Petrol / CNG / LPG

SERVICE STATION MANUAL

509/510, NUCLEUS, 1, CHURCH ROAD, PUNE - 411 001

 FOREWARD
This manual has been prepared with the aim to provide
the necessary instructions to Piaggio Vehicles Private
Limited dealers for the maintenance and repairs of
the Petrol / CNG / LPG.
àñVmdZm
"Amno' dmhZ Ho$ aIaImd VWm _aå_V Ho$ {bE {n`m{O`mo ìhoB©H$ëg
àmBìhoQ> {b{_Qo>S> Ho$ {dH«o$VmAm| H$mo Amdí`H$ AZwXoe XoZo Ho$ CÔoí`
go hr `h _¡Ý`wAb V¡`ma {H$`m J`m h¡ &

This service manual deals with the following matters: Bg _¡Ý`wAb _| {ZåZm§{H$V {df`m| H$m C„oI h¡ &

l General instructions for vehicle maintenance.
l General instructions for fault analysis and
diagnosis.
l Illustrations and instructions for dismantling, over-
hauling and re-assembly.
l Assembly play of the major components of
powerpack and brakes.
l List of special tools for operation to be carried out
on the vehicle.
l dmhZ Ho$ aIaImd Ho$ {bE gm_mÝ` AZwXoe &
l Xmof H$mo Ty§>T>Zo VWm {dûbofU Ho$ {bE gm_mÝ` AZwXoe &
l dmhZ H$mo ImobZo, Amoda hm°qbJ VWm OmoS>Zo Ho$ ~mao _| {MÌ
VWm AZwXoe &
l nm°da n¡H$ VWm ~«oH$ Ho$ à_wI KQ>H$m| H$m Ag|ãbr ßbo &
l dmhZm| Ho$ n[aMmbZ Ho$ {bE {deof Am¡Omam| H$s gyMr &

It is recommended that various maintenance

procedures, as well as, procedures for dismantling,
overhauling are followed scrupulously with the use of
special tools recommended to avoid damage to the
components; keep the repairs-cost and vehicle down-
time bare minimum.
We also recommend that only genuine spare parts
are used to ensure prolonged, trouble-free service from
your . hr à`moJ H$a| &
`h g§ñVwV {H$`m OmVm h¡ {H$ KQ>H$m| Ho$ ZwH$gmZ H$mo Q>mbZo Ho$ {bE
gy{MV {deof Am¡Omam| H$s _X²X go {d{^ÝZ aIaImd à{H«$`m VWm
Amoda hm°qbJ à{H«$`m H$m gmdYmZr go nmbZ {H$`m OmE Vm{H$
dmhZ H$s _aå_V bmJV VWm dmhZ Iam~r H$s Ad{Y H$_ go H$_
hmo &
h_ `h ^r g§ñVwV H$aVo h¡ {H$ AmnHo$ "Amno' go XrK© VWm {Z~m©Y
godm (g{d©g) gw{Z{üV H$aZo Ho$ {bE Agbr nwOm]H$m (ñnoAa nmQ©>g)²

The information, technical specifications, repairs/
overhauling procedures contained in this “Service
Station Manual” are subject to change without any
notice because of continuous ‘Research and
Development’ activities going on at the manufacturing
units. Such amendments will be informed to you from
time to time through Technical Bulletins.
In case of any further inquiry please write to :
CËnmXZ BH$mB© _| {Za§Va hmo aho AZwg§YmZ VWm {dH$mg H$m`©H«$_m| Ho$
H$maU, Bg g{d©g ñQo>eZ _¡Ý`wAb _| Xr JB© OmZH$mar, VH$ZrH$s
ã`m¡ao VWm _aå_V/Amoda hm°qbJ à{H«$`m Am{X _§o {~Zm gyMZm Ho$
n[adV©Z {H$E Om gH$Vo h¡ & BZ g§emoYZm| H$s OmZH$mar "Qo>ŠZrH$b
~wboQ>rZ' ìXmam AmnH$mo g_` g_` na Xr OmEJr &
`{X AmnH$mo H$moB© g_ñ`m hmo Vmo H¥$n`m g§nH©$ H$a| &

SERVICE DEPARTMENT
g{d©g {S>nmQ>©_|Q>
{n`m{O`mo ìhoB©H$ëg àmBìhoQ> {b{_Q>oS>
PIAGGIO VEHICLES PRIVATE LIMITED
509 / 510 "Ý`wpŠbAg',
509/510, NUCLEUS
1, MM© amoS>, nwUo - 411 001
1, CHURCH ROAD, PUNE - 411 001
\$moZ : (91-20) 30519500 \°$Šg : (91-20) 26053875
PH. : (91-20) 30519500 FAX : (91-20) 26053875

3
4
CONTENTS

Sr. No. Description Page No.

1) Technical Specifications 10
2) Installation of instruments and controls in the cabin 12
3) General instructions for maintenance and lubrication 13
4) Lubrication Diagram 15
5) Valve Timing Diagram 30
6) Electricals
a) Setting the Headlamp 32
b) Charging Circuit 33
c) Electrical Wiring Diagram 34
7) Dismantling 36
a) Engine 38
b)
c)
Gearbox & Differential
Steering & Front Suspension
DE 40
45
d)
MA
Rear Suspension, Transmission & Flexible Coupling 49

BE
e) Brakes 50
8) Assembly Play 52
9) Overhauling & Checkings
TO
a)
X
Engine overhauling
E
56
b)
c)
IND
Gearbox & Differential overhauling
Brakes overhauling
75
77
d) Tightening torques 78
10) Re-assembly
a) Engine 82
b) Gearbox & Differential 96
c) Steering & Front Suspension 101
d) Rear Suspension, Transmission & Flexible Coupling 104
e) Brakes 107
f) Door Packing 109
g) Windshield Glass 109
11) Painting Instructions 111
12) Operations and checks before driving 112
13) Fuel consumption test 113
14) Tools for dismantling, overhauling and Re-assembly with illustrations 114
15) Fault finding (Petrol & Gas)

5
AZw gw{M

AZw. H«$. {ddaU n¥ð> H«$.

1) VH$ZrH$s ã`moao ({ZX}e) 10

2) Ho${~Z _| CnH$aUm| VWm {Z`§ÌH$m| H$m g§ñWmnZ 12
3) aIaImd VWm bw{~«Ho$eZ Ho$ {bE gm_mÝ` AZwXoe 14
4) bw{~«Ho$eZ S>m`J«m_ 15
5) dmëd Q>mBq_J S>m`J«m_ 30
6) {dÚwVr` :
a) hoS> b¢n \$moH$g H$aZm 32
b) Mm{OªJ g{H©$Q> 33
c) {dÚwVr` dm`[a¨J S>m`J«m_ 34
7) ImobZm : 36
a) B§OZ 38
b) {J`a ~m°Šg VWm {S>\«|${e`b
DE 40
c) pñQ>A[a¨J VWm AmJo H$m gñn|eZ

MA
d) {nN>bm gñn|eZ, Q´>m§g{_eZ d bMrbo `moOH$ (H$nqbJ)
45
49
e) ~«Š og
BE 50
8) Ag|ãbr ßbo
TO 52
9)
X
Amoda hm°qbJ d Om§M nS>Vmb
E
D
a) B§OZ Amodahm°b H$aZm 56

IN
b) MoqH$J Am¡a A°S>OñQ>_|Q>g - B§OZ
c) ~«oŠg Amoda hm°qbJ
75
77
d) Q>mH©$ Qo>~b 78
10) nwZ:g§`moOZ ([aAg|ãbr) :
a) B§OZ 82
b) {J`a ~m°Šg VWm {S>\«|${e`b 96
c) pñQ>`[a¨J VWm AJbm gñn|eZ 101
d) {nN>bm gñn|eZ, Q´>m§g{_eZ d bMrbo `moOH$ (H$nqbJ) 104
e) ~«Š og 107
f) XadmOo H$m AñVa (S>moAa n°qH$J) 109
g) qdS>erëS> ½bmg 109
11) a§JmB© Ho$ ~mao _| AZwXoe 111
12) n[aMmbZ go nhbo Om§M d H$madmB© 112
13) B§YZ InV narjm 113
14) ImobZo, Amodahm°qbJ d nwZ:g§`moOZ([aAg|ãbr) Ho$ Qy>ëg g{MÌ 114
15) Iam~r Ty±>T>Zm (_oH°${ZH$b d {dÚwVr`) 17

6
Passenger (Petrol)
`mÌr dmhZ

PETROL

FOR GAS

7
IDENTIFICATION DATA - PETROL nhMmZ ã`m¡am
Your Petrol & Gas vehicle is powered AmnHo$ " noQ´>mob' H$mo 4 ñQ´>moH$ noQ´>mob B§OZ go e{º$
by 4 Stroke Petrol engine. {_bVr h¡&
For identification of engine, serial number is punched B§OZ H$s nhMmZ Ho$ {bE {g[a`b Z§~a hm\$ H«±$H$Ho$g Ho$ Cna A§{H$V {H$`m
on the half crankcase. J`m h¡Ÿ& (XoIo {MÌ-1)
(Refer fig. 1)

ENGINE NUMBER SYSTEM :

TBP1M LP3000010 (14 Digits)
Petrol T B P 1 M L P 3 0 0 0 0 1 0
LPG T B P 2 M K P 3 0 0 0 0 1 1
CNG T B P 3 M M P 3 0 0 0 0 1 2
World
Month
code

Model code Engine running serial number.

Year
manufacturer
code 3 stands for Baramati location
identifier (3 digit)

FOR PETROL FOR GAS

TBP3M MP3001040 - CNG

TBP1M LP3000010 TBP2M KP3000010 - LPG

8
CHASSIS IDENTIFICATION SYSTEM : Mo{gg IDENTIFICATION SYSTEM :
MBX0002CFPM000001 (17 Digits) MBX0002CFPM000001 (17 Digits)
VIN SYSTEM

M B X 0 0 0 2 C F P M 0 0 0 0 0 1

Project

Month
World

Model
code

code

code
code

Year
manufacturer
identifier (3 digit)
Vehicle Descriptor section (6 digit) Vehicle indicator section ( 8 digit )

Similarly the serial number of the chassis is punched
on the left hand side of the main centre beam in the
cabin.
These serial numbers will be reproduced on all the
documents which will serve to identify your vehicle.
These serial numbers of the engine and the chassis
will also be useful in ordering VOR spares from
Authorised Dealers.
Cgr àH$ma Mo{gg H$m {g[a`b Z§~a Ho${~Z _| _oZ g|Q>a ~r_ Ho$ ~m`o Amoa
A§{H$V hmoVm h¡Ÿ&
`o {g[a`b Z§~a g^r XñVmd|Omo na {\$ago {bIo hmoJ| {Oggo AmnHo$ dmhZ
H$mo nhMmZm Om gH$Vm h¡ & B§OZ VWm Mo{ggna A§{H$V {g[a`b Z§~a
A{YH¥$V S>rbam| go dr.Amo.Ama. ñnoAa nmQ©>g àmá H$aZo _| Cn`moJr {gÕ
hm|JŸo &

FOR PETROL FOR GAS

MBX0002EFPM000002 - CNG
MBX0002DFPM000003 - LPG

MBX0002CFPM000001

9
INSTALLATION OF INSTRUMENTS AND Ho${~Z _| gmYZm| VWm {Z`§ÌH$mo (B§ñQ®>_|Q> A±S> H§$Q´>mob)
CONTROLS IN THE CABIN
H$s pñWVrŸ&
1. Clutch Lever
1. ŠbM brda
2. Gear Change Twist Grip
2. {J`a M|O pìQ>>ñQ> {J«n
3. Instrument Cluster
3. BÝñQ¯>_|Q> ŠbñQ>a
4. Accelerator Twist Grip 4. EpŠgboQ>a pìQ>>ñQ>> {J«n
5. R. C. Lever 5. Ama. gr. brda
6. Hand Brake Control Lever 6. h¢S> ~«oH$ {Z`§ÌU brda
7. Choke Lever 7. MmoH$ brda
8. Brake Pedal 8. ~«oH$ noS>b
9. Wiper Switch 9. ìhm`na pñdM
10. Light Switch 10. bmB©Q> pñdM
11. hPmS>© dm°{ZªJ pñdM
11. Hazard Warning Switch
12. hoS> b°ån, gmB©S> B§{S>Ho$Q>a, hm°Z© pñdM
12. Head Lamp, Side Indicator, Horn Switch
13. ECU
13. Electronic Control Unit (ECU) (for CNG / LPG)
14. B{¾eZ pñdM
14. ON/OFF Switch (Ignition Switch)
15. ŠbM pñdM
15. Clutch Switch
16.
16. Mobile Charger (for Petrol)

11 10 9
2 1 15

12
15 14 13
4

10
SWITCHES
I) ON/OFF Switch (Ignition switch)
- Positions on switch “A”
(Refer Fig. )
A. All off, extractable key.
B. All function enabled. Key not extractable.
● To stop the engine turn the key (anticlockwise
direction) manually from position B to A.
pñdMog² :
I) Am°Z/Am°\$ pñdM (B{¾eZ pñdM) -
pñdM H$s pñW{V`m±-“A” (XoIo {MÌ - 6)
A. nyar Vah go ~§X, {ZH$mbZo `mo½` Mm~r&
B. g^r {dÚwVr` g{H©$Q> Mmby hmoVo h¡& Mm~r {ZH$mb Zht gH$Vo h¡&
· B§OZ ~§X H$aZo Ho$ {bE Mm~r H$mo (K‹S>r Ho$ CëQ>r {Xem _|) pñW{V
B go A VH$ Ky_mB©E&

II) Mobile Charger (Refer Fig. )

II ) _mo~mB©b MmO©a (XoI| {MÌ -)
III) Switches - Switch Positions
(Refer Fig. ) III) pñdMog - pñdM H$s pñW{V`m±
B Light Switch (XoIo {MÌ-)
0 Light OFF B bmBQ> pñdM

1 Parking Light ON 0 bmBQ> ~§X

1 nm{Hª$J bmBQ> Mmby
2 Head Light ON
2 hoS> bmBQ> Mmby
C Wiper Switch
C dm`na pñdM
D Hazard Warning Switch
D hPmS>© dm{ZªJ pñdM

III
I II

A
B

C B
D

11
IV) Fuel Gauge Indications-(Ref. Fig.8) IV) B§YZ _mnZ `§Ì {ZX}e - (XoIo {MÌ - 8)
E - Fuel tank empty
E - B§YZ Q¢>H$ Imbr
‘I’ - Fuel available to the capacity of half of the
fuel tank ‘I’ - B§YZ Q¢>H$ _| B§YZ AmYm ^am h¡ &
F - Fuel available to the full capacity of the
F - B§YZ Q¢>H$ _| BªYZ nyam ^am h¡ &
tank

V) Handle Bar Switches - V) h¡ÊS>b ~ma pñdMog

(Refer Fig. 8A) (XoIo {MÌ - 8A)
E - Horn Push Button E - hm°Z© ~OmZo H$m ~Q>Z
F - Direction Indicator F - {Xem {ZX}eH$
G - High / Low Beam Switch
G - bmBQ> OmXm/H$_ H$aZo H$m pñdM
H - Engine Start Push Button
H - B§OZ ñQ>mQ>© nwe ~Q>Z

F
IV
V

Fig. 8 Fig. 8A

12
VI) Warning Indicators (Refer Fig. 9) VI ) MoVmdZr {ZX}eH$ (XoIo {MÌ - 9)
A - Turn signal indicator L/R Light A - Xm`|/~m`| Ky_Zo H$m {ZX}eH$ bmBQ
B - High beam indicator light B - OmXm bmBQ> H$m {ZX}eH$ bmBQ
C - Battery charging indicator light C - ~°Q>ar Mm{OªJ {ZX}eH$ bmBQ
D - Oil pressure indicator light D - Am`b Ho$ X~md H$m {ZX}eH$ bmBQ
VII) Speedo Meter (Refer Fig. 9A) VII) ñnrS>mo _rQ>a (XoI| {MÌ -9A)
E - Speedo Meter E - ñnrS>mo _rQ>a
F - Odometer F - AmoS>mo _rQ>a
VII) Clutch Switch (Refer Fig. 9B) VII) ŠbM pñdM (XoI| - {MÌ 9B)
A switch is provided for protection of starter motor Á`mXm H«±$H$ H$aZo go ñQ>mQ>©a _moQ>a Iam~ hmoZo go ~MmZo Ho$ {bE `h
from over cranking, unless declutch, engine will pñdM {X`m h¡& {S>ŠbM Z H$aZo go B§OZ ewê$ Zhr hmoJm&
not start.

A B
C

VI

Fig. 9B Fig. 9

VII

Fig. 9A

13
TECHNICAL SPECIFICATION H$m`© {ZînmXZ
PERFORMANCE dmhZ _| (Am` Eg 1460-1974) S>rOb H$m Cn`moJ hmoVm h¡.
The vehicle runs with Petrol / CNG / LPG gr_m :
Petrol : Only with Petrol
B§YZ Q¢>H$ H$s A{YH$V_ j_Vm :10.5 brQ>a
CNG : Petrol / CNG
LPG : Petrol / LPG A{YH$V_ J{V :
Max Petrol tank capacity : 10.5 liters in Petrol dmhH$ g_oV ^ma j_Vm : 670{H$.J«m.
3 Liters in CNG/LPG
Max LPG tank capacity : 18.4 liters
: (80% tank capacity) Q>m`a àoea
Max CNG tank capacity : 30 liters (4.2Kg) AmJo H$m n{h`m 2.1 {H$.J«m./g|._r.2
Max speed : 60 km/hour {nN>bm n{h`m 2.4 {H$.J«m./g|._r.2
Pay load including driver : 670kg (petrol) AmH$ma VWm dOZ : n{h` m| H$m _mJ© - 1260 {_._r.
: 695kg (LPG/CNG)
Tyre Pressure
n{h`m| H$m AmYma - 1940 {_._r.
A{YH$V_ Mm¡S>mB© : 1400 {_._r.
Front Wheel 2.1 Kgsq.cm
A{YH$V_ b§~mB© : 2700 {_. _r.
Rear Wheels 2.4 Kg/sq.cm
A{YH$V_ D±§$MmB© : 1260 {_. _r.
Sizes and weight
Wheel track - Petrol : 1140 mm
Q>{ZªJ gH©$b S>m` _rQ>a : 5500 {_. _r.
CNG : 1140 mm {Z^m©a dOZ : 360 {H$.J«m.
LPG : 1140 mm B§OZ : EH$ {gqbS>a, 4- ñQ´>moH$ S>rOb B§OZ, grYm AàË`j
Wheel base : 1920 mm A§V:jonU (B§OoŠeZ), `h {J`a ~mŠg VWm {S>\«|${e`b Ho$ gmW
Max width Petrol : 1335 mm {nN>bo ìhrb EŠgb na bJm`m J`m h¡Ÿ&
CNG : 1335 mm ~moa VWm ñQ´>moH$ : 74 x 64 {_. _r.
Max length : 2700 mm
Max height : 1780 mm {dñWmnZ ({S>gßbog_|Q>) : 275 gr.gr.
Turning circle diameter : 5700 mm H§$àoeZ AZwnmV : 9:1
Un-laden weight : 360 kg with 90% of fuel.
B§YZ A§V:jonU (B§OoŠeZ) : PFE 1Q60 â`wb B§OoŠeZ n§n,
: 417 kg (CNG/LPG) gmYZ : H±$_emâQ> Ûmam Mbm`m J`m 7 {_._r.
amB©Q> h¢S> hobrŠg 15Ø JmB©S> ~moëQ>
Grand Clearance : 160 mm
\$m°bmoAa Hoo$ gmW&
Max Gradeability : 18% (Petrol)
18% (CNG) {J`a AZwnmV :
16% (LPG) n¡g|Oa
Engine : Single cylinder, nhbm {J`a 1:25.52
4-stroke petrol engine,
forced air cooled. Xygam {J`a 1:15.16
Vrgam {J`a 1:9.25
Bore and stroke : 62.6x64 mm
Mm¡Wm {J`a 1:6.2
Displacement : 196.9 cc
[adg© {J`a 1:30.62
Compression ratio : 9.5:1
{dX`wVr` gmYZ - 12 dmoëQ> S>r.gr.
Fuel injection : Carburettor UCAL
equipment VM-UVD22 ~¡Q>ar - 12 dmoëQ> 35 Eånr`a Amda
Oval ventury dia. 22 mm
main jet ñQ>m{Qª>J V§Ì : 0.6 {H$bmo dmQ>, 12 dmoëQ>
Speed Petrol : 1100 ± 250 rpm
{dÚwVr` ñQ>mQ>©a _moQ>a
amon ñQ>m{Q>ªJ Ho$ {bE MH$arŸ&
Speed CNG/LPG : 1200 ± 250 rpm
Maximum net power : 10.02hp @ 4500 rpm (Petrol)
10.46 hp@ 4600 rpm (LPG)
9.12 hp @ 5000 rpm (CNG)

14
Maximum Torque : 16.3 Nm @ 3000 rpm (Petrol)
13.10 Nm @ 3000 rpm (CNG)
: 16.67 Nm @ 3000 rpm (LPG)
Overall Gear Ratio :
Passenger Petrol /LPG CNG
1st Gear 25.3 : 1 28.26 : 1
2nd Gear 15.01 : 1 16.77 : 1
3rd Gear 9.13 : 1 10.20 : 1
4th Gear 6.10 : 1 6.82 : 1
Reverse Gear 22.89 : 1 28.45 : 1
Electrical equipment : 12 V DC
Battery : 12 V 35 AH
Starting system : 0.6 KW, 12 V electrical
starter motor.
Sparl Plug : BOSCH UR4DC
Spark Plug Gap : 0.7 ~ 1.0 mm
BRAKES
Service : Drum brake hydraulically
actuated,internal
expanding shoe type
combined with hydraulic
actuation (Foot operated)
Parking : Mechanical on rear
wheels with flexible
transmission operated by
hand lever.
Suspension
Front : Hydraulic shock absorber
with co-axial coil spring,
leading arm.
Rear : Hydraulic shock absorber
with rubber bumper, semi
trailing arm.
Clutch : Multiplate, wet clutch,
Manually operated.
Charging system : 3 phase fly wheel
magneto 220 watt with
Electronic Voltage
Regulator, 13.5~14.5 V.
Carburettor
Petrol LPG CNG
Main Jet 87.5 85 65
Starter Jet 17.5 17.5 17.5
Slow / Pilot Jet 15 15 15
Air Screw 1½ ± ½ 1½ ± ½ 1½ ± ½
Float Level 16 16 16
Float Chamber 31.5 31.5 31.5
Fuel Capacity

15
Do’s
1. It is recommended to start the vehicle on Petrol
mode while first starting in the Morning.
2. To switch over from petrol to CNG/LPG operation,
bring the vehicle at halt mode, set the fuel selector
switch to ‘0’ (Off) position, allow the engine to run
till it jerks & then change the switch position to
gas mode (CNG/LPG).
3. In case of leakage in CNG System immediately
turn ‘OFF’ CNG cylinder valve also.
4. Ensure tight fitment of gas filler plug on filler valve
to avoid gas flow intruption.
5. Use rated fuse only.
6. When the vehicle is taken for body repair (welding
etc.) the CNG/LPG tank should be emptied /
removed.
7. Test CNG/LPG cylinder at every 5 years.
8. Ensure the tightness of ducting connection & gas
vent out to the atmosphere in case of leakage.
9. Always cut off battery connection during night halt
by using battery cut off switch.
10. In case of leakage, switch off the ignition and
consult Piaggio authorised Service Station.
11. Ensure battary is in fully charged condition at all
point of time.

Don’ts
1. Do not switch over to GAS mode (CNG/LPG )
while vehicle is running in petrol mode.
2. Do not fill LPG beyond 80 % of the tank capacity.
3. Do not fill CNG cylinder beyond 200 bar pressure.
4. Do not open the pressure regulator or any CNG/
LPG Kit components, at your own.
5. Do not keep any flammable items near the CNG/
LPG system.
6. Do not allow anybody to smoke while refilling.
7. Do not use any accessories in gas kit.
8. Do not tamper the carburetor settings /
adjustments.
9. Do not use domestic LPG cylinder.

16
DO’S & DONT’S :
 Check for leakage only with neutral soap solu tion.
Make the joints leak proof. If leakage does not
stop then contact the nearest authorized service
station.
 When the vehicles are taken for repair (welding
etc.), the LPG/CNG container should be emptied
and removed.
 Use only tested / approved LPG/ CNG container.
 Use only tested / approved multifunction valve.
 If rubber hoses develop visible cracks immedi ately
replace them.
 Use only 5 Amp fuse for LPG/CNG controller.
 Switch OFF the mobile phones while refueling.
 Don’t smoke while re-fueling.
 Don’t keep any flammable items near the LPG /
CNG system.
 Don’t open the regulator or any LPG/CNG compo-
nent on your own

SAFETY TIPS :
 Do not switchover LPG/CNG mode while the ve-
hicle is running in petrol mode.
 Do not open the pressure regulator and other LPG/
CNG components on your own.
 In case of leakage, switch off the ignition.
 Use genuine spares only.
 Always ensure that the ducting connections are
tight and the gas vents out to the atmosphere
incase of leakage.
 Don’t entertain any welding / tin work near the con-
tainer.
 Always work in good ventilated workshop area.
 Don’t take any flammable material near gas com-
ponents.
 Never discharge LPG/CNG in public places or in
prohibited or closed areas
 Use the correct rated fuse in the electrical unit.
 Always keep the earthing of the wiring harness
intact at all times.
 Avoid short circuit of electrical connections.

17
While taking delivery of your Petrol you AmnHo$ " noQ´>mob' {H$ {S>{bdar boZona AmnHo$ {bE
are privileged to have the following : CnbãY h¡ :
1. Operation Maintenance Manual & Warranty Manual 1. n[aMmbZ VWm aIaImd nwpñVH$m d dmaÝQ>r nwpñVH$m
2. First Aid Kit 3. Jack & Handle (Optional) 2. àmW{_H$ CnMma {H$Q> 3. O¡H$ Am¡a h¡ÊS>b (Am°ßeZb)
4. Spare Fuses Kit 5. Battery Warranty Card 4. A{V[aº$ â`yO 5. ~¡Q>ar dmaÝQ>r H$mS©>
6. Tool Kit 7. Head Lamp Bulb Set 6. Qy>b {H$Q 7. hoS> b¡ån ~ë~ goQ>

You are also entitled for : BgHo$ Abmdm AmnHo$ {bE :

Free Services as per details given in your Warranty AmnHo$ dmaÝQ>r nwpñVH$m _| {X`o J`o {dñV¥V {ddaU Ho$ AZwgma g^r {n`m{O`mo
Manual at all Piaggio Authorised Dealer. Should you A{YH¥$V {S>ba go _mo\$V gpìh©qgJ& AmnHo$ dmhZ g§~§Yr {H$gr ^r àH$ma
require any assistance, please contact, Head -
Customer Care, Piaggio Vehicles Pvt. Ltd., Pune. H$s A{YH$Va ghm`Vm H$s Amdí`H$Vm hmo Vmo _w»` J«mhH$ godm, {n`m{O`mo
We do checkups at following intervals for your ìhoB©H$ëg àm. {b., nwUo go g§nH©$ H$a|&
Petrol {ZåZ{b{IV g_` Ho$ A§Vamb na Amn Ho$ " noQ´>mob' Ho$
{bE gpìh©g CnbãY h¡&
Services Valid for kms / days whichever occurs gpìh©g H$s._r. / {XZ Omo nhbo hmo, VH$ hr bmJy h¡
earlier.
1 br _wâV 750 - 1000 H$s. _r. `m 30 {XZ
1st Free 750 - 1000 kms or 30 days
2 ar noS> 5500 - 6000 H$s. _r. `m 75 {XZ
2nd Paid 5500 - 6000 kms or 75 days
3 ar _wâV 10500 - 11000 H$s. _r. `m 120 {XZ
3rd Free 10500 - 11000 kms or 120 days
4th Paid 15500 - 16000 kms or 165 days 4 Wr noS> 15500 - 16000 H$s. _r. `m 165 {XZ

5th Free 20500 - 21000 kms or 210 days 5 dr _wâV 20500 - 21000 H$s. _r. `m 210 {XZ

6th Paid 25500 - 26000 kms or 255 days 6 Q>r noS> 25500 - 26000 H$s. _r. `m 255 {XZ
7th Free 30500 - 31000 kms or 300 days 7 dr _wâV 30500 - 31000 H$s. _r. `m 300 {XZ
8th Paid 35500 - 36000 kms or 345 days 8 dr noS> 35500 - 36000 H$s. _r. `m 345 {XZ
Note : For keeping warranty of your vehicle valid gyMZm : AmnH$m dmhZ dmaÝQ>r _| aIZo Ho$ {bE eoS>çwb Ho$ {ZX}emZwgma
please ensure all services are availed as per g^r gpìh©gog H$m Cn`moJ H$a|&
prescribed schedule.

18
FOR SAFE DRIVING
We are giving below some simple advises, which will
be helpful to you for safe driving in daily use. Your
driving skills and your mechanical knowledge form
the foundation for safe driving practices. We suggest
that you practice driving your vehicle in a non-traffic
situation until you are thoroughly familiar with your
vehicle and its controls.
DRIVE WITHIN THE BOUNDARIES OF YOUR OWN
SKILLS AT ALL TIMES
- On bad surface roads reduce the speed and drive
cautiously.
- Don’t apply the brakes suddenly on wetted
surfaces, on unmetalled roads or on slippery
roadbed.
- While going down on slopes don’t proceed with
the speed gear in neutral, reduce the speed by
closing the throttle control. Make the deceleration
easier by using the brakes, but don’t apply brakes
too long, to avoid dangerous overheating which in
turn reduces efficiency of the brakes. Change to
lower gear to increase the engine braking effects.
- To get rapid “pickup”, for instance during an
overtaking, engage a lower gear in order to have
the necessary power at once.
- Don’t engage the lower gear with the engine at high
RPM in order to avoid the wear due to out of
revolution.
- Before taking a curve close the throttle and if
required, change into lower gear.
- While travelling on gradients, change into lower
gear so as to get the required pickup.
- Do not overload passenger Petrol.
Note : Adjustments, repairs, if necessary, must
be entrusted to authorised service station
only.
gwa{jV S´>m`qdJ Ho$ {bE
h_ `hm° ZrMo Hw$N> AmgmZ gwPmd Xo aho h¡ Omo amoμO_am© Ho$ Cn`moJ _o AmnHo$
{bE _XXJma {gÕ hmoJr & dmhZ MbmZo _| AmnH$s Iy~r VWm _oH°${ZH$b
kmZ hr gwa{jV S´>m`qdJ H$s AmYma {ebm h¡ & h_mam gwPmd h¡ {H$ Amn AnZo
dmhZ go VWm BgHo$ {Z`§ÌH$m|go nyar Vah go dm{H$\$ hmoZo Ho$ {bE ^rS> a{hV
gS>H$m| na dmhZ MbmZo H$m Aä`mg H$ao &
h_oem AnZr Hw$ebVm H$s gr_m _| hr dmhZ MbmE± &
- C~S> Im~S> amñVm| na J{V H$_ H$ao VWm gmdYmZr go dmhZ MbmE± &
- Jrbo, H$ƒo VWm {\$gbZ ^ao amñVm| na VmËH$mb ~«oH$ Z X~mE± &
- T>bmZ na CVaVo g_` Ý`wQ´>b {J`a _o JmS>r Z MbmE± W«moQ>b {Z`§ÌU
H$mo ~§X H$a Ho$ dmhZ H$s J{V H$_ H$ao & J{V H$mo AmgmZr go H$_ H$aZo
Ho$ {bE ~«oŠg H$m BñVo_mb H$a| & bo{H$Z A{YH$ Ja_ hmoZo go ~MZo Ho$
{bE A{YH$ Xoa VH$ ~«oŠg X~mH$a Z aIo, Š`m|{H$ Bggo ~«oŠg H$s
H$m`©j_Vm H$_ hmo gH$Vr h¡ & B§OZ ~«oqH$J B\o$ŠQ> ~T>mZo Ho$ {bE {ZMbo
{J`a _o S>mbo§ &
- AmodaQo>H$ H$aVo g_` Vwa§V "{nH$ An' Ho$ {bE n`m©á e{º$ àmá H$aZo
Ho$ {bE {ZMbo {J`a _| JmS>r aI| &
- n[aH«$_U go ~mha hmoZo H$s dOh go hmoZo dmbr j{V go ~MZo Ho$ {bE
B§OZ H$mo OmXm Ama.nr.E_. (High RPM) _| {ZMbo {J`a _| Z aIo&
- _moS> H$mo nma H$aVo g_` W«moQ>b H$mo ~§X H$a| Am¡a `{X Amdí`H$ hmo Vmo
{ZMbo {J`a _o S>mb| &
- T>bmZ na MbmVo g_` {ZMbo {J`a _o S>mbo Vm{H$ Amdí`H$ {nH$ An
àmá H$a gHo$&
- n°g|Oa noQ´>mob _| OmXm ^ma Z S>m{bEŸ&
gyMZm : ghr g_§OZ Am¡a gwYma Ho$ {bE Ho$db A{YH¥$V {dH«o$Vm
na hr ^amogm H$ao &

19
 PRE – DELIVERY INSPECTION (PDI)
Before delivering the Petrol to the
customer, please see that the following work is carried
out.
1. Wash the vehicle.
2. Check the vehicle thoroughly for any damages,
breakages, leakages. Rectify, if necessary.
3. Check oil level in the engine crankcase and
transmission. Top up, if necessary.
4. Check the brake oil level in the tandem master
cylinder reservoir. Make sure there is no leakage.
5. Check and tighten, if necessary all nuts, bolts
and delivery union, high pressure pipe connection,
etc.
6. Check and tighten, if necessary engine mounting
bolts, banjo bolts on the fuel supply lines etc.
7. Grease lubrication point on F.M. housing.
8. Check tyre inflation pressure in all the four tyres
(including spare wheel) and inflate to proper
pressure.
9. Check foot and hand brakes, adjust if necessary.
10. Check all the lights – viz. Headlight, Dimmer,
Blinkers, Horn, Stoplight, Number plate lamp,
Switches are working properly.
11. Start the engine and check, idle running of the
engine and normal running. Make sure there is no
abnormal noise in the engine.
12. Check all the gauges – Speedometer, Lub oil
pressure indicator glow lamp, Headlight high beam
indicator glow lamp are working properly.
13. Start the vehicle and take a test run. Check that
all gears are engaged smoothly, the clutch works
normally and the steering can be operated with
ease and directs the vehicle properly.
14. Ensure that there is no unusual sound like rattling
or squeaking when the vehicle runs at normal
speeds.
15. Ensure all tools, accessories and documents as
per manufacturer’s check – list are received with
the vehicle.
16. Fit the items supplied loose with the vehicle as
per the instructions given by the manufacturer.
17. Fill Battery card and hand over the same to the
customer.
18. Fit windshields assembly (in case of passenger
vehicle only) supplied seperately alongwith the
vehicle.
19. Fill PDI report which is attached to this booklet
and send the same to our warranty claim section,
Baramati.
20. Fill PDI report which is attached to this booklet
and send the same to our warranty claim section,
Baramati.
20
JmS>r XoZogo nhbo H$s OmZodmbr Om±M
J«mhH$ H$mo noQ´>mob JmS>r XoZogo nhbo H¥$n`m BZ
~mVm| H$mo AÀN>r Vah go Xo{IE H$s ZrMo {X`m hwAm H$m`© nyam
{H$`m J`m h¡ &
1. JmS>r H$mo nmZr go YmoH$a gm\$ H$a| &
2. JmS>r _| Hw$N> Iam~r, Qy>Q> - \y$Q> Am¡a {bHo$Oog Zhr h¡ BgH$m nyar
Vahgo§ narjU {H${OE & Amdí`H$Vm Ho$ AZwgma CgH$m g§emoYZ
H$aHo$ Cgo R>rH$ H$a|&
3. B§OZ Ho$ H«¢$H$ Ho$g Am¡a Q´>mÝg{_eZ _| ^ao hþE Am`b Ho$ ñVa H$m
narjU {H${OE& H$_ hmoZo na ñVa nyam H$a| &
4. Q¡>ÝS>_ _mñQ>a {gb|S>a _| ~«oH$ Am`b Ho$ ñVa H$m narjU {H${OE &
Bg ~mV H$mo {Z{üV {H${OE H$s WmoS>m ^r brHo$O Zhr h¡ &
5. AJa Amdí`H$Vm hmo Vmo â`wEb B§OoŠeZ n§nna hmoZo dmbo {S>{bdar
`w{Z`Z Am¡a hmB© àoea nmB©n H$ZoŠeZ Ho$ g^r ZQ> Am¡a ~moëQ> H$g| &
6. B§OZ _mD§${Q>J ~moëQ>,B§YZ nhþ§MZo dmbo _mJ©na hmoZo dmbo ~|Omo ~moëQ>
Am{X H$m narjU H$a Ho$ g^r ZQ> Am¡a ~moëQ> H$g|&
7. \o$Aa _rQ>a hmD$qOJ na {XE bw~«rHo$eZ nm°B§Q> _| J«rg JZ go J«rg
Xr{OE &
8. ñnoAa ìhrb g{hV Mmam| Q>m`amo _| hmoZodmbr hdm Ho$ X~md H$m narjU
H$aH|$ hdm H$m X~md C{MV a{IE &
9. \y$Q> Am¡a h¡ÊS> ~«oH$ H$m narjU H$aHo$ AJa OéaV hmo Vmo CZH$mo
ES>OñQ> {H${OE&
10. hoS> bmBQ>, {S>_a, ãbtH$a, hmZ©, ñQ>mn bmBQ>, Z§~a ßboQ> b¡ån AmXr
~mVm| H$m narjU {H${OE Am¡a BgH$s ^r Om±M {H${OE H$s g~ pñdMog²
R>rH$ T§>Jgo H$m_ H$aVo h¡ &
11. B§OZ ewê$ H$aHo$ CgHo$ Am`S>b aqZJ {H$ Om±M H$aHo$ Cgo Zm_©b
a{IE & Bg ~mV H$mo AÀN>r Vahg| Xo{IE H$s B§OZ _| H$moB© {d{MÌ
AmdmO Zhr AmVr h¡&
12. BZ g~ ~mVm| H$s Zmn (Gauges) H$m narjU {H${OE - ñnrS>mo
_rQ>a, by~ Am`b H$m àoea Am¡a hoS> b¡ån B§{S>Ho$qQ>J b¡ån AÀN>r
Vah go H$m_ H$aVo h¡&
13. JmS>r ewé H$aHo$ dh H¡$go MbVr h¡ BgH$s Om±M {H${OE & g^r {J`a
gabVm nyd©H$ H$m`© H$aVo h¡, ŠbM H$m H$m_ AÀN>r Vah go MbVm
h¡, h¡ÊS>b H$s H$m`©dmhr ghOVm go hmoVr h¡ Am¡a dh JmS>r H$mo
C{MV {Xem _| bo OmVm h¡ BZ g~ ~mVm| H$m narjU {H${OE &
14. O~ dmhZ gm_mÝ` JVr go MbVm h¡ V~ Cg_| H$moB© AZmdí`H$
AmdmO Zht AmVr BgH$m narjU {H${OE &
15. CËnmXH$ H$s narjU-gyMr (MoH$ {bñQ>) Ho$ AZwgma Am¡Oma (Qy>ëg),
A°ŠgogarO Am¡a H$mJO nÌ JmS>r Ho$ gmW àmá hwE h¡ BgH$m narjU
{H${OE&
16. Iwbr én _| Xr JB© (MrO|) CËnmXH$ H$s gyMZmAm| Ho$ AZwgma {\$Q>
{H${OE &
17. ~¡Q>ar H$mS©> R>rH$ Vahgo ^aH|$ Cgo J«mhH$ H$mo gm¡n {X{OE &
18. ñdV§Ì én _| Xr JB© {dÝS>erëS> Ag|ãbr (Ho$db n¡g|Oa dmhZm| Ho$
{bE) JmS>r Ho$ gmW OmoS> {X{OE Ÿ&
19. Bg nwpñVH$m _| OmoS>m J`m àr-{S>brdar BÝgnoŠeZ [anmoQ>© ^a H$a
Cgo dmaÝQ>r Šbo_ goŠeZ, ~mam_Vr Ho$ nmg ^oO Xr{OE Ÿ&
20. Bg nwpñVH$m _| OmoS>m J`m àr-{S>brdar BÝgnoŠeZ [anmoQ©> ^a H$a
Cgo dmaÝQ>r Šbo_ goŠeZ, ~mam_Vr Ho$ nmg ^oO Xr{OE &
 PERIODIC MAINTENANCE SCHEDULE FOR PETROL / CNG / LPG

10000

15000

20000

25000

30000

35000

40000

45000

50000

55000

60000
1000

5000
SUB ACTIVITY REPLACE AT EVERY

REPLACE AIR FILTER CARTIDGE @ ★ ★ ★ ★ ★ ★

ENGINE OIL # ★ ★ ★ ★ ★ ★
FUEL FILTER ★ ★ ★
LUBE OIL FILTER ★ ★ ★ ★ ★ ★
TRANSMISSION OIL ❉ ★ ★
BRAKE OIL $ AFTER EVERY 40000 KMS OR NOT MORE THAN 2 YEARS
FLEXIBLE BRAKE HOSES AFTER EVERY 31000 KMS
SPARK PLUG ★ ★ ★ ★ ★ ★
1ST STAGE FILTER ONCE IN A YEAR OR FOUND FULLY CHOKED.
GAS SOLENOID FILTER ★ ★ ★ ★ ★ ★
LOW PRESSURE HOSES ONCE IN A YEAR
FLEXIBLE HOSES ONCE IN A YEAR
FILTER ELEMENT (LPG) EVERY 5000 KMS OR IF ENGINE DOES NOT STARTS
STARTING OF GAS SUPPLY NOT SUFFICIENT
CHECK & ENGINE OIL LEVEL AFTER EVERY 500 KMS
ADJUST TAPPET SETTING ● ● ● ● ● ● ● ● ● ● ● ● ●
CARBURETTOR INSPECT ● ● ● ● ● ● ● ●
TRANSMISSION OIL LEVEL ● ● ● ● ● ●
PARKING BRAKES ● ● ● ● ● ● ● ● ● ● ● ●
STEERING COLOUMN RING NUT ● ● ● ● ● ●
SHOCK ABSORBER ● ● ● ● ● ● ● ● ● ● ● ●
CONTROL CABLES ● ● ● ● ● ● ●
FLEXIBLE COUPLING BOLTS ● ● ● ● ● ● ● ● ● ● ● ● ●
BATTERY LEVEL (ELECTROLYTE) ● ● ● ● ● ● ● ● ● ● ● ● ●
CHAIN TENSIONER INSPECT ● ● ● ● ● ● ● ●
HEADLAMP ADJUSTMENT ● ● ● ● ● ●
ALL WHEELS, HUBS, COUPLINGS & AXLE NUTS ● ● ● ● ● ● ● ● ● ● ● ● ●
SPEEDOMETER/ODOMETER FUNCTIONING ● ● ● ● ● ● ● ● ● ● ● ● ●
ALL BRAKE CONNECTION FOR LEAKAGE ● ● ● ● ● ● ● ● ● ● ● ● ●
ALL ENGINE MOUNTING FASTNERS ● ● ● ● ● ● ● ● ● ● ● ● ●
PETROL FUEL FILTER ● ● ● ● ● ●
BRAKE OIL LEVEL ● ● ● ● ● ● ● ● ● ● ● ●
TYRE PRESSURE ● ● ● ● ● ● ● ● ● ● ● ● ●
FUEL PIPES AND UNIONS ● ● ● ● ● ● ●
EXHAUST SYSTEM (SILENCER) (FASTNERS) ● ● ● ● ● ● ● ● ● ● ● ● ●
GAS LEAK IF ANY ● ● ● ● ● ● ● ● ● ● ● ● ●
ELECTRICAL CONNECTION ● ● ● ● ● ● ● ● ● ● ● ● ●
OVER ALL KIT CHECKING AND SERVICE 30000 KMS OR ONCE IN SIX MONTHS
(LPG / CNG) WHICH EVER IS EARLIER
LUBRICATE LEVERS ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
CONTROL CABLE LEVERS ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
FRONT SUSPENSION ARM KNUCKLE ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
CLEAN DRY TYPE AIR FILTER ❑ ❑ ❑ ❑ ❑ ❑ ❑
CYLINDER HEAD FINS ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑
ENGINE OIL STRAINER ● ● ● ● ● ● ●
1ST STAGE FILTER ● ● ● ● ● ● ● ● ● ● ● ●
1ST STAGE REDUCTION UNIT ONCE IN YEAR
GAS AIR MIXER ● ● ● ●
TWO STAGE REGULATOR SERVICING ONCE IN YEAR &
REPLACE RUBBER PARTS IF FOUND DAMAGED.
TYRE ROTATION ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃
PARTIAL ENGINE OVERHAUL ❃

@-If the vehicle is used under dusty condition, clean air filter bowl and replace cartridge more frequently
# - Engine oil grade - Selenia ‘ life oil’ 15 W - 50 (SL)
❉ - Transmission oil grade - Selenia ‘ life oil’ 80 W - 90
$ - Tutela Selenia ‘ life Brake Oil (DOT - 3)
♦ - Lubricate with Servo Molex grease.
CNG cylinder hydrostatic test - Every ‘5’ years from the date of previous testing.

21
 grEZ²Or/EbnrOr H$s Amd{YH$ aIaImd AZwgy{M

10000

15000

20000

25000

30000

35000

40000

45000

50000

55000

60000
1000

5000
g~ A°ŠQ>rpìhQ>r nwZñWm©nZ (~Xb|) ha ~ma

nwZñWm©nZ E`a {\$ëQ>a H$m{Q>©O @ ★ ★ ★ ★ ★ ★

(~Xb|) B§OZ Am`b # ★ ★ ★ ★ ★ ★
B§YZ Am`b {\$ëQ>a ★ ★ ★
bw~ Am`b {\$ëQ>a ★ ★ ★ ★ ★ ★
Q´>mÝg{_eZ Am`b ❉ ★ ★
~«oH$ Am`b $ ha 40000 {H$. _r. `m Xmo gmb Ho$ ~mX
~«oH$ hmog (a~a H$m) à{V 31000 {H$. _r. Ho$ ~mX
ñnmH©$ ßbJ ★ ★ ★ ★ ★ ★
\$ñQ>© ñQ>oO {\$ëQ>a gmb _| EH$ ~ma `m nyar Vah go MmoH$ hmoZo Ho$ ~mX
J¡g gmoboZm°B©S> {\$ëQ>a ★ ★ ★ ★ ★ ★
bmo àoea hmoOog gmb _| EH$ ~ma
grEZOr / EbnrOr hmog gmb _| EH$ ~ma
{\$ëQ>a Ebr_oÝQ> (EbnrOr) ha 5000 {H$. _r. `m B§{OZ J¡g gßbm` ewê$ H$aoŸ&>
Om±M VWm B§OZ Am`b bodb à{V 500 {H$. _r. Ho$ ~mX
g§_OZ H$a| Q>n¡ Qo > goQ>tJ ● ● ● ● ● ● ● ● ● ● ● ● ●

H$m~w©aoQ>a H$s Om±M ● ● ● ● ● ● ● ●

Q´>mÝg{_eZ Am`b bodb ● ● ● ● ● ●

nm{Hª$J ~«oŠg ● ● ● ● ● ● ● ● ● ● ● ●
pñQ>`[a¨J H$m°b_ [a¨J ZQ> ● ● ● ● ● ●

emH$ A°~gm~©a ● ● ● ● ● ● ● ● ● ● ● ●
{Z`§ÌU Ho$~ëg ● ● ● ● ● ● ●

âb¡pŠg~b H$nqbJ ~moëQ²>g ● ● ● ● ● ● ● ● ● ● ● ● ●

~¡Q>ar bodb (BboŠQ´>mobmBQ>) ● ● ● ● ● ● ● ● ● ● ● ● ●

MoZ Q>oÝeZa ● ● ● ● ● ● ● ●

hoS> b¡§n g_§OZ ● ● ● ● ● ●

g^r ìhrëg, hãO², H$nqb½O² Am¡a A°Šgb ZQ²>g ● ● ● ● ● ● ● ● ● ● ● ● ●

ñnrS>mo_rQ>a/AmoS>mo_rQ>a> H$s H$m`©Vm ● ● ● ● ● ● ● ● ● ● ● ● ●

g^r ~«oH$ H$ZoŠeÝg \$m°a brHo$O ● ● ● ● ● ● ● ● ● ● ● ● ●

Amb B§{OZ _mD§$Q>tJ \$mñQ>Zg© ● ● ● ● ● ● ● ● ● ● ● ● ●

noQ´>mob â`wEb {\$ëQ>a ● ● ● ● ● ●

~«oH$ Am`b bodb ● ● ● ● ● ● ● ● ● ● ● ●

Q>m`a àoea ● ● ● ● ● ● ● ● ● ● ● ● ●
B§YZ nmB©ßg² Am¡a `w{ZAÝg ● ● ● ● ● ● ●

EŠPm°ñQ> {gñQ>_ (gm`b|ga) (\$mñQ>Zg©) ● ● ● ● ● ● ● ● ● ● ● ● ●

J¡g {bHo$O (grEZOr/EbnrOr) ● ● ● ● ● ● ● ● ● ● ● ● ●

BbopŠQ>´H$b H$ZoŠeZ (ìhoBH$b/{H$Q>) ● ● ● ● ● ● ● ● ● ● ● ● ●

AmoìhaAm°b {H$Q> MoqH$J A°ÝS> g{d©g(grEZ²Or/EbnrOr) ha 3000 {H$._r. `m 6 _{hZmo§ _o EH$ ~ma Omo nhbm hmo
{MH$ZmE§ ♦ brdg© ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
{Z`§ÌU Ho$~b brdg© ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
\«§$Q> gñn|eZ Am_© ZH$b ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖ ❖
gm\ H$a| S´>m` Q>mB©n EAa {\$ëQ>a ❑ ❑ ❑ ❑ ❑ ❑ ❑
{gbtS>a hoS> {\$Ýg ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑
B§OZ Am`b ñQ´>oZa ● ● ● ● ● ● ●

\$ñQ>© ñQ>oO {\$ëQ>a ● ● ● ● ● ● ● ● ● ● ● ●

\$ñQ>© ñQ>oO [aS>ŠeZ `yZrQ> ha gmb
J¡g EAa {_Šga ● ● ● ●

Qy> ñQ>oO ao½`wboQ>a gmb _| EH$ ~ma g{d©gtJ `m H$moB© Qy>Q> {XImB© XoZo go&
Q>m`a amoQ>oeZ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃ ❃
Am§{eH$ B§OZ Amoda hm°b ❃
@ - `{X dmhZ H$ƒo Yyb ^ao amñVo na Mbm`m OmVm h¡, E`a {\$ëQ>a ~mD$b gm\$ H$a| VWm H$m{Q´>©O g_` go nhbo ~Xb|&
# - B§OZ Am`b J«oS> - gobo{Z`m ‘ bmB©\$ Am`b’ 15 W - 50 (SL)
❉ - Q´> mÝg{_eZ Am`b J«oS> - gobo{Z`m ‘ bmB©\$ Am`b’ 80 W - 90
$ - Qw>Q>obm gobo{Z`m ‘ bmB©\$ ~«oH$ Am`b (DOT - 3)
♦ - gdm} _moboŠg J«rg H$s ghm`Vm go {MH$ZmE§&
grEZ²Or {gbtS>a hm`S´>m°brH$ Q>oñQ> - nhbo Q>oñQ>tJ Ho$ ~mX ha "5' gmb _|

22
INSTRUCTIONS FOR MAINTENANCE
AND LUBRICATION
Principal Operations to be carried out :
1st 1000 kms
- Replace engine oil
- Replace lube oil filter
- Check spark plug gap
Every 5000 kms
- Rotate the tyres
- Lubricate front suspension arm knuckle.
- Lubricate levers and control cable levers.
- Check battery level and top up with distilled water
only
- Check and top up brake oil level
- Check and correct tyre pressure
- Clean air filter cartridge
- Check and adjust tappet clearance
- Check & top up gear box oil
- Check & top up engine oil
- Check exhaust system
Every 10000 kms
- Check fuel pipe & unions
- Inspect fuel filter
- Replace engine oil
- Replace lube oil filter
- Replace air filter cartridge
- Replace spark plug
aIaImd VWm bw{~«Ho$eZ AZwXoe
{H$E OmZo `mo½` à_wI n[aMmbZ
1st 1000 {H$. _r.
- B§OZ Am`b H$mo ~Xb| ▲
▲ - by~ Am`b {\$ëQ>a H$mo ~Xb|
- ñnmH©$ ßbJ J°n H$s Om±M H$ao
ha- 5000 {H$. _r.
- Q>m`a H$mo H«$_dma ~Xb|
- \«§$Q> gñnoÝeZ Am_© ZH$b {MH$ZmZm
- H§$Q´>mob Ho$~b Am¡a brda H$mo {MH$ZmZm
- ~¡Q>ar Ho$ ñVa H$s Om±M H$ao, `{X H$_ hmo Vmo {S>pñQ>ëS> dm°Q>a ^a|
- ~«oH$ Am`b ñVa H$s Om±M H$a| VWm nyam ^a| ●
● - Q>m`a àoea H$s Om±M H$a| VWm R>rH$ H$a|
- E`a {\$ëQ>a H$m{Q´>©O H$mo gm\$ H$a|
- Q¡>noQ> pŠb`aoÝg H$s Om±M VWm g_§OZ H$a| ★$
★
- {J`a ~m°Šg Am`b Ho$ ñVa H$s Om±M H$a| VWm nyam ^a|
- B§OZ Am`b Ho$ ñVa H$s Om±M H$a| VWm nyam ^a|
- EŠPm°ñQ> {gñQ>r_ H$s Om±M H$a|
ha 10000 {H$. _r.
- â`wEb nmB©n Am¡a Á`moS>m| H$s Om±M H$a|
★ - â`wEb {\$ëQ>a H$s Om±M H$a| ★
▲
- B§OZ Am`b ~Xb| ▲
❖
- by~ Am`b {\$ëQ>a H$mo ~Xb|
- E`a {\$ëQ>a H$m{Q´>©O ~Xb| ❖

Every 20000 kms - ñnmH©$ ßbJ H$mo ~Xb|

- Replace fuel filter ha-20000 {H$. _r.
Every 30000 kms - â`wEb {\$ëQ>a H$mo ~Xb|
- Replace transmission oil ◆ ha- 30000 {H$. _r.
- Q´>mÝg{_eZ Am`b H$mo ~Xb| ◆
▲- Engine oil grade - Selenia ‘ life oil’ 15 W - 50
(SL) ▲ - B§OZ Am`b J«oS> - gobo{Z`m ‘ bmB©\$ Am`b’ 15 W - 50 (SL)
◆ - Transmission oil grade - Selenia ‘ life oil’ 80 ◆ - Q´>mÝg{_eZ Am`b J«oS> - gobo{Z`m ‘ bmB©\$ Am`b’ 80 W - 90
W - 90 ● - Qw>Q>obm gobo{Z`m ‘ bmB©\$ ~«oH$ Am`b (DOT - 3)
● - Tutela Selenia ‘ life Brake Oil (DOT - 3)
★ - {n`m{O`mo ìhoB©H$ëg àm. {b. Ho§o$ A{YH¥$V S>rba / g{d©g ñQo>eZ
★ - Consult Piaggio Vehicles Pvt. Ltd. Authorised Dealer
/ Service Station H$mo g§nH©$ H$a| &
❖ - If the vehicle is used on dusty road, clean the ❖ - `{X dmhZ H$ƒo Yyb^ao amñVo na MbVm h¡, Vmo E`a {\$ëQ>a H$ìha
air filter cover & H$mo gm\$ H$a|, Am¡a E`a {\$ëQ>a H$m{Q>©´O H$mo {Z`{_V ~Xbr ŸH$a|&
replace the air filter cartridge more frequently

23
Filters
Air Cleaner :
A dry type air filter is mounted on the Engine and
conected to the inlet port on cylinder head with the
help of rubber hose and flange. And is readily
accessible for day - to day maintenance. Remove
and replace rubber bellow if, damaged. For replacing
air filter cartridge. Remove air cleanar bottom cover
check air filter cartridge and if requied replaced with
new a one.
Primary fuel filter (Petrol)
Check at every 10,000 kms and replaced if clogged.
For replacement of fuel filter proceed as follow.
1) Disconnect pipe connections by removing worm
clamps of both incoming and outgoing pipes.
2) Fit the new filter.
3) Connect incoming and outgoing pipes with worm
clamps.

Replacing Paper Cartridge in Air Filter Assembly.
The air filter can be accessed from engine door.
Remove lock from LH side & unscrew one wing nut
from RH side (Refer Fig. 3) & safely drop down the
rear door (tail gate) to approach the air filter. Remove
the knob of the filter cover (Refer fig. 24). Remove
the cover (Refer fig. 25) & then remove filtering
cartridge by pulling outward direction only. (Refer Fig.
26).
Replace old filter cartridge with new one. Refit the
filter cover. (Check for ‘O’ ring.) (Refer Fig. 26A)
Maintenance :
In order to maintain, high level of ‘filtration efficiency’
of the air cleaner unit, it is advisable that the air filter
element (Filtering carriage) & cover of the air cleaner
body is regularly cleaned by compressed air from
outside & inside (with air pressure not more than 5
kg/cm2). This will result in better performance of the
engine.
E`a {\$ëQ>a Ag|ãbr Ho$ nona H$m{Q©>O H$mo ~XbZm
B§OZ H$m XadmOm ImobH$a EAa {\$ëQ>a VH$ nhþ±M gH$Vo h¡Ÿ& ~mE± Amoa go
bm°H$ Imobo Am¡a Xm{hZo Amoa go qdJ ZQ H$mo Imob Xo Am¡a XadmO| H$mo ZrMo
Ü`mZnyd©H$ N>moS> X| (XoIo {MÌ 3)
{\$ëQ>a H$ìha H$m Zm°~ {ZH$mbo (XoIo {MÌ 24)& T>¸$Z (XoIo {MÌ 25>)
{ZH$mbo Am¡a Ho$db ~mhar ~mOy _| WmoS>m qIMVo hþE {\$ëQ>atJ H$m{Q>´>O
{ZH$mboŸ (XoIo {MÌ 26)&
nwamZm {\$ëQ>a H$m{Q´>©O ZE {\$ëQ>a H$m{Q´>©O Ho$ gmW ~XboŸ& {\$ëQ>a H$ìha H$mo
dmnrg {~R>m X|Ÿ& (‘O’ [a¨J H$s Om±M H$a|&)(XoIo {MÌ 26 A)&
aIaImd :
E`a {\$ëQ>a H$mo nyU©ê$ngo H$m`©j_ aIZo Ho$ {bE E`a {\$ëQ>a E{b_|Q>
({\$ëQ>atJ H$m{Q©>O) VWm EAa pŠbZa Ho$ T>ŠH$Z H$mo ^rVa Am¡a ~mha go
X~mB© hþB© hdm go (hdm H$m X~md 5 kg/cm2 go OmXm Z hmo) {Z`{_V
H$mbmd{Y _| gm\$ H$a|& Bggo B§OZ H$s H$m`©j_Vmna AÀN>m Aga nS>Vm
h¡&

Fig. 25 Fig. 26

24
 Fig. 26A

Note : While replacing the air filter element, check for gyMZm : EAa {\$ëQ>a E{b_|Q> ~XbVo g_` “O” ar§J H$mo Om±Mo VWm
“O” ring condition of air filter cover. If found damage Iam~ hmoZo na ~Xb Xo&
replace it.

25
CHANGING OIL
● Ride the vehicle for at least 2 kms. to get the correct
lubricant temperature. Do not warm up the engine
by idling.
● Clean the dipstick area and area to avoid dust /
sand entry entrapping into crankcase before
opening and closing.
● Lift the dipstick for air vent & for refilling.
● Remove the drain plug from pan and drain the oil.
(Refer Fig 21)
● Allow the oil to drain completely for 20 minutes.
● Remove the oil filter.
● Fill the new oil filter with fresh engine oil (As per the
grade and brands recommended in the operation
and Maintenance Manual) upto the thread portion.
(Allow the air to come out from oil cartridge). Fill the
oil slowly and apply oil on “O” ring face.
● Mount the oil filter with oil, on engine by hand tight.
● Clean the filter on drain plug. Clean the seating
surface of oil pan threaded boss & plug and then
fasten the drain plug, by hand upto stop & then,
apply the tightening torque of 24 ~ 33 Nm. (24 mm
DE Spanner)
● Fill the fresh oil 1.6 Lit. through dipstick seat.
● Ensure the oil level with dipstick at Max. level
position.
● Refit the dipstick.
● Keep the accelerate position in idling speed
condition.
● Crank the engine. Watch the warning indicator oil
pressure light (Red) goes OFF after cranking the
engine.
● Once after the warning light gets off allow the
engine to start with idling speed.
26
Vob ~XbZm
● B§OZ Am`b H$m R>rH$ Vmn_mZ {_bZo Ho$ {bE dmhZ H$mo H$_ go H$_
2 {H$._r. MbmE& B§OZ H$m Vmn_mZ Am`S>qbJ na aIHo$ Z ~‹T>mE&
● {S>npñQ>H$ H$s OJh Am¡a Am`b S>mbZodmbo ßbJH$mo AÀN>r Vahg|
gm\$ H$a|, Vm{H$ \$g| hþE Yyb {_Å>r Ho$ H$U Vob Ho$ gmW H«¢$H$Ho$g _o
Z Om nmE§&
● hdm Ho$ {ZH$mg Ho$ {bE Am¡a Am`b {\$a go ^aZo Ho$ {bE {S>npñQ>H$
~mha {ZH$mb| Ÿ&
● S´>oZ ßbJ H$mo Imob X| Am¡a Am`b {ZH$b OmZo X|& (XoIo {MÌ 21)
● 20 {_{ZQ> VH$ Am`b nyar Vahgo ~mha OmZo XoŸ&
● Am`b {\$ëQ>a {ZH$mb Xo Ÿ&
● Am`b {\$ëQ>a_| "n[aMmbZ VWm aIaImd' nwpñVH$m_| {g\$m[ae {H$`m
J`m Z`m Am`b YraoYrao S>mbo& `o gw{Z{üV H$a| H$s Am`b {\$ëQ>a Ho$
W«oqS>J H$s OJh VH$ Am`b ^am hmoŸ&(hdm H$mo Am°`b H$m{Q´>Ogo ~mha
AmZo XoŸ&) “O” [a¨J Ho$ Cna Am°`b bJm Xo Am¡a Yrao Yrao J{V go Am°`b
^ao&
● Am`bgo ^ao hþE Am`b {\$ëQ>a H$mo B§OZ na hmW go H$g|&
● S´>oZ ßbJ na pñWV {\$ëQ>a H$mo gm\$ H$a|& S´>oZ ßbJ Ho$ dm°ea H$mo ~Xb
Xo VWm Am°B©b n°Z ~m°g Am¡a ßbJ OmoS>Zo H$s OJh H$mo gm\$ H$ao Am¡a
Am°B©b n°Z Ho$ Cna S´>oZ ßbJ OmoS> Xo (Q>m°H©$ 24 ~ 33 Nm)& (24 {_.{_.
S>rB© ñn¡Za )
● ~mŠg na {XE {N>Ðgo 1.6 brQ>a Z`m Am`b S>mb|&
● `o gw{Z{üV H$a| H$s, Am`b H$m ñVa {S>npñQ>H$ na {XE JE A{YH$V_
ñVaHo$ {ZemV VH$ h¡&
● {S>npñQ>H$ dmnrg {~R>m`|&
● EŠgrboQ>a H$mo Am`S>b ñnrS> na aI| &
● B§OZ H$mo H«¢$H$ H$a|Ÿ& gw{ZpíMV H$a| {H$, B§OZ H$mo H«¢$H$ H$aZo H$o$ ~mX
MoVmdZr Vob X~md bmB©Q> (bmb) ~§X hmo &
● bmb bmB©Q> ~§X hmoZo na B§OZ H$mo Am`S>b JVr _o ewê$ aI|
Transmission : Q´>m§g{_eZ :
Drain off oil through the drain plug provided on the bottom {J`a ~m°Šg Ho$ {ZMbo ^mJ _| {XE JE Só>Z ßbJ H$mo ImobH$a Am°`b
side of the gearbox. Refit the drain plug and fill the oil {ZH$mb| (XoIo {MÌ 23) & Só>Z ßbJ H$mo {\$a go bJm X|& VWm {S>npñQ>H$ na
through the dipstick hole till the oil level reaches to
maximum position marked on the dipstick. (0.85 Lit.)
{MÝhrV A{YH$V_ pñWVr VH$ {S>npñQ>H$ Ho$ N>oX _| go Am°`b ^a| &
(0.85 brQ>a) (XoIo {MÌ 22>)
Use Taper funnel for oil filling.
Am°`b ^aZo Ho$ {b`o Q>ona \$Zob H$m BñVo_mb H$ao
Oil Recommended grade
Engine oil grade Selenia ‘ápe life oil’
SAE15 W-50 (SL)
Differential Selenia ‘ápe life oil’
SAE 80 W-90

27
LUBRICATION
SYSTEM
LUBRICATION SYSTEM (Fig NO. )
To reduce the friction between two moving parts,
lubricate them periodically. Insufficient lubrication will
cause rapid wear damaging the parts prematurely.
Caution - Warning
The engine can be damaged if allowed to operate
with insufficient oil.Nothing more than lubrication
oil can influence the performances and life of an
engine.Use of an inferior quality oil or failure to
regularly change the oil will increase the risk of
piston seizure, will cause the piston rings to jam
and will lead to rapid wear on the cylinder liner, the
bearings and all other moving parts. Engine life
will also be notably reduced.The oil viscosity must
suit the ambient temperature in which the engine
operates.

Caution - Warning
Old engine oil can cause skin cancer if repeatedly
left in contact with the skin and for long periods of
time. If contact with the oil is unavoidable, you are
advised to wash your hands with soap and water
as soon as possible. Dispose of old oil in the correct
way as it is highly polluting.
 Lubricate every time after washing the vehicle and
whenever the vehicle is operated under wet, rainy
conditions. Before lubricating, clean off rusty parts
and wipe off old grease, oil or dirt.

1. Oil Level
2. Intake Oil Filter
3. Flow Filter Cartridge
4. Pressure Sensor
5. Oil Pump
6. By-Pass Valve
7. φ1.1 mm Dowel
8. Spray Piston Cooling
9. Return oil from the timing
chain compartment

31
LUBRICATION FLOW CHART
On Piston bottom spray Camshaft & Rocker lever
oil by nozzle

Cylinder head
Piston cooling nozzle
from crank bore groove

Cylinder Block
Con rod bearing

Oil spray Nozzle (Fit in

FSHC oil gallery)
Crankpin – from journal
inclined hole
Crankcase top face
through oil gallery from
Journal Diameter & crankbore
bearing

Crank bore (Crankshaft,

con rod bearing, crank
Crank bore oil groove bearing)

6) FSHC Crankcase
Relief Valve TSHC main Oil gallery
main oil gallery

Oil sensor –
Oil sump - excess oil sense oil present
Oil drain Plug in gallery 5) Oil filter
after more pressure

4) Lub oil pump outlet

by gallery

3) Lub oil pump inlet by

gallery

2) Primary Oil filter

1) Oil sump

32
SPARK PLUG REMOVAL PROCEDURE (Refer
Fig. 31a)
- Remove the spark plug by using plug spanner,
provided in vehicle tool kit.
- Check the gap 0.7 ~ 1.0 mm. Change the spark
plug if the gap is larger than 1.0 mm.
- Refit the spark plug in its location. Rotate 900 (¼ turn).
After the spark plug washer is fully in contact with its
seat.
ñnmH©$ ßbJ {ZH$mbZo Ho$ {bE àH«$s`m
(XoIo {MÌ 31a)
- Qy>bH$sQ> _| {XE hþE ßbJ ñn°Za H$s ghm`Vm go ñnmH©$ ßbJ {ZH$mb|Ÿ&
- J¡n H$s Om±M H$a|& (0.7 go 1.0 {_.{_.) `Xr `h J¡n 1.0 {_.{_. go
μOmXm hmo Vmo ñnmH©$ ßbJ ~Xb X|&
- ñnmH©$ ßbJ AnZr OJh na R>rH$go bJmE& ñnmH©$ ßbJ dmea, ñnmH©$
ßbJ Ho$ ZrMbo {hñgo go nyU©V: Ow‹S>Zo Ho$ ~mX 900 (¼ Kw_mZm) VH$
Kw_mB©E&

Fig. 31a

Tyre Pressure Q>m`a àoea

Front Wheel Rear Wheel AmJo H$m n{h`m {nN>bm n{h`m
2 2
Passenger Vehicle 2.1 kg/cm 2.4 kg/cm n¡goÝOa dmhZ 2.1 {H$. J«m./go§._r.2 2.4 {H$. J«m./g|._r.2
(30 psi) (34 psi) (30 psi) (34 psi)

33
CHANGING WHEELS & TYRES
The wheel jack and the spare wheel are stored in the
interior of the cabin.
For removing the jack unhook the straps from their
clamps. Remove the jack from the clamp, pull the
hand brake, and loose the wheel retaining nuts. Place
the jack as shown in fig 28. Then jackup the vehicle
until the clearance between the wheel and the ground
is some cms. (approx. 3 cms.). Then remove the
securing nuts and take out the wheel.
On reassembling progressively screw the wheel nuts
and lower the vehicle slowly to the ground, then tighten
the nuts. When possible, change the wheel with the
vehicle on the level, if that is not possible, place wedge
under rear wheel. (Refer Fig 27, 28 & 30)
Fig. 27
34
n{h`o VWm Q>m`a ~XbZm
n{h`o H$m O¡H$ VWm A{V[aº$ n{h`m Ho${~Z Ho$ A§XéZr {hñgo _| aIo J`o h¡&
O¡H$ {ZH$mbZo Ho$ {bE nÅ>m| H$mo CZHo$ Šb¡ån go {ZH$mb|& O¡H$ H$mo Šb¡ån go
{ZH$mbo§ VWm h¡ÊS> ~«oH$ H$mo ItMo Am¡a n{h`o Ho$ ZQ>m| H$mo T>rbm H$ao & O¡gm
{MÌ 28 _| {XIm`m J`m h¡ O¡H$ H$mo aIo, CgHo$ ~mX dmhZ H$mo O¡H$ H$s
ghm`Vm go BVZm D$na CR>mE§ {H$ n{h`o VWm O_rZ Ho$ ~rM A§XmOZ 3 go.
_r. H$m \$mgbm hmo & CgHo$ ~mX ZQ> H$mo ImobH$a n{h`o H$mo ~mha {ZH$mb|&
n{h`o H$mo {\$a go {~R>mVo g_` n{h`o Ho$ ZQ> H$mo {~R>mE§ {\$a dmhZ H$mo Yrao
go ZrMo CVmaZo Ho$ ~mX ZQ>m| H$mo H$g X| & `{X g§^d hmo dmhZ H$mo EH$ ñVa
na aIH$a n{h`m ~Xb|, `{X `h g§^d Zht h¡ Vmo {nN>bo n{h`o Ho$ ZrMo
nƒS> aIo (XoIo {MÌ 27,28 VWm 30>)
Fig. 28
TYRE ROTATION (Refer Fig. 30)
1. Rotation of tyres in a vehicle is recommended for
uniform pattern of wear on all the wheel positions
to achieve optimum tyre life.
2. It is preferred that rotation is carried out at around
every 5000 kms. However in case of any sign of
uneven wear, rotation can be done earlier.
3. Prior to rotation it is advisable to check the
condition of suspensions etc., particularly for the
positions where uneven wear is observed.
Fig. 29
35
Q>m`a H$mo H«$_dma ~XbZm (XoIo {MÌ 30)
1. Q>m`a H$s Am`w A{YH$ go A{YH$ ~‹T>mZo Ho$ {bE VWm CZHo$ {KgZo _|
EH$énVm hmo Bg{bE Q>m`am| H$mo H«$_dma ~XbZo H$s gbmh Xr OmVr h¡
&
2. ha 5000 {H$. _r. Ho$ ~mX n{h`m| H$m ~XbZm C{MV hmoJm {\$a ^r
`{X `h nm`m OmE {H$ n{h`m| H$m {KgmZ EH$ O¡gm Zht h¡ Vmo `h
{H«$`m OëXr ^r H$a gH$Vo h¡ &
3. n{h`o H$mo ~XbZo go nhbo gñn|eZ H$s pñWVr H$s Om±M H$aZm C{MV
hmoJm {deofH$a {Og ^mJ _| n{h`o {Kg JE h¡, CgH$s Om±M Oéar h¡&
Fig. 30
BRAKE INSPECTION ~«oH$ H$mo g_§{OV H$aZm
If the wheels rotate freely when the brake pedal and `{X g^r n{hE ~«oH$ noS>b VWm h¡ÊS>> ~«oH$ brda Ho$ gm_mÝ` pñW{V _o§ hmoVo
the hand brake lever are in their ‘Rest position’ and if
the wheels stop rotating immediately when the brake
hþE AmgmZrgo Ky_Vo hm| VWm ~«oH$ noS>b n[aMm{bV H$aZo na Vwa§V éH$Vo hm|
pedal is operated, it indicates that the brakes are Vmo ~«oH$ H$s pñWVr ghr h¡ `h _mZ gH$Vo h¡ &
correctly set. Bg dmhZ _| {~R>m`o hþE ~«oH$ ñd`§g_§{OV hmoZo Ho$ H$maU ~«oH$
As brakes fitted in this vehicle are self adjusting Ag_§OZ H$s pñWVr _o A{YH¥$V gìhug ñQo>eZ _| g§nH©$ H$a| &
type, in case of improper adjustment refer ~«oH$ âbwB©S> ñVa (XoIo {MÌ 31) : ~«oH$ Am`b Ho$ ñVa H$s Om±M Cna
authorised service station.
BRAKE FLUID LEVEL (Refer Fig. 31)
go dmhZ Ho$ XmE± ~mOy go H$s OmVr h¡ &
Brake oil level can be checked from the top side, from
RHS of the vehicle.

Max.
Min.

Fig. 31

36
TUNING PROCEDURE
(PETROL & GAS)
OPERATIONS AND CHECKS BEFORE PUTTING
THE VEHICLE IN OPERATION :

After engine and other unit overhauls and before

handing over the vehicle to its owner, check for
the following :

1. Check nuts and bolts for tightness, particularly

the wheels and brake drums securing nuts.

2. Efficiency of front and rear suspension.

3. Top-up oil in engine and gearbox.

4. Check for any leakage of oil and fuel.

5. Brake efficiency.

6. Check tyre pressure.

7. Controls adjustment.

8. Fluid level in master cylinder reservoir.

9. Efficiency of electrical equipment.

10. Check electrolyte level in the battery.

11. Road holding.

12. Clean the vehicle. For engine outer surfaces use

paraffin, for paint work use water and chamois
leather.

13. Headlamp adjustments.

14. Check battery connections. +ve (Positive) and

–ve (Negative) terminals must be connected with
the respective cables. Incorrect connections may
damage the regulator.

39
Fuel consumption test :

Before conducting the fuel consumption test proceed

as follows :

1) Fill the petrrol tank to its full capacity

2) Carry out the air bleeding from the fuel system

3) Again ensure the petrol tank level and if required

top up.

For conducting fuel consumption test proceed as

follows :

1) Load the vehcile with no. Passengers as

recomanded (3+1)

2) Distance to be covered : 30 kms i.e 15 kms going

and 15 kms return.

Tyre pressure to be maintained :

Wheels Front Rear

Pressure 2.1 kg/Sq.cm 2.4 kg/Sq.cm

After covering 30 kms. Top up the pertol tank to the

original level (Measured quantity)

Calulate the fuel consumption as : Kms covered

devided by the quantity of oil consumed.

Note : The consumption depends on the operating

conditions.

40
TUNING PROCEDURE
1. SCOPE :
This standard specifies the Starting & Tuning
Procedure in Field of 3 wheeler 4 stroke vehicles with
Spark Ignition (SI) Engines .

2. APPLICABILITY :
This standard is applicable to the Ape City Vehicles
with PAX-200 cc engine

3. PURPOSE :
The purpose of the standard is to provide uniform
method of Starting and Tuning criteria APE City Petrol,
CNG & LPG vehicles in Field.

4. GENERAL REQUIREMENTS :
4.1 Vehicle should be serviced as per Service check
list .
4.2 All lubricants points shall be lubricated with
specified lubricants like grease, oil etc. to the
specified quantities.
4.3 Controls like brakes, clutch, accelerator and gear
shifter shall be adjusted properly to provide
specified clearances, free play etc.
4.4 Ensure flexible hoses for CNG/LPG are not kinked,
twisted and properly bend radius is provided.
4.5 Check CNG filling valve & Pressure gauge
position. Also check Filler valve of LPG vehicle
4.6 Ensure no leakage in intake system.

5. LEAKAGE TEST on LPG & CNG

5.1 CNG vehicle Apply 12 V DC supply externally to
the gas solenoid valve. Ensure all joints (Bull nose
connector, 4 sides of junction block, first stage
regulator out CNG regulator) are leak proof by
using mild soap water solution or equivalent
solutions. Test to be conducted with cylinder
pressure of min 50 bar.
5.2 LPG vehicle Apply 12 V DC supply externally to
the Multi function valve solenoid valve. Ensure
all joints of multi function valve are leak proof by
using mild soap water solution or equivalent
solutions. Test to be conducted with cylinder
pressure of 10 bar.

6.0 IDLE SETTING & STARTING PROCEDURE ON

PETROL MODE
6.1 IDLE SETTING ON PETROL MODE
The vehicles must be filled with sufficient (0.6 ltrs )
petrol.
1. Engine tachometer device installation
a. Inductive sensor, to use the High Voltage
wiring
2. Muffler leakage test
a. Start the engine and leave it at idling
b. Tap the exhaust tube of the muffler with a
rubber plug
i. If the engine speed drops down and the
engine stops the test is OK
41
 ii. If the engine doesn’t stop the test is NOT
OK ?the vehicle must be repaired
3. CO probe installation
a. Remove the tapping screw
b. Check the thread condition
c. Install the probe
4. CO probe leakage test
a. Climp the rubber tube close to the muffler
b. Check the gas flow into the CO tester: must
me zero
5. Engine tachometer test
a. Check the correct functionality of the engine
tachometer: the engine runs with 1 spark every
2 turns.
6. Warm up vehicle for min 3 kms on road
7. Engine at idle, in NEUTRAL
8. Check idle speed:
a. Set the speed: 1150-1250 rpm
9. CO test
a. CO+CO2 must be correlated
i. In case of NOT check leakage
b. Check the CO% level at Idle RPM
i. If the CO% is into the tolerance : 4%
vol the test is OK
ii. If it’s not the test is NOT OK ?the vehicle
must be repaired
10.Actions before Idle test
a. Remove the CO probe
b. Apply the muffler tap.
i. If the vehicle is PETROL VERSION then
execute the “Muffler leakage test (see point 2)

6.2 STARTING PROCEDURE ON PETROL MODE

6.2.1 VEHICLE COLD STARTING PROCEDURE:
1. Ensure vehicle is in Neutral gear
2. Keep Choke is in ON position
3. Press Clutch lever ,
4. Start Vehicle by pressing Push button till engine
starts.(Starter will run for max. 7 sec and stops
automatically) ,open accelerator slightly if required.
5. If engine does not start ,Make Ignition Switch
Off and again Switcth ON
6. Repeat point 3 &4.
7. Hold accelerator partially open ( i.e.8 to 20 % )for
min .1 minute.
8. Set Choke to OFF position .
9. Allow engine to attain stable Idling
10.Then proceed
OR
11.Start running vehicle in Choke ON position for @
0.5 kms and then remove choke in vehicle
running condition.
12.Then proceed.

6.2.2 VEHICLE HOT /WARM ENGINE STARTING

PROCEDURE
1. Do NOT use Choke
2. Rotate acclerator to 1/8 Turn and start engine.

42
3. Then proceed.

7.0 IDLE SETTING & TUNING PROCEDURE ON

BI-FUEL VEHICLES
7.1 IDLE SETTING Petrol mode.
As per procedure 6.1 and set RPM to 1500+/-50 rpm
with CO-3-3.5 % vol.

7.2 TUNING PROCEDURE ON CNG/LPG fuel

• Keep the change over switch on Neutral position.
• Consume the complete petrol in carburetor bowl.
• Put the vehicle change over switch on LPG / CNG
mode.
• Change over the Gas Analyzer mode to LPG/CNG
mode
• Put the ignition switch in ON position and wait for
the yellow LED on vehicle changeover switch to
glow off & then crank the engine.
• Rave up Engine and set Lambda & CO as per
annexure -1

7.3 Idle RPM & CO setting in Gas mode

• Put engine in idle condition.
• Check and set the idle rpm to 1250±50 rpm and
Lambda to 1.2±0.05 by Idle setting screw on Pr.
Reducer and mark by paint before putting cap on
Idle screw.
• Rave up the engine to moderate RPM (@ half
throttle opening) with accelerator control and then
release the same to reconfirm the RPM & Co
setting as specified.
• If the idle CO & RPM are within specified limits
proceed to further steps / if not repeat the RPM &
CO setting.

Notes :
1) Ensure min. 80 bar Gas pressure for CNG vehicle
tune-up & min. 4 ltrs of LPG gas availability in the
cylinders
2) For critical performance components i.e
Regulators ,Carburetor, Mixer assly ,Restrictors,
Intake and exhaust system ,please ref.annex-2

7.4 VEHICLE COLD STARTING PROCEDURE:

It is necessary to start vehicle on Petrol mode to
improve engine life.
1. Ensure vehicle is in Neutral gear
2. Keep Choke is in ON position
3. Press Clutch lever ,
4. Start Vehicle by pressing Push button till engine
starts.(Starter will run for max. 7 sec and stops
automatically) ,open accelerator slightly if required.
5. If engine does not start ,Make Ignition Switch Off
and again Switcth ON
6. Repeat point 3 &4.
7. Hold accelerator partially open ( i.e.8 to 20 % )for
min .1 minute.
8. Set Choke to OFF position .

43
9. Allow engine to attain stable Idling
10.Then proceed OR
11. Start running vehicle in Choke ON position for @
0.5 kms and then remove choke in vehicle running
condition.
12.Then shift to CNG/ LPG mode.

7.4.1 VEHICLE HOT /WARM ENGINE STARTING

PROCEDURE on CNG/LPG
1. Rotate acclerator to 1/8 Turn and start engine.
2. Then Proceed.

Recommended instruments
1) Gas analyzer : AVL make, 4 Gas analyzer (Model
4000L) of equiv
2) Engine Tachometer: Any reliable capable of taking
signal from HT cord.
3) Chassis dyno. Suitable for 3 wheeler application.
4) Special connector

Fig.
Oil Filling:-
i) Crank case + 1600ml of SAE 15W50 oil.
gear box:
ii) Differential gear 850ml of SAE 80W90 oil.
housing:

3. Tyre Inflation Pressure:

I. Front wheel: 2.1 Kg/cm2

II. Rear wheels: 2.4 Kg/cm2

Annexture: 1
Engine Rave –up Setting on CNG/LPG mode
Engine RPM Emission to be Set
Lambda CO (% vol)
6000: set 1.31-1.36 0.06 - 0.05
4700: Confirm 0.877-0.965 3.88-1.93

44
Annexture: 1

45
 TORQUE CHART
(ENGINE & VEHICLE)
 TORQUE VALUES - ENGINE

SR.NO. PART DECRIPTION TORQUE VALUE IN NM

1 Ball bearing 8 ~ 10

2 Stem 18 ~ 20

3 FSHC on TSHC - "22" BOLTS 11 ~ 13

4 Oil plug 24 ~ 33

5 Oil filter screw on FSHC 35 ~ 40

6 Oil filter 4~6

7 Oil pressure switch on FSHC 12 ~ 14

8 Taper thread plug on TSHC 9 ~ 11

9 Oil drain Screw on TSHC 15 ~ 17

10 DGC Assy. On TSHC - 10 bolts 24 ~ 27

11 Lock plate on Diff. cage - "6" screw 65 ~ 70

12 Bolt spring retaining 20 ~ 25

13 Sensor plate support 9 ~ 10

14 Brake light switch 2~3

15 Oil pump 5~6

16 Oil pump crown 10 ~ 14

17 Chain tightening rod - One screw 11 ~ 14

18 Oil pump bulkhead 4~6

19 Nut on studs ( Cyl. Head) - Pre tighten 6~8

20 Steel sheet on cylinder head 11 ~ 13

21 D comp. mass containment on timing crown 7 ~ 8.5

22 Cam clutch on hub 11 ~ 13

23 Cam clutch Assy 75 ~ 85

24 Chain tensioner support 8 ~ 10

25 Chain tensioner 5 ~6

26 Cylinder head nuts 25 ~ 28

27 Cylinder head lateral screws 11 ~ 13

28 Valve adjustment 6~8

29 Starter motor 11 ~ 13

30 Clutch Assy 30 ~ 35

31 Cylinder head cover 11 ~ 13

32 Clutch cover / TSHC 11 ~ 13

49
SR.NO. PART DECRIPTION TORQUE VALUE IN NM

33 Oil bulk head 4~6

34 Bellow on clutch cover - clip 1 ~ 1.5

35 Oil exhaust screw 15 ~ 17

36 Starter cover on crankcase - 10 screws 11 ~ 13

37 Gear shifter Assy. 11 ~ 13

38 Pick up coil 3~4

39 Oil dipstik 1.5 ~ 2.5

40 Intake shroud 3~4

41 Exhaust shroud 1~2

42 Fan support on starting cover 11 ~ 13

43 Rotor on crankshaft 75 ~ 85

44 H.T. Coil 11 ~ 13

45 Fan Assy. 11 ~ 13

46 Fan cover on fan Assy. 1~2

47 carburettor & Intake fitting 11 ~ 13

48 Spark plug 11 ~ 13

49 Fare meter 11 ~ 13

50 Bolt spring retaining 20 ~ 25

50
SR POSITION THREAD SIZE TIGHTENING
NO DIA (mm) x PITCH(mm) TORQUE (Kg-m)

VEHICLE

1 Handlebar on Steering Column 4-5

2 Nut on Front Shock-Absorber (Bottom) 10 - 13

3 Ring Nut for Upper Ball Bearing Track 5-7

4 Hub on Steering Column 10 - 12

5 Nut on Rear Shock-Absorber (Upper) 3–4

6 Nut on Rear Shock-Absorber (Lower) 4.5

7 Wheel Rim to Brake Drum 10 - 16

8 Bolt-Tightening Rear Hub on Triangle 4.7 - 6

(Bkt. Rear Suspension)

9 Bolt for tightening triangle 4-5

(Bkt. Rear Suspension) on Engine Support

10 Nut for Elastic Coupling 4-5

11 Nut for Tightening Coupling on Axle Shaft 5-7

12 Caulking Nut on the Wheel Axle 14 - 18

13 Rear Buffer for Engine 4-5

14 Front Buffer for Engine 7

15 Clutch cover nut 6x1 0.6 - 0.8

16 Differential cage tightening nut 10 x 1.25 6.5 - 7

17 Gear box cover nut 8 x 1.25 2.2 - 25

18 Gear box nuts with PTO cover 8 x 1.25 3.6

19 Gear Shifter Housing 6x1 0.6 - 0.8

20 Fare meter Hsg. bolt 6x1 0.6 - 0.8

21 Gear box main Hsg. stud 8 x 1.25 2 - 2.5

22 Oil sump 8 x 1.25 2.3

23 Intake Flange 8 x 1.25 2.6

51
TROUBLE SHOOTING
(PETROL & GAS)
 FAULT FINDING
A. Engine Section
I. Engine Fails to Start
Fault Causes
1) Engine does not start a Grounded spark plug
b Broken OR Disconnected cable
c Faulty coil
d Faulty rotor
e Cable clamp loose /Oxidized
f Demagnetised fly wheel
g Clogged pipes
h Clogged Fuel filter
i Presence of air in the fuel circuit i Check and tighten fuel line connections,
j Clogged tank breather(cap)
k Clogged carburattor breathers
l Dirty carburattor
m Low barrtery
n Faulty starting switch
o Faulty starting motor
p Sticking valves
q Broken timing belt
Gas Kit
a Gas solenoid not working
b Gas LPG tank empty
c Shut off manual knob closed
d Gas in copper tube choked
e No spark
f Presence of petrol in the vehicle f Consume Petrol in carburettor by runing
carburettor
g Disengagement of low pressure
hose from the mixer/reducer
h Excess gas flow / rich mixture
55
Remedies
a Check and replace ,if necessary
b Check and replace the cable, if necessary
c Replace if required
d Replace if required
e Tighten/Change
f Check and Replace , if necessary
g Flush out the lines,tighten the
connections& bleed the fuel system
h Replace the fuel filter
replace leaking pipes, copper washers
and bleed out the entire fuel supply line.
j Check and replace,if necessary
k Flush and clean the breather hole
l dismantle and Clean it throuhly and re
asemble
m Check and re charge the battery
n Check and replace, if necessary
o Check and replace, if necessary
p Free the valves & lap the valves
q Check and replace, if necessary
a i) Loose connection of battery / couplers
ii) Make firm connections
iii) Check gas line fuse if found blown off,
iv)Replace fuse with correct rating
v) Check solenoid operation.
b Fill LPG tank with gas
c Open shut - off valve on multi valve
d Clean the dust particles with
compressed air
e Check spark at spark plug.
the vechicle on petrol, then switch over
to LPG mode.
g Put it in the right position and clamp
it firmly
h Adjust the gas flow in the power valve.
Fault Causes
i Gas air mixer not working
properly
2. Engine starts & stops a Clogged pipes
b Clogged Fuel filter
c Presence of air in the fuel circuit c Check and tighten fuel line connections,
d Clogged tank breather(cap)
e Clogged carburettor breathers
f Dirty carburattor
g Blocked carburettor needle valve
h Faulty coil
i Air filter clogged
j Disturbed carburation
k Low idle setting
l Sticking valves
3. No power a Demagnetised fly wheel
b Disturbed carburation
c Sticking valves
d Worn / blocked pistion rings
e worn / blocked cylinder
Gas Kit
a Gas cylinder almost empty
b Gas hose connection broken
/ crushed
c Poor gas air mixing
d Inadequate flow of gas
4. Noisy a Excessive Tappet clearance
5.White smoke a Excessive idle operation
b Incomplete running-in
c Worn / blocked pistion rings
d worn / blocked cylinder
e Oil level too high
6.Black smoke a Clogged carburattor breathers
b Dirty carburattor
c Air filter clogged
56
Remedies
i Remove mixer clean the mixer & gas
entering holes
a Flush out the lines,tighten the
connections& bleed the fuel system
b Check and replace,if necessary
replace leaking pipes, copper washers
and bleed out the entire fuel supply line.
d Check and replace,if necessary
e Flush and clean the breather hole
f dismantle and Clean it throuhly and re
asemble
h Check and Replace, if required
i Replace the catridge
j Adjust the carburation
k adjust the idle setting
l Free the valves & lap the valves
a Check and Replace , if necessary
b Adjust the carburation
c Free the valves & lap the valves
d Check and replace, if necessary
e Check and replace, if necessary
a Check & fill
b Make flexible and uncrushed connetion
c Check the vehicle carburetion
d Adjust the power valve to an optimam
level
a Check and Adjust the tappet clearance.
a Check and set the Engine idling rpm
c Check and replace, if necessary
d Check and replace, if necessary
e Check and correct the oil level
a Flush and clean the breather hole
b dismantle and Clean it throuhly and re
asemble
c Replace the catridge
Fault Causes
7. Hunting a Clogged Fuel filter
b Clogged tank breather(cap)
c Dirty carburattor
d Disturbed carburation
8. Excessive Lube a Worn / blocked pistion rings
Oil consumption
b worn / blocked cylinder
c Oil level too high
9. Over heats a Engine over loaded
b Clogged fly wheel and side walls
c Sticking valves
10.Poor acceleration a Faulty coil
b Demagnetised fly wheel
c Clogged carburattor breathers
d Dirty carburattor
e Blocked carburattor needle valve
f Air filter clogged
g Engine over loaded
h Disturbed carburation
i Worn / blocked pistion rings
j Worn / blocked cylinder
11. spark plug failure a.Grounded spark plug
b.Broken OR Disconnected
c.Faulty coil
d.Demagnetised fly wheel
12. Un stable engine a.Faulty coil
operation
b.Clogged carburattor breathers
c.Dirty carburattor
13.Poor combustion a.Faulty coil
b.Demagnetised fly wheel
14.High Oil pressure a. Pressure regulating valve
Jamed / dirty
57
Remedies
a Replace the fuel filter
b Check and replace,if necessary
c dismantle and Clean it throuhly and re
asemble
d Adjust the carburation
a Check and replace, if necessary
b Check and replace, if necessary
c Check and correct the oil level
a Reduce the load to the specified
b Clean and blow with pressurised air on
the fly wheel walls
c Free the valves & lap the valves
a Check and Replace, if required
b Check and Replace , if necessary
c Flush and clean the breather hole
d dismantle and Clean it throuhly and re
asemble
f Replace the catridge
g Reduce the load to the specified
h Adjust the carburation
i Check and replace, if necessary
j Check and replace, if necessary
a.Check and replace ,if necessary
b.Check and replace the cable, if necessary
c.Replace if required
d. Check and Replace , if necessary
a.Replace if required
b.Flush and clean the breather hole
c. dismantle and Clean it throuhly and re
asemble
a.Replace if required
b. Check and Replace , if necessary
a. clean the valve and replce, if
necessary
 Fault Causes
15.Low oil pressure a.Grounded spark plug
b.Broken OR Disconnected
c. Pressure regulating valve
Jamed / dirty
d.Worn Oil pump
e.Air in Oil intake pipe
f.Defective pressure gauge /
pressure switch
g.Oil intake pipe clogged
h.Oil filter clogged
16. Hunting a. Oil filter clogged
b. Pressure regulating valve jamed
oe dirty
c. Excessive valve clearance
17. High fuel a. Clogged fuel filter
Consumption b. Clogged tank breather cap
c. Dirty carburettor
e. Improper carburettor / kit setting
Gas Kit
a. Choked air cleaner cartridge
b. Leakage of high - pressure line /
Multi function valve gas solenoid
/ joints
c. Excess flow of gas
d. High idling speed
18. Selector switch a. No power supply to switch
not working couplers / adopters
b. Improper inductive pick up signal
c. Improper adjustments of timing
delay
58
Remedies
a.Check and replace ,if necessary
b.Check and replace the cable, if necessary
c. clean the valve and replce, if necessary
d.Replace the oil mpump.
e. Check and tighten fuel line connections,
replace leaking pipes, copper washers
and bleed out the entire fuel supply line.
f. Replace the pressurre gauge/ pressure
switch
g. Flush out the lines,tighten the
connections& bleed the fuel system
h. replace the Oil filter
a. replace
c. Adjust the valve clearance.
a. replace the fuel filter.
b. Ensure proper yank breathing
c. clean.
e. Adjust
Clean/replace
b. Check and arrest the leakage.
c. Adjust the power valve to an
optimum level
d. Adjust idling in vehicle carburettor and
gas idling in vaporise
a. Loose connection of battery /
couplers / adapters. Make firm
connection. check main line fuse
& confirm the recommended fuse
ignition coil.
b. Maintain firm connection from ignition coil.
c. Correct the delay setting.
 Fault Causes
19.Automatic fill limitor a. Wrong Multi function valve fitment
not working properly. angle.
b. Parking the vehicle in slop during.
filling
c. Wrong fittment of Multi function valve.
20. Engine run on gas a. Idle adjustments made on vehicle
with erratic idling carburetor
b. Erratic idling setting - vaporiser
c. Failure of ignition system
d. Spark plug - failure
e. Air cleaner choking
f. Reducer idling spring damage
g. Throttle not closing fully
h. Vacuum circuit leakage
High Fuel Consumption
a. Fuel system. a. Fuel leakage.
b. Poor quality fuel.
b. Lack of proper a. Valve clearance incorrect, valve
maintenance. sticky.
b. Air cleaner paper cartridge clogged.
c. Exhaust muffler blocked.
d. Engine compression low.
e. Engine internal friction high.
c. Operating conditions. a. Engine / vehicle overloaded.
b. Clutch slipping, plates worn out.
c. Brake setting improper / wheel jam.
d. Tyres under-inflated.
e. Untimely gear shifting/ unsteady
driving.
59
Remedies
a. Check MF valve fitment angle (30
degree) with respect to the horizontal axis.
b. Check the plain surface level during gas
filling.
c. Check the free movment of float unit.
a. Check & adjust idle in the vehicle
carburetor in petrol mode
b. Check & adjust idling at vaporiser in
gas mode.
c. Check the ignition coil and the chord and
replace.
d. replace the vacuum hose.
e. Clean, if necessary replace.
f. Replace
g. Check throttle cable & throttle
h. Replace the vacuum hose.
a. Rectify leakage.
b. Drain fuel tank and refill with clean
Petrol.
a.Rectify and readjust.
b. Replace the cartridge.
c. Knock out soot/black carbon.
d. Get the engine overhauled.
e. Check / Replace bearings, piston rings etc.
a. Avoid overloading.
b. Replace clutch plates, adjust.
c. Reset.
d. Inflate to correct pressure.
e. Improve driving habits.
VII. Loss of Power
a. Faulty fuel system. a. Adulterated fuel.
b. Air in fuel system.
air in the fuel system.
c. Obstructed fuel pipes.
d. Fuel filter clogged.
e. Carburettor setting wrong
b. Operation / Setting / a. Tappet clearance incorrect.
Maintenance.
b. Valve sticky / valve spring broken.
c. Air cleaner cartridge / exhaust
clogged.
d. Engine internal friction high,
probably because of partial seizure.
e. Engine compression low
because of piston ring /liner wear.
f. Clutch slipping, plates worn out.
g. Brake setting improper / wheel jam.
h. Under-inflated tyres.
VIII. Excessive Lub Oil Consumption
a. Faulty lub oil system. a. Leakages.
b. Oil level in the sump too high.
60
a. Drain fuel tank and fill clean diesel.
b. Rectify leakage and bleed the entire
c. Flush out pipes, tighten fuel connections.
d. Replace.
e. Readjust the setting
a. Readjust.
b. Rectify / Replace.
c. Replace air cleaner cartridge / knock out
soot / black carbon from exhaust.
d. Check piston / liner wear, Main and Con
Rod bearing seizure and rectify.
e. Check and replace liner, piston rings etc.
f. Adjust or replace clutch plates.
g. Reset.
h. Inflate to correct pressure.
a. Replace gaskets, washers or leaking
pipes etc.
b. Drain out excess lub oil.
 Fault Causes Remedies

b. Mechanical adjustments. a. Broken or worn piston rings. a. Replace.

b. Excessive clearance in the b. Replace bearing using u/s main and
crankshaft and bearings. conrod to suit ground crankshaft.
c. Worn or scored liner / piston. c. Replace.

IX. Abnormal Lube Oil Pressure

a. Faulty lub oil system. a. Internal fuel leak.
b. Restriction in the lub oil suction
line of the pump.
c. Faulty Relief Valve.
d. Oil level in the sump too low.
e. Wrong grade of lub oil
(Low Viscosity).
b. Operation. a. Engine overheated due to over
loading
b. Lub oil needs changing.
c. Mechanical adjustment a. Excessive bearing clearances
b. Engine due for overhaul.
c. Worn lub oil pump.
d. Faulty oil pressure switch.
a. 1. Avoid long idlings.
2. Check liner / piston ring wear.
b. Rectify.
c. Check relief valve spring tension.
Replace, if required.
d. Fill in lub oil to correct level.
e. Use proper grade lub oil.
a. Avoid overloading.
b. Change lub oil.
a. Check and rectify.
b. Overhaul the engine.
c. Replace.
d. Replace.

X.Unusual Noise

a. Mechanical faults a. Worn or loose gudgeon pin bush a. Replace

(Sharp rap at idling speed)
b. Con rod bearing worn or loose b. Replace
(Metallic knock especially during
idling speed and de-acceelerating
but disappearing when engine is
under load).
c. Main bearing loose / worn (heavy c. Replace
metallic knock when engine is
accelerating under load).
d. Tappet clearances excessive, d. Replace / Readjust
valve burnt/warped (constant
rapid clicking).
e. Piston ring stickly / seized e. Get the engine overhauled
cylinders / piston worn out.

61
 Fault Causes Remedies
a. Engine overheating a. combustion chamber heavy a. Decarbonise
carbon depositing

B. Vehicle Section
a. Faulty clutch a. Clutch adjustment improper a. Adjust the clutch cable
b. Driving plates with cork linings b. Check plate thickness. If worn beyond
worn out or burnt. service limit, replace.
c. Clutch slipping. c. Check spring tension and replace, if
necessary.
b. Gear disengages a. Excessive play. a. Adjust.
automatically.
b. Gear change cable out of adjustment. b. Adjust.
c. Pin for bracket broken or c. Replace the spring
missing or has become weak
e. Sector assy. Chamfered grooves e. Replace
Wrongly assembled
f. Speed gear teeth worn out or broken f. Replace
c. Controls on handlebar a. Inner cables rusty/Jam. a. Replace
not operating properly
b. Inner cables strands broken-loose b. Replace
c. Excessive play c. Adjust the inner cable with adjusting
screw
d. Outer cable damaged d. Replace
e. improper cable routing e. Readjust the routing
d. Front suspension noisy a. Hub bearing worn or with a. Replace
excessive play
b. Lack of grease in the wheel hub b. Dismantle and grease.
housing.
c. Shock absorber defective or weak. c. Replace.
d. Draw cup (roller bearings) of the d. Replace.
swinging arm worn.
e. Front suspension spring broken e. Replace.
or has lost its tension.
f. loose steering column f. Tighten
e. Vehicle pulling to one. a. Steering column bend. a. Check steering column and replace if
side. necessary.
f. Handle movement a. Ring nut too tight / become stiff. a. Adjust
not free/jam

62
 Fault
g. Rear suspension noisy. a. Bearing of wheel shaft worn or
h. Excess tyre wear.
i. Vehicle pulling to one side. a. Incorrect pressure in one side tyre.
j. Poor braking.
k. Brakes jam even when a. Return spring weak or broken.
pedal is released.
l. Spongy brakes.
m. Jaws sliding on drums a. Insufficient clearance between
n. Battery not getting
charged.
Causes Remedies
b. Track bearings / balls pitted b. Replace.
a. Check and replace.
with excessive play.
b. Lack of grease in the wheel hub b. Apply grease.
housing.
c. Hydraulic dampers weak/ c. Replace.
defective/leaking.
d. Buffer connecting swinging arm d. Replace.
to the chassis damaged.
a. Tyre pressure not correct. a. Check and inflate tyre correctly.
b .Brakes adjustment incorrect. b. Adjust.
c. Wornout steering pin c. Replace.
d. Wheel bearing exessive play d. Replace.
a. Check and inflate the tyre to correct
pressure.
b. Brakes adjustment incorrect. b. Adjust.
c. Rear swing arm deformed. c. Straighten if possible, or replace.
d. Buffer worn out. d. Replace the buffer.
a. Insufficient quantity of brake oil a. Check and top-up.
in reservoir (TMC).
b. Use of improper oil. b. Replace.
c. Leakage of oil from pipe union, c. Overhaul and replace the damaged
cylinders and flexible pipes. parts.
d. Worn out liners / brake drum d. Replace.
e. Hard brake liners & mirror e. Replace
finish on drum
a. Replace.
b. Rubber packing blown or sticked. b. Overhaul the unit, replace all rubber
parts and brake fluid. Bleed the brake system
a. Air in the braking system. a. Repeat bleeding operation.
b. Flexible pipe inflates under b. Replace.
pressure.
c. Air leakage in the master c. Replace the oil seals.
cylinder due to insufficient
sealing by the oil seals.
d. Warnout liners brake drive
e. Hard brake liners mirrors finish
on drien
a. Adjust the clearance.
jaws and drums.
b. Jaws return spring weak or broken. b. Replace.
c. Drums worn or scored. c. Replace.
d. Oil on brake jaws. d. Wash and roughen with sand paper.
a. Interrupted charging circuit a. Connect wire properly / clean battery
(Loose Connections). terminals.
b. Voltage regulator faulty. b. Replace.
c. F.M.A. short circuited. c. Replace.
d. Battery cell damaged. d. Replace battery.
e. Safety regulator short circuited e. Replace
63
FAULT FINDING
A. LPG / CNG kit
I. No Starting - Engine Fails To Start
Fault Causes Remedies
No gas supply a) No gas in tank a) Fill gas in tank
b) Service shut off valve ‘off’ b) Open service shut off valve
of multifunction
c) Cylinder shut off valve ‘off’ c) Open CNG shut off valve
(applicable for position CNG)
Solenoid valve not a)Insufficient battery voltage a) Check battery voltage - charge if
it is works discharged), Fuse blown
off - replace it, electrical connection }
loose - make proper connection.
LPG / CNG filter a) LPG / CNG filter clogged a) Clean / replace clogged
Dust plug is not in a) Improper dust plug closing a) Put the dust plug into correct
position position (applicable for CNG)
Electrical System a) Faulty battery charging circuit a) Check & ensure the battery
[First ensure point charging circuit components.
(a) and then only (FMA output, RR unit & battery
check point (b)] connections)
b) Problem in gas kit/starter motor b) Check & rectify the Gas kit /
starter Motor.
II. Engine Idling Rpm
Instability
Carburetor screw not in a) Incorrect idling speed a) Adjust carburetor idle screw & ensure
(Carburator and regulator)
correct position idling speed 1200 correct
position+50 rpm in petrol mode.
Excessive rich mixer a) Incorrect idling speed a) Adjust idling screw provided on regulator
(Carburator and regulator) for correct Air /
gas mixture & idling rpm 1000 ± 50 Ensure
carburetor slide is smoothly working.
Excessive lean mixture a) Incorrect idling speed a) Adjust idling screw provided on regulator
(Carburator and regulator)& idling rpm 1350
IIl. No or Less Power :
Air filter Choked. Clogged air filter a) Clean air filter.
Excessive rich / Lean Incorrect power setting b) Adjust power screw provided
Gas / Air mixture. between the mixer unit & regulator.
Air / Gas mixer clogged. Clogged mixer unit c) Clean air /Gas mixer unit.
Petrol residue in Residue petrol in carburator d)Reuse residual petrol for Carburetor.
carburetor

64
CNG KIT GENERAL TROUBLE SHOOTING”
SR . NO PROBABLE CAUSES
ENGINE STARTING DIFFICULTY
ON PETROL MODE
1 Empty petrol tank
2 Defective Petrol feed pump / petrol
solenoid valve
3 Improper earthing
4 Selector switch
HIGH CONSUMPTION OF GAS
1 Chocked air cleaner element
2 Leakage through joints.
3 Excess flow of Gas
4 High Idling speed
5 Tyre inflation pressure
ENGINE RUN ON GAS BUT DOESN’T
REACH FULL POWER
1 CNG Cylinder almost Empty
2 Excessive/Less flow of gas
3 CNG filter blocked
4 Gas hose connection broken/crushed
5 Low Engine compression pressure
6 Air Cleaner choking
7 Gas Air mixer clogged
8 Petrol residue in carburetor
ENGINE RUN ON GAS WITH ERRATIC IDLING
1 Carburetor Idle adjustment not correct
per idle adjustment procedure .
2 Idling gas flow not correct
3 Idling spring damaged
4 Leakage through Air intake system
5 Air cleaner choking
6 Weak Spark
7 Spark plug gap not proper
8 Throttle not closing fully
65
CORRECTIVE ACTION
Fill the petrol
Replace
Make firm earthing
Malfunctioning Check & replace the ECU
Clean / replace
Check & arrest the leakage
Adjust the power screw provided on
Regulator to optimum level as per power
adjustment procedure.
Check & adjust the Regulator
Idling screw as per idling adjustment
procedure in CNG mode
Check & correct
Check CNG pressure & fill the Gas
Adjust the power screw provided on
Regulator to optimum level as per power
adjustment procedure.
Clean or Replace CNG filter
Replace
Check block, piston and piston rings for
wear. Replace if required.
Clean, if necessary replace.
Remove mixer, Clean the mixer and gas
entering holes
Consume residual petrol from carburetor
Check & adjust Carburetor Idle screw as
Check & adjust the Regulator Idling screw
as per idling adjustment procedure in CNG
mode
Replace it
Correct
Clean, if necessary replace
Check ignition system & correct
Adjust spark plug gap / Replace if required
Check throttle cable & throttle
SR . NO PROBABLE CAUSES CORRECTIVE ACTION
ENGINE STARTING DIFFICULTY ON GAS MODE
1 Disengagement of Low pressure hose from Place the hose in right position and clamp it
mixer or Regulator firmly
2 Gas air mixer blocked Remove mixer assembly, Clean the mixer & gas entering holes.
3 Selector switch in neutral position Select gas mode.
4 Selector switch mal functioning Check & replace if necessary.
5 Presence of Petrol in the Carburetor consume petrol from the Carburetor then
only switch over to CNG mode
6 No spark Check spark at spark plug and set the
spark plug gap / replace if required.
7 Empty Cylinder Fill the gas in cylinder
8 Excess flow of Gas. Check solenoid valve operation. If faulty,
replace it.
9 Cylinder Shut off Valve closed Open CNG Cylinder Valve
10 Dust Plug not in position Place the dust plug in correct position and
check micro switch connection.
11 CNG filter blocked Clean or Replace CNG filter
12 Excess gas flow / rich mixture Adjust and optimize the gas flow

66
DO’S & DON’T’S
Shut OFF the manual service valve provided on the
Multifunction
Valve when the vehicle is not in use for longer period.
In case of leakage immediately turn `OFF’ the manual
service valve provided on the Multifunction Valve. Take
the vehicle to a safer place.
Check for leakage with neutral soap solution and make
joint leak proof. If leakage does not stop, then con-
tact nearest authorised service station.
When the vehicle is taken for body repair (welding
etc.), the Auto LPG tank should be emptied and re-
moved from vehicle.
Park away the vehicle from open fire & spark prone
areas.
Use only CCOE approved and BIS certified Auto LPG
tanks.
Use only correct rated fuse for LPG system.
Use genuine spares
Switch OFF the mobile phone(s) while refilling.
Always visit the authorised service station for repairs
/ servicing.
Don’t check leakage with a naked flame.
Don’t open the regulator or any LPG component on
your own.
Never tune or repair kit components by unauthorised
and untrained staff.
Don’t smoke inside the vehicle and also while refill-
ing.
Don’t keep any flammable items near the LPG sys-
tem.

67
SPECIAL TOOLS
 SPECIAL TOOLS
Sr. No. Parameter Special Tool Qnty. Status Remark
1 Cluster gear NR Bearing Pressing 1
Removal 1
2 Main shaft NR Bearing Pressing 1
3 Oil seal on Main shaft ball bearing Pressing 1
4 Idler gear bush Pressing 1 Common - 1 Tonner
Removal 1 Common - 1 Tonner
5 Valve spring Compressor 1 "C" clamp + tool
6 Tappet Setting tool 1
7 Oil Pump driving gear Holding tool 1
8 Piston TDC location Locator 1
9 Nut on Crankshaft Holding tool 1
10 Oil Filter Fitment / Removal 1
11 Selection of BP kit gasket Mtg. tool 1 Mtg. tool + Two hollow rods
12 Rings fitment on piston Insertion tool 1 Round shape cup
13 Piston Assy Holding tool 1
14 BP Kit Compression tool 1
15 Pinion shaft ball bearing Pressing 1
16 Differential cage ball bearing Pressing 1 Common - 1 Tonner
17 Fixture for Engine & Gear box Stand 1
Plate ( Pax) 1
18 Support For bearings on G.B.Cover Fixture 1
19 Dismentling of Diff. Cage & shaft Base plate 1
20 Spark Plug Fitment / Removal 1
21 Clutch Assy. Holding tool 1 Common - 1 Tonner
22 Magneto Rotor Holding tool 1
23 Magneto Rotor Puller 1
24 Crankshaft Holding tool 1
25 Pinion shaft Removal 1
26 Differential gear Assy. Removal 1 Common - 1 Tonner
27 Steering column lock nut Fitment / Removal 1

General Common Tools (for Engine assembly / disassembly)

a. T spanner 8 mm, 10 mm

b. Socket 13 mm, 18 mm, deep socket

c. Circlip plier Outer

d. Screw driver Star (Philips)

e. Allen key 4 mm, 5 mm

71
 TOOL INDEX FOR SPECIAL SERVICE TOOLS
SR. Referred SR. Referred
NO. TOOL NO. TOOL
on page on page

1 1a

Cluster Gear NR Cluster Gear NR

Bearing Removal tool Bearing Pressing tool
Part No. - 441026 Part No. - 441025

2 3

Main Shaft NR Bearing Pressing tool Oil seal on Main shaft ball bearing
Part No. - 441027 pressing
Part No. - 441028

4 4a

Idle Gear bush Removal tool Idle Gear bush Pressing tool
( common for 1 tonner) (common for 1 tonner)
Part No. - 9-2-540-6 Part No. - 9-2-570-4

72
SR. Referred SR. Referred
NO. TOOL NO. TOOL
on page on page

5 6

Valve spring Compressor Tappet setting tool

Part No. - 441046 Part No. - 441029

7 8

Oil pump Driving Gear holding tool Piston TDC locator

Part No. - 441030 Part No. - 441031

9 10

Hex Nut on Crankshaft - Holding tool Oil Filter - Fitment & Removal tool
Part No. - 441032 Part No. - 441033

11 12

Selection of BP kit gasket Rings fitment on piston

(insertion tool)
Part No. - 441034 Part No. - 441035

73
SR. Referred SR. Referred
NO. TOOL NO. TOOL
on page on page

13 14

Piston Assy. - Holding tool BP kit - Comression tool

Part No. - 441036 Part No. - 441037

15 16

Pinion shaft ball bearing pressing tool Differential cage ball bearing
Part No. - 441038 pressing tool
Part No. - 9-2-600-9

17 18

Engine Stand ( Pax 200) Support for bearing on G.B.

Part No. - Cover - Fixture
Part No. - 441040

19 20

Dismentling of Diff. cage and shaft - Spark plug fitment and removal tool
Base Plate Part No. - 441041
Part No. - 441039

74
SR. Referred SR. Referred
NO. TOOL NO. TOOL
on page on page

21 22

Clutch Assy. holding tool Magneto rotor holding tool

Part No. - 9-2-020-9 Part No. - 441042

23 24

Magneto rotor puller Crank shaft holding tool

Part No. - 441047 Part No. - 441043

25 26

Pinion shaft fitting tool Differential gear Assy. removal

Part No. - 441044 Part No. - 9-2-040-1

27

Steering column lock nut

Part No. - 441045

75
 INSTALLATION OF
INSTRUMENTS AND
CONTROLS
INSTRUCTIONS BEFORE STARTING {H$gr ^r g~ Ag|ãbr `m {H$gr H§$nmoZÝQ> H$mo dmñV{dH$
FOR DISMENTLING {S>g_|Q>qbJ H$aZo go nhbo H¥$n`m {ZåZ{b{IV _hÎdnyU© nhbwAm|
Before starting actual dismantling of any H$s Amoa Ü`mZ XoŸ:
subassembly or any component please pay
attention to following aspects : 1. AZmdí`H$ ê$n go H§$nmoZÝQ>g² / Ag|ãbr H$mo ImobZo go
1. Ascertain the correct cause of the trouble to avoid
~MZo Ho$ {bE g_ñ`m H$m Agbr H$maU OmZ boŸ&
unnecessary stripping down of the components / 2. Om±M Ho$ {bE Amdí`H$ Am¡Oma CnbãY h¡ `m Zhr `h gw{ZpíMV
assemblies.
H$a boŸ& JbV Am¡Omam|H$m à`moJ Z H$aoŸ& Bggo XwK©Q>ZmE± VWm
2. Ensure availability of proper tools required for the KQ>H$m|H$m (H§$nmoZÝQ>g²) ZwH$gmZ hmo gH$Vm h¡Ÿ&
job. Do not try to use improper tools. This may
cause accidents and damage the components. 3. ImobZo go nhbo Ag|ãbr, g~ Ag|ãbr / KQ>H$m| H$mo AÀN>r
3. Clean the assemblies, sub-assemblies /
Vah go gm\$ H$a boŸ& Bg ~mV H$m Ü`mZ aIo {H$ J§XJr/ Yyb
components thoroughly before stripping down, Iwbo H§$nmoZÝQ>g² _| Z OmEŸ&
taking care to see that dirt / dust does not enter
inside stripped down components. 4. H$m_ H$m n[aga gm\$ aIoŸ&
4. Keep the work area absolutely clean. 5. B§YZ / bw~«rH§$Q> Am`b aIZo Ho$ {bE gm\$ Q´>o VWm _mnH$ H¡$Z
H$m à`moJ H$aoŸ& `{X B§OZ Ho$ B§YZ A§V:jonU gmYZ Imobo JE
5. Use clean trays and measuring cans etc. For
storing fuels / lubricants and keeping stripped
h¢ Vmo ñQ>moaoO Ho$ {bE S>rOb BñVo_mb H$aoŸ&
down components. Use petrol for storage, when
6. H§$nmoZÝQ>g² H$mo gm\$ H$aVo g_` H$nS>o H$m à`moJ H$aoŸ& B§OZ
carburettor of the engine is being dismantled.
VWm {J`a ~m°Šg H$s _aå_V / Amodahm°qbJ H$aVo g_` H$m°Q>Z
6. Use cloth for cleaning the components. Do not doñQ> H$m à`moJ Z H$aoŸ&
use cotton-waste while repairing / overhauling
engine and gearbox. 7. H§$nmoZÝQ>g² H$mo ImobVo VWm {\$ago bJmVo g_` Q>m°H©$g², C{MV
7. Keep the information viz. tightening torques, Q>m°ba§gog, pŠb`aÝgog H$s OmZH$mar AnZo nmg aIoŸ&
permissible tolerances, clearances handy while
8. {\$ago Ag|ãbr H$aVo g_` BñVo_mb {H$`m J`m bw{~«Ho$qQ>J
dismantling and re-assembling the components.
Am`b `m J«rO H$m à`moJ Z H$aoŸ& à`moJ _| bmE JE Am`b
8. Do not apply used lubricating oils or grease to the VWm J«rO _| YmVw{_{lV Yyb `m A°~{o« gd H$U hmoZo H$s g§^mdZm
components while re-assembling. The used oil or
grease may contain metallic dust or foreign
hmoVr h¡Ÿ& Omo H§$nmoZÝQ>g² H$mo ZwH$gmZ nhþ±Mm gH$Vo h¡Ÿ&
abrasive particles, which may spoil / damage the 9. Am`b grb `m {~`[a¨J bJmVo g_` Z`m bw{~«Ho$qQ>J Am`b
components.
bJmE§ - Vm{H$ {bßgH$mo ZwH$gmZ Z nhþ±Mo VWm Ag|ãbr ghr
9. Before fitting bearings or oil seals, apply fresh hmoŸ&
lubricating oil, so that the lips will not get damaged
and assembly will be smooth. 10. ~mñHo$Q²>g, Q>°~ dm°eg©, bm°H$ dm°eg© ""Amo'' [a¨½O, Am`b
10. Gaskets, tab washers, lock washers, .o. rings,
grëg VWm gapŠbßg, Omo Amodahm°b {H$E OmZodmbo dmhZ go
oil seals and circlips removed from the vehicle {ZH$mbo JE h¡; {\$ago à`moJ _| Z bmEŸ&
being overhauled should not be re-used.
11. B§YZ {\$ëQ>a E{b_|Q>g² (nona Q>mB©n) {\$ago à`moJ _| Z bmE±Ÿ&
11. Fuel filter elements (paper type) should not be re-
used.

79
REMOVAL OF
POWER PACK
FROM
VEHICLE
ENGINE - POWER PACK

Power pack is a combination of Engine &

Transmission. It converts the fuel energy into
Mechanical energy for the engine and deliver the
required various torque and power to the Rear axle
through Gear Box.

Power pack needs to be taken down from chassis

for attending jobs like :

Crankshaft, Camshaft, Crankcase replacement

Oil pump checking & Replacement

Main bush of Crankcase

And for all major repairs of Gear box Assy.

REMOVAL OF POWER PACK FROM VEHICLE :

First disconnect Positive terminal (Red wire Coupler

of Harness) of Battery by removing one nut using 10
mm Ring spanner.

Then disconnect Negative terminal (Green wire Coupler

of Harness) of Battery by removing one nut using 10
mm Ring spanner.

83
Disconnect Earth cable mounted on Cylinder head by
removing one bolt using 8 mm Ring spanner.

Remove Rear bottom panel (Below the tail gate) by

removing "7" bolts using 10 mm Ring spanner / Socket.
OR remove '4' bolts & lift the panel.

REMOVAL OF MUFFLER ASSY.:

a) Remove 2 nuts of muffler bend pipe (On cylinder

head) by using 10 mm Ring spanner

84
b) Remove bolts 2 Nos. of muffler bkt . (On Rear
engine mounting at bottom) by using 10 mm Ring
spanner

c) Remove bolts 2 Nos. of muffler bkt . (On Gear

box) by using 13 mm Ring spanner

Remove Starter Motor (Cable connection) by removing

one nut using 10 mm Ring spanner.

85
Remove oil pressure Switch - by pulling cable outside

Disconnect wiring couplers inside the Engine

compartment.

REMOVAL OF CARBURETTOR -

a) Remove choke cable by removing nut using 14

mm size spanner

b) Remove carburettor throttle cap

86
Disconnect the fuel pipe (from filter to Carb) from
Carburettor end & insert one bolt into pipe to stop the
flow of fuel.

Remove the clamp screw of Carburetor hose using

Screw driver

Remove Carb. Flange bolts (2 Nos.) using 8 mm Ring

spanner

87
Hold the clutch cable at rear end by plier & disconnect
the same by loosening the nut

Disconnect the Gear cables (2 Nos.) by removing the

nut using 8 mm Ring spanner

Remove Front Engine mounting (Engine elastic

support) by removing 2 bolts & Nuts using 16 mm &
17 mm Spanners.

88
Remove the Flexible coupling bolts (3 Nos. each on
both sides - LH & RH) by using 16 mm & 17 mm
Spanners

Remove Support Arm Engine Rear sub Assy. by

removing one bolt & Nut using 13 mm Ring & Size
spanner.

• Push the vehicle forward by avoiding any

interference to powerpack.

• Pull the powerpack assy. on a suitable stand.

(Stand provided in special took kit).

89
 DISMENTLING OF
ENGINE ASSEMBLY
DISMENTLE OF ENGINE :

Removal of Engine Drain plug :

Remove Engine Oil Drain plug by removing 24 mm

Hex nut by using 24 mm Ring spanner.

Removal of Gear Box Drain Bolt :

Remove Gear Box Oil Drain bolt (13 mm) by using 13

mm Size spanner.

Remove Dipstick from Gear box cover by rotating the

same in anticlockwise direction.

93
Remove Spark plug cap by pulling it upward

Remove Spark plug with 16mm long socket (Special

tool)

Removal of fan Cover :

Remove Fan cover by unscrewing "5" screws by using

Screw Driver.

94
Remove shroud exhaust side by unscrewing " 2"
screws by Philips head screw driver

Note : Remove carefully the Interlock of fan cover

with fan support cover.

Removal of Carburettor :

Remove "2" Nos. of bolt (M6 x 20)by using 8 mm

Socket OR 8 mm ring spanner and take out the
Carburettor from Intake Flange of Carburettor.

95
Then remove inlet Manifold (Fitting) by removing "2'
bolts (M6 x 20) using "8" mm size spanner.

& then remove Gasket.

Remove shroud intake side by unscrewing "3" screws

using Philips head screw driver

96
Removal of Fan Assy.

Remove Fan Assy. by removing "3' (M6) bolts using

"10" mm T spanner OR 10 mm socket.

Removal of Rotor Assy.

Insert "2" bolts for holding the Rotor. Use "18" mm

Socket to remove Rotor Nut.

Use special tool " Y" (Universal holder) to hold the

Rotor Assy. (Tool's pin to be inserted in holes provided
on Rotor)

Fit another special tool (Magneto puller) on Crankshaft

threading to pull the magneto out.

97
Note: Keep the Magneto over the rubber mat to avoid
dust, Oil spill off & avoid fasteners kept sticky to the
magneto.

Removal of Fan Support Cover :

Remove "4" Nos. of bolts (M6 x 20) from Fan Support

cover by using "8" mm T Spanner

Remove "6" Nos. of screws from Fan support cover

by using Screw Driver.

Removal of Pulsor Coil :

Remove "2" Nos. of screws from Pulsor (Pick Up Coil)

by using Screw Driver.

98
Removal of Stator Plate Assy. :

Remove "3" Nos. of screws from Stator plate by using

Screw Driver. Disconnect the Oil pressure switch
connection.

Note : Pulsar coil & Stator assembly are One unit.

Removal of Crankshaft Key :

Remove key from Crankshaft by using Screw Driver

(Gentle hammer on Screw driver)

Removal of H.T.Coil :

Remove "2" Nos. of bolts from H.T.Coil mounting

bracket by using "8" mm T Spanner

99
Removal of Starter Cover :

Remove Starter cover by removing "10" Nos. bolts

(M6 x 30) by using "8" mm 'T' Spanner . Gentle tap to
cover for easy dismantle.

Tensioner spring came out with Starter cover.

Removal of Starter Motor Assy. :

Remove Starter Motor by removing "2" Nos. bolts by

using "8" mm 'T' Spanner.

Removal of Ring nut

Removal of Ring nut on Crankshaft using special tool

(Hex spanner)

100
Removal of One Way Clutch :

Note : One Way Clutch is used to avoid Engine

Cranking while Engine is in Running Condition-Extra
Safety For Starter Motor

Remove One way Clutch & Gear by using Special

tool & 36mm Socket. To Hold the Special Tool -in
opposite direction to loosen the Hexagon Nut on
the Crank shaft.

Note : Don't try to hold the crankshaft by other method

-to avoid Damage to Crankshaft.

Remove Intermediate Starter gear

101
Removal of Gear Shifter Assy. :

Remove Gear Shifter Assy. by removing "2" allen bolts

(M6 x 45) with washers by using "6" mm 'Allen Key &
then Remove Gasket

Note : Replace shifter assembly Gasket after one

time use.

Removal of Rocker cover (Head cover) :

Remove "4" Nos. of bolts (M6 x 20) from Rocker cover

by using "8" mm "T" Spanner.

102
Removal of D Comp. :

Remove D' Compression Mass containment sheet by

holding Sprocket by using Allen Key and remove sheet
by using "4" mm Allen key. Remove Sprocket (Timing
crown). Hold the chain by Special tool / Screw driver

Removal of Chain Tensioner :

Remove support (guide) '8' mm bolt by "8" mm T

Spanner.

103
and Chain tensioner '2' bolts by using '10' mm "T"
spanner.

Removal of Cylinder Head Assy. :

Remove "4" Nos. flange nut of 12 mm using T spanner

/ socket. Remove cylinder head Assy. & oil seal.

Remove two bolts (Joining of Cylinder block &

head) using 8 mm size spanner

PHOTO
6207

104
Remove cylinder head gasket

Remove Cylinder Block Assy.

Remove Chain Tensioner support by using "8" mm T

Spanner.

Remove chain from Block Side

105
Remove piston Assy. :

Use special tool to hold the Piston Assy. Insert

tool in Con rod as shown in fig.

Remove piston pin circlip using plier & then remove

pin by pushing other side.

Remove piston Assy.

Removal of Oil filter :

Remove Oil filter by using Special tool

Removal of Flywheel Side Half Crankcase -

Remove FSHC by using "22" bolts (M6 x 35) using
"8" mm T Spanner Remove Retainer spring by using
tool.

106
Removal of Clutch Cover :

Remove Clutch cover by removing "12 Nos." bolt by

using "8" mm 'T' Spanner.

Note : Ensure Pressure Relief Spring & Valve is

taken out carefully with Clutch Cover.

Remove circlip (Dia 48 ext) using plier.

Remove shoulder ring 1.7 mm thick

Remove plain washer on Cluster gear. Rotate cluster

gear "D" slot towards 1st gear

Remove Stem gear operating by using 14 mm size

spanner in clockwise direction. (Do not rotate to loosen
the stem in anticlockwise direction, it may cause the
damages of threads)

Remove speed gears one by one 1st, 2nd, 3rd & 4th
etc.

Remove the cross (Before removing please ensure

that Cross ends towards slot of shaft for easy removal)

II. GEARBOX :
Dismantling Clutch assy. :
ŠbM Ag|ãbr ImobZm :
1. Remove reverse gear spring. Remove bolt R.C. 1. [adg© {J`a pñà¨J Imobo VWm ~moëQ> Ama.gr. {ZH$mboŸ&
spring retaining.
2. _oZ S>mCqOJ go ŠbM H$da OmoS>Zodmbo Mmam| ZQ>g² hQ>mEŸ& 10
2. Remove all the 4 nuts securing the clutch cover {_. _r. H$m Q>çwã`wba ñn¡Za à`moJ H$aoŸ&
to the main housing. Use 10 mm tubular spanner.
3. bm°qH$J pŠbn hQ>mEŸ& VWm CgHo$ ~mX W«ñQ> ßboQ> {ZH$mboŸ&
3. Remove the locking clip, and then remove the
thrust plate. 4. ~moëQ> na pñWV Q>¡~ dm°ea Imobo, ŠbM H$mo H«¢$H$emâQ> go
4. Unlock the tab washer on the bolt and remove the OmoS>Zodmbo ~moëQ> H$mo {ZH$mboŸ&
bolt securing clutch to crankshaft by unscrewing
5. H«¢$H$emâQ> go nyar ŠbM ~m°Šg Ag|ãbr Am¡a ñnoga dm°ea ~mha
it.
{ZH$mboŸ&
5. Take out complete clutch box assy. and spacer
washer from crankshaft. nm°dan¡H$ go {J`a ~m°Šg Ag|ãbr AbJ H$aZm
Removing Gearbox assy. from the power-pack : 1. Q>çwã`yba ñn¡ZaÛmam ZQ> ImobH$a ŠbM H$da {ZH$mboŸ&
1. Remove clutch cover by removing nuts by a
tubular spanner.

107
2. Remove complete clutch box along with engine 2.
gear, by taking the thrust plate, tab washer, spacer
washer and screw securing clutch unit out.
3. Remove nuts, washers from studs on PTO cover.
3.
4. Take out the gearbox by pulling it from the engine.
4.
Removing Gearbox cover :
1. Unscrew bolt R. C. (12837054) Please do not tap {J`a ~m°Šg H$da hQ>mZm
on bolt R. C. for removing gearbox cover. Remove 1.
fare meter housing by removing screws (for
passenger autorickshaw only).
2. Take out the engine support front tube by removing
bolts. 2.
3. Take out speedo pinion, oil seal and bush from
main housing.
4. Unscrew nuts, spring and plain washer used for
3.
fastening gearbox cover to main housing.
5. Take out gearbox cover from main housing, by
tapping gently using plastic hammer. 4.
Dismantling Engine Side Cover from Main Housing
Sub Assy. : _oZ hmD$qOJ g~ Ag|ãbr go B§OZ gmB©S> H$da ImobZmŸ&
1. Remove gearshifter housing assy. from engine
1.
side cover by unscrewing the bolts securing with
its gasket.
2. Open the cover plate screws and take out the 2.
cover plate with its .o. ring.
3. Remove the circlip on cluster gear. 3.
4. Remove nuts, spring and plain washers from
engine side cover to main housing assy. 4.
5. Gently tap out the engine side cover from main
housing using plastic hammer. 5.
ŠbM ~mŠg H$mo B§{OZ {J`a Ho$ gmW {ZH$mboŸ& `h W«ñQ> ßboQ>,
Q>¡~ dmea, ñnoga dmea VWm ŠbM ñH«y$ H$mo {ZH$mbZo Ho$ ~mX
{ZH$boJmŸ&
nr.Q>r.Amo. H$dana pñWV ñQ>S>ggo ZQ>g², dm°eg© hQ>mEŸ&
B§OZ go {J`a ~m°Šg ItMVo hþE ~mha {ZH$mboŸ&
~moëQ> {ZH$mbo R. C. (12837054)& H¥$n`m {J`a ~m°Šg H$da
{ZH$mbZo Ho$ {bE Bg ~moëQ>na Q>¡n Z H$aoŸ& ñH«y$ {ZH$mbH$a
\o$Aa _rQ>a hmD$qOJ hQ>mEŸ& (Ho$db n¡g|Oa [ajm Ho$ {bE)
B§OZ gnmoQ>© Q>çw~ (\«§$Q>) H$mo ~moëQ> ImobH$a ~mha {ZH$mboŸ&
_oZ hmD$qOJ go ñnrS>mo {n{Z`Z, Am`b grb VWm ~we ~mha
{ZH$mboŸ&
_oZ hmD$qOJ go {J`a ~m°Šg H$gZo Ho$ {bE à`moJ _| bmE JE
ZQ>g² pñà¨J d ßboZ dm°ea ImoboŸ&
_oZ hmD$qOJ go {J`a ~m°Šg H$da {ZH$mbo BgHo$ {bE ßbmpñQ>H$
h¡_a go Yrao Yrao R>moHo$Ÿ&
{J`a {eâQ>a hmD$qOJ H$mo B§OZ gmBS> H$da go J¡ñHo$Q> Ho$
gmW, ~moëQ> ImobH$a {ZH$mboŸ&
H$da ßboQ> ñH«y$ Imobo d H$da ßboQ> CgH$s Amo [a¨J Ho$ gmW
~mha {ZH$mboŸ&
ŠbñQ>a {J`a na pñWV gapŠbn hQ>mEŸ&
_oZ hmD$qOJ Ag|ãbr Ho$ B§OZ gmB©S> H$da go ZQ>g² pñà¨J d
ßboZ dm°eg© hQ>mEŸ&
ßbmpñQ>H$ h¡_a go Yrao Yrao R>moH$Vo hþE _oZ hmD$qOJ go B§OZ
gmB©S> H$da H$mo ~mha {ZH$mboŸ&

Remove Differential Gear Box Cover - '10' mm "10"

bolts using "10" mm T Spanner

108
Remove Idler gear

Remove Differential side Pinion shaft circlip by

using plier.

Remove Plug for fare meter from Reverse shaft

Removal of Clutch Assy. :

Remove thrust plate over clutch.

Lock the clutch Assy. By using Holding Strip (Special

tool) . Remove Clutch Assy. Lock (Thrust plate). Then
remove inside lock using plier. Remove Clutch Assy
bolt by using "13" mm Socket.

Remove Splined washer after removing the clutch

Assy.

109
Removal of Oil Pump Assy.:

Oil pump cover (Oil bulkhead) remove by removing

'2' bolts , using "8" mm "T" Spanner.

Hold the Oil pump Sprocket by using Special tool.

Using "8" mm T Spanner remove the Cover.

Remove oil pump driving chain & Sprocket over

Crankshaft.

Remove Cam chain & Sprocket over Crankshaft.

110
Remove the distance washer.

Removal Oil Pump Assy.

Remove Oil pump assy. by removing '2' bolts

using "8" mm T Spanner.

Remove Timing Chain Sprocket.

Remove Chain from Block side.

111
Removal of Crankshaft Assy. :

Remove Cluster gear & Secondary gear shaft

(Chances of "O" ring on shaft damage)

Remove Chain tensioner lever by removing one bolt

using 8 mm T spanner.

Remove Main shaft ball bearing (6203) by lifting in

upward direction.

Remove Idler gear bush by using special tool & 14,17

& 24 mm spanners.

Remove NRB of Cluster gear (In RH crankcase) by

using special tool & 14,17 & 24 mm spanners.

Remove Cluster gear NRB in LH Crankcase

Remove Main shaft NRB in LH Crankcase.

Remove Reverse light switch Assy. -

Remove "2" Allen bolts of mounting bracket by using

"4" mm Allen key

Remove Reverse Switch by loosening "2" screws

using Screw Driver.

112
Remove "10" mm bolt (Below the switch) by "10" mm
Socket.

Remove Main shaft Circlip by using Plier.

Remove "two" bolts inside the Oil Filter (Crankcase

casting)

113
Remove Oil Filter using Special tool.

PHOTO

Remove fare meter cover by removing "3" bolts using

"8" mm T spanner.

114
ENGINE ASSEMBLY
Fitment of Main shaft Ball bearing

Fit the Main shaft ball bearing in crankcase

Place the plain washer & bolt for locking . Tighten

bolt to secure ball bearing by "8" mm T spanner
(Torque Apply - 8 ~10 Nm)

Cluster gear NRB in Main crankcase by using special

tool. (Identification Number on top side)

117
Fitment of Idler gear bush by using special tool

Fitment of Oil pump Assy. By using "2" bolts 8 mm T

spanner. (Slot should be match with Crankcase)

Cluster gear fitment in NRB

118
Teeth of cluster gears - 1st - 10, 2nd -15, 3rd - 21, 4th
- 26, & Helical gear - 65, Idler gear - 19/27, FD gear -
76, Engine gear - 35/26 (clutch side)
Insert Main shaft in ball bearing. Insert thrust washer
in Main shaft

Insert Cross in Main shaft through groove.

Rotate in order to pass the Cross through all slots.

119
Fitment of Stem gear operating in Cross in anti clock
wise direction . Before fitment, apply loctite super rapid
638 on threaded portion. Tighten it by torque wrench.
(Apply torque - 18 ~ 20 Nm)

Insert all the speed gear as per the locations - 4th ,

3rd, 2nd, & 1st keeping collar side on top (Ensure
cluster gear slot position towards speed gears - to
insertion of speed gears easy)

Teeth of Speed gears - 1st speed gear - 46, 2nd

speed gear -41,3rd speed gear- 35, 4th speed gear -
29 And RC gear - 23.
Insert slot washer in shaft spline side.

120
Fit the circlip on shaft after washer by using plier.

Then insert the washer on Cluster gear (For checking

- Lift the stem gear in upward direction & rotate the
cluster gear assy. For free rotation)

Insert plain washer on half bearing location

Then insert Crankshaft Assy. (Ensure Flywheel side

in upward)

121
Insert washer on Crankshaft from Magneto side

Apply grease on gasket & fit it on crankcase.

Ensure NRB (2 NOS.) & half bearing in LH crankcase

and then fit the LH Crankcase on Main crankcase

Tighten all 22 Nos. bolts using "T" spanner as per the

sequence. (Apply Torque - 11 ~ 13 Nm).

122
Crank shaft end float - 02 ~ 0.5 mm.

Ensure one bolt to be fitted in Oil filter inner area.

Fit Oil filter screw as per torque (35 ~ 40 Nm)

Take Oil plug (24 mm) and apply grease (Dow corning
silica gel) on "O" ring. Fitment as per torque (24 ~ 33
Nm)

Take Starter Motor, Apply grease on "O" ring with

AGIP MU3. Fit it on Crankcase.

Tighten it by using '2 ' bolts by 8 mm T spanner. (Apply

Torque - 11 ~ 13 Nm)

123
Insert Starter gear (Starter intermediate gear) , lubricate
it (Gear and shaft) with grease (AGIP MU3) and fit it
on Crankcase.

Take Cam clutch and fit it on clutch hub. Apply loctite

242 and tighten it with "3" screws. Apply torque - 11 ~
13 Nm with torque wrench.

Lubricate inside toothed crown with Engine oil (15 W

50)

Insert One way clutch Assy. (Cam clutch assy.) with

gear and fit it on Crankshaft Assy. With its teeth
matching with starter gear.

124
Insert washer on one way clutch Assy.

Insert clutch nut on Crankshaft

Using special tools, tightened the One way clutch

Assy. Nut on Crankshaft (Hold the Crankshaft by using
special tool & use "36"mm socket) . Apply torque - 75
~ 85 Nm

125
Take Starter cover gasket. Take Starter cover. Take
oil seal and apply Engine oil (15 W 50) on inner &
outer surface. Fit the oil seal with correct orientation
(Nip side upside)

Fit the Starter plate cover on Crankcase

Tighten 10 bolts for FSHC and Starter cover by using

8 mm T spanner. Apply torque - 11 ~ 13 Nm

126
Fit the of Oil filter using special tool. Apply torque - 4
~ 6 Nm.

Before fitment apply grease (Dow corning silica gel)

on "O" ring of Oil filter. Fill Engine oil (15 W 50) in oil
filter.

** "O" ring of Oil filter to be replaced in every interval.

Take the Gear shifter gasket & place it on its location.

Fitment of Gear shifter Assy.

Take Gear shifter Assy., position it on 3rd gear (Pull

the stem slightly upward) .

127
Adjust the position of lever and then fit the Shifter
Assy. (Slider of Gear shifter Assy. Matching with Stem)

Take allen bolt "2" Nos. with plain washer and spring
washer and tighten with torque wrench. Apply torque -
11 ~ 13 Nm

Fit the H.T Coil with plug cap & HT cord

128
Ensure earth cable of HT Coil fitted on Crankcase

Fit the key on Crankshaft. Take Stator plate & fit it on

Starter cover. Take "3" screws, apply loctite 242 and
tighten it with screw driver.

Fit the Pulsor coil (Pick up coil) damper in slot.

129
Fit the Pulsor coil (Pick up coil) by "2" bolts using T
spanner. Apply torque - 3 ~ 4 Nm

Take fan support, position it on Starter cover and fit it

by "4" bolts with washers tighten with torque wrench.
Apply torque = 11 ~ 13 Nm.

Insert Woodruff key in Crankshaft location

130
Take Rotor Assy. & position it on Crankshaft

Using "18" mm socket & Special tool (Y) , fit the Nut
on crankshaft. Apply torque - 75 ~ 85 Nm

Fit the Fan cover on Magneto Assy.

131
By "3" bolts with plain washer - torque

Insert sprocket on Crankshaft (Match the slot of gear

and pin on Crankshaft).

Fitment of Chain from Crankshaft sprocket (Timing

pinion gear) and fit the timing chain on timing pinion
gear a slid it through Cylinder block. Insert plain washer
on chain on Crankshaft

132
Insert Oil pump gasket & fit it on Crankcase. Fit the
Oil pump on gasket. Tighten with " 2" bolts with torque
wrench. Apply torque - 5 ~ 6 Nm.

Insert sprocket on Oil pump (D slot on sprocket should

be match with Oil pump slot) . Insert chain with gear
on Crankshaft and other end of chain on Oil pump
sprocket.

Take Oil pump controlling pinion & fit it on timing pinion

gear.

Take Oil pump crown with chain, fit it on oil pump and
align chain with Oil pump controlling pinion.

Tighten the bolt on Oil pump Assy. Using special tool

- Torque

133
Take the Oil deflector plate (Oil pump bulk head) , fit
it on crown and tighten with "2" bolts. Apply torque - 4
~ 6 Nm

Take the Chain tensioning rod, fit it on Crankcase and

tighten with bolt and washer by "T" spanner. Apply
torque - 11 ~ 14 Nm.

Insert separator on Main shaft

134
Fit the circlip in groove by using Plier

Fit the Differential gear Assy. with gears (Refer

Annexure No. 1)

Take differential cover gasket & place it on

Transmission side half crankcase. Fit the Differential
cover by using "10" bolts - 13 mm T spanner. Apply
torque - 24 ~ 27 Nm

135
Fit the retainer spring by using tool.

Insert star washer on Crankshaft (Clutch side)

Place Engine gear in Clutch Assy. - Refer Annexure

No. 4

136
Insert Clutch Assy. With Engine gear on Crankshaft
splines.

Fit the bolt with slot washer .

Use special tool to hold the clutch Assy. Torque -

Lock the clutch Assy.

Rotate engine stand towards Cylinder head side. Take

Cylinder studs (Height - 171.5 + 0.5 mm) and fit it on
Crankcase (Ensuring pre coated side of studs inside
the crankcase). Tighten the studs with torque wrench.

137
Then insert Cylinder Block gasket. Measure Bumping
clearance for selection of suitable gasket using special
tool & dial gauge.

Fit the Piston Assy. (Piston matching with Cylinder

grade) on small end of Crankshaft.

Lubricate Piston pin with Engine oil (15 W50) and

install the pin onto the Piston and small end of
crankshaft. Lock the piston pin by circlip . (Close the
crankcase hole by cloth to avoid circlip fell inside)

Ensure "Arrow" mark on Piston should be in downward

direction)

138
Ring Installation - First install Oil control ring ("Top"
mark should be upper side) and then compression
ring . 2nd Ring - " E TOP" mark on upper side, 1st
Ring - "DY" mark on upper side.

Ring gap - 0.2 ~ 0.4 mm

Use special tool between Joint crankcase & Piston

Assy. (insert from con rod) to restrict the movement
of piston) .

Lubricate all piston rings with Engine oil (15 W 50)

and ensure orientation of piston rings 120 degree apart
from each other.

139
Take Piston compressor (special tool) and fit it around
the piston rings to compress.

Lubricate Cylinder with Engine oil (15W50) . Insert

the Cylinder block on the crankcase passing over
piston rings and then remove the piston locking tool
& piston ring compressor tool.

Insert gasket between Cylinder block & head with

correct orientation.

Gasket selection :

To select gasket : fit the dial gauge on provided tool

,set the dial to "0" on surface plate and place the
stand on the head studs and tighten to 3.5 kgm torque.

Bring the piston to TDC - note the Dial gauge needle

shows the anti clock direction and stops at one
reading. Count the reading and refer the table to select
the gasket below the cylinder assy. (Gasket sizes
available 0.4, 0.6, 0.8 mm).

140
Gasket selection table :

Reading on dial gauge Gasket size in mm

0.5 - 0.6 0.40

0.3- 0.5 0.60

0.2 - 0.3 0.80

Fit the Gasket -size number facing bottom direction.

Mount the cylinder Piston assy. with rings - fix the
metal sheet metal gasket and mount the Head assy.
and tight 2.5 - 2.8 kgm.

Insert two side bolts (joining of Cylinder block & head)

- torque

Lubricate studs with engine oil (15 W 50) & fit "4" nuts
on studs and pre tighten with torque wrench (Apply
torque - 6 ~ 8 Nm)

Fit "2" bolts on cylinder head (lateral screws) and

tighten it with torque wrench (Apply torque - 11 ~ 13
Nm)

Take Oil exhaust bolt, fit it on Cylinder head and pre

fit 2 ~ 3 threads. Check valve clearance, adjustment
with feeler gauge and tighten Rocker arm adjustment
nut.

141
Fit the chain tensioner gasket on Cylinder block. Take
Chain tensioner support and fit it on gasket. Tighten it
with " 2 " bolts (Apply torque - 8 ~ 10 Nm) . Take
spring chain tensioner bolt and washer. Fit it on chain
tensioner and tighten with torque wrench (Apply torque
- 5 ~ 6 Nm)

** After fitment of Chain tensioner, tighten "4" head

nuts with torque wrench (Apply torque - 25 ~ 28 Nm)

Tightening cylinder head : Tighten the 4 nuts in the sequence

shown. Lubricate threads before tightening.

Clearance inlet valve

Intake side

Flywheel side

Clutch side

Exhaust
side Clearance exhaust valve

Timing - Keep the Piston in TDC position and lock it

with help of timing locking tool.

Take timing crown, install timing chain on it and fit it

on Camshaft , match its arrow mark with dot mark on
cylinder head casting .

142
Fitment of D comp mechanism

Fitment of De compression mechanism :

Take De compressor mass Assy. Install spring on it

and fit it on timing crown (Sprocket) . Lock the sprocket
with timing locking tool for De compression mass
containment and fit it on sprocket and tighten it with
"2" allen bolts (Apply torque - 7 ~ 8.5 Nm) with torque
wrench.

Take spring for Oil pressure valve & fit it in Crankcase

location .

143
Take Clutch cover gasket. Fit it on TSHC (Clutch side).

Ensure the spring between clutch cover & Oil pressure

valve should match / align.

Tighten the cover by "12" bolts using 8 mm T spanner

(Apply torque - 11 ~ 13 Nm)

Take Spark plug gasket and fit it on Spark plug area

of Cylinder head. Take "O" ring and fit it on cylinder
head cover and lubricate with Dow corning silica gel.

Fit the Head cover on cylinder head. Take earthing

cable and fit it along with one screw and tighten it with
"4" bolts. (Apply torque - 11 ~ 13 Nm)

144
Fitment of Inlet & Exhaust shroud :

Take the shroud intake side. Fit it on the Cylinder

head by one bolt with clamp and tighten it with torque
wrench (Apply torque - 3 ~ 4 Nm)

Take the Exhaust shroud . Fit it on the Cylinder head

by two bolts to join the boots and tighten it with torque
wrench (Apply torque - 1 ~ 2 Nm)

Take Fan Cover & Fit it on Fan Assy. by tightening "

5 " screws with torque wrench (Apply torque - 1 ~ 2
Nm)

Fit the intake Manifold by "2" bolts & put the adopter
on it and then fit the carburettor (As mentioned below)

145
Take Carburettor, fit the carburetor Assy. on intake
fitting. Tighten it with torque wrench (Apply torque -
11 ~ 13 Nm) .

Take Fare meter. Fit it on DGC by using " 3 " bolts

and tighten with torque wrench (Apply Torque - 11 ~ -
13 Nm)

146
1) Differential cage Assy. -
Place the Differential cage on fixture and fit the
Differential gear (1 No.) in cage.
Place the Sun gear (1 No.) on Differential gear.
Take Differential pin & push the pin through two Sun
gears.
Place 2nd Diff. gear & fit it on Sun gear in opposite
direction. Ensure alignment with each other.
Place the washer on differential gear & then fit the
circlip.
Take Differential crown & fit the Differential cage with
gears in opposite direction.
Take "3" Nos. locking plates & fit it on Cage. Tight
the same with "6" bolts by T Spanner (Apply torque -
65 ~ 70 Nm) and then bend the locking plate.
Rotate the complete Assy. Fit the stopper on Cage &
bend the strips of the stopper in Cage groove of both
sides.

147
DIFFERENTIAL GEAR ASSEMBLY :

148
2) Differential Gear Cover Assy.

Take DGC Assy. with bearing & oil seal and put on
fixture

Take the "O" ring & fit it on DGC

Take a lever & hold in a position as shown in fig. Take

the slider & fit it on the lever and secure the circlip.

Take the Lever Assy. Fit it on DGC & secure with pin.

Take pinion shaft gear & fit it on Pinion shaft ensuring

slider of Inverter control align with slot of Pinion gear

Take spring pin & fit it on inverter control to secure it

with DGC

Take complete Differential gear Assy. & fit it on DGC

aligning with pinion gear.

Fit idler gear in bush.

Rotate DGC assy. & position it on fixture

Take spring & fit it on bolt spring retaining (Apply torque

- 20 ~25 Nm) and align with inverter control.

149
3) Cylinder head Assy . -

Take cylinder head , Fit it on fixture / hold it on bench

vice.

Take camshaft bearings front end & rear end ensuring

bearing shield side outside.

Lubricate camshaft bearing hole area with Engine oil

(15W50) & fit the camshaft with bearing on cylinder
head.

Lubricate rocker arm axle resting hole with Engine oil

(15W50).

Take Exhaust side rocker arm, Lubricate it (inside hole

of exhaust side rocker arm) with Engine oil (15W50).

Position exhaust side rocker arm on rocker arm axle

and fit it on cylinder head exhaust side.

Take Intake side rocker arm, Lubricate it (inside hole

of intake side rocker arm)

with Engine oil (15W50).

Fit Intake side rocker arm on rocker arm axle and fit it
on cylinder head intake side

150
4) Clutch Assy. :

Take clutch box & hold it in bench vice / fit it on fixture.

Keep 6 nos. of bush on clutch box & then 6 nos. of

cup clutch spring on bush (Refer fig. No.1)

Keep shim on clutch box. Then take clutch shaft Assy.

& fit it on clutch spring.

Take engine gear & put it on clutch shaft assy. &

ensure free rotation of gear on shaft .

Fit 5 Nos. driven plate & 4 Nos. drive plate one-by-

one start from driven plate and then fit the Ring on
clutch box outer side. Fit the pressure plate at end

Tighten the clutch assy. Bolt with Torque wrench (Apply

torque - 30 ~ 35 Nm) . Take thrust plate & fit it on
clutch assy. with spring clip
CLUTCH ASSEMBLY

151
5) Clutch Cover sub Assy. :

Take clutch cover & keep it on fixture

Take connector and add loctite 603 on outer side of

connector. Fit connector (Dimension - 19 ± 0.5 mm)
on clutch cover

Press the connector manually.

Rotate clutch cover. Take spring & position it on

plunger shaft

Take pin & circlip, fit the circlip on one side of pin

Take link & insert it through clutch cover blow. fit it on

clutch cover

Take pin with circlip assy. & Fit it on clutch cover to

lock link

Take circlip & fit it on other side of pin

Take retaining plate & fit it on clutch cover spring

Take circlip & fit it on retaining plate

Fit the clutch cover bellow on clutch cover & secure

with hose clip (Apply torque - 1.0 ~ 1.5 Nm)

152
SPARK PLUG

1. Drop down the tail gate by unlocking the lock on

LH side & unscrewing the wing nut as shown in
the fig.
2. Remove the spark plug noise suppressor cap and
clean around the spark plug base.
3. Remove the spark plug by using plug spanner.
4. Check the insulator for cracks or damage, and
the electrodes for wear, fouling or discoloration.
5. If the electrode is having carbon deposits, clean
the electrode using the spark plug cleaner.
6. Replace the plug if necessary.

153
Recommended Spark Plug: Bosch UR3DC

7. Measure the spark plug gap between the center

and side electrodes with a wire gauge.
Initial spark plug gap: 0.7 to 0.8 mm

8. Adjusting the spark plug gap by bending the side

electrode is not recommended. The operation may
damage the engine
9. If the gap is more than 1.1 mm than replace the
spark plug. Don't adjust the spark plug Gap.
10. Tighten the spark plug by using plug spanner.
Torque: 10 to 12 Nm
11. Install the spark plug noise suppressor cap.

154
VALVE CLEARANCE

NOTE : Inspect and adjust the valve clearance when

the engine is cold condition.

1. Drop down the tail gate by unlocking the lock on

LH side & unscrewing the wing nut as shown in
the fig.
2. Remove the spark plug noise suppressor cap and
clean around the spark plug base.
3. Remove the spark plug by using plug spanner.
4. Remove the M6 X 20 bolts (4nos, 8mm T spanner)
and remove cylinder head cover.
5. Match the arrow mark on the timing crown and
index mark on the cylinder head casting.

6. Make sure that the piston is at TDC (Top Dead

Center) in the compression stroke.
7. Rocker arms should be slightly loose. If the rocker
arms are tight, turn the crankshaft clockwise 360°
(one full turn) and align the arrow mark on the
timing crown and index mark on the cylinder head.
8. Check the valve clearance by inserting a feeler
gauge between the valve adjusting screw and valve
stem.

155
VALVE CLEARANCE: INLET: 0.10 to 0.15 mm,
EXHAUST: 0.13 to 0.17 mm.

If the valve clearance is incorrect, loosen the valve

adjusting screw lock nut and adjust the valve clearance
by turning the adjusting screw until there is a slight
drag on the feeler gauge.

Hold the adjusting screw and tighten the lock nut.

Recheck the valve clearance.

Install the removed parts in the reverse order of

removal.

156
GEAR BOX
6. For removing the ball bearing from engine side
cover, remove the bearing using tool no.
(Fig. No. 12)
Fig. No. 12
7. For removal of needle bush from engine side cover
use tool no. (Fig. No. 13)
Fig. No. 13
Dismantling Sub Assy.
1. Open the circlip on the main shaft and take out
the shoulder ring, 1st speed gear, 2nd speed gear,
3rd speed gear and the 4th speed gear
subsequently.
2. Take out the cluster gear.
3. Open the circlip on the main shaft with an external
circlip plier.
4. Take out the main shaft with the stem by tapping
it from the differential side using tool no. 9-3- 220-
1.
5. Grip main shaft with stem & cross thru soft material
in vice. Tighten stem LH thread by spanner till it
breaks at threading end. Take out stem. Rotate
cross by 180 Degree to make broken piece of
stem accessible thru main shaft hollow end.
159
6. B§OZ gmB©S> H$da go ~m°b {~`[a¨J hQ>mVo g_` Qy>b H«$.
9-2-140-8 H$m à`moJ H$aoŸ& ({MÌ H«$. 12 )
7. B§OZ gmB©S> H$da go ZrS>b ~we {ZH$mbZo Ho$ {bE Qy>b H«$.
9-2-130-2 H$m à`moJ H$aoŸ& ({MÌ H«$. 13)
_oZ hmD$qOJ g~ Ag|ãbr H$m ImobZmŸ&
1. _oZ emâQ> na pñWV gapŠbn Imobo VWm H«$_e: àW_, {ÛVr`,
V¥Vr` VWm Mm¡Wo ñnrS> {J`a emoëS>a [a¨J g_oV ~mha {ZH$mboŸ&
2. ŠbñQ>a {J`a ~mha {ZH$mboŸ&
3. _oZ emâQ> na pñWV gapŠbn, ~mø gapŠbn ßb`ma Ûmam
ImobŸo &
4. ñQ>o_ Ho$ gmW _oZemâQ> {S>\«$o§{e`b gmB©S> go R>moH$Vo hþE Qy>b
H«$. 9-3- 220-1 Ûmam Imobo&
5. H«$mg VWm ñQ>o_ Ho$ gmW _oZemâQ> {H$gr _wbm`_ MrO H$s
ghm`Vmgo ìhmBg _| nH$S>oŸ& ñQ>o_ Ho$ W«oS>g² H$mo ~m`r Va\$
ñn¡Za H$s ghm`Vmgo BVZm Kw_mE H$s dmo W«oS>g² Ho$ Am{Ia _|
Qy>Q> OmEŸ& ñQ>o_ H$mo ~mha {ZH$mbo & H«$mg H$mo 1800 _| Kw_mE
Vm{H$ ñQ>o_ H$m Qy>Q>m hþAm VwH$S>m _oZ emâQ> Ho$ EH$ Va\$ go
 Unscrew broken piece of stem in cross by 4 point
screw driver.
6. Take out the cross, shoulder ring and circlip from
the main shaft.
7. Ball bearing can be pulled out from the main
housing using tool no. 9-2-510-8. (Fig. No. 14)
Fig. No. 14
8. Bush for idler gear can be pulled out from the main
housing using tool no. 9-2-540-6. (Fig. No. 15)
Fig. No. 15
9. The needle bush for cluster gear can be removed
as described below :
On the plain washer below the bush, threaded holes
are provided. Put two screws in these holes and go
on tightening them simultaneously. The bush will come
out.
Dismantling of Differential Assy. / Shaft Pinion :
1. Remove the gearbox cover assy. as described in
the preeeding paragraph. Remove the idler gear.
2. Screw out the dipstick.
3. Take out circlip fixed on differential cage bu using
external circlip piler.
160
{ZH$mbm Om gHo$Ÿ& H«$mg _| ~Mm hþAm ñQ>o_ H$m Qy>Q>m hþAm
VwH$S>m ñH«y$ S´>mBda H$s ghm`Vm go {ZH$mboŸ&
6. H«$mg, emoëS>a [a¨J VWm gapŠbn H$mo _oZemâQ> go {ZH$mboŸ&
7. Qy>b H«$.9-2-510-8 H$s ghm`Vm go _oZ hmD$qOJ go ~m°b
{~`[a¨J ~mha ItMo & ({MÌ H«$.14)
8. Qy>b H«$. 9-2-540-6 H$m à`moJ H$aVo hþE _oZ hmD$qOJ go Am`S>ba
{J`a H$m ~we ~mha ItMm Om gH$Vm h¡ & (XoIo H«$. 15)
9. ŠbñQ>a {J`a H$m ZrS>b ~we {ZåZ{b{IV Ho$ AZwgma hQ>m`m
Om gH$Vm h¡ Ÿ&
~we Ho$ ZrMo ßboZ dm°ea na W«oS>oS> N>oX {XE JE h¡Ÿ& Xmo ñH«y$ BZ N>oXm|
H$gVo OmEŸ& ~we ~mha AmEJm Ÿ&H$
{S>\«|${e`b Ag|ãbr / emâQ> {n{Z`Z H$mo ImobZm
1. à{H«$`m AZwÀN>Xo _| {XE JE AZwgma {J`a ~m°Šg H$da Ag|ãbr
hQ>mEŸ& Am`S>ba {J`a {ZH$mboŸ&
2. {S>n pñQ>H$ Kw_mH$a {ZH$mboŸ&
3. {S\«|${e`b Ho$O na bJmB© J`r gapŠbn ~mø gapŠbn ßbm`a
H$s ghm`Vm go {ZH$mboŸ&
4. Keep gearbox cover sub assy. on base for 4. {S\«|${e`b H$oO Ag|ãbr VWm emâQ> {n{Z`Z ImobZo Ho$ {bE
dismantling differential cage and shaft pinion using [J`a ~m°Šg H$da g~ Ag|ãbr Qy>b H«$. 9-2-650-9 na aIoŸ&
tool no.
5. Take out gently differential assy. and shaft pinion
5. Qy>b H«$. 9-2-040-1 H$s ghm`Vm go Yrao go {S>\$|« {e`b Ag|ãbr
by using tool no. (Fig. No. 16) VWm emâQ> {n{Z`Z ~mha {ZH$mboŸ& ({MÌ H«$. 16 )

9-2-040-1

9-2-650-9

Fig. No. 16

6. Remove the reverse control gear unit and the shaft 6. [adg© H§$Q´>mob {J`a `y{ZQ> VWm emâQ> {n{Z`Z {ZH$mbo &
pinion.
7. Remove the spring dowel and take out the lever 7. pñà¨J S>m°dob hQ>mE Am¡a brda VWm goŠQ>a Ago§ãbr {ZH$mboŸ&
and sector assy.
8. Qy>b 9-2-540-6 H$m à`moJ H$aVo hþE {J`a ~m°Šg H$da go
8. Remove the idler gear bush from the gearbox cover
using tool no. (Fig. No. 17) Am`S>ba {J`a ~we hQ>mEŸ& (XoIo H«$. 17)

9-2-540-6

Fig. No. 17

161
9. Remove the circlips from the gearbox cover. 9. {J`a ~m°Šg H$da go gapŠbn hQ>mEŸ&
10. Take out the bearing from the gearbox cover using 10. Qy>b H«$. 9-2-840-7 VWm 9-2-820-5 H$m Cn`moJ H$aVo hþE,
tool no. and (Fig. No. 18 & 19)
{J`a ~m°Šg H$da go {~`[a¨J {ZH$mboŸ& ({MÌ H«$. 18 VWm
19)

9-2-840-7

Fig. No. 18

9-2-820-5

Fig. No. 19

Dismantling Differential Cage Assy. :

1. Take out circlip by using circlip plier. {S>\«|${e`b Ho$O Ag|ãbr H$mo ImobZm ({S>g_|Q>qbJ)
2. Unfold differential pin locking stopper and remove 1. gapŠbn ßbm`a Ho$ à`moJ go gapŠbn ~mha {ZH$mboŸ&
it from differential cage. 2. {S>\«|${e`b {nZ bm°qH$J ñQ>m°na H$mo Imobo VWm {S>\«|${e`b
3. Take out differential pin, satellite gear, sun gear Ho$O go Cgo {ZH$mboŸ&
and washer.
3. {S>\«|${e`b {nZ, g°Q>obmBQ> {J`a, gZ {J`a VWm dm°ea
4. Remove screws to separate F.D. gear and {ZH$mboŸ&
differential cage.
4. E\$.S>r.{J`a VWm {S>\«|${e`b \o$O AbJ H$aZo Ho$ {bE ñH«y$
III. STEERING AND FRONT SUSPENSION :
{ZH$mbo.

162
 STEERING
&
FRONT SUSPENSION
Dismantling of Handle Bar and Steering Column : III.
1. Remove the cover on the handlebar. h¢S>b ~ma VWm pñQ>`[a¨J H$mb_ H$mo ImobZm :
2. Disconnect the terminals of the gear change
control cables, clutch and accelerator. 1.
3. Disconnect all electrical wires of the switch on 2.
the handlebar. Identify each wire with respect to
its terminals.
3.
4. Unloose the nut from the bolt on the sleeve
securing handlebar and pull the handlebar out.
5. Lift the front portion of the vehicle on the jack and 4.
remove the tyre.
6. Remove front brake connections and drain the 5.
brake fluid.
6.
7. Remove the ring nut on the steering column by
using tool no. 19-1-36084. Release the steering
column taking care to collect the steel balls.
Inspect the steel balls, if necessary replace.
(Fig. No. 20)
pñQ>`[a¨J VWm \«§$Q> gñn|eZ
h¢S>b ~ma H$m H$da hQ>mEŸ&
{J`a M|O H§$Q´>mob Ho$~b, ŠbM VWm EpŠgboQ>a H$m Q>{_©Zb
AbJ H$ao Ÿ&
h¢S>b ~ma na pñWV H$s g^r {dÚwVr` dm`a AbJ H$aoŸ& àË`oH$
dm`a CgHo$ Q>{_©Zb Ho$ AZwgma {ZYm©[aV H$aoŸ&
h¢S>b~ma H$mo nS>H$Vo hþE ñbrd na pñWV ~moëQ>go ZQ> Imobo
VWm h¢S>b~ma ~mha {ZH$mboŸ&
dmhZ H$m AJbm ^mJ O¡H$na D$na CR>mE VWm Q>m`a {ZH$mboŸ&
AmJo Ho$ ~«oH$ H$ZoŠeZ hQ>mE VWm ~«oH$ âbwB©S> {ZH$mb XoŸ&
Qy>b H«$. 19-1-36084 H$m à`moJ H$aVo hþE pñQ>`[a¨J H$m°b_ na
pñWV [a¨J ZQ> hQ>mEŸ& ñQ>rb ~m°Šg EH${ÌV H$aVo hþE pñQ>`[a¨J
H$m°b_ hQ>mE ñQ>rb ~mëg H$s Om±M H$ao Am¡a Amdí`H$Vm hmo
Vmo ~XboŸ& ({MÌ H«$. 20)

19-1-36084

8. Inner track of the lower bearing : for dismantlingFig.

it No. 20
use tool no. 19-1-36485 (Fig. No. 21)
8. bmoAa {~`[a¨J H$m Am§V[aH$ Q´>¡H$ ImobZo Ho$ {bE Qy>b H«$.
9. Lower track of upper steering column bearing : by
19-1-36485 H$m BñVo_mb H$aoŸ& ({MÌ H«$. 21)
using the tool no. 19-1-20842 (a) extract the

19-1-36485

Fig. No. 21

165
 housing (b) from the head tube. (Fig. No. 22) 9. Aßna pñQ>`[a¨J H$m°b_ {~`[a¨J H$m bmoAa Q´>¡H$ : Qy>b H«$.
19-1-20842 (a) H$m à`moJ H$aVo hþE hoS> Q>çy~go hmD$qOJ
~mha {ZH$mboŸ& ({MÌ H«$. 22)

19-1-20842

10. Upper track of the lower steering column Fig. No. 22

bearing : by using tool no 19-1-20004 extract the
housing (a) from the tube. (Fig. No. 23) 10. bmoAa pñQ>`[a¨J H$m°b_ {~`[a¨J H$m Aßna Q´>¡H$ : Qy>b H«$.
19-1-20004 H$m à`moJ H$aVo hþE Q>çy~go hmD$qOJ (a)
{ZH$mboŸ& ({MÌ H«$. 23)

19-1-20004

Dismantling the Front Wheel Hub : Fig. No. 23

Hold the steering column on a bench vice and
\«§$Q> ìhrb h~ H$mo ImobZm :
dismantle it in a following sequence :
1. Dismantle shock absorber and suspension spring EH$ ~o§M dm°Bg na pñQ>`[a¨J H$mb_ nH$S>H$a aIo VWm Cgo
by unscrewing the upper and lower bolts. {ZåZ{b{IV H«$_ go {S>g_|Q>b H$ao :
2. Remove the dust cover plug with the screwdriver.
1. Cnar VWm {ZMbo ~moëQ> H$mo ImobH$a em°H$ A°ãOm°d©a VWm
3. Remove the spot punch nut on the wheel axle by
gñn|eZ pñà¨J H$mo {ZH$mboŸ&
unscrewing it.
4. Dismantle the brake drum from the hub by 2. S>ñQ> H$da ßbJ ñH«y$ S´>mBda H$s ghm`Vm go hQ>mEŸ&
removing the circlip.
3. ìhrb A°Šgbna pñWV ñnm°Q> n§M ZQ> AZñH«y$ H$aHo$ hQ>mEŸ&
5. With help of a plastic hammer remove the wheel
hub from its axle. 4. gapŠbn hQ>mVo hþE h~go ~«oH$ S´>_ {S>g_|Q>b H$aoŸ&
6. Remove the circlip for retaining the ball bearing
5. ìhrb h~ CgHo$ EŠgb go ßbmpñQ>H$ h¡_a H$s ghm`Vm go hQ>mEŸ&
with an internal circlip plier. (Fig. No. 24)
7. Place the hub on a base. With a punch, push out 6. Am§V[aH$ gapŠbn ßbm`a ìXmam ~mb {~`[a¨J [aQ>oqZJ gapŠbn
the ball bearing (c) as in figure. (Fig. No. 25) hQ>mEŸ& ({MÌ H«$. 24)
166
8. Remove the oil seal. 7. h~ H$mo EH$ ~og na aIoŸ& {MÌ Ho$ AZwgma ~m°b {~`[a¨J (O)
H$mo n§M H$s ghm`Vm go ~mha {ZH$mboŸ& ({MÌ H«$. 25 )
8. Am`b grQ> hQ>mEŸ&

Fig. No. 24
9. Place the hub as shown in figure (Fig. No. 25)
and push with a punch for extracting the draw cup
(roller bearing) (d) (19-1-35784) 9. {MÌ Ho$ AZwgma h~ aIo ({MÌ H«$. 25) VWm S´>m° H$n (amoba
{~`[a¨J) {ZH$mbZo Ho$ {bE n§M go T>Ho$bo (d) (19-1-35784)

19-1-35784

Fig. No. 25
Dismantling of Swinging Arm from Steering
Column :
The dismantling operation of connecting parts between pñQ>`[a¨J H$mb_ go pñd[JJ Am_© AbJ H$aZm :
steering column and front wheel swinging arm (pin,
needle bushes, oil seals and dust cover unit ) is done
pñQ>`[a¨J H$mb_ VWm \«§$Q> ìhrb pñd§qJJ Am_© Ho$ ~rM Ho$ OmoS>Zodmbo
by means of hydraulic press having minimum capacity nyOm] ({nZ, {ZS>b ~weog² Am`b grb VWm S>ñQ> H$da `w{ZQ>) H$mo
of 10 M.T. ImobZo H$m n[aMmbZ hmBS´>mo{bH$ àog Ûmam {OgH$s j_Vm H$_ go
a. Dismantling of two retaining washers. H$_ 10 _| Q>Z hmo Ho$ Ûmam {H$`m OmVm h¡Ÿ&

167
 Use a proper punch as shown in figure, and
remove the washer. For the second washer repeat
the operation using the punch on the opposite
side. (Fig. No. 26)
a. Xmo [aQ>oqZJ dm°eam| H$mo ImobZmŸ&
{MÌ Ho$ AZwgma `mo½` n§M H$m à`moJ H$ao Am¡a dm°ea hQ>mEŸ& Xygao
dm°ea Ho$ {bE dhr {H«$`m XmohamVo hþE {ZH$mboŸ& ({MÌ H«$. (26)

Fig. No. 26
b. Dismantling of Pin and Needle Bushes.
Place the steering column assy. on the hydraulic
press and with the help of a suitable punch, b. {nZ VWm {ZS>b ~weog H$mo ImobZm : pñQ>`[a¨J H$m°b_ Ag|ãbr
remove the pin and the first needle bush. hmBS´>mo{bH$ àog na aIo Am¡a `mo½` n§M H$s ghm`Vm go {nZ VWm
(Fig. No. 27) nhbm {ZS>b ~we hQ>mE ({MÌ H«$. 27)

Fig. No. 27

After removing the pin and the first needle bush the
swinging arm can be removed from the steering
column.
{nZ VWm nhbm {ZS>b ~we hQ>mZo Ho$ ~mX pñQ>`[a¨J H$m°b_ go pñd¨qJJ
Am_© hQ>m`m Om gH$Vm h¡Ÿ&
For removing second needle bush use the punch and
plastic hammer. Xygam {ZS>b ~we hQ>mZo Ho$ {bE n§M VWm ßbmpñQ>H$ h¡_a H$m à`moJ
H$aoŸ&
IV. REAR SUSPENTION :

168
REAR SUSPENTION
&
BRAKE
1. Jack up the vehicle and remove the tyre. IV. [aAa gñn|eZ :
2. Remove the circlip for brake drum and remove
1. dmhZ H$mo O¡H$ go Cna CR>mE VWm Q>m`a {ZH$mboŸ&
the brake bundy tube.
3. Remove the handbrake cable. 2. ~«oH$ S´>_ H$ gapŠbn {ZH$mbo Am¡a ~«oH$ ~§S>r Q>çy~ {ZH$mboŸ&
4. Unloose the connection between brake bundy 3. h¢S> ~«oH$ Ho$~b {ZH$mboŸ&
tube and brake hose (engine bracket side) of the
brake pipe. 4. ~«oH$ nmBn Ho$ ~«oH$ ~§S>r Q>çy~ VWm ~«oH$ hmoO (B§OZ ~«°Ho$Q>
5. To remove the axle shaft unloose the bolt of hub gmB©S>) Ho$ ~rM Ho$ H$ZoŠeZ ImoboŸ&
collar (a) and remove the axle shaft. (c) (Fig. No. 28) 5. EŠgb emâQ> ImobZo Ho$ {bE h~ H$m°ba (a) H$m ~moëQ> Imobo
Am¡a EŠgb emâQ> (c) hQ>mEŸ& ({MÌ H«$. 28)

Fig. No. 28
6. Remove the bottom bolt of the shock absorber
6. C{MV ñn¡Za H$s ghm`Vm go em°H$ A°ãOm°d©a H$m ZrMo H$m ~moëQ>
using appropriate spanner.
hQ>mEŸ&
7. Release the two bolts securing swing arm to the
7. B§OZ ~«°Ho$Q> go pñd¨J Am_© OmoS>Zodmbo Xmo ~moëQ> Imobo Am¡a `w{ZQ>
engine bracket and remove the unit.
{ZH$mboŸ&
8. Remove the flexible coupling by unscrewing the
8. h~ VWm âbopŠg~b H$nqbJ H$mo OmoS>Zodmbo ~moëQ> ImobH$a
bolts securing the hub and flexible coupling.
âbop½P~b H$nqbJ hQ>mEŸ&
9. With a box wrench release the spot punch nut
9. ìhrb EŠgb go ~m°Šg a|M H$s ghm`Vm go ñnm°Q> n§M ZQ> Imobo
from the wheel axle and remove the hub.
VWm h~ {ZH$mbo&
10. To remove the wheel hub from back plate, unscew 10. ~¡H$ ßboQ> go ìhrb h~ hQ>mZo Ho$ {bE 4 ~moëQ> Imobo Am¡a Am_©
the 4 bolts and release the hub from the arm. go h~ {ZH$mboŸ&
11. To remove oil seal (a). 11. Am`b grb (a) {ZH$mboŸ&
12. Remove rear axle lock. 12. [a`a EŠgb bm°H$ {ZH$mboŸ&
13. tap out rear axle with help of plastic hammer and 13. ßbmpñQ>H$ h¡_a VWm Aë`w{_{Z`_ n§M H$s ghm`Vm go [a`a
aluminium punch. EŠgb H$mo R>moH$ H$a ~mha {ZH$mboŸ&
14. Remove the circlip retaining the bearing (b) by 14. B§Q>Z©b gapŠbn ßbm`a H$s ghm`Vm go {~`[a¨J (b)[aQ>qo ZJ
using internal circlip plier. (Fig. No. 29) gapŠbn H$mo {ZH$mboŸ& ({MÌ H«$. 29)

Fig. No. 29

171
15. Place the hub on a base as shown in figure. By 15. {MÌmZwgma h~ H$mo ~og na aIo Am¡a n§M VWm am°S> H$s ghm`Vm
means of a rod or a punch push out the bearing.
go {~`[a¨J (a) H$mo {ZH$mboŸ& ({MÌ H«$. 30)
(a) (Fig. No. 30)

Fig. No. 30

16. Remove the oil seal on the other side of the hub. 16. h~ Ho$ Xygar Amoa go Am`b grb hQ>mEŸ&
17. Remove the draw cup (roller bearing) s(b) by 17. h~ H$mo EH$ ~og na aIH$a O¡gm {MÌ _| {XIm`m J`m h¡Ÿ& n§M
placing the hub on a base and using a punch as H$m à`moJ H$aHo$ S´>m° H$n (amoba {~`[a¨J) (b) H$mo hQ>mEŸ&
shown in the figure. (Fig. No. 31) ({MÌ H«$. 31)

Fig. No. 31

V. BRAKE : V. ~«oH$ :
DISMANTLING PROCEDURE FOR TANDEM dmhZ go Q>|S>_ _mñQ>a {gqbS>a (Q>r.E_.gr.) Ag|ãbr H$mo ImobZo
MASTER CYLINDER (TMC) ASSEMBLY FROM THE H$s à{H«$`mŸ& ({MÌ H«$. 32)
VEHICLE: (Fig. No. 32)
1. Q>r.E_.gr. nwe am°S> na pñWV bm°H$ ZQ> "E' H$mo {T>bm H$aoŸ&
1. Loose the lock nut “A” on the TMC push rod.
2. ~«oH$ bmBQ> pñdM H$mo _mD§$qQ>J ~¡«Ho$Q> go hQ>mEŸ&
2. Remove the brake light switch from its mounting
3. ~«oH$ noS>b H$mo \$moH©$ go OmoS>Zodmbo hoŠg°JmoZb gm°Ho$Q> hoS> H¡$n
bracket.
ñH«y$ {ZH$mboŸ&
3. Remove the hexagonal socket head cap screw
“B” which connects brake pedal to the fork. 4. \$moH©$ H$mo AbJ H$aZo Ho$ {bE ~«oH$ noS>b H$mo CgHo$ {ndQ> Ho$

4. Rotate the brake pedal about its pivot to make

BX©{JX© Kw_mEŸ&
the fork free. 5. Q>r.E_.gr. nwe am°S> H$mo H$g H$a nH$S>Vo hþE \$moH©$ H$mo
5. Unscrew the fork from TMC by holding the TMC Q>r.E_.gr. go Kw_mH$a {ZH$mboŸ&
push rod tight. 6. Q>r.E_.gr. go ~«oH$ H$ZoŠeÝg AbJ H$aoŸ& ~«oH$ âbwBS> H$mo a§JrZ
6. Disconnect the brake connections from TMC. ^mJm|na Z {JamE, Š`m|{H$ ~«oH$ âbwBS> a§Jmo Ho$ {bE AË`§V
Do not allow brake fluid to get on the painted surface, hm{ZH$maH$ hmoVm h¡Ÿ&
as brake fluid is extremely damaging to paint.

172
7. Take out TMC from the TMC mounting bracket
by removing the fastners securing it on the
bracket.
Fig. No. 32
Dismantling the TMC assy. : (Fig. No. 33)
1. Wipe out external surface of the master cylinder
free of dust / grit.
2. Remove the boot (14).
3. Press the push rod (11) down. Remove the circlip
(9), stop washer (10) and push rod (11).
4. Take out the primary piston assy. (18).
5. Press the secondary piston assy. (19) with the
help of a wooden or nylon rod and unscrew the
secondary piston stopper (4) along with its gaskets
(5).
6. To remove the secondary piston assy. (19), tap
gently the master cylinder facing downwards on
a wooden block. The piston will come out upto
the bore face, then tap the master cylinder on the
flange.
7. Remove the secondary piston assy. (19).
8. TMC reservoir can be removed by unscrewing the
two philips head screws securing it.
19
5 4
Fig. No. 33
173
7. Q>r. E_. gr. H$mo Q>r. E_. gr. _mD§$qQ>J ~«°Ho$Q> go \$mñQ>Zg©
hQ>mH$a ~mha {ZH$mb| {OZHo$ Ûmam Cgo ~«°Ho$Q>go H$gm J`m h¡ &
Q>r. E_. gr. Agoãbr H$mo ImobZm : ({MÌ H«$. 33)
1. _mñQ>a {gqbS>a Ho$ ~mhar gVh go Yyb / aoV nm|N> gm\$ H$a|&
2. ~yQ> H$mo hQ>mE§ & (14)
3. nwe am°S> (11) H$mo ZrMo T>Ho$bo gapŠbn (9) hQ>mE§, dm°ea
(10) VWm nwe am°S> (11) H$mo {ZH$mb| &
4. àmW{_H$ {nñQ>Z Ag|ãbr (18) H$mo {ZH$mb| &
5. {ÛVr` {nñQ>Z Ag|ãbr H$mo bH$S>r `m Zm`bmZ Ho$ amS> Ûmam
X~mE Am¡a {nñQ>Z ñQ>mna H$mo CgH$s JmñHo$Q> (5) Ho$ gmW
Kw_mH$a {ZH$mb| &
6. {ÛVr` {nñQ>Z Ag|ãbr (19) hQ>mZo Ho$ {bE bH$S>r Ho$ ãbm°H$
na AYmo_wI _mñQ>a {gqbS>a H$mo Yrao - Yrao R>moH|$ & {nñQ>Z
No>X Ho$ _wI VH$ ~mha AmEJm, {\$a _mñQ>a {gqbS>a H$mo âb|O
na {~R>m X| & hëH$m gH$ hmoHo$ {nñQ>Z ~mha AmEJm &
7. {ÛVr` {nñQ>Z Ag|ãbr (19) hQ>mE§ &
8. Q>r. E_. gr. [aOdm©`a H$mo Cgo H$gZo dmbo Xmo {\${bßg hoS> ñH«y$
ImobH$a hQ>m`m Om gH$Vm h¡ &
10 9 14
18 11
BRAKES :
Clean all dismantled parts of the master cylinder with
fresh specified brake fluid or alcohol.
Caution: Never use the drained / used brake fluid for
cleaning or other purposes. Always use specified brake
fluid from a sealed and fresh container. Always use a
clean tray free from dust, water, mineral oil like diesel,
kerosene, petrol, etc.for cleaning any brake parts.
Note : Check the cylinder bore for rust, pitting,
scratches. Damaged bores must not be used.
Polishing of the bore and piston with the
abrasive material is strictly prohibited as it
will damage the bore / pistons.
Wheel Cylinders :
Remove the wheel cylinder from the brake back plate.
Strip down the unit completely and wash all the parts
in Acetone. Do not use petrol or kerosene for cleaning
the brake parts. The rubber components will get
damaged if petrol or kerosene is used for cleaning.
Dry the components with compressed air.
Check the internal surface of the wheel cylinder. If
the surface is scratched or corroded, the cylinder will
have to be replaced. Damaged wheel cylinders will
cause damage to the piston and packings.
25 Bolts for Securing Diff. Cage 10 x 1.25 6.5 - 7
174
~«oŠg :
_mñQ>a {gqbS>a Ho$ Imobo JE g^r nwO} {Z{X©ï> ZE ~«oH$ âbwB©S> `m
AëH$mohmobgo gm\$ H$a| &
gmdYmZr - g\$mB© VWm AÝ` H$maUm|Ho$ {bE JmS>rgo {ZH$mbo J`o /
BñVo_mb {H$`o J`o ~«oH$ âbwB©S> H$m à`moJ Z H$a| & h_oem grb {H$E
JE \«$o e H§$Qo>Za H$m {Z{X©ï> âbwBS© > hr BñVo_mb H$a| & h_|em Yyb{da{hV
gm\$gwWam Qó>, nmZr, {_Zab Am`b O¡go S>rμOb, Ho$amo{gZ, noQ´>mob
Am{X H$m à`moJ ~«oŠg Ho$ {H$gr ^r nwO©o gm\$ H$aZo Ho$ {bE Z H$a| &
ZmoQ> - _mñQ>a {gqbS>a Ho$ ~moa H$mo O§J, JS>Xmo VWm {KgmZ Ho$ {bE
MoH$ H$a| & `{X {H$gr àH$ma H$m S¡>_oO hmo Vmo Cgo BñVo_mb Z H$a|,
Z hr {H$gr A~«o{gd go nm{be H$aZo H$s H$mo{ee H$a| & `h {nñQ>Z
VWm ~moa XmoZmo H$mo Iam~ H$aVm h¡ &
ìhrb {gqbS>g©
ìhrb {gqbS>a H$mo ~«oH$ ~¡H$ ßboQ> go {ZH$mbo & `y{ZQ> H$mo nyar Vah go
Imobo VWm g^r nwO} A°grQ>moZ _| YmoE± & ~o«H$ Ho$ nwO©o gm\$ H$aZo Ho$
{bE noQ´>mob VWm Ho$amogrZ H$m à`moJ Z H$a| & Bggo a~a go ~Zo KQ>H$m|
H$mo ZwH$gmZ nhy§MoJm & KQ>H$m| H$mo H§$àoñS> E`a go gwImE± &
ìhrb {gqbS>a Ho$ Am§V[aH$ gVh H$s Om§M H$a| & `{X gVh na
Iamo§Mo AmB© h¡ `m O§J bJr h¡ Vmo {gqbS>a H$mo ~XbZm hmoJm & Iam~
ìhrb {gqbS>a go {nñQ>Z VWm n°qH$½O H$mo ZwH$gmZ hmo gH$Vm h¡&
 CLUTCH ASSY.
&
GEAR SHIFTER ASSY.
Clutch :
After dismantling the clutch assy., as described earlier,
proceed as follows to overhaul the clutch unit.
Replacing the Plates :
1. Compress the spring by using tool no. 9-2-010-3.
(Fig. No. 68)
2. Remove the retaining circlip and clutch ring.
3. Take out the clutch plates.
4. Check the wear on the driving and driven plates
and tension of the springs.
a b
9-2-010-3
Fig. No. 68
The standard thickness of the clutch plates is 3 – 3.4
mm. If they are worn down to 2.7 mm thickness,
replace the clutch plates.
Checking Total Axial Play of Clutch Plates :
When replacing clutch components (plates or springs),
it should be checked that after assembly the total
axial play for the clutch plates to disengage and the
transmissible static movements are within the limits
indicated below :
a. Use tool with dial gauge. Screw “c” securing the
dial gauge firm.
b. Mount clutch assy. on the tool.
c. Tighten the wing nut “b” as much as to disengage
the plates. Reading on the dial gauge should be
3.7 – 5.5 mm for new clutch assy. Reading should
be 3.7 – 6.5 mm on clutches run-in on test stand.
Checking the Transmissible Static Movement :
a. Secure the clutch assy. in a vice by means of
the pin and bush, “a”.
b. Fit part “b” on the engine gear so that the three
stirr-ups engage under the set of helical teeth,
while their screws fit between teeth of the gear
when tightening.
c. Take a torque wrench having sufficient accuracy
to required values of 2 – 6 kgm and see if the
177
ŠbM :
Bggo nhbo ~VmE AZwgma ŠbM Ag|ãbr ImobZo Ho$ nümV {ZåZ{b{IV
Ho$ AZwgma ŠbM `y{ZQ> Amoda hm°b H$a|&
ßboQ>g² ~XbZm :
1. Qy>b H«$. 9-2-010-3 H$m BñVo_mb H$a pñà§J H$mo g§nr{S>V H$a|&
({MÌ H«$. 68)
2. ŠbM [a¨J VWm [aQo>qZJ gapŠbn hQ>mE±&
3.. ŠbM ßboQ> ~mha {ZH$mb|&
4. S´>mBqdJ VWm {S´>doZ ßboQ>g H$m {Kgmd VWm pñ৽O Ho$ Q|>eZ H$s
Om§M H$a| &
c
ŠbM ßb¡Q>g² H$s ñQ¡>S>S©> _moQ>mB© 3 – 3.4 _r _r. hmoVr h¡ & `o _moQ>mB©
2.7 {_. {_. hmo Om`o Vmo ßb¡Q>g² ~Xb| &
ŠbM ßboQ>m| na Hw$b A°pŠg`b ßbo H$s Om§M H$aZm :
ŠbM Ho$ KQ>H$m| H$mo (ßboQ>g VWm pñ৽O) ~XbVo g_` Bg ~mV H$s
Om§M H$s OmE {H$ Ag|ãbr Ho$ ~mX g§MaUr` ñQ¡>{Q>H$ J{V VWm _wº$
H$aZo Ho$ {bE ŠbM ßboQ>m|H$m Hw$b EpŠg`b ßbo, Ho$ AZwgma gr_m
Ho$ ^rVa h¡ &
a. S>m`b JoO dmbm Qy>b BñVo_mb H$a| & ñH«y$ - ײaÅ> S>m`b JoO
H$mo nŠH$m H$gVm h¡ &
b. Qy>bna ŠbM Ag|ãbr MT>mE±&
c. qdJ ZQ> ײaQ> BVZm H$g| {H$ ßboQ>g _wº$ hmo OmE± & ZE ŠbM
Ag|ãbr H$m _mn S>m`b JoO na 3.7 – 5.5 {_._r. hmoZm Mm{hE
& Qo>ñQ> ñQ¢>S>na ŠbMog aZ BZ na arqS>J 3.7 – 6.5 {_._r.
hmoZm Mm{hE &
g§MaUr` ñQ¡>{Q>H$ _wd_|Q> H$s Om§M :
a. {nZ VWm ~we “a” Ho$ ìXmam dmBg _| ŠbM Ag|ãbr H$mo ~m§Yo&
b. nmQ © > “b” > B§OZ-{J`a na H$g X| Vm{H$ VrZ ñQ>m`aßg,
ho{bH$b Xm§Vmo Ho$ goQ>Ho$ A§Xa \§$g OmE, O~ CZHo$ ñH«y$ H$gVo
g_` XmÌo VWm {J`a Ho$ ~rM H$go OmVo h¡ &
c. EH$ Q>m°H©$ ao§M bo, {OgH$s n`m©á n[aewÜXVm Amdí`H$ 2 – 6
{H$.J«m.- _r. d°ë`y h¡, VWm XoI| {H$ _mo_|Q> ZE ŠbMm|na 5 - 7
moment corresponds to 5 – 7 kgm on new clutches
and 4.9 – 7 kgm on used clutches.
Clutch Control Adjustment :
An adjuster screw is provided for adjusting the clutch
play on the clutch cover. The free play of 2 mm is to
be maintained for smooth operation of the clutch.
GEARBOX :
Gear Change Control Adjustment :
The gear cables (2 nos.) are provided for engaging
the gears. Adjusting screws are provided for adjusting
the play and cable tension. If there is excessive play,
it can be adjusted by the adjusting screws. Similarly,
after engaging a particular gear, if the gear mark does
not match with the mark on the handlebar, the
appropriate adjusting screw can be tightened and
correspondly another screw can be slackened to
maintain the cable tension.
Gear Shifter :
Remove the gear shifter assy. from the engine side
cover.
1. Place the gear shifter assembly on the tool no.
9-2-220-5 & mount the tool on a soft vice.
2. Insert ‘C’ clamp tool no. 9-2-030-5 between roller
bracket and gear shifter housing as shown in
figure (Fig. No. 69 d)
0
3. Rotate the gear shifter lever through 180 in a
clock wise direction.
4. Push the taper pin a little inwords.
5. Rotate the lever to its original position.
6. Pull out the taper pin by using a plier.
7. Slide the gear shifter lever with slider block out.
8. Remove the sector & connector plate assembly.
9. Remove the ‘C’ clamp previously inserted (Take
care that the spring does not fly off.)
10. Remove the roller bracket by unscrewing the
screw on the gear shifter housing.
11. Assemble roller bracket on gear shifter housing.
12. Put spring between housing and roller bracket.
13. Assemble sector plate assembly with pin by
rotating sector plate assy. anticlockwise. (Fig No.
69 a).Tool No. 12-6120-01-5.
178
{H$.J«m. - _r h¡ VWm dhr d°ë`y BñVo_mb {H$E JE ŠbMm|na 4.9 –
7 {H$.J«m. - _r h¡ `o XoIo &
ŠbM {Z`§ÌU g_m`moOZ :
ŠbM H$da Ho$ Cna ŠbM ßbo g_§{OV H$aZo Ho$ {bE EH$ g_§OZ
ñH«y$ {X`m J`m h¡ & ŠbM Ho$ ñ_yW n[aMmbZ Ho$ {bE 2 {_._r.
H$m \«$s ßbo ~ZmE aIZm Oéar h¡&
{J`a ~m°Šg :
{J`a M|O {Z`§ÌU g_m`moOZ :
{J`a Ho$~b (g§»`m 2) {J`a H$mo nH$S>H$a (B§JoO) aIZo Ho$ {bE
{XE JE h¡ & g_m`moOZ ñH«y$, ßbo VWm Ho$~b Q|>eZ H$mo g_m`mo{OV
H$aZo Ho$ {bE {XE JE h¡ & `{X CZ_| A{YH$ ßbo h¡ Vmo Cgo ñH«y$ Ho$
Ûmam g_m`moOZ {H$`m Om gH$Vm h¡ & Cgr àH$ma `{X H$moB© {deof
{J`a E§JoO H$aZo Ho$ ~mX {J`a {MÝh h¢S>b ~ma Ho$ {MÝh Ho$ AZwê$n
Zht hmoVm h¡ Vmo C{MV g_§OZ ñH«y$ T>rbm H$a|, Vm{H$ Ho$~b H$m Q|>eZ
~ZmE aIm Om gHo$&
{J`a {eâQ>a :
{J`a {eâQ>a Ag|ãbr B§OZ gmB©S> H$da go {ZH$mbo&
1. {J`a {eâQ>a Ag|ãbr H$mo Qy>b H«$. 9-2-220-5 na aIo
Am¡a Qy>b {H$gr gm°âQ> dmBg na ~m§Yo &
0
2. O¡go H$s {MÌ H«$. 69 d> _| {XIm`m J`m h¡ 180 Šb¡ån
(Qy>b H«$. 9-2-030-5) amoba ~«¡Ho$Q> Am¡a {J`a {eâQ>a
hmD$qOJ Ho$ ~rM S>mbo &
0
3. {J`a {eâQ>a {bda H$mo KS>r H$s gyB© {H$ {Xem _| 180 Kw_mE§&
4. Qo>na {nZ H$mo WmoS>mgm A§Xa H$s Va\$ T>Ho$b| &
5. {bda H$mo CgH$s nwdm©dñWm VH$ bmZo Ho$ {bE Kw_mE§ &
6. ßbm`a H$s ghm`Vmgo Qo>na {nZ ~mha {ZH$mb| &
7. {J`a {eâQ>a {bda ñbmBS>a ãbmH$ Ho$ gmW ~mha {ZH$mbo &
8. goŠQ>a Am¡a H$ZoŠQ>a ßboQ> Ag|ãbr {ZH$mb| &
9. nhbogo S>mbm hþAm ‘C’³ Šb¡ån {ZH$mb| & (`h gw{Z{üV H$a| H$s
pñà§J AnZr OJh go CS>H$a ~mha Z Am OmE§ &)
10. {J`a {eâQ>a hmD$qOJ na pñWV ñH«y$ ImobH$a amoba ~«¡Ho$Q>
{ZH$mb| &
11. amoba ~«¡Ho$Q> {J`a {eâQ>a hmD$qOJ Ho$ Cna Ago~b H$a| &
12. hmD$qOJ Am¡a amoba ~«¡Ho$Q> Ho$ ~rM pñà§J S>mb| &
13. KS>r H$s gyB H$s {déÕ {Xem _| goŠQ>a ßboQ> Agoãbr H$mo Kw_mVo
hþE§ {nZ H$mo goŠQ>a ßboQ> Ag|ãbr Ho$ gmW OmoS>o & ({MÌ H«$. 69
a) Bg H$m`© Ho$ {bE Qy>b H«$. 12-6120-01-5 H$m à`moJ H$a|
&
14. Insert ‘C’ clamp between roller bracket and gear
shifter housing as show in Fig. No. 69 b. Tool
No. 9-2-030-5.
15. Take out sector plate assy. with pin. Ensure roller
bracket & spring are held in position by ‘C’ clamp
as shown in Fig. No. 69 c.
16. Insert sector and connector plate assy. with ‘O’
ring in third gear position as shown in Fig. No. 69
d.
17. Insert gear shifter lever with slider block in pin.
18. Release ‘C’ clamp by pulling out. Ensure roller is
free on sector and connector plate by rotation of
sector and connector plate assy.
19. Insert taper pin in lever and pin. Caulk small end
of taper pin.
20. Check 16.61+/- 0.2 mm distance of slider block
in second gear position from gear shifter housing
face, as shown in Fig. No. 69 e.
14. O¡go H$s {MÌ H«$. 69 b> _| {XIm`m J`m h¡, Qy>b H«$.9-2-030-5
à`moJ _| bmVo hþE gr Šb¡ån H$mo amoba ~«¡Ho$Q> VWm {J`a {eâQ>a
hmD$qOJ Ho$ ~rM S>mb| &
15. goŠQ>a ßboQ> Ag|ãbr {nZ Ho$ gmW ~mha {ZH$mb| & O¡gm H$s {MÌ
H«$. 69 c> _| {XIm`m J`m h¡, gr Šb¡ån go amoba ~«H¡ $o Q> Am¡a
pñà§J AnZr pñWVr _o h¡, `o gw{Z{üV H$a| &
16. goŠQ>a Am¡a H$ZoŠQ>a ßboQ> Ag|ãbr VWm ‘O’ [a¨J {Vgao {J`a
Ho$ pñWVr _| S>mb| &
17. ñbmBS>a ãbmH$ Ho$ gmW {J`a {eâQ>a {bda {nZ _| S>mb| &
18. ItMH$a gr Šb¡ån {ZH$mb| & goŠQ>a Am¡a H$ZoŠQ>a ßboQ> Ag|ãbr
Kw_mH$a `o gw{Z{üV H$a| H$s amoba goŠQ>a Am¡a H$ZoŠQ>a Ag|ãbrna
\«$s h¡ &
19. Qo>na {nZ, {bda VWm {nZ _| S>mb| & Qo>na {nZ H$m N>moQ>m E§S>
H$m°H$ H$ao &
20. O¡go H$s {MÌ H«$. 69 e> _| {XIm`m J`m h¡, `o Om§M H$ao H$s
Xwgao {J`a H$s pñWVr _| ñbm`S>a ãbm°H$ H$m {J`a {eâQ>
hmD$qOJ \o$g go A§Va 16.61+/- 0.2 {_. _r. h¡ &

C CLAMP
TOOL NO.
9-2-0305

SECTOR PLATE ASSLY.

TOOL NO. 12 6120 01 5

Fig. No. 69a Fig. No. 69b Fig. No. 69c

Fig. No. 69d Fig. No. 69e

Fig. No. 69

179
SUB ASSEMBLY
GEAR BOX
GEARBOX : {J`a ~m°Šg :
SUB-ASSEMBLY OF ENGINE SIDE COVER: B§OZ gmB©S> H$da H$s g~ Ag|ãbr :
1. Fit needle bush on engine side cover using a 1. 9-2-120-6 n§M H$s ghm`Vm go B§OZ gmB©S> H$da na ZrS>b
punch 9-2-120-6. (Fig. No. 94) ~we {~R>mE± & ({MÌ H«$. 94)

9-2-120-6

Fig. No. 94
2. 9-2-110-0 Qy>b H$m à`moJ H$aHo$ ~m°b {~`[a¨J {\$Q> H$a| &
2. Fit the ball bearing using tool no. 9-2-110-0.
(Fig. No. 95) ({MÌ H«$. 95)

9-2-110-0

Fig. No. 95
SUB-ASSEMBLY OF MAIN HOUSING :
1. Fit bush for idler gear into the main housing using
tool no. 9-2-570-4. (Fig. No. 96)

9-2-570-4

Fig. No. 96

183
3. Fit the ball bearing into the housing using tool 8. _oZ emâQ> Ho$ {ZMbo (bmoAa) gapŠbn J«yd _| emoëS>a [a¨J
no. 9-2-530-0 and lock it by the circlip.
VWm gapŠbn {\$Q> H$a| &
4. Fit hollow dowels and studs in the main housing
(long two dowels to engine side cover side). 9. H«$mg H$mo _oZ emâQ> _| S>mb| & ñQo>_ H$s MyS>r`m|na bmoŠQ>mB©Q>
242 H$m BñVo_mb H$a| & ñQo>_ H$mo 35 go 40 N- _r. na
5. Place the cluster gear assy. in the housing.
H$g|&
6. Insert the main shaft in the ball bearing using
tool no. 9-2-410-1. (Fig. No. 97) At this time, 10. A~ Mm¡Wm, Vrgam,Xygam VWm nhbm ñnrS> {J`a, emoëS>a [a¨J
ensure that the relieved part of the shoulder on
the main shaft is facing the cluster gear assembly. Am¡a gapŠbn H$mo _oZ emâQ> _| H«${_H$ ê$n_| {\$Q> H$a| &

7. Fit the external circlip on the main shaft from the 11. ñnrS>mo S´>mB©d g§`moOZ Ho$ {bE _oZ hmD$qOJ _| {nZ {\$Q> H$a| &
differential side.

9-2-410-1

Fig. No. 97
8. Fit shoulder ring and circlip in the lower circlip
groove on main shaft.

9. Insert cross in the main shaft. Apply loctite 242

on stem threading. Tighten stem with 35-40 N-m
torque.

10. Now fit the fourth, third, second and first speed
gears, shoulder ring and circlip on main shaft
sequentially.

11. Fit the pin for speedo drive arrangement in the

main housing.

184
MAIN HOUSING TO ENGINE SIDE COVER SUB-
ASSEMBLY :

1. Fit the engine side cover sub-assembly on main

housing sub-assembly with a gasket in between,
by gently tapping the engine side cover with
plastic hammer.

2. Do not assemble cluster gear with bearing, by

hammering. Pull cluster gear for assembling the
bearing by tightening M 6 x 1 screw on retaining
plate.

3. After ensuring the face to face fitting, place

washers and nuts on the studs and tighten them
to the specified torques.

4. Fit external circlip on cluster gear.

5. Fit cover plate with “O” ring on the engine side

cover with the four countersunk screws and
conical lock washers.

6. Fit the gear shifter housing assembly on the

engine side cover (by perfectly matching the
groove 1st , 2nd etc.) on its sector plate and the
respective position of the cross (whether locked
with 1st, 2nd etc.gears) with the two socket head
screws and washers, with a gasket in between
engine side cover and gear shifter housing
assembly.

7. Ensure proper and smooth gear shifting by hand.

SUB-ASSEMBLY OF GEARBOX COVER :

1. Take differential cage housing.

2. Assemble final drive gear with differential cage

by fastening 6 screws.

3. Assemble sun gear, satellite gear and satellite

gear pin.

4. Fit the satellite gear pin by folding the locking

stopper.

5. Assemble sun gear.

6. Fit washer and insert circlip inside differential

cage.

7. Fit the idler gear bush in the cover by using tool

no. 9-2-570-4.

8. Fit spring dowel for R.C. sector stopping.

185
9. Fit the bearing for differential cage assembly
using tool no. 9-2-600-9 and 9-2-830-1 with Base
plate no. 9-2-660-5 the shaft pinion bearing in the
cover and fit circlip on both the bearings. (Fig.
No. 98)

9-2-660-5
9-2-600-9

Fig. No. 98
10. Fit slider block in lever with circlip.
11. Assemble sector lever assembly on differential
cover and lock it with spring dowel.
12. Assemble the differential cage assembly in the
cover. Fit the circlip.
13. Assemble shaft pinion and reverse control gear,
fit circlip on shaft pinion and oil seal.
14. Fit the oil level arm with sealing washer and idler
gear.
15. Mount the reverse control cable stopper bracket
with washers and screws on gearbox cover.
SUB-ASSEMBLY OF FARE METER HOUSING :
(Only applicable in case of Passenger version)
1. Assemble pin on fare meter pinion.
2. Fit the pin, the plug and the bush on fare meter
housing assembly. Use tool no. 9-2-921-7 & 9-2-
922-2. (Fig. No. 99)

9-2-921-7

9-2-922-2

Fig. No. 99

186
3. Assemble fare meter pinion and fare meter gear. 3. \o$`a _rQ>a {n{Z`Z VWm \o$`a _rQ>a {J`a Ag|~b H$ao§&

4. Fill the adopter with multi-purpose grease and 4. AS>m°ßQ>a H$mo ~hþÔoer` J«rg go ^a| VWm Ag|~b H$a|& ~moëQ>
assemble. Fit bolt and lock nut.
S>mbo Am¡a Cgo ZQ> go H$g| &
5. Fit the grease nipple.
5. J«rO {Zßnb H$mo {\$Q> H$ao§&
6. Check that the fare meter pinion and gear are
6. Om§M H$a| {H$ \o$`a _rQ>a {n{Z`Z VWm {J`a AmgmZr go Ky_ aho
rotating freely.
h¡&
7. Fit speedo gear, bush and oil seal. (Ensure fitment
of speedogear by rotating differential cage) 7. ñnrS>mo {J`a, ~we VWm Am`b grb {\$Q> H$ao§& ({S>\«|${e`b
Ho$O H$mo amoQo>Q> H$aHo$ ñnrS>mo {J`aH$m {\$Q>_|Q> gw{Z{üV H$a| &)
8. Fit the complete assembly on the gearbox cover
with gasket, washers and locking screws. 8. nyar Ag|ãbr {J`a ~m°Šg H$da na JmñHo$Q>, dm°ea VWm bm°qH$J
ñH«y$ Ho$ gmW {\$Q> H$a| &
ENGINE SIDE COVER – MAIN HOUSING –
GEARBOX COVER ASSEMBLY : (i.e. Gearbox
assembly complete)
B§OZ gmB©S> H$da - _oZ hmD$qgJ-{J`a ~m°Šg H$da Ag|ãbr :
(nyar {J`a ~m°Šg Ag|ãbr)
1. Fit bolt R.C. (128307014) on gear box cover. Fit
the gearbox cover sub-assembly (as described 1. ~moëQ> Ama. gr. (128307014) {J`a ~m°Šg H$da na bJmE&
earlier) on the main housing by tapping it with a {J`a ~m°Šg H$da g~ Ag|ãbr (O¡gm nhbo dU©Z {H$`m J`m h¡
plastic hammer. &) ßb°pñQ>H$ h¡_a go Yrao Yrao R>m|H$ H$a _oZ hmD$qOJ na {\$Q>
H$ao| &
2. Fasten the nuts and washers to the gearbox
cover.
2. ZQ>g² VWm dm°eg© H$mo {J`a ~m°Šg H$da _| bJmE§ &
3. Ensure smooth power transmission and the
differential action. 3. ghr nmda Q´>m§g{_eZ VWm {S>\«|${e`b EŠeZ gw{Z{üV H$a|&

ENGINE TO GEARBOX ASSEMBLY : B§OZ go {J`a ~m°Šg Ag|ãbr

1. Place the gasket on the PTO cover of engine. 1. B§OZ Ho$ nr.Q>r.Amo. H$da na JmñHo$Q> aI| &

2. Place the gearbox assembly over the four studs 2. B§OZ Ho$ nr.Q>r.Amo H$da na Mma ñQ>S>m| Ho$ D$na {J`a ~m°Šg
on the PTO cover of the engine in proper position. Ag|ãbr C{MV pñW{V _| aI|&

3. Fasten the four nuts with washers securing 3. B§OZ Ag|ãbr na dm°ea Am¡a Mma ZQ>m| H$s ghm`Vm go {J`a
gearbox assembly on to the engine assembly. ~mŠg Ag|ãbr H$mo {\$Q> H$a| & Bg ~mV H$m Ü`mZ aI| {H$
Take care that no hardware falls inside the
gearbox. {J`a ~m°Šg Ho$ A§Xa H$moB© hmS©>do`a {Ja Vmo Zht J`m h¡ &

4. Apply the specified torque. 4. {d{eð> Q>m°H©$ bJmE± &

187
SUB ASSEMBLY
BRAKE
BRAKES : ~«Šo g :
Re-assembly of Tandem Master Cylinder : (Fig. No. 110) Q¡>ÝSo>_ _mñQ>a {gqbS>a H$s [aAg|ãbr ({MÌ H«$. 110)
1. Lubricate the piston with the fresh recommended 1. ZE g§ñVwV ~«oH$ âbwBS> go {nñQ>Z H$mo {MH$ZmE§ &
brake fluid.
2. Q>r.E_.gr.H$mo gm°âQ> Om° dmBg _| Šb¢n H$a| &
2. Clamp the TMC in soft jaw vice.
3. Xygar {nñQ>Z Ag|ãbr (19) A§Xa S>mb| & Bg ~mV H$m Ü`mZ
3. Insert the secondary piston assy. (19) by taking aI| {H$ grb H$mo ZwH$gmZ Zht hþAm h¡ &
care that the seals may not get damaged.
4. goH§$S>ar {nñQ>Z Ag|ãbrH$mo Zm`bm°Z `m bH$S>r H$s S§>S>r H$s
4. Press the secondary piston assembly to its full
stroke with the help of nylon or wooden rod and ghm`Vm go CgHo$ nyao ñQ´>moH$ _o X~mE±, VWm Cgo Bg pñW{V_|
holding the same in this position, assemble the aIH$a, JmñHo$Q> (5) g{hV goH§$S>ar {nñQ>Z ñQ>m°na (4) H$mo
secondary piston stopper (4) along with gasket (5). Ag|~b H$a| &
5. Insert the primary piston assembly (18). 5. àmW{_H$ {nñQ>Z (18) Ag|ãbr H$mo A§Xa S>mb| &
6. Insert the push rod (11). 6. nwe am°S> (11) H$mo A§Xa S>mb| &
7. Insert the stop washer (10). 7. ñQ>m°n dmea (10) H$mo A§Xa S>mb| &
8. Lightly push the primary piston assembly inside 8. àmW{_H$ {nñQ>Z Ag|ãbr H$mo Yrao go ~moa Ho$ A§Xa T>Ho$bo
the bore and then insert the circlip (9). {\$a gapŠbn H$mo (9) A§Xa S>mb|&
9. Mount the boot (14). 9. ~yQ> (14) H$mo M‹T>mE± &

10 9 14
19 18 11

5 4
Fig. No. 110
Re-assembling of Tandem Master Cylinder
Assembly on the Vehicle : (Fig. No. 111)
1. Mount the TMC on TMC mounting bracket with
the fasteners.
2. Connect the front and rear brake connections to
the respective ports of the TMC. While tightening
the end connectors of brake tube, ensure that
the threading in the ports does not get damaged.
3. Hold the push rod tight and screw the fork on it.
4. Connect the brake pedal to the fork with hex
socket head cap screw and nylock nut.
191
Q¡>ÝSo>_ _mñQ>a {gqbS>a Ag|ãbr H$mo dmhZ na [aAg|ãbr H$aZm
: ({MÌ H«$. 111)
1. Q>r.E_.gr. H$mo Q>r.E_.gr. _mD§$qQ>J ~«H ¡ $o Q> H$mo H$gZr (\$mñQ>Zg©)
H$s ghm`Vm go MT>mE± &
2. AmJo Ho$ VWm {nN>bo ~«oH$ H$ZoŠeZm| H$mo Q>r.E_.gr. Ho$ g§~§{YV
nmoQ©> _| OmoS|> & ~«oH$ Q>çy~ Ho$ E§S> H$ZoŠQ>a H$mo H$gVo g_` `h
gw{Z{üV H$a| {H$ nmoQ©> Ho$ W«oqS>J H$mo ZwH$gmZ Zht nhþ±Mm h¡ &
3. nwe am°S> H$mo H$gH$a nH$S|> VWm \$moH©$ H$mo Cgna ñH«y$ H$s
ghm`Vm go bJmE±&
4. ~«oH$ noS>b H$mo \$moH©$ _| hoŠg gmHo$Q> h¡S> ñH«y$ VWm ZmBbmH$
ZQ>Ho$ gmW OmoS|>&
5. Tighten the lock nut on the push rod against the 5. bm°H$ ZQ> H$mo nweam°S> \$moH©$ Ho$ {dn[aV H$g| &
fork.
6. ~«oH$ bmB©Q> pñdM H$mo CgHo$ ñWmZna bJmE§ &
6. Mount the brake light switch at its position.

7. Follow the brake bleeding procedure before 7. dmhZ ewê$ H$aZo go nhbo ~«oH$ ãbrqS>J à{H«$`m H$m nmbZ H$a|&
starting the vehicle.
BRAKE
TMC ASSY.
PEDAL
TMC MTG. BKT.
PIVOT

BRAKE CONNECTIONS FORK BRAKE LIGHT SWITCH

A B

Fig. No. 111

Brake Bleeding Procedure : ~«oH$ ãbrqS>J à{H«$`m :

a. Connect the bleeder tube to the bleeding nipple
a. ãbrqS>J Q>çy~ H$mo ìhrb {gqbS>a _| {XE JE ãbrqS>J {Zßnb
provided on the wheel cylinder and let the other
end of the bleeder tube dip in the brake fluid in go OmoS|> VWm ãbrS>a Q>çy~ H$m A§{V_ gram H§$Qo>Za _| pñWV
the container. ~«oH$ âbwB©S> _| Sy>~Zo X| &
b. Depress the brake pedal and release it a no. of b. ~«oH$ noS>b H$mo H$B© ~ma X~mE± VWm N>moSo> &
times.

c. Depress pedal to its down-most position. Loosen c. noS>b H$mo A§{V_ pñW{VVH$ X~mE± & ãbrqS>J {Zßnb H$mo T>rbm
the bleeding nipple. Press the brake pedal as far H$a| & ~«oH$ noS>bH$mo {OVZm g§^d hmo X~mE± & ãbrqS>J {Zßnb
as it will go. Tighten the bleeding nipple and H$mo H$g X| VWm ~«oH$ noS>b H$mo N>moS> X| &
release the brake pedal.

Repeat this operation on all the three wheels till

Bg à{H«$`m H$mo VrZm| ìhrb na V~ VH$ XmohamE± O~ VH$ àUmbr go
the air is removed from the system. Keep on hdm Z {ZH$mb OmE& ãbrqS>J à{H«$`m Omar aIZo VH$ _mñQ>a {gqbS>a
topping up the master cylinder as the bleeding _o ~«oH$ âbwB©S> S>mbVo aho &
operation is carried out.

192
 SUB ASSEMBLY
STEERING
&
FRONT SUSPENSION
STEERING AND FRONT SUSPENSION :
ASSEMBLY OF SWINGING ARM TO STEERING
COLUMN :
1. Connect by hand the swinging arm to the steering
column. Before carrying out the connection fit
the two dust covers on the swinging arm as
shown in figure.(Fig. No. 100 & 101)
Fig. No. 100
Fig. No. 101
2. Place the swinging arm – steering column assy.
on the hydraulic press.
3. Grease and put the pin in its position as shown
in the figure and press it using the hydraulic press.
4. When the pin has been fitted, fit the spacer by
means of light mallet blows.
5. Fit the oil seals dipped in mineral oil, using a
proper punch by light mallet blows. Repeat the
operation on the other side also.
6. Place the needle bush and with the hydraulic
press fit the needle bush in its place. Repeat the
operation on the other side also.
7. Place the washers in their place and with a
hydraulic press fit the washers until the washers
are wedged on the swinging arm.
pñQ>`[a¨J VWm AmJo H$m gñn|eZ :
pñd§qJJ Am_© go pñQ>`[a¨J H$mb_ VH$ H$s Ag|ãbr :
1. hmW go pñd§qJJ Am_© H$mo pñQ>`[a¨J H$m°b_ go OmoS|>, O¡gm {MÌ
_| {XIm`m h¡ ({MÌ H«$. 100 -101) OmoS>Zo go nhbo pñd§qJJ
Am_© na Xmo S>ñQ> H$da {\$Q> H$a| &
2. hmBS´>mo{bH$ àog na pñd§qJJ Am_© - pñQ>`[a¨J H$m°b_ Ag|ãbr
aI|&
3. O¡gm {MÌ _| {XIm`m J`m h¡ {nZ H$mo J«rO H$aHo$ CgH$s pñW{V
_| aI| VWm hmBS´>mo{bH$ àog H$m à`moJ H$aHo$ Cgo X~mE± &
4. {nZ {\$Q> H$aZo Ho$ nümV ñnoga H$mo bmB©Q> _°boQ> ãbmoO H$s
ghm`Vm go {\$Q> H$a| &
5. Am`b grëg H$mo {_Zab Am`b _| Sw>~moH$a, `moo½` n§M VWm
bmB©Q> _°boQ> ãbmoO H$s ghm`Vmgo {\$Q> H$a| & Xygar Va\$ ^r
`ht n[aMmbZ XmohamE± &
6. ZrS>b ~we H$mo AnZr OJh na aI| VWm hmBS´>mo{bH$ àog H$s
ghm`Vm go ZrS>b ~weH$mo AnZr OJh na {\$Q> H$a| & `h
n[aMmbZ Xygar Va\$ ^r XmohamE± &
7. dm°eg© H$mo AnZr OJh na aI| VWm hmBS´>mo{bH$ àog H$s
ghm`Vm go CÝh| àog H$a| O~VH$ do pñd§qJJ Am_© na H$go Zht
OmVo &
195
8. Remove the spacer previously fitted and fill
grease in the space.
9. Displace the dust cover until they are located in
the space.
ASSEMBLY OF FRONT WHEEL HUB AND
STEERING COLUMN :
a c
Fig. No. 102
1. Fit the ball bearing “a” by means of a punch as
indicated, then fit the circilip into its seat with the
help of internal circlip plier. (Fig. No. 102)
2. Fit the draw cup (roller bearing) “c” with the use of
a punch as shown in the figure using tool no. 19-
1-35784. For each re-assembling operation use
new draw cups, by observing the following rules.
(Fig. No. 102)
a. Wash the draw cups (roller bearings) in neat
petrol to eliminate the slush.
b. After the greasing place them with stamped
mark side towards the outside.
3. Fit the oil seal on the hub with the help of a punch.
4. Fill the hub with grease between both the bearings.
5. Fit the hub on the axle by means of a tube for
pushing it, then remove the excess grease.
6. Tighten the nut on the wheel axle along with the
washer and lock it (this nut must be replaced after
each dismantling operation).
7. Spot punch the nut collar on the proper notch
existing on the wheel axle.
8. Fix the lower and upper tracks for bearing on the
frame in their seat by means of the tool no.
19-1-21330 as shown in the figure. (Fig. No. 103)
9. Put the dust cover “a” and the inner track C on
steering column pushing them in position with tool
no. 19-1-36486. (Fig. No. 103)
10. Check that the bearing tracks are fitted on the
frame so that they butt up against its seats.
196
8. nhbo àog {H$E JE ñnoga H$mo hQ>mE± VWm Imbr OJh _| J«rO
S>mb| &
9. S>ñQ> H$da H$mo V~VH$ X~mE O~ VH$ dh Imbr OJh _|
ñWm{nV Z hmo OmE &
AmJo Ho$ ìhrb Ho$ h~ VWm pñQ>`[a¨J H$m°b_ H$s Ag|ãbr
19-1-35784
1. O¡gm {XIm`m J`m h¡ ~m°b {~`[a¨J ײaÄm H$mo n§M H$s ghm`Vm go
{\$Q> H$a| & {\$a A§VJ©V gapŠbn ßbm`a H$s ghm`Vm go
gapŠbn H$mo CgH$s grQ> _| {\$Q> H$a|& ({MÌ H«$. 102)
2. {MÌ Ho $ AZw g ma Qy > b H« $ . 19-1-35784 Ho $ à`mo J
go S´>m° H$n (amoba {~`[a¨J) “c” H$mo n§M Ho$ à`moJ go {\$Q> H$a|&
àË`oH$ [aAg|ãbr n[aMmbZ Ho$ {bE Z`m S´>m° H$n (amoba
{~`[a¨J) à`moJ _| bmE±, BgHo$ {bE {ZåZ{b{IV {Z`_m| H$m
nmbZ {H$`m OmE & ({MÌ H«$. 102)
a. S´>m° H$ßg (amoba {~`[a¨J) H$mo ewÜX noQ´>mob go YmoE±
Vm{H$ JÝXJr {ZH$b OmE &
b. J«rO H$aZo Ho$ nümV CÝh| Bg Vah go aIo H$s ñQ¡>ånS²>
H$s JB© ({ZemZ) ~mOy ~mhago {XImB© Xo &
3. h~ na pñWV Am`b grb H$mo n§M H$s ghm`Vm go {\$Q> H$a| &
4. XmoZm| {~`[a¨J Ho$ ~rM h~ H$mo J«rO go ^a X|&
5. h~ H$mo EŠgb na Q>çy~ H$s ghm`Vm go {\$Q> H$a| & CgHo$
nümV A{YH$ J«rO {ZH$mb X| &
6. ìhrb EŠgb na pñWV ZQ> H$mo dmea Ho$ gmW H$g X| VWm
bm°H$ H$a| & (Bg ZQ> H$mo ha ~ma ImobZo Ho$ nümV ~Xbm OmE)
7. ìhrb EŠgb na pñWV C{MV Zm°M na ZQ> H$m°ba H$mo ñnm°Q>
n§M H$a| &
8. O¡gm {MÌ _| {XIm`m J`m h¡ ({MÌ H«$. 103) Qy>b H«$. 19-1-
21330 H$s ghm`Vm go {~`[a¨J Ho$ D$na Ho$ VWm {ZMbo Q´¡>Šg
H$mo CZHo$ grQ>Ho$ \«o$_ na {\$Q> H$a| &
9. Qy>b H«$. 19-1-36486 H$s ghm`Vm go S>ñQ> H$da “a” VWm
A§VJ©V Q´¡>H$ >“b H$mo pñQ>`[a¨J H$m°b_ na C{MV pñW{V_| aI|&
({MÌ H«$. 103)
10. Om§M H$a| {H$ {~`[a¨J Q¡«>Šg \«o$_ na {\$Q> h¡ Vm{H$ do AnZo grQ>
Ho$ D$na R>rH$ go ~¡R> JE h¡ &
 19-1-36486
19-1-21330

b
a

Fig. No. 103

11. Check that the no. of balls corresponds to the
prescribed no. The balls should be applied on
bearing track by means of a grease coat.
12. Fit the steering assembly in the head tube and fit
the upper track of the upper bearing and the locking
ring.
13. By raising the steering column assembly, screw
by hand the ring nut “a” of the upper bearing until
it contacts the balls; then with the tool no. 19-1-
36084 screw the ring nut until the steering column
rotates freely. (Fig. No. 104)
11. Om§M H$a| {H$ ~m°bm|H$s g§»`m {Z{X©ï> g§»`m Ho$ AZwê$n h¡&
{~`[a¨J Q´>¡H$$na J«rO H$moQ> H$s ghm`Vm go Ôam} (coat) bJmE§&
12. pñQ>`[a¨J Ag|ãbr H$mo hoS> Q>çy~ _| {\$Q> H$a| VWm Cnar {~`[a¨J
Ho$ D$nar Q´>¡H$ VWm bmqH$J [a¨J H$mo {\$Q> H$a|&
13. pñQ>n[a¨J H$mb_ Ag|ãbr H$mo Cna CR>mH$a D$nar {~`[a¨J Ho$
[a¨J ZQ> “a” H$mo hmW go Kw_mH$a H$g| O~ VH$ dh ~m°ëg H$mo
Zht Ny>Vm & {\$a Qy>b H«$. 19-1-36084 H$s ghm`Vm go [a¨J
ZQ> H$mo V~ VH$ Kw_mE± O~ VH$ pñQ>`[a¨J H$m°b_ AmgmZrgo
Ky_Zo Z bJo & ({MÌ H«$. 104)

19-1-36084

Fig. No. 104

14. Fit the dust cover. 14. S>ñQ> H$da H$mo {\$Q> H$a| &
15. Fit the handlebar assembly and tighten the bolt 15. h¢S>b~ma Ag|ãbr H$mo {\$Q> H$a| VWm ñbrd na pñWV ~moëQ> H$mo
located on the sleeve.
H$g X| &
16. Connect all cables and wires to their concerned
positions. 16. g^r Ho$~b VWm dm`a CZHo$ Cn`wº$ ñWmZm|_| OmoS> X| &

197
RE-ASSEMBLY OF REAR SUSPENSION :
{nN>bo gñn|eZ H$s [aAg|ãbr
1. Place the rear hub on a base.
1. {nN>bo h~ H$mo ~og na aI|&
2. By using tool no.19-1-35781, punch fit the draw
cup (roller bearing) “a” as shown in figure (Fig. 2. Qy>b H«$. 19-1-35781 n§M Ho$ à`moJ go S´>m° H$n (amoba
No. 105). {~`[a¨J) “a” H$mo {MÌ Ho$ AZwgma {\$Q> H$a| &({MÌ H«$.
3. Fit the oil seal “b” using tool no. 19-1-35783 (Fig. 105)
No. 105). 3. Qy>b H«$. 19-1-35783 Ho$ à`moJ go Am`b grb H$mo {\$Q> H$a|&
19-1-35781 ({MÌ H«$. 105)

19-1-35783

a b

Fig. No. 105

4. Place the hub in the inverted position on a base.
5. Fit the ball bearing “a” using tool no. 19-1-21071 4. h~ H$mo ~og na nbQ>H$a pñW{V_| aI|&
(Fig. No. 106). 5. Qy>b H«$. 19-1-21071 Ho$ à`moJ go ~m°b {~`[a¨J “a” H$mo {\$Q>
H$a| & ({MÌ H«$. 106)

b
a c

Fig. No. 106

6. With the use of internal circlip plier fit the circlip
into its seat on the hub.
7. Using a proper punch fit the oil seal in the hub.
8. Insert the spacer “a” and protection cap “b” in the
bracket. Insert the circlip in the hub. Secure the
hub “c” to the bracket rear suspension by means
of four bolts, positioning the brake back plate “d”
in between hub and bracket. (Fig. No. 107).
6. Am§V[aH$ gapŠbn ßbm`a H$s ghm`Vm go gapŠbn H$mo h~ H$s
grQ> _| {~R>mE &
7. C{MV n§M Ho$ à`moJ go Am`b grb H$mo h~ _| {~R>mE &
8. ñnoga “a” VWm àmoQo>ŠeZ H¡$n “b”> ~«¡Ho$Q> _| S>mb| & gapŠbn
H$mo h~ _| S>mb| & h~ “c” H$mo Mma ~moëQ> H$s ghm`Vm go h~
VWm ~«°Ho$Q> Ho$ ~rM ~«oH$ ßboQ> “d” H$s pñW{V _| ~«¢Ho$Q> {nN>bo
g§ñn|eZ _| ñWm{nV H$a| & ({MÌ H«$. 107)

198
 d

c
a b

Fig. No. 107

9. Fill the grease in between both the bearings and 9.
fit the wheel axle by using a wooden hammer.
10. Fit the wheel axle shaft hub on the axle. 10.
11. Fit the washer and tighten the nut on the axle. 11.
12. Lock the nut by spot punching carefully by means 12.
of a steel punch as shown in the figure. (Fig. No. 108)
XmoZm| {~`[a¨J Ho$ ~rM J«rO S>mb| VWm ìhrb EŠgb H$mo bH$S>r
Ho$ h¡_a go {\$Q> H$a| &
EŠgbna ìhrb EŠgb emâQ> h~ H$mo {\$Q> H$a| &
dm°ea H$mo {\$Q> H$a| VWm ZQ> H$mo EŠgb na H$g| &
{MÌ Ho$ AZwgma ñQ>rb n§M H$s ghm`Vm go ZQ> H$mo Ü`mZ go
ñnm°Q> n§qMJ H$aHo$ bm°H$ H$a| & ({MÌ H«$. 108)

b
a

F
R.1.7 R.1
Fig. No. 108
13. Fit the elastic coupling on the wheel hub by three 13. VrZ ~moëQ> ìXmam ìhrb h~ na BbmpñQ>H$ H$nqbJ {\$Q> H$a| &
bolts.
14. VrZ ~moëQ> H$s ghm`Vm go EŠgb gmBS> h~ H$mo BbmpñQ>H$
14. Fit the axle side hub on the elastic coupling by H$nqbJ na {\$Q> H$ao§&
three bolts.

199
15. Introduce a wedge “a” into the notch of the hub 15. h~ EŠgb emâQ> gmB©S> Ho$ Zm°M _| doO “a” BÝQ´>moS>çyg H$a| &
axle shaft side. (Fig. No. 109)
({MÌ H«$. 109)
b
c

Fig. No. 109

16. Fit the axle shaft with pin and slider blocks into 16. EŠgb emâQ> H$mo {nZ VWm ñbmBS>a ãbm°Šg Ho$ gmW gZ
the sun gear.
{J`a _| {\$Q> H$a| &
17. Tighten the cover oil seal hood to the differential. 17. H$da Am`b grb hÿS> H$mo {S>\«|${e`b Ho$ gmW H$g X| &
18. Locate the axle shaft, with the notch for hub union 18. EŠgb emâQ> H$mo AmT>r pñW{V_| h~ `y{Z`Z ~moëQ> Ho$ Zm°M Ho$
bolt in horizontal position and turn towards gmW nH$S|> VWm ZrMo H$s Amoa Kw_mE± &
bottom.
19. h~ H$mo EŠgb emâQ> E§S> _| {\$Q> H$a| &
19. Fit the hub into the axle shaft end.
20. B§OZ hmoëS>a ~«¡Ho$Q> _| Xmo {nZH$m à`moJ H$aHo$ nyar `y{ZQ> H$mo
20. Fit the total unit provisionally by using two pins AñWm`r én_| {\$Q> H$a| &
in the engine holder bracket.
21. {nZm| H$mo g§~§{YV ~moëQ> ìXmam ~Xb X| & VWm ZQ> H$mo bm°H$
21. Replace the pins with concerning bolts and lock
the nut.
H$a| &
22. Om§M H$a| {H$ EŠgb emâQ> VWm h~ H$m OmoS> C{MV h¡ &
22. Check if the connection of the axle shaft and
hub is proper, adjust with some plastic hammer Amdí`H$ hmo Vmo {H$gr ßb¡pñQ>H$ h¡_a go R>moH$ H$a g_§{OV
strokes, if required. H$a| &
23. Release the wedge introduced earlier in the collar 23. Bggo nhbo H$mba Šb¢n _| bJm`m J`m doO {ZH$mbo & ~moëQ>
clamp. Fix the bolt “c” and lock with connecting “c” {\$Šg H$a| VWm g§~§{YV ZQ> go bmH$ H$a| &
nut.
24. {nN>bo em°H$ A°ãOm°d©a H$m {ZMbm ~moëQ> {\$ago bJmE§ &
24. Refit the bottom bolt of the rear shock-absorber.
25. ~«oH$ nmB©n H$ZoŠeZ {\$a go bJmE§ &
25. Refit the brake pipe connections.

200
Windshield Glass Replacement
Replacement of Windshield Glass : qdS>erëS> ½bmg H$mo ~XbZm
1. Put pressure from inner side of the cabin by hand 1. ½bmg Ho$ D$nar {H$Zmam| H$mo Ho${~Z Ho$ A§Xa H$s Va\$ go hmW
on the upper corners of the glass.
go X~mE± &
2. The packing will come out and consequentially
will release the glass. 2. n¡qH$J {ZH$b AmEJm Am¡a gmW gmW ½bmg ^r {ZH$boJm &

3. Carefully clean the rim with petrol. 3. {H$Zmam| H$mo noQ´>mob H$s ghm`Vm go gm\$ H$a| &
4. Fit a new rubber packing around the glass border 4. ½bmg Ho$ {H$Zmam| na Z`m a~a n¡qH$J {\$Q> H$a| VWm {MÌ Ho$
and insert a strong pack – thread into the packing AZwgma n¡qH$J aog _| _O~yV n¡H$ W«oS> S>mb| & ({MÌ H«$. 112)
race as shown in the figure. (Fig. No. 112)

Fig. No. 112

5. To avoid water leakages spread some sealent 5. nmZr Ho$ [agmd go ~MZo Ho$ {bE Ho$~rZ _| ½bmg Ho$ {H$Zmam|na
along the border of the glass seating on the cabin. grb|Q> bJmE± &
6. Then fit the glass (with packing and packing 6. CgHo$ ~mX ½bmg H$mo CgH$s grqQ>J _| {\$Q> H$a| & (n¡qH$J VWm
thread) in its seating and adjust by hand. n¡qH$J W«oS> H$s ghm`Vm go) Am¡a hmW go g_§{OV H$a| &

203
7. By acting from the inner of the cabin pull the pack
thread end for allowing the packing to overcome
the rim, also use a screw driver. (Fig. No. 113)
7. n¡qH$J H$mo {H$Zmam| go D$na CR>mZo Ho$ {bE Ho${~Z Ho$ A§Xa go
n¡H$ W«oS> E§S> H$mo ItMo & ñH«y$ S´>mBda H$m BñVo_mb H$a| &
({MÌ H«$. 113)

Fig. No. 113

Use the same procedure for fitting rear and side {nN>bo VWm ~mOw Ho$ ½bmg H$mo {~R>mZo Ho$ {bE `hr à{H«$`m
glasses.
XmohamE± &

204
PAINTING INSTRUCTIONS
PAINTING INSTRUCTIONS : n|qQ>J AZwXoe (a§J H$aZo Ho$ AZwXoe) :
For obtaining perfect results in retouching paint Q>qMJ n|Q> dH©$ Ho$ AÀNo> n[aUm_ nmZo Ho$ {bE {ZåZ{b{IV n[aMmbZ
work, the following operations should be carried
out : H$mo AnZmE± &

a. Major retouch-up: where the exposed metal is a. _w»` [aQ>M-An : Ohm± Iwbo YmVw _| O§J bJm hmo `m {\$ë_ n|Q>
rusted or the film paint is not sufficiently adherent. R>rH$ Vah go Z {MnH$m hmo &
1. Thoroughly rub down the effected zone until 1. à^m{dV joÌ H$mo nyar Vah go {Kg| O~VH$ A§Xa H$m YmVw nyar
the underlying metal surface gets completely
Vah go ~mha Z Am OmE & Bgo gwImE± VWm gm\$ gwWao a¡J go
exposed. Carefully dry and dust using clean
rags. gm\$ H$ao§ &
2. Spray the rust preventive and dry. 2. O§J {àd|{Q>d H$mo ñào H$a| VWm gwImE± &
3. Apply filler (putty) and dry. 3. {\$ba H$mo bJmE± (putty) VWm gwImE± &
4. Rub down with emery paper ( grade 320 or 4. E_ar nona go {Kgo & (320 J«oS> `m Am¡a AÀN>m)
finer).
5. gVh na ñào H$a| VWm gwImE± & D$nar H$moQ> na ñào H$a| VWm
5. Spray on the surface and dry. Spray on the
top coat and allow to air dry.
hdm _| gyIZo X| &

b. Minor re-touches (where the application of a rust
preventive is unnecessary).
1. Rub down the effected zone to completely
expose the underlying metal surface.
Carefully dry and dust using clean rags.
2. If necessary, apply filler (putty), dry and rub
down with emery paper (grade 320 or finer).
b. N>moQo> N>moQo> [aQ>Mog² : (Ohm± na O§J {àd|{Q>ìh H$m bJmZm Oéar
Zht h¡)
1. à^m{dV joÌ H$mo A§Xa H$s YmVw {XImB© XoZo VH$ {Kg| & Ü`mZ
go gwImE± VWm gm\$ gwWao a¡J H$m à`moJ H$a gm\$ H$a|&
2. Amdí`H$ hmo Vmo {\$ba (putty) bJmE±& gwImE± VWm E_ar
nona go M_H$mE± (320 J«oS> VH$ `m A{YH$ AÀN>m)&

3. Spray on top coat and dry. 3. D$nar H$moQ> na ñào H$a| VWm gwImE±&

207
 FUEL SYSTEM
BLEEDING PROCEDURE
FUEL SYSTEM BLEEDING PROCEDURE
Fuel supply to the engine is gravity feed.
However when a dry tank is filled with petrol, the air in
the system flows out through the bleeder passage
provided in the carburattor.
B§YZ ì`dñWm ãbrqS>J à{H«$`m
B§OZ H$mo B§YZ JwéËdmH$f©U go {_bVm h¡Ÿ&
Imbr Q>§H$s _| noQ´>mob ^aZo Ho$ ~mX, B§YZ àUmbr _| pñWV hdm H$m~w©aoQ>a
_| {XE hþE ãbrS>a n¡goO go ~mha OmZo {XOrE&

3
1. Fuel Tank
1. â`wEb Q>¢H$
2. Fuel Filter 2. â`wEb {\$ëQ>a
3. Fuel Pipe 3. â`wEb nmB©n
4. Carburettor 4. H$m~wa© Qo >a
5. Venting Pipe 5. ìhopÝQ>¨J nmB©n
Engine
2

4 5

FUEL SYSTEM BLEEDING PROCEDURE (Refer B§YZ ì`dñWm ãbrqS>J à{H«$`m (XoIo {MÌ-10)
Fig. 10)
In petrol mode, the petrol is fed by the electric feed noQ´>mob pñWVr _|, BbopŠQ´>H$ \$sS> n§n go noQ´>mob {X`m OmVm h¡Ÿ&
pump.
grEZ²Or/EbnrOr J¡g àoea ao½`wboQ>a go OmVm h¡ Am¡a {_Šga Ag¢ãbr
CNG/LPG gas passes through the pressure regulator
Ho$ Ûmam B§OZ H$mo {X`m OmVm h¡Ÿ&
and supplied to the engine through mixer assembly.
However when a dry tank is filled with petrol, crank Imbr Q>§H$s _| noQ´>mob ^aZo Ho$ ~mX, B§YZ àUmbr _| pñWV hdm H$m~w©aoQ>a
the engine to allow the air in the system to flow out _| {XE hþE ãbrS>a n¡goO go ~mha OmZo Ho$ {bE B§OZ H$mo ewê$ H$a|Ÿ&
through the bleeder passage provided in the
carburattor.

1
4
1. Fuel Tank 1. â`wEb Q>¢H$
2. Fuel Filter 2. â`wEb {\$ëQ>a
3. Elec. Feed Pump 3. BboŠQ´>rH$ \$sS> n§n
4. Three Way 4. W«r do H$ZoŠQ>a (Y)
(Y) Connector
5. H$m~wa© Qo >a
5. Carburettor
Engine 2 6. ìhopÝQ>¨J nmB©n
6. Venting Pipe 3
6
5

211

Fig. 10
CARBURETTOR
CIRCUITS
CARBURETTOR :
● In Variable depression carburettor
● The throttle valve is present in the venturi zone
which is controlled by the rider
● The throttle opening causes the change in venturi
area
● The change in venturi area causes a change in
the air flow and the vacuum (depression at the
venturi zone and fuel delivery point).
● Depending on the quantity of air, the construction
of the carburettor ensures that varying quantities
of fuel are delivered so that the air fuel ratio is
maintained to the required level at various operating
conditions.

SPECIFICATION :
Venturi size: 22mm Starter Jet (GS1 & GS2)
(Oval Shape) : #17.5 & Ø0.7mm
Main Jet : # 87.5 Starter Air Passage (ØA
&ØB)- 4 & 2.5mm
Pilot Jet : # 15 Fuel level- 31.4±0.5 mm
Main Air Jet : Ø0.8 Maximum Air Flow Rate:
28.882 g/sec
Needle Jet : O-4
(Marking)
Jet Needle :
T-UFSC6882
Groove Position
:Middle (2nd from top)
Piston valve Stroke
: 24.9mm

Variable depression carburettor consists of

● In Variable depression carburettor
● Float System
● Piston Valve / Throttle Valve which is located at
the venturi / fuel delivery zone
● Pilot System
● Main System
● Starter system

215
Float system :
● Starter system
● The float system operates continuously,
maintaining fuel level through out the engine
operation.
● Fuel from the fuel tank enters float chamber through
needle valve.
● The fuel level raises, float also raises moving the
Needle valve up.
● Float is designed such a way, that when the fuel
reaches the correct level, Needle valve closes the
fuel passage.
● As the fuel is consumed by the Engine and fuel
level drops, floats open the needle valve and allows
fuel to come in, till the correct level is reached
again.
● Fuel in the float chamber is always at Atmospheric
pressure by Air vent.

Pilot System :
● The Engine is cranked, air is drawn through the
pilot air passage and flows to Pilot jet emulsion
tube.
● Air screw provided in the passage is used to adjust
the proper amount of air flow.
● The suction created in the manifold, draws out fuel
from the pilot jet. The air from the Air screw
passage mixes with fuel then atomising is occur.
● The fully atomised Air fuel mixture, that flows from
the pilot jet to inlet manifold.
● The Engine idling speed is controlled by Idling
Adjuster & Air screw.

216
Main System :
● The piston valve opens, air flow creates suction
to draw fuel from Main jet.
● Air metered through the Main air jet mixes with
fuel in the Emulsion tube (Jet holder),atomising
the fuel.
● The mixture further mixup with air from main
bore,enters the Engine in optimum A/F mixture.

Starter System :
● It is used to start the Engine during cold condition.
● Due to low temperature, the fuel is not atomised
completely and condensed in the manifold. During
this condition, rich fuel mixture is delivered to
Engine.

Air fuel mixture requirement at steady state :

● Idling and Low speed
● Rich mixture is required to achieve proper
combustion and also to overcome inertia
● Medium speed or Cruise
● Lean mixture is preferred to utilize all the fuel
particle and there by achieving better fuel efficiency
● High speed
● Rich mixture is needed to utilize all the air particle
and there by achieving maximum power.

217
Air fuel mixture requirement at transients :
● Cold starting
● During cold start, the engine parts are not hot
enough to vaporize the droplets of fuel and ignite
the air fuel mixture.
● This difficulty requires a richer mixture than the
normal.
● Warm up
● During warm-up a rich mixture is required, but the
degree of richness is gradually reduced as the
engine temperature rises.
● Acceleration
● During acceleration the throttle valve is suddenly
opened & hence manifold pressure is increased.
● Momentary leanness happens because of
difference in inertia of liquid fuel and air & decrease
in evaporation due to higher manifold pressure.
● This difficulty requires a richer mixture than the
normal.

218
VALVE TIMING DIAGRAM (Fig. No. 4)

valve timing diagram all versions

i.e. Petrol, CNG and LPG

219
1. Electrical Wiring Diagram Petrol

220
Electrical System for Petrol noQ´>mob Ho$ {bE {dÚwVr` ì`dñWm
1. Battery (12 V - 35 Ah) 1. ~¡Q>ar (12 V - 35 Ah)
2. Cabin Light Lamp (12 V - 5 W) 2. Ho${~Z H$s bmB©Q> (12 V - 5 W)
3. Engine Compartment Light (12 V - 5 W) 3. B§OZ H§$nmQ©>_|Q> H$s bmB©Q> (12 V - 5 W)
4. Front Turn Signal Light (12 V - 21W) 4. _wS>Zo Ho$ {g½Zb H$s AmJo H$s bmB©Q> (12 V - 21W)
5. Front Position Light (12 V - 5 W) 5. AmJo H$s bmB©Q> H$s pñWVr (12 V - 5 W)
6. Main Battery Fuse (30A) 6. _w»` ~¡Q>ar â`wO (30A)
7. Fuse Box with 6 Fuses of 10 Amps 7. â`wO ~mŠg N> â`wO Ho$ gmW (10 Epån`a)
8. Fly Wheel Mounted Alternator 8. âbmB© ìhrb _mD§$Qo>S> AmëQ>aZoQ>a
9. Flasher Relay 9. âb¡ea [abo
10. Fuel Level Gauge on tank 10. â`wEb bodb JoO - Q¢>H$
11. Instrument Cluster 11. BÝñQ¯>_|Q> ŠbñQ>a
12. Horn 12. hm°Z©
13. Head Light High / Low Beam (12V - 35/35 W) 13. hoS>bmB©Q >~r_ (hm`/bmo) (12V - 35/35 W)
14. Ignition Switch 14. Bp½Z{e`Z pñdM
15. Light Switch (3 Position) 15. bmB©Q> pñdM - (3 pñW{V`m±)
16. Handle Bar Switch (High & Low beam / Horn / 16. h|S>b ~ma pñdM (VoO Am¡a Yr_r bmBQ>, hm°Z©, Q>Z© B§{S>Ho$Q>a
Turn Indicator & Start) Am¡a ñQ>mQ>©)
17. Oil Pressure Switch (On engine) 17. Am`b àoea pñdM (B§OZ Ho$ Cna)
18. Rear Turn Signal Light (12 V - 21W) 18. _w‹S>Zo Ho$ {g½Zb H$s {nN>br bmB©Q (12 V - 21W)
19. Registration No. Plate Light (12 V-5W) 19. a{OñQ´o>eZ Z§~a ßboQ> bmB©Q> (12 V-5W)
20. Reverse Light (12 V-21W) 20. [adg© bmB©Q> (12 V-21W)
21. Reverse Gear Switch 21. [adg© {JAa pñdM
22. Brake Switch 22. ~«oH$ pñdM
23. Parking / Stop Lamp (12 V - 5W/21W) 23. nm{Hª$J /ñQ>m°n bmB©Q> (12 V-5W/21W)
24. Starter Motor (12V) 24. ñQ>mQ©>a _moQ>a (12V)
25. Voltage Regulator 25. dmoëQo>O {Z`§ÌH$
26. Windshield Wiper Motor 26. qdS>{eëS> dmBna _moQ>a
27. Windshield Wiper Switch (2 Position) 27. qdS>{eëS> dmBna pñdM (2 pñW{V`m±)
28. Tell Tale (High Beam Indicator Light) 28. Qo>b Qo>b (VoO {H$aU {ZX}eH$ bmB©Q>)
29. Tell Tale (Turn Signal Indicator L/R Light) 29. Qo>b Qo>b (XmB© Am¡a ~mB© Amoa _w‹S>Zo Ho$ {ZX}eH$ H$s bmB©Q>)
30. Tell Tale (Battery Charging Indicator Lamp) 30. Qo>b Qo>b (~¡Q>ar Mm{OªJ B§S>rHo$Q>a bmB©Q>)
31. Tell Tale (Oil Pressure Indicator Lamp) 31. Qo>b Qo>b (Am`b àoea {ZX}eH$ bmB©Q>)
32. 4ST Starter Relay 32. 4ST ñQ>mQ>©a [abo
33. Safety Starter Relay 33. goâQ>r ñQ>mQ>©a [abo
34. Hazard Warning Switch 34. hOmS>© dm{ZªJ pñdM
35. Fuel Level Indicator 35. â`yAb bodb B§{S>Ho$Q>a
36. Ignition Coil 36. B{¾eZ H$m°B©b
37. Spark Plug 37. ñnmH©$ ßbJ
38. Mobile Charger 38. _mo~mB©b MmO©a
39. Clutch Switch 39. ŠbM pñdM
40. CDI Unit 40. gr.S>r.AmB©. `w{ZQ>

221
c. Electrical Wiring Diagram CNG

222
Electrical System for CNG grEZ²OrHo$ {bE {dÚwVr` ì`dñWm
1 Battery (12 V - 35Ah) 1 ~¡Q>ar (12 V - 35Ah)
2 Cabin Light (12 V - 5 W) 2 Ho${~Z H$s bmB©Q (12 V - 5 W)
3 Engine Compartment Light (12 V - 5 W) 3 B§OZ H§$nmQ©>_|Q> H$s bmB©Q (12 V - 5 W)
4 Front Turn Signal Light (12 V - 21W) 4 _wS>Zo Ho$ {g½Zb H$s AmJo H$s bmB©Q> (12 V - 21W)
5 Front Position Light (12 V - 5 W) 5 AmJo H$s bmB©Q> (12 V - 5 W)
6 Main Battery Fuse (30A) 6 _w»` ~¡Q>ar â`wO - 30 Epån`a
7 Fuse Box with 6 Fuses of 10 Amps
7 â`wO ~mŠg N> â`wO Ho$ gmW (10 Epån`a)
8 Fly Wheel Mounted Alternator
8 âbmB© ìhrb _mD§$Qo>S> AmëQ>aZoQ>a
9 Flasher Relay
9 âb¡ea [abo
10 Starter Safety Relay
10 ñQ>mQ>©a goâQ>r [abo
11 Instrument Cluster
11 BÝñQy>_|Q> ŠbñQ>a
12 Horn
12 hm°Z©
13 Head Light High / Low Beam (12 V- 35 / 35 W)
14 Ignition Switch 13 hoS>bmB©Q >~r_ (hm`/bmo) (12V - 35/35 W)
15 Light Switch (3 Position) 14 Bp½Z{e`Z pñdM
16 Handle Bar Switch (High & Low Beam/Horn / Turn 15 bmB©Q> pñdM - (3 pñW{V`m±)
Indicator & Start) 16 h¢Sb ~ma pñdM - (VoO Am¡a Yr_r bmBQ>, hm°Z©, _wS>Zo Ho$ {g¾b
17 Oil Pressure Switch (On Engine) Am¡a ñQ>mQ>©)
18 Rear Turn Signal Light (12 V - 21W) 17 Am`b àoea pñdM (B§OZ Ho$ Cna)
19 Registration No. Plate Light (12 V-5W) 18 _w‹S>Zo Ho$ {g½Zb H$s {nN>br bmB©Q> (12V - 21 W>)
20 Reverse Light (12 V -21W) 19 a{OñQ´o>eZ Z§~a ßboQ> bmB©Q> (12V - 5 W)
21 Reverse Gear Switch 20 [adg© bmB©Q> (12V - 21 W)
22 Brake Switch 21 [adg© {JAa pñdM
23 Parking / Stop Lamp (12 V - 5W/21W) 22 ~«oH$ pñdM
24 Starter Motor (12V) 23 nm{Hª$J /ñQ>m°n b¡ån (12V-5W/21W)
25 Voltage Regulator 24 ñQ>mQ©>a _moQ>a (12V)
26 Windshield Wiper Motor 25 dmoëQo>O {Z`§ÌH$
27 Windshield Wiper Switch (2 Position) 26 qdS>{eëS> dmBna _moQ>a
28 Tell Tale (High Beam Indicator Light) 27 qdS>{eëS> dmBna pñdM (2 pñW{V`m§)
29 Tell Tale (Turn Signal Indicator L/R Light) 28 Qo>b - Qo>b (VoO {H$aU {ZX}eH$ bmB©Q>)
30 Tell Tale (Battery Charging Indicator Lamp) 29 Qo>b - Qo>b (XmB© Am¡a ~mB© Amoa _w‹S>Zo Ho$ {ZX}eH$ H$s bmB©Q>)
31 Tell Tale (Oil Pressure Indicator Lamp) 30 Qo>b - Qo>b (~¡Q>ar Mm{OªJ B§S>rHo$Q>a bmB©Q)
32 4ST Starter Relay 31 Qo>b - Qo>b (Am`b àoea {ZX}eH$ bmB©Q>)
33 Relay Start Safety 32 4ST ñQ>mQ>©a [abo
34 Hazard Warning Switch 33 gonQ>r [abo (ñQ>mQ>©a)
35 Dust Plug Micro Switch (Near Gas Filling Point) 34 hOmS>© dm{ZªJ pñdM
36 Ignition Coil (On Engine)
35 S>ñQ> ßbJ _m`H«$mo pñdM (J°g {\$btJ nm°BªQ> Ho$ nmg)
37 Spark Plug (On Engine)
36 B{¾eZ H$m°B©b (B§OZ Ho$ D$na)
38 Relay Run Safety
37 ñnmH©$ ßbJ (B§OZ Ho$ D$na)
39 Electronic Control Unit
38 goâQ>r ñQ>mQ>©a [abo
40 CNG Pressure Indicator
39 BboŠQ´>m°{ZH$ H§$Q´>mob `w{ZQ>
41 CNG Pressure Gauge
42 Petrol Feed Pump Motor / Solenoid 40 grEZ²Or àoea `w{ZQ>
43 Gas Solenoid Valve on Regulator 41 grEZOr àoea JoO
44 CDI Unit 42 noQ´>mob {\$S> n§n _moQ>a / gmoboZm°B©S>
45 Clutch Switch 43 ao½`wboQ>a na pñWV J¡g gmobmoZm°B©S> ìhmëd
44 grS>rAmB© `w{ZQ>
45 ŠbM pñdM

223
c. Electrical Wiring Diagram LPG

224
Electrical System for LPG EbnrOr Ho$ {bE {dÚwVr` ì`dñWm
1 Battery (12V-35AH) 1 ~¡Q>ar (12 V - 35Ah)
2 Cabin Light (12V-5W) 2 Ho${~Z H$s bmB©Q (12 V - 5 W)
3 Engine Compartment Lamp (12V-5W) 3 B§OZ H§$nmQ©>_|Q> H$s bmB©Q (12 V - 5 W)
4 Turn Indicator Lamp (12V-21W) 4 _wS>Zo Ho$ {g½Zb H$s AmJo H$s bmB©Q> (12 V - 21W)
5 Position Lamp (12V-5W) 5 AmJo H$s bmB©Q> H$s pñWVr (12 V - 5 W)
6 Main Battery Fuse (30A) 6 _w»` ~¡Q>ar â`wO - (30 Epån`a)
7 Fuse Box with 6 Fuses (10A) 7 â`wO ~mŠg N> â`wO Ho$ gmW (10 Epån`a)
8 Flywheel Mounted Alternator 8 âbmB© ìhrb _mD§$Qo>S> AmëQ>aZoQ>a
9 Flasher Relay 9 âb¡ea [abo
10 Gas Solenoid on Multifunction Valve 10 J°g gmoboZm°B©S> Am°Z _ëQ>r\$ŠeZ dmëd
11 Instrument Cluster 11 BÝñQy>_|Q> ŠbñQ>a
12 Horn 12 hm°Z©
13 Head Lamp High/Low Beam (12V-35-35W) 13 hoS>bmB©Q >~r_ (hm`/bmo) (12V - 35/35 W)
14 Ignition Switch 14 Bp½ZeZ pñdM
15 Light Switch (3 Position) 15 bmB©Q> pñdM - (3 pñW{V`m±)
16 Handle Bar Switch (High & Low beam / Horn / 16 h¢Sb ~ma pñdM - (VoO Am¡a Yr_r bmBQ>, hm°Z©, _wS>Zo Ho$ {g¾b
Turn Indicator & Start) Am¡a ñQ>mQ>©)
17 Oil Pressure Switch (On Engine) 17 Am`b àoea pñdM (B§OZ Ho$ Cna)
18 Rear Turn Signal Light (12V-21W) 18 _w‹S>Zo Ho$ {g½Zb H$s {nN>br bmB©Q> (12V - 21 W>)
19 Registration No. Plate Light (12V-5W) 19 a{OñQ´o>eZ Z§~a ßboQ> bmB©Q> (12V - 5 W)
20 Reverse Lamp (12V-21W) 20 [adg© bmB©Q> (12V - 21 W)
21 Reverse Gear Switch 21 [adg© {JAa pñdM
22 Brake Switch 22 ~«oH$ pñdM
23 Parking/Stop Lamp (12V-5W/21W) 23 nm{Hª$J / ñQ>m°n bmB©Q> (12V-5W/21W)
24 Starter Motor (12V) 24 ñQ>mQ©>a _moQ>a (12V)
25 Voltage Regulator 25 dmoëQo>O {Z`§ÌH$
26 Windshield Wiper Motor 26 qdS>>{eëS> dmBna _moQ>a
27 Windshield Wiper Switch (2 Position) 27 qdS>{eëS> dmBna pñdM (2 pñW{V`m±)
28 Tell Tale (High Beam Indicator Light) 28 Qo>b - Qo>b (VoO {H$aU {ZX}eH$ bmB©Q>)
29 Tell Tale (Turn Signal Indicator L/R Light) 29 Qo>b - Qo>b (XmB© Am¡a ~mB© Amoa _w‹S>Zo Ho$ {ZX}eH$ H$s bmB©Q>)
30 Tell Tale (Battery Charging Indicator Lamp) 30 Qo>b - Qo>b (~¡Q>ar Mm{OªJ B§S>rHo$Q>a bmB©Q)
31 Tell Tale (Oil Pressure Indicator Lamp) 31 Qo>b - Qo>b (Am`b àoea {ZX}eH$ bmB©Q>)
32 4ST Starter Relay 32 4ST ñQ>mQ>©a [abo
33 Starter Safety Relay 33 ñQ>mQ>©a gonQ>r [abo
34 Hazard Warning Switch 34 hOmS>© dm{ZªJ pñdM
35 Petrol Feed Pump Motor / Solenoid 35 noQ´>mob {\$S> n§n _moQ>a / gmoboZm°B©S>
36 Ignition Coil (On Engine) 36 B{¾eZ H$m°B©b (B§OZ Ho$ D$na)
37 Spark Plug (On Engine) 37 ñnmH©$ ßbJ (B§OZ Ho$ D$na)
38 Gas Solenoid Valve on Regulator 38 ao½`wboQ>a na pñWV J¡g gmobmoZm°B©S> ìhmëd
39 Electronic Control Unit 39 BboŠQ´>m°{ZH$ H§$Q´>mob `w{ZQ>
40 Clutch Switch 40 ŠbM pñdM
41 CDI Unit 41 grS>rAmB© `w{ZQ>

225
ELECTRICALS : {dÚwVr` :
a. SETTING THE HEADLAMPS a. hoS> b¢n H$mo goQ> H$aZm

A = Distance between headlamp centers - B = C x A = hoS> bmB©Q> H|$Ð {~ÝXwAm| H$s Xyar, B = C x 0.9
0.9
C = Height from the ground of headlamp center C = hoS> bmB©Q> H|$Ð {~ÝXwAm| H$s g_Vb go D±$MmB© (AZw_mZV : 832
(Approximately 832 mm) mm )

B = C x 0.95 when setting of the headlamp is being B = C x 0.95 hoS> bmB©Q> H$s goQ>tJ H$aVo g_` dmhZ nX}go 5 _rQ>a H$s
carried out, the vehicle should be at 5 mtrs. from
the screen.
Xyar na aI|Ÿ&
SETTING THE HEAD LAMPS ho S > b¢ n H$mo go Q > H$aZm
Place the unloaded vehicle on a level floor at about
Imbr dmhZ H$mo g_Vb O_rZna Yw§Ybo g\o$X nX} (ñH«$sZ) go 10 _rQ>a
10 mts. from a twilight white screen (See Fig. 32) and
take care that the vehicle axis is perpendicular to the Xyar na IS>m H$a| (XoIo {MÌ 32) Bg ~mV H$m Ü`mZ aIo {H$ dmhZ H$m
screen. Aj nX}go 900 H$m H$moZ ~ZmVm h¡&
Please ensure that correct tyre pressure is maintained H¥$n`m gw{Z{üV H$a| {H$ Jm‹S>r Ho$ g^r n{h`m| _o hdm H$m X~md ghr h¡ &
in all the wheels.
Draw on the screen two vertical lines “a-a” at a distance nX}na (a-a) Xmo IS>r aoImE± IrM| {OZHo$ ~rM H$s Xyar “A” hmoZr Mm{hE&
“A”, corresponding to the headlamp distance between A~ EH$ Am‹S>r aoIm (b-b) ItM| {OgH$s D§$MmB© g_Vb go 0.9 x C hmo&
centerlines. XoI| {H$ bmo ~r_ H$s {ZMbr gVh {S>_mH}$eZ aoIm Omo Jm‹To> Am¡a hbHo$
Draw a horizontal line “b-b” whose height from the ^mJ Ho$ ~rM _o h¡, dh (b-b) aoIm go D$na Zhr hmoZr Mm{hE & CgHo$ ~mX
ground corresponds to 0.9 x C, with the head lamps hmB© ~r_ H$mo AmZ H$a| VWm OmM| H$s àË`oH$ hoS>bmB©Q> H$s _Ü` {H$aU
switched ON in the low beam position, the horizontal
line of demarkation between the dark zone and lighted
IμS>r aoIm (a-a) Ho$ AZwê$n `m WmμoS>r gr ~mha h¡&
one should not be above the horizontal “b-b” line. Then
switch on the high beam and check that the depth
beam center of each headlamp is on the corresponding
vertical “a-a” or slightly outside.
Note : On both head lamps two setting screws gyMZm : XmoZm| hoS> b¢n na Xmo goqQ>J ñH«y$ {~R>mE hmoVo h¡, {Oggo
are fitted, that allow the correction of the {H$aU H$m AngaU (BpÝŠbZoeZ) H$mo D$na VWm ZrMo bJo ñH«y$ go
inclination (upper screw) or of the R>rH$ H$a gH$Vo h¡& `h hoS> b¢n Ho$ AJbo {hñgo _| hmoVo h¡ &Am¡a hoS>
divergence (lower screw) of the luminous
beam. The mentioned screws are located b¢n hmoëS>a àmoQo>ŠeZ H$mo hQ>mZo go AmgmZr go XoIo Om gH$Vo h¡ &
in the front part of the headlamp and are (XoIo {MÌ 33>)
easily accessible by removing the
headlamp holder protection. (Refer Fig. 33)

226
ELECTRICAL
CIRCUIT
DIAGRAMS
CNG BATTERY CHARGING SYSTEM

229
CNG STARTER CIRCUIT

230
CNG - IGNITION SYSTEM / GAS KIT : CIRCUIT DIAGRAM

231
GAS SYSTEM (CNG)
WITH KIT
ABOUT CNG
CNG contains methane (CH4) and small amount of
ethane (C2H6) and other hydrocarbons. The
technology for the use of CNG as an alternate energy
sources has got wide acceptance and the contribution
of CNG in reducing the pollution is well known.
Besides , an attractive saving in running cost has
favored the increasing demand for the CNG Vehicles.
Also the use of CNG enhances the conservation of
valuable energy sources and reducing the
environmental pollution.”

DESCRIPTION OF CNG SYSTEM

CNG system is an alternate fuel technology adapted
to petrol vehicles without alterting the basic engine.
In case of 3 wheelers CNG cylinder is located below
the driver seat. This cylinder is rated for a maximum
filling pressure of 200 bar. This cylinder connection
goes through the filling unit, two stage pressure
regulator (200 bars 7 ~ 8 bars - 1 bar) and a manual
flow adjuster to a gas-air mixer fitted between air
cleaner unit and carburettor. CNG Cylinder consist of
a cylinder valve, which has safety features like in-
built excess temperature & pressure relief device &
a Manual shut off valve. A pressure gauge is fitted
on junction block, which senses the gas pressure in
the cylinder and sends the signal to the indicator fitted
on the dashboard, which indicates the quantity by
means of glowing LEDs. In CNG Mode operation,
power supply to the petrol solenoid valve get cut, thus
prevents the flow of petrol to the carburettor. The CNG
solenoid valve is energized and delivers the gas to
Two stage regulator. The regulator reduces the gas
pressure to the atmospheric level in Two stages. (200
bars - 7~8 bars atm pressure)The gas air mixer draws
gas proportional to the engine requirement & feeds
the engine through vehicle air intake system. The
vehicle can be re-fueled through the refueling unit at
the filling station.

235
APE CITY CNG VEHICLE LAYOUT

1 FIRST STAGE REDUCTION UNIT (HPR) 8 SCREW FOR CLIP

ALONG WITH FILTER VALVE 9 WASHER FOR CLAMP
2 FLEXIBLE HOSE ASSLY (HPR-SOL VALVE) 10 HOSE LOW PRESSURE CNG
3 ASSLY CNG REGULATOR 11 MIXER ASSEMBLY
4 HOSE SOLENOID TO LPR 12 CNG PRESSURE GUAGE WITH SENSOR
5 FILTER SOLENOID VALVE WITH BRACKET 13 STICKER
6 CLIP 14 KIT WIRING HARNESS
7 CLAMP FOR FLEXIBLE HOSE 15 ECU WITH LED INDICATOR

236
APE CITY CNG FLOW DIAGRAM

1 FIRST STAGE REDUCTION UNIT (HPR) 6 HOSE LOW PRESSURE CNG

ALONG WITH FILTER VALVE
7 CLIP
2 FLEXIBLE HOSE ASSLY (HPR-FILTER
SOL.VALVE) 8 CNG PRESSURE GAUGE WITH SENSOR

3 ASSEMBLY CNG REGULATOR 9 RESTRICTOR-1 FOR CNG/LPG

10 RESTRICTOR-2 FOR CNG
4 HOSE SOLENOID TO LPP
11 STICKER
5 FILTER SOL. VALVE WITH BRACKET

237
 CNG WORKING SYSTEM (FLOW CHART)

CNG cylinder with cylinder valve


First stage reduction unit (H.P.R)
(Directly fitted on CNG cylinder valve)


Filter solenoid valve
(Through flexible hose)


Two stage CNG regulator (L.P.R)
(Through flexible hose)


Mixer assembly
(Through Low Pressure hose)


Combustion Chamber

Description Of CNG System

The Natural gas from CNG cylinder is supplied through
CNG cylinder valve. CNG valve has safety features
like inbuilt bust disc back-up with fusible plug.
? Normally cylinder valve is in open condition. During
servicing of kit components it is required to close this
valve.

Fig.
Fusible alloy back-up with bust disc

238
Fig.
First stage reduction unit (H.P.R) directly fitted on CNG
cylinder valve reduces 200 bar CNG pressure up to 7-
8 bar and hence there is no high pressure line in CNG
system. This innovative idea introduced by Vanaz.
Whenever the gas is coming downstream from the
First stage reduction unit (HPR) it is automatically
get filtered. A pressure gauge with pressure sensing
device is fitted on first stage reduction unit, which
senses the quantity of gas in the cylinder and sends
the signal to the ECU with level indicator fitted on the
dashboard.
The CNG refuelling unit is a part of HPR. A micro
switch and dust plug is fitted on the first stage reduc-
tion unit for safety purpose. Also safety relief valve is
provided on HPR for safety purpose. Always ensure
that the dust plug is in the position before starting the
vehicle.
First stage reduction unit (HPR) reduce cylinder pres-
sure of200 bar. up to 7-8 bar. HPR and Gas solenoid
valve connected to each other through Flexible hose.
HPR has also non-return valve. Main function of the
Non-Return valve is to restrict return flow of the gas
through filler valve.

Pressure
Gauge

Micro
Switch
Filler
valve

Fig.

239
The CNG solenoid valve is energized and delivers
the gas to 2 stage regulator (LPR) Operating voltage
:- 8 to 12 V.
Drain oil by opening Filter Drain plug after every 20,000
km running of vehicle.
Replace CNG Paper filter @ every 30,000 km or After
1 year. Replace all ‘O’ rings @ every 30,000 km.

Fig.

Fig.
Description Of CNG System
Gas solenoid valve & 2 stage pressure regulator (LPR)
connected to each other through Flexible hose. The
main function of 2 stage pressure regulator is to re-
duce CNG pressure up to atmospheric level in two
stages.
Two stage pressure regulator reduces 0.38 bar.( Gauge
pressure) Pressure in Primary stage and in second-
ary stage it reduces pressure up to Atmospheric level
i.e. 0 bar. ( Gauge pressure).
Idling and flow adjustment screw provided on 2 stage
pressure regulator (LPR)

240
Fig.

Fig.
MIXER ASSEMBLY

Fig.

241
ELECTRONIC CONTROL UNIT

Fig.
It is electrically (12 Volt) operated, which controls
gas & petrol supply. It has Three positions.
‘-’ means Gas mode.
‘O’ Neutral .
‘=’ means Petrol mode.
It has level indicator to show gas available in the CNG
cylinder.
This ECU is having feature of prime time, which acts
as a choke in case of CNG. For ECU 5 A fuse is
used.

242
243
CNG SOLENOID VALVE SERVICING
i) Draining of oil
- Close CNG Cylinder Valve.
- Remove drain plug, which is at the bottom
of Gas Solenoid Valve with size spanner 16.
- Drain the oil.
- Re-assemble the drain plug.
After servicing, check joints for leakage by using
neutral soap solution.
iii) Cleaning of Filter
- Close CNG Cylinder Valve.
- Remove the bowl.
- Remove Filter
- Check its condition. Clean with air. If
necessary replace.
- Re-assemble with same procedure.
After servicing, check joints for leakage by using
neutral soap solution.

Filter

244
FIRST STAGE REDUCTION UNIT SERVICING (HPR)
i) Filter cleaning
- Close CNG Cylinder Valve
- Open the Retainer (Part no.33) with 6 mm Allen
key and remove Filter (Part no. 25)
- Check the Filter for clogging
- Clean with petrol and then with pressurized air
- Replace Retainer `O’ Rings (Part nos.13,
34,30)
- Re-assemble with same procedure
- Replace Filter as per maintenance schedule.
After servicing, check joints for leakage by using neu-
tral soap solution.
ii) Servicing of Unit
- Close CNG Cylinder Valve & remove the First
Stage Reduction Unit having left hand thread.
- Remove cylinder (Part no.19) by using 21 size
spanner
- Remove Spring (Part no.16) and Piston assebly
(Part no. 15) with nose plyer
- Inspect the cross holes with pressurized air
- Replace Bull nose connector `O’ Rings (Part no
.13) , `O’ Rings on Piston (Part. No. 18), Dust
plug `O’ Ring (Part. No. 2)
- Re-assemble the unit following the same proce
dure.
After servicing, check joints for leakage by using neu-
tral soap solution.
iii) Replacement of NRV (Non Return Valve)
- Close CNG Cylinder Valve & remove the First
Stage Reduction Unit having left hand thread.
- Remove Refuelling Adaptor (Part. No. 1).
- Remove sub-assembly seat (Part no. 7) and
Spring (Part no. 8).
- Replace sub-assembly seat.
- Re-assemble with same procedure.
After servicing, check joints for leakage by using neu-
tral soap solution.
iv) Replacement of Microswitch
- Close CNG Cylinder Valve & remove the First
Stage Reduction Unit having left hand thread.
- Remove Screw (Part no. 27).
- Remove Microswitch (Part no. 28).
- Re-assemble with same procedure.
Note:
1. Keep the removed parts in clean area.
2. Don’t damage or misplace the bolts, Spring wash-
ers & Nuts
3. Avoid duplicates. Use genuine spares only
4. Do not plug the SRV.
5. Ensure that after every re-fuelling duct plug is prop-
erly fitted into the refuelling adaptor.

245
TECHNICAL ADVANCEMENT OF CNG KIT FOR PAX
200 COMPARE TO APE CITY & APE 501

1) In case of APE City or APE 501, Three Stage CNG

Regulator is used and which is mounted at rear of the
vehicle in engine compartment. As such CNG at 200
bar is transferred from CNG cylinder up to the inlet of
the Three Stage Regulator by using rigid Steel Tubes.
However in case of APE PAX 200, a First Stage Regu-
lator is directly mounted on CNG Cylinder Valve and
it reduces 200 bar CNG pressure inside the CNG cyl-
inder to low pressure. As such system became low
pressure and to transfer the low pressure CNG up to
the 2-stage CNG Regulator, Flexible Hoses are used.

2) Due to the low-pressure system, it became very

safe and there are less hazards to the human being in
case of any leakage.

3) As low pressure hoses are used, it is easy to in-

stall / service the CNG system.

246
GAS SYSTEM (LPG)
WITH KIT
ABOUT LPG :
‘‘Liquefied Petroleum Gas is stored in a cylinder in
liquid state at room temperature under its own vapour
pressure. The max. vapour pressure at 60?c will be
20 bar. It contains 30 – 50 % propane and the balance
is largely butane with small quantities of ethane,
ethylene, pentane.”

DESCRIPTION OF LPG SYSTEM

LPG system is an alternate fuel technology adapted
to petrol vehicles without altering the basic engine.
”In case of 3 wheelers LPG cylinder is located below
the driver seat. The cylinder is rated for a max. filling
pressure of 10 bar. This cylinder connection goes
through the filter, 2 stage LPG regulator (20 bars-10
bars-1 bar)and a manual flow adjuster to a gas-air mixer
fitted between air cleaner and carburetor.”LPG cylinder
consists of a Multifunction Valve, which has safety
features like 80% fill limiter, excess flow valve, safety
relief valve, fusible plug, container gauge, solenoid
valve, etc.”In LPG mode operation, power supply to
the petrol solenoid valve get cut, thus prevents the
flow of petrol to the carburetor. The Solenoid valve on
multifunction valve is energized and delivers the gas
through paper type filter to Two stage LPG regulator.
The regulator reduces the gas pressure to the
atmospheric level in Two stages. The gas air mixer
draws gas proportional to the engine requirements and
feeds the engine through vehicle air intake system.
The vehicle can be refueled through the filler unit at
the refueling station.”

249
INSTALLATION OF INSTRUMENTS AND Ho${~Z _| gmYZm| VWm {Z`§ÌH$mo (B§ñQ®>_|Q> A±S> H§$Q´>mob)
CONTROLS IN THE CABIN (Fig.1) H$s pñWVrŸ&
1. Clutch Lever 1. ŠbM brda
2. Gear Change Twist Grip 2. {J`a M|O pìQ>>ñQ> {J«n
3. Instrument Cluster 3. BÝñQ¯>_|Q> ŠbñQ>a
4. Accelerator Twist Grip
4. EpŠgboQ>a pìQ>>ñQ>> {J«n
5. R. C. Lever
5. Ama. gr. brda
6. Hand Brake Control Lever
7. Choke Lever 6. h¢S> ~«oH$ {Z`§ÌU brda
8. Brake Pedal 7. MmoH$ brda
9. Wiper Switch 8. ~«oH$ noS>b
10. Light Switch 9. ìhm`na pñdM
11. Hazard Warning Switch 10. bmB©Q> pñdM
12. Head Lamp, Side Indicator, Horn Switch 11. hPmS>© dm°{ZªJ pñdM
13. Electronic Control Unit (ECU) 12. hoS> b°ån, gmB©S> B§{S>Ho$Q>a, hm°Z© pñdM
14. Ignition Switch 13. BboŠQ´>m°{ZH$ H§$Q´>mob `wZrQ> (B.gr.`w.)
15. CNG Cylinder 14. B{¾eZ pñdM
16. Pressure guage
17. Refueling
18. LPG Cylinder
19. Multifunction valve
20. Manual shut off valve CNG Cylinder
21. Battery cut off switch
22. Pressure regulator

11 10 9
2 1

18

17
19
12
14 13
4
5
7

20

8
21

16

15 22

Fig.4

250
APE PAX 200 LPG VEHICLE LAYOUT

1 Allen screw 13 Seal box

2 Multi function valve 14 Housing assly. for filler connector
3 Copper tube assly - MFV to filter 15 Filter solenoid valve with bkt.
4 Filler connector 16 Copper tube assly. for refuelling
5 Clip 17 Screw for clip
6 LPG hose regulator to mixer 18 Washer for screw clamp
7 Assembly LPG regulator 19 Spring washer M6
8 Vent hose assembly-1 20 Hex head screw M6x16
9 Vent hose assembly-2 21 Mixer assly.
10 Clamp for copper tube 22 Electronic control unit
11 Copper tube assly-filter to regulator 23 Wire harness
12 Sticker

251
APE CITY LPG FLOW DIAGRAM

1 FILLER CONNECTOR WITH CAP 11 HOSE REGULATOR TO MIXER

2 COPPER TUBE ASSY FOR REFUELLING 12 CLIP
3 VENT HOSE ASSEMBLY-1 13 CLAMP FOR COPPER TUBE
4 MULTI FUNCTION VALVE 14 STICKER
5 ALLEN SCREW 15 HOUSING ASSEMBLY FOR FILLER
CONNECTOR
6 SEAL BOX
16 VENT HOSE ASSEMBLY -2
7 COPPER TUBE ASSY -MFV TO FILTER
17 RESTRICTOR - 1 FOR CNG/LPG
8 FILTER SOLENOID VALVE WITH BRACKET
18 RESTRICTOR - 2 FOR LPG
9 COPPER TUBE ASSY-FILTER TO LPR
10 ASSEMBLY LPG REGULATOR

252
Description of LPG Kit component:
Auto LPG Tank :
LPG tank are made with high quality steel usually in
three pieces joined by submerged Arc welding. These
tanks are manufactured to operate at the rate of 10
Kg/cm2 and hydraulic pressure tested up to 45 bar.
Tanks are constructed in different lengths & diam-
eters to select according to the space available in the
vehicle. The liters capacity varies with the dimensions
of the tank. It is mandatory to fill only 80 % of the
total capacity for safety reasons. Over filling beyond
80% limit can result dangerous conditions. The tank
must be installed rigidly inside the vehicle.
The tank is provided with standard multi function valve
is fitted & maintained. It is possible to refill and ex-
tract of LPG from the tank. For the Multi function valve
to function correctly, it is necessary for the diameter
and the inclination of the tank to correspond to those
of Multi function valve.
It is responsibility of the installer to check the first
refilling, that the Multi function valve works perfectly,
in particular concerning the correct functioning of the
80% fill limiter.
The tanks are tested and approved by the CHIEF
Controller of Explosives, Nagpur.
Note : A test certificate is valid for 5 years for each
tank from the date of manufacturing.
Tank Specification:
Diameter – 200 mm
Total capacity – 18.13 liters.
80% filling – 14.5 liters.
Multi function valve (MFV):
MFV is a component of LPG fuel system that is in-
stalled in the tank and incorporates devices for filling
and extracting fuel. It also incorporates many safety
features. MFV are constructed in ‘0’ degree to ‘90’
degree with respect to the vertical plane and in vari-
ous sizes. In three wheeler the MFV extracts the
vapour gas from LPG tank.
This is the component, has the following safety fea-
tures. These features help in maintaining the safety
function of the LPG system.
80 % filling limit
Excess flow control valve
Thermal fuse
Lever indicator
Remote control shut off valve ( Solenoid valve on the
MFV outlet).
MFV specification :
Size – Diameter – 200 mm
Fitment – 30 degree from vertical plane.
253
Vapour box & Ventilation hose :
This encloses the MFV & the piping inside the ve-
hicle compartments. In case of leakage of MFV or
from the pipeline, the leaked gas will be gone to the
atmosphere outside the vehicle compartment through
the enclosed ventilation hose.
This vapour box is provided with two openings on the
body. This is used for connecting the ventilation hose,
which effectively encloses the copper tube & also
takes out the leaked gas if any from Cylinder or MFV.
LPG Copper tube :
This connects auto LPG tank to filler valve as well as
the pressure – reducer.
Specification :
Filler valve to Multi function valve – ID=6 mm, OD =
8mm.
Multi function valve outlet to pressure reducer – ID=
4mm & OD = 6mm.
Re-filling Valve :
This valve is used for refilling auto LPG tank. It has a
non return valve to avoid revering of fuel during filling.
Electronic control unit :
This is a three way switch. One can select 100%
petrol or 100% LPG operation (LPG) or ‘0” position,
which cuts off both petrol & LPG to enable Fuel switch
operation. This switch also shows indication when the
gas level comes to reverse level by means of LED.
There is a push button in the switch for choke, which
can be used to used to prime the gas for easy stabil-
ity of the vehicle.
LPG system wiring harness is routed from ECU to
the LPG kit compartments. TO protect the switch and
other electrical units from accidental excess current
and subsequent damage, an on line fuse has to be
used. Standard automotive blade type 5 amps should
be used. Higher rated fuse can cause damage to the
ECU switch.
Operating procedure – ECU :
1) For LPG operation, the Switch should be kept in
‘LPG’ mode.
2) Crank the Engine.
3) After starting the vehicle, accelerate the engine
progressively.
4) To Switch over from LPG to Petrol, change the
switch position directly to ‘Petrol” position.
5) To Switch over from Petrol to LPG operation, bring
the vehicle to halt. Set the ECU in ‘0’ position.
Allow the Engine to return till it jerks. Now change
the switch to position ‘LPG”. The Engine will start
to run on LPG.
6) If the switch over from ‘Petrol” to LPG is made
without going through “0” position, the Engine may
back fire & stop.
7) Frequent change over between “Petrol” to “LPG”
will lead to wastage of Petrol / LPG.
8) All electrical accessories like Battery, Ignition Coil
and Spark plug must be maintained in good work
ing condition.
Gas filling in Auto LPG Tank:
Tank must be filled only to a maximum of 80% of
their capacity. This 80% limit makes the tank safer in
case of temperature / pressure rises beyond its limit.
Over filling beyond 80% limit can result in dangerous
conditions. Tank is fitted with MFV, filling by blocking
the flow when effective capacity is reached. LPG can
be recharged only from authorized auto LPG dispens-
ing stations approved by Government of India.
When the vehicle is refueled with the LPG, always
ensure that the dust cover is put back on the filler
valve. Gas filling from external tanks or from exter-
nal source is not recommended as this would result
in non functioning of MFV 80% cut off.
Servicing of field components :
A) 2’ Stage Regulator :
First stage –
1) Open the reducer I- stage cover bolts ( 4 Nos.)
by proper “8” mm spanner.
2) Remove the diaphragm and spring from the seat.
3) Inspect the seat and diaphragm for its condition.
4) After inspection, re – assemble the unit with the
same procedure.
5) During opening of first stage cover, make sure
that proper clamping has been done since the
dia phragm is spring loaded.
6) Don’t use sharp ended tools for opening dia
phragm.
7) Clean the diaphragm with dust free cloth.
8) Do not repair the punctured / damaged diaphragm
9) While opening the 1st stage seat , use proper star
screw driver. Do not damage the screws.
10) During overhauling, keep the 1st stage seat pin
safely and do not replace any other cotter pin in
place of the original.
11) Always replace the 1st stage seat while overhaul
ing.
12) Do not fix the 1st stage seat with any adhesive.
Second stage –
1) Open the reducer II stage cover bolts ( 4 Nos.)
by proper ”8” mm spanner.
2) Press the vacuum diaphragm fully, and slowly
remove the II stage diaphragm from seat.
254
3) Loosen & remove the idling knob and remove the
spring from lever seat.
4) Remove the II stage lever by loosening the two
star screws.
5) Remove the vacuum diaphragm and spring from
its position.
6) Inspect the seat and diaphragm condition and re
place if necessary.
7) After inspection, re assembles the unit with the
same procedure.
8) During overhauling, check the straightness of the
II stage lever. In case of any deformation, try and
correct to the precise straightness.
9) If there is any damage on the adjuster spring seat
, replace the II stage lever.
10) While replacing the II stage seat make sure the
seat is properly inserted / press fitted.
11) Do not use any adhesive to fix the seat, which
may spoil the seat.
12) Always replace the new seat during overhauling.
Multi Function valve servicing :
1) Make sure no LPG is present during removal of
MFV from the tank.
2) Loosen & remove the pipe line connection to the
MFV.
3) Remove the gas level inductive pick up from the
socket.
4) Remove the ventilation hose from the vapour box.
5) Loosen and remove the mounting align screw
from the MFV.
6) Remove the MFV with vapour box & bottom “O”
ring from the tank.
7) Check the float function ( For its free movement)
8) Check the suction tube filter for any blocks or
damage.
9) Check the MFV rubber seal for its condition.
10) Check the Inlet valve spring for proper seating.
11) Make sure the correct function of Manual cock.
12) Replace “O” ring , seal and other serviceable com
ponents if in need.
13) Assemble the MFV as per the above procedure.
Make sure the inclination of the MFV is the same
as tank size & its mounting angle.
LPG WORKING SYSTEM (FLOW CHART)

Filler Valve

Inlet of multifunction valve (Through Copper Tube)

LPG Cylinder

Outlet of multifunction valve (Through Copper Tube)

Filter solenoid valve (Through Copper Tube)

Two Stage Regulator (LPR) (Through Low Pressure Hose)

Mixer Assembly

Combustion Chamber

255
Fig.
In case of PIAGGIO 3 wheelers Auto LPG Tank is
located below drivers seat.
Auto LPG Tank consists of a Multifunction Valve,
which has safety features like 80% fill limiter, excess
flow valve, safety relief valve, fusible plug, content
gauge, solenoid valve, etc. In LPG mode operation,
power supply to the petrol Solenoid Valve get cut and
prevents the flow of petrol to the carburettor. The So-
lenoid valve on multifunction valve is energized and
delivers the gas to Two stage LPG regulator.
The regulator reduces the gas pressure to the atmo-
spheric pressure in two stages. The gas air mixer
draws gas proportional to the engine requirements and
feeds the engine through vehicle air intake system.
The vehicle can be refuelled through the filler unit at
the refuelling station.
LPG CONTAINER

Fig.
It is specially developed for Automobile.

256
Approved by Petroleum and Explosives Safety
Organisation (Formerly - Department of Explosive),
Nagpur & certified by Bureau of Indian Standards (BIS).
MULTIFUNCTION VALVE
Following are the safety features of the Multifunc-
tion valve :
1) 80% Fill limiter : LPG can not fill more than 80%
of total capacity of Auto LPG tank
2) Excess Flow Valve : When copper tube ruptured
due to accident, flow rate of LPG will increase. In
that case excess flow valve will operate and re-
strict the LPG flow.
3) Pressure relief valve (PRV) : When LPG pressure
inside the Auto LPG tank increase above 2.2MPa,
PRV will release LPG to atmosphere.
4) Fusible Plug : When temperature of Auto LPG tank
reaches 120±10°C, fusible alloy will melt and LPG
inside Auto LPG tank will release to atmosphere.
5) Solenoid Valve : This will automatically cut off the
LPG flow once the ECU cuts the supply.
6) Content Gauge : This will show level of LPG in-
side the Auto LPG tank.
7) Manual service valve : This is provided to close
LPG flow manually for kit servicing.

Fig.

Fig.

257
Fig.
COPPER TUBE ASSEMBLY FOR RE-FUELLING

Fig.
COPPER TUBE ASSEMBLY

Fig.
Description Of Vanaz LPG System :
The LPG solenoid valve is energized and delivers
the gas to two stage regulator.
Operating voltage :- 8 to 12 V.
Drain oil by opening Filter Drain plug and clean
LPG Filter after every 5,000 km running of vehicle.
Replace LPG Paper filter @ every 15,000 km or
After 1 year. Replace all ‘O’ rings @ every 15,000
km.

258
Fig.

Fig.
The main function of 2 stage pressure regulator is to
reduce LPG pressure up to atmospheric level in two
stages.
2 stage pressure regulator reduces 0.25 bar.( Gauge
pressure) Pressure in Primary stage and in second-
ary stage it reduces pressure up to Atmospheric level
i.e. 0 bar. ( Gauge pressure). Idling and flow adjust-
ment screw provided on two stage pressure regulator.

Fig.

259
Fig.
MIXER ASSEMBLY

Fig.
ELECTRONIC CONTROL UNIT

Fig.
It is electrically (12 Volt) operated, which controls gas
& petrol supply. It has Three positions.
‘-’ means Gas mode.
‘O’ Neutral .
‘=’ means Petrol mode.
It has level indicator to show gas available in the LPG
cylinder.
This ECU is having feature of prime time, which acts
as a choke in case of CNG. For ECU 5 A fuse is
used.

260
NOTE : In case of dedicated (single mode) vehicles
Selector Switch is removed.
WIRE HARNESS

261
DO’S & DON’T’S
Shut OFF the manual service valve provided on the
Multifunction Valve when the vehicle is not in use for
longer period.
In case of leakage immediately turn `OFF’ the manual
service valve provided on the Multifunction Valve. Take
the vehicle to a safer place. Check for leakage with
neutral soap solution and make joint leak proof. If
leakage does not stop, then contact nearest
authorised service station.
When the vehicle is taken for body repair (welding
etc.), the Auto LPG tank should be emptied and re-
moved from vehicle.
Park away the vehicle from open fire & spark prone
areas.
Use only CCOE approved and BIS certified Auto LPG
tanks.
Use only correct rated fuse for LPG system.
Use genuine spares
Switch OFF the mobile phone(s) while refilling.
Always visit the authorised service station for repairs
/ servicing.
Don’t check leakage with a naked flame.
Don’t open the regulator or any LPG component on
your own.
Never tune or repair kit components by unauthorised
and untrained staff.
Don’t smoke inside the vehicle and also while refill-
ing.
Don’t keep any flammable items near the LPG sys-
tem.
Test Auto LPG tank for strength in every five years.
Do the tank
Do not switch over to LPG mode while the vehicle is
running in petrol mode.
Don’t try to fill Auto LPG tank beyond 80% of tank
capacity.
Test Auto LPG tank for strength in every five years.
Do the tank re-testing at the government approved
agencies only.
Always work in good ventilated workshop area.

262
 MIXER ASSEMBLY SERVICING
Unscrew the mixer clamp and remove mixer
Clean the mixer venturi holes and nozzle with pres-
surized air and then with duct free cloth.

263
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