark plug using spark plug spanner Clean insulator tip and electrodes using a pointed scrapper or plug cleaner Open filter box cover RH Remove centre mounting nut Take out the air filter element Tap off the dirt Periodical Maintenance ENGINE OIL OIL LEVEL CHECK Place the motorcycle on the centre stand Before che...

Страница 38: ...r frequency Keep vehicle on level ground Start the engine and warm up sufficiently so that the oil drains faster Max Min DRAINING PROCEDURE Keep a clean tray under the engine Remove the two Hex Flange Bolts M5 X 16 Sump drain Cap O ring and Suction filter Assy Remove the Magnetic Plug assy along with its washer PrimaryDrainCap SecondaryDrainPlug TILT VEHICLE RH LH Periodical Maintenance NOTE Repla...

Страница 39: ...ity 2 40 Litres Check the oil level Oil level should be up to MAX level Periodical Maintenance REAR WHEEL CHAIN SLACKNESS ADJUSTMENT Check slackness It should be in between 25 to 30 mm If more or less adjust as follows Initially clean then lubricate chain EP90 oil and rotate rear wheel Remove split pin and Hex castle nut on the RH side Loosen anchor nut Loosen the brake rod nut ...

Страница 40: ... 000 KMS Remove the brake cover plate Clean the brake cam and apply grease Refit the cover plate BRAKE PEDAL PLAY ADJUSTMENT PEDAL FREE PLAY 20 TO 30 MM Turn in out the adjuster nut for correct pedal play REAR BRAKE SWITCH ADJUSTMENT Loosen bottom nut and tighten top nut till the brake light comes on when brake pedal is pressed Tighten the bottom nut duly ensuring that the brake lamp is not glowin...

Страница 41: ...ce the spring preload for low load operation The adjuster provided on the bottom of the spring has five notches To carry out the adjustment proceed as follows Using special tool place it on the slot provided on the adjuster Turn the adjuster such that the adjuster moves up to increase the spring preload and vice versa to reduce the spring preload FRONT FORK A OIL LEVEL CHECK EVERY 6000 KMS Take ou...

Страница 42: ...up if level is below Min mark To Top up the fluid remove the master cylinder top cover 2 screws and take out cover plate diaphragm Top up brake Fluid DOT 3 or DOT 4 upto MAX level CAUTION As the brake fluid is highly corrosive take care that it does not spill over other parts It is suggested to wipe brake fluid immediately if there is any spill over in other parts using a soft cloth preferably a w...

Страница 43: ...the balls and races thoroughly for damages pittings discolouration Change them if found defective Pack grease and balls Lithium Calcium based on the bottom ball race as shown in Fig B A Pack grease in the top ball race Assemble the steering stem CLUTCH CABLE FREE PLAY 2 3MM LEVER END Check clutch cable button seating position inside lever and condition of the cable Screw in or out the cable adjust...

Страница 44: ... 10 mm spanner to adjust cable outer and lock the nut Move the rubber boot over the lock nuts THROTTLE CABLE ASSY REPLACEMENT CLASSIC 500 While replacing throttle cable following procedure is recommended A Connect throttle cable to Rotor throttle grip assembly B Connect cable to throttle body and ensure the recommended free play C Route and strap the cable properly B ADJUSTMENT AT THROTTLE BODY EN...

Страница 45: ...ner toadjustcableouterandlockthenut Move the rubber boot over the lock nuts 2 to 3 mm Step 1 Two nuts A B shall assemble outside the throttle guide bracktet as showm in Fig A B C Step 2 One nut C shall assemble inside the throttle guide bracket at extreme left position as shown in Fig Step 3 Throttle guide bracket screws X Y shall assemble with the throttle switch body bracket at extreme right pos...

Страница 46: ...n Fig X Y SLOT POSITION NOTE After TPS cable switch fitment please ensure that cable lock nuts A B C mounting screws X Y are being tightened THROTTLE CABLE ASSY REPLACEMENT CLASSIC 350 While replacing throttle cable following procedure is recommended A Connect throttle cable to Rotor throttle grip assembly B Connect cable to TPS switch as illustrated in step no 1 2 at Page No 03 20 C Connect cable...

Страница 47: ... measure the height from the mixing chamber body face to top of the float is 17 1 mm as shown in Fig If the float height is incorrect correct it by bending the float assembly tongue Check the float height again NOTE After adjustment of float height please ensure free movement of float in its pivot pin Check for the smooth running of the Engine If erratic turn pilot screw in or out upto one turn Ad...

Страница 48: ...en check for blown out cylinder head gasket improper torque of Rocker bearing bolts or cylinder head nuts valve seat damage leakage valvestem bend cylinder head warpage improper valve timing If compression pressure reading increases then check for Improper alignment of piston ring end gap position piston ring jamed in groove scoring seizure of cylinder barrel piston worn out piston rings worn out ...

Страница 49: ... in the valve seat without rotating Remove the valve and inspect the width of each seat The seat contact should be within the specified width and should be even all around the circumference Standard 0 9 1 1 mm Service Limit 1 5 mm Valve seat width is not within specification reface the valve seat CAUTION If a valve face is burnt or badly wornout or if it contacts the seat unevenly replace the valv...

Страница 50: ... with a 45 degree cutter when a valve guide is replaced Contact area is too high or too low re face the valve seat Periodical Maintenance Use a 45 degree cutter to remove the roughness or irregularities from the seat Using 32 degree cutter remove top 1 4 of the existing valve seat material Using 60 degree cutter remove the bottom 1 4 of the old seat Remove the cutter and inspect the area Install a...

Страница 51: ...l compound off the cylinder head and valve Recheck the seat contact after lapping Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air Install the valve spring seats and new valve stem seals Lubricate each valve stem with clean engine oil Insert the intake and exhaust valve into the valve guides 1 CYLINDER HEAD 2 SPLIT COLLAR 3 RETAINER SPRING 4 VALVE...

Страница 52: ...er while tightening the lock nut which prevent the rotation of the sleeve during tightening the lock nut The backlash is first adjusted between pinion to exhaust gear and then exhaust to inlet gear to get effective backlash adjustment The tightening torque for M10 lock nut is 2 KG M This must be ensured Periodical Maintenance VALVE TIMING CUM ECCENTRIC CAM SPINDLE Bring piston to TDC so that the k...

Страница 53: ... Inlet Exhaust lock nut in the spindle must be tightened to the specified torque BATTERY ELECTROLYTE LEVEL CHECKING Electrolyte level can be seen through the casing Electrolyte to be filled upto MAX Mark NOTE When electrolyte level drops to MIN Level then top up distilled water upto MAX Level Specific Gravity Fully charged 1 24 to 1 26 Needs to be recharged 1 15 or less than that TERMINAL CLEANING...

Страница 54: ...ENGINE SECTION FOUR 04 ...

Страница 55: ...04 2 Engine Lubrication System ...

Страница 56: ...el to lubricate crank shaft as well as barrel piston assembly The second branch goes to hydraulic tappet to maintain the oil pressure con stantly The third branch goes to rocker assembly and drains down to RH cover chamber through the push rod tunnel LUBRICATION OIL Specification MOTUL 3000 4T PLUS 15W50 API JASO MA SL GRADE ESTER Semi Synthetic Oil capacity 2 75 l Initial oil filling through Oil ...

Страница 57: ...low oil pump delivers oil with a pressure of 4 5 Bar This provides good lubrication to all the moving parts and enhances the life of the moving parts in the engine CLASSIC 350 Output 4 5 Litre per minute at 2750 RPM CLASSIC 500 Output 9 Litre per minute at 2750 RPM ...

Страница 58: ...ng motion and friction provides improved tappet and cam life 2 Control of valve train lash adjustment The RHVL compensates for changes in the length of valve train components by wear or variations in engine temperature ESCAPINGOIL D PUSHROD SEAT B OVER HEAD OILFLOW PATH C DISC VALVE OILINLET OIL HEAD OIL DELIVERY CONTROL VALVE LOCKINGACTION CHECK BALL A HIGH PRESSURE CHAMBER OIL FLOW PATH H HIGHPR...

Страница 59: ...rs the high pressure chamber during each base circle event is equal to the volume of oil that is lost through the plunger to body diametral clearance during the valve lift event Leakdown The overhead oil supply is accurately me tered from the low pressure chamber which is at engine oil pressure by using a flat metal disk metering valve C in Fig ure which wobbles against a cylindrical radius curved...

Страница 60: ...ain speed 350 rpm approx a pin rotates to protrude above the base circle of the exhaust cam c The pin momentorily open the exhaust valve on the compression stroke lowering the pressure in the cylinder head combustion chamber thus leading to freeness when starting engine BENEFITS OF AUTO DECOMPRESSOR Easy for kick or self start system Avoids back kick and hence life of the sprag clutch system enhan...

Страница 61: ...ive side This provides better rigidity of the sprag mechanism during initial cranking The auto decompressor mechanism further helps in reducing the load on the sprag during intitial cranking and also prevents reversal phenomenon of the crank shaft Electric Starting System Sprag Mechanism ...

Страница 62: ...LH below the chain tensioner pad The spring loaded plunger applies force on the chain tensioner pad thereby lifting it and holding aginst the primary chain to the required tension The oneway rachet mechanism in the auto chain tensioner ensures that the plunger does not drop down due to the downward force of the chain tensioner pad It normally does not require any maintenance or service Auto Chain ...

Страница 63: ...ilt deflector to deflect the oil that may come along with the fumes from the crankcase This oil gets drained through a small hole provided at the bottom of the breather chamber The emission passes through the deflector chamber and goes to the air filter housing and passes through the inlet manifold back into the cylinder head Engine Breather System Breather arrangement inside the RH cover ...

Страница 64: ...ottle body The clamps on the throttle body may be loosened and the throttle body rotated outwards from the top to access the screw without removing the fuel tank and to adjust the idle speed with the bike running Turn the screw CLOCKWISE in to DECREASE the idle speed Turn the screw ANTICLOCKWISE out to increase the idle speed Remember that this is an AIR BYPASS screw not a throttle stop screw Turn...

Страница 65: ...04 12 Crankcase RH Coverside View A2 Key No s 22 23 24 25 26 27 A1 Key No s 7 8 9 10 11 A3 Key No s 22 23 26 63 64 65 A4 Key No s 50 51 52 ...

Страница 66: ...8 O RING 1 29 CAP PIVOT PIN 1 30 COPPER WASHER 1 Key No Description Qty Key No Description Qty Crankcase RH Coverside View 31 HEX FLANGE BOLT M5 X 12 1 32 HEX SOCKET HEAD CAP SCREW M6 X 60 2 33 STARTER MOTOR ASSEMBLY 1 34 COVER STARTER MOTOR 1 35 HEX SOCKET BUTTON HEAD SCREW M5 X 12 1 36 DOWEL PIN 2 37 TAPPET DOOR 1 38 CSK SOCKET HEAD SCREW M5 X 12 4 39 FLY WHEEL MAGNETO ASSEMBLY 1 40 MAGNETO KEY ...

Страница 67: ...04 14 Crankcase LH Inside View ...

Страница 68: ...FT 1 4 CIRCLIP 2 5 BALL BEARING 6305 C3 25 X 62 X17 1 6 BEARING SPACER CRANKCASE LH 1 7 ROLLER BEARING NU 305 C4 25 X 62 X 17 1 8 WASHER THRUST 1 9 NEEDLE BEARING 1 10 HEX SOCKET HEAD CAP SCREW M5 X 16 2 11 RETAINER PLATE MAINSHAFT BEARING 1 12 STUD M6 X 133 2 13 BALL BEARING 6006 C3 G B MAIN SHAFT 1 14 BEARING SPACER LH CRANKSHAFT 1 Key No Description Qty ...

Страница 69: ...04 16 Crankcase RH Inside View ...

Страница 70: ... 1 17 PAWL CAMPLATE 1 18 MACHINED WASHER 6 4 1 19 NUT M6 X 1 FLANGE NYLOC TYPE1 20 STOP PLATE 1 21 HEX SCREW M8 X 23 1 Key No Description Qty Key No Description Qty Crankcase RH Inside View 22 OIL THROWER 1 23 HEX SOCKET HEAD CAP SCREW M5 X 35 3 24 SUCTION FILTER ASY 1 25 O RING DRAIN CAP 1 26 SUMP DRAIN CAP 1 27 HEX FLANGE BOLT M5X16 2 28 WASHER DRAIN PLUG 1 29 DRAIN PLUG 1 30 MAGNET 1 31 DOWEL H...

Страница 71: ...04 18 Engine Cover RH ...

Страница 72: ...HER 1 16 O RING 1 17 SPRING CAP 1 18 O RING 1 19 ELEMENT OIL FILTER 1 20 HEX FLANGE BOLT M6 X 1 X 45 2 21 HEX FLANGE BOLT M6 X 1 X 70 7 22 HEX FLANGE BOLT M6 X 1 X 85 2 23 OIL LEVEL WINDOW 1 24 WASHER INSPECTION SCREW 1 25 INSPECTION SCREW IGNITION TIMING 1 26 O RING 1 27 OIL FILLER CAP METAL 1 28 SEALING WASHER 1 29 BOLT BREATHER 1 30 CLIP BREATHR PIPE 1 31 BREATHER PIPE 1 32 OIL SEAL KICK START ...

Страница 73: ...04 20 Crankcase LH Coverside View ...

Страница 74: ...6 COLLAR MAINSHAFT 1 17 CLUTCH ASSEMBLY COMPLETE 1 18 PLAIN WASHER 1 19 NYLOCK NUT 1 20 BALL BEARING 6001 1 21 CLUTCH PUSH PAD 1 22 STUD M6 X 106 1 23 NUT M6X1 FLANGE NYLOC TYPE 20 24 STUD M6 X 168 1 25 STUD M6 X 196 2 26 PRIMARY CHAIN 1 27 HEX SOCKET HEAD CAP SCREW M6X20 2 28 AUTO CHAIN TENSIONER ASSEMBLY 1 29 O RING CHAIN TENSIONER ASSEMBLY 1 30 CHAIN TENSIONER PAD 1 31 BUSH CHAIN TENSIONER PAD ...

Страница 75: ...04 22 Engine Cover LH ...

Страница 76: ...LY 1 5 SLEEVE GEAR LEVER 1 6 OIL SEAL 14 X 20 X 3 1 7 OIL FILLER PLUG 1 8 O RING PLUG 1 9 CLUTCH CABLE ASSEMBLY 1 10 CLUTCH OPERATING LEVER ASSEMBLY 1 11 PIN CLUTCH OPERATING LEVER 1 12 CABLE CLEVIS CLUTCH OPERATING LEVER 1 13 SPRING CLUTCH OPERATING LEVER 1 14 LOCK PIN SPRING CLUTCH OPERATING MECH 1 15 OIL SEAL INA G 12 X 18 X 5 1 16 BUSH 1 Key No Description Qty ...

Страница 77: ...04 24 Gear Train Assembly ...

Страница 78: ...EMBLY 1 5 CIRCLIP 1 6 MAIN SHAFT 3RD GEAR ASSEMBLY 1 7 MAIN SHAFT 1ST GEAR 1 8 LAY SHAFT 1 9 LAY SHAFT 2ND GEAR ASSY WITH BUSH 1 10 LAY SHAFT HIGH GEAR 1 11 LAY SHAFT 3RD GEAR 4TH DOUBLE GEAR 1 12 LAY SHAFT 1ST GEAR ASSEMBLY 1 13 SELECTOR FORK LH 1 14 SELECTOR FORK CENTRE 1 15 SELECTOR FORK RH 1 16 SELECTOR FORK SHAFT 1 17 CIRCLIP 1 18 CAM PLATE ASSEMBLY 1 19 ROLLER 4 20 WASHER THRUST 1 ...

Страница 79: ...04 26 5 Gear Shifting Kick Starter ...

Страница 80: ...CAP SCREW M6 X 12 2 9 PIVOT BEARING ROCKER SHAFT BOTTOM 1 10 ASSEMBLY GEAR LEVER SHAFT 1 11 STOP PIN 1 12 O RING 1 13 HEX SOCKET HEAD CAP SCREW M5 X 40 2 Key No Description Qty A1 KICKSTARTER SHAFT SUB ASSEMBLY 1 1 KICKSTART SHAFT 1 2 SPRING 1 3 PLUNGER 1 4 PAWL 1 5 WASHER THRUST 1 6 KICKSTART GEAR ASSEMBLY 1 7 KICKSTARTER GEAR 35T 1 8 BUSH 1 9 CIRCLIP 1 10 SPRING 1 11 HEX SCREW M6 1 Key No Descri...

Страница 81: ...04 28 CRANK SHAFT ASSY PISTON ASSY Cylinder Head Barrel Piston Crankshaft A1 Key No s 7 8 9 10 11 A2 Key No s 29 39 ...

Страница 82: ...REW M6 X 55 8 14 GASKET ROCKER COVER EXHAUST 1 15 GASKET ROCKER COVER INLET 1 16 ROCKER COVER EXHAUST 1 17 ROCKER COVER INLET 1 18 WASHER SEAL 3 19 HEX HEAD SCREW ROCKER COVER 3 20 WASHER SEAL 1 21 HEX HEAD SCREW ROCKER COVER 1 22 VALVE EXHAUST 1 23 VALVE INLET 1 24 DAMPER PAD CYLINDER BARREL 3 25 DAMPER PAD CYLINDER BARREL TAPPER 6 26 DAMPER PAD LH CYLINDER HEAD 2 27 DAMPER PAD RH CYLINDER HEAD 4...

Страница 83: ...rrel 6 INLET SIDE VIEW EXHAUST SIDE VIEW Damper Pad Position Details 570482 b 570478 b 570480 b 570482 b 570479 b Part No Description Quantity per engine Image 570478 b Damper pad cylinder head LH 2 570479 b Damper pad cylinder head RH 4 Part No Description Quantity per engine Image NUMBER OF DAMPER PADS PER ENGINE 15 ...

Страница 84: ...ENGINE DISMANTLING INSPECTION ASSEMBLY SECTION FIVE 05 ...

Страница 85: ... gasket Crank shaft main bearings LH RH replacement Gears Mainshaft or Layshaft Sleeve Gear repair replacement Mainshaft or Layshaft Bearings replacement Self starter Idler Gear jack Shaft replacement Kick Starter Gear Pawl Spring or Plunger replacement Roller Hydraulic Valve Lifter RHVL replacement ENGINE DISASSEMBLY Cylinder Head Sub Assembly Cylinder Barrel Sub Assembly Cover RH Sub Assembly Co...

Страница 86: ...mounting of the fuel tank Lift the tank from the seat side remove CAUTION Keep a cloth on the front end of the fuel tank below the handle bar clamp to avoid damage to the fuel tank while removing Engine Dismantling Inspection Assembly Remove the mounting bolts as shown and remove the seat Manual Bi starter Remove the 2 screws at the bottom of the LH switch module and separate the module from the h...

Страница 87: ...cables REMOVAL OF THROTTLE BODY Loosen the throttle body flange bellow clip Remove the throttle body by pushing towards Air Filter box CLUTCH CABLE REMOVAL Slacken the adjuster at the clutch cover end and disconnect the cable from the lever Take out clutch cable from the cover Disconnect the cable from the lever Engine Dismantling Inspection Assembly ...

Страница 88: ...e to be removed Remove the flange nut 2 nos from cylinder head Remove the Silencer Assembly with Exhaust pipe Remove the Suppressor Cap BATTERY REMOVAL Ensure ignition switch is in OFF position Remove battery cover on LH side REMOVAL OF SILENCER AND EXHAUST PIPE Remove the centre silencer bracket mounting screw with plain washer Engine Dismantling Inspection Assembly ...

Страница 89: ...OVAL OF E START MOTOR Remove the cover screw Remove the terminal rubber boot Remove the terminal nut take out the terminal wire lead Remove the 2 mounting allen screws Gently lift the motor and remove the motor along with the housing Remove the 2 dowels for the housing drive Remove 4 screws of the starter drive housing and tap gently to free the housing Engine Dismantling Inspection Assembly ...

Страница 90: ...e the mounting nuts and remove the side stand REMOVAL OF REAR BRAKE SWITCH Disconnect the brake switch spring from brake lever Disconnect the rear brake switch coupler from the wiring harness Slacken the nyloc nuts remove the brake light switch Remove the piece mudguard bracket bolt along with 2 plain washers 1 star washer Remove rider foot rest LH RH C5 Engine Dismantling Inspection Assembly ...

Страница 91: ... DRAIN Always best to drain the engine oil in warm condition Remove the 2 Flanged hex bolts Remove the drain cap with O ring Remove suction filter Remove the magnetic drain plug with washer Remove the 4 allen screws each on the rocker bearing inlet exhaust Remove the inlet and exhaust rocker bearing with dowel and rocker arm Magnetic Drain Bolt Engine Dismantling Inspection Assembly ...

Страница 92: ...park plug Remove inlet and exhaust pushrods Remove the multi layer steel MLS head gasket Remove the Cylinder head assy REMOVAL OF VALVES Remove the Inlet Exhaust valves by using special tool No ST25123 1 Valve spring compressor as shown Engine Dismantling Inspection Assembly ...

Страница 93: ...NOTE Always replace valve stem seal in case of removal of valve from Cylinder head NOTE Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel as shown NOTE Ensure piston is at TDC NOTE Similarly follow the same process to remove Exhaust Valve Remove Inlet Valve as shown Remove gudgeon pin and piston Remove gudgeon pin and piston Engine Dismantling In...

Страница 94: ...4 to hold connecting rod as shown Fig REMOVAL OF COVER RH SUB ASSEMBLY Remove kickstarter lever Remove oil filter cover bolts CAUTION Care must be taken while re moving cover due to spring force Remove oil filter cap O ring Spring Remove the 3 O rings Oil filter element spring cap washer Oil filter element Engine Dismantling Inspection Assembly ...

Страница 95: ...upler from the wiring harness before removing RH Cover Place a plastic tray below the RH cover for collecting the oil that will drip while removing the cover Remove the 11 bolts securing cover RH Gently tap pull out the cover evenly It may be necessary to tap the cover slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove Engine Dis...

Страница 96: ...il seal and jet crankshaft Remove Ignition Timing check bolt and washer if not removed earlier Remove breather chamber gasket NOTE This Oil seal is recommended to be replaced at every 20 000 kms inter val Remove oil filler cap and O ring Engine Dismantling Inspection Assembly Engine Dismantling Inspection Assembly ...

Страница 97: ...ing firmly and evenly on the crankcase top position Use Special tool No ST 25128 2 Magneto removing tool to remove rotor assembly Remove the 3 allen screws 2 dowels from Cam steady plate Remove Cam steady plate and the shims NOTE Check the number of shims on inlet and exhaust cams It is important to reduce noise and axial play between the cam gear face and the cam steady plate OUTSIDE OIL SEAL INS...

Страница 98: ...e Cam gear inlet Remove Cam gear Exhaust Auto decompressor sub assy Exhaust cam with auto decompressor Remove flyweight along with return spring over actuating pin lever as shown in Fig Remove mounting allen screw on flyweight sub assembly DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR NOTE Ensure spring bend lug being seated inside flyweight hole properly Engine Dismantling Inspection Assembly ...

Страница 99: ...remove Oil pump assy Remove the woodruff key CAUTION Ensure O ring must be located on the oil pump body outlet Remove Gear lever shaft with bush spacer shaft Remove the Oil pump assembly with O ring Remove Gear lever from engine LH cover side Engine Dismantling Inspection Assembly ...

Страница 100: ...as shown in Fig Remove the two bolts and remove the rocker shaft upper pivot bearing with O ring Remove the two screws holding the lower pivot bearing Remove the rocker shaft assembly by gently tilting and twisting out Remove nut and lock washer Straighten lock tab and Unlock the FD sprocket nut Engine Dismantling Inspection Assembly ...

Страница 101: ...Fig Remove 4 Nos Kicker Cover screws NOTE Use special tool while removing FD sprocket if necessary Remove kicker shaft cover with oil seal Remove Kick starter return spring from kickshaft spindle Remove Kick starter return spring locking bolt with washer Engine Dismantling Inspection Assembly ...

Страница 102: ...pring from clutch operating shaft Tap and remove the Clutch cover It may be necessary to tap the cover slightly to remove PULL LOCK PIN Remove the 11 bolts holding the cover LH Remove inspection plug along with O ring Remove Clutch operating shaft oil seal and 2 Nos of Dowels Engine Dismantling Inspection Assembly ...

Страница 103: ...etainer cup Use Special tool No ST 25591 4 Clutch centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch Remove auto chain tensioner bottom bolt O ring and its spring Unlock clip and press push rod to slacken duplex chain Remove nyloc nut plain washer Remove 17mm Hex bolt on the Engine sprocket Engine Dismantling Inspection Assembly ...

Страница 104: ...as to hold the springs down loosen remove the other 4 bolts Remove sprag clutch bearing NOTE Flange wide faces of the sprag clutch bearing must face outwards DISMANTLING OF CLUTCH ASSEMBLY Remove 2 hex bolts at opposite locations Remove the special tool holding both evenly to release the spring tension NOTE Loosen bolts in opposite direction simul taneously 5 threads each FLANGE FACE Engine Disman...

Страница 105: ...big washer Remove special distance washer sprag clutch on Crankshaft LH Remove clutch hub centre friction and steel plates Remove collar on main shaft distance collar from Crankcase LH Remove hex nut and washer to remove chain tensioner pad Engine Dismantling Inspection Assembly ...

Страница 106: ...len screws Remove double gear shaft and double gear starter drive Remove the jack gear after removing the circlip Remove the rear engine mounting nut along with the washer Remove the front engine mounting nut Loosen chain stay bolt Engine Dismantling Inspection Assembly ...

Страница 107: ...Mounting Bracket Remove the front and rear engine studs slide the engine assembly off the frame Remove Engine Front Mounting Bracket Loosen the crankcase stud nuts and allen screws as per the following sequence Tap gently and remove the crankcase LH Engine Dismantling Inspection Assembly ...

Страница 108: ...H 2 Nos Dowel pins Remove clutch bearing retainer plate holding screws and remove the retainer plate from crankcase LH Remove clutch ball bearing from crankcase LH Remove needle roller bearing for lay shaft from crankcase LH Remove roller bearing NU 305 from crankcase LH Engine Dismantling Inspection Assembly ...

Страница 109: ...H Remove crank shaft needle roller bearing from crankcase RH Remove circlip and sleeve gear ball bearing 6007 from crankcase RH Remove lay shaft needle bearing from crankcase RH Remove nyloc nut machined washer pawl camplate return spring and bolt pawl from crankcase RH Engine Dismantling Inspection Assembly ...

Страница 110: ... inlet hydraulic tappets carefully from Crankcase top side CAUTION Store the tappets carefully right side up as detailed earlier GEAR TRAIN REMO GEAR TRAIN REMO GEAR TRAIN REMO GEAR TRAIN REMO GEAR TRAIN REMOV V V V VAL AL AL AL AL Remove the bolt copper washer cap pivot pin and O ring above the cam plate pivot pin Remove the 3mm roller locating pin Remove Tappet cover by dismantling 4 Allen screw...

Страница 111: ...ain shaft with all gears Remove special thrust washer Layshaft from Crank case RH NOTE Turn cam plate to select 3rd gear position before removing for ease of re moval reassembly Check that the 4 rollers are in place in the cam plate correctly while removing to avoid damage to the pins or its location in the cam plate Remove selector fork sub assembly from main shaft lay shaft sliding gears to take...

Страница 112: ...tre selector fork from the selector shaft and then LH selector fork LAYSHAFT SUB ASSEMBLY DISMANTLING OF LAYSHAFT SUB ASSEMBLY Remove Lay shaft 1st gear and thrust washer Remove Double gear LS 3rd and 4th gear Remove the high gear Engine Dismantling Inspection Assembly ...

Страница 113: ...ear and thrust washer MAIN SHAFT SUB ASSEMBLY DISMANTLING OF MAINSHAFT SUB ASSEMBLY Remove the main shaft 3rd gear Remove the main shaft 2nd gear Remove main shaft 1st gear Layshaft Engine Dismantling Inspection Assembly ...

Страница 114: ...thrust washer REMOVAL OF SLEEVE GEAR ASSEMBLY REMOVAL OF SLEEVE GEAR SUB ASSEMBLY Remove open end needle bearing Remove closed end needle bearing REMOVAL OF KICK STARTER ASSEMBLY Remove 3 allen screws to take out oil thrower plastic cap Engine Dismantling Inspection Assembly ...

Страница 115: ...VAL OF KICK STARTER SUB ASSEMBLY Remove circlip thrust washer Remove the thrust washer Remove the Kick pinion gear Remove the thrust washer from kick spindle Remove the Kick pawl plunger and spring from kickstarter shaft Engine Dismantling Inspection Assembly ...

Страница 116: ...2 ClutchSprocketdrumbearing 8 Ballbearing6007C3 CrankcaseRHwithSleevegear 1 9 NeedlebearingHk2012 BK2016 Sleevegearbearings 2 10 Ballbearing6001 C3 Clutch pushrod Lifter plate bearing 1 11 NRB35X42X20 Connecting rod big end 1 S No USAGE DESCRIPTION QTY 1 PRIMARY REDUCTION 2 15 Clutch outer sprocket 56 Primary drive sprocket 26 2 GEAR BOX ASSY 1st Gear LS MS 28 16 3 06 2nd Gear 20 23 2 01 3rd Gear ...

Страница 117: ...nce washer sprag clutch Double step facing inside should rest on Crankshaft and Crankcase LH side bearing Sprag Clutch Bearing Wide Flanges side facing upwards Clutch plain plate All plates smooth teeth face in same direction while fitting on Clutch hub FD sprocket Side face circular groove facing outwards Oil pump inner and outer trochoid gear Punch mark facing outwards Cam Gear sub assy exhaust ...

Страница 118: ...ET ASSY 1 00 10 15 570087 STUD 133L M6 CRANKCASE SET ASSY 1 00 10 16 570091 STUD 80L M6 CRANKCASE SET ASSY 1 00 10 17 145866 FLANGED HEX NUT M6 X 1 CRANKCASE SET ASSY 1 00 10 18 570030 HEX SOCKET HD CAP SCREW M6 X 20 AUTO CHAIN TENSIONER ASSY COVER LH 1 00 10 19 570095 CHAIN TENSIONER STUD M8 AUTO CHAIN TENSIONER ASSY 2 50 25 20 141051 HEX NUTM8 AUTO CHAIN TENSIONER ASSY KS CRANK 2 50 25 21 570100...

Страница 119: ...ET HD CAP SCREW M6 X 85 COVER RH 1 00 10 45 570423 HEX SOCKET HD CAP SCREW M6 X 40 COVER RH 1 00 10 46 570021 HEX SOCKET HD CAP SCREW M6 X 80 COVER RH 1 00 10 47 570425 HEX SOCKET HD CAP SCREW M5 X 12 COVER PLATE BREATHER CHAMBER 0 60 6 48 570431 HEX FLANGE BOLT CAP OIL FILTER 0 60 6 49 570131 HEX SOCKET HD CAP SCREW M6 X 60 ROCKER BEARING 1 00 10 50 570129 HEX HEAD SCREW ROCKER COVER MTG ROCKER C...

Страница 120: ...ce for inspection and reas sembly Lubricate all moving parts prior to reassembly While fixing bearings or bushes in the crankcases it is necessary to heat the crankcase for ease of fixing Cool the crankcases after the fixing the bearings bushings before further assembly Fix the clutch bearing retainer plate with 2 allen bolts Torque 0 60 KG M 6 NM Insert 1st circlip in Crank case LH Engine Dismant...

Страница 121: ...ter 1st circlip Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig Assemble sleeve gear ball bearing 6007 R1 C3 and circlip NOTE Ensure the rubber sealed face is facing the FD sprocket side while assem bling the 6007 bearing Insert circlip and then assemble crankshaft RH side needle roller bearing into Crank case Engine Dismantling Inspection Assembly ...

Страница 122: ...rt sleeve Gear into Crankcase RH NOTE Do not hammer directly over sleeve Gear It is recommended to use arbor press NOTE Apply LOCKTITE 542 thread sealant be fore assembling bolt pawl Assemble exhaust and inlet hydraulic tappets carefully into Crank case RH lubricate and check free upward downward movement inside Crank case RH tunnel CAUTION Please ensure the roller should be facing downwards durin...

Страница 123: ...Flanged hex bolts Torque 0 6 KG M to fix drain cap with O ring Assemble magnetic drain plug assy Torque 2 KG M with washer on crankcase RH NOTE Apply LOCKTITE 542 thread sealant before assembling the drain plug ASSEMBLING OF KICK STARTER SUB ASSEMBLY Insert the spring plunger and pawl in the kick starter spindle Fix the thrust washer on kick spindle DRAIN BOLT Engine Dismantling Inspection Assembl...

Страница 124: ...thrust washer above the kick spindle Fix kickstarter sub assy in to Crankcase RH as shown in Fig NOTE Ensure kick pawl is seated over the trip plate in the Crank case RH Ro tate kick Gear and confirm free wheel movement Assemble oil thrower under the kickstarter Gear Torque 0 6 KG M Assemble Kick starter return spring by hooking into kickshaft spindle TRIP PLATE Engine Dismantling Inspection Assem...

Страница 125: ...e the spring as shown in Fig Assemble striker spring on rocker shaft assy NOTE NOTE NOTE NOTE NOTE Ensure striker spring both ends are seated on striker lever rocker shaft NOTE NOTE NOTE NOTE NOTE Ensure oil seal is replaced before fixing kick shaft cover Assemble rocker shaft sub assy carefully into Crank case window after fixing the dowel over the Crank case RH along with bottom pivot Bearing NO...

Страница 126: ...ng stop pin along with O ring by using special tool No ST 25123 4 as shown in Fig NOTE NOTE NOTE NOTE NOTE Apply thread lock sealant before fixing spring stop pin to avoid oil seepage Assemble High gear Assemble thrust washer and then 2nd gear on layshaft ASSEMBLING OF LAYSHAFT SUB ASSEMBLY Assemble Double gear LS 3rd and 4th gear Assemble thrust washer and then Lay shaft 1st gear LAYSHAFT SUB ASS...

Страница 127: ...d fix circlip to lock the 4th Gear Assemble main shaft 3rd gear Smear oil on the 3rd 4th gear with bush before assembly on Mainshaft Assemble main shaft 1st gear Assemble main shaft 2nd gear as shown MAIN SHAFT SUB ASSEMBLY NOTE NOTE NOTE NOTE NOTE Ensure 2nd gear selector fork groove side is facing towards MS 4th gear Engine Dismantling Inspection Assembly ...

Страница 128: ... selector fork sub assembly over main and Layshaft sub assy as shown in Fig Always assemble the cam plate on selector fork sub assembly in 3rd gear position ensure the 4 rollers are in good condition and located properly Locate special thrust washer Layshaft on Crank case RH and stick using grease NOTE NOTE NOTE NOTE NOTE Ensure special thrust washer profile is facing towards sleeve gear Engine Di...

Страница 129: ...Fig NOTE NOTE NOTE NOTE NOTE Apply LOCTITE 577 thread sealant to pivot pin to avoid oil seepage if any NOTE NOTE NOTE NOTE NOTE Ensure alignment of main shaft with sleeve gear hole fork shaft with fork hole inside the Crank case RH and sliding gear with lay shaft Insert 3 mm locating pin to lock piviot pin as shown in Fig 3RD GEAR POSITION Assemble thrust washer and then LS 1st gear on the Layshaf...

Страница 130: ... fitted on the crank shaft before assembling in the crankcase RH Assemble O ring cap pivot copper washer and tighten bolt Torque 1 KG M Assemble special thrust washer lay shaft on Crank case LH Assemble the 2 dowel pins on the crankcase and apply LOCKTITE 5699 RTV silicon liquid gasket on the RH Crank case seating surface NOTE Ensure special thrust washer profile facing towards Crank shaft bearing...

Страница 131: ...e stud nuts and allen screws as per the following sequence Assemble Front Engine Mounting Brackets and tighten bolts Torque 2 5 KG M Check connecting rod bend as shown in Fig Assemble Rear Engine Mounting Bracket and the piece mudgaurd holding bracket Torque 2 5 KG M NOTE NOTE NOTE NOTE NOTE Ensure R R R R R index mark side is facing towards RH side FD Sprocket of the engine Engine Dismantling Ins...

Страница 132: ...s Crank case LH Assemble neutral switch with packing Fit the rear engine mounting stud Locate the crankcase on the frame and fit the front engine mounting stud Fit the centre stand and foot rest supports Locate the double gear for starter drive in the crankcase and insert shaft Ensure cut portion of shaft is facing upwards CUT PORTION Engine Dismantling Inspection Assembly ...

Страница 133: ...the main cable on the starter motor on tighten Insert rubber boot properly Fix the E Start motor cover Fix the E Start motor with 2 allen bolts Torque 1 KG M along with earthing cable NOTE Apply LOCKTITE 577 thread seal ant to mounting bolts to avoid oil seepage if any Assemble spacer distance washer on Crankshaft LH CAUTION CAUTION CAUTION CAUTION CAUTION This double stepped faceshould be inside ...

Страница 134: ...mbling as it will damage the O ring NOTE Ensure wide flanges face of the sprag clutch bearing must face outwards Assemble Engine primary sprocket and sprag clutch gear assembly CAUTION Lubricate the needle bearing well before assembling on the sprag clutch Assemble chain tensioner pad washer and hex nut Torque 2 5 KG M Assemble the primary chain auto chain tensioner body assy with O ring and tight...

Страница 135: ...n plate Similarly follow the same to sub assemble all the clutch plates Assemble wheel clutch on clutch hub CAUTION CAUTION CAUTION CAUTION CAUTION Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk slippage Insert clutch sub assy into clutch sprocket after placing the thrust washer Assemble clutch springs 6 Nos on clutch sub assy then place clutch sp...

Страница 136: ... Tighten bolts diagonally and evenly 5 threads each Torque 1 KG M Remove the 2 long bolts and the special tool Fix the 2 hex bolts Assemble Duplex chain over Engine sprag clutch sprocket and Clutch assembly Mount on main shaft Fix 17 mm hex head bolt with washer on sprag clutch assy Torque 4 8 KG M Use Special tool No ST 25591 4 Clutch centre holding tool to lock Clutch sprocket and engine sprag c...

Страница 137: ... tighten the nyloc nut on Clutch Torque 4 2 KG M Fix the spring and bolt with O ring for the auto chain tensioner Torque 1 KG M Assemble clutch bearing cup ball bearing 6001 clutch push pad Assemble gear lever shaft bush Assemble gear lever oil seal on cover LH Engine Dismantling Inspection Assembly ...

Страница 138: ...lutch operating shaft and lock the pin Assemble oil filler plug with O ring Locate 11 bolts on cover LH and tighten Torque 1 KG M Assemble the cover LH on Crank case LH NOTE NOTE NOTE NOTE NOTE Ensure 2 Nos dowel pins are located properly Apply LOCKTITE 5699 RTV silicon liquid gasket Engine Dismantling Inspection Assembly ...

Страница 139: ... shown in Fig Assemble FD Sprocket NOTE Care to be taken while fixing the FD sprocket direction circular groove in dex mark facing outwards Assemble lock type washer and nut Torque 7 5 KG M Lock the tab over the FD sprocket nut Fix Rear Chain master link plate and lock clip Engine Dismantling Inspection Assembly ...

Страница 140: ...aft assembly into RH Crank case window and then fix gear shaft spacer Locate the actuating pin in the Exhaust cam NOTE Ensure spring eyelet is seated properly inside flyweight hole Lubricate and ensure free movement of the returning of the flyweight Assemble the flyweight along with return spring over activating pin and tighten with allen screw ASSEMBLING PROCEDURE OF AUTO DECOMPRESSOR Engine Dism...

Страница 141: ...KG M ASSEMBLY PROCEDURE OF CAM GEARS Fix oil pump drive pinion and lock it with the circlip NOTE Ensure the short boss of the gear is facing outwards in case of 350cc and long boss of the gear is facing outwards in case of 500cc VALVE TIMING Bring piston to TDC so that the woodruf key in the timing shaft is at 12 Clock position Add one shim each on inlet and exhaust cam NOTE To reduce axial play i...

Страница 142: ...rotor plain washer and nut and tighten Torque 4 8 KG M NOTE Use special tool No ST 25592 4 to lock connecting rod movement during tightening magneto nut Fix oil seal 2 Nos at Kick Shaft hole on Crank case RH cover Fix breather chamber gasket OUTSIDE OIL SEAL INSIDE OIL SEAL Assemble 6 allen screws to fix breather chamber cover plate Torque 0 60 KG M Engine Dismantling Inspection Assembly ...

Страница 143: ...ip on cover RH inside Assemble Stator on cover RH and tighten with 3 mounting screws Torque 1 KG M Assemble Pulser coil on cover RH and tighten with 2 screws Torque 1 KG M NOTE Apply LOCKTITE 595 silicon ad hesive sealant to magneto wire cable grommet to avoid oil seepage Assemble 2 dowels and RH Crank case cover gasket NOTE Replace the oil seal every 20 000 kms interval Engine Dismantling Inspect...

Страница 144: ...owels Assemble the O rings Oil filter element washer and plate as shown Assemble O ring Spring and gasket oil filter cap CAUTION Care must be taken while fix ing cover due to spring force and gasket Assemble oil filter cover Torque 0 60 KG M Assemble kickstarter lever Torque 2 5 KG M Engine Dismantling Inspection Assembly ...

Страница 145: ...om the skirt area and groove area of piston without causing any scratches or scoring Clean piston rings and piston pin with cleaning solvent and dry it with compressed air Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves Check the piston rings end gap at the bottom end of the Cylinder CAUTION Set each piston ring squarely into the Cylinder barrel...

Страница 146: ...ble in the ring grooves Stagger piston rings end gap as shown in Fig Locate the top ring Index mark 1 IP facing upwards NOTE Top ring has rectangular cross section with black colour Nitride coat ing CAUTION Ensure the open end of any piston ring does not align with the pis ton pin boss EX IN Locate the piston on the connecting rod and insert the piston pin into the piston Fit the circlips on eithe...

Страница 147: ...re with fresh engine oil and then assemble over the piston by gently twisting and tilting NOTE NOTE NOTE NOTE NOTE Do not use any sharp objects to press piston rings against groove Use thumb finger force to locate rings in its position properly A B C CYLINDER HEAD CLEANING Scrap off the carbon deposit on the face of the Cylinder head and exhaust port INSPECTION Visually check for any cracks breaks...

Страница 148: ...r with small bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance Replace valve if the valve head is knife edged Check the valve stem for run out Check inlet and exhaust valve stem for wear Check the valve seat to valve head seating as below Engine Dismantling Inspection Assembly ...

Страница 149: ...sed grind the valve to the seat as below Apply fine grinding paste on to the valve seating area Using a suction valve grinder valve lapping stick rotate the valve back and forth several times Lift and turn the valve by half and grind valve on its seat WARNING Do not allow the grinding paste to seep into the valve stem and valve guide Repeat the process of valve lapping as explained several times f...

Страница 150: ...can also be checked as follows ASSEMBLY Install the valve spring seats and new valve stem seals NOTE Please ensure cleaning of the cyl inder head with solvent and blow thor ough all oil passages with compressed air Lubricate each valve stem with fresh engine oil and fix the inlet and exhaust valve into the valve guides Compress the valve springs using special tool ST 25123 1 valve spring compresso...

Страница 151: ...f any NOTE Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring Similarly check for inlet valve seat leakage Assemble the Cylinder head assy on the Barrel Tighten the 6 flanged hex nuts diagonally and evenly Assemble the spark plug Check run out of the push rods Engine Dismantling Inspection Assembly ...

Страница 152: ...semble the Inlet Exhaust Rocker covers dowels rubber gasket then tighten rocker cover bolt with rubber washer Torque 1 KG M Assemble tappet door by applying LOCKTITE 5699 RTV silicon gasket on Crank case RH then tighten screws Torque 0 60 KG M Tighten the swing arm nut to specified torque Engine Dismantling Inspection Assembly ...

Страница 153: ...nect all the electrical couplers Connect the brake light switch to the pedal Connect the fuel hose to the pump Assemble the battery connect the terminals Check for proper working of all electrical equipments Fix the dual seat Start machine and run in idle RPM for few minutes Switch off check oil level add oil to bring level below Max level Adjust rear brake and chain terminals Align the rear wheel...

Страница 154: ...ENGINE MANGEMENT SYSTEM SECTION SIX 06 ...

Страница 155: ...e exhaust oxy gen feed back etc from the respective sensors provided in the vehicle and determines both the ignition timing and the ideal amount of fuel to be injected to optimize the air fuel ratio THE BENEFITS OF EMS ARE Good acceleration Sustained high speed cruising and driveability Low exhaust emission Excellent cold starting ability Better fuel economy ENGINE MANAGEMENT SYSTEM FUNCTIONAL DIA...

Страница 156: ...ONIC CONTROL UNIT ECU THROTTLE BODY ASSEMBLY FUEL INJECTOR ASSEMBLY FUEL PUMP MODULE ALTERNATOR TEMPERATURE SENSOR CRANK POSITION SENSOR ROLLOVER SENSOR MALFUNCTION INDICATOR LAMP MIL Function of Components in EMS ...

Страница 157: ... to the respective controlling devices E2PROM is an abbreviation for Electronically Erasable Programmable Read Only Memory This is an exclusive recording unit for breakdown information history preservation The main advantage is the system is nonvolatile and stores the data even when the electricity is off While in operation the other breakdown information gets recorded automatically Specification ...

Страница 158: ...s a timed injection system and the injection is done close to the inlet valve The injector operates based on the pulse width signal given by the ECU The fuel injector is as sembled in the inlet manifold located between the inlet port on the cylinder head and air filter It is placed at an angle in the intake manifold so as to give maximum fuel spray and minimum wall wetting THE ADVANTAGES OF FUEL I...

Страница 159: ...ation appears in the MIL if the fuel in the tank is less than 2 5 litres Assembled in fuel tank bottom RH side Specification Operating voltage 9V to 16V DC Fuel level in tank to switch ON 2 5 0 5 Litres Lamp load 12V 4W Max Tightening torque 12 14 N m Operating temperature 10 C to 85 C Specification Operating Voltage 6 14 5 V Operating temperature 20º C to 60º C Controlled Pressure Regulator 294 K...

Страница 160: ... opening A throttle plate butterfly valve is used for regulating the airflow The throttle body also has a throttle position sensor TPS a manifold pressure sensor MAP and a manual Bi Starter Specification Operating Voltage 5 V Out Put Voltage 0 5V Throttle Angle 0 80º Throttle Resistance Maximum 5 K Throttle Out Put Voltage at Idling 0 6 0 2V Storage Temperature 20º C to 80º C Function of Component...

Страница 161: ...VALVE POSITION TO KNOW The mode in which the engine is operating i e idle part throttle wide open throttle etc Emission controls at wide open Throttle WOT Air fuel ratio correction Power increase correction Fuel cutoff control MANIFOLD PRESSURE SENSOR MAP The MAP provides instantaneous manifold pressure information to the ECU This is neces sary to calculate air density and determine the engine s a...

Страница 162: ...RH cover The crank position sensor is an inductive pulse generator the crank sensor scans 23 short and 1 long protrusion on the alternator The long protrusion is located at 5º before top dead center and is used by the powertrain control module as a reference mark for the crank shaft position The crank position sensor sends an alternating voltage signal to the powertrain control module which is use...

Страница 163: ...ly to the injector and the ignition thus stalling the engine to prevent further damage that may be caused if the engine is still running with the throttle stuck wide open and the gears are engaged The Rollover Sensor is located under the seat on the vehicle mounting strip of the frame ROLL OVER SENSOR Assembled under the seat Specification Operating Voltage 12V Operating Angle 60 10 Operating Temp...

Страница 164: ...llowing frequency of the MIL blinking MIL BLINK MAL FUNCTION INDICATION MIL will glow continuous Engine will start but not perform to its potential LONG 0 SHORT 6 Throttle Position Sensor TPS circuit malfunctioning LONG 0 SHORT 9 Manifold Absolute Pressure MAP circuit malfunctioning LONG 1 SHORT 1 Engine oil Temperature TE circuit malfunctioning MIL will glow continuous Engine will NOT Start but w...

Страница 165: ...t not perform to its potential P0120 Throttle Position Sensor TPS circuit malfunctioning P0105 Manifold Absolute Pressure MAP circuit malfunctioning P0195 Engine oil Temperature TE circuit malfunctioning Engine will NOT Start but will crank MIL will glow continuous P1630 Rollover Sensor circuit malfunctioning P0201 Injector circuit malfunctioning P0351 Ignition Coil circuit malfunctioning P0230 Fu...

Страница 166: ...FUNCTION INDICATOR LAMP to switch off Start the engine only after this happens 5 DO NOT rev the engine fully immediately after starting OR just before shutting off the engine 6 DO NOT remove the fuel hose high pressure from the fuel pump to fuel injector when engine is running OR with the ignition switch ON Fuel flows at a very high pressure during these times 7 DO NOT use a booster or high voltag...

Страница 167: ...rrelaydefective Checkpowerrelayconnectionor B IgnitionRelated looseconnections replace if found to be faulty Roll over sensor not connected Checkrolloversensorcoupler looseconnection connection Fuelpumprelaydoesnotwork Checkproperconnectivityinwiring harness couplercontinuitywith voltmeter Checkfuelpumprelay C FuelPump resistance Replacerelayifdefective Fuelpumpclogged internalshort Checkforproper...

Страница 168: ...ntinuityandcorrect manifoldpressuresensor 5 Highfuelconsumption Stuckbutterflyinthrottlebody Check correct UnevenIdling PoorPickup brokenthrottleCables SmokyExhaust Engine Looseconnectionsorproblemin Checkcontinuityandcorrect runsbadly throttlepositionSensor Check correct Defectivetemperaturesensor Check correct PoorOutputfromchargingcoils CheckOutputvoltage 6 Batterydischarging inmagneto 10V 16vA...

Страница 169: ...CV CARBURETOR SECTION SEVEN 07 ...

Страница 170: ...er ring 14 Body CV carburetor 15 Air vent hose 16 Needle jet 17 O ring 18 Jet holder 19 Main jet 20 Float Needle Valve assy 21 Float pin 22 Screw 23 O ring Float chamber 24 Float chamber body assy 25 Washer screw mounting 26 Screw assy 27 Hose drain 28 Drain screw 29 Idle adjust screw bolt 30 Packing washer 31 Spring Idle screw 32 Pilot jet 33 Pilot air jet 34 Clip Hose drain 35 Choke Plunger assy...

Страница 171: ...ystem High Speed System CARBURETOR REMOVAL REMOVAL 3 Turn the fuel tap to the OFF position 3 Disconnect fuel hose from carburetor by pressing clip 3 Loosen cable outer nut and lock nut by 10 mm spanner Slip the tip of the cable from the slot in the throttle pully 3 Drain the petrol from carburetor float chamber in a separate pan tray by loosing drain screw NOTE After following the above said pro c...

Страница 172: ...by solvent wipe dust carbon particals by banian cloth 3 Unscrew the top cover fixing screws and remove the diaphragm top cover piston valve spring from the carburetor as shown in Fig 3 Gently remove thorottle piston valve assembly as shown in Fig Note Care to be taken while removing diaphragm top cover due to spring force DRAIN HOSE 3 Unscrew the float body fixing screws and remove the float chamb...

Страница 173: ...to dust dirt gum or car bon deposit especially in the main air passage pilot air passages including by pass holes and pilot outlet 3 Now clean all the carburetor components and apply compressed dry air in all passages of mixing body unit 3 Unscrew the mixture control screw along with its spring plate washer and o ring TORQUE SPECIFICATION PILOT JET 8 kgf cm MAIN JET 18 kgf cm MAIN JET HOLDER 18 kg...

Страница 174: ...troliem jelly over mix ture screw thread portion before fixing into mixing body to avoid mixture screw jam problem Pre set mixture screw position to 3 turns out from fully close position 3 Check float level height specified 17 1 mm on both sides of float by vernier caliper or steel scale If necessary adjust 3 Assemble float body along with needle valve assy and then fix float toggle pin Tighten th...

Страница 175: ...hrottle pistion valve before fixing into mixing body 3 Assemble throttle piston sub assembly by locating rubber tip tab being seated on the mixing body Fix pistion valve spring and top cover as shown in Fig 3 Assemble air vent hose and then drain hose 3 Assemble choke plunger sub assembly into mixing body and tighten the nut NOTE Do not clean diaphragm by brake fluid or compressed air INSTALLATION...

Страница 176: ...d readjust the mixture screw if necessary 2 Now turn the Mixture screw in or out slowly and select a position where the engine rpm reaches to the peeak highest speed position while setting Now stop adjustment of Mixture screw Normally this will occur inbetween 3 1 turns of Mixture screw from fully close position 5 After adjusting idling speed check for its stability flat spot missing if any by acc...

Страница 177: ...rder to avoid blockage of jets and channels 3 Maintaining a full tank of petrol doesn t allow fuel tank to rust and there by reduces rust deposits in the carburetors 3 Drain the carburetor at every 3 000 Kms interval by removing the drain screw to drain all the deposits from float chamber body 3 When using the choke do not open the throttle as it may cause flooding 3 Clean Air filter regularly as ...

Страница 178: ... to spec Flooding Check float for damage puncture or float height IDLING NOT Pilot jet clogging Clean jet with spray replace STABLE Incorrect mixture screw setting Adjust mixture screw as per specification High Low fuel level Adjust float height to spec Piston valve sticky Clean piston valve mixing body and ensure no damage in piston valve and diaphragm FLOODING High fuel level Adjust float height...

Страница 179: ...CHASSIS WHEELS BRAKES SECTION EIGHT 08 ...

Страница 180: ...0 5 0 5 0 5 0 5 0 5 0 4 500355 SCREW M6 FUEL PUMP MOUNTING SCREWS 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 1 1 1 1 1 5 580342 FLANGED HEX BOLT X 120 ENGINE MOUNTING FRONT 7 0 0 7 0 0 7 0 0 7 0 0 7 0 0 7 0 7 0 7 0 7 0 7 0 6 580338 FLANGED HEX BOLT M8 X 120 ENGINE MOUNTING FRONT TOP 3 0 0 3 0 0 3 0 0 3 0 0 3 0 0 3 0 3 0 3 0 3 0 3 0 7 580341 FLANGED HEX BOLT M8 X 112 ENGINE MOUNTING FRONT BOTTOM 3 0 0 3 0 0 3 0...

Страница 181: ...2 1 2 26 571054 OXYGEN SENSOR EXHAUST PIPE 2 5 0 2 5 0 2 5 0 2 5 0 2 5 0 2 5 2 5 2 5 2 5 2 5 27 550086 NYLOCK NUT M6 FUEL INJECTOR ASSEMBLY THROTTLE FLANGE 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 1 1 1 1 1 28 570091 STUD 80L FUEL INJECTOR ASSEMBLY 0 1 0 0 1 0 0 1 0 0 1 0 0 1 0 1 1 1 1 1 FRONT WHEEL HYDRAULIC DISC BRAKE 1 560525 HEXNUTWITHNYLOCKINSERT M16 1 5 FRONT WHEEL SPINDLE NUT 5 7 5 7 5 7 5 7 5 7 5 0 7...

Страница 182: ...el Place a 4 mm thick wooden or plastic wedge between the brake pads to avoid the pistons from coming out too far from the brake caliper if the front brake lever is depressed accidentally CAUTION Do not depress the front brake lever when the front wheel is re moved FRONT WHEEL BEARINGS REMOVAL Remove the dust seals on either sides of the wheel hub Drive out bearings by tapping on the spacer using ...

Страница 183: ...master cylinder in the handle bar is parallel to the ground whenever checking fluid level Clean master cylinder filler cap before removing Use only DOT 3 or DOT 4 grade brake fluid from a sealed container Do not mix different types of brake fluid as they may not be compatible Whenever the disc brake system is overhauled ensure that the old fluid is drained out completely and then fill with fresh b...

Страница 184: ...AND MASTER CYLINDER Place a clean tray or container below the calliper assembly to collect the old oil Loosen and remove the banjo bolt with the washers from the Caliper assembly Drain out the entire brake fluid from the master cylinder and brake hose by depressing and releasing the brake lever Fix a transparent flexible tube of length 12 30 Cms firmly on the bleeder nipple and insert the other en...

Страница 185: ...process Fill the master cylinder with brake fluid from a sealed container till the MAX level Fix the diaphragm plate and top cover Do not tighten the screws completely since it may be required to top up fluid during the bleeding process Remove the calliper assembly from the fork leg and drain out the brake fluid When a slight firmness is felt on the lever and it depresses only halfway hold the lev...

Страница 186: ...nto the brake hose and the wheel caliper When the bleeder screw is loosened and the air escapes out along with the brake fluid through the bleeder nipple the brake lever will further depress Allow the lever to depress fully and hold DO NOT RELEASE DO NOT RELEASE DO NOT RELEASE DO NOT RELEASE DO NOT RELEASE THE LEVER THE LEVER THE LEVER THE LEVER THE LEVER Tighten the bleeder screw firmly and then ...

Страница 187: ...nd locks in applied position Also check and ensure there are no more air bubbles coming into the master cylinder Check the fluid level and top up to MAX level Refit the diaphragm and the top cover and tighten with the screws DISASSEMBLY OF MASTER CYLINDER Remove the Master Cylinder top cover screws Place a clean tray or container below the calliper assembly to collect the old brake fluid Loosen an...

Страница 188: ...he remove the brake hose from the master cylinder end Remove the brake lever pivot lock nut brake lever pivot and the brake lever Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar Remove the conical spring Piston compression spring Remove the boot and the Circlip from the master cylinder body Chassis Wheels Brakes ...

Страница 189: ...mm CLEANING Clean the hydraulic disc brake parts only with clean and new brake fluid as using any other cleaning material can damage the parts and make the brakes ineffective CAUTION Do not clean the hydraulic disc brake parts with any other cleaning material solvents or water USE NEW BRAKE USE NEW BRAKE USE NEW BRAKE USE NEW BRAKE USE NEW BRAKE FLUID ONLY FLUID ONLY FLUID ONLY FLUID ONLY FLUID ON...

Страница 190: ...Tighten the master cylinder assy clamp top bolt first and then tighten the bottom bolt Torque 0 90 KG M Assemble the brake lever in the front bracket and tighten with the bolt first and then tighten the lock nut Torque values Bolt lever 0 6 KG M Nut lever 0 6 KG M Locate the circlip into the groove of the master cylinder Ensure the circlip is seated correctly inside the groove Assemble the Brake S...

Страница 191: ...brake light switch Fill the brake fluid till MAX mark and bleed the system Assemble the diaphragm plate and cover Tighten screws gently Torque 0 15 KG M Assemble the rear view mirror DISASSEMBLY OF WHEEL CALIPER Disconnect the brake Hose by removing the Banjo bolt and sealing washers Remove the Grub screws Loosen both the pin bolts Loosen and remove the 2 mounting bolts holding the caliper to the ...

Страница 192: ... downwards Blow compressed air with a nozzle at a low pressure into the oil passage hole on the caliper so that the pistons can be removed Remove the Bellow Boot Remove pin bolt Remove mounting bracket from the Caliper assembly Remove the brake pads from the caliper assembly Chassis Wheels Brakes ...

Страница 193: ...uld be taken to avoid any damage on the bore of the sliding surface INSPECTION Check the caliper cylinder surface and Piston outer surface for scoring or other damages Measure the caliper cylinder I D Service limit 25 46 mm Measure the caliper piston O D Service limit 25 31 mm CAUTION Enough care should be taken to avoid damages of the piston O D while servic ing handling Remove the Bleed screw CA...

Страница 194: ...et on the caliper Body Smear fresh brake fluid on the caliper boot and bellow and assemble them as shown If the Caliper Boot and Bellow are hard or deteriorated replace them with new ones Coat the caliper cylinders and Pistons with clean brake fluid and install the Pistons into the caliper body with the dished end facing inwards Chassis Wheels Brakes ...

Страница 195: ...re disc plate is in between both brake pads Torque 2 7 to 3 0 KG M Fix the Grub screws on the pins and tighten to a torque of 0 2 to 0 3 KG M P Connect the brake hose to the caliper with New sealing washers and tighten the Banjo bolt Torque 3 5 to 3 8 KG M Fill fresh brake fluid in the Master cylinder and bleed the air out of the hydraulic brake system Tighten the Pin bolts with a torque of 1 5 2 ...

Страница 196: ...ear chain and rear wheel sprocket Place the vehicle on its center stand Ensure the rear wheel is lifted off the ground by placing suitable wedges under the centre stand legs Remove the split pin and the castle nut from the rear hub spindle Pull out the spindle with the chain adjuster and remove the spacer from the LH side Tilt the vehicle to the right and free it form the sprocket lugs and slid it...

Страница 197: ...gently to avoid damage to the lugs Remove the dust seals Drive out the bearings 2 Nos and take out the spacer BRAKE DRUM ASSEMBLY Remove the drive chain from the sprocket Disconnect the brake operating rod from the cam lever Remove the cover plate anchor nut from the chain stay Remove the nut from hub spindle short Chassis Wheels Brakes ...

Страница 198: ...ck all parts for breaks cracks dents scoring glazing or any other damage Check bearings for free rotation axial play and radial clearance Replace if necessary Lubricate bearing by MP grease and then assemble into sprocket drum by using bearing punch as shown in Fig CLEANING Clean all parts except brake shoes cush drive and tyre with solvent and dry with compressed air ASSEMBLY Assemble in the reve...

Страница 199: ...SUSPENSION STEERING SECTION NINE 09 ...

Страница 200: ... STROKE 1 Bolt cap 2 O ring 3 Main tube 4 Spacer 5 Seal dust 6 Fork oil seal circlip 7 One way check valve 8 Fork piston 9 Copper washer allen bolt 10 Oil control collar 11 Thorough oil hole 12 Bottom tube 13 Orifices 14 Piston ring 15 Washer spring seat S No Description S No Description 9 15 Front Fork Working Principle for Classic 500 350 ...

Страница 201: ...p the fork bottom tube downwards and remove the bottom tube REMOVAL OF FORK SEALS Loosen the pinch bolt on fork crown bottom Remove the plug screw from the head lamp casing and using special tool ST 25108 3 unscrew and remove the main tubes cover tubes bush and washer Remove the circlip from the bottom tube and take out the spacer and dust seal Place special tool ST 25114 4 on bottom tube and leve...

Страница 202: ...ead lamp assembly Loosen the head lamp casing allen screw INSPECTION Visually inspect all parts for damages cracks bends wear marks or any other damage Check the main tube for any bend P Remove the handle bar clamp bolts and nuts and take out handle bar P Remove the stem lock nut and washer carefully P Tap the steering stem downwards taking care to collect the steering race balls 38 nos for inspec...

Страница 203: ...Inspect the races for Grooves Excessive uneven wear Replace if found defective Check all parts for cracks pitting or any other damage REASSEMBLY OF STEERING Using a hollow drift fix the bottom ball race the steering stem Fix the ball race on the frame head tube top Apply grease on steering stem bottom ball race and Top ball races in the frame head tube Fix the ball race along with cover on the fra...

Страница 204: ...of the shock absorbers The main function is to increase the resistance of fluid flow into the reserve tube This improves valving performance during the beginning of rebound stroke Another function is to minimize aeration of the shock absorber s hydraulic fluid The pressure of the nitrogen gas air prevents air bubbles or foam from weakening the hydraulic effectiveness of fluid flow through both the...

Страница 205: ... hole provided in the screw Puncturing the rubber and start pumping the air into the chamber till the pressure reached to 100 PSI 7 BAR Tolerance for filling pressure can be 6 7 BAR to 7 BAR Fit the small screw with O Ring NOTE The shock absorber needs recharging when the system pressure is less than 5 BAR SWING ARM REMOVAL Remove the chain link and take out the chain Disconnect the brake rod nut ...

Страница 206: ...c nut washer Using a mandrel drive out the plastic bush from either sides of the swing arm and remove the steel spacer BUSH SPACER BUSH CAUTION Do not remove plastic bush unless it is defective Always use reamer to ream the bush after pressing into swing arm tube Suspension Steering ASSEMBLY Press the new plastic bush into the swing arm tube ...

Страница 207: ...t the swing arm hex bolt after applying grease Place a washer and tighten nut After tightening the swing arm hex nyloc nut Remove special Tool ST 25110 3 Fix both side caps swing pivot carefully Assemble both side shock absorbers washers and dome nuts as shown in Fig Assemble the chain guard Assemble the rear wheel and adjust drive chain free play Suspension Steering ...

Страница 208: ...nd return spring two nos 1 Remove the split pins washers from the both ends of the centre stand spindle 2 Drive out the centre stand spindle ASSEMBLY Assemble the centre stand in the reverse order of disassemble as shown in Fig 1 2 Suspension Steering ...

Страница 209: ...ELECTRICALS SECTION TEN 10 ...

Страница 210: ...f spongy Lead Pb Negative active material Electrolyte Diluted sulphuric acid H2 SO4 Separator Micro porous acid resistant electrical insulator between positive negative plates Container Polypropylene casing to house the plate group electrolyte Cover To seal the battery container Filling Plugs To facilitate filling of electrolyte and water topping up Gang Piece To vent gases through common manifold...

Страница 211: ...ging Keep fire and spark away from battery charging area Never run the motorcycle without connecting the battery as it may lead premature failure of electrical parts CHARGING INITIAL CHARGE NEW BATTERY ELECTROLYTE Diluted sulphuric acid with distilled water to a specific gravity of 1 240 PREPARATION Take required distilled water in a Hydrometer or equivalent container Slowly add sulphuric acid to ...

Страница 212: ... Connect the battery to the charger and charge as detailed below Battery Duration Charging Current 12V 14AH 10Hrs 1 4 Amps RECHARGING USED BATTERIES When the specific gravity of electrolyte is less than 1 220 drain out the electrolyte and refill with fresh electrolyte of strength 1 240 and charge the battery as detailed above when a charged battery remains unused for more than 3 weeks check the el...

Страница 213: ... deterioration of dry charge properties New dry charged batteries need initial charging duration of 8 to 10 hours Upto 3 months from the date of manufacturing Beyond 3 months the batteries may need extended duration of initial charging subject to storage conditions Charged batteries if kept idle should be boost charged once in 3 to 4 weeks It is always a good practice to boost charge the batteries...

Страница 214: ...E Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark is used for a long period the electrode gradually burns away and carbon builds up along the inside part Once in 3000 kms or earlier the plug should be removed for inspection cleaning and resetting the gap Voltage Fully charged Fully Discharged 13 2 10 8 INSPECTION Clean the electrodes a...

Страница 215: ... 3 0 8 to 1 5 ohms c Yellow 3 to yellow 1 0 8 to 1 5 ohms PULSAR COIL SPECIFICATION Resistance mode Across the wires 180 240 ohms CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green to white wire IGNITION COIL SPECIFICATION Resistance mode across a Between Brown to Red white 4 to 8 ohms b Between Brown to HT lead 12 5 to 16 Kilo Ohms CHECKING PROCEDURE Set...

Страница 216: ... 11 5 to 13 V BATTERY WHEN CHARGING SPECIFICATION Voltage mode 13 to 14 5 V with head light on 3000 RPM HORN SPECIFICATION Continuity Mode Beep Sound RELAY STARTER SPECIFICATION Resistance 4 to 5 ohms CHECKING PROCEDURE Set the multimeter in resistance mode Check the Resistance between a Green white to white wire Checking Procedure of Electrical Components ...

Страница 217: ...RH mode If indicators not functional replace it by a new IC Flasher RR UNIT CHECKING PROCEDURE Set the multimeter in voltage mode DCV 20 Connect the multimeter to Battery terminals and then check the voltage as shown in Fig Start and accelerate upto 3000 RPM and then check online voltage inbetween 12 2 to 13 5 voltage CAUTION Never try to repair tamper IC Flasher NOTE Repeat the test with head lig...

Страница 218: ...component is OK MODE RED BLUE BLUE WHITE ON OFF DO S AND DON TS DO S Check battery for electrolyte level periodically and top up with distilled water only For longer battery life de clutch before starting If the battery is weak below 10 V start with the kick starter and do not try to start with self starter Always maintain correct Engine oil level Check for Engine backfire if it exist it will dama...

Страница 219: ...10 11 Complete Wiring Diagram Classic 500 ...

Страница 220: ...10 12 Complete Wiring Diagram Classic 350 ...

Страница 221: ...ng with taillamp bracket 3 Fuse blown when Head light high beam 1 Check the Headlight wiring harness ON 4 Relay starter not working 1 Check the coil resistance 2 If you can hear the sound of relay actuation but starter motor does not rotate change the relay starter 5 Battery discharging frequently 1 Check the alternator o v should be 8 V to 10 V AC 1000rpm open circuit across any two of its wire y...

Страница 222: ...TROUBLE SHOOTING SECTION ELEVEN 11 ...

Страница 223: ...not working connection Check fuel pump relay for proper working Fuel Injector blocked Replace fuel injector MIL glowing continuously Check Sensor connections correct Weak Battery Dead Battery Charge Replace the battery Electrical connections Loose Check Correct Electrode Gaps incorrect Adjust the gap Wrong specification spark plug Replace with right plug Defective spark plug Change Spark Plug Spar...

Страница 224: ...uel line Fuel hose cracked resulting in fuel leaking Check and replace out and not getting supplied to injector Fuel pump pressure insufficient fuel pump Check fuel pump coupler not working connection Check fuel pump relay for proper working Fuel Injector partially blocked Replace fuel injector Loose damaged throttle body to engine Check and correct hose air filter to throttle body Weak Battery Ch...

Страница 225: ...ogged Clean the fuel line Fuel hose cracked resulting in fuel leaking Check and replace out and not getting supplied to injector Fuel pump pressure insufficient fuel Check fuel pump coupler pump not working connection Check fuel pump relay for proper working Fuel Injector partially blocked Replace fuel injector Loose damaged throttle body to engine Check and correct hose air filter to throttle bod...

Страница 226: ...tuck throttle inner cable Clean Replace cable Loose damaged throttle body to engine Tighten replace the hose hose air filter to throttle body Suction leakage Check and correct Air filter Blocked Dirty Torn Check and correct Excessive carbon deposit Decarbonise the engine Fuel is stale due to vehicle being in storage Clean petrol tank and carburetor for a long period and fill the tank with fresh pe...

Страница 227: ... backlash noise Adjust the Cam spindles to when accelerated achieve correct cam gears meshing Damaged cams Check and Replace Worn out damaged Big end bearings Check and Replace Complaint Premature Wear of Engine Components Cracked or improperly fitted suction Air filter Check and Correct Replace Dirty adulterated fuel Check and Correct Replace Dirty adulterated Wrong Grade oil Replace oil at regul...

Страница 228: ...ctly Wheels misaligned Ensure proper alignment Under inflated tyres Inflate to correct pressure Complaint Electricals Bulbs do not light Loose improper connection Check Correct Bulb fused Check Correct Fuse blown Check Correct Switch defective Check Correct Switch defective Check Correct Flasher defective Check Correct Complaint Electric start not working Battery discharged fully Check Recharge MI...

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