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Displacement | 149.2 cc |
---|---|
Bore x Stroke | 57.3 mm x 57.8 mm |
Compression Ratio | 9.1:1 |
Fuel System | Carburetor |
Transmission | 5-speed |
Clutch | Wet multi-plate |
Frame Type | Tubular diamond |
Front Suspension | Telescopic hydraulic fork |
Rear Suspension | Dual shock absorbers |
Front Brake | Disc |
Rear Brake | Drum |
Fuel Tank Capacity | 12.5 liters |
Engine Type | Single cylinder, 4-stroke, air-cooled |
Manual intended for qualified technicians; risks of improper service.
Proper service ensures customer safety and vehicle reliability.
Basic shop safety practices for technicians.
Clear understanding of practices, appropriate clothing, and safety equipment.
Replace gaskets, O-rings, etc. with new ones; tighten bolts in a criss-cross pattern.
Highlights key features of the motorcycle's engine, frame, brakes, etc.
Safety precautions for carbon monoxide, gasoline, hot components, battery, and electricals.
Detailed specifications for frame, engine, brakes, suspension, etc.
Maintenance service limits for components like throttle grip, spark plug, etc.
Torque values for maintenance, lubrication, and cylinder head.
List of special tools with their part numbers and applications.
Warning about hot exhaust system and general service notes.
Torque specifications for exhaust muffler components.
Common issues and probable causes related to the exhaust system.
Steps to remove and install the seat.
Steps to remove and install the fuel tank.
Steps to remove and install the front fender.
Steps to remove and install the exhaust muffler.
Steps for removing and installing the rear shock absorber.
Maintenance specifications for throttle grip, spark plug, valve clearance.
Detailed schedule of maintenance tasks at various service intervals.
Procedure for checking and adjusting valve clearance.
Steps for draining and refilling engine oil, including torque values.
How to inspect and adjust drive chain slack.
Replacing front and rear brake shoes based on wear indicators.
Engine oil capacity and recommended oil specifications.
Common problems like low oil level, contamination, and low pressure.
Steps for removing the oil pump from the engine.
Inspecting oil pump components and checking clearances.
Diagram showing lubrication points for control cables and bearings.
Fuel system specifications including tank capacity and carburetor details.
Diagnosing engine start issues, lean/rich mixture, and poor performance.
Steps to remove the air cleaner housing.
Steps to remove and disassemble the carburetor.
Removing and inspecting the float and float pin.
Engine oil capacity specifications.
Torque values for engine mounting bolts and plates.
Steps to disconnect wires, cables, and remove nuts.
Steps for installing the engine, including mounting bolts and torque.
Specifications for cylinder compression, valve clearance, and rocker arm.
Diagnosing compression issues and excessive noise.
Procedure for measuring cylinder compression and interpreting results.
Steps to remove and install the cylinder head cover.
Removing camshaft set plate, camshaft, and rocker arm shaft bolts.
Refacing valve seats using cutters to correct wear.
Specifications for cylinder I.D., taper, warpage, and piston clearances.
Diagnosing compression issues, smoke, noise, and overheating.
Inspecting cylinder wall for scoring and wear.
Inspecting piston and rings for cracks, wear, and clearances.
Cleaning and installing piston rings onto the piston.
Specifications for clutch and kick starter components.
Common problems related to clutch lever, engagement, slips, and shifting.
Removing oil filter rotor cover, GPD holder, and clutch components.
Checking friction discs for scoring and measuring thickness.
Measuring mainshaft O.D. and applying oil to components.
Specifications for gear reduction and starter driven gear.
Diagnosing engine not starting due to faulty starter clutch or motor.
Removing side cover, alternator connector, and crankcase cover bolts.
Removing stator socket bolts and ignition pulse generator.
Checking roller contact surface and needle bearing for wear.
Specifications for shift fork, shift drum, and transmission components.
Diagnosing transmission jump out of gear and hard shifting.
Steps to separate crankcase halves, remove bolts and plugs.
Separating crankcase halves, removing crankshaft, and shift forks.
Measuring shaft O.D. and calculating bush clearances.
Removing crankshaft from the right crankcase.
Specifications for minimum tyre tread depth, cold tyre pressure, etc.
Torque values for front axle nut, fork cap, bridge bolts, etc.
Diagnosing front wheel wobbling, soft suspension, and brake issues.
Removing rear view mirrors and disconnecting clutch switch connectors.
Lifting wheel, removing axle nut, and front brake panel.
Checking wheel axle, bearing, and rim runout.
Inspecting brake drum and lining thickness.
Removing front wheel, fender, and fork bridge bolts.
Disconnecting cables, removing headlamp, wheel, and fender.
Adjusting steering bearing nut for free rotation and specified torque.
Specifications for rear wheel, brake, and suspension components.
Diagnosing rear wheel wobbles, soft suspension, and brake issues.
Removing brake rod, cotter pin, nuts, and rear wheel.
Checking wheel bearing play and replacing if noisy.
Measuring brake drum I.D.
Removing seat, covers, carrier, muffler, and mounting bolts.
Lifting wheel, removing pivot nut, chain covers, and exhaust muffler.
Specifications for battery capacity, fuse, and alternator.
Diagnosing battery overcharging and abnormal charging voltage.
Preparation of electrolyte and temperature correction factors.
Checking regulated voltage at different engine speeds.
Procedure for testing current leakage in the system.
Specifications for spark plug, peak voltage, ignition timing, and coil.
Diagnosing ignition coil and pulse generator issues.
Checking spark plug, primary peak voltage, and connections.
Checking ignition timing at idle and advance.
Specification for starter motor brush length.
Flowchart for diagnosing starter motor not turning issues.
Disconnecting cables and removing mounting bolts.
Inspecting commutator bars for discoloration and wear.
Specifications for headlamp, position lamp, tail lamp, etc.
Diagnosing lighting issues like no lights when ON.
Steps for removing and installing the headlamp bulb.
Steps for removing and installing the position lamp.
Steps for removing and replacing turn signal bulbs.
Removing visor, headlamp, and meter assembly.
Removing and installing the neutral switch.
Checking operation of the stop lamp switch.
Checking continuity of handlebar switch connectors.
Troubleshooting steps for engine starting issues.
Diagnosing causes for lack of engine power.
Troubleshooting poor performance at low speeds.
Diagnosing poor performance at high speeds.
Troubleshooting issues related to steering and handling.