1-43 GENERAL INFORMATION Tightening Torque - Engine Sr.No. Parameter Torque Values (Kgf-m) 1 Cover cylinder head bolts 1 - 1.2 2 Cylinder head bolts M10 : 6 - 6.5 and M6 :1 - 1.2 3 Intake Manifold fitted on head bolts 0.7 - 0.9 4 Camshaft sprocket bolt 4.2 - 4.4 5 Chain tensioner bolt 1 - 1.2 6 Chain guide bolt 1 - 1.2 7 Primary gear nut 15 - 15.5 8 Clutch nut 12 - 12.5 9 Rotor bolt 10 - 10.5 10 Output sprocket bolt fitted on output shaft 1 - 1.2 11 Guide gear bolt fitted on gear change drum 1 - 1.2 12 Gear change lever bolt 1 - 1.2 13 Gear change linkage bolt 1.6 - 1.8 14 Cover engine oil filter bolt 1 - 1.2 15 Inhibitor bolt 1 - 1.2 16 Drain bolt 1 - 1.2 17 Cover water pump bolts 1 - 1.2 18 Balancer driven gear nut 5.9 - 6.1 19 Balancer driven gear bolt 3.9 - 4.1 20 Rotor water pump nut 0.7 - 0.9 21 Evacuation pump bolts 1 - 1.2 22 Oil pump bolts 1 - 1.2 23 Radiator nuts 0.8 - 1 24 Pipe coolant T Pipe bolts 1 - 1.2 25 Clutch cover bolts 1 - 1.2 26 Position plate bolt fitted on clutch cover 0.6 - 0.8 27 Magneto cover bolts 1 - 1.2
1-44 GENERAL INFORMATION Tightening Torque - Engine Sr.No. Parameter Torque Values (Kgf-m) 28 Cover LH RR Bolts 1 - 1.2 29 Air filter assembly bolts 1 - 1.2 30 Cover air filter bolts 0.25 - 0.3 31 Silencer mounting bolt at cylinder head 2 - 2.2 32 Silencer mounting bolt on RH Stay 2 - 2.2 33 End chamber mounting bolt 2.6 - 2.8 34 End chamber clamp bolt 1.8 - 2 35 Belly Pan mounting bolt 0.5 - 0.7 36 One way clutch bolts on rotor 1.4 - 1.6 37 Starter Motor bolts 1 - 1.2 38 ECU mounting bracket nuts 0.8 - 1 39 OHC Cover bolts (camholder) 0.8
1-45GENERAL INFORMATION Tightening Torque - Frame Sr.No. Parameter Torque Values (Kgf-m) 1 Rider footrest bolt 1.8 - 2 2 RR Unit bolts 1 - 1.2 3 HT Coil bolts 1 - 1.2 4 Front seat bolts 0.8 - 1.2 5 Engine mounting bolt front Top : 2.4 – 2.6 | Bottom : 4.5 - 5 6 Engine mounting bolt rear 6.5 7 Steering slotted nut 0.5 8 RSA Top nut 4.5 - 5 9 RSA Bottom nut 4.5 - 5 10 Swing arm shaft nut 13 - 15 11 LH Stay bolt 2.4 - 2.6 12 RH Stay bolt 2.4 - 2.6 13 ECU Mounting bracket nut 0.8 - 1 14 Front fender bolt 1 - 1.2 15 Side stand bolt 1.8 - 2.2 16 Front axle nut 2.4 - 2.6 17 Axle clamping allen bolt 1.3 - 1.6 18 Rear axle nut 9 - 11 19 Front disc mtg bolt 2.7 - 3.3 20 Front Sensor disc bolt 2.7 - 3.3 21 Front Caliper mtg bolts 2.2 - 2.8 22 Rear disc mounting bolt 0.9 - 1.1 23 Rear Sensor disc bolt 0.6 - 0.8 24 ABS Mtg bolt 0.7 25 Rear Master cylinder mtg bolt 0.6 - 0.8 26 Rear sprocket nut on coupling 3.4 - 3.8 27 Rear brake pedal bolt 3 - 3.5
1-46 GENERAL INFORMATION Tightening Torque - Frame Sr.No. Parameter Torque Values (Kgf-m) 28 Handle bar upper holder bolts 1.8 - 2.2 29 Handle Bar lower holder bolts 2 - 2.2 30 Weight handle bar bolts 1 - 1.2 31 Fork top mtg bolt 2.5 - 3.5 32 Fork under bracket bolt 1.4 -1.8 33 Tank mounting bolt 1.8 - 2.2 34 Speedometer mtg nuts 0.4 35 Headlight mounting nuts / bolts 0.4 - 0.5 36 Chain cover bolt 0.8 - 1 37 Leg guard bolt 1.8 - 2 38 Grab handle bolt 1.8 - 2.2 39 Steering top bolt 5 - 5.5 40 Upper bracket pinch bolt 1.4 - 1.6
Chapter 2 Understanding The Motorcycle Table of Contents Identify ................................................................ 2-2 Speedometer Related Information .................... 2-3 Identification ...................................................... 2-5 Read Before You Ride ...................................... 2- 8 Oil / Grease / Loctite Application Matrix ........... 2-14 Salient Features ................................................ 2-16 Hose / Speed Sensor Routing .......................... 2-19 Upside Down (USD) Fork Information .............. 2-26 Luggage Straps ................................................. 2-27 2
2-2 UNDERSTANDING THE MOTORCYCLE Identity Frame Number Location at Head Pipe on Left Side of Motorcycle e.g.,PMNDM250NMMLxxxxx (Alpha-Numeric - 17Digits) Engine Number Location on LHSide Crackcase Near Gear Change Lever e.g., JFXCMMxxxxx) (Alpha-Numeric - 11Digits)
2-3 UNDERSTANDING THE MOTORCYCLE Speedometer Related Image & Power On Cycle Secondary Speedometer display will work when Ignition switch is in ‘ON’ position. 1. Malfunction Indicator ( ) : It glows wheneverany abnormality is noticed in functioning of FI system components. 2. Low Battery Indicator : It indicates battery needs charging. 3. Bajaj Logo : Bajaj logo flying ‘B’ glows continuously. 4. Hi Beam Indicator : When Headlight is ‘ON’ & Hi Beam is selected , Hi Beam indicator will glow. 5. ABS Indicator (Yellow) ( ( ABS ) ) : With Ignition switch ON the ABS indicator glows. When vehicle speed is more than 5 Km/h the ABS indicator goes OFF, if this indicator glows while vehicle is running, it means there is problem in ABS. 6. Coolant Temperature Indicator ( ) : It glow when engine coolant temperature is more than 1100C. 7. Side Stand Indicator : It glows when Side Stand is in operated condition & ignition switch is 'ON'. 4 5 6 7 8 1 2 3 9 10 11 12 13 14 Primary Speedometer display Will work when ignition switch Is in ‘ON’ position. 1. Tachometer Dial: It shows engine speed in RPM. 2. Service Reminder ( ) : ‘Wrench’ symbol glows when ODO meter reading reaches to set Kms. It indicates vehicle is due for periodic service. This Icon will flash at : 1st : 450 km, 2nd : 4450km, 3 rd : 9450 km, 4th : 14450 km and subsequently at each 5000 kms. Icon will continue to glow till it is reset. This icon is to be reset after service is carried out. 3. ODO meter : The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to ‘Zero’. 4. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero. Roll over to zero after 999.9 km & continue updating. 5. Mode Button : Mode button used for changing the mode while selecting & setting Trip1, Trip2, ODO, Clock & Service reminder. 6. Neutral Indicator : When the transmission is in Neutral, Neutral indicator will glow.
2-4 UNDERSTANDING THE MOTORCYCLE Speedometer Related Information 7. Low Oil Pressure Indicator ( ) : It glows when engine oil pressure is low. 8. Turn Signal Indicator ( LH & RH ) : When turn signal switch is pushed to Left or Right, Turn Signal Indicator - LH or RH will flash. 9. Digital Clock : It indicates time in HR : MM ( AM / PM ). 10. Fuel Level Indicator : It shows approximate fuel level in fuel tank. 11. Low Fuel Level Indicator : It blinks incase of low fuel level (1 bar or less). 12. Speedometer : Vehicle speed will be displayed in digital from in Km / Hr. 13. Set Button : Set button used for setting Clock & Service reminder. 14. Engine RPM Limit : It blinks when engine RPM is more than 9500 RPM. - Within initial 2000 kms. running (RUNNING IN period) - Beyond 2000 kms. running Note : After switching 'ON' the ignition switch, the following indications will remain 'ON' till engine is started. Coolant Temperature Indicator l Low Battery Indicator l Low Oil Pressure l Malfunction Indicator • RPM limit indicator starts blinking @ 6700 to 7000 RPM. • RPM limit indicator continuously glows ON if RPM is > 7000 km. • RPM limit indicator starts blinking @ 9200 to 9500 RPM. • RPM limit indicator continuously glows ON if RPM is > 9500 km.
2-5 UNDERSTANDING THE MOTORCYCLE Identification Steering Cum Ignition Lock Steering cum Ignition Lock : It has three positions. LOCK: Steering locked. Ignition OFF. OFF: Steering unlock. Ignition OFF. ON: Steering unlock. Ignition ON. To Lock the Steering : To lock the steering, turn the handle bar to the left side. Push & Rotate the key to “LOCK” position & 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 & Rotate it clockwise to “OFF” or “ON” position. Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear Seat’.
2-6 UNDERSTANDING THE MOTORCYCLE Identification CAUTION : While starting ensure that engine kill switch is in ON ( ) position. Keeping the kill switch in OFF position, engine will not start. Control Switch RH A. Engine Kill Switch : The engine kill switch is used for switching ON OFFthe engine Twin Channel ABS System B. Starter Button : Starter button operates the electric starter. It is recommended to start the engine with the transmission in neutral. Vehicle in Gear - Press clutch lever & operate starter button to start the engine. C. Head Light Switch : It has 2 positions. Control Switch LH D. Hi / Lo Beam Switch : 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 E. 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 & release. F. Horn Button : ( ) Press button for sounding horn. G. Pass Switch : Press the switch to put on Hi Beam filament of head light. It is used to give signal to vehicles coming from opposite side while overtaking. Twin channel ABS system Always maintain a safe distance between you and objects ahead. Vehicle speeds should always be reduced during extreme road conditions. The braking distance for motorcycle equipped with an anti-lock braking system may be longer than for those without it on rough road conditions. During these conditions the vehicle should be driven at reduced speeds.
Ignition Switch Engine Light Switch Low / Hi Beam Selector Switch The Following Lights Will Glow Effect if Pass Switch is Pressed 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 & Low beam w.illglow Started Toward right (Pilotmode) Any Mode OR Front Position lamp Tail Lamp Rear Number Plate Lamp Control Switch Illumination Both speedometer illumination Headlamp Hi beam Headlamp Low beam will also glow Toward Left (Headlight mode) Low beam mode ( ) Front Position lamp Tail Lamp Rear Number Plate Lamp Control Switch Illumination Both speedometer illumination Headlamp low beam Headlamp Hi beam will also glow. Hi beam mode ( ) Front Position lamp Tail Lamp Rear Number Plate Lamp Control Switch Illumination Both speedometer illumination Headlamp Hi beam & low beam No effect 2-7 UNDESTANDING THE MOTORCYCLE Identification When you apply Front / 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. Also 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. If the ABS warning light is ON and stays ON, you may have a problem with the ABS. In this case, however, your regular brakes will work normally. INSTRUCTION Incase, Malfunction indicator, BS indicator, coolant temperature indicator, low battery & low engine oil pressure indicator glows in speedometer, bring the vehicle to nearest BAL dealership for inspection / repair. Automatic Headlamp & Lights Operation Note : • 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 low / hi beam selector switch, keeping the light switch in head light mode. ON ( )
2-8 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Digital LCD Speedo Console Function : Display information on key important factors and alarm indications. Neutral position of gear. Side indicator pilot indication. Hi beam indicator Malfunction indication of EMS ABS malfunction indicator Warning indicator N How To Operate • Put 'ON' ignition key and kill switch. All 4 icons on top will pop-up and few will vanish away automatically. All other will show static display until the vehicle moves on road. • Other displays are dynamic which functions individually for respective applications. Tachometer : A analogue display tachometer showing 0~13 x 1000 RPM display for understanding the engine RPM. Engine RPM Limiter : A amber colour LED bulb starts blinking when the engine RPM reaches to 9500 RPM cautioning the rider crossing safety zone. The Engine RPM limit indicator will glow as per following conditions: 1. Within initial 2000 km running (Running in period) - Speedometer RPM limit indicator blinks at 6700 to 7000 RPM. - Speedometer RPM limit indicator continuously glows > 7000 RPM. 2. Beyond 2000 Km running. - Speedometer RPM limit indicator blinks at 9200 to 9500 RPM. - Speedometer RPM limit indicator continuously glows ON RPM is > 9500 RPM. Fuel Gauge : A vertical 8 bar equally segmented graphical indicator indicates fuel level inside the fuel tank. Low Fuel Level Indicator : Icon will blink continuously when the fuel level drops below 3.5 liters thus reminding the rider for refueling. Side Stand : A indication display of stand ON will appear when stand is put ON. Easy to read Digital Speedo Display showing • Vehicle speed - Km / H.r • Odometer - Kms covered. • Resetting trip meter - for recording distance covered in trip with resetting provision (TRIP 1 & TRIP 2). • Digital clock - displays time in HR : MM (AM / PM). Service Reminder : A service reminder will pop-up reminding you that vehicle is due for next service. ABS
2-9 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. NOTE Service reminder setting is to be done by MODENAS Authorised Service Centers / Dealers 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. Once engine starts do not rev up engine while vehicle is parked on the stand. Benefits • Comfort. • Hassle free starting. NOTE
2-10 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Malfunction Indicator Function • It gives indication signal about error in Engine Management System. 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 Authorised Service Station. Benefits • Great safety. • 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 temparature and extreme stress for optimum performance Benefits • Effective cooling and lubrication helps to deliver the higher engine performance under every possible load condition.
2-11 UNDERSTANDING THE MOTORCYCLE Read Before You Ride VRLA Battery Feature • Zero maintenance battery. Advantage • No top up required. Benefits • Effective cooling & lubrication helps to deliver the higher engine performance under every possible load condition. 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 & 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. 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 : 100 / 80 - R17, Tubeless Rear : 130 / 70 - R17, Tubeless
2-12 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Recommended Oil Grade and Quantity 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 Coolant • Ensure coolant in expansion tank is between Min and Max level mark. • Top up with recommended brands. 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 well with seating posture, starting, acceleration and braking of the vehicle. • Use side indicators before turning. • Fuel pump inside the tank is lubricated and cooled by. Mfr. Castrol - Radicool, Motul - Motocool Expert Quantity Drain and Refill - 1000 ml. Grade SAE 10W50 of API 'SN' + JASO 'MA2' Grade, Fully Synthetic Quantity Drain and Refill 1700 ml. Engine Overhaul 1950 ml.
2-13 UNDERSTANDING THE MOTORCYCLE Read Before You Ride Monsoon Care Fit and Finish Parts • It is suggested to take proper care in heavy monsoon / high rainfall area. The appropriate surface preventive coat is to be applied to avoid rusting / poor surface finish on account of adverse atmospheric conditions. • Clean and lubricate all the important parts as detailed in a Periodic Chart given in Owner's Manual. 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 / charged during periodic services
2-14 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& Refill at Service - 1700 ml / Engine O/H - 1950ml 2. Fork oil PRF001 Quantity / fork leg : 325 ml 3. Gasket Liquid Gasket (Loctite 5910) • Crankcase joining surface. 4. Grease HP Lihton RR-3 Grease Steering races & balls 5. Spray Chain Spray Sealed type drive chain 6. Grease All purpose • Front & 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 & 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
2-15 UNDERSTANDING THE MOTORCYCLE Oil / Grease / Loctite Application Matrix Sr. No. Lubricant / Loctite Grade Application • All ball bearings & needle roller bearing. • Crank shaft big end bearing • Transmission shaft & gear teeths • Fork shaft 9 Engine Oil SAE 10W50 API ‘SN’ or JASO ‘MA2’ Grade , Fully Synthetic. • Drum groove & cam drum change • Block / piston skirt • Cam shaft lobes • Clutch damper spring • Cam chain • Oil pump rotor while assly
2-16 UNDERSTANDING THE MOTORCYCLE Attribute KeyFeatures Advantages Benefits Performance • 4 Valve liquid cooled (2 spark plugs). • Engine power : 27 Ps at 8500 rpm. • Engine torque : 23.5 Nm at 6500 rpm. • New generation Closed Loop Bosch Fuel Injection. • DC ignition system. • Liquid cooled. • Heavy duty gear box. • Viscous paper type air filter element. • Smooth power delivery. • Optimum engine torque spread throughout the rpm brand. • Seamless changes in ignition maps for the good engine performance. • Optimum cooling efficiency in all riding conditions. • Advanced air flow designto aid liquid cooling. • Suited for high speed driving. Absolute joy ride due to : • Highly optimized power & torque output. • Razor sharp response to throttle. • Smooth & positive gear shifting. Attribute KeyFeatures Advantages Benefits Safety • Advance Twin Channel ABS. Front disc 300 mm Rear disc 230mm • Tubeless, radial tyres. • Uber responsive braking. Advanced twin channel ABS design for best braking efficiency in all kinds of road conditions. • Smooth ride, good handling performance, slow deflation in case of punctures for good control. • Safety on road. Ensure no wheel lock or skidding of brake application force, in the wet or dry. • First full LED mosaic headlamp with Auto Headlamp ON (AHO) makes the visible from a distance of 1.5 km. • Powerful full LED mosaic headlamp. • Slipper clutch. • Uber responsive braking. Advanced twin channel ABS design for best braking efficiency in all kinds of road conditions. • Smooth ride, good handling performance, slow deflation in case of punctures for good control. • Specially designed low profile rear tyres - better feedback & stability while cornering. Salient Features
2-17 UNDERSTANDING THE MOTORCYCLE Attribute KeyFeatures Advantages Benefits Style • Stylish spilt seats. • Up Side Down (USD forks) • Exposed, endless type of drive chain. • Refreshing colours. • Silencer with belly pan including extended tail end chamber with double barrel exhaust. • Clear lens LED blinkers. • Long & Low Stance Cruiser Bike. Brimming with tecnology that makes the bike smooth, safe & 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 37 mm dia. USD front forks. • Ergonomic riding position, an engaging yet easy riding stance. • Chest out riding posture with comfortable ergonomic reach, Sporty stance & comfortable seating arrangement. • Style that lets you break free from the mundane. • Sharper, precise handling stubbier looks. Salient Features
2-18 UNDERSTANDING THE MOTORCYCLE Convenience Key Features Advantages Benefits • LCD display. • Low Battery level indicator • Low Engine oil pressure indicator. • Digital speed indicator. • Engine over speed limiter. • Tachometer for engine speed. • Maintenance free sealed VLRA battery. • Fully equipped with fault / safety indications, clock, service reminder & 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. • 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. • Designed to present relevant information to the rider based on riding conditions. • Outstanding clarity inthe day or night. Salient Features
2-19 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. Rear Brake Hose - ABS Unit to Caliper Routing Route brake hose from ABS unit as shown in photograph. • Tie brake hose to frame with cable tie (PA402204) as shown by white circle.
2-20 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing Route brake hose through metal brackets as shown by black circle. Tie brake hose & 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 Tie brake hose to frame with cable tie (PA402204) as shown by white circle. Route brake hose through metal brackets as shown by black circle. Tie brake hose to frame with cable tie (PA402204) as shown by white circle.
2-21 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 through clamp ABS hose (DT131875 fitted on frame, above radiator) as shown by white arrow. Route brake hose as shown in photograph. Route brake hose from master cylinder as shown in photograph.
2-22 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.
2-23 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) as shown by white arrow. 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.
2-24 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. Skill tip for removing front & rear wheel speed sensor coupler : Press the lock as shown by white arrow & pull out speed sensor coupler in the direction of black arrow. Headlight assembly removed for better clarity of cable routing Speed sensor coupler connected to mating coupler Route speed sensor cable as shown in photograph & pass cable through window provided on speedo flap.
2-25 UNDERSTANDING THE MOTORCYCLE Hose / Speed Sensor Routing 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 & rear speed sensor cable together with cable tie (PA402204) as shown by black circle. 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.
2-26 UNDERSTANDING THE MOTORCYCLE Upside Down (USD) Fork Information Advantages of Upside Down (USD) Fork Assembly : Lighter in handling (turning and maneuvering 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. Dominar 250 – USD Fork Assembly Outer tube Dust cap Inner Pipe Axle clamp • Outer tube - Upper side & Inner tube - Bottom side Upside Down (USD) Fork Assembly Information
2-27 UNDERSTANDING THE MOTORCYCLE Luggage Straps Fit front LH & RH luggage straps as shown in photograph & tighten mounting bolts to recommended torque (0.8 - 1.2 Kgfm). Note : The straps at front should be parallel to vehicle Center plane, as shown in photograph. Take rear LH & RH luggagestraps. Fit rear LH & RH luggage straps as shown in photograph & tighten mounting boltsto recommended torque (0.8 – 1.2 Kgfm) Note: The straps at rear should be perpendicular to vehicle center plane, as shown in photograph. Refit the pillion rider seat. Rear luggage strap (2 Nos) Remove pillion rider seat. Remove rider seat mounting bolts (2 nos) using 10 mm spanner. Take front LH & RH luggage straps. Luggage Straps Fitment
2-28 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.
2-29 UNDERSTANDING THE MOTORCYCLE Luggage Straps USAGE OF LUGGAGE STRAPS WITH BUNGEE CORD Open Pillion seat & take out front and rear luggage straps. (refer photographs A) Re-fit pillion seat on its position (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) 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. 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 : Caution : Luggage straps can be used only for strapping a luggage bag or similar as shown in the pictures (C & D). The total weight of the bag and its contents shall not exceed 15 Kg. 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 & Insert the folded straps under rider seat. 2. Rear straps to be folded neatly to approach the hooks & insert straps in hooks. B A 1 2 C Luggage straps Bungee cord hooked in luggage straps D
1 Chapter 3 Preventive Maintenance Table of Contents Inline Fuel Filter Replacement .......................... 3-2 Air Filter Element Replacement ........................ 3-5 Air Filter Drain Tube Cleaning ........................... 3-6 Engine Oil Replacement ................................... 3-7 Spark Plug Cleaning ......................................... 3-18 Tappet Clearance Setting ..................................3-20 Coolant Level Check & Adjust ........................... 3-25 Sealed Drive Chain on Vehicle ..........................3-26 Front Caliper Overhaul & Brake Pad Wear/ Check / Replacement ........... 3-28 Brake Fluid Replacement ………....................... 3-32 Brake Fluid Top Up / Clutch Cable Free Play Check & Adjust .................................................. 3-33 Throttle Cable Free Play Check & Adjust / Side Stand Pin Clean & Lubrication ………….... 3-34 Brake Pedal Pivot Pin Lubrication ……..............3-35 Steering Play Check & Adjust / Control Switch Contacts Cleaning ............................................. 3-37 EVAP Drain Tube Cleaning / Ignition Switch Contacts Cleaning ………………………............. 3-38 31
3-2 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement • Remove side cover LH mounting screws (3 nos). • Remove side cover RH mounting screws (3 nos.). • Lift petrol tank cover. • Pull outside side cover LH & RH front lug from hole. • Cut the cable tie of wiring harness. • Use new cable tie while fitment. Remove petrol tank cover 1. Remove pillion rider seat as shown at picture. 2. Remove 2 bolts with washer using 10 mm ‘T’ spanner. 1 2 • Front LH Side - Remove 1 allen bolt with metal collar using 5 mm allen key. • Front RH Side - Remove 1 allen bolt with metal collar using 5 mm allen key. • Rear - Remove 2 screw with plastic washer using Philips Screwdriver. • LH Side - Remove 2 allen bolt with metal collar using 5 mm allen key. • RH Side - Remove 2 allen bolt with metal collar using 5 mm allen key.
3-3 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement LH • Remove secondary speedometer coupler connection. • 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. 10 mm spanner Front Bracket 14 mm spanner Front 12 mm spanner 12 mm spanner RH
3-4 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement • Remove injector pipe from inline fuel filter. • Using coolant clamp plier, remove EVAP pipe from fuel tank. • Take out fuel tank. • Remove tube fuel pump to inline fuel filter. • Remove tube inline fuel filter to fuel pump.
3-5 PREVENTIVE MAINTENANCE 3-2 PREVENTIVE MAINTENANCE Inline Fuel Filter Replacement / Air Filter Element Replacement Air Filter Element Replacement • Take out inline fuel filter. • Remove fuel tank. • Remove air filter cover mounting screw (4 nos.) with phillips head screw driver. • Remove intake pipe metal wire hook. 1 - Take out air filter. 2 - Air filter element. 1 2
3-6 PREVENTIVE MAINTENANCE 3-2 PREVENTIVE MAINTENANCE Air Filter Drain Tube Cleaning Front Side - Remove 2 bolts (RH and LH) with metal collar using 5 mm allen key. Pull out drain tube. 1 - Press drain tube toward engine side. 2 - Take out filter drain tube. Remove clamp using coolant clamp plier. Take out air filter drain tube plug & drain accumulated oil. • Pull out air filter drain tube locking clip. 1 2
3-7 PREVENTIVE MAINTENANCE Air Filter Drain Tube Cleaning / 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 & take out drain bolt. • Check drain tube for crack / damage. • Refit drain tube & its clip. • Refit drain tube on vehicle. • 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. • Clean the oil strainer by kerosene / diesel. • Blow air of 2 bar pressure from inside.
3-9 PREVENTIVE MAINTENENCE Engine oil Replacement Evacuation Strainer Cleaning • Remove terminal from horn. • Ensure that 'O' ring is in good condition. • Ensure that oil strainer is in good condition. • Do not use abrasive material / tool to clean oil strainer. • Remove under belly pan mounting bolts (4 nos.) with paper washer using 4 mm allen key. - LH& RH side bolt 2 paper washer per bolt. - Front side 2 nos bolts • Take out under belly pan.
3-10 PREVENTIVE MAINTENANCE Engine oil Replacement • Remove underbelly pan structure front mounting bolts (2 nos. allen bolt & 1 nos bolt) with 5 mm allen key & 8 mm spanner. • Pull radiator assembly towards front wheel side. • Remove radiator mounting nuts (4 nos.) with metal washers using 10 mm spanner. • Remove horn mounting bolt with mm spanner.
3-11 PREVENTIVE MAINTENANCE Engine oil Replacement • Take out underbelly pan structure front. • Cut the cable tie (circle) & remove oxygen sensor coupler connection (arrow). Note : Use new cable tie during fitment. • Remove exhaust pipe - A mouth flange nuts (2 nos.) & clamp bolt (1 nos) with 12 mm spanner. 1. Take out exhaust pipe from vehicle. 2. Use new silencer gasket during fitment. • Remove evacuation strainer plug using 13 mm spanner & take out evacuation strainer along with plug. Exhaust Pipe 1 2
2 3-12 PREVENTIVE MAINTENANCE Brush Engine oil Replacement • Pull plug from evacuation strainer. • Clean evacuation strainer using a brush by kerosene / diesel. 1. Ensure that evacuation strainer ‘O’ rings are in good condition. 2. Clean evacuation strainer plug. • Replace ‘O’ rings evacuation strainer plug with new one once opened. • Blow air of 2 bar pressure. 1
3-13 PREVENTIVE MAINTENANCE Engine oil Replacement • Fit evacuation strainer on evacuation strainer fitment tool (P/N : 37 0042 82) as shown in photograph. • Fit evacuation strainer in crankcase LH. • Pre-fit evacuation strainer plug & tighten it to recommend torque. • Note : Re-fit all removed parts. • Remove engine oil filter cover mounting bolts (2 nos.) with 8 mm spanner. 2 • Take out evacuation strainer fitment tool.
3-14 PREVENTIVE MAINTENANCE Engine oil Replacement • Rotate engine oil filter cover & take out engine oil filter cover. • Replace engine oil filter cover ‘O’ ring with new one once opened. • Take out engine oil filter using circlip plier & replace it with a new one. Important :- Ensure that engine oil filter is dipped in engine oil (10W50) before fitment. • Pre-fit engine oil filter cover mounting bolts & tighten it to recommended torque by torque wrench ( 1 - 1.2Kgf-m ) as shown picture A. • Pre-fit drain bolt & tighten it to recommend torque by torque wrench (1 - 1.2 Kgf-m). • It is important to measure oil quantity after draining. This is important to understand the oil consumption pattern. During interval - from oil change to next oil change, engine oil consumption quantity should not be more than 50 ml per 1000 kms. If oil drop is more, check for external oil leakage, smokey exhaust & piston ring wear. • Use genuine engine oil only as per recommended grade (10W50). • Fit oil strainer as shown picture B. ‘O’ Ring Oil Filter A B
3-15 PREVENTIVE MAINTENANCE Engine oil Replacement • Measure fresh 1700 ml of 10W50 engine oil in calibrated jar. • Ensure that engine oil filler cap ‘O’ ring is in good condition. • Ensure that engine oil filler cap is fully tighten. • Fill 1700 ml of 10W50 engine oil in engine with tunnel. • Note : Drain & Refill Quantity : 1700 ml. Overhaul Quantity : 1950 ml. • Remove engine oil filter cap.
3-16 PREVENTIVE MAINTENANCE Engine oil Replacement Engine Oil Top Up. • Wash the vehicle thoroughly. • Ensure oil filling & drain quantity get measured in calibrates measuring jar. • Plastic measuring jar level marking to be verified by transferring oil in borosil make measuring jar. • Drain the engine oil as explained in engine oil replacement SOP. • Warm up engine, ensure engine oil temperature is 60ºC as shown in photograph. OR • Run vehicle Multi Roller Test Bench (MRTB) for 3 mins @ 50 kmph speed. • Measuring engine oil drained quantity (while measurement jar to be kept on flat surface). • Check the quantity of drained engine oil. 60ºC
3-17 PREVENTIVE MAINTENANCE Engine oil Replacement • Refit oil strainer. • Remove engine oil filter cap. • Ensure that oil filter cap ‘O’ ring is in good condition. • Top up drained oil with fresh 10W50 engine oil so as to match 1700 ml volume (considering @ 150 ml engine oil is available at evacuation chamber side). • Example : Drained engine oil - 1350 ml Engine oil in evacuation side chamber -150 ml Engine to be top up = 1700 - (1350 + 150) = 1700 - 1500 = 200 ml • Refill the engine oil in engine. • Ensure that engine oil filler cap is fully tighten. • Reconfirm engine oil level in vehicle upright position, it should be in between MIN & MAX level. • Pre-fit drain bolt followed by tightening to recommended torque by torque wrench. • Tightening torque : 1.0 - 1.2 Kgf-m