I Read ..... I Learn: Discover 125 ST Training Notes International Business

Contents
1 I Read ..... I Learn 1

Identification...................................................................... 2
Salient Features................................................................. 3
Technical Specifications..................................................... 7
PDI Checklist..................................................................... 9
Periodic Maintenance & Lubrication Chart..................... 12
Periodic Maintenance Point............................................. 14
2 Fuel System 29
Carburettor Specifications............................................... 30
Tune up for Optimum Mileage....................................... 31
3 Engine & Transmission 33

Standard Operating Procedure...................................... 34
Special Tools................................................................... 40
Gear Transmission Power Flow........................................43
Service Limits................................................................... 48
Tightening Torques...........................................................51
4 Vehicle (Frame) 55
Standard Operating Procedure.......................................56
Service Limits................................................................... 59
Tightening Torques........................................................... 60
Special Tools....................................................................62
5 Electricals 65
Electricals......................................................................... 66
Dos & Dont's................................................................... 67
Electrical Checking Procedure......................................... 74
Standard Operating Procedure...................................... 83
Electrical circuit Diagram................................................ 91
DISCOVER 125 ST TRAINING NOTES INTERNATIONAL BUSINESS

1
I Read ..... I Learn
Identification
Salient Features
Technical Specifications
PDI Checklist
Periodic Maintenance & Lubrication Chart
Periodic Maintenance Points
DISCOVER 125 ST TRAINING NOTES INTERNATIONAL BUSINESS DISCOVER 125 ST TRAINING NOTES
1 INTERNATIONAL BUSINESS
IDENTIFICATION SALIENT FEATURES
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric codes to
identify your particular vehicle from others of the same model and type.
PERFORMANCE
Frame Number Location

On Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location

On LH Side Crankcase Near Gear Change Lever
(Alpha-Numeric - 11 Digits)
Part Locations
Features Advantages Benefits
1. RH Control Switch 7. Mono Shock absorber
2. LH Control Switch 8. Cover Mud Rear • DTSi engine - 124.6 cc • New generation technology engineered • Higher power & pick up.
3. Speedo Console 9. Assembly Chain Cover • Engine power : 13 PS @ 9000 rpm for high power / pickup and
• Engine torque : 10.79 N.m @6500 performance as well.
4. Single Down Tube Frame 10. Tail Lamp • 4 valve engine
5. Front Disc Brake 11. Grip Frame
6. Silencer • 5 Speed Transmission • Wider range of gear ratios to utilize • Better drive-ability and the best fuel
• ExhausTEC high torque of engine economy
1 2 • Molycoat piston • Reduced friction • Increased fuel efficiency.

• Nozzle oil jet in lubrication circuit • Better cooling of piston • Better life of component.
3 • Protection from seizure
• Electric start • Quick and easy starting. • Feather touch engine starting
11 • DC ignition & Digital CDI • Consistent engine performance • Power and pick up.
10
• DC Lighting system • Intensity & illumination of head light do • Constant bright beam from head light
not change with engine rpm. even at low engine / vehicle speed.
9
8
7 4
6
DISCOVER 125 ST TRAINING NOTES

2 INTERNATIONAL BUSINESS DISCOVER 125 ST TRAINING NOTES
SALIENT FEATURES SALIENT FEATURES
STYLE COMFORT AND CONVENIENCE
Features Advantages Benefits Features Advantages Benefits
• Athletic and muscular petrol tank, side • Trip meter • For recording distance covered in a trip • Easy to record trip distance.
covers and seat cowling. / tour. Also helps in calculating
mileage.
• New head lamp with attractive fairing
and twin pilot lamps. • Fuel Gauge • Displays approx. petrol qty. remaining • More convenience.
in the petrol tank.
• Innovative and Distinctive Graphics.
• Stylish and eye catching looks • Sporty styling
• Low battery indicator • Reminds user to get battery charged in • For maintaining battery in healthy
• Combination of Black & Chrome styling • Improves personality of the rider.
• New Speedometer time. condition.
• Black colored engine, 10 spoke alloy • Engine ‘Oil Level Window’ • For easy inspection & monitoring oil • No hassle of removing, cleaning,
wheels, silencer and other components. level. dipping ‘Dip Stick’ to check oil level.
• Telescopic front fork with anti-friction • Minimum friction between fork pipes. • Comfortable ride on all types of roads
bush & 130 mm stroke. • Longest suspension stroke in its class and for any distance.
• Nitrox Rear Mono Suspension with 110 of bikes. • Better life of front fork oil seal & other
mm wheel travel. parts of fork.
• MF battery with unique vent • Low maintenance - No spillage of • No hassle of frequent topping up of
mechanism. electrolyte. battery.

SALIENT FEATURES TECHNICAL SPECIFICATIONS
SAFETY Engine & Transmission

Type : Four stroke, Natural air cooled, SI Engine
No. of cylinders : One
Bore : 54.00 mm
Stroke : 54.4 mm
Engine displacement : 124.6 cc
Compression ratio : 9.8 + 0.5 : 1
Idling Speed : 1400 + 100 rpm
Max. net power : 13 PS @ 9000 rpm
Max. net torque : 10.79 Nm @ 6500 rpm
Ignition System : DC
Ignition Timing : Variable as per maps in CDI
Fuel : Unleaded Petrol, 87 RON Minimum
Carburettor : BS 26 Manual Choke
Spark Plug : Champion PRZ9HC & BOSCH UR4AC Resistive
Spark Plug Gap : 0.7 to 0.8 mm
Lubrication : Forced Lubrication
Starting : Kick & Electric Start
Features Advantages Benefits Clutch : HTTS 90 kg
Transmission : 5 Speed Constant Mesh (1 down 4 up)
• Robust semi double cradle frame with • Excellent ride and handling stability, • Safe to drive on highway.
longest wheel base - 1306 mm - in its balance and vehicle dynamics. Primary reduction : 3.571 : 1 (75/21)
class of motorcycles. Gear Ratios 1st Gear : 2.833 : 1 (34/12)
2nd Gear : 1.823 : 1 (31/17)
• 200 mm dia front disc, & 130 mm dia • Efficient and effective braking. • Safety.
3rd Gear : 1.333 : 1 (28/21)
rear brake drum.
4th Gear : 1.086 : 1 (25/23)
• Powerful head light, Number Plate • Bright and powerful illumination. • Safe night driving. 5th Gear : 0.909 : 1 (20/22)
lamp, and Pass switch. • Clear visibility of rear number plate Final Drive Ratio : 3.214 : 1 (45/14)
from long distance.
• Pass switch facilitates over taking.
• 10 spoke alloy wheels & unidirectional • Better road grip and nimble handling. • Easy to maneuver and safe to drive.
Chassis & Body
tyres. No maintenance of spoke tightening.
Frame Type : Semi double cradle
• Enhanced life of disc pads. • For maintaining disc brake good Suspension Front : 130 mm Fork travel, Telescopic
• Disc brake system with disc cover. condition & durability. Rear : 110 mm Rear Wheel travel, Mono with nitrox
Brakes Front : Disc
Rear Drum
Brake Size Front : 200 mm Disc brake
Rear : 130 mm Drum brake
Tyres Front : 2.75 x 17, 41 P Unidirectional
Rear : 3.0 x 17, 50 P Unidirectional
2
Tyre Pressure Front : 1.75 Kg / Cm (25.0 PSI)
2
Rear (Solo) : 2.00 Kg / Cm (28.0 PSI)
Rear (with Pillion) : 2.25 Kg / Cm2 (32.0 PSI)
Rims Front : 1.4” x 17” Alloy Wheel
Rear : 1.6" x 17” Alloy Wheel
Fuel Tank Capacity : 10.0 Liters
Usable Reserve : 3.5 Liters
Unusable Reserve : 1.6 Liter

TECHNICAL SPECIFICATIONS PDI CHECKLIST
Controls Frame No. M D 2 D S J Z Z Z

Steering : Handlebar Engine No. J E B
Accelerator : On handle bar, RH grip
Gears : Left foot pedal operated, Step shift Dealer’s Name Dealer’s Code
Brakes Front : Lever operated, RH hand.
Rear : Pedal operated by RH foot Date of PDI PDI done by
Please insure that following checks are carried out during PDI before delivery of vehicle.
Electricals
3 if OK or Observations /
To Check Check For
System : 12 V (DC) 7 if NOT OK Remarks
Battery : 12V 5Ah MF ENGINE
Head Lamp : 12 V 35/35 W, HS-1 Engine Oil : Oil level between lower & upper mark / Top up if required
Stop / Tail Lamp : 12V, 21/5W Bajaj DTS-i 10000 Oil Oil leakage if any - Specify source of oil leakage
Side Indicator Lamp : 12V, 10 W (4 Nos. - Clear Bulbs)
Idling RPM (Warm up) Check in warm up condition -600 C / Adjust if required (1400 + 100 rpm)
Speedometer Lamp : 12V 2W (2 nos.)
Kick Operation Smooth operation
Neutral Indicator : 12V, 2W (Green)
Turn Signal Indicator : 12V, 2W (Green) Gear shifting Smooth operation
Hi-beam Indicator : 12V, 2W (Blue) Engine noise No abnormal noise
Rear Number plate lamp : 12V, 3W Silencer noise No abnormal noise from silencer & shields
Horn : 12 V DC, 70 mm dia.
Engine foundation nut / bolts (Side cover RH to be removed)
Dimensions Fasteners (Check torque) a) Front mounting nuts- 3.5 Kgm

b) Rear monting nuts- 4.0 Kgm
Length : 1980 mm
c) Top mounting nuts- 1.8 ~ 2.2 Kgm
Width : 714 mm
Silencer mounting bolt
Height : 1078 mm
Wheel Base : 1306 mm a) Silencer mouth flange nut- 2.0 ~2.2 Kgm
Saddle Height : 800 mm b) Silencer bracket bolts- 3.5 Kgm
Ground Clearance : 170 mm G S lever mounting bolts- 1.6 ~ 1.8 Kgm
Kick Boss bolt- 2.0 ~ 2.2 Kgm
Weights
FUEL SYSTEM
Vehicle Kerb Weight : 125 kg Fuel Tank / Pipes No leakage / Correct fitment
Gross Vehicle Weight : 255 kg Fuel Cock Smooth operation
Performance FRAME
Tyre Pressure Front : 1.75 Kg / Cm2 (25.0 PSI)
Maximum speed : 102 km/h (with single rider 68 Kg) Rear (with Pillion) : 2.25 Kg / Cm2 (32.0 PSI)
Front & Rear Wheel Free rotation
Notes : Side stand & Center stand Smooth operation
• Values given above are nominal & for guidance only, 15% variation is allowed to cater for
production & measurement. Mirror Proper fitment
• All dimensions are under un-laden conditions. Clear rear view

• Definitions of terminologies wherever applicable are as per Relevant IS/ISO standards. Head lamp Focus adjustment
• Specifications are subject to change without notice.

PDI CHECKLIST PDI CHECKLIST
3 if OK or Observations / 3 if OK or Observations /
To Check Check For To Check Check For
7 if NOT OK Remarks 7 if NOT OK Remarks
CONTROLS All Bulbs Working Head light, Pilot lamps - 2, Tail / stop lamp, Side indicators,
Brakes Front- a) No oil leakage from master cylinder & caliper Speedo bulb, Number plate lamps
b) Check oil level in master cylinder Switch Operation RH & LH control switch, Ignition switch & Brake switch (Front & Rear)
Rear- Brake pedal free play 20 ~ 25 mm Starter Motor Working / Engagement in gear & neutral
Throttle Grip free play - 2 ~ 3 mm. Smooth operation No abnormal noise
Clutch Cable Smooth operation, Free play - 2 ~ 3 mm Speedometer Working of Speedometer, Odometer & Tripmeter
Proper routine ( From outside leg guard) Working of all signal indicators icons (Turn pilot, Neutral, High beam,
Speedo cable Proper routine Side stand, Battery charge & Bajaj logo)
Drive Chain Slackness standard - 20 ~ 25 mm Headlamp assembly No excess gap & Uneven gap
Drive chain lock position & proper fitment Horn Ensure no distorted sound
Equal marking of chain adjuster on both side TEST DRIVE
SUSPENSION Starting Cold start & Warm start
Front Fork No leakage. Smooth working Idling speed (Warm condition) (1400 + 100 rpm)
Rear Shock Absorber Spring adjuster notch position : 2nd notch (Standard) Drive ability Throttle response
Steering Smooth operation (No play / No Sticky movement) Brakes effectiveness- Front & Rear
Lock Operation Steering cum Ignition lock, Seat lock, LH side cover/Petrol tank cap lock CO % Check CO should be 1.5 to 2.5 % in engine warm condition at idling RPM
Front axle nut - 4.5 ~ 5.5 Kgm (before cat converter)
Rear axle nut - 8.0 ~ 10.0 Kgm Cleaning Wash & Clean vehicle properly
Fork pipe top bolts - 3.0 ~ 3.2 Kgm
Fork under bracket bolts - 3.0 ~ 3.2 Kgm
IMPORTANT NOTE :
Look for any external damages in transit : Please check, record & rectify send report with photos.
Handle bar holder bolt - 2.0 to 2.2 Kgm
• Moisture / Oil collecting tube of air filter should be properly fitted and routed correctly.
Fork center nut- 4.5 to 5.0 Kgm
• Spark plug cap must be tightly secured.
Rear shock upper nut - 3.0 ~ 3.2 Kgm • TPS on carburettor for functioning.
Fasteners (Check torque) Rear shock mounting bottom bolt - 3.0 ~ 3.2 Kgm
Swing arm shaft nut - 8.0 ~ 10.0 Kgm
Front Caliper mounting bolts- 3.0 ~ 3.3 Kgm
Side stand lock nut- 2.8 ~ 3.2 Kgm
Main step holder bolt - 2.0 to 2.2 Kgm
Stay LH / RH mounting bolt- 1.5 to 1.8 Kgm
Rear brake pedal mounting bolt- 1.8 ~ 2.2 Kgm
Tail lamp No excess / uneven gap between tail lamp & seat cowl
ELECTRICAL
Battery Open circuit voltage (12.5 V DC) & Charge status using load tester.
Electrolyte level.
Tightness of battery terminals / cables
Proper routine of overflow pipe
Fuse Position of fuse box

PERIODIC MAINTENANCE AND
LUBRICATION CHART PERIODIC MAINTENANCE & LUBRICATION CHART
RECOMMENDED FREQUENCY RECOMMENDED FREQUENCY

Sr. Operation Subsequent Sr. Operation
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th No. Servicing 1st 2nd 3rd 4th 5th 6th 7th Subsequent
500 4500 9500 14500 19500 24500 29500 500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~ Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000 750 5000 10000 15000 20000 25000 30000
1st - 500~750 Kms / 30~45 40. Silencer tail pipe cleaning-Pulsar 150/180 CL CL CL CL CL CL CL
1. Servicing 3 3 3 3 3 3 3
days,2nd onward@5000Kms 41. Engine compression pressure C C C
2. Idle speed / CO% C, A C, A C, A C, A C, A C, A C, A C, A 42. Cylinder head de-carbonising CL CL If required
3. Valve tappet clearance C, A C, A C, A C, A C, A C, A C, A C, A 43. Engine air breather tube R R Replace at 20000 Kms
4. Engine oil (Bajaj DTSI 10000 oil)* C, A R Top-up R Top-up R Top-up R Top-up@every 5000 Kms. 44. Drive chain slackness C,A C,A C,A C,A C,A C,A C,A C,A
Replace in 1st service & at 45. Drive chain lubrication on vehicle C,L C,L
every 10000 Kms 46. Drive chain link lock R R R R R R R Whenever drive chain opened.
5. Oil strainer (Bajaj DTSi 10000 oil)* CL CL CL CL CL 47. Drive chain wear -- Remove & Lubricate C,L C,L C,L C,L C,L C,L C,L
6. Engine oil filter (Bajaj DTSi 10000 oil)* R R R R R Replace at every oil change 48. Drive chain ("O" ring design)** L Lubricate at every 500 km.(By customer)
7. Body centrifugal filter -- Pulsar / Platina CL CL CL 49. Wheel bearing C,R C,R C,R C,R C,R C,R Check & replace if required
8. Spark plug gap CL,A CL,A CL,A CL,A CL,A CL,A CL,A 50. Spoke tightening-Front & Rear** C,T C,T C,T C,T C,T C,T C,T C,T
9. Spark plug R R Replace at every 20000kms 51. Tyre tread wear C,R C,R C,R C,R C,R C,R Check & replace if required
10. Air cleaner element*** CL, R CL CL CL R CL CL R Replace at every 15000kms 52. Front fork oil R R R R Replace at every 10000kms
11. Air filter cover ‘O’ ring R R R Replace at every 15000kms 53. Front fork oil seal R R R R Replace at every 10000kms
12. In line paper filter along with hose & clamps** R R R Replace at every 15000kms 54. Auto choke** C C C C C C C
13. Fuel cock sediment bowl cleaning CL CL CL CL CL CL CL 55. Gap betn Reed switch & TPS magnet** C,A C,A C,A C,A C,A C,A C,A C,A
14. Fuel cock-Paper filter element & seal** R R R Replace at every 15000kms 56. Rr. Shock Absorber- Check gas pressure** C,A C,A Not required for new design
15. Carburettor CL,A CL,A CL,A (Filling from bottom)
16. Carburettor float chamber cleaning CL CL CL CL 57. Starter Clutch** (Dry Application) L L L L L L L
17. Carburettor rubber duct C,R C,R Check & replace if required 58. Wiring harness C C C C
18. Fuel pipes C,R C C C R C C R Replace at every 15000kms 59. Ignition switch contacts cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL
19. Coolant level check in expansion tank** C,A C,A C,A C,A C,A C,A C,A At every service 60. Clutch switch & brake switch
20. Coolant in expansion tank** R Replacement at every 30000 Kms or 2 year (whichever occurs earlier) (Horizontal base) contacts cleaning** C,CL,L C,CL,L C,CL,L C,CL,L
21. Coolant hose damage/clamps/leakage** C,R C,R C,R C,R C,R C,R C,R Check & replace if required 61. Clutch switch (Vertical base)** C,R C,R C,R C,R Check & replace if required
22. Coolant hose damage/clamps/leakage** R Replacement at every 35000 Kms or 3 years (whichever occurs earlier) 62. Rear brake switch C,A C,A C,A C,A C,A C,A C,A C,A
23. Radiator fins** C,A C,A C,A C,A C,A C,A C,A 63. Starter motor connections** C,T C,T C,T C,T C,T C,T C,T
24. Battery electrolyte level & specific gravity** C C C C C C C C 64. Starter relay connections** C,T C,T C,T C,T C,T C,T C,T
25. Battery connections C,T C,T C,T C,T C,T C,T C,T 65. HT coil connections C,T C,T C,T C,T C,T C,T C,T
26. Clutch plate C,R C,R Check & replace if required 66. Oil pressure indicator check on console** C C C C C C C C
27. Clutch play C,A C,A C,A C,A C,A C,A C,A C,A 67. General lubrication L L L L L L L L
28. Throttle play C,A C,A C,A C,A C,A C,A C,A C,A 68. Main stand & side stand pin** C,L C,L C,L C,L
29. Brake play C,A C,A C,A C,A C,A C,A C,A C,A 69. Swing arm pivot pin (for non silent bush)** L L L L L L L
30. Brake lining or pad wear C,R C,R C,R C,R R C,R C,R C,R Replace at every15000 Kms 70. Engine foundation silent bushes** R R R Replace at every 15000Kms
31. Brake fluid level / top up** C,A C,A C,A C,A C,A C,A C,A Check & Top up if required 71. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
in every service 72. Steering stem bearing*** C,CL,L,R C,CL,L,R C,CL,L,R C,CL,L,R Check & replace if required
32. Brake fluid R R 73. Cap steering bearing (Plastic)** C,R C,R C,R C,R
33. Front brake hose R R 74. Step -Pillion LH & RH (Ball & Plate)** C,CL C,CL C,CL C,CL C,CL C,CL C,CL
34. Master cylinder piston kit R R 75. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
35. Caliper piston seal and Dust seal R R * It is strongly recommended to use only “Bajaj DTS-i 10000” Genuine engine oil. In case any other engine oil of same specifications is used, the frequency of Sr. No. 4, 5
36. Brake cam & pedal pivot pin** L L L L L L L & 6 will be every 5000 Kms.
37. Rear sprocket fasteners C,T C,T C,T C,T C,T C,T C,T C,T ** As applicable to model
*** More frequent cleaning may be required when driving in dusty condition.
38. Rear wheel rubber shock damper C,R C,R C,R C,R Check & replace if required
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
39. Silencer drain hole cleaning CL CL CL CL CL CL CL Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory & the same are chargeable to customer.

PERIODIC MAINTENANCE POINTS PERIODIC MAINTENANCE POINTS
Periodic Maintenance (in accordance with the periodic maintenance chart) of a vehicle it is utmost important to prolong vehicle Fuel Cock Filter Replacement
life, trouble free running & ensure safety while driving.
Put fuel cock knob position OFF.
Washing (Water Servicing) - Dos & Don’ts
Do’s Don’ts
3 Rinse the Bike thoroughly with water to remove 7 Do not direct pressurized water jet on head lamp
loose dirt and mud. glass, tail lamp glass, electrical components (H.T.
Coil, C.D.I., Flasher, Horn & LH / RH control
switches) to avoid water entry & subsequent
damage.
3 Clean the Bike with a Sponge or soft cloth using 7 Do not direct pressurized water jet on steering races Remove fuel cock sediment bowl by ring spanner.
water. (cones) to avoid rusting & subsequent pitting of
steering balls & races.
3 Clean the exterior surfaces of engine metal parts by 7 Do not direct pressurized water jet on plastic parts,
kerosene / diesel spray & plastic / nylon brush. decals & spark plug cap.
7 Avoid directing water jet in to silencer muffler outlet.
3 Cover silencer tail end by PVC cap.
7 Do not use detergent or strong solvent to clean
3 Clean the plastic parts using a soft cloth or sponge painted / plated parts. Avoid cleaning products that
dampened with a solution of mild car shampoo / are not specifically designed for automobile surfaces.
liquid soap & water. Rub the soiled area gently Strong detergent residues can corrode alloy parts
rinsing it frequently with fresh water. and also painted surfaces loose their shine / gloss. Take out fuel cock sediment bowl
Caution : Water may enter on the brake liners during washing & brake slippage may occur. Ensure
that brake liners are dry before driving the vehicle.
Clean sediment bowl thoroughly with low pressure compressed air.

Pull out paper filter element with seal Paper Filter Element Replacement
Remove side cover LH by following steps given below
• Insert the key into the cover lock and turn the key clockwise.
• Pull front side first & slide side cover toward front. Take out ‘Side cover’.
Replace paper filter element with seal at every 15000 kms
Remove seat by following step given below
• Pull the ‘Seat Release Cable’ to release seat lock. Keeping cable pulled, lift
the seat from rear end and slide it towards tail lamp to remove seat assembly.
• To avoid cross fitment of sediment bowl. Do pre fitment of sediment bowl by

hand & thereafter tightening by ring spanner.
Remove 4 nos M10 bolts of air intake duct
• Put fuel cock knob position ON / Reserve & confirm no fuel leakage.
Remove intake duct from clamp

Take out paper filter element Do’s :

• Clean at every 5000 kms. in dusty areas increase the cleaning frequency.
• Replace at every 15000 kms.
Dont’s :
Do not clean paper air filter element with Petrol / Kerosene / Diesel / Water, also do not apply oil on paper element.
‘O’ Ring Drive Chain Lubrication - on Vehicle
• Place the bike upright.

• Normal dust should be wiped clean using a lint free cloth.
• Hold the Chain Lube Spray Can (OKS Spray) vertically upright & shake it
Paper Filter Element Cleaning vigorously till the noise of steel ball inside the can is heard uniformly. Fix the
extension tube (red pipe provided with the can).
• Remove the seat assly.
Air Gun
• Remove air filter cover by removing bolts.
• Carefully remove the filter element from air filter assly.
Filter Element • Clean air filter element by low pressure compressed air. (Air pressure less than • Hold the can at the back of the rear sprocket in line with chain rotation and
Carburettor side 2 bar) keep the nose of the extension tube at about 5~10 cms away from the chain.
• Slightly twist the element as shown in the photograph. • Rotate the wheel in reverse direction & spray the lube on the middle portion of
the chain so that lubricant will get spread on roller & bushes and on both
• Hold the filter element by its PU foam only. Do not touch the paper surface to sides of the chain.
avoid soiling. • Spray the lube on full length of chain by rotating the wheel to a complete
• Wipe out air filter top & bottom cover by wet clean cotton cloth. rotation.
Air Gun
Filter Element • After completing this, rotate the wheel 3 ~ 4 times so that the lubricant
Dirty side spreads & settles.
• Wipe out any excess lubricant if it has dripped down or sprayed on the wheel /
tyre.
Post Cleaning Actions :

• Assemble filter element into the air filter box. Maintain tightening torque as per specification over the mounting bolts of
assembly cover side.
• Assemble back seat assembly in the vehicle after the complete assembly of air filter assembly.

‘O’ Ring Drive Chain Cleaning by Removing from Vehicle (Diesel + SAE 90 oil 1:1) Engine Oil Level Checking
• Park the vehicle on level surface on center stand to check the oil level.
• Inspect the oil level through oil inspection window.
Max. Level
• It should be in between upper and lower mark.
1st Stage:
Clean with • Top up if required.
Diesel +
Min. Level
oil 1:1 Recommended Bajaj DTS-i 10000 20W50 grade BGO
Grade
3rd Stage:
Recommended Drain & Refill 1000 ml
Dip into
Quantity
SAE 90 oil Engine Overhaul 1100 ml
2nd Stage:
Clean with Oil Strainer Cleaning
Diesel
+ oil 1:1 Remove :
• Cap strainer (18 mm A/F) with ‘O’ ring.
• Pull out strainer (mesh filler oil with ‘O’ ring) by nose plier.
Soak into • Drain engine oil.
SAE 90 oil
Blow Low
Pressure
Compressed
Air Remove :
Final Stage : • Clean oil strainer with Kerosene / Diesel & blow low pressure compressed air
Hook chain from inside i.e. air must be blown in opposite direction of oil flow.
for dripping
of excess oil
Note :
• During re-assembly of drive chain always use new link lock.
• Ensure ‘O’ ring fitment.

Paper Oil Filter Replacement Tappet Clearance Setting
Remove : • Ensure that the engine is in cold condition.

• 3 bolts (8 mm A/F) • Ensure the ‘T’ mark on the ‘Rotor’ match with the mark on the ‘Crankcase
• Take out ‘Cover oil filter’ with ‘O’ ring. LH’. At this stage the ‘Piston’ is at TDC & both the rocker arms are free.
• Take out ‘Paper oil filter’ along with • Holding tappet screw firmly with special tool loosen the tappet screw nut.
spring. • Put the feeler gauge, measure and adjust the clearance.
• Replace ‘Paper oil filter’ during 1st • Lock the nut holding screw with special tool after getting required clearance.
free service and thereafter at every • Again check the tappet clearance with gauge. The feeler gauge should slide
5000 Kms. with slight resistance between tappet screw tip & valve stem head. Tighten the
check nut with a spanner.
Caution : ¡ Inlet Valve : 0.05 mm

Before fitting ‘Paper oil filter’ ¡ Exhaust Valve : 0.1 mm
ensure intact condition of oil ¡ M & T Equipment : Feeler Gauge
seal from its rear side & one
¡ Special Tool : Valve Adjusting Screw Holder
way valve from its front side.
Part No. : F41ZJW33
Note : Tappet setting of 2 Intake & 2 exhaust valve must be done
individually as per SOP.
One Way Valve Oil Seal
Nitrox Mono Rear Shock Absorber Silencer Drain Hole Cleaning
Adjusting Spring Tension • Clean the silencer drain hole in

• RSA spring tension can be adjusted with the help of 9 stepped adjuster cam every service by using silencer
to suit individual requirement as per load & road conditions. drain hole cleaning tool as shown
in photograph.
• Turn the adjuster cam on shock absorber to required position. Setting the
adjuster cam to higher notch position increases the spring stiffness & vice-
Mono RSA versa (Tool Part No.: 37 0041 70)
with Nitrox • Shock Absorbers adjusted either too soft or too stiff could adversely affect
riding comfort & vehicle stability.
Notch Position 1 2 3 4 5 6 7 8 9
Spring Action Soft Stiff
Note: Standard setting is done in 2nd notch.
Special Tool for Mono RSA adjuster

3 Dos 7 Don'ts Readiness of CO Gas Analyser Taking the Reading

Handling
Warm up the CO Gas Analyzer • Remove M-5 bolt & aluminum
• Use appropriate screw drivers for • Never use oversize screw drivers
for 10~15 minutes before washer fitted to the nozzle (12mm
dismantling. • Don’t over tighten the jets & screws.
proceeding further. Warming up OD) shown in figure, of the
This will damage the jets & their
is essential every time machine connecting tube welded to silencer
seats.
is put on to purge out any pipe before CAT converter.
gases left in side. • Use a Silicon Rubber tube of
Cleaning approximately 300mm to fit onto
Carry out Span Check as per
• For cleaning always use carburettor • Never clean the carburettor with manufacturer's Recommendation the nozzle. Only a Silicon rubber
cleaner like - water. to confirm the OK condition of tube should be used, as it has
- Acetone • Jets & air passages will get clogged the Equipment (If Span Check better high temp. resistance & will
- Carbon Tetra chloride due to sediments if cleaned by does not confirm the reading, not deform / melt due to high
- CVC spray water. then carry out Gas Calibration temp. at the nozzle.
as per mfgrs. recommendation). • Connect the other end of the Silicon Rubber tube to the
Float Height Checking
Set the Equipment display to Zero before taking the flexible probe pipe of machine. Ensure that the inner
• In this carburettor measure float • Do not blow compressed air on reading. diameter of Silicon tube perfectly matches with outer
height in inverted vertical position. ‘needle jet’ from ventury / mixing diameter of flexible probe pipe of Gas Analyzer.
• Always maintain standard float cap side otherwise ‘needle jet’ would • The Silicon rubber tube must fit snugly onto the nozzle to
height. get blown-off . Readiness of the Vehicle prevent any air / exhaust gas leakage.
• Note the CO / HC readings when the reading display
• Ensure float is in good Condition. • Do not reuse squeezed / punctured Before checking CO emission, prepare the vehicle for stabilizes.
float. This could lead to petrol over checking the CO. • As per Emission Norms the recommended CO% for 2
flow. • Warm up the engine to its normal operating temp. by Wheelers is 3.5% at idling RPM. But CO% for Bajaj
riding 5~6 Kms. The c'case cover should be warm Vehicles, for best results in terms of fuel efficiency are
0
enough by feel. (Engine Oil Temp. = 60 C). different for different models. The ideal CO% is between
1.5 to 2.5% at idling RPM = 1400 + 100.
• Place a magnet holder on jet • Do not blow compressed air from Caution: In choke ‘ON’ condition CO % is high : 9~10%. • If the reading is shown excess or less than BAL
needle ‘e-clip’ & then Place spring.. carburettor breather tube otherwise Hence warming up of engine is a must. specifications, try to achieve by adjusting Air Screw.
float would get Squeezed/damaged.
• Turning in VC Screw will lead to more CO% and turning
• Screw in VC Screw completely. Engine should die out will lead to less CO%.
down in this condition.
Note: Remember the VC Screw should not be taken out more
• Check Float Pin for - • Do not reuse Float Pin if - Note: If engine does not go off, then attend to the than the recommended position. Every time VC Screw setting
- Tip having no wear mark. - Worn out tip additional air supply problem in the carburetor circuit & is changed specified Idling RPM must be restored and then
- Spring loaded pin is free in - Spring loaded pin sticky otherwise intake system. After solving the problem once again reading should be considered.
it would lead to flooding / over flow confirm that engine should die down on closing the VC
movement. • If the CO% is not falling within recommended % in spite
Screw.
of adjusting the VC Screw then find out the cause &
• Replace Jet Needle & Needle Jet • Do not shift ‘e-clip’ to upper or lower rectify. After rectifying the problem confirm the CO% in the
as a pair if wornout. groove of jet needle otherwise it • Confirm the VC Screw same way as mentioned above.
• Always ensure that ‘e-clip’ is fitted would lead to lean air fuel mixture setting as per specification.
in specified groove of Jet Needle. or rich air fuel mixture respectively. Important: For Better Mileage and Performance,
• Set Idling speed to specified achieve CO% as recommended.
Idling 1400 + 100 rpm.
Raise engine to moderate In Discover 125 ST motorcycle for better mileage &
• Replace piston / throttle valve if • Don’t fit worn out / non specified performance achieve values given below.
worn out size jets speed at no load condition
• Don’t fit worn out / cut ‘O’ ring on for about 15 seconds. Then
• Ensure fitment of spring, a plain Recommended CO% value w.r.t. VC Screw
air screw otherwise it would lead to bring back to specified idling and Idling RPM for Better Fuel Efficiency
washer & an ‘O’ ring on Air Screw
idling Instability. RPM. Model Recommended CO% VC Screw Position Recommended Idling RPM
Discover Set VC screw to 1400 + 100 rpm
1.5% ~ 2.5%
Overhaul Carburettor at every 10,000 Kms and Inspect the parts 125 ST get CO% 2 + 0.5

3 Dos 7 Don'ts 3 Dos 7 Don'ts

• Ensure Cylinder Head Cover • Don’t fill excess engine oil beyond std. engine oil capacity • Confirm the crankshaft • Don’t hammer crankshaft while fitting it in crankcase otherwise
breather passage is clear by otherwise oil will ooze out from engine breather pipe / leak centering & free rotation after it would lead to its run out & subsequent engine noise
blowing compressed air in from gasket - oil seal fitment otherwise non centered
opposite direction of flow of crankshaft would lead to
fumes. Clogged breather engine knocking.
passage would lead to oozing
out of oil through oil seals, 'O’
Rings, Gaskets & Breather
pipe.
• Always follow loosening / • Don’t over tighten cylinder head cover bolts otherwise plastic • Always tighten clutch cover • Don’t over tighten clutch cover & crankcase bolts otherwise
tightening sequence of cylinder cylinder head cover may get cracked. and crankcase bolts to their crankcase parent hole threading would get damaged.
head bolts otherwise its surface • If cylinder head cover bolts are not tightened to specified specified torque (0.9 ~ 1.1
may get warped torque & in criss-cross pattern it would lead to oil leakage. Kgm) in crisscross pattern
• Tighten nut- bolts in criss-cross
pattern for matching of mating
surfaces to avoid distortion
otherwise It leads to oil
leakage.
• Standard Tightening Torque :
0.9~1.1 Kgm
• Always apply loctite to oil • While assembling oil Pump

pump securing screws / bolts shaft having integral nylon
gear, don’t hammer / tap the
gear for matching. Instead,
rotate the gear slowly ‘D’ slot
on shaft so that perfectly
matches with the ‘D’ slot of • Always replace circlips & locks of transmission gears, kick • Do not wash air filter paper element with kerosene / petrol /
inner rotor. shaft assembly if removed. Circlips / locks tend to loose their diesel.
spring tension once removed.
• Do not wash engine bearings with water otherwise they will
• While assembling cylinder block, always apply engine oil to get permanently spoiled
• Always use Loctite to bolts, • If nut, bolts & screws are assembled with out loctite cylinder walls & piston rings for ease of fitment & to prevent
screws & nuts wherever application it would lead to their loosening & subsequent dry running. • Do not blow compressed air on engine bearing otherwise they
recommend. problem in engine. will get permanently spoiled.
• Always apply oil during assembling engine components,
particularly at friction prone area to avoid dry running. • Do not tap engine components by hammer in order to avoid
damage. Engine components are precisely machined, they are
• Confirm seating of circlip locks by rotating on their seat to critical & costly.
avoid further consequences.
• While installing engine bearings always tap / press on the race

which is taking seat to avoid damage to the bearing otherwise
• Blow dust free / moisture free • If air is blown in to orifices, oil passages of the engine in the axial / radial clearance may increase.
air in all the orifices, passages direction of oil flow, the passage would get jammed / clogged
of the engine components & instead of getting cleared.
confirm that the oil passages
are clear.
• The dust free air must be
blown opposite to the direction
of oil flow.

NOTES
2
Fuel System
Carburettor Specifications
Tune up for Optimum Mileage
36
28 29
DISCOVER 125 ST TRAINING NOTES INTERNATIONAL BUSINESS DISCOVER 125 ST TRAINING NOTES INTERNATIONAL BUSINESS
CARBURETTOR SPECIFICATIONS TUNE UP FOR OPTIMUM MILEAGE
UCAL TPS - Reed Switch : Checking AIR FILTER:

• Clean at Every :
Continuity check magnet in front 5000 Kms.
of reed switch. • Replace at Every :
Multimeter will show continuity & 15,000 Kms.
beep sound will be heard. Cleaning procedure as per SOP
COMPRESSION PRESSURE
• Standard :
11 to 13 Kg/cm2
• Service Limit :
Continuity check magnet away
form a reed switch. 9.5 Kg/cm2
Multimeter will not show continuity

& 1 will be displayed on
multimeter. TAPPET CLEARANCE
• Inlet Valve :
0.05 mm
• Exhaust Valve :
0.1 mm
• Do setting for individual valve
Engine Tune-up
SPARK PLUG : CARBURATTOR
BOSCH UR4AC, Champion • Idling : 1400 + 100 rpm.
PRZ9HC
• Jet Needle Clip Position :
• Spark Plug Gap :
0.7 to 0.7~0.8 mm. second groove from top
0.8MM
• Replace at Every : • CO % : 1.5 ~ 2.5 %.
20000 Kms • V.C. Screw Setting : To achieve
CO% between 1.5 ~ 2.5
Item Specification Other Mandatory Checks

Make UCAL a. Ensure no fuel leakage through fuel cock, fuel lines.
b. Ensure free rotation of both wheels.
Type UCD26 c. Ensure correct tyre pressure - Front wheel : 25 PSI,
Idling Speed 1400 + 100 rpm Rear wheel : 32 PSI
d. Set control cable free play:
VC Screw Setting set 2 % co • Clutch lever 2~3 mm.
Main Jet 117.5 • Rear brake pedal 15~20 mm.
e. Chain slackness : 20~25 mm.
Needle Jet Marking O-9 f. Check & confirm proper functioning of spark plug.
Jet Needle ‘e’ Clip Position 2nd Groove from top
Pilot Jet 12.5
Throttle Valve Mark 110
Float Height 10.5 mm
Starter Jet Size 17.5
Choke Manual Choke

NOTES
3
Engine & Transmission
Standard Operating Procedure
Special Tools
Gear Transmission Power Flow
Service Limits
Tightening Torques
36
32 33
STANDARD OPERATING PROCEDURE STANDARD OPERATING PROCEDURE
Cylinder Block Dismantling on Vehicle • Remove fuel gauge connection & take out the fuel tank
• Remove LHS side cover by using

vehicle key (pull out cover from
front side grommet & pull towards
front side)
• Remove LH & RH spark plug cap
• Remove the seat assembly by pulling the seat lock cable.
• Remove breather tube connection
• Remove RHS side cover by removing 1 philips screw & pull out from rubber
grommets (2 nos.)
• Remove silencer assembly
• Remove fuel tank mounting bolt

(10 mm A/F)
• Remove fuel pipe

• Remove engine mounting upper bracket (3 nos. 12 mm A/F) Sleeve • Remove RHS spark plug & spark
plug sleeve. (2.5 mm Allen key)
2.5 mm grub screw
• Remove carburettor front & rear • Remove RH & LH H.T. Coil (2 nos.
clamps bolts, 10 mm A/F)
• Remove intake manifold bolts (2 nos., 8 mm A/F) • Remove cylinder head cover (4
nos. bolt, 8 mm A/F)
• Remove TPS connection & take • Remove chain tensioner (2 nos.

out the carburettor assembly bolt, 8 mm A/F)
• Remove thermal sensor connection

• Align the ‘T’ mark of sprocket & by • Remove piston pin lock after that remove piston pin
using special tool remove -
- Allen bolt, special washer,

sprocket, collar.
• Remove head bolts as per given sequence. While removing head bolt number • Remove piston
1 1 & 3. Before removing bolt 1 & 3 ensure that both H.T. coil should be
4 removed otherwise both bolts will foul with H.T. coil.
3
2
• Remove head & head gasket Note :

• Cylinder head & gear box dismantling & assembly is similar to Pulsar 135 LS.
• No exclusive special tool is required for Discover 125 ST.
• Remove cylinder & cylinder gasket

SPECIAL TOOLS - ENGINE SPECIAL TOOLS - ENGINE
Special Tools Clutch Dismantling Tool

Part No. : F41AJA58
Cam Sprocket Holder
Application : To dismantle & assembled
Part No. : F41ZJZ47 clutch of DISCOVER DTS-Si
Application : For holding sprocket during kick start as well as self start
removal / refitting of Cam vehicle.
sprocket allen bolt.
Spark Plug Spanner

Part No. : 37 1040 51
Magneto Rotor Holder (For Self Start)
Application : For removing and refitting
Part No. : F41ZJZ44 spark plug R.H. and L.H. side.
Application : To hold rotor while loosening /
tightening its nut.
Valve Tappet Adjuster

Part No. : F41ZJW33
Magneto Rotor Puller (For Self Start)
Application : To hold the Valve Tappet
Part No. : F41ZJZ46 screw while adjusting tappet
Application : To pull out the rotor from clearance.
crankshaft assembly.
Rocker Shaft Remover

Part No. : 37 10CS 22
Primary Gear Holder
Application : To remove Rocker Shaft from
Part No. : F41AJA11 cylinder head.
Application : To hold primary and secondary
gear while loosening/tightening
the primary gear nut & special
nut securing clutch.
Bearing Extractor
Part No. : 37 1030 48
Socket for Clutch Nut
Application : To Pull out main ball bearing
Part No. : F41ZJA54 from crankshaft
Application : To loosen / tighten special nut
securing clutch.

SPECIAL TOOLS - ENGINE GEAR TRANSMISSION POWER FLOW
Adaptor & Valve Spring Compressor Construction & Working

Adaptor Part No. : 37 1031 08
Input Shaft and its gears :
Valve Spring Compressor : 37 1031 07 6 4 5
• First gear is integral with Input Shaft. 3
Application : To assemble / dismantle 2
• Second gear is fixed on Input Shaft 1
intake, exhaust valve by
splines.
compressing spring in cylinder
head. • Third gear is fixed but sliding on Input
Shaft splines.
• Forth gear is a freely rotating gear on
Drift Piston Pin Input Shaft. 7
Part No. : 37 1010 06 • Fifth (top) gear is freely rotating on Input
splines.
Application : To remove refit piston pin.
Output Shaft and its gears :
• First gear is a freely rotating gear on
Output Shaft. A bush which is free inside
gear I.D. & shaft O.D. is fitted between 9
first gear and Output shaft. 12 10 11 8
• Second gear is a freely rotating gear on
Output Sprocket Holder
Output Shaft. A bush which is free inside
Part No. : 37 1030 53 gear I.D. & shaft O.D. is fitted between
Application : To hold the output sprocket first gear and Output shaft.
1. Input shaft. 7. Output shaft
while removing sprocket allen • Third gear is freely rotating on Output
2. First gear input. 8. First gear output.
bolts. splines.
3. Second gear input. 9. Second gear output.
• Forth gear is fixed but sliding on Output
4. Third gear input. 10. Third gear output.
Shaft splines.
5. Fourth gear input. 11. Fourth gear output.
• Fifth gear is fixed but sliding on Output
6. Fifth gear input. 12. Fifth gear output.
Shaft splines.
Driver for Fitting Bushing Gear Shift Drum
Part No. : E6101100TE
First Gear Position : When First Gear is 5
Application : To assemble “Bushing with 4
engaged, Power from clutch flows as follows. 2 3
PTFE Lining” at parent hole of 1
crankcase RH for “Gear Shift
Clutch
Drum” mounting.
Input Shaft
Bearing Driver Set 1st Gear Input

Part No. : 37 1030 61
st
Application : Common bearing driver set for 1 Gear Output
fitting & removing bearings
from crankcase. th
4 Gear Output
5
4
Output Shaft 3
2 1
Final Drive to the Rear Wheel

GEAR TRANSMISSION POWER FLOW GEAR TRANSMISSION POWER FLOW
Second Gear Position : When Second Gear 5 Forth Gear Position : When Forth Gear is 5
4 4
is engaged, power from clutch flows as 2 3 engaged, power from clutch flows as follows. 2 3
follows. 1 1
Clutch
Clutch
Input Shaft
Input Shaft
rd
3 Gear Input
nd
2 Gear Input
4th Gear Input
2nd Gear Output
th
4 Gear Output
th
5 Gear Output 5 5
4 4
3 Output Shaft 3
2 1 2 1
Output Shaft
Third Gear Position : When Third Gear is 5 Fifth Gear Position : When Fifth Gear is 5
4 4
engaged, power from clutch flows as follows. 3 engaged, power from clutch flows as follows. 2 3
2
1 1
Clutch Clutch
Input Shaft Input Shaft
rd rd
3 Gear Input 3 Gear Input
th
3rd Gear Output 5 Gear Input
th
4 Gear Output 5th Gear Output
5 5
4 4
Output Shaft 3 Output Shaft 3
2 1 2 1
Final Drive to the Rear Wheel Final Drive to the Rear Wheel

GEAR TRANSMISSION POWER FLOW GEAR TRANSMISSION POWER FLOW
2
14
3
4 15
5 13 21
16 20
6 4 3 1 17
3 12 4
19
7 2 18
4
11 17 3
10 16
8
5 6
15
14
4
9
7
10 8
4
3
13 9
11
19
18
12
20
22
21
No. Description No. Description No. Description No. Description
1 Shaft Input 12 Gear 5th Driven Forging Route 1 Lever Assy Gear Change Complete 12 ‘O’ Ring
2 Gear 4th Drive 13 Gear 3rd Driven 2 Bolt - Flange :- M6 13 Damper
3 Spline Washer 14 Gear 4th Driven 3 Lever Change Arm 14 Lever Comp Gear Shift
4 Ring - Snap 15 Bush 1st Driven 4 Bolt Gear Change Lever 15 Extension Spring
5 Gear 3rd Drive 16 Gear 1st Driven 5 Tie Rod 16 Spring Gear Shift Return
6 Gear 5th Drive Forging Route 17 Washer Thrust 6 Pin 17 Inhibitor Comp. Gear Shift
7 Gear 2nd Drive 18 Collar Sprocket Drive 7 Washer Nylon 18 Spring (Inhibitor)
8 Washer Thrust 2nd Drive 19 ‘O’ Ring 8 Boot Change Lever 19 Step Washer
9 Shaft Output Forging Route 20 Sprocket Output 9 Lever Complete Change 20 Washer (Spring Steel)
10 Gear 2nd Driven 21 Plate Lock - Sprocket Output 10 Washer Plain 21 Nut - Hexagon With Flange : M6
11 Bush 2nd Driven 22 Bolt Flanged 11 Bolt

SERVICE LIMITS - ENGINE SERVICE LIMIT - ENGINE
Compression Pressure Valve Clearance Rocker Arm Shaft Diameter Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance
10mm
20mm
40mm
Intake Exhaust
2
Std. Limit 11.0 ~ 13.0 kg/cm Std. Limit In 0.05 Ex 0.1 Std. Limit 7.994 ~ 8 Group A 54.008 ~ 54.018 Group A 53.969 ~ 53.981 Std. Limit 0.027 ~ 0.049
Ser. Limit Min 9.5 kg/cm 2
Ser. Limit — — Ser. Limit 7.98 Group B — Group B — Ser. Limit Max 0.06
Cam Sprocket Diameter Cam Height Cam Lobe Width Piston Ring Groove Clearance Piston Ring End Gap Clutch Spring Free Length
Intake Exhaust Top Second Oil Ring Top Second Oil Ring
Std. Limit 61.165 ~ 61.285 Std. Limit 29.411 29.457 Std. Limit 9.0 Std. Limit 0.03~0.07 0.02~0.06 0.03~0.11 Std. Limit 0.1~0.25 0.3~0.45 0.2~0.7 Std. Limit 25.5
Ser. Limit 60.865 ~ 61.285 Ser. Limit 29.336 29.382 Ser. Limit — Ser. Limit 0.15 0.15 — Ser. Limit 0.4 0.6 — Ser. Limit 24.5
Valve Spring Free Length Valve Stem Diameter Valve Stem Bend Friction Plate Thickness Steel Plate Thickness Steel Plate Warp
Intake Exhaust
Std. Limit 38.68 Std. Limit 4.475~4.49 4.455~4.47 Std. Limit 0.01 Std. Limit 2.95 ~ 3.05 Std. Limit 1.6 ~ 1.7 Std. Limit 0.1
Ser. Limit 35.23 Ser. Limit 4.46 4.45 Ser. Limit > 0.01 Replace Ser. Limit 2.7 Ser. Limit 1.55 Ser. Limit 0.15
Valve Stem to Guide Clearance Cylinder Head Warp Camshaft Chain Length Friction Plate Warp Clutch Hub Height Shift Fork Guide Pin Diameter
20 Link Length
1st 2nd 21st

MEASURE THIS LENGTH
Intake Exhaust
Std. Limit 0.01 ~ 0.037 0.025 ~ 0.052 Std. Limit 0.03 mm Std. Limit 127.00 ~ 127.48 mm Std. Limit 0.1 Std. Limit 21.0 ~ 21.2 Std. Limit 4.45 ~ 4.49
Ser. Limit Max 0.07 Max 0.07 Ser. Limit 0.05 mm Ser. Limit 128.9 mm Ser. Limit — Ser. Limit 21.4 Ser. Limit 4.4
ALL DIMENSIONS ARE IN MM ALL DIMENSIONS ARE IN MM

SERVICE LIMIT - ENGINE TIGHTENING TORQUES
Shaft Fork Shift O.D. Fork Shift I.D. Shift Drum Groove Width Spark Plug Cap Strainer (18 mm A/F Bolt) Cap Oil Filter
Std. Limit 9.972 ~ 9.987 Std. Limit 10.0 ~ 10.022 Std. Limit 4.55 ~ 4.70
Ser. Limit 9.96 Ser. Limit 10.03 Ser. Limit 4.75
1.3 ~ 1.5 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm
Crankshaft Run Out Con Rod Side Clearance Clutch Stackup Height Silencer Mounting Nuts Silencer Bracket Bolt Engine Mounting Nut - Top
Std. Limit 0.02 Std. Limit 0.1 ~ 0.35 Std. Limit 20.95 ~ 21.85
Ser. Limit 0.05 Ser. Limit - Ser. Limit 19.6
2.0 ~ 2.2 Kgm 3.5 Kgm 1.8 ~ 2.2 Kgm
Engine Mounting Nut - Rear Engine Mounting Nut - Front Clutch Cover Bolts
ALL DIMENSIONS ARE IN MM
NOTES
4.0 Kgm 3.5 Kgm 0.9 ~ 1.1 Kgm
Cylinder Head Bolts (12 mm) Cam Sprocket Allen Bolt Rotor Mounting Nut
2.2 ~ 2.5 Kgm 1.6 ~ 1.8 Kgm 5.0 ~ 5.5 Kgm

TIGHTENING TORQUE - ENGINE TIGHTENING TORQUE - ENGINE
Primary Gear Nut Clutch Nut (L.H. Thread) Clutch Spring Bolts Cylinder Head Cover Bolts Chain Tensioner Mounting Bolts Magneto Cover Bolts
5.0 ~ 5.5 Kgm 5 ~ 5.5 Kgm 1.0 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm
Drum / Cam Allen Bolt Stud Inhibitor Nut Oil Pump Mounting Screws Bolt Kick Lever Manifold Mounting Bolts
0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.5 ~ 0.7 Kgm 2.0 ~ 2.2 Kgm 0.9 ~ 1.1 Kgm
Output Sprocket Bolts Crankcase Joining Bolts Crankcase Joining Bolts
NOTES
0.8 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm
Stator Plate Bolts Kick Guide Bolts Starter Motor Mounting Bolts
0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm

NOTES
4
Vehicle (Frame)
Standard Operating Procedure
Service Limits
Tightening Torques
Special Tools
20 Link Length
1st 2nd 20th
MEASURE THIS LENGTH
36
54 55
Removal of Rear Suspension Accelerator Cable Routing
• Remove side cover LH • Route the accelerator cable as shown in photograph.
• Remove side cover RH
• Remove RSA top bolt from LHS • Route the cable from outside of rod
using M-8 Allen key joining lamp shade
• Remove RSA lower bolt from RHS • Route accelerator cable through
using M-8 Allen key PVC clamp located near RHS
petrol tank damper.
• Connect the cable at carburettor

end.
• Pull out RSA from RHS from the gap in between stay RHS & frame
Clutch Cable Routing
• Route the clutch cable from inner

side of rod joining lamp shade.
• Route the clutch cable through the

clamp bolted on chassis.
• Route the clutch cable from outside

the leg guard.
• Route the clutch cable through

clutch cable bracket mounted on
clutch cable.

STANDARD OPERATING PROCEDURE SERVICE DATA - FRAME
Front Hose Brake Hose Routing Brake Panel Cam Hole Dia. Brake Cam Diameter Brake Shoe Lining Thickness
• Route front brake hose through clamp provided on RHS of front fender.
Std. Limit 12.00 ~ 12.027 Std. Limit 11.957 - 11.984 Std. Limit 3.9 ~ 4.5
Ser. Limit 12.18 Ser. Limit 11.83 Ser. Limit 2.0
Brake Drum Inside Dia. Front / Rear Axle Run Out Axial Wheel Run Out
• Route the front brake hose through 'U' type clamp provided on lower T.
100 mm
Std. Limit 130 - 130.16 Std. Limit TIR 0.05 Std. Limit TIR 0.5 or less
Ser. Limit 130.75 Ser. Limit TIR 0.2 Ser. Limit TIR 2.0
Radial Wheel Run Out Drive Chain Slack Drive Chain Length
Speed Sensor Cable Routing
20 Link Length
• Route speed sensor cable through clamp provided on LHS of front fender.
1st 2nd 20th

MEASURE THIS LENGTH
Std. Limit TIR 0.5 or less Std. Limit 20 ~ 25 Std. Limit 254.0 ~ 254.6
Ser. Limit TIR 2.0 Ser. Limit 35 Ser. Limit 260.0
Rear Sprocket Warp Tyre Tread Depth Front Fork Spring Free Length
• Route the speed sensor cable with grommet through 'U' type clamp provided
on lower T.
Free Length
Std. Limit TIR 0.4 or Less Std. Limit Front : 5.0 Rear : 6.0 Std. Limit 392.5
Ser. Limit TIR 0.5 or less Ser. Limit Up to TWI Ser. Limit 387.5

TIGHTENING TORQUES TIGHTENING TORQUES
Front Axle Nut Rear Axle Nut Tie Rod Nut Front Fender Mounting Bolts Rider Foot rest Mounting LH Stay Bolts
4.5 ~ 5.5 Kgm 8.0 ~ 10.0 Kgm 3.0 ~ 4.0 Kgm 2.0 ~ 2.2 Kgm 2.0 ~ 2.2 Kgm 1.5 ~ 1.8 Kgm
Rear Sprocket Mounting Nut Handle Bar Holder Bolts Fork Center Nut RH Stay Bolts Front Fork Oil Grade & Capacity
Grade :
SAE 10W20
Bajaj Genuine
Fork Oil
Fork Oil Level

Quantity :
140 + 2.5 ml /
Fork Leg Assly
(Drain & Refill)
3.0 ~ 3.8 Kgm 2.0 ~ 2.2 Kgm 4.5 ~ 5.0 Kgm 1.5 ~ 1.8 Kgm
Steering Stem Nut Slotted Fork Pipe Top Bolts Fork Under Bracket Bolts
Grease Application Points Loctite Applications

Type of Type of Loctite &
S.N. Vehicle Component S.N. Vehicle Fastener
Grease Loctite Colour
1. Bearing balls of steering HP Lithon RR3 1. Rider step mtg. bolts Thread Locker
243
2. Swing arm shaft 2. RSA lower bolt Dark Blue Colour
3. Front wheel axle
4. Rear wheel axle
0.5 Kgm 3.0 ~ 3.2 Kgm 3.0 ~ 3.2 Kgm
5. Brake pedal pivot A.P Grease
6. Center stand shaft
RSA Mounting Nut (Upper) Swing Arm Shaft RSA Lower Bolt
7. Side stand ‘U’ bracket
8. Gear shifter lever pivot
3.0 ~ 3.2 Kgm 8.0 ~ 10.0 Kgm 3.0 ~ 3.2 Kgm

SPECIAL TOOLS - VEHICLE SPECIAL TOOLS - VEHICLE
Special Tools Bearing Race Extractor

Part No. : 37 1030 48
Special Tool to Remove Anti-Friction Bush Application :
Application : To Pull out steering race from ' Fork Under
To remove anti-friction & oil seal bush from Holder bracket'
front fork outer pipe.
Steering Cone Remover

Part No. : 37 1805 06
Fork Oil Seal Driver
Application :
Part No. : 37 1830 07
To remove steering cones
Application : from frame.
To fit fork oil seal in its seat provided at outer
pipe ID.
Special Tool to Adjust RSA Spring

Part No. : 37 0041 70
Stem Bearing Driver
Application :
Part No. : 37 1830 05
To adjust rear shock absorber spring tension.
Application :
To fit bearing race on fork under holder
bracket
Front fork cylinder holder handle with

adaptor
Part No. : 37 1830 06
Application :
To hold fork cylinder while loosening /
tightening fork allen head bolt at bottom.
Installer Upper & Lower Bearing Race

Frame
Part No. : 37 1801 06
Application :
To install upper & lower steering races /
cones into their seats inside frame.

NOTES
5
Electricals
Battery
Dos & Don'ts
Electrical Checking Procedures
Standard Operating Procedures
Electrical Circuit Diagrams

ELECTRICALS DOS & DON'TS - GENERIC
Battery Technical Specification Battery

For Self Start
• Make Exide
3 Dos
• Voltage 12 Volt
3 • Do hold the box.
• Type MF Battery
• Capacity 5 Ah
• Specific gravity of electrolyte 1.24 for use
for initial filling of new battery above 100C
• Initial charging duration 10 ~15 hrs
• Charging current specification 0.5 Amp
Battery Features
3 • Apply petroleum jelly to poles / terminals.
• Frequency of electrolyte topping-up is very less compared to conventional battery.
• Low self discharge.
• Unique vent system / mechanism.
• Enhanced safety
• Compact design-High efficiency in compact package.
Battery Charging Procedure

In case battery is discharged follow the procedure given below by using constant current. “Battery Charger” of 0.5 Amp. • Use proper tools.
charging current specification for 5 Ah battery 3
• Remove battery from vehicle
• Clean battery throughly
• Remove vent / filler plug strip
• Top up level with distilled water in between Min and Max. level
• Connect to battery charger & ensure respective terminal are connected properly
• Set charging current at 0.5 A DC for 5 Ah Battery
• Charge battery for 3 ~ 4 hrs, then check voltage and specific gravity.
• Voltage should be 12.5 volts and specific gravity in all 6 cells should be 1.240. This is a confirmation check for a fully
• Use only distilled water to top up battery.
charged battery. 3
• Disconnect the battery from the changer.
• Fit vent / filler plug strip firmly.
• Reconnect battery terminals
• Apply petroleum jelly to the battery terminals.
How to Determine Condition of Battery
Hydrometer
Specific Gravity check: - Whether battery is fully charged or partially charged, it will always
show same “no load voltage” of 12 volts or more (unless battery cells are damaged due to • Always maintain electrolyte
Read sulphation etc). But specific gravity of the fully charged battery and partially charged battery 3 level between maximum &
Here
will be different. Fully charged battery will show Sp. gravity of 1.240 while partially charged minimum level marks.
battery will show less specific gravity. Therefore, specific gravity check is very important to
know condition of the battery.

DOS & DON'TS - GENERIC DOS & DON'TS - GENERIC
Battery Battery
7 Don’ts 3 Dos
• Do not hold the wires. • Always charge battery by constant current method with
7 3 the help of specified charger.
• Do not apply grease to poles / terminals. • Check open circuit voltage by multi meter.
7 3
• Do not hammer battery terminals. • Always maintain battery top

3 cover clean and dry. Always 3
keep Vent Mechanism area
clean & clear.
• Do not use mineral water, • Use hydrometer for checking specific gravity
7 drinking water to top up
7 3
battery.
• Do not increase the level of electrolyte beyond maximum 3 • Use battery load tester for checking battery charge
level mark otherwise it would over flow through Vent condition.
Mechanism & damage other parts.

Battery HORN
7 Don’ts 3 Dos 7 Don'ts

Ensure that horn is firmly fitted on
• Do not quick charge battery by current higher than
7 specified current.
frame
• Constant voltage charging method must be strictly

avoided.
• Do not use local make battery charger.
Ensure that horn is free from dust Do not apply pressurised water
and mud accumulation. jet directly on horn resonator.
• Do not short circuits the poles.
Ensure that horn wires are intact. Never adjust nut on horn cap
side & bracket end (back side)
as it will result in horn
7 malfunctioning & failure.
• Do not short circuit the leads.

7 Ensure that horn switch button is Do not remove silicon sealant
operating freely. from adjustment screw as it will
result in water entry in horn.
Ensure that battery is fully charged.
• Do not fit extra electrical accessories (Tampering of

7 wiring for fitting buzzer etc.) other wise wiring would get
short & battery would get discharged. This will shorten
the life of battery.
• Adjust horn by phillips screw driver Do not hit by mallet / screw
- without removing silicon sealant driver on horn resonator.
from the adjustment screw.
- by rotating the screw in the
direction of arrow provided in the
screw.
Ensure that resonator is not pressed

by any portion of cables or wiring
harness as it will result in distorted
sound.

IGNITION SYSTEM LIGHTS
3 Dos • Always install recommended capacity of battery on the bike. 3 Dos • Check that all bulbs are firmly fitted in bulb holder.
• Always replace spark plug by correct heat range plug. • Ensure that there is no dust and water entry in bulb housing.
• Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler • Ensure that all fixing screw of bulb housing are intact.
gauge.
• Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is
• Replace spark plug at every 20,000 kms. intact.
• Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3 • Check DC Voltage Regulator’s output voltage periodically. Ensure that
~ 1.5 Kgm. voltage is within specified limits.
• Ensure H.T. cable secondary connection is firmly fitted in spark plug cap a n d • Check that couplers and wires of bulbs are in good condition.
H.T. coil.
• Check flashing rate of indicator bulbs.
• Check that CDI coupler is tightly fitted.
• Ensure that magneto coupler is firmly fitted.
• Always use a right size socket during removal and re-installation of spark
7 Don'ts • Do not install a lower / higher capacity battery than what is recommended.
plug. • Do not use Higher / Lower wattage Bulbs.
• During periodic service make use of spark plug cleaning & testing machine • While washing Vehicle do not direct pressurized water jet on Head Light, Tail
to clean spark plug electrodes & to check proper functioning of both the Light,Indicators.
spark plugs. • Do not ride on brakes.
• Do not start Vehicle with light control switch in ON condition.
7 Don'ts • Do not replace spark plug by non recommended one (different heat range).
• Do not replace CDI by local make or different make.
SWITCHES
• Never short circuit H.T. coil primary wire to ground. It could lead to CDI
failure.
• Do not adjust the spark plug gap with any instruments like screw Driver,
3 Dos • Always clean switch assembly with soft cloth.
• After washing the vehicle ensure to apply dry air on switches before
pliers etc.
operation.
• Do not drive the vehicle without battery. Driving motorcycle in battery
• Ensure that rear brake switch is free from dust, dirt and mud Accumulation.
removed condition could cause damage to electrical components like voltage
regulator because of no load Condition. • Always ensure that grommets provided on clutch switch, front brake switch
and rear brake switch are intact.
• Always apply WD-40 Rust Spray to sticky switches.
7 Don'ts • Do not apply direct pressurized water jet on control switches.

• Do not lubricate electrical switches by oil or grease.
• Do not over tighten the switches.
• During warranty period do not dismantle control switches.
• Do not add extra electrical loads e.g. musical horns, additional horns,
buzzers as it will reduce switch contact life & battery life &battery life.
• Do not tamper / alter rear brake switch spring.
• Do not operate switch immediately after water servicing.

ELECTRICAL CHECKING PROCEDURE ELECTRICAL CHECKING PROCEDURE
Fuse Inspection (Capacity = 10 Amp) Clutch Switch
Fuse The clutch switch has 3 wires. In neutral conditions, clutch switch is in
non-operated condition closing ‘C’ & ‘NC’ terminals. In gear condition,
• Inspect the fuse element. clutch switch is operated there by connecting ‘C’ & ‘NO’ terminals.
• Check continuity of fuse.
• If it is blown out, replace. Meter Range Light Green Yellow / Green Black /Yellow
• If a fuse fails repeatedly, check the electrical system to determine the cause. Replace it
OFF - Clutch l l l
with a new fuse of proper amperage capacity. lever not pressed
• If fuse is replaced by lower capacity fuse, it may lead to repetitive fuse blowing
problem. ON - Clutch
l l l
lever pressed
Note : Never use higher capacity fuse.
Caution : When replacing a fuse be sure the new fuse matches the specified fuse rating Ignition Switch
for that circuit. Installing that a fuse with a higher rating may cause damage to wiring &
components.
Measuring & Testing Equipment : Multimeter
Meter Range Connections Continuity Check

Front Brake Light Switch
Continuity Meter +ve Meter -ve OFF - No continuity
Mode Brown White wire ON - Continuity
• Turn ‘ON’ the ignition switch.
• The brake light LED bank should glow brightly when the front brake lever is
SOP :
pressed.
• If it does not, check the front brake switch. • Switch OFF Ignition key.
• Disconnect Ignition switch’s coupler.
Brown Blue Continuity check by multimeter • Remove Ignition Switch from vehicle .
• Check continuity between wires in ‘ON’ & ‘OFF’ position.
Lever Pressed l l Continuity is shown
Lever Released l l No Continuity Standard Value :
• Beep Sound & Continuity in ‘ON’ position. No continuity in ‘OFF’ position.
Note: • Don’t use duplicate or non-OE Ignition key.

Rear Brake Light Switch
• Never lubricate Ignition switch by oil / grease.
• Turn ‘ON’ the ignition switch.
• Check the operation of the rear brake light switch by depressing the brake pedal
• If it does not operate check continuity of rear brake switch.
Brown Blue Continuity check by multimeter
Brake Pedal Pressed l l Continuity is shown

Brake Pedal Released l l No Continuity

Empty Tank Fuel Gauge - Tank Unit Engine Thermal Sensor
Measuring & Testing Equipment : Multimeter Measuring & Testing Equipment : Multimeter
Meter Range Connections Standard Value Meter Range Connections Standard Value
Meter +ve Meter -ve As per chart Engine Resistance
200 Ohms Meter +ve Meter -ve
White / Yellow Black / Yellow given below Temp (0C) K Ohms(W)
@ 10 0C 20.702 KW + 10%
0
@ 20 C 12.889 KW + 10%
Standard Value :-
@ 30 0C 8.653 KW + 10%
Full Tank Fuel Level Standard value 20 K Ohms Black / White Earth / Ground
@ 40 0C 5.636 KW + 10%
in Ohm
@ 50 0C 3.818 KW + 10%
Empty Tank 97
@ 60 0C 2.782 KW + 10%
Reserve 58
19.3 Half Tank 44
Full Tank 20
Battery Charging Coil
Note: If display in speedo console is not proper then please check following Measuring & Testing Equipment : Multimeter
• Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is firm. Meter Range Connections Standard Value
Meter +ve Meter -ve 0.9~1.1 Ohms
200 Ohms at 250C
Blue / White Blue / White
Starter Relay SOP :
• Switch OFF engine.
Measuring & Testing Equipment : Test Jig or Multimeter • Disconnect stator plate coupler
Connection : Test Jig - Connect starter relay coupler to Test Jig & it show result as • Connect multimeter between two Blue / White wires.
• Check resistance value between Blue / White & Blue / White.
OK / Defective
Meter Range Connections Standard Value

Meter +ve Meter -ve Pick-up Coil
200 Ohms
Starter Relay Starter
Coil Red - Relay Coil 4 Ohms + 10% Measuring & Testing Equipment : Multimeter
Yellow Wire Black Wire
Meter Range Connections Standard Value
Meter +ve Meter -ve
SOP : 2 K Ohms 180 ~ 220 Ohms
White / Red Black / Yellow
• Switch OFF engine.
• Disconnect coupler from Relay. SOP :
• Connect multimeter to Starter Relay coil terminals. • Switch Off Ignition Key.
• Check resistance. • Disconnect Stator Plate Coupler
• Connect multimeter between White / Red &
Black / Yellow wires.
• Measure resistance
Note: Ensure gap 0.5~0.7 mm between pole of pick-up coil & rotor peep.

Starter Motor - Current Drawn Horn
Measuring & Testing Equipment : DC Clamp Meter Measuring & Testing Equipment : DC Clamp Meter
Meter Range Connections Standard Value Meter Range Connections Standard Value
Encircle clamp meter 30 ~ 38 Amps Encircle clamp meter jaws
200 DC A transformer jaws around Spark Plug 200 DC A 2.2 Amps
around Brown wire of horn
thick Red wire of starter motor. Caps removed
SOP : SOP :
• Switch ‘ON’ Ignition Key & disconnect both spark plug caps • Encircle clamp meter jaws around Brown wire of Horn.
• Select range & set clamp meter Zero reading. • Press horn switch & check instantaneous current drawn by horn.
• Encircle red input wire of starter motor by clamp meter jaws.
• Crank engine by pressing self starter button.
• Press self starter button 3 seconds & check cranking current displayed on clamp
meter LCD display.
Starter Motor Armature

Speedometer
Measuring & Testing Equipment : Multimeter
Meter Range Connections Standard Value Twin pod analog type speedometer houses :
• Speedo-Odometer unit
Continuity Meter +ve Meter -ve No continuity
mode • Trip meter with push type ‘Knob / Lever’ for resetting zero.
Commutator segment Shaft is shown
• Fuel meter.
• Turn signal indicator.
SOP :
• Dismantle starter motor & take out Armature. • High beam indicator.
• Check continuity between starter motor shaft & each segment on • Neutral indicator.
commutator. • Low battery indicator & Bajaj Logo.
• Replace armature if continuity is shown.
Low battery indicator
Starter Motor Armature When ignition switch is turned ‘ON’, battery indicator glows on
Measuring & Testing Equipment : Multimeter Upon Starting Engine :-
Meter Range Connections Standard Value Condition 1 : Battery indicator glows off if battery charging system is OK /
battery is in charged condition.
Meter +ve Meter -ve
Continuity Continuity is Condition 2 : Battery indicator continuously glows on if battery
mode Any segment Adjacent segment shown
on commutator on commutator charging voltage is less than 13 V (means charging system
is malfunctioning) / battery is deep discharged.
SOP : Thus low battery indicator reminds to charge battery /
• Dismantle starter motor & take out armature correct battery charging system in time.
• Check continuity between each pair of adjacent segments on commutator.
• Replace armature if ‘No’ continuity is shown between any two adjacent
pair of commutator segments.

DC Charging Voltage Measurement

H. T. Coil H. T. Coil Resistance Checking
Primary
Use fully charged battery while measuring Measuring & Testing Equipment : Multimeter
Ensure VB = 12.5 + 0.3 V before checking • Measure the primary winding resistance as follows
VB = Battery open circuit terminal voltage with Battery terminals in
disconnected condition. Meter Range Connections Standard Value
To measure the DC voltage; set the meter at 20V DC range. Connect the Meter +ve Meter -ve 0
meter +ve lead to Battery +ve terminal & meter -ve lead to battery -ve 200 Ohms 0.3 ~ 0.5 Ohms at 25 C
terminal without disconnecting battery wires. Start the engine & set it at White / Yellow Black / Yellow
1500 RPM. Measure the voltage with headlight switch in ‘ON’ position.
• Measure the secondary winding resistance as follows
Switch OFF Ignition key & disconnect the meter leads.
H.T. Coil • Remove the plug cap by turning it counter clockwise.
Secondary
Meter Range Meter Connections Specified at
4500 RPM Meter Range Connections Standard Value
+ve lead -ve lead Meter +ve Meter -ve 0
20 V DC Battery Battery 14.2 + 0.4 Volts 20 K Ohms 4.5 ~ 6.5 K Ohms at 25 C
+ve terminal -ve terminal
White / Yellow Black / Yellow
• If the value does not match as per, specifications replace the coil.
Note : For DC voltage measurement connect multimeter in parallel circuit.
• If the meter reads as specified, the ignition coil windings are probably
good. However, if the ignition system still does not perform then check
spark output of HT coil using CDI / HT coil tester.
H. T. Coil Spark Output Checking
S.N. LED Status Spark Status Conclusion
Continuous
1. Glows Ignition system is OK
Bluish Spark
HT Coil / Spark plug / Plug cap

2. Glows No Spark
may be defective
Intermittent HT Coil / Spark plug / Plug cap

3. Glows Spark may be defective
Does not Check pick up coil & Exciter coil

4. No Spark
Glow if found OK then replace CDI

ELECTRICAL CHECKING PROCEDURE STANDARD OPERATING PROCEDURE
CDI Assembly Head light bulb Replacement SOP
Identification :
• Remove RHS & LHS head light mounting bolt (4 nos. 10 mm A/F)
• Case colour - Gray
• Coupler - Single black colour 12 pin.
• Make - Varroc
Measuring & Testing Equipment : CDI / HT
Coil Tester.
LHS SOP for CDI Checking

• Remove wiring harness couplers 2 nos.
Measuring & Testing Equipment : CDI / HT Coil tester.
• Hang the unit on leg guard of the vehicle.
• Remove Spark Plug cap & connect to suitable terminal S1/S2 on the unit.
• Connect 'Red' probe of the unit to HT coil primary terminal.
• Connect 'Black' probe to earth.
• Start the engine.
RHS • Status of LED & Spark window indicates the result as below.
• Remove head light protection rubber cap.
S.N. LED Status Spark Status Conclusion
Continuous
1. Glows Ignition system is OK
Bluish Spark
HT Coil / Spark plug / Plug cap

2. Glows No Spark
may be defective
Intermittent HT Coil / Spark plug / Plug cap

3. Glows Spark may be defective
Check pick up coil & Exciter coil • Remove head light bulb socket
Does not No Spark
4. if found OK then replace CDI
Glow

• Remove head light bulb lock as shown in photograph. • Remove 2 Philips head screws of windshield
• Take out head light for replacement • Remove 3 nos of 10 mm A/F

bolts.
• Take out speedometer flap.
• Remove side indicator and head

light couplers.
Speedometer Replacement SOP
• Remove RHS & LHS head light mounting bolt (4 nos. 10 mm A/F) • Take out speedometer assembly
Head Light Replacement
• Remove speedometer cable,

couplers and take out head light • Remove the speedometer assembly as per the above SOP.
assembly from vehicle.

• Remove 4 nos. 10 mm A/F bolts Head Light Focus Adjustment

& 4 nos. of phillips screws
• Loosen RHS & LHS head light mounting bolt (4 nos. 10 mm A/F) as shown in
photograph.
• Adjust the head light focus by moving H/L fairing upward or downward from
bottom side.
• Tighten RHS & LHS head light mounting bolt (4 nos. 10 mm A/F)
• Take out the bracket
Foam Application - Head Light Fairing
• To avoid rattling noise of H/L fairing, please ensure foam application as shown
in photograph.
• Remove 6 nos. of phillips screws

& take out the headlight assly.

Wiring Harness Routing Clamp wiring harness near LHS H.T. coil using PVC clamp.
Place couplers of tail lamp, number plate lamp, LH & RH rear side indicator in
bellow as shown in photograph.
Route wiring harness through button clamp located near LHS petrol tank
rubber damper.
Route wiring harness from LHS beneath rod joining 2 members of frame as
shown in photograph.
Clamp wiring harness near air filter using PVC clamp. Route wiring harness beneath the rod joining lamp shade through LHS.
Clamp wiring harness above battery using PVC clamp.

STANDARD OPERATING PROCEDURE ELECTRICAL CIRCUIT DIAGRAMS
Precautions to be taken in field to avoid wiring harness failures. B/R

DC C.D.I. ASSY. IGNITION CIRCUIT
12 POLE COUPLER REED
1. Ensure wiring harness is properly routed & clamped. H.T.
COIL
SWITCH
2. Ensure firm connections of all couplers.
Pi
B/Y
B
3. Ensure wiring harness couplers are placed properly in bellows provided at head lamp fairing & tail lamp side.
4. Ensure correct routing of wiring harness which will avoid pinching of wires. SPARK PLUG B/R
B/W
5. Do not apply pressurized water jet on wiring harness. B
W/R
6. Do not fit extra electrical accessories. Such as-
7
Br/L
B/Y
• Remote
• Extra & bigger horns
O O
• Musical brake light N F
IGNITION SWITCH
H.T.COIL SPARK PLUG
F
Br Br/L
• Buzzer
W W
• Higher wattage Headlamp bulb.
• Flasher operating all 4 side indicators simultaneously W/R
7. Do not replace fuse with higher capacity fuse. B/W
B/Y
8. Do not cut wiring conduit / wires midway.
W
9. Never remove conduit from wiring harness
B/Y
MAIN FUSE
W/R
THERMAL
SENSOR (10 Amps.)
10. Never bypass fuse.
W/B
11. Do not repair wiring harness instead replace for safety.
MAGNETO
12. Do not ground any wire for checking current-spark. R
BATTERY
ER
PU IL
LS
Wiring harness failure due any one of the reason mentioned above should not be covered under warranty replacement.
CO
12V-5Ah
STARTER MOTOR CIRCUIT

START
Lg SWITCH
NEUTRAL
BULB
R/Y
Br
12V 2W
Br
R/Y
Br
O O
N F
F
IGNITION SWITCH
Br Br/L
W W
Lg
R
B/Y
W
Lg
STARTER
MOTOR
FUSE
Br/L Br (10 Amps.)
W/B
CABLE ASSY.
FUSE
BATTERY
(10 Amps.)
NEUTRAL TO EARTH
Lg
B
SWITCH
B/Y
R/Y R
B/Y Lg
CLUTCH
SWITCH BATTERY
12V-5Ah
Y/G Y/G
Y/G STARTER RELAY
100A RATING

ELECTRICAL CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAMS
SPEEDOMETER
BULB 3W
R R CAPACITOR
LIGHT SYSTEM CIRCUIT REAR BRAKE
BRAKE LAMP CIRCUIT
HEAD LAMP
CONTROL UNIT FRONT BRAKE SWITCH
B/Y W
SWITCH
CONTROL SWITCH RH
HI BEAM R/B R/B
ON PO
INDICATOR LIGHT
Br
DC. REGULATOR ASSLY
V
OFF
Br
W
2W
L
B/Y SWITCH WITH CAPACITOR
Br
B/Y
L
L/W
Y/L
R
Y
L/W
B/Y
W
L/W
B/Y
Y/L
Br
V
R
V
Br
Br
L
L
EARTH
L/W
L/W
B/Y
B/Y
FRAME
R
W
O O
N F
F O
Br O
Br Br/L
N F
IGNITION F
IGNITION SWITCH
SWITCH
W W Br Br/L
B/Y B/Y L L
W W TAIL
R/W R/W R LAMP
TAIL LAMP ASSY
R
ASSY B/Y B/Y
B/Y
B/Y
L/W
L/W
R/B R/B
HEAD LAMP B/Y B/Y

ASSY / LAMP
12V-35/35W
R/Y R/Y
W
HS1
W
R/B
POSITION
R/Y
Y/L
R
Br
LAMP B/Y
12V-5W FUSE
2 Nos (10 Amps.) FUSE
L/W
L/W
R
(10 Amps.)
W/B
W/B
R/B
Y/L
R/Y
R
Y
R/B
BATTERY Br/L Br
12V-5Ah EARTH
LO HI FRAME
FUSE R
FUSE (10 Amps.) + -
PASS DIMMER
SWITCH SWITCH Br/L
(10 Amps.)
Br BATTERY
12V-5Ah
CAPACITOR BATTERY CHARGING CIRCUIT HORN & NEUTRAL LIGHT CIRCUIT

W
SPEEDOMETER
ASSLY
Lg
W
DC. REGULATOR ASSLY Br

WITH CAPACITOR
W
O O
Lg
N F
F
IGNITION SWITCH
Br Br/L
B/Y
W W
B/Y
B/Y
B
EARTH-FRAME
W EARTH FRAME
Br
B
W
W
B/Y
L/W
L/W
B
FUSE
MAIN FUSE (10 Amps.)
(10 Amps.)
W/B
W/B
L/W
L/W
HORN
NEUTRAL
HORN SWITCH SWITCH
BATTERY
12V-5Ah
BATTERY FUSE R
CHARGING (10 Amps.)
COIL R
Br/L Br BATTERY
12V-5Ah

ELECTRICAL CIRCUIT DIAGRAMS
SIDE INDICATOR CIRCUIT

SIGNAL
Gr Gr
LAMP
FRONT RH
LAMP TURN
B/Y B/Y SIGNAL
12V-10W
RELAY
Gr Gr SIGNAL
Gr
SPEEDOMETER
LAMP
REAR RH
ASSLY
LAMP
Br
O
G B/Y B/Y 12V-10W
B/Y
O O
N F
F
IGNITION SWITCH
Br Br/L
W W
B/Y SIGNAL
LAMP
Gr
G
O
REAR LH
LAMP
W G G 12V-10W
FUSE
(10 Amps.)
Gr
G
O
W/B
SIGNAL B/Y B/Y

LAMP
FRONT LH R O L
LAMP G G
12V-10W TURN SIGNAL SWITCH
R
BATTERY
Br/L 12V-5Ah
Br
FUSE
(10 Amps.)


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I Read ..... I Learn: Discover 125 ST Training Notes International Business

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Contents

1 I Read ..... I Learn 1

3 Engine & Transmission 33

DISCOVER 125 ST TRAINING NOTES INTERNATIONAL BUSINESS

Periodic Maintenance & Lubrication Chart

Periodic Maintenance Points

Frame Number Location

Engine Number Location

1 2 • Molycoat piston • Reduced friction • Increased fuel efficiency.

DISCOVER 125 ST TRAINING NOTES

STYLE COMFORT AND CONVENIENCE

Features Advantages Benefits Features Advantages Benefits

DISCOVER 125 ST TRAINING NOTES

SAFETY Engine & Transmission

DISCOVER 125 ST TRAINING NOTES

Controls Frame No. M D 2 D S J Z Z Z

Dimensions Fasteners (Check torque) a) Front mounting nuts- 3.5 Kgm

• All dimensions are under un-laden conditions. Clear rear view

DISCOVER 125 ST TRAINING NOTES

DISCOVER 125 ST TRAINING NOTES

RECOMMENDED FREQUENCY RECOMMENDED FREQUENCY

DISCOVER 125 ST TRAINING NOTES

Clean sediment bowl thoroughly with low pressure compressed air.

DISCOVER 125 ST TRAINING NOTES

Remove side cover LH by following steps given below

Replace paper filter element with seal at every 15000 kms

Remove seat by following step given below

• To avoid cross fitment of sediment bowl. Do pre fitment of sediment bowl by

Remove intake duct from clamp

DISCOVER 125 ST TRAINING NOTES

Take out paper filter element Do’s :

‘O’ Ring Drive Chain Lubrication - on Vehicle

• Place the bike upright.

• Carefully remove the filter element from air filter assly.

Post Cleaning Actions :

DISCOVER 125 ST TRAINING NOTES

DISCOVER 125 ST TRAINING NOTES

Paper Oil Filter Replacement Tappet Clearance Setting

Remove : • Ensure that the engine is in cold condition.

Caution : ¡ Inlet Valve : 0.05 mm

Nitrox Mono Rear Shock Absorber Silencer Drain Hole Cleaning

Adjusting Spring Tension • Clean the silencer drain hole in

Note: Standard setting is done in 2nd notch.

Special Tool for Mono RSA adjuster

DISCOVER 125 ST TRAINING NOTES

3 Dos 7 Don'ts Readiness of CO Gas Analyser Taking the Reading

DISCOVER 125 ST TRAINING NOTES

3 Dos 7 Don'ts 3 Dos 7 Don'ts

• Always apply loctite to oil • While assembling oil Pump

• While installing engine bearings always tap / press on the race

DISCOVER 125 ST TRAINING NOTES

Tune up for Optimum Mileage

UCAL TPS - Reed Switch : Checking AIR FILTER:

Multimeter will not show continuity

Item Specification Other Mandatory Checks

DISCOVER 125 ST TRAINING NOTES

• Remove LHS side cover by using

• Remove LH & RH spark plug cap

• Remove the seat assembly by pulling the seat lock cable.

• Remove breather tube connection

• Remove silencer assembly

• Remove fuel tank mounting bolt