Pulsar 125 Fi TRG Note

Training Notes
Pulsar 125 Fi
The Training No tes are a comp rehensive
training guide on ser vice and
main tenance ope rations and procedures
to be followed by se rvice personnel
at authorised se rvice cent res and
dealerships whilst at tending to the Bajaj
Pulsar 125 Fi.
The Training Note covers standard
workshop producers,
simplified for easy learning and
understanding for service technicians
worldwide.
NOTICE Copyright
All information contained in this Training Note is based on All Intellectual Property Rights, including but not limited
the latest product information at the time of publication. to Copyright, applying to this drawing and the information
Bajaj Auto Limited accepts no liability for any inaccuracies contained therein vest solely and exclusively with Bajaj
or omissions in this publication, although every possible Auto Limited. No part of this drawing may be copied or
care has been taken to make it as complete and accurate reproduced, either in part or in full by any means, whether
as possible. All procedures and specifications subject to mechanical or electronic, without prior written permission
change without prior notice. The right is reserved to make of the authorized signatory of Bajaj Auto Limited. Bajaj
such changes at any time without prior notice. reserves all rights to deal with violations of this clause in
accordance with applicable laws.
DOC. NO.: 71112877, REV. 00, OCT 2018
CIN L65993PN2007PLC130076 © Bajaj Auto Limited, 11 th SEPT 2012.
Contents
I Read... I Learn 1
CHAPTER 1
Identification...........................................................................................................2
Salient Features......................................................................................................5
Technical Specifications.........................................................................................7
Pre-Delivery Inspection Checklist..........................................................................9
Periodic Maintenance & Lubrication Chart..........................................................11
Fuel System 13
CHAPTER 2 Wiring Harness routing........................................................................................14
Working of Systems ............................................................................................20
Fuel Injection - Advantages Over Carburetion.....................................................30
EMS Sensor & Actuators......................................................................................31
Malfunction Indication...........................................................................................35
Tune up for Optimum Mileage..............................................................................37
CHAPTER 3
Engine & Transmission 39
Tightening Torques...............................................................................................40
Service Limits.......................................................................................................42
Special Tools.........................................................................................................44
Engine Dismantling...............................................................................................47
Frame 60
CHAPTER 4
Tightening Torques...............................................................................................61
Service Limits.......................................................................................................62
Special Tools.........................................................................................................63
Combi Brake System-SOP....................................................................................66
Standard Operating Procedures...........................................................................69
Electricals 82
CHAPTER 5
Battery..................................................................................................................83
VRLA Battery Initial Filling..................................................................................83
Do's & Don'ts......................................................................................................85
Electrical Checking Procedure.............................................................................89
Standard Operating Procedure..........................................................................105
Key LearningPoints
Understanding the complete

Vehicle
Technical Specifications and Performance

Parameter
Pre delivery inspection care &

periodic maintenance
CHAPTER 1
I Read ..... I Learn

Identification
Salient Features
Technical Specifications
Pre-Delivery Inspection Checklist
Periodic Maintenance & Lubrication Chart
Bajaj Pulsar 125 Fi Training Notes

1
1 I Read ..... I Learn
Identification
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.
Frame Number Location

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

On LH Side Crankcase Near
Gear Change Lever (Alpha-Numeric - 11 Digits)
Control Switches
Left Handle Bar Switches

A A. Dipper Switch : When headlight is ON,High or Low beam can be selected
with the dipper switch. Hi beam indicator light located on Speedo console
will light up when high beam is selected.
: High Beam : Low beam
B
B. Turn Signal Switch : When the turn signal knob is turned to Left ( )
C or Right ( ) respective indicator will start blinking, to stop blinking push
the knob in & release.
C. Horn Button : ( ) Press button for sounding horn.

D
D. Pass Switch : Press the switch to flash the head light. It is used to give
signal to vehicles coming from opposite side while overtaking.
Bajaj Auto International Business

2
125 Fi
Identification
RH Control Switch
E. Starter Button :
F
Starter button operates the electric starter when clutch lever is
depressed with transmission in any gear.
It is recommended to start the engine with the transmission in neutral.
F. Engine Kill Switch :
E
The engine kill switch is for emergency use. During emergency move
the engine kill switch to the ‘OFF’ ( ) position.
Speedometer display will work when both Ignition switch & kill switch are
in ‘ON’ position.
CAUTION : While starting ensure that engine kill switch is in ON ( )

position. Keeping the kill switch in OFF position, engine will not start.
Steering Cum Ignition Lock

Steering cum Ignition Lock :
It has three positions.
OFF: Steering unlock. Ignition OFF.
ON: Steering unlock. Ignition ON.
To Lock the Steering : To lock the steering, turn the handle bar to the left
side. Push & release the key. Turn the key to “LOCK” position and remove
the key. Steering lock can be done on left handle position only.
To Unlock the Steering : To unlock steering, insert the key in steering cum
ignition lock & turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank
cap’ & ‘Rear Seat’.

3
Identification
Instrument Cluster Information
7 6
3
2 5
1
11
4
9
10
8
Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position.
1. Fuel Level Indicator: It shows fuel level in fuel tank.

2. Tachometer Dial: It shows engine speed in RPM.
3. Turn Signal Indicator (LH & RH): When Turn signal switch is turned to Left or Right, Turn pilot indicator LH or RH will
flash.
4. Neutral Indicator: When the transmission is in Neutral, Neutral indicator will glow.
5. Hi Beam Indicator: When Headlight is ‘ON’ & Hi beam is selected with engine running, Hi beam indicator will glow.
6. Side Stand Indicator : When Side stand is ‘ON’, the Side stand indicator will lit.
7. Speedometer: Vehicle speed will be displayed in digital form in Km / Hr.
8. Odometer : The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to ‘Zero’.
9. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero.
10. Set Button : Set button used for setting Clock & Service reminder.
11. Malfunction Indicator : It glows whenever any abnormality is noticed in functioning of Fi system related components.

4
125 Fi
Salient Features
PERFORMANCE
Key Features Advantages
 All new 4 valve 125cc  Optimum power • Refined Engine with
delivery without proprietary DTS-I
DTSi Engine
sacrificing low end technology that
 Engine power: 12 Ps at torque delivers a balanced
 Better drivability &
8500 RPM mix of power &
knock free performance.
 Engine torque: 10.78 Nm  Steady & Stable efficiency.
performance. • More power in all load
at 6500 RPM
 Reduced of bore friction
 DC ignition system. – Long life for the conditions, Better torque
Piston. delivery at lower RPM
 Molycote piston
 Better Heat Disputation • Eco Friendly - Lower
 Oil jet for cooling piston -Improved life of engine
components. emissions & high fuel
 Heavy duty gear box. efficiency
 H i g h S p e e d
 Viscous type air filter performance. • Smooth gear shifts for
element.  Optimum utilization of start stop traffic
engine torque.
 Paper element type oil
conditions
 More effective filtration
filtration system. • Quick starts in wintry
 Paper type oil filtration conditions.
 Advanced Engine system filters out micro
level dirt/dust particles • Minimal wear & tear of
Management System
from engine oil. engine parts, thus
incorporated in ECU  Adaptive ignition maps lower maintenance &
(EPM 44 type) for Optimum Engine longer life.
Performance.
STYLE
Key Features Advantages Benefits
• LED tail lamp • Classic & Efficient LED • Premium looks with
Tail Lamp. enhanced battery life
• Fuel tank • Streamlined Fuel tank
with a capacity of
10.5L.
• Imposing Front Fascia
• Open chested handle
bar position with a • Sleek & aggressive
symmetrical head light stance with a trendy
and a dual tone color dual tone colour
scheme palette for a modern &
trendy appearance

5
Salient Features
CONVENIENCE
• MIL indicator. (Applicable • FI & related system errors • Information easily
to Fi variant only) are indicated by blinking available at a glance.
patterns
• Maintenance free sealed • Hassle free ownership -

VRLA batter y. (For Fi • Electrolyte top up not
required for life - Zero
variant)
battery maintenance
SAFETY
• Powerful DC lighting • Intensity & illumination • Bright & even visibility
system with AHO of the head light does at all speeds & driving
not change with change conditions.
in engine/ Vehicle
• Tubular frame chassis speed.
with 1325 mm wheel- • Long life of chassis,
base & 5 spoke alloy • Strong chassis with good stability &
wheel. superior handling manoeuvrability
• Disc brake at Front & • 240mm ventilated disc • Safe & effective
Drum at Rear (With CBS) brake at front & 130 braking
mm Drum at rear

6
125 Fi
Engine & Transmission
Type : 4 stroke, single cylinder air cooled
No. of cylinders : One
Bore : 52 mm
Stroke : 58.6 mm
Engine displacement : 124.4 cc
Idling Speed : 1400 ± 100 rpm
Compression ratio : 9.8 ± 0.5 : 1
Max. net power : 12 Ps @ 8500 rpm
Max. net torque : 10.78 Nm (1.1Kg-m) @ 6500 rpm
Ignition System : Inductive DC ignition
Ignition Timing : Variable as per map in ECU
Spark Plug : 2 plugs
Spark Plug Gap : 0.7 ~ 0.8 mm
Lubrication : Wet sump, Forced lubrication
Transmission : 5 speed constant mesh
Primary reduction : 3.57
Gear shifting : 1 down 4 up
Primary reduction : 3.57
Gear Ratios 1st Gear : 2.833
2nd Gear : 1.823
3rd Gear : 1.333
4th Gear : 1.086
5th Gear : 0.909
Final Drive Ratio : 3.071:1(43/14)
Chassis & Body

Frame Type : Tubular
Suspension Front : 130 mm fork travel
Rear : 105mm wheel travel, twin shocks
Brakes Front : Hydraulically Disc type
Rear : Hydraulically Disc type
Tyres Front : 2.75-17, Tube type
Rear : 100/90-17, Tube type
Tyre Pressure Front : 1.75 kg/cm2 (25.0 PSI)
Rear (Solo) : 2.00 kg/cm2 (28.5 PSI)
Rear (with Pillion) : 2.25 kg/cm2 (32.0 PSI)
Rims Front : 1.4X17", spoke alloy wheel
Rear : 2.15X17" Spoke alloy wheel
Fuel Tank Capacity (Full) : 10.5 liters
Usable reserve : 2.5liters
Unusable reserve : 2 liters

7
Controls
Steering : Handlebar
Accelerator : On handle bar, RH grip
Gears : Left foot pedal operated, Step shift
Brakes Front : On handle bar, RH lever
Rear : Pedal operated by RH foot lever (CBS)
Clutch : Lever operated, left hand
Electricals
System : 12 V (DC)
Battery : 12V 6 Ah VRLA (Valve Regulated Lead Acid)
Head Lamp : 12V 35/35W
Position Lamp : 12V 5 W (2 nos.)
Rear number plate lamp : 12V 3 W
Tail / Stop Lamp : LED Type
Side Indicator Lamp : 12V 10W (4 nos. - Amber bulbs)
Neutral Indicator : LED - Green
High Beam Indicator : LED Type
Turn Signal Indicator : LED Type
Side Stand Indicator : LCD
Speedometer Lamp : LCD
Low battery indicator : 12V, 2W
Rear number plate lamp : 12V 3W
Horn : 12V DC, Type 2A (70 mm dia.) X 2
Dimensions
Length : 1995 mm
Width : 765 mm
Height : 1045 mm
Wheel Base : 1325 mm
Ground Clearance : 170 mm
Weights
Vehicle Kerb Weight : 125 kg
Gross Vehicle Weight : 200 kg
Performance
Maximum Speed, km/h : 95 Kmph
Climbing Ability : 26%
Notes :
• Values given above are nominal & for guidance only, 15% variation is allowed to cater for production & measurement.
• All dimensions are under un-laden conditions.
• Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
• Specifications are subject to change without notice.

8
125 Fi
Pre Delivery Inspection Care

9
Pre Delivery Inspection Care
Recommended Oil SAE 20W50 of API 'SL', JASO MA Grade. Bajaj DTS-i Oil.
Replacement Frequency* 1st replacement at 500-750 Kms./ 1st service. Thereafter at

every 5000 Kms.
Recommended Quantity Drain & Refill 1000 ml., Engine Overhaul 1100 ml.

10
125 Fi
Periodic Maintenance & Lubrication Chart

Recommended frequency
Service 1st 2nd 3rd 4th 5th 6th 7th

Sr. PM check points 500 4500 9500 14500 19500 24500 29500 Remarks
No.
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
1 Servicing & water wash

       1st - 750 Kms / 30 Days 2nd onward
@5000 Kms
2 Valve tappet clearance A A A A A A A A
3 Engine oil & Oil filter R R R R R R R R 20W50API SL JASO MA Grade. Bajaj DTS-i Oil
4 Oil strainer CL CL CL CL CL CL CL CL Clean at 5000 Kms
5 Paper oil filter R R R R R R R R Clean at 5000 Kms
6 Spark plug functioning / Gap CL, A, R CL, A CL, A R Replace at every 30000Kms
7 Air cleaner element Clean / Replace CL,R CL CL CL R CL CL R Clean at every 5000Kms Replace @ every 15000Kms
8 Air filter cover 'O' Ring R R R Clean at every 15000 kms
9 In line fuel filter R R Replace at every 20000 kms
10 Fuel pipes C,R C C C C R C C Clean at every 15000 kms
11 Clutch lever free play C,A C,A C,A C,A C,A C,A C,A C,A
12 Throttle grip play C,A C,A C,A C,A C,A C,A C,A C,A
13 CBS free play CL,R CL CL CL,R CL CL CL,R
14 Brake lining or pad wear CL,R CL CL CL,R CL CL CL,R Replace at every 15000 kms
15 Brake fluid level**- top up / replace C,A,R CL,L C,A CL,L CL,L Use recommended brake fluid (DOT3/DOT4)
16 Brake cam & pedal pivot pin L L L
17 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
18 Steering stem bearing C,L,R C,L,R C,L,R C,L,R
19 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
20 Rear sprocket fasteners C,T C,T C,T C,T C,T C,T C,T C,T
21 Main stand & side stand pin** CL,L C,R C,R C,R
22 Silencer drain hole cleaning CL CL CL CL CL CL CL CL Clean at every 5000Kms
23 Engine air breather tube C,R C C C R C C Replace at every 20000Kms
Drive chain slackness adjustment &

24 C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L A- slackness whenever reqd.
lubrication
25 Wiring Harness & Battery Connections C,T C,T C,T C,T C,T C,T C,T C,T
Routine, tie bands & clamps tightness
26 General Lubrication L L L L L L L L
EVAP hoses- Check functionality

27 C,R
leakage or any other damage **
28 EVAP drain tube cleaning** C,L C,L C,L C,L C,L C,L C,L C,L
29 Starter clutch (Dry type) L L L L L L L Use recommended molykote grease
30 Force distribution unit drain hole C,L C,L C,L C,L C,L C,L C,L C,L
* More frequent cleaning may be required when driving in dusty condition. A - Adjust C- Check CL- Clean L- Lubricate T- Tighten R- Replace
** As applicable to model
11
Notes

12
Key Learning Points
Understanding of complete EMS sytem
Function / construction / working

of system
CHAPTER 2
Fuel System

13
2
Wiring Harness Routing
Horn, HT coils, Lambda Sensor,

Roll over sensor,
front-rear harness connection
Ignition Switch, Control Switch LH Battery, regulator,

Front RH blinker, Front LH blinker ECU, Purge valve
Control Switch RH, Front brake switch
Clutch Switch, Speedometer

14
125 Fi
Speedometer
Head lamp
Control switch RH Control switch LH

Kill switch Clutch switch
Front RH blinker Front LH blinker
Ignition switch Vehicle speed sensor
Front-rear Roll over sensor

harness
connection ECU
HT coil-1
Lambda Sensor
Starter relay
LH Horn
Engine temp. sensor

15
2
Battery Positive
Battery Negative
Fuse Box
Side stand switch
Starter Relay
Purge valve
EVAP
TPS Front-rear
T Map harness connection
Regulator
Purge valve HT coil 2
IACV RH Horn
Rear Brake
switch Starter Motor
Chassis Engine earth
earth

16
125 Fi
Purge valve EVAP
Regulator Fuel injector

T Map
TPS
Purge valve IACV

Rear brake switch
Front-rear Assembly
harness reference
connection point
ECU Magneto
Front-rear
harness
connection
ECU Earth
Regulator earth
Bajaj Pulsar 125 Fi Training Notes 17

Tail lamp
Number plate lamp
Rear blinker RH
Rea blinker LH
CAN interface
Chassis Earth Flasher
CAN Termination
unit
Termination Compensation Main relay

unit Resistor Unit Fuel pump relay
Intermediate
start relay Head lamp
control relay
18
125 Fi
Fuel System & EMS
It Supplies air to the Throttle body via It measures the temperature of the
a nozzle as per the duty cycle decided engine. The readings from this sensor are
by RPM , Temp of the engine . Thermal
then fed back to the ECU, which uses
In other words, it helps in providing Sensor
Purge Valve this data to adjust the fuel injection
additional air during cold starting
(Just like stepper motor) and also and ignition timing.
stabilizes the idle rpm by adjusting
the air supply
For RH spark Plug
For LH spark Plug

19
2 Fuel System & EMS

20
125 Fi
Fuel System & EMS

21
2 Fuel System & EMS
Thermal Sensor
Purge Valve
Indicator
Thermal Sensor

22
125 Fi
Fuel System & EMS

23
2 Fuel System & EMS
Working
Upon acceleration the throttle valve position changes. The wiper type
blades moves over the coil winding as it is pivoted directly on the
throttle valve shaft.
Throttle position at zero (closed} position When the throttle valve is

closed, the blade is at the grounded end of the coil. A small voltage
signal is send to ECU at this position which senses that the throttle
position is at zero.
Further movement of throttle position As the throttle valve moves

towards the open position, the wiper type blade swings towards 5 volt
end of the coil. This sends an increasing voltage signal to the ECU.
Thus the continuously charging voltage regularly communicates the
ECU the exact position of the throttle valve.

24
125 Fi
Fuel System & EMS

25
2 Fuel System & EMS
Working
The moving weights are suspended freely. When the vehicle
leans down on either of the LH I RH side the position of these
weights changes. The change of position of the weights is
sensed by the sensor. If the inclination angle exceeds beyond
60° to the vertical the sensor will give signal to ECU to cut off
the ignition system.
This is a useful safety feature because inclination angle

exceeding 60° indicates that the rider has dropped the bike
or is involved in an accident. Thus safety of the bike and rider
is ensured.

26
125 Fi
Fuel System & EMS
Working
As the rotor rotates the notched square blocks on the rotor periphery causes
voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts
the number of pulses per second and understands at what RPM the engine is
operating and accordingly precise fuel metering and ignition spark advance is
controlled.
There are 23 square notches I square blocks on the rotor outer periphery and are
placed equidistance.
At a particular location there is wide gap seen between 2 square notches I square
blocks. This can also be determined as square notch missing.
This missing square notch area represents the BTDC position. At this BTDC
position voltage pulse is sensed by the crank angle sensor and is communicated
to ECU.
ECU uses this information to control ignition spark advance.

27
2 Fuel System & EMS
When certain troubles are develop in the electronic control system, the
ECU stores the same in its memory & turns ON Malfunction Indicator
Light ( ) on the speedometer.
This alerts the driver that there is some problem and repair / service in
needed.
If a single sensor or its harness part fails the ECU may substitute a value
for failed sensor. This allows the engine to appear to run normal. A fault
that turns on the malfunction indicator light may also put the engine into
its limp-in mode. This means that limited operation strategy (LOS) chip in
the ECU has taken over. It provides basic instructions to the
microprocessor if a part of the electronic system fails. The engine runs
but with fixed ignition timing and air fuel ratio. The injector pulse width
does not change. This allows the vehicle to be driven but with greatly
reduced performance. The benefit of this is the vehicle can be limp-in for
service instead of being towed or transported into a cargo.
The technician can retrieve the stored trouble code from ECU memory
using the diagnostic tool. To use the code the technician can refer the
Diagnostic Chart or the Flash Code. This chart explains where lies the
problem and its probable cause.

28
125 Fi
Engine
THERMAL
PERGE
VALVE
Glows

2
Advantages of Fuel Injection

• Increased power output per unit of displacement.
• Higher torque at low engine rpm.
• Improved cold start, warm up and sudden
acceleration (No chance of wetting intake manifold).
• Lower fuel consumption.
• Overall superb drive-ability.
• Lower maintenance cost.
• Communicates malfunctioning of fuel injection
system, if any.
• Low emission level.
Limitations of Carburettor :
• Restricted air flow due to venture design causes power
loss (volumetric efficiency is limited).
• As intake manifold contains combustible mixture,
danger of back fire from the cylinder into the manifold
is always there.
• At high altitude or in warm weather, possibility of
vapour lock.
• After burning noise in silencer on sudden deceleration.
• Does not support sudden acceleration.
• Difficult cold starting and requires choke for starting.
• In cold conditions, fuel wets the wall of the induction
manifold causing running difficulties.
• Difficult cold starting and requires choke for starting.
• Inconsistence in fuel efficiency. Maintenance cost is
reasonably more. High emission level.
30
125 Fi
Fuel System & EMS

31
2 Fuel System & EMS
Mail Relay
Purge Valve

32
125 Fi
Fuel System & EMS

33
2 Fuel System & EMS
Throttle Body & its Care.
The Sensors are located on Vehicle & Engine. But, most of the sensors are
located on the throttle body. The throttle body has a butterfly valve & is
located between the air filter and the intake manifold. It regulates how much
air can go to the engine, based on riders input through the opening &
closing of Throttle.
Throttle body is to be serviced only at Bajaj Authorized Dealership by

cleaning and wiping of the bore and throttle blade. This is important to keep
the vehicle running smoothly & efficiently.
Don'ts:
• Do not adjust the Throttle Stop screw located on the throttle body.
This has been factory adjusted.
• Do not pull out the sensor couplers of the throttle body forcefully. It
has self-locking lugs which might break
• Do not dismantle/Open the throttle body.
• Do not clean the carbon soot deposited at the interface of the blade &
bore.
• Do not tamper with the throttle body in any manner.
5 Purge valve

34
125 Fi
Fuel System & EMS

35
2 Fuel System & EMS

36
125 Fi
Fuel System & EMS
Tune up for Optimum Mileage
Spark Plug :-
BOSCH / Champion
Spark plug gap : 0.7 ~ 0.8 mm
0.7 ~ 0.8 mm
Replace at every : 30,000 Kms
Air Filter Element :-

Clean at Every : 10,000 Kms
Replace at every : 15,000 Kms
Compression Pressure :-
Standard : 12 to 13 Kg/cm2
Service Limit : 9.5 Kg / cm2
Tappet Clearance :-
Intake Valve : 0.05 mm
Exhaust Valve : 0.08 mm
Other Mandatory Checks

a. Ensure no fuel leakage through fuel cock, fuel lines.
b. Ensure free rotation of both wheels.
c. Ensure correct tyre pressure -
Front wheel : 25 PSI
Rear wheel : 32 PSI
d. Set control cable free play:
• Clutch lever 2~3 mm.
• Rear brake pedal 15 ~ 20 mm.
e. Chain slackness : 25~30 mm.
f. Check & confirm proper functioning of spark plug.
g. Use of recommended grade of bajaj genuine oil and ensure oil level between MIN & MAX level.

37
2 Fuel System & EMS
Notes

38
Key Learning Points
Appropriate Torque Application for Various

Engine Components
Engine Dismantling procedure
Understanding of Standard Limits and

Service Limits for all Engine Components
CHAPTER 3

Tightening Torques
Service Limits
Special Tools
Engine Dismantling

3 Engine & Transmission
Tightening Torques
Spark Plug (2 Numbers) Oil Strainer Cap (18 mm A/F) Cap Oil Filter Cover Bolt
1.3 ~ 1.5 kgm 0.7 ~ 0.8 Kgm 1.0 ~ 1.1 Kgm

Chain Tensioner Mounting Bolts Cylinder Head Cover Bolts Output Sprocket Bolts
1.0 ~ 1.1 Kgm 1.0 ~ 1.1 Kgm 0.8 Kgm

Clutch Cover Bolts Oil Pump Mounting Screws Crankcase Joining Bolts
1.0 ~ 1.1 Kgm 0.8 ~ 0.9 Kgm 1.0 ~ 1.1 Kgm

Magneto Cover Bolts Nut Securing Primary Gear Camshaft Sprocket Allen Bolt
1.0 ~ 1.1 Kgm 6.0~6.5 Kgm 1.6 ~ 1.8 kgm

40
125 Fi
Tightening Torques
Nut Securing Clutch Assembly Magneto Rotor Mounting Nut Starter Motor Mounting Nut
6.0 ~ 6.5 kgm 6.0 ~ 6.5 Kgm 0.7 ~ 0.8 Kgm

Inhibitor Nut Drum / Cam Allen Bolt Clutch Spring Bolts
1.0 ~ 1.1 Kgm 1.0 ~ 1.1 Kgm 1.0 ~ 1.1 Kgm

Manifold Mounting Bolts Cylinder Head Big Bolts
1.0 ~ 1.1 Kgm 2.2 ~ 2.5 Kgm

Service Limits
Compression Pressure Valve Clearance Clutch Spring Free Length
Intake Exhaust
2
Std. Limit 12.0 ~ 13.0 kg/cm Std. Limit 0.05 mm 0.08 mm Std. Limit 25.5 mm
Ser. Limit 9.5 kg/cm 2
Ser. Limit — — Ser. Limit 24.9 mm
Rocker Arm Shaft Diameter Cam Sprocket Diameter Cam Height
Intake Exhaust
Std. Limit 7.994 mm Std. Limit 30.49 mm 30.44 mm
Std. Limit 59.91~60.11 mm
Ser. Limit – Ser. Limit 30.29 mm 30.24 mm
Cam Lobe Width Valve Spring Free Length Valve Stem Diameter
Intake Exhaust
Std. Limit 8.9 ~ 9.1 mm Std. Limit 37.92 mm Std. Limit 4.475~4.490mm 4.455~4.470mm
Ser. Limit -- Ser. Limit - Ser. Limit 4.465 mm 4.445 mm
Valve Stem Bend Valve Stem to Guide Clearance Cylinder Head Warp
Intake Exhaust
Std. Limit 0.01 mm Std. Limit 0.01~0.037 0.03~0.057 Std. Limit 0.03 mm
Ser. Limit 0.015 mm Ser. Limit 0.047 mm 0.067 mm Ser. Limit 0.05 mm

42
125 Fi
Service Limits ALL DIMENSIONS ARE IN MM
Camshaft Chain Length Cylinder Inside Diameter Piston Diameter

20 Link Length
10mm
20mm
40mm
1st 2nd 21st

MEASURE THIS LENGTH
Std. Limit 127 ~ 127.5 mm Group A 51.965 ~ 0.007 mm

Std. Limit 52 ~ 52.010 mm
Ser. Limit 127.254 mm Group B -
Piston Cylinder Clearance Piston Ring Groove Clearance (mm) Steel Plate Warp
Top Second Oil Ring

0.020 ~ 0.02 ~ 0.04 ~
Std. Limit 0.028 ~ 0.052 mm Std.Limit 0.050 0.055 0.110 Std. Limit 0.1 mm
Ser. Limit 0.1 mm Ser.Limit 0.15 0.15 0.16 Ser. Limit 0.15 mm
Piston Ring End Gap (mm) Friction Plate Warp Gear Shift Fork Guide Pin Dia
Top Second Oil Ring

Std. Limit 0.1~0.25 0.15~0.3 0.2~0.7 Std. Limit 0.1 mm Std. Limit 4.45 ~ 4.49 mm
Ser. Limit 0.5 0.7 1 Ser. Limit 0.15 mm Ser. Limit 4.4 mm
Shaft Fork Shift O.D Rocker Arm I.D Steel Plate Thickness
Std. Limit 9.972 ~ 9.987 mm Std. Limit 10 ~ 10.022 mm Std. Limit 1.6~1.7 mm
Ser. Limit 9.96 mm Ser. Limit 10.03 mm Ser. Limit 1.5 mm

Special Tools
Cam Sprocket Holder
Part No : 37 1043 07
Application : For holding sprocket during

removal / refitting of Cam sprocket Allen
bolt.
Magneto Rotor Holder
Part No : 37 1043 06
Application : To hold rotor while loosening /

tightening its nut.
Magneto Rotor Puller
Part No : 37 0043 69
Application : For pulling out magneto rotor

from crank shaft
Primary Gear Holder

Part No : F4 1AJA 11
Application : To hold primary and secondary
gear loosening /tightening the
primary gear nut & special
nut securing clutch.
Tappet Adjuster
Part No : 37 1043 55
Application : To loosen / tighten tappet
adjuster

44
125 Fi
Special Tools
Socket clutch nut
Part No : 37 1043 16
Application : To loosen / tighten special nut

securing clutch.
Clutch Dismantling Tool
Part No : 37 1043 58
Application : To dismantle & assembled

clutch.
Spark Plug Spanner
Part No : 37 1043 56
Application : For removing and refitting

spark plug R.H. and L.H. side.
Rocker Shaft Remover
Part No : 37 10CS 22
Application : To remove Rocker Shaft from

cylinder head.
Bearing Extractor
Part No : 37 1030 48
Application : To Pull out main ball

bearing from crankshaft.

Special Tools
Adaptor & Valve Spring Compressor
Adapter Part No : 37 1031 08

Valve Spring Compressor : 37 1031 07
Application : To assemble / dismantle

intake, exhaust valve.
Drift Piston Pin
Part No : 37 1010 06
Application : To remove & refit piston pin.
Output Sprocket Holder
Part No : 37 1030 53
Application : To hold the output sprocket

while removing sprocket allen bolts.
Driver for Fitting Bushing Gear Shift Drum
Part No E6101100
Application : To assemble “Bushing with

PTFE Lining” at parent hole of crankcase RH
for “Gear Shift Drum” mounting.
Bearing Driver Set
Part No : 37 1030 61
Application : Common bearing driver set for

fitting & removing bearings from crankcase.

46
125 Fi
Engine Dismantling
Top Side Dismantling
Remove
• Cylinder head cover bolts
• Take out cylinder head cover &
gasket.
Note - Always loosen cylinder Head
mounting bolts in criss - cross
pattern
Remove
• TDC finder cap
• Check the cam sprocket T mark.
Note - Align the rotor mark w.r.t
Crankcase marking.
Remove
• Cam chain tensioner bolt
• Rotate chain tensioner screw in
clockwise direction to take plunger
backwards and lock it.
Remove
• Chain tensioner
• Take out chain tensioner along with
gasket

Engine Dismantling
Remove
• Cam sprocket bolt
Cam Sprocket Holder

Special Tool Part no. : 37 1030 54
Remove
• Cam sprocket
• Cam Sprocket Collar
Remove
• RH & LH side spark plug by using
spark plug removing tool.
Spark plug removal tool
Special Tool Part no. 37 1040 51
Remove
• Spark plug sleeve using
Note : Do not pull spark plug sleeve

by plier, to avoid any damage on it.

48
125 Fi
Engine Dismantling
Remove
• Cylinder Head Bolt.
Spark plug sleeve removing tool

Remove
• Cam sprocket Circlip
• Circlip of rocker arm shaft (Inlet &
Exhaust)
Remove
• Rocker arm shaft (Intake &
Exhaust) by using rocker shaft
removing tool
• Take out rocker arm & rocker arm
shaft.
Rocker Shaft Remover Tool
Special Tool Part no. : 37 10DH 35
Remove
• Intake & Exhaust valves along with-
• Retainer
• Valve spring
• Oil seal
• Valve spring seat using valve
spring compressor.

Engine Dismantling
Take Out
• Camshaft Assembly.
Adaptor & Valve Spring Compressor

Compressor - 37 1031 07
Adaptor - 37 1031 08
Remove
• Dowels on cylinder block.
• Cylinder head gasket.
Remove
• Chain guide
• Cylinder block.
Remove
• Dowels
• Cylinder block gasket.

50
125 Fi
Engine Dismantling
Remove
• Piston pin locking clip
• Piston pin
• Take out piston.
Note - Cover the crankcase bore with
clean cloth before removing piston pin
locking clip.
Clutch Side Dismantling

Remove
• Engine oil filter cover
• T spanner & take out engine oil
filter
Remove
• Clutch cover mounting
• Spanner & take clutch release shaft

& Clutch cable bracket.
Remove
• Clutch thrust bearing
• Primary gear nut with by using
clutch nut removing special tool.
• Clutch nut by holding the primary
gear
Note - Lock the special tool between
primary gear teeth & clutch housing
gear from top.
Primary Gear holder - F41AJA11
Clutch nut Removing tool - 37104316

Engine Dismantling
Take Out
• Clutch nut
• Belleville washer
• Plain washer
Remove
• Clutch stack complete
• Plain washer.
Remove
• Kick return spring
• Take out kick shaft assembly.
Remove
• lever comp gear shift.

52
125 Fi
Engine Dismantling
• Using clutch dismantling tool
Remove
• 4 bolts
• 4 springs
• Clutch holder
• Clutch hub
• Friction plates
• Steel / pressure plates (4 Nos)
• Wheel clutch
Clutch Dismantling tool
Special Tool Part no. : F4 1AJA 58
Remove
• Inhibitor Assembly
• Guide gear shift
• Take out guide gear shift
Remove
• Oil pump driven gear
• Oil pump screws

• Take out the oil pump
Remove
• Primary gear nut
• Take out
• Belleville washer
• Plain washer
• Primary gear

Engine Dismantling
Remove
• Timing chain from sprocket
• Starter motor bolt
• Take out starter motor
Magneto Side Dismantling

Remove
• Magneto cover bolts
Remove
• Stator plate
• Pick up coil screws
Remove
• Dowels
• Take out magneto cover gasket.

54
125 Fi
Engine Dismantling
Remove
• Gear starter clutch locking plate
screw
• Rotor bolt
• Plain washer
Remove
• Rotor
• Gear Starter Clutch
Remove
• Magneto rotor key.
• Starter counter gear assembly.
Magneto rotor puller
Remove
• LH crankcase bolts
• RH crankcase bolts

Engine Dismantling
Remove
• RH crankcase
Remove
• Crankshaft
• Fork shaft
• Input & output fork shaft
Remove
• Gear change drum
• Input fork & output forks
Remove
• Input & output gear shaft assembly
• washer plain of input gear shaft.

56
125 Fi
Engine Dismantling
Remove
• Crankshaft damper from crankcase
LH.
Remove
• Input shaft bearing locking plate
• Kick shaft locking plate bolts
Remove
• Input shaft bearing using bearing driver set.
Remove
• Bolt gear shift change
• Gear change drum bush using
bearing driver set.

Engine Dismantling
Remove
• Output shaft oil seal
• Gear change lever oil seal
Remove
• Output shaft bearing using bearing
driver set
• Neutral switch

58
125 Fi
Notes

Key Learning Points
Appropriate Torque Application for Various

Frame Components
Understanding of Standard Operating

Procedure
Understanding of Standard Limits and

Service Limits for all Frame Components
CHAPTER 4
Frame & Suspension

Tightening Torques
Service Limits
Special Tools
Standard Operating Procedure

4 Frame & Suspension
Tightening Torques
Front Axle Nut Rear Axle Nut RSA Lower Bolt
4.5 ~ 5.5 kgm 8.0 ~ 10.0 Kgm 2.8 ~ 3.2 Kgm

Rear Sleeve Nut Rear Sprocket Mounting Nut Handle Bar Holder Bolts
3.0 ~ 4.0 Kgm 3.2 ~ 3.8 Kgm 2.0 ~ 2.2 Kgm

Fork Center Nut Steering Stem Nut Slotted RSA Mounting Nut (Upper)
5.0 Kgm 0.5 Kgm 3.0 ~ 3.2 Kgm

Swing Arm Shaft Disc Mounting Bolt (Front)
4.5 ~ 5.5 Kgm 2.7 ~ 3.3 Kgm

61
125 Fi
Frame & Suspension
Service Limits
Brake Pad Thickness-Front Front Disc Run Out Axle Wheel Run Out
Std. Limit 5 mm Std. Limit — Std. Limit TIR 0.5 mm or less

Ser. Limit 1 mm Ser. Limit 0.15 mm Ser. Limit TIR 0.2 mm
Radial Wheel Run Out Tyre Tread Depth Rear Sprocket Warp
Front Rear
Std. Limit TIR 0.5 mm or less Std. Limit 5 mm 1 mm Std. Limit TIR 0.4 mm or Less
Ser. Limit TIR 0.2 mm Ser. Limit 6.8 mm 1.5 mm Ser. Limit TIR 0.5 mm
Drive Chain Slack Front Fork Oil Grade & Capacity Drive chain Length
Grade : 20 Link Length
Fork Oil Level
SAE 10W20
Bajaj Genuine
Fork Oil
Quantity :
O/H: 140 + 2.5ml
Drain & Refill:
(Per Fork Leg 1st 2nd 20th
Assly)
MEASURE THIS LENGTH
Std. Limit 25 ~ 30 mm Std. Limit N/A Std. Limit 254.0~254.6 (20 links)
Ser. Limit 40 mm Ser. Limit N/A Ser. Limit 260 (20 links)
Axle Run Out
100 mm
Std. Limit TIR 0.05 mm

Ser. Limit TIR 0.2 mm

Special Tools
Fork Oil Seal Driver
Part No : 37 1830 07
Application :
To fit fork oil seal in its seat
provided at outer pipe ID.
Stem Bearing Driver

Part No : 37 1830 05
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.
Pigtail 4 Pole to 2 Pole converter :
Part No. : 37 2040 35
Application : For connecting fuel

pump delivery
checking unit to fuel
pump.

63
125 Fi
Frame & Suspension
Special Tools
Bearing Race Extractor
Part No. : 37 00DJ 01
Application :
To Pull out steering race from
Fork Under Holder Bracket.
Steering Cone Remover

Part No. : 37 1805 06
Application :
To remove steering cones from
frame.
Swing arm NRB extractor &

fitment tool
Part No. : 74 9309 93
Application :
For extracting & fitment of NRB
Tube Spanner
Part No. : 37 1043 57
Application :
For oil pressure sensor removal
& fitment on vehicle.
Fork Special Bolt Tightening Tool
Part No. : 37 0043 40
Application : For tightening & loosening

fork bolt

Special Tools
Combi Brake Adjustment Tool
Part No. : 37 0043 54
Application : For Adjusting Brake free

play.

65
125 Fi
Frame & Suspension
CBS - Combi Brake System-SOP

1. Introduction
1.1. Purpose of SOP: The purpose of this SOP is to describe the procedure for brake free play setting for Motorcycle
having front disc and rear drum brake configuration. This SOP would assist technician to set Motorcycle brake free play as
per CBS system design to ensure satisfactory performance of vehicle brake system.
1.2. Definitions and Abbreviations:

CBS: Combined Braking System
Front brake free play: Lever travel measured at spherical ball end just before front brake actuation
Rear brake free play: Brake pedal travel measured at foot resting pad just before rear brake actuation
CBS front brake free play: Brake pedal travel measured at foot resting pad just before front brake actuation
CBS front brake delay: Brake pedal travel measured at foot resting pad after rear brake actuation to front
brake actuation (CBS front brake free play - Rear brake free play)
2. Description
1.1. Front disc brake free play setting: Check front brake lever operation for smooth working. Ensure front wheel
for free rotation / freeness (Front brake lever travel should be in the range of 10-20 mm. Front brake play may not be
necessary to check as brake bleeding already been done and system is self compensatory)
Note: Ensure brake bleeding has been done if wheel rotation is not free. Brake lever should return completely in non
operating state after brake bleeding done.
1.2. CBS free play setting:

1. Check that the CBS cable is assembled and operating satisfactory and front wheel rotation is free (Ensure front
brake bleeding done.
2. Ensure CBS front brake cable adjuster nut 'B' is in completely loosened state.
3. Set rear brake free play 15-20 mm that is measured at brake pedal foot resting pad by tightening nut 'A'. Ensure
rear wheel freeness after setting.
4. Put CBS brake play setting tool between sub lever and master cylinder body slot as shown in Fig 4. Ensure setting
tool fits tightly between sub lever and master cylinder body slot. If tool moves freely in the slot, adjust tool length
by rotating knob provided on tool till it tightly fits between two slots.
5.Tighten CBS front brake cable adjuster nut 'B' by hand till it is not allowed to rotate.
6. Remove adjustment tool and press the rear brake pedal 2-3 times. Check front wheel freeness. If wheel is not free,
loosen adjustment nut in step of half thread till wheel gets free. CBS front brake delay should be in the range
of 5- 10 mm measured at brake pedal foot resting pad.
Fig 1: CBS disc drum Layout
Front brake Master

Cylinder assembly
Front brake
CBS cable
CBS brake pedal
assembly
Rear Brake Rod

Fig 2: Front brake MC assembly
Main lever
Sub lever
Fig 3: CBS brake pedal assembly
Free play measured

at foot resting pad
CBS front
brake cable
Adjuster Nut (A)
Adjuster Nut (B)

67
125 Fi
Frame & Suspension
Fig 4: CBS front brake adjustment tool
Knob on setting
tool for adjustment
Slot on MC body and Setting tool

sub lever for setting tool
2.3. Dos/Don'ts/check points for CBS free play setting

1. Do not adjust/set brake adjuster nut A/B simultaneously.
2. Do not set/touch rear brake adjustment nut (Adjuster nut 'A') after CBS front brake setting.
3. Setting procedure to be followed from Sr No 2 to 6 if any part of CBS system replaced or tampered or customer
complain of CBS brake ineffective/higher free play.
4. Ensure front and rear wheel freeness after free play setting.
5. Do not overtighten adjustment nut 'B' by any kind of tool and sufficient pretension available in the nut to avoid nut
loosening.
6. Free play Setting to be check/done at every service interval.
2.4. Free play setting guideline incase of rear wheel puncture:

• Brake rod adjuster nut 'A' needs to be loosened in case of rear wheel puncture to remove wheel. After puncture repair
done, adjust brake rod adjuster nut 'A' to get the brake pedal free play feel of customer. After adjustment ensure point
no 5 in 2.3 (Dos/Don'ts/check points for CBS free play setting).
• As this will be done at road side garage where special tools / measuring instrument / free play setting guideline may
not be known. As free play may not be in the specified range the optimum braking efficiency can not be achieved.
• Hence, it is recommended to do setting as per SOP / guideline after any front / rear wheel repairs (puncture / brake
shoe replacement / CBS cable replacement, any brake free play adjustment / drive chain repair, replacement,
adjustment).
2.5. CBS free play setting values
Individual front brake CBS front brake delay

Rear brake free play (mm)
free play (mm) (mm)
10-20 15-20 5-10


Caliper Piston Seals & Dust Seals Replacement
• Clean master cylinder & caliper thoroughly by low pressure water spray
before opening master cylinder top cover & caliper bleeder screw.
• Drain the brake fluid from caliper assembly by removing rubber cap of air
bleeder screw & using transparent PVC tube which will avoid spillage of
brake fluid on caliper body / disc pads & also powder coating peel off /
inefficient braking.
• Remove front brake hose caliper end banjo bolt with 14 mm spanner.
Note :
Keep the plastic jar below caliper assembly.

69
125 Fi
Frame & Suspension
• Remove caliper pin holder bracket as shown in photograph.
• Clean the anchor pins thoroughly.
• Remove pad spring.


• Remove piston by applying low pressure compressed air through banjo bolt
hole. Due to compressed air pressure, the piston will be pushed out of
caliper body.
Caution :
Do not apply high compressed air of pressure > 2 bars. This could cause
the pistons to fly out from caliper body, causing damage to it & any one in
the vicinity.
• Replace caliper assembly major /

Caliper Minor Kit minor kit.
• Smear silicon grease on piston
Caliper Major Kit OD & rubber parts.
• Fit oil seals & dust seals.

• Fit pistons in caliper body.

71
125 Fi
Frame & Suspension
• Fit brake pad.

• Clean the brake pads by smooth
emery paper.
• Fit caliper assembly on front fork mounting & tighten mounting bolts with
12 mm spanner.
• Fit brake hose caliper end banjo bolt with 14 mm spanner.

• Fill the brake fluid above MIN level.

73
125 Fi
Frame & Suspension
• Remove the air by bleeding process as follows
- Remove rubber cap from caliper’s bleeder screw.
- Fit a proper tube which fits snugly tight on the bleeder screw nipple.
- Insert ring spanner through the pipe fitted on the bleeder screw nipple.
- Connect the tube siphon pump’s pipe and loosen the bleeder screw by the
ring spanner.
- Press the bellow of the Siphon pump in its valve open position. Then close
the valve of the pump and release the bellow. Simultaneously press the
brake lever to take out air trapped in the system. Carry out the same
procedure until the entire air trapped in the system gets removed.
- During this process continuously monitor and maintain the brake fluid level
in the master cylinder reservoir slightly above the minimum mark.
MIN
Master Cylinder Piston Kit Replacement
• Clean master cylinder & caliper thoroughly by keeping nozzle in spray mode
before opening master cylinder top cover & caliper bleeder screw.
• Drain the brake fluid from caliper assembly by loosening air bleeder screw
& using transparent PVC tube which will avoid spillage of brake fluid on
caliper body / disc pads & also powder coating peel off / inefficient braking.

92 74

• Remove front brake switch terminals.
• Remove front brake hose master cylinder end banjo bolt with 14 mm
spanner.

75
125 Fi
Frame & Suspension

• Remove master cylinder reservoir cover mounting screws with phillips head
screw driver & take out -
- Master cylinder reservoir cover
- PVC cap &
- Rubber diaphragm
• Remove actuating shaft & grommet.
• Remove circlip & take out piston

assembly.
• Clean master cylinder using brake

fluid & apply low compressed air.

94 76
• Smear silicon grease on new piston seals of master cylinder piston kit.
• Insert the piston assembly in master cylinder from front brake lever side.
• Fit the circlip
• Fit actuating shaft & grommet
• Fit master cylinder on handle bar & tighten 8 mm 2 bolts with T spanner.
• Fit front brake lever & connect front brake switch terminals.
• Fit front brake hose & tighten banjo bolt.
• Fill brake fluid into master cylinder reservoir just above MIN level & carry out air
bleeding.
• Fit diaphragm & master cylinder reservoir cap.
• Drive the vehicle and confirm brake effectiveness.

77
125 Fi
Frame & Suspension
Front Brake Hose Replacement
• Clean brake system by keeping nozzle in spray mode.

• Drain the brake fluid from caliper assembly by opening air bleeding bolt.
• Cut the cable tie tied to front brake at master cylinder end & take put front
brake hose.
• Refit the new brake hose pipe & replace copper washers fitted at both ends
with new one.
• Route the front brake hose as shown in front brake hose routing given in
control cable routing section & tighten master cylinder & caliper end banjo
bolts.
• Remove master cylinder reservoir cover, PVC cap & take out rubber
diaphragm.
• Fill the brake fluid in master cylinder reservoir & carry out bleeding
operation.
• Fit rubber diaphragm, PVC cap & master cylinder reservoir cover.

Front Brake Fluid Replacement
• Clean brake system by keeping nozzle in spray mode.

• Drain the brake fluid from caliper assembly by opening air bleeding bolt.
• Tighten the air bleeder bolt on caliper assembly.
• Remove master cylinder reservoir cover mounting screws with phillips head
screw driver & take out -
- Master cylinder reservoir cover
- PVC cap &
- Rubber diaphragm
• Fill the DOT 3 / DOT 4 brake fluid in master cylinder.

• Conduct the air bleeding operation & maintain the brake fluid level above
MIN mark.
• Refit the rubber diaphragm, PVC cap & master cylinder reservoir cap &
tighten the mounting screws.
• Drive the vehicle & check the brake effectiveness.
• Use DOT-3 / DOT-4 brake fluid from a sealed container.
MIN • Ensure no leakage of brake fluid through brake hose / benjo bolts / caliper
assembly.
• Carry out air bleeding if required.

79
125 Fi
Frame & Suspension
Shock Absorber Adjustment

• RSA spring tension can be adjusted with the help of special tool as shown
in photograph to suit individual requirement as per load & road conition.
• Turn the adjuster cam on shock absorber to same required position. Setting
the adjuster cam to higher notch position increases the spring stiffness &
vice as versa.
• Shock absorber adjusted either too soft or too stiff could adversely affect
riding comfort & vehicle stability.

Notes

81
Key Learning Points
Understand the initial battery charging

procedure.
Electrical Checking Procedure.
Understand the standard operating procedure

for electrical components removal & re-fitment
Various wiring circuits.
CHAPTER 5
Electrical
Battery
Do's & Don'ts Generic
Electrical Checking Procedure
Relay Checking Procedure.

82
5 Electrical
Battery
Battery Technical Specification
• Make Exide
• Terminal Voltage 12.8 Volt
• Type VRLA Battery
• Capacity 8 Ah
• Charging Current Specification 4.0 Amp
• Charging Voltage Specification 14.5 + 0.1 V
• Battery Charger Metafab / Apple Energy Make
VRLA Battery Initial Filling

Step 1: Get the battery ready
Place the battery on a flat leveled and preferably on a
insulated surface.
Remove the filler port seal of the battery.
Filler port seal
Step 2: Get the electrolyte ready

Remove electrolyte container from the packing.
Remove the sealing cap plug strip.
Keep the sealing cap plug strip aside as this is to be
used as battery sealing plug strip later.
Note: Do not puncture the seals manually.
Plug cap strip
Seal

83
125 Fi
Electrical
Battery
Step 3: Fill the battery
Hold the electrolyte container upside down.
Place the container upright on battery. Match the 6
seals with the respective filler ports.
Note: Ensure the container is upright and not tilled. If
tilled the electrolyte might fail to flow.
Now force the container down until seals get pierced,
and electrolyte flows into the battery.
Step 4: Check the electrolyte flow

Make sure that air bubbles are visible in the electrolyte and which is seen in all the 6
tubes of the container.
Leave the container on the battery as it is for 30 minutes.
Step 5: Take away the bottles

Be sure that the entire electrolyte has flown down inside the battery.
Tap the bottom of the container and gently remove the empty container.
Step 6: Attach the sealing cap

Fit the sealing cap plug strip tightly on the filler ports of the battery.
Ensure by pressing firmly that the cap has become flush with the top surface of battery.
Step 7: Charge the battery

Charge the battery on BAL recommended VRLA battery charger as per std. SOP.
Never use conducting materials like

screw drivers which can produce the
Caution spark near battery terminals.
Do not add any additional electrolyte.

5 Electrical
Battery
Dos & Don’ts
 Dos  Don’ts
 • Apply petroleum jelly • Do not apply grease to
to battery terminals.
 poles / terminals.
• Use proper tools. (10  • Do not hammer battery

 mm T spanner or terminals.
phillips screw driver).

• Always charge the • Do not use any other
 battery with the help  battery charger for
of BAL recommended charging VRLA battery.
VRLA battery charger.
• Check open circuit • Do not short circuits

 voltage by multimeter. the poles to check
battery condition.

• Always use Midtronics • Do not fit extra
 battery tester for
 electrical accessories.
checking condition of This will result in
VRLA battery. wiring getting short &
battery would get
discharged. This will
shorten life of battery.

85
125 Fi
Electrical Electrical
Dos & Don'ts - Generic

Horn
 Dos  Don’ts
Ensure that horn is firmly Do not apply pressurised
fitted on fairing structure water jet directly on horn
central. resonator.
Ensure that horn is free from Never adjust nut on horn cap
dust and mud accumulation. side & bracket end (back side)
as it will result in horn
malfunctioning & failure.
Ensure that horn wires are

 Do not remove silicon sealant
intact.
from adjustment screw as it
will result in water entry in
horn.

Ensure that horn switch button
is operating freely.
Ensure that battery is fully Do not hit by mallet / screw

charged. driver on horn resonator.

5 Electrical

• Adjust horn by phillips screw
driver
- without removing silicon
sealant from adjustment
screw.
- by rotating the screw in
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
 Dos
• Always install recommended capacity of battery on the bike.
• Always replace spark plug by correct heat range plug.
• Check and adjust spark plug gap periodically. Adjust it to 0.7~0.9 mm b y wire
gauge.
• Replace spark plug at every 40,000 kms.
• Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3 ~
1.5 Kgm.
• Ensure H.T. cable secondary connection is firmly fitted in spark plug cap and H.T.
coil.
• Ensure that magneto coupler is firmly fitted.
• Always use a right size socket during removal and re-installation of spark plug.
• During periodic service make use of spark plug cleaning machine to clean spark
plug electrodes & check proper functioning of all spark plugs.
 Don’ts
• Do not replace spark plug by non recommended one (different heat range).
• Never short circuit H.T. coil primary wire to ground. It could lead to ECU failure.
• Do not adjust spark plug gap with any instruments like screw driver, pliers etc.

87
125 Fi

Lights
 Dos
• Ensure that there is no dust and water entry in bulb housing.
• Ensure that all fixing screw of bulb housing are intact.
• Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is intact.
• Check DC Voltage Regulator’s output voltage periodically. Ensure that voltage is
within specified limits.
• Check that couplers and wires of bulbs are in good condition.
 Don’ts
• Do not install a lower / higher capacity battery than what is recommended.
• While washing vehicle do not direct pressurized water jet on Head Light, Tail
Light, Indicators.
• Do not drive the vehicle by keeping brake pedal pressed.
• Do not start Vehicle with light control switch in ON condition.
Switches
 Dos
• Always clean switch assembly with soft cloth.
• After washing the vehicle ensure to apply dry air on switches before operation.
• Ensure that rear brake switch is free from dust, dirt &mud Accumulation.
• Always ensure that grommets provided on clutch switch, front brake switch and
rear brake switch are intact.
• Always apply WD-40 electrical contact cleaning spray to sticky switches.
 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.
• 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.

5 Electrical

Fuse Box
Fuse 30A, 7.5A, 10A & 15A are located inside the main fuse box as
shown in photograph.
1. To open main fuse box cover. Lift

Press lock provided on RH side of
fuse box & lift the fuse box cover. Press
All fuses will be accessible.
2. Remove fuse by nose plier & check continuity as shown in photograph.
OR
2. On vehicle
Check the continuity of fuse with Digital multi meter
Continuity shown – Fuse ok
No Continuity – Fuse blown off
If it is blown off, replace by new one of same capacity.
When replacing a fuse, be sure the

new fuse matches with specified fuse
rating for that circuit. Installing a
Caution
fuse with a higher rating may cause
damage to wiring & components.

89
125 Fi
Electrical

Ignition Switch
Measuring & Testing Equipment : Multimeter
Meter Range Connections Continuity Check

Continuity Meter +ve Meter -ve OFF - No continuity
Mode Brown White wire ON - Continuity
SOP :
• Switch OFF Ignition key.
• Disconnect Ignition switch’s coupler.
• Check continuity between wires in ‘ON’ & ‘OFF’ position.
Standard Value :
• Beep Sound & Continuity in ‘ON’ position. No continuity in ‘OFF’
position.
Engine Kill Switch

Meter Wire Connections Condition Result
Range Meter +ve Meter -ve Engine ON condition Continuity is shown
Continuity
Gray/Red Brown/Blue Engine OFF condition No continuity
Mode

SOP :
• Put ignition switch OFF.
• Put kill switch OFF.
• Set multimetr at continuity range.
• Connect multimeter as shown in the table.

5 Electrical

Front Brake Light Switch
Brown Blue Continuity check by multimeter
Lever Pressed   Continuity is shown
Lever Released   No Continuity
SOP :
• Turn ‘ON’ the ignition switch.
• The brake light should glow brightly when the front brake lever /
rear brake pedal is pressed.
• If it does not, check the front brake switch.
Rear Brake Light Switch

Brown Blue Continuity check by multimeter
Brake Pedal Pressed   Continuity is shown
Brake Pedal Released   No continuity

SOP :
• Turn ‘ON’ the ignition switch.
• The brake light should glow brightly when the front brake lever /
rear brake pedal is pressed.
• If it does not, check the front brake switch.
Clutch Switch
Meter Range Yellow / Green Black / Yellow
OFF – Clutch lever not Pressed  
ON – Clutch lever Pressed  

91
125 Fi
Electrical
Horn
Clamp Meter Range Connections Standard Value
Encircle clamp meter jaws 2.2 Amps
200 DC A
around Brown wire of horn
Measuring & Testing Equipment : DC Clamp Meter

SOP :
• Encircle clamp meter jaws around Brown wire of Horn.
• Press horn switch & check instantaneous current drawn by horn.
2.2

5 Electrical

Fuel Gauge - Tank Unit
Empty Tank Measuring & Testing Equipment : Multimeter
Meter Range Connections Standard Value

Meter +ve Meter -ve As per chart
200 Ohms
White / Yellow Black / Yellow given below
Standard Valve :
ON Resistance OFF Resistance
Full
Of Bars Displayed
(Ω) with tolerance of + 2 Ω (Ω) with tolerance of + 2 Ω
1st Bar 62 71
2nd Bar (Reserve Zone) 52 57
3rd Bar 44 48
4th Bar 37 40
Full Tank 5th Bar 24 30
6th Bar 14 20
Note:
If display in speedo console is not proper then please check following
-
• Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is
firm.

93
125 Fi
Electrical

Starter Relay
Location : Mounted on chassis in RHS seat cowling near relays.
Starter Relay Coil Resistance Checking

Measuring & Testing Equipment : Multi meter

200 Ohms Meter +ve Meter -ve
Starter Relay Starter 3.1 Ohms + 10%
Coil Red - Relay Coil
Yellow Wire Black Wire
SOP :
• Switch OFF engine.
• Disconnect coupler from Relay.
• Connect multi meter to Starter Relay coil terminals.
• Check resistance.
Starter Relay Continuity Checking

Measuring & Testing Equipment : Multi meter
SOP :
• Connect external 12V DC supply to starter relay coil terminals.
• ‘Tuk’ sound will be heard.
• Set multi meter on continuity mode.
• Connect multi meter at relay contact terminals.
• Continuity (beep sound) indicates starter relay is OK.

5 Electrical

Spark Plug
RHS Spark Plug : 2 Nos

BOSCH UR4AC or Champion PRZ9HC
• Spark Plug Gap 0.7 ~ 0.8 mm

• Clean & adjust frequency - every 10,000 Kms.
• Replacement frequency 30,000 Kms.
Spark Plug Gap : 0.7 ~ 0.8 mm
Spark Plug Cap

SOP :
• Remove spark plug cap from HT coil cable.
• Set multi meter on 2 K Ohm range.
• Connect multi meter probes as shown in photograph.
• Standard value, 1 K Ohm + 150 Ohm.

95
125 Fi
Electrical

Stator Plate (Battery Charging Coil)
Battery Charging Coil
This is 3 phase starter winding (oil dipped type)
Number of poles - 18
Coils : Battery charging coil
SOP :
• Disconnect magneto coupler.
• Set multimeter at 200 Ohm range.
• Connect multimeter as shown in table & note reading.
Connections Standard
Sr. Meter Range
Meter +ve Meter -ve Resistance Value
1 Y1 Y2
2 200 Ohm Y2 Y3 0.5 + 1 Ohm
3 Y3 Y1
Regulator Rectifier (RR) Unit

Location : On frame LH side (Inside LH seat cowl)
Function :
• This is 3 phase RR unit & it convert 3 phase AC voltage generated by
magneto to DC voltage & also DC voltage is regulate at 14.5 V + 0.2 V DC at
all engine speeds.
• This voltage is used for charging of 8 Ah VRLA battery.

5 Electrical

Starter Motor - Current Drawn
Location : Above crankcase joining area.

Encircle clamp meter transformer jaws 75 ~ 80 Amps Spark
200 DC A
around thick Red wire of starter motor plug caps removed
SOP :
• Remove lower fairing LH & RH by removing 6 nos. each Philips screws.
• Disconnect all 3 spark plug caps (care to be taken so that spark plug
does not jump to metal part)
• Switch ‘ON’ Ignition switch & kill switch.
• Select range & set clamp meter zero reading.
80
• Encircle red input wire of starter motor by clamp meter jaws.

• Crank the engine by pressing self starter button.
• Press self starter button for 3 seconds & check cranking current
displayed on clamp meter
LCD display

97
125 Fi
Electrical
Roll Over Sensor

Wire Connections
Standard
Sr.No. Parameter Vehicle position Meter
Meter -ve Reading
+ve
Red/ Yellow/
1 Input voltage NA 5 VDC
Blue Black
Brown/G Yellow/
Normal position 4.8~4.9 VDC
reen Black
2 Output voltage
Tilled position Brown/G Yellow/
2~2.2VDC
(> 600) reen Black
SOP :
• Switch ON ignition switch & kill switch.
• Set Multimeter to 20 VDC.
• Connect Multimeter as shown.

5 Electrical

Oxygen (Lambda) Sensor
Wire Connections
Meter Range Standard Reading
Meter +ve Meter -ve
Pin no. 1 Pin no. 2 9 ~ 10 Ohm @ 250C
200 Ohms Meter displays 1 on LHS
Pin no. 3 Pin no. 4
@ 250C (open circuit)
SOP :
• Ensure ignition switch is OFF.
• Remove the harness side lambda sensor coupler.
• Set Multimeter on 200 Ohm range & connect as per table.
• Set Multimeter on 200 Ohm range & connect as per table.
Crank Angle Sensor & Neutral Switch

Wire Connections
Sr.No . Component meter range Standard Value Results
Meter + ve Meter -ve
Crank angle Resistance Black/
1 White/ Red 345 ~ 385 Ohms OK
sensor 2 K Ohms Yellow
Black/ Beep sound Ok
2 Neutral switch Continuity Green
Yellow No Beep sound Defective
SOP :
• Switch OFF ignition switch & kill switch.
• Connect Multimeter as shown.

99
125 Fi
Electrical

T MAP Sensor
Wire Connections
Sr.No. Parameter Meter Range StandardReading
Meter +ve Meter -ve
1 Resistance 20 K Ohms Pin no. 1 Pin no. 2 1.5 ~ 2.5KOhm
2 Input voltage 20 VDC Pink / Black Pink / Blue 5 VDC
White/
3 Output voltage 20 VDC Orange
Pink / Blue 3.15 ~ 4.45 VDC
Note :
For resistance checking remove coupler of TMAP sensor &
connect the Multimeter prob to Pin 1 & Pin 2 as shown.
T MAP Sensor
Input Voltage Checking Note :
For input & output voltage checking connect coupler of TMAP
sensor.
Output Voltage Checking

5 Electrical

TPS
Meter Wire Connections

Sr.No. Parameter StandardReading
Range Meter +ve Meter -ve
1 Input voltage 20 VDC Red/Blue Yellow/Black 3.3 VDC
Output voltage idle
2 20 VDC Red/Blue Yellow/Black 2.9~ 3.0VDC
throttle
Output voltage wide
3 20 VDC Red/Blue Yellow/Black 0.35 ~ 0.65 VDC
openthrottle
SOP :
• Remove petrol tank cover & petrol tank.
• Remove air filter cover along with paper filter element.
• Connect Multimeter as shown in table given below.
Input Voltage Checking
Side Stand Switch

Wire connection
Sr.No. Parameter Magnet Position Meter - Std. Reading
Meter +ve
ve
Input voltage (Side stand Red/ Yellow/
1 N.A. 5 VDC
position- any) Blue Bl ack
Output voltage (Side Magnet in front of side Yellow/

Pink 2~2.2 VDC
standposition- OFF) standswitch Bl ack
2
Side stand Magnet awayfrom Yellow/
Pink 4.8 ~ 4.9 VDC
position-ON side stand switch Bl ack

101
125 Fi
Electrical

Side Stand Switch
SOP :
• Switch ON ignition switch & kill switch.
• Set Multimeter to 20 VDC.
• Connect Multimeter as shown in table given below.
Fuel Pump
Meter Range Wire Connections Continuity Check
Meter +ve Meter –ve

200 Ohms 2.1 Ohms
Orange/Blue Black/Yellow
Note :
• Battery should be fully charged.
• Fuse and ignition switch should be OK.
• Audible sound will be heard which will confirm fuel is working.
• Check main relay first if fuel pump is not working.

5 Electrical

Injector
Wire Connections
Sr.No Parameter Meter Range Standard Reading
Meter + ve Meter -ve
12 +0.6 Ohms @
1 Resistance 2K Ohms Pin no. 1 Pin no. 2 0
25 C
Note :
• Remove petrol tank cover & petrol tank .
• Remove air filter cover along with paper filter element.
• Disconnect the injector coupler.
• Connect Multimeter to Pin 1 & Pin 2 of injector.
H.T. Coil
Primary Winding Resistance Checking
Meter Range Wire Connections Standard Value

200 Ohms 2.3 + 10% Ohms
Orange/White Pin-1 Black Pin-2
Secondary Winding Resistance Checking

Meter Range Wire Connections Standard Value
20 K Ohms Pin of Orange / 13 + 20% K Ohms
HT output
White

103
125 Fi
Electrical

Intermediate Relay Coil Resistance Checking
Continuity
Meter Range Wire Connections
Check
200 Ohms Relay coil Relay coil 80 ~ 140 Ohms
Terminal 1 Terminal 2
Note :
• Switch off the engine.
• Remove relay from coupler.
• Connect the digital multi meter to relay coil terminals and
check resistance.
Intermediate Relay Continuity Checking

Primary Winding Resistance Checking
Note :
• Connect external 12DC supply to relay coil terminals.
• “TUK” sound will be heard.
• Set digital Multimeter on continuity mode & connect the
digital multimeter to relay contacts terminals & check
continuity.
• Continuity (beep sound) indicated relay is Ok.

5 Electrical

ECU Removal & Re-Fitment
Remove
• Battery case bolts
• Lift battery case along with ECU.
Remove
• ECU mounting bracket nut .
Take Out
• ECU bracket.
• Battery case.
Remove
• Pull ECU lock.
• Till it become perpendicular to

grey part.

105
125 Fi

Take Out
• ECU.
• ECU Fitment
• Ensure that coupler & ECU
"Top" written face should be
towards upside.
Fit
• ECU in coupler completely.
• Apply lock.

106
5
Notes

107
Bajaj Auto Limited
Akurdi Pune 411 035 India
Tel | +91 20 27472851

Fax | +91 20 27407385
www.bajajau t o.com
CIN number : CIN L65993PN2007PLC130076

Pulsar 125 Fi TRG Note

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Training Notes

Understanding the complete

Technical Specifications and Performance

Pre delivery inspection care &

I Read ..... I Learn

Pre-Delivery Inspection Checklist

Periodic Maintenance & Lubrication Chart

Bajaj Pulsar 125 Fi Training Notes

Frame Number Location

Engine Number Location

Left Handle Bar Switches

C. Horn Button : ( ) Press button for sounding horn.

Bajaj Auto International Business

CAUTION : While starting ensure that engine kill switch is in ON ( )

Steering Cum Ignition Lock

OFF: Steering unlock. Ignition OFF.

ON: Steering unlock. Ignition ON.

Bajaj Pulsar 125 Fi Training Notes

1. Fuel Level Indicator: It shows fuel level in fuel tank.

Bajaj Auto International Business

Bajaj Pulsar 125 Fi Training Notes

• Maintenance free sealed • Hassle free ownership -

Bajaj Auto International Business

Chassis & Body

Bajaj Pulsar 125 Fi Training Notes

Bajaj Auto International Business

Pre Delivery Inspection Care

Bajaj Pulsar 125 Fi Training Notes

Pre Delivery Inspection Care

Replacement Frequency* 1st replacement at 500-750 Kms./ 1st service. Thereafter at

Bajaj Auto International Business

Periodic Maintenance & Lubrication Chart

Service 1st 2nd 3rd 4th 5th 6th 7th

750 5000 10000 15000 20000 25000 30000

1 Servicing & water wash

2 Valve tappet clearance A A A A A A A A

4 Oil strainer CL CL CL CL CL CL CL CL Clean at 5000 Kms

5 Paper oil filter R R R R R R R R Clean at 5000 Kms

8 Air filter cover 'O' Ring R R R Clean at every 15000 kms

9 In line fuel filter R R Replace at every 20000 kms

10 Fuel pipes C,R C C C C R C C Clean at every 15000 kms

13 CBS free play CL,R CL CL CL,R CL CL CL,R

16 Brake cam & pedal pivot pin L L L

18 Steering stem bearing C,L,R C,L,R C,L,R C,L,R

22 Silencer drain hole cleaning CL CL CL CL CL CL CL CL Clean at every 5000Kms

23 Engine air breather tube C,R C C C R C C Replace at every 20000Kms

Drive chain slackness adjustment &

EVAP hoses- Check functionality

29 Starter clutch (Dry type) L L L L L L L Use recommended molykote grease

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Understanding of complete EMS sytem

Function / construction / working

Bajaj Pulsar 125 Fi Training Notes

Horn, HT coils, Lambda Sensor,

Ignition Switch, Control Switch LH Battery, regulator,

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Wiring Harness Routing

Control switch RH Control switch LH

Front-rear Roll over sensor

Engine temp. sensor

Bajaj Pulsar 125 Fi Training Notes

Bajaj Auto International Business

Wiring Harness Routing