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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
33
Vehicle (Frame)
55
Electricals
65
Electricals......................................................................... 66
Dos & Dont's................................................................... 67
Electrical Checking Procedure......................................... 74
Standard Operating Procedure...................................... 83
Electrical circuit Diagram................................................ 91
INTERNATIONAL BUSINESS
1
I Read ..... I Learn
Identification
Salient Features
Technical Specifications
PDI Checklist
Periodic Maintenance & Lubrication Chart
Periodic Maintenance Points
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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
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.
3
11
10
Features
Advantages
Benefits
5 Speed Transmission
ExhausTEC
Molycoat piston
Nozzle oil jet in lubrication circuit
Reduced friction
Better cooling of piston
Protection from seizure
Electric start
DC ignition & Digital CDI
DC Lighting system
9
8
7
6
5
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SALIENT FEATURES
SALIENT FEATURES
STYLE
Advantages
Features
Benefits
Sporty styling
Improves personality of the rider.
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Features
Advantages
Benefits
Trip meter
Fuel Gauge
More convenience.
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SALIENT FEATURES
TECHNICAL SPECIFICATIONS
Engine & Transmission
SAFETY
Features
Advantages
Benefits
Safety.
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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
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
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
:
:
:
:
:
:
:
:
:
:
:
:
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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 :
Kick Operation
Smooth operation
Gear shifting
Smooth operation
Engine noise
No abnormal noise
Silencer noise
Length
Width
Height
Wheel Base
Saddle Height
Ground Clearance
: 1980 mm
: 714 mm
: 1078 mm
: 1306 mm
: 800 mm
: 170 mm
Weights
FUEL SYSTEM
: 125 kg
: 255 kg
Performance
Fuel Cock
Smooth operation
FRAME
Tyre Pressure
Maximum speed
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
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
Clutch Cable
3 if OK or
7 if NOT OK
To Check
Switch Operation
RH & LH control switch, Ignition switch & Brake switch (Front & Rear)
Starter Motor
Speedometer
Working of all signal indicators icons (Turn pilot, Neutral, High beam,
Speedo cable
Proper routine
Drive Chain
Slackness standard - 20 ~ 25 mm
Headlamp assembly
Horn
TEST DRIVE
Starting
SUSPENSION
Front Fork
Steering
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
IMPORTANT NOTE :
Look for any external damages in transit : Please check, record & rectify send report with photos.
Moisture / Oil collecting tube of air filter should be properly fitted and routed correctly.
Tail lamp
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
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Observations /
Remarks
Sr. Operation
No.
Servicing
Kms
1.
Servicing
2.
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.
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
4.
C, A
Top-up
Top-up
Top-up
5.
CL
CL
CL
R
6.
7.
CL
CL
8.
CL,A
CL,A
CL,A
CL,A
CL,A
CL
CL
CL
9.
Spark plug
10.
CL, R
11.
12.
CL
14.
15.
Carburettor
16.
CL
CL
CL
CL
C,L
C,L
C,L
C,L
C,L
C,L
C,L
48.
49.
Wheel bearing
C,R
50.
C,T
C,R
C,R
C,R
C,R
C,T
C,T
C,T
C,T
C,T
C,R
C,R
C,R
CL
CL
Replace at every 15000kms
54.
Auto choke**
55.
C,A
56.
C,A
57.
C,T
C
C,A
C,T
C,A
C,A
C,A
C,A
C,A
C,A
C,A
CL,A
CL
C,A
C,R
C,CL
C,CL
C,CL
C,CL
58.
Wiring harness
59.
At every service
60.
C,CL,L
C,CL,L
C,CL,L
61.
C,R
C,R
C,R
C,R
62.
C,A
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.
C,T
C,T
C,T
C,T
C,T
C,T
C,T
64.
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
65.
HT coil connections
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,R
26.
Clutch plate
C,R
66.
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.
29.
Brake play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
30.
C,R
C,R
C,R
C,R
C,R
C,R
C,R
31.
C,A
C,A
C,A
C,A
C,A
C,A
C,A
Brake fluid
69.
70.
71.
Steering play
in every service
72.
73.
C,L
C,A
74.
C,CL
75.
C,T
35.
36.
37.
C,T
38.
C,R
39.
CL
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,R
CL
12
CL
C,R
CL
CL
C,R
CL
CL
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C,A
C,A
C,A
C,A
C,R
R
L
C,A
C,R
C,T
L
R
C,R
R
L
C,L
R
C,CL,L,R
C,CL,L,R
33.
C,L
C,CL,L,R
34.
C,L
C,A
27.
32.
C,R
C,A
C,A
C,A
CL
C,R
C,A
C,R
C,A
C,R
C,R
C,A
53.
C,A
C,T
47.
C,A
C,A
Battery connections
C,A
C,A
25.
C,L
45.
46.
C,A
C,L
R
C,A
19.
Radiator fins**
C,A
If required
C,A
C,R
23.
CL
24.
CL
CL
CL
CL
C,R
43.
CL
22.
42.
44.
CL
C,R
C,R
CL
C,R
C,R
CL
51.
Fuel pipes
52.
17.
20.
40.
41.
18.
21.
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
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 (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.
Dos
Donts
Caution : Water may enter on the brake liners during washing & brake slippage may occur. Ensure
that brake liners are dry before driving the vehicle.
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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.
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.
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.
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O Ring Drive Chain Cleaning by Removing from Vehicle (Diesel + SAE 90 oil 1:1)
Max. Level
1st Stage:
Clean with
Diesel +
oil 1:1
Park the vehicle on level surface on center stand to check the oil level.
Top up if required.
Min. Level
3rd Stage:
Dip into
SAE 90 oil
2nd Stage:
Clean with
Diesel
+ oil 1:1
Recommended
Grade
Recommended
Quantity
Soak into
SAE 90 oil
Blow Low
Pressure
Compressed
Air
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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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
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
9
Stiff
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3 Dos
7 Don'ts
Handling
Cleaning
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25
1.5% ~ 2.5%
Set VC screw to
get CO% 2 + 0.5
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7 Don'ts
3 Dos
7 Don'ts
3 Dos
Dont fill excess engine oil beyond std. engine oil capacity
otherwise oil will ooze out from engine breather pipe / leak
from gasket - oil seal
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NOTES
2
Fuel System
Carburettor Specifications
Tune up for Optimum Mileage
36
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CARBURETTOR SPECIFICATIONS
UCAL
AIR FILTER:
Clean at Every :
5000 Kms.
Replace at Every :
15,000 Kms.
Cleaning procedure as per SOP
COMPRESSION PRESSURE
Standard :
11 to 13 Kg/cm2
Service Limit :
9.5 Kg/cm2
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
VC Screw Setting
set 2 % co
Main Jet
117.5
O-9
Pilot Jet
12.5
110
Float Height
10.5 mm
17.5
Choke
Manual Choke
30
CO % : 1.5 ~ 2.5 %.
V.C. Screw Setting : To achieve
CO% between 1.5 ~ 2.5
Item
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NOTES
3
Engine & Transmission
Standard Operating Procedure
Special Tools
Gear Transmission Power Flow
Service Limits
Tightening Torques
36
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Remove fuel gauge connection & take out the fuel tank
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Sleeve
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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
Note :
Cylinder head & gear box dismantling & assembly is similar to Pulsar 135 LS.
No exclusive special tool is required for Discover 125 ST.
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Special Tools
: F41ZJZ47
: F41AJA58
: F41ZJZ44
: 37 1040 51
: F41ZJZ46
: F41ZJW33
: 37 10CS 22
: F41AJA11
: 37 1030 48
: F41ZJA54
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: 37 1010 06
: 37 1030 53
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.
: E6101100TE
4
1
Clutch
Input Shaft
: 37 1030 61
st
1 Gear Output
th
4 Gear Output
5
Output Shaft
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4
1
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
Clutch
Input Shaft
Input Shaft
Clutch
rd
rd
3 Gear Input
3 Gear Input
5 Gear Input
th
th
4 Gear Output
5
Output Shaft
4
1
Output Shaft
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4
1
14
15
13
21
16
12
20
17
4
19
4
11
10
16
18
3
17
14
15
4
7
8
10
3
4
13
11
19
18
12
20
22
21
No.
1
2
3
4
5
6
7
8
9
10
11
No.
Description
Shaft Input
Gear 4th Drive
Spline Washer
Ring - Snap
Gear 3rd Drive
Gear 5th Drive Forging Route
Gear 2nd Drive
Washer Thrust 2nd Drive
Shaft Output Forging Route
Gear 2nd Driven
Bush 2nd Driven
12
13
14
15
16
17
18
19
20
21
22
46
Description
Gear 5th Driven Forging Route
Gear 3rd Driven
Gear 4th Driven
Bush 1st Driven
Gear 1st Driven
Washer Thrust
Collar Sprocket Drive
O Ring
Sprocket Output
Plate Lock - Sprocket Output
Bolt Flanged
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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
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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Piston Diameter
10mm
20mm
40mm
Std. Limit
Ser. Limit
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
Intake
54.008 ~ 54.018
Top
Top
Std. Limit
61.165 ~ 61.285
Std. Limit
29.411
29.457
Std. Limit
9.0
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
Exhaust
0.15
Intake
0.15
0.4
0.6
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
Ser. Limit
2.7
Ser. Limit
1.55
Ser. Limit
0.15
20 Link Length
1st
2nd
21st
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
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TIGHTENING TORQUES
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
Std. Limit
0.02
Std. Limit
0.1 ~ 0.35
Std. Limit
20.95 ~ 21.85
Ser. Limit
0.05
Ser. Limit
Ser. Limit
19.6
Spark Plug
3.5 Kgm
4.0 Kgm
3.5 Kgm
NOTES
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5 ~ 5.5 Kgm
NOTES
0.8 Kgm
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NOTES
4
Vehicle (Frame)
Standard Operating Procedure
Service Limits
Tightening Torques
Special Tools
20 Link Length
1st 2nd
20th
36
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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.
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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
100 mm
Std. Limit
130 - 130.16
Std. Limit
TIR 0.05
Std. Limit
Ser. Limit
130.75
Ser. Limit
TIR 0.2
Ser. Limit
TIR 2.0
Route speed sensor cable through clamp provided on LHS of front fender.
1st 2nd
20th
Std. Limit
Std. Limit
20 ~ 25
Std. Limit
254.0 ~ 254.6
Ser. Limit
TIR 2.0
Ser. Limit
35
Ser. Limit
260.0
Route the speed sensor cable with grommet through 'U' type clamp provided
on lower T.
Free Length
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Std. Limit
Std. Limit
392.5
Ser. Limit
Ser. Limit
387.5
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TIGHTENING TORQUES
TIGHTENING TORQUES
LH Stay Bolts
RH Stay Bolts
Grade :
SAE 10W20
Bajaj Genuine
Fork Oil
Quantity :
140 + 2.5 ml /
Fork Leg Assly
(Drain & Refill)
Loctite Applications
0.5 Kgm
2.
3.
4.
5.
6.
7.
8.
HP Lithon RR3
1.
2.
A.P Grease
1.
Type of
Grease
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Special Tools
: 37 1030 48
Application
Application
: 37 1830 07
Application :
To fit fork oil seal in its seat provided at outer
pipe ID.
Part No.
: 37 1805 06
Application
: 37 1830 05
Application
Part No.
: 37 0041 70
Application
: 37 1830 06
Application
: 37 1801 06
Application
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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
Exide
Voltage
12 Volt
Type
MF Battery
Capacity
5 Ah
10 ~15 hrs
0.5 Amp
Battery Features
3 Dos
3
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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Battery
7 Donts
7
3 Dos
3
7
7
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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
7
Do not short circuit the leads.
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3 Dos
LIGHTS
3 Dos
Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler
gauge.
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.
Ensure H.T. cable secondary connection is firmly fitted in spark plug cap a n d
H.T. coil.
7 Don'ts
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.
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
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
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Clutch Switch
Fuse
Light Green
Yellow / Green
Black /Yellow
OFF - Clutch
lever not pressed
ON - Clutch
lever pressed
Blue
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.
Blue
Continuity is shown
No Continuity
74
Continuity Check
OFF - No continuity
ON - Continuity
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Empty Tank
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
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%
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 :
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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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
Standard Value
2.2 Amps
SOP :
Encircle clamp meter jaws around Brown wire of Horn.
Press horn switch & check instantaneous current drawn by horn.
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.
Connections
Meter +ve
Meter -ve
Any segment
on commutator
Adjacent segment
on commutator
Standard Value
Condition 1
Continuity is
shown
Condition 2
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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H. T. Coil
Primary
+ve lead
20 V DC
Specified at
4500 RPM
Meter Connections
H.T. Coil
Secondary
Connections
Meter +ve
Battery
+ve terminal
Battery
-ve terminal
Meter -ve
Connections
-ve lead
14.2 + 0.4 Volts
Standard Value
20 K Ohms
Meter +ve
Standard Value
Meter -ve
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.
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Spark Status
Conclusion
1.
Glows
Continuous
Bluish Spark
Ignition system is OK
2.
Glows
No Spark
3.
Glows
Intermittent
Spark
4.
Does not
Glow
No Spark
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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)
LHS
RHS
Spark Status
Conclusion
1.
Glows
Continuous
Bluish Spark
Ignition system is OK
2.
Glows
No Spark
3.
Glows
Intermittent
Spark
4.
Does not
Glow
No Spark
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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.
Route wiring harness through button clamp located near LHS petrol tank
rubber damper.
Route wiring harness beneath the rod joining lamp shade through LHS.
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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
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.
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
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.
IGNITION SWITCH
1.
2.
3.
4.
5.
6.
IGNITION CIRCUIT
DC C.D.I. ASSY.
B/R
B/Y
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12V-5Ah
STARTER RELAY
100A RATING
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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
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
CAPACITOR
Br
SPEEDOMETER
BULB 3W
B/Y
R
Br
Br/L
TAIL LAMP
ASSY
B/Y
B/Y
TAIL
LAMP
ASSY
R/B
B/Y
R/Y
R/B
FUSE
(10 Amps.)
FUSE
(10 Amps.)
R/B
Br/L
BATTERY
12V-5Ah
PASS
SWITCH
HI
DIMMER
SWITCH
FUSE
(10 Amps.)
Br/L
CAPACITOR
EARTH
FRAME
Br
+
BATTERY
12V-5Ah
Lg
Br
B/Y
IGNITION SWITCH
O
N
Br
FUSE
(10 Amps.)
Br
Br/L
B/Y
O
F
F
Lg
LO
B/Y
Y/L
R/B
W/B
W/B
L/W
L/W
Y/L
R/Y
R/Y
R
Br
EARTH-FRAME
L/W
L/W
Br
EARTH FRAME
B/Y
B/Y
R/Y
FUSE
(10 Amps.)
L/W
W/B
W/B
MAIN FUSE
(10 Amps.)
L/W
POSITION
LAMP
12V-5W
2 Nos
B/Y
L/W
R/B
HEAD LAMP
ASSY / LAMP
12V-35/35W
HS1
L/W
B/Y
B/Y
HORN
NEUTRAL
SWITCH
HORN SWITCH
BATTERY
CHARGING
COIL
92
BATTERY
12V-5Ah
FUSE
(10 Amps.)
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R
Br
Br/L
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BATTERY
12V-5Ah
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
Br/L
R
BATTERY
12V-5Ah
Br
FUSE
(10 Amps.)
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SIGNAL
LAMP
REAR LH
LAMP
12V-10W