RTR 160 & 180

TVS APACHE RTR 160 & 180 SERVICE MANUAL

SERVICE MANUAL

PT TVS Motor Company Indonesia

Office Sales & Marketing
PT TVS Motor Company Indonesia
Gedung Wirausaha Lantai 3 JI. HR Rasuna Said Kav. C-5
Kuningan, Jakarta 12920, Indonesia
Telp : +62 21 300 20570 Fax: +62 21 300 20576 www.tvsmotor.co.id

Factory
JI. Surya Madya Kav. 1-30, Kawasan Industri Surya Cipta,
Desa Kutanegara, Ciampel, Karawang, Jawa Barat 41361, Indonesia
Telp: +62 267 86 10121 Fax: +62 267 86 10124

PT TVS MOTOR COMPANY INDONESIA

Printed in March 2010 PT TVS Motor Company Indonesia 2009, All rights reserved
 RTR 160 & 180

TVS APACHE RTR 160 & 180 SERVICE MANUAL

SERVICE MANUAL

PT TVS Motor Company Indonesia

Office Sales & Marketing
PT TVS Motor Company Indonesia
Gedung Wirausaha Lantai 3 JI. HR Rasuna Said Kav. C-5
Kuningan, Jakarta 12920, Indonesia
Telp : +62 21 300 20570 Fax: +62 21 300 20576 www.tvsmotor.co.id

Factory
JI. Surya Madya Kav. 1-30, Kawasan Industri Surya Cipta,
Desa Kutanegara, Ciampel, Karawang, Jawa Barat 41361, Indonesia
Telp: +62 267 86 10121 Fax: +62 267 86 10124

PT TVS MOTOR COMPANY INDONESIA

Printed in March 2010 PT TVS Motor Company Indonesia 2009, All rights reserved
RTR 160 & 180

SERVICE MANUAL
 NOTICE

PT TVS MOTOR COMPANY INDONESIA reserves all the rights to make

changes at any time without prior notice and without any prior information or
obligation.

All information included in this manual is based on the latest product

information available at the time of approval for printing.

No part of this publication should be reproduced without the written

permission from PT TVS MOTOR COMPANY INDONESIA.
 FOREWORD

We are happy to provide you the first edition of TVS Apache RTR 160 & RTR 180 bike
service manual.

This manual is prepared to provide assistance during the process of servicing the
TVS RTR 160 Single Disc, Dual Disc & RTR 180 Dual Disc bikes. This manual
describes about the basic operations of this new product, do‘s and don‘t‘s, service
limits of individual components and sub systems while servicing the TVS Apache
RTR bike. We request all of our technicians to carefully go through this manual and
follow the instructions given.

All instructions and illustrations of this manual are prepared based on the latest
information available during the preparation of manual. Modifications or any
improvements will be communicated through ‘Service Information Bulletin’ from
time to time.

This manual will help to technicians who already have technical knowledge about
bike.

While servicing, certain parts may require replacement, for ordering spares please
refer ‘Apache RTR 160 & RTR 180 parts catalogue’.

Incase, you face any critical problems during the course of servicing and if you need
any further clarifications or technical assistance you may contact our service
personnel.

You may also contact us at

PT TVS Motor Company Indonesia,

Kantor Sales & Marketing,
Gedung Wirausaha Lantai 3 Ji,
HR Rasuna Said Kav. C-5
Kuningan, Jakarta 12920
Indonesia
Tel: +62 21 300 20570 Fax: +62 21 300 20576
HOW TO READ THIS MANUAL

This service manual is split into seven chapters as “General information“, “Periodic maintenance“, “Servicing of engine”,
“Fuel, Lubrication and Exhaust system“, “Electrical system“, “Chassis” and “Service information”.

Mostly the pages run through two columns in the inside pages with instructions on left side and the illustrations on the right
side. Some of exploded views occupy full pages. In between running instructions and notations used are as per the examples
given below:

Heading:- CHAIN ASSEMBLY DRIVE

Sub heading:- Chain slackness

Note:- This provides further clarification for clear understanding of any particular information/operation/data.

Note:
Before reassembling chain assembly, clean
the sprocket engine and sprocket rear.

Caution/warning:- This indicates special procedures of precautions to be followed by the technicians during service.
Avoiding these messages may cause injury to them as well as damage to the components.

Caution:
Do not use molter grease to lubricate ‘O’
ring chain.

Hand tools:- 17 mm spanner

Part number Part description

Special tools:- N5310070 Tool nut crankshaft RH

Service limits:- Service limit 0.05 mm

GROUP INDEX

1 GENERAL INFORMATION Page 1-1 to 1-13

2 PERIODIC MAINTENANCE Page 2-1 to 2-40

3 SERVICING OF ENGINE Page 3-1 to 3-54

4 FUEL, LUBRICATION AND EXHAUST SYSTEM Page 4-1 to 4-19

5 ELECTRICAL SYSTEM Page 5-1 to 5-24

6 CHASSIS Page 6-1 to 6-52

7 SERVICE INFORMATION Page 7-1 to 7-15

 CONTENTS Chapter 1

DESCRIPTION PAGE NO.

VIEWS OF TVS APACHE RTR SINGLE DISC - 160 1

VIEWS OF TVS APACHE RTR DUAL DISC - 160 1
VIEWS OF TVS APACHE RTR DUAL DISC - 180 2
VEHICLE IDENTIFICATION NUMBERS 2
FRAME NUMBER 3
ENGINE NUMBER 4
TECHNICAL SPECIFICATIONS 5
DIMENSIONS AND WEIGHT 5

GENERAL INFORMATION
ENGINE 5
TRANSMISSION 5
GEAR RATIO 6
CHASSIS 6
ELECTRICAL 6
CAPACITIES 7
RUNNING- IN PERIOD 8
PRECAUTIONS AND GENERAL INSTRUCTIONS 8
LIST OF HAND TOOLS REQUIRED 9
LIST OF SPECIAL TOOLS REQUIRED 9
APPLICATION OF SPECIAL TOOLS 10
 CONTENTS Chapter 2

DESCRIPTION PAGE NO.

PERIODIC MAINTENANCE SCHEDULE 1

LUBRICATION SCHEDULE 3
21 FREE SERVICE POINTS 4
MAINTENANCE AND TUNE-UP PROCEDURE 10
AIR CLEANER ASSEMBLY 10
CARBURETTOR ASSEMBLY 11
HOSE FUEL 12
CAP FUEL STRAINER 13

PERIODIC MAINTENANCE
ENGINE CUM TRAMSISSION OIL CHANGE 13
ENGINE CUM TRAMSISSION OIL LEVEL 14
FILTER COMP ENGINE OIL 14
COMPRESSION PRESSURE 15
HEAD COMPLETE CYLINDER, PISTON AND PISTON RINGS 16
VALVE, VALVE GUIDE AND SEAT VALVE 16
VALVE (TAPPET) CLEARANCE 17
SPARK PLUG 19
BATTERY ASSEMBLY 20
HEAD LAMP BEAM ADJUSTMENT 21
CABLE ASSEMBLY THROTTLE - FREE PLAY 22
CABLE ASSEMBLY CLUTCH - FREE PLAY 22
BRAKES 23
FRONT BRAKE (DISC) 23
REAR BRAKE (DRUM ) 27
REAR BRAKE (DISC) 28
WHEEL ASSEMBLY FRONT 30
WHEEL ASSEMBLY REAR ( DRUM) 31
INSPECTION 32
WHEEL ASSEMBLY REAR (DISC) 33
CHAIN ASSEMBLY DRIVE 34
STEERING 37
FRONT FORK OIL 38
TYRES 38
BOLTS AND NUTS 39
LUBRICATION POINTS 40
 CONTENTS Chapter 3

DESCRIPTION PAGE NO.

ENGINE OVERHAUL 1
CLUTCH REMOVAL AND SERVICING 1
INSPECTION 5
REASSEMBLY 6
ENGINE ASSEMBLY REMOVAL FROM VEHICLE 7
ENGINE ASSEMBLY - DISASSEMBLY 13
TRANSMISSION 29
SHAFT COMPLETE DRIVE DISMANTLING 29
INSPECTION 31

SERVICING OF ENGINE
REASSEMBLY 31
COVER CYLINDER HEAD - DISASSEMBLY 32
INSPECTION 33
REASSEMBLY 34
HEAD COMPLETE REAR 34
DISASSEMBLY 34
DECARBONISING 36
INSPECTION 37
CYLINDER HEAD ASSEMBLY EXPLODED VIEW 40
REASSEMBLY 41
LEAK CHECK AND LAPPING 41
ENGINE COMPONENTS INSPECTION 42
ENGINE COMPONENTS REASSEMBLY 47
ENGINE ASSEMBLY REASSEMBLY 49
VALVE TIMING AND VALVE CLEARANCE 54
RUNNING IN AFTER OVERHAUL 54
 CONTENTS Chapter 4

DESCRIPTION PAGE NO.

COVER FUEL TANK - REMOVAL 1

FUEL LUBRICATION AND EXHAUST SYSTEM

REASSEMBLY 1
FUEL TANK COMPLETE AND FUEL COCK ASSEMBLY 2
REMOVAL 2
CLEANING 3
FUEL COCK ASSEMBLY 3
FUEL HOSES 3
CARBURETTOR ASSEMBLY 4
REMOVAL FROM THE VEHICLE 4
DISASSEMBLY 5
PISTON VALVE DISASSEMBLY 8
MAINTENANCE 9
CLEANING 9
INSPECTION - NEEDLE VALVE ASSEMBLY 10
REASSEMBLY 10
CARBURETTOR TUNING 11
LUBRICATION SYSTEM 12
OIL STRAINER 12
OIL PUMP ASSEMBLY 14
LUBRICATION FLOW CHART 14
FILTER COMP ENGINE OIL 14
EXHAUST EMISSION CONTROL 15
WHY DOES THE GASOLINE FAIL TO BURN COMPLETELY 15
POLLUTION CONTROL 15
EXHAUST SYSTEM 16
SECONDARY AIR INJECTION VALVE 16
WORKING PRINCIPLE 16
FUNCTION 17
REMOVAL 17
PREVENTIVE MAINTENANCE 18
MEASURING CO LEVEL IN EXHAUST EMISSSION 18
TO CHECK AND SET THE CO 18
 CONTENTS Chapter 5

DESCRIPTION PAGE NO.

WIRE COLOUR CODE INDEX 1

PRECAUTIONS 2
CONNECTOR 2
COUPLER 2
FUSE 2
SEMI-CONDUCTOR EQUIPPED PART 2
CONNECTING BATTERY 3
IGNITION SYSTEM 3
IGNITION LOCK 4
ENGINE KILL SWITCH 5
PULSAR COIL 5

ELECTRICAL SYSTEM
IGNITION COIL 5
SUPPRESSOR CAP 6
SPARK PLUG 6
THROTTLE SWITCH 6
LIGHTING SYSTEM 7
LIGHTING SWITCH 8
BEAM CONTROL SWITCH 8
AC DC PASS BY LAMP 8
PASS BY RELAY 8
PASS BY SWITCH 9
12V REGULATION SYSTEM 9
RR UNIT 9
LIGHTING PERFORMANCE CHECK 9
LIGHTING CUM CHARGING COIL 10
CHARGING AND DC SYSTEM 10
HORN 12V DC 11
TURN SIGNAL LAMP FRONT & REAR 11
NEUTRAL LAMP 12
STOP LAMP 12
FUEL LEVEL INDICATOR 13
CHARGING PERFORMANCE CHECK 13
CHARGING COIL 13
ELECTRIC STARTER SYSTEM 14
ELECTRIC STARTER SWITCH 15
SWITCH ASSEMBLY CLUTCH 15
STARTER RELAY 15
BULBS REPLACEMENT 16
LAMP ASSEMBLY TURN SIGNAL - BULB 16
HEAD LAMP ASSEMBLY LAMP 16
POSITION LAMP BULB REPLACEMENT 17
SPEEDOMETER ASSEMBLY 17
ODO / TRIP METER SETTING 17
DIGITAL CLOCK SETTING 18
REPLACEMENT 18

Continued...
 CONTENTS Chapter 5
LAMP ASSEMBLY REAR COMBINATION 20
NUMBER PLATE ILLUMINATOR BULB 21
ADJUSTMENT 21
HEADLAMP BEAM ADJUSTMENT 21
SWITCH ASSEMBLY STOP LAMP 21
BATTERY ASSEMBLY 22
REMOVAL 22
SERVICING 22
ELECTROLYTE LEVEL 22
BATTERY CHARGER 23
CHARGING PROCEDURE 23
INDICATION OF FULL CHARGE 24
REVERSE POLARITY 24

ELECTRICAL SYSTEM
 CONTENTS Chapter 6

DESCRIPTION PAGE NO.

WHEEL ASSEMBLY FRONT 1

DISC PLATE REPLACEMENT 1
INSPECTION 2
TUBELESS TYRE RTR 180 3
REASSEMBLY 4
DISC BRAKE SYSTEM 6
CALIPER ASSEMBLY FRONT -REMOVAL AND DISMANTLING 6
INSPECTION OF CALIPER ASSEMBLY 9
ASSEMBLING OF CALIPER ASSEMBLY 9
DISC PLATE SERVICING 10
DISC PLATE REPLACEMENT 10
MASTER CYLINDER - REMOVAL AND DISMANTLING 11
INSPECTION 13
REASSEMBLY 13

CHASSIS
FORK ASSEMBLY FRONT 15
OIL REPLACEMENT 15
LEG ASSEMBLY FRONT FORK - DISMANTLING 19
INSPECTION 20
REASSEMBLY 21
LOWER BRACKET COMPLETE - DISMANTLING 22
INSPECTION 23
REASSEMBLY 24
WHEEL ASSEMBLY REAR (DISC BRAKE) - REMOVAL 26
DISC REPLACEMENT 26
REMOVAL OF BEARING 26
SPROCKET DRUM ASSEMBLY - REMOVAL 27
INSPECTION 29
REASSEMBLY 30
TUBELESS TYRE RTR 180 33
PUNCTURE REPAIR 33
VALVE TUBELESS TYRE REPLACEMENT 34
DISC BRAKE SYSTEM REAR 35
CALIPER ASSEMBLY -REMOVAL AND DISMANTLING 35
CALIPER ASSEMBLY - INSPECTION 38
CALIPER ASSEMBLY - REASSEMBLY 38
DISC PLATE SERVICING 39
DISC PLATE REPLACEMENT 39
MASTER CYLINDER - REMOVAL AND DISMANTLING 39
INSPECTION 42
REASSEMBLY 42

Continued...
 CONTENTS Chapter 6

WHEEL ASSEMBLY REAR (DRUM BRAKE) - REMOVAL 44

PANEL ASSEMBLY REAR - DISMANTLING 44
REMOVAL OF BEARING 45
INSPECTION 45
REASSEMBLY 45
SWING ARM COMPLETE 47
REMOVAL 47
INSPECTION 49
REASSEMBLY 49
FLAP REAR FENDER (RTR 180) 51
MIRROR ASSEMBLY L&R 52
REMOVAL 52
REASSEMBLY 52

CHASSIS
 CONTENTS Chapter 7

DESCRIPTION PAGE NO.

SERVICE DATA 1
VALVE AND VALVE GUIDE 1
CAM SHAFT COMPLETE & HEAD COMPLETE CYLINDER 1
CYLINDER, PISTON AND RINGS PISTON 2
CRANKSHAFT COMPLETE 2
CLUTCH 3
TRANSMISSION SPECIFICATION 3
TRANSMISSION 3
SUSPENSION 3

SERVICE INFORMATION
BEARING SPECIFICATION 4
CARBURETTOR ASSEMBLY 5
ELECTRICAL 6
BRAKE AND WHEEL ASSEMBLY 7
TIGHTENING TORQUE - ENGINE 8
TIGHTENING TORQUE - CHASSIS 9
SPECIAL MATERIAL REQUIRED FOR MAINTENANCE 10
USE OF GENUINE TVS MOTOR COMPANY PARTS 10
FUEL 10
TROUBLE SHOOTING 11
STARTING TROUBLE 11
POOR PICK-UP 12
SMOKY EXHAUST (WHITE SMOKE) 12
SMOKY EXHAUST (BLACK SMOKE) 13
ENGINE OVER HEATING 13
HEAD LAMP NOT WORKING 13
HORN NOT WORKING 14
HIGH FUEL CONSUMPTION 14
EXCESSIVE CO 14
JERKY MOVEMENT / ABNORMALITY OF ENGINE RPM 14
WIRING DIAGRAM- TVS APACHE RTR 160 & 180 15
 GENERAL INFORMATION

TVS APACHE RTR160 SINGLE DISC

1

Fig. 1.1

TVS APACHE RTR160 DUAL DISC

E
AG
IM
IS
TH
CE
LA
P
RE
SE
EA
PL

Fig. 1.1

General information 1-1

 GENERAL INFORMATION

TVS APACHE RTR180 DUAL DISC

E
AG
IM
IS
TH
CE
PLA
RE
SE
EA
PL

Fig. 1.3

VEHICLE IDENTIFICATION NUMBERS

LOCATIONS
MD
634

FRAME NUMBER
KE42
92H

l The frame serial number is engraved on the frame

090
96

of right side of the steering head pipe. (Fig. 1.4)

Fig. 1.4
ENGINE NUMBER

l The engine serial number is engraved on the left

side crankcase near cylinder block. (Fig. 1.5)

95
92 213 0
OE4H

Fig. 1.5

General information 1-2

 SYSTEM FOLLOWING IN FRAME NO. IDENTIFICATION
PT TVS MOTOR COMPANY INDONESIA

Z - PT TVS MOTOR COMPANY INDONESIA

6 - TVS MOTOR COMPANY INDIA Year code

D - India Engine type Plant code

K - Indonesia
GENERAL INFORMATION

M - Asia Month code

M D 6 3 4 K E 4 2 9 2 H 0 9 0 9 6

Frame type

Check digit Manufacturer serial no.

Vehicle type

Variant identifier

General information 1-3

1
 SYSTEM FOLLOWING IN ENGINE NO. IDENTIFICATION
PT TVS MOTOR COMPANY INDONESIA

General information 1-4

Engine type

FILLER Plant code

GENERAL INFORMATION

0 E 4 H 9 2 2 1 3 0 9 5

Month code

Year code Manufacturer serial no.

GENERAL INFORMATION

1
TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
DIMENSIONS AND WEIGHT
Overall length 2020 mm 2085 mm
Overall width 730 mm
Overall height 1050 mm 1105 mm
Seat height 790 mm
Ground clearance 180 mm 165 mm
Wheel base 1300 mm 1326mm
Kerb weight (with toolkit and 90% of fuel) 136 kg 139 kg 137 kg
Pay load 130 kg
Maximum laden weight 266 kg 269 kg 267 kg

ENGINE
Type 4 stroke, air cooled, single cylinder OHC
Bore 62 mm 62.5 mm
Stroke 52.9 mm 57.8 mm
Piston displacement 159.7 cc 177.4 cc
Carburettor type (Ucal Mikuni) BS26 X39Z1 BS29
Air filter Double polyurethane foam filter element
Oil filter Wire mesh and micronic paper filter
Lubrication system Forced wet sump
Compression ratio 9.5 : 1
Maximum power @ 8500 rpm 11.19 kW(15.2 BHP) 12.52kW(17BHP)
Maximum torque @ 6000 rpm 13.1 Nm 15.5 Nm
Maximum speed 118 km / hr 124 km / hr
Engine idling rpm 1400 ± 100 rpm
Starting system Kick starter & Electric starter

TRANSMISSION
Clutch Wet, multi-plate type - Manual over ride
Transmission 5 speed constant mesh
Gear shift pattern 1 down and 4 up, toe shift
Primary reduction (Helical gears) 3.095 (65/21)
Final reduction (Chain and Sprocket) 3.384 (44/13) 3.286 (46/14)
Overall reduction (at top gear) 9.22 8.95

General information 1-5

 GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
GEAR RATIO
First gear 2.917 (35/12)
Second gear 1.857 (26/14)
Third gear 1.333 (24/18)
Fourth gear 1.050 (21/20)
Fifth gear (top gear) 0.880 (22/25)

CHASSIS
Frame Double cradle synchro - stiff
Front suspension and travel Telescopic, oil damped 105 mm travel
Rear suspension and travel Monotube inverted gas filled 5 step adjustable
hydraulic shocks with rectangular swing arm.
Steering angle 82°
Caster angle 25.5°
Trail length 81.3 mm 84.3 mm
Turning radius 2010 mm 2150 mm
Brakes - Front (Hand operated) 270 mm dia petal disc
- Rear (Foot operated) 130 mm (Drum) 200 mm dia petal disc
Tyre size - Front 90/90 x 17“ 90/90 x 17“ (Tube Less)
- Rear 100/80 x 18“ 100/80 x 17“ (Tube Less)
Tyre pressure - Solo (Front) 1.75 kg / cm2 (25 PSI)
(Rear) 2.00 kg / cm2 (28 PSI)
- Dual (Front) 1.75 kg / cm2 (25 PSI)
(Rear) 2.25 Kg / cm2 (32 PSI)

ELECTRICAL
Type AC generator
Ignition system IDI - Dual mode digital ignition
Ignition timing (At coinciding mark) 5.0º ± 2º at 1500 rpm
(Full advance) 34.0º ± 2º at 10000 rpm
Spark plug (BOSCH) UR5DDC - Twin electrode
Battery type 12 V, 9.0 Ah
Body earthing Negative terminal

General information 1-6

GENERAL INFORMATION

1
TECHNICAL SPECIFICATIONS

Apache RTR 160 Apache RTR 180

Single Disc Dual Disc Dual Disc
ELECTRICAL
Generator 12 V, 100 W
Head lamp 12 V, 35/35 W HS1 (Halogen)
Position lamp 12 V, 4 W x 2 Nos
Tail lamp 12 V, 0.5 W (LED)
Brake lamp 12 V, 3.5 W (LED)
Turn signal lamp 12 V, 10 W x 4 Nos
Number plate lamp 12V, 4 W
Instrument panel lamp LCD / LED indicators
Horn type 12 V, DC x 2Nos
Fuse 12V, 10 A

CAPACITIES
Fuel tank (including reserve) 16.0 litres
Reserve 2.5 litres
Front fork oil (grade) Teleshockab oil
Front fork oil (qty) GIL 140 ± 2.0 ml per leg 140 ± 2.0 ml per leg
TOP 152 ± 2.5 ml per leg
Engine cum transmission oil (grade) 4T oil
Engine cum transmission oil (quantity) 1000 ml (During service)
1100 ml (During overhaul)
Disc brake fluid DOT 3 / DOT 4

Note:
Specifications are subject to change on account of continuous improvements in
the product.

General information 1-7

 GENERAL INFORMATION

RUNNING - IN PERIOD

The first 1000 kms is a crucial part. Proper running-in operation during this time helps in ensuring a longer life and smooth
performance of TVS Apache RTR.

The reliability and performance of TVS Apache RTR depends on special care and restraint exercised during running-in
period. It is especially important that you avoid operating the engine in a manner, which could expose the engine parts to
excessive heat. Maximum recommended speed during running-in is 50 kmph.

Do not ride at constant low speed for a longer time during any portion of the running-in period. Keep varying the engine
speed for better mating of parts.

PRECAUTIONS AND GENERAL INSTRUCTIONS

Observe the following precautions without fail when dismantling and reassembling.

l Do not run the engine indoors with little or no ventilation.

l Be sure to replace gaskets, O-rings, circlips and cotter pins with new ones, for safety.
l When tightening nuts and bolts, start first with the larger or centre ones. Tighten these to the specified torque following a
crisscross pattern.
l Use specified special and common tools only.
l Avoid any dent or damage to fork inner tube through contact of internal objects.
l When engine and final drive components are disassembled and inspected, coat the mating surfaces with a lubricant to
prevent corrosion.
l When assembling components, use recommended lubricants.
l After assembling, check every part for proper installation, movement and operation.
l Always ensure mutual safety when working with the partners.
l Use only TVS Motor Company genuine parts and recommended lubricants.

General information 1-8

 GENERAL INFORMATION

LIST OF HAND TOOLS REQUIRED

1. Flat head spanners:

1
7 mm, 8 mm, 10 mm, 12 mm and 14 mm.

2. Ring spanners:
8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm , 17 mm, 22 mm, 27 mm, and 32 mm.

3. Tubular spanners:
8 mm, 10 mm, 12 mm, 14 mm, 16 mm and 17 mm.

4. Socket spanners:
8 mm, 10 mm, 12 mm, 13 mm, 14 mm, 17 mm, 22 mm, 27 mm and 32 mm.

5. Allen keys:
4 mm, 6 mm, 8 mm, 10 mm and 12 mm.

6. Screw drivers:
Flat screw driver-small, flat screw driver, phillips head screw driver no.1, phillips head screw driver no. 2 and phillips head
screw driver no. 3.

7. Hammers:
Nylon hammer, rubber mallet and metal hammer.

8. Pliers:
Straight nose plier, combination plier, water pump plier, external circlip plier-6 inch and external circlip plier-7 inch.

9. Others:
Drift, chisel, plug spanner, compression gauge, special adopter, micrometer, vernier calliper, dial gauge, battery charger,
feeler gauge, pocket tester, impact driver set, tachometer, hydrometer and hot plate.

LIST OF SPECIAL TOOLS REQUIRED

Sl. no. Part no. Description

1 0312401 Universal oil seal remover

2 1313501 Front fork oil seal installer
3 2310300 Assembly tool steering cups
4 M1310010 Holder assembly magneto
5 M1310020 Puller assembly magneto
6 M1310070 Tappet adjuster
7 M1310110 Puller assembly crankcase
8 M1310160 Holder front fork cylinder
9 N2310010 Clutch holding tool
10 N2310020 Clutch nut tightening tool
11 N2310070 Mandrel gear shaft oil seal
12 N2310080 Mandrel drive shaft R side bearing
13 S1310020 Extractor assembly inlet and exhaust valve
14 S1311110 Extractor main bearing

General information 1-9


GENERAL INFORMATION
APPLICATION OF SPECIAL TOOLS
1. Un versa o sea remover - 0312401
l Used o remove o sea rom he ron ork ou er
ube and crankcase F g 1 7
2. Front fork o sea nsta er - 1313501
l To ns a ron ork o sea and dus cap F g 1 8
3. Assemb y too steer ng cups - 231030000
l To ns a cup bo om and cup op n he rame
s eer ng s em Fg1 9
4. Ho der assemb y magneto - M1310010
l To ho d magne o ro or wh e oosen ng or
gh en ng he nu magne o F g 1 10
General information 1-10
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F g 1 10
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GENERAL INFORMATION
5. Pu er assemb y magneto - M1310020
l To remove magne o ro or rom he cranksha
assemb y F g 1 11
6. Tappet ad uster - M1310070
l Used o oosen and gh en he appe ad us ng
screw F g 1 12
7. Pu er assemb y crankcase - M1310110
l To separa e crankcase Land R F g 1 13
8. Ho der front fork cy nder - M1310160
l To ho d he ron ork p s on wh e remov ng or
assemb ng p s on bo n G L make eg assy
F g 1 14
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F g 1 11
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General information 1-11

GENERAL INFORMATION
9. C utch ho d ng too - N2310010
l To ho d d sc c u ch pressure wh e oosen ng and
gh en ng he nu c u ch sha F g 1 15
10. C utch nut t ghten ng too - N2310020
l Used o oosen and gh en he nu c u ch sha
F g 1 16
11. Mandre gear shaft o sea - N2310070
l To ns a o sea n gear sh sha F g 1 17
12.Mandre dr ve shaft R s de bear ng -
N2310080
l To ns a o sea n k ck s ar er sha
General information 1-12
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F g 1 15
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F g 1 16
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a g
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im
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se
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e
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as
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F g 1 17
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F g 1 18 a
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im
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dd
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a
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le a
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P
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F g 1 18
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GENERAL INFORMATION
13.Extractor assemb y n et and exhaust va ve -
S1310020
l To remove and ns a he n e & exhaus va ve
co er va ves F g 1 19
14.Extractor ma n bear ng - S1311110
l To remove ma n bear ng
F g 1 20
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rom cranksha .....................................................................................................................................................................................................
s
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ge
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General information 1-13
 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

For a trouble free performance of the vehicle and its longer life, the vehicle should be periodically inspected for a wear of
component, carbon deposits, stretched cables, etc. The worn-out components to be replaced or repaired and necessary
adjustment to be made for certain items for better performance of the vehicle as indicated in the table.

Note:
More frequent maintenance checks may be performed on vehicles that are used in severe conditions like
dusty environment, dense traffic conditions, sustained full throttle operation and un-metalled roads.

PERIODIC MAINTENANCE SCHEDULE - FREE SERVICES

2
Period 1 month 3 months 6 months 9 months 12 months
ITEM km 500 - 600 2000 - 2500 4500 - 5000 7500 - 8000 11500 - 12000
Engine cum transmission oil R R R R R
Oil filter R R R R R
Oil sump filter I&C I&C I&C I&C I&C
Spark plug I&C I&C I&C R I&C
Compression pressure – – I – I
Air cleaner elements2 I&C I&C I&C I&C I&C
Engine pipe breather – C C C C
Carburettor assembly3 – C&A C&A C&A C&A
3
Tappet clearance I&A I&A I&A I&A I&A
Fuel cock sediment bowl C C C C C
Clutch cable I&A I&A I&A I&A I&A
Throttle cable – I&A I&A I&A I&A
Steering play & smooth operation I&A I&A I&A I&A I&A
3
All fasteners I&A I&A I&A I&A I&A
3
Drive chain C, L & A C, L & A C, L & A C, L & A C, L & A
All bulbs and horn I I I I I
Head lamp beam I&A I&A I&A I&A I&A
Battery electrolyte level I&T I&T I&T I&T I&T
4
Specific gravity and voltage I I I I I
Brakes I&A I&A I&A I&A I&A
Tyres (air pressure) I&A I&A I&A I&A I&A
Idling CO% I&S I&S I&S I&S I&S

R - Replace, C - Clean, I - Inspect, T - Top up, A - Adjust, TI - Tighten, T - Top up, S - Set
2 3 4
Replace parts if necessary If necessary Recharge if necessary (..........contd.)

Periodic maintenance 2-1

 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE - PAY SERVICES

Period 15 months 18 months 21 months 24 months 27 months 30 months

ITEM km 14500-15000 17500-18000 20500-21000 23500-24000 26500-27000 19500-30000

Engine cum transmission oil R R R R R R

Oil filter R R R R R R
Oil sump filter I&C I&C I&C I&C I&C I&C
Spark plug R I&C I&C R I&C R
Compression pressure – I I I I I
Air cleaner elements2 I&C I&C I&C I&C I&C I&C
Engine breather pipe C C C C C C
Carburettor assembly3 C&A C&A C&A C&A C&A C&A
3
Tappet clearance I&A I&A I&A I&A I&A I&A
Head cylinder / piston – D – – – –
Fuel cock sediment bowl C C C C C C
Clutch cable I&A I&A I&A I&A I&A I&A
Throttle cable I&A I&A I&A I&A I&A I&A
Steering play & smooth operation I&A I&A I&A I&A I&A I&A
Front fork oil – R – – – –
3
All fasteners I&A I&A I&A I&A I&A I&A
3
Drive chain I&A I&A I&A I&A I&A I&A
All bulbs and horn I&A I&A I&A I&A I&A I&A
Head lamp beam I&A I&A I&A I&A I&A I&A
Battery electrolyte level I&T I&T I&T I&T I&T I&T
4
Specific gravity and voltage I I I I I I
Brakes I&A I&A I&A I&A I&A I&A
Tyres (air pressure) I&T I&T I&T I&T I&T I&T
Idling CO% I&S I&S I&S I&S I&S I&S

R - Replace, C - Clean,I - Inspect,T - Top up, A - Adjust, D - Decarbonise, TI - Tighten, S - Set

2 3 4
Replace parts if necessary If necessary Recharge if necessary

Periodic maintenance 2-2

 PERIODIC MAINTENANCE

LUBRICATION SCHEDULE
Running parts must be lubricated periodically. Insufficient lubrication will cause rapid wear and severe damages to the
components. Lubricate following parts as per the schedule:

Period INITIAL EVERY EVERY EVERY

ITEM KM 500 - 600 2000 - 2500 4500 - 5000 9500 - 10000

Throttle grip

Brake cam
–

–
–

–
–

Grease
Grease

Grease
2
Kick starter pedal pivot SAE 20W40 SAE 20W40 SAE 20W40 SAE 20W40

Brake pedal shaft Grease Grease Grease Grease

Throttle cable & clutch cable 4T oil 4T oil 4T oil 4T oil

Drive chain Recommended chain spray

Steering stem races Clean and lubricate with fresh Grease at every 12000 km

Swing arm races Clean and lubricate with fresh Grease every year

Warning:
Do not apply more grease on cam brakes. The grease may get on to the brake shoe linings resulting in brake
slippage.

Note:
Before lubricating each part, clean them thoroughly, remove rusty spots if any. Lubricate exposed parts which
are subjected to rust with either engine oil or grease whenever the vehicle is used / operated under wet or
rainy conditions.

Periodic maintenance 2-3

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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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21 FREE SERVICE CHECK POINTS .....................................................................................................................................................................................................
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1 O change and o eve check .....................................................................................................................................................................................................
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l Check o eve on he gauge make sure ha o .....................................................................................................................................................................................................
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eve s be ween m n mum and max mum eve .....................................................................................................................................................................................................
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F g 2 1A Re er page no 2-13 or o change .....................................................................................................................................................................................................
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procedure .....................................................................................................................................................................................................
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l Wh e chang ng eng ne o nspec s ra ner or .....................................................................................................................................................................................................
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any damage Rep ace requ red F g 2 1B .....................................................................................................................................................................................................
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1000 m dur ng serv ce F g 2 1A F g 2 1B
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O Quan y .....................................................................................................................................................................................................
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1100 m dur ng overhau .....................................................................................................................................................................................................
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Rep ace eng ne o a every serv ce .....................................................................................................................................................................................................
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2 O f ter change .....................................................................................................................................................................................................
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l Change o er a every serv ce F g 2 2 Re er .....................................................................................................................................................................................................
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page no 2-14 or o er chang ng procedure .....................................................................................................................................................................................................
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Rep ace o er a every serv ce w h new one .....................................................................................................................................................................................................
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3 A r f ter c ean ng .....................................................................................................................................................................................................
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l Check er e emen or any damage a every .....................................................................................................................................................................................................
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serv ce Rep ace necessary .....................................................................................................................................................................................................
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l C ean er comp e e a r by mmers ng n su ab e .....................................................................................................................................................................................................
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so ven Kerosene and wash horough y F g 2 3 .....................................................................................................................................................................................................
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Re er page no 2-10 or a r er c ean ng .....................................................................................................................................................................................................
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procedure .....................................................................................................................................................................................................
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4 Carburettor .....................................................................................................................................................................................................
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l nspec carbure or ven ur or any b ack carbon .....................................................................................................................................................................................................
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depos on c ean horough y F g 2 4B Re er .....................................................................................................................................................................................................
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chap er 4 - Fue ubr ca on and exhaus sys em .....................................................................................................................................................................................................
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page 4-9 or ur her de a s .....................................................................................................................................................................................................
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l Check d e RPM ad us necessary F g 2 4B .....................................................................................................................................................................................................
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Re er page no 2-12 or d e rpm ad us men .....................................................................................................................................................................................................
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procedure .....................................................................................................................................................................................................
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d e RPM 1400 ±100 .....................................................................................................................................................................................................
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F g 2 4A F g 2 4B
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Periodic maintenance 2-4
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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5 Spark p ug c ean ng .....................................................................................................................................................................................................
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l Check he co our o spark p ug and c ean a every .....................................................................................................................................................................................................
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serv ce F g 2 5 Re er page no 2-19 or ur her .....................................................................................................................................................................................................
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de a s .....................................................................................................................................................................................................
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Rep ace spark p ug w h a new one a every .....................................................................................................................................................................................................
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8000 kms .....................................................................................................................................................................................................
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2
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Spark p ug BOSCH UR5DDC .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Do not ad ust the spark p ug e ectrode gap. t .....................................................................................................................................................................................................
Fg 2 5
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s str ct y not recommended .....................................................................................................................................................................................................
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6 Va ve and tappet c earance .....................................................................................................................................................................................................
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l Check and rese appe c earance necessary .....................................................................................................................................................................................................
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F g 2 6 Re er page no 2-17 or ur her de a s .....................................................................................................................................................................................................
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Va ve Standard .....................................................................................................................................................................................................
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n e va ve 0 06 mm .....................................................................................................................................................................................................
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Exhaus 0 08 mm .....................................................................................................................................................................................................
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7 Steer ng ad ustment and hand e bar freeness .....................................................................................................................................................................................................
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l Check hand e bar reeness ad us necessary .....................................................................................................................................................................................................
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8 Fue ne check .....................................................................................................................................................................................................
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l nspec ue hose or any damage A so c ean ue .....................................................................................................................................................................................................
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cock sed men bow F g 2 8 Re er chap er 4 - .....................................................................................................................................................................................................
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Fue ubr ca on and exhaus sys em or ue cock .....................................................................................................................................................................................................
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c ean ng procedure .....................................................................................................................................................................................................
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Periodic maintenance 2-5

PERIODIC MAINTENANCE
9 Cha n ad ustment
l nspec dr ve cha n or s ackness ad us he
s ackness ound more or ess han spec ed m
F g 2 9 Re er page no 2-34 or cha n ad us men
procedure
S ackness 20 - 30 mm
l Lubr ca e dr ve cha n per od ca y or be er
per ormance
10 Brake f u d eve check
l Check ron brake u d eve
ower eve op up w h resh brake u d F g 2 10
Re er page no 2-23 or ur her de a s
l A so check rear brake u d eve n Apache RTR
DD ensure ha brake u d s be ween m n mum
and max mum eve F g 2 11 Re er page no
2-28 or ur her de a s
l Rep ace he brake u d once n a year or every
20000kms
11 Rear brake ad ustment
l Check rear brake ree p ay n case o rear drum
brake mode ad us necessary F g 2 12
Re er page no 2-27 or brake ad us ng
procedure
Free p ay 15 - 25 mm
Periodic maintenance 2-6
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Fg 2 9
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ound be ow he .....................................................................................................................................................................................................
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F g 2 10
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M MAX MUM LEVEL
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M M N MUM LEVEL
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F g 2 11
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F g 2 12
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...............................................................................................................................................................

PERIODIC MAINTENANCE
12 Brake sw tches
l Check proper work ng o brake sw ches and
ad us he rear brake sw ch necessary
F g 2 13
13 Thrott e free p ay ad ustment
l Check hro e ree p ay and se he p ay requ red
F g 2 14 Re er page no 2-22 or hro e ree
p ay ad us men procedure
l Check smoo h opera on o gr p comp hro e
ubr ca e nner cab e necessary
14 C utch ever p ay ad ustment
l Measure ree p ay a ever end p ay ound more
or ess ad us o spec ed eve F g 2 15 Re er
page no 2-22 or c u ch ree p ay ad us men
procedure
Free p ay 5 - 10 mm
15 Check a sw tches and bu bs
l Check proper unc on ng o a sw ches and
bu bs F g 2 16
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2
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F g 2 13
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F g 2 14
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F g 2 15
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F g 2 16
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Periodic maintenance 2-7

PERIODIC MAINTENANCE
16 Check a bo ts and nuts
l Check gh ness o bo s and nu s espec a y
eng ne moun ng ron and rear whee ax e nu s
and sw ng arm moun ng F g 2 17
17 Head amp beam ad ustment
l Check head amp beam pos on and ad us
requ red F g 2 18 Re er page no 2-21 or head
amp beam ad us men procedure
18 Battery top up and vo tage check
l Check ba ery e ec ro y e eve
be ween m n mum and max mum eve
up w h d s ed wa er on y
l Check ba ery vo age vo age s esser han 12V
charge he ba ery F g 2 19 Re er page no 2-20
or ur her de a s
19 Tyre pressure check
l Check yre pressure and ma n a n spec ed yre
pressure or good road s ab y and onger yre e
n a e yres o he pressure as g ven be ow
F g 2 20
Tyre pressure Front
Kg/cm² ps
So o r d ng 1 75 25
Dua r d ng 1 75 25
Periodic maintenance 2-8
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F g 2 17
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R DER WE GHT
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H m
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mm
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H m
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F g 2 18
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shou d be .....................................................................................................................................................................................................
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no op .....................................................................................................................................................................................................
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F g 2 19
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Rear .....................................................................................................................................................................................................
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Kg/cm² ps .....................................................................................................................................................................................................
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2 00 28 .....................................................................................................................................................................................................
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2 25 32 .....................................................................................................................................................................................................
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F g 2 20
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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20 Em ss on check .....................................................................................................................................................................................................
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l Check and se CO eve a eng ne d ng speed .....................................................................................................................................................................................................
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F g 2 21 Re er chap er 4 - Fue ubr ca on and .....................................................................................................................................................................................................
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exhaus sys em or carbure or c ean ng .....................................................................................................................................................................................................
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procedure .....................................................................................................................................................................................................
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M O
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Q M
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d ng CO% RTR-160 0 8 ~1 8 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
O
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d ng CO% RTR-180 2~3

21 Test dr ve
l Tes dr ve he veh c e and ascer a n smoo h
unc on ng o a con ro s and par s
l C ean he veh c e be ore de very
2
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F g 2 21
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Periodic maintenance 2-9

PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP
PROCEDURE
A R CLEANER ASSEMBLY
nspect and c ean at n t a 500 km and every
3000 km there after. Rep ace the parts f
necessary.
l The c ogged a r c eaner assemb y ncreases he
res s ance or a r n ake resu ng n decreased
power ou pu and ncreased ue consump on
Check and c ean he er comp e e a r c eaner n
he o ow ng procedure:
l Loosen and remove M6X16 - 1 no CRR pan head
screw rom cover rame L moun ng F g 2 22
Ph ps head screw dr ver
l Take ou cover rame L by care u y d s oca ng
rom ugs
l Loosen and remove CRR pan head screws
M5x16 - 4 nos Take ou n e comp e e a r
c eaner and rap comp e e ame a ong w h he
er comp e e a r c eaner F g 2 23
Ph ps head screw dr ver
l Separa e he er comp e e a r c eaner bo h
ayers rom rap comp e e ame F g 2 24
Periodic maintenance 2-10
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F g 2 23
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F g 2 24
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 PERIODIC MAINTENANCE

l Fill a pan of suitable size with cleaning solvent

(Kerosene). Immerse the filter complete air cleaner
in solvent and wash it thoroughly. KEROSENE
(Fig. 2.25)

Caution:
Do not use benzine for cleaning the filter
complete air cleaner.
1 2
l Squeeze the solvent off the washed filter by
pressing it between palms of hands. Do not twist or
wring the filter, else it will develop fissures. 4T OIL

l Immerse the filter in a pool of 4T oil, and squeeze

the excess oil off the filter to make it slightly wet.

l Clean case complete air cleaner thoroughly.

l Reassemble parts in the reverse order of 3 4

dismantling.

Caution: Fig. 2.25

Before and after cleaning operation,
examine the filter complete air cleaner for
any tear or cut. Replace if found torn or cut.

Position the filter complete air cleaner snugly

and correctly, so that no incoming air will by
pass it. Remember, rapid wear of valves, B
guide valves, seals valve stem oil, piston,
rings piston and cylinder is often caused by a
defective or incorrectly fitted filter element.

Check that gasket inlet (A) and gasket trap

flame (B) is intact and in good condition. A
(Fig. 2.26)

Fig. 2.26
CARBURETTOR ASSEMBLY

Clean & adjust at every 3000 km

l If engine performance is good, the adjuster (A)

(MCS screw) need not be disturbed. The idling
speed can be adjusted only by the adjuster (B)
(idling screw) to 1400 ± 100 rpm. Rotating the A
adjuster in clockwise direction increases the rpm
and rotating in counter clockwise decreases the B
rpm. (Fig. 2.27)

Note:
Inspect and set idling speed after attending
other maintenance jobs.

Fig. 2.27

Periodic maintenance 2-11

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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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l here s per ormance de er ora on c ean he .....................................................................................................................................................................................................
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carbure or and une .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Before tun ng carburettor, correct the free .....................................................................................................................................................................................................
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p ay of cab e assemb y thrott e to 1.0 mm to .....................................................................................................................................................................................................
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2.0 mm. (refer page no. 2-22 for deta s) .....................................................................................................................................................................................................
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Tune the carburettor as ment oned be ow: .....................................................................................................................................................................................................
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l Turn he m x ure vo ume con ro screw o spec ed .....................................................................................................................................................................................................
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urns ou rom he u y n gh pos on F g 2 28 .....................................................................................................................................................................................................
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MCS Pos on .....................................................................................................................................................................................................
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Apache RTR 160 2 ±1 .....................................................................................................................................................................................................
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Apache RTR 180 3 ±2 .....................................................................................................................................................................................................
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F a screw dr ver sma .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Do not over t ghten the m xture vo ume .....................................................................................................................................................................................................
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contro screw aga nst ts seat as t w damage .....................................................................................................................................................................................................
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the m x ng body assemb y and ts seat ng. .....................................................................................................................................................................................................
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l S ar he eng ne and a ow o warm up F g 2 28
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l Connec achome er cord o he H T Lead o know .....................................................................................................................................................................................................
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he eng ne rpm .....................................................................................................................................................................................................
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Tachome er .....................................................................................................................................................................................................
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l Ad us d ng screw so ha eng ne rpm d es a .....................................................................................................................................................................................................
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1400 ± 100 rpm F g 2 29 .....................................................................................................................................................................................................
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l A er ad us ng d ng rpm check CO% and .....................................................................................................................................................................................................
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read us he m x ure vo ume con ro screw .....................................................................................................................................................................................................
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necessary re er chap er ”Fue ubr ca on and .....................................................................................................................................................................................................
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exhaus sys em“ page no 4-11 or de a s .....................................................................................................................................................................................................
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C ean ng Procedure .....................................................................................................................................................................................................
F g 2 29
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l For remov ng d sman ng and c ean ng o he .....................................................................................................................................................................................................
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carbure or assemb y re er chap er “ ue o and .....................................................................................................................................................................................................
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exhaus sys em” page no 4-9 .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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After remount ng carburettor assemb y check .....................................................................................................................................................................................................
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for smooth operat on of gr p comp ete .....................................................................................................................................................................................................
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thrott e .....................................................................................................................................................................................................
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HOSE FUEL .....................................................................................................................................................................................................
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Rep ace at every three years .....................................................................................................................................................................................................
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l nspec hose ue and connec ons or any damage .....................................................................................................................................................................................................
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and eakage F g 2 30 any eakage no ced .....................................................................................................................................................................................................
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rep ace he par F g 2 30
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Periodic maintenance 2-12
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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CAP FUEL STRA NER .....................................................................................................................................................................................................
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Change at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
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there after. .....................................................................................................................................................................................................
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l D r y cup ue s ra ner w h sed men or wa er .....................................................................................................................................................................................................
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a ec s he smoo h ow o benz ne and may cause .....................................................................................................................................................................................................
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oss o eng ne power .....................................................................................................................................................................................................
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2
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l Loosen and remove cup ue s ra ner re a n ng .....................................................................................................................................................................................................
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cock assemb y ue n OFF pos on F g 2 31 .....................................................................................................................................................................................................
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F g 2 31
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10mm spanner .....................................................................................................................................................................................................
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l Remove O r ng and er F g 2 32 .....................................................................................................................................................................................................
F LTER
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l C ean er and cup ue s ra ner .....................................................................................................................................................................................................
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O R NG
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l Reassemb e par s n he reverse order o remova .....................................................................................................................................................................................................
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ENG NE CUM TRANSM SS ON O L CHANGE .....................................................................................................................................................................................................
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Rep ace at n t a 500 km and every 3000 km .....................................................................................................................................................................................................
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there after. .....................................................................................................................................................................................................
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F g 2 32
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l A er cer a n per od o use he eng ne cum .....................................................................................................................................................................................................
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ransm ss on o w ge con am na ed and .....................................................................................................................................................................................................
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acce era es he wear o s d ng and n er ock ng .....................................................................................................................................................................................................
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sur ace Rep ace eng ne cum ransm ss on o .....................................................................................................................................................................................................
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per od ca y by o ow ng he procedure g ven .....................................................................................................................................................................................................
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be ow: .....................................................................................................................................................................................................
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l S ar he eng ne and a owo warm up Remove .....................................................................................................................................................................................................
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gauge o eve o ac a e easy dra n ng o o .....................................................................................................................................................................................................
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F g 2 33 .....................................................................................................................................................................................................
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l Keep a bow under he eng ne .....................................................................................................................................................................................................
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F g 2 33
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l Loosen and remove hexagona ange head bo s .....................................................................................................................................................................................................
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M6x20 - 3 nos F g 2 34 .....................................................................................................................................................................................................
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8 mm spanner .....................................................................................................................................................................................................
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l Remove cap o s ra ner a ong w h O r ng and .....................................................................................................................................................................................................
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dra n he eng ne cum ransm ss on o .....................................................................................................................................................................................................
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F g 2 34
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Periodic maintenance 2-13

PERIODIC MAINTENANCE
l Loosen CRR pan head screw M4x10 - 2 nos and
remove he s ra ner comp e e eng ne o
F g 2 35 nspec s ra ner or any damage
Rep ace necessary O herw se c ean and
reassemb e n he reverse order o remova
Note:
Wh e reassemb ng, ensure that ‘O’ r ng s
f tted n cap o stra ner.
l F recommended 4T o re er chap er ”genera
n orma on” page no 1-9 or o recommenda on
1000 m Dur ng serv ce
O Quan y
1100 m Dur ng overhau
l Reassemb e gauge o eve
ENG NE CUM TRANSM SS ON O L LEVEL
l P ace he veh c e on cen re s and on a a sur ace
l Unscrew gauge o eve and w pe c ean y nser
he gauge n o s pos on by hread ng n
l Check o eve The o eve shou d be be ween
m n mum and max mum eve F g 2 36
l o eve s be ow he m n mum eve op-up w h
he recommended o up o he max mum eve
l Reassemb e gauge o eve
F LTER COMPLETE ENG NE O L
Rep ace at n t a 500 km and every 3000 km
there after.
l Be ore remov ng er comp e e eng ne o dra n
he eng ne cum ransm ss on o as per he
procedure men oned above
l Loosen and remove hexagona ange bo s
M6x65 - 2 nos and M6x16 - 1 no F g 2 37
8 mm spanner
Periodic maintenance 2-14
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F g 2 35
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MAX MUM
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O R NG
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M N MUM
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F g 2 36
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F g 2 37
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...............................................................................................................................................................

PERIODIC MAINTENANCE
l Remove cap o er a ong w h O r ng and
spr ng o er cap
l Remove er comp e e eng ne o A and O r ng
B F g 2 38
Note:
Keep a bow wh e open ng cap o f ter to
co ect the eft over o .
Wh e reassemb ng, remember to assemb e
the ‘O‘ r ngs (A & D) and spr ng o f ter (B).
(F g. 2.39)
Locate sea end (C) of the f ter towards
crankshaft. (F g. 2.39)
Whenever the f ter comp ete eng ne o s
rep aced, t s recommended that the eng ne
cum transm ss on o s a so rep aced.
l Reassemb e par s n he reverse order o
d sman ng
COMPRESS ON PRESSURE
nspect every 6000 km upto 18000 km and
every 3000 km there after.
l Warm-up he eng ne o norma
empera ure be ore s ar ng es
l Sw ch o he eng ne d sconnec sparkp ug cap
and remove sparkp ug
l Moun he compress on gauge adap or o spark
p ug ho e ensur ng no eak F g 2 40
Compress on gauge and spec a adap or
l W h he ue cock knob and gn on sw ch n
OFF pos on open he hro e u y Now crank
he eng ne by k ck s ar er or ve o s x k cks No e
he h ghes read ng on compress on gauge
compress on pressure
Compress on Pressure
S andard 10 - 13 kg/cm² 142 - 184 ps
Serv ce L m 8 kg/cm² 113 ps
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A
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2
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F g 2 38
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A
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B
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C
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D
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F g 2 39
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opera ng .....................................................................................................................................................................................................
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F g 2 40
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Periodic maintenance 2-15

PERIODIC MAINTENANCE
l compress on pressure s h gh nd ca es h gh
carbon depos on on combus on chamber and
p s on crown
l compress on pressure s ow pour 3 o 5 cc o
resh eng ne o n o he cy nder hrough
sparkp ug ho e and re-check he compress on
l compress on ncreases rom prev ous va ue
check or:
- Leaky gaske cy nder head
- Worn p s on r ngs
- Worn cy nder and p s on
- P s on r ng s ruck n he grooves
l compress on s same as he prev ous va ue
check he va ves or eakage
HEAD COMPLETE CYL NDER, P STON AND
P STON R NGS
Decarbon se at every 18000 km.
l Carbon depos s n he combus on chamber o
head comp e e cy nder and on p s on crown w
ncrease he compress on ra o and may cause
pre- gn on or over hea ng Carbon depos on a
exhaus s de o head comp e e cy nder w
preven smoo h ow o exhaus reduc ng he
eng ne power ou pu Remove carbon depos s
per od ca y us ng su ab e c ean ng so ven
F g 2 41
Note:
Decarbon se the combust on chamber after
remov ng both the va ves.
l Ensure no o damage he sur ace o he
combus on chamber wh e decarbon s ng
VALVE, GU DE VALVE AND SEAT VALVE
Decarbon se at every 18000 km.
l Carbon depos s on va ve s em F g 2 42 rubs
con nuous y on gu de va ve and h s w resu n
ncreased c earance be ween he va ve and gu de
va ve
Periodic maintenance 2-16
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...............................................................................................................................................................

PERIODIC MAINTENANCE
l Check and c ean carbon depos s on va ve s em
and gu de va ve
l Carbon depos on on va ve sea ng causes
mproper sea ng o va ve hereby caus ng
eakage and h s w a ec d ng rpm p ck up and
ue consump on Th s w a so ead o erra c
runn ng and s ar ng roub e
l C ean sea va ve w h benz ne and nspec or
wear Rep ace va ve here s any p ng or sharp
edges a he sea ng area re er chap er “serv c ng
o eng ne“ or va ve gu de va ve and va ve sea
serv c ng procedure
VALVE (TAPPET) CLEARANCE
nspect and ad ust at n t a 500 km and every
3000 km there after.
l Remove cover rame R by un ock ng he cover
rame ock us ng con ro key F g 2 43
l Take ou cover rame R by care u y d s oca ng
rom he ugs
l Gen y pu ou cab e comp e e sea and ake ou
he sea assemb y by d s oca ng rom he ug
F g 2 44
l Turn ue cock knob o OFF pos on and
d sconnec ue hose rom he carbure or assemb y
l Remove hexagona ange bo M8x25 - 1no
rom he ue ank moun ng a ong w h bush ue
ank rear moun ng F g 2 45
l Remove ue ank comp e e rom s pos on by
d s oca ng rom he cush on ue ank ron and
d sconnec ng ue sender un w r ng socke
Note:
Wh e reassemb ng fue tank comp ete,
ensure that fue sender un t w r ng socket s
connected and fue tank dra n hose s routed
proper y.
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Periodic maintenance 2-17
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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l D sconnec HT H gh Tens on card and remove .....................................................................................................................................................................................................
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he sparkp ug A F g 2 46 B
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B
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l Remove bo h he cap nspec on ho e B .....................................................................................................................................................................................................
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F g 2 46
A
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l Remove p ug TDC A and p ug cranksha ho e B .....................................................................................................................................................................................................
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F g 2 47 .....................................................................................................................................................................................................
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A
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17 mm spanner .....................................................................................................................................................................................................
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l A gn he TDC mark A on ro or assemb y w h .....................................................................................................................................................................................................
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cen re o he nspec on ho e prov ded n he cover .....................................................................................................................................................................................................
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magne o by ro a ng he ro or assemb y F g 2 48 .....................................................................................................................................................................................................
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A
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17 mm ubu ar spanner .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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At th s po nt both the rocker arm shou d have .....................................................................................................................................................................................................
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free p ay. Otherw se rotate the rotor .....................................................................................................................................................................................................
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assemb y one more comp ete round and .....................................................................................................................................................................................................
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a gn the mark aga n. .....................................................................................................................................................................................................
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F g 2 48
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l Measure va ve c earance when he eng ne s n .....................................................................................................................................................................................................
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co d cond on F g 2 49 .....................................................................................................................................................................................................
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0310100 Fee er gauge .....................................................................................................................................................................................................
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Va ve Standard .....................................................................................................................................................................................................
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n e va ve 0 06 mm .....................................................................................................................................................................................................
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Exhaus 0 08mm .....................................................................................................................................................................................................
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Periodic maintenance 2-18

PERIODIC MAINTENANCE
l c earance measured s ncorrec oosen he nu
appe ad us ng F g 2 50
9 mm spanner
l Ad us va ve c earance us ng a spec a oo
F g 2 50
M1310010 Too appe ad us er
Fee er gauge
l A er ob a n ng spec ed c earance gh en he nu
appe ad us ng ho d ng he screw appe
ad us ng n he same pos on us ng spec a oo
SPARKPLUG
l Check sparkp ug or s ype F g 2 51
Sparkp ug BOSCH UR5DDC
C ean at n t a 500 km and every 3000 km
there after. Rep ace at every 8000 km.
l s very mpor an o ake spec a care or
sparkp ug a ng wh ch eads o s ar ng
prob em and poor per ormance
l Carbon depos s on sparkp ug gap preven good
spark ng and cause m s r ng Remove sparkp ug
and c ean proper y
Caut on:
Before remov ng sparkp ug, use compressed
a r to b ow away any d rt around sparkp ug
mount ngto prevent t from fa ng ns de the
cy nder. C ose the p ug ho e w th c ean c oth.
l Check spark p ug or wear o cen ra and ground
e ec rodes e her o hem are worn-ou rep ace
he sparkp ug w h a new one
Caut on:
Do not ad ust the spark p ug e ectrode gap
Do not use f ared stee cab es to c ean
sparkp ug.
Use on y recommended make and type of
sparkp ug
l Do no over gh en or cross hread he
sparkp ug as o herw se a um n um hreads o
head comp e e w be damaged
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Periodic maintenance 2-19

PERIODIC MAINTENANCE
BATTERY ASSEMBLY
Check and top-up at n t a 500 km and every
3000 km there after.
l V sua y nspec he sur ace o ba
con a ner any s gn o crack ng
eakage rom s des o he ba ery
no ced rep ace ba ery assemb y w
l he ba ery assemb y ead erm na s are ound
rus y w h an ac d c wh e powdery subs ance hen
c ean hem w h sand paper
l Check ou pu vo age o he ba ery
l shou d be more han 12 8 V when measured
us ng a mu me er F g 2 52
Note:
f battery output vo tage s ess than 11V,
then the battery shou d be recharged
l Add d s ed wa er as necessary o keep he
sur ace o he e ec ro y e above he ower eve ne
bu no above he upper eve ne F g 2 53
Caut on:
Do not add tap water or ac d for topp ng up
the battery assemb y. Use on y d st ed water.
Note:
wh e remov ng the battery assemb y
term na s, remove ’– ve’ term na f rst. Wh e
reconnect ng, connect ’+ ve’ term na f rst.
l Per od ca y check he e ec ro y e or spec c
grav y by us ng a hydrome er o nd he s a e o
charge ba ery s ge ng d scharged requen y
check he charg ng sys em F g 2 54
E ectro yte spec f c grav ty at 30° C
Battery type Charged Under charged
12V 9 0 Ah 1 28
l spec c grav y read ng s no n norma
cond on nd ca es ha ba ery assemb y needs
recharg ng Recharge he ba ery assemb y w h
cons an curren ba ery charger
Periodic maintenance 2-20
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ery assemb y .....................................................................................................................................................................................................
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or e ec ro y e .....................................................................................................................................................................................................
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assemb y are .....................................................................................................................................................................................................
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h a new one .....................................................................................................................................................................................................
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F g 2 52
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F g 2 53
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HYDROMETER
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1 24
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1 24 .....................................................................................................................................................................................................
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F g 2 54
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PERIODIC MAINTENANCE
HEAD LAMP BEAM ADJUSTMENT
nspect and ad ust at n t a 500 km and every
3000 km there after.
l Keep ng he b ke n a s ra gh ne s on he b ke o
a m he head amp beam ver ca y Focus head amp
h gh beam on a ver ca screen wh ch s a a
d s ance o 10 me ers rom he head amp s cen re
po n Ad us head amp assemb y such ha he oca
po n o h gh beam on he screen s 100 mm ower
han he head amp beam cen re F g 2 55
Note:
Head amp focus shou d be ad usted on y
when the head amp n h gh beam.
Head amp ens cen e
100 mm
Head beam oca po n
10 me e s
F g 2 55
l For ad us ng he beam ocus s gh y oosen
hexagona screw M6x20 - 1 no o hous ng
head amp ron bo om moun ng F g 2 56
l Care u y ad us he head amp assemb y by
press ng orward or reverse o ob a n he spec ed
ocus eng h Ho d ng he head amp n ha
pos on gh en he screw
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R DER WE GHT
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F g 2 56
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Periodic maintenance 2-21

PERIODIC MAINTENANCE
CABLE ASSEMBLY THROTTLE - FREE PLAY
nspect and ad ust at every 3000 km.
l For check ng cab e assemb y hro e p ay rs
d s oca e he boo hro e A rom s pos on
F g 2 57
l Gen y pu he cab e assemb y hro e ho d ng he
ad us er B o check he ree p ay ree p ay s
more or ess ad us as o ows:
Free p ay 1 0 - 2 0 mm
l Loosen ock nu A and urn ad us er B n or ou
un he spec ed p ay s ob a ned F g 2 58
8 mm spanner
l T gh en ock nu A wh e ho d ng he ad us er B
n p ace F g 2 58
l A er ad us ng s ar he veh c e e he eng ne run
n d e urn he hand e bar o ex reme r gh and e
check whe her d ng rpm var es var es check
rou ng o cab e and read us he ree p ay
CABLE ASSEMBLY CLUTCH - FREE PLAY
nspect and ad ust at n t a 500 km and every
3000 km there after.
l Cab e assemb y c u ch ree p ay s one o he mos
mpor an ad us men s wh ch may need o check
regu ar y or smoo her gear sh ng and be er e
o he c u ch p a es
l Measure ree p ay a he ever assemb y c u ch end
as shown n he gure F g 2 59
Note:
Ad ust c utch p ay when the eng ne s n co d
cond t on.
Free p ay 5 - 10 mm
l p ay s more or ess oosen he ock nu A and
urn he ad us ng nu B C ockw se ro a on
reduces he p ay and coun er c ockw se ro a on
ncreases he p ay A er ad us ng o spec ed p ay
gh en he ock nu A ho d ng he ad us ng nu
B n he ha pos on F g 2 60
12 mm spanner
Periodic maintenance 2-22
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F g 2 57
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F g 2 58
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F g 2 59
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F g 2 60
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PERIODIC MAINTENANCE
BRAKES
Warn ng:
Brakes are for persona safety and shou d
a ways be ma nta ned n proper cond t on.
FRONT BRAKE (D SC BRAKE)
Check and top-up brake f u d at n t a 500
km and every 3000 km there after. Change
the brake f u d and rep ace the pr mary,
secondary cups of cy nder assemb y master
(p ston k t) at every 20000 km. Rep ace hose
comp ete brake at every three years.
Brake f u d and ts hand ng
nspect ng brake f u d eve
l Be sure o check u d eve n he reservo r For
nspec ng brake u d eve p ace he b ke rm y
on cen er s and w h he hand ebar pos oned
s ra gh
l he eve s ound o be ower han he mark
LOWER prov ded on he reservo r rep en sh he
reservo r w h he resh brake u d F g 2 61
Brake u d DOT 3 or DOT 4
Note:
S nce the G yco based brake f u d used by
the manufacturer n these b kes, do not use,
do not use or m x d fferent types of f u d such
as s con based and petro eum based f u d
for ref ng the system, otherw se damage
susta ned w be ser ous.
Do not use any brake f u d taken out from o d
or used, or unsea ed conta ners.
Ensure no water enters the brake f u d
conta ner. Because brake f u d has
hygroscop c property, and ts bo ng po nt
fa s excess ve y f water s m xed w th t.
Check brake hose for any cracks and hose
o nts for eakage.
Caut on:
Do not squeeze the brake ever when the
reservo r cap s removed, otherw se brake
f u d w somet mes sp out.
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F g 2 61
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Periodic maintenance 2-23

PERIODIC MAINTENANCE
Caut on:
Do not put the removed reservo r cap on the
speedometer or tachometer. Brake f u d w
damage the pa nt surface and nstrument
c uster enses.
A r b eed ng from brake system
l brake ever rave becomes excess ve or he ever
ee s a so or spongy ee ng a r b eed ng mus be
carr ed ou as per o ow ng procedure:
Note:
t s best, f two persons perform a r b eed ng.
Keep the f u d eve n the reservo r ust above
the ‘Lower‘ mark dur ng the b eed ng
procedure.
1 A ach b eeder ube o he b eeder screw a er
remov ng he cap b eeder as shown n F g 2 62
A ransparen ube s use u n nd ng a r bubb e
expe ed rom he sys em
2 The open end o ube mus be submerged n a
c ean con a ner par a y ed w h brake u d
3 F he reservo r w h he brake u d
4 F x he cap on he reservo r o preven a spou o
brake u d and en ry o dus
5 Deve op pressure n he hydrau c sys em by
opera ng rap d y he brake ever severa mes and
hen ho d ng he ever gh
6 Unscrew open he b eeder by ha urn and
depress he ever a he way ns de Do no re ease
he ever un he b eeder screw s gh ened u y
F g 2 63
10 mm spanner
7 Repea s ep 5 and 6 un a r bubb es d sappear n
he b eeder ube or con a ner and screw n c ose
he b eeder screw secure y
8 Remove b eeder ube and ns a he b eeder va ve
dus cap
9 Check u d eve n he reservo r and rep en sh
necessary a er he comp e on o b eed ng
opera on
10 Re ns a d aphragm and gh en reservo r cap
secure y
Caut on:
Do not reuse the brake f u d dra ned from the
system.
Periodic maintenance 2-24
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F g 2 62
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F g 2 63
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...............................................................................................................................................................

PERIODIC MAINTENANCE
Brake f u d rep acement
l Bo ng po n o brake u d a s cons derab y w h
absorp on o mo s ure wh ch may ake p ace
dur ng a ong per od o use There ore s .....................................................................................................................................................................................................
recommended o rep ace o d brake u d w h resh
one per od ca y
Rep ace brake u d every 1 year or 20 000 km
l On chang ng brake u d ex reme a en on
shou d be pa d so as no o m x any ore gn
ma er a s because hey wou d b ock he re urn por
o he mas er cy nder resu ng n he brake
dragg ng or squeak ng
When brake u d needs o be changed per orm he
o ow ng procedure:
1 A ach a b eeder ube o he b eeder Dra n ou
o d brake u d by squeez ng he brake ever w h
b eeder opened cond on un he brake u d
d sappears n he b eeder ube
2 Once he brake u d s dra ned ou rom he
sys em comp e e y carry ou he same procedure
as descr bed n a r b eed ng rom brake sys em
Hose comp ete brake
l nspec hose comp e e brake or any cracks or
eakage eakages ound rep ace hose as be ow:
l F ush brake u d by open ng b eeder a ca per
assemb y w h a ube on he b eeder head o a
c ean con a ner re er a r b eed ng
l Remove ban o bo s 2 nos a bo h ends o he
hose comp e e brake Take ou he gaske s
F g 2 64A & 2 64B
12 mm spanner
l Remove he screw a ong w h spr ng washer and
ake ou c amp hose under bracke F g 2 65
l Remove hexagona screw a ong w h he spr ng
washer and ake ou c amp brake hose F g 2 65
l Remove brake hose rom he veh c e
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F g 2 64A F g 2 64B
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F g 2 65
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Periodic maintenance 2-25
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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mmed ate y w pe off the brake f u d .....................................................................................................................................................................................................
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contact ng any part of the b ke. The f u d .....................................................................................................................................................................................................
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reacts chem ca y w th pa nt, p ast cs, rubber .....................................................................................................................................................................................................
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mater a s etc., and w damage them .....................................................................................................................................................................................................
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severe y. .....................................................................................................................................................................................................
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l Reassemb e new brake hose n he reserve order o .....................................................................................................................................................................................................
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d sman ng .....................................................................................................................................................................................................
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l T gh en ban o bo s a bo h he ends a ong w h .....................................................................................................................................................................................................
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gaske s 2 nos each s de .....................................................................................................................................................................................................
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12 mm spanner .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Ensure to assemb e new gaskets on the .....................................................................................................................................................................................................
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ban o bo ts. Do not use o d gaskets. .....................................................................................................................................................................................................
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l B eed he a r rom he brake c rcu a er .....................................................................................................................................................................................................
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reassemb ng he brake hose re er a r b eed ng .....................................................................................................................................................................................................
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sys em page 2-24 .....................................................................................................................................................................................................
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Rep ace brake hose a every 3 year or 60 000 km .....................................................................................................................................................................................................
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Brake pads rep acement .....................................................................................................................................................................................................
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l Remove ca per moun ng bo s and ake ou he .....................................................................................................................................................................................................
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ca per F g 2 66 .....................................................................................................................................................................................................
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12 mm spanner .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Remove front brake ever before d smant ng .....................................................................................................................................................................................................
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the ca per assemb y. .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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C ean mud and dust off around the front .....................................................................................................................................................................................................
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whee and ca per pr or to d smant ng. .....................................................................................................................................................................................................
F g 2 66
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l Remove p ug p n 2 nos rom he body ca per .....................................................................................................................................................................................................
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F g 2 67 .....................................................................................................................................................................................................
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F a head screw dr ver .....................................................................................................................................................................................................
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F g 2 67
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Periodic maintenance 2-26

PERIODIC MAINTENANCE
l Loosen and ake ou p n hanger 2nos
5 mm a en key
l Pu ou pad comp e e nner and pad comp e e
ou er by hand F g 2 69
nspect on of brake pads
l Observe wear m ne marked on he pad and
check wear cond on o brake pads F g 2 70
wear exceeds he m ne hen rep ace he pads
as a se w h a new one
Note:
Brake pad wear can be checked w thout
remov ng the ca per assemb y from the fork.
Caut on:
t s recommended to rep ace brake pads
on y as a set for better brak ng performance.
l App y grease o he p n bo s o he bracke
comp e e ron
l For reassemb y o brake pads o ow he reverse
order o d sman ng procedure
REAR BRAKE (DRUM BRAKE MODEL)
nspect and ad ust at n t a 500 km and every
3000 km there after.
l Measure he rave d s ance o brake peda
comp e e by app y ng he rear brake F g 2 71
Peda ree p ay 15 - 25 mm
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F g 2 70
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F g 2 71
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Periodic maintenance 2-27

PERIODIC MAINTENANCE
l d s ance s more or ess urn he rear brake
ad us ng nu o ge he spec ed p ay C ockw se
ro a on o nu decreases he p ay and coun er
c ockw se ro a on ncreases he p ay F g 2 72
14 mm spanner
l Brake n ng wear nd ca or A s prov ded on he
pane assemb y rear re er page 2-32 or brake
wear m de a s
REAR BRAKE (D SC BRAKE MODEL)
nspect ng brake f u d eve
l Be sure o check u d eve n he reservo r For
nspec ng brake u d eve pu he b ke rm y on
cen er s and and remove cover rame R re er
page 2-17 or remov ng cover rame R
l eve s ound o be ower han he mark M N
prov ded on he reservo r rep en sh w h he
spec ed resh brake u d F g 2 73 re er page
2-24 or brake u d and s hand ng a r b eed ng
and brake u d rep acemen de a s
Hose comp ete brake
l nspec hose comp e e brake or any damage or
eakage eakages ound rep ace he hose as
be ow:
l F ush he brake u d by open ng b eeder screw a
ca per assemb y w h a ube on he b eeder head
o a c ean con a ner re er brake b eed ng
l Remove ban o bo s 2 nos a bo h he ends o
hose comp e e brake and ake ou gaske s
F g 2 74A & F g 2 74B
12 mm spanner
l D s oca e hose rom he gu de hose sw ng arm
F g 2 75
l Remove brake hose rom he veh c e
Caut on:
mmed ate y w pe off the brake f u d
contact ng any part of the b ke. The f u d
reacts chem ca y w th pa nt, p ast cs, rubber
mater a s etc., and w damage them
severe y.
Periodic maintenance 2-28
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A
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F g 2 72
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MAX MUM LEVEL
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M
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M M N MUM LEVEL
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F g 2 73
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F g 2 74A F g 2 74B
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F g 2 75
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PERIODIC MAINTENANCE
l Reassemb e new brake hose n he reserve order o
d sman ng
l T gh en ban o bo s a bo h he ends a ong w h
gaske s 2 nos each s de
Caut on:
Ensure that new gaskets are assemb ed w th
the ban o bo ts. Do not use o d gaskets. A so
take spec a care to ensure that brake hose s
not n contact w th any mov ng component.
l B eed a r rom he brake c rcu a er reassemb ng
he brake hose re er a r b eed ng sys em
Rep ace brake hose every 3 year or 60 000 km
Rear Brake pads rep acement
l Loosen and remove rear whee ax e U nu
F g 2 76A
22 mm spanner
l S gh y pu ou ax e rear rom he e s de wh e
gen y app ng a r gh s de F g 2 76B
l D s oca e ca per assemb y rom he s o prov ded
on sw ng arm comp e e by pu ng owards rear
s de
l Remove spacer rear ax e R F g 2 77
l Loosen and remove p ug p n 1no rom he body
comp e e ca per assemb y F g 2 78A
F a head screw dr ver
l Loosen and ake ou p n hanger 1no
F g 2 78B
5 mm a en key
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Periodic maintenance 2-29

PERIODIC MAINTENANCE
l Pu ou pad comp e e nner and pad comp e e
ou er by hand F g 2 79
nspect on of brake pads
l Observe he wear m ne marked on he pad
and check wear cond on o brake pads
F g 2 70 wear exceeds he m ne hen
rep ace he pads as a se w h a new one Re er
page no 2-27 or nspec on o brake pads
WHEEL ASSEMBLY FRONT (D SC BRAKE MODEL)
Remova
l P ace he b ke on cen er s and and p ace a ack or
b ock o keep he ron whee o he ground
l Remove U nu a ong w h he punched washer
F g 2 80
17 mm spanner
l Draw ou ax e ron rom L s de a ong w h washer
wh e gen y app ng a R s de F g 2 81
l Take ou whee assemb y ron a ong w h he d sc
p a e and spacer comp e e L
l Take ou speed sensor rom he whee assemb y
ron and hang on he rame se
Note:
After tak ng out front whee assy keep some
cush on n between the brake pads, to avo d
b nd ng.
Reassemb y
l Reassemb e whee assemb y ron n he reverse
order o d sassemb y and remova
l Be ore assemb ng ron whee assemb y ubr ca e
he ax e ron and bear ngs
l Make sure ha he s o A n he speed sensor s .....................................................................................................................................................................................................
over he s opper B on he ron ork ou er ube L
F g 2 82
Periodic maintenance 2-30
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F g 2 79
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B
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A
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F g 2 82
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...............................................................................................................................................................

PERIODIC MAINTENANCE
l Remove ack or b ock p aced wh e remov ng he
whee assemb y
l Be ore gh en ng U nu o ax e ron s roke he
ork assemb y ron severa
proper ork ac on
l T gh en U nu
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mes o check or .....................................................................................................................................................................................................
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2
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Note: .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Wh e remount ng front whee assemb y .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
ensure to ocate the d sc n between the .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
brake pads after remov ng cush on. .....................................................................................................................................................................................................
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WHEEL ASSEMBLY REAR (DRUM BRAKE MODEL) .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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l Remove nu rear brake rod ad us er A F g 2 83 .....................................................................................................................................................................................................
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14 mm spanner .....................................................................................................................................................................................................
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A C
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l Remove sp pn B rom he orque nk rear .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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moun ng F g 2 83 .....................................................................................................................................................................................................
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Nose p er .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
B
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l Remove hexagona nu M8 C a ong w h he .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
F g 2 83
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
wave spr ng washer and ake ou bo orque nk .....................................................................................................................................................................................................
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rear F g 2 83 .....................................................................................................................................................................................................
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14 mm spanner .....................................................................................................................................................................................................
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l D s oca e rod rear brake comp e e rom he ever .....................................................................................................................................................................................................
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rear brake cam .....................................................................................................................................................................................................
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l Take ou p n rear brake rod spr ng rear brake rod .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
ad us er and punched washer .....................................................................................................................................................................................................
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l Loosen and remove U nu M14x1 5 rom he .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
ax e comp e e rear a ong w h he washer .....................................................................................................................................................................................................
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F g 2 84 .....................................................................................................................................................................................................
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F g 2 84
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22 mm spanner .....................................................................................................................................................................................................
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l Pu ou ax e comp e e rear by gen y app ng a .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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o her s de F g 2 85A .....................................................................................................................................................................................................
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l Remove spacer rear ax e R F g 2 85B .....................................................................................................................................................................................................
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l Wh e ng he b ke o he e s de ake ou he .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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whee assemb y rear .....................................................................................................................................................................................................
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F g 2 85A F g 2 85B
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...............................................................................................................................................................
Periodic maintenance 2-31
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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l Take ou pane assemb y rear rom he whee .....................................................................................................................................................................................................
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assemb y rear F g 2 86 .....................................................................................................................................................................................................
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F g 2 86
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Pane assemb y (rear whee ) .....................................................................................................................................................................................................
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l Remove brake shoe se rear rom he pane .....................................................................................................................................................................................................
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assemb y rear a ong w h spr ng brake shoe .....................................................................................................................................................................................................
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F g 2 87 .....................................................................................................................................................................................................
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NSPECT ON .....................................................................................................................................................................................................
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Before nspect on, c ean a necessary .....................................................................................................................................................................................................
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components w th su tab e c ean ng so vent .....................................................................................................................................................................................................
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and ubr cate them. .....................................................................................................................................................................................................
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F g 2 87
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Shoe comp ete brake .....................................................................................................................................................................................................
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l nspec n ng brake shoe sur ace or g aze M nor .....................................................................................................................................................................................................
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g aze can be correc ed by c ean ng w h coarse .....................................................................................................................................................................................................
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emery paper .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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After po sh ng shoe comp brake, c ean the .....................................................................................................................................................................................................
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surface w th dry c oth. .....................................................................................................................................................................................................
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l H gh y g azed shoes mus be rep aced .....................................................................................................................................................................................................
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l Measure n ng brake shoe h ckness as shown .....................................................................................................................................................................................................
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F g 2 88 he h ckness measured s ess han .....................................................................................................................................................................................................
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he serv ce m rep ace shoe comp e e brake w h .....................................................................................................................................................................................................
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a new one as a se .....................................................................................................................................................................................................
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Vern er ca per .....................................................................................................................................................................................................
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Serv ce m 1 5 mm .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Rep ace shoe comp ete brake on y as a set . .....................................................................................................................................................................................................
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l nspec brake shoe spr ng or correc s ness and .....................................................................................................................................................................................................
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any damage .....................................................................................................................................................................................................
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F g 2 88
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...............................................................................................................................................................
Periodic maintenance 2-32
 .....................................................................................................................................................................................................
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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Brake drum (a oy whee rear) .....................................................................................................................................................................................................
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l Measure nner d ame er o he brake drum rear .....................................................................................................................................................................................................
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whee a 3 o 4 p aces d ame er exceeds he .....................................................................................................................................................................................................
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serv ce m hen rep ace he a oy whee rear w h .....................................................................................................................................................................................................
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a new one F g 2 89 .....................................................................................................................................................................................................
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Vern er ca per .....................................................................................................................................................................................................
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2
.....................................................................................................................................................................................................
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Serv ce m 130 7 mm .....................................................................................................................................................................................................
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l nspec brake drum nner sur ace or grease or .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
scra ches Use a rag soaked n acquer h nner or .....................................................................................................................................................................................................
F g 2 89
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
so ven o c ean he drum M nor scra ches can be .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
po shed w h an emery paper .....................................................................................................................................................................................................
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l he brake drum scored heav y hen rep ace he .....................................................................................................................................................................................................
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a oy whee rear .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
WHEEL ASSEMBLY REAR (D SC BRAKE MODEL) .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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Remova .....................................................................................................................................................................................................
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l Remove U nu M14x1 50 rom he ax e .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
comp e e rear a ong w h washer F g 2 90A .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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F g 2 90A F g 2 90B
.....................................................................................................................................................................................................
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22mm spanner .....................................................................................................................................................................................................
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l Pu ou ax e comp e e rear by gen y app ng a .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
o her end F g 2 90B .....................................................................................................................................................................................................
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l D s oca e ca per assemb y rom he s o prov ded .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
on sw ng arm comp e e by pu ng owards rear .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
s de .....................................................................................................................................................................................................
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l Remove spacer rear ax e R F g 2 91 .....................................................................................................................................................................................................
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l Wh e ng he b ke o he e s de ake ou .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
whee assemb y rear .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................

Reassemb y
l Reassemb e whee assemb y rear n he reverse
order o d sassemb y and remova
l Make sure ha he p pe A n he ca per assemb y
s be ween he gu des B on he sw ng arm
comp e e F g 2 92
F g 2 91
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A
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F g 2 92
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...............................................................................................................................................................
Periodic maintenance 2-33

PERIODIC MAINTENANCE
CHA N ASSEMBLY DR VE
nspect, c ean and ad ust at n t a 500 km
and every 3000 km. f necessary, check and
ad ust at every 1000 km.
Lubr cate on the veh c e at every 1000 km by
proper ubr cant.
l P ace he b ke rm y on cen re s and
l Pu he ransm ss on n neu ra gear and urn he
rear whee s ow y by hand
l V sua y nspec cha n assemb y dr ve or he be ow
s ed poss b e abnorma es
- Loose p ns
- Damaged ro ers
- Rus ed nks
- Tw s ed or se zed nks
- Excess ve wear
l any de ec s ound cha n assemb y dr ve mus be
rep aced w h a new one
Cha n s ackness:
l P ace he b ke rm y on cen re s and
l Check he dr ve cha n or spec ed s ackness
F g 2 93
S ackness
l s ackness ound more or ess ad us as o ows:
l Loosen U nu o ax e comp e e rear F g 2 94
22 mm spanner
Periodic maintenance 2-34
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F g 2 94
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PERIODIC MAINTENANCE
l Loosen hexagona nu o sprocke drum assemb y
moun ng F g 2 95
27 mm spanner
l Loosen ock nu A and B and urn he nu cha n
ad us er C and D ook ng a he ne mark on cha n
ad us er L and R E and F Thread ng n reduces he
s ackness and hread ng ou ncreases he s ackness
A er ach ev ng spec ed s ackness gh en he ock
nu A and B F g 2 96 & F g 2 97
10 mm spanner
l T gh en U nu o ax e comp e e rear and
hexagona nu o sprocke drum assemb y
moun ng o he spec ed orque Re er chap er-7
“Serv ce n orma on” page no 7-8 or orque
de a s
Caut on:
To ma nta n proper whee a gnment, ad ust
both the cha n ad uster un form y.
Warn ng:
Ad ustment of cha n s ackness w d sturb the
or g na brake ad ustment. Hence t s h gh y
essent a to check and read ust the rear
brake.
Cha n c ean ng
C ean and ubr cate cha n assemb y dr ve off
the veh c e at every 3000 Km.
l Loosen hex bo s M6x12 - 2 nos rom cover
comp e e cha n and ake ou cover comp e e
cha n F g 2 98
10 mm spanner
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F g 2 97
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Periodic maintenance 2-35

PERIODIC MAINTENANCE
l Un ock nk se o cha n assemb y dr ve and
remove F g 2 99
Comb na on p er
l C ean cha n assemb y dr ve by d pp ng
kerosene or d ese Brush o any d r s ck ng o
l A er ak ng ou rom he soak ng w pe o excess
kerosene or d ese w h so c o h and a ow o dry
Warn ng:
Do not use meta w re brush or any other
hard brushes, as th s w damage ‘O’ r ng.
Do not soak the cha n n kerosene or d ese
for more than 10 m ns.
Cha n wear
l Coun 21 p ns on he cha n assemb y dr ve and
measure he d s ance be ween 20 p ch
F g 2 100 measured d s ance exceeds he
serv ce m rep ace he cha n w h a new one
Serv ce m 256 mm
Vern er ca per
Cha n ubr cat on
measured d s ance s w h n he m ubr ca e cha n
by carry ng ou o ow ng s eps :
l M x grease and 4T eng ne o n 1:1 propor on
horough y
l Lubr ca e he cha n by sock ng n h s m x ure or
m n mum 15 m ns F g 2 101
l Dra n he excess m x ure by hang ng cha n n
ver ca d rec on or 10m ns
Caut on:
Do not use mo ten grease to ubr cate ‘O’
r ng cha n.
l Reassemb e cha n n he reverse order o remova
Note:
Before reassemb ng cha n assemb y, c ean
the sprocket eng ne and sprocket rear.
Warn ng:
Assemb e nk set cha n ock p ate n such
way that the s t end faces the oppos te
d rect on of the cha n rotat on to avo d severe
damages. (F g. 2.102)
Periodic maintenance 2-36
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F g 2 99
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D RECT ON OF TRAVEL
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F g 2 102
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...............................................................................................................................................................

PERIODIC MAINTENANCE
STEER NG
nspect and ad ust at n t a 500 km and every
3000 km there after.
l S eer ng shou d be ad us ed correc y or smoo h
movemen o hand ebar and or sa e r d ng S
s eer ng preven s smoo h movemen o hand e bar
resu ng n poor d rec ona s ab y and oo oose
s eer ng causes v bra on and damage o he
s eer ng bear ngs
l Check o see ha here s no p ay n he s eer ng
bear ngs F g 2 103 any p ay s ound ad us
he s eer ng as exp a ned be ow:
l Remove hexagona socke head screw M6x30 -
2 nos rom he cover upper bracke moun ng
and remove cover upper bracke F g 2 104
5mm A en key
l S gh y oosen he ock nu s eer ng F g 2 105
32 mm spanner
l Us ng spec a oo urn he arres or s eer ng s em
e her c ockw se or an c ockw se o reduce or o
ncrease s eer ng p ay respec ve y F g 2 106
0313801 Un versa c amp wrench
l T gh en ock nu s eer ng o he spec ed orque
Re er chap er-7 “Serv ce n orma on” page no
7-8 or orque de a s
Note:
After ad ustment ensure smooth movement
of hand e bar. When s ow y moved by hand,
t shou d move free y from the centre pos t on
to e ther eft or r ght w th ts own we ght.
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F g 2 106
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Periodic maintenance 2-37
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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l any p ay s s ound nspec o ow ng ems and .....................................................................................................................................................................................................
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rep ace a ec ed par s wherever necessary re er .....................................................................................................................................................................................................
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chap er “chass s“ or remova check ng and .....................................................................................................................................................................................................
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reassemb y procedures .....................................................................................................................................................................................................
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• Wear o race s eer ng nner and ou er .....................................................................................................................................................................................................
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• Wear o cup bo om and cone bo om .....................................................................................................................................................................................................
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• Wear or damage o ba s s eer ng .....................................................................................................................................................................................................
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• Number o ba s .....................................................................................................................................................................................................
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• D s or on o ower bracke comp e e .....................................................................................................................................................................................................
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Number of ba s .....................................................................................................................................................................................................
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Upper race 22 nos 4 762 mm d a .....................................................................................................................................................................................................
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Lower race 19 nos 6 35 mm d a .....................................................................................................................................................................................................
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FRONT FORK O L .....................................................................................................................................................................................................
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nspect for eakage at n t a 500 km and .....................................................................................................................................................................................................
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every 3000 km there after. Change every .....................................................................................................................................................................................................
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18000 km. .....................................................................................................................................................................................................
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l Remove bo h eg assemb es ron ork Re er .....................................................................................................................................................................................................
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chap er “chass s“ or remova c ean ng and .....................................................................................................................................................................................................
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assemb y procedures .....................................................................................................................................................................................................
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l Dra n ork o and c ean he eg assemb es .....................................................................................................................................................................................................
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l Pour recommended brand o o spec ed amoun .....................................................................................................................................................................................................
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rom he op o he nner ube assemb y .....................................................................................................................................................................................................
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F g 2 107 .....................................................................................................................................................................................................
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O quant ty per eg .....................................................................................................................................................................................................
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G L make 140 ± 2 0 m .....................................................................................................................................................................................................
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TOP make 152 ± 2 5 m .....................................................................................................................................................................................................
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Spec ca on Te eshockab o .....................................................................................................................................................................................................
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Warn ng: .....................................................................................................................................................................................................
F g 2 107
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Apache RTR comes w th ‘G L or TOP’ make of .....................................................................................................................................................................................................
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front fork, care must be taken such that eg .....................................................................................................................................................................................................
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assemb y o quant ty a ways matches w th ts .....................................................................................................................................................................................................
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respect ve make. .....................................................................................................................................................................................................
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nspect at n t a 500 km and at every 3000 .....................................................................................................................................................................................................
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km there after. .....................................................................................................................................................................................................
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Periodic maintenance 2-38

PERIODIC MAINTENANCE
Tyre tread cond t on:
l Us ng he veh c e w h excess ve y worn yres w
decrease r d ng s ab y and consequen y nv e a
dangerous s ua on due o oss o con ro
h gh y recommended o rep ace he yre w h a
new one when he groove dep h o yre rom read
sur ace reaches he o ow ng spec ca ons:
F g 2 108
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2
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Serv ce m t .....................................................................................................................................................................................................
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Fron 1 5 mm .....................................................................................................................................................................................................
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F g 2 109
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Rear 1 5 mm .....................................................................................................................................................................................................
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Tyre dep h gauge .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Tyre depth a so can be checked by tyre wear .....................................................................................................................................................................................................
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nd cator. (F g. 2.109) .....................................................................................................................................................................................................
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Tyre pressure: .....................................................................................................................................................................................................
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l Under n a ed yres wear as er a ec s ab y and .....................................................................................................................................................................................................
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smoo h corner ng Over n a ed yres decrease .....................................................................................................................................................................................................
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area o yre con ac w h ground caus ng sk d or .....................................................................................................................................................................................................
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F g 2 110
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oss o con ro .....................................................................................................................................................................................................
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l Ma n a n proper yre pressure or good road .....................................................................................................................................................................................................
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s ab y and onger yre e n a e yres n co d .....................................................................................................................................................................................................
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cond on o he pressure as g ven be ow: .....................................................................................................................................................................................................
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F g 2 110 .....................................................................................................................................................................................................
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Tyre pressure gauge .....................................................................................................................................................................................................
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Tyre pressure Front Rear .....................................................................................................................................................................................................
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Kg/cm² ps Kg/cm² ps .....................................................................................................................................................................................................
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So o r d ng 1 75 25 2 00 28 .....................................................................................................................................................................................................
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Dua r d ng 1 75 25 2 25 32 .....................................................................................................................................................................................................
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BOLTS AND NUTS .....................................................................................................................................................................................................
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nspect and t ghten at n t a 500 km and .....................................................................................................................................................................................................
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every 3000 km there after. .....................................................................................................................................................................................................
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l A he nu s and bo s mus be n good cond on .....................................................................................................................................................................................................
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or sa e y They mus be checked and re - gh ened .....................................................................................................................................................................................................
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as necessary o he spec ed orque Re er .....................................................................................................................................................................................................
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chap er-7 “serv ce n orma on“ page no 7-8 or .....................................................................................................................................................................................................
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orque de a s .....................................................................................................................................................................................................
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Periodic maintenance 2-39
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PERIODIC MAINTENANCE .....................................................................................................................................................................................................
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LUBRICATION POINTS .....................................................................................................................................................................................................
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Warn ng: .....................................................................................................................................................................................................
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Do not app y too much grease to the brake cam shafts. f grease gets on the n ngs, brake s ppage w
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resu t. .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Lubr cate exposed parts wh ch are sub ect to rust, w th e ther motor o or grease whenever the veh c e has
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been operated under wet or ra ny cond t ons. .....................................................................................................................................................................................................
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Before ubr cat ng each part, c ean off any rusty spots and w pe off any grease, o , d rt or gr me.
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STEER NG STEM BEAR NGS .....................................................................................................................................................................................................
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G ease THROTTLE GR P G ease
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BRAKE CAM G ease
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n case o d um b ake
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K CK STARTER PEDAL P VOT
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OL
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DR VE CHA N
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G ease + 4T o
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BRAKE PEDAL SHAFT
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G ease .....................................................................................................................................................................................................
SW NG ARM BEAR NGS G ease
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F g 2 111 .....................................................................................................................................................................................................
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Periodic maintenance 2-40

SERVICING OF ENGINE
ENGINE OVERHAUL
Be ore beg nn ng eng ne overhau observe eng ne
cond ons or he o ow ng:
l C ean ness
l Compress on pressure
l Any abnorma no se
l O eak seepage any
To overhau he gears sha comp e e coun er sha
comp e e dr ve k ck s ar er and cranksha assemb y
he crank cases need o be separa ed
CLUTCH REMOVAL AND SERV C NG
C u ch assemb y can be serv ced w h he eng ne
moun ed on he veh c e Norma y c u ch s serv ced
or:
l Loss o power
l Jerk ng o veh c e
l Any abnorma no se rom c u ch
l Dra n eng ne cum ransm ss on o as exp a ned n
chap er “Per od c ma n enance” A er dra n ng
a ways measure he o quan y us ng a measur ng
ar
l Remove er comp e e eng ne o as exp a ned n
chap er “Per od c ma n enance”
l Remove hexagona bo M8x35 - 1no rom he
ever assemb y k ck s ar er moun ng and pu ou
ever assemb y k ck s ar er F g 3 1
13 mm spanner
l Loosen ock nu A and ad us ng nu B rom he
cab e assemb y c u ch moun ng F g 3 2
12 mm spanner
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A
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Fg 3 2
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Servicing of engine 3-1
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Us ng 20 mm open end spanner ro a e he arm .....................................................................................................................................................................................................
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c u ch re ease owards ron n such a way ha .....................................................................................................................................................................................................
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cab e assemb y c u ch can be d s oca ed rom he .....................................................................................................................................................................................................
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arm c u ch re ease F g 3 3 .....................................................................................................................................................................................................
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20 mm spanner .....................................................................................................................................................................................................
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l D s oca e cab e assemb y c u ch rom he bracke .....................................................................................................................................................................................................
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c u ch cab e F g 3 4 .....................................................................................................................................................................................................
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l Remove un on bo o p pe a ong w h gaske o .....................................................................................................................................................................................................
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p pe un on 2 nos Fg 3 5 .....................................................................................................................................................................................................
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10 mm spanner .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Wh e reassemb ng ensure the presence of .....................................................................................................................................................................................................
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gaskets at both s de of the p pe comp ete o . .....................................................................................................................................................................................................
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Fg 3 5
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l Remove hexagona ange bo s M6x30 - 10 nos .....................................................................................................................................................................................................
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rom he cover c u ch moun ng F g 3 6 8
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9
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7
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10
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8 mm spanner .....................................................................................................................................................................................................
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l Take ou cover c u ch by gen y app ng 6

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Ny on hammer .....................................................................................................................................................................................................
5
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4 1
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l Take ou gaske cover c u ch and dowe p n c u ch .....................................................................................................................................................................................................
3 2
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cover 2 nos .....................................................................................................................................................................................................
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Fg 3 6
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Servicing of engine 3-2

SERVICING OF ENGINE
l Co ec p n c u ch re ease rom cover c u ch /
c u ch assemb y
l Take ou adop er p n c u ch re ease rom he c u ch
assemb y F g 3 7
Note:
ns de the adopter c utch re ease, a stee ba
s prov ded. Wh e reassemb ng ensure the
presence of the ba .
l Remove hexagona ange head bo s M6x20 - 4
nos rom he p a e c u ch re ease moun ng
Fg 3 8
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Fg 3 7
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3
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10 mm spanner .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Carry out un form oosen ng and t ghten ng .....................................................................................................................................................................................................
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of p ate c utch re ease bo ts n cr sscross .....................................................................................................................................................................................................
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pattern to avo d uneven oad ng of p ate. .....................................................................................................................................................................................................
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l Take ou p a e c u ch re ease .....................................................................................................................................................................................................
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Fg 3 8
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l Take ou spr ng c u ch 4 nos Fg 3 9 .....................................................................................................................................................................................................
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l Us ng spec a oo ho d he d sc c u ch pressure and Fg 3 9
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remove nu c u ch sha s o ed nu F g 3 10 .....................................................................................................................................................................................................
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N2310010 C u ch ho d ng oo .....................................................................................................................................................................................................
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N2310020 C u ch nu gh en ng oo .....................................................................................................................................................................................................
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24 mm spanner .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Assemb e a the bo ts (4 nos) of p ate c utch .....................................................................................................................................................................................................
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re ease a ong w th the c utch ho d ng spec a .....................................................................................................................................................................................................
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too . Do not exper ment w th two bo ts .....................................................................................................................................................................................................
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mounted d agona y. F g 3 10
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Servicing of engine 3-3

SERVICING OF ENGINE
l Take ou spr ng d sc rom c u ch sha F g 3 11
Note:
Wh e reassemb ng, ocate the spr ng d sc n
such a way that the concave face d ameter of
washer faces towards outs de.
l Pu ou d sc c u ch pressure a ong w h he hub
c u ch p a e c u ch dr ve 5 nos and p a e c u ch
dr ven 4 nos as a se F g 3 12
l Separa e d sc c u ch pressure hub c u ch p a e
c u ch dr ve and p a e c u ch dr ven F g 3 13
l Remove hrus washer c u ch hub rom he sha
comp e e coun er F g 3 14A
l Pu ou gear assemb y pr mary dr ven rom he
sha comp e e coun er a ong w h c p pr mary
dr ven gear F g 3 14B
Note:
Wh e reassemb ng, ock the gear assemb y
pr mary dr ven w th gear comp ete k ck
starter dr ven gear groove.
Servicing of engine 3-4
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F g 3 11
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F g 3 12
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F g 3 13
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F g 3 14A F g 3 14B
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SERVICING OF ENGINE
INSPECTION
Plate clutch drive
l Inspect plate clutch drive thickness using vernier
caliper. (Fig. 3.15).
l If thickness is less than the service limit, change the
plate clutch drive as a set.
Vernier caliper
Service limit
l Inspect claw width of plate clutch drive using
vernier caliper. (Fig. 3.16). If the claw width is less
than the service limit change the plate clutch drive
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2.6 mm .....................................................................................................................................................................................................
F g 3 15
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as a set.
Vernier caliper
Service limit 15.2 mm
l Also check plates for burning due to excessive
friction / contaminated or low oil level. Inspect
plate clutch drive claws for indents (cut marks) due
to regular thrust from the housing clutch.
Plate clutch driven
l Inspect plate clutch driven distortion using a feeler
gauge and surface plate as shown in the figure.
(Fig. 3.17)
l Check plates individually. Hold the plates with
three fingers and insert the feeler gauge between
the surface plate and driven plate at 3 to 4
locations.
l If distortion is more than the service limit change
3
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F g 3 16
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the plate clutch driven as a set. F g 3 17

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Service limit 0.1 mm .....................................................................................................................................................................................................
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Spring clutch .....................................................................................................................................................................................................
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l Measure free length of the spring clutch. If it .....................................................................................................................................................................................................
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reaches the service limit, replace with new one. .....................................................................................................................................................................................................
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(Fig. 3.18) .....................................................................................................................................................................................................
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Vernier caliper .....................................................................................................................................................................................................
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Service limit 28.7 mm .....................................................................................................................................................................................................
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F g 3 18
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Servicing of engine 3-5


SERVICING OF ENGINE
Caution:
Spring clutch is graded and identified with
different colour codes. While reassembling
ensure the spring clutches of same colour
codes are assembled.
Gear assembly primary driven (housing clutch)
l Inspect housing clutch for the indents / cuts
created by the plate clutch drive. (Fig. 3.19)
Hub clutch
l Inspect hub clutch for wear. If any ridges or cuts
formed in the hub clutch by the clutch plates, then
replace with a new one. Also check lubrication
holes for any blockage. (Fig. 3.20)
REASSEMBLY
l Reassemble parts in the reverse order of
disassembly.
l While reassembling, inspect the bearing clutch
release plate for any abnormal noise and smooth
rotation. Replace bearing with a new one if found
defective.
l While reassembling, ensure the clutch plates are
held firmly together by checking the play between
the drive plates after tightening the plate clutch
release. (Fig. 3.21)
l Before reassembling cover clutch, ensure that the
pin clutch release and ball are assembled properly
inside the adopter clutch release. Also inspect the
gasket cover clutch for any damage.
l Adjust clutch play. (refer chapter-2 “periodic
maintenance” page no. 2-22 for adjustment
procedure)
l Refill engine cum transmission oil. (refer chapter-2
“periodic maintenance” page no. 2-13 for oil
filling procedure)
Servicing of engine 3-6
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..............................................................................................................................................

SERVICING OF ENGINE
ENGINE ASSEMBLY - REMOVAL FROM THE
VEHICLE
The procedure for engine assembly removal is
sequentially explained in the following steps:
l Clean engine assembly thoroughly before taking it
out from the vehicle.
l Drain engine cum transmission oil as explained in
the chapter “periodic maintenance”.
l Remove clutch assembly as explained earlier.
(refer page no. 3.1)
l Turn the fuel cock knob to ‘OFF’ position.
Dislocate hose clip and disconnect fuel hose from
carburettor assembly. (Fig. 3.22)
Nose plier
l Loosen and remove (M6x16 - 1no) CRR pan head
screw from the cover frame L mounting. (Fig. 3.23)
l Take out cover frame L by carefully dislocating it
from the lugs.
l Unlock cover frame R by control key. (Fig. 3.24)
l Take out cover frame R by carefully dislocating it
from the lugs.
l Gently pull out cable complete seat and take out
seat assembly by dislocating it from the lugs.
(Fig. 3.25)
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F g 3 22
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F g 3 23
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Fig. 3.25
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Servicing of engine 3-7

SERVICING OF ENGINE
l Remove hexagona ange bo M8x25 - 1 no
rom he ue ank moun ng a ong w h bush ue
ank rear moun ng F g 3 26
12 mm spanner
l Remove ue ank comp e e rom s pos on by
d s oca ng rom he cush on ue ank ron and
d sconnec ng ue sender un w r ng socke
Note:
wh e reassemb ng fue tank comp ete,
ensure that fue sender un t w r ng socket s
connected and fue tank dra n hose s routed
proper y .
l D sconnec HT cord rom he spark p ug and
remove spark p ug F g 3 27
P ug spanner
l D s oca e boo A remove + ve erm na screw
and d sconnec he w re rom he mo or assemb y
s ar er F g 3 28
l Remove moun ng bo B M6x25 - 1no o mo or
assemb y s ar er mo or assemb y and d sconnec
he – ve w re F g 3 28
Ph ps head screw dr ver
Note:
Before d sconnect ng w res from the starter
motor assemb y, make sure that battery
assemb y s d sconnected from the w r ng
harness.
l D s oca e hose c p A & B rom he ube brea her
and ake ou ube brea her F g 3 29
Nose p er
Servicing of engine 3-8
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F g 3 29
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SERVICING OF ENGINE
l D s oca e hose c p A rom he hose a r n e and
pu ou hose a r n e F g 3 30
Nose p er
l Remove CRR pan head screw M6x16 - 2 nos
a ong w h punched washer rom he a r c eaner
moun ng F g 3 31
l Loosen c amp ou e p pe screw A F g 3 32
l Remove a r c eaner assemb y
l Loosen c amp n ake p pe screw B rom he o her
s de o he carbure or F g 3 32
l Gen y pu ou carbure or assemb y rom he p pe
comp e e n ake and p ace on he rame a ong
w h cab e assemb y hro e and cab e comp e e
choke
l Remove hexagona screw A M6x20 - 1 no rom
he arm gear sh er and remove SBHC screw B
rom he gear sh er ever moun ng F g 3 33
10 mm spanner
5 mm a en key
l Pu ou gear sh er nkage assy
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F g 3 30
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F g 3 31
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F g 3 32
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F g 3 33
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Servicing of engine 3-9

SERVICING OF ENGINE
l Remove CRR pan head screw (M6x20 - 2 nos)
from the cover engine sprocket and take out cover
engine sprocket. (Fig. 3.34)
Philips head screw driver
l Remove hexagonal screw (M5x10 - 2 nos) from
the lock plate engine sprocket. (Fig. 3.35)
8 mm spanner
l Take out lock plate after dislocating it from the
shaft complete drive grooves.
l Pull out chain assembly drive along with sprocket
engine.
l Dislocate sprocket from the drive chain. Hang the
drive chain in the frame.
l Disconnect all the wiring sockets from magneto
assembly connected to wiring harness. (Fig. 3.36)
l Remove hexagonal flange bolt (M8x25 - 2 nos)
from the muffler complete front mounting.
(Fig. 3.37)
12 mm spanner
Servicing of engine 3-10
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F g 3 34
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F g 3 35
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F g 3 36
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F g 3 37
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SERVICING OF ENGINE
l Remove hexagona bo M8x60 - 1 no rom he
mu er assemb y rear moun ng a ong w h
punched washers and U nu F g 3 38
12 mm spanner
l Take ou mu er assemb y by d s oca ng
he cy nder head assemb y
l Take ou gaske exhaus rom he head comp e e
cy nder F g 3 39
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F g 3 38
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Sma screw dr ver
Note:
Wh e reassemb ng rep ace the gasket
exhaust p pe w th a new one.
l Remove hexagona screw M6x16 - 1 no a ong
w h spr ng washer and ake ou p pe comp e e
secondary a r n ec on a ong w h he O r ng
F g 3 40
8 mm spanner
Note:
Wh e reassemb ng do remember to
assemb e ‘O’ r ng n the p pe comp ete
secondary a r n ect on.
l D s oca e hose c p A and d sconnec he hose a r
cu va ve B F g 3 41
l D s oca e hose c p no 1 C and d sconnec he
hose a r ou e D rom he secondary a r n ec on
va ve F g 3 41
Nose p er
3
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F g 3 39
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F g 3 40
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A D
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F g 3 41
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Servicing of engine 3-11

SERVICING OF ENGINE
l Remove eng ne assemb y op moun ng
hexagona ange bo M8x55 - 3 nos F g 3 42
12 mm spanner
l Take ou bo h he bracke eng ne moun ng upper
L and R a ong w h he secondary a r n ec on
va ve
l Remove hexagona ange bo M8x72 - 1 no
rom he ron moun ng o eng ne F g 3 43
12 mm spanner
l Remove hexagona bo s M8x16 - 4 nos rom
he bracke comp e e eng ne moun ng ron L & R
and separa e he bracke comp e e guard cen er
F g 3 44
12 mm spanner
l Take ou bracke eng ne moun ng ron L & R
l Remove hexagona ange bo s M8x95 - 1 no
and M8x120 - 1 no rom he rear moun ng o
he eng ne assemb y F g 3 45
12 mm spanner
Note:
Wh e remov ng mount ng bo ts, a ways
bottom bo t shou d be removed f rst.
Eng ne mount ng nuts are of se f ock ng type
and therefore shou d not be reused.
l Gen y he eng ne assemb y w h bo h he hands
and ake ou rom he r gh hand s de o he veh c e
P ace he eng ne assemb y on a eng ne res
Servicing of engine 3-12
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F g 3 42
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F g 3 43
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F g 3 44
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F g 3 45
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SERVICING OF ENGINE
ENG NE ASSEMBLY - D SASSEMBLY
l Remove c rc p rom he sha comp e e gear sh
and ake ou washer F g 3 46
0310017 Snap r ng p er - Ex erna
l Remove CRPH screw M6x12 - 2 nos rom he
re a ner dr ve sha moun ng F g 3 47
l Loosen CRR pan head screw and d sconnec he
neu ra ear h w re rom he body gear sh sw ch
F g 3 48
l Remove CRR pan head screw M5x20 -3 nos
a ong w h spr ng and p a n washer rom he body
gear sh moun ng F g 3 49
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F g 3 46
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F g 3 47
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F g 3 48
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F g 3 49
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Servicing of engine 3-13

SERVICING OF ENGINE
l Take out gasket gear shift switch.
l Remove contact complete gear shift switch (A) by
loosening recessed CSK head screw (B).
(Fig. 3.50)
Note:
While reassembling contact comp gear shift,
locate the projection of contact to the groove
on shaft for proper indication of neutral
position.
l Remove hexagonal flange bolts (M6x40 - 9 nos)
from the cover magneto mounting. (Fig. 3.51)
8 mm spanner
l Remove cover magneto by gently tapping with the
nylon hammer along with starter assembly.
Nylon hammer
l Take out gasket magneto cover and dowel pin.
l Remove spacer starter idle gear (A) and pin
magneto cover (B). (Fig. 3.52)
l Take out gear starter idle (C). (Fig. 3.52)
Nose plier
l Remove stopper starter gear. (Fig. 3.53)
Servicing of engine 3-14
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F g 3 50
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4
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1
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9
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7
8 6
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F g 3 51
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F g 3 52
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F g 3 53
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SERVICING OF ENGINE
l Remove un on bo o p pe 2 nos a ong w h
gaske s o p pe un on 4 nos and ake ou he
p pe comp e e head T/M o F g 3 54
10 mm spanner
Caut on:
Wh e reassemb ng un on bo ts, ensure that
bo t hav ng sma er o de very ho e (b ack
f n sh) s assemb ed on the crankcase
comp ete L and other two bo ts hav ng arger
o de very ho e (br ght f n sh) are assemb ed
on crankcase comp ete R and head assemb y
cy nder. (F g. 3.55A)
Note:
Wh e reassemb ng, ocate the gasket o
p pe un on on both the s de of the p pe end as
shown n the f gure. (F g. 3.55B)
l Remove hexagona ange bo M6x25 - 1 no
rom he mo or assemb y s ar er moun ng and
remove he mo or assemb y s ar er a ong w h he
O r ng F g 3 56
8 mm spanner
Note:
Wh e reassemb ng motor assemb y starter,
make sure the presence of ‘O’ r ng.
l Remove bo gear sh cam s opper and pu ou
s opper comp e e gear sh a ong w h he spr ng
gear sh cam s opper and sh m F g 3 57
10 mm spanner
Note:
Wh e reassemb ng, ensure that sh m s
ocated proper y under the stopper comp ete
gear sh ft, before t ghten ng the bo t gear
sh ft cam stopper. After t ghten ng check cam
stopper for free movement.
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F g 3 54
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F g 3 55A F g 3 55B
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F g 3 56
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F g 3 57
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Servicing of engine 3-15
...............................................................................................................................................................
 .....................................................................................................................................................................................................
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Remove recessed CSK head screw M6x16 - 1 no .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
rom he ndex s ar moun ng and ake ou ndex .....................................................................................................................................................................................................
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s ar F g 3 58 .....................................................................................................................................................................................................
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Ph ps head screw dr ver .....................................................................................................................................................................................................
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F g 3 58
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l Remove sha comp e e gear sh by pu ng .....................................................................................................................................................................................................
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ou s de F g 3 59 .....................................................................................................................................................................................................
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F g 3 59
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l Remove p n ho der comp e e rom he cam gear .....................................................................................................................................................................................................
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sh F g 3 60 .....................................................................................................................................................................................................
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F g 3 60
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l Remove CRR pan head screw M6x12 - 1 no rom .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
he re a ner T/M o gu de and ake ou he re a ner .....................................................................................................................................................................................................
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F g 3 61A .....................................................................................................................................................................................................
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Ph ps head screw dr ver .....................................................................................................................................................................................................
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l Gen y pu ou gu de T/M o rom he crankcase .....................................................................................................................................................................................................
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assemb y F g 3 64B .....................................................................................................................................................................................................
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Nose p er .....................................................................................................................................................................................................
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F g 3 61A F g 3 61B
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...............................................................................................................................................................
Servicing of engine 3-16
 .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Remove E-r ng rom he o pump sha and ake .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
ou gear o pump dr ven F g 3 62 .....................................................................................................................................................................................................
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Sma a screw dr ver .....................................................................................................................................................................................................
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F g 3 62
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l Remove p n o pump dr ven gear A F g 3 63 .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
Nose p er .....................................................................................................................................................................................................
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3
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l Remove CRR CSK head screw M6x20 - 3 nos .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
A
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
rom he pump assemb y o and pu ou pump .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
assemb y F g 3 63 .....................................................................................................................................................................................................
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Ph ps head screw dr ver .....................................................................................................................................................................................................
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F g 3 63
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l Un o d washer pr mary dr ven gear F g 3 64 .....................................................................................................................................................................................................
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Ch se / me a hammer .....................................................................................................................................................................................................
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F g 3 64
.....................................................................................................................................................................................................
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l Us ng spec a oo ho d he ro or assemb y .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
and remove hexagona nu M6x1 5 F g 3 65 .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
M1310010 Ho der assemb y magne o .....................................................................................................................................................................................................
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22 mm spanner .....................................................................................................................................................................................................
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l Take ou washer pr mary dr ve gear .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
Note: .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
Wh e reassemb ng, rep ace washer w th a .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
new one. .....................................................................................................................................................................................................
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F g 3 65
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Servicing of engine 3-17
...............................................................................................................................................................
 .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Remove gear o pump dr ve A F g 3 66 .....................................................................................................................................................................................................
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l Remove gear pr mary dr ve B F g 3 66 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
A
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Note: .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
B
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Wh e reassemb ng pr mary dr ve gear, .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
assemb e pr mary gear n such a way that ts .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
stepped s de s fac ng towards crankshaft .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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bear ng. .....................................................................................................................................................................................................
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F g 3 66
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
l Take ou key 4x4x15 rom he cranksha .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
assemb y F g 3 67 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Nose p er .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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F g 3 67
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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l Remove bo ad us er assemb y ens oner and ake .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
ou he bo F g 3 68 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
10 mm spanner .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
F g 3 68
.....................................................................................................................................................................................................
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l Take ou O r ng A F g 3 69 .....................................................................................................................................................................................................
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l Remove hexagona screws M6x20 - 2 nos rom

he ad us er assemb y ens oner moun ng and
ake ou ad us er a ong w h he gaske F g 3 69
10 mm spanner
Servicing of engine 3-18
A
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F g 3 69
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SERVICING OF ENGINE
l Remove bo h he cap nspec on ho e a ong w h
O r ng F g 3 70
17 mm spanner
Note:
Wh e reassemb ng cap nspect on ho e
ensure that ‘O’ r ng s f tted.
l A gn TDC mark A on ro or assemb y w h he
crankcase mark B by ro a ng he ro or assemb y
F g 3 71
17 mm ubu ar spanner
Note:
At th s po nt both the arm comp ete va ve
rocker shou d be free. Otherw se rotate the
rotor assemb y for a another fu rotat on and
a gn the mark aga n.
l Remove hexagona ange bo s M6x55 - 4 nos
A M6x45 - 2 nos B and M6x35 - 4 nos C
rom cover cy nder head moun ng a ong w h 4
nos o gaske cy nder head F g 3 72
10 mm spanner
Note:
Wh e reassemb ng, nsert a the bo ts f rst
and check equa he ght of bo ts from the r
respect ve seat ng surfaces. Before
t ghten ng, nspect the gasket cy nder head
cover bo t for any damage. Rep ace f
necessary.
l Take ou p n cy nder head cover knock - 2nos A
F g 3 73
Nose p er
l Take ou p ug cy nder head B F g 3 73
Caut on:
Wh e reassemb ng, app y qu d gasket on
p ug cy nder head per phery.
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F g 3 70
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B
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3
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A
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F g 3 71
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B
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C
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C
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A
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B
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C
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C
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F g 3 72
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F g 3 73
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Servicing of engine 3-19
...............................................................................................................................................................

SERVICING OF ENGINE
l Dislocate cam chain from the cam sprocket and
take out cam shaft assembly. (Fig. 3.74)
l Hold chain complete camshaft drive using a good
quality copper wire to prevent the chain from
falling into crankcase assembly and hang it on the
head complete cylinder.
l Unfold the washer sprocket. (Fig. 3.75)
Chisel / metal hammer
l Remove hexagonal screws (M6x12 - 2 nos) from
the sprocket camshaft. (Fig. 3.76)
8 mm spanner
l Remove washer sprocket and sprocket 34T.
l Take out pin sprocket knock from the camshaft
complete. (Fig. 3.77)
Nose plier
Servicing of engine 3-20
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F g 3 74
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F g 3 75
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F g 3 76
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F g 3 77
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...................................................................................................................................................................................

SERVICING OF ENGINE
l Take out C-ring camshaft from the head complete
cylinder. (Fig. 3.78)
Nose plier
l Remove hexagonal flange nuts (M6 - 2 nos)
fastened to head complete cylinder and cylinder
complete. (Fig. 3.79)
10 mm spanner
l Remove hexagonal flange nuts (M6 - 2 nos)
fastened to cylinder complete and crankcase
complete L. (Fig. 3.79)
10 mm spanner
l Remove domed nut with flange (M8 - 4 nos) from
the head complete cylinder mounting, in a
diagonal sequence. (Fig. 3.80)
12 mm spanner
l Remove punched washers (4 nos) from the head
complete cylinder. (Fig. 3.81)
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F g 3 78
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F g 3 79
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F g 3 80
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F g 3 81
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Servicing of engine 3-21

SERVICING OF ENGINE
l Ho d ng he cha n gen y he head comp e e
cy nder as an assemb y a ong w h ens oner cam
cha n F g 3 82
Note:
Gent y tap w th rubber ma et f requ red for
easy remova of head comp ete cy nder.
l Take ou gaske cy nder head F g 3 83
Note:
Wh e reassemb ng, check the gasket for any
damage, scor ng, deformat on or eakage
marks. f found defect ve rep ace the gasket
w th a new one.
l Remove dowe p n cy nder head knock 2 -nos
l Remove gu de cam cha n A rom he cy nder
comp e e F g 3 84
l Gen y pu ou cy nder comp e e by ho d ng he
connec ng rod by hand o avo d any damages o
he p s on assemb y and crankcase F g 3 85
l Remove gaske cy nder and dowe p n cy nder
knock
Nose p er
Servicing of engine 3-22
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F g 3 82
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F g 3 83
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A
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F g 3 84
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F g 3 85
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...............................................................................................................................................................

SERVICING OF ENGINE
l P ace a c ean c o h n he crankcase assemb y bore
o preven he a ng o c rc p p s on p n ns de he
crankcase wh e remov ng F g 3 86
l Remove c rc p p s on p n rom any one s de o he
p s on F g 3 86
Nose p er
l Gen y push and ake ou p n p s on rom he
p s on and hen ake ou p s on a ong w h he
r ngs p s on F g 3 87
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F g 3 86
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3
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F g 3 87
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l Remove hexagona ange bo M6x55 - 1 no .....................................................................................................................................................................................................
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rom he crankcase assemb y R F g 3 88 .....................................................................................................................................................................................................
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8 mm spanner .....................................................................................................................................................................................................
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F g 3 88
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l Us ng spec a oo ho d he ro or assemb y and .....................................................................................................................................................................................................
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remove hexagona ange nu M12x1 25 o ro or .....................................................................................................................................................................................................
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assemb y moun ng F g 3 89 .....................................................................................................................................................................................................
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M1310030 Ho der assemb y magne o .....................................................................................................................................................................................................
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17 mm spanner .....................................................................................................................................................................................................
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F g 3 89
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Servicing of engine 3-23
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Remove ro or assemb y by us ng a spec a oo .....................................................................................................................................................................................................
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F g 3 90 .....................................................................................................................................................................................................
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M1310020 Pu er assemb y magne o .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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A ways keep the rotor assemb y on a non .....................................................................................................................................................................................................
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meta c surface w th open s de, fac ng .....................................................................................................................................................................................................
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upwards. .....................................................................................................................................................................................................
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The magneto rotor assemb y a ways comes .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
out a ong w th c utch starter one way and .....................................................................................................................................................................................................
F g 3 90
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
gear comp ete starter c utch. (F g. 3.91) .....................................................................................................................................................................................................
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F g 3 91
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l Remove cha n comp e e camsha dr ve .....................................................................................................................................................................................................
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F g 3 92 .....................................................................................................................................................................................................
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F g 3 92
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l Take ou woodru key F g 3 97 .....................................................................................................................................................................................................
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Nose p er .....................................................................................................................................................................................................
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F g 3 93
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...............................................................................................................................................................
Servicing of engine 3-24
 .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Remove hexagona ange bo s M6x55 - 8 nos .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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A M6x75 - 3 nos B and M6x95 - 1 no C rom A
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
B
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
he crankcase moun ng F g 3 94 C A
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B
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8 mm spanner .....................................................................................................................................................................................................
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A
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Note: .....................................................................................................................................................................................................
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Wh e reassemb ng, nsert a the bo ts f rst A B
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and check equa he ght of bo ts from the r A
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respect ve seat ng surfaces. .....................................................................................................................................................................................................
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A
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A
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A
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F g 3 94
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l Us ng spec a oo separa e he crankcase .....................................................................................................................................................................................................
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assemb y by pu ng he crankcase comp e e L .....................................................................................................................................................................................................
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F g 3 95 .....................................................................................................................................................................................................

3
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M1310110 Pu er assemb y .....................................................................................................................................................................................................
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17 mm spanner .....................................................................................................................................................................................................
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8 mm spanner .....................................................................................................................................................................................................
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l Take ou p n crankcase 2 nos .....................................................................................................................................................................................................
F g 3 95
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Nose p er .....................................................................................................................................................................................................
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C B
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l Take ou sh m 16x30 5x0 5 A rom he sha A
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k ck s ar er F g 3 96 .....................................................................................................................................................................................................
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l Take ou sh m 15x30x1 B rom he sha .....................................................................................................................................................................................................
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comp e e dr ve F g 3 96 .....................................................................................................................................................................................................
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l Take ou bear ng k ck s ar er dr ven gear a ong .....................................................................................................................................................................................................
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w h he hrus washer and sh m C F g 3 96 .....................................................................................................................................................................................................
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F g 3 96
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l Take ou gear k ck s ar er dr ve rom he sha k ck .....................................................................................................................................................................................................
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s ar er F g 3 97 .....................................................................................................................................................................................................
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F g 3 97
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Servicing of engine 3-25
...............................................................................................................................................................

SERVICING OF ENGINE
l Take ou sha sh ork 2 nos rom he ork gear
sh s F g 3 98A & F g 3 98B
Nose p er
l D s oca e ork gear sh no 1 ork gear sh no 2
and ork gear sh h gh speed rom cam gear sh
l Take ou cam gear sh rom he crank case
assemb y F g 3 99
l Take ou ork gear sh no 1 ork gear sh no 2
and ork gear sh h gh speed rom gears a ong
w h spacer ro er gear sh ork p n 3 nos
F g 3 100
l Take ou sha comp e e dr ve and sha comp e e
coun er a ong w h he gears as an assemb y
F g 3 101
Servicing of engine 3-26
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F g 3 98A F g 3 98B
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F g 3 99
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F g 3 100
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F g 3 101
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...............................................................................................................................................................

SERVICING OF ENGINE
l Take ou hrus washer 20x27x1 rom he sha
comp e e dr ve sea ng area above he ba
bear ng F g 3 102
l Pu ou cranksha assemb y by gen y app ng
rom he o her s de F g 3 103
Ny on hammer
l Ro a e he sha k ck s ar er us ng ever assemb y
k ck s ar er and re ease he s ar er k ck rom he
gu de k ck s ar er F g 3 104
l Take ou s ar er k ck and spr ng k ck s ar er rom
he sha k ck s ar er F g 3 105
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F g 3 102
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3
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F g 3 103
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F g 3 104
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F g 3 105
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Servicing of engine 3-27
 .....................................................................................................................................................................................................
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Pu ou sha k ck s ar er a ong w h sh m spr ng .....................................................................................................................................................................................................
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k ck sha re urn and gu de k ck s ar er spr ng .....................................................................................................................................................................................................
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F g 3 106 .....................................................................................................................................................................................................
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F g 3 106
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l Separa e gu de k ck s ar er spr ng spr ng k ck sha .....................................................................................................................................................................................................
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re urn and sh m 14x32x1 F g 3 107 .....................................................................................................................................................................................................
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F g 3 107
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l Us ng spec a oo remove ba bear ng 6207 .....................................................................................................................................................................................................
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rom he cranksha assemb y n case he bear ng .....................................................................................................................................................................................................
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comes w h cranksha F g 3 108 .....................................................................................................................................................................................................
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S1311110 Ex rac or ma n bear ng .....................................................................................................................................................................................................
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17 mm spanner .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Remove bear ngs, on y f they need to be .....................................................................................................................................................................................................
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rep aced. Unnecessary remova of bear ngs .....................................................................................................................................................................................................
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shou d be avo ded, otherw se can damage .....................................................................................................................................................................................................
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the bear ng and can cause deter orat on to F g 3 108

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the nterference f t. t s suff c ent to c ean and .....................................................................................................................................................................................................
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ubr cate the bear ng n assemb ed cond t on. .....................................................................................................................................................................................................
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l Us ng spec a oo ba bear ngs 6207 63/28 .....................................................................................................................................................................................................
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6001 RS 6006 and 6204 RS can be removed .....................................................................................................................................................................................................
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and reassemb ed F g 3 109 .....................................................................................................................................................................................................
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S1310500 Bear ng ns a er se .....................................................................................................................................................................................................
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Me a hammer .....................................................................................................................................................................................................
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F g 3 109
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Servicing of engine 3-28
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Us ng spec a oo remove he o sea s F g 3 110 .....................................................................................................................................................................................................
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0312401 Un versa o sea remover .....................................................................................................................................................................................................
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F g 3 110
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TRANSM SS ON .....................................................................................................................................................................................................
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SHAFT COMPLETE DR VE - D SASSEMBLY .....................................................................................................................................................................................................
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3
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l Take ou gear comp e e k ck s ar er de .....................................................................................................................................................................................................
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F g 3 111 .....................................................................................................................................................................................................
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F g 3 111
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l Take ou gear comp e e 1s dr ven F g 3 112A .....................................................................................................................................................................................................
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l Take ou sh m 16 6x24x1 rom he sha .....................................................................................................................................................................................................
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F g 3 112B .....................................................................................................................................................................................................
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F g 3 112A F g 3 112B
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l Take ou gear 4 h dr ve F g 3 113 .....................................................................................................................................................................................................
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F g 3 113
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Servicing of engine 3-29

SERVICING OF ENGINE
l Remove c rc p 20x1 2 F g 3 114
0310017 Snap r ng p er - Ex erna
l Take ou sh m A F g 3 115
l Take ou gear 3rd dr ven B
l Take ou gear 5 h dr ven F g 3 116
l Take ou gear 2nd dr ven a ong w h bush
F g 3 117
Note:
Wh e reassemb ng gears ensure the proper
assemb y of bush.
Servicing of engine 3-30
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F g 3 114
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B
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F g 3 115 .....................................................................................................................................................................................................
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A
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F g 3 115
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F g 3 116
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F g 3 117
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...............................................................................................................................................................

SERVICING OF ENGINE
NSPECT ON
Shaft comp ete dr ve / shaft comp ete counter /
cam gear sh ft / dr ve gears and dr ven gears.
l Be ore nspec on c ean a he componen s
horough y w h c ean ng so ven
l Care u y nspec a par s or any scor ng marks
breakage wear o sp ned sur ace o he sha s /
gear ee h Rep ace damaged par s w h he new
ones
l Us ng a ee er gauge check he c earance
be ween ork gear sh and s sea ng groove on
he gear F g 3 118 measured c earance
exceeds he serv ce m de erm ne whe her he
gear or he ork gear sh shou d be rep aced w h
a new one
0310100 Fee er gauge
Descr pt on Serv ce m t
Fork gear sh o
0 50mm
groove c earance
REASSEMBLY
l For reassemb y reverse he remova procedure
Wh e reassemb ng gears a en on mus be g ven
o he oca ons and pos ons o washers and
c rc ps The exp oded v ew c ear y gu des proper
moun ng o he gears washers and c rc ps
F g 3 119
Caut on:
A ways use new c rc ps at the t me of
reassemb y.
When nsta ng a new c rc p, care must be
taken not to expand the end gap arger than
the requ red to s p c rc p over the shaft.
After nsta ng a new c rc p, a ways ensure
that t s comp ete y seated n ts groove and
secure y be ng ocked.
The f at surface of the c rc p shou d a ways
face towards the component be ng ocked.
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F g 3 118
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Servicing of engine 3-31

SERVICING OF ENGINE
GEAR COMPLETE K S DLE
GEAR COMPLETE 1s DR VEN
SH M 16 6x24x1
GEAR 4 h DR VEN .....................................................................................................................................................................................................
SH M 15x30x1
SH M
SH M
BEAR NG K S DR VE GEAR
SHAFT COMPLETE COUNTER
GEAR 4 h DR VE
F g 3 119
COVER CYL NDER HEAD - D SASSEMBLY
l Remove bo h he p ug rocker arm sha
exhaus a ong w h he gaske F g 3 120
8 mm a en key
Servicing of engine 3-32
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C RCL P 20x1 .....................................................................................................................................................................................................
2
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GEAR 3 d DR VEN
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GEAR 5 h DR VEN
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SHAFT COMPLETE DR VE
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SH M .....................................................................................................................................................................................................
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GEAR 2nd DR VEN
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BUSH
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THRUST WASHER 20x27x1
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GEAR 5 h DR VE
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GEAR 2nd DR VE
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C RCL P
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GEAR 3 d DR VE
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ne &
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F g 3 120
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SERVICING OF ENGINE
l Thread n M6 bo n o sha rocker arm and gen y
pu ou bo h he sha va ve rocker arm rom he
cover cy nder head F g 3 121
l Remove arm va ve rocker comp e e A .....................................................................................................................................................................................................
F g 3 121
l S m ar y remove o her arm va ve rocker comp e e
B F g 3 121
NSPECT ON
Cover cy nder head
l A er c ean ng qu d gaske rom he sur aces o
he cover cy nder head nspec sur ace or any
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A
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F g 3 121
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3
scra ches h gh and ow spo s no ced remove .....................................................................................................................................................................................................
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hem us ng a ne emery paper 400 grade p aced .....................................................................................................................................................................................................
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over he sur ace p a e .....................................................................................................................................................................................................
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l Us ng ee er gauge and sur ace p a e check cover .....................................................................................................................................................................................................
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cy nder head or d s or on F g 3 122 .....................................................................................................................................................................................................
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Fee er gauge .....................................................................................................................................................................................................
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Sur ace p a e .....................................................................................................................................................................................................
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F g 3 122
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Serv ce m 0 05 mm .....................................................................................................................................................................................................
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Shaft va ve rocker arm .....................................................................................................................................................................................................
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l nspec sha va ve rocker arm or any damages .....................................................................................................................................................................................................
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l Measure ou er d ame er OD o sha va ve rocker .....................................................................................................................................................................................................
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arm OD s ess han serv ce m rep ace he .....................................................................................................................................................................................................
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sha F g 3 123 .....................................................................................................................................................................................................
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Ou s de m crome er .....................................................................................................................................................................................................
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F g 3 123
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Serv ce m 11 686 mm .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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The OD shou d be checked at the seat ng .....................................................................................................................................................................................................
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area of arm comp ete va ve rocker. .....................................................................................................................................................................................................
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Servicing of engine 3-33

SERVICING OF ENGINE
Arm comp ete va ve rocker
l n TVS Apache RTR arm comp e e va ve rocker has
ro er o ower Ro er o ower s a s ee ro er
housed w h a need e cage Th s decreases he
oad exer ed by he va ve ra n on eng ne by
reduc ng he r c on F g 3 124
l nspec arm comp e e va ve rocker rocker arm or
wear damage or c ogged o ho e Measure he
n erna d ame er D D s more han he serv ce
m rep ace he arm F g 3 125
ns de m crome er
S andard 12 30 mm
REASSEMBLY
l Reassemb e cover cy nder head n reverse order
o remova
Caut on:
Wh e reassemb ng shaft va ve rocker arm,
re ef cut g ven n both the shaft shou d face
each other to enab e the cover cy nder head
bo ts to enter nto the groove. (F g. 3.126)
HEAD COMPLETE CYL NDER
D SASSEMBLY
l Remove bo cam cha n ens oner and remove he
ens oner cam cha n F g 3 127
12 mm spanner
l Take ou he gaske
Note:
Wh e reassemb ng tens oner cam cha n
ensure that gasket s assemb ed (copper).
Servicing of engine 3-34
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F g 3 124
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F g 3 125
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F g 3 126
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F g 3 127
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SERVICING OF ENGINE
l Moun he spec a oo o remove he va ves as he
movab e aw o he oo res s on re a ner va ve
spr ng F g 3 128A and he xed end o res a he
cen er o he va ve ace F g 3 128B
l S ow y gh en he spec a oo o compress he
spr ng va ve
Ex rac or assemb y n e and
S1310020
exhaus va ve
Caut on:
To prevent oss of tens on of the spr ng va ve,
do not compress the spr ng more than
requ red.
l Remove wo co er va ve rom he va ve s em
F g 3 129
Nose p er
l Loosen and ake ou spec a oo
l Remove re a ner va ve spr ng spr ng va ve ou er
and spr ng va ve nner F g 3 130
l Gen y push down he va ve rom op and remove
he va ve rom combus on chamber s de
F g 3 131
Note:
Wh e remov ng va ve, check for the free
movement of va ve. A so check va ve for
bend and runout. Rep ace the va ve ncase of
bend or runout.
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F g 3 128A F g 3 128B
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F g 3 129
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F g 3 131
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Servicing of engine 3-35

SERVICING OF ENGINE
l Take ou sea va ve s em o F g 3 132
Nose p er
Note:
Wh e reassemb ng, rep ace the sea va ve
stem o w th a new one.
l Take ou sea va ve spr ng F g 3 133
Nose p er
l Repea same procedure or remova o o her va ve
Note:
The p pe comp ete ntake need to be
removed on y ncase of rep acement. For
remov ng the p pe ntake oosen and remove
the CRR pan head screws (2 nos). (F g. 3.134)
DECARBON S NG
Head comp ete cy nder
l Carbon depos s on he combus on chamber o
he head comp e e cy nder ncrease he
compress on ra o wh ch wou d resu n pre-
gn on and over hea ng Carbon depos ed a
exhaus man o d preven s smoo h ow o exhaus
hereby reduc ng he eng ne power ou pu
l Decarbon se combus on chamber o head
comp e e cy nder us ng su ab e decarbon s ng
spray F g 3 135
Note:
Decarbon se head comp ete cy nder
combust on chamber after remov ng both
the va ves. Use su tab e c ean ng so vent.
Caut on:
Do not damage the surface of combust on
chamber wh e decarbon s ng.
Servicing of engine 3-36
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F g 3 132
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F g 3 133
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F g 3 134
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F g 3 135
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...............................................................................................................................................................

SERVICING OF ENGINE
Seat va ve
l Carbon depos s on va ve sea ng causes
mproper sea ng o va ves hereby caus ng
eakage and h s a so a ec s d ng p ckup and
m eage Th s a so eads o erra c runn ng and
s ar ng roub e
Va ve and va ve gu de
l Carbon depos s on va ve s em rubs con nuous y
on gu de va ve resu s n ncreased c earance
be ween s em and gu de va ve C ean va ve s em
w h he c ean ng so ven F g 3 136
l C ean gu de va ve and remove any carbon bu d
up by us ng carbon removers
l C ean o her par s o head comp e e cy nder
horough y w h su ab e c ean ng so ven
INSPECTION
Head comp ete cy nder
Note:
Remove stud bo ts cy nder head (2 nos) from
the head comp ete cy nder before remov ng
scratches.
l P ace head comp e e cy nder on a sur ace p a e
us ng s ra gh edge and ee er gauge check
d s or on
l measured va ue exceeds he m rep ace he
head comp e e cy nder w h a new one
F g 3 137
Fee er gauge
Sur ace p a e
Serv ce m 0 05 mm
Cam cha n
l Measure d s ance across 20 p ches 21 nks o
know he serv ce m o cam cha n F g 3 138
Vern er ca per
Serv ce m 127 22
l Rep ace ound beyond he m
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F g 3 136
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F g 3 137
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1 2 3 19 20 21
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F g 3 138
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Servicing of engine 3-37

SERVICING OF ENGINE
Camshaft comp ete
l Check camsha comp e e or runou wear o cam
obes and ourna s Any o hese cou d cause he
eng ne o produce abnorma no se v bra on or
ack o power ou pu
l Wornou cam obes may ead o mproper va ve
opera on resu ng n reduced power ou pu
l Measure cam obe he gh he obe he gh s ess
han spec ed serv ce m hen rep ace he
camsha comp e e w h a new one F g 3 139
Ou s de m crome er
Serv ce m t
ne 33 510 mm
Exhaus 33 390 mm
l nspec ba bear ngs 6003 - 2 nos o camsha
or abnorma p ay or p ng
l Measure runou w h a d a gauge Rep ace he
camsha w h a new one
exceeds he m F g 3 140
0313070 V - b ock se 4“x3“x3“
0313050 D a gauge 1/100 mm
0313060 Magne c s and
Serv ce m 0 08 mm
Va ve ntake and va ve exhaust
l nspec bo h he va ves or rueness burn ng
scra ches abnorma wear or bend
l Measure ou s de d ame er o va ve s em on he
opera ona area F g 3 141
Ou s de m crome er
S andard n e 4 990 - 4 975 mm
S andard exhaus 4 970 - 4 955 mm
Servicing of engine 3-38
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F g 3 139
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measured runou .....................................................................................................................................................................................................
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F g 3 140
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F g 3 141
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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l Us ng spec a oo s measure he runou on va ve .....................................................................................................................................................................................................
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s em and va ve ace Rep ace va ve w h a new .....................................................................................................................................................................................................
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one measured runou exceeds he serv ce m .....................................................................................................................................................................................................
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F g 3 142 .....................................................................................................................................................................................................
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0313070 V - b ock se 4“x3“x3“ .....................................................................................................................................................................................................
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0313050 D a gauge 1/100 mm .....................................................................................................................................................................................................
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0313060 Magne c s and .....................................................................................................................................................................................................
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Serv ce m t .....................................................................................................................................................................................................
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Runou on s em 0 05 mm .....................................................................................................................................................................................................
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Runou on ace 0 075 mm F g 3 142

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l Check va ve or smoo h movemen n he gu de .....................................................................................................................................................................................................
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va ve .....................................................................................................................................................................................................
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3
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l Measure h ckness o va ve head h ckness s .....................................................................................................................................................................................................
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ess han he serv ce m rep ace he va ve w h a .....................................................................................................................................................................................................
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new one F g 3 143 .....................................................................................................................................................................................................
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Vern er ca per .....................................................................................................................................................................................................
T
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Serv ce m t .....................................................................................................................................................................................................
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n e and exhaus 0 5 mm m n .....................................................................................................................................................................................................
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F g 3 143
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Va ve stem cond t on .....................................................................................................................................................................................................
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A
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l nspec va ve s em end ace A or p ng and wear .....................................................................................................................................................................................................
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p ng or wear no ced resur ace he va ve s em .....................................................................................................................................................................................................
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end ensur ng he eng h 1 s no reduced o ess 1
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han 3 8 mm h s end eng h urns ess han .....................................................................................................................................................................................................
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3 8 mm he va ve mus be rep aced w h a new .....................................................................................................................................................................................................
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one F g 3 144 .....................................................................................................................................................................................................
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F g 3 144
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Spr ng va ve .....................................................................................................................................................................................................
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l Measure ree eng h o he nner and ou er spr ngs .....................................................................................................................................................................................................
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F g 3 145 hey are be ow serv ce m rep ace .....................................................................................................................................................................................................
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hem w h new ones .....................................................................................................................................................................................................
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Vern er ca per .....................................................................................................................................................................................................
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Serv ce m t .....................................................................................................................................................................................................
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nner spr ng 30 00 mm .....................................................................................................................................................................................................
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Ou er spr ng 30 00 mm .....................................................................................................................................................................................................
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F g 3 145
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Servicing of engine 3-39
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SERVICING OF ENGINE .....................................................................................................................................................................................................
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CYLINDER HEAD ASSEMBLY - EXPLODED VIEW .....................................................................................................................................................................................................
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PLUG ROCKER ARM SHAFT .....................................................................................................................................................................................................
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SHAFT ROCKER ARM .....................................................................................................................................................................................................
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HEX FLANGE BOLT M6.....................................................................................................................................................................................................
45 2no
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HEX FLANGE BOLT.....................................................................................................................................................................................................
M6 55 4no
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GASKET CYL .....................................................................................................................................................................................................
HEAD COVER BOLT 4no
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HEX FLANGE BOLT M6 35 4no
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CAP NSPECT ON HOLE
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O .....................................................................................................................................................................................................
R NG
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NUT TAPPET AD UST NG
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SCREW TAPPET AD UST NG
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ROCKER ARM COMLETE
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PLUG CYL NDER HEAD TENS ONER CAM CHA N
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COTTER VALVE REC CSK HD SCREW 2no
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RETA NER VALVE SPR NG
COVER CYL NDER HEAD .....................................................................................................................................................................................................
CLAMP NTAKE P PE
.....................................................................................................................................................................................................
A .....................................................................................................................................................................................................
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P N CYL HEAD COVER KNOCK 2no SPR NG VALVE NNER
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O R NG
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C R NG CAM SHAFT .....................................................................................................................................................................................................
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SPARK PLUG .....................................................................................................................................................................................................
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SPR NG VALVE OUTER
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A .....................................................................................................................................................................................................
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SEAT VALVE SPR NG
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SEAL VALVE STEM O L
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PUNCHED DOOMED NUT W TH FLANGE 4no
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P PE COMPLETE NTAKE
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WASHER 2no .....................................................................................................................................................................................................
GASKET CYL HD NUT 2no
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COPPER WASHER
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GASKET O L P PE UN ON
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BOLT CAM CHA N TENS ONER
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BALL BEAR NG 2no
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PN
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HEAD ASSEMBLY CYL NDER .....................................................................................................................................................................................................
CAM SHAFT
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STUD BOLT .....................................................................................................................................................................................................
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CYL HEAD 2no .....................................................................................................................................................................................................
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VALVE EXHAUST
VALVE NTAKE .....................................................................................................................................................................................................
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P N SPROCKET KNOCK
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HOLDER COMPLETE DECOMPRESS ON
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THRUST WASHER
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FLANGE CAM SHAFT
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A .....................................................................................................................................................................................................
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CHA N COMP CAM SHAFT DR VE
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CLOSED CO L END OF THE SPR NGS .....................................................................................................................................................................................................
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SHOULD REST ON THE SEAT VALVE SPR NG .....................................................................................................................................................................................................
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SPROCKET CAM SHAFT
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WASHER SPROCKET
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HEX SCREW M6 12 2no
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F g 3 146 .....................................................................................................................................................................................................
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Servicing of engine 3-40

SERVICING OF ENGINE
REASSEMBLY
Head comp ete cy nder
l For reassemb y reverse he remova procedure
and ak ng care o he o ow ng po n s Re er
exp oded v ew or assemb y de a s F g 1 146
l Assemb e sea va ve spr ng and a new sea va ve
s em o
l Wh e assemb ng va ves nser smoo h y n o he
gu de o avo d he damage o he sea va ve s em
o .....................................................................................................................................................................................................
l Assemb e spr ng va ve nner and spr ng va ve ou er
and re a ner va ve spr ng
Note:
The d ameter of va ve ntake s arger than
the d ameter of va ve exhaust.
Lubr cate both the va ve stems before
nsta ng.
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