SERVICE MANUAL

SER.MAN/TVS APACHE RTR 310 - REVISION - 0 - OCT 23

 NOTICE

All information included in this publication is based on the latest product

information available at the time of approval for printing.

All the illustrations given in this manual may vary from the actual
vehicles.

TVS MOTOR COMPANY LIMITED reserves the right to make changes

at any time without prior notice and without incurring any obligation
whatsoever.

No part of this publication should be reproduced without written

permission from TVS MOTOR COMPANY LIMITED.
 FOREWORD

We are happy to provide you the first edition of new TVS Apache RTR 310 motorcycle’s service
manual.

This manual is prepared to provide the assistance during the process of servicing the new
TVS Apache RTR 310 motorcycles. This manual describes about the basic operations of this new
product, do‘s and don‘t‘s, service limits of individual components and sub systems while servicing the
TVS Apache RTR 310 motorcycles. We request you to carefully go through this manual and follow the
instructions given.

All the instructions and illustrations of this manual is prepared based on the recent information available
during the preparation of manual. Modifications or any improvements on the product will be
communicated through ‘SERVICE INFORMATION BULLETINS’ from time to time.

This manual will help to the technicians who already have technical knowledge about the motorcycles.

While servicing, certain parts may require replacement. For ordering spares, please refer
Parts catalogue of TVS Apache RTR 310 motorcycles. The illustrations in this manual may not give
you the exact name, part number and quantities.

Incase, you face any critical problems during the course of servicing and if you need any further
clarifications or technical assistance you may contact our area service personal.

You may also contact us at

TVS Motor Company Limited,

Marketing (Service) Department,
Post box No.4, Harita, Hosur - 635 109,
Tamilnadu, India.
 SERVICE MANUAL
GENERAL INFORMATION

HOW TO READ THIS MANUAL

This service manual is split into eight chapters as “General information“, “Periodic maintenance“, “Servicing of
engine”, “Fuel, lubrication and exhaust system“, “Electrical system“, “Chassis”, “Diagnostics procedure” and
“Service information”.

Mostly the pages run through two columns in the inside pages with instructions on left side and the illustrations on
the right side. Some of the exploded views occupy full pages. In between the running instructions we have used the
notations as per the examples given below:

Heading:- CYLINDER HEAD ASSEMBLY

Sub heading:- Cover Cylinder Head

Note :- This provides further clarification for clear understanding of any particular information/operation/data.

NOTE
While reassembling replace the seal valve
stem oil with a new one.

Caution / warning :- This indicates special procedures or precautions to be followed by the mechanics during the
service. Avoiding these messages may cause injury to them as well as damage to the
components.

CAUTION
Check that the gasket inlet is intact and in
good condition.

Hand tools :- 17 mm spanner

Part number Description

Special tools :- N731 015 0 Adapter magneto puller

Service limits :- Service limit 0.05 mm

SERVICE MANUAL
GENERAL INFORMATION

1 GENERAL INFORMATION Page 1-1 to 1-60

2 PERIODIC MAINTENANCE Page 2-1 to 2-62

3 ENGINE Page 3-1 to 3-70

4 FUEL, LUBRICATION AND EXHAUST SYSTEM Page 4-1 to 4-29

5 ELECTRICAL SYSTEM Page 5-1 to 5-63

6 CHASSIS Page 6-1 to 6-91

 SERVICE MANUAL
GENERAL INFORMATION

DESCRIPTION PAGE NO Chapter 1

TVS Apache RTR 310 - VIEWS 9
VEHICLE IDENTIFICATION NUMBERS 10
FRAME NUMBER LOCATION 10
ENGINE NUMBER LOCATION 10
FRAME AND ENGINE NUMBER CODES 10
YEAR AND MONTH CODES 11
CODE FOR THE PRODUCTION YEAR 11
CODE FOR THE PRODUCTION MONTH 11
TECHNICAL SPECIFICATIONS 12
FUEL AND OIL RECOMMENDATIONS 15
ADVANTAGES & SPECIAL FEATURES OF TVS Apache RTR 310 16
WARRANTY TERMS 18
RUNNING- IN PERIOD 18
PRECAUTIONS AND GENERAL INSTRUCTIONS 19
LIST OF HAND TOOLS REQUIRED 19

GENERAL INFORMATION
LIST OF SPECIAL TOOLS REQUIRED 20
SPECIAL TOOLS & ITS APPLICATION 21
PARKING THE VEHICLE ON PADDOCK STAND 30
Rear wheel paddock stand installation 30
Front wheel paddock stand installation 31
OPERATING THE RAMP 32
PARTS IDENTIFICATION - LH 33
PARTS IDENTIFICATION - RH 33
SEAT ASSEMBLIES 34
Seat assembly rear (passenger seat) - Removal 34
Utility box - Removal 34
Seat assembly front (raider seat) - Removal 35
FUEL TANK ASSEMBLY COVERS - REMOVAL 36
Cover fuel tank rear LH & RH - Removal 36
Side cowl L & R - Removal 37
Side cowl L & R - Disassembly 38
Cover fuel tank inner front LH & RH - Removal 39
Cover fuel tank assembly - Removal 40
Cover fuel tank front inner LH & RH - Removal 42
Cover fuel tank center front - Removal 43
Cover fuel tank front LH & RH - Removal 44
Cover fuel tank L & R - Removal 45
HEAD LAMP - ASSEMBLY 47
Speedometer assembly 48
COVER RADIATOR LH & RH ASSEMBLY 50
ENGINE GUARD BOTTOM / ENGINE GUARD ASSEMBLY 52
TAIL COVER ASSEMBLY 54
TAIL LAMP ASSEMBLY 58
FENDER FRONT ASSEMBLY 59
 SERVICE MANUAL
GENERAL INFORMATION

TVS Apache RTR 310 - VIEWS

Fig. 1.1 LEFT SIDE VIEW

Fig. 1.2 RIGHT SIDE VIEW

 SERVICE MANUAL
GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBERS

LOCATIONS

FRAME NUMBER

l The frame identification number is engraved

on the frame at the right side of the steering.
(Fig. 1.3)

Fig. 1.3
ENGINE NUMBER

l Remove the engine guard bottom and engine

guard assembly as explained in page
no. 1-00 & 1-00.

l The engine identification number is engraved

on the right side of engine as shown. (Fig. 1.4) BS1CP1400004

Fig. 1.4

FRAME AND ENGINE NUMBER CODES

FRAME NUMBER M D 6 3 8 C S 1 0 N 1 L 1 4 5 2 8

World manufacturer Vehicle type Month code

identifier Manufacturing serial no.
Frame type Check digit Plant code

Variant identifier Engine type Year code

Month code
Engine type Year code Manufacturing serial no.
Filler Plant code

ENGINE NUMBER B S 1 C P 1 4 0 0 0 0 4
 SERVICE MANUAL
GENERAL INFORMATION

YEAR AND MONTH CODES

YEAR CODE YEAR CODE

CODE YEAR CODE YEAR

J 2018 G 2046
K 2019 H 2047
L 2020 J 2048
M 2021 K 2049
N 2022 L 2050
P 2023
R 2024
S 2025 MONTH CODE
T 2026
V 2027 CODE MONTH
W 2028
X 2029 A JANUARY
Y 2030 B FEBRUARY
1 2031 C MARCH
2 2032 D APRIL
3 2033 E MAY
4 2034 F JUNE
5 2035 G JULY
6 2036 H AUGUST
7 2037 K SEPTEMBER
8 2038 L OCTOBER
9 2039 N NOVEMBER
A 2040 P DECEMBER
B 2041
C 2042
D 2043
E 2044
F 2045
SERVICE MANUAL
GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

DIMENSIONS AND WEIGHT

Overall length 1991 ± 20 mm (Base)

2190 ± 20 mm (with Top Box)

Overall with 831 ± 10 mm (Base)

881 ± 10 mm (with Hand / knuckle guard)
1154 ± 10 mm (Base)
Overall height 1236 ± 10 mm (with Visor)
1294 ± 10 mm (with Top Box)
Saddle height 800 ± 10 mm
Ground clearance 180 ± 5 mm
Wheel base 1358 ± 10 mm

Kerb weight 169 kg (Base)

170 kg (Dynamic, Dynamic pro & Dynamic + Dynamic pro)
130 (Base, Dynamic & Dynamic pro)
Pay load
144 (Dynamic + Dynamic pro + Accessories)
299 (Base)
Gross vehicle weight 300 (Dynamic & Dynamic pro)
314 (Dynamic + Dynamic pro + Accessories)
ENGINE
Bore 80 mm
Stroke 62.1 mm
Displacement 312.12 cc
Compression ratio 12.17 ± 0.35 : 1
No. of valves 4
(Urban and Rain mode) 19. 9 kW @ 7500 rpm
Maximum power
(Sport, Track and Super Moto mode) 26. 16 kW @ 9700 rpm

Maximum torque (Urban and Rain mode) 27. 3 Nm @ 6600 rpm

(Sport, Track and Super Moto mode) 28. 7 Nm @ 6650 rpm

Maximum speed (Urban and Rain mode) 135 km / h

(Sport, Track and Super Moto mode) 150 km / h
Engine idling rpm 1600 ± 200 rpm
Idling CO% CO < 0.5%
Idling HC ppm HC < 500 ppm
Camshaft Double over head camshaft
Fuel feed Closed loop EFI system
Cooling system Liquid cooling
Air filter Dry paper type
Oil filter Wire mesh and Micronic paper filter
Lubrication system Wet sump lubrication
Starting system Electric starter
SERVICE MANUAL
GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

TRANSMISSION
Clutch system Wet multi plate - Assist and slipper type
Gear shift pattern One down five up
Number of gears Six speed, toe shift
Primary transmission Spur gears
Secondary transmission Chain and sprockets
First gear ratio 3.000
Second gear ratio 2.063
Third gear ratio 1.588
Fourth gear ratio 1.286
Fifth gear ratio 1.095
Sixth gear ratio 0.955
Primary reduction 3.083
Secondary reduction 2.706
FRAME AND SUSPENSION
Frame type Trellis type frame
USD fork 41 mm diameter
(Base Variant)
Fork leg L has only spring
Front suspension
Fork leg R has spring & damping cartridge
(BTO Variants)
Both fork legs L & R has spring & damping cartridge
Rear suspension Solid Die cast Aluminium swing arm directly hinged
monoshox, pre load adjustable.
Fork stroke length 140 mm
Rear suspension travel 138 mm
Steering angle 34° ± 2°
Caster angle 25° ± 1°
Turning radius 2500 ± 200 mm
Gradability 10°
Banking angle 49.6° ± 1°
SERVICE MANUAL
GENERAL INFORMATION

TECHNICAL SPECIFICATIONS

ELECTRICAL
Type Three phase AC generator
Ignition system Dynamically controlled - high energy integrated ignition
system
Spark plug NGK (LMAR9D - J)
Spark plug gap 0.8 ± 0.1 mm
Battery type 12V / 8 Ah MF wet charge type
Body earthing Two grounds are mounted on engine body
(1. Engine ground and 2.Ignition ground) and
one ground mounted on fuel tank
Generator 12V, 290W
Headlamp 12V, LED (46W)
DRL lamp 12V, LED (9W)
Tail / brake lamp 12V, LED (1W / 3W approx.)
Turn signal lamp 12V, LED (4W each)
Number plate lamp 12V, LED (1.5W)
Instrument panel TFT / LED indicators
Horn type 12V DC two numbers
Fuse Mini fuse - 7.5A x 2, 10A x 2, 15A x 2 and 30A x 1
Voltage regulator Three phase shunt full DC RR unit
BRAKES
Brakes type Disc brake with ABS
Front brake size Hand operated 300 mm disc
Rear brake size Foot operated 240 mm disc
WHEEL
Front tyre make and model MICHELIN M/C 54 W - Road 5 Radial
Rear tyre make and model MICHELIN M/C 66 W - Road 5 Radial
Front tyre size M/C 54 H Tubeless - 110/70 ZR17 M/C 54 W Tubeless
Rear tyre size M/C 66 H Tubeless - 150/60 ZR17 M/C 66 W Tubeless
Front tyre pressure 2.25 kg (32 PSI) for both solo and dual
Rear tyre pressure 2.25 kg (32 PSI) for both solo and dual
FREE PLAYS
Clutch free play 8 - 12 mm
Drive chain free play 30 - 40 mm
 SERVICE MANUAL
GENERAL INFORMATION

FUEL AND OIL RECOMMENDATIONS

TVS Apache RTR 310 has a four stroke engine. Do not mix oil with petrol. Be sure to use the following specified
fuel and oil.

Fuel
Recommended fuel grade BS VI petrol with minimum RON 91 (containing upto 20%
of ethanol by volume)
Fuel capacity (usable) 11 ± 0.5 ltr
Minimum required quantity of fuel 2 ltr
Engine oil
Recommended manufacturer TVS / MOTUL
TVSM TRU4 SAE 15W50 Synthetic oil /
Recommended grade
MOTUL 300V 15W50 4T 100% Synthetic oil

Recommended quantity 1700 ml

(fresh assembly / full drain along with filter change)
Coolant oil
Recommended manufacturer Glysantine
Recommended grade G48
Recommended quantity 1 litre (coolant and distilled water ratio 50:50)
Front fork oil
Recommended manufacturer Kayaba
Recommended grade KHL 15-10

Recommended quantity Leg L - 480 ± 2 ml & Leg R - 440 ± 2 ml (base variant)

Both Leg L & R - 440 ± 2 ml (BTO variants)

OTHER LUBRICANTS
Cone set grease
Recommended manufacturer As recommended by TVS Motor Company
Recommended grade BEM 34-132
Recommended quantity 15 gm (in sachet)
Chain cleaner
Recommended manufacturer MOTUL
Recommended grade C1
Chain lube
Recommended manufacturer MOTUL
Recommended grade C2
Brake fluid
Recommended manufacturer BASF HYDRAULAN 404 / EQUIVALENT
Recommended grade DOT 4
 SERVICE MANUAL
GENERAL INFORMATION

ADVANTAGES AND SPECIAL FEATURES OF TVS Apache RTR 310

RT DSC

Race Tuned Dynamic Stability Control - BTO

Cornering ABS
Wheelie Control
Cornering Traction Control
Rear Lift Off Control
Cornering Cruise Control
Slope Dependent Control

- The First-in-class technology optimises braking even while cornering via an advanced system that uses a 6D
internal measurement unit. It adjusts braking and power input to assist riders during critical lowsiding
situations and counters righting up when braking in bends.

- Unique Reverse Inclined DOHC Engine - The TVS Apache RTR 310 has a 312.2 cc engine with a compact
engine layout for mass centralization. The forged aluminium pistons are 5% lighter for the best-in-class Power
to-Weight ratio, and the engine is tuned to deliver higher peak torque across the powerband.

- Engine Coolant Optimization - The cylinder head on the TVS Apache RTR 310 is designed to have best-in-class
heat management by reducing the engine temperature. This again allows for better performance and higher
revving.

- 6-Speed Gearbox with Bidirectional Quickshifter - Precision shifts and quick launches come easy with the
bottom mounted shift-lever and gears with negative back rack angle machined in all the gears lug to lug.
Performance is taken up a notch by the quickshifter that saves milliseconds with every gearshift.

- Throttle-By-Wire - A flick of the wrist now delivers precise performance like never before. The state-of-the-art
system in the TVS Apache RTR 310 comprises of an intelligent throttle body with a turbulence system along
with a sharper throttle grip with reverse blip for instant power.

- Race Tuned Linear Stability Control (Cruise Control) - Make those long distance seem shorter on the TVS
Apache RTR 310. Engage Cruise Control and maintain that set speed without any throttle or clutch input.

- Race Tuned Slipper Clutch - The slipper clutch on the TVS Apache RTR 310 allows for rapid downshifts that
prevent rear wheel hopping. Brake later and corner more precisely. The assist function provides enhanced
torque-carrying capacity with reduced clutch operating force.

- Liquid-Cooled oil-Coolant Technology - TVS Apache RTR 310 has 23 rows of tubes for optimized cooling
efficiency to keep the high revving engine at the optimum temperature to derive maximum performance.

- GTT - Glide Through Technology - This first-in-segment feature in the TVS Apache RTR 310 allows the
motorcycle to start moving with the slow release of the clutch and no throttle operation. All this happens
without the need to synchronise the throttle and clutch lever or worrying about the engine stalling.

- The Freestyler Frame - The Hyper Spec trellis frame with a light aluminium sub-frame is the spine of the
freestyler. It provides the TVS Apache RTR 310 with excellent dynamic response at higher speeds and ease of
manoeuvrability.

- Freestyle Ergonomics - The rider triangle is optimised in the TVS Apache RTR 310 for better load distribution on
the shoulder. This ensures excellent steering control and good lower back comfort so that the rider can keep
freestyling all day long.
SERVICE MANUAL
GENERAL INFORMATION

- Responsive KYB Suspension - Honed and tuned by the experts from KYB, the Monoshock with monotube
floating piston technology provides precise damping and smooth dynamic response to achieve best-in-class
lateral acceleration and cornering speeds.

- Supermoto Mode - Adding flair to the freestyler, the all-new Supermoto mode in the TVS Apache RTR 310
disengages the rear ABS while maximising the power output. It act as the perfect recipe to keep the rider
drifting with style.

- Superior Michelin Road 5 Tyres - The TVS Apache RTR 310 is equipped with Michelin Road 5 tyres. Engineered
with next-gen compounds and featuring Michelin's patented ACT+ technology, these tyres provide superior
grip for cornering and offer a premium ride feel.

- Sporty Steel Tapered Handlebars - Designed with performance-focused ergonomics in mind, the tapered
handlebars give the rider precise control and feedback.

- Race-tuned Linear Stability Control (Linear Traction Control) - This first-in-class technology in the TVS Apache
RTR 310 controls torque to ensure optimal transfer of driving force to the road. It prevents the rear wheel from
spinning during acceleration in slippery conditions and surfaces.

- Adjustable Hand Levers - Set how the rider want to freestyle. The adjustable levers offer 4 levels of
adjustment for increased accessibility for devices riding styles.

- Multi-Information Race Computer - Meet the advanced digital face of the freestyler. The horizontal 5" TFT race
computer is the control hub that enables you to change and tune settings like the traction control, cruise
control, headlamp brightness and even music for the rider's Bluetooth device.

- Ride Modes - The TVS Apache RTR 310 is equipped with 5 ride modes to help th freestyler adapt and deliver
remarkable performance in any condition.

- TVS SmartXonnect - The SmartXonnect app links your smartphone to the TVS Apache RTR 310. The cutting-
edge Bluetooth connected app offers a range of telemetry and data. The app displays a detailed post-ride /
race analysis which includes distance covered, gear shifting points, ride pattern analysis, and much more.
 SERVICE MANUAL
GENERAL INFORMATION

WARRANTY TERMS

TVS RTR 310

Standard warranty - 24 months from the date of sale or 30,000 km, whichever of the two occurs earlier.

Additional warranty - 36 months from the completion of standard warranty or 50,000 km, whichever of
the two occurs earlier.

RUNNING - IN PERIOD

Running-in is essential to preserve engine life and performance over time. Twisty roads and gradients are ideal to run
in the engine, brakes and suspension effectively. The first 1,000 km is a running-in period for the motorcycle.
Maximum engine speed during running-in 0 to 1,000 km - below 7,000 rpm.

During the first 1,000 km, avoid the full throttle starts and rapid acceleration, which could expose the engine parts to
excessive stress. It is advisable to run the engine at varying load and rpm, though still within recommended rpm
limit. Avoid riding at constant engine rpm for prolonged periods.

During initial running, use brakes gently. Do not brake hard or keep brake applied for too long to enable a correct
break-in of brake pad friction material against the brake discs.

To allow all the mechanical parts of motorcycle to adapt each another, and to avoid reduction of engine components
life, it is advisable to avoid sudden acceleration and running the engine at high rpm for too long, especially uphill.

Check the drive chain frequently and if required adjust it. Also ensure that the chain is lubricated as required to
increase its service life.
 SERVICE MANUAL
GENERAL INFORMATION

PRECAUTIONS AND GENERAL INSTRUCTIONS

Observe the following precautions without fail when dismantling and reassembling.

l Do not run the engine indoors with little or no ventilation.

l Be sure to replace gaskets, O-rings, circlips and cotter pins with new ones, for safety.
l When tightening nuts and bolts, start first with the larger or centre ones. Tighten these to the specified torque
using a crisscross pattern.
l Use specified special and common tools only.
l When engine and final drive components are disassembled and inspected, coat the mating surfaces with a
lubricant to prevent corrosion.
l When assembling components, use recommended lubricants.
l After assembling, check every part for proper installation, movement and operation.
l Always ensure mutual safety when working with the partners.
l Use only genuine TVS Motor Company parts and recommended lubricants.

LIST OF HAND TOOLS REQUIRED

1. Flat head spanners:

8 mm, 10 mm, 12 mm, 14 mm 17 mm, 21 mm and 41mm.
2. Ring spanners:
8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 16 mm , 17 mm, 22 mm, 24 mm, 27 mm, 32 mm
and 41mm.
3. Tubular spanners:
8 mm, 10 mm, 12 mm, 14 mm, 16 mm and 17 mm.
4. Socket spanners:
12 mm, 13mm, 14 mm, 17 mm, 22 mm, 27 mm and 32 mm.
5. Allen keys:
4 mm, 5 mm, 6 mm, 8 mm, 10 mm and 12 mm.
6. Screw drivers:
Flat screw driver-small, flat screw driver, phillips head screw driver no.1, phillips head screw driver no. 2 and
phillips head screw driver no. 3.
7. Hammers:
Nylon hammer, rubber mallet and metal hammer.
8. Pliers:
Straight nose plier, combination plier, water pump plier, external circlip plier-6 inch and snap ring circlip plier-7
inch.
9. Others:
Drift, chisel, plug spanner, compression gauge, special adopter, micrometer, vernier calliper, dial gauge, surface
plate, hot plate and jack.
 SERVICE MANUAL
GENERAL INFORMATION

LIST OF SPECIAL TOOLS REQUIRED

Sl. no. Part no. Description
1 NB31 009 0 U69 Engine holder and rotary stand
2 N731 014 0 Tool tdc lock
3 NB31 010 0 Tool piston ring assy
4 N731 017 0 Adapter compression gauge
5 N731 015 0 Adapter magneto puller
6 N731 009 0 Tool IG index - Tool ignition coil
7 NB31 008 0 Tool piston circlip assy
8 N731 016 0 Service tool clutch nut
9 N731 028 0 Mandrel coolant seal 35 27
10 N731 024 0 Mandrel ball bearing 26 10
11 N731 023 0 Mandrel needle bearing 12 8
12 N731 022 0 Mandrel needle bearing 20 14
13 N731 019 0 Mandrel oil seal 24 15
14 N731 007 0 Piston rod holder
15 N731 021 0 Mandrel needle bearing 32 25
16 N731 010 0 Plate engine support
17 N731 013 0 Stem oil holder
18 S131 002 0 Extractor assy inlet & exhaust
19 N731 025 0 Mandrel ball bearing 40 17
20 N731 002 0 Tool - Damper rod
21 N731 001 0 Tool cartridge holder
22 ME-9905 051 5 Engine oil filter tool
23 N731 005 0 Tool space holder
24 N731 006 0 Installer front fork oil seal
25 NB31 005 0 Slit insert
26 N721 001 0 Adjuster shock absorber rear
27 N731 008 0 Tool swingarm service
28 NB31 002 0 Steering cone remover
29 NB31 003 0 Remover steering cup
30 NB31 001 0 Mandrel steering cone
31 NB31 004 0 Assy tool steering cups
32 N731 026 0 Mandrel ball bearing
33 ME-31 180 0 Fork oil level
34 ME-9901 059 5 Caliper pin remover tool
 SERVICE MANUAL
GENERAL INFORMATION

SPECIAL TOOLS & ITS APPLICATION

1. NB31 009 0 U69 Engine holder and rotary

stand. (Fig. 1.5)

Fig. 1.5

2. N731 014 0 Tool tdc lock. (Fig. 1.6)

Fig. 1.6
3. NB31 010 0 Tool piston ring assembly.
(Fig. 1.7)

Fig. 1.7
4. N731 017 0 Adapter compression gauge.
(Fig. 1.8)

Fig. 1.8
 SERVICE MANUAL
GENERAL INFORMATION

5. N731 015 0 Adapter magneto puller.

(Fig. 1.9)

Fig. 1.9
6 N731 009 0 Tool IG index - Tool ignition coil.
(Fig. 1.10)

Fig. 1.10
7. NB31 008 0 Tool piston circlip assembly.
(Fig. 1.11)

Fig. 1.11

8. N731 016 0 Service tool clutch nut.

(Fig. 1.12)

Fig. 1.12
 SERVICE MANUAL
GENERAL INFORMATION

9. N731 028 0 Mandrel coolant seal 35 27.

(Fig. 1.13)

Fig. 1.13

10.N731 024 0 Mandrel ball bearing 26 10.

(Fig. 1.14)

Fig. 1.14
11. N731 023 0 Mandrel needle bearing 12 8.
(Fig. 1.15)

Fig. 1.15
12.N731 022 0 Mandrel needle bearing 20 14.
(Fig. 1.16)

Fig. 1.16
 SERVICE MANUAL
GENERAL INFORMATION

13 .N731 019 0 Mandrel oil seal 24 15.

(Fig.1.18)

Fig. 1.18

14.N731 007 0 Piston rod holder. (Fig.1.19)

Fig. 1.19

15.N731 021 0 Mandrel needle bearing 32 25.

(Fig.1.20)

Fig. 1.20

16.N731 010 0 Plate engine support. (Fig.1.21)

Fig. 1.21
 SERVICE MANUAL
GENERAL INFORMATION

17. N731 013 0 Stem oil holder. (Fig.1.22)

Fig. 1.22
18.S131 002 0 Extractor assy inlet & exhaust.
(Fig.1.23)

Fig. 1.123

19.N731 025 0 Mandrel ball bearing 40 1.

(Fig.1.24)

Fig. 1.24

20.N731 002 0 Tool - Damper rod. (Fig.1.25)

Fig. 1.25
 SERVICE MANUAL
GENERAL INFORMATION

21. N731 001 0 Tool cartridge holder. (Fig.1.26)

Fig. 1.26
22.ME-9905 051 5 E n g i n e o i l f i l t e r t o o l .
(Fig.1.27)

Fig. 1.27

23.N731 005 0 Tool space holder. (Fig.1.28)

Fig. 1.28

24.N731 006 0 Installer front fork oil seal.

(Fig.1.29)

Fig. 1.29
 SERVICE MANUAL
GENERAL INFORMATION

25.NB31 005 0 Slit insert. (Fig.1.30)

Fig. 1.30
26.N721 001 0 Adjuster shock absorber rear.
(Fig.1.31)

Fig. 1.31

28.NB31 002 0 Steering cone remover.

(Fig.1.32)

Fig. 1.32

29.NB31 003 0 Remover steering cup. (Fig.1.33)

Fig. 1.33
 SERVICE MANUAL
GENERAL INFORMATION

30.NB31 0 01 0 Mandrel steering cone.

(Fig.1.34)

Fig. 1.34
31. NB31 004 0 Assembly tool steering cups.
(Fig.1.35)

Fig. 1.35
32.N731 026 0 Mandrel ball bearing. (Fig.1.36)

Fig. 1.36

33.ME-31 180 0 Fork oil level. (Fig.1.37)

Fig. 1.37
 SERVICE MANUAL
GENERAL INFORMATION

34.ME-9901 059 5 Caliper pin remover tool.

(Fig.1.38)

Fig. 1.39
 SERVICE MANUAL
GENERAL INFORMATION

PARKING THE VEHICLE ON PADDOCK STAND

Component : Paddock stand
Objective : To park the vehicle on paddock stand
Repair cycle : Whenever required

CAUTION
Ensure the ramp is free from oil and other
slippery materials.

Do not sit on the vehicle when parked with

a paddock stand.
A
Rear wheel paddock stand installation:

l Park the vehicle on the ramp using side stand. A

l Make sure the vehicle is parked in the middle
of the ramp and there is enough space on all
sides of the vehicle.

NOTE
Ask a helper to hold the vehicle firmly on
the ramp until the vehicle rests firmly on Fig. 1.40
the paddock stand.

l Loosen the clamping screws (A) of the stand

adopters. (Fig. 1.40)
B
l Move away the adapters (B & C) in such a way
C
that the swing arm fits between them.
(Fig. 1.41A& B)

l Ensure that the axle is not covered and the

paddock does not rest on the sprocket / drive
chain and position the stand.

l Make sure that the vehicle is secured so that it Fig. 1.41A Fig. 1.41B
cannot topple sideways.

l Push the stand down until the motorcycle is

standing upright and the handle of auxiliary
stand is resting on the floor properly. (Fig. 1.42)

l Now, tighten the clamping screws (A).

(Fig. 1.40)
CAUTION
While installing (or) removing the rear
paddock stand, care should be taken not to
damage the swing arm and sprocket / drive
chain. Fig. 1.42
 SERVICE MANUAL
GENERAL INFORMATION

Front wheel paddock stand installation:

A
l Make sure the vehicle is parked in the middle
of the ramp and there is enough space on all
sides of the vehicle.
A
l Loosen the clamping screws (A) of the stand
adopters. (Fig. 1.43)

Fig. 1.43

l Move away the adopters (B) in such a way that

the front forks fit between them. (Fig. 1.44A)

l Centre the stand relative to the front wheel and

push it against the front axle.

NOTE B C

Ask a helper to hold the vehicle firmly on

the ramp until the vehicle rests firmly on
the paddock stand.

l Align the two adapters (C) so that the front Fig. 1.44A Fig. 1.44B
forks are securely seated. (Fig. 1.44B)

l Apply uniform pressure to push down the

p a d d o ck s t a n d a n d c a r e f u l l y l i ft t h e
motorcycle.(Fig. 1.45)

CAUTION
While installing (or) removing the front
paddock stand, care should be taken not to
damage the front fork assembly.

Fig. 1.45
 SERVICE MANUAL
GENERAL INFORMATION

OPERATING THE RAMP

Component : Vehicle service ramp

Objective : To operate the service ramp (lift & down)
Repair cycle : Whenever required

CAUTION
Ensure the ramp is free from oil and other
slippery materials.

Ramp uplift:

l Park the vehicle on the ramp using a paddock

stand.

l Press the controller button to lift the ramp to Ramp operation switch
the desired height. (Fig. 1.46)

CAUTION
Before lifting the ramp make sure that the
vehicle is completely placed on the
paddock stand firmly. Fig. 1.46

l Push the locking bar into the locking blocks.

l Slightly lift down the ramp and ensure the ramp

is safely locked.

Ramp lift down:

WARNING
Do not get inside the ramp which is
inraised condition and may cause injury /
death.

l Pull out the locking bar and press the down

button on the controller box and lift down the
ramp until it completely touche the ground.
 SERVICE MANUAL
GENERAL INFORMATION

PARTS IDENTIFICATION - LH

Cover fuel tank center front

Cover fuel tank L

Passenger seat
Raider seat

Head lamp assembly Tail cover R

Cover fuel tank front L Cover fuel tank rear L

Side cowl L

Engine guard front L

Cover frame bottom L
Engine guard center

Fig. 1.47

PARTS IDENTIFICATION - RH

Cover fuel tank R

Cover fuel tank rear R

Cover fuel tank front R

Tail cover R
Side cowl R
Fender front top

Cover frame bottom R

Engine guard front R Fender front bottom
Fig. 1.48
 SERVICE MANUAL
GENERAL INFORMATION

SEAT ASSEMBLIES

Component : Seat assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To remove the seat assemblies
Repair cycle : As required

Seat assembly rear (passenger seat) - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.
A
l Insert the control key into the seat lock (A) and
turn it in clockwise direction. (Fig. 1.49)

Control key

l Remove the rear seat by gently lifting it from

rear end and tapping at the front end. (Fig. 1.50)
Fig. 1.49
l To reassemble, insert the front end of the seat
into the frame hook and press it at the rear end
until a click sound is heard.

l To reassemble the seat assembly rear, reverse

the removal procedure.

NOTE
Ensure the seat is locked securely in
position after installation.

Utility box - Removal Fig. 1.50

l To remove the utility box, remove the seat

assembly rear as explained above.

l Gently take out the utility box (B) by dislocating

it from the seat release cable (C) as shown.
(Fig. 1.51)
B
C
l Now, separate and take out the utility box lugs
from it location.

l To reassemble the utility box, reverse the

removal procedure.

Fig. 1.51
NOTE
While reassembling the utility box, ensure
the utility box lugs are properly inserted
into the location.
 SERVICE MANUAL
GENERAL INFORMATION

Seat assembly front (raider seat) - Removal

l To remove the seat assembly rear and utility

box, as explained in pervious page.

l To remove the seat assembly front (D), remove

the seat assembly rear as explained in pervious
page and take out the control key from the lock.
(Fig. 1.52)

l Gently pull the seat release cable (E) to release E

the seat lock. Hold the seat release cable in D
pulled condition, lift the seat from rear end and
remove along with its cushion and bush.
(Fig. 1.52)

l Carefully take out the seat assembly front lugs

Fig. 1.52
from it location.

l To reassemble, insert the front end of the seat

into the frame and on the seat mounting
bracket.

l To reassemble the seat assembly front,

reverse the removal procedure.

NOTE
Ensure the seat is locked securely in
position after installation.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To remove the cover fuel tank rear LH & RH
Repair cycle : Whenever required

Cover fuel tank rear LH & RH - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Take out the cover fuel tank rear L from the

cover fuel tank assembly by carefully pulling
out its lugs from cover fuel tank assembly.
(Fig. 1.53)

l In similarly manner, remove the cover fuel tank

rear R.

CAUTION
While reassembling, care should be taken
not to break the lugs of the cover fuel tank
rear L & R. Incase it is damaged, replace it
with a new one. Fig. 1.53

While reassembling the cover fuel tank

rear, see that the rubber cushions provided
for the cover fuel tank rear lug seating are
in place.

l To re-fix the cover fuel tank rear, insert the

cover fuel tank rear lugs into their seating
locations at the cover fuel tank assembly.

NOTE
Make sure that the cover fuel tank rear is
locked securely in its position after
installation.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To remove the side cowl L & R
Repair cycle : Whenever required

Side cowl L & R - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the hexagonal socket cap flange bolt

(M5x15 - 2 Nos.) from the rear mounting of side
cowl L. (Fig. 1.54A & B)

5 mm Allen key

Tightening torque 3 ± 1 Nm
Fig. 1.54A Fig. 1.54B

l Remove the CRR flanged pan head screw

(M5x16 - 2 Nos.) from the mounting of cover
fuel tank inner LH & RH. (Fig. 1.55A & B)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Gently take out the side cowl L & R by carefully

pulling out the lugs of the side cowl from the
sub frame front assembly and cover fuel tank
inner LH & RH.
Fig. 1.55A Fig. 1.1
NOTE
While reassembling the side cowl, ensure
that the side cowl L & R lugs are properly
seated with the cover fuel tank inner LH &
RH and the cover fuel tank inner front LH &
RH.

CAUTION
Care should be taken not to damage the side
cowl lugs during removal / reassembly.

l Reassemble the parts in the reverse order of

removal.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To disassemble side cowl L & R assembly
Repair cycle : Whenever required

Side cowl L & R - Disassembly

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the side cowl L & R. Refer page no 1-

00 for removal procedure.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 2 Nos.) from the mounting of bezel
side cowl L with the side cowl L assembly.
(Fig. 1.56)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 1.56

l Gently press and release the bezel side cowl L

lug from the lock of side cowl L assembly.
(Fig. 1.57)

l Now, separate the bezel side cowl L along with

the grill side cowl L.

CAUTION
Care should be taken not to damage the
locking lugs during removal / reassembly.

l In the same manner, remove the bezel side Fig. 1.57

cowl R and separate it from the side cowl R
assembly.

l Reverse the removal procedure to reassemble

the bezel side cowl.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To remove cover fuel tank inner front LH & RH
Repair cycle : As required

Cover fuel tank inner front LH & RH - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the cover fuel tank rear LH & RH.

Refer page no 1-00 for removal procedure.

l Remove the side cowl L & R. Refer page no 1-

00 for removal procedure.

l Remove the hexagonal socket cap flange bolt

(M6x16 - 2 Nos.) from the mounting of cover A
fuel tank inner front LH. (Fig. 1.58)

5 mm Allen Key

Tightening torque 3 ± 1 Nm

l Now, take out the cover fuel tank inner front Fig. 1.58
LH.

CAUTION
Care should be taken not to damage the
lugs during removal / reassembly.

NOTE
While reassembly, ensure that the slot (A)
cover fuel tank inner front LH & RH are
properly aligned with the side cowl L & R
and the cover fuel tank. (Fig. 1.17)

l In similar manner, remove the cover fuel tank

inner front RH and separate it from the cover
fuel tank assembly.

l To reassemble the cover fuel tank inner front

LH & RH in the reverse order of removal.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assemblies

Component condition : Vehicle on ramp and component accessible
Objective : To remove cover fuel tank assembly
Repair cycle : Whenever required

Cover fuel tank assembly - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove both rider and passenger seat. Refer

page no 1-00 for removal procedure.

l Remove the cover fuel tank rear L & R

assembly. Refer page no 1-00 for removal
procedure.

l Remove the side cowl L & R assembly. Refer

page no 1-00 for removal procedure.

l Remove the cover fuel tank inner front LH &

RH. Refer page no 1-00 for removal procedure.

l Remove the hexagonal screw (M6x20 - 2 Nos.)

along with cup washer from both LH and RH
mounting of cover fuel tank assembly.
(Fig. 1.59A & B)

10 mm spanner

Tightening torque 3 ± 1 Nm Fig. 1.59A Fig. 1.59B

l Remove the hexagonal bolt (M6x33 - 1 No.)

along with punched washer (6.5x24x1.6 -
1 No.)from the rear mounting of cover fuel tank
assembly. (Fig. 1.60)

10 mm spanner

Tightening torque 3 ± 1 Nm

l Take out the cushion fuel tank rear upper

(1 No.) from the fuel tank cover assembly.

NOTE Fig. 1.60

Ensure to assemble the cushion fuel tank

upper during reassembly without fail.
 SERVICE MANUAL
GENERAL INFORMATION

l Remove the hexagonal cap flange bolt LH & RH

(M5x15 - 2 Nos.) from the mounting of cover
fuel tank center front. (Fig. 1.61A & B).

5 mm Allen key

Tightening torque 3 ± 1 Nm

Fig. 1.61A Fig. 1.61B

l Remove the control key (A) from the ignition

lock. (Fig. 1.62) A

l Gently rotate and take out the ignition lock cap

(B) in anti-clockwise direction. (Fig. 1.62)
B
CAUTION
Care should be taken not to rotate the
ignition lock cap too much faster during
removal / reassembly to avoid damage to
it. Incase ignition lock cap is damaged, it
should be replaced with the new one. Fig. 1.62
l Carefully lift the rear portion of cover fuel tank
assembly and gently take out the cover fuel
tank assembly by carefully dislocating it from
the fuel tank assembly.

CAUTION
During removal, do not lift the cover fuel
tank assembly more than required as it may
damage the painted surface.

l Take out the cushion fuel tank lower along with

spacer fuel tank rear from the rear mounting of
cover fuel tank assembly either from the cover
assembly or from the mounting location. Also,
ensure to re-fix the cushion during reassembly
for the proper seating of cover assembly.

NOTE
While reassembling the cover fuel tank
assembly, ensure the availability and
proper seating of seal fuel tank cap.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assembly

Component condition : Vehicle on ramp and component accessible
Objective : Cover fuel tank front inner LH & RH - Removal
Repair cycle : Whenever required

Cover fuel tank front inner LH & RH - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the seat assembly. Refer page no 1-00

for removal procedure.

l Remove the cover fuel tank assembly. Refer

page no 1-00 for removal procedure.

l Remove the hexagonal socket cap flange bolt

(M6x16 - 2 Nos.) from the mounting of cover
fuel tank front inner LH & RH. (Fig. 1.63)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 1.63
l Gently press to release the locks and separate
the cover fuel tank front inner LH & RH by
sliding them out from the cover fuel tank L & R
front.(Fig. 1.64)

NOTE
Care should be taken not damage the
locking lugs during removal / reassembly.

While reassembling, ensure to fix the

retainer clip nut without fail.

Fig. 1.64
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assembly

Component condition : Vehicle on ramp and component accessible
Objective : Cover fuel tank center front - Removal
Repair cycle : Whenever required

Cover fuel tank center front - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the seat assembly. Refer page no 1-00

for removal procedure.

l Remove the bracket ignition lock. Refer page

no 1-00 for removal procedure.

l Remove the cover fuel tank front inner LH &

RH. Refer page no 1-00 for removal procedure.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 2 Nos.) from the mounting of cover
fuel tank front center. (Fig. 1.65)

Phillips head screw driver

Fig. 1.65
Tightening torque 1 ± 0.2 Nm

l Gently release the lugs and slide out the cover

fuel tank front center from the cover fuel tank
front LH & RH. (Fig. 1.66)

CAUTION
Care should be taken not damage the
locking lugs during removal / reassembly.

Fig. 1.66
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assembly

Component condition : Vehicle on ramp and component accessible
Objective : Cover fuel tank center front - Removal
Repair cycle : Whenever required

Cover fuel tank front LH & RH - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the seat assembly. Refer page no 1-00

for removal procedure.

l Remove the cover fuel tank assembly. Refer

page no 1-00 for removal procedure.

l Remove the cover fuel tank front inner LH &

RH. Refer page no 1-00 for removal procedure.

l Remove the cover fuel tank center front. Refer

page no 1-00 for removal procedure.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 4 Nos.) from the mounting of cover
fuel tank front LH with the cover fuel tank LH.
(Fig. 1.67)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

l Gently separate and take out the cover fuel

tank front LH by releasing the locks carefully.

Fig. 1.67
l Similarly, remove the CRR flanged pan head
tap screw (ST4.2x13 - 4 Nos.) from the
mounting of cover fuel tank front RH with the
cover fuel tank RH. (Fig. 1.68)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

l Gently separate and take out the cover fuel

tank front RH by releasing the locks carefully.

CAUTION
Fig. 1.68
Care should be taken not damage the
locking lugs during removal / reassembly.
 SERVICE MANUAL
GENERAL INFORMATION

FUEL TANK ASSEMBLY COVERS - REMOVAL

Component : Cover fuel tank assembly

Component condition : Vehicle on ramp and component accessible
Objective : Cover fuel tank L & R - Removal
Repair cycle : Whenever required

Cover fuel tank L & R - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the seat assembly. Refer page no 1-00

for removal procedure.

l Remove the cover fuel tank assembly. Refer

page no 1-00 for removal procedure.

l Remove the cover fuel tank front inner LH &

RH. Refer page no 1-00 for removal procedure.

l Remove the cover fuel tank center front. Refer

page no 1-00 for removal procedure.

l Remove the cover fuel tank front LH & RH.

Refer page no 1-00 for removal procedure.

l Remove the CRR pan head screw (M6x12 -

2 Nos.) from the cover fuel tank L & R.
(Fig. 1.69)

Phillips head screw driver

Tightening torque 3 ± 1 Nm Fig. 1.69

l Gently press and release the locks from the

cover fuel tank L&R lugs and separate the
cover fuel tank L & R. (Fig. 1.70)

CAUTION
Care should be taken not damage the
locking lugs during removal / reassembly.

Fig. 1.70
 SERVICE MANUAL
GENERAL INFORMATION

Reassembly

l For reassembly, reverse the procedure of

removal.

NOTE
Ensure the availability of cushions and
retainer clips at the respective mounting
places before reassembling the covers and
also before assembling the cover fuel tank
assembly into the fuel tank assembly.

l Assemble the covers separately and then

assemble them as a set into the fuel tank
assembly.

l Refer exploded view on page no. 1-71 for

details.

Cover fuel tank exploded view

Fig. 1.71
 SERVICE MANUAL
GENERAL INFORMATION

HEAD LAMP - ASSEMBLY

Component : Head lamp assembly

Component condition : Vehicle on ramp and component accessible
Objective : Head lamp assembly - Removal
Repair cycle : Whenever required

Head lamp assembly - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the hexagonal socket cap flange bolt

(M6x20 - 4 Nos.) along with punched washer
(6.5x16x1.2 - 4 Nos.) from both upper and lower
bracket complete. (Fig. 1.72 A & B)

5 mm Allen key

Tightening torque 7 ± 1 Nm

NOTE Fig. 1.72A Fig. 1.72B

Hold the head lamp assembly during

removal of bolts to avoid falling and
stretching of the wiring harness.

Ensure the availability of grommet, bushes

and punched washers at mounting places
during reassembly.

l Now, carefully disconnect the wiring sockets

of head lamp assembly and turn signal lamps
front LH & RH from the main wiring harness
and take out the head lamp assembly.
(Fig. 1.73)

CAUTION
Care should be taken not to drop down the
head lamp assembly during removal /
reassembly, it may lead to damage or
replace.
Fig. 1.73
l Reverse the removal procedure for
reassembling the head lamp assembly.

l After reassembling the head lamp assembly,

ensure to check the head lamp beam and
adjust if required, as explained in chapter
“periodic maintenance” page no. 2-25.

l To disassemble the assembly, refer to chapter

“Electrical system” page no. 5-00.
 SERVICE MANUAL
GENERAL INFORMATION

SPEEDOMETER ASSEMBLY

Component : Speedometer assembly

Component condition : Vehicle on ramp and component accessible
Objective : Speedometer assembly - Removal
Repair cycle : Whenever required

Speedometer assembly TFT - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove hexagonal socket cap flange bolt

(M6x16 - 2 Nos.) from the mounting of cover
speedometer. (Fig. 1.74)

5 mm Allen key

Tightening torque 3 ± 1 Nm

l Gently dislocate and take out the cover

speedometer from the bracket speedometer.

NOTE Fig. 1.74

Ensure not to damage the speedometer

cover lugs during removal / reassembly.

l Carefully disconnect the main wiring harness

couplers (2 Nos.) from the speedometer
assembly. (Fig. 1.75)

CAUTION
While disconnecting the lock type coupler,
be sure to push and release the lock before
attempting to disconnect.

Fig. 1.75

l Remove the hexagonal socket cap flange bolt

(M5x20 - 4 Nos.) from the mounting of the
speedometer assembly.(Fig. 1.76)

5 mm Allen key

Tightening torque 3 ± 1 Nm

l C a r e f u l l y d i s l o c a t e a n d t a ke o u t t h e
speedometer assembly from the bracket
speedometer.

Fig. 1.76
 SERVICE MANUAL
GENERAL INFORMATION

CAUTION
Care should be taken not to drop down the
speedometer assembly during removal /
reassembly, as it may lead to damage or
replace.

l To reassemble the speedometer assembly in

the reverse order of removal procedure.

l Fix the cover speedometer and tighten it using

the mounting bolts.
NOTE
After reassembling the speedometer
assembly in the vehicle, ensure to check
t h e f u n c t i o n s o f t h e s p e e d o m e te r
assembly.
 SERVICE MANUAL
GENERAL INFORMATION

COVER RADIATOR LH & RH ASSEMBLY

Component : Cover radiator assembly LH & RH

Component condition : Vehicle on ramp and component accessible
Objective : Cover radiator assembly LH & RH - Removal
Repair cycle : Whenever required

Cover radiator - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the hexagonal socket cap flange bolt

(M6x16 - 1 Nos.) from the mounting of cover
radiator assembly LH. (Fig. 1.77)

5 mm Allen key

Tightening torque 3 ± 1 Nm

l Carefully dislocate and take out the cover

radiator assembly LH from the radiator
assembly.
Fig. 1.77

l Similarly, remove the hexagonal socket cap

flange bolt LH (M6x16 - 1 Nos.) from the
mounting of cover radiator assembly RH.
(Fig. 1.78)

5 mm Allen key

Tightening torque 3 ± 1 Nm

l Take out the cover radiator assembly RH by

carefully dislocating it from the radiator
assembly.

Fig. 1.78
CAUTION
While reassembling the cover radiator
assembly LH & RH. Care should be taken
not to damage the radiator hoses .
 SERVICE MANUAL
GENERAL INFORMATION

Cover radiator LH - Disassembly

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the required cover radiator assembly

LH or RH. Refer page no 1-00 for removal
procedure.

l Remove the CRR pan head screw (M6x12 -

2 Nos.) from the mounting of deflector with the
cover radiator. (Fig. 1.79)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Separate the deflector from the cover radiator

assembly. Fig. 1.79

l Assemble back the deflector to the cover

radiator and fix them back to the radiator
assembly as a set.
 SERVICE MANUAL
GENERAL INFORMATION

ENGINE GUARD BOTTOM / ENGINE GUARD ASSEMBLY

Component : Engine guard bottom / engine guard assembly

Component condition : Vehicle on ramp and component accessible
Objective : Engine guard bottom / engine guard assembly - Removal
Repair cycle : Whenever required

Engine guard bottom / engine guard assembly

- Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the hexagonal screw (A) (M6x25 -

2 Nos.) along with punched washer from the
mounting of engine guard bottom. (Fig. 1.80)
B
10 mm Spanner A

Tightening torque 3 ± 1 Nm

l Remove the hexagonal screw (B) (M6x12 -

2 Nos.) along with punched washer from the
mounting of engine guard bottom. (Fig. 1.80) Fig. 1.80

10 mm Spanner

Tightening torque 3 ± 1 Nm

l Carefully dislocate and take out the engine

guard bottom.

l Remove the hexagonal screw (M6x20 - 2 Nos.)

from the LH and RH mounting of engine guard
assembly. (Fig. 1.81 A & B).

10mm Spanner

Tightening torque 3 ± 1 Nm

Fig. 1.81A Fig. 1.81B

l Remove the hexagonal socket cap flange bolt

(M6x16 - 4 Nos.) along with the cup washers
from the front mounting of engine guard
assembly. (Fig. 1.82).

5 mm Allen key

Tightening torque 3 ± 1 Nm

l Now, gently take out the engine guard as an

assembly by carefully dislocating it from its
mounting locations.
Fig. 1.82
 SERVICE MANUAL
GENERAL INFORMATION

NOTE
Ensure the availability of cup washers and
grommets at the mounting locations of
engine guard assembly.

l Remove the CRR flanged pan head tap screw

(ST4.2x13 - 6 Nos.) from the mounting of
engine guard front LH & RH with engine guard
center. (Fig. 1.83 A & B)

Phillips head screw driver

Fig. 1.83A Fig. 1.83B
Tightening torque 1 ± 0.2 Nm

l Gently press and release the locks of the

engine guard front LH & RH locked with the
engine guard center and carefully separate
them. (Fig. 1.84)

l Reassemble the parts in the reverse order of

removal while ensuring the availability of
mounting cushions and cup washers at the
respective mounting locations.

CAUTION
Fig. 1.84
While separating, care should be taken not
to damage the engine guards and its
mounting lugs.

Ensure the availability of grommets and

cup washers at the respective mounting
locations of the engine guard assembly.

l To reassemble the engine guard as an

assembly in the reverse order of removal
procedure.

l Re-fix the engine guard bottom and tighten

with the mounting screws and washers.
 SERVICE MANUAL
GENERAL INFORMATION

TAIL COVER ASSEMBLY

Component : Tail cover assembly

Component condition : Vehicle on ramp and component accessible
Objective : Tail cover assembly - Removal
Repair cycle : Wherever is required

Tail cover assembly - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure. A

l Remove both rider and passenger seats. Refer

page no 1-00 for procedure.

l Carefully disconnect and dislocate the cable

seat lock (A) from the seat latch . (Fig. 1.85)

Nose plier
Fig. 1.85

l Remove the CRR pan head screw (M6x16 -

2 Nos.) from the mounting of tail cover center
front with the tail cover assembly. (Fig. 1.86)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 1.86

l Carefully disconnect and dislocate the cable

seat lock (A) from the rider seat lock. (Fig. 1.87)

Nose plier

l Gently dislocate the tail cover center's lugs

from the tail cover assembly and slide out the
tail cover center.
A
NOTE
Care should be taken not to damage the tail
cover center's lugs while separating it from
Fig. 1.87
the tail cover assembly.
 SERVICE MANUAL
GENERAL INFORMATION

l Remove the hexagonal socket cap screw

(M8x25 - 4 Nos.) from the mounting of both LH
& RH pillion handle. (Fig. 1.88 A & B)

6 mm Allen key

Tightening torque 19 ± 1 Nm

l Gently dislocate and take out the pillion handle

LH & RH from the sub frame.

Fig. 1.88A Fig. 1.88B

l Remove the hexagonal screw (M6x20 - 2 Nos.)

along with punched washer (6.5x16x1.2 -
2 Nos.) from the front mounting of tail cover
assembly. (Fig. 1.89)

10 mm Spanner

Tightening torque 3 ± 1 Nm

Fig. 1.89

l Remove the hexagonal screw (M6x16 - 2 Nos.)

along with punched washer (6.5x16x1.2 -
2 Nos.) from the rear mounting of tail cover
assembly. (Fig. 1.90)

10 mm Spanner

Tightening torque 3 ± 1 Nm

CAUTION
While reassembling, ensure to re-fix the
retainer clips at the respective mounting Fig. 1.90
locations without fail.

l Remove the hexagonal socket cap flange bolt

(M5x15 - 2 Nos.) from both LH & RH bottom
m o u n t i n g o f t a i l c o v e r a s s e m b l y.
(Fig. 1.91)

5 mm Allen key

Tightening torque 3 ± 1 Nm

Fig. 1.91
 SERVICE MANUAL
GENERAL INFORMATION

l Slightly pull the tail cover assembly towards

rear and disconnect the tail lamp assembly
coupler from the main wiring harness.
(Fig. 1.92)

CAUTION
Care should be taken not to stretch the
wiring harness too much, as it may damage
the harness and ultimately result in an
entire harness replacement.

l Carefully dislocate and take out the tail cover Fig. 1.92
assembly along with the tail lamp assembly
from the sub frame assembly.

NOTE
Ensure the availability of retainer clips at
the respective mounting places during
reassembly of the tail cover assembly into
the sub frame assembly.

l Reassemble the parts in the reverse order of

removal while ensuring the availability of
mounting cushions at all the mounting
locations.
 SERVICE MANUAL
GENERAL INFORMATION

Tail cover assembly - Disassembly

l Park the vehicle on the paddock stand. Refer A

page no 1-00 for installation procedure.

l Remove both rider and passenger seats. Refer

page no 1-00 for procedure.

l Remove the tail cover assembly. Refer page no

1-00 for procedure.

l Remove the hexagonal nut (M6 - 1 No.) along

with punched washer (6.5x16x1.2) from the Fig. 1.93
mounting of bracket tail lamp. (Fig. 1.93)

10 mm Spanner

Tightening torque 3 ± 1 Nm

l Hold the bracket tail lamp by hand while

removing the hexagonal nut to avoid falling.

NOTE
Ensure to re-fix the bracket tail lamp
without fail during reassembly of the tail
cover assembly while ensuring the Fig. 1.94
availability of rubber grommet.

l Remove the CRR pan head screw (M6x16 -

4 Nos.) from the mounting of tail cover LH &
RH with the tail lamp assembly. (Fig. 1.94)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Remove the CRR pan head screw (M6x16 -

2 Nos.) from both LH & RH mounting of tail
cover LH & RH with the tail cover bottom.
(Fig. 1.95 ) Fig. 1.95
l Gently separate the tail cover LH & RH, tail
cover bottom and tail lamp assembly by
releasing the locking lugs with the tail cover
bottom. (Fig. 1.96)
CAUTION
Care should be taken not to damage the tail
cover LH & RH lugs while separating the
them from the tail cover bottom .

l Reassemble the parts in the reverse order of

removal while ensuring the mounting cushions
and cup washers at the respective mounting
Fig. 1.96
locations.
 SERVICE MANUAL
GENERAL INFORMATION

TAIL LAMP ASSEMBLY

Component : Tail lamp assembly

Component condition : Vehicle on ramp and component accessible
Objective : Tail lamp assembly - Removal
Repair cycle : Whenever required

Tail lamp - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove both rider and passenger seats. Refer

page no 1-00 for procedure.

l Remove the tail cover assembly. Refer page no

1-00 for procedure.
er of
ts l Disassemble the tail cover assembly as
explained in page no 1-00 in-order to remove
the tail lamp assembly from the tail cover
assembly.

l Once the tail lamp assembly is separated from

the tail cover assembly, remove the CRR pan
head screw (M6x16 - 1 No.) from the mounting
of cover tail lamp center with the tail lamp
assembly. (Fig. 1.97)
Fig. 1.97
Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Gently separate the cover tail lamp center from

the tail lamp assembly.

NOTE
Take additional care not to damage the
coupler / tail lamp assembly during
removal and reassembly.

l Reassemble the parts in the reverse order of

removal.
 SERVICE MANUAL
GENERAL INFORMATION

FENDER FRONT ASSEMBLY

Component : Fender front assembly

Component condition : Vehicle on ramp and component accessible
Objective : Fender front - Removal
Repair cycle : As required

Front fender assembly - Removal

l Park the vehicle on the paddock stand. Refer

page no 1-00 for installation procedure.

l Remove the shoulder bolt (M5x15 – 4 Nos.)

from the mounting of fender front top
assembly. (Fig. 1.98)

5 mm Allen key

Tightening torque 3 ± 1 Nm

l Gently dislocate and take out the fender front

assembly from the front fork assembly.

CAUTION Fig. 1.98

Care should be taken not to damage /

scratch the painted parts of the fender
assembly and front fork assembly during
fender assembly removal / reassembly.

l Remove the CRR pan head tap screws (M6x16

- 2 Nos.) from the mounting of fender front top
with the fender front bottom. (Fig.1.99)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

Fig. 1.99
l Remove the CRR flanged pan head tap screws
(ST4.2x13 - 2 Nos.) from the mounting of
fender front top and fender front bottom.
(Fig.1.100)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 1.100
 SERVICE MANUAL
GENERAL INFORMATION

NOTE
Care should be taken not to damage the
fender front top locking lugs while
separating the fender front top from the
fender front bottom. (Fig.1.101)

l Reassemble the parts in the reverse order of

removal.

Fig. 1.101
 SERVICE MANUAL
PERIODIC MAINTENANCE

DESCRIPTION PAGE NO Chapter 2

PERIODIC MAINTENANCE SCHEDULE 1
ENGINE CUM TRANSMISSION OIL 3
ENGINE CUM TRANSMISSION OIL - REPLACEMENT 3
OIL LEVEL INSPECTION / TOP-UP 5
FILTER COMPLETE ENGINE OIL 6
FILTER COMPLETE ENGINE OIL INSPECTION / REPLACE 6
SPARK PLUG 7
SPARK PLUG - REPLACEMENT 7
AIR CLEANER ELEMENT 9
AIR SUCTION SYSTEM / ENGINE BREATHER 11
TAPPET CLEARANCE (VALVE CLEARANCE) 12
ADJUSTMENTS 19
CLUTCH OPERATIONS 21
STEERING SYSTEM 23
WHEEL FREENESS 29

PERIODIC MAINTENANCE
FRONT FORK OIL 30
FRONT REAR SUSPENSION 31
BOLTS AND NUTS 32
CHAIN ASSEMBLY DRIVEN 33
CLUTCH GUIDE BOTTOM 37
ALL BULBS, HORN AND SWITCHES 38
HEAD LAMP BEAM 39
BATTERY 41
BRAKE SYSTEM 42
TYRES 48
FUEL FILTER 50
FUEL HOSE / SYSTEM 51
COOLANT LEVEL AND WATER HOSES 52
RADIATOR FINS AND FAN 54
SWING ARM BEARINGS 55
SIDE STAND FUNCTION 56
FUSE AND FUSE PULLER 57
BRAKE PEDAL AND GEAR SHIFT LEVER 58
IGNITION CUM STEERING LOCK 59
MALFUNCTION CODE 60
 SERVICE MANUAL
PERIODIC MAINTENANCE

PERIODIC MAINTENANCE
For a trouble free performance of the vehicle and its longer life, the vehicle should be periodically inspected for wear
of components, carbon deposits, stretched cables, etc. The worn-out components to be replaced or repaired and
necessary adjustment to be made for certain items for better performance of the vehicle as indicated in the table.

NOTE
More frequent maintenance checks may be performed on vehicles that are used in severe conditions like
dusty environment, dense traffic conditions, sustained full throttle operation and un-metalled roads.

PERIODIC MAINTENANCE SCHEDULE

List of operations and type of intervals Free service
Service 1st 2nd 3rd Remarks
(km or month whichever of the two km x 1000 1 5 10
- occurs early) months 2 6 12
Engine oil filter along with drain bolt washer Replace R – R
Air cleaner element Replace – – R
Spark plug – – –
Tappet clearance (valve clearance) Inspect and adjust – – I&A Adjust if required
Clutch operations Inspect and adjust I&A I&A I&A Adjust if required
Steering play Inspect and adjust I&A – I&A
Front and rear suspension Inspect – – I
Wheel bearing freeness Inspect – – I Replace if required
Air suction system / engine breather Inspect – – I
Front fork oil replacement – – –
All fasteners Inspect and tighten I & TI I & TI
Drive chain slackness / lubrication Inspect, adjust and Inspect, adjust and
lubricate lubricate every 500 km
Drive chain wear Inspect – – I
All lamps and horn Inspect – I I
Head lamp beam (focus) Inspect and adjust I&A I&A I&A
Battery voltage Inspect I I I Recharge if necessary
Brake light switch operation Inspect I I I
Front and rear brake fluid level** Inspect and replace I I R
Front and rear brake pad wear Inspect – I I Replace if necessary
Disc plates Inspect – – I Replace if necessary
Brake hose / rubber parts of
Inspect – – I Replace if necessary
master cylinder and caliper front and rear
Tyre air pressure at cold condition Inspect and adjust I&A I&A I&A
Clean and lubricate with
Steering stem bearing Inspect and lubricate I&L – I&L
fresh BEM 34-132
Free from any mud /
Speed sensor Inspect I I I
clogging with dirt

Fuel filter – – –

R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set

** Replace brake fluid at 10000 kms and every 20000 kms or 2 years thereafter
 SERVICE MANUAL
PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

List of operations and type of intervals Free service
Service 1st 2nd 3rd Remarks
(km or month whichever of the two km x 1000 1 5 10
- occurs early) months 2 6 12

Coolant level, water hoses and O-rings# Inspect I I I Replace if necessary

Fuel hose / system Inspect I – I
Swing arm bearing Inspect I I I Replace if necessary
Clean, inspect
Side stand C, I&L C, I&L C, I&L
and lubricate
Side stand switch function and
physical damage Inspect I I I

Drive chain guide wear Inspect – – I Replace if necessary

Instrument cluster MIL lamp function Inspect I I I
Radiator fan / fins and deflector Inspect I I I Clean if required
Reading fault codes using diagnostic tool Inspect I I I
Availability of fuse puller and fuse condition Inspect I I I
Brake pedal / gear shift lever mounting pin Inspect I I I Lubricate using grease
Ignition cum steering lock Inspect I I I Lubricate using oil

R - Replace; I - Inspect; T - Top up; C - Clean; A - Adjust; L - Lubricate; TI - Tighten; S - Set

#
Coolant, hoses and O-rings must be replaced every 30000 kms or every 3 years.
At higher odometer readings, the above service intervals to be followed.
 SERVICE MANUAL
PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

List of operations and type of intervals Paid service
Service 4th 5th 6th 7th 8th 9th 10th 11th
(km or month whichever of the two occurs early) Km x 1000 15 20 25 30 35 40 45 50
Months 18 24 30 36 42 48 54 60
Engine oil filter along with drain bolt washer - R - R - R - R
Air cleaner element - R - R - R - R
Spark plug - R - R - R - R
Tappet clearance (valve clearance)* - I&A - I&A - I&A - I&A
Clutch operations (adjust if required) I&A I&A I&A I&A I&A I&A I&A I&A
Steering play I&A I&A I&A I&A I&A I&A I&A I&A
Front and rear suspension - I - I - I - I
Wheel bearing freeness (replace if required) - I - I - I - I
Air suction system / engine breather - I - I - I - I
Front fork oil replacement - R - R - R - R
All fasteners I & TI - I & TI - I & TI I & TI - I & TI
Drive chain slackness / lubrication Inspect, adjust and lubricate every 500 km
Drive chain wear (replace if required) - - I - I I - I
All lamps and horn I I I I I I I I
Headlamp beam (focus) I&A I&A I&A I&A I&A I&A I&A I&A
Battery voltage (recharge if required) I I I I I I I I
Brake light switch operation I I I I I I I I
Front and rear brake fluid level** I R I R I R I R
Front and rear brake pad wear (replace if required) I I I I I I I I
Disc plates (replace if required) - I - I - I - I
Brake hose / rubber parts of master cylinder and Caliper
Front and rear (replace if required) - I - I - I - I

Tyre air pressure (at cold condition) I&A I&A I&A I&A I&A I&A I&A I&A
Steering stem bearing (Inspect & lubricate with Grease if required) - I&L - I&L - I&L - I&L
Speed sensor (free from any mud / clogging with dirt) I I I I I I I I
Fuel filter - R - - - R - -
Coolant level, water hoses and O-rings (replace ifrequired)*** I I I I I I I I
Fuel hose / system - I - I - I - I
Swing arm bearing (replace if required) I I I I I I I I
Side stand C, I & L C, I & L C, I & L C, I & L C, I & L C, I & L C, I & L C, I & L
Side stand switch function and physical damage I I I I I I I I
Drive chain guide wear (replace if required) - I - I - I - I
Instrument cluster MIL lamp function I I I I I I I I
Radiator fan / fins and deflector (clean if required) I I I I I I I I
Reading fault codes using diagnostic tool I I I I I I I I
Availability of fuse puller and fuse condition I I I I I I I I
Brake pedal / gear shift lever mounting pin (lubricate using grease) I I I I I I I I
Ignition cum steering lock (lubricate using oil) I I I I I I I I

* Adjust if necessary
** Replace brake fluid first at 10000 kms and every 20000 kms or 2 years thereafter
*** Coolant, hoses and O-rings must be replaced every 30000 kms or every 3 years.
At higher odometer readings, the above service intervals to be followed.
 SERVICE MANUAL
PERIODIC MAINTENANCE

ENGINE CUM TRANSMISSION OIL

Component : Engine cum transmission oil replacement

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace at initial 1000 km or 2 months & every 10000 km or 12 months thereafter
(months or km whichever occurs earlier).

Engine cum transmission oil - Replacement

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the cover bottom assembly. Refer

chapter “general information” page no 1-00 for
installation procedure.

After long period of use, the engine cum

transmission oil will get contaminated and
accelerates the wear of sliding and interlocking
surface. Replace the engine cum transmission oil
periodically by following the procedure given
below:

l Using a clean cloth, the surrounding surfaces

of plug oil filler and plug oil drain, start the
engine and warm to normal operating
temperature (oil temperature to 65 to 70° C).

CAUTION
Before draining the engine cum
transmission oil, Check the engine
temperature on instrument cluster and
switch ‘OFF’.

l Remove the plug oil filler to facilitate easy

draining of oil. (Fig. 2.1)

Tightening torque 4 ± 1Nm

WARNING
Hot engine oil may cause burns, always
wear gloves when handling engine oil Fig. 2.1
and/or touching hot surfaces.

Do not come in direct contact with engine

oil. Always wear suitable protective
equipment when working with hazardous
chemicals like oil, coolant etc.
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Keep a measuring jar under the engine and

remove the plug oil drain along with aluminum
washer (16x20x1.5) from the crankcase
assembly. (Fig. 2.2)

8 mm Allen key

Tightening torque 24 ± 3.6 Nm

NOTE
Ensure the availability of aluminum
washer during reassembly. Fig. 2.2

l Measure the drained oil quantity. If the quantity

of oil drained is very less, then the engine
needs servicing.

l Fill TVSM TRU4 SAE 15W50 Synthetic oil /

MOTUL 300V 15W50 4T 100% Synthetic oil.

1700 ml (fresh assembly/ full B

Capacity
drain along with filter change)

l Clean and inspect the plug oil drain (A) and

aluminum washer (B) for any abnormality.
Replace if required. (Fig. 2.3) A

Installation

l To reassemble the drain plug in the reverse

order of removal procedure.

l Run the engine in idle condition and ensure Fig. 2.3

that there is no oil leak from drain plug.
 SERVICE MANUAL
PERIODIC MAINTENANCE

ENGINE CUM TRANSMISSION OIL

Component : Oil level inspection / Top-up

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect and top-up at regular intervals

Oil level inspection /Top-up

l Ensure that the engine is in cold condition.

Place the vehicle on paddock stand on a flat
surface with front wheel touching the ground.

l Unscrew the plug oil filler and wipe it clean.

Insert the gauge in its hole by threading it in
completely.

l The oil level should be between minimum and

maximum levels of plug as shown. (Fig. 2.4)

l If the oil level is below the minimum level, top-

up with the recommended oil upto the
maximum level and refit the plug oil filler.
Maximum Minimum
NOTE
Fig. 2.4
While reassembling the plug oil filler, check
the condition of ‘O’ ring and replace if
necessary. Wipe off the mating surfaces of
the plug to avoid any oil seepage before
reassembling the plug.

If the engine is started once or if the engine

is in warm condition, the oil level must be
checked after waiting for 10 ~ 15 minutes to
ensure correct oil level.
 SERVICE MANUAL
PERIODIC MAINTENANCE

FILTER COMPLETE ENGINE OIL

Component : Filter complete engine oil inspection

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace at initial 1000 km or 2 months & every 10000 km or 12 months thereafter
(months or km whichever occurs earlier).

Filter complete engine oil inspection / Replace

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the cover bottom assembly. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Before removing the filter complete engine oil,

drain the engine cum transmission oil as per
the guidelines. Refer pervious page.

l Using a special tool loose and remove filter

complete engine oil along with packing oil
filter cap from the crankcase assembly.
(Fig. 2.5)
Fig. 2.5
ME-99050515

Tightening torque 16 ± 2 Nm

CAUTION
While removing the filter complete engine
oil with special tool, care should be taken
not to damage the filter complete engine
oil / crankcase.

NOTE
While reassembling, ensure to assemble
the packing oil filter cap (A). (Fig. 2.6)
Illustration
Locate the packing oil filter cap towards
the crankshaft assembly.

Whenever the filter complete engine oil is

replaced, it is recommended to replace the Fig. 2.6
engine cum transmission oil along with it.

Installation

l To reassemble the filter complete engine oil in

the reverse order of removal procedure.
 SERVICE MANUAL
PERIODIC MAINTENANCE

SPARK PLUG

Component : Spark plug replacement

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace at every 20,000 km or every 2 years whichever occurs eariler

Spark plug - Replacement

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.
A
l Neglecting the spark plug leads to difficult in
starting and poor performance.

l Before removing spark plug, clean the ignition

coil assembly and surroundings to prevent any
Fig. 2.7
foreign materials falling inside the cylinder
head cover during spark plug removal.

l Gently pull the coupler lock (A) and disconnect

the ignition coil coupler from the ignition coil
assembly. (Fig. 2.7)

NOTE
Care should be taken not to stretch the
wires as it may damage the wiring harness
/ connector.

l Using a special tool carefully dislocate and pull

out the ignition coil assembly from the cylinder Fig. 2.8
head cover. (Fig. 2.8)

N7310090

CAUTION
While handling the ignition coil assembly,
do not hold at center portion. Hold only at
the top sides. (Fig. 2.9)

Fig. 2.9
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Insert the spark plug tool vertically on the

cylinder head cover hole and remove the spark
plug from the cylinder head assembly.
(Fig. 2.10)

N7310090

l Close the spark plug hole with a clean cloth.

NOTE
Care should be taken not to damage the
spark plug insulator during removal / Fig. 2.10
reassembly.

Visually inspect the spark plug condition

for any damage, if found replace the spark
plug with new a one.

l Use only the recommended make and type of

spark plug for the good performance of engine.

Spark plug NGK (LMAR9D - J)

Installation

l To reassemble the spark plug in the reverse

order of removal.

CAUTION
Do not over tighten or cross thread the
sparkplug as otherwise the threads of
cylinder head may get damaged.
 SERVICE MANUAL
PERIODIC MAINTENANCE

AIR CLEANER ELEMENT

Component : Air cleaner element

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace at every 10,000 km or every 12 months whichever occurs earier

Air cleaner element

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank cover assembly. Refer

chapter “general information” page no 1-00 for
removal procedure.

l Clogged air filter element increases the

resistance for air intake resulting in decreased
power output and increased fuel consumption.
In case any such complaints in the vehicle are
observed, check and replace the air filter (paper
Fig. 2.11
filter) in the following manner:

l Dislocate the hose canister from the cover air

cleaner complete lugs. (Fig. 2.11)

l Carefully press and dislocate the snap clip

(2 Nos.) from the cover air cleaner complete.
(Fig. 2.12)

Nose plier

NOTE
Ensure to lock the snap clip until a click
s o u n d i s h e a r d d u ri n g r e m o va l / Fig. 2.12
reassembly.

l Gently push the cover air cleaner complete and

dislocate its lugs from the case air cleaner
complete. (Fig. 2.13)

NOTE
Carefully should be taken not to damage
the cover air cleaner complete lugs during
removal / reassembly.

Fig. 2.13
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Gently lift and take out the filter holder

complete (A) (paper element) from the case air
cleaner complete. (Fig. 2.14)

NOTE A

Replace the filter holder complete early if it

is clogged with excessive dirt (based on the
usage and environment) or is found with
any damage.

l Inspect the filter holder complete (paper

element) for any blockage / abnormality. Fig. 2.14
(Fig. 2.15)

CAUTION
While handling the filter holder complete
(paper element), do not hold at paper
element portion. Hold only at the sides.

l In case of any block or damage is found in the

filter holder complete (paper element), replace
the filter with new one.

CAUTION
Fig. 2.15
Do not clean the filter holder complete
(paper element). Cleaning paper filter
element with compressed air / solvent /
other chemicals can damage the filter and
consequently reduce the engine life.

l Inspect and ensure that the cover air cleaner

complete (A) and case air cleaner complete (B) A
is clear from any dust, dirt and foreign particles.
(Fig. 2.16 A & B)

l Before reassembling the filter holder complete

(paper element), clean the cover air cleaner and B
case air cleaner using a clean cloth and
cleaning solvent.

Installation

l To reassemble the cover air cleaner complete

Fig. 2.16A Fig. 2.16B
in the reverse order of removal procedure.

NOTE
Use only hands to assemble the cover air
cleaner complete (paper filter). Do not use
any tool. Ensure that the hands are free
from oil / dust.
 SERVICE MANUAL
PERIODIC MAINTENANCE

AIR SUCTION SYSTEM / ENGINE BREATHER

Component : Air induction system / Hose breather PCV

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 10,000 km or every 12 months whichever occurs earier

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank cover assembly. Refer

chapter “general information” page no 1-00 for
removal procedure.

l Visually inspect the air inlet of the air cleaner

assembly for any blockage / obstructions for
the free flow of air to the air cleaner. If found
any, rectify the same for the proper function
and life of the engine. (Fig. 2.17)

Fig. 2.17
l Similarly, inspect the hose breather PCV
(engine breather) for any blockage / leak. If
found any rectify the same. (Fig. 2.18)

Fig. 2.18
 SERVICE MANUAL
PERIODIC MAINTENANCE

TAPPET CLEARANCE (VALVE CLEARANCE)

Component : Tappet clearance (valve clearance)

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 10,000 km or every 12 months whichever occurs earlier. Adjust if
required

Tappet clearance - Adjustment

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the radiator assembly. Refer chapter

“chassis” page no 1-00 for removal procedure.

l Remove the ignition coil. Refer page no 1-00 for

removal procedure.

l Remove the spark plug. Refer page no 1-00 for

removal procedure.

l Remove the bolt cylinder head cover

(4 Nos.) along with grommet (4 Nos.) from the
mounting of cover cylinder head. (Fig. 2.19A)

6 mm Allen key

Tightening torque 10 ± 1.5 Nm

l Now, take out the cover cylinder head.

(Fig. 2.19B)
Fig. 2.19A Fig. 2.19B

NOTE
Apply oil on grommet surface before
assembling the bolts

Tighten the cylinder head cover bolts in

diagonal sequence.
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Gently take out the packing seal cover cylinder

- 1 (A) and packing seal cover cylinder - 2 (B)
either from the cover or from the cylinder head
assembly. (Fig. 2.20 )

NOTE
A
Inspect the condition of the packing seals.
If found any distortion / damage, replace
the seals with the new one. Else keep the
packing seals safely.

Fig. 2.20

l Remove the plug cap (TDC) (A) along with

gasket oil gallery plug from the cover clutch
assembly. (Fig. 2.21)

5 mm Allen key

Tightening torque 10 ± 1.5 Nm A

NOTE
While reassembling the plug cap, ensure
the presence and condition of the gasket .
Fig. 2.21
l Remove the plug crankshaft hole (A) along with
'O' ring (22.7x3.1) from the cover magneto
assembly. (Fig. 2.22)

10 mm Allen key A

Tightening torque 10 ± 1.5 Nm

NOTE
While reassembling, ensure to replace the
‘O’ ring with a new one.

l Now, slowly rotate the crankshaft until the ‘EX’ Fig. 2.22
mark (A) on the exhaust side timing sprocket
and ‘IN’ mark (B) on the inlet side timing
sprocket with the edge of cylinder head
assembly as shown. (Fig. 2.23)

12 mm extended socket spanner

B IN

NOTE EX A
At this point all the four rocker arms should
have free play. Otherwise rotate the rotor
assembly one more complete round and
align the marks again.
Fig. 2.23
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Lock the crankshaft using the TDC mark tool.

(Fig. 2.24)

N7310140

NOTE
Ensure there is no gap between TDC mark
A
tool shank and crankcase assembly. If gap
is exist, the crankshaft is not aligned with
the TDC mark. If there is a gap, slightly
rotate the crankshaft again and lock it.
Fig. 2.24
Care should the taken not to damage the
threads of TDC cap hole during the
assembly and removal of the tool.

Once again check and confirm the free play

of rocker arms. (Fig. 2.235

l Check both inlet and exhaust valves clearance

when the engine is in cold condition and note
down the readings.(Fig. 2.26)

For example - Starting from left, if the

measured value is:
Fig. 2.25
Exhaust 1 0.35 mm
Exhaust 2 0.26 mm
Inlet 1 0.15 mm
Inlet 2 0.09 mm

Feeler gauge

Valve Standard
Inlet valve 0.07 + 0.012 mm
Exhaust 0.23 + 0.28 mm

NOTE
Fig. 2.26
Ensure to inspect the clearance of all the
inlet & exhaust valves without fail.

l If clearance measured in any of the valve is not

within the specified limit mentioned above,
replace the button tappet of the respective
valve in the following manner:

l Remove the hexagonal socket caps flange bolt

(M7x38 - 2 Nos.) from the mounting of guide
cam chain complete upper. (Fig. 2.27)

6 mm Allen key
Fig. 2.27
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Remove the bolt cam chain tensioner along

with copper washer (8x13x1 - 1 No.) (Fig. 2.28)

5 mm Allen key

Tightening torque 12.1 ± 1.8 Nm

NOTE
While reassembling the bolt cam chain
tensioner ensure the presence of copper
washer.
Fig. 2.28
Apply LOCTITE 243 to the bolt while
reassembling.

l Now, take out the guide cam chain complete

upper (A) from the cylinder head assembly. A
(Fig. 2.29)

CAUTION
Care should be taken not to damage the
guide cam chain complete upper during
removal / reassembly

l Remove the bolt cam chain tensioner along Fig. 2.29

with copper washer (8x13x1 - 1 No.) from the
mounting of guide cam chain.(Fig. 2.30)

5 mm Allen key

Tightening torque 12.1 ± 1.8 Nm

NOTE
Ensure the presence of copper washer
during reassembly.

Apply LOCTITE 243 to the bolt while

reassembling. Fig. 2.30
l Remove the shoulder bolt (M5x14 - 2 Nos.)
from the mounting of deflector. (Fig. 2.31)

5 mm Allen key

Tightening torque 2 ± 0.3 Nm

l Gently takeout the deflector from its location.

NOTE
Ensure to re-fix the deflector without fail
during reassembly.
Fig. 2.31
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Remove the tensioner camchain along with the

gasket tensioner adjuster. (Fig. 2.32)

30 mm spanner

Tightening torque 30 ± 2.1 Nm

NOTE
While reassembling, inspect the gasket
tensioner adjuster for any damage. If
found, replace the gasket with a new one.
Fig. 2.32
l Remove the hexagonal socket caps flange bolt
(M7x38 - 7 Nos.) along with special washer
(7.2x15x2 - 3 Nos.) from the mounting of
housing cam shaft. (Fig. 2.33)

6 mm Allen key

NOTE
While reassembling, inspect the special
washer for any damage. If found, replace
the special washer with new one (as a set).

Fig. 2.33

l Gently dislocate the camchain (A) from the

camshaft exhaust assembly (B) and take out
the camshaft exhaust assembly. (Fig. 2.34 A &
B)

l Hold the camchain using a good quality copper A

wire to prevent the chain from falling into the
crankcase assembly.

Fig. 2.34A

Fig. 2.34B
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Gently lift the finger follower (A & B) exhaust

valve 1 as shown. (Fig. 2.35)
A B

Fig. 2.35
l Now, carefully take out the button tappet (C)
from the exhaust valve 1 as the tappet
clearance measured at this valve is more than
the specified limit (refer the example given on
page no. 00). (Fig. 2.36) C D

NOTE
Care should be taken not the drop the
button tappet inside the cylinder head
assembly.

Fig. 2.36
l Measure the button tappet (C) thickness (size)
using the micrometer as shown and note down
the reading. (Fig. 2.37)

Micrometer

Measured size = 2.04 mm ( for reference )

l After measuring the old button, find out the Illustration

button size required to replaced by following
the method given below:

Formula :
Fig. 2.37
Required button size = (Measured valve
clearance - Specified valve clearance) + Old
button size.

l Example:-

Measured valve clearance = 0.35 mm

(from the example given on page no. XX)

Specified valve clearance = Exhaust -

0.23 to 0.28 mm (mean = 0.26 mm)

Measured button tappet size = 2.04 mm

(from reference given on page no. XX)
 SERVICE MANUAL
PERIODIC MAINTENANCE

So:-
Required button thickness
= (0.35 - 0.26) + 2.04 mm
= 0.09 + 2.04 mm
= 2.13 mm

l Based on the above calculation choose nearest

size button from the table given below:-

l Insert button size table :

l In the above case either 2.12 mm or 2.14 mm

size button can be used to keep the valve
clearance within the specified limit.

l In similar manner, calculate and find out the

required button size for all the four valves.

l After completing valve clearance inspection

and correcting them, assemble back the parts
in the reverse order of removal.

l Fix the cam chain to camshaft assembly inlet

and exhaust while aligning the 'EX' mark (A) on
the exhaust side timing sprocket and 'IN' mark A B
(B) on the inlet side timing sprocket with the
edge of cylinder head assembly as shown. EX IN
(Fig. 2.38)

l Re-fix the housing cam shaft and tighten the

mounting bolts in the sequence given below.

l First, fix and tighten the inner mounting bolts

Fig. 2.38
(1, 2 & 3) to the pre-tightening torque.
(Fig. 2.39)

Tightening torque 5 ± 0.75 Nm

l Then assemble and tighten the guide cam

chain bottom mounting bolt (4). (Fig. 2.39)

Tightening torque 12 ± 1.8 Nm

l Assemble the guide cam chain top mounting

bolts (5 & 6) and outer mounting bolts (7, 8 , 9 & Illustration
10) and tighten them to the pre-tightening
torque. (Fig. 2.39)

Tightening torque 5 ± 0.75 Nm

l Finally tighten the mounting bolts (1 to 3 & 5 to

10) final tightening torque, (Fig. 2.39)

Tightening torque 15 ± 2.25 Nm

Fig. 2.38
 SERVICE MANUAL
PERIODIC MAINTENANCE

ADJUSTMENTS

Component : Clutch lever - Position adjustment

Component condition : Vehicle on ramp and component accessible
Objective : To set lever position to the rider’s convenient
Repair cycle : As and when required

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.
l TVS Apache RTR 310 comes with an adjustable
clutch lever. There are four positions provided
for adjusting the lever to suit the rider's palm
size.

l The lever can be adjusted by adjusting the

position adjuster knob (A) and its provided in
the lever itself(Fig. 2.39)

l ‘Position-1’ is the closest position of the lever B

to handle bar grip and ‘Position-4’ is the
farthest.

l To adjust the lever position, push the lever

forward and rotate the position adjuster to any A
of the four positions by aligning the 'arrow
mark' (B) on the lever to the number provided
Fig. 2.39
on the adjuster.

NOTE
The standard position of the clutch lever
will be 2 & 3.
 SERVICE MANUAL
PERIODIC MAINTENANCE

ADJUSTMENTS

Component : Front brake lever - Position Adjustment

Component condition : Vehicle on ramp and component accessible
Objective : To set the lever position to the rider’s convenient
Repair cycle : As and when required

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.
l TVS Apache RTR 310 comes with an adjustable
clutch lever. There are four positions provided
for adjusting the lever to suit the rider's palm
size.

l The lever can be adjusted by adjusting the

position adjuster knob (A) is provided in the
lever itself.(Fig. 2.40)

l ‘Position-1’ is the closest position of the lever

to handle bar grip and ‘Position-4’ is the
farthest.

l To adjust the lever position, push the lever B

forward and rotate the position adjuster to any

4
3
of the four positions by aligning the 'arrow 1

2
mark' (B) on the lever to the number provided
on the adjuster.
A
NOTE
The standard position of the clutch lever Fig. 2.40
will be 2 & 3.
 SERVICE MANUAL
PERIODIC MAINTENANCE

ClUTCH OPERATIONS

Component : Cable assembly clutch - Operation / Free play

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1,000 km or 2 months & every 5000 km or 6 months thereafter
(months or km whichever occurs earlier) Adjust if required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Inspect the cable assembly clutch (clutch

cable) for smooth operation. In case any sticky /
hard movement is found, replace the clutch
cable.

l Clutch cable free play is one of the most

important adjustment which needs to be
checked regularly for better life of clutch plates.

l Measure the free play at the clutch lever end as

shown in the figure before the clutch begins to
disengage. (Fig. 2.41)

Free play 8 ~ 12 mm (min) Fig. 2.41

NOTE
Clutch cable free play should be adjusted
when the engine is in cold condition only.

l For checking the clutch free play, first dislocate

the clutch boot clutch (A) from its position.
(Fig. 2.42)
A

Fig. 2.42
l If the play is more or less, loosen the ring nut
(A). Turn ferrule nut (B) ‘in’ or ‘out’ while holding
the clutch cable (C) until specified play is
B
obtained. Hold the ferrule nut in the same
position and tighten the ring nut (A). (Fig. 2.43)

l If clutch play is still exceeding the limit then,

inspect and adjust the clutch cable bottom end
at the crankcase assembly. C
A

Fig. 2.43
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Loosen the lock nut (D). Turn adjuster nut (E) ‘in’
or ‘out’ while holding the clutch cable until
specified play is obtained. Hold the adjuster nut
in the same position and tighten the lock nut.
E
(Fig. 2.44)
F
12 mm spanner

Fig. 2.44
 SERVICE MANUAL
PERIODIC MAINTENANCE

STEERING SYSTEM

Component : Steering system - Play inspection / adjustment

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1,000 km or 2 months & every 10000 km or 12 months thereafter
(months or km which ever occurs earlier)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Steering should be adjusted correctly for the

smooth movement of handle bar and for safe
riding. Stiff steering prevents smooth
movement of handlebar, resulting in poor
directional stability. Too loose steering will
cause vibration and damage to the steering
bearings.

l To check the steering play, with the vehicle off

stand, shake the handle forward and backward
while holding the front brake.

l Similarly, the play can be checked by holding

inner and outer tube as shown. (Fig. 2.45)

NOTE
Ensure to check the steering play on both
inner and outer tube of top and bottom
sides.
Fig. 2.45

WARNING
Do not use C-clamps for tightening the
arrester steering because it leads to
clearance between arrester system and
upper bracket followed by steering shake /
noise and durability complaint.
 SERVICE MANUAL
PERIODIC MAINTENANCE

Step - 1

l Loosen the hexagonal socket cap screw LH &

RH (M8x30 - 2 Nos.) from the mounting of
upper bracket. (Fig. 2.46 A & B)

6 mm Allen key

Fig. 2.46A Fig. 2.46B

l Loosen the hexagonal socket cap screw

(M10x30 - 1 No.) from the mounting of upper
bracket. (Fig. 2.47)

6 mm Allen key

Fig. 2.47

l Remove the hexagonal socket head cap screw

(M6x16 - 2 Nos.) from the mounting of bracket
steering lock. (Fig. 2.48)

5 mm Allen key

Tightening torque 7 ± 1 Nm

l Dislocate the cap locknut (A) from the bolt

steering adjuster. (Fig. 2.49A)
Fig. 2.48

NOTE
While reassembling, ensure to re-fix the
cap without fail.
A
l Loosen the bolt steering adjuster from the
lower bracket complete. (Fig. 2.49B)

6 mm Allen key

l After confirming all the above mentioned

mounting bolts are loosened properly proceed
to Step - 2 procedures given below;
Fig. 2.49A Fig. 2.49B
 SERVICE MANUAL
PERIODIC MAINTENANCE

Step - 2

l Turn the handle bar assembly fully towards

right side of the vehicle and tighten the bolt
steering adjuster to the specific torque.
(Fig. 2.50)

6 mm Allen key

Tightening torque 25 ± 4 Nm

Fig. 2.50

l Gently turn the handle bar assembly to the lift

and right, six or seven times for proper seating
of steering bearings. (Fig. 2.51)

Fig. 2.51

l Turn the handle bar fully towards the left

direction and loosen the bolt steering adjuster
about 60°. (Fig. 2.52)

6 mm Allen key 600

Fig. 2.52

l Now, once again turn the handle bar assembly

fully towards right side and tighten the bolt
steering adjuster to the specified torque.
(Fig. 2.53)

6 mm Allen key

Tightening torque 15 ± 2 Nm

l After tightening the bolt steering to the

specified torque proceed to the Step - 3.

Fig. 2.53
 SERVICE MANUAL
PERIODIC MAINTENANCE

Step - 3

l Tighten the hexagonal socket cap screw LH &

RH (M8x30 - 2 Nos.) of upper bracket to the
specified torque. (Fig. 2.54)

6 mm Allen key

Tightening torque 19 ± 3 Nm

Fig. 2.54

l Tighten the hexagonal socket cap screw

(M10x30 - 1 No.) from the mounting of upper
bracket.(Fig. 2.55)

6 mm Allen key

Tightening torque 19 ± 3 Nm

l Once again check and confirm the tightness of

the allen bolts.

l Now, once again tighten the bolt steering

adjuster to the specified torque. Fig. 2.55

6 mm Allen key

Tightening torque 38 ± 5 Nm

l After ensuring there is no play in the steering,

assemble the cap bolt steering adjuster.

l Assemble the mounting bracket of steering

lock and tighten the hexagonal socket head cap
screw (M6x16 - 2 Nos.).

5 mm Allen key

Tightening torque 7 ± 1 Nm

NOTE
After adjustment the steering, ensure the
handle bar moves smoothly without any
jerk or sticky feel. When slowly moved by
hand, the handle bar should move freely
from center position to either left or right
with its own weight.

Check the head lamp beam position and

adjust if required after reassembling.
 SERVICE MANUAL
PERIODIC MAINTENANCE

l If any play is still found, inspect the following

items and replace the affected parts.

l Wear of the race steering inner

l Wear of cup bottom and cone bottom
l Wear or damage of steering balls
l Number of balls in cage
l Distortion of lower bracket complete
l Rusting of races and balls
l Grease washout

l Refer chapter "Chassis" page no. 6.00 for

removal, inspection and reassembly procedure
of above items.
 SERVICE MANUAL
PERIODIC MAINTENANCE

STEERING SYSTEM

Component : Steering stem bearings

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months thereafter
(whichever occurs earlier). Lubricate with grease if required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Ensure that the steering is adjusted properly

without any play.

l Slowly turn the handle bar left and right five or

six times and check for any noise or struck.

l Also, ensure the handle bar moves smoothly

without any jerk or sticky feel. When slowly
moved by hand, the handle bar should move
freely from center position to either left or right
with its own weight.)

l If found any, service the steering system as

explained in chapter "Chassis" page no. 6-00.
 SERVICE MANUAL
PERIODIC MAINTENANCE

WHEEL FREENESS

Component : Front and Rear wheel

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 10000 km or 12 months (whichever occurs earlier). Replace if
required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Slowly rotate both the wheels by hand and

observe for any abnormal noise / tightness.
(Fig. 2.56)

l If found any, inspect for the proper functioning

of brakes. If found OK then, inspect for the
proper play in the drive chain (refer page no.
2-20).

l Still any uneven bearing noise or any

obstructions in free rotation due to damaged
wheel bearings, replace the wheel bearings if
required. Refer chapter “Chassis“ page no.
6-00 for removal and inspection procedure.
Fig.2.56

NOTE
Tight wheel rotation increases fuel
consumption.
 SERVICE MANUAL
PERIODIC MAINTENANCE

FRONT FORK OIL

Component : Front fork - Oil replacement

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace every 20000 km or every 24 months whichever occurs earlier

Front fork oil - Replace

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Front fork oil needs to be replaced at every

20000 km or every 2 years for the proper
function of fork assembly.

l Inspect both the leg assemblies of front fork

for any oil leakage in every service. (Fig. 2.57)

l If any leak is found, both the front fork leg

assemblies need to be serviced.

l Refer chapter “Chassis” page no. 6-24 for oil

replacement and servicing procedure.
Fig. 2.57
 SERVICE MANUAL
PERIODIC MAINTENANCE

FRONT AND REAR SUSPENSION

Component : Front and Rear suspension - Inspection

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 10000 km or 12 months (months or km whichever occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Inspect the front fork (both the legs) for

smooth operation / proper action. (Fig. 2.58). If
any abnormality is found, service the leg
assemblies as explained in chapter “Chassis”
page no. 6-24.

l Similarly, inspect the rear shock absorbers for

smooth operation / proper action. (Fig. 2.59). If
any abnormality is found, replace the shock
absorbers as explained in chapter “Chassis”
page no. 6-24.

l Check the shock absorbers for any mud / dirt

accumulation. If found, clean them thoroughly.
Fig. 2.58
l Inspect for any oil leak in the shock absorbers.
Replace the shock absorbers if found any.

Fig. 2.59
 SERVICE MANUAL
PERIODIC MAINTENANCE

BOLTS AND NUTS (FASTENERS)

Component : All bolts and nuts (fasteners)

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect and tighten at initial 1,000 km or 2 months & every 10,000 km or 12 months
thereafter (months or km whichever occurs earlier).

All bolts and nuts (fasteners)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l All the nuts and bolts are important parts and

they must be in good condition for safety. They
must be re-tightened at the regural intervals to
the specified torque using a torque wrench.
(Fig. 2.60)

l Refer chapter “Service information” page no.

8-7 & 8-9 for torque details.

SHOCK ABSORBER
TOP MOUNTING (56 ± 8.4 Nm)

MUFFLER ASSEMBLY
(19.5 ± 2 Nm)

SHOCK ABSORBER
BOTTOM MOUNTING (56 ± 8.4 Nm)

REAR WHEEL NUT (100 ± 15 Nm) FRONT AXLE BOLT (50 ± 7 Nm)

Fig. 2.60
 SERVICE MANUAL
PERIODIC MAINTENANCE

CHAIN ASSEMBLY DRIVE (Drive chain)

Component : Drive chain - Slackness adjustment / lubrication

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect, adjust and lubricate every 500 km

Drive chain - Adjustment

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

NOTE
However, the drive chain must be cleaned
(on the vehicle) with dry cloth if the chain is
found with less dust / mud and lubricate
with MOTUL C2 spray for better chain life
and smooth vehicle running.

l If the chain is too dirty, clean the chain in the

following manner:

CAUTION
The chain fitted the motorcycle has X-rings
to protect the moving parts of the chain
from dirt, and to hold the lubricant inside. If
the chain is cleaned using any other
solvent other than those specified for
X-ring chains or washed using steam or
water cleaners or a wire brush or an
abrasive cleaner, the X-ring seals might be
damaged irreparably

l Slowly rotate the wheel in driving direction or

wheel rotation direction and spray the cleaning
spray.

l Leave the cleaning solvent to soak for few

minutes. Wipe off the solvent on the chain with
a dry, clean cloth thoroughly. Use a soft brush if
the chain is dirty.

l After cleaning the drive chain, using fingers

check the slackness of the chain at the lower
portion, midway between the sprockets.
(Fig. 2.61)

l The slackness should be between the

specified limit at the various points of the chain.

Slackness 30 ~ 40 mm
Fig. 2.61
 SERVICE MANUAL
PERIODIC MAINTENANCE

l If slackness found is more or less, adjust the

slackness as follows:

NOTE
Excess chain slackness consumes more
fuel and creates chain noise.

The chain should be adjusted at the point

of least deflection.

l Slightly loosen the hexagonal lock nut

(M18x1.5) of axle rear. (Fig. 2.62)

28 mm spanner

Tightening torque 100 ± 15 Nm

Fig. 2.62

l Loosen the wheel hugger bracket mounting

screw (A). (Fig. 2.63)

6 mm Allen key

Tightening torque 8 ± 1 Nm

Fig. 2.63
l Release and loosen the lock nut (A & B) and
turn the adjuster bolts (C & D) ‘in’ or ‘out’ to
obtain the specified slackness in the chain.
(Fig. 2.64 A & B) A D

10 mm spanner

Tightening torque 19 ± 2.85 Nm

C B

Fig. 2.64A Fig. 2.64B

 SERVICE MANUAL
PERIODIC MAINTENANCE

l Ensuring that the both chain adjusters (E & F)

are equally adjust by looking at the line mark
on chain adjusters to the same scale value on E F
both LH & RH sides, until the specified play
(slackness) is obtained. (Fig. 2.65A & B)

CAUTION
Adjust both the chain adjuster exactly the
same amount to maintain in the correct
wheel alignment.

l After obtaining the specified play, rotate the

rear wheel by hand and apply the rear brake. Fig. 2.65A Fig. 2.65B

l Hold the brake pedal in applied condition and

tighten the rear axle nut to the specified
torque.
A
l Now, tighten the lock nuts (A & B). (Fig. 2.66)

l After ensuring the chain is cleaned thoroughly

and the solvent is wiped off completely.
B

Fig. 2.66
l Slowly rotate the rear wheel in driving direction
or wheel rotation direction. Apply
recommended spray liberally as shown to the
drive chain inner lower runs. (Fig. 2.67)

Spray type MOTUL C2 spray

WARNING
Avoid getting lubricant on the brakes or
tyres. Avoid applying excess chain
lubricant to prevent spray onto your
clothes and motorcycle.
Fig. 2.67

CAUTION
Use only MOTUL C2 spray to lubricate the
chain. Using non-specific lubricants may
cause severe damage to the chain and the
front and rear sprocket.
 SERVICE MANUAL
PERIODIC MAINTENANCE

Drive chain wear

l Inspect at every 10000 km or 12 months
whichever occurs earlier
l Visually inspect the chain and sprockets for any
wear / damage. If found any, replace them.
l Similarly, if the drive chain adjusted to its
maximum adjustment limit, replace the chain
and both the sprockets.
l Refer chapter "Chassis" page no. 6.00 for the
replacement procedure.

NOTE
Replace the chain and both the sprockets
always as a set.
 SERVICE MANUAL
PERIODIC MAINTENANCE

CHAIN GUIDE BOTTOM (DRIVE CHAIN)

Component : Chain guide bottom

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1,000 km or 2 months & every 5,000 km or 6 months thereafter
(months or km whichever occurs earlier).

Chain guide bottom

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Visually inspect the chain guide for any

damage. Replace chain guide assembly if any
damage is found.

l Rotate the chain guide slowly and check for any

abnormal noise / tightness. Replace the chain
guide assembly if found any.

l To replace the chain guide:

l Remove the shoulder bolt (M8x1.25 - 1 No.)

along with washer and nut from the mounting
of chain guide. (Fig. 2.68)

12 mm spanner

Tightening torque 19 ± 3 Nm

NOTE
While removing the chain guide bottom
hexagonal bolt hold the hexagonal nut
along with washer in order to avoid falling.

Installation

l To reassemble the parts in the reverse order of Fig. 2.68

removal procedure.
 SERVICE MANUAL
PERIODIC MAINTENANCE

ALL BULBS, HORN AND SWITCHES

Component : Bulbs, horn and switches

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 5,000 km or every 6 months (whichever occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Inspect for the proper functioning of all bulbs,

horn and switches. In case any abnormality is
found, check and replace them. Refer chapter
“Electrical system” for checking and
replacement procedures.
 SERVICE MANUAL
PERIODIC MAINTENANCE

HEAD LAMP BEAM

Component : Head lamp - Beam adjustment

Component condition : Vehicle on flat surface
Objective : Periodic service
Repair cycle : Inspect at initial 1,000 km or 2 months & every 10,000 km or 12 months thereafter
(months or km whichever occurs earlier). Adjust if required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l To check and adjust the headlamp focus:

l Inflate the tyres to the correct pressure.

l Place the motorcycle upright in a uniform flat

surface while ensuring the headlamp center is
5 meter away from a vertical wall or screen as
shown in the figure. (Fig. 2.69)

l Mark a horizontal line on the wall or screen

around 800 ± 10 mm from the ground level and
mark a vertical line in the middle of the
horizontal line. (Fig. 2.69)

l Sit on the vehicle to check the headlamp focus

after completing the above procedure. Start
the vehicle and turn the headlamp to ‘high
beam’ mode. Rotate the handle bar left / right
side and focus the headlamp on the vertical line
of the wall / screen.

l Now, turn the headlamp to low beam mode

and ensure the headlamp low beam focus falls
between 800 ± 10 mm from the ground level
as shown. (Fig. 2.69)

l Incase if any deviation is found, adjust the

headlamp focus as explained below:

l Slightly loosen the top and bottom mounting

bolts (A & B) on both sides of the headlamp.
(Fig. 2.70)

l Now tilt the headlamp ‘up’ or ‘down’ so that the

focus of the headlamp falls below the low
beam cut-off line (800 ± 10 mm) marked on the Fig. 2.70
vertical wall or screen. After adjusting the
focus, tighten the top and bottom mounting
bolts to the specified torque.

Tightening torque 7 ± 1 Nm
 SERVICE MANUAL
PERIODIC MAINTENANCE

NOTE
Headlamp focus should be adjusted only
when the headlamp is in low beam. The
adjustment levels mentioned is for solo
riding condition.

For dual riding condition, the headlamp

beam may be adjusted as per need for
better visibility.

l The specification for headlamp beam

adjustment is applicable only for India. For
other countries adopt the local rules and
regulations.

NOTE
Avoid staring at LED head lamp to avoid
damage to the eyes.

Fig.2.69
 SERVICE MANUAL
PERIODIC MAINTENANCE

BATTERY

Component : Battery - Voltage checking

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1,000 km or 2 months & every 5,000 km or 6 months thereafter
(whichever occurs earlier). Recharge if necessary.

Battery voltage

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

NOTE
While removing the battery terminals, remove
the ‘- ve’ terminal first. While reconnecting,
connect the ‘+ ve’ terminal at last.

l Visually inspect the surface of the battery

container. If any sign of cracking of the battery
is noticed, replace the battery with a new one.

l Measure the open circuit voltage of battery

using pocket tester. (Fig. 2.71)
V

12.8 DC

Pocket tester

Open circuit voltage 12.8 Volts (min)

l If the voltage measured is less than specified

limit, charge the battery using a charger
recommended by TVS motor company limited.
(refer chapter “Electrical System” page no.
5-42 for removal and charging procedure).
Fig.2.71
l If the battery lead terminals are found rusty
with acidic white powdery substance, then
clean them with sand paper / warm water.

l After doing the necessary check and charging,

re-fit the battery in the reverse order of removal
and reconnect the terminals. Apply petroleum
jelly in the terminals to avoid corrosion.
 SERVICE MANUAL
PERIODIC MAINTENANCE

BRAKE SYSTEM

Component : Front and rear brake system

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect front and rear brake fluid level at initial 1,000 km or 2 months & every 5,000 km
or 6 months thereafter (whichever occurs earlier). Replace brake fluid first at 10,000
km and every 20000 km thereafter.
Inspect front and rear brake pad wear at every 5,000 km or 6 months (whichever
occurs earlier). Replace if required.
Inspect disc plates at every 10,000 km or 12 months (whichever occurs earlier).
Replace if required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

Brake effectiveness

l Inspect the front and rear brake for its

effectiveness. If the brakes are more spongy or
ineffective, it may be because of air entry in the
brake system.

l Refer chapter “Chassis” page no. 6-10 for the

procedure of brake bleeding.

Brake fluid level - Front

l Park the vehicle on the paddock stand.Refer A

chapter “general information” page no 1-00 for
installation procedure.
MIN
l Inspect the brake fluid level in master cylinder
through the inspection window. The level
should be above the minimum (MIN) mark (A)
provided on the inspection window. (Fig. 2.72)

l If the level is found below the lower level mark

on the cylinder, then replenish the level up to Fig.2.72
the top by following the procedure given
below:

l Remove the mounting screw of reservoir cap.

(Fig. 2.73)

l Remove the reservoir cap and take out the

plate diaphragms.

l Fill the brake fluid of recommended grade.

Brake fluid BASF HYDRAULAN 404 /

EQUIVALENT - GRADE DOT 4 Fig.2.73
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Reassemble the parts and apply the front brake

to check the effectiveness.

l If the lever travel is more or the lever feels soft

or spongy, air bleeding from the system to be
carried out. Refer chapter “Chassis” page no.
6-12 for bleeding procedure.

Installation

l To reassemble the parts in the reverse order of

removal procedure.

Brake fluid level - Rear

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

l The brake fluid level in the reservoir should be

at the max mark provided in the reservoir. MIN
(Fig. 2.74)

l If the level is found the lower level mark on the

reservoir, then replenish the level up to the top
by following the procedure given below:
Fig.2.74
l Remove the hexagonal socket cap flange bolt
(M6x16 - 1 No.) from the reservoir mounting.
(Fig. 2.75)

5 mm Allenkey

Tightening torque 4.5 ± 0.5 Nm

l Now, take out the reservoir along with the

spacer.

l Remove the cap and take out the diaphragm.

l Fill fresh brake fluid of recommended grade.

Fig.2.75
Brake fluid BASF HYDRAULAN 404 /
EQUIVALENT - GRADE DOT 4

l Reassemble the parts and apply the rear brake

to check the effectiveness.

l If the lever travel is more or the lever feels soft

or spongy, you must carry out the air bleeding
from the brake system. Refer chapter
“Chassis” page no. 6-10 for bleeding
procedure.
 SERVICE MANUAL
PERIODIC MAINTENANCE

Disc pad front and rear wear

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.
Illustration
l Observe the wear limit line marked on the pad
and check wear condition of brake pads.
(Fig. 2.76)

l When the wear exceeds the limit line replace

the pad as a set. Refer chapter “Chassis” page
no. 6-8 for the brake pads replacement Fig.2.76
procedure.

NOTE
Brake pad wear can be checked without
removing the caliper assembly from the
fork and front wheel.

CAUTION
Replace the brake pad as a set, otherwise
braking performance will be adversely
affected.

Installation

l To reassemble the parts in the reverse order of

removal procedure.

Disc plates front and rear

l Visually inspect the front and rear disc plates

for any wear or damage. If found any, replace
the respective disc plate.

l Measure the thickness of the disc plates using

micrometer atleast 4 different locations as
shown. (Fig. 2.77)
Fig. 2.77
l If the measured thickness of the disc plates is
less than the recommended value, replace the
respective disc plate with a new one.

Disc plate thickness

Front brake disc thickness 4.5 mm (min)
Rear brake disc thickness

l Refer chapter "Chassis" page no. 6.00 for

replacement procedure.
 SERVICE MANUAL
PERIODIC MAINTENANCE

BRAKES SYSTEM

Component : Wheel speed sensor (WSS) / Toner ring - Front & Rear
Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months and every 5000 km or 6 months (whichever
occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

Improper gap between wheel speed sensor and

the toner ring and dirt / mud accumulation on them
(especially iron particles) results in improper
function of ABS.

l Ensure the gap between the wheel speed

A
sensor (A) and toner ring (B) and inspect for any
dirt / mud accumulation on them visually.
(Fig. 2.78 A & B)

l Clean them using plain water only on the

vehicle itself. Do not use any solvents, oil etc.
B
l After cleaning check for any malfunction codes Fig.2.78A
using ride scan tool. Refer chapter "Diagnostic
procedure" page 7-00 for details.

NOTE
A
During cleaning process care should be
taken not damage the toner ring and
sensor.

Do not insert any metal part between the B

toner ring and sensor.

While water washing do not point the

pressurised jet directly on the toner ring /
Fig. 2.78B
wheel speed sensor as it may damage the
toner ring teeth / sensor and result in
malfunction of ABS.

l Replace the wheel speed sensor in case of any

damage (refer chapter “Chassis” page no 5-34
for removal and replacement procedure).

l If the toner ring teeth are found damaged, then

replace the toner ring with a new one (refer
chapter “Chassis”page no. 6-2 for removal and
replacement procedure).
 SERVICE MANUAL
PERIODIC MAINTENANCE

BRAKE SYSTEM

Component : Brake hoses / rubber parts of master cylinder and caliper front & rear
Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at every 10,000 km or 12 months (whichever occurs earlier). Replace if
necessary.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Inspect all the brake hoses for any kind of

physical damage / deterioration, leak at joints
and proper routing. (Fig. 2.79 A)

l If found deviation in routing correct them. But if

found any leak or damage / deterioration
replace the respective hose with a new. Refer
chapter "Chassis" page no. 6-00 for the detail
procedure.

l In similar manner, inspect the front and rear

master cylinders, brake calipers for any oil leak.
(Fig. 2.79 B)
Fig. 2.79A Fig. 2.79B
l Also inspect the rubber boots of both front and
rear master cylinders, rear caliper assemblies.
(Fig. 2.80)

l Service the defective parts as explained in

chapter "Chassis" page no. 6-00.

Fig. 2.80
 SERVICE MANUAL
PERIODIC MAINTENANCE

BRAKE SYSTEM

Component : Brake light switch Front & Rear

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months thereafter
(whichever occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Turn the ignition 'ON'.

l Apply front brake and check for the working of

brake light. Similarly, Apply rear brake and
check for the working of brake light. (Fig. 2.81)

l If the light does not working, check and ensure

the proper contact between switch and the
brake lever / pedal. Also ensure the proper
operation of switches.

l If the contact and the operation is found OK,

disconnect the wiring harness from the switch
and check the continuity using multimeter with Fig.2.81
brake pressed and released condition.

l If the switches are found OK, check the wiring

continuity.

l If the wiring continuity also found OK, replace

the tail lamp assembly. Else replace the
respective brake switch.

l Refer chapter "Electrical system" page no. XX

for the detail procedure.
 SERVICE MANUAL
PERIODIC MAINTENANCE

TYRES

Component : Front and Rear wheel

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect and set at initial 1000 km or 2 months & every 5000 km or 6 months
thereafter (whichever occurs earlier)

l Visually inspect the front and rear wheel rims

for any defects. If found any, inspect the rims
and replace if necessary.

Tyre pressure:

l Insufficient tyre pressure not only fasten tyre

wear, but also seriously affects the stability of
the vehicle and may lead to rim bend or
damage. (Fig. 2.82)

l Under-inflated tyres make smooth cornering Fig.2.82

difficult and over-inflated tyres decreases the
contact with the ground which can lead to
skidding and loss of control.

As the tyre pressure is affected by changes in

the temperature and altitude, the tyre pressure
need to checked and adjusted more frequently
if the vehicle is used on such condition.

l Maintain proper tyre pressure for good road

stability and longer tyre life. Inflate tyres in cold
condition to the pressure as given below:

Tyre pressure gauge

Tyre pressure Front Rear

Kg/cm² (psi) Kg/cm² (psi)
Solo riding
2.25 Kg/cm² (32 psi)
Dual riding

Tyre tread conditions.

l Whenever the tyre pressure is checked,

ensure to check the tyre treads and side walls
for wear, damage and foreign objects.

l The tyres also to be checked for:

l Bumps or bulges in the sides of the tyre or in

the tread. Cuts, splits or cracks in the tyre
(replace the tyre without fail if found any of the
above issues to ensure the safety of the rider).
 SERVICE MANUAL
PERIODIC MAINTENANCE

l Replace the tyre when the tyre wears off to the

tyre wear indicator level which is indicated by
the tyre wear indicator (TWI) mark (A) on the
side surface of the tyre. (Fig. 2.83) A

TW
I
l Tread depth of the tyre should be minimum 2
mm if the vehicle speed is higher than 100
km/h, and it shall be minimum 1 mm if the
vehicle speed is lesser than 100 km/h.

2mm (> 100 km/h)

Tread depth (min)
1mm (< 100 km/h) Fig. 2.83

Tyre replacement

l The tyres fitted on your motorcycle were

d e s i g n e d t o m a t ch t h e p e r fo r m a n c e
capabilities of your motorcycle and provide the
best combination of handling, braking
durability and comfort. The recommended
tyres for your motorcycle are:

MICHELIN M/C 54 H Tubeless

Tyre Front
110/70 Zr17 M/C 54 W Tubeless

MICHELIN M/C 66 H Tubeless

Tyre Rear
110/70 Zr17 M/C 54 W Tubeless
 SERVICE MANUAL
PERIODIC MAINTENANCE

FUEL FILTER

Component : Fuel filter and hoses

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Replace at every 20000 km or 24 months (whichever occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the cover fuel tank assembly. Refer

chapter“general information” page no 1-00 for
removal procedure.

l Disconnect all the hoses and dispose the

clamps. (Fig. 2.84)

l Cut the wire tags.

Fig. 2.84
l Install new filter and secure with new wire
tags.

l Inspect and replace new fuel hoses if required

and fix with new clamps.

NOTE
Always replace the clamps if removed. Do
not reuse.
 SERVICE MANUAL
PERIODIC MAINTENANCE

FUEL HOSES / SYSTEM

Component : Fuel hoses

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 10000 km or 12 months (whichever
occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

l Visually inspect the fuel hoses for any leakage

or bulging.Replace the fuel hoses immediately
if found leaky / damaged.

l Using Ride Scan tool check the fuel pump and

fuel injector actuation.
 SERVICE MANUAL
PERIODIC MAINTENANCE

COOLANT LEVEL AND WATER HOSES

Component : Coolant reservoir and its hoses

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months (whichever
occurs earlier). Replace if required.

NOTE
Coolant, hoses and O-rings must be
replaced every 30000 km or every 3 years.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure. B

l Turn On the engine. MAX

MIN
l Visually inspect the coolant level in the coolant
reservoir (use a torch if required).
A
l The coolant level should be between minimum
and maximum level (A & B) of the coolant
reservoir. (Fig. 2.85) Fig. 2.85

l If the level is below minimum level top-up the

specified coolant upto the maximum level
mark.

Glycentine G48, Coolant + Water, @ 50 : 50 :

total filling 1 litre

CAUTION
Use of improper coolant may cause
damage, such as corrosion in the engine
parts, blockage of the cooling passage or
radiator and premature wear of the water
pump seal.

l Do not use tap water, or mineral water while

topping-up the coolant.

l Visually check all the rubber hoses, pipes and

joints for any cracks, leakage, damage or
deformation. If found any replace the
respective parts.

l Perform coolant leakage test to determine

coolant leakage in the system.Based on the
coolant leakage test results, replace the
required components.
 SERVICE MANUAL

NOTE
The cooling fan may switch ON after the
ignition is turned OFF to reduce the heat
and to protect the engine which is normal.

l Do not top-up the coolant when the engine is

hot. Top-up the coolant only in the reservoir
tank.

WARNING
Do not open the radiator cap when engine
is hot. Hot coolant may cause serious
burns/injury. Always wear protective
equipment while handling hot coolant.
 SERVICE MANUAL
PERIODIC MAINTENANCE

RADIATOR FINS AND FAN

Component : Radiator fin, fan and deflector

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months there after
(whichever occurs earlier). Replace if required.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Visually inspect the radiator fins for any

damage. Also inspect for any leakage.
(Fig. 2.86)

l Perform coolant leakage test to determine

coolant leakage in the system. Based on the
coolant leakage test results, replace the
required components.

l Clean the dust and debris on the radiator with

water jet at recommended pressure.

l If any damage is found in the radiator, replace it

with a new one as explained in chapter "Fuel Fig. 2.86
and lubrication" page no. 00.

l Check the radiator fan cut-in and cut-off

temperature under room temperature
conditions.
- Cut in at 108° C
- Cut off at 101° C

l Check radiator fan operation using Ride Scan

Tool.

NOTE
Engine will switch OFF if the coolant
temperature exceeds the cut-off
temperature.If this is observed do not
switch ON the engine even for testing
purposes till the coolant temperature
returns to normal.
 SERVICE MANUAL
PERIODIC MAINTENANCE

SWING ARM BEARINGS

Component : Swing arm

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months (whichever is
earlier). Replace is required

l Park the vehicle on the ramp. Pump the rear

seat up and down.

l Check for any abnormal noise or grease

leakage in the swing arm mounting area. If
found any, service / replace the swing arm
bushes. (Fig. 2.87)

l Refer chapter “Chassis” page no. 6-64 for

removal, servicing and lubrication of swing arm
bushes.

Fig. 2.87
 SERVICE MANUAL
PERIODIC MAINTENANCE

SIDE STAND FUNCTION

Component : Side stand

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Clean, Inspect and lubricate at initial 1000 km or 2 months & every 5000 km or 6
months thereafter (whichever occurs earlier)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Open the side stand and check for the damage

in rubber boot on the spring. If found damaged,
replace the spring. (Fig. 2.88)

l Lubricate the contact point on the chassis and

stand.

l Tighten the side stand bolt to the specified

torque.

8 mm Allen key

Tightening torque 38 ± 6 Nm Fig. 2.88 PERIODIC MAINTENANCE

l Using Ride Scan tool check the status of the

side stand and voltage in EMS.
 SERVICE MANUAL
PERIODIC MAINTENANCE

FUSE AND FUSE PULLER

Component : Fuses and puller

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect and lubricate at initial 1000 km or 2 months & every 5000 km or 6 months
thereafter (whichever occurs earlier)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove both the seats. Refer chapter “general

information” page no 1-00 for installation
procedure.

l Check the availability of fuse puller on the

battery clamp. If misplaced, get a new fuse
puller. (Fig. 2.89)

Fig. 2.89

l Open the fuse box. Inspect the fuses are

intact. If required pull out the fuses and check
its condition. Replace if found defective.
(Fig. 2.90)

l Fuses are arranged inside fuse box as shown in

table. (Fig. 2.91)
Fig. 2.90
Fuse Colour Electrical load
F1 - 7.5A Brown Lambda / purge value / ECU
/ REL coils / injector /
/ main relay / speedo
F2 - 7.5A Brown Fan radiator
F3 - 30A Green Main fuse
F4 - 15A Blue HECU
F5 - 15A Red All lights / horn LH & RH /
USB charger
F6 - 10A Red EFI / speedometer / telematic

Fig. 2.91
 SERVICE MANUAL
PERIODIC MAINTENANCE

BRAKE PEDAL AND GEAR SHIFT LEVER

Component : Gear shift lever and Rear brake pedal

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 5 months thereafter
(whichever occurs earlier). Lubricate using grease

Gear shift lever:

l Lubricate the mounting area of gear shift lever

using grease for easy operation of lever and
smooth gear shifting. (Fig. 2.92)

Fig.2.92

l Lubricate the mounting area of rear brake pedal

using grease for easy and effective braking.
(Fig. 2.93)

Fig. 2.93
 SERVICE MANUAL
PERIODIC MAINTENANCE

IGNITION CUM STEERING LOCK

Component : Ignition cum steering lock

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months thereafter
(whichever occurs earlier). Lubricate using grease

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Inspect the proper working of ignition cum

steering lock. (Fig. 2.94)

l L u b r i c a t e t h e i g n i t i o n key s l o t w i t h
recommended spray regularly.

l Keep the key slot free from dust.

Fig. 2.94
 SERVICE MANUAL
PERIODIC MAINTENANCE

MALFUNCTION CODE

Component : Instrument cluster / Diagnostic tool

Component condition : Vehicle on ramp and component accessible
Objective : Periodic service
Repair cycle : Inspect at initial 1000 km or 2 months & every 5000 km or 6 months thereafter
(whichever occurs earlier).

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

l Check the instrument cluster for any

malfunction indication. If found any, analyze
the error using ride scan tool and rectify it by
following the corrective actions provided in the
ride scan tool (refer chapter "Diagnostic
procedure" page no. 7-XX for usage of ride scan
tool).

l Using the ride scan tool, analyze any ABS and

engine related malfunction created and
recorded during every maintenance service. If
so rectify it by following the corrective actions
provided in the ride scan tool (refer chapter
“Diagnostic procedure” page no. 7-1 for the
detailed procedure of diagnostic system).

l If there is no error code recorded, then proceed

further for carrying out regular maintenance
jobs.
 SERVICE MANUAL
GENERAL INFORMATION

DESCRIPTION PAGE NO Chapter 3

COVER CLUTCH REMOVAL AND SERVICING 3
CLUTCH REMOVAL 3
OIL PUMP 12
ENGINE REMOVAL 14
ENGINE FROM SUB FRAME FRONT 14
CYLINDER HEAD ASSEMBLY 20
CYLINDER HEAD ASSEMBLY - DISASSEMBLY 25
CYLINDER HEAD DECARBONISING 30
CYLINDER HEAD ASSEMBLY - RE-FIXING 37
CRANKCASE AND GEAR BOX REMOVAL 39
TRANSMISSION GEARS - SERVICING 52
ENGINE COMPONENTS - INSPECTION 57
PISTON AND CONNECTING ROD - SERVICING 61
CRANKCASE AND GEAR BOX REASSEMBLY 66

ENGINE
 SERVICE MANUAL
ENGINE

COVER CLUTCH REMOVAL AND SERVICING

Component : Clutch servicing

Component condition : Vehicle on ramp and component accessible
Objective : Clutch cover removal
Repair cycle : As required

Clutch removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the engine guard. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the deflector R and cover radiator R.

Refer chapter “general information” page no 1-
00 for removal procedure.

WARNING
Be ensure vehicle should study position
before working on engine, always use the
engine stand for the safety purpose.

Clutch assembly can be serviced with the engine

mounted on the vehicle itself. Normally, clutch is
serviced for:

l Lose of power / low pick up

l Jerking of vehicle
l Any abnormal noise from clutch

l Drain the engine cum transmission oil Refer

chapter “Periodic maintenance” page no 1-00
for draining procedure.

l Drain the radiator coolant oil Refer chapter

“Periodic maintenance” page no 1-00 for
draining procedure.
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket cap flange bolt

(A) (M6x25 - 1No.) along with the aluminium
washer 6.2x12x1 from the mounting of water A
pump cover. (Fig. 3.1)

5 mm Allen key

Tightening torque 10 ± 1.5 Nm

WARNING
Cooling system is a pressurized system. Do
not drain coolant oil when engine is in hot Fig. 3.1
condition. Do not open the radiator cap
when radiator is in hot condition. Hot
coolant may cause burns.

l Keep a measuring jar near the engine and drain

the coolant oil from the clutch cover. (Fig. 3.2)

Measuring jar

CAUTION
Carefully collect the coolant oil on the
measuring jar and wipe off the excessive.
Fig. 3.2

l Using the special tool, dislocate the hose

clamp (A) and disconnect the hose radiator
outlet from the radiator assembly. (Fig. 3.3)

Special tool
A

Fig. 3.3
l Remove the hexagonal socket cap flange bolt
(M6x45 - 3 Nos.) and (M6x25 - 1 No.) (B) from
the mounting of water pump cover and takeout
B
the water pump cover along with the hose
radiator outlet. (Fig. 3.4)

5 mm Allen key

Tightening torque 10 ± 1.5 Nm

Fig. 3.4
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket cap flange bolt

(M5x12 - 1 No) along with the copper washer
(5.2x10x1.5 - 1No.) from the mounting of
impeller. (Fig. 3.5)

5 mm Allen key

Tightening torque 6 ± 0.9 Nm

NOTE
While reassembling ensure to assemble
the copper washer without fail. Fig. 3.5

l Dislocate the drain hose (A) from the cover

clutch. (Fig. 3.6)

Fig. 3.6

l Remove the hexagonal socket cap flange bolt

(M6x30-13 Nos.) from the cover clutch
mounting. (Fig. 3.7)

5 mm Allen key

Tightening torque 10.5 ± 0.5 Nm

l Take out cover clutch by gently tapping at the

ends using nylon hammer.

WARNING Fig. 3.7

Bearing should be removed only incase of
replacement.

l Heat the cover clutch upto 125° by placing the

cover clutch on the hot plate. (Fig. 3.8)

Hot plate

l Draw out the ball bearing (10x26x8 - 1 No)

along with oil (seal 22x10x6) from the cover
clutch.

Fig. 3.8
 SERVICE MANUAL
ENGINE

l Take out gasket clutch cover (A) and dowel pin A

from the cover clutch (2 Nos.). (Fig. 3.9)

l Remove the hexagonal bolt (M6x25 - 3 Nos.) Fig. 3.9

from the plate clutch release mounting.
(Fig. 3.10)

10 mm Spanner

Pre tightening torque 5 Nm

Final tightening torque 10 ± 1.5 Nm

NOTE
Please follow the uniform loosening and
tightening of plate clutch release bolts to
avoid uneven loading of plate. Fig. 3.10

l Take out plate clutch release.

l Take out the spring clutch (3 Nos.). (Fig. 3.11)

CAUTION
While reassembling, ensure all the three
clutch springs are having same colour
grade.

Fig. 3.11
l Pull out disc clutch pressure along with the hub
clutch, plate clutch driven (7 Nos.) and plate
clutch drive judder type-B (1 No.), spring clutch
judder (1 No), plate clutch drive (6 Nos.) as a
set. (Fig. 3.12)

CAUTION
Ensure that the one plate clutch drive (the
top one) is seated in smaller slotted groove
of the clutch housing as shown. Care
should be taken to reassemble the top
drive plate in the same position.
Fig. 3.12
 SERVICE MANUAL
ENGINE

l Separate the hub clutch, plate clutch driven

(7 Nos.), plate clutch drive (6 Nos.), plate clutch
drive type 2 (2 Nos.) plate clutch drive judder
type - B (1 No.), spring clutch judder (1 No),
washer clutch judder (1 No.).(Fig. 3.13)
Clutch plate illustration

Fig. 3.13

l Remove the plunger assembly (A) from the

clutch push rod. (Fig. 3.14)

Fig. 3.14

l Remove the clutch push rod (B). (Fig. 3.15)

Fig. 3.15
l Using TDC lock special tool (A) and lock the
crankcase in the TDC position. (Fig. 3.16) B

l Using special tool, hold the hub clutch (B) and

remove the hexagonal flange nut (C) along with
the plate clutch drive. (Fig. 3.16)
A
24 mm Spanner
C

NOTE
While reassembling ensure to assemble
the plate clutch drive without fail.
Fig. 3.16
 SERVICE MANUAL
ENGINE

l Take out the hub clutch along with the shim

(22x40x2) from the gear assembly primary
drive. (Fig. 3.17)

Fig. 3.17

l Gently pull out gear assembly primary driven

along with needle bearing (28x33x13) from
drive shaft. (Fig. 3.18)

Fig. 3.18

l Gently takeout the needle bearing (28x33x13 -

2 Nos.) from the gear assembly primary driven.
(Fig. 3.19)

NOTE
While reassembly visually inspect the
needle bearing and replace if required.

Fig. 3.19

l Takeout the spacer clutch from the drive shaft.

(Fig. 3.20)

Fig. 320
 SERVICE MANUAL
ENGINE

l Takeout the shim (22x40x2) from the drive

shaft. (Fig. 3.21)

INSPECTION
Fig. 3.8
Plate clutch drive

l Inspect the plate clutch drive thickness using

vernier caliper. (Fig. 3.22)

Vernier caliper

Service limit 2.6 mm (min)

l If the thickness is less than the service limit,

replace the plate clutch drive as a set.

Fig. 3.22
l Inspect the claw width of plate clutch drive
using vernier caliper. (Fig. 3.23)

Vernier caliper

Service limit 15.2 mm (min)

l If the claw width is less than the service limit,

replace the plate clutch drive as a set.

l Also inspect the plates for burning due to

excessive friction / contaminated or low oil
level. Inspect the plate drive claws for indents
Fig. 3.23
(cut marks) due to the thrust from housing
clutch.

l If found any, replace the plate clutch drive as a

set.
 SERVICE MANUAL
ENGINE

Plate clutch driven

l Inspect the plate clutch driven distortion using

a feeler gauge and surface plate as shown in
the figure. (Fig. 3.24)

l Check the plates individually. Hold the plates

with three fingers and insert the feeler gauge
between the surface plate and driven plate at
3 to 4 locations.

Feeler gauge
Fig. 3.24
Service limit 0.10 mm (max)

l If the distortion is more than the service limit,

change the plate clutch driven as a set

Spring clutch

l Check the spring clutch free length using a

vernier caliper. If the spring reaches the service
limit, replace all the spring as a set. (Fig. 3.25)

Service limit 25.8 mm (min)

Fig. 3.25
CAUTION
Spring clutch is graded and identified with
different colour codes. While reassembling,
ensure the springs of same colour codes
are assembled for the proper working of
clutch.

Gear assembly primary driven (housing clutch)

l Inspect the housing clutch for any indents /

cuts created by the plate clutch drive.
(Fig. 3.26)
Fig. 3.26

Hub clutch

l Inspect the hub clutch for wear. If any ridges or

cuts are formed in the hub clutch by the clutch
plates, then replace with a new one. Also check
lubrication holes for any blockage. (Fig. 3.27)

Fig. 3.27
 SERVICE MANUAL
ENGINE

Spacer clutch
Dia
l Inspect the spacer clutch for any wear or
scoring mark on both inner and outer surface. If
found, replace the spacer with a new one.

l Also inspect the outer diameter of the spacer

clutch. If the diameter is found lesser than the
service limit, replace the spacer with a new
one. (Fig. 3.28)

Vernier caliper
Fig. 3.28
Service limit
25.957 mm (max)
Outer diameter
00.000 mm (min)

Installation

l Reassemble parts in the reverse order of

disassembly.

l While reassembling, inspect the bearing clutch

release plate for any abnormal noise and
smooth rotation. Replace bearing with a new
one if found defective.

l While reassembling, ensure the clutch plates

are held firmly together by checking the play
between the drive plates after tightening the
plate clutch release. (Fig. 3.29)

l Inspect the gasket cover clutch for any damage

and replace if required.
Fig. 3.29
l Fix the dowels and gasket without fail and fix
back the cover clutch. Tighten the mounting
bolts to specified torque along with the bracket
clutch cable.

Tightening torque 11 ± 2 Nm

l Refill the engine cum transmission oil (refer

chapter “Periodic maintenance” page no. 2-3
for oil filling procedure).

CAUTION
While removal of clutch cover, ensure to
replace the old water pump packing, clutch
cover gasket and coolant drain plug
washer without fail.
 SERVICE MANUAL
ENGINE

OIL PUMP

Component : oil pump servicing

Component condition : Vehicle on ramp and component accessible
Objective : Oil pump removal
Repair cycle : As required

Oil pump removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the engine guard. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the deflector R and cover radiator R.

Refer chapter “general information” page no 1-
00 for removal procedure.

l Drain the engine cum transmission oil Refer

chapter “Periodic maintenance” page no 1-00
for draining procedure.

l Remove the cover clutch assembly. Refer page

no 1-00 for removal procedure.

WARNING
Be ensure vehicle should study position
before working on engine, always use the
engine stand for the safety purpose.

l Drain the radiator coolant oil Refer chapter

“Periodic maintenance” page no 1-00 for
draining procedure.
 SERVICE MANUAL
ENGINE

l Oil pump is an internal combustion engine part

that circulates the engine oil under pressure to
the rotating bearings, the sliding piston and the A
camshaft of the engine. This lubricates the
engine bearings and also assists to cooling the
engine.

l Remove the rotor with oil pump (A & B) from

the oil pump pins with shaft. (Fig. 3.30 A & B)

Nose plier

Fig. 3.30A
NOTE
While reassembling the oil pump, ensure
that the rotor with oil pump gears faces
toward outside and also check rotor with
oil pump are properly seated with the oil B
pump pins with shaft.

CAUTION
Oil pump should be removed only incase of
replacement.

NOTE Fig. 3.30B

Do not reuse the old water pump packing,
clutch cover gasket and coolant drain plug
washer. Always replace it when opened.
 SERVICE MANUAL
ENGINE

ENGINE REMOVAL

Component : Engine
Component condition : Vehicle on ramp and component accessible
Objective : To remove engine from sub frame front
Repair cycle : Whenever required

Engine - Removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the engine guard. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the air cleaner assembly . Refer

chapter “general information” page no 1-00 for
removal procedure.

l Remove the throttle body assembly. Refer

chapter “general information” page no 1-00 for
removal procedure.

l Remove the cover engine sprocket. Refer

chapter “general information” page no 1-00 for
removal procedure.

l Remove the cover frame bottom assembly.

Refer chapter “general information” page no 1-
00 for removal procedure.

l Remove the deflector R and cover radiator R.

Refer chapter “general information” page no 1-
00 for removal procedure.

l Remove the radiator assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the muffler assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the raider footrest disc LH. Refer page

no 1-00 for removal procedure.
 SERVICE MANUAL
ENGINE

l Drain the engine cum transmission oil Refer

chapter “Periodic maintenance” page no 1-00
for draining procedure.

l Remove the cover clutch assembly. Refer page

no 1-00 for removal procedure.

WARNING
Be ensure vehicle should study position
before working on engine, always use the
engine stand for the safety purpose.

l Drain the radiator coolant oil Refer chapter

“Periodic maintenance” page no 1-00 for
draining procedure.

l Gently push the rod clutch release complete A

and dislocate the clutch cable from the rod
clutch release slot (A). (Fig. 3.31)

NOTE
While removing the cable not to stretch too
much as it may damage the clutch cable.

Fig. 3.31

l Remove the hexagonal socket cap flange bolt

(M6x16 – 2 Nos). from the bracket clutch cable.
(Fig. 3.32)

5 mm Allen key

Tightening torque 10 ± 1.5 Nm

l Take out the bracket clutch cable along with the

clutch cable from the crank case assembly.

Fig. 3.32
l Remove the hexagonal flange bolt
(M8x30 - 1 No) along with spacer bush and
spring disc from the sprocket engine.
(Fig. 3.33)

12 mm Spanner

Tightening torque 28 ± 4.2 Nm

Fig. 3.33
 SERVICE MANUAL
ENGINE

l Pull out the sprocket engine along with drive

chain assembly from shaft drive. (Fig. 3.34)

l Dislocate sprocket from the drive chain. Hang

the drive chain in the frame itself.

Fig. 3.34

l Dislocate the wiring harness lock clamp from

the crankcase assembly. (Fig. 3.35)

CAUTION
Do not stretch the wiring harness too much
as it may damage the wires, which might
result in replacement of the wiring
harness.

Fig. 3.35

l Disconnect the magneto coupler (A) and stator

coil coupler (B) from the main wiring harness.
(Fig. 3.36)

Fig. 3.36

l Disconnect the magneto coupler (C) from the

main wiring harness. (Fig. 3.37)

Fig. 3.37
 SERVICE MANUAL
ENGINE

l Disconnect the thermal sensor coupler (D)

from the main wiring harness. (Fig. 3.38)

Fig. 3.38

l Disconnect the gear position sensor coupler

(E) from the main wiring harness. (Fig. 3.39)

NOTE E
When disconnecting the couplers, be sure
to hold the couplers itself and do not pull
the lead wires.

Fig. 3.39

l Dislocate and pull out the magneto wiring

harness hose clip from the sub frame front.
(Fig. 3.40)

l Gently cut the cable tie and dislocate the wiring

harness from its routing at 3 places.

NOTE
Ensure to re-route wiring harness without
fail.

Fig. 3.40
l Remove the hexagonal bolt (M2x20 – 1 No.)
and dislocate the negative cable (A) from the
mounting of cylinder head assembly.
(Fig. 3.41)

8 mm spanner A

Tightening torque 12.5 ± 2.5 Nm

Fig. 3.41
 SERVICE MANUAL
ENGINE

l Remove the hexagonal bolt (M6x20 – 1 No.)

and dislocate the negative cable (B) from the
mounting of magneto cover assembly.
(Fig. 3.42) B

8 mm spanner

Tightening torque 12.5 ± 2.5 Nm

NOTE
While installing, ensure to remount the
earth wire without fail. Fig. 3.42

l Dislocate the boot cover (A) from the starter

motor assembly. (Fig. 3.43) A

NOTE
Make sure to re-fix the boot cover on its
location.

Fig. 3.43
l Remove the hexagonal socket cap flange nut
(M6x25-1No.) from the mounting starter motor
assembly. (Fig. 3.44)

10 mm spanner

Tightening torque 4.5 Nm

l Gently take out the starter motor wiring

harness and hang it carefully.

CAUTION
Before removing engine from the vehicle, Fig. 3.44
assemble the engine support plate below
the engine and tighten the engine support
plate to its specified limits. (Fig. 3.45A)

12 mm Spanner

Place the jack below the engine support

plate and rotate in it clockwise direction to
lift the jack. (Fig. 3.45B)

21mm Spanner

Ensure that the vehicle was fully balanced

with jack to the engine support plate.
Fig. 3.45A Fig. 3.45B
 SERVICE MANUAL
ENGINE

l Loosen the hexagonal nut (M10x1.5 - 2 Nos)

along with plain washer from the mounting of
s u b f r a m e f r o n t t o p a n d b o tt o m .
(Fig. 3.46 A & B)

16 mm spanner

Tightening torque 45 Nm

Fig. 3.46A Fig. 3.46B

l Remove the hexagonal socket screw (M8x30 -
2 Nos.) from the mounting of sub frame front
LH & RH. (Fig. 3.47 A & B)

8mm Allen key

Tightening torque 45 Nm

Fig. 3.47A Fig. 3.47B

l Gently draw out the hexagonal flange bolt

(M10x1.5x150 – 2 Nos.) from the mounting of
sub frame front. (Fig. 3.48)

l Use the workshop crane and gently lift the

frame along with the front and rear wheel
assembly.

l Carefully lift engine assembly with both the

hands and place the engine assembly on a
engine rest (stand).

Fig. 3.48

l Assemble the engine rest bracket one end (A)

on the cylinder head assembly and another end
(B) on the crankcase assembly. (Fig. 3.49)
A
l Tighten the engine rest bracket to its specified
limits.

l Once again check and confirm engine B

assembly is fully tighten with the engine rest
bracket.

Fig. 3.49
 SERVICE MANUAL
ENGINE

CYLINDER HEAD ASSEMBLY - SERVICING

Component : Cylinder head

Component condition : Mounted on engine stand
Objective : To remove cylinder head
Repair cycle : Whenever required

Cylinder head removal

l Remove the engine assembly from the sub

frame front. Refer page no 1-00 for removal
procedure.

l Remove the ignition coil from the cylinder head

assembly. (Fig. 3.50)

Fig. 3.50

l Using a special tool, remove the spark plug

from the cylinder head assembly. (Fig. 3.51)

Pre tightening torque 15 ± 1.5 Nm

Final tightening torque 12 ± 1.5 Nm

Fig. 3.51

l Remove the bolts cylinder head cover (M6x20 -

4 Nos.) along with grommet (4 Nos.) from the
mounting of cover cylinder head. (Fig. 3.52A )

6mm Allen key

Tightening torque 10 ± 1.5 Nm

l Now, take out the cover cylinder head.

(Fig. 3.52B)

Fig. 3.52A Fig. 3.52B

 SERVICE MANUAL
ENGINE

l Gently take out the packing seal cover cylinder

(A). (Fig. 3.53)

NOTE
While reassembling, inspect the condition
of the packing seal. If any distortion /
damage is found, replace the packing seal
with a new one.
A

Fig. 3.53

l Remove the hexagonal socket caps flange bolt

(M7x38 - 2 Nos.) from the mounting of guide
cam chain plas complete upper. (Fig.3.54)

6mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 15 ± 2.25 Nm

Fig. 3.54

l Remove the bolt cam chain tensioner (M8x36 -

1 No.) along with copper washer (18x13 - 1 No.)
from the mounting of cylinder head assembly.
(Fig. 3.55)

5 mm Allen key

Tightening torque 12 ± 1.8 Nm

NOTE
While reassembling the guide cam chain
plas complete upper. Ensure the presence Fig. 3.55
of copper washer.

l Now, take out the guide cam chain plas (A) A

complete upper from the housing camshaft.
(Fig. 3.56)

CAUTION
Care should be taken not to damage the
cam chain plas complete upper during
removal / reassembly.

Fig. 3.56
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket caps flange bolt

(M7x38 - 7 Nos.) along with special washer
(7.2x15 - 3 Nos.) from the mounting of housing
camshaft. (Fig. 3.57)

6 mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 15 ± 2.25 Nm

NOTE
Fig. 3.57
While reassembling, Inspect the special
washer for any damage. If found, replace
the special washer with new one.

l Now, take out the housing camshaft along with

the ‘O’ ring.

NOTE
While reassembling, Inspect the condition
of ‘O’ ring for any damage. If found, replace
the O’ ring with new one.

l Remove the bolt cam chain tensioner (M8x36 -

1 No.) along with copper washer (18x13 - 1 No.)
from the mounting of cylinder head assembly.
(Fig. 3.58)

5 mm Allen key

Tightening torque 12 ± 1.8 Nm

NOTE
Ensure the presence of copper washer
during removal / removal.
Fig. 3.58
l Remove the screw tapped adjusting bolt
(M24x12.2 - 1No.) from the mounting of
cylinder head assembly. (Fig. 3.59)

30 mm Allen key

Tightening torque 30 ± 2.1 Nm

NOTE
While reassembling, inspect the gasket
tensioner adjuster for any damage. If
found, replace the gasket tensioner
adjuster with new one.
Fig. 3.59
 SERVICE MANUAL
ENGINE

l Gently dislocate the cam chain (A) from the

camshaft exhaust (B) and camshaft intake (C)
and take out the camshaft exhaust and intake
assembly. (Fig. 3.60) C

A
l Hold the cam chain using a good quality copper
wire to prevent the chain from falling into the
crankcase assembly. Hang the cam chain on
the cylinder head assembly itself. B

NOTE
While reassembling the camshaft exhaust Fig. 3.60
and intake assembly make sure that the
camshaft exhaust and intake assemblies
are properly inserted into the cylinder head
assembly slot. A

l Exhaust camshaft can be identified by the

presence of de-compressing (A) position.
(Fig. 3.61)

Fig. 3.61

l Gently lift the finger follower from the rocker

arm valve assembly. (Fig. 3.62)

NOTE
During reassembly, the marking on the
sprocket is to be aligned with the cylinder
head face.

Fig. 3.62
l Now, carefully take the button tappet
(4 Nos.) from the rocker arm valve assembly.
(Fig. 3.63)

Fig. 3.63
 SERVICE MANUAL
ENGINE

l Remove the bolt cylinder head (M9 - 4 Nos.)

from the mounting of cylinder head assembly.
(Fig. 3.64)

8 mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 20 ± 3 Nm

Final tightening torque 1200 ± 30

Fig. 3.64

l Remove the hexagonal socket cap flange bolt

(M6x35 - 2 Nos.) from the mounting of cylinder
head assembly. (Fig. 3.65)

5 mm Allen key

Tightening torque 10 ± 1.5 Nm

Fig. 3.65

l Holding the cam chain, gently lift the cylinder

head assembly and takeout the cylinder head
assembly from its mounting. (Fig. 3.66)

Fig. 3.66
l Take out the tubular dowels (A) (2 Nos.) either
from cylinder head assembly or from cylinder
block. (Fig. 3.67) B

l Take out the gasket cylinder head (B).

(Fig. 3.67)

NOTE A
A
While reassembling, check the gasket for
any damage, scoring, deformation or
leakage marks. If found replace the gasket
with a new one.
Fig. 3.67
 SERVICE MANUAL
ENGINE

CYLINDER HEAD ASSEMBLY - DISASSEMBLY

Component : Cylinder head

Component condition : Component on workbench
Objective : Cylinder head disassembly
Repair cycle : Whenever required

Cylinder head disassembly

l Remove the cylinder head assembly as

explained in page no 1-00 for removal
A
procedure.

l Take out the gasket exhaust pipe (A) either

from cylinder head assembly or muffler
assembly. (Fig. 3.68)

NOTE
While reassembling ensure to re-fix the Fig. 3.68
gasket exhaust pipe without fail.

l Remove the hex socket cap flange bolt

(M6x16 – 2Nos.) from the mounting of pipe
intake complete. (Fig. 3.69)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

Fig. 3.69
l Remove the set screw (M7x30 – 2 Nos.) along
with the gasket oil gallery plug cap (2 Nos.)
from the mounting of cylinder head assembly.
(Fig. 3.70)

5mm Allen key

Tightening torque 15 ± 2.2 Nm

NOTE
While reassembling the plug cap, visually
inspect the condition of gasket oil gallery
plug cap. If required, replace the gasket oil
Fig. 3.70
gallery plug cap with new one.
 SERVICE MANUAL
ENGINE

l Using small flat screw driver, gently push the

shaft finger follower and takeout the shaft
finger follower from the cylinder head
assembly. (Fig. 3.71)

Small flat screw driver

Fig. 3.71

l Locate the special tool to remove the valves as

the movable jaw of the tool rests on the
retainer valve spring (Fig. 3.72A) and the other
end (fixed jaw) to rest at the center of the valve
face. (Fig. 3.72B)

l Slowly tighten the special tool to compress the

springs valve.

S131 002 0 Extractor assembly, inlet and

exhaust vale

CAUTION Fig. 3.72A Fig. 3.72B

To prevent the loss of tension of the

springs, do not compress the spring more
than required.

l Remove four cotter valve from the valve stem.

(Fig. 3.73)

Nose plier

l Loosen and take out the special tool.

l In similar manner, remove the cotter valves

from the valve stem. Fig. 3.73
l Takeout the retainer valve spring (500) exhaust
(A) from the spring valve exhaust. (Fig. 3.74)
A B
l Similar takeout the retainer valve spring (500)
intake (B) from the spring valve intake outer
also. (Fig. 3.74)

Fig. 3.74
 SERVICE MANUAL
ENGINE

l Remove the spring valve intake outer (A) and

spring valve exhaust (B). (Fig. 3.75)
B A

Fig. 3.75

l Remove the spring valve intake inner (C).

(Fig. 3.76)
C

Fig. 3.76
l Gently push down the valve from top and
remove it from the combustion chamber side.
(Fig. 3.77)

CAUTION
While removing the valve, check for the
free movement of the valve. If there is no
free movement, check the valve for bend
and runout. Replace the valve In case of
bend or runout.

l Remove the oil seal valve stem (500) (A), value

seat spring exhaust (B) and value seat spring Fig. 3.77
intake (C). (Fig. 3.78A)

Nose plier

B
NOTE A
While reassembling, replace the oil seal
valve stem with a new one. Always use non C
metal cladding oil seal valve stem.

l In similar manner, remove the remaining oil

seal valve stem (500) (A), value seat spring
exhaust (B) and value seat spring intake (C)
also. (Fig. 3.78B)
Fig. 3.78A Fig. 3.78B
 SERVICE MANUAL
ENGINE

l Using a special tool, dislocate the hose clamp

(D14) (A) and disconnect the hose bypass (B)
from the cylinder head assembly. (Fig. 3.79) A

Special tool

Fig. 3.79

l Using a special tool, dislocate the hose clamp

(D27) (C) and disconnect the hose radiator
outlet (D) from the cylinder head assembly.
(Fig. 3.80)

Special tool C

l Remove the hexagonal socket cap flange bolt Fig. 3.80

(M5x12 - 2 Nos.) from the mounting of housing
thermostat. (Fig. 3.81)

Tightening torque 6 Nm

l Gently takeout the housing thermostat.

Fig. 3.81
l Carefully dislocate and pullout the thermostat
from the cylinder head assembly. (Fig. 3.82)

Fig. 3.82
 SERVICE MANUAL
ENGINE

l Remove the temperature sensor engine from

the mounting of cylinder head assembly.
(Fig. 3.83)

19 mm Spanner

Tightening torque 13.3 ± 1.5 Nm

Fig. 3.83

l Carefully pull out the hose air inlet 1 & 2 from

the cylinder head assembly. (Fig. 3.84)

Nose plier

Fig. 3.84
 SERVICE MANUAL
ENGINE

CYLINDER HEAD ASSEMBLY - DECARBONISING

Component : Cylinder head

Component condition : Component on workbench
Objective : Cylinder head decarbonising
Repair cycle : As required

Cylinder head decarbonising

l Carbon deposits on the combustion chamber

of the cylinder head complete 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.

l Decarbonise the combustion chamber of

cylinder head complete using suitable
decarbonising spray. (Fig. 3.85) Fig. 3.85

NOTE
Decarbonise the head complete cylinder
combustion chamber after removing both
the valves. Use suitable cleaning solvent.

CAUTION
Care should be taken not to damage the
surface of the combustion chamber while
decarbosnising.

Seat value

l 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

l Carbon deposits on the valve stem rubs

continuously on guide valve and this will result
increased clearance between the stem and
guide valve. Clean the valve stem with the
cleaning solvent. (Fig. 3.86) Valve stem illustration
l Clean the guide valve to remove any carbon
buildup by using carbon removers.

l Clean other parts of the head complete

cylinder thoroughly with suitable cleaning
solvent. Fig. 3.86
 SERVICE MANUAL
ENGINE

CYLINDER HEAD ASSEMBLY - INSPECTION

Component : Cylinder head servicing

Component condition : Component on workbench
Objective : Cylinder head inspection
Repair cycle : As required

Cylinder head inspection

l After cleaning the liquid gasket from the

surface of the cylinder head complete, 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. 3.87)

Surface plate

l Using a feeler gauge, check for the distortion of

cylinder head complete surfaces. If the reading Fig. 3.87
exceeds the limit, replace the head complete
cylinder with a new one. (Fig. 3.88)

Feeler gauge

Surface plate

Service limit 0.05 mm (max)

Camshaft assembly inspection

l Check the camshaft assembly for runout, wear

of cam lobes and journals. Any of these could Fig. 3.88
cause the engine to produce abnormal noise,
vibration or lack of power output.

l Measure the cam lobe height. If the lobe

height is less than the service limit, replace the
camshaft complete with a new one. (Fig. 3.89)
Camshaft illustration
Outside micrometer

Service limit
Inlet 34.3 mm (min)
Exhaust 34.190 mm (min)

Fig. 3.89
 SERVICE MANUAL
ENGINE

l Inspect the ball bearings of camshaft for

abnormal play, shake or pitting.

l Measure the runout of the camshaft with a dial

gauge. Replace the camshaft with a new one if
the runout exceeds the service limit. (Fig. 3.90)
Illustration
V-block set (4”x3”x3”)

Dial gauge (1/100 mm) / Magnetic stand

Service limit 0.080 mm (max)

Fig. 3.90

Valve intake and valve exhaust inspection

l Inspect each valve for trueness, burning,

scratches, abnormal wear or bend.

l Measure the outside diameter of valve stem

on the operational area. (Fig. 3.91)

Outside micrometer

Service limit
Inlet 4.970 mm (min)
Fig. 3.91
Exhaust 4.960 mm (min)

l Using the special tools, measure the runout on

valve stem and valve head. Replace the valve
with new one if runout exceeds the service
limit. (Fig. 3.92)

V-Block set (4”x3”x3”)

Dial gauge (1/100 mm) / Magnetic stand

Service limit
Runout on stem 0.05 mm (min)
Runout on head 0.05 mm (min) Fig. 3.92

l Check the valve for smooth movement in the

guide valve.

l Measure the thickness of valve head. If the

thickness is less than the service limit, replace
the valve with a new one. (Fig. 3.93)

Vernier caliper T

Service limit
Inlet & Exhaust 1.8 mm (min)
Fig. 3.93
 SERVICE MANUAL
ENGINE

Valve stem condition

l Inspect the valve stem end face (A) for pitting

and wear. If pitting or wear noticed, replace the
valve with a new one. (Fig. 3.94)

illustration

Spring valve Fig. 3.94

l Measure the free length of the valve springs. If

the length is smaller than the service limit,
replace the springs. (Fig. 3.95)

Vernier caliper

Service limit
Spring length exhaust 1.8 mm (min)
Spring length intake outer 1.8 mm (min)
Spring length intake inner 1.8 mm (min)

Fig. 3.95
Tensioner cam chain

l Inspect the tensioner cam chain for any

distortion / damage, cuts or crack. If found any,
replace the tensioner with new one. (Fig. 3.96)

l After assembling the tensioner cam chain,

make sure it moves freely in the cylinder head
assembly.

Fig. 3.96

Cam chain

l Visually inspect the cam chain for loose pins,

twist / seized links etc. If found any replace the
cam chain with a new one. (Fig. 3.97)
illustration

Fig. 3.97
 SERVICE MANUAL
ENGINE

Shaft finger follower

l Inspect the shaft finger follower for any

damage.

l Measure the outer diameter (OD) of shaft

finger follower. If the OD is less than the
service limit, replace the shaft. (Fig. 3.98)

l Similarly check the remaining shaft finger

follower also.

Outside micrometer Fig. 3.98

Service limit 7.995 ~ 7.98

NOTE
The OD should be checked at the shaft
finger follower assembly seating area.

REASSEMBLY

Head complete cylinder

l For reassembly, reverse the disassembly

procedure while taking care of the following
instructions. Refer exploded view of cylinder
head assembly for assembly details. (Fig. 3.99)

NOTE
Use only new ‘O’ rings and oil seals. Do not
use old ones.
 SERVICE MANUAL
ENGINE

CYLINDER HEAD EXPLODED VIEW

Ignition coil

Cylinder head cover screw

Cylinder head cover washer Cylinder head cover

Cylinder head cover gasket

Cam bridge washer

Cam bridge washer

Cam bridge screw Cam bridge

Spark plug Valve spring top seat

Valve stem lock Valve spring
Pipe intake component

Inlet valve
Thermostat
Exhaust valve
Hex socket cap flange bolt Thermostat housing
Coolant temperature sensor
Cover SAI valve
SEC Air induction valve component
Arrestor plate Pre-tensioner
Rocker arm pin Cam shaft Cam shaft chain guide
Rocker arm
Cylinderical head bolt Cam chain guide washer
Shim
Dowel Cam chain guide bolt
Cam chain

Cam shaft gear

Cylinder head gasket
Copper washer
Bolt Cam chain tensioner

Cam chain guide

Fig. 3.99
 SERVICE MANUAL
ENGINE

l Assemble the seat valve spring and a new seal

valve stem oil.

l While assembling the valves, insert smoothly

into the guide to avoid any damage to the seal
valve stem oil.

l Assemble the valve spring and retainer valve

spring.

l Using the special tool compress the spring and

assemble the cotter valves. (Fig. 3.100)
Fig. 3.100
l Lubricate the valve stems before installing.
Ensure proper seating of the cotter valves in its
groove by gently tapping on retainer valve
spring. (Fig. 3.101)

Leak check and lapping

l After assembling the valves, pour petrol into

the intake port and look for leakage of the
petrol around valve intake seating.

l Similarly check the exhaust valves also.

l If any leakage noticed, replace the defective Fig. 3.101

parts (valves or cylinder head assembly).

l For lapping, remove the cylinder head

assembly components as explained earlier.
Apply lapping compound uniformly right round
on the valve face. (Fig. 3.102)
Value stem illustration

l Hold the valve with lapping stick, rub the valve

against it seating by applying very light
pressure till perfect seating is obtained.
Fig. 3.102
(Fig. 3.103)

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

l Clean thoroughly the valve seat and valve

ensuring that there is no compound left out.
Reassemble the valves in the cylinder head
assembly as explained earlier and recheck for
leaking.
Fig. 3.103
 SERVICE MANUAL
ENGINE

CYLINDER HEAD ASSEMBLY - RE-FIXING

Component : Cylinder head servicing

Component condition : Mounted on engine stand
Objective : Cylinder head re-fixing
Repair cycle : Whenever required

Cylinder head re-fixing

l Remove the plug crankshaft hole (A) along with

‘O’ ring from the cover magneto assembly.
(Fig. 3.104)

17 mm Allen key

Tightening torque 10 ± 1.5 Nm

NOTE A

While reassembling, ensure to replace the

‘O’ ring with a new one.

Fig. 3.104
l Now, slowly rotate the crankshaft until the ‘EX’
mark on exhaust side (A) and ‘IN’ mark on the
intake side (B) align with the edge of cylinder
head assembly. (Fig. 3.105)
A B

EX IN

l Place TDC mark tool (A) on the crankcase

assembly and rotate the TDC mark tool
towards clockwise direction to lock the Fig. 3.105
crankshaft. (Fig. 3.106)

Tool TDC mark

NOTE
A
Ensure there is no gap between TDC mark
tool and crankcase assembly. If gap is exist,
the crankshaft is not aligned with the TDC
mark.

Care should the taken not to damage the

plug (TDC) cap hole during removal /
assembly. Fig. 3.106
 SERVICE MANUAL
ENGINE

l Align the TDC mark on rotor assembly with

centre of the inspection hole (A) provided in the
cover magneto by rotating the rotor assembly.
(Fig. 3.107)
A
17 mm tubular spanner

NOTE
At this point check all the rocker arm
(4 nos.) should have free play. Otherwise
rotate the rotor assembly one more
complete round and align the mark again. Fig. 3.107

l Set the tappet clearance as explained in

chapter “Periodic maintenance” page no. 2-12.

l Reassemble the engine assembly to the sub

frame front.

l Assemble the spark plug and ignition cool.

l Re-fill the engine cum transmission oil as

explained in chapter “Periodic maintenance”
page no. 2-3 and ensure correct oil level.
 SERVICE MANUAL
ENGINE

CRANKCASE AND GEAR BOX REMOVAL - SERVICING

Component : Crankcase and gear box

Component condition : Mounted on engine stand
Objective : Crankcase and gear box removal
Repair cycle : Whenever required

Crankcase and gear box removal

l Remove the engine assembly from the sub

frame front. Refer page no 1-00 for removal
procedure.

l Remove the clutch cover, clutch assembly and

water pump assembly. Refer page no 1-00 for
removal procedure.

l Remove the cylinder head assembly. Refer

page no 1-00 for removal procedure.

l Remove the hexagonal socket cap flange bolt

(M6x30 - 10 Nos.) from the mounting of cover
magneto assembly. (Fig. 3.108)

5 mm Allen key
Fig. 3.108
Tightening torque 10.5 ± 0.5 Nm

Nylon hammer

l Carefully take out the cover magneto by gently

tapping with the nylon hammer along with
starter assembly.

l Take out the gasket magneto cover and dowel

pin (2 Nos.) either from the crankcase or from
the cover magneto. (Fig. 3.109)

Nose plier

Fig. 3.109

l Remove the pin magneto (A) along with gear C

starter idle (B) and gear intermediate assembly B
from the crankcase assembly. (Fig. 3.110)

Nose plier A
A
CAUTION
While reassembling ensure to align
properly the gear starter idle gear teeth to
starter motor and gear intermediate gear
teeth to gear starter clutch assembly.
Fig. 3.110
 SERVICE MANUAL
ENGINE

l carefully pullout the adapter engine breather

(A) from the balancer shaft assembly.
(Fig. 3.111) A

NOTE
While reassembling adapter engine
B
breather, make sure that the adapter
engine breather edge slot (B) is properly
seated with crankcase assembly. (Fig. 3.00)

While reassembling, ensure that the

presence of ‘O’ ring in the adapter. Fig. 3.111

l Remove the TDC allen bolt and install the

special tool (A) on the crankcase to avoid
magneto rotation. (Fig. 3.112)

TDC allen tool A

l Using the special tool, remove the rotor

assembly mounting hexagonal flange nut
(M16x1.5). (Fig. 3.113)

N731 015 0 Adapter magneto puller Fig. 3.112

17 mm spanner

Tightening torque 120 ± 8.4 Nm

NOTE
Apply ANABOND 112 or equivallent before
tightening the nut.

l Takeout the rotor assembly along with the one

way clutch.

NOTE Fig. 3.113

Always keep rotor assembly on a non
metallic surface with open side facing A
upwards.

l Gently separate the one way clutch (A) from

the rotor assembly. (Fig. 3.114)

NOTE
Do not separate the one way clutch until it
is necessary, to avoid falling of rollers from
one way clutch. Always keep them in
assembled condition.
Fig. 3.114
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket cap screw (A)

(M5x16 - 1No.) along with punched washer
(A5.5) from the mounting of stopper complete. A
starter gear. (Fig. 3.115)

4mm Allen key

Tightening torque 6 ± 0.9 Nm

NOTE
While reassembling, ensure that stopper
complete starter gear located properly Fig. 3.115
above gear starter clutch assembly.

l Gently remove the gear starter clutch

assembly (A) along with the needle bearing
from the crank shaft. (Fig. 3.116)

NOTE
A
While reassembling gear starter clutch
assembly, ensure to assemble the needle
bearing without fail.

Inspect the needle bearing for any damage,

if found replace the needle bearing with Fig. 3.116
new one.

l Take out the needle bearing (B) from the gear

B
starter clutch assembly. (Fig. 3.117)

Fig. 3.117
l Take out the woodruff key (A) from the drive
shaft. (Fig.3.118)

Nose plier A

Fig. 3.118
 SERVICE MANUAL
ENGINE

l Pull out the guide cam chain (A) and tensioner

camchain plas (B) from the cylinder block. B
(Fig. 3.119) A

l Remove the shaft complete gearshift

assembly along with punched washer by
pulling shaft outside. (Fig. 3.120)

l Take out the punched washer either from the Fig. 3.119
shaft complete gearshift assembly or from the
crankcase assembly.

l Remove bolt gear shift cam stopper and take

out stopper complete gear shift along with the
spring gear shift cam stopper and shim
(6x14x1). (Fig. 3.121)

6 mm Allen key

Tightening torque 10 Nm with loctite

NOTE
Fig. 3.120
While reassembling, ensure that shim is
located properly under the stopper
complete gear shift, before tightening the
b o l t ge a r s h i ft c a m s to p p e r. A fte r
tightening check cam stopper for free
movement.

l Remove the hexagonal socket cap screw (A)

(M6x20 - 1Nos.) from the mounting of index
star assembly and pull out the index star
assembly from the cam gearshift assembly.
(Fig. 3.122)

Philips head screw driver Fig. 3.121

Tightening torque 10 ± 1.5 Nm

NOTE
A
Locate the pins provided on the index star
assembly into the holes provided on the
cam gearshift and ensure the proper
seating of index star with the cam gearshift
during reassembly. (Fig. 3.122)

Apply ANABOND 112 or equivalent in the

mounting screw during reassembly and
wipe-off the excessive.
Fig. 3.122
 SERVICE MANUAL
ENGINE

l Remove the counter shaft cam chain drive (A)

along with cam chain (B) from the crankcase B
assembly. (Fig. 3.123)

Fig. 3.123
l Remove the hexagonal socket cap flange bolt
(M6x16 - 4 Nos.) from the mounting of heat
exchanger water and oil assembly takeout the
of heat exchanger water and oil assembly
along with mounting ring bracket. (Fig. 3.124)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

NOTE
While reassembling the heat exchanger
water and oil assembly, ensure to Fig. 3.124
assemble the mounting ring bracket
without fail.
A
l Gently takeout the seal heat exchanger (A)
from the crankcase assembly. (Fig. 3.125)

NOTE
Inspect the condition of the seal heat
exchanger, if found any replace with new
one.

l Remove the hexagonal socket cap flange bolt

(M6x25 - 2 Nos.) from the mounting of starter Fig. 3.125
motor assembly. (Fig. 3.126)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

l Carefully dislocate and takeout the starter

motor along with ‘O’ ring from the crankcase
assembly.

NOTE
While reassembling motor starter, ensure
the presence of ‘O’ ring.
Fig. 3.126
 SERVICE MANUAL
ENGINE

l Using a special tool, remove the filter comp

engine oil with packing along with packing oil
filter cap from the crank case assembly.
(Fig. 3.127)

27mm Spanner

Tightening torque 16 ± 2 Nm

NOTE
While reassembling the filter comp engine
oil with packing, check the condition of Fig. 3.127
packing oil filter cap and replace if
necessary.

l Remove the hexagonal socket cap flange bolt

(M6x30 - 13 Nos.) from the mounting of oil pan.
(Fig. 3.128)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

l Using nylon hammer gently tapping on the oil

pan and separate the oil pan by carefully pulling
out the crankcase assembly. Fig. 3.128

Nylon hammer

l Carefully takeout the oil pan along with the

bracket engine guard mounting L & R.

l Remove the dowel cylinder head cover knock

(2 Nos.) either from oil pan (or) from crankcase
assembly. (Fig. 3.129)

Nose plier

Fig. 3.129
l Dislocate the clip cable tie (A) along with the
drain hose from the crankcase assembly.
(Fig. 3.130)
A
NOTE
While reassembling, ensure to re-fix the
clip cable tie along with the drain hose on
the crankcase assembly.

Fig. 3.130
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket cap flange bolt

(M6x25 - 2 Nos.) along with the ‘O’ ring from
the mounting suction tube complete.
(Fig. 3.131)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

Fig. 3.131

l Remove the ‘O’ ring (17x2) (A) from the suction

tube complete. (Fig. 3.132)

NOTE A
While reassembling, ensure to replace the
‘O’ ring with a new one.

Fig. 3.132

l Remove the hexagonal socket cap flange bolt

(M6x70 - 7 Nos.) from the mounting of
crankcase assembly step 1 upper. (Fig. 3.133)

5mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 10 ± 1.5 Nm

Fig. 3.133
l Remove the hexagonal socket cap flange bolt
(M6x40 - 3 Nos.) from the mounting of
crankcase assembly step 1 upper. (Fig. 3.134)

5mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 10 ± 1.5 Nm

Fig. 3.134
 SERVICE MANUAL
ENGINE

l Remove the hexagonal socket cap flange bolt

(M6x70 - 6 Nos.) from the mounting of
crankcase assembly step 1 lower. (Fig. 3.135)

5mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Final tightening torque 10 ± 1.5 Nm

Fig. 3.135

l Remove the bolt (M9x95 - 4 Nos.) from the

crankcase assembly step 1 lower mounting.
(Fig. 3.136)

13mm Spanner

Pre tightening torque 10 ± 1.5 Nm

Main tightening torque 900 ± 30

Fig. 3.136

l Carefully separate crankcase assembly step 1

upper by carefully pulling out the crankcase
assembly step 1 lower. (Fig. 3.137)

l Using nylon hammer gently tap on the

crankcase assembly step 1 upper for easy
separation of crankcase assembly step 1 lower
along with the cam gear shift assembly,
adaptor oil fill and switch gear position.

Nylon hammer

Fig. 3.137
l Remove the hexagonal socket cap screw
(M5x12 - 2 Nos.) along with the fixing plate
(2 Nos.) from the mounting of crankcase
assembly step 1 lower. (Fig. 3.138)

4mm Allen key

Tightening torque 6 ± 0.9 Nm

NOTE
While reassembling, ensure to re-fix the
fixing plate before mounting of hexagonal
socket cap screw
Fig. 3.138
 SERVICE MANUAL
ENGINE

l Dislocate the fork gearshift No.1 (A) (2 Nos.)

and fork gearshift (B) No.2 from the grooves of
cam gearshift. (Fig. 3.139)
A B
l Pull out both the shaft gearshift forks (C) and
takeout the shaft gearshift forks along with the
fork gearshift No.1 (2 Nos.) and fork gearshift
No.2 from the crankcase assembly step 1
lower. (Fig. 3.139)

C
NOTE
Two different types of shift forks are used in Fig. 3.139
the gear shifting system of this engine.
Ensure to re-fix the right fork at right
location. If required, note the location of
forks during removal.

l Remove the hexagonal socket cap flange bolt

(M6x30 - 2 Nos.) from the mounting of adaptor
oil fill. (Fig. 3.140)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

l Takeout the adaptor oil fill along with ‘O’ ring Fig. 3.140
and gasket oil level plug.

NOTE
Before reassembling adaptor oil fill, ensure
the condition of gasket oil level plug if
required replace with new one. (Fig. 3.141)

l Remove the hexagonal socket cap screw

(M5x16 – 2 Nos.) along with ‘O’ ring from the Fig. 3.141
switch gear position mounting. (Fig. 3.142)

4mm Allen key

Tightening torque 6 ± 0.9 Nm

l Gently, pull out the switch gear position from

its location.

NOTE
Care should be taken not to damage the
switch gear position during removal and
reassembly of engine.
Fig. 3.142
 SERVICE MANUAL
ENGINE

NOTE
While reassembling the switch gear
position, ensure that the switch gear
position slot (A) assembled on the
crankcase assembly and switch gear
position slot (B) assembled on the cam
shaft assembly. (Fig. 3.143) B

Fig. 3.143
l Loosen the fixing bolt cam gear shift (A) and
takeout the cam gearshift (B) from the
crankcase assembly step 1 lower. (Fig. 3.144) B
A

Fig. 3.144

l Using the special tool, bearing installer set, ball

bearing (20x42x12) can be removed and
reassembled from the crankcase assembly
step 1 lower. (Fig. 3.145)

Special tool

Metal hammer

l Using the special tool, bearing installer set,

needle bearing (20x32x12) can be removed
and reassembled from the crankcase
assembly step 1 lower. (Fig. 3.146) Fig. 3.145

Special tool

NOTE
Remove the bearings, only if you need to
replace. Unnecessary removal of bearings
should be avoided, otherwise can damage
the bearings and can cause deterioration to
the interference fit. It is sufficient to clean
and lubricate the bearings in assembled
condition.

Fig. 3.146
 SERVICE MANUAL
ENGINE

l Remove the counter shaft assembly (A), drive

shaft assembly (B), crankshaft assembly (C)
B
and balancer shaft (D) from the crankcase A
assembly step 1 upper in the following
manner. (Fig. 3.147)
D

Fig. 3.147

l Remove counter shaft assembly and drive

shaft assembly as a set from the crankcase
assembly step 1 upper. (Fig. 3.148)

NOTE
While reassembling, ensure that the drive
shaft and counter shaft circlips are properly
seated on the crankcase assembly step 1
upper.

Fig. 3.148

l Remove the oil pump derive pin (A) and

balancing shaft (B) from the balancer shaft
assembly. (Fig. 3.149)

A
Nose plier

NOTE
B
Ensure the proper seating of the oil pump
derive pin of the balancing shaft in the
balancer shaft assembly.
Fig. 3.149
l Remove the balancer shaft assembly with
crankshaft assembly from the crankcase
assembly step 1 upper. (Fig. 3.150)

Fig. 3.150
 SERVICE MANUAL
ENGINE

l Set the piston to TDC position and remove the

connecting rod assembly bolts (M8x32.6 - 2
Nos.) from the piston assembly mounting.
(Fig. 3.151)

8mm Spanner

Pre tightening toqure 10 ± 1.5 Nm

Main tightening toqure 45°

Final tightening toqure 90°

Fig. 3.151
Final torque 47~66 Nm

l Takeout the connecting rod cap from the piston

assembly. (Fig. 3.152)

Fig. 3.152

l Gently remove the crankshaft assemble from

the crankcase assembly step 1 upper.
(Fig. 3.153)

Fig. 3.153
l Remove the jet oil spray nozzle (M0x00 - 1 No.)
from the crankcase assembly step 1 upper
mounting. (Fig. 3.154)

6mm Allen key

Tightening torque 15 ± 2 Nm

NOTE
While reassembling, ensure to assemble
the jet oil spray nozzle without fail.
Fig. 3.154
 SERVICE MANUAL
ENGINE

l Push the connecting rod from the bottom end

and remove the piston along with connecting
rod and piston rings from the top of the engine.
Ensure the connecting rod does not come in
contact with the cylinder bore while removing.
(Fig. 3.155)

Fig. 3.155

l Remove the shell bearing balancer shaft (A)

(2 Nos.) and shell bearing crankshaft (B)
(2 Nos.) from the crankcase assembly step 1 A
upper. (Fig. 3.156)

A B
Nose plier

Fig. 3.146

l Gently tapping on the sleeve cylinder and

remove the sleeve cylinder along with ‘O’ ring
from the crankcase assembly step 1 upper.
(Fig. 3.147)

Nylon hammer

l Now, carefully take out the sleeve cylinder.

l Inspect the sleeve cylinder for any breakage, if

found any replace with new one. Fig. 3.147

NOTE
While reassembling, always ensure to
replace the ‘O’ rings on the sleeve cylinder
with the new one. (Fig. 3.148)

CAUTION
Remove the sleeve cylinder, only if you
need to replace. Unnecessary removal of
sleeve cylinder should be avoided,
otherwise can damage the sleeve cylinder
and piston with connecting rod.
Fig. 3.148
 SERVICE MANUAL
ENGINE

TRANSMISSION GEARS - SERVICING

Component : Drive shaft assembly and counter shaft assembly removal

Component condition : Component on workbench
Repair cycle : whenever required

Drive shaft assembly removal

l Take out the ball bearing (25 x 52 x 15).

(Fig. 3.149A)

l Take out the punched washer (29 x 17 x 1.5).

(Fig. 3.149B)

Fig. 3.149A Fig. 3.149B

l Take out the gear 1st driven. (Fig. 3.150A)

l Take out the needle bearing (20 x 24).

(Fig. 3.150B)

Fig. 3.150A Fig. 3.150B

l Take out the punched washer (29 x 20 x 1.5).

(Fig. 3.151A)

l Take out the 5th driven. (Fig. 3.151B)

Fig. 3.151A Fig. 3.151B

 SERVICE MANUAL
ENGINE

l Remove the circlip (25 x 12). (Fig. 3.152A)

Snap ring plier - External

l Take out the special washer (24 x 29 x 1.5).

(Fig. 3.152B)

Fig. 3.152A Fig. 3.152B

l Take out the gear 3th driven. (Fig. 3.153A)

l Take out the needle bearing (20 x 24).

(Fig. 3.153B)

Fig. 3.153A Fig. 3.153B

l Take out the gear 4th driven. (Fig. 3.154A)

l Take out the needle bearing (20 x 24).

(Fig. 3.154B)

Fig. 3.154A Fig. 3.154B

l Take out the special washer (24 x 29 x 1.5).
(Fig. 3.155A)

l Remove the circlip (25 x 12). (Fig. 3.155B)

Snap ring plier - External

Fig. 3.155A Fig. 3.155B

 SERVICE MANUAL
ENGINE

l Remove the 6th driven. (Fig. 3.156A)

l Remove the circlip (25 x 12). (Fig. 3.156B)

Snap ring plier - External

Fig. 3.156A Fig. 3.156B

l Take out the gear 3th driven. (Fig. 3.157A)

l Take out the special washer (24 x 29 x 1.5).

(Fig. 3.157B)

Fig. 3.157A Fig. 3.157B

l Take out the gear 2nd driven. (Fig. 3.158A)

l Take out the needle bearing (20 x 24).

(Fig. 3.158B)

Fig. 3.158A Fig. 3.158B

l Take out the special washer (24 x 29 x 1.5).
(Fig. 3.159A)

l Remove the circlip (52 x 20). (Fig. 3.159B)

Snap ring plier - External

Fig. 3.159A Fig. 3.159B

 SERVICE MANUAL
ENGINE

l Remove the circlip (25 x 12). (Fig. 3.160A)

Snap ring plier - External

l Remove the ball bearing (25 X 52 x 15from the

drive shaft. (Fig. 3.160B)

Fig. 3.160A Fig. 3.160B

Counter shaft

l Take out the ball bearing (25 x 52 x 15).

(Fig. 3.161A)

l Take out the 2nd driven. (Fig. 3.161B)

Fig. 3.161A Fig. 3.161B

l Take out the gear 6th driven. (Fig. 3.162A)

l Take out the needle bearing (18 x 22).

(Fig. 3.162B)

Fig. 3.162A Fig. 3.162B

l Take out the special washer (22 x 28 x 1.5).
(Fig. 3.163A)

l Remove the circlip (21 x 1.2). (Fig. 3.163B)

Snap ring plier - External

Fig. 3.163A Fig. 3.163B

 SERVICE MANUAL
ENGINE

l Take out the gear 3rd and 4th driven.

(Fig. 3.164A)

l Remove the circlip (21 x 1.2). (Fig. 3.164B)

Snap ring plier - External

Fig. 3.164A Fig. 3.164B

l Take out the special washer (22 x 28 x 1.5).

(Fig. 3.165A)

l Take out the gear 5th driven. (Fig. 3.165B)

Fig. 3.165A Fig. 3.165B

l Take out the needle bearing (18 x 22).

(Fig. 3.166A)

l Remove the ball bearing (25 x 52 x 15) from the

counter shaft. (Fig. 3.166B)

Fig. 3.166A Fig. 3.166B

 SERVICE MANUAL
ENGINE

ENGINE COMPONENTS - INSPECTION

Component : Bearing, oil seal, crankshaft and balancer shaft - inspection

Component condition : Component on workbench
Repair cycle : whenever required

Bearing, oil seal, crankshaft and balancer shaft-

inspection

Bearing PLAY PLAY

l Wash bearings with a cleaning solvent and

lubricate with engine oil before inspecting.

l Inspect play of each bearing before fixing it.

Hold inner race and rotate the outer race by
hand and observe for any abnormal noise and
smooth rotation. Replace bearing with a new
one if found defective. (Fig. 3.167)

NOTE
Fig. 3.167
Do not use compressed air to clean the
bearings.

Oil seal

l Damage to the oil seal lip (A) may result in

leakage of oil. Inspect for damage and always
replace damaged oil seals with the new ones.
A
(Fig. 3.168)

Crankshaft assembly - Runout

Fig. 3.168
l Support crankshaft assembly with ‘V’ blocks of
anvil. Mount the dial indicator at positions
shown to read the runout. Runout should be
within the service limit. (Fig. 3.169)

l Excessive runout of crankshaft assembly

causes abnormal engine vibration and bearing
noises. Such vibration shortens engine life.

V - block set (4“x3“x3“)

Dial gauge (1/100 mm)

Magnetic stand

Service limit 0.1 mm (max) Fig. 3.169

 SERVICE MANUAL
ENGINE

l Using a special tool, measure the diameter of

the crankshaft main bearing. Replace the
bearing with new one if the measurement
exceeds the service limit. (Fig. 3.170)

Vernier caliper
Illustration
Service limit 0.000 mm (max)

Fig. 3.170

l Measure the thickness of bearing groove shell

as shown. (Fig. 3.171)

If the thickness measured is less then the

service limit, replace the bearing groove shell
with new one.
Illustration
Micrometer

Service limit 0.000 mm (max)

Fig. 3.171

l Measure the thickness of bearing shell as

shown. (Fig. 3.172)

If the thickness measured is less then the

service limit, replace the bearing shell with
new one.
Illustration
Micrometer

Service limit 0.000 mm (max)

Fig. 3.172
 SERVICE MANUAL
ENGINE

Balancer shaft

l Inspect the balancer shaft for any twist or

bend. If found any replace the balancer shaft
assembly. (Fig. 3.173)
Illustration

Fig. 3.173

l Using a special tool, measure the diameter of

the balancer shaft bearing. Replace the bearing
with new one if the measurement exceeds the
service limit. (Fig. 3.174)

Vernier caliper
Illustration
Service limit 0.000 mm (max)

Fig. 3.174

l Measure the thickness of bearing shell as

shown. (Fig. 3.175)

l If the thickness measured is less then the

service limit, replace the bearing shell with
new one.
Illustration
Micrometer

Service limit 0.000 mm (max)

Fig. 3.175
 SERVICE MANUAL
ENGINE

ENGINE COMPONENTS - INSPECTION

Component : Guide cam chain and crankcase assembly step 1 upper - inspection
Component condition : Component on workbench
Repair cycle : Whenever required

Guide cam chain

l Inspect the guide cam chain for any distortion /

damage, cuts or crack. If found any, replace the
guide with new one. (Fig. 3.176)

Crankcase assembly step 1 upper

Fig. 3.176
l Measure the crankcase assembly step 1 upper
ID (bore) using the bore gauge. crankcase
assembly step 1 upper should be checked in
two axis with reference to the cylinder axis at
three locations as shown in the figure.
(Fig. 3.177 & Fig. 3.177)

l If the wear exceeds the service limit, replace

the crankcase assembly step 1 upper or
rework the cylinder to next oversize by using a
boring machine. The cylinder must be honed
after boring.

l The crankcase assembly step 1 upper are

manufactured with slightly increasing
diameters which are all identified with their
respective colour and codes as below:
Fig. 3.177
Size Code / Standard Service limit
Colour (in mm) (in mm)
- A 00.000 ~ 00.000
- B 00.000 ~ 00.000 00.000 ~ 00.000
- C 00.000 ~ 00.000
1st OS 00.00
2st OS 00.00

00 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 to the next
oversize or replaced. Fig. 3.177
 SERVICE MANUAL
ENGINE

PISTON AND CONNECTING ROD - SERVICING

Component : Piston and connecting rod

Component condition : Component on workbench
Objective : Piston and connecting rod removal / replace
Repair cycle : Whenever required

Piston and connecting rod removal / replace

l Remove the piston along with connecting rod

and piston rings as explained in pervious page.

l Remove the circlip pin piston from any one side

of the piston. (Fig. 3.178)

Nose plier

Fig. 3.178

l Gently, push and take out the piston pin from

the piston and then remove the piston along
with the rings. (Fig. 3.179)

Fig. 3.179

l Remove the shell bearing from the connecting

rod cap. (Fig. 3.180)

Nose plier

Fig. 3.180
 SERVICE MANUAL
ENGINE

Installation

l Using a special tool, install the circlip pin piston

to the piston. (Fig. 3.181)

Special tool

l Reassemble the parts in the reverse order of

removal.

Piston - Inspection Fig. 3.181

l Remove the piston ring top (1st) (A), piston ring

2nd (B) and piston ring oil (oil rings) (C).
(Fig. 3.182) A
B
C
CAUTION
Do not expand the rings more, it may lose
its mechanical properties.

l Decarbonise the piston and piston ring groove.

(Fig. 3.183)

l After cleaning the grooves, fit the rings and Fig. 3.182

rotate them in their respective grooves to
make sure that they rotate freely.

l Carbon in the grooves is liable to cause the

rings piston to stuck in the grooves, and this
will lead to reduced engine power output.

NOTE
While cleaning the ring grooves of the
piston, ensure not to damage the grooves.
Use an old broken ring to clean the
grooves.
Fig. 3.183
l If a piston sliding surface is badly scored or
scuffed due to overheating, it must be
replaced. Shallow grooves or minor scuff can
be removed by smoothening with a fine emery
paper (400 grade). (Fig. 3.185) Inspect the
piston for damage or crack. Replace if required.

l Measure the diameter at right angle to the pin

piston and at a point which is 10 mm from the
bottom to check wear. If the diameter is lower
than the service limit, replace the piston.
(Fig. 3.185)

Outside micrometer
Fig. 3.185
 SERVICE MANUAL
ENGINE

Size Code / Standard Service limit

Colour (in mm) (in mm)
- A 00.000 ~ 00.000
- B 00.000 ~ 00.000 00.000 ~ 00.000
- C 00.000 ~ 00.000
1st OS 00.00
2st OS 00.00

l Cylinder to piston clearance is the difference 00 mm

between piston diameter and bore diameter.

l Check the pin piston bore ID of piston for wear

out. (Fig. 3.186) Fig. 3.186

Inside micrometer

Service limit 00.000 mm (max)

Piston pin

l Check the piston pin OD using a micrometer.

(Fig. 3.103) If the reading exceeds the service
limit, replace the pin piston. Otherwise, the pin
may create unwanted noise. (Fig. 3.187)
Dia
Outside micrometer
Fig. 3.187
Service limit 00.000 mm (min)

Piston rings

l Inspect the piston rings for distortion, it will

cause the rings to stick or roll in the grooves.
Replace the distorted rings.

l As the rings wear out, its end gap increases

resulting in reduced engine power output.

l The rings (Top and 2nd) closed end gap should

be checked to assess the serviceability of the
ring piston. Fig. 3.188

l Install the ring in the crankcase assembly step

1 upper, using the piston, push the ring into the
crankcase assembly step 1 upper bore at 20
mm from the bottom. This will make the ring to FEELER GAUGE
seat squarely in the crankcase assembly step 1 RING PISTON
upper. Using a feeler gauge measure the close
end gap. (Fig. 3.189)

l If the gap exceeds the limit, replace rings with

new ones.

Feeler gauge

Service limit 00.000 mm (max) Fig. 3.189

 SERVICE MANUAL
ENGINE

l To know the service condition of the ring,

check the free end gap using a vernier caliper.
(Fig. 3.190)

Vernier caliper

Service limit (1st) 0.0 mm (max)

Service limit (2st) 0.0 mm (max)

REASSEMBLY
Fig. 3.190
l Assemble the separator oil ring (spacer - 3rd
ring) locating its end gap towards inlet side of
the piston at 60 degree to the left bottom from
the center as shown. (Fig. 3.191)

NOTE
Ring illustration
Assemble the separator oil ring in such a
way that its triangle shaped end (Fig. 3.107)
faces upwards (triangle facing towards
piston top).

Fig. 3.191
l Assemble the oil ring bottom (bottom rail - 5th
ring) locating its end gap towards inlet side of
the piston at 30 degree to the right top from the TOWARDS UP
center as shown. (Fig. 3.106)

l Assemble the oil ring top (top rail - 4th ring)

locating its end gap towards exhaust side of
the piston at 30 degree to the right bottom
from the center as shown. (Fig. 3.106)

SEPARATOR OIL RING (SPACER)

l Assemble the piston ring 2nd, by locating its
end gap at 120 degree to the right from the
center of the piston inlet side as shown. Fig. 3.107
(Fig. 3.108)

Assemble the piston ring 1st, by locating its

end gap towards the center of the piston inlet
side as shown. (Fig. 3.108)

NOTE Ring illustration

Avoid damage to the piston skirt surface

and rings piston during installation.

Before installing the piston, the rings

should rotate freely in their respective
grooves. Fig. 3.108
 SERVICE MANUAL
ENGINE

NOTE
Install the piston ring 1st and piston ring
2nd with the marking on the ring ‘TOP1’
and ‘TOP2’ (Fig. 3.193) facing up (mark
facing towards piston top).

CAUTION
Always assemble the spacer first. Because
this will accommodate the oil rails.

Fig. 3.193

l Assemble the piston in such a way that the

arrow mark indicated in the piston crown faces
towards the exhaust port of the cylinder.
(Fig. 3.200) ARROW MARK

l While installing the cylinder block, slightly

lubricate the inner wall of the cylinder with
fresh 4T oil.

l Reassemble the parts carefully in the reverse

order of removal.

Fig. 3.200
l Ensure that the transmission is in sixth gear
and align the TDC mark on rotor assembly with
centre of the inspection hole (A) provided in the
cover magneto by rotating the rotor assembly.
(Fig. 3.201) A

l Assemble the sprockets along with the cam

chain in the camshaft exhaust assembly and
camshaft intake assembly while aligning the
crankshaft until the ‘EX’ mark on exhaust side
(A) and ‘IN’ mark on the intake side (B) align
with the edge of cylinder head assembly.
(Fig. 3.202)
Fig. 3.201
l Set the tappet clearance as explained in
chapter “Periodic maintenance” page no. 2-12.

l Reassemble the parts in the reverse order of B

dismantling.
A
l Assemble the spark plug and ignition coil.

l Re-fill the engine cum transmission oil as

explained in chapter “Periodic maintenance”
page no. 2-3 and ensure it level.

Fig. 3.202
 SERVICE MANUAL
ENGINE

CRANKCASE AND GEAR BOX REASSEMBLY

Component : Crankcase and gear box reassembly

Component condition : Mounted on engine stand
Objective : Crankcase and gear box reassembly
Repair cycle : Whenever required

Crankcase and gear box reassembly

l Remove the gasket material if any on the

matching surface of the crankcase assembly
step 1 upper & lower and throughly remove oil
stains.

l Before installing sleeve assembly, inspect

properly for any damage. (Fig. 3.203)

CAUTION
Always recommended to replace the Fig. 3.203
‘O’ ring on the liner with new one.

l Assemble the sleeve on the crankcase

assembly step 1 upper. (Fig. 3.204)
A
NOTE
W h i l e a s s e m b l i n g e n s u re t h a t t h e
crankcase assembly step 1 upper hole (A)
align with sleeve lubrication slip.

Make sure sleeve liner should match with

the coolant jack hole
Fig. 3.204
l Using wooden plank, gently tap to install the
sleeve assembly on the crankcase assembly
step 1 upper. (Fig. 3.205)
A
Nylon hammer

Fig. 3.205
 SERVICE MANUAL
ENGINE

l Assemble the shell bearing balancer shaft (A)

(2 Nos.) and shell bearing crankshaft (B)
(2 Nos.) on the crankcase assembly step 1 A
upper. (Fig. 3.206)

A B
Nose plier

NOTE B
Check the colour marking on the shell
bearing. Ensure that the shell bearing is on
same colour during assembly. Failure of
mismatching colour it may lead to damage Fig. 3.206
the engine. Refer engine service data for
more details.

l Using a special tool, assemble the piston with

connecting rod assembly on the crankcase
assembly step 1 upper. (Fig. 3.207)

Piston rings compression tool

NOTE
Before assembling the piston, make sure
piston rings are properly assembled with
piston. Fig. 3.207

l Assemble the he jet oil spray nozzle (M0x00 -

1 No.) from the crankcase assembly step 1
upper mounting. (Fig. 3.208)

6mm Allen key

Tightening torque 15 ± 2 Nm

Fig. 3.208
l Assemble the crankshaft assemble on the
crankcase assembly step 1 upper. (Fig. 3.209)

NOTE
Do not hit the crankshaft with force while
reassembling.

Fig. 3.209
 SERVICE MANUAL
ENGINE

l Set the piston to TDC position and assemble

the connecting rod cap bolts (M8x32.6 - 2 Nos.)
on the piston assembly mounting. (Fig. 3.210)

8mm Spanner

Pre tightening torque 10±1.5 Nm

Main tightening torque 45°

Final tightening torque 90°

Final torque 47~66 Nm Fig. 3.210

NOTE
Check the connecting rod cap shell bearing
for any worn-out or cracks on the surface
during assemble.

Make sure that the mark on the connecting

rod and connecting rod cap are aligned
properly.

l Assemble the balancer shaft and crankshaft A

assemble on the crankcase assembly step 1
upper. (Fig. 3.211)

NOTE
Ensure that the balancer shaft and
crankshaft gears (A) are properly aligned. Fig. 3.211

CAUTION
Check the colour marking on the shell
bearing. Ensure that the shell bearing is on
same colour during assembly. Failure of
mismatching colour it may lead to damage
the engine. Refer engine service data for
more details. B

l Assemble the balancing shaft (A) and oil pump

derive pin (B) on the balancer shaft assembly.
(Fig. 3.212)
A
Nose plier

NOTE Fig. 3.212

Ensure the proper seating of the oil pump
derive pin of the balancing shaft in the
balancer shaft assembly.
 SERVICE MANUAL
ENGINE

l Assemble the counter shaft assembly and

drive shaft assembly as a set on the crankcase
assembly step 1 upper. (Fig. 3.213)

NOTE
Ensure that the drive shaft and counter
shaft bearing circlips are properly seated
on the crankcase assembly step 1 upper
grooves.

Fig. 3.213

l Once again check either that the counter shaft

assembly (A), drive shaft assembly (B),
B
crankshaft assembly (C) and balancer shaft (D)
A
are properly assembled on the crankcase
assembly step 1 upper in the following
manner. (Fig. 3.214) D

NOTE C
Apply liquid gasket on the crankcase
assembly step 1 upper alone. While
applying glue take care of the oil hole
present in the path of sealing face. Fig. 3.214

Liquid sealant Dow corning D3100

l Assemble the cam gearshift (A) and tighten the A

fixing bolt cam gear shift (B) on the crankcase B
assembly step 1 lower. (Fig. 3.215)

l Assemble the fork gearshift No.1 (A) (2 Nos.) Fig. 3.215

and fork gearshift (B) No.2 on the grooves of
cam gearshift. (Fig. 3.216)

l Assemble both shaft gearshift forks (C) and on

the shaft gearshift forks along with the fork
A B
gearshift No.1 (2 Nos.) and fork gearshift No.2
on the crankcase assembly step 1 lower.
(Fig. 3.216)

NOTE
Two different types of shift forks are used C
in the gear shifting system of this engine.
Ensure that proper fork at right location.
Fig. 3.216
 SERVICE MANUAL
ENGINE

l Carefully assemble the crankcase assembly

step 1 upper on the crankcase assembly step 1
lower. (Fig. 3.217)

l Using nylon hammer gently tap on the

crankcase assembly step 1 upper for easy
assemble of crankcase assembly step 1 lower
along with the cam gear shift assembly,
adaptor oil fill and switch gear position.

Nylon hammer

Fig. 3.217
l Assemble and tighten the bolt (M9x95 -
4 Nos.) of the crankcase assembly step 1 lower
mounting. (Fig. 3.218)

13mm Spanner

Pre tightening torque 10 ± 1.5 Nm

Main tightening torque 90° ± 3°

NOTE
Tighten the screws in crisscross pattern.
Fig. 3.218
l Assemble and tighten the hexagonal socket
cap flange bolt (M6x70 - 6 Nos.) of the
mounting of crankcase assembly step 1 lower.
(Fig. 3.219)

5mm Allen key

Tightening torque 0 ± 0 Nm

NOTE
Tighten the screws in crisscross pattern.

l Assemble and tighten the hexagonal socket Fig. 3.219

cap flange bolt (M6x40 - 3 Nos.) of the
mounting of crankcase assembly step 1 upper.
(Fig. 3.220)

5mm Allen key

Pre tightening torque 5 ± 0.75 Nm

Main tightening torque 10 ± 1.5

NOTE
Tighten the screws in crisscross pattern.
Fig. 3.220
 SERVICE MANUAL
ENGINE

l Assemble and tighten the hexagonal socket

cap flange bolt (M6x70 - 7 Nos.) of the
mounting of crankcase assembly step 1 upper.
(Fig. 3.221)

5mm Allen key

Tightening torque 0 ± 0 Nm

NOTE
Tighten the screws in crisscross pattern.
Fig. 3.221

l Assemble and tighten the hexagonal socket

cap flange bolt (M6x30 - 13 Nos.) of the
mounting of oil pan. (Fig. 3.222)

5mm Allen key

Tightening torque 10 ± 1.5 Nm

l Using nylon hammer gently tapping on the oil

pan to assemble the oil pan on the crankcase
assembly.

Nylon hammer Fig. 3.222

NOTE
Tighten the screws in crisscross pattern.

l Make sure to assemble the filter comp engine

oil with packing along with packing oil filter cap,
starter motor assemble, heat exchanger water
assemble, oil pump assemble, water pump
assemble, cylinder head assemble, magneto
cover and clutch cover in the order of removal
procedure.

l Assemble the tightening bolts and tighten in

specified torque.

CAUTION
While reassembling the magneto rotor on
the crankshaft assembly, ensure that there
is no oil trace on the taper surfaces of both
rotor and crankshaft. If found any, clean
them thoroughly with the cleaning solvent
before assembling them.
 SERVICE MANUAL
ENGINE

Valve timing and valve clearance

Valve timing

l Ensure that the transmission is in gear and A

align the TDC mark on rotor assembly with
centre of the inspection hole (A) provided in the
cover magneto by rotating the rotor assembly.
(Fig. 3.223)

Fig. 3.223

l Assemble the sprockets along with the cam

chain in the camshaft exhaust assembly and
camshaft intake assembly while aligning the
crankshaft until the ‘EX’ mark on exhaust side B
(A) and ‘IN’ mark on the intake side (B) align
with the edge of cylinder head assembly. A
(Fig. 3.224)

Fig. 3.224
valve clearance

l Adjust the valve clearance (tappet) to the

specified limit as explained in chapter “Periodic
maintenance” page no. 2-12.

l Before starting the vehicle, fill up the engine

cum transmission oil and carry out the other
adjustments and tunning of the engine as
prescribed in chapter “Periodic maintenance”.

Running-in after overhaul

l The re-built / overhauled engine should

undergo running-in.

l Do not over load the engine immediately after

overhaul as it may result in rapid wear of
components due to over straining, overheat
and overloading.

l This will have impact through out the life of the

rebuilt components resulting in under
performance of vehicle.
 SERVICE MANUAL
ELECTRICAL

DESCRIPTION PAGE NO Chapter 5

WIRE COLOUR CODE INDEX 3
EMS SYSTEM 5
EMS SYSTEM CHECKING PROCEDURE 8
IGNITION LOCK 8
ENGINE KILL SWITCH 9
PULSAR COIL 10
IGNITION COIL 12
SPARK PLUG 13
ENGINE CONTROL UNIT (ECU) 14
THROTTLE BODY 17
FUEL PUMP MODULE ASSEMBLY 20
OXYGEN SENSOR 21
THERMAL SENSOR 22
CANISTER PURGE VALUE 23

ELECTRICAL SYSTEM
MAIN RELAY / RELAY FUEL PUMP AND RADIATOR RELAY 24
RELAY SELF STARTER (STARTER RELAY) 26
GEAR POSITION SENSOR 27
QUICK GEAR SHIFTER SENSOR 29
SIDE STAND SWITCH 30
RELAY SELF STARTER 32
LIGHTING SYSTEM 33
LIGHTING / DC SYSTEM CHECKING PROCEDURE 36
SWITCH BEAM CONTROL CUM PASS-BY SWITCH 36
HORN LH AND RH 37
TURN SIGNAL LAMPS FRONT AND REAR 38
SWITCH ASSEMBLY STOP LAMP - FRONT & REAR 39
ELECTRIC STARTER SWITCH 40
CLUTCH SWITCH 41
CONTROL SWITCH 42
CRUISE CONTROL SWITCH 43
HAZARD SWITCH 44
HEAD LAMP ASSEMBLY FRONT 45
12V REGULATION SYSTEM CHECKING PROCEDURE 50
REGULATOR AND RECTIFIER (RR UNIT) 50
ABS SYSTEM CHECKING PROCEDURE 54
SENSOR WIRING COUPLER FRONT 54
SENSOR WIRING COUPLER REAR 58
 SERVICE MANUAL
ELECTRICAL

WIRE COLOUR CODE INDEX

S.NO. CODE WIRE COLOUR

01 BOr BLACK WITH ORANGE TRACER
02 BIB BLUE WITH BLACK TRACER
03 BrY BROWN WITH YELLOW TRACER
04 BrG BROWN WITH GREEN TRACER
05 BI BLUE
06 BV BLACK WITH VIOLET TRACER
07 BP BLACK WITH PINK TRACER
08 BIG BLUE WITH GREEN TRACER
09 BR BLACK WITH RED TRACER
10 Br BROWN
11 BrR BROWN WITH RED TRACER
12 BW BLACK WITH WHITE TRACER
13 BLg BLACK WITH LIGHT GREEN TRACER
14 BLbl BLACK WITH LIGHT BLUE TRACER
15 BIBr BLUE WITH BROWN TRACER
16 BlY BLUE WITH YELLOW TRACER
17 BIGr BLUE WITH GRAY TRACER
18 GY GREEN WITH YELLOW TRACER
19 G GREEN
20 GR GREEN WITH RED TRACER
21 GGr GREEN WITH GRAY TRACER
22 GV GREEN VOILET
23 GrP GRAY WITH PINK TRACER
24 GBr GREEN WITH BROWN TRACER
25 Lg LIGHT GREEN
26 LgBI LIGHT GREEN WITH BLUE TRACER
27 LblR LIGHT BLUE WITH RED TRACER
28 LBIGr LIGHT BLUE WITH GRAY TRACER
29 LgR LIGHT GREEN WITH RED TRACER
30 LBIG LIGHT BLUE WITH GREEN TRACER
31 OrY ORANGE WITH YELLOW TRACER
32 OrBr ORANGE WITH BROWN TRACER
33 OrGr ORANGE WITH GREY TRACER
34 OrR ORANGE WITH RED TRACER
35 Or ORANGE
36 OrB ORANGE WITH BLACK TRACER
37 OrBI ORANGE WITH BLUE TRACER
 SERVICE MANUAL
ELECTRICAL

WIRE COLOUR CODE INDEX

S.NO. CODE WIRE COLOUR

38 OrG ORANGE WITH GREEN TRACER
39 OrP ORANGE WITH PINK TRACER
40 OrW ORANGE WITH WHITE TRACER
41 PGr PINK WITH GREY TRACER
42 PW PINK WITH WHITE TRACER
43 POr PINK WITH ORANGE TRACER
44 PB PINK WITH BLACK TRACER
45 PLg PINK WITH LIGHT GREEN TRACER
46 PV PINK WITH VIOLET TRACER
47 PLbl PINK WITH LIGHT BLUE TRACER
48 PBI PINK WITH BLUE TRACER
49 PBr PINK WITH BROWN TRACER
50 R RED
51 RB RED WITH BLACK TRACER
52 RBI RED WITH BLUE TRACER
53 ROr RED WITH ORANGE TRACER
54 RP RED PINK
55 RW RED WITH WHITE TRACER
56 V VIOLET
57 VB VIOLET WITH BLACK TRACER
58 VW VIOLET WITH WHITE TRACER
59 VG VIOLET GREEN
60 VBI VIOLET WITH BLUE TRACER
61 VGr VIOLET WITH GREEN TRACER
62 VOr VIOLET WITH ORANGE TRACER
63 VY VIOLET YELLOW
64 W WHITE
65 Wbr WHITE WITH BROWN TRACER
66 WOr WHITE WITH ORANGE TRACER
67 WY WHITE WITH YELLOW TRACER
68 WLg WHITE WITH LIGHT GREEN TRACER
69 WBI WHITE WITH BLUE TRACER
70 YW YELLOW WITH WHITE TRACER
71 YB YELLOW WITH BLACK TRACER
72 YR YELLOW WITH RED TRACER
 SERVICE MANUAL
ELECTRICAL

TVS Apache RTR 310 electrical system is divided into four basic systems (circuits) named:

1. EMS / Electric starter (ES) circuit 2. DC / Lighting circuit 3. Strater circuit / ABS circuit

EMS SYSTEM

The EMS system of the Apache RTR 310 consists of engine control unit (ECU), battery, 3-phase magneto assembly,
fuses, ignition lock, battery, engine kill switch, main relay, relay fuel pump, fuel pump module, ignition coil, fuel
injector, purge valve, O2 sensor, throttle body, manifold absolute pressure and air temperature sensors (MAP),
throttle position sensor (TPS), Gear position sensor, Side stand switch, Clutch switch, electric starter switch, spark
plug and diagnostic coupler, GPS sensor coolant temperature sensor, shift assets sensor and speedometer.

The output from the pulsar coil is directly connected to the ECU and the output from the magneto assembly is
supplied to the regulator for regulation and rectification purpose, the output of the regulator is supplied to the
following :-

1. Ignition lock
2. HECU (10A & 15A)
3. EFI relay through EMS / Speedo (7.5A)
4. Telematic unit
5. Relay fan through fuse fan radiator (7.5A)
6. Battery through Main fuse(30A)

One part is connected to ignition lock. and the ignition lock is supplied to lightening DC circuit and another part is
supplied to EFI / SPEEDO / USB CHARGER.

Second part is supplied to the HECU unit through the fuse (10A & 15A) for the functioning of ABS system.

The third part is supplied to EFI relay (Main relay) through fuse EMS / speedo (7.5A) and the ECU get power supply
from the EFI relay, The negative supply (ground) required by the EFI relay (main relay) is supplied by the ECU based
on the input signals from ignition key and engine kill switch.

Fourth part is supplied to the telematic unit for controls the wireless tracking, diagnostics and communication from
the vehicle.

Fifth part is supplied to the relay fan through fuse fan radiator (7.5A).then based on the ecu signal the power will
supply to the fan radiator since fan radiator is directly connected to the ground it will get starts.

sixth part is supplied to the battery through the main fuse (30A) for charging purpose. Since the battery is already
grounded, the battery gets charged.

The output from the ignition lock is also divided and supplied to the following:

1. ECU
2. IMU
3. Diagnostic coupler
4. Mobile charger
5. Relay fuel pump
6. HECU
7. Speedo meter
 EMS CIRCUIT
WY

ECU
BrR
TO STARTER STARTER RELAY WLg
PULSAR TO TELEMATIC UNIT
RELAY W W
COIL
PULSAR COIL I/P (+) Br Br MAIN FUSE (30A)
RBI RBI R
APS PULSAR COIL (-) Br TO RELAY
Br
Br Br REGULATOR TARTER
BOr VG Br BW RBI RBI RBI RBI
BIG PEDAL POSITION SENSOR 1
FUSE FUSE R
BLg PEDAL POSITION SENSOR 2 FUSE EMS / FUSE FAN
HECU HECU
SPEEDO (7.5A) RADIATOR (7.5A)
GR VBI Br (10A) (15A)
RBI RBI

IGNITION BW
SERVICE MANUAL

ES SWITCH MAGNETO ASSEMBLY ROr OrY OrBI YW + -

LOCK TO HECU
BIB WLg ON BATTERY
ES SWITCH I/P FUSE (20A) LIGHTING / FUSE (10A) EFI / TO HECU TO HECU
SPEEDO / USB CHARGER 8Ah MF
DC CIRCUIT
BrY Or OrB OrB OrGr OrGr OrGr
KILL SWITCH I/P
TO LIGHTING /
DC CIRCUIT
KILL SWITCH IGNITION KEY

FUEL PUMP RELAY OrBI

OrG
CAN LOW
RB
CAN HIGH BW BW
ETC WY RP BW
PGr
WY WLg BrG
BLg TPS 1 WY OrGr
WLg OrGr OrGr OrBr PLg RP
PLbl TPS 2 OrG
IMU MOBILE
GGr ETC (-) DIAGNOSTIC RELAY FUEL EFI RELAY RELAY FAN M
OrGr CHARGER
COUPLER PUMP 35A 35A 35A FAN
GR ETC (+) RADIATOR
RGr MAIN RELAY DRIVER OrG OrG
POWER SUPPLY TO RELAY
STARTER
RADIATOR FAN RELAY
BR
CANISTER PURGE OrBI
IGNITION DRIVER 1 BLbl
INJECTOR DRIVER

O2 SENSOR HEATER BW
O2 SENSOR GROUND OrBr
ENGINE
O2 SENSOR SUPPLY
GROUND
POr
MAP VB OrG PW OrG BI BLbl PBI OrG
AIR TEMP SENSOR SENSOR
BW
MAP SENSOR PBr VW PLg OrG
SENSOR SUPPLY 2 BIG FUEL IGNITION VALVE FUEL PUMP
O2 SENSOR INJECTOR COIL PURGE MODULE
SENSOR GND 2
BOr
GY
ETS
SENSOR GND 1

SIDE STAND SWITCH 2

SIDE STAND SWITCH 1

GPS OrBI
FUEL SENSOR BATTERY
SENSOR SUPPLY 1 OrGr
BW
IGNITION
POWER GROUND 1
BIBr
WBr CAN LOW
CLUTCH SWITCH
BIBr BOr GR BLg BLg BLg PB CAN HIGH
QUICK SHIFT SENSOR VY WOr
BW PV
BR
POWER GROUND 2 BIG CLUTCH
SWITCH GPS SPEEDO WLg
BOr

GR SHIFT ASSIST SIDE STAND COOLANT TEMPERATURE TO HECU

SENSOR SWITCH SENSOR
BLg
BIG
WY

BOr TO HECU
ELECTRICAL
 SERVICE MANUAL
ELECTRICAL

One part is supplied to the ECU to determine the ignition lock 'ON/OFF' position.

Another part is connected to the loads fuse (30A), which is utilised for lighting and other DC purposes.

Third part is supplied to Diagnostic coupler communicates with the ECU with the help of CAN high and CAN low
wires. An output from the ECU is given to the diagnostic coupler called as test switch input for diagnostic purpose.

Forth part is supplied to mobile charger for charging purpose, since it is directly connected to ground.

Fifth part is supplied to Relay fuel pump and based on the ECU input signal its send the signal to fuel pump module,
since it is directly connected to ground it will get starts. Then the fuel pump module send the signal to speedo meter
for fuel level indication, since its directly connected to ground.

Sixth part of output of the ignition lock is supplied to the HECU to determine the ignition lock 'ON/OFF' position.

Another part is supplied to the digital speedometer for its memory purpose, to retain data such as date, time and etc.

Side stand sensor position to be checked before supplying power to ignition system. On receipt of engine kill switch
output (OFF condition in run position) main relay is switched OFF by ECU only when ignition key is OFF. The ECU
supplies the negative input to the main relay and the relay gets energized.

On receipt of the ignition lock input, the ECU sends the input voltage to the kill switch, Accelerator position sensor
(APS), Shift assist sensor, MAP sensor, O2 sensor, gear position sensor (GPS) and the side stand switch.

The APS, MAP sensor, O2 sensor & heater. quick shift assist sensor coolant temperature sensor and GPS get ground
supply also from ECU directly.

On receipt engine kill switch output (ON condition), the ECU supplies the negative input to the EFI relay and the relay
gets energised. The output from the EFI relay is connected to the ignition coil, fuel injector, valve purge, O2 sensor,
relay starter motor and relay fuel pump (two inputs).The main relay output is also connected to the ECU for its
understanding.

Based on the modes (URBAN, SPORTS and RAIN), the ECU determines the input from the APS and amount of
throttle open from TPS, manifold absolute pressure and temperature of intake air from MAP sensor, temperature of
engine from ETS and the condition of air fuel mixture from O2 sensor. Based on these inputs, the ECU connects the
ground to the purge valve and fuel injector whenever is required. So, the fuel injector and the purge valve actuates
accordingly.

Based on the APS, TPS, MAP, ETS and O2 sensor inputs, an ignition signal is supplied to the ignition coil from ECU
whenever required. Since the ignition coil is given with positive supply from EFI relay and the signal from ECU, it
supplies the high energy voltage to the spark plug whenever required and the spark plug produces the spark.

An input from the ECU is connected to the speedometer from ECU for the indication of EMS system malfunction.

CAN High and Low wires are connected between the ECU, speedometer, HECU and diagnostic coupler for
communication purpose. Similarly, an output from fuse loads is connected to the diagnostic coupler for power input.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Ignition lock

Component condition : Vehicle on ramp
Objective : Ignition lock checking procedure (with pocket tester)
Repair cycle : Whenever required

Ignition lock

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l The ignition lock is mounted on the cover fuel

tank assembly front. (Fig. 5.1)

l Disconnect the coupler of ignition lock from

the main wiring harness and inspect the
Fig. 5.1
ignition lock for continuity with the pocket
tester (multimeter). (Fig. 5.2)

Pocket tester

LOCK POSITION 2RBI 2OrB

OFF O O
ON O O

l Replace the ignition lock if there is no

continuity found in ignition lock ‘ON’ position.

CAUTION Fig. 5.2

Do not stretch the wires too much as it may
damage the wiring harness, which might
result in replacement of the wiring
harness.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Engine kill switch

Component condition : Vehicle on ramp
Objective : Engine kill switch checking procedure (with pocket tester)
Repair cycle : Whenever required

Engine kill switch

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Engine kill switch cum electric starter switch

and APS is located at the right side of the
handle bar assembly on the switch assembly
handle RH. (Fig. 5.3)

l Turn ‘ON’ the ignition and carefully disconnect

the switch assembly handle RH coupler from
the main wiring harness and inspect the
engine kill switch for continuity with a pocket
tester (multimeter).

Pocket tester Fig. 5.3

LOCK POSITION BOr BrY

OFF O O
ON O O

l Replace the grip complete throttle electronic

assembly handle RH as a set if there is no
continuity.

CAUTION
Do not stretch the wires too much as it may
damage the wiring harness, which might
result in replacement of the wiring
harness.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Electric starter switch

Component condition : Vehicle on ramp
Objective : Electric starter switch checking procedure
Repair cycle : Whenever required

Electric starter switch

l Switch electric starter is located at the bottom
side of switch assembly RH on the right hand
side of the handle bar. (Fig. 5.4)

l Inspect the switch for continuity using a pocket

tester with the engine kill switch is in ‘ON’.

l Set the pocket tester at voltage position.

Pocket tester

SWITCH POSITION BrY Bor

PRESS - ON O O
RELEASE - OFF O O
Fig. 5.4
l If there is no continuity is found, replace the
switch assembly RH as a set.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Pedal position sensor (APS)

Component condition : Vehicle on ramp
Objective : Pedal position sensor checking procedure (with pocket tester)
Repair cycle : Whenever required

Pedal position sensor (APS)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l APS cum Engine kill switch and electric starter

switch is located at the right side of the handle
bar assembly on the switch assembly handle
RH. (Fig. 5.5)

l Turn ‘ON’ the ignition and carefully disconnect

the switch assembly handle RH coupler from
the main wiring harness and inspect the pedal
position sensor for continuity with a pocket
tester (multimeter).
Fig. 5.5
Pocket tester

LOCK POSITION BOr BrY

OFF O O
ON O O

l Replace the grip complete throttle electronic

assembly handle RH as a set if there is no
continuity.

CAUTION
Do not stretch the wires too much as it may
damage the wiring harness, which might
result in replacement of the wiring
harness.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Pulsar coil / Stator assembly (starter generator)

Component condition : Vehicle on ramp
Objective : Pulsar coil / Stator assembly checking procedure (with pocket tester)
Repair cycle : Whenever required

Pulsar coil

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Disconnect the pulsar coil coupler socket from

the main wiring harness. (Fig. 5.6)

l Set the pocket tester at Ohms position.

Fig. 5.6
Pocket tester

l Connect the pocket tester ‘+ve‘ lead to the

white wire (W) of pulsar coil and ‘–ve‘ lead to
the brown wire (Br) of pulsar coil.(Fig. 5.7)
0.000
l Measure the resistance. If the resistance
measured is not within the specified limit,
replace pulsar coil with a new one.
A V

Pulsar coil (Br - W) 104 ~ 156 Ohms at 25° C

l Connect TVS Ride Scan Tool and run diagnosis

to check the pulsar coil performance.
Fig. 5.7
 SERVICE MANUAL
ELECTRICAL

Stator assembly (starter generator)

l Since there is a 3 phase magneto assembly

used in this vehicle, the stator assembly
checking procedure is entirely different from
other vehicles. The resistance of the stator
assembly is to be checked between all the
t hree faces. Follow the procedure given
bellow:

l Carefully disconnect the starter generator

coupler from the main wiring harness.
(Fig. 5.8)

NOTE
Since the reading will be in milli Ohms,
special pocket tester (multimeter) should
be used to measure the resistance
between phase. (Fig. 5.9)

l Set the pocket tester knob at Ohms position.

Pocket tester
Fig. 5.8
l There are three brown wire (Br) coming out of
the stator assembly. Connect the pocket tester
‘+ve’ lead to the first brown (Br) wire and ‘-ve’
lead to the second brown (Br) wire and 0.000
measure the resistance.

l Similarly, check the resistance between the

second and the third brown wires. Also the
third and the first brown wires. If any one A V

phase resistance is not within the limit, replace

the magneto stator assembly with a new one.

Resistance across
0.19 ohms at 20%
any two phase Fig. 5.9

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Ignition coil assembly

Component condition : Vehicle on ramp
Objective : Ignition coil assembly checking procedure (with pocket tester)
Repair cycle : Whenever required

Ignition coil

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.
A
l Remove the fuel tank assembly. Refer chapter
“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.
B
l The ignition coil is mounted on top of the
cylinder head assembly (A). (Fig. 5.10)

l Pull the lock and carefully disconnect the

wiring socket of ignition coil from the main
Fig. 5.10
wiring harness (B). (Fig. 5.10)

l Set the pocket tester at Ohms position.

Pocket tester
0.000
l Connect the Pocket tester’s ‘+ve’ and ‘-ve’ lead
to the terminals of the ignition coil coupler as
shown to measure the primary winding
A V

resistance. If the resistance is not within the

specified limit, replace the ignition coil
assembly with a new one. (Fig. 5.11)

Primary resistance Milli ohms<=870

Fig. 5.11

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Spark plug

Component condition : Vehicle on ramp
Objective : Spark plug checking procedure
Repair cycle : Replace spark plug at every 20000 km.

Spark plug

Replace spark plug at every 20000 km.

l Neglecting the sparkplug leads to poor

performance of the engine. If the sparkplug is
used for a longer period, the electrodes
gradually burn away and carbon builds up along
the inside part (refer chapter ”periodic
maintenance” page no. 2-0 for replacement of
the spark plug).

l In case of any deterioration in performance of

the engine, replace the spark plug with a new
one.(Fig. 5.12). (refer chapter “periodic
maintenance” page no. 2-0 for details of
sparkplug cleaning and gap adjustment).

CAUTION Fig. 5.12

Always use recommended make and type
of spark plug only.

Spark plug NGK (LMAR9D - J)

 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Engine control unit (ECU)

Component condition : Vehicle on ramp
Objective : Engine control unit (ECU) checking procedure
Repair cycle : Whenever required

Engine control unit (ECU)

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l The engine control unit (ECU) is placed at the

LH side of the vehicle and it mounted on the
sub frame front. (Fig. 5.13)

l ECU can be checked by using a diagnostic tool.

Refer chapter “Diagnostic procedure” for the
diagnostic tool usage procedure.

CAUTION
ECU should be removed only in case of
r e p l a c e m e n t a f t e r p e r f o rm i n g a l l
diagnostic procedure. Fig. 5.13

Care should be taken not to drop the ECU

during its removal / reassembly. In case
ECU is dropped then, it should be replaced
with a new one.

l Carefully dislocate the wiring harness from the A

ECU bracket slot (A). (Fig. 5.14)

NOTE
Ensure to re-fix the wiring harness in its
location without fail during reassembly.
Fig. 5.14
 SERVICE MANUAL
ELECTRICAL

l Gently cut the cable strap on the ECU bracket

at 3 places (3 Nos.) and dislocate the wiring
harness from its routing. (Fig. 5.15)

NOTE
While reassembling, ensure to re-fix the
wiring harness on the ECU bracket with
new cable strap without fail.

Fig. 5.15

l Remove the shoulder bolt (M5 - 3 Nos.) from

the mounting of ECU bracket. (Fig. 5.16A & B)

5mm Spanner

Tightening torque 6 ± 1 Nm

l Now, slightly pull down and dislocate the ECU

mounting bracket along with the ECU from the
sub frame front.

Fig. 5.16A Fig. 5.16B

l Carefully release the ECU bracket locking lugs

top and bottom from the ECU mounting
bracket take out the ECU from mounting
bracket.(Fig. 5.17)

NOTE
Do not stretch the wires too much as it may
damage the wiring harness, which might
result in replacement of the wiring
harness.

Fig. 5.17
l Release the lock of the ECU holder by pulling in
on both the sides at top. A click sound ensures
the unlocking. (Fig. 5.18)

Fig. 5.18
 SERVICE MANUAL
ELECTRICAL

l Lift the ECU mounting bracket fully to vertical

position and carefully take out the ECU from
the holder. (Fig. 5.19 A & B)

CAUTION
Avoid direct contact with the ECU pins /
landing pads as it may affect the function of
the ECU.

l For reassembly, open the ECU mounting Fig. 5.19A Fig. 5.19B
bracket in vertical position and insert the ECU
into the wiring connector with correct
orientation. (Fig 5.20)

NOTE
Ensure that the ECU legs and the ECU
wiring connector slots are aligned
together.

CAUTION
Do not apply additional force to insert the
ECU inside the wiring connector. Fig. 5.20

l Close the ECU mounting bracket. The ECU will

be pulled inside by the wiring connector
automatically. (Fig. 5.21)

l Make sure the ECU mounting bracket is locked

with a click sound.

l Fix back the boot and hang the ECU in the

mounting bracket.

NOTE
Ensure the ECU profile is aligned with the Fig. 5.21
ECU bracket curvature.

ECU bracket should be clean and free from

dust during reassembly.

l Connect TVS Ride Scan Tool and run

diagnosis after installation of ECU assembly.

Installation

l To reassemble the ECU assembly in the

reverse order of removal procedure.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Throttle body

Component condition : Vehicle on ramp
Objective : Throttle body checking procedure
Repair cycle : Whenever required

Throttle body

l The throttle body has the following sensor

attached:

l Electronic throttle body (ETB)

l Temperature manifold pressure sensor
(TMAP)
l Fuel injector A

Electronic throttle body (ETB)

l A electronic throttle position sensor gives

exact position of the signal to the ECU in the
form of variable resistance. Check the
resistance of the electronic throttle position
sensor in the following manner:

Fig. 5.22
l Carefully release the lock (A) to disconnect the
ETC coupler from the electronic throttle body.
(Fig. 5.22).
0.000
l Set the pocket tester at ohms position.

Pocket tester

l Connect the pocket tester’s ‘+ve’ lead to the A V

pin no. 2 (PGr) and ‘–ve’ lead to the pin no. 5

(GGr) of the electronic throttle body sensor and
measure the resistance when engine is in cold
condition. (Fig. 5.23)
Fig. 5.23
Resistance 1.17 ~ 2.6 k ohms

l Use TVS Ride Scan Tool to determine the

electronic throttle position sensor and output
resistance.
 SERVICE MANUAL
ELECTRICAL

Temperature manifold absolute pressure

sensor (TMAP )

l The TMAP sensor is used to measure the

pressure and temperature of the air-fuel
mixture in the manifold, the data is given to the
ECU in the form of resistance.Check the
resistance of the TMAP sensor in the following
manner:

l Set the pocket tester at ohms position.

Pocket tester

l Carefully press and disconnect the TMAP

coupler from electronic throttle body.
(Fig. 5.24)

l Connect the pocket tester’s ‘-ve’ lead to the pin

no. 1 (BOr) and ‘+ve’ lead to the pin no. 3 (BIG)
of the TMAT sensor coupler and measure the
resistance when engine is in cold condition.
(Fig. 5.25)

Resistance 2.375 ~ 2.625 k ohms

l Use TVS Ride Scan Tool to determine the Fig. 5.24

temperature manifold absolute pressure
sensor and output resistance.

Throttle body handling 0.000

l When handling the electronic throttle body
assembly, it is not allowed to release the
quadrant from WOT (wide open throttle) to idle
position without connecting the cable. A V

l When handling the electronic throttle body

assembly, it is not allowed to hold the throttle
body assembly by holding any of the sensor
connectors.
Fig. 5.25
Assembly

l Make sure that no particle (metallic, or any

other kind) gets inside the air channel, canister
tube and connector before mounting the
throttle body on vehicle.

l Never connect / disconnect the connector of

the throttle body sensors when:

a) Engine is running
b) Key on, engine running or not
c) Just after key on – key off
 SERVICE MANUAL
ELECTRICAL

l Ensure leak proof connection after assembly to

achieve best performance.

Fuel injector

CAUTION
Before attempting to work on the fuel
system, release the fuel pressure from the
system (refer chapter “Fuel, Lubrication
and Exhaust system” page no. 4-0 for the
procedure).
Fig. 5.26
l The fuel injector is used to inject the fuel into
the combustion chamber based on the signal
from the ECU. (Fig. 5.26) Check the resistance
of the fuel injector in the following manner:

l Set the pocket tester at ohms position.

Pocket tester
A
l Carefully dislocate the pin (A) and disconnect
the fuel injector coupler from the injector and
check the resistance between two terminals of
the injector. (Fig. 5.27)
Fig. 5.27
Resistance 0.2 ohms

l In case of any malfunction, refer chapter “Fuel,

lubrication and exhaust system” page no.4-0
for removal and reassembly procedure.

NOTE
While reassembling the fuel injector,
ensure to replace the 'O' ring with a new
one.

Handling

l Injector assembly should not be exposed to

alcohol or gasoline prior to assembly as this
can cause the ‘O’ rings to swell.

l Injector assembly can withstand ambient

pressure. But submersion or pressure
washing is not recommended as it will result in
component damage. Do not use the injector
assemblies that have been dropped or
subjected to extensive physical abuse.

l Use TVS Ride Scan Tool to determine the fuel

injector sensor and output resistance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Fuel pump module assembly

Component condition : Vehicle on ramp
Objective : Fuel pump module assembly checking procedure
Repair cycle : Whenever required

Fuel pump module assembly

l The fuel pump module assembly is fitted in the

fuel tank, is used to pressurize and supply the
fuel available in the fuel tank to the fuel injector.
(Fig. 5.28)

l The fuel pump working can be checked by

using the diagnostic tool (refer chapter
“Diagnostic procedure” page no. 7-1 for
details).

l In case of any malfunction, (refer chapter “Fuel,

lubrication and exhaust system” page no. 4-3
for removal and reassembly procedure.

CAUTION Fig. 5.28

Before attempting to work on the fuel

system, release the fuel pressure from the
system (refer chapter “Fuel, lubrication and
exhaust system” page no. 4-1 for the
procedure).

Handling

l Fuel pump module should not be held by the

solenoid pump, filter, or wire. It should be held
only by the flange as shown in figure.
(Fig. 5.29)

l Pre-filter of fuel pump should not get bent

during the assembly of the pump into the fuel
tank.

l Do not assemble the fallen or damaged fuel

pump module in the tank. If the fuel tank falls
down, replace the fuel pump module.
Fig. 5.29
l Connect TVS Ride Scan Tool and run
diagnosis a fter installation of fuel pump
module assembly.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Oxygen sensor

Component condition : Vehicle on ramp
Objective : Oxygen sensor checking procedure
Repair cycle : Whenever required

Oxygen sensor

l An oxygen sensor is fitted on the muffler

assembly to measure the percentage of
oxygen in the exhaust system. (Fig. 5.30)
Check the resistance of the oxygen sensor in
the following manner:

NOTE
Use diagnostic tool to confirm the working
o f o x y g e n s e n s o r. ( R e fe r c h a p t e r
“Diagnostic procedure” 7-1 for details). Fig. 5.30

l Carefully disconnect the oxygen sensor

coupler from the wiring harness by releasing
its lock. (Fig. 5.31)

l Connect the pocket tester’s ‘-ve’ lead to the

violet with white wire (VW) and ‘+ve’ lead to
the pink with light green wire (PLg) of the
oxygen sensor coupler.

l Set the pocket tester at ohms position.

Pocket tester
Fig. 5.31
Resistance 8.2 ohms

l In case any defect is found, remove the oxygen

sensor from the muffler assembly and replace
it with a new one.(Fig. 5.32)

17 mm Spanner

Tightening torque 17.5 ± 2.5 Nm

CAUTION
Care should be taken not to damage the
oxygen sensor during its removal / fitment.

l Use TVS Ride Scan Tool to determine the

oxygen sensor and output resistance. Fig. 5.32
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Thermal sensor

Component condition : Vehicle on ramp
Objective : Thermal sensor checking procedure
Repair cycle : Whenever required

Thermal sensor

l A thermal sensor is fixed on the cylinder block

behind the radiator assembly to sense the
engine coolant temperature and give input to
the ECU in the form of resistance. Check the
resistance of the thermal sensor in the
following manner:

l Set the pocket tester at ohms position.

Pocket tester
Fig. 5.33
l Carefully disconnect the thermal sensor
coupler from the main wiring harness.
(Fig. 5.33)
0.000
l Connect the pocket tester’s ‘+ve’ lead to the
pin (1) pink with black wire (PB) and ‘–ve’ lead
to the pin (2) black with light green wire (BLg) of
the thermal sensor coupler and measure the A V

resistance when engine is in cold condition.

(Fig. 5.34)

2.29 k ~ 2.62 k Ohms

Resistance
at 20° C
Fig. 5.34
l If the resistance measured is not within the
specified limit, replace the thermal sensor with
a new one.

Removal

l Carefully disconnect the thermal sensor

coupler from the wiring harness.

l Remove the thermal sensor from the cylinder

block. (Fig. 5.35)

17 mm Spanner
Fig. 5.35
Tightening torque 13.3 ± 1.5 Nm

l Connect TVS Ride Scan Tool and run

diagnosis after installation of thermal sensor
assembly.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Canister purge value

Component condition : Vehicle on ramp
Objective : Canister purge value checking procedure
Repair cycle : Whenever required

Canister purge value

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Purge valve is fitted on the sub frame front

bracket below the fuel tank assembly.
(Fig. 5.36)

l Set the pocket tester at ohms position.

Pocket tester Fig. 5.36

l Dislocate the pin (A) and disconnect the

coupler from the main wiring harness.
(Fig. 5.37)

A
l Connect the pocket tester’s ‘+ve’ and ‘–ve’
leads to the terminals of the canister purge
valve and measure the resistance. (Fig. 5.38)

Resistance 26 ± 2 Ohms at 20° C

l If the resistance measured is not within the

specified limit, replace the valve with a new Fig. 5.37
one by following the procedure given in
(chapter “Fuel, lubrication and exhaust
system” page no. 4-6).

l Connect TVS Ride Scan Tool and run 0.000

diagnosis after installation of purge value
assembly.

A V

Fig. 5.38
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Main relay / relay fuel pump and radiator relay

Component condition : Vehicle on ramp
Objective : Relay checking procedure
Repair cycle : Whenever required

Main relay / relay fuel pump and radiator relay

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Fan relay (A), pump relay (B) and EFI relay (C)
are fitted on the holder located below the rear
seat assembly. (Fig. 5.39)
C
B
l Remove the relays along with the boot from A
the holder and take out the boot from the
relays.

CAUTION
Care should be take not to damage the
boot / relay holder and the wires are not
stretched too much during the removal /
reassembly of the relays. Fig. 5.39

l Inspect the relays by checking the continuity

using a pocket tester.

l Set the pocket tester at ohms position.

Pocket tester

Fan relay

RELAY CONDITION YW RP
NOT ENERGIZED O O
ENERGIZED O O

Relay fuel pump

RELAY CONDITION OrGr OrBr

NOT ENERGIZED O O
ENERGIZED O O

EFI pump

RELAY CONDITION OrG OrBl

NOT ENERGIZED O O
ENERGIZED O O
 SERVICE MANUAL
ELECTRICAL

(To energise the main relay / relay fuel pump and

radiator pump, keep the vehicle in neutral
condition and turn ‘ON’ the ignition).

l If there is no continuity found, replace the

respective relay and once again check for
continuity. Again, if problem persists, inspect
the continuity in wiring harness. Else, replace
the ECU and check.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Relay self starter (starter relay)

Component condition : Vehicle on ramp
Objective : Starter relay checking procedure
Repair cycle : Whenever required

Relay self starter (starter relay)

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Relay self starter is located at the RH side of

the vehicle below the fuel tank assembly near
the cylinder head assembly. (Fig. 5.40)

l Inspect the relay by checking the continuity

using a pocket tester.

l Set the pocket tester at ohms position.

Pocket tester

RELAY CONDITION R RW
NOT ENERGIZED O O
ENERGIZED O O

(To energise the starter relay, keep the vehicle in Fig. 5.40
neutral condition, press and hold the starter
switch with the ignition lock and engine kill switch
in ‘ON’ condition).

l If there is no continuity found, replace the

starter relay and once again check for
continuity. Again, if problem persists, then
replace the ECU and check.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Gear position sensor

Component condition : Vehicle on ramp
Objective : Gear position sensor checking procedure
Repair cycle : Whenever required

Gear position sensor

l The gear position sensor is mounted on the

crankcase assembly LH side below the cover
engine sprocket. (Fig. 5.41)

l Gear position sensor senses the exact position

of the gear and generates the voltage
accordingly. These voltages are sent to the
digital speedometer and the ECU. To measure
the voltage level of the gear position sensor at
various positions, follow the procedure given
below: Fig. 5.41

l Set the pocket tester at voltage position.

Pocket tester

l Disconnect the gear position sensor’s socket

from the wiring harness. (Fig. 5.42)

l Connect the pocket tester’s ‘+ve‘ lead to the

pin (1) blue green wire (BLg) of the wiring
harness and ‘-ve’ lead to the body earth and
measure the input voltage. (Fig. 5.43)

Voltage 5 Volts Fig. 5.42

l If there is no voltage input, then check the

continuity of the wiring harness between the
gear position sensor coupler and the ECU 0.000
coupler.

WIRE GPS ECU

COLOUR COUPLER COUPLER
GR 0 0 A V

PV 0 0
BLg 0 0

l If there is no continuity found in the wiring

harness, replace the wiring harness and check Fig. 5.43
for the gear indication in the speedometer.

l If the continuity is found OK while checking

with the pocket tester, then check the gear
position sensor in the following manner:
 SERVICE MANUAL
ELECTRICAL

l Reconnect the gear position sensor coupler.

l Set the pocket tester knob at voltage position.

l Connect the pocket tester ‘+ ve’ lead to the pin

(1) blue with green wire (BIg) of the gear
position sensor and the ‘-ve’ lead to the pin (2)
violet yellow wire (VY) and measure the
voltage variation.

l The voltage of the gear position sensor at

various positions are as follows:

GEAR POSITION VOLTAGE

First gear 0.568 ± 0.050 V
Neutral 0.954 ± 0.050 V
Second gear 1.341 ± 0.050 V
Third gear 2.114 ± 0.050 V
Fourth gear 2.887 ± 0.050 V
Fifth gear 3.660 ± 0.050 V
Sixth gear 4.433 ± 0.050 V
SP 0.040 ± 0.050 V
EP 4.600 ± 0.050 V

l If found any deviation in the voltage reading

then replace the gear position sensor.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Quick gear shifter sensor

Component condition : Vehicle on ramp
Objective : Quick gear shifter sensor checking procedure
Repair cycle : Whenever required

Quick gear shifter sensor

l The quick gear shifter sensor is mounted on

the gear shift link assembly. (Fig. 5.44)

l A quick gear shifter sensor is a device that

eliminates the need to use the clutch or throttle
when shifting gears on a manual transmission.

l Quick gear shifter sensor the exact position of

t h e g e a r a n d g e n e r a t e s t h e vo l t a g e
accordingly. These voltages are sent to the
digital speedometer and the ECU. Quick gear Fig. 5.44
shifter sensor can be checked by doing a good
(or) bad analysis (replacing the quick gear
shifter sensor).

l If the malfunction indicator glows continuously

on the speedometer (A) diagnosis the fault
using beep count. (Fig. 5.45). Refer chapter
“Diagnostics procedure” for connecting the ILLUSTRATION
ride scanner tool.

Fig. 5.45

l Disconnect the quick shifting sensor’s socket

from the wiring the harness. (Fig. 5.46)

l Set the pocket tester at voltage position.

Pocket tester
ILLUSTARTION
l Connect TVS Ride Scan Tool and run
diagnosis to check the vehicle performance.

Fig. 5.46
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Side stand switch

Component condition : Vehicle on ramp
Objective : Side stand switch checking procedure
Repair cycle : Whenever required

Side stand switch

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Side stand switch is mounted at the LH side of

the vehicle on the side stand mounting
bracket. (Fig. 5.47)

To check the side stand switch:

l Inspect the side stand switch by checking the

voltage using a pocket tester.

l Set the pocket tester knob at voltage position.

Pocket tester
Fig. 5.47
l Check and ensure the battery voltage is within
the specifications.

Battery voltage 12.6 ± 0.3 Volts

l If the battery voltage is found less than the

specified voltage, re-charge the battery as
explained in page no. 3-54.

l Disconnect the side stand switch coupler from

the main wiring harness. (Fig. 5.48)

Turn ‘ON’ the ignition.

l Connect the pocket tester’s ‘+ve‘ lead to the Fig. 5.48

white with brown wire (WBr) of side stand
switch coupler at the wiring harness side and
‘–ve‘ lead to the black with light green wire
(BLg) of side stand switch coupler at the wiring
harness side and measure the voltage.
(Fig. 5.49)

l The voltage measured should be within the

specified limit.

Voltage 5 ± 0.15 Volts

Fig. 5.49
 SERVICE MANUAL
ELECTRICAL

l If there is no voltage output found in the side

stand switch, then check the continuity of the
wiring harness between the ECU coupler and
the side stand switch coupler using a pocket
tester.

l Set the pocket tester knob at continuity mode.

Pocket tester

WIRE ECU COUPLER SIDE STAND

COLOUR SWITCH
CODE COUPLER
BLg O O
WOr O O
WBr O O

l If there is no continuity in the wiring harness,

replace the wiring harness and check for side
stand indication in the speedometer and check
the not starting when the side stand is in ‘ON’
condition.

l If the continuity is found OK, replace the

respective unit and check for their working as
explained above.

l If the voltage is found OK while checking with

the pocket tester, then check the side stand
switch in the following manner:

l Reconnect the side stand switch coupler

l Set the pocket tester knob at voltage position

Pocket tester

l Connect the pocket tester’s ‘+ve‘ lead to the

white with brown wire (WBr) and ‘–ve‘ lead to
the black with light green wire (BW) of side
stand switch coupler and measure the voltage
when the side stand is in ‘ON’ condition.
(Fig. 5.50)

l The voltage measured should be:

Fig. 5.50
Voltage 10 Volts

l The measured voltage is less than the

indicated voltage, replace the side stand
switch with a new one.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

EMS SYSTEM CHECKING PROCEDURE

Component : Relay self starter (Starter relay)

Component condition : Vehicle on ramp
Objective : Relay self starter checking procedure
Repair cycle : Whenever required

Relay self starter

l Relay self starter is located on the LH side of
the vehicle near cylinder head assembly.
(Fig. 5.51)

l Inspect the switch for continuity using a pocket

tester.

l Set the pocket tester at voltage position.

Pocket tester

RELAY CONDITION BrR OrG Fig. 5.51

NOT ENERGIZED O O
ENERGIZED O O

l To energise the starter relay keep the vehicle in

neutral condition, press and hold the starter
switch with the ignition lock; and engine kill
switch in ‘ON’ condition.

l If there is no continuity found, replace the

starter relay and once again check for
continuity. Again, if problem persists, then
replace the ECU and check.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING SYSTEM

The lighting system of Apache RTR310 consists of battery, main fuse (30A), ignition lock, fuse (20A) lighting and DC
circuit , switch beam control and switch pass-by.The working of the lighting system is as follows. (Fig. 5.38)

A 12V DC output from the battery is connected to the main fuse (30A). The output of the ignition lock is connected to
the ignition lock through the fuse (20A) lightening and DC circuit system, number plate lamp, tail lamp / brake lamp,
head lamp / DRL lamp. Since the number plate lamp, tail lamp / brake lamp, head lamp / DRL lamp is connected to the
ground directly, they start glowing on receipt of the ignition lock input.

The out put of the FUSE (20A)Lighting / DC circuit split into many parts and supplied to the following:
- Horn
- Head lamp / DRL
- Number plate lamp
- Tail lamp / brake lamp
- Stop lamp switch front and rear
- Switch beam control and switch pass by

The DC output from the Fuse (20A) Lighting / DC circuit is directly connected to the head lamp, the position lamps
glows once the ignition lock is turned 'ON'.

The DRL unit triggers an 'enable signal' to the headlamp for low beam and high beam operation. The low beam glow
once the engine is started.

The DC output from the Fuse (20A) Lighting / DC circuit supplies the input voltage to the switch beam control for high
beam operation of the headlamp. This switch beam supplies the power input to the head lamp high beam whenever
ignition turned on and by pressing the high beam control switch or pass-by switch energizes the relay because the
relay is grounded directly.

The output of the Fuse (20A) Lighting / DC circuit is connected to the switch assembly stop lamp front and rear, the
output of these switches is supplied to the Speedo meter (brake lamp switch). Since the brake lamp switch is
connected to the common earth junction directly, it turns 'ON' once the input is received from any one of the brake
switches.

The tail lamp gets the input from the Fuse (20A) Lighting / DC circuit and it's connected with common ground. Once
the ignition lock is turned ON.

The output of the Fuse (20A) Lighting / DC circuit is connected to the horn, the output of horn is connected to the
horn switch. Once press the horn switch the output signal is supplied to horn, it will get energized . Since the switch
is directly connected to the vehicle ground.
 LIGHTING / DC CIRCUIT
Br Br MAIN FUSE (30A)
RBI RBI R
Br TO RELAY
Br
REGULATOR STARTER
Br RBI RBI RBI RBI RBI
BW
Br
R
TO TELEMATIC FUSE FUSE FUSE EMS / FUSE FAN
UNIT RBI HECU (10A) HECU (15A) SPEEDO (7.5A) RADIATOR (7.5A)

MAGNETO ASSEMBLY IGNITION ROr OrY OrBI PLg - BW

LOCK ON +
BATTERY
TO HECU TO HECU TO EFI RELAY TO RELAY FAN 8Ah MF
OrB OrB
FUSE (10A) EFI / SPEEDO /
USB CHARGER
NUMBER PLATE LAMP - 1.5 W
FUSE (20A) LIGHTING / TO OTHER CIRCUIT
SERVICE MANUAL

DC CIRCUIT OrGr

Or Or Or

HORN R Or
Or Or BW

SWITCH HORN
HORN L Or
Or
G G BW

Or
HEAD LAMP - 46W /
DRL - 9W STOP LAMP SWITCH FRONT
RIGHT
Or Or Or WB

BW
BlY Or WB

STOP LAMP SWITCH REAR TAIL LAMP - 1W / BRAKE LAMP - 3W

YB
WBI
WB
LEFT
YB Or
GV
HI LOW
DRL BW WBI
SWITCH BEAM CONTROL
BlY
YB Or
SWITCH PASS-BY
YB NAVIGATION SWITCH
TSL FRONT L - 1W TSL FRONT R - 1W YB
GV
WBI

BIGr YR GrP GBr BW

YB WB
BW BW HIGH BEAM BRAKE LAMP SWITCH
BlY BW
LgBI PWM BRAKE LAMP
BIGr
GV
DRL CONTROL SWITCH 4
LgBI
FRONT CONTROL SWITCH 3
INDICATOR R
VGr VGr
CONTROL SWITCH 2
FRONT INDICATOR L
Lg
REAR INDICATOR R CONTROL SWITCH 1
TSL FRONT L - 1W TSL FRONT R - 1W LblR
V HAZARD
REAR INDICATOR L
WY ON
Lg CAN HIGH FROM ECU
GROUND BW OFF
V BW WLg
BW BW CAN LOW FROM ECU
V GY
FUEL SENSOR HAZARD SWITCH
GROUND FROM FUEL PUMP MODULE
BW
BATTERY FROM FUSE EMS
OrBI CRUISE SWITCH
BLINKER SWITCH LgGr
CRUISE SET /+
LgR
R INDICATOR SWITCH R LgG
OrP CRUISE SET /-
+5V OUTPUT
CRUISE ON / OFF
L INDICATOR SWITCH L OrG
VOr
BW
BW SPEEDO ASSEMBLY
ELECTRICAL
 SERVICE MANUAL
ELECTRICAL

Based on the blinker switch position (LH or RH), the speedo assembly turn on the respective turn signal lamps (LH or
RH) starts flashing along with the turn signal lamp indicator of speedometer assembly. Since the turn signal lamp is
directly connected to ground.

Once press the cruise switch vertically the signal supplies (ON/OFF) to the speedo assembly. Then the cruise control
will get activated, the cruise control indicator of the instrument cluster glows. push the cruise control switch knob
towards ‘Set/-’ position or ‘Set/+’ position that signal supplies to speedo assembly, based on this signal the speedo
assembly set the speed (Decrease or increase) of the vehicle. Since the cruise switch is directly connected to
ground.

When hazard switch is ON the output signal is given to the speedo assembly, then the speedo assembly signal
sends to turn signal lamp front and rear both the sides. Since the lamps are gets ground on common earth and starts
flashing along with the turn signal lamp indicator of speedo assembly.

The navigation switch is having 4 buttons like a ENT, UP, DOWN and RETURN button. based on the switch selection
the signal sends to speedo assembly. Then the speedo assembly displays the settings details. Since the navigation
switch is directly connected to ground.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Switch beam control cum pass-by switch

Component condition : Vehicle on ramp
Objective : Switch beam control cum pass-by switch checking procedure
Repair cycle : Whenever required

SWITCH BEAM CONTROL CUM PASS-BY

SWITCH

l Switch beam control cum pass-by switch is

provided on the switch assembly LH at the left
hand side of the handle bar. (Fig. 5.52)

For switch beam control

l Check the switch for continuity with the pocket

tester.

Pocket tester

SWITCH POSITION YB Or
PRESS UP ( ) - HIGH O O
PRESS DOWN ( ) - LOW O O

l If there is no continuity found when the switch Fig. 5.52

is in ‘HIGH’ beam mode, replace the switch
assembly LH with a new one.

For pass-by switch

l Check the switch for continuity with the pocket

tester.

Pocket tester

SWITCH POSITION YB Or
PRESS - ON O O
RELEASE - OFF O O

l If there is no continuity found, replace the

switch assembly LH with a new one.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Horns (12V DC)

Component condition : Vehicle on ramp
Objective : Horn LH and RH checking procedure
Repair cycle : Inspect at every 5000 km or 6 months whichever occurs earlier.

Horn LH and RH
l The horns are mounted on the sub frame front
at the LH & RH side of the vehicle near to the
radiator assembly mounting. (Fig. 5.53)

l The DC output orange (Or) wire from the

ignition lock through the load fuse is connected
to the horn switch and the output of horn
switch green (G) wire is connected to the
horns. Common earth junction is directly
connected to the horns through the horn
switch.
Fig. 5.53
l The horn switch is located on the switch
assembly LH at the left side of the handle bar.
(Fig. 5.54)

l Inspect the switch for continuity with the

pocket tester.

l Set the pocket tester at voltage position.

Pocket tester

SWITCH POSITION G BW
PRESS - ON O O
RELEASE - OFF O O Fig. 5.54

l If there is no continuity is found, replace the

switch assembly LH.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Turn signal lamps front and rear

Component condition : Vehicle on ramp
Objective : Turn signal lamps front and rear checking procedure
Repair cycle : Inspect at every 5000 km or 6 months whichever occurs earlier.

Turn signal lamps front and rear

l The switch for turn signal lamps is located on
the switch assembly LH at the left hand side of
the handle bar. (Fig. 5.55)

l Disconnect the turn signal lamps coupler from

the main wiring harness and inspect the switch
for continuity with the pocket tester. (Fig. 5.56)

l Set the pocket tester at voltage position.

Pocket tester
Fig. 5.55
SWITCH POSITION LgR OrP VOr BW
TO LEFT ( ) O O O
PRESS RELEASE O O
TO RIGHT ( ) O O O

l If there is no continuity is found, replace switch

assembly LH.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.

Fig. 5.56
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Switch assembly stop lamp front & Rear stop switch (Brake switch)
Component condition : Vehicle on ramp
Objective : Switch assembly stop lamp - front & rear checking procedure
Repair cycle : Inspect at every 5000 km or 6 months whichever occurs earlier.

Switch assembly stop lamp - front & rear

l The DC output from the fuse (20A) is
connected to the switch assembly stop lamp
front and rear through an orange wire (Or) and
the output from the switches is supplied to the
speedometer through white with black (WB)
and the speedometer supplies to the brake
lamp through a white with blue wire (Wbl).

l Switch assembly stop lamp front is fitted in the

front brake lever assembly RH. (Fig. 5.57)
Fig. 5.57
l Rear stop switch is fitted on the rider footrest
disc RH, near the mounting of the swing arm
assembly and operated by the brake pedal.
(Fig. 5.58)

l Inspect both the switches for continuity with

the pocket tester.

l Set the pocket tester at voltage position.

Pocket tester

SWITCH POSITION Or WBI

APPLY BRAKE - ON O O
RELEASE - OFF O O
Fig. 5.58
l If there is no continuity is found, replace the
particular brake switch with a new one.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Clutch switch

Component condition : Vehicle on ramp
Objective : Clutch switch checking procedure
Repair cycle : Whenever required

Clutch switch
l Clutch switch is located below the bracket
holder comp lever clutch which is mounted on
LH side of the handle bar . (Fig. 5.59)

l Inspect the switch for continuity using a pocket

tester.

l Set the pocket tester at voltage position.

Pocket tester

SWITCH POSITION BOr BlBr Fig. 5.59

PRESS - ON O O
RELEASE - OFF O O

l If there is no continuity is found, replace the

switch assembly LH.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Control switch assembly

Component condition : Vehicle on ramp
Objective : Control switch assembly checking procedure
Repair cycle : Whenever required

Control switch assembly

l Control switch assembly is provided on the
switch assembly LH at the left hand side of the
handle bar. (Fig. 5.60)

l Carefully disconnect the control switch

assembly coupler from the main wiring
harness (Fig. 5.61) and inspect the switch for
continuity using a pocket tester.

l Set the pocket tester at voltage position.

Pocket tester Fig. 5.60

SWITCH FUNCTION BlGr YR GrP GBr BW

UP O O
DOWN O O
LEFT O O
RIGHT O O

l If there is no continuity found, replace the

switch assembly LH.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
Fig. 5.61
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Cruise control switch

Component condition : Vehicle on ramp
Objective : Cruise control switch checking procedure
Repair cycle : Whenever required

Cruise control switch

l Cruise control switch is provided on the switch
assembly LH at the left hand side of the handle
bar. (Fig. 5.62)

l Carefully disconnect the control switch

assembly coupler from the main wiring
harness (Fig. 5.63) and inspect the switch for
continuity using a pocket tester.

l Set the pocket tester at voltage position.

Fig. 5.62
Pocket tester

SWITCH FUNCTION LgGr LgG OrG BW

UP (Set +) O O
DOWN (Set -) O O
ON / OFF O O

l If there is no continuity found, replace the

switch assembly LH

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.

Fig. 5.63
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Hazard switch

Component condition : Vehicle on ramp
Objective : Hazard switch checking procedure
Repair cycle : Whenever required

Hazard switch assembly

l Hazard switch is provided on the switch
assembly LH at the left hand side of the handle
bar. (Fig. 5.64)

l The DC output from the ignition lock is

connected to the hazard switch through an
speedometer assembly.

l Remove the speedometer cover. Refer chapter

“general information” page no 1-00 for removal
procedure.
Fig. 5.64
l Carefully disconnect the speedometer coupler
(A & B) from the main wiring harness and
inspect the switch for continuity using a pocket
tester. (Fig. 5.65)

l Set the pocket tester at continuity position. B

A
Pocket tester

l Inspect the switch for continuity using pocket

tester.

SWITCH POSITION LbIR BW

TO (ON) O O
Fig. 5.65
TO (OFF) O O

l If there is no continuity found, replace the

switch assembly LH

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

LIGHTING / DC SYSTEM CHECKING PROCEDURE

Component : Head lamp assy - Front

Component condition : Vehicle on ramp and component accessible
Objective : Head lamp assembly front assemble and disassemble
Repair cycle : Inspect at every 5000 km or 6 months whichever occurs earlier.

Head lamp assembly front

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the hexagonal socket cap flange bolt

(M5x12 2 Nos.) from the mounting of
speedometer cover. (Fig. 5.66)

l Carefully press and pull out the speedometer

cover from its location.

CAUTION
Care should be taken not to damage the
speedometer cover locks. Otherwise it
may lead to replacement.
Fig. 5.66

l Remove the hexagonal socket cap flange bolt

(M6x16 - 2 Nos.) from the mounting of the
head lamp top assembly LH & RH. (Fig. 5.67)

5 mm Allen Key

Tightening torque 7 ± 1 Nm

Fig. 5.67
l Remove the hexagonal socket cap flange bolt
(M6x16 – 2 Nos.) from the mounting of the
head lamp assembly bottom RH & LH.
(Fig. 5.68)

5 mm Allen Key

Tightening torque 7 ± 1 Nm

Fig. 5.68
 SERVICE MANUAL
ELECTRICAL

l Gently tilt the head lamp assembly. Disconnect

the head lamp coupler from the main wiring
harness. (Fig. 5.69)

NOTE
While disconnecting the coupler, make
sure to hold the coupler itself and do not
pull the lead wires.

Fig. 5.69

l Release the lock and disconnect the turn signal

lamp connector LH and RH. (Fig. 5.70)

l Gently tilt and take out the head lamp

assembly from its location.

CAUTION
Take additional care not to damage head
lamp assembly during assemble and
disassemble.

Fig. 5.70

Head lamp assembly - Disassemble:

l Remove the CRR flanged pan head tap screw

(ST 4.2x13 - 2nos.) from the mounting of
housing head lamp front L&R.(Fig. 5.71A & B)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

l Dislocate the lugs and take out the housing

head lamp front L&R form its location.
Fig. 5.71A Fig. 5.71B
NOTE
Care should be taken not to damage the
lugs it may lead to replace the part.

l Remove the CRR flanged pan head tap screw

(ST 4.2x13 - 1nos.) from the mounting of
housing head lamp front L&R.(Fig. 5.72)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 5.72
 SERVICE MANUAL
ELECTRICAL

l Remove the rubber boot 4 Nos. form the stay

headlamp assembly.(Fig. 5.73)

CAUTION
While reassembling, ensure the presence
of the boot in the stay headlamp.

Fig. 5.73

l Remove the hexagonal nut (M6x1 - 4nos.)

along with the punched washer (6.5x16x1.2)
from the mounting of the stay headlamp.
(Fig. 5.74)

10 mm Spanner

Tightening torque 6 ± 1 Nm

NOTE
Care should be taken not damage the
grommets and while reassembly ensure Fig. 5.74
the presence of the grommet.

l Remove the CRR flanged pan head tap screw

(ST 4.2x13 - 2nos.) from the mounting of the
stay headlamp. (Fig. 5.75A & B)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 5.75A Fig. 5.75B

l Remove the CRR flanged pan head tap screw
(ST 4.2x13 - 2nos.) from the mounting of the
housing headlamp centre front. (Fig. 5.76)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

NOTE
Ensure to re-fix the retainer nut in its
location without fail during reassembly.
Fig. 5.76
 SERVICE MANUAL
ELECTRICAL

l Carefully dislocate the stay headlamp from the

grommet and takeout the stay head lamp from
its location.

CAUTION
Take care of the grommet while removing
from the stay headlamp

l Remove the CRR flanged pan head tap screw

(M6x16 - 2 Nos.) from the mounting of
headlamp assembly.(Fig. 5.77)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Remove the CRR pan head tap screw Fig. 5.77

(M4.2x13 - 2 Nos.) from the mounting of
headlamp assembly.(Fig. 5.78)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 5.78

l Remove the CRR pan head screw (M6x16 - 1

Nos.) from the mounting of the headlamp
assembly. (Fig.5.79)

Phillips head screw driver

Tightening torque 3 ± 1 Nm

l Carefully dislocate housing headlamp center

front lug from head lamp assembly and takeout
the head lamp assembly.

Fig. 5.79
 SERVICE MANUAL
ELECTRICAL

CAUTION
While removing the head lamp assembly
care should be taken not to drop down the
head lamp assembly it may damage (or)
replace.

l Remove the hexagonal nut L & R (M10x1.25 -

2 Nos.) along with wave spring washer (M10)
from the mounting of housing head center
front. (Fig. 5.80)

14 mm Spanner Fig. 5.80

Tightening torque 6 ± 2 Nm

l Now takeout the turn signal lamp LED L&R

from the housing head center front.

l Remove the CRR flanged pan head tap screw

(ST 4.2x1 - 2 Nos.) from the mounting of the
housing head lamp front top.(Fig. 5.81)

Phillips head screw driver

Tightening torque 1 ± 0.2 Nm

Fig. 5.81

l Remove the CRR flanged pan head tap screw

(ST 4.2x1 - 2 Nos.) from the mounting of the
housing head lamp front top.(Fig. 5.82)

Phillips head screw driver

A
Tightening torque 1 ± 0.2 Nm

l Carefully dislocate housing head front top lug

(A) from housing head lamp center front.

Installation
Fig. 5.82
l To reassemble the parts in the reverse order of
removal procedure.
 SERVICE MANUAL
ELECTRICAL

12V REGULATION SYSTEM CHECKING PROCEDURE

Component : Regulator and Rectifier (RR UNIT)

Component condition : Vehicle on ramp
Objective : Charging performance checking procedure
Repair cycle : Whenever required

REGULATOR AND RECTIFIER (RR UNIT)

l The RR unit (regulator cum rectifier) is fitted

below the head lamp assembly in front of
radiator assembly. (Fig. 5.83)

l The RR unit consists as the name implies,

regulator which regulates the voltage between
12V to 14V constantly, and rectifier used for
converting AC current to DC for charging and
other purpose.

CHARGING PERFORMANCE CHECK

Fig. 5.83
l Park the vehicle on the paddock stand. Refer
chapter “general information” page no 1-00 for
installation procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Set the pocket tester at voltage position.

Pocket tester

l Connect the pocket tester’s ‘+ve‘ lead to the 12.0 1

V
DC

positive terminal of the battery and ‘–ve‘ lead of

pocket tester to the negative terminal of the
battery. (Fig. 5.84)

l Start and warm up the engine. Switch ON the

head lamp high beam.

l Gradually increase the throttle while observing

the rpm indicator of speedometer. Once the
rpm reaches 4000, check the pocket tester Fig. 5.84
reading. The reading should be

Charging 14.5 ± 0.3V at 2500 rpm and

performance above

NOTE
W hile checking the charging current,
switch on the head lamp high beam to
know the correct reading.
 SERVICE MANUAL
ELECTRICAL

l If the reading measured is not within the limit,

check the stator generator resistance as
explained in page no. 0-0.

l If the stator generator resistance is found OK,

then replace the RR unit with a new one and re-
check.

l Connect TVS Ride Scan Tool and run

diagnosis to check the vehicle performance.
 SERVICE MANUAL
ELECTRICAL

Self starter / ABS circuit

Self starter

The self starter system of the Apache RTR 310 consists of battery, fuses, ignition lock, engine kill switch, starter
switch, clutch switch, ECU, EFI relay, starter relay and the starter motor. The working of the self starter system is as
follows. (Fig. 5.54)

A 12V DC output from the battery is connected to the ignition lock and fuse EMS / speedo (7.5A) through the main
fuse (30A). The output of the ignition lock is connected to the ECU as an input and the output of the fuse EMS /
speedo is given to the EFI relay (two inputs) for its activation and for output from the relay.

One more output from the battery is connected directly to the starter relay as an input to the starter motor. This input
will be supplied to the starter motor whenever the relay starter motor gets energised.

On receipt of the ignition lock input, the ECU supplies input voltage to kill switch. And the output of the kill switch is
supplied back to the ECU and also to the electric starter switch.

After receiving the input from engine kill switch, the ECU connects the negative supply to the EFI relay and the EFI
relay gets energised. The output of the EFI relay is supplied to the starter relay for its activation.

On pressing the ES switch, the ES switch output is supplied to the ECU. On receipt of this input, the ECU determines
the condition of the transmission (whether the transmission is in neutral or not) through GPS and the position of side
stand (whether it is in fully up condition or not) through the side stand switch. The ECU also determines the input
from clutch switch in case if the transmission is in gear condition.

After analysing all the conditions the ECU connects the ground supply to the starter relay and the starter relay gets
energised and supplies the input to the starter motor. Since the starter motor is connected to the ground directly, it
cranks on receipt of the input from the starter relay.
 SELF START / ABS CIRCUIT
Br Br MAIN FUSE (30A)
RBI RBI R
Br Br
REGULATOR
Br RBI RBI RBI RBI RBI
BW
Br
R
TO TELEMATIC FUSE FUSE FUSE FAN FUSE EMS /
RBI UNIT HECU (10A) HECU (15A) RADIATOR (7.5A) SPEEDO (7.5A)

MAGNETO ASSEMBLY IGNITION ROr OrY PLg OrBI - BW

LOCK ON + R
BATTERY
TO RELAY FAN 5Ah MF
OrB OrB

OrGr OrBI OrG

SERVICE MANUAL

TO SPEEDO
FUSE (20A) LIGHTING /
DC CIRCUIT FUSE (10A) EFI /
SPEEDO / BrR
USB CHARGER OrGr
TO SPEEDO
Or
TO LIGHTING / DC CIRCUIT
OrGr
TO MOBILE STARTER
CHARGER OrBI RW RELAY
HECU OrG
ROr ROr OrGr
TO DIAGNOSTIC
FROM FUSE 10A
OrY COUPLER RW
FROM FUSE 15A
OrGr RB
TO RELAY
IGNITION
FUEL PUMP BrR
CAN HIGH

CAN LOW OrGr EFI RW

WLg RELAY 35A

OrR WY WLg
WSS REAR
TO DIAGNOSTIC TO DIAGNOSTIC STARTER
COUPLER COUPLER OrGr RB MOTOR M
WSS REAR WY WLg
WSS FRONT TO SPEEDO TO SPEEDO WY

WSS FRONT WLg WLg

WLg
GROUND OrGr
ES SWITCH
BW BIB
WY FROM BATTERY
RBl OrG
ECU
TO RELAY FAN
BrY

OrG
BV OrW BP OrR KILL SWITCH TO RELAY FUEL PUMP
TELEMATIC UNIT BOr
BW
OrG
BOr
FUEL INJECTOR
BIBr
PV
MAP SENSOR
OrG
CLUTCH SWITCH BLg GR IGNITION COIL
BOr
SHIFT ASSIST SENSOR BLg OrG
COOLANT TEMPERATURE O2 SENSOR
SENSOR
BOr
BLg OrG
APS
ETC PURGE VALVE

BLg GR
BV OrW BP OrR SIDE STAND SWITCH ETC

BLg GR
APS APS

BLg GR

PV

WHEEL SPEED WHEEL SPEED GPS

ELECTRICAL

SENSOR FRONT SENSOR REAR

 SERVICE MANUAL
ELECTRICAL

ABS SYSTEM

ABS circuit of the Apache RTR 310 consists of battery, fuses, ignition lock, HECU, wheel speed sensors front and
rear. The working of the ABS circuit is as follows. (Fig. 5.58)

A 12V DC output from the battery is connected to the ignition lock and fuse HECU (10A & 15A) through the main fuse
(30A). The output of the ignition lock is connected to the HECU through fuse (10A) EFI as an input and the output of
the fuse HECU (10A & 15A) is given to the HECU for its understanding of ignition 'ON' condition.

Input signals from both front and rear wheel speed sensors are connected to the HECU. Based on these signals the
HECU modulates the braking force.

The HECU sends input to the speedometer in case of any mal function in the system. The speedometer indicates it
through the MIL lamp.

In the same manner the HECU sends the input signal to the speedometer for speed indication. Based on this input
the speedometer indicates the speed, ODO etc.

The HECU is connected with diagnostic coupler for external diagnostics using diagnostic tool. It also connected with
ECU, speedometer and diagnostic coupler through CAN communication.

A 12V DC output from the battery is connected to the ignition lock and telematic unit through the main fuse (30A).
The output of the ignition lock is connected to the telematic unit through fuse (10A) EFI as an input.

The telematic unit is receives the signal from Diagnostic coupler, speedo meter, HECU and ECU through CAN
communication for the purpose of telematic unit collects telemetry data from the vehicle, such as position, speed,
engine data, connectivity quality, etc., from various sub-systems over data and control busses. It may also provide in-
vehicle connectivity Bluetooth when applicable.
 SERVICE MANUAL
ELECTRICAL

ABS SYSTEM CHECKING PROCEDURE

Component : Wheel speed sensor - Front

Component condition : Vehicle on ramp
Objective : Sensor wiring coupler checking procedure
Repair cycle : Inspect at initial 1000 km or 2 months and every 5000 km or 6 months (whichever
occurs earlier).

Sensor wiring coupler

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter A

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.
l Wiring coupler of the wheel speed sensor front
is located at the left side of the bracket ECU
Fig. 5.85
below the fuel tank assembly. (Fig. 5.85)

l Inspect the wiring coupler of the wheel speed RELE

ASE
sensor for any loose connection. Disconnect PRESS

A
A
the coupler by pressing the rear end of lock (A)
and reconnect again. (Fig. 5.86)

l Rotating the front wheel by hand, check for

indication of speed in the speedometer or
using PC diagnostic hardware and software
after reconnecting the coupler.

Installation
Fig. 5.86
l To reassemble the parts in the reverse order of
removal procedure.
 SERVICE MANUAL
ELECTRICAL

Checking wiring harness continuity

l Remove the battery bracket. Refer chapter

“chassis ” page no 1-00 for removal procedure.

l Disconnect the wiring coupler of wheel speed A

sensor as explained in previous page.

l Switch ‘OFF’ the ignition. Remove the main

wiring harness socket connected to the HECU
unit by pressing the lock (A) and pushing the
socket lever towards front as shown in the
figure. (Fig. 5.87)
Fig. 5.87
CAUTION
Care should be taken not to damage the
socket lever and socket lock. Otherwise it
may lead to wiring harness replacement.

NOTE
When disconnecting the coupler, make
sure to hold the coupler itself and do not
pull the lead wires.

l Inspect the continuity between the wheel

speed sensor coupler and the HECU coupler of
the main wiring harness using a pocket tester.
Illustration
(Fig. 5.88)

Pocket tester

SPEED SENSOR HECU CONTINUITY

WIRE COLOUR COUPLER Fig. 5.88
CONTACT
BV YES
POINT No.11
CONTACT
OrW YES
POINT No.2

NOTE
While checking the continuity care should
be taken not to damage the wiring
couplers.

l If there is no continuity, replace the wiring

harness and check the wheel speed indication
in the speedometer or using diagnostic
software by rotating the front wheel.
 SERVICE MANUAL
ELECTRICAL

Toner ring to sensor air gap

l Using a feeler gauge, measure the gap

between the toner ring and the wheel speed
sensor as shown in the figure at 4 to 5 places.
(Fig. 5.89)

Feeler gauge

Service limit 0.5 ~ 2.8 mm

l The gap should be within the limit at all the

places. If the gap is not within the limit, then Fig. 5.89
inspect the toner ring for any bend and the
wheel sensor mounting screw for proper
tightness. If these are OK, then follow the
procedure given below:

l Remove CRR pan head screw (M5x12 - 1 No.)

from wheel speed sensor mounting. (Fig. 5.90)

5 mm Allen key

Tightening torque 4.5 ±0.5 Nm

Fig. 5.90

l Gently pull out and dislocate the sensor from

its mounting. (Fig. 5.91)

Fig. 5.91
l If the gap is less, then add a special shim
between the sensor and the bracket sensor
front where the sensor screw getting
mounted. (Fig. 5.92)

l Reassemble the sensor and recheck the gap

once again ILLUSTRATION
NOTE
Inspect the wheel speed indication as
explained earlier after re-fixing the sensor.
Fig. 5.92
 SERVICE MANUAL
ELECTRICAL

Removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“fuel, lubrication and exhaust system” page no
1-00 for removal procedure.

l Disconnect the wiring coupler of wheel speed

sensor as explained in page no. 3-38.

l Remove the wheel speed sensor mounting

screw as explained in page no. 3.39 and take
out the sensor from the bracket.

l Dislocate the sensor cable from the holding

clamps at 3 places.(Fig. 5.93)

l Take out the sensor while taking care of wiring Fig. 5.93
routing.

l Fix a new sensor and properly reroute the

cable.

NOTE
Inspect the wheel speed indication as
explained earlier after fixing a new sensor.

Installation

l To reassemble the parts in the reverse order of

removal procedure.

Sensor Alignment

l Visually inspect the sensor for any

misalignment. Remove and reassemble the
sensor properly if required.

l Inspect for any looseness in the mounting

screw of wheel sensor. (Fig. 5.94) Tighten the
screw if necessary.

l Inspect the gap between sensor and toner ring

as explained in page no. 3-39 to ensure that
there is no misalignment.

Fig. 5.94
 SERVICE MANUAL
ELECTRICAL

ABS SYSTEM CHECKING PROCEDURE

Component : Wheel speed sensor - Rear

Component condition : Vehicle on ramp
Objective : Sensor wiring coupler checking procedure
Repair cycle : Inspect at initial 1000 km or 2 months and every 5000 km or 6 months (whichever
occurs earlier).

Sensor wiring coupler

l Wiring coupler of the wheel speed sensor rear A

is located below the front seat assembly near
the cylinder head assembly.(Fig. 5.95)

l Inspect the wiring coupler of the wheel speed

sensor for any loose connection. Disconnect
the coupler by pressing the rear end of lock (A)
and reconnect again. (Fig. 5.96)

l Rotating the rear wheel by hand, check for

indication of speed in the speedometer or Fig. 5.95
using PC diagnostic hardware and software
after reconnecting the coupler.
RELE
ASE
Installation PRESS

A
A
l To reassemble the parts in the reverse order of
removal procedure.

Checking wiring harness continuity

l Remove the battery bracket. Refer chapter

“chassis ” page no 1-00 for removal procedure.

l Disconnect the wiring coupler of the wheel

Fig. 5.96
speed sensor as explained above.

l Switch ‘OFF’ the ignition. Remove the main

wiring harness socket connected to the HECU
unit by pressing the lock (A) and pushing the A
socket lever towards front as shown in the
figure. (Fig. 5.97)

CAUTION
Care should be taken not to damage the
socket lever and its lock. Otherwise it may
lead to wiring harness replacement.
Fig. 5.97
 SERVICE MANUAL

l Inspect the continuity between the wheel

speed sensor coupler and the HECU coupler of
the main wiring harness using a pocket tester.
(Fig. 5.98)

Pocket tester
Illustration
SPEED SENSOR HECU CONTINUITY
WIRE COLOUR COUPLER
CONTACT
BP YES
POINT No.1
CONTACT
OrR YES
POINT No.10 Fig. 5.98

NOTE
While checking the continuity care should
be taken not to damage the wiring
couplers.

l If there is no continuity, replace the wiring

harness and check the wheel speed indication
in the speedometer or using diagnostic
software by rotating the front wheel.

Toner ring to sensor air gap

l Using a feeler gauge measure the gap

between the toner ring and the wheel speed
sensor of the front wheel as shown in the
figure at 4 to 5 places. (Fig. 5.99)

Feeler gauge

Service limit 0.5 ~ 2.8 mm

Fig. 5.99
l The gap should be within the limit at all the
places. If the gap is not within the limit, then
inspect the toner ring for any bend and wheel
sensor mounting screw for proper tightness. If
these are OK, then follow the procedure given
below:

l Remove CRR pan head screw (M5x12 - 1 No)

from wheel speed sensor mounting.
(Fig. 5.100)

5 mm Allen key

Tightening torque 4.5 ± 0.5 Nm Fig. 5.100

 SERVICE MANUAL
ELECTRICAL

l Gently pull out and dislocate the sensor from

the bracket complete rear. (Fig. 5.101)

Fig. 5.101

l If the gap is less, then add a special shim

between the sensor and the bracket complete
rear. where the sensor screw is getting
mounted. (Fig. 5.102)

l Reassemble the sensor and recheck the gap

once again ILLUSYARTION
NOTE
Inspect the wheel speed indication as
explained earlier after re-fixing the sensor.
Fig. 5.102
Removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Disconnect the wiring coupler of the wheel

speed sensor as explained earlier

l Remove the wheel speed sensor mounting

screw as explained earlier and take out the
sensor from the bracket.

l Dislocate the sensor cable from the holding

clamps. (Fig. 5.103)

l Take out the sensor while taking care of wiring

routing.

l Fix a new sensor and properly reroute the

cable.

NOTE
Inspect the wheel speed indication as
explained earlier after fixing a new sensor. Fig. 5.103
 SERVICE MANUAL
ELECTRICAL

Rear sensor alignment

l Visually inspect the sensor for any

misalignment. Remove and reassemble the
sensor properly if required..

l Inspect for any looseness in the mounting

screw of wheel sensor. (Fig. 5.104) Tighten the
screw if necessary.

l Inspect the gap between the sensor and the

toner ring as explained in page no. 3.42 to
ensure that there is no misalignment. Fig. 5.104
 SERVICE MANUAL
CHASSIS

DESCRIPTION PAGE NO Chapter 6

WHEEL ASSEMBLY FRONT 3
Wheel assembly front - removal 3
Toner ring - removal 5
Disc plate replacement 5
Removal of bearing 6
Wheel assembly front - inspection 7
Wheel bearing - inspection 8
Axle front - inspection 8
Alloy wheel front - inspection 8
Tyre front - inspection 9
Wheel assembly front Reassembly 10
DISC BRAKE SYSTEM - FRONT 11
Brake pads removal 11
Inspection of brake pads 12
BRAKE FLUID AND ITS HANDLING 13
Inspecting brake fluid level 13
Air bleeding from the brake system 14
Brake fluid replacement 16
BUNDY MASTER CYLINDER FRONT 18
Master cylinder bundy tube replacement 18
Reassembly 20
BUNDY TUBE CALIPER ASSEMBLY FRONT 21
Master cylinder to caliper assembly bundy tube replacement 21
Reassembly 23
CALIPER ASSEMBLY FRONT 24
Caliper assembly front Removal 24
Caliper assembly front - Disassembly 25

CHASSIS
FRONT BRAKE MASTER CYLINDER 26
Master cylinder front- removal 26
Inspection of master cylinder 28
Reassembly 29
SUSPENSION SYSTEM - FRONT 31
Fork assembly front removal LH & RH 31
Fork assembly front LH - Oil change (Non Adjustable) 33
Fork assembly front LH - Oil seal replacement (Adjustable) 34
Fork assembly front RH - Oil change 35
Fork assembly front RH oil seal replacement 37
Inspection 39
Reassembly 40
LOWER BRACKET 42
Lower bracket removal 42
Inspection 46
Reassembly 46
Steering cone top and bottom 48
Steering balls 48
Steering race outer 48
 SERVICE MANUAL
CHASSIS

DESCRIPTION PAGE NO Chapter 4

WHEEL ASSEMBLY REAR
Wheel assembly rear removal
Toner ring removal
Disc plate replacement
Wheel bearing removal
Disc plate - servicing
Disc plate replacement
Sprocket drum assembly - disassembly
Inspection
Tyre inflation pressure
Sensor speed wheel / toner ring abs inspection
Reassembly
SUSPENSION SYSTEM - REAR
Rear shock absorber removal
Rear shock absorber adjustment

DRIVE CHAIN ASSEMBLY

Drive chain assembly removal
SWING ARM ASSEMBLY
Swing arm assembly - Disassembly
Inspection
Reassembly
DISC BRAKE SYSTEM REAR
Brake pads
Inspection of brake pads
Brake fluid
Inspection of brake fluid level

CHASSIS
Air bleeding
Brake fluid replacement
Hose complete brake - rear
BUNDY TUBES REPLACEMENT REAR
Bundy tube replacement of HECU to caliper assembly rear
Reassembly
Bundy tube replacement of HECU to master cylinder
Reassembly
CALIPER ASSEMBLY REAR
Caliper assembly rear removal
Caliper assembly rear - Disassembly
Caliper assembly inspection
Caliper Assembly - Reassembly
MASTER CYLINDER REAR
Master cylinder rear removal
Master cylinder rear assembly - Disassembly
Inspection
Reassembly
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY FRONT

Component : Wheel assembly front

Component condition : Vehicle on ramp and component accessible
Objective : Wheel assembly front removal
Repair cycle : As and when required

Wheel assembly front - removal

l Park the vehicle on the paddock stand front.

Refer chapter “general information” page no 1-
00 for installation procedure.

Worn-out or loose bearings allow free play

in wheel and make the wheel rotation
tight. Check for free rotation of wheel
before removing the wheel assembly.

l Loosen the hexagonal head cap screw

(M10x25 - 4 No.) from the mounting of leg
assembly LH & RH. (Fig. 4.1A & B)

6 mm Allen key

Tightening torque 19 ± 3 Nm
Fig. 4.1A Fig. 4.1B
l Remove the hexagonal flange head screw
(M12x1.5 - 1 No.) from the mounting of wheel
assembly front. (Fig. 4.2)

18 mm Spanner

Tightening torque 50 ± 7 Nm

Fig. 4.2
l Drag out front axle from the wheel assembly
front by hammering the other end of the axle.
(Fig. 4.3)

Fig. 4.3
 SERVICE MANUAL
CHASSIS

l Carefully take out the wheel assembly front

from its location along with disc plate, toner
ring and spacer axle front. (Fig. 4.4)

CAUTION
Before removing the wheel assembly make
sure front fork assembly properly seated on
the paddock stand front.

NOTE
Before tightening hexagonal flange head Fig. 4.4
screw, stroke the fork assembly front
several times to check for proper fork
action. Tighten the hexagonal flange head
screw after ensuring the fork action.

While remounting front wheel assembly,

locate the disc in between the brake pads

l Take out spacer axle front from the wheel

assembly front.(Fig. 4.5)

Fig. 4.5
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY FRONT

Component : Wheel assembly front - disassembly

Component condition : Vehicle on ramp and component accessible
Objective : Toner ring / Disc plate / Bearing removal
Repair cycle : As and when required

Toner ring - removal

l Remove the special screw (M8x20 - 5 Nos.)

from the mounting of toner ring ABS and take
out the toner ring ABS from the wheel
assembly front. (Fig. 4.6)

8 mm Spanner

Tightening torque 5 ± 1 Nm

NOTE
Fig. 4.6
Toner ring should be removed only in case
of replacement.

CAUTION
Do not use different toner ring. Do not
attempt to correct the toner ring bend
manually or by using any other tool /
mode.

Use only correct screws to avoid fouling of

with the adjacent parts.

Disc plate replacement

l Re m ove t h e h ex a g o n a l fla n g e s c r ew
(M5x14 - 5 Nos.) from the mounting of disc
plate and take out disc plate from the alloy
wheel front. (Fig. 4.7)

6 mm Allen key

Pre-tightening torque 11 ± 1 Nm

Final-tightening torque 31 ± 0. 5 Nm

NOTE
Fig. 4.7
Apply ANABOND 112 / SPECFIT GRADE
680 on threads of screws before tightening
them and wipe off the excessive.

Care should be taken not to damage the

toner ring during removal and reassembly
of disc plate.
 SERVICE MANUAL
CHASSIS

Removal of bearing

l Using special tool, remove the dust seal from

the wheel assembly front. (Fig. 4.8)

031 240 1 Universal oil seal remover

CAUTION
Bearings should be removed only in case of
replacement.

Fig. 4.8

l Heat the wheel assembly front up to 125° C by

placing the wheel on a hot plate.(Fig. 4.9)

Hot plate

Fig. 4.9

l Gently tap out the right and left bearing with a

suitable mandrel and take out the spacer
complete front hub. (Fig. 4.10)

Nylon hammer

Drift

Fig. 4.10
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY FRONT

Component : Wheel assembly front - inspection

Component condition : Vehicle on ramp and component accessible
Objective : Disc plate - Inspection
Repair cycle : Inspect at every 6,000 kms and replace at every 30,000 kms.

Inspection

NOTE
Before inspection, clean all necessary
components with suitable cleaning
solvent and lubricate them.

Disc plate (While mounted on wheels)

l Face out of the disc plate should not be more

than the limit specified below. Measure the
disc plate face out on the largest periphery of
the disc plate with a dial indicator.(Fig. 4.11)

l If the face out exceeds the limits, check

whether the cause lies in the front wheel
bearing or the disc plate itself. Replace
defective parts.
Fig. 4.11
Magnetic stand

Dial gauge (0.01)

Standard 0.2 mm

Service limit 0.3 mm

NOTE
Wipe out the disc plate surface with a dry
soft cloth before inspection.

l Measure the thickness of disc plate at the

worn-out portion as shown. (Fig. 4.12)

Micrometer

Thickness 4.5 mm

l Measure the disc plate thickness at four

different places. If the measured thickness is
less than the limits, replace the disc plate (refer
page no. 01-0 for disc plate removal procedure).

Fig. 4.12
 SERVICE MANUAL
CHASSIS

Wheel bearing
PLAY PLAY
l Inspect the wheel bearings inner race for play
by hand while fixing it in the hub complete front
wheel. (Fig. 4.13)

l Rotate the inner race by hand to inspect

whether abnormal noise occurs or rotating
smoothly. Replace bearing if found defective.

Axle front
Fig. 4.13
l Using the special tools, check the axle front for
run out (straightness) and replace the axle with
a new one if run out exceeds the limit.
(Fig. 4.14)

Dial gauge (0.01 mm)

Magnetic stand

V - block - 4“x3“x3“

Service limit 0.25 / 100 mm

WARNING Fig. 4.14

Do not attempt to straighten a bent axle.

Alloy wheel front

l Using the special tools, measure the run-out of

alloy wheel front. An excessive amount of run
out is usually due to a bent alloy wheel.
(Fig. 4.15)

Dial gauge (0.01 mm)

Magnetic stand

Service limit 1 mm

l Replace the alloy wheel front in case of any

abnormality.
Fig. 4.15
 SERVICE MANUAL
CHASSIS

Tyre front

l Using the vehicle with excessively worn-out

tyres will decrease riding stability and
consequently invite a dangerous situation due
to loss of control. It is highly recommended to
replace the tyre with a new one when the
groove depth of tyre from tread surface
reaches the following specifications: (Fig. 4.16)

Tyre depth gauge / Vernier caliper

Service limit 1.00 mm Fig.4.16

NOTE
Tyre depth can also be checked by tyre A
wear indicator (A) (TWI). (Fig. 4.17)

TW
I
Fig. 4.17

l While reassembling the tyre, after removing

from the alloy wheel, ensure that the arrow
mark (A) provided on the tyre faces the
direction of wheel rotation. (Fig. 4.18)
A

Tyre inflation pressure

l Inflation pressure affects the tyre life to a

Fig.4.18
greater extent. So it is necessary to maintain
proper inflation pressure. (Fig. 4.19)

Tyre pressure gauge

Pressure:

Solo and dual 2.25 kg/cm² (32 PSI)

NOTE
Tyre pressure should be checked only when
the tyre is cold.
Fig.4.19
 SERVICE MANUAL
CHASSIS

REASSEMBLY

l Reassemble the wheel assembly front in the

reverse order of disassembly and removal.
Before assembling front wheel assembly,
lubricate the axle front and bearings.

l Before tightening hexagonal flange head

screw, stroke the fork assembly front several
times to check for proper fork action. Tighten
the hexagonal flange head screw only after
ensuring the fork action.

NOTE
Wheel balancing to be done whenever the
tyre is removed and reassembled from the
wheel rim (alloy wheel).

l Refer the exploded view for details. (Fig. 4.20)

Front wheel exploded view

Fig. 4.20
 SERVICE MANUAL
CHASSIS

DISC BRAKE SYSTEM - FRONT

Component : Disc brake system front

Component condition : Vehicle on ramp and component accessible
Objective : Front brake pad replace
Repair cycle : Check the front brake pad conditions at every 5,000 kms and replace if required

Brake pads

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the split pin (A) from the caliper A

assembly front wheel. (Fig. 4.21)

NOTE
While reassembly make sure to assemble
the split pin without fail. Fig. 4.21

l Loosen the pad pin from the mounting of

caliper assembly front wheel. (Fig. 4.22)

T27 Temper star Allen key

Tightening torque 6 ± 1 Nm

l Gently press the pad spring and take out the

pad pin from the caliper assembly front wheel.

Fig. 4.22

l Take out the pad spring from the caliper

assembly front wheel. (Fig. 4.23).
A
NOTE
While reassembling the pad spring, ensure
to assemble the pad spring arrow (A) facing
upwards.

Fig. 4.23
 SERVICE MANUAL
CHASSIS

l Pull out the pad complete inner and pad

complete outer by hand. (Fig. 4.24)

Inspection of brake pads Fig. 4.24

l Observe the wear limit line marked on the pad

and check the wear condition of brake pads. WEAR LIMIT
(Fig. 6.24) When the wear exceeds the limit
line, replace the pads with new ones.
(Fig. 4.25)

NOTE
The pads must be replaced as a set.

l Reassemble the brake pad in the reverse order

of removal.
Fig.4.25
 SERVICE MANUAL
CHASSIS

BRAKE FLUID AND ITS HANDLING

Component : Brake fluid inspection

Component condition : Vehicle on ramp and component accessible
Objective : Brake fluid inspection
Repair cycle : Replace the brake fluid every 10,000 Km.

Inspecting brake fluid level

l Before inspecting the brake fluid level, Park the

vehicle on the paddock stand with the
handlebar kept straight.

l Inspect the brake fluid level in the reservoir, If

the oil level is found to be lower than the ‘MIN’
level mark (A) provided on the reservoir,
replenish the reservoir with the brake fluid A
graded below. (Fig. 4.26)

TVS Grade DOT 4

NOTE
Since the brake system of this motorcycle
has glycol based brake fluid, do not use or
mix different types of brake fluid such as
Fig. 4.26
silicon based and petroleum-based fluid
for refilling the system, otherwise damage
sustained will be serious.

Do not use any brake fluid taken from old or

used or unsealed containers.

Do not squeeze the brake lever while the

reservoir cap is removed. Otherwise brake
fluid will sometimes spout out.

CAUTION
Do not place the removed reservoir cap on
the speedometer or on any other painted
surfaces. Brake fluid will damage the
instrument cluster lenses and painted
parts.

Ensure no water enters the brake fluid

container. Because brake fluid has
hygroscopic property, and its boiling point
falls excessively if water is mixed with it.

Check the brake hose for cracks and hose

joints for leakage. If found any, replace the
hose.
 SERVICE MANUAL
CHASSIS

Air bleeding from the brake system

Since brake fluid from the master cylinder is

supplied to the caliper assembly through HECU, it
is necessary to have a pressurised brake fluid to
facilitate the bleeding process in ABS.

It is recommended to use Pneumatic brake

bleeder from recommended suppliers for
bleeding purpose. (Fig. 4.27)

If the front brake lever travel becomes more or if

any soft or spongy feel is observed in the lever, you Fig. 4.27
must carry out the air bleeding from the brake
system. Follow the procedure given below for
bleeding the air:

NOTE
Cover all painted surfaces with suitable
covers. Brake fluid may damage paint
work. If brake fluid falls on any painted
surface, wash immediately. Do not wipe it
clean.

l Park the vehicle on the paddock stand

l Remove the cap bleeder from the bleeder

screw front nipple. Insert a ring spanner on the
bleeder. (Fig. 4.28)

l Fix the caliper end of the bleeding machine to

the bleeder.

8 mm Ring spanner

Tightening torque 8 ± 1.5 Nm

NOTE
Place a tray below the caliper to avoid for Fig. 4.28
any spillage.

l Remove the flat screw (M4x12 - 2 Nos.) from

the master cylinder assembly front and
remove the reservoir cap. (Fig. 4.29)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Take out the plate diaphragm and diaphragm

from the reservoir.

Fig. 4.29
 SERVICE MANUAL
CHASSIS

l Fill the TVS Grade DOT 4 brake fluid till the

upper permissible level in the master cylinder.

l Connect the other end of the bleeding machine

to the pneumatic pressure port after loosening
the bleeding screw.

NOTE
Fill the fluid constantly into the master
cylinder. Ensure the master cylinder should
not go to dry.

l Now lock the bleeding screw front and operate

the front brake lever for 4-5 times, and loosen
the bleeding screw front by pressing the front
brake lever. Repeat the same process until no
air bubbles are coming out from caliper
bleeding nipple. (Fig. 4.30)

Fig. 4.30

l Once all the air bubbles have escaped, tighten

and lock the bleeder screw front. (Fig. 4.31)

8 mm Ring spanner

Tightening torque 8 ± 5 Nm

Fig. 4.31

l Disconnect the bleeding machine from caliper

bleeder screw. Fill the brake fluid to A
permissible level (A) and check level in
inspection window (B). (Fig. 4.32)

M
IN
B

Fig. 4.32
 SERVICE MANUAL
CHASSIS

l Install the reservoir cap front along with plate

diaphragm with diaphragm and tighten the flat
screws. (Fig. 4.33)

Phillips head screw driver

Tightening torque 1.25 ± 0.25 Nm

l Fix the cap bleeder on the bleeder screw and

check for smooth operation of the front brakes.

NOTE
Fig. 4.33
Do not reuse the brake fluid drained from
the system.

WARNING
Wipe off all fluid from the floor and ramp.
Brake fluid is slippery and may cause injury
or death.

Brake fluid replacement

l Boiling point of brake fluid falls considerably

with absorption of moisture which may take
place during a long period of use. Therefore, it
is recommended to replace old brake fluid with
new one periodically.

Replace brake fluid if required

l On changing brake fluid, extreme attention

should be paid so as not to mix any foreign
materials because they would block the return
port of the master cylinder resulting in the
brake dragging or squeaking.

Perform the following procedure to change the

brake fluid:

1. Drain the brake fluid by referring the air

bleeding procedure as explained on page no.
6- 62.

2. Repeat the same procedure 3 or more times

to completely drain out the old fluid from the
system.

3. Check the front brake lever for any

sponginess or more travel. If found any, carry
out the air bleeding again.
SERVICE MANUAL
CHASSIS

4. After completing the bleeding operation,

check the fluid level in the reservoir and
replenish if necessary.

NOTE
Fill the brake fluid constantly into the
master cylinder. Ensure the master cylinder
does not go dry.
 SERVICE MANUAL
CHASSIS

BUNDY MASTER CYLINDER FRONT

Component : Bundy tube master cylinder front

Component condition : Vehicle on ramp and component accessible
Objective : Bundy tube master cylinder front removal
Repair cycle : Inspect every 10,000 Km (Replace if required).

Master cylinder bundy tube replacement

NOTE
Clean the area around HECU to remove dirt
before opening fluid lines to prevent dirt
entry into HECU ports.

Before removing the bundy tubes, drain

the brake fluid from the bundy tube and
ensure it does not come in contact with
any painted surface.

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assemblies. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the hexagonal socket cap screw

(M8x25 - 2 Nos.) along with the punched
washer (8.5x18x2.3 - 2 Nos.) from the
mounting of sub frame rear LH & RH. (Fig 4.34) A

l Dislocate and take out the bracket seat

mounting front assembly from its
mounting.(A)

5 mm Allen key

Tightening torque 24 ± 3.6 Nm Fig. 4.34

CAUTION
Additional care should be taken not to
damage the bundy tube hoses and battery
terminalis during removal / reassembly.
 SERVICE MANUAL
CHASSIS

l Carefully remove the bundy tube master

cylinder front mounting banjo bolt (A) along
with washer banjo (2 Nos.) from the HECU
body. (Fig. 4.35)

12 mm Spanner A

Tightening torque 24 ± 3.6 Nm

NOTE
As soon as the bundy tube is removed,
secure the HECU port (bundy tube Fig. 4.35
mounting port) using suitable dummy plug
to avoid any dirt entry into the port.

Care should be taken to avoid damages to

the HECU by impact of tools.

l Remove bundy tube master cylinder front

mounting banjo bolt at master cylinder and
take out the washer banjo (2 Nos.) from both
the sides of the tube. (Fig. 4.36)

12 mm Spanner

Tightening torque 24 ± 3.6 Nm Fig. 4.36

l Dislocate the bundy tube (A) from the cable

clamp, strapped with the frame. (Fig. 4.37)

l Now, take out the bundy tube master cylinder

from the vehicle while taking care of the A
routing.

NOTE
It is advised to pull out or insert the flexible
portion (brake hose) of the bundy tube
through gaps to ensure that there is no
bending or damage to bundy tube (steel Fig. 4.37
portion) during its removal / reassembly.

Care should be taken to avoid permanent

bending due to over flexing of bundy tube
during removal and reassembly.

Do not damage the HECU by impact of

tools while removing bundy tubes.
 SERVICE MANUAL
CHASSIS

Reassembly

Reverse the removal process for reassembling

new bundy tube while taking care of the following:

l Ensure to assemble new washer banjo at both

the sides of bundy tube while mounting the
bundy tube with the master cylinder and the
bundy tube master cylinder with the HECU
body.

l Properly reroute and relocate the bundy tube in

the guide brake hoses.

l Reassemble the seat assemblies, fuel tank

assembly and bracket seat mounting front
assembly.

l Bleed the air from the brake circuit after

reassembling the bundy tube (refer page no.
6-00).
 SERVICE MANUAL
CHASSIS

BUNDY TUBE CALIPER ASSEMBLY FRONT

Component : Bundy tube caliper assembly front

Component condition : Vehicle on ramp and component accessible
Objective : Bundy tube removal from master cylinder to caliper assembly
Repair cycle : Inspect every 10,000 Km (Replace if required).

Master cylinder to caliper assembly bundy

tube replacement

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the seat assemblies. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the bracket seat mounting front

assembly. Refer page no 1-00 for removal
procedure.
A
l Remove the mounting banjo bolt (A) of bundy
tube caliper assembly along with washer banjo
(2 Nos.) from the HECU body. (Fig. 4.38)

12 mm Spanner

Tightening torque 24 ± 3.6 Nm Fig. 4.38

NOTE
As soon as the bundy tube is removed,
close the HECU port (bundy tube mounting
port) using suitable dummy plug to avoid
any dirt entry into the port.

Care should be taken to avoid damages to

the HECU by impact of tools.

l Remove the banjo bolt along with the washer

banjo (2 Nos.) from the mounting of caliper
assembly front. (Fig. 4.39)

12 mm Spanner

Tightening torque 24 ± 3.6 Nm

Fig. 4.39
 SERVICE MANUAL
CHASSIS

l Dislocate the wheel speed sensor cable

guides from the brake hose (4 Nos). (Fig. 4.40)

Fig. 4.40

l Loosen the hexagonal socket cap flange bolt

(M6x16 - 2 Nos.) from the mounting of bundy
tube caliper assembly bracket slot (A) with
lower bracket. (Fig. 4.41)

l Gently dislocate the bundy tube caliper

A
assembly from the bundy tube caliper
assembly bracket slot.

5 mm Allen key

Tightening torque 8 ± 1.2 Nm

Fig. 4.41

l Dislocate the bundy tube (A) from the cable

clamp, strapped with the frame. (Fig. 4.42)

l Now, take out the bundy tube caliper assembly

from the vehicle. while removal of bundy tube
take care of the routing.

A
CAUTION
It is advised to pull out or insert the flexible
portion (brake hose) of the bundy tube
through gaps to ensure that there is no
bending or damage to bundy tube (steel Fig. 4.42
portion) during removal / reassembly of
the bundy tubes.

Care should be taken to avoid permanent

bending due to over flexing of bundy tube
during removal and reassembly.

Do not damage the HECU by impact of

tools while removing bundy tubes.
 SERVICE MANUAL
CHASSIS

Reassembly

Reverse the removal process for reassembling

new bundy tube while taking care the following:

l Ensure to assemble new washer banjo at both

the sides of brake hose while mounting the
brake hose with the caliper assembly and the
bundy tube caliper assembly front with the
HECU body.

l Properly reroute and relocate the bundy tube

brake hose in bundy tube caliper assembly
bracket slot with lower bracket.

l Refix the wheel speed sensor cable guide

(4 Nos.) in the brake hose. Reassemble fuel
tank assembly, seat assemblies and bracket
seat mounting front assembly.

l Bleed the air from brake circuit after

reassembling (refer page no. 6-62).
 SERVICE MANUAL
CHASSIS

CALIPER ASSEMBLY FRONT

Component : Caliper assembly front.

Component condition : Vehicle on ramp and component accessible
Objective : Caliper assembly front - removal and disassembly
Repair cycle : Inspect every 10,000 Km (Replace if required).

Caliper assembly front - removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the Brake pads front. Refer chapter

“ C h a s s i s ” p a g e n o 6 - 0 9 fo r r e m ova l
procedure.

l Remove the banjo bolt along with the banjo

washer (2 Nos.) and take off the bundy tube
from the caliper assembly front wheel.
(Fig. 4.43)

12 mm Spanner

Tightening torque 24 ± 3.6 Nm

Fig. 4.43
l loosen the pin bolt (2 Nos.) from the mounting
of caliper assembly front.(Fig.4.44)

T50 Bit

Tightening torque 17 ± 0.5 Nm

Fig. 4.44
l Remove the hexagonal flange bolt (M8x50 - 2
Nos.) from the mounting of caliper assembly
front.(Fig.4.45)

12 mm Spanner

Tightening torque 28 ± 4.2 Nm

l Now, gently take out the caliper assembly from

its mounting.

Fig. 4.45
 SERVICE MANUAL
CHASSIS

Caliper assembly front - disassembly

l Remove the calipler assembly as explained in

pervious page.

l Remove the pin bolt from the caliper assembly

front.
 SERVICE MANUAL
CHASSIS

FRONT BRAKE MASTER CYLINDER

Component : Front master cylinder

Component condition : Vehicle on ramp and component accessible
Objective : Front master cylinder - removal and disassembly
Repair cycle : Inspect every 10,000 Km (Replace if required).

Master cylinder front- removal

l Dislocate the rubber boot (A) and loosen the

lock nut (B) from mirror assembly RH. Now,
Rotate anticlockwise direction and take out the
A B
mirror assembly RH. (Fig. 4.46A & Fig. 4.46B).

14 mm spanner

Tightening torque 29 ± 6 Nm

CAUTION
Fig. 4.46A Fig. 4.46B
While reassembling the mirror, care should
be taken not to damage the mounting
threads of the master cylinder.

l Bleed out the brake system completely as

explained earlier.

l Remove the banjo bolt along with the washer

banjo (2 Nos.) and dislocate the bundy tube
from the master cylinder assembly. (Fig. 4.47)

12 mm Spanner

Tightening torque 24 ± 3.6 Nm

Fig. 4.47
l Remove the special bolt and nylon lock nut
from the mounting of master cylinder
assembly and Take out the brake lever kit from
the master cylinder assembly. (Fig. 4.48)

10 mm Spanner

Tightening torque 6 ± 1 Nm

NOTE
While removing, hold the nylon lock nut by
hand to avoid falling down.
Fig. 4.48
 SERVICE MANUAL
CHASSIS

l Remove the flat screws (2 Nos.) from the

mounting of master cylinder fluid reservoir
cap. (Fig. 4.49)

Phillips head screw driver

Tightening torque 1 ± 0.5 Nm

l Take out the reservoir cap along with plate

diaphragm and diaphragm from the master
cylinder assembly.

Fig. 4.49

l Remove the hexagonal socket cap screw

(2 Nos.) from the mounting of bracket brake
switch with switch assembly stop lamp front.
(Fig. 4.50)

1.5 mm Allen key

Tightening torque 0.16 ± 0.2 Nm

l Take out the bracket brake switch along with

switch assembly stop lamp front.

NOTE Fig. 4.50

While reassembling the switch assembly

stop lamp front, ensure to assemble the
bracket brake switch without fail.

l Remove the hexagonal flange bolt

(M6x25 - 2 Nos.) from the mounting of clamp
master cylinder front. (Fig. 4.51)

10 mm Spanner

Tightening torque 8 ± 1.2 Nm

NOTE Fig. 4.51

Hold the master cylinder while removing
the clamp master cylinder mounting bolts
in-order to avoid falling.

l Now, carefully takeout the master cylinder

assembly front from its mounting.

l Slowly pull out the push rod front along with

the boot front (A) and spring push rod front (B) B
from the master cylinder assembly front.
(Fig. 4.52) A

Nose plier
Fig. 4.52
 SERVICE MANUAL
CHASSIS

l Holding the master cylinder by hand slightly

press the piston with thumb finger and remove
the circlip (A) from the master cylinder using a
circlip plier without damaging the piston and
the cylinder. (Fig. 4.53)

Circlip plier A

NOTE
Ensure that the circlip is seated properly in
its position after installation.
Fig. 4.53

l Slowly pull out the piston MC front along with

primary seal (A), secondary seal (B) and piston
spring (C).(Fig. 4.54)

l Clean the master cylinder assembly front

thoroughly by using fresh brake fluid.
A

CAUTION
C
Never use kerosene, petrol or other B
solvents for cleaning the brake system.
Otherwise rubber parts will get damaged.
Fig. 4.54
NOTE
If any piston MC parts got damage replace
as a set.

Inspection of master cylinder

Inspect the following parts:

- Master cylinder for any scratches or any

otherdamages.

- piston MC front and piston spring surface

for scratches or other damages.

- Piston boot and other components for wear

and damages.

- Master cylinder recuperation and feed port

for any blockage, if so clear the block using
compressed air.

l After the above inspection, if found any defect,

replace the respective parts.
 SERVICE MANUAL
CHASSIS

REASSEMBLY

l Reassemble the master cylinder assembly in

the reverse order of dismantling. Refer
(Fig. 4.55) exploded view for reassembly.

CAUTION
Apply the brake fluid to the cylinder bore
and all internal parts before inserting
piston assembly into the bore.

Master cylinder exploded view

Fig. 4.55
 SERVICE MANUAL
CHASSIS

l Remount the master cylinder to the handle bar

assembly. (Fig. 4.56)

10 mm spanner

Tightening torque 8 ± 1.2 Nm

NOTE
Always tighten the top bolt first and then
the bottom one. Mount master cylinder to
the handle bar such that reservoir becomes
horizontal when the bike is placed on Fig. 4.56
paddock stand and steering is kept
straight.

l Fix the bundy tube to the master cylinder outlet

port along with the banjo bolt and washer banjo
(2 Nos.).
M
l Fill the reservoir with fresh TVS Grade DOT 4 IN

brake fluid above the level ‘MIN’ mark on the

reservoir and bleed the system thoroughly.
(Fig. 4.57)

l Fix the reservoir cap along with diaphragm and

plate diaphragm and tighten screws. Connect Fig. 4.57
the bracket brake switch with switch assembly
stop lamp front.

l Replace the following parts every 21,000 km:

- Piston along with spring

- Reservoir cap and diaphragm.

- Primary seal and secondary seal

 SERVICE MANUAL
CHASSIS

SUSPENSION SYSTEM - FRONT

Component : Fork assembly front

Component condition : Vehicle on ramp and component accessible
Objective : Fork assembly front removal LH & RH
Repair cycle : As and when required

Fork assembly front removal LH & RH

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00
for installation procedure.

l Place the plate engine support along with jack

under engine assemble as explained in page
no 1-00 for installation procedure.

l Remove the front wheel assembly. Refer

chapter “Chassis” page no 1-00 for installation
procedure.

l Remove the front finder assembly. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the hexagonal flange bolt (M8x50 - 2

Nos.) from the mounting of caliper assembly
front.(Fig.4.58)

12 mm Spanner

Tightening torque 28 ± 4.2 Nm

l Now, gently dislocate and hang the caliper

assembly from its mounting. keep cushion in
between the brake pads.

Fig. 4.58

l Remove the hexagonal socket cap flange bolt

(M5x12 - 2 Nos.) from the mounting cable
guide. (Fig. 4.59)

4 mm Allen key

Tightening torque 4.5 ± 0.5 Nm

Fig. 4.59
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal socket cap flange bolt

(1 No.) from the mounting of sensor speed
wheel. (Fig. 4.60)

5 mm allen key

Tightening torque 4.5 ± 0.5 Nm

NOTE
Care should be taken not to damage the
wheel speed sensor during its removal and
fitment. Fig.4.60

l Gently push and dislocate the speed wheel

sensor from leg assembly LH.

l Loosen the hexagonal socket cap screw

(M8x30 - 2 Nos.) from the mounting of upper
bracket MC LH & RH. (Fig. 4.61A & B)

6 mm Allen key

Tightening torque 19 ± 3 Nm

Fig. 4.61A Fig. 4.61B

l Loosen the hexagonal socket cap screw

(M8x30 - 4 Nos.) from the mounting of lower
bracket complete LH & RH. (Fig. 4.62 A & B)

6 mm Allen key

Tightening torque 19 ± 3 Nm

NOTE
Hold the fork leg assembly while loosening
the bottom mounting bolts. Else it may fall.
Fig. 4.62A Fig. 4.62B
l Loosen the nut front fork and carefully pull out
the fork leg assembly LH. (Fig. 4.63 A & B)

17 mm Spanner

Tightening torque 20 ± 0.5 Nm

l In similar manner pull out the fork leg assembly

RH and take it out from its mounting.

Fig. 4.63A Fig. 4.63B

 SERVICE MANUAL
CHASSIS

FORK ASSEMBLY FRONT

Component : Fork assembly front

Component condition : Vehicle on ramp and component accessible
Objective : Fork assembly front oil and oil seal replacement LH & RH.
Repair cycle : Replace the oil every 20,000 Km.

Fork assembly front LH - Oil change (Non

Adjustable)

l Remove the front fork assembly LH as

explained in previous page.

l Remove the nut front fork from along with 'O'

ring from the mounting of leg assembly
.(Fig. 4.64)

17 mm Spanner

Tightening torque 20 ± 0.5 Nm Fig. 4.64

CAUTION
Remove the cap nut with constant
handgrip on nut. The nut is subject to
hydraulic pressure load and may jump out
in case of loose handling.

l Loosen the nut front fork (M8 - 2 No.) by

holding the damper piston nut. (Fig. 4.65)

16 / 17 mm Spanner

Tightening torque 17 ± 3 Nm

Fig. 4.65
l Remove the nut front fork along with ‘O’ ring
from the damper piston. (Fig. 4.66)

NOTE
While reassembling replace the ‘O’ ring
with a new one.

Fig. 4.66
 SERVICE MANUAL
CHASSIS

l Turn the leg assembly front fork upside down.

Holding the outer tube by hand, pump the inner
tube ‘in’ and ‘out’ to drain the oil completely.
(Fig. 4.67A)

NOTE
Hold the leg assembly front fork inverted
for few minutes to drain the oil completely.

l Fill the specified amount of fresh fork oil in

front fork assembly LH. (Fig. 4.67B)
Fig. 4.67A Fig. 4.67B
Oil specification KHL 15-10

Front fork oil capacity 480 ± 2 ml

NOTE
Make sure that measuring jar is clear from
any dust, burr, dirt and foreign particles.
Also ensure that workplace is neat and
clean.

l Now, stroke the inner tube up and down 10

times to remove the air bubble.

Fork assembly front LH - Oil seal replacement

(Adjustable)

l Remove the seal dust front fork (dust seal)

from the outer tube while ensuring no damage
to the dust seal, inner surface of outer tube and
outer surface of inner tube. (Fig. 4.68A)

• Remove the snap ring from the outer tube

while ensuring no damage to the inner surface
of outer tube and outer surface of inner
tube.(Fig. 4.68B)

Fig. 4.68A Fig. 4.68B

Flat screwdriver

NOTE
While reassembling, replace the dust seal
and snap ring if any damage is found.

• Gently pull out and dislocate the inner tube

from the fork tube outer. Fig. 6.69
NOTE
While dislocating the inner tube care
should be taken not to drop down the inner
tube it may cause replace.
 SERVICE MANUAL
CHASSIS

• Using flat screw driver takeout the fork tube

outer bush from the inner tube. (Fig. 4.69A)

• Lift and takeout the washer front fork from the

inner tube assembly LH. (Fig. 4.69B)

CAUTION
Take extra care not to cause any dent,
damage and scratches to inner tubes
during disassembly and reassembly.

Fig. 4.69A Fig. 4.69B

• Using the special tool remove the oil seal from
the inner tube assembly. (Fig. 4.70)

N731 006 0 Tool fork oil seal

NOTE
While reassembling, replace the oil seal
with the new one.

Fork assembly front RH - Oil change

l Remove the front fork assembly RH from the Fig. 4.70

vehicle as explained earlier.

l Remove the nut front fork from along with 'O'

ring from the mounting of leg assembly
.(Fig. 4.71)

17 mm Spanner

Tightening torque 20 ± 0.5 Nm

CAUTION
Remove the cap nut with constant
handgrip on nut. The nut is subject to
Fig. 4.71
spring load and may jump out in case of
loose handling.

l Install the spacer holder tool (A) on the spacer

front fork and press it down with force.

l By press the spacer holding tool, take the A

additional help from the other technician and
insert a spacer holder (B) between the nut front B
fork and damper piston front fork. (Fig. 4.72)

Special tool N7310050

Fig. 4.72
 SERVICE MANUAL
CHASSIS

WARNING
The spacer holder tool will be having
c o m p re s s e d p o te n t i a l e n e rgy. Ta ke
additional care while performing this
operation, failure of which will cause
severe injury or death.

• Press the both spacer holder tool and insert the

17 mm open spanner above the nut front fork
and insert the 16 mm open spanner below the
damper piston front fork nut. (Fig. 4.73)
Fig. 4.73
• Now, loosen the nut front fork with 17 mm
open spanner.

l Remove the nut front fork along with ‘O’ ring

from the damper piston. (Fig. 4.74)

NOTE
While reassembling replace the ‘O’ ring
with a new one.

Fig. 4.74

l Takeout the spacer front fork from the fork tube

outer. (Fig. 4.75)

Fig. 4.75
l Remove the slider (A) and spring (B) front fork
from front fork RH. (Fig. 4.76A & B)

Fig. 4.76A Fig. 4.76B

 SERVICE MANUAL
CHASSIS

l Drain the fork oil into a measuring jar.

(Fig. 4.77A)

NOTE
Hold leg assembly front fork inverted for
few minutes to drain the oil completely.

l Fill the specified amount of fresh fork oil in

front fork assembly RH. (Fig. 4.77B)

Oil specification KHL 15-10

Fig. 4.77A Fig. 4.77B
Front fork oil capacity 440 ± 2 ml

NOTE
Make sure that measuring jar is clear from
any dust, burr, dirt and foreign particles.
Also ensure that workplace is neat and
clean.

l Now, stroke the inner tube up and down 10

times to remove the air bubble.

NOTE
To change the fork oil, don't disassemble
the fork's inner & outer tubes.

Fork assembly front RH oil seal replacement

l Drain out the front fork oil as explained in

previous page

l Fix a damper locking tool on the damper and

lock it. (Fig. 4.78A)
Fig. 4.78A Fig. 4.78B
• Lock the damper lifting tool and using allen bit,
remove the hexagonal socket head cap screw
along with sealing ring and take out the damper
piston front fork from its location. (Fig. 4.78B)

6 mm Allen key

Tightening torque 23 ± 3 Nm

NOTE
While reassembly of damper piston front
fork apply the adhesive agent on the
threads.
 SERVICE MANUAL
CHASSIS

l Remove the seal dust front fork (dust seal)

from the outer tube while ensuring no damage
to the dust seal, inner surface of outer tube and
outer surface of inner tube. (Fig. 4.79A)

• Remove the snap ring from the outer tube

while ensuring no damage to the inner surface
of outer tube and outer surface of inner
tube.(Fig. 4.79B)

Flat screwdriver

NOTE Fig. 4.79A Fig. 4.79B

While reassembling, replace the dust seal

and snap ring if any damage is found.

• Gently pull out and dislocate the inner tube

from the fork tube outer.

NOTE
While dislocating the inner tube care
should be taken not to drop down the inner
tube it may cause replace.

• Using flat screw driver takeout the fork tube

outer bush from the inner tube assembly.
(Fig. 6.80A)

• Lift and takeout the washer front fork from the

inner tube assembly LH. (Fig. 4.80B)

NOTE
Take extra care not to cause any dent,
damage and scratches to inner tubes
during disassembly and reassembly.
Fig. 4.80A Fig. 4.80B
• Using the special tool remove the oil seal from
the inner tube assembly LH. (Fig. 4.81)

NOTE
While reassembling, replace the oil seal
with the new one.

Fig. 4.81
 SERVICE MANUAL
CHASSIS

FORK ASSEMBLY FRONT

Component : Fork assembly front

Component condition : Vehicle on ramp and component accessible
Objective : Front fork assembly LH & RH - Inspection
Repair cycle : Inspect every 10,000 Km.

INSPECTION

l Before inspection, clean all the components

A
with a cleaning solvent.

l Visually inspect the outer tube (A) and inner

tube (B) for wear and any damage. (Fig.4.82)
Replace with a new leg assembly if any
damage is noticed.
B
l Inspect the outer surface of inner tube and
sliding surface (inner surface) of outer tube for
any scuffing, scratches, dents, plating peel off Fig. 4.82
etc. Replace the inner tube - damper piston
front fork assembly (Only for RH) or outer tube
if it has surface defects / flaws. If the inner tube A B
D
has damage / dent on surface, replace the oil
seal and inner tube together.

l Similarly, inspect the oil seal (A),dust seal front

fork (B), snap ring (C), fork tube outer bush (D)
and washer front fork (E) of inner tube for any
damage or wear replace if found any. (Fig. 4.83)
E C

Fig. 4.83

l Inspect the front fork nut ‘O’ ring for any

damage or bulge. Replace if found any.
(Fig. 4.84)

NOTE
Before installing cap nut front fork, lightly
apply grease to the ‘O’ ring.

Fig. 4.84
 SERVICE MANUAL
CHASSIS

Spring Front Fork

l Measure the free length (A) of the spring front

fork. If the length is shorter than service limit or
deformation of spring, replace it with a new
one. (Fig. 4.85)

Service limit length (A) 502 m

REASSEMBLY

l Reassemble and remount the front fork Fig. 4.85

assemblies LH & RH in the reverse order of
disassembly while carrying out the following
steps.

l Refer front fork assembly RH exploded view

(Fig. 4.86) for assembly details.

l Make sure all the components are clean.

Lubricate the inner surface of the outer tube
and outer surface of the inner tube.

l Assemble the inner tube along with dust seal,

oil seal, washer and fork tube outer bush. Now
insert the inner tube in the outer tube. ILLUSTRATION

Fig. 4.86
l Assemble the new oil seal using special tool.
(Fig. 4.87)

N731 006 0 Tool fork oil seal

NOTE
Before installing the oil seal, apply
littlevgrease (MOS ) on the lip of oil seal.

l Assemble the snap ring.

Fig. 4.87
 SERVICE MANUAL
CHASSIS

l Reassemble the dust seal using special tool.

(Fig. 4.88)

N731 006 0 Tool fork oil seal

l Fill up the fork oil as per specification.

NOTE
After filling up, slowly pump the leg
assembly front fork up and down 10 times
to remove air lock / gaps. Before installing
the lock nut, apply grease to the ‘O’ ring. Fig. 4.88

l Before installing nut front fork, lightly apply

grease to the ‘O’ ring. Remount for leg
assembly. (Fig. 4.89)

l Remount the front fork assembly to the vehicle

in reverse order of dismantling.

l Tighten top mounting screws (fork upper

mounting) to the specified torque (refer
chapter ”Chassis page no. 6-33 for tightening
torque).

l Tighten hexagonal bolts of lower bracket (fork Fig. 4.89

bottom mounting) to the specified torque (refer
chapter ”Service information page no. 8-10 for
torque sheet).

l Reassemble the front fender and front wheel

assembly in the reverse order of removal.

l Re-fix the caliper assembly front fork and

ensure the proper working of brake.
 SERVICE MANUAL
CHASSIS

LOWER BRACKET

Component : Lower bracket complete (steering stem) - Disassembly

Component condition : Vehicle on ramp and component accessible
Objective : Lower bracket removal
Repair cycle : As and when required

Lower bracket removal

l Park the vehicle on the paddock stand. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Place the plate engine support along with jack

under engine assemble as explained in page
no 1-00 for installation procedure.

l Remove the seat assembly. Refer chapter

“general information” page no 1-00 for
installation procedure.

l Remove the fuel tank assembly. Refer chapter

“general information” page no 1-00 for
installation procedure.

l Remove the front fender assembly. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the front wheel assembly. Refer

chapter “general information” page no 1-00 for
installation procedure.

l Remove the front fork assembly. Refer chapter

“general information” page no 1-00 for
installation procedure.

l Remove the cap steering lock nut from the bolt

steering adjuster. (Fig.4.90)

Flat screwdriver Fig. 4.90

l Remove the bolt steering adjuster from the

lower bracket complete. (Fig. 4.91)

10 mm Allen key

Tightening torque 38 ± 5 Nm

Fig. 4.91
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal socket head cap screw

(M6x16 - 2 Nos.) from the mounting of bracket
Steering lock. (Fig. 4.93)

6 mm Allen key

Tightening torque 7 ± 1 Nm

l Now, take out the Bracket steering lock from

sub frame front.

Fig. 4.93

l Loosen the hexagonal socket cap screw

(M8x30 - 1 No.) from the mounting of upper
bracket MC. (Fig. 4.94)

6 mm Allen key

Tightening torque 19 ± 3 Nm

Fig. 4.94

l Remove the hexagonal socket cap screw

(M8x30 - 2 Nos.) from the mounting of lower
bracket (bundy tube & speed sensor bracket).
(Fig. 4.95)

5 mm Allen key

Tightening torque 8 ± 1.2 Nm

Fig. 4.95
l Now, remove the hexagonal socket cap screw
(M8x30 - 1 No.) from the mounting of upper
bracket MC, while holding the lower bracket
complete. (Fig. 4.96)

6 mm Allen key

Tightening torque 19 ± 3 Nm

l Gently lift the handle bar assembly, support

and hang it at the side of the fuel tank
complete.
Fig. 4.96
 SERVICE MANUAL
CHASSIS

NOTE
Ensure that the control cables are not
stretched too much or bent.

Ensure not to scratch / damage the painted

surface of the fuel tank.

l Remove the dust cover steering from the

steering pivot pipe(Frame).(Fig. 4.97A)

l Remove the steering race inner from the Fig. 4.97A Fig. 4.97B
steering pivot pipe(Frame). (Fig. 4.97B)

l Carefully take out the lower bracket complete

along with the ball cage complete bottom and
dust seal steering lower from the steering
pivot pipe (Frame). (Fig. 4.98)

Fig. 4.98

l Remove the ball cage complete (14 balls) from

the lower bracket complete upper. (Fig. 4.99)

NOTE
Steering ball case should handled carefully,
since it tends to fall during removal.

Fig. 4.99
l using hammer and steering cup remover draw
out the steering cone top and bottom from the
steering pivot pipe (frame). (Fig. 4.100A & B)

Nb310030 Removal steering cup

NOTE
While fixing the special tool, ensure that
the tool is seated properly on the steering
pivot tube and the lock plate of the tool is
locked with the steering stopper properly.
Fig. 4.100A Fig. 4.100B
 SERVICE MANUAL
CHASSIS

l Remove the ball cage complete (14 balls) from

t h e l owe r b r a cke t c o m p l e t e b o tt o m .
(Fig. 4.101)

Fig. 4.101

l using special tool, remove the dust seal

steering lower along with the steering race
inner from the lower bracket complete.
(Fig. 4.102A & B)

Nb310020

Fig. 4.102A Fig. 4.102B

 SERVICE MANUAL
CHASSIS

LOWER BRACKET

Component : Lower bracket complete (steering stem) - Disassembly

Component condition : Vehicle on ramp and component accessible
Objective : Lower bracket Inspection
Repair cycle : As and when required

INSPECTION

l Before inspection clean all the components

with kerosene. Inspect the removed parts for
the following abnormalities and replace the
defective with new ones.

- Handle bar distortion.

- Dust seal and steering race inner and outer for

wear, pitting, rusting and indentation.
(Fig. 6.00)
ILLUSTRATION
- Worn or damaged steel balls / ball case and
rusting. (Fig. 4.103)

NOTE
Always replace the steering race inner and
Fig. 4.103
outer as a set only.

REASSEMBLY

l Reassemble the lower bracket complete, leg

assembly front fork LH & RH, handle bar
assembly, front brake hose and wheel
assembly front in the reverse order of
disassembly while carrying out the following
steps:

l Refer lower bracket complete exploded view

(Fig. 6.00) for reassembly. ,
 SERVICE MANUAL
CHASSIS

EXPLODED VIEW OF LOWER BRACKET

Fig. 4.104
 SERVICE MANUAL
CHASSIS

Steering cone top and bottom

l Assemble the steering cone top and bottom by

using a special tool. (Fig. 4.105)

231 030 0 Assemble tool steering cups

NOTE
Always replace steering cone as a set.

Fig. 4.105
Steering balls

l Apply grease to the ball cage complete at

bottom and top when installing the steel balls.

N
(Fig. 4.106A & B)

O
TI

TI
RA
Bechem premium grade 3

RA
ST

ST
l Install specified quantity of steering balls at ball

LU
cage at top and bottom (refer page no. 6-36 for

LU
the specified quantity). IL

IL
Steering race outer
Fig. 4.106A Fig. 4.106B
l Install steering race outer along with the dust
seal steering lower to the lower bracket
complete (steering stem) by using the special
tool and apply grease. (Fig. 4.107)

431 031 0 Mandrel steering cone bottom

l Reassemble the lower bracket complete along

with steering race outer and dust seal steering
lower in the reverse order of disassembly.

031 380 1 Universal clamp wrench

l Now, Hold the lower bracket in hand and

Fig. 4.107
reassemble the steering race inner and dust
cover steering. (Fig. 4.108A & B)

l Turn the lower bracket complete right and left,

five or six times for proper seating of steering
ball and re-tight the arrester to specified
torque.

l Assemble the upper bracket along with handle

bar assembly. Finally tighten the bolt steering
adjuster to the specified torque.

l For steering adjustment . Refer chapter

“Periodic maintenance” page no 2-24.
Fig. 4.108A Fig. 4.108B
SERVICE MANUAL
CHASSIS

WARNING
Steering should be adjusted correctly for
smooth movement of handle bar and for
safe riding. Stiff steering prevents smooth
movement of handle bar resulting in poor
directional stability and too loose steering
causes vibration and damage to the
steering races.

NOTE
After adjustment, ensure the handlebar
moves smoothly without any jerk or sticky.
When slowly moved by hand it moves
freely from center position to either left
and right with its own weight.
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY REAR

Component : Wheel assembly rear

Component condition : Vehicle on ramp and component accessible
Objective : Wheel assembly rear removal
Repair cycle : As and when required

Wheel assembly rear removal

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove the hexagonal socket head cap screw

(M8x45 - 1 No.) from the rear hugger
bracket.(Fig. 4.109)

6 mm Allen key

Tightening torque 19 ± 1 Nm

Fig. 4.109
l Remove the hexagonal socket head cap screw
(M8x32 - 1 No.) from the rear hugger
bracket.(Fig. 4.110)

6 mm Allen key

Tightening torque 19 ± 1 Nm

Fig. 4.110
l Sightly loosen the hexagonal socket head cap
screw (M8x32 - 1 No.) from the rear hugger
bracket and lift the rear hugger upwards for
easy removal of rear wheel assembly.
(Fig. 4.111)

6 mm Allen key

Tightening torque 19 ± 1 Nm

Fig. 4.111
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal socket cap flange

screw (M6x20 - 1 No.) from the mounting of
sensor speed wheel and dislocate the speed
sensor from its location for easy access of
wheel removal . (Fig.4.112)

5 mm Allen key

Tightening torque 4.5 ± 0.5 Nm

Fig. 4.112

l Re m ove t h e h ex a g o n a l fla n g e U n u t
(M18x1.5 - 1 No.) along with the punched
washer (18.5x32x1.5 - 1No.) from the mounting
of axle rear. (Fig. 4.113)

27 mm Spanner A

Tightening torque 100 ± 15 Nm

l Now, gently take out the chain adjuster L

casting (A) from its mounting.(Fig. 6.113)

Fig. 4.113

l Loosen the chain adjuster nut and bolt equally

on both sides and dislocate the chain assembly
from the sprocket rear 41T. (Fig. 4.114)

10 mm Spanner

Fig. 4.114
l Drag out the axle rear (20x310 - 1 No.) from the
rear wheel assembly and carefully take out the
rear wheel assembly along with toner ring
ABS, disc plate and sprocket rear 41T.
(Fig. 4.115)

NOTE
While removing the rear wheel hold the
rear bracket complete because it may fall
down.

Fig.4.115
 SERVICE MANUAL
CHASSIS

l Remove the sprocket assembly from the rear

wheel assembly LH side along with the drum
rear sprocket, ball bearing, circlip, dust seal and
spacer axle rear. (Fig.4.116)

Fig. 4.116
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY REAR

Component : Wheel assembly rear

Component condition : Vehicle on ramp and component accessible
Objective : Toner ring ABS / Disc plate / Sprocket rear removal
Repair cycle : As and when required

TONER RING REMOVAL

l Take out the spacer axle rear RH from the disc

plate assembly. (Fig. 4.117)

l Remove hexagonal flange bolt (M5x14 - 5 Nos.)

from the of mounting toner ring ABS
(Fig. 6.118)
Fig. 4.117
8 mm Spanner

Tightening torque 5 ±1 Nm

l Take out the toner ring ABS from the wheel

assembly rear.

NOTE
Toner ring should be removed only incase
of replacement.

CAUTION
Fig.4.118
Do not use different toner ring. Do not
attempt to correct the toner ring by
bending manually or by using any other
tool / mode.

l Use only correct screws to avoid fouling of with

the adjacent parts.

DISC PLATE REPLACEMENT

l Remove toner ring as explained earlier.

l Remove the special screw (5 Nos.) from the

disc plate mounting and take out disc plate
from the alloy wheel rear. (Fig. 4.119)

5 mm Allen key

Pre torque 11 ± 1 Nm

Final torque 31 ± 0.5 Nm Fig. 4.119

 SERVICE MANUAL
CHASSIS

Wheel bearing removal

WARNING
It is recommended to remove the bearings
only in case of replacement.

NOTE
Before heating the wheel assembly rear it
is recommended to remove the absorber
rear wheel from alloy wheel rear.
(Fig. 4.120) Fig. 4.120

l Using the special tool remove the dust seal

from the mounting of wheel assembly rear.
(Fig. 4.121)

031 240 1 Universal oil seal remover

CAUTION
While reassembling, always replace the
dust seal with new one.

Fig. 4.121

l Place the wheel assembly rear (brake drum) on

a hot plate and heat to approximately 125°C.
(Fig. 4.122)

Hot plate

Fig.4.122
l Draw out the ball bearing from the wheel
assembly. (Fig. 4.123)

Drift

Ball pin hammer

Fig. 4.123
 SERVICE MANUAL
CHASSIS

DISC PLATE - SERVICING

Inspection

l Inspect the disc plate as explained in front disc

plate servicing (refer page 6-3 for disc plate
inspection).

Disc Plate Replacement

l Replace the disc plate if found to be defective

(refer page no. 6-20 for removal procedure).

SPROCKET DRUM ASSEMBLY - DISASSEMBLY

l Remove the spacer axle rear RH from the

wheel assembly sprocket side.(Fig. 4.124)

Fig. 4.124
l Using the special tool remove the dust seal
from the sprocket assembly. (Fig. 4.125)

031 240 1 Universal oil seal remover

CAUTION
While reassembling, always replace the
dust seal with new one.

Fig. 4.125
l Remove the circlip from the sprocket
assembly. (Fig. 4.126)

Nose plier

NOTE
Ensure that the circlip is seated properly in
its position after installation.

Fig. 4.126
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal flange nut

(M8x30 - 6 Nos.) from the sprocket assembly.
(Fig. 4.127)

12 mm Spanner

Tightening torque 30 ± 2 Nm

l Take out the sprocket and bolt from the

mounting of rear sprocket. (6 Nos.)

Fig.4.127

l Heat the drum rear sprocket on a hot plate to

approximately 125° C. (Fig. 4.128A)

Hot plate N
O
l Draw out the ball bearing along with shaft rear ATI
sprocket mounting drum from its mounting. TR
S
(Fig. 4.128B)
LU
IL
Drift

Nylon hammer
Fig. 4.128A Fig. 4.128B
 SERVICE MANUAL
CHASSIS

WHEEL ASSEMBLY REAR

Component : Wheel assembly rear

Component condition : Vehicle on ramp and component accessible
Objective : Toner ring ABS / Disc plate / Sprocket rear - Inspection
Repair cycle : As and when required

INSPECTION

Before inspection, clean all the components with

kerosene and lubricate the bearings immediately
after cleaning.

l Inspect wheel bearings, axle complete rear

and alloy wheel rear (refer page no. 6-4 for
checking procedure).

l Clean and inspect the drive chain as explained

in chapter ”Periodic maintenance” page 2-22.

Sprocket Rear
ILLUSTRATION
l Inspect sprocket rear teeth for wear. If they are
worn-out as illustrated (Fig. 4.129), replace the
sprocket with a new one.

Absorber Rear Wheel Hub Shock Fig. 4.129

l Inspect the absorber rear wheel hub shock for

wear, deformation or damage. Replace with
new one if required. (Fig. 4.130)

Tyre inflation pressure Fig. 4.130

l Tyre inflation pressure affects the tyre life to a

great extent. So it is necessary to maintain the
proper tyre pressure. (Fig. 4.131)

Tyre pressure gauge

Tyre pressure

Solo riding 2.00 kg/cm² (28 PSI)

Dual riding 2.25 kg/cm² (32 PSI)

Fig. 4.131
 SERVICE MANUAL
CHASSIS

Sensor speed wheel / Toner Ring ABS

Inspection

l Dirt / mud accumulation (especially iron

A
particles) in the toner rings and wheel speed
sensors results improper function of ABS.

l Inspect front sensor speed wheel (A) and toner

ring (B) for any dirt / mud accumulations B
visually. (Fig. 4.132)

l Clean them using a clean cloth and solvents

like diesel / kerosene (No need to remove the Fig. 4.132
sensor / toner ring from the vehicle).

CAUTION
During cleaning process care should be
taken not damage the toner ring and
sensor.

Do not insert any metal part between the

toner ring and sensor.

While water washing do not point the

pressurised jet directly on the toner ring /
wheel speed sensor as it may damage the
toner ring teeth / sensor and result in
malfunction of ABS.

l Replace the sensor speed wheel in case of any

damage (refer chapter “Electrical System”
page no 5-33 for removing and replacing
procedure of wheel speed sensor).

l If the toner ring teeth are found damaged then,

replace the toner ring with a new one (refer
chapter “Chassis”page no. 6-2 for removing
and replacing procedure of toner ring).

REASSEMBLY

l Reassemble and remount the wheel assembly

rear in the reverse order of disassembly. Refer
wheel assembly exploded view (Fig. 4.134) for
assembly details.

l Before assembling rear wheel assembly,

lubricate the axle rear and bearings. B
A
l Make sure that the slot (A) in the bracket
complete caliper assembly fits over the
stopper (B) on the swing arm assembly.
(Fig. 4.133)
Fig. 4.133
 SERVICE MANUAL
CHASSIS

NOTE
After remounting the wheel assembly rear,
readjust the chain slackness (refer chapter
“Periodic maintenance” page no. 2-22).

Exploded view

Fig. 4.134
 SERVICE MANUAL
CHASSIS

SUSPENSION SYSTEM - REAR

Component : Rear shock absorber

Component condition : Vehicle on ramp and component accessible
Objective : Rear shock absorber removal
Repair cycle : As and when required

Rear shock absorber removal

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Place the plate engine support along with jack

under engine assemble as explained in page no
1-00 for installation procedure.

l Remove the Rear wheel assembly. Refer

chapter “Chassis” page no 6-01 for removal
procedure.

l Remove the snap rivet plastic (2 Nos.) from the

mounting of wheel hugger top and take it out
from its location. (Fig. 4.135A & B)

Philips screw driver

Fig. 4.135A Fig. 4.135B

NOTE
Care should be taken not to damage the
snap rivet while assembly or disassembly.

l Remove the shoulder bolt M5 (1 No.) from the

mounting of chain cover. (Fig. 4.136A)

l Remove the shoulder bolt M5 (1 No.) from the

mounting of wheel hugger RH side with swing
arm assembly. (Fig. 4.136B)

5 mm Allen key
Fig. 4.136A Fig. 4.136B
Tightening torque 4 ± 0.6 Nm

l Remove the shoulder bolt M5 (2 No.) from the

mounting of wheel hugger rear. (Fig. 4.137)

5 mm Allen key

Tightening torque 4 ± 0.6 Nm

Fig. 4.136A Fig. 4.136B

 SERVICE MANUAL
CHASSIS

l Carefully dislocate the hose complete brake

rear and sensor speed wheel from the hose
clamps of swing arm assembly. (Fig. 4.138)

NOTE
Care should be taken while removal of
hose clamp and speed wheel sensor not
stretch too much it may lead to damage or
replace.

l Now, carefully dislocate and take out the wheel

hugger from its mounting. Fig. 4.138

l Remove the hexagonal socket cap screw

(M10x70 - 1 No.) along with the from the shock
absorber mounting top.(Fig. 4.139)

8 mm Allen key

Tightening torque 56 ± 8.4 Nm

l Remove the hexagonal socket cap screw

(M10x70 - 1 No.) from the shock absorber
mounting bottom.(Fig. 4.140)

8 mm Allen key Fig. 4.139

Tightening torque 56 ± 8.4 Nm

l Gently dislocate and take out the shock

absorber along with the sleeve float control
from its mounting.

CAUTION
Care should be taken not to drop down the
shock absorber assembly during removal /
reassembly it may damage the shock
absorber function.
Fig. 4.140
NOTE
While reassembling the shock absorber
inspect the condition of sleeve float
control.

l Reassemble the rear shock absorber and other

parts in the reverse order of removal.
 SERVICE MANUAL
CHASSIS

REAR SHOCK ABSORBER ADJUSTMENT

Component : Rear shock absorber adjustment

Component condition : Vehicle on ramp and component accessible
Objective : Rear shock absorber adjustment
Repair cycle : As required

Rear shock absorber adjustment

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Rear shock absorber provided with 10 step

adjustable to meet different load condition.
(Fig. 4.141). There are 10 notches for adjusting
spring load.

l If the spring is adjusted to the minimum notch,

then the shock absorber will be softer which is
good for light loads. If the spring is adjusted to
ILLUSTRATION
maximum notch, then it will be stiffer which is
good for heavy loads.

l Adjust the spring pre-load by shifting the

adjuster to the required notch according to the
different load conditions. Fig. 4.141

l Insert the handle ring spanner tool into the

shock absorber adjustment holder and rotate
the adjuster to adjust the per-load. (Fig. 4.142)

l Carefully rotate the adjuster in clockwise to

increase the pre-load (hard suspension) or
else, rotate the adjuster in anti-clockwise to
decrease the pre-load (soft suspension).

CAUTION
Adjust step by step, do not go at a stretch.
Apply torque to rotate the adjuster until Fig. 4.142
desired pre-load is obtained.
 SERVICE MANUAL
CHASSIS

DRIVE CHAIN ASSEMBLY

Component : Drive chain assembly

Component condition : Vehicle on ramp and component accessible
Objective : Drive chain assembly removal
Repair cycle : As required

Drive chain assembly removal

l Place the plate engine support along with jack

under engine assemble as explained in page no
1-00 for installation procedure.

l Remove the Rear hugger. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove the rear wheel assembly. Refer

chapter “Chassis” page no 6-00 for removal
procedure.

l Remove the chain cover. Refer chapter

“general information” page no 1-00 for
removal procedure.

l Remove the wheel hugger. Refer chapter

“chassis” page no 6-10 for removal procedure.

l Remove the hexagonal socket cap flange bolt

(M6x20 - 3 Nos.) from the mounting of cover
engine sprocket and take out the cover engine
sprocket from its mounting. (Fig. 4.143)

6 mm Allen key

Tightening torque 4 ± 0.6 Nm

Fig. 4.143
l Remove the hexagonal socket cap screw
(M8x25 - 4 Nos.) along with the spacer from
the mounting of cover frame bot RH&LH and
take out the cover from its mounting.
(Fig. 4.144)

6 mm Allen key

Tightening torque 3 ± 1 Nm

Fig. 4.144
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal flange bolt

(M8x35 - 1 No.) along with the spacer bush
from the mounting of sprocket engine 17T and
take out the sprocket engine 17T from its
mounting. (Fig. 4.145)

17 mm Spanner

Tightening torque 28 ± 4.2 Nm

Fig. 4.145

l loosen the hexagonal socket cap flange bolt

(M6x25 - 1 No.) from the mounting of gear
shifter assembly. (Fig. 4.146)

5 mm Allen key

Tightening torque 8 ± 1 Nm

Fig. 4.146

l Remove the hexagonal socket cap screw

(M8x30 - 3 Nos.) from the mounting of rider
footrest disc LH. (Fig. 4.147)

5 mm Allen key

Tightening torque 24 ± 6 Nm

l Now, gently take out the rider footrest disc LH

along with the rider foot peg assembly L, gear
shifter link assembly and pillion foot peg L.

Fig. 4.147
l Remove the hexagonal socket cap screw
(M10x70 - 1 No.) from the shock absorber
mounting bottom.(Fig. 4.148)

8 mm Allen key

Tightening torque 56 ± 8.4 Nm

l Now, dislocate the shock absorber from the

swing arm assembly.

Fig. 4.148
 SERVICE MANUAL
CHASSIS

l Dislocate the brake hose from the swing arm

complete. (Fig. 4.149A)

l Now, gently dislocate and hang the caliper

assembly rear from its mounting. keep cushion
in between the brake pads. (Fig. 4.149B)

Fig. 4.149

l Remove the hexagonal flange nut lock

(M14x1.5 - 1 No.) along with the punched
washer (15X28X2.5) from the mounting of sub
frame front LH. (Fig. 4.150)

22 mm Spanner

Tightening torque 135 ± 20.25Nm

Fig. 4.150

l Slightly lift the swing arm up words and drag

out the bolt swing arm (M14x283 - 1 No.) along
with the spacer swing arm from the mounting
of sub frame front RH. (Fig. 4.151)

NOTE
While dragging out the bolt swing arm
hold the spacer it may fall down.

Fig. 4.151

l Gently take out swing arm complete along with

the drive chain assembly from the sub frame
front. (Fig. 4.152)

Fig. 4.152
 SERVICE MANUAL
CHASSIS

SWING ARM ASSEMBLY

Component : Swing arm assembly

Component condition : Vehicle on ramp and component accessible
Objective : Swing arm assembly - Disassembly
Repair cycle : As required

Swing arm assembly - Disassembly

l Remove the swing arm assembly as explained

in previous page.

l Draw out the thrust washer LH from the swing

arm assembly.(Fig. 4.153)

l In similar manner remove the RH side also.

Fig. 4.153
l Draw out the sleeve swing arm LH side along
with the dust seal from the swing arm
assembly. (Fig. 4.154)

Fig. 4.154
l Remove hexagonal socket cap screw (2 Nos.)
top and bottom along with the holding plate
and take out buffer chain from the swing arm
assembly. (Fig . 4.155A & B)

4 mm Allen key

Tightening torque 6 ± 0.9 Nm

Fig. 4.158A Fig. 4.158B

 SERVICE MANUAL
CHASSIS

l Using the special tool remove the needle

bearing (2 Nos.) LH side from the swing arm
assembly. (Fig. 4.159)

N931 015 0 Tool swing arm service

NOTE
Swing arm needle bearing should be
removed only in case of replacement.

l In similar manner remove the needle bearing

RH side of the swing arm. Fig. 4.159

l Reassemble the needle bearing using the

special tool. (Fig. 4.160)

N931 015 0 Tool swing arm service

INSPECTION

Shaft Complete Swing Arm Fig. 4.160

l Using the special tools, check bolt swing arm
for run-out and replace it with a new one if run-
out exceeds the limit. (Fig. 4.161)

Dial gauge (0.01mm)

V - block ILLUSTRATION
Magnetic stand

Service limit 0.6 mm

Fig. 4.161
 SERVICE MANUAL
CHASSIS

REASSEMBLY

l Reassemble and remount the swing arm

complete in the reverse order of removal. Refer
ex p l o d e d v i ew fo r a s s e m b l y d e t a i l s .
(Fig. 6.162)

Swing arm exploded view

Fig. 4.162
 SERVICE MANUAL
CHASSIS

DISC BRAKE SYSTEM REAR

Component : Disc brake system rear

Component condition : Vehicle on ramp and component accessible
Objective : Disc brake system removal
Repair cycle : As required

Brake pads

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove the clip from the mounting of caliper

assembly rear. (Fig.4.163)

Fig. 4.163

l Using special tool remove the pad pin from the

mounting of caliper assembly rear disc ABS.
(Fig.4.164)

ME-99010595 Caliper pin remover tool

l Take out the pad complete inner and pad

complete outer from the caliper assembly Fig. 4.164
rear. (Fig. 4.165)

Fig. 4.165
 SERVICE MANUAL
CHASSIS

Inspection of Brake Pads

l Observe the wear limit line marked on the pad

and check the wear condition of brake pads.
(Fig. 4.166) When the wear exceeds the limit
line, replace the pad with new ones.
ILLUSTRATION

BRAKE FLUID
Fig. 4.166
Inspection of Brake Fluid Level

l Place the vehicle on paddock stand Inspect the

brake fluid level in the reservoir.

l The brake fluid level in the reservoir should be

fill beyond the mark MIN provided in the
reservoir. (Fig. 4.167)

l If the level is below MIN level mark, replenish

the level up to the maximum level.

l Remove the cap and take out the diaphragm

and fill fresh brake fluid of recommended
Fig. 4.167
grade. (Fig. 4.168)

Brake fluid TVS Grade DOT4

CAUTION
Since the brake system of this motorcycle
has glycol based brake fluid, do not use or
mix different types of brake fluid such as
silicon based and petroleum-based fluid
for refilling the system, otherwise damage
sustained will be serious.

Do not use any brake fluid taken from old or

Fig. 4.168
used or unsealed containers.

Do not place the removed reservoir cap on

any painted surfaces. Brake fluid will
damage the painted parts.

Ensure no water enters the brake fluid

container. Because brake fluid has
hygroscopic property, and its boiling point
falls excessively if water is mixed with it.

Check the brake hose for cracks and hose

joints for leakage. If found any, replace the
hose.
 SERVICE MANUAL
CHASSIS

Air Bleeding

l If the rear brake pedal travel becomes more or

if any soft or spongy feel is observed in the
lever, you must carry out the air bleeding from
the brake system. Follow the procedure given
below for bleeding the air:

CAUTION
Cover all painted surfaces with suitable
covers. Brake fluid may damage paint
work. If brake fluid falls on any painted
surface, wash immediately with water. Do
not wipe it clean.

NOTE
Use the recommended bleeding machine
for bleeding procedure. (Fig. 4.169)
ILLUSTARTION

Fig. 4.169

l Remove the cap bleeder from rear brake

caliper bleeding nipple and insert a ring
spanner on the bleeding nipple. (Fig. 4.170)

11 mm Spanner

Tightening torque 8 ± 1.5 Nm

Fig. 4.170
l Fix the caliper end of the bleeding machine to
the bleeding nipple. (Fig. 4.171)

NOTE
Place a tray below the caliper to avoid for
any spillage.

Fig. 4.171
 SERVICE MANUAL
CHASSIS

l Remove the cap and take out the diaphragm

from the rear brake fluid reservoir and fill the
TVS Grade Dot 4 Brake Fluid till the upper
permissible level in the reservoir. (Fig. 4.172)

l Connect the other end of the bleeding machine

to the pneumatic pressure port after loosening
the bleeding screw.

NOTE
Fill the fluid constantly into the reservoir.
Ensure the rear brake fluid reservoir does Fig. 4.172
not go dry.

l Now lock the bleeding screw and operate the

rear brake pedal 4-5 times, and loosen the
bleeding screw by pressing the brake pedal.
Repeat the same process until no air bubbles
are coming out from caliper bleeding
nipple.(Fig. 4.173)

Fig. 4.173

l Once all the air bubbles have escaped tighten

and lock the bleeding nut. (Fig. 4.174)

11 mm Spanner

Tightening torque 8 ± 1.5 Nm

.

Fig. 4.174
l Disconnect the caliper end of the bleeding
machine and fill the brake fluid to permissible
level.(Fig. 4.175)

l Install the rear brake fluid reservoir cap and

diaphragm.

l Fix the rubber cap bleeder rear on the bleeding

nipple and check for the smooth operation of
the rear brakes.

Fig. 4.175
 SERVICE MANUAL
CHASSIS

CAUTION
Do not reuse the brake fluid drained from
the system.

WARNING
Wipe off all fluid from the floor and ramp.
Brake fluid is slippery and may cause
injury/death.

Brake Fluid Replacement

l Boiling point of brake fluid falls considerably

with absorption of moisture which may take
place during a long period of use. Therefore, it
is recommended to replace the old brake fluid
with new periodically.

Replace brake fluid if required

l On changing brake fluid, extreme attention

should be paid so as not to mix any foreign
materials because they would block the return
port of the master cylinder resulting in the
brake dragging or squeaking.

Perform the following procedure to change the

brake fluid:

1. Drain the brake fluid by referring the air

bleeding procedure as explained on previous
page.

2. Repeat the same procedure 3 or more times to

completely drain out the old fluid from the
system.

3. Check the rear brake pedal for any sponginess

or more travel. If found any, carry out the air
bleeding again.

4. After completing the bleeding operation, check

the fluid level in the reservoir and replenish if
necessary.

NOTE
Fill the brake fluid constantly into the
master cylinder. Ensure the master cylinder
does not go dry.
 SERVICE MANUAL
CHASSIS

HOSE COMPLETE BRAKE - REAR

l Inspect the hose complete brake for any crack

or leakage. If leakages found, replace the hose
as described below:

l Flush the brake fluid out by opening the

bleeder at caliper assembly with a tube on the
bleeder head to a clean container (refer brake
bleeding).

l Remove the banjo bolt (2 Nos.) along with

washer banjo (4 Nos. on each end) from both
the ends of the hose complete brake.
(Fig. 4.176A & B)

12 mm Spanner

Tightening torque 24 ± 3 Nm

NOTE
Ensure the reassembly of new washer
banjo on both the sides of the hose while
reconnecting the hose without fail to avoid Fig. 4.176A Fig. 4.176B
leakage.

l Dislocate the hose complete brake rear from

the clamps of swing arm assembly and
carefully take it out. (Fig. 4.177)

CAUTION
Immediately and completely wipe off any
brake fluid contacting any part of the
otorcycle. The fluid reacts chemically with
paint, plastics, rubber materials etc., and
will damage them severely.

l Reassemble the new brake hose in the reverse

order of dismantling.
Fig. 4.177
l Assemble and tighten the banjo bolts at both
the ends of the hose along with new washer
banjo. (2 Nos.)

l Bleed the air from the brake circuit after

reassembly of brake hose (refer air bleeding
procedure on page no. 6-41)

Replace brake hose if required

 SERVICE MANUAL
CHASSIS

BUNDY TUBES REPLACEMENT REAR

Component : Bundy tube replacement rear

Component condition : Vehicle on ramp and component accessible
Objective : Bundy tube replacement of HECU to caliper assembly rear.
Repair cycle : As and when required

BUNDYTUBES REPLACEMENT REAR

NOTE
Clean the area around HECU to remove dirt
before opening fluid lines to prevent dirt
entry into HECU ports.

Before removing the bundy tubes, drain

the brake fluid from the bundy tube and
ensure it does not come in contact with
any painted surface.

Before working on the HECU remove the

battery terminals for safety purpose.

Bundy tube replacement of HECU to caliper

assembly rear.

Removal

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove Batter y bracket. Refer chapter

“Chassis” page no 6-16 for removal procedure.

l Carefully remove the banjo bolt along with

washer banjo (2 Nos.) from the mounting of
HECU body. (Fig. 4.177)

12 mm open end spanner

Tightening torque 24 ± 3 Nm

Fig. 4.177
 SERVICE MANUAL
CHASSIS

NOTE
As soon as the bundy tube is removed,
close the HECU port (bundy tube mounting
port) using suitable dummy plug to avoid
any dirt entry into the port

Care should be taken to avoid damages to

the HECU by impact of tools.

l Dislocate the brake hose from the clamp brake

(A) hoses provided in the swing arm itself.
A
l Also dislocate the sensor speed wheel cable
guides from the brake hose (4 Nos.).
(Fig.4.178) A

Fig. 4.178
l Remove the banjo bolt along with the banjo
washer (2Nos) from the mounting of caliper
assembly rear. (Fig. 4.179)

12 mm spanner

Tightening torque 24 ± 3 Nm

l Now, take out the bundy tube caliper assembly

rear from the vehicle while taking care of the
routing of the bundy tube.

NOTE
Fig. 4.179
It is advised to pull out or insert the flexible
portion (brake hose) of the bundy tube
through gaps to ensure that there is no
bending or damage to bundy tube during
removal / reassembly.

Care should be taken to avoid permanent

bending due to over flexing of bundy tube
during removal and reassembly.

Do not damage the HECU by impact of

tools while removing bundy tubes.
 SERVICE MANUAL
CHASSIS

Reassembly

l Reverse the removal procedure for

reassembling new bundy tube while taking
care of the following:

l Ensure to assemble new washer banjo at both

the sides of brake hose while mounting brake
hose with the caliper assembly.

l Properly reroute and relocate the bundy tube in

the clamp brake hoses.

l Refix the speed wheel sensor cable guides

(4 Nos.) in the brake hose.
.
l Reassemble seat assembly.

l Bleed the air from the brake circuit after

reassembling the bundy tube (refer page no.
6- 41).
 SERVICE MANUAL
CHASSIS

BUNDY TUBES REPLACEMENT REAR

Component : Bundy tube replacement rear

Component condition : Vehicle on ramp and component accessible
Objective : Bundy tube replacement of HECU to master cylinder
Repair cycle : As required

Bundy tube replacement of HECU to master

cylinder

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove seat assembly. Refer chapter

“general information” page no 1-00 for removal
procedure.

l Remove Batter y bracket. Refer chapter

“Chassis” page no 6-16 for removal procedure.

NOTE
Before working on the HECU remove the
battery terminals for safety purpose.

l Remove the banjo bolt along with washer

banjo (2 Nos.) from the mounting of HECU
body. (Fig. 4.180)

12 mm Spanner

Tightening torque 24 ± 3 Nm

NOTE
As soon as the bundy tube is removed,
close the HECU port (bundy tube mounting
port) using suitable dummy plug to avoid
Fig. 4.180
any dirt entry into the port.

Care should be taken to avoid damages to

the HECU by impact of tools.

l Remove the banjo bolt along with washer

banjo (2 Nos.) from the mounting of master
cylinder assembly rear. (Fig. 4.181)

12 mm spanner

Tightening torque 24 ± 3 Nm

Fig.4.181
 SERVICE MANUAL
CHASSIS

l Now, take out the bundy tube master cylinder

rear from the vehicle while taking care of the
routing of bundy tube.

NOTE
It is advised to pull out or insert the flexible
portion (brake hose) of the bundy tub
through gaps to ensure that there is no
bending or damage to bundy tube (steel
portion) during removal / reassembly of
bundy tubes.

Care should be taken to avoid permanent

bending due to over flexing of bundy tube
during removal and reassembly.

Do not damage the HECU by impact of

tools while removing bundy tubes.

Reassembly

l Reverse the removal procedure for

reassembling new bundy tube while taking
care of the following:

l Ensure to assemble new washer banjo at both

the sides of brake hose while mounting the
brake hose with the master cylinder.

l Reassemble the seat assembly.

l Bleed the air from the brake circuit after

reassembling the bundy tube (refer page no.
6- 41).
 SERVICE MANUAL
CHASSIS

CALIPER ASSEMBLY REAR

Component : Caliper assembly rear

Component condition : Vehicle on ramp and component accessible
Objective : Caliper assembly rear removal
Repair cycle : As required

Caliper assembly rear removal

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove the rear wheel assembly. Refer

chapter “Chassis” page no 6-00 for removal
procedure.

l Bleed out brake fluid from the brake system.

l Remove the banjo bolt along with the washer

banjo (2 Nos.) from the mounting of caliper
assembly rear. (Fig.4.182)

12 mm spanner

Tightening torque 24 ± 3 Nm
Fig.4.182
l Remove the mounting hexagonal socket cap
flange screw (M6X20 - 1 No.) of real wheel
speed sensor and gently pull out the sensor
from the caliper assembly mounting bracket .
(Fig. 4.183)

5 mm Allen key

Tightening torque 4.5 ± 0.5 Nm

Fig.4.183
l Remove the clip from the caliper assembly
rear. (Fig. 4.184)

NOTE
Make sure presence of the clip in caliper
assembly while reassembly.

Fig.4.184
 SERVICE MANUAL
CHASSIS

l Install the special tool and remove the pad pin

from the caliper assembly rear disc ABS and
take out the pad pin from its mounting
(Fig.4.185)

ME-99010595 Caliper pin remover tool

Fig. 4.185

l Take out the pad complete inner and pad

complete outer from the body caliper rear
(Fig.4.186)

l Remove the wheel assembly rear along with

the disc plate (refer page no. 6-18 for wheel
assembly rear removal)

Fig.4.186

l Dislocate and take out bracket complete along

with the caliper assembly. from the swing arm.
(Fig. 4.187)

Caliper assembly rear - Disassembly Fig. 4.187

l Remove pad spring from the body caliper rear

(Fig.4.188)

Nose plier

Fig. 4.188
 SERVICE MANUAL
CHASSIS

l Remove bracket complete rear caliper by

sliding out after dislocating primary pin and
secondar y pin from the pin grooves.
(Fig.4.189)

Fig. 4.189

l Remove the plate bracket from the bracket

complete rear. (Fig. 4.190)

Fig. 4.190

l Insert a spacer between piston caliper and the

caliper housing (at pad position) and then apply
compressed air through the inlet port of the
caliper to slide pistons out. (Fig. 4.191)

CAUTION
Be careful while applying compressed air
as it will shoot the piston forcefully. Do not
use high pressure air to prevent damage to
the piston.

Do not use nose plier to pull out the piston Fig.4.191

as it may cause scratches.

l Carefully pull out and take out the seal piston

from the caliper assembly. (Fig. 4.192)

Fig. 4.192
 SERVICE MANUAL
CHASSIS

l Remove dust seal (A)and seal piston (B) with a

bent plastic / brass tool to avoid scratches on
the caliper bore. (Fig. 4.193)

B
A

Fig. 4.193

l Unplug cap bleeder and remove bleeder screw.

(Fig.4.194)

11 mm spanner

Tightening torque 8 ± 1.5 Nm

l Clean the parts thoroughly with fresh brake

fluid.

CAUTION
Never use kerosene, petrol or other Fig. 4.194
solvents for cleaning the brake system.
Otherwise rubber parts will be damaged.
Do not wash the pads and also take care
that the brake fluid is not splashed on the
pads.
 SERVICE MANUAL
CHASSIS

CALIPER ASSEMBLY REAR

Component : Caliper assembly rear

Component condition : Vehicle on ramp and component accessible
Objective : Caliper assembly inspection
Repair cycle : As required

Caliper assembly inspection

Inspect the following parts:

- Pin hangers for any bend.

- Bracket complete front for loose lugs.
- Piston and caliper bore for any scratches.
- Piston and dust seals for any damage.

l After completion of above inspection, replace

the defective parts as required.

Caliper Assembly - Reassembly

l Insert the dust seals in the caliper housing

grooves and ensure perfect seating without
any twist of the seals (refer exploded view on
page no. 6-58 for details).

l Smear the piston with fresh TVS Grade DOT 4

brake fluid and slowly insert into the bore of
caliper body without tapering. Ensure the
piston is sliding easily into the bore.

l Assemble the spring pad in the caliper

housing. Assemble boot-B and bush boot pin in
the caliper housing.

l Apply little grease to the pin bolts of bracket

complete caliper and assemble the bracket by
ensuring proper seating of both the boots in
their respective grooves.

l Assemble the pad inner and pad outer.

l Assemble the pin hangers by locating it

properly in the holes of the pad inner and outer.

l Fix the plug pins, bleeder screw and cap

bleeder.

l remount wheel assembly rear along with

spacer RH.
 SERVICE MANUAL
CHASSIS

l Remount caliper assembly rear by locating the

slot provided on bracket comp caliper with the
stopper provided on swing arm complete
Assemble the axle and tighten the ‘U’ nut of
rear axle.

l Remount brake hose along with the washer

banjo (2 Nos.). Bleed the system by referring
the procedure explained on page no. 6-41.

l Refer the caliper assembly rear exploded view

for details. (Fig. 4.195)

Exploded View

Fig. 4.195
 SERVICE MANUAL
CHASSIS

MASTER CYLINDER REAR

Component : Master cylinder rear

Component condition : Vehicle on ramp and component accessible
Objective : Master cylinder rear removal and disassembly
Repair cycle : As required

Master cylinder rear removal

l Park the vehicle on the paddock stand rear.

Refer chapter “general information” page no 1-
00 for installation procedure.

l Remove the hexagonal socket cap screw

(M8x25 - 2 Nos.) along with the spacer from
the mounting of cover frame bot R and takeout
the cover frame from its mounting. (Fig. 4.196)

6 mm Allen key

Tightening torque 3 ± 1 Nm

Fig. 4.196
l Disconnect the rear stop switch coupler from
the wiring harness. (Fig. 4.197)

Fig. 4.197
l Remove the banjo bolt along with the washer
banjo (2 Nos.) from the mounting of master
cylinder assembly rear wheel. (Fig. 4.198)

12 mm Spanner

Tightening torque 24 ± 3 Nm

Fig.4.198
 SERVICE MANUAL
CHASSIS

l Remove the hexagonal socket cap flange bolt

(M8x30 - 3 Nos.) from the mounting of rider
footrest disc RH.(Fig. 4.199)

6 mm Allen key

Tightening torque 3 ± 1 Nm

Fig. 4.199

l Remove the hexagonal socket cap screw

(M8x35 - 1 No.) along with the step washer and
hexagonal flange nut (M8x125 - 1 No.) along
with the punched washer (340x84x45 - 1 No.)
and flange bush exhaust mounting from
muffler assembly. (Fig. 4.200)

6 mm Allen key / 12 mm Spanner

Tightening torque 19.5 ± 2 Nm

Fig.4.200

l Remove the split pin from the master cylinder

assembly and takeout the master cylinder
from the rider footstep disc RH.(Fig. 4.201)

Nose plier

Fig.4.201
l Remove the hose clip (100x100 - 1 No.) and
dislocate the hose reservoir from master
cylinder rear.(Fig. 4.202)

Nose plier

Fig. 4.202
 SERVICE MANUAL
CHASSIS

l Gently dislocate the bracket auxiliary mounting

complete upper (A) from the bracket auxiliary
mounting (B). (Fig. 4.203)
B
CAUTION
While dislocating of footrest care should be
take it may lead to injury.

Fig. 4.203

l Remove the hexagonal socket cap flange bolt

(2Nos) from the mounting of master cylinder
body rear. (Fig. 4.204)

5 mm Allen key

Tightening torque 8 ± 2 Nm

l Now, take out the master cylinder assembly

rear from its location.

Fig. 4.204
Master cylinder rear assembly - Disassembly

l Remove the bush rod (A) and boot (B) from the
master cylinder body rear.(Fig. 4.205)

NOTE
While removing the boot care should be
taken not to damage it.
A B

Fig.4.205
l Remove the circlip by using the circlip plier
from the master cylinder body rear. (Fig.4.206)

Circlip plier

Fig. 4.206
 SERVICE MANUAL
CHASSIS

l Slowly pull out the piston dia (12) along with

the spring, primary seal and primary washer
from the mounting of master cylinder body
rear. (Fig. 4.207)

l Remove the spacer from the master cylinder Fig. 4.207

body rear. (Fig. 4.208)

Fig. 4.208

l Remove the O ring from the master cylinder

body rear. (Fig. 4.209)

NOTE
While reassembly make ensure O ring
should be replaced, if any damage found

l Clean the system thoroughly using fresh brake

fluid.

CAUTION Fig. 6.209

Never use kerosene, petrol or other
solvents for cleaning the brake system.
Otherwise rubber parts get damaged.
 SERVICE MANUAL
CHASSIS

MASTER CYLINDER REAR

Component : Master cylinder rear

Component condition : Vehicle on ramp and component accessible
Objective : Master cylinder rear inspection
Repair cycle : As required

Inspection

Inspect the following parts:

- Master cylinder for any scratches or other

damage.
- Piston and cup surface for scratches or other
damage.
- Piston boot and other components for wear
and damage.
- Master cylinder recuperation and feed port for
any blockage, if so clear the blockage using
compressed air.

l After completion of above inspection, replace

defective parts as required.

REASSEMBLY

l Reassemble master cylinder in the reverse

order of dismantling. Refer exploded view for
assembly details. (Fig. 6.151)

l Apply brake fluid to the cylinder bore and all

internal parts before inserting the piston into
the bore.

l Fix the hose complete brake rear to the master

cylinder outlet port along with the banjo bolt
and new washer banjo (2 Nos.).

l Fill the reservoir with DOT3 or DOT4 brake fluid

up to the permissible level.

l Fix the reser voir cap along with plate

diaphragm and diaphragm.

l Bleed the system thoroughly by referring the

bleeding procedure on page no. 6-41.

l Once again inspect and if required top-up the

brake fluid and tighten reservoir mounting
screw.
 SERVICE MANUAL
CHASSIS

Replace following parts if required.

- Piston along with P-cup, S-cup, spring and

boot assembly.
- Diaphragm plate and diaphragm.
- Caliper seal piston and dust seal-2.

Master cylinder exploded view

Fig. 4.210