Manual de Taller BAJAJ BOXER S MANUAL TALLER

Contents

Service Wise Part Kit

Periodic Maintenance & Lubrication Chart

Pre Delivery Inspection

Working Thumb Rules for First Time Right - Do’s & Don’ts

Salient Features

Technical Specifications

Engine Tune-Up for getting Optimum Mileage

Chain Cleaning Procedure

Air Filter Cleaning Procedure

Tightening Torques - Frame

Service Data - Engine

Important Assembly Skill Tips

Special Tools - Engine & Vehicle

Service Data - Frame

Tightening Torques - Engine

Electricals and Battery Maintenance

Main Electrical Wiring Diagram

9

13

14

15

18

17

23

19

25

26

28

29

10

12

1

4

7

3

Individual Circuit Diagrams

STYLE :

Renowned HAMARA BAJAJ Indian looks for “Catching

selection & attraction” of customers.

• New Bajaj logo on petrol tank gives inspiring

confidence look of advanced technology.

• New decals enhances the brand image of Vehicle.

• Sleek & new age headlight fairing on ‘BOXER-S’

The ‘BOXER-S’ are brought up with a advanced

technology, packed with enhanced Power, Greater Torque

spread all across Engine rpm band.

§ The improved Engine which deliver 8.2Ps power,

makes it the most powerful bike in its class with a

mission to cross others on run with big lead.

§ The improved Engine delivers a Turning Force of 8.05

N-M, which enables hassle free take off and afford to

run the vehicle at lower engine rpm in higher gears.

The ‘BOXER-S’ engine breath through Keihin 16 mm

throat and fires on the optimized ‘Lean Burn’ principle to

cope up severe conditions.

§ Low emission of Carbon Monoxide makes the most

environment friendly vehicle in its class.

§ The ‘BOXER-S’comes with ‘Digital Twin Map CDI’

(DTM) with ‘Throttle Responsive Ignition Control

System’ (TRICS) which optimizes engine performance

at all level of work condition.

§ The ‘DTM’ CDI Ignition System ensures highly

intensified current working accurately advanced timing

for complete combustion of the air fuel mixture for

optimum power.

§ The ‘TRICS’ alters the ignition timing as per the engine

needs at higher throttle position for consistent power

delivery. The other benefit of ‘TRICS’ are-

§ Makes engine High knock resistant at high throttle

position.

§ The ‘BOXER-S’ engines have ‘Positive Crankcase

Ventilation’ system

§ It avoids scattering of hazardous engine oil fumes in to

the atmosphere. Thus reduces the air pollution.

§ It also avoids entering of dust particles from the

atmosphere in to the engine through breather pipe.

Thus eliminating contamination of engine oil, which

further minimizes wear and tear of engine components

and ensures their life.

Salient Features

POWER & PERFORMANCE :

1

The ‘BOXER-S’ is equipped with upgraded Ceriani Front

Telescopic Suspension & Optimized Rear shock absorber.

§ The dual rated coil spring in the front suspension

enhances damping effect of the hydraulic suspension

to give exemplary comfort and no fatigue to rider’s

shoulders.

§ Variable rate coil spring double acting rear shock

absorber is mounted in angular plane gives better

comfort to rider on rough road and high speed.

Smoother gear shifting is a result of introducing the star

and roller mechanism.

§ New friction free bush for gear change drum helps in

shifting the gear smoothly.

§ Star and roller mechanism for gear shifting makes the

easy operation of shifting of gear specially in city

driving condition.

§ Revised transmission gear ratio afforded to run the

vehicle in fourth gear in city drive at comparatively low

rpm without shifting the gears in lower range.

The ‘BOXER-S’ M/S gives more comfort by adding value

in other mechanism like

§ Effort for kicking are minimized by introducing starting

kick with increase in leverage.

§ Multi focal reflector for brighter head light .

§ Chassis is designed to make sure, safe & comfortable

driving on rough roads.

§ Stylish thick & wider foam seat provided in ‘BOXER-S’.

CONVENIENCE & COMFORT

Salient Features

2

Technical Specifications

ENGINE & TRANSMISSION:

Type : 4 stroke, Natural air cooled

No. Of cylinders : One.

Bore : 53.00 mm.

Stroke : 45.00mm.

Engine displacement : 99.27cc.

Compression ratio : 9.5 + 0.5 : 1

Idling Speed : 1300 + 150 rpm (in warm

condition)

Maximum net power : 8.2Ps (6.03kW) @7500rpm

Maximum net torque : 8.05 Nm at 5500 rpm

Ignition System : CDI

0

Ignition Timing : 10 BTDC @ 1300+200rpm

0

: 33 BTDC @ 4500+200rpm

Fuel : Unleaded petrol.

Carburettor : Keihin -Fie PB 16

Spark Plug : Champion PRZ9HC

: MICO UR 3 AC

Spark Plug gap : 0.6 to 0.7 mm

Lubrication : Wet sump, Forced

Starting : Kick start

Clutch : Wet, multidisc

Transmission : 4 speed constant mesh

Overall Gear Ratios :

st

1 Gear : 37:51 : 1 (37/11)

nd

2 Gear : 20.33: 1 (31/17)

rd

3 Gear : 13.29 : 1 (31/26)

th

4 Gear : 10.38 : 1 (27/29)

Final Drive Ratio : 03.30 : 1 (47/13)

Primary Gear Ratio : 03.09 : 1 (71/23)

CHASSIS AND BODY

Frame type : Tubular.

Suspension :

Front : Ceriani type, Telescopic,

Stroke = 110 mm

Rear : Trailing arm with coaxial

shock absorbers and coil

springs

Brakes Type Front : Drum type

Rear : Drum type

Brake size Front : 110 mm (drum)

Rear : 130 mm (drum)

Tyres Front : 2.75 x 17

Rear : 3.0 x 17

Tyre Pressure :

2

Front : 1.75 kg/cm (24.5 psi)

2

Rear (Solo) : 2.00 kg/cm (28 psi)

2

(With Pillion) : 2.25 Kg/cm (36 psi)

Rims : Front : 1.4 x 17, 1.6 x 17

Rear : 1.6 x 17, 1.85 x 17

Fuel tank capacity :

Full : 9.3 litr (Aprox)

Reserve : 2.2 litr (Aprox)

Usable Reserve : 1.2 litr (Aprox)

CONTROLS

Steering : Handle bar

Accelerator : Twist grip type on right

side of handle bar

Gears : Left foot pedal operated

Clutch : Lever operated on left side

of handle bar

Brakes Front : Lever operated on RH of

handle bar

Rear : Pedal operated by right

foot.

ELECTRICALS

System : 12 Volts AC + DC

Head lamp : 35 / 35 W

Tail/stop lamp : 5 / 10 W

Turn signal lamp : 10 W

Neutral Ind.. Lamp : 3W

Turn pilot Indi. lamp : 3W

Hi beam ind. lamp : 3W

Speedometer lamp : 3W

Horn : 12 V DC

Battery : 12 V - 2.5 Ah

DIMENSIONS

Length : 1970 mm

Width : 770 mm

Height : 1065 mm

Wheel base : 1235 mm

Min. Turning radius : 1900 mm

Ground Clearance : 150 (Min.)

WEIGHTS

Vehicle kerb weight : 109 Kg.

Gross vehicle weight : 239 Kg.

PERFORMANCE

Maximum speed : 90 km/h

with single rider (68kg)

0

Climbing ability : 25% (14 ) max.

NOTES

• Values given above are nominal and for guidance only, 15%

variation is allowed to cater for production and measurement

variation.

• All dimensions are under unladen condition.

• Definitions of terminologies wherever applicable are as per

relevant IS / ISO standards.

• Specifications are subject to change without notice.

3

Working Thumb Rules for First Time Right

Do’s

þ Blow air filters in opposite to airflow to enable dust to get out freely.

þ Blow dry air and confirm airflow through carburettor passages to enhance proper cleaning of

passages.

þ Blow compressed air in all the orifices in the engine parts and oil passages and confirm the

cleanliness.

þ Breather slots in the crankcase should always be kept clean to allow to escape oil fumes from engine,

otherwise it may lead to oozing out of oil through oil seals and ‘O’ rings.

þ Always apply oil during assembling, particularly at friction prone area to increase the life of the

components.

þ Always fit piston rings as per specified position.

þ Always replace ‘copper washer’ whenever the engine is overhauled.

þ Confirm seating of circlips by rotating on their seat to avoid further consequences.

þ Confirm the crankshaft centering and free rotation after fitment.

þ Whenever installing the spark plug, first screw by hand and then tighten to specified torque. This is

to ensure proper fitment and avoid thread damage.

þ Always ensure correct fitment of magneto rotor by rotating it.

þ Always connect battery with positive terminal first, then negative to avoid damage to the electrical

components in case of short circuits.

þ Always maintain correct tyre pressure, otherwise incorrect tyre pressure effects on performance of the

vehicle, riding comfort and safety.

þ Always use only genuine Bajaj parts and recommended lubricants to increase the life of the vehicle

and long term economy.

þ While replacing the chain lock link, always install the open end of the lock facing against the direction

of rotation of chain.

þ While fitting tyres, ensure the lie running alongwith the beed wire should be equidistant to wheel rim

circumference.

þ Always keep the work area clean and uncluttered to create good working atmosphere.

þ Clean the vehicle / engine before opening to enable to follow the repair in proper way help in proper

diagnosis, etc.

þ Watch for sharp edges. This avoids injury while repairing.

þ Always use correct size spanners / screw drivers to avoid damages to the nuts, bolts, etc.

þ Use special tools wherever recommended to help in smoother, safer and faster work.

þ Whenever some part is jam, check the cause (rust etc.), tap, if necessary, by mallet to avoid damage

to the component.

þ Clean the mating surface scratch free to avoid permanent damage to the surface, thus leading to

leakage and ultimately cost of replacement of the parts.

þ Inspect the parts visually as well as dimensionally, as applicable.

4

Visual

Dimensional / Numerical

Abrasion / Scratches

Alignment

Crack

Bent

Dent

Wear

Play / Slackness

Seizure

Deterioration

Proper Threading

Warp

Clearance

Any other specifications

Recommended / Allowable Tolerances / Clearance are absolute must.

Note :

þ Check the oil at drain for - Quantity, Quality, Burr Contents, Contamination, etc. this may help in

diagnosing problems.

þ While installing the bearings always tap on the race which is taking seat to avoid damage to the

bearing as the standard axial / radial clearances may increase.

þ Always use Loctite to bolts / screws wherever recommended.

þ Tighten the nut / bolts to correct torque to avoid damages to the components.

þ Tighten nut / bolts in criss-cross pattern for mating surface to avoid distortion of the parts which

leads to leakage, etc.

þ Always clean the air filter element with Kerosene / Diesel.

Working Thumb Rules for First Time Right

5

Don’ts

ý Do not use worn tools / spanners which leads damage to parts / even accident.

ý Do not apply excess force while loosening - check for rusting or jamming.

ý Do not re-use ‘o’ rings / gaskets ‘ oil seals / circlips as they loose their strength/properties, once they

are opened.

ý Do not wash air filter element with water.

ý Do not wash bearings with water otherwise they will get permanently spoiled.

ý Do not over tighten the carburettor jets, it will spoil the carburettor body.

ý Do not blow compressed air with float assembled otherwise float gets distorted.

ý Do not use hammer for engine parts to avoid damages to the components, because engine

components are critical and costly.

ý Do not check the current by earthing the lead cable of ignition coil, it may damage the igniter unit /

CDI unit.

ý Do not remove battery terminals during engine running to avoid damages.

ý Don’t push start the vehicle as it gives jerks/impacts to the engine components.

ý Never add acid to battery once it has undergone charging to avoid damage to the battery cells.

ý Never quick charge the battery – this shortens the life of the battery. Follow proper procedure to

increase the life of the battery cells.

ý Never apply grease to the battery terminals. Always apply petroleum jelly to avoid corrosion at the

terminals.

ý Do not apply direct water jet on electrical components, otherwise it will lead to failure of electrical

components.

ý Do not tune the carburettor in cold condition. Always remember tuning of carburettor must be done in

warm up condition of engine.

ý Do not remove carburettor from engine in hot condition to avoid distortion.

ý Do not adjust spark plug gap and tappet clearance with hacksaw blade or with judgement of eye

otherwise, it will effect the engine performance. Always use wire gauge for spark plug and feeler

gauge for tappet setting.

ý Do not use of wire or pin to clean the carburettor jets. Otherwise it will damage jet sizes orclogs the

jet hole if the wire get break.

ý Do not use ordinary wire in place of fuse. Otherwise it may lead to severe consequences.

Working Thumb Rules for First Time Right

6

Pre-Delivery Inspection

FRAME :

FUEL SYSTEM :

To Check Check For

ENGINE :

Engine oil SAE20W40 of API

‘SG’ + JASO ‘MA’ grade.

Oil level. Top up if required.

Oil leakage if any.

Idling Speed Check / Adjust if required. (1300 + 150 rpm)

Smooth operation.

Leakages / Fitment.

Smooth Operation.

Leakages (External), Pipe connections

Check and Tighten if required

Front brake lever play (2~3mm)

Rear brake pedal play (15~20mm)

Lever free play (2~3mm)

Smooth operation

Grip free play 2~3 mm.

Smooth operation

Self return, Cable free play,

Routing and Functions of TPS

Slackness (30~35mm)

Lubrication (SAE 90)

Check chain lock position.

Radial 0.5mm or less

Axial 0.8 mm or less

2

1.75 Kg/cm (25 PSI)

2

2.00 Kg/cm (28.0 PSI)

2

2.25 Kg/cm (32.0 PSI)

Cylinder head bolts (2.0~2.4 kg.m)

Engine mounting bolts (4.0~4.5 kg.m)

Oil drain plug (2.7~3.3 kg.m)

Spark plug (1.1~1.5 kg.m)

Kick operation

Wheels

CONTROLS

Brakes

Clutch

Throttle

TPS

Choke Working and Smooth operation.

Rim Run out with tyre

Spokes

Drive Chain

Fuel Tank / Pipes

Fuel Tap

Carburetor

Fasteners

(Check torque and correct if required)

Tyre Pressure :

Front

Rear (Solo)

Rear (Pillon)

DIRECTION OF

CHAIN ROTATION

7

To Check Check For

Front Fork

Rear Shockabsorber

Oil leakage & Smooth operation.

Smooth operation (Loose/Tight)

Steering & Ignition, Fuel tank, Seat lock, Side cover LH.

Front axle nut (5.0 + 0.5 kgm)

Rear axle nut (5.5 + 0.5 kgm)

Fork lower clamping bolt (3 + 0.5 kgm)

Trailing arm nut (4.5 + 0.5 kgm)

Rear shocker mounting nut (4.5 + 0.5 kgm)

Steering top bolt (2.5 + 0.5 kgm)

Holder handle upper bolts (4 Nos.) (1.4 + 0.2 kgm)

Holder handle flanged nuts (2 Nos.) 3.5 + 0.3 kgm)

Proper notch setting - same on both sides - 2nd notch.

Smooth operation.

Steering

SUSPENSION

Lock Operation

ELECTRICAL

Fasterners

(Check torque and correct if required)

Battery

All bulbs Working

Horn

TEST DRIVE (4~5 Kms)

Starting *

Drive Ability

CO % Check

Cleaning

Switch Operation LH and RH control, Ignition switch, Brake switch (Front/Rear).

Throttle response.

Clutch operation / Gear shifting.

Brakes (Front & Rear).

Speedometer & Odometer

CO should be 2.0 % in warm condition.

Wash & Clean vehicle properly.

Cold start and Warm start.

Idling speed (in warm condition) 1300 + 150 rpm.

Working

Head, Pilot, Tail / Stop, Speedometer, Side indicator lights.

Routing of Breather pipe, Fuse.

Electrolyte level to max level mark.

Specific gravity 1.240, Charging status - full

Connect -ve terminal & apply petroleum jelly.

Any other defects

Look for any external damages in Transit : Please check, record and rectify.

1. Moisture / Oil collecting tube of Air Filter should be properly fitted and routed correctly.

Pre-Delivery Inspection

8

Periodic Maintenance & Lubrication Chart

• : Indicates operation to be performed

* : More frequent cleaning may be required when driving in dusty condition.

Note : Parts / Lubricants to be replaced as per Periodic Maintenance and

Lubrication chart are mandatory and the same are chargeable to customer.

A : Adjust CL : Clean

C : Check L : Lubricate

T : Tighten R : Replace

Front Fork oil28.

Every 10000 Km

R

Front Fork27.

Every 5000 Kms

C

l l

Drive chain

Valve lapping

Drive chain slack

Valve oil seal

32.

34.

33.

35.

Every 500 Kms

Every 30000 Kms

Every 2500 Kms

Every 30000 Kms

L

C,A

R

Spoke tightness & Rim run out22. C,A

l l l l

General lubrication23. L

l

Swing arm pivot pin26. L

Every 10000 Km

Rear shock absorber30. C,R

l l l l l

Steering stem bearing24.

Every 10000 Km

L

1 Year

Wheel bearing25.

Every 10000 Km

L

1 Year

Front Brake Cable31. C,R

2 Years

Sr.

No.

Operation

Servicing

Valve Clearance

Engine oil (SAE 20W40 of API SG + JASO MA)

Oil Strainer

Air cleaner element *

Air Cleaner element

Carburetor / Idle speed / CO %

Fuel System leakages

Fuel Pipes

Spark Plug / Gap

Spark Plug

Brake light switch

Clutch play

Throttle play

TPS adjustment and proper functioning

Front brake lever play

Rear brake pedal play

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Whichever

comes first

OR

Kms

750 2,500 5,000

150

2,500

2259030

Days

RECOMMENDED FREQUENCY

Subsequent

Every 2,500 Km

Every 75 days

Every 5000 Kms

Every 10000 Kms

Every Year

Every 10000 Kms

Initial

A

R

CL

R

CL,A

C,R

R

CL,A

R

C,A

l

l l

l

Steering play19. C,A,R

l l l l l

All fasteners tightness20. T

l l l l l

Tyre tread wear21. C,R

l l l l

l

Brake lining wear18. C,R

l l l l l

Battery electrolyte level29. C,A

15 Days

9

Service Wise Part Kit

Engine Oil

Clutch Cover Gasket

NIL

Engine Oil

Drive Chain lock and link set

Item Description

Qty

900 ml

1

NIL

900 ml

1

Engine oil

900 ml

Clutch Cover Gasket

1

Fork Oil

300 ml

Fork Oil Seal and Dust Seal Kit

1

Air Breather Tube

Air Filter Foam element

Air Filter Cover "O" Ring

Rear Wheel Damper

Drive Chain Lock and Link Set

1

240

30 - 45

Days

75 days from

the last

service

2000 - 2500

500 - 750

4500 - 5000

Kms limit

7000 - 7500

9500 - 10,000

12000 - 12500

Engine Oil

900ml

Drive Chain lock and link set

1

Spark Plug

1 pair

Cylinder head gasket ( If required )

1

Clutch plate ( If required )

1

Brake Shoes (if worn out)

Steering stem bearing (If required)

2

1

Chain sprocket kit ( If required )

1

24500 - 25000

75 days from

the last

service

14500 - 15000

Nil Nil

17000 - 17500

19500 - 20000

22000 - 22500

NIL NIL

Engine oil

900 ml

Clutch Cover Gasket

1

Fork Oil

300 ml

Fork Oil Seal and Dust Seal Kit

1

Air Breather Tube

Air Filter Foam element

Air Filter Cover "O" Ring

Rear Wheel Damper

Drive Chain Lock and Link Set

1

10

Service Wise Part Kit

11

Item Description

Qty

Days

Kms limit

Fuel pipes

1

Carburettor duct

1

NIL

Engine Oil

900ml

Clutch Cover Gasket

1

Air Filter Foam element

1

Spark Plug

1

Fork Oil

300 ml

Drive Chain lock and link set

1

Brake shoes ( If worn out )

1 pair

Cylinder head gasket ( If required )

1

Air filter cover O ring

1

Air breather tube

1

Steering stem bearing (If required)

2

75 days from

the last

service

27000 - 27500

29500 - 30000

Valve oil seal

1

Front brake cable

1

Acclerator cable

1

NIL

Clutch cable

1

Fork Oil Seal and Dust Seal Kit

1

Rear Wheel Damper

1

Engine Tune-Up for Getting Optimum Mileage

· Return spring should

be OK.

· End point should be

intact properly at

point (A) and (B).

Check swivel bracket movement by roating it with hand. It

should not be sticky in operation and should return back

itself on releasing.

A

B

Gap

2.5mm max.

• Keep throttle at zero position (Fig.1).

• On connecting multimeter to TPS

coupler it should show continuity.

• When throttle is open and TPS

magnet crosses to straight edge of

fix bracket (Fig.2) multimeter should

show discontinuity.

• O n D e-a cce ler ati on, whe n T PS

magnet re-coinsides with straight

edge of fix bracket (Fig.2). Multimeter

should show continuity.

TPS : CHECKING

Fig.1

Fig.2

TPS: PERIODIC MAINTENANCE

· Magnet should not touch with reed switch

· Gap between Magnet and Reed switch

should not be more than 2.5 mm.

· Movement of accelerator/TPS cable

should be free.

· Greasing on TPS pin at every 5000 Km.

• TPS cable free play -

Zero

• Note : TPS cable free

play should always

be zero.(B)

• Swivel bracket must

rest on stopper as

shown in picture.(c)

• Never foul TPS cable

b y e x t e r n a l

accessories

TPS : SETTING

B

C

• Accelerator cable play : 2 ~ 3 mm (A)

SPARK PLUG : UR 3AC, PRZ

9HC.

SPARK PLUG : 0.6 to 0.7 mm

gap

Replace at every : 10,000Km.

AIR FILTER :

• Clean every 2,500 Km

• Replace every 10,000 Km.

COMPRESSION PRESSURE

2

• Std Limit : 12~14 Kg/cm

2

• Service Limit: 10.5Kg/cm

TAPPET CLEARANCE

• Inlet valve: 0.05 mm

• Exhaust valve: 0.08 mm

CARBURATTOR :

• Idling: 1300 + 150 rpm.

th

• Jet needle 'E' clip position 4

from top.

• Air screw setting: 2.5+1.5 turns

• CO % : 1.5 to 2.5 %.

ENGINE TUNE -UP

0.6 to

0.7MM

A

AA

a. Ensure no fuel leakage through fuel cock,

fuel lines.

b. Ensure free rotation of both wheels.

c. Ensure correct tyre pressure - Front

wheel : 25 PSI, Rear wheel : 28 PSI (Solo)

32 PSI (Pillion)

d. Set control cable free play:

• Clutch lever 2~3 mm.

• Choke Cable 2~3 mm

• Accelerator Cable 2~3 mm

• Front brake lever 2~3 mm.

• Rear brake pedal 20~30 mm.

e. Chain slackness : 30 to 35 mm.

f. Gap between Sensor strip of Magneto

Rotor & Pole of Pick-up coil 0.5~0.7 mm

OTHER MANDATORY CHECKS

12

Air Filter Cleaning Procedure

13

AIR FILTER

CLEANING

STAND

KEROSENE

20W40 ENGINE OIL

KEROSENE

Primary & Secondary Air Foam Filter

Precautions :

1. N e v e r u s e h i g h f l a s h p o i n t

petrochemicals for cleaning air filter

foam.

This increases :

• Possibility of foam catching

flame.

• Poracity & may lead to dust

passing through it inlong term.

2. Don’t twist air filter foam, as it may

lead to tear / bulge.

3. F o a m l u b r i c a t i o n i s u t m o s t

important since dry foam can lead

to dust entry inside engine.

4. Never use other grade oil for

lubrication of the foam.

5. Dry excess amount of oil by cotton

cloth.

6. Replace kerosene and engine oil

after cleaning 20 to 25 foams.

7. In dusty area, increase cleaning

frequency of foam.

1st Stage:

Clean With

Kerosene

Squeeze

2nd Stage:

Clean With

Kerosene Again

Blow Low

Pressure

Compressed Air

3rd Stage:

Dip Into Engine Oil

(20W40)

Squeeze & Remove

Excess Oil

Dry With

Cotton Cloth

Chain Cleaning Procedure

14

1st Stage

Clean with Kerosene

3rd Stage

Dip into SAE 90 Oil

Final Stage

Hook Chain for

dripping of excess oil

Soak into SAE 90 Oil

2nd Stage:

Clean with Cleaner

Kerosene again

Blow Compressed Air

Valve Spring Free Length

Standard

Service Limit

39.55

36.10

Camshaft Chain 20 Links

Standard

Service Limit

127.00 ~ 127.48

128.90

20-link length

1st 2nd 21st

MEASURE THIS LENGTH

Rocker Arm Shaft Diameter

Standard

Service Limit

9.98 ~ 9.99

9.95

Cam Sprocket Diameter

Standard

Service Limit

56.71

56.40

Service Data - Engine

Rocker Arm ID

Standard

Service Limit

10 ~ 10.015

10.05

Shift Fork Guide Pin Diameter

Standard

Service Limit

3.9 ~ 4.0

3.8

Standard

Service Limit

0.05

Cylinder Head Warpage

Shift Drum Groove Width

Standard

Service Limit

5.05 ~ 5.20

5.30

Friction Plate Thickness

Standard

Service Limit

2.90 ~ 3.05

2.70

Clutch Spring Free Length

Standard

Service Limit

26.4 ~ 27.0

26.0

Valve Clearance

Standard

Inlet

Service Limit

Exhaust

0.05 0.1

Valve Clearance Dia

Standard

Inlet

Service Limit

Exhaust

5.49~5.51

5.48

5.48~5.49

5.47

15

Cylinder Inside Diameter

Standard

Group A: 52.997~53.003

Group B: 53.003~53.009

10mm

20mm

40mm

Standard

Group A: 52.981~52.986

Group B: 52.987~52.993

Piston Diameter

7.0 mm

Standard

Top

Service Limit

Second

0.20~0.35 0.35~0.50

0.65 0.85

Piston Ring End Gap

Crankshaft Run Out

Standard

Service Limit

TIR 0.02 Max.

TIR 0.05

Conrod Big End Axial Clearance

Standard

Service Limit

0.1 ~ 0.2

0.7

ALL DIMENSIONS ARE IN MM

Service Data - Engine

Standard

Service Limit

0.05

Valve Stem Bend

Cam Height

Standard

Inlet

Service Limit

Exhaust

29.000 29.000

28.925 28.925

Valve Head Thickness

Standard

Inlet

Service Limit

Exhaust

0.55~0.80 0.85~1.15

0.4 0.5

CARBURETTOR SPECIFICATIONS

Item

Make & Type Keihin PB 16

Idling speed 1300+150 rpm

Air screw 1.5 + 1 Turn

Jet needle clip position 4TH from Top

Main jet # 78

Pilot jet # 40

Jet needle no. # NFHA

Float height 11.7mm

16

Brake Panel Cam Hole Dia.

Standard

Service Limit

12.0 ~ 12.03

12.8

Axle Run Out

Standard

Service Limit

TIR 0.05

TIR 0.2

100 mm

Drive Chain Slack

Standard

Service Limit

20 ~ 30

> 30

Brake Cam Diameter

Standard

Service Limit

11.95 ~ 11.98

11.88

Drive Chain Length

Standard

Service Limit

254 ~ 254.6

260

20-link length

1st 2nd 21st

MEASURE THIS LENGTH

Brake Shoe Lining Thickness

Standard

Service Limit

3.9 ~ 4.5

2.5

Front Tyre Tread Depth

Standard

Service Limit

5.0

1.0

Service Data - Frame

Brake Drum Inside Diameter

Standard

Service Limit

110.00 ~ 110.16

110.75

Axial Wheel Run Out

Standard

Service Limit

TIR 1.0 or Less

TIR 2.0 or Less

Radial Wheel Run Out

Standard

Service Limit

TIR 0.8

TIR 2.0

Rear Tyre Tread Depth

Standard

Service Limit

7.0

1.0

TIR 0.4 or Less

TIR 0.5 or Less

Rear Sprocket Warp

Standard

Service Limit

17

Always Use special tool No E6101100 (A) for fitting bush for gear drum

change (B) in Crankcase

Always ensure fitting of a washer provided below 2nd gear Input.

Fit one washer (A) stopper cam gear shift (B) and coller type bolt (C).

The stopper cam gear shift should not get jam after tightening the bolt

Torque - .9 to 1.1 kgm

Use loctite no - 242.

For removing & tightening centrifugal filter nut-

Use Special Tool - 3710 DJ43

While removing cam chain sprocket -

Use special tool No - E6101200 (A) to Hold Cam Sprocket to loosen &

tighten centre allen bolt.

Note: i) Allen bolt has RH thread

ii) Use loctite no - 242

While fitting cam chain sprocket -

Fit one coller cam (A) below the Sprocket (B) and one washer special (C)

above Cam sprocket before tightening the allen bolt.

Groove side surface of washer special should be kept towards Cam

Sprocket.

Important Assembly Skill Tips

18

Special Tools - Engine

19

Bearing Race Extractor

Drawing No.:

37 00DJ 01

Application :

Used for removing the lower bearing

race from ‘T’

Special Nut

Drawing No.:

37 10DJ 43

Application :

Used to remove / fit of centrifugal

oil filter nut.

Note : Existing tool can be used by reducing diameter to 25.9 + 0.1 mm

Dia. = 25.9+0.1

Adaptor & Valve Spring compressor

Adaptor - Drawing No.: 37 10DJ 78

Valve Spring Compressor - Drawing

No.: 37 1031 07

Application :

Used for assembling / dismantling

inlet, exhaust valves by compressing

spring in cylinder head.

Drift

Drawing No.:

74 9309 89

Application :

To remove piston pin.

Output Sprocket Holder

Drawing No.:

37 1030 53

Application :

To hold the output sprocket while

removing sprocket bolt

Special Tools - Engine

20

Cam Sprocket Holder

Part No. : F41AJA08

Application:

For holding sprocket during removal

/ refitting of Cam sprocket allen bolt.

Magneto Rotor Holder

Part No. : F41AJA09

Application :

To hold rotor while loosening /

tightening its nut.

Magneto Rotor Puller

Part No. : F41AJA10

Application :

To pull out the rotor from crankshaft

assembly.

Primary Gear Holder

Part No. : F41AJA11

Application :

To hold primary & secondary gear

while loosening / tightening the

primary gear nut & s p e c i a l n u t

securing clutch.

Socket for Clutch Nut

Part No. : F41ZJA54

Application :

To loosen / tighten special nut

securing clutch.

Special Tools - Engine

21

Spark Plug Spanner

Part No. : 37 1040 51

Application :

For removing & refitting spark plug

exhaust & Intake side.

Valve Tappet Adjuster

Part No. : 37103153

Application :

To hold Valve Tappet screw while

adjusting tappet clearance.

Drift Piston Pin

Part No. : 37 1010 06

Application :

To remove refit piston pin.

Special Tools - Vehicle

22

Fork Oil Seal Driver

Part No. : 37 1830 07

Application :

To fit fork oil seal in its seat provided at outer

pipe ID.

Stem Bearing Driver

Part No. : 37 1830 05

Application :

To fit bearing race on fork under holder

bracket.

Front fork cylinder holder handle with

adaptor

Part No. : 37 1830 06

Application :

To hold fork cylinder while loosening /

tightening fork allen head bolt at bottom.

Installer Upper & Lower Bearing Race

Frame

Part No. : 37 1801 06

Application :

To install upper & lower steering races /

cones into their seats inside frame.

Bearing Race Extractor

Part No. : 37 1030 48

Application :

To Pull out steering race from ' Fork Under

Holder bracket'

Steering Cone Remover

Part No. : 37 1805 06

Application :

To remove steering cones from frame.

Generator Cover Mtg. Bolts

0.9 to 1.1 kgm

Tightening Torques - Engine

Engine Mounting Bolts

M8-2.3-2.9 Kg-m / M10-4.0-4.5 Kg-m

Engine Mounting Bolts

M8-2.3-2.9 Kg-m / M10-4.0-4.5 Kg-m

Engine Mounting Bolts

M8-2.3-2.9Kg-m / M10-4.0-4.5 Kgm

Spark Plug

1.1 to 1.5 kgm.

Cylinder Head Bolts

M8 - 0.9 to 1.1 kgm

Cylinder Head Bolts

M8 - 2.0 to 2.4 kgm.

Intake Pipe Bolts

1.3 to 1.6 kgm.

Oil Pipe Banjo Bolts

A - 1.3~1.7 kgm / B - 2.2~2.8 kgm

Silencer Mounting Nuts

1.4 to 1.9 kgm.

Engine Drain Bolt

2.7 to 3.3 kgm.

Clutch Cover Mtg. Bolts

0.9 to 1.1 kgm.

Shift Drum Position Lever Nut

0.9 to 1.1 Kg-m (Loctite-243)

Crankcase Joining Bolts

1.0 to 1.1 kgm.

Fly Wheel Nut

5.4 to 5.6 kgm (Loctite 243)

23

1.3 to 1.5 kgm (Loctite 243) 0.8 to 1.0 kgm

Valve Adj. Screw Lock Nut

Tightening Torques - Engine

Rotor Nut

4.0 to 4.5 kgm.

Clutch Nut

9.0 to 10.0 kgm

Chain Tensioner Mtg. Bolts

0.45 to 0.61 kgm

Shift Shaft Return Spring Pin

2.8 to 3.2 kgm (Loctite 638)

Neutral Switch

1.1 to 1.3 kgm (Loctite 243)

OHC & Tappet Cover Mtg. Bolts

0.45 to 0.61 kgm.

Cam Sprocket Mtg. Bolt

24

Steering Stem Head Bolt

2.5 + 0.5 kgm

Tightening Torques - Frame

Front Axle Nut

5.0 + 0.5 kgm

Rear Axle Nut

5.5 + 0.5 kgm

Coupling Sleeve Nut

6.5 + 0.5 kgm

Rear Sprocket Mtg. Nut

3.5 + 0.3 kgm

Torque Link Nut

2.5 + 0.3 kgm

Steering Stem Lock Nut

0.5 + 0.1 kgm.

Front Fork Clamp Bolt

3.0 + 0.5 kgm.

Front Fork Top Bolt

2.5 + 0.5 kgm.

Front Fork Bottom Allen Bolt

2.0 + 0.5 kgm

Front Fork Oil Drain Plug

0.6 + 0.9 kgm.

Handle Bar Clamp Bolts

1.4 + 0.2 kgm

25

Electricals and Battery Maintenance

Meter positive (+ve) lead connection

A

B

B 0

C

D

E

F

G

Range

Diode

Meter negative (-)

lead connection

0.7-1.5 0.7-1.50.5-1.0

0.5-1.0 0.5-1.0

0

A

B

C

D

E

F G

CDI Unit

NNoottee : Use Digital Multimedia of make Kusum - Model 603

Pickup Coil:

Connection Reading

Meter +ve Meter -ve (Ohms)

White / Red White / Green 180 - 240

Excitor Coil :

Connection Reading

Meter +ve Meter -ve (Ohms)

Red White / Green 270 - 350

Battery Charging Coil :

Connection Reading

Meter +ve Meter -ve (Ohms)

Blue / White White / Green 0.5 - 1.0

Lighting Coil :

Connection Reading

Meter +ve Meter -ve (Ohms)

Yellow / Red White / Green 0.5 - 1.0

Rectifier & Regulator Assembly

AC voltage measurement:

Range Meter +ve Meter -ve Reading

AC 25 V Red / Black Black / Yellow 13 - 14 V at

4000 rpm

DC charging voltage measurement:

Range Meter +ve Meter -ve Reading

DC 25 V White wire of Battery - ve 13 - 15 V at

RR unit terminal 4000 rpm

DC charging current measurement:

Range Meter +ve Meter -ve Reading

20 A White wire of Battery + ve 1 - 2 Amp

RR unit terminal at 4000 rpm

Range

(Ohms)

Range

(Ohms)

Range

(Ohms)

Range

(Ohms)

26

Electricals and Battery Maintenance

1. Resistance values of charging coil, pick up coil, lighting coil & Battery charging coil

a. Lighting coil resistance between Y & B/Y – 0.4 ± 0.04 ohms

b. Battery charging coil resistance bet L/W & B/Y - 0.5 ± 0.05 ohms

c. Exciter coil resistance bet Red & B/Y – 310 ± 30 ohms

d. Pulser coil resistance bet R/W & B/Y – 220 ± 20 ohms

2. Resistance values of H.T. Coil

a. Primary coil winding - 0.45 ± 0.04 ohms

b. Secondary coil winding - 4.7 ± 0.4 K ohms

3. Battery charging procedure

a. Each cell of battery is to be filled up with battery grade sulphuric acid (electrolyte) of sp.

gravity 1.24 ± 0.01 up to max ( upper ) level mark. the initial temperature of the electrolyte

should not exceed 35°c.

b. Keep the batteries for a period of 2 hrs. top up the electrolyte level to the upper level mark if

required with electrolyte of specific 1.24 ± 0.01.

c. Ensure that the temperature of electrolyte has fallen below 40°c. then charge the battery at the

rate of 0.25 amp (in constant current mode) for min. 12 hrs and check for,

- All the cells are gassing freely.

- Terminal voltage & specific gravity readings for 3 consecutive hrs.

Values of voltage & specific gravity remain constant at the end of charging.

This is known as full charged condition of a battery. at this point, specific gravity of electrolyte should be

1.24 ± 0.01.

If electrolyte sp. gravity is noted to be more or less than the specified range as mentioned above, adjust

the same by either diluting with distilled water or topping with electrolyte of sp. gravity 1.24 ± 0.01.

But each correction must be followed by about one hour charging for proper mixing before sp. gravity

reading is taken again. ensure proper final levels.

d. Temperature of electrolyte in any of the cells during charging should not allowed to exceed 50°c.

if this occurs charging is to be interrupted. charging can be continued after the temperature of

the electrolyte in the cells has fallen below 40°c.

e. Battery terminal voltage at the end of the charging & in connected condition to the charger

should be 16.0v min & specific gravity should be 1.24 ± 0.01. battery charging current should be

0.25 amp const.

f. Terminal voltage of the battery after settlement of 24 hrs. should be 12.4v min.

g. After completion of charging, batteries are to be washed under tap water & then to be cleaned,

dried properly.

27

Main Electrical Wiring Diagram

28

Individual Electrical Circuit Diagrams

Battery Circuit

29

Individual Electrical Circuit Diagrams

Ignition Circuit

30

Individual Electrical Circuit Diagrams

Battery Circuit

31

Notes