38 Manual de Servicio Discover 125 UG Training Notes PDF

Training Notes
The Training Notes are a comprehensive

training guide on service and
maintenance operations and procedu res
to be followed by service personnel
at authorised service centres and
dealerships whilst attending to the
Bajaj Discover125-UG.The Training Note
covers standard workshop procedures
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.: 71112879, REV. 00, March 2018
CIN L65993PN2007PLC130076 © Bajaj Auto Limited, 11th SEPT 2012.
Contents
I Read ..... I Learn 01
CHAPTER 1 Identification 02
Salient Features 03
Technical Specification 06
Pre-Delivery Inspection Check List 08
Periodic Maintenance & Lubrication Chart 10
Fuel System 13
CHAPTER 2 Carburettor Specifications 14
Overview of Fuel System 15
Secondary Air Induction (SAI) System 16
Evaporative Emission System 18
Tune-up for Optimum Mileage 19
Engine & Transmission 21

CHAPTER 3 Special Tools 22
Engine Removal from Frame 25
Engine Dismantling & Assembling 27
Service Limits 38
Tightening Torque 40
Engine Lubrication Flow of Oil 42
Dos & Don’ts 44
Vehicle (Frame) 46
CHAPTER 4 Special Tools 47
Service Limits 49
Tightening Torques 50
Dos & Don’ts 51
Electricals 53
CHAPTER 5 Battery Specifications 54
Electrical Checking Procedure 55
Important SOP 61
Dos & Don’ts 67
Electrical Wiring Diagrams 68
Key Learning Points
Understanding the Complete Anatomy of

the Vehicle
Technical Specifications and Performance

Parameters
Briefing and Educating the Customer on

Appropriate Riding and Usage Discipline,
and Routine Maintenance
CHAPTER 1
I Read ..... I Learn

Identification
Salient Features
Technical Specifications
Pre-Delivery Inspection Check List
Periodic Maintenance & Lubrication Chart
Bajaj Discover 125 UG Training Notes

1
1 I Read ..... I Learn
Identification
Chassis Number & Engine Number Location
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)
Speedometer Details
1. Speedometer:
Vehicle speed will be displayed in speedometer in Km / Hr.
2. Odometer :
The Odometer shows the total distance that the vehicle has covered.
Odometer can not be reset to ‘Zero’.
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. Fuel Level Indicator:
It shows fuel level in fuel tank.
6. Low Fuel Indicator :
It blinks incase of low fuel level (1 bar or less).
7. Hi Beam Indicator:
When Headlight is ‘ON’ & Hi beam is selected, Hi beam indicator will
glow.
8. Low Battery Indicator :
It indicates battery needs charging.
9. Bajaj Logo:
Bajaj logo flying ‘B’ continuously glow.
10. Service Reminder:
If the Odometer reading reaches below values : 450 Km, 4450 Km, 9450
Km, 14450 Km & so on after every 5000 Km up to 999450 Km (If prior
reset is not done). It should continue the same sequence above even
after roll over.
11. Side Stand :
Active Low (Vin < 0.5V)
Bajaj Auto International Business
2
Salient Features
ENGINE:
Features :-
• 124.5 cc Engine.
• 4 stroke, Air cooled, Single Cylinder, SOHC, DTS-I
• 11 Ps @ 7500 rpm & 11 Nm @ 5500 rpm
• Cellulose-based clutch for easy gear shifts.
Benefits :-
• Most fuel efficient bike.
• Better drive-ability and the beat fuel economy.
• Easy maneuverability during traffic.
BRAKES & TYRES:

Features :-
• 200 mm dia front brake disc and 130 mm dia rear brake drum.
Benefits :-
• Spider mug-wheels
FRAME:
Features :-
• Telescopic front fork with anti-friction bush & 140 mm stroke.
• Nitrox rear suspension with 120 mm wheel travel.
Benefits :-
• 16% longer travel vs. competition bike.
• Superior comfort, even on bad roads.

3
Salient Features
STYLE & COMFORT:
Features :-
• Youthful Styling.
• Dual texture seat fabric with stitch line.
• Modern Side Panels.
• Enhanced Comfort.
• Dual-textured seat with stitch-line.
• Enhanced cushion for greater riding comfort.
ELECTRICALS:
Features :-
• DC Head Lamp with 12V, 35/35W, (Halogen)
• Double LED DRL headlamps
• Textured Tail-lamp Bezel
• 12V-5Ah MF Type (Electric Start)
Benefits :-
• Bold, head-turner.
• ‘Invented Horns’, makes a statement even from a distance.
• Lower battery power consumption, leading to higher mileage.

4
Salient Features
ELECTRICALS:
Features :-
• Full Function Digital Instrument Cluster.
• Digital speedometer for accurate speed reading.
• Back-lit Display adds style and ease of reading.

5
Engine & Transmission
Type : 4 stroke, Air cooled, Single Cylinder, SOHC,
DTS-I
No. of cylinders : Single
Bore : 52.0 mm
Stroke : 58.60 mm
Engine displacement : 124.5 cc
Compression ratio : 9.8 : 1
Idling speed : 1400 ± 100 in warm condition
Max. net power : 11 Ps @ 7500 rpm
Max. net torque : 11 Nm @ 5500 rpm
Ignition system : Load based CDI controlled
Carburettor : VM20 (UCAL)
Spark plug : Champion PRZ9HC & BOSCH UR4AC (Resistive)
Spark plug gap : 0.7 to 0.8 mm.
Lubrication : Wet sump, Forced lubrication
Primary resuction : 3.57 : 1 (75/21)
Gear ratios 1st Gear : 2.83 : 1 (34/12)
2nd Gear : 1.824 : 1 (31/17)
3rd Gear : 1.333 : 1 (28/21)
4th Gear : 1.087 : 1 (25/23)
5th Gear : 0.909 : 1 (20/22)
Final drive ration : 3.0 : 1 (42/14)
Transmission : 5 Speed Constant mesh (1D 4UP)
Chassis & Body

Frame Type : Semi double cradle frame
Suspension Front : 140 mm Fork travel, Telescopic
Rear : 120 mm Rear Wheel travel, Nitrox (Gas filled)
Brakes Front : Hydraulic operated, 200 mm dia. disc
Rear : Mechanically expanding shoes, 110 mm dia. drum
Tyres Front : 2.75 X 17
Rear : 100/90- 17
Tyre Pressure Front : 1.75 Kg/cm2 (25 PSI)
Rear (Solo) : 2.00 Kg/cm2 (28.5 PSI)
Rear (with Pillion) : 2.25 Kg/cm2 (32 PSI)
Rims Front : 1.4 X 17" Die Cast Aluminium Alloy Wheel
Rear : 2.15 X 17" Die cast Aluminium Alloy Wheel
Fuel Tank Capacity : 8.0 Liters
Usable Reserve : 1.5 Liters
Unusable Reserve : 0.8 Liters
Speedometer : Digital

6
Electricals
System : 12 Volt (DC)
Battery : 12V-5Ah MF Type
Head Lamp : 12V, 35W / 35W, HS-1 (Halogen),Blue ting DRL
Watts 5.4 & Position lamp is 0.4 Watt.
Stop / Tail Lamp : 12V, 5W / 21 W
Side Indicator Lamp : 12V, 10W (4 Nos. - RY 10W)
Position Lamp : DRL
Rear No. Plate Lamp : 12V, 3W
Speedometer Lamp : LED
Neutral Indicator : LED
Turn Signal Indicator : LED
Hi-beam Indicator : LED
Reserve indicator : LCD
Fuel Gauge : LCD
Horn : 12V, DC
Dimensions
Length : 2035 mm
Width : 760 mm
Height : 1085 mm
Wheel Base : 1305 mm
Saddle height : 805 mm
Turning Circle Radius : 2100 mm (min)
Ground Clearance : 165 mm
Weights
Vehicle Kerb Weight : 122 Kg.
Gross Vehicle Weight : 252 Kg.
Engine Oil
Grade : 20W50 API SL / JASO MA
Drain & Refill : 1000 ml
Overhaul : 1100 ml
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.

7
Pre Delivery Inspection Check List
1. Check points before starting of the vehicle

Check & correct the below check points before starting the vehicle
? If Ok
To Check Check for
X If Not Ok
Engine oil Oil level between lower & upper mark / Top up if required
Fuel tank / pipes No leakage / Correct fitment
Mirror Fitment & adjustment to ensure clear rear view
Lock Operation Steering cum Ignition lock, LH side cover lock, Petrol tank cap lock
Check battery Terminal voltage. Fully charged battery voltage should be >
Battery 12.4 V DC. Charge battery if required using recommended battery charger.
Tightness of battery terminals / cables / Petroleum Jelly application
Front: 1.75 kg/cm (25.0 psi)
Tyre Pressure
Rear: 2.25 kg/cm (32.0 psi)
Front brake cable free play 4 ~ 5 mm
Brakes
Rear brake pedal free play 20 ~ 25 mm
Clutch cable Free play 2 ~ 3 mm
Slackness 25 ~ 30 mm
Drive chain Equal marking of chain adjusters on both side
No touching to chain case after adjustment.
? If Ok
Ço Check Check for
X If Not Ok
Engine foundation bolts - Front 1.8 to 2.2 Kg.m
Fasteners (Check torque) Engine foundation bolts - Rear 2.8 to 3.2 Kg.m
Recommended torque wrench
Engine foundation bolts - Top 1.8 to 2.2 Kg.m
to be used for applying torque
on nut - bolts as mentioned in Front Axle Nut 4.5.0 to 5.5 Kg.m
PDI check sheet using Rear Axle Nut 8.0 to 10.0 Kg.m
reference torque chart as Front Fork top bolts 3.0 to 3.2 Kg.m
given.
Front Fork under bracket bolts 3.0 to 3.2 Kg.m
However, if any major parts are
required to be removed (Except RSA mounting nut (Upper) 3.0 to 3.2 Kg.m
side cover & seat) for RSA mounting nut (Lower) 2.8 to 3.2 Kg.m
accessibility of torque wrench, in Swing arm shaft nut 4.5 to 5.5 Kg.m
those cases the tightness can
Rider Foot Rest Mounting 1.8 to 2.2 Kg.m
be ensured using open end /
ring spanner / box type spanner
as applicable without removing LH & RH Pillion stay Bolts 1.8 to 2.2 Kg.m
those major parts

8
Pre Delivery Inspection Check List
2. Check points during / after starting the vehicle
Check & correct the below check points during / after starting the vehicle
RH & LH control switch, ignition switch, clutch switch & brake switch (Front &
Switch operation
Rear)
Horn Ensure no distorted sound
All Bulbs working Headlight, Tail / Stop lamp, Side indicators, Speedo bulbs, Number plate bulb
Speedometer Working of speedometer, Odometer, Fuel gauge.
(As applicable) Working of all signal indicators icons (Neutral, Turn signal, High beam)
Headlamps Focus confirmation
3. Check points during Test ride
Check & correct the below check points during Test ride
Gear shifting Smooth operation
Throttle response
Drive-ability
Brake effectiveness - Front & Rear
Engine noise No abnormal noise
Smooth working by pumping movement & smooth operation (No play / No
Front fork / steering
Sticky movement)
Oil leakages Specify source of leakages & rectify if any.
4. Idling RPM / CO%
Check & correct the below check points in engine warm condition
Idling RPM
SAI connected – 1350 to 1450 rpm (@ 60°C)
(Engine warm up
SAI disconnected – 1300 to 1400 rpm (@ 60°C)
condition)
SAI connected - < 1% (@ 60°C at idling rpm)
CO% Check
SAI disconnected – 4.0% to 5.0% (@ 60°C at idling rpm)
5. Visual inspection for dent, scratches, rust ...
6. Clean the vehicle thoroughly before delivery to customer.

9

Recommended Frequency
Service 1st 2nd 3rd 4th 5th 6th 7th
Sr
PM Check Point 500 4500 9500 14500 19500 24500 29500 Remark
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Ensure to prevent water
entry in Petrol tank,
1 Servicing with water wash
     Silencer & electrical parts.
Use caustic free detergent
for washing.
"BGO DTS-i 10W30 for 100cc
Engine oil (Bajaj DTSi 10000 oil) & Top Top Top
2 C,R R R R R models. BGO DTS-i 20W50 for
engine oil filter* Up Up Up models above 125cc. "
3 Oil strainer, Body centrifugal filter** CL CL CL CL CL Oil strainer cleaning at the time
of oil change.
Clean body centrifugal filter at

1st free service & at 20,000 kms
Use recommended molycote

4 Starter Clutch (Dry Type)** L L L L L L L grease
5 Spark plug CL,A,R CL,A CL,A R

Foam & Paper as applicable.O ring
6 Air Cleaner Element *** & Cover "O" Ring CL,R CL CL CL R CL CL R check at every service & Replace if
cut/damaged
7 In line paper filter or Fuel cock paper filter R R R
8 Fuel cock sediment bowl cleaning CL CL CL
9 Carburetor rubber duct C,R C,R Check & replace if required
10 Fuel pipe C,R C C C R C C R
11 Valve tappet clearance C,A C,A C,A C,A C,A C,A C,A C,A
• During 1st free service : Use lint

free cloth for cleaning & SAE 90 oil
for lubrication without removing
from vehicle.
(If chain is excessively dirty, then
chain has to be removed, cleaned
Non-Sealed drive chain cleaning & CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, using diesel & lubricated using
12 CL,L,A molten IOC servo compound
lubrication A A A A A A A
chain grease.)
• During all other services:

Remove, clean using diesel &
lubricated using molten chain
grease.
• During regular service use OKS

spray for chain cleaning, without
removing chain from vehicle.
CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L,
13 Sealed drive chain cleaning & lubrication CL,L,A • If chain is excessively dirty, then
A A A A A A A chain has to be cleaned by removing
from vehicle.
(Customer to apply OKS chain lube
spray at every 500 Kms)
C C C C C C C C Replace if damaged
14 Engine air breather tube
15 Silencer drain hole cleaning CL CL CL CL CL CL CL
CL CL CL CL CL CL CL
16 Silencer tail pipe cleaning **
Brake lining or pad wear & lubricate brake C,L,R C C,L,R C,L,R R C,L,R C,L,R R Replace brake shoe/pads at
17 every 15,000 kms
cam & pivot pin** Check pad wear indicator

10

Recommended Frequency
Service 1st 2nd 3rd 4th 5th 6th 7th
Sr
PM Check Point 500 4500 9500 14500 19500 24500 29500 Remark
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Use recommended
18 Brake fluid level ** - top up / replace C,A,R C,A R DOT 3/4 brake fluid
Disc brake assembly–-check functionality,

19 C C C C Replace if damaged
leakage or any other damage
20 All cables & rear brake pedal - free play C,A C,A C,A C,A C,A C,A C,A C,A
Not applicable for VRLA
21 Battery electrolyte level , specific gravity C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T batteries
Wiring harness & battery connection - C,A,

22 C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness T
Ignition switch barrel cleaning & handle bar Use recommended Wd40
23 C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL spray
control switches contacts cleaning
24 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
Check & replace if

Steering stem bearing *** & cap steering C,CL, C,CL, C,CL,
25 C,CL damaged.Use HP Lithon
bearing (Plastic)** L,R L,R L,R RR3 grease for lubrication
Use recommended AP
26 Main stand & side stand pin ** CL,L CL,L CL,L CL,L grease
Not applicable in case of

27 Swing arm pivot pin (For non silent bush)** L L L L L L L needle roller bearing
28 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
29 Engine foundation silent bushes ** C C C Replace if damaged
General lubrication - clutch lever, front brake Use recommended AP

30 L L L L L L L L grease
lever, kick lever
31 Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
Use recommended 'Ready

to Use coolant'.Replace at
32 Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A R every 30000 Kms or 2
years (Whichever occurs
earlier)
33 Coolant hose damage / clamps / leakage ** C C C C C C C Check & replace if required
34 Radiator fins ** C C C C C C C Check & replace if required
35 Spoke tightening ** - Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
Front fork dust seal area & inner pipe Applicable for front fork
36 CL CL CL CL CL CL CL with rubber bellow
cleaning**
SAI system / EVAP hoses - Check functionality,
37 leakage or any other damage**
C, R C, R C, R C, R C, R C, R C, R C, R Replace if cut / damaged
38 Pillion foot rest hinge lubrication** L L L L L L L L Use RR 3 Grease
39 EVAP Y connector drain tube CL CL CL CL CL CL CL CL
* It is strongly recommended to use only Bajaj genuine oil, in case of any other engine oil of same specification is used the would be every 5000 kms
** As applicable to model
*** more frequent cleaning is required while driving in dusty environment
C: Check, A: Adjust, CL: Clean, R: Replace, T: Tighten, L: Lubricate
Note :- Periodic parts / lubricants as per periodic maintenance & Lubrication chart are mandatory & the same is chargeable to customer

11
Notes

12
Key Learning Points
Understanding of
Carburettor
Understanding of CO checking procedure

and Tune-up for optimum mileage
Understanding of SAI system
CHAPTER 2
Fuel System
Carburettor Specifications
Overview of Fuel System
Secondary Air Induction (SAI) System
Evaporative Emission System
Tune-up for Optimum Mileage

13
2 Fuel System
Carburettor Specifications
Item Specification
Make UCAL
Type UVD 20
VC Screw Setting 2.5± 1.5
Idling Speed 1400 ± 100 rpm
Main Jet 102.5
Jet Needle ‘e’ clip Position Single
Jet Needle Marking JN
Pilot Jet 17.5
Float Height 14.4 mm
Starter Jet 30
Throttle valve mark CA
Choke Manual

14
Fuel System
Overview of Fuel System
Hose to Intake SAI
Carburettor
Air Filter
Intake Manifold
Breather Tube
Hose to Manifold
SAI System
Drain Tube

15
2 Fuel System

Hose Pipe Connecting
SAI to Cylinder Head

Intake Manifold to SAI

Air Filter to SAI
SAI Unit
Secondary Air Induction (SAI) System :
Engine vacuum
pulling diaphragm
Air Inlet
Air Inlet
Vaccum In
No fresh air
Air outlet supply to
Exhaust manifold
Air outlet
ON Acceleration ON De-acceleration
Function:
To reduce the concentration of exhaust gases in exhaust system thus reducing the emission.
Construction:
• Consists of diaphragm valve and reed valve.
• Connected to air filter assembly, exhaust valve passage in the cylinder head and intake manifold.

16
Fuel System

Working:
On Acceleration
During the exhaust phase of the engines operation, exhaust gases enter the exhaust system at high velocity.
This Causes a drop in the pressure which enables the reed valve to open.
• Fresh and filtered air from air filter is inducted in the exhaust passage, just after the valve.
• The oxygen in the air enables ‘CO’ to further oxidize and convert into ‘CO2’ & HC into H2O. Thus CO
(%) & HC (ppm) at the Silencer tail end is reduced. This results in reduction of exhaust emission.
• The read valve opening and closing is based on pressure in the exhaust system.
On De-acceleration
When throttle is closed, some amount of fuel particles get discharged into the exhaust. If air is injected into
the Exhaust system at this point of time, these fuel particles can get ignited. This causes after burn or
misfiring sound in the exhaust system.
• To avoid this, air flow is momentarily stopped by closure of the diaphragm in the injection valve during de-
acceleration.
How Diaphragm Works:

• Diaphragm is connected to inlet manifold.
• On de-acceleration vacuum increases in the manifold.
• This pulls the diaphragm against the spring tension and restricts the air flow.
• Once the vacuum reduces the diaphragm opens due to spring tension and air starts flowing.
Advantages:
• Reduced emission of Carbon Monoxide & Hydro Carbons.
• Environment friendly vehicle.

17
2 Fuel System
Evaporative Emission System

Working:
EVAP is a evaporative Emission system which prevents fuel vapours going to atmosphere by converting fuel
vapours into fuel droplets through canister.
These fuel droplets are feed to engine through one way mechanically operated Purge valve.
In Port
Tank Port
Purge
Port
Drain Port
Out Port
Breather
Port
Function of canister: Purge valve:

The canister is filled with about a pound or two of activated Purge valve is one way valve which controls the
charcoal. The charcoal acts like a sponge and absorbs and flow of HC vapours from canister to carburettor.
stores fuel vapours. The vapours are stored in the canister
until the engine is started, warm and being driven.
Working Principle of EVAP System:

A passage is provided from tank to canister through tank cap. This passage aids in breathing as well as passing
HC vapours to canister. Canister acts as storage for these vapours and these vapours are purged to engine
through purge valve due to manifold suction in vehicle.

18
Fuel System
Tune-up for Optimum Mileage

Engine Tune up Other Mandatory Checks
FOAM FILTER: a. Ensure no fuel leakage through fuel
• Clean at Every : cock, fuel lines.
5000 Kms. b. Ensure free rotation of both wheels.
• Replace at Every :
c. Ensure correct tyre pressure -
15,000 Kms.
Front wheel : 25 PSI,
Rear (Solo) : 28.5 PSI
Rear (Pillion) : 32 PSI
c. Check and confirm proper functioning

CARBURATTOR of spark plug.
• Idling : 1400 + 100 rpm. d. Use of recommended grade of bajaj
• Jet Needle Clip Position: genuine oil & engine oil level between
MIN & MAX level.
Single groove
• VC Screw Setting : e. Set control cable free play:
2.5 ± 1.5 • Clutch lever 2~3 mm.
• Rear brake pedal 20 ~ 25 mm.
f. Chain slackness : 25 ~ 30 mm.
SPARK PLUG :
• Spark Plug Gap :

0.7 ~ 0.8 mm.
• Replace at Every :
0.7 to 30,000 Kms
0.8 mm
COMPRESSION PRESSURE
• Standard :
12 to 13 Kg/cm2
• Service Limit :
9.5 Kg/cm2
TAPPET CLEARANCE
• Inlet Valve :
0.05 ~ 0.07 mm
• Exhaust Valve :
0.10 ~ 0.12 mm

19
2 Fuel System
Notes

20
Key Learning Points
Appropriate torque application for various

engine component
Standard operating procedure for

engine dismantling
Understanding of lubrication path

in engine
CHAPTER 3

Special Tools
Engine Removal from Frame
Engine Dismantling & Assembling
Service Limits
Tightening Torque
Engine Lubrication Flow of Oil
Dos & Don’ts

21
3 Engine & Transmission
Special Tools
Cam Sprocket Holder
Part No. : 37 10DH 36
Application : For holding cap sprocket,

during removal & re-fitment.
LH Spark plug removal
Part No. : 37 2540 34
Application : For removing LH spark

plug from cylinder head.
Magneto Rotor Puller (For Self Start)
Part No. : F4 1ZJZ 10
Application : To pull out the rotor from

crankshaft assembly.
Adapter & Valve Spring Compressor
Part No. : Adapter : 37 1031 08

Part No. : Valve Spring Compressor :
37 1031 07
Application : To assemble / dismantle

intake, exhaust valve by compressing
spring in cylinder head.
Rocker Shaft Remover
Part No. : 37 10DH 35
Application : To remove Rocker Shaft

from cylinder head.

22
Special Tools
Bearing Driver Set
Part No. : 37 1030 61
Application : For pressing bearings in

crankcase.
Input Shaft Bearing Extractor
Part No. : 37 10DJ 01
Application : To Pull out main ball

bearing from crankshaft, steering races
from fork under holder bracket.
RH Spark Plug Removal Tool
Part No. : 37 1040 51
Application : For removing RH spark

plug.
Piston Pin Removal Tool
Part No. : 37 1010 06
Application : For removing piston pin

from piston.
Engine Temperature Sensor Removal

Tool
Part No. : 37 1043 46
Application : For removing & fitting

Engine temperature sensor.

23
Special Tools
Primary Gear Holder
Part No. : F4 1AJA 11
Application : To hold primary &

secondary gear while loosening /
tightening the primary gear nut and
special nut securing clutch.
Valve Tappet Adjuster
Part No. : F4 1ZJW 33
Application : To hold the Valve Tappet

screw while adjusting tappet clearance.
Output Sprocket Holder
Part No. : 37 1030 53
Application : To hold the output

sprocket while removing sprocket allen
bolts.

24

Pull out :
• Rubber cap of thermal sensor.
Remove :
• Ring terminal using 8 mm
spanner.
• Carburetor assembly.
Remove
• Stator plate coupler
connections.
• Neutral switch connection.
• Remove spark plug caps.
Pull out :
• Starter motor wire rubber cap.
Remove :
• Starter motor connection.
Remove :
• Kick lever mounting bolt.
• Take out kick lever.

25

Remove :
• Clutch cable mounting bolts.
• Take out bracket clutch cable.
• Earthing connection.
Pull out :
• SAI hose clips.
Take out
• SAI hose from intake manifold.
• Engine breather pipe from
cylinder head.
Remove
• Silencer mounting front bolt.
Remove
• Engine mounting rear bottom.
• Take out engine assymbly.

26

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.

27

Remove
• Cam sprocket bolt
Skill Tip: Using Cam Sprocket

Holder Special tool to hold the cam
sprocket
Remove
• Cam sprocket
• Cam sprocket collar
Remove
• RH & LH side spark plug by
using spark plug removing tool.
Remove
• Spark plug sleeve using
Note : Do not pull spark plug sleeve by

plier, to avoid any damage on it.
Remove
• Cylinder head bolts.
1st

28

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.
Skill Tip: Using Rocker Shaft

Removal Special tool to remove
the Rocker Arm Shaft.
Remove
• Intake & Exhaust valves along
with -
- Retainer
- Valve spring
- Oil seal
- Valve spring seat using valve
spring compressor.
• Take out cam shaft assembly.
Skill Tip: Using Adaptor & Valve

Spring Compressor Special tool to
compress the valve springs.
Remove
• Dowels on cylinder block.
• Cylinder head gasket.

29

Remove
• Chain guide.
• Cylinder block.
Remove
• Dowels.
• Cylinder block gasket.
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

30

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.
Skill Tip:
1. Using Primary Gear Holder Special tool to hold the primary gear.
2. Using Clutch Nut removing tool to loosen / tighten special nut securing clutch.
Remove
• Clutch nut
• Belleville washer
• Plain washer
Remove
• Clutch stack complete
• Plain washer

31

Remove
• Kick return spring
• Take out kick shaft assembly.
Remove
• Lever comp gear shift
Remove
• 4 bolts
• 4 springs
• Clutch holder
• Clutch hub
• Friction plates
• Steel / pressure plates (4 Nos)
• Wheel clutch
Skill tip: Using Clutch Dismantling

tool to dismantle & assembled
clutch.
Remove
• Inhibitor Assembly
• Guide gear shift
• Take out guide gear shift

32

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

Remove
• Magneto cover bolts

33

Remove
• Stator plate
• Pick up coil screws
Remove
• Dowels
• Take out magneto cover
gasket.
Remove
• Gear starter clutch locking plate
screw
• Rotor bolt
• Plain washer
Remove
• Rotor
• Gear starter clutch
Remove
• Magneto rotor key
• Starter counter gear assembly
Skill Tip: Using Magneto Rotor

Puller Special tool to remove
magneto rotor from crankshaft.

34

Crankcase Splitting
Remove
• LH crankcase bolts
• RH crankcase bolts
• Put the engine on engine work

table
Remove
• RH crankcase
Remove
• Crankshaft
t• Fork shaft
• Input & output fork shaft
Remove
• Gear change drum
• Input fork & output fork

35

Remove
• Input & output gear shaft
assembly
• washer plain of input gear
shaft.
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.

36

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

37
Service Limits
Compression Pressure Valve Clearance Rocker Arm Shaft Dia.
Std. Limit 12.0 ~ 13.0 Kg/cm2 Inlet Exhaust Std. Limit 10.0
Std. Limit 0.05~0.07 0.10~0.12
Serv. Limit 9.5 Kg/cm2 Serv. Limit ---- ---- Serv. Limit 9.965
Cam Sprocket Root Diameter Cam Height Valve Stem Diameter
Std. Limit 68.0 Inlet Exhaust Inlet Exhaust

Std. Limit 18.071 18.104 Std. Limit 4.965~4.98 4.945~4.96
Serv. Limit 67.6 Serv. Limit 18.02 18.05 Serv. Limit 4.955 4.935
Valve Stem Bend Piston Ring End Gap Steel Plate Thickness
TOP SECOND OIL RING

Std. Limit 0.01
Std.Limit 0.1~0.25 0.15~0.3 0.2~0.7 Std. Limit 1.55 ~1.65
Serv. Limit > 0.01 replace Serv.Limit 0.5 0.6 1.0 Serv. Limit 1.5
Friction Plate Thickness Cam Chain 20 Links Length Cylinder Head Warp
20-link length
1st 2nd 21st

MEASURE THIS LENGTH
Std. Limit 2.95 ~ 3.05 Std. Limit 130.3 ~ 130.43 Std. Limit 0.03
Serv. Limit 2.75 Serv. Limit 131.06 Serv. Limit 0.05

38
Service Limits
Piston Diameter Cylinder Inside Diameter Piston Ring / Groove Clearn.
10mm
20mm
40mm
Std. TOP&SECOND OIL

51.958 ~ 51.972 Std. Limit 50 ~ 50.01
Limit
Std. Limit 0.025~0.060 0.04~0.010
Serv.
---- Serv. Limit ----
Limit Serv. Limit 0.15 0.16
Piston / Cylinder Clearance Valve Spring Free Length Clutch Spring Free Length
Std. Limit 0.028 ~ 0.052

Std. Limit 38.74 Std. Limit 44~46.4
Serv. Limit 0.1 Serv. Limit 37.5 Serv. Limit 43
Pressure Plate Warp Gear Shift Fork Guide Pin Dia. Shift Drum Groove Width
Std. Limit 0.1 Std. Limit 4.45 ~ 4.49 Std. Limit 4.55 ~ 4.70
Serv. Limit 0.2 Serv. Limit 4.40 Serv. Limit 4.75
ALL DIMENSIONS ARE IN MM

39
Tightening Torques
Cylinder Head Cover Bolts Cylinder Head Bolts Chain Tensioner Mounting Bolts
1.0 ~ 1.1 Kgm. M8 : 2.3 ~ 2.5 Kgm. 1.0 ~ 1.1 Kgm.
Output Sprocket Bolts Inhibitor Nut Stator Motor Mounting Nut
0.6 ~ 0.8 Kgm. 1.0 ~ 1.1 Kgm. 1.0 ~ 1.1 Kgm.
Clutch Cover Bolts Cap Oil Filter Cover Bolts Crankcase Joining Bolts
1.0 ~ 1.1 Kgm. 1.0 ~ 1.1 Kgm. 1.0 ~ 1.1 Kgm.
Oil Pump Screws Cam Sprocket Allen Bolt Magneto Cover Bolts
0.5 ~ 0.7 Kgm. 1.6 ~ 1.8 Kgm. 1.0 ~ 1.1 Kgm.
Clutch Nut (L.H. Thread) Magneto Rotor Mounting bolt Manifold Mounting Bolts
6.0 ~ 6.5 Kgm. 6.5 ~ 7.0 Kgm. 1.0 ~ 1.1 Kgm.

40
Tightening Torques
Spark Plugs Engine Mounting Nut - Rear Engine Mounting Nut - Front
1.3 ~ 1.5 Kgm. 2.8 ~ 3.2 Kgm 1.8 ~ 2.2 Kgm.
Engine Mounting Nut - Top Oil Drain Bolt (18 mm A/F) Drum / Cam Allen Bolt
1.8 ~ 2.2 Kgm. 1.0 ~ 1.1 Kgm. 1.0 ~ 1.1 Kgm.

41
Engine Lubrication - Flow of Oil
Oil strainer
Oil pump inlet
INLET Oil pump outlet
OUTLET
RH side crankcase oil passage
PASSAGE Clutch cover oil passage

Inlet hole of paper filter chamber
Paper oil filter
Outlet hole of paper filter chamber

Clutch cover passage
towards
crankshaft
towards
Crankcase RH
RH side
Oil
crankcase
plunger
hole

42
Engine Lubrication - Flow of Oil
LH side
crankcase passage
Crank big end pin

through crankshaft
drilled hole Crankcase LH hole
Con rod slots
Two fountains for

lubricating cylinder
piston parts
L.H. Crankcase
passage towards Towards block
nozzle
Nozzle Gap between bolt

oil jet and cylinder block
& cylinder head

43
Dos & Don’ts

Dos Don’ts
Always replace Do not reuse ‘O’
gasket ‘O’ rings of rings, gasket, Oil
engine If dismantled. seals, Circlip, Springs
& locks as they use
their strength &
properties, once they
are opened.
Whenever installing Do not adjust spark

Spark Plug, first plug electrode gap
screw by hand & by hacksaw blade or
then tighten to with judgment of eye
specified torque. 0.7 to otherwise it will affect
0.8 mm
the engine
performance.
Always set / adjust Do not set valve

valve tappet tappet clearance in
clearance in engine engine hot condition.
cold condition.
Always below light Do not reuse torn

pressure compressed ‘Oil strainer’
air from inside while otherwise it will affect
cleaning ‘Oil strainer’ lubrication system of
that is opposite to engine &
the direction of flow subsequently would
of oil. lead to seizure.

44
Notes

45
Key Learning Points
Appropriate torque application for

various Frame component
Understanding of special tools and

its applications
Standard operating procedure
CHAPTER 4
Frame & Suspension

Special Tools
Service Limits
Tightening Torque
Dos & Don’ts

46
4 Frame & Suspension
Special Tools
Fork Oil Seal Extraction Tool
Part No. : 37 0043 25
Application : For extracting front fork oil

seal from outer tube.
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.
Fork Seat Pipe Holder
Part No. : 37 0043 20
Application : For holding fork seat pipe

during outer tube bottom bolt removal.
Steering Slotted Nut Special Tool
Part No. : 37 0043 02
Application : To remove / tighten

steering slotted nut.

47
Frame & Suspension
Special Tools
Front Fork Inner Tube Extractor
Part No. : 74 9310 15
Application : To remove front fork inner

tube from outer tube.
Installer Upper & Lower Bearing race

Frame
Part No. : 37 1801 06
Application : To install upper & lower

steering races / cones into their seats
inside frame.
Steering Cone Remover
Part No. : 37 1805 06
Application : To remove steering cones

from frame.

48
Service Limits
Brake Panel Cam Hole Dia. Brake Cam Front Diameter Brake Drum Inside Dia. Rear
Std. Limit 12.00 ~ 12.027 Std. Limit 11.957 ~ 11.984 Std. Limit 130 ~ 130.16
Ser. Limit 12.15 Ser. Limit 11.83 Ser. Limit 130.75
Brake Shoe Rear Liner Thickness Front Fork Spring Free Length Axle Run Out
Free Length
Std. Limit 3.9 ~ 4.5 Std. Limit 446.5 Std. Limit TIR 0.1
Ser. Limit 2.0 Ser. Limit 441.5 Ser. Limit TIR 0.2
Axial Wheel Run Out Radial Wheel Run Out Drive Chain Slack
Std. Limit TIR 0.5 or Less Std. Limit TIR 0.5 or Less Std. Limit 25 ~ 30
Ser. Limit TIR 2.0 Ser. Limit TIR 2.0 Ser. Limit 45
Drive Chain 20 Link Length Rear Sprocket Warp Tyre Tread Depth
20 Link Length
1st 2nd 20th

MEASURE THIS LENGTH
Std. Limit 254 ~ 254.6 Std. Limit TIR 0.4 or less Std. Limit Rear : 6.5, Front : 5.0
Ser. Limit 260.0 Ser. Limit TIR 0.5 Ser. Limit Upto TWI

49
Frame & Suspension
Tightening Torques
Front Axle Nut Rear Axle Nut Torque Rod Nut
4.5 ~ 5.5 Kgm 8.0 ~ 10.0 Kgm 3.0 ~ 3.2 Kgm
Rear Sleeve Nut Rear Sprocket Mounting Nut Handle Bar Holder Bolts
8.0 Kgm 3.2 ~ 3.8 Kgm 2.0 ~ 2.2 Kgm
Fork Pipe Top Bolts Steering Center Nut (Slotted) Fork Under Bracket Bolts
3.0 ~ 3.2 Kgm 0.5 Kgm 3.0 ~ 3.2 Kgm
R.S.A. Mounting Nut Upper Swing Arm Shaft R.S.A. Lower Bolt
3.0 ~ 3.2 Kgm 4.5 ~ 5.5 Kgm 2.8 ~ 3.2 Kgm
Front Fender Mounting Bolts Rider Foot Rest Mounting
0.8 ~ 1.2 Kgm 1.8 ~ 2.2 Kgm

50
Dos & Don’ts

Dos Don’ts
Replace front fork oil Do not add any
with SAE 10W20 other mineral based
grade fork oil. oil to front fork.
Maintain correct tyre Do not over / under

pressure as per inflate the tyres.
specification.
Check for split pin at Avoid Bends /

torque rod nut. Distortion of torque
link rod.
Lubricate the swing Do not reuse the old

arm Bushes / Shafts. swing arm Bushes /
Bearings.

51
Frame & Suspension
Notes

52
Key Learning Points
Understanding of Battery
specifications & charging procedure
Checking and inspection of all

Electrical component
Standard operating procedure for

Head light assembling and dismantling
CHAPTER 5
Electricals
Battery Specifications
Electrical Checking Procedures
Important SOP
Dos & Don’ts
Electrical Wiring Diagrams

53
5 Electricals
Battery Specifications
Battery Technical Specification
• Make Exide / Amco

• Voltage 12 Volt
• Type MF Battery
• Capacity 5 Ah
• Specific gravity of electrolyte 1.24 for use above 100C, 1.28 for use
for initial filling of new battery below 100C
• Initial charging duration 13 hrs (This ensures 100% battery
Is charged).
• Charging current specification 0.5 Amp
Initial Charging Procedure for dry charged Battery

• Fill each cell with battery grade sulfuric acid of the correct sp. gravity (1.24 at room temp. for use above
100C & 1.28 at room temp. for use below 100C)
• Allow the battery to stand for 30 min. after filling.
• Keep vent plugs open. Connect battery to charger & charge at 0.5 Amp. Charging voltage of charger
should be 14.5 volt min. without connecting the battery.
• Charge continuously for 13 hours (charging duration will depend upon the condition of the battery) Specific
gravity of fully charge battery after rest period of 1 hour will be 1.24 & battery voltage will be 12.9 Volts.
• After charging push vent plugs strip firmly into place & wash off acid spillage with water & dry the battery.
• Using the battery load tester confirm for good indication of state of charge of battery.
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. Charging voltage of charger should be more than 14.5
volt without connecting the battery .
• Charge battery (battery charging time depends upon the charging condition of the battery)
• Check specific gravity of each cell & voltage after 1 hour it should be 12.5 volt & specific gravity 1.24 for
the 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.

54
Electricals
Electrical Checking Procedure

Front & Rear Brake Light Switch
Measuring & Testing Equipment : Multimeter
Brown Blue Continuity check by multimeter
Lever/Pedal Pressed Continuity is shown
Lever/Pedal Released No continuity
SOP :
• Turn ‘ON’ the ignition switch.
• The brake light should glow on when the front brake lever / rear
brake pedal is pressed.
• If it does not, check the front brake switch.
Clutch Switch
• Check continuity of clutch switch as follows.
Black / Yellow Yellow / Green Light Green
OFF – Clutch lever not pressed
ON – Clutch lever pressed
Ignition Switch
Brown White
OFF
ON

55
5 Electricals

Fuel Gauge - Tank Unit
Meter Range Connections Standard Value
Meter +ve Meter -ve

200 Ohms As per chart given below
White / Yellow Black / Yellow
Standard Value
Fuel Level Fuel Quantity(L) Standard Value( O)
Empty Tank 1.4 98
Half Tank 5 45
Full Tank 8 8
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.
Stator Relay Inspection

Meter +ve Meter -ve

200 Ohms 3.9 Ω ± 10%
Yellow / Red Black
SOP :
• Connect external 12V DC supply to Radiator relay coil terminals.
• ‘Tuk’ sound will be heard.
• Set multimeter on continuity mode.
• Connect multimeter at to relay contact terminals.
• Continuity (beep sound) indicates Radiator relay is OK.

56
Electricals

Engine Thermal Sensor
Meter +ve Meter -ve Engine Temp (0C) Resistance K Ohms

200 Ohms
As shown in photo 25 0C 10.50 ± 7% KΩ
Battery Charging Coil

Meter +ve Meter -ve

200 Ohms 0.9 Ohms
Blue-White or Yellow Blue-White or Yellow
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 Resistance

Meter +ve Meter -ve

200 Ohms 215 ± 20Ω
White / Red Black / Yellow
SOP :
• Switch Off Ignition Key.
• Disconnect Stator Plate Coupler
• Connect multimeter between White / Red & Black / Yellow wires.
• Measure resistance
Note: Ensure gap 0.5~0.7 mm between pole of pick-up coil & rotor
peep.

57
5 Electricals

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 +ve Meter -ve
200 Ohms Starter Relay Starter 3.9 Ω ± 10%

Coil Red - Relay Coil
Yellow Wire Black Wire
SOP :
• Switch OFF engine.
• Disconnect coupler from Relay.
• Connect multimeter to Starter Relay coil terminals.
• Check resistance.
Horn
Meter Range Conditions Standard Value

Encircle clamp meter jaws 2.2 Ampere
200 DC A
around Brown wire of horn
SOP :
• Encircle clamp meter jaws around Brown wire of Horn.
• Press horn switch & check instantaneous current drawn by horn.
H.T. Coils
H.T. Coil : (Inspection Using Multimeter)
• Measure the primary winding resistance as follows
• Connect the multimeter between input terminal & GND plate on the core.
• Measure the secondary winding resistance as follows
• Remove the plug cap by turning it counter clockwise.
• Connect the multimeter between H.T. cable end & GND plate on the core.
• Measure primary winding & secondary winding resistance.
• 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 as it should
after all other components have been checked test replace the coil with
one OK coil.
• Visually inspect the secondary winding lead.
• If it shows any damage, replace the coil.
Primary Winding 0.45±10%  at 250C
Secondary Winding 5.0±10% K W at 250C

58
Electricals

Battery Charging Voltage Measurement
Use fully charged battery while measuring

At 4500 RPM with
Meter Range Connections Heal Light ON
Meter +ve Meter -ve

20 K Ohms 14.4 + 0.2 Volts
Battery +ve Terminal Battery -ve Terminal

59
5 Electricals
Notes

60
Electricals
Important SOP
Wind shield (Visor) Replacement
• Remove wind shield mounting
screws (Torque value : 0.14 –
0.16 Kg.m) with plastic
washers using phillips head
screw driver & take out wind
shield.
A • Ensure that 4 nos well nuts & Damper

4 nos dampers shown in
photograph A are in good
condition. Replace them with
new one if found cut / Well
nut
damaged.
A • Ensure that 3 nos foam strips

shown in photograph A & 1 B
nos foam strips as shown in
Foam strips photograph B are in
good condition. Replace them
Foam strips
with new one if found cut /
damaged.
Note :- While refitment, ensure
the tightness of screws to
avoid rattling noise.
Bulb Headlight Replacement

• Remove headlight assembly
mounting bracket –
- Bottom bolt with metal washer
using 8 mm spanner holding
nut with 10 mm spanner.
- Top side 2 nos. bolt with metal
washer using 10 mm spanner.
• Take out headlight assembly.

61
5 Electricals
Important SOP
• Pull out dust cap.
• Remove headlight bulb

coupler.
• Press bulb holding clip as

shown by pink arrow & take
out clip as per blue arrow.
• Take out headlight bulb.
After fitment of all removed
parts, adjust headlight focus
as per SOP.
Flap Speedometer & Speedometer Assembly Replacement

• Remove headlight bulb.
• Pull out rubber bellow, remove

speedometer couplers & DRL
couplers.
• Remove wind shield (visor).

Also check dampers & foam
strips condition as explained in
wind shield replacement SOP.
• Remove speedo flap mounting

-
- Front side screw (1 nos) with
plastic washer using phillips
head screw driver.
- Top side screws (2 nos) with
plastic washer using phillips
head / Minus screw driver.

62
Electricals
Important SOP
- LH & RH Side bolts (2 nos) with 10 mm spanner as shown
by blue arrows.
- Bottom side screws (2 nos) with metal washer using phillips

head / Minus screw driver as shown by blue circles.
- Take out flap speedometer along with speedometer assembly.
• Ensure that beading strips (4

nos) on speedo flaps are in
good condition. Replace with
new one if found cut /
damaged.
• Ensure that foam strip (2 nos)

on speedo flaps are in good
condition. Replace with new
one if found cut / damaged /
Permanent set
• Remove speedometer
mounting screws (4 nos.) with
metal washers using phillips
head screw driver & take out
speedometer assembly from
flap speedometer.
Note :- While refitment,
ensure the tightness of
screws & nut - bolts to
avoid rattling noise.

63
5 Electricals
Important SOP
Headlight Fairing / Headlight with DRL / Headlight Mounting Bracket Replacement
• Remove flap speedometer
along with speedometer
assembly.
• Remove headlight fairing

mounting screws (2 nos) with
metal washer using phillips
head screw driver.
• Take out headlight fairing.
• Ensure that foam strips (6 Foam strips

nos) on headlight are in good
condition. Replace with new
one if found cut / damaged /
permanent set.
• Remove headlight mounting nuts (4 nos.) with metal washer

using 8 mm spanner.
• S e p a r a t e o u t Ta k e o u t
headlight assembly mounting
bracket & headlight assembly
with DRL.
• Take out collars (4 nos.) as

shown in photograph - A.
A
B • Ensure that grommets (6 nos) as shown
in photograph - B by pink arrow are in
good condition. Replace with new one if
found cut / damaged
• Remove LH & RH Side bracket

RH
bracket mounting bolts (2 nos - each shown
by blue arrows in photograph-B) Torque
LH
bracket value : 0.31 - 0.42 Kg.m) using 10 mm
spanner & take out LH & RH side
bracket.

64
Electricals
Important SOP
Grommet Top bracket Grommet
C D
Locking
clip
Locking clip
Pivot stud
Pivot stud
Central bracket
• Remove Top bracket pivot stud locking clip with plastic washer using
Clip removal E small screw driver as shown in photograph – C, D & E.
Ensure that grommets (2 nos) as shown in photograph - C & D are
in good condition. Replace with new one if found cut / damaged.
• Take out pivot studs & top bracket.
Note :- While refitment, ensure the tightness of screws & nut -
bolts to avoid rattling noise.
Harness Headlight Replacement

• Remove headlight assembly
mounting bracket –
- Bottom bolt with metal washer
using 8 mm spanner holding
nut with 10 mm spanner
- Top side 2 nos bolt with metal
washer using 10 mm spanner.
• Pull out dust cap.
• Remove headlight bulb coupler.

65
5 Electricals
Important SOP
• Remove DRL couplers &
harness headlight coupler.
• Take out harness headlight.

66
Electricals
Dos & Don’ts

Dos Don’ts
Horn
• Adjust horn sound by • Never adjust the nut on horn cap side
rotating the Phillips screw in and bracket end (horn back side) as it
the direction of arrow will result in horn malfunctioning & failure.
provided on horn.
• Do not remove silicon sealant from
adjustment screw as it will result in water
entry inside the horn.
Ignition System
• Replace spark plugs at • Do not replace spark plug by non
every 30,000 kms. recommended type (different heat range).
• Ensure that PVC cap on • Do not remove grease from CDI and
magneto and CDI coupler magneto coupler as it is provided for rust
are intact. prevention.
• Grease used in CDI and

magneto coupler is in place.
Switches
• After washing the vehicle • Do not apply direct pressurized water jet
ensure to apply dry air on on control switches.
switches before operation.
• Do not lubricate electrical switches by oil
• Ensure that grommets or grease.
provided on clutch switch,
front brake switch and rear • Do not over tighten the switch mounting
brake switch are intact. screw.

67
68
5
CAPACITOR REGULATOR
INPUT
INPUT
OUTPUT
GROUND
B/Y W L/W L/W
Electricals
Battery Charging Circuit

B/Y W L/W L/W
Electrical Circuit Diagrams
L/W L/W FUSE

BOX
10 A
W/B
L/W L/W
W/B B
+ -
MAGNETO ASSEMBLY BATTERY - 5Ah

FRONT INDICATOR LAMP RH DC FLASHER REAR INDICATOR LAMP RH
12 V, 10 W 12 V, 10 W
Gr Gr Gr Gr
B/Y B/Y B/Y B/Y

Electricals
Br O
Side Indicator Circuit
SPEEDOMETER
W W REAR INDICATOR LAMP LH
BATTERY (Before Ignition) PIN 1
Gr Br 12 V, 10 W
RIGHT TURN INDICATOR PIN 7
G Gr B/Y B/Y
LEFT TURN INDICATOR PIN 8
B/Y G
GND PIN 11
Br G G
SUPPLY (After Ignition) PIN 20
Br
10 A
IGNITION SWITCH
ONOFF Br/L
Gr O G
Br Br/L
W W
FUSE BOX
W W/B
10A
Gr O G
FRONT INDICATOR LAMP LH

12 V, 10 W
R OFF L W/B B
B/Y B/Y
+ -
SIDE INDICATOR SWITCH
G G (CONTROL SWITCH LH) BATTERY - 5Ah

69
70
HORN
5
Horn Circuit
Br B/V
Electricals

Br
10 A
Br/L W
B/V B/Y FUSE

IGNITION SWITCH BOX
10 A
ONOFF
Br Br/L
W/B
W W
B B/Y
W/B B
+ -
HORN SWITCH
(CONTROL SWITCH LH) BATTERY - 5Ah
CLUTCH SWITCH (CONTROL SWITCH RH) NEUTRAL SWITCH
START
SWITCH
Electricals
Br/B R/Y
LG
Starter Motor Circuit
Y/G B/Y LG
Br/L R/Y
Y/G B/Y LG
SPEEDOMETER
W W
LG Br
NEUTRAL PIN 9
B/Y LG
GND PIN 11
Br
G/W FUSE BOX
W W/B
10A
Br
R Y/G R/Y
10 A
Br/L B R/Y
IGNITION SWITCH M
ONOFF
Br Br/L W/B B
+ -
W W R R R
STARTER MOTOR STARTER RELAY BATTERY - 5Ah

71
72
REAR BRAKE SWITCH
5
Br L
BRAKE LAMP
L L
B/Y B/Y
Br L
Brake Lamp Circuit
Electricals
Br

10 A
IGNITION SWITCH
Br/L
ONOFF
Br Br/L
FUSE BOX
W W
W W/B
10A
L Br
L Br
W/B B
+ -
FRONT BRAKE SWITCH BATTERY - 5Ah

(CONTROL SWITCH RH)
Light Switch
ON
SPEEDOMETER
OFF
W W
R/B Br
Electricals
HIGH BEAM PIN 3 TAIL LAMP

Br Y/L
B/Y G/W B/Y B/Y
GND PIN 11
R/B
R Br Br
ILLUMINATION PIN 13
Br V
SUPPLY (After Ignition) PIN 20 Br V
Lighting Circuit with DRL
HEAD LAMP
WITH DRL
NUMBER PLATE LAMP
B/Y B/Y
R/B R/B
B/Y B/Y Br Br
R/Y R/Y
Br
V
B/Y
Br
Br R/Y V R/B
Br
V
FUSE BOX
10 A W W/B
Y R/YY/L R/B
10A
Br/L
ON OFF
Br Br/L PASS HI / LO
SWITCH SWITCH B
HI
W W LO
+ -
IGNITION SWITCH (CONTROL SWITCH LH) BATTERY - 5Ah

73
74
FUEL LEVEL SENSOR
5
W/Y B/Y
Fuel Meter Circuit

Electricals
W/Y B/Y

SPEEDOMETER
W W
W/Y W/Y
FUEL SENSOR PIN 5
B/Y Br
GND PIN 11
Br
B/Y
FUSE BOX
W W/B
10A
Br
10 A
Br/L
IGNITION SWITCH
ONOFF
Br Br/L W/B B
+ -
W W
BATTERY - 5Ah
VEHICLE SPEED SENSOR
R/W R/W
Electricals
B/Y B/Y
L/W L/W
SPEEDOMETER
Vehicle Speed Sensor Circuit
W W
L/W Br
SPEED SENSOR INPUT PIN 6
B/Y G/W
GND PIN 11
R/W
SPEED SENSOR SUPPLY PIN 19

Br
Br
FUSE BOX
10 A W W/B
10A
Br/L
ON OFF
Br Br/L
B
W W
+ -
IGNITION SWITCH BATTERY - 5Ah

75
76
H.T. COIL 2 H.T. COIL 1 CDI 5
RHS LHS
SPARK SPARK
Ignition Circuit
PLUG PLUG
GROUND
HT COIL O/P 1
BATTERY +VE
HT COIL O/P 2
PULSER INPUT
THERMISTER INPUT
Electricals
B/R B/Y B B/Y

SPEEDOMETER W
B/R
Br/L
B/W
W/R
G/W
W Br
B
RPM SIGNAL PIN 10
B/Y
GND PIN 11 B
Br
SUPPLY (After Ignition) PIN 20 G/W
Br W
W/R B/Y
FUSE
10 A BOX
10 A
Br/L W/R B/Y W/B
B/W
ONOFF
Br Br/L
W/B B
W W COIL
PULSING + -
IGNITION SWITCH ETS MAGNETO ASSEMBLY BATTERY - 5Ah

Electricals
Notes

77
Bajaj Auto Limited
Akurdi Pune 411 035 India
Tel | +91 20 27472851

Fax | +91 20 27407385
www.bajajauto.com
CIN number : CIN L65993PN2007PLC130076

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Training Notes

The Training Notes are a comprehensive

Engine & Transmission 21

Understanding the Complete Anatomy of

Technical Specifications and Performance

Briefing and Educating the Customer on

I Read ..... I Learn

Pre-Delivery Inspection Check List

Periodic Maintenance & Lubrication Chart

Bajaj Discover 125 UG Training Notes

Engine Number Location

BRAKES & TYRES:

Bajaj Discover 125 UG Training Notes

Bajaj Auto International Business

Bajaj Discover 125 UG Training Notes

Chassis & Body

Bajaj Auto International Business

Bajaj Discover 125 UG Training Notes

Pre Delivery Inspection Check List

1. Check points before starting of the vehicle

Bajaj Auto International Business

Pre Delivery Inspection Check List

2. Check points during / after starting the vehicle

5. Visual inspection for dent, scratches, rust ...

6. Clean the vehicle thoroughly before delivery to customer.

Bajaj Discover 125 UG Training Notes

Periodic Maintenance & Lubrication Chart

Clean body centrifugal filter at

Use recommended molycote

5 Spark plug CL,A,R CL,A CL,A R

7 In line paper filter or Fuel cock paper filter R R R

8 Fuel cock sediment bowl cleaning CL CL CL

9 Carburetor rubber duct C,R C,R Check & replace if required

10 Fuel pipe C,R C C C R C C R

• During 1st free service : Use lint

• During all other services:

• During regular service use OKS

15 Silencer drain hole cleaning CL CL CL CL CL CL CL

Bajaj Auto International Business

Periodic Maintenance & Lubrication Chart

Disc brake assembly–-check functionality,

Wiring harness & battery connection - C,A,

Check & replace if

Not applicable in case of

29 Engine foundation silent bushes ** C C C Replace if damaged

General lubrication - clutch lever, front brake Use recommended AP

Use recommended 'Ready

33 Coolant hose damage / clamps / leakage ** C C C C C C C Check & replace if required

34 Radiator fins ** C C C C C C C Check & replace if required

38 Pillion foot rest hinge lubrication** L L L L L L L L Use RR 3 Grease

39 EVAP Y connector drain tube CL CL CL CL CL CL CL CL

Bajaj Discover 125 UG Training Notes

Bajaj Auto International Business

Understanding of CO checking procedure

Understanding of SAI system

Overview of Fuel System

Secondary Air Induction (SAI) System

Evaporative Emission System

Tune-up for Optimum Mileage