5-34 ENGINE & TRANSMISSION Engine Dismantling • Remove ‘T’ pipe mounting bolts (2 nos.) and take out ‘T’ pipe along with ‘O’ ring. Crankcase Splitting • Ensure that ‘T’ pipe ‘O’ ring is in good condition. • Remove water pump cover mounting bolts (5 nos.), take out water pump cover along with ‘O’ ring and ensure that water pump ‘O’ ring is in good condition. • Remove dowel pins (2 nos.). • Remove water pump mounting nut with 10 mm spanner counter clock wise and take out water pump.
5-35 ENGINE & TRANSMISSION Engine Dismantling • Remove chain guard mounting screws (3 nos.), take out chain guard. • Remove starter motor, take out starter motor mounting bolts.
5-36 ENGINE & TRANSMISSION Engine Dismantling • Remove RH side crankcase mounting bolt (1 nos.). Note : Open this bolt before splitting crankcase. • Remove LH side crankcase assembly and remove crankshaft assembly. • Take out dowels (2 nos.) and balancer bearing lock plate mounting bolt. • Take out balancer bearing lock plate mounting bolt and remove output fork gear shift shaft along with springs. • Remove LH side crankcase mounting bolts (16 nos.), bolts shown by arrow in photograph is long in length than others.
5-37 ENGINE & TRANSMISSION Engine Dismantling • Remove output fork gear shift (2 nos.) and input fork gear shift shaft. • Remove input fork gear shift and gear change drum. • Remove input and output shaft, assembly and oil rail.
5-38 ENGINE & TRANSMISSION Engine Dismantling • Remove output shaft oil seal lock and output shaft oil seal using long noise plyer. • Using oil seal fitment tool (Part No. 37104256, refer page Chapter 1-11) for oil seal fitment. • Remove output shaft bearing using bearing driver set (Part No. 37103061, refer page Chapter 1-11) and lever complete gear shift of seal. Crankcase LH Dismantling • Remove input shaft bearing using bearing extractor (Part No. 3710DJ76, refer page Chapter 1-12) and output shaft bush.
5-39 ENGINE & TRANSMISSION Engine Dismantling • Remove gear change drum bearing lock plate and take out gear change drum bearing lock plate bolt. • Using bearing driver set remove input shaft bearing and output shaft bearing. • Remove gear change drum bearing. • Remove complete gear shift stopper using 12 mm spanner. Crankcase RH Dismantling • Remove water pump oil seal (2 nos.) using water pump oil seal fitment tool (Part No. 37 0041 56, refer page Chapter 1-11) for oil seal fitment. • Remove input shaft bearing lock plate and take out input shaft bearing lock plate bolt.
5-40 ENGINE & TRANSMISSION Reliefvalve A Engine Oil Flow Path A Oil pumpinlet Oilstrainer Engine oil filter Oil pumpoutlet End Engine oil filter chamber RHcrankcase RH crankcase oilgallery RH Crankcase hole for entry in clutchcover LH Crankcase oil galler y RH crankshaftjournal bearing lubrication
5-41 ENGINE & TRANSMISSION Engine Oil Flow Path Clutchcover Towardscrankshaft 2 nos. oil jet for clutchlubrication Clutch cover top side Connectingrod lubrication End End A RH crankcasehole Top side holein RHcrankcase B
5-42 ENGINE & TRANSMISSION C Cylinder block In & out Engine Oil Flow Path CONTINUE FROM Cylinder head In &out CONTINUE FROM A C Tooil jet Tonozzle End LH crankshaftjournal bearinglubrication B
5-43 ENGINE & TRANSMISSION Engine Oil Flow Path CONTINUE FROM To oil jet Input & outputshaft bearing lubrication Oil jet for stator lubrication Hole on magnetocover Oil rail for gear lubrication Oil rail fitment hole on LHcrankcase Hole on LH crankcasefor entry in magnetocover LH Crankcase Oil Gallery C
5-44 ENGINE & TRANSMISSION Engine Oil Flow Path Crankshaft chamber Evacuation strainer Evacuation pumpinlet Evacuation pumpoutlet Release engine oil in gear box chamber throughevacuation pipe Evacuation passage
Chapter 6 1 Frame And Suspension Table of Contents 6 Exploded View ............................................ 6-2 Tightening Torques Frame .......................... 6-3 Evaporative Emission System .................... 6-8 Important SOP ............................................ 6-10 Special Tools ............................................... 6-13 Front Fork Oil Leakage Confirmation ........... 6-15 Dust Seal And Oil Seal Replacement ........... 6-18 Oil Seal And Dust Seal Fitment .................... 6-24 Fork Inner Pipe Replacement ....................... 6-29 Twin Channel Antilock Brake System ........... 6-34 ABS Failure Code ......................................... 6-36
6-2 FRAME AND SUSPENSION Exploded View Frame and Frame Fitting Swing Arm / Rear Shock Absorber
6-3 FRAME AND SUSPENSION Exploded View Pillion Foot Rest / Holder Stand Assembly LH RH
6-4 FRAME AND SUSPENSION Exploded View Handle Bar Assy
6-5 FRAME AND SUSPENSION 9 ~ 11 Kgf-m 3.4 ~ 3.8 Kgf-m 2.0 ~ 2.2 Kgf-m 5.0 ~ 5.5 Kgf-m 0.5 Kgf-m 2.5 ~ 3.5 Kgf-m 1.4 ~ 1.8 Kgf-m 4.5 ~ 5.0 Kgf-m 2.7 ~ 3.3 Kgf-m 0.9 ~ 1.1 Kgf-m 2.7 ~ 3.3 Kgf-m 1.0 ~ 1.2 Kgf-m 13.0 ~ 15.0 Kgf-m Tightening Torques Frame 4.5 ~ 5.0 Kgf-m 2.4 ~ 2.6 Kgf-m Front Axle Nut Front Caliper Mounting Bolts Front Fender Mounting Swing Arm Shaft RSA Mounting Bolts (Lower) Disc Mounting Bolts (Front) Disc Mounting Bolts ( Rear) Fork Upper Bracket Bolts Fork Under Bracket Bolts RSA Mounting Bolts(Upper) Handle Bar Holder Bolts Fork Centre Nut Steering Stem Nut Slotted Rear Axle Nut Rear Sprocket Mounting Nut
6-6 FRAME AND SUSPENSION Tightening Torques Frame 6.5 Kgf-m 2.4 ~ 2.6 Kgf-m 4.5 ~ 5.0 Kgf-m Engine Foundation Bolts - Rear Engine Foundation Bolts – Front Top Engine Foundation Bolts – Fr. Bottom 3.0 ~ 3.5 Kgf-m 1.8 ~ 2.2 Kgf-m 0.8 ~ 1.0 Kgf-m Rear Brake Pedal Bolt Side Stand Bracket Mounting Bolts Bracket Rear Plat No. s 0.8 ~ 1.0 Kgf-m 1.8 ~ 2.0 Kgf-m Handle Bar Weight LH & RH Pillion Stay Bolts 2.5 ~ 3.5 Kgf-m Fork Pipe Top Bolts
6-7 FRAME AND SUSPENSION Tightening Torques Frame Drive Chain Length Std. Limit 317.5 mm Serv.Limit 323.8 mm Drive Chain Slack Std. Limit 20 ~ 30 mm Serv.Limit 35 ~ 40 mm Std. Limit TIR0.1 mm or Less Serv.Limit TIR 0.2 mm orLess Axle Run Out Tyre Tread Depth Axial Wheel Run Out Std. Limit Fr – 9.44mm Rr – 9.0mm Serv.Limit Fr – 4.74mm Rr– 3.9mm Disc Pad Thickness Std. Limit 0.8 mm Serv.Limit TIR 2.0 mm Radial Wheel Run Out Front Fork Oil Grade And Capacity Std. Limit - Serv.Limit - Rear SprocketWarp Std. Limit 0.2mm Serv.Limit 0.5mm Std. Limit 0.8 mm Serv.Limit TIR 2.0 mm Fork oil level Front Fork SpringFree Length Std. Limit 385mm Serv.Limit 381mm Grade : PRF001 Fork Oil Quantity: 440ml / leg Front Rear Std. Limit 4.2 - 4.8 mm 5.7 – 6.3 mm Serv.Limit Up to TWI
6-8 FRAME AND SUSPENSION Evaporative Emission System And Working EVAP is an evaporative Emission system which prevents fuel vapors going to atmosphere by converting fuel vapors into fuel droplets through canister . These fuel droplets are feed to engine through one way electrically operated Purge valve. EVAP Canister Tank Port Breather Drain Port Port Purge Port Purge Valve The canister is filled with about a pound or two of activated charcoal. The charcoal acts like a sponge and absorbs and stores fuel vapours. The vapours are stored in the canister until the engine is started, is warm and is being driven. Working Principle of EVAP System A passage is provided from tank to canister through tank cap. This passage aids in breathing as well as passing HC vapours to canister. Canister acts as storage for these vapors and these vapors are purged to engine through purge valve due to manifold suction in vehicle. Purge valve is one valve which controls the flow of HC vapors from canister of manifold. Evaporative Emission System And Working
6-9 FRAME & SUSPENSION Evaporative Emission System • Route • EVAP hose from petrol tank to Y connect. • Y connector drain tube as shown in photograph. Evaporative Emission System - Routing • Note • Ensure that it is tide along with canister to purge valve hose to frame with rubber clamp. • Route • Canister to purge valve. • Route • Hose pipe from purge valve to throttle body as shown in photograph and ensure that it is tide with rubber clamp to frame. • Route • Hose from Y connector canister.
6-10 FRAME & SUSPENSION Important SOP • Remove LH and RH side cover lug from grommet and take out LH and RH side cover. • Remove LH and RH side cowl, side cover simultaneously and take out LH and RH side cowl and side cover simultaneously. • Remove air filter box mounting bolts (3 nos.). Air Filter Box And Throttle Body with Sensors Remove • Remove RH side cover and take out RH seat cowl, RH side cover screw and metal washer (4 nos.). • Remove breather pipe clip and breather pipe from cylinder head cover.
6-11 FRAME & SUSPENSION Important SOP Air Filter Box And Throttle Body With Sensors Removal - TMAP. - TPS. • Remove drain pipe clip. Pull drain pipe from crankcase end throttle body clips bolts (2 nos.). • Disconnect all coupler connection from throttle body : - Stepper motor. - Injector. • Lift air filter and throttle body. • Pull out canister to throttle body hose pipe clip. • Canister to throttle body hose pipe. • After removal of throttle body from engine, remove throttle cable and TPS coupler from TPS.
6-12 FRAME & SUSPENSION Important SOP Seat Cowling Removal • Remove seat cowl mounting bolts as follows : • 2 bolt with metal washer and 1 screw. • Remove RH side screw, plastic washer and bottom side screw. • Remove rear side lugs (3 nos.) from seat cowl slots. • Seat cowl lug from central bottom cover slot. • Take out RH seat cowl. • Remove pillion seat and rider seat. • Take out grab handle mounting bolts (4 nos.).
6-13 FRAME & SUSPENSION Special Tools Oil Seal and Guide Bush Fitment Tool Part No : 37 004289 For fitment of oil seal and guide bush. Hot Air Blow Gun Part No : 37 004413 For heating fork inner pipe before removal of screw cap inner pipe. Fork Clamping Block Part No : 37 004412 - Holding piston during lock nut removal and fitment. - Holding fork inner pipe during screw cap inner pipe removal and fitment. Adaptor - Screw Cap Inner Pipe Part No : 37 004189 For tightening and loosening screw cap inner pipe Adaptor - Fork Top Bolts Part No : 37 004414 For tightening and loosening, fork top bolts.
6-14 FRAME & SUSPENSION Front Fork Oil Leakage Confirmation Tip Edge • Take out dust cap and dust seal from its seat and clean oil / dust accumulated on oil seal surface area by lint free cotton cloth as shown in photograph - B. • Check point before use : If tip / edge is damaged, then scrap the fork seal cleaner and order new one. • Fork oil seal cleaner : Dia. 35 - 45 mm Identification - Grey color • Clean front fork by water wash (Water pressure jet to be applied from top to bottom side). • Remove front fender and fork protector. • Wipe off water by clean lint free cotton cloth as shown in photograph - A. • Inspect inner pipe for scoring marks using ball pen point as shown in photograph. Turn one complete round of ball pen on outer surface of inner pipe. A B
6-15 FRAME & SUSPENSION • If oil comes out and seen on inner pipe “Oil seal” cleaning side then follow steps as given below : Front Fork Oil Leakage Confirmation • If scoring marks are not observed, then drive the vehicle in dust cap and dust seal removed condition for about 2 kms on rough road. • If no oil comes out on inner pipe, then refit dust seal and dust cap in outer pipe and handover vehicle to customer and keep vehicle under monitoring. • If deep scoring marks are observed (which can be felt while checking by ball pen tip) on inner pipe, then replace inner pipe with axle clamp, dust seal and oil seal. (Do not replace fork inner pipe only by observing scoring marks visually). Refer “Fork inner pipe replacement” SOP for fork inner pipe and oil seal-dust seal replacement. • Insert fork seal cleaner tool on inner pipe as shown in photo graph in such way that oil seal cleaning side is ready for use. Oil Seal Cleaning Insert fork seal cleaner tool’s oil seal side between oil seal and inner pipe. After insertion, rotate in clockwise direction by 90 deg. and confirm cleaner is inserted correctly. Now rotate the fork seal cleaner in anti-clockwise direction for 2 turns without any jerks. For ease in rotation of the special tool it is recommended to removed front wheel and fender. Note
6-16 FRAME & SUSPENSION Front Fork Oil Leakage Confirmation • Take out fork seal cleaner tool from fork inner pipe. • Clean dust / foreign particles accumulated on oil seal side edge by clean lint free cotton cloth. • Repeat the steps as per the point 10 and 11 for one more time. • Carry out front fork pumping for 8 ~ 10 times. • Clean oil traces on oil seal surface area. • Drive the vehicle in dust cap and dust seal removed condition for about 2 kms on rough road. • If no oil traces are observed, then refit dust seal and dust cap in outer pipe and handover vehicle to customer and keep vehicle under monitoring. • If oil traces are observed, replace the dust seal and oil seal in pair. Refer “Dust seal and Oil seal Replacement” SOP. Dust Seal Cleaning • Insert the fork seal cleaner tool on inner. Insert dust cleaning side between dust seal and inner pipe as shown in photograph. • Rotate the tool for two turns in anti-clockwise direction. Clean dust seal and inner pipe by clean lint free cotton. • Rotate the tool for two turns in anti-clockwise direction. Clean dust seal and inner pipe by clean lint free cotton cloth.
• Lift the vehicle from front side using suitable arrangement. • Remove caliper mounting bolts (2 nos.) with 12 mm spanner and take out caliper assembly. 6-17 FRAME & SUSPENSION Dust Seal And Oil Replacement 3 4 1 2 1. Remove front fender and fork protector mounting bolts (3 nos.) with 5 mm Allen key. 2. Take out fork protector. 3. Cut wheel speed sensor cable tie by adjusting fender position as shown in photograph. 4. Remove wheel speed sensor mounting bolt with 8 mm spanner as shown in photograph and take out wheel speed sensor.
6-18 FRAME & SUSPENSION Dust Seal And Oil Seal Replacement 1 2 3 4 5 6 7 8 1. For vehicle LH side fork top bolt loosening : Using adaptor fork top bolt (P/N : 37004414), loosen fork top bolt on vehicle only. 2. Skill tip : Loosen 1 - 2 threads of upper bracket side bolt before opening fork top bolt. 3. For vehicle RH side fork top bolt loosening. 4. Loosen 1 - 2 threads of clamp holder RH mounting bolts with 8 mm spanner. 5. Remove front axle bolt with 13 mm spanner holding axle with 10 mm Allen key. 6. Loosen clamping bolts (2 nos.) with 6 mm Allen key. 7. Remove front axle bolt with 13 mm spanner holding axle with 10 mm Allen key. 8. Loosen upper bracket side bolt with 6 mm Allen key.
1 6-19 FRAME & SUSPENSION 1. Take out fork leg assembly from vehicle. 2. Remove outer pipe from fork top bolt threading as shown in photograph. Dust Seal And Oil Seal Replacement • Loosen under bracket side bolts (2 nos.) with 6 mm Allen key. 3. Hold piston rod using fork clamping block (P/N 37 004412) and bench vice as shown in photograph. 4. Remove fork pipe top bolt using adaptor fork top bolt (P/N 37 004414) holding lock nut on piston rod with19 mm spanner. 2 3 5 6 4 Lock Nut 1 Note Hold the fork leg assembly to avoid dropping of a leg assembly during loosening of under bracket side bolts. Note Cover the outer pipe by clean cotton cloth to avoid metal contact. 5. Take out fork pipe top bolt 6. Take out lock nut.
6-20 FRAME & SUSPENSION Dust Seal And Oil Seal Replacement • Remove fork leg from clamping block and vice. • Drain fork oil. • Hold fork leg assembly and pull out the outer pipe (as shown in photograph). • Remove the dust cap. • Take out rubber damper
6-21 FRAME & SUSPENSION Dust Seal And Oil Seal Replacement Hot Air Blow Gun (P/N : 37 004413) Information : A - Outlet Nozzle B - Heating mode selection button C - Chord with pin D - Slow heating mode E - Fast heating mode F - Heat mode selectionbutton “OFF” 1 2 A B C D E F Ensure no dent / damage happen to fork outer pipe while using screw driver when removing oil seal circlip. NOTE • Using hot air blow gun heat the fork outer pipe suitably to remove the oil seal. 1. Using appropriate size flat head screw drive, remove dust seal. 2. Remove the oil seal circlip. NOTE Please refer the information on hot air blow gun before its usage.
6-22 FRAME & SUSPENSION Dust Seal And Oil Seal Replacement Precautions to be taken: • Always keep nozzle away from chord. • Always ensure that heat selection button is “OFF” and disconnected from power supply when unattended. • Always store in dry and locked up place. • Always stay alert during usage gun. • Do not touch the outlet nozzle in any condition during usage or immediately after usage. Do not direct hot air blast towards people or flammable objects. • Connect hot air blow gun chord socket to 230V AC single phase power supply and start the supply. • Put Heating mode selection button to “fast heating mode” and hold gun at a distance @ 40 mm from Outer pipe as shown in photograph for suitably. • Put OFF supply to hot air gun and keep it on safe place. • Tap the fork outer pipe to remove the oil seal & spacer. @ 40 mm Ensure no presence of Fork oil on fork outer pipe while heating NOTE Keep a piece of cloth and tap the pipe gently of remove oil seals. CAUTION The outer pipe will be in hot condition. Please make sure suitable care.
6-23 FRAME & SUSPENSION Oil Seal And Dust Seal Fitment • Use special tool for oil seal fitment (P/N : 37 004289). 1. Assembled condition of special tool. 2. Split condition of special tool • Oil seal fitment in inner tube : 5. Insert dust cap on inner tube followed by dust seal 6. Insert the circlip. 7. Insert the oil seal. 8. Insert washer. 5 6 7 8 1 3 Inner surface in contact with inner pipe 2 4 “Oil seal side” Embossed Clean fork outer pipe with diesel or kerosene before fitting new oil seal. 3. Application of special tool on fork inner pipe. 4. Identification : Oil seal side, to be used for oil seal fitment is marked on the special tool. Do not use special tool if dent / scratch mark found on tool inner surface (in contact with inner pipe), oil seal fitment side. NOTE NOTE
6-24 FRAME & SUSPENSION 15. Fit lock oil seal using appropriate size flat head screw driver. 11. Washer. 12. Oil Seal. • Ensure that ‘click’ sound is heard during lock oil seal fitment in it’s groove. • Ensure that lock oil seal is freely rotating in groove by using screw driver. Oil Seal And Dust Seal Fitment 11 10 12 9 13 14 One by one fit following parts : 9. Insert the outer pipe. 10. Turn it upside. 13. Assemble special tool on inner and make ready to lift the oil seal. 14. Fit the oil seal firmly. Confirm seal fitment and then remove special tool. 15
6-25 FRAME & SUSPENSION Oil Seal & Dust Seal Fitment • Tighten fork top bolt in outer pipe. • Check the working of fork leg assembly by pressing outer tube from top side 2 / 3 times. 3. Fill the correct quantity of (440 ml / leg assembly) of recommended fork oil. 4. Fit the bump stop rubber 5. Tighten lock nut completely. 6. Tighten fork top bolt completely as shown in photograph. 7. Hold piston rod using fork clamping block (P / N : 37 004412) and bench vice as shown inphotograph. 1. Fit dust seal. 2. Fit dust cap. 1 2 3 4 5 6 7 Cover the outer pipe by clean cotton cloth to avoid metal contact. • Holding fork top bolt, loosen lock nut by hand till it touches to top bolt. • Tighten lock nut with 19 mm spanner, holding fork top bolt as shown in photograph. Note
6-26 FRAME & SUSPENSION • Tighten upper bracket (1.8 ~ 2.0 Kgf-m) and Under bracket (1.3 ~ 1.6 Kgf-m) side bolts to recommended torque. Take out front axle. • Tighten front fork top bolt using adaptor - fork top bolt to recommended torque on vehicle. • Fit front wheel and axle. Tighten axle bolt to recommended torque. • Tighten the clamping allen bolts (1.3 ~ 1.7 Kgf-m) to recommended torque. • Prefit front wheel speed sensor bolt, tie wheel speed sensor cable using cable tie (shown by blue circle) and tighten it to recommended torque. Ensure that wheel sensor cable is routed as shown in "Front wheel sensor routing“ section. Oil Seal And Dust Seal Fitment • Fit fork protector and fender front, tighten its mounting allen bolts to recommended torque. • Fit caliper assembly and tighten its mounting bolts to recommended torque. • Take the vehicle down and remove overhead structure hanging belt from vehicle. • Fit the fork leg assembly on vehicle. • Insert axle to ensure both fork pipes are in same plane. Ensure axle should be free in both clamps hole.
Oil Seal & Dust Seal Fitment “Key Precautions” to remember during dust seal and oil seals replacement. • Always use “Adaptor-Fork top bolt with nylon insert” for removing and tightening fork top bolt. If not used, top bolt will gets damage. • Take due care while handling fork inner pipe and outer pipe to avoid dent / damage / paint chip off. • Take utmost care for maintaining overall cleanliness during oil seals / dust seal replacement. • Use recommended fork oil grade and quantity for desired fork performance. (DO NOT USE FORK OIL BEING USED FOR OTHER MOTORCYCLE i.e. 10W 20) 6-27 FRAME & SUSPENSION Fork Oil Level Grade : PRF001 Fork Oil Quantity : 440 ml / Leg Front Fork Oil Grade & Quantity Oil Seal And Dust Seal Fitment
6-28 FRAME & SUSPENSION • Hold fork inner pipe using fork clamping block (P/N 37 004412) and bench vice as shown in photograph. • Connect hot air blow gun chord socket to 230V AC single phase power supply and start the supply. • Put Heating mode selection button to “fast heating mode” and hold gun at a distance @ 40 mm from inner pipe as shown in photograph suitably. • Put OFF supply to hot air gun and keep it on safe place. Fork Inner Pipe Replacement • Remove screw cap inner pipe with adaptor screw cap inner pipe (P/N : 37 004189). • Use adaptor screw cap inner pipe (P/N : 37 004189). Please follow the oil seal removal SOP that is communicated from page 6-19 to 6-24. Further follow the below process to remove the fork inner pipe for replacement. Note Loctite is applied to screw cap inner pipe threads. Note
6-29 FRAME & SUSPENSION Fork Inner Pipe Replacement 3. Take out screw cap inner pipe from piston rod assembly. 4. Take out fork inner pipe from clamping block & vice. 5. Take out fork oil as shown in photograph. 6. Take out spacer 1. Take out adaptor screw cap inner pipe. 1 2 4 Piston rod assembly 3 Screw cap inner 2. Take out piston rod assembly along with screw cap inner. 5 6
6-30 FRAME & SUSPENSION Fork Inner Pipe Replacement Threaded portion to be cleaned using nylon brush Threaded portion to be cleaned using nylonbrush 1. Take out spacer tube Fork sub parts cleaning : • Clean fork inner pipe, internal threaded portion and screw cap inner external threaded portion using nylon brush. 2. Take out main spring 1 2 • Clean fork inner pipe, outer tube with clean lint free cotton cloth. • Pour diesel / kerosene in fork inner pipe by closing other end with hand. • After pouring diesel / kerosene, shake fork inner pipe as shown in photograph. • Pour diesel / kerosene in fork outer tube by closing other end with hand. • After pouring diesel / kerosene, shake fork outer tube. • Blow low pressure compressed air through inner pipe and outer pipe.
6-31 FRAME & SUSPENSION Assembly • Insert the following parts in fork inner pipe as shown in photograph : 1. Main spring 2. Spacer tube 3. Spacer 4. Insert piston assembly. 5. Apply 2 to 3 drops of “Loctite Thread locker (243)” on threading of screw cap inner pipe. Main spring to be assembled as shown in photograph. Fork Inner Pipe Replacement • All fork sub parts to be cleaned using diesel / kerosene 4 5 1 2 3 Closed coils downwards i.e towards axle clamp. Note Ensure rubber parts (O-rings, seal etc) are not to be cleaned with above mention cleaning agent. Note Loctite should not drop on any other part except thread area of screw cap inner pipe. Note
6-32 FRAME & SUSPENSION • Then use adaptor - screw cap inner pipe special tool for complete tightening as shown in photograph. • Hold fork inner pipe with clamping block and clamp it on bench vice. Fork Inner Pipe Replacement • Insert screw cap inner pipe. Prefit it with hand and confirm proper thread matching. Clean the Loctite spillage if any. Note
6-33 FRAME AND SUSPENSION Function To prevent the wheels from sudden locking during braking situations. • Front brake fluid reservoir is located on RH side of Handle bar. • Rear brake fluid reservoir is located behind RH pillion holder bracket. • Reduced braking distance. Twin Channel Antilock Brake System ABS Indication Abs Indicator (Yellow) ( ) : With Ignition switch ON and KILL switch ON the ABS indicator glows. When vehicle speed is more than 10 Km / Hours the ABS indicator goes off, if this indicator glows while in running, it means there is problem with ABS system. ABS • In case ABS indicator gets ON during vehicle running, bring the vehicle to nearest BAL dealership for inspection / repair . • 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 twin channel 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 your ABS is active. • 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. Note
Twin Channel Antilock Brake System Block Diagram Front Wheel Speed Sensor Rear Wheel Speed Sensor Front Brake Lever Rear Brake Pedal ABS UNIT Front Wheel Rear Wheel Front Master Cylinder Rear Master Pedal 6-34 FRAME AND SUSPENSION Working : In ABS system, the ABS unit detects the possibility of wheel getting locked by taking input from speed sensor located at both wheels. When the wheels are about to lock, the hydroelectrical controller controls brake caliper fluid pressure and thus prevent wheels from getting locked, avoiding possibility of accident. ABS Unit : ABS unit is a combination of electrical and hydraulic controls. The ABS ECU receives pulse signal from both the wheel speed sensors accordingly it control flow of brake fluid to caliper. ABS unit is located on frame below fuel tank. The master cylinder to caliper assembly hydraulic connections are routed through ABS unit. The signal from the front and rear wheel sensor opens or closes the solenoid valves in ABS unit there by controls flow of hydraulic oil to caliper assembly. Solenoid Valve (Inlet) : It allows flow of brake fluid to caliper while braking. Solenoid Valve (Outlet) : In case of wheel locking situation, it releases braking force applied on disc by allowing brake to flow back to reservoir. Wheel Speed Sensors : These are hall effect type sensor. It senses the pulse from sensor disc mounted on wheels and convey it to ABS unit.
6-35 FRAME AND SUSPENSION ABS Failure Code Failure Modes of ABS WSS Failures Internal Failures CAN Network Failures Sensor Short to GND Valve Related Failures Time Out Error Internal IC Failures Invalid Message Error Sensor Short to VCC Sensor Plausibility Error No Communication Error InternalμC Failures ABS / ESP
6-36 FRAME AND SUSPENSION Fault Category of ABS DTC Fault Category Short Description DTC Healing Condition Fault Repair Action C1021 ECU internal / Supply Error ECU internal / Supply Error 1. Not healable, if it is ECU internal. 2. Once power supply is stable. 1.Perform ignition cycle. If fault still present. Check power supply, if fluctuation is found replace the battery. 2.Perform ignition cycle. If fault still present. Exchange the Electronic Control Unit. C1019 Valve relay Power supply failure at UBVR pin / Valve relay Failure / Over heated due to Diagnostic Request Power supply is stable / once valve is cool down. Perform ignition cycle. If fault still present. Check power supply C1015 Motor Return Flow Pump supply error The failure condition should not be present. The failure will heal when the following set of operations is performed. 1. Ignition cycle. 2. Wait for 30 seconds. 3.Accelerate to 30 kmph. Hold for 7 seconds. 4. Accelerate to 60 kmph. Examine the fuse of the Voltage supply (UB_MR) for correct function and exchange if defective but only when Voltage supply Ignition / Kl.15 (12V) is switched off (no Voltage supply at the Electronic control unit (ECU). Remove line interruption. Remove voltage drop at contact points. Improve ground connection. Charge battery. If fault still exists, exchange battery, if fault still exists, exchange the Electronic Contol Unit (ECU). C1058 Bike Voltage Under voltage error Voltage drops below 9V,when voltage returns to normal range Examine the fuse of the Voltage supply and exchange if defective. Remove line interruption. Remove voltage drop at contact points. Improve ground connection. Charge battery. If failure still exists, exchange battery. If failure still exists, disconnect supply point of the interference voltage from Voltage supply. Repair Vehicle electrical system. C1052 Valves Valve failure detected in Rear inlet Valve Not healable, since it is ECU internal Exchange the Electronic control unit (ECU) C1048 Valves Valve failure detected in Rear Outlet Valve Not healable, since it is ECU internal Exchange the Electronic control unit (ECU) C1024 WSS WSS Generic failure The failure condition should not be present. 1. Ignition cycle. 2. Wait for 30 seconds. 3.Perform Slalom driving and accelerate to 65 - 70 kmph. Check the Wheel Speed sensor, Examine Harness. Replace if and short Circuit is found in harness in sensor. Check knuckle, replace if any metal particle found. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform at least 3 ABS intervention(Panic Braking). Check DTC again. If DTC is still in current state, replace the WSS. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform ABS intervention (Panic Braking).Check DTC again. ABS Failure Code
6-37 FRAME AND SUSPENSION Fault Category of ABS ABS Failure Code DTC Fault Category Short Description DTC Healing Condition Fault Repair Action C1034 WSS Front WSS Plausibility error The failure condition should not be present. The fault will heal when the following sequence of operations is performed. 1. Ignition ON. 2. Wait for 5 seconds. 3. Accelerate to 60 KMPH. Check the Front End Wheel Speed sensor, examine Harness. Replace if any short circuit is found in harness of sensor. Check knuckle, replace if any metal particle found. Perform Clear DTC Change ignition cycle. Run vehicle at 65 KMPH. Perform at least 3 ABS intervention(Panic Braking). Check DTC again. If DTC is still in current state, replace the WSS. Perform, clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform ABS intervention (Panic Braking). Check DTC again. C1033 WSS Front Wheel Speed Sensor Short to another WSS Failure condition should not be present. Ignition cycle should be performed. Fault will be healed after 5 seconds after ignition cycle. Accelerate to 60 KMPH. Check the Front End Wheel Speed sensor, Examine Harness. Replace if and short Circuit is found in harness of sensor. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform at least 3 ABS intervention (Panic Braking). Check DTC again. If DTC is still in current state, replace the WSS. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform ABS intervention(Panic Braking). Check DTC again. C1031 WSS Rear Wheel Speed Sensor Short to another WSS Failure condition should not be present. Ignition cycle should be performed. Fault will be healed after 5 seconds after ignition cycle. Accelerate to 60 KMPH. Check the Rear End Wheel Speed sensor, Examine Harness. Replace if and short Circuit is found in harness of sensor. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform at least 3 ABS intervention (Panic Braking). Check DTC again. If DTC is still in current state, replace the WSS. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform ABS intervention(Panic Braking). Check DTC again. C1032 WSS Rear WSS Plausibility error The failure condition should not be present. The fault will heal when the following sequence of operations is performed. 1. Ignition ON. 2. Wait for 5 seconds. 3. Accelerate to 60 KMPH. Check the Rear End Wheel Speed sensor, Examine Harness. Replace if and short Circuit is found in harness of sensor. Check knuckle, replace if any metal particle found. Perform Clear DTC Change ignition cycle. Run vehicle at 65 KMPH. Perform at least 3 ABS intervention(Panic Braking). Check DTC again. If DTC is still in current state, replace the WSS. Perform Clear DTC. Change ignition cycle. Run Vehicle at 65 KMPH. Perform ABS intervention (Panic Braking). Check DTC again. C1054 Valves Valve failure detected in Front inlet Valve Not healable, since it is ECU internal. Exchange the Electronic Control Unit (ECU) C1049 Valves Valve failure detected in Front Outlet Valve Not healable, since it is ECU internal. Exchange the Electronic Control Unit (ECU)
6-38 FRAME AND SUSPENSION DTC Fault Category Short Description DTC Healing Condition Fault Repair Action C1059 Bike Voltage Over Voltage Error When voltage returns to normal range Examine the fuse of the Voltage supply and exchange if defective. Removeline interruption. Remove voltage drop at contact points. Improve ground connection. Charge battery. If failure still exists, exchange battery. If failure still exists, disconnect supply point of the interference voltage from voltage supply. Repair vehicle electrical system. U2922 CAN Communication Bus Off Failure on CAN Failure condition should not be present. Ignition cycle should be performed. Fault will be healed after 30 seconds after ignition cycle. Remove short circuit of the CAN-Bus lines CAN-H and CAN-L to each other or of the CAN-Bus line CAN-H to positive. Remove short between CAN-L to battery high, and CAN-H to battery ground. Examine the CAN-Bus termination resistor for correct resistor value and rectify if not correct. Remove cause of the signal level fault. Remove cause of bus disturbance, if any. U2921 CAN Communication CAN Bus Error Passive Failure CAN Failure condition should not be present. Ignition cycle should be performed. Fault will be healed after 30 seconds after ignition cycle. Remove short between CAN-L to battery high and CAN-H to battery ground. Examine the CAN-Bus termination resistor for correct resistor value and rectify if not correct. Remove cause of the signal level fault. Remove cause of bus disturbance, if any. C1200 Variant Code Variant Code Read Error Wrong Variant Code in ECU EEPROM, it will be healed once write Variant Code is written in EEPROM Write Correct variant code in EEPROM using Write Service C1100 Variant Code Variant Code Read Error, no data found while reading variant code Error While Reading Variant Code from EEPROM Variant code not written in EEPROM, it will be healed once write Variant Code is written in EEPROM Write Correct variant code in EEPROM using Write Service C2944 CAN Communication Meter info not received through CAN Meter info not received through CAN / CAN BUS ERROR, DTC will be healed once info is received Remove short between CAN-L to battery high, and CAN-H to battery ground. Examine the CAN-Bus termination resistor for correct resistor value and rectify if not correct. Remove cause of the signal level fault. Remove cause of bus disturbance, if any. C2934 CAN Communication Engine info not received through CAN / CAN BUS ERROR Once message is received on CAN Remove short between CAN-L to battery high and CAN-H to battery ground.Examine the CAN-Bus termination resistor for correct resistor value and rectify if not correct. Remove cause of the signal level fault. Remove cause of bus disturbance, if any. Fault Category of ABS ABS Failure Code
6-39 FRAME AND SUSPENSION DTC Fault Category Short Description DTC Healing Condition Fault Repair Action C2925 CAN Communication Engine info not received through CAN / CAN BUS ERROR Once message is received on CAN Remove short between CAN-L to battery high and CAN-H to battery ground. Examine the CAN-Bus termination resistor for correct resistor value and rectify if not correct. Remove cause of the signal level fault. Remove cause of bus disturbance, if any. C1333 Pressure Sensor Pressure Sensor Supply Error Once supply is OK 1.Perform ignition cycle. If fault still present. Check power supply, if fluctuation is found replace the battery. 2.Perform ignition cycle. If fault still present. Exchange the Electronic Control Unit. C1332 Pressure Sensor Pressure Sensor internal failure Not healable, since it is ECU internal. 1.Perform ignition cycle. If fault still present. Check power supply, if fluctuation is found replace the battery. 2.Perform ignition cycle. If fault still present. Exchange the Electronic Control Unit. C1331 Pressure Sensor Pressure Sensor Supply Error Once supply is OK 1.Perform ignition cycle. If fault still present. Check power supply, if fluctuation is found replace the battery. 2.Perform ignition cycle. If fault still present. Exchange the Electronic Control Unit. C1077 Pressure Sensor Pressure sensor Plausibility Error Once pressure sensor system value matches with internal Value 1.Perform ignition cycle. If fault still present. Check power supply, if fluctuation is found replace the battery. 2.Perform ignition cycle. Drive vehicle and check if lamp is getting off without applying brake. 3.Drive vehicle and check if lamp is getting on after applying brake. 4.Check brake system, replace if any abnormal condition found. 5.Perform ignition cycle. Drive vehicle and check if lamp is getting off without applying brake. 6.Drive vehicle and check if lamp is getting on after applying brake 7.Replace ABS if failure is still present. Fault Category of ABS ABS Failure Code