Service Manual Classic 500 & 350
SECTION ONE 01 INTRODUCTION
Foreword PREPARATION FOR SERVICE Good preparation is very important for carrying out correct service job. The motorcycle should be cleaned well before starting a repair job. Cleaning will occasionally uncover sources of trouble. Availability of tools, measuring instruments and parts should be ensured before commensing an overhaul, since Interruption to locate tools or parts can cause distraction and needless delay. Use of special tools will ensure a quality service.
Contents HOW TO USE YOUR SERVICE MANUAL Hydraulic Tappets (RHVL) Auto decompressor Electric starting system & sprag mech. Auto Chain Tensioner Assembly Engine breather System Inlet manifold & Throttle body Blow up Charts Pictorial presentation of various activities, make this manual easy to understand and user friendly. This service manual is divided into 10 Sections 01 to 10. Page numbers for each section starts with 01. Thus, page 05-10 indicates 10th page of section 5.
Contents SECTION EIGHT 08 CHASSIS, WHEELS & BRAKES - Maintenance Spark plug maintenance & Inspecton Checking procedure of electrical components: Torque Specification - Chassis Front wheel removal & reassembly - Starter coil - Pulsar coil - Ignition coil - Suppressor Cap - Battery - Horn - Relay starter - E-Starter motor - IC Flasher - RR Unit Electrical parts Inspection - Clutch switch - Starter switch Do’s and Dont’s Disc brake - General instruction - Overhauling caliper & master Cyl.
SECTION TWO 02 GENERAL
Salient Features of the Unit Construction Engine & Engine Management System UNIT CONSTRUCTION ENGINE ELECTRONIC FUEL INJECTION SYSTEM • HIGH TORQUE ENGINE • • ENHANCED POWER DELIVERY IMPROVED ACCELERATION HIGH SPEED CRUISING • HYDRAULIC TAPPETS • EXCELLENT COLD STARTING ABILITY • AUTO DECOMPRESSOR • • AUTO CHAIN TENSIONER FOR PRIMARY CHAIN • HIGH CAPACITY TRACHOIDAL OIL PUMP FOR BETTER LUBRICATION ACCURATELY CONTROLLED, AIR FUEL MIXTURE & IGNITION TIMING BY THE ENGINE CONTROL UNIT • IMP
Basic Terminology of IC Engines ENGINE : The Engine converts Chemical energy availbale in petrol into heat energy then to mechanical energy for motion. It is the powerplant of the vehicle where the power is generated for moving the vehicle. Fuel Power Air BORE : Bore is the inside diameter of the cyclinder block in which Piston moves up and down. TDC : TDC stands for Top Dead Center. It is the top most position to which the piston can travel in the cylinder barrel.
Basic Terminology of IC Engines TOTAL VOLUME : It is the sum of the swept voume (Displacement volume) and Clearance volume. Total Volume = Swept volume + Clerance volume. COMPRESSION RATIO : It is a ratio between total volume in the engine to the clearance volume available at the end of compression stroke.
Basic Terminology of IC Engines IHP : IHP stands for Indicated Horse Power. Indicated Horse Power is the power actually developed inside the engine cylinder by combustion process. It is utilised to drive the piston. FHP : FHP stands for Frictionl Horse Power. It is the amount of horse power used or lost to overcome the friction between various moving components of the engine.
Basic Terminology of IC Engines IGNITION TIMING : Ignition timing is the timing in degrees of rotation of crank shaft at which spark commences so that the spark from the spark plug can ignite the mixture in the combusion chamber at the end of TDC during compression stroke. TDC Position Ignition Timing If spark occurs earlier than specified ignition timing, it is called “Advance” timing. If spark occurs after the specified ignition timing, it is called “Retard” timing.
Technical Specifications A. ENGINE AND ENGINE SYSTEMS CLASSIC 500 CLASSIC 350 1. Engine Type 4 Stroke Single Cyl., Air cooled 4 Stroke Single Cyl. Air cooled 2. Bore 84mm 70mm 3. Stroke 90mm 90mm 4. Displacement 499cc 346cc 5. Compression ratio 8.5:1 8.5:1 6. Max Power @ rpm 27.2 HP @ 5250 rpm 19.6 HP @ 5250 rpm 7. Max Torque @ rpm 41.3 Nm @ 4500 rpm 28 Nm @ 4000 rpm 8. Idle rpm 1050 ± 200 rpm 1050 ± 200 rpm 9. Starting Kick & Electric Start Kick & Electric Start 10.
Technical Specifications C. CHASSIS CLASSIC 500 CLASSIC 350 1. Frame Tubular Tubular 2. Front Suspension Telescopic, hydraulic damping, Stroke 130 mm Telescopic, hyd. damping, Stroke 130 mm 3. Rear Suspension Swing arm with gas shock absorbers Swing arm with gas shock absorbers 4. Fr. Fork oil capacity 195 cc per leg 195 cc per leg 5. Front fork oil 1F Endurance Fork Oil 1F Endurance Fork Oil 6.
Technical Specifications 4. Spark plug - primary Mico - WR7 DDC 4 Mico - WR5DC 5. Spark plug - secondary Super Bosch UR5DC Super Bosch UR5DC 6. Spark plug gap 0.7 to 0.8 mm 0.7 to 0.8 mm 7. Head lamp 12V, 60/55w 12V, 60/55w 8. Tail / Brake Lamp 12V 5 / 21W 12V 5 / 21W 9. Speedometer lamp 12V, 3.4W 12V, 3.4W 10. Hi beam indicator 12V, 2W 12V, 2W 11. Neutral lamp Tell tale 12V, 2W 12V, 2W 12. Turn Signal Tell Tale 12V, 2W 12V, 2W 13. Turn signal 12V, 10W 12V, 10W 14.
02-10 Production Sl. No. Month Manufacturing Year of Manufacturing Dummy No Type of Fuel Feed Type of Transmission Type of Start Swept Volume Type of Engine Manufacture’s Code ME3 X X X X X O 9 A 00001 Production Sl. No. Month Manufacturing Year of Manufacturing Dummy No Type of Fuel Feed Type of Transmission Type of Start Swept Volume Type of Engine U 3 S 5 C O 9 A 00001 The engine number is punched on the left hand side Crankcase - below the Cylinder barrel.
List of Special Tools & Its Application SL. NO. PART NO. DESCRIPTION APPLICATION 1 ST-25118 - 4 Cylinder head nut tightening tool To remove and tightening of cylinder head nut. 2 ST-25123 - 1 Valve spring compressor To compress the valve spring for removal and fitting of valve. 3 ST-25612-4 Rotor tightening & loosening tool To hold magneto rotor while loosening magneto nut. 4 ST-25128 - 2 Puller for magneto rotor Removal of magneto rotor assy.
List of Special Tools & Its Application ST-25118-4 Cylinder head nut tightening tool Application : To remove and tightening of cylinder head nut. ST-25123-1 Valve spring compressor Application : To compress the valve spring for removal and fitting of valve. ST-25612-4 Rotor tightening & loosening Tool Application: To hold magneto rotor while loosening of magneto nut. ST-25128-2 Puller Magneto (Rotor Extractor) Application : Removal of magneto rotor assy.
List of Special Tools & Its Application ST-25592-4 Application : To hold the connecting rod in its top position. Connecting rod locking tool ST-25151-4 Puller for chain case outer Application :To remove Crank case LH cover. ST-25591-4 Sprocket & clutch tightening tool Application : To hold Clutch housing & sprag sprocket while dismantling / tightening the Clutch & Sprag Sprocket bolt.
List of Special Tools & Its Application ST-25153-4 Extractor for Gear box rocker pivot pin ST-25835-2 FD sprocket removing tool ST-25834-2 Front fork Dismantling tool Application : To remove gear rocker shaft spring top pivot pin and gear cam plate pivot pin. Application : To remove front drive sprocket from Sleeve Gear. Application : To hold pipe seat of front fork while dismantling & tightening of front fork main tube with bottom case (fork end assy.).
List of Special Tools & Its Application ST-25113-4 Application : Fitment of oil seal into front fork bottom case. Mandrel for oil seal ST-25112-4 Expander for front fork oil seal Application : Expanding the oil seal lip while inserting main tube into bottom case of front fork ST-25110-3 Gauge plate for tightening chain stay Application : Alignment of Swing Arm while mounting / tightening into chassis. ST-25244-4 Application :To adjust gas filled shock absorber spring load.
CONTROL CABLES AND WIRING HARNESS ROUTING Control Cables & Wiring Harness Routing UNDER TANK AND SEAT TOP VIEW UNDER TANK LH VIEW UNDER TANK RH VIEW 02-16
General Vehicle Information HARNESS ROUTING STEERING RH MAGNETO WIRES ROUTING PLUG WIRE ROUTING STARTER RELAY CABLE ROUTING 02-17
General Vehicle Information HANDLE BAR INSTRUMENT PANEL & CABLE ROUTING HORN WIRE ROUTING FUSE CARRIERS ARRANGEMENT (CLASSIC 500) FUSE CARRIERS ARRANGEMENT (CLASSIC 350) 02-18
General Vehicle Information THROTTLE BODY MOUNTING TAIL LAMP & TRAFFICATOR WIRES ROUTING ECU MOUNTING (CLASSIC 500) TCI UNIT MOUNTING (CLASSIC 350) 02-19
SECTION THREE 03 SERVICE DATA
Service Limits of Components (All units in mm unless specified) WEAR LIMITS Wear limits are given as new min, new max and service limits. New components must be within the limits specified. Components within service limits may be reused after careful inspection. Use of parts beyond service limit can reduce the operating life of the component and may affect the motorcycle performance seriously. Cylinder bore Ring to groove clearance : Comp.
Service Limits of Components (All units in mm unless specified) Piston Pin diameter Piston ring end gap : compression Classic 500 Classic 350 From top 1st 2nd 1st New Min. 0.20 0.35 0.15 0.20 New Max. 0.35 0.50 0.3 0.4 Service Limit 0.70 0.85 0.6 0.7 Classic 500 Classic 350 2nd New Min. 19.992 19.992 New Max. 19.997 19.997 Service Limit 19.982 19.982 Piston ring end gap - Oil Ring Big end axial play Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.20 0.20 New Min.
Service Limits of Components (All units in mm unless specified) Valve stem OD (Inlet) Connecting rod bend Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.00 0.00 New Min. 6.965 6.965 New Max. 0.05 0.05 New Max. 6.980 6.980 Service Limit 0.08 0.08 Service Limit 6.955 6.955 Cylinder Head warpage Valve to guide (inlet) clearance Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.00 0.00 New Min. 0.02 0.02 New Max. 0.05 0.05 New Max. 0.05 0.
Service Limits of Components (All units in mm unless specified) Valve to guide (Exhaust) Clearance Hydraulic Tappet OD Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.04 0.04 New Min. 21.387 21.387 New Max. 0.07 0.07 New Max. 21.405 21.405 Service Limit 1.00 1.00 Service Limit 21.380 21.380 Valve Spring : length Hydraulic Tappet guide bore Classic 500 Classic 350 Classic 500 Classic 350 New Min. 42.80 42.80 New Min. 21.417 21.417 New Max. 44.80 44.80 New Max.
Service Limits of Components (All units in mm unless specified) Selector fork shaft outer diameter Main shaft Outer diameter B A Classic 500 Classic 350 Location A B A Classic 500 Classic 350 B New Min. 19.99 23.93 19.99 23.93 New Max. 20.00 23.95 20.00 23.95 Service Limit 19.97 23.90 19.97 23.90 New Min. 9.96 9.96 New Max. 9.98 9.98 Service Limit 9.94 9.
Service Limits of Components (All units in mm unless specified) Lay shaft 1st gear inner diameter Pivot cam plate outside diameter Classic 500 Classic 350 Classic 500 Classic 350 New Min. 18.03 18.03 New Min. 12.98 12.98 New Max. 18.06 18.06 New Max. 13.00 13.00 Service Limit 18.09 18.09 Service Limit 12.96 12.96 Lay shaft 2nd gear inner diameter Clutch spring Length Classic 500 Classic 350 Classic 500 Classic 350 New Min. 24.00 24.00 New Min. 64.5 64.5 New Max. 24.03 24.
Service Limits of Components (All units in mm unless specified) Clutch steel plate : Distortion Throttle cable free play Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.00 0.00 New Min. - - New Max. 0.05 0.05 New Max. 1 mm 1 mm Service Limit 0.10 0.10 Service Limit 2 mm 2 mm Duplex Chain - Length across 21 pins Drive chain : slackness Classic 500 Classic 350 Classic 500 Classic 350 New Min. 190.00 190.00 New Min. 20.00 20.00 New Max. 191.00 191.00 New Max. 30.
Service Limits of Components (All units in mm unless specified) Brake drum rear : Internal dia. Sprocket REPLACE GOOD Classic 500 Classic 350 Classic 500 Classic 350 New Min. New Max. Service Limit Sharp, bend broken teeth New Min. 152.40 152.40 New Max. 152.50 152.50 Service Limit 153.50 153.50 Drive chain length across 21 pins Wheel rim: Face out / Run out Classic 500 Classic 350 Classic 500 Classic 350 New Min. 320 320 New Min. 0 0 New Max. 322 322 New Max. 1.0 mm 1.
Service Limits of Components (All units in mm unless specified) Caliper Piston Outer Diameter Main tube - run out OD Classic 500 Classic 350 Classic 500 Classic 350 New Min. 0.00 0.00 New Min. - - New Max. - - New Max. - - Service Limit 0.04 0.04 Service Limit 25.31mm 25.31mm Front fork assembly spring : length Master Cylinder piston OD Classic 500 Classic 350 Classic 500 Classic 350 New Min. 538 538 New Min. - - New Max. 544 544 New Max.
Service Limits of Components (All units in mm unless specified) Tyre tread : Depth Swing Arm bush & spacer SPACER Classic 500 Classic 350 New Min. - - New Max. - - Service Limit 1.00 mm 1.00 mm O.D. I.D. Classic 500 Classic 350 Location Spark Plug Gap Classic 500 Classic 350 New Min. 0.7 0.7 New Max. 0.8 0.8 Service Limit - - 03-11 Bush Spacer Bush Spacer after I.D after I.D reaming reaming I.D. I.D. New Min. 18.9 18.7 18.9 18.7 New Max. 19.0 18.8 19.0 18.
Periodical Maintenance The maintenance schedule detailed here will help you maintain your Classic Motorcycles meticulously and to get a long trouble free service. The schedule provided herein is based upon average riding conditions and indicates the Kms at which regular inspections, adjustments, replacements and lubrications are to be carried out.
Periodical Maintenance AIRFILTER CLEANING ✰ Open filter box cover RH ✰ Remove centre mounting nut ✰ Take out the air filter element ✰ Tap off the dirt ✰ Check and set electrode gap to 0.7 to 0.8 mm. ✰ Refit the spark plug and connect the H.T. lead NOTE : A serviceable spark plug produces thick light blue spark across the electrode. If spark plug produces yellow / red, side sparks, replace it with new. ENGINE OIL OIL LEVEL CHECK ✰ ✰ Blow compressed air from outside to inside.
✰ Two level marks are provided on the Oil level window in Cover RH Max. & Min. ✰ If oil level is below the Min mark top up, till the level in between Max and Min mark. Do not overfill. TILT VEHICLE RH & LH Periodical Maintenance NOTE : Oil capacity Min to Max mark is approx 350 ml. ✰ Max Min After the oil drains out, remove vehicle from centre stand and tilt the vehicle to both LH and RH sides 3 to 4 times to drain out maximum oil. ✰ Quantity of oil that can be drained in 2.
Periodical Maintenance ✰ Assemble cleaned suction filter element in to Crank case and fix suction filter cap with “O” ring. ✰ Fill up with 15W50 API, SL grade, MOTUL 3000 4T Plus engine oil. ✰ Refil oil quantity 2.40 Litres. ✰ Check the oil level. ✰ Oil level should be up to “MAX” level. ✰ Loosen anchor nut.
Periodical Maintenance ✰ Turn the adjuster cams on both sides till 25 to 30 mm chain slackness is achieved BRAKE PEDAL PLAY ADJUSTMENT PEDAL FREE PLAY 20 TO 30 MM ✰ Check and ensure that the number of notches from the punch mark on the cam to the notch resting on the pin are equal on both sides. ✰ Rotate the wheel and apply brake and tighten all the nuts and lock the split pin.
Periodical Maintenance ✰ Using special tool, place it on the slot provided on the adjuster. ✰ Turn the adjuster such that the adjuster moves up to increase the spring preload and vice versa to reduce the spring preload. NOTE : Always re-check after adjustment of brake pedal level and free play. REAR SHOCK ABSORBERS ADJUSTMENT ✰ The rear shock absorber spring preload can be increased or reduced according to road and load conditions. CAUTION Adjust both left and right shock absorbers to the same notch.
Periodical Maintenance ✰ Top up, with 1F Endurance Fork Oil or equivalent, if required ✰ To Top up the fluid, remove the master cylinder top cover 2 screws and take out cover, plate & diaphragm. ✰ Top up brake Fluid DOT 3 or DOT 4 upto “MAX” level. B. OIL CHANGE (EVERY 12,000 KMS) ✰ Remove the fork ends from the vehicle. ✰ Check as detailed in the Section 8 CAUTION : As the brake fluid is highly corrosive, take care that it does not spill over other parts.
Periodical Maintenance B A ✰ Tighten stem lock nut as shown picture ‘B’ ✰ Check play. ✰ Steering to be free with out any play. ✰ Tighten all the screws in reverse order. ✰ Pack grease in the top ball race. ✰ Assemble the steering stem. CLUTCH CABLE FREE PLAY : (2-3MM) LEVER END ✰ Check clutch cable button seating position inside lever and condition of the cable. ✰ Screw in or out the cable adjuster for setting the required play at lever end (2 to 3 mm).
Periodical Maintenance ✰ (B ) ADJUSTMENT AT THROTTLE BODY END (CLASSIC 500) After adjustment refix cable boot. PRIMARY CHAIN TENSION ADJUSTMENT ✰ This vehicle is fitted with Auto chain tensioner. Hence there is no need for periodic manual adjustment. ✰ Loosen the lock nuts on both the cables. ✰ Adjust both cables unitform and tighten the lock nuts.
Periodical Maintenance C A B 2 to 3m m (C) REPLACEMENT PROCEDURE OF THROTTLE POSITION SWITCH (TPS) ASSY. Slide the rubber boot, use 10 mm spanner to adjust cable outer and lock the nut. Move the rubber boot over the lock nuts. While replacing TPS assy. following steps are important to achive ignition timing changing shall take place at 40% of throttle opening to obtain more mileage and reduced emissions.
Periodical Maintenance X SLOT POSITION CAUTION : Y After adjustment of free play, please ensure that throttle pully being rested on the idling screw. Other wise engine speed increases erratically. NOTE : After TPS cable / switch fitment, please ensure that cable lock nuts (A, B, C) & mounting screws (X, Y) are being tightened. THROTTLE CABLE ASSY REPLACEMENT (CLASSIC 350) (D) ADJUSTMENT OF INNER CABLE FREE PLAY AT CARBURETOR ✰ Loosen the lock nut in throttle cable to adjust free play up to 1 mm.
Periodical Maintenance FLOAT HEIGHT ADJUSTMENT ✰ Remove the float chamber body and “O” ring. ✰ Hold the mixing chamber body in inverted position as shown in Fig. ✰ ✰ ✰ ✰ Hold the float so that its tongue just contacts the spring loaded plunger of the float needle valve. With a Vernier Caliper, measure the height from the mixing chamber body face to top of the float is 17.1 mm(as shown in Fig.) NOTE : After adjustment of float height, please ensure free movement of float in its pivot pin.
Periodical Maintenance ✰ Switch “OFF” Ignition and engine stop switch condition. repeat the procedure as explained in the step-A. ✰ If compression pressure does not increase, then check for - blown out cylinder head gasket - improper torque of Rocker bearing bolts or cylinder head nuts. - valve seat - damage / leakage - valvestem bend - cylinder head warpage ✰ Hold the throttle open fully and kick several times (5 to 6 times). ✰ Note down the reading and repeat the above process 3 times.
Periodical Maintenance ✰ ✰ Remove the piston rings carefully. For cleaning the groove in the piston, a piece of broken piston ring thrust into a wooden handle and filed to a chisel point can be used. Standard : 0.9 - 1.1 mm Service Limit : 1.5 mm CYLINDER HEAD AND VALVES ✰ VALVE SEAT INSPECTION ✰ The seat contact should be within the specified width and should be even all around the circumference Valve seat width is not within specification, reface the valve seat.
Periodical Maintenance ✰ Contact area is too high or too low. re-face the valve seat. VALVE SEAT REFACING ✰ ✰ ✰ Valve Seat cutters, a grinder or equivalent valve seat refacing equipment are recommended to correct worn valve seat. ✰ Use a 45 degree cutter to remove the roughness or irregularities from the seat. ✰ Using 32 degree cutter, remove top 1/4 of the existing valve seat material. ✰ Using 60 degree cutter, remove the bottom 1/4 of the old seat. ✰ Remove the cutter and inspect the area.
Periodical Maintenance ✰ After cutting the seat, apply lapping compound to the valve face and lap the valve applying light pressure. NOTE : Excessive lapping pressure may deform or damage the seat. Change the angle of lapping tool frequently to prevent uneven seat wear. Lapping compound can cause damage if it enters between the valve stem and guide. ✰ After lapping, wash any residual compound off the cylinder head and valve. ✰ Recheck the seat contact after lapping.
Periodical Maintenance VALVE TIMING CUM ECCENTRIC CAM SPINDLE Bring piston to TDC so that the key way in the Rotor assembly is at 12 O’ Clock position. Check position of the exhaust cam teeth between two punch marks with punch mark on the Fly wheel RH shaft timing gear. ✰ Ensure to hold the eccentric sleeve by spanner while tightening the lock nut which prevent the rotation of the sleeve during tightening the lock nut.
Periodical Maintenance ✰ Over size Cam Spindle (For Spares) 570040 : 0.1 mm Over size Spindle 570041 : 0.2 mm Over Size Spindle CAUTION : - - During first service, the backlash between the cam gears must be checked. If not with in the desirable limit and if a slight cam noise is observed, then further adjustment of the eccentric sleeve has to be carried out as mentioned above.
SECTION FOUR 04 ENGINE
Engine Lubrication System 04-2
Lubrication System ROCKER PUSH ROD FLY HYDRAULIC OIL PUMP CAM STRAINER CRANK OIL SUMP LUBRICATION SYSTEM : Oil from the oil tank is circulated to various parts through a powerful oil pump. The oil in the sump gets filtered through an oill strainer located in the crankcase and then pumped into the oil filter element located in the RH Cover. From here oil is circulated to 3 main areas. The first branch goes to flywheel to lubricate crank shaft as well as barrel piston assembly.
Lubrication System OIL PUMP : TROCHOID TYPE Trichoidal high flow oil pump delivers oil with a pressure of 4.5 Bar. This provides good lubrication to all the moving parts and enhances the life of the moving parts in the engine. CLASSIC 350 CLASSIC 500 Output : 4.
Hydraulic Tappets (Roller Hydaulic Valve Lifter (RHVL) WHAT IS HYDRAULIC TAPPET : Hydraulic tappet (also called RHVL Roller Hydraulic Valve Lifter) is the element connects between cam profile to push rod and it operates with aid of the hydraulic pressure to eliminate the clearance and noise between valve train parts. BENEFIT OF HYDRAULIC TAPPET : 1. 2. Roller follower on cam with hydraulic tappet avoid sliding motion and friction, provides improved tappet and cam life.
Hydraulic Tappets (Roller Hydaulic Valve Lifter (RHVL) WORKING PRINCIPLE : The overhead oil supply is accurately metered from the “low pressure chamber”, which is at engine oil pressure, by using a flat metal disk (metering valve C, in Figure), which wobbles against a cylindrical radius curved surface on the bottom of the push rod seat (D, in Figure). Oil then flows up through the hole in the push rod seat to lubricate the overhead valve train components (oil flow path B, in Figure).
Auto Decompressor AUTO DECOMPRESSOR - WORKING PRINCIPLE a. The Flyweight type decompressor consists of a flyweight mechanism mounted on the cam gear exhaust. b. When the engine is cranking below a certain speed (350 rpm approx.), a pin rotates to protrude above the base circle of the exhaust cam. c. The pin momentorily open the exhaust valve on the compression stroke, lowering the pressure in the cylinder head combustion chamber thus leading to freeness when starting engine.
Electric Starting System & Sprag Mechanism WORKING PRINCIPLE The sprag is located in the primary sprocket on the crankcase drive side. This provides better rigidity of the sprag mechanism during initial cranking. The auto decompressor mechanism further helps in reducing the load on the sprag during intitial cranking and also prevents reversal phenomenon of the crank shaft.
Auto Chain Tensioner Assembly WORKING PRINCIPLE The auto chain tensioner has a spring loaded plunger mechanism with a ratchet arrangement. It eliminates need for manual adjustment of the primary chain tension. It is assembled on the crankcase LH below the chain tensioner pad. The spring loaded plunger applies force on the chain tensioner pad thereby lifting it and holding aginst the primary chain to the required tension.
Engine Breather System Breather arrangement inside the RH cover WORKING PRINCIPLE The engine breather system is located on the RH cover of the crankcase. A connecting hole directs the engine breathing into a chamber in the RH cover which has an inbuilt deflector to deflect the oil that may come along with the fumes from the crankcase. This oil gets drained through a small hole provided at the bottom of the breather chamber.
Inlet Manifold & Throttle Body The inlet manifold has the fuel injector located on top portion and the throttle body attach to it. The throttle body has a butterfly valve attached which is operated by the throttle cables attached to a small drum on the right side. A manual Bi starter is located on the left side and is operated with spring and plunger type arrangement. An idle air bypass screw is provided on the throttle body.
Crankcase RH - Coverside View 04-12 A1 A3 Key No’s 7,8,9,10,11 Key No’s 22,23,26,63,64,65 A2 A4 Key No’s 22,23,24,25,26,27 Key No’s 50,51,52
Crankcase RH - Coverside View Key No. A1 A2 A3 A4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Description CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY. OIL PUMP ASSEMBLY - 500CC OIL PUMP ASSEMBLY - 350CC GEAR CHANGER ASSEMBLY CAM STEADY PLATE DOWEL 6 MM HEX. SOCKET HEAD CAP SCREW, M6 X 30 HEX.
Crankcase LH - Inside View 04-14
CRANK CASE LH Crankcase LH - Inside View Key No. Description Qty. A1 CAM GEAR ASSEMBLY-EXHAUST WITH DECOMPRESSOR ASSY. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 FLANGE HEX NUT - M8 X 1.
Crankcase RH - Inside View 04-16
CRANK CASE RH - INSIDE VIEW Crankcase RH - Inside View Key No. 1 Description Qty. Key No. HYDRAULIC VALVE LIFTER ROLLER 2 2 BEARING NRB 1 3 DEEP GROOVE BALL BEARINGSLEEVE GEAR 1 4 CIRCLIP 6.2 X 2N 1 5 NEEDLE BEARING 1 6 WASHER, THRUST 1 7 CRANK SHAFT ASSEMBLY 1 8 OIL DRAIN BOLT WITH MAGNET 1 9 SLEEVE GEAR 1 10 NEEDLE BEARING 1 11 NEEDLE BEARING 1 12 NEEDLE ROLLER 2 13 BRACKET - PIN - HYDRAULIC TAPPET 1 HEX.
Engine Cover RH 04-18
Engine Cover RH Key No. Description Qty. Key No. A1 RH COVER SUB ASSEMBLY Description Qty. 1 22 HEX. FLANGE BOLT, M6 X 1 X 85 2 1 COVER RH 1 23 OIL LEVEL WINDOW 1 2 GASKET, COVER PLATE 1 24 WASHER, INSPECTION SCREW 1 3 COVER PLATE, BREATHER CHAMBER 25 1 INSPECTION SCREW, IGNITION TIMING 1 4 HEX.
Crankcase LH - Coverside View 04-20
Crankcase LH - Coverside View Key No. Description Qty. Key No. A1 SPRAG CLUTCH ASSEMBLY Description 1 22 STUD M6 X 106 Qty. 1 1 HEX. HEAD SCREW 1 23 NUT M6X1, FLANGE NYLOC TYPE 20 2 WASHER 1 24 STUD M6 X 168 1 3 ENGINE SPROCKET 1 25 STUD M6 X 196 2 4 NEEDLE BEARING 1 26 PRIMARY CHAIN 1 5 DISTANCE WASHER, SPRAG CLUTCH 27 1 HEX.
Engine Cover LH 04-22
Engine Cover LH Key No. Description Qty. A1 LH COVER SUB ASSEMBLY 1 A2 CLUTCH OPERATING LEVER 1 1 COVER, LH 1 2 HEX.
Gear Train Assembly 04-24
Gear Train Assembly Key No. Description Qty. A1 LAY SHAFT SUB ASSEMBLY 1 A2 MAIN SHAFT SUB ASSEMBLY 1 1 MAIN SHAFT 1 2 MAIN SHAFT 2ND GEAR 1 3 WASHER, THRUST 3 4 MAIN SHAFT 4TH GEAR ASSEMBLY 1 5 CIRCLIP 1 6 MAIN SHAFT 3RD GEAR ASSEMBLY 1 7 MAIN SHAFT 1ST GEAR 1 8 LAY SHAFT 1 9 LAY SHAFT 2ND GEAR ASSY.
Gear Shifting / Kick Starter 5 04-26
Gear Shifting / Kick Starter Key No. Description Qty. 1 SS ROCKER SHAFT ASSEMBLY, 1 2 PIN PIVOT 1 3 STRIKER, GEAR CHANGE 1 4 SPRING 1 5 SPRING, GEAR CHANGE STRIKER 1 6 SPACER 1 7 PIVOT BEARING, ROCKER SHAFT UPPER 1 8 HEX. SOCKET HEAD CAP SCREW, M6 X 12 2 9 PIVOT BEARING, ROCKER SHAFT BOTTOM 1 10 ASSEMBLY, GEAR LEVER SHAFT 1 11 STOP PIN 1 12 O-RING 1 13 HEX. SOCKET HEAD CAP SCREW, M5 X 40 2 Key No. A1 Description Qty.
Cylinder Head, Barrel, Piston & Crankshaft A1 Key No’s 7,8,9,10,11 A2 Key No’s 29,39 PISTON ASSY. CRANK SHAFT ASSY.
Cylinder Head, Barrel, Piston & Crankshaft Key No. Description Qty. Key No. A1 CYLINDER HEAD ASSEMBLY 1 A2 CYLINDER PISTON ASSEMBLY 1 CYL. HEAD SUB ASSY. (CYL. HEAD, VALVE GUIDE, VALVE SEATS) 1 1 2 SPARK PLUG - M 14 1 3 DOWEL (6 MM) 8 4 SEAT, SPRING 2 5 VALVE STEM SEAL 2 6 VALVE SPRING 2 7 RETAINER, SPRING 2 8 SPLIT COLLAR 4 9 ROCKER BEARING SET-EXHAUST 1 10 ROCKER ARM, EXHAUST 1 11 ROCKER ARM - INLET 1 12 ROCKER BEARING SET-INLET 1 13 HEX.
Damper Pad Position Details NUMBER OF DAMPER PADS PER ENGINE = 15 570482/b INLET SIDE VIEW 570479/b 570478/b 570482/b 570480/b Part No. Description Quantity per engine 570478/b Damper padcylinder head LH 2 Damper padcylinder head RH 4 570479/b Image EXHAUST SIDE VIEW 570479/b 570479/b 570482/b 570482/b 570480/b Part No.
SECTION FIVE 05 ENGINE DISMANTLING INSPECTION & ASSEMBLY
Engine Dismantling, Inspection & Assembly ENGINE DISASSEMBLY COMPONENTS THAT CAN BE REMOVED WITHOUT REMOVING THE ENGINE FROM FRAME.
Engine Dismantling, Inspection & Assembly DISMANTLING PROCEDURE CAUTION : ✰ Disconnect fuel hose. Take care to ensure fuel does not spill. ✰ Disconnect fuel pump module and low fuel sensor couplers. Keep a cloth on the front end of the fuel tank, (below the handle bar clamp) to avoid damage to the fuel tank while removing. ✰ Remove the front and rear flange nuts, washer at the front & rear mounting of the fuel tank. ✰ Lift the tank from the seat side & remove.
Engine Dismantling, Inspection & Assembly ✰ REMOVAL OF THROTTLE CABLE Disconnect the cable from the lever. ✰ Slacken the adjusters at the throttle body end for both cables. CLUTCH CABLE REMOVAL ✰ Slacken the adjuster at the clutch cover end and disconnect the cable from the lever. ✰ Take out clutch cable from the cover. ✰ Remove the clutch cable from the clutch lever at handle bar end. REMOVAL OF THROTTLE BODY 05-4 ✰ Loosen the throttle body flange & bellow clip.
Engine Dismantling, Inspection & Assembly REMOVAL OF SILENCER AND EXHAUST PIPE ✰ ✰ ✰ Remove the flange nut 2 nos. from cylinder head. ✰ Remove the Silencer Assembly with Exhaust pipe. ✰ Remove the Suppressor Cap Remove the centre silencer bracket mounting screw with plain washer. Remove the rear mounting at the pillion foot rest end BATTERY REMOVAL NOTE : Loosen the rear brake rod adjuster nut so that the brake pedal can be depressed to allow the exhaust pipe to be removed.
Engine Dismantling, Inspection & Assembly ✰ ✰ Remove the terminal nut & take out the terminal wire lead. ✰ Remove the 2 mounting allen screws. Always remove earth wire terminal first. ✰ Lift the motor upwards and pull out of the housing in the front. REMOVAL OF E-START MOTOR ✰ Remove 4 screws of the starter drive housing and tap gently to free the housing. ✰ Gently lift the motor and remove the motor along with the housing. Remove the 2 dowels for the housing drive.
Engine Dismantling, Inspection & Assembly REMOVAL OF DRIVE CHAIN ✰ Rotate the rear wheel to bring the chain lock to a convenient position and remove the chain lock. ✰ Remove the chain link and the drive chain. REMOVAL OF SIDE STAND ✰ Disconnect the rear brake switch coupler from the wiring harness ✰ Slacken the nyloc nuts & remove the brake light switch.
Engine Dismantling, Inspection & Assembly ENGINE OIL DRAIN CYLINDER HEAD ASSEMBLY Always best to drain the engine oil in warm condition. ✰ Remove the 4 allen screws along with rubber seals from Inlet and exhaust rocker covers. ✰ Remove the Inlet & Exhaust Rocker cover, dowel & rubber gasket. ✰ Remove the 4 allen screws each on the rocker bearing inlet & exhaust. ✰ Remove the inlet and exhaust rocker bearing with dowel and rocker arm. ✰ Remove the 2 Flanged hex bolts.
Engine Dismantling, Inspection & Assembly ✰ ✰ Remove inlet and exhaust pushrods ✰ Remove the Cylinder head assy. ✰ Remove the multi layer steel (MLS) head gasket. Remove the Spark plug REMOVAL OF VALVES ✰ ✰ Remove the 6 flanged hex nuts, securing the cylinder head. 05-9 Remove the Inlet & Exhaust valves by using special tool No.
Engine Dismantling, Inspection & Assembly ✰ ✰ CYLINDER BARREL SUB ASSY. Remove the Inlet Valve spring retainer, split collar and Spring. ✰ Gently tap Cylinder barrel and remove along with 2 dowel pins. Remove Inlet Valve as shown NOTE : Ensure piston is at TDC. ✰ Remove gudgeon pin and piston. NOTE: Similarly follow the same process to remove Exhaust Valve. ✰ NOTE : Carefully remove the piston pin clip from the piston while covering Crank case neck with a shop towel, as shown.
Engine Dismantling, Inspection & Assembly NOTE : Carefully remove the piston rings from the piston without deforming. ✰ Remove Cylinder barrel bottom Gasket. ✰ ✰ Remove oil filter cover bolts. ✰ Remove oil filter cap, “O”ring & Spring. Use Special tool No. ST - 25592-4 to hold connecting rod as shown Fig. CAUTION : Care must be taken while removing cover due to spring force. REMOVAL OF COVER RH SUB ASSEMBLY : ✰ ✰ Remove kickstarter lever.
Engine Dismantling, Inspection & Assembly ✰ ✰ Remove the 11 bolts securing cover RH. Gently tap & pull out the cover evenly It may be necessary to tap the cover slightly to remove since the magnetic forces in the rotor can be acting on the stator and making it difficult to remove ✰ Remove RH cover gasket & 2 dowels. ✰ Remove Pulser coil by removing 2 screws ✰ Remove Stator assembly removing 3 mounting screws.
Engine Dismantling, Inspection & Assembly ✰ Remove circlip, oil seal and jet crankshaft NOTE : This Oil seal is recommended to be replaced at every 20,000 kms interval. ✰ Remove oil filler cap and “O” ring ✰ Remove Ignition Timing check bolt and washer (if not removed earlier). 05-13 ✰ Remove Breather bolt and washer ✰ Remove 6 Nos.
Engine Dismantling, Inspection & Assembly ✰ Remove the 2 oil seals from the Kick Shaft hole ✰ Remove the 3 allen screws & 2 dowels from Cam steady plate. ✰ Remove Cam steady plate and the shims. INSIDE OIL SEAL OUTSIDE OIL SEAL COMPONENTS FOR DISMANTLING FROM CRANKCASE RH REMOVAL OF ROTOR ASSEMBLY ✰ ✰ Loosen and remove magneto lock nut and plain washer. Ensure the connecting rod is locked properly with the special tool resting firmly and evenly on the crankcase top position.
Engine Dismantling, Inspection & Assembly ✰ Remove oil pump plastic gear after removing circlip. Observe short boss of pump drive gear should face outwards in case of 350cc and long face should face outwards in case of 500cc ✰ Exhaust cam decompressor. with auto DISMANTLING PROCEDURE OF AUTO DECOMPRESSOR ✰ ✰ ✰ Remove mounting allen screw on flyweight sub assembly. ✰ Remove flyweight along with return spring over actuating pin lever as shown in Fig. Remove Cam gear inlet.
Engine Dismantling, Inspection & Assembly ✰ Remove the actuating pin in the Exhaust cam. ✰ ✰ Remove the woodruff key. CAUTION : Remove the Oil pump assembly with “O” ring. Ensure "O" ring must be located on the oil pump body outlet. ✰ ✰ Remove Gear lever from engine LH cover side. ✰ Remove Gear lever shaft with bush (spacer shaft). Remove the 4 allen screws to remove Oil pump assy.
Engine Dismantling, Inspection & Assembly ✰ ✰ ✰ Remove rocker shaft return spring pivot pin with “O” ring by using special No. ST 25123-4 Extractor for 5 speed gear box pivot pin as shown in Fig. ✰ Remove the rocker shaft assembly by gently tilting and twisting out. ✰ Straighten lock tab and Unlock the FD sprocket nut. ✰ Remove nut and lock washer. Remove the two bolts and remove the rocker shaft upper pivot bearing with “O” ring. Remove the two screws holding the lower pivot bearing ..
Engine Dismantling, Inspection & Assembly ✰ Remove FD Sprocket ✰ Remove kicker shaft cover with oil seal. ✰ Remove Kick starter return spring locking bolt with washer. ✰ Remove Kick starter return spring from kickshaft spindle. NOTE : Use special tool while removing FD sprocket if necessary. ✰ ✰ Pull out Sleeve gear Spacer by using monkey / gas plier as shown in Fig. Remove 4 Nos. Kicker Cover screws.
Engine Dismantling, Inspection & Assembly DISMANTLING COVER LH SUB ASSEMBLY : ✰ Remove the 11 bolts holding the cover LH. ✰ It may be necessary to tap the cover slightly to remove. ✰ Remove lock pin and spring from clutch operating shaft. PULL LOCK PIN ✰ Remove inspection plug along with “O” ring ✰ Tap and remove the Clutch cover. 05-19 ✰ Remove clutch operating shaft assy from clutch cover. ✰ Remove Clutch operating shaft oil seal and 2 Nos. of Dowels.
Engine Dismantling, Inspection & Assembly ✰ Remove gear lever shaft bush and oil seal. ✰ Use Special tool No. ST - 25591-4 Clutch centre nut holding tool to lock Clutch outer sprocket and engine drive sprag clutch. COMPONENTS FOR DISMANTLING FROM CRANKCASE LH REMOVAL OF CLUTCH ASSY. ✰ ✰ ✰ Remove nyloc nut & plain washer. ✰ Remove 17mm Hex bolt on the Engine sprocket. Remove clutch push pad, ball bearing & bearing retainer cup. Remove auto chain tensioner bottom bolt,“O”ring. and its spring.
Engine Dismantling, Inspection & Assembly ✰ DISMANTLING OF CLUTCH ASSEMBLY Remove Duplex chain along with Sprag clutch and Clutch assembly. ✰ Remove Engine sprocket and sprag clutch gear assembly. ✰ Remove sprag clutch bearing. FLANGE FACE NOTE : ✰ Remove 2 hex bolts at locations ✰ Fix Special tool No. ST - 25594-4 Clutch Spring Compressing Tool and tighten the 2 long bolts fully so as to hold the springs down loosen & remove the other 4 bolts.
Engine Dismantling, Inspection & Assembly ✰ Remove Spring retainer plate & 6 Springs. ✰ Remove collar on main shaft (distance collar from Crankcase LH). ✰ Remove clutch drum sprocket with big washer. ✰ Remove special distance washer sprag clutch on Crankshaft LH. ✰ Remove clutch hub, centre, friction and steel plates. ✰ Remove hex nut and washer to remove chain tensioner pad.
Engine Dismantling, Inspection & Assembly ✰ Remove Auto chain tensioner body assy. by removing the 2 Nos. allen screws. ✰ Remove double gear shaft and double gear starter drive. ✰ Remove the front engine mounting nut ✰ Remove the jack gear after removing the circlip. ✰ Loosen chain stay bolt ✰ 05-23 Remove the rear engine mounting nut along with the washer.
Engine Dismantling, Inspection & Assembly ✰ Remove centre stand & footrest supports. ✰ Remove the front and rear engine studs & slide the engine assembly off the frame. ✰ Remove Engine Front Mounting Bracket. ✰ Remove Mudguard mounting clip & Rear Engine Mounting Bracket. 05-24 ✰ Loosen the crankcase stud nuts and allen screws as per the following sequence. ✰ Tap gently and remove the crankcase LH.
Engine Dismantling, Inspection & Assembly ✰ Remove special thrust washer (lay shaft ) from Crank case LH & 2 Nos. Dowel pins. ✰ Remove clutch ball bearing from crankcase LH. ✰ Pull out the crank shaft from the crankcase RH. ✰ Remove needle roller bearing for lay shaft from crankcase LH. ✰ Remove clutch bearing retainer plate holding screws and remove the retainer plate from crankcase LH. ✰ Remove roller bearing NU 305 from crankcase LH.
Engine Dismantling, Inspection & Assembly ✰ Remove spacer, circlip, crank shaft bearing 6305 from crankcase LH. ✰ Remove last circlip from crankcase LH. ✰ Remove crank shaft needle roller bearing from crankcase RH. ✰ ✰ ✰ 05-26 Remove circlip and sleeve gear ball bearing 6007 from crankcase RH. Remove lay shaft needle bearing from crankcase RH. Remove nyloc nut, machined washer, pawl - camplate, return spring and bolt pawl from crankcase RH.
Engine Dismantling, Inspection & Assembly ✰ Remove Tappet cover by dismantling 4 Allen screws. ✰ Remove the exhaust and inlet hydraulic tappets carefully from Crankcase top side. EX. tappet ✰ INLET tappet Remove the Tappet cover. NOTE: Remove Inlet tappet first and then the exhaust tappet. CAUTION : Store the tappets carefully & right side up as detailed earlier. GEAR TRAIN REMO VAL REMOV ✰ Remove the Allen screw, and the bracket - join - hydraulic tappets.
Engine Dismantling, Inspection & Assembly ✰ Pull out cam plate pivot pin with “O” ring by using special tool No. ST 25153-4 Extractor shown below. ✰ Remove LS 1st gear and thrust washer from the Layshaft. ✰ Gently slide out the gear train assembly along with the cam plate, Fork shaft, Forks, Layshaft double gear(LS3 & LS4) and main shaft with all gears. NOTE: Turn cam plate to select 3rd gear position before removing for ease of removal / reassembly.
Engine Dismantling, Inspection & Assembly ✰ ✰ Remove centre selector fork from the selector shaft and then LH selector fork. DISMANTLING OF LAYSHAFT SUB ASSEMBLY ✰ Remove Lay shaft 1st gear and thrust washer. Remove circlip from the selector shaft if required. ✰ Remove Double gear (LS 3rd and 4th gear). ✰ Remove the high gear.
Engine Dismantling, Inspection & Assembly ✰ Remove 2nd gear and thrust washer. DISMANTLING OF MAINSHAFT SUB ASSEMBLY ✰ ✰ Remove main shaft 1st gear. Layshaft ✰ Remove the main shaft 2nd gear. MAIN SHAFT SUB ASSEMBLY ✰ 05-30 Remove the main shaft 3rd gear.
Engine Dismantling, Inspection & Assembly ✰ ✰ ✰ REMOVAL OF SLEEVE GEAR SUB ASSEMBLY Remove circlip & 1st. thrust washer. ✰ Remove open end needle bearing. ✰ Remove closed end needle bearing. Remove 4th gear and 2nd thrust washer. Main shaft REMOVAL OF KICK STARTER ASSEMBLY REMOVAL OF SLEEVE GEAR ASSEMBLY ✰ 05-31 Remove 3 allen screws to take out oil thrower (plastic cap).
Engine Dismantling, Inspection & Assembly ✰ Pull out kick starter sub assy. as shown in Fig. REMOVAL OF KICK STARTER SUB ASSEMBLY ✰ ✰ ✰ Remove the Kick pinion gear. ✰ Remove the thrust washer from kick spindle. ✰ Remove the Kick pawl, plunger and spring from kickstarter shaft. Remove circlip & thrust washer. Remove the thrust washer.
Engine Dismantling, Inspection & Assembly VITAL PARTS I. BEARINGS S.No. USAGE DESCRIPTION QTY 1. NBI 45 × 30 × 20 Crankcase RH - Crankshaft bearing 1 2. Ball Bearing 6305 C3 (25×62×17) Crankcase LH - Crankshaft bearing 1 3. Roller Bearing Nu305 C4 (25×62×17) Crankcase LH - Crankshaft bearing 1 4. Ball bearing 6006, C3 Crankcase LH - Main Shaft bearing 1 5. Lay Shaft bearing 550032/a Fitted on Crankcase RH and Crankcase LH 2 6. NRB 3 × 21.8 Locating Pin-Pivot, cam plate 1 7.
Engine Dismantling, Inspection & Assembly UNIDIRECTIONAL FITTINGS LIST ✰ Deep groove ball bearing 6007-RSH/ C3 in Crankcase RH- Rubber sealed facing FD sprocket side. ✰ Cam Gear Inlet- Single punch mark must align with single punch mark of Cam gear exhaust. ✰ Gear rocker shaft bottom pivot bearing-Smooth machined surface side facing upwards. ✰ Oil pump drive pinion - Short boss facing outwards. ✰ Main shaft 2nd Gear- Selector fork groove side facing towards M.S. 4th Gear.
Engine Dismantling, Inspection & Assembly TORQUE SPECIFICATION - ENGINE S. PART No No. DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. 1 570013 HEX SOCKET HD CAP SCREW, M5 X 16 RETAINER PLATE / SUCTION FILTER MTG 0.60 6 2 570016 HEX.SOCKET HD.CAP SCREW, M5 X 45 E START HOUSING COVER 0.60 6 3 570094 HEX.SOCKET HD.CAP SCREW, M5 X 25 E START HOUSING COVER 0.60 6 4 570232 HEX.SOCKET HD.CAP SCREW, M6 X 12 STOP PLATE, PIVOT PIN / COVER LH / PIVOT BRG LOWER 1.
Engine Dismantling, Inspection & Assembly TORQUE SPECIFICATION - ENGINE S. PART No No. DESCRIPTION LOCATION TORQUE VALUE Kg / M. N / M. 30 570215 BOLT, PAWL (M6 X 1) GEAR BOX INDEX 1.00 10 31 570233 HEX.SOCKET HD.CAP SCREW, M5 X 40 PIVOT BEARING, ROCKER SHAFT LOWER 0.60 6 32 550138 CSK SOCKET HEAD SCREW M5 X 0.8 X 16, COVER, KICKSTART SHAFT 0.60 6 33 145090 HEX SCREW M6 X 16 KICKSTART, SPRING 1.00 10 34 570240 HEX.SOCKET HD.CAP SCREW, M5 X 35 COVER K.S. GEAR 0.
Engine Dismantling, Inspection & Assembly ENGINE ASSEMBLY Please ensure all the parts are cleaned and stored in a sequence for inspection and reassembly. Lubricate all moving parts prior to reassembly. While fixing bearings or bushes in the crankcases, it is necessary to heat the crankcase for ease of fixing. Cool the crankcases after the fixing the bearings / bushings before further assembly. ASSEMBLY OF ENGINE BEARINGS CRANKCASE LH ✰ Assemble Needle roller bearing for lay shaft.
Engine Dismantling, Inspection & Assembly ✰ CRANKCASE RH Assemble 6305 - C3 bearing after 1st circlip. Insert 2nd circlip then bearing spacer in Crank case LH as shown in Fig. ✰ Assemble Needle bearing for lay shaft. ✰ Assemble sleeve gear ball bearing (6007 R1/C3) and circlip. NOTE : Ensure the rubber sealed face is facing the FD sprocket side, while assembling the 6007 bearing. ✰ ✰ Assemble NU 305 big roller bearing after bearing spacer in LH Crank case for crankshaft.
Engine Dismantling, Inspection & Assembly ✰ Assemble closed end needle bearing inside sleeve Gear. ✰ Assemble open end needle bearing. Check bearing seating position and for free rotation. ✰ Insert sleeve Gear into Crankcase RH. NOTE : Do not hammer directly over sleeve Gear. It is recommended to use arbor press. ✰ Assemble exhaust and inlet hydraulic tappets carefully into Crank case RH lubricate and check free upward & downward movement inside Crank case RH tunnel.
Engine Dismantling, Inspection & Assembly ✰ Fit bracket lock clip to hold needle roller pin of hydraulic valve lifter and tighten with allen screw (Torque 1 KG-M). ✰ Assemble magnetic drain plug assy. (Torque 2 KG-M) with washer on crankcase RH. DRAIN BOLT ✰ NOTE : Assemble cleaned suction filter element into Crank case RH. Apply LOCKTITE 542 thread sealant before assembling the drain plug.
Engine Dismantling, Inspection & Assembly ✰ ✰ Assemble the Kick pinion gear over kick pawl mechanism. Fix kickstarter sub assy in to Crankcase RH as shown in Fig. TRIP PLATE ✰ ✰ NOTE : Ensure kick pawl is seated over the trip plate in the Crank case RH. Rotate kick Gear and confirm free wheel movement. Insert the thrust washer above the kick spindle. ✰ Assemble oil thrower under the kickstarter Gear (Torque 0.6 KG-M). ✰ Assemble Kick starter return spring by hooking into kickshaft spindle.
Engine Dismantling, Inspection & Assembly ✰ ✰ Insert spring locking bolt with washer into kick spring eyelet and rotate clockwise to lock Kick starter return spring on the Crank case and tighten (Torque 1 KG-M). Assemble striker spring on rocker shaft assy. NOTE : Ensure striker spring both ends are seated on striker lever rocker shaft. ✰ ✰ Apply LOCTITE 5699 RTV silicon liquid gasket then assemble kick shaft Cover with oil seal on Crank case RH by 4 screws (Torque 0.6 KG-M).
Engine Dismantling, Inspection & Assembly ✰ Assemble lower pivot bearing 2 allen bolts (Torque 0.6 KG-M). ✰ Assemble High gear. ✰ Assemble Double gear (LS 3rd and 4th gear). ✰ Assemble thrust washer and then Lay shaft 1st gear. NOTE : It is recommended to tighten the upper pivot bearing first and then the bottom pivot bearing to avoid gear shifting problems. ✰ Assemble rocker return spring stop pin along with “O” ring by using special tool No. ST 25123-4 as shown in Fig.
Engine Dismantling, Inspection & Assembly ASSEMBLING OF MAINSHAFT SUB ASSEMBLY ✰ ✰ ✰ Assemble main shaft 3rd gear. ✰ Assemble main shaft 2nd gear as shown. Smear oil and assemble the 1st thrust washer and then the 4th gear on the main shaft. Assemble 2nd thrust washer and fix circlip to lock the 4th Gear. NOTE : Ensure 2nd gear selector fork groove side is facing towards MS 4th gear. ✰ ✰ Assemble main shaft 1st gear. Smear oil on the 3rd & 4th gear with bush before assembly on Mainshaft.
Engine Dismantling, Inspection & Assembly ✰ Assemble circlip on the selector shaft. ✰ Assemble LH selector fork on the selector shaft and then insert centre fork so that the cut shoulders of both the forks are matched. ✰ ✰ Assemble selector fork sub assembly over main and Layshaft sub assy. as shown in Fig. ✰ Always assemble the cam plate on selector fork sub assembly in 3rd gear position & ensure the 4 rollers are in good condition and located properly.
Engine Dismantling, Inspection & Assembly ✰ ✰ Assemble the thrust washer, LS2nd gear & High gear with Lay shaft mounted on the Crank case RH as shown in Fig. Insert cam plate piviot pin with “O” ring with special tool No. ST 25123-4 as shown in Fig. NOTE : Apply LOCTITE 577 thread sealant to pivot pin to avoid oil seepage if any. ✰ Hold the cam plate and gear train sub assembly along with Fork shaft, Forks, Lay shaft double gear (LS3 & LS4) and main shaft with all gears (in 3rd gear position).
Engine Dismantling, Inspection & Assembly ✰ Assemble “O” ring, cap pivot, copper washer and tighten bolt (Torque 1 KG-M). NOTE : ✰ ✰ Ensure the bearing inner races (small one on timing shaft & big one on drive shaft) are fitted on the crank shaft before assembling in the crankcase RH. Check Crank shaft big end bearing axial play is within service limit. Check Crank shaft run out is within service limit.
Engine Dismantling, Inspection & Assembly ✰ Insert the jack shaft from the crankcase LH inside & fix the woodruf key. ✰ Assemble the crankcase LH over RH Crank case by tapping gently. Simultaneously holding self motor jack shaft carefully. ✰ ✰ Check connecting rod bend as shown in Fig. ✰ Assemble Front Engine Mounting Brackets and tighten bolts (Torque 2.5 KG-M). ✰ Assemble Rear Engine Mounting Bracket and the piece mudgaurd holding bracket (Torque 2.5 KG-M).
Engine Dismantling, Inspection & Assembly ✰ ✰ Assemble neutral switch with packing. ✰ Fit the centre stand and foot rest supports. ✰ Ensure the woodruf key is located correctly on the jack shaft and fix the circlip. Locate the crankcase on the frame and fit the front engine mounting stud. NOTE : Ensure step face of jack shaft gear should face inside (Towards Crank case LH) ✰ ✰ Fit the rear engine mounting stud. Locate the double gear for starter drive in the crankcase and insert shaft.
Engine Dismantling, Inspection & Assembly ✰ Fix the dowels in the crankcase and carefully fix the motor with housing starter drive. Apply LOCKTITE 5699 RTV silicon liquid gasket on the joint face. NOTE : Apply LOCKTITE 577 thread sealant to mounting bolts to avoid oil seepage if any. ✰ Fix the 4 Allen screws of housing starter drive and tighten (Torque 0.6 KG-M). ✰ Fix the main cable on the starter motor on tighten. Insert rubber boot properly.
Engine Dismantling, Inspection & Assembly SPRAG CLUTCH ASSEMBLY ✰ Assemble Engine primary sprocket and sprag clutch gear assembly. 0.2 to 0.5 mm DETAILS B CAUTION : Lubricate the needle bearing well before assembling on the sprag clutch. ✰ Assemble the primary chain auto chain tensioner body assy. with “O” ring and tighten with 2 allen screws (Torque1 KG-M). ✰ Ensure the distance between sprag clutch gear end face and engine sprocket end face should be maintained between 0.2 to 0.
Engine Dismantling, Inspection & Assembly ✰ Assemble collar on main shaft (distance collar on Crankcase LH). CAUTION : Ensure smooth face of all clutch plain plates are kept in the same direction to avoid clutch jerk / slippage. ✰ Assemble wheel clutch on clutch hub. ✰ Insert clutch sub assy. into clutch sprocket. after placing the thrust washer. ✰ Assemble clutch springs 6 Nos. on clutch sub assy. then place clutch spring holder.
Engine Dismantling, Inspection & Assembly ✰ ✰ Use Special tool No. ST - 25594-4 Clutch spring compressing tool to compress the clutch springs over spring holder and tighten with 2 long bolts. Assemble Duplex chain over Engine sprag clutch sprocket and Clutch assembly. Mount on main shaft. ✰ Use Special tool No. ST 25591-4 Clutch centre holding tool to lock Clutch sprocket and engine sprag clutch assy. ✰ Fix 17 mm hex head bolt with washer on sprag clutch assy. (Torque 4.8 KG-M).
Engine Dismantling, Inspection & Assembly ✰ Assemble clutch bearing cup, ball bearing (6001) & clutch push pad. Use Torque wrench to tighten the nyloc nut on Clutch (Torque 4.2 KGM). ✰ Assemble gear lever shaft bush. Fix the spring and bolt with “O” ring for the auto chain tensioner (Torque 1 KG-M). ✰ Assemble gear lever oil seal on cover LH . ✰ Fix the washer and nyloc hex nut 24 mm over clutch assembly and tighten.
Engine Dismantling, Inspection & Assembly ✰ Assemble Clutch operating shaft oil seal. ✰ Assemble clutch operating shaft assembly on cover LH. ✰ ✰ Assemble oil filler plug with ring. ✰ Assemble the cover LH on Crank case LH. “O” NOTE : Ensure 2 Nos. dowel pins are located properly. Apply LOCKTITE 5699 RTV silicon liquid gasket. Assemble spring for clutch operating shaft and lock the pin. ✰ 05-55 Locate 11 bolts on cover LH and tighten (Torque 1 KG-M).
Engine Dismantling, Inspection & Assembly ✰ Assemble clutch cable on Crank case cover LH and fix to clevis. ✰ Assemble Sleeve gear Spacer over sleeve as shown in Fig. ✰ ✰ Assemble lock type washer and nut (Torque 7.5 KG-M). ✰ Lock the tab over the FD sprocket nut. ✰ Fix Rear Chain master link, plate and lock clip. Assemble FD Sprocket . NOTE : Care to be taken while fixing the FD sprocket direction circular groove index mark, facing outwards.
Engine Dismantling, Inspection & Assembly ✰ ASSEMBLING PROCEDURE OF AUTO DECOMPRESSOR Assemble oil pump on Crank case RH and tighten with 4 allen screws (Torque 0.35 to 0.6 KG-M). ✰ Locate the actuating pin in the Exhaust cam. CAUTION : Ensure "O" ring is located on the oil pump body outlet. ✰ Assemble the flyweight along with return spring over activating pin and tighten with allen screw. ✰ Lubricate and ensure free movement of the returning of the flyweight.
Engine Dismantling, Inspection & Assembly ✰ VALVE TIMING ✰ Bring piston to TDC so that the woodruf key in the timing shaft is at 12’ Clock position. Fix oil pump drive pinion and lock it with the circlip.
Engine Dismantling, Inspection & Assembly ✰ ✰ Fix Cam steady plate and check for axial play of Cam Gears to avoid noise problem. Fix oil seal 2 Nos. at Kick Shaft hole on Crank case RH cover. INSIDE OIL SEAL OUTSIDE OIL SEAL ✰ Assemble the dowels and allen screws on Cam steady plate and tighten (Torque 1 KG-M). ✰ Assemble magneto rotor, plain washer and nut and tighten (Torque 4.8 KG-M). NOTE : Use special tool No. ST 25592-4 to lock connecting rod movement during tightening magneto nut.
Engine Dismantling, Inspection & Assembly ✰ Assemble Breather bolt and washer (Torque 2.0 KG-M). ✰ Assemble Ignition Timing inspection bolt with copper washer (if not assembled earlier) Torque 1.5 KGM. ✰ Assemble jet Crankshaft, oil seal Crank feed and circlip on cover RH inside. ✰ Assemble Stator on cover RH and tighten with 3 mounting screws (Torque 1 KG-M). ✰ Assemble Pulser coil on cover RH and tighten with 2 screws (Torque 1 KG-M).
Engine Dismantling, Inspection & Assembly ✰ Assemble cover RH carefully by aligning kickshaft and dowels. ✰ ✰ Fix cover RH and tighten with 11 allen screws (Torque 1 KG-M). CAUTION : Care must be taken while fixing cover due to spring force and gasket. ✰ Assemble “O”ring, Spring and gasket oil filter cap. Assemble 0.60 oil filter cover (Torque KG-M). ✰ ✰ Assemble the “O” rings, Oil filter element, washer and plate as shown. 05-61 Assemble kickstarter lever (Torque 2.5 KG-M).
Engine Dismantling, Inspection & Assembly ✰ Fix Cylinder barrel bottom Gasket. PISTON SUB ASSEMBLY CLEANING ✰ ✰ ✰ ✰ ✰ Insert piston rings on its appropriate grooves and check side clearance between the ring and grooves. ✰ Check the piston rings end gap at the bottom end of the Cylinder. Remove piston rings from piston. Scrap the carbon deposits from the piston groove with the help of scrapper.
Engine Dismantling, Inspection & Assembly ✰ ✰ Check the piston pin for wear. Measure outside dia of piston pin at 3 points. Locate the top ring (Index mark “1 IP” facing upwards). NOTE : Top ring has rectangular cross section with black colour (Nitride coating). ✰ Stagger piston rings end gap as shown in Fig. EX IN ASSEMBLY IN EX NOTE : After installation, the ring should rotate freely rotatable in the ring grooves.
Engine Dismantling, Inspection & Assembly ✰ CYLINDER BARREL CLEANING ✰ Scrap the carbon deposit from the top edge of the bore. ✰ Clean the barrel with cleaning solvent and dry it with compressed air. Assemble the multi layer steel (MLS) head gasket on the barrel & 2 Nos. dowels. INSPECTION ✰ Visually check for cracks, scratches, breakage of fins, scoring, seizure mark etc of the Cylinder bore. ✰ Check Cylinder liner for wear at 3 locations measure the cylinder ID in X and Y axis.
Engine Dismantling, Inspection & Assembly ✰ Check the Cylinder head face for warpage on surface plate as shown in Fig. ✰ Check the valve guide for wear with small bore gauge and valve stem OD by vernier caliper to measure valve to guide clearance. ✰ Replace valve if the valve head is knife edged. 05-65 ✰ Check the valve stem for run out. ✰ Check inlet and exhaust valve stem for wear. ✰ Check the valve seat to valve head seating as below.
Engine Dismantling, Inspection & Assembly ✰ ✰ Make pencil marks on the seating area of valve head as shown in Fig. In case if the pencil marks are not erased, grind the valve to the seat as below - Apply fine grinding paste on to the valve seating area. ✰ Assemble valves into the valve seat. WARNING : Do not allow the grinding paste to seep into the valve stem and valve guide. ✰ Using a suction valve grinder rotate the valve back and forth, several times.
Engine Dismantling, Inspection & Assembly VALVE SEAT INSPECTION : ✰ ✰ ✰ ✰ NOTE : Please ensure cleaning of the cylinder head with solvent and blow thorough all oil passages with compressed air. Check and ensure proper seating with pencil marks as explained above. Valve seating on valve seat can also be checked as follows: Assemble the valve assembly in position. Keep the Cylinder head on a table. Fill petrol on top of the valves. Seepage of petrol past the valve seat indicates improper valve seating.
Engine Dismantling, Inspection & Assembly ✰ Similarly follow the same process to assemble the exhaust Valve as shown in Fig. ✰ Tighten the 6 flanged hex nuts diagonally and evenly. ✰ Assemble the spark plug ✰ Check run out of the push rods. NOTE: Please ensure split collars are locked on the valve stem groove by tapping gently with a plastic hammer on retainer spring. VALVE LEAKAGE TEST ✰ Pour solvent into exhaust port and check for valve seat leakage if any.
Engine Dismantling, Inspection & Assembly ✰ Assemble pushrods. inlet and exhaust ✰ Assemble the inlet and exhaust rocker bearing with dowel and tighten allen screws ✰ Assemble the Inlet & Exhaust Rocker covers, dowels & rubber gasket then tighten rocker cover bolt with rubber washer (Torque 1 KGM)) . 05-69 ✰ Assemble tappet door by applying LOCKTITE 5699 RTV silicon gasket on Crank case RH then tighten screws (Torque 0.60 KG-M). ✰ Tighten the swing arm nut to specified torque.
Engine Dismantling, Inspection & Assembly ✰ ✰ ✰ Tighten the front engine mounting stud nuts to the specified torque. ✰ Assemble throttle body and connect the throttle cables. ✰ Fill recommended the engine oil to the correct level and tighten filler cap with “O” ring. ✰ Assemble the exhaust pipe and silencer in the reverse order of disassembly. Fix the clutch cable & the manual Bi Starter to the handle bar levers. Connect all the electrical couplers. Connect the brake light switch to the pedal.
SECTION SIX 06 ENGINE MANGEMENT SYSTEM
Engine Management System (EMS) The Classic 500 is fitted with an intelligent Engine Management System (EMS). It consists of an Electronic Control Unit (ECU) which constantly takes inputs like engine speed, engine temperature, throttle position, manifold air pressure, exhaust oxygen feed back etc, from the respective sensors, provided in the vehicle and determines both the ignition timing and the ideal amount of fuel to be injected, to optimize the airfuel ratio.
Function of Components in EMS ELECTRONIC CONTROL UNIT (ECU) ALTERNATOR THROTTLE BODY ASSEMBLY TEMPERATURE SENSOR FUEL INJECTOR ASSEMBLY CRANK POSITION SENSOR FUEL PUMP MODULE ROLLOVER SENSOR MALFUNCTION INDICATOR LAMP (MIL) 06-3
Function of Components in EMS ELECTRONIC CONTROL UNIT (ECU) The ECU consists of a microprocessor. It controls the output devices by giving pulses to the respective devices. It has two memories Flash Memory and E2 PROM. Flash memory is an exclusive recording unit for controlling program and setting data. It collects different inputs from various sensors and calculates optimised values and gives outputs to the respective controlling devices.
Function of Components in EMS FUEL INJECTOR Exploded view of fuel injector Assembled between throttle body and cylinder head Specification: Operating Voltage : 10 – 14 V. Operating temperature : –30º C to + 120º C. Fuel Injection pressure : 294 kpa (2.9 bar) Solenoid Operating Resistance : 10.3 ± 0.5 Ohms Fuel Injector is a solenoid operated electromagnetic valve, which atomizes the fuel by forcing it through a small nozzle under high pressure.
Function of Components in EMS FUEL PUMP MODULE Specification: Operating Voltage : 6 – 14.5 V. Operating temperature : –20º C to + 60º C. Controlled Pressure Regulator : 294 KPa. Inbuilt Filter Capability : Upto 10 Microns Assembled on the fuel tank bottom left side The fuel pump creates a positive pressure in the fuel lines and pumps gasoline through the injector. The Pump operation is determined by the ECU so that it gives exactly the required volume of fuel.
Function of Components in EMS THROTTLE BODY MODULE Specification: Operating Voltage : 5 V. Out Put Voltage : 0 – 5V. Throttle Angle : 0 – 80º Throttle Resistance Maximum : 5 K©. Throttle Out Put Voltage at Idling : 0.6 ± 0.2V. Storage Temperature : –20º C to + 80º C Assembled between air filter and inlet manifold The throttle body is a part of the air induction system. It controls the amount of air flowing into the engine, in response to throttle opening.
Function of Components in EMS THROTTLE POSITION SENSOR (TPS): TPS is used to monitor the position of the throttle and is located on the butterfly spindle so that it can directly monitor the position of the butterfly throttle valve. The sensor is usually a potentiometer and therefore provides a variable resistance depending upon the position of the butterfly valve and hence throttle position can be sensed by the ECU. The sensor signal is used by the ECU as an input to its control system.
Function of Components in EMS ENGINE OIL TEMPERATURE SENSOR Specification: Operating temperature : –30º C to +120º C Operating Voltage : 5 ± 0.5 V. Resistance Value w.r.t. Temperature –20º C –– 18.8 Kilo Ohms + 40º C –– 1.136 Kilo Ohms Assembled on the cylinder head + 100º C –– 0.1553 Kilo Ohms Engine temperature sensor is used to measure the engine oil temperature. It senses the oil temperature and provides the input to the ECU which calculates the average engine temperature.
Function of Components in EMS ROLL OVER SENSOR Specification: Operating Voltage : 12V. Operating Angle : 60° + 10°. Operating Temperature : –20°C to +85°C. Assembled under the seat The Roll over sensor is also known as a bank angle sensor.
Malfunction Identification of EMS There are three levels of identifying a malfunction in the ECU or the sensors. LEVEL 1 VISUAL This is indicated by the lamp in the MIL glowing continuously. Check for any sensor loose connections and plug in properly. If still MIL GLOWS, then check for the the problem by Test Pin or by DOL TOOL. LEVEL 2 TEST PIN An open single pole connector is provided close to the UCE.
Malfunction Identification of EMS LEVEL 3 DOL This is done by connecting a DOL tool to the connector near the ECU. This will accurately determine the defective sensor and show the details on the diagnostic screen with the following respective codes as shown below. P Code MAL FUNCTION INDICATION MIL will glow continuous. Engine will start but not perform to its potential.
Instructions (Do’s & Don’ts) on EMS 1) DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR the engine is running. 2) DO ensure the battery is in good condition & Fully Charged Battery. 3) DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands retracted.
Trouble Shooting (EMS) S No Symptom Possible Cause Engine stop switch is in OFF position 1 MIL does not glow when ignition key switched ON Check battery electrolyte level & Sp. gravity. Recharge battery Fuse blown. Check all fuses. Assess cause of failure, rectify & replace fuse Sensor couplers / wires loose contact.
Trouble Shooting (EMS) S No E 4 5 6 7 Symptom Ignition related Vehicle Starts but Switches off Possible Cause Remedy Spark plug Fouled Replace spark plug Spark plug cap shorting Replace spark plug cap Ignition coil wire loose connection or broken. Check for proper wire connection. Replace damaged wire connections Faulty HT coil power relay. Check power relay resistance / wire connections. Replace if faulty.
SECTION SEVEN 07 CV CARBURETOR
CV Carburetor - Exploded View 41 1. 2. 3. 4. Top cover fixing screw Diaphragm top cover Piston valve spring Jet Needle plate fix screw 5. Jet needle fixing plate 6. Jet needle retainer spring 7. Jet needle washer 8. Jet needle E-ring 9. Jet needle ring 10. Jet needle 11. Piston valve assy. 12. Diaphragm (piston valve) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. Diaphragm retainer ring Body CV carburetor Air vent hose Needle jet O-ring Jet holder Main jet Float Needle Valve assy.
Functions of Carburetor CARBURETOR PERFORMS THREE IMPORTANT FUNCTIONS : CARBURETOR REMOVAL REMOVAL : 1. 3 It varies the air-fuel ratio according to the operating conditions and requirements of the engine. 2. It produces a mixture which is properly atomized. Atomization is the mixing of air and fuel to form a fine spray or mist and to deliver the mixture to the engine. 3. It regulates the amount of air - fuel mixture required by the engine.
Dismantling Proceedure - Carburetor 3 Remove drain hose and air vent hose. DRAIN HOSE Note : Care to be taken while removing diaphragm top cover due to spring force. 3 Gently remove thorottle piston valve assembly as shown in Fig. NOTE : Inspect both hose pipes for clog. Clean thoroughly before fixing. 3 By using the right size spanner to remove the choke plunger sub assy. along with the spring. 3 Unscrew the float body fixing screws and remove the float chamber body assy.
Dismantling Proceedure - Carburetor 3 Unscrew the main jet, main jet holder and pilot jet from the mixing body. NOTE : Carefully remove “O” ring mixture screw. CAUTION : Spray carburetor cleaner in all passages to ensure that there is no blockage due to dust, dirt, gum or carbon deposit, especially in the main air passage, pilot air passages, including bypass holes and pilot outlet. NOTE : Ensure that float body and needle valve are being removed before carrying out any other jobs.
Assembling Proceedure - Carburetor 3 Assemble spring, washer and “O” ring on the mixture screw body carefully and then fix into the mixing body unit. Assemble Main jet holder with “O” ring and then Main jet as shown in Fig. JET HOLDER MAIN JET 3 MIXTURE SCREW 3 NOTE : Do not inter change”O” ring and washer sequence to avoid tuning problem. Apply a coat of petroliem jelly over mixture screw thread portion before fixing into mixing body to avoid mixture screw jam problem.
Assembling Proceedure - Carburetor NOTE : Do not clean diaphragm by brake fluid or compressed air. NOTE : Ensure that float body swinging freely on float toggle pin. Recheck again float height after the adjustment. 3 Assemble float chamber body along with “O” ring as shown in Fig. 3 Inspect rubber diaphragm and retainer ring. In case of dust or carbon particals wipe with banian cloth carefully before assembling into mixing body. 3 Assemble air vent hose and then drain hose.
Assembling Proceedure - Carburetor 3 Adjust throttle cable free play at carburetor 1 mm. 2. Now turn the Mixture screw in or out slowly and select a position where the engine rpm reaches to the peeak / highest speed position while setting. Now stop adjustment of Mixture screw. Normally this will occur inbetween 3 + 1 turns of Mixture screw from fully close position. 3. Now adjust the idle screw to bring down the engine revolution to the specified idle 1050 + 200 RPM.
Carburetor Maintenance PROCEDURE FOR SETTING IDLING SPEED AND CO% 3 3 3 MAINTENANCE TIPS 3 If the engine performance is good, the Mixture screw (MCS) need not be disturbed. The idling speed can be adjusted only with the idling screw. If there is a performance deterioration, clean carburetor and readjust the idling speed and mixture screw setting. 3 3 CARRY OUT THE CO% EMISSION CHECK AS FOLLOWS: 3 3 3 3 3 3 3 Warmup the engine by riding the vehicle for about 4 kms.
Carburetor Maintenance 3 While assembling the jet needle ensure that the jet needle ring pin coincides with the corresponding hole in piston valve. 3 Generally, it is not advisable to remove the jet needle. if it is necessary, un screw the jet needle fixing plate screws and remove the jet needle along with the jet needle retainer spring. 3 Ensure that the seating area of the choke plunger assembly is not worn or damaged. If worn or damaged, replace the plunger assembly.
SECTION EIGHT 08 CHASSIS, WHEELS & BRAKES
Torque Specification - Chassis S. PART No No. DESCRIPTION Handle LOCATION TORQUE VALUE Kg / M. N/M. Bar 1 146032 Handle Bar Clip Bolts Handle Bar Clip 1.20 12 3 560574 Master Cylinder Cap Screws Master Cylinder Reservoir Cap 0.13 1.5 2 560609 Fr. Brake Lever Pivot Bolt Fr. Brake Lever Pivot 1.20 12 4 560579 Brake Lever Pivot Lock Nut Brake Lever Pivot 1.00 10 5 110116 Steering Stem Top Nut - Steering Stem Top Replacing new ball races-Tighten upto 7-8 Kg.
Torque Specification - Chassis S. PART No No. DESCRIPTION LOCATION TORQUE VALUE Kg / M. N/M. 18 580360 HEX. CASTLE NUT REAR WHEEL SPINDLE NUT 7.00 70 19 170352 DOMED NUT REAR SHOCK ABSORBER TOP & BOTTOM 4.00 40 20 145881 FLANGED HEX BOLT M8 X 45 REAR MUDGUARD CARRIER FRONT MOUNTING C5 3.00 30 CHAIN GUARD MTG. / REAR M.GUARD REAR MTG. 3.00 30 21 580592 FLANGE HEX. BOLT M8 X 10 22 141051 HEX NUT M8 SEAT MOUNTING REAR C5 3.
Front Wheel Removal ✰ ✰ Place the vehicle on its center stand. Place a suitable wooden block below the front end of engine to support the vehicle so that the front wheel is lifted up by 25mm from the ground. ✰ Disconnect speedo cable. ✰ Tap the axle gently to remove it out of the fork end and the wheel ✰ ✰ ✰ Tilt the vehicle slightly to the right side and take out the wheel along with the speedo drive and the bush.
Chassis, Wheels & Brakes ✰ ✰ Remove the wedge between the brake pads and position the wheel between the fork legs, taking care to ensure the brake disc in seated correctly between the brake pads in the caliper Fix the wheel axle from the right side fork leg, carefully ensuring that the holes int eh fork legs and the wheel assembly are aligned. Do nto force the axle or tap heavily on the axle as it will damage the bearing inner races and the threads on the axle.
Chassis, Wheels & Brakes ✰ ✰ Remove the Master Cylinder top cover, diaphragm plate & diaphragm. ✰ Loosen the bleeder screw by 1 turn approximately ✰ Depress brake lever slowly and fully and release. This will force the brake fluid out of the bleeder screw. Repeat this process till the brake fluid drains out completely from the master cylinder and the wheel calliper assembly. Remove the protective boot from the bleeder nipple on the calliper assembly.
Chassis, Wheels & Brakes ✰ ✰ Remove the calliper assembly from the fork leg and drain out the brake fluid ✰ Fix the diaphragm, plate and top cover. Do not tighten the screws completely since it may be required to top up fluid during the bleeding process. ✰ Depress the brake lever completely and release fully so as to allow the brake fluid to fill up in the brake hose and caliper. ✰ When a slight firmness is felt on the lever and it depresses only halfway, hold the lever firmly in that position.
Chassis, Wheels & Brakes ✰ Loosen the bleeder screw by ½ turn to allow air bubbles in the brake system to escape out. ✰ Check the fluid level and top up to “MAX” level and refit the diaphragm and the top cover and tighten with the screws. ✰ Check for any leaks at the banjo or the bleeding screw area and ensure all mounting bolts are tightened to the correct torque.
Chassis, Wheels & Brakes ✰ When a slight pressure “build up” is felt on the lever, depress and hold. DO NOT RELEASE THE LEVER. The air in the hydraulic system will be expelled upwards during this operation, allowing the fluid to fill up in the calliper and the brake hose completely. ✰ Remove the Master Cylinder top cover, diaphragm plate & diaphragm. ✰ Place a clean tray or container below the calliper assembly to collect the old brake fluid.
Chassis, Wheels & Brakes ✰ Remove the Rear view mirror RH. ✰ Remove the master cylinder clamp bolts and remove the master cylinder from the handle bar. ✰ Disconnect the Front brake switch wire and remove the switch from the master cylinder. ✰ Remove the boot and the Circlip from the master cylinder body.
Chassis, Wheels & Brakes INSPECTION CAUTION : ✰ Check both the rubber seals on the plunger for wear, cracked edges or any other damage. Replace seals whenever the plunger is removed ✰ Check the master cylinder housing and piston for any scoring, pitting due to corrosion or any other damages. Do not clean the hydraulic disc brake parts with any other cleaning material, solvents or water. USE NEW BRAKE FLUID ONLY. ✰ Check the master cylinder bore for any damages, scoring marks etc.
Chassis, Wheels & Brakes ✰ ✰ Locate the circlip into the groove of the master cylinder. Ensure the circlip is seated correctly inside the groove. ✰ Assemble the Brake Switch ✰ Fix the master cylinder assembly on the handle bar with the ’UP’ mark facing upwards. ✰ Tighten the master cylinder assy. clamp top bolt first and then tighten the bottom bolt. Torque 0.90 KG-M. Assemble the rubber Boot.
Chassis, Wheels & Brakes ✰ Position the brake hose on the master cylinder such that it is pointing downwards correctly and tighten with the banjo bolt. Replace the banjo bolt sealing washers whenever the bolt is removed. ✰ Tighten the banjo bolt firmly Torque 3.5 KG-M. ✰ ✰ ✰ ✰ Connect the brake light switch. Fill the brake fluid till “MAX” mark and bleed the system. Assemble the diaphragm, plate and cover. Tighten screws gently Torque 0.15 KG-M. Assemble the rear view mirror.
Chassis, Wheels & Brakes ✰ ✰ ✰ ✰ Remove the brake pad tensioner spring plate. ✰ Remove the Bellow & Boot. ✰ Hold the caliper body with the pistons facing downwards. ✰ Blow compressed air with a nozzle at a low pressure, into the oil passage hole on the caliper, so that the pistons can be removed Remove pin bolt. Remove the brake pads from the caliper assembly. Remove mounting bracket from the Caliper assembly.
Chassis, Wheels & Brakes CAUTION : Do not use high pressure air or any pliers or sharp objects to remove the pistons as their working surface can get damaged. Measure the caliper piston O.D. Service limit – 25.31 mm CAUTION : Ensure the pistons do not fly out of the caliper body due to high air pressure. Support the pistons Enough care should be taken to avoid damages of the piston O.D. while servicing/ handling.
Chassis, Wheels & Brakes ✰ ✰ ✰ Coat the caliper cylinders and Pistons with clean brake fluid and install the Pistons into the caliper body with the dished end facing inwards. ✰ Install the Pad tension spring plate into the Caliper body. ✰ Assemble Bleed screw with the dust cap on the caliper body. ✰ Assemble the Mounting Bracket on the caliper Body. If the Caliper Boot and Bellow are hard or deteriorated, replace them with new ones.
Chassis, Wheels & Brakes ✰ ✰ ✰ First install the brake pad at the piston side and then install the other brake pad ✰ Tighten the Pin bolts with a torque of 1.5 2.0 KG - M after mounting the caliper assembly on the fork assembly. ✰ Fix the Grub screws on the pins and tighten to a torque of 0.2 to 0.3 KG-M. P Connect the brake hose to the caliper with New sealing washers and tighten the Banjo bolt.
Chassis, Wheels & Brakes WHEEL DISC INSPECTION Check the wheel disc periodically for any oil or grease stains, slush, grit, scoring marks etc. Keep the disc clean and dry at all times for the brakes to work at peak efficiency. If the Disc is scored heavily, replace the disc. IF the scoring is very mild, remove the same using a mild abrasive paper. ✰ Check the Disc thickness and the ‘Run-Out’ of Disc.11 Sl. No.
Chassis, Wheels & Brakes ✰ BRAKE DRUM ASSEMBLY Remove the cush drives (4 Nos.) from the hub. ✰ Remove the drive chain from the sprocket. ✰ Disconnect the brake operating rod from the cam lever. ✰ Remove the cover plate anchor nut from the chain stay. ✰ Remove the nut from hub spindle short. CAUTION : The cush drives are locked to the hub with rubber lugs. Pull out the cush rubbers gently to avoid damage to the lugs ✰ Remove the dust seals.
Chassis, Wheels & Brakes ✰ ✰ Remove sprocket drum assy. from the swing arm along with brake shoes and cover plate carefully. Disconnect chain if not removed earlier. ✰ Take out sprocket drum, brake shoes, and spacer ✰ Remove the oil seal. ✰ Drive out the bearing from the hub sprocket. Clean the brake shoe & cush drive with dry cloth / cloth wet with solvent. INSPECTION ✰ Visually check all parts for breaks, cracks, dents, scoring, glazing or any other damage.
SECTION NINE 09 SUSPENSION & STEERING
Front Fork Working Principle 3 3 for Classic 500 & 350 FORK STROKE LENGTH : 130 MM FORK MOVEMENT IS CONTROLLED BY THE COMPRESSION SPRING AND HYDRAULIC DAMPING FORCE S.No. Description 1. 2. 3. 4. 5. 6. 7. 8. 15 Bolt cap “O” ring Main tube Spacer Seal dust Fork oil seal & circlip One way check valve Fork piston 9 S.No. 9. 10. 11. 12. 13. 14. 15.
Suspension & Steering FRONT FORK DIS ASSEMBLY ✰ ✰ REMOVAL OF FORK SEALS Place motorcycle on centre stand. ✰ Remove speedo cable, front wheel and mudguard. ✰ Remove caliper mounting bolts and take out the caliper. DISMANTLING PROCEDURE ✰ Remove the allen screw from the bottom tube and drain the oil. 09-3 Gently tap the fork bottom tube downwards and remove the bottom tube. ✰ Loosen the pinch bolt on fork crown bottom.
Suspension & Steering INSPECTION ✰ Visually inspect all parts for damages, cracks, bends, wear marks or any other damage. ✰ Check the main tube for any bend. ✰ Measure the spring length. ✰ Inspect the other internal parts for any visual damage. P Remove the handle bar clamp bolts and nuts and take out handle bar. P Remove the stem lock nut and washer carefully. P Tap the steering stem downwards, taking care to collect the steering race balls (38 nos) for inspection. ✰ Remove head lamp casing.
Suspension & Steering ✰ Take out ball race from steering stem. REASSEMBLY OF STEERING ✰ Using a hollow drift, fix the bottom ball race the steering stem. ✰ Fix the ball race on the frame head tube (top). ✰ Fix the ball race along with cover on the frame head tube (Bottom). ✰ Apply grease on steering stem bottom ball race and Top ball races in the frame head tube. CLEANING ✰ Clean all the parts carefully for inspection. ✰ Rub the bearing race balls in a clean cloth.
Suspension & Steering ✰ Locate 19 balls each on the ball races - steering stem bottom and frame had tube top. ✰ Assemble front forks, mudguard & front wheel in reverse order of disassembly. Assemble the handle bar and other parts. ✰ Adjust the steering stem play correctly & tighten the steering stem rinch bolt under the handle bar bracket. GAS FILLED SHOCK ABSORBER WORKING PRINCIPLE ✰ Locate the head lamp casing over the frame down tube such that the centre holes align.
Suspension & Steering REMOVAL AND ASSEMBLY OF REAR SHOCK ABSORBER ✰ ✰ The shock absorber needs recharging when the system pressure is less than 5 BAR. Fit the small screw with “O” Ring. NOTE: Remove the top and bottom mounting nuts and washers. SWING ARM REMOVAL ✰ Pull out the shock absorber from bottom and slide out from frame. ✰ Assemble in the reverse of removal. ✰ Remove the chain link and take out the chain. ✰ Disconnect the brake rod nut. ✰ Remove the rear wheel sprocket assembly (1).
Suspension & Steering ✰ Remove the chain guard. ASSEMBLY ✰ Remove the swing arm cap swing pivot. ✰ ✰ Remove the swing arm hex nyloc nut & washer. Press the new plastic bush into the swing arm tube. BUSH SPACER BUSH ✰ Tap and pull out the swing arm flange hex bolt. ✰ Using a mandrel, drive out the plastic bush from either sides of the swing arm and remove the steel spacer. ✰ CAUTION : Do not remove plastic bush, unless it is defective.
Suspension & Steering ✰ ✰ Apply grease inside the bush and then insert spacer as shown in Fig. ✰ After tightening the swing arm hex nyloc nut. Remove special Tool ST 25110-3. ✰ Fix both side caps swing pivot carefully. ✰ Assemble both side shock absorbers, washers and dome nuts as shown in Fig. ✰ Assemble the chain guard. ✰ Assemble the rear wheel and adjust drive chain free play. Position special tool ST 25110-3 on shock absorber mounting pins.
Suspension & Steering CENTER STAND DISASSEMBLY ✰ Disconnect the stand return spring two nos. (1) ✰ Remove the split pins & washers from the both ends of the centre stand spindle (2). ✰ Drive out the centre stand spindle. 2 1 ASSEMBLY ✰ Assemble the centre stand in the reverse order of disassemble as shown in Fig.
SECTION TEN 10 ELECTRICALS
Electricals BATTERY ELECTRICAL SYMBOLS 01. Alternating current (AC) ... 02. Direct current (DC) ... 03. Wired across ... 04. Connection ... 05. Switch ... 06. Ground ... 07. Cell ... 08. Battery ... 09. Bulb ... 10. Coil ... 11. Resistor ... 12. Capacitor ... 13. Armature and brush ... 14. Fuse ... 15. Volt meter ... 16. Ammeter ... 17. Transformer ... 18. Transistor ... 19. Rectifier / Diode ... 20. Zener Diode ... CONSTRUCTION 21. Silicon Controlled Rectifier ...
Electricals PRECAUTIONS : ✰ Wear rubber gloves while handling a battery. ✰ Use only constant current battery charger of correct charging rate, to charge batteries. ✰ Remove the filler caps only to fill distilled water OR if the battery is to be charged. Hydration may occur when atmospheric air contacts the plates. ✰ Keep all the filler caps removed while charging the battery. ✰ Use only distilled water to top up the level after the initial charging.
Electricals TEMPERATURE OF ELECTROLYTE : CAUTION : ✰ Always connect the positive and negative terminals of battery into the positive and negative sockets provided in the constant current battery charger. Cool the electrolyte to about 30 deg. C before filling it in the battery, just below the maximum level indicated. SOAKING PERIOD: ✰ Always disconnect the Negative (-ve) terminal first & then the Positive (+ve).
Electricals MAINTENANCE ✰ Check the electrolyte level and top up, if necessary to the ‘MAX’ mark with distilled water every week. CAUTION : For topping, use only distilled water. ✰ Keep the battery surface clean and dry. ✰ Never over charge the battery - it damages the battery & plates may buckle. ✰ Remove the battery from the motorcycle and store it separately when the motorcycle is not in operation for more than one month. 10-5 ✰ Protect battery from direct sunlight, heat, rain and dust.
Electricals Specific Gravity Fully charged Carbon deposits on the spark plug establishes a ‘shunt’ between center and earth electrodes, that prevents good sparking and causes misfiring. Clean the deposits off periodically, with a spark plug cleaning tool / machine. ✰ Check spark plug for pitted out the earth and center electrodes. If the earth electrode has worn off to a knife edge and center electrode has reduced in height, replace it with new. Requires Recharging 1 .24 P ✰ 1 .
Checking Procedure of Electrical Eomponents Stator coil ✰ Pulsar coil ✰ Ignition coil ✰ Suppressor Cap ✰ Battery ✰ Horn ✰ Relay Starter ✰ Starter motor ✰ IC Flasher ✰ RR Unit PULSAR COIL ✰ SPECIFICATION Resistance mode - Across the wires 180 - 240 c ✰ (ohms). ✰ CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between a. Green to white wire.
Checking Procedure of Electrical Components CAUTION : HORN Brown or white/red to core no connectivity. ✰ SPECIFICATION Continuity Mode - Beep Sound SUPPRESSOR CAP - M14 ✰ SPECIFICATION Resistance Mode - 4.5 to 6 K ohms RELAY STARTER ✰ SPECIFICATION Resistance 4 to 5 ohms. BATTERY ✰ CHECKING PROCEDURE ✰ SPECIFICATION Set the multimeter in resistance mode. Voltage mode - 11.5 to 13 V Check the Resistance between BATTERY WHEN CHARGING a. Green/white to white wire.
Checking Procedure of Electrical Components CAUTION : Never try to repair / tamper IC Flasher. E- STARTER MOTOR RR UNIT ✰ SPECIFICATION ✰ CHECKING PROCEDURE Resistance 0.3 to 0.5 ohms. Set the multimeter in voltage mode (DCV 20). Connect the multimeter to Battery terminals and then check the voltage as shown in Fig. ✰ CHECKING PROCEDURE Set the multimeter in resistance mode. Check the Resistance between motor terminal & aluminium body.
Checking Procedure of Electrical Components ELECTRICAL PARTS INSPECTION DO’S AND DON’TS CLUTCH SWITCH ✰ Check battery for electrolyte level periodically and top up with distilled water only. ✰ For longer battery life, de-clutch before starting. ✰ If the battery is weak (below 10 V), start with the kick starter and do not try to start with self starter. ✰ Always maintain correct Engine oil level. ✰ Check for Engine backfire, if it exist & it will damage the sprag clutch & gears.
Complete Wiring Diagram - Classic 500 10-11
Complete Wiring Diagram - Classic 350 10-12
Trouble Shooting - Electricals PROBLEMS 1. E-start motor not working. PROBLEM CAUSES 1. Fuse blown. 2. If the battery voltage increases with RPM increase, replace RR Unit. 3. Faulty relay starter. 4. Starter motor cables loose connection. 5. Starter motor failure. 2. Fuse blown when pilot lamp switched 1. Rear harness cable routing fouling with ‘ON’ the tyre. 2. Rear harness cable fouling with taillamp bracket. 3. Fuse blown when Head light high beam 1. Check the Headlight wiring harness ‘ON’ 4.
SECTION ELEVEN 11 TROUBLE SHOOTING
Trouble Shooting This section discusses trouble shooting on various performance problems. This following check list can be helpful in locating most of the operating troubles. Observation Causes Remedies Complaint : Engine fails to start Ignition switch in ‘OFF’ Position Switch ‘ON’ ignition Stop switch in ‘OFF’ Position Push stop switch to ‘ON’ position.
Trouble Shooting Observation Poor Cranking Causes Remedies Loose spark plug Tighten spark plug Loose cylinder head nuts Blown cylinder head gasket Auto Decompressor mechanism stuck in open position Valves Leaking due to poor seating/burnt valves or seats Piston Rings Worn out Worn out / scored/ glazed cylinder barrel Piston rings stuck in piston grooves Tighten cylinder head nuts Change cylinder head gasket Ensure flyweight in exhaust cam gear assembly in free to operate.
Trouble Shooting Observation Fuel Related Electricals Related Causes Remedies Fuel is stale due to vehicle being in storage for a long period Fuel adulterated No fuel in the tank Fuel pump pressure low Fuel Injector partially blocked Incorrect Electrode gap Spark plug electrode dirty / fouled Wrong specification spark plug Loose HT connections/ damaged HT lead Clean petrol tank and carburetor and fill the tank with fresh petrol Refill with good fuel Fill up the tank Check and correct Replace fuel inje
Trouble Shooting Observation Electricals Related Causes Remedies Incorrect Electrode gap Adjust the gap Spark plug electrode dirty / fouled Clean park plug & Reset gap. Wrong specification spark plug Fit the correct Spark Plug Loose HT connections/ damaged HT lead Fix connections firmly/ Replace Lead.
Trouble Shooting Observation Causes Remedies Wrong grade/recycled lube oil Replace it with right grade oil Damaged valve stem seal Replace the seal Worn out / scored valve guide / valve stem Check and Replace Vertically aligned piston ring Smoke through exhaust Properly stagger the piston end gaps rings Excessive piston ring end gap Replace the piston rings Wrong fitment of piston rings Refit the piston rings correctly Connecting Rod Bent Replace the crankshaft Clearance Excess between Piston
Trouble Shooting Observation Causes Remedies Burrs in splined position of the shaft Check and Replace Improper position of the return spring.
