Service Manual AVENGER 220

Notice Contents
Technical Specifications.............................................1
Feature Advantage benefit.........................................2
PDI Checklist..............................................................4
FAQs (Product & Warranty Related)......................... 6
Read before you ride.................................................9
Advantages of DC Ignition .....................................10
Periodic Service Wise Part Kit.................................11
Periodic Maintenance & Lubrication Chart.............13
Skill Tips for Windshield Fitment.............................15
Notice
Details of Exclusive Special Tools...........................16
All information contained in this Note is based on the latest Details of other Common Special Tools.................17
information at the time publication. Bajaj Auto Limited. Engine Removal from Chassis.................................18
Accepts no liability for any inaccuracies or omissions in this
publication, although every possible care has been taken to Parts Inspection Parameter......................................34
make it as complete and accurate as possible. All Part Identification Avenger 220 v/s 200.................37
procedures and specifications subject to change without
Important Assembly Point........................................41
prior notice. The right is reserved to make changes at time
without prior notice. Engine Reassembly.................................................. 46
Tightening Torques - Engine................................... 58
Service Data - Engine..............................................60
Carburettor................................................................62
DOC. NO. : 71111153 REV. NO.: 00, OCT. 10 Engine Mounting on Chassis...................................63
Front Fork Dismantling & Assembly........................65
Swing Arm Dismantling............................................68
Service Data - Chassis............................................70
Tightening Torques - Frame....................................71
Maintenance - Electricals........................................ 72
Harness Rooting.......................................................82
Electrical Circuit Diagrams.......................................83
Logical Approach to Top Issues............................ 88
Service Notes Service Notes

Technical Specifications Feature Advantage Benefits
ENGINE & TRANSMISSION : Rim Front : 1. 85 X 17

Type : 4 stroke, Natural air cooled Rear : 2.75 X 15
No. of cylinders : One Fuel tank capacity : 14 Liters (3.4Liters of
Bore : 67.00 mm reserve)
Stroke : 56.40 mm CONTROLS :
Steering : Handle bar Feature Advantage Benefit
Engine displacement : 219.89 cc
Compression ratio : 9.5 + 0.5 : 1 Accelerator : Twist grip type on right The Style :
hand of handle bar 1 Low - slung cruiser looks. Low slung, dynamic cruiser Look completely different
Idling Speed : 1400 + 100 rpm
Gears : Left foot pedal operated 2 Silver outlook : Chrome plated head Looks. Flam boyant silver - from other motorcycle drivers.
Maximum net power : 19.04 PS @ 8000 rpm Chrome looks all over. Style staement of your own.
Clutch : Lever operated on left lamp, mirrors, indicators, tank cover, back rest,
Maximum net torque : 17.5 Nm @ 7000rpm rear shocker, wheel rims-spokes,Silver painted Just makes you feel like god.
side of handle bar
Ignition system : Microprocessor controlled Brakes Front : Lever operated on right engine & stainless steel silencer.
Digital DC CDI side of handle bar Round Head lamp /spoke wheels reminding the
Ignition Timing : 100 BTDC at 1500 r/min 3 retro style.
Rear : Pedal operated by right
280 BTDC at 3500 r/min foot. 4 Beautifully sculpted tank for a special retro feel.
Fuel : Unleaded Petrol 5 Painted white decals on petrol tank.
ELECTRICALS
Carburetors : Side Draught UCAL 6 Stylish wind shield.(Optional)
System : 12 Volts (A.C. + D.C.)
MIKUNI BS 29 7 Available in 4 beauitfull colours.
Battery : 12V 9Ah 8 Naked chain with O ring.
Spark Plug : 2Nos. Champion RG4HC Head lamp : 60/55 W
(Resistive) 9 Stylish bucket seat with back rest for pillion.
Tail/stop lamp : 5 / 18 W 10
Spark plug gap : 0.8 to 0.9mm Stylish instrumentation easy to read.
Turn signal lamp : 10 W
Lubrication : Wet sump, Forced Turn signal pilot lamp : 3 W
Clutch : Wet, multi disc type. Hi beam indicator lamp : 1.7 W
Transmission : 5 speed constant mesh Fuel gauge lamp : 1.7 W
Primary reduction : 3.47 : 1 (66/ 19) Fuel gauge : 2 W
Gear Ratio : Speedometer lamp : 3.0 W
1st Gear : 26.04 : 1 (36/13) Horn : 12 V DC Feature Advantage Benefit
2nd Gear : 17.67 : 1 (32/17) DIMENSIONS : The Performance :
3rd Gear : 12.97 : 1 (29/21) Length : 2195 mm 1 4 stroke DTSi 220 CC engine generating 19.04 PS
DTSi technology advantages :
4th Gear : 10.15 : 1 (26/24) Width : 750 mm 2 Digital twin spark ignition. 1. Good power and pick up.
5th Gear : 8.65 : 1 (24/26) Height : 1070 mm 3 Digital DC CDI with TPS control 2. Better fuel efficiency.
4 DC ignition system with low trigger start.
Final Drive Ratio : 2.71 : 1 (38/14) Wheel base : 1475 mm 3. Lesser emissions.
5 29 dia CV carburettor - Manual choke.
CHASSIS AND BODY : Ground Clearance : 169 mm (Min) Ride that can be enjoyed due
6 New starter clutch. to Power packed performance.
Frame type : Double cradle type Turning circle dia. : 2540 mm (Min) DC Ignition system advantages :
7 Oil cooled engine - bigger oil cooler. 1. Easy to start due to low trigger
Suspension Front : Telescopic, WEIGHTS : start RPM.
8 Controlled lubrication system for clutch.
Stroke = 140 mm Vehicle kerb weight : 154 Kg. 2. Cold startability improved.
9 Bigger exhaustech box
Rear : Swing arm with 5 steps Max. total weight : 286 Kg. 10 Bigger catalytic converter.
adjustable SAs with triple PERFORMANCE :
rated spring (90 mm travel). Maximum speed : 110km/h with single rider
Brake Front : Hydraulically operated disc (68kg)
Rear : Mechanical expanding Climbing ability : 28 % (160 Max)
shoe & drum type
Tyres Front : 90/90 - 17 49P NOTES :
Ø Values given above are nominal and for guidance
Rear : 130/90 - 15 M/C 66P
only, 15% variation is allowed to cater for Feature Advantage Benefit
Tyre pressure : production and measurement variation.
Front : 1.5kg / cm2 (21PSI) Ø All dimension are under un-laden condition. The Safety :
Rear (Solo) : 1.5kg /cm2 (21PSI) Ø Definitions of terminologies wherever applicable are
1 Bigger front disc brakes Confidence inspiring brakes.
(with Pillion) : 1.75kg / cm2 (25PSI) as per relevant IS/ISO standards
Ø Specifications are subject to change without notice. 2 Modified rear brake arrangement. Confidence inspiring brakes.
1 Service Notes Service Notes 2

Feature Advantage Benefits PDI Check List
Feature Advantage Benefit Following is the checklist for carrying out PDI of “Avenger DTS-i 220cc” motorcycle. It is important to carry
The Safety : out PDI checks for ensured delivery of trouble free vehicle to the customer.
1 High strength tubular -double cradle chassis. Better strength and stability on drive.
Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as
2 DC head lamp -halogen 60/55 W bright Better illumination during low idling
per the points given below. This ensures healthy vehicle delivery to the customer
head lamp. speeds too. Safety on drive by better
braking / lights.
3 1000 combination ignition lock - twin track key Pilfer proof.
4 Wind shield as an option. Wind resistance taken care.
Engine oil SAE20W50 of API
SG or SL + JASO MA grade
(BAJAJ GENUINE DTSI OIL)
Feature Advantage Benefit

The Comfort :
1 Forward foot riding posture for driver. Comfortable and relaxed riding posture. Strain free ride.
2 Low saddle height- broad saddle seat. Bucket seat for comfort over all drives. Fatigue free driving.
3 Special backrest for the pillion. Pillion too has been taken care. Safe and comfortable feeling.
4 Low centre of gravity. Better road grip and stability while on drive. Good road holding - stability.
5 Longest front telescopic suspension. More stroke length to absorb shocks. Smooth ride at any terrian.
6 Wide tyres at front and rear. Better grip available. Excellent road holding characteristics.
7 Rubber mounted handle bar. Isolation of vibrations due to rubber dampening. No vibrations on drive.
Swing arm with needle bearings at
8 Smooth swinging at pivot points. Smooth drive.
pivot 1.50 Kg/Cm2 (21.0 PSI)
9 Wind shield for protection. Protection against wind blow from front. Protection on drive. 1.50 Kg/Cm2 (21.0 PSI)
2
10 Duel foam density seat. Ensuring comfort for driver as well as pillion. Comfort on any kind of road. 1.75 KG/Cm (25.0 PSI)
Feature Advantage Benefit

The Convenience :
1 Push button indicator cancellation. Just push the indicator button to cancel.
2 Low Battery level indicator. Get the warning before battery conks off.
3 Tripmeter to record distance travelled. Better to claim conveyance bills.
4 Fuel gauge to indicate fuel level. Easy to read.
Easy to ride without any
5 Intelligent battery save function during driving / operating /
Disables cranking after three cranks,thus saving battery.
excess cranking. maintenance hassles.
6 Intelligent battery save function during Head light controller shuts off the head light when ever
continuous head lamp ON condition. engine stops,thus saving battery drain.
7 Low maintenance battery. Do not worry to fill up electrolyte level.
8 High capacity O ring chain. Dust would not enter inside chain.

PDI Check List FAQ's
Frequently asked questions by customers at service reception : T h e s e q u e s t i o n s a r e p o s e d b y

customers at the service stations. Everybody from your dealership need to give the same answer.Pl
read these answers carefully and start speaking in one langauge.
Ï Engine is overheating ? - heat being felt at legs.
B The engine mounting orientation on Avenger DTS-i is vertical.
When vehicle is running, the cooling air draught is getting directed from front side.
That cool air picks up the heat from engine and cools it down.Then it flows on driver's legs.
The more the hot air the driver feels, more heat has been picked up by air, thus giving better engine
cooling. Nothing to worry about this. Engine is having additional oil cooling too.
We would just get checked spark plug colour which would indicate us safely about engine health.
Nothing would happen to engine once that confirmation is over.
Do not worry, we are here to take care of any issue.
Ï Engine noise level is going up after a long drive of 35 + kms.
B To increase fuel efficiency, one has to reduce friction inside the engine.
Avenger engines have been provided with roller rocker arrangement inside cylinder head to reduce
friction. After long drive, when metalic parts expands,the noise level too goes up.
Routing of Breather pipe, Fuse
While the film of lubrication oil takes care of friction,noise level builds up slightly.
Fuel meter Properly working
Hence nothing to worry about noise level post prolonged drives.No harm would happen to your engine.
Ï Gear shifting neutral finding is difficult when standing in standstill position at signals.
/ Good sound B Since this is a sliding mesh gear box,without moving the wheels slightly -the gear dogs may not get
engaged.Hence it is important to rock the wheels slightly to facilitate shifting down to neutral.
(technicain has to confirm himself that the gear shifting is not hard,do not have clutch drag etc before
explaining this to customer.use check list for confirming all parameters)
Ï Fuel gauge is not accurate ? Does not show litre by litre.
B The reading which gauge is suppose to show is in three stages E,half and Full.
Its an indicator and can not be as precise as is expected.
Ï Can I use higher- better grade of oil ?
B As long as it meets the specification as given by BAJAJ auto.
20 W50/SG-SL + JASO MA grade. Anything above this can be used.
Ï There is a peculier noise from engine told by mechanic as Knocking ?
B The Avenger engine employees DTSi technolodgy.The two spark waves from spark plugs collides with
each other and that crates a noise ,being perceived as combustion noise.This noise level do not have
any effect whatsoever on engine performance and noise.Just
Ï Can I use accessories like remote control,imported air filters,add on horns etc ?
B All the parts related to engine and electrical parts are designed to certain specs.Changing/modifying any
part would affect the performance.Hence we do not advise fitment of such parts and warranty would
also stand negated in all such cases.Hence its bett

FAQ's FAQ's
FAQs on warranty policies : Ï I should get all modified parts fitted on my old vehicle - why not ?
Whenever customer ask few questions to WM at the time of a warranty denial on few items, std B Products are being continuously modified by BAJA auto for enhancing performance. This is a way of
answer given is - "it is as per Bajaj warranty policy". Since customer is not getting a logical answer, he life.
goes dis-satisfied.Hence as like Product FAQs the answers However this does not mean that all the modifications need to be passed on to all consumers. neither
Ï Why parts like clutch plates, chain- sprockets, steering races, timing chain, brake shoes etc are it happens in any other industry.
not covered under warranty ? Ï Why the warranty is not extended and applicable for the part replaced now ?
B These are the parts which are prone to wear and tear due to vehicle usage, external factors. The very B When the vehicle was sold to you the contract of warranty was for 2 years post sale of the vehicle.
fact that they have lasted long up to 1000 kms + do suggest that there was no manufacturing defect The warranty is not individually specified for individual parts. Hence it’s not possible to extend the
to start with If they had failed now it is something to warranty. However if faikure happens on same part again
Ï Why only block piston and crankshaft given under fuel adulteration claims ? Ï Why warranty seizes if all free/paid service schedule is not maintained ?
B 1. Component failure due to adulterated fuel is not a manufacturing defect. Periodic maintenance care is extremely important for a moving machine line an automobile. If vehicle is
not maintained/serviced prudently as specified by manufacturers, the performance would go down
2. Engine manufactured for sustaining adulterated fuels would cost too heavy on customer's products.
drastically. That may cause few premature failures which c
3. Since this is not a manufacturing defect, can not be covered under warranty. Ï Why the life of a component is so less ? (sprocket - 13000 kms ?,clutch plates - 17000 kms,
4. However since this is an accident (use of an adulterated fuel), Bajaj auto and its dealers are ready to Drive chain - 16000 kms ?)
contribute and help out customer. All the parties should share the cost of repairs. B Apart from material strength, the life of wear and tear items is dependant upon the maintenance
Bajaj auto would give 40 % cost. Customer would give 33 % and dealer would charge 50 % labour care/driving pattern in which the vehicle is running. A prudently maintained/driven vehicle would give
and forego his spare parts discounts. The dealer is suppose to save and reuse certain components to thrice the life of a part as compared to badly driven, badl
reduce cost of repairs.
Thus earlier burden of Rs 7000 to customer would go down to @ 3000. Since this is not a genuine
manufacturing defect it would not be covered at the time of a second time failure.
Entire automobile fraternity to raise this issue with concerned Government officials.
The calculation details of reimbursement are given in the sheet attached.
Create the awareness amongst customers regarding proper use of fuel/fuel additives and consequences
of bad fuel quality.
Ï Why Battery/tyres are not given by selling dealer under warranty ?
B World over the policy of warranty of proprietary parts is the same. They are warranted by respective
manufacturers.
They are experts in analyzing the failures and have special equipments for checking the parts.
Further the Batteries can not be transported due to environmental factors.
Ï Why the part as failed on my vehicle so early - why cant you replace complete vehicle ?
The vehicle is manufactured by using 4 Ms. men. machine, material and method. Something can
go wrong in rare case.
B The automobile is not a stationary machine like many other consumer durables.
To cover up any manufacturing lapse the warranty is given by Bajaj auto.
We sincerely apologies for this to have happened on your vehicle. But the faulty part replacement
would restore the vehicle performance. We are equipped with, trained to carry out those repairs.
Since the vehicle is an assly. of so many parts, complete replacement is not a logical solution for this
defect removal.
Further the change of vehicle is not permitted by RTO, once registered.
However we guarantee the optimum performance of your vehicle and we are committed for that.

Read Before You Ride Advantages of DC Ignition
A Starting the vehicle : Trigger start rpm down to 200 from 350.
Hi spark intensity at lo rpm due to DC input.
1 Put the Ignition and Kill switch in ON position.
Lower starting current drawn by
2 Confirm that the vehicle is in neutral. Starter motor.38 Amps (46)
3 Button start the engine without opening throttle. Better brush life due to low current carry.
B Warning indicators : Quick / easy start.

1 Low battery charge level indicator. Manual choke provided.
This is provided on right hand side of tank cover. The indicator will glow as soon as the ignition switch
is made ON. The low battery charge level indicator light will go of as soon as the engine fires.
Maintaining Battery charge level is very essential, for starting of vehicle.
C Important Does and Don'ts :
1 The powerful engine with quick throttle response would make the driver to open the accelerator with
caution. Do not open the throttle suddenly. Easy Cold starting.
2 Use both the brakes at a time. Use of front brake for dead stop would give better control. Since the Sealed couplers everywhere to arrest water entry.
front axle weight is more, the rear brake has been deliberately toned down to avoid skidding.
3 As soon as the fuel meter indicator pointer goes into red band, fill up the fuel at the nearby filling
station.
4 Use better quality fuel only. Anything above 87 octane rating. Do not use any additives with the petrol.
Since this is a precision machine, adulterated fuel should never be used.
5 Chain with built in O ring is fitted on this vehicle. The lubrication at every 500 kms with SAE 90 oil and No starting Trouble
after Washing.
adjustment at every 1000 kms would be essential. Pl see to it that the chain never runs dry.
6 Do not add any additional electrical / electronic gadgets on the vehicle, as they would disturb
functioning of engine management system. Sealed couplers everywhere to arrest water entry.
7 During washing of the vehicles, pl do take care of different electrical parts. Do not direct the jet of
water towards electrical parts.
" Wishing you a Pulsating ride "…………. "Happy Riding".
No start – Water entry

post monsoon.
Better battery charging current at lower rpm and throughout the

Battery life rpm range. (At 20 kmph speed 1.25 Amps more charging current).
Thus no issues even on vehicles running at slow speeds in city.
Battery warranty period matched with vehicle warranty period.
MF battery against MF battery.

New warranty claiming
system.
HRD tester for better health

check.
Portable booster battery
charger.

Periodic Service Wise Part Kit Periodic Service Wise Part Kit
For optimum & consistent performance form the engine/vehicle, replacement of periodic parts during respective Service Type Days Kms limit
periodic service as recommended below is very important. Following table gives service wise parts that are
required to be replaced. Part name Qty
Service Type Days Kms limit
Part name Qty
Engine Oil Replace 11 00mm
Carburettor rubber duct 1
Engine Oil 1100 ml
1st Free 30 - 45 days 500 - 750 after 120 days Fork Oil (Per leg) 191+2.5 ml
Clutch cover gasket 1 th
4 Paid from the 29500-30000 Front fork oil seal (If required) 2
2nd Free 240 days 4500 - 5000 Body starter clutch lubricate NIL
last service Cylinder head gasket ( If required ) 1
Engine Oil 1100 ml
Brake shoes / disc pad (If worn out) 1
Air Filter Foam element 1
Steering race & ball kit 1
Rear Brake shoe 1
Fork Oil (Per leg) 191+2.5 ml Valve Oil seal 2
3rd Free 240 days 9500 - 10000 Front fork dust seal & Oil seal (If required) 2 each Cylinder head stud copper washers 4
Cylinder head gasket (If required) 1
Body starter clutch lubricate NIL
Steering races & ball kit 1
Front disc pad inspect (If worn out) 1 Spark Plug Replace 2
Rear wheel damper rubber 1 Air Filter Foam element 1
Body starter clutch lubricate NIL
after 120 days Body starter clutch lubricate NIL Note:
st
1 Paid from the 14500 - 15000 1. Always use Bajaj genuine parts & recommended lubricants
Spark Plug Replace 2
last service
Engine Oil 1100 ml Recommended Oil :
“Bajaj DTS-i 10000” a high performance engine oil developed by Bajaj auto..
Air Filter Foam element 1
Air Filter cover O ring 1 Bajaj Auto recommends “Bajaj DTS-i 10000” engine oil for 10,000 kms drain interval, better
Engine Breather pipe 1 performance of engine components & warranty benefits.
after 120 days
2 Paid
nd from the 19500 - 20000 Carburettor Rubber duct 1
last service Fork Oil (Per leg) 191+2.5 ml
Bajaj DTS-i 10000 SAE 20W50 of API ‘SL’, JASO MA Grade.
Front fork dust seal & Oil seal (If required) 2 each
Steering races & ball kit 1 Replacement Frequency* 1st replacement at 750 Kms. / 1st service. Thereafter at every
Brake shoes (If worn out ) 1 10,000 Kms.
Rear wheel damper rubber 4 Recommended Quantity Drain & Refill 1100 ml., Engine Overhaul 1200 ml.
after 120 days *For any other branded oil of equivalent grade replacement frequency will be 5000 Kms.
3rd Paid from the 24500 - 25000 Body starter clutch lubricate NIL
last service CAUTION :
• It is most important to adhere to recommended grade & frequency of oil change for the purpose of
long life of critical engine components.
• Do not reuse drained oil.

Periodic Maintenance & Periodic Maintenance &
Lubrication Chart Lubrication Chart
RECOMMENDED FREQUENCY RECOMMENDED FREQUENCY

Sr. Operation Sr. Operation
No. No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
Servicing 1st 2nd 3rd 4th 5th 6th 7th
Kms 750 5000 10000 15000 20000 25000 30000
Kms 750 5000 10000 15000 20000 25000 30000
32. Drive chain ‘O’ ring type (If applicable) L At every 500 Kms
1. Servicing 3 3 3 3 3 3 3 1st - 750 Kms / 30 Days
2nd onward @5000 Kms 33. Drive chain remove, clean, insp. & lubricate (O/H) CL, L CL, L CL, L CL, L At every 10000 Kms
2. Engine idling speed / CO% A A A A A A A A 34. Drive chain link lock R R R R Replace at every 10000 Kms
3. Valve tappet clearance A A A A A A A A 35. Wheel bearing (for non sealed bearings only) C, L C, L At every 20000 Kms
4. Engine oil* - Bajaj DTS-i 10000 R R R R R Replace at 10000 Kms* 36. Tyre tread wear (replace if worn out till TWI limit) C, R C, R C, R C, R C, R C, R At every 5000 kms i.e. at
5. Oil strainer / Centrifugal filter CL CL CL CL CL Clean at 10000 Kms every service after 2nd service
6. Spark plugs functioning / Gap (If applicable) C, A, R C, A C, A C, A R C, A C, A R Replace at every 15000 Kms 37. Front fork oil R R Replace at every 20000 Kms
7. Air cleaner element Clean / Replace VV CL, R CL CL CL R CL CL R Clean at every 5000 Kms 38. Auto choke, Thermal sensor (If applicable) C, A C, A C, A C, A C, A C, A C, A C, A At every 5000 Kms
Replace at every 15000 Kms 39. TPS (If applicable) C, A C, A C, A C, A C, A C, A C, A C, A At every 5000 Kms
8. Air filter cover ‘O’ Ring R R Replace at every 20000 Kms 40. RSA - Check gas pressure (If applicable) C, A C, A At every 20000 Kms.
9. Fuel cock sediment bowl cleaning CL CL CL CL CL CL CL 41. Starter clutch bush kit for dry type (If applicable) CL, R CL, R CL, R
10. Carburettor float bowl cleaning CL CL CL CL Clean at every 10000 Kms 42. Clutch switch cleaning (If applicable) CL CL CL CL
11. Carburettor rubber duct C, R C C C C R C C Replace at every 20000 kms 43. General lubrication L L L L L L L L
12. Fuel pipes C, R C C C C R C C Replace at every 20000 kms 44. Swing arm pivot pin lubrication L L Lubricate at every 20000 Kms
13. Battery electrolyte level C, A C, A C, A C, A C, A C, A C, A C, A 45. Engine foundation silent bush (If applicable) R R R Replace at every 15000 Kms
14. Clutch lever free play C, A C, A C, A C, A C, A C, A C, A C, A 46. Lubrication of gear starter clutch L L L L L L L L-Every 5,000 kms.
15. Throttle grip play C, A C, A C, A C, A C, A C, A C, A C, A 47. Clutch, Accelerator cable R R-Every two years
16. Rear brake pedal free play C, A C, A C, A C, A C, A C, A C, A C, A
17. Brake lining or pad wear CL, R CL CL CL, R CL CL CL, R Replace at every 10000 kms C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note : Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.
18. Brake fluid level / Top up / Replace (If applicable) C, A, R C, A C, A C, A C, A C, A C, A R Replace at every 30000 kms
19. Master cylinder cup and dust seal (If applicable) R R Replace at every 30000 kms
20. Caliper piston seal and dust seal (If applicable) R R Replace at every 30000 kms
21. Brake hose pipe (If applicable) C, R C, R Replace at every 30000 kms
22. Brake cam & pedal pivot pin L L L
23. Steering play C, A C, A C, A C, A C, A C, A C, A C, A
24. Steering stem bearing C, L, R C,L,R C,L,R C,L,R
25. All fasteners tightness C, T C, T C, T C, T C, T C, T C, T C, T
26. Rear sprocket fasteners C, T C, T C, T C, T C, T C, T C, T C, T
27. Rear wheel rubber shock damper C, R C, R C, R C, R Replace at every 10000 kms
28. Silencer drain hole cleaning CL CL CL CL CL CL CL CL Clean at every 5000 Kms
29. Cylinder head de-carbonising, valve lapping &
Replace valve oil seals CL CL CL Clean at every 15000 Kms
30. Engine air breather tube R R Replace at every 20000 Kms
31. Drive chain slackness adjustment & lubrication C, A, L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L Lubricate at every 500 kms.
A- slackness whenever reqd.

Skill Tips for Windshield Exclusive Special Tools
Windshield is supplied as an accessory not part of standard fitment. Windshield adds to aesthetics. The tilt of Below listed tools were used for eliminator motorcycle & same tools are recommended for Avenger motor cycle
the shield is adjustable. Following is customer information & right procedure for fitting the Windshield. also.
Customer Information:
As the Windshield is an accessory item, while selling, following information must be clearly communicated to all Tool No. & Description Tool Application
customers who intend to buy.
? ` The windshield is available as an accessory. This is to add aesthetics & style statement. 74 9309 87
? ` It will not completely stop airflow from front and hence full-face helmet would still be necessary. Front Fork Oil seal Driver
Used for fitting fork oil seal on Front fork
? ` Windshield can be adjusted forward or backward as per the requirement of driver's height. (New Tool Developed)
? ` The control on road would still be based on driver's vision from above the windshield.
? ` Curvature on the windshield can sometimes distort the image if looked from a specific angle.
E6 0690 00
Windshield Assly. & fitment procedure: Bearing remover shaft with head
A. Wi ndshi el d is available in a Kit form (P.No. 52 JM0018 ). Used for removing & fitment of bearing in
wheel.
Nut
B. Fitment Procedure:
Plate 74 9310 15
? `Remove holder handle bar lower stud cap nuts
Front fork inner tube extractor
( 2 nos ) & plate . Used for removing front fork inner tube from
? `Disconnect speedometer cable from speedometer. outer tube.
? `Route speedometer cable top end through windshield &
frame bracket as shown. Tighten speedometer cable top nut.
? `Locate "windshield with its mounting bracket" on to Frame
Bracket 74 9309 93
holder handle bar lower mounting stud & tighten the Bearing Puller
cap nuts ( 2 nos) with holding the handle bar. For removing & fitting needle roller bearing in
? `Do not fit plate (DV181018) over or below windshield swing arm
frame bracket. It will reduce holding area for nut.
? `Check for proper fitment of the windshield.
Based on the user requirement angular position of windshield

can be adjusted by + 5 Degrees.
The procedure for adjustment is given below: -

? L̀oosen RH side 2 bolts of windshield frame.
? L̀oosen LH side 1 nut & 1 bolt of windshield frame.
Adjust windshield forward or backward as per requirement

& tighten these nut / bolts after adjustment is over.
The tighteninthese nut/bolts is 2.5 Kg.m

Other Common Special Tools Engine Removal from Chassis
REMOVAL OF ENGINE FROM CHASSIS:

Special Tool Name Special Tool No. Application
Remove
Sprocket Catcher 37 10DH 36 For holding sprocket during removal / refitting of Cam sprocket allen bolt. Ø 2 bolts [A] and [B] from both sides
Camshaft Big Bearing Puller 37 10DH 32 To remove bigger bearing C Ø Back rest assembly
A
Ø 2 bolts [A] and [B] and remove grip frame lower LH, Grip frame LH, and
Camshaft Small Bearing Puller 37 10DH 31 To remove small bearing of camshaft. B
cover LH
Rocker Shaft Remover 37 10DH 35 To remove rocker shaft from cylinder head cover. Ø Carry out the same procedure on RH side.
Silent Bush Puller 37 10DH 33 To remove & refit silent bush from cylinder head cover. E D Ø Screw [C] from rear end of seat assembly.
Rotor Puller with Butt Pin 37 10DJ 32 Used to pull out the rotor from crankshaft assembly.
Primary Gear Holder 37 10DJ 28 Use to hold primary gear while loosening / tightening the clutch nut.
D
Remove
Balancer Gear Holder 37 10DJ 63 Used to load pre-tensioned scissor gears of Assly balancer Idler gear. A Ø Bolt flanged [A] from both sides of seat.
Special Nut 37 10DJ 43 Used to remove / fit of centrifugal oil filter nut. Ø Seat Assembly.
Ø 2 philip head screws [B] of side cover LH.
Bearing Race Extractor 37 00DJ 01 Used for removing the lower bearing race from ‘T’
Ø Side cover LH [C].
B
Bearing Extractor 37 10DJ 76 Used to extract the input shaft bearing from crankcase LH. C Ø Side cover Assembly RH [A] by unlocking it with the help of key.
Bearing Puller 37 10DJ 77 Used to pull out the bearing for body balancer from crankcase LH.
Adaptor & Valve Spring Used for assembling / dismantling inlet, exhaust valves by compressing
37 10DJ 78 / 37103107
Compressor spring in cylinder head.
Rotor Holder H6 0721 00 To hold rotor while loosening bolt. Disconnect:
B
Ø Magneto wiring coupler [A] &coupler harness for petrol tank assly.
Drift 74 9309 89 To remove piston pin.
Remove:
To align the clutch hub concentric w.r.t clutch wheel, clutch housing and Ø 2 bolts [B]
Thrust Plate Aligner / Holder T 10111 68 C
thrust plate for assembly of clutch. Ø Petrol tank assembly [C].
Output Sprocket Holder 37 1030 53 To hold the output sprocket while removing sprocket bolt
A
Common bearing driver set for fitting and removing bearings from
Bearing Driver Set 37 1030 61 crankcase.
For adjusting the notch position of RSA to achieve hard or soft rear
Rear Shock Absorber Adjuster 37 00DH 14 suspension. Remove :
A E
Ø 2 bolts [A]
Used for compressing the piston rings when assembling piston in the
Piston Ring Holder 37 10DJ 30
cylinder block. Ø One bolt at Gear change lever [B]
D
Ø Gear lever holder assembly along with Gear change mechanism and gaurd
step [C].
C
B Ø 2 bolts [D].
Ø Small sprocket cover [E]
Remove
Ø Drain bolt [A]
Ø Drain Engine oil
A Ø Re-fit & tighten the drain bolt

Engine Removal from Chassis Engine & Transmission
Remove Engine Top End Dismantling :

Ø 2 Bolts [A]
Remove :
Ø Plate Sprocket [B]
A Ø Sprocket from output shaft • Pull out the cover on the spark plug cap RH and the spark plug cap itself
• Using a plug spanner, loosen the spark plug and remove the spark plug RH
B • Loosen & unscrew the allen head grub screw of the sleeve spark plug RH.
Remove : Note :
B Ø Fuel pipe from Carburettor Wrap a piece of cloth around the protruding edge of the sleeve spark plug and
Ø PCV Pipe [A] from Crankcase using a plier, pull out the sleeve.
A
Ø Carburettor cables .
Ø Loosen Carburettor clamps [B].
Ø Carburettor assly.
Remove :
• There are 2 ‘O’ rings fitted in the cylinder head, one on the cam chain wall
Remove :
and the other near the spark plug threading
Ø 2Bolt [A] for bracket cable.
Ø Clutch cable connections.
• Using a thin, sharp pointed tool pierce the ‘O’ rings and remove them. (If
B C required only)
A Ø Clutch cable [B]
Ø 2 nuts [C] for silencer.
Note : Remove these only if the ‘O’ ring protrusion in the bore is non-existant
Ø Both Spark Plug Cap
(which means that the ‘O’ ring has set and it has lost its compression or sealing
Ø Connection from Starter Motor
ability.) If the ‘O’ ring has to be removed for any reason, it should be replaced
with new one.
Remove : Remove :
E
Ø 1 bolt [E]. • Loosen bolt (A) and unscrew chain tensioner plunger
Ø Silencer assly.
B • Cam chain tensioner assembly 2 bolts (B)
A • Cam chain tensioner assembly
• Gasket
Remove :
Remove : • Both tappet caps
B Ø 2Bolts [A] & [B]holding engine to rear chassis.
Ø Engine Mounting Bkt front side
A Ø Engine mounting Bkt Top
Ø Engine from chassis
Remove :
• Magneto cover 5 bolts (A)
• Disconnect neutral switch coupler
• Magneto cover
A • Rotate crankshaft to get piston at TDC.
• Ensure both tappets are at free state (i.e. at the end
of compression stroke)

Engine & Transmission Engine & Transmission
Remove : Remove :
• Loosen 2 dummy plug (A) • 2 Banjo bolts (A)
A • Copper gasket
A • Bolt (B)
B • Oil Pipe
Remove : Remove :
• Cylinder head securing head cover 2 bolts (A) • Non tensioner side chain guide
A B • Cylinder head securing head cover 4 bolts (B) • Cylinder block assembly
C
• Cylinder head securing head cover 4 domed cap nuts (C)
• 4 copper plated steel washers
Note :
Using Special Tool : Drift - 74 9309 89
Improper tightening sequence may cause warpage in cylinder head cover and it
can be damaged permanently. Remove :
• Piston pin lock LH & RH side
Remove : • Piston pin
• Cylinder head cover complete • Piston assembly
• Cam shaft cap
Note :
• 2 Dummy plugs
Place a piece of clean lint free cloth above hallow portion of crankcase to arrest
• Dummy plug gasket
piston pin circlip if it falls during fitment.
Using Special Tool : Sprocket Catcher - 3710 DH 36

When tapping the drift for removal of piston pin, confirm that the connecting rod is held firmly
Remove : against the direction of tapping to avoid damage to big end bearing connecting rod of crankshaft.
• Allen bolt (A) Warning
• Spacer
A • Cam sprocket Remove :
• Collar • Block gasket
A
• Cam shaft assly • 2 Dowels (A)
Note : Note :
Hold the cam chain up right using soft copper wire or thread. Do not use cotton Tie the cam chain firmly using soft copper wire/thread firmly to avoid it slipping
waste for holding the cam chain. down into crankcase and jamming the crankshaft rotation.
Remove : Engine LH : Magneto Side

• Cylinder head assembly Using Sp. Tool : Rotor Holder - H6 0721 00
• 2 Dowels
A • Hold the rotor assembly
• Gasket cylinder head
Remove :
• Rotor bolt (A)
• Washer

Using Special Tool - Rotor Puller with butt pin : 37 10DJ A Engine RH : Clutch Side
32
Remove :
Remove :
• 1 screw - (A)
• Rotor assembly
• Starter motor cover
• Woodruff key
Note :
The rod clutch lifter, plunger oil, plate plunger oil and spring joint may fall out
Note :
of their respective places into the oil collection tray. If so, ensure that these are
Holding the gear complete starter clutch rotate the rotor and pull it out in collected & accounted for before proceeding.
Anticlockwise direction to prevent rollers and springs coming out.
Remove :
• Bracket clutch cable (C)
• 12 Clutch cover bolts
• These components remain hot for a long time especially if removed from a hot e n g i n e . Wear
Note :
suitable hand protection to prevent burns. C
• Rotor puller has left hand threads The rod clutch lifter, plunger oil, plate plunger oil and spring joint may fall out
Warning
of their respective places into the oil collection tray. If so, ensure that these are
collected & accounted for before proceeding.
Remove :
• Gasket
B Remove :
• Bolt (A)
• 2 Dowels
• Plate starter clutch gear return (B)
• Clutch cover gasket
A • Gear starter clutch
• Starter Motor (B)
B
Remove :
• Collar (A)
Using Sp. Tool : Primary Gear Holder 37 10DJ 28
A • Shaft
Remove :
• Gear comp. starter counter assly A • 3 phillips head screws (A)
• Centrifugal oil filter cover
• Gasket
Remove :
• 3 Screw (A) Note :
• Guide starter assembly along with oil seal. Some amount of oil is trapped in cover and body of centrifugal oil filter, this oil
should be drained into the oil tray.
Note :
Removal of guide starter assembly is to be removed only if required. Using Sp Tool : Special Nut Puller - 37 10DJ43
Using Sp Tool : Primary Gear Holder - 3710 DJ28
CAUTION Remove :
Ensure that the woodruff key of rotor is removed prior to the removal of guide starter • Centrifugal oil filter special nut
assembly. The lips of magneto oil seal housed in guide starter assembly will get
damaged if not done so. • Belleville washer
• Body centrifugal oil filter assly

Remove : Remove :
• Bearing with plunger • Bolt (A)
A
• Locking plate
• Body balancer gear assly
Using Sp Tool : Special Nut Puller - 37 10DJ 43 Remove :

Using Sp Tool : Primary Gear Holder - 3710DJ28 • Primary gear • Cam chain • Parallel Pin
Remove : • square key • Cam chain sprocket
• Input shaft special nut Note :
• Belleville washer Take care that square key does not fall inside the crankcase hollow portion while
• Clutch assly comp removing.
• Spacer
Note : Remove :
The existing Special Nut Puller 37 10DJ 43 can be used by grinding the tool OD • 3 Bolts (A)
to 25.9 + 0.1 mm • Oil pump assembly
• 2 Dowels
A
Dia. = 25.9+0.1
Remove :
A The oil pump may be hot, hence use suitable hand protection. Also, since the oil pump
• Assly balancer Idler gear cover bolts (A) - 3 Nos. houses the oil strainer / mesh also, it may retain some quantity of oil. This oil may be hot.
• Cover Warning Hence proper care should be taken to drain it.
• Washer
• 2 Dowel Note : The oil which is in the oil pump housing should also be drained out into the oil drain tray for
measuring drained oil.
Remove : Remove :
• Gear change lever
Note :
For ease in removal of clutch house insert special tool
(P. No.-37 10DJ 63) in Assly Balancer Idler Gear.
Remove :
• Assly balancer idler gear Remove :
• 2 Washer • The entire gear box assembly together.

Remove :
Dismantling of Sub Assemblies
• Spring • Spacer
A • Allen bolt (A) • Parallel Pin Crankcase Clutch Side :
• Guide gear Using Sp. Tool : Bearing Driver set - 37 1030 61
Remove :
• Bearing (A) for input shaft assembly from
Note : Check and inspect the drum change arm stopper for free movement always. crankcase RH
Using Sp. Tool : Bearing Extractor - 37 1030 68
Engine Central Part : Remove :
Remove : A • Needle roller bearing (B) for output shaft
A • Bolt (A) on RH side crankcase (Clutch side) B
assembly from crankcase RH
Remove : Crankcase Clutch Side :

• Bolt (B) on LH side crankcase (Magneto side) Using Sp. Tool : Bearing Extractor - 37 1030 72
B
Remove :
• Bearing (C) for drum change
Remove : Crankcase Magneto Side :

• 8 bolts on LH side crankcase Remove :
• Split the Crankcase halves. A • Oil Seal
Note : Using Sp. Tool : Bearing Extractor - 37 1030 72

Remove :
Before separating crankcase halves confirm that all the crankcase joining bolts
are removed and the sprocket cam drive with parallel pin on crankshaft assembly • Bearing (A) for output shaft assembly from
is removed. crankcase LH
Remove : Using Sp. Tool : Bearing Extractor - 37 10DJ 77

• 2 Shafts (A) & (B) of gear shifter fork. Remove :
• 3 fork shifts (1 small for input 2 big for output shaft. • Bearing (A) for body balancer gear bearing from
A crankcase LH
• 3 Rollers
B A • Drum change
Remove :
• Crankcase gasket
• 2 dowels
• Crankshaft assly

Using Sp. Tool : Bearing Extractor - 37 10DJ 76 Top End :

Remove :
Cylinder Head :
• Bearing (A) for input shaft assembly from
A A Using Sp. Tool : Valve Spring Compressor - 371031
crankcase LH
B 07
Using Sp. Tool : Adapter - 37 10DJ 78
D
Remove :
• 2 Cotter valve (A)
C • Valve spring retainer (B)
Remove : • Springs inner (D)
• Bolt (A) G • Spring outer (C)
• Bearing stopper F • Valve from below (E)
Using Sp. Tool : Bearing Driver set - 37 1030 74 • Washer (F)
A Remove : • Valve steam seal (G)
E
• Bearing for gear drum from crankcase Similarly carry out the same procedure to dismantle
the other valve from the cylinder head assembly.
Dismantling of Subassemblies :
Magneto Cover :
Chain Tensioner Assembly :
Remove :
It is not recommended to dismantle Chain Tensioner Assly.
• 2 allen bolts (A) crank angle sensor (E) mounting
• 3 Allen bolts (B) of stator assembly
• Stator coil assembly (D) along with Pulsar coil
Cylinder Head Cover :

Clutch Assembly :
Using Sp. Tool : Rocker pin remover - 37 10DH35 E
F Remove :
B
Remove :
D • 4 bolts (A)
A
• Rocker shaft (A)

• Holder clutch (B)
• Rocker arm
C C • 4 springs (C)
• Set of washers (1 wave and 2 plane) (B) B
G A
• Clutch center (D)
• Plain washer
Note :
• Bellivellie washer
Similarly remove the other Rocker shaft & Rocker Arm from head over.
• Disc clutch friction (E) (Qty. 6)
• Plate clutch (F)
• Plate clutch pressure (G) (Wheel clutch)
• Clutch housing
• Thrust washer - conical from inner ID

Oil Pump : Input Shaft Assembly

B C EF I K
• 1st gear is integral with the shaft (A)
Remove :
• Remove thrust washer (B) and slide out gear 2nd drive (C)
• Clip (A)
• Remove gear 5th drive (D) and collect the splined washer
C • Oil strainer element (B) with 'O' ring (C) (E)behind it.
• Remove circlip (F) and remove gear 3rd drive (G)
B
• Remove circlip (H) and collect the splined washer (I)
• Remove gear 4th (J) and collect the thrust washer (K)
A
D G H J A behind it.
Bearing Removal from Assly Balancer Idler Gear Cover and Crankcase RH Output Shaft Assembly
L M H FE CB A
Using Sp. Tool : Bearing Extractor - 37 10CD 30 • There are no integral gears on output shaft.
Remove : • Remove thrust washer (A) and slide off the gear1st driven
• Needle roller bearing from RH crankcase. (B) and collect the steel bush (1st driven gear is mounted
on steel bush (C) with shoulder ring
• Slide off the gear 4th driven (D).
• Remove circlip (E) and spline washer (F). Remove the gear
A
Assembly Balancer Idler Gear 3rd driven (G).
C D
Remove : • Collect the thrust washer (H) behind the 3rd gear on output
• Thrust washers (A) shaft (I)
• Circlip (B) from any one side of the gear • Remove circlip (J) and collect the washer (K)
• Remove gear 2nd driven (L) mounted on bush (N) with
• Scissor gear (C) JK N I G D
shoulder ring
• Torsion Spring (D) • Slide out gear 5th driven (M)
B D E CB A
Similarly carry out the same procedure on other side of the gear to
dismantle the idler gear completely.
Crankcase Magneto Side
Remove :
Gear Complete Starter Counter Assembly • 3 Screws (A)
• Place the gear comp. starter counter assly on the arbor press • Guide starter assembly (B) on which oil seal is mounted.
as shown in the figure. • Oil seal (C)
C
• Using Bearing driver set (P. No. 37 1030 61) A
• Damper (D)
D
Remove :
B
• Needle roller bearing

Engine & Transmission Parts Inspection Parameter
Clutch Cover Spark Plug

Remove : Ø Type / Heat value - RG 4HC
G A • Parallel Pin (A) Ø Gap between electrodes - 0.7 to 0.8 mm
B Ø Electrode condition - No errosion
• Clutch shaft release completely (B) by slightly rotating it
Ø Colour at the electrodes tip - Brownish
so,
Ø Threads of reach portion - Ok / No damage
• Rack (C)
• Plunger oil (D)
H • Plate plunger oil (E) Cylinder Head
• Spring joint ‘A’ (F) Ø Mating surface No warpage / No scratches (Allowable warpage 0.05 mm)
Ø Identification mark - DJ letter embossed on casting
• Oil filler plug (G)
Ø No fins breakage ·
• Circlip & Valve assembly (H)
C Ø Spark plug hole threads - Ok / No damage
• Wire clip (I)
Ø Carbon built up in combustion chamber cavity- Clean it
• Oil inspection window Ø Valve seat No pitting / No carbon deposition
• Flanged bolt (8 Nos.) (J) Ø Proper fitment of Dampers - 3 nos
K • Set of damper (K) Ø Proper fitment of ‘O’rings
F • Set of plate (L) Ø Proper fitment of valve steam seals on guide
J E • Grommet (M) Ø Valve guide for cracked if any
L D
Cylinder Block
Ø No fins breakage
Ø No Scoring marks
Camshaft Dismantling Ø No Seizure marks
Using Special Tool : Bearing Pullers - Ø Ok Seating – mating surface
A
37 10DJ 74 for Bearing 39 2270 20, Ø Smooth Honing pattern
37 10DJ 75 for Bearing 39 1485 20 Ø Correct / Same grouping mark with respect to piston (A & B group)
Ø Inner diameter of block as mentioned in service data.
Remove :
Ø Ovality - Not more then 0.05 mm.
C • Bigger Bearing using sp. tool Ø Damper rubbers Properly fitted on fins
B from camshaft assembly(A) Ø Proper fitment of ‘O’rings on bottom side
• Small Bearing (B)
• Washer (C) Piston
Ø Grouping mark with respect to cylinder blockmust be same.
Ø Diameter of the piston - As mentioned in service data
Gear Starter Clutch Ø No Scoring marks on the skirt
Remove : Ø No Blow by marks
• Place the gear starter clutch on arbor press as shown in Ø No Seizure marks.
photo Ø Manufacturing / identification code and date code
Ø Piston pin wall thickness - As mentioned in service data
• Using Bearing Driver Set (P. No.: 37 1030 61)
Remove : Rings
• Needle roller bearing Ø No uneven wear around circumference / breakage.
Ø Discolouration at working face.
Ø Carbon built up on inner face if any.
Ø Piston ring end gap - As per Service data
Ø Piston ring width (thickness) - As per Service data
Ø No Rings stickyness
Ø Piston ring identification mark Top ring = Top1
Second ring = Top 2

Parts Inspection Parameter Parts Inspection Parameter
Crankshaft Clutch Hub / Clutch Wheel

Ø Big end axial play - As per Service data. Ø Contact surface for friction plates-should not be worn out excessively
Ø Big end radial play - As per Service data.
Ø Runout - As per Service data. Ø Pressure Plate free movement in clutch hub
Ø Threading condition - Ok / No damages. Ø Guide split washer free movement in clutch wheel
Ø Key way condition - Ok / No damages. Ø Holes for lubrication
Ø Big end bearing - Freeness / Jam Ø Guide split free rotation on clutch turb.
Ø Con-rod - No bending / twisting
Ø Oil passage - No blockage.
Transmission
Ø No Teeth breakage or crack
Ø No Wear pattern on teeth
Crankcase Ø No Wear of dog teeth & dog holes on gear
Ø Mating surface - Smooth / No scratches.
Ø No Cracks, damages, breakage. Ø No Seizure mark on gear seat.
Ø Bearing seat, oil seal seat & proper pressing / positioning of oil seals, needle Ø Free movement of gears on the shaft
roller, ball bearings etc. Ø Free movement of Fork shift on the pin
Ø No Blow holes in casting
Ø Breather pipe / hole - No clogging
Ø Oil passage- Clean / No clogging Drum
Ø Threads of holes & studs - Ok / No damages
Ø Proper pressing of insert in seat. Ø Presence of Neutral rivet on the Drum
Ø Legible number punching on LH Crank Case Ø Free rotation of Drum in insert
Ø Hole available for parallel pin.
Bearings Ø Gear shift drum groove profile - Ok / No damage
Ø Axial play - Ok / Not excessive Ø Free movement of Fork shift guide pin in the drum groove
Ø Radial play - Ok / Not excessive
Ø Bearing Seat - No sign of high spot on seating area.
Carburettor
Ø Bearing class & code numbers as per specification. Ø Float
– No punctured ,
– Alignment w.r.t float pin - Ok
– No Crimped / Sqneezed,
– Not touching to bowl walls
Ø Needle
Clutch – No groove formation on the tip
Clutch plates / Steel plates - – Smooth action of spring loaded pin ,
Ø Thickness as per service data – Smooth movement in its seat.
Ø Warpage as per service data Ø Volume control screw
Ø No Seizure / Damaged bonding of friction material – Not bent / threads ok. / Not Jammed Jets
Ø Tangs (Lugs) / Teeth - No wearing – Correct size, no wear of jet hole, no clogging
Ø Identification mark – on tangs Ø Piston valve
Ø No Foreign material imbedded – Smooth free sliding, clearance in its seat, no excess wear mark.
Ø Color change / Signs of overheating if any Ø Starter plunger
– No wearing out / spring ok / ‘O’ ring intack
Clutch housing -
Ø No Wear marks on slots.
Cam Shaft
Ø Clearance between clutch plate tangs and slot in the clutch housing should
Ø Presence of locating washer
not be excessive
Ø Free rotating of bearings / bearing seal.
Ø Free movement of plates in clutch housing slots.
Ø Sprocket -no burr / No deformation / No uneven wearing of teeth
Ø Revetting of clutch housing should not be loose.
Ø Lobe height - as per service data
Ø Free rotation of housing on Bush and also bush should rotate freely on Input
Ø No Dent / wear marks on cam lobe
shaft
Ø Freeness of D-com on system
Ø D-com spring fitment

Parts Identification Parts Identification
Avenger 200 Avenger 220
Part Name : Oil Cooler Part Name : Oil Cooler
Identification : 3 Tubes Identification : 4 Tubes

Mark Mark
Part Name : Indicator Flasher Part Name : Indicator Flasher
Identification : Identification : Potting Material

Mark : Non potted Mark
Part Name : AC CDI Part Name : DC CDI
Identification : Grey Identification : Blue

Mark Mark
Part Name : Carburettor BS II Part Name : Carburettor BS III
Identification : JM 200 Identification : PD 220

Mark Mark

Parts Identification Parts Identification
Avenger 200 Avenger 220
Part Name : Control Housing Part Name : Control Housing

RHS RHS
Identification : Kill position up Identification : Kill position down

Mark : Mark :
Part Name : Fuel Meter Part Name : Fuel Meter (guage)
Identification : Identification : Battery Level

Mark Mark : Indicator on RHs
Part Name : Controller Head L Part Name : Controller Head L
Identification : N/A Identification : New Unit

Mark : Mark :

Important Assembly Points Important Assembly Points
Valve Timing : • When splitting crankcase always remove 1 long bolt fitted from clutch side
first.
T
• Ensure the sprocket marks (A) are aligned horizontally with cylinder head top
machined face and the piston is at TDC.
A A
• Remove long bolt immediately after removal of long bolt clutch side.
• Ensure proper fitment of bolt with copper washer to avoid oil leakage.
• Secure the ‘Cam Chain Sprocket’ in the Special tool firmly & then tighten the
sprocket allen bolt (A).
0
• Ensure that the ‘O’ mark on washer always faces outwards when tightening
the allen bolt.
A • Shifter fork is having a roller. These rollers are having one side tapered inner
dia.
• Rocker arm has 20 rollers inside the outer cage. • Taper portion of roller should face towards fork gear shift.
• NR bearing doesn’t have inner cage.
• Take utmost care while dismantling. Rollers should not fall inside engine.
• Apply grease to fix needle rollers inside rocker arm.
• Load the assly balancer idler gear with 2.5 teeth's from either side using the
special tool.
Ensure
Belleville
Washer • While assembling hub clutch place plain washer first & then place Belleville
Plain washer. Concave face should be upwards i.e. towards technician.
Washer
Clutch
Hub • Fit primary gear drive (A).
• The mark teeth of the primary gear should match with the line mark on the
crankcase. This indicated that the piston is at TDC position. This procedure
B A • After placing Belleville, fit clutch plate with 40 friction material cubs (A) with
should be carried before fitting the ‘Clutch Housing’ & this position should not
more I.D.
be disturbed while fitting the ‘Clutch Housing’.
• Place 4 Nos. for 180 cc & 3 Nos. for 150 cc of clutch plates with 48 fiction
material cubs (B) alternatively along with steel plates.
• Fit top clutch plate with 40 friction material cubs (C). • Take ‘Assembly Balancer Idler Gear’ along with Thrust Washer which is pre-
C loaded and is held in special tool, Slide down the special tool with ‘Gear’ to
engage the bottom half of the ‘Assembly Balancer Idler Gear’ with the ‘Body
• Input shaft has special nut. Balancer Gear Assembly’
• Thick spacer tapered I.D. should be placed on tapered portion of Input Shaft. • Fit ‘Thrust washer’ on the other side.
• Input Shaft has left hand threads. • On assembly of ‘Assembly Balancer Idler Gear’ the itched / Dot mark of Body
Balancer Gear Assembly’ should match with the line mark on the ‘Crankcase’.

Important Assembly Points Important Assembly Points
• Holding the ‘Assembly Balancer Gear’ in special tool now slide inside the Check crankcase breather tube condition.
‘Clutch Housing’ so that the‘Clutch Housing’ smoothly engages with the top
half of ‘Assembly Balancer Idler Gear’.
• Remove Spl. tool gently.
• Fit 2 dowels and Assly Balancer Idler GearCover
• Ensure perfect marking of gear marks with respect to crankcase mark.
Even tightening of clutch holder bolts (Diagonally)

Do not dismantle the cam chain tensioner assembly.
Always ensure piston ring position.
• Top Ring : Open end facing towards exhaust.
• Second Ring : Open end facing towards inlet.
• Upper Rail : Open end 300 facing towards exhaust.
• Bottom Rail : Open end 300 facing towards inlet. Correct use of tool while removing centrifugal oil filter nut.
• Expander : Open ends at center and joints butting together facing up.
• When tightening the special nut for centrifugal filter the Primary gear holder
should hold between the ‘Primary Gear’ and ‘Clutch Housing’ from bottom
side. (Note that oil pump assly is removed).
Confirmation of rubber at breather passage in RH Cover.
• When loosening the special nut for ‘Centrifugal Filter’ the Primary gear holder
should be hold between the ‘Primary Gear’ and Clutch Housing’ from upper
side.
Confirmation of No leakage from oi pipe lines (Visual Inspection)
• Never rest the Rotor holder against Gear change pedal lever
Drain plug tightening torque control During opening/closing.
• The existing special nut puller for Pulsar can be use for Pulsar UG-4 by
reducing its diameter to 25.9 + 0.1 mm.

Important Assembly Points Assembly of Sub Assemblies
Check the condition of Chain guide (wear) at tensioner side

Assembly of Sub Assemblies
Using Special Tool T1011168

Align the Clutch Assembly into Clutch Housing
Fit :
• Spacer
Clean the burr from magnetic drain plug.
• Clutch Assly
Note :
• Ensure concentricity of Thrust Plate w.r.t Clutch Wheel, Clutch Center, Clutch
Housing. Using Special Tool.
Removal of Centrifugal oil filter screw using Impact Spanner • The Special Tool helps in preventing the cracking / Bending of Thrust Plate
while removing and refitting the thrust plate.
Oil Pump
Fit :
A • 'O' ring (A) on the Oil Strainer (B)
Cleaning of centrifugal oil filter at the time of engine overhaul B • Clip (C)
C
Assembly Balancer Idler Gear Bearing
Using Bearing Driver set (P. No.: 37 1030 61)

Starter Motor alignment while mounting Fit :
• Needle roller bearings in crankcase RH and Cover
Note :
Apply oil on bearing OD before pressing bearings for smooth bearing
Check drain oil quality whether it is lean or thick. Also check the drain quantity. Fit :
A C D • Springs (D)
• Scissor Gears (C)
• Circlip (B)
• Thrust washer
Similarly carry out the same procedure on other side of the
gear to assemble the Balancer Idler Gear completely.
B D E CB A Note :
Ensure that one spring end butts against spring dowel in
Balancer Idler Gear and the other end of spring should but
against the lug on Scissor Gear.

Assembly of Sub Assemblies Assembly of Sub Assemblies
Loading the assembly Balancer Idler Gear Clutch Cover

Using Special Tool - Balancer Gear Holder 37 10DJ 63 Fit :
• Slide the Assembly Balancer Idler Gear in special A • Valve assly & Circlip (H)
G
tool. B • Oil inspection window
• Wire clip
• Rotate the Scissor Gear anticlockwise till the lug
• Set dampers (K)
contacts the torsion spring.
• Set of plates (L)
• Using a marker, mark the Balancer Idler Gear and • Bolts (J)
Scissor Gear Tooth H
• Rack (C)
Using Special Tool • Shaft Clutch Release (B) in Clutch Cover by rotating it
• Turn the Scissor Gear anticlockwise such that 2 teeth pre-load is achieved. slightly to match the teeth.
This can be confirmed by the markings done previously. C • Parallel Pin (A) to lock the Shaft Clutch Release
• Holding the Scissor Gear pre-loaded in the above position slide the Scissor • Washer
Gear into the special tool completely. • Spring torsion clutch lever
• External lever
Repeat the same procedure for loading the other Scissor Gear. K • Bolt
Note : F • Spring joint ‘A’ (F)
J E
D • Plunger Plate (E)
Keep this Assembly balancer idler gear in loaded condition with special tool. L
Note :
Gear Complete Starter Counter Assembly
Ensure fitment of set of dampers and plate before fitting the
Using Arbour Press
above.
Fit :
• Needle Roller Bearing L M H FE CB A Output Shaft Assembly
Fit : from LH side of shaft
• Gear 5th driven (M)
• Bush (N) with shoulder ring
Crankcase LH (Magneto Side)
• Gear 2nd driven (L)
Fit : • Washer (K)
• Guide Starter Assembly • Circlip (J)
A
• 3 Screws (A) (Use loctite 243) Fit : from RH side of shaft
• Thrust washer (H) behind the 3rd gear on output shaft
• Gear 3rd driven (G)
JK N I G D • Spline washer (F).
Input Shaft Assembly
• Circlip (E)
B C EF I K Fit : From LH side of shaft (A)
• Gear 4th driven (D)
• Thrust washer (K)
• Steel bush (C) with shoulder ring
• Gear 4th (J) • Gear1st driven (B)
• Splined washer (I) • Thrust washer (A)
• Circlip (H)
• Gear 3rd drive (G)
• Circlip (F)
D G H J A • Splined washer (E)
• Gear 5th drive (D)
• Gear 2nd drive (C)
• Thrust washer (B)

Fit :
Assembling of Engine
• Parallel Pin.
• Sprocket Cam Drive
Fit : (In Magneto side Crankcase)
• Cam Chain
• Input and Output Shaft Assembly simultaneously.
• Fork shifts along with rollers on Input and Output Shaft Assembly (2 bigger Note :
fork shifts on output shaft and 1 smaller on input shaft). Hold the cam chain upright using a soft copper wire or a thread.
Note :
Fit :
For ease of assembly of gears, remove gear 1st driven and insert both the input
•‘Square Key
and output shaft assemblies with gears in mesh into their respective bearings. The
•‘Primary Gear’.
gear box should be in neutral gear before ‘RH Crankcase’ is assembled on to
‘LH Crankcase’.
Note :
Fit :
Ensure fitment of 2 ‘Plain Washers’ on either side of ‘Kick Shaft Assembly’.
• Drum Change
• Shaft Gear Shift Fit :
• 2 Dowels • Body Balancer Gear

• Lock
• Gasket A
• Bolt (A) (Use Loctite 243)
CAUTION
Fit :
Use a sharp blade or knife to cut off any protruding ‘Gasket’. This is very important
for preventing any oil leakage from ‘Crankcase’ and ‘Cylinder Block Joint’. Don't • Parallel Pin
apply grease / any adhesive to Gaskets as it can damage the gasket properties. A • Spacer
• Guide gear shifter
Fit : • Allen Bolt (A)
• Crankshaft
CAUTION Fit :
• Spring
Check oil supply to big end bearing by pumping oil in the clutch side end of
crankshaft and let oil dribble / ooze out of con-rod big end sides. Note :
a. Apply Loctite 638 at ‘Bolt Shift Change’ (B) if removed.
b. Ensure free movement on ‘Stopper Gear Shift’ in ‘Bolt Shift Change’.
Clutch Side :
Fit :
Fit :
• Crankcase RH
• Gear change lever assembly
• Bolts (LH & RH Side)

Fit : Fit :
• Thrust Washer • Bearing with plunger
• Assly Balancer Idler Gear with Special Tool
• Thrust washer
Fit : Using Special Tool : Primary Gear Holder - 37 10DJ 28

Align gear timing marks of .. Using Sp. Tool : Centrifugal Oil Filter Nut - 37 10DJ 43
• Primary gear mark w.r.t crankcase mark Fit :
• Body balancer assly mark w.r.t crankcase mark • Centrifugal Oil Filter
• Washer
• Special Nut
Fit :
• Clutch housing Using Special tool : Primary gear holder 37 10DJ 28
Fit :
Note : • Gasket
• Ensure perfect matching of gear alignment marks w.r.to crankcase marks. • 3 screws
• Refer the skill tips section for understanding procedure for gear alignment • Cover
marks given on "Know on Your finger tips"
Fit : Fit :
• 2 Dowels • 2 Dowels
• Assly Balancer Idler Gear Cover • Oil Pump Assembly
• 3 Bolt • 3 Bolts
Using Special Tool - Primary gear holder : 37 10DJ 28 Fit :

& Using Special Tool - Special Nut : 37 10DJ 43 • Starter Motor
Fit : • Clutch cover gasket
• Spacer • 2 Dowels
• Clutch Assembly Complete
Note :
• Washer
Do not apply any grease to stick ‘Gaskets’ to the ‘Clutch Cover / Magneto Cover’
• Special Nut
or ‘Crankcase’. As grease can damage the gasket properties..
Note :
Special nut for input shaft has LH threads. Fit :
• Clutch Cover
• 10 bolts
• Bracket Clutch Cable
• Starter Motor Cap
• Screw’

Magneto Side Using Special Tool : Drift 74 9309 89

Fit : Fit :
• Shaft Starter Counter • Piston
• Gear complete starter counter assly • Piston Pin
• Collar • Circlip
Note :
Always apply a thin layer of MOS2 grease on to the roller bearing of starter
Note :
counter gear.
Place clean piece of lint free cloth on the ‘Crankcase’ bottom end because there
Fit : is a chance of ring snap falling into crankcase while fitment.
• Woodruff key
• Magnet along with gear starter clutch
Note :
• Always apply a thin layer of engine oil to the roller bearing of gear starter Using Special Tool : Piston Ring Holder 37 10DJ 30
clutch. Fit :
• Add few drops of engine oil on OD of gear starter clutch for lubrication. • Slide the Cam Chain upright with soft copper wire
/ Thread into cylinder
Fit : • Slide the piston assembly into cylinder
• Plate starter clutch return (A)
A • Bolt (B). Use loctite 243
Note :
Apply thin layer of oil in cylinder bore and piston assly before sliding inside for
B
ease in fitment and to prevent dry running.
Using Special Tool : Rotor Holder H6 0721 00 Fit :

Fit : • Head gasket
• Washer • 2 Dowels (A)
A
• Bolt • Chain Guide (Non tensioner side)
Note :
Holding the chain firmly bring the piston assly to TDC position and Ensure ‘T’
Top End mark on the rotor is matching with generator cover mark.
Fit :
Fit :
• 2 Dowels
• Cylinder Head Assly
• Block Base Gasket
• 2 Dowels

Fit : Fit :
• Spark Plug Sleeve • Cam Shaft Cap
• Grub Screw • Apply thin layer of liquid gasket to head cover
• Spark Plug • Head Cover
Note : Note :
Before fitting the sleeve spark plug apply thin layer of molybdenum di-sulphide • Do not apply liquid gasket on to the cam shaft cap and other inside
grease on the entry chamfers for the ‘O’ rings. mounting areas.
Fit :
• Cam Shaft Fit :
• Collar • Copper Plated Washer
III II I II • Tighten bolts as per sequence
Ist : 4 Domed cap nut
IInd : 4 Long bolts of Head Cover
IIIrd : 2 Longest bolts of Head cover
Using Sp. Tool - 37 10DH 36
Fit : Note :
• Cam Sprocket Improper tightening sequence of bolts may cause permanent warpage in cylinder
• Special Washer head cover and it can get damaged.
• Allen Bolt
Fit :
• Cam Chain Tensioner
Note :
• 2 bolt
• Ensure the sprocket marks are aligned horizontally with cylinder head top
• Release the tensioner plunger bolt
machined face and the piston is at TDC.
• Dust cap and ‘O’ ring’
• Secure the ‘Cam Chain Sprocket’ in the special tool firmly and then tighten
the sprocket allen bolt.
• Ensure that the ‘O’ mark on washer always faces outwards when tightening Adjust :
the allen bolt. • Check and adjust the tappet clearance
Inlet Valve Exhaust Valve

0.05 mm 0.1 mm
Note :
Always ensure that the piston is at the end of compression stroke and ‘T’ mark on
rotor is in line with the crankcase mark. When adjusting tappet clearance.

Assembly of Sub Assemblies Tightening Torque - Engine
Fit : Cylinder Head Bkt.Mtg.Bolts Engine Mounting Bolts Engine Mounting Nuts Chain Tensioner Mtg.Bolts
• Tappet cap with ‘O’ ring
Fit : M8 - 2.2Kgm. M8 - 2.2 kgm. M10 - 2.4 kgm. M8 - 2.2 kgm. M10 - 2.4 kgm. 1.1 Kgm
• 2 Dowel
• Gasket Output Sprocket Bolts Silencer Mtg. Bolt Silencer Mtg.Nuts Gear Cover Bolts
Fit :
• Magneto cover
• 5 Bolts 1.1 Kgm 3.5 to 4.0 Kgm 1.4 to 1.9 Kgm 1.0 to 1.1 Kgm (Loctite- 243)
• Neutral switch coupler
Crankcase Joining Bolt Crankcase Joining Bolts Crankcase Joining Bolt Clutch Cover Bolts
Using Special Tool- Output Sprocket holder- 37 1030 53

Fit :
• Bush (Apply MOS2 grease at entry area)
• Sprocket
• Plate drive sprocket 1.2 Kgm 1.1 Kgm 1.1 kgm (Loctite- 243) 1.1 Kgm
• 2 bolts (Use loctite 243)
Oil Pump Mounting Bolts Centrifugal oil Filter Nut Rotor Cover Bolts Clutch Nut (L.H. Threads)
Fit :
A • Oil pipe
• Copper gasket - New
• Banjo bolt (A)
B
• Bolt (B)
1.1 kgm 5.5 Kgm 1.1 kgm 7.0 Kgm
Cylinder Head cover Nuts Cylinder Head Cover Bolts Camshaft Sprocket bolt Starter Motor bolts
3.5 Kgm 1.0 Kgm 1.4 Kgm (Loctite- 243) 1.1 Kgm

Tightening Torque - Engine Service Data - Engine
Rotor Mounting Bolt Idler gear Bkt.Holder Bolts Spark plug Drain Bolt Compression Pressure Valve Clearance Rocker Arm Shaft Dia.
4.5 Kgm 1.0 to 1.1 Kgm 1.4 Kgm 2.5 Kgm

Std. Limit 11.0 ~ 13.0 Kg/cm
2 Inlet Exhaust Std. Limit 7.994 ~ 8.0
Std. Limit 0.05 0.10
2
Serv. Limit 9.0 ~ 10.0 Kg/cm Serv. Limit 0.03 0.08 Serv. Limit 7.98
Cam Sprocket Diameter Cam Height

Notes Valve Spring Free Length
Std. Limit 61.165 ~ 61.285 Inlet Exhaust Inner Outer

Std. Limit 31.1 30.5 Std. Limit 38.6 41.4
Serv. Limit 61.1 Serv. Limit 30.9 30.3 Serv. Limit 37.6 40.4
Valve Stem Diameter Valve Stem Bend Valve Head Thickness
Inlet Exhaust Inlet Exhaust

Std. Limit TIR 0.01
Std. Limit 4.483 4.464 Std. Limit 0.5 0.8
Serv. Limit 4.463 4.444 Serv. Limit TIR 0.03 Serv. Limit 0.3 0.6
Cylinder Head Warp Camshaft Chain Lth. 20 Links Cylinder Inside Diameter
20-link length
10mm
20mm
40mm
1st 2nd 21st

MEASURE THIS LENGTH
Std. Limit 127.00 ~ 127.20 Std. Group A Group B

Limit 67.020~67.028 67.028~67.035
Serv. Limit 0.05
Serv. Limit 128.0 Serv. Group A Group B
Limit 67.028~67.038 67.038~67.045

Service Data - Engine Carburettor
Piston Diameter Piston / Cylinder Clearance Piston Ring / Groove Clearn.
Top Cap
7mm
Std. Group A Group B TOP SECOND Choke

Std. Limit 0.030 ~ 0.050
Limit 66.978~66.988 66.988~66.998
Std. Limit 0.03~0.07 0.02~0.06
Serv. Group A Group B
Serv. Limit —
Limit 66.988~66.998 66.998~67.008 Serv. Limit 0.17 0.16
Engine Air Filter Side

Piston Ring End Gap Clutch Spring Free Length Friction Plate Thickness
Side
VC Screw
Fuel Inlet
TOP SECOND Std. Limit 37.0 Std. Limit 2.9 ~ 3.1
Std. Limit 0.2~0.35 0.5~0.65
Serv. Limit 35.0 Serv. Limit 2.75
Serv. Limit 0.60 0.90
Pressure Plate Warp Shift Fork Guide Pin Dia. Shift Drum Groove Width Drain Screw
Float chember bowl
CARBURETTOR :
Item Specification
Std. Limit 0.2 Std. Limit 4.5 Std. Limit 7.50

Make and Ucal - Mikuni UCD29
Type CV Type
Serv. Limit 0.3 Serv. Limit 4.3 Serv. Limit 7.35 Idling Speed 1400 + 100 rpm
VC Screw setting 2.5 + 2 turns out
Crankshaft Run Out Main Jet 112.5
Air Jet 135
Jet needle mark 4DIN8
Jet needle clip position 2nd from top
Pilot Jet 15
Starter jet Fixed Type
Throttle valve Fixed Type
Choke lever 2 stage with push
Std. Limit 0.02 Max.
& pull type
Serv. Limit 0.05 mechanism
ALL DIMENSIONS ARE IN MM

Engine Mounting on Chassis Engine Mounting on Chassis
Fit D Fit
B Ø Engine on Chassis Ø Sprocket cover [A]
B A
Ø 2 Bolts [A] & [B] holding Engine to rear side Ø 2 bolts [E]
E
A with earthing lead. Ø Gear lever holder assembly along with Gear change mechanism and gaurd
Ø Engine mounting Bkt front side D step [C].
Ø Engine mounting Bkt Top C
Ø One bolt at gear change lever [D]
C B
Ø 2 bolts [B]
E
Fit Fit
Ø Silencer assly. Ø Petrol tank assly
Ø 1 Bolt [A] Ø 2 Bolts [A]
A
Connect
Ø Coupler harness [C[ for Petrol tank
Ø Magneto wiring coupler
C Ø Side cover assly RH [A] by unlocking it with the help of key
Fit Fit
C
Ø 2 nut [A] for Silencer Ø Side cover LH
Ø Both spark plug cap Ø 2 philip head screw [B] of side cover LH
B A Ø 2 bolts [C] for bracket clutch cable. Ø Seat assly
C
Ø Clutch cable [B] connection Ø Bolt flanged [C] for both sides of seat
B
Fit Fit
Ø Carburettor assly C Ø Grip frame cover LH & Cover LH
Ø Tighten carburettor clamps [A] A B Ø 2 Bolts [A ]
A Ø Carburettors cables D Ø Carry out same procedure on RH side
Ø Screw [C] at rear end of seat assly.
Ø PCV pipe to Crankcase [B] E
B Ø Back rest assly
Ø Fuel pipe from Carburettor Ø 2 bolts [A] & [B] on both sides
Fit Remove :
Ø Sprocket on out put shaft B Ø Speedometer cable from speedometer assembly
Ø Plate Sprocket [A]
Ø 2 Bolt [A] and remove speedometer assembly [B]
A Ø 2 Bolts [B]
Ø Speedometer light coupling
B A
Fit
Ø Drain bolt [A] Recommended oil grade
Ø Fill engine Oil
SAE 20W50 OF API ‘SG’ + JASO MA
A
Drain & Refill = 1100 ml
Oil Qty
Engine O/H = 1200 ml

Front Fork Dismantling Front Fork Dismantling
Remove Using Special Tool Front Fork Tube Extractor : 74 9310 15

Ø Cotter pin
A Remove
Ø Castle nut [A]
Ø Front axle Ø The inner tube assembly will not come out itself because of two DU bushes
Ø Speedometer Gear Case assly [B] fitted. one bush is fitted on inner tube and other bush is fitted in outer tube.
A
Ø Fit the front fork tube on the vehicle by assembling the special tool [A] & lock it at
Ø Pull out front wheel assly .
number plate mounting screw
B Ø Rotate the special tool handle to separate the inner tube from outer tube as shown in
the fig.
Remove D Remove
A Ø 2 Bolts [A] (2 on either side) E C Ø Piston assembly [B]
Ø Front mudguard assembly. F Ø Inner Tube [C] of shock absorber with bush.
Ø Oil seal [D] for outer tube.
G Ø Oil seal stopper ring [E]
B
Ø Oil seal [F] and spacer.
Ø Bushing [G]
A
Remove
A Ø Bolt fork top
Ø 2 allen bolts [A]
Ø Pull down fork leg assly slowly rotating it;
Front Fork Assembling
Ø Similarly carry out the same procedure to take out other side fork leg
Special Tool: Fork for cylinder holder adapter: 37 1830 08/11
A Fit
Ø Place Fork cylinder set in the inner tube, cylinder base and place it in outer
Remove tube. Hold the piston with the help of special tool.
A
B Ø Bolt [A] from the top of front fork assembly along with the ‘O’ ring [B] B C Ø Bolt it from lower side of outer tube with Allen key.
A
C Ø Collar fork [C]
D Ø Seat fork spring [D] Ø Guide bush , washer
Ø Spring [E]
E
Ø Fork oil in a container. Ø Oil seal using special tool [A].
Recommended oil capacity Ø Snap Ring
Approx 191 + 2.5 ml. (Newly assembled)
Approx. 165ml.(Drain and refill) Ø Dust seal
A
Ø Spring and fill oil.
Remove Ø Seat fork spring and Collar fork.
Ø The dust seal & the snap ring over the oil seal.
Ø Allen screw that is located at bottom with the help of allen key [A]. by holding Ø Bolt
the fork piston with the help of a adapter [B] and holder [C]. Similarly carry out the same procedure to assemble the other fork.
Special tool :
C Front fork Cylinder Holder Handle : 37 1830 06.
A B B Fit
Adapter For Fork : 37 1830 11 C Ø Slide in front shock absorber assembly from bottom by removing nut.
Ø Front indicator assembly[A].
Ø 2 Allen bolts [B].
B Ø 1 Special bolt [C] at the top of the front shock absorber.
Similarly carry out the same procedure for fitting of the other shock absorber.
A Connect the coupler connections for front indicator assembly to wiring
harness.

Front Fork Dismantling Swing Arm Dismantling
Fit Remove
A
Ø Front mudguard assembly. Ø The gear linkage bolt[A]
Ø 2 Bolts [A] (2 on either side) Ø Disconnect linkage from gear chain lever
Fit
Remove
Ø Front wheel assembly. Ø Bolts[A]
C
Ø Front axle [A]. Ø Engine sprocket cover (small chain cover)
B A
Ø Tighten castle nut & fit split pin.
A Ø Calliper assembly [B] and tighten 2 bolts [C].
Ø Speedometer cable connection.
Fit C Remove
Ø Loosen chain adjuster nuts on both the sides [A]
Ø Speedometer light coupling Ø Rear brake adjuster nut[B]
Ø 2 Bolt [A] for speedometer assembly A
Ø Disconnect the brake cable
Ø Split pin for rear axle nut
Ø Rear axle nut & washer [C]
B
A
Remove
Ø Locking circlip
Ø Nut [A] to disconnect the tie rod from the brake pedal
Ø Chain lock & take out the drive chain
Ø Rear axle nut & rear wheel
A
Remove
Ø Rear shock absorber lower bolt from both the sides

Swing Arm Dismantling Service Data - Chassis
Remove Br. Panel Cam Hole Dia. Brake Cam Diameter Fr. Brake Pad Thickness Br. Shoe Lining Thickness
Ø Rubber gaurd
Ø Chain adjuster from both the ends
Ø Chain gaurd by removing 3 screws
Ø The nut / bolt & take out the tie rod
Ø Sleeves from the needle bearings from both front ends of swing arm
Ø Bracket at both ends
Fit
Ø For fitting the neddle bearing, place the sleeve by special tool (Tool No. 74 Standard 12.0-12.03 Standard 11.95-11.98 Standard 7.4 Standard 3.85 - 4.15
9309 93) Service Limit 12.15 Service Limit 11.88 Service Limit 3.8 Service Limit 2.0
with collorside outward
Ø Place needle bearing on special tool Brake Drum Indise Dia. Axle Run Out Axial Wheel Run Out with tyre Radial Wheel Run Out with tyre
Ø Insert the tool along the bearing on the swing arm
Ø The adopter on the other end of the tool
Ø Tighten the nut till the needle bearing fits completely
Ø The second bearing similarly.
Ø The oil seats on both the side of the needle bearing for both the bearings
Ø Bracket between the front and the Swing arm.
Ø Insert sleeves for needle bearing on both the ends. 100 mm
Ø Oil seals from both sides
Ø Needle roller bearing from both sides
Ø For removing needle roller beatings use special tool 74 - 9309 - 93 Standard 130.00 - 130.16 Standard TIR 0.1 or Less Standard TIR 0.1 or Less Standard TIR 0.8 or Less
Service Limit 130.75 Service Limit TIR 0.2 Service Limit TIR 2.0 Service Limit TIR 2.0
Fit
Ø The tie rod on the Swing arm. Drive Chain Slack Drive Chain Length(20 Link) Rear Sprocket Warp Tyre Tread Depth
Ø Insert the bolt and tighten the nut
Ø Mount the chain gaurd and tighten all the three bolts
Ø Rubber Gaurd 20-link length
Ø Swing arm shaft and fit the cover

Ø Tighten the nut for bracket bolt
1st 2nd 21st

MEASURE THIS LENGTH
Fit
Ø Rear shock absorber and tighten the upper nut and lower bolt
Ø Now place the rear wheel properly Rear Front
Ø axle along with the washer
Ø install the drive chain properly Standard 25-35 Standard 254 - 254.6 Standard TIR 0.4 or less Standard 7.3 4.5
Ø Chain link Service Limit 25-40 Service Limit 259 Service Limit TIR 0.5 Service Limit 2.0 1.0
Ø Chain lock
Ø Adjust the chain slackness
Ø Remember, the mark on the chain adjuster must be equal on both the sides Fr. Fork Spring Free Lth. Front Fork Oil
Note : All dimensions are in mm
Fork Oil Level

218 + 2.0 mm.
Fit
Ø Tie rod on rear brake panel
Ø Tie rod on rear brake panel Free Length
Ø Insert the bolt & tighten the nut
Ø Split pin Oil grade= SAE10 W 20
Ø Brake inner cable & tighten the adjuster Drain & Refill = 165 ml
Standard 398.5 Oil Qty
Complete Overhaul =191+2.5 ml
Service Limit 391.00

Tightening Torque - Frame Maintenance - Electricals
Front Axle Nut Rear Axle Nut Torque Rod Nut Sleeve Nut
Battery
Technical Specification :
• Type & Capacity 12V - 9 AH
• Specific gravity of electrolyte 1.24 for use above 100C
for initial filling of new battery
• Specific gravity of electrolyte 1.28 for use below 100C
for initial filling of new battery
7.0 to 9.0Kgm. 9.0 to 11.0 Kgm. 3.2 to 3.8Kgm. 8.0 Kgm.
• Initial charging duration 10 ~ 15 hrs
Rear Sprocket Mtg. Nut Handlebar Holder Bolts Steering Top Bolt Steering Stem Nut (Slotted) • Initial charging current 0.9 to 1 Amp
Initial Charging Procedure Battery Installation:

1. Fill each cell with battery grade sulfuric acid Install the battery on vehicle as described below
of the correct Sp. gravity (1.24 at room temp.
for use above 100C and 1.28 at room temp. a. Ensure that in all six cells the level of
for use below100C). electrolyte is near the maximum level mark.
2.4 to 3.0 Kgm. 4.0 to 5.0 Kgm. 4.5 Kgm. 3.0 to 4.0 Kgm 2. Allow the battery to stand for 30 min. after b. To clean and dry the surface wipe the top of
filling. the battery with a clean cloth. Install the
Upper Clamp Bolt Lower Clamp Bolt R.S.A Mtg. Nuts Swing Arm Pivot Nut 3. Keep vent plugs open. Connect battery to
charger and charge at 0.9 Amp.
4. Charge continuously for 10~15 hours taking Hydrometer
Sp. gravity readings every hour. Fully charged
condition is indicated when all cells are
gassing freely and evenly and show no rise in Read
specific gravity over 3 successive readings. Here
5. After charging push vent plugs strip firmly into
2.0 Kgm 3.0 to 4.0 Kgm 3.2 to 3.8 kgm 9.0 to 11.0 Kgm place and wash off acid spillage with water
and dry the battery.
Caliper Mounting Bolts Brake Disc Allen Bolts Banjo Bolt Caliper 6. Using the battery load tester confirm for good
indication of state of charge of battery.
Checking the Specific Gravity

The charge condition of the individual cell can be battery inside the box provided on floor board.
checked by measuring Sp. gravity of electrolyte in Fasten the battery firmly with bracket & allied
that cell. The specific gravity of electrolyte can be fasteners.
checked by using Hydrometer having small c. Connect cables to the positive and negative
2.2 to 2.8 Kgm 2.5 to 3.1 Kgm 2.2 to 2.8 Kgm diameter spout. terminals properly. Reverse connections will
For measuring the Sp. gravity bring the electrolyte damage the charging system permanently.
in the Hydrometer to eye level, and read the d. Always connect “negative (earthling) terminal”
graduations on the float scale bordering on the at Iast.
lower meniscus (i.e. curved down portion of e. Clean battery terminals and cable connections.
electrolyte surface) as shown in the figure. After Smear them with petroleum jelly to avoid
charging is over, fit the filling caps strip, wash corrosion.
acid spillage with water. Dry the battery. Ensure
terminals are clean. g. Check that the battery cable connections are
firm and cables do not rub against any metal
components.

Maintenance - Electricals Maintenance - Electricals
Battery Charging Procedure : Non Use Maintenance Voltage of the sulphated battery : -
This is a M.F (Maintenance Free) battery. This When the vehicle is likely to remain off-road for Cells of the sulphated battery will show low
battery is not having any exhaust tube instead it longer, time (say more than a month) then Non specific gravity. Follow the procedure given below.
has a unique vent mechanism. Use Maintenance should be carried out as
• Check voltage before charging.
follows otherwise the battery may get sulphated
The electrolyte level in this M.F. battery needs to • Charge for 2 hours
and permanently damaged.
be topped up with distilled water not exceeding
the max level if found that the electrolyte level is a. Remove the battery from vehicle. • Check voltage every 1 hour. If voltage increases
below min level / dropped down. In case battery b. Maintain electrolyte at ‘Upper Level’. then continue charging. But if voltage does not
in discharged and needs to be charged using c. During off service period, battery should be increase, discontinue charging. Otherwise
battery changed procedure is as follows : charged once a month or if the battery DC battery charger will get permanently damaged. If
• Remove battery from vehicle voltage drops below 12.3 V. battery is not badly sulphated (i.e. voltage more
than 9 volts), then battery can be revived by
• Clean battery throughly d. Keep the battery fully charged. special treatment. In such case it is advisable to
• Remove gang bar strip. e. Store the battery in cool, dry place. give sulphated battery to authorised dealer of
f. Keep the battery away from rain, dew, battery manufacturer for necessary special
• Top up level with distilled water to max level moisture and direct sunlight. treatment.
when the electrolyte level is less than half of
min & max level. How to Determine Condition of Battery
Battery Sulphation
• Connect battery to charge & ensure respective Specific gravity check: - Whether battery is fully
terminal are connected properly. A sulphated battery is one which has been left charged or partially charged, it will always show
• Set charging current at 0.9 A DC. standing in a discharged condition or same “no load voltage” of 12 volts or more
• Charge battery for 3/4 hrs., then check voltage undercharged to the point where abnormal lead (unless battery cells are damaged due to
and special gravity. sulphate has formed on the plates (Sulphate cells sulphation etc). But specific gravity of the fully
looks like white crystal like sugar). Where this charged battery and partially charged battery will
• Battery open circuit voltage should be > 12.5
happens, the chemical reactions within the battery be different. Fully charged battery will show Sp.
volts (when disconnected from charger) &
are affected and results in loss of capacity. Mostly gravity of 1.240 while partially charged battery
special gravity in all 6 cells should be 1.240.
the causes of sulphation are as under : will show less specific gravity. Therefore, specific
This is a confirmation check for a fully
charged battery. gravity check is very important to know condition
a. Undercharging.
of the battery.
• Disconnect the battery from the charger.
b. Standing in a partially or completely discharge
• Fit gang bar plug firmly.
condition for long time.
• Using the battery load tester confirm for good
indication of state of charge of battery. c. Low electrolyte level : If electrolyte level is Note :
• Connect battery on to vehicle. permitted to fall below the top of the battery Use of battery load tester will give the correct
• Apply petroleum jelly on battery terminal. plates, then the exposed surfaces will harden indication of state of charge of battery on load
and will become sulphated. conditions.
d. Adding acid : If acid is added to a cell in which
Battery Maintenance
sulphation exists the condition will be
For the optimum performance and longer battery aggravated.
life the maintenance of battery is important.
e. High specific gravity : If specific gravity is higher
a. Always keep the battery clean and dry. than the recommended value, then sulphation
b. Visually inspect the surface of the battery may occur.
container. If there are any signs of cracking or
f. High temp.: High temperature accelerates
electrolyte leakage from battery, replace the
sulphation, particularly of an idle, partially
battery.
discharged battery.
Never add acid or ordinary tap water for
topping up since this will shorten Battery life.

SWITCHES : 5) Left Hand Switch 8) Stator coil inspection :

a) Pass Switch:
1) Front Brake Light Switch Inspection :
l Turn on the ignition switch. a) Battery charging coil:
Black Red/Yellow Red/Black Yellow
l The brake light should glow on when the front
brake (Lever is pressed) is applied. Push l l l l
Range Meter +ve Meter -ve Reading
l If it does not, replace the switch. OFF l l l l
X1W Blue/White Blue/White 1.3 ± 0.13W
Brown Blue
b) Dipper Switch
Lever Pressed l l b) Lighting coil
Blue Yellow/Blue Red/Black
Lever Released l l Hi l l l Range Meter +ve Meter -ve Reading
2) Rear Brake Light Inspection Low l l l 200W Yellow/Red Black/Yellow 0.7 ± 0.2W
l Turn on the ignition switch.
l Check the operation of the rear brake light switch c) Turn Signal:
by depressing the brake pedal.
l If it does not adjust the brake light Grey Orange Green
Brown Blue LH l l l
OFF l l l
Pedal Pressed l l
RH l l l
Pedal Released l l
A 9) Starter Relay Inspection:
d) Horn Switch: l l
3) Neutral Switch: l Remove the right side cover and starter relay.
l The neutral switch will be in on position only Black Black / Yellow l Connect the hand tester [A] and 12 V battery [B] to
when the Engine is in neutral position. ‘OFF’ l l l l the starter relay [C] as shown.
l The neutral light will not glow when vehicle is in C
l
geared position. ‘ON’ (Pressed) l l
l l If the relay does not work as specified, the relay is
defective. Replace the relay.
Earthing Light Green
6) Clutch Switch
+ -
Testing Relay
‘ON’(Vehicle in Neutral ) l l Black/ Yellow/ Light
B
Tester Range: x 1 W range
‘OFF’(Vehicle in Gear) l l Yellow Green Green
Criteria : When battery is connected 0 W
‘OFF’
4) Right Hand Switch: l l When battery is disconnected ¥ W
Clutch lever related
a) Light Switch: Starter Circuit Relay Inspection
‘ON’
Yellow/Blue Yellow Red Clutch pressed l l l Remove the side cover and starter circuit
“OFF” l l l relay.
“PO” l l l 7)Ignition Switch l Connect the hand tester [A] and 12 V battery [B] as
Red/ shown.
“ON” l l l Red Brown White Black/White Black/Yellow
White
Relay Coil Terminal [1] and [2]
b) Starter Switch: ‘OFF’ l l l Relay Switch Terminal [3] and [4]
Brown /Black Red / Yellow
‘ON’ l l
Pressed l l
PE
Released l l Park l l

12) CDI Unit (Ignitor) inspection: 14) Fuse Inspection (Capacity = 10Amp) 10) a. Rectifier & Regulator Assembly :
1) Inspect the fuse element. C/1)AC Voltage Measurement:
l ‘CDI unit’ can be checked alongwith
OK H.T. coil on Electronic Test Jig” 2) If it is blown out, replace the fuse. To measure AC Voltage, open the headlight
3) If a fuse fails during operation, the electrical system housing. Start the engine and set it at 4000±25
to determine the cause, and then replace it with a
RPM. Ensure that the headlight, tail light,
new fuse of proper amperage.
speedometer light are 'ON' and the dipper
switch is at 'Hi beam' position.
CAUTION: When replacing a fuse,be sure the new
fuse matches the specified fuse rating for that Connect A.C. voltmeter in parallel across the
circuit. Installing of a fuse with a higher rating may AC circuit load by connecting the +ve meter
cause damage to wiring and electronic components.
lead to red / black lead from the dipper switch
and the -ve meter lead to ground.
Measure AC lighting voltage at 4000 ± 25
RPM. The voltage should be 13.5 ± 0.5 V.
Stop the engine. Disconnect the meter leads.
13) H. T. Coils: Reassemble the headlight housing.
l Measure the primary winding resistance as

follows. Meter Range Specification at 4000 ± 25 RPM
l Connect the hand tester between the coil
AC 25V 13.7 ± 0.3 V
terminals.
l Measure the secondary winding resistance as
follows.
l Remove the plug cap by turning it c o u n t e r
clockwise.
l Connect the tester between the spark plug leads.
l Measure primary winding resistance.
l Measure secondary winding resistance.
l If the valve does not match as per, replace the
H.T. coil can be checked along with OK
CDI Unit on electronic test jig. coil.
Ignition Coil Winding Resistance:
Primary Windings 0.40 to 0.49 W

Secondary windings 4.23 to 5.17 K W
l If the meter reads as specified, the ignition coil

windings are probably good. However, if the
ignition system still does not perform as it
should after all other components have been
checked test replace the coil with one known.
l Visually inspect the secondary winding lead.
l If it shows any damage, replace the coil.

C/3) Battery DC Charging current: (Use fully

ILLUMINATION
R/L R
charged battery while measuring
To measure DC charging current, set the meter at
CONTROL SWITCH RH
LAMP 12V, 1.7W B/Y B/Y LIGHT
SWITCH
R/B
ON
PO
OFF 20 A DC. Connect meter +ve lead to white / black
lead from RR Unit & meter -ve lead to Battery +ve
HIGH BEAM
INDICATOR
L/W
L/W
W
LAMP B/Y
Multimeter
Y/L
12V, 3.4W
R
lead.
Y
connected
in Parrallel with Multimeter connected
headlight for P
REGULATOR
in Series with Battery Start the Engine & set it at 3000 RPM. Measure the
Y/L
R
Y
A O
checking AC R O F
charging Voltage
K N F R R
for checking DC DC charging current .The DC charging current
charging Current should be 0.9A max Stop the Engine & .
Y/R
Y
13.5
Disconnect meter leads. Connect the RR Unit &
Y/R
Y
0.9
A.C.Lighting
B/Y B/Y B/Y B/Y
Battery
L/W
L/W
W
R/W R/W R/W R
+
- IGNITION
SWITCH
TAIL LAMP ASSY
P TAIL /
STOP LAMP
Circuit
Checking Range Connections Specification
12V, 5/21W
HEAD LAMP
ASSY/LAMP
12V-60/
55W H4 FUSE
Meter +ve Meter -ve 2 A max.at
R/B
(10 Amps.)
Y/R
B/Y
B/Y
R/Y White/Black Battery (+) lead 3000± 25RPM

DC10A terminal of
W/B
(White)
L/W
L/W
B
R/R
R/W
Y/R
B/Y
B/Y
POSITION R
R/B
R/B
R/Y
Y/L
Y
LAMP 12V-4W
R/W
LO HI R OL
BATTERY
12V-9Ah
PASS
SWITCH
DIMMER
SWITCH
CONTROL SWITCH LH
COIL PULSING
STARTER RELAY 11) Turn signal relay inspection:
l Remove the right cover.
MAGNETO WITH DAMPER
MAGNETO
l Check the condition of the relay for the following
troubles.
Battery Charging Circuit Checking (1) Neither right nor left turn signals come on at all:
REGULATOR
l Check that battery voltage is normal.

l Unplug the relay leads and use an ohmmeter to
C/2) DC Charging Voltage Measurement: (Use Ignition check that there is resistance.
Switch Brown l Turn the meter to the 25V range, connect the (+)
fully charged battery while measuring)To L Green meter lead to the brown lead that was disconnect
L/W
L/W
measure the DC Voltage; set the meter at 25V DC from the relay, and connect the (-) meter lead to
Orange the lead to the orange lead.
range Connect the meter +ve lead to white from R l With the ignition switch on, first switch the turn
RR Unit, and meter -ve lead to ground. Start the Grey signal switch to the R and then to the L position.
Multimeter connected in engine and set it at 4000± 25RPM . Measure the The meter should register battery voltage at either
Parrallel with Battery for Black/White position.
checking DC charging voltage with and without headlight switch to the l If it does not, the fuse, ignition switch or wiring is at
L/W
L/W
voltage ON position. Stop the engine Disconnect the meter fault.

14.2
leads. (2) Both right or both left turn signals come on and stay on or flash too slowly:
l Check that battery voltage is normal.
Meter Range Specification at 4000 ± 25RPM l Check that all wiring connections are good.
FUSE
(10 Amps.)
l Check that the turn signal bulbs and indicator bulbs are of the correct wattage.
DC 25V 14 ~ 15V l If all of the above check good, replace the relay.
W/B
(3) A single light on one side comes on and stays on:

L/W
L/W
R l Either the light that does not come one is burned out of the incorrect wattage, or the wiring is broken or improperly
connected.
BATTERY
(4) Neither light on one side comes:

12V-9Ah
STARTER RELAY
WITH DAMPER
l Unless both lights for that side are burned out, the trouble is with the turn signal switch.
MAGNETO
5) Flashing rate is too fast:
l If this occours on both the right and left sides, check that the battery is not being overcharged.
Battery Charged Circuit Checking l If the magneto and the battery voltage are normal replace the turn signal bulbs are of too high a
Wattage.

Head Light Adjustment Harness Routing
Headlight Beam Horizontal Adjustment

33 32 31
18 14
12
15
Ø Turn the horizontal adjuster [A] on the headlight with a screwdriver in or out
20
23
A 24
unit the beam points straight ahead. 16
Ø Turn the horizontal adjuster clockwise to face the headlight left 30
B Headlight Beam Vertical Adjustment 9
36 37
Ø Turn the Vertical adjuster [B] on the headlight in or out to adjust the headlight 10 28
COUPLERS INSIDE BELLOW
29
vertically. 22
Ø Turn the vertical adjuster clockwise to face the headlight up
Note : On high beam, the brightest points should be slightly below horizontal
with the motorcycle on its wheels and the rider seated. Adjust the headlight to 17
5 11
8 6 7
the proper angle according to local regulations.
27
34
Headlight Bulb Replacement

35 13
19
Ø Remove the headlight rim screw [A]

Ø Pull the headlight unit [B] and drop it out
3
A
26
2
25
B
1
Remove
21
A
Ø Bulb Socket [A]
Ø Dust Cover [B]
Remove
Ø The hook [A]

Electrical Circuit Diagrams Electrical Circuit Diagrams
BATTERY CHARGING CIRCUIT IGNITION CIRCUIT
CAPACITOR REGULATOR CAPACITOR REGULATOR B/R
TPS
C.D.I. ASSY.
Pi
H.T.COIL 2 SPARK PLUG
G/W
W
B /Y
W
B/Y
Y
Y
Y
G/W W
B/Y
W
R
Y
Y
Y
2P SEALED 4P SEALED
COUPLER COUPLER
W
Gr/R
W/R
B/R
B/Y
Pi
G/W
B/ Y
Gr/R
B
R
W
W
G/W
B/Y
W
R
W
W/R
CHARGE
INDICATOR LAMP
B
Gr/R
W
R
CHARGE O O
INDICATOR F
IGNITION SWITCH
N F
LAMP Br Br/L
Gr
W
W W
W/R
H.T.COIL 1 SPARK PLUG
B/Y
B/Y
Y
Y
Y
W
B/Y
EARTH-FRAME
Y
Y
Y
W
MAIN 4P SEALED
COUPLER FUSE(15A)
FUSE (15A)
4P SEALED
W/B
W/B
B/Y
COUPLER
W/R
Y
Y
Y
R
R
+ - BATTERY
B/Y
B/Y
BATTERY 12 V 9Ah
Y
Y
Y
G
SIN
UL
IL P
CO
MAGNETO
S ING
UL
IL P
CO
MAGNETO

Electrical Circuit Diagrams Electrical Circuit Diagrams
STARTER MOTOR CIRCUIT SIDE INDICATOR CIRCUIT
CONTROL SWITCH RH
KILL TURN SIGNAL

STARTER KILL RELAY
SWITCH SWITCH
RUN
SIGNAL Gr
LAMP Gr Gr
FRONT B/Y
SIGNAL
Gr/R
RH
Br/B
Br/L
LAMP
R/Y
REAR RH
B/Y B/Y
Br
O
B/Y
SECONDARY FUSE
BOX ASSEMBLY(10A)
Br/L Br
R/Y
O
O F
N F Gr Gr Gr
Br Br/L
O O
IGNITION SWITCH
N F G
G G
F
W W W Br Br/L
IGNITION SWITCH
W
W W W
STARTER B/Y
MOTOR
W
EARTH-FRAME
Gr
Lg
O
G
W
B /Y
MAIN
FUSE MAIN
(15A) FUSE
B
G G (15A)
SIGNAL
W/B
W/B
Y/G R/Y LAMP B /Y
B/Y FRONT B /Y
LH
R/Y
B/Y
R R
Gr
O
G
EARTH-FRAME + - +
NO B/Y B/Y
BATTERY BATTERY B /Y B /Y
B 12 V 9Ah SIGNAL
B Y/G 12 V 9Ah LAMP
CLUTCH G G
STARTER RELAY REAR LH
SWITCH R O L
EARTH-FRAME
Lg Lg NEUTRAL TURN SIGNAL
NC SWITCH
SWITCH

Electrical Circuit Diagrams Logical Approach to Top Issues
DC LIGHTING CIRCUIT Gear

Gear Shifting Hard
Shifting Hard
Clutch cable free play Sprocket cover Over run at extreme

LIGHT SWITCH 3~5 mm
3~5 mm exerting skew load on ends of Guide gear
HEAD LAMP
CONTROLLER FRONT BRAKE
SWITCH
gear shift shaft shift
PO
OFF ON REAR BRAKE
REGULATOR SWITCH
Clutch cable freeness Axial float in Clutch Drum stopper & roller
R/L R • Hard gear shifting is nothing but a hard Housing should have free
Position of Lever
L/W
B/Y
SPPEDO
Y\L
Br
R
movement
Y
movement or sticky movement of gear
Br
L
ILLUMINATION
Y
LAMP
Assy. - Clutch cable
B/Y B/Y
change lever while shifting the gears. Axial float in Input
Br
holder on Cover RH
L
• Apart from gear shift mechanism and shaft Tight movement of
B/Y
transmission assembly the hard respective shift fork

Clutch getting
V
Gear change lever
Y\L
shifting may be due partial guide pin in the shift
Y
Br
disengaged
L
sticky on crank case /
Br
disengagement of clutch as well
L
HIGH BEAM
R/B R/B drum groove
INDICATOR
LAMP B/Y B/Y • For gear shifting problems, careful completely (Clutch bent / excessive play
Br/L
Br
examination of all the relevant drag)
Freeness of forks in
SECONDARY FUSE
components Gear change lever
locating pins / guide
R
BOX ASSEMBLY(10A)
is very important. Gear change pedal not springs hard / broken

ways of drum / in
fouling with the rider
Br/L
P O Y
A O
R N
F
Gears
K F
Br
R footrest. Lever gear shift slider
W
IGNITION
mechanism freeness
SWITCH W W
B/Y
L L
TAIL
Shift fork / pin Bent or
B/Y
LAMP
R/W R/W R/W R ASSY seized
Welding of slider arm
reset should be
Shift fork / pin Bent or
B/Y symmetric.
seized
W
R/ B
FUSE Worn out jaws of Gear
HEAD LAMP
ASSY/LAMP
B/Y
W/B (15A)
change lever Free movement /
R/ Y sliding of gears on
Y
POSITION B/Y
B/Y Input shaft & Output
LAMP
R
+ Jammed or tight drum
R/W BATTERY shaft
12 V 9Ah EARTH-FRAME shifter
R/B
R/Y
Y/L
V
B/Y
EARTH-FRAME
R/Y
R/B
R/B
Y/L
Y
LO HI MAGNETO
PASS DIMMER
SWITCH SWITCH

Logical Approach to Top Issues Logical Approach to Top Issues
Battery getting discharged

Neutral finding difficult
Clutch cable free play 3~5 Replace starter Battery does not Battery charging Battery draining
mm relay, if found to hold charge system defects continuously
be unmodified
Park the vehicle on centre stand and check
for following in cold & in hot conditions Check battery Check loose Brake switch sticky
Check battery terminals loose / connection at
condition using HRD broken sockets
Start the vehicle & put it in 1st gear. Clutch Starter motor
tester
lever should be fully pressed armature jam
Check for Battery Check DC charging
Check battery no sulphation current
Stop the rotating rear wheel to reduce Excess load taken
load voltage using
inertia effect by one way clutch
multimeter
Check for Shelf life Check for blown
of battery fuse
Rear wheel does not Heavy current
Rear wheel starts Charge Battery
rotate on its own. No getting drawn from
rotating on its own.
Clutch drag is noticed Check for Battery RR unit output starter motor
Pulling power felt at
maintenance record
wheel
Neutral finding Neutral Charging coil Excessive cranking
not ok even finding ok Customer driving resistance due to faulty engine
Confirm Clutch cable
when vehicle when vehicle habits & daily usage
freeness
rolled with rolled with – continuous drain
clutch lever clutch lever Ignition switch loose Bulbs of excess
Check position of on battery
pressed pressed connections wattage used
Lever Assly - Clutch
cable holder on Cover Vehicle left unused
Check for Educate RH Magneto rotor Extra accessories
parameters of customer on for more than a
charge level fitted
Gear shifting feature of month
If clutch drag present –
hard sliding mesh
Replace friction plates
gear box

Logical Approach to Top Issues Logical Approach to Top Issues
Brake related problems Oil Leakages
Customer education Poor braking Spongy braking Brake noisy Confirm whether
Seepage or leakage
Disc Drum Disc Drum Disc Drum

• Riding on brake Confirm correctness
• Simultaneous of oil quantity
application of front Hydraulic fluid Excess play Hydraulic fluid Sticky Dirt / dust in Dirt / dust
and rear brakes replacement in brake pedal leakage movement of brake pads between
• Regular brake rod brake shoes
Glossy brake Sticky brake Low fluid level Confirm source of
maintenance of Glossy brake and drum
pads pedal / lever in master Run out in oil leakage
brakes pads
• Rear brake of P 220 cylinder brake drum
Worn out Sticky brake Glossy brake
toned down for
brake pads rod Air in Bent wheel shoes
safety (using FAQs ) Sticky caliper Reasons for Location of oil For confirmation,
hydraulic axle oil leakages leakages Precautions
movement clean the area and
Greasy / oily system Glossy brake
Worn out disc test drive the vehicle
brake shoes Dust between drum liner on receipt
Run out / brake shoes Improper tightening Mating surfaces Gaskets matching
Incorrect
Leakage of Worn out warpage in and drum with dowel pins
fitment of disc of fasteners
hydraulic fluid brake shoes / disc Dry brake
drum Brake shoe cam O- rings Post rectification, test
Sticky caliper Sticky caliper pivot pin bent Sticky caliper Torn / non - genuine drive the vehicle and
Oil seal replacements
piston Incorrect piston / position piston gaskets / packings re-confirm
Worn out using special tools
fitment of cam movement offset movement Oil seals
lever angle brake cam
Excessive Damaged / dislocated
Worn out
worn out of O-rings Gaskets Inspect for depth and
caliper piston
brake cam width of O’groove
seals
Excessive Damaged / lip hard Copper washer
Worn out
play in wheel Oil seals
master Proper seating of
bearings
cylinder O- ring
piston cups
Improper mating
surfaces
Projection of O- ring
after fitment in O- ring
Incorrect O- ring groove
groove

Logical Approach to Top Issues
Abnormal Engine noise
Knocking Tappet Cam chain Clutch Gear Piston

noise noise noise Crank shaft
transmission slapping big end noise
noise noise
Customer Excessive Loose / Loose /
education on valve clearance elongated chain Clutch nut No oil in Excessive
DTSi Excessive big
engine clearance
technology end side
between Cyl..
using FAQ Loose Worn out clearance
Excessive & piston
tappet screws sprocket gap between Broken teeth
Fuel clutch of gears
adulteration housing slot Excessive Excessive big
Rocker arm Worn out & clutch plates end radial
clearance
bearing broken chain guide clearance
Excessive between
High play between connecting
compression Clutch gear and shaft rod & piston pin
Worn out Sticky push Worn out /
housing riveting
cam lobe rod of tensioner damaged
loose
Non- cage of big
Excessive
genuine Connecting end bearing
play between
Cylinder rod bend /
meshed
head gasket twisted
gears
Carbon
deposition on
Cyl. head / Understand the “Noise” as stated by the customer. Ask customer
piston crown like –
In which driving condition is the noise coming?
In which gear is the noise occurring?
At what speed is the noise coming?
Whether it is persistent or intermittent?
Observation of oil contents (foreign particles) is also equally

important - whether the burr collected is of brass, Aluminum, or
Iron .
93 Service Notes

Service Manual AVENGER 220

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Notice Contents

Service Notes Service Notes

ENGINE & TRANSMISSION : Rim Front : 1. 85 X 17

1 Service Notes Service Notes 2

Feature Advantage Benefit

Feature Advantage Benefit

3 Service Notes Service Notes 4

Frequently asked questions by customers at service reception : T h e s e q u e s t i o n s a r e p o s e d b y

5 Service Notes Service Notes 6

7 Service Notes Service Notes 8

B Warning indicators : Quick / easy start.

No start – Water entry

Better battery charging current at lower rpm and throughout the

Battery warranty period matched with vehicle warranty period.

MF battery against MF battery.

HRD tester for better health

9 Service Notes Service Notes 10

11 Service Notes Service Notes 12

RECOMMENDED FREQUENCY RECOMMENDED FREQUENCY

13 Service Notes Service Notes 14

Based on the user requirement angular position of windshield

The procedure for adjustment is given below: -

Adjust windshield forward or backward as per requirement

15 Service Notes Service Notes 16

REMOVAL OF ENGINE FROM CHASSIS:

17 Service Notes Service Notes 18

Remove Engine Top End Dismantling :

19 Service Notes Service Notes 20

Using Special Tool : Sprocket Catcher - 3710 DH 36

Remove : Engine LH : Magneto Side

21 Service Notes Service Notes 22

23 Service Notes Service Notes 24

Using Sp Tool : Special Nut Puller - 37 10DJ 43 Remove :

25 Service Notes Service Notes 26

Remove : Crankcase Clutch Side :

Remove : Crankcase Magneto Side :

Note : Using Sp. Tool : Bearing Extractor - 37 1030 72

Remove : Using Sp. Tool : Bearing Extractor - 37 10DJ 77

27 Service Notes Service Notes 28

Using Sp. Tool : Bearing Extractor - 37 10DJ 76 Top End :

Cylinder Head Cover :

• Rocker shaft (A)

29 Service Notes Service Notes 30

Oil Pump : Input Shaft Assembly

31 Service Notes Service Notes 32

Clutch Cover Spark Plug

33 Service Notes Service Notes 34

Crankshaft Clutch Hub / Clutch Wheel

35 Service Notes Service Notes 36

Avenger 200 Avenger 220

Part Name : Oil Cooler Part Name : Oil Cooler

Identification : 3 Tubes Identification : 4 Tubes

Part Name : Indicator Flasher Part Name : Indicator Flasher

Identification : Identification : Potting Material

Part Name : AC CDI Part Name : DC CDI

Identification : Grey Identification : Blue

Part Name : Carburettor BS II Part Name : Carburettor BS III

Identification : JM 200 Identification : PD 220

37 Service Notes Service Notes 38

Avenger 200 Avenger 220

Part Name : Control Housing Part Name : Control Housing

Identification : Kill position up Identification : Kill position down

Part Name : Fuel Meter Part Name : Fuel Meter (guage)