SERVICE INFORMATION MANUAL

BSVI

Revision 0

SERVICE MANUAL

TABLE OF CONTENTS

VISOR ................................................................................................................................1

HOUSING INSTRUMENT CLUSTER .................................................................................2

HEADLAMP ASSEMBLY ...................................................................................................4

HEADLAMP HOUSING COMPONENTS ............................................................................5

HEADLAMP ASSEMBLY AND HEADLAMP BRACKET ....................................................6

AIR FILTER HOUSING .......................................................................................................8

THROTTLE BODY REMOVAL .........................................................................................11

CONTROL SWITCH RH - REPLACEMENT ......................................................................15

CONTROL SWITCH LH - REPLACEMENT ......................................................................16

ELECTRONIC CONTROL UNIT (ECU) ............................................................................17

ABS ..................................................................................................................................18

ENGINE KILL SWITCH CUM ELECTRIC STARTER SWITCH .........................................19

SWITCH BEAM CONTROL CUM PASS-BY SWITCH ......................................................20

TURN SIGNAL LAMP SWITCH ........................................................................................21

EXHAUST SYSTEM - REMOVAL AND INSTALLATION ................................................22

IGNITION COIL ................................................................................................................23

EMS CIRCUIT ..................................................................................................................24

LIGHTING / DC CIRCUIT ................................................................................................25

SELF START / HECU CIRCUIT .......................................................................................26

WIRING HARNESS ROUTING ........................................................................................27

VISOR

Component

: Visor

Component condition

: Vehicle on ramp and component accessible

Objective

: Visor removal

Repair cycle

: As required

01

SERVICE MANUAL

VISOR

Removal

• Park the vehicle on the front paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove allen bolts (4 Nos.) from the headlamp

housing assembly.

Tool

5 mm allen key

Torque

5 Nm

Care should be taken not to scratch or damage the visor

during removal / installation.

Installation

• Installation is the reverse of removal.

CAUTION

02

SERVICE MANUAL

HOUSING INSTRUMENT CLUSTER

HOUSING INSTRUMENT CLUSTER

Component

: Housing Instrument cluster

Component condition

: Vehicle on ramp and component accessible

Objective

: Housing Instrument cluster removal

Repair cycle

: As required

Removal

• Park the vehicle on the front paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove visor. Refer

for procedure.

Visor removal

• Remove side cowl upper LH. Refer Side cowl

upper removal for procedure.

• Remove side cowl upper RH. Refer Side cowl

upper removal for procedure.

• Remove Housing head lamp rear LH and RH. Refer

Housing headlamp rear for procedure.

• Pull the instrument cluster with housing out of the

headlamp assembly.

• Disconnect the couplers (2 Nos.) from the

instrument cluster.

• While disconnecting the lock type coupler, be sure

to release the lock before disconnecting it and push

it back fully from the instrument cluster.

• Take out the cluster with housing from the

headlamp assembly.

• Remove the mounting nuts (3 Nos.) and separate

the cluster from the housing.

Tool

10 mm hexagonal socket or spanner

Torque

15 Nm

Installation

• Installation is the reverse of removal.

• Connect

and run diagnosis

TVS Ride Scan Tool

after installation.

03

SERVICE MANUAL

HOUSING INSTRUMENT CLUSTER

HEADLAMP ASSEMBLY

Component

: Headlamp assembly

Component condition

: Vehicle on ramp and component accessible

Objective

: Headlamp assembly removal

Repair cycle

: As required

Removal

• Park the vehicle on the front paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove visor. Refer

for procedure.

Visor removal

• Remove mirror. Refer

for

Mirror removal

procedure.

• Remove side cowl upper LH. Refer Side cowl

upper removal for procedure.

• Remove side cowl upper RH. Refer Side cowl

upper removal for procedure.

• Remove Housing head lamp rear LH and RH. Refer

Housing headlamp rear for procedure.

• Remove bottom cover. Refer

for

Bottom cover

procedure.

• Remove engine center guard. Refer Engine center

guard removal for procedure.

• Remove engine guard LH & RH. Refer Engine

guard removal for procedure.

• Remove instrument cluster. Refer Instrument

cluster removal for procedure.

• Remove the hexagonal bolts (2 Nos.).

Tool

12 mm hexagonal socket

Torque

15 Nm

• Disconnect the headlamp connector and remove

the cable strap.

• Remove the headlamp assembly from the vehicle.

04

SERVICE MANUAL

HEADLAMP ASSEMBLY

05

SERVICE MANUAL

HEADLAMP HOUSING COMPONENTS

HEADLAMP HOUSING COMPONENTS

Component

: Headlamp housing components

Component condition

: Headlamp assembly on workbench

Objective

: Headlamp housing components replacement

Repair cycle

: As required

Removal

• Park the vehicle on the front paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove visor. Refer

for procedure.

Visor removal

• Remove mirror. Refer

for

Mirror removal

procedure.

• Remove side cowl upper LH. Refer Side cowl

upper removal for procedure.

• Remove side cowl upper RH. Refer Side cowl

upper removal for procedure.

• Remove Housing head lamp rear LH and RH. Refer

Housing headlamp rear for procedure.

• Remove bottom cover. Refer

for

Bottom cover

procedure.

• Remove engine guard LH & RH. Refer Engine

guard removal for procedure.

• Remove instrument cluster. Refer Instrument

cluster removal for procedure.

• Remove headlamp assembly. Refer Head lamp

removal for procedure.

• Place the headlamp assembly on workbench.

• Replace the headlamp housing components as

required. Refer the exploded view for mounting

fasteners.

• Remove 10 mm nuts (4 Nos.) and pan head screws

(4 Nos.).

10 mm hexagonal socket /

Tool

Star screw driver

Torque

10 Nm

• Remove headlamp carrier.

HEADLAMP ASSEMBLY AND HEADLAMP BRACKET

Component

: Headlamp assembly and Headlamp bracket

Component condition

: Vehicle on ramp and component accessible

Objective

: Headlamp assembly and Headlamp bracket removal

Repair cycle

: As required

06

SERVICE MANUAL

HEADLAMP ASSEMBLY

• Remove pan head screws (3 Nos.).

Tool

Star screw driver

Torque

5 Nm

• Gently remove the headlamp assy and replace with

a new one.

Ensure not to look directly into the headlamp, its Bi-LED

headlamp may affect your vision or blind your vision

temporarily.

• Remove pan head screw and separate the bracket

from the headlamp housing.

Tool

Star screw driver

Torque

5 Nm

Installation

• Installation is the reverse of removal.

07

SERVICE MANUAL

HEADLAMP ASSEMBLY

CAUTION

Removal

• Park the vehicle on the paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove the front and rear seat assembly. Refer

Seat assembly removal for procedure.

• Remove the following cowls:

• Refer

for procedure.

Bottom cover Rear

• Refer

for procedure.

Bottom cover Front

• Refer

for procedure.

Side cowl upper LH

• Refer

for procedure.

Side cowl upper RH

• Refer

for procedure.

Fuel tank cover

• Refer

for procedure.

Side cowl LH

• Refer

for procedure.

Side cowl RH

• Refer

for procedure.

Engine guard Center

• Refer

for procedure.

Engine guard LH

• Refer

for procedure.

Engine guard RH

• Refer

for procedure.

Headlamp housing LH

• Refer

for procedure.

Headlamp housing RH

• Remove the fuel tank cover and fuel tank assembly.

Refer

for procedure.

Fuel tank – Removal

• Remove radiator. Refer

for

Radiator - Removal

procedure.

While removing the air filter housing, ensure not to place

your hands near to the radiator fan if the battery terminals

are not disconnected.

The radiator fan switches ON and OFF automatically

based on the engine temperature. So, the battery

terminals should always be disconnected before touching

or dismantling the radiator fan.

• Disconnect negative terminal of the battery.

• Using the special tool, remove breather hose from

the crankcase.

• Dislocate the breather hose from the hose clamp.

AIR FILTER HOUSING

Component

: Air filter housing

Component condition

: Vehicle on ramp and component accessible

Objective

: Air filter housing removal

Repair cycle

: As required

08

SERVICE MANUAL

AIR FILTER HOUSING

CAUTION

• Remove the clamp by pressing the locking pips of

clamp using special tool to unfix the clamp from the

air filter assembly.

• Remove the mounting screw (3 Nos.) from the air

filter housing.

Tool

5 mm allen key

Torque

10 Nm

• Release the hose clip to dislocate the air filter

housing from the throttle body.

• Remove the air filter housing assembly from the

frame.

• Close all intakes opening with suitable plugs.

09

SERVICE MANUAL

AIR FILTER HOUSING

Installation

• Installation is the reverse of removal.

• Connect

and run diagnosis

TVS Ride Scan Tool

after installation.

10

SERVICE MANUAL

AIR FILTER HOUSING

THROTTLE BODY REMOVAL

Component

: Throttle body

Component condition

: Vehicle on ramp and component accessible

Objective

: Throttle body Removal

Repair cycle

: As required

Removal

• Park the vehicle on the paddock stand. Refer

Parking vehicle on Paddock stand for

procedure.

• Remove the front and rear seat assembly. Refer

Seat assembly removal for procedure.

• Remove the following cowls:

• Refer

for procedure.

Bottom cover Rear

• Refer

for procedure.

Bottom cover Front

• Refer

for procedure.

Side cowl upper LH

• Refer

for procedure.

Side cowl upper RH

• Refer

for procedure.

Fuel tank cover

• Refer

for procedure.

Side cowl LH

• Refer

for procedure.

Side cowl RH

• Refer

for procedure.

Engine guard Center

• Refer

for procedure.

Engine guard LH

• Refer

for procedure.

Engine guard RH

• Refer

for

Headlamp housing LH and RH

procedure.

• Remove the fuel tank cover and fuel tank assembly.

Refer

for procedure.

Fuel tank – Removal

• Remove radiator. Refer

for

Radiator - Removal

procedure.

• Remove air filter housing and ducts. Refer Air filter

housing for procedure.

• Disconnect negative terminal of the battery.

• Removal the purge valve hose from the throttle

body.

• Be sure to release the lock for disconnecting the

TPS coupler from the throttle body.

11

SERVICE MANUAL

THROTTLE BODY REMOVAL

• Disconnect the fuel injector coupler from the

throttle body.

• Disconnect the T-MAP sensor coupler from the

throttle body.

Clamp Disassembly Sequence

• Remove the turbulence hose from the throttle body

for easy access of the locking pip in the clamp by the

tool.

12

SERVICE MANUAL

THROTTLE BODY REMOVAL