JOBS TO BE CARRIED OUT DURING FIRST FREE SERVICE 1. Note down the customer’s observations.
2. Wash Motorcycle and blow it dry with compressed air.
3. Clean Spark Plug and reset the gap if necessary.
4. Check Valve clearance, adjust if necessary.
5. Clean and tune Carburettor, set the idle RPM, as recommended. Check for the easy operation of Choke Lever.
6. Open and clean Fuel Cock and Fuel Filter. Check for any cracks or damage on Fuel Hose.
7. Clean Air Filter Element and lubricate it with (4T) oil.
8. Replace Engine Oil and check for any leakages.
9. Wash Engine Oil Filter Screen with petrol.
10. Check operation of Front & Rear Brakes, adjust if necessary. Grease the Brake Cam.
11. For proper Clutch functioning, check alignment marks on Crank Case L.H., Adjust if necessary.
12. Check for Wheel Runout/Spokes looseness, repair if necessary.
13. Check Wheel Bearings (Front & Rear) for looseness, damage.
14. Check for Steering looseness / tightness, adjust if required.
15. Check Front Fork operation / oil leakages, repair if reqrired.
16. Check for Rear Shock Absorber operation.
17. Check Chain Slackness, alignment. Adjust if necessary. Clean and lubricate.
18. Clean Battery, check electrolyte level and proper routing of Breather Pipe.
19. Tighten all Nuts and Bolts. Specially, Cylinder Head, Engine Mounting, Rear Swing Fork, Front & Rear Wheel
Axles & Rear Shock Absorber Mountings to the specified torque.
20. Check all electrical operations.
21. Check and correct air pressure in Front and Rear Tyres.
22. Lubricate all the pivot points.
23. Check exhaust emission for ‘CO’ level at idling, correct if required.
24. Clean and polish Motorcycle after taking ROAD TEST.
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PRE-DELIVERY INSPECTION REPORT
f. Wheels
Tyre :Tyre pressure Solo Double
(PSI)
Front 25 25
Rear 32 32
R i m : Runout - Radial - 1.5 mm (Max)
- Lateral - 1.5 mm (Max)
Spokes : No loosenes
g. Locks Operation : • Ignition
• Steering• Fuel Tank Cap• Side Cover (L.H.)
h. Fasteners Specified Torque
(Ft-Lb)
1. Front Wheel Axle Nuts25-40
2. Front Fork (Crown Handle & Inner Tube)13-202. Front Fork under Bracket Stem Nut 18-223. Handle Bar Mounting Bolts13-204. Rear Shock Absorber Mounting Bolts22-355. Rear Swing Arm Pivot Shaft Nut32-526. Rear Wheel Axle/Sprocket. Shaft Nuts60-70
B. ENGINE
a. Engine Oil : • Oil Level (For checking - Refer Pg. 6-11)
• Check for any Leakages
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b. Spark Plug :Recommended No. (P-RA7HC - Champion)
Gap 0.9 ±0.2 mm
c. Valve Clearance : (Cold condition)
(If required) Inlet0.08 ~ 0.12 mm
Exhaust0.10 ~ 0.14 mm
(After matching of the mark on sprocket cam chain with mark on Cylinder
Head Casting and ensuring the Piston at TDC of compression stroke.)
d. Kick Operation: For free Movement
e. Carburetor : • Idle RPM
In warmed up condition
(1300~1500 RPM)
• Check for Overflow
f. Drive Chain : • Alignment
• Slackness (20 ~ 30 mm)
g. Fasteners Specified Torque
(Ft-Lb)
1. Cylinder Head Bolts14-17
2. Engine Mounting
a) Engine Mounting Front and Stay Front25-29
b) Stay Engine Front and Frame25-29c) Engine Mounting Rear and Frame25-29d) Engine Mounting Upper &
Stay Engine Upper25-29e) Stay Engine Upper and Frame25-29f) Engine Mounting Front Lower and Frame25-29
3. Front and Rear Silencer Mounting Nut9-124. Crown Handle Centre Bolt20-31
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