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CYAN BLACKMAGENTA YELLOW
Bajaj Auto LimitedAkurdi Pune 411 035 India
Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com
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The description and illustrations in this Service Ready Reckoner are not
to be taken as binding on the manufacturer. The essential features of
the type described and illustrated herein remaining unaltered, BAJAJ
AUTO LIMITED reserve the right to carry out at any moment, without
being obliged to bring this Service Ready Reckoner up-to-date,
modifications on the vehicle, parts or accessories, as may be
convenient and necessary.
Copying, quoting or reproducing any part of this Service Ready
Reckoner without the written permission of BAJAJ AUTO LIMITED, is
expressly prohibited.
DOC. NO. 36 02 0355 REV. NO.: 00, SEP. 04
NOTICE
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T E C H N I C A L S P E C I F I C A T I O N S
Type Four stroke, Single cylinder, Natural air cooled.
No.ofcylinders One
Bore 57.00 mm.
Stroke 48.80 mm.
Enginedisplacement 124.52 cc.
Compressionratio 9.5 +0.5:1Idling Speed 1400 +100 rpm.
Max.netpower 8.47 kW (11.51 Ps) at 8000 rpm.
Max. nettorque 10.8 Nm at 6500 rpm.
Ignition System Micro controller based digital C.D.I.
0 0Ignition Timing 10 BTDC at 1400 rpm., 26 BTDC at 3500 rpm
Carburettor Keihin NCV 24, Side Draught, CV Type.
SparkPlug 2 Nos. Champion RG4HC (Resistive)
SparkPlugGap 0.6 to 0.7 mm.
Lubrication Wet sump, Forced.
Starting Kick StartElectric start.
ENGINE
DISCOVER
Clutch Wet, Multidisc type.
Transmission 4 speed constant mesh.
stGear Ratios: 1 ge ar 2. 92 : 1
nd2 gear 1.72 : 1
rd3 ge ar 1. 16 : 1
th4 g ea r 0 .8 8 : 1
Final drive ratio 3.21 : 1
Frame Type Double cradle.
Suspension Front (Stroke 135mm.) Telescopic
Rear Trailing arm with coaxial hydraulic shockabsorbers, and triple rate coil springs.
Brakes Front Mechanically expandingshoe and drum type.
Rear Mechanically expanding shoe and drum type.
Tyres Front 2.75 x 17, 6 PR
Rear 3.00 x 17, 6 PR
Tyre Pressure2Front 1.75 Kg/cm (24.5 Psi)2Rear Solo 2.00 Kg/cm (28.0 Psi)2Rear Pillion 2.25 Kg/cm (32.0 Psi)
CHASSIS & BODY
DISCOVER
T E C
Rims
Fuel
Stee
Acce
Gear
ClutcBrak
Syst
Batte
Head
Pilot
Tail/S
Turn
Hi be
Spee
CON
ELEC
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P . D . I . C H E C K L I S T TO CHECK CHECK FOR
ENGINE :
FRAME :
Engine oil SAE 20W40API SG+JASO MAGrade
Idling Speed (Warm up)
Kick operation
Fasteners (Check torque
Fuel Tank / Pipes
Fuel Tap
Carburettor
A. WHEELS
Tyre Pressure
Rim runout (With tyre)
Oil level. Top up if required.Oil leakage if any.
Check / adjust if required.(1400 + 100 rpm)
Smooth Operation.
Engine mtg. at Cyl. Head (2.2 Kgm.)& correct if required) at Front & Rear (3.2 Kgm.)
Oil drain plug (3.0 Kgm.)
Leakages / Fitment.
Smooth operation.
Leakages, Fitment - Orientation & angleBreather pipe routing.
2Front - 1.75 Kg/cm
2Rear - 2.00 Kg/cm (Solo),
2 2.25 Kg/cm (Double)
Radial - (0.8 mm or less)
Axial - (1.0 mm or less)
FUEL SYSTEM :
TO CHECK CHECK FOR
FRAME :
Spokes Check & tighten if required.
Drive chain Slackness (25-35 mm)
Lubrication (SAE 90)
Check chain lock position.
Front brake lever free play (2-3 mm)
Rear brake pedal free play (25-30 mm)Lever free play (2-3 mm)Smooth operation.
Grip free play (2-3 mm)Smooth operation.
Choke Free play (2-3 mm) & smooth operation.
Smooth operation, Oil leakage.
Proper notch setting # Preload setting:2nd notch (same on both side)
Smooth operation (Loose or tight).
D) LOCK OPERATION Steering and Ignition, Fuel tank,Seat lock, Side cover LH.
B) CONTROLS
Brakes
Clutch
Throttle
C) SUSPENSION
Front fork
Rear shock absorber
Steering
DIRECTION OFCHAIN ROTATION
P . DTO C
E) FA
A. BAT
B.ALL
C. SW
D. STA
A. STA
ELECT
TEST
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P E R I O D I C M A I N T E N A N C E A N D L U B R I C A T I O N C H A R T : Indicates operation to
be performed. : More frequent cleaning
may be required whendriving in dustycondition.
A - Adjust
CL- Clean
C - Check
L - Lubricate
T - TightenR - Replace
Note:Parts/Lubricants to bereplaced as per PeriodicMaintenance and LubricationChart are mandatory and thesame are chargeable tocustomer.
1 . S er vi ci ng
2. Idle speed / CO% C,A
3. Engine oil (SAE 20W40 of API SG+JASO MA) R Every 5000 kms.
4. Valve clearance A Every 5000 kms.
5. Oil strainer / Centrifugal filter CL Every 10000 kms.
6. Air cleaner element CL
7. Air cleaner element R Every 10000 kms.
8. Carburettor CL,A
9. Fuel system leakages C,R
10. Fuel pipes R 1 Year Every 1 Year
11. Spark plug / gap CL,A
12. Spark plug (2 Nos.) R Every 10000 kms.
13. Battery electrolyte level C,A 15 Days
14. Brake light switch C,A
15. Clutch play A
16. Throttle play A
17. Rear brake pedal play A
18. Brake lining wear C,R
19. Steering play C,A
20. All fasterners t ightness including engine mtg. T
Sr.No. Operation
Whichevercomes first
750 2,500
RECOMMENDED FREQUENCY
Initial Subsequent
5,000 7,500 Every 2,500kmKms.
DaysOR
3 0 9 0 1 50 22 5 E ver y 7 5 d ay s
P E
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Sr.No.
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Cylinder Head with Cover
DH 1015 29
Rubberised silent bush fitted in head cover.
Cylinder Head with Cover
DH 1015 29
Bigger combustion chamber cavity.
DH mark is embossed on casting.
Cylinder Complete
DH 1015 27
Bigger bore.
-----
Piston Assembly
DH 1015 30
DHU mark is embossed on piston crown.
Large in diameter.
Part No.
-----
P A
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Piston Pin
DH 1012 70
No chamfer.
Cam Chain
DH 1010 50
More in length 313 mm.
Chain Guide
DH 1010 10
Length is 178 mm.
Length is more.
Wall thickness is more.
Part No.
Part Name
Description
Identification Mark
Guide Chain (Tight)
DH 1010 17
No curvature at bottom location.
P A
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Crankshaft Assembly
DH 1010 57
DH mark is embossed on con-rod.
Clutch Spring
DH 1014 83
Spring has 5 coil turns.
Spring is marked with Yellow colour paint.
Clutch Hub
DH 1014 34
Height is 22.5 mm.
Height is more.
Part No.
Part Name
Description
Identification Mark
Guide Split
DH 1013 74
Splines on ID
Web shape is different.
P A
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Part No.
Part Name
Description
Identification Mark
Gear Change Lever
DH 1011 34
Open end welding dimension is 38.2.
Guide Gear Shift
DH 1014 95
More wide.
Have 5 pins.
Rotor Assembly
DS 1110 08
Pick up coil sensor projection length is 18.13 mm.
Pick up coil sensor is less in length.
18.53mm.
Part No.
Part Name
Description
Identification Mark
Wiring Harness
DH 2010 29
Yellow colour insulation tape fitted on harness.
P A
20.00mm
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P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i
Part No.
Part Name
Description
Identification Mark
Part Name
Description
Identification Mark
CDI
DH 1110 19
DH mark is embossed on body.
Rear Wheel Sprocket
DJ 1510 18
Has 42 teeths.
42 T mark and yellow passivated.
Part No.
P A
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T I G
OUTPU
1.1 kg
START
1.1 kg
CYL. H
2.0 to
17
E N G I N E E X P L O D E D V I E W
CYLINDER HEAD ASSEMBLY
CYLINDER BLOCK / PISTON
CRANKSHAFT
CRANKCASE & COVERS
TRANSMISSION
STATOR & ROTOR ASSEMB LY
SILENCER
CLUTCH MECHANISM
OIL PUMP & FILTER
CLUTCH COVER
CHAIN TENSIONER & CHAIN GUIDE
KICK MECHANISM
STARTER MECHANISM (ELECTRIC)
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T I G H T E N I N G T O R Q U E S - E N G I N EOIL PUMP MOUNTING BOLTS
1.1 kgm.
CENTRIFUGAL OIL FILTER NUT
5.5 kgm. 5.5 kgm.
CLUTCH NUT (L.H. THREADS)
ROTOR MOUNTING BOLT
4.5 kgm.
KICK GUIDE BKT. HOLDER BOLTS
1.1 kgm.
GENERATOR COVER BOLTS
1.1 kgm.
CYLINDER HEAD COVER NUTS
3.5 kgm. 1.1 kgm.
CYLINDER HEAD COVER BOLTS CAM SPROCKET ALLEN BOLT
1.4 kgm.
STARTER MOTOR BOLTS
1.1 kgm.
DRAIN CAP
3.0 kgm.
SPARK PLUGS (2 NOS.)
1.4 kgm.
T I GFRONT
4.0 to
2.0 kg
HANDL
R.S.A.
UPPELOWE
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S E R V I C E D AT A - E N G I N ECOMP. PRESSURE
Standard2
12-14 kg/cmService Limit 29.1-14 kg/cm
CAM HEIGHT
Standard 30.80 30.4
S er vice L im it 3 0.5 3 0.00
Ex.Inlet
VALVE STEM DIAMETER
4.46
4.40
4.46
4.40
Inlet E xh au stStandard
Service Limit
VALVE STEM BEND
TIR 0.01Standard
TIR 0.03Service Limit
VALVE HEAD THICKNESS
0.5 0.8I nl et E xh au st
Standard
0.3 0.6Service Limit
CAM SHAFT CHAIN 20 LINKS
127 - 127.2Standard
128Service Limit
20-link length
1st 2 nd 21st
MEASURE THIS LENGTH
CYLINDER INSIDE DIA.
57.010-57.017Standard
57.017-57.024Service Limit
10mm20mm
40mm
PISTON DIAMETER
56.978-56.900Standard
56.988-56.998Service Limit
7mm
ALL DIMENSIONS ARE IN MM.
PISTON/CYL. CLEARANCE
0.019 - 0.039
0.05
Standard
Service Limit
ROCKER ARM INSIDE DIA.
10.00 - 10.01Standard10.04Service Limit
CAM SPROCKET DIAMETER
61.4Standard61.3Service Limit
VALVE SPRING FREE LENGTH
41.6Outer
37.9Inner
Standard
Service Limit 40.6 36.9
CYLINDER HEAD WARP
Standard 0.00
S erv ice L imi t 0. 05
VALVE CLEARANCE
0.05
Inlet
0.10
Exhaust
Standard0.05 0.10Service Limit
ROCKER ARM SHAFT DIA.
9.97 - 9.98Standard9.92Service Limit
S EPISTON R
StandardService
PRESS
Standard
Service
CRANK
Standard
Service
ALL DIM
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S E R V I C E D AT A - FR AM EBR. PANEL CAM HOLE DIA.
S ta nd ar d 1 2. 0- 12 .0 3
S er vi ce Li mi t 1 2. 15
FR. BRAKE PAD THICKNESS
7.4
3.8
Standard
Service Limit
BR. SHOE LINING THICKNESS
3.85-4.15
2.0
Standard
Service Limit
BRAKE DRUM INDISE DIA.
130.00 - 130.16
130.75
Standard
Service Limit
AXLE RUN OUT
TIR 0.1
TIR 0.2
Standard
Service Limit
100 mm
AXIAL WHEEL RUN OUT
TIR 0.8
TIR 2.0
Standard
Service Limit
RADIAL WHEEL RUN OUT
TIR 0.8
TIR 2.0
Standard
Service Limit
DRIVE CHAIN SLACK
25 - 35
35 - 45
Standard
Service Limit
DRIVE CHAIN LENGTH
254 - 254.6
259
Standard
Service Limit
20-linklength
1st 2 nd 21st
MEASURE THIS LENGTH
REAR SPROCKET WARP
TIR 0.4
TIR 0.5
Standard
Service Limit
BRAKE CAM DIAMETER
11.95-11.98
11.88
Standard
Service Limit
ALL DIMENSIONS ARE IN MM.
FRONT FORK OIL
Grade :
SAE 10W20
Capacity :
145 + 2.5 ml(per leg)
Oil changefrequency :After every10,000 Kms.
FR. TYRE TREAD DEPTH
5.0
1.0
Standard
Service Limit
REAR TYRE TREAD DEPTH
6.6
1.5
Standard
Service Limit
FR. FORK SPRING FREE LTH.
420
416
Standard
Service Limit
Free Length
E L E
POSITIO12V-5W
TINDICAT
INDICAT
IL
HEAASS
12V-35/3
IGNSW
SIGNF
LAMP
TINDICAT
** LAMP12V, 3.4W
(QTY. 2)
METERASSY.
* LAMP12V, 1.7W
(QTY. 4)
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E L E C T R I C A L W I R I N G D I A G R A M - ( K I C K S T A R T )
R/B
CAPACITOR
W
W/R
L/W
L/W
REGULATOR
FUSE (15A)
W/B
B/Y
GR
BATTERY12V 2.5AH
B/Y
R
Y
B/Y
B/Y
Y/R
Gr
R
COIL
PUL
SING
MAGNETO
Lg
Lg
R/B
B/Y
W/Y
FUEL LEVEL GUAGE
Br
B/Y
W/Y
Lg
Gr
G
R
R/B
G
R/B
R/W
Br/W
B/Y
R
/B Y
B/Y
R B/
WY
OFF
ON
YR B/Y
B/Y
Br
B
OGr
G B
GG
B Y/
/B Y
/B Y
/B Y/B Y
Gr
/B Y/B Y
/B Y/B Y
L
/B Y
RR
/B Y
L
GrGr
Br
L
LBr
OBr
GG
BY/
Br
L
LBr
R Y/
Br
W
B W//B W
W
Br
Lg
W/Y
B/Y
Br
GrGr
NEUTRALSWITCH
HORN
SIGNALLAMPREAR LH
SIGNAL
LAMPREAR RH
REAR BRAKESWITCH
TURN SIGNALRELAY
FRONT BRAKESWITCH
SIGNAL LAMPFRONT LH
HEAD LAMPASSY/LAMP
12V-60/55WPOSITION
LAMP12V-4W
IGNITIONSWITCH
SIGNAL LAMPFRONT RH
LAMP 12V-10W
EARTH-FRAME
Y/L
Y R
LIGHT SWITCH
ON
OFF
PO
CONTROL SWITCH RH
R/B OG
rG B
R LLO HI O
B/YY
R/B
R/B
Y/L
R/Y
Y
Y/L
TAIL LAMPASSY
TAIL/STOPLAMP
12V-5/10W
SPARKPLUG
B
H.T.COIL
B/Y
B
C.D.I.ASSY.
SWITCH ASSY.
W/R
RB/W
B/R
W/GW/G
SPARKPLUG
H.T.COIL
**LAMP12V,3W(QTY.3)
*LAMP12V,1.4W(QTY.5)
FUEL METER
ILLUMINATIONLAMP **
ILLUMINATIONLAMP **
ILLUMINATIONLAMP **
TURN SIGNALINDICATOR LAMP *
(FRONT LH )
HIGH BEAMINDICATOR LAMP *
NEUTRAL LAMP *
TURN SIGNALINDICATOR LAMP *
(FRONT RH)
PASSSWITCH
CONTROL SWITCH LH
HORNSWITCH
TURNSIGNALSWITCH
DIMMERSWITCH
I N D
P
3
P
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I N D I V I D U A L C I R C U I T D I A G R A M ( E S ) STARTER MOTOR ANDBATTERY CHARGING CIRCUIT
CLUTCHSWITCH
EARTH-FRAME
NEUTRALLAMP
CONTROL SWITCH RH
STARTERSWITCH
INTERLOCKRELAY
STARTERMOTOR
NEUTRALSWITCH
MAGNETO
STARTER RELAY
FUSE(15 Amps.)
BATTERY12V 9Ah
NO
P
NC
OFF
ON
IGNITION
SWITCH
R.R.UNIT
Lg
Br
Lg
Lg
Lg
Lg
Br
Br
W
W
W
B/Y
B/Y
G/W
G/W
G/W
Br/W
R/Y
Br/W
R/Y
R/Y
R/Y
R
R
R B
B
Y/G
Y/G
Y/G
B/Y
B/Y
B/Y W
L/W
L/W
L/W
L/W
B/Y
B/Y
I N D
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I N D I V I D U A L C I R C U I T D I A G R A M ( E S ) SIDE INDICATOR ANDHORN CIRCUIT
HORN
MAGNETO
STARTERMOTOR
FUSE(15 Amps.)
STARTERRELAY
O
CONTROL SWITCH LH
HILR
OFF
ON
HORNSWITCH
TURN SIGNALSWITCH
SIGNALLAMP
REARLH12V 10W
SIGNALLAMP
REAR RH12V 10W
TURNSIGNAL RELAY
SIGNALLAMP
FRONT LH12V 10W
IGNITIONSWITCH
SIGNALLAMP
FRONT RH12V 10W
LHTURNSIGNAL
INDICATORLAMP
12V 1.4W
RH TURNSIGNAL
INDICATORLAMP
12V 1.4W
+
BATTERY12V-9Ah
Gr Gr
Gr
Gr
Gr
Gr
B/Y
B/Y
B/Y
B/Y
B/Y
B/Y
B/Y
G
G
G
GG
Br
W
W B/Y
B/Y
Br
O
O
O
B
B
Br
B/Y
BR
W/B
W
I N D
ON
IGNSW
FUMET
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Warm up the CO Gas Analyzer for1 0 t o 1 5 m i n u t e s b e fo r eproceeding further. Warming up isessential every time machine isput on to purge out any gases leftin side.
Carry out Span Check as permanufacturer's recommendationto confirm the OK condition of theEquipment (If Span Check does
not confirm the reading, then carry
Readiness of CO Gas Analyzer:
S T A N D A R D P R O C E D U R E F O R C O C H E C K I N G A N D S E T T I N G
out Gas Cal ibration as per manufacturersrecommendation). Set the Equipment display to Zerobefore taking the reading.
Readiness of the Vehicle:
Before checking the COemission, prepare the vehiclefor checking the CO >>>
Warm up the engine toits normal operatingtemperature by riding 5
to 6 Kms. The Clutch cover should be warmenough by feel.
Ensure the Choke is in OFF position.
Screw in Volume Control Screw completely. Engineshould die down in this condition.
Note: If engine does not go off, then attend to theadditional air supply problem in the carburetor circuit &intake system. After solving the problem once againconfirm that engine should die down on closing the
Volume Control Screw.
Confirm the Volume Control Screw to it recommendedposition of 2.5 turns.
Set Idling speed to specified Idling to 1400 + 100 rpm
of respective engines. Raise the engine to moderatespeed at no load condition for about 15 seconds.Then bring back to specified idling RPM.
Taking the Reading:
Insert 'Special Probe' inthe Silencer tail endpipe properly. Use rightmouth piece of theprobe to suit with tailend pipe of respectivevehicle. The specialprobe is a combinationof adaptor and probe. Itcomes with adjustablestand.
S T APre
intamoingand
Ns
A2
Vd
CV
IfSb
-
No
be Evespesho
Ifoc
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T U N E - U P F O R O P T I M U M M I L E A G EReed Switch : Maintenance Reed Switch : Checking
Reed Switch : Setting
Magnet should not touch
with reed switch.
Gap between Magnet &
Reed Switch should not be
more than 2.5 mm.
Movement of throttle lever
with magnet assembly and
Reed Switch fitted should
be free.
Check throttle lever movement by rotating it with
hand. It should not be sticky in operation and
should return back it self on releasing.
Accelerator cable play: 2-3
m m b y a d j u s t i n g th e
Adjuster (A).
Protude stopper (B) of the
throttle lever bracket must
on idling screw (C) tip.
Ke e p th r ot t l e a t z e r o
position. (Fig. 1).
On connecting multimeter to
Reed Switch coupler it
should show continuity.
When throttle is open andR e e d S w i t c h m a g n e t
crosses to straight edge of
fix bracket of Reed Switch
(Fig. 2) multimeter should
show discontinuity.
0.00
On De-acceleration, when of
Reed Switch magnet re-
coinsides with straight edge
of fix bracket of Reed
Switch (Fig. 3) Multimeter
should show continuity.
1
1
Gap2.5mm max.
B
A
C
Fig. 1
Fig. 2
Fig. 3
T U
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W A R R A N T Y A N D S E R V I C E SSr. No. Service Type Kms./days *
1 1s t F re e w it h 0 0, 50 0 - 00, 750 Kms . o r 30 da ys .Oil change
2 2nd Free 02,000 - 02,500 Kms. or 90 days.3 3r d F re e w it h 0 4, 50 0 - 05, 000 Kms . o r 15 0 da ys .
Oil change4 4th Free 07,000 - 07,500 Kms. or 225 days.5 1s t Pa id wi th 0 9, 50 0 - 10, 000 Kms . o r 30 0 da ys .
Oil change6 2nd Paid 12,000 - 12,500 Kms. or 375 days.7 3r d Pa id wi th 1 4, 50 0 - 15, 000 Kms . o r 45 0 da ys .
Oil change8 4th Paid 17,000 - 17,500 Kms. or 525 days.9 5t h P ai d w it h 1 9, 50 0 - 20, 000 Kms . o r 60 0 da ys .
Oil change10 6th Pai d 22,000 - 22,500 Kms. or 675 days.1 1 7 th Pa id wi th 2 4, 50 0 - 25 ,0 00 Km s. or 67 5 d ay s.
Oil change12 8th Pai d 27,000 - 27,500 Kms. or 675 days.
1 3 9 th Pa id wi th 2 9, 50 0 - 30 ,0 00 Km s. or 67 5 d ay s.Oil change
Warranty2 Years Or 30,000 Kms.
Warranty2 Years Or 30,000 Kms.
whichever occurs earlier.
R E S I S T A N C E S
Range(Ohms)
Connections Reading(Ohms)Meter +ve Meter -ve
X 10 200 + 30White/Red Black/Yellow
PICKUP COIL :
Range(Ohms)
Connections Reading(Ohms)Meter +ve Meter -ve
X 1 15 + 3Red Black/Yellow
CHARGING COIL
Range
(Ohms)
Connections Reading
(Ohms)Meter +ve Meter -veX 1 1.0 + 0.3Bl ue /Whi te Bl ac k/ Yel low
BATTERY CHARGING COIL(KS)
Range(Ohms)
Connections Reading(Ohms)Meter +ve Meter -ve
X 1 1.2 + 0.3Blue/White Blue/White
BATTERY CHARGING COIL(ES)
Range(Ohms)
Connections Reading(Ohms)Meter +ve Meter -ve
X 1 1.0 + 0.3Ye ll ow /Re d B la ck/ Ye ll ow
LIGHTING COIL (KS)
Range(Ohms)
Connections Reading(Ohms)Meter +ve Meter -ve
X 1 0.7 + 0.3Ye ll ow /Re d B la ck/ Ye ll ow
LIGHTING COIL (ES)
L O:
Appl
Appl
243
:
243
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I M P O R T A N T E N G I N E A S S E M B L Y 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 givenbelow firmly and then tighten the sprocket allen bolt(A).
Ensure that the O mark on washer always facesoutwards when tightening the allen bolt (A).
Valve timing Ensure the sprocket marks (A) are aligned
horizontally with cylinder head top machined face. Ensure the piston is at TDC. Ensure T mark on rotor matching t he ccase mark.
The clutch collar having hole is to be slided into theclutch housing for effective lubrication.
Bigger gear to be assembled facing the dust cap sidewhile assembling the starter counter gear.
Chain top edge to be kept between the two marksduring chain slackness adjustment.
Remove the allen head grub screw before removingthe sleeve spark plug.
Before fitting the sleeve spark plug apply thin layer ormolybdenum di-sulphide grease on the entrychamfers for the O rings.
Always blow compressed air through the oilpassages in reverse direction of oil flow and ensurethe passages are clear.
Apply a thin layer of liquid gasket on body of thestarter 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.
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F R E Q U E N T L Y A S K E D Q U E S T I O N S - F A Q S What are the features of Di scover DTS-i motorcycle?
Discover DTS-i has many Unique; Advanced & Contemporaryfeatures 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 andoption of Round Headlamp as well that matches to the profile ofthe vehicle.
Advanced Features:
Digital Twin Spark Ignition System (DTS-i) with Twin Map foraccurate ignition timing.
Throttle Responsive Ignition Control System (TRICS).
Optimized engine combustion characteristics to provide ultimateperformance.
Contemporary Features:
Strongest & Sturdier frame & stiffer rectangular cross-sectionedswing arm to with stand twists and all kind of road tortures.
Longest wheel base in its class for better road holdingcharacteristics.
Highest rear wheel travel to ensure most comfortable ride in allterrain.
Longest fr. suspension travel in its class to provide pleasant ride.
Brightest Headlamp with 60 / 55 Watt Halogen bulb for safer nightride.
What is DTS - i ?
DTS-i stands for Digital Twin Spark Ignition - an Advanced Technologywhich will be the heart of a new breed of high performance enginesfrom Bajaj.
What is the Advanced Technology in DTS-i ?
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 Timingand TRICS or Throttle Responsive Ignition Control System, which is anon-contact switch on the Carburetor body and this changes theIgnition Map based on Throttle position.
Combined actions of these technological breakthroughs enhances theOverall Performance likes Power, Pick-up, and Mileage etc.
Why Twin Spark Plugs ?
Conventionally in a 4-stroke engine the spark plug is at one end of thecombustion chamber. It means the Air fuel mixture combustion isbetter around the sparkplug, rather than the opposite side of thecombustion chamber. Because of the longer time needed for thecombustion to take place on the far side (opposite side of the sparkplug) overall combustion is slow, leading to poor combustion efficiency.
In fact Discover DTS-i delivers power & performance of 125 ccengine 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.
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F R E Q U E N T L Y A S K E D Q U E S T I O N S - F A Q S How DTS-i is different from VT-I in TVS Centra and AMI in Hero
Honda Ambition ?
VT-I of TVS Centra and AMI of Hero Honda Ambition only haveswithchable Ignition timing maps and Digital CDIs. The switch of TVSCentra is not Maintenance free and the switch of Hero HondaAmbition is a contact type, which means problems or wear and tear.
Why the Tyre size is of 17" where as normally all othermotorcycles 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 ExcellentRoad holding, Better Balancing and Extra ordinary High speedStability. With this, there is absolutely no need of 18" tyre.
B Rather here, the 17" tyre, due to reduced weight and lesser roadcontact area, it will contribute in enhancing the mileage as comparedto 18" tyre.
DTS-i technology from Bajaj Auto Limited is the future of bikes.
Why Dual Oil Filtration system is not given in Discover DTS-iwhere as this feature is given in Wind 125?
Discover DTS-i engine too has dual oil filtration system. The firststage filtration is done by extra large strainer with fine mesh. And thesecond stage filtration is taken care by in built Centrifugal Oil filtermounted on crankshaft.
With extra large strainer and Centrifugal Oil filter, the level of filtrationwould be similar to the engine having Primary Strainer and Paper Oilfilter.
Being 125 cc and having higher power, why Discover DTS-i hasnot been incorprated with 5-speed gear transmission ?
Considering utilization of power produced by this engine, to achievebetter low-end torque, pick up and to obtain maximum mileage gearratios have been uniformly spread across all gears appropriately. Withthis 4-speed transmission is enough to perform the task.
When Discover DTS-i has so advanced engine, then how comeSAI system & BS Valve is not provided in this?
That is one of the speciality of DTS-i engine. The optimizedcombustion process because of two Spark plugs, Digitallyma na ge daccurate Ignition and TRICS all together address the advantages oflow emission, better cold startability, enhanced drivability delivered bySAI System and B S Valve.
That means, again lesser the components, more the benefits.
Why primary kick mechanism isnt provided in Discover DTS-iengine?
To reduce engine components which minimizes the engine weight as
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Combustion at accurate timing with respect to engine rpm atdifferent speeds and loads on the engine.
Altering of Ignition timing depending upon different throttlepositions.
As these activities consistently take place, the fuel efficiency is boundhappen in Discover DTS-i' engine.
Moreover, other certain virtual elements are there to support thisengine for delivering better mileage. The other virtual elements are -
Lesser weight of the engine as compared to other 125 CC engines.
Lesser road resistance due to lesser road contact area on accountof 17" tyres.
Virtual Instructor to the Rider in the form of Ride Control Switch' toride the vehicle in Fuel Efficiency Zone'.
Truly speaking, if Discover DTS-i' is ridden within 'Fuel EfficiencyZone' as per instruction of Ride Control Switch, it can put all other 125CC engined vehicles on shame and even able to compete shoulder toshoulder with other 100 CC engined vehicles.
What is Exhaust TEC'?
B Exhaust TEC is a device incorporated in exhaust system of DiscoverDTS-i engine. TEC stands for Torque Expansion Chamber. Itimproves Scavenging process.
B The exhaust system has this revolutionary feature, which drasticallyimproves engine torque at low revs without compromising anything atmid or high engine revs. It has been extensively optimized to get themaximum possible performance out of the engine. The Silencer alsohas a characteristic tonal quality to it. It gives out a pleasant sounding
F R E Q U E N T L Y A S K E D Q U E S T I O N S - F A Q Slow frequency boom, which many people associate with the typical'Bullet' kind of silencer sound. While meeting the mandatory currentNoise norms, it gives the vehicle an identity, which is different fromany other bike, so as to make it very unique.
Normally higher power bikes are heavier in weights. How aboutDiscover?
B Higher the Power Heavier the Engine has become now a vintagestory (or has become a old proverb) Bajaj R & D with its capability hasengineered and developed Discover DTS-i engine with Higher Powerto Weight Ratio as compared to other 125 CC engines.
B On one side it was successful to make the engine deliver more power
and on the other side it has tried to reduce the engine weight bysimplifying the design as compared to other 125 CC engines.
B The Power to Weight Ratio that means the Power produced per tonweight of the vehicle in comparison with other vehicle is given below.
Is Power & Pick-up of Discover DTS-i marginally or substantiallybetter than current 100 cc popular bikes or there's a substantialimprovement?
B No. The Power & Pick up of Discover DTS-i is far.. far better thanthe popular 100 CC bikes and even much better than any other 125 CCbike on the road.
B The Power & Torque comparison is follows.
D is co ve r V ic to r 1 25 F az erFreedomPrima 125
Power to WeightRatio i.e. Power perTon weight of thevehicle 92 81.86 86.4 96.39
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