Vento zipr3i User manual

Chap ter
1. General Informatio n.........................Page 1
2. Periodic m a intance and service.......Page 4
3. Engine.......................................... ....Page 23
4. Fuel and Lubrication System...... .....Page 37
5. Electrical System.... .........................Page 48
6. Servicing Information...................... ..Page 62
This service manual has been specially prepared to provide all the necessary information for the
proper maintenance and servicing of VENTO Zip r3i Scooter.
This manual contains an introductory description on VENTO Zip r3i
and procedures for
Inspection/Service and overhaul of its main components. This Manual is intended those who have
enough knowledge and skills for servicing of VENTO
vehicles. Without such knowledge and skills
you should not attempt servicing by relying on this manual only. Instead, please contact your nearly
authorized VENTO motorcycle dealer.
Service Manual
Table of Contents
Rev. 1 Date
01/05/2004

CHAPTER 1
1- 1 GENERAL INFORMATION
TYPE & IDENTIFICATION
FRAME NUMBER
FRAME NUMBER is Engraving on the steel tube of frame as shown in figure.
ENGINE NUMBER
ENGINE NUMBER is Engraving on re ar side
Crankcase Shown figure.
Both FRAME NUBER AND ENGINE NUMBER are designed
Specially for registration your scooter and for spare part
Orders.
FUEL AND ENGINE OIL RECOMMENDATION
Be sure to use specified fuel and engine oil.
Some specification s are as follows:
FUEL
Gasoline should be Unleaded, the octane number must be 85 ~95 or more.
ENGINE OIL
For engine lubrication, you can use specified high quality two-stroke engine oil (without
being diluted).
GEAR OIL
Use high quality, all-purpose SAE10W/40 Gear oil for this scooter. Make sure that the Engine
oil/Gear oil w hat you are using should come under API classification.
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 restraint during its early life.
General requirements are as follows
Limit break - in speed
At the first 1000 ms ( 630 miles mileage use throttle opening less than 1/2.
Up to 1600 Kms 1000 miles mileage use throttle opening less than 3/4.
Upon reaching an odometer reading of 1600 k ms (1000 miles) you can subject the motorcycle
to full throttle operation.
Do not maintain constant engine speed for on extended time period during any portion of the
BREAK -IN period, try to vary the throttle position.

1- 2 GENERAL INFORMATION
PRECAUTIONS AND GENERA L INSTRUCTIONS
GENERAL PRECAUTIONS:
WARNING
Proper service and repair procedures are important for the safety of the service mechanic and the
reliability of the vehicle.
When two or more persons are working together, pay attention to the safety of each o ther.
When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outwards
and ventilation should be proper.
When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you f ollow all off the material manufacturer s instructions.
Don t use gasoline as a cleaning agent.
After servicing the motorcycle check all lines i.e. fuel, oil and brake lines for leaks.
Whenever you remove Oil seals, Gaskets, packing, O-rings, Locking washers, Cotter pins, Circlips,
and certain other parts as specified, are sure to replace them with ones. Also before installing these
new parts be sure to remove any left out material from the mating surfaces.
Never reuse a circlip, when installing a new circlip, take care not to expand the end gap larger than
required to slip the circlip the shaft. After installing a circlip, always ensure that it is completely
seated in its groove and securely fitted.
Do not use self - locking nuts a few times over.
If part s replacement is necessary, replace the parts with VENTO Genuine parts or their equivalent.
When removing parts that are to be reused, keep them arranged in an orderly manner so that they
may be reinstall in proper order and orientation.
Always use special tools when required.
Always use specified lubricant, bond& 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 th en
Negative terminal / Cable.
During Service to electrical parts, if no need of battery power then, please disconnect the Negative
terminal / Cable of the battery.
During tightening of Cylinder head and crank case bolts and nuts start with larger diameter and
ending with smaller diameter, from inside to outside diagonally, with the specified tightening torque
values.
After reassembly, recheck parts for tightness and operation.
REPLACEMENT COMPONENTS
Be sure to use genuine VENTO spare parts or their eq uivalent. Genuine VENTO components are high
quality parts, which are designed specially for VENTO vehicles.
CAUTION
Scooter/motorcycle may damage by using non genuine parts or parts that is not equivalent to
VENTO parts and will be affecting performance a lso.

1- 3 GENERAL INFORMATION SPECIFICATIONS
DIMENSIONS AND NET WEIGHT
Overall Length.......................1620mm
Overall Width...........................625mm
Overall Height.......................1010 mm
Wheelbase........................... ..1170mm
Ground Clearance......................90mm
Dead Weight............................... . 78kg
CHASSIS
Front shock absorber
Telescopic, Coil spring, without oil damped.
Rear shock absorber
Swin g arm type Coil spring, with oil damped.
Steering angl e
48º (toward the left \ toward the right)
Front Tire size........................ ........ 3.50 - 10
Rear Tire size.............................. . ..3.50 - 10
Front brake Disc............................ ..... 160
Rear brake Drum........................... . .... 110
ENGINE
Type.....................Two - stroke, Air Cooled
Intake system.............. . ..........Reed valve
No. of Cylinder..................................... .. .1
Bore................................ ........... .. 40.0mm
Stroke...................................... .... 39.6mm
Displacement..................................... .. .49.8CC
Compression Ratio........................ .. .. 6.9:1
Carburetor.............................. ... Side draft
Air cleaner...... . ... Dual polyurethane foam
Starting S ystem
Electric start & Kick pedal for Manual Start.
Lubricating System
Auto lubrication, by Oil Pump
ELECTRICAL
Ignition System .......................Electronic
CDI
Ignition Timing...................... 15
0
at 50 00 RPM
Spark Plug.........................NGK/R/BR8HSA
Storage Battery....................YUASA/YB4L -4
Battery Capacity.............................12V - 4Ah
Magneto..................................................AC
Fuse.................................... ..............10Amp
Headlight ............................ 12V 35 / 35 Watt
Turn Indicators (X4) ................... 12V / 3
Watt
Tail light/stop light ....................... 12V /
5Watt
Meter light..................................12V / 3Watt
Oil level Indicato r light...............12V / 3 Watt
Tran signal Indicator light ........... 12V / 3Watt
High beam Indicator light............12V/3 Watt
CAPACITY
Fuel Tank........................................5.2L
Engine Lubricating Oil Tank............1.0L
Gear Oil.... .......................................0.1L
TRANSMISSIO N
Clutch System
Dry shoe, Automat ic, Centrifugal Type
Gears shifting mechanism
Automatic Primary Reduction 1
Gear Reduction ratio
The first gear ................... 3.692(48/13)
The second gear ...... ....... 3.000(36/12)
Drive System ................... V- Belt driv

Rev no.01/ page 6 of 128
CHAPTER 2
PERIODIC MAINTENANCE AND SERVICE
Contents
Periodic maintenance and service schedule .. ..............................5
Storage battery................................ .............. ............. ..................7
Service and adjustment procedures. ............. ...............................9
Cylinder head nut and exhaust pipe bolt .....................................9
Cylinder head and cylinder ................................... .. .....................9
Spark plug ..................................................... ..............................10
Air cleaner............... ....................................... ..............................11
Fuel level line.......... ............. .......................... ..............................12
Throttle cable ................................................. ..............................12
Engine idle speed ........................................... ..............................12
Oil pump ......................................................... ..............................13
Gear oil .........................................................................................14
Braking ........................................................... . .............................. 15
Tire .................................................................. .............................. 17
Steering .......................................................... .............................. 17
Front shock absorbe r ..................................... .............................. 18
Rear shock absorber ..................................... ............................... 18
Vehicle bolts and nuts .................................................................. . 18

Rev no.01/ page 7 of 128
2- 1 PERIODIC MAINTENANCE 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 7560 11340 15120
Kilometer 1000 6000 12000 18000 24000
Interval
Months. 2 12 24 36 48
Storage battery I I I I I
Cylinder head nut
and exhaust pipe
bolt T T T T T
Cylinder head and
cylinder
C C C C
Spark plug
C R C R
Air cleaner
Inspect & Clean every 3000 Kms (1890 miles)
Replace every 120 00 Kms(1750 Miles)
Idle speed (rpm) I I I I I
Throttle cable play I I I I I
Oil pump I I I I I
Gear oil I R R
I I I I I
Fuel line
Replace every 4 years
Brake I I I I I
I I I I I
Brake hose
Replace every 4 years
I I I I I
Brake fluid
Repl ace every 2 years
Steering I I I I I
Front fork I I I I I
Rear shock
absorber I I I I I
Tire I I I I I
Vehicle body bolts
and nuts T T T T T
Note:
I=inspect clean adjust lubricate or replace if necessary
A=adjust C=clean R=replace T=tighten

Rev no.01/ page 8 of 128
2- 2 PERIODIC MAINTENANCE PROCEDURE
BATTERY INSPECTION AND CHECKING PROCEDURE
Storage Battery
Inspect at initially 1000Kms 630 miles 2
months and every 6000 Kms 3780 miles 12
months .
Open seat, and then re mo ve the battery box cap in
the Middle of helmet box.
Disconnect Negative terminal / Cable first then Positive terminal / Cable of Battery .
Measure the voltage between the +ve and ve terminal of Battery charge the Batt ery if the
voltage is below the specified limit.

Rev no.01/ page 9 of 128
BATTERY TESTING PROCEDURE
Remove the battery from the Motorcycle/Scooter. Connect the battery on load tester ensuring Red lead of
tester to (+ve) and Black lead to (-ve) terminal of battery. Check the terminal voltage of battery. It should
be 12~14.5 Volts. Press the push button on the tester and watch the voltmeter reading on load. The
battery voltage should not drop down less than 9 volts; this indicates that the battery is perfect to take load
of self-starter motor. Check the specific gravity of each cell should not be less than 1.220.Put the battery
on charge, if required and carry out load test.
Diagnose the nature of failure as under:
BATTERY CELL DEAD TEST: On load if battery voltage is found less than 9.5Volt and one or more cell
shows specific gravity less than 1.220 then change the battery.
OPEN CIRCUIT: During the charging of battery does not pickup the charge. In any of the above case,
replace the battery.
RECOMDED BATTERY LOAD TESTER: MA KE ELAK, MODEL: --- BCT7
CAUTION: During Inspection, if the battery on the vehicle is found defective, before replacing with
a new battery, it is important to check the battery charging circuit.
BATTERY CHARGING CIRCUIT TEST
The MAGNETO generated AC c urrent, which is rectified into DC current by Voltage Regulator .It, is
automatically charging the battery depending upon condition of the battery, load and engine rpm.
Regulator is connected in parallel to the circuit. Hence this type of system is called PARALLEL LOAD
REGULATOR .
Connect DC Voltmeter and DC Ammeter, start the engine with fully charged good battery. The
Voltage Regulator output is as follows.
Battery charging current range in between 0.6 Amp to 2Amp.
The engine speed @ 5000 rpm with headla mp on condition.
Battery terminal charging voltage > 11.5 V at any load condition (depending upon the
condition of battery)
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: ------ Series connection inline with positive battery wire to measure DC Amp.
VOLTMETER: --- Parallel connection between positive & negative terminal of the battery to measure DC-
Volts.

Rev no.01/ page 10 of 128
IMPORTANT TIPS ON BATTERY
SPECIFIC
GRAVIT Y
The Specific Gravity of fully charged battery should be 1.220~1.240
Use Hydrometer to check each cell of battery.
WARNING Remove negative terminal first, then positive terminal.
If the battery is corroded by sulfur. Please exchange it. If the terminal
of the battery has too much precipitate, please exchange it.
CHARGING Charging is necessary at less than 1.220 Specific Gravity for old
battery. It changes according to electrolyte temperature.
Connect positive terminal of charger to positive battery wire &
negative terminal of charger to negative battery wire.
CHARGING
CURREENT
For 2.5 Ah battery the charging current should be Maximum 0.25Amp.
For 6.0 Ah battery the charging current should be Maximum 0.6Amp.
CHARGING TIME For new battery 8 - 12 hrs.
For old battery 12 - 14 hrs.
WARNING Always open all the caps of battery before charging.
Keep flames & sparks away from the battery.
Turn ON or OFF Switch at charger & not at battery terminal
Don t charge the battery, if electrolyte temperature is more tha n 45 ºC.
Do not quick charge the battery.
INSTALLATION Connect positive terminal first, then negative terminal.
BATTERY
CAPACITY
12Volt - 6Ah YTX7A - BS/YUASA
RECOMMENDED
BATTERY
CHARGER
Make: ELAK Model C1/48
RECOMMENDED
HYDROMETER
Make: THIMSO N Model: 108
NOTE
Always top up battery with the distilled water up to the maximum
level (Never use Acid to top up the old battery).
Always ensure new battery is being charged in cold condition after
filling with the electrolyte.
Always ensure that battery breather tube is not clogged, crimped
or bent. Breather tube should be properly routed.
Incase if Motorcycle/ Scooter is not being used for longer
period, then first charge the battery fully & then connect only
positive terminal to Motorcycle /

Rev no.01/ page 11 of 128
2- 3 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE
Cylinder head nuts and exhaust pipe
bolts
Tighten at Initially 1000 km 630 miles or 2
Months and every 6000 km 3780 miles or 12
months .
If cylinder head nuts are not tightened to the specified torque,
may result in leakage of compressed fuel-air mixture and reduce
output, tighten the cylinder head nuts in the following procedures:
1. Remove the frame lower covers.
2. Remove the cylinder head cover bolt.
3. Remove spark plug Suppressor cap.
4. Tighten the nuts evenly one by one to the specified
torque. Tighten the nuts in the Specified order.
Tightening Torque
Cylinder head nut 15 - 18N.m
Exhaust pipe bolt 15 - 18N.m
Cylinder and cylinder head
Remove carbon every 6000 km 3780 miles or 12
months .
Carbon deposits in the combustion chamber and the cylinder head will
raise the compression ratio and may cause preignition and overheating.
Carbon deposition at the exhaust port of the cylinder will prevent the flow of
exhaust gases, reducing the output. Remove carbon deposits periodically as
per specified schedule.
carbon

Rev no.01/ page 12 of 128
2- 4 P ERIODIC MAINTENANCE AND ADJUSTMENTS PROCEDURE
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 electrode gradually burns away and carbon builds up
along the inside part. In accordance with the periodic table, the plug
should be removed for inspection, cleaning and to reset the gap.
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 poin ted end.
Check to see the worn out or burnt condition of the electrodes. If it
is extremely worn or burnt, replace the plug and also replace the
plug if it has a broken insulator, damaged thread etc.
Thickness gauge
Spark plug gap 0.6~0.7 mm (0.024 - 0. 028 inch)
Check the spark plug for burnt condition. If abnormal replace the
Tighten the spark plug to the specified torque.
Spark Plug
Tightening torque: 15 - 18 N.m
NOTE :
To check the spark plug, first make sure that the fuel
used is unleaded gasoline.
Confirm the Specification thread send and reach while
replacing the spark plug.

Rev no.01/ page 13 of 128
2- 5 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDUR E
AIR CLEANER :
Clean every 3000 Kms 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.
Remove clamp and screw take out air cleaner
Unscrew tapping screw remove air cleaner cover washing pan of a proper size with Fill a
Non - flammable cleaning solven t. Pu t the air
Cleaner element in the cleaning solvent and wash properly.
Squeeze the cleaning solvent out of the washed element
By pressing it between the palms of both hands: do not twist
Or wring the air cleaner element or it will develop tears.
Immer se cleaned filter element in CCI or CCI Super oil and
Squeeze the oil out of the element leaving it slightly wet
With oil. Fit the element to the Air cleaner case properly
Install Air cleaner in the reverse order of removal.
CAUTION
Before and during the cleaning operation, inspect the core for tears. A torn filter element must be
replaced with new one.
Be sure to position the filter element snugly and correctly
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.
- Non - flammable cleaning solvent (Kerosene)
- CCI OR CCI Super oil or SAE 80 or90 Gear oi l.

Rev no.01/ page 14 of 128
THROTTLE CABLE
Adjust at initially 1000Kms 630 miles or after 2 months .
And after every 6000 Kms 3780 miles or after 12
months .
Loosen locknut and adjust throttle cable play by
t urning adjuster in or out to obtain the
following cable play. After adjusting the cable
Play tightens the locknut.
Cable plays 0.5 - 1.0MM 0.02. - 0.040 inch
ENGINE IDLE SPEED
Adjust at initially 1000Kms 630 miles or after 2
months and Every 6000 kms (378 0 miles or after 12
months thereafter.
Adju st the throttle cable play.
warm up the engine at normal running condition
NOTE :
A warm engine means an engine that has been
run for 10 minutes .
@
Conn ect an Digital Tachometer to the connecting portion of the magneto lead wire as shown
In the illustration. Use the selector key C position.
Adjust the Idling Screw @ to obtain the Idling RPM as follows:
Idling Speed 1800 ± 100 RPM
Finally adjust th e throttle cable play .
FUEL LINE
Inspect at initially 1000 km 630 miles or after 2
months) and Every 6000 km (3780 miles or after12
months ), replace after every 4 years.

Rev no.01/ page 15 of 128
2- 6 PERIODIC MAINTENANCE PROCEDURE
OIL PUMP:
Inspect at Initially 1000 Kms 630 m iles 2 months and
every 6000 kms 3780 miles or 12 months there after.
The oil pump to the engine feeds the engine oil. The amount of oil fed to
it is regulated by engine speed and oil pump control lever, which is controlled
by amount of throttle openi ng.
Check the oil pump in the following manner to confirm correct operation for
Throttle valve full opening position.
Turn the throttle grip full open.
Check whether mark on the oil pump control lever
Is aligned with the index mark when the throttle valv e is positioned as above.
If the marks are not aligned, loosen lock nuts and turn the adjuster in or out to align the marks.
After align the marks, tighten the locknuts.
Caution
Oil pump cable adjustment must be done after throttle
cable adjustm ent.

Rev no.01/ page 16 of 128
2-7 PERIODIC MAINTENANCE PROCEDURE
GEAR OIL:
Inspect at initially 1000 km 600 miles or 2 months
and every 6000 km 3780 miles or 12 months
thereafter.
Inspect gear oil periodically as follows:
Remove the cover and hose.
Remove the kick - start lever.
Remove clutch cover
Remove oil level bolt and inspect oil level, if oil level is below the
oil hole level, Add oil until oil flows from the level hole.
Tighten oil level bolt to the specified torque.
Tightening torque
9- 15N.m(0.9 - 1.5 kg -m)
BRAKE:
Inspect at initially 1000 km 600 miles 2 months and
every 6000 km 4000 miles 12 months thereafter,
replace brake fluid after every 2 years, replace
brake hose after every 4 years.
Front brake fluid level
Keep the scooter upright a nd place the handlebar straight.
Check brake fluid level by observing the lower limit line
On the brake fluid reservoir.
When the level is below the lower limit line, replenish with
Brake fluid that meets the following specification.
Specification and cl assification DOT 3 or DOT4
WARNING
The brake system of this scooter is filled with a glycol-based brake fluid. Do not use or mix
different types of fluid such as silicone-based and petroleum-based. Do not use any brake fluid
taken from old, used or unsealed containers. Never re-use the brake fluid left over from the last
servicing or stored for long periods.
WARNING
Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted
surfaces. Check the brake hoses joints for cra cks and oil leakage before riding.

Rev no.01/ page 17 of 128
2-8 PERIODIC MAINTENANCE PROCEDURE
BRAKE PADS (FRONT BRAKE)
Observing the limit can check the Wear condition of brake pads
Line marked on the pad. When the wear exceeds the limit mark, replace
t he pads with new ones.
CAUTION:
Replace the brake pad as a set, otherwise braking efficiency will be
Adversely affected.
AIR BLEEDING FORM THE BRAKE FLUID CIRCUIT (FRONT BRAKE)
Air trapped in the fluid circuit acts like a cushion to absorb a large
proportion of the pressu re developed by the master cylinder and thus
interferes with the full braking performance of the brake caliper. The
presence of air is indicated by sponginess of the brake lever and
also by lack of braking force. Considering the danger to which such
t rapped air exposes the machine and rider, it is essential that, after
remounting the brake and restoring the brake system to the normal
condition, the brake fluid circuit be purged of air in the following manner:
Fill up the master cylinder reservoir to the upper end of the inspection
Window. Replace the reservoir cap to prevent entry of dirt.
Attach a pipe to the caliper bleeder valve, and insert the free end of t he pipe into a receptacle.
Bleed air from the bleeder valve.
Squeeze and release the brake lever several times in rapid succession. And squeeze the lever fully
without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid
runs into the receptacles: this will remove the tension of the brake lever causing it to touch the
handlebar grip. Then, close the valve, pump and squeeze the lever, and open the valve. Repeat this
process until the fluid flowing into the receptacle no longer contains air bubbles.
NOTE
When bleeding the braking system, replenish the brake fluid reservoir if necessary. Make sure that there
is always some fluid visible in the reservoir.
Close the bleeder valve, disconnect the pipe. Fill the reservoir with specified brake fluid to the
UPPER end of the inspection window.
TIGH TENING TORQUE BLEEDER VALVE: 6 - 9N.m (0.6 - 0.9kg - m, 4.5 - 6.5lb -ft)
CAUTION
Handle brake fluid with care: The brake fluid reacts chemically with paint, plastics, and rubber
materials, etc.

Rev no.01/ page 18 of 128
2- 9 PERIODIC MAINTENANCE AND ADJUSTMENT PROCEDURE :
BRAKELEVR PLAY (REAR BRAKE) :
Turn adjusting nut 2 so that the play @ of Brake
Lever is 15 - 25mm (0.6~0.8) as shown.
BRAKE SHOE WEAR:
This vehicle is equipped with the brake lining limit
Indicator on the rear brake.
Inspect br ake lining limit as follows :
First check if the brake system is properly
Adjusted.
When operating the brake, check to see that
the tip of indicator is within the range . 3
If the tip of indicator is beyond the range,
4
the brake shoe assembly should be replaced
with a new set of shoes.

Rev no.01/ page 19 of 128
TIRE
Inspect at initially 1000Kms 630 miles 2 months and
every 6000KM 3780 miles 12 months thereafter
Tire pressure
If the tire pressure i s too high, the steering will be
Adversely affected and tire wear increased. Conversely, if tire
pressure is too low, stability will be adversely affected.
Therefore, maintain the correct tire pressure for good
Drivability and to prolong tire life.
CAUTIO N:
The standard tire fitted on the scooter is 3.50 - 10 for front and rear
The use of other Than standard may cause handling instability. It is highly
recommended to use genuine tire.
Tire treads condition
Operating the scooter with the excessively worn t ires will decrease
riding stability and consequently invite dangerous situation. It is highly
Recommended to replace the tire when the remaining depth of tire tread
reaches the following specification.
Tire Tread depth limit: 1.6 mm 0.064 Inch
Use Tire depth gauge
STEERING
Inspect at initially 1000 kms 630 miles 2
months and every 6000 kms (3780 miles)
thereafter.
Steering should be adjusted properly for smooth turning of handlebars
and safe running. Over tight steering prevents smooth turning
of handlebars and too loose steering will cause poor stability.
Check that there is no play in the front fork assembly by supporting the
machine so that the front wheel is off the ground, with wheel straight
ahead, grasp lower shock absorber near the axl e and pull forward. If play is
found, perform steering bearing adjustment.

Rev no.01/ page 20 of 128
FRONT FORK:
Inspect &Adjust at initially 1000 kms 630 miles 2
months and every 6000 km 3780 miles 12 months
thereafter.
Inspect the front shock absorber for oil leakage or other damage, and replace the defective parts, if
necessary.
REAR SHOCK ABSORBER:
Inspect &Adjust at initially 1000 kms 630 miles 2
months and every 6000 km 3780 miles 12 months
thereafter.
Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear
and damage, and replace the defective parts, if necessary.
CHASSIS BOLTS AND NUTS:
Inspect &Adjust at initially 1000 kms 630 miles 2
months and every 6000 km 3780 miles 12 months
thereafter.
These bolt s and nuts listed below are important safety components. They must be
tightened to the specified torque.
No. Item N m Kg -m
1 Front axle nut 37 - 44 3.7 - 4.4
2 Steering stem locknut 37 - 44 3.7 - 4.4
3 Handlebar tightening nut 37 - 44 3.7 - 4.4
4 Handlebar positioning bolt 37 - 44 3.7 - 4.4
5 Brake hose tightening bolt 22 - 29 2.2 - 2.9
6 Brake master cylinder tightening nut 22 - 29 2.2 - 2.9
7 Brake caliper tightening bolt 22 - 29 2.2 - 2.9
8 Rear wheel tightening nut 85 - 98 8.5 - 9.8
9 Rear shock absorber upper tighteing
b olt
37 - 44 3.7 - 4.4
10 Rear shock absorber lower tightening
bolt
22 - 29 2.2 - 2.9
11 Rear brake cam lever tightening bolt 5-9 0.5 - 0.9
12 Engine mounting bolt/nut 37 - 44 3.7 - 4.4
13 Engine mounting bracket nut 37 - 44 3.7 - 4.4