Discover Dts i Srr

5/24/2018 Discover Dts i Srr

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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


2/24


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


3/24


1

T E C H N I C A L S P E C I F I C A T I O N S

Type Four stroke, Single cylinder, Natural air cooled.

No.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


4/24


3

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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5

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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7

P A R T S I D E N T I F I C A T I O N - P U L S A R 1 5 0 D T S i

Part Name

Description

Identification Mark

Part No.

Part Name

Description

Identification Mark

Part No.

Part Name

Description

Identification Mark

Part No.

Part Name

Description

Identification Mark

Cylinder Head with Cover

DH 1015 29

Rubberised silent bush fitted in head cover.

Cylinder Head with Cover

DH 1015 29

Bigger combustion chamber cavity.

DH mark is embossed on casting.

Cylinder Complete

DH 1015 27

Bigger bore.

-----

Piston Assembly

DH 1015 30

DHU mark is embossed on piston crown.

Large in diameter.

Part No.

-----

P A


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9


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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11


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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13


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



10/24


15


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



11/24


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)



12/24


19

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



13/24


21

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



14/24

23

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)



15/24

25

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



16/24

27

I N D I V I D U A L C I R C U I T D I A G R A M ( E S ) STARTER MOTOR 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



17/24

29

I N D I V I D U A L C I R C U I T D I A G R A M ( E S ) SIDE INDICATOR 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



18/24

31

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



19/24

33

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



20/24

35

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)


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)


X 1 1.2 + 0.3Blue/White Blue/White

BATTERY CHARGING COIL(ES)

Range(Ohms)


X 1 1.0 + 0.3Ye ll ow /Re d B la ck/ Ye ll ow

LIGHTING COIL (KS)

Range(Ohms)


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



21/24

P R

Whthe

Afteng

Impcov

Drastra

As

com If c

dire

Whcondam

Staapp

Clu

Pr

37

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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