Pusat Panggilan Pelanggan 1 800 880 181 WhatsApp Talian Khidmat Pelanggan +6019-570 8135 Ahli Kumpulan : Pengedar : 99923-L056-00 (JILID 1 - 11/2022) EDARAN MODENAS SDN. BHD (EMOS) EON HEAD OFFICE COMPLEX NO 2 LEVEL 2 PERSIARAN KERJAYA TAMAN PERINDUSTRIAN GLENMERIE, SECTION U1 40150 SHAH ALAM, SELANGOR DARUL EHSAN TEL: +603-7880 2775 FAX: +603-7880 2290 SERVICE MANUAL SERVICE CENTER Kedah Kawasan Perindustrian Gurun, 08300 Gurun, Kedah. : 04-466 8236 / 8238 : 04-466 8109 Selangor No. 62 & 64, Jalan Pluto Ay, U5 Ay, Seksyen U5, 40150 Shah Alam, Selangor. : 04-466 8160 : 03-784 50972 Johor No. 1, Jalan Kempas 2, Taman Tanah Tampoi 81200 Johor Bahru, Johor. : 07-236 1695 / 04-466 8148 : 07-235 2693 Pahang No. A 149, Lrg Seri Teruntum 8, Jln Dato Wong Ah Jang, Tmn Tunas Maju, 25200 Kuantan, Pahang. : 09-512 3380 / 04-466 8199 : 09-512 3383 Perak No 123, Jalan Raja Musa Aziz, 30300 Ipoh, Perak : 05-249 8961 / 04-466 8117 : 05-249 8965 DM400 UG Euro 4
SERVICE MANUAL DM400 UG Euro 4
15 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval systems, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Motosikal Dan Enjin Nasional Sdn. Bhd. (MODENAS), Gurun, Kedah. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your dealer for the latest information on products improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. DM400 UG Euro 4
15 DOMINAR 400 UG Euro 4 SERVICE MANUAL © 2022 by Motosikal Dan Enjin Nasional Sdn. Bhd. First Edition, November 2022 All rights reserved. Any reproduction or unauthorized use without the written permission of Motosikal Dan Enjin Nasional Sdn. Bhd. is expressly prohibited.
15 READ OWNER'S MANUAL BEFORE OPERATING A ABDC AC ATDC BBDC BTDC °C DC F °F ft g h W ampere after bottom dead center alternating current after top dead center before bottom dead center before top dead center degree celcius direct current farad degree fahrenheit foot, feet gram hour watt L lb m min N Pa PS psi r rpm TDC TIR V Ω liter pound meter minute newton pascal horse power pound per square inch revolution revolution per minute top dead center total indicator reading volt ohm This warning may apply to any of the following components of any assembly containing one or more of these components; (a) brake shoes or pads (b) clutch friction material (c) gasket (d) insulator SAFETY INSTRUCTION (a) Operate if possible outdoor or in a well ventilated place. (b) Preferably use hand tools or low speed tool equipped, if necessary with an appropriate dust extraction facility. If high speed tools are used, they should always be fully equipped. (c) If possible, dampen before cutting or drilling. (d) Dampen dust and place it in properly close receptacle and dispose it of safely. WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions LIST OF ABBREVIATIONS
15 FOREWORD This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contain enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair work satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipments are specified, do not use makeshifts tools because the use of substitute tools may adversely affect safe operation. For the duration of your warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your motorcycle; Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and non-scheduled maintenance. Use proper tools and genuine MODENAS motorcycle parts. Special tools, gauges, and testers that are necessary when servicing MODENAS motorcycle are introduced by the Special Tool Catalogue. Genuine parts provided as spare parts are listed in the Parts Catalogue. Follow the procedures in this manual carefully. Don't take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed. 1. 2. 3. 4. 5. How To Use This Manual In preparing this manual, we divided the product into its major systems. These systems become the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the products systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want information on spark plug, for example, go to the Periodic Maintenance Chart first. The chart will show you the information on how frequent to clean the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the spark plug section. Whenever you see these WARNING, CAUTION and NOTE symbols, heed the instruction! Always follow safe operating and maintenance practice. This warning symbol identifies special instructions or procedures which, if not followed, could result in personal injury, or loss of life. WARNING 15 READ OWNER'S MANUAL BEFORE OPERATING A ABDC AC ATDC BBDC BTDC °C DC F °F ftg hW ampere after bottom dead center alternating current after top dead center before bottom dead center before top dead center degree celcius direct current farad degree fahrenheit foot, feet gram hour watt L lbm min N PaPS psi r rpm TDC TIR V liter pound meter minute newton pascal horse power pound per square inch revolution revolution per minute top dead center total indicator reading volt ohm This warning may apply to any of the following components of any assembly containing one or more of these components; (a) brake shoes or pads (b) clutch friction material (c) gasket (d) insulator SAFETY INSTRUCTION (a) Operate if possible outdoor or in a well ventilated place. (b) Preferably use hand tools or low speed tool equipped, if necessary with an appropriate dust extraction facility. If high speed tools are used, they should always be fully equipped. (c) If possible, dampen before cutting or drilling. (d) Dampen dust and place it in properly close receptacle and dispose it of safely. WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions LIST OF ABBREVIATIONS This warning symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destructions of equipment. CAUTION This manual also contains three more symbols (in addition to WARNING, CAUTION and NOTE) which will help you distinguish different types of information. This note symbol indicates points of particular interest for more efficient and convenient operation. NOTE
15 FOREWORD Indicates a procedural step or work to be done. Indicates a conditional step or what action need to take based on the procedural step or sub-step it follows. Indicates a procedural step or how to do the work of the procedural step it follows. In most chapters, an exploded view illustration of the system components follow the Table of Contents. In these illustrations you will find the instruction indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.
15 QUICK REFERENCE GUIDE 2 General Information 1 Understanding The Motorcycle Maintenance Fuel System & EMS Engine & Transmission Frame & Suspension Electrical System Appendix 4 3 6 5 8 7 This quick reference guide will assist you in locating a desired topic or procedure. Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page.Refer to the sectional table of contents for the exact pages to locate the specific topic required.
Before Servicing ……………………………………………………... 1-2 Model Identification ………………………………………………….. 1-5 General Specification ……………………………....……………….. 1-7 Periodic Maintenance Chart …......................................................1-9 Special Tools ………………………………………..….................... 1-13 Part Comparison ……………………………………………............. 1-19 Tightening Torque ……………………………………………........... 1-25 Table Of Contents General Information Chapter 1 1
1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, it is recommended to read the applicable document carefully to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations and certain knowledge is required for successful work. Especially note the following ; 1. Dirt Before removal and disassembly, clean the motorcycle. Any dirt or other parts entering shall work as an abrasive and shorten the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings. 2. Battery Ground Remove the ground ( - ) lead from the battery before performing any disassembly operations on the motorcycle. This prevent : (a) The possibility of accidentally turning the engine over while partially disassembled. (b) Sparks at electrical connections which will occur when they are disconnected. (c) Damage to the electrical system. 3. Tightening Sequence Generally, when installing a part with several bolts or nuts, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a cross pattern. This is to avoid distortion of the part and or causing gas or oil leakage. 4. Torque When torque values are given in this Services Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. 5. Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems difficult to remove or install, then stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the screw heads. 6. Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. 7. High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. 8. Gasket, O-Ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. 9. Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available is Loctite Lock’s Seal (Blue). 10. Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly.
1-3 PREVENTIVE MAINTENANCE Before Servicing 11. Ball Bearing and Needle Bearing Do not remove any ball or needle bearings that are pressed in unless it is necessary. If they are removed, replace them with new ones. When installing bearings, press it in with the marked side facing out using a suitable driver until it is bottomed. Bearings should be pressed into places by pushing evenly the bearing race, which is affected by friction. 12. Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, because generally removal damages seals. When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. 13. Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little high temperature grease on the lips to reduce rubber to metal friction. 14. Circlip, Retaining Ring Replace any circlips and retaining rings that were removed with new ones, as removal shall weaken and deforms them. When installing circlips and retaining rings, take care to compress or expand them slightly then only install them. 15. Cotter Pin Replace any cotter pins that were removed with new ones, as removal shall deform and breaks them. 16. Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface that has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and grease in particular should be used only in certain application and may be harmful if used in any application for which they are not intended. This manual recommended ‘molybdenum disulfide’ grease (MoS2) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such special lubricants. 17. Electrical Wires All the electrical wires are either single-colour or two-colour and, with only a few exceptions, must be connected to wires of the same colour. On any of the two colour wires there is a greater amount of one colour and lesser amount of a second colour. So first the primary colour and then the secondary colour identify a two colour wire. For example, a yellow wire with thin red stripes is referred to as ‘yellow / red’ wire; it would be a ‘red / yellow’ wire if the colours were reversed to make red the main colour. 18. ReplacementParts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed.
1-4 GENERAL INFORMATION Before Servicing 19. Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there are any doubt, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Colour change Deterioration Seizure 20. Specifications Specification terms are defined as follows : ‘Standards’ show dimensions or performances which brand new parts or systems have ‘Service Limit’ indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts. 21. E.F.I (Electronic Fuel Injection) EFI replace carburator to supply air and fuel into the engine. It increase fuel efficiency, increase performance and give good emmission compare to carburator. 22. Catalytic Converter Catalytic Converter located in the muffler will convert toxic pollutants into less toxic pollutants. This will give the good emmission to meet the specification regulation set by the goverment.
3-2 PREVENTIVE MAINTENANCE 1-5 GENERAL INFORMATION Model Identification DOMINAR 400 UG EURO 4
3-2 PREVENTIVE MAINTENANCE 1-6 GENERAL INFORMATION Model Identification LOCATION OF PARTS 1 Grab Handle 2 Backrest 3 Pillion Seat 4 LED Tail Lamp 5 Rear Number Plate Lamp 6 Reflex Reflector 7 Rear Disc Brake 8 Rear Pedal Brake 9 Engine Oil Level Window 10 Belly Pan 11 Coolant Inspection Window 12 Leg Guard 13 Front Disc brake 14 Front Fork 15 LED Head Lamp 16 Windshield 17 Front Brake Lever 18 Primary Speedometer 19 Secondary Speedometer 20 Rider Seat 1 2 3 19 4 5 6 8 7 9 10 11 12 13 14 16 17 15 18 20
3-2 PREVENTIVE MAINTENANCE 1-7 GENERAL INFORMATION General Specifications Engine Bore Stroke Compression Ratio Engine Displacement Max. Net Power Max. Net Torque Ignition System Fuel System Spark Plug Spark Plug Gap Lubrication Gear Shifting Pattern Engine Oil Grade Drain And Refill Quantity Overhaul Quantity Engine Cooling : 4 Stroke, Single Cylinder, DOHC : 89.0 mm : 60.0 mm : 12.1 : 1 : 373.27 cc : 29.41 kW @ 8800 RPM : 35 Nm @ 6500 RPM : 12V DC : Fuel Injection : 3 Nos. LHS - RHS : CHAMPION PRG6HCC / BOSCH UR6CE CENTRAL : CHAMPION RER6YCA / BOSCH YR5NEO : 0.8 ~ 0.9 mm : Pressurized Oil Supply : 1 Down 5 Up : SAE 10W50 API SN OR JASO MA2 : 1700 ml : 1950 ml : Liquid Cooled Engine And Transmission Body And Chassis Frame Type Suspension Front Rear Brakes Front & Rear Tyres Front Rear Tyre Pressure Front Rear (Solo) Rear (With Pillion) Rim Size Front Rear Fuel Tank Capacity Reverse Fuel Grade : Perimeter : USD Front Fork (Up Side Down Front Fork) : Nitrox Mono Shock Absorber : Twin Channel ABS : 110 / 70 - R17, MC 54S, Tubeless : 150 / 60 - R17, MC 66S, Tubeless : 2.04 Kg/Cm2 (29 PSI) : 2.25 Kg/Cm2 (32 PSI) : 2.25 Kg/Cm2 (32 PSI) : 3.00 x 17 : 4.00 x 17 : 13 Litres : Nil : Super Unleaded RON - 95 and above (Research Octane Number) Grade Quantity : PRF001 : 440 ml Fork Oil
1-8 GENERAL INFORMATION General Specifications System Battery Head Lamp Position Lamp Tail / Stop Lamp Side Indicator Lamp Neutral Indicator Hi-Beam Indicator Turn Signal Indicator Speedometer Back Light Fuel Level Indicator Low Oil Pressure Indicator Malfunction Indicator Coolant Temperature Indicator Low Battery Indicator Bajaj Logo RPM Limit Service Reminder Side Stand Indicator ABS Indicator Rear Number Plate Lamp Horn : 12V (DC) : 12V 8Ah, VLRA : LED : LED : LED : LED (4 Nos.) : LED : LED : LED : LCD : LCD Bar : LED, Red Alert Message In Dot Matrix Display : LED : LED, Red Alert Message In Dot Matrix Display : LED, Red Alert Message In Dot Matrix Display : LCD : LCD, Red Alert Message In Dot Matrix Display : LED, Red Alert Message In Dot Matrix Display : LED : LED : LED : 12V Electrical Length Width Height Wheel Base Ground Clearance Seat Height : 2156 mm : 863 mm : 1243 mm : 1453 mm : 157 mm : 2156 mm Dimension Vehicle Kerb Weight Gross Vehicle Weight : 192 Kg : 342 Kg Weight
1-9 GENERAL INFORMATION * It is strongly recommended to use only genuine oil. In case of any other engine oil of same specifications is used the frequency would be every 5000 km. ** As applicable to model *** More frequent cleaning is required while driving in dusty environment. I : Inspect, A : Adjust, C : Clean, R : Replace, T : Tighten, L :Lubricate Operation Frequency Whichever Comes First Remarks Odometer Reading 500 - 750 KM 4500 - 5000 KM 9500 - 10000KM 14500 - 15000 KM 19500 - 20000 KM 24500 - 25000 KM 29500 - 30000 KM 1 Servicing with water. Protect to prevent water entry petrol tank, silencer and electrical parts. Use caustic free detergent for washing. √ √ √ √ √ √ √ 2 Engine oil*. Use SAE 10W50 API SN or JASO ‘MA2’ complaint. Oil level window cleaning at 10000 km by petrol spray and nylon brush. C I R R R R R R 3 Engine oil filter. Replace oil filter in 1st service and at every 10000 km. R R R R 4 Oil strainer and Evacuation oil strainer. Cleaning at the time of oil change. C C C C 5 Air cleaner element** and air filter cover ‘O’ ring. Drain tube cleaning. Replace viscus filter at every 20000 km. C C C C R C C 6 In-line fuel filter. Replace at every 15000 km. I R I R 7 In-line fuel filter nylon hoses with quick connector. Replace if required. 8 Spark plug clean & check gap. Replace at every 30000 km. C A C A R 9 Valve tappet clearance. Check and adjust every 20000 km. I A 10 Throttle body rubber duct (Sleeve) for hard resulting in loose fitment. Replace if required. I R I R I R I R 11 Engine breather tube for cracks. Replace if required. 12 EVAP System Hoses – check for cracks Drain EVAP “Y” connection drain tube. Replace if found cut / damaged. I R 13 Radiator fin If found damaged, replace it. I R I R I R I R I R I R Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
1-10 GENERAL INFORMATION * It is strongly recommended to use only genuine oil. In case of any other engine oil of same specifications is used the frequency would be every 5000 km. ** As applicable to model *** More frequent cleaning is required while driving in dusty environment. I : Inspect, A : Adjust, C : Clean, R : Replace, T : Tighten, L :Lubricate Operation Frequency Whichever Comes First Remarks Odometer Reading 500 - 750 KM 4500 - 5000 KM 9500 - 10000KM 14500 - 15000 KM 19500 - 20000 KM 24500 - 25000 KM 29500 - 30000 KM 14 Check Coolant level in expansion tank / Hose clamp adjustment. Coolant top up if required. I A I A I A I A I A I A I A 15 Coolant and Radiator hoses. Replacement at every 30000 km or 3 years. Use recommended coolant. R 16 Engine foundation silent bushes for cracks. Replace if required I R I R I R 17 Silencer drain hole cleaning C C C C C 18 Water Pump seals. R 19 Wiring harness connections, routine and conduit / PVC sleeve inspection. Damaged conduit / PVC sleeves protection by applying electrical tape film. I A T I A T I A T I A T I A T I A T I A T 20 Battery connections and health by load tester +ve terminal cap fitment. Apply petroleum jelly on battery terminals. Use midtronics battery tester. I A L T I A L T I A L T I A L T I A L T I A L T I A L T 21 Ignition switch contacts cleaning Use recommended WD40 spray. C L C L C L C L C L 22 HT coil connections (Primary and Secondary). I T I T I T I T I T I T 23 Starter motor and starter relay connections. I T I T I T I T I T I T 24 Oil pressure indicator check on console post ignition ON. Icon should disappear post engine ON. After 4000 rpm, no icon should be display. I R I R I R I R I R I R I R 25 Check fault code, Clear fault history. Update latest hex file if applicable. I I I I I I I Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
1-11 GENERAL INFORMATION * It is strongly recommended to use only genuine oil. In case of any other engine oil of same specifications is used the frequency would be every 5000 km. ** As applicable to model *** More frequent cleaning is required while driving in dusty environment. I : Inspect, A : Adjust, C : Clean, R : Replace, T : Tighten, L :Lubricate Operation Frequency Whichever Comes First Remarks Odometer Reading 500 - 750 KM 4500 - 5000 KM 9500 - 10000KM 14500 - 15000 KM 19500 - 20000 KM 24500 - 25000 KM 29500 - 30000 KM 26 Sealed drive chain wear **. Clean, lubricate and adjust. Replace if required. During 1st free service use spray for chain cleaning without removing chain from vehicle. During other services clean chain with diesel + SAE 90 oil ration of 50 : 50 and lubricate by SAE 90 oil. (Customer to use chain lube spray at every 500 km). C L A C L A C L A C L A C L A C L A C L A 27 Side stand pivot pin. Used recommended grease. C L C L 28 Steering play. I A I A I A I A I A I A I A 29 Steering stem bearing and cap steering bearing(Plastic) **. Replace if required. Use recommended grease for lubrication. I C L I C L I C L 30 Front fork oil and seals. Replace recommended oil, oil seal and dust seal in pair a every 30000 km. I R I R I R I R I R I R R 31 Step-pillion LH and RH (Ball and Plate) Replace ball and plate if required. C L C L C L C L C L C L 32 Swing arm NRB more play. Lubricate NRB at every 40000 km use recommended grease. L 33 Brake pads Front and Rear for wear limit. Replace at every 15000 km. I R I R I R I R I R I R R 34 Check source of leakage if any in the brake system. Check front and rear brake hose condition. Check brake fluid level and top up if needed. Check and top up DOT 4 brake oil in every service. Replace DOT 4 brake oil and master / calliper seals at every 3000 km. I A R I A R I A R I A R I A R I A R R 35 Rear sprocket fasteners for looseness. Use model wise torque values. I T I T I T I T 36 Rear wheel rubber shock dampers for excess play. Replace rear wheel rubber shock damper if required. I R I R I R Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected.
1-12 GENERAL INFORMATION Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. Operation Frequency Whichever Comes First Remarks Odometer Reading 500 - 750 KM 4500 - 5000 KM 9500 - 10000KM 14500 - 15000 KM 19500 - 20000 KM 24500 - 25000 KM 29500 - 30000 KM 37 Fairing and windshield well nuts for rubber cracks. Replace if rubber found hard. I R I R I R I R I R 38 Clutch and throttle cable free play. Replace cables if operation found hard. I A I A I A I A I A I A I A 39 Head light focus adjustment. I A I A I A I A I A I A I A 40 Check and confirm all bulbs / switch working. If found sticky then use recommended WD40. I A I A I A I A I A I A I A 41 General lubrication - Clutch Lever. Used recommended grease. L L L L L L L 42 Tyre air pressure. Ensure model wise tyre air pressure. I A I A I A I A I A I A I A 43 Mirror position and joint firmness. I A I A I A I A I A I A I A 44 All fastener tightness : Use model wise torque values. I T I T I T I T I T I T I T 1. Front and rear axle. 2. Swing arm axle 3. Engine foundation. 4. Rider foot rest. 5. Pillion stay. * It is strongly recommended to use only genuine oil. In case of any other engine oil of same specifications is used the frequency would be every 5000 km. ** As applicable to model *** More frequent cleaning is required while driving in dusty environment. I : Inspect, A : Adjust, C : Clean, R : Replace, T : Tighten, L :Lubricate
1-13 GENERAL INFORMATION Exclusive Special Tools - Engine Crankshaft Locking Tool 37 1043 32 For locking crankshaft For fitting evacuation oil strainer For central spark plug removal & fitment on vehicle For pre-fitment of central spark plug on vehicle For holding clutch centre while removing & fitting clutch nut For oil pressure sensor removal & fitment on vehicle For cylinder head cover RH side bolt removal & fitment on vehicle Evacuation Strainer Fitment Tool 37 0042 82 Universal Joint - Central spark plug 37 1043 33 Rubber Tube - Central spark plug 37 1043 34 Universal Joint - Cylinder Head Cover 37 1043 35 8 mm Allen Key with socket 37 1043 36 21 mm Tube Spanner 37 1043 37 Clutch Centre Holding Tool 37 1043 38 For removal & fitment of cylinder head LH side bolts
1-14 GENERAL INFORMATION Exclusive Special Tools - Engine Piston Rings Expander Tool 37 1043 39 For removing piston pin from piston For removing primary gear (in case of removing jammed primary gear For shim removal from cylinder head and small hardware items fallen inside engine For taking down engine from frame & while refitting engine on frame Piston Pin Circlip Fitting Tool 37 1043 40 Piston Pin Removal Tool 37 1043 41 Primary GearExtractor 37 1043 42 Balancer Driven Gear Extractor 37 1043 43 Engine Jack for Fitment of Engine on Frame 37 1043 44 Flexible Wire with Magnetic Tip 37 1043 45 Coolant Temperature Sensor Removal Tool 37 1043 46 For expending piston rings while removing & fitting piston rings on piston For fitment piston pin circlip For removing & fitting coolant temperature sensor For removing balancer driven gear (in case of jammed primary gear
1-15 GENERAL INFORMATION Common Special Tools - Engine Magneto Rotor Puller 37 0042 76 For removing magneto rotor from crankshaft For removing spark plug from cylinder head For balancer lock nut removing & torque application while tightening For fitment of output shaft oil seal tool For pressing bearings in crankcase For removing of rocker shaft tool For fitment of balancer & radiator pump oil seal LH & RH Spark plug removal 37 2540 34 Balancer Lock Nut Tightening / Removing 37 0041 60 Output Shaft Oil Seal Fitment Tool 37 1042 56 Balancer + Radiator Oil Seal Fitting Tools 37 0041 56 Rocker Shaft RemoverTool 37 10DH 35 Bearing Driver Set 37 1030 61 For compressing inlet & exhaust valve springs Adaptor & Valve Spring Compressor Compressor 37 1031 07 Adaptor 37 1031 08
1-16 GENERAL INFORMATION Common Special Tools - Engine Imput Shaft Bearing Extractor 37 10DJ 76 For removing bearing of input shaft For holding cam sprocket while removing cam sprocket allen bolt For removing sleeve of spark plug For checking engine oil pressure For removing & fitting of coolant hose clamps Cam Sprocket Holder 37 1043 07 Spark Plug Sleeve Removal Tool 37 1043 09 Coolant Clamp Plier 37 2540 35 Engine Oil Pressure Checking Unit 37 2040 31 For connecting fuel pump delivery checking unit to fuel pump Pigtail 4 Pole to 2 Pole Converter 37 1840 35 Central Spark Plug Removal Tool 37 1043 33 For removing central spark plug
1-17 GENERAL INFORMATION Special Tools - Frame And Suspension Fork Pipe Splitting Tool 37 1740 26 For splittingn fork inner pipe & outer pipe For holding fork seat pipe during removal of outer tube bottom bolt For tightening & loosening screw cap inner pipe For fitment of oil seal & guide bush For cone fitment on under bracket Fork Seat Pipe Holder 37 1740 25 Adaptor - Screw Cap Inner Pipe 37 0044 38 Under Bracket Cone Fitment Tool 37 1840 15 Oil Seal & Guide Bush Fitment Tool 37 0044 39
1-18 GENERAL INFORMATION Special Tools - Frame And Suspension Fork Clamping Block 37 0044 40 Oil Seal Protector Tool 37 0044 40 - Holding piston during lock nut removal & fitment. - Holding fork inner pipe during screw cap inner pipe removal & fitment. - To be used during fitment of oil seal and dust seals only and not for removal . Adaptor - Fork top bolts 37 0044 14 Hot Air Blow Gun 37 0044 13 - For tightening & loosening, fork top bolts. - For heating fork inner pipe before removal of screw cap inner pipe.
Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Wiring Harness Wiring Harness Part No JF402248 JF402264 Description With 30A Main Fuse in Fuse Box Without 30A Main Fuse in Fuse Box Part Comparison 1-19 GENERAL INFORMATION Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Starter Relay Starter Relay Part No JN351604 JP403000 Description • Without Main fuse 30A • Coupler : 2 pin, Blue color • With Main fuse 30A • Coupler : 4 pin, Natural (White) color Fuse box for Main Fuse 30A
Part Comparison 1-20 GENERAL INFORMATION Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Belly pan Belly pan Part No JF181314 N/A Description Design is different than Dominar 400UG Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Bracket Belly Pan Mtg Bracket Belly Pan Mtg Part No DT181307 JF181743 Description Design is different than Dominar 400UG
Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Leg Guard Leg Guard Part No LH - JF231209 , RH - JF231210 LH - JF231250 , RH - JF231251 Description Design is different than Dominar 400UG Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Bracket Belly Pan Mtg RR Bracket Belly Pan Mtg RR Part No JF181309 JF181744 Description Design is different than Dominar 400UG Part Comparison 1-21 GENERAL INFORMATION
Part Comparison 1-22 GENERAL INFORMATION Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Windshield Windshield Part No DT181306 52JF2443 Description Design is different than Dominar 400UG Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Bracket No Plate Bracket No Plate Part No JF181307 JF181307 Description Design is different than Dominar 400UG
Part Comparison 1-23 GENERAL INFORMATION Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name N / A Carrier Unit Navigation Part No N / A JF 232002 Description Design is different than Dominar 400UG Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name N / A Socket Charger Part No N / A JF403400 Description Design is different than Dominar 400UG
1-24 GENERAL INFORMATION Part Comparison Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name N / A Hand Guard Part No N / A N/A Description Design is different than Dominar 400UG Model Dominar 400 UG Dominar 400 UG Euro 4 Photograph Part Name Grab Handle Grab Handle Part No LH - 56DT5U36 , RH - 56DT5V36 56JF1B4X Description Design for top case placement
1-25 GENERAL INFORMATION Tightening Torque - Engine Sr.No. Parameter Torque Values (Kgf-m) 1 Cover cylinder head bolts 1 - 1.2 2 Cylinder head bolts M10 : 6 - 6.5 and M6 :1 - 1.2 3 Intake Manifold fitted on head bolts 0.7 - 0.9 4 Camshaft sprocket bolt 4.2 - 4.4 5 Chain tensioner bolt 1 - 1.2 6 Chain guide bolt 1 - 1.2 7 Primary gear nut 15 - 15.5 8 Clutch nut 12 - 12.5 9 Rotor bolt 10 - 10.5 10 Output sprocket bolt fitted on output shaft 1 - 1.2 11 Guide gear bolt fitted on gear change drum 1 - 1.2 12 Gear change lever bolt 1 - 1.2 13 Gear change linkage bolt 1.6 - 1.8 14 Cover engine oil filter bolt 1 - 1.2 15 Inhibitor bolt 1 - 1.2 16 Drain bolt 1 - 1.2 17 Cover water pump bolts 1 - 1.2 18 Balancer driven gear nut 5.9 - 6.1 19 Balancer driven gear bolt 3.9 - 4.1 20 Rotor water pump nut 0.7 - 0.9 21 Evacuation pump bolts 1 - 1.2 22 Oil pump bolts 1 - 1.2 23 Radiator nuts 0.8 - 1 24 Pipe coolant T Pipe bolts 1 - 1.2 25 Clutch cover bolts 1 - 1.2 26 Position plate bolt fitted on clutch cover 0.6 - 0.8 27 Magneto cover bolts 1 - 1.2
1-26 GENERAL INFORMATION Tightening Torque - Engine Sr.No. Parameter Torque Values (Kgf-m) 28 Cover LH RR Bolts 1 - 1.2 29 Air filter assembly bolts 1 - 1.2 30 Cover air filter bolts 0.25 - 0.3 31 Silencer mounting bolt at cylinder head 2 - 2.2 32 Silencer mounting bolt on RH Stay 2 - 2.2 33 End chamber mounting bolt 2.6 - 2.8 34 End chamber clamp bolt 1.8 - 2 35 Belly Pan mounting bolt 0.5 - 0.7 36 One way clutch bolts on rotor 1.4 - 1.6 37 Starter Motor bolts 1 - 1.2 38 ECU mounting bracket nuts 0.8 - 1 39 OHC Cover bolts (camholder) 0.8
1-27 GENERAL INFORMATION Tightening Torque - Frame Sr.No. Parameter Torque Values (Kgf-m) 1 Rider footrest bolt 1.8 - 2 2 RR Unit bolts 1 - 1.2 3 HT Coil bolts 1 - 1.2 4 Front seat bolts 0.8 - 1.2 5 Engine mounting bolt front Top : 2.4 – 2.6 | Bottom : 4.5 - 5 6 Engine mounting bolt rear 6.5 7 Steering slotted nut 0.5 8 RSA Top nut 4.5 - 5 9 RSA Bottom nut 4.5 - 5 10 Swing arm shaft nut 13 - 15 11 LH Stay bolt 2.4 - 2.6 12 RH Stay bolt 2.4 - 2.6 13 ECU Mounting bracket nut 0.8 - 1 14 Front fender bolt 1 - 1.2 15 Side stand bolt 1.8 - 2.2 16 Front axle nut 2.4 - 2.6 17 Axle clamping allen bolt 1.3 - 1.6 18 Rear axle nut 9 - 11 19 Front disc mtg bolt 2.7 - 3.3 20 Front Sensor disc bolt 2.7 - 3.3 21 Front Caliper mtg bolts 2.2 - 2.8 22 Rear disc mounting bolt 0.9 - 1.1 23 Rear Sensor disc bolt 0.6 - 0.8 24 ABS Mtg bolt 0.7 25 Rear Master cylinder mtg bolt 0.6 - 0.8 26 Rear sprocket nut on coupling 3.4 - 3.8 27 Rear brake pedal bolt 3 - 3.5
1-28 GENERAL INFORMATION Tightening Torque - Frame Sr.No. Parameter Torque Values (Kgf-m) 28 Handle bar upper holder bolts 1.8 - 2.2 29 Handle Bar lower holder bolts 2 - 2.2 30 Weight handle bar bolts 1 - 1.2 31 Fork top mtg bolt 2.5 - 3.5 32 Fork under bracket bolt 1.4 -1.8 33 Tank mounting bolt 1.8 - 2.2 34 Speedometer mtg nuts 0.4 35 Headlight mounting nuts / bolts 0.4 - 0.5 36 Chain cover bolt 0.8 - 1 37 Leg guard bolt 1.8 - 2 38 Grab handle bolt 1.8 - 2.2 39 Steering top bolt 5 - 5.5 40 Upper bracket pinch bolt 1.4 - 1.6
Chapter 2 2 Understanding The Motorcycle Table Of Contents Identify ………………………………...……...…...... 2-2 Speedometer Related Image ……………………... 2-3 Speedometer Related Information ……………….. 2-7 Mobile Charger Information (USB Port) .………... 2-15 Mobile Holder Mounting ..........………………….... 2-16 Identification ...……………………………………… 2-17 Removal Pillion Seat, Rider Seat, Tool Kit ........... 2-21 Fitment Of Rider Seat And Pillion Seat ………….. 2-22 Luggage Straps …………………………………..... 2-23 Grab Handle ........................................................ 2-26 Read Before You Ride ......................................... 2-27 Oil / Grease / Loctite Application Matrix ............... 2-32 Upside Down (USD) Fork Information ................. 2-34 Salient Features .................................................. 2-35 Hose / Speed Sensor .......................................... 2-38 BOSCH Diagnostic Tool Updating ....................... 2-45
2-2 UNDERSTANDING THE MOTORCYCLE Identity Frame Number Location at Head Pipe on Left Side of Motorcycle e.g.PMNDM400NNMLxxxxx (Alpha-Numeric - 17Digits) Engine Number Location on LHSide Crackcase Near Gear Change Lever e.g. JFXCNCxxxxx) (Alpha-Numeric - 11Digits)
Primary Speedometer Display Will Work When Ignition Switch Is In ‘ON’ Position. 1. Bajaj Logo : Bajaj logo flying ‘B’ glows with ignition ‘ON’. 2. Alarm / Information : messages will be displayed on Primary speedometer in Dot Matrix format. 3. Tachometer Dial : It shows engine speed in RPM. 4. ABS Indicator ( ) : With ignition switch ON the ABS indicator glows. When vehicle speed is more than 5 KM/HR, the ABS indicator goes OFF, if this indicator glows while is running, it means there is problem in ABS. 5. Hi Beam Indicator : When Headlight is ‘ON’ and ‘HI’ beam or ‘PASS’ is selected then ‘HI’ beam indicator will glow. 6. Neutral Indicator : When the transmission is in Neutral, neutral indicator will glow - ‘N’ in primary speedometer and ‘0’ will be displayed in secondary speedometer. 7. Malfunction Indicator ( ) : It glows whenever any abnormality is noticed in functioning of FI system components. 8. Turn Signal Indicator (LH and RH) : When turn signal switch is pushed to left or right. Turn signal indicator - LH or RH will flash. 9. Generic Alarm Indicator ( ) : It remains continuously ON if alarm message = 1, it blinks if alarm messages are more than 1. 10. Engine RPM Limit Indicator : It reminds rider to drive in safe engine RPM. 11. Speedometer : Vehicle speed will be displayed in digital from in KM/H. 12. Fuel Level Indicator : It shows approximate fuel level in fuel tank 13. Low Fuel Level Indicator : Fuel bar = 1 - Bar 1 glows steady and low fuel symbol blinks. Fuel bar = < 1 - and low fuel symbol both blinks. Fuel bar = 2 - Low fuel symbol glows steady. When initial 2000km running (RUNNING IN PERIOD) • RPM limit indicator blinks at 6700 to 7000 RPM. • RPM limit indicator continuously glows if RPM is > 7000 Km. Beyond 2000 km running : • RPM limit indicator blinks at 9200 to 9500 RPM. • RPM limit indicator continuously glows if RPM is > 9500 Km. 2-3 UNDERSTANDING THE MOTORCYCLE Speedometer Related Image Primary Speedometer Information. 1 7 5 2 6 9 10 8 4 12 3 11 13 ABS
2-4 UNDERSTANDING THE MOTORCYCLE Speedometer Related Image Secondary Speedometer Information 1 5 2 6 4 3 Secondary Speedometer Display Will Work When Ignition Switch Is In ‘ON’ Position. 1. Mode Button : Mode button used for changing the mode while selecting and setting Trip1, Trip2, ODD, INFO, CLOCK and SERVICE REMINDER. 2. Gear Indication : It will display gear position from 1 to 6. It will display 0 when vehicle is in neutral position. 3. Trip Meter : Trip1 and Trip2 shows the distance travelled since it last reset to zero. Rolls over to zero after 999.9 Km and continue updating. 4. Odometer : The odometer shows the total distance that the vehicle has covered. Odometer cannot be reset to ‘ZERO’ range 0 to 999999 Km. 5. Digital Clock : It indicates time in HR : MM (AM / PM). 6. Set Button : Set button used for setting Clock and Service Reminder. On pressing set button display in primary speedometer scrolls. Trip Meter Reset • M (MODE) and S (SET) push button is provided for selecting and resetting ‘ODO / TRIP1 / TRIP2’ : 1. Press M (MODE) push button for less than 2 second Mode changes from ‘ODO / TRIP1 / TRIP2’. 2. Press S (SET) push button for more than 5 second Selected ‘TRIP1 / TRIP2 will reset. Other TRIP mode will continue updating.
2-5 UNDERSTANDING THE MOTORCYCLE Speedometer Related Image • Digital clock indicates time in HR and MM separated by colon ( : ). • It is 12 hour clock. • Initially icon ( : ) will be blinking. • Clock setting is possible in TRIP1 mode only. 1. Press M (Mode) push button for less than 2 second. TRIP1 mode selected. 2. Press mode and set push button together for more than 2 second. Icon ( : ) stops blinking. Digits starts blinking. 3. Press mode button for less than 1 second. Hours digits will increase. 4. Press set button for less than 1 second. Minutes digits will increase. 5. Press mode and set button together for more than 2 second. Set value will be saved. Exit clock setting mode. Digits stop blinking icon ( : ) start blinking. 6. Clock set mode is selected and no editing is carried out for more than 5 second. Auto exit without saving set value. If engine / vehicle RPM is given then will exit from clock set mode without saving set value. Clock Reset Information
2-6 UNDERSTANDING THE MOTORCYCLE Speedometer Related Image Always maintain a safe distance between you and objects ahead. Vehicle speeds should always be reduced during extreme road conditions. The braking distance for motorcycle equipped with an anti-lock braking system may be longer than for those without it on rough road conditions. During these conditions the vehicle should be driven at reduced speeds. When you apply front brake / rear brake under conditions which may lock the wheels, you feel a corresponding sensation (pulsation) in front brake lever / rear brake pedal. This is normal and it means ABS is active. Also it is recommended to use both front and rear brakes simultaneously. Always slow down when cornering. The anti-lock brake system cannot prevent accidents resulting from excessive speeds. If the ABS warning light is ON and stays ON, you may have a problem with the ABS. In this case, however your regular brakes will work normally. INSTRUCTIONS • Incase, malfunction indicator and ABS indicator glows and alarm message of high coolant temperature, low battery and low engine oil pressure is displayed in speedometer : bring the vehicle to nearest Modenas Service Centre / Dealer for inspection or repair. • Never drive by disconnecting wheel speedo gear cable. Twin Channel ABS System ‘Wrench’ symbol glow when ODO meter reading reached to set KM. This icon will glow at : 1st : 450 km 2nd : 4450 km 3rd : 9450 km 4th : 14450 km And subsequently at each 5000 km. Bring the motorcycle at Modenas Service Centre or Authorised Dealer for re-setting the service reminder icon. Service Reminder Reset ( ) Note
2-7 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Select INFO mode Primary Speedometer will display following • Average fuel consumption in TRIP2 • Average speed in TRIP2. • Time vehicle was running in TRIP2. • Vehicle may travel xx KM depending on fuel available in tank. If SET button is held pressed for more than 5 sec. Distance indicated under TRIP2 and all above information will be reset to 0. Press S (SET) button momentarily for scrolling disp.lay Primary Speedometer will display active warning messages Press S (SET) button momentarily for scrolling disp.lay Primary Speedometer will display following • Average fuel consumptionin TRIP1. • Average speed in TRIP1. • Time vehicle was running in TRIP1. • Vehicle may travel xx KM depending on fuel available in tank. If SET button is held pressed for more than 5 sec. Distance indicated under TRIP1 and all above information will be reset to 0. Select TRIP 1 mode Primary Speedometer will display • Dynamic fuel consumption • Distance to service in KM. • Gear and time display. Press S (SET) button Select ODO mode Select TRIP 2 mode User can select any of the above screens and the screen at ignition OFF condition will be retained in next ignition ON cycle. Press S (SET) button Procedure to access information available in Primary and Secondary Speedometer : 1. Function line ODO, TRIP1, TRIP2, INFO are displayed in Secondary Speedometer. 2. Changeover from ODO TRIP1 TRIP2 INFO can be done by pressing M (Mode) button in Secondary Speedometer. Speedometer Functionality Details
2-8 UNDESTANDING THE MOTORCYCLE Primary Speedometer : Dot matrix display functions - Lines Definition of terms : Speedometer Related Information Dynamic Fuel Consumption Instantaneous fuel consumption (KM / L), update after every 1.5 second according to the throttle. Value change start for next 1.5 second as per throttle input changes during that period and hence this is dynamic value changing frequently as per throttle input. Average Fuel Consumption Average fuel consumption (KM / L) for a particular trip selected, updates after every 1 minute according to throttle input changes. It is a cumulative value of fuel consumption for a given trip once selected and the data from 0 KM till next reset will be displayed based on cumulative average. Active Warning Information about warning alarms displayed in DOT matrix. Active Speed Average speed (KM / H) with which the vehicle was driven in a particular trip since last reset, a cumulative average from 0 KM till trip reset. Trip Time Engine run time (minutes) in particular trip since last reset, sum of all engine run events from 0 KM till trip reset. Fuel Range (Distance To Empty) Approximate Distance (KM) which can be covered in a particular trip till fuel tank becomes empty based on the average fuel consumption calculated and hence the value changes as per throttle input changes. The value indicates is to be treated as a reference or guidance to estimate probable distance covered with the rest fuel. (To be treated as an indication only). Notes : 1. If TRIP1 / 2 is reset Trip1 / 2 time, Average Speed, Average Fuel Consumption get reset to zero. 2. 24 hour clock and Trip1 / 2 (and associated values) get reset if permanent battery supply is removed. 3. Odometer value and units are retained if permanent battery supply is removed.
2-9 UNDESTANDING THE MOTORCYCLE Speedometer Related Information Primary Speedometer : Dot matrix display functions - Alarms. Message Display Area Information messages Information messages will be displayed according to selection of ODO / TRIP1 / TRIP2 / Info in Secondary Speedometer ODO TRIP1 TRIP2 INFO Dynamic fuel consumption Average fuel consumption 1 Average fuel consumption 2 Active warning 1 Average Speed 1 Average Speed 2 Active warning 2 Gear & Clock Indication Trip1 Fuel range Trip Time 2 Fuel range Active warning 3 Active warning 4 Distance to Service
2-10 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Speedometer : Dot matrix display information (ODO) Information messages in Odo Mode Information messageswill be displayed according to selection of ODO and pressing S (SET) button of secondary speedometer in below sequence : ODO (Seen in secondary speedo). Dynamic fuel consumption. (Seen in dot matrix window of primary speedo). Distance to Service. (Seen in dot matrix window of primary speedo).
2-11 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Speedometer : Dot matrix display information (Trip1) Information messages in Trip1 Mode Information messages will be displayed according to selection of Trip1 and pressing S (SET) button of secondary speedometer in below sequence : TRIP1 (Seen in secondary speedo) Average fuel consumption 1 (Seen in dot matrix window of primary speedo) Average Speed 1 (Seen in dot matrix window of primary speedo) Trip Time 1 (Seen in secondary speedo) Fuel range (Distance to Empty) (Seen in dot matrix window of primary speedo)
2-12 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Speedometer : Dot matrix display information (Trip2) Information messages in Trip2 Mode Information messages will be displayed according to selection of Trip2 and pressing S (SET) button of secondary speedometer in below sequence : TRIP2 (Seen in secondary speedo) Average fuel consumption 2 (Seen in dot matrix window of primary speedo) Average Speed 2 (Seen in dot matrix window of primary speedo) Trip Time 2 (Seen in dot matrix window of primary speedo). Fuel range (Distance to Empty) (Seen in dot matrix window of primary speedo)
Information messages will be displayed according to selection of Info and pressing S (SET) button of secondary speedometer Generic alarm LED will be ON if warning message is triggered. If more than one messages, the generic alarm LED will start blinking at 1 Hz. Info (Seen in secondary speedo) Secondary speedo Active warning 1 (Seen in dot matrix window of primary speedo) Active warning 2 Refer list of warning messages. Active warning 3 Refer list of warning messages. 2-13 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Speedometer : Dot matrix display warning messages (Info) Warning messages in Info mode :
2-14 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information Priority Parameter Alarm message text description 1 ECU CAN communication failure ECU communication lost. 2 ABS CAN communication failure ABS communication lost. 3 S CAN communication failure Secondary speedo communication lost. 4 Engine Kill ON Engine Kill ON. 5 Side Stand Down Side Stand Down. 6 Low Oil Pressure Low Oil Pressure. 7 High Coolant Temperature High Coolant Temperature 8 Low Battery Low Battery (Battery voltage 11.5V DC for more than 60 sec) 9 Low Fuel level / REFUEL Low Fuel Level (Fuel bars = 2). REFUEL (Fuel bars = 1). 10 Fuel Level Sensor failure Fuel level sensor failure (open or short circuit in fuel level sensor). 11 Coolant Sensor failure Coolant sensor failure. 12 Service Reminder (Icon) Service Reminder with service icon. Primary Speedometer : Warning Message S CAN - Secondary speedo P CAN - Primary speedo If there is more than one message, display priority will be as per above table If there are more than 1 message they will scroll after every 5 sec. Note