Discover 125 - TRG Note-Ib

Contents
I Read ..... I Learn
Identification...................................................................... 2
Salient Features................................................................. 3
Technical Specifications..................................................... 7
PDI Checklist..................................................................... 9
Periodic Maintenance & Lubrication Chart..................... 12
Periodic Maintenance Point............................................. 14
Fuel System
29
Carburettor Specifications............................................... 30
Tune up for Optimum Mileage....................................... 31
Engine & Transmission
33
Standard Operating Procedure...................................... 34

Special Tools................................................................... 40
Gear Transmission Power Flow........................................43
Service Limits................................................................... 48
Tightening Torques...........................................................51
Vehicle (Frame)
55
Standard Operating Procedure.......................................56

Service Limits................................................................... 59
Tightening Torques........................................................... 60
Special Tools....................................................................62
Electricals
65
Electricals......................................................................... 66
Dos & Dont's................................................................... 67
Electrical Checking Procedure......................................... 74
Standard Operating Procedure...................................... 83
Electrical circuit Diagram................................................ 91
DISCOVER 125 ST TRAINING NOTES
INTERNATIONAL BUSINESS
1
I Read ..... I Learn
Identification
Salient Features
Technical Specifications
PDI Checklist
Periodic Maintenance & Lubrication Chart
Periodic Maintenance Points
SALIENT FEATURES
IDENTIFICATION
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric codes to
identify your particular vehicle from others of the same model and type.
PERFORMANCE
Frame Number Location

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

On LH Side Crankcase Near Gear Change Lever
(Alpha-Numeric - 11 Digits)
Part Locations
1.
2.
3.
4.
5.
6.
RH Control Switch
LH Control Switch
Speedo Console
Single Down Tube Frame
Front Disc Brake
Silencer
7.
8.
9.
10.
11.
Mono Shock absorber

Cover Mud Rear
Assembly Chain Cover
Tail Lamp
Grip Frame
3
11
10
Features
Advantages
Benefits
New generation technology engineered

for high power / pickup and
performance as well.
Higher power & pick up.
5 Speed Transmission
ExhausTEC
Wider range of gear ratios to utilize

high torque of engine
Better drive-ability and the best fuel

economy
Molycoat piston
Nozzle oil jet in lubrication circuit
Reduced friction
Better cooling of piston
Protection from seizure
Increased fuel efficiency.

Better life of component.
Electric start
DC ignition & Digital CDI
Quick and easy starting.

Consistent engine performance
Feather touch engine starting

Power and pick up.
DC Lighting system
Intensity & illumination of head light do

not change with engine rpm.
Constant bright beam from head light

even at low engine / vehicle speed.
DTSi engine - 124.6 cc

Engine power : 13 PS @ 9000 rpm
Engine torque : 10.79 N.m @6500
4 valve engine
9
8
7
6
5
SALIENT FEATURES
SALIENT FEATURES
STYLE
COMFORT AND CONVENIENCE
Advantages
Features
Benefits
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
Stylish and eye catching looks

Combination of Black & Chrome styling
Sporty styling
Improves personality of the rider.
Black colored engine, 10 spoke alloy

wheels, silencer and other components.
Features
Advantages
Benefits
Trip meter
For recording distance covered in a trip

/ tour. Also helps in calculating
mileage.
Easy to record trip distance.
Fuel Gauge
Displays approx. petrol qty. remaining

in the petrol tank.
More convenience.
Low battery indicator
Reminds user to get battery charged in

time.
For maintaining battery in healthy

condition.
Engine Oil Level Window
For easy inspection & monitoring oil

level.
No hassle of removing, cleaning,

dipping Dip Stick to check oil level.
Telescopic front fork with anti-friction

bush & 130 mm stroke.
Nitrox Rear Mono Suspension with 110
mm wheel travel.
Minimum friction between fork pipes.

Longest suspension stroke in its class
of bikes.
Comfortable ride on all types of roads

and for any distance.
Better life of front fork oil seal & other
parts of fork.
MF battery with unique vent

mechanism.
Low maintenance - No spillage of

electrolyte.
No hassle of frequent topping up of

battery.
SALIENT FEATURES
TECHNICAL SPECIFICATIONS
SAFETY
Features
Advantages
Benefits
Robust semi double cradle frame with

longest wheel base - 1306 mm - in its
class of motorcycles.
Excellent ride and handling stability,

balance and vehicle dynamics.
Safe to drive on highway.
200 mm dia front disc, & 130 mm dia

rear brake drum.
Efficient and effective braking.
Safety.
Powerful head light, Number Plate

lamp, and Pass switch.
Bright and powerful illumination.

Clear visibility of rear number plate
from long distance.
Pass switch facilitates over taking.
Safe night driving.
10 spoke alloy wheels & unidirectional

tyres.
Better road grip and nimble handling.
Easy to maneuver and safe to drive.

No maintenance of spoke tightening.
Enhanced life of disc pads.

Disc brake system with disc cover.
For maintaining disc brake good

condition & durability.
Type
No. of cylinders
Bore
Stroke
Engine displacement
Compression ratio
Idling Speed
Max. net power
Max. net torque
Ignition System
Ignition Timing
Fuel
Carburettor
Spark Plug
Spark Plug Gap
Lubrication
Starting
Clutch
Transmission
Primary reduction
Gear Ratios
1st
2nd
3rd
4th
5th
Gear
Gear
Gear
Gear
Gear
Final Drive Ratio
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Four stroke, Natural air cooled, SI Engine

One
54.00 mm
54.4 mm
124.6 cc
9.8 + 0.5 : 1
1400 + 100 rpm
13 PS @ 9000 rpm
10.79 Nm @ 6500 rpm
DC
Variable as per maps in CDI
Unleaded Petrol, 87 RON Minimum
BS 26 Manual Choke
Champion PRZ9HC & BOSCH UR4AC Resistive
0.7 to 0.8 mm
Forced Lubrication
Kick & Electric Start
HTTS 90 kg
5 Speed Constant Mesh (1 down 4 up)
3.571 : 1 (75/21)
2.833 : 1 (34/12)
1.823 : 1 (31/17)
1.333 : 1 (28/21)
1.086 : 1 (25/23)
0.909 : 1 (20/22)
3.214 : 1 (45/14)
:
:
:
:
Semi double cradle

130 mm Fork travel, Telescopic
110 mm Rear Wheel travel, Mono with nitrox
Disc
Drum
200 mm Disc brake
130 mm Drum brake
2.75 x 17, 41 P Unidirectional
3.0 x 17, 50 P Unidirectional
2
1.75 Kg / Cm (25.0 PSI)
2
2.00 Kg / Cm (28.0 PSI)
2.25 Kg / Cm2 (32.0 PSI)
1.4 x 17 Alloy Wheel
1.6" x 17 Alloy Wheel
10.0 Liters
3.5 Liters
1.6 Liter
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
:
:
:
:
:
:
:
:
:
:
:
:
TECHNICAL SPECIFICATIONS
PDI CHECKLIST
Controls
Steering
Accelerator
Gears
Brakes
Front
Rear
:
:
:
:
:
Handlebar
On handle bar, RH grip
Left foot pedal operated, Step shift
Lever operated, RH hand.
Pedal operated by RH foot
Frame No.
M D 2 D S
Engine No.
Dealers Name
Dealers Code
Date of PDI
PDI done by
Please insure that following checks are carried out during PDI before delivery of vehicle.
Electricals
System
Battery
Head Lamp
Stop / Tail Lamp
Side Indicator Lamp
Speedometer Lamp
Neutral Indicator
Turn Signal Indicator
Hi-beam Indicator
Rear Number plate lamp
Horn
:
:
:
:
:
:
:
:
:
:
:
12 V (DC)
12V 5Ah MF
12 V 35/35 W, HS-1
12V, 21/5W
12V, 10 W (4 Nos. - Clear Bulbs)
12V 2W (2 nos.)
12V, 2W (Green)
12V, 2W (Green)
12V, 2W (Blue)
12V, 3W
12 V DC, 70 mm dia.
Dimensions
To Check
3 if OK or
7 if NOT OK
Check For
ENGINE
Engine Oil :
Oil level between lower & upper mark / Top up if required
Bajaj DTS-i 10000 Oil
Oil leakage if any - Specify source of oil leakage
Idling RPM (Warm up)
Check in warm up condition -600 C / Adjust if required (1400 + 100 rpm)
Kick Operation
Smooth operation
Gear shifting
Smooth operation
Engine noise
No abnormal noise
Silencer noise
No abnormal noise from silencer & shields

Engine foundation nut / bolts (Side cover RH to be removed)
Fasteners (Check torque)
a) Front mounting nuts- 3.5 Kgm

b) Rear monting nuts- 4.0 Kgm
Length
Width
Height
Wheel Base
Saddle Height
Ground Clearance
: 1980 mm
: 714 mm
: 1078 mm
: 1306 mm
: 800 mm
: 170 mm
c) Top mounting nuts- 1.8 ~ 2.2 Kgm

Silencer mounting bolt
a) Silencer mouth flange nut- 2.0 ~2.2 Kgm
b) Silencer bracket bolts- 3.5 Kgm
G S lever mounting bolts- 1.6 ~ 1.8 Kgm
Kick Boss bolt- 2.0 ~ 2.2 Kgm
Weights
FUEL SYSTEM
Vehicle Kerb Weight

Gross Vehicle Weight
: 125 kg
: 255 kg
Performance
Fuel Tank / Pipes
No leakage / Correct fitment
Fuel Cock
Smooth operation
FRAME
Tyre Pressure
Maximum speed
Front : 1.75 Kg / Cm2 (25.0 PSI)
: 102 km/h (with single rider 68 Kg)
Rear (with Pillion) : 2.25 Kg / Cm2 (32.0 PSI)

Front & Rear Wheel
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.
Free rotation
Side stand & Center stand

Mirror
Smooth operation
Proper fitment
Clear rear view
Head lamp
Focus adjustment
Observations /
Remarks
PDI CHECKLIST
PDI CHECKLIST
To Check
3 if OK or
7 if NOT OK
Check For
CONTROLS
Brakes
Observations /
Remarks
Check For
All Bulbs Working
Head light, Pilot lamps - 2, Tail / stop lamp, Side indicators,
Front- a) No oil leakage from master cylinder & caliper
Speedo bulb, Number plate lamps
b) Check oil level in master cylinder

Rear- Brake pedal free play 20 ~ 25 mm
Throttle
Grip free play - 2 ~ 3 mm. Smooth operation
Clutch Cable
Smooth operation, Free play - 2 ~ 3 mm
3 if OK or
7 if NOT OK
To Check
Switch Operation
RH & LH control switch, Ignition switch & Brake switch (Front & Rear)
Starter Motor
Working / Engagement in gear & neutral

No abnormal noise
Speedometer
Working of Speedometer, Odometer & Tripmeter
Proper routine ( From outside leg guard)
Working of all signal indicators icons (Turn pilot, Neutral, High beam,
Speedo cable
Proper routine
Side stand, Battery charge & Bajaj logo)
Drive Chain
Slackness standard - 20 ~ 25 mm
Headlamp assembly
No excess gap & Uneven gap
Drive chain lock position & proper fitment
Horn
Ensure no distorted sound
Equal marking of chain adjuster on both side
TEST DRIVE
Starting
SUSPENSION
Cold start & Warm start

Idling speed (Warm condition) (1400 + 100 rpm)
Front Fork
No leakage. Smooth working
Rear Shock Absorber
Spring adjuster notch position : 2nd notch (Standard)
Steering
Smooth operation (No play / No Sticky movement)
Lock Operation
Steering cum Ignition lock, Seat lock, LH side cover/Petrol tank cap lock
Drive ability
Throttle response
Brakes effectiveness- Front & Rear
CO % Check
CO should be 1.5 to 2.5 % in engine warm condition at idling RPM

(before cat converter)
Front axle nut - 4.5 ~ 5.5 Kgm

Cleaning
Rear axle nut - 8.0 ~ 10.0 Kgm
Wash & Clean vehicle properly
Fork pipe top bolts - 3.0 ~ 3.2 Kgm
IMPORTANT NOTE :
Look for any external damages in transit : Please check, record & rectify send report with photos.
Fork under bracket bolts - 3.0 ~ 3.2 Kgm

Handle bar holder bolt - 2.0 to 2.2 Kgm
Fasteners (Check torque)
Moisture / Oil collecting tube of air filter should be properly fitted and routed correctly.
Fork center nut- 4.5 to 5.0 Kgm
Spark plug cap must be tightly secured.
Rear shock upper nut - 3.0 ~ 3.2 Kgm
TPS on carburettor for functioning.
Rear shock mounting bottom bolt - 3.0 ~ 3.2 Kgm

Swing arm shaft nut - 8.0 ~ 10.0 Kgm
Front Caliper mounting bolts- 3.0 ~ 3.3 Kgm
Side stand lock nut- 2.8 ~ 3.2 Kgm
Main step holder bolt - 2.0 to 2.2 Kgm
Stay LH / RH mounting bolt- 1.5 to 1.8 Kgm
Rear brake pedal mounting bolt- 1.8 ~ 2.2 Kgm
Tail lamp
No excess / uneven gap between tail lamp & seat cowl
ELECTRICAL
Battery
Open circuit voltage (12.5 V DC) & Charge status using load tester.
Electrolyte level.
Tightness of battery terminals / cables
Proper routine of overflow pipe
Fuse
Position of fuse box
10
11
Observations /
Remarks
PERIODIC MAINTENANCE AND

LUBRICATION CHART
PERIODIC MAINTENANCE & LUBRICATION CHART

RECOMMENDED FREQUENCY
Sr. Operation
No.
Servicing
Kms
1.
Servicing
2.
Idle speed / CO%
1st
500
~
750
2nd
3rd
4th
5th
6th
7th
4500 9500 14500 19500 24500 29500
~
~
~
~
~
~
5000 10000 15000 20000 25000 30000
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
3.
Valve tappet clearance
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
4.
Engine oil (Bajaj DTSI 10000 oil)*
C, A
Top-up
Top-up
Top-up
5.
Oil strainer (Bajaj DTSi 10000 oil)*
CL
CL
CL
R
6.
Engine oil filter (Bajaj DTSi 10000 oil)*
7.
Body centrifugal filter -- Pulsar / Platina
CL
CL
8.
Spark plug gap
CL,A
CL,A
CL,A
CL,A
CL,A
CL
CL
CL
9.
Spark plug
10.
Air cleaner element***
CL, R
11.
Air filter cover O ring
12.
In line paper filter along with hose & clamps**
Fuel cock sediment bowl cleaning
CL
14.
Fuel cock-Paper filter element & seal**
15.
Carburettor
16.
Carburettor float chamber cleaning
CL
CL
CL
CL
Drive chain wear -- Remove & Lubricate
Replace at every oil change
C,L
C,L
C,L
C,L
C,L
C,L
C,L
48.
Drive chain ("O" ring design)**
49.
Wheel bearing
C,R
50.
Spoke tightening-Front & Rear**
C,T
Lubricate at every 500 km.(By customer)

C,R
C,R
C,R
C,R
C,R
C,T
C,T
C,T
C,T
C,T
C,R
C,R
C,R
Replace at every 15000kms
CL
CL
54.
Auto choke**
55.
Gap betn Reed switch & TPS magnet**
C,A
56.
Rr. Shock Absorber- Check gas pressure**
C,A
57.
Starter Clutch** (Dry Application)
C,T
C
C,A
C,T
C,A
C,A
C,A
C,A
C,A
C,A
C,A
Not required for new design
CL,A
(Filling from bottom)
CL
C,A
C,R
C,CL
C,CL
C,CL
C,CL
Check & replace if required
58.
Wiring harness
59.
Ignition switch contacts cleaning
At every service
60.
Clutch switch & brake switch

C,CL,L
C,CL,L
C,CL,L
C,CL,L
61.
Clutch switch (Vertical base)**
C,R
C,R
C,R
C,R
62.
Rear brake switch
C,A
Replacement at every 30000 Kms or 2 year (whichever occurs earlier)

C,R
Replacement at every 35000 Kms or 3 years (whichever occurs earlier)
(Horizontal base) contacts cleaning**
C
C,CL
C
C,CL
C,A
C,CL
C,A
C,A
C,A
C,A
C,A
C,CL
C,A
C,A
C,A
C,A
C,A
C,A
63.
Starter motor connections**
C,T
C,T
C,T
C,T
C,T
C,T
C,T
64.
Starter relay connections**
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
65.
HT coil connections
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,R
26.
Clutch plate
C,R
66.
Oil pressure indicator check on console**
Clutch play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
67.
General lubrication
28.
Throttle play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
68.
Main stand & side stand pin**
29.
Brake play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
30.
Brake lining or pad wear
C,R
C,R
C,R
C,R
C,R
C,R
C,R
31.
Brake fluid level / top up**
C,A
C,A
C,A
C,A
C,A
C,A
C,A
Brake fluid
Replace at every15000 Kms
69.
Swing arm pivot pin (for non silent bush)**
70.
Engine foundation silent bushes**
Check & Top up if required
71.
Steering play
in every service
72.
Steering stem bearing***
73.
C,L
C,A
74.
Step -Pillion LH & RH (Ball & Plate)**
C,CL
75.
All fasteners tightness
C,T
35.
Caliper piston seal and Dust seal
36.
Brake cam & pedal pivot pin**
37.
Rear sprocket fasteners
C,T
38.
Rear wheel rubber shock damper
C,R
39.
Silencer drain hole cleaning
CL
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,R
CL
12
CL
C,R
CL
CL
C,R
CL
CL
C,A
C,A
C,A
C,A
C,R
R
L
C,A
C,R
C,T
L
R
C,R
R
L
Cap steering bearing (Plastic)**
Front brake hose
C,L
R
C,CL,L,R
Master cylinder piston kit
C,CL,L,R
33.
C,L
C,CL,L,R
34.
C,L
C,A
27.
32.
C,R
Whenever drive chain opened.
C,A
C,A
C,A
CL
C,R
C,A
C,R
C,A
Front fork oil seal
C,R
C,R
C,A
53.
C,A
C,T
47.
C,A
C,A
Battery connections
Drive chain lubrication on vehicle

Drive chain link lock
C,A
C,A
25.
C,L
45.
46.
Replace at 20000 Kms
C,A
Coolant level check in expansion tank**
C,L
Replace in 1st service & at
R
C,A
19.
Radiator fins**
C,A
every 10000 Kms
If required
Battery electrolyte level & specific gravity**
C,A
C,R
23.
Engine air breather tube
CL
24.
CL
CL
CL
Drive chain slackness
CL
C,R
Coolant hose damage/clamps/leakage**
Cylinder head de-carbonising
43.
CL
22.
42.
44.
CL
C,R
C,R
Top-up@every 5000 Kms.
CL
Tyre tread wear
C,R
C,R
Front fork oil
Carburettor rubber duct
Coolant in expansion tank**
CL
51.
Fuel pipes
Coolant hose damage/clamps/leakage**
Silencer tail pipe cleaning-Pulsar 150/180

Engine compression pressure
52.
17.
20.
40.
41.
18.
21.
1st - 500~750 Kms / 30~45

days,2nd onward@5000Kms
CL,A
CL
2nd
3rd
4th
5th
6th
7th Subsequent
4500 9500 14500 19500 24500 29500
~
~
~
~
~
~
5000 10000 15000 20000 25000 30000
CL,A
1st
500
~
750
CL
R
CL
Servicing
CL,A
R
CL
RECOMMENDED FREQUENCY
Operation
CL,A
R
CL
Sr.
No.
Kms
CL
13.
CL
Subsequent
C,A
Replace at every 15000Kms
C,A
C,CL,L,R Check & replace if required
C,R
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
C,T
C,T
C,T
C,T
C,T
C,T
* It is strongly recommended to use only Bajaj DTS-i 10000 Genuine engine oil. In case any other engine oil of same specifications is used, the frequency of Sr. No. 4, 5
& 6 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.
13
PERIODIC MAINTENANCE POINTS
Periodic Maintenance (in accordance with the periodic maintenance chart) of a vehicle it is utmost important to prolong vehicle
life, trouble free running & ensure safety while driving.
Fuel Cock Filter Replacement

Put fuel cock knob position OFF.
Washing (Water Servicing) - Dos & Donts
Dos
Donts
Rinse the Bike thoroughly with water to remove

loose dirt and mud.
Do not direct pressurized water jet on head lamp

glass, tail lamp glass, electrical components (H.T.
Coil, C.D.I., Flasher, Horn & LH / RH control
switches) to avoid water entry & subsequent
damage.
Clean the Bike with a Sponge or soft cloth using

water.
Do not direct pressurized water jet on steering races

(cones) to avoid rusting & subsequent pitting of
steering balls & races.
Clean the exterior surfaces of engine metal parts by

kerosene / diesel spray & plastic / nylon brush.
Do not direct pressurized water jet on plastic parts,

decals & spark plug cap.
Avoid directing water jet in to silencer muffler outlet.
Cover silencer tail end by PVC cap.
Clean the plastic parts using a soft cloth or sponge

dampened with a solution of mild car shampoo /
liquid soap & water. Rub the soiled area gently
rinsing it frequently with fresh water.
Do not use detergent or strong solvent to clean

painted / plated parts. Avoid cleaning products that
are not specifically designed for automobile surfaces.
Strong detergent residues can corrode alloy parts
and also painted surfaces loose their shine / gloss.
Remove fuel cock sediment bowl by ring spanner.
Take out fuel cock sediment bowl
Caution : Water may enter on the brake liners during washing & brake slippage may occur. Ensure
that brake liners are dry before driving the vehicle.
Clean sediment bowl thoroughly with low pressure compressed air.
14
15

Pull out paper filter element with seal
Paper Filter Element Replacement

Remove side cover LH by following steps given below
Insert the key into the cover lock and turn the key clockwise.
Pull front side first & slide side cover toward front. Take out Side cover.
Replace paper filter element with seal at every 15000 kms

Remove seat by following step given below
Pull the Seat Release Cable to release seat lock. Keeping cable pulled, lift
the seat from rear end and slide it towards tail lamp to remove seat assembly.
To avoid cross fitment of sediment bowl. Do pre fitment of sediment bowl by

hand & thereafter tightening by ring spanner.
Put fuel cock knob position ON / Reserve & confirm no fuel leakage.
Remove 4 nos M10 bolts of air intake duct
Remove intake duct from clamp
16
17

Take out paper filter element
Dos :
Clean at every 5000 kms. in dusty areas increase the cleaning frequency.
Replace at every 15000 kms.
Donts :
Do not clean paper air filter element with Petrol / Kerosene / Diesel / Water, also do not apply oil on paper element.
O Ring Drive Chain Lubrication - on Vehicle

Place the bike upright.
Normal dust should be wiped clean using a lint free cloth.
Hold the Chain Lube Spray Can (OKS Spray) vertically upright & shake it
vigorously till the noise of steel ball inside the can is heard uniformly. Fix the
extension tube (red pipe provided with the can).
Paper Filter Element Cleaning

Remove the seat assly.
Air Gun
Remove air filter cover by removing bolts.

Carefully remove the filter element from air filter assly.
Filter Element
Carburettor side
Clean air filter element by low pressure compressed air. (Air pressure less than
2 bar)
Hold the can at the back of the rear sprocket in line with chain rotation and
keep the nose of the extension tube at about 5~10 cms away from the chain.
Slightly twist the element as shown in the photograph.
Rotate the wheel in reverse direction & spray the lube on the middle portion of
the chain so that lubricant will get spread on roller & bushes and on both
sides of the chain.
Hold the filter element by its PU foam only. Do not touch the paper surface to
avoid soiling.
Wipe out air filter top & bottom cover by wet clean cotton cloth.
Spray the lube on full length of chain by rotating the wheel to a complete
rotation.
Air Gun
Filter Element
Dirty side
After completing this, rotate the wheel 3 ~ 4 times so that the lubricant
spreads & settles.
Wipe out any excess lubricant if it has dripped down or sprayed on the wheel /
tyre.
Post Cleaning Actions :

Assemble filter element into the air filter box. Maintain tightening torque as per specification over the mounting bolts of
assembly cover side.
Assemble back seat assembly in the vehicle after the complete assembly of air filter assembly.
18
19
O Ring Drive Chain Cleaning by Removing from Vehicle (Diesel + SAE 90 oil 1:1)
Engine Oil Level Checking
Max. Level
1st Stage:
Clean with
Diesel +
oil 1:1
Park the vehicle on level surface on center stand to check the oil level.
Inspect the oil level through oil inspection window.
It should be in between upper and lower mark.
Top up if required.
Min. Level
3rd Stage:
Dip into
SAE 90 oil
2nd Stage:
Clean with
Diesel
+ oil 1:1
Recommended
Grade
Bajaj DTS-i 10000 20W50 grade BGO
Recommended
Quantity
Drain & Refill 1000 ml

Engine Overhaul 1100 ml
Oil Strainer Cleaning

Remove :
Cap strainer (18 mm A/F) with O ring.
Pull out strainer (mesh filler oil with O ring) by nose plier.
Soak into
SAE 90 oil
Blow Low
Pressure
Compressed
Air
Drain engine oil.
Remove :
Final Stage :
Hook chain
for dripping
of excess oil
Clean oil strainer with Kerosene / Diesel & blow low pressure compressed air
from inside i.e. air must be blown in opposite direction of oil flow.
Note :
During re-assembly of drive chain always use new link lock.
Ensure O ring fitment.
20
21
Paper Oil Filter Replacement
Tappet Clearance Setting

Ensure that the engine is in cold condition.
Remove :
3 bolts (8 mm A/F)
Take out Cover oil filter with O ring.
Take out Paper oil filter along with
spring.
Replace Paper oil filter during 1st
free service and thereafter at every
5000 Kms.
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 the
check nut with a spanner.
Caution :
Before fitting Paper oil filter
ensure intact condition of oil
seal from its rear side & one
way valve from its front side.
Inlet Valve
0.05 mm
Exhaust Valve
0.1 mm
M & T Equipment
Feeler Gauge
Special Tool
Valve Adjusting Screw Holder

Part No. : F41ZJW33
Note : Tappet setting of 2 Intake & 2 exhaust valve must be done

individually as per SOP.
Oil Seal
One Way Valve
Nitrox Mono Rear Shock Absorber
Silencer Drain Hole Cleaning
Adjusting Spring Tension
Mono RSA
with Nitrox
RSA spring tension can be adjusted with the help of 9 stepped adjuster cam
to suit individual requirement as per load & road conditions.
Turn the adjuster cam on shock absorber to required position. Setting the
adjuster cam to higher notch position increases the spring stiffness & viceversa (Tool Part No.: 37 0041 70)
Shock Absorbers adjusted either too soft or too stiff could adversely affect
riding comfort & vehicle stability.
Notch Position
Spring Action
Soft
Clean the silencer drain hole in

every service by using silencer
drain hole cleaning tool as shown
in photograph.
9
Stiff
Note: Standard setting is done in 2nd notch.
Special Tool for Mono RSA adjuster
22
23
3 Dos
7 Don'ts
Use appropriate screw drivers for

dismantling.
Never use oversize screw drivers

Dont over tighten the jets & screws.
This will damage the jets & their
seats.
For cleaning always use carburettor

cleaner like - Acetone
- Carbon Tetra chloride
- CVC spray
Never clean the carburettor with

water.
Jets & air passages will get clogged
due to sediments if cleaned by
water.
Handling
Cleaning
Float Height Checking
In this carburettor measure float

height in inverted vertical position.
Always maintain standard float
height.
Do not blow compressed air on

needle jet from ventury / mixing
cap side otherwise needle jet would
get blown-off .
Ensure float is in good Condition.
Do not reuse squeezed / punctured

float. This could lead to petrol over
flow.
Place a magnet holder on jet

needle e-clip & then Place spring..
Do not blow compressed air from

carburettor breather tube otherwise
float would get Squeezed/damaged.
Readiness of CO Gas Analyser
Taking the Reading

Remove M-5 bolt & 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 300mm 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.
The Silicon rubber tube must fit snugly onto the nozzle to
prevent any air / exhaust gas leakage.
Note the CO / HC readings when the reading display
stabilizes.
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
1.5 to 2.5% 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 more CO% and turning
out will lead to less CO%.
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.
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.
Readiness of the Vehicle

Before checking CO emission, prepare the vehicle for
checking the CO.
Warm up the engine to its normal operating temp. by
riding 5~6 Kms. The c'case cover should be warm
0
enough by feel. (Engine Oil Temp. = 60 C).
Caution: In choke ON condition CO % is high : 9~10%.
Hence warming up of engine is a must.
Screw in VC Screw completely. Engine should die

down in this condition.
Check Float Pin for - Tip having no wear mark.
- Spring loaded pin is free in
movement.
Do not reuse Float Pin if - Worn out tip

- Spring loaded pin sticky otherwise
it would lead to flooding / over flow
Replace Jet Needle & Needle Jet

as a pair if wornout.
Always ensure that e-clip is fitted
in specified groove of Jet Needle.
Do not shift e-clip to upper or lower

groove of jet needle otherwise it
would lead to lean air fuel mixture
or rich air fuel mixture respectively.
Replace piston / throttle valve if

worn out
Ensure fitment of spring, a plain
washer & an O ring on Air Screw
Dont fit worn out / non specified

size jets
Dont fit worn out / cut O ring on
air screw otherwise it would lead to
idling Instability.
Note: Remember the VC Screw should not be taken out more

than the recommended position. Every time VC Screw setting
is changed specified Idling RPM must be restored and then
reading should be considered.
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 VC
Screw.
If the CO% is not falling within recommended % in spite

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

setting as per specification.
Important: For Better Mileage and Performance,

achieve CO% as recommended.
Set Idling speed to specified

Idling 1400 + 100 rpm.
Raise engine to moderate
speed at no load condition
for about 15 seconds. Then
bring back to specified idling
RPM.
In Discover 125 ST motorcycle for better mileage &

performance achieve values given below.
Recommended CO% value w.r.t. VC Screw
and Idling RPM for Better Fuel Efficiency
Model Recommended CO% VC Screw Position Recommended Idling RPM
Discover
125 ST
Overhaul Carburettor at every 10,000 Kms and Inspect the parts
24
25
1.5% ~ 2.5%
Set VC screw to
get CO% 2 + 0.5
1400 + 100 rpm
7 Don'ts
3 Dos
7 Don'ts
3 Dos
Ensure Cylinder Head Cover

breather passage is clear by
blowing compressed air in
opposite direction of flow of
fumes. Clogged breather
passage would lead to oozing
out of oil through oil seals, 'O
Rings, Gaskets & Breather
pipe.
Dont fill excess engine oil beyond std. engine oil capacity
otherwise oil will ooze out from engine breather pipe / leak
from gasket - oil seal
Confirm the crankshaft

centering & free rotation after
fitment otherwise non centered
crankshaft would lead to
engine knocking.
Dont hammer crankshaft while fitting it in crankcase otherwise

it would lead to its run out & subsequent engine noise
Always follow loosening /

tightening sequence of cylinder
head bolts otherwise its surface
may get warped
Tighten nut- bolts in criss-cross
pattern for matching of mating
surfaces to avoid distortion
otherwise It leads to oil
leakage.
Standard Tightening Torque :
0.9~1.1 Kgm
Dont over tighten cylinder head cover bolts otherwise plastic

cylinder head cover may get cracked.
If cylinder head cover bolts are not tightened to specified
torque & in criss-cross pattern it would lead to oil leakage.
Always tighten clutch cover

and crankcase bolts to their
specified torque (0.9 ~ 1.1
Kgm) in crisscross pattern
Dont over tighten clutch cover & crankcase bolts otherwise

crankcase parent hole threading would get damaged.
Always replace circlips & locks of transmission gears, kick

shaft assembly if removed. Circlips / locks tend to loose their
spring tension once removed.
Do not wash air filter paper element with kerosene / petrol /

diesel.
Always apply loctite to oil

pump securing screws / bolts
While assembling oil Pump

shaft having integral nylon
gear, dont hammer / tap the
gear for matching. Instead,
rotate the gear slowly D slot
on shaft so that perfectly
matches with the D slot of
inner rotor.
Always use Loctite to bolts,

screws & nuts wherever
recommend.
If nut, bolts & screws are assembled with out loctite

application it would lead to their loosening & subsequent
problem in engine.
Do not wash engine bearings with water otherwise they will

get permanently spoiled
While assembling cylinder block, always apply engine oil to

cylinder walls & piston rings for ease of fitment & to prevent
dry running.
Do not blow compressed air on engine bearing otherwise they

will get permanently spoiled.
Always apply oil during assembling engine components,

particularly at friction prone area to avoid dry running.
Do not tap engine components by hammer in order to avoid

damage. Engine components are precisely machined, they are
critical & costly.
Confirm seating of circlip locks by rotating on their seat to

avoid further consequences.
Blow dust free / moisture free

air in all the orifices, passages
of the engine components &
confirm that the oil passages
are clear.
The dust free air must be
blown opposite to the direction
of oil flow.
If air is blown in to orifices, oil passages of the engine in the

direction of oil flow, the passage would get jammed / clogged
instead of getting cleared.
26
While installing engine bearings always tap / press on the race

which is taking seat to avoid damage to the bearing otherwise
axial / radial clearance may increase.
27
NOTES
2
Fuel System
Carburettor Specifications
Tune up for Optimum Mileage
36
28
29
CARBURETTOR SPECIFICATIONS
TUNE UP FOR OPTIMUM MILEAGE
UCAL
AIR FILTER:
TPS - Reed Switch : Checking

Continuity check magnet in front
of reed switch.
Multimeter will show continuity &
beep sound will be heard.
Clean at Every :
5000 Kms.
Replace at Every :
15,000 Kms.
Cleaning procedure as per SOP
COMPRESSION PRESSURE
Standard :
11 to 13 Kg/cm2
Continuity check magnet away

form a reed switch.
Service Limit :
9.5 Kg/cm2
Multimeter will not show continuity

& 1 will be displayed on
multimeter.
TAPPET CLEARANCE
Inlet Valve :
0.05 mm
Exhaust Valve :
0.1 mm
Do setting for individual valve
Engine Tune-up
CARBURATTOR
SPARK PLUG :
BOSCH UR4AC, Champion
PRZ9HC
0.7 to
0.8MM
Specification
Make
UCAL
Type
UCD26
Idling Speed
1400 + 100 rpm
VC Screw Setting
set 2 % co
Main Jet
117.5
Needle Jet Marking
O-9
Jet Needle e Clip Position
2nd Groove from top
Pilot Jet
12.5
Throttle Valve Mark
110
Float Height
10.5 mm
Starter Jet Size
17.5
Choke
Manual Choke
30
Jet Needle Clip Position :

second groove from top
Spark Plug Gap :

0.7~0.8 mm.
Replace at Every :
20000 Kms
CO % : 1.5 ~ 2.5 %.
V.C. Screw Setting : To achieve
CO% between 1.5 ~ 2.5
Other Mandatory Checks
Item
Idling : 1400 + 100 rpm.
a. Ensure no fuel leakage through fuel cock, fuel lines.

b. Ensure free rotation of both wheels.
c. Ensure correct tyre pressure - Front wheel : 25 PSI,
Rear wheel : 32 PSI
d. Set control cable free play:
Clutch lever 2~3 mm.
Rear brake pedal 15~20 mm.
e. Chain slackness : 20~25 mm.
f. Check & confirm proper functioning of spark plug.
31
NOTES
3
Standard Operating Procedure
Special Tools
Gear Transmission Power Flow
Service Limits
Tightening Torques
36
32
33
STANDARD OPERATING PROCEDURE
Cylinder Block Dismantling on Vehicle
Remove fuel gauge connection & take out the fuel tank
Remove LHS side cover by using

vehicle key (pull out cover from
front side grommet & pull towards
front side)
Remove LH & RH spark plug cap

Remove the seat assembly by pulling the seat lock cable.
Remove breather tube connection

Remove RHS side cover by removing 1 philips screw & pull out from rubber
grommets (2 nos.)
Remove silencer assembly

Remove fuel tank mounting bolt
(10 mm A/F)
Remove fuel pipe
34
35

Remove engine mounting upper bracket (3 nos. 12 mm A/F)
Sleeve
Remove RHS spark plug & spark

plug sleeve. (2.5 mm Allen key)
2.5 mm grub screw
Remove carburettor front & rear

clamps
Remove RH & LH H.T. Coil (2 nos.

bolts, 10 mm A/F)
Remove intake manifold bolts (2 nos., 8 mm A/F)
Remove cylinder head cover (4

nos. bolt, 8 mm A/F)
Remove TPS connection & take

out the carburettor assembly
Remove chain tensioner (2 nos.

bolt, 8 mm A/F)
Remove thermal sensor connection
36
37

Align the T mark of sprocket & by
using special tool remove -
Remove piston pin lock after that remove piston pin
- Allen bolt, special washer,

sprocket, collar.
Remove head bolts as per given sequence. While removing head bolt number
1 & 3. Before removing bolt 1 & 3 ensure that both H.T. coil should be
removed otherwise both bolts will foul with H.T. coil.
1
4
Remove piston
3
2
Remove head & head gasket
Note :
Cylinder head & gear box dismantling & assembly is similar to Pulsar 135 LS.
No exclusive special tool is required for Discover 125 ST.
Remove cylinder & cylinder gasket
38
39
SPECIAL TOOLS - ENGINE
Special Tools
Clutch Dismantling Tool

Part No.
Cam Sprocket Holder
Part No.
: F41ZJZ47
Application : For holding sprocket during

removal / refitting of Cam
sprocket allen bolt.
: F41AJA58
Application : To dismantle & assembled

clutch of DISCOVER DTS-Si
kick start as well as self start
vehicle.
Spark Plug Spanner

Part No.
Magneto Rotor Holder (For Self Start)
Part No.
: F41ZJZ44
: 37 1040 51
Application : For removing and refitting

spark plug R.H. and L.H. side.
Application : To hold rotor while loosening /

tightening its nut.
Valve Tappet Adjuster

Part No.
Magneto Rotor Puller (For Self Start)
Part No.
: F41ZJZ46
Application : To pull out the rotor from

crankshaft assembly.
: F41ZJW33
Application : To hold the Valve Tappet

screw while adjusting tappet
clearance.
Rocker Shaft Remover

Part No.
Primary Gear Holder
Part No.
: 37 10CS 22
Application : To remove Rocker Shaft from

cylinder head.
: F41AJA11
Application : To hold primary and secondary

gear while loosening/tightening
the primary gear nut & special
nut securing clutch.
Bearing Extractor
Part No.
Socket for Clutch Nut
Part No.
: 37 1030 48
Application : To Pull out main ball bearing

from crankshaft
: F41ZJA54
Application : To loosen / tighten special nut

securing clutch.
40
41
GEAR TRANSMISSION POWER FLOW

Adaptor & Valve Spring Compressor
Construction & Working
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.
: 37 1010 06
Application : To remove refit piston pin.
Output Sprocket Holder

Part No.
: 37 1030 53
Application : To hold the output sprocket

while removing sprocket allen
bolts.
Input Shaft and its gears :

First gear is integral with Input Shaft.
Second gear is fixed on Input Shaft
splines.
Third gear is fixed but sliding on Input
Shaft splines.
Forth gear is a freely rotating gear on
Input Shaft.
Fifth (top) gear is freely rotating on Input
splines.
Output Shaft and its gears :
First gear is a freely rotating gear on
Output Shaft. A bush which is free inside
gear I.D. & shaft O.D. is fitted between
first gear and Output shaft.
Second gear is a freely rotating gear on
Output Shaft. A bush which is free inside
gear I.D. & shaft O.D. is fitted between
first gear and Output shaft.
Third gear is freely rotating on Output
splines.
Forth gear is fixed but sliding on Output
Shaft splines.
Fifth gear is fixed but sliding on Output
Shaft splines.
1.
2.
3.
4.
5.
6.
12
Input shaft.
First gear input.
Second gear input.
Third gear input.
Fourth gear input.
Fifth gear input.
11
10
7.
8.
9.
10.
11.
12.
Output shaft
First gear output.
Second gear output.
Third gear output.
Fourth gear output.
Fifth gear output.
Driver for Fitting Bushing Gear Shift Drum

Part No.
: E6101100TE
Application : To assemble Bushing with

PTFE Lining at parent hole of
crankcase RH for Gear Shift
Drum mounting.
First Gear Position : When First Gear is

engaged, Power from clutch flows as follows.
4
1
Clutch
Input Shaft
Bearing Driver Set

Part No.
1st Gear Input
: 37 1030 61
Application : Common bearing driver set for

fitting & removing bearings
from crankcase.
st
1 Gear Output
th
4 Gear Output
5
Output Shaft
Final Drive to the Rear Wheel
42
43
4
1

5
Second Gear Position : When Second Gear

is engaged, power from clutch flows as
follows.
Forth Gear Position : When Forth Gear is

engaged, power from clutch flows as follows.
4
1
Clutch
Clutch
Input Shaft
Input Shaft
rd
3 Gear Input
nd
2 Gear Input
4th Gear Input
2nd Gear Output
th
4 Gear Output
5
th
5 Gear Output
Output Shaft
4
1
Output Shaft
4
1

Third Gear Position : When Third Gear is

Clutch
Input Shaft
Input Shaft
Clutch
rd
rd
3 Gear Input
3 Gear Input
3rd Gear Output
5 Gear Input
th
5th Gear Output
th
4 Gear Output
5
Output Shaft
4
1
Output Shaft
Fifth Gear Position : When Fifth Gear is

44
45
4
1
14
15
13
21
16
12
20
17
4
19
4
11
10
16
18
3
17
14
15
4
7
8
10
3
4
13
11
19
18
12
20
22
21
No.
1
2
3
4
5
6
7
8
9
10
11
No.
Description
Shaft Input
Gear 4th Drive
Spline Washer
Ring - Snap
Gear 3rd Drive
Gear 5th Drive Forging Route
Gear 2nd Drive
Washer Thrust 2nd Drive
Shaft Output Forging Route
Gear 2nd Driven
Bush 2nd Driven
12
13
14
15
16
17
18
19
20
21
22
46
Description
Gear 5th Driven Forging Route
Gear 3rd Driven
Gear 4th Driven
Bush 1st Driven
Gear 1st Driven
Washer Thrust
Collar Sprocket Drive
O Ring
Sprocket Output
Plate Lock - Sprocket Output
Bolt Flanged
No.
1
2
3
4
5
6
7
8
9
10
11
No.
Description
Lever Assy Gear Change Complete
Bolt - Flange :- M6
Lever Change Arm
Bolt Gear Change Lever
Tie Rod
Pin
Washer Nylon
Boot Change Lever
Lever Complete Change
Washer Plain
Bolt
12
13
14
15
16
17
18
19
20
21
47
Description
O Ring
Damper
Lever Comp Gear Shift
Extension Spring
Spring Gear Shift Return
Inhibitor Comp. Gear Shift
Spring (Inhibitor)
Step Washer
Washer (Spring Steel)
Nut - Hexagon With Flange : M6
SERVICE LIMITS - ENGINE

Compression Pressure
SERVICE LIMIT - ENGINE

Valve Clearance
Rocker Arm Shaft Diameter
Cylinder Inside Diameter
Piston Diameter
Piston Cylinder Clearance
10mm
20mm
40mm
Std. Limit
Ser. Limit
11.0 ~ 13.0 kg/cm

Min 9.5 kg/cm
Cam Sprocket Diameter
Intake
Exhaust
Std. Limit
In 0.05
Ex 0.1
Ser. Limit
Cam Height
Std. Limit
Ser. Limit
7.994 ~ 8
Group A
7.98
Group B
Exhaust
Group A
53.969 ~ 53.981
Std. Limit
0.027 ~ 0.049
Group B
Ser. Limit
Max 0.06
Piston Ring Groove Clearance
Cam Lobe Width
Intake
54.008 ~ 54.018
Top
Piston Ring End Gap
Second Oil Ring
Top
Clutch Spring Free Length
Second Oil Ring
Std. Limit
61.165 ~ 61.285
Std. Limit
29.411
29.457
Std. Limit
9.0
Std. Limit 0.03~0.07 0.02~0.06 0.03~0.11
Std. Limit 0.1~0.25 0.3~0.45 0.2~0.7
Std. Limit
25.5
Ser. Limit
60.865 ~ 61.285
Ser. Limit
29.336
29.382
Ser. Limit
Ser. Limit
Ser. Limit
Ser. Limit
24.5
Valve Spring Free Length
Valve Stem Diameter
Exhaust
0.15
Friction Plate Thickness
Valve Stem Bend
Intake
0.15
0.4
0.6
Steel Plate Thickness
Steel Plate Warp
Std. Limit
38.68
Std. Limit
4.475~4.49
4.455~4.47
Std. Limit
0.01
Std. Limit
2.95 ~ 3.05
Std. Limit
1.6 ~ 1.7
Std. Limit
0.1
Ser. Limit
35.23
Ser. Limit
4.46
4.45
Ser. Limit
> 0.01 Replace
Ser. Limit
2.7
Ser. Limit
1.55
Ser. Limit
0.15
Valve Stem to Guide Clearance
Cylinder Head Warp
Camshaft Chain Length
Friction Plate Warp
Clutch Hub Height
Shift Fork Guide Pin Diameter
20 Link Length
1st
2nd
21st
MEASURE THIS LENGTH
Intake
Exhaust
Std. Limit
0.01 ~ 0.037
0.025 ~ 0.052
Std. Limit
0.03 mm
Std. Limit
127.00 ~ 127.48 mm
Std. Limit
0.1
Std. Limit
21.0 ~ 21.2
Std. Limit
4.45 ~ 4.49
Ser. Limit
Max 0.07
Max 0.07
Ser. Limit
0.05 mm
Ser. Limit
128.9 mm
Ser. Limit
Ser. Limit
21.4
Ser. Limit
4.4
ALL DIMENSIONS ARE IN MM

48
49
TIGHTENING TORQUES
SERVICE LIMIT - ENGINE

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
Ser. Limit
19.6
Spark Plug
Cap Strainer (18 mm A/F Bolt)
Cap Oil Filter
1.3 ~ 1.5 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
4.0 Kgm
3.5 Kgm
0.9 ~ 1.1 Kgm
Cylinder Head Bolts (12 mm)
Cam Sprocket Allen Bolt
Rotor Mounting Nut
2.2 ~ 2.5 Kgm
1.6 ~ 1.8 Kgm
5.0 ~ 5.5 Kgm
NOTES
50
51
TIGHTENING TORQUE - ENGINE
TIGHTENING TORQUE - ENGINE
Primary Gear Nut
Clutch Nut (L.H. Thread)
Clutch Spring Bolts
Cylinder Head Cover Bolts
Chain Tensioner Mounting Bolts
Magneto Cover Bolts
5.0 ~ 5.5 Kgm
5 ~ 5.5 Kgm
1.0 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
Drum / Cam Allen Bolt
Stud Inhibitor Nut
Oil Pump Mounting Screws
Bolt Kick Lever
Manifold Mounting Bolts
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
0.5 ~ 0.7 Kgm
2.0 ~ 2.2 Kgm
0.9 ~ 1.1 Kgm
Output Sprocket Bolts
Crankcase Joining Bolts
Crankcase Joining Bolts
NOTES
0.8 Kgm
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
Stator Plate Bolts
Kick Guide Bolts
Starter Motor Mounting Bolts
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
0.9 ~ 1.1 Kgm
52
53
NOTES
4
Vehicle (Frame)
Standard Operating Procedure
Service Limits
Tightening Torques
Special Tools
20 Link Length
1st 2nd
20th
MEASURE THIS LENGTH
36
54
55
Removal of Rear Suspension
Accelerator Cable Routing

Remove side cover LH
Route the accelerator cable as shown in photograph.
Remove side cover RH
Remove RSA top bolt from LHS

using M-8 Allen key
Route the cable from outside of rod

joining lamp shade
Remove RSA lower bolt from RHS

using M-8 Allen key
Route accelerator cable through

PVC clamp located near RHS
petrol tank damper.
Connect the cable at carburettor
end.
Pull out RSA from RHS from the gap in between stay RHS & frame
Clutch Cable Routing
Route the clutch cable from inner
side of rod joining lamp shade.
Route the clutch cable through the
clamp bolted on chassis.
Route the clutch cable from outside

the leg guard.
Route the clutch cable through
clutch cable bracket mounted on
clutch cable.
56
57
SERVICE DATA - FRAME

Front Hose Brake Hose Routing
Brake Panel Cam Hole Dia.
Brake Cam Diameter
Brake Shoe Lining Thickness
Route front brake hose through clamp provided on RHS of front fender.
Std. Limit
12.00 ~ 12.027
Std. Limit
11.957 - 11.984
Std. Limit
3.9 ~ 4.5
Ser. Limit
12.18
Ser. Limit
11.83
Ser. Limit
2.0
Brake Drum Inside Dia. Front / Rear

Route the front brake hose through 'U' type clamp provided on lower T.
Axle Run Out
Axial Wheel Run Out
100 mm
Std. Limit
130 - 130.16
Std. Limit
TIR 0.05
Std. Limit
TIR 0.5 or less
Ser. Limit
130.75
Ser. Limit
TIR 0.2
Ser. Limit
TIR 2.0
Radial Wheel Run Out
Speed Sensor Cable Routing
Drive Chain Slack
Drive Chain Length

20 Link Length
Route speed sensor cable through clamp provided on LHS of front fender.
1st 2nd
20th
MEASURE THIS LENGTH
Std. Limit
TIR 0.5 or less
Std. Limit
20 ~ 25
Std. Limit
254.0 ~ 254.6
Ser. Limit
TIR 2.0
Ser. Limit
35
Ser. Limit
260.0
Rear Sprocket Warp
Front Fork Spring Free Length
Tyre Tread Depth
Route the speed sensor cable with grommet through 'U' type clamp provided
on lower T.
Free Length
58
Std. Limit
TIR 0.4 or Less
Std. Limit Front : 5.0 Rear : 6.0
Std. Limit
392.5
Ser. Limit
TIR 0.5 or less
Ser. Limit Up to TWI
Ser. Limit
387.5
59
TIGHTENING TORQUES
TIGHTENING TORQUES
Front Axle Nut
Rear Axle Nut
Tie Rod Nut
Front Fender Mounting Bolts
Rider Foot rest Mounting
LH Stay Bolts
4.5 ~ 5.5 Kgm
8.0 ~ 10.0 Kgm
3.0 ~ 4.0 Kgm
2.0 ~ 2.2 Kgm
2.0 ~ 2.2 Kgm
1.5 ~ 1.8 Kgm
Rear Sprocket Mounting Nut
Handle Bar Holder Bolts
Fork Center Nut
RH Stay Bolts
Front Fork Oil Grade & Capacity
Fork Oil Level
Grade :
SAE 10W20
Bajaj Genuine
Fork Oil
Quantity :
140 + 2.5 ml /
Fork Leg Assly
(Drain & Refill)
3.0 ~ 3.8 Kgm
2.0 ~ 2.2 Kgm
4.5 ~ 5.0 Kgm
Steering Stem Nut Slotted
Fork Pipe Top Bolts
Fork Under Bracket Bolts
1.5 ~ 1.8 Kgm
Loctite Applications
Grease Application Points

S.N. Vehicle Component
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
Bearing balls of steering
2.
Swing arm shaft
3.
Front wheel axle
4.
Rear wheel axle
5.
Brake pedal pivot
6.
Center stand shaft
7.
Side stand U bracket
8.
Gear shifter lever pivot
S.N. Vehicle Fastener
HP Lithon RR3
1.
Rider step mtg. bolts
2.
RSA lower bolt
Type of Loctite &

Loctite Colour
Thread Locker
243
Dark Blue Colour
A.P Grease
3.0 ~ 3.2 Kgm
8.0 ~ 10.0 Kgm
1.
Type of
Grease
60
61
SPECIAL TOOLS - VEHICLE
SPECIAL TOOLS - VEHICLE
Special Tools
Bearing Race Extractor

Part No.
: 37 1030 48
Special Tool to Remove Anti-Friction Bush
Application
Application
To Pull out steering race from ' Fork Under

Holder bracket'
To remove anti-friction & oil seal bush from

front fork outer pipe.
Steering Cone Remover

Fork Oil Seal Driver
Part No.
: 37 1830 07
Application :
To fit fork oil seal in its seat provided at outer
pipe ID.
Part No.
: 37 1805 06
Application
To remove steering cones

from frame.
Special Tool to Adjust RSA Spring

Stem Bearing Driver
Part No.
: 37 1830 05
Application
Part No.
: 37 0041 70
Application
To adjust rear shock absorber spring tension.
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.
62
63
NOTES
5
Electricals
Battery
Dos & Don'ts
Electrical Checking Procedures
Standard Operating Procedures
Electrical Circuit Diagrams
64
65
ELECTRICALS
DOS & DON'TS - GENERIC

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
1.24 for use

above 100C
Initial charging duration
10 ~15 hrs
Charging current specification
0.5 Amp
Battery Features
Frequency of electrolyte topping-up is very less compared to conventional battery.

Low self discharge.
Unique vent system / mechanism.
Enhanced safety
Compact design-High efficiency in compact package.
3 Dos
3
Do hold the box.
Apply petroleum jelly to poles / terminals.
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 1.240. 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.
Use proper tools.
Use only distilled water to top up battery.
How to Determine Condition of Battery

Hydrometer
Read
Here
Specific Gravity check: - Whether battery is fully charged or partially charged, it will always
show same no load voltage of 12 volts or more (unless battery cells are damaged due to
sulphation etc). But specific gravity of the fully charged battery and partially charged battery
will be different. Fully charged battery will show Sp. gravity of 1.240 while partially charged
battery will show less specific gravity. Therefore, specific gravity check is very important to
know condition of the battery.
66
67
Always maintain electrolyte

level between maximum &
minimum level marks.

Battery
Battery
7 Donts
7
Do not hold the wires.
Do not apply grease to poles / terminals.
3 Dos
3
Check open circuit voltage by multi meter.
Do not hammer battery terminals.
Always charge battery by constant current method with

the help of specified charger.
Always maintain battery top

cover clean and dry. Always
keep Vent Mechanism area
clean & clear.
Use hydrometer for checking specific gravity
7
7
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.
68
Use battery load tester for checking battery charge

condition.
69

Battery
7 Donts
Do not quick charge battery by current higher than
specified current.
HORN
7 Don'ts
3 Dos
Ensure that horn is firmly fitted on
frame
Constant voltage charging method must be strictly

avoided.
Do not use local make battery charger.
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.
Do not short circuits the poles.
7
Do not short circuit the leads.
Ensure that battery is fully charged.
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.
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.
70
71

IGNITION SYSTEM
3 Dos
Always install recommended capacity of battery on the bike.
LIGHTS
3 Dos
Check that all bulbs are firmly fitted in bulb holder.
Always replace spark plug by correct heat range plug.
Ensure that there is no dust and water entry in bulb housing.
Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler
gauge.
Ensure that all fixing screw of bulb housing are intact.
Replace spark plug at every 20,000 kms.
Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is
intact.
Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3
~ 1.5 Kgm.
Check DC Voltage Regulators output voltage periodically. Ensure that

voltage is within specified limits.
Ensure H.T. cable secondary connection is firmly fitted in spark plug cap a n d
H.T. coil.
Check that couplers and wires of bulbs are in good condition.

Check flashing rate of indicator bulbs.
Check that CDI coupler is tightly fitted.

Ensure that magneto coupler is firmly fitted.
Always use a right size socket during removal and re-installation of spark
plug.
7 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.
During periodic service make use of spark plug cleaning & testing machine
to clean spark plug electrodes & to check proper functioning of both the
spark plugs.
Do not ride on brakes.

Do not start Vehicle with light control switch in ON condition.
7 Don'ts
Do not replace spark plug by non recommended one (different heat range).
Do not replace CDI by local make or different make.
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.
SWITCHES
3 Dos
Always clean switch assembly with soft cloth.

After washing the vehicle ensure to apply dry air on switches before
operation.
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.
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.
7 Don'ts
Do not apply direct pressurized water jet on control switches.

Do not lubricate electrical switches by oil or grease.
Do not over tighten the switches.
During warranty period do not dismantle control switches.
Do not add extra electrical loads e.g. musical horns, additional horns,
buzzers as it will reduce switch contact life & battery life &battery life.
Do not tamper / alter rear brake switch spring.
Do not operate switch immediately after water servicing.
72
73
ELECTRICAL CHECKING PROCEDURE
Fuse Inspection (Capacity = 10 Amp)
Clutch Switch
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.
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
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
Ignition Switch
Measuring & Testing Equipment : Multimeter
Meter Range
Continuity
Mode
Connections
Meter +ve
Meter -ve
Brown
White wire
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.
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
Brake Pedal Pressed
Continuity is shown
Brake Pedal Released
No Continuity
74
Continuity Check
OFF - No continuity
ON - Continuity
Continuity check by multimeter
75

Engine Thermal Sensor
Fuel Gauge - Tank Unit
Empty Tank

Meter Range
Connections
Meter +ve
Meter -ve
White / Yellow
Black / Yellow
200 Ohms
Standard Value
As per chart
given below
Meter Range
Connections
Meter +ve
Meter -ve
Standard Value
Engine
Temp (0C)
@ 10 0C
0
Standard Value :-
Full Tank
Fuel Level
Empty Tank
19.3
20 K Ohms
Standard value
in Ohm
97
Reserve
58
Half Tank
44
Full Tank
20

Meter Range
200 Ohms
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
200 Ohms
Connections
Meter +ve
Meter -ve
Starter Relay
Coil Red Yellow Wire
Starter
Relay Coil
Black Wire
20.702 KW + 10%
12.889 KW + 10%
8.653 KW + 10%
5.636 KW + 10%
3.818 KW + 10%
2.782 KW + 10%
Battery Charging Coil
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.
Meter Range
@ 20 C
@ 30 0C
Black / White Earth / Ground
@ 40 0C
@ 50 0C
@ 60 0C
Resistance
K Ohms(W)
Connections
Meter +ve
Meter -ve
Blue / White
Blue / White
Standard Value
0.9~1.1 Ohms
at 250C
SOP :
Switch OFF engine.
Disconnect stator plate coupler
Connect multimeter between two Blue / White wires.
Check resistance value between Blue / White & Blue / White.
Standard Value
Pick-up Coil
4 Ohms + 10%
SOP :

Meter Range
2 K Ohms
Switch OFF engine.

Disconnect coupler from Relay.
Connect multimeter to Starter Relay coil terminals.
Check resistance.
Connections
Meter +ve
Meter -ve
White / Red Black / Yellow
Standard Value
180 ~ 220 Ohms
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.
76
77

Horn
Starter Motor - Current Drawn
Measuring & Testing Equipment : DC Clamp Meter
Measuring & Testing Equipment : DC Clamp Meter

Meter Range Connections
Encircle clamp meter
200 DC A
transformer jaws around
thick Red wire of starter motor.
Standard Value
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.
Meter Range
Connections
200 DC A
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.
Starter Motor Armature

Speedometer

Meter Range
Connections
Continuity
mode
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.
Twin pod analog type speedometer houses :

Speedo-Odometer unit
Trip meter with push type Knob / Lever for resetting zero.
Fuel meter.
Turn signal indicator.
High beam indicator.
Neutral indicator.
Low battery indicator & Bajaj Logo.
Low battery indicator
Starter Motor Armature
When ignition switch is turned ON, battery indicator glows on

Upon Starting Engine :-

Meter Range
Continuity
mode
Connections
Meter +ve
Meter -ve
Any segment
on commutator
Adjacent segment
on commutator
Standard Value
Condition 1
Battery indicator glows off if battery charging system is OK /

battery is in charged condition.
Continuity is
shown
Condition 2
Battery indicator continuously glows on

if battery
charging voltage is less than 13 V (means charging system
is malfunctioning) / battery is deep discharged.
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.
78
Thus low battery indicator reminds to charge battery /

correct battery charging system in time.
79

DC Charging Voltage Measurement
H. T. Coil
Primary
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
+ve lead
20 V DC
Specified at
4500 RPM
Meter Connections
H. T. Coil Resistance Checking

Measure the primary winding resistance as follows
Meter Range
200 Ohms
H.T. Coil
Secondary
Connections
Meter +ve
Battery
+ve terminal
Battery
-ve terminal
Note : For DC voltage measurement connect multimeter in parallel circuit.
Meter -ve
White / Yellow Black / Yellow
0.3 ~ 0.5 Ohms at 25 C
Measure the secondary winding resistance as follows

Remove the plug cap by turning it counter clockwise.
Meter Range
Connections
-ve lead
14.2 + 0.4 Volts
Standard Value
20 K Ohms
Meter +ve
Standard Value
Meter -ve
White / Yellow Black / Yellow
4.5 ~ 6.5 K Ohms at 25 C
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
80
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

may be defective
4.
Does not
Glow
No Spark
Check pick up coil & Exciter coil

if found OK then replace CDI
81
Head light bulb Replacement SOP
CDI Assembly
Identification :
Case colour - Gray
Coupler - Single black colour 12 pin.
Make - Varroc
Measuring & Testing Equipment : CDI / HT
Coil Tester.
Remove RHS & LHS head light mounting bolt (4 nos. 10 mm A/F)
SOP for CDI Checking
LHS
Remove wiring harness couplers 2 nos.

Measuring & Testing Equipment : CDI / HT Coil tester.
Hang the unit on leg guard of the vehicle.
Remove Spark Plug cap & connect to suitable terminal S1/S2 on the unit.
Connect 'Red' probe of the unit to HT coil primary terminal.
Connect 'Black' probe to earth.
Start the engine.
RHS
Status of LED & Spark window indicates the result as below.

S.N. LED Status
Spark Status
Conclusion
1.
Glows
Continuous
Bluish Spark
Ignition system is OK
2.
Glows
No Spark

may be defective
3.
Glows
Intermittent
Spark

may be defective
4.
Does not
Glow
No Spark
Check pick up coil & Exciter coil

if found OK then replace CDI
82
Remove head light protection rubber cap.
Remove head light bulb socket
83

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

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

light couplers.
Speedometer Replacement SOP

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

Remove speedometer cable,
couplers and take out head light
assembly from vehicle.
84
Remove the speedometer assembly as per the above SOP.
85

Remove 4 nos. 10 mm A/F bolts
& 4 nos. of phillips screws
Head Light Focus Adjustment

Loosen RHS & LHS head light mounting bolt (4 nos. 10 mm A/F) as shown in
photograph.
Adjust the head light focus by moving H/L fairing upward or downward from
bottom side.
Tighten RHS & LHS head light mounting bolt (4 nos. 10 mm A/F)
Take out the bracket
Foam Application - Head Light Fairing

To avoid rattling noise of H/L fairing, please ensure foam application as shown
in photograph.
Remove 6 nos. of phillips screws

& take out the headlight assly.
86
87
Wiring Harness Routing
Clamp wiring harness near LHS H.T. coil using PVC clamp.
Place couplers of tail lamp, number plate lamp, LH & RH rear side indicator in
bellow as shown in photograph.
Route wiring harness from LHS beneath rod joining 2 members of frame as
shown in photograph.
Clamp wiring harness near air filter using PVC clamp.
Route wiring harness through button clamp located near LHS petrol tank
rubber damper.
Route wiring harness beneath the rod joining lamp shade through LHS.
Clamp wiring harness above battery using PVC clamp.
88
89
ELECTRICAL CIRCUIT DIAGRAMS
Precautions to be taken in field to avoid wiring harness failures.
12 POLE COUPLER
REED
SWITCH
Pi
H.T.
COIL
Br/L
B/Y
W/R
O O
N F
F
B/W
B/R
SPARK PLUG
H.T.COIL SPARK PLUG

Br
Br/L
W/R
MAIN FUSE
(10 Amps.)
W/B
THERMAL
SENSOR
B/Y
B/Y
B/W
W/R
MAGNETO
R
BATTERY
12V-5Ah
CO
PU IL
LS
ER
Wiring harness failure due any one of the reason mentioned above should not be covered under warranty replacement.
STARTER MOTOR CIRCUIT

START
SWITCH
Br
R/Y
Br
R/Y
Lg
NEUTRAL
BULB
12V 2W
O O
N F
F
Br
Br/L
Lg
IGNITION SWITCH
Br
FUSE
(10 Amps.)
B/Y
R/Y
Lg
CLUTCH
SWITCH
90
Y/G
Y/G
CABLE ASSY.
BATTERY
TO EARTH
NEUTRAL
SWITCH
Lg
Y/G
STARTER
MOTOR
FUSE
(10 Amps.)
Br
Br/L
B/Y
Lg
B/Y
W/B
7.
8.
9.
10.
11.
12.
Ensure wiring harness is properly routed & clamped.

Ensure firm connections of all couplers.
Ensure wiring harness couplers are placed properly in bellows provided at head lamp fairing & tail lamp side.
Ensure correct routing of wiring harness which will avoid pinching of wires.
Do not apply pressurized water jet on wiring harness.
Do not fit extra electrical accessories. Such as Remote
Extra & bigger horns
Musical brake light
Buzzer
Higher wattage Headlamp bulb.
Flasher operating all 4 side indicators simultaneously
Do not replace fuse with higher capacity fuse.
Do not cut wiring conduit / wires midway.
Never remove conduit from wiring harness
Never bypass fuse.
Do not repair wiring harness instead replace for safety.
Do not ground any wire for checking current-spark.
IGNITION SWITCH
1.
2.
3.
4.
5.
6.
IGNITION CIRCUIT
DC C.D.I. ASSY.
B/R
B/Y
91
BATTERY
12V-5Ah
STARTER RELAY
100A RATING

R
BRAKE LAMP CIRCUIT
HEAD LAMP
CONTROL UNIT
B/Y
Br
L
L
L/W
L/W
O
N
B/Y
R/W
R/W
O
F
F
IGNITION SWITCH
Br/L
Br
Br
Br
B/Y
B/Y
W
L/W
B/Y
EARTH
FRAME
R
O
F
F
Br
DC. REGULATOR ASSLY

WITH CAPACITOR
Br
R
R
B/Y
Y
V
B/Y
Y/L
Y/L
OFF
L/W
LIGHT
SWITCH
Br
PO
ON
L/W
R/B
B/Y
O
N
REAR BRAKE
SWITCH
FRONT BRAKE
SWITCH
CONTROL SWITCH RH
R/B
HI BEAM
INDICATOR
2W
IGNITION
SWITCH
LIGHT SYSTEM CIRCUIT
CAPACITOR
Br
SPEEDOMETER
BULB 3W
B/Y
R
Br
Br/L
TAIL LAMP
ASSY
B/Y
B/Y
TAIL
LAMP
ASSY
R/B
B/Y
R/Y
R/B
FUSE
(10 Amps.)
FUSE
(10 Amps.)
R/B
Br/L
BATTERY
12V-5Ah
PASS
SWITCH
HI
DIMMER
SWITCH
FUSE
(10 Amps.)
Br/L
BATTERY CHARGING CIRCUIT
CAPACITOR
EARTH
FRAME
Br
+
BATTERY
12V-5Ah
HORN & NEUTRAL LIGHT CIRCUIT

SPEEDOMETER
ASSLY
Lg
DC. REGULATOR ASSLY

WITH CAPACITOR
W
Br
B/Y
IGNITION SWITCH
O
N
Br
FUSE
(10 Amps.)
Br
Br/L
B/Y
O
F
F
Lg
LO
B/Y
Y/L
R/B
W/B
W/B
L/W
L/W
Y/L
R/Y
R/Y
R
Br
EARTH-FRAME
L/W
L/W
Br
EARTH FRAME
B/Y
B/Y
R/Y
FUSE
(10 Amps.)
L/W
W/B
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
HORN
NEUTRAL
SWITCH
HORN SWITCH
BATTERY
CHARGING
COIL
92
BATTERY
12V-5Ah
FUSE
(10 Amps.)
R
Br
Br/L
93
BATTERY
12V-5Ah
SIDE INDICATOR CIRCUIT

SIGNAL
LAMP
FRONT RH
LAMP
12V-10W
Gr
Gr
B/Y
B/Y
TURN
SIGNAL
RELAY
Gr
Gr
B/Y
B/Y
Br
SPEEDOMETER
ASSLY
Gr
SIGNAL
LAMP
REAR RH
LAMP
12V-10W
B/Y
IGNITION SWITCH
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
TURN SIGNAL SWITCH
Br/L
R
BATTERY
12V-5Ah
Br
FUSE
(10 Amps.)
94
SIGNAL
LAMP
REAR LH
LAMP
12V-10W

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Contents

I Read ..... I Learn

Engine & Transmission

Standard Operating Procedure...................................... 34

Standard Operating Procedure.......................................56

DISCOVER 125 ST TRAINING NOTES

DISCOVER 125 ST TRAINING NOTES

DISCOVER 125 ST TRAINING NOTES

Frame Number Location

Engine Number Location

Mono Shock absorber

New generation technology engineered

Higher power & pick up.

Wider range of gear ratios to utilize

Better drive-ability and the best fuel

Increased fuel efficiency.

Quick and easy starting.

Feather touch engine starting

Intensity & illumination of head light do

Constant bright beam from head light

DTSi engine - 124.6 cc

DISCOVER 125 ST TRAINING NOTES

DISCOVER 125 ST TRAINING NOTES

COMFORT AND CONVENIENCE

Athletic and muscular petrol tank, side

Stylish and eye catching looks

Black colored engine, 10 spoke alloy

DISCOVER 125 ST TRAINING NOTES

For recording distance covered in a trip

Easy to record trip distance.

Displays approx. petrol qty. remaining

Low battery indicator

Reminds user to get battery charged in

For maintaining battery in healthy

Engine Oil Level Window

For easy inspection & monitoring oil

No hassle of removing, cleaning,

Telescopic front fork with anti-friction

Minimum friction between fork pipes.

Comfortable ride on all types of roads

MF battery with unique vent

Low maintenance - No spillage of

No hassle of frequent topping up of

DISCOVER 125 ST TRAINING NOTES

Robust semi double cradle frame with

Excellent ride and handling stability,

Safe to drive on highway.

200 mm dia front disc, & 130 mm dia

Efficient and effective braking.

Powerful head light, Number Plate

Bright and powerful illumination.

Safe night driving.

10 spoke alloy wheels & unidirectional

Better road grip and nimble handling.

Easy to maneuver and safe to drive.

Enhanced life of disc pads.

DISCOVER 125 ST TRAINING NOTES

For maintaining disc brake good

Final Drive Ratio

Four stroke, Natural air cooled, SI Engine

Semi double cradle

Chassis & Body

DISCOVER 125 ST TRAINING NOTES