um Renegade Commando User manual

SERVICE MANUAL BODY –
RENEGADE MOTORCYCLE
300 CC

RENEGADE COMMANDO
RENEGADE SPORTS

VEHICLE MAJOR DIMENSIONS

VEHICLE IDENTIFICATION NUMBER (VIN)
VIN number is punched on the Right Side of the Frame,
Generally on the Head Tube as shown in the Picture (Yellow
marked area).

LOCATION OF IMPORTANT BODY PARTS
1. Storage box
2. Air cleaner
3. Tool box
4. Cushioned backrest
5. Rear fender assembly
6. Rear Wheel
7. Rear Brake panel
8. RH side cover
9. Fuel Tank
10. Chassis

LOCATION OF IMPORTANT BODY PARTS
1. Radiator
2. Carburetor/Throttle body
3. Battery
4. Rear sprocket & Chain drive
5. Pillion hand hold
6. Main stand
7. Side stand
8. Front wheel & Front fender
9. Front Hydraulic brake assembly
10. Handle bar assembly
11. Front fork assembly

VEHICLE SPECIFICATIONS
GROUP
DESCRIPTION
RENEGADE
COMMANDO
RENEGADE
SPORTS S
SUSPENSION
FRAME
TUBULAR
TUBULAR
SUSPENSION –
FRONT
HYDRAULIC
TELESCOPIC D
41 MM
HYDRAULIC
TELESCOPIC D
41 MM
SUSPENSION –
REAR
TWIN
HYDRAULIC
WITH SPRING
TWIN
HYDRAULIC
WITH SPRING
VEHICLE
DIMENSIONS
KERB WEIGHT
172 Kg (with
90% fuel* oil)
172 Kg (with
90% fuel* oil)
WHEELBASE
1545 MM
1545 MM
WIDTH
780 MM
780 MM
LENGTH
2257 MM
2227 MM
HEIGHT
1140 MM
1140 MM
MIN GROUND
CLEARANCE
200 MM
200 MM
SEAT HEIGHT
750 MM
750 MM
FUEL TANK
CAPACITY
18 LIT
18 LIT
RESERVE
2 Lit (Approx)
2 Lit (Approx)

VEHICLE SPECIFICATIONS
GROUP
DESCRIPTION
RENEGADE
COMMANDO
RENEGADE
SPORTS S
WHEEL
RIM &
TYRE
WHEEL RIM SIZE –
FRONT
2.50 x 16
2.75 –17
WHEEL RIM SIZE –
REAR
3.50 x 15
3.5 –15
TYRE SIZE –FRONT
110 / 90 - 16
(TVS)
110 / 70 - 17
(TVS) (Tubeless)
TYRE SIZE –REAR
140 / 90 - 15
(TVS)
140 / 90 - 15
(TVS) (Tubeless)
TYRE TYPE
TUBE
TUBELESS
BRAKES
BRAKES –FRONT
DISC D 280 MM,
2 Piston Caliper
DISC D 280 MM,
2 Piston Caliper
BRAKES –REAR
Drum, 130 mm
Drum, 130 mm
WHEELS
Steel Spokes
Alloy Wheel
BRAKE OII
CAPACITY
60 ML
60 ML
BRAKE OIL GRADE
DOT 3 / DOT 4
DOT 3 / DOT 4

DISMENTALLING & ASSEMBLING OF VEHICLE
1. Seat rear & front.
2. Side cover RH
3. Side cover LH
4. Engine decoration covers LH & RH side.
5. Fuel tank.
6. Air cleaner
7. Rear fender
8. Rear sprocket, brake panel & rear wheel
9. Rear swing arm
10. Front wheel
11. Front fender
12. Front fork
13. Steering stem
14. Rear brake pedal
15. Radiator
16. Side & main stand
17. Sub frame &engine mounting with chassis

1-REAR & FRONT SEAT ASSEMBLY
Remove rear seat
Flange bolt-M6*16
(T wrench-10mm)
Remove front seat
flange bolts-M6*12*2 No’s
(T wrench-10mm)

2-RIGHT SIDE COVERS
RIGHT SIDE COVER
Remove Lower side cover
RH by unlocking with key.
Remove rear side cover RH
by pulling out side
carefully.
Remove 3 pan head
screws, M6*16, to remove
front side cover RH.
Reassembly in the reverse
order of removal and
disassembly.

3- LEFT SIDE COVERS
LEFT SIDE COVER
Remove rear side cover LH
by pulling out side
carefully.
Remove 3 screws to
remove front side cover
LH.
M6*16 No’s-Pan head
Reassembly in the reverse
order of removal and
disassembly.

4-ENGINE DECORATION COVER LH & RH SIDE
Remove LH & RH side Engine
decoration cover.
Allen screw M6*16*2 No’s each
side (Allen key 4mm)
Reassembly in the reverse
order of removal and
disassembly.

5-FUEL TANK
Drain all the petrol from
Fuel tank.
Disconnect fuel tube from
fuel knob.
Remove Fuel tank rear side
bolt.
M8*35 with plain washer-
(T Wrench 12mm)
Remove rubber cushion.
Disconnect fuel gauge &
speedometer couplers.
GASOLINE IS HIGHLY
FLAMMABLE AND EXPLOSIVE.
KEEP HEAT, SPARK & FLAME
AWAY
Reassembly and installation
the fuel tank in the reverse
order of removal and
disassembly.

6-AIR CLEANER
After removing Fuel tank as
per procedure given(Refer-
Point 5).
AIR FILTER ASSY can be
taken out.
Flange bolts M6*16*3 No’s
(T wrench10mm)
Tightening torque-10~12 Nm
Remove tool kit box by pulling it
outside.

AIR CLEANER ELEMENT
CLEANING
Remove Rh side cover
assembly as per steps given
in point number-2.
Remove intake pipe by
removing 3 screws 20 mm
length.
Remove air cleaner
element for cleaning.
CLEAN THE ELEMENT BY AIR.
REPLACE IF DAMAGED
Reassembly in the reverse
order of removal and
disassembly.

7-REAR FENDER
Remove rear seat.
Remove storage box
screws M5*17*3 No’s.
Remove backrest
Allen bolt M8*16mm*2
No’s with spring washer
(2 each RH & LH side).
Tool-Allen key 6mm
Loosen RL & LH Rear Shock
absorber upper mounting
dome nut M10 (T-18).
Remove both side rear
fender decoration plates.
Allen bolts-M8*30 (Allen
key-6 mm ).
Remove Tail lamp lower
nut M6 , 1 No.-Ring
spanner-8*9).

Remove Rear fender
carefully
Rear fender bracket is mounted
on main frame with the help of
M6*16*4 bolts.
Reassembly in the reverse
order of removal and
disassembly.
ENSURE THAT REAR
FENDER IS REMOVED
WITHOUT ANY
SCRATCHES ON IT.
DISCONNECT ALL THE
WIRING FROM REAR
FENDER BEFORE
REMOVING.

8-REAR SPROCKET, REAR BRAKE PANEL & REAR WHEEL
Remove rear brake cam
nut.
CHECK THAT BRAKE CAM IS
WORKING SMOOTHLY,
APPLY GREASE IF REQUIRED
Remove Brake panel nut
from position rod.
Remove Rear axle nut M
with the help of ring
spanners.

Remove rear axle from the
wheel.
Remove Left bush rear
sprocket & Flange Rear wheel
carefully from rear wheeling
arm.
Check damper rear wheel for
any damage.
Replace if found damaged.