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FUEL, LUBRICATION AND EXHAUST SYSTEM
COVER FUEL TANK - REMOVAL (DUAL
DISC VERSION)
l Loosen and remove CRR pan head screw M6x12
moun ed a nner s de o cover ue ank F g 4 1
l Loosen and remove CRR pan head screw M6x12
moun ed a bo om o cover ue ank F g 4 2
l D s oca e cover ue ank ugs rom he cush on by
s gh y push ng cover ue ank owards ron and
pu ou cover ue ank
l Loosen and remove CRR anged pan head ap
screw 4 3x13 - 2nos rom he cover ue ank
nner F g 4 3A
l Loosen and remove CRR anged pan head ap
screw 4 3x13 - 2nos moun ed a nner s de o
cover ue ank F g 4 3B
l Separa e cover ue ank nner
l Carry ou s m ar procedure o separa e ano her
s de cover ue ank
REMOVAL
l Reassemb e componen s n he reverse order o
remova
Note:
Wh e reassemb ng of cover fue tank, make
sure the presence of cush on cover fue tank
(A) (2 nos) and reta ner c p (B) (2 nos) at fue
tank comp ete. (F g. 4.4)
Worn or damaged cush ons shou d be
rep aced w th new one
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4
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Fg 4 2
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F g 4 3A F g 4 3B
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Fg 4 4
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Fue , ubr cat on and exhaust system 4-1

FUEL, LUBRICATION AND EXHAUST SYSTEM
FUEL TANK COMPLETE AND FUEL
COCK ASSEMBLY
l The ue ank comp e e s oca ed on rame ube
near he s eer ng p vo w h a ockab e cap
assemb y ue ank A and manua y opera ed ue
cock assemb y a he bo om e s de o he ank B
Fg 4 5
l The cap assemb y ue ank can be opened w h
he gn on key
l A ue sender un s moun ed a he bo om s de o
he ue ank F g 4 6
Ma n - 16 res
Tank capac y
Reserve - 2 5 res
l C ean ue ank comp e e per od ca y nspec
ank or any eakage any eakage s no ced
rep ace he ue ank w h a new one
REMOVAL
l Re er chap er “per od c ma n enance“ page no
2-11 or remova procedure o he ank comp e e
ue rom veh c e
Note:
Before remov ng fue tank comp ete, dra n
the benz ne comp ete y.
l Remove hexagona screws M6x20 - 2 nos a ong
w h punched washers and gaske s rom he ue
cock assemb y moun ng and ake ou he ue
cock assemb y a ong w h O r ng ue cock o n
Fg 4 7
10 mm spanner
Note:
Wh e reassemb ng the fue cock assemb y,
ensure that ‘O’ r ng and gasket are f tted.
l Remove CRR anged pan head screws
M4x12 - 4 nos rom he ue sender un
moun ng and ake ou he ue sender un a ong
w h he gaske F g 4 8
Ph ps head screw dr ver
Fue , ubr cat on and exhaust system 4-2
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Fg 4 8
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FUEL, LUBRICATION AND EXHAUST SYSTEM
CLEAN NG
l C ean ue ank comp e e horough y w h a
su ab e c ean ng so ven
Note:
Before reassemb ng fue tank comp ete,
the so vent used for c ean ng shou d be
c eaned and dr ed.
Caut on:
Wh e remov ng and c ean ng the fue tank
comp ete, care shou d be taken not to
damage the pa nted surface.
FUEL COCK ASSEMBLY
l F er A s xed o he ue cock assemb y and
nser ed o he ue ank comp e e ha ac a es
he ma n and reserve eve F g 4 9
l Genera y wa er and o her mpur es ge co ec ed
n benz ne The er he ps n er ng he ne
mpur es n benz ne be ore hey en er he ue
cock assemb y C ean he er per od ca y
V sua y nspec he er rep ace w h a new
ncase o s ound damage
l The ue cock assemb y s a so prov ded w h a cup
ue s ra ner B and a er The cup ue s ra ner
co ec s he mpur es and here ore mus be
per od ca y checked and c eaned F g 4 9
10 mm spanner
Note:
Rep ace ‘O’ r ng w th a new one wh e
reassemb ng. (F g. 4.10)
l Use compressed a r o c ean any obs ruc on n he
passage o he ue cock assemb y
l F na y reassemb e componen s n he reverse
order o d sman ng
HOSE FUEL
l V sua y nspec he hose ue or crack or eakage
a s moun ng po n any crack or eakage
no ced rep ace hose ue w h a new one
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Fg 4 9
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O R NG
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F g 4 10
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Fue , ubr cat on and exhaust system 4-3
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FUEL, LUBRICATION AND EXHAUST SYSTEM .....................................................................................................................................................................................................
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CARBURETTOR ASSEMBLY .....................................................................................................................................................................................................
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REMOVAL FROM THE VEH CLE .....................................................................................................................................................................................................
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l The ma n enance o he carbure or assemb y .....................................................................................................................................................................................................
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requ res c ean ng per od ca y n order o avo d .....................................................................................................................................................................................................
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b ockage o e s passages and se ng d e CO% .....................................................................................................................................................................................................
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recommended by he manu ac urer .....................................................................................................................................................................................................
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l To remove carbure or o ow he o ow ng .....................................................................................................................................................................................................
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procedure: .....................................................................................................................................................................................................
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l Loosen and remove M6x16 - 1 no CRR pan F g 4 11
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head screw rom cover rame L moun ng .....................................................................................................................................................................................................
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F g 4 11 .....................................................................................................................................................................................................
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Ph ps head screw dr ver .....................................................................................................................................................................................................
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l Take ou cover rame L by care u y d s oca ng .....................................................................................................................................................................................................
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rom he ugs .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Before remov ng the carburettor assemb y .....................................................................................................................................................................................................
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turn the knob fue cock to ‘OFF’ pos t on and .....................................................................................................................................................................................................
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d sconnect the hose fue from the carburettor. .....................................................................................................................................................................................................
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(F g. 4.12) .....................................................................................................................................................................................................
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F g 4 12
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l Loosen and remove CRR pan head screws .....................................................................................................................................................................................................
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M6x16 - 2 nos a ong w h he punched washers .....................................................................................................................................................................................................
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rom a r c eaner assemb y moun ng F g 4 13 .....................................................................................................................................................................................................
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F g 4 13
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l Loosen CRR pan head screw o c amp ou e p pe .....................................................................................................................................................................................................
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and d s oca e ou e p pe rom he carbure or .....................................................................................................................................................................................................
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F g 4 14 .....................................................................................................................................................................................................
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F g 4 14
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Fue , ubr cat on and exhaust system 4-4

FUEL, LUBRICATION AND EXHAUST SYSTEM
l Loosen and remove hro e cab e assemb y
ad us er and d sconnec cab e rom he
carbure or assemb y F g 4 15
10 mm spanner
l Loosen and remove gu de ho der assemb y and
ake ou cab e assemb y choke a ong w h he
p unger s ar er spr ng s ar er O r ng s ar er and
cap s ar er F g 4 16
12 mm spanner
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F g 4 15
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4
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F g 4 16
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l Loosen CRR pan head screw o he c amp n ake .....................................................................................................................................................................................................
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p pe and gen y pu ou carbure or assemb y rom .....................................................................................................................................................................................................
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he p pe n ake F g 4 17 .....................................................................................................................................................................................................
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F g 4 17
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D SASSEMBLY .....................................................................................................................................................................................................
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l Remove hose a r ven A and hose dra n B .....................................................................................................................................................................................................
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F g 4 18 .....................................................................................................................................................................................................
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Nose p er .....................................................................................................................................................................................................
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A
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B
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F g 4 18
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Fue , ubr cat on and exhaust system 4-5

FUEL, LUBRICATION AND EXHAUST SYSTEM
l Remove screw d aphragm cover 2 nos and ake
ou cover d aphragm F g 4 19
Ph ps head screw dr ver
l Take ou spr ng d aphragm F g 4 20A
l Remove p s on va ve assemb y a ong w h he
d aphragm F g 4 20B
l Loosen and remove d ng screw A a ong w h
spr ng d ng screw and pack ng d ng screw
F g 4 21
l Remove m x ure con ro screw B a ong w h
spr ng MCS washer MCS and O r ng MCS
F g 4 21
F a screw dr ver
l Loosen screw oa chamber 2 nos and remove
oa body assemb y a ong w h he sea bow
F g 4 22
Fue , ubr cat on and exhaust system 4-6
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F g 4 15
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F g 4 20A F g 4 20B
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A
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F g 4 21
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F g 4 22
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...............................................................................................................................................................

FUEL, LUBRICATION AND EXHAUST SYSTEM
l Remove screw va ve sea F g 4 23
l Separa e oa assemb y p n oa and he need e
va ve assemb y F g 4 24
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F g 4 23
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4
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F g 4 24
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l Remove p o e F g 4 25 .....................................................................................................................................................................................................
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F a screw dr ver sma .....................................................................................................................................................................................................
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F g 4 25
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l Remove ma n e A F g 4 26 .....................................................................................................................................................................................................
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F a screw dr ver b g A
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B
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l Remove e ho der a ong w h he O r ng B .....................................................................................................................................................................................................
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F g 4 26 .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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The et ho der need to be removed on y f .....................................................................................................................................................................................................
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necessary. .....................................................................................................................................................................................................
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F g 4 26
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Fue , ubr cat on and exhaust system 4-7

FUEL, LUBRICATION AND EXHAUST SYSTEM
l Remove a r e rom he m x ng body oca ed a he
ar er end F g 4 27
F a screw dr ver
P STON VALVE D SASSEMBLY
Warn ng:
t s recommended not to d sassemb e the
p ston va ve assemb y dur ng every serv ce of
the carburettor.
l Remove r ng p s on va ve and care u y remove
d aphragm rom he p s on va ve F g 4 28
l Remove screw p a e e need e 2 nos and ake
ou p a e e need e spr ng e need e and
pack ng e need e F g 4 29
l Push e need e rom he bo om and remove he e
need e w h E r ng e need e and r ng e need e
F g 4 30
l Reassemb e p s on va ve assemb y n he reverse
order o he remova
Fue , ubr cat on and exhaust system 4-8
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F g 4 27
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F g 4 28
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F g 4 29
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F g 4 30
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...............................................................................................................................................................

FUEL, LUBRICATION AND EXHAUST SYSTEM
l Do no change he pos on o he E r ng on e
need e 2nd rom he op no ch F g 4 31 and e
s zes wh ch w have e ec on he eng ne
per ormance and ead o prema ure wear o
eng ne par s decreased ue economy and poor
p ck-up
Note:
Wh e reassemb ng ocate the pro ect on of
r ng et need e n the ho e prov ded n the
p ston va ve.
Wh e assemb ng d aphragm on the p ston
va ve, ocate pro ect on of the d aphragm on
the groove of p ston va ve. (F g. 4.32)
l A er assemb ng make sure ha he e need e
moves up and down on s de ways by gh nger
orce
MA NTANANCE
l Ma n a n ng a u eve o benz ne n he ue ank
comp e e does no a ow o rus and a so reduces
rus depos on n he carbure or assemb y
l Wh e he choke ever s n ON pos on do no
open he hro e o herw se may cause ood ng
o he carbure or
l C ean er comp e e a r c eaner regu ar y as a
b ocked or damaged er w have adverse e ec
on carbure or / eng ne per ormance
CLEAN NG
l Spray carbure or c eaner n a passages
F g 4 33 o ensure no b ockage due o dus d r
gum or carbon depos
l Then b ow w h compressed a r F g 4 34
Caut on:
Do not use w res to c ean the ets.
Remove a rubber parts from the carburettor
assemb y before c ean ng t w th a c ean ng
so ut on. Th s w prevent damage or
deter orat on of the rubber parts.
Do not use compressed a r on an assemb ed
carburettor wh ch may cause damage to the
f oat system.
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F g 4 31
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4
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F g 4 32
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F g 4 33
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F g 4 34
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Fue , ubr cat on and exhaust system 4-9
 .....................................................................................................................................................................................................
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FUEL, LUBRICATION AND EXHAUST SYSTEM .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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INSPECTION - NEEDLE VALVE ASSEMBLY .....................................................................................................................................................................................................
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l Any foreign particles on needle valve assembly .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
and its seating may cause improper sealing .....................................................................................................................................................................................................
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resulting in over flow of petrol. Similar kind of .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
problem also occur in case of needle valve .....................................................................................................................................................................................................
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assembly and its seating area are worn-out. .....................................................................................................................................................................................................
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Conversely if the needle valve assembly sticks, the .....................................................................................................................................................................................................
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benzine does not flow into the float body assembly. .....................................................................................................................................................................................................
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l If needle valve assembly is wornout as shown .....................................................................................................................................................................................................
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(Fig. 4.35) replace it with a new one. .....................................................................................................................................................................................................
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F g 4 35
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l Inspect piston valve, needle jet, jet needle, pilot jet, .....................................................................................................................................................................................................
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main jet, mixture control screw and ‘O‘ rings for .....................................................................................................................................................................................................
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any wear or abnormal damage. If any damage is .....................................................................................................................................................................................................
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noticed, replace damaged parts with new ones. .....................................................................................................................................................................................................
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REASSEMBLY .....................................................................................................................................................................................................
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Reassemble parts in the reverse order of dismantling .....................................................................................................................................................................................................
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procedure, and ensuring the following. Refer carburettor .....................................................................................................................................................................................................
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exploded view for assembly details. (Fig. 4.36) .....................................................................................................................................................................................................
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EXPLODED VIEW .....................................................................................................................................................................................................
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Sc ew .....................................................................................................................................................................................................
Sc ew .....................................................................................................................................................................................................
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d aph agm cove p a e e need e .....................................................................................................................................................................................................
E ng .....................................................................................................................................................................................................
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h o e sha .....................................................................................................................................................................................................
Cove .....................................................................................................................................................................................................
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d aph agm .....................................................................................................................................................................................................
Pack ng .....................................................................................................................................................................................................
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h o e sha .....................................................................................................................................................................................................
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e .....................................................................................................................................................................................................
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Hose a ven
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need e .....................................................................................................................................................................................................
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O ng .....................................................................................................................................................................................................
A e 1 45
Sp ng h o e sha .....................................................................................................................................................................................................
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e need e .....................................................................................................................................................................................................
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Sp ng MCS .....................................................................................................................................................................................................
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Washe MCS .....................................................................................................................................................................................................
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E ng Pack ng .....................................................................................................................................................................................................
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e need e e need e .....................................................................................................................................................................................................
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Sp ng
R ng .....................................................................................................................................................................................................
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Sp ng d ng sc ew
.....................................................................................................................................................................................................
e need e O ng MCS .....................................................................................................................................................................................................
d aph agm .....................................................................................................................................................................................................
Pack ng
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
d ng sc ew
Je need e MCS sc ew .....................................................................................................................................................................................................
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Sp ng
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P o e
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sa e
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Gu de ho de
e d ng
Need.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
sc ew assemb y
.....................................................................................................................................................................................................
e .....................................................................................................................................................................................................
O ng P unge
.....................................................................................................................................................................................................
Need e
D aph agm .....................................................................................................................................................................................................
sa e Cap s a e
e ho de .....................................................................................................................................................................................................
va ve
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assemb y
.....................................................................................................................................................................................................
O ng
Je F oa.....................................................................................................................................................................................................
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Sc ew sa e
ho de .....................................................................................................................................................................................................
assemb y va ve sea
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P n oa
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Th o e va ve
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Sea bow
Ma n e .....................................................................................................................................................................................................
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P s on va ve Sp ng
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F oa body h o e sha
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assemb y .....................................................................................................................................................................................................
Th o e sha
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Bush
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h o e sha
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Sc ew oa .....................................................................................................................................................................................................
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Sc ew
chambe .....................................................................................................................................................................................................
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h o e va ve
R ng p s on va ve .....................................................................................................................................................................................................
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Sc ew d a n
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Hose d a n.....................................................................................................................................................................................................
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F g 4 36 .....................................................................................................................................................................................................
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Fue , ubr cat on and exhaust system 4-10


FUEL, LUBRICATION AND EXHAUST SYSTEM
Note:
Ensure that the p ot et s not t ghtened
beyond the m t as th s w cause damage to
ts head and remova from the m x ng body
becomes very d ff cu t.
l Wh e reassemb ng he carbure or a ways use
new gaske s and O r ngs
l Assemb e p s on va ve n such a way ha he hook
ke pro ec on o d aphragm ma ches w h he
groove o m x ng body F g 4 37
l Remoun carbure or assemb y on he veh c e n
he reverse order o remova
Note:
Wh e reassemb ng, check for smooth
movement of choke p unger and p ston va ve
n the carburettor m x ng body.
CARBURETTOR TUN NG
l A er remoun ng carbure or assemb y on he
veh c e ad us he m x ure vo ume con ro screw
MCS A as per he spec ca on Turn ng ou
makes r ch m x ure and urn ng n makes ean
m x ure F g 4 38
MCS Pos on
Apache RTR 160 2 ± 1 urns ou
Apache RTR 180 3 ± 2 urns ou
Caut on:
Before ad ust ng m xture vo ume contro
screw (MCS), veh c e to be warmed up for a
m n mum per od of 3 m nutes.
d e speed sett ng
l Ad us d e speed as per spec ca on Turn ng n
he ad us er B ncreases he rpm Turn ng ou
reduces he d ng rpm F g 4 38
d e speed 1400 ±100
Tachome er
CO sett ng
l However a er ad us ng d e speed he proper
se ng o d e CO s recommended n order o
make he b ke env ronmen r end y by mee ng he
em ss on regu a ons
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F g 4 37
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4
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A
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B
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F g 4 38
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Fue , ubr cat on and exhaust system 4-11
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FUEL, LUBRICATION AND EXHAUST SYSTEM .....................................................................................................................................................................................................
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l Ad us d e speed once aga n and check CO% .....................................................................................................................................................................................................
Carburettor spec f cat ons RTR 160
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Ro a e he hro e gr p 2-3 mes and check CO% .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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a s ab e d ng rpm Descr pt on Spec f cat on
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.....................................................................................................................................................................................................
Carbure or ype Uca M kun BS26 - X39Z1
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
d ng CO% RTR 160 0 8~1 8 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
Ma n e 105
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
d ng CO% RTR 160 2~3 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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Need e e P-2
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Exhaus gas ana yser .....................................................................................................................................................................................................
Je need e 4DHZ56
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Note: E- r ng pos on 2nd rom op
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t s recommended to ad ust a r screw and .....................................................................................................................................................................................................
P o e 15
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
d e screw by us ng exhaust gas ana yser and .....................................................................................................................................................................................................
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tachometer respect ve y. Ar e 145
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Thro e va ve 120° 26 BC 1/84
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.....................................................................................................................................................................................................
LUBRICATION SYSTEM MCS screw 2½ ± 1½ urns ou
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
d ng rpm 1400 ± 100
.....................................................................................................................................................................................................
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l Lubr ca on sys em cons s s o a s ra ner a sump .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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an o pump and a er a cover c u ch The o d ng CO % w h SA 0 8 ~ 1 8 By Vo ume
.....................................................................................................................................................................................................
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c rcu s as shown n ubr ca on char F g 4 39 .....................................................................................................................................................................................................
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Carburettor spec f cat ons RTR 180
.....................................................................................................................................................................................................
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l A ways c ean he o passages whenever repa r s .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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per ormed Descr pt on Spec f cat on
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Carbure or ype Uca M kun BS29
.....................................................................................................................................................................................................
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l Rep ace o a ong w h he o er as per .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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ma n enance schedu e re er chap er “Per od c Ma n e 125
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ma n enance” .....................................................................................................................................................................................................
Need e e P-0
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Je need e 4DHL42
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E- r ng pos on 2nd rom op
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P o e 20
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Ar e 145
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Thro e va ve 120° 26 BC 1/84
.....................................................................................................................................................................................................
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MCS screw 3 ± 2 urns ou
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d ng rpm 1400 ± 100
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d ng CO % w h SA 2 ~3 % By Vo ume
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O L STRA NER .....................................................................................................................................................................................................
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l O s ra ner s prov ded a he bo om o .....................................................................................................................................................................................................
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crankcase R F g 4 40 .....................................................................................................................................................................................................
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l Per od ca y c ean he o s ra ner and nspec or .....................................................................................................................................................................................................
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any damage .....................................................................................................................................................................................................
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F g 4 40
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Fue , ubr cat on and exhaust system 4-12
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FUEL, LUBRICATION AND EXHAUST SYSTEM .....................................................................................................................................................................................................
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CAM SPROCKET 16T .....................................................................................................................................................................................................
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CRANKSHAFT BEAR NG .....................................................................................................................................................................................................
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ROCKER ARM BEAR NG DR VE
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CONNECT NG ROD SMALL END P STON P N
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SHAFT L
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P STON P STON R NGS CYL NDER WALL
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GEARS .....................................................................................................................................................................................................
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CAM LOBES BEAR NG.....................................................................................................................................................................................................

COUNTER
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CAMSHAFT BEAR NGS SHAFT L
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CRANKSHAFT R
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BEAR NG
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4
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CRANKSHAFT
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CAMSHAFT TM O L GU DE CRANKCASE L B G END BEAR NG
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CYL NDER HEAD CRANKSHAFT R END CRANKCASE R
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P PE TM O L .....................................................................................................................................................................................................
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COVER CLUTCH CRANKCASE R O L PUMP
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O L STRA NER
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CRANKCASE L CRANKCASE R
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sump .....................................................................................................................................................................................................
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O L SUMP
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F g 4 39 .....................................................................................................................................................................................................
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Fue , ubr cat on and exhaust system 4-13

FUEL, LUBRICATION AND EXHAUST SYSTEM
O L PUMP ASSEMBLY
l The pump assemb y o s moun ed n he
crankcase R us be ow he gear pr mary dr ve
F g 4 41
l For rep acemen o pump assemb y o rs dra n
eng ne o and remove cover c u ch re er chap er
“serv c ng o eng ne” or de a s
l Remove E-r ng A and pu ou gear o pump
dr ven B F g 4 41
F a screw dr ver sma
l Remove p n o pump dr ven gear A F g 4 42
Nose p er
l Remove CSK head screw M6x20 - 3 nos
ake ou pump assemb y o F g 4 42
l For reassemb y o ow remova sequence n
reverse order
l A er assemb ng o pump assemb y ro a e he
gear o pump dr ven by hand and check or s cky
ro a on or any damage
Note:
Wh e assemb ng, make sure that the dr ve
p n of pump dr ven gear s n p ace
F LTER COMPLETE ENG NE O L
l The er comp e e eng ne o shou d be
per od ca y nspec ed c eaned and changed
necessary w h a new one F g 4 43
Note:
Whenever the f ter comp ete eng ne o s
rep aced, t s recommended that eng ne o
s a so rep aced.
l The procedure or chang ng o and er comp e e
eng ne o s exp a ned n de a n chap er
“per od c ma n enance” page no 2-13
Fue , ubr cat on and exhaust system 4-14
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and .....................................................................................................................................................................................................
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FUEL, LUBRICATION AND EXHAUST SYSTEM
EXHAUST EMISSION CONTROL
l The pollutants emitted from the exhaust system are
harmful to environment. If combustion is
obsolutely complete, there would not be any
atmospheric pollution from the exhaust system.
Water and carbon dioxide are the products of
perfect and complete combustion. However,
complete combustion is difficult to achieve in
internal combustion engines.
l There are three major pollutants in the exhaust
emission. They are:-
1. Unburnt hydrocarbons (HC)
2. Carbon monoxide (CO)
3. Nitrogen oxides (NO2)
WHY DOES THE GASOLINE FAIL TO BURN
COMPLETELY?
l There are several reasons for incomplete
combustion. Some of them are:-
1. Weak spark
2. Improper air-fuel mixture ratio
3. Adulterated petrol
4. Wrong ignition timing
5. Low compression
6. Excessive valve over lap
7. Improper idle speed
8. Incorrect exhaust system
POLLUTION CONTROL
l With the enforcement of various motor vehicle
rules, standards have been set for allowable
percentage of CO emitted from the exhaust gases
as shown below:
By mass Below 2.0 gm / km
By volume Below 3.5 %
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Fue , ubr cat on and exhaust system 4-15

FUEL, LUBRICATION AND EXHAUST SYSTEM
EXHAUST SYSTEM
l The exhaust system consists of parts right from
exhaust valve to muffler assembly through which
the exhaust gasses pass.
l Normally in four stroke vehicles, the muffler
assembly will not be so dirty as two stroke vehicles
unless the system is corrupted because of oil
mixing with petrol unknowingly etc.
l But whenever the muffler assembly is removed
from the engine, the exhaust gasket should be
replaced to avoid leakage.
SECONDARY AIR INJECTION VALVE
l Secondary air injection valve is mounted on the
frame below the tank complete fuel near engine
assembly top mounting bracket. (Fig. 4.44)
WORKING PRINCIPLE
l This is the unit used in exhaust emission control
system. The secondary air injection system induces
filtered air into the exhaust manifold. Whenever
there is negative pressure pulses in the exhaust
system, the fresh air will be taken into the exhaust.
This charge of fresh air dilutes considerable
amount of hydrocarbons (HC) and carbon
monoxide (CO) in the exhaust gases into
carbondioxide (CO ) and water (H O). (Fig. 4.45)
2 2
l There is a reed valve which acts as a check valve,
prevents reverse airflow from exhaust. Only fresh
air is allowed into the exhaust manifold.
l There is also a diaphragm assembly in this valve.
Under sudden closure of throttle, high vacuum is
generated in the intake manifold. Because of this
high vacuum, the diaphragm assembly is pulled
up and the fresh air intake to exhaust is cut off.
Under the sudden closed throttle condition, some
amount of high density unburnt gases are
exhausted. These unburnt gases when come in
contact with fresh air in the hot exhaust, they ignite
and create a bursting sound (after burn). Because
of this after burn, high temperature is created in
this system and this high temperature causes pre-
ignition in the combustion chamber also. Because
of this pre-ignition, knocking effect is created and
thus the efficiency of the engine is decreased.
Fresh air cut off at the closed throttle condition, will
help to avoid the after burn.
Fuel, lubrication and exhaust system 4-16
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SECONDARY A R
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VACCUM
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N ECT ON VALVE
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A R CLEANER
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........................

FUEL, LUBRICATION AND EXHAUST SYSTEM
FUNCT ON
l C ean a r rom a r c eaner assemb y s passed
hrough he n e por A The ou e B wh ch has
a reed va ve connec ed o exhaus man o d
Ano her ne rom n ake man o d D s connec ed
o chamber C The por D has a sma or ce
han he o her por s The resh and ered a r
passes rom por A o por B When here s a
suc on n chamber C he d aphragm s pu ed up
c os ng he va ve a D The a r ow rom por A o
B s c osed Depend ng upon he vacuum crea ed
n he n ake man o d he amoun o a r ow rom
por A o B s con ro ed F g 4 46
REMOVAL
l Remove hose c p A rom hose a r n e and pu
ou he hose rom secondary a r n ec on va ve
F g 4 47
l Remove hose c p B rom hose a r ou e and pu
ou he hose rom secondary a r n ec on va ve
F g 4 47
Nose p er
l Remove c p A rom he hose a r cu va ve and
pu ou he hose rom secondary a r n ec on
va ve F g 4 48
Nose p er
l Remove hexagona bo M6x30 - 2 nos rom
secondary a r n ec on va ve moun ng and ake
ou he va ve a ong w h punched washers 4 nos
F g 4 49
10 mm spanner
l For reassemb y reverse he remova sequence
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D APHRAGM
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NTAKE MAN FOLD
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REED
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STOPPER
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A EXHAUST
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D MAN FOLD
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SPR NG
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MAN FOLD
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VALVE
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FROM A R F LTER
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F g 4 46
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F g 4 48
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F g 4 49
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Fue , ubr cat on and exhaust system 4-17

FUEL, LUBRICATION AND EXHAUST SYSTEM
PREVENT VE MA NTENANCE (EM SS ON)
l Wh e every new veh c e eav ng he ac ory s
cer ed and s mee ng he exhaus em ss on
s andards he CO eve n he exhaus gases may
ge a ered depend ng upon a ude and a so over
a per od o me depend ng upon usage or ack o
ma n enance s here ore necessary whenever
he veh c e s serv ced nspec he CO eve and
une up he eng ne o ma n a n he em ss on
s andards
Caut on:
ncreased CO eve n exhaust gases not on y
po utes the a r bad y but a so affects the
eng ne performance.
MEASUR NG CO LEVEL N EXHAUST EM SS ON
l When he eng ne per ormance s genera y good
un ng o carbure or assemb y by ad us men o
m x ure con ro screw and d ng screw w he p o
con ro he CO eve n exhaus gases Many
equ pmen s are ava ab e o measure CO eve n
exhaus gases Be ore measur ng he em ss on s
mpor an o unders and he measur ng procedure
con ro s and ma n enance aspec s o ha
equ pmen by re err ng o he nd v dua
manu ac urer s manua
TO CHECK AND SET THE CO
l Use he em ss on un ng k K310440 supp ed by
TVS-M and o ow he gu de nes g ven be ow:-
Gu de nes:
1 Warm up he veh c e by runn ng he eng ne n
d ng speed or 5 - 8 m nu es or run he veh c e
or 3 o 4 kms a 40 kmph speed
2 Check he d ng rpm w h he he p o achome er
requ red ad us d ng rpm as per he
spec ca on re er chap er “per od c
ma n enance“ page no 2-5 or de a s
3 ncase o erra c d ng var a on beyond spec
se r gh he same be ore proceed ng or se ng he
CO
4 F x he ube ex ens on on o he s encer T gh en
he c amps o avo d any eakage
Fue , ubr cat on and exhaust system 4-18
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FUEL, LUBRICATION AND EXHAUST SYSTEM
5 nser he probe o exhaus gas ana yser n o he
ex ens on ube o he ex en o 30 o 60 cms
6 Press he key M or Hor ba or En er Key or
Hermann exhaus gas ana yser o measure he
CO em ss on
7 Wa or ew seconds he read ng s ab zes on
he screen
8 No e he CO and HC read ngs are shown on he
screen
Note:
On comp et on of CO check, keep the
ana yser n ‘measurement mode‘ for approx.
30 m nutes for fresh a r c rcu at on. Then turn
the power ‘OFF‘.
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EXHAUST GAS EM SS ON TUN NG
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ANALYSER EQU PMENT
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PROBE .....................................................................................................................................................................................................
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F g 4 37 .....................................................................................................................................................................................................
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Fue , ubr cat on and exhaust system 4-19