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• Page 1
  Service manual…
• Page 2
  All the information contained in this Service information contained are conferred solely and Manual is based on the most recent information at exclusively to Bajaj Auto Limited. No part of these the time of publication. Bajaj Auto Limited drawings can be copied, reproduced, either partially or…

• Page 4: Table Of Contents

  Content Read and learn CHAPTER Identification ………………….. 2 Read before driving ………………9 Technical specifications ………………. 15 highlights ……… 19 Checklist Pre Delivery (PDI) …………23 Maintenance and Lubrication box …………26 Standard Operating Procedures …………. 28 CHAPTER Fuel System and EMS Electric Branch Addressing ……….

• Page 5: Read And Learn

  CHAPTER 1 Read and learn  Identification  Read before driving  Technical specifications  Product highlights  Checklist  Pre Delivery (PDI)  Table of Maintenance and Lubrication  Standard Operating Procedures Manual de Servicio Bajaj Dominar 400…

• Page 6: Identification

  Numbers chassis and engine are used to register the motorcycle. They are the only alphanumeric codes that distinguish your carfrom others of the same model and type. Chassis Number Location In the mounting seat (17 Alphanumericdigits) Engine Number Location In the crankcase on the left side, near the shifter (Alphanumeric 11 digits) Bajaj Auto International Business…

• Page 7
  6. Neutral indicator: When the transmission is in neutral, •Indicator Low Oil Pressure •Malfunction Indicator the indicator lights. Instructions: If indicators malfunction or ABS light up while driving, drive it to the nearest Bajaj for review or repair. Manual de Servicio Bajaj Dominar 400…
• Page 8
  2. Low Battery Indicator: Indicates that you need to charge the battery. 3. Bajaj Logo: The logo of Bajaj ‘B’ is permanently on. 4. Indicator Light High: If the headlight is on high beam and selected, the indicator lights.
• Page 9
  • The digital clock indicates the time in the format HH and MM separated by ‘:’ • It is a 12-hour clock • Initially it will flash ‘:’ • It is only possible to set the clock in TRIP1 mode. Clock Manual de Servicio Bajaj Dominar 400…
• Page 10
  To unlock the handle:Insert the key into the lock. Push and turn clockwise to the ‘OFF’ or ‘ON’ position Key: A common key is used for the ignition, the fuel tank cap and the rear seat. Bajaj Auto International Business…
• Page 11
  The braking distance for a vehicle equipped with an anti lock system, can be decreased compared with vehicles that do not have this system. While this condition is maintained, the vehicle must be driven at reduced speed. Manual de Servicio Bajaj Dominar 400…
• Page 12
  Front beam, low light Front position light Hi Light ( Rear lighthouse Back plate light No Effect Toward the left Lighting control (Low beam Light Lighting of both speedometers Mode) Front light, low and high light Bajaj Auto International Business…

• Page 13: Read Before Driving

  •Place the ignition switch and switch off the ‘ON’ position. The 4 icons on top light up and some will automatically turn off. All others will remain on until the vehicle is moving. •Other screens are dynamic, they work individually according to your application. Manual de Servicio Bajaj Dominar 400…

• Page 14
  • The time according to the local time. • Restart the TRIP odometer to calculate the distance traveled in a trip. Note: The service reminder configuration must be done only by the Bajaj authorized Distributor or Center.  Headlight always on Features •On start of the vehicle, the headlight turns on automatically.
• Page 15
  •It operates automatically when an error is detected. Visual signal! •The amber indicator lights on the left, this indicates that the EMS reports an error. Immediately take the vehicle to an Authorized Service Bajaj Benefits •Great security. •Stops the damage that may occur.
• Page 16
  • Control the speed of the vehicle safely.  Tubeless tires Advantage • If they are punctured, they do not suddenly deflate and help reduce unsprung mass. • Less resistance to rolling, which ensures stability. Benefits • High stability and less maintenance. Bajaj Auto International Business…
• Page 17
   Check and inflate the tires once a week.  Refuel gas in trusted pumps.  Use only good quality fuel.  Check coolant and engine oil levels. Fill up to the MAX level. Manual de Servicio Bajaj Dominar 400…
• Page 18
  • Turn off the engine when stopped. • Do not drive with the brake pedal or the brake handle down. The brake light will remain on and drain the battery. • Inspect/ recharge your battery in each periodic maintenance. Bajaj Auto International Business…

• Page 19: Technical Specifications

  : Wet sump, forced lubrication Transmisión : 6-speed, constant Mesh Gear Shift Pattern 1 Down 5 UP Engine Oil Grade : Bajaj DTS-I 10000 (SAE 10W50 API ‘SJ’ o JASO ‘MA2’) Oil Change : 1500 ml Engine Overhaul : 1800 ml CHASSIS AND BODY…

• Page 20
  •The values ​ ​ s hown are nominal and approximate, 15% variation to the production center and measurement is allowed. •All dimensions are taken under unloaded conditions. •Definitions of terms, where applicable, are those of the SI / ISO Standards. •Specifications subject to change without notice. Bajaj Auto International Business…
• Page 21
  •Guide pins kick •Bolts sprocket •Mounting bolt oil pump •Cap screws shooting input shaft •Pin chain guide Loctite 243 thread sealant •Nut inhibitor •Clutch nut •Pin changes •Neutral switch •Stator bolts •Clamp screws branch stator Manual de Servicio Bajaj Dominar 400…
• Page 22
  • Steering axle Bajaj DTS-I 10000 •Drum slot changes and shift cam (SAE 10W50 API ‘SJ’ o •Piston skirt and cylinder JASO ‘MA2’) •Camshaft lobes •Clutch spring • cam chain •Rotor pump oil to join him Bajaj Auto International Business…
• Page 23
  Lions POSTURE The design principles characteristic of the Dominar 400, inspired by the lion’s feline posture, are visible from its clear Agressive front, its large and contoured tank and its endless and formidable rear lights. A look at the Dominate is enough to be impressed by its dominantattitude.

• Page 24: Highlights

  The sliding clutch Dominate 400 adds excitement to toasphalt for driving a solid. This builds confidence, every ride,offering precise gear changes each RPM and bothbeginners and experts, to go out and dominate the total control while the driver decelerates. slopes. Bajaj Auto International Business…

• Page 25
  It deserves a great bike disc brake equally great to control your great power and is exactly what the Master 400 account. The front brake disc320mm is the largest in its class and provides unrivaled braking power. Manual de Servicio Bajaj Dominar 400…
• Page 26
  The LCD speedometer Master 400 divides the screen into a primary and a secondary console, reducing the reflection in the cabin. thus giving the driver a clear view of pure and distractions while dominating the asphalt. Bajaj Auto International Business…

• Page 27: Checklist Pre Delivery (Pdi)

  Cable Clutch Free Play 2 ~ 3 mm /Accelerator Play : 20 ~ 30 mm Markings on chain tensioner must be the same on both sides Drive chain should not touch the chain cover Manual de Servicio Bajaj Dominar 400…

• Page 28
  Headlight, rear light, directional, speedometer lights, light focus (If applicable) Operating speedometer, odometer, speedometer, fuel gauge, clock. Operation of all icons Signal Indicators (Neutral, turn signals, high beam, clock, low battery reminder service and Bajaj logo) Speedometer Important: (if applicable) Do not disconnect the speedometer cable sensor.
• Page 29
  Ensure availability of rear wheel support in the area of ​ ​ P DI The revision and repair should be performed only by trained company personnel Cross out the points that are not applicable to this model Manual de Servicio Bajaj Dominar 400…
• Page 30
  Use all-purpose grease Side door latch Lm, Lb Lm, Lb Lm, Lb Lm, Lb recommended Adjusting all fasteners Rv, A Rv, A Rv, A Rv, A Rv, A Rv, A Rv, A Rv, A Bajaj Auto International Business…
• Page 31
  Rv: Review, Rg: Regulate, RLL: Complete; Lm: Clean, Re: Replace, A: Press, Lb: Lubricate The following items will be charged to the customer: Oil, coolant, filters, all types of grease, cleaners, cables, damaged and worn parts, O-rings, seals, pipes, packaging, etc. Manual de Servicio Bajaj Dominar 400…
• Page 32
  •2 screws with plastic washer. Remove •Bolts back cover of the fuel tank. •2 bolts along with the collar on the left side. •2 bolts along with the collar on the right side. Forward;Remove •2 bolts with metal collar. Bajaj Auto International Business…
• Page 33
  Note:Use a new clamp when placing the cable) Remove •Screw left side cover. •Pull tab side cover. •Cut the clamp. Remove •Connecting the secondary speedometer. •Remove the tank cover. Remove •3 bolts fuel tank support. Delantero Manual de Servicio Bajaj Dominar 400…
• Page 34
  •Disconnect the connector at the fuel pump. •Injector pipe from the fuel filter. Remove •EVAP pipe from the fuel tank. •Remove fuel tank. Remove •4 cover screws air filter. •Intake pipe hook chassis. serve •The air filter cover. Bajaj Auto International Business…
• Page 35
  •Ensures that the marking T on the sprocket of the camshaft is up. Confirmation that the piston is at TDC: Remove •Bolt insert crankcase. Note:If the tool to lock the crankshaft fits, then the piston is at TDC. Manual de Servicio Bajaj Dominar 400…
• Page 36
  SOP: Regulación de la Luz de Válvulas Remove •The heat-resistant rubber covered slots clamps. Un clip tube breather. Remove •4 bolts cylinder head cover. Remove the head cover. Note •Use the universal joint to remove the bolts. •Use extension as shown. Bajaj Auto International Business…
• Page 37
  •Use a threaded bolt M5 to Rosca M5 remove the rocker arm shafts. Aprox. 24 mm Note: With one hand, one firmly rocker pressure to the pinion of the camshaft to avoid falling washers. serve •Rocker arm shaft washers Manual de Servicio Bajaj Dominar 400…
• Page 38
  C — Measured valve clrnc E-Shim to be used D — Increase in valve clrnc = B-C = A-D E — Shim to be used = A — D = 2.40 — 0.04 = 2.36 mm Bajaj Auto International Business…
• Page 39
  • Prefix the bolts on the cylinder head cover, adjust them to the tightening torque recommended with a torque wrench. • Replace the heat-resistant rubber cover and make sure the slots are properly placed in the clamps • Assemble all parts that have been removed. Manual de Servicio Bajaj Dominar 400…
• Page 40
  •If the chain slack is not the standard, then: Loosen •Rear axle nut. •Release adjuster locknut and increase or reduce the slack Adjustment notches must match on both the sides Bajaj Auto International Business…
• Page 41
  SOP: Revisión y Regulación de la Cadena de Arrastre •Make sure that the markings on left and right tensioner are also aligned •Adjusting nut after the specified tightening torque (10 kgm) axis. •Check to make sure the rear wheel rotate freely. Manual de Servicio Bajaj Dominar 400…
• Page 42
  •Clean the surface of the master cylinder. •Loosen the bleed screw. •Place the PVC hose. •Drain fluid from the brake caliper. •Remove 2 screws holding the master cylinder •Remove the cover from the master cylinder. •PVC cap and the rubber diaphragm. Bajaj Auto International Business…
• Page 43
  -Fill with a recommended brake fluid, so that the liquid level of the Brake is on the «MIN» mark. -Place all the removed parts again. -Review the effectiveness of the brake. If it finds it spongy, purge the air from thesystem. Manual de Servicio Bajaj Dominar 400…
• Page 44
  Sistema de Combustible y EMS Notas Bajaj Auto International Business…

• Page 45: System Operation

  Understand the electric branch’s addressing Fuel Injection System Malfunction Codes and their driving cycle. CAPÍTULO 2 Sistema de Combustible y EMS Addressing the Electric Branch System Operation Fuel Injection System EMS Sensors and Actuators Indication of Malfunction Manual de Servicio Bajaj Dominar 400…

• Page 46
  Purge Valve, Regulator, Intermediate Start Relay, Electronic Console, Clutch Switch Control MainRelay, Fan Relay, Fuel Pump Relay, Fuse Box, Command Der,Control Command Left Switch On, LCM, ABSFuse, Main Fuse, Rear Light, Left and Right Switch Off Directionals,CAN Interface. Front Speed Sensor Bajaj Auto International Business…
• Page 47
  Wheel speed sensor front Control switch RH, Control switch LH, Kill switch, Clutch switch, Front blinker RH Front Blinker LH HT coil 1 HT coil 2 Head Lamp Ignition Switch HT coil 2 Horn Manual de Servicio Bajaj Dominar 400…
• Page 48
  High Coil 1 Connection oft he Sensor of the angle of the crankshaft Connection Oil Horn Pressure Switch Lambda sensor Overturning Land ECU Sensor ABS ECU connection Fan Motor radiator Fuel Sensor connection pump module angle crankshaft Bajaj Auto International Business…
• Page 49
  Side Stand Ground conn switch Engine Earth Regulator Reference point Ground of the Assembly Regulator Earth of the ECU ECU harness Chassis Earth support Bracket Chassis Earth Connection of the Switch of Side stand Manual de Servicio Bajaj Dominar 400…
• Page 50
  Starter Relay Fan Relay Starter Relay Intermediate Purge valve CAN Interface Brake Light Rear Fuses Turn indicator Light plate Batt Positive ABS Fuse Box Connection of the Magneto to the Ground ECU earth Chassis Ground Regulator Regulator Bajaj Auto International Business…
• Page 51
  Direccionamiento del Ramal Eléctrico — ABS Coil High 1 TMAP Rear brake switch Rear Speed Coolant Sensor Temperature Sensor Starter Motor Relay Fuel Pump Starter relay Starter intermediate Real Fan Relay Purge Main Relay Valve Connector Starter Relay Manual de Servicio Bajaj Dominar 400…
• Page 52
  Foto Descripción Observaciones Coil 1 For the central spark plug Coil 2 To the left and right plugs rollover sensor signal to the ECU when the tilt angle is>60 ° Bajaj Auto International Business…
• Page 53
  The fuel filter retains fuel impurities. It is important to prevent blockage of the fuel pump and injector nozzles measure. Resistance Fuel Pump = 2.7 + 0.1 Ohms Manual de Servicio Bajaj Dominar 400…
• Page 54
  The inward movement of the injector is restricted only <0.1mm. Also the period when the injector is open is very short (1.5 to 10 milliseconds). Thus, the opening and closing time is critical to meter fuel accurately. The fuel spray mixes with the incoming air since both move toward the intake valve giving a precise mixture for combustion. Bajaj Auto International Business…
• Page 55
  Indicator Crankshaft angle sensor Icon Speedometer Neutral Switch Radiator Fan It also contains the Sensor T Map Fault Codes for Accelerator Position Sensor the diagnosis Coolant Temperature Sensor MPRD = relay driver Main Power Manual de Servicio Bajaj Dominar 400…
• Page 56
  Set of actuators Actuator is a term generally used to describe a control mechanism. Ejm: a device that converts an electrical signal into mechanical motion, for example: Injector Fuel Pump Solenoid / Relay Start Bajaj Auto International Business…
• Page 57
  5 ​ ​ v olt resistance. This sends a signal to the ECU highervoltage. Thus the DC voltage load to the ECU communicates regularly theexact position of the throttle valve. Fully open throttle 5 volts valve from the Manual de Servicio Bajaj Dominar 400…
• Page 58
  (The values ​ ​ d o not match exactly, it’s just a representation for better understanding). This NTC thermistor is used to measure engine temperature in the engine management system (EMS) Temp. C Termistor 90 100 Característica del Termistor NTC Bajaj Auto International Business…
• Page 59
  This is a very useful feature because security exceed 60 °indicates that the driver has fallen vehicle or is in the midst of an accident. A) Yes security driver and the vehicle is assured. Manual de Servicio Bajaj Dominar 400…
• Page 60
  This missing notch area represents the position before top dead center (TDC). Inthis position before TDC pulse voltage is sensed by the sensor and crank angle is communicated to the ECU. The ECU uses this information to control the ignition advance Bajaj Auto International Business…
• Page 61
  ECU using the diagnostic tool. To use the code, the technician can refer to the Table of diagnosis or flash code. This chart explains where the problem lies and what is the likely cause. Notas Manual de Servicio Bajaj Dominar 400…
• Page 62
  Difficulties in cold starting requires choke (choke) toturn. Cold fuel wets the walls co l l ec t or of admi if ng causing starting problems. Inconsistency in fuel efficiency. The maintenance costis reasonably higher. Higher emission levels. Bajaj Auto International Business…
• Page 63
  TOOL COLLECTOR adjust the fuel injection OF DIAGNOSIS PRESSURE volume. Detect the position It works when the Of the accelerator coolant temperature OF THE reaches 98 ° C, RADIATOR stops at 92 ° C. Manual de Servicio Bajaj Dominar 400…
• Page 64
  •Greater torque at low rpm. •Better cold start, warm-up and rapid acceleration. •Lower fuel consumption — better fuel efficiency. •Excellent maneuverability in general. •Lower maintenance costs. •If so, it communicates malfunctioning fuel injection system. •Lower emissions. Notes Bajaj Auto International Business…
• Page 65
  3 — InJECTOR 4 — Sensor T MAP 5 — TPS 6 — FUEL PUMP 7 — PRIMARY COIL 8 — SECONDARY COIL 9 — Indicador MALFUNCTION 10 — Conector DIAGNOSTICS 11 — RADIATOR Manual de Servicio Bajaj Dominar 400…

• Page 66: Fuel Injection System

  ECU increases or decreases the rate pressure of air entering the will be affected. of air to the engine proper intake manifold and delivers a sensor signal to the ECU 5 VDC. Bajaj Auto International Business Bajaj Auto International Business…

• Page 67
  Unstable idle speed. The start will be affected. Port Diagnostic Tool Can raise / lower the signal from There will be no communication with the diagnostic tool BOSCH — a link error the ECU will be displayed. Manual de Servicio Bajaj Dominar 400…

• Page 68: Malfunction Indication

  Malfunction Indicator Light (MIL) Control Circuit P1604 Malfunction Indicator Light (MIL) Control Circuit p0650 Overturning Sensor Short to Battery P1504 Overturning sensor Ground fault p1503 Overturning sensor circuit signal inadmissible P1501 Overturning sensor Open circuit P1502 Bajaj Auto International Business Bajaj Auto International Business…

• Page 69
  Ignition Coil A Primary Control Circuit / Open P0351 Ignition Coil B Primary Control Circuit / Open P0352 Light Alert Temperature, High Circuit P0655 Light Alert Temperature, Low Circuit P0656 Temperature Alert light, open circuit P0657 Bajaj Dominate Service Manual 400…
• Page 70
  Sistema de Combustible y EMS Notas Bajaj Auto International Business…
• Page 71
  CHAPTER 3 Engine and transmission Torques Service Data Disassemble Special Tools Engine Motor Flow Chart CAPÍTULO 3 Motor y Transmisión CHAPTER 3 Engine and transmission Torques Service Data Disassemble Special Tools Engine Motor Flow Chart Manual de Servicio Bajaj Dominar 400…
• Page 72
  Magneto Cover Bolts Clutch Cover Bolts 1.0 ~ 1.2 Kgm. 1.2 ~ 1.4 Kgm. 1.0 ~ 1.2 Kgm. Primary Gear Nut Camshaft Pinion Bolt Clutch Nut 14.5 ~ 15 Kgm. 2.7 ~2.9 Kgm. 12 ~ 12.2 Kgm. Bajaj Auto International Business…
• Page 73
  1.1 ~ 1.2 Kgm. 1.1 ~ 1.1 Kgm. 14.5 ~ 15 Kgm. Small head bolts Large head bolts Allen bolt Driven Balancer 3.9 ~ 4.1 Kgm. 1.0 ~ 1.2 Kgm. 6.0 ~ 6.5 Kgm. Manual de Servicio Bajaj Dominar 400…
• Page 74
  LIMIT 2.72 mm LIMIT 0.2 mm CAM SPROCKER DIAMETER PRESSURE PLATE WARPAGE ROCKER ARM SHAFT DIAMEETER Diá. Exterior: 70.84 mm 0.1 mm 10.0 mm Diá. Primitivo: 72.762 mm LIMIT 0.15 mm LIMIT 9.97 mm LIMIT – Bajaj Auto International Business…
• Page 75
  Rings Slot GAP FIRST SECOND Group A 88.942 ~ 88.958 mm 0.20~0.35 0.40~0.55 0.2~0.70 0.030~0.070 0.030~0.070 0.060~0.140 Group B 88.978 mm LIMIT 0.55 mm 0.75 mm 1 mm LIMIT 0.15 mm 0.15 mm 0.16 mm Manual de Servicio Bajaj Dominar 400…
• Page 76
  9.966 ~ 9.984 mm 10 ~ 10.027 mm 5.050 ~ 5.150 mm limit 9.922 mm limit 10.067 mm limit 5.155 mm Guide pin thickness L. Estándar 4.960 ~ 4.990 mm L. Servicio 4.91 mm Bajaj Auto International Business…
• Page 77
  (1,2) 1) 4.5 kg.m (44.1 N.m) 2) 4.5 kg.m (44.1 N.m) Step 3: Motor support bolts (3,4,5) 3) 4.5 kg.m (44.1 N.m) 4) 2.6 kg.m (25.5 N.m) 5) 2.6 kg.m (25.5 N.m) Manual de Servicio Bajaj Dominar 400…
• Page 78
  Motor y Transmisión Notas Bajaj Auto International Business…
• Page 79
  Código : 37 1043 33 Aplicación : to remove central spark plug Rubber Tube for central spark plug placement Código : 37 1043 34 Aplicación : For placing the central spark plug Manual de Servicio Bajaj Dominar 400…

• Page 80: Special Tools

  21mm Código : 37 1043 37 Aplicación : To remove and adjust the oil pressure sensor. clutch holder Código : 37 1043 38 : to lock the clutch while removing Aplicación clutch center nut. Bajaj Auto International Business…

• Page 81
  : 37 1043 41 Aplicación : removes the gudgeon pin Extractor Primary Gear Código : 37 1043 42 Aplicación : To remove gear primary. Note: It is used in case the primary gear islocked. Manual de Servicio Bajaj Dominar 400…
• Page 82
  : 37 1043 45 Aplicación : Removes valve shims and parts that may fall in to the engine. Extractor Exhaust Coolant Temperature Sensor Código : 37 1043 46 Aplicación : To remove and place the coolant temperature sensor. Bajaj Auto International Business…
• Page 83
  Balancer nut tool Código : 37 0041 60 Aplicación : To remove or tighten the balancer Oil Shaft Seal Fixer Output Código : 37 1042 56 Aplicación : To place the retainer output shaft oil Manual de Servicio Bajaj Dominar 400…
• Page 84
  : 37 1030 61 Aplicación : : To press the bearings in the crankcase. Valve spring compressor Código : Compresor: 37 1031 07 Adaptador: 37 1031 08 Aplicación :To compress the springs valve intake and exhaust. Bajaj Auto International Business…
• Page 85
  Tool to remove the spark plug boot Código : 37 1043 09 Aplicación : To remove the spark plug boot. Right Spark plug wrench Código : 37 1040 51 Aplicación : To remove the right plug. Manual de Servicio Bajaj Dominar 400…
• Page 86
  Motor y Transmisión Herramientas Especiales Comunes Pliers clamps coolant Código : 37 2540 35 Aplicación : Remove coolant hose clamps Gauge for measuring oil pressure Código : 37 2040 31 Aplicación : To check pressure engine oil. Bajaj Auto International Business…
• Page 87
  •Make sure the brand T on the Coinciding with the wheel mark camshaft sprocket is up. The mark on theleft crankcase False pin. • Crankshaft safety with the tool to block the crankshaft Manual de Servicio Bajaj Dominar 400…
• Page 88
  Remove •Bolts cam chain tensioner (2 und.)•Remove the cam chain tensioner with packaging.•Tensioner bolt cam chain. serve •Sprocket cam •Collar camshaft. •Tie cam chain with a copper wire Remove •right plug using the special tool. Bajaj Auto International Business…
• Page 89
  8 mm and 5 mm. •Remove the cylinder head Desarmado de la Culata Remove •Caps rocker arm shafts intake and exhaust (2 und.) Remove •Rocker arm shafts intake and exhaust using the appropriate special tool. Manual de Servicio Bajaj Dominar 400…
• Page 90
  •Using the valve spring compressor the adapter, remove the valves andaccessories. Remove •Screws intake pipe (3 und) with a Phillips screwdriver and remove the intake pipe. •Make sure the O-ring of the intake pipe is in good condition. Bajaj Auto International Business…
• Page 91
  •Sensor oil pressure, using the special tool (Code: 37104337) •Make sure the sensor gasket is in good condition. Remove •Central plug. •Temp sensor using a key 18 serve •Head gasket and pins (2 und.) Manual de Servicio Bajaj Dominar 400…
• Page 92
  • Cylinder. Remove •Cylinder gasket and the pins (2 und.) •Cover the housing side a clean cotton cloth. Remove •circlip piston pin. •Using the tool to remove the piston (Code: 37104341), remove the piston pin and piston Bajaj Auto International Business…
• Page 93
  •The engine oil filter. Desarmado de la Cubierta de Culata Remove •Releasing the clutch shaft with the washer and the torsion spring. Remove •Cover gasket and pin clutch (2 und.) serve •Camshaft chain Manual de Servicio Bajaj Dominar 400…
• Page 94
  Remove •The primary gear nut with a wrench 24 mm. Flat washer serve Cranksha (spacer) -Primary gear nut ftSprocke -Belleville washer -Flat washer (spacer) Primary -Crankshaft sprocket gearnut Belleville washer Remove •Bolts stop plate (3 und.) Bajaj Auto International Business…
• Page 95
  Motor y Transmisión Desarmado del Motor Remove stop plate serve •Clutch springs (3 und.) And clutch pressure plate. serve •Pushrod •Clutch discs and spacers serve •Belleville washer •Flat washer Manual de Servicio Bajaj Dominar 400…
• Page 96
  •Using the center holder clutch (Code: 37104338), remove the clutch nut using a wrench 24 mm. serve •Belleville washer flat washer serve •Centering clutch with the thick washer. Take out • Clutch housing and the clutch spacer Bajaj Auto International Business…
• Page 97
  Motor y Transmisión Desarmado del Motor remove •primary gear and keyway Remove •Retaining ring gear driver oil pump washer. Remove •The driving gear of the oil pump Remove •Safety pin driver gear oil pump washer. Manual de Servicio Bajaj Dominar 400…
• Page 98
  (2 und.) serve •Cam changes Remove •Pin inhibitor with an allen wrench of 5 serve •Inhibited washer (2 und.) And spring Remove •Star pin changes allen wrench 5 serve •Star changes along with the horn. Bajaj Auto International Business…
• Page 99
  •Bolts holding the magneto cover (15 und.) serve •Magneto Cover Desarmado de la Cubierta de Culata Remove •Bolts guide plates stator branch (3 und.) serve •guide plates Remove •Bolts holding the stator (3 und.) Manual de Servicio Bajaj Dominar 400…
• Page 100
  Motor y Transmisión Desarmado del Motor Remove •Grommet plate magneto. serve • Stator. Remove • Packing the cover of the magneto. • 2 pins Remove •Pin guide plate starter clutch. serve •Guide plate starter clutch Remove •Flywheel bolt. Bajaj Auto International Business…
• Page 101
  Using the magneto flywheel puller (Code Remove •Flywheel magneto •Using given the locknut Balancer (Code 37 0041 60), remove the nut balancer. serve •Belleville washer and flat washer Remove •Pin Balancer drive gear. • Washer Manual de Servicio Bajaj Dominar 400…
• Page 102
  • The balancer drive gear. Take out • The driven gear of the balancer and pin/key. Remove •Counter gear starter. •Bolts crank angle sensor (2 und.) Remove •Bolts neutral switch (2 und.) take out •Neutral switch. Bajaj Auto International Business…
• Page 103
  •The bolts plates that guide the sensor wire crank angle. Remove •Grommet crankcase. serve •integrated crank angle sensor and neutral switch. Remove •Bolts holding the evacuation pump (3 und.) serve •The evacuation pump. Remove •Safety pin. remove • Axis Manual de Servicio Bajaj Dominar 400…
• Page 104
  •Make sure the O-ring of the pipe T is in good condition. Remove •Bolts holding the cover of the water pump (5 und.) serve •Water pump with O-ring. •Make sure the O-ring of the water pump is in good condition. Remove •Pegs (2 und.) Bajaj Auto International Business…
• Page 105
  •The bolts holding the engine starter serve •The starter motor. Remove •Bolts holding the housing on the left side (16 und.) With a key of 8 mm -Bolt highlighted with a circle is longer than the others. Manual de Servicio Bajaj Dominar 400…
• Page 106
  •The pins (2 und.) •Plate bolt securing the balancer bearing. Take out • The balancer and the plate that ensures the bearing of the balancer. Remove • The axis of the changes nails exit together with the springs. Bajaj Auto International Business…
• Page 107
  •Nail shaft input changes. Remove •Claw input changes. •Drum changes Remove •Output and input shafts.• Oil rail Desarmado del Cárter Izquierdo Remove •Shaft bearing usin doel extractor input. (Code 37 10DT 77) •Speaker output shaft. Manual de Servicio Bajaj Dominar 400…
• Page 108
  •Retainer water pump (2 units) Note Use fastener catch water pump (Code 37 004156) to position the retainer. Remove •Plate bolt securing the bearing of the input shaft. serve •The plate securing the bearing of the input shaft. Bajaj Auto International Business…
• Page 109
  •The plate bearing the drum changes using the guide set bearings. •Using the guide set bearings: -Input shaft bearing. -Output shaft bearing. — Bearing of the drum of changes. Remove •Top of the cam changes with a key of 12 mm. Manual de Servicio Bajaj Dominar 400…
• Page 110
  Engine Oil Flow Oil Strainer Entry Oil Pump Relief valve Pump Filter Engine Oil Output Oil Filter Crankcase Oil Oil gallery in the right case Bearing lubrication Crankcase hole for entry to Gallery Left crankcase oil Crankcase Clutch Bajaj Auto International Business…
• Page 111
  Motor y Transmisión Flujo del Aceite del Motor CONTINUA DESDE Clutch cover Towards the Crankshaft 2 injectors to lubricate the clutch Sup part Cub. Clutch Crankcase hole Lubrication Crankshaft Superior hole crankcase Manual de Servicio Bajaj Dominar 400…
• Page 112
  Motor y Transmisión Flujo del Aceite del Motor CONTINUA DESDE Entry and exit in the cylinder ENTRY EXIT Entry and Exit in the Head ENTR SALIDA CONTINUA DESDE Bearing Lubrication Left Crankcase The oil injector To the Nozzle Bajaj Auto International Business…
• Page 113
  Bearing lubrication Left hole in the crankcase for Oil for lubricating rail entry into the Cub. Magneto of Lineshaft the broadcast Injector to lubricate the Magneto Hole in the Cub. from Magneto Manual de Servicio Bajaj Dominar 400…
• Page 114
  Motor y Transmisión Flujo del Aceite del Motor Crankshaft Chamber Pasaje para evacuación Evacuation Strainer Evacuation pump inlet Evacuation pump output Release of oil in the chamber of the transmission case by the evacuation pipe Bajaj Auto International Business…
• Page 115
  Motor y Transmisión Notas Manual de Servicio Bajaj Dominar 400…
• Page 116
  Puntos Clave de Aprendizaje Aplicación correcta del apriete para los diferentes componentes del Chasis Comprender el uso de las herramientas especiales SOP Importantes. CAPÍTULO 4 Chasis y Suspensión Torques Data Service Special tools Important Manual de Servicio Bajaj Dominar 400…
• Page 117
  Disc plate mount rear 3.2 ~ 3.8 kgm 2.7 ~ 3.3 kgm 0.9 ~ 1.1 kgm Swing arm mount Caliper mount front fender mount 4.0 ~ 5.0 kgm 0.8 ~ 1.0 kgm 13.0 ~ 15.0 kgm Bajaj Auto International Business…
• Page 118
  Fork leg bend Drive chain length Length of 19 Links MEASURE THIS LENGTH 20 ~ 25 mm TIR 0.1mm or less 317.5 (19 links) 323.8 limit 35 ~ 40 mm limit TIR 0.2mm limit Manual de Servicio Bajaj Dominar 400…
• Page 119
  Aplicación : To attach the seat while fork bolt telescopic outer tube is removed. Fork seal driver Código : 37 1740 24 Aplicación : install fork seals Steering bearing remover. Código : 37 1840 14 Aplicación : To remove steering race. Bajaj Auto International Business…
• Page 120
  : 37 2040 35 Aplicación : To connect the unit review supply fuel pump to the fuel pump. Adjustment Tool Special Bolt steering. Código : 37 0043 40 Aplicación : To tighten and loosen the bolt telescopic. Manual de Servicio Bajaj Dominar 400…
• Page 121
  Notes : •If the ABS indicator lights while driving, drive to the nearest Technical Service Bajaj for review / repair. •Always keep a safe distance between you and objects front of you. The vehicle speed should be reduced if the road conditions are extreme.

• Page 122: Chassis And Suspension

  If a wheel lock reduces the force applied to the disc pressure, allowing the brake fluid to flow back into the reservoir. Sensors Wheel Speed: These are speed sensors hall effect type. They detect the pulse sensor mounted wheel disc and send it to the ABS unit. Speed Manual de Servicio Bajaj Dominar 400…

• Page 123
  Y al recipiente Conector Y Tubería del Tanque al Conector Y Tubería del Conector Y al tubo . colector de drenaje de combustible Tapón Cuerpo del Acelerador Tubería del Conector Y al cuerpo del acelerador Conector Bajaj Auto International Business…
• Page 124
  Head •Hose vessel purge valve. Head •The hose from the purge valve to throttle body and ensure that it is subject to the plastic bracket to thechassis. Manual de Servicio Bajaj Dominar 400…
• Page 125
  •The tab cover side of the grommet. serve •right side cover. Remove •Seat cowling left. •Left side cover simultaneously. Remove •Bolts box supporting air filter (3 units). Remove •Clip vent pipe •Vent pipe of the head cover. Bajaj Auto International Business…
• Page 126
  -Stepper motor — Injector — TMAP — TPS •Lift the air filter and the throttle body. •Pull the hose clip container to the throttle body. Remove •The hose of the container to the throttle body. Manual de Servicio Bajaj Dominar 400…
• Page 127
  •Bolts (2 units) of the right rear handle serve •Rear handle. Remove •Bolts seat cover as follows: •One bolt metal washer.•Metal washer • 1 screw Remove •Tinillo the right side• Flat washer.• Screws on the back. Bajaj Auto International Business…
• Page 128
  Chasis y Suspensión SOP Importantes Remove •Rear fins (3 units) of the slots in seat cover. •Fins seat cover of the lower central slot. serve •Right seat cover. Manual de Servicio Bajaj Dominar 400…
• Page 129
  Chasis y Suspensión Notas Bajaj Auto International Business…

• Page 130: Battery

  The various electrical circuits CAPÍTULO 5 Sistema Eléctrico Drums What to do and what not to do Review Procedure Review Procedure Power Relay Standard Operating Procedures Electrical circuit diagrams Manual de Servicio Bajaj Dominar 400…

• Page 131
  Remove the electrolyte container packaging. Remove the strip ofcaps. Do not remove the seals. Keep pulling plugs as it will be used in the battery for ports again. Note : do not puncture the seals manually Corks strip seals Bajaj Auto International Business…
• Page 132
  Charge the battery with a battery charger VRLA (sealed) recommended by deacuerdo the standard operating procedure (SOP) Bajaj. Never use conductive materials such as screwdrivers that can produce sparks near the battery terminals. No need to add Cuidado electrolyte. Manual de Servicio Bajaj Dominar 400…
• Page 133
  Do not install accessories Midtronics tester To electric extras This will check the status cause the circuit to of the VRLA battery. short-circuit and the battery to discharge. This will reduce the life of the battery. Bajaj Auto International Business…
• Page 134
  Do not remove the silicone intact. seal the adjustment screw as this could allow water ingress. Make sure the horn button works properly. Make sure the battery is fully Do not hit horn with charged screwdriver or hammer. Manual de Servicio Bajaj Dominar 400…
• Page 135
  • Do not replace the spark plug with a non-recommended (different temperature range). • Never short the primary coil wire high ground. It could cause failures in the ECU. • Do not adjust the light of the spark plug with instruments such as screwdrivers, pliers, etc. Bajaj Auto International Business…
• Page 136
  • Do not add extra electrical loads, such as: music speakers, additional speakers, buzzers, etc. because it will reduce the life of the switch and battery. • Do not alter the spring rear brake switch. • Do not operate the switches immediately after washing. Manual de Servicio Bajaj Dominar 400…
• Page 137
  Off the int. Off ECU and the engine can not F7-7.5 Amp start F8-7.5 Amp speedometer primary and secondary speedo does not work The ABS system does not work. ABS indicator stays on F9-7.5 Amp ABS 9MECU and thes peedometer does not show speed Bajaj Auto International Business…
• Page 138
  You can accessall fuses. To open the fuse box ABS: lift Press both sides of the fuse box and lift theABS. Now you can access all ABS presss press fuses. Manual de Servicio Bajaj Dominar 400…
• Page 139
  If the fuse is blown, replace it with a new one of the same amperage. When replacing a fuse, make sure new fuse matches the specified amperage for that circuit. Install a larger capacity fuse may cause damage to the branch or Cuidado components. Bajaj Auto International Business…
• Page 140
  Blue /Red no continuity Test and measurement equipment:Multimeter SOP: •Turn the ignition switch OFF. •Turn off the switch OFF. •Set the multimeter to continuity mode. •Connect the multimeter as shown in the table above. Manual de Servicio Bajaj Dominar 400…
• Page 141
  •Check operation of rear brake switch pressing the brake pedal.•If the brake light does not come on, check the rear brake switch. Clutch switch Test and measurement equipment:Multimeter SOP: •Check the clutch switch for continuity as follows: range yelow /green black/yellow pressed handle released handle Bajaj Auto International Business…
• Page 142
  Enclose with brown clip 2.2 A 200 CC A speakerwire. Test and measurement equipment:CLAMP CC SOP: •Enclose with brown clip speaker wire. •Press the horn button and check the current instantaneous drop caused by the horn. Manual de Servicio Bajaj Dominar 400…
• Page 143
  Resistance (+2 ohm) bars in speedo full tank Full Tank Note: If the display of the speedometer is not adequate, then check the following: •Battery voltage. •The connector speedometer and fuel gauge are securely attached. Standard Bajaj Auto International Business…
• Page 144
  •Connect an external supply 12 V DC to the relay terminals. •You should hear a sound ‘tuc’. •Set the multimeter to continuity mode. •Connect the multimeter to the relay terminals. •Continuity (beep sound) indicates that the starter relay is in good condition. 200 Manual de Servicio Bajaj Dominar 400…
• Page 145
  Signal from the one (central) coil output high. •Electrode light: 0.8 ~ 0.9 mm •Frequency regulation and cleaning: Every 20,000 Km.•Replacement Frequency: 40,000 Km. Spark plug cap •Central plug cap •Right spark plug cap. •Left spark plug cap. Bajaj Auto International Business…
• Page 146
  DC voltage, also regulates the DC voltage to 14.5 V + 0.2 V DC at all engine speeds. • This voltage is used to charge the VRLA 8Ah battery. (sealed battery) Manual de Servicio Bajaj Dominar 400…
• Page 147
  • Press the start button for 3 seconds and check the current shown in Flasher Location: Under the passenger seat, near the suspension unit. There is not a method ofrevision. To test its operation try replacing it. Bajaj Auto International Business…
• Page 148
  1.6 A will continuously flow through the branch electric. To avoid this, this relay is provided. 4. Intermediate Relay: This relay is used in the starter motor to activate the start relay. Manual de Servicio Bajaj Dominar 400…
• Page 149
  (2 und by side)together with the plastic washer. Take out • Left and right side masks • Make sure the part sponges inside of the masks are in goodcondition. Bajaj Auto International Business…
• Page 150
  • The headlight connector and remove front light. Remove • The screws (3 und) together with themetal washers of the headlight with a Phillips screwdriver Take out • The headlight of the fairing .. Manual de Servicio Bajaj Dominar 400…
• Page 151
  Rear left and right handles with a6mm Allen key and remove thegrippers. Remove • The bolts (2 und) of the upper part of the fender and the bolts (3 und) with a 10 mm wrench and a Phillips screwdriver. Bajaj Auto International Business…
• Page 152
  10 mm wrench and a star screwdriver. Take out • Rubber protector of the couplings and disconnect them as follows: • Rear lighth • Right rear directional • Left rear directional • Rear plate holder light Manual de Servicio Bajaj Dominar 400…
• Page 153
  Remove • The rear fender as shown shows in the photo.Remove • Seat insurance plate. Remove • The plate, of the seat insurance cable,of the cable bra. • Seat insurance cable. Take out • Rear fender. Bajaj Auto International Business…
• Page 154
  • Back plate together with the support. Remove • Screw of the pigtail of thefender. Take out • Fender’s queue Remove • the bolts (4 und) of the lower tray and the screws (2 und) Manual de Servicio Bajaj Dominar 400…
• Page 155
  Take out • Directional cable, such asIt is shown in the photo. • The directional cable of the cable support. Remove • The nut that supports the directional. Take out • Directional, nut and washer. Bajaj Auto International Business…
• Page 156
  • Screw (2 und) of light of the carrier plate. Take out • The light of the plate holder Remove • Reinforcement bracket screw of the rear fender Take out • Reinforcement support ofrear fender. Manual de Servicio Bajaj Dominar 400…
• Page 157
  Procedimientos de Operación Estándar Remove • Seat insurance plate ..Take out • Seat insurance together with support of the seat insurance cable. • The rear fender shown in the photo can be replaced by new one. Bajaj Auto International Business…
• Page 158
  • The nuts (4 und) of the bracket of the ECU with a 10 mm wrench and take out the support of the ECU. • Battery box. Tire • The ECU insurance as shown in the photo. Manual de Servicio Bajaj Dominar 400…
• Page 159
  ECU that has the inscription «Top» is up. • Position the ECU completely in the connector and place the safe. Empuje Presione Reemplazo del Velocímetro Secundario Take out gas.• Tank cover Remove • Speedometer bolts secondary (2 und) Bajaj Auto International Business…
• Page 160
  Take out • The secondary speedometer. Removal of the Rollover Sensor Remove • Fuel tank • Tilt sensorconnector. Remove • The bolts (2 und) of the tilt sensor support. Take out • Tilt sensor support. Manual de Servicio Bajaj Dominar 400…
• Page 161
  Sistema Eléctrico Procedimientos de Operación Estándar Remove • The nuts that support the tipping sensor (2 und), holding the screw with a Phillips screwdriver. • Separate the rollover sensor from its mounting plate. Bajaj Auto International Business…
• Page 162
  MAGNETO REGULATOR GROUND Yellow CONTROLLER blue White Brown Black Pink rrrhah Green Light green Violet AAAAAA Saw: B / NAAAB / N SPEEDOMETER 2 G / Rs INT OFF SUPPLY V / B PIN 3 PIN B / NB LAND V / RA OUTPUT FUSE IND.
• Page 163
  COIL HIGH 2 ROLLOVER SENSOR MAIN RELAY INT. OFF POSITION SENSOR (CONTROL COMMAND DER) CRANK B / R RM / Az / AM / V A: Yellow M / BR / B R / B Az / V N / A Na / BN / R Az: Blue B: Black G / Rs G N / A…
• Page 164
  IGNITION SWITCH OUTPUT FUSE 30A ONOFF M / Az B / N ENT. FUSE RB / N M / Az Yellow blue White Brown Black Pink Green Light green Violet Saw: HORN SWITCH (LEFT control command) HORN VRLA BATTERY — 8AH…
• Page 165
  INT. FRONT BRAKE INT. REAR BRAKE Yellow blue White Az M Brown Black Pink Green Light green Az M Violet Saw: IGNITION SWITCH OUTPUT FUSE 30A ONOFF M / Az B / N ENT. FUSE RB / N M / Az N / A N / A VRLA BATTERY — 8AH…
• Page 166
  INT. OFF (COMMAND ROLLOVER SENSOR MAIN RELAY PUMP combined Vertex Laser Yellow CONTROL DER) blue White Brown RM / Az / AM / V Black Na / B Na / Az G / B Rs / Az RELAY M / BR / B R / B Az / V Pink Green…
• Page 167
  UNIT COMMAND CONTROL DER SUSPENSION SWITCH MAIN RELAY INTERMEDIATE RELAYS BUTTON INT. OFF BOOT CLUTCH RM / Az A / G N / A Rs / RR / A A / RR / A R / VM / B M / BR / B R / B Az / V N / A A / G…
• Page 168
  main relay Yellow blue White Brown RM / Az Black M / BR / BR / B Az / V Pink Green G / Rs G Light green Violet Saw: SPEEDOMETER 2 MG / MA / M SUM. ON SUM. INT. Rs PIN 1 PIN 3 Na / M GROUNDING PIN 5 V / B…
• Page 169
  INT. OFF (COMMAND MAIN RELAY CONTROL DER) RM / Az R / B Az / V M / BR / B G / R G / Rs SPEEDOMETER 2 POWER SUPPLY PIN 2 PIN 1 Z / R Z / R I / P REFRIG IND TEMP.
• Page 170
  DIRECTIONAL DER POST DER DIRECTIONAL N / A N / A N / A SPEEDOMETER 1 BGVG BGVG 10 PIN BATTERY / Rs V / B PIN / Rs V / 17 PIN 19 PIN I / P DIRECTIONAL DER PIN 16 20 GROUND I / P DIRECTIONAL IZQ INT.
• Page 171
  SPEEDOMETER 1 I / P LEVEL OF COMB PINS 7 ABA / DRUMS / B PIN 10 G / Rs V MV / B INT. PIN OFF 19 PIN EARTH 20 SWITCH IGNITION ONOFF M / Az B / N 7.5A 7.5A F1 30A FUSE OUTPUT…
• Page 172
  Yellow INT. OFF (COMMAND FUEL INJECTOR CRANKSHAFT POSITION SENSOR MAIN RELAY blue CONTROL DER) White Brown Black RN / A B / R RM / Az Pink M / BR / B R / B Az / V M / B N / B Green Light green…
• Page 173
  Yellow MAIN RELAY INT. OFF (COMMAND blue CONTROL DER) White Brown Black RM / Az Pink M / BR / B R / B Az / V Green Light green G / R G / Rs Violet Saw: PURGE VALVE V / Rs M / B IGNITION SWITCH…
• Page 174
  INT. OFF (COMMAND CONTROL MAIN RELAY Yellow DER) blue White Brown RM / Az Black R / B Az / V Pink M / BR / B Green G / Rs G Light green Violet Saw: SPEEDOMETER 2 MG / Rs MA / SUM.
• Page 175
  SPEEDOMETER 1 BM / G BM / Rs 10 PIN BATTERY Rs / Rs V / B A / MV / I / P INT. OIL PRESSURE PIN 14 GROUNDING PIN 19 PIN 20 INT. OFF A / M OUTPUT FUSE 7.5A 7.5A IGNITION SWITCH…
• Page 176
  Yellow blue White ANGLE SENSOR Brown CRANK COIL HIGH 2 MAIN RELAY INT. OFF (COMMAND CONTROL DER) Black Pink Green B / R / Az G / RM Light green Violet M / BR / B R / B Az / G Saw: N / A Na / BN / R…
• Page 177
  Yellow SPEED SENSOR SPEED SENSOR blue LATER FORWARD CAN INTERFACE White Brown Black N / A Az A G / V Pink Green Light green Violet Saw: EARTH ABS Az / Rs R / B Az / Na B N / A SPEEDOMETER 2 I / P Vehicle Speed ​…
• Page 178
  Yellow Blue COMMAND CONTROL DER MAIN RELAY White INT. LIGHTS ON CONTROL Brown N: Black A / Az N / A LED Pink V: Green RM / Az M / BR / B R / B Az / V Rs / RM / B Light Green Vi: Speedometer 2 Violet…
• Page 179
  Bajaj Auto Limited Akurdi Pune 411 035 India Tel | +91 20 27472851 Fax | +91 20 27407385 www.bajajauto.com CIN number : CIN L65993PN2007PLC130076…