Bajaj Dominar 400 Service Station Manual 2017 – Complete Workshop Repair PDF

Description

Bajaj Dominar 400 Service Station Manual – Complete Workshop Repair PDF

The Bajaj Dominar 400 Service Station Manual is the full workshop-level repair and overhaul reference for the Dominar 400, issued under document number 71112502 at revision 07, August 2017. Its 349 pages cover both the Twin Channel ABS and the Non-ABS variants, moving from workshop safety and general handling practice through complete engine dismantling, frame and suspension overhaul, fuel injection diagnosis and ECU flashing. Every procedure in this Bajaj Dominar 400 Service Station Manual assumes a trained technician working with the specified special tools, a calibrated torque wrench and proper measuring instruments in a clean, properly equipped bay. It is a bench document, not a rider’s handbook.

File Details

• Manual type: Service Station Manual (workshop repair and overhaul)
• Brand / manufacturer: Bajaj Auto Limited, Akurdi, Pune
• Model: Bajaj Dominar 400 (Twin Channel ABS and Non-ABS)
• Document number: 71112502
• Revision: 07, August 2017
• Language: English
• Page count: 349 pages
• File format: PDF

Chapters Covered

• Foreword
• Workshop Safety – personal protective equipment, air tool precautions, CO gas analyser handling, hydro-electric lift safety, fire extinguisher placement
• General Information – battery ground, part handling and storage, inspection, tightening sequence and torque, gasket and O-ring practice, bearings, oil and grease seals, circlips, lubrication, electrical wires, instruments
• Customer Information – safe riding tips, monsoon care, daily safety checks, running-in, fuel saving, non-use maintenance, accessories, warranty policy
• Technical Specifications – engine, chassis and body, electricals, dimensions, weights, oil / grease / Loctite application matrix
• I Read …. I Learn – vehicle identification and controls, periodic maintenance and lubrication chart, preventive maintenance schedule execution, pre-delivery inspection checklist, vehicle information for customer, preventive maintenance SOP
• Engine & Transmission – tightening torques, service limits, important bolts tightening sequence, exclusive special tools, common special tools, important SOP, engine removal from frame, engine dismantling, engine oil flow path, evacuation system, engine assembly skill tips, part comparison
• Frame & Suspension – tightening torques, service limits, special tools, twin channel ABS, cable routing, evaporative emission system, important SOPs, part comparison
• Electrical – battery, dos and don’ts, electrical checking procedure, fuel injection system, relay checking procedure, standard operating procedure, ECU flashing, part comparison, electrical circuit diagrams
• Diagnosis & Troubleshooting
• Warranty Judgment Manual

Read end to end, this Bajaj Dominar 400 Service Station Manual gives a technician the entire working life of the machine: how to safely raise and strip it, which fasteners carry which torque, where the service limits sit before a part must be replaced, how the lubrication and evacuation circuits actually route oil, and how the fuel injection and ABS electronics are wired and diagnosed. The front sections establish workshop discipline and pre-delivery standards, the middle third is pure mechanical overhaul, and the closing third is electrical, electronic and diagnostic work supported by complete circuit diagrams.

What This Manual Enables You to Do

Because the manual is organised system by system with tightening torques, service limits and part comparisons placed directly alongside the procedures, it supports the full range of jobs on this motorcycle rather than a single repair.

• Remove the engine from the frame and fully dismantle it – cylinder head, camshaft, valves, piston, cylinder block, crankcase splitting, balancer assembly, gear cluster and shift mechanism
• Reassemble the engine with correct tightening sequences, thread locking agents, liquid gasket application and lubrication points
• Clean and service the oil strainer, evacuation strainer, engine oil filter, water pump seals and coolant circuit
• Set valve tappet clearance and calculate replacement shim sizes from measured clearances
• Overhaul the front fork – splitting the inner and outer tubes, replacing oil seals, anti-friction bushes and refilling fork oil to the specified quantity
• Service the rear shock absorber mountings, swing arm, chain slider, chain cover and drive chain adjustment
• Perform steering overhaul and set steering play with the specified special tool and torque
• Diagnose the fuel injection system sensor by sensor – coolant temperature, engine oil pressure, roll over, side stand, oxygen / lambda, crank angle, TMAP and throttle position
• Test the fuel pump free flow and fuel pressure, the injector resistance, the HT coils and the stepper motor
• Trace and repair the wiring harness using the ABS and Non-ABS circuit diagrams, plus the ABS-specific harness routing illustrations
• Update ECU firmware and enter the VIN using the Bosch diagnostic tool following the ECU flashing procedures
• Work to the preventive maintenance schedule, lubrication chart and pre-delivery inspection checklist

Engine, Transmission and Chassis Content in Detail

The engine and transmission chapter is the largest part of this Dominar 400 workshop manual. It opens with a consolidated tightening torque table and a service limit table covering compression pressure, valve tappet clearance, rocker arm shaft diameter, cam lobe heights, valve spring free length, valve stem diameters and guide clearances, cylinder bore, piston diameter and piston-to-cylinder clearance, piston ring groove clearances and end gaps, clutch spring free length, friction and steel plate thickness and warp, gear shift fork and drum dimensions, crankshaft run out and clutch stack-up height. Important bolt tightening sequences are illustrated with numbered diagrams for the cylinder head, crankcase and clutch cover.

Dismantling content walks through engine removal from the frame using the engine jack, cylinder head cover and cam sprocket removal, timing chain handling, rocker arm and shim removal, valve spring compression, cylinder block and piston removal, clutch cover and clutch assembly dismantling, oil pump and evacuation pump removal, magneto cover and stator plate removal, and crankcase splitting. The oil flow path is presented as a full schematic showing the route from the oil strainer through the pump, relief valve, engine oil filter chamber, crankcase galleries, crankshaft journal bearings, oil jets and nozzles, and the gear lubrication rail. The evacuation system is documented separately.

Assembly skill tips and part comparison tables follow, covering fork gear shift identification, crankshaft oil passage checking, primary gear washer sequence, balancer gear alignment marks, guide gear shift fitment, piston ring fitment, gasket replacement and oil passage cleaning with low pressure air.

Electrical, Fuel Injection and ABS Coverage

The electrical chapter begins with the 12 V 8 Ah VRLA battery, its charge condition checking and charging procedure, then moves into fuse identification with a full applicability matrix showing the effect of each fuse blowing – main fuse, electrical cluster, main relay and ECU, HT coil supply, radiator fan, lighting, engine kill switch input, speedometer and ABS. Component-level checking procedures follow for the ignition switch, kill switch, front and rear brake light switches, clutch switch, horn current draw, fuel gauge tank unit resistance values, starter relay coil resistance, spark plugs and caps, battery charging coil, regulator rectifier, starter motor cranking current and flasher.

The fuel injection section maps every input and output to the ECU with its malfunction effect, then gives measured values for the coolant temperature sensor, engine oil pressure sensor, roll over sensor, oxygen sensor, crank angle sensor, TMAP sensor, throttle position sensor and side stand switch. Actuator checks cover fuel pump free flow and pressure, the fuel injector, HT coils, stepper motor, radiator fan operation temperatures and the diagnostic tool coupler. ECU flashing is documented step by step, including software installation, tool updating, hex file downloading and VIN entry for a replacement ECU.

Specifications and Service Data You Can Work From

Technical data is not confined to a single chapter. The technical specification section lists the 373.27 cc four-stroke single cylinder engine with 89.0 mm bore and 60.0 mm stroke, 1600 +/- 100 RPM idle, 35 PS at 8000 RPM and 35 N.m at 6500 RPM, wet sump forced lubrication, six speed constant mesh transmission with a one down five up pattern, and Bajaj DTS-I 10000 SAE 10W50 API SJ or JASO MA2 oil at 1500 ml drain and refill or 1800 ml on engine overhaul. Chassis data covers the perimeter frame, telescopic front fork, nitrox mono shock absorber, tubeless 110/70-R17 front and 150/60-R17 rear tyres, tyre pressures, rim sizes, 13 litre fuel tank and RON 91 fuel grade. Electrical specification tables list every lamp, indicator and sensor type.

The oil, grease and Loctite application matrix is one of the most practically useful pages in the Bajaj Dominar 400 Service Station Manual, mapping each lubricant and thread locker to its grade and its exact application – fork oil quantity per leg, HP Lithon RR-3 for steering races, OKS spray for the sealed drive chain, PETAMO GHY441 for water pump oil seals, WD-40 for switch contacts, and Loctite 243 for every listed fastener including cam sprocket, output sprocket, oil pump, chain guide, clutch and stator mountings.

Who This Workshop Manual Is For

This Bajaj Dominar 400 Service Station Manual suits independent motorcycle workshops, trained technicians, service centre staff and technically confident owners who maintain their own machine. It also covers the pre-delivery inspection checklist, the information to be explained to a customer at handover, and the warranty judgment reference. Because it is written for professional workshop use, some procedures depend on the exclusive and common special tools listed in the manual – those tool part numbers and their applications are documented so they can be sourced or substituted correctly.

IMAGES PREVIEW

Instant PDF Delivery

You receive the complete Bajaj Dominar 400 Service Station Manual as a PDF immediately after payment, with no shipping and no waiting for a physical book. Open it on a workshop laptop, tablet or phone, print the pages you need for the bench, and keep the whole 349-page workshop reference on hand for every engine rebuild, fork overhaul, injection fault and electrical repair on the Dominar 400.