TYPE: SCOOTER
REF. NO: SER/SAM/SC/13/11-12 Dt. 15/03/2012
CIRCULATE TO:
AMD (
)
AD (
)
MODEL(S): All TVSM Vehicles
ASC ( )
SUBJECT: Modification in Wego Carburettor Air Vent Hose routing & Cord Set Switch (Head lamp)
A. Carburettor Air Vent Hose routing:
We have come across few cases of Wego vehicles reporting for Starting difficulties and vehicle
switching off while running problems due to blockage of Carburettor Air Vent Hose as shown in below figure. We
have also observed from the warranty returned Carburettors that some of the dealers are replacing the entire
Carburettor assembly without looking for blockage of Air Vent Hose and the cleaning.
Carburettor assembly - WEGO
Air Vent Hose
blockage
If there is partial blockage of the Air Vent Hose there will be unstable idling RPM. If this hose is
almost blocked, the vehicle may start as usual, but when the customer stops the vehicle on road like in traffic signal,
without switching off the engine, the idle RPM slowly comes down and engine gets off.
CC : All TM (Ser), ASMs, NSMs, Warranty section
Service Advisor
Workshop In-Charge
Parts In-Charge
TVSM Service Personnel
Signature/Date
Signature/Date
Signature/Date
Signature/Date
TE-Tools & Equipment
GN-General
MP-Moped MC-Motorcycle
SC-Scooter RF-Refit
SER/SAM/SC/13/11-12 Dated. 15/03/2012
To overcome this problem of Air Vent Hose blockage due to mud entry and also to prevent
possibility of water entry, the routing of Carburettor Air Vent Hose is modified in vehicles produced from 25.12.2011.
The Air Vent Hose is now guided by,
1. Strapping along with SAI Intake Hose using the Clamp Rear Fender Part No : 0258570 (Ref location “A”)
2. Clamped with Frame Tube (Ref location “B”) by the Strap which is already used for Wiring harness strapping
purpose.
Carburettor assembly – New Air Vent Hose routing
The Vent
Hose should
go through
the Strap for
clamping the
Wiring
harness.
Clamp Rear Fender
(Part no. - 0258570)
B
A
We have also observed blockage of Pilot Jet on warranty returned Carburettors. After cleaning the same the
Carburettors are performing very well.
Service Advice:
1. On Vehicles with pre-modified Vent Hose routing, reporting for regular servicing please check for blockage of
Vent Hose and clean the same if required.
2. After cleaning the Vent Hose, re-route the Vent Hose as explained above.
3. Replacement of the entire Carburettor assembly in warranty without cleaning the blocked Vent Hose and
Carburettor parts must be avoided to prevent possible rejection at our end. This is applicable for both pre
and post modified vehicles.
B. Cord Set Switch (Head lamp):
We have also come across some cases of vehicle reporting for Head lamp switching off while
running. We understand from our observation during dealer visits that the dealer Technicians is replacing the head
lamp switch. Our further analysis on the problem reveals that the problem is not with the Headlamp switch instead
this problem happens due to the loose connection of
TE-Tools & Equipment
GN-General
MP-Moped MC-Motorcycle
SC-Scooter RF-Refit
SER/SAM/SC/13/11-12 Dated. 15/03/2012
the head lamp switch couplers. The couplers gets pulled from the head lamp switch since the wires of both the
Couplers (blue and white) are sleeved together till the coupler end as shown in fig 1.
To prevent the coupler coming out of the switch, these wires of the Cord Set Switch have been
taped separately as shown in Fig.2. This modification on cord set switch has been implemented effective Frame
number MD626AG42B1H17398.
Cord set switch
Couplers
Head lamp
Switch(Whit
e and Blue
Couplers)
Before (Fig.1)
After (Fig 2)
Coupler
starter
switch
(Red
coupler)
Wire of both the
couplers taped
separately
Wire of both coupler
tapped together causing
strain on the couplers
Service Advice:
1. On all pre-modified Wego vehicles reporting for regular servicing even if there is no complaint of
headlamp loose connection, please check and correct the taping of Cord Set Switch as per Work
Instruction given in Annexure of this Samachar.
2. On vehicles reporting for this problem, replacement of Head lamp switch is not required. Without
correcting the cord set switch, the customer may report for the problem repeatedly even after replacing
the Headlamp switch. Dealers are requested not to replace the Switch Assembly Head lamp, as those
switches received in warranty are found functionally OK.
Please brief the above to all concerned in your dealership & ASC.
Sincerely yours,
S R RATH
VICE PRESIDENT (SERVICE)
TE-Tools & Equipment
GN-General
MP-Moped MC-Motorcycle
SC-Scooter RF-Refit
Annexure for SER/SAM/SC/13/11-12 Dated. 15/03/2012
Work Instruction of resolving Head lamp going off while running due to loose connection.
1. Dismantle the Housing Head lamp Front along with Head lamp assembly (Fig.no.1).
2. Remove the couplers of Cord Set Switch from the Head lamp switch as shown in fig no. 02.
Fig no. 01
Fig no. 02
3. Using suitable Knife gently cut open the insulation tape about 20 – 25 mm to separate the wires of both Blue
and White Coupler as shown in fig no.03. Care must be taken not to cut / damage the wires of cord set
switch while separating.
4. Tape all the three branch of wires separately as shown in fig no.04.
`
Fig no. 03
Fig no. 04
5. Finally assemble the Couplers and Tape the Couplers along with switch to retain the Coupler with switch as
shown in fig no.05.
Fig no. 05
6. Reassemble the Housing Head lamp Front in the reverse order of removal procedure.
TE-Tools & Equipment
GN-General
MP-Moped MC-Motorcycle
SC-Scooter RF-Refit