VENTO MOTORCYCLES - Absolutely Scooters & Supply
Contents
1. BREAK IN PROCEDURES E PRECAUTIONS AND GENERAL INSTRUCTIONS SPEGIFICATIONS E A VENTO MOTORCYCLES Rev no 01 page 401 84 Created by docuPrinter trial version MODEL IDENTIFICATION TYPE amp IDENTIFICATION FRAME NUMBER FRAME NUMBER is Engraving on the steel tube of frame as shown in figure ENGINE NUMBER ENGINE NUMBER _ is Engraving on side of the Crankcase as Shown in figure Both FRAME NUBER AND ENGINE NUMBER are designed Q especially for registration your scooter and for spare parts order 7 x FUEL AND ENGINE OIL RECOM ATION Be sure to use specified fuel and engine Some specifications are as opge FUEL 9 e Gasoline lt N nleaded the octane number must be 85 95 or more ENGINE 7 For engine rication use specified high quality SAE10W 40 or SAE 10W 50 engine oil OIL A high quality all purpose SAE 90 Gear oil for this scooter VENTO MOTORCYCLES Rev no 01 page 501 84 Created by docuPrinter trial version BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and res2. Created by docuPrinter frial version 0 01 CRANKCASE INSTALLATION REMOVAL INSTALLATION Bot 1 Left crankcase 80 Right Ka 121 EA 7 30 Crankshaft um re A n Right m assy 121 Left 2 80 Bot A Oil seal 50 Oil seal 5 NOTICE gt When installing crankshaft remember to apply left crankcase bearin mkome little oil and then vertically put the oil into bearing hole assemble timing chain with crankshaft x check crankshaft connecting rod should be rotate freely and feel that axial clearance exists for rod big end gt It is permitted to disassemble or assemble left and right wit wooden hammer or plastic hammer but never with metal hammer otherwise crankcase will damaged gt Check Crankshaft connecting rod should turn freely after assembling the crank case without block gt Tighten the crankcase with bolt with specified torqupr110 12 NM D ated by docuPrinter trial version 1 TRANSMISSION CASE INSTALLATION REMOVAL Transmission case assy Q L Left crankcase assy 10 Transmission case cover assy 020 WW Middle shaft assy 14 output shaft 050 Input shaft bearing input shaft 3 middle shaft output bearing lt Middle shaft bearing Output shaft oil seal and bearing Inp
3. MUFFLER ASSEMBLY lt Disassembly Nut M 13 Flat 11 Spring 8 01210 Bolt M8X125020 bot 8 40 A Special 150 Exhaust pipe 10 Exhaust pipe Bolt 5 101 bolt M8X55090 Nut eeu Outside Le Muffler E E board 27 Inner bushii 2 Assembly Inner ds od bush 4O Muffler connecting Herd 3 Outside orie tM 5070 Bolt MCQ 20 bolt M8X55090 6 NS Bolt M8X1 28101 bolt 8 40 A Exhaust 5 e 111 spad nu D Flat gasket 8 1111 spring 120 nut lt SS 13 12 lt gt If 11 lt 4 A Le em a UMP Created by Neevia docuPrintertrial 1 M80130 1 a o d j PPS ad a c version FRONT FORK ASSEMBLY Asse Disassembly Nut 10 125 500100 0 front right absorber Front left absorber 09 080 Special 1 021 Anti dust spring assy Upper steel bowl 030 Upper 59 040 Under connecting support 174 Taper colle bearing 94 150 Upper steel bowl h Under steel ive 0110 ex y 0120 Frame 120 Under stel bow holder 21711 teel bowl holder 050 c ei bearing 6 Under de assy 171 Upper steel ball assy 40 Upper steel bowl 730 Anti dust spring assy 2 7 Spe
4. 2 vi QV A e lt VENTO MOTORCYCLES Created by Neevia docuPrinter trial version CARBURETOR REMOVAL amp INSTALLATION REMOVAL 1 Remove rear seat of motorcycle 2 Turn fuel switch OFF position 3 Disconnect fuel pipe from carburetor by pressing clip 4 Loosen the clamp over air cleaner connecting tube Air duct 5 Drain the fuel from carburetor float chamber in a separate pan loosening drains screw 6 Remove spark plug wire HT lead along with suppressor cap from the spark plug 7 Remove insulator mounting bolts 2 Nos 8 Pull out the carburetor assy Along with insulator from air duct to the LH side 9 Open the carburetor top cap pull out the throttle valve along with needle clip spring Se bt 10 Remove the overflow drain pipe lt INSTALLATION A FOLLOW THE REVERSE ORDER OF REMOVAL a NOTE d e After installation check for any fuel leakage from the carburetor or fuel line e Check for the throttle smooth movement if necessary adjust throttle grip Tree pla 2 to 4 mm CARBURETTOR ASSEMBL DISASSEMBLY PROCEDURE FOR CARBURETTOR CLEANING e Remove the throttle valve from the accelerator cable by comp Remove the tip of the cable from the slot of the valve Remove the jet needle from the throttle valve along with clip and plate Remove the airscrew with spring Remove the Idling screw with spring Remove the float chamber by unscrewing three screws Pull out the float ar
5. Rev no 01 page 57of 84 Created by Neevia docuPrinter trial version FRONT WHEEL ASSEMBLY Disassembly Locknut 130 Front wheel centre 160 Front wheel left seat assy Fror wheel assy Et wheel seal 80 Trei Rim assy Him 4 Front m busb D valve 3 valve Cap 2 Speedometer gear 121 11 Gear set oil 1100 gear Rev no 01 page 58of 84 Assembly Speedometer 11 Gear seat seal 10 i 1121 Him 14 front middle b c 0 090 valve has ap 2 Tire 11 iRim Front ke ring 8 D heel assy front wheel Wi bush gear seat assy cO front es centre bot Gr nuth130 Created by docuPrinter trial version REAR WHEEL ASSEMBLY lt Disassembly Assembly e Rear 12 3 valve capi 2 Q Rear brake camshaft K Seal 3 5 Rear brake m 9 Rear wheel assy Trei Rear A assy Brake shoe 5 1110 Brake shoe spring A Brake tension 0100 Bolt M6X35 6 ie board 8 7 Brake tension spring 0100 Anti dust cover 7 Anti dust board 8 Bolt M6X35 6 Rear braking rocker arm 9 Brake shoe pulling spring 4 Seal ring 13 Brake shoe 1111 Rear brake camshaft 5 Rear rimi 112 Valve 030 nv Tire 1 Rear rim Rear wheel assy md Created
6. e Check the clearance of Inlet valve and Exhaust valve e Inlet valveli0 03 0 05mmUExhaust valveli0 05 0 06mm1L If clear nce is not at the specified limit then adjust Tappet clearance to the specified T MARK ON FLYWHEEL SIGN ON RIGHT COVER VENTO rEsr Rev no 01 page 4501 84 Created by Neevia docuPrinter trial version TESTING PROCEDURE STEP 1 10 Warming up the engine to normal running temperature hot condition 20 Remove spark plug and connect compression pressure gauge 30 Ensure that a Fuel switch cock is in OFF position b Ignition switch is in DFF position 40 Accelerate throttle to FULL condition amp then kick several times 6 to 8 times 50 Note down reading and repeat the above process three times and calculate their i e average value as actual compression pressure lt s 60 The specified Compression pressure of engine is 10 2 A STEP 2 When the compression pressure is below 10Kg cm then refi Q plug amp start and warm up the Engine again Remove spark plug and put few drops of engine oil T et combustion chamber Connect Compression gauge amp repeat above said procedure as explained in STEP 1 e lf the Compression pressure reading increases then check for following Worn out cylinder 2 b Worn out piston piston rings Scoring Seizu
7. e Never make mistake in positioning the first ring and the second ring Keep exhaust port the second ring oil ring slice VENTO MOTORCYCLE Sr the gap of groove Created by Neevia docuPrinter trial version 1 C LEFT CRANKCASE COVER INSTALLATION REMOVAL Left crankcase cover assy Brake cable clip 1 main stand stopping holder ventilation pipe clip 3 throttle cable holder 4 Left crankcase cover 5 Guide board 6 O INSTALLATION The installation sequence is just reverse of the removal lt NOTICE When installing ventilation board respectively of 4 tapping screws with specified totg ue 3 6N M and tighten the board plate with same tool then respectively cover tapping screw h When installing left crankcase cover tap it to its proper position with wooden hammer or plastic hammer not with metal hammer to avoid damaging the face of crankcase amp cr se cover Brake cable clip 1 main stand stopper holder 2 ventilated clip rottle fixing stand 4 must be positioned correctly Tighten all the bolts diagonally with specified torquet0 12N VENTO MOTORCYCLES ated by Neevia docuPrinter version 01 pa RIGHT CRANKCASE COVER ACCESSORIES REMOVAL Specified Torque Value Nut 14 50N M Screw 12 Oil filter screw cap 24 Fan assy 13 4 Magnet motor bolt 17 7N M d
8. 020 AUTO REDUCTOR Get AND ROLLING POLE SPRING 150 4 ATMOLYSIS SHAFT AND LEFT BEARING 130 7 STOPPER 15 ATMOLYSIS SHAFT SPROCKET 5 1111 AXIS 76 AND BUSH 77 0 SHAFT ASSY MASS D AND SPRINGC ATMOLYSIS SHAFT SUPPORTER 110 CAM SHAF HOLDER Go ASEG Go BUSH 7 IMASS 18 AND o STOPPER 05 4 AND 30 ROCKER SHAFT 2 ATMOLYSIS SHAFT FIXER ASSY ATMOLYSIS SHAFT FIXER AND ATMOLYSIS SHAFT NOTE When installing rocker shaft remember to assemble rocker with lubrication and keep groove of center rocker shaft on the same level as the hole of rocker seat Created by Neevia docuPrinter trial version 1 L it N VENTO MOTORCYCLES PISTON INSTALLATION page Created Neevia docuPrinter trial version REMOVAL THE FIRST RING THE SECOND RING OIL RING 000 OIL RING II OIL RING GASKET PISTON 10 gt ae 8 oil ring RAM i Ss 12 C a 2 lg 011 ring OIL RING a PER e gasket 1 ring 2 ge Weg AE 55 SPRING CLIP INSTALLATION The sequence is just reverse of removal NOTE e first ring is white ring and the second ring is black one A The sides of the first ring and the second one with English Letters are up f Letter IN is towards inlet port and the first ring is dead against oil ring slice
9. VENTO MOTORCYCLES Motorcycle division Doc Title SERVICE MANUAL Phantom R4i Doc no Model code VS 01 A 4 A Brand Name VENTO Revision Number 01 Date of release 26 01 2004 Page 1 of 84 DESCRIPTION PAGE DESCRIPTION GENERAL 4 INFORMATION 33 Left crankcase Accessories Model 5 identification 36 Crank case lation Break in 6 procedures 37 Transmi case installation Precautions 6 General instructions 40 drive face 8 Specifications 45 clearance adjustment procedure PERIODIC pression Test 12 MAINTENANCE 46 13 Storage battery 47 AIR FUEL SYSTEM 15 Spark plug 56 Carburetor Tuning 16 Air cleaner 57 CHASSIS 17 Special tools list 58 Front Wheel assembly Specified torque values Front fork assembly ENGINE Hydraulic Brake Disc System Gear Ratio ELECTRICAL Engine disassembly 25 amp Assembly 77 TROUBLE SHOOTING Camshaft holder 29 assembly 77 Engine Piston installation Carburetor Left crankcase cover installation Electrical Right crank case cover Accessories Battery Right crank case Accessories Brakes Date of Issue Revision Number Date of Issue 26 01 2004 sign and Development Dept VENTO MOTORCYCLES Rev no 01 page lof 84 Created by docuPrinter trial version T O T O Y E S U S A 9 R4i Service av g Maintenance Manual a lt VENTO M
10. Inspect amp Clean every 3000 Kms 18 Air cleaner Replace every 12000 Kms 1750 Miles Idle speed rpm 7 Throttle cable play Oil pump Gear oil Brake Fuel W ryA years b every 4 years eplace every 2 years Brake hose Brake fluid Steering Front fork Rear shoc k Vehicle body bolts and uts Note thh MATOR E K re if necessary T tighten Created by docuPrinter trial version STORAGE BATTERY BATTERY INSPECTION AND CHECKING PROCEDURE Inspect at initially 1000 630 miles 2 months land every 6000 Kms 13780 miles i 12 months gt Open the cover as shown in picture and then remove the esi S battery box A gt Measure the voltage between the ve and ve terminal of Battery charge the Battery if the voltage is below the specified limit VENTO MOTORCYCLES Created by Neevia docuPrinter ev 01 page 1407 trial version SPARK PLUG Neglecting the spark plug maintenance eventually leads to difficult starting and poor performance If the spark plug is used for a long time the electrod
11. Series connection inline with positive battery wire to measure DC Amp lt VOLTMETER Parallel connection between positive amp negative terminal of the battery to measure DC Volts Electrical starting power flow chart Circuit process A Storage battery O Fuse Main switch Alarm Q Stop switch Start switch imm Start relay e QF Be SN FS lt Rev no 01 page 7201 84 Created by docuPrinter trial version ELECTRONIC IGNITION COMPONENTS TEST For any ignition problems always check the components as per the following procedure 1 SPARK PLUG Check spark plug after cleaning in Spark plug cleaning and testing Machine lace if e SHORT e WORN OUT ELECTRODE e INSULATOR BROKEN 2 SUPPRESSOR CAP SPARK PLUG CAP Check the resistance of suppressor cap by multimeter if 5 0 K ohms a 3 COMBINATION SWITCH Check the continuity by multimeter x otherwise replace it 4 H T COIL d Mobike H T coil has separate ground terminal Black e Check primary coil resistance between green and yellow black wire terminal if less than 1 0 ohms otherwise replace H T coil Check secondary coil resistance between H T cable and earth wire it should be 7 5 1K ohms in total includes 5 0 K ohms series the suppressor cap otherwise replace coil PICK UP COIL Check for its resistance value acroGijue white and green whi
12. VENTO MOTORCYCLES Rev 01 page 8of 84 Created by docuPrinter trial version Headlight high beam Low beam Taillight brake light Turning signal light Head light Indica N I Turn Signal ps High bea tor light 4 ITEM PARAMETER SPECIFICATION Ignition system CDI Ignition timing MAGNETO F mark 13 BTDC 1400RPM Il Full advance 28 BTDC 4000 RPM Magneto output 114W 4000RPM lt lt Spark plug C7HSA O Spark plug gap 0 6 0 7mm SS Fuse 8A Horn 100dB N Battery 12V Deeg LIGHT 12V 18W 18Wx2 12V 15W 5W 12V 10Wx2 Front amp Rear 12V 3Wx2 12V 1 7WX2 12V 1 7WX2 LED lt lt lt O x lt VENTO MOTORCYCLES Rev 01 page 9of 84 Created by docuPrinter trial version o ITEM SPECIFICATION PARAMETER DRIVING SYSTEM Clutch system Dry shoe Transmission system Automatic CVT Primary gear reduction 10 86 2 64 Gear ratio 2 8 42 15 Q First 3 077 40 13 Q Second 85 5km h Max speed Model code PD24J Q Piston Dia 24mm Main jet 191 Slow running jet 19 CARBURETOR Idle speed air adjusting screw aset vA rounds Float height 15 1 Jet needle position from 2 3 Groove D s SN lt lt VENTO MOTORCYCLES Rev no 01 page 10of 84 Created by docuPrinter trial version Front Shock absorber Liquid pressure type
13. compressibility 130 mm Rear shock absorber Liquid pressure type compressibility 75mm Front wheel specification 130 60 13 Rear wheel specification 130 60 13 lt Tire pressure front 32 PSI Tire pressure rear 32 PSI SUSPENSION Diba Tps 2 Rear brake Drum Type Q Fuel tank capacity 6 0 Liter Engine Oil capacity 1 0 Liter Q xO 4 lt VENTO MOTORCYCLES Rev 01 page 1101 84 Created by docuPrinter trial version CHAPTER 2 PERIODIC MAINTENANCE AND SERVICE Periodic maintenance and service schedule Storage Battery Spark Plug D Air Cleaner Special Tools SS Specified Torque Values VENTO MOTORCYCLES Created by Neevia docuPrinter trial version 1 PERIODIC MAINTENANCE AND SERVICE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Mileages are expressed in terms of Kilometer Miles and time for your convenience Note More frequent servicing may be performed on motorcycles that are used under bad road condition PERIODIC MAINTENANCE CHART Miles 630 3780 Interval Kilometer 1000 6000 Months 2 12 Storage battery Cylinder head nut and exhaust pipe bolt L Cylinder head and C cylinder Spark plug C
14. 1 Engine Rubber Chain Anti Oil Asbestos 1 Engine VENTO MOTORCYCLES GEAR RATIO Created Neevia docuPrinter trial version page NO GEAR No teeth POSITION 1 Kick starter gear 38 Engine 2 Kick starter transition small 43 Engine gear 3 Kick starter transition big gear 49 Engine 4 Crank kick starter driven gear 20 Engine 5 Starting motor drive gear 9 Engine 6 Electric starter transition gear 49 17 sikur q 7 Clutch gear 60 Gear Ratio Gear No teeth Gear 2 8 Ay 15 13 B 40 4 SPROCKET INFORMATION No Sprocket No teeth POSITION 1 Right il pump driver 18 Engine sprock t wheel imp sprocket wheel 22 Engine eft crank shaft drive sprocket Engine Cam shaft sprocket 34 Engine VE DIR IONAL FITMENT OF ENGINE PARTS Read the following instruction carefully and assure spare parts installed in right osition otherwise it may damage engine seriously ated by trial version ev 01 pa 1 All marks of the following parts should be towards combined surface of left crankcase and transmission case Output shaft of left crankcase middle shaft output shaft bearing 6004 6002 6301 and output shaft of transmission case middle shaft output shaft bearing 6203 6202 6204 2 The s
15. Starting gear sector D Kick starting gear assy 1100 Y Nut 150CVT nut washer 14 ICentric disci 130 Starter spring plate 11 V Belt 1600 wheel disc 1121 Starter driven gear 2 2 10 Drive wheel Ai Bush 50 O I Bush D Drive wheel assy 141 Pin 2 1 A Starter driven 2 Drive 6 te wun Starter spring plate 11 11 disc 1121 Kick starting gear assy 10 Starting gear sector assy 1911 cogn 13 Wasber 14 Nut 1151 NOTE gt When installing starter gear wheel and kick start gear assy Assemble with little grease keep arrow mark transmission gear dead against crankshaft align kick start gear dead against marking point on transmission gear carefully pull kick start shaft spring to correct pesition with special tool be careful that spring doesn t turn back position starting spring correctly and tighten the nut with specified torque 10 12NM gt When installing V Belt rotate driven wh y anticlockwise install V Belt into groove of driven wheel then cover driving impeller groove with t and install driven wheel assy into input axes and then assemble centric disc dish washer a gt Finally tighten lock nut 15 an wan specified torque 45 55NM and then release driven wheel disc freely Assembled bush sli eely and convex side of wasber 17 washert114 should towards out side
16. and mixes with clean air in right proportion lt the carburetor and then air fuel mixture is supplied to the combustion chamber of the engine In engine this air fuel mixture is controlled by the intake valve and camshaft rocker arm mechanism AIR FUEL FLOW CHART E O AIR FUEL lt Atmosphere Fuel tank A Air cleaner assy Strainer fuel SS Filters Sedimente Flame Filter 2 Venturi Inlet CR Chamber Menturtoutlet lt A Combustion chamber 49 lt VENTO MOTORCYCLES Rev no 01 page 50of 84 Created by Neevia docuPrinter trial version AIR FUEL MIXTURE RATIO CARBURETTOR CIRCUITS Starting 7 8 1 The Phantom R4i Scooter has 6 main circuits Idling speed 10 12 1 1 Fuel Intake circuit Slow speed 12 14 1 2 Choke circuit QV Medium speed 15 17 1 3 Idling speed circuit High speed 13 15 1 4 Slow speed circuit 5 Medium speed circuit 6 High speed creat VENTO MOTORCYCLES Rev no 01 page 5 lof 84 Created by Neevia docuPrinter trial version CARBURETOR CIRCUITS 1 FUEL INTAKE CIRCUIT From fuel tank fuel comes into float chamber of carburetor by gravity feed Separate vent is provided at LH side of carburetor body to maintain inside atmospheric pressure When fuel starts filling the float chamb
17. direction Replace the battery and be sure to connect the battery properly Rev no 01 page 85of 84 Created by Neevia docuPrinter trial version Battery discharges too rapidly Sulfation acidic White powdery substance or spots on surface of cells 1 Dirty container top and sides 2 Battery is too old 1 Cracked battery case 2 Battery has left in a run down condition for a long time Clean Replace Replace the battery Replace the battery Battery 1 Too low or high charging rate When battery Replace the battery 2 Sulfation is not in use should be checked at least once a 4 month to avoid Sulfation lt 2 Left unused the battery too long in cold Replace the battery if Ga ted climate CHASSIS Complaint Symptom and possible causes Heavy steering 1 Steering stem nut over tightened 2 Broken bearing ball race in steering Replace stem 3 Distorted steering stem Replace 4 Not enough pressure in tires 4 Adjust tire pressure Wobbly 1 Loss of balance between right and left Replace handlebars front suspension 9 2 Distorted front axle or cro tire Replace 3 Distorted front fork v Repair or replace Wobbly front 1 Distorted wheel Replace wheel 2 Worn front eck ngs Replace 3 Defective or jficorrect tire Replace 4 59 Retighten 5 m the rear shock absorber Retighten 6 mounting bus
18. less than 9 5Volt and on more cell shows specific gravity less than 1 220 then change the battery e OPEN CIRCUIT During the charging of battery does not pickup the charge In any Ane above case replace the battery e RECOMDED BATTERY LOAD TESTER MAKE ELAK MODEL BCT7 e CAUTION During Inspection if the battery on the vehicle is found defe new battery it is important to check the battery charging circuit e before replacing with a BATTERY CHARGING CIRCUIT TEST POWER SWITCH BATTERY RECTIFIER MAGHETO MOTOR generated AC current which is rectified into DC current by Voltage Regulator It is utematically charging the battery depending upon condition of the battery load and engine rpm Regulator is in parallel to the circuit Hence this type of system is called PARALLEL LOAD REGULATOR d Connect DC Voltmeter and DC Ammeter start the engine with fully charged good battery The Voltage Regulator output is as follows e Battery charging current range in between 0 6 Amp to 2Amp e The engine speed 5000 rpm with headlamp on condition e Battery terminal charging voltage gt 11 5 V at any load condition depending upon the condition of battery Rev no 01 page 71of 84 Created by Neevia docuPrinter trial version NOTE 1 Incase charging output is less than 0 6 Amp or more than 2 0Amp then replace the Voltage Regulator with new one and recheck NOTE 2 AMMETER
19. master cylinder piston moves forward as it crosses the inlet port the piston starts pressurizing the brake fluid in the master cylinder The pressurized brake fluid gets transferred to the caliper through the brake hose As the brake lever released the piston return spring forces the piston to return to its original position As the brake fluid from the caliper returns slowly negative pressure is being created between the secondary and primary brake seals This causes the collapse of the primary brake seal which in turns allows brake fluid to flow to master cylinder through compensating port to counter the negative pressure As the brake fluid returns from the caliper the excess amount of brake fluid drawn from master cylinder ER gt air Zei e e D fig 5 Rev 01 page 6401 84 Created by docuPrinter trial version 1 cap 5 Clip ring Tens pring 2 Oil gasket 6 Bowl 0 Outlet oil hole 3 Inlet oil hole 7 Stopper 1 supplement hole 8 Bowl f 12 Master cylinder 4 Stopper anti dust cover MASTER CYLINDER ASSY Fig 6 Rev no 01 page 6501 84 Created by docuPrinter trial version DISC BRAKE CALIPER ASSY em oil plug seal ring NORMAL POSITION O S lt lt Rev 01 page 84 Created by Neevia d
20. screw amp remove air cleaner cover gt e Fill a washing pan of a proper size with Non flammable cleaning solvent Q e Putthe air Cleaner element in the cleaning solvent and wash properly O e Squeeze the cleaning solvent out of the washed element lt By pressing it between the palms of both hands do not twist or wring the air cleaner element or it will develop tears A e Immerse cleaned filter element in or Super oil and pe fei out of the element leaving it slightly wet with oil Fit the element to the Air cleaner case rly e Install Air cleaner the reverse order of removal A CAUTION Before and during the cleaning operation inspect the core ars A torn filter element must be replaced with new one Be sure to position the filter element snugly So that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted filter element 7 Air cleaner A Non flammable cleaning B CCI OR CCI Super oil or SAE Gear oil 6 Qo VENTO MOTORCYCLES Created by Neevia docuPrinter trial version 01 pa SPECIAL TOOLS LIST NECESSARY TOOLS TO DISASSEMBLE AND INSTALL MOTORCYCLE ENGINE AS FOLLOWS TOOLS CODE PURPOSE T01 TAPPET ADJUSTING TOOL S T02 GUIDE CYLINDER 01518 10 12 130 e TOOL FOR FLY WHEEL DISASSEMB
21. ERFORMS THE FOLLOWING FUNCTIONS e LUBRICATION gt Prevents friction metal to metal contact e COOLING gt Prevents overheating V e ANTI RUST gt Prevents Corrosion 2 e CLEANING Prevents sludge formation remove carb articles e SEALING AGENT i Seals combustion chamber s gt ANTI WEAR Improves the life of moving A ts V The type of lubrication used in the engine of motorcycle is voie wet sump splash A Pressure feed lubrication O ENGINE OIL CIRCULATION Oil pump assembled in right crankcase sucks oilthrough main gears on right crankshaft Oil in crankcase is filtered through the oil filter N crankcase and then flows across oil pump rotor where produces large pressure amp d umped in three different routes VENTO MOTORCYCLES Rev no 01 page 43of 84 Created by Neevia docuPrinter trial version LUBRICATION DIAGRAM ge d ES is WZ C Camshaft assy Rocker arm OCH Zee ii Ki L Filter assy VENTO MOTORCYCLES Rev no 01 page 44of 84 Created by Neevia docuPrinter trial version VALVE CLEARANCE ADJUSTMENT PROCEDURE Engine in cool condition e Remove cylinder head cover e Remove fan cover e Keep T mark on flywheel to the same line with the mark on right crankcase cover e Ensure timing mark of cam sprocket in the same line with joint surface of
22. Hcover CDI uit charging and pick up coil are used for ignition purpose e Lighling Coil amp battery charging coil wire connections goes to Regulator cum Rectifier for lighting amp battery charging purpose de d a color code amp various coil resistance values are as follows S NO COIL RESISTANCE VALUE WIRE COLOR CODE DESCRIPTION U CHARGING COIL 300 500 Q Red and black PICK UPCOL _ 200 200 20 Blue and white green and white S Lighting battery LESS THAN 2 OHMS Green red white and charging coil LESS THAN 2 OHMS black black Rev no 01 page 70of 84 Created by Neevia docuPrinter trial version NOTE All the resistance value are measured with reference to ground wire Black BATTERY TESTING PROCEDURE Remove the battery from the Motorcycle Scooter Connect the battery on load tester ensuring Red lead tester to ve and Black lead to ve terminal of battery Check the terminal voltage of battery It shou 12 14 5 Volts Press the push button on the tester and watch the voltmeter reading on load Th ery voltage should not drop down less than 9 volts this indicates that the battery is perfect to take loa elf starter motor Check the specific gravity of each cell should not be less than 1 220 Put the battery charge if required and carry out load test e Diagnose the nature of failure as under j e BATTERY CELL DEAD TEST On load if battery voltage is found
23. IT Slow speed requires very less acceleration Air fuel mixture is being supplied by slow jet and also from main jet This is due to partial opening of throttle valve lifts needle jet upwards Hence some quantity of air fuel mixture coming out from main jet diffuser also mixes along with slow jet mixture to increase the mixture quantity as required by engine 5 MEDIUM SPEED CIRCUIT Economy speed range Further acceleration the a tye mixture supplied to e ly from main jet During dhis slow jet stops supplying mixture due to venturi oe air is h drawn to maing ugh metered air jet Br be for better mixing of ith air in the main jet diffus Main jet started SECH air fuel mixture in e range i e more air with quantity of fuel as per engine AIR SCREW 4 x Z A j gt ae de 47 MAIN JET SLOW JET lt VENTO MOTORCYCLES Rev no 01 page 53of 84 Created by Neevia docuPrinter trial version 6 HIGH SPEED CIRCUIT During acceleration the throttle valve piston is fully raised more air is being supplied due to higher velocity Hence pressure drops at the opening of throttle jet needle Where as more fuel is sucked from the main jet due to tapperness of jet needle A jet holder is provided to the main jet to avoid fuel flow strain turbulence effect in the float chamber created during the very high speed to diffuser As shown in the figure
24. OTORCYCLES Rev no 01 page 2of 84 Created by docuPrinter trial version FORWARD This service manual contains an introductory description On VENTO Phantom R4i and procedures for its Inspection service and overhaul of its main components Other information s considered as generally known is not included Read GENERAL INFORMATION section to familiarize yourself with outline of the vehicle and MAINTENANCE and other sections to use as a guide for proper inspection and service This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service The VENTO Phantom has following features such as V belt drive automatic transmission Fan air cooling system CDI Ignition system Auto Ignition system Alarm System Remote start system K nough knowledge and skills for servicing NTO vehicles Without such knowledge and skills should not attempt servicing by relying on ths RFP MOPAR ES contact your nearly authorized VENTO service center Rev 01 page 3of 84 INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE PROCEDURE 2 ENGINE 3 AIR FUEL SYSTEM 4 CHASSIS 5 ELECTRICAL 6 TROUBLE SHOOTING 7 Created by docuPrinter trial version CHAPTER 1 GENERAL INFORMATION CONTENTS MODEL IDENTIFICATION O FUELAND ENGINE
25. arging gt 11 5 Volt Rectified DC voltage for battery charging 0 6 to 2 0 Amp at 5000 RPM Rev no 01 page 77of 84 Created by docuPrinter trial version PRE DEIVERY INSPECTION P D 1 It is very important to check every Motorcycle Scooter to a thorough 1 before delivery P do the following procedures and send main information to dealer Q 1 Wash the vehicle with mild automobile detergents amp clean vehicle externally with brush A blow dry with compressed air For painted parts clean with water amp wipe y With chamois leather or soft cloth Do not wash motorcycle under excessive wat ressure amp soap or bleaching powder 2 Check amp carry out paint touch up if required 3 Check proper fastening of all external nuts and bolts inclu Ae that of carburettor mounting Cylinder head cover engine mounting bolts Rear amp Fro 4 Install Connect charged battery connect breather properly amp ensure proper routing Follow strictly instruction for initial charging of battery 5 After warming up the engine open timing whole inspection cap amp then check oil splash for lubrication 7 6 Check amp correct tyre pressure if required 7 Check spark plug gap amp adjust bi 8 Check proper functioning Inelectrical electronic system and control switches 9 Check proper functioni ed and refit properly celerator cable and choke 10 Check and adjust P
26. asket pin Spring clip piston pin piston Cooling Fan flywheel Stator coil Right crankcase r oil gauge Right crankcase lt Start end right crankcase crank ASSEMBLY Left crankcase assy gearbox assy gearbox Crankshaft left and right crank case S Oil pump starter clutc Right g lt filter oil gauge Stator oil flywheel cooling fan Piston piston pih circlip cylinder gasket dowel pin cylinder cover gasket dowel pin Cam camshaft holder Chain adjustof cylinder head cover Left crankcase outside assy Left crankcase m dowel pin Guide fan cover fan cover carburetor Before installation wash engine parts and lubricate refer to recommended torque value for tightening fasteners VENTO MOTORCYCLES Pay special attention to single direction fixing accessories Start and inspect oil circulation lubrication system after assembly the engine eated by Neevia docuPrin 1 ter trial version ENGINE COWL ASSEMBLY Disassembly Y V Specified torque value Screw 10 Fan cover screw 6 2NM Bolt 1 Fan cover bolt 7 11NM Top cowling Guide fan cover screw 10 2 RA Bottom cowling Guide fan cover bolt 1 11NM Fan cover assy 8 cowling de Seal gasket 2 Bottom cowling seal de gasket 3 Cooling pipe 5 Coil clip 12 Cover 13 Cover 9 e Assembly sequence is just reverse of d
27. by Neevia docuPrinter trial version Complaint Symptom and possible causes Remedy Unstable 1 Defective regulator rectifier Replace charging 2 Lead wire insulation frayed due to Replace vibration resulting in intermittent shorting 3 Magneto coil internally shorted Replace Starter button 1 Run down Battery Repair or replace is not 2 Defective switch contacts Replace effective 3 Brushes not seating properly on Repair or replace commutator in starter motor 4 Defective starter relay Replace 5 Defective starter pinion gears Replace 6 Defective front or rear brake lights Repair org switch circuit 4 4 Complaint Symptom possible causes Remedy Battery runs 1 The system is not correct Check the magneto and regulator rectifier down quickly ell plates have lost much of their active material as a result of over charging 3 Ashort circuit condition exists within the battery due to excessive accumulation of sediments caused by the incorrect electrolyte 4 Battery is too old circuit connections and make necessary adjustments to obtain specified charging operation Replace the battery and correct the charging system Replace the battery Replace the battery eversed battery polarity 1 The battery has been connected the wrong way round in the system so that it is being charged in the reverse
28. cial locknut 010 Front left absorber 190 front right absorber 08 Bolt M1 D E 100 1 e A 2 NS lt De 4 li 77 X0 ag 10 di IL TX P ZS gb j e fu OH WV Wem 10 10 H EP X c Created by Neevia decuPrinter trial vergan di L C aL DI FRONT SHOCK ABSORBER Disassembly Bolt 1 O seal A 2 Absorber spring 3 Piston ever 417 Screw 5 and gasket Inner tube assy 6 C Piston venir ring we Buffer 8 Outer tu Ba Anti dust girias Oil seal 90110 Seal 121 SN a cud ube 0130 Buffer Assembly Install pistongin into piston lever Insta into piston lever Install above assy into inner tube assy Cover piston lever An buffer prick bush Install above accessories into aluminum outer tube Tighten M Fixing torque is 20 Nm Oil seal assy Oil seal ere ring Anti dust ring assy Add oil for absorber 100 2 ml Buffer siking seal ase Bolt Fixing torque is 23 Nm Rev no 01 page 6301 84 Created by Neevia docuPrinter trial version HYDRAULIC BRAKE DISC SYSTEM Hydraulic brakes operating principle It is operating on the principle that the liquid is not compressible so the force and motion can be transmitted Through a liquid media MASTER CYLINDER As the brake lever is pressed the
29. d once in a year After man soon season BLEEDING OPERATION 2 2 brake components with fresh recommended 0 3T 4 to UPPER LEVEL disconnected perform bleeding operation thoroughly at Drake nug y N 2 Operate brakexlever several times to build the reassembly N 80Do not polish brake pads with sand paper as hard 2 keep a waleh particles deposited in the lining may damage steel disc transparent plastic tube to the bleeder valve 9riDo not use cotton cloth to wipe master cylinder rake lever in applied parito Ane Ioosen bore as rind from cloth will remain in cylinder bore er valve along with brake fluid air bubbles will come out through the tube Tighten the bleeder gt ct 2 00 g I a 5 surface valve and then release the brake lever This 100 use new rubber seals boots washers A that fresh ai t into th circlip sequence ensures that no fresh air enters into the 7 system OVERHAUL OF MASTER CYLINDER gt 5 Repeat the operation as per above step till the Remove handle lever Screw and left handle clear flow of brake fluid comes out through the 21 Take SO oi Gavet s transparent tube in between if required fill the reservoir EE with brake fluid up to UPPER LEVEL mark again 40 Remove piston assy oak Assemble the maste
30. e O ring 23 Nut 14 Fan bolt 12 11N M J Spring 22 Gasket 15 Trigger screw 11 6N M 4 Filter assy 21 Flywheel 16 d Oil filter screw cap 24 57N M 4 Oil gauge 6 Screw 11 Other bolts for right crankcase cover 11N M 5 Pickup assy 10 4 Other bolts Bolt 7 4 Right crankcase Cable holder 4 end cover 3 4 INSTALLATION The installation sequence 7 reverse of removal NOTICE 1 The clearance between eel trigger and pickup is 0 5 0 2 2 Check specified ee between flywheel trigger and pickup QT Created by Neevia docuPrinter trial version OU RIGHT CRANK CASE ACCESSORIES REMOVAL 10 Electric start transition 50 70 special tool T050 de Gaskei 21 Electric start transition gear 60 Oil pump sprocket end cover 8 gt Start clutch complete 30 090 Q Half round 41 Oil pump chain Oil pump 0 120 Special Screw 0130 screw 1141 Oil pump Cover 1 Rotor 18 Dim 170 Oil pump Cover 180 Specified Torque value 1 Clutch locknut 35 40N M 2 Oil pump fixing bolt 10 12 N M 3 Sprocket wheel locknut 10 12 N M 4 Sprocket wheel end cover bolt 8 10 N M Created by Neevia docuPrinter trial version 01 pa LEFT CRANKCASE ACCESSORIES INSTALLATION REMOVAL INSTALLATION NUT 97 Wasber Drive Impelleri60
31. e gradually burns away and carbon builds up along the inside part In accordance with the periodic table the plug should be 4 removed for inspection cleaning and to reset the Carbon deposits on the spark plug will prevent good sparking and cause misfiring Clean the carbon deposits periodically CARBON DEPOSIT Check to see the carbon deposit on the Spark Plug If the carbon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a Pe in pointed end Check to see the worn out or burnt condition of the electrodes If it is extremely worn or burnt replace Ws the plug and also replace the plug if it has a S insulator damaged thread etc Thickness P Spark plug 10 6 0 7 mm 0 024 0 028 inch Check the spark plug for burnt condition Tighten the spark plug to the ech c Spark plug Tightening torque LAE a f abnormal replace the VENTO MOTORCYCLES Created by Neevia docuPrinter trial version ev 01 pa AIR CLEANER Clean every 3000 1890 miles Replace every 12000 Kms 1750 Miles If the air cleaner is clogged with dust Air Intake resistance will be increased with a result decrease in power output and will be increase in fuel consumption Check and clean the filter element in the following manner e Remove clamp and screw amp take out air cleaner e Unscrew tapping
32. e lines for leaks Whenever you remove Oil seals Gaskets packings O rings Locking washers Cotter pi parts as specified be sure to replace them with ones Also before installing these new pants material from the mating surfaces irclips and certain other sure to remove any left out o Never reuse a circlip when installing a new circlip take care not to expand the end Jap larger than required to slip the circlip the shaft After installing a circlip always ensure that it is completely seat its groove and securely fitted o Do not use self locking nuts a few times over o If parts replacement is necessary replace the parts with VENTO Ge parts or their equivalent o When removing parts that are to be reused keep them arranged i manner so that they may be reinstall in proper order and orientation o Always use special tools when required Always use specified lubricant bond amp sealant While removing the battery disconnect the Negative terminal Cable first then Positive terminal Cable and when reconnecting the battery connect the Positive terminal Cable first then Negative terminal Cable o During Service to electrical parts if no need of the battery ry powers then please disconnect the Negative terminal Cable o During tightening of Cylinder head a case bolts and nuts start with larger diameter and ending with smaller diameter from inside to outside diagonal th
33. e of the throttle valve with the guide pin in the carburetor body Check for its smooth movement 9 Tighten the top cap over carburetor body Rev no 01 page 5501 84 Created by docuPrinter trial version CARBURETOR TUNING OR ADJUSTMENT PROCEDURE After installation the carburetor in the engine as per above said procedure follow the following steps x 1 Warming up the engine to the normal running temperature 2 Adjust Idling speed to 1400 RPM by throttle stop Idle screw 3 Turn the airscrew all the way inside until seats lightly in the carburetor body 1 If engine stops then OK Incase does not stop check for air leakage from insulator ring ap y 2 Readjust air screw position to 34 turns out i 3 Startthe engine and increase the Idling speed by turning the Idle stop screw in anticlockwGe direction till the engine speed increases to the range of 2000 to 2500 RPM 4 Open the air screw outwards anticlockwise slowly till engine RPM increases to the highest speed position while setting Now stop adjusting air screw Maximum recommended air turns out 5 Readjust Idling speed to 1400 100 RPM by the throttle stop screw 4 ensure t Monoxide CO 1 5 to 2 0 6 After adjusting Idling speed check for its stability flat spot missing if an E few times Repeat above said steps until engine speed increases smoothly Q NOTE e Do no
34. e specified tightening torque values o After reassembly recheck partsffor tightness and operation REPLACEMENT CO SONENTS NTO spare parts or their equivalent Genuine VENTO components are high quality parts ally for VENTO vehicles Be sure to use genug which are designed s may damage using genuine parts or parts that is not equivalent to VED parts and will be affecting performance also VENTO MOTORCYCLES Rev 01 page 701 84 Created by docuPrinter trial version SPECIFICATIONS ENGINE valve clearance DESCRIPTION PARAMETER VEHICLE Overall length 1950mm Overall width 675mm Overall height 1130mm Wheelbase 1375mm Minimum ground 115mm Cylinder BoreXStroke Displacement Compression Ratio Valve Engine oil capacity Oil Grade Lubricating system Oil pump style Air cleaner Cylinder pressure Close Perte Clearance Exhaust valve Idle speed Max Torque Max Output power Starting system Dry weight of engine Inlet port je d dd Type 4 Stroke Air Cooled Single Cylinder 52 4X57 8 124 6 cc 10 3 1 Two Valve b 0 9L SAE10W 40 or SAE 10W 50 Pressure amp splash type lubrication otor type 10 0 20 Cm 3 BTDC 30 ABDC 30 BBDC 5 ATDC 0 03 0 05mm 0 05 0 06mm 1400 100rpm 8 3N m 6500rpm 6 32KW 7500rpm Electric amp by kick 26kg 5
35. en piston anid 0 025 0 035mm 0 025 0 035 cylinder Piston pin OD 15 002 15 005mm 15 005 15 008mm Piston pin lt Piston pin ID 14 997 15 000mm 15 000 15 003mm Clearance between The first ring 0 013 0 045mm piston ring and groove iu oi 0 013 0 045mm The first ring 0 1 0 2mm Clearance between The second piston ring and rin 0 1 0 2mm hatch 9 Oil ring 0 3 0 4mm VENTO MOTORCYCLES Rev no 01 page 47of 84 Created by Neevia docuPrinter trial version CHAPTER 4 AIR FUEL SYSTEM Carburetor specification Type CV Model PD24J Piston dia 24mm Main jet 191 Slow jet 19 Mixture screw 1 5 0 5 turnout Needle position 4 groove from top Float height 15 1mm FUEL CONSUMPTION CURVE Perfect state mileage m 20 30 an BD 21 UIT speed Ikmh VENIO MOI ORCYCLES Rev 01 page 480 84 Created by Neevia docuPrinter trial version screw E d 5 ben isi ei x L lt VENTO MOTORCYCLES Rev no 01 page 4901 84 Created by Neevia docuPrinter trial version Mixture ratio adjusting screw __ 1902 jet foam tube JET di schar ging pastern tube AIR FUEL FLOW CIRCUIT Fuel is being supplied to the carburetor from fuel tank by gravity feeding controlled fuel cock assy Air filter box is fitted on the left side of the motorcycle Fuel gets atomized
36. eplace 44 6 Worn shoe Replace 7 Friction surfaces of shoes are dirty with Replace oil 8 Excessively worn drum Replace 9 Too much brake lever play Adjust Rev no 01 page 8701 84 Created by docuPrinter trial version Brake 1 Carbon adhesion on pad surface Repair surface with sandpaper Q squeaking 2 Tilted pad Modify pad fitting or replace 3 Damaged wheel bearing Replace Q 4 Worn pad or disc Replace 5 Foreign material entered into brake Replace brake fluid A fluid em 6 Clogged return port of master cylinder Disassemble and clean master cylinder 7 Brake shoe surface glazed Repair surface with sandpaper 8 Loose front wheel axle or rear wheel Tighten to spe fied orque axle nut A 9 Worn shoe Replace Q Excessive d brake lever 1 Air entered into hydraulic system stroke 2 Insufficient brake fluid Replenish fluid to specified level amp bleed air 3 Improper quality of brake fluid Replace with specified fluid 4 Worn brake cam lever Replace 5 Excessively worn shoes ap orum Replace Leakage of 1 Insufficient We Tighten to specified torque brake fluid joints 2 Cracked hose Replace 3 Worn piston seats Replace piston and or cup Rev no 01 page 88of 84 Created by Neevia docuPrinter trial version
37. er float rises up words along with the float pin and after certain level it stops further flow of fuel Adjust float height 121 1mm This avoids overflow of Carburetor fuel switch balance tupe discharging oil tube 2 CHOKE CIRCUIT Choke is provided for easy starting since it requires rich mixture Hence choke knob is being operated from the carburetor Due to this an air stopper Butterfly valve comes on the way to the venturi Air filter side of the carburetor thus reducing th amount of air being mixed withefuel Excessive fuel is being sucked fr the slow jet and less qua air enters from the cho e and from the small open low the throttle valve e engine starts ating lever itself so the choke actuating CHOKE LEVER ar fe SLOW JET ey VENTO MOTORCYCLES Rev no 01 page 52of 84 Created by docuPrinter trial version 3 IDLING CIRCUIT After starting operation choke is released more air starts flowing thru the venturi From slow jet fuel is sucked due to venturi effect A separate passage from the air filter side is coming at the diffuser of the slow jet for the atomization of fuel in slow jet This atomized fuel is sucked into the venturi as started above from the slow jet As shown in figure The amount of air for atomization is regulated by air screw located at bottom side of the carburetor body 4 SLOW SPEEDCIRU
38. hing Replace 7 dts or bolts for engine mounting Tighten ie springs Replace suspension too Kot h oil in the fork Replenish soft Not enough oil in the fork eplenish Froni Too viscous fork oil Replace suspensio stiff Too much fork oil Drain excess oil Noisy t 1 Not enough fork oil Replenish suspension 2 Loose nuts nuts on suspension Retighten pt rear 1 Distorted wheel rim wheel 2 Defective or incorrect tire Replace 3 Loose nuts on the rear shock absorber Replace 4 Worn engine mounting bushing Retighten Rev no 01 page 86of 84 Created by Neevia docuPrinter trial version lt 5 Loose nuts or bolts for engine mounting Replace 6 Worn rear wheel bearing Retighten Replace Ee i65 1 Weakened shock absorber spring p 2 Oilleaks from rear shock absorber p soft Replace SU Noisy rear suspension 1 Loose nuts on shock absorber Retighten 2 Worn engine mounting bushing Replace 3 Loose bolts on shock absorber Retighten Pd BRAKES Complaint Pa Symptom and possible causes Remedy Insufficient akage of brake fluid from hydraulic Repair or replace brake power system 2 Worn pads Replace 3 Oil adhesion on engaging surface of Clean disc and pads lt pads Replace SS 4 Worn disc Bleed air 7 5 Air entered into hydraulic system R
39. ide of driven wheel disc rolling needle bearing with mark needs to be toward seeable direction and the side of ball bearing with mark needs to be towards clip 3 The convex side of the gasket between drive wheel disc and driven wheel disc is towards locknut 2 4 The side of Kick stater gear and transition gear with mark is towards left cover 5 Chain guide groove should be towards chain and column rod of chain guide ws Ben than the surface of cylinder 6 White piston ring is the first one black piston ring is the groove of 1st and 3rd ring towards exhaust port groove of ring 2 and ring 4 are towards inlet pica e with English letter is towards the top of piston O 7 IN mark on piston should be towards carburetor side 8 Valve spring dense end is towards valve guide 7 9 The side of camshaft bearing 6002 with mark should be towards cam 10 The side of oil pump with letters is tow ards outside 11 The side of left and right with W mark is towards the reverse of combined surface of left and right crankcase VENTO MOTORCYCLES ated by Neevia docuPrinter version 01 pa ENGINE DISASSEMBLY AND ASSEMBLY DISASSEMBLY Guide fan cover fan cover carburetor Left crankcase cover gasket Outside part of left crankcase Chain adjustor cylinder head cover transmission gear motor holder cam Cylinder cover gasket pin Cylinder g
40. isassembly P d Created by Neevia docuPrinter trial version ev 01 pag ENGINE REMOVAL AND INSTALLATION x Disassembly Cylinder head usi Right against mark T on magneto The bottom of SSES port Timing chain tensioner Cam shaft holder assy cam shaft chain Cam shaft holder assy cam shaft fixer assy Cylinder head assy correct timing same level as Valve lock clip valve spring holder Inlet exhaust valve spring Rocker shaft Cylinder head VENTO MOTORCYCLES Specified Torque value Created docuPri Assembly Cylinder head Exhaust amp Inlet valve oil seals assy gasket Inlet amp exhaust valve spring spri Cylinder head qs Cam shafttlgin cam shaft holder assy cam shaft holder assy Right against mark T on magneto rotor and mark on EE timing marking on the joint surface of cylinder head Timing chain tensioner adjust Adjust specified valve clearance gt Inlet valve clearance 0 03 0 05mm Exhaust valve clearance 0 05 0 06mm ter trial version 1 Cylinder head cover fixing bolt 10 12N M 2 Chain Tensioner bolt and fixing bolt 10 12 3 Cam shaft holder nut 22 25 4 Inlet pipe locknut 10 12 5 Timing bolt 10 12 N M CAM SHAFT HOLDER ASSEMBLY DISASSEMBLY ASSEMBLY CAM SHAFT HOLDER amp CAM SHAFT ASSY MEL ad vanno CAM SHAFT HOLDER ADJUSTING GASKET ROCKER
41. kcase Engine 1 Crank right cover Engine BEARING 13NOS Description Location 1 6203 1 Output shaft gearbox cover Engine Created by Neevia docuPrinter trial version 1 2 6202 1 Middle shaft gearbox cover 3 6204 1 Output shaft gearbox cover 4 6004 1 Output shaft left Crank case 5 6002 1 Middle shaft left Crank case 6 6301 1 Output shaft left Crank case 7 TM SCD4ASSCS12 1 Left crank left Crank case 8 TM SCD4ASSCS12 1 Right crank right Crank case 8 K28x33x14 1 Be SE connecting 9 K28x32x17 1 Clutch hub clutch gear 10 6902NSE28 x15x7 1 Driven disc output shat 11 HK20 x29x18RS 1 Driven disc output Haft 12 6002 2 Camshaft eer VENTO MOTORCYCLES PIN SHAFT 2NOS Created by Neevia docuPrinter trial version 1 S NO Size mm Qty Description Location 1 5 1 Starter clutch Engine 2 40x6 5 1 Oil pump Engine GASKET 7 NOS lt S NO Gasket Type Qty Anti Oil Asbestos 1 Q Cylinder head cover Rubber Engine Cylinder head Steel Engine Anti Oil Asbestos Cylinder body Rubber 1 Engine Anti Oil Aebestos Crankcase Rubber 1 Engine Right crankcase cover lt 1 Engine Rubber Left crankcase cover
42. kcase cover Oil filter cover cap Nut for oil pump Nut for oil pump sprocket Nut for oil pump Nut for oil pump cover Screw for starting clutch Screw for super starting clutch outside Bolt for right crankcase Double head bolt for left and right crankcase Fixing bolt for self start motor Bolt for left crankcase cover and wiring harness Tapping screw for ventilating guide board of left crankcase cover Nut for drive disc Nut for driven disc Nut for driven disc clutch lt Nut for press board of kick Mad Bolt for transmission case cover Bolt for transmission case 02 N Nut for position shaft of lefycrank shaft CHAPTER 3 VENTO MOTORCYCLE GINE DETAIL INFORMATION OF IMPORTANT PARTS ated by Neevia docuPrinter trial version page 40 45NM 22 25NM O RINGS 7 NOS Size mm Qty Description Location 9 1 6 2 Inlet and exhaust valve guide Engine 13 7 1 5 1 Chain guide Engine 9 5 1 5 1 Chain adjustor Engine 180x3 5 1 Oil Level gauge 30 5 3 1 Filter spring 40 7 1 9 2 Driven wheel disc 27 2 1 Inlet seat OIL SEALS 4 Nos 7 f 1 Description Location 1 20x32x6 Output shaft gearbox cover Engine S NO Size mm 3 20x29x6 2 27x42x7 A 1 Output shaft left crankcase Engine 1 Crank left cran
43. lt lt T04 TOOLS TO DISASSEMBLE vi 05 DISASSEMBLING TOO S amp R OIL DRAINAGE T06 COMPRESSION T dirum GAUGE T07 DISASSEMBLING TOOL FOR PISTON PIN T08 oO PLUG SOCKET 09 TOOL FOR OPENING OF FLY WHEEL BOLT T10 CULTCH CLAMP lt xO O C VENTO MOTORCYCLES ated by Neevia docuPrinter frial version 01 pa A VENT JRCYCLES J e lt Z Created by Neevia docuPrinter trial version 2 Ei Q lt ECIFIED IORQUE VALUES IT 1595 FOR THE COMPONENTS FASTENERS TIGHTEED AS PER SPECIFIED TOR xO QTY TORQUE VENTO MOTORCYCLES Created by Neevia docuPrinter trial version ev 01 JO Tapping screw for fan cover assy Screw for fan cover assy Tapping screw for top and bottom guide fan cover Screw for top and bottom guide fan cover Tapping screw and nut for ventilating air chamber of cylinder head cover Bolt for cylinder head cover Nut for double head blot on cam fixing holder Nut for chain guide Screw for chain adjustor Bolt for cylinder head Bolt for cylinder Spark plug Double head bolt for cylinder head inlet port Double head bolt for cylinder head exhaust port Nut for carburetor joint pipe Screw for cooling fan Screw for flywheel Nut for magnet Assay Screw for pick up coil Nut for right cran
44. m pin to remove the float Remove the main jet along with jet holder a edle Remove the slow jet Now clean all the carburetor compressed air in all passages galleries 9 the spring up from the seat in long slit ze Don t remove clip from he je este groove e Ensure that float and float valve is being removed before carrying out any other jobs on carburetor So that these components Will ot get damage ASSEMBLY PROCEDURE OF RETTOR 1 Screw the slow jet En at all holes are clearly visible on the slow jet body 2 Fix needle jet from t hole Ensure that the smaller dia face towards carburetor body hole 1 Tighten the need holder Ensure that all holes clearly visible on the needle jet holder body 2 Screw the along with jet holder 3 Insert the float arm pin through the pivot and the float 4 Check flo 5 9 6 ght Specified 12 5 1mm Dif necessary then adjust Fix the float chamber le screw and airscrew along with spring Initial airscrew setting one and half turn out jet needle along with clip and plate into the throttle valve Ensure that needle lock clip is in 3 ve position from top onnect the throttle valve to the accelerator cable first compress the spring into the cap Insert the tip of the cable through the slot in the throttle valve base and fix cable in long slit rest position Sc 3 Align the groove on the sid
45. ng screw focus d adjusting nut remove and insta HEAD LIGHT ASSEMBL The assembly night small light 12V 3 Wx2 is the reverse of disassembly INDICATOR dd Remove and replace bulb 12V10 W SPeepoygfe DISASSEMBLY 9 Remove front cover of handlebar O Remove connector of headlight Remove Indicator lt N Take out flasher from its retainer and remove connector Remove fixing screw lt Front back board Remove rotating meter and the core of odometer Replace bulbUincluding high beam turning signal light fuel gauge meter indicator light SPEEDOMETER ASSEMBLY The assembly sequence is the reverse of disassembly Rev no 01 page 75of 84 Created by Neevia docuPrinter trial version Rev no 01 page 76 1 84 Created by Neevia docuPrinter trial version MAIN ELECTRICAL COMPONENTS SPECIFICATION SOME IMPORTANT SPECIFICATION ELECTRICAL BATTERY CHARGING SYSTEM SPECIFICATION gt 12volt 5AahYYTX7A BS Specific gravity at 270 Fully charged 1 220 1 240 A Battery Needs charging Charging current Charging time Capacity Battery Battery charging coil resistance charger at 200 68 Between Black and Black White wirin Jess than 2 Ohms Lamp cable Yellow and Green White Less than 2 Ohms VOLTAGE REGULATOR OUTPUT Regulated voltage for lighting circuit 14 5Volt Rectified DC voltage for battery ch
46. nger is not operating properly A Check and replace 5 Clogged fuel pipe Clean 6 Clogged enrichner choke or air cleaner Check and clean Idling or low 1 Pilot jet pilot air jet are clogged or loose Check and clean speed 2 Air leaking from carburetor s joint vacuum pipe joint or Check and replace troubles starter 3 Pilot outlet is clogged Check and clean 4 Starter plunger is not fully close Check and replace Complaint Symptom and possible causes Remedy Medium or 1 Main jet or maig air jet is clogged Check and clean high speed 2 Needle Clogged Check and clean trouble 3 Fueld velis improperly set 4 valve is not operating Check and replace uel filter is clogged efective fuel tap Check and clean Check throttle valve for operation Replace 1 Needle valve is worn or damaged Replace 2 Spring in needle valve is broken 3 Float is not working properly Replace 4 Foreign material has adhered to Check and adjust needle valve Clean 5 Fuel level is too high or low Adjust float height Created Rev no 01 page 8301 84 by Neevia docuPrinter trial version ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or 1 Defective CDI amp ignition coil unit Replace poor sparking 2 Defective spark plug Replace 3 Defective magneto stator coil Replace 4 Loose connection of lead wire Connect tighten 5 Defective
47. ngs Replace 5 Worn piston rings or cylinder Replace 6 Worn Valves or stems Replace 7 Worn oil rings side rails Replace Engine lacks 1 Excessively worn c re piston rings Replace power 2 Sticky piston ring ves Replace 3 Compression leaks af valves amp gaskets Replace amp repair 4 Spark plug g incorrect Adjust or replace 5 Clogged element Clean 6 fuel level out of adjustment Adjust or replace 7 park plug Clean 8 ing air from intake pipe Clean or replace the 9 E or worn V belt gaskets 40 Damaged worn rollers in the movable drive face Replace 17Weak movable driven face spring Replace Too rich fuel air mixture due to defective starter system Replace Replace Heavy carbon deposits on piston crown Clean Replace and clean Adjust or replace Retighten replace gaskets Add specified oil Change amp use specified Created by Neevia docuPrinter trial version Rev no 01 page 8201 84 oil 7 Use of incorrect spark plug Change amp use specified 8 Clogged exhaust pipe muffler Clean or replace 9 Clogged air intake with dust Clean CARBURETOR Complaint Symptom and possible causes Trouble with 1 Starter jet is clogged starting 2 Air leaking from a joint between starter body and carburetor 3 Air leaking carburetor s joint or vacuum hose joint Gheck and replace 4 Starter plu
48. ning without sticky and then use circlip 15 in proper position e Before installing driven step less shifting disc cover the driven step less disc with 2 O rings 8 and assemble seal 10 Created by Neevia docuPrinter trial version 01 pa KICK SHAFT ASSEMBLY REMOVAL Kick start shaft assy 111 Gasket 20 Spring 30 Hin D Kick start shaft Ai INSTALLATION The installation sequence is the reverse of removal NOTICE Daub bush 1 iwith proper lubrication to install it e Daub shaft end with proper lubrication to install busb p e sure to install pin proper tightly VENTO MOTORCYCLES TRANSMISSION GEAR SHAFT ASSEMBLY Transition gear assy 730 including 2500 Q e REMOVAL Transition gear shaft assy Fixing 161 Adjustment 47 Tension spring 121 Transition gear shaft 11 050 Installation The installat Notice e Before instalilg transition gear install clip 5 in transmi gear groove Transfnissioh gear can turn back well quence is the reverse of remc Rev no 01 page 390 84 Created by Neevia docuPrinter trial version MOVABLE DRIVE FACE REMOVAL INSTALLATION Face fixed drive 1111 Face movable drive 050 Bush 20 Washer 060 Plate Drive 080 Steel bush 4 Cushion 90 Washer 030 Roller 070 Roller 070 3 Cu
49. nter trial version 4 Piston rings or ring grooves worn Noise seems to come from crankshaft 1 Worn or burnt crankshaft bearings 2 Worn or burnt conrod big end bearings 3 Due to wear rattling bearings 4 Too large thrust clearance Excessive valve chatter 1 Too large valve clearance 2 Weakened or broken valve springs 3 Worn rocker arm or cam surface 4 Worn and burnt camshaft journal Noise seems to come from Timing chain 1 Stretched chain 2 Worn sprocket 3 Chain tensioner not working Noise seems to come from clutch 1 worn or slipping drive belt 2 Worn rollers in the movable drive face E Noise seems to come from SE Replace Replace Replace Replace Replace Adjust Replace Replace Replace 1 Gears worn or rubbing gt 2 Badly worn splines 3 Worn or damaged bearing of driv shaft or rear Replace axle shaft Replace Replace Slipping clutch 1 Replace 2 Replace 3 Replace 4 Replace Engine idles poorly 1 Excessively worn cylinder or piston rings Replace 2 Sticky piston rings in grooves Replace or clean 3 leaks from crankshaft oil seal or Replace v s Spark plug gaps too wide Defective CDI amp ignition coil unit Adjust or replace Replace Defective magneto stator coil Replace Float chamber fuel level out of adjustment in Replace carburetor Clean or adjust Clogged jets in carbure
50. ocuPrinter trial version OVERHAULING PROCEDURE OF DISC BRAKE orl Rev no 01 page 67of 84 Created by docuPrinter trial version IGENERAL INSTRUCTION OVERHAULING OF DISC BRAKE CALIPER 1 Never handle brake fluid by bare hands for a longer 1 Disconnect the brake hose from caliper and collect time the brake fluid and plug the hole brake fluid comes in contact with eyes wash eyes with cold water and consult a doctor immediately 2 Loosen the mounting bolts of caliper assay and take Never allow brake fluid to come in contact with any out ND f painted parts as it peels off paint If it happens wipe 3 Disassemble bolt braking caliper assy brake immediately with damp cloth wash with water and brake shoe spring Never clean any hydraulic brake parts with mineral oil based cleaner Le Kerosene petrol or 4 Disassemble oil stopper oil stopper anti dusteover diesel etc Always clean all the hydraulic brake and square seal ring Removal steps Eege parts only with fresh brake fluid 5 Connect air pressure hose at inlet of the talliper and D Never lubricate any components of hydraulic apply air pressure so calliper pi Will come out system with mineral base oil or grease slowly 4 D Ae the brake fluid is hygroscopic absorbs moisture Assemble the disc brake caliporparts in reverse order of from atmosphere by nature it is better to replace the disassembly order brake flui
51. pick up coil Replace Spark plug 1 Mixture too rich Adjust carburetorm soon becomes 2 Idling speed too high fouled with 3 Incorrect gasoline carbon 4 Dirty element in air cleaner 5 Spark plug loose 6 Too cold spark plugs Spark plugs 1 Worn piston rings become fouled 2 Worn piston or cylinder d too soon 3 Excessive clearance of valve stems in valve Replace guides 4 Worn stem oil seals Replace Pd Spark plug 1 Spark plug too hot Replace with specified cold plugs electrodes 2 Overheated the engines Tune up overheat or 3 Loose spark plugs Retighten burn 4 Too lean mixture Adjust carburetor 5 g oil Check oil pump Magneto does not charge the battery Not enough Fn Open or short in ires or loose lead connection Shorted gr ed or open magneto coil Repair or retighten Replace Replace Magneto charge but charging rate is below the specifications d wifes tend to get shorted or open circuited osely connected at terminal Defective regulator rectifier Repair or retighten Replace Replace 4 Defective cell plates in the battery Replace the battery Magneto 1 Internal short circuit in the battery Replace the battery 2 Resistor element in the regulator rectifier Replace damaged or defective 3 Regulator rectifier unit poorly grounded Clean and tighten ground connection Rev 01 page 84of 84 Created
52. r cylinder parts s rev se order of disassembly sequence NOTE Apply brake fluid on cylinder piston seals amp then insert into the body SPECIFICATION OF VEHICLE PARTS Rev no 01 page 68of 84 Created by docuPrinter trial version Front wheel absorber control Description STANDARD Tire air pressure Driver 32 PSI Driver and passenger 32 PSI Free distance of front absorber spring 130MM lt Disc brake system Description STANDARD S Specified disc brake oil DOT3 or DOT4 CH The thickness of the brake shoe 6MM The thickness of brake plate 4MM Rear wheel O Description STANDARD Tire air pressure Driver 32 PSI Q Driver and passenger 32 PSI CH The free play of brake lever 20MM Diameter of rear brake hub 130MM G The thickness of the rear brake pad kit 4mm 01 690 84 Created by docuPrinter trial version CHAPTER 6 ELECTRICAL e 2 MAGNETO ASSY Q Coil for lighting and battery charging Charging Coil Pickup Cail CONSTRUCTION Magneto assembly ids d of a stator amp rotor Assy Type of stator coils XN i n star connection STATOR ASSEMBLY e Six coils ot Seven coils for light battery charging amp one coil for charging purpose Pick up amp stator assembly is externally mounted on crank case R
53. ra if required 11 Check front bra aver free play and adjust if required amp rear brake lever for efficient working amp proper adjustments id level in the master cylinder and top up with specified brake fluid if required heck wheels for proper alignment free rotation and proper tightening drive the motorcycle for proper balancing and adjust steering movement if required H Check and adjust head light focussing if required 4 48 Check proper functioning of Speedometer Odometer and Tachometer 19 Check for any oil fuel leakage rectify it if required Rev 01 page 7801 84 Created by docuPrinter trial version PDI CHECK POINTS PDI CHECK POINTS lt Check proper det lt all electrical swit he Check turn signals for ee ioni eck brake lever free proper functioning Ensure to install first fully play 10 20 mm charged battery then start the 4 Check throttle grip free play 2 4mm motorcycle Check tire pressure 2 25Kg cm2 32PSI Check proper fitment of Spark plug Suppressor cap Check tire pressure Check brake oil level lt x 2 25Kg cm2 32PSI Check torque of engine O mounting bolts adjust Idling 100 Check CH Speed Check engine oil level Rev no 01 page 7901 84 Created by Neevia docuPrinter trial version CHAPTER 7 TROUBLE SHOOTING 2 Sticky piston rings in groo
54. re of cylinder 2 di Piston ring jammed in groove e Ifthe Compression pressure d Snot increase then check for following Incorrect Valve Tappet Te Improper torque of c er nuts or cylinder head bolts Valve seat damage or Valve leakage O Valve is bend O Improper V T ing fti Cylinderi ad warp age gu Blowrfouboylinder head gasket STEP 3 M pressure is more than 12 Kg Cm2 Then engine requires Decarbonisation of cylinder KO combustion chamber amp piston Also check for smoky exhaust Oo O O O VENT QTAND SRD DIMENSION OF ENGINE Rev no 01 page 460f 84 Created by docuPrinter trial version Cylinder head valve ITEM STANDARD CYLINDER PRESSURE KEN kg cm Inlet 0 03 0 05mm Valve clearance Exhaust 0 05 0 06mm Inlet 26 72 0 05 Cam shaft cam lobe height Exhaust 26 68 0 05 Inlet 4 970 4 980 m Stem OD Exhaust Inlet 5 000 5 04 Valve Stem ID 5 7 Exhaust 5 00 05 0 2mm The clearance Inlet 020 0 042mm between valve stem gt and valve guide Exhaust 035 0 057mm Inner Spring gt 32 8mm Spring free length Outer Spring 35 55mm Cylinder Piston e A B Inner diameteref cylinder Bore 52 400 52 405mm 52 405 52 410 mm Cylinder piston See of piston 52 370 52 375mm 52 375 52 380 betwe
55. shion gaske Bush 14 7 Plate Washer 60 gk Face movable drive bi o ed drive 010 NOTE e Before installing part 8 insert 3 cushion gaskets into 8 Bushli2Ushould be slide freely lt lt VENTO MOTORCYCLES Rev no 01 page 40of 84 Created by docuPrinter trial version SUPER CLUTCH INSTALLATION REMOVAL Clutch gear 010 l a Rolling needle bearing 2 mG M6130 bub A A dix V Rolling 7 and spri Clutch outside circle rubbe Spring 1100 Clutch side circle 111 Installation The installation sequence is just reverse of removal NOTE e Should not be loose clutch side K ew and spring seat after installation e Clutch gear should turn only one dir etion Cre POWER From kick start Kicking start shaft Kicking start axes 5 Start gear Transition little gear Transition big gear Crank start driven gear Crank 11 Created by Neevia TRANSMISSION From engine M Piston 1 24 Y b Connecting rod 2 Crank 11 lt Driving disc Driven disc 6 Clutch 7 Gearbox input axes XI Reduction Ratio Reduction Ratio 015 420 2 Reduction Ratio 13 400 uPrinter trial version LUBRICATION THE ENGINE OIL P
56. t apply force or over tight the air screw Damage ma occur against the air screw seat e Incase the Idling speed is too low engine will stop if it is too high will cause fuel consumption incase the air screw is being tightened WARNING While running engine in Idling speed turn the handle bar to the extreme left or right hand side if any change in idling speed noticed the accelerator cable rongly routed or improperly adjusted Correct the same before test ride Rev 01 page 56of 84 Created by docuPrinter trial version CHAPTER 5 CHASSIS INSTALLATION OF VEHICLE BODY Specified Torque Value NO ITEM TORQUE FRONT WHEEL FRONT ABSORBER 1 Front wheel axis locknut 55 62Nm 2 Fixing bolt between front absorber and support un 4 37 44N m connecting board assy 3 Fixing bolt for disc brake and front absorber 2 22 29N m Handlebar 4 4 Fixing bolt for handlebar and supporting under connecting 4 37 44N m board Frame lt 1 Fixing bolt for frame and engine bracket 2 37 44N m 2 Fixing bolt for frame and rear absorber 2 37 44N m Rear wheel rear absot 1 Rear wheel locknut j 1 100 130Nm Fixing bolt for left and engine 1 22 29N m rear absorber and muffler connecting 4 22 29N m engine and muffler 2 22 29N m It for engine and engine bracket 1 37 44N m
57. te wire it should be 150 to 300 ohms at 200 otherwise replace pick Remove spark plug amp then cennet a L E D of 1 5 volts across blue white and green white wire kick the start lever to rota cas L E D should flash otherwise replace the pick up coil 6 0 1 UNIT TEST in place of O K C D I where C D I already working ike starts easily then unit is good otherwise replace the C D l unit ing of ignition timing auto advance by timing light otherwise replace Rev no 01 page 73of 84 Created by Neevia docuPrinter trial version E Q IGNITION TIMING TEST A 2 Connect the timing light Stroboscope 3 Start the engine and aim the timing light at ignition mark on the eer fly wheel As shown in figure During idling speed Ignition mark F align with I mark of timing inspection hole i e 13 Before TDC 1400 RPM See Tachometer eDuring Acceleration IPFULL ADVANCE index mark align with l mark of timing verbe hole Le 28 before TDC 4000 RPM If the ignition timing is not correct replace CDI and then check with new one 1 Remove the ignition timing inspection hole cap SM 4 ignition timing signal Rev 01 page 401 84 Created by Neevia docuPrinter trial version HEAD LIGHT INDICATOR amp METER LIGHT HEAD LIGHT DISASSEMBLY Q Remove front cover TM Leg shied Remove headlight mt 8W x2 Dy unscrewing fixi
58. tor Replace Worn rocker arm or cam surface Replace Symptom and possible causes Remedy Rev 01 page 8101 84 Created by Neevia docuPrinter trial version Defective oil pump or clogged oil circuit Fuel level too low in float chamber Air leakage from intake pipe mM Not enough oil in the engine Used incorrect engine oil Engine runs 1 Excessively worn cylinder or piston rings Replace poorly in 2 Sticky piston ring in grooves Replace or clean high speed 3 Spark plug gaps too less Adjust range 4 Ignition not advanced sufficiently due to poorly Replace working CDI amp ignition coil unit 5 Defective magneto stator coil Replace 6 Float chamber fuel level too low Adjust or replace 7 Clogged air cleaner element Clean 8 Clogged fuel hose resulting in inadequate fuel Clean and prime supply to carburetor 9 Clogged fuel cock vacuum pipe Clean 10 Weakened valve springs Replace 1 11 Worn camshaft Replace 12 Valve Timing out of adjustment ug 13 Too wide spark plug gap LL 14 Defective Ignition coil CDI unit 15 Defective Pickup coil or CDI 16 Too low float chamber fuel level Dirty or heavy 1 Too much engine oil in the engine Check with Oil level exhaust gauge drain excessive smoke oil 2 Defective Valve and seals Check amp Replace 3 Worn out valve guide seals leaks of valves Check amp Replace 4 Weakened valve spri
59. traint during its early e General requirements are as follows Limit break in speed V ex At the first 1000 Kms 630 miles mileage use throttle opening less than 1 2 Q Up to 1600 Kms 1000 mies imileage use throttle opening less than 3 4 O e Upon reaching an odometer reading of 1600 Kms operation e Do not maintain constant engine speed for on extended time period during any period try to vary the throttle position o e Q lt SS lt gt 5 VENTO MOTORCYCLES Rev no 01 page 6of 84 1000 miles you can operate the m torcycle to full throttle of the BREAK IN Q Created by docuPrinter trial version PRECAUTIONS AND GENERAL INSTRUCTIONS GENERAL PRECAUTIONS WARNING Proper service and repair procedures are important for the safety of the service mechanic and the reliability of the vehicle o When two or more persons are working together pay attention to the safety of each other o When it is necessary to run the engine indoors make sure that the exhaust gas is forced outwards and ventilatlops should be proper o When working with toxic or flammable materials make sure that the area you work in is well ventilat follow all off the material manufacturer s instructions o Don tuse gasoline as a cleaning agent d 7 o After servicing the motorcycle check all lines i e fuel oil and brak
60. ut shaft oil seal and beari 6 INSTALLATION installation sequence is just reverse of the removal i NOTE e Check Correct position of each bearing the mark of bearing AQ be outside and its rotation should be freely without any obstruction e During assembly of oil seal should be apply little oil dgmage the oil seal e Various gears should be positioned properly and should be turn freely e To assemble 6 Bolts first of all pre fasten pin bolt tighten various bolts with specified torque 10 12NM e specified torque 2 oil bolts is Oy Gears 1 B1 B2 Created by Neevia docuPrinter trial version 01 pa CLUTCHSHOE MOVABLE DRIVEN FACE REMOVAL DISASSEMBLY Driven wheel disc assy spring bush 6 clip circle 17 Clutch dec 1 fixing axes 113 I sliding 120 clutch side 0180 Nut 2 Sea 17 i driven step less shifting disci 197 Spring 190 clutch mass 200 e Clutch driving board 030 rolling needle 0 160 Spring holder bush 4 clip circle 5 ball bearing 140 Compression spring 15 1 rear transmission main disci 111 71 ASSEMBLY The assembly sequence is just reverse of removal NOTE e When reinstalling clutch driving board assy be sure to use gw limiter and pin shaft and ensure stable connection e When installing ball bearing and roller needle netz ome lubrication to ensure free tur
61. ve 3 Compression leaks from the joint in crankcase cylinder or cylinder hea 4 Damaged or leaks of valve 5 Spark plug too lo 6 7 Worn out ore Too sony cranking starter motor Plug not spa spark plug efective CDI amp ignition coil unit or stator coil or short in high tension cord efective ignition switch j fuel reaching to the carburetor Clogged hole in the fuel tank cap Clogged or defective fuel cock Defective carburetor float valve Clogged fuel hose or defective vacuum hose ENGINE Complaint Symptom and possible causes Remedy Engine does not start or Compression too low is hard to start 1 Excessively worn cylinder or piston rings Replace Repair or replace Repair or replace Repair or replace Retighten Replace or rebore See electrical section Replace Replace Clean Replace Replace Replace Clean or replace Clean or replace Replace Clean or replace 1 Carbon deposited on the spark plug Clean 2 Defective CDI amp ignition coil unit Replace 3 Clogged fuel hose Clean Am 4 Clogged jets in carburetor Clean lt 5 Clogged exhaust pipe Clean Noisy engine Noise appears to come from piston 1 Piston or cylinder worn out Replace 2 Combustion chamber fouled with carbon Clean 3 Piston pin bearing or piston pin bore worn Replace Rev 01 page 800 84 Created by docuPri
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