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CHASSIS .....................................................................................................................................................................................................
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WHEEL ASSEMBLY FRONT - REMOVAL .....................................................................................................................................................................................................
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l Remove whee assemb y ron a ong w h d sc p a e .....................................................................................................................................................................................................
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spacer comp e e L and speed sensor re er .....................................................................................................................................................................................................
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chap er “per od c ma n enance” page no 2-30 .....................................................................................................................................................................................................
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or remova procedure .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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After tak ng out front whee assemb y keep .....................................................................................................................................................................................................
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some cush on n between the brake pads, to .....................................................................................................................................................................................................
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avo d b nd ng. .....................................................................................................................................................................................................
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D SC REPLACEMENT .....................................................................................................................................................................................................
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l Remove screw spec a M8 - 6 nos rom he d sc .....................................................................................................................................................................................................
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p a e moun ng and ake ou d sc p a e rom he .....................................................................................................................................................................................................
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a oy whee ron F g 6 1 .....................................................................................................................................................................................................
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6 mm a en key .....................................................................................................................................................................................................
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Fg 6 1
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Remova of bear ngs .....................................................................................................................................................................................................
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l Hea he whee assemb y ron brake drum by .....................................................................................................................................................................................................
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p ac ng he whee assemb y ron on a ho p a e .....................................................................................................................................................................................................
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up o 125° C F g 6 2 .....................................................................................................................................................................................................
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Ho p a e .....................................................................................................................................................................................................
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Fg 6 2
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6
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l Tap ou bear ng L & R and spacer comp e e ron .....................................................................................................................................................................................................
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hub w h a su ab e mandre F g 6 3 .....................................................................................................................................................................................................
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Ny on hammer .....................................................................................................................................................................................................
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Fg 6 3
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Chassis 6-1
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CHASSIS .....................................................................................................................................................................................................
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NSPECT ON .....................................................................................................................................................................................................
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PLAY PLAY
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Before nspect on, c ean a necessary .....................................................................................................................................................................................................
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components w th su tab e c ean ng so vent .....................................................................................................................................................................................................
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and ubr cate them. .....................................................................................................................................................................................................
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Whee bear ngs .....................................................................................................................................................................................................
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l nspec whee bear ngs nner race or p ay by .....................................................................................................................................................................................................
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hand wh e x ng n he hub comp e e ron .....................................................................................................................................................................................................
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whee F g 6 4 .....................................................................................................................................................................................................
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Fg 6 4
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l Ro a e nner race by hand o nspec whe her .....................................................................................................................................................................................................
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abnorma no se occurs or ro a ng smoo h y .....................................................................................................................................................................................................
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l Rep ace bear ng ound de ec ve .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Worn or oose whee bear ng must be .....................................................................................................................................................................................................
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rep aced w th a new one before attempt ng .....................................................................................................................................................................................................
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to true a a oy whee . .....................................................................................................................................................................................................
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Ax e front .....................................................................................................................................................................................................
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l Us ng he spec a oo s check ax e ron or run ou .....................................................................................................................................................................................................
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s ra gh ness and rep ace he ax e w h a new one .....................................................................................................................................................................................................
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run ou exceeds he m F g 6 5 .....................................................................................................................................................................................................
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0313050 D a gauge 0 01mm .....................................................................................................................................................................................................
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0313060 Magne c s and .....................................................................................................................................................................................................
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0313070 V - b ock - 4“x3“x3“ .....................................................................................................................................................................................................
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Serv ce m 0 25 / 100 mm .....................................................................................................................................................................................................
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Warn ng: .....................................................................................................................................................................................................
Fg 6 5
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Do not attempt to stra ghten a bent ax e. .....................................................................................................................................................................................................
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A oy whee front .....................................................................................................................................................................................................
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l Us ng he spec a oo s measure run ou o a oy .....................................................................................................................................................................................................
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whee ron An excess ve amoun o run-ou s .....................................................................................................................................................................................................
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usua y due o a ben a oy whee F g 6 6 .....................................................................................................................................................................................................
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0313050 D a gauge 0 01 mm .....................................................................................................................................................................................................
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0313060 Magne c s and .....................................................................................................................................................................................................
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Serv ce m 1 0 mm .....................................................................................................................................................................................................
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Fg 6 6
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Chassis 6-2
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CHASSIS .....................................................................................................................................................................................................
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Tyre front .....................................................................................................................................................................................................
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l Using vehicle with excessively worn tyres will .....................................................................................................................................................................................................
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decrease riding stability and consequently invite a .....................................................................................................................................................................................................
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dangerous situation due to loss of control. It is .....................................................................................................................................................................................................
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highly recommended to replace the tyre with a .....................................................................................................................................................................................................
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new one when the groove depth of tyre from tread .....................................................................................................................................................................................................
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surface reaches the service limit. (Fig. 6.7) .....................................................................................................................................................................................................
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Tyre depth gauge .....................................................................................................................................................................................................
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Service limit 1.5 mm .....................................................................................................................................................................................................
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Fg 6 7
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Note: .....................................................................................................................................................................................................
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Tyre depth can also be checked by tyre wear .....................................................................................................................................................................................................
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indicator (TWI). (Fig. 6.8) .....................................................................................................................................................................................................
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Fg 6 8
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Tyre inflation pressure .....................................................................................................................................................................................................
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l Inflation pressure affects tyre life to a greater extent. .....................................................................................................................................................................................................
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So it is necessary to maintain proper inflation .....................................................................................................................................................................................................
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pressure. (Fig. 6.9) .....................................................................................................................................................................................................
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Tyre pressure gauge .....................................................................................................................................................................................................
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Pressure: .....................................................................................................................................................................................................
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Front Rear .....................................................................................................................................................................................................
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Kg/cm2 (psi) Kg/cm2 (psi) .....................................................................................................................................................................................................
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Solo riding 1.75 (25) 1.75 (25) Fg 6 9
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Dual riding 2.00 (28) 2.25 (32) .....................................................................................................................................................................................................
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6
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Note: .....................................................................................................................................................................................................
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Tyre pressure should be checked when the .....................................................................................................................................................................................................
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tyre is cold. .....................................................................................................................................................................................................
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TUBELESS TYRE - 180 .....................................................................................................................................................................................................
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Refer page no 6-33 for puncture repairing procedure .....................................................................................................................................................................................................
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and replacement of valve tubeless tyre. .....................................................................................................................................................................................................
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Chassis 6-3
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CHASSIS .....................................................................................................................................................................................................
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REASSEMBLY .....................................................................................................................................................................................................
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l Reassemb e whee assemb y ron n he reverse .....................................................................................................................................................................................................
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order o d sassemb y and remova P ease re er .....................................................................................................................................................................................................
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whee assemb y ron exp oded v ew F g 6 10 & .....................................................................................................................................................................................................
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F g 6 11 or assemb y de a s and carry ou .....................................................................................................................................................................................................
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o ow ng s eps: .....................................................................................................................................................................................................
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FRONT WHEEL ASSEMBLY (RTR 160) - EXPLODED VIEW .....................................................................................................................................................................................................
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D SC PLATE
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SCREW SPEC AL 6 NOS .....................................................................................................................................................................................................
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SPACER COMPLETE
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BALL BEAR NG
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AXLE D A 12X221 5 .....................................................................................................................................................................................................
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PUNCHED WASHER .....................................................................................................................................................................................................
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12 5X22X2 3 2 NOS .....................................................................................................................................................................................................
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TYRE FRONT .....................................................................................................................................................................................................
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ALLOY WHEEL FRONT
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SPEED SENSOR
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SPACER COMPLETE
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FRONT HUB BEAR NG
.....................................................................................................................................................................................................
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U NUT M 12X1 25
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TUBE ASSEMBLY .....................................................................................................................................................................................................
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F g 6 10 .....................................................................................................................................................................................................
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...............................................................................................................................................................
Chassis 6-4
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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FRONT WHEEL ASSEMBLY (RTR 180) - EXPLODED VIEW .....................................................................................................................................................................................................
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D SC PLATE
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SCREW SPEC AL 6 NOS.....................................................................................................................................................................................................
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SPACER COMPLETE
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BALL BEAR NG
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AXLE D A 12X221 5 .....................................................................................................................................................................................................
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PUNCHED WASHER .....................................................................................................................................................................................................
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12 5X22X2 3 2 NOS .....................................................................................................................................................................................................
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TYRE FRONT .....................................................................................................................................................................................................
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ALLOY WHEEL FRONT
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SPEED SENSOR
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SPACER COMPLETE
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FRONT HUB BEAR NG
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U NUT M 12X1 25
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6
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VALVE TUBELESS TYRE
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F g 6 11 .....................................................................................................................................................................................................
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...............................................................................................................................................................
Chassis 6-5
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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l Be ore assemb ng ron whee assemb y ubr ca e .....................................................................................................................................................................................................
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he ax e ron and bear ngs A
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l Wh e assemb ng ma ch he p p A n he speed .....................................................................................................................................................................................................
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sensor w h he s opper B on he ron ork ube .....................................................................................................................................................................................................
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ou er L F g 6 12 .....................................................................................................................................................................................................
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B
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l Remove ack or b ock p aced dur ng he remova .....................................................................................................................................................................................................
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o whee assemb y .....................................................................................................................................................................................................
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l Be ore gh en ng U nu o ax e ron s roke he .....................................................................................................................................................................................................
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ork assemb y ron severa mes o check or .....................................................................................................................................................................................................
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proper ork ac on .....................................................................................................................................................................................................
F g 6 12
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l T gh en he U nu .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Wh e remount ng front whee assemb y .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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ocate the d sc n between the brake pads .....................................................................................................................................................................................................
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after remov ng cush on. .....................................................................................................................................................................................................
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DISC BRAKE SYSTEM FRONT .....................................................................................................................................................................................................
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l Re er chap er “per od c ma n enance” or remova .....................................................................................................................................................................................................
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nspec on and rep acemen o he o ow ng: .....................................................................................................................................................................................................
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- Brake pads .....................................................................................................................................................................................................
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- Hose comp e e brake .....................................................................................................................................................................................................
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l A so re er or brake u d hand ng rep acemen .....................................................................................................................................................................................................
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and a r b eed ng n he brake sys em .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
CAL PER ASSEMBLY - REMOVAL AND .....................................................................................................................................................................................................
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D SMANTL NG .....................................................................................................................................................................................................
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l B eed ou brake u d rom he brake c rcu .....................................................................................................................................................................................................
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l Remove ban o bo and ake ou gaske s .....................................................................................................................................................................................................
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F g 6 13 .....................................................................................................................................................................................................
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F g 6 13
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12 mm spanner .....................................................................................................................................................................................................
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l Remove ca per assemb y moun ng bo s and ake .....................................................................................................................................................................................................
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ou he ca per assemb y F g 6 14 .....................................................................................................................................................................................................
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12 mm spanner .....................................................................................................................................................................................................
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F g 6 14
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...............................................................................................................................................................
Chassis 6-6
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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l Remove p ug p n 2 nos rom he body F g 6 15 .....................................................................................................................................................................................................
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F a head screw dr ver .....................................................................................................................................................................................................
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F g 6 15
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l Remove p n hanger 2 nos F g 6 16 .....................................................................................................................................................................................................
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5 mm a en key .....................................................................................................................................................................................................
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F g 6 16
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l Pu ou pad comp e e nner and pad comp e e .....................................................................................................................................................................................................
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ou er by hand F g 6 17 .....................................................................................................................................................................................................
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F g 6 17
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6
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l Remove spr ng pad rom he ca per hous ng .....................................................................................................................................................................................................
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F g 6 18 .....................................................................................................................................................................................................
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Nose p er .....................................................................................................................................................................................................
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F g 6 18
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Chassis 6-7

CHASSIS
l Remove bracke comp e e ron by s d ng ou a er
d s oca ng he boo -B and bush boo p n rom he
p n grooves F g 6 19
l Care u y pu ou boo s rom he ca per assemb y
hous ng F g 6 20
l nser a spacer n be ween he p s on ca per and
he ca per body a pad pos on and hen app y
compressed a r hrough n e por o he ca per o
s de bo h he p s ons ou F g 6 21
Caut on:
Be carefu wh e app y ng compressed a r as
t pushes the p stons forcefu y. Do not use
h gh pressure a r wh ch may damage to
p stons.
Note:
Take out both the p ston s mu taneous y.
Never use nose p er to pu out the p ston as
t may cause scratches.
l Remove dus sea s 1 and 2 rom he ca per bore
care u y F g 6 22
Chassis 6-8
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F g 6 19
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F g 6 20
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F g 6 21
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F g 6 22
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...............................................................................................................................................................

CHASSIS
l Unp ug he cap b eeder and Remove b eeder
screw F g 6 23
10 mm spanner
l C ean par s horough y w h he resh brake u d
Caut on:
Never use kerosene, petro or other so vents
for c ean ng the brake system. Otherw se
rubber parts w be damaged. Do not wash
the pads and a so take care that brake f u d s
not sp ashed on pads.
NSPECT ON OF CAL PER ASSEMBLY
nspec he o ow ng par s:
- P n hangers or any bend
- Bracke comp e e ron or oose ugs
- P s on and ca per bore or any scra ches
- P s on and dus sea s or any damage
- A rubber boo s
l A er comp e on o above nspec on rep ace
de ec ve par s
ASSEMBL NG OF CAL PER ASSEMBLY
l nser dus sea -1 2 nos and dus sea -2 2 nos
n he ca per hous ng sea grooves and ensure
per ec sea ng w hou any w s o he sea s re er
exp oded v ew on page no 6-14 or assemb y
de a s
l S ow y nser bo h he p s ons smeared w h new
DOT3 or DOT4 brake u d s ra gh n o he bore
w hou damag ng he p s on and ensure ha
p s ons s de ns de
l Assemb e spr ng pad on he ca per hous ng
l Assemb e boo -B and bush boo p n on he ca per
hous ng
l App y e grease on p n bo s o he bracke
comp e e ron Assemb e bracke comp e e ron
by ensur ng bo h he boo s are proper y sea ed n
he groove prov ded n p n bo s
l Assemb e pad nner and pad ou er
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F g 6 23
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6
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Chassis 6-9
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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l Assemb e p n hangers by oca ng proper y n he .....................................................................................................................................................................................................
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ho es o pad nner and ou er .....................................................................................................................................................................................................
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l F x he p ug p n .....................................................................................................................................................................................................
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l F x he b eeder screw a ong w h cap b eeder screw .....................................................................................................................................................................................................
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l Remoun ca per assemb y o he ork ou er ube .....................................................................................................................................................................................................
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and remoun brake hose a ong w h he gaske s .....................................................................................................................................................................................................
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l B eed he sys em horough y .....................................................................................................................................................................................................
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D SC PLATE SERV C NG .....................................................................................................................................................................................................
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nspect on (w th d sc mounted on whee s) .....................................................................................................................................................................................................
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l Face ou o he d sc p a e shou d no be more han .....................................................................................................................................................................................................
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he m spec ed be ow Measure d sk p a e ace .....................................................................................................................................................................................................
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ou on he arges per phery o he d sc p a e w h a .....................................................................................................................................................................................................
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d a nd ca or as shown n he g 6 24 he ace .....................................................................................................................................................................................................
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ou exceeds he m s check whe her he cause .....................................................................................................................................................................................................
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es n he ron whee bear ng or he d sc p a e se .....................................................................................................................................................................................................
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Rep ace de ec ve par s .....................................................................................................................................................................................................
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F g 6 24
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0313060 Magne c s and .....................................................................................................................................................................................................
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0313050 D a gauge 0 01 .....................................................................................................................................................................................................
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S andard 0 05 mm .....................................................................................................................................................................................................
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Serv ce m 0 10 mm .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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W pe out d sc p ate surface w th a dry soft .....................................................................................................................................................................................................
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c oth before nspect on. .....................................................................................................................................................................................................
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l Remove d sc p a e rom he a oy whee and .....................................................................................................................................................................................................
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measure h ckness o he d sc p a e a he worn-ou .....................................................................................................................................................................................................
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por on as shown n he g 6 25 h ckness s .....................................................................................................................................................................................................
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esser han he serv ce m s hen rep ace he d sc .....................................................................................................................................................................................................
F g 6 25
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pae .....................................................................................................................................................................................................
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M crome er .....................................................................................................................................................................................................
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S andard 4 0 mm .....................................................................................................................................................................................................
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Serv ce m 3 5 mm .....................................................................................................................................................................................................
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D SC REPLACEMENT .....................................................................................................................................................................................................
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l Rep ace brake d sc p a e s ound de ec ve .....................................................................................................................................................................................................
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re er page no 6-1 or remova procedure .....................................................................................................................................................................................................
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Chassis 6-10

CHASSIS
MASTER CYL NDER - R E M OVA L
D SMANTL NG
l B eed ou brake sys em comp e e y
l Remove hose comp e e brake rom he mas er
cy nder and ake ou gaske s F g 6 26
12 mm spanner
l Remove rear v ew m rror R
l D sconnec erm na s rom he sw ch ron s op
amp sw ch F g 6 27
l Remove mas er cy nder
unscrew ng screws 2 nos
l Take ou p a e d aphragm
l Take ou d aphragm rom he reservo r assemb y
l Remove ever R by remov ng he hand ever bo
and ange nu F g 6 29
10 mm spanner
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AND .....................................................................................................................................................................................................
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F g 6 26
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F g 6 27
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u d reservo r cap by .....................................................................................................................................................................................................
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F g 6 28 .....................................................................................................................................................................................................
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F g 6 28
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6
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F g 6 29
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Chassis 6-11

CHASSIS
l Remove ho der by unscrew ng ho der moun ng
bo s 2 nos and ake ou he mas er cy nder
F g 6 30
10 mm spanner
l Remove sw ch assemb y rom he mas er cy nder
by remov ng he screw F g 6 31
Ph ps screw dr ver
l Remove boo rom he cy nder by us ng a b un
oo F g 6 32
Note:
Wh e remov ng boots assemb y care must be
taken not to damage t.
l By ho d ng mas er cy nder by hand s gh y press
he p s on w h humb nger and remove he
c rc p rom he mas er cy nder by us ng c rc p
p er w hou damag ng he p s on and cy nder
F g 6 33
C rc p p er
Chassis 6-12
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F g 6 30
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F g 6 31
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F g 6 32
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F g 6 33
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CHASSIS .....................................................................................................................................................................................................
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l S ow y pu ou p s on a ong w h he P - cup S - .....................................................................................................................................................................................................
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cup and spr ng F g 6 34 .....................................................................................................................................................................................................
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l C ean he sys em horough y us ng resh brake .....................................................................................................................................................................................................
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ud .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
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Never use kerosene, petro or other so vents .....................................................................................................................................................................................................
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for c ean ng the brake system. Otherw se .....................................................................................................................................................................................................
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rubber parts w be damaged. .....................................................................................................................................................................................................
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NSPECT ON .....................................................................................................................................................................................................
F g 6 34
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nspec o ow ng par s: .....................................................................................................................................................................................................
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- Mas er cy nder or any scra ches or o her .....................................................................................................................................................................................................
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damage .....................................................................................................................................................................................................
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- P s on and cup sur ace or scra ches or o her .....................................................................................................................................................................................................
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Damage .....................................................................................................................................................................................................
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- P s on boo and o her componen s or wear .....................................................................................................................................................................................................
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and damage .....................................................................................................................................................................................................
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- Mas er cy nder recupera on and eed por or .....................................................................................................................................................................................................
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any b ockage so c ear b ockage us ng .....................................................................................................................................................................................................
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compressed a r .....................................................................................................................................................................................................
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l A er comp e ng above nspec on rep ace .....................................................................................................................................................................................................
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de ec ve par s .....................................................................................................................................................................................................
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REASSEMBLY .....................................................................................................................................................................................................
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l Reassemb e mas er cy nder n he reverse order o .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
d sman ng Re er g 6 36 or assemb y de a s .....................................................................................................................................................................................................
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Caut on: .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
App y brake f u d to the cy nder bore and a .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
nterna parts before nsert ng p ston .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
assemb y nto the bore. .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................

6
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
l Remoun mas er cy nder o he hand e bar and x .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
he ho der n UP d rec on F g 6 35 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
10 mm spanner .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
A ways t ghten the top bo t f rst and then the .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
bottom one. .....................................................................................................................................................................................................
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F g 6 35
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...............................................................................................................................................................
Chassis 6-13
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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SCREW RESERVO R CAP 2 Nos
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
BOOTS ASSEMBLY .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
RESERVO R CAP
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
S CUP .....................................................................................................................................................................................................
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P STON .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
P CUP .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
HAND LEVER PLATE D APHRAGM
.....................................................................................................................................................................................................
SPR NG BOLT .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
SNAP R NG .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
D APHRAGM
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
HOLDER BOLT 2 Nos
.....................................................................................................................................................................................................
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HOLDER
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GASKET 4 Nos
.....................................................................................................................................................................................................
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MASTER CYL NDER
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
BANJO BOLTS
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
2 Nos
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
FLANGE BOLT
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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SW TCH ASSEMBLY .....................................................................................................................................................................................................
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SCREW & WASHERS .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
SCREW M6x10
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
SUB W R NG HARNESS
.....................................................................................................................................................................................................
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CLAMP BRAKE HOSE LOWER
.....................................................................................................................................................................................................
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BLEEDER SCREW .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
CAP BLEEDER .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
CLAMP BRAKE HOSE
.....................................................................................................................................................................................................
HEX SCREW M6x20
.....................................................................................................................................................................................................
UPPER
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
PLUG P N 2 Nos .....................................................................................................................................................................................................
SPR NG WASHER 2 Nos
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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BOOT B .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
P STON CAL PER .....................................................................................................................................................................................................
2 Nos
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
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SPR NG PAD
.....................................................................................................................................................................................................
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P N HANGER 2 Nos .....................................................................................................................................................................................................
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PAD COMPLETE OUTER
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
CAL PER ASSEMBLY .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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BUSH BOOT P N DUST SEAL 1 2 Nos .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
DUST SEAL 2 2 Nos .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
PAD COMPLETE NNER
.....................................................................................................................................................................................................
HEX FLANGE BOLT M8x27
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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BRACKET COMPLETE FRONT
.....................................................................................................................................................................................................
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F g 6 36 .....................................................................................................................................................................................................
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Chassis 6-14

CHASSIS
Note:
Mount master cy nder to the hand e bar such
that reservo r becomes hor zonta when the
b ke s p aced on centre stand and steer ng s
kept stra ght.
l F x hose comp e e brake o he mas er cy nder
ou e por a ong w h he ban o bo and gaske s
l F he reservo r w h resh DOT3 or DOT4 brake
u d above he eve LOWER marked on he
reservo r F g 6 37
l B eed he sys em horough y
l F x he reservo r cap a ong w h d aphragm and
gh en screws
l Connec erm na s o he brake gh sw ch
Rep ace o ow ng par s a every 2 years or
40 000 km:
- P s on a ong w h P-cup S - cup Spr ng and
boo assemb y
- Reservo r cap and d aphragm
- Ca per dus sea -1 and dus sea -2
FORK ASSEMBLY FRONT
O L REPLACEMENT
l D sman e whee assemb y ron re er chap er
“per od c ma n enance” page no 2-30 or
d sman ng procedure
l Remove ca per assemb y a ong w h hose
comp e e brake Keep some cush on n be ween
he brake pads o avo d b nd ng
l Remove hexagona screws M8x20 - 4 nos a ong
w h wave spr ng washer 4 nos rom he ender
ron moun ng F g 6 38
13 mm spanner
l Take ou brace ron ender
.....................................................................................................................................................................................................
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F g 6 37
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6
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F g 6 38
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...............................................................................................................................................................
Chassis 6-15
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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l Remove cap ron ork A 2 nos rom he hand e .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
bar assemb y F g 6 39 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
l Loosen a en screws B M6x30 -2nos and ake .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
A A
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
ou cover assemb y upper bracke F g 6 39 .....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
.....................................................................................................................................................................................................

5 mm a en key
l Loosen nu ron ork A by 2-3 hreads be ore
remova o eg assemb y L & R F g 6 40
12 mm a en key
l Loosen hexagona socke head screws B
M8x40 - 2 nos rom he ower bracke comp e e
ork upper moun ng F g 6 40
8 mm a en key
l Loosen hexagona screws M8x40 - 2 nos rom
he ower bracke comp e e ork ower moun ng
F g 6 41
13 mm spanner
Caut on:
Ho d fork eg assemb y wh e oosen ng the
hexagona bo t to avo d sudden fa of eg
assemb y.
l Pu ou eg assemb y R F g 6 42
l S m ar y pu ou eg assemb y L
l den y he make o eg assemb y re er page no
6-18 or den ca on de a s
Note:
Take extra care not to cause any dent,
damage and scratches to nner tubes dur ng
d smant e and reassemb y.
Chassis 6-16
B B
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F g 6 39
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A A
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B B
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F g 6 40
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F g 6 41
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F g 6 42
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CHASSIS .....................................................................................................................................................................................................
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l Remove nu ron ork a ong w h O r ng .....................................................................................................................................................................................................
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F g 6 43 .....................................................................................................................................................................................................
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14 mm a en key .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Wh e reassemb ng rep ace the ‘O’ r ng w th .....................................................................................................................................................................................................
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a new one. .....................................................................................................................................................................................................
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F g 6 43
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l Take ou spacer ron ork washer spr ng sea .....................................................................................................................................................................................................
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and spr ng ron ork F g 6 44 .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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A ow o to dra n comp ete y from the spr ng .....................................................................................................................................................................................................
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front fork by ho d ng ha fway fted for .....................................................................................................................................................................................................
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m n mum one m nute. .....................................................................................................................................................................................................
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F g 6 44
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l Turn eg assemb y ron ork ups de down ho d ng .....................................................................................................................................................................................................
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ou er ube by hand pump nner ube n and ou .....................................................................................................................................................................................................
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o dra n he o comp e e y F g 6 45 .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Ho d eg assemb y front fork nverted for few .....................................................................................................................................................................................................
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m nutes to dra n the o comp ete y. .....................................................................................................................................................................................................
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l C ean eg assemb y ron ork w h kerosene .....................................................................................................................................................................................................
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F g 6 45
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l F measured amoun o ork o as per he .....................................................................................................................................................................................................
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6
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spec ca on F g 6 46 .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Make sure that measur ng ar s c ear from .....................................................................................................................................................................................................
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any dust, burr, d rt and fore gn part c es. A so .....................................................................................................................................................................................................
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ensure that workp ace s neat and c ean. .....................................................................................................................................................................................................
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O quan y G L make 140 ± 2 0 m per eg .....................................................................................................................................................................................................
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O quan y TOP make 152 ± 2 5 m per eg .....................................................................................................................................................................................................
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O spec ca on Te eshockab o .....................................................................................................................................................................................................
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F g 6 46
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Chassis 6-17

CHASSIS
Note:
F on y fresh fork o n case dra ned o s
contam nated. After f ng o , s ow y pump
eg assemb y front fork ‘up’ and ‘down’ to
remove a r ock / gaps.
l Bo h apache RTR SD & DD comes w h G L or
TOP make o ron ork assy Make can be
den ed by he mark G L or TOP wh ch are
prov ded on he ower end o he r respec ve ou er
ube L & R F g 6 47
Note:
A ways f the o quant ty as spec f ed w th
respect to the make of eg assemb y. Do not
nterchange the o quant ty between G L and
TOP make.
n a front fork, assemb ng d ffrent eg
assemb y such as Leg assemb y L w th G L
make and eg assemb y R w th TOP make or
v se versa s not recommended. Refer serv ce
nformat on bu et n for nterchangeab ty of
parts & eg assemb y between G L & TOP
make.
l Check spr ng ron ork eng h re er page no 6-19
or check ng procedure
l ns a spr ng ron ork w h s sma er p ch end
ac ng upward F g 6 48
l Assemb e washer spr ng sea and spacer ron ork
l Be ore ns a ng nu ron ork gh y app y grease
o he O r ng
l Remoun eg assemb y ron ork L & R
l T gh en op moun ng screws 2 nos ork upper
moun ng o he spec ed orque Re er Chap er
”Serv ce n orma on page no 7-9 or orque
shee
l T gh en hexagona bo s 2 nos ork ower
moun ng o he spec ed orque
l Reassemb e ron ender and ron whee assemb y
n he reverse order o remova
Note:
Wh e reassemb ng eg assemb y care must
be taken not to cause any dent, damage and
scratches to nner tubes.
Chassis 6-18
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F g 6 48
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...............................................................................................................................................................

CHASSIS
LEG ASSEMBLY FRONT FORK - D SMANTL NG
l Remove bo h he eg assemb y ron ork L and R
re er page no 6-16
l Remove op moun ng nu s spacer ron ork
washer spr ng sea and spr ng ron ork
l Dra n he o comp e e y re er page no 6 -17 or
o dra n ng procedure
l Ho d ng he p s on by us ng a spec a oo remove
hexagona a en screw us ng a en key
F g 6 49
M1310160 Ho der ron ork cy nder
6 mm a en key
l Pu ou nner ube assemb y a ong w h he p s on
rom he ork ou er ube
l Remove p ece o ock rom he bo om o he
p s on ron ork does no come ou w h p s on
remove rom he ork ou er ube F g 6 50
Note:
Take extra care not to cause any dent,
damage and scratches to outer tube nner
wa & p ece o ock.
l Remove p s on ron ork and spr ng ron ork rom
he nner ube assemb y F g 6 51
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F g 6 50
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6
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F g 6 51
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Chassis 6-19
 .....................................................................................................................................................................................................
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CHASSIS .....................................................................................................................................................................................................
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l Remove dus sea rom he ork ou er ube .....................................................................................................................................................................................................
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F g 6 52A .....................................................................................................................................................................................................
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l Remove snap r ng rom he ork ou er ube .....................................................................................................................................................................................................
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F g 6 52B .....................................................................................................................................................................................................
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F a screw dr ver .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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Take extra care not to cause any dent, .....................................................................................................................................................................................................
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damage and scratches to outer tube nner .....................................................................................................................................................................................................
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wa . .....................................................................................................................................................................................................
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F g 6 52A F g 6 52B
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l S gh y hea he ork ou er ube by p ac ng on .....................................................................................................................................................................................................
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he ho p a e Remove sea o us ng he spec a .....................................................................................................................................................................................................
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oo F g 6 53 .....................................................................................................................................................................................................
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Ho p a e .....................................................................................................................................................................................................
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0312401 Un versa o sea remover .....................................................................................................................................................................................................
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Note: .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
Take extra care not to cause any dent, .....................................................................................................................................................................................................
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.....................................................................................................................................................................................................
.....................................................................................................................................................................................................
damage and scratches to outer tube nner .....................................................................................................................................................................................................
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wa . .....................................................................................................................................................................................................
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F g 6 53
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Caut on: .....................................................................................................................................................................................................
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Rep ace sea o w th a new one at the t me of .....................................................................................................................................................................................................
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reassemb y. .....................................................................................................................................................................................................
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l Be ore nspec on c ean a he componen s w h .....................................................................................................................................................................................................
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a c ean ng so ven .....................................................................................................................................................................................................
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l nspec p s on ron ork and p s on r ng or wear .....................................................................................................................................................................................................
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and any damage F g 6 54 Rep ace w h new .....................................................................................................................................................................................................
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one any damage s no ced .....................................................................................................................................................................................................
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l nspec ou er sur ace o he nner ube assemb y F g 6 54
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and s d ng sur ace o ork ou er ube or any .....................................................................................................................................................................................................
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scu ng or aws Rep ace nner ube/ou er ube .....................................................................................................................................................................................................
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any sur ace de ec s and aws are ound .....................................................................................................................................................................................................
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Spr ng front fork .....................................................................................................................................................................................................
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l Measure ree eng h A o he spr ng ron ork .....................................................................................................................................................................................................
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he eng h s shor er han serv ce m or .....................................................................................................................................................................................................
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de orma on o spr ng rep ace w h a new one A
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F g 6 55 .....................................................................................................................................................................................................
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Serv ce m G L make 435 0 mm .....................................................................................................................................................................................................
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Serv ce m TOP make 393 5 mm F g 6 55
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Chassis 6-20

CHASSIS
REASSEMBLY
Reassemb e and remoun he eg assemb es ron ork
n he reverse order o d sassemb y wh e carry ng ou
he o ow ng s eps:
l Re er eg assemb y ron ork exp oded v ew
F g 6 56 or assemb y de a s
l C ean a he componen s comp e e y and ensure
ha componen s are ree rom any d r bus and
ore gn par c es
l nser p s on ron ork a ong w h spr ng ron ork
s ow y so ha s des down n o he nner ube
assemb y and pro rudes rom he bo om
Assemb e p ece o ock
l Lubr ca e nner sur ace o he ork ou er ube and
ou er sur ace o he nner ube assemb y by ork o
be ore assemb ng he sea o
l App y hread ock o he hexagona a en screw o
he p s on ron ork be ore assemb y
Caut on:
Rep ace a en screw pack ng w th a new one
dur ng reassemb y
l ns a new sea o us ng a spec a oo F g 6 57
1313501 Fron ork o sea ns a er
Note:
Before nsta ng sea o app y tt e grease on
the p of sea o .
l Reassemb e snap r ng
Note:
Take extra care not to cause any dent,
damage and scratches to nner tube.
l Reassemb e dus sea us ng a spec a oo
F g 6 58
l F ork o as per spec ca on re er page no 6-16
l Assemb e washer spr ng sea & spacer ron ork
l Remoun ron ork assemb y
Note:
After f ng o , s ow y pump the eg assemb y
front fork up and down to remove a r ock /
gaps.
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F g 6 56
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F g 6 57
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6
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F g 6 58
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Chassis 6-21

CHASSIS
Note:
nsta spr ng w th ts sma er p tch fac ng
upward. Before nsta ng the nut front fork,
app y grease to the ‘O’ r ng.
LOWER BRACKET COMPLETE (STEER NG STEM) -
D SMANTL NG
l Remove hous ng head amp ron re er chap er
“e ec r ca sys em” page no 5-16 or remova
procedure
l D sconnec con ro cab es wh ch are rou ed
hrough he bracke comp e e head amp hous ng
and d s oca e rom he bracke
l D sconnec socke speed sensor
l D sconnec a he w r ng socke s
l Remove bo h he eg assemb y ron ork re er
page no 6-14
l Remove bracke comp e e head amp hous ng
a ong w h urn s gna amps L & R hous ng head
amp rear L & R and speedome er assemb y as sub
assemb y by remov ng moun ng screws M6x20 -
2 nos F g 6 59
10 mm spanner
Note:
Wh e reassemb ng bracket comp ete head
amp hous ng ensure that p ug (2 nos) are
ocated at the bottom egs of the bracket.
l Remove ock nu s eer ng and spec a washer
F g 6 60
32 mm spanner
l Gen y he hand e bar assemb y Suppor and
hang he hand e bar assemb y a he s de o he
ue ank comp e e
Note:
Ensure that the cab es are not too much
stretched or bent.
l Gen y draw ou ower bracke comp e e by
oosen ng and remov ng he arres er s eer ng s em
us ng a spec a oo wh e ho d ng he ower
bracke comp e e F g 6 61
0313801 Un versa c amp wrench
Chassis 6-22
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F g 6 59
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F g 6 60
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F g 6 61
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Note: .....................................................................................................................................................................................................
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Steer ng ba s tend to fa , hence they shou d .....................................................................................................................................................................................................
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be co ected carefu y. .....................................................................................................................................................................................................
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l Remove dus sea s eer ng upper F g 6 62A .....................................................................................................................................................................................................
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l Remove race s eer ng ou er F g 6 62B .....................................................................................................................................................................................................
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l Remove upper and ower s eer ng ba s .....................................................................................................................................................................................................
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Pos t on Qty S ze .....................................................................................................................................................................................................
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Upper 22 nos 4 762 mm .....................................................................................................................................................................................................
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Lower 19 nos 6 350 mm F g 6 62A F g 6 62B

l Draw ou race s eer ng nner
end o he s eer ng p vo p pe
spec a oo F g 6 63
3310280 Mandre s eer ng cups
l Draw ou cup bo om
us ng spec a oo
l Remove cone bo om and dus sea s eer ng ower
ed on he ower bracke comp e e F g 6 64
Ch se / me a hammer
NSPECT ON
Be ore nspec on wash a
so ven
l nspec removed par s or he o ow ng
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ed on he op .....................................................................................................................................................................................................
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rame us ng .....................................................................................................................................................................................................
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ed on he bo om end .....................................................................................................................................................................................................
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F g 6 63
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he componen s w h a .....................................................................................................................................................................................................
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F g 6 64
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abnorma es and rep ace de ec ve par s w h he
new
- Hand e bar d s or on
- Hand e ho der comp e e or wear
- Races or wear and p ng F g 6 65
- Worn or damaged s ee ba F g 6 65
- D s or on o ower bracke comp e e F g 6 65
6
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F g 6 65
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Chassis 6-23

CHASSIS
REASSEMBLY
l Reassemb e ower bracke comp e e eg assemb y
ron ork L & R hand e bar assemb y and whee
assemb y ron n he reverse order o d sassemb y
wh e carry ng ou he o ow ng s eps:
l Re er ower bracke comp e e exp oded v ew
F g 6 66 or assemb y de a s
ARRESTER
LOWER BRACKET COMP
F g 6 66
Race steer ng nner and cup bottom
l Assemb e cup bo om and race s eer ng nner by
us ng a spec a oo F g 6 67
231030000 Assemb e oo s eer ng cups
Note:
A ways rep ace cup, cone and races as a set.
Chassis 6-24
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STEER NG.....................................................................................................................................................................................................
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DUST.....................................................................................................................................................................................................
SEAL
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RACE STEER NG OUTER
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BALL STEER NG UPPER
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3 16 22 Nos
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RACE STEER NG NNER
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CUP BOTTOM
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BALL STEER NG LOWER
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D A 6 35 19 Nos
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CONE BOTTOM
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DUST SEAL STEER NG BOTTOM
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F g 6 67
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