CYAN BLACK MAGENTA YELLOW

Bajaj Auto Limited

Akurdi Pune 411 035 India
Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com
Service
Ready
Reckoner
Service
Ready
Reckoner
CYAN BLACK MAGENTA YELLOW
The description and illustrations in this Service Ready Reckoner are not
to be taken as binding on the manufacturer. The essential features of
the type described and illustrated herein remaining unaltered, BAJAJ
AUTO LIMITED reserve the right to carry out at any moment, without
being obliged to bring this Service Ready Reckoner up-to-date,
modifications on the vehicle, parts or accessories, as may be
convenient and necessary.
Copying, quoting or reproducing any part of this Service Ready
Reckoner without the written permission of BAJAJ AUTO LIMITED, is
expressly prohibited.
DOC. NO. 36 02 0355 REV. NO.: 00, SEP. 04
NOTICE
TECHNICAL SPECIFICATIONS
PRE-DELIVERY INSPECTION CHECK LIST
ENGINE EXPLODED VIEW
TIGHTENING TORQUES - ENGINE AND FRAME
SERVICE DATA - ENGINE AND FRAME
ELECTRICAL WIRING DIAGRAMS
WARRANTY, SERVICES AND RESISTANCES
LOCTITES
PARTS IDENTIFICATION
PRECAUTIONARY MEASURES
IMPORTANT ENGINE ASSEMBLY TIPS
PERIODIC MAINTENANCE AND LUBRICATION
FREQUENTLY ASKED QUESTIONS (FAQs)
INDIVIDUAL CIRCUIT DIAGRAMS
STANDARD PROCEDURE FOR CO CHECKING AND SETTING
TUNE UP FOR OPTIMUM MILEAGE
CYAN BLACK MAGENTA YELLOW
1
T E C H N I C A L S P E C I F I C A T I O N S
Type Four stroke, Single cylinder, Natural air cooled.
No. of cylinders One
Bore 57.00 mm.
Stroke 48.80 mm.
Engine displacement 124.52 cc.
Compression ratio 9.5 +0.5:1
Idling Speed 1400 +100 rpm.
Max. net power 8.47 kW (11.51 Ps) at 8000 rpm.
Max. net torque 10.8 Nm at 6500 rpm.
Ignition System Micro controller based digital C.D.I.
0 0
Ignition Timing 10 BTDC at 1400 rpm., 26 BTDC at 3500 rpm
Carburettor Keihin NCV 24, Side Draught, CV Type.
Spark Plug 2 Nos. Champion RG4HC (Resistive)
Spark Plug Gap 0.6 to 0.7 mm.
Lubrication Wet sump, Forced.
Starting Kick Start
Electric start.
ENGINE
DISCOVER
Clutch Wet, Multidisc type.
Transmission 4 speed constant mesh.
st
Gear Ratios: 1 gear 2.92 : 1
nd
2 gear 1.72 : 1
rd
3 gear 1.16 : 1
th
4 gear 0.88 : 1
Final drive ratio 3.21 : 1

Frame Type Double cradle.
Suspension Front (Stroke 135mm.) Telescopic
Rear Trailing arm with coaxial hydraulic shock
absorbers, and triple rate coil springs.
Brakes Front Mechanically expanding
shoe and drum type.
Rear Mechanically expanding shoe and drum type.
Tyres Front 2.75 x 17, 6 PR
Rear 3.00 x 17, 6 PR
Tyre Pressure
2
Front 1.75 Kg/cm (24.5 Psi)
2
Rear Solo 2.00 Kg/cm (28.0 Psi)
2
Rear Pillion 2.25 Kg/cm (32.0 Psi)
CHASSIS & BODY
DISCOVER
2
T E C H N I C A L S P E C I F I C A T I O N S
Rims Front 1.60 x 17
Rear 1.85 x 17
Fuel Tank Capacity 10 litres with 2.3 litres of reserve
Steering Handle Bar
Accelerator Twist grip type on RH side of handle bar
Gears Left foot pedal operated
Clutch Lever operated on LH side of handle bar
Brakes Front Lever operated on RH side of handle bar
Rear Pedal operated by right foot
System 12 V (AC+DC)
Battery 12V 9Ah For ES, 12V 2.5Ah For KS
Head Lamp 35/35 W-HS1 For ES, 60/55 W-HS4 For KS
Pilot Lamp 5W - 2 Nos. For ES 4W - 1 No. For KS
Tail/Stop lamp 5/21 W
Turn signal lamp 10 W
Hi beam indi. lamp 1.7 W
Speedometer lamp 3.4 W
CONTROLS
ELECTRICALS
DISCOVER
Turn Pilot Indi. Lamp 1.7W - 2 Nos.
Neutral indi. lamp 1.7 W
Fuel Gauge 3.4 W
Horn 12V DC
Length 2030 mm.
Width 760 mm.
Height 1065 mm.
Wheel base 1305 mm.
Turning circle radius 2100 mm. (Minimum)
Ground clearance 175 mm. (Minimum)
Vehicle kerb weight 129 kg. For ES 125 kg. For KS
Gross veh. weight 259 Kg. For ES 255 kg. For KS
Maximum speed 100 Km/hr. with single rider (65 Kg)
0
Climbing ability 25% (14 Maximum)
DIMENSIONS
WEIGHTS
PERFORMANCE
DISCOVER
Notes:

Values given above are nominal and for guidance only. 15% variation is allowed to
cater for production and measurement variation.
All dimensions are under unladen condition.
Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
Specifications are subject to change without notice.
CYAN BLACK MAGENTA YELLOW
3
P. D . I . C H E C K L I S T
TO CHECK CHECK FOR
ENGINE :
FRAME :
Engine oil SAE 20W40
API SG+JASO MA
Grade
Idling Speed (Warm up)
Kick operation
Fasteners (Check torque
Fuel Tank / Pipes
Fuel Tap
Carburettor
A. WHEELS
Tyre Pressure
Rim runout (With tyre)
Oil level. Top up if required.
Oil leakage if any.
Check / adjust if required.
(1400 + 100 rpm)
Smooth Operation.
Engine mtg. at Cyl. Head (2.2 Kgm.)
& correct if required) at Front & Rear (3.2 Kgm.)
Oil drain plug (3.0 Kgm.)
Leakages / Fitment.
Smooth operation.
Leakages, Fitment - Orientation & angle
Breather pipe routing.
2
Front - 1.75 Kg/cm
2
Rear - 2.00 Kg/cm (Solo),
2
2.25 Kg/cm (Double)
Radial - (0.8 mm or less)
Axial - (1.0 mm or less)
FUEL SYSTEM :
TO CHECK CHECK FOR
FRAME :
Spokes Check & tighten if required.
Drive chain Slackness (25-35 mm)
Lubrication (SAE 90)
Check chain lock position.
Front brake lever free play (2-3 mm)
Rear brake pedal free play (25-30 mm)
Lever free play (2-3 mm)
Smooth operation.
Grip free play (2-3 mm)
Smooth operation.
Choke Free play (2-3 mm) & smooth operation.
Smooth operation, Oil leakage.
Proper notch setting # Preload setting:
2nd notch (same on both side)
Smooth operation (Loose or tight).
D) LOCK OPERATION Steering and Ignition, Fuel tank,
Seat lock, Side cover LH.
B) CONTROLS
Brakes
Clutch
Throttle
C) SUSPENSION
Front fork
Rear shock absorber
Steering
DIRECTION OF
CHAIN ROTATION
4
P. D . I . C H E C K L I S T
TO CHECK CHECK FOR
E) FASTENERS Check split pin of Front & Rear axle nut.
Rear shock mounting nut (3.5 Kgm.)
Front fork top clamping bolts.
(2.5 to 3.0 Kgm.)
A. BATTERY Electrolyte level / Specific gravity 1.240.
Charging, Connect -ve terminal and
apply petroleum jelly.
Routing of Breather pipe, Fuse.
B. ALL BULBS WORKING Head light, Pilot, Tail / Stop, Side indicator,
Speedometer, Indicator lamps and
Fuel Gauge.
C. SWITCH OPERATION LH and RH control switch.
Ignition switch.
Ride control brake switch (Front & Rear)
and Clutch switch.
D. STARTER MOTOR Proper working / Engagement.
(Use choke for cold starting)
A. STARTING* Cold start and Warm start.
Idling speed (Warm condition)
1400 + 100 rpm
ELECTRICAL
TEST DRIVE (2-3 kms)
Any other defects
Look for any external damages in Transit : Please check, record & rectify.
1. Moisture / Oil collecting tube of Air Filter should be properly fitted and
routed correctly.
TO CHECK CHECK FOR
B. DRIVIABILITY Throttle response
Gear shifting / Clutch operation
Brakes (Front & Rear)
Speedometer, Odometer and Trip meter.
C. CO % CHECK CO should be 1.75-2.25% in warm condition
D. CLEANING Wash & Clean vehicle properly.
* IMPORTANT :

BEFORE STARTING, PLEASE ENSURE FOLLOWING.

Check the fitment of Reed Switch and Magnet.
Max. gap between Magnet and Reed Switch to be 2.5 mm.
Check for working of the Reed Switch assly. and Magnet by using multimeter.
Press and Confirm that both the Spark Plug caps have been fitted correctly.
Confirm tightness and correct fitment of primary leads to both the H.T. Coils.
AFTER STARTING, PLEASE ENSURE FOLLOWING.
Confirm that both the Spark Plugs are firing by using a Timing light or
Stroboscope with the engine idling.
CYAN BLACK MAGENTA YELLOW
5
P E R I O D I C MA I N T E N A N C E A N D L U B R I C A T I O N C H A R T
l : Indicates operation to
be performed.
: More frequent cleaning
may be required when
driving in dusty
condition.
A - Adjust
CL - Clean
C - Check
L - Lubricate
T - Tighten
R - Replace
Note:
Parts/Lubricants to be
replaced as per Periodic
Maintenance and Lubrication
Chart are mandatory and the
same are chargeable to
customer.
1. Servicing l l l l l
2. Idle speed / CO% C,A l l l l l
3. Engine oil (SAE 20W40 of API SG+JASO MA) R l l Every 5000 kms.
4. Valve clearance A l Every 5000 kms.
5. Oil strainer / Centrifugal filter CL Every 10000 kms.
6. Air cleaner element CL l l l l l
7. Air cleaner element R Every 10000 kms.
8. Carburettor CL,A l l l l l
9. Fuel system leakages C,R l l l l l
10. Fuel pipes R 1 Year Every 1 Year
11. Spark plug / gap CL,A l l l l l
12. Spark plug (2 Nos.) R Every 10000 kms.
13. Battery electrolyte level C,A 15 Days l l l l l
14. Brake light switch C,A l l l l l
15. Clutch play A l l l l l
16. Throttle play A l l l l l
17. Rear brake pedal play A l l l l l
18. Brake lining wear C,R l l l l l
19. Steering play C,A l l l l l
20. All fasterners tightness including engine mtg. T l l l l l
Sr.
No. Operation
Whichever
comes first
750 2,500
RECOMMENDED FREQUENCY
Initial Subsequent
5,000 7,500 Every 2,500km Kms.
Days
OR
30 90 150 225 Every 75 days
6
P E R I O D I C MA I N T E N A N C E A N D L U B R I C A T I O N C H A R T
l : Indicates operation to
be performed.
: More frequent cleaning
may be required when
driving in dusty
condition.
A - Adjust
CL - Clean
C - Check
L - Lubricate
T - Tighten
R - Replace
Note:
Parts/Lubricants to be
replaced as per Periodic
Maintenance and Lubrication
Chart are mandatory and the
same are chargeable to
customer.
21. Engine mounting silent blocks R Every 20000 kms.
22. Tyre tread wear C,R l l l l
23. General lubrication L l l l l l
24. Steering stem bearing L 1 Year Every 10000 kms.
25. Wheel bearing L 1 Year Every 10000 kms.
26. Swing arm mounting bush R l Every 20000 kms.
27. Front fork C l l l
28. Front fork oil R Every 10000 kms.
29. Spoke tightness and rim runout C,A l l l l l
30. Rear shock absorber C,R l l l l l
31. Drive chain L Every 500 km
32. Drive chain slack A Every 2500 km
33. Drive chain wear / Remove and Lubricate C,R l Every 5000 kms
34. Gap between Reed switch and TPS magnet C,A l l l l l
Sr.
No. Operation
Whichever
comes first
750 2,500
RECOMMENDED FREQUENCY
Initial Subsequent
5,000 7,500 Every 2,500km Kms.
Days
OR
30 90 150 225 Every 75 days
CYAN BLACK MAGENTA YELLOW
7
P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Cylinder Head with Cover
DH 1015 29
Rubberised silent bush fitted in head cover.
Cylinder Head with Cover
DH 1015 29
Bigger combustion chamber cavity.
DH mark is embossed on casting.
Cylinder Complete
DH 1015 27
Bigger bore.
-----
Piston Assembly
DH 1015 30
DHU mark is embossed on piston crown.
Large in diameter.
Part No.
-----
8
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
P A R T S I D E N T I F I C A T I O N - D I S C O V E R
Cylinder Head with Cover
DS 1011 09
Steel bush fitted in head cover.
Cylinder Head with Cover
DS 1011 09
Smaller combustion chamber cavity.
DS mark is embossed on casting.
Cylinder Complete
DS 1012 54
Smaller bore.
-----
Piston Assembly
DS 1010 13
Two valve relieve grooves are provided on piston crown.
Smaller in diameter.
-----
CYAN BLACK MAGENTA YELLOW
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Piston Pin
DH 1012 70
No chamfer.
Cam Chain
DH 1010 50
More in length 313 mm.
Chain Guide
DH 1010 10
Length is 178 mm.
Length is more.
Wall thickness is more.
Part No.
Part Name
Description
Identification Mark
Guide Chain (Tight)
DH 1010 17
No curvature at bottom location.
10
P A R T S I D E N T I F I C A T I O N - D I S C O V E R
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Piston Pin
DS 1010 86
Chamfer is provided.
Cam Chain
DS 1010 36
One chain link mark with white paint.
Less in length 300 mm.
Chain Guide
Length is 168 mm.
Length is less.
Wall thickness is less.
DS 1010 11
Part No.
Part Name
Description
Identification Mark
Guide Chain (Tight)
DS 1010 12
Curvature at bottom location.
CYAN BLACK MAGENTA YELLOW
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Crankshaft Assembly
DH 1010 57
DH mark is embossed on con-rod.
Clutch Spring
DH 1014 83
Spring has 5 coil turns.
Spring is marked with Yellow colour paint.
Clutch Hub
DH 1014 34
Height is 22.5 mm.
Height is more.
Part No.
Part Name
Description
Identification Mark
Guide Split
DH 1013 74
Splines on ID
Web shape is different.
12
P A R T S I D E N T I F I C A T I O N - D I S C O V E R
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Crankshaft Assembly
DS 1011 84
Groove for square key cotter on clutch side shaft.
Clutch Spring
DS 1011 16
Spring has 4 coil turns.
Spring is marked with Red colour paint.
Clutch Hub
DH 1013 46
Height is 20.5 mm.
Height is less.
Part No.
Part Name
Description
Identification Mark
Guide Split
DS 1011 06
No splines on ID.
Web shape is different.
CYAN BLACK MAGENTA YELLOW
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Gear Change Lever
DH 1011 34
Open end welding dimension is 38.2.
Guide Gear Shift
DH 1014 95
More wide.
Have 5 pins.
Rotor Assembly
DS 1110 08
Pick up coil sensor projection length is 18.13 mm.
Pick up coil sensor is less in length.
18.53 mm.
Part No.
Part Name
Description
Identification Mark
Wiring Harness
DH 2010 29
Yellow colour insulation tape fitted on harness.
14
P A R T S I D E N T I F I C A T I O N - D I S C O V E R
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Gear Change Lever
DS 1011 34
Open end welding dimension is 36.53
Guide Gear Shift
DS 1010 79
Small in size and shape.
Have 4 pins.
Rotor Assembly
DS 1110 08
Pick up coil sensor projection length is 20.00 mm.
Pick up coil sensor is more in length.
20.00 mm.
Part No.
Part Name
Description
Identification Mark
Wiring Harness
DS 2010 01 For KS Version and DS 2010 32 For ES Version.
Red colour insulation tape fitted on harness.
CYAN BLACK MAGENTA YELLOW
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part Name
Description
Identification Mark
CDI
DH 1110 19
DH mark is embossed on body.
Rear Wheel Sprocket
DJ 1510 18
Has 42 teeths.
42 T mark and yellow passivated.
Part No.
16
P A R T S I D E N T I F I C A T I O N - D I S C O V E R
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
CDI
DS 1110 03
DS mark is embossed on body.
Rear Wheel Sprocket
DS 1510 59
Has 45 teeths.
45 TALS mark and black in colour.
CYAN BLACK MAGENTA YELLOW
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T I G H T E N I N G T O R Q U E S - E N G I N E
CHAIN TENSIONER MTG. BOLTS
1.1 kgm.
OUTPUT SPROCKET BOLTS
1.1 kgm. 1.5 kgm.
GUIDE GEAR ALLEN BOLT
CRANKCASE JOINING BOLT
1.1 kgm.
STARTER COUNTER BOLT
1.1 kgm.
CLUTCH COVER BOLTS
1.1 kgm.
CYL. HEAD BKT. MTG. BOLTS
2.0 to 2.2 kgm. 3.0 to 3.2 kgm.
ENGINE MOUNTING BOLTS
2.0 to 2.2 kgm.
ENGINE MOUNTING NUTS
SILENCER MOUNTING NUTS
2.5 kgm.
SILENCER MOUNTING BOLT
3.5 kgm.
CRANKCASE JOINING BOLTS
1.1 kgm.
17
E N G I N E E X P L O D E D V I E W
CYLINDER HEAD ASSEMBLY
CYLINDER BLOCK / PISTON
CRANKSHAFT
CRANKCASE & COVERS
TRANSMISSION
STATOR & ROTOR ASSEMBLY
SILENCER
CLUTCH MECHANISM
OIL PUMP & FILTER
CLUTCH COVER
CHAIN TENSIONER & CHAIN GUIDE
KICK MECHANISM
STARTER MECHANISM (ELECTRIC)
CYAN BLACK MAGENTA YELLOW
19
T I G H T E N I N G T O R Q U E S - E N G I N E
OIL PUMP MOUNTING BOLTS
1.1 kgm.
CENTRIFUGAL OIL FILTER NUT
5.5 kgm. 5.5 kgm.
CLUTCH NUT (L.H. THREADS)
ROTOR MOUNTING BOLT
4.5 kgm.
KICK GUIDE BKT. HOLDER BOLTS
1.1 kgm.
GENERATOR COVER BOLTS
1.1 kgm.
CYLINDER HEAD COVER NUTS
3.5 kgm. 1.1 kgm.
CYLINDER HEAD COVER BOLTS CAM SPROCKET ALLEN BOLT
1.4 kgm.
STARTER MOTOR BOLTS
1.1 kgm.
DRAIN CAP
3.0 kgm.
SPARK PLUGS (2 NOS.)
1.4 kgm.
20
T I G H T E N I N G T O R Q U E S - F R A ME
REAR SPROCKET MTG. NUT
1.8 to 2.5 kgm.
SLEEVE NUT
8.0 kgm.
FRONT AXLE NUT
4.0 to 5.0 kgm.
REAR AXLE NUT
8.0 to 10.0 kgm. 3.0 to 4.0 kgm.
TORQUE ROD NUT
2.0 kgm.
HANDLE BAR HOLDER BOLTS STEERING TOP BOLT
4.5 to 5.0 kgm. 0.5 kgm.
STG. STEM NUT (SLOTTED) LOWER CLAMP BOLTS
3.0 to 3.2 kgm.
UPPER CLAMP BOLT
3.0 to 3.2 kgm.
SWING ARM PIVOT NUT
4.5 to 5.5 kgm.
R.S.A. MTG. NUTS/BOLTS
UPPER - 3.5 to 4.0 kgm.
LOWER - 2.5 kgm.
CYAN BLACK MAGENTA YELLOW
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S E R V I C E D A TA - E N G I N E
COMP. PRESSURE
Standard
2
12-14 kg/cm
Service Limit
2
9.1-14 kg/cm
CAM HEIGHT
Standard 30.80 30.4
Service Limit 30.5 30.00
Ex. Inlet
VALVE STEM DIAMETER
4.46
4.40
4.46
4.40
Inlet Exhaust
Standard
Service Limit
VALVE STEM BEND
TIR 0.01 Standard
TIR 0.03 Service Limit
VALVE HEAD THICKNESS
0.5 0.8
Inlet Exhaust
Standard
0.3 0.6 Service Limit
CAM SHAFT CHAIN 20 LINKS
127 - 127.2 Standard
128 Service Limit
20-link length
1st 2nd 21st
MEASURE THIS LENGTH
CYLINDER INSIDE DIA.
57.010-57.017 Standard
57.017-57.024 Service Limit
10mm
20mm
40mm
PISTON DIAMETER
56.978-56.900 Standard
56.988-56.998 Service Limit
7mm
ALL DIMENSIONS ARE IN MM.
PISTON/CYL. CLEARANCE
0.019 - 0.039
0.05
Standard
Service Limit
ROCKER ARM INSIDE DIA.
10.00 - 10.01 Standard
10.04 Service Limit
CAM SPROCKET DIAMETER
61.4 Standard
61.3 Service Limit
VALVE SPRING FREE LENGTH
41.6
Outer
37.9
Inner
Standard
Service Limit 40.6 36.9
CYLINDER HEAD WARP
Standard 0.00
Service Limit 0.05
VALVE CLEARANCE
0.05
Inlet
0.10
Exhaust
Standard
0.05 0.10 Service Limit
ROCKER ARM SHAFT DIA.
9.97 - 9.98 Standard
9.92 Service Limit
22
S E R V I C E D A TA - E N G I N E
PISTON RING/GROOVE CLEARANCE
Standard 0.02-0.06
Top
0.01-0.05
Second
Service Limit 0.16 0.15
PRESSURE PLATE WARP
0.15 Standard
0.25 Service Limit
CONROD BIG END AXIAL CLEARANCE
Standard 0.1-0.35
Service Limit 0.45
ENGINE OIL SPECIFICATIONS
Grade : SAE 20W40 of API SG +
JASO MA grade or superior.
Quantity : 1000 ml (Drain and Refill)
Oil Change : Every 2,500 km.
Frequency Check and Top-up if required.
Oil Strainer Cleaning : Every 10,000 km.
CARBURETTOR
SPECIFICATIONS
Item DISCOVER
Make & type NCV 24
Keihin Side
Draught, CV
Idling speed 1400 + 100
VC screw 2.5 + 1.0
Turn
Jet needle Fixed,
clip position No clip
provision.
Main jet #128
Pilot jet #35
CO% 1.75-2.25
SHIFT DRUM GROOVE WIDTH
5.05-5.15 Standard
5.25 Service Limit
SHIFT FORK PAD THICKNESS
4.97
4.90
Standard
Service Limit
SHIFT FORK GUIDE PIN DIA.
Standard 4.97
Service Limit 4.90
FRICTION PLATE THICKNESS
2.9-3.1 Standard
2.75 Service Limit
CLUTCH SPRING FREE LTH
30.4 Standard
29.4 Service Limit
CRANK SHAFT RUN OUT
TIR 0.02 max. Standard
TIR 0.05 Service Limit
PISTON RING END GAP
0.15-0.30
Top
0.30-0.45
Second
Standard
0.55 0.70 Service Limit
ALL DIMENSIONS ARE IN MM.
CYAN BLACK MAGENTA YELLOW
23
S E R V I C E D A TA - F R A ME
BR. PANEL CAM HOLE DIA.
Standard 12.0-12.03
Service Limit 12.15
FR. BRAKE PAD THICKNESS
7.4
3.8
Standard
Service Limit
BR. SHOE LINING THICKNESS
3.85-4.15
2.0
Standard
Service Limit
BRAKE DRUM INDISE DIA.
130.00 - 130.16
130.75
Standard
Service Limit
AXLE RUN OUT
TIR 0.1
TIR 0.2
Standard
Service Limit
100 mm
AXIAL WHEEL RUN OUT
TIR 0.8
TIR 2.0
Standard
Service Limit
RADIAL WHEEL RUN OUT
TIR 0.8
TIR 2.0
Standard
Service Limit
DRIVE CHAIN SLACK
25 - 35
35 - 45
Standard
Service Limit
DRIVE CHAIN LENGTH
254 - 254.6
259
Standard
Service Limit
20-link length
1st 2nd 21st
MEASURE THIS LENGTH
REAR SPROCKET WARP
TIR 0.4
TIR 0.5
Standard
Service Limit
BRAKE CAM DIAMETER
11.95-11.98
11.88
Standard
Service Limit
ALL DIMENSIONS ARE IN MM.
FRONT FORK OIL
Grade :
SAE 10W20
Capacity :
145 + 2.5 ml
(per leg)
Oil change
frequency :
After every
10,000 Kms.
FR. TYRE TREAD DEPTH
5.0
1.0
Standard
Service Limit
REAR TYRE TREAD DEPTH
6.6
1.5
Standard
Service Limit
FR. FORK SPRING FREE LTH.
420
416
Standard
Service Limit
Free Length
24
E L E C T R I C A L WI R I N G D I A G R A M - ( E L E C T R I C S T A R T )
G/W B/Y
R/Y
Y/R
L/W L/W Y
B/YW
B/Y
Br/B
RELAY
(FOR INTERLOCKING)
B/Y
(P.NO. DS 20 1016)
(P.NO. DJ 20 1024)
R/W
HORN
Y
Y/L R/BY
PASS
SWITCH
CONTROL SWITCH RH
R/Y R Y Y/L
PO
OFF ON
LIGHT
SWITCH
STARTER
SWITCH
RBr/B Y Y/L
R/Y
BBr
W
B/Y
Y/RW/R
L/W RL/W
COIL
PULSING
MAGNETO
C.D.I. ASSY.
BB/W
B/Y
B
B
STARTER MOTOR
R
FUSE
(15 Amps.)
R
W/B
B
R/Y
STARTER RELAY
WITH DAMPER BATTERY
12V-9Ah
Lg
Lg
R/B
B/Y
W/Y
FUEL LEVEL
GUAGE
POSITION LAMP
12V-5W- 2 Nos.
Br
B/Y
W/Y
Lg
Gr
G
R
R/B
G
FUEL
METER **
TURN SIGNAL
INDICATOR LAMP *
(FRONT LH )
HIGH BEAM
INDICATOR LAMP *
R/B
R/W
ILLUMINATION
LAMP **
R
B/Y
B/Y
B/Y
R/B
O
CONTROL SWITCH LH
W Y
HI LO L R
O
F
F
O
N
Y/R L/WL/WW/R
RB/Y
B/Y
GrGB
B G GrO R/B
G G
B/Y
/ B Y
B/Y
B/Y B/Y
Gr
B/Y B/Y
B/Y B/Y
L
B/Y
R R/W
B/Y
L
Gr Gr
BrL
L Br O Br
G G
B/Y
BrL
L Br
R/Y
Br
W
B/W B/W
W
Br
Lg
W/Y
B/Y
Br
Gr Gr
NEUTRAL
SWITCH
HORN
SWITCH
TURN
SIGNAL
SWITCH
DIMMER
SWITCH
SIGNAL
LAMP
REAR LH
SIGNAL
LAMP
REAR RH
REAR BRAKE
SWITCH
TURN SIGNAL
RELAY
REGULATOR
FRONT BRAKE
SWITCH
SIGNAL LAMP
FRONT LH
HEAD LAMP
ASSY/LAMP
12V-35/35W HS1
IGNITION
SWITCH
NEUTRAL
LAMP *
SIGNAL LAMP
FRONT RH
LAMP 12V-10W
EARTH-FRAME
CABLE ASSY. RED
CABLE ASSY. EARTH
CLUTCH
SWITCH
B/Y
G/W
Br
B/Y
G/W
LgY/G
SPARK
PLUG
H.T.COIL
B/R
SWITCH ASSY.
R
TAIL LAMP
ASSY
TAIL/STOP
LAMP
12V-5/21 W
TURN SIGNAL
INDICATOR LAMP *
(FRONT RH)
NC
NO
P
** LAMP
12V, 3.4W
(QTY. 2)
METER
ASSY.
* LAMP
12V, 1.7W
(QTY. 4)
SPARK
PLUG
H.T.COIL
CYAN BLACK MAGENTA YELLOW
25
E L E C T R I C A L WI R I N G D I A G R A M - ( K I C K S T A R T )
R/B
CAPACITOR
W
W
/R
L/W
L/W
REGULATOR
FUSE (15A)
W
/B
B/Y
G R
BATTERY
12V 2.5AH
B/Y
R
Y
B/Y
B/Y
Y/R
Gr R
COIL
PULSING
MAGNETO
Lg
Lg
R/B
B/Y
W
/Y
FUEL LEVEL GUAGE
Br
B/Y
W/Y
Lg
Gr
G
R
R/B
G
R/B
R/W
Br/W
B/Y
R
/ B Y
B/Y
R B /
W Y
O
F
F
O
N
Y RB/Y
B/Y
Br B
O GrGB
G G
B Y /
/ B Y
/ B Y
/ B Y / B Y
Gr
/ B Y / B Y
/ B Y / B Y
L
/ B Y
R R
/ B Y
L
Gr Gr
BrL
L Br O Br
G G
B Y /
BrL
L Br
R Y /
Br
W
B W / / B W
W
Br
Lg
W/Y
B/Y
Br
Gr Gr
NEUTRAL
SWITCH
HORN
SIGNAL
LAMP
REAR LH
SIGNAL
LAMP
REAR RH
REAR BRAKE
SWITCH
TURN SIGNAL
RELAY
FRONT BRAKE
SWITCH
SIGNAL LAMP
FRONT LH
HEAD LAMP
ASSY/LAMP
12V-60/55W
POSITION
LAMP12V-4W
IGNITION
SWITCH
SIGNAL LAMP
FRONT RH
LAMP 12V-10W
EARTH-FRAME
Y/L
YR
LIGHT SWITCH
ON
OFF
PO
CONTROL SWITCH RH
R/BO GrGB
R L LO HI O
B/Y Y R/B
R/B
Y/L
R/Y
Y
Y/L
TAIL LAMP
ASSY
TAIL/STOP
LAMP
12V-5/10 W
SPARK
PLUG
B
H.T.COIL
B/Y
B
C.D.I. ASSY.
SWITCH ASSY.
W
/R
R B/W
B/R
W/G W/G
SPARK
PLUG H.T.COIL
** LAMP
12V, 3W
(QTY. 3)
* LAMP
12V, 1.4W
(QTY. 5)
FUEL METER
ILLUMINATION
LAMP **
ILLUMINATION
LAMP **
ILLUMINATION
LAMP **
TURN SIGNAL
INDICATOR LAMP *
(FRONT LH )
HIGH BEAM
INDICATOR LAMP *
NEUTRAL LAMP *
TURN SIGNAL
INDICATOR LAMP *
(FRONT RH)
PASS
SWITCH
CONTROL SWITCH LH
HORN
SWITCH
TURN
SIGNAL
SWITCH
DIMMER
SWITCH
26
I N D I V I D U A L C I R C U I T D I A G R A M ( E S )
AC LIGHTING
CIRCUIT
ON
PASS SWITCH
CONTROL SWITCH RH
PO
OFF
POSITION
LAMP
12V-5W
HI LO
DIMMER SWITCH
R.R. UNIT
HEAD
LAMP
ASSY/
LAMP
12V-35/
35W HS1
TAIL/STOP
LAMP
12V-5/21W
INDICATOR
LAMP
HIGH BEAM
12V 1.4W
ILLUMINATION
LAMP
TACHOMETER
12V 3W
ILLUMINATION
LAMP
FUEL METER
12V 3W
ILLUMINATION
LAMP
SPEEDOMETER
12V 3W
MAGNETO
POSITION
LAMP
12V-5W
CONTROL SWITCH LH
B/Y
B/R
B/Y
B/Y
B/Y
B/Y
R/W
R/W
R/W
R
/W
R
R
R
R
Y
Y
/L
Y
Y
/L
Y
B
/Y
Y
/R
Y
/R
Y
R
R
R
B/Y
B/Y
B
/Y
B
/Y
R/Y
R
/Y
B
/R
B/R
B/R
B
/R
B
/R
B/Y
B
/Y
R/W
R
B/Y
CYAN BLACK MAGENTA YELLOW
27
I N D I V I D U A L C I R C U I T D I A G R A M ( E S )
STARTER MOTOR AND
BATTERY CHARGING CIRCUIT
CLUTCH
SWITCH
EARTH-FRAME
NEUTRAL
LAMP
CONTROL SWITCH RH
STARTER
SWITCH
INTERLOCK RELAY
STARTER
MOTOR
NEUTRAL
SWITCH
MAGNETO
STARTER RELAY
FUSE
(15 Amps.)
BATTERY
12V 9Ah
NO
P
NC
O
F
F
O
N
IGNITION
SWITCH
R.R. UNIT
Lg
Br
L
g
Lg
L
g
Lg
Br
B
r
W
W
W
B
/Y
B/Y
G/W
G
/W
G
/W
B
r/W
R
/Y
Br/W
R/Y
R
/Y
R/Y
R
R
R B
B
Y
/G
Y/G
Y
/G
B
/Y
B
/Y
B
/Y
WL
/W
L
/W
L
/W
L
/W
B
/Y
B/Y
28
I N D I V I D U A L C I R C U I T D I A G R A M ( E S )
IGNITION
CIRCUIT
O
F
F
O
N
SPARK
PLUG H.T.COIL
C.D.I. ASSY.
REED SWITCH
ASSY.
COIL
PULSING
MAGNETO
IGNITION
SWITCH
SPARK
PLUG H.T.COIL
B/Y
B
/Y
B/Y
B
/Y
B
B
B
B
B
B
B
B/R
B
/R R
B
/W
B/W
W
/R
W/R
R
R
G
Y
CYAN BLACK MAGENTA YELLOW
29
I N D I V I D U A L C I R C U I T D I A G R A M ( E S )
SIDE INDICATOR AND
HORN CIRCUIT
HORN
MAGNETO
STARTER
MOTOR
FUSE
(15 Amps.)
STARTER
RELAY
O
CONTROL SWITCH LH
HI
L R
O
F
F
O
N
HORN
SWITCH
TURN SIGNAL
SWITCH
SIGNAL
LAMP
REAR LH
12V 10W
SIGNAL
LAMP
REAR RH
12V 10W
TURN SIGNAL RELAY
SIGNAL
LAMP
FRONT LH
12V 10W
IGNITION
SWITCH
SIGNAL
LAMP
FRONT RH
12V 10W
LH TURN
SIGNAL
INDICATOR
LAMP
12V 1.4W
RH TURN
SIGNAL
INDICATOR
LAMP
12V 1.4W
+
BATTERY
12V-9Ah
Gr Gr
G
r
G
r
Gr
Gr
B/Y
B/Y
B/Y
B
/Y
B/Y
B
/Y
B/Y
G
G
G
G
G
Br
W
W B
/Y
B/Y
B
r
O
O
O
B
B
B
r
B
/Y
B
R
W
/B
W
30
I N D I V I D U A L C I R C U I T D I A G R A M ( E S )
FUEL GAUGE AND
BRAKE LIGHT CIRCUIT
MAGNETO
STARTER
MOTOR
FUSE
(15 Amps.)
STARTER RELAY
BATTERY
12V-9Ah
O
F
F
O
N
REAR
BRAKE SWITCH
FRONT
BRAKE SWITCH
IGNITION
SWITCH
TAIL LAMP
ASSY
TAIL/STOP
LAMP
12V-5/21 W
FUEL
METER
FUEL LEVEL
GUAGE
Br
B
r
Br
B
/Y
B/Y
R B
W
/B
W
W
W/Y
W/Y
B
rLL
L
B/Y
B
r
CYAN BLACK MAGENTA YELLOW
31
Warm up the CO Gas Analyzer for
10 t o 15 mi nut es bef or e
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
Readiness of CO Gas Analyzer:
S T A N D A R D P R O C E D U R E F O R C O C H E C K I N G A N D S E T T I N G
out Gas Cal i br at i on as per manuf act ur er s
recommendation). Set the Equipment display to Zero
before taking the reading.
Readiness of the Vehicle:
Before checki ng the CO
emission, prepare the vehicle
for checking the CO >>>
Warm up the engine to
i t s nor mal oper at i ng
temperature by riding 5
to 6 Kms. The Clutch cover should be warm
enough by feel.
Ensure the Choke is in OFF position.
Screw in Volume Control Screw completely. Engine
should die down in this condition.
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
Volume Control Screw.
Confirm the Volume Control Screw to it recommended
position of 2.5 turns.
Set Idling speed to specified Idling to 1400 + 100 rpm
of respective engines. Raise the engine to moderate
speed at no load condition for about 15 seconds.
Then bring back to specified idling RPM.
Taking the Reading:
Insert 'Special Probe' in
the Silencer tail end
pipe properly. Use right
mouth pi ece of the
probe to suit with tail
end pipe of respective
vehi cl e. The speci al
probe is a combination
of adaptor and probe. It
comes with adjustable
stand.
32
S T A N D A R D P R O C E D U R E F O R C O C H E C K I N G A N D S E T T I N G
Precaution: Always ensure rubberised taper portion is
intact with the tail end of the silencer and adaptor is
mounted on the stand at suitable height such that
ingression of fresh air does not take place. The probe
and silencer should be held in same axis.
Note the CO / HC Readings when the reading display
stabilizes.
As per Emission Norms the recommended CO% for
2 Wheelers is 4.5% at Idling RPM. But CO% for Bajaj
Vehicles, for best results in terms of fuel efficiency are
different for different models. For Discover the ideal
CO% is between 1.75 to 2.25% at Idling rpm with
Volume Control Screw between 0.5 to 4.5 turns out.
If the reading is shown excess or less than BAL
Specifications for respective model, then try to achieve
by adjusting Volume Control Screw.
- Turning out Volume Control Screw will lead to more
CO% & turning in will lead to less CO%.
Note: Remember the Volume Control Screw should not
be taken out more than the recommended position.
Every time Volume Control Screw setting is changed
specified Idling RPM must be restored and then reading
should be considered.
After rectifying the problem confirm the CO% in the
same way as mentioned above.
Imp: For Better Mileage and Performance, achieve CO%
as recommended.
In Discover for better mileage and performance achieve
values given below.
Recommended CO% value w.r.t. Volume Control Screw
and Idling RPM for Better Fuel Efficiency
Model
Recommended
CO%
Volume Control Screw
Position
Recommended
Idling RPM
Discover 1.75% 2.25% 0.5 to 4.5 1400 + 100
If the CO% is not falling with in recommended % in spite
of adjusting the Volume Control Screw then find out the
cause and rectify the same.
CYAN BLACK MAGENTA YELLOW
33
T U N E - U P F O R O P T I MU M MI L E A G E
Reed Switch : Maintenance Reed Switch : Checking
Reed Switch : Setting
Magnet should not touch
with reed switch.
Gap between Magnet &
Reed Switch should not be
more than 2.5 mm.
Movement of throttle lever
with magnet assembly and
Reed Switch fitted should
be free.
Check throttle lever movement by rotating it with
hand. It should not be sticky in operation and
should return back it self on releasing.
Accelerator cable play: 2-3
mm by adj ust i ng t he
Adjuster (A).
Protude stopper (B) of the
throttle lever bracket must
on idling screw (C) tip.
Keep t hr ot t l e at zer o
position. (Fig. 1).
On connecting multimeter to
Reed Switch coupler it
should show continuity.
When throttle is open and
Reed Swi t ch magnet
crosses to straight edge of
fix bracket of Reed Switch
(Fig. 2) multimeter should
show discontinuity.
0.00
On De-acceleration, when of
Reed Switch magnet re-
coinsides with straight edge
of fix bracket of Reed
Switch (Fig. 3) Multimeter
should show continuity.
1
1
Gap
2.5mm max.
B
A
C
Fig. 1
Fig. 2
Fig. 3
34
T U N E - U P F O R O P T I MU M MI L E A G E
Engine Maintenance
SPARK PLUG:
RG 4 HC.
Spark Plug Gap :
0.6 to 0.7 mm.
Replace at every :
10,000 Kms.
0.6 to
0.7MM
AIR FILTER:
Clean at every 2,500 Kms.
Replace at every
10,000 Kms.
COMPRESSION PRESSURE
Standard :
2
12 to 14 Kg/cm
Service Limit:
2
9.1 to 14 Kg/cm
Other Mandatory Checks
a. Ensure no fuel leakage through fuel cock, fuel
lines.
b. Ensure free rotation of both the wheels.
c. Ensure correct tyre pressure -
Front wheel : 28 PSI, Rear wheel : 32 PSI
d. Set control cable free play:
Clutch lever 2-3 mm.
Front brake lever 2-3 mm.
Rear brake pedal 25-30 mm.
e. Chain slackness : 25 to 35 mm.
TAPPET CLEARANCE
Inlet valve: 0.05 mm
Exhaust valve: 0.1 mm
CARBURATTOR
Idling : 1400 + 100 rpm.
Vol ume Cont rol screw
setting : 2.5 + 2.0 turns.
CO % : 1.75 to 2.25 %.
CYAN BLACK MAGENTA YELLOW
35
WA R R A N T Y A N D S E R V I C E S
Sr. No. Service Type Kms./days *
1 1st Free with 00,500 - 00,750 Kms. or 30 days.
Oil change
2 2nd Free 02,000 - 02,500 Kms. or 90 days.
3 3rd Free with 04,500 - 05,000 Kms. or 150 days.
Oil change
4 4th Free 07,000 - 07,500 Kms. or 225 days.
5 1st Paid with 09,500 - 10,000 Kms. or 300 days.
Oil change
6 2nd Paid 12,000 - 12,500 Kms. or 375 days.
7 3rd Paid with 14,500 - 15,000 Kms. or 450 days.
Oil change
8 4th Paid 17,000 - 17,500 Kms. or 525 days.
9 5th Paid with 19,500 - 20,000 Kms. or 600 days.
Oil change
10 6th Paid 22,000 - 22,500 Kms. or 675 days.
11 7th Paid with 24,500 - 25,000 Kms. or 675 days.
Oil change
12 8th Paid 27,000 - 27,500 Kms. or 675 days.
13 9th Paid with 29,500 - 30,000 Kms. or 675 days.
Oil change
Warranty
2 Years Or 30,000 Kms.
Warranty
2 Years Or 30,000 Kms.
whichever occurs earlier.
R E S I S T A N C E S
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 10 200 + 30 White/Red Black/Yellow
PICKUP COIL :
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 15 + 3 Red Black/Yellow
CHARGING COIL
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Blue/White Black/Yellow
BATTERY CHARGING COIL(KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.2 + 0.3 Blue/White Blue/White
BATTERY CHARGING COIL(ES)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 0.7 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (ES)
36
L O C T I T E S
CYAN BLACK MAGENTA YELLOW
35
WA R R A N T Y A N D S E R V I C E S
Sr. No. Service Type Kms./days *
1 1st Free with 00,500 - 00,750 Kms. or 30 days.
Oil change
2 2nd Free 02,000 - 02,500 Kms. or 90 days.
3 3rd Free with 04,500 - 05,000 Kms. or 150 days.
Oil change
4 4th Free 07,000 - 07,500 Kms. or 225 days.
5 1st Paid with 09,500 - 10,000 Kms. or 300 days.
Oil change
6 2nd Paid 12,000 - 12,500 Kms. or 375 days.
7 3rd Paid with 14,500 - 15,000 Kms. or 450 days.
Oil change
8 4th Paid 17,000 - 17,500 Kms. or 525 days.
9 5th Paid with 19,500 - 20,000 Kms. or 600 days.
Oil change
10 6th Paid 22,000 - 22,500 Kms. or 675 days.
11 7th Paid with 24,500 - 25,000 Kms. or 675 days.
Oil change
12 8th Paid 27,000 - 27,500 Kms. or 675 days.
13 9th Paid with 29,500 - 30,000 Kms. or 675 days.
Oil change
Warranty
2 Years Or 30,000 Kms.
Warranty
2 Years Or 30,000 Kms.
whichever occurs earlier.
R E S I S T A N C E S
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 10 200 + 30 White/Red Black/Yellow
PICKUP COIL :
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 15 + 3 Red Black/Yellow
CHARGING COIL
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Blue/White Black/Yellow
BATTERY CHARGING COIL(KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.2 + 0.3 Blue/White Blue/White
BATTERY CHARGING COIL(ES)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 0.7 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (ES)
36
L O C T I T E S
Bolt for Plate stopper bearing.
Screw for Pick up mounting on cover.
Screw for Stator mounting on cover.
Allen bolt for Sprocket fitment on cam shaft.
Flanged bolt for Oil pump fitment on crankcase
RH.
Allen bolt for Chain tensioner to crankcase RH.
Flanged bolt for Assembly of crankcase LH & RH.
Allen bolt for Sprocket fitment on output shaft.
Screw for Kick lever.
Flanged bolt for Starter motor fitment on cover RH.
Screw for Starter motor cover.
Flanged bolt for Stopper for plate starter clutch
gear return.
Clutch nut.
Apply before assembly: 638 (Colour - Green)
Guide gear allen bolt.
Kick guide bolts.
Drum stopper arm bolt.
Starter counter one way clutch allen bolts.
Oil separator plate screws.
Bolt holding spring for stopper arm.
Stopper bolt - changer lever spring.
Apply before assembly : 243 (Colour - Blue)
243
CYAN BLACK MAGENTA YELLOW
35
WA R R A N T Y A N D S E R V I C E S
Sr. No. Service Type Kms./days *
1 1st Free with 00,500 - 00,750 Kms. or 30 days.
Oil change
2 2nd Free 02,000 - 02,500 Kms. or 90 days.
3 3rd Free with 04,500 - 05,000 Kms. or 150 days.
Oil change
4 4th Free 07,000 - 07,500 Kms. or 225 days.
5 1st Paid with 09,500 - 10,000 Kms. or 300 days.
Oil change
6 2nd Paid 12,000 - 12,500 Kms. or 375 days.
7 3rd Paid with 14,500 - 15,000 Kms. or 450 days.
Oil change
8 4th Paid 17,000 - 17,500 Kms. or 525 days.
9 5th Paid with 19,500 - 20,000 Kms. or 600 days.
Oil change
10 6th Paid 22,000 - 22,500 Kms. or 675 days.
11 7th Paid with 24,500 - 25,000 Kms. or 675 days.
Oil change
12 8th Paid 27,000 - 27,500 Kms. or 675 days.
13 9th Paid with 29,500 - 30,000 Kms. or 675 days.
Oil change
Warranty
2 Years Or 30,000 Kms.
Warranty
2 Years Or 30,000 Kms.
whichever occurs earlier.
R E S I S T A N C E S
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 10 200 + 30 White/Red Black/Yellow
PICKUP COIL :
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 15 + 3 Red Black/Yellow
CHARGING COIL
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Blue/White Black/Yellow
BATTERY CHARGING COIL(KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.2 + 0.3 Blue/White Blue/White
BATTERY CHARGING COIL(ES)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 1.0 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (KS)
Range
(Ohms)
Connections Reading
(Ohms) Meter +ve Meter -ve
X 1 0.7 + 0.3 Yellow/Red Black/Yellow
LIGHTING COIL (ES)
36
L O C T I T E S
Bolt for Plate stopper bearing.
Screw for Pick up mounting on cover.
Screw for Stator mounting on cover.
Allen bolt for Sprocket fitment on cam shaft.
Flanged bolt for Oil pump fitment on crankcase
RH.
Allen bolt for Chain tensioner to crankcase RH.
Flanged bolt for Assembly of crankcase LH & RH.
Allen bolt for Sprocket fitment on output shaft.
Screw for Kick lever.
Flanged bolt for Starter motor fitment on cover RH.
Screw for Starter motor cover.
Flanged bolt for Stopper for plate starter clutch
gear return.
Clutch nut.
Apply before assembly: 638 (Colour - Green)
Guide gear allen bolt.
Kick guide bolts.
Drum stopper arm bolt.
Starter counter one way clutch allen bolts.
Oil separator plate screws.
Bolt holding spring for stopper arm.
Stopper bolt - changer lever spring.
Apply before assembly : 243 (Colour - Blue)
243
I MPORTANT ENGI NE ASSEMBLY TI PS
Engine Mounting Bolt Tighten Sequence
Whenever engine is mounted on the frame or during periodic services always
tighten engine mounting bolts in the sequence shown in the figure. This will
ensure proper mounting of the engine and will reduce the vibrations and also
increase the life of mounting rubber bushes.
5
7
6
10
9
8
3
4
2
1
CYAN BLACK MAGENTA YELLOW
38
Confirm the free rotation; shifting of gears after assembling.
Always align the gear box into neutral gear position and then assemble
both the crank cases.
Bolt sizes are different. Ensure 1 longest bolt is fitting in clutch side
crankcase and 1 long bolt is fitting towards breather side cranckase.
Confirm the free rotation of crank shaft and centering of crankshaft.
While fitting kick spring, make sure that spring sharp edge does not
scratch against crankcase surface and damage the surface finish.
Special nut has left hand threads and round cut mark around the nut.
Do not lock the rotor holder special tool against the pickup coil sensor
on rotor and gear change shaft.
Always lubricate the needle roller bearing when over hauled. Incorrect
bolt size fitment on body starter may result in locking of rotor or gear
counter assembly.
Place a piece of clean cloth above hollow portion of crank case to
arrest piston pin circlip if it falls during fitment.
Before fitting the sleeve spark plug apply thin layer of molybdenum
disulphide grease on the entry chamfers for the O rings.
Ensure that the O mark on washer always faces upwards.
Ensure the sprocket marks are aligned horizontally with cylinder head
top machined face and the piston is at TDC.
Improper tightening sequence may cause warpage in cylinder head
cover and it can be damage permanently.
Precautions to be taken while assembling of engine
P R E C A U T I O N A R Y ME A S U R E S
While removing engine foundation bolts, first remove the topmost and
then go down progressively.
After removing all the engine connections lift up and remove the
engine from RHS of the vehicle.
Improper loosening sequence may cause warpage in cylinder head
cover and it can be damage permanently.
Drain the engine oil into a clean tray by loosening and removing
strainer cap located on LH side of crankcase.
As fas as possible do not let oil to wet the top of the piston, or the
combustion chamber in the cylinder.
If cylinder block is tight in dowels, lightly tap with hands in upward
direction. If still tight use a plastic or woodem rod and pry it upwards.
When taping the drift for removal of gudgeon pin, confirm that the
connecting rod is held firmly against the direction of tapping to avoid
damage to big end bearing of crank shaft.
Starter cover base is fitted on the crankcase with liquid gasket
application hence tap gently for easy detachment.
Clutch nut have left hand threads.
Precautions to be taken while dismantling of engine
37
I MP O R T A N T E N G I N E A S S E MB LY T I P S
Input Shaft has special nut.
Input Shaft has Left hand threads.
No need of applying Loctite 243.
Washer for Input shaft nut is same as of primary gear.
The special nut has ring mark for identification.
Secure the cam chain sprocket by the tool given
below firmly and then tighten the sprocket allen bolt
(A).
Ensure that the O mark on washer always faces
outwards when tightening the allen bolt (A).
Valve timing
Ensure the sprocket marks (A) are aligned
horizontally with cylinder head top machined face.
Ensure the piston is at TDC.
Ensure T mark on rotor matching the ccase mark.
The clutch collar having hole is to be slided into the
clutch housing for effective lubrication.
Bigger gear to be assembled facing the dust cap side
while assembling the starter counter gear.
Chain top edge to be kept between the two marks
during chain slackness adjustment.
Remove the allen head grub screw before removing
the sleeve spark plug.
Before fitting the sleeve spark plug apply thin layer or
molybdenum di-sulphide grease on the entry
chamfers for the O rings.
Always blow compressed air through the oil
passages in reverse direction of oil flow and ensure
the passages are clear.
Apply a thin layer of liquid gasket on body of the
starter cover.
When splitting crankcase always remove.
First : 1 longest bolt fitted from clutch side.
Second : 1 long bolt fitted from magneto side and
then remove all bolts from magneto side.
A A
A
CYAN BLACK MAGENTA YELLOW
39
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
What are the features of Discover DTS-i motorcycle?
B Discover DTS-i has many Unique; Advanced & Contemporary
features as mentioned below.
Unique Features:
High Power of____________ 11.51 Ps.
Greater Torque of_________ 10.80 N-m.
Max. Speed of____________100 Kmph.
Least emission of CO, so great environment friendly vehicle.
Unique and cute Headlamp fairing with twin pilot lamps and
option of Round Headlamp as well that matches to the profile of
the vehicle.
Advanced Features:
Digital Twin Spark Ignition System (DTS-i) with Twin Map for
accurate ignition timing.
Throttle Responsive Ignition Control System (TRICS).
Optimized engine combustion characteristics to provide ultimate
performance.
Contemporary Features:
Strongest & Sturdier frame & stiffer rectangular cross-sectioned
swing arm to with stand twists and all kind of road tortures.
Longest wheel base in its class for better road holding
characteristics.
Highest rear wheel travel to ensure most comfortable ride in all
terrain.
Longest fr. suspension travel in its class to provide pleasant ride.
Brightest Headlamp with 60 / 55 Watt Halogen bulb for safer night
ride.
What is DTS - i ?
B DTS-i stands for Digital Twin Spark Ignition - an Advanced Technology
which will be the heart of a new breed of high performance engines
from Bajaj.
What is the Advanced Technology in DTS-i ?
B DTS-i engines incorporate Two Spark Plugs (hence called Twin Spark)
in the cylinder head, a Microprocessor controlled (like computers)
Digitally operated CDI which accurately controls the Ignition Timing
and TRICS or Throttle Responsive Ignition Control System, which is a
non-contact switch on the Carburetor body and this changes the
Ignition Map based on Throttle position.
B Combined actions of these technological breakthroughs enhances the
Overall Performance likes Power, Pick-up, and Mileage etc.
Why Twin Spark Plugs ?
B Conventionally in a 4-stroke engine the spark plug is at one end of the
combustion chamber. It means the Air fuel mixture combustion is
better around the sparkplug, rather than the opposite side of the
combustion chamber. Because of the longer time needed for the
combustion to take place on the far side (opposite side of the spark
plug) overall combustion is slow, leading to poor combustion efficiency.
In fact Discover DTS-i delivers power & performance of 125 cc
engine and economy of 100 cc engine. More over the Comfort,
Convenient & Safety are ultimate to any motorcycle on Indian road
with the capacity of 100 to 135 cc engine.
40
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
B Placing another Spark plug opposite to the original one enables the
sparks to occur simultaneously, thus reducing the time for combustion
to take place, thereby increasing combustion efficiency and its speed
with tremendous benefits.
What is the DIGITAL in Digital Twin Spark ignition ?
B Conventional Analogue type CDIs work in a very constricted manner.
They are unable/constrained to control the ignition advance or retard
for specific points in the entire engine rpm range. They could either
advance or retard but not do both for specific points in the engine rpm
range.
B The Ignition System of DTS-i is Digitally operated. An 8 bit
Microprocessor is programmed to decide and control the Ignition
Advance or Retard at any point in the entire engine rpm range. It is
like a computer being programmed to run in a specific way. There is
tremendous consistency and accuracy in the Ignition Timing, which
enhances the overall Performance.
B This Digital CDI has also been programmed to cut the sparks to the
spark plugs at high rpms thereby preventing anybody from damagi ng
the engine. All these advantages are only possible with Digital Chips.
What is TRICS and what is so special about it ?
B A non-contact type switch is mounted on the cable pulley shaft of the
Digital CDI to change the Ignition Advance/Retard map. The amount
of angular movement of the cable pulley shaft depends on the speed
and load demands of the Rider.
B With the adaptation of TRICS, the engine also becomes highly Knock
resistant.
B Throttle Responsive Ignition Control System activates and swaps
between two different Ignition Maps for getting an optimum Ignition
Advance/Retard Timing, for different speed an load conditions. The
switching over of the Ignition maps is Seamless and the switch itself is
completely maintenance free for the life of the Vehicle.
What are the benefits of DTS-i in a nutshell ?
B Digitally managed Optimum Ignition Timing over the entire engine rpm
range for more accuracy and efficiency. And faster & complete
combustion process leading to complete utilization of air-fuel
mixture and thereby results in
Enhanced Power.
Enhanced Pick-up.
Enhanced Mileage.
Enhanced Drivability in all engine operating conditions.
Less Emission of CO. that meets 2005 Emission norms.
Can existing non DTS-i 2 Wheelers be converted into DTS-i
technology ?
B No, the DTS-i technology demands major technological changes in
the engine and vehicle, hence it is almost impossible to convert an
existing 2-wheeler to accept DTS-i technology.The conversion is not
economically viable, as it means almost a complete replacement of
the vehicle/engine.
Does DTS-i costs more in Maintenance ?
B No. The DTS-i technology is tried and tested under extreme
conditions by Bajaj Auto Limited. The systems/parts of DTS-i are
virtually maintenance free.
CYAN BLACK MAGENTA YELLOW
41
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
How DTS-i is different from VT-I in TVS Centra and AMI in Hero
Honda Ambition ?
B VT-I of TVS Centra and AMI of Hero Honda Ambition only have
swithchable Ignition timing maps and Digital CDIs. The switch of TVS
Centra is not Maintenance free and the switch of Hero Honda
Ambition is a contact type, which means problems or wear and tear.
Why the Tyre size is of 17" where as normally all other
motorcycles traditionally have 18" tyres?
B Discover DTS-i motorcycle has some special geometry as far as
Ride Comfort & Pleasure is concerned. The Specialties are
The longest Wheel Base >>> 1305 mm.
Lowest Center of Gravity.
Longest Front Suspension Travel >>> 135 mm.
Wider distance between both Front fork tubes.
Rear Shock Absorber having Triple Rating Spring & longer stroke.
>>> 85 mm.
Longest Rear Wheel Travel. >>> 110 mm.
All these things are enabling Discover DTS-i to deliver Excellent
Road holding, Better Balancing and Extra ordinary High speed
Stability. With this, there is absolutely no need of 18" tyre.
B Rather here, the 17" tyre, due to reduced weight and lesser road
contact area, it will contribute in enhancing the mileage as compared
to 18" tyre.
DTS-i technology from Bajaj Auto Limited is the future of bikes.
Why Dual Oil Filtration system is not given in Discover DTS-i
where as this feature is given in Wind 125?
B Discover DTS-i engine too has dual oil filtration system. The first
stage filtration is done by extra large strainer with fine mesh. And the
second stage filtration is taken care by in built Centrifugal Oil filter
mounted on crankshaft.
B With extra large strainer and Centrifugal Oil filter, the level of filtration
would be similar to the engine having Primary Strainer and Paper Oil
filter.
Being 125 cc and having higher power, why Discover DTS-i has
not been incorprated with 5-speed gear transmission ?
B Considering utilization of power produced by this engine, to achieve
better low-end torque, pick up and to obtain maximum mileage gear
ratios have been uniformly spread across all gears appropriately. With
this 4-speed transmission is enough to perform the task.
When Discover DTS-i has so advanced engine, then how come
SAI system & BS Valve is not provided in this?
B That is one of the speciality of DTS-i engine. The optimized
combustion process because of two Spark plugs, Digitallyma n a g e d
accurate Ignition and TRICS all together address the advantages of
low emission, better cold startability, enhanced drivability delivered by
SAI System and B S Valve.
B That means, again lesser the components, more the benefits.
Why primary kick mechanism isnt provided in Discover DTS-i
engine?
B To reduce engine components which minimizes the engine weight as
42
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
well, the kick mechanism is provided is similar to Caliber & Boxer
range of motorcycles.
B Minimized weight contributes in enhancing the mileage and lesser the
components contribute to cost benefits, which we can pass on to our
valued customers.
Why De-compression mechanism like in Pulsar engines is not
provided in Discover DTS-i engine?
B Normally De-compression mechanism is required in higher capacity
engines where one would feel resistance in operating the kick while
starting the engine. Discover DTS-i engine does not require this.
Why Aircraft Type Fuel Tank Cap similar to Pulsar Fuel Tank Cap
is not provided ?
B Petrol tank caps are designed considering shape of Petrol Tanks. The
cap provided on Discover Petrol tank goes well with its shape.
Why the engine noise level is towards higher side in Discover
DTS-i?
B As we have seen that the Discover DTS-i engine is designed and
developed to achieve optimized combustion process. This is achieved
by having higher compression ratio and so many other design
parameters related to Intake and combustion process.
B This complete combustion process will generate some combustion
noise. This noise will be a characteristic of high performance engines
like DTS-i engines.
To minimize this noise, & control vibrations as well, rubber dampers
have been incorporated in the clutch cover & magneto cover.
B Still such noise will always be heard on high performance engines. So
to achieve more from the limited capacity engines we need to accept
the facts.
Of course this fact is not harmful and will not effect on the
performance of the engine.
Why 4-Plate clutch on this engine, where as Wind 125 and
Pulsar engines have 5-Plate clutch ?
B The clutch of Discover DTS-i engine is bigger so the plates (friction
plates) are wider in size. Due to this, the more contact area in line
with 5-Plate clutch is obtained. With this, 4-Plate clutch is big enough
to handle power transmission characteristics.
Why Crankshaft Balancer is not provided in Discover DTS-i
engine?
B The Crankshaft design and geometry is optimized and the Static &
Dynamic balancing factors are well taken care by this crankshaft with
respect to relative rotating components. Thus the crankshaft of
Discover DTS-i engine does not need balancer.
How come 'Discover DTS-i' is expected to give better mileage in
spite of higher capacity 125cc engine?
B So many parameters aspects are incorporated in Discover DTS-i' to
enable it deliver better mileage.
B On technological front, as we have seen so far the package of DTS-i
like Twin Spark Plugs, Digital CDI, Twin Ignition Maps & TRICS in this
Lean Burn engine, all together have improved combustion process
that is leading to -
Complete combustion of air - fuel mixture.
CYAN BLACK MAGENTA YELLOW
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
0
5
10
15
Power 11.51 8 7.5
Torque 2 0.98 0.9
Discover CT 100 Passion+
7.5
0.9
Splendor
7.7
0.82
Crux
8
0.92
Freedom
0
5
10
15
Power 11.51 10.8 10.7 9.66
Torque 2 1.06 1.07 0.97
Discover Fazer Fredom 125 Victor 125
Will 125 cc bikes become standard on the road as against current
100cc bikes?
B 100 cc bikes are plying on Indian roads now for over a decade. It's a
normal tendency of a person that when he plans to change the
vehicle, he always look for better better power, better capacity, better
pick up. And when because of advancement in engine technology, if
better capacity, say 125 cc engines offers similar economy of 100 cc,
then it influences the trend. We strongly feel 125cc bikes wil become
standard on the Indian road and 100cc bikes will go the way mopeds
have gone.
Does Discover has all the technologies of Pulsar? OR Is DTS-i in
Discover DTS-i' different than in Pulsar?
B The DTS-i technology as such from Bajaj is the same on Pulsar as
well as Discover. The package of DTS-i that comprises Twin Spark
Plugs, Digital CDI, Twin Ignition Maps and TRICS are very much
there and function similar as in case of Pulsar. But the values of
performance are as per the respective engine requirements.
B You can very well see that how the DTS-i technology has enabled
Discover DTS-i' to be close to its Big Brother Pulsar 150 cc.
B Discover DTS-i' almost equal to Regular Pulsar 150 cc and close to
Pulsar 150 cc with DTS-i engine. The table below indicates the
comparison.
B More over it even looks like mini Pulsar as well.
Is 125cc Discover DTS-i' is poor man's Pulsar?
B Yes. Why not? It not only resembles Pulsar in masculine physique but
also it is quite sturdier and rigid in built. The Frame, the square box
swing arm all makes it as strong as Pulsar. So it is a mini Pulsar with
economy.
Power Torque
Maximum
Speed
Vehicle
13.02 Ps
11.68 N-mm
(1.19 Kg-m)
120 Kmph Pulsar DTS-i 150 cc
Pulsar 150 cc Regular
Discover DTS-i
12 Ps
10.8 N-m
(1.1 Kg-m)
100 Kmph
11.51 Ps
10.8 N-m
(1.1 Kg-m)
> 100 Kmph
Combustion at accurate timing with respect to engine rpm at
different speeds and loads on the engine.
Altering of Ignition timing depending upon different throttle
positions.
As these activities consistently take place, the fuel efficiency is bound
happen in Discover DTS-i' engine.
Moreover, other certain virtual elements are there to support this
engine for delivering better mileage. The other virtual elements are -
Lesser weight of the engine as compared to other 125 CC engines.
Lesser road resistance due to lesser road contact area on account
of 17" tyres.
Virtual Instructor to the Rider in the form of Ride Control Switch' to
ride the vehicle in Fuel Efficiency Zone'.
Truly speaking, if Discover DTS-i' is ridden within 'Fuel Efficiency
Zone' as per instruction of Ride Control Switch, it can put all other 125
CC engined vehicles on shame and even able to compete shoulder to
shoulder with other 100 CC engined vehicles.
What is Exhaust TEC'?
B Exhaust TEC is a device incorporated in exhaust system of Discover
DTS-i engine. TEC stands for Torque Expansion Chamber. It
improves Scavenging process.
B The exhaust system has this revolutionary feature, which drastically
improves engine torque at low revs without compromising anything at
mid or high engine revs. It has been extensively optimized to get the
maximum possible performance out of the engine. The Silencer also
has a characteristic tonal quality to it. It gives out a pleasant sounding
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q S
low frequency boom, which many people associate with the typical
'Bullet' kind of silencer sound. While meeting the mandatory current
Noise norms, it gives the vehicle an identity, which is different from
any other bike, so as to make it very unique.
Normally higher power bikes are heavier in weights. How about
Discover?
B Higher the Power Heavier the Engine has become now a vintage
story (or has become a old proverb) Bajaj R & D with its capability has
engineered and developed Discover DTS-i engine with Higher Power
to Weight Ratio as compared to other 125 CC engines.
B On one side it was successful to make the engine deliver more power
and on the other side it has tried to reduce the engine weight by
simplifying the design as compared to other 125 CC engines.
B The Power to Weight Ratio that means the Power produced per ton
weight of the vehicle in comparison with other vehicle is given below.
Is Power & Pick-up of Discover DTS-i marginally or substantially
better than current 100 cc popular bikes or there's a substantial
improvement?
B No. The Power & Pick up of Discover DTS-i is far.. far better than
the popular 100 CC bikes and even much better than any other 125 CC
bike on the road.
B The Power & Torque comparison is follows.
Discover Victor 125 Fazer
Freedom
Prima 125
Power to Weight
Ratio i.e. Power per
Ton weight of the
vehicle
92 81.86 86.4 96.39
43