Bajaj Dominar 400 Service Manual Download Page 125

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120

Bajaj Auto International Business

SOP Importantes

Chasis y Suspensión

Removal of Air Filter Box / Sensors Throttle Body

Remove

•The tab cover side of the grommet.
serve
•right side cover.

Remove

•Seat co

ling left.

•Left side cover simultaneously.

Remove

•Clip vent pipe
•Vent pipe of the head cover.

Remove

•Bolts box supporting air filter (3
units).

Remove

•Right seat cover
•Cover scre

s seat (4 und.)

•Metal

asher

serve
•right side cover.

Summary of Contents for Dominar 400

Page 1: ...Service manual ...

Page 2: ...for any inaccuracy or omission in this publication although all care has been taken to make it as complete and accurate as possible All procedures and specifications can be changed without prior notice It reserves the right to make changes at any time without prior notice All intellectual property rights including but not limited to copyright applying to this drawing and the information contained ...

Page 3: ......

Page 4: ... actuators 60 Malfunction indication 64 41 CHAPTER 3 CHAPTER 3 CHAPTER 3 Engine and transmission Tightening Torques 68 Service Data 70 Special tools 75 Disassembling the Engine Motor 83 Flow Chart 116 67 CHAPTER 4 CHAPTER 4 CHAPTER 4 Chassis and Suspension Tightening Torques 111 Service Data 112 Special tools 113 Important SOPs 120 111 CHAPTER 5 CHAPTER 5 CHAPTER 5 Electric system Battery 126 Do s...

Page 5: ...Pre Delivery PDI Table of Maintenance and Lubrication Standard Operating Procedures Key Learning Points Knowing the complete anatomy of the vehicle Technical Specifications and Performance Parameters Briefing to educate the customer about Appropriatemanagement responsible use and regular maintenance Standard Operating Procedures for periodic maintenance ...

Page 6: ...to register the motorcycle They are the only alphanumeric codes that distinguish your carfrom others of the same model and type Chassis Number Location In the mounting seat 17 Alphanumericdigits Engine Number Location In the crankcase on the left side near the shifter Alphanumeric 11 digits ...

Page 7: ...modes Trip1 Trip2 odometer and clock reminder service 6 Neutral indicator When the transmission is in neutral the indicator lights 7 Low Oil Pressure Indicator Blinks when the engine oil pressure is low 8 Directional indicator Left and Right When the directional switch is pressed to the left or der left directionalindicator or der It will light 9 Digital Clock Indicates the time HH MM AM PM 10 Fue...

Page 8: ... the indicator Secondary speedo Speedometer screen operate when the ignition switch is in the ON position 1 malfunction indicator Blinks when an abnormality is seen in operation of injection system or its components 2 Low Battery Indicator Indicates that you need to charge the battery 3 Bajaj Logo The logo of Bajaj B is permanently on 4 Indicator Light High If the headlight is on high beam and sel...

Page 9: ...nd within 10 seconds press the SET button for more than 5seconds Reminder Service will restart the icon will turnoff 3 The mileage of the next maintenance will be displayed The text of the Odometer TRIP 1 TRIP 2 will turn off for 5 sec 4 After 5 seconds the text will reappear with their respective reading of kilometers 3 Reinitiate the Clock The digital clock indicates the time in the format HH an...

Page 10: ... stop blinking and blinking Exits the mode automatically without saving the value If you start the engine it will exit the clock setting mode without saving the configured values 5 6 Press the button M and S together for more than 2seconds Steering stem and ignition lock It has 3 positions LOCK Locked Handle direction Off vehicle OFF Handle unlocked Vehicle off ON Handle unlocked vehicle on To loc...

Page 11: ...gh indicator light on the dash will light up when this option is selected Low Beam High Beam E Turn Indicator Switch When the directional switch is pressed the Left or Right the corresponding directional will flash To prevent it from spilling press the button and release F Horn Button Press to sound the horn G Pass Switch Press the switch to turn on the high beam of the headlight It is used to war...

Page 12: ...ls will feel a click on the handle brake pedal This is normal and indicates that the ABS is activated It is recommended to use both brakes front and rear simultaneously Always slow down when turning The anti lock system does not prevent accidents due to excessive speed If the ABS indicator is on and stays on you may have a problem with the ABS In this case however the brakes will function as norma...

Page 13: ...en the side Stand is extended an indicator stays on Easy to read display showing Vehicle speed km h Odometer Kilometers traveled Restarting the TRIP odometers To record the distance traveled in a stretch with the possibility to reset TRIP TRIP 1 2 Digital Clock displays the time in HH MM AM PM Reminder Service An indicator lights to remind you to perform periodic maintenance How do they work Place...

Page 14: ...er Headlight always on Features On start of the vehicle the headlight turns on automatically Advantage Continuous lighting DC Benefits Better lighting while driving Safety on the road Start button Function Cranking the engine only with a soft touch How does it work Place the lock off switch to ON Put the vehicle in neutral or press the handle if the vehicle is on any changes Press the start button...

Page 15: ...enefits Great security Stops the damage that may occur Side Stand Protection Features Protection to avoid driving with extended side stand Advantage The EMS receives the signal that the side stand is extended and does not allow the engine to start Benefits Safety for the driver Features water cooled engine water cooled engine Advantage It maintains the viscosity of the engine oil even at high temp...

Page 16: ...er safety when braking Benefits Ease to stop the vehicle at the desired point Control the speed of the vehicle safely Tubeless tires Advantage If they are punctured they do not suddenly deflate and help reduce unsprung mass Less resistance to rolling which ensures stability Benefits High stability and less maintenance VRLA Battery Sealed Features Battery is zero maintenance Advantage Does not requ...

Page 17: ...Safe Driving Tips Always wear an approved helmet while driving Never use your mobile phone while driving Always keep the rear view mirrors clean Use both brakes front and rear simultaneously Applying only one of them can cause skidding or loss of control of the vehicle Do not apply the front brake when you bend a corner or in turns Familiarize yourself with the driving starting acceleration and br...

Page 18: ...cate all important parts as detailed in the Periodic Maintenance chart of the UserManual Additional care Engine oil Check it each week Park the vehicle on a level to check the oil level Always keep the oil level between the upper and lower marks Replace oil according to Table Periodic Maintenance How to keep the battery in good condition Turn off the engine when stopped Do not drive with the brake...

Page 19: ...nition system Fuel system Plugs Plug Gap Lubrication Transmisión Gear Shift Pattern Engine Oil Grade Oil Change 1500 ml Engine Overhaul 1800 ml ENGINE AND TRANSMISSION Frame Type Suspension Perimeter Front Telescopic Forks Rear Mono Shock Nitrox Front Rear Double Channel ABS Brakes Tyres Front 110 70 R17 Tubeless a for reference Rear 150 60 R17 Tubeless only Front Tyre Pressure 2 04 kg cm 2 29 PSI...

Page 20: ... red Battery Low indicator logo Bajaj RPM limit Reminder Service Side Stand indicator ABS indicator Light backplate Horn LED Red LED Blue LED Amber LCD LED Red LED Yellow LED 12V DC Length 2156 mm Width 813 mm 1112 mm 1453 mm Height Distance between axels Ground clearance 157 mm Note The values shown are nominal and approximate 15 variation to the production center and measurement is allowed All d...

Page 21: ...ant Gasketing Loctite5910 Bonding surface of the casing 1 Bajaj DTS I 10000 SAE 10W50 API SJ o JASO MA2 SAE 10W20 Quantity Draining and filling in maintenance Engine Repair1500 ml 1800 ml Quantity 420 ml 2 HP Lihton RR 3 Spray Spray OKS X ring chain Runways and steering rods 4 all purpose Shaft front and rear wheel Swing Arm Shaft Pivot pin of the brake pedal Axis central inn U of lateral support ...

Page 22: ...licación Lubricante Loctite Bajaj DTS I 10000 SAE 10W50 API SJ o JASO MA2 All ball bearings and needle Crankshaft bearing Driveshaft and gear teeth Steering axle Drum slot changes and shift cam Piston skirt and cylinder Camshaft lobes Clutch spring cam chain Rotor pump oil to join him 9 Oil ...

Page 23: ...ithout effort POSTURE AND DESIGN Lions POSTURE The design principles characteristic of the Dominar 400 inspired by the lion s feline posture are visible from its clear Agressive front its large and contoured tank and its endless and formidable rear lights A look at the Dominate is enough to be impressed by its dominantattitude Leo y Aprendo Características Destacadas 19 Manual de Servicio Bajaj Do...

Page 24: ...superior adhesion evenat high speeds The low profile radial tires specially designedadd to the experience by offering better response andcornering stability The night is now under their control Trapezoid metal stamping The new trapeze Master 400 provides greater adhesion toasphalt for driving a solid This builds confidence bothbeginners and experts to go out and dominate the slopes Slip clutch The...

Page 25: ...gh reserve power for extra acceleration The smooth and precise changes are a result a slight forged crankshaft and transmission gears high speed make this unstoppable beast of the night SENSITIVE BRAKE Dual channel ABS The Master 400 is equipped with a braking system ABS dual channel keeps this beast at bay This ensures that not startle night while guarantees security and complete control regardle...

Page 26: ...meet European standards making the bike is visible 1 5 km away Illuminate NIGHT Split Screen LCD The LCD speedometer Master 400 divides the screen into a primary and a secondary console reducing the reflection in the cabin thus giving the driver a clear view of pure and distractions while dominating the asphalt ILUMINE LA NOCHE 22 Bajaj Auto International Business 1 Características Destacadas Leo ...

Page 27: ...ear view Coolant Coolant level between the mark of the MIN and MAX levels filled if necessary with cold engine and with the vehicle parked on a levelsurface Make sure there are no leaks Locks operation Ignition lock seat lock left side cover lock and fuel tank cap Battery Terminal voltage 12 4 V DC for maintenance free battery and 12 8 V DC for VRLA sealed using the battery tester adjustment batte...

Page 28: ... 6 N m 2 Checkpoints during after starting the vehicle Proofread the following during after starting the vehicle operation switches Operation of switches Switches right and left control switch clutch switch and brake front and rear Horn Make sure the sound is not distorted All the lights working If applicable Headlight rear light directional speedometer lights light focus Speedometer if applicable...

Page 29: ...peed CO Check and correct the checkpoints shown below with the engine warm Idling speed Check when the engine is warm to 60 c 1600 100 rpm Review CO The CO should be between 1 5 2 5 with engine warm and idling 5 Visual inspection of dents scratches rust 6 Clean the vehicle thoroughly before delivery to the customer Ensure availability of rear wheel support in the area of PDI The revision and repai...

Page 30: ...m Lm Lm Lm 12 Cleaning chamber end of the tail pipe of the muffler Lm Lm Lm Lm Lm Lm Lm The end of the chamber must be cleaned using a brush 13 Pivot pin brake pedal Rv Lb R e Rv Rv Lb Re Rv Lb Re Rv Lb Re Rv Lb Re Rv Lb Re Rv Lb Re Use all recommended grease 14 brake pad Check wear indicator Rv Re Rv Re Rv Re Rv Re Re Rv Re Rv Re Re Replace shoes pads every 15 000 km 15 Brake fluid level Fill Rep...

Page 31: ... Nº Puntos de Revisión del Mantenimiento Periódico FRECUENCIA RECOMENDADA Observaciones Servicio 1ro 2do 3ro 4to 5to 6to 7mo Km 24 General lubrication handle clutch brake handle Lb Lb Lb Lb Lb Lb Lb Lb All purpose grease 25 Coolant level in the expansion tank Rv Rll Rv Rll Rv Rll Rv Rll Rv Rll Rv Rll Rv Rll Rv Rll Recommended ready to use 26 Pipe work damaged cooling clamps leak Rv Rv Rv Rv Rv Rv ...

Page 32: ...r s seat bolts 2 Take out Driver s seat Remove Cover bolts fuel tank as follows Later 2 screws with plastic washer Remove Bolts back cover of the fuel tank 2 bolts along with the collar on the left side 2 bolts along with the collar on the right side IZQ DER Forward Remove 2 bolts with metal collar ...

Page 33: ...dometer Remove the tank cover Delantero DER Remove 3 bolts fuel tank support Lift the fuel tank Pull the tab on the left cover Cut the branch cableclamp Note Use a new clamp when placing the cable Remove Screw left side cover Pull tab side cover Cut the clamp SOP Regulación de la Luz de Válvulas ...

Page 34: ...o Remove 4 cover screws air filter Intake pipe hook chassis Remove EVAP pipe from the fuel tank Remove fuel tank Disconnect the connector at the fuel pump Injector pipe from the fuel filter serve The air filter cover SOP Regulación de la Luz de Válvulas ...

Page 35: ...bolts clutch wrench 8 mm and remove the cover Ensure that the piston is at TDC by aligning the input gear with the mark on the crankcase Ensures that the marking T on the sprocket of the camshaft is up Confirmation that the piston is at TDC Remove Bolt insert crankcase Note If the tool to lock the crankshaft fits then the piston is at TDC SOP Regulación de la Luz de Válvulas ...

Page 36: ...prendo Un clip tube breather Remove 4 bolts cylinder head cover Remove the head cover Note Use the universal joint to remove the bolts Use extension as shown Remove The heat resistant rubber covered slots clamps SOP Regulación de la Luz de Válvulas ...

Page 37: ... specifications Intake 0 5mm Exhaust 0 8 mm Remove Plugs rocker arm shafts Use a threaded bolt M5 to remove the rocker arm shafts Rosca M5 Aprox 24 mm Note With one hand one firmly rocker pressure to the pinion of the camshaft to avoid falling washers serve Rocker arm shaft washers SOP Regulación de la Luz de Válvulas ...

Page 38: ...ickness of the vehicle shim B Standard valve clrnc C Measured valve clrnc D Increase in valve light C B E Shim to be used A D Shim A C B D Shim to be used For exhaust valve A 2 40 mm B 0 10 mm C 0 14 mm D 0 04 mm E Shim to be used A D 2 40 0 04 2 44 mm Calculation of the shim when the light of Valves is lower than the standard value A Thickness of the vehicle shoehorn B Standard valve clrnc C Meas...

Page 39: ...tance to slide it after adjusting the valve clrnc Complete an engine rotation and check the clrcn again for valves Prefix the bolts on the cylinder head cover adjust them to the tightening torque recommended with a torque wrench Replace the heat resistant rubber cover and make sure the slots are properly placed in the clamps Assemble all parts that have been removed SOP Regulación de la Luz de Vál...

Page 40: ... to find the position where the chain is adjusted At the lowest point of the chain slack lift and press down the chain to measure the clearance with a metal ruler or the special tool If the chain slack is not the standard then Loosen Rear axle nut Release adjuster locknut and increase or reduce the slack Adjustment notches must match on both the sides ...

Page 41: ...nar 400 Make sure that the markings on the left and right tensioner are also aligned Adjusting nut after the specified tightening torque 10 kgm axis Check to make sure the rear wheel rotate freely SOP Revisión y Regulación de la Cadena de Arrastre ...

Page 42: ...Replacing brake fluid Remove 2 screws holding the master cylinder Remove the cover from the master cylinder PVC cap and the rubber diaphragm Clean the surface of the master cylinder Loosen the bleed screw Place the PVC hose Drain fluid from the brake caliper ...

Page 43: ...l of the brake fluid must be between the MAX and MIN marks If the brake fluid level is below the mark MIN Remove Cover master cylinder PVC cover Rubber diaphragm Fill with a recommended brake fluid so that the liquid level of the Brake is on the MIN mark Place all the removed parts again Review the effectiveness of the brake If it finds it spongy purge the air from thesystem Fill the master cylind...

Page 44: ...40 Bajaj Auto International Business 2 Sistema de Combustible y EMS Notas ...

Page 45: ... EMS CAPÍTULO 2 Addressing the Electric Branch System Operation Fuel Injection System EMS Sensors and Actuators Indication of Malfunction Key Learning Points Understand the electric branch s addressing Fuel Injection System Malfunction Codes and their driving cycle ...

Page 46: ...ay Suspension Unit Purge Valve Regulator Intermediate Start Relay MainRelay Fan Relay Fuel Pump Relay Fuse Box LCM ABSFuse Main Fuse Rear Light Left and Right Directionals CAN Interface Electronic Console Clutch Switch Control Command Der Control Command Left Switch On Switch Off Front Speed Sensor Stepper motor fuel level sensor fuel injector TMAP CTS TPS switch Side stop rear brake switch fuel p...

Page 47: ...aj Dominar 400 Control switch RH Kill switch Front blinker RH Control switch LH Clutch switch Front Blinker LH Wheel speed sensor front Electronic Cluster HT coil 1 Head Lamp HT coil 2 Ignition Switch Horn HT coil 2 Direccionamiento del Ramal Eléctrico ABS ...

Page 48: ...Coil 1 Connection oft he Sensor of the angle of the crankshaft Connection Oil Pressure Switch Lambda sensor Horn Overturning Sensor connection Fan Motor radiator Fuel Sensor connection pump module angle crankshaft Land ECU ABS ECU ABS Direccionamiento del Ramal Eléctrico ABS ...

Page 49: ... Stand Ground conn switch Engine Earth Angle sensor Crankshaft Switch Oil pressure Lamda sensor Speedometer 2 Fuel Pump Module Reference point of the Assembly Earth of the ECU Chassis Earth Chassis Earth Connection of the Switch of the Side stand Regulator Ground Regulator ECU harness support Bracket Direccionamiento del Ramal Eléctrico ABS ...

Page 50: ... TPS ECU ECU earth Chassis Ground Brake Light Rear Turn indicator Light plate ABS Fuse Box Connection of the Magneto to the Ground Regulator Regulator Fuel pump relay Starter Relay Intermediate CAN Interface Main Relay Fan Relay Starter Relay Purge valve Fuses Batt Positive Direccionamiento del Ramal Eléctrico ABS Sistema de Combustible y EMS ...

Page 51: ...minar 400 Coolant Temperature Sensor TMAP Rear brake switch Rear Speed Sensor TPS Starter Motor Coil High 1 Starter Real Purge Valve Relay Fuel Pump Starter relay intermediate Fan Relay Main Relay Connector Starter Relay Direccionamiento del Ramal Eléctrico ABS ...

Page 52: ...sary to control a circuit by a low power signal Measures the pressure of engine oil flowing through the internal galleries and communicates the signal to the speedometer TMAP Fuel pump relay It is a micro mechanical sensor measures the absolute pressure in the intake manifold and compares it with a reference vacuum pressure to atmospheric pressure TPS Fan Relay Stepper motor To measure the exact p...

Page 53: ...s flow keeps the cold fuel and prevents the formation of fuel vapor pockets The fuel pump is lubricated and cooled by the fuel flowing into the engine including the brushes and through the armature It is therefore important that the pump will never start without an adequate level of fuel in the fuel tank The fuel filter retains fuel impurities It is important to prevent blockage of the fuel pump a...

Page 54: ...injector has nozzles that are opened and closed by a solenoid coil in the injector body When the winding is energized the armature is attracted and become magnetically compresses the spring which lifts the valve needle Thus the pivot atomize the fuel into a fine spray with a pressure close to 2 5 bar 36 lbf in2 until the ECU cuts the electric solenoid signal The inward movement of the injector is ...

Page 55: ...tion Sensor Coolant Temperature Sensor MPRD relay driver Main Power actuators MPRD Relay Stepper Motor Injector Fuel Pump High Coil Left and Right Engine Malfunction Indicator Icon Speedometer Radiator Fan It also contains the Fault Codes for the diagnosis Introduction The automotive engine has two sets of power generation known as the carburetionsystem and Ignition System Carburetor delivers an a...

Page 56: ... The digital output is fed to rail input output for transport to the heart of the computer Thus the ECU collects all signals calculates and processes to the actuators to synchronize exactly the advance of the ignition timing and fuel injection to theengine for different load conditions and speed SensorArray A sensor is a device that detects or measures the amount usually in electrical form so that...

Page 57: ...unded and the other is connected to a source of 5 volts from the ECU The pen has a contact leading to the spiral shaft and connected to the throttle valve Also the position of the throttle valve is important to control the idle speed Resistance spiral Butterfly valve Closed Pivot Nib Fully open throttle valve Outputvo ltage tothe ECU 5 volts from the ECU Functioning By accelerating the position of...

Page 58: ...iconductor whose resistance changes with temperature The resistivity decreases with an increase in engine temperature and having a negative temperature coefficient NTC and vice versa The characteristics of the engine temperature are plotted The values do not match exactly it s just a representation for better understanding This NTC thermistor is used to measure engine temperature in the engine man...

Page 59: ...the vehicle does not turn on for safety and this evil operation will be displayed in the speedometer y x 0 Sensor Main switch magnet Functioning Mob weights are suspended il is freely When the vehicle leans on either the left or right sides of these weights position changes The change in position of the weights is read by the sensor If the inclination angle exceeds 60 from the vertical the sensor ...

Page 60: ...to the ECU The ECU counts the number of pulses per second and interprets few RPM is rotating the engine and accordingly the amount precise fuel delivery and spark advance for ignition iscontrolled These notches 23 square square blocks on the outer periphery of the rotor areequidistant from each other In a particular location there is a greater spacing between the square grooves square blocks This ...

Page 61: ...an also put the engine in its limited way This means that the chip limited operation strategy LOS ECU has begun operations This provides basic instructions to the microprocessor if part of the electronic systemfails Motor runs but with an ignition timing and air fuel ratio fixed The injector pulse does not change This allows the vehicle to be driven but with a very lowyield The benefit of this is ...

Page 62: ...aintenance costs Limitations of the Carburetion Restricted air flow due to venturi design causeslosses of power limited volumetric efficiency As the intake manifold to combust the mixturecontains there is a risk of detonation from the cylinder to the manifold At a higher altitude or in hot climates there is the possibility of vapor lock After burning sound in the muffler in case of sudden decelera...

Page 63: ...le of inclination of the motor and if it is greater than 60 ECU shorted and the supply of fuel Measures the proportion of oxygen in the exhaust and assist the ECU to adjust the amount of fuel to be injected Measure the crankshaft speed and assist the ECU to determine the injection and ignition timing It measures the temperature and air pressure in the intake and assists the ECU to adjust the fuel ...

Page 64: ... RPM and give optimum engine performance Advantages over carburetion system Increased power output per unit displacement Greater torque at low rpm Better cold start warm up and rapid acceleration Lower fuel consumption better fuel efficiency Excellent maneuverability in general Lower maintenance costs If so it communicates malfunctioning fuel injection system Lower emissions Notes ...

Page 65: ...o Bajaj Dominar 400 Sensores y Actuadores del EMS 1 4 2 3 5 6 7 8 10 1 MPRD RELAY P4 P3 P2 P1 9 11 2 STEPPER MOTOR 3 InJECTOR 4 Sensor T MAP 5 TPS 6 FUEL PUMP 7 PRIMARY COIL 8 SECONDARY COIL 9 Indicador MALFUNCTION 10 Conector DIAGNOSTICS 11 RADIATOR ...

Page 66: ...uit 7 Se 7 Se sensor Throttle Position Monitors the throttle position and gives a voltage input to the ECU according to the partial or total acceleration mode ECU increases or reduces the rate of fuel injected to the engine MAP sensor 8 T Monitors the temperature and pressure of air entering the intake manifold and delivers a signal to the ECU 5 VDC ECU increases or decreases the rate of air to th...

Page 67: ...ing smoke in the exhaust or ignition failures Blows or sounds in combustion 3 High Coils Grounding from ECU Misfiring or intermittent problems If there is no spark will not be possible to start the vehicle 4 Radiator Fan The radiator fan relay lights The radiator fan will not run and the coolant temperature can be increased excessively affecting engine components Icon dashboard lights to 115 C and...

Page 68: ...inder 1 Injector Circuit Low 13 P0201 one Cylinder 1 Injector Circuit Open 14 P0032 one HO2S Heater Control Circuit High Bank 1 Sensor 1 fifteen P0031 one HO2S Heater Control Circuit Low Bank 1 Sensor 1 16 P0030 one HO2S Heater Control Circuit Bank 1 Sensor 1 17 P0692 one Radiator Fan Control Circuit High 18 P0691 one Radiator Fan Control Circuit Low 19 P0480 one Relay Radiator Fan Fault Circuit C...

Page 69: ...118 one Sensor Coolant Temperature Sensor 1 Circuit High 43 P1608 Motor Speed Signal Circuit High 44 P1607 Engine Speed Signal Circuit Low Four Five P1606 Motor Speed Signal Circuit Open 46 P0563 3 High Voltage System 47 P0562 3 Low Voltage System 48 P1510 3 Voltage system ECU detects failure 49 P0501 3 Vehicle Speed Sensor A Range Performance fifty P0641 one Reference voltage sensor A circuit err...

Page 70: ...66 Bajaj Auto International Business 2 Sistema de Combustible y EMS Notas ...

Page 71: ... Motor y Transmisión CHAPTER 3 Engine and transmission Torques Service Data Disassemble Special Tools Engine Motor Flow Chart CAPÍTULO 3 CHAPTER 3 Engine and transmission Torques Service Data Disassemble Special Tools Engine Motor Flow Chart ...

Page 72: ...1 2 Kgm Primary Gear Nut 1 0 1 2 Kgm Clutch Nut 1 2 1 4 Kgm Camshaft Pinion Bolt 0 7 0 8 Kgm Clutch Cover Bolts 1 0 1 2 Kgm Magneto Cover Bolts 1 8 2 0 Kgm Temperature Sensor 1 0 1 2 Kgm Stator mounting pin 1 0 1 2 Kgm Oil Pump Bolts 1 0 1 2 Kgm OIL FILTER COVER 1 0 1 2 Kgm SPROCKET Pinion Bolts 1 0 1 2 Kgm Nut of the Silencer 1 9 2 1 Kgm Chain Tensioner Bolts ...

Page 73: ...agneto flywheel nut SHIFTER Nut Starter Motor 3 9 4 1 Kgm 6 0 6 5 Kgm 1 0 1 2 Kgm 1 1 1 2 Kgm Allen bolt Driven Balancer 14 5 15 Kgm Large head bolts 10 10 5 Kgm Star Allen bolt 1 1 1 2 Kgm Driver installation Balancer 1 1 1 1 Kgm Small head bolts 1 0 1 2 Kgm Clutch presser bolts ...

Page 74: ... STD LIMIT 8 kg cm CompresSión 52 1 mm STD LIMIT 51 mm CLUTCH SPRING FREE LENGTH VALVES 0 05mm INTAKE 0 03 0 070 STD LIMIT 0 08mm EXHAUST 0 080 0 120 sTACK HEIGHT CLUTCH 1 6 mm STD LIMIT 1 5 mm 2 92 3 08 mm STD LIMIT 2 72 mm PRESSURE PLATE THICKNESS FRICTION PLATE THICKNESS FRICTION PLATE WARPAGE 0 1 mm 0 2 mm STD LIMIT PRESSURE PLATE WARPAGE 0 1 mm STD LIMIT 0 15 mm CAM SPROCKER DIAMETER Diá Exte...

Page 75: ...mm INTAKE 4 96 mm STD LIMIT 4 963 mm EXHAUST 4 95 mm 0 037 0 052 INTAKE 0 062 STD LIMIT 0 03 0 057 EXHAUST 0 067 VALVE Stem and Valve Guide 0 05 mm STD L Servicio 89 01 89 024 mm STD LIMIT STD LIMIT 89 054 mm Cylinder head warpage Cylinder bore Light between piston and cylinder 0 060 0 075 mm 0 115 mm Piston diameter 88 942 88 958 mm Group A Group B 88 978 mm Rings Slot GAP 0 20 0 35 FIRST SECOND ...

Page 76: ...nal Business 3 Guide pin thickness Día Ext Eje de Uña de Cambios 5 050 5 150 mm std limit 5 155 mm 10 10 027 mm std limit 10 067 mm 9 966 9 984 mm std limit 9 922 mm Drum Grooves Width Changes rocker arm inner diameter 4 960 4 990 mm 4 91 mm L Estándar L Servicio ...

Page 77: ...Kg m 9 8 11 8 N m 1 2 3 4 5 1 2 3 4 5 6 7 9 14 12 15 10 11 8 13 Cylinder head bolts Crankcase Bolts Union Magneto Cover Bolts Clutch cover bolts Motor bracket bolts Steps for tightening bolts Step 1 All bolts must be pre adjusted 1 to 5 step 2 The chassis bolts must adjust first 1 2 1 4 5 kg m 44 1 N m 2 4 5 kg m 44 1 N m Step 3 Motor support bolts 3 4 5 3 4 5 kg m 44 1 N m 4 2 6 kg m 25 5 N m 5 2...

Page 78: ...Motor y Transmisión Notas 74 Bajaj Auto International Business 3 ...

Page 79: ...043 32 Aplicación To lock the crankshaft Tool Position evacuation strainer Código 37 0042 82 Aplicación To place the strainer universal joint for central spark plug 37 1043 33 Código Aplicación to remove central spark plug Rubber Tube for central spark plug placement Código 37 1043 34 Aplicación For placing the central spark plug ...

Page 80: ... and replace the bolts on the right side of the headcover long 8mm Allen Código 37 1043 36 Aplicación To remove and adjust bolts on the left side of the cylinder head oil pressure remover 21mm Código 37 1043 37 Aplicación To remove and adjust the oil pressure sensor clutch holder 37 1043 38 Código Aplicación to lock the clutch while removing clutch center nut ...

Page 81: ...icación To expand the piston rings are placed or removed Fixer gudgeon pin Código 37 1043 40 Aplicación To remove the piston pin Remover the gudgeon pin Código 37 1043 41 Aplicación removes the gudgeon pin Extractor Primary Gear Código 37 1043 42 Aplicación To remove gear primary Note It is used in case the primary gear islocked ...

Page 82: ...ar Note It is used in case the primary gear islocked Tool to place the strainer purge Código 37 0042 82 Aplicación To place the strainer purge Flexible wire magnetized tip Código 37 1043 45 Aplicación Removes valve shims and parts that may fall in to the engine Extractor Exhaust Coolant Temperature Sensor Código 37 1043 46 Aplicación To remove and place the coolant temperature sensor ...

Page 83: ...76 Aplicación To remove the fly wheel from crankshaft Left Spark Plug Wrench 37 2540 34 Código Aplicación To remove the spark plug left of the cylinder head Balancer nut tool Código 37 0041 60 Aplicación To remove or tighten the balancer Oil Shaft Seal Fixer Output Código 37 1042 56 Aplicación To place the retainer output shaft oil ...

Page 84: ...n To fit the Balancer and the Water Pump Retainer Rocker shaft remover Código 37 10DH 35 Aplicación To remove the shafts of the rockers Bearing installer set Código 37 1030 61 Aplicación To press the bearings in the crankcase Valve spring compressor Compresor 37 1031 07 Código Adaptador 37 1031 08 Aplicación To compress the springs valve intake and exhaust ...

Page 85: ...J 76 Aplicación To remove the bearing of the input shaft Camshaft Sprocket holder Código 37 1043 07 Aplicación To hold the pinion allen bolt while the cam isremoved Tool to remove the spark plug boot Código 37 1043 09 Aplicación To remove the spark plug boot Right Spark plug wrench Código 37 1040 51 Aplicación To remove the right plug ...

Page 86: ...tas Especiales Comunes 82 Bajaj Auto International Business 3 Pliers clamps coolant 37 2540 35 Código Aplicación Remove coolant hose clamps Gauge for measuring oil pressure Código 37 2040 31 Aplicación To check pressure engine oil ...

Page 87: ...he clutch cover Remove Bolts head cover 4 und Following a cross pattern and remove the headcover Make sure the piston is at TDC by aligning the mark on the primary gear with the mark on the crankcase Make sure the brand T on the camshaft sprocket is up False pin Crankshaft safety with the tool to block the crankshaft Motor y Transmisión Desarmado del Motor 83 Manual de Servicio Bajaj Dominar 400 ...

Page 88: ...ft Tie cam chain with a copper wire Remove Bolts cam chain tensioner 2 und Remove the cam chain tensioner with packaging Tensioner bolt cam chain Remove Strap tensioner bolt cam chain Using a small screwdriver turn the tensioning screw to pull the plunger back and lock it Remove right plug using the special tool ...

Page 89: ...5 mm T spark plug using the special tool Desarmado de la Culata Remove Bolts holding the cylinder head 8 mm 4 and 5 mm und 2 und with allen wrenches 8 mm and 5 mm Remove the cylinder head Remove Caps rocker arm shafts intake and exhaust 2 und Remove Rocker arm shafts intake and exhaust using the appropriate special tool ...

Page 90: ...es andaccessories Remove Retaining ring camshaft serve Camshaft Belleville washer Flat washer serve Remove the intake and exhaust rocker arms Remove Belleville washer 1 und and flat washers 2 units Remove Screws intake pipe 3 und with a Phillips screwdriver and remove the intake pipe Make sure the O ring of the intake pipe is in good condition ...

Page 91: ... de Servicio Bajaj Dominar 400 Remove Right spark plug Remove Sensor oil pressure using the special tool Code 37104337 Make sure the sensor gasket is in good condition Remove Central plug Temp sensor using a key 18 mm serve Head gasket and pins 2 und ...

Page 92: ...aj Auto International Business 3 Remove Cylinder Remove circlip piston pin Cover the housing side a clean cotton cloth Remove Cylinder gasket and the pins 2 und Using the tool to remove the piston pin Code 37104341 remove the piston pin and piston ...

Page 93: ...od condition serve The engine oil filter Clutch side disassembly Remove Bolts holding the cover oil filter 2 und With a key of 8 mm and remove the oilfilter cover Remove Releasing the clutch shaft with the washer and the torsion spring Desarmado de la Cubierta de Culata Remove Cover gasket and pin clutch 2 und serve Camshaft chain ...

Page 94: ...mary gear nut with a wrench 24 mm serve Primary gear nut Belleville washer Flat washer spacer Crankshaft sprocket Remove Pin guide cam chain with an allen wrench 5mm and remove the chainguide Remove Bolts stop plate 3 und Flat washer spacer Belleville washer Primary gearnut Cranksha ftSprocke t ...

Page 95: ...smisión Desarmado del Motor 91 Manual de Servicio Bajaj Dominar 400 Remove stop plate serve Clutch springs 3 und And clutch pressure plate serve Pushrod Clutch discs and spacers serve Belleville washer Flat washer ...

Page 96: ...aj Auto International Business 3 Using the center holder clutch Code 37104338 remove the clutch nut using a wrench 24 mm serve Belleville washer flat washer serve Centering clutch with the thick washer Take out Clutch housing and the clutch spacer ...

Page 97: ...ado del Motor 93 Manual de Servicio Bajaj Dominar 400 Remove Retaining ring gear driver oil pump and washer Remove The driving gear of the oil pump remove primary gear and keyway Remove Safety pin driver gear oil pump and washer ...

Page 98: ...ts holding the oil pump 3 und serve Oil pump Remove Pin driven gear of the oil pump and the pins 2 und serve Cam changes Remove Pin inhibitor with an allen wrench of 5 mm serve Inhibited washer 2 und And spring Remove Star pin changes allen wrench 5 mm serve Star changes along with the horn ...

Page 99: ...mado del Lado del Magneto Remove Bolts holding the magneto cover 15 und serve Magneto Cover Remove parallel pin drum changes using magnetic wire tip Desarmado de la Cubierta de Culata Remove Bolts guide plates stator branch 3 und serve guide plates Remove Bolts holding the stator 3 und ...

Page 100: ... del Motor 96 Bajaj Auto International Business 3 Remove Packing the cover of the magneto 2 pins Remove Pin guide plate starter clutch serve Guide plate starter clutch Remove Grommet plate magneto serve Stator Remove Flywheel bolt ...

Page 101: ...ual de Servicio Bajaj Dominar 400 Using given the locknut Balancer Code 37 0041 60 remove the nut balancer serve Belleville washer and flat washer Using the magneto flywheel puller Code Remove Flywheel magneto Remove Pin Balancer drive gear Washer ...

Page 102: ... and pin key Take out The balancer drive gear Remove Counter gear starter Bolts crank angle sensor 2 und Remove Bolts neutral switch 2 und take out Neutral switch Motor y Transmisión Desarmado del Motor 98 Bajaj Auto International Business 3 ...

Page 103: ... Remove Grommet crankcase serve integrated crank angle sensor and neutral switch Remove Bolts holding the evacuation pump 3 und serve The evacuation pump Remove Safety pin remove Axis Motor y Transmisión Desarmado del Motor 99 Manual de Servicio Bajaj Dominar 400 ...

Page 104: ...ng the pipe T 2 und serve Pipe T together with the O ring Remove Bolts holding the cover of the water pump 5 und serve Water pump with O ring Make sure the O ring of the water pump is in good condition Remove Pegs 2 und Motor y Transmisión Desarmado del Motor 100 Bajaj Auto International Business 3 ...

Page 105: ... serve The chain guard Remove The bolts holding the engine starter serve The starter motor Remove Bolts holding the housing on the left side 16 und With a key of 8 mm Bolt highlighted with a circle is longer than the others Motor y Transmisión Desarmado del Motor 101 Manual de Servicio Bajaj Dominar 400 ...

Page 106: ...crankcase Remove Crankshaft serve The pins 2 und Plate bolt securing the balancer bearing Take out The balancer and the plate that ensures the bearing of the balancer Remove The axis of the changes nails exit together with the springs Motor y Transmisión Desarmado del Motor 102 Bajaj Auto International Business 3 ...

Page 107: ...Claw input changes Drum changes Remove Output and input shafts Oil rail Remove Shaft bearing usin doel extractor input Code 37 10DT 77 Speaker output shaft Motor y Transmisión Desarmado del Motor 103 Manual de Servicio Bajaj Dominar 400 Desarmado del Cárter Izquierdo ...

Page 108: ...s Note Use fastener catch water pump Code 37 004156 to position the retainer Remove Output shaft bearing Detent cam changes Remove Plate bolt securing the bearing of the input shaft serve The plate securing the bearing of the input shaft Motor y Transmisión Desarmado del Motor 104 Bajaj Auto International Business 3 Desarmado del Cárter Derecho ...

Page 109: ...nges Using the guide set bearings Input shaft bearing Output shaft bearing Remove The bolt securing plate bearing drum changes serve The plate bearing the drum changes using the guide set bearings Motor y Transmisión Desarmado del Motor 105 Manual de Servicio Bajaj Dominar 400 ...

Page 110: ...ransmisión Engine Oil Flow Entry Oil Pump Oil Strainer Filter Engine Oil Output Oil Pump Relief valve FIN A Filter Crankcase Oil Oil gallery in the right case Crankcase hole for entry to Clutch Gallery Left crankcase oil Bearing lubrication Crankcase ...

Page 111: ...cate the clutch Towards the Crankshaft Sup part Cub Clutch Lubrication Crankshaft FIN FIN A Crankcase hole Superior hole crankcase B Motor y Transmisión Flujo del Aceite del Motor 107 Manual de Servicio Bajaj Dominar 400 CONTINUA DESDE ...

Page 112: ... EXIT Entry and Exit in the Head ENTR A AD SALIDA A The oil injector To the Nozzle C FIN CONTINUA DESDE Bearing Lubrication Left Crankcase CONTINUA DESDE Motor y Transmisión Flujo del Aceite del Motor 108 Bajaj Auto International Business 3 ...

Page 113: ...ft Hole in the Cub from Magneto Injector to lubricate the Magneto Oil for lubricating rail the broadcast CONTINUE FROM Hole to place the rail Left crankcase oil Left hole in the crankcase for entry into the Cub Magneto Oil gallery Crankcase Left Motor y Transmisión Flujo del Aceite del Motor ...

Page 114: ...e del Motor 110 Bajaj Auto International Business 3 Crankshaft Chamber Pasaje para evacuación Evacuation Strainer Evacuation pump inlet Evacuation pump output Release of oil in the chamber of the transmission case by the evacuation pipe ...

Page 115: ...Motor y Transmisión Notas Manual de Servicio Bajaj Dominar 400 ...

Page 116: ...asis y Suspensión CAPÍTULO 4 Torques Data Service Special tools Important SOP Puntos Clave de Aprendizaje Aplicación correcta del apriete para los diferentes componentes del Chasis Comprender el uso de las herramientas especiales SOP Importantes ...

Page 117: ...rm mount Disc plate mount rear 2 7 3 3 kgm front fender mount 1 8 2 0 kgm Bottom Bolt Shock Absorber Post 3 2 3 8 kgm 2 5 3 0 kgm Disc Mount Bolt 2 0 2 2 kgm Sup Telescopic Support Bolts 0 5 kgm Nut Shock Absorber Post Higher 9 0 11 0 kgm Fork Bracket Bolts 2 5 2 8 kgm Directional Slotted Nut 5 0 5 5 kgm Bolts Support lower bracket 9 0 11 0 kgm Central Telescopic Nut Chasis y Suspensión ...

Page 118: ...6 35mm Del 1 0mm std limit Post 6 0mm Post 0 9mm brake pad thickness TIR 0 8 mm or less std limit TIR 2 0 mm Radial Wheel Wear 4 0 3mm Forward To wear mark std limit 6 0 3mm rear Oil grade and capacity Telescópicas L Estándar L Servicio Sprocket warp 0 2 or less std limit TIR 1 0 mm or less std limit TIR 2 0 mm Grade Oil SAE 10W20Telescopic Bajaj Amount per bar Repair 420 25 ml Draining and fillin...

Page 119: ...te the inner tube Telescopic forks Cylinder Seat Holder Telescopic Código 37 1740 25 Aplicación To attach the seat while fork bolt telescopic outer tube is removed Fork seal driver Código 37 1740 24 Aplicación install fork seals Steering bearing remover Código 37 1840 14 Aplicación To remove steering race Chasis y Suspensión ...

Page 120: ...r 4 to 2 poles Código 37 2040 35 Aplicación To connect the unit review supply fuel pump to the fuel pump Adjustment Tool Special Bolt steering Código 37 0043 40 Aplicación To tighten and loosen the bolt telescopic Stem bearing installer Código 37 1840 15 Aplicación install consets stem bearings ...

Page 121: ...brake fluid park the vehicle using the rear wheel inn Make sure the brake fluid level is always MIN mark on the inspection window If the level drops use onlyBrake fluid DOT 4 A bottle sealed to replenish or replace the brake fluid ABS Notes If the ABS indicator lights while driving drive to the nearest Technical Service Bajaj for review repair Always keep a safe distance between you and objects fr...

Page 122: ...fluid to the caliper ABS unit is located on the chassis under the fuel tank Hydraulic connections from the master cylinder to the caliper are directed bythe ABS unit The sensor signal of the front and rear wheels opening or closing solenoid valves in the ABS unit and thereby controlthe flow of brake fluid to the caliper Solenoid valve Input Allows flow of brake fluid when the caliper brake Solenoi...

Page 123: ...ge valve is a non return valve controlling the flow of vapors from the vessel HC intake manifold ECU input Exit Entry Operating principle EVAP System There is a passage from the tank to the container through the fuel cap This passage helps breathing system and also the passage of the vapors of HC to the container The container acts as an accumulator of these vapors which are purged to the engine v...

Page 124: ...er Note Make sure that with the hose running from the container to the vent valve is bolted to the chassis clamp plastic Head Hose vessel purge valve Head The hose from the purge valve to the throttle body and ensure that it is subject to the plastic bracket to thechassis Head EVAP hose from the fuel tank connector Y The drain tube connector and as shown ...

Page 125: ...hrottle Body Remove The tab cover side of the grommet serve right side cover Remove Seat cowling left Left side cover simultaneously Remove Clip vent pipe Vent pipe of the head cover Remove Bolts box supporting air filter 3 units Remove Right seat cover Cover screws seat 4 und Metal washer serve right side cover ...

Page 126: ...npipe Pull the drainpipe housing end Bolts throttle body 2 und Remove Disconnect all connections to the throttle body Stepper motor Injector TMAP TPS Lift the air filter and the throttle body Pull the hose clip container to the throttle body Remove The hose of the container to the throttle body ...

Page 127: ...e remove the throttle cable and connector TPS TPS Remove Throttle cable TPS connection remove seat cover Remove Passenger seat Bolts 2 units of the right rear handle serve Rear handle Remove Bolts seat cover as follows One bolt metal washer Metal washer 1 screw Remove Tinillo the right side Flat washer Screws on the back ...

Page 128: ...Remove Rear fins 3 units of the slots in the seat cover Fins seat cover of the lower central slot serve Right seat cover 123 Manual de Servicio Bajaj Dominar 400 Chasis y Suspensión SOP Importantes ...

Page 129: ...124 Bajaj Auto International Business 4 Notas Chasis y Suspensión ...

Page 130: ...dure Review Procedure Power Relay Standard Operating Procedures Electrical circuit diagrams Key Learning Points Understanding the initial procedure battery charge Electrical check procedure Understanding the standard operating procedures for removing and placing the electrical components The various electrical circuits ...

Page 131: ... fill ports seals Corks strip Initial Battery Charge Sealed VRLA Battery Step 1 Prepare the battery place the battery on a flat and level preferably in an isolatedsurface Remove the seal from the filling ports Battery Step 2 Prepare the electrolyte Remove the electrolyte container packaging Remove the strip ofcaps Do not remove the seals Keep pulling plugs as it will be used in the battery for por...

Page 132: ...30 minutes Step 5 Remove the bottles Make sure all the electrolyte has drained the battery Take the container at the bottom and gently remove the empty tank Step 6 Place the strip plugs Lace strip plugs in the filling of the battery Pressing firmly sure the caps are flush with the upper surface of the battery Step 7 Battery Charge Charge the battery with a battery charger VRLA sealed recommended b...

Page 133: ...the voltage with the multimeter open circuit 3 7 NO short the terminal to check the battery status 3 Always use a Midtronics tester To check the status of the VRLA battery 7 Do not install accessories electric extras This will cause the circuit to short circuit and the battery to discharge This will reduce the life of the battery Use appropriate tools T 10 mm or Phillips screwdriver 3 7 Do not ham...

Page 134: ... the support back side as it may cause to malfunction or fail Make sure the horn cables are intact Do not remove the silicone seal the adjustment screw as this could allow water ingress 7 3 Make sure the horn button works properly Make sure the battery is fully charged Do not hit horn with screwdriver or hammer 129 Manual de Servicio Bajaj Dominar 400 Sistema Eléc St iri s c t o ema Eléctrico What...

Page 135: ...Make sure the magneto connector is firmly seated Always use the correct die to remove and replace the spark plug size During periodic maintenance makes use of the machine to clean spark plugs and clean the electrodes and check the correct operation of both spark plugs Do not do Do not replace the spark plug with a non recommended different temperature range Never short the primary coil wire high g...

Page 136: ... music speakers additional speakers buzzers etc because it will reduce the life of the switch and battery Do not alter the spring rear brake switch Do not operate the switches immediately after washing Control Commands 7 What not to do Check that all bulbs are firmly placed in the socket Make sure all screws socket of bulbs are intact Make sure the reflector glass headlight rear lamp lights direct...

Page 137: ...ghts All lights headlights directional horn do not work the lights 7 F7 7 5 Amp Power switch Off the int Off ECU and the engine can not start 8 F8 7 5 Amp speedometer primary and secondary speedo does not work 9 F9 7 5 Amp ABS 9MECU The ABS system does not work ABS indicator stays on and thes peedometer does not show speed Matriz de Aplicabilidad y Efectos de Mal Funcionamiento 10A ABS fuse for so...

Page 138: ...he fuse box as shown in the photo Location of fuses 10A and 25A ABS Near to main fuse box 1 To open the main fuse box Press the latch on the right side of the fusebox and lift the box cover You can accessall fuses Press lift To open the fuse box ABS Press both sides of the fuse box and lift theABS Now you can access all ABS fuses presss lift press ...

Page 139: ...icle Check the continuity of the fuse with a multimeter If you showcontinuity the fuse is OK If you do not show continuity the fuse is blown If the fuse is blown replace it with a new one of the same amperage Cuidado When replacing a fuse make sure new fuse matches the specified amperage for that circuit Install a larger capacity fuse may cause damage to the branch or components ...

Page 140: ... Test and measurement equipment Multimeter SOP Turn the ignition switch OFF Turn off the switch OFF Set the multimeter to continuity mode Connect the multimeter as shown in the table above on continuity no continuity off Condición continuity mode range Conexión ve Gray Red Conexiones Conexión ve Brown Blue Resultado continuity white range OFF No continuity ON ON Continuity Marrón Brown ve connecti...

Page 141: ...uipment Multimeter SOP Place the ignition switch ON Check operation of rear brake switch pressing the brake pedal If the brake light does not come on check the rear brake switch Rear brake light Pressured handle Shows continuity no cnotinuity brown blue result l l l l pressed continuity no continuity released l l l l Test and measurement equipment Multimeter SOP Check the clutch switch for continu...

Page 142: ...for the clutch switch and neutral switch circuit These diodes are called reverse diode protection Protection diodes reverse give a correct indication of neutral in the board Symptoms of malfunction neutral indicator lights on the speedometer when the engine is engaged and pressing the clutch handle Note 1 A review procedure with the multimeter is not recommended 2 To confirm the diagnosis replace ...

Page 143: ... Note If the display of the speedometer is not adequate then check the following Battery voltage The connector speedometer and fuel gauge are securely attached Standard Valor Estándar Resistance 2 ohm bars in speedo 12 8 32 7 42 6 52 5 62 4 72 3 82 2 92 1 full tank 138 Bajaj Auto International Business 5 Procedimiento de Revisión Eléctrica Sistema Eléctrico ...

Page 144: ...the starter relay Test and measurement equipment Multimeter SOP Connect an external supply 12 V DC to the relay terminals You should hear a sound tuc Set the multimeter to continuity mode Connect the multimeter to the relay terminals Continuity beep sound indicates that the starter relay is in good condition 200 200 Ohm range 3 9 Ohm 10 Start RelayRed YellowCabl e Conexión ve connections Start Rel...

Page 145: ...maker type RG6HCC Signal from the double coil output high Champion central plug Make Type RER6YCA Signal from the one central coil output high Electrode light 0 8 0 9 mm Frequency regulation and cleaning Every 20 000 Km Replacement Frequency 40 000 Km Central LHS Central plug cap Spark plug cap Right spark plug cap Left spark plug cap ...

Page 146: ...winding of the type submerged in oil Number of poles 18 Coils Battery charging coil SOP Disconnect the magnet coupling Set the multimeter in the 200 Ohm range Connect the multimeter as shown in the table and write down the reading Stator Location On the chassis on the left side Inside the left seat fairing Function This is a three phase regulator rectifier unit and converts the three phase AC volt...

Page 147: ...d set the clamp meter to zero Surround the red input cable of the starter motor with the clamp Start by pressing the start button Press the start button for 3 seconds and check the current shown in the 200 CC A range 75 80 A Withoutspark plug caps Surround the starter motor cable with theclamp meter connections std value Location Under the passenger seat near the suspension unit There is not a met...

Page 148: ...ay is used to turn the radiator fan motor on or off The power of the motor is 30W hence for to prevent the 2 5A CC from flowing through the electric branch the relay is incorporated 3 Fuel Pump Relay The engine power of the fuel pump is 18W This engine is continuous and while the vehicle is running the fuel pump module will remain on and a maximum current of 1 6 A will continuously flow through th...

Page 149: ...sher outer metal washer Removal of the Headlight Take out Windshield and front plate holder together with its support Remove Using a star pattern remove the side screws of the leftand right mask 2 und by side together with the plastic washer Take out Left and right side masks Make sure the part sponges inside of the masks are in goodcondition ...

Page 150: ...with the plastic washer Screws 4 und with washer metallic Take out The headlight of its support Remove The headlight connector and remove the front light Remove The screws 3 und together with themetal washers of the headlight with a Phillips screwdriver Take out The headlight of the fairing Make sure that the nuts 4 und on the fairing fairing are in good condition terms ...

Page 151: ...he fender and the bolts 3 und with a 10 mm wrench and a Phillips screwdriver Removal of the Rear Lighth Make sure that the rubber eyelets 2 und and the ear of the headlight are in good condition terms Headlight Focus Adjustment Front Dado de 10mm Extensión Llave de trinquete Adjust the adjustment bolt of the Focus of the headlight with thehandlebar turned to the right and withthe help of an extens...

Page 152: ...stándar Rear lighth Right rear directional Left rear directional Rear plate holder light Remove 2 bolts with the metal washer on the bottom of the rear fender and 2 screws using a 10 mm wrench and a star screwdriver Take out Rubber protector of the couplings and disconnect them as follows ...

Page 153: ...ke out Rear fender Remove The plate of the seat insurance cable of the cable bra Seat insurance cable Remove The rear fender as shown shows in the photo Remove Seat insurance plate Remove Bolt reinforcement supportrear fender Bolts 2 und ofthe support rear fender Sistema Eléctrico ...

Page 154: ... head screws 4 und And pull out the rear headlight Retiro del Direccional Posterior Passenger seat Plate holder support nuts back 2 und Take out Back plate together with the support Remove Screw of the pigtail of thefender Take out Fender s queue Remove the bolts 4 und of the lower tray and the screws 2 und ...

Page 155: ...ower tray to remove or easily place the directional cable Take out The cap of the connections and disconnect the coupling of thedirectionals Take out Directional cable such asIt is shown in the photo The directional cable of the cable support Remove The nut that supports the directional Take out Directional nut and washer Sistema Eléctrico ...

Page 156: ...ht directional Nut that supports the reflector with an 8 mm wrench and remove the reflector Remove Screw 2 und of light of the carrier plate Take out The light of the plate holder Remove The connector of the back plate of the insulating washer of the reinforcement support Remove Reinforcement bracket screw of the rear fender Take out Reinforcement support ofrear fender ...

Page 157: ... Business 5 Procedimientos de Operación Estándar The rear fender shown in the photo can be replaced by new one Remove Seat insurance plate Take out Seat insurance together with support of the seat insurance cable Sistema Eléctrico ...

Page 158: ...U y Caja de la Batería Remove Battery and rubber box Fuse box Remove Bolts 4 und that support the boxBattery Lift the battery case together with theECU Remove The nuts 4 und of the bracket of the ECU with a 10 mm wrench and take out the support of the ECU Battery box Tire The ECU insurance as shown in the photo ...

Page 159: ...icular to the gray part Take out the ECU To place the ECU again Make sure the connector and the face of the ECU that has the inscription Top is up Empuje Presione Position the ECU completely in the connector and place the safe Take out gas Tank cover Remove Speedometer bolts secondary 2 und Reemplazo del Velocímetro Secundario Sistema Eléctrico ...

Page 160: ...00 Sistema Eléctrico Procedimientos de Operación Estándar Take out The secondary speedometer Removal of the Rollover Sensor Remove The bolts 2 und of the tilt sensor support Remove Fuel tank Tilt sensorconnector Take out Tilt sensor support ...

Page 161: ...ional Business 5 Procedimientos de Operación Estándar Remove The nuts that support the tipping sensor 2 und holding the screw with a Phillips screwdriver Separate the rollover sensor from its mounting plate Sistema Eléctrico ...

Page 162: ...LER LOCK IGNITION ONOFF M B M Az B N F1 F2 F8 7 5 A 7 5 A 30A OUTPUT FUSE INPUT FUSE B NR M Az B NB A M V RA M B SPEEDOMETER 2 INT OFF SUPPLY LAND G Rs V B PIN 3 PIN 5 IND LOW BATTERY I P 6 V PIN R SPEEDOMETER 1 BATTERY INT OFF B G Rs PIN 10 PIN 19 GROUNDING PIN 20 V B IND LOW BATTERY Na P V R V R PIN 1 A M TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light green Saw Violet ...

Page 163: ... ECU 2 Input Power Driver Crankshaft Principal Conductor Relay Accelerator Position Sensor I P Engine Temp Sensor Ground Sensor 1 Int Lateral Tip Over Parador Sensor ground Sensor 2 Ignition Key Supply of Sensor 2 Crankshaft input Power supply after main relay driver on Power Ground 2 Rs Rs Az M VA NG R Rs Az N AM BNN A 44 40 39 38 33 27 26 25 24 23 2 April 11 18 19 N RB R Az VV AA B F1 F4 F7 7 5A...

Page 164: ...circuit FUSE BOX VRLA BATTERY 8AH R N HORN NM IGNITION SWITCH ONOFF B M M Az B N HORN SWITCH LEFT control command N AN N AN F1 F6 OUTPUT FUSE 30A ENT FUSE RB N M 15A M Az TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light green Saw Violet ...

Page 165: ...ht FUSE BOX Electric system IGNITION SWITCH ONOFF B M M Az B N F1 F6 OUTPUT FUSE 30A ENT FUSE RB N M 15A M Az VRLA BATTERY 8AH R N INT REAR BRAKE Az M Az M INT FRONT BRAKE Az M Az M Az N A Az N A BRAKE LIGHT TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light green Saw Violet ...

Page 166: ...Ground 2 M VA NG R Rs Az M BN A 39 38 33 27 25 23 14 November Az VB Az F1 F4 F7 7 5A OUTPUT FUSE 30A ENT FUSE R M Az B N Na BG R 15A 15A F3 R B M Az B N INT OFF COMMAND CONTROL DER G RM Az ON OFF G Rs G R ROLLOVER SENSOR GN AM V R Az A NM V M BR B R B Az V MAIN RELAY Na B Na Az G B Rs Az RELAY PUMP combined Vertex Laser VRLA BATTERY 8AH R N N A Na Az FUEL PUMP TO Yellow Az blue B White M Brown N B...

Page 167: ...M B INTERMEDIATE RELAYS N A A G CLUTCH SWITCH N A A G UNIT SUSPENSION G Rs AV VRLA BATTERY 8AH R N STARTER RELAY R M STARTER MOTOR R BR A N AR A R ECU Starter relay relay Principal Conductor Int Neutral I P Int Power On Neutral Ground 2 Keys Power Sum after the main relay A VG Rs N AM B 42 33 23 25 November 10 22 R G Az G LG SPEEDOMETER 1 I P INT NEUTRO INT OFF G Vc Rs PIN 13 PIN 19 PIN 20 GROUND ...

Page 168: ...th Sensor 2 Indicator Lateral Parador Power Supply Sensor 2 Keys Sum Pot then main relay Power Earth Rs A N Na MG Rs R Az M BN A 40 38 35 33 27 25 23 11 Az G M BR BR B Az V main relay F1 F6 F7 7 5A 30A OUTPUT FUSE ENT FUSE R M Az B N MG R 15A 15A F3 R B M Az B N SPEEDOMETER 2 SUM ON SUM INT OFF MG Rs PIN 1 PIN 3 GROUNDING PIN 5 V B PIN 7 IND LATERAL PARADOR Na M MA M Na M F8 7 5A M Az A M TO Yello...

Page 169: ...z V MAIN RELAY FUSE BOX F2 F5 F7 7 5A FUSE 7 5A OUTPUT ENT FUSE R M Az B N Na G R 7 5A 15A F3 R B B NB N IGNITION SWITCH B M Az B N ON OFF M SPEEDOMETER 2 SUPPLY INT OFF LAND Z R V B PIN 3 PIN 5 Z R SPEEDOMETER 1 I P TEMP REFRIGERANT DRUMS B G Rs PIN 8 PIN 10 Na P REFRIG IND TEMP HIGH PIN 11 V B B A M G A M Na BV N FAN MOTOR RELAY FAN MOTOR G AN A RN 19 TEMP SENSOR ENGINE Rs Az A B F1 30A F8 7 5A ...

Page 170: ...A M IGNITION SWITCH B M Az B N ON OFF M DIRECTIONAL IZQ N A G N AG DER DIRECTIONAL I P DIRECTIONAL DER PIN 16 G N A G N A DIRECTIONAL POST IZQ N A G N A G DIRECTIONAL DER POST VRLA BATTERY 8AH R N LED FLASHER MN A DIRECTIONAL SWITCH COMMAND CONTROL LH V Na G Az OFF R V Na G F6 15A B N M M Az 10 PIN BATTERY BGVG Rs V B F1 30A RB N TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc L...

Page 171: ...USE OUTPUT ENT FUSE RB N VRLA BATTERY 8AH R N SPEEDOMETER 1 DRUMS B AB G Rs V B PIN 10 SWITCH IGNITION B M Az B N ONOFF M I P LEVEL OF COMB PINS 7 B ABA MV B V R FUEL PUMP RS RB A V B F2 7 5A B NB F8 7 5A M Az A M INT PIN OFF 19 PIN EARTH 20 TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light green Saw Violet ...

Page 172: ...cotr Driver Injector Throttle Position Sensor Main Relay Earth Power Supply Sensor 2 Keys Crankshaft Sensor 2 Input Power Earth Sum Pot then main relay A BG R Rs Az N AN AM B 38 33 27 26 23 25 April 5 11 18 B RN B Az VV A M BR B R B Az V MAIN RELAY CRANKSHAFT POSITION SENSOR F1 F7 7 5A OUTPUT FUSE 30A ENT FUSE R M Az B N G R 15A F3 R B B N FUEL INJECTOR N B M B TO Yellow Az blue B White M Brown N ...

Page 173: ... RELAY F1 F7 7 5A OUTPUT FUSE 30A ENT FUSE R M Az B N G R 15A F3 R B B N SENSOR TEMP ENGINE Rs Az A B ECU Driver Relay Throttle Position Sensor Main I P Engine Temp Sensor Land Earth Sensor 1 Sensor 2 Purge Valve container Power Supply Sensor 2 Keys Sum Pot then main relay Power Earth Rs Az A NV Rs G R Rs Az M BN A 44 38 34 33 27 25 23 18 Nov 19 Az VV AA B PURGE VALVE V Rs M B TO Yellow Az blue B ...

Page 174: ...th G Rs M BN A 33 25 23 SPEEDOMETER 2 SUM INT OFF MG Rs V BM R PIN 3 IND MAL PIN 10 OPERATION SWITCH IGNITION B M Az B N ONOFF M SUM ON PIN 1 M BR B R B Az V MAIN RELAY MA MV BM R F1 F6 15A 30A RB N 15A F3 R B B N Aug 11 MIL Cond Main relay M R Az V F7 7 5A M Az A M OUTPUT FUSE ENT FUSE F8 7 5A M Az G R M Az M 5 PIN EARTH TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light gre...

Page 175: ...SURE SENSOR M Rs VRLA BATTERY 8AH R N F1 30A OUTPUT FUSE ENT FUSE RB N F8 7 5A SPEEDOMETER 1 INT OFF BM G Rs Rs V B GROUNDING PIN 19 PIN 20 I P INT OIL PRESSURE PIN 14 IGNITION SWITCH B M Az B N OFF M 10 PIN BATTERY BM Rs A MV B F2 7 5A B N B M Az A M ON TO Yellow Az blue B White M Brown N Black R Red Rs Pink V Green Vc Light green Saw Violet ...

Page 176: ...Sum Pot then main relay Power driver Power Earth G Rs N AM BBN A 33 26 25 24 23 2 4 7 11 B RB RB V Az G F1 F4 F7 7 5A 30A OUTPUT FUSE ENT FUSE R M Az B N Na B G R 15A 15A F3 R B M BR B R B Az G MAIN RELAY M Az B N SPEEDOMETER 1 INT OFF BNG Rs G B GROUNDING PIN 19 PIN 20 INDICATOR RPMs I P PIN 12 BNA MV B FRONT LIGHT INT IGNITION INDICATOR RPMs B V N A B V 10 PIN BATTERY F2 30A B N B F8 7 5A M Az A...

Page 177: ...z B B G B VRLA BATTERY 8AH R N ABS ABS MOTOR PUMP INDICATOR I P SPEED SENSOR POST SUM SUM SPEED SENSOR REAR SENSOR FRONT VEL CAN UNDERGROUND CHASSIS SOLENOID VALVE Na P OPTIONAL SPEED SENSOR INT Off I P FRONT SPEED SENSOR CAN HIGH GROUND CHASSIS 18 17 14 13 12 11 10 9 August 4 3 2 1 B NB N Az Na R BB RAN AB Az Az BG V Az Rs Az N A EARTH ABS N A B Az R B BOX ABS F1 25A RB N F2 10A CAN INTERFACE N A...

Page 178: ...5A M Az A M M LAND RR AR B IND LIGHT HIGH INT INPUT OFF G Rs V G Rs R R AR N Az N N A M ECU Power Keys Power Earth G Rs N A 33 23 eleven INT LIGHT HIGH LOW THE HI LED MR AA Az R B M B INT PASS COMMAND CONTROL IZQ Az N A M COMMAND CONTROL DER G RM Az ON OFF G G Rs RM B N A INT LIGHTS ON PO N A LED CONTROL A Az Saw A Az M M B PLATE LIGHT MN A MN A N AR N AM FARO POST LB HB 7 Na pvel Engine HIGH LIGH...

Page 179: ...Bajaj Auto Limited Akurdi Pune 411 035 India Tel 91 20 27472851 Fax 91 20 27407385 www bajajauto com CIN number CIN L65993PN2007PLC130076 ...

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