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 Front Axle Nut Rear Axle Nut Rear Sprocket Mounting Nut Handle Bar Holder Bolts Fork Center Nut Steering Stem Nut Slotted Fork Upper Bracket Bolts RSA Mounting Bolt (Lower) Fork Under Bracket Bolts RSA Mounting Bolts(Upper) Disc Mounting Bolts (Front) Disc Mounting Bolts (Rear) Front Caliper Mounting Bolts Front Fender Mounting Swing Arm Shaft 4.5 ~ 5.0 Kgf-m 2.4 ~ 2.6 Kgf-m
6-6 FRAME AND SUSPENSION Tightening Torques Frame 2.5 ~ 3.5 Kgf-m 0.8 ~ 1.0 Kgf-m 1.8 ~ 2.0 Kgf-m 3.0 ~ 3.5 Kgf-m 1.8 ~ 2.2 Kgf-m 0.8 ~ 1.0 Kgf-m 6.5 Kgf-m 2.4 ~ 2.6 Kgf-m s Fork Pipe Top Bolts Handle Bar Weight LH & RH Pillion Stay Bolts Engine Foundation Bolts - Front Top Engine Foundation Bolts - Front Bottom Engine Foundation Bolts – Rear(Top & Bottom) Side Stand Bracket Mounting Bolts Bracket Rear Plate No
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 & 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: 325ml/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 & 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 vapours 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 vapours from canister of manifold. Evaporative Emission System & 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 • Route • Hose from Y connector to canister. • Route • 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 & ensure that it is tide with rubber clamp to frame.
6-10 FRAME & SUSPENSION Important SOP Air Filter Box / Throttle Body with Sensors Remove • Remove • RH side cover. • Take out • RH seat cowl. • RH side cover screw (4 nos.) • Metal washer • Remove • RH side cover lug from grommet. • Take out • RH side cover. • Remove • LH seat cowl. • LH side cover simultaneously. • Remove • Air filter box mounting bolts (3 nos.). • Remove • Breather pipe clip. • Breather pipe from cylinder head cover.
6-11 FRAME & SUSPENSION Important SOP Air Filter Box / Throttle Body with Sensors Removal - TMAP. - TPS. • Remove • Drain pipe clip. • Pull drain pipe from crankcase end. • Throttle body clips bolts (2 nos.). • Remove • Disconnect all coupler connection from throttle body : - Stepper motor. - Injector. • Lift air filter & throttle body. • Pull out canister to throttle body hose pipe clip. • Canister to throttle body hose pipe.
6-12 FRAME & SUSPENSION Important SOP • Remove • Throttle Cable. • TPS coupler connection. • After removal of throttle body from engine, remove throttle cable & TPS coupler from TPS Seat Cowling Removal • Remove • Rider seat. • RH grab handle mounting bolts (2 nos.). • Take out • Grab handles. • Remove • Seat cowl mounting bolts as follows : • 1 bolt with metal washer. • Metal washer. • 1 Screw. • Remove • RH side screw. • Plastic washer. • Bottom side screws.
6-13 FRAME & SUSPENSION Important SOP • Remove • Rear side lugs (3 nos.) from seat cowl slots. • Seat cowl lug from central bottom cover slot. • Take Out • RH seat cowl.
6-14 FRAME & SUSPENSION Special Tools Oil Seal & Guide Bush Fitment Tool Part No : 37 004289 For fitment of oil seal & 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 & fitment. - Holding fork inner pipe during screw cap inner pipe removal & fitment. Adaptor - Screw Cap Inner Pipe Part No : 37 004189 For tightening & loosening screw cap inner pipe Adaptor - Fork Top Bolts Part No : 37 004414 For tightening & loosening, fork top bolts.
A 6-15 FRAME & SUSPENSION Front Fork Oil Leakage Confirmation Tip Edge Take out dust cap & dust seal from its seat & 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 & order new one. Fork oil seal cleaner : Dia. 35 - 45 mm Identification - Grey colour Clean front fork by water wash (Water pressure jet to be applied from top to bottom side). Remove front fender & 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.
6-16 FRAME & SUSPENSION If oil comes out & 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 & dust seal removed condition for about 2 kms on rough road. If no oil comes out on inner pipe, then refit dust seal & dust cap in outer pipe & handover vehicle to customer & 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 & oil seal. (Do not replace fork inner pipe only by observing scoring marks visually). Refer “Fork inner pipe replacement” SOP for fork inner pipe & 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 & inner pipe. After insertion, rotate in clockwise direction by 90 deg. & confirm cleaner is inserted correctly. Now rotate the fork seal cleaner in anti-clockwise direction for 2 turns without any jerks. Note : For ease in rotation of the special tool it is recommended to removed front wheel & fender.
6-17 FRAME & SUSPENSION Front Fork Oil Leakage Confirmation Rotate the tool for two turns in anti-clockwise direction. Clean dust seal & inner pipe by clean lint free cotton cloth. Dust Seal Cleaning 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 & 11 for one more time. Carry out front fork pumping for 8 ~ 10 times. Clean oil traces on oil seal surface area. Insert the fork seal cleaner tool on inner pipe. Insert dust-cleaning side between dust seal & inner pipe as shown in photograph. Rotate the tool for two turns in anti-clockwise direction. Clean dust seal & inner pipe by clean lint free cotton. Drive the vehicle in dust cap & dust seal removed condition for about 2 kms on rough road. If no oil traces are observed, then refit dust seal & dust cap in outer pipe & handover vehicle to customer & keep vehicle under monitoring. If oil traces are observed, replace the dust seal & oil seal in pair. Refer “Dust seal & Oil seal Replacement” SOP.
Lift the vehicle from front side using suitable arrangement. Remove caliper mounting bolts (2 nos.) with 12 mm spanner & take out caliper assembly. 1. Remove front fender & 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 & take out wheel speed sensor. 6-18 FRAME & SUSPENSION Dust Seal & Oil Replacement 3 4 1 2
6-19 FRAME & SUSPENSION Dust Seal & Oil Seal Replacement 1. For vehicle LH side fork top bolt loosening : Using adaptor fork top bolt (P/N : 37 004414), 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 2 3 5 4 6 7 8
1 6-20 FRAME & SUSPENSION 1. Take out fork leg assembly from vehicle. 2. Remove outer pipe from fork top bolt threading as shown in photograph. 5. Take out fork pipe top bolt. 6. Take out lock nut. Dust Seal & Oil Seal Replacement Loosen under bracket side bolts (2 nos.) with 6 mm allen key. Hold the fork leg assembly to avoid dropping of a leg assembly during loosening of under bracket side bolts. NOTE 3. Hold piston rod using fork clamping block (P/N 37 004412) & bench vice as shown in photograph. Note : Cover the outer pipe by clean cotton cloth to avoid metal contact. 4. Remove fork pipe top bolt using adaptor fork top bolt (P/N 37 004414) holding lock nut on piston rod with 19 mm spanner. Lock Nut 1 2 3 4 5 6
6-21 FRAME & SUSPENSION Dust Seal & Oil Seal Replacement Remove fork leg from clamping block & vice. Drain fork oil. Hold fork leg assembly. Remove the dust cap. Take out rubber damper Pull out the outer pipe.
6-22 FRAME & SUSPENSION Dust Seal & 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” Dust Seal & Oil Seal Replacement Using hot air blow gun heat the fork outer pipe suitably to remove the oil seal. Please refer the information on hot air blow gun before its usage. NOTE Ensure no dent / damage happen to fork outer pipe while using screw driver when removing oil seal circlip. NOTE A B C D E F 1 2 1. Using appropriate size flat head screwdriver, remove dust seal. 2. Using appropriate size flat head screwdriver, remove the oil seal circlip.
6-23 FRAME & SUSPENSION Dust Seal & Oil Seal Replacement Precautions to be taken: Always keep nozzle away from chord. Always ensure that heat selection button is “OFF” & disconnected from power supply when unattended. Always store in dry & 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 & start the supply. Put Heating mode selection button to “fast heating mode” & hold gun at a distance @ 40 mm from Outer pipe as shown in photograph for suitably. Put OFF supply to hot air gun & 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 CAUTION Keep a piece of cloth & tap the pipe gently of remove oil seals. The outer pipe will be in hot condition. Please make sure suitable care.
6-24 FRAME & SUSPENSION Oil Seal & Dust Seal Fitment 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. Note : Clean fork outer pipe with diesel or kerosene before fitting new oil seal. Use special tool for oil seal fitment (P/N : 37 004289). 1. Assembled condition of special tool. 2. Split condition of special tool. Inner surface in contact with inner pipe Do not use special tool if dent / scratch mark found on tool inner surface (in contact with inner pipe), oil seal fitment side. 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. NOTE “Oil seal side” Embossed 1 2 3 4 7 8 5 6
6-25 FRAME & SUSPENSION 9. Insert the outer pipe. 10. Turn it upside down. 15. Fit lock oil seal using appropriate size flat head screw driver. One by one fit following parts. 11. Washer 12. Oil Seal 13. Assemble special tool on inner pipe & make ready to lift the oil seal. 14. Fit the oil seal firmly. Confirm seal fitment & then remove special the tool. 15 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 & Dust Seal Fitment 11 10 12 9 13 14
6-26 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 qty. of (325 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) & bench vice as shown inphotograph. 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 1. Fit dust seal. 2. Fit dust cap. 1 2 3 4 5 6 7
6-27 FRAME & SUSPENSION Oil Seal & Dust Seal Fitment 7. Fit fork protector & fender front. 8. Tighten its mounting allen bolts to recommended torque. 1. 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. 2. Tighten upper bracket (1.8 ~ 2.0 Kgf-m) & Under bracket (1.3 ~ 1.6 Kgf-m) side bolts to recommended torque. Take out front axle. 3. Tighten front fork top bolt using adaptor - fork top bolt to recommended torque on vehicle. 4. Fit front wheel & axle. Tighten axle bolt to recommended torque. 5. Tighten the clamping allen bolts (1.3 ~ 1.7 Kgf-m) to recommended torque. 6. Prefit front wheel speed sensor bolt, tie wheel speed sensor cable using cable tie & tighten it to recommended torque. Ensure that wheel sensor cable is routed as shown in “Front wheel sensor routing” section. 6 7 8 4 3 5 1 2 9 9. Fit caliper assembly & tighten its mounting bolts to recommended torque. 10. Take the vehicle down & remove overhead structure hanging belt from vehicle. 10
Oil Seal & Dust Seal Fitment “Key Precautions” to remember during dust seal & oil seals replacement. Always use “Adaptor-Fork top bolt with nylon insert” for removing & tightening fork top bolt. If not used, top bolt will gets damage. Take due care while handling fork inner pipe & 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 & quantity for desired fork performance. (DO NOT USE FORK OIL BEING USED FOR OTHER MOTORCYCLE i.e. 10W20) 6-28 FRAME & SUSPENSION Fork Oil Level Grade : PRF001 Fork Oil Quantity : 325 ml / leg Front Fork Oil Grade & Quantity
6-29 FRAME & SUSPENSION Hold fork inner pipe using fork clamping block (P/N 37 004412) & bench vice as shown in photograph. Connect hot air blow gun chord socket to 230V AC single phase power supply & start the supply. Put Heating mode selection button to “fast heating mode” & hold gun at a distance @ 40 mm from inner pipe as shown in photograph suitably. Put OFF supply to hot air gun & keep it on safe place. Fork Inner Pipe Replacement Remove screw cap inner pipe with adaptor screw cap inner pipe (P/N : 37 004189). NOTE NOTE 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. Loctite is applied to screw cap inner pipe threads. Use adaptor screw cap inner pipe (P/N : 37 004189).
6-30 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. Piston rod assembly Screw cap inner 2. Take out piston rod assembly along with screw cap inner. 1 2 3 4 5 6
Threaded portion to be cleaned using nylon brush Threaded portion to be cleaned using nylonbrush 6-31 FRAME & SUSPENSION Fork Inner Pipe Replacement 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 & outer pipe. 1. Take out spacer tube. Fork sub parts cleaning : Clean fork inner pipe, internal thread portion & screw pipe cap inner external threaded portion using nylon brush. 2. Take out main spring. 1 2
6-32 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. Loctite should not drop on any other part except thread area of screw cap inner pipe. Main spring to be assembled as shown in photograph. Fork Inner Pipe Replacement NOTE NOTE All fork sub parts to be cleaned using diesel / kerosene Ensure rubber parts (O-rings, seal etc) are not to be cleaned with above mention cleaning agent. Closed coils downwards i.e towards axle clamp. NOTE 1 2 3 4 5
6-33 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 & clamp it on bench vice. Fork Inner Pipe Replacement NOTE Clean the Loctite spillage if any. Insert screw cap inner pipe. Prefit it with hand & confirm proper thread matching.
Max Min 6-34 FRAME AND SUSPENSION Rear Brake Fluid Reservoir Front & Rear Brake Fluid Level • Front brake fluid reservoir is located on RH side of Handle bar. • Rear brake fluid reservoir is located behind RH pillion holder bracket. • To check the brake fluid level, Park the vehicle using rear wheel stand. Front Brake Fluid Reservoir • Always ensure that brake fluid level is above ‘MIN’ mark given on inspection Window. • In case of level drop, use only DOT - 4 brake fluid (from sealed container) for top up & replacement. Notes: • In case ABS indicator gets ON during vehicle running, bring the vehicle to nearest MODENAS dealership / MODENAS service center 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 & rear brakes simultaneously . • Always slow down when cornering. The anti-lock brake system cannot prevent accidents resulting from excessive speeds. 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) ( ABS ) : With Ignition switch ON & KILL switch ON the ABS indicator glows. When vehicle speed is more than 10 Km/hr the ABS indicator goes off, if this indicator glows while in running, it means there is problem with ABS system.
Twin Channel Antilock Brake System Block Diagram Working : In ABS system, the ABS unit detects the possibility of wheels getting locked by taking input from speed sensor located at both wheels, When the wheels are about to lock, the hydro-electricals controller controls brake caliper fluid pressure & thus prevent wheels from getting locked, avoiding possibility of accident. ABS Unit : ABS unit is a combination of Electrical & hydraulic controls. The ABS ECU receives pulse signal from both the wheel speed sensors accordingly it controls 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 & 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 fluid to flow back to reservoir . Wheel Speed Sensors : These are HALL effect type speed sensor. It senses the pulse from sensor disc mounted on wheels & convey it to ABS unit. 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 6-35 FRAME AND SUSPENSION
6-36 FRAME AND SUSPENSION ABS Failure Code Failure Modes of ABS ABS/ESP 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
6-37 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
6-38 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)
6-39 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
6-40 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
1 Chapter 7 Electrical System Table of Contents Battery ............................................................... 7-2 Do’s and Dont’s ................................................. 7-4 Electrical Checking System .............................. 7-8 Standard Operating Procedure ........................ 7-19 Battery Charging & Low Battery Indication Circuit ................................................................. 7-36 Ignition Circuit …………………………………… 7-37 Horn Circuit ........................................................ 7-38 Brake Lamp Circuit ............................................. 7-39 Fuel Pump Circuit ............................................... 7-40 Starter Motor Circuit ...…………………………… 7-41 Side Stand Circuit ............................................... 7-42 Radiator Fan Motor Circuit ................................. 7-43 Side Indicator Circuit .......................................... 7-44 Fuel Meter Circuit ............................................... 7-45 Fuel Injector Circuit ............................................ 7-46 EVAP Purge Valve Circuit ................................. 7-47 MIL Indication Circuit .......................................... 7-48 Low Oil Pressure Indication Circuit ................... 7-49 Engine RPM Indication Circuit ........................... 7-50 ABS Circuit ......................................................... 7-51 Lighting Circuit .................................................... 7-52 71
7-2 ELECTRICAL SYSTEM Battery Battery Technical Specification • Make Exide • Terminal Voltage 12 Volt • Type VRLA Battery • Capacity 8 Ah • ChargingCurrentSpecification 4.0 Amp • ChargingVoltageSpecification 14.5 + 0.1 V • Battery Charger Metafab/ AppleEnergy Make VRLA Battery Initial Filling Step 1: Get the battery ready Place the battery on a flat leveled and preferably on a insulated surface. Remove the filler port seal of the battery. Fill erport seal Seal Plug cap strip Step 2: Get the electrolyte ready Remove electrolyte container from the packing. Remove the sealing cap plug strip. Keep the sealing cap plug strip aside as this is to be used as battery sealing plug strip later.
7-3 ELECTRICAL SYSTEM Battery Step 3 : Fill the battery Hold the electrolyte container upside down. Place the container upright on battery. Match the 6 seals with the respective filler ports. Note: Ensure the container is upright and not tilled. If tilled the electrolyte might fail to flow. Now force the container down until seals get pierced. Step 4 : Check the electrolyteflow Make sure that air bubbles are visible in the electrolyte and which is seen in all the 6 tubes of the container. Leave the container on the battery as it is for 30 minutes. Step 5 : Take away the bottles Be sure that the entire electrolyte has flown down inside the battery. Tap the bottom of the container and gently remove the empty container. Step 6 : Attach the sealing cap Fit the sealing cap plug strip tightly on the filler ports of the battery. Ensure by pressing firmly that the cap has become flush with the top surface of battery. Step 7 : Charge the battery Charge the battery on recommended VRLA battery charger as per standard SOP. Never use conducting materials like screwdrivers which produce the spark near battery terminals. Do not add any additional electrolyte. NOTE
7-4 ELECTRICAL SYSTEM Do’s and Dont’s Do's Dont's • Do not apply grease to poles/terminals. • Apply petroleum jelly to battery terminals. 3 • Always charge the battery with the help of recommended VRLA battery charger. • Do not use any other battery charger for charging VRLA battery. • Check open circuit voltage by multimeter • Do not short circuits the poles to check battery condition. • Always use battery tester for checking condition of VRLA battery. • Do not fit extra electrical accessories. This will result in wiring getting short & battery would get discharged. This will shorten life of battery. • Use proper tools. (10 mm T spanner or phillips screw driver). • Do not hammer battery terminals.
7-5 ELECTRICAL SYSTEM Do’s and Dont’s Do's Dont’s Ensure that horn is firmly fitted on fairing structure central. Do not apply pressurised water jet directly on horn resonator. Ensure that horn is free from dust and mud accumulation. Never adjust nut on horn cap side & bracket end (back side) as it will result in horn malfunctioning & failure. Ensure that horn wires are intact. Do not remove silicon sealant from adjustment screw as it will result in water entry into horn. Ensure that horn switch button in good condition. Ensure that battery is fully charged. Do not hit by mallet/screw driver on horn resonator. Adjust horn by phillips screw driver - without removing silicon sealant from adjustment screw. - by rotating the screw in direction of arrow provided in the screw. Ensure that resonator is not pressed by any portion of cables or wiring harness as it will result in distorted sound.
7-6 ELECTRICAL SYSTEM Do’s and Dont’s Ignition System Do's • Always install recommended capacity of battery on the bike. • Always replace spark plug by correct heat range plug. • Check & adjust spark plug gap periodically. Adjust it to 0.7 ~ 0.9 mm by wire gauge. • Replace spark plug at every 40,000 kms. • Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3 ~ 1.5 Kgf-m. • Ensure H.T. cable secondary connection is firmly fitted in spark plug cap and H.T. coil. • Ensure that magneto coupler is firmly fitted. • Always use a right size socket during removal and re-installation of spark plug. • During periodic service make use of spark plug cleaning machine to clean spark plug electrodes & check proper functioning of all spark plugs. Dont’s • Do not replace spark plug by non recommended one (different heat range). • Never short circuit H.T. coil primary wire to ground. It could lead to ECU failure. • Do not adjust spark plug gap with any instruments like screw driver, pliers etc.
7-7 ELECTRICAL SYSTEM Do’s and Dont’s Lights Do's • Ensure that there is no dust and water entry in bulb housing. • Ensure that all fixing screw of bulb housing are intact. • Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is intact. • Check DC Voltage Regulator’s output voltage periodically. Ensure that voltage is within specified limits. • Check that couplers and wires of bulbs are in good condition. Dont’s • Do not install a lower / higher capacity battery than what is recommended. • While washing vehicle do not direct pressurized water jet on Head Light, Tail Light, Indicators. • Do not drive the vehicle by keeping brake pedal pressed. • Do not start Vehicle with light control switch in ON condition switches Do‘s • Always clean switch assembly with soft cloth. • After washing the vehicle ensure to apply dry air on switches before operation. • Ensure that rear brake switch is free from dust, dirt & mud accumulation. •Always ensure that grommets provided on clutch switch, front brake switch and rear brake switch are intact. • Always apply WD-40 electrical contact cleaning spray to sticky switches. Dont’s • Do not apply direct pressurized water jet on control switches. • Do not lubricate electrical switches by oil or grease. • Do not over tighten the switches. •Do not add extra electrical loads e.g. musical horns, additional horns, buzzers as it will reduce switch contact life & battery life &battery life. • Do not tamper / alter rear brake switch spring. • Do not operate switch immediately after water servicing.
7-8 ELECTRICAL SYSTEM Electrical Checking System Sr.No. Fuse Effect of Fuseblowing No & Rating Description 1 N/A N/A N/A 2 F2-7.5 Amp Electrical cluster Primary Speedo cluster will not work. Secondary Speedo work. 3 F3-15 Amp Main relay Contacts + ECU ECUfunction OFF& Main relay do not get ON. 4 F4-15 Amp H.T. Coils Supply 12V Supply to H.T. coils is disconnected ignition system will not work. 5 F5-7.5 Amp Radiator Fan Radiator fan motor not working. 6 F6-15 Amp Lighting All lightings (Head light, indicator, tail light, horn) do not work & vehicle getstart. 7 F7-7.5 Amp Engine Kill Switch Input Engine Kill Switch & ECUis disabled enginecannotstart. 8 F8-7.5 Amp Speedometer Primary, Secondary Speedometer don’t work. 9 F9-7.5 Amp ABS 9MECU ABS System will not work, ABS indicator remains ON & vehicle speed is not indicated in speedometer. Applicability Matrix & Malfunctioning Effect • Effect it ABS Fuse (10A) & (15A) is blown off : ABS Fuse 10A - for Solenoid. ABS Fuse 15A - for Pump. Location : Near Fuse Box. Effect : ABS do not work. ABS indication continuous ON in speedometer. Vehicle will work as a normal disc brake vehicle. • Effect it Fuse in (Fuse Box Assembly) is blown off
7-9 ELECTRICAL SYSTEM Electrical Checking System Lift Press • Checking Procedure Fuse 7.5A, 10A & 15A are located inside the main fuse box as shown in photograph. • ABS Fuse 10A & 15A Location : It is located near main fuse box as shown in photograph. • All fuses will be accessible as shown in photograph. • To open main fuse box cover. Press lock provided on RH side of fuse box & lift the fuse box cover as shown in photograph.
7-10 ELECTRICAL SYSTEM Electrical Checking System OR Press Press • Remove fuse by nose plier as shown in photograph. • On vehicle Check the continuity of fuse with Digital multi meter. Continuity shown - Fuse ok. No Continuity - Fuse blown off. If it is blown off, replace by new one of same capacity. Lift • ABS fuses will be accessible as shown in photograph • Check continuity as shown in photograph. • To open ABS fuse box cover. Press both sides simultaneously and lift ABS fuse box cover as shown in photograph.
7-11 ELECTRICAL SYSTEM Electrical Checking System Ignition Switch Measuring & Testing Equipment : Multimeter SOP : • Switch OFF Ignition key. • Disconnect Ignition switch’s coupler. • Check continuity between wires in ‘ON’ & ‘OFF’ position. Standard • Beep Sound & Continuity in ‘ON’ position. No continuity in ‘OFF’ position. Kill Switch Measuring & Testing Equipment : Multimeter SOP : • Put ignition switch OFF. • Put kill switch OFF. • Set multimeter at continuity range. • Connect multimeter as shown in the table. Front Brake Light Switch Meter Range Wire Connections Condition Result Meter +ve Meter -ve Engine ONcondition Continuity isshown Continuity Mode Gray/Red Brown/Blue Engine OFF condition No continuity Meter Range Connections ContinuityCheck Continuity Mode Meter +ve Meter -ve OFF - No continuity Brown White wire ON - Continuity Measuring & Testing Equipment : Multimeter SOP : • Turn ‘ON’ the ignition switch. • The brake light LED bank should glow brightly when the front brake lever is pressed. • If it does not, check the front brake switch. Brown Blue Continuity check bymultimeter Lever Pressed l l Continuity isshown Lever Released l l No Continuity