CYAN MAGENTA YELLOW BLACK

Bajaj Auto Limited

Service
Akurdi Pune 411 035 India
Tel +91 20 27472851
Ready
Fax +91 20 27407385
www.bajajauto.com
Reckoner
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NOTICE TECHNICAL SPECIFICATIONS

The description and illustrations in this Service Ready Reckoner are not PRE-DELIVERY INSPECTION CHECK LIST
PERIODIC MAINTENANCE AND LUBRICATION
to be taken as binding on the manufacturer. The essential features of
PARTS IDENTIFICATION
the type described and illustrated herein remaining unaltered, BAJAJ
ENGINE EXPLODED VIEW
AUTO LIMITED reserve the right to carry out at any moment, without TIGHTENING TORQUES - ENGINE AND FRAME
being obliged to bring this Service Ready Reckoner up-to-date, SERVICE DATA - ENGINE AND FRAME
modifications on the vehicle, parts or accessories, as may be ELECTRICAL WIRING DIAGRAMS

convenient and necessary. INDIVIDUAL CIRCUIT DIAGRAMS

STANDARD PROCEDURE FOR CO CHECKING AND SETTING
Copying, quoting or reproducing any part of this Service Ready TUNE UP FOR OPTIMUM MILEAGE
Reckoner without the written permission of BAJAJ AUTO LIMITED, is WARRANTY, SERVICES AND RESISTANCES

expressly prohibited. LOCTITES

IMPORTANT ENGINE ASSEMBLY TIPS
DOC. NO. 36 02 0355 REV. NO.: 00, SEP’. 04 PRECAUTIONARY MEASURES
FREQUENTLY ASKED QUESTIONS (FAQs)
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TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS

DISCOVER DISCOVER DISCOVER DISCOVER
ENGINE Clutch Wet, Multidisc type. Rims Front 1.60 x 17 Turn Pilot Indi. Lamp 1.7W - 2 Nos.
Rear 1.85 x 17 Neutral indi. lamp 1.7 W
Type Four stroke, Single cylinder, Natural air cooled. Transmission 4 speed constant mesh.
st
Fuel Tank Capacity 10 litres with 2.3 litres of reserve Fuel Gauge 3.4 W
No. of cylinders One Gear Ratios: 1 gear 2.92 : 1
2nd gear 1.72 : 1 CONTROLS Horn 12V DC
Bore 57.00 mm.
3rd gear 1.16 : 1 Steering Handle Bar
DIMENSIONS
Stroke 48.80 mm. 4th gear 0.88 : 1 Accelerator Twist grip type on RH side of handle bar Length 2030 mm.
Engine displacement 124.52 cc. Final drive ratio 3.21 : 1 Gears Left foot pedal operated Width 760 mm.
Compression ratio 9.5 +0.5:1 CHASSIS & BODY Clutch Lever operated on LH side of handle bar Height 1065 mm.
Idling Speed 1400 +100 rpm. Frame Type Double cradle. Brakes Front Lever operated on RH side of handle bar Wheel base 1305 mm.
Rear Pedal operated by right foot Turning circle radius 2100 mm. (Minimum)
Max. net power 8.47 kW (11.51 Ps) at 8000 rpm. Suspension Front (Stroke 135mm.) Telescopic
ELECTRICALS Ground clearance 175 mm. (Minimum)
Max. net torque 10.8 Nm at 6500 rpm. Rear Trailing arm with coaxial hydraulic shock
absorbers, and triple rate coil springs. System 12 V (AC+DC) WEIGHTS
Ignition System Micro controller based digital C.D.I. Vehicle kerb weight 129 kg. For ES 125 kg. For KS
Brakes Front Mechanically expanding Battery 12V 9Ah For ES, 12V 2.5Ah For KS
Ignition Timing 100 BTDC at 1400 rpm., 260 BTDC at 3500 rpm shoe and drum type. Gross veh. weight 259 Kg. For ES 255 kg. For KS
Head Lamp 35/35 W-HS1 For ES, 60/55 W-HS4 For KS
Carburettor Keihin NCV 24, Side Draught, CV Type. Rear Mechanically expanding shoe and drum type. PERFORMANCE
Tyres Front 2.75 x 17, 6 PR Pilot Lamp 5W - 2 Nos. For ES 4W - 1 No. For KS
Spark Plug 2 Nos. Champion RG4HC (Resistive) Maximum speed 100 Km/hr. with single rider (65 Kg)
Rear 3.00 x 17, 6 PR Tail/Stop lamp 5/21 W Climbing ability 25% (140 Maximum)
Spark Plug Gap 0.6 to 0.7 mm.
Tyre Pressure Turn signal lamp 10 W Notes: • Values given above are nominal and for guidance only. 15% variation is allowed to
Lubrication Wet sump, Forced. Front 1.75 Kg/cm2 (24.5 Psi) cater for production and measurement variation.
Rear Solo 2.00 Kg/cm2 (28.0 Psi) Hi beam indi. lamp 1.7 W • All dimensions are under unladen condition.
Starting Kick Start • Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
Electric start. Rear Pillion 2.25 Kg/cm2 (32.0 Psi) Speedometer lamp 3.4 W • Specifications are subject to change without notice.

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P. D . I . C H E C K L I S T P. D . I . C H E C K L I S T
TO CHECK CHECK FOR TO CHECK CHECK FOR TO CHECK CHECK FOR TO CHECK CHECK FOR
ENGINE : FRAME : E) FASTENERS Check split pin of Front & Rear axle nut. B. DRIVIABILITY Throttle response
Engine oil SAE 20W40 Oil level. Top up if required. Spokes Check & tighten if required. Rear shock mounting nut (3.5 Kgm.) Gear shifting / Clutch operation
API ‘SG’+JASO ‘MA’ Oil leakage if any. Front fork top clamping bolts. Brakes (Front & Rear)
Grade Drive chain Slackness (25-35 mm)
(2.5 to 3.0 Kgm.) Speedometer, Odometer and Trip meter.
DIRECTION OF
CHAIN ROTATION Lubrication (SAE 90)
Idling Speed (Warm up) Check / adjust if required. ELECTRICAL
Check chain lock position. C. CO % CHECK CO should be 1.75-2.25% in warm condition
(1400 + 100 rpm)
A. BATTERY Electrolyte level / Specific gravity 1.240.
B) CONTROLS D. CLEANING Wash & Clean vehicle properly.
Kick operation Smooth Operation. Charging, Connect -ve terminal and
Brakes Front brake lever free play (2-3 mm) apply petroleum jelly.
* IMPORTANT :
Fasteners (Check torque Engine mtg. at Cyl. Head (2.2 Kgm.) Rear brake pedal free play (25-30 mm) Routing of Breather pipe, Fuse. BEFORE STARTING, PLEASE ENSURE FOLLOWING.
& correct if required) at Front & Rear (3.2 Kgm.)
Clutch Lever free play (2-3 mm) • Check the fitment of Reed Switch and Magnet.
Oil drain plug (3.0 Kgm.) B. ALL BULBS WORKING Head light, Pilot, Tail / Stop, Side indicator,
Smooth operation. • Max. gap between Magnet and Reed Switch to be 2.5 mm.
Speedometer, Indicator lamps and
FUEL SYSTEM : • Check for working of the Reed Switch assly. and Magnet by using multimeter.
Throttle Grip free play (2-3 mm) Fuel Gauge. • Press and Confirm that both the Spark Plug caps have been fitted correctly.
Fuel Tank / Pipes Leakage’s / Fitment. Smooth operation. • Confirm tightness and correct fitment of primary leads to both the H.T. Coils.
C. SWITCH OPERATION LH and RH control switch.
Fuel Tap Smooth operation. AFTER STARTING, PLEASE ENSURE FOLLOWING.
Choke Free play (2-3 mm) & smooth operation. Ignition switch.
Carburettor Leakages, Fitment - Orientation & angle • Confirm that both the Spark Plugs are firing by using a Timing light or
Breather pipe routing. Ride control brake switch (Front & Rear) Stroboscope with the engine idling.
C) SUSPENSION
and Clutch switch.
FRAME : Front fork Smooth operation, Oil leakage.
D. STARTER MOTOR Proper working / Engagement. Any other defects
A. WHEELS Rear shock absorber Proper notch setting # Preload setting: (Use choke for cold starting)
Tyre Pressure Front - 1.75 Kg/cm2 2nd notch (same on both side)
TEST DRIVE (2-3 kms)
Rear - 2.00 Kg/cm2 (Solo), Steering Smooth operation (Loose or tight). Look for any external damages in Transit : Please check, record & rectify.
2.25 Kg/cm2 (Double) A. STARTING* Cold start and Warm start. 1. Moisture / Oil collecting tube of Air Filter should be properly fitted and
D) LOCK OPERATION Steering and Ignition, Fuel tank, Idling speed (Warm condition) routed correctly.
Rim runout (With tyre) Radial - (0.8 mm or less)
Axial - (1.0 mm or less) Seat lock, Side cover LH. 1400 + 100 rpm

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PERIODIC MAINTENANCE AND LUBRICATION CHART PERIODIC MAINTENANCE AND LUBRICATION CHART
Whichever RECOMMENDED FREQUENCY l : Indicates operation to Whichever RECOMMENDED FREQUENCY l : Indicates operation to
Sr. comes first be performed. Sr. comes first be performed.
Operation Initial Subsequent Operation Initial Subsequent
No. « : More frequent cleaning No. « : More frequent cleaning
Kms. 750 2,500 5,000 7,500 Every 2,500km may be required when Kms. 750 2,500 5,000 7,500 Every 2,500km may be required when
OR OR
Days 30 90 150 225 Every 75 days driving in dusty Days 30 90 150 225 Every 75 days driving in dusty
condition. condition.
1. Servicing l l l l l 21. Engine mounting silent blocks R Every 20000 kms.
2. Idle speed / CO% C,A l l l l l 22. Tyre tread wear C,R l l l l
A - Adjust A - Adjust
3. Engine oil (SAE 20W40 of API SG+JASO MA) R l l Every 5000 kms. 23. General lubrication L l l l l l
CL - Clean CL - Clean
4. Valve clearance A l Every 5000 kms. 24. Steering stem bearing L 1 Year Every 10000 kms.
C - Check C - Check
5. Oil strainer / Centrifugal filter CL Every 10000 kms. 25. Wheel bearing L 1 Year Every 10000 kms.
L - Lubricate L - Lubricate
6. Air cleaner element « CL l l l l l 26. Swing arm mounting bush R l Every 20000 kms.
T - Tighten T - Tighten
7. Air cleaner element R Every 10000 kms. 27. Front fork C l l l
R - Replace R - Replace
8. Carburettor CL,A l l l l l 28. Front fork oil R Every 10000 kms.
9. Fuel system leakages C,R l l l l l 29. Spoke tightness and rim runout C,A l l l l l
10. Fuel pipes R 1 Year Every 1 Year Note: 30. Rear shock absorber C,R l l l l l Note:
Parts/Lubricants to be Parts/Lubricants to be
11. Spark plug / gap CL,A l l l l l replaced as per Periodic
31. Drive chain L Every 500 km
replaced as per Periodic
12. Spark plug (2 Nos.) R Every 10000 kms. Maintenance and Lubrication 32. Drive chain slack A Every 2500 km Maintenance and Lubrication
13. Battery electrolyte level C,A 15 Days l l l l l Chart are mandatory and the 33. Drive chain wear / Remove and Lubricate C,R l Every 5000 kms Chart are mandatory and the
14. Brake light switch C,A l l l l l same are chargeable to 34. Gap between Reed switch and TPS magnet C,A l l l l l same are chargeable to
customer. customer.
15. Clutch play A l l l l l
16. Throttle play A l l l l l
17. Rear brake pedal play A l l l l l
18. Brake lining wear C,R l l l l l
19. Steering play C,A l l l l l
20. All fasterners tightness including engine mtg. T l l l l l

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PARTS IDENTIFICATION - PULSAR 150 DTSi PARTS IDENTIFICATION - DISCOVER

Part Name Cylinder Head with Cover Part Name Cylinder Head with Cover
Part No. DH 1015 29 Part No. DS 1011 09

Description ----- Description -----

Identification Mark Rubberised silent bush fitted in head cover. Identification Mark Steel bush fitted in head cover.

Part Name Cylinder Head with Cover Part Name Cylinder Head with Cover
Part No. DH 1015 29 Part No. DS 1011 09

Description Bigger combustion chamber cavity. Description Smaller combustion chamber cavity.

Identification Mark DH mark is embossed on casting. Identification Mark DS mark is embossed on casting.

Part Name Cylinder Complete Part Name Cylinder Complete

Part No. DH 1015 27 Part No. DS 1012 54

Description Bigger bore. Description Smaller bore.

Identification Mark ----- Identification Mark -----

Part Name Piston Assembly Part Name Piston Assembly

Part No. DH 1015 30 Part No. DS 1010 13

Description Large in diameter. Description Smaller in diameter.

Identification Mark DHU mark is embossed on piston crown. Identification Mark Two valve relieve grooves are provided on piston crown.

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PARTS IDENTIFICATION - PULSAR 150 DTSi PARTS IDENTIFICATION - DISCOVER

Part Name Piston Pin Part Name Piston Pin
Part No. DH 1012 70 Part No. DS 1010 86

Description Wall thickness is more. Description Wall thickness is less.

Identification Mark No chamfer. Identification Mark Chamfer is provided.

Part Name Cam Chain Part Name Cam Chain

Part No. DH 1010 50 Part No. DS 1010 36

Description More in length 313 mm. Description Less in length 300 mm.

Identification Mark Identification Mark One chain link mark with white paint.

Part Name Chain Guide Part Name Chain Guide

Part No. DH 1010 10 Part No. DS 1010 11

Description Length is more. Description Length is less.

Identification Mark Length is 178 mm. Identification Mark Length is 168 mm.

Part Name Guide Chain (Tight) Part Name Guide Chain (Tight)
Part No. DH 1010 17 Part No. DS 1010 12

Description Description

Identification Mark No curvature at bottom location. Identification Mark Curvature at bottom location.

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PARTS IDENTIFICATION - PULSAR 150 DTSi PARTS IDENTIFICATION - DISCOVER

Part Name Crankshaft Assembly Part Name Crankshaft Assembly
Part No. DH 1010 57 Part No. DS 1011 84

Description Web shape is different. Description Web shape is different.

Identification Mark DH mark is embossed on con-rod. Identification Mark Groove for square key cotter on clutch side shaft.

Part Name Clutch Spring Part Name Clutch Spring

Part No. DH 1014 83 Part No. DS 1011 16

Description Spring has 5 coil turns. Description Spring has 4 coil turns.

Identification Mark Spring is marked with Yellow colour paint. Identification Mark Spring is marked with Red colour paint.

Part Name Clutch Hub Part Name Clutch Hub

Part No. DH 1014 34 Part No. DH 1013 46

Description Height is more. Description Height is less.

Identification Mark Height is 22.5 mm. Identification Mark Height is 20.5 mm.

Part Name Guide Split Part Name Guide Split

Part No. DH 1013 74 Part No. DS 1011 06

Description Description

Identification Mark Splines on ID Identification Mark No splines on ID.

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PARTS IDENTIFICATION - PULSAR 150 DTSi PARTS IDENTIFICATION - DISCOVER

Part Name Gear Change Lever Part Name Gear Change Lever
Part No. DH 1011 34 Part No. DS 1011 34

Description Description

Identification Mark Open end welding dimension is 38.2. Identification Mark Open end welding dimension is 36.53

Part Name Guide Gear Shift Part Name Guide Gear Shift
Part No. DH 1014 95 Part No. DS 1010 79

Description More wide. Description Small in size and shape.

Identification Mark Have 5 pins. Identification Mark Have 4 pins.

18.53 mm. Part Name Rotor Assembly 20.00 mm. Part Name Rotor Assembly
Part No. DS 1110 08 Part No. DS 1110 08

Description Pick up coil sensor is less in length. Description Pick up coil sensor is more in length.

Identification Mark Pick up coil sensor projection length is 18.13 mm. Identification Mark Pick up coil sensor projection length is 20.00 mm.

Part Name Wiring Harness Part Name Wiring Harness

Part No. DH 2010 29 Part No. DS 2010 01 For KS Version and DS 2010 32 For ES Version.

Description Description

Identification Mark Yellow colour insulation tape fitted on harness. Identification Mark Red colour insulation tape fitted on harness.

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PARTS IDENTIFICATION - PULSAR 150 DTSi PARTS IDENTIFICATION - DISCOVER

Part Name CDI Part Name CDI
Part No. DH 1110 19 Part No. DS 1110 03

Description Description

Identification Mark DH mark is embossed on body. Identification Mark DS mark is embossed on body.

Part Name Rear Wheel Sprocket Part Name Rear Wheel Sprocket
Part No. DJ 1510 18 Part No. DS 1510 59

Description Has 42 teeths. Description Has 45 teeths.

Identification Mark 42 ‘T’ mark and yellow passivated. Identification Mark 45 ‘TALS’ mark and black in colour.

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ENGINE EXPLODED VIEW TIGHTENING TORQUES - ENGINE

CYL. HEAD BKT. MTG. BOLTS ENGINE MOUNTING BOLTS ENGINE MOUNTING NUTS CHAIN TENSIONER MTG. BOLTS

2.0 to 2.2 kgm. 3.0 to 3.2 kgm. 2.0 to 2.2 kgm. 1.1 kgm.

OUTPUT SPROCKET BOLTS SILENCER MOUNTING BOLT SILENCER MOUNTING NUTS GUIDE GEAR ALLEN BOLT

CYLINDER BLOCK / PISTON

CYLINDER HEAD ASSEMBLY
SILENCER
1.1 kgm. 3.5 kgm. 2.5 kgm. 1.5 kgm.
CLUTCH MECHANISM
OIL PUMP & FILTER STARTER COUNTER BOLT CRANKCASE JOINING BOLTS CRANKCASE JOINING BOLT CLUTCH COVER BOLTS
CLUTCH COVER
CHAIN TENSIONER & CHAIN GUIDE
CRANKSHAFT
KICK MECHANISM
CRANKCASE & COVERS
TRANSMISSION
STATOR & ROTOR ASSEMBLY
STARTER MECHANISM (ELECTRIC) 1.1 kgm. 1.1 kgm. 1.1 kgm. 1.1 kgm.

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TIGHTENING TORQUES - ENGINE TIGHTENING TORQUES - FRAME

OIL PUMP MOUNTING BOLTS CENTRIFUGAL OIL FILTER NUT GENERATOR COVER BOLTS CLUTCH NUT (L.H. THREADS) FRONT AXLE NUT REAR AXLE NUT TORQUE ROD NUT SLEEVE NUT REAR SPROCKET MTG. NUT

4.0 to 5.0 kgm. 8.0 to 10.0 kgm. 3.0 to 4.0 kgm. 8.0 kgm. 1.8 to 2.5 kgm.
1.1 kgm. 5.5 kgm. 1.1 kgm. 5.5 kgm.

CYLINDER HEAD COVER NUTS CYLINDER HEAD COVER BOLTS CAM SPROCKET ALLEN BOLT STARTER MOTOR BOLTS
HANDLE BAR HOLDER BOLTS STEERING TOP BOLT STG. STEM NUT (SLOTTED) UPPER CLAMP BOLT LOWER CLAMP BOLTS

2.0 kgm. 4.5 to 5.0 kgm. 0.5 kgm. 3.0 to 3.2 kgm. 3.0 to 3.2 kgm.
3.5 kgm. 1.1 kgm. 1.4 kgm. 1.1 kgm.

ROTOR MOUNTING BOLT KICK GUIDE BKT. HOLDER BOLTS SPARK PLUGS (2 NOS.) DRAIN CAP R.S.A. MTG. NUTS/BOLTS SWING ARM PIVOT NUT

UPPER - 3.5 to 4.0 kgm. 4.5 to 5.5 kgm.

4.5 kgm. 1.1 kgm. 1.4 kgm. 3.0 kgm. LOWER - 2.5 kgm.

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S E R V I C E D A TA - E N G I N E S E R V I C E D A TA - E N G I N E
COMP. PRESSURE VALVE CLEARANCE ROCKER ARM SHAFT DIA. ROCKER ARM INSIDE DIA. CAM SPROCKET DIAMETER PISTON RING/GROOVE CLEARANCE PISTON RING END GAP CLUTCH SPRING FREE LTH FRICTION PLATE THICKNESS
CARBURETTOR
SPECIFICATIONS
Item DISCOVER
Make & type NCV 24
Keihin Side
Draught, CV
Inlet Exhaust Top Second Top Second Idling speed 1400 + 100
Standard 12-14 kg/cm2 Standard 0.05 0.10 Standard 9.97 - 9.98 Standard 10.00 - 10.01 Standard 61.4 Standard 0.02-0.06 0.01-0.05 Standard 0.15-0.30 0.30-0.45 Standard 30.4 Standard 2.9-3.1
Service Limit 9.1-14 kg/cm
2
Service Limit 0.05 0.10 Service Limit 9.92 Service Limit 10.04 Service Limit 61.3 Service Limit 0.16 0.15 Service Limit 0.55 0.70 Service Limit 29.4 Service Limit 2.75 VC screw 2.5 + 1.0
CAM HEIGHT VALVE SPRING FREE LENGTH VALVE STEM DIAMETER VALVE STEM BEND VALVE HEAD THICKNESS PRESSURE PLATE WARP SHIFT FORK GUIDE PIN DIA. SHIFT FORK PAD THICKNESS SHIFT DRUM GROOVE WIDTH Turn
Jet needle Fixed,
clip position No clip
provision.
Main jet #128
Pilot jet #35
Inlet Ex. Outer Inner Inlet Exhaust Inlet Exhaust CO% 1.75-2.25
Standard 30.80 30.4 Standard 41.6 37.9 Standard 4.46 4.46 Standard TIR 0.01 Standard 0.5 0.8 Standard 0.15 Standard 4.97 Standard 4.97 Standard 5.05-5.15
Service Limit 30.5 30.00 Service Limit 40.6 36.9 Service Limit 4.40 4.40 Service Limit TIR 0.03 Service Limit 0.3 0.6 Service Limit 0.25 Service Limit 4.90 Service Limit 4.90 Service Limit 5.25

CYLINDER HEAD WARP CAM SHAFT CHAIN 20 LINKS CYLINDER INSIDE DIA. PISTON DIAMETER PISTON/CYL. CLEARANCE CRANK SHAFT RUN OUT CONROD BIG END AXIAL CLEARANCE
ENGINE OIL SPECIFICATIONS
20-link length

10mm
Grade : SAE 20W40 of API ‘SG’ +
20mm
JASO ‘MA’ grade or superior.
40mm

Quantity : 1000 ml (Drain and Refill)

1st 2nd 21st
MEASURE THIS LENGTH
7mm Oil Change : Every 2,500 km.
Frequency Check and Top-up if required.
Standard 0.00 Standard 127 - 127.2 Standard 57.010-57.017 Standard 56.978-56.900 Standard 0.019 - 0.039 Standard TIR 0.02 max. Standard 0.1-0.35 Oil Strainer Cleaning : Every 10,000 km.
Service Limit 0.05 Service Limit 128 Service Limit 57.017-57.024 Service Limit 56.988-56.998 Service Limit 0.05 Service Limit TIR 0.05 Service Limit 0.45
ALL DIMENSIONS ARE IN MM. ALL DIMENSIONS ARE IN MM.

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S E R V I C E D A TA - F R A M E ELECTRICAL WIRING DIAGRAM - (ELECTRIC START)

BR. PANEL CAM HOLE DIA. BRAKE CAM DIAMETER FR. BRAKE PAD THICKNESS BR. SHOE LINING THICKNESS BRAKE DRUM INDISE DIA.
Gr Gr
SIGNAL LAMP
FRONT RH B/Y B/Y
LAMP 12V-10W

B/R

SWITCH ASSY.
FUEL
METER ** Br Br
C.D.I. ASSY.
B/Y B/Y

METER W/Y W/Y CONTROL SWITCH RH

ASSY. Lg Lg
NEUTRAL
LAMP * Gr Gr
G G LIGHT STARTER RELAY
TURN SIGNAL SWITCH SWITCH (FOR INTERLOCKING)
* LAMP INDICATOR LAMP * R/B R/B
12V, 1.7W (FRONT LH ) FRONT BRAKE TURN SIGNAL REAR BRAKE
(QTY. 4) R/W R PO SWITCH RELAY SWITCH
Standard 12.0-12.03 Standard 11.95-11.98 Standard 7.4 Standard 3.85-4.15 Standard 130.00 - 130.16 HIGH BEAM ON P
NC

OFF
INDICATOR LAMP * H.T.COIL SPARK

B/W
PLUG

B/Y
NO

B
** LAMP
Service Limit 12.15 Service Limit 11.88 Service Limit 3.8 Service Limit 2.0 Service Limit 130.75 12V, 3.4W
(QTY. 2)
ILLUMINATION
LAMP ** FUEL LEVEL
REGULATOR
B
GUAGE

Br/B
R/Y
Y/L

R
Y
AXLE RUN OUT AXIAL WHEEL RUN OUT RADIAL WHEEL RUN OUT DRIVE CHAIN SLACK DRIVE CHAIN LENGTH

Br
L
G/W
Y/G
B/Y
Lg

Br

Br

Br
O

L
TURN SIGNAL
INDICATOR LAMP *

L/W
L/W
Y/R
B/Y
(FRONT RH)

W
Y
20-link length

W/Y

B/Y
Br/B

Br
R/Y
Y/L

L
Y

B/Y

Br
L
H.T.COIL SPARK Gr Gr

B/Y
PLUG SIGNAL

B/Y
W
Y
B/Y B/Y LAMP
REAR RH

O O
1st 2nd 21st N F
F

100 mm MEASURE THIS LENGTH Br Br

IGNITION
SWITCH W W
B/W B/W L L TAIL LAMP
ASSY
B/Y B/Y B/Y B/Y
R/W TAIL/STOP
R/W R LAMP
12V-5/21 W
Standard TIR 0.1 Standard TIR 0.8 Standard TIR 0.8 Standard 25 - 35 Standard 254 - 254.6
Service Limit TIR 0.2 Service Limit TIR 2.0 Service Limit TIR 2.0 Service Limit 35 - 45 Service Limit 259
B/Y
SIGNAL
G G LAMP

REAR SPROCKET WARP REAR TYRE TREAD DEPTH FR. TYRE TREAD DEPTH FR. FORK SPRING FREE LTH. FRONT FORK OIL
REAR LH
R/B

B/Y
HEAD LAMP B/Y
ASSY/LAMP
12V-35/35W HS1
R/Y
Grade : R
EARTH-FRAME

W/R
SAE 10W20

L/W
L/W
Y/R

B/Y
POSITION LAMP B/Y

Lg

R
12V-5W- 2 Nos.

R/B

B/Y
R

Gr
R

G
B
Y
Capacity : STARTER MOTOR

145 + 2.5 ml

W
Lg
B/ Y FUSE

W/R
Br
(per leg)

L/W
L/W
Y/R

B/Y
B
Free Length SIGNAL LAMP (15 Amps.)

B
FRONT LH G G

R/B
R/Y

R/B

B/Y
Y/L

W/B
Gr

G
Y

B
CABLE ASSY. EARTH
Oil change
R/Y
frequency : G/W
LO HI R O L
R

Standard TIR 0.4 Standard 6.6 Standard 5.0 Standard 420 After every CLUTCH
G/W PASS
SWITCH
DIMMER
SWITCH
TURN
SIGNAL
SWITCH
HORN
SWITCH
HORN
(P.NO. DS 20 1016) STARTER RELAY
SWITCH WITH DAMPER BATTERY
10,000 Kms. B/Y NEUTRAL
12V-9Ah

Service Limit TIR 0.5 Service Limit 1.5 Service Limit 1.0 Service Limit 416 B/Y
CONTROL SWITCH LH
(P.NO. DJ 20 1024)
SWITCH
MAGNETO
COIL
PULSING
CABLE ASSY. RED

ALL DIMENSIONS ARE IN MM.

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AC LIGHTING
ELECTRICAL WIRING DIAGRAM - (KICK START) INDIVIDUAL CIRCUIT DIAGRAM (ES) CIRCUIT
Gr Gr
SIGNAL LAMP
FRONT RH
B/Y CONTROL SWITCH RH
B/ Y B/ Y
LAMP 12V-10W
PO
R
B/R
ON
INDICATOR R.R. UNIT
LAMP B/Y
OFF
SWITCH ASSY.

B/Y
HIGH BEAM R
W/G W/G
C.D.I. ASSY.
12V 1.4W
FUEL METER Br Br
B/Y B/Y B/Y
W/Y W/Y
Lg Lg
ILLUMINATION

Y/L
* LAMP NEUTRAL LAMP * LAMP

R
Y
12V, 1.4W Gr Gr FRONT BRAKE TURN SIGNAL REAR BRAKE
(QTY. 5)
TURN SIGNAL G G SWITCH RELAY SWITCH TACHOMETER
INDICATOR LAMP *
(FRONT LH )
R/B R/B H.T.COIL SPARK
PLUG
12V 3W R/W

B/W

W/R
B/R
CONTROL SWITCH RH

B/Y
R/W R FUEL LEVEL GUAGE

R
REGULATOR
B/Y

R/W
HIGH BEAM CAPACITOR
INDICATOR LAMP * LIGHT SWITCH B

Y/R
B/Y
ILLUMINATION

Y
** LAMP PO
ILLUMINATION ON
12V, 3W
LAMP

OFF
LAMP **
R

Br
(QTY. 3)

L
FUEL METER

Br

Br
O

L
ILLUMINATION
LAMP ** 12V 3W R/W

W/Y
B/Y
ILLUMINATION

Y/L
B/Y

R
Y
LAMP **
TURN SIGNAL
ILLUMINATION

B/R
B/ Y
INDICATOR LAMP *

W
LAMP

Br
(FRONT RH)

L
SPEEDOMETER TAIL/STOP

Br
L
B/Y
SPARK Gr Gr
12V 3W R/W Y LAMP
H.T.COIL PLUG SIGNAL
LAMP
12V-5/21W
B/ Y B/ Y
REAR RH B/Y
O
O F
N F

IGNITION
Br Br R R/W
SWITCH W W
TAIL LAMP
B/ W B/ W L L ASSY
B/ Y B/ Y B/ Y B/ Y
R
TAIL/STOP POSITION R
R R LAMP
LAMP B/R
12V-5/10 W
12V-5W
B/Y

R
B/ Y
SIGNAL
HEAD B/R
B/Y

G G LAMP
R/ B
REAR LH
LAMP

B/Y
HEAD LAMP
ASSY/LAMP ASSY/
B/ Y
LAMP

B/Y
W/R
L/W

B/Y
12V-60/55W
B/Y

Y
POSITION
12V-35/

Lg
R/ Y EARTH-FRAME

Y/L
LAMP12V-4W 35W HS1

Y/R
B/ Y B/Y
R/Y
R/B
R/B

B/Y
Gr

Y
Y/L

Br/W
O
G
B

R
Y

FUSE (15A)

L/W
Y/R

B/Y
POSITION

W/B
Gr

B/Y
R
LAMP
Lg

B/ Y
12V-5W
Y

Br
B

SIGNAL LAMP
G G

B/R

B/R
FRONT LH
R

R/Y
MAGNETO
R/B

G
B/Y
R/B

R/B

Gr
R/Y

Y/L
Y

O
G
B

HORN NEUTRAL
SWITCH

G
LS IL
IN
PU CO
MAGNETO
LO HI R O L
B/Y

B/Y
BATTERY LO HI
TURN 12V 2.5AH
PASS DIMMER SIGNAL HORN
SWITCH SWITCH SWITCH SWITCH
PASS SWITCH DIMMER SWITCH
CONTROL SWITCH LH
CONTROL SWITCH LH

25 26
CYAN MAGENTA YELLOW BLACK

STARTER MOTOR AND IGNITION

INDIVIDUAL CIRCUIT DIAGRAM (ES) BATTERY CHARGING CIRCUIT INDIVIDUAL CIRCUIT DIAGRAM (ES) CIRCUIT
CONTROL SWITCH RH INTERLOCK RELAY B/R
STARTER Lg
Lg SWITCH
NC

REED SWITCH

B
P C.D.I. ASSY. ASSY.

Y/G
Br
NEUTRAL NO SPARK
LAMP
H.T.COIL PLUG
R.R. UNIT

Br/W

R/Y
Lg

B/R
R
G/W
B/Y

Br
B G

L/W

L/W
B/Y

W/R
B/W
B/Y
Br/W Y
O

B
O F
N F

B/Y

B
SPARK
Br
H.T.COIL PLUG
IGNITION W
SWITCH

B
W

O O
N F
F
B/Y

W
Y/G
Lg

B
EARTH-FRAME R/Y

B/W
STARTER

R/Y
Lg MOTOR

G/W
R

L/W

L/W
B/Y

R
Y/G
IGNITION
FUSE SWITCH
NEUTRAL (15 Amps.)
SWITCH

B/Y
R B
G/W
R/Y

B/Y
BATTERY
12V 9Ah MAGNETO
MAGNETO B W/R
B/Y
CLUTCH STARTER RELAY
SWITCH
COIL
PULSING

B/Y
B/Y

27 28
CYAN MAGENTA YELLOW BLACK

SIDE INDICATOR AND FUEL GAUGE AND

INDIVIDUAL CIRCUIT DIAGRAM (ES) HORN CIRCUIT INDIVIDUAL CIRCUIT DIAGRAM (ES) BRAKE LIGHT CIRCUIT
Gr Gr Br
SIGNAL
LAMP
FRONT RH
12V 10W
B/Y
W/Y

Gr
FUEL
METER FRONT REAR
BRAKE SWITCH BRAKE SWITCH

LH TURN FUEL LEVEL

SIGNAL TURN SIGNAL RELAY GUAGE

B/Y

Br
INDICATOR
LAMP
12V 1.4W B/Y

G
B/Y
RH TURN
SIGNAL

Br

Br
L

L
INDICATOR
LAMP

Br
SIGNAL

O
12V 1.4W B/Y IGNITION
LAMP
G

REAR RH SWITCH
L
12V 10W W/Y
Gr O O
O O N F
F
N F
F Br
Br
IGNITION
SWITCH

B/Y
W W
W
B/Y B/Y
TAIL LAMP
ASSY
Gr B/Y TAIL/STOP
LAMP
12V-5/21 W
B/Y

G
SIGNAL
G

LAMP

W
O
REAR LH
12V 10W
STARTER
MOTOR

W
Br

B
Gr

B/Y MAGNETO
B

B/Y
SIGNAL FUSE
(15 Amps.) STARTER MAGNETO
LAMP FUSE
FRONT LH MOTOR

W/B
(15 Amps.)
12V 10W G

W/B
B
R
R B
HI
R O L +

STARTER BATTERY B/Y

TURN SIGNAL HORN
SWITCH SWITCH RELAY 12V-9Ah BATTERY
HORN 12V-9Ah
CONTROL SWITCH LH STARTER RELAY

29 30
CYAN MAGENTA YELLOW BLACK
STANDARD PROCEDURE FOR CO CHECKING AND SETTING
Readiness of CO Gas Analyzer:
Warm up the CO Gas Analyzer for
10 to 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 manufacturers
recommendation). Set the Equipment display to Zero
before taking the reading.
Readiness of the Vehicle:
Before checking the CO
emission, prepare the vehicle
for checking the CO >>>
• Warm up the engine to
its normal operating
temperature by riding 5
to 6 Kms. The Clutch cover should be warm
enough by feel.
• Ensure the Choke is in OFF position.
31
STANDARD PROCEDURE FOR CO CHECKING AND SETTING
• Screw in Volume Control Screw completely. Engine Precaution: Always ensure rubberised taper portion is • After rectifying the problem confirm the CO% in the
should die down in this condition. intact with the tail end of the silencer and adaptor is same way as mentioned above.
mounted on the stand at suitable height such that
Note: If engine does not go off, then attend to the ingression of fresh air does not take place. The probe Imp: For Better Mileage and Performance, achieve CO%
additional air supply problem in the carburetor circuit & and silencer should be held in same axis. as recommended.
intake system. After solving the problem once again In Discover for better mileage and performance achieve
confirm that engine should die down on closing the • Note the CO / HC Readings when the reading display values given below.
Volume Control Screw. stabilizes.
• As per Emission Norms the recommended CO% for
• Confirm the Volume Control Screw to it recommended 2 Wheelers is 4.5% at Idling RPM. But CO% for Bajaj
Recommended CO% value w.r.t. Volume Control Screw
position of 2.5 turns. Vehicles, for best results in terms of fuel efficiency are
and Idling RPM for Better Fuel Efficiency
• Set Idling speed to specified Idling to 1400 + 100 rpm different for different models. For Discover the ideal
Recommended Volume Control Screw Recommended
of respective engines. Raise the engine to moderate CO% is between 1.75 to 2.25% at Idling rpm with Model
CO% Position Idling RPM
speed at no load condition for about 15 seconds. Volume Control Screw between 0.5 to 4.5 turns out.
Then bring back to specified idling RPM.
• If the reading is shown excess or less than BAL Discover 1.75% – 2.25% 0.5 to 4.5 1400 + 100
Specifications for respective model, then try to achieve
Taking the Reading: by adjusting Volume Control Screw.
- Turning out Volume Control Screw will lead to more
• Insert 'Special Probe' in CO% & turning in will lead to less CO%.
the Silencer tail end
pipe properly. Use right Note: Remember the Volume Control Screw should not
mouth piece of the be taken out more than the recommended position.
probe to suit with tail Every time Volume Control Screw setting is changed
end pipe of respective specified Idling RPM must be restored and then reading
vehicle. The special should be considered.
probe is a combination
of adaptor and probe. It
• If the CO% is not falling with in recommended % in spite
comes with adjustable
of adjusting the Volume Control Screw then find out the
stand.
cause and rectify the same.
32
CYAN MAGENTA YELLOW BLACK
TUNE-UP FOR OPTIMUM MILEAGE
Reed Switch : Maintenance
Check throttle lever movement by rotating it with
hand. It should not be sticky in operation and
should return back it self on releasing.
• Magnet should not touch
with reed switch.
• Gap between Magnet &
Reed Switch should not be
more than 2.5 mm.
• Movement of throttle lever
Gap
2.5mm max. with magnet assembly and
Reed Switch fitted should
be free.
Reed Switch : Setting
• Accelerator cable play: 2-3
mm by adjusting the
Adjuster (A).
A
• Protude stopper (B) of the
throttle lever bracket must
on idling screw (C) tip.
C of fix bracket of Reed
B Switch (Fig. 3) Multimeter
33
TUNE-UP FOR OPTIMUM MILEAGE
Reed Switch : Checking
1 • Keep throttle at zero
position. (Fig. 1).
• On connecting multimeter to
Reed Switch coupler it
should show continuity.
Fig. 1
0.00
• When throttle is open and
Reed Switch magnet
crosses to straight edge of
fix bracket of Reed Switch
(Fig. 2) multimeter should
show discontinuity.
Fig. 2
1
• On De-acceleration, when of
Reed Switch magnet re-
coinsides with straight edge
should show continuity.
Fig. 3
Engine Maintenance TAPPET CLEARANCE
• Inlet valve: 0.05 mm
SPARK PLUG: • Exhaust valve: 0.1 mm
RG 4 HC.
Spark Plug Gap :
0.6 to 0.7 mm.
0.6 to
0.7MM
Replace at every :
10,000 Kms.
CARBURATTOR
• Idling : 1400 + 100 rpm.
• Volume Control screw
AIR FILTER: setting : 2.5 + 2.0 turns.
• Clean at every 2,500 Kms.
• CO % : 1.75 to 2.25 %.
• Replace at every
10,000 Kms.
Other Mandatory Checks
a. Ensure no fuel leakage through fuel cock, fuel
lines.
b. Ensure free rotation of both the wheels.
COMPRESSION PRESSURE c. Ensure correct tyre pressure -
• Standard : Front wheel : 28 PSI, Rear wheel : 32 PSI
12 to 14 Kg/cm2 d. Set control cable free play:
• Service Limit: • Clutch lever 2-3 mm.
9.1 to 14 Kg/cm2 • Front brake lever 2-3 mm.
• Rear brake pedal 25-30 mm.
e. Chain slackness : 25 to 35 mm.
34
CYAN MAGENTA YELLOW BLACK

WARRANTY AND SERVICES RESISTANCES LOCTITES IMPORTANT ENGINE ASSEMBLY TIPS

Sr. No. Service Type Kms./days * PICKUP COIL : Apply before assembly: 638 (Colour - Green) Engine Mounting Bolt Tighten Sequence
Range Connections Reading Whenever engine is mounted on the frame or during periodic services always
1 1st Free with 00,500 - 00,750 Kms. or 30 days. (Ohms) Meter +ve Meter -ve (Ohms) • Guide gear allen bolt.
tighten engine mounting bolts in the sequence shown in the figure. This will
Oil change
X 10 White/Red Black/Yellow 200 + 30 • Kick guide bolts.
2 2nd Free 02,000 - 02,500 Kms. or 90 days. ensure proper mounting of the engine and will reduce the vibrations and also
• Drum stopper arm bolt. increase the life of mounting rubber bushes.
3 3rd Free with 04,500 - 05,000 Kms. or 150 days. CHARGING COIL • Starter counter one way clutch allen bolts.
Oil change Range Connections Reading • Oil separator plate screws.
4 4th Free 07,000 - 07,500 Kms. or 225 days. (Ohms) Meter +ve Meter -ve (Ohms)
5 1st Paid with 09,500 - 10,000 Kms. or 300 days. • Bolt holding spring for stopper arm.
X1 Red Black/Yellow 15 + 3
Oil change • Stopper bolt - changer lever spring. 6
6 2nd Paid 12,000 - 12,500 Kms. or 375 days. BATTERY CHARGING COIL (KS) 7
7 3rd Paid with 14,500 - 15,000 Kms. or 450 days. Range Connections Reading Apply before assembly : 243 (Colour - Blue)
Oil change (Ohms) (Ohms) 5
Meter +ve Meter -ve • Bolt for Plate stopper bearing.
8 4th Paid 17,000 - 17,500 Kms. or 525 days. Black/Yellow 1.0 + 0.3
X1 Blue/White • Screw for Pick up mounting on cover.
9 5th Paid with 19,500 - 20,000 Kms. or 600 days.
Oil change BATTERY CHARGING COIL (ES) • Screw for Stator mounting on cover.
10 6th Paid 22,000 - 22,500 Kms. or 675 days. Range Connections Reading • Allen bolt for Sprocket fitment on cam shaft.
11 7th Paid with 24,500 - 25,000 Kms. or 675 days. (Ohms) Meter +ve Meter -ve (Ohms) 243 • Flanged bolt for Oil pump fitment on crankcase
Oil change RH. 3
X1 Blue/White Blue/White 1.2 + 0.3
12 8th Paid 27,000 - 27,500 Kms. or 675 days. • Allen bolt for Chain tensioner to crankcase RH. 2
LIGHTING COIL (KS) • Flanged bolt for Assembly of crankcase LH & RH. 8 4
13 9th Paid with 29,500 - 30,000 Kms. or 675 days. Range Connections Reading
Oil change • Allen bolt for Sprocket fitment on output shaft. 9
(Ohms) Meter +ve Meter -ve (Ohms)
• Screw for Kick lever. 10
X1 Yellow/Red Black/Yellow 1.0 + 0.3
•
Warranty LIGHTING COIL (ES) •
Flanged bolt for Starter motor fitment on cover RH.
Screw for Starter motor cover. 1
2 Years Or 30,000 Kms. Range Connections Reading • Flanged bolt for Stopper for plate starter clutch
whichever occurs earlier. (Ohms) Meter +ve Meter -ve (Ohms) gear return.
X1 Yellow/Red Black/Yellow 0.7 + 0.3 • Clutch nut.

35 36
CYAN MAGENTA YELLOW BLACK
I M P O R T A N T E N G I N E A S S E M B LY T I P S
• ‘Input Shaft’ has special nut.
• ‘Input Shaft’ has Left hand threads.
• No need of applying Loctite 243.
• Washer for Input shaft nut is same as of primary gear.
• The special nut has ring mark for identification.
• Secure the cam chain sprocket by the tool given
below firmly and then tighten the sprocket allen bolt
(A).
• Ensure that the ‘O’ mark on washer always faces
outwards when tightening the allen bolt (A).
A
Valve timing
• Ensure the sprocket marks (A) are aligned
horizontally with cylinder head top machined face.
• Ensure the piston is at TDC.
• Ensure ‘T’ mark on rotor matching the c’case mark.
A A
• The clutch collar having hole is to be slided into the
clutch housing for effective lubrication.
• Bigger gear to be assembled facing the dust cap side
while assembling the starter counter gear.
37
• Chain top edge to be kept between the two marks
during chain slackness adjustment.
• Remove the allen head grub screw before removing
the sleeve spark plug.
• Before fitting the sleeve spark plug apply thin layer or
molybdenum di-sulphide grease on the entry
chamfers for the ‘O’ rings.
• Always blow compressed air through the oil
passages in reverse direction of oil flow and ensure
the passages are clear.
• Apply a thin layer of liquid gasket on body of the
starter cover.
• When splitting crankcase always remove.
First : 1 longest bolt fitted from clutch side.
Second : 1 long bolt fitted from magneto side and
then remove all bolts from magneto side.
PRECAUTIONARY MEASURES
Precautions to be taken while dismantling of engine
• While removing engine foundation bolts, first remove the topmost and
then go down progressively.
• After removing all the engine connections lift up and remove the
engine from RHS of the vehicle.
• Improper loosening sequence may cause warpage in cylinder head
cover and it can be damage permanently.
• Drain the engine oil into a clean tray by loosening and removing
strainer cap located on LH side of crankcase.
• As fas as possible do not let oil to wet the top of the piston, or the
combustion chamber in the cylinder.
• If cylinder block is tight in dowels, lightly tap with hands in upward
direction. If still tight use a plastic or woodem rod and pry it upwards.
• When taping the drift for removal of gudgeon pin, confirm that the
connecting rod is held firmly against the direction of tapping to avoid
damage to big end bearing of crank shaft.
• Starter cover base is fitted on the crankcase with liquid gasket
application hence tap gently for easy detachment.
• Clutch nut have left hand threads.
Precautions to be taken while assembling of engine
• Confirm the free rotation; shifting of gears after assembling.
• Always align the gear box into neutral gear position and then assemble
both the crank cases.
• Bolt sizes are different. Ensure 1 longest bolt is fitting in clutch side
crankcase and 1 long bolt is fitting towards breather side cranckase.
• Confirm the free rotation of crank shaft and centering of crankshaft.
• While fitting kick spring, make sure that spring sharp edge does not
scratch against crankcase surface and damage the surface finish.
• Special nut has left hand threads and round cut mark around the nut.
• Do not lock the rotor holder special tool against the pickup coil sensor
on rotor and gear change shaft.
• Always lubricate the needle roller bearing when over hauled. Incorrect
bolt size fitment on body starter may result in locking of rotor or gear
counter assembly.
• Place a piece of clean cloth above hollow portion of crank case to
arrest piston pin circlip if it falls during fitment.
• Before fitting the sleeve spark plug apply thin layer of molybdenum
disulphide grease on the entry chamfers for the ‘O’ rings.
• Ensure that the ‘O’ mark on washer always faces upwards.
• Ensure the sprocket marks are aligned horizontally with cylinder head
top machined face and the piston is at TDC.
• Improper tightening sequence may cause warpage in cylinder head
cover and it can be damage permanently.
38
CYAN MAGENTA YELLOW BLACK
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S
Ï What are the features of ‘Discover DTS-i’ motorcycle?
B ‘Discover DTS-i’ has many Unique; Advanced & Contemporary
features as mentioned below.
Unique Features:
• High Power of____________ 11.51 Ps.
• Greater Torque of_________ 10.80 N-m.
• Max. Speed of____________100 Kmph.
• Least emission of CO, so great environment friendly vehicle.
• Unique and cute Headlamp fairing with twin pilot lamps and
option of Round Headlamp as well that matches to the profile of
the vehicle.
Advanced Features:
• Digital Twin Spark Ignition System (DTS-i) with Twin Map for
accurate ignition timing.
• Throttle Responsive Ignition Control System (TRICS).
• Optimized engine combustion characteristics to provide ultimate
performance.
Contemporary Features:
• Strongest & Sturdier frame & stiffer rectangular cross-sectioned
swing arm to with stand twists and all kind of road tortures.
• Longest wheel base in its class for better road holding
characteristics.
• Highest rear wheel travel to ensure most comfortable ride in all
terrain.
• Longest fr. suspension travel in its class to provide pleasant ride.
39
• Brightest Headlamp with 60 / 55 Watt Halogen bulb for safer night
ride.
In fact ‘Discover DTS-i’ delivers power & performance of 125 cc
engine and economy of 100 cc engine. More over the Comfort,
Convenient & Safety are ultimate to any motorcycle on Indian road
with the capacity of 100 to 135 cc engine.
Ï What is ‘DTS - i’ ?
B DTS-i stands for Digital Twin Spark Ignition - an Advanced Technology
which will be the heart of a new breed of high performance engines
from Bajaj.
Ï What is the Advanced Technology in DTS-i ?
B DTS-i engines incorporate Two Spark Plugs (hence called Twin Spark)
in the cylinder head, a Microprocessor controlled (like computers)
Digitally operated CDI which accurately controls the Ignition Timing
and ‘TRICS’ or Throttle Responsive Ignition Control System, which is a
non-contact switch on the Carburetor body and this changes the
Ignition Map based on Throttle position.
B Combined actions of these technological breakthroughs enhances the
Overall Performance likes Power, Pick-up, and Mileage etc.
Ï Why Twin Spark Plugs ?
B Conventionally in a 4-stroke engine the spark plug is at one end of the
combustion chamber. It means the Air fuel mixture combustion is
better around the sparkplug, rather than the opposite side of the
combustion chamber. Because of the longer time needed for the
combustion to take place on the far side (opposite side of the spark
plug) overall combustion is slow, leading to poor combustion efficiency.
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S
B Placing another Spark plug opposite to the original one enables the
sparks to occur simultaneously, thus reducing the time for combustion
to take place, thereby increasing combustion efficiency and its speed
with tremendous benefits.
Ï What is the ‘DIGITAL’ in Digital Twin Spark ignition ?
B Conventional Analogue type CDI’s work in a very constricted manner.
They are unable/constrained to control the ignition advance or retard
for specific points in the entire engine rpm range. They could either
advance or retard but not do both for specific points in the engine rpm
range.
B The Ignition System of ‘DTS-i’ is Digitally operated. An 8 bit
Microprocessor is programmed to decide and control the Ignition
Advance or Retard at any point in the entire engine rpm range. It is
like a computer being programmed to run in a specific way. There is
tremendous consistency and accuracy in the Ignition Timing, which
enhances the overall Performance.
B This Digital CDI has also been programmed to cut the sparks to the
spark plugs at high rpm’s thereby preventing anybody from dam agi ng
the engine. All these advantages are only possible with Digital Chips.
Ï What is ‘TRICS’ and what is so special about it ?
B A non-contact type switch is mounted on the cable pulley shaft of the
Digital CDI to change the Ignition Advance/Retard map. The amount
of angular movement of the cable pulley shaft depends on the speed
and load demands of the Rider.
B With the adaptation of TRICS, the engine also becomes highly Knock
resistant.
B ‘Throttle Responsive Ignition Control System’ activates and swaps
between two different Ignition Maps for getting an optimum Ignition
Advance/Retard Timing, for different speed an load conditions. The
switching over of the Ignition maps is Seamless and the switch itself is
completely maintenance free for the life of the Vehicle.
Ï What are the benefits of ‘DTS-i’ in a nutshell ?
B Digitally managed Optimum Ignition Timing over the entire engine rpm
range for more accuracy and efficiency. And faster & complete
combustion process – leading to complete utilization of air-fuel
mixture and thereby results in –
• Enhanced Power.
• Enhanced Pick-up.
• Enhanced Mileage.
• Enhanced Drivability in all engine operating conditions.
• Less Emission of CO. that meets ‘2005 Emission norms’.
Ï Can existing non DTS-i 2 Wheelers be converted into DTS-i
technology ?
B No, the ‘DTS-i’ technology demands major technological changes in
the engine and vehicle, hence it is almost impossible to convert an
existing 2-wheeler to accept ‘DTS-i’ technology.The conversion is not
economically viable, as it means almost a complete replacement of
the vehicle/engine.
Ï Does ‘DTS-i’ costs more in Maintenance ?
B No. The ‘DTS-i’ technology is tried and tested under extreme
conditions by Bajaj Auto Limited. The systems/parts of ‘DTS-i’ are
virtually maintenance free.
40
CYAN MAGENTA YELLOW BLACK
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S
Ï How ‘DTS-i’ is different from VT-I in TVS Centra and AMI in Hero
Honda Ambition ?
B VT-I of TVS Centra and AMI of Hero Honda Ambition only have
swithchable Ignition timing maps and Digital CDI’s. The switch of TVS
Centra is not Maintenance free and the switch of Hero Honda
Ambition is a contact type, which means problems or wear and tear.
“DTS-i technology from Bajaj Auto Limited is the future of bikes”.
Ï Why the Tyre size is of 17" where as normally all other
motorcycles traditionally have 18" tyres?
B ‘Discover DTS-i’ motorcycle has some special geometry as far as
Ride Comfort & Pleasure is concerned. The Specialties are
• The longest Wheel Base >>> 1305 mm.
• Lowest Center of Gravity.
• Longest Front Suspension Travel >>> 135 mm.
• Wider distance between both Front fork tubes.
• Rear Shock Absorber having Triple Rating Spring & longer stroke.
>>> 85 mm.
• Longest Rear Wheel Travel. >>> 110 mm.
All these things are enabling ‘Discover DTS-i’ to deliver Excellent
Road holding, Better Balancing and Extra ordinary High speed
Stability. With this, there is absolutely no need of 18" tyre.
B Rather here, the 17" tyre, due to reduced weight and lesser road
contact area, it will contribute in enhancing the mileage as compared
to 18" tyre.
41
Ï Why Dual Oil Filtration system is not given in ‘Discover DTS-i’
where as this feature is given in Wind 125?
B ‘Discover DTS-i’ engine too has dual oil filtration system. The first
stage filtration is done by extra large strainer with fine mesh. And the
second stage filtration is taken care by in built Centrifugal Oil filter
mounted on crankshaft.
B With extra large strainer and Centrifugal Oil filter, the level of filtration
would be similar to the engine having Primary Strainer and Paper Oil
filter.
Ï Being 125 cc and having higher power, why ‘Discover DTS-i’ has
not been incorprated with 5-speed gear transmission ?
B Considering utilization of power produced by this engine, to achieve
better low-end torque, pick up and to obtain maximum mileage gear
ratios have been uniformly spread across all gears appropriately. With
this 4-speed transmission is enough to perform the task.
Ï When ‘Discover DTS-i’ has so advanced engine, then how come
SAI system & BS Valve is not provided in this?
B That is one of the speciality of ‘DTS-i’ engine. The optimized
combustion process because of two Spark plugs, Digitallym a n a g e d
accurate Ignition and TRICS all together address the advantages of
low emission, better cold startability, enhanced drivability delivered by
SAI System and B S Valve.
B That means, again lesser the components, more the benefits.
Ï Why primary kick mechanism isn’t provided in ‘Discover DTS-i’
engine?
B To reduce engine components which minimizes the engine weight as
F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S
well, the kick mechanism is provided is similar to ‘Caliber’ & ‘Boxer’
range of motorcycles.
B Minimized weight contributes in enhancing the mileage and lesser the
components contribute to cost benefits, which we can pass on to our
valued customers.
Ï Why ‘De-compression’ mechanism like in Pulsar engines is not
provided in ‘Discover DTS-i’ engine?
B Normally ‘De-compression’ mechanism is required in higher capacity
engines where one would feel resistance in operating the kick while
starting the engine. ‘Discover DTS-i’ engine does not require this.
Ï Why Aircraft Type Fuel Tank Cap similar to Pulsar Fuel Tank Cap
is not provided ?
B Petrol tank caps are designed considering shape of Petrol Tanks. The
cap provided on Discover Petrol tank goes well with its shape.
Ï Why the engine noise level is towards higher side in ‘Discover
DTS-i’?
B As we have seen that the ‘Discover DTS-i’ engine is designed and
developed to achieve optimized combustion process. This is achieved
by having higher compression ratio and so many other design
parameters related to Intake and combustion process.
B This complete combustion process will generate some combustion
noise. This noise will be a characteristic of high performance engines
like ‘DTS-i’ engines.
To minimize this noise, & control vibrations as well, rubber dampers
have been incorporated in the clutch cover & magneto cover.
B Still such noise will always be heard on high performance engines. So
to achieve more from the limited capacity engines we need to accept
the facts.
Of course this fact is not harmful and will not effect on the
performance of the engine.
Ï Why 4-Plate clutch on this engine, where as ‘Wind 125’ and
Pulsar engines have 5-Plate clutch ?
B The clutch of ‘Discover DTS-i’ engine is bigger so the plates (friction
plates) are wider in size. Due to this, the more contact area in line
with 5-Plate clutch is obtained. With this, 4-Plate clutch is big enough
to handle power transmission characteristics.
Ï Why Crankshaft Balancer is not provided in ‘Discover DTS-i’
engine?
B The Crankshaft design and geometry is optimized and the Static &
Dynamic balancing factors are well taken care by this crankshaft with
respect to relative rotating components. Thus the crankshaft of
‘Discover DTS-i’ engine does not need balancer.
Ï How come 'Discover DTS-i' is expected to give better mileage in
spite of higher capacity 125cc engine?
B So many parameters aspects are incorporated in ‘Discover DTS-i' to
enable it deliver better mileage.
B On technological front, as we have seen so far the package of DTS-i
like Twin Spark Plugs, Digital CDI, Twin Ignition Maps & TRICS in this
‘Lean Burn’ engine, all together have improved combustion process
that is leading to -
• Complete combustion of air - fuel mixture.
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F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S F R E Q U E N T LY A S K E D Q U E S T I O N S - F A Q ’ S
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• Combustion at accurate timing with respect to engine rpm at low frequency ‘boom’, which many people associate with the typical Ï Does Discover has all the technologies of Pulsar? OR Is ‘DTS-i’ in
different speeds and loads on the engine. 'Bullet' kind of silencer sound. While meeting the mandatory current 10 ‘Discover DTS-i' different than in Pulsar?
• Altering of Ignition timing depending upon different throttle Noise norms, it gives the vehicle an identity, which is different from 5 B The ‘DTS-i’ technology as such from Bajaj is the same on Pulsar as
positions. any other bike, so as to make it very unique. well as Discover. The package of ‘DTS-i’ that comprises Twin Spark
0
Discover CT 100 Passion+ Splendor Crux Freedom Plugs, Digital CDI, Twin Ignition Maps and TRICS are very much
As these activities consistently take place, the fuel efficiency is bound Ï Normally higher power bikes are heavier in weights. How about
Discover? there and function similar as in case of Pulsar. But the values of
happen in ‘Discover DTS-i' engine. Power 11.51 8 7.5 7.5 7.7 8
performance are as per the respective engine requirements.
Moreover, other certain virtual elements are there to support this B ‘Higher the Power Heavier the Engine’ has become now a vintage Torque 2 0.98 0.9 0.9 0.82 0.92
story (or has become a old proverb) Bajaj R & D with its capability has B You can very well see that how the ‘DTS-i’ technology has enabled
engine for delivering better mileage. The other virtual elements are - 15
engineered and developed ‘Discover DTS-i’ engine with Higher Power ‘Discover DTS-i' to be close to its Big Brother Pulsar 150 cc.
• Lesser weight of the engine as compared to other 125 CC engines. to Weight Ratio as compared to other 125 CC engines. B ‘Discover DTS-i' almost equal to Regular Pulsar 150 cc and close to
• Lesser road resistance due to lesser road contact area on account 10
B On one side it was successful to make the engine deliver more power Pulsar 150 cc with ‘DTS-i’ engine. The table below indicates the
of 17" tyres. 5
and on the other side it has tried to reduce the engine weight by comparison.
• Virtual Instructor to the Rider in the form of ‘Ride Control Switch' to
ride the vehicle in ‘Fuel Efficiency Zone'. simplifying the design as compared to other 125 CC engines. B More over it even looks like mini Pulsar as well.
0
B The Power to Weight Ratio that means the Power produced per ton Discover Fazer Fredom 125 Victor 125
Truly speaking, if ‘Discover DTS-i' is ridden within 'Fuel Efficiency Maximum
weight of the vehicle in comparison with other vehicle is given below. Power 11.51 10.8 10.7 9.66 Vehicle Power Torque
Zone' as per instruction of Ride Control Switch, it can put all other 125 Speed
CC engined vehicles on shame and even able to compete shoulder to Power to Weight Freedom Torque 2 1.06 1.07 0.97 11.68 N-mm
Discover Victor 125 Fazer Pulsar DTS-i 150 cc 13.02 Ps 120 Kmph
shoulder with other 100 CC engined vehicles. Ratio i.e. Power per Prima 125 (1.19 Kg-m)
Ton weight of the Ï Will 125 cc bikes become standard on the road as against current 10.8 N-m
Ï What is ‘Exhaust TEC'? vehicle 92 81.86 86.4 96.39 Pulsar 150 cc Regular 12 Ps 100 Kmph
100cc bikes? (1.1 Kg-m)
B Exhaust ‘TEC’ is a device incorporated in exhaust system of ‘Discover
Ï Is Power & Pick-up of ‘Discover DTS-i’ marginally or substantially B 100 cc bikes are plying on Indian roads now for over a decade. It's a 10.8 N-m > 100 Kmph
DTS-i’ engine. ‘TEC’ stands for ‘Torque Expansion Chamber’. It ‘Discover DTS-i’ 11.51 Ps (1.1 Kg-m)
better than current 100 cc popular bikes or there's a substantial normal tendency of a person that when he plans to change the
improves ‘Scavenging’ process.
improvement? vehicle, he always look for better better power, better capacity, better
B The exhaust system has this revolutionary feature, which drastically pick up. And when because of advancement in engine technology, if Ï Is 125cc ‘Discover DTS-i' is poor man's Pulsar?
B No. The Power & Pick up of ‘Discover DTS-i’ is far.. far… better than
improves engine torque at low revs without compromising anything at better capacity, say 125 cc engines offers similar economy of 100 cc, B Yes. Why not? It not only resembles Pulsar in masculine physique but
the popular 100 CC bikes and even much better than any other 125 CC
mid or high engine revs. It has been extensively optimized to get the then it influences the trend. We strongly feel 125cc bikes wil become also it is quite sturdier and rigid in built. The Frame, the square box
bike on the road.
maximum possible performance out of the engine. The Silencer also standard on the Indian road and 100cc bikes will go the way mopeds swing arm all makes it as strong as Pulsar. So it is a mini Pulsar with
has a characteristic tonal quality to it. It gives out a pleasant sounding B The Power & Torque comparison is follows. have gone. economy.

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