Pusat Panggilan Pelanggan 1 800 880 181 Ahli Kumpulan : 99923-L055-00 (JILID 1 - 4/202 3) 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 DM250 WhatsApp Talian Khidmat Pelanggan +6019-570 8135 Pengedar : SERVICE CENTER Kedah Kawasan Perindustrian Gurun, 08300 Gurun, Kedah. : 04-466 8236 : 04-466 8109 Selangor No. 62 & 64, Jalan Pluto Ay, U5 Ay, Seksyen U5, 40150 Shah Alam, Selangor. : 04-466 8160 : 03-7845 1025 Johor No. 1, Jalan Kempas 2, Taman Tanah Tampoi 81200 Johor Bahru, Johor. : 07-236 1695 : 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 : 09-512 3383 Perak No 123, Jalan Raja Musa Aziz, 30300 Ipoh, Perak : 05-249 8962/63 : 05-249 8969
SERVICE MANUAL DM250
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. DM 250
15 DOMINAR 250 SERVICE MANUAL © 202 3 by Motosikal Dan Enjin Nasional Sdn. Bhd. First Edition, April 202 3 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 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.
Table of Contents Before Servicing .................................................1-2 Model Identification ............................................1-5 General Specification .........................................1-6 Periodic Maintenance Chart ..............................1-8 Exclusive Special Tools - Engine ......................1-10 Common Special Tools - Engine .......................1-12 Special Tools - Frame & Suspension ................1-14 Part Comparison ................................................. 1-16 1 Chapter 1 General Information
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 manufacture 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 250
3-2 PREVENTIVE MAINTENANCE 1-6 GENERAL INFORMATION General Specifications Engine & Transmission : 4 Stroke, SingleCylinder : 72mm : 61.1mm : 11.9 :1 : 248.77 cc : 1550 + 100 RPM : 19.86 kW @ 8500 RPM : 23.5 N.m @ 6500 RPM : DC, Fuel Injection : Fuel Injection : 2 Nos LHS : (CHAMPION (RG6HCC) / BOSCH (UR6CE) CENTRAL : (CHAMPION (RER6YCA) / BOSCH (YR5NEO) : 0.8 ~ 0.9 mm : Pressurized oil supply : 6 Speed constant mesh : 1 Down 5 Up : 2.67 (80T / 30T) : 1st gear : 2.67 (32 / 12) 2nd gear : 1.86 (26 / 14) 3rd gear : 1.42 (27 / 19) 4th gear : 1.14 (24 / 21) 5th gear : 0.96 (22 / 23) 6th gear : 0.84 (21 / 25) : 3.00 (45T / 15T) : SAE 10W50 API SN JASO MA2 GRADE, FULLY SYNTHETIC : 1700 ml : 1950 ml : Liquid cooling Engine Bore Stroke Compression Ratio Engine Displacement Idling Speed Max. net Power Max.net Torque Ignition System Fuel System Spark Plug Spark Plug Gap Lubrication Transmission Gear Shifting Pattern Primary Reduction Gear Ratios Final Drive Reduction Engine Oil Grade Refill Quantity Overhaul Quantity Engine Cooling
1-7 GENERAL INFORMATION General Specifications Body and Chassis Perimeter Front : Brakes : 13 Liters Rim Size : Super Unleaded RON - 95 & above (Research Octane Number) USD Front Fork (Up Side Down Front Fork) Front & Rear : Frame Type : Suspension Twin channel ABS Rear : Nitrox Mono Shock Absober Front : 100 / 80 - R17, 52P,Tubeless Rear : Tyres 130 / 70 - R17, 62P,Tubeless Tyre Pressure (25 PSI) Rear(Solo) : Front :1.76 Kgf / Cm2 Rear(with Pillion) :2.25 Kgf / Cm2 2.00 Kgf / Cm2 (28.4 PSI) (32 PSI) 2.50 x 17” 3.00 x 17” Front : Rear : Fork Oil Fuel Tank Capacity Fuel Grade Quantity Grade : PRF001 : 325 ml
1-8 GENERAL INFORMATION General Specifications Weight Vehicle Kerb Weight Vehicle Gross Weight : 180 Kg : 330 Kg Electrical Dimension : 2156 mm : 1112 mm : 1453 mm : 800 mm : 836 mm : 157 mm Length Width Height Wheel Base Ground Clearance Seat Height 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 TemperatureIndicator Low Battery Indicator Bajaj Logo RPM Limit Service Reminder Side Stand Indicator ABS Indicator Rear Number Plate Lamp Horn : 12V, 2.5A : LED : LED, Yellow : 12V (DC) : 12V 8Ah, VRLA : LED : LED : LED : LED : LED : LED : LED : LCD : LCD Bar : LED : LED : LED : LED : LED : LED : LCD : LED
1-9 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. Frequency Operation Whichever comes first Remarks Odometer Reading Servicing 500~750 KM 4,500~5,000 KM 9,500~10,000 KM 14,500~15,000 KM 19,500~20,000 KM 24,500~25,000 KM 29,500~30,000 KM 1. Clean the vehicle with water & dry completely Ensure to prevent water entry in Petrol tank. Silencer & electrical parts. Use caustic free detergent for washing .During water wash ensure to cover silencer tail properly. √ √ √ √ √ √ √ √ 2. Engine Oil* SAE 10W50, Grade APISN, JASO “MA2 Fully Synthetic R,Top Up R R R R R R R 3. Engine Oil Filter R R R R R R R R 4. Oil Strainer Oil strainer cleaning at the time of oil change. C C C C C C C C 5. Spark Plug C&A every 20,000km, change every40,000km C,I,A C,I,A 6. Air Cleaner Element Cleaning is notrequired. Change every20,000km R R 7. In line paper filter Change every 20,000km R R 8. Fuel Pipe Replace if required C,R C,R 9. Valve Tappet clearance Check and adjust every 20,000km C,A C,A 10. Sealed drive chain cleaning & lubrication C, L,A C, L,A C, L,A C, L,A C, L,A C, L,A C, L,A C, L,A 11. Air filter drain tube C,L C,L C,L C,L 12. Silencer drain hole cleaning C,L C,L C,L C,L C,L C,L C,L C,L 13. End chamber tail pipe cleaning C,L C,L C,L C,L C,L C,L C,L 14. Brake pedal pivot pin Use recommended AP grease. C,L,R C C,L, R C,L,R C,L,R C,L,R C,L,R C,L,R 15. Brake lining or pad - Check wear indicator Replace brake shoes /brake pad at every 15000 Kms C,R C,R C,R C,R R C,R C,R R 16. Brake fluid level** - top up / replace Use recommended brakefluid (DOT4). C,A,R C,A R 17. Disc brake assembly - Check functionality, leakage or any damage C C C C C C C C 18. All cables - free play C,A C,A C,A C,A C,A C,A C,A C,A 19. Wiring harness & Battery connections - routing, tie bands & clamps tightness. C,A,T C,A,T C,A, T C,A,T C,A,T C,A,T C,A,T C,A,T 20. Ignition switch barrel cleaning & handle bar control switches contacts cleaning Use recommended WD40 spray I,C I,C I,C I,C I,C I,C I,C I,C * 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 kms ** 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 End chamber to be cleaned using brush Customer to apply OKS chain lube or equivalent spray at every 500 kms.
1-10 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. Frequency Operation Whichever comes first Remarks Odometer Reading Servicing 500~750 KM 4,500~5,000 KM 9,500~10,000 KM 14,500~15,000 KM 19,500~20,000 KM 24,500~25,000 KM 29,500~30,000 KM 21. Battery charge condition Use recommended midtronix battery tester & VRLA battery charger. C,A C,A C,A C,A C,A C,A C,A C,A 22. Steering play C,A C,A C,A C,A C,A C,A C,A C,A 23. Steering stem bearing*** & Cap steering bearing (Plastic)** Check and replace if damaged. Use grease for lubrication. I,C L,R I,C, L,R I,C, L,R I,C, L,R 24. Side stand Pivot bolt area Use recommended grease. C,L C,L C,L C,L C,L 25. All fasteners tightness I,T I,T I,T I,T I,T I,T I,T I,T 26. General lubrication - Clutch lever , front brake lever , kick lever Use recommended AP grease. L L L L L L L L 27. Coolant level in expansion tank Use recommended 'Ready touse coolant'. 28. Coolant hose damage/clamps/leakage I,R I,R I,R I,R I,R I,R I,R 29. Radiator fins I I I I I I I 30. EVAP Y Connector drain tube cleaning** Applicable for Product with EVAP system only. I,L I,L I,L I,L I,L I,L I,L I,L 31. Front fork pipe & dust cap cleaning Pull down the front fork dust cap and clean the fork pipe and dust cap with water, refit the dust capto its original position after cleaning C,L C,L C,L C,L C,L C,L C,L C,L * 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 kms ** 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 I,C,R I,C,R I,C,R I,C,R I,C,R I,C,R I,C,R I,C,R
1-11 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
1-12 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
1-13 GENERAL INFORMATION Common Special Tools - Engine Magneto Rotor Puller 37 0042 76 For removing magneto rotor from crankshaft For removing LH 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 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
For removing central spark plug 1-14 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
1-15 GENERAL INFORMATION Special Tools - Frame & Suspension Fork Pipe Splitting Tool 37 1740 26 For splitting 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
1-16 GENERAL INFORMATION Special Tools - Frame & 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.
Swing Arm Assembly Swing Arm Assembly 56DT28Y9 JF122100 NA Design is different than Dominar 400UG Part Comparison Frame Assembly Frame Assembly JF111192 JF111280 NA Bracket starter relay and bush design is different than Dominar 400UG Bracket starter relay Bush Bracket starter relay Bush Model Dominar 400UG Dominar 250 Model Dominar 400UG Dominar 250 Photograph Photograph Part Name Part No Description Part Name Part No Description 1-17 GENERAL INFORMATION
Cap - Tube Swing Arm JF122104 With Cap - Tube Swing Arm 1-18 GENERAL INFORMATION Chain Adjuster Chain Adjuster JF122049 JF122115 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph NA Part Name Part No Description NA NA NA Part Comparison
Cover Chain Assembly Cover Chain Assembly DT181308 JF181377 NA Design is different than Dominar 400UG Chain Slider Chain Slider JF12016 JF122105 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-19 GENERAL INFORMATION
Rear Wheel Rear Wheel JF131217 JF131242 • With machined surface • Size ( 4.0 x 17'' ) provided on wheel • Without machined surface • Size ( 3.0 x 17'' ) provided on wheel Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Rear - Disc Brake Rear - Disc Brake JF131861 Same as existing Dominar 400UG Outer diameter - Ø 230 mm Same as existing Dominar 400UG Model Dominar 400UG Dominar 250 Part Name Part No Description Part Comparison 1-20 GENERAL INFORMATION
Front Wheel Front Wheel JF131026 JF131039 • With machined surface • Size ( 3'' x 17'' ) provided on wheel • Without machined surface • Size ( 2.5'' x 17'' ) provided on wheel Front - Disc Brake Front - Disc Brake JF131876 JF131861 Outer diameter - Ø 320 mm Outer diameter - Ø 300 mm Tyre Tyre Front - JG131038 , Rear - JG131245 Front - DT131018 , Rear - DT131222 Front - 110 / 70 , Rear - 150 / 60 Front - 100 / 80 , Rear - 130 / 70 Sprocket - Rear Wheel ( Sub Part of Kit Chain Sprocket ) Sprocket - Rear Wheel ( Sub Part of Kit Chain Sprocket ) Refer SPC Refer SPC No. of teeth - 45 No. of teeth - 46 Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description Part Comparison 1-21 GENERAL INFORMATION
Underbracket Underbracket JF121020 JF121069 Inner diameter - Ø 54 mm Inner diameter - Ø 48 mm Front Fork Assembly Front Fork Assembly JF121018 JF121068 • Fork inner tube outer diameter - Ø 43 mm • Without bush on inner pipe • Fork inner tube outer diameter - Ø 37 mm • With bush on inner pipe Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Ø 54 Ø 48 Bush Part Comparison 1-22 GENERAL INFORMATION
Front Fender Front Fender DT181425 JF181479 NA Design is different than Dominar 400UG Upper Bracket Upper Bracket JF151040 JF151057 Inner diameter - Ø 51 mm Inner diameter - Ø 45 mm Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Ø 51 Ø 45 Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-23 GENERAL INFORMATION
Bracket Speedometer Bracket Speedometer JF171087 JF171043 (Same as existing Dominar 400) NA Design is different than Dominar 400UG Flap - Front Fender Flap - Front Fender JF181423 JF181480 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-24 GENERAL INFORMATION
Speedometer Tank Assembly Speedometer Tank Assembly DT402410 JF402407 (Same as existing Dominar 400) Without Mode and Set push buttons With Mode and Set push buttons Speedometer Assembly Speedometer Assembly DT402409 JF402418 Without Mode and Set push buttons With Mode and Set push buttons Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-25 GENERAL INFORMATION
Starter Relay Starter Relay JN351604 JP403000 • Without Main fuse 30A • Coupler : 2 pin, Blue color • With Main fuse 30A • Coupler : 4 pin, Natural (White) color Wiring Harness Wiring Harness JF402248 JF402264 • Primary speedometer coupler - 12 pin • With gear indicator switch coupler - 6 pin • Starter relay coupler - 2 pin • With 30A Main Fuse in Fuse Box • Primary speedometer coupler - 16 pin • Without gear indicator switch coupler - 6 pin • Starter relay coupler - 4 pin • Without 30A Main Fuse in Fuse Box Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Fuse box for Main Fuse 30A Part Comparison 1-26 GENERAL INFORMATION
Oxygen Sensor Oxygen Sensor JG511010 JP591065 NA Design is different than Dominar 400UG Bracket Starter Relay Bracket Starter Relay JF111097 JF113857 NA Bracket starter relay design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-27 GENERAL INFORMATION
Silencer Assembly Silencer Assembly JF591212 JF591303 NA Exhaust pipe design is different than Dominar 400UG T Joint Assembly T Joint Assembly DT601219 DT601211 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-28 GENERAL INFORMATION Exhaust pipe Exhaust pipe
Bracket Belly Pan - Front Bracket Belly Pan - Front DT181307 JF181354 NA Design is different than Dominar 400UG Belly Pan Middle Belly Pan Middle JF181313 JF181351 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison 1-29 GENERAL INFORMATION
1-30 GENERAL INFORMATION Bracket Belly Pan - Rear Bracket Belly Pan - Rear JF181309 JF181355 NA Design is different than Dominar 400UG Connecting tube Connecting tube Air Filter Assembly Air Filter Assembly JF581029 JF581035 Connecting tube : Outer diameter - Ø 65 mm Inner diameter - Ø 55.6 mm Connecting tube : Outer diameter - Ø 57 mm Inner diameter - Ø 48.1 mm Ø 65 Ø 57 Ø 48.1 Ø 55.6 Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison
Throttle Body Assembly Throttle Body Assembly JF611203 JF611206 Lenght : 84 mm Lenght : 80.5 mm 1-31 GENERAL INFORMATION Output Sprocket (Sub Part of Kit Chain Sprocket) Output Sprocket (Sub Part of Kit Chain Sprocket) Refer SPC Refer SPC No of teeth : 15 No of teeth : 14 Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description 84 80.5 Part Comparison
Radiator Fan Radiator Fan JF601400 JF601235 NA Design is different than Dominar 400UG HT Coil Assembly HT Coil Assembly DT351204 JF351213 Twin ouput Single ouput Kit Piston Rings Kit Piston Rings Refer SPC (Piston ring top, Piston ring second and Piston oil ring) Refer SPC (Piston ring top, Piston ring second and Piston oil ring) Outer diameter - Ø 89 mm Outer diameter - Ø 72 mm ABS Unit ABS Unit JF131882 JF131911 Outer diameter - Ø320 mm Software is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description Model Dominar 400UG Dominar 250 Part Name Part No Description 1-32 GENERAL INFORMATION Part Comparison
1-33 GENERAL INFORMATION Cam Holder Assembly Cam Holder Assembly Refer SPC Refer SPC NA Design is different than Dominar 400UG Cylinder Head Assembly Cylinder Head Assembly Refer SPC Refer SPC Triple spark design Twin spark design Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison
1-34 GENERAL INFORMATION Valve Intake Valve Intake JY511221 JY511248 • Outer diameter : Ø 36 mm • Identification : JYI • Outer diameter : Ø 29 mm • Identification : KTI Valve Exhaust Valve Exhaust JY511270 JP511228 • Outer diameter : Ø 29 mm • Identification : DTE • Outer diameter : Ø 24 mm • Identification : KTS Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description JYI Ø 36 Ø 29 DTE Ø 29 Ø 24 Part Comparison
1-35 GENERAL INFORMATION Camshaft Assembly - Exhaust Camshaft Assembly - Exhaust JF511255 JF511260 • With double groove • Collar away from cam sprocket • Without groove • Collar near to cam sprocket Camshaft Assembly - Intake Camshaft Assembly - Intake JF511253 JF511258 • With double groove • Collar away from cam sprocket • With single groove • Collar near to cam sprocket Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison
1-36 GENERAL INFORMATION Gasket Cylinder Head Gasket Cylinder Head JY511139 JY511149 NA Design is different than Dominar 400UG Cylinder Block (Sub part of Kit Block Piston) Cylinder Block (Sub part of Kit Block Piston) Refer SPC Refer SPC • Inner diameter : Ø 89 mm • 373.23 cc embossed • Inner diameter : Ø 72 mm • 248.77 cc embossed Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Ø 89 Ø 72 Part Comparison
1-37 GENERAL INFORMATION CrankShaft Assembly CrankShaft Assembly JY531020 JY531060 NA Connecting rod and web crankshaft design is different than Dominar 400UG Piston (Sub Part of Kit Block Piston) Piston (Sub Part of Kit Block Piston) Refer SPC Refer SPC • Outer diameter : Ø 89 mm • With Square mark • Outer diameter : Ø 72 mm • With Triangle mark Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description EX IN EX IN Part Comparison
Sensor Pick Up and Switch neutral Sensor Pick Up and Switch neutral JF351804 JF351805 • With 6 pin coupler & 4 pin coupler • With Seven actuating point • With 4 pin coupler • With Single actuating point 1-38 GENERAL INFORMATION Rotor Rotor JF351013 JY351025 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison Actuating points Actuating points
Intake Pipe Intake Pipe DT581401 DT581408 Outer diameter : Ø 65 mm Outer diameter : Ø 57 mm 1-39 GENERAL INFORMATION Body Starter Clutch Body Starter Clutch JF351014 JF351019 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Ø 65 Ø 57 Part Comparison
1-40 GENERAL INFORMATION Cable relay to Starter Motor Cable relay to Starter Motor JF402212 JP402203 Center distance : 650 mm Center distance : 840 mm Fork Protector Fork Protector LH - JF181471 , RH - 181472 LH - JF181481 , RH - 181482 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison LH RH LH RH
Pipe Tank Expansion Pipe Tank Expansion JF601213 JF601220 NA Design is different than Dominar 400UG 1-41 GENERAL INFORMATION Balancer Assembly Balancer Assembly JY531220 JF531214 NA Design is different than Dominar 400UG Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Part Comparison
1-42 GENERAL INFORMATION Leg Guard Leg Guard LH - JF231209 , RH - 231210 LH - JF231239 , RH - JF231240 Without bush With bush Clutch Assembly Clutch Assembly No. of plates 7 7 Fitment area Side friction plate (3nos) Side friction plate (4nos) Side friction plate (3nos) Side friction plate (4nos) Orientation Straight petals Straight petals Same as Dominar 400 Offset petals No. of petals 4 8 4 0 4 0 Dimension of petals on friction plate Model Dominar 400UG Dominar 250 Photograph Part Name Part No Description Parameters Dominar 400UG Dominar 250 4.7 10.5 4.7 8 Clutch housing, Hub & whell are same for both Dominar 400 & Dominar 250 Dominar 400UG center friction plate - Straight petals Dominar 250 center friction plate - Offset petals Part Comparison