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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

DISCOVER 125 ST TRAINING NOTES

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DISCOVER 125 ST TRAINING NOTES

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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

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DISCOVER 125 ST TRAINING NOTES

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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.

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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.

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SALIENT FEATURES

TECHNICAL SPECIFICATIONS
Engine & Transmission

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.

DISCOVER 125 ST TRAINING NOTES

For maintaining disc brake good


condition & durability.

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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

DISCOVER 125 ST TRAINING NOTES

:
:
:
:
:
:
:
:
:
:
:
:

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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.

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Free rotation

Side stand & Center stand


Mirror

Smooth operation
Proper fitment
Clear rear view

Head lamp

Focus adjustment

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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

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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
Replace at every 15000kms

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

Replace at every 15000kms

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

Check & replace if required

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

Check & replace if required

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

DISCOVER 125 ST TRAINING NOTES

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

INTERNATIONAL BUSINESS

Check & replace if required

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

Check & replace if required

C,A

27.

32.

Check & replace if required

Replace at every 10000kms

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

Replace at every 15000kms

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

Check & replace if required

Coolant level check in expansion tank**

C,L

Replace in 1st service & at

R
C,A

Replace at every 10000kms

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.

Replace at every 20000kms

18.

21.

1st - 500~750 Kms / 30~45


days,2nd onward@5000Kms

Replace at every 15000kms

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.

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PERIODIC MAINTENANCE POINTS

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.

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PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS


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

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PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS


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.

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PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS

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.

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PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS

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

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PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS

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

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1.5% ~ 2.5%

Set VC screw to
get CO% 2 + 0.5

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1400 + 100 rpm

PERIODIC MAINTENANCE POINTS

PERIODIC MAINTENANCE POINTS

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.

DISCOVER 125 ST TRAINING NOTES

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.

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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.

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NOTES

2
Fuel System
Carburettor Specifications
Tune up for Optimum Mileage

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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

DISCOVER 125 ST TRAINING NOTES

Idling : 1400 + 100 rpm.

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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.

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NOTES

3
Engine & Transmission
Standard Operating Procedure
Special Tools
Gear Transmission Power Flow
Service Limits
Tightening Torques

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STANDARD OPERATING PROCEDURE

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

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE


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

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE


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

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SPECIAL TOOLS - ENGINE

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.

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GEAR TRANSMISSION POWER FLOW

SPECIAL TOOLS - ENGINE


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

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4
1

GEAR TRANSMISSION POWER FLOW

GEAR TRANSMISSION POWER FLOW


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

Final Drive to the Rear Wheel


Final Drive to the Rear Wheel

Third Gear Position : When Third Gear is


engaged, power from clutch flows as follows.

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

Final Drive to the Rear Wheel

Final Drive to the Rear Wheel

DISCOVER 125 ST TRAINING NOTES

Fifth Gear Position : When Fifth Gear is


engaged, power from clutch flows as follows.

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4
1

GEAR TRANSMISSION POWER FLOW

GEAR TRANSMISSION POWER FLOW

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

DISCOVER 125 ST TRAINING NOTES

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

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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

DISCOVER 125 ST TRAINING NOTES

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

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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


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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

ALL DIMENSIONS ARE IN MM

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

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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

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NOTES

4
Vehicle (Frame)
Standard Operating Procedure
Service Limits
Tightening Torques
Special Tools

20 Link Length

1st 2nd

20th

MEASURE THIS LENGTH

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE

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.

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SERVICE DATA - FRAME

STANDARD OPERATING PROCEDURE


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

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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

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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

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Grease

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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.

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NOTES

5
Electricals
Battery
Dos & Don'ts
Electrical Checking Procedures
Standard Operating Procedures
Electrical Circuit Diagrams

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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.

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Always maintain electrolyte


level between maximum &
minimum level marks.

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DOS & DON'TS - GENERIC

DOS & DON'TS - GENERIC


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.

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Use battery load tester for checking battery charge


condition.

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DOS & DON'TS - GENERIC

DOS & DON'TS - GENERIC


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.

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DOS & DON'TS - GENERIC

DOS & DON'TS - GENERIC


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.

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ELECTRICAL CHECKING PROCEDURE

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

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Continuity Check
OFF - No continuity
ON - Continuity

Continuity check by multimeter

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ELECTRICAL CHECKING PROCEDURE

ELECTRICAL CHECKING PROCEDURE


Engine Thermal Sensor

Fuel Gauge - Tank Unit

Empty Tank

Measuring & Testing Equipment : Multimeter

Measuring & Testing Equipment : Multimeter


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

Measuring & Testing Equipment : Multimeter


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 :

Measuring & Testing Equipment : Multimeter


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.

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ELECTRICAL CHECKING PROCEDURE

ELECTRICAL CHECKING PROCEDURE


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

Measuring & Testing Equipment : Multimeter


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 :-

Measuring & Testing Equipment : Multimeter


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.

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Thus low battery indicator reminds to charge battery /


correct battery charging system in time.

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ELECTRICAL CHECKING PROCEDURE

ELECTRICAL CHECKING PROCEDURE


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


Measuring & Testing Equipment : Multimeter
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

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S.N. LED Status

Spark Status

Conclusion

1.

Glows

Continuous
Bluish Spark

Ignition system is OK

2.

Glows

No Spark

HT Coil / Spark plug / Plug cap


may be defective

3.

Glows

Intermittent
Spark

HT Coil / Spark plug / Plug cap


may be defective

4.

Does not
Glow

No Spark

Check pick up coil & Exciter coil


if found OK then replace CDI

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STANDARD OPERATING PROCEDURE

ELECTRICAL CHECKING PROCEDURE

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

HT Coil / Spark plug / Plug cap


may be defective

3.

Glows

Intermittent
Spark

HT Coil / Spark plug / Plug cap


may be defective

4.

Does not
Glow

No Spark

Check pick up coil & Exciter coil


if found OK then replace CDI

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Remove head light protection rubber cap.

Remove head light bulb socket

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE


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.

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Remove the speedometer assembly as per the above SOP.

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE


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.

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STANDARD OPERATING PROCEDURE

STANDARD OPERATING PROCEDURE

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.

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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

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Y/G

Y/G

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CABLE ASSY.
BATTERY
TO EARTH

NEUTRAL
SWITCH

Lg

Y/G

STARTER
MOTOR
FUSE
(10 Amps.)

Br

Br/L

B/Y

Lg

B/Y

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

STANDARD OPERATING PROCEDURE

91

BATTERY
12V-5Ah
STARTER RELAY
100A RATING

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ELECTRICAL CIRCUIT DIAGRAMS


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

ELECTRICAL CIRCUIT DIAGRAMS

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

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BATTERY
12V-5Ah

FUSE
(10 Amps.)

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R
Br

Br/L

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BATTERY
12V-5Ah

ELECTRICAL CIRCUIT DIAGRAMS

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.)

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SIGNAL
LAMP
REAR LH
LAMP
12V-10W