Training Notes

The Training Notes are

a

compr

ehensive

training guide

on

service

and

maintenance operations

and

pr

ocedu r

es

to be

followed

by

service

personnel

at

authorised service centres

and

dealerships whilst attending

to the

Bajaj Discover125-UG.

The Training

Note

covers standard workshop procedures

simplified for easy learning and

understanding for service

technicians

worldwide.

NOTICE

All information contained in this Training Note is based on

the latest product information at the time of publication.

Bajaj Auto Limited accepts no liability for any inaccuracies

or omissions in this publication, although every possible

care has been taken to make it as complete and accurate

as possible. All procedures and specifications subject to

change without prior notice. The right is reserved to make

such changes at any time without prior notice.

Copyright

All Intellectual Property Rights, including but not limited

to Copyright, applying to this drawing and the information

contained therein vest solely and exclusively with Bajaj

Auto Limited. No part of this drawing may be copied or

reproduced, either in part or in full by any means, whether

mechanical or electronic, without prior written permission

of the authorized signatory of Bajaj Auto Limited. Bajaj

reserves all rights to deal with violations of this clause in

accordance with applicable laws.

©

Bajaj Auto Limited, 11

th

SEPT 2012.

DOC. NO.: 71112879,

REV. 00, March 2018

CIN L65993PN2007PLC130076

Contents

CHAPTER

1

I Read ..... I Learn

Identification

Salient Features

Technical Specification

Pre-Delivery Inspection Check List

Periodic Maintenance & Lubrication Chart

01

02

03

06

08

10

CHAPTER

2

Fuel System 13

14

15

16

18

19

CHAPTER

3

Engine & Transmission

21

22

25

27

38

40

42

44

CHAPTER

4

Vehicle (Frame)

Special Tools

Service Limits

Tightening Torques

Dos & Don’ts

46

47

49

50

51

CHAPTER

5

Electricals

54

55

61

67

68

53

Carburettor Specifications

Overview of Fuel System

Secondary Air Induction (SAI) System

Evaporative Emission System

Tune-up for Optimum Mileage

Special Tools

Engine Removal from Frame

Engine Dismantling & Assembling

Service Limits

Tightening Torque

Engine Lubrication Flow of Oil

Dos & Don’ts

Battery Specifications

Electrical Checking Procedure

Important SOP

Dos & Don’ts

Electrical Wiring Diagrams

I Read ..... I Learn

CHAPTER 1

Identification

Salient Features

Technical Specifications

Pre-Delivery Inspection Check List

Periodic Maintenance & Lubrication Chart

1

Bajaj Discover 125 UG Training Notes

Key Learning Points

Understanding the Complete Anatomy of

the Vehicle

Technical Specifications and Performance

Parameters

Briefing and Educating the Customer on

Appropriate Riding and Usage Discipline,

and Routine Maintenance

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Speedometer Details

1. Speedometer:

Vehicle speed will be displayed in speedometer in Km / Hr.

2. Odometer :

The Odometer shows the total distance that the vehicle has covered.

Odometer can not be reset to ‘Zero’.

3. Turn Signal Indicator (LH & RH) :

When Turn signal switch is turned to left or Right, Turn pilot Indicator -

LH or RH will flash.

4. Neutral Indicator:

When the transmission is in Neutral, Neutral indicator will glow.

5. Fuel Level Indicator:

It shows fuel level in fuel tank.

6. Low Fuel Indicator :

It blinks incase of low fuel level (1 bar or less).

7. Hi Beam Indicator:

When Headlight is ‘ON’ & Hi beam is selected, Hi beam indicator will

glow.

8. Low Battery Indicator :

It indicates battery needs charging.

9. Bajaj Logo:

Bajaj logo flying ‘B’ continuously glow.

10. Service Reminder:

If the Odometer reading reaches below values : 450 Km, 4450 Km, 9450

Km, 14450 Km & so on after every 5000 Km up to 999450 Km (If prior

reset is not done). It should continue the same sequence above even

after roll over.

11. Side Stand :

Active Low (Vin < 0.5V)

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)

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.

Chassis Number & Engine Number Location

Identification

I Read ..... I Learn

3

Bajaj Discover 125 UG Training Notes

Salient Features

ENGINE:

BRAKES & TYRES:

FRAME:

Features :-

• 124.5 cc Engine.

• 4 stroke, Air cooled, Single Cylinder, SOHC, DTS-I

• 11 Ps @ 7500 rpm & 11 Nm @ 5500 rpm

• Cellulose-based clutch for easy gear shifts.

Benefits :-

• Most fuel efficient bike.

• Better drive-ability and the beat fuel economy.

• Easy maneuverability during traffic.

Features :-

• 200 mm dia front brake disc and 130 mm dia rear brake drum.

Benefits :-

• Spider mug-wheels

Features :-

• Telescopic front fork with anti-friction bush & 140 mm stroke.

• Nitrox rear suspension with 120 mm wheel travel.

Benefits :-

• 16% longer travel vs. competition bike.

• Superior comfort, even on bad roads.

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Salient Features

STYLE & COMFORT:

Features :-

• Youthful Styling.

• Dual texture seat fabric with stitch line.

• Modern Side Panels.

• Enhanced Comfort.

• Dual-textured seat with stitch-line.

• Enhanced cushion for greater riding comfort.

ELECTRICALS:

Features :-

• DC Head Lamp with 12V, 35/35W, (Halogen)

• Double LED DRL headlamps

• Textured Tail-lamp Bezel

• 12V-5Ah MF Type (Electric Start)

Benefits :-

• Bold, head-turner.

• ‘Invented Horns’, makes a statement even from a distance.

• Lower battery power consumption, leading to higher mileage.

5

Bajaj Discover 125 UG Training Notes

Salient Features

I Read ..... I Learn

ELECTRICALS:

Features :-

• Full Function Digital Instrument Cluster.

• Digital speedometer for accurate speed reading.

• Back-lit Display adds style and ease of reading.

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Technical Specifications

Engine & Transmission

Chassis & Body

Type : 4 stroke, Air cooled, Single Cylinder, SOHC,

DTS-I

No. of cylinders : Single

Bore : 52.0 mm

Stroke : 58.60 mm

Engine displacement : 124.5 cc

Compression ratio : 9.8 : 1

Idling speed : 1400 ± 100 in warm condition

Max. net power : 11 Ps @ 7500 rpm

Max. net torque : 11 Nm @ 5500 rpm

Ignition system : Load based CDI controlled

Carburettor : VM20 (UCAL)

Spark plug : Champion PRZ9HC & BOSCH UR4AC (Resistive)

Spark plug gap : 0.7 to 0.8 mm.

Lubrication : Wet sump, Forced lubrication

Primary resuction : 3.57 : 1 (75/21)

Gear ratios 1st Gear : 2.83 : 1 (34/12)

2nd Gear : 1.824 : 1 (31/17)

3rd Gear : 1.333 : 1 (28/21)

4th Gear : 1.087 : 1 (25/23)

5th Gear : 0.909 : 1 (20/22)

Final drive ration : 3.0 : 1 (42/14)

Transmission : 5 Speed Constant mesh (1D 4UP)

Frame Type : Semi double cradle frame

Suspension Front : 140 mm Fork travel, Telescopic

Rear : 120 mm Rear Wheel travel, Nitrox (Gas filled)

Brakes Front : Hydraulic operated, 200 mm dia. disc

Rear : Mechanically expanding shoes, 110 mm dia. drum

Tyres Front : 2.75 X 17

Rear : 100/90- 17

2

Tyre Pressure Front : 1.75 Kg/cm (25 PSI)

2

Rear (Solo) : 2.00 Kg/cm (28.5 PSI)

2

Rear (with Pillion) : 2.25 Kg/cm (32 PSI)

Rims Front : 1.4 X 17" Die Cast Aluminium Alloy Wheel

Rear : 2.15 X 17" Die cast Aluminium Alloy Wheel

Fuel Tank Capacity : 8.0 Liters

Usable Reserve : 1.5 Liters

Unusable Reserve : 0.8 Liters

Speedometer : Digital

7

Bajaj Discover 125 UG Training Notes

Technical Specifications

Electricals

System : 12 Volt (DC)

Battery : 12V-5Ah MF Type

Head Lamp : 12V, 35W / 35W, HS-1 (Halogen),Blue ting DRL

Watts 5.4 & Position lamp is 0.4 Watt.

Stop / Tail Lamp : 12V, 5W / 21 W

Side Indicator Lamp : 12V, 10W (4 Nos. - RY 10W)

Position Lamp : DRL

Rear No. Plate Lamp : 12V, 3W

Speedometer Lamp : LED

Neutral Indicator : LED

Turn Signal Indicator : LED

Hi-beam Indicator : LED

Reserve indicator : LCD

Fuel Gauge : LCD

Horn : 12V, DC

Grade : 20W50 API SL / JASO MA

Drain & Refill : 1000 ml

Overhaul : 1100 ml

Notes :

• Values given above are nominal & for guidance only, 15% variation is allowed

to cater for production & measurement.

• All dimensions are under un-laden conditions.

• Definitions of terminologies wherever applicable are as per Relevant IS/ISO

standards.

• Specifications are subject to change without notice.

Dimensions

Weights

Engine Oil

Length : 2035 mm

Width : 760 mm

Height : 1085 mm

Wheel Base : 1305 mm

Saddle height : 805 mm

Turning Circle Radius : 2100 mm (min)

Ground Clearance : 165 mm

Vehicle Kerb Weight : 122 Kg.

Gross Vehicle Weight : 252 Kg.

I Read ..... I Learn

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Pre Delivery Inspection Check List

1. Check points before starting of the vehicle

Check & correct the below check points before starting the vehicle

To Check Check for

? If Ok

X If Not Ok

Engine oil Oil level between lower & upper mark / Top up if required

Fuel tank / pipes

No leakage / Correct fitment

Mirror

Fitment & adjustment to ensure clear rear view

Lock Operation Steering cum Ignition lock, LH side cover lock, Petrol tank cap lock

Battery

Check battery Terminal voltage. Fully charged battery voltage should be >

12.4 V DC. Charge battery if required using recommended battery charger.

Tightness of battery terminals / cables / Petroleum Jelly application

Tyre Pressure

Front: 1.75 kg/cm (25.0 psi)

Rear: 2.25 kg/cm (32.0 psi)

Brakes

Front brake cable free play 4 ~ 5 mm

Rear brake pedal free play 20 ~ 25 mm

Clutch cable

Free play 2 ~ 3 mm

Drive chain

Slackness 25 ~ 30 mm

Equal marking of chain adjusters on both side

No touching to chain case after adjustment.

Fasteners (Check torque)

Recommended torque wrench

to be used for applying torque

on nut - bolts as mentioned in

PDI check sheet using

reference torque chart as

given.

However, if any major parts are

required to be removed (Except

side cover & seat) for

accessibility of torque wrench, in

those cases the tightness can

be ensured using open end /

ring spanner / box type spanner

as applicable without removing

those major parts

Engine foundation bolts - Front 1.8 to 2.2 Kg.m

Engine foundation bolts - Rear 2.8 to 3.2 Kg.m

Engine foundation bolts - Top 1.8 to 2.2 Kg.m

Front Axle Nut 4.5.0 to 5.5 Kg.m

Rear Axle Nut 8.0 to 10.0 Kg.m

Front Fork top bolts 3.0 to 3.2 Kg.m

Front Fork under bracket bolts 3.0 to 3.2 Kg.m

RSA mounting nut (Upper) 3.0 to 3.2 Kg.m

RSA mounting nut (Lower) 2.8 to 3.2 Kg.m

Swing arm shaft nut 4.5 to 5.5 Kg.m

Rider Foot Rest Mounting 1.8 to 2.2 Kg.m

LH & RH Pillion stay Bolts 1.8 to 2.2 Kg.m

Ço Check Check for

? If Ok

X If Not Ok

9

Bajaj Discover 125 UG Training Notes

Pre Delivery Inspection Check List

I Read ..... I Learn

2. Check points during / after starting the vehicle

Check & correct the below check points during / after starting the vehicle

Switch operation

RH & LH control switch, ignition switch, clutch switch & brake switch (Front &

Rear)

Horn Ensure no distorted sound

All Bulbs working Headlight, Tail / Stop lamp, Side indicators, Speedo bulbs, Number plate bulb

Speedometer

(As applicable)

Working of speedometer, Odometer, Fuel gauge.

Working of all signal indicators icons (Neutral, Turn signal, High beam)

Headlamps Focus confirmation

3. Check points during Test ride

Check & correct the below check points during Test ride

Gear shifting Smooth operation

Drive-ability

Throttle response

Brake effectiveness - Front & Rear

Engine noise No abnormal noise

Front fork / steering

Smooth working by pumping movement & smooth operation (No play / No

Sticky movement)

Oil leakages Specify source of leakages & rectify if any.

4. Idling RPM / CO%

Check & correct the below check points in engine warm condition

Idling RPM

(Engine warm up

condition)

SAI connected – 1350 to 1450 rpm (@ 60°C)

SAI disconnected – 1300 to 1400 rpm (@ 60°C)

CO% Check

SAI connected - < 1% (@ 60°C at idling rpm)

SAI disconnected – 4.0% to 5.0% (@ 60°C at idling rpm)

5. Visual inspection for dent, scratches, rust ...

6. Clean the vehicle thoroughly before delivery to customer.

Periodic Maintenance & Lubrication Chart

      

10

Bajaj Auto International Business

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Sr

No

PM Check Point

Recommended Frequency

Remark

Service

1st

2nd

3rd

4th

5th

6th

7th

Kms

500

4500

9500

14500

19500

24500

29500

~

750

5000

10000

15000

20000

25000

30000

1

Servicing with water wash

Ensure to prevent water

entry in Petrol tank,

Silencer & electrical parts.

Use caustic free detergent

for washing.

2

Engine oil (Bajaj DTSi 10000 oil) &

engine oil filter*

C,R

R

T

op

Up

R

Top

Up

R

T

op

Up

R

"BGO DTS-i 10W30 for 100cc

models. BGO DTS-i 20W50 for

models above 125cc. "

3

Oil strainer, Body centrifugal filter**

CL

Oil strainer cleaning at the time

of

oil

change.

Clean body

centrifugal

filter at

1st

free

service

&

at 20,000 kms

4

Starter Clutch (Dry

Type)**

L

Use recommended molycote

grease

5

Spark plug

CL,A,R

CL,A

R

6

Air Cleaner Element *** & Cover "O" Ring

CL,R

CL

R

CL

R

Foam & Paper as applicable.O ring

check at every service & Replace if

cut/damaged

7

In line paper filter or Fuel cock paper filt er

R

8

Fuel cock sediment bowl cleaning

CL

9

Carburetor rubber duct

C,R

Check & replace if required

10

Fuel pipe

C,R

C

R

C

R

1

V

alve tappet clearance

C,A

12

Non-Sealed drive chain cleaning &

lubrication

CL,L,A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

• During

1st

free

service

: Use

lint

free cloth

for cleaning &

SAE

90 oil

for

lubrication

without removing

from vehicle.

(If chain

is excessively dirty, then

chain

has to

be

removed, cleaned

using

diesel &

lubricated

using

mo

l

te

n

I

OC

se

r

v

o

c

o

mp

o

u

nd

chain

grease.)

• Dur

ing

all o

th

e

r

ser v

i

c

e

s:

R

emo

v

e

, c

l

e

a

n u

sin

g

d

i

esel

&

l

u

br

icate

d u

sing

mo

l

t

en

cha

i

n

grease.

13

Sealed drive chain cleaning & lubrication

CL,L,A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

CL,L,

A

•

During

regular

service

use

OKS

s

pra

y

f

o

r

c

h

ain c

lean

in

g

,

w

i

t

ho

u

t

removing chain

from vehicle.

• If chain is

excessively dirty,

then

chain

has

to

be

cleaned

by

removing

from vehicle.

(Customer to

apply

OKS chain

lube

spray at

every 500 Kms)

14

Engine air breather tube

C

Replace if damaged

15

Silencer drain hole cleaning

CL

16

Silencer tail pipe cleaning **

CL

17

Brake lining or pad wear & lubricate brake

cam & pivot pin** Check pad wear indicator

C,L,R

C

C,L,R

R

C,L,R

R

Replace brake shoe/pads at

every 15,000 kms

Periodic Maintenance & Lubrication Chart

* It is strongly recommended to use only Bajaj genuine oil, in case of any other engine oil of same specification is used the would be every 5000 kms

** As applicable to model

*** more frequent cleaning is required while driving in dusty environment

C: Check, A: Adjust, CL: Clean, R: Replace, T: Tighten, L: Lubricate

Note :- Periodic parts / lubricants as per periodic maintenance & Lubrication chart are mandatory & the same is chargeable to customer

11

Bajaj Discover 125 UG Training Notes

I Read ..... I Learn

Sr

No

PM Check Point

Recommended Frequency

Remark

Service

1st

2nd

3rd

4th

5th

6th

7th

Kms

500

4500

9500

14500

19500

24500

29500

~

750

5000

10000

15000

20000

25000

30000

18

Brake fluid level ** - top up / replace

C,A,R

C,A

R

Use recommended

DOT

3/4 brake fluid

19

Disc brake assembly–-check functionality

,

leakage or any other damage

C

Replace if damaged

20

All cables & rear brake pedal - free play

C,A

21

Battery electrolyte level , specific gravity

C,A,T

Not applicable for VRLA

batteries

22

Wiring harness & battery connection -

routing, tie bands & clamps tightness

C,A,T

C,A,

T

C,A,T

23

Ignition switch barrel cleaning & handle bar

control switches contacts cleaning

C,CL

Use recommended Wd40

spray

24

Steering play

C,A

25

Steering stem bearing *** & cap steering

bearing (Plastic)**

C,CL,

L,R

C,CL,

L,R

C,CL,

L,R

C,CL

Check & replace if

damaged.Use HP

Lithon

RR3 grease for lubrication

26

Main stand & side stand pin **

CL,L

Use recommended AP

grease

27

Swing arm pivot pin

(For non silent bush)**

L

Not applicable in case of

needle roller bearing

28

All fasteners tightness

C,T

29

Engine foundation silent bushes **

C

Replace if damaged

30

General lubrication - clutch lever

, front brake

lever

, kick lever

L

Use recommended

AP

grease

31

Idle speed / CO%

C,A

32

Coolant level in expansion tank

**

C,A

R

Use recommended 'Ready

to Use coolant'.Replace at

every 30000 Kms or 2

years (Whichever occurs

earlier)

33

Coolant hose damage / clamps / leakage **

C

Check & replace if required

34

Radiator fins **

C

Check & replace if required

35

Spoke tightening ** - Front & Rear

C,T

36

Front fork dust seal area & inner pipe

cleaning**

CL

Applicable for front fork

with rubber bellow

37

SAI system / EV

AP

hoses - Check functionality

,

leakage or any other damage**

C, R

Replace if cut / damaged

38

Pillion foot rest hinge lubrication**

L

Use RR 3 Grease

39

EVAP

Y

connector drain tube

CL

Notes

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