M OT O RCY C L E S

TRAINING NOTE

NOTICE

All information contained in this Training Note is based on the latest

product information at the time of publication. Bajaj Auto Limited
accepts no liability for any inaccuracies or omissions in this
publication, although every possible care has been taken to make it
as complete and accurate as possible. All procedures and
specifications subject to change without prior notice. The right is
reserved to make such changes at any time without prior notice.

DOC. NO.: 71112092

DISCOVER 125 M TRAINING NOTES

REV. 00, AUG 2014

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Contents
1

Technical Specifications

Salient Feature............................................................................ 2
Technical Specifications.......................................................... 6
Standard Service Limit............................................................ 9

Preventive Maintenance

12

PM Chart....................................................................................... 13
Periodic Maintenance SOP.................................................... 15

Fuel System

28

CO Checking & Setting ....................................................... 29

Engine Tune Up......................................................................... 30
Carbutor Specification & Sercuits..................................... 31

Engine

32

General Precautions................................................................. 33
Standard maintenance sop................................................... 38
Bolts Tightening Sequence................................................... 43
Lubrication Circuit.................................................................... 48
Tightening Torque.................................................................... 52
Special Tools............................................................................... 55

Vehicle

59

Standard Operating Procedure........................................... 60

Special Tools................................................................................ 70
Tightening Torque..................................................................... 72

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Electricals

75

Battery............................................................................................ 76
Dos & Dont's.............................................................................. 77
Checking Procedure................................................................. 82
Electrical circuit Diagram....................................................... 93

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1
Technical Specifications
Salient Feature
Technical Specifications
Standard And Service Limit

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SALIENT FEATURES
PERFORMANCE

Features

Advantages

Benefits

4 Valve Engine.

New generation technology

engineered for high power /
pickup and performance as well.

Higher power & pick up.

Engine power :
11.5 PS @8000 RPM
Engine torque :
10.8 N-m at 6000 RPM.
DC ignition system.

Wider range of gear ratios to

utilize high torque of engine.

More power at all load

conditions, better torque at low
RPM, less emissions. Smooth
gear shifting.

Seamless changes in ignition

maps for better engine
performance.

Molycote piston.
Nozzle oil jet in lubrication
circuit.

Reduced friction & better

cooling of piston.

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SALIENT FEATURES
STYLE

Features

Advantages

Benefits

Stylish and eye catching looks.

Combination of Black & Chrome
styling.

Sporty styling.
Improves personality of the
rider.

Athletic and muscular petrol

tank, side covers and seat
cowling.
New head lamp with attractive
fairing and twin pilot lamps.
Innovative and Distinctive
Graphics.
New Speedometer.
Black colored engine.
New look 10 spoke alloy
wheels, silencer.

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SALIENT FEATURES
COMFORT AND CONVENIENCE

Features

Advantages

Benefits

Telescopic front fork with125

mm stroke.

Longest suspension stroke in its

class of bike.

Excellent drive ability, smooth &

comfortable ride on all types of
roads & for any distance.

Nitrox(Gas filled) Twin

suspension at Rear with 100mm
wheel travel.

Less vibration.

Internal weight is provided in

handle bar.

Display approx petrol quantity

remaining in petrol tank reminds
rider for refueling.

More convenience.

For easy inspection of oil

window.

Easy monitoring of oil level.

Less fatigue to rider.

Fuel gauge.
Engine oil level window.
Self start.
Quick & easy starting.

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SALIENT FEATURES
SAFETY

Features

Advantages

Benefits

130 mm drum brake & 200mm

dia disc brake at front &
130 mm rear drum brake.

Excellent ride and handling

stability, balance, highest
stability & excellent road grip &
vehicle dynmics.

Safety on road in high speed

driving.

High strength robust semi

double cradle chassis.
Wheelbase 1255 mm.
Unidirectional tyres.

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SALIENT FEATURES
Engine & Transmission
Type

: Four stroke

No. of cylinders

: One

Bore

: 54.00 mm

Stroke

: 54.4 mm

Engine displacement

: 124.6 cc

Compression ratio

: 9.8 : 1

Idling Speed

: 1400 + 100 rpm

Max. net power

: 11.5 PS @ 8000 RPM

Max. net torque

: 10.8 N.m @ 6000 RPM

Ignition System

: DC

Ignition Timing

: Multimap CDI

Fuel

: Unleaded Petrol, 87 RON Minimum

Carburettor

: UCAL make with manual choke

Spark Plug

: Champion P-RZ9HC / BOSCH UR4AC

Spark Plug Gap

: 0.7 to 0.8 mm

Lubrication

: Wet sump forced lubrication

Starting

: Kick & Electric Start

Clutch

: Multiplate wet clutch

Transmission

: 4 Speed-constant mesh

Primary reduction

: 3.571 : 1 (75/21)

Gear Ratios

1st Gear
2nd Gear
3rd Gear
4th Gear

Final Drive Ratio

:
:
:
:
:

3.100
1.733
1.227
0.909
3.0

:
:
:
:

1 (31/10)
1 (26/15)
1 (27/22)
1 (22/20)
: 1 (42/14)

Chassis & Body

Frame Type
Suspension

Front

Rear
Brakes
Front
Rear
Brake Size
Front
Rear
Tyres
Front
Rear
Tyre Pressure
Front
Rear (Solo)
Rear (with Pillion)
Rims
Front
Rear
Fuel Tank Capacity
Usable Reserve
Unusable Reserve

DISCOVER 125 M TRAINING NOTES

: Semi double cradle

: 125 mm Fork travel, Telescopic, without
antifriction bush
: 100 mm Rear Wheel travel
: Drum
Drum
: 130 mm Drum brake
: 130 mm Drum brake
: 2.75 x 17, 41 P Unidirectional
: 3.0 x 17, 50 P Unidirectional
: 1.75 Kg / Cm2 (25 PSI)
: 2.00 Kg / Cm2 (28.5 PSI)
: 2.25 Kg / Cm2 (32 PSI)
: 1.4 x 17 Die Cast Aluminium Alloy Wheel
: 1.6" x 17 Die Cast Aluminium Alloy Wheel
: 9.5 Liters
: 1.6 Liters
: 1.3 Liters

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TECHNICAL SPECIFICATIONS
Controls
Steering

: Handlebar

Accelerator

: On handle bar, RH grip

Gears

: Left foot pedal operated, Step shift

Brakes

Front
Rear

: Lever operated, RH hand.

: Pedal operated by RH foot

Clutch

: Lever oprated LH

Electricals
System

: 12 V (DC)

Battery

: 12V 5Ah MF

Head Lamp

Stop / Tail Lamp

12V, 21/5W

Side Indicator Lamp

12V, 10 W (4 Nos.)

Speedometer Lamp

12V 2W (2 nos.)

Neutral Indicator

12V, 2W (Green)

Turn Signal Indicator

12V, 2W (Green)

Hi-beam Indicator

12V, 2W (Blue)

Rear Number plate lamp

Horn

: 2A @ 12 V

Bajaj Logo

Length

: 1986 mm

Width

Height

: 1044 mm

Wheel Base

1255 mm

Saddle Height

795 mm

Ground Clearance

165 mm

Vehicle Kerb Weight

117 kg

Gross Vehicle Weight

247 kg

Maximum speed

: 100 km/h

12 V 35/35 W, HS-1

12V, 3W
T5 LED / T10 1.7W

Dimensions
678 mm

Weights

Performance
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.

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TECHNICAL SPECIFICATIONS

Sr.
No.

Lubricant /
Loctite

Application

Grade

9.

Oil for drive

chain

10.

Electrical contact
WD-40 Spray
cleaning spray

11.

Loctite

SAE 90

Loctite 243

12.

Loctite

Pre-coated or Loctite 243

13.

Liquid gasket

Three Bond

DISCOVER 125 M TRAINING NOTES

Remark

Non O ring type

drive chain

During all services

Ignition switch
Brake & clutch switch
LH/RH control switch

All services

Rear fender bottom

mounting.
Cam sprocket allen
bolt
Pickup coil screws
Stopper plate screws
(gear starter clutch)
Kick guide bolts
Output sprocket bolts
Oil pump mounting
bolt.
Allen bolt securing
guide gear on shift
drum.
Screw securing
stopper for input
shaft bearing.
Special bolt guide
chain slack side.
Nut inhibitor mounting
Nut clutch mounting
Damper plate bolts
clutch cover.
Damper plate bolts
magneto cover.
Stator mounting bolts
Stator harness clamp
plate screw.

Crankcase joining
surface.

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STANDARD AND SERVICE LIMIT

Compression Pressure

Valve Clearance

Std. Limit

12 ~ 13 kg/cm

Ser. Limit

Min 9.5 kg/cm

Cam Sprocket Diameter

Rocker Arm Shaft Diameter

Intake

Exhaust

Std. Limit

In 0.05

Ex 0.10

Std. Limit

7.994 ~ 8

Ser. Limit

Ser. Limit

7.98

Cam Height

Cam Lobe Width

Intake

Exhaust

Std. Limit

61.165 ~ 61.285

Std. Limit

29.411

29.457

Std. Limit

9.0

Ser. Limit

60.865 ~ 61.285

Ser. Limit

29.335

29.382

Ser. Limit

Valve Spring Free Length

Valve Stem Diameter

Valve Stem Bend

Intake

Exhaust

Std. Limit

38.68

Std. Limit

4.475~4.49

4.455~4.47

Std. Limit

0.01

Ser. Limit

35.23

Ser. Limit

4.46

4.45

Ser. Limit

> 0.01 Replace

Valve Stem to Guide Clearance

Cylinder Head Warp

Camshaft Chain Length

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

Ser. Limit

Max 0.07

Max 0.07

Ser. Limit

0.05 mm

Ser. Limit

128.9 mm

ALL DIMENSIONS ARE IN MM

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STANDARD AND SERVICE LIMIT

Cylinder Inside Diameter

Piston Diameter

Piston Cylinder Clearance

10mm
20mm
40mm

6mm

( Meassure at 6mm from bottom )

Std. Limit

54.008 ~ 54.018

Std. Limit

53.969 ~ 53.981

Std. Limit

0.027 ~ 0.047

Ser. Limit

Ser. Limit

Ser. Limit

Max 0.06

Piston Ring Groove Clearance

Top

Piston Ring End Gap

Second Oil Ring

Top

Clutch Spring Free Length

Second Oil Ring

Std. Limit 0.03~0.07 0.02~0.07 0.03~0.15

Std. Limit 0.1~0.25 0.3~0.45 0.2~0.7

Std. Limit

25.5

Ser. Limit

Ser. Limit

Ser. Limit

24.5

0.15

0.15

Friction Plate Thickness

0.4

0.6

Steel Plate Thickness

Steel Plate Warp

Std. Limit

2.90 ~ 3.0

Std. Limit

1.55 ~ 1.65

Std. Limit

0.1

Ser. Limit

2.7

Ser. Limit

1.55

Ser. Limit

0.15

Friction Plate Warp

Clutch Hub Height

Shift Fork Guide Pin Diameter

Std. Limit

0.1

Std. Limit

21.0 ~ 21.2

Std. Limit

4.45 ~ 4.49

Ser. Limit

Ser. Limit

21.4

Ser. Limit

4.4

ALL DIMENSIONS ARE IN MM

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STANDARD AND SERVICE LIMIT

Shaft Fork Shift O.D.

Fork Shift I.D.

Shift Drum Groove Width

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

Con Rod Side Clearance

Crankshaft Run Out

Clutch Stackup Height

Std. Limit

0.02

Std. Limit

0.1 ~ 0.35

Std. Limit

20.95 ~ 21.85

Ser. Limit

0.05

Ser. Limit

0.7mm

Ser. Limit

ALL DIMENSIONS ARE IN MM

NOTES

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2
Preventive Maintenance
PM Chart
Periodic Maintenance SOP

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PERIODIC MAINTENANCE AND

LUBRICATION CHART
RECOMMENDED FREQUENCY
Sr.
PM Check Points
No.

Servicing
Kms

1st
500
~
750

1.

Servicing with water wash.

2.

Engine oil * (Bajaj DTSi 10000 oil) and

engine oil filter

C,R

3.

Oil strainer, Body centrifugal filter #

CL

CL

2nd 3rd
4th
5th
6th
7th
4500 9500 14500 19500 24500 29500
~
~
~
~
~
~
5000 10000 15000 20000 25000 30000

Top-up

Top-up

CL

Top-up

CL

CL

Subsequent / Remark

1st - 500~750 Kms / 30~45

days, 2nd onward@5000Kms
Top-up @ every 5000 Kms.
Replace oil & Oil filter in 1st
service & at every 10000 Kms
Oil strainer cleaning at time of oil
change for Discover & Pulsar 135
# Clean body centrifugal filter at
750 km & at 20k km. -- Pulsar &
Platina

4.

Starter Clutch** (Dry Application)

5.

Spark plug

6.

Air cleaner element & cover O ring ***

7.

In line paper filter or Fuel cock paper filter.

8.

Fuel cock sediment bowl cleaning

9.

Carburettor rubber duct

C,R

CL,A,R
CL,R

CL,A
CL

CL

CL

CL,A
R

CL

L
R

CL

Replace at every 15000kms

Replace at every 15000kms

CL

CL

CL
C,R

Check & replace if required

10.

Fuel pipes

C,R

11.

Valve tappet clearance

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

12.

Drive chain ("O" ring & non "O" ring)

lubrication on vehicle

CL,A,L

CL,A,L

13.

Drive chain ("O" ring & non "O" ring)

Remove & Lubricate.

CL,L,A

14.

Engine air breather tube

15.

Silencer drain hole cleaning

16.

O ring chain cleaning / lubrication

by OKS spray
CL,L,A

CL,L,A

CL,L,A

CL,L,A

CL,L,A

CL,L,A

CL

CL

CL

CL

CL

CL

CL

Silencer tail pipe cleaning-Pulsar 150/180

CL

CL

CL

CL

CL

CL

CL

17.

Brake lining or pad for wear & lubricate brake

cam & pivot pin** Check pad wear indicator

C,L,R

C,L,R

C,L,R

C,L,R

C,L,R

18.

Brake fluid level / top up / replace

C,A,R

19.

Disc brake assly -- Check functionally,

leaks or cracks in overall system

C,L,R

C,A

All cable play & rear brake adjust.

Check brake, clutch switch function ability &
brake & clutch system working.

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

21.

Battery electrolyte level, specific gravity &

connections

C,A,T

C,A,T

C,A,T

C,A,T

C,A,T

C,A,T

C,A,T

C,A,T

22.

Wiring harness routine, tie bands & clamps

tightness.

23.

Ignition switch barrel cleaning & handle bar

control switches contacts cleaning,

C,CL

C,CL

C,CL

C,CL

C,CL

C,CL

C,CL

C,CL

24.

Steering play

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

25.

Steering stem bearing*** and Cap steering

bearing (Plastic)**

26.

Main stand & side stand pin***

27.

Swing arm pivot pin (for non silent bush)**

C,CL,L,R

C,CL,L,R

CL,L

CL,L

CL,L

Activity required for regular & MF

battery.

C,CL,L,R

Replace at every 15000 Kms.

20.

Replace at every 15000 kms

C,CL,L,R Check & replace if required

CL,L
L

Only for MOS2 nylon bush design

Pulsar 150

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PERIODIC MAINTENANCE & LUBRICATION CHART

RECOMMENDED FREQUENCY

Sr. Operation
No.

Servicing
Kms
C,T

1st
500
~
750

2nd 3rd
4th
5th
6th
7th
Subsequent
4500 9500 14500 19500 24500 29500
~
~
~
~
~
~
5000 10000 15000 20000 25000 30000

28.

All fasteners tightness

29.

Engine foundation silent bushes**

30.

General lubrication

31.

Idle speed / CO%

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

32.

Coolant level check in expansion tank**

33.

Coolant hose damage / clamps / leakage**

34.

Radiator fins**

35.

Coolant in expansion tank**

C,A

C,T

C,T

C,T

C,T

C,T

C,T

C,T

C,A

C
C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

C,A

Check & replace if required

C,A

Replacement at every 30000 Kms

or 2 year (whichever occurs earlier)

* 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. 2 & 3 will be every 5000 Kms.
** As applicable to model
*** More frequent cleaning may be required when driving in dusty condition.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory & the same are chargeable to customer.

Oil / Grease / Loctite application matrix

Sr.
No.

Lubricant /
Loctite

1.

Engine oil

2.

Fork oil

3.

Application

Remark

Engine

Quantity :
Service - 1 L
Eng. O/h - 1.1 L

SAE 10W20

Front fork

Quantity / fork leg :

Service - 140 + 2.5 ml

Brake fluid

N.A

N.A

N.A

4.

Grease

Lithium RR-3

Steering races & balls

HP make

5.

Grease

All purpose

Front & real wheel

axle
Swing arm shaft
Brake pedal pivot pin
Center stand shaft
Side stand U bracket
Gear shifter pivot
Clutch & front brake
lever

Grade
DTSi 10000,
API SL SAE 20W50
JASO MA

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PERIODIC MAINTENANCE SOP

Engine Oil Replacement

Clean the vehicle

Ride the vehicle for 2/3 km to warm up
Park the vehicle on level surface

Remove :
Strainer cap
Strainer
Drain engine oil in a clean container.

Measure the quantity of drained oil.

Inspect the drained oil quality.

Tighten drain plug to recommended torque by torque wrench.

Clean oil strainer as per SOP before filling new engine oil.

Tighten the strainer cap.

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PERIODIC MAINTENANCE SOP

Remove :
3 bolts
Oil Filter

Replace oil filter by new one before filling new engine oil.

Use Bajaj Genuine oil only as per the recommended grade (20W40).

Ensure oil filler cap O ring is in good condition

Ensure oil filler cap is fully tight.

Note :

Air Filter Element Removal and cleaning

Remove LH Side panel by using

vehicle key.

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PERIODIC MAINTENANCE SOP

Remove the seat assembly by

pulling seat lock cable.

Remove the Screw of RH Side panel

and take out the panel.

Put off fuel cock.

Remove fuel pipe clip & take out
the pipe from tank side.

Remove fuel tank mounting bolt using 10 mm spanner.

Take out fuel tank by disconnecting the fuel gauge coupler.

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PERIODIC MAINTENANCE SOP

Air Gun

Remove the air filter cover rear side two bolts / screws.

Remove the air filter cover front side

Take out the air filter cover along

with air filter element by sliding
towards rear side.

Clean the paper filter element as per

the SOP. Use low pressure point
(1.75 Bar) for paper filter cleaning.

Filter Element
Carburettor side

Air Gun

Filter Element
Dirty side

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PERIODIC MAINTENANCE SOP

Locate the air filter element inside

air filter cover & slide air filter cover
by holding air filter element towards
front side.

Per-fit the long pivot bolt by hand &

tighten the rear side bolts / screw (2
nos) by 10mm T spanner.

Apply torque of 1.1 Kg-m to long pivot bolt / screw.

Note :
Do not apply excess torque / uncontrolled tightening

Non O ring Drive Chain Cleaning Lubricating SOP (on Vehicle) - For 1st service only

Open the window cover for lubrication of chain.

Remove mud / muck from engine sprocket area by diesel / kerosene & nylon
brush. Apply low pressure (nozzle jet in spray mode) water jet.

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PERIODIC MAINTENANCE SOP

Lubricate chain with SAE 90 oil. Ensure oil is directed on to the ends of the bushes
& links on either side.

Rotate the rear wheel for proper lubrication of entire chain.

Wipe off excess oil or dripping oil & close the window cover.

Non O ring Drive Chain Cleaning SOP (By removing from vehicle) - 2nd service onwards

Remove chain cover.

Open drive chain link lock & take out drive chain.

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PERIODIC MAINTENANCE SOP

In first stage, clean the drive chain in chain cleaning stand 1st pot containing Diesel
/ Kerosene

In second stage, clean the drive chain in chain cleaning stand 2nd pot containing
Diesel / Kerosene.

Blow the compressed air on drive chain

In third stage, dip the drive chain into 3rd pot containing SAE90 oil.
Soak the drive chain into SAE 90 oil.

Hook the drive chain for dipping off excess oil.

While refitting drive chain on vehicle, ensure new drive chain link lock is fitted.
Note :
Ensure that drive chain slackness should not be less than 20 mm.

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PERIODIC MAINTENANCE SOP

Tappet Clearance Setting

Ensure that the engine is in cold condition.

Ensure the T mark on the Rotor match with the mark on the Crankcase LH.
At this stage the Piston is at TDC & both the rocker arms are free.

Holding tappet screw firmly with special tool loosen the tappet screw nut.

Put the feeler gauge, measure and adjust the clearance.

Lock the nut holding screw with special tool after getting required clearance.

Again check the tappet clearance with gauge. The feeler gauge should slide
with slight resistance between tappet screw tip & valve stem head. Tighten t h e
check nut with a spanner.

Inlet Valve

0.05 mm

Exhaust Valve

0.1 mm

M & T Equipment

Special Tool

:
:

Feeler Gauge
Valve Adjusting Screw Holder
Part No. : F41ZJW33

Note : Tappet setting of 2 Intake & 2 exhaust valve must be done individually as
per SOP.

SOP for Drive Chain Slackness Adjustment

Put vehicle on center stand.

Remove rubber cap from chain inspection window.
Rotate rear wheel slowly in one direction to find out the position at which chain is getting tight.

At this lowest point of chain

slackness, lift & press down on the
chain to measure chain slackness by
steel rule.

To set chain slackness, first loosen

the rear brake rod nut by using a flat
or ring spanner.
Remove the lock pin by using
combination plier and loosen the
tie rod nut by using ring spanner.

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PERIODIC MAINTENANCE SOP

Loosen the rear axle nut by using

17 mm ring spanner.
Loosen the bearing carrier nut
by using 24 mm ring spanner.

Check & confirm that the marks on left hand & right hand chain adjusters
are equally aligned.

To keep the chain & rear wheel properly aligned, the arrow mark on the
left and right adjusters must be equidistant from their respective rear edge
of 'swing arm notch'.

Rotate rear wheel, apply rear brake & hold brake pedal in applied position
this will ensure that brake liner & brake panel take a concentric position
wrt brake drum.

Hold the left chain adjuster nut in flat spanner and tighten the lock nut.
Repeat the same procedure for right chain adjuster lock nut.

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PERIODIC MAINTENANCE SOP

Tighten the bearing carrier nut to the specified torque.

Tighten the rear axle nut to the specified torque.

Tighten the tie rod nut to the specified torque.

Adjust rear brake pedal free play. Recommended rear brake pedal free
play is 20~25 mm.

Check and ensure that rear wheel is rotating freely.

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PERIODIC MAINTENANCE SOP

Preventive Maintenance
1. What is Preventive Maintenance ?
Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs &
failures. The primary goal of PM is to up keep health of product through out it's life.
2. Why Preventive Maintenance ?
Preventive Maintenance is predetermined work to a. Ensure safe functioning of product with intended reliability.
b. Reduce cost of repairs & replacement.
c. Protect assets & prolong the useful life of component / product.
3. How to perform ?
a. Clean / Inspect / Lubricate / Adjust / Replace as per the PM chart & encyclopedia guidelines.
b. To correct deficiencies found through testing & inspection.
4. How to ensure execution & competency ?
a. Training programs, encourage & appreciates for abnormality identification & prevention.
b. Audit & review to assure quality performance.
c. For better understanding show Periodic Service DVD to technicians at suitable interval.
5. How to promote compliance to PM schedule ?
a. Work shop side 1. Ensure adherence to S.O.P. while carrying out repairs through stage wise, service wise check sheet
deployment.
2. Monitor effectiveness of technicians through final inspection.
3. Monitor consumption of Periodic parts vis a vis vehicle serviced month wise.
b. Customer side 1. Display periodic parts replacement chart in customer interaction explaining adverse effects, if not done.
6. Preventive Maintenance effectiveness - Indicators to be monitor by WM at service station
a. Reduction in repeat complaint.
b. Parts, components performing to intended life.
c. Reduction in brake down.

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PERIODIC MAINTENANCE SOP

Importance of PM schedule execution
Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary
goal of PM is to up keep health of product through out it's life.
PM Activity

Benefits

Engine oil replacement / top up.

Better lubrication of engine components.

Engine oil filter replacement.

Smooth functioning of engine parts.

Oil strainer cleaning.

Idle speed & CO% setting.
Spark plug cleaning.
Better drive ability.

Air filter cleaning.

Fuel cock bowl cleaning.

consistancy in mileage.

Carburettor cleaning.
Battery electrolyte level checking
Petroleum jelly application on battery terminals
Battery terminals connection tightening
Electrolyte specific gravity checking
Battery charge / condition checking by battery tester
Charging of battery on BAL recommended battery
charger
Clutch free play setting
Accelerator free play setting
Front brake free play setting (applicable to drum brake)
Disc brake system checking
Drive chain (non 'O' ring) lubrication on vehicle
Drive chain ('O' ring) lubrication on vehicle
Drive chain (non 'O' ring) overhaul
Drive chain ('O' ring) overhaul

No chain noise issues.

Optimum performance of drive chain.

Drive chain slackness checking & adjustment

Wiring harness checking
Ignition switch & handle bar control switches contacts
cleaning checking & cleaning.

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NOTES

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3
Fuel System
CO Checking And Setting
Engine Tune-Up
Standard Operating
Procedure
Carburetor Specification
& Circuits

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CO CHECKING & SETTING

Readiness of CO Gas Analyser

Taking the Reading

Warm up the CO Gas Analyzer

for 10~15 minutes before
proceeding further. Warming up
is essential every time machine
is put on to purge out any
gases left in side.

Remove M-5 bolt and aluminum

washer fitted to the nozzle (12mm
OD) shown in figure, of the
connecting tube welded to silencer
pipe before CAT converter.

Use a Silicon Rubber tube of

approximately 300 mm to fit onto
the nozzle. Only a Silicon rubber
tube should be used, as it has
better high temp. resistance & will
not deform / melt due to high
temp. at the nozzle.

Connect the other end of the

Silicon Rubber tube to the flexible probe pipe of machine.
Ensure that the inner diameter of Silicon tube perfectly
matches with outer diameter of flexible probe pipe of Gas
Analyzer.

Readiness of the Vehicle

The Silicon rubber tube must fit snugly onto the nozzle to
prevent any air / exhaust gas leakage.

Before checking CO emission, prepare the vehicle for

checking the CO.

Note the CO / HC readings when the reading display

stabilizes.

Caution: In choke ON condition CO % is high : 9~10%.

Hence warming up of engine is a must.

As per Emission Norms the recommended CO% for 2

Wheelers is 3.5% at idling RPM. But CO% for Bajaj
Vehicles, for best results in terms of fuel efficiency are
different for different models. The ideal CO% is between
1.75 to 2.25% at idling RPM = 1400 + 100.

If the reading is shown excess or less than BAL

specifications, try to achieve by adjusting Air Screw.

Turning in VC Screw will lead to less CO% and turning out

will lead to more CO%.

Carry out Span Check as per

manufacturer's Recommendation
to confirm the OK condition of
the Equipment (If Span Check
does not confirm the reading,
then carry out Gas Calibration
as per mfgrs. recommendation). Set the Equipment
display to Zero before taking the reading.

Warm up the engine to its normal operating temp. by

riding 5~6 Kms. The c'case cover should be warm
enough by feel. (Engine Oil Temp. = 600C).

Set CO to 1.75 ~ 2.25 %.

Note: If engine does not go off, then attend to the

additional air supply problem in the carburetor circuit &
intake system. After solving the problem once again
confirm that engine should die
down on closing the Air Screw.

Set CO to 1.75 ~ 2.25 %.

Set Idling speed to specified

Idling 1400 + 100 rpm.
Raise the engine to
moderate speed at no load
condition for about 15
seconds. Then bring back to
specified idling RPM.

Note: Remember the Air Screw should not be taken out more
than the recommended position. Every time Air Screw setting
is changed specified Idling RPM must be restored and then
reading should be considered.

If the CO% is not falling within recommended % in spite

of adjusting the Air Screw then find out the cause &
rectify. After rectifying the problem confirm the CO% in
the same way as mentioned above.

Important: For Better Mileage and Performance, achieve CO%

as recommended.
In Discover 125 M motorcycle for better mileage and
performance achieve values given below.

Recommended CO% value w.r.t. VC Screw

and Idling RPM for Better Fuel Efficiency

DISCOVER 125 M TRAINING NOTES

Model

Recommended CO%

Recommended Idling RPM

Discover
125 M

1.75% ~ 2.25%

1400 + 100 rpm

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ENGINE TUNE-UP
PAPER FILTER:

Reed Switch Maintanance

Clean at Every :
5000 Kms.

Check throttle lever movement by rotating it with hand. It should

not be sticky in operation and should return back it self on releasing.

Replace at Every :
15,000 Kms.

Magnet should not touch with reed switch.

Gap between Magnet & Reed Switch should be
2 ~ 3 mm.
Movement of throttle lever with magnet
Assly and Reed Switch fitted should be free.

COMPRESSION PRESSURE
Standard :
11 to 13 Kg/cm2
Service Limit :
9.5 Kg/cm2

REED SWITCH : SETTING

Accelerator cable play: 2-3 mm by
adjusting the Adjuster (A).
Protude stopper (B) of the throttle lever
bracket must on idling screw (C) tip.

TAPPET CLEARANCE
Inlet Valve :
0.05 mm

Exhaust Valve :
0.1 mm

REED SWITCH : CHECKING

Keep throttle at zero position. (Fig. 1).
On connecting multimeter to Reed Switch
Coupler it should show continuity.

CARBURATTOR
Idling : 1400 + 100 rpm.
Jet Needle Clip Position :
2nd groove from top
VC Screw Setting : 2.5 + 1
To achieve CO% 2% + 0.5%

Fig.1
When throttle is open and Reed Switch
magnet crosses to straight edge of fix
bracket of Reed Switch (Fig. 2) multimeter
should show discontinuity.

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.
Front brake lever 4~5 mm.
Rear brake pedal 15~20 mm.
e. Chain slackness : 20~25 mm.
f. Check & confirm proper functioning of spark plug.

Fig.2
On De-acceleration, when of Reed Switch
Magnet re-coinsides with straight edge of
Fix bracket of Reed Switch (Fig. 3)
Multimeter should show continuity.

Fig.3

Engine Tune-up

0.7 to
0.8MM

SPARK PLUG :
BOSCH UR4AC, Champion
PRZ9HC
Spark Plug Gap :
0.7~0.8 mm.
Replace at Every :
30,000 Kms

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CARBURETOR SPECIFICATION & CIRCUITS

Item

Specification

Make

UCAL

Type

BS 26

Idling Speed

1400 + 100 rpm

VC Screw Setting

2 + 1 ( To achieve CO% - 2 + 0.5% )

Main Jet

105

Needle Jet Marking

NRAD

Jet Needle e Clip Position

Single Groove from top

Pilot Jet

12.5

Throttle Valve Mark

GOH

Float Height

11.7 mm

Starter Jet

40

Choke

Manual Choke

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4
Engine
GENERAL PRECAUTIONS
STANDARD OPERATING PROCEDURE
BOLTS TIGHTENING SEQUENCE
LUBRICATION CIRCUIT
TIGHTENING TORQUE
SPECIAL TOOLS - ENGINE

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GENERAL PRECAUTIONS
General precautions to be taken while opening, assembling & storage of engine parts.
Battery Ground
Before completing any service on the motorcycle, disconnect the
battery cables from the battery to prevent the engine from accidentally
turning over. Disconnect the ground cable (-) first and then the positive
(+). When completed with the service, first connect the positive (+) cable
to the positive (+) terminal of the battery then the negative (-) cable to
the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible
sharp edges on the parts.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign
materials entering into sealed areas during vehicle disassembly can cause
excessive wear and decrease performance of the vehicle.

Arrangement and Cleaning of Removed Parts

Use engine parts handling trays for storage of engine parts.

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GENERAL PRECAUTIONS
Storage of Removed Parts
After all the parts including subassembly parts have been cleaned, store
the parts in a clean area. Put a clean cloth or plastic sheet over the parts
to protect from any foreign materials that may collect before reassembly.

Inspection

Visual Inspection of Removed Parts

Reuse of worn or damaged parts may lead to serious accident. Visually

inspect removed parts for corrosion, discoloration, or other damage. Refer
to the appropriate sections of this manual for service limits on individual
parts. Replace the parts if any damage has been found or if the part is
beyond its service limit.

Replacement Parts
Replacement parts must be BAJAJ genuine or recommended by BAJAJ.
Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter pins must be
replaced with new ones whenever disassembled.

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GENERAL PRECAUTIONS
Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start
them all in their holes and tighten them to a snug fit. Then tighten them
according to the specified sequence to prevent case warpage or deformation
which can lead to malfunction. Conversely when loosening the bolts, nuts or
screws, first loosen all of them by about a quarter turn and then remove
them.

Tightening
Sequence

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious
damage. Tighten fasteners to the specified torque using a good quality
torque wrench.

Force
Use common sense during disassembly and assembly, excessive force can
cause expensive or hard to repair damage. When necessary, remove screws
that have a non-permanent locking agent applied using an impact driver. Use
a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings after
disassembly can reduce sealing performance. Remove old gaskets and clean
the sealing surfaces throughly so that no gasket material or other material
remains. Install the new gaskets and replace the used O-rings when reassembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require liquid gasket or a non-permanent locking
agent, clean the surfaces so that so oil residue remains before applying
liquid gasket or non-permanent locking agent. Do not apply them
excessively. Excessive application can clog oil passages and cause serious
damage.

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GENERAL PRECAUTIONS
Bearing Installing
For items such as bearings or oil seals that must be pressed into place,
apply small amount of oil to the contact area. Be sure to maintain proper
alignment and use smooth movements when installing. use only bearing
driver set for bearing installation.

Ball Bearing And Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely
necessary. Replace with new ones whenever removed. Press bearings with
the manufacturer and size marks facing out. Press the bearing into place by
putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner and
outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary.
Replace with new ones whenever removed. Press new oil seals with
manufacture and size marks facing out. Make sure the seal is aligned
properly when installing.

Circlips, Cotter Pins

Replace old circlip with new one

Replace the circlips or cotter pins that were removed with new ones.
Take care not to open the clip excessively when installing to prevent
deformation.

Lubrication
It is most important to lubricate rotating or sliding parts during assembly
to minimize wear during initial operation. Apply the specific oil or grease as
specified ( Lithium RR-3).

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GENERAL PRECAUTIONS
Direction of Engine Rotation
When rotating the crankshaft by hand, the free play amount of rotating
direction will affect the adjustment. Rotate the crankshaft to positive
direction (clockwise viewed from clutch cover side).

Electrical Wires
A two-colour wire is identified first by the primary colour and then the
stripe colour. Unless instructed otherwise, electrical wires must be connected
to those of the same colour.

Instrument
Use a meter that has enough accuracy for an accurate measurement.
Read the manufacturer's instructions throughly before using the meter.
Incorrect values may lead to improper adjustments.

Ignition Switch Operation

To Lock the Steering: To lock the steering, turn the handle bar to the left or right. Push
& Rotate the key to LOCK position and remove the key.

To Unlock the Steering: To unlock steering, insert the key in steering cum ignition lock
Push & Rotate it clockwise to OFF (

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37

) or ON (

) position

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STANDARD OPERATING PROCEDURE

Cylinder block piston opening on vehicle, assembling & storage

Wash the vehicle as per SOP.

Remove the fuel tank as per the steps given in Air filter element cleaning SOP.

Clean chassis & wiring harness area which is below fuel tank so that dust will not
enter inside engine.

Remove :

2 Nuts

Remove :

silencer mounting bolt.

Remove :

RHS & LHS plug caps.

Remove :

Engine Top mounting bolts (3 nos) .

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STANDARD OPERATING PROCEDURE

Remove :
RHS HT coil.

Remove :
Cylinder head cover bolts (4 nos) in criss-cross pattern by 8 mm
spanner.

Remove :
Intake manifold by removing the mtg bolts.

Remove :
RHS spark plug.

Remove :
Spark plug sleeve by removing the grub screw.

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STANDARD OPERATING PROCEDURE

Take out the chain tensioner.

Align the timing marks.

Remove :

thermal sensor connection

By using the cam sprocket holder special tool remove the allen bolt & take out the
cam sprocket.

First remove the small bolt of cylinder head by 12 mm spanner.

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STANDARD OPERATING PROCEDURE

Remove :

cylinder head 4 bolts in criss-cross pattern.

Remove :

plate cylinder head.

Remove :

cylinder head assembly.

Take out the cylinder head gasket.

Take out the tight side chain guide.

Remove :

block and piston.

Replace :

the defective parts and do the

fitment in the reverse order of
removal SOP.

Piston rings orientation

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STANDARD OPERATING PROCEDURE

Crankshaft Removal & fitment
Remove :
the engine from vehicle.
cylinder head cover & cylinder head assembly.

Remove :
block & piston assembly.

Spit the crankcase & remove

crankshaft assembly.

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BOLTS TIGHTENING SEQUENCE

Cylinder head bolts

Big bolts

Small bolt

Remove small bolt first using 12 mm ring spanner.

Remove 4 nos. big bolts in criss-cross fashion using 12 mm ring spanner.
While fitting bolts follow sequence opposite to removal.

Tightening sequence - Clutch cover, Magneto cover, Crankcase joining

Clutch Cover to C'case RH Mtg.

Clutch Cover to C'case LH Mtg.

Clutch Cover to C'case RH Mtg.

Torque Value : 0.90 ~ 1.1 Kg-m

Torque Value : 0.90 ~ 1.1 Kg-m

Torque Value : 0.90 ~ 1.1 Kg-m

Magneto Cover to C'case LH Mtg.

Torque Value : 0.90 ~ 1.1 Kg-m

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BOLTS TIGHTENING SEQUENCE

Engine Foundation nut / bolts

2
6
5
3
5

1
4

All bolts should be pre-fit first (1 to 6)

Bolts on frame should be tightened first (1,2)
- 3.4 ~ 3.6 kgm.
- 1.8 ~ 2.2 Kgm.
Bolts on engine should be tightened then (3,4,5)
- 2.8 ~ 3.2 Kgm.
- 2.8 ~ 3.2 Kgm.
- 3.4 ~ 3.6 kgm.
Bolt on engine upper mount should be tightened finally
- 1.8 ~ 2.2 Kgm.

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PERIODIC MAINTENANCE SOP

SOP for Carburettor cleaning

Loosen drain screw and flush out petrol from the Carburetor bowl.
Then re-tighten the drain screw.
Loosen clamps of rubber duct.

Remove intake manifold bolts and take out carburetor along with manifold and
duct.
Remove Philips screws securing the Carburetor bowl to the Carburetor body.
Take out Carburetor bowl

Clean the Carburetor bowl by petrol & soft nylon brush.

Clean the Carburetor bowl by petrol & soft nylon brush.

Clean the carburettor jets by low pressure compressed air.

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PERIODIC MAINTENANCE SOP

Clean the carburettor passages by low pressure compressed air.

Refit carburettor bowl.

Tighten the screws of Carburetor bowl

Refit carburettor on vehicle & confirm no fuel leakage.

Inspect the jets for correct size.

Inspect float & float pin for any crack / damage, replace if found cracked /
damaged.

After fitment of carburettor on vehicle, route air breather pipe through guided path
provided on air filter assembly as shown in photograph.

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PERIODIC MAINTENANCE SOP

Volume Meter Screw Setting
Note :
Carburetor air screw & idling screw adjustment.

Adjust the idling screw by using tscho meter & take out panel.

Remove :

R H side panel by using vehicle for a .

Set the VC screw (2 + 1) to achieve CO% between 1.75 ~ 2.25 %

NOTES

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LUBRICATION CIRCUIT
Lubrication Circuit

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LUBRICATION CIRCUIT

Oil strainer

Oil pump inlet

INLET

Oil pump outlet

OUTLET

RH side crankcase oil passage

PASSAGE

Clutch cover Inlet hole of paper filter chamber

Paper filter

Clutch cover Outlet hole of paper filter chamber

RH side
crankcase
hole

Oil plunger

continued.....

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LUBRICATION CIRCUIT

Crankshaft drilled
hole - RH side

LH side
crankcase hole

Crank big end pin

Orifice

Con rod slots

LH crankcase
passage

Two fountains for

lubricating cylinder
piston parts

L.H. Crankcase
passage towards
nozzle

Piston Under
Cooling

Gap between bolt

and cylinder block
& cylinder head

Cylinder head hole

Small oil sump for lubricating various

cylinder head parts

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LUBRICATION CIRCUIT
Oil passage checking

Nozzle Oil Jet

Nozzle Oil Jet is press fitted in the crankcase L.H. and it is an important part of lubrication circuit. It sprays the oil, at pressure,
on the piston ribs to take out heat. Thus keeps piston relatively cool & protects it from seizure.

Checking & Cleaning SOP

Blow compressed air from the hole provided on Nozzle Oil Jet to clear the
crankcase passage (as shown arrow & photograph).

Pump oil through L.H. crankcase oil passage leading to Nozzle Oil Jet and
check whether oil comes out from hole provided on the Nozzle Oil Jet.

Check & Clean Nozzle Oil Jet whenever cylinder piston is seized / engine is
overhauled.

Do not use plier.

Do not repair by removing from crankcase.

Do not apply loctite in case Nozzle gets loose.

Clutch Cover Orifice Oil Jet Cleaning

Remove & clean orifice oil jet

friction plates are replaced.

by blowing compressed air whenever clutch

Apply one drop of loctite 243 to threads of orifice oil jet before refitting.

Orifice oil jet must be fitted such that its top surface is 0.5 mm down the
surface of clutch cover. Tightening torque 0.3 ~ 0.5 kgm.

Caution: Dont over tighten orifice oil jet.

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TIGHTENING TORQUE
Spark Plug

Cap Strainer (18 mm A/F Bolt)

Cap Oil Filter

0.5 Kgm

0.9 ~ 1.1 Kgm

0.9 ~ 1.1 Kgm

Silencer Mounting Nuts

Silencer Bracket Bolt

Engine Mounting Nut - Top

2.0 ~ 2.2 Kgm

3.5 Kgm

1.8 ~ 2.2 Kgm

Engine Mounting Nut - Rear

Engine Mounting Nut - Front

Clutch Cover Bolts

M8 1.8 ~ 2.2, M10 2.8 ~ 3.2 Kgm

3.4 ~ 3.6 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

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TIGHTENING TORQUE
Primary Gear Nut

Clutch Nut (L.H. Thread)

Clutch Spring Bolts

5.0 ~ 5.5 Kgm

5~5.5 Kgm

0.9~1.1Kgm

Drum / Cam Allen Bolt

Stud Inhibitor Nut

Oil Pump Mounting Screws

0.9 ~ 1.1 Kgm

0.9 ~ 1.1 Kgm

0.5 ~ 0.7 Kgm

Output Sprocket Bolts

Crankcase Joining Bolts (LH)

Crankcase Joining Bolts (RH)

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

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TIGHTENING TORQUE
Cylinder Head Cover Bolts

Chain Tensioner Mounting Bolts

Magneto Cover Bolts

0.9 ~ 1.1 Kgm

0.9 ~ 1.1 Kgm

0.9 ~ 1.1 Kgm

Bolt Kick Lever

Manifold Mounting Bolts

2.0 ~ 2.2 Kgm

0.9 ~ 1.1 Kgm

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SPECIAL TOOLS - ENGINE

Special Tools
Cam Sprocket Holder
Part No.

Application :

F41ZJZ47
For holding sprocket during
removal / refitting of Cam
sprocket allen bolt.

Magneto Rotor Holder

Part No.

Application :

F41ZJZ44
To hold rotor while loosening /
tightening its nut.

Magneto Rotor Puller

Part No.

Application :

F41ZJZ46
To pull out the rotor from
crankshaft assembly.

Primary Gear Holder

Part No.

Application :

F41AJA11
To hold primary and secondary
gear while loosening/tightening
the primary gear nut & special
nut securing clutch.

Socket for Clutch Nut

Part No.

Application :

F41ZJA54
To loosen / tighten special nut
securing clutch.

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SPECIAL TOOLS - ENGINE

Clutch Dismantling Tool
Part No.

Application :

F41AJA58
To dismantle & assembled
clutch of Discover DTS-Si kick
start as well as self start
vehicle.

Spark Plug Spanner

Part No.

Application :

37 1040 51
For removing and refitting
spark plug R.H. and L.H. side.

Valve Tappet Adjuster

Part No.

Application :

F41ZJW33
To hold the Valve Tappet screw
while adjusting tappet
clearance.

Rocker Shaft Remover

Part No.

Application :

37 10CS 22
To remove Rocker Shaft from
cylinder head.

Bearing Extractor
Part No.

Application :

37 1030 48
To Pull out main ball bearing
from crankshaft

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SPECIAL TOOLS - ENGINE

Adaptor & Valve Spring Compressor

Adaptor Part No. : 37 1031 08
Valve Spring Compressor : 37 1031 07
Application :

To assemble / dismantle intake,

exhaust valve by compressing
spring in cylinder head.

Drift Piston Pin

Part No.

Application :

37 1010 06
To remove refit piston pin.

Output Sprocket Holder

Part No.

Application :

37 1030 53
To hold the output sprocket
while removing sprocket allen
bolts.

Driver for Fitting Bushing Gear Shift Drum

Part No.

Application :

E6101100TE
To assemble Bushing with
PTFE Lining at parent hole of
crankcase RH for Gear Shift
Drum mounting.

Bearing Driver Set

Part No.

Application :

37 1030 61
Common bearing driver set for
fitting & removing bearings
from crankcase.

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SPECIAL TOOLS - ENGINE

NOTE
NOTES

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5
Vehicle
Standard Operating Procedure
Special Tools
Tightening Torq

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STANDARD OPERATING PROCEDURE

Accelerator Cable Routing
Route the cable from outside of rod joining lamp shade.

Route accelerator cable through PVC clamp located near RHS petrol tank
damper.
Connect the cable at carburettor end.

Route accelerator cable from out side the engine top mounting hanger as
shown in photograph.

Connect the accelerator cable at carburettor end as shown in photograph.

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STANDARD OPERATING PROCEDURE

Clutch Cable Routing
Route the clutch cable as shown in photograph.

Route the clutch cable through the clamp welded on chassis.

Route the clutch cable from outside the leg guard.

Route the clutch cable through clutch cable bracket mounted on clutch cover.

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STANDARD OPERATING PROCEDURE

Front Brake Cable Routing
Route front brake cable through clamp provided on LHS of front fender.

Route the front brake cable along with speedometer cable up to speedometer.

Speedometer Cable Routing

Route speedometer cable through clamp provided on LHS of front fender.

Route the speedometer cable with grommet through 'U' type clamp provided
on lower T.

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STANDARD OPERATING PROCEDURE

SOP for Front Fork Dust Seal & Oil Seal Replacement

Remove Front axle nut by 17mm ring spanner & take out front axle.

Loosen nut securing front brake

cable (14mm AF ) & take out the
front brake panel assembly.

Take out front wheel assembly.

Also check front axle freeness in
outer tube.

Remove Front fork top bolt by 17mm ring spanner.

Remove under bracket fork bolt by 13mm ring spanner

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STANDARD OPERATING PROCEDURE

Remove :
front fender by removing bolts (4 nos) by 12 mm ring spanner.

Take out front fork leg assembly from vehicle.

Remove :
front fork top nut by 27 mm double ended spanner.

Take out front fork spring

Take out fork oil & collect in measuring jar.

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STANDARD OPERATING PROCEDURE

Using cylinder piston holder hold cylinder piston , remove 6mm bolt by Allen key.

Remove Fork inner pipe along with

cylinder piston.
Remove dust seal & oil seal lock.
Do not use screw driver for removal
of dust seal.

Insert oil seal extraction special tool

in outer tube.

Oil Seal Extraction Tool :

Part No : 37 0042 92
(Old Part No - T4 1V24 07)
Applicable to Boxer / CT100 / Caliber
/ Platina / 1004G.

Tighten the special tool A nut by holding B mm nut so that special tool lug holds
the oil seal.

Tighten the special tool 30 mm nut by holding 12 mm nut to extract the oil seal.

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STANDARD OPERATING PROCEDURE

Take out front fork oil seal from special tool.

Before re-fitment, clean Fork leg assembly thoroughly with diesel.

Clean fork inner pipe & outer tube with clean cloth

Clean fork inner pipe.

Pour diesel in fork outer tube by closing other end with hand.
After pouring diesel, close both ends of fork outer tube with hands & shake outer
tube.

Nylon brush can be used for

removing burr / muck particles for
inner / outer tube.

Blow compressed air through form

inner pipe & fork outer tubes.

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STANDARD OPERATING PROCEDURE

Hold cylinder piston on cylinder piston holder as shown in photograph.

Assemble the oil lock cap & fork inner pipe.

Assembly the outer tube as shown in photograph.

Insert allen bolt from bottom side of outer tube & Tighten the allen bolt by 6mm
allen key.

Note :
Apply Loctite thread locker 243 on allen bolt.

Remove cylinder piston holder

photograph.

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& hold the fork leg assembly as shown in

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STANDARD OPERATING PROCEDURE

Insert oil seal by hand followed by

fitment of oil seal by using Oil seal
fitment tool as shown in
photograph. Make sure that oil seal
is properly fitted.

Note :
Never reuse oil seal.
Always replace the fork oil seal
along with dust seal of same
manufacturer.
Front fork oil seal fitment direction
should be as shown in photograph.

Oil Seal fitment punch

Part No : 37 1830 07

Replace oil seal fitment punch if nylon sleeve

found damaged

Assemble the Oil seal lock & dust seal.

Assemble front fork spring.

Refill correct qty (140 +/- 2.5 ml) of Bajaj Genuine fork oil (SAE10W20)
Tighten the front fork top nut by 27mm double ended spanner.

Assemble front fork leg assembly on vehicle

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STANDARD OPERATING PROCEDURE

Pre-fit Front fork top bolt by 17mm ring spanner followed by torque (3.0 ~ 3.2
Kg.m) application

Pre-fit under bracket fork bolt by 13mm ring spanner followed by torque (3.0 ~ 3.2
Kg.m) application.

Pre-fit Front fender bolts (4 nos) by 12 mm ring spanner followed by torque (2.0 ~
2.2 Kg.m) application

Tighten14 mm nut securing front brake cable & Refit the front brake panel in front
wheel .

Refit wheel on vehicle & pre-fit front axle nut by 17mm ring spanner followed by
torque (3.2 ~ 3.8 Kg.m) application .

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SPECIAL TOOLS - VEHICLE

Special Tools
Special Tool to Remove Oil Seal
Part No.

: 37 0042 92 (Old T4 1V24 07)

Application

To remove anti-friction & oil seal bush from

front fork outer pipe.

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.

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SPECIAL TOOLS - VEHICLE

Bearing Race Extractor
Part No.

: 37 1030 48

Application

To Pull out steering race from ' Fork

Holder bracket'

Under

Steering Cone Remover

Part No.

: 37 1805 06

Application

To remove steering cones

from frame.

NOTES

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TIGHTENING TORQUE
Front Axle Nut

Rear Axle Nut

Torque Rod Nut on Panel

4.5 ~ 5.5 Kgm

8 ~ 10 Kgm

3.0 ~ 3.2 Kgm

Rear Sprocket Mounting Nut

Handle Bar Holder Bolts

Fork Center Nut

3.2 ~ 3.8 Kgm

4.5 ~ 5 Kgm

4.5 ~ 5.0 Kgm

Steering Stem Nut Slotted

Fork Pipe Top Bolts

Fork Under Bracket Bolts

0.5 Kgm

3.0 ~ 3.2 Kgm

3.0 ~ 3.2 Kgm

RSA Mounting Nut (Upper)

Swing Arm Shaft

RSA Lower Bolt

3.0 ~ 3.2 Kgm

4.5 ~ 5.5 Kgm

3.0 ~ 3.2 Kgm

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TIGHTENING TORQUE
Rider Foot Rest Mounting

LH Stay Bolts

2.0 ~ 2.2 Kgm

2.0 ~ 2.2 Kgm

1.8 ~ 2.2 Kgm

RH Stay Bolts

Front Fork Oil Grade & Capacity

Rear sceeve Nut

Fork Oil Level

Front Fender Mounting Bolts

Grade :
SAE 10W20
Bajaj Genuine
Fork Oil
Quantity :
140 + 2.5 ml /
Fork Leg Assly
(Drain & Refill)

1.8 ~ 2.2 Kgm

8.0 Kgm

Side Stand Nut

2.8 ~ 3.2 Kgm

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NOTES
NOTES

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6
Electrical
Battery
Dos & Dont's
Checking Procedure
Electrical circuit Diagram

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BATTERY
Battery Technical Specification
For Self Start
Make

Exide

Voltage

12 Volt

Type

MF Battery

Capacity

5 Ah

Specific gravity of electrolyte

for initial filling of new battery

1.245 for use

above 100C

Initial charging duration

10 ~15 hrs

Charging current specification

0.5 Amp

Battery Charging Procedure

In case battery is discharged follow the procedure given below by using constant current. Battery Charger of 0.5 Amp.
charging current specification for 5 Ah battery
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 1.245. This is a confirmation check for a fully
charged battery.
Disconnect the battery from the changer.
Fit vent / filler plug strip firmly.
Reconnect battery terminals
Apply petroleum jelly to the battery terminals.

6 Channel Battery Charger

Make

Teknikraft

Model

12M6, with stand

Suitable for charging 6 batteries
(2.5Ah/5Ah/7Ah/9Ah)
Constant current type having 0.25 Amp.
/0.5 Amp./0.7 Amp./0.9 Amp. current
settings.

Electrical System : DC Type

Headlamp will get ON in Engine is running condition only.
Stator plate has 12 coils battery charging & pick up coil.

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DOS & DON'TS - GENERIC

Battery

Dos

Donts

Do hold the box.

Do not hold the wires.

Apply petroleum jelly to

poles / terminals.

Do not apply grease to

poles / terminals.

Use proper tools.

Do not hammer battery

terminals.

Use only distilled water

top up battery.

Always maintain electrolyte

level between maximum &
minimum level marks.

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Do not use mineral water,

drinking water to top up
battery.

Do not increase the level of

electrolyte beyond
maximum level mark
otherwise it would over flow
through Vent Mechanism &
damage other parts.

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DOS & DON'TS - GENERIC

Battery

Dos

Always charge battery by

constant current method
with the help of specified
charger.

Donts

Do not quick charge battery

by current higher than
specified current.
Constant voltage charging
method must be strictly
avoided.
Do not use local make
battery charger.

Check open circuit voltage

by multi meter.

Do not short circuits the

poles.

Always maintain battery top

cover clean and dry. Always
keep Vent Mechanism area
clean & clear.

Use hydrometer for

checking specific gravity

Do not short circuit the

leads.

Do not fit extra electrical

accessories (Tampering of
wiring for fitting buzzer etc.)
other wise wiring would get
short & battery would get
discharged. This will shorten
the life of battery.

Use midtronics battery

tester for checking battery
charge condition.

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DOS & DON'TS - GENERIC

HORN

Don'ts

Dos
Ensure that horn is firmly fitted on
frame

Ensure that horn is free from dust and

mud accumulation.

Do not apply pressurised water

jet directly on horn resonator.

Ensure that horn wires are intact.

Never adjust nut on horn cap

side & bracket end (back side)
as it will result in horn
malfunctioning & failure.

Ensure that horn switch button is

operating freely.

Do not remove silicon sealant

from adjustment screw as it will
result in water entry in horn.

Ensure that battery is fully charged.

Adjust horn by phillips screw driver

- without removing silicon sealant
from the adjustment screw.
- by rotating the screw in the
direction of arrow provided in the
screw.

Do not hit by mallet / screw

driver on horn resonator.

Ensure that resonator is not pressed

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

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DOS & DON'TS - GENERIC

IGNITION SYSTEM

Dos

Always install recommended capacity of battery on the bike.

Always replace spark plug by correct heat range plug.
Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler
gauge.
Replace spark plug at every 20,000 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 a n d
H.T. coil.
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
plug.
During periodic service make use of spark plug cleaning machine to clean
spark plug electrodes & check proper functioning of both the spark plugs.

Don'ts

Do not replace spark plug by non recommended one (different heat range).
Do not replace CDI by local make or different make.
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,
pliers etc.
Do not drive the vehicle without battery. Driving motorcycle in battery
removed condition could cause damage to electrical components like voltage
regulator because of no load Condition.

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DOS & DON'TS - GENERIC

LIGHTS

Dos

Check that all bulbs are firmly fitted in bulb holder.

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 Regulators 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.

Do not use Higher / Lower wattage Bulbs.
While washing Vehicle do not direct pressurized water jet on Head Light, Tail
Light,Indicators.
Do not ride on brakes.
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 and mud Accumulation.
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.

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.

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ELECTRICAL CHECKING PROCEDURE

Fuse Inspection (Capacity = 10 Amp)
Fuse

Inspect the fuse element.

Check continuity of fuse.
If it is blown out, replace.
If a fuse fails repeatedly, check the electrical system to determine the cause.
Replace it with a new fuse of proper amperage capacity.
If fuse is replaced by lower capacity fuse, it may lead to repetitive fuse blowing
problem.
Note : Never use higher capacity fuse.
Caution : When replacing a fuse be sure the new fuse matches the specified
fuse rating for that circuit. Installing that a fuse with a higher rating may cause
damage to wiring & components.

Front Brake Light Switch

Turn ON the ignition switch.
The brake light LED bank should glow brightly when the front brake lever is
pressed.
If it does not, check the front brake switch.

Brown

Blue

Continuity check by multimeter

Lever Pressed

Continuity is shown

Lever Released

No Continuity

Rear Brake Light Switch

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

Continuity is shown

Brake Pedal Released

No Continuity

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ELECTRICAL CHECKING PROCEDURE

Clutch Switch
The clutch switch has 3 wires. In neutral conditions, clutch switch
is in
non-operated condition closing C & NC terminals. In gear condition,
clutch switch is operated there by connecting C & NO terminals.
Meter Range

Light Green

Yellow / Green

Black /Yellow

OFF - Clutch
lever not pressed
ON - Clutch
lever pressed

Ignition Switch
Measuring & Testing Equipment : Multimeter

Brown

White

Black-White

Black-Yellow

OFF

ON

SOP :
Switch OFF Ignition key.
Disconnect Ignition switchs coupler.
Remove Ignition Switch from vehicle .
Check continuity between wires in ON & OFF position.
Standard Value :
Beep Sound & Continuity in ON position. No continuity in OFF position.
Note:

Dont use duplicate or non-OE Ignition key.

Never lubricate Ignition switch by oil / grease.

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ELECTRICAL CHECKING PROCEDURE

Fuel Gauge - Tank Unit

Empty Tank

Measuring & Testing Equipment : Multimeter

Meter Range

Connections
Meter +ve
Meter -ve
White / Yellow
Black / Yellow

200 Ohms

Standard Value
As per chart
given below

Standard Value :-

Full Tank

Fuel Level

Fuel Quantity (L)

Standard value in

Less than 2

100

Ohm
Empty Tank
Reserve

3.5

70

50

19.3
Half Tank

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.

Starter Relay
Measuring & Testing Equipment : Test Jig or Multimeter
Connection : Test Jig - Connect starter relay coupler to Test Jig & it show result as
OK / Defective
Meter Range

Connections
Meter +ve

200 Ohms

Starter Relay
Coil Red Yellow Wire

Standard Value

Meter -ve
Starter
Relay Coil
Black Wire

3.5 ~ 4.3 Ohms

SOP for checking starter relay :

Connect external 12V DC supply to starter relay coil terminals.
Click sound will be heard.
Set multimeter on continuity mode.
Connect multimeter at to relay contact terminals.
Continuity (beep sound) indicates starter relay is OK.

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ELECTRICAL CHECKING PROCEDURE

Engine Thermal Sensor
Measuring & Testing Equipment : Multimeter
Meter Range

Connections
Meter +ve

20 K Ohms

Black / White

Meter -ve

Earth / Ground

Standard Value
Engine
Temp (0C)

Resistance
K Ohms()

@ 10 0C

20.32 K +7%
10.5 K +7%
8.04 K +7%
5.52 K +7%
3.68 K +7%
2.69 K +7%

@ 25 C
@ 30 0C
@ 40 0C
@ 50 0C
@ 60 0C

Battery Charging Coil

Measuring & Testing Equipment : Multimeter

Connections

Meter Range
200 Ohms

Meter +ve

Meter -ve

Blue / White

Blue / White

Standard Value

0.9 ~ 1.2 Ohms

SOP :
Switch OFF engine.
Disconnect stator plate coupler
Connect multimeter between two Blue / White wires.
Check resistance value between Blue / White & Blue / White.

Pick-up Coil
Measuring & Testing Equipment : Multimeter
Meter Range
2 K Ohms

Connections
Meter +ve
White / Red

Standard Value

Meter -ve
Black / Yellow

180 ~ 220 Ohms

SOP :
Switch Off Ignition Key.
Disconnect Stator Plate Coupler
Connect multimeter between White / Red &
Black / Yellow wires.
Measure resistance

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ELECTRICAL CHECKING PROCEDURE

Starter Motor - Current Drawn
Measuring & Testing Equipment : DC Clamp Meter
Meter Range
200 DC A

Connections

Standard Value

Encircle clamp meter

transformer jaws around
thick Red wire of starter motor.

30 ~ 38 Amps
Spark Plug
Caps removed

SOP :

Switch ON Ignition Key & disconnect both spark plug caps

Select range & set clamp meter Zero reading.

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.

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ELECTRICAL CHECKING PROCEDURE

Starter Motor Armature
Measuring & Testing Equipment : Multimeter
Meter Range
Continuity
mode

Connections

Standard Value

Meter +ve

Meter -ve

Commutator segment

Shaft

No continuity
is shown

SOP :
Dismantle starter motor & take out Armature.
Check continuity between starter motor shaft & each segment on
commutator.
Replace armature if continuity is shown.

Starter Motor Armature

Measuring & Testing Equipment : Multimeter
Meter Range
Continuity
mode

Connections

Standard Value

Meter +ve

Meter -ve

Any segment
on commutator

Adjacent segment
on commutator

Continuity is
shown

SOP :
Dismantle starter motor & take out armature
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.

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ELECTRICAL CHECKING PROCEDURE

Horn
Measuring & Testing Equipment : DC Clamp Meter
Meter Range
200 DC A

Connections
Encircle clamp meter jaws
around Brown wire of horn

Standard Value
2.2 Amps

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

DC Charging Voltage Measurement

Use fully charged battery while measuring
Ensure

VB = 12.5 + 0.3 V before checking

VB = Battery open circuit terminal voltage with Battery terminals in
disconnected condition.

To measure the DC voltage; set the meter at 20V DC range. Connect the
meter +ve lead to Battery +ve terminal & meter -ve lead to battery -ve
terminal without disconnecting battery wires. Start the engine & set it at
1500 RPM. Measure the voltage with headlight switch in ON position.
Switch OFF Ignition key & disconnect the meter leads.

Meter Range

Meter Connections
+ve lead

20 V DC

Battery
+ve terminal

Specified at
4500 RPM

-ve lead
Battery
-ve terminal

14.4 + 0.3 Volts

Note : For DC voltage measurement connect multimeter in parallel circuit.

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ELECTRICAL CHECKING PROCEDURE

H. T. Coil Resistance Checking
Measuring & Testing Equipment : Multimeter
Measure the primary winding resistance as follows
Meter Range

Connections
Meter +ve

Standard Value

Meter -ve
0.3 ~ 0.5 Ohms at 250C

200 Ohms
White / Yellow Black / Yellow

Measure the secondary winding resistance as follows

Remove the plug cap by turning it counter clockwise.

Meter Range

Connections
Meter +ve

Standard Value

Meter -ve
4.5 ~ 5.5 K Ohms at 250C

20 K Ohms
White / Yellow Black / Yellow

If the value does not match as per, specifications replace the coil.
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

1.

Glows

Continuous
Bluish Spark

Ignition system is OK

2.

Glows

No Spark

HT Coil / Spark plug / Plug cap

may be defective

3.

Glows

Intermittent
Spark

HT Coil / Spark plug / Plug cap

may be defective

4.

Does not
Glow

No Spark

Check pick up coil & Battery

if found OK then replace CDI

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ELECTRICAL CHECKING PROCEDURE

CDI Assembly
Identification :
Case colour - Purpal
Coupler - Single black colour 12 pin.
Make - Varroc
Measuring & Testing Equipment : CDI / HT
Coil Tester.

SOP for CDI Checking

LHS

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.
Status of LED & Spark window indicates the result as below.
RHS
S.N.

LED Status

Spark Status

Conclusion

1.

Glows

Continuous
Bluish Spark

Ignition system is OK

2.

Glows

No Spark

HT Coil / Spark plug / Plug cap

may be defective

3.

Glows

Intermittent
Spark

HT Coil / Spark plug / Plug cap

may be defective

4.

Does not
Glow

No Spark

Check pick up coil & Exciter coil

if found OK then replace CDI

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ELECTRICAL CHECKING PROCEDURE

Read Switch : Maintenance
Check throttle lever movement by rotating it with hand. It should not be sticky in operation and should return back it self on
releasing.

Magnet should not touch with reed switch.

Gap between Magnet & Reed Switch should be

2 ~ 3 mm.

Movement of throttle lever with magnet assly and Reed Switch fitted should be free.

Reed Switch : Setting

Accelerator cable play: 2-3 mm by adjusting the Adjuster (A).
Protude stopper (B) of the throttle lever bracket must on idling screw (C) tip.

Reed Switch : Checking

Keep throttle at zero position. (Fig. 1).
On connecting multimeter to Reed Switch coupler it should show continuity.

Fig.1

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ELECTRICAL CHECKING PROCEDURE

When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of
Reed Switch (Fig. 2) multimeter should show discontinuity.

Fig.2
On De-acceleration, when of Reed Switch magnet re-coinsides with straight edge of fix
bracket of Reed Switch (Fig. 3) Multimeter should show continuity.

Fig.3

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ELECTRICAL CIRCUIT DIAGRAMS

IGNITION CIRCUIT

B/R
DC C.D.I

Pi
B

B/Y

REED
SWITCH

H.T.
COIL

IGNITION SWITCH

B/Y

Br/L

W/R

O O
N F
F

B/W

B/R

SPARK PLUG

[Link] SPARK PLUG

Br

Br/L

W/R

MAIN FUSE
(10 Amps.)
W/B

THERMAL
SENSOR

B/Y

W/R

B/Y

B/W

MAGNETO
R
CO
PU IL
LS
ER

BATTERY
12V-5Ah

STARTER MOTOR CIRCUIT

START
SWITCH

Br

R/Y

Br

R/Y

Lg
NEUTRAL
BULB
12V 2W

O O
N F
F
Br/L

Lg

Br

W/B

FUSE
(10 Amps.)

R/Y

Lg

CLUTCH
SWITCH
Y/G

Y/G

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CABLE ASSY.
BATTERY
TO EARTH

NEUTRAL
SWITCH

Lg

Y/G

STARTER
MOTOR
FUSE
(10 Amps.)

Br

Br/L

B/Y

Lg

B/Y

B/Y

IGNITION SWITCH

Br

93

BATTERY
12V-5Ah
STARTER RELAY
100A RATING

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ELECTRICAL CIRCUIT DIAGRAMS

R

CAPACITOR

B/Y
CONTROL SWITCH RH

L/W
L/W

R
R

V
Br

B/Y

Y/L
Y/L

EARTH
FRAME

B/Y

OFF

R
O O
N F
F

FUSE
(10 Amps.)
Br

IGNITION
SWITCH

DC. REGULATOR ASSLY

WITH CAPACITOR

B/Y

PO

ON

LIGHT
SWITCH

W
L/W

R/B

R/B

HI BEAM
INDICATOR
2W

LIGHTING CIRCUIT

B/Y

SPEEDOMETER
BULB 3W

Br/L

Br
W

B/Y

R/W

R/W

B/Y
R
TAIL LAMP
ASSY

R/B
B/Y

R/Y

FUSE
(10 Amps.)

R/B

Y/L

R/B

W/B

L/W

L/W

Y/L

Br

B/Y

R/Y

R/B

R/Y

R/Y

BATTERY
12V-5Ah
HI

LO

DIMMER
PASS
SWITCH SWITCH

BATTERY CHARGING CIRCUIT

CAPACITOR
W

DC. REGULATOR ASSLY

WITH CAPACITOR

B/Y

W
B/Y

EARTH-FRAME

L/W

L/W

L/W

W/B

MAIN FUSE
(10 Amps.)

L/W

POSITION
LAMP
12V-5W
2 Nos

B/Y

L/W

R/B
HEAD LAMP
ASSY / LAMP
12V-35/35W
HS1

L/W

B/Y

B/Y

BATTERY
CHARGING
COIL

DISCOVER 125 M TRAINING NOTES

94

BATTERY
12V-5Ah
R

INTERNATIONAL BUSINESS

ELECTRICAL CIRCUIT DIAGRAMS

BRAKE LAMP CIRCUIT

REAR BRAKE
SWITCH

Br

L
L

L
L

Br

Br
Br

FRONT BRAKE
SWITCH

Br

Br/L

B/Y

B/Y

TAIL
LAMP
ASSY

IGNITION SWITCH

O O
N F
F

W/B

FUSE
(10 Amps.)

Br/L

Br
EARTH
FRAME

FUSE
(10 Amps.)

+
BATTERY
12V-5Ah

SPEEDOMETER
ASSLY

HORN & NEUTRAL LIGHT CIRCUIT

Lg

Br

Br/L

Br

B/Y

Lg

O
F
F

B/Y

Br

EARTH FRAME

FUSE
(10 Amps.)
W/B

IGNITION SWITCH

O
N

HORN

NEUTRAL
SWITCH

HORN SWITCH
FUSE
(10 Amps.)

DISCOVER 125 M TRAINING NOTES

R
Br

Br/L

95

BATTERY
12V-5Ah

INTERNATIONAL BUSINESS

ELECTRICAL CIRCUIT DIAGRAMS

SIDE INDICATOR CIRCUIT

SIGNAL
LAMP
FRONT RH
LAMP
12V-10W

Gr

B/Y

B/Y

TURN
SIGNAL
RELAY

Gr

Gr

B/Y

B/Y

Br

Gr

SPEEDOMETER
ASSLY
IGNITION SWITCH

Gr

SIGNAL
LAMP
REAR RH
LAMP
12V-10W

B/Y

O O
N F
F
Br

Br/L

Gr

B/Y

FUSE
(10 Amps.)
W/B

Gr

SIGNAL
LAMP
FRONT LH
LAMP
12V-10W

B/Y

B/Y
R O L

TURN SIGNAL SWITCH

Br/L

R
BATTERY
12V-5Ah

Br
FUSE
(10 Amps.)

DISCOVER 125 M TRAINING NOTES

96

INTERNATIONAL BUSINESS

SIGNAL
LAMP
REAR LH
LAMP
12V-10W

NOTES

DISCOVER 125 M TRAINING NOTES

97

INTERNATIONAL BUSINESS

M OT O RCY C L E S

Baja Auto Limited

Akurdi Pune 411035 India
Tel
+91 20 27472851
Fax
+91 20 27407385
[Link]
CIN L65993PN2007PLC130076