Contents

CHAPTER

2

3

4

5

I Read ..... I Learn

Fuel System

Engine & Transmission

Frame & Suspension

Carburetor Specification

Engine Tune up

Tightening Torques

Service Limits

Special Tools

Removal of Engine from Frame

Tightening Torques

Service Limits

Special Tools

Standard Operating Procedure

5

47

51

82

Vehicle Identification & Controls

Salient Features

Periodic Maintenance & Lubrication Chart

Pre-delivery Inspection Checklist

PM SOP’s

SOP for Engine Dismantling

Engine Lubrication Flow of Engine Oil

Important Bolts Tightening Sequence

83

85

87

89

52

55

57

60

63

79

81

49

48

6

8

10

12

15

Contents

CHAPTER

5

Electrical

Battery Technical Specification

Standard Operating Procedure

Electrical Checking Procedure

Electrical Circuit Diagrams

92

93

95

98

107

Bajaj Platina 125 Training Notes

1

I Read... I learn

CHAPTER 1

Vehicle identification & controls

Salient Features

Technical Specifications

PM Schedule

PDI Check sheet

PM SOP

Key Learning Points

Understanding the complete anatomy of

Vehicle

Technical Speciﬁcations and Performance

Parameter

Brieﬁng and Educating the customer on

Appropriate Riding and usage Discipline

and Routing Maintenance

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 Side of Steering Tube

(Alpha-Numeric - 17 Digits)

Engine Number Location

On LH Side Crankcase Near Gear

Change Lever (Alpha-Numeric - 11 Digits)

1. Odometer : The Odometer shows the total

distance that the vehicle has accumulated.

2. Speedometer : The Speedometer pointer

shows the speed of vehicle.

3. Neutral Indicator : When the transmission

is in Neutral & Ignition switch is ‘ON’, the

Neutral indicator will get ‘ON’.

4. Steering cum Ignition Switch : Key

operated switch for ignition ‘ON’ / ‘OFF’ &

locking handle bar.

5. Fuel level indicator : It shows approximate fuel

level in fuel tank.

6. Bajaj logo : Bajaj logo flying ‘B’ .

7. Hi Beam Indicator : When Headlight is

‘ON’ & Hi beam is selected with engine

running, Hi beam indicator will get ‘ON’.

8. Turn Signal Indicator (LH & RH) : When

Turn signal switch is turned to Left or Right,

Turn pilot indicator - LH or RH will flash.

Chassis Number & Engine Number Location

Speedometer Details

Vehicle Identification & Controls

2

Bajaj Auto International Business

1

I Read... I learn

1

2

3

5

6

7

8

N

4

: All lamps 'OFF'.

: While engine running, Head lamp, Pilot

lamp, Tail lamp & Meter lamps ‘ON’.

Right Handle Bar Switches

E. Head Light Switch : It has 2 positions.

To Lock the Steering : To lock the steering, turn the handle bar to the left

or right. Push the key inside & turn toward ‘LOCK’ position. Match the

lock position & turn key to ‘LOCK position. Lock steering & remove key.

To Unlock the Steering : To unlock steering, insert the key in steering

cum ignition lock & turn it clockwise to “OFF” or “ON” position.

Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank

cap’ & ‘Side cover RH lock’.

F. Starter Button : It operates the electric starter when clutch lever is

depressed with transmission in any gear. It is recommended to start

engine with transmission in neutral.

Steering cum Ignition Lock

Key Position

Function

LOCK: Steering locked. Ignition OFF.

OFF: Steering unlock. Ignition OFF.

ON: Steering unlock. Ignition ON.

I Read... I learn

Vehicle Identification & Controls

3

Bajaj Platina 125 Training Notes

Left Handle Bar Switches

A. Hi / Low Beam Switch : When headlight is ON, High or Low beam

can be selected with the Hi / Lo switch. Hi beam indicator light in

speedo console will glow when high beam is selected.

: High Beam : Low beam

B. Turn Signal Switch: When the turn signal switch is turned to

Left ( ) or Right ( ), corresponding turn signals flash on & off.

To stop flashing, press the switch IN.

C. Horn Switch : ( ) Press horn switch for sounding horn.

A

B

C

D

E

F

D. Pass Switch : ( ) Press the switch to flash the head light in hi

beam mode. It is used to give signal to vehicles coming from

opposite side while overtaking.

PERFORMANCE

Attribute

Key Features Advantages

Benefits

· 2 Valve Engine

· Engine power: 11 PS

@ 8000 RPM

· Engine torque: 10.9 N-

m @ 6000 RPM.

· DC ignition system.



· Electric / Kick start

New generation technology

engineered for high power,

pick up & performance.

· Wider range of gear

ratios to utilize high

torque of engine.

· Seamless changes in

ignition maps for better

engine performance.

· Quick & easy starting

· High power & pick up.

· More power at all loads

c o n d i t i o n s , b e t t e r

torque at low RPM,

less emissions.

STYLE

· Athletic & Muscular

petrol tank, side covers

& seat cowling.

· New head lamp with

attractive fairing.

· Innovative & distinct

decals.

· New look Speedometer.

· Black colored engine

· New look 5 spokes alloy

wheels & silencer

· Stylish & eye catching

looks.

· Combination of black &

chrome styling.

· Sporty styling.

COMFORT

· Telescopic front fork with

135 mm stroke with anti-

friction bush

· Hydraulic spring in spring

Twin suspension at Rear

· VRLA battery

· Better shocks dampening

on rough road drives.

· L on g es t s u s p en s io n

stroke in its class of

bikes

· No topping required

· Excellent drive ability,

smooth & comfortable

ride on all types of

r o a d s & f o r a n y

distance

· No hassle of frequent

topping up of electrolyte

level.

· Instant Self start

Salient Features

2

Bajaj Auto International Business

1

I Read... I learn

CONVENIENCE

Attribute

Key Features Advantages

Benefits

· Fuel Gauge

· Engine oil level window

Self Start

· Displays approx. petrol

quantity remaining in petrol

tank reminds rider for

refueling.

· For easy inspection of oil

level

· More convenience

· Easy monitoring of oil

level.

SAFETY

Attribute

Key Features Advantages

Benefits

· Disk Brake :

· 200 mm disk brake at

front & 110 mm drum

brake at rear.

· High strength robust

Tubular Single Down

Tube with Lower

Cradle frame

Wheelbase 1255 mm

· Excellent ride & handling

stability, balance & vehicle

dynamics.

· Highest stability & excellent

road grip.

· Safe to drive on highway

I Read... I learn

Salient Features

3

Bajaj Platina 125 Training Notes

Engine & Transmission

Type : 4 stroke engine, Single Cylinder, Air cooled, DTS-I

No. of cylinders : Single

Bore : 52 mm

Stroke : 58.6 mm

Engine displacement : 124.45 cc

Compression ratio : 9.8 : 1

Idling Speed : 1400 ± 100 rpm in warm condition

Max. net power : 11 Ps @ 8000 RPM

Max. net torque : 10.9 Nm @ 6000 rpm

Ignition System : CDI / 12V DC

Carburettor : VM20 UCAL

Spark Plug : Champion P- RZ9HC / BOSCH UR4AC

2 Nos

Spark Plug Gap : 0.7 to 0.8 m.m.

Lubrication : Wet sump, Forced lubrication

Clutch : Wet, Multi disc type

Starting : Electric & kick start

Gear shifting pattern : 1 Down 4 Up

Transmission : 5 Speed Constant mesh

Primary reduction : 3.571 : 1 (75/21)

Gear Ratios 1st Gear : 2.833 : 1 (34/12)

2nd Gear : 1.823 : 1 (31/17)

3rd Gear : 1.333 : 1 (24/18)

4th Gear : 1.086 : 1 (25/23)

5th Gear : 1.909 : 1 (20/22)

Final Drive Ratio : 3.00 : 1 (42/14)

Frame Type : Tubular Single Down Tube with Lower

Cradle frame

Suspension Front : Hydraulic, Telescopic, 135 mm travel

Rear : SNS, Stroke 95 mm

Brakes Front : Disc Brake - Hydraulic operated

Rear : Mechanically expanding shoes

Brake Size Front : Disc dia. 200 mm

Rear : Drum dia. 110 mm

Tyres Front : Front : 2.75 x 17, 41 P

Rear : Rear : 3.00 x 17, 50 P

Tyre Pressure Front : 1.75 kg/cm2 (25 PSI)

Rear (Solo) : 2 kg/cm2(28 PSI)

Rear (Solo+Pillion) : 2.25 kg/cm2(32PSI)

Rims Front : Front-1.4 X 17” Die cast Aluminium alloy wheel

Rear : Rear-1.6 x 17” Die cast Aluminium alloy wheel

Fuel Tank Capacity : 11.5 Liters

Usable Reserve : 1.5 Liters

Unusable Reserve : 0.5 Liters

Chassis & Body

Technical Specifications

2

Bajaj Auto International Business

1

I Read... I learn

System : 12V, DC

Battery : 12V 3Ah VRLA

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

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

Side Indicator Lamp : 12V, 10W (4 Nos. - RY10W)

Position Lamp : 4.09 W max for DRL & 0.42 W max for

position

Speedometer Lamp : 12V 2 W X 2

Neutral Indicator : 12V 2 W (Green)

Turn Signal Indicator : 12V 2 W (Green)

Hi-beam Indicator : 12V 2 W (Blue)

Horn : 12V 2 A

Fuel Gauge : Analog

Vehicle Kerb Weight : 113 Kg.

Gross Vehicle Weight : 241 Kg.

Maximum speed : 95 km/hr (with single rider 68 kg)

Notes :

• Values given above are nominal and for guidance only.

• 15% variation is allowed to cater for production and measurement

• All dimensions are under UNLADEN condition.

• Definitions of terminologies wherever applicable are per relevant IS/ISO standards.

• Specifiactions are subject to change without any notice.

Steering : Handle bar

Accelerator : On handle bar, RH grip

Gears : Left foot pedal operated, Step shift

Brakes Front : On handle bar, RH lever

Rear : Pedal operated by RH foot

Clutch : Lever operated, LH

Controls

Electricals

Length : 2003 mm

Width : 704 mm

Height : 1069 mm

Wheel Base : 1255 mm

Ground Clearance : 200 mm

Dimensions

Weights

Performance

I Read... I learn

Technical Specifications

3

Bajaj Platina 125 Training Notes

7.

Oil for drive chain SAE 90

Non sealed type drive chain

Electrical contact

cleaning spray

WD-40 Spray

Ignition switch / Brake & clutch switch /

LH/RH control switch.

8.

11.

Loctite

Rear fender bottom mounting / Cam sprocket allen bolt /

Pickup coil screws / Stopper plate screws / (gear starter clutch)

/ Kick guide bolts / Output sprocket bolts / Oil pump mounting

bolt / Allen bolt securing guide gear on shift drum /

Screw securing stopper for input shaft bearing / Special bolt

guide chain slack side / Nut inhibitor mounting / Nut clutch

mounting / Damper plate bolts clutch & magneto cover /

Stator mounting bolts / Stator harness clamp plate screw.

Thread locker 243

Liquid gasket

Loctite L 5702

• Crankcase joining surface.

Sr.

No.

Lubricant /

Loctite

Grade

Application

1.

Engine oil

Fork oil

SAE 20W50 API-"SL"/

JASO-"MA 2"

SAE 10W20

Quantity :

Refill at Service - 1000 ml / Engine O/H - 1100 ml

Quantity / fork leg : 150 + 2.5 ml

2.

Grease

Lithon RR-3

Molycote

Gear starter clutch & Rollers starter clutch

Steering races & balls HP make

4.

Grease

All purpose

• Fr. & rear wheel axle.

• Swing arm shaft

• Brake pedal pivot pin

• Center stand shaft

• Side stand U bracket

• Gear shifter pivot

• Clutch & fr brake lever

6.

5.

3.

Oil / Grease / Loctite application matrix

2

Bajaj Auto International Business

1

I Read... I learn

Sr

No

PM

Check Point

Recommended Frequency

Remark

Ser

vice

1st 2nd 3rd

Kms

500 4500 9500

~

750 5000 10000

1

W

ater wash & dr

y the vehicle

completely

Take care that

no water

enters

in

P

e

trol

t

ank, S

i

le

nc

e

r &

in

electrical

parts.

Use caustic

free

detergent for

washing.

2

Engine oil & Engine oil filter

C,R R

R

R R R

3 Oil strainer

CL

CL CL

CL

Oil strainer cleaning at ever

y oil

change

4

Starter Clutch (Dry Type)** L L

L L L

L

Use recommended molycote

grease

5

Spark plug CL

,A,R

CL

,A

CL

,A

R

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

CL,R

CL

R CL

CL

R

7

Fuel cock sediment bowl cleaning CL

CL

8

Carburetor rubber duct C,R

C,R

Check & replace if required

9

Fuel pipe

C,R

C

R C

C R

10 Valve tappet clearance

C,A

C,A C,A

C,A

11

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

Customer to apply OKS chain lube

spray or equivalent at every 500

kms.

12 Engine air breather tube

C

C C

C

C C

13

Silencer drain hole cleaning

CL CL

CL

CL CL

14

Silencer tail pipe cleaning **

CL CL

CL

15

Brake lining wear / lubricate Brake cam - Check

brake wear indicator

C,L,R

C

C,L,R

C,L,R C,L,R C,L,R

C,L,R C,L,R

Use recommended AP

grease

Periodic Maintenance & Lubrication Chart

2

Bajaj Auto International Business

1

I Read... I learn

Ever

y 5000 Km

after Previous Ser

vice

SAE 20W50 API-"SL"/

JASO-"MA 2"

C

le

an Fo

a

m

/

P

a

per Ele

me

n

t

as

applicable. Replace Air

filter

element

cover

O

Ring ever

y

5000 kms.

16

Brake fluid level**-top up / replace C,A,R

C,A

R

Use recommended brake fluid

(

DOT

3 /

DOT

4)

Use RR 3 grease or Lequivalent

17

Disc brake assly - Check functionality

, leakage or

any other damage

C

18

19

Pillion footrest hinge lubrication **

All cables & rear brake pedal free play

C,A

20

Wiring harness & Batter

y connections routine, tie

bands & clamps tightness

C,A,T

21

Ignition switch barrel cleaning & handle bar

control switches contacts cleaning

C,CL

C,

CL

C,CL

C,

CL

C,

CL

C,CL

C,

CL

C,CL

Use recommended Wd40

spray

Sr

No

PM

Check Point

Recommended Frequency

Remark

Ser

vice

1st

2nd

3rd

Kms

500

4500

9500

~

750

5000

10000

Ever

y 5000 Km

after Previous Ser

vice

22

Steering play

C,A

C,A C,A C,A

C,A

23

Steering stem bearing *** & cap steering bearing

(Plastic)**

C,

CL

,

L,R

C,CL

,L,

R

C,

CL,L

,R

C,CL

,L,

R

Check & replace

if

damaged.

U s

e

L I

M A

P L

E

X

H T X 3 o

r

equivalent

grease for lubrication

24

Main stand & side stand pin **

CL,L CL

,L

CL

,L

CL

,L

Use recommended

AP

grease

25 Swing arm pivot pin

(For non silent bush)**

L L

L

Not applicable in case of

needle roller bearing

26

All fasteners tightness

C,T

C,T C,T

C,T

27 Engine foundation silent bushes ** C

C C

Replace if found cut / damaged

28

General lubrication - clutch lever

, front brake

lever

, kick lever

L L

L

Use recommended

AP grease

29

Idle speed / CO% C,A C,A C,A

C,A C,A

C,A

30

SAI, EV

AP hoses- Check functionality leakage or

any other damage ** C,R

C,R

C,R C,R

C,R

Replace

if found

cut

/

damaged.

A

p

pl

ic

ab

le

fo

r p

ro

d

u

c

t wi

t

h

EV

AP system

only.

35 EV

AP drain tube cleaning** C,L

C,L

A

ppl

i

c

able

f

o

r

pr

o

du

c

t wit

h

EVAP

system

only

.

* It is strongly recommended to use only recommended grade of oil.

** As applicable to model

*** More frequent cleaning may be required while driving in dusty environment.

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

I Read... I learn

Periodic Maintenance & Lubrication Chart

3

Bajaj Platina 125 Training Notes

C,L

Note :

Periodic parts, Oil, Coolant, Filters, All types of greases, Cleaning agents, Cables, Wear & tear parts, Rubber 'O' rings / oil seals /

pipes, Gaskets to be replaced as per Periodic Maintenance and Lubrication Chart and is mandatory.

Pre-Delivery Inspection Checklist

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, Seat lock, LH side cover lock,

Petrol tank cap lock

Batterry

Check battery Terminal voltage. Fully charged battery voltage

should be > 12.4 V DC. Charge battery if required using

recommended battery charger.

Tyre Pressure

2

Front: 25 PSI (1.75 Kg / cm )

2

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

Brakes Rear brake pedal free play 20 ~ 25 mm

Clutch Cable Free play 2 ~ 3 mm

Drive chain

Slackness 20 ~ 30 mm

Equal marking of chain adjusters on both side

No touching to chain case after adjustment.

2

Bajaj Auto International Business

1

I Read... I learn

Following is the checklist for carrying out PDI of "Platina 125" motorcycle. This checklist is to understand various

check points those are to be checked / inspected before delivery of the new vehicle.

Each vehicle should be checked as per the points given below. This ensures trouble free vehicle delivery to the customer.

Tightness of battery terminals / cables / Petroleum Jelly

application.

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

(As applicable)

Headlight, Tail / Stop lamp, Side indicators, Speedo bulbs, Number plate

lamp,

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 foundation bolts (Front & Rear only)

Front - 1.8 ~ 2.2 Kg.m

Rear - 2.8 ~ 3.2 Kg.m

Front axle nut - 4.5 to 5.5 Kg.m

Rear axle nut - 5.5 to 6.5 Kg.m

Swing arm shaft nut - 5.2 ~ 6.0 Kg.m

Front fork top bolts - 3.0 ~ 3.2 Kg.m

Rider foot rest bolts LH / RH - 1.8 to 2.2 Kg.m

2.8 to 3.2 Kg.m

RSA Mounting top / bottom nut -

2.8 ~ 3.2 Kg.m

Front fork under bracket bolts -

3.0 ~ 3.2 Kg.m

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

s i d e c o v e r & s e a t ) f o r

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

I Read... I learn

Pre-Delivery Inspection Checklist

3

Bajaj Platina 125 Training Notes

To Check Check for

If Ok

X If Not Ok

Engine noise No abnormal noise

Front fork / steering

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

Sticky movement)

Oil / Coolant leakages Identify source of leakages & rectify if any.

4. Idling RPM / CO%

Check & correct the below check points in engine warm condition

Idling RPM

0

Check in warm up condition at 60 C (1400 + 100 rpm)

CO% Check CO should be 1.5 ~2.5% in engine warm condition at idling rpm

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

6. Clean the vehicle thoroughly before delivery to customer.

Pre-Delivery Inspection Checklist

2

Bajaj Auto International Business

1

I Read... I learn

⚠️ Fin de la Vista Previa Gratuita

¿Te vas a quedar a medias con el diagnóstico?

Este manual contiene cientos de páginas con información técnica crítica que te estás perdiendo justo ahora:

⚡ Diagramas Eléctricos Full Color: Encuentra cortes y fallas en minutos.
🔧 Tablas de Torque Exactas: Evita robar tornillos o dañar el motor.
⚙️ Despiece Completo: Paso a paso del armado del motor y transmisión.
📥 Descarga en PDF: Guárdalo, imprímelo y úsalo sin internet en tu taller.

🎁 OFERTA ESPECIAL - 50% DE DESCUENTO

Llévate este manual + La Biblioteca VIP Completa

Más de 1.000 manuales (Yamaha, Honda, Suzuki y más) listos para descargar.

⭐ DESBLOQUEAR ACCESO VIP AHORA

📥 ¿Necesitas el PDF Original?

¿Te vas a quedar a medias con el diagnóstico?

Llévate este manual + La Biblioteca VIP Completa