SERVICING OF 4 STROKE ENGINE CONTENTS

DESCRIPTION
Dismantling of Engine
Activities to be done before Separating the Engine from Chassis
Dislocating Electrical connections
Hand starter Mechanism
Removal of clutch
Engine oil draining
Dismantling Starter motor
Cover crank case R
Gear oil pump
Primary drive gear
Clutch assembly
Clutch components inspection
Reverse gear mechanism
Gear shifter mechanism
Oil pump assembly
Intake manifold and cowl air cooling
Removal of Spark plug
Cover cylinder head
Cylinder head
Fan air cooling & Magneto assembly
Cylinder block
Piston & Piston rings
Differential & Hand starter mechanism
Separating engine from chassis
Separating Crank case RH $ Crank case LH
Drive shaft and Counter shaft
Differential sub assembly
Inspection of Engine Component
Bearings
Crank shaft assembly
Cylinder block
Piston
Piston Rings
Clutch components
Cylinder head assembly
Valve & valve spring
Cylinder block
Cam shaft
Engine Re-assembly
Hand Starter mechanism
Oil pump re assembly
Assembly of Piston $ Piston rings
Lapping of Valves
Valve timing and Tappet adjustment
Exploded view of Head complete cylinder block assembly

32
32
34
34
35
35
36
36
37
37
37
38
39
39
40
40
41
41
41
46
47
48
49
50
51
52
54
54
54
55
56
56
57
58
59
60
60
61
63
63
64
65
65
66
68
31

ENGINE DISMANTLING
Activities to be done before Separating Engine from Chassis
Loosen and remove 2 nos. of M6 hexagonal flanged nuts
along with spring washers. (Fig.4_2.1)
Separate the carburettor from intake manifold along with
adaptor.
10 mm DE spanner
Fig.4_2.1

Separate silencer from engine (Refer Periodic Maintenance)

Loosen and remove 2 no. M6X16 hexagonal flange bolts

(B)toseparate the starter motor bracket from cover
crankcase R.

Loosen 1 no. M6X50 hexagonal flange bolt (A) to separate

bracket SAI (Secondary Air Injection) unit from cover
crankcase R. ( Fig.4_2.2 )

B
B

8 mm T spanner

Dislocate the hose clip SAI hose air outlet (A) from pipe complete secondary air injection. (Fig.4_2.3)

Fig.4_2.2

Dislocate the hose clip and disconnect the hose cut off
valve of SAI (B)from the pipe intake. (Fig.4_2.3)
Nose plier

A
Dislocate the hose clip hose vacuum (A) of LPG reducer
unit and disconnect it from pipe intake. (Fig.4_2.4)

Dislocate the hose clip hose positive crankcase ventilation

(B) and separate it from air filter. (Fig.4_2.4)
Fig.4_2.3

Nose Plier

Disconnect the Oil pressure switch (C & D ) from wiring

harness. (Fig.4_2.4)

Loosen the lock nut of clutch cable adjuster.

Loosen and take out the adjuster nut from bracket clutch.

Disconnect the clutch cable inner from rod complete

clutch release.
12 mm spanner

Fig.4_2.4

32

 Loosen the lock nut on cable gear shift white and take it out
the adjuster from crank case R. (Fig.4_2.5 )
10 mm spanner
Loosen the lock nut on the cable gear shift black and take
put the adjuster from Crank case R (Fig.4_2.5 )
12 mm spanner

Loosen and remove the hexagonal nut from the pulley gear
shift along with 1 spring and 1 plain washer. (Fig.4_2.6 )

Fig.4_2.5

Pull out the pulley gear shifter from the shaft gear shift.
13 mm spanner
Loosen and separate the gear cable adjuster bolt from the
cover clutch.

Unlock the clip bellow muff cup. (Fig.4_2.7 )

Fig.4_2.6

Flat head screw driver

Separate the bellow from muff cup.
? Inspect the bellow muff cup for damages. If damaged
replace the muff cup with new one.

? Loosen remove the trailing arm hexagonal nut along with

spring washer. (Fig.4_2.8 )
Fig.4_2.7

22 mm spanner
? Gently tap and take out the bolt M14X 2 X 245 along with
plain washer.
?

Pull the trailing arm and pull out the propeller shaft LH
from the muff - cup along with slider and pin.

Take out the buffer 9mm from the engine side muff cup

Fig.4_2.8

33

Electrical connections
( Red )

( Black )

Loosen and disconnect the 1 positive ( Red ) and negative

wiring (Black 2 nos.) connections of starter motor from
starter relay (Fig.4_2.9)
10 mm spanner

Fig.4_2.9

Disconnect the neutral switch connection coupler from

wiring harness. (1 )

Dislocate the grommet from cover TCI. (2)

Disconnect the magneto output and pulsar coil couplers
from regulator cum rectifier unit and TCI unit. (3) (Fig.4_2.10)

2
HAND STARTER MECHANISM
Fig.4_2.10

Take out the spring clip front, hand starter from support
shaft hand starter engine end.
Take out the split pin from the pin hand starter and take
it out. Separate the eye bolt from shaft complete rear hand
starter. (Fig.4_2.11)
Nose plier

Fig.4_2.11

Press the support shaft hand starter and separate it from

the shaft complete rear hand starter.
Separate the shaft complete rear hand starter from the
dog driven. (Fig.4_2.12)

Fig.4_2.12

Note : While re assembly ensure the proper play of hand starter for the smooth operation
8 mm T spanner

34

REMOVAL OF CLUTCH
? Clutch plates can be replaced with the engine on the
chassis
Engine oil Draining
? Loosen and remove the gauge oil level engine. (Fig.4_2.13)
Note : While re assembling the gauge oil level ensure
8
mm
T spanner
the
presence
of O ring and replace with new one if
damaged, also ensure proper seating.
?
?

Keep a measuring Jar below the engine

Loosen 2 nos. M6 hexagonal flanged nuts and remove
cover oil strainer along with O ring. (Fig.4_2.14 ) (1& 2 )
8mm T spanner

Fig.4_2.13

(1)

(2)

Note : While re assembling the cover oil stainer

8
mm Tthe
spanner
ensure
presence of O ring and replace with new
one if damaged, also ensure proper seating.
(3)

Drain the engine oil

Pull out the Strainer complete engine oil and inspect for any
damage. Replace if necessary. Other wise clean and reassemble the strainer. (Fig.4_2.14) (3)
? Fill recommended Active 4T Oil
?
?

Engine oil capacity 1750ml refilling 1800ml overhauling

Fig.4_2.14

Note : Before adding the fresh oil, check up the

condition of oil filter complete engine oil and replace,
oil filter if required with new one.
While re-assembling the strainer complete engine oil
match the tapper portion of strainer to crank case.
Filter complete Engine Oil
? Bfore replacing oil filter drain the engine oil as per the
guideline given above.
? Loosen 3 nos.M6X16 hexagonal flanged bolts uniformly
and remove cover oil filter (D) along with O ring.(E)
(Fig.4_2.15)
8mm T spanner,
Note : During assembly of cover oil strainer ensure that
the arrow mark on the cover oil filter, should face
towards upside. (Fig.4_2.15 ) Also ensure O ring is not
damaged and seated properly in the groove provided
in the cover oil filter.
Taake out the sprinf oil filter (C) and filter complete engine
oil (A) and O ring (B) (Fig.4_2.16)
? While assembling locate seal end ( F ) of the filer towards
crank shaft. (Fig.4_2.16)
? Ensure that the spring oil filter is seated into the slot in the
cover oil filter.

Fig.4_2.15

Fig.4_2.16

Caution : Loosen 3 bolts gradually from the cover oil filter to avoid thred damage
35

Note : Keep an oil bowl while opening the a oil filter to

8
mm Tthe
panner
collect
left over oil.
When ever the filter complete engine oil is replaced, it is
recommended that engine oil is also to be replaced

? Re assemble the parts in reverse order of dismantling.

Clamp Starter motor
? Loosen and remove 2 nos. M6X16 hexagonal flanged bolt
from bracket starter motor. (Fig.4_2.17 )
? Separate the starter motor bracket from the starter motor
and cover crank case R (Fig.4_2.17)
? Take out the bracket starter motor.
? Loosen and remove 1 no. M6X50 hexagonal flange bolt
? Take out the bracket SAI unit. (Fig.4_2.17)

Fig.4_2.17

8mm T spanner
Note : While assembly, ensure the bracket SAI is fitted
8with
mmthe
T spanner
welded nuts facing towards the engine.

? Loosen and remove 2 nos. M6X50 hexagonal flange bolt

and remove the bracket clutch abutment. (Fig.4_2.18)
8mm T spanner
Cover crank case R
? Loosen and remove 9 nos. M6X50 hexagonal flange bolt
from Cover crank case R. (Fig.4_2.19)
? Loosen and remove 2 nos. M6X122 hexagonal flange bolt
from Cover carnk case R. (Fig.4_2.19)

Fig.4_2.18

2 nos. M6X122
hexagonal flange bolt

8mm T spanner
?

Gently tap the cover clutch and separate the cover clutch
from the cover crankcase R.

9 nos. M6X50
hexagonal flange bolt

Nylon hammer
?

Take out the gasket Cover crank case R

Note : During assembly scrap out the gasket parts
8
mm T spanner
sticking
on the cover clutch machined surface to avoid
oil leakage, always replace with new gasket.
Fig.4_2.19

Take out the pin clutch release and rod complete clutch
release along with plain washer and spring clutch cable
return. (Fig.4_2.20 )

Take out the ball bearing from plate clutch

release.(Fig.4_2.20 )

Note: During assembly lock the spring clutch cable

return on the projection given on cover clutch.
Press the rod complete, clutch release and position the
pin clutch release in the slot on the bottom of the rod
complete, clutch release.
Fig.4_2.20

36

Oil pump assembly

? Loosen 1 no. M5X10 Hexagonal bolt from the gear drive oil
pump along with 2 nos. of 5.5X10X1 mm punched
washers.
? Take out the gear oil pump drive. (Fig.4_2.21)
8 mm T spanner
?

Take out the chain oil pump drive.

Note : While re assembling the cahin oil pump drive
8
mm Tthe
spanner
ensure
chain is assembled in the direction marked
on the link.

Lock the gear assembly primary driven and gear primary

drive using special tool. (Fig.4_2.22)
G3310710

Fig.4_2.21

Holding Tool Primary Driven Gear

Loosen and remove the nut clutch using special tool and
ring spanner.
22.mm Ring spanner
G3310430

Tightening tool, clutch nut

Note: To loosen the clutch nut, rotate in clockwise direction.

Tightening torque

45 55 Nm

Fig.4_2.22

Engine oil capacity 1750ml refilling 1800ml overhauling

?

Take out the spring disc of 16.5 X 27 X 1.5. (Fig.4_2.22)

Primary Drive Gear

? Loosen and remove hexagonal nut, Gear Primary drive

along with a spring disc of 16.5 X 27 X 1.5. (Fig.4_2.23)
22 mm ring spanner
Note : While assembling the nut clutch and nut Primary
Drive gear apply the thread lock paste on the thread.
?
?

Fig.4_2.23

Take out the Primary Drive Gear (Fig.4_2.23)

Take out the woodruff key 6.5X13X4 from the crankshaft.
Nose plier
Clutch Sub Assembly
on plate clutch release. (Fig.4_2.25)
10 mm T Spanner
Note : While assembling the bolt disc clutch apply the
thread lock paste on the thread.

Fig.4_2.24

37

? Take spring clutch 4 nos.

? Take out the hub clutch and shim 8 mm thick (Fig.4_2.25)
?

Take out the washer and spring clutch judder. (Fig.4_2.25)

Note :While assembly, ensure that the conical surface
8
spanner
ofmm
the Tjudder
ring faces outside.

Take out the plate clutch drive of lesser width 1 nos.

Take out the plate clutch drive 4 nos. and plate clutch driven
4 nos. (Fig.4_2.25)

Take out the disc clutch release and gear assembly primary
driven from the counter shaft (Fig.4_2.25)

Take out the spacer gear primary driven along with the shim
of 20X32X1.5.

Fig.4_2.25

CLUTCH INSPECTION
Plate clutch drive and driven
?

As clutch plates remain in oil, they are subject to lesser wear

and tear, and therefore last longer. Their life depends
largely on the quality of transmission oil used and the way
clutch is used.

The plates are to be replaced when found worn-out,

distorted, bulged out or burnt.

Measure the thickness and claw width of plate clutch drive

(6 nos.) using special tool. (Fig.4_2.26)

Measure the ticke ness of plate clutch driven.

Fig.4_2.26

Vernier caliper & Feeler gauge

Service limit
Plate clutch drive thickness
Plate clutch drive claw width
Plate clutch driven distortion

mm
2.6
9.5
0.10
Fig.4_2.27

SPRING CLUTCH
?

Spring clutch which have lost their tension cause clutch

slippage, resulting in loss of power and rapid wear of the
clutch plates.

Remove the spring clutch (6 nos.) from the hub clutch

sleeve.

Measure the free length of the spring clutch (6 nos.). (Fig.

3.56)
Service limit
Free length of spring clutch

mm
31

Note: If any one of them is less than the service limit,

replace all the springs with a new as a set.

Fig.4_2.28

38

REVERSE GEAR MECHANISM

Loosen and remove 1 no. M6X30 hexagonal flange bolt
from retainer arm reverse.

T spanner 8mm

Note : While assembling the bolt retainer arm reverse

apply the thread lock paste on the thread.

Take out the Retainer arm reverse (2) and plate stopper
reverse (3) from index star( Fig.4_2.29 )
Fig.4_2.29

Remove the circlip from arm stopper reverse. ( Fig.4_2.30)

External circlip plier
Separate the Arm stopper reverse fand Plate lock arm
spring reverse from drive shaft.
? The profile on the plate of the spring reverse gear stopper
lever sits on the profile cut on shaft drive.( Fig.4_2.30)
? Separate the spring gearshift cam lock arm from Plate lock
arm spring reverse position

GEAR SHIFTER MECHANISM

Fig.4_2.30

? Loosen the bolt, Gear Shift Cam Stopper

? Take out the stopper complete gear shift and special washer
of 6X12X1along with spring gear shift cam Stopper
(Fig.4_2.31)
T spanner 10mm
?Pull out the locator pin index ( Fig.4_2.31)

Nose plier
Note: The spring has to be located on the groove
provided on stopper while assembly
?

Take out the spacer gear shift shaft (1). ( Fig.4_2.32)

Pull out the gearshift shaft (2). ( Fig.4_2.32)

Take out the index cam gearshift (3) ( Fig.4_2.32)

Separate the gear from shaft gearshift by taking out the lock
pin (4). ( Fig.4_2.32)

Take out the dowel pin of 9 mm dia. 2 nos from the crank
case RH.

Fig.4_2.31

3
1

Nose plier
2
Note: While assembling make sure that punch mark
on the index star and arrow on gear, shift shaft are
coinciding to ensure neutral position.

Fig.4_2.32

39

Oil pump assembly

Loosen and remove 2 nos. M6X16 hexagonal flange bolt.

(A )

Loosen and remove 1 no. M6X25 plated hexagonal flange

bolt (Fig. 4_2.33 ) (A)
T spanner 8mm
?

Separate the rotor and stator gear from oil pump and clean
the gear as well as pump body in kerosene.
Note : While assembling the rotor gaers of oil pump
make sure that c mark on the gear should face upside
Fig.4_2.33

Intake manifold and Cowl air cooling

Loosen and remove 2 nos. M6X20 allen bolts from intake
manifold along with spring washers. ( Fig.4_2.34)
5 mm Allenkey
Separate the intake manifold from the cylinder head.
?
?
?

Remove the gasket intake manifold ( Fig.4_2.34).

Clean the intake inlet.
Uniformly loosen and remove 4 nos. M6X25 plated
hexagonal flange bolts diagonally from the cowl top air
cooling. ( Fig.4_2.34)

Take out the cowl top air cooling.

Loosen and remove 2 nos. M6X25 plated hexagonal flange

bolts and separate the cowl air cooling RH.( Fig.4_2.35)

Fig.4_2.34

T spanner 8 mm
?

Remove the cap timing mark inspection on cowl air cooling

LH. ( Fig.4_2.35)

Rotate fan and match the timing mark on magneto rotor to

the arrow mark on the cowl air cooling RH.
17 mm Tubular spanner, nose plier
Note: At this point the arm complete valve rocker should be
free, other wise rotate rotor 360 & align the mark again

Loosen and remove 2 nos. M6X20 hexagonal flange bolt

with clamp wire routing. from cowl LH air cooling

Loosen and remove nos. M6X20 hexagonal flange bolt

from cowl LH air cooling. ( Fig.4_2.36)

Remove the Cowl LH air cooling.

Fig.4_2.35

T spanner 8 mm
Caution: During the assembly of Cowl LH, RH and
top make sure that all three should be seated
properly to avoid air leakage to get proper cooling.

Fig.4_2.36

40

Removal of Starter Motor

For removing the bracket starter motor refer Chapter
servicing of engine page number 36
Loosen & remove hex bolts of M8X40 (2 nos) along with
spring washer from crankcase LH. (Fig.4_2.37 )
Ring spanner 14 mm
?

Separate the starter motor from the crank case LH.

Removal Of Spark Plug

Fig.4_2.37

Loosen and remove spark plug. (Fig.4_2.38)

Tubular spanner 16 mm
Spark plug specifiaction

Bosch UR 6 DC

Note: Before reassembling the Spark plug, clean the plug and
reset the gap to the specified limit.
? For inspection and cleaning procedure for spark plug refer

chapter Periodic maintenance page number 13

Cover Cylinder Head
Fig.4_2.38

Remove both the cap inspection hole along with O ring

from the cover cylinder head. (Fig.4_2.39)
Ring spanner 13 mm
Note: While reassembling, the cap inspection ensure the
presence of the O ring.
Before removing the Cowl LH air cooling align the mark on
the magneto rotor to mark on thr Cowl LH,

Loosen and remove 4 nos. M6X35 hexagonal flange bolts

with green passivation from cover cylinder head.

Loosen and remove 2 nos. M6X45 plated hexagonal flange

bolts from cover cylinder head. (Fig.4_2.40)

Loosen and remove 4nos. M6X55 plated hexagonal flange

bolts along with rubber seal washers. (Fig.4_2.40)

Remove cover cylinder head by tapping with nylon hammer.

During assembly apply liquid gasket.
10 mm T spanner, Nylon hammer

Anabond spec

Fig.4_2.39

Anabond 116

Note: During the assembly of M6X55 bolts on cover

cylinder head apply thread lock.
While reassembling, insert all the bolts and ensure
equal height of the bolts from their respective seating
surface. Before tightening, also inspect the gasket
cylinder head cover bolt for any damage, replace if
necessary.

Fig.4_2.40

41

Loosen and remove both the plug rocker arm shafts (inlet &
exhaust side) along with the gasket from the cover cylinder
head. (Fig.4_2.41)
Allen Key 8 mm

Screw inn a M6 bolt in to the shaft valve rocker arm, gently

pull out the shaft valve rocker arm from the cover cylinder
head. ( (Fig.4_2.41)
Note: While assembling the shaft valve rocker arm ,
ensure that the cut mark on the shaft valve rocker arm
matches with the cut on the cover cylinder head.

Remove the arm complete valve rocker. (Fig.4_2.42)

Take out the arm complete valve rocker fron the cover
cylinder head.(Fig.4_2.42)

Inspection of the cover cylinder head and arm complet

valve rocker.

Similarly remove the other arm complete valve rocker from

the cover cylinder head.

Take out the pin cylinder head cover knock of dia 8mm (A)
(2 nos.) (Fig.4_2.43)

Take out the plug cylinder head (B). (Fig.4_2.43).

Fig.4_2.41

Fig.4_2.42

Nose plier
?

Remove the bolt adjuster assembly tensioner (A) and take

out the bolt along with the spring and O ring. (Fig.4_2.44)
10 mm spanner

Remove the hexagonal flange bolts of (B) (M6x16 - 2 nos.)

from the adjuster assembly tensioner mounting and take out
the adjuster along with gasket. (Fig.4_2.44)

Fig.4_2.43

8 mm spanner
(A)

Note: While assembling the chain tensioner replace the

gasket chain tensioner and O ring with new one.
Adjust the tensioner for properly to avoid noise and
chain wear.

(B)
(B)
Fig.4_2.44

42

? Unfold the washer sprocket (A) (Fig.4_2.45)

Chisel & Metal Hammer.

? Press and hold the right side bearing portion of cam shaft
complete firmly. Hold the rotor assembly using special
tool, remove the hexagonal bolts (B) (M6x12 - 2 nos.) from
sprocket camshaft mounting. ( (Fig.4_2.45)
?

Remove the washer sprocket.

G3310680

Holder assembly magneto

Fig.4_2.45

10 mm T spanner
Caution: Ensure that washer sprocket and bolts sproket
does not fall insude the engine.
?

Pull out the sprocket camshaft along with the chain

complete camshaft drive from the camshaft complete.
Dislocate the chain complete from the sprocket and take out
the sprocket camshaft. (Fig.4_2.46)

Hold the chain complete camshaft drive using a good

quality copper wire to prevent the chain from falling into the
crankcase assembly and hang it on the head complete
cylinder.

Fig.4_2.46

? Remove the pin sprocket knock (A) from the camshaft

complete (B) and take out the cam shaft (B) from the cylinder
head. (Fig.4_2.47)
Nose plier

20 0

Caution: Ensure that pin sprocket knock from cam shaft

does not fall inside engine.

? Take out the C washer from the groove on the head.

Fig.4_2.47

? Remove the hexagonal flange nuts (M6 - 2 nos.) fastened to

head complete cylinder and cylinder block complete.
Similarly, remove the hexagonal bolts (M6X20 - 2 nos.)
fastened to cylinder block complete and crankcase
complete R (Fig.4_2.48)

20
0

10 mm DE spanner

Caution: Before loosening the cylinder head nuts

always loosen the above 2 nuts and 2 bolts first.
Fig.4_2.48

43

? Loosen and remove 1no. Of hex flange nut (A) from top LH

side of the cylinder head.

? Take out the copper washer (Gasket cylinder head nut ) of

8.5X17X2.3 (Fig.4_2.49)

? Loosen and remove Hex. Flange nut 3 nos. from cylinder

head

? Ttake out the plain washer of 8.5X18.5X2.3 three nos.

12 mm T Spanner
B

Caution: While reassembling, ensure that the gaskets

cylinder head nut are assembled only on the bolts top
cylinder stud L.
?

Fig.4_2.49

Holding the chain, gently lift the head complete cylinder as

an assembly along with tensioner cam chain guide.
(Fig.4_2.50 )
Note: Gently tap with rubber mallet if required for easy
removal of head complete cylinder.

Take out the gasket cylinder head. (Fig.4_2.50 )

Note: During assembly of cylinder head replace the
gasket with new one. Ensure the profile of the gasket is
matching with the profile of the cylinder block

Fig.4_2.50

Inspect the chain guide(Tensioner side) for wear $ tear

and damage. If so replace the chain guide with new
one.
?

To replace the chain guide loosen and remove Hex. Special

bolt of M8X40 along with aluminum plain washer of
8X14.5X1 mm. (Fig.4_2.51 )

Remove the dowel pin of 11D X12H 2nos. from the cylinder
block.
12 mm T Spanner & Nose plier
Caution: While assembling the the tensioner cam chain
ensure the assembly of Aluminiu, washer (gasket )

Locate the special tool to remove the valves as the movable

jaw of the tool rests on retainer valve spring (Fig.4_2.52 )
and the other end (fixed jaw) to rest at the center of the valve
face. (Fig.4_2.52 )

Slowly tighten the special tool movable jaw to compress the

spring valve.
S1310020

Fig.4_2.51

Extractor assy. Inlet & Exhaust valve

Caution: To prevent the loss of tension of the spring

valve, do not compress the spring more than required.

Fig.4_2.52

44

? Remove two cotter valve from the valve stem. (Fig.4_2.53)

Nose plier

? Loosen and take out the special tool.

Note: While assembling the cotter valve grooved
portion of the cotter valve should be upside

? Take out the retainer valve spring.(Fig.4_2.54 )

?

Remove the Spring valve outer of 23D X 30H and Spring

valve inner of 16.5D X 30H. (Fig.4_2.54)

Fig.4_2.53
Retainer valve spring
Spring valve outer

Note: While assembling the spring valve inner and

outer, locate the coil with lesser pitch towards seat valve
spring (downwards).

Spring valve inner

Gently, push down the valve from top and remove the valve
from the combustion chamber side.(Fig.4_2.55)

Note: While removing the valve, check for the free

movement of the valve. If not check the valve for bend
and runout. Replace the valve incase of bend or runout.

Repeat the same procedure for other valve also.

Remove the seal valve stem oil. (Fig.4_2.56)

Fig.4_2.54

Nose plier
Note: While reassembling, replace the seal valve stem
oil with a new one.

Remove the seat valve spring.(Fig.4_2.56)

Fig.4_2.55

Nose plier
?

Repeat the same procedure for the removal of other valve.

Decarbonising, cleaning and inspection of cylinder head,

block and valve assembly refer page no12
Note: Inspect the seat valve guide for damage if so
replaces the seal valve guide with new one.

Fig.4_2.56

45

Fan Air Cooling & Magneto

? Loosen and remove 3 nos. M6X25 plated hexagonal flange

bolt along with spring and plane washer using 8mm T
spanner. (Fig.4_2.57)
8mm T spanner

MAGNETO

? Hold the magneto rotor assembly using special tool.

Fig.4_2.57

? Loosen 1 M12X1.25 Flange nut (Fig.4_2.58)

17 mm spanner
G3310680

Holder assembly magneto

Note: While reassembling, apply thread lock on the

flange nut magneto assembly.

? Hold the magneto in its position and fix the puller

assembly magneto on magneto by tightening 3 bolts on the
rotor (Fig.4_2.59)

Fig.4_2.58

13 mm spanner

? Insert a rod in the hole provided on the puller and rotate in

clock wise direction to pull out the rotor from the stator
assembly (Fig.4_2.59)
G3310410

Puller assembly magneto

? Take out the Back plate cowling

Fig.4_2.59

Take out the woodruff key of 6.5X13X4 from the crank shaft
assembly. (Fig.4_2.60 )
Nose plier

Caution: While pulling the rotor from crank shaft fix

the Special tool properly to avoid damage on the
crank shaft.

Fig.4_2.60

46

 Loosen and remove 2 hexagonal flange bolts M6X25

from pulsar coil and take out the pulsar coil. (Fig. 4_2.61)(1)

8mm T spanner
Separate magneto wiring harness guide. (Fig. 4_2.61)(2)

Pull out the wiring harness grommet from the crank

case LH (Fig. 4_2.61)(3)

Fig.4_2.61

Loosen and remove 3 nos. M6X20 hexagonal flange bolts.

(Fig. 4_2.62)
8mm T spanner
Takeout the stator assembly. (Fig. 4_2.62)
Take out oil seal retainer. (Fig. 4_2.62)
Note: While assembly, ensure that the wiring harness is
routed from under the stator and below the clamp
wiring harness.
While assembly, ensure that the pulsar coil is fitted
with the metallic pip facing the rotor.
Ensure the presence of oil seal retainer on the crank
case L

Fig.4_2.62

Loosen 2 nos. M6X20 hexagonal flange bolts and separate

the switch gear position from the crankcase. (Fig. 4_2.63)
8mm T spanner
Note: While assembly, inspect the 'O' ring switch gear
position for any damage..

Take out the pin contact switch along with spring contact
switch. (Fig. 4_2.63)

Fig.4_2.63

Nose Plier
Cylinder Block
Pull out the guide cam chain from the cylinder block
complete. (Fig. 4_2.63)
Note: While assembly, make sure that chain guide

20

(opposite to tensioner). Should seet properly on the

groove of the cylinder block.
Remove the tie from the chain and take out the the chain
from the Crank shaft.
Fig.4_2.68

47

? Pull up the cylinder block by keeping the connecting rod

holding tool below the piston to avoid damage the of piston
while removing the cylinder block.. (Fig. 4_2.65)

Connecting rod holding tool

G3310290

? Place a clean cloth in the crankcase assembly bore to

prevent circlip piston pin from falling inside the crankcase
while removing the circlip. (Fig. 4_2.66)
? Remove the circlip piston pin from any one side of the
piston. (Fig. 4_2.66)

Fig.4_2.65

Nose Plier

? Gently push and take out the pin piston from the piston and
then remove the piston along with the rings piston from the
connecting rod.
Note: During assembly, set the circlip properly on the
piston groove & rotate the circlip by using small
connector to ensure the proper seating of the circlip on
the groove.
Fig.4_2.66

Piston

? Remove the ring piston 1st (A) (Fig. 4_2.67)

? Remove the ring piston 2st (B) (Fig. 4_2.67)
? Remove ring piston oil (C) (Fig. 4_2.67)
Caution: Do not expand the rings more, it may loose
it's mechanical properties.

De carbonising & cleaning of piston refer page no 57

Take out the gasket cylinder block.

Take out the dowel pins of D11 X 12M (2nos.) from Cylinder block & crank

Fig.4_2.67
caseRH.

Nose Plier

Un lock the muff cup bolt lock plate.

Flat chisel & Hammer

? Hold the muff cup using special tool and loosen the
M8X20 bolt from muff cup along with lock plate.
? Pull out the muffcup from the differential. (Fig. 4_2.68)
G3310690

Holding tool, dog driven and Muff cup

T spanner 13mm , Nose plier

Tightening torque

182 Nm

Fig.4_2.68

48

Differential
: Assembly

? Loosen & remove hex Dom bolt of M8X25 (1 nos) from dog
driven using 12 mm ring spanner.
Ring spanner

12mm

? Hold the dog driven using special tool and rotate a little bit
in clock wise direction then tap gently, allow the dog to
rotate in anti-clockwise direction and take out the dog
from shaft hand starter. (Fig. 4_2.69).
G3310690

Holding tool, dog driven and Muff cup

Note: While assembly ensure the projected portion

of dog driven must match with the projection on
crankcase.

Fig.4_2.69

? Loosen one hexagonal flanged Bolt M6x55 from damper

hand starter and take out the damper hand starter.

? Loosen & remove 2 M6X16 hexagonal flange bolt from the

cover fare meter drive, and separate the cover fare meter.
T spanner

8mm

? Take out the fare meter drive unit. (Fig. 4_2.69).

? Separate the worm fare meter from cap complete fare
meter unit.

? Separate O - ring from the cap complete fare meter

unit.(Fig. 4_2.69).

Fig.4_2.70

Small flat head screwdriver

? Loosen 7 nos. M6X30 hexagonal flanged bolts and 2 nos.

M6X55hexagonal flanged bolts from the cover differential.
(Fig. 4_2.71)
T spanner
8mm

? Take out the cover differential and gasket cover differential.

? Take out the dowel pin of D10X12H (1nos) on crankcase LH

2n

os.

7n

differential side.

os.

Nose Plier
Note: While assembly ensure , the differential final
drive gear cut portion faces upward.

Fig.4_2.71

? Take out the differential assembly by gently tapping it from

the other side. (After removing Muff cup RH )
Nylon Hammer

Hand Starter Mechanism

? Take out the spacer from spring hand starter. (Fig.
4_2.72)(1)

? Dis-locate spring hand starter from bolt, Kick starter shaft

spring hook and locator hole on shaft hand starter. (Fig.
4_2.72)(2)

? Take out the spring hand starter from shaft hand starter.
? Take out the plane washer of 18X39X2.8 from shaft hand
starter. (Fig. 4_2.72)(3)

Fig.4_2.72

49

Note: During the assembly of Spring hand starter shaft

ensure that spring is seated properly on the hole of the
hand starter shaft and hook provided on crank case LH

? Take out the gear final drive from the drive shaft. (Fig.
4_2.73)
Note: while assembling the gear final drive ensure that
the slotted surface of the gear should face upside.
Fig.4_2.73

SEPARATING ENGINE FROM CHASSIS

? Loosen and remove 1 no. nut, link rear engine cradle along
with spring washer and plane washer and take out the
flanged bolt.
13 mm spanner

? Loosen and remove 2 hexagonal nuts by holding the bolt

from the rear engine mounting cradle and remove the nut
along with two punched washers and one spring washer at
top. (Fig. 4_2.74)

Fig.4_2.74

17 mm ring spanner & 14 mm spanner

? Take out the hexagonal bolts M10x1.25x110 rear engine

mounting bolts along with two plain washers. (Fig. 4_2.74)

? Loosen and remove 4 hexagonal nuts along with spring

washer from bottom and rear side of passenger seat and
take out the passenger seat assembly.
10 mm spanner

Always remove the -ve

terminal first, while
dismantling the battery and
+ve terminal first during the
assembly of battery

? Loosen and remove screws 2 nos. of lid battery box from the
passenger cabin. (Fig.4_2.75)

Fig.4_2.75

Cross head screw driver.

? Loosen and remove knob clamp battery and take out the
clamp battery.(Fig.4_2.75)

? Disconnect the negative terminal and then the positive

terminal. (Fig.4_2.75)
Philips head screw driver and 8 mm spanner

? Lift and take it out battery using special tool. (Fig. 4_2.76)
G3310430

Lifting tool Battery

Fig.4_2.76

50

? Loosen and remove the front engine-mounting hexagonal

nut along with one plain washer and one spring washer.
(Fig. 4_2.77) (1)

17mm socket and ratchet spanner

? Loosen and remove the hexagonal flange bolt M10X1.25

by holding the nut in bet-ween the engine & front engine
mounting cradle . (Fig. 4_2.77) (2)
2

14 mm spanner & 17 mm Spanner

Note: While tightening the front engine mounting bolt,
tight the bolt to exact torque and make sure that cup
bottom engine mounting should be able to rotate
slightly by two finger.

Fig.4_2.77

? Tilt the engine to the LH side so that propeller shaft RH

? Lift the engine, separate it out from the chassis and place
the engine on the engine stand.

? Lift the engine and mount it on the engine fixture.

M6X75 (1 nos)

along with slider and pin comes out of muff-cup.

M6X94 (2 nos)

Separating Crank Case LH & RH

? Loosen & remove hex flange bolt of M6X50 (9 nos), M6X94

Fig.4_2.78

(2 nos) & M6X75 (1 nos) from the crankcase LH. (Fig.

4_2.78)
8mm T spanner.

? Remove the muff cup from the RH side as same procedure

mentioned in the page number .48

? Take out the differential assembly from crank case LH.

? Loosen & remove the hex flange bolt of M6X50 (3 nos) from
crankcase RH. (Fig. 4_2.79)
8mm T spanner.

? Separate the crankcase RH from the crankcase LH by gently

Fig.4_2.79

tapping the crankcase RH by using nylon mallet.

Nylon Mallet

? Take out the gasket crankcase. (Fig. 4_2.80) (1)

1
Note: While assembly, replace the gasket with new one.

? Take out plain washer of 17X24X1 (1 nos) from the drive

shaft assembly. (Fig. 4_2.80) (2)
Fig.4_2.80

51

TRANSMISSION

(Reverse gear)

Fig.4_2.81

? Take out Pin gear shift fork high - speed of D12X83H.

? Take out Pin gear shift fork low speed of D10X64H
Nose Plier

? Dis-locate the forks from groove cam gearshift

? Pull out the cam gearshift from Crank case LH. (Fig.4_2.82)
? Take out the fork gearshift low speed with roller.
? Separate the roller from the fork. (Fig.4_2.81)
? Take out the fork gearshift high speed along with roller
? Take out the fork gearshift reverse using nose plier.
Note: The fork with roller out of two one should
assemble top of the drive shaft assembly another fork
with out roller should be on the counter shaft assembly..

Fig.4_2.82

? Take out the counter and drive shaft gear assembly together

from the crank case LH.

? Pull out the hand starter shaft assembly from the crankcase
LH. (Fig.4_2.83) (1)

? Take out spring ratchet hand starter from crankcase LH. (2)
? Take out the plain washer hand starter shaft of thickness

20.5X34X1.3 from crankcase LH. (Fig.4_2.83) (3)

? Take out plain washer counter shaft of 21X30X1.8 from the

crankcase LH. (Fig.4_2.83) (4)

? Tap the crankshaft and take out the crankshaft.

Fig.4_2.83
52

SHAFT COUNTER AND SHAFT DRIVE ASSEMBLY

Fig.4_2.84
? COUNTER SHAFT ASSEMBLY

SHAFT DRIVE ASSEMBLY

Take out the gear first drive.

Take out the gear 1st driven.

While reassembly ensure that the spline surface faces top

Take out the gear 3rd drive

Take out the gear 3nd driven. This gear has the collar for
fork gear shift low speed.

Take out spline shim

Take out the circlip using nose plier and spline shim

Take out the gear 2nd drive. This gear has the collar for
fork gear shift high speed.

Take out the gear 2nd driven.

Take out spline shim and circlip.

Take out gear 4th driven. This gear has the collar for fork
gear shift reverse.

Take out the circlip and spline shim

Take out the gear complete reverse driven.(Fig.4_2.84)

Take out the circlip and shim.

Take out the gear 4th drive.

Take out the shim. (Fig.4_2.84)

Removal & Installation of Crank case Oil seals

and Bearings

? Using special tool the bearings 6001,6002,6003, 6205,

? Using special tool the ball bearings 6001,6002, 6003,

? Using special tool the needle bearing HK1812B

6205, 6206, 16007 can be removed.

G3310470

Ball Bearing Puller

? Using special tool the needle bearing HK1812B can be

installed.
G3310480

6206, 16007 can be installed with the suitable adaptor.

Assembly tool ball bearing
G3310510

can be installed.
G3310530

Assembly tool needle bearing

? Using special tool oil seals can be assembled with

the suitable adaptor

Needle Bearing Puller

G3310720,540,600

Assembly tool oil seals

53

DIFFERENTIAL SUB ASSEMBLY

? Fix differential assembly onto Differential fixture.

Differential Fixture

G3310740

? Unlock the lock plate, differential using chisel and mallet.

? Loosen and remove 6 M8X20 hexagonal screws using
14mm spanner and take out the lock plates.
? Separate the Gear, Final Driven from the housing
differential.
? Take out the bevel gear.
? Take out the lock pin satellite gear.
? Pull out the pin satellite gear and take out the satellite gears.
? Take out the shim differential housing.( Fig.4_2.85 )
? Separate the other bevel gear from differential housing.

5
2

Fig.4_2.85

ENGINE COMPONENTS INSPECTION

Bearings
?

Wash the bearings with a cleaning solvent and lubricate

with engine oil before inspecting.

Inspect the play of each bearing before fixing it. Hold the
inner race and rotate the outer race by hand and observe
for any abnormal noise and smooth rotation. Replace the
bearing with a new one if found defective. (Fig.4_2.86)
Note: Do not use compressed air to clean the bearings.

Fig.4_2.86

Oil Seal
? Damage to the lip (A) of the oilseal may result in leakage of
the oil. Inspect for damage and be sure to repalce the
damaged oilseals with the new ones. (Fig.4_2.87)

CRANKSHAFT COMPLETE
Runout
? Support the crankshaft assembly with V blocks of anvil.
Mount the dial indicator at the positions shown to read the
runout. Runout should be within the service limit.
(Fig.4_2.88)
?

Fig.4_2.87

Excessive runout of crankshaft assembly causes abnormal

engine vibration and bearing noises. Such vibration
shortens engine life.
031 307 0

V - block set (4x3x3)

031 305 0

Dial gauge (1/100 mm)

031 306 0

Magnetic stand

Service limit

1 mm
Fig.4_2.88
54

Condition of the big end bearing

?

Measure the big end wear of connecting rod by the

deflection of small end. If the deflection exceeds the limit,
replace the crankshaft assembly with a new one.
(Fig.4_2.89)
Service limit 3 mm

Fig.4_2.89
?

Also, holding the crankshaft assembly in hand, shake the

connecting rod to find out the radial play. If any play is
noticed, then replace the crankshaft assembly with a new
one. (Fig.4_2.90)

Fig.4_2.90
?

Measure the connecting rod big end side clearance with a

feeler grauge. If the clearance exceeds the service limit,
replace the crankshaft assembly with a new one.
(Fig.4_2.91)
031 010 0

Feeler gauge

Service limit .65mm

Fig.4_2.91
Connecting rod small end diameter
?

Measure the internal diameter (I.D) of the connecting rod

small end. If the I.D is more than the service limit, replace
the crankshaft with a new one. (Fig.4_2.92)
Service limit 15.040 mm

Fig.4_2.92

55

CYLINDER
?

The wear of the cylinder wall is determined from the

diameter reading taken at three locations from the top of
the cylinder. (Fig.4_2.93 and Fig.4_2.94)
Cylinder gauge

Set the dial of the bore gauge using this diameter on the
micrometer. Measure the bore diameter at 20 mm from the
cylinder top surface. (Fig.4_2.93)

If the wear exceeds the service limit, replace the cylinder

block or rework the cylinder to the next oversize by using a
boring machine. The cylinder must be honed after boring.

The cylinder blocks are manufactured with slightly

increasing diameters which are all identified with their
respective colours as below. Cylinder blocks will have
colour markings.

Fig.4_2.93

Service limit 62.125 mm

PISTON
?

Measure the piston diameter using micrometer at right

angles to the piston pin and at a point which is 7.5 mm from
the skirt end. (Fig.4_2.95)
Micrometer

Fig.4_2.94

Service limit 62.885 mm

Note: Minor surface flaws on the cylinder wall due to
seizure or similar abnormalities may be corrected by
using fine emery paper (400 grade). If the flaws are
deep grooves, the cylinder must be reworked with a
boring machine to the next oversize or replaced
Cylinder to piston clearance
7.5

Cylinder to piston clearance is the difference between

piston diameter and bore diameter. Be sure to measure the
diameter at right angles to the piston pin and at a point A
which is 21mm from the bottom.
Item

Standard mm

Service limit

Cylinder

62.015 - 62.0 20

61.125

Piston

61. 985 60.990

61.885

Clearance

0.035 0.045

0.135

Fig.4_2.95

Remove the ring piston 1st (A),the ring piston 2nd (B) and
ring piston oil ( C ) (Fig.4_2.96)
Caution: Do not expand the rings more, it may loose its
mechanical properties

Fig.4_2.96
56

Decarbonise the piston and ring grooves. After cleaning the

grooves, fit the rings and rotate them in their respective
grooves to make sure that they rotate freely.

Carbon in the groove is liable to cause the rings piston to

stuck in the groove, and this will lead to reduced engine
power output. (Fig.4_2.97)
Note: While cleaning the ring grooves on the piston,
take care not to damage the grooves. Use an old
broken ring to clean the grooves.
Fig.4_2.97
Ring Piston

As the rings wear out, its end gap increases resulting in

reduced engine power output.
The end gap of each ring is to be measured with the ring
fitted squarely in the cylinder bore at 20 mm from the
cylinder bottom. (Fig.4_2.98)
Service limit

0.7

mm

Feeler gauge
?
?

20 mm

Fig.4_2.98

If the gap exceeds the limit, replace the rings as a set.

Inspect for proper tension of the rings by measuring its free
end gap. if it is less than the service limit, replace the rings
as a set. (Fig.4_2.99)
Service limit

mm

First ring

5.7

Second ring

4.4

Vernier Caliper
Before connecting the piston to the connecting rod, be sure
to apply lubricating oil to the connecting rod big end and
small end bearings and piston.
?The arrow mark on the piston crown must point to the inlet
side.
?

Fig.4_2.99

CLUTCH
Plate clutch drive and driven
?

As clutch plates remain in oil, they are subject to lesser wear

and tear, and therefore last longer. Their life depends
largely on the quality of transmission oil used and the way
clutch is used.

The plates are to be replaced when found worn-out,

distorted, bulged out or burnt.

Measure the thickness and claw width of plate clutch drive

(6 nos.) using special tool. (Fig.4_2.100 and Fig.4_2.101)

Fig.4_2.100
57

Vernier caliper
Service limit

mm

Plate clutch drive thickness

2.6

Plate clutch drive claw width

9.5

? Using special tool check the wear and distortion of plate

clutch driven (5 nos.) as shown in figure. (Fig.4_2.102)
Feeler gauge & Vernier caliper
Fig.4_2.101
Service limit
Plate clutch driven distortion

mm
0.1

Spring Clutch
?

Spring clutch which have lost their tension cause clutch

slippage, resulting in loss of power and rapid wear of the
clutch plates.

Remove the spring clutch (6 nos.) from the hub clutch. For
removal of spring clutch refer page no 37

Measure the free length of the spring clutch (6 nos.).

(Fig.4_2.103)

Fig.4_2.102

Vernier caliper
Service limit
Free length of spring clutch

mm
32.4

Note: If any one of them is less than the service limit,

replace all the springs with a new as a set.
Shaft complete counter /shaft complete drive/ camshaft /
drive gears and driven gears.
?

Before inspection, clean all the components thoroughly

with cleaning solvent.

Carefully inspect all parts for any scoring marks, breakage,

wear and tear of splined surface of the shafts / gear teeth.
Replace the damaged parts with new ones.

Using a feeler gauge, check the clearance between fork

gear shift and its seating groove on the gear. (Fig. 3.57) If
the clearance excess the service limit, determine whether
the gear or the fork gear shift should be replaced with a new
one.

Fig.4_2.103

Feeler gauge
Service limit

mm

Fork gear shift to groove clearance

0.5

Fig.4_2.104
58

Cover Cylinder Head

? After cleaning the liquid gasket from the surfaces of the

cover cylinder head, inspect the surface for any scartches,
high and low spots. If noticed, remove them using a fine
emery paper (400 grade) placed over the surface plate.
(Fig.4_2.105)

? Using feeler gauge and surface plate, check for distortion

of cover cylinder head. (Fig.4_2.106)

Fig.4_2.105

Feeler gauge
Service limit
Cover cylinder head

mm
0.05

Shaft valve rocker arm

? Inspect the shaft valve rocker arm for any damages

? Measure the outer diameter (OD) of shaft valve rocker arm.
If the OD is less than the service limit, replace the shaft.
(Fig.4_2.107)

Fig.4_2.106

Out side Micrometer

Standard diameter

11.984~11.966 mm

Note: The OD should be checked at the seating area

of arm complete valve rocker.
Arm complete valve rocker

? Inspect the arm complete valve rocker (rocker arm) for

wear, damge or clogged oil hole. Measure the internal
diameter (ID). If the ID is more than the service limit, replace
the arm. (Fig.4_2.108)

Fig.4_2.107

Inside Micrometer
Standard diameter

12.0~12.018 mm

Note: While reassembling the arm complete valve

rocker, locate the wave spring washer in the left side
(sprocket side) of the cover cylinder head assembly.
Caution: While reassembling the relief cut given in
both the shaft valve rocker arm should face each
other to enable the cover cylinder head bolts to enter
into the groove. (Fig.4_2.108)

Fig.4_2.108
59

Cylinder head
Decarbonising

? Carbon deposits on the combustion chamber of the head

complete cylinder will increase the compression ratio which
will result in pre-ignition and over heating. Carbon
deposited at the exhaust manifold will prevent smooth flow
of exhaust, thereby reducing the engine power output.
? Decarbonise the combustion chamber of head complete
cylinder using suitable decarbonising spray. (Fig.4_2.109)
Note: Decarbonise the head complete cylinder
combustion chamber after remvoing both the valves.
Use suitable cleaning solvent.

Fig.4_2.109

Caution: Do not damage the surface of the combustion

chamber while decarbonising.
Seat Valve
?

Carbon deposition on valve seating will cause valves not to

seat properly thereby causing leakage and this will affect
idling, pickup and mileage. This will also lead to erratic
running and starting trouble.

Valve and valve guide

?

Carbon deposits on the valve stem rubs continuously on

guide valve and this will result in increased clearance
between the stem and guide valve. Clean the valve stem
with the cleaning solvent. (Fig.4_2.110)

Clean the guide valve to remove any carbon builtup by

using carbon removers.

Clean other parts of head complete cylinder thoroughly

with suitable cleaning solvent.

Fig.4_2.110

Inspection of Cylinder Head

?

After cleaning the liquid gasket from the surfaces of the

head complete cylinder, inspect the surface for any
scratches, high and low spots. If noticed, remove them
using a fine emery paper (400 grade) placed over the
surface plate. (Fig.4_2.111)

Fig.4_2.111

Using straight edge and feeler gauge, check for the

distortion of head complete cylinder. If the reading exceeds
the limit, replace the head complete cylinder with a new
one. (Fig.4_2.112)
Feeler gauge, Straight Edge scale & Surface plate.
Standard diameter

0.05 mm
Fig.4_2.112
60

Cam Shaft Complete

? Check the camshaft complete for runout, wear of cam

lobes and journals. Any of these could cause the engine to
produce abnormal noise, vibration or lack of power output.
? Wornout cam lobes may lead to improper valve operation
resulting in reduced power output.
? Measure the cam lobe height. If the lobe height is less than
the service limit then, replace the camshaft complete with a
new one. (Fig.4_2.113)
Out side Micrometer

Fig.4_2.113

Inlet cam lobe height (Standard)

25.51mm

Exhaust cam lobe height (Standard)

25.51mm

? Inspect the ball bearings (6002 - 2 nos.) of camshaft for

abnormal play or pitting.
? Measure the runout with a dial gauge. Replace the
camshaft with a new one if the runout exceeds the limit.
(Fig.4_2.114)
Dial gauge
Service limit

0.08 mm
Fig.4_2.114

Valve Intake and Exhaust

? Inspect each valve for trueness, burning, scratches,

abnormal wear or bend.
? Measure the outside diameter of valve stem on the
operational area. (Fig.4_2.115)
Out side Micrometer
Inlet (Standard)

4.990~4.975mm

Exhaust (Standard)

4.970~4.955mm

? Using the special tools, measure the runout on valve stem

and valve face. Replace the valve with new one if runout
exceeds the service limit.(Fig.4_2.116)

Fig.4_2.115

V Block set (4X3X3), Dial gauge (1/100mm ) &

Magnetic stand
Service limit

mm

Runout of stem

0.05

Runout of face

0.075

Fig.4_2.116
61

? Check the valve for smooth movement in the guide valve.

? Measure the thickness of valve head. If the thickness is less
than the service limit, replace the valve with a new one.
(Fig.4_2.117)
Vernier caliper
Service limit
Inlet & Exhaust valve

mm
0.05
Fig.4_2.117

Valve stem condition

? Inspect the valve stem end face (A) for pitting and wear. If
pitting or wear noticed, resurface the valve stem end,
provided the length (1) is not reduced to less than 3.8 mm.
If this length becomes less than 3.8 mm, the valve must be
replaced with a new one. (Fig.4_2.118)
Valve Spring

? Measure the free length of the inner and outer springs.

(Fig.4_2.119)
Fig.4_2.118
Vernier caliper
Valve spring inner (Standard inner )

30.91 mm

Valve spring outer (Standard inner )

30.82 mm

Note: The diameter of valve intake is larger than the

diameter of valve exhaust.
Lubricate both the valve stems before installing.
Ensure proper seating of the cotter valve in its groove
by gently tapping on valve stem
Fig.4_2.119
Cam Chain tensioner assembly

? Check the adjuster assembly tensioner arm (A), if the arm is

found to be in the extreme out position, then replace the
cam chain with a new one. (Fig.4_2.120)

Caution: While reassembling the adjuster assembly

tensioner, push the arm (A) fully inside by pressing
the lock provided on it.

Fig.4_2.120
62

ENGINE REASSEMBLY
Using special tool, pull the crankshaft and assemble the
crankshaft to LH main bearing. (Fig.4_2.121)
G3310500

Assembly tool Crank shaft

After fitting the crankshaft, lock the connecting rod and

remove the tool.
Connecting rod holding tool

17mm spanner

Hand starter & Transmission

Fig.4_2.121

Ensure that the ratchet hand starter and gear hand starter
are assembled together. (Fig.4_2.122)
Spring ratchet hand starter should lock properly in the
crankcase groove provided.(Fig.4_2.122) (1)
Reassemble the transmission assembly.
Apply grease in the gear shift fork roller before fitting
it to the fork
Position the fork gear shift on Cam, Gear Shift grooves.
Scrape out old gasket from crankcase machined surface
and replace gaskets.
Re - assemble two dowel pins before assembling the
crankcase RH on LH.
GEAR SHIFTER AND REVERSE GEAR MECHANISM
? While reassembling index star, assemble stopper complete
gear shift and washer along with spring, gear shift cam
stopper.
? The spring has to be located on the groove provided on
stopper while assembly.
? Tighten the bolt, gear shift cam stopper.
? Pull the stopper complete gear shift and assemble the
index star and insert the pin, index star.
? Re - assemble the gear, shift shaft.
? While assembling make sure that punch mark on the
index star and arrow on gear, shift shaft are coinciding to
ensure neutral position. (Fig.4_2.122) (1)
? Re - assemble the reverse gear mechanism.
? The profile on the Plate lock arm spring reverse matches
with the profile cut on shaft drive. (Fig.4_2.122) (2)
? The spring is locked onto the profile on the crankcase
? Rest all the parts of gear shifting assemble in the reverse
order of dismantling procedure.

Fig.4_2.122
1

Fig.4_2.123

PRIMARY DRIVE GEAR

? Reposition the wood ruff key and Re-assemble the primary
drive gear
? Place the shim and tighten the nut primary drive gear bby
locking the connecting rod.
? Lock the gears with special tool and tighten the primary
drive gear nut. (Fig.4_2.124)
22 mm spanner, Holding tool primary drive gear and
Holding tool connecting rod
Tightening Torque

Fig.4_2.124

60 - 70 Newton meter
63

HAND STARTER SHAFT - SPRING ASSEMBLY

Place the plain washer on the hand starter shaft.
Insert the spring such that spring end should go through the
hole provided on the hands starter shaft and assemble the
spacer spring properly through the groove.
Rotate the hand starter shaft and clamp the hook end of
spring on the bolt, kick starter shaft spring hook.
(Fig.4_2.125)
Assemble one no. of dowel pin on the cover differential and
place the gasket then assemble cover differential.
? Before assembling magneto stator coil ensure that the
retainer oil seal magneto side crankshaft is fitted.
?
? Assemble the spacer magneto before assembling the
magneto rotor.(Fig.4_2.126)
?
? Re - assemble the pin clutch release, rod clutch release
along with spring return clutch cable and plain washer on
the cover clutch. (Fig.4_2.126)
?
? Re - assemble two dowel pins onto the crankcase RH before
Re - assembling cover clutch.
?
?
? OIL PUMP
?
? During the re-assembly of oil pump make sure that C
mark on gaer (1) and gear (2) of the gears oil pump are in
the same phase. (Fig.4_2.127 ) (A)
?
? During the assembly of chain oil pump drive make sure that
arow mark punched on the chan should face upside.
(Fig.4_2.127 ) (B)
?
? Piston and Piston ring assembly
?
? During the assembly piston on the connecting rod ensure
the IN mark should be on the intake manifold side and
small mark should be on the exhaust side of the engine
(Fig.4_2.128 ) (A)
?
? Assemble the separator oil ring locating its end gap
towards exhaust side of the piston at 45 degree to the left
from the centre. (Fig.4_2.128 ) (B)

Fig.4_2.125

Fig.4_2.126

(A)

(B)

Fig.4_2.127

(A)

(B)

IN

Note: Assemble the separator oil ring in such a way to

ensure its triangle shaped end (Fig.4_2.128) (B) facing
upward (triangle facing towards piston top).
Fig.4_2.128
64

 Assemble the oil ring (bottom) locating its end gap towards
exhaust side of the piston at 45 degree to the right from the
centre. ( Fig.4_2.128 ) (B)
Assemble the oil ring (top) locating its end gap towards
exhaust side of the piston at 45 degree to the left from the
centre. (Fig.4_2.128)(B)
Assemble the ring piston 2nd locating its end gap towards
inlet side of the piston at 30 degree to the left from the
center. (Fig.4_2.129 )
Assemble the ring piston 1st locating its end gap towards
inlet side of the piston at 30 degree to the right from the
center. (Fig.4_2.129)

Fig.4_2.129

Note: Avoid damage to the piston and rings piston

during installation.
Before installing the piston, the rings should rotate
freely in their respective grooves.
Install the 1st and 2nd rings with the marking on the
ring TOP1 and TOP2 (Fig.4_2.130) facing up (Mark
facing towards Piston top)

While assembling the spring valve outer (A) and spring

valve inner (B), locate the coil with lesser pitch towards seat
valve spring (downwards). (Fig.4_2.131)

Fig.4_2.130

(A)

(B)
Greater pitch length

Valve leak testing and Lapping

Assemble the inlet and exhaust vlave to the cylinder head in

the reverse order of the dismantling procedure. Refer page
number 37
After assembling the valve pour the petrol into the inlet port
and look for leakage of petrol around the inlet valve
seating. (Fig.4_2.132)
If any leakage noticed, rectify the valve and its seat by
lapping.

Lesser pitch length

Bottom sode

Bottom sode

Fig.4_2.131

(A)

(B)

Valve Lapping
First apply the course valve lapping compound uniformly
right round on the valve face. (Fig.4_2.132)
Lapping compound
Insert thE valve back to its position on head. Fix the suction
head valve lapping stick on the valve and turn it side to side.
Continue lapping till the grinding noise comes down.
Fig.4_2.132
65

? Then take out the valve and clean the lapping compound
off it and also in the head.

? Then take your fine lapping compound and do the same

thing with it until the leaks stopst. Clean off the valve and
inside the heads again. (Fig.4_2.133)

? Re-assemble the valves to the cylinder head as explained

earlier.
Warning: While lapping, avoid entering of compound
into the valve guide through the stem, which will
increase the clearance between guide and valve.

Fig.4_2.133

? For assembling the cylinder head and cover cylinder head

refer the dismantling procedure in reverse order. Page
Number 42
Valve timing and Valve Tappet clearance

? While reassembling the sprocket cam shaft, ensure the

following :

2
1

? Before doing the valve timing assemble Magneto assembly,

fan and cowl complete bottom air cooling.

? Rotate the flywheel rotor by rotating the fan and match the
TDC mark (1) on the rotor assembly and the mark (2) on the
cowl complete bottom air cooling. (Fig.4_2.134)

Fig.4_2.134

17 mm Tubular spanner & Rod

? At this position of the rotor assembly, ensure that the mark

(3) on sprocket cam shaft matches with the surface edge
bottom of the cylinder head (A). (Fig.4_2.135)
Valve Tappet clearance

? Valve tappet clearance should be adjusted only after

matching the timing mark as explained above.
Note: At this point the arm complete valve rocker
should have free play. Other wise rotate the fan
assembly about 360 and align the mark again.

Fig.4_2.135

Check the valve clearance only when the engine is in

cold condition and spark plug should be removed.

? Insert the appropriate feeler gauge in between the rocker

arm and valve stem, inspect the clearance. (Fig.4_2.136)

? If there is any variation on gap mentioned below adjust the

same for proper gap as explained below.
Inlet valve clearance

0.06 mm

Exhaust valve clearance

0.08 mm
Fig.4_2.136
66

? Loosen the tappet hex. nut. (Fig.4_2.137)

9 mm ring spanner

? Place the feeler gauge (A) and adjust the clearance using
the special tool (B). (Fig.4_2.138)
G4310010

Tightening tool, clutch nut

Feeler gauge

? Always while setting the clearance make sure that little

resistance in the feeler gauge. then lock the nu using the
ring spanner.

Fig.4_2.137

Caution: While tightening the lock nut, ensure that the

tappet adjuster has not rotated.

? After adjustment check the clearance with next oversize

feeler gauge to ensure the tappet is set accurately.

? Re assemble the cap timing mark inspection hole back to

the cowl bottom air cooing.

? Re assemble the other engine parts in reverse rorder.

Fig.4_2.138

? Re assemble the SAI pipe to the exhaust side of the cylider

block and tighten M6X50 hex. Flange bolt.( Fig.4_2.139)

Note: Before assembling the SAI pipe make sure the

presence of O ring.

? Make sure that SAI pipe is properly seated in the position.

? If any damage on the O ring replace the O ring with new
one.( Fig.4_2.139 )
Fig.4_2.139

? Tighten the the 2 hex bolts of M6X16 2 nos. from the chain

tensioner. ( Fig.4_2.140)
? Tighten the center bolts of the chain tensioner properly for

proper functioning .( Fig.4_2.140 )

Fig.4_2.140
67

Head Complete Cylinder

For re assembling the Head complete cylinder refer the reverse procedure of the removal and the things to be taken
carerefer the above figure.

68