I Read ..... I Learn: Discover Dts-Si Training Notes Dealer Development Center

Contents
1 I Read ..... I Learn 1

3
Identification....................................................................
4
Salient Features................................................................
8
Technical Specifications...................................................
10
FAQs...............................................................................
12
Comparison with Competitors Vehicle..........................
2 I Check.....I Maintain 15
PDI Check List................................................................
16
PDI SOP & Time Chart...................................................
18
Periodic Maintenance Chart..........................................
21
Periodic Service SOP.....................................................
23
Periodic Maintenance Points.........................................
27
3 Fuel System 37
39
Carburettor Specifications.............................................
40
Carburettor Working of Systems...................................
44
Carburettor Dos & Don’ts.............................................
45
CO Checking & Setting.................................................
46
Tune up for Optimum Mileage.....................................
4 Engine & Transmission 47

48
Digital Twin Spark Swirl Induction................................
49
Special Tools.................................................................
53
Service Limits.................................................................
56
Gear Transmission Power Flow.....................................
59
Tightening Torques........................................................
62
Engine Lubrication - Flow of Oil..................................
66
Dos & Don’ts................................................................
DISCOVER DTS-Si TRAINING NOTES DEALER DEVELOPMENT CENTER

Contents
1
5 Vehicle (Frame) 71
Tightening Torques........................................................
72
Service Limits................................................................
74
Special Tools.................................................................
75
Nitrox Rear Shock Absorber.........................................
77
I Read ..... I Learn

6 Electricals 79 Identification
Battery...........................................................................
81
Salient Features
Dos & Don’ts - Generic...............................................
82
Electrical Checking Procedure......................................
89 Technical Specifications
Head Light Control Unit................................................
99 FAQs
Electrical Diagrams.......................................................
101
Comparison with
Competitors Vehicle
7 Workshop Safety 107
1
DISCOVER DTS-Si TRAINING NOTES DEALER DEVELOPMENT CENTER DISCOVER DTS-Si TRAINING NOTES DEALER DEVELOPMENT CENTER
Notes IDENTIFICATION
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric codes to
identify your particular vehicle from others of the same model and type.
Frame Number Location

On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location

On LH Side Crankcase Near Gear Change Lever
(Alpha-Numeric - 11 Digits)
1. RH Control Switch 7. DTS-Si Engine - 5 Speed Transmission

2. Speedo Console 8. Nitrox Rear Suspension
3. Front Fork with Anti Friction Bush 9. Silencer
4. Semi Double Cradle 10. LED Tail Lamp with Twin Colour Lens
5. Paper Oil Filter 11. Grab Handle
6. Engine Oil Level Window 12. LH Control Switch
1
2
12
11
10
8 7 6 5 4
2 3
SALIENT FEATURES SALIENT FEATURES
PERFORMANCE STYLE
Features Advantages Benefits Features Advantages Benefits
• DTS-Si engine - 94.38 cc • New generation technology engineered • Most fuel efficience bike. • Athletic and muscular petrol tank, side
• Engine power : 7.7 PS for best mileage and performance as Mileage 89 Km/L in IDC condition. covers and seat cowling.
• Engine torque : 7.85 Nm well.
• New head lamp with attractive fairing
• 5 Speed Transmission • Wider range of gear ratios to utilize • Better drive-ability and the best fuel and twin pilot lamps.
• ExhausTEC high torque of engine economy
• Innovative and Distinctive Graphics.
• Molycoat piston • Reduced friction • Increased fuel efficiency. • Stylish and eye catching looks • Sporty styling
• Nozzle oil jet in lubrication circuit • Better cooling of piston • Better life of component. • LED tail lamp having bright chrome • Combination of Black & Chrome styling • Improves personality of the rider.
• Protection from seizure masking.
• Electric start • Quick and easy starting. • Feather touch engine starting • Front Blinkers mounted on front fork
• DC ignition & Digital CDI • Consistent engine performance • No hassle of choke operation. pipes.
• Auto choke • Consistent mileage, power and pick up.
• Black colored engine, wheels, silencer
• Optimum ride control switch • Indicates optimum throttle opening for • Enhanced fuel efficiency. and other components.
best mileage. • Greater safety while driving.
• DC Lighting system • Intensity & illumination of head light do • Constant bright beam from head light
not change with engine / vehicle speed even at low engine / vehicle speed.
4 5
SALIENT FEATURES SALIENT FEATURES
COMFORT AND CONVENIENCE SAFETY
Features Advantages Benefits Features Advantages Benefits
• Trip meter • For recording distance covered in a trip • Easy to record trip distance. • Robust semi double cradle frame with • Excellent ride and handling stability, • Safe to drive on highway.
/ tour. Also helps in calculating longest wheel base - 1305 mm - in its balance and vehicle dynamics.
mileage. class of motorcycles.
• Fuel Gauge • Displays approx. petrol qty. remaining • More convenience. • 130 mm dia front brake drum and 110 • Efficient and effective braking.
in the petrol tank. mm dia rear brake drum. • Safety.
• Low battery indicator • Reminds user to get battery charged in • For maintaining battery in healthy • Powerful head light, Number Plate • Bright and powerful illumination.
time. condition. lamp, and Pass switch. • Clear visibility of rear number plate
from long distance. • Safe night driving.
• Engine ‘Oil Level Window’ • For easy inspection & monitoring oil • No hassle of removing, cleaning, • Pass switch facilitates over taking.
level. dipping ‘Dip Stick’ to check oil level.
• Alloy wheels & unidirectional tyres. • Better road grip and nimble handling. • Easy to maneuver and safe to drive.
• Telescopic front fork with anti-friction • Minimum friction between fork pipes. • Comfortable ride on any type of roads No maintenance of spoke tightening.
bush & 130 mm stroke. • Longest suspension stroke in its class and for any distance.
• Nitrox Rear Suspension with 110 mm of bikes. • Better life of front fork oil seal & other
wheel travel. parts of fork.
• MF battery (ES version) with unique • Low maintenance - No spillage of • No hassle of frequent topping up of
vent mechanism. electrolyte. battery.
• Clear lens LED Tail Lamp with 12 nos. • Stylish looks. • Low Maintenance cost and enhanced
of LEDs • Minimum consumption of battery. battery life.
• Long life.
6 7
TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS
Engine & Transmission Controls

Type : Four stroke, Natural air cooled Steering : Handlebar
No. of cylinders : One Accelerator : On handle bar, RH grip
Bore : 47.00 mm Gears : Left foot pedal operated, Step shift
Stroke : 54.40 mm Brakes Front : On handle bar, RH lever.
Engine displacement : 94.38 cc Rear : Pedal operated by RH foot
Compression ratio : 9.8 + 0.3 :1
Idling Speed : 1400 + 100 rpm in warm condition Electricals
Max. net power : 5.62 KW, 7.7 PS @ 7500 rpm
System : 12 V (DC)
Max. net torque : 7.85 Nm, 0.8 Kgm @ 5000 rpm
Battery : 12V 5Ah MF Type (Electric Start), 2.5Ah (Kick Start)
Ignition System : DC, Microprocessor controlled Digital CDI with TRICS
Head Lamp : 12 V 35/35 W, HS-1 (Halogen)
Ignition Timing : Variable Timing with Multiple maps
Tail / Stop Lamp : LED Type
Fuel : Unleaded Petrol, 87 RON Minimum
Side Indicator Lamp : 12 V 10 W (4 Nos. - Amber Bulbs )
Carburettor : Keihin (AW7) - PTE - 16 KFI
Position Lamp : 12 V 5 W (2 Nos.)
Spark Plug : Champion PRZ9HC & BOSCH UR4AC (Resistive)
Rear Number Plate Lamp : 12 V 5 W
Spark Plug Gap : 0.7 to 0.8 mm
Speedometer Bulb : 3.0 W
Lubrication : Wet sump, Forced Lubrication
Neutral Indicator : 1.7 W
Starting : Kick Start, Electric Start
Turn Signal Indicator : 1.7 W
Clutch : Wet, Multi Disc Type
Hi-beam Indicator : 1.7 W
Transmission : 5 Speed Constant Mesh
Battery Low Charge Indicator : 1.7 W
Primary reduction : 3.75 : 1 (75/20)
Horn : 12 V DC
Gear Ratios 1st Gear : 2.833 : 1 (34/12)
Fuel Gauge : Cross Coil Movement
2nd Gear : 1.824 : 1 (31/17)
3rd Gear : 1.333 : 1 (28/21) Dimensions
4th Gear : 1.087 : 1 (25/23)
5th Gear : 0.909 : 1 (20/22) Length : 2040 mm
Final Drive Ratio : 3.0 : 1 (42/14) Width : 682 mm
Overall Gear Ratios 1st Gear : 31.88 : 1 Height : 1087 mm
2nd Gear : 20.52 : 1 Wheel Base : 1305 mm
3rd Gear : 15.00 : 1 Saddle Height : 800 mm
4th Gear : 12.23 : 1 Turning Circle Radius : 2100 mm (min)
5th Gear : 10.23 : 1 Ground Clearance : 165 mm
Chassis & Body Weights

Frame Type : Semi Double Cradle Vehicle Kerb Weight : 115.0 Kg (Electric Start)
Suspension Front : 130 mm Fork travel, Telescopic : 112.5 Kg (Kick Start)
Rear : 110 mm Rear Wheel travel, Nitrox (Gas Filled) Gross Vehicle Weight : 245.0 Kg (Electric Start)
Brakes Front & Rear : Mechanically expanding shoes : 242.5 Kg (Kick Start)
Brake Size Front : 130 mm Drum
Rear : 110 mm Drum Performance
Tyres Front : 2.75 x 17, 41 P, Unidirectional
Rear : 3.00 x 17, 50 P, Unidirectional Maximum speed : 85 Kmph (with single rider 68 Kg)
Tyre Pressure Front : 1.75 Kg / Cm2 (25.0 PSI) Climbing ability : 25% (140 Max)
Rear (Solo) : 2.00 Kg / Cm2 (28.5 PSI)
Rear (with Pillion) : 2.25 Kg / Cm2 (32.0 PSI) Notes :
Rims Front : 1.4 x 17” Die Cast AI. Alloy Wheel • Values given above are nominal & for guidance only, 15% variation is allowed to cater for
Rear : 1.6 x 17” Die Cast AI. Alloy Wheel production & measurement.
Fuel Tank Capacity : 8.0 Liters • All dimensions are under un-laden conditions.
Usable Reserve : 1.5 Liters • Definitions of terminologies wherever applicable are as per Relevant IS/ISO standards.
Unusable Reserve : 0.8 Liter • Specifications are subject to change without notice.
8 9
FREQUENTLY ASKED QUESTIONS - FAQ’s FREQUENTLY ASKED QUESTIONS - FAQ’s
Ï Why the New Discover is priced higher than Splendor?  What are the advantages of Nitrox shock absorber?
B The new Discover DTS-Si is not priced higher than Splendor. Its price is at par. In fact Discover has extra features (in B As air content from the main cylinder is eliminated (unlike regular SA), foaming due heat generation (heat due to
comparison with Splendor) like - continuous up & down movement) during long run will not happen in the cylinder.
• Digital Twin Spark technology • ExhausTEC B This gives comfortable & smooth ride even during long distance running,
• DC Ignition system • 5-Speed gearbox B It also ensures no jerks during normal riding on rough roads.
• Nitrox Suspension • LED Tail Lamp
 What are the advantages of twin pilot lamps?
… Further Discover DTS-Si comes with Self start as a variant. On to top it all Discover DTS-Si is the World's best
B In DISCOVER DTS-Si, twin pilot lamps are housed in head light assembly which not only add to aesthetics but provide
mileage bike.
following advantages & benefits also:
Ï How can you say that Discover DTS-Si is the most fuel efficient bike? B During twilight zone (dawn / dusk), no need to put on headlight. Instead pilot lamps can be switched on for safe driving.
B ARAI (Automotive Research Association of India - an Indian Government authorized body) which certifies the mileage for B Sporty looks.
all Indian bikes has given the certificate to Discover DTS-Si for the highest mileage of 89 Km/L in Indian Driving Cycle
(IDC condition). And also it is a well known fact that Indian bikes give the highest mileage in the world (as stated by  How does DC ignition / Lighting system work? What are its advantages?
SIAM, Society of Indian Automobile Manufactures). Thus we can say that Discover DTS-Si is the most fuel efficient bike B Both Ignition & Lighting works on Direct Current (DC) supplied by the Battery and not directly from the AC current
in the world. generated by Magneto.
Ï How does Discover manage to give this much mileage? B Advantages of DC Electrical System -
B Following technological features make Discover DTS-Si world's most fuel efficient bike. 1. Easy & quick starting of engine due to consistent power supply even at low engine rpm
• DTS-Si - Digital Twin spark Swirl Induction system. 2. Consistent engine performance Power, Pick up, Mileage
• Oval Pent Roof Combustion Chamber - helps in achieving best possible combustion of lean air fuel mixture. 3. Constant bright beam of head light even at very low engine / vehicle speed
• ExhausTEC - Improves engine's low end torque which contributes in better mileage.  Would my motorcycle start if battery is down / discharged ? Or Would my motorcycle start if fuse gets blown-off?
• Molycoat Piston (MOS2) - Reduces friction thus waste of power which helps in increased fuel B Yes. DC electrical system of Discover DTS-Si is designed in such a way that engine can be started by kick even if
efficiency. battery is discharged or fuse gets blown off. But it is advised to get the battery charged immediately if found discharged.
• Five Speed Transmission - Effective utilization of engine torque & improved drive-ability that contributes
in better fuel efficiency.  In case battery is disconnected or removed and given for charging to service center, can the bike be started ?
B No. this should not be done.
Ï Will Discover 135 continue to sell?
Though engine can be started without battery, it should not be done since the electrical & electronic components of
B Yes, Discover 135 will continue to sell because there is a strong demand for this bike as well.
vehicle would get damaged due to electrical surge.
Ï What is the difference between Discover 135 and this Discover DTS-Si?
 Does DC system vehicle cost more in maintenance?
B Discover 135 is engineered to deliver more power (13.10 PS) while Discover DTS-Si is to deliver world's best mileage.
Other differences are: B No. It is important to ensure Good health of battery that's all!
• Discover 135 is sportier looking while Discover DTS-Si is a family bike.  Can existing DTS-i Bajaj bike be converted into DTS-Si technology?
• Discover 135 has Digital Instrument Cluster, Disc brake, Wider Tyres, Petrol Tank Spoilers and many other sports B No. It is not possible.
bike features
• Discover 135 gives on-road mileage of 55-60 Km/L while Discover DTS-Si gives about 80+ Km/L.  Is the life of DTS-Si engine compromised since the engine gives very high mileage?
 Is this the same Discover 112 which used to come earlier? B Absolutely No. DTS-Si engine components are made of superior material composition and are well designed to withstand
higher combustion pressure achieved due to higher turbulence and fast burning of lean air-fuel mixture.
B No, It is a new Discover engineered to give the best mileage in its class. It is a 100 cc bike with DTS-Si engine which
comes from the DTS-i family. It has the same durability and ride feel which all Discover bikes enjoy. B More over, the other parameters that contribute for more mileage are
1. Reduced engine friction
 What is the benefit of Auto Choke? 2. Mass / weight reduction of engine components.
B Basically the choke is a system of carburetor, which enables easy engine starting in cold condition. In case of manual
choke, if rider forgets to put off choke, this effects on fuel efficiency adversely. DTS-Si technology is tried and tested under extreme conditions by Bajaj Auto Ltd.
B However, in Auto choke system incorporated on Discover DTS-Si no manual intervention is required for switching on or
off the choke. It operates automatically as per the need of engine.
10 11
COMPARISON WITH COMPETITORS VEHICLES COMPARISON WITH COMPETITORS VEHICLES
BAJAJ BAJAJ
DISCOVER Hero Honda Hero Honda Advantages of DISCOVER Hero Honda Hero Honda Advantages of
Description Description
DTS-Si Passion Plus Splendor Plus BAJAJ DISCOVER DTS-Si DTS-Si Passion Plus Splendor Plus BAJAJ DISCOVER DTS-Si
POWER AND PERFORMANCE COMFORT AND CONVENIENCE
Engine Cubic Capacity 4 Stroke 4 Stroke 4 Stroke DTS-Si technology Telescopic

94.38 CC 97.2 CC 97.2 CC engineered for the best mileage hydraulic fork Telescopic Telescopic
Front and Rear suspension travel
Front Suspension Hydraulic fork Hydraulic fork
130 mm is longest in its class of bikes.
7.7 PS @ 7.5 PS @ 7.5 PS @ Travel (Stroke) Less stroke Less stroke
Engine Horse Power
7500 rpm 8000 rpm 8000 rpm
Excellent engine performance Nitrox Conventional Conventional
7.85 Nm @ 7.95 Nm 7.95 Nm (Gas filled) hydraulic hydraulic The best ride comfort on any kind of road
Engine Torque and for any distance.
5000 rpm @ 5000 rpm @ 5000 rpm Rear Suspension 110 mm shock shock
Wheel travel absorbers absorbers Freedom from back-ache.
Transmission 5 Speed 4 Speed 4 Speed Utilisation of high torque of engine. 5 step adj. Less travel Less travel
Max Speed 85 Kmph 85 Kmph 82 Kmph Better drive ability & the best mileage
Solenoid operated auto choke for easy and
Auto Choke YES NO NO quick starting even in severe cold conditions.
Ignition System DC System Electronic Electronic Excellent start-ability and drive-ability
Digital CDI CDI CDI No hassle of frequent topping up
Battery MF for ES Regular Regular
of electrolyte level.
Patented Non
Not Not Seamless changes in ignition maps according
TRICS contact TPS to change in vehicle load For understanding battery charge status.
available available Low Battery Indicator YES NO NO
Hall Sensor Reminds rider to charge battery in time.
ExhausTEC No No Trip Meter YES NO NO For recording Km reading during a trip / tour.
Exhaust System Knock free engine & high ‘Low End Torque’
Technology ExhausTEC ExhausTEC
Lockable Helmet Holder NO YES NO
Ride Control Not Not Ride control switch indicates optimum
Optimum Ride Control SAFETY & OTHER FEATURES
Switch provided provided throttle opening for best mileage
Kick Start Tubular Tubular Tubular Strong & robust frame

Starting Mechanism Electric + (Electric Only Quick & effort less engine starting Frame semi-double double double Excellent vehicle dynamics
Kick Start Optional) Kick Start cradle cradle cradle Excellent balance & stability
Fuel Tank Capacity 8 Liters 12.8 Liters 11 Liters
Kerb Weight 115 Kg 116 Kg 109 Kg Light weight & Robust
17” Premium
STYLE Wheels aluminum 18” alloy 18” spokes
wheels wheels Nimble handling & better agility
Conventional alloy wheels
Styling Sporty Old styling Stunning looks
Looks Styling Front Front Front
2.75x17, 41P 2.75x18, 4PR 2.75x18, 4PR
Unique Regular Regular Tyres
Graphics Best in its class Excellent road grip. Wider rear tyre.
Graphics Graphics Graphics
Rear Rear Rear
Stylish head Multi 3.0x17, 50P 3.0x18 6PR 2.75x18 6PR
Old
lamp with visor reflector head Largest wheel base in its class of bikes
Head Light with Fairing fashioned You can not take your eyes off it ! Wheel Base 1305 mm 1235 mm 1230 mm
and twin light with age Excellent stability
fairing
pilot lamps old fairing
More ground clearance to suit
Ground Clearance 165 mm 159 mm 159 mm Indian riding conditions
Minimum consumption of battery energy.
Tail Lamp LED Regular Regular Brakes Front Front Front
Long life - No maintenance
130 mm drum 130 mm drum 130 mm drum
For clear visibility of Rear no. plate Excellent braking efficiency
Rear no. plate lamp YES NO NO even from long distance Rear Rear Rear
Twin prismatic pilot lamp 2 numbers NO NO Also safe driving during dawn & dusk 110 mm drum 110 mm drum 110 mm drum
12 13
Notes
2
I Check.....I Maintain
PDI Check List
PDI SOP & Time Chart
Periodic Maintenance Chart
Periodic Maintenance Points
14 15
PDI CHECKLIST PDI CHECKLIST
Frame No. M D 2 D S P A Z Z To Check Check For

3 if OK or Observations /
7 if NOT OK Remarks
Engine No. J B B Rear Shock Absorber Spring adjuster notch position : 1st notch (Standard)
Steering Smooth operation (No play / Sticky movement)
Dealer’s Name Dealer’s Code
Lock Operation Steering cum Ignition, Seat, LH side cover lock
Date of PDI PDI done by Fasteners (Check torque) Front axle nut - 3.2 ~ 3.8 Kgm
Please insure that following checks are carried out during PDI before delivery of vehicle. Rear axle nut - 4.0 ~ 5.0 Kgm
3 if OK or Observations / Front fender bolts - 1.0 ~ 1.2 Kgm

To Check Check For 7 if NOT OK Remarks Fork pipe top bolts - 3.0 ~ 3.2 Kgm
ENGINE Fork under bracket bolts - 3.0 ~ 3.2 Kgm
Engine oil SAE 20W40 Oil level OK / Top up if required Holder handle upper bolts (4 Nos) - 2.0 ~ 2.2 Kgm
API ‘SJ’ OR ‘SL’
+ JASO MA Grade Oil leakage if any - Specify source of oil leakage Rear shock upper nut - 3.5 ~ 4.0 Kgm
Idling RPM (Warm up) Check / Adjust if required (1400 + 100 rpm) Swing arm - 4.5 ~ 5.5 Kgm
Kick Operation Smooth operation, Tightness of kick boss bolt Rear shock mounting bottom nut / bolt - 3.0 ~ 3.2 Kgm
Fasteners (Check torque) Magneto, Clutch & Oil filter cover bolts - 0.9 ~ 1. Kgm Steering stem head nut - 4.5 ~ 5.0 Kgm
Rider foot rest - 2.0 ~ 2.5 Kgm ELECTRICAL
Engine foundation nut / bolts - M 10 : 3.2 Kgm, M 8 : 2.2 Kgm) Battery Charge status (12.5 V open circuit terminal voltage)
Cap oil strainer - 0.9 ~ 1.1 Kgm Tightness of battery terminals / cables
Kick boss bolt - 2.2 ~ 2.5 Kgm Position of fuse box
Silencer bracket bolts - 3.5 Kgm, Mouth nuts - 2.0 ~ 2.2 Kgm All Bulbs Working Head light, Pilot lamps - 2, LED tail / stop, Side indicators, Speedo bulb,
Cylinder head cover bolts - 0.9 ~ 1.1 Kgm No. plate lamp, Turn pilot, High beam, Battery & Neutral indicator
FUEL SYSTEM Switch Operation RH & LH control switch, Ignition switch & Brake switch (Front & Rear)
Fuel Tank / Pipes No leakage / Correct fitment Starter Motor Proper working / Engagement
Carburettor No leakage / Correct fitment TEST DRIVE
Fuel Cock Smooth operation Starting Cold start & Warm start
FRAME Idling speed (Warm condition) (1300 + 50 rpm)
Tyre Pressure Front : 1.75 Kg / Cm2 (25.0 PSI) Drive ability Throttle response
2
Rear (Solo) : 2.00 Kg / Cm (28.5 PSI) Brakes - Front & Rear
2
Rear (with Pillion) : 2.25 Kg / Cm (32.0 PSI) Speedometer, Odometer & Trip meter
CONTROLS CO % Check Co should be 2 + 0.5 % in engine warm condition at idling RPM
Brakes Front brake lever free play - 4 ~ 5 mm Cleaning Wash & Clean vehicle properly
Rear brake lever free play - 15 ~ 20 mm
Throttle Grip free play - 2 ~ 3 mm. Smooth operation IMPORTANT NOTE :
Look for any external damages in transit : Please check, record & rectify send report with photos.
Clutch Smooth operation, No juddering, Free play - 2 ~ 3 mm
• Moisture / Oil collecting tube of air filter should be properly fitted and routed correctly.
Clutch Cable Routing : Pass cable through the clamp (JZ 1138 01) • Both RH & LH side spark plug caps must be tightly secured and ensure proper functioning of spark plugs.
Drive Chain Slackness standard - 20 ~ 25 mm, Service Limit - 35 mm • Auto choke functioning on carburettor. Apply 12 V DC supply to terminal & check its functioning without removing from the carburettor.
• TPS on carburettor for functioning.
SUSPENSION
• Thermal sensor resistance at room temperature (250C to 350C) with multi meter. (7 K Ohm to 10.5 K Ohm)
Front Fork No leakage. Smooth working
16 17
PDI - SOP AND TIME CHART PDI - SOP AND TIME CHART
Position Position
GP Tools, Special Tools, GP Tools, Special Tools,
of the Standard of the Standard
Sr. PNR & PNR-A, Sr. PNR & PNR-A,
Activity / Inspection Points Technician Man Consumables Activity / Inspection Points Technician Man Consumables
No. M & T Instruments, No. M & T Instruments,
w.r.t. Minutes w.r.t. Minutes
Equipments Equipments
Vehicle Vehicle
1 Identify & park the vehicle on work bay 0.80 Lifter bay Inspect rear shock absorber setting and Standard setting :
19 RH 0.09 Special tool, Spanner
Correct if necessary 1 st notch
Remove the thermocol & additional
2 0.06
packing if any Cloth, Graphite,
Check rear brakes for efficient working 14-15 No. OE spanner,
20 Rear 0.08 Grease, Fine polish
3 Open petrol tank & pour petrol 0.23 Measuring jar, Funnel Petrol, Waste cloth and Adjust if required Nose plier
paper
Check for smooth operation of Pencil type pressure gauge,
4 LH 0.12 Check & Correct tyre inflation pressure -
fuel cock lever 21 Rear 0.24 Analogue / Digital type
Rear wheel pressure gauge, Air filling alve
5 Check accelerator cable free play LH 0.08 8-9 No. OE spanner, Nose plier
Check all important nut bolts for torque
Check TPS on carburettor for proper and tightness
6 functioning as per the procedure LH 4.60 Multi meter, 8 No. Ring spanner
• Rider foot rest bolts
Check thermal sensor resistance at (Torque - 2.0~2.2 Kgm)
7 room temperature (250C to 350C) with LH 0.60 Multi meter, 8 No. Ring spanner • Silencer mouth nuts
multi meter. (7 K Ohm~10.5 K Ohm) (Torque - 2.0~2.2 Kgm)
• Engine foundation bolts 12-13, 14-15, 16-17, 18-19
8 Check gear shifter lever operation LH 0.07 8 No. ‘T’ spanner
(Torque - M10: 3.2 Kgm, M8 : 2.2 Kgm) Ring spanner, 32 No. socket spanner
Check battery voltage, Top up electrolyte Screw driver, Distilled water, Filler, Cloth, Fine polish 22 • Handle bar upper bracket mounting bolt LH / RH 1.90 with Handle ratchet, Piston grip PNR
9 level by distilled water (If required), Apply LH 0.57 8 mm ‘T’ spanner, Hydrometer, paper, Petroleum • Handle bar lower bracket mounting bolt Dial type torque wrench
petroleum jelly, Connect terminals properly Battery charger, Battery load tester jelly, Distilled water • Fork side & top bolts
• Steering special nut
Lubricate drive chain and Check / Adjust 10-11 OE spanner, 14-15,16-17, • Front axle nut
10 LH 0.38 Cloth, SAE 90 oil
chain slackness if required 24-27 ring spanner • Swing arm pivot axle nut
Inspect rear shock absorber setting and Standard setting : • Silencer cover shield allen bolts
11 LH 0.09 Special tool, Spanner • Both LH / RH engine mountings bolts
correct if necessary 1st notch
• RSA dome nuts, Lower bolts
Check front brakes for efficient working
12 Front / RH 0.20 14-15 Ring OE spanner Check the following and
and adjust if required
Lubricate if necessary
Check and Adjust steering & handle bar 12-13 Ring spanner, Fork spanner,
13 RH / Front 0.16 a. Rear brake lever
for free movement 32 no. socket & Handle ratchet
b. Rear brake pedal / cam LH / RH /
Check front mudguard alignment w.r.t. 23 c. Pillion foot rest Front / 1.10 Oil can SAE 20W40 oil
14 Front 0.04
front wheel d. Center stand Rear
e. Side stand
Pencil type pressure gauge, f. Kick lever boss pin
Check and correct tyre inflation pressure - Analogue / Digital type
15 Front 0.20 g. Clutch lever
Front wheel pressure gauge, Air filling alve h. Front brake lever / cam
Check & Top up engine oil level SAE 20W40 API 24 0.33
16 RH 0.08 Check all locks for proper operation LH / RH
if required ‘SJ’ / ‘SL’ +
JASO ‘MA’ Ensure proper functioning of both the
25 spark plugs. Spark plug caps must be LH / RH 0.70
Check clutch cable operation & Adjust tightly secured
17 RH 0.10 12-13 OE spanner
free play if required
Start vehicle, Check operation of electrical
Check auto choke functioning on like - Head light, Number plate light, LED
carburettor. Apply 12V supply to its tail light, Brake light, Horn, Speedometer,
Multi meter, Auxiliary 12V DC 26 LH / RH 0.33
18 terminals & check for proper RH 1.00 Trip meter, Odometer, Side indicators,
power source
functioning without removing it Pilot lights & pass light working
from the carburettor
18 19
PDI - SOP AND TIME CHART PERIODIC MAINTENANCE & LUBRICATION CHART
Position RECOMMENDED FREQUENCY

GP Tools, Special Tools, Whichever
of the Standard Sr. comes first
Sr. PNR & PNR-A, No. Operation Initial Subsequent
Activity / Inspection Points Technician Man Consumables
No. M & T Instruments,
w.r.t. Minutes Kms. 500-750 2,500 5,000 7,500 Every 2,500km
Equipments OR
Vehicle
Days 30 - 45 240 days from date of sale Every 75 days
CO-HC analyzer, 1. Servicing ü ü ü ü ü
27 Check idling RPM & CO% LH / RH 0.68 Small screw driver Tachometer,
Silicon tube 2. Engine Idling speed / CO% C,A C,A C,A C,A Check & Adjust
(300mm length) 3. Valve tappet clearance C,A C,A Every 5,000 kms
28 OE accessories fitment - Mirrors RH & LH LH / RH 0.76 17 mm OE spanner 4. Engine oil R R Every 5,000 kms
29 OE accessories fitment - Leg guard LH / RH 3.96 12 No. box / Ring spanner Piston grip PNR 5. Oil strainer / Centrifugal Filter CL CL Every 5,000 kms
30 OE accessories fitment - Saree guard LH 0.55 12-13 Ring spanner, 6. Engine oil Filter (Paper Oil Filter) R R Every 5,000 Kms
6 mm, 8mm allen key 7. Spark Plug functioning/Gap/Replacement (2 Nos) C,A C,A C,A C,A R - Every 15000 Kms
Test drive the vehicle, Check working of 8. Air cleaner element H CL CL CL CL R - Every 15,000 Kms
31 speedometer. Study of job card and 1.14 OE spanner, Ring spanner
Verify work done. Take vehicle out & park 9. Air filter Cover ‘O’ Ring R - Every 25,000 Kms
10. Carburettor Overhaul & Adjustment C, A C, A C, A C, A CL - Every 10,000 Kms
32 Clean / Wash the vehicle before delivery 1.00
11. Carburettor Rubber Duct R - Every 10,000 Kms
Total SMM 22.24
12. Fuel pipes C,CL C,CL C,CL C,CL R - Every 20,000 kms
Repair for any other defects seen or
33 13. Battery electrolyte level C,A C,A C,A C,A Every 2,500 Kms
observed during test drive
14. Clutch Lever free play C,A C,A C,A C,A Every 2,500 Kms
Expected Output in 480 Minutes / Man / 22 Vehicles
15. Throttle Grip play C,A C,A C,A C,A Every 2,500 Kms
16. Rear brake pedal free play C,A C,A C,A C,A Every 2,500 Kms
GPT : General Purpose Tools SPT : Special Tools PNR : Pneumatic Nut Runner RSD : Ratchet Screw Driver
PNR-A : Pneumatic Nut Runner Attachments M&T : Measuring & Testing Equipment 17. Brake lining or pad wear C C C C R - Every 10,000 Kms
18. Brake Fluid level top -up / Replace C C C C R - Every 10,000 kms
or 1 Year
Note : 19. Brake cam & pedal pivot pin L- Every 15,000 Kms
1. Total time taken for carrying out PDI of ‘Discover DTS-Si’ is within 22 minutes approximately.
20. Steering play C,A C,A C,A C,A Every 2,500 Kms
2. That means in a shift of 480 minutes, One technician can do 22 vehicles PDI comfortably.
21. Steering stem bearing L - Every 10,000 Kms
R - If required
22. All fasteners tightness C,T C,T C,T C,T C,T - Every 2,500 Kms
23. Rear sprocket fasteners T - Every 10,000 Kms
24. Silencer drain hole cleaning CL CL CL CL CL - Every 2,500 Kms
25. Cylinder head de-carbonising, valve lapping & Every 30,000 Kms
Replace Valve oil Seals
26. Engine air breather tube C C C C R - Every 1 Year
27. Drive chain lubrication & slackness adjustment C,A,L C,A,L C,A,L C,A,L L - Every 500 Kms &
Adjust slack every 2500 Kms
28. Drive Chain remove, clean, inspect & lubricate ü Every 5,000 kms
29. Drive Chain Link Lock R R - Every 5,,000 kms
30. Rear wheel rubber shock damper R - Every 10,000 kms
or 1 Year
20 21
PERIODIC MAINTENANCE & LUBRICATION CHART PERIODIC SERVICE SOP
Whichever RECOMMENDED FREQUENCY Position

Sr. GP Tools, Special Tools,
comes first of the Standard
No. Operation Initial Subsequent Sr. PNR & PNR-A,
Kms. 500-750 2,500 5,000 7,500 Every 2,500km w.r.t. Minutes
OR Equipments
Vehicle
Days 30 - 45 240 days from date of sale Every 75 days
31. Wheel bearing (for non sealed bearings only) L - Every 10,000 Kms 1 Wash vehicle thoroughly To be done by washing boy
32. Tyre tread wear (replace if worn out till TWI limit) C C C C - Every 2,500 Kms 2 Identify the vehicle 0.30
33. Master cylinder cup and Dust seal R - Every 2 Years 3 Bring vehicle & position on bay 0.50
34. Brake Hose Pipe R - Every 2 Years 4 Raise the lift 0.30
35. Caliper Piston seal & dust seal R - Every 2 Years Start vehicle & Warm up. Remove RH,
36. Front fork oil R - Every 10,000 Kms 5 LH side covers, Seat assembly, RH & LH 2.30 GPT : Connector, Vehicle key
Petrol tank and keep properly
37. TPS, Thermal Sensor & Auto Choke Functioning C,A C,A C,A C,A C,A - Every 2,500 Kms
38. Rr. Shock Absorber- Check gas pressure C,A - Every 10,000 Kms GPT : Extension & Tommy bar,
Plastic tray
39. Starter Clutch bush kit CL,R - Every 15,000 Kms Equipment : Oil disposer,
6 Drain engine oil LH 1.30 Cloth
40. Clutch switch cleaning CL - Every 10,000 Kms Air gun
PNR : Pistol grip,
41. General lubrication L L L L L - Every 2,500 Kms 18mm socket set
42. Swing arm pivot pin Lubrication L - Every 15,000 Kms GPT : Handle ratchet Cloth, 20W40 oil,
43. Fuel cock sediment bowl CL CL - Every 5000 Kms Equipment : Filter cleaning stand Diesel, ‘O’ ring,
7 Check oil strainer. Replace if torn LH 0.80
PNR : Pistol grip PNR, Oil strainer,
18mm socket set ‘O’ ring cap
Check battery, Top up with distilled water,
GPT : 8 mm ‘T’ spanner, Electrolyte,
Clean the terminals & apply petroleum
l : Indicates operation to be performed. Philips screw driver Distilled water,
8 jelly, Route cables properly & Fit the LH 1.80
« : More frequent cleaning may be required when driving in dusty condition. Equipment : Battery charger Petroleum jelly,
terminal caps properly, Recharge battery
M&T : Multi meter, Hydrometer Cotton waste
A - Adjust • C - Check • CL - Clean • L - Lubricate • T - Tighten • R - Replace if required.
Note : Check TPS carburettor for proper GPT : Nose plier
9 LH 4.00
Parts / Lubricants to be replaced as per Periodic Maintenance & Lubrication Chart are mandatory and the functioning as per the procedure M&T : Multi meter
same are chargeable to customer.
Check thermal sensor resistance at GPT : 8 mm ring spanner
room temperature (250C to 350C) Equipment : Auxiliary 12 V DC
10 with Multi meter LH 0.60 power source
(7 K Ohm to 10.5 K Ohm) M&T : Multi meter, Hydrometer
Engine Oil Specification 11 Check accelerator & adjust free play LH 0.40 GPT : 8 No. OE spanner
GPT : Spark plug spanner, Cloth, Fine

Recommended SAE 20W40 of API ‘SJ’ + JASO ‘MA’ OR Clean, Check and Adjust LH side polish paper,
Wire brush
Grade SAE 20W40 of API ‘SL’ + JASO ‘MA’ 12 spark plug electrode gap. Replace LH 2.40 Equipment : Air gun, Plug cleaner Spark plug
if necessary Champion
M&T : Feeler gauge
PRZ9HC and
Recommended Drain & Refill : 1000 ml (1 Liter) BOSCH UR4AC
Quantity Engine Overhaul : 1100 ml (1.1 Liter) GPT : 8-9 No. ring spanner,
6 No. allen key,
Check and adjust tappet valve clearance 8 mm ‘T’ spanner,
13 (If required). During 4th servicing or at RH / LH 2.40 Spark plug spanner Cloth
5000 kms. whichever is later. PNR : Pistol grip
SPT : Tappet holder
M&T : Feeler gauge
22 23
PERIODIC SERVICE SOP PERIODIC SERVICE SOP
Position Position
GP Tools, Special Tools, GP Tools, Special Tools,
of the Standard of the Standard
Sr. PNR & PNR-A, Sr. PNR & PNR-A,
Activity / Inspection Points Technician Man Consumables Activity / Inspection Points Technician Man Consumables
No. M & T Instruments, No. M & T Instruments,
w.r.t. Minutes w.r.t. Minutes
Equipments Equipments
Vehicle Vehicle
Check LH side important fasteners & tight GPT : ‘-’ screw driver,
Check / Adjust front brake and Cloth, Fine
• Side bolts of front fork 25 Front 0.80 17 ring spanner, 10, 14 OE spanner
wheel freeness polish paper
• Engine foundation bolts GPT : Handle ratchet, 12,13,14, Equipment : Air gun
• Side stand 16,17 ring spanner, 6 mm allen key
14 LH 0.60 GPT : Air gun with feeler
• RSA top nut & bottom bolt PNR : Pistol grip PNR, 26 Check and Adjust front tyre air pressure Front 0.40 Cloth
M&T : Pencil type pressure gauge
• Front fork top bolts 12,14 socket set
• Saree guard bolts GPT : 17 ring spanner,
• LH stay assembly bolts 32 mm socket, Handle ratchet
27 Check and Adjust steering Front 0.80 SPT : Fork spanner
GPT : 10,11 OE spanner,
Cloth, PNR : Pistol grip PNR, Socket set
Adjust chain slackness & Lubricate. 14,15,24,27 ring spanner
15 Rear, LH 3.90 SAE 90 oil, Diesel,
Remove & clean if required PNR : Pistol grip, Socket set Check RH side important fasteners & tight
Equipment : Air gun Kerosene
• Rider foot rest bolts
GPT : Nose plier, Screw driver, Cloth, Graphite, (Torque : 2.0 ~ 2.2 Kgm)
Check rear brakes for efficient working • Silencer mouth nuts
16 RH 0.60 14,17 Ring spanner Grease, Fine
and adjust if required (Torque : 2.0 ~ 2.2 Kgm)
Equipment : Air gun polish paper
• Engine foundation bolts
GPT : Air gun with feeler (Torque : M10 : 3.2 Kgm, M8 : 2.2 Kgm)
17 Check and Adjust rear tyre air pressure Rear, RH 0.40 Cloth GPT : 12,13,14,15,16,17,18,19
M&T : Pencil type pressure gauge • Front axle nut
• Side bolts of front fork ring spanner, 6 mm allen key,
28 Front 1.30 4 mm allen key
GPT : 8 mm ‘T’ spanner Cloth, • Handle bar bolts
Clean air filter, Replace if necessary Equipment : Filter cleaning stand, 20W40 oil, Diesel, • RSA top nut & bottom bolt PNR : Pistol grip, Socket set
18 RH 4.50 Air gun Kerosene,
& Clean fire arrestor • Swing arm axle nut
PNR : Pistol grip, Screw driver bits Air filter element • Silencer protective cover bolts
• Rear view mirror
GPT : Philips screw driver,
• Kick boss bolt
Soft nylon brush, Plastic tray,
• Front fork top bolt
19 Drain carburettor, Overhaul if required RH 1.30 8 No. ring / OE spanner Cloth, Diesel
• RH stay assembly bolts
Equipment : Air gun
• Swing arm axle
M&T : Float gauge
Lubricate as per lubrication schedule
20 Check clutch and Adjust free play RH 0.30 GPT : 12 No. OE spanner
• Clutch lever
Check auto choke functioning on • Rear brake pedal / cam 20W40 oil,
carburettor : Apply 12V supply to its M&T : Multi meter, 29 • Pillion foot rest LH 1.1 GPT : Oil can, Grease gun Graphite, Grease,
21 terminals & check for proper functioning RH 1.00 Auxiliary 12 V DC power source Cloth
• Center stand
without removing it from carburettor • Side stand
• Kick boss pin
Paper oil filter,
GPT : 8 No. ‘T’ spanner Kerosene / Diesel, Refit RH & LH side covers, Seat,
22 Replace paper oil filter RH 1.91 30 LH 0.5 GPT : Nose plier, Connector
PNR : Pistol grip, Socket 8 mm Nylon brush, Petrol tank assembly
Cotton cloth
31 Check fuel lines & Clean petrol tank lid RH / LH 0.50 GPT : Air gun
GPT : 6” comb plier, Funnel Oil SAE 40 API
23 Fill engine oil (Qty : 1000 ml) RH 1.35 Equipment : Oil disposer, Air gun ‘SJ’ / ‘SL’ + JASO Check Speedometer, Trip meter, Odometer
32 for proper functioning & correct if required Front 0.50
M&T : Measuring jar 1 liter MA grade
GPT : Spark plug spanner, Start vehicle, Check operation of electrical
Wire brush Cloth, like : Head light, LED tail light, No. plate
Clean, Check & Adjust RH side GPT : Nose plier, Connector,
24 RH 2.40 PNR : Pistol grip Fine polish paper, 33 light, LED brake light, Horn, Speedometer, RH / LH 0.95
spark plug ‘+’ screw driver
Equipment : Air gun, Plug cleaner Spark plug Odometer, Pass, Parking light, Front &
M&T : Feeler gauge Rear side indicator, Fuel indicator
24 25
PERIODIC SERVICE SOP PERIODIC MAINTENANCE POINTS
Position Periodic Maintenance (in accordance with the periodic maintenance chart) of a vehicle it is utmost important to prolong vehicle
GP Tools, Special Tools, life, trouble free running & ensure safety while driving.
of the Standard
Sr. PNR & PNR-A,
w.r.t. Minutes
Equipments
Vehicle
Washing (Water Servicing) - Dos & Don’ts
Ensure proper functioning of both the
34 spark plugs. Spark plug caps must be RH / LH 0.70
tightly secured. Do’s Don’ts
GPT : Connector, ‘+’ screw driver
3 Rinse the Bike thoroughly with water to remove 7 Do not direct pressurized water jet on head lamp
Equipment : CO-HC analyser,
35 Tune engine and carburettor RH / LH 2.00 loose dirt and mud. glass, tail lamp glass, electrical components (H.T.
Tachometer, Silicon tube
300 mm length Coil, C.D.I., Flasher, Horn & all electrical digit
console switches) to avoid water entry & subsequent
36 Study job card & Verify work 1.00
damage.
37 Lower the lift 0.3
3 Clean the Bike with a Sponge or soft cloth using 7 Do not direct pressurized water jet on steering races
38 Take out and park the vehicle 0.5
water. (cones) to avoid rusting & subsequent pitting of
LH 23.10 steering balls & races.
39 Sub Total
RH 21.21 7 Do not direct high pressurized water jet on plastic,
Carry out any additional work as indicated 3 Clean the exterior surfaces of engine metal parts by spark plug cap don’t direct jet on components
40 by the customer or as required. 5.0 kerosene / diesel spray & plastic / nylon brush. especially on decals.
LH 28.10 3 Cover silencer tail end by PVC cap. 7 Avoid directing water jet in to silencer muffler outlet.
Total Time
RH 26.21 3 Clean the plastic parts using a soft cloth or sponge 7 Do not use detergent or strong solvent to clean
Test drive the vehicle, Check speedometer dampened with a solution of mild car shampoo / painted / plated parts. Avoid cleaning products that
41 working. Study the job card & Verify work 1.5 To be done by expert liquid soap & water. Rub the soiled area gently are not specifically designed for automobile surfaces.
done. Take vehicle out & park rinsing it frequently with fresh water. Strong detergent residues can corrode alloy parts
42 Clean the vehicle at the time of delivery 1.0 To be done by delivery boy and also painted surfaces loose their shine / gloss.
Caution : Water may enter on the brake liners during washing & brake slippage may occur. Ensure that
GPT : General Purpose Tools SPT : Special Tools PNR : Pneumatic Nut Runner RSD : Ratchet Screw Driver brake liners are dry before driving the vehicle.
PNR-A : Pneumatic Nut Runner Attachments M&T : Measuring & Testing Equipment
Note : Engine Oil Level Checking

1. Total time taken for carrying out Periodic Service is 54 minutes approximately.
2. That means in a shift of 480 minutes, One technician can do 9 vehicles periodic service comfortably. • Park the vehicle on level surface on center stand to check the oil level.
3. It is definite that the output of 18 vehicles per bay per day can be achieved comfortably with 1B 2T working. • Inspect the oil level through oil inspection window.
Max. Level • It should be in between upper and lower mark.
• Top up if required.
Min. Level
Recommended SAE 20W40 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ grade
Grade
Recommended Drain & Refill 1000 ml

Quantity
Engine Overhaul 1100 ml
26 27
PERIODIC MAINTENANCE POINTS PERIODIC MAINTENANCE POINTS
Oil Strainer Cleaning Air Filter
Remove : Remove : A
• Cap strainer (18 mm A/F) with ‘O’ ring. • RH side panel by loosening a Phillips
• Pull out strainer (mesh filler oil with ‘O’ ring) by nose plier. screw.
• Drain engine oil. • 3 flange bolts (A) (8m A/F). B

• Air filter cover (B) A
Remove :
Remove : • Air filter element assembly along with
• Clean oil strainer with Kerosene / Diesel & blow low pressure compressed air its cage.
from inside i.e. air must be blown in opposite direction of oil flow. • Separate foam filter from cage.
Note / Skill Tip :

• Clean flame arrestor in kerosene &
blow air.
• First assemble air filter along with
cage & flame arrestor into ‘Cover Air Filter’. Then slide this assembly by
matching air filter w.r.t. groove provided inside the ‘Box Air Filter.
• Ensure that rubber ‘O’ ring is placed properly before fitting cover.
Paper Oil Filter Replacement
Air Filter Cleaning
Remove :
• 3 bolts (8 mm A/F) Primary & Secondary Air Foam Filter AIR FILTER CLEANING STAND
• Take out ‘Cover oil filter’ with ‘O’ ring. Precautions :
• Take out ‘Paper oil filter’ along with 1. Never use high flash point petro-chemicals for
spring. cleaning air filter foam.
• Replace ‘Paper oil filter’ during 1st This increases :
free service and thereafter at every • Possibility of foam catching flame.
5000 Kms. • Poracity & may lead to dust passing
through it in long term.
2. Don’t twist air filter foam, as it may lead to
Caution : tear / bulge.
Before fitting ‘Paper oil filter’ 3. Foam lubrication is utmost important since dry
ensure intact condition of oil seal foam can lead to dust entry inside engine.
from its rear side & one way 4. Never use other grade oil for lubrication of the
valve from its front side. foam.
5. Dry excess oil by cotton cloth.
6. Replace kerosene and engine oil after cleaning
20W40
20 to 25 foams. KEROSENE KEROSENE ENGINE OIL
One Way Valve Oil Seal
7. In dusty area, increase cleaning frequency of
foam.
28 29
1st Stage: CLEANING PROCEDURE Battery (MF)

Clean with
Kerosene 12V 5Ah for ES Version & 2.5Ah for KS version
• Remove L.H. cover.
• Check Battery electrolyte level in each cell and ensure that the level is
between the Max & Min mark lines. If level is below Min level mark then
remove the battery filler caps and fill with distilled water until the electrolyte
level in each cell reaches the Max level line.
3rd Stage: • Apply petroleum jelly to battery terminals & cable clamps.
Squeeze
Dip into
Note: Use only distilled water to top up the battery. Tap water is not a substitute
engine oil
for distilled water & will shorten the life of the battery.
Nitrox Rear Shock Absorber
Adjusting Spring Tension

Squeeze & • RSA spring tension can be adjusted with the help of 5 stepped adjuster cam
2nd Stage:
remove to suit individual requirement as per load & road conditions.
Clean with
Kerosene excess oil • Turn the adjuster cam on each shock absorber to same required position.
again Setting the adjuster cam to higher notch position increases the spring stiffness
& vice-versa.
• Shock Absorbers adjusted either too soft or too stiff could adversely affect
riding comfort & vehicle stability.
Notch Position 1 2 3 4 5
Blow Low Pressure Dry with
Spring Action Soft Stiff
Compressed Air cotton cloth
• LH & RH RSA spring adjuster cams must be adjusted equally to the same
position, otherwise vehicle may wobble / become in stable.
Note: Standard setting is done in 1st notch.
Drive Chain Slack / Lubrication

Spark Plug Cleaning
• Park the motorcycle on its center stand.
• Rotate the rear wheel to find the position where the chain is tightest &
Remove :
measure the vertical movement midway between the sprockets (from chain
• Clean spark plug with the help of spark plug cleaning machine. inspection window).
• If the drive chain is too tight or too loose, adjust within the standard limit.
Recommended Spark Plug Champion PRZ9HC & BOSCH UR4AC • Check drive chain slackness at every 1000 kms.
Electrode Gap 0.7 ~ 0.8 mm
Drive Chain Slackness
Replace Spark Plug After every 15,000 Kms. Standard : 20 ~ 25 mm Service Limit : 35 mm
30 31
Chain Slack Adjustment SOP Drive Chain Cleaning
• Loosen the rear brake adjuster • Pre-Tighten the coupling sleeve

nut. nut, axle nut & tighten the left
and right adjusting nuts slightly.
Take care that the adjustment 1st Stage:
does not get disturbed during Clean with
the adjusting nut tightening. Kerosene
• Pull out the lock clip. • Tighten both chain adjuster
3rd Stage:
• Loosen torque rod (tie rod) locknuts securely.
Dip into
securing bolt fitted on rear SAE 90 oil
brake panel.
2nd Stage:
Clean with
• Loosen the left and right chain • Rotate the wheel and apply Kerosene
adjuster locknuts. rear brake so that rear brake again
panel will take its own position.
Measure the chain slack again
at the tightest position, and Soak into
readjust if necessary. SAE 90 oil
• Loosen the axle nut. • Tighten the coupling sleeve nut

to the specified torque. Blow Low Pressure
Compressed Air
Final Stage :
Hook chain for
dripping of
• Loosen the coupling sleeve • Tighten the axle nut to the
excess oil
nut. specified torque.
Tyre Air Pressure

• Adjust the chain slackness by • Tighten torque rod securing bolt & refit lock clip.
evenly setting both R.H. and • Adjust rear brake properly by tightening brake adjuster Remove :
L.H. chain adjusters. nut.
• Inflate tyres as per recommended pressure to get better tyre life & optimum
• The arrow marks on L.H. and mileage.
R.H. chain adjusters must be • Check tyre pressure every week.
equidistant from swing arm
slot edge). It ensures chain &
wheel proper alignment. Front 1.75 Kg/ cm2 (25 PSI)
Rear - with Solo 2.00 Kg/ cm2 (28.5 PSI)
Rear - with Pillion 2.25 Kg/ cm2 (32.0 PSI)
32 33
Tappet Clearance Setting Accelerator Free Play Adjustment
• Ensure that the engine is in cold condition. • Turn the adjuster until the proper amount of free play can be obtained.
• Ensure the ‘T’ mark on the ‘Rotor’ match with the mark on the ‘Crankcase • Tighten the lock nut against the adjuster.
LH’. At this stage the ‘Piston’ is at TDC & both the rocker arms are free. • If the accelerator free play can not be adjusted with the adjuster at the
• Holding tappet screw firmly with special tool loosen the tappet screw nut. handle bar end, use the adjuster at the lower ends of the accelerator cable
• Put the feeler gauge, measure and adjust the clearance. situated on carburettor.
• Lock the nut holding screw with special tool after getting required clearance. • Loosen the 2 lock nuts on accelerator cable bracket end & adjust free play
by adjuster provided on the cable.
• Again check the tappet clearance with gauge. The feeler gauge should slide
with slight resistance between tappet screw tip & valve stem head. Tighten the • Tighten both the lock nuts on bracket by holding one nut and tightening the
check nut with a spanner. other, after ensuring the required free play.
¡ Inlet Valve : 0.05 mm ¡ Accelerator Grip Free Play : 2 ~ 3 mm

¡ Exhaust Valve : 0.1 mm
¡ M & T Equipment : Feeler Gauge Engine Compression Pressure
¡ Special Tool : Valve Adjusting Screw Holder
Part No. : F41ZJW33 Dry Compression Test
• Start the engine & warm it up by driving vehicle for 2 ~ 3 Kms.
• Remove exhaust side spark plug.
Caution: Disconnect H.T. cable lead from intake side spark plug
Clutch Lever Free Play Adjustment • Thread in compression gauge with adapter into cyl. hd. spark plug hole.
• Open the throttle fully & apply 5 sharp kicks.
• Slide the dust cover at lever yoke end. • Note reading displayed on compression gauge dial.
• Check that the clutch cable outer end is fully seated in the adjuster. • Set compression gauge pointer to zero position by pressing release valve.
• Turn the adjuster until the proper amount of free play can be obtained. • Take such 3 readings. Calculate mean reading .
• Tighten the lock nut against the adjuster. If the clutch free play cannot be • Confirm that mean compression pressure is between 11 to 13 Kg/Cm2
adjusted with the adjuster at the handle bar end, use the adjuster at the
lower ends of the clutch cable secured on clutch cover. ¡ Service limit is 9.5 Kg/Cm2
• Loosen the 2 lock nuts (12mm A/F) on clutch cable bracket and adjust
threading in the adjuster provided on the clutch cover. Tighten both the lock Wet Compression Test
nuts on clutch cable bracket by holding one nut and tightening the other, after • If the mean compression pressure reading is less than service limit specified,
the required free play is set. put few drops of engine oil through the cylinder head spark plug hole & apply
2 ~ 3 idle kicks.
¡ Clutch Lever Free Play : 2 ~ 3 mm
• Again conduct compression pressure test.
• If wet compression pressure reading is considerably greater than dry
compression pressure reading, this means there is compression leakage past
the rings. In this case check cylinder piston assembly as per visual &
dimensional inspection parameters.
• If Wet Compression pressure reading is same as dry compression pressure
reading then the cause could be pitted valve seat, bent valves or torn
cylinder head gasket etc.
34 35
Notes
3
Fuel System
Carburettor Specifications
Carburettor Working of Systems
Carburettor Dos & Don’ts
CO Checking & Setting
Tune up for Optimum Mileage
36 37
Notes CARBURETTOR SPECIFICATIONS
Keihin
Item Specification
Make KFI
Type PTE 16
Idling Speed 1400 + 100 rpm
AW7
Air Screw Setting Suitable for a CO% of 2 + 0.5 @
600C oil temperature
PTE
Main Jet # 80
Jet Needle mark 1196
Identification : ‘AW7’ mark on casting, Yellow coupler

Needle Jet Marking 1010KPL0-3200
for Auto choke unit. Jet Needle ‘e’ clip Position 2nd from TOP
Pilot Jet # 38
Throttle valve Mark 82B
Starter Jet #35
Float Height 11.7 mm
Choke Solenoid Operated Auto Choke
38 39
CARBURETTOR WORKING SYSTEMS CARBURETTOR WORKING SYSTEM
STARTER SYSTEM - AUTO CHOKE - A STARTER SYSTEM - AUTO CHOKE - B
Solenoid
Operated
Choke
Plunger
Solenoid
Operated
Choke Unit
‘O’ Ring Throttle Valve
In closed
Position
Plunger
In Lifted Delivery Of
Condition Air - Fuel
Mixture
Plunger Mixing
Chamber
Starter Circuit
Throttle Valve Outlet
In Closed Mixing
Position Chamber Starter Circuit
Tube
Engine Side
Air Cleaner
Side of
Starter
the Carburettor
Air Circuit Tube
Inlet
Fuel Well Float Chamber

Starter Jet
(Bowl)
Float
Chamber (Bowl) Fuel Well
• The plunger is operated by the the magnetic flux generated in the solenoid coil. As the plunger is lifted off its seat , it
At the time of cold starting, the engine parts are not hot enough to vaporize the droplets of fuel. Hence, a richer mixture than uncovers a fuel passage that from the starter jet. Lifting the plunger further uncovers the air-inlet passage.
that provided by the pilot system is required. To provide this richer mixture, a starter circuit is added to the carburettor
• With the throttle valve in fully closed position almost all the air that goes to the engine must pass through the starter
• The starter circuit consists of a starter jet to meter the fuel and a solenoid operated choke plunger. passage. This creates enough suction to draw fuel up from the bowl in to the mixing chamber below the plunger. Here
the fuel is mixed with the air & the rich mixture is supplied to the engine through the outlet hole located on the engine
side of the carburettor.
40 41
CARBURETTOR WORKING SYSTEM CARBURETTOR WORKING SYSTEM
PILOT SYSTEM - Slow Speed System MAIN SYSTEM - High Speed System
E Clip
2nd Notch
Cap Throttle (Std.)
Spring
Cap Throttle
TPS
Side View
Venturi
(Hall Sensor)
Air Screw
Magnet (TPS) Petrol Inlet
Magnet For
TPS TPS
(Hall Sensor)
Fuel Inlet
Side View
Throttle Jet Needle
Venturi
Valve
Engine
Side Air
Filter
Side
Air Fuel
Air Screw Mixer
Engine
Side Air
Filter
Delivery Needle Jet
Of Air - Fuel Side
Mixture
Air
Air Inlet Jet Needle (For Main Jet)
Idling
Adjusting Air
Screw Intake
Fuel Level
Air Needle
Float Valve Needle Jet
(For Pilot Jet)
Float Chamber
(Bowl)
Float Float Pin Main Jet
Pilot Jet
Pilot Jet
Petrol Clearance
Between
Float Jet needle
Main Jet Chamber & needle Jet
(Bowl)
• This System consists of jet needle, needle jet and main jet. To assist in atomization, an air bleed circuit is incorporated in
the main metering system and it aids fuel vaporization by introducing air into the fuel before it enters the air stream.
• The pilot system provides the air fuel fixture at idling and at small throttle opening when the main system is not in • For VM type the midrange circuit is actually a combination of circuits that work together to achieve correct air fuel
operation. mixture. The pilot circuit is still operational but its contribution to the total air fuel mixture is relatively less.
• The jet needle is a tapered needle attached to the throttle valve which points downward, through the centre of carburettor
• Fuel from the bowl is metered by the pilot jet and mixed with the air proportionately controlled by the air screw. The
venturi. The tapered end of the jet needle moves inside the needle jet which is located in the carburettor body.
atomized fuel reaches the venturi through the pilot outlet and mixes with the air flowing through venturi. The pilot outlet is
located on the manifold side of the carburettor and is just covered by the throttle valve wall. Since the throttle valve is • The position of the jet needle relative to the needle jet determines the amount of fuel flowing through the clearance
almost closed at idling speed, the pilot outlet is only partially exposed to the manifold vacuum. Hence it gives minimum between them.
fuel just to run the engine. When the throttle valve is raised opening throttle, pilot outlet is fully exposed to the manifold
vacuum and supplies fuel to its full extent which is sufficient to meet the engine requirement at slow speed. • Changing the position of the jet needle relative to the slide (Throttle Valve) changes the air fuel mixture. The jet needle is
moved relative to the slide by changing the position of the ‘ e- clip’ up or down in the grooves on the jet needle. Moving
• Air-fuel mixture becomes lean when Air Screw (AS) is loosened (AS turned anticlockwise) and rich when it is tightened the ‘e-clip’ towards the top of the needle has the effect of reducing the fuel flow, thus leaning out the mixture. Bringing
(AS turned clockwise). the ‘e-clip’ towards the lower grooves will have the effect of richening the mixture.
42 43
CARBURETTOR DOS & DON’TS CO CHECKING & SETTING
3 Dos 7 Don'ts Readiness of CO Gas Analyser Taking the Reading

Handling
Warm up the CO Gas Analyzer • Remove M-5 bolt & aluminum
• Use appropriate screw drivers for • Never use oversize screw drivers
for 10~15 minutes before washer fitted to the nozzle (12mm
dismantling. • Don’t over tighten the jets & screws.
proceeding further. Warming up OD) shown in figure, of the
This will damage the jets & their
is essential every time machine connecting tube welded to silencer
seats.
is put on to purge out any pipe before CAT converter.
gases left in side. • Use a Silicon Rubber tube of
Cleaning approximately 300mm to fit onto
Carry out Span Check as per
• For cleaning always use carburettor • Never clean the carburettor with manufacturer's Recommendation the nozzle. Only a Silicon rubber
cleaner like - water. to confirm the OK condition of tube should be used, as it has
- Acetone • Jets & air passages will get clogged the Equipment (If Span Check better high temp. resistance & will
- Carbon Tetra chloride due to sediments if cleaned by does not confirm the reading, not deform / melt due to high
- CVC spray water. then carry out Gas Calibration temp. at the nozzle.
as per mfgrs. recommendation). • Connect the other end of the Silicon Rubber tube to the
Float Height Checking
Set the Equipment display to Zero before taking the flexible probe pipe of machine. Ensure that the inner
• In this carburettor measure float • Do not blow compressed air on reading. diameter of Silicon tube perfectly matches with outer
height in inverted vertical position. ‘needle jet’ from ventury / mixing diameter of flexible probe pipe of Gas Analyzer.
• Always maintain standard float cap side otherwise ‘needle jet’ would • The Silicon rubber tube must fit snugly onto the nozzle to
height. get blown-off . Readiness of the Vehicle prevent any air / exhaust gas leakage.
• Note the CO / HC readings when the reading display
• Ensure float is in good Condition. • Do not reuse squeezed / punctured Before checking CO emission, stabilizes.
float. This could lead to petrol over prepare the vehicle for checking • As per Emission Norms the recommended CO% for 2
flow. the CO. Wheelers is 3.5% at idling RPM. But CO% for Bajaj
• Warm up the engine to its Vehicles, for best results in terms of fuel efficiency are
normal operating temp. by different for different models. The ideal CO% is between
riding 5~6 Kms. The c'case 1.5 to 2.5% at idling RPM = 1400 + 100.
• Place a magnet holder on jet • Do not blow compressed air from cover should be warm • If the reading is shown excess or less than BAL
needle ‘e-clip’ & then Place spring.. carburettor breather tube otherwise enough by feel. (Engine Oil specifications, try to achieve by adjusting Air Screw.
float would get Squeezed/damaged. Temp. = 600C). • Turning in Air Screw will lead to more CO% and turning
out will lead to less CO%.
Caution: In choke ‘ON’ condition
CO % is high : 9~10%. Hence Note: Remember the Air Screw should not be taken out more than
• Check Float Pin for - • Do not reuse Float Pin if - warming up of engine is a must. the recommended position. Every time Air Screw setting is changed
- Tip having no wear mark. - Worn out tip specified Idling RPM must be restored and then reading should be
- Spring loaded pin sticky otherwise considered.
- Spring loaded pin is free in • Screw in Air Screw completely. Engine should die
movement. it would lead to flooding / over flow down in this condition. • If the CO% is not falling within recommended % in spite
of adjusting the Air Screw then find out the cause &
• Replace Jet Needle & Needle Jet • Do not shift ‘e-clip’ to upper or lower Note: If engine does not go off, then attend to the additional rectify. After rectifying the problem confirm the CO% in the
as a pair if wornout. groove of jet needle otherwise it air supply problem in the carburetor circuit & intake system. same way as mentioned above.
• Always ensure that ‘e-clip’ is fitted would lead to lean air fuel mixture After solving the problem once again confirm that engine
should die down on closing the Air Screw. Important: For Better Mileage and Performance, achieve
in specified groove of Jet Needle. or rich air fuel mixture respectively. CO% as recommended.
• Confirm the Air Screw setting as per specification. In Discover DTS-Si motorcycle for better mileage &
• Replace piston / throttle valve if • Don’t fit worn out / non specified performance achieve values given below.
• Set Idling speed to specified Idling 1400 + 100 rpm.
worn out size jets Raise the engine to moderate speed at no load
• Ensure fitment of spring, a plain • Don’t fit worn out / cut ‘O’ ring on condition for about 15 seconds. Then bring back to Recommended CO% value w.r.t. Air Screw
washer & an ‘O’ ring on Air Screw air screw otherwise it would lead to specified idling RPM. and Idling RPM for Better Fuel Efficiency
idling Instability. Model Recommended CO% Air Screw Position Recommended Idling RPM
Discover Set air screw to 1400 + 100 rpm
1.5% ~ 2.5%
Overhaul Carburettor at every 10,000 Kms and Inspect the parts DTS-Si get CO% 2 + 0.5
44 45
TUNE UP FOR OPTIMUM MILEAGE
TPS - Hall Sensor Checking AIR FILTER :
4
• Clean at Every :
Continuity check in coupler disconnected 2,500 Kms.
condition :
SOP : • Replace at Every :
• Disconnect TPS coupler 15,000 Kms.
• Check Continuity between Blue &
Black / Yellow wire COMPRESSION PRESSURE
• There should NOT BE any continuity.
• Standard :
11 to 13 Kg/cm2
Input supply voltage check : • Service Limit : Engine & Transmission
SOP : 9.5 Kg/cm2
• Connect TPS coupler Digital Twin Spark Swirl Induction
• Switch ‘ON’ ignition key.
• Check voltage between Brown and TAPPET CLEARANCE Special Tools
Black / Yellow wires of TPS Hall • Inlet Valve :
Sensor. 0.05 mm Service Limits
• Standard value : 12.5 + 0.4 volts
• Exhaust Valve : Gear Transmission Power Flow
(Battery voltage).
0.1 mm
Voltage check in POT condition: Tightening Torques
SOP : CARBURATTOR
• TPS coupler is in connected condition. • Idling : 1400 + 100 rpm. Engine Lubrication - Flow of Oil
• Switch ‘ON’ ignition key. • Jet Needle Clip Position :
• Check voltage between Blue & Black / Dos & Don’ts
Yellow wire in Partial Open Throttle For Keihin : 3rd from top
(POT) condition. • CO % : 2.0 + 0.5 %.
• Standard value : < 1 volt in Partial • Set air screw to get CO%
Open Throttle position. 2 + 0.5
Voltage check in WOT condition:

SOP :
Other Mandatory Checks
• TPS coupler is in connected condition. a. Ensure no fuel leakage through fuel cock, fuel lines.
• Switch ‘ON’ ignition key. b. Ensure free rotation of both wheels.
• Check voltage between Blue & Black / c. Ensure correct tyre pressure - Front wheel : 25 PSI,
Yellow wire in Wide Open Throttle Rear wheel : 32.0 PSI
(POT) condition. d. Set control cable free play:
• Standard value : 2.7 to 5.0 (+0.2) • Clutch lever 2~3 mm.
volts in Wide Open Throttle position. • Front brake lever 4~5 mm.
• Rear brake pedal 15~20 mm.
e. Chain slackness : 20~25 mm.
Engine Tune-Up f. Check & confirm proper functioning of both spark
plugs.
SPARK PLUG : g. Check & confirm resistance of thermal sensor at
Champion PRZ9HC, BOSCH UR4AC room temp. (250C ~ 350C). It must be 7K ohm ~
• Spark Plug Gap : 10.5K ohm.
0.7 ~ 0.8 mm. h. Ensure that thermal sensor wire is firmly connected.
0.7 to
0.8MM
• Replace at Every : i. Ensure that the solenoid operated auto choke is
switching ‘OFF’ once engine cylinder block temp.
15000 Kms
reaches > 300C (greater than or equal to 300C temp.).
46 47
DIGITAL TWIN SPARK SWIRL INDUCTION SPECIAL TOOLS - ENGINE
Introduction Exclusive Special Tools
In a conventional single spark plug engine the spark plug is located on one side of cylinder head combustion chamber. When Cam Sprocket Holder
spark is put to ignite air-fuel mixture, the flame has to travel from one side of combustion chamber to other side. More time Part No. : F41ZJZ47
is required for flame to reach farthest part of combustion chamber. Thus the combustion is slow & inefficient.
Application : For holding sprocket during
removal / refitting of Cam
sprocket allen bolt.
DTS-i System
In DTSi engine two spark plugs are located in cylinder head combustion
chamber on LH & RH side. LH spark plug is called primary spark plug & RH
spark plug is called secondary spark plug. The LH spark plug is fired at 350 Magneto Rotor Holder (For Self Start)
rpm approximately while RH spark plug is fired at 750 rpm approximately. Part No. : F41ZJZ44
Thus LH spark plug does the primary work of starting. Once the engine starts, Application : To hold rotor while loosening /
both the spark plugs fire simultaneously. The air-fuel mixture is ignited from tightening its nut.
both the sides of combustion chamber & the time required for burning is less
than single spark engine.
The flame spreads faster & the combustion is rapid & more effective. The
obvious benefit of this is more power - pickup, better mileage & lower emission
/ pollution. Magneto Rotor Puller (For Self Start)
Part No. : F41ZJZ46
DTS-Si System Application : To pull out the rotor from

crankshaft assembly.
The DTS-i is the mother technology for the latest DTS-Si Technology. When
burning lean Air-Fuel mixtures, the 2 plugs provide rapid combustion, but at
light loads, an opportunity exists to improve the combustion further. This is
improved in DTS -Si engine by generating high turbulence in the combustion
chamber.
In DTS-Si engine, the construction of cylinder head is such that the intake &
exhaust valves & their passages are offset to each other. When air fuel
mixture enters from intake passage & intake valve into combustion chamber it
gets rotated because of offset valve position & due to the shape of ‘as cast’
combustion chamber. The air-fuel mixture is mixed properly due to swirling
Offset Valves
motion & every particle of petrol is surrounded by air.
Intake & their
Passage Passages In DTS-Si engine, both the spark plugs fire @ 250 rpm simultaneously. When
spark is put from both the spark plugs, the air fuel mixture is ignited. The flame
spreads very rapidly creating turbulence. Because of higher turbulence more
force gets applied on piston top face which results into very high engine torque.
The high torque is utilized effectively by transmission system to deliver the best
in class mileage & good power.
JA
Exhaust
Passage
48 49
SPECIAL TOOLS - ENGINE SPECIAL TOOLS - ENGINE
Other Common Special Tools Other Common Special Tools
Primary Gear Holder Valve Tappet Adjuster

Part No. : F41AJA11 Part No. : F41ZJW33
Application : To hold primary and secondary Application : To hold the Valve Tappet
gear while loosening/tightening screw while adjusting tappet
the primary gear nut & special clearance.
nut securing clutch.
Socket for Clutch Nut Rocker Shaft Remover

Part No. : F41ZJA54 Part No. : 37 10CS 22
Application : To loosen / tighten special nut Application : To remove Rocker Shaft from
securing clutch. cylinder head.
Rotor Dismantling Tool (For Kick Start) Bearing Extractor

Part No. : F41AJA58, F41AJA57 Part No. : 37 1030 48
Application : For removing magneto rotor of Application : To Pull out main ball bearing
DISCOVER DTS-Si kick start from crankshaft
vehicle.
Clutch Dismantling Tool Adaptor & Valve Spring Compressor

Part No. : F41AJA58 Adaptor Part No. : 37 1031 08
Application : To dismantle & assembled Valve Spring Compressor : 37 1031 07
clutch of DISCOVER DTS-Si
Application : To assemble / dismantle
kick start as well as self start
intake, exhaust valve by
vehicle.
compressing spring in cylinder
head.
Spark Plug Spanner Drift Piston Pin

Part No. : 37 1040 51 Part No. : 37 1010 06
Application : For removing and refitting Application : To remove refit piston pin.
spark plug R.H. and L.H. side.
50 51
SPECIAL TOOLS - ENGINE SERVICE LIMIT - ENGINE
Other Common Special Tools Compression Pressure Valve Clearance Rocker Arm Shaft Diameter
Output Sprocket Holder

Part No. : 37 1030 53
Application : To hold the output sprocket
while removing sprocket allen
bolts.
Intake Exhaust
2
Std. Limit 11.0 ~ 13.0 kg/cm Std. Limit 0.05 0.10 Std. Limit 7.994 ~ 8.0
Ser. Limit 9.5 kg/cm 2
Ser. Limit — — Ser. Limit 7.98
Driver for Fitting Bushing Gear Shift Drum
Cam Sprocket Diameter Cam Height Cam Lobe Width
Part No. : E6101100TE
Application : To assemble “Bushing with
PTFE Lining” at parent hole of
crankcase RH for “Gear Shift
Drum” mounting.
Intake Exhaust
Bearing Driver Set
Std. Limit 61.65 ~61.285 Std. Limit 28.88 28.84 Std. Limit 6.0
Part No. : 37 1030 61 Ser. Limit 60.865 ~ 61.285 Ser. Limit 28.80 28.17 Ser. Limit —
Application : Common bearing driver set for
fitting & removing bearings Valve Spring Free Length Valve Stem Diameter Valve Stem Bend
from crankcase.
Intake Exhaust
Std. Limit 42.17 Std. Limit 4.47~4.49 4.45~4.47 Std. Limit TIR 0.01
Ser. Limit 38.72 Ser. Limit 4.46 4.45 Ser. Limit > 0.01 Replace
Valve Stem to Guide Clearance Cylinder Head Warp Camshaft Chain Length
20 Link Length
1st 2nd 21st

MEASURE THIS LENGTH
Intake Exhaust
Std. Limit 0.01~0.37 0.025~0.052 Std. Limit 0.03 Std. Limit 127.00 ~ 127.48
Ser. Limit 0.07 0.07 Ser. Limit 0.05 Ser. Limit 128.9
52 53
SERVICE LIMIT - ENGINE SERVICE LIMIT - ENGINE
Cylinder Inside Diameter Piston Diameter Piston Cylinder Clearance Shaft Fork Shift O.D. Fork Shift I.D. Bush Fork Shift I.D.
10mm
20mm
40mm
6 mm
Group A 47.008 ~ 47.018 Group A 46.968 ~ 46.978 Std. Limit 0.02 ~ 0.04 Std. Limit 9.972 ~ 9.987 Std. Limit 10.0 ~ 10.022 Std. Limit 4.5 ~ 4.525
Group B 47.018 ~ 47.028 Group B 46.978 ~ 46.988 Ser. Limit 0.06 Ser. Limit 9.96 Ser. Limit 10.03 Ser. Limit 4.54
Piston Ring Groove Clearance Piston Ring End Gap Clutch Spring Free Length Shift Drum Groove Width Crankshaft Run Out Con Rod Side Clearance
Top Second Oil Ring Top Second Oil Ring

Std. Limit 0.03~0.07 0.02~0.06 0.03~0.15 Std. Limit 0.1~0.25 0.25~0.4 0.2~0.7 Std. Limit 27.0 ~ 26.4 Std. Limit 7.55 ~ 7.7 Std. Limit 0.02 Max Std. Limit 0.1 ~ 0.35
Ser. Limit 0.15 0.15 — Ser. Limit 0.5 0.6 — Ser. Limit 26.0 Ser. Limit 7.75 Ser. Limit 0.05 Ser. Limit 0.7
Friction Plate Thickness Steel Plate Thickness Steel Plate Warp Clutch Stackup Height
Std. Limit 2.9 ~ 3.05 Std. Limit 1.65 ~ 1.70 Std. Limit 0.1 Std. Limit 22.05 ~ 21.35
Ser. Limit 2.7 Ser. Limit 1.60 Ser. Limit 0.15 Ser. Limit 19.6
Friction Plate Warp Clutch Hub Height Shift Fork Guide Pin Diameter
Std. Limit 0.1 Std. Limit 21.0 ~ 21.2 Std. Limit 4.45 ~ 4.49
Ser. Limit — Ser. Limit 21.4 Ser. Limit 4.4 ALL DIMENSIONS ARE IN MM
54 55
GEAR TRANSMISSION POWER FLOW GEAR TRANSMISSION POWER FLOW
Construction & Working Second Gear Position : When Second Gear 5

4
is engaged, power from clutch flows as 2 3
Input Shaft and its gears : follows. 1
6 4 5
• First gear is integral with Input Shaft. 3
2
• Second gear is fixed on Input Shaft 1 Clutch
splines.
• Third gear is fixed but sliding on Input Input Shaft
Shaft splines.
• Forth gear is a freely rotating gear on 2nd Gear Input
Input Shaft. 7
• Fifth (top) gear is freely rotating on Input 2nd Gear Output
splines.
Output Shaft and its gears : 5th Gear Output 5

4
• First gear is a freely rotating gear on 3
Output Shaft. A bush which is free inside 2 1
Output Shaft
gear I.D. & shaft O.D. is fitted between 9
first gear and Output shaft. 12 10 11 8
Final Drive to the Rear Wheel
• Second gear is a freely rotating gear on
Output Shaft. A bush which is free inside
gear I.D. & shaft O.D. is fitted between
first gear and Output shaft.
1. Input shaft. 7. Output shaft
• Third gear is freely rotating on Output
2. First gear input. 8. First gear output.
splines.
3. Second gear input. 9. Second gear output.
• Forth gear is fixed but sliding on Output
4. Third gear input. 10. Third gear output.
Shaft splines.
5. Fourth gear input. 11. Fourth gear output.
• Fifth gear is fixed but sliding on Output
6. Fifth gear input. 12. Fifth gear output.
Shaft splines.
First Gear Position : When First Gear is 5 Third Gear Position : When Third Gear is 5
4 4
engaged, Power from clutch flows as follows. 2 3 engaged, power from clutch flows as follows. 3
1 2
1
Clutch Clutch
Input Shaft Input Shaft
1st Gear Input 3rd Gear Input
1st Gear Output 3rd Gear Output
4th Gear Output 4th Gear Output

5 5
4 4
Output Shaft 3 Output Shaft 3
2 1 2 1
Final Drive to the Rear Wheel Final Drive to the Rear Wheel
56 57
GEAR TRANSMISSION POWER FLOW TIGHTENING TORQUE - ENGINE
Forth Gear Position : When Forth Gear is 5 Spark Plug (2 Numbers) Cap Strainer (Drain Bolt) Cap Oil Filter
4
engaged, power from clutch flows as follows. 2 3
1
Clutch
Input Shaft
3rd Gear Input
4th Gear Input

1.3 ~ 1.5 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm
4th Gear Output Silencer Mounting Nuts Silencer Bracket Bolt Engine Mounting Bolts
5
4
Output Shaft 3
2 1
2.0 ~ 2.2 Kgm 3.5 Kgm 2.0 ~ 2.2 Kgm M8 : 12 MM

Engine Mounting Bolts Clutch Cover Bolts Cylinder Head Bolts (Short)
Fifth Gear Position : When Fifth Gear is 5

4
engaged, power from clutch flows as follows. 2 3
1
Clutch
3.0 ~ 3.2 Kgm M10 : 14 MM 0.9 ~ 1.1 Kgm 2.2 ~ 2.5 Kgm
Input Shaft
Cylinder Head Bolts (Long) Cam Sprocket Allen Bolt Rotor Mounting Nut
rd
3 Gear Input
5thGear Input
5th Gear Output

5
4
Output Shaft 3
2 1
2.2 ~ 2.5 Kgm 1.6 ~ 1.8 Kgm 5.0 ~ 5.5 Kgm
58 59
TIGHTENING TORQUE - ENGINE TIGHTENING TORQUE - ENGINE
Stator Plate Bolts Primary Gear Nut Clutch Nut (L.H. Thread) Starter Motor Mounting Bolts Bolt Kick Lever Cylinder Head Cover Bolts
0.9 ~ 1.1 Kgm 5.0 ~ 5.5 Kgm 5.0 ~ 5.5 Kgm 0.9 ~ 1.1 Kgm 2.2 ~ 2.5 Kgm 0.9 ~ 1.1 Kgm
Clutch Holder Bolts Guide Gear allen Bolt Stud Inhibitor Nut Carburettor Mounting Bolts Chain Tensioner Mounting Bolts Magneto Cover Bolts
Thermal Sensor Oil Pump Mounting Screws Output Sprocket Bolts Manifold Mounting Bolts
0.5 Kgm 0.5 ~ 0.7 Kgm 0.8 Kgm 0.9 ~ 1.1 Kgm
Crankcase Joining Bolts Crankcase Joining Bolts Kick Guide Bolts
0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm
60 61
ENGINE LUBRICATION - FLOW OF OIL ENGINE LUBRICATION - FLOW OF OIL
Nozzle Oil Jet Lubrication Circuit
‘Nozzle Oil Jet’ is press fitted in the crankcase L.H. and it is an important part of lubrication circuit. It sprays the oil, at
pressure, on the piston ribs to take out heat. Thus keeps piston relatively cool & protects it from seizure. Towards Nozzle Oil Jet
Towards Oil Jet
Head
Connecting
Road
Oil Plunger
(Crankshaft)
Oil Passage for

Nozzle Oil Jet
Clutch
Cover
Crank Shaft
Checking & Cleaning SOP

• Blow compressed air from the hole provided on ‘Nozzle Oil Jet’ to clear the Paper
crankcase passage (as shown arrow & photograph). Oil Filter
• Pump oil through L.H. crankcase oil passage leading to ‘Nozzle Oil Jet’ and
check whether oil comes out from hole provided on the ‘Nozzle Oil Jet’.
• Check & Clean ‘Nozzle Oil Jet’ whenever cylinder piston is seized / engine is
overhauled.
• Do not use plier. Outlet
• Do not repair by removing from crankcase.

• Do not apply loctite in case Nozzle gets loose.
Clutch Cover Orifice Oil Jet Cleaning
• Remove & clean ‘orifice oil jet’ by blowing compressed air whenever clutch Inlet
friction plates are replaced. Oil Pump
• Apply one drop of loctite 243 to threads of ‘orifice oil jet’ before refitting. Assly
• Orifice oil jet must be fitted such that its top surface is 0.5 mm down the
surface of clutch cover. Tightening torque 0.3 ~ 0.5 kgm. Oil Strainer Oil Pump Gear
Caution: Don’t over tighten orifice oil jet.
62 63
ENGINE LUBRICATION - FLOW OF OIL ENGINE LUBRICATION - FLOW OF OIL
Oil strainer
Crankshaft drilled LH side
hole - RH side crankcase hole
Oil pump inlet
Crank big end pin Orifice
INLET Oil pump outlet

LH crankcase
OUTLET Con rod slots
passage
RH side crankcase oil passage
Two fountains for

lubricating cylinder
piston parts
PASSAGE Clutch cover -
Inlet hole of paper filter chamber
Paper filter
L.H. Crankcase
passage towards
nozzle
Clutch cover -
Outlet hole of paper filter chamber
Nozzle Gap between bolt
oil jet and cylinder block
& cylinder head
RH side
Oil plunger crankcase Cylinder head hole
hole
Small oil sump -

for lubricating various
cylinder head parts
continued.....
64 65
DOS & DON’TS DOS & DON’TS
3 Dos 7 Don'ts 3 Dos 7 Don'ts

• Always replace engine oil by • Don’t over tighten ‘Cap oil • Always ensure correct fitment • While removing rotor, don't
recommended quantity and strainer’ (Drain bolt). of magneto rotor by rotating it rest the rotor holder (Special
quality of oil. (Tightening torque : 0.9 ~ 1.1 in both the Directions. tool no: F41AJA09) against
Recommended grade : Kgm) • Always rotate ‘Gear Starter stopper provided for ‘Gear
20 W 40API ‘SJ’ grade. Clutch’ in clockwise direction & Starter clutch’.
Engine oil capacity : pull it out. Immediately place
Drain & Refill : 1000 ml and Plastic cap into one way clutch
Overhaul : 1100ml rollers for securing them their
position.
• Always ensure firm connection • Don’t drop down thermal • Ensure crankcase / clutch • Don’t blow compressed air into crankshaft oil passage. This
of thermal sensor’s wiring sensor on floor otherwise it cover oil passages are clear would damage crank big end bearing.
harness connection. may get damaged by pumping oil from ‘Oil Can’.
permanently.
• Don’t over tighten thermal
sensor fitted on cylinder block
(Tightening torque 0.5 Kgm)
• Always replace gaskets, ‘O’ • Don't reuse 'O' rings, gaskets, • Always fit piston ring as per • Don’t fit 2nd piston ring ‘UP’ side ‘Down’. This could lead to
rings of engine if dismantled. Oil seals, Circlip locks as they standard SOP & ensure their smokey exhaust & higher engine oil consumption.
use their strength & properties, end position.
once they are opened.
• Whenever installing Spark • Don't adjust spark plug • Always blow light pressure • Don’t reuse torn ‘Oil strainer’ otherwise it will affect lubrication
Plugs, first screw by hand and electrode gap by hacksaw compressed air from inside system of engine & subsequently would lead to seizure.
then tighten to specified blade or with judgement of while cleaning ‘Oil strainer’
torque. This is to ensure eye otherwise it will affect the that is opposite to the direction
proper fitment & avoid thread engine performance. of flow of oil.
damage. 0.7 to
0.8MM
• Always use wire gauge for
setting spark plug
Electrode gap.
• Always set / adjust valve • Don't adjust valve tappet clearance by hacksaw blade or with • Always tighten engine • Don’t over tighten engine foundation bolts
tappet clearance in engine judgement of eye otherwise it will affect the engine foundation bolts as per
cold condition. performance. recommended sequence.
Intake : 0.0 5mm • Don't set valve tappet clearance in engine hot condition.
Exhaust : 0.10mm
• Always use feeler gauge for
setting valve tapper clearance
66 67
DOS & DON’TS DOS & DON’TS
3 Dos 7 Don'ts 3 Dos 7 Don'ts

• Ensure Cylinder Head Cover • Don’t fill excess engine oil beyond std. engine oil capacity • Confirm the crankshaft • Don’t hammer crankshaft while fitting it in crankcase otherwise
breather passage is clear by otherwise oil will ooze out from engine breather pipe / leak centering & free rotation after it would lead to its run out & subsequent engine noise
blowing compressed air in from gasket - oil seal fitment otherwise non centered
opposite direction of flow of crankshaft would lead to
fumes. Clogged breather engine knocking.
passage would lead to oozing
out of oil through oil seals, 'O’
Rings, Gaskets & Breather
pipe.
• Always follow loosening / • Don’t over tighten cylinder head cover bolts otherwise plastic • Always tighten clutch cover • Don’t over tighten clutch cover & crankcase bolts otherwise
tightening sequence of cylinder cylinder head cover may get cracked. and crankcase bolts to their crankcase parent hole threading would get damaged.
head bolts otherwise its surface • If cylinder head cover bolts are not tightened to specified specified torque (0.9 ~ 1.1
may get warped torque & in criss-cross pattern it would lead to oil leakage. Kgm) in crisscross pattern
• Tighten nut- bolts in criss-cross
pattern for matching of mating
surfaces to avoid distortion
otherwise It leads to oil
leakage.
• Standard Tightening Torque :
0.9~1.1 Kgm
• Always apply loctite to oil • While assembling oil Pump

pump securing screws / bolts shaft having integral nylon
gear, don’t hammer / tap the
gear for matching. Instead,
rotate the gear slowly ‘D’ slot
on shaft so that perfectly
matches with the ‘D’ slot of • Always replace circlips & locks of transmission gears, kick shaft • Don't wash air filter foam element with water.
inner rotor. assembly if removed. Circlips / locks tend to loose their spring • Don't clean air filter foam element with petrol otherwise foam
tension once removed. would catch fire during 'After fire process'. This would lead to
• While assembling cylinder block, always apply engine oil to dust entry inside engine.
• Always use Loctite to bolts, • If nut, bolts & screws are assembled with out loctite cylinder walls & piston rings for ease of fitment & to prevent dry • Don't wash engine bearings with water otherwise they will get
screws & nuts wherever application it would lead to their loosening & subsequent running. permanently spoiled
recommend. problem in engine. • Always apply oil during assembling engine components, • Don't blow compressed air on engine bearing otherwise they
particularly at friction prone area to avoid dry running. will get permanently spoiled.
• Confirm seating of circlip locks by rotating on their seat to avoid • Don't tap engine components by hammer in order to avoid
further consequences. damage. Engine components are precisely machined, they are
• While installing engine bearings always tap / press on the race critical & costly.
which is taking seat to avoid damage to the bearing otherwise
axial / radial clearance may increase.
• Blow dust free / moisture free • If air is blown in to orifices, oil passages of the engine in the
air in all the orifices, passages direction of oil flow, the passage would get jammed / clogged
of the engine components & instead of getting cleared.
confirm that the oil passages
are clear.
• The dust free air must be
blown opposite to the direction
of oil flow.
68 69
Notes
5
Vehicle (Frame)
Tightening Torques
Service Limits
Special Tools
Nitrox Rear Shock Absorber
70 71
TIGHTENING TORQUE - FRAME TIGHTENING TORQUE - FRAME
Front Axle Nut Rear Axle Nut Torque Rod Nut RSA Lower Bolt Front Fender Mounting Bolts LH & RH Stay Bolts
Rear Sleeve Nut Rear Sprocket Mounting Nut Handle Bar Holder Bolts Rear Brake Pedal Bolt Front Fork Oil Grade & Capacity
Grade :
SAE 10W20
Bajaj Genuine
Fork Oil
Fork Oil Level

Quantity :
140 + 2.5 ml /
Fork Leg Assly
(Drain & Refill)
6.0 ~ 7.0 Kgm 3.2 ~ 3.8 Kgm 2.0 ~ 2.2 Kgm 2.0 ~ 2.2 Kgm
Steering Stem Head Special Nut Steering Stem Nut Slotted Fork Pipe Top Bolts
Grease Application Points Engine Mounting Bolt Tightening Sequence
Type of
S.N. Vehicle Component
Grease
1. Bearing balls of steering
2. Swing arm shaft & Bushes 5 2

3. Front wheel axle
Servo GEM
3
4.5 ~ 5.0 Kgm 0.5 Kgm 3.0 ~ 3.2 Kgm 4. Rear wheel axle RR3
grease
5. Brake pedal pivot
Fork Under Bracket Bolts RSA Mounting Nut (Upper) Swing Arm Shaft
4
6. Center stand shaft
7. Side stand ‘U’ bracket
Loctite Applications
Type of Loctite &
1
S.N. Vehicle Fastener
Loctite Colour
1. Rider step mtg. bolts 243
2. RSA lower bolt Dark Blue colour
3.0 ~ 3.2 Kgm 3.5 ~ 4.0 Kgm 4.5 ~ 5.5 Kgm
72 73
SERVICE LIMIT - FRAME SPECIAL TOOLS - VEHICLE
Brake Panel Cam Hole Dia. Brake Cam Diameter Brake Shoe Lining Thickness Exclusive Special Tools
Special Tool to Remove Anti-Friction Bush

Application :
To remove anti-friction & oil seal bush from
front fork outer pipe.
Std. Limit 12.00 ~ 12.03 Std. Limit 11.95 ~ 11.98 Std. Limit 3.9 ~ 4.5
Ser. Limit 12.8 Ser. Limit 11.88 Ser. Limit 2.5
Br. Drum Inside Dia. Frt. & Rr. Axle Run Out Axial Wheel Run Out
100 mm
Std. Limit 130~130.16 Std. Limit TIR 0.05 Std. Limit TIR 0.8 or Less
Ser. Limit 130.75 Ser. Limit TIR 0.2 Ser. Limit TIR 2.0
Radial Wheel Run Out Drive Chain Slack Drive Chain Length
20 Link Length
Other Common Special Tools
Fork Oil Seal Driver

1st 2nd 20th
Part No. : 37 1830 07
MEASURE THIS LENGTH
Application :
Std. Limit TIR 0.8 or Less Std. Limit 20 ~ 25 Std. Limit 254.0 ~ 254.6 To fit fork oil seal in its seat provided at outer
Ser. Limit TIR 2.0 Ser. Limit 35 Ser. Limit 260.0 pipe ID.
Rear Sprocket Warp Tyre Tread Depth Front Fork Spring Free Length
Stem Bearing Driver

Part No. : 37 1830 05
Application :
Free Length
To fit bearing race on fork under holder
bracket
Std. Limit TIR 0.4 or Less Std. Limit Front : 5.0 Rear : 6.0 Std. Limit 392+4
Front :
Ser. Limit Upto Rear :
Ser. Limit 0.5 TWI Upto TWI — —
74 75
SPECIAL TOOLS - VEHICLE NITROX REAR SHOCK ABSORBER
Front fork cylinder holder handle with adaptor

Part No. : 37 1830 06
Application :
Adjuster
To hold fork cylinder while loosening /
tightening fork allen head bolt at bottom. Membrane
Canister
Inner Tube
Gas Cap
Air Hose Upper Chamber
Valve Assly
Installer Upper & Lower Bearing Race Frame
Circlip
Part No. : 37 1801 06 Cover Cap
Piston Ring
Piston
Application : Rebound Spring Lower Chamber
To install upper & lower steering races / Rod Guide

Oil Seal
cones into their seats inside frame. Bump Stopper
Piston Rod
Outer Spring
Bearing Race Extractor

Part No. : 37 1030 48
Application :
To Pull out steering race from ' Fork Under
Holder bracket'
SOP for refilling pressure in gas filled shock absorber

• Remove the phillips headed small screw and ‘O’ ring.
Steering Cone Remover
• Fix the cylindrical guide clamp on the canister such that it should be
Part No. : 37 1805 06 concentric with air valve assembly rubber seal pin.
Application : • Hold the pump as shown and pierce the syringe needle into the center of
To remove steering cones rubber seal pin.
from frame. • The adaptor should rest into the clamped cylindrical guide.
• Rear the gas pressure on the dial gauge. If the gas pressure is below 6.5
Kg/Cm2 refill the air by operating pump. To fill the required air pressure into
the canister membrane, apply full stroke of pump as shown; otherwise air will
not get filled in membrane at required pressure.
Special Tool to Adjust RSA Spring • Keep on pumping the air till you get 7.5 Kg/cm2 on the gauge.
Part No. : 37 00DS 01 • Pull out the air pump along with adaptor, cap & needle syringe carefully and
take out the guide clamp.
Application :
• Finally fix the phillips headed screw with ‘O’ ring.
To adjust rear shock absorber spring tension
by adjusting the position of spring cam Periodic Maintenance Schedule
between 1st to 5th notch position.
Refill pressure every 10000 kms. Replace nitrox chamber screw
assembly (DJ 1710 34) at every 20000 kms.
76 77
Notes
6
Electricals
Battery
Dos & Don’ts - Generic
Electrical Checking Procedure
Head Light Control Unit
Electrical Diagrams
78 79
Notes ELECTRICALS
Battery Technical Specification

For Self Start For Kick Start
• Make Exide Exide
• Voltage 12 Volt 12 Volt
• Type MF Battery Regular Battery
• Capacity 5 Ah 2.5 Ah
• Specific gravity of electrolyte 1.24 for use 1.24 for use
for initial filling of new battery above 100C above 100C
• Initial charging duration 10 ~15 hrs 10 ~15 hrs
• Charging current specification 0.5 Amp 0.25 Amp
Battery Features
• Frequency of electrolyte topping-up is very less compared to conventional battery.
• Low self discharge.
• Unique vent system / mechanism.
• No vent tube hence no discharge of electrolyte through vent tube.
• Enhanced safety
• Compact design-High efficiency in compact package.
Battery Charging Procedure

In case battery is discharged follow the procedure given below by using constant current. “Battery Charger” of 0.5 Amp.
charging current specification for 5 Ah battery & 0.25 Amp for 2.5 Ah battery
• Remove battery from vehicle
• Clean battery throughly
• Remove vent / filler plug strip
• Top up level with distilled water in between Min and Max. level
• Connect to battery charger & ensure respective terminal are connected properly
• Set charging current at 0.5 A DC for 5 Ah Battery & 0.25 A DC for 2.5 Ah battery.
• Charge battery for 3 ~ 4 hrs, then check voltage and specific gravity.
• Voltage should be 12.5 volts and specific gravity in all 6 cells should be 1.240. This is a confirmation check for a fully
charged battery.
• Disconnect the battery from the changer.
• Fit vent / filler plug strip firmly.
• Reconnect battery terminals
• Apply petroleum jelly to the battery terminals.
How to Determine Condition of Battery
Hydrometer
Specific Gravity check: - Whether battery is fully charged or partially charged, it will always
show same “no load voltage” of 12 volts or more (unless battery cells are damaged due to
Read sulphation etc). But specific gravity of the fully charged battery and partially charged battery
Here
will be different. Fully charged battery will show Sp. gravity of 1.240 while partially charged
battery will show less specific gravity. Therefore, specific gravity check is very important to
know condition of the battery.
80 81
DOS & DON’TS - GENERIC DOS & DON’TS - GENERIC
Battery Battery
3 Dos 3 Dos
3 • Use battery load tester for checking battery charge • Use proper tools.
condition. 3
• Check open circuit voltage by multi meter. • Always charge battery by constant current method with
3 3 the help of specified charger.
3 • Do hold the box. • Always maintain battery top

3 cover clean and dry. Always 3
keep Vent Mechanism area
clean & clear.
3 • Apply petroleum jelly to poles / terminals. • Always maintain electrolyte

3 level between maximum &
minimum level marks.
• Use proper equipments for • Use only distilled water to top up battery.
3 checking specific gravity & 3 3
voltage.
82 83
Battery Battery
7 Don’ts 7 Don’ts
• Do not hold the wires. • Do not quick charge battery by current higher than
7 7 specified current.
• Constant voltage charging method must be strictly
avoided.
• Do not use local make battery charger.
• Do not apply grease to poles / terminals. • Do not fit extra electrical accessories (Tampering of
7 7 wiring for fitting buzzer etc.) other wise wiring would get
short & battery would get discharged. This will shorten
the life of battery.
• Do not short circuit the leads. • Do not increase the level of electrolyte beyond maximum
7 level mark otherwise it would over flow through Vent
Mechanism & damage other parts.
• Do not short circuits the poles. • Do not use mineral water,

7 drinking water to top up
7
battery.
• Do not use improper tools.
84 85
HORN IGNITION SYSTEM
3 Dos 7 Don'ts 3 Dos • Always install recommended capacity of battery on the bike.
• Always replace spark plug by correct heat range plug.
Ensure that horn is firmly fitted on Never remove resonator cap as
• Check & adjust spark plug gap periodically. Adjust it to 0.6~ 0.7mm by feeler
frame it could result in water entry &
gauge.
subsequent malfunctioning of
horn • Replace spark plug at every 15,000 kms.
• Check for firm fitment of spark plug in cylinder head -Tightening torque 13. ~
1.5 Kgm.
Ensure that horn is free from dust Do not apply pressurised water • Ensure H.T. cable secondary connection is firmly fitted in spark plug cap a n d
and mud accumulation. jet directly on horn resonator. H.T. coil.
• Check that CDI coupler is tightly fitted.
• Check for proper functioning of TPS - Hall sensor.
• Ensure that magneto coupler is firmly fitted.
Ensure that horn wires are intact. Never adjust nut on horn cap • Ensure that rubber cap on magneto and CDI coupler are intact & grease
side & bracket end (back side) used in CDI and magneto coupler is in place.
as it will result in horn • Always use a right size socket during removal and re-installation of spark
malfunctioning & failure. plug.
• During periodic service make use of spark plug cleaning & testing machine
to clean spark plug electrodes & to check proper functioning of both the
Ensure that horn switch button is Do not remove silicon sealant spark plugs.
operating freely. from adjustment screw as it will • During periodic service check & confirm resistance of thermal sensor &
result in water entry in horn. proper
• Functioning of auto choke.
Ensure that battery is fully charged. 7 Don'ts • Do not replace spark plug by non recommended one (different heat range).
• Do not replace CDI by local make or different make.
• Never short circuit H.T. coil primary wire to ground. It could lead to CDI
failure.
• Do not remove grease from CDI and magneto coupler as it is provided for
rust prevention.
• Adjust horn by phillips screw driver Do not hit by mallet / screw
- without removing silicon sealant driver on horn resonator. • Do not adjust the spark plug gap with any instruments like screw Driver,
from the adjustment screw. pliers etc.
- by rotating the screw in the • Do not drive the vehicle without battery. Driving motorcycle in battery
direction of arrow provided in the removed condition could cause damage to electrical components like voltage
screw. regulator because of no load Condition.
Ensure that resonator is not pressed
by any portion of cables or wiring
harness as it will result in distorted
sound.
86 87
DOS & DON’TS - GENERIC ELECTRICAL CHECKING PROCEDURE
LIGHTS Fuse Inspection (Capacity = 10 Amp)
Fuse
3 Dos • Check that all bulbs are firmly fitted in bulb holder.
• Ensure that there is no dust and water entry in bulb housing.
• Inspect the fuse element.
• Ensure that all fixing screw of bulb housing are intact. • Check continuity of fuse.
• Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is • If it is blown out, replace.
intact. • If a fuse fails repeatedly, check the electrical system to determine the cause. Replace it
with a new fuse of proper amperage capacity.
• Check DC Voltage Regulator’s output voltage periodically. Ensure that
voltage is within specified limits. • If fuse is replaced by lower capacity fuse, it may lead to repetitive fuse blowing
problem.
• Check that couplers and wires of bulbs are in good condition.
Note : Never use higher capacity fuse.
• Check flashing rate of indicator bulbs.
Caution : When replacing a fuse be sure the new fuse matches the specified fuse rating for
that circuit. Installing that a fuse with a higher rating may cause damage to wiring &
7 Don'ts • Do not install a lower / higher capacity battery than what is recommended. components.
• Do not use Higher / Lower wattage Bulbs.
• While washing Vehicle do not direct pressurized water jet on Head Light, Tail
Light,Indicators. Front Brake Light Switch
• Do not ride on brakes.

• Turn ‘ON’ the ignition switch.
• Do not start Vehicle with light control switch in ON condition. • The brake light LED bank should glow brightly when the front brake lever is
pressed.
• If it does not, check the front brake switch.
Brown Blue Continuity check by multimeter

SWITCHES
Lever Pressed l l Continuity is shown
3 Dos • Always clean switch assembly with soft cloth. Lever Released l l No Continuity
• After washing the vehicle ensure to apply dry air on switches before
operation.
• Ensure that rear brake switch is free from dust, dirt and mud Accumulation. Rear Brake Light Switch
• Always ensure that grommets provided on clutch switch, front brake switch • Turn ‘ON’ the ignition switch.
and rear brake switch are intact. • Check the operation of the rear brake light switch by depressing the brake pedal
• Always apply WD-40 Rust Spray to sticky switches. • If it does not operate check continuity of rear brake switch.
7 Don'ts • Do not apply direct pressurized water jet on control switches. Brown Blue Continuity check by multimeter
• Do not lubricate electrical switches by oil or grease. Brake Pedal Pressed l l Continuity is shown
• Do not over tighten the switches. Brake Pedal Released l l No Continuity
• During warranty period do not dismantle control switches.
• Do not add extra electrical loads e.g. musical horns, additional horns,
buzzers as it will reduce switch contact life & battery life &battery life.
• Do not tamper / alter rear brake switch spring.
• Do not operate switch immediately after water servicing.
88 89
ELECTRICAL CHECKING PROCEDURE ELECTRICAL CHECKING PROCEDURE
Clutch Switch Standard Value :-

Full Tank Fuel Level Fuel Quantity Standard value Reading on
The clutch switch has 3 wires. In neutral conditions, clutch switch is in Liter Ohm Fuel Meter
non-operated condition closing ‘C’ & ‘NC’ terminals. In gear condition, Empty Tank 1.4 98 + 5 ‘E’ mark
clutch switch is operated there by connecting ‘C’ & ‘NO’ terminals. Reserve 2.3 81 + 4 Bet ‘E’ mark & 1st line
Between R & Half 3.0 + 0.5 62 + 4 1st Line
Meter Range Light Green Yellow / Green Black /Yellow Half Tank 5.0 + 0.5 44 + 4 2nd Line
OFF - Clutch l l l
Full Tank 8.0 6 ~ 12 4th Line
lever not pressed
ON - Clutch Note: If display in speedo console is not proper then please check following
l l l
lever pressed • Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is firm.
Ignition Switch Starter Relay
Measuring & Testing Equipment : Multimeter

Measuring & Testing Equipment : Test Jig or Multimeter
Meter Range Connections Continuity Check Connection : Test Jig - Connect starter relay coupler to Test Jig & it show result as
Continuity Meter +ve Meter -ve OFF - No continuity OK / Defective
Mode Brown White wire ON - Continuity
Meter Range Connections Standard Value Measured Value
Meter +ve Meter -ve
SOP : 200 Ohms
Starter Relay Starter
• Switch OFF Ignition key.
Coil Red - Relay Coil 4 Ohms + 10%
• Disconnect Ignition switch’s coupler. Yellow Wire Black Wire
• Remove Ignition Switch from vehicle .
• Check continuity between wires in ‘ON’ & ‘OFF’ position. SOP :
• Switch OFF engine.
Standard Value :
• Beep Sound & Continuity in ‘ON’ position. No continuity in ‘OFF’ position. • Disconnect coupler from Relay.
• Connect multimeter to Starter Relay coil terminals.
Note: • Don’t use duplicate or non-OE Ignition key. • Check resistance.
• Never lubricate Ignition switch by oil / grease.
Capacitor
Empty Tank Fuel Gauge - Tank Unit
Checking Method :
Measuring & Testing Equipment : Multimeter Touch +ve wire of capacitor to earth. Spark will occur.
This Indicates capacitor is OK.
Meter Range Connections Standard Value
Meter +ve Meter -ve As per chart Note: Capacitor is very important for Battery charging function, so ensure capacitor coupler is
200 Ohms
White / Yellow Black / Yellow given below always firmly connected.
90 91
Engine Thermal Sensor H. T. Coil Inspection
Measuring & Testing Equipment : Multimeter H.T. Coils : (Inspection Using Multimeter)
• Measure the primary winding resistance as follows
Meter Range Connections Standard Value
• Connect the hand tester between the coil terminals.
Engine Resistance • Measure the secondary winding resistance as follows
Meter +ve Meter -ve
Temp (0C) K Ohms(W)
• Remove the plug cap by turning it counter clockwise.
@ 10 0C 20.702 KW + 10%
0
• Connect the tester between the spark plug leads.
@ 20 C 12.889 KW + 10%
• Measure primary winding & secondary winding resistance.
@ 30 0C 8.653 KW + 10%
20 K Ohms Black / White Earth / Ground • If the value does not match as per, specifications replace the coil.
@ 40 0C 5.636 KW + 10%
• If the meter reads as specified, the ignition coil windings are probably good.
@ 50 0C 3.818 KW + 10%
However, if the ignition system still does not perform as it should after all other
@ 60 0C 2.782 KW + 10%
components have been checked test replace the coil with one OK coil.
• Visually inspect the secondary winding lead.
• If it shows any damage, replace the coil.
Battery Charging Coil
Primary Winding 0.40 to 0.50 Ohms at 250C
Measuring & Testing Equipment : Multimeter Secondary Winding 4.23 to 5.17 K Ohms at 250C

Meter +ve Meter -ve 0.9~1.1 Ohms
200 Ohms TPS-HALL SENSOR
Blue / White Blue / White at 250C
SOP : A. Continuity Check in Coupler Disconnected condition

• Disconnect stator plate coupler Measuring & Testing Equipment : Multimeter
• Connect multimeter between two Blue / White wires.
• Check resistance value between Blue / White & Blue / White. Meter Range Connections Standard Value Measured Value
Continuity Meter +ve Meter -ve No continuity
Mode Blue Black / Yellow must be shown.
Pick-up Coil
SOP :
Measuring & Testing Equipment : Multimeter • Disconnect TPS coupler
• Check Continuity between Blue & Black / Yellow wire
Meter Range Connections Standard Value Measured Value • There should NOT BE any continuity.
Meter +ve Meter -ve
2 K Ohms 180 ~ 220 Ohms
White / Red Black / Yellow
B. Input (supply) Voltage check
SOP :
Measuring & Testing Equipment : Multimeter
• Switch Off Ignition Key.
• Disconnect Stator Plate Coupler Meter Range Connections Standard Value Measured Value
• Connect multimeter between White / Red &
Meter +ve Meter -ve 12.5 + 0.4 Volts
Black / Yellow wires. 20 V DC (Battery Voltage)
• Measure resistance Brown Black/ Yellow
SOP :
Note: Ensure gap 0.5~0.7 mm between pole of pick-up coil & rotor peep. • Connect TPS coupler.
• Switch 'ON' Ignition Key.
• Check voltage between Brown & Black/Yellow wires of TPS Hall Sensor.
92 93
C. Voltage check in POT condition Auto Choke Working
Measuring & Testing Equipment : Multimeter In Engine running condition & when engine RPM are greater than 1500 the solenoid operated choke is
switched 'ON' for specified time depending upon engine temperature. The chart of choke operation vis-a-vis
Meter Range Connections Standard Value Measured Value engine temperature is given below.
Meter +ve Meter -ve < 1 Volt in Partial
20 V DC H Incase if engine temperature
Blue Black / Yellow Open Throttle Temperature of Engine Approximate time for which
Engine RPM shoots (in between) above 300C,
Sensed by Thermal Sensor solenoid choke is 'ON'
choke gets switched off & the
SOP : < 150C A minute or Two period of choke operation would
• TPS coupler is in connected condition. 15 ~ 20 C 0
get reduced.
Few Seconds
• Switch 'ON' Ignition key.
RPM > 1500 20 ~ 25 C 0
Fewer Seconds
• Check voltage between Blue & ‘Black / Yellow’ wire in Partial Open Throttle (POT)
0
condition. 25 ~ 30 C Very Few Seconds
0
> 30 C CHOKE OFF
D. Voltage check in WOT condition

AUTO CHOKE
Measuring & Testing Equipment : Multimeter This choke circuit is by-starter type and choke actuation is electric, automatically
controlled by an electronic circuit. No user intervention is necessary. ‘CDI’ controls the
Meter Range Connections Standard Value Measured Value Auto Choke circuit. When engine is started either by kick or self start mechanism,
Meter +ve Meter -ve 2.7 ~ 5.0 Auto the thermal sensor senses engine temperature. If engine temperature is below
20 V DC
(+0.2) Volts in Choke predefined temperature, the coil in solenoid choke gets energized & the choke
Blue Black / Yellow Unit
WOT position plunger gets lifted. The choke is switched off as soon as engine attains predefined
temperature. During choke operation, additional air-fuel mixture is supplied for starting
SOP : the engine. This increases the mixture strength and it facilitates easy and quick
• TPS coupler is in connected condition. engine start even in very cold conditions.
• Switch 'ON' Ignitions key. • The choke operation is optimized for starting under all conditions for minimizing
• Check voltage between Blue & Black / Yellow wire in Wide Open Throttle fuel consumption as well as for optimizing battery life
condition (WOT). • Temperature sensor is mounted on cylinder block for giving engine temperature
input to CDI.
Plunger in Lifted Plunger in Normal
Auto Choke Solenoid Coil Condition Condition
Auto Choke Functional Check
Measuring & Testing Equipment : Multimeter Visual Confirmation on component :
Check 1:
Meter Range Connections Standard Value Measured Value • Remove Choke Unit from Carburettor assembly.
Meter +ve Meter -ve • Switch 'ON' Ignition Key.
200 Ohms 12 + 10 %
Brown Orange/Brown • Solenoid operated choke plunger must get lifted for a second & then again
plunger must fall down in engines OFF condition. With one Rotation of crankshaft
SOP : i.e. one pulse, choke is on for approx. 10 Sec. If engine temperature is less than
• Disconnect coupler of solenoid operated choke. 300C
• Connect Multimeter lead wires to Brown & Orange / Brown wires. Check 2 :
• Check resistance of Coil • Connect solenoid operated choke connection to external supply of 12volt DC &
check / confirm the working of choke (whether solenoid operated choke gets 'ON'
i.e. plunger remaining lifted as long as the external supply is in connection.
Connection of External Supply (Another battery)

+ ve terminal - ve terminal
Brown Orange / Brown
94 95
Check 3 : Horn
• Remove Choke Unit from carburettor assembly but coupler is connected to
harness. Measuring & Testing Equipment : DC Clamp Meter
• Disconnect Black/White wire of Thermal Sensor. (Means thermal sensor is in
‘Open’ condition) Meter Range Connections Standard Value Measured Value
• Solenoid operated choke plunger must get lifted for few seconds (Approximately
10 seconds) in engine idling condition. Encircle clamp meter jaws 2.2 Amps
200 DC A
around Brown wire of horn
Check 4 :
• Remove Choke Unit from carburettor assembly but coupler is connected to SOP :
harness. • Encircle clamp meter jaws around Brown wire of Horn.
• Short Black / White wire to ground /earthing. (Means thermal sensor is in ‘Short’ • Press horn switch & check instantaneous current drawn by horn.
condition).
• Solenoid operated choke plunger must get lifted for few seconds (Approximately
10 seconds) in engine idling condition.
Starter Motor - Current Drawn
Measuring & Testing Equipment : DC Clamp Meter

Speedometer
Encircle clamp meter 30 ~ 38 Amps
200 DC A transformer jaws around Spark Plug
thick Red wire of starter motor. Caps removed Twin pod analog type speedometer houses :
• Speedo-Odometer unit
SOP : • Trip meter with push type ‘Knob / Lever’ for resetting zero.
• Switch ‘ON’ Ignition Key & disconnect both spark plug caps (care to be taken so • Fuel meter.
that spark plug does not jump to metal part) • Turn signal indicator.
• Select range & set clamp meter Zero reading. • High beam indicator.
• Encircle red input wire of starter motor by clamp meter jaws. • Neutral indicator.
• Crank engine by pressing self starter button. • Low battery indicator.
• Press self starter button 3 seconds & check cranking current displayed on clamp
meter LCD display.
Low battery indicator
When ignition switch is turned ‘ON’, battery indicator glows on
Upon Starting Engine :-
Condition 1 : Battery indicator glows off if battery charging system is OK /

battery is in charged condition.
Condition 2 : Battery indicator continuously glows on if battery

charging voltage is less than 13 V (means charging system
is malfunctioning) / battery is deep discharged.
Thus low battery indicator reminds to charge battery /
correct battery charging system in time.
96 97
ELECTRICAL CHECKING PROCEDURE HEAD LIGHT CONTROL UNIT
DC Charging Voltage Measurement Function

• It is also called as Battery Protector Unit.
Use fully charged battery while measuring • It prevents the head lamp from switching ‘ON’ when Ignition Switch &
Ensure VB = 12.5 + 0.3 V before checking Head Light Switch is ‘ON’ but engine is not running. This means ‘Head
VB = Battery open circuit terminal voltage with Battery terminals in Light Control Unit’ allows switching ON of head lamp when Ignition
disconnected condition. switch is switched ON, engine is started & Head Light Switch is
switched ON.
To measure the DC voltage; set the meter at 20V DC range. Connect the
meter +ve lead to Battery +ve terminal & meter -ve lead to battery -ve Thus it protects the battery from getting drained.
terminal without disconnecting battery wires. Start the engine & set it at
1500 RPM. Measure the voltage with headlight switch in ‘ON’ position.
Switch OFF Ignition key & disconnect the meter leads.
Meter Range Meter Connections Specified at

Measured Value
1500 RPM Construction
+ve lead -ve lead
20 V DC Battery Battery 14.2 + 0.4 Volts INPUT OUTPUT
+ve terminal -ve terminal
Note : For DC voltage measurement connect multimeter in parallel circuit. Yellow / Blue Wire from Violet Wire to
RH Control Switch LH Control Switch
Battery DC Charging current Coil

Black-Yellow Wire
Use fully charged battery while measuring. Blue / White
Ensure VB = 12.5 + 0.3 V before checking. from Magneto
To measure the DC charging current, set the meter to 10A DC range.
Disconnect Red wire from Battery +ve terminal connect meter +ve lead to Ground Earth
Red wire of wiring of wiring harness & -ve lead to +ve terminal of battery.
Start the engine & set it at 4000 RPM. Put ON the headlight & measure
the DC charging current. The DC charging current should be 0.7 A max.
Switch OFF Ignition key & disconnect the meter leads. Connect the RR unit Working
& battery. • This unit works on relay principle.
• When Ignition Key is turned ‘ON’, RH control switch (H/L Switch) is switched on to ‘Head Light ON Position’, Y/L wire
Meter Range Meter Connections Specification Measured Value
from RH Switch supplies input voltage (12V DC) to ‘Head Light Control Unit’.
Meter +ve Meter -ve 0.7 A Max. @
DC 10 Amp • When engine is started the L/W wire from Magneto supplies 12V DC supply to the coil incorporated in the unit. The other
Red wire of Battery +ve 4000 RPM with
Harness Terminal fully charged end of the coil is ground earth, hence the circuit gets completed & the coil gets energized.
battery Due to this relay gets operated & an output voltage of 12V DC is supplied to the ‘LH Control Switch’ through Violet wire.
Depending upon LH Control Switch position, Head Lamp glows in either high beam or low beam position.
Note : For DC current measurement connect multimeter in series circuit.
98 99
HEAD LIGHT CONTROL UNIT ELECTRICAL CIRCUIT DIAGRAMS
CHECKING PROCEDURE B CAPACITOR

DC C.D.I. ASSY.
IGNITION CIRCUIT
B/R
A) Measuring & Testing Equipment : Multimeter
2 POLE
W
6 POLE COUPLER Pi
Meter Range Connections Standard Value Measured Value Br/L
Pi
VOLTAGE 2 POLE 4 POLE
Meter +ve Meter -ve 0.9~1.1 Ohms REGULATOR H.T. COIL
TPS
200 Ohms
W/R
Br/L
B/R
B/Y
B/Y
HALL
B
Blue / White Blue / White at 250C W
Pi
SENSOR
W
W SPARK PLUG
B
L/W
L/W
SOP : W
Br/L
W/R
B/Y
Br
SPARK PLUG
• Disconnect stator plate coupler H.T. COIL
• Connect multimeter between two Blue / White wires.
L/W
L/W
W
O O
• Check resistance value between Blue / White & Blue / White. N F
F
W
Br Br/L Br/L
IGNITION
SWITCH
W W
B) Measuring & Testing Equipment : Multimeter
W
B/Y
W
W/R
L/W
L/W
Meter +ve Meter -ve
20 V DC 12 V DC FUSE
Violet Wire Black / Yellow
W/R
B/Y
(10 Amps.)
W/B
MAGNETO
B
SOP : R
ING
PU COIL
LS
BATTERY
• Switch ON Ignition Key. 12V-5Ah MF
• Switch ON RH Side H/L Switch to head light ON position

• Start Engine.
CAPACITOR
• Measure voltage between Violet wire & Ground earth i.e. Black / Yellow wire B AUTO CHOKE
CIRCUIT
W
DC CDI ASSLY
DC REGULATOR
C) Measuring & Testing Equipment : Multimeter
W
W
4 POLE COUPLER
Meter Range Connections Standard Value Measured Value W 2 POLE
Meter +ve Meter -ve

20 V DC 12 V DC
Yellow/ Blue Black / Yellow O O
W
HALL
N F
O/Br
W/R
B/W
Br/L
B/Y
IGNITION SWITCH
F SENSOR
Br Br/L Br/L
SOP : B/Y
Br/L
W W W
• Switch ON Ignition Key.
B/Y
W
• Switch ON RH Side H/L Switch to head light ON position
W
W/R
Br/L
Br/L
B/Y
• Measure voltage between Yellow / Blue & Ground earth i.e. Black / Yellow wire B/W
O/Br O/Br
Br/L
B/W
D) If there is Input Voltage at Yellow / Blue & Black / Yellow wire then - EARTH-FRAME
B/Y
W/R
O/Br
• First check the resistance of magneto coil. Rectify / Replace coil if resistance is not as per Specifications.
W
• If there is no Input voltage between Yellow / Blue & Black / Yellow wire, check/ rectify RH control switch & its wiring THERMAL SOLENOID MAIN FUSE
SENSOR (10 Amps.)
harness. W/B
W/R
• If there is Input voltage between Yellow/ Blue & Black / Yellow wire but no Output voltage between Violet wire & R B
Black / Yellow wire, replace ‘Head Light Control Unit.
ING
PU OIL
BATTERY
B/Y
C
LS
12V-5Ah MF
MAGNETO
100 101
ELECTRICAL CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAMS
CAPACITOR
STARTER
SWITCH
B
CAPACITOR STARTER MOTOR B HORN CIRCUIT
CIRCUIT
W
W
R/W
Br
DC REGULATOR
DC REGULATOR
W
W
W
W
W
Lg W
NEUTRAL LAMP O O
12V-2W N F
IGNITION SWITCH
F W
Br W Br Br/L
R/W
Br
O O
Lg
Br
IGNITION SWITCH
N F
F W
W
Br Br/L
W
B/Y
W W EARTH
FRAME
W
Br/L
Br/L
B/Y
Lg STARTER
B/Y
W
B
Y/G
B/Y
R MOTOR
W
Br
B
MAIN FUSE
(10 Amp.) B/Y
B
Br
W
B/Y
W/B
R/W
Y/G
CLUTCH EARTH-FRAME
SWITCH MAIN FUSE
B
L
Br/L
(10 Amps.)
Y/G Y/G PASS DIMMER TURN HORN W/B
R SWITCH SWITCH SIGNAL SWITCH HORN
NEUTRAL SWITCH
SWITCH BATTERY 70 MM DIAPHRAGM
Br/L CONTROL SWITCH LH R B
STARTER RELAY 12V-5Ah MF LIGHTING FUSE
(10 Amps.)
LIGHTING FUSE BATTERY
(10 Amps.) 12V-5Ah MF
B
CAPACITOR
BATTERY CHARGING B
CAPACITOR
BRAKE LAMP
CIRCUIT CIRCUIT
W
W
DC REGULATOR REAR BRAKE

SWITCH
DC REGULATOR
FRONT BRAKE W
W
SWITCH
Br
L
W
W
Br
L
L/W
L/W
W
LOW
B/Y
Br W
BATTERY
Br
L
CHARGING
Br
L
INDICATOR
O O
G/W
Br
12V-1.7W G/W
N F
IGNITION SWITCH
F
Br
O O
IGNITION SWITCH
N F
F Br
Br Br/L L TAIL /
W W
B/Y
STOP
W
LAMP
B/Y B/Y
W
W
W
Br/L
W
Br
Br/L
Br
L/W
L/W
B/Y
W
W
Br/L Br MAIN FUSE
(10 Amps.) MAIN FUSE
B/Y
L/W
L/W
LIGHTING FUSE (10 Amps.)

(10 Amps.) W/B
W/B
Br/L
Br
R B EARTH-FRAME R B
EARTH-FRAME BATTERY BATTERY

BATTERY
CHARGING 12V-5Ah MF LIGHTING FUSE
12V-5Ah MF
COIL (10 Amps.)
102 103
ELECTRICAL CIRCUIT DIAGRAMS ELECTRICAL CIRCUIT DIAGRAMS
B
CAPACITOR SIDE INDICATOR LIGHT START
HEADLAMP
CONTROL UNIT
CAPACITOR &
BRACKET ASSLY LIGHT SYSTEM
TURN SIGNAL
W
W RELAY CIRCUIT SWITCH
ON PO
SWITCH
W
CIRCUIT
SIGNAL Gr Gr
W
OFF
LAMP
B/Y
V
FRONT RH DC REGULATOR DC. REGULATOR ASSLY
LAMP SPEEDOMETER WITH CAPACITOR
Y/L
Br
L/W
B/Y BULB 3 W
R
Y
12V-10W
Br
O
R
W
L/W
B/Y
W
B/Y
Gr W
TURN SIGNAL
L/W
B/Y
Br
V
INDICATOR R/B
LAMP 12V-2W G HIGH BEAM
W
Y/L
R
V
INDICATOR
1.7 W EARTH-FRAME
Gr R
O O SIGNAL
G
O
Gr Gr O F
N F
N
LAMP F
B/Y
F
O
Br Br/L Br REAR RH Br Br/L
IGNITION
IGNITION B/Y 12V 10W SWITCH
W W TAIL
SWITCH B/Y B/Y LAMP
R/W ASSY
W
W W R/W R LED
W
Gr
Br
Br/L
R
G
L/W
L/W
W
B/Y
B/Y
B/Y SIGNAL R/B R/B
O
LAMP
Gr
G
O
HEAD LAMP B/Y B/Y

REAR LH
G
W ASSY / LAMP
G G
Br/L
12V 10W 12V-35/35W HS1 R/Y R/Y
L/W
L/W
W
Br
MAIN FUSE
B/Y POSITION LAMP B/Y R
(10 Amps.) 12V-5W- 2 Nos
R/B
R/Y
Y/L
Br
FUSE
Gr
W/B
G
O
R (10 Amps.)
G G
W/B
SIGNAL LAMP R B
FRONT LH R O L
LIGHTING FUSE TURN SIGNAL HORN R
(10 Amps.) SWITCH SWITCH BATTERY
R/B
R/B
Y/L
Y
BATTERY
CONTROL SWITCH LH 12V-5Ah MF 12V-5Ah
LO HI
LIGHTING FUSE
PASS DIMMER
(10 Amps.)
CAPACITOR SWITCH SWITCH
B FUEL GAUGE Br/L Br
CIRCUIT
W
DC REGULATOR
W
W
W/Y W
FUEL METER
(INSIDE
FUEL LEVEL
INSTRUMENT
GAUGE
CLUSTER)
Br
W/Y
B/Y
W/Y
Br
O O
W
IGNITION SWITCH
N F
F
Br Br/L
B/Y
Br W
W W
W
Br/L
Br
B/Y
MAIN FUSE
B/Y
(10 Amps.)
W/B
Br/L
Br
EARTH
FRAME
R B
LIGHTING FUSE BATTERY

(10 Amps.) 12V-5Ah MF
104 105
Notes
7
Workshop Safety
106 107
WORKSHOP SAFETY WORKSHOP SAFETY
o Technicians must put on shoes & dressing should not be very loose. o Safety Precautions while Operating Air Tools
o Technicians must use Personnel Protective Equipment (PPE) like - Hand Gloves Air tools operate on compressed air supplied by the shop air system
- Mask (Compressor & Air supply system).
- Safety Goggle
Observe the following safety related precautions when using an air tool.
- Ear Plug
o Wear Nitrile Rubber Hand Gloves while handling petrochemicals like petrol, • It is advisable to fit a pressure regulator (FRL:- Filter Regulator Lubricator)
Oil, Kerosene etc. in the pneumatic line which supplies air pressure to the air tool. It
regulates the outlet pressure to @6.5 Kg/cm2. This avoids the risk of
personal injury.
• Never use the blow gun to blow dust off your clothes and never point it at
anyone. The air pressure can drive dust particles at high speed. These
particles can penetrate into the flesh or eyes. High pressure air hitting on
open wound can force air into the blood stream. This can result in death.
• Never look into the air outlet of a pneumatic tool.
• Never blow-clean brake or clutch parts. This could put asbestos dust
particles into the air which are harmful to inhale. (These particles are
cancerous - can lead to Cancer).
o Precautions to be taken while handling MRTB Test

- Take care that the vehicle is properly clamped in the clamping device, otherwise it
may go back with a force and can injure the rider.
- Keep yourself cool while taking tests. It is very necessary to be alert.
- Mount the vehicle in the center of the rollers. o Hand Tools
- Fuel pipe should not touch heated part of the vehicle, it may cause fire. - Do not use worn out hand tools.
- Make sure to put on air blower while conducting test to avoid engine overheating.
o Calibration of Workshop Equipment
- Lock The Front Wheel Properly
- Calibrate all Workshop and M & T Equipment once in a year.
- Ensure that exhaust blower is running.
- Wear Helmet o Avoid direct body contact with Petrol, Kerosene.
- Wear ear plugs Caution : Prolonged contact of used oil may cause cancer.
o Precautions to be taken while handling CO Gas Analyser o Waste Oil Disposal
- Use hand gloves for protection from hot silencer.
- Sell used oil to Government approved re-cycle agencies.
- Use mask for protection from exhaust gases.
- Collect used oil in oil disposer / barrel.
- Ensure proper ventilation.
- Don’t throw oil into sewage line.
o Fire Extinguisher - Don’t spill oil on the floor.
- Install ‘ISI’ approved. Fire extinguishers - CO2 gas cylinders.
- Refill CO2 before the gas expires.
- Install Co2 gas cylinder at appropriate place so that there is no obstruction / good
accessability.
108 109
WORKSHOP SAFETY
o Precautions to be taken while handling Hydro-Electric Lift

- While raising / lowering the lifter bay ensure that vehicle is firmly hold on the
lifter bay to avoid accident.
- After raising the lifter bay, lock the lift.
- Don’t put leg/hand in between while raising / lowering the lifter Bay.
• Safety Tips
- Do not lower the lifter bay table without unlocking the mechanical lift lock.
- Do not keep your leg between the top and bottom frame while lowering the
lifter bay.
- Do not work with loose clothing while working on the lifter bay.
- Do not keep hydraulic joints loose.
- Do not stand on the lifter bay’s top, when it is being operated.
- Special care is to be adopted to avoid injuries if either leg or hand is entagled
between.
- Keep off direct fire near the power pack.
- Avoid oil spillage around the working area for safety reasons.
o Brake Shoe Cleaning

- Don’t inhale brake shoe lining dust. The dust could be Cancerous.
o Battery Acid Handling

- Use hand gloves.
- Wear Apron.
- Wear Safety Goggle
- Avoid contact of battery acid with skin
- Use plastic trays for keeping batteries while charging.
- Avoid Spillage of battery acid.
o Brake Fluid Handling

- Store brake fluid in sealed container
- Avoid contact of brake fluid with skin.
- Don’t spill the brake fluid on painted components
o Electrical Wiring
- Carry out periodic checks & repairs
- Electrical board & Main Switch must be located such that
they are easily accessible.
110
DISCOVER DTS-Si TRAINING NOTES DEALER DEVELOPMENT CENTER

I Read ..... I Learn: Discover Dts-Si Training Notes Dealer Development Center

Uploaded by

Copyright:

Available Formats

I Read ..... I Learn: Discover Dts-Si Training Notes Dealer Development Center

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

I Read ..... I Learn: Discover Dts-Si Training Notes Dealer Development Center

Uploaded by

Copyright:

Available Formats

Contents

1 I Read ..... I Learn 1

4 Engine & Transmission 47

DISCOVER DTS-Si TRAINING NOTES DEALER DEVELOPMENT CENTER

I Read ..... I Learn

Frame Number Location

Engine Number Location

1. RH Control Switch 7. DTS-Si Engine - 5 Speed Transmission

Features Advantages Benefits Features Advantages Benefits

COMFORT AND CONVENIENCE SAFETY

Features Advantages Benefits Features Advantages Benefits

Engine & Transmission Controls

Chassis & Body Weights

POWER AND PERFORMANCE COMFORT AND CONVENIENCE

Engine Cubic Capacity 4 Stroke 4 Stroke 4 Stroke DTS-Si technology Telescopic

Kick Start Tubular Tubular Tubular Strong & robust frame

PDI SOP & Time Chart

Periodic Maintenance Chart

Periodic Maintenance Points

Frame No. M D 2 D S P A Z Z To Check Check For

3 if OK or Observations / Front fender bolts - 1.0 ~ 1.2 Kgm

Position RECOMMENDED FREQUENCY

Whichever RECOMMENDED FREQUENCY Position

GPT : Spark plug spanner, Cloth, Fine

Note : Engine Oil Level Checking

Recommended Drain & Refill 1000 ml

Oil Strainer Cleaning Air Filter

• Drain engine oil. • 3 flange bolts (A) (8m A/F). B

Note / Skill Tip :

1st Stage: CLEANING PROCEDURE Battery (MF)

Nitrox Rear Shock Absorber

Adjusting Spring Tension

Note: Standard setting is done in 1st notch.

Drive Chain Slack / Lubrication

Chain Slack Adjustment SOP Drive Chain Cleaning

• Loosen the rear brake adjuster • Pre-Tighten the coupling sleeve

• Loosen the axle nut. • Tighten the coupling sleeve nut

Tyre Air Pressure

Tappet Clearance Setting Accelerator Free Play Adjustment

¡ Inlet Valve : 0.05 mm ¡ Accelerator Grip Free Play : 2 ~ 3 mm

Carburettor Working of Systems

Carburettor Dos & Don’ts

CO Checking & Setting

Tune up for Optimum Mileage

Identification : ‘AW7’ mark on casting, Yellow coupler

STARTER SYSTEM - AUTO CHOKE - A STARTER SYSTEM - AUTO CHOKE - B

Fuel Well Float Chamber

3 Dos 7 Don'ts Readiness of CO Gas Analyser Taking the Reading

TPS - Hall Sensor Checking AIR FILTER :

Voltage check in WOT condition:

Introduction Exclusive Special Tools

DTS-Si System Application : To pull out the rotor from

Other Common Special Tools Other Common Special Tools

Primary Gear Holder Valve Tappet Adjuster

Socket for Clutch Nut Rocker Shaft Remover

Rotor Dismantling Tool (For Kick Start) Bearing Extractor

Clutch Dismantling Tool Adaptor & Valve Spring Compressor

Spark Plug Spanner Drift Piston Pin

Output Sprocket Holder