SERVICING OF ENGINE

ENGINE OVERHAUL
Be ore beg nn ng eng ne overhau observe eng ne
cond ons or he o ow ng:
l

C ean ness

Compress on pressure

Any abnorma no se

O eak seepage any

To overhau he gears sha comp e e coun er sha

comp e e dr ve k ck s ar er and cranksha assemb y
he crank cases need o be separa ed

CLUTCH REMOVAL AND SERV C NG

C u ch assemb y can be serv ced w h he eng ne
moun ed on he veh c e Norma y c u ch s serv ced
or:
l
l
l

Loss o power
Jerk ng o veh c e
Any abnorma no se rom c u ch

l Dra n eng ne cum ransm ss on o as exp a ned n

chap er Per od c ma n enance A er dra n ng

a ways measure he o quan y us ng a measur ng
ar
l Remove

er comp e e eng ne o as exp a ned n

chap er Per od c ma n enance

l Remove hexagona bo

M8x35 - 1no rom he

ever assemb y k ck s ar er moun ng and pu ou
ever assemb y k ck s ar er F g 3 1

13 mm spanner

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Fg 3 1

l Loosen ock nu A and ad us ng nu B rom he

cab e assemb y c u ch moun ng F g 3 2

12 mm spanner

Fg 3 2

Servicing of engine 3-1

SERVICING OF ENGINE
l Us ng 20 mm open end spanner ro a e he arm

c u ch re ease owards ron n such a way ha

cab e assemb y c u ch can be d s oca ed rom he
arm c u ch re ease F g 3 3
20 mm spanner

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Fg 3 3

l D s oca e cab e assemb y c u ch rom he bracke

c u ch cab e F g 3 4

Fg 3 4

l Remove un on bo o p pe a ong w h gaske o

p pe un on 2 nos

Fg 3 5

10 mm spanner
Note:
Wh e reassemb ng ensure the presence of
gaskets at both s de of the p pe comp ete o .

Fg 3 5

l Remove hexagona

ange bo s M6x30 - 10 nos

rom he cover c u ch moun ng F g 3 6

8 mm spanner
l Take ou cover c u ch by gen y app ng

Ny on hammer
l Take ou gaske cover c u ch and dowe p n c u ch

cover 2 nos

10

Fg 3 6

Servicing of engine 3-2

SERVICING OF ENGINE
l Co ec p n c u ch re ease rom cover c u ch /

c u ch assemb y
l Take ou adop er p n c u ch re ease rom he c u ch

assemb y F g 3 7
Note:
ns de the adopter c utch re ease, a stee ba
s prov ded. Wh e reassemb ng ensure the
presence of the ba .

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Fg 3 7

l Remove hexagona

ange head bo s M6x20 - 4

nos rom he p a e c u ch re ease moun ng
Fg 3 8

10 mm spanner
Note:
Carry out un form oosen ng and t ghten ng
of p ate c utch re ease bo ts n cr sscross
pattern to avo d uneven oad ng of p ate.
l Take ou p a e c u ch re ease

Fg 3 8

l Take ou spr ng c u ch 4 nos

Fg 3 9

l Us ng spec a oo ho d he d sc c u ch pressure and

remove nu c u ch sha s o ed nu

F g 3 10

N2310010

C u ch ho d ng oo

N2310020

C u ch nu gh en ng oo

24 mm spanner
Caut on:
Assemb e a the bo ts (4 nos) of p ate c utch
re ease a ong w th the c utch ho d ng spec a
too . Do not exper ment w th two bo ts
mounted d agona y.

Fg 3 9

F g 3 10

Servicing of engine 3-3

SERVICING OF ENGINE
l Take ou spr ng d sc rom c u ch sha

F g 3 11

Note:
Wh e reassemb ng, ocate the spr ng d sc n
such a way that the concave face d ameter of
washer faces towards outs de.

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F g 3 11

l Pu ou d sc c u ch pressure a ong w h he hub

c u ch p a e c u ch dr ve 5 nos and p a e c u ch
dr ven 4 nos as a se F g 3 12

F g 3 12

l Separa e d sc c u ch pressure hub c u ch p a e

c u ch dr ve and p a e c u ch dr ven F g 3 13

F g 3 13

l Remove hrus washer c u ch hub rom he sha

comp e e coun er F g 3 14A

l Pu ou gear assemb y pr mary dr ven rom he

sha comp e e coun er a ong w h c p pr mary

dr ven gear F g 3 14B
Note:
Wh e reassemb ng, ock the gear assemb y
pr mary dr ven w th gear comp ete k ck
starter dr ven gear groove.

F g 3 14A

Servicing of engine 3-4

F g 3 14B

SERVICING OF ENGINE
INSPECTION
Plate clutch drive
l Inspect plate clutch drive thickness using vernier

caliper. (Fig. 3.15).

l If thickness is less than the service limit, change the

plate clutch drive as a set.

Vernier caliper
Service limit

2.6 mm

l Inspect claw width of plate clutch drive using

vernier caliper. (Fig. 3.16). If the claw width is less

than the service limit change the plate clutch drive
as a set.
Vernier caliper
Service limit

15.2 mm

l Also check plates for burning due to excessive

friction / contaminated or low oil level. Inspect

plate clutch drive claws for indents (cut marks) due
to regular thrust from the housing clutch.

Plate clutch driven

l Inspect plate clutch driven distortion using a feeler

gauge and surface plate as shown in the figure.

(Fig. 3.17)
l Check 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.
l If distortion is more than the service limit change

the plate clutch driven as a set.

Service limit

0.1 mm

Spring clutch
l Measure free length of the spring clutch. If it

reaches the service limit, replace with new one.

(Fig. 3.18)
Vernier caliper
Service limit

28.7 mm

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F g 3 15

F g 3 16

F g 3 17

F g 3 18

Servicing of engine 3-5

SERVICING OF ENGINE
Caution:
Spring clutch is graded and identified with
different colour codes. While reassembling
ensure the spring clutches of same colour
codes are assembled.

Gear assembly primary driven (housing clutch)

l Inspect housing clutch for the indents / cuts

created by the plate clutch drive. (Fig. 3.19)

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F g 3 19

Hub clutch
l Inspect hub clutch for wear. If any ridges or cuts

formed in the hub clutch by the clutch plates, then

replace with a new one. Also check lubrication
holes for any blockage. (Fig. 3.20)

REASSEMBLY
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. 3.21)
l Before reassembling cover clutch, ensure that the

pin clutch release and ball are assembled properly

inside the adopter clutch release. Also inspect the
gasket cover clutch for any damage.
l Adjust clutch play. (refer chapter-2 periodic

maintenance page no. 2-22 for adjustment

procedure)
l Refill engine cum transmission oil. (refer chapter-2

periodic maintenance page no. 2-13 for oil

filling procedure)

Servicing of engine 3-6

F g 3 20

F g 3 21

SERVICING OF ENGINE
ENGINE ASSEMBLY - REMOVAL FROM THE
VEHICLE
The procedure for engine assembly removal is
sequentially explained in the following steps:
l Clean engine assembly thoroughly before taking it

out from the vehicle.

l Drain engine cum transmission oil as explained in

the chapter periodic maintenance.

l Remove clutch assembly as explained earlier.

(refer page no. 3.1)

l Turn the fuel cock knob to OFF position.

Dislocate hose clip and disconnect fuel hose from

carburettor assembly. (Fig. 3.22)
Nose plier
l Loosen and remove (M6x16 - 1no) CRR pan head

screw from the cover frame L mounting. (Fig. 3.23)

l Take out cover frame L by carefully dislocating it

from the lugs.

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F g 3 22

F g 3 23

l Unlock cover frame R by control key. (Fig. 3.24)

l Take out cover frame R by carefully dislocating it

from the lugs.

F g 3 24

l Gently pull out cable complete seat and take out

seat assembly by dislocating it from the lugs.

(Fig. 3.25)

Fig. 3.25

Servicing of engine 3-7

SERVICING OF ENGINE
l Remove hexagona

ange bo M8x25 - 1 no
rom he ue ank moun ng a ong w h bush ue
ank rear moun ng F g 3 26

12 mm spanner
l Remove ue ank comp e e rom s pos on by

d s oca ng rom he cush on ue ank ron and

d sconnec ng ue sender un w r ng socke
Note:
wh e reassemb ng fue tank comp ete,
ensure that fue sender un t w r ng socket s
connected and fue tank dra n hose s routed
proper y .
l D sconnec HT cord rom he spark p ug and

remove spark p ug F g 3 27
P ug spanner

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F g 3 26

F g 3 27

l D s oca e boo A remove + ve erm na screw

and d sconnec he w re rom he mo or assemb y

s ar er F g 3 28
l Remove moun ng bo

B M6x25 - 1no o mo or
assemb y s ar er mo or assemb y and d sconnec
he ve w re F g 3 28

Ph ps head screw dr ver

Note:
Before d sconnect ng w res from the starter
motor assemb y, make sure that battery
assemb y s d sconnected from the w r ng
harness.
l D s oca e hose c p A & B rom he ube brea her

and ake ou ube brea her F g 3 29

Nose p er

F g 3 28

F g 3 29

Servicing of engine 3-8

SERVICING OF ENGINE
l D s oca e hose c p A rom he hose a r n e and

pu ou hose a r n e F g 3 30
Nose p er

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F g 3 30

l Remove CRR pan head screw M6x16 - 2 nos

a ong w h punched washer rom he a r c eaner

moun ng F g 3 31

F g 3 31

l Loosen c amp ou e p pe screw A

F g 3 32

l Remove a r c eaner assemb y

l Loosen c amp n ake p pe screw B rom he o her

s de o he carbure or F g 3 32
l Gen y pu ou carbure or assemb y rom he p pe

comp e e n ake and p ace on he rame a ong

w h cab e assemb y hro e and cab e comp e e
choke

F g 3 32

l Remove hexagona screw A M6x20 - 1 no rom

he arm gear sh er and remove SBHC screw B

rom he gear sh er ever moun ng F g 3 33

10 mm spanner
5 mm a en key
l Pu ou gear sh er nkage assy

F g 3 33

Servicing of engine 3-9

SERVICING OF ENGINE
l Remove CRR pan head screw (M6x20 - 2 nos)

from the cover engine sprocket and take out cover

engine sprocket. (Fig. 3.34)
Philips head screw driver

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F g 3 34

l Remove hexagonal screw (M5x10 - 2 nos) from

the lock plate engine sprocket. (Fig. 3.35)

8 mm spanner
l Take out lock plate after dislocating it from the

shaft complete drive grooves.

l Pull out chain assembly drive along with sprocket

engine.
l Dislocate sprocket from the drive chain. Hang the

drive chain in the frame.

l Disconnect all the wiring sockets from magneto

assembly connected to wiring harness. (Fig. 3.36)

F g 3 35

F g 3 36

l Remove hexagonal flange bolt (M8x25 - 2 nos)

from the muffler complete front mounting.

(Fig. 3.37)
12 mm spanner

F g 3 37

Servicing of engine 3-10

SERVICING OF ENGINE
l Remove hexagona bo

M8x60 - 1 no rom he
mu er assemb y rear moun ng a ong w h
punched washers and U nu F g 3 38
12 mm spanner

l Take ou mu er assemb y by d s oca ng

rom

he cy nder head assemb y

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F g 3 38

l Take ou gaske exhaus rom he head comp e e

cy nder F g 3 39
Sma screw dr ver
Note:
Wh e reassemb ng rep ace the gasket
exhaust p pe w th a new one.

F g 3 39

l Remove hexagona screw M6x16 - 1 no a ong

w h spr ng washer and ake ou p pe comp e e

secondary a r n ec on a ong w h he O r ng
F g 3 40
8 mm spanner
Note:
Wh e reassemb ng do remember to
assemb e O r ng n the p pe comp ete
secondary a r n ect on.

F g 3 40

l D s oca e hose c p A and d sconnec he hose a r

cu va ve B

F g 3 41

l D s oca e hose c p no 1 C and d sconnec he

hose a r ou e D rom he secondary a r n ec on

va ve F g 3 41
Nose p er

F g 3 41

Servicing of engine 3-11

SERVICING OF ENGINE
l Remove

eng ne assemb y op moun ng

hexagona ange bo M8x55 - 3 nos F g 3 42

12 mm spanner
l Take ou bo h he bracke eng ne moun ng upper

L and R a ong w h he secondary a r n ec on

va ve

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F g 3 42

l Remove hexagona

ange bo M8x72 - 1 no
rom he ron moun ng o eng ne F g 3 43

12 mm spanner

F g 3 43

l Remove hexagona bo s M8x16 - 4 nos

rom
he bracke comp e e eng ne moun ng ron L & R
and separa e he bracke comp e e guard cen er
F g 3 44

12 mm spanner
l Take ou bracke eng ne moun ng ron L & R
l Remove hexagona

ange bo s M8x95 - 1 no
and M8x120 - 1 no rom he rear moun ng o
he eng ne assemb y F g 3 45

12 mm spanner
Note:
Wh e remov ng mount ng bo ts, a ways
bottom bo t shou d be removed f rst.
Eng ne mount ng nuts are of se f ock ng type
and therefore shou d not be reused.
l Gen y

he eng ne assemb y w h bo h he hands

and ake ou rom he r gh hand s de o he veh c e
P ace he eng ne assemb y on a eng ne res

F g 3 44

F g 3 45

Servicing of engine 3-12