Chapter 7 Frame & Suspension Frame & Suspension 7 Chapter

A Service Data - Frame B Dismantling & Assembling Front Fork

Brake Pad Thickness Axle Run Out Axial Wheel Runout with Tyre Remove :
• Pinch clamp bolt (A)
A

100 mm Remove :
• Axle Nut (A)
Std. Limit Front: 5.0 Rear: 7.3 Std. Limit TIR 0.1 or Less Std. Limit TIR 1.0 or Less A
• Axle
Serv. Limit Front: 1.0 Rear: 2.0 Serv. Limit TIR 0.2 Serv. Limit TIR 2.0
• Wheel sensor case complete

Radial Wheel Runout with Tyre Drive Chain Slack Drive Chain Length (19 Link) • Wheel Assembly

19 Link Length
Note :
Place a wedge between pads of front caliper assly as a percaution

Remove :
1st 2nd 20th • 4 Bolts (A)
A
MEASURE THIS LENGTH • Brace fender
• Mudguard
Std. Limit TIR 0.8 or Less Std. Limit 15 ~ 25 Std. Limit 301.6 ~ 302.1
Serv. Limit TIR 2.0 Serv. Limit 30 ~ 40 Serv. Limit 307.0 Note :
Painted parts should be handled with almost care to avoid scratches when dismantled
Rear Sprocket Warp Front Fork Spring Free Length
Remove :
• Bolt (A)
A
• Bracket with wheel sensor case complete
• Wheel sensor harness coupler
Free Length

Remove :
Std. Limit 0.4 or Less Std. Limit 373.0
• Allen bolt (A)
Serv. Limit 0.5 Serv. Limit 368.0
• Slide aside handle bar LH
A
Note :
Front Fork Oil
Painted parts should be handled with almost care to avoid scratche when dismantled.

Loosen :
233 + 2.0 mm.
Fork Oil Level

B
• Allen bolt (A)
Oil Grade : SAE 10W20 • Allen bolt (B)
Oil Quantity : Drain & Refill
295 ml A
: Complete Overhaul
320 + 2.5 ml

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Chapter 7 Frame & Suspension Frame & Suspension 7 Chapter

Loosen : Collect all the front fork parts as ;

A • Bolt (A) • Oil seal
• Slide down the fork pipe assly • Spacer
• Guide bush
• Fork piston complete
• Spring
Remove :
• Stay fork piston
• Allen bolt (A)

A Assembling Front Fork

Fit :
• Fork piston comp (A) with spring in fork inner pipe

Remove : A B • Stay fork piston (B)

• Drain the oil in the container

• Washer Using Special Tool 37 1740 05
• Spring Fit :
• Outer pipe
Recommended Oil Capacity Per Fork Tube
• Washer
Approx 320 + 2.5 ml (Drain & Refill)
• Allen bolt
Note :
Using Special Tool 37 1740 03
Ensure that the washer is collected from the drained oil container as it gets dropped
into the oil. Fit :
• Guide bush
Remove :
• Washer
• Dust seal
• Oil seal
• Snap ring
• Snap ring
• Dust seat

Fit :
Using Special Tool 37 1740 05
• Spring
Remove :
• Washer
• Allen bolt
• Coller
• Copper platted washer
Note : • Fill fork oil
Mount the special tool firmly on the bench vice and insert
Recommended Oil Capacity Per Fork Tube
the fork pipe. In special tool for firm locking.
Approx 320 + 2.5 ml (Drain & Refill)
Using Special Tool 37 1740 04
Remove :
Fit :
• Insert the fork pipe assembly into the lower 'T' and
tighten lower 'T' bolt. • Allen bolt (A)
• Rotate the special tool handle for separation of inner A
and outer pipe
Note :
Ensure that the snap ring and the bottom allen bolt is removed first.

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Chapter 7 Frame & Suspension Frame & Suspension 7 Chapter

Fit :
C Dismantling & Assembling Front Fairing / Head Light Assembly
A • Slide the front fork assly in the fork holder
• Bolt (A) Fairing Removal :
Remove :
A • Loose pintch clamp bolt (A)

Fit :
• Allen bolt
• Handle bar Remove :
B A
• 2 Allen bolts (B) • Axle Nut (A)
• Axle
• Speedo sensor coupler disconnect
Fit :
• Bracket with wheel sensor case complete
A
• Bolt (A) Remove :
• Wheel sensor harness coupler • Mudgaurd Bolts (A) 4 Nos
A
• Brace fender

Fit :

A • Mudguard
• Brace fender Remove :
• 4 bolts (A) • Oil cooler bolts (A)
• Sleeve 2 Nos
A • Washer 2 Nos
Fit :
• Wheel sensor case on front wheel

A • Wheel assly Disconnect :

• Axle • Wiring harness flexible clamp
• Axle nut (A) • All harness couplers
Note :
Remove the wedge placed between pads of front caliper assly.

Fit : Remove :
• Pinch clamp bolt (A) • 2 Bolts (A) of central mounting
A • Nut 2 Nos
A
• Washer 2 Nos

Remove :
• Slide down the fairing assly down through the fork l;egs

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Chapter 7 Frame & Suspension Frame & Suspension 7 Chapter

Fairing Fitting : D Dismantling & Assembling of Rear Seat Cover / LED Tail Lamp Assly
Fit :
• Guide the fairing assly upward through the fork legs Assembling the Cover Seat
Fit :
• Tail lamp assembly into cover seat.
Fit : • 4 screws

• Mounting the fairing on chassis central bracket

• Bolt 2 Nos
• Washer 2 Nos
• Nut 2 Nos Fit :
• The cover seat
Fit : • Grab rail bolts
• Connect all wiring harness couplers • Cover seat bolts
• Route the harness properly
• Speedo sensor coupler

Fit :
• Connect the coupler
Fit :
• Route the wires and cables properly
• Sleeve 2 Nos
• Washer 2 Nos
A • Oil cooler botls (A)

Fit :
Fit : • Rider and pillion seat
• LH & RH pannel
A • Brace fender
• Mudgaurd bolts (A) 4 Nos

Dismantling the Cover Seat

Fit :
• Speedo sensor assly Remove :
• LH Pannel
• Axle
A • RH Pannel
• Axle nut (A)

Fit :
• Pinch clamp bolt (A) Remove :
A • Pull the pillion seat lock cable
• Pillion seat
• Pull the rider seat lock cable
• Rider seat

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Chapter 7 Frame & Suspension Frame & Suspension 7 Chapter

Remove :
E Parts Inspection Parameters
• Tail lamp connection

Note : Front Axle :

Ensure correct routine of wires and cables. • Axle bend / twisted / ok
• Axle threads washed away / damaged ok
• Axle outer diameter scratched / dents / damaged
Remove :
• Grab rail bolts
• Cover seat bolts Front Fork Assly :
Fork Outer tube :
• Surface finish smooth / silver painted / No damages / dent / scratches
• No cracks / bends / blow holes
Remove : • Seat for guide bush, oil seal fitment deformed / cracked / ok
• Pull out the cover seat • Groove for snap ring fitment not machined / Improper / ok
Note : • Mudguard brace fender mounting threads damaged / washed away / ok
Grip and pull out the cover seat firmly as bottom inside end is plugged into rubber • Axle passing hole, caliper assly mounting hole, diameter free from casting
grommet. material / rough finish
• Internal bore rough / smoothly machined
Remove : • Lower clamping allen bolt fitment threads damaged / washed away / ok
• 4 Screws
• Tail lamp assly Fork Inner Pipe :
• Surface finish of inner pipe scratched / scoring marks / dents / damaged /
ok
• Non return valve fitted on bottom side internally damaged / noisy / ok

Fit : • Internal threading for allen bolt fitment washed away damaged / ok
• Inspect the tail lamp assly • Hole for oil passage on bottom side clogged / free
• Seat for slide bush fitment damaged / ok
• Slide bush OD scratched / dent marks / ok
• Slide bush having adequate tension

Fork Spring :
• Fork spring twisted / bend / ok
• Fork spring length as per service limit
• Fork spring tension adequate

Fork Cylinder Set :

• Fork cylinder twisted / bend / ok
• Fork cylinder piston ring cracked / broken / worn out / ok
• Fork cylinder spring bend / twisted / broken / ok
• Fork cylinder spacer cracked / work out / damaged / ok

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Chapter 7 Frame & Suspension
F Know It On Your Finger Tip
Head light bulb Hi-beam &
Low-beam are to be adjusted
A
by turning ‘IN’ & ‘OUT’ of
screw A & B.
B axle nut.
Slide down the complete
faring gently to remove it
from the vehicle.
When fitting oil seal ensure
that the laser marking on oil
seal should face towards
technician.
Pulsar DTS-Fi Training Notes
Frame & Suspension 7 Chapter
G Evaluate Yourself
While removing & fitting the
front axle always :-
• first loosen the pinch bolt
& then the axle nut.
Evaluate yourself
• Lastly tighten the pinch 1. Front fork spring service limit is -
bolt after tightening the a. 455.5 mm b. 448.5 mm c. 368.0 mm
2. Recommended front fork oil level inside the pipe is -
a. 168 ml - Drain & Refill. 194 + 2.5 ml. - Complete overhaul
b. 320 ml - Drain & Refill. 295 + 2.5 ml. - Complete overhaul
Ensure that all the couplers c. All above are correct.
are placed inside the rubber
boot. 3. To remove the fairing assly front mudguard needs to be removed -
a. True b. False
4. Projector type bulb has vertical adjustment facility -
a. True b. False
5. Tightening torque for pinch clamp bolt is -
a. 2.0 ~ 2.2 Kgm b. 2.0 ~ 2.6 Kgm c. 2.2 ~ 2.8 Kgm
6. Front axle tightening torque is similar with Rear Axle -
a. True b. False
7. Fairing cannot be removed without removing front number plate mounting bolts -
a. True b. False
8. BCU can be removed without removing fairing -
a. True b. False
9. The fork outer tube bottom allen bolt holds
a. Fork inner pipe b. Fork cylinder c. Fork outer pipe
10. Slide bush (DU) is located between inner & outer pipe on bottom side of fork inner pipe ?
a. True b. False
11. Guide bush is located between inner and outer pipe on upper side of fork inner pipe.
a. True b. False
12. Guide bush & slide bush can be interchanged -
a. True b. False
13. Tail lamp LED assly can be removed without removing cover seat
a. True b. False
14. Oil cooler mounting bolts are to be removed while fairing removal -
a. True b. False
15. It is recommended to fit the fork oil seal with its Part name and Part no written facing downward
a. True b. False
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Chapter 7 Frame & Suspension

Notes :

Chapter 8 A
Brakes & Wheels
Dismantling & Assembling Rear Disc Brake 148

B Tubeless Tyres 157

• Function, Construction & Working
• Advantages Over Conventional Tyres
• Precautions to be Followed
• Puncture Repair Procedure

C Parts Inspection Parameters 164

D Know It On Your Finger Tip 166

E Evaluate Yourself 167

Key Learning Points

After reading this chapter you should be able to understand..
• Dismantling & Assembling of hydraulic disc brake system as per standard
operating procedure & precautions to be followed.
• Air bleeding procedure for disc brake system.
• Advantages of tubeless tyres & various puncture repair procedures.
• Important tips to be followed while handling brake fluid.

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