SERVICE MANUAL

PETROL
 FOREWORD
This manual has been prepared with the aim to provide the necessary instruction
to Atul Auto Limited dealer for the maintenance and repair of the “AAL” vehicle.

This service manual deals with the following matters:

l General instruction for vehicle maintenance.

l General instruction for fault analysis and diagnosis.
l Illustration and instructions for dismantling, over - hauling and re-assembly.
l Assembly play of the major components of power pack and brakes.
l List of special tools for operation to be carried out on the vehicle.
l Torque of vehicles fasteners.

It is recommended that various maintenance procedure as well as procedures for

dismantling, overhauling are followed seriously with the use of special tools
recommended to avoid damage to the components, keep the repair-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 “AAL”.

The information, technical specifications, repairs/overhauling procedures

contained in this “service station manual” are subject 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:

SERVICE DEPARTMENT

ATUL AUTO LIMITED

CIN No. : L54100GJ1986PLC016999
Address 1 : 8-B, National highway, Near microwave tower, Shapar(Veraval), Rajkot - 360002
Address 2 : Khata No. 171, S/No. 590, Opp. moghal mataji mandir, Vill. Bhayla, Tal. Bavla,
Dist. Ahmedabad -382220
Phone : +91-2827-666000
Fax : +91-2827-666029
E-mail : export@atulauto.co.in
Web : www.atulauto.co.in
 Index
Sr.no. Description Page no.

1. Identification Number 01
2. Technical Specification 02
3. Location of Controls & switches 04
4. Lights On Cluster Assembly 07
5. Fuse Box & Relay Box 08
6. Running In 09
7. Service Schedule 10
8. Periodic Maintenance Chart 11
9. Engine Oil Filling Process 23
10. Engine 24
11. Carburetor 46
12. Vehicle 50
13. Positive Crankcase Ventilation System 67
14. Electric Circuit 68
15. Electrical Ready Table 73
16. Tips To Keep Vehicle In Good Condition 80
17. Service Limit 81
18. Tyre Thread Depth Measurement 90
19. Torque Chart (Engine) 97
20. Torque Chart (Vehicle) 98
21. Special Tools (Engine) 99
22. Special Tools (Vehicle) 105
PERIODIC MAINTENANCE INDEX

Sr.no. Description Page no.

1. Periodic Maintenance Schedule 11

2. Air Filter cleaning 12
3. Engine Oil Replacement 12
4. Differential Oil Replacement 12
5. Oil Filter Replacement 13
6. Spark Plug Cleaning 13
7. Fuel Filter Cleaning 14
8. Decarbonization 14
9. Cylinder Head 14
10. Piston 15
11. Compression Pressure 15
12. Valve Tappet Adjustment 16
13. Valve Timing 17
14. Valve Leakage Testing & Lapping 17
15. Battery 18
16. Brake 19
17. Control Cables Adjustment 21
18. Muff Cup Greasing 21
19. Lubricating Steering Parts 22
20. Tyre Pressure 22
21. Tyre Rotation 22
IDENTIFICATION NUMBER

Chassis Identification number

Chassis Identification number location

Ÿ VIN number located on the chassis left hand
side.
MC
G5
4R3PB
K20
000
01

PLANT CODE
RAJKOT R
AHMEDABAD A
COMPANY CODE PLANT CODE ENGINE CODE MONTH SERIAL NUMBER

M C G 5 2 R 3 P B A 2 1 0 0 0 0 1

MODEL CODE VEHICLE CODE YEAR

Engine Identification number

SERIAL NUMBER
SINGLE CYLINDER, PLANT CODE Engine no.
4S, 200CC, PETROL

B B R 2 0 A 0 0 0 1
ENGINE TYPE CODE
WITH HAND-START A YEAR MONTH
W/O HAND-START B

1
TECHNICAL SPECIFICATION
EEngine & transmission

Type : Four stroke, Spark ignition, Forced air cooled

No. of cylinders : Single
Bore : 61 mm
Stroke : 68 mm
Engine displacement : 198.6 cc
Idling speed : 1400 ± 50 rpm
Max. Torque : 15.80 Nm @3000 ± 250 rpm @crankshaft
Max. Power : 8.60 kW @6000 ± 50 rpm @crankshaft
Air filter : Paper filter
Oil filter : Micro paper filter
Ignition system : Electronic, Spark ignition
Carburetor : UCAL
Spark plug : Resister type (Bosch & NGK)
Spark plug gap : 0.65 mm to 0.75 mm
Lubrication : Positive lubrication, Wet sump
Cooling System : Oil cooler assy. with Fan
Tappet clearance : 0.13 mm (Inlet & Exhaust)

Fuel Tank Capacity

Petrol : 10.5 Liter
Starting : Electric push start
Clutch : Wet, multi-disc type.
Transmission : 4 speed forward + 1 reverse, Constant mesh
Differential : Integral with engine
Chassis type : Monocoque long-member & tubular cross-member.

Suspension

Front & Rear : Helical Compression Spring & double acting hydraulic shock absorber

Brakes

Front & Rear : Dual circuit Hydraulically expanding shoe type

Tyre

Tyre pressure
Front : 2.65 kg/cm2 (38 PSI)
Rear : 2.65 kg/cm2 (38 PSI)
Tyre size : 4 x 8 inch

Electricals

System : 12 V, DC
Battery : 12V, 32 A
Head lamp : 35/35 W, Twin head lamp
Side indicator lamp : 21 W
Parking lamp : 21 W
Reverse lamp : 10 W
Battery indicator : 12 V, 2 W
Cluster indicator : 12 V, 2 W
Horn : 12 V, DC
Wiper system : Electrical wiper motor

2
TECHNICAL SPECIFICATION

Fuse : 30 A (main fuse),

15 A, 10 A & 7.5 A (in fuse box)
Starter motor : 12 V, 0.6 KW

Weights

Max. FAW : 150 kg

Max. RAW : 550 kg
Kerb weight : 380 kg
Gross vehicle weight : 700 kg
Pay load : 320 kg [3P + 1D]

Dimensions

Overall length : 2765 mm

Overall width : 1420 mm
Overall height : 1800 mm
Wheel base : 1950 mm
Ground clearance : 185 mm

Starter motor : 12V , 0.6 kw

Wiper motor : 12 V, 36W (Single blade)
Wiping system : Single blade with single frequency

3
LOCATION oF CONTROLS & SWITCHES

Steering lock

Set button

Mode button

Overheat Lamp

4
LOCATION OF CONTROLS

5
 .

FUEL GAUGE : This gauge indicates availability of fuel on vehicle’s digital

display in the form of bar. (E) indicates lower amount of fuel in tank where as (F)
indicates full. Also it shows the filler position on vehicle.

6
LIGHTS ON CLUSTER ASSEMBLY
High Beam Indicator : It indicates head lamp is at High beam position.
Battery Charging Indicator : It indicates that the battery is charging. When ignition key is ON,
light blows and when engine started light OFF. If not, visit nearest dealership.
Side Indicator : It indicates when side light ON (Left or Right Indicator)
Neutral : It indicates whether vehicle is in neutral position of gear or not.
Oil Pressure Indicator : It indicates engine oil pressure is low, when engine started light blow OFF,
if glows you have to visit nearest dealership.
Fuel Meter : It indicates petrol level in fuel tank. Kindly maintain fuel level.
Odometer & Speedometer : It indicates kilometer covered the vehicle & at what speed vehicle is
running. If found failure kindly visit nearest dealership.
Overheat Indication : It indicates if the cooling system doesn’t work & the engine temperature is
too high to get overheat. If found failure kindly visit nearest dealership.

MODE / SET button feature

CLOCK
SERVICE REMINDER
TRIP A

SERVICE REMINDER :-
• 950km the symbol will appear after service.
• The mode button press continuously the service symbol will blink.
• Press the set button.
The next reminder will appear after 4500km. Every 4500km the service reminder will appear. Then every services
completed we can set the mode and set button as above. This service reminder will applicable up to 35000km only.

CLOCK:-
• Press the mode button for 6 to 8 second, the clock hour digits will blink.
• Press the set button and set HOURS.
• Single press mode button so MINUTES digits will blink then press set button and set the minutes, leave it
automatically.
• The clock setting are completed.

TRIP A :-
• Press the set button for 3 to 5 second, the TRIP METER turn zero.

7
LH Indicator & RH Indicator 7. Fuel Feed Pump
Instrument Cluster & Speed Sensor 8. Hazard Switch
Head Lamp Cabin Lamp
High Beam Engine Compartment Lamp
Low Beam d. Brake Switch
Reverse Lamp e. Horn
RR Unit f. Instrument Cluster
Fare Meter 9. Oil cooler fan
Wiper Motor
FM Unit
CDI Unit

LH
WIPER REV. LAMP HD LAMP,
FUEL INSTR. INDICATOR,
MOTOR RR UNIT HIGH
FEED CDI UNIT CLUSTER RH
FM UNIT FARE METER BEAM,
PUMP SPEED INDICATOR
LOW BEAM.
SENSOR

7.5A F7 10A F6 10A F5 7.5A F4 10A F3 10A F2 10A F1

HAZARD SW.
CABIN LAMP
OIL COOLER ENGINE COMP.
FAN LAMP
BRAKE SW.
HORN
INSTRUMENT
CLUSTER
F14 F13 F12 F11 F10 7.5A F9 15A F8

8
RUNNING IN PERIOD
1) Running a brand new engine or an overhauled engine at its full rated load, right from
the beginning is harmful to the engine.
2) It is therefore recommended that for the first 2000kms. (the running in period) the
speed limits given in this book are not exceeded and load does not exceed 70% of the
full rated load.
3) Do not race the engine excessively.
4) Do not start moving or race engine immediately after starting. For a minute run engine
at idle speed to give oil a chance to work up into engine

Distance in Km 1st Gear 2nd Gear 3rd Gear 4th Gear

0 - 2000 10 Km 16 km 25 km 40 km

FUEL AND OIL RECOMMENDATIONS

APPLICATION QTY. GRADE

ENGINE OIL 1.8 ltr.

(SAE20W50)(API SL/ SM)
DIFFERENTIAL OIL 250 ml

BRAKE FLUID 250 ml DOT 3/4

GREASE (MUFF CUP) 120 g RR3

GREASE (STEERING) 30 g RR3

9
SERVICE SCHEDULE:-

1st Service 1,000 km or 30 days, which ever is earlier

2nd Service 6,000 km or 90 days, which ever is earlier

3rd Service 11,000 km or 150 days, which ever is earlier

4th Service 16,000 km or 210 days, which ever is earlier

5th Service 21,000 km or 270 days, which ever is earlier

10
 PERIODICAL MAINTENANCE CHART
Periodical maintenance chart
SR. RECOMMENDED ODOMETER READING ( km)
NO. OPERATION 1000 6000 11000 16000 21000 26000 31000

1. Servicing
2. Check and adjust control cable
3. Clean fins from cyl. head, cyl. block & oil cooler
4. Check brake fluid top up, if required Replace every 40,000 km
5. Clean air filter element Replace after every 20,000 km
6. Differential oil replacement
7. Replace engine oil & oil filter
8. Check battery electrolyte level & top up
9. Spark plug : clean & check the gap Replace after every 10,000 km
10. Check brake liner wear, replace if required Replace every 10,000 km
11. Check front/rear shock absorber
12. Tight nuts, bolts, fasteners
13. Check / adjust fork assembly
14. Tight bearing race & lock nut (fork assy.)
15. Tyre rotation
16. Check all electrical
17. Check fuel leakage
18. Cup fuel strainer cleaning
19. Carburetor cleaning
20. Check & adjust valve (tappet) clearance, if required
21. Check engine compression pressure
22. De-carbonising (cyl.head,cyl.block,valve)
23. Valve timing

Lubrication chart
SR. RECOMMENDED ODOMETER READING ( km)
OPERATION USE
NO. 1000 6000 11000 16000 21000 26000 31000
1. Engine oil replace
SAE API SL
2. Differential oil replace
20W50
3. Engine & Differential oil top up Check & top up every 1000km

4. Steering race , balls GREASE-RR3

5. Propeller shaft flanges greasing (muff cup) GREASE-RR3
6. Rear axle bearing GREASE-RR3
7. Battery terminal PETROLEUM JELLY
8. Gear shifter GREASE-RR3
9. Brake / clutch lever fulcrum point GREASE-RR3
10. Check brake fluid in master cyl. DOT-3/4
11. Muff-cup greasing (greasing nipple) GREASE-RR3
12. Fare meter / VSS greasing nipple GREASE-RR3

Cleaning solvent chart

SR.
OPERATION USE
NO.
1. Carburetor cleaning Carbon tetra chloride
2. Cylinder head, Valve, Piston & Piston ring
Carbon tetra chloride, Acetone carbon chloride
decarbonizing

11
PERIODIC MAINTENANCE PROCESS
Air filter assembly cleaning : Engine oil replacement :
01. Open the rear engine inspection door. 01. Start the engine to warm up the engine oil.
02. Air filter assembly located at LH top side of 02. Place a jar under the transmission oil drain cap.
engine compartment. 03. Remove the oil strainer plug with help of
03. Open the clip of air filter cap in sequence as 22mm socket spanner, then pull out the strainer.
shown in fig.

2
3

04. Take out the air filter cap as well as air filter 04. Loosen the drain bolt using 14mm spanner &
element. drain the oil.

05. Clean the oil strainer by kerosene if damage,

NOTE: Make sure that dust ejecting valve should be in
down word position.
Three groves are provided at air filter housing,
while mounting clips to housing make sure that
clips are properly inserted inside of these
grooves while assembly
replace with new one.
06. Refit the oil strainer & tighten the oil strainer plug
with 0.9 to 1.1 kg.m torque. Tighten the drain
plug with 2.7 to 3.3 kg.m torque.
07. Refill 1800 ml with SAE 20W50 Oil.
08. Re-insert & tighten gauge oil level completely.

Air filter housing Air filter cover Replace at initial 1,000 km and there after
every 5,000 km.

Differential oil replacement :

01. Place a jar under the differential oil drain plug.

Air filter element

Replace air filter element after every 20,000 km.

12
PERIODIC MAINTENANCE PROCESS
Spark plug cleaning :
02. Loosen the plug using 16mm spanner & drain the
differential oil.
03. Refit & tighten the oil drain plug with 1.5 to 01. Disconnect the suppressor cap from spark plug.
1.8 kg.m torque . 02. Before removing the spark plug, clean spark plug
04. Loosen gauge oil level along with gasket . surrounding area (by compressed air) & close the
05. Refill 250 ml with SAE 20W50. plug hole with clean cloth.
06. Refit & tighten the gauge oil level 03. Remove the spark plug using 22 mm spark plug
special tool.
Replace at initial 1,000 km and there after
every 10,000 km.

Oil filter replacement :

01. Drain the engine oil.
02. Remove oil cooler pipe by loosening 17 mm
banjo bolt along with copper washer.

0.65 - 0.75 mm

04. Check the condition of spark plug.

03. Loosen 3 nos. M8x20 hex. flanged bolts

uniformly.

0.65 to

Used 0.75 mm

New 05. Clean by spark plug cleaning machine

(sand blasting & compressed air cleaning).
06. Adjust the spark plug gap 0.65~0.75 mm
04. Take out the cover oil filter, oil filter, spring and (feeler gauge).
gasket. 07. Don’t use flared steel cables.
05. While replacing the oil filter, we have to replace 08. Refit & tight with 1 to 1.5 kg.m torque.
engine oil also.
06. Refit in reverse order.
Clean & Check gap at initial 1,000 km and
there after every 5,000 km.
Replace at initial 1,000 km and there after
every 5,000 km.
Replace every 10,000 km.

13
PERIODIC MAINTENANCE PROCESS

Fuel filter cleaning : Decarbonization :

01. Open clips by using piler on both side Valve & Valve guide:
02. Take out fuel filter outside.
01. Carbon deposition on valve seating will cause
valves not to seat properly thereby causing
leakage and this will affect idling, pickup, mileage,
erratic running & starting problem.
02. Carbon deposits on the valve stem rubs
continuously on guide valve and this will result in
increased clearance between the stem and guide
valve.
03. Clean the valve stem with the cleaning solvent
04. For dismantle it use valve guid removal special
tool.

De-carbonize the valve & valve guide every

03. Clean fuel filter. 20,000 km.
04. Refit in reverse order.
Cylinder Head
Clean initial 1000 km & there after every 01. Remove carbon deposits periodically using
10,000 km. suitable cleaning solvent.
02. Decarbonize the head complete cylinder
combustion chamber after removing both the
valves.
03. Do not damage the surface of the combustion
chamber while decarbonizing.

NOTE: Carbon deposits in the combustion chamber of

the head complete cylinder and on the piston crown will
increase the compression ratio and may cause pre-
ignition or over heating. Carbon deposited at the exhaust
side of the head complete cylinder will prevent smooth
flow of exhaust, reducing the engine power output.

De-carbonize the valve & valve guide every

20,000 km.

14
PERIODIC MAINTENANCE PROCESS

Piston Compression pressure :

01. Keeps a clean cotton cloth on the crankcase 01. Warm up the engine.
assembly bore to prevent circlip piston falling 02. Stop the engine & disconnect the spark plug
inside the crankcase while removing the circlip . using spark plug special tool.
02. Remove circlip piston on one side.
03. Decarbonize the piston and ring grooves with fine
emery paper or recommended decarbonizing
solution.

03. Stop the fuel supply.

04. Mount the compression gauge adaptor to plug
hole.(without leak)
05. Switch ‘on’ ignition, open the throttle fully, and
crank the engine five to six times with push button
NOTE :During the assembly of piston on the connecting , and note the highest reading as the compression
rod ensure the ‘IN’ mark should be on the intake manifold pressure.
side.

Piston rings :
01. The rings should be rotate freely in their grooves. Check the compression pressure every
10,000 km.
02. While cleaning the ring grooves, use an old
broken rings.

03. Carbon in the groove is liable to cause the rings

piston to stuck in the groove, and this will lead to
reduce engine power output.

15
PERIODIC MAINTENANCE PROCESS
Valve tappet adjustment : Valve tappet adjustment :
01. Check the valve clearance only when the
For Tappet adjustment remove engine inspection cover engine is in cold condition and spark plug
which is located below passenger seat. should be removed.
02. Valve tappet clearance should be adjusted only
after matching the timing mark.

03. At this point the arm complete valve rocker should

have free ply. Otherwise rotate the fan assembly
about 360° and align the mark again.
(compression stroke)
04. Use proper feeler gauge.

Valve Clearance: Intake 0.13 mm

Exhaust 0.13 mm

If there is any variation on gap

05. Loosen the tappet hex. nut.

06. Place the feeler gauge and adjust the clearance
using the special tool.
07. Always while setting the clearance make sure that
little resistance in the feeler gauge.
08. While tighten the lock nut, ensure that the tappet
adjuster has not rotated.
09. After adjustment check the clearance with next
oversize feeler gauge. Make sure, it should not
enter.

Inspect and set the valve tappet adjustment

initial 1,000 km & there after every 10,000 km.

16
PERIODIC MAINTENANCE PROCESS
Valve timing : Valve leakage testing & lapping :
While reassembling the sprocket cam shaft, ensure the After assembling the valve,
followings:
01. Pour the petrol into the inlet port and look for
01. Before doing the valve timing, assemble Magneto leakage of petrol around the inlet valve seating.
assembly, fan and cowl complete bottom air
cooling.
02. Rotate the fly wheel rotor and match the TDC
mark on the rotor assembly and the mark on the
cowl complete bottom air cooling.

02. If any leakage notice, rectify the valve and its seat
by lapping.
03. Apply the lapping compound on the valve
uniformly.
03. At this position of the rotor assembly, ensure that
the mark on the sprocket cam shaft matches
with the surface edge bottom of the cylinder
head.

04. Insert the valve on head and turn side to side

(by lapping stick) till the grinding noise comes
down.
05. Take out & clean the valve & head.
06. Do the same process until the leakage stops.

Inspect and set the valve timing adjustment

initial 1,000 km & there after every 5,000 km.

WARNING: While lapping, avoid entering of compound

into the valve guide through the stem, which
will increase the clearance between guide
and valve.

17
PERIODIC MAINTENANCE PROCESS
Battery :
The battery is located at the rear side of passenger seat.

01. To check the battery voltage, remove the terminal

protector and connect the multi meter to the
terminals and note the reading.
02. Require voltage reading is 12.6 to 12.8 V.

03. Also check the electrolyte level by simply

remove the electrolyte cap and fill with specific
electrolyte or distilled water only.
04. If battery reading is showing less then required
level contact to nearest work shop.

Note : While removal of battery terminals always remove

the negative (BLACK) terminal first then remove positive
(RED) terminal.
While connecting of battery terminals always
connect positive (RED) terminal first then connect
negative(BLACK) terminal.

18
PERIODIC MAINTENANCE PROCESS

Wheel
Cylinder

(Auto Adjuster)

Brake : Brake assembly :

All the three brakes are single pedal operated
Clean all dismantled parts of the master cylinder with
hydraulic brake. However rear wheel hand brake can be
fresh specified brake fluid or alcohol.
operated by hand mechanically on both the rear wheel.
Salient Features:
Caution : Never use the drained / used brake fluid for 1) Automatic shoe wear adjustment
cleaning or other purposes. Always use specified brake fluid 2) Brake shoes with bonded liner
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.
Construction:

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 / piston.
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.
Refer figure brake assembly it consists of wheel
cylinder, brake shoe, return spring, screw with adjuster, strut,
pawl, strut spring etc. In this system, as the hydraulic
pressure acts on the piston of the wheel cylinder, they force
the brake shoes out ward restricting the rotation of the drum.
As the shoes get worn, the pistons have to move a longer
distance. This is compensated by auto Adjuster mechanics &
consistent pedal travel is maintained. This brake is self
adjusting.

Check the internal surface of the wheel cylinder. If the

surface is scratched or corroded, the cylinder will have t o
be replace. Damaged wheel cylinders will cause
damage to the piston and packing.

19
PERIODIC MAINTENANCE PROCESS

Working of auto adjuster : Brake bleeding procedure :

In normal operation tip of adjuster lever (i.e. pawl) a. Connect the bleeder tube to the bleeding nipple provided
slides tooth surface between "A" and "B" without indexing on the wheel cylinder and let the other end of the bleeder
(function clearance) as shown in fig. As the liner wears, tube dip in the brake fluid in the container.
beyond a designed shoes center clearance, the tip of adjuster b. Depress the brake pedal and release it a no. of times.
lever (pawl) jump to next tooth "C" on adjuster wheel c. Depress pedal to its down-most position. Loosen the
(sprocket) & indexes by one tooth. bleeding nipple. Press the brake pedal as far as it will go.
Tighten the bleeding nipple and release the brake pedal.
Parking Brake: d. Repeat this operation on all the three wheels till the air is
removed from the system. Keep on topping up the
master cylinder as the bleeding operation is carried out.
The hand brake lever is fitted in cabin. Single cable is
fitted in handbrake lever. The two end of inner cable, fitted
with rear brake plate's trailing brake shoes control lever,
which is operated by pully given on hand brake lever. This
system ensures equal braking action on the two rear wheel.
Lock the hand brake outer cables on back plate with cup
retain spring.
After assembly, ensure the hand brake locks the wheels
with in 5 notches.
This can be adjusted by loosening both the lock nuts as
shown in fig. and by turning adjusting screw IN or OUT for
required notches. Tighten both the lock nuts to its position.

20
PERIODIC MAINTENANCE PROCESS
Gear cables adjustment : Note: If still the cables are not adjusted
properly then only move to next step.
01. Before starting gear cable adjustment, ensure that 02. Remove gear shifter cover by loosening both
the vehicle must be in neutral position. screw with spanner (8mm).
02. Remove two screw on the cover of handle bar 03. Loosen the screw, hold gear cable and pull the
with the help of T-spanner (10mm). cable until cable adjusted.

03. Remove the handle bar cover gently. 04. Tighten both screw with spanner (8mm).
04. Insert Allen key (3mm) in hole provided at tube of 05. Refit the handle bar cover.
handle bar.

05. Place both screw along with washer over handle

05. Adjust the adjuster screw of grey cable then the bar cover.
black cable beneath handle bar area with 06. Tighten both screw with T-spanner (10mm).
spanners.

06. If still cables are not adjusted well then move to

gear shifter side, adjust the adjuster screw with
two spanner, first grey cable then black cable at
handle bar area.

21
PERIODIC MAINTENANCE PROCESS
Control cables adjustment : Muff cup greasing :
Reverse gear lever : 01. Un-lock the clip bellow muff cup using philip head
screw diver.

01. Loosen both lock nuts.

02. Keep the reverse gear shifter lever in engaged
position.
03. Keep the reverse gear lever at gear box end also
in engaged position.
04. Remove the wire slackness with the help of
adjusting screw by taking out or taking in
as shown in fig.
05. If you take the adjusting screw IN, wire slackness
will be increased.
06. If you take the adjusting screw OUT, wire
slackness will be decreased.
07. After completion of adjustment tighten the lock 02. Separate the bellow.
nuts. 03. Wipe out the old grease.
Lock nut Adjusting screw
IN

IN
OUT

OUT

Gear shifting cable : 04. Fill the muff cup with fresh grease (RR3). (120 g)
05. Refit the bellow.
01. Loosen both lock nuts.
02. Adjust an adjusting screw as required. Note : For RH engine side clamp bellow use special tool.
03. To increase the tension, take the adjusting screw
OUT.
04. To decrease the tension, take the adjusting screw
IN.
05. After completion of adjustment, tighten the lock
nuts.

Adjusting of clutch free play:

Adjust the free play of clutch lever as shown in
fig. by taking adjusting screw IN/OUT as required. To
increase the play take adjusting screw IN. To decrease
the play take adjusting screw OUT and try to maintain
minimum 2mm free play. 06. Remove the grease nipple. Put fresh grease
through to the cup.
Adjusting screw Lock nut 07. Tighten the nipple after greasing.

OUT IN

22
PERIODIC MAINTENANCE PROCESS
Lubricating steering parts : Maximum grip on the road is vital for road safety. This can
only be achieved with the correct pressure in your tyres.

The diagram below shows how much grip a tyre has on

the road depending on its pressure.

Tyre pressure :-
2
RIK - Front - 2.65 kg/cm or 38 PSI
Rear - 2.65 kg/cm2 or 38 PSI

Tyre rotation :

Front Front

01. Lubricate the steering races at every 10,000 km. Spare wheel Spare wheel
02. Replace the races, if found any pitting mark.
03. Ensure proper tightening of steering fork nut
with 5 - 7 kg.m torque.
Rear Rear Rear Rear
Tyre rotation only Tyre face change only
Tyre Pressure
1) The correct tyre pressure is vital for both safety
Cycle 1 Cycle 2
and for extending the life of your tyre. Tyre rotation : The wheels are interchangeable
2) You should check your tyre pressures monthly, provided they are correctly inflated. To even out tyre
including the spare and before any long distance thread wear it is recommended to rotate it after
driving. Make sure the tyre pressures match the every 5000 km and inflate it to the specified
pressures recommended by the vehicle pressure. The best tyres should always be kept at
manufacturer.
the rear wheels which are driving wheels, thereafter
follow the sequence of rotation.

Cycle 1 : After every 5,000 km

Inter change front & rear wheel, spare & rear left
wheel as shown.

Cycle 2 : After every 10,000 km

Change front tyre face & interchange rear wheels
as shown.

23
ENGINE OIL FILLING PROCESS
Step 1 :- Open tail gate show in Step 1.
Step 2 :- Remove tappet cover at exhaust side by using spark plug spanner & rod as shown in Step 2.
Step 3 :- Take out tappet cover as shown in Step 3.
Step 4 :- Top up or refill Engine oil as per requirement as shown in Step 4.

Note :- Always use ATUL genuine oil for top up or refill.

Make sure oil level don’t go beyond maximum level on dipstick.

Step 5 :- Refit tappet cover at exhaust side by using spark plug spanner & rod as shown in Step 5.

Note :- Make sure that O ring fitted properly in tappet cover.

Don’t over-tight tappet cover
Replace tappet cover O ring, if found damaged

Step 6 :- Refit engine inspection cover as shown in Step 6.

STEP 1 STEP 2 STEP 3

STEP 4 STEP 5 STEP 6

24
ENGINE INDEX
Engine index
Sr.no. Description Page no.

Dismantling of engine

1. Removal of Muff cup, Cowling & Oil cooler 025

2. Removal of Cylinder head 025
3. Cylinder Head Dismantling 026
4. Removal of Cylinder Block 026
5. Removal of Piston Assembly 026
6. Removal of Fan 027
7. Removal of Magneto Rotor & Starter Plate 027
8. Removal of Clutch cover 027
9. Removal of Clutch 029
10. Removal of Oil Pump 029
11. Removal of Primary Gear From Crank Shaft 029
12. Removal of Metallic Guide Chain 029
13. Removal of Guide Cam Chain 029
14. Removal of Gear Shifter Assembly 030
15. Separation of Crankcase 030
16. Dismantling of Main Shaft 031
17. Removal of Differential Cover 032
18. Dismantling Differential Unit 032
19. Removal of Reverse Gear Selector Assembly 032

Engine re-assembly

1. Reverse gear selector assembly re-assembly 033

2. Differential unit re-assembly 033
3. Differential cover re-assembly 033
4. Main shaft re-assembly 034
5. Crankcase clutch side cover re-assembly 035
6. Gear shifter assembly re-assembly 035
7. Guide cam chain re-assembly 035
8. Metallic guide chain re-assembly 036
9. Primary gear of crank shaft re-assembly 036
10. Oil pump re-assembling 036
11. Clutch re-assembly 037
12. Clutch cover re-assembly 038
13. Stator plate re-assembly 039
14. Starter motor re-assembly 039
15. Piston ring re-assembly 040
16. Piston assembly re-assembly 040
17. Assembling of cylinder block 040
18. Cylinder head re-assembling 040
19. Cowls, Oil cooler & Muff cup re-assembly 041

25
ENGINE DISMANTLING
Dismantling of engine
Removal of muff cup, cowling & oil cooler :
1) Drain engine oil and differential oil.
2) Open the muff cup lock using philips head screw driver
& open the bolt using 13mm socket spanner using
special tool [42290019].
3) Remove the oil cooler by loosening the oil cooling pipe
bolts & mounting bolts using 10 mm spanner.
4) Open magneto side plastic cowling duct using 8mm
open spanner.
5) Open differential side cowl using 10mm T-spanner.
26
Removal of cylinder head :
1) Remove spark plug from cylinder head with the help of
spark plug special tool.
2) Remove chain tensioner by removing 2 bolts using
8mm spanner, holding it with cylinder block.
3) Remove OHC cover by removing 2 nuts using 10mm
spanner.
B
A) OHC cover , B) Chain tensioner
4) Remove 3 bolts and take out the intake manifold from
cylinder head using 10mm spanner.
A B
A) Intake manifold B) Bolts
5) Remove two tappet covers using 24mm spanner. .
6) Rotate magneto assembly and ensure that the piston
is at TDC and line on camshaft sprocket is matching
with marking on cylinder head, so that both the tappets
are free.
7) Take out the sprocket from cam by removing two bolts
using 8mm spanner.
8) Release the chain from sprocket and suitably hold it by
a wire.
9) Remove 4 dome cap nuts using 12mm spanner and 2
tightening bolts using 8mm spanner and pull out
cylinder head. Then remove the head gasket.
ENGINE DISMANTLING

C B

A
SHAFT ROCKER ARM

SPROCKET

BOLT CAM SHAFT SHAFT ROCKER ARM

SCREW
A) Sprocket B) Tappet cover SCREW PAN CROSS
NUT
STOPPER
C) Dome cap nut D) Tightening nut

Cylinder head dismantling :

1) Remove stopper plate by removing screw.

2) Take out inlet rocker arm shaft by using a bolt.
3) Take out exhaust rocker arm shaft by nose plier.
4) Take out both the rocker arms. COLLET
5) Take out camshaft using special tool [42290016]. RETAINER VALVE SPRING
6) Take out the collet, retainer, spring, seat spring, oil seal
SPRING ENGINE VALVE
& valve by using special tool.
OIL SEAL
A) Stopper plate B) Rocker arm shaft C)Bolt
SEAT SPRING

C
A VALVE

B
7) Repeat the same procedure for the other valve.
8) Remove the valve guide oil seal with the help of plier.

Removal of cylinder block :

1) Remove guide chain (N.S.)

A) Cam shaft removal special tool 2) Pull out the cylinder block assembly.

A A

A) Chain tensioner (non tension side)

B B) Cylinder block
Removal of piston assembly :
1) Remove a snap ring.
2) Take out the gudgeon pin.
3) Now remove the piston.
B) Valve removal special tool

27
ENGINE DISMANTLING

C B
A B
A

A) Rotor B) Puller
A) Snap ring B) Gudgeon pin C) Piston 3) Remove stator plate by removing 3 mounting screws
using 8mm spanner. Then remove pickup coil by
Removal of fan : removing 2 philips head screws.
1) Remove fan from the rotor by removing 3 bolts using 4) Remove starter motor by removing three bolts using
8mm spanner. 10mm spanner .

A c
B A

A) Stator plate B) Pickup coil C) Starter motor

Removal of clutch cover :

A) Bolt for fan
1) Remove the banjo using 16/10 mm spanner along
Removal of magneto rotor & stator plate : with washer.

1) Remove the magneto nut by holding it with rotor holder

special tool [42290028] using 19 mm socket spanner.

A
B

A) Starter motor nut B) Magneto nut

C) Magneto Removal of rotor nut.

2) Pull out the rotor with the help of rotor puller special tool
[42290027] .

28
ENGINE DISMANTLING
2) Remove oil filter cover by removing 3 nuts using 8 mm Remove of endurance clutch
spanner. Then remove filter element spring and 1 Remove rod push & Bearing from clutch housing.
gasket.
3) Remove cap and pull out the strainer.

A B
D

A C
B A) Rod Push B) Bearing
2) Loose 6 nos bolts gradually one after another end
remove holder clutch.
A) Oil filter cap B) Oil strainer cap 3) Take out spring clutch (6 nos).
C) Driven dog D) Clutch release outer
4) Loosen the bolt and remove the driven dog from kick
shaft.
5) Pull out clutch release outer along with rubber duct.
6) Now remove clutch cover by removing flanged bolts
using 8mm spanner.

4) Remove the hub clutch nut & washer clutch by using

special tool [42290026].

NOTE: For easy assembling mark the length of bolt on B

the body with marker .

A) Clutch nut B) Washer

5) Remove the hub clutch and Judder Spring and judder
plate.

7) Remove plunger oil spring mounted on crankshaft

end. C

A) Clutch hub B) Judder spring C) Judder plate

A

A) Plunger shaft spring

29
ENGINE DISMANTLING
6) Remove the reduce friction plate (1 nos), pressure plate Removal of primary gear from crank shaft :
(6 nos) & friction plate (6 nos). 1) Hold the primary gear with the help of special tool
[42290021].
C 2) Remove 22mm nut with wave washer from crankshaft end.
B 3) Remove the oil pump drive gear and pinion gear and
A carefully collect the 2 woodruff keys.

A) Reduce friction plate B) Pressure plate C) Friction

plate

7) Remove disc clutch pressure & gear assembly p r i m a r y

driven along with collar & washer.

A B
C

E
A) Disc clutch pressure B) Gear assembly primary gear
D

A) Crank shaft nut B) Wave washer

B C) Oil pump drive gear D) Pinion gear
E) Woodruff keys
A NOTE : Collar face of oil pump drive gear & pinion gear
should be face each other.

Removal of metallic guide chain :

1) Remove metallic chain guide using 8mm Spanner

A) Collar B) Washer and take out timing chain. Refit in reverse order of
dismantling.
Removal of oil pump :

1) Remove a long philips head screws and 2 short philips

head screw and separate the oil pump assembly
ensure that two o-ring & one dowel are there. Refit in
reverse order of dismantling.

Removal of guide cam chain :

1) Pull out the pin with the help of plier and remove the
guide cam chain (Tension side).

30
ENGINE DISMANTLING
.

B
A) Guide cam chain B) Pin giude Removal of flanged bolts from crankcase clutch side

Removal of gear shifter assembly :

1) Remove gear shifter cover using 7mm spanner.

Removal of bolts from c’case magneto side

2) Remove the spring pin using roll pin punch and mallet. 2) Remove crankshaft assembly by tapping it with a
mallet from crankcase magneto side along with rubber
pad.

3) Remove flange using 8 mm spanner. 3) Remove multiple gear shaft , main shaft and cluster
shaft & washers.

A B

Separation of crankcase : A) Main shaft B) Cluster shaft

1) Remove crankcase bolts (12 nos) using 8 mm spanner.

31
ENGINE DISMANTLING
Dismantling of main shaft : 5) Remove gear selector along with circlip.

1) Remove circlip using nose plier along with washer.

A
B
B A

A) Gear selector B) Circlip

A) Circlip B) Washer
6) Remove cross by rotating it then remove spacer.
2) Remove gears one by one from shaft.

A
B
4th gear

3rd gear
2nd gear

1st gear
3) Remove the ring along with steel ball & spring.
A) Cross B) Washer

7) The step the of cross always match with gear selector

groove side as shown in fig.
A

B
B
A) Ring B) C
Steel ball C) Spring

4) Remove the guide stem by unlocking the lock

washer using 11 mm spanner.(thread the guide stem
in anti- clock wise)
A) Gear selector groove B) Cross step

A B

A) Lock washer B) Guide stem

32
ENGINE DISMANTLING
Removal of differential cover : 5) Remove pin satellite gear.
1) Loosen 8 flange bolts using 8 mm spanner & remove 6) Remove satellite gear & bevel gear along with wave
differential cover. washer.
Note: Write the length of bolt on cover as shown.

C
B
D

A) Satellite gear B) Bevel gear

Dismantling differential unit : C) Wave washer D) Pin bevel gear
1) Remove differential unit from the engine.
Removal of reverse gear selector assembly :

1) Remove the idler gear along with washers.

2) Disconnect the tension spring with a plier.
3) Remove roll spring pin and reverse control lever.
A) Idle gear B) Washer C) Tension spring
D) Roll spring pin E) Reverse control lever

A C

D
2) Unlock the lock plate using chisel & mallet.
3) Remove the bolts using 13 mm socket spanner. B
A) Lock plate

4) Separate the final differential gear & remove the lock

pin.

A
B

A B

A) Differential gear B) Pin A) Reverse gear B) Reverse control lever

33
ENGINE REASSEMBLY

Engine re-assembly : ENGINE RE-ASSEMBLY

A
Reverse gear selector assembly re-assembly :
1) Insert reverse control lever & reverse gear.

B C

A
B A) Satellite gear B) Bevel gear
C) Wave washer D) Bevel gear pin(central pin)

2) Install lock pin using plier. Assemble the bevel gear and
differential gear.
A) Reverse control lever B) Reverse gear

2) Install spring roll pin with reverse lever.

A) Reverse control lever
A B

A) Lock pin B) Differential gear

3) Tighten the six bolts along with lock plate using 13mm
socket spanner with 2.6 kg.m torque & lock the lock
3) Install idler gear along with two washers then install plate using screw driver.
tension spring using plier.
A) Idle gear B) Washer
C) Tension spring D) Roll spring pin
A

A C

D
B
A) Lock plate

4) Now install differential unit in the gear box.

Differential unit re-assembly :

1) Install bevel gear & satellite gear along with washer

then install bevel gear pin.

A) Differential cage

Differential cover re-assembly :

1) Tighten 8 nos. flanged bolts using 8mm spanner with

0.9-1.1 kg.m torque & assemble the differential cover.

34
ENGINE REASSEMBLY
3) Assemble the guide stem along with lock washer using
11mm fix spanner and lock the washer with help of
screw driver.
NOTE: Guide stem threads is anti-clock wise
B

Main shaft re-assembly :

1) Insert the washer then insert the cross by

rotating it. A) Guide stem B) Lock washer
Note: Cross is having 2 side, one is flat & second one is
projection surface. Projection surface should be in 4) Insert the cup along with steel balls & springs.
inside the gear selector.

A
B

A
B
C

A) Ring B) Steel ball C) Spring

C 5) Assemble all gears along with washer and insert circlip

along with washer using plier.

4th gear

3rd gear
A) Washer B) Cross C) Gear selector 2nd gear
D) Cross projection surface
1st gear
2) Assemble gear selector along with circlips using plier.

A
B
B

A
A) Circlip B) Washer
A) Circlip B) Gear selector
6) Assemble the cluster shaft along with washer then
install the main shaft assembly.

35
ENGINE REASSEMBLY

A
B
C

A) Washer B) Cluster shaft assembly

C) Main shaft assembly MAGNETO SIDE

7) Install the crank shaft along with rubber pad. Gear shifter assembly re-assembly :

A 1) Assemble flange bolts using 8 mm spanner.

A) Rubber pad B) Crank shaft assy.

Crankcase clutch side cover re-assembly :

2) Assemble spring pin .
1) Tighten all 12nos. bolts of crank case cover using 8mm
T-spanner.

3) Assemble the gear shifter cover using 7mm spanner.

Guide cam chain re-assembly :

1) Assemble the guide cam chain by matching the hole.

CLUTCH SIDE

36