Vento Phantom R4i Service Maintenance Manual

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Doc.Title :SERVICE MANUAL Phantom R4i

Doc.no(Model code):VS-01-A-4-A

Brand Name :VENTO

PAGE

Revision Number

Design and Development Dept.

VENTO MOTORCYCLES

Motorcycle division

DESCRIPTION

PAGE

GENERAL

INFORMATION

Model

identification

Break in

procedures

Precautions &

General

instructions

Specifications

PERIODIC

MAINTENANCE

Specified torque

values

ENGINE

Gear Ratio

Engine disassembly

& Assembly

Camshaft holder

assembly

Piston

installation

Left crankcase

cover installation

Right crank case

cover Accessories

Right crank case

Accessories

Date of Issue

Revision Number

26.01.2004

Rev no.01/ page 1of 84

Revision Number : 01

Date of release :26.01.2004

Page

DESCRIPTION

Left crankcase Accessories

Crank case installation

Transmission Case Installation

Movable Drive Face

Valve Clearance Adjustment procedure

Compression Test

Carburetor Tuning

Hydraulic Brake Disc System

Electrical

Trouble Shooting

Engine

Carburetor

Electrical

Battery

Brakes

Date of Issue

:1 of 84

Table of Contents

Summary of Contents for Vento Phantom R4i

Page 1 VENTO MOTORCYCLES Motorcycle division Doc.Title :SERVICE MANUAL Phantom R4i Doc.no(Model code):VS-01-A-4-A Brand Name :VENTO Revision Number : 01 Date of release :26.01.2004 Page :1 of 84 PAGE DESCRIPTION PAGE DESCRIPTION GENERAL INFORMATION Left crankcase Accessories Model identification Crank case installation...
Page 2 Phantom R4i Service & Maintenance Manual VENTO MOTORCYCLES Rev no.01/ page 2of 84...
Page 3 FORWARD INDEX This service manual contains an introductory description On VENTO Phantom R4i, and procedures for its GENERAL INFORMATION Inspection/service and overhaul of its main components. Other information’s considered as generally known is not included. PERIODIC MAINTENANCE PROCEDURE Read GENERAL INFORMATION section to...
Page 4: General Information
BREAK-IN PROCEDURES……………………………………………… PRECAUTIONS AND GENERAL INSTRUCTIONS…………………… SPECIFICATIONS ……………………………………………………… ILLEGAL COPYING It is the policy of Vento Motorcycles to actively protect its copyrights and trademarks. Legal action will be taken against anyone who unlawfully copies the cover or contents of this manual.
Page 5: Model Identification
Gasoline should be Unleaded, the octane number must be 85 ~95 or more. • ENGINE OIL For engine lubrication, use specified high quality SAE10W-40 or SAE 10W-50 engine oil. GEAR OIL Use high quality, all-purpose SAE 90 Gear oil for this scooter. VENTO MOTORCYCLES Rev no.01/ page 5of 84...
Page 6 Upon reaching an odometer reading of 1600 Kms (1000 miles) you can operate the motorcycle to full throttle • operation. Do not maintain constant engine speed for on extended time period during any portion of the ‘‘BREAK-IN’’ • period, try to vary the throttle position. VENTO MOTORCYCLES Rev no.01/ page 6of 84...
Page 7: Precautions And General Instructions
After reassembly, recheck parts for tightness and operation. REPLACEMENT COMPONENTS Be sure to use genuine VENTO spare parts or their equivalent. Genuine VENTO components are high quality parts, which are designed specially for VENTO vehicles. CAUTION Scooter/motorcycle may damage by using non genuine parts or parts that is not equivalent to VENTO parts and will be affecting performance also.
Page 8 Exhaust open BBDC Close ATDC Tappet Clearance Inlet valve 0.03~0.05mm Exhaust valve 0.05~0.06mm Idle speed 1400±100rpm Max. Torque 8.3N.m@6500rpm Max. Output power 6.32KW@7500rpm Starting system Electric& by kick Dry weight of engine 26kg VENTO MOTORCYCLES Rev no.01/ page 8of 84...
Page 9 12V 18W/18W×2 Taillight/brake light 12V 15W/5W Turning signal light 12V 10W×2 Front & Rear Head light Indicator 12V 3 W×2 Turn Signal Indicator 12V 1.7WX2 High beam indicator 12V 1.7WX2 Alarm indicator light VENTO MOTORCYCLES Rev no.01/ page 9of 84...
Page 10 85±5km/h Max speed Model code PD24J Piston Dia 24mm Main jet #191 Slow running jet Idle speed air adjusting screw CARBURETOR Inside1 ± rounds Float height 15±1mm Jet needle position from top Groove VENTO MOTORCYCLES Rev no.01/ page 10of 84...
Page 11 Rear wheel specification 130/60-13 Tire pressure front 32 PSI Tire pressure rear 32 PSI Front brake Disc Type SUSPENSION Rear brake Drum Type Fuel tank capacity 6.0 Liter Engine Oil capacity 1.0 Liter VENTO MOTORCYCLES Rev no.01/ page 11of 84...
Page 12 CHAPTER 2 PERIODIC MAINTENANCE AND SERVICE • Periodic maintenance and service schedule • Storage Battery • Spark Plug • Air Cleaner • Special Tools • Specified Torque Values VENTO MOTORCYCLES Rev no.01/ page 12of 84...
Page 13 Replace every 4 years Brake fluid Replace every 2 years Steering Front fork Rear shock absorber Tire Vehicle body bolts and nuts Note: VENTO MOTORCYCLES I=inspect clean adjust lubricate or replace if necessary A=adjust C=clean R=replace T=tighten Rev no.01/ page 13of 84...
Page 14: Storage Battery
► Disconnect Negative terminal / Cable first then Positive terminal / Cable of Battery ►Measure the voltage between the +ve and –ve terminal of Battery, charge the Battery if the voltage is below the specified limit. VENTO MOTORCYCLES Rev no.01/ page 14of 84...
Page 15: Spark Plug
Spark plug Tightening torque: 15-18N.m NOTE: To check the spark plug, first make sure that the fuel used is unleaded gasoline. Confirm the Specification, thread size and reach while replacing the spark plug. VENTO MOTORCYCLES Rev no.01/ page 15of 84...
Page 16: Air Cleaner
Remember, rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fitted filter element. А- Non-flammable cleaning solvent (Kerosene) Air cleaner B- CCI OR CCI Super oil or SAE 80 or90 Gear oil. VENTO MOTORCYCLES Rev no.01/ page 16of 84...
Page 17 TOOL FOR FLY WHEEL DISASSEMBLY TOOLS TO DISASSEMBLE VALVE SPRING DISASSEMBLING TOOLS FOR OIL DRAINAGE COMPRESSION PRESSURE GAUGE DISASSEMBLING TOOL FOR PISTON PIN SPARK PLUG SOCKET ELECTRIC TOOL FOR OPENING OF FLY WHEEL BOLT CULTCH CLAMP VENTO MOTORCYCLES Rev no.01/ page 17of 84...
Page 18 ○ ○ ○ ○ VENTO MOTORCYCLES Rev no.01/ page 18of 84...
Page 19 S P E C I F I E D T O R Q U E VA L U E S IT IS IMPORTANT FOR THE COMPONENTS / FASTENERS TO BE TIGHTEED AS PER SPECIFIED TORQUE NA ME TORQUE VENTO MOTORCYCLES Rev no.01/ page 19of 84...
Page 20 Bolt for transmission case cover 22-25NM Nut for oil hole of left crank shaft. 40-45NM Nut for position shaft of left crank shaft 22-25NM CHAPTER 3 E N G I N E VENTO MOTORCYCLES DETAIL INFORMATION OF IMPORTANT PARTS Rev no.01/ page 20of 84...
Page 21 Size (mm) Qty. Description Location 20x32x6 Output shaft---gearbox cover Engine 27x42x7 Output shaft—left crankcase Engine 20x29x6 Crank—left crankcase Engine 19.8x30x5 Crank—right cover Engine BEARING—13NOS VENTO MOTORCYCLES S.NO. Code Qty. Description Location 6203 Output shaft—gearbox cover Engine Rev no.01/ page 21of 84...
Page 22 Right crank—right Crank case Engine Crank pin—crank connecting K28x33x14 Engine big end K28x32x17 Clutch hub—clutch gear Engine 6902NSE28 x15x7 Driven disc—output shaft Engine HK20 x29x18RS Driven disc—output shaft Engine 6002 Camshaft— Holder Engine VENTO MOTORCYCLES PIN SHAFT—2NOS Rev no.01/ page 22of 84...
Page 23 Anti-Oil Asbestos Cylinder body Engine Rubber Anti-Oil Asbestos Crankcase Engine Rubber Anti-Oil Asbestos Right crankcase cover Engine Rubber Anti-Oil Asbestos Left crankcase cover Engine Rubber Anti-Oil Asbestos Chain adjuster Engine Rubber VENTO MOTORCYCLES GEAR RATIO Rev no.01/ page 23of 84...
Page 24 Left crank shaft drive Engine sprocket Cam shaft sprocket Engine UNIDIRECTIONAL FITMENT OF ENGINE PARTS VENTO MOTORCYCLES Read the following instruction carefully and assure spare parts installed in right position, otherwise it may damage engine seriously. Rev no.01/ page 24of 84...
Page 25 The side of oil pump with letters is towards outside. The side of left and right crankcase bush with “W” mark is towards the reverse of combined surface of left and right crankcase. VENTO MOTORCYCLES Rev no.01/ page 25of 84...
Page 26 NOTE: Before installation, wash engine parts, and lubricate, refer to recommended torque value for tightening • fasteners. VENTO MOTORCYCLES Pay special attention to single direction fixing accessories. • Start and inspect oil circulation /lubrication system after assembly the engine. •...
Page 27 Cooling pipe (5) Coil clip (12) Cover (13) • Assembly sequence is just reverse of disassembly C Y L I N D E R H E A D A S S E M B LY VENTO MOTORCYCLES Rev no.01/ page 27of 84...
Page 28: Engine Removal And Installation
Use special tool T04 Timing chain tensioner(adjust) Inlet valve, exhaust valve Valve oil seal assy. Adjust specified valve clearance Rocker shaft ►Inlet valve clearance: 0.03~0.05mm ► Exhaust valve clearance: 0.05~0.06mm Cylinder head VENTO MOTORCYCLES Specified Torque value Rev no.01/ page 28of 84...
Page 29 ATMOLYSIS SHAFT FIXER AND ATMOLYSIS SHAFT NOTE : When installing rocker shaft, remember to assemble rocker with lubrication, and VENTO MOTORCYCLES keep groove of center rocker shaft on the same level as the hole of rocker seat. Rev no.01/ page 29of 84...
Page 30: Piston Installation
VENTO MOTORCYCLES PISTON INSTALLATION Rev no.01/ page 30of 84...
Page 31 Never make mistake in positioning the first ring and the second ring. • Keep exhaust port, the second ring, oil ring slice( ). • The gap of spring clip is 80º-100º against the gap of groove. • VENTO MOTORCYCLES Rev no.01/ page 31of 84...
Page 32 & crankcase cover. 3. Brake cable clip (1), main stand stopper holder (2), ventilated clip (3), throttle-fixing stand (4) must be positioned correctly. 4. Tighten all the bolts diagonally with specified torque10-12N.M. VENTO MOTORCYCLES Rev no.01/ page 32of 84...
Page 33 Cable holder (4) Gasket (1) INSTALLATION The installation sequence is just reverse of removal. NOTICE 1. The clearance between flywheel trigger and pickup is 0.5±0.2mm. 2. Check specified clearance between flywheel trigger and pickup. VENTO MOTORCYCLES Rev no.01/ page 33of 84...
Page 34 Oil pump cover 18 Specified Torque value 1. Clutch locknut: 35~40N.M 2. Oil pump fixing bolt: 10~12 N.M VENTO MOTORCYCLES 3. Sprocket wheel locknut: 10~12 N.M 4. Sprocket wheel end cover bolt: 8~10 N.M 5. Pump cover fixing screw: 3~5 N.M...
Page 35 ►Finally, tighten lock nut (15)and nut 8 with specified torque 45~55NM and then release driven wheel disc freely. Assembled bush slides freely and convex side of washer 7 and washer 14 should towards out side. VENTO MOTORCYCLES Rev no.01/ page 35of 84...
Page 36: Crankcase Installation
► Check Crankshaft/ connecting rod should turn freely after assembling the crank case, without block ► Tighten the crankcase with bolt with specified torque 10~12 NM . VENTO MOTORCYCLES Rev no.01/ page 36of 84...
Page 37 To assemble 6 Bolts, first of all pre-fasten pin bolt, tighten various bolts, with specified torque • 10~12NM. The specified torque 2 oil bolts is 22~25 NM. • Gears Gears qty. Gear Ratio 3.077 VENTO MOTORCYCLES Rev no.01/ page 37of 84...
Page 38 • without sticky, and then use circlip (15) in proper position. Before installing driven step less shifting disc, cover the driven step less disc with 2 O-rings (8) and • assemble seal (l0). VENTO MOTORCYCLES Rev no.01/ page 38of 84...
Page 39 Transmission gear can turn back well. • Daub bush 1 with proper lubrication to • install it. Daub shaft end with proper lubrication • to install bush 6 . Be sure to install pin proper tightly. • VENTO MOTORCYCLES Rev no.01/ page 39of 84...
Page 40 Plate Drive 8 Washer 6 Bush 2 Face movable drive 5 Face fixed drive 1 NOTE: Before installing part (8), insert 3 cushion gaskets into (8). • Bush 2 should be slide freely. • VENTO MOTORCYCLES Rev no.01/ page 40of 84...
Page 41 Installation The installation sequence is just reverse of removal. NOTE : Should not be loose clutch side cover, screw M6 and spring seat after installation. • Clutch gear should turn only one direction. • VENTO MOTORCYCLES Rev no.01/ page 41of 84...
Page 42 Driving disc Transition big gear Driven disc (6) Crank start driven gear Clutch (7) Crank (11) Gearbox input axes (10) X Reduction Ratio Y Primary Reduction Ratio 15/42 Z Secondary Reduction Ratio 13/40 VENTO MOTORCYCLES Rev no.01/ page 42of 84...
Page 43 Oil pump assembled in right crankcase sucks oil through main gears on right crankshaft. Oil in crankcase is filtered through the oil filter core of left crankcase, and then flows across oil pump rotor where produces large pressure & filtered oil is pumped in three different routes. VENTO MOTORCYCLES Rev no.01/ page 43of 84...
Page 44 L U B R I C AT I O N D I A G R A M Rocker arm Camshaft assy. Crank assy, Oil pump assy. Filter assy. VENTO MOTORCYCLES Rev no.01/ page 44of 84...
Page 45 Check the clearance of Inlet valve and Exhaust valve, • Inlet valve 0.03~0.05mm Exhaust valve 0.05~0.06mm If clearance is not at the • specified limit, then adjust Tappet clearance to the specified limit. VENTO MOTORCYCLES COMPRESSION TEST Rev no.01/ page 45of 84...
Page 46 Blown out cylinder head gasket. STEP- 3 Incase compression pressure is more than 12 Kg/Cm2. Then engine requires Decarbonisation of cylinder • head / (combustion chamber) & piston. Also check for smoky exhaust. VENTO MOTORCYCLES STANDARD DIMENSION OF ENGINE Rev no.01/ page 46of 84...
Page 47 Clearance between The first ring 0.013-0.045mm piston ring and The second 0.013-0.045mm groove ring Piston ring The first ring 0.1-0.2mm Clearance between The second piston ring and 0.1-0.2mm ring hatch Oil ring 0.3-0.4mm VENTO MOTORCYCLES Rev no.01/ page 47of 84...
Page 48 CHAPTER 4 AIR FUEL SYSTEM Carburetor specification Type Model PD24J Piston dia 24mm Main jet Slow jet Mixture screw 1.5±0.5 turnout Needle position groove from top Float height 15±1mm FUEL CONSUMPTION CURVE VENTO MOTORCYCLES Rev no.01/ page 48of 84...
Page 49 VENTO MOTORCYCLES Rev no.01/ page 49of 84...
Page 50 AIR- FUEL FLOW CHART FUEL Atmosphere Fuel tank Air cleaner assy. Strainer fuel cock Filters Sedimentation bowl Flame Trap Filter Venturi Inlet Floater Chamber Diffuser of Jet Venturi outlet Combustion chamber VENTO MOTORCYCLES Rev no.01/ page 50of 84...
Page 51 AIR FUEL MIXTURE RATIO: CARBURETTOR CIRCUITS: Starting 7~8: 1 The Phantom R4i Scooter has 6 main circuits Idling speed 10~12: 1 1. Fuel Intake circuit Slow speed 12~14: 1 2. Choke circuit Medium speed 15~17: 1 3. Idling speed circuit...
Page 52 VENTO MOTORCYCLES Rev no.01/ page 52of 84...
Page 53 (Brass tube) for better mixing of fuel with air in the main diffuser. Main started supplying fuel mixture economy range i.e. more air with less quantity of fuel as per engine requirement. VENTO MOTORCYCLES Rev no.01/ page 53of 84...
Page 54 A jet holder is provided to the main jet avoid fuel flow strain (turbulence) effect in the float chamber created during the very high speed to diffuser (As shown in the figure) VENTO MOTORCYCLES Rev no.01/ page 54of 84...
Page 55 8. Align the groove on the side of the throttle valve with the guide pin in the carburetor body. Check for its smooth movement. 9. Tighten the top cap over carburetor body. VENTO MOTORCYCLES Rev no.01/ page 55of 84...
Page 56 While running engine in Idling speed turn the handle bar to the extreme left or right hand side, if any change in idling speed noticed, the accelerator cable may be wrongly routed or improperly adjusted. Correct the same before test ride. VENTO MOTORCYCLES Rev no.01/ page 56of 84...
Page 57 Fixing bolt for left, rear absorber and engine 22-29N.m Fixing bolt for right, rear absorber and muffler connecting 22-29N.m board Engine Fixing bolt for engine and muffler 22-29N.m Fixing bolt for engine and engine bracket 37-44N.m VENTO MOTORCYCLES Rev no.01/ page 57of 84...
Page 58: Front Wheel Assembly
7 , gear seat assy. Bearing 9 valve (3 valve cap 2 front wheel centre bolt 6 Speedometer gear (11), Gear set oil seal 10 , gear locknut 13 seat 12 VENTO MOTORCYCLES Rev no.01/ page 58of 84...
Page 59: Rear Wheel Assembly
Rear braking rocker arm (9) Brake shoe pulling spring 4 Seal ring (13) Brake shoe assy. 11 Rear brake camshaft (5) Tire (1), Rear rim Rear wheel assy. Rear rim 12 Valve 3 ,valve cap 2 VENTO MOTORCYCLES Rev no.01/ page 59of 84...
Page 60: Muffler Assembly
Special nut 5 Outside orientation bush 8 Bolt M8X125 2 , bolt M8X40 4 Muffler connecting board 3 Flat gasket φ8 11 , spring gasketφ8 12 , nut M8 13 Inner orientation bush 14 VENTO MOTORCYCLES Rev no.01/ page 60of 84...
Page 61: Front Fork Assembly
Taper roller bearing (6) Special locknut 1 Upper steel bowl holder 5 Front left absorber assy. 9 , front right absorber assy. 8 Under steel bowl holder 11 Bolt M10X125X50 10 Frame assy. 12 VENTO MOTORCYCLES Rev no.01/ page 61of 84...
Page 62: Front Shock Absorber
Add oil for absorber (100±2 ml ) Oil seal stopper ring 11 Buffer spring seal Oil seal assy. 12 O-seal ring Aluminum outer tube 13 Bolt Buffer prick 9 Fixing torque is 23 Nm VENTO MOTORCYCLES Rev no.01/ page 62of 84...
Page 63 VENTO MOTORCYCLES Rev no.01/ page 63of 84...
Page 64 As the brake fluid returns from the caliper, the excess amount of brake fluid drawn from master cylinder. VENTO MOTORCYCLES Rev no.01/ page 64of 84...
Page 65 1.Oil cap 5.Clip ring 9.Tension spring 2.Oil gasket 6.Bowl 10.Outlet oil hole 3.Inlet oil hole 7.Stopper 11.Supplement hole 4. Stopper anti-dust cover 8. Bowl 12.Master cylinder MASTER CYLINDER ASSY. Fig.6 VENTO MOTORCYCLES Rev no.01/ page 65of 84...
Page 66 DISC BRAKE CALIPER ASSY. VENTO MOTORCYCLES Rev no.01/ page 66of 84...
Page 67 OVERHAULING PROCEDURE OF DISC BRAKE VENTO MOTORCYCLES Rev no.01/ page 67of 84...
Page 68 Remove piston assy. Assemble the master cylinder parts in reverse order of disassembly sequence. NOTE: Apply brake fluid on master cylinder piston seals & then insert into the master cylinder body. VENTO MOTORCYCLES SPECIFICATION OF VEHICLE PARTS Rev no.01/ page 68of 84...
Page 69 Tire air pressure Driver 32 PSI Driver and passenger 32 PSI The free play of brake lever 20MM Diameter of rear brake hub 130MM The thickness of the rear brake pad kit 4 mm VENTO MOTORCYCLES Rev no.01/ page 69of 84...
Page 70 CHARGING COIL Red and black 300~500 PICK-UP COIL 200±20 Blue and white/green AT 20ºC and white VENTO MOTORCYCLES LESS THAN 2 OHMS Lighting battery Green, red, white and charging coil black/black LESS THAN 2 OHMS Rev no.01/ page 70of 84...
Page 71 Regulator output is as follows. Battery charging current range in between 0.6 Amp to 2Amp. • VENTO MOTORCYCLES The engine speed @ 5000 rpm with headlamp on condition. • Battery terminal charging voltage > 11.5 V at any load condition (depending upon the condition of •...
Page 72 VOLTMETER: ---Parallel connection between positive & negative terminal of the battery to measure DC-Volts. Electrical starting power flow chart Circuit process Storage battery Fuse Main switch Alarm System Stop switch Start switch Start relay Start motor Connect ground magnet motor VENTO MOTORCYCLES Rev no.01/ page 72of 84...
Page 73 Connect the defective C.D.I. in place of O.K. mobike C.D.I. where C.D.I. already working • satisfactory.If mobike starts easily, then unit is good, otherwise replace the C.D.I.unit. Check for functioning of ignition timing auto advance by timing light, otherwise replace • C.D.I.unit (As shown in figure) VENTO MOTORCYCLES Rev no.01/ page 73of 84...
Page 74 •During Acceleration “II”FULL ADVANCE index mark align with“I”mark of timing inspection hole i.e. 28º before TDC @ 4000 RPM.If the ignition timing is not correct, replace CDI, and then check with new one. VENTO MOTORCYCLES Rev no.01/ page 74of 84...
Page 75 Front board, back board Remove rotating meter and the core of odometer Replace bulb including high beam, turning signal light, fuel gauge, meter indicator light VENTO MOTORCYCLES SPEEDOMETER ASSEMBLY The assembly sequence is the reverse of disassembly. Rev no.01/ page 75of 84...
Page 76 VENTO MOTORCYCLES Rev no.01/ page 76of 84...
Page 77 Less than 2 Ohms VOLTAGE REGULATOR OUTPUT: Regulated voltage for lighting circuit <14.5Volt Rectified DC voltage for battery charging > 11.5 Volt Rectified DC voltage for battery charging 0.6 to 2.0 Amp at 5000 RPM VENTO MOTORCYCLES Rev no.01/ page 77of 84...
Page 78 16. Tests drive the motorcycle for proper balancing and adjust steering movement, if required. 17. Check and adjust head light focussing if required. 18. Check proper functioning of Speedometer, Odometer and Tachometer. 19. Check for any oil/fuel leakage, rectify it if required. VENTO MOTORCYCLES Rev no.01/ page 78of 84...
Page 79 Check proper fitment of Spark plug / Suppressor Check brake oil level Check tire pressure 2.25Kg/cm2 (32PSI) Check torque of engine mounting bolts Check and adjust Idling ±100) Speed (1400 Check engine oil level VENTO MOTORCYCLES Rev no.01/ page 79of 84...
Page 80: Trouble Shooting
5. Clogged exhaust pipe. Clean. Noisy engine. Noise appears to come from piston 1. Piston or cylinder worn-out. Replace. VENTO MOTORCYCLES 2. Combustion chamber fouled with carbon. Clean. 3. Piston pin, bearing or piston pin bore worn. Replace. Rev no.01/ page 80of 84...
Page 81 7. Float-chamber fuel level out of adjustment in Replace. carburetor. Clean or adjust. 8. Clogged jets in carburetor. Replace. 9. Worn rocker arm or cam surface Replace. Complaint Symptom and possible causes Remedy VENTO MOTORCYCLES Rev no.01/ page 81of 84...
Page 82 3. Fuel level too low in float chamber. Adjust or replace. 4. Air leakage from intake pipe. Retighten/replace gaskets. VENTO MOTORCYCLES 5. Not enough oil in the engine Add specified oil. 6. Used incorrect engine oil Change & use specified...
Page 83 2. Spring in needle valve is broken. fluctuations. 3. Float is not working properly. Replace. 4. Foreign material has adhered to Check and adjust. needle valve. Clean. 5. Fuel level is too high or low. VENTO MOTORCYCLES Adjust float height. Rev no.01/ page 83of 84...
Page 84 Replace the battery. Magneto 1. Internal short-circuit in the battery. Replace the battery. overcharges. 2. Resistor element in the regulator/rectifier Replace. damaged or defective. 3. Regulator/rectifier unit poorly grounded. Clean and tighten ground connection. VENTO MOTORCYCLES Rev no.01/ page 84of 84...
Page 85 Replace the battery. Reversed 1. The battery has been connected the Replace the battery and be sure to connect the VENTO MOTORCYCLES battery polarity. wrong way round in the system, so that it battery properly. is being charged in the reverse direction.
Page 86 Replenish. suspension. 2. Loose nuts/nuts on suspension. Retighten. Wobbly rear 1. Distorted wheel rim. wheel. VENTO MOTORCYCLES 2. Defective or incorrect tire. Replace. 3. Loose nuts on the rear shock absorber. Replace. 4. Worn engine mounting bushing. Retighten. Rev no.01/ page 86of 84...
Page 87 5. Air entered into hydraulic system. Replace. 6. Worn shoe. Replace. 7. Friction surfaces of shoes are dirty with Replace. VENTO MOTORCYCLES oil. 8. Excessively worn drum. Replace. 9. Too much brake lever play. Adjust. Rev no.01/ page 87of 84...
Page 88 5. Excessively worn shoes and/or drum. Replace Leakage of 1. Insufficient tightening of connection Tighten to specified torque. brake fluid. joints. 2. Cracked hose. Replace. 3. Worn piston seal. Replace piston and/or cup. VENTO MOTORCYCLES Rev no.01/ page 88of 84...