Bajaj Dominar 400UG 2019 Training Notes
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Bajaj Dominar 400UG 2019 Training Notes

Bajaj Dominar 400UG 2019 Training Notes

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Training Notes
(Note: The 'Rev.03, Aug 2019' is a supplementary training note for new Dominar 400UG.
For information on old Dominar 400 please refer training note 'Rev.00, Feb 2017')
Dominar 400UG

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Summary of Contents for Bajaj Dominar 400UG 2019

  • Page 1 Training Notes (Note: The ‘Rev.03, Aug 2019' is a supplementary training note for new Dominar 400UG. For information on old Dominar 400 please refer training note ‘Rev.00, Feb 2017') Dominar 400UG...
  • Page 2 Copyright, applying to this drawing and the information Bajaj Auto Limited accepts no liability for any inaccuracies contained therein vest solely and exclusively with Bajaj or omissions in this publication, although every possible Auto Limited.

  • Page 3: Table Of Contents

    Contents Supplementary Dominar 400 UG CHAPTER Technical Specifications..................2 PDI Check Sheet....................5 Tightening Torque & Service................10 Speedometer Related Information................17 BOSCH Diagnostic Tool Updation.................28 Wiring Harness Routing..................39 EVAP Routing......................43 Hose / Speed Sensor Routing................45 USD Fork Information...................52 Special Tools......................53 Important SOP......................54 Part Identification....................86 Electrical Circuit Diagrams..................111...
  • Page 4 PDI Check Sheet Torque Values & Service Limits Speedometer Related Information BOSCH Diagnostic Tool Updation Wiring Harness Routing EVAP Routing Hose / Speed Sensor Routing USD Fork Information Special Tools Important SOP Part Identification Electrical Circuit Diagrams Bajaj Dominar 400UG 177 1...

  • Page 5: Technical Specifications

    : Pressurized oil supply Engine Cooling : Water (Liquid) cooling Engine Oil Details : Grade : Bajaj DTS-I 10000 (SAE 10W50 API ‘SL’ / JASO ‘Ma2’) Drain & Refill : Dominar UG : 1700 ml : Dominar : 1500 ml...
  • Page 6 : LED, Blue Turn Signal Indicator : LED, Green Speedometer Back Light : LCD, Blue Fuel Level Indicator : LCD Bar Low Oil Pressure Indicator : LED, Red Alert message in DOT matrix display Malfunction Indicator : LED, Yellow Bajaj Dominar 400UG...

  • Page 7: Preventive Maintenance Chart

    • Wipe off water by compressed air & then by clean lint free cotton cloth. Ensure that all water traces are removed from inner pipe & dust cap. • Refit the dust cap. Bajaj Auto International Business...

  • Page 8: Pdi Check Sheet

    - Oil level to Engine Oil 2. Oil leakages, window. be checked at if any. 2. Bajaj Genuine oil vehicle upright 10W50. 2. Check this point after position, both test ride on road. wheel resting on plain surface) 1.
  • Page 9 Tyre Pressure foot pump / 2. Refill air using Front & Rear tyre. case / swing arm for Pneumatic by Pneumatic specs. connection connection / Good quality with air filling foot pump. provision. Bajaj Auto International Business...
  • Page 10 Rear Top & Bottom - 6.5 Kgf (63.8 Nm) 2. Check Points during / after starting the vehicle RH & LH control Check for smooth switch, Switch Operation operation & ignition switch, functioning clutch switch & brake switches Bajaj Dominar 400UG...
  • Page 11 Smooth operation In case of any issue Throttle response, A. P. Grease, during test ride, vehicle Brakes Driveability Feeler gauge, to be attended in effectiveness - Multimeter. workshop. Front & Rear Engine noise No abnormal noise Bajaj Auto International Business...
  • Page 12 5. Visual inspection for dent, scratches, rust etc 6. Clean the vehicle thoroughly before delivery to customer. Note : Vehicle FIFO system required with monitoring system. Vehicles to be dispatched to network only after carrying out PDI activity at Dealership. Not applicable for Dominar Bajaj Dominar 400UG...

  • Page 13: Tightening Torque - Engine

    10.8 - 11.8 Inhibitor nut 1.1 - 1.2 10.8 - 11.8 Manifold mounting bolts 0.7 - 0.9 6.9 - 8.8 Clutch spring bolts 0.8 - 1.2 7.8 - 11.8 Stator mounting bolt 1.0 - 1.2 9.8 - 11.8 Bajaj Auto International Business...
  • Page 14 TDC Locking hole dummy bolt Slack side chain guide bolt Chain guide top bolt Chain guard screws Plug Evacuation strainer Pick up coil harness plate bolt Pick up coil bolt Sprocket drive lock nut (Crankshaft sprocket nut) Bajaj Dominar 400UG...
  • Page 15 1.8 - 2.2 17.7 - 21.6 Flange bolt - Tank rear mtg 1.8 - 2.2 17.7 - 21.6 Swing arm shaft 13.0 - 15.0 127.5 - 147.2 Bracket rear no. plate 0.8 - 1.0 7.8 - 9.8 Bajaj Auto International Business...
  • Page 16 44.1 - 49.1 Engine foundation bolts - Rear (Top & bottom) 63.8 - 0.0 Engine foundation bolts - Front-Top 2.4 - 2.6 23.5 - 25.5 Clamping allen bolt on Axle clamp RH 1.3 - 1.7 12.8 - 16.7 NOTES: Bajaj Dominar 400UG...
  • Page 17 Clutch spring free length 52.1 Friction plate thickness 2.92~3.08 2.72 Steel plate thickness Friction plate warp Steel palte warp 0.15 Gear shift fork guide pin diameter 4.960~4.990 4.91 Gear shift drum groove width 5.050~5.150 5.155 Crankshaft runout 0.02 Bajaj Auto International Business...
  • Page 18 Sr. No. Limits (mm) Connecting rod side (axial) clearance Cam lobe width "Ex 9.4-9.6 & 8.4-8.6 In 9.4-9.6 " Shaft fork shift OD 9.966~9.984 9.922 Fork shift ID 10~10.027 10.067 Clutch assly stackup height 32.936-33.34 30.6 NOTES: Bajaj Dominar 400UG...
  • Page 19 Drive chain length 317.5 323.8 Rear sprocket warp Fr. Fork spring free length 345 mm 320 mm Tyre tread depth Front : 4 +/-0.3 mm UP TO TWI Rear : 6 +/-0.3 mm UP TO TWI NOTES: Bajaj Auto International Business...

  • Page 20: Speedometer Related Information

    & Turn Indicators) are turned ON. • All LCD segments and icons are turned ON. • DOT matrix display continues to show default display of BAJAJ logo. • Speed display shows 188 & Tachometer bar increases from 0 to 13000 & comes back to Zero.
  • Page 21 • Fuel bar = 1- Bar 1 glows steady & low fuel symbol blinks. Low fuel • Fuel bar is less than 1-Bar 1 & low fuel symbol both will blink simultaneously. • Fuel bar = 2-Low fuel symbol shall remain ON continuously. Bajaj Auto International Business...
  • Page 22 5 sec. Primary speedometer will display active warning Select INFO mode Press SET button messages User can select any of the above screens and the screen at ignition OFF condition will be retained in next ignition ON cycle. Bajaj Dominar 400UG...
  • Page 23 Dynamic fuel consumption Average fuel consumption 1 Average fuel consumption 2 Active warning 1 Average Speed 1 Average Speed 2 Active warning 2 Distance to Service Trip Time 1 Trip Time 2 Active warning 3 Fuel range Fuel range Active warning 4 Bajaj Auto International Business...
  • Page 24 (Seen in secondary speedo) Note: Secondary speedo is mounted on tank. Primary speedo Dynamic fuel consumption (Seen in dot matrix window of primary speedo) Primary speedo Distance to Service (Seen in dot matrix window of primary speedo) Bajaj Dominar 400UG 195 21...
  • Page 25 Trip Time 1 (Seen in dot matrix window of primary speedo) Primary speedo Fuel range (Distance to Empty) (Seen in dot matrix window of primary speedo) Note: Will be able to see after few kms ride. Bajaj Auto International Business...
  • Page 26 Primary speedo Trip Time 2 (Seen in dot matrix window of primary speedo) Primary speedo Fuel range (Distance to Empty) (Seen in dot matrix window of primary speedo) Note: Will be able to see after few kms ride. Bajaj Dominar 400UG...
  • Page 27 (Seen in dot matrix window of primary speedo) Refer list of warning messages - Alarm message Active warning 2 displayed on next page. Refer list of warning messages- Alarm message Active warning 3 displayed on next page. Bajaj Auto International Business...
  • Page 28 Odometer roll over Odometer reading > 9,99,999 kms. ODO roll over = 2 if ODO has crossed 9,99,999 kms. twice Notes - Generic alarm LED status - Continuously on for error message =1 - Blink for error message >1 Bajaj Dominar 400UG...
  • Page 29 For resetting trip meter set button is to be pressed for more than 5 sec. TRIP 1,TRIP 2 & ODO shall update simultaneously. CLOCK - • Type: Digital 7 segment with 3-1/2 digits. • Indication: 12 hour format with AM & PM. HH : MM With ( : ) blinks. Bajaj Auto International Business...
  • Page 30 Prior service reminder reset : Distance to service < = 450 km AND prior service reset is not done for present applicable interval e.g. If you are resetting @ > = 14000 km & < 14500, next service schedule shall be displayed as 19450 km Bajaj Dominar 400UG...

  • Page 31: Bosch Diagnostic Tool Updation

    • Addition of “X” character in VIN update. • Avenger 160S ABS added and place created for Platina, Discover models. C021 (As on 16th C019 • Dominar brand added separately. Aug 2019) ES 300 B278 B270 (As on 16th Aug 2019) Bajaj Auto International Business...
  • Page 32 Secondary speedo 1v07.s19 0v74 1v08.s19 0v78 1v12.s19 0v79 1v15.s19 0v80 1v16.s19 0v81 Below matrix is of Hex files for EMS & ABS Hex file Model BAK10AS1922001.hex Dominar UG EURO3 (Without EVAP) BAK101N1922004.hex Dominar UG BS4 (With EVAP) Bajaj Dominar 400UG...
  • Page 33 Select the year “2019” from Model years appeared on tool screen & press Enter. • Select the “Dominar” from Make appeared on tool screen & Press Enter. • Select the “Dominar K10 UG” from models appeared on tool screen & Press Enter. Bajaj Auto International Business...
  • Page 34 29. For latest information refer the technical bulletin. • 8 digit CODE will be displayed on tool screen. • Press Enter. • Message as shown in photograph will appear on tool screen. • Select Yes & press Enter. Bajaj Dominar 400UG...
  • Page 35 Note : After flashing LCD (P) or LCD (S), reset the clock. Note : As per given table as shown in ‘Page number 29' pairing should be done, if not done properly it may cause error of sync. Bajaj Auto International Business...
  • Page 36 Hex file name (which is already flashed for LCD (P)) “K10_Primary . Hex” will appear on tool screen. • Press Enter. • Select the “SW Version” from Read Mfg Info menu appeared on tool screen & Press Enter. Bajaj Dominar 400UG...
  • Page 37 Already available in secondary speedometer “Gear indicator & Time“ feature will be available in Primary Speedometer after flashing of both the speedometers. NOTE : For Neutral gear position, Primary speedometer shows “N” & Secondary speedometer shows “0”. Bajaj Auto International Business...
  • Page 38 If S CAN FAILURE message is not present, ride the vehicle to some KM and check is Dynamic fuel consumption is updating or not. i ) if dynamic fuel is updating, reflash speedometer software in both speedometer. ii) if Dynamic fuel consumption is not updating, replacement is required to confirm the defect. Bajaj Dominar 400UG...
  • Page 39 8 digit code will appear on tool screen. Note down this eight digit code for key generation. DO NOT disconnect the diagnostic tool. • Using BuiltOTP software (already available with you), generate key. (Same way as done during ECU flashing) Bajaj Auto International Business...
  • Page 40 • Message as shown in photograph-J will appear on tool screen. • Entered the noted Km reading. • Press Enter. • Message as shown in photograph-K will appear on tool screen. • Select Yes & press Enter. Bajaj Dominar 400UG...
  • Page 41 Supplementary Dominar 400 UG BOSCH Diagnostic Tool Updation • Message as shown in photograph-L will appear on tool screen. • Enter Km reading will be displayed on secondary speedometer as shown. • Press Enter & disconnect the tool. Bajaj Auto International Business...

  • Page 42: Wiring Harness Routing

    Supplementary Dominar 400 UG Wiring Harness Routing 1. Route wiring harness as shown in photograph. 2. Route wiring harness as shown in photograph. 3. Route wiring harness as shown in photograph. Bajaj Dominar 400UG...
  • Page 43 Supplementary Dominar 400 UG Wiring Harness Routing 4. Route wiring harness as shown in photograph. 5. Route wiring harness as shown in photograph. 6. Route wiring harness as shown in photograph. Bajaj Auto International Business...
  • Page 44 Supplementary Dominar 400 UG Wiring Harness Routing 7. Route wiring harness as shown in photograph. 8. Route wiring harness as shown in photograph. 9. Route wiring harness as shown in photograph. Bajaj Dominar 400UG...
  • Page 45 Supplementary Dominar 400 UG Wiring Harness Routing 10. Route wiring harness as shown in photograph. 11. Route wiring harness as shown in photograph. 12. Route wiring harness as shown in photograph. Bajaj Auto International Business...

  • Page 46: Evap Routing

    Supplementary Dominar 400 UG EVAP Routing Bajaj Dominar 400UG...
  • Page 47 Supplementary Dominar 400 UG EVAP Routing Bajaj Auto International Business...

  • Page 48: Hose / Speed Sensor Routing

    Input Tie brake hose to frame with • cable tie (PA402204) as shown by pink circle. Rear Brake Hose - ABS Unit to Caliper Routing Route brake hose from ABS unit as shown in photograph. • Output Bajaj Dominar 400UG...
  • Page 49 Tie brake hose & rear speed sensor cable together with cable tie • (PA402204) as shown by pink circle. Route brake hose through metal bracket as shown by blue circle. • Cable tie (PA402204) - 6 Nos Bajaj Auto International Business...
  • Page 50 Route brake hose as shown in photograph. • Route brake hose through clamp ABS hose (DT131875 fitted on • frame, above radiator) as shown by pink arrow. Brake hose Throttle cable Route brake hose as shown in photograph. • Input Bajaj Dominar 400UG...
  • Page 51 Tie brake hose to speedo flap with cable tie (JD402217) as shown by • pink circle. Route brake hose through clamp brake hose (JF113851) as shown • by pink arrow. Route brake hose as shown in photograph. • Bajaj Auto International Business...
  • Page 52 Route speed sensor coupler through “W clamps” (DT131878) (fitted • on brake hose) as shown by pink arrow. Route speed sensor cable through slot (as shown by pink arrow) • provided on clamp brake hose. Bajaj Dominar 400UG...
  • Page 53 Press the lock as shown by blue arrow & pull out speed sensor coupler in the direction of pink arrow. Speed sensor coupler Rear Speed Sensor Routing Route rear speed sensor cable through rubber cap - bleeder nut as • shown by yellow circle. Bajaj Auto International Business...
  • Page 54 Connect speed sensor coupler to it’s mating coupler in harness • Speed sensor coupler which is also tied to frame with cable tie shown by pink circle. connected to mating coupler Extra length of speed sensor to be kept behind the frame at shown location Bajaj Dominar 400UG...

  • Page 55: Usd Fork Information

    • 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 Bajaj Auto International Business...

  • Page 56: Special Tools

    For fitment of oil seal & guide bush. Fork clamping Block Part no : 37 0044 12 - Holding piston during lock nut removal & fitment. - Holding fork inner pipe during screw cap inner pipe removal & fitment. Bajaj Dominar 400UG...

  • Page 57: Important Sop

    • Fit rear LH & RH luggage straps as shown in photograph & tighten mounting bolts to 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. Bajaj Auto International Business...
  • Page 58 “Rear Luggage Straps” Routing when not in use • Fold rear luggage straps as shown in photograph to approach towards hook. Hooks Straps • Insert luggage straps in hooks as shown in photograph. Luggage straps should be kept below the pillion seat Bajaj Dominar 400UG...

  • Page 59: Luggage Straps

    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. Bajaj Auto International Business...
  • Page 60 • Pull out lock clip fitted on brake pad pin using plier to avoid lock clip bending / breakage issue. • loosen brake pad pin using star bit Star bit T - 30 T-30 from force ratchet box. to be used from Force ratchet box Bajaj Dominar 400UG...
  • Page 61 U s e c o t t o n c l o t h w h i l e removing pistons from caliper body as “piston fly out” may cause damage to it & any one in the vicinity. Bajaj Auto International Business...
  • Page 62 • Refit the oil seals & dust seals in caliper body. • Smear the silicon grease on piston OD & rubber seals. • Fit all the pistons in caliper body. • Clean the brake pads by smooth emery paper. Bajaj Dominar 400UG...
  • Page 63 • Prefit the brake hose mounting bolts & tighten it to recommended torque (2.1 – 2.8 Kgfm) by torque wrench. Note : Always replace banjo bolt copper washers whenever opened with new one. Bajaj Auto International Business...
  • Page 64 • Fill the master cylinder reservoir by recommended brake fluid. • Carry out air bleeding.(Refer PM Encyclopedia page no. - 155 Air Bleeding SOP) • Tighten the bleeder nut & fit it’s rubber cap. • Fit rubber diaphragm, PVC cap & master cylinder cover. Bajaj Dominar 400UG...
  • Page 65 Remove dummy bolt from crankcase using 10 mm spanner & Fit the crankshaft locker tool (P/N : 37104332) in dummy hole. If the crankshaft locker tool fits in crankshaft, it means that piston is at TDC. Bajaj Auto International Business...
  • Page 66 • By adjusting throttle cable, take out cover cylinder head & it’s gasket. • With the help of feeler gauge, check the tappet clearance. Specifications : Intake : 0.08 - 0.12 mm Exhaust : 0.13 - 0.17 mm Intake side Exhaust side Bajaj Dominar 400UG...
  • Page 67 • Take out guide chain top. • By adjusting throttle cable, take out cam holder. • Holding the cam chain take out camshaft assembly. • Tie cam chain using copper wire & take out other cam shaft assembly. Bajaj Auto International Business...
  • Page 68 C - Measured Tappet Clearance E - Shim to be used = A +D D - Increase in Tappet clearance = C - B = 2.40 + 0.04 E - Shim to be used = A+D = 2.44 mm Bajaj Dominar 400UG...
  • Page 69 Front Fork Oil Leakage Confirmation Fork oil seal cleaner Dia. 35 – 45 mm Edge Identification - Grey colour Check point before use : If tip / edge is damaged, then scrap the fork seal cleaner & order new one. Bajaj Auto International Business...
  • Page 70 - B. • 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. Bajaj Dominar 400UG...
  • Page 71 • 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 remove wheel & Front fender Bajaj Auto International Business...
  • Page 72 • 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. Bajaj Dominar 400UG...
  • Page 73 • Cut wheel speed sensor cable tie by adjusting fender position as shown in photograph. • Remove wheel speed sensor mounting bolt with 8 mm spanner as shown in photograph & take out wheel speed sensor. Bajaj Auto International Business...
  • Page 74 10 mm allen key. • Loosen clamping bolts (2 nos) with 6 mm allen key. • Take out front axle & front wheel. • Loosen upper bracket side bolt with 6 mm allen key. Bajaj Dominar 400UG...
  • Page 75 • Remove fork pipe top bolt using adaptor fork top bolt (P/N 37 0044 14) holding lock nut on piston rod with 19 mm spanner. • Take out fork pipe top bolt & lock nut. Bajaj Auto International Business...
  • Page 76 • Remove fork leg from clamping block & vice. • Take out rubber damper. • Drain fork oil. • Hold fork leg assembly as shown in photograph & pull out the outer pipe. • Remove the dust cap. Bajaj Dominar 400UG...
  • Page 77 Hot Air Blow Gun(P/N 37 0044 13) Information : A – Outlet Nozzle B – Heating mode selection button C – Chord with pin D – Slow heating mode E – Fast heating mode F – Heat mode selection button “OFF” Bajaj Auto International Business...
  • Page 78 • Tap the fork outer pipe to remove the oil seal & spacer. Note: Keep a piece of cloth & tap the pipe gently to remove oil seals. Caution: The outer pipe will be in hot condition. Please take suitable care. NOTES: Bajaj Dominar 400UG...
  • Page 79 (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. Bajaj Auto International Business...
  • Page 80 15 - Fit lock oil seal using appropriate size flat head screw driver. • 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. Bajaj Dominar 400UG...
  • Page 81 • Tighten lock nut with 19 mm spanner, holding fork top bolt as shown in photograph. • Prefit fork top bolt in outer pipe. • Check the working of fork leg assembly by pressing outer tube from top side 2/3 times. Bajaj Auto International Business...
  • Page 82 • Fit fork protector & fender front, tighten its mounting allen bolts to recommended torque. • Fit caliper assembly & tighten its mounting bolts to recommended torque. • Take the vehicle down & remove overhead structure hanging belt from vehicle. Bajaj Dominar 400UG...
  • Page 83 • Use recommended fork oil grade & quantity for desired fork performance. (DO NOT USE FORK OIL BEING USED FOR OTHER MOTORCYCLE i.e. 10W20) Front Fork Oil Grade & Quantity Grade : PRF001 Fork Oil Quantity : 440 ml/leg NOTES: Bajaj Auto International Business...
  • Page 84 Ensure no presence of Fork oil on fork inner pipe while Note: heating Loctite is applied to screw cap inner pipe threads. • Remove screw cap inner pipe with adaptor screw cap inner pipe (P/N - 37 0041 89). Bajaj Dominar 400UG...
  • Page 85 • Take out screw cap inner pipe Screw cap inner Piston rod assembly from piston rod assembly. • Take out fork inner pipe from clamping block & vice. • Take out fork oil as shown in photograph. • Take out : Spacer Bajaj Auto International Business...
  • Page 86 • 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. Bajaj Dominar 400UG...
  • Page 87 • Apply 2 to 3 drops of “Loctite Thread locker (243)” on threading of screw cap inner pipe. Note : Loctite should not drop on any other part except thread area of screw cap inner pipe. Bajaj Auto International Business...
  • Page 88 • Then use Adaptor – screw cap inner pipe special tool for complete tightening as shown in photograph. For fitting of the oil seal & dust seal please follow the SOP that is mentioned on page no. 232 to 235. NOTES: Bajaj Dominar 400UG...

  • Page 89: Part Identification

    Gasket Cover Head Gasket Cover Head Part No JF511046 JY511128 Description Suitable for single cam shaft design Suitable for twin cam shaft design Identification Visual Visual For part numbers refer spare part catalogue available on Portal Bajaj Auto International Business...
  • Page 90 • Top face - Straight design Identification Visual Visual Photograph Gasket Cylinder Head Gasket Cylinder Head Part Name Part No JF511049 JY511139 Chain guide cavity is different than Chain guide cavity is different Dominar 400 Description Dominar 400UG Identification Visual Visual Bajaj Dominar 400UG...
  • Page 91 • Intake Valve : Total length – 89.8 mm • E xhaust Valve : Total length – 103 mm Identification Intake : JFI embossed & Intake : JFE embossed Intake : JYI embossed & Intake : DTE embossed Bajaj Auto International Business...
  • Page 92 Part Name Rocker Arm Rocker Arm Intake - JF511233, Exhaust - JF511234 JU511204 – 3 nos, JY511212-Decomp rocker arm Part No Description Design is different than Dominar 400 UG Design is different than Dominar 400 Identification Visual Visual Bajaj Dominar 400UG...
  • Page 93 Twin cam shaft assembly Identification Visual Visual Photograph Fitted in engine Guide Chain Top Guide Chain Top Part Name Part No JY511058 Description • Without guide chain top • With guide chain top Identification Visual Visual Bajaj Auto International Business...
  • Page 94 Block (Sub part of Kit cylinder block - piston) Part Name Part No 36JF0059 Refer SPC • Chain guide cavity is different than • Chain guide cavity is different than Description Dominar 400UG Dominar 400 • “JF521008” embossed • “JF521009” embossed Identification Visual Visual Bajaj Dominar 400UG...
  • Page 95 Marked as “K10” Marked as “K10 UG” Identification Visual Visual Photograph Connecting tube Connecting tube Assembly Air Filter Assembly Air Filter Part Name Part No DT581079 JF581029 Description Bent connecting tube Straight connecting tube Identification Visual Visual Bajaj Auto International Business...
  • Page 96 Lug is rectangular type Lug is round type Identification Visual Visual 4.75 mm 6.6 mm Photograph Sprocket Crankshaft Sprocket Crankshaft Part Name Part No JF511223 JY511220 Description Teeth width : 4.75 mm Teeth width : 6.6 mm Identification Visual Visual Bajaj Dominar 400UG...
  • Page 97 Part No Description No of link : 106 No of link : 130 Identification Visual Visual Photograph Balancer Assembly Balancer Assembly Part Name Part No DT531200 JY531220 Description Web without step Web with step Identification Visual Visual Bajaj Auto International Business...
  • Page 98 Gear Indicator switch + Crank Angle Sensor Part Name Part No DT351800 JY351800 • Provision for Neutral Switch only • Provision for Neutral & Gear Indication Description • W ith single coupler • W ith 2 couplers Identification Visual Visual Bajaj Dominar 400UG...
  • Page 99 • S traight at muffler fitment side • B end at end chamber fitment side Identification Visual Visual Photograph Assembly Muffler Assembly Muffler Part Name Part No JF591065 Description With muffler Without muffler Identification Visual Visual Bajaj Auto International Business...
  • Page 100 Assembly Clutch Assembly Clutch Part Name Part No JF551500 JF551419 Description No. of petals on friction plate : 48 No. of petals on friction plate : 40 Visual – K10 marking Visual – K10UG marking Identification Bajaj Dominar 400UG...
  • Page 101 Shape is different than Dominar 400UG Shape is different than Dominar 400 Identification Visual Visual Photograph Speedometer Speedometer Part Name Part No JF402406 DT402409 Description With MODE & SET push buttons Without MODE & SET push buttons Identification Visual Visual Bajaj Auto International Business...
  • Page 102 • 6 point mounting top cover Identification Visual Visual Photograph Bracket Secondary Speedometer Bracket Secondary Speedometer Part Name Part No JF171043 JF171087 Description • Shape is different than Dominar 400UG • Shape is different than Dominar 400 Identification Visual Visual Bajaj Dominar 400UG...
  • Page 103 Dominar 400UG is different than Dominar 400 • Bracket purge valve mounting - Location & • Bracket purge valve mounting-Location & shape shape is different than Dominar 400UG is different than Dominar 400 Bajaj Auto International Business...
  • Page 104 Shape is different than Dominar 400UG Shape is different than Dominar 400 Identification Visual Visual Photograph Part Name ABS Unit ABS Unit Part No JF131815 JF131882 Description Big size ABS unit Small size ABS unit Identification Visual Visual Bajaj Dominar 400UG...
  • Page 105 Front fender removed for clarity purpose Front fender removed for clarity purpose Part Name Protector Fork Protector Fork LH - JF181471, RH - JF181472 Part No Description Without protector fork With protector fork Visual Visual Identification Bajaj Auto International Business...
  • Page 106 Part No JF121030 JF151040 • With larger Handle holder lower mounting lugs • With smaller Handle holder lower mounting lugs Description • Inner diameter : Ø 43 mm • Inner diameter : Ø 51 mm Identification Visual Visual Bajaj Dominar 400UG...
  • Page 107 Identification Visual Visual Photograph Part Name Front wheel Front wheel Part No JF131012 JF131026 Description Brake fitment on wheel – On Vehicle LH side Brake fitment on wheel – On Vehicle RH side Identification Visual Visual Bajaj Auto International Business...
  • Page 108 • Allows more precise braking &crispier feeling brakes. Photograph Part Name Front Fender Front Fender Part No Refer SPC Refer SPC Description Shape is different than Dominar 400UG Shape is different than Dominar 400 Visual Visual Identification Bajaj Dominar 400UG...
  • Page 109 Bracket Side stand Bracket Side stand Part No DT113205 JF113209 With provision for side stand switch & Without provision for side stand switch & Description cover side stand switch fitment cover side stand switch fitment Identification Visual Visual Bajaj Auto International Business...
  • Page 110 Side stand Side stand Part No JF113204 JF113212 Description Straight design Bent design Identification Visual Visual Photograph Part Name Reservoir Rear Brake Reservoir Rear Brake Part No JG131821 Refer SPC Description Circular design Rectangular design Identification Visual Visual Bajaj Dominar 400UG...
  • Page 111 Mirror Mirror LH - JL 2316 00, RH - JL 2316 01 LH - JF231608, RH - JF231609 Part No Description Shape is different than Dominar 400UG Shape is different than Dominar 400 Identification Visual Visual Bajaj Auto International Business...
  • Page 112 Metal shroud Fan fitment on radiator Assembly Radiator Fan Assembly Radiator Fan Part Name Part No JG601237 JF601400 Description Without plastic shroud & metal shroud fitted With plastic shroud & metal shroud fitted on fan on fan Bajaj Dominar 400UG...
  • Page 113 RH Pipe Inner & LH Pipe Inner & Piston rod assembly - YJF19005 Axle Clamp - YJF19003 Axle Clamp - YJF19004 Spring & Screw cap inner pipe -YJF19006 Rubber Damper -YJF19008 Spacer Assembly-YJF19007 Lock nut - YJF19009 NOTES: Bajaj Auto International Business...

  • Page 114: Electrical Circuit Diagrams

    Brake Lamp Circuit Refer Existing Dominar 400 SSM Fuel Pump Circuit Refer Existing Dominar 400 SSM Fuel Injector Circuit Refer Existing Dominar 400 SSM Purge Valve Circuit Refer Existing Dominar 400 SSM Lighting Circuit Refer Existing Dominar 400 SSM Bajaj Dominar 400UG...
  • Page 115 Supplementary Dominar 400 UG Electrical Circuit Diagrams Battery Charging & Low Battery Indication Circuit Bajaj Auto International Business...
  • Page 116 Supplementary Dominar 400 UG Electrical Circuit Diagrams Side Stand Circuit Bajaj Dominar 400UG...
  • Page 117 Supplementary Dominar 400 UG Electrical Circuit Diagrams Radiator Fan Motor Circuit Bajaj Auto International Business...
  • Page 118 Supplementary Dominar 400 UG Electrical Circuit Diagrams Side Indicator Circuit Bajaj Dominar 400UG...
  • Page 119 Supplementary Dominar 400 UG Electrical Circuit Diagrams Fuel Meter Circuit Bajaj Auto International Business...
  • Page 120 Supplementary Dominar 400 UG Electrical Circuit Diagrams MIL Indication Circuit Bajaj Dominar 400UG...
  • Page 121 Supplementary Dominar 400 UG Electrical Circuit Diagrams Low Oil Pressure Indication Circuit Bajaj Auto International Business...
  • Page 122 Supplementary Dominar 400 UG Electrical Circuit Diagrams Engine RPM Indication Circuit Bajaj Dominar 400UG...
  • Page 123 Supplementary Dominar 400 UG Electrical Circuit Diagrams ABS Circuit Bajaj Auto International Business...
  • Page 124 Supplementary Dominar 400 UG Electrical Circuit Diagrams Gear Indication Circuit Bajaj Dominar 400UG...
  • Page 125 Supplementary Dominar 400 UG Electrical Circuit Diagrams Starter Motor Circuit Bajaj Auto International Business...
  • Page 126 Dominar 400UG Bajaj Auto Limited Akurdi Pune 411 035 India Tel | +91 20 27472851 Fax | +91 20 27407385 www.bajajauto.com CIN number : CIN L65993PN2007PLC130076...

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