2-15 UNDERSTANDING THE MOTORCYCLE Mobile Charger Information (USB Port) • Mobile charging socket is provided near ignition switch as an OE fitment. • The charger socket has been provided with cap to protect charger from dust and water. Always ensure charger cap is firmly closed on socket when charger socket is not in use. • This charger can be used for charging mobile only in engine running condition. • The mobile charger will supply output voltage only in engine running condition. • Use suitable USB cable for mobile charging. USB Port : 12.8V DC USB Charger inspection in case issue of mobile not charging gets report : • Switch ON the ignition. • Check USB supply voltage with Digital Mulltimeter (Two Pole Coupler). • If input supply to USB charger is > 12.8V, the USB charger will be definitely ON. • If input supply to USB charger is < 11.7V, the USB charger will be definitely OFF. • In case the supply voltage is < 11.7V, start the engine and keep it in idle condition till the input supply voltage is > 12.8V. • Connect USB charging cable. • Connect available mobile. • Ensure mobile screen showing battery is charging mode. CAUTION • Do not use mobile phone while driving. Momentary lapse in concentration might result in an accident. • Please ensure charger socket cap firmly closed on socket while washing of vehicle and in the event of rain.
2-16 UNDERSTANDING THE MOTORCYCLE Mobile Holder Mounting (Carrier Unit Navigation) • Provision for fitment of mobile holder a carrier unit navigation is provided above speedometer as an OE fitment. • Purchase mobile holder from local market and fix it on the carrier Unit Navigation. Refer illustrative photo. • While driving, mobile can be used only for GPS navigation. (Using mobile for any other functions e.g. voice call, messaging, listening music etc will jeopardize the rider safety). Modenas Service Centers / Authorize Dealers will not be responsible for any damages of mobile. CAUTION Max allowed payload : 700 gram = mobile + holder Note CAUTION Ensure mobile is firmly secured in mobile holder.
LOCK : Steering locked. Ignition OFF. OFF : Steering unlock. Ignition OFF. ON : Steering unlock. Ignition ON. 2-17 UNDERSTANDING THE MOTORCYCLE Identification Steering Cum Ignition Lock : It has three positions. To Lock The Steering : To lock the steering, turn the handle bar to the left side. Turn handle bar to the left or right. Push and rotate the key to ‘LOCK’ position and remove the key. Steering locking on handle position left hand side only. To Unlock The Steering : Insert the key in steering cum ignition lock. Push and Rotate it clockwise to ‘OFF’ or ‘ON’ position. Key : A common key is used for ‘Steering Cum Ignition Lock’, ‘Fuel Tank Cap’, ‘Rear Seat’. ‘Cranking ON and Off Duration’ Control : • During Engine crank cycle cranking is allowed only for fixed duration and in between successive crank (in case engine does not start) here is a cooling off period. • Cranking on - off duration control feature to avoid battery discharge : - 1st Crank ON (5 second) and Disable for 2 second. - 2nd Crank ON (5 second) and Disable for 2 second. - 3rd Crank ON (5 second) and Disable for 10 second. After a gap of 10 second cranking cycle continues. Starter disabled if side stand down : • With side stand down condition and vehicle in gear, engine cranking is disabled through ECU. • Headlight control on RPM - Headlamp will be turned ON only at engine running condition. Fuel Tank Cap : • To open the fuel tank cap, open the flap. Insert the key in the lock and turn it clockwise and lift fuel tank cap. • To lock the ‘Fuel Tank Cap’, insert the key in the lock and turn it clockwise and press fuel tank cap. ‘Click’ sound ensures cap is fully locked. PRECAUTION : Don’t attach metallic ‘Key Chain’ as it may damage paint of petrol tank cover. • There is no fuel cock. • Always maintain minimum 3 Litre petrol in fuel tank. • Do not use adulterated fuel or fuel additives as it will result in rusting and clogging of injector, fuel pump module and catalytic convertor.
2-18 UNDERSTANDING THE MOTORCYCLE Identification Control Switch RH A C B A. Engine Kill Switch. The engine kill switch is used for switching ON and OFF the engine. B. Head Light Switch. It has 2 positions : C. Starter Button. Starter button operates the electric starter. It is recommended to start the engine with the transmission in neutral. Vehicle in Gear : Pull clutch lever and operate starter button to start the engine.
2-19 UNDERSTANDING THE MOTORCYCLE Identification C. Horn Button. Press button for sounding horn ( ). A. High / Low Beam Switches. When headlight is ON, HIGH or LOW beam can be selected with this switch. Hi beam indicator light located on speedo console will glow when high beam is selected. : High Beam : Low Beam B. Turn Signal Switch. When the turn signal knob is pushed to Left ( ) or Right ( ) respective indicator will start blinking. To stop blinking push the knob in and release Control Switch LH D. Pass Switch. Press the switch to put on HI BEAM of head light. It is used to give signal to vehicles coming from opposite side while overtaking. D A B C
IGNITION SWITCH ENGINE LIGHT SWITCH LOW / HI BEAM SELECTOR SWITCH THE FOLLOWING LIGHT WILL GLOW EFFECT IF PASS SWITCH IS PRESSED ON ( ) OFF Any Position OR Any Mode OR Front Position Lamp, Tail Lamp, Rear Number Plate Lamp, Control Switch Illumination, Both Speedometer Illumination Headlamp Hi Beam and Lo Beam will glow STARTED Toward Right (Pilot Mode) Any Mode OR Front Position Lamp, Tail Lamp, Rear Number Plate Lamp, Control Switch Illumination, Both Speedometer Illumination, Headlamp Hi Beam Headlamp Lo Beam will also glow Toward Left (Head Light Mode) Low Beam Mode ( ) Front Position Lamp, Tail Lamp, Rear Number Plate Lamp, Control Switch Illumination, Both Speedometer Illumination, Headlamp Low Beam Headlamp Lo Beam will also glow High Beam Mode ( ) Front Position Lamp, Tail Lamp, Rear Number Plate Lamp, Control Switch Illumination, Both Speedometer Illumination, Headlamp Hi Beam and Low Beam No effect 2-20 UNDERSTANDING THE MOTORCYCLE Identification Automatic Headlamp and Lights Operation • Your vehicle has a safety feature which turns ON the headlamp automatically, once the engine is started. This provides better visibility to other road users. • While riding, low beam or hi beam mode can be switched ON by operating the Hi / Lo beam selector switch, keeping the light switch head light mode.
2-21 UNDERSTANDING THE MOTORCYCLE Removal Pillion Seat, Rider Seat And Tool Kit Removal Of Rider Seat • First remove pillion seat. • Remove rider seat mounting bolts (B). • Pull backward rear end of rider seat. • Take out rider seat. A B Tool Kit Location • Tool kit fitment location is provided below pillion seat assembly. • Tool kit to be clamped on pillion seat assembly by rubber strap. Removal Of Pillion Seat • Insert key into lock (A). • Turn the key clockwise. • Lift rear end of rear seat. • Pull pillion seat backward side. • Take out pillion
2-22 UNDERSTANDING THE MOTORCYCLE Fitment Of Rider Seat And Pillion Seat E Fitment Of Rider Seat • Match the bracket of rider seat (A) with slot (B). Ensure availability of rubber damper of seat centre. • Slide rider seat toward petrol tank. • Match rider seat rear brackets (C) with the holes (D) provided on chassis and tighten the bolts (E). Fitment Of Pillion Seat • First make sure rider seat is fitted properly. • Insure tool kit is located properly on pillion seat. • Place pillion seat on fitment location. • Match the bracket of pillion seat (F) with hook (G). • Slide pillion seat towards rider seat. • Insert lock rod (H) of seat into seat lock (I). • Press rear portion of seat from top. D C B A G H I F
2-23 UNDERSTANDING THE MOTORCYCLE Luggage Straps • Take rear LH and RH luggagestraps. • Rear luggage straps = 2 nos. • Remove pillion rider seat. • Remove rider seat mounting bolts (2 nos) using 10 mm spanner. • Take front LH and RH luggage straps. Luggage Straps Fitment • Fit rear LH and RH luggage straps as shown in photograph and tighten mounting boltsto recommended torque (0.8 - 1.2 Kgfm) The straps at rear should be perpendicular to vehicle center plane, as shown photograph. • Refit the pillion rider seat. Note : RH Luggage Strap LH Luggage Strap Velcro Rear Luggage Strap • Fit front LH and RH luggage straps as shown in photograph and tighten mounting bolts to recommended torque (0.8 - 1.2 Kgf-m). Note The straps at front should be parallel to vehicle centre plane (as shown in photograph).
2-24 UNDERSTANDING THE MOTORCYCLE Front Luggage Straps Routing when not in use : • Fold front luggage straps neatly. Join LH and RH strap at Velcro as shown in photograph. Rear Luggage Straps Routing when not in use : • Fold rear luggage straps as shown in photograph to approach towards hook. Luggage Straps • Insert luggage straps in hooks as shown in photograph. • Luggage straps should be kept below the pillion seat. • Insert the folded straps under rider seat as shown in photograph. Straps Rider Seat Hooks Straps
2-25 UNDERSTANDING THE MOTORCYCLE Luggage Straps USAGE OF LUGGAGE STRAPS WITH BUNGEE CORD If provided, luggage straps below pillion seat, then these straps to be used for bungee cords for clamping luggage on vehicle. Procedure to use luggage straps : • Open pillion seat and take out front and rear luggage straps. (Refer photograph A). • Re-fit pillion seat on its position (Refer photograph B). • Now you can use luggage straps to hook ‘Bungee Cord’ (not supplied with vehicle) for clamping luggage on vehicle ©. (Maximum allowed luggage load is 15 kg). B A 1 2 Bungee cord hooked in luggage straps C D Caution Luggage straps can be used only for strapping a luggage bag similar as shown in the picture (C and D). The total weight of the bag and its contents shall not exceed 15 kg. While using the strap the user shall ensure that necessary precautions are taken in order to ensure that the : • Luggage / luggage bag is well balanced on the seat and securely tied with help of suitable cord / rope which are strong enough for the purpose. • Parts of the vehicle are not damaged due to in appropriate luggage or due to the additional hardware used for securing same. It is not recommended to use these straps to carry any articles which may damage the vehicle parts or affect the stability of the bike while driving. Warranty is not applicable for any damages arising due to luggage over weight, sharp edges. When luggage straps are not in use follow below steps : 1. Front straps to be folded with Velcro on strap ends and insert the folded straps under rider seat. 2. Rear straps to be folded neatly to approach the hook insert straps in hooks.
2-26 UNDERSTANDING THE MOTORCYCLE Grab Handle Grab handle has been provided at back side of pillion seat as an OE fitment. Description Of Grab Handle Purchase top case assembly with base plate from local market. Recommendation GIVI E300 N2 Make. Before installation of top case assembly on Grab Handle, back rest assembly needs to be removed. Grab Handle Back Rest Top Case Assembly Base Plate CAUTION Ensure to assemble top case as forward as possible with respect to pillion seat. CAUTION • Grab handle should not be used to lift the vehicle from back side, it may result in damage to grab handle. • The max allowed pay load on grab is 7 Kg. (Top case inclusive). Do not exceed allowable load limit as it may cause damage to grab handle
2-27 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Mode Selection Switch Function • Trip meter, Digital clock and Service reminder setting. Advantage : Facility to change : • Time as per local time. • Reset trip meter to calculate the distance covered in a trip. Head Light Always ON Feature : • DC head light will glow on start of vehicle automatically. Advantage : • Continuous DC head light on facility. Benefits : • Brighter illumination throughout the ride. • Road safety. Soft Self Start Function : • Cranks engine just by feather touch. How to Operate : • Switch 'ON' ignition and kill switch. • Put vehicle into neutral or declutch if in gear. • Press self start button. Do not open throttle (accelerator) while starting. Onceengine starts do not rev up engine while vehicle is parked on the stand. Benefits : • Comfort. • Hassle free starting. NOTE Service reminder setting is to be done by MODENAS Service Centers / Authorised Dealers
2-28 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Malfunction Indicator Function • It gives indication signal about error in Engine Management System (EMS). How to Operate • This operates automatically as and when the error is generated. Visual Signal • Amber colour icon on the middle indicator will pop-up, this is an indication that EMS has an error. Immediately take the vehicle to a MODENAS Authorized Service Station. Benefits • Great safely • Arrest consequential damages arising. Side Stand Riding Protection Feature • Protection against side stand riding. Advantage • The EMS systems senses the side stand on signal and does not allow the engine to run with side stand in ON position. Benefits • Rider's safety. Liquid Cooled Engine Feature • Liquid cooled engine. Advantage • Maintains lubricating oil viscosity even at high temperature and extreme stress for optimum performance. Benefits • Effective cooling and lubrication helps to deliver the higher engine performance under every possible load condition.
2-29 UNDERSTANDING THE MOTORCYCLE Read Before You Ride VRLA Battery Feature • Zero maintenance battery. Advantage • No top up required. Benefits • Effective cooling and lubrication helps to deliver the higher engine performance under every possible load condition. Tubeless Tyres Advantage • If punctured do not deflate suddenly and helps in reducing unsprung mass. • Less rolling resistance ensures complete road stability. Benefits • High stability and less maintenance. Tyre Size • Front : 110 / 70 - R17, Tubeless. • Rear : 150 / 60 - R17, Tubeless. Gear Shifting Pattern Feature • 1 down 5 up shift mechanism. Advantage • Bike will never be left into neutral condition. Benefits • Safe to drive at all speed conditions. Disc Brakes - Front And Rear Feature • Hydraulic disc brakes. Advantage • Most efficient and safe braking. Benefits • Ease in stopping the vehicle at desired spot. • Safely controlling the vehicle speed.
2-30 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Recommended Oil Grade and Quantity Mfr. Castrol - Radicool, Motul - Motocool Expert Quantity Drain and Refill - 1000 ml. Grade SAE 10W50 of API 'SN' + JASO 'MA2' grade or superior Quantity Drain and Refill 1700 ml. Engine Overhaul 1950 ml. Recommended Coolant Brand Safe Riding Tips : • Always wear standard helmet while riding. • Never use mobile phones while riding. • Always keep rear view mirrors clean. • Use both, front and rear disc brakes simultaneously. Applying only one brake may cause loss of control and skidding or diving. • Do not apply front brake when cornering or at turns. • Familiarise yourself with seating posture, starting, acceleration and braking of vehicle. • Use side indicators before tuning. • Fuel pump inside the tank is lubricated and cool by. Coolant • Ensure coolant in expansion tank is between MIN and MAX level mark. • Top up with recommended brands. Fuel Saving Tips Avoid Following : - Sudden pick-up and frequent braking. - Needless and excessive idling. - Excessive high speed riding. • Check and inflate tyre pressure once in a week • Fill petrol at reputed petrol pumps. • Use only branded fuel. • Inspect the coolant and engine oil level. Top-up to MAX level.
2-31 UNDERSTANDING THE MOTORCYCLE Monsoon Care Fit And Finish Parts : • It is suggested to take proper care in heavy monsoon / high fall rain area. The appropriate surface preventive coat is to be applied to avoid rusting / poor surface finish on account of adverse conditions. • Clean and lubricate all the important as detailed in a Periodic Chart given in Owner’s Manual. Read Before You Ride Additional Care Engine Oil : Check Every Week. • Park the vehicle on level surface to check the oil level. • Always maintain engine oil level between the upper and lower level. • Replace the oil in accordance with Periodic Maintenance Chart Battery How To Keep Battery Healthy : • Switch ‘OFF’ ignition when engine is not running • Do not ride with the brake pedal / brake lever depressed. The brake light would remain active and drain the battery. • Get your battery checked / charge during periodic services.
2-32 UNDERSTANDING THE MOTORCYCLE Oil / Grease / Loctite Application Matrix Sr. No. Lubricant / Loctite Grade Application 1. Engine oil (SAE 10W50 API ‘SN’ or JASO ‘MA2’ Grade, Fully Synthetic) • Quantity : Drain andRefill at Service - 1700 ml Engine Overhaul - 1950 ml 2. Fork oil PRF001 • Quantity / Fork Leg : 440 ml 3. Gasket Liquid Gasket (Loctite 5910) • Crankcase joining surface. 4. Grease HP Lihton RR-3 Grease • Steering races and balls 5. Spray Chain Spray • Sealed type drive chain 6. Grease All purpose • Front and rear wheel axle. • Swing arm shaft • Brake pedal pivot pin • Center stand shaft • Side stand U bracket • Gear shifter pivot • Clutch lever Lubricating Grease • Water pump oil seals 7 Electrical contact cleaning spray Cleaning Spray • Ignition switch / brake and clutch switch / LH / RH control switch. 8 Loctite Thread locker 243 • Cam sprocket allen bolt • Pick up coil screws • Gear starter clutch stopper plate screws • Kick guide bolts • Cam sprocket allen bolt • Output sprocket bolts • Oil pump mtg bolt • I / P Shaft bearing stopper screws • Chain guide bolt • Inhibitor nut • Clutch nut • Bolt shift change • Neutral switch • Stator mtg bolts • Stator harness clamp screws
2-33 UNDERSTANDING THE MOTORCYCLE Oil / Grease / Loctite Application Matrix Sr No. Lubricant / Loctite Grade Application 9. Engine Oil SAE 10W50 API ‘SN’ or JASO ‘MA2 GRADE, FULLY SYNTHETIC • All ball bearing and needle roller bearing. • Crank shaft big end bearing. • Transmission shaft and gear teeth's. • Fork shaft. • Drum groove and cam drum change. • Block / piston skirt. • Cam shaft lobes. • Clutch damper spring. • Cam chain. • Oil pump rotor while installation.
Dominar 400 UG EURO 4 - USD Fork Assembly Outer Tube Dust Cap Inner Pipe Axle Clamp • Outer tube - Upper side And Inner tube - Bottom side 2-34 UNDERSTANDING THE MOTORCYCLE Upside Down (USD) Fork Information Upside Down (USD) Fork Assembly Information Advantages Of Upside Down (USD) Fork Assembly : • Lighter in handling (turning and manoeuvring specially during city driving). • Higher rigidity of USD on account of larger guide span and longer outer tube, provide better high speed handling and braking performance. • Soft bottoming feel even in harsh potholes and on bad roads because of rubber bump stopper inside the fork assembly. • Enhances vehicle premium looks.
2-35 UNDERSTANDING THE MOTORCYCLE Salient Features Attribute Key Features Advantages Benefits Performance • 4 Valve liquid cooled Engine with 3 spark plugs • Engine power : 29.41 Ps at 8650 rpm. • Engine torque : 35 Nm at 7000 rpm. • Smooth power delivery • Optimum engine torque spread throughout the rpm band. • 29.41 Ps of enormous power and 35 Nm of high torque. • 14% more power. • Class leading drivability. Absolute joy to ride due to : • Highly optimized power and torque output. • Razor response to throttle inputs. • More power in all load conditions, good torque availability at lower rpm’s. • Consistent low emission outputs. • Smooth and positive gear shifting. • Lightweight forged crankshaft and optimised gear train makes for precise and smooth shifting at any rpm. • New generation Closed Loop Bosch Fuel Injection • DC ignition system. • Consistent engine performance - Power, Pick up, Mileage and Emissions. • Seamless changes in ignition maps for good engine performance. • Liquid cooled • Optimum cooling efficiency in all riding conditions. • Advanced air flow design to aid liquid cooling. • Heavy duty gear box. • Suited for high speed driving. • Optimum utilization of engine torque. • Viscous paper type air filter element • Improved efficiency of filtration.
Attribute Key Features Advantages Benefits Safety • Advance Twin Channel ABS. Front disc 320 mm. Rear disc 230 mm. • Uber responsive braking. Advanced twin channel ABS design for best braking efficiency in all kinds road conditions. • Safety on road. Ensures no wheel lock or skidding of wheels, irrespective of brake application force in the wet or dry. • First full LED mosaic headlamp with Auto Headlamp ON (AHO) makes the bike visible from a distance of 1.5 km. • Specially designed low profile rear tires : Better feedback and stability while cornering. • Tubeless radial tires. • Smooth ride, good handling performance, slow deflation in case of punctures for good control. • Powerful full LED mosaic headlamp. • Unparalleled visibility, enables you plan counter measures well in advance. • Slipper clutch • Ensures no rear wheel hop or skidding during deceleration when shifting to low gears. Attribute Key Features Advantages Benefits Style • Stylish spilt seats. • Up Side Down (USD forks). • Clip on – spilt type handlebar. NOT CLIP ON. • Exposed, endless type of drive chain. • Long and Low Stance Cruiser Bike. Brimming with technology that make bike smooth, safe and yet gives gut wrenching acceleration. • Massive front-loaded LEO stance. • Aggressive naked face, large contoured tank. • Better sonic impact. Added muscular appeal. • A low-slung saddle and a mega 43 mm diameter USD front forks, the biggest by far. • Ergonomic riding position, an engaging yet easy riding stance. • Unique dual-spring mono suspension. • Chest out riding posture with comfortable ergonomic reach. Sporty stance and comfortable seating arrangement. • Style that lets you break free from the mundane. • Sharper, precise handling stubbier looks. • New refreshing color and graphics. • Twin channel silencer with belly pan and an entirely new exhaust, including extended tail end chamber with double barrel exhaust. • Clear lens LED blinkers. 2-36 UNDERSTANDING THE MOTORCYCLE Salient Features
Convenience Key Features Advantages Benefits • Split reverse LCD display. • Low Battery level indicator. • Low Engine Oil Pressure indicator. • Digital Speed indication. • Engine Over Speed Limiter. • Tachometer for engine speed. • Maintenance free sealed VLRA battery. • Dynamic Fuel consumption. • Gear indicator. • Fully equipped with fault / safety indications, clock, service reminder and trip meter with digital fuel gauge. • Early warning to prevent battery getting fully discharged. • Early warning to save damages to engine. • Easy to read at a glance. • Warns the rider to control revving of engine. • For monitoring engine speed and optimum sport riding. • Electrolyte topping up not required for its life. • Instantaneous consumption of fuel (km / L), updates every 1.5 second according to rider riding pattern. • Shows / display the gear. • Ready information to customer available at a glance. • The intelligent splitting of information between the tank and console reduces clutter in the cockpit. • Indication for customer to take remedial action. • Easy to ride without any driving / operating / maintenance hassles. • Designed to present relevant information to the rider based on riding conditions. • Reverse type console provides outstanding clarity in the day or night. 2-37 UNDERSTANDING THE MOTORCYCLE Salient Features
2-38 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing • Rear Brake Hose - Master Cylinder to ABS Unit Routing • Route brake hose from rear master cylinder as shown in photograph. • Route brake hose through metal bracket as shown by black circle. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle. Rear Brake Hose - ABS Unit to Caliper Routing • Route brake hose from ABS unit as shown in photograph.
2-39 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing • Route brake hose through metal brackets as shown by black circle. • Tie brake hose and rear speed sensor cable together with cable tie (PA402204) as shown by white circle. • Route brake hose through metal bracket as shown by white circle. Cable tie (PA402204) - 6Nos • Route brake hose through metal bracket as shown by black circle. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle. Rear Brake Hose - ABS Unit to Caliper Routing • Route brake hose from ABS unit as shown in photograph.
2-40 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing Front Brake Hose - Master Cylinder to ABS Unit Routing • Route brake hose as shown in photograph. • Route brake hose as shown in photograph. • Route brake hose from master cylinder as shown in photograph. • Route brake hose through clamp ABS hose (DT131875 fitted on frame, above radiator) as shown by white arrow.
2-41 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing • Tie brake hose to speedo flap with cable tie (JD402217) as shown by white circle. • Route brake hose as shown in photograph. Front Brake Hose - ABS Unit to Caliper Routing • Route brake hose from ABS unit as shown in photograph. • Route brake hose through clamp brake hose (JF113851) as shown by white arrow.
2-42 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing Front Speed Sensor Routing • Tie the speed sensor cable to fork leg with cable tie as shown by white circle. • Route speed sensor coupler through “W clamps” (DT131878) (fitted on brake hose). • Route speed sensor cable through slot (as shown by white arrow) provided on clamp brake hose. • Route brake hose as shown in photograph. Cable tie (JD402217) - 1 nos.
2-43 UNDERSTANDING THE MOTORCYCLE Rear Speed Sensor Routing • Route rear speed sensor cable through rubber cap, bleeder nut as shown by black circle. Hose / Speed Sensor Routing • Take out speed sensor cable from window provided on speedo flap. Connect cable to it’s mating coupler. Headlight assembly removed for better clarity of cable routing Speed sensor coupler connected to mating coupler • Route speed sensor cable as shown in photograph and pass cable through window provided on speedo flap. Speed sensor coupler • Skill tip for removing front and rear wheel speed sensor coupler : Press the lock as shown by white arrow and pull out speed sensor coupler in the direction of black arrow
2-44 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing • Route sensor cable through metal bracket as shown by white circle. • Tie sensor cable to frame with cable tie as shown by black circle. • Connect speed sensor coupler to it’ s mating coupler in harness which is also tied to frame with cable tie shown by pink circle. • Route sensor cable through metal brackets as shown by white circles. • Route sensor cable through W clamps (DT131878) (fitted on brake hose) shown by white arrows. • Tie brake hose and rear speed sensor cable together with cable tie (PA402204) as shown by black circle.
2-45 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating Bosch Diagnostic Tool Type Existing SW ID New SW ID Remark Following features included : Flashing of Primary, Secondary speedometers for Dominar 400UG. LCD (P) : Primary speedometer fitted above headlight assembly. LCD (S) : Secondary speedometer fitted in cover petrol tank. Refer Dominar 400 / Pulsar RS 200 Service station manual for Bosch tool updating SOP. ES 200 C016 C021 (As on 16th Aug 2019) ES 300 B264 B278 (As on 16th Aug 2019) • Normal service reminder reset : Distanceto service > 450 km AND prior service reset is not done for present applicable interval. e.g. If you are resetting @ > = 9450 km and < 14000, next service schedule shall be displayed as 14450 km. • Prior servicereminder reset : Distance to service < = 450 km AND prior service reset is not done for present applicable interval. e.g. If you are resetting @ > = 14000 km and < 14500, next service schedule shall be displayed as 19450 km. BOSCH Diagnostic Tool Updation Normal And Prior Service Reminder Reset
Bosch Diagnostic Tool Type Existing SW ID New SW ID Remark • Addition of “X” character in VIN update. • Avenger 160S ABS added and place created for Platina, Discover models. • Dominar brand added separately. ES 200 C019 C021 (As on 16th Aug 2019) ES 300 B270 B278 (As on 16th Aug 2019) 2-46 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating Below matrix is of Hex files for EMS and ABS Sr. No Primary Speedo Secondary Speedo 1 1v07.s19 0v74 2 1v08.s19 0v78 3 1v12.s19 0v79 4 1v15.s19 0v80 5 1v16.s19 0v81 Hex file Model BAK10AS1922001.hex Dominar UG EURO3 (Without EVAP) BAK101N1922004.hex Dominar UG BS4 (With EVAP) Refer Dominar 400 / Pulsar RS 200 Training Notes for “Hex File Download” SOP Hex files should be paired for primary and secondary as per the below matrix. If not paired there might be a possibility of synchronizing or communication error.
2-47 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updation • “Tool usage” message will appear on diagnostic tool screen. Press Enter. • Select “Vehicle Diagnostics” from main menu appeared on tool screen a n d Press Enter. • Select the year “2019” from Model years appeared on tool screen a n d press Enter. • Select the “Dominar” from Make appeared on tool screen and Press Enter. • Select the “Dominar K10 UG” from models appeared on tool screen and Press Enter. Primary And Secondary Speedometer Flashing • Switch ON ignition switch and Kill switch. • Remove pillion rider seat with vehicle ignition key. • Connect diagnostic tool coupler to CAN communication port.
2-48 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating • Select the LCD (P) or LCD (S) from control units appeared on tool screen depending upon speedometer is to be flashed. • For illustrative purpose - select “LCD (P)” and Press ENTER. • Select the “Flash ECU” from Diagnostic Menu appeared on tool screen and Press ENTER. • Select the hex file “K10_Primary_1v16.s19” from Flash ECU appeared on tool screen a n d Press ENTER. Note : For information on speedo hex files refer the matrix on page number 29. For latest information refer the technical bulletin. • Message as shown in photograph will appear on tool screen. • Select YES and press ENTER. • 8 digit CODE will be displayed on tool screen. • Press ENTER.
2-49 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating • Enter the default key “FA - 1F - 70 - 82” as shown in photograph and Press Enter. Note : After flashing primary speedometer check secondary speedometer hex file, it should be matched as per the given matrix. If not, do the flashing and pair the correct hex file as per matrix. Hex files to be shared by respective country service managers. • Key should be generated by built OTP application. • Message as shown in photograph - A will appear on tool screen. This indicates flashing is in process. It will take @ 3 to 5 min. • Message as shown in photograph - C will appear on tool screen. This indicates flashing is completed. • At the same time speedometer (Selected for flashing) goes ON as shown in photograph - D. • Press Enter and disconnect the diagnostic tool. • Note : After flashing LCD (P) or LCD (S), reset the clock. Note : As per given table as shown in ‘Page number 29' pairing should be done, if not done properly it may cause error of sync. • Message shown in photograph will appear on tool screen. • Message shown in photograph will appear on tool screen. • Select Yes and Press Enter. A B C D • At the same time speedometer (selected for flashing) goes OFF, only generic Alarm ( ) will glow or blink as shown in photograph - B.
2-50 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating • Reconnect the tool. • Select : Vehicle Diagnostics / 2019 / Dominar / Dominar K10UG • Message as shown in photograph will appear on tool screen. • Select LCD ( P ) or LCD ( S ) from control units appeared on tool screen depending upon speedometer flashed. • Select “LCD ( P )” and Press Enter. • Select the “Read Mfg Info” from Diagnostic Menu appeared on tool screen and Press Enter. • Select the “Hex Prog FILE Name” from Read Mfg Info menu appeared on tool screen a n d Press Enter. • Hex file name (which is already flashed for LCD ( P ) “K10_Primary . Hex” will appear on tool screen and Press Enter. Confirmation • Select the “SW Version” from Read Mfg info menu appeared on tool screen and Press Enter.
2-51 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updation • Check whether hex file version selected for LCD ( P ) flashing is same as version appeared on tool screen. • Similarly for LCD (S), hex f i l e ver si on can be checked. • Press Enter and disconnect the tool. Version shown on tool screen 001_16 Read as1v16 Version available in hex file name – 1v16. Read as 1.16 Version shown on tool screen 000_81 Read as 0v81 Version available in hex file name – 0v81. Read as 0.81 Steps to be carried out after primary speedometer and secondary speedometer flashing. • Press MODE Button to select ODO mode. • Press SET button till Gear indicator and Time feature appears on Primary speedometer. • Once done above steps, Gear indicator and Time feature appears every time when ignition switch is made ON. “Gear indicator and Time” feature will be available in Primary Speedometer after flashing of both the speedometers. NOTE : For Neutral gear position, Primary speedometer shows “N” . Secondary speedometer shows “0”. • SW version “001_16” will appear on tool screen as shown in photograph. Note : 001_16 nothing but the same as 1v16.
2-52 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating Replacement of speedometer on vehicle 1) Replacement only one of the speedometer. a) Replacement of primary speedometer : After ignition on, primary speedometer will show Synchronisation in progress and then synchronization completed. No need to do anything on primaryspeedometer if replaced. b) Replacement of secondary speedometer : After ignition on, primary speedometer will automatically write ODO value in new secondaryspeedometer. Message Synchronisation in progress and then synchronization completed can be seen on the primary speedometer during the process. To confirm, please check ODO value after. ODO value shall be updated to the current ODO reading of vehicle. No need to write ODO using D and F tool. Precaution. a) When replacing new speedometer on vehicle, make sure ignition is Off. b) Switch ON ignition only when speedometer are connected. 2) Replacement of both Primary and secondary speedometer. Precaution to be taken : i. Note down ODO value before replacing speedometer on vehicle. ii. Do not replace speedometers while ignition is on. iii. Replace both speedometer and then only switch on ignition. • If ignition is made on after replacing one of the speedometer, then ODO value will update automatically to the previous value. Types of error and proposed actions to be taken for speedometer from service team : 1) Primary speedometer showing “S CAN Failure” on dot matrix. Action : Replacement of secondary speedometer required. Check software version before replacing. If software version is as per released version, replace speedometer. If software version is old, reflash and check again. 2) Secondary speedometer ODO area showing “-------” . continuously Action : Replacement of primar y speedometer required. Check software version before replacing. If software version is as per released version, replace speedometer . If software version is old, re-flash and check again. 3) Primaryspeedometer is not changing dot matrix message when mode and set button pressed on secondary : Action : a) Check if Primary speedometer is showing ‘S’ CAN FAILURE message. If yes, replace secondary speedometer. b) If S CAN FAILURE message is not present, ride the vehicle to some KM and check is Dynamic fuel consumption is updating or not. i ) if dynamic fuel is updating, reflash speedometer software in both speedometer. ii) if Dynamic fuel consumption is not updating, replacement is required to confirm the defect.
2-53 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating ODO Writing Precaution : Note down Km covered before removing both speedometers from vehicle. When to Do : Primary and secondary speedometer are replaced on vehicle, ODO reading is to be entered in new speedometer after fitment in vehicle. • Message as shown in photograph - H will appear on tool screen. • Press Enter. • 8 digit code will appear on tool screen. Note down this eight digit code for key generation. DO NOT disconnect the diagnostic tool. • Using Built OTP software (already available with you) generate key. (Same way as done during ECU flashing). • Select the “Write Data” from Diagnostic Menu appeared on tool screen and Press Enter. • Connect the tool and select : Vehicle Diagnostics / 2019 / Pulsar / Dominar K10UG • Message as shown in photograph - G will appear on tool screen. • Select LCD (P) from control units on tool screen and Press Enter. NOTE : For ‘ODO write’, select only LCD (P).
2-54 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating • Message as shown in photograph - J will appear on tool screen. • Entered the noted Km reading. • Press Enter. • Message as shown in photograph - K will appear on tool screen. • Select Yes and Press Enter. • Message as shown in photograph - I will appear on tool screen. • Select Yes and press Enter. • Enter the key generated from Built OTP soft ware. • Press Enter. Sample key entered in tool. Do not enter this key.
2-55 UNDERSTANDING THE MOTORCYCLE BOSCH Diagnostic Tool Updating • Message as shown in photograph - L will appear on tool screen. • Enter Km reading will be displayed on secondary speedometer as shown. • Press Enter and disconnect the tool. L
Inline Fuel Filter Replacement ........................ Air Filter Element Replacement ….………...... Air Filter Drain Tube Cleaning ……................. Engine Oil Replacement ………………..…….. Engine Oil Checking ……….………………….. Spark Plug Cleaning ....................................... Tappet Clearance Setting …………………….. Coolant Level Check And Adjust .................... Sealed Drive Chain On Vehicle ...................... Front Caliper Overhaul .................................... Brake Pad Wear / Check / Replacement ........ Brake Fluid Replacement …............................ Brake Fluid Top Up ......................................... Brake Pedal Pivot Pin Lubrication .................. Stand Side Pin Clean And Lubrication Clutch Cable Free Play And Adjust ................ Throttle Cable Free Play Check And Adjust ... Steering Play Check And Adjust ..................... Control Switch Contacts Cleaning .................. EVAP Drain Tube Cleaning ............................ Ignition Switch Contacts Cleaning .................. Chapter 3 Preventive Maintenance Table of Contents 3 3-2 3-5 3-6 3-7 3-18 3-19 3-21 3-26 3-27 3-29 3-30 3-33 3-34 3-35 3-37 3-38 3-39 3-40 3-41 3-42 3-43
3-2 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement • Remove side cover LH mounting screws (2 nos.). • Lift petrol tank cover. • Pull outside cover LH front lug from hole. • Cut the cable tie of wiring harness. • Use new cable tie while fitment. • Front Side - Remove 2 bolts (RH and LH) with metal collar using 5 mm Allen key. • LH Side - Remove 2 bolts with metal collar using 5mm Allen key. • RH Side - Remove 2 bolts with metal collar using 5mm Allen key. • Remove petrol tank cover mounting bolts as follows. • Rear - Remove 2 screws with plastic washer using Philips head screw driver. • Remove pillion rider seat as shown at picture. • Remove 2 bolts with washer using 10 mm ‘T’ spanner.
3-3 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement LH • Take out petrol tank cover. • Remove front bracket (1 nos.) and petrol tank mounting bolts (3 nos.). • Lift petrol tank, remove fuel pump module coupler. • Remove secondary speedometer coupler connection. 10 mm spanner Front Bracket 14 mm spanner 12 mm spanner RH 12 mm spanner LH
3-4 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement • Remove injector pipe from inline fuel filter. • Take out fuel tank. • Remove tube fuel pump to inline fuel filter. • Remove tube inline fuel filter to fuel pump. • Using coolant clamp plier, remove EVAP pipe from fuel tank.
3-5 PREVENTIVE MAINTENANCE 3-2 PREVENTIVE MAINTENANCE Air Filter Element Replacement Air Filter Element Replacement • Take out inline fuel filter. • Remove fuel tank. • Remove air filter cover box mounting screw (4 nos.) with Philips head screw driver. • Remove intake pipe metal wire hook. 1. Take out cover air filter box. 2. Air filter element. 1 2
3-6 PREVENTIVE MAINTENANCE 3-2 PREVENTIVE MAINTENANCE Air Filter Drain Tube Cleaning • Pull out tube drain, drain accumulated oil. • Pull out air filter tube drain locking clip. • Check entry duct, tube breather, tube oil return and tube drain. If crack or damage, change it. • No 1 : Entry Duct. • No 2 : Tube Breather. • No 3 : Tube Oil Return. • No 4 : Tube Drain. 2 3 4 1
3-7 PREVENTIVE MAINTENANCE Engine Oil Replacement Engine Oil Replacement • Park the vehicle on side stand. • Ensure vehicle is throughly clean. • Ensure engine is in warm condition before opening engine drain bolt. • Ensure that side stand is not bend. • Remove engine drain bolt with 18 mm spanner and take out drain bolt. • Drain the engine oil. • Take out oil strainer.
3-8 PREVENTIVE MAINTENANCE Engine oil Replacement Engine Oil Strainer Cleaning • Drain the engine oil in a clean container till last drop. • Measure the quantity of drained engine oil using calibrated measuring jar (use measuring jar 1.5 to 2 Liters capacity). • Replace 'O’ ring on drain bolt with new one once opened. • Check the quality of engine oil. • Clean the ferrous burr accumulated on top magnetic drain bolt. 1 - Clean the oil strainer by kerosene / diesel. 1 2 2 - Blow air of 2 bar pressure from inside.
3-9 PREVENTIVE MAINTENENCE Engine oil Replacement Evacuation Strainer Cleaning • Remove under belly pan mounting bolts (4 nos.) with paper washer using 4 mm allen key. LH and RH side bolt 2 paper washer per bolt. RH LH • Take out under belly pan. • Ensure that ‘O’ ring is good condition. • Ensure that oil strainer is in good condition. • Do not use abrasive material or tool to clean oil strainer.