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CYAN MAGENTA YELLOW BLACK

Bajaj Auto Limited Akurdi Pune 411 035 India T el el + 91 91 2 0 27472851 Fax +91 20 20 27407385 27407385 www.bajajauto.com

Service Ready Reckoner


NOTICE

TECHNICAL SPECIFICATIONS

The description and illustrations in this Service Ready Reckoner are not to be taken as binding on the manufacturer. The essential features of the type described and illustrated herein remaining unaltered, BAJAJ

PRE-DELIVERY INSPECTION CHECK LIST PERIODIC MAINTENANCE AND LUBRICATION PARTS IDENTIFICATION ENGINE EXPLODED VIEW

AUTO LIMITED reserve the right to carry out at any moment, without

TIGHTENING TORQUES - ENGINE AND FRAME

being obliged to bring this Service Ready Reckoner up-to-date,

SERVICE DATA - ENGINE AND FRAME

modifications on the vehicle, parts or accessories, as may be

ELECTRICAL WIRING DIAGRAMS INDIVIDUAL CIRCUIT DIAGRAMS

convenient and necessary.

STANDARD PROCEDURE FOR CO CHECKING AND SETTING

Copying, quoting or reproducing any part of this Service Ready

TUNE UP FOR OPTIMUM MILEAGE

Reckoner without the written permission of BAJAJ AUTO LIMITED, is

WARRANTY, SERVICES AND RESISTANCES LOCTITES

expressly prohibited.

IMPORTANT ENGINE ASSEMBLY TIPS

DOC. NO. 36 02 0355

REV. NO.: 00, SEP’. 04

PRECAUTIONARY MEASURES FREQUENTLY ASKED QUESTIONS (FAQs)


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

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

DISCOVER

DISCOVER

ENGINE

Clutch

Wet, Multidisc type.

Type

Four stroke, Single cylinder, Natural air cooled.

Transmission

No. of cylinders

One

Gear Ratios: 1 ge ar ar nd 2 gear rd 3 ge ar ar th 4 g ea ea r

Bore

57.00 mm.

Stroke

48.80 mm.

4 speed constant mesh. st

2. 92 92 : 1.72 : 1. 16 16 : 0 .8 8 :

1 1 1 1

DISCOVER Rims

DISCOVER Turn Pilot Indi. Lamp 1.7W - 2 Nos.

Front 1.60 Front 1.60 x 17 Rear Re ar 1. 1.85 85 x 17 17

Fuel Tank Capacity

10 litres with 2.3 litres of reserve

CONTROLS Accelerator

Twist grip type on RH side of handle bar

Gears

Left foot pedal operated

Length Width Height Wheel base Turning circle radius Ground clearance

9.5 +0.5:1

CHASSIS CHAS SIS & BODY

Idling Speed

1400 +100 rpm.

Frame Type

Max. net power

8.47 kW (11.51 Ps) at 8000 rpm.

Suspension

Max. net torque

10.8 Nm at 6500 rpm.

Ignition System

Micro controller based digital C.D.I.

Front (Stroke (Stroke 135mm.) 135mm.) Telesco Telescopic pic Rear Trailin Trailingg arm with coaxial coaxial hydraulic hydraulic shock shock absorbers, and triple rate coil springs.

System

12 V (AC+DC)

Brakes

Front Mechanica Mechanically lly expand expanding ing shoe and drum type. Rear Mech Mechanica anically lly expanding expanding shoe shoe and drum type.

Battery

12V 9Ah For ES,

Head Lamp

35/35 W-HS1 For ES, 60/55 W-HS4 For KS

Front Fro nt 2.7 2.755 x 17, 17, 6 PR

Pilot Lamp

5W - 2 Nos. For ES

Rearr 3.0 Rea 3.000 x 17, 17, 6 PR

Tail/Stop lamp

5/21 W

Turn signal lamp

10 W

Hi beam indi. lamp

1.7 W

Speedometer lamp

3.4 W

0

Ignition Timing

10 BTDC at 1400 rpm., 26 BTDC at 3500 rpm

Carburettor

Keihin NCV 24, Side Draught, CV Type.

Spark Plug

2 Nos. Champion RG4HC (Resistive)

Spark Plug Gap

0.6 to 0.7 mm.

Lubrication

Wet sump, Forced.

Starting

Kick Start Electric start.

Tyres

Clutch

Tyre Pressure Front Fro nt 1.75 1.75 Kg/cm c m2 (24 (24.5 .5 Psi) Psi) Rear Solo 2.00 Kg/cm2 (28.0 Psi) Rear Pillio Pillionn 2.25 Kg/cm2 (32.0 Psi)

12V DC

DIMENSIONS

Compression ratio

0

3.4 W

Horn Handle Bar

Final drive ratio

Double cradle.

1.7 W

Fuel Gauge

Steering

Engine displacement 124.52 cc.

3.21 : 1

Neutral indi. lamp

Brakes

Lever operated on LH side of handle bar Front Lever operate operatedd on RH side of handle handle bar Rear Pedal operated operated by right foot oot

ELECTRICALS

2030 mm. 760 mm. 1065 mm. 1305 mm. 2100 mm. (Minimum) 175 mm. (Minimum)

WEIGHTS 12V 2.5Ah For KS

4W - 1 No. For KS

Vehicle kerb weight Gross veh. weight

129 kg. For ES 259 Kg. For ES

125 kg. For KS 255 kg. For KS

PERFORMANCE Maximum speed Climbing ability Notes:

•

• • •

100 Km/hr. with single rider (65 Kg) 0 25% (14 Maxim Maximum) um)

Values given above are nominal and for guidance only. 15% variation is allowed to cater for production and measurement variation. All dimensions are under unladen condition. Definitions of terminologies wherever applicable are as per relevant IS/ISO standards. Specifications are subject to change without no tice.


P.D.I. CHECKLIST TO CHECK

P.D.I. CHECKLIST

CHECK FOR

TO CHECK

ENGINE :

FRAME :

Engine oil SAE 20W40 API ‘SG’+JASO ‘MA’ Grade

Oil level. Top up if required. Oil leakage if any.

Idling Speed (Warm up)

Check / adjust if required. (1400 + 100 rpm)

Spokes

Check & tighten if required.

Drive chain

Slackness (25-35 mm)

DIRECTION OF CHAIN ROTATION

Lubrication (SAE 90) Check chain lock position.

Smooth Operation.

Fasteners (Check torque & correct if required)

Engine mtg. at Cyl. Head (2.2 Kgm.) at Front & Rear (3.2 Kgm.) Oil drain plug (3.0 Kgm.)

FUEL SYSTEM : Leakage’s / Fitment. Smooth operation. Leakages, Fitment - Orientation & angle Breather pipe routing.

Brakes

Front brake lever free play (2-3 mm) Rear brake pedal free play (25-30 mm)

Clutch

Lever free play (2-3 mm) Smooth operation.

Throttle

Grip free play (2-3 mm) Smooth operation.

Choke

TO CHECK

Check split pin of Front & Rear axle nut. Rear shock mounting nut (3.5 Kgm.) Front fork top clamping bolts. (2.5 to 3.0 Kgm.)

B. DRIVIABILITY

Throttle response Gear shifting / Clutch operation Brakes (Front & Rear) Speedometer, Odometer and Trip meter meter..

C. CO % CO % CHECK

CO should be 1.75-2.25% in warm condition

D. CLEANING

Wash & Clean vehicle properly.

ELECTRICAL

B. ALL BULBS WORKING

C. SWITCH OPERATION

C) SUSPENSION Front fork

Smooth operation, Oil leakage.

A. WHEELS Tyre Pressure

Rear shock absorber

Proper notch setting # Preload setting: 2nd notch (same on both side)

Steering

Smooth operation (Loose or tight).

D) LOCK OPERATION

Steering and Ignition, Fuel tank, Seat lock, Side cover LH.

Rim runout (With tyre)

CHECK FOR

E) FASTENERS

Free play (2-3 mm) & smooth operation.

FRAME : 2

Front - 1.75 Kg/cm 2 Rear - 2.00 Kg/cm (Solo), 2 2.25 Kg/cm (Double) Radial - (0.8 mm or less) Axial - (1.0 mm or less)

TO CHECK

A. BATTERY

B) CONTROLS

Kick operation

Fuel Tank / Pipes Fuel Tap Carburettor

CHECK FOR

D. STARTER MOTOR

Electrolyte level / Specific gravity 1.240. Charging, Connect -ve terminal and apply petroleum jelly. Routing of Breather pipe, Fuse. Head light, Pilot, Tail / Stop, Side indicator, Speedometer, Indicator lamps and Fuel Gauge. LH and RH control switch. Ignition switch. Ride control brake switch (Front & Rear) and Clutch switch. Proper working / Engagement. (Use choke for cold starting)

TEST DRIVE (2-3 kms) A. STARTING*

Cold start and Warm start. Idling speed (Warm condition) 1400 + 100 rpm

CHECK FOR

* IMP IMPORT ORTANT ANT : BEFORE STARTING, PLEASE ENSURE FOLLOWING. Check the fitment of Reed Switch and Magnet. • •

Max. gap between Magnet and Reed Switch to be 2.5 mm.

•

Check for working of the Reed Switch assly. and Magnet by using multimeter.

•

Press and Confirm that both the Spark Plug caps have been fitted correctly.

•

Confirm tightness and correct fitment of primary leads to both the H.T. Coils.

AFTER STARTING, PLEASE ENSURE FOLLOWING. Confirm that both the Spark Plugs are firing by using a Timing light or Stroboscope with the engine idling. •

Any other defects

Look for any external damages in Transit : Please check, record & rectify. 1. Moisture / Oil collecting collecting tube of Air Filter should be properly fitted and routed correctly.


PERIODIC MAINTENANCE AND LUBRICATION CHART RECOMMENDED FREQUENCY

Whichever comes first

Sr. No. Operation

OR

Initial

Subsequent

Kms. 750 2,500 5,0 5,000 00 7,500

Every Eve ry 2,5 2,500k 00km m

Days 3 0

90

1 50 50

22 5

E ve ver y 7 5 d ay ay s

















1.

S er er vivi cici ng ng

2.

Idle speed / CO%

C,A



3.

Engine Eng ine oil (SA (SAE E 20W4 20W400 ofAPI SG+ SG+JAS JASO O MA) MA)

R



4.

Valve clearance

A

5.

Oil strainer / Centrifugal filter

CL

6.

Air clea cleaner ner elem element ent 

CL

7.

Air cleaner element

R

8.

Carburettor

CL,A











9.

Fuel system leakages

C,R











10.

Fuel pipes

11.

Spark plug / gap









12.

Spark plug (2 Nos.)

13.

Battery electrolyte level

C,A











14.

Brake light switch

C,A











15.

Clutch play Cl

A











16.

T hrottle play Th

A











17.

Rear brake pedal play

A











18.

Brake lining wear

C,R











19.

Steering play

C,A











T











20. All fas faster terner nerss tight g htness n ess inclu includin dingg engin enginee mtg. g.

R





Every 5000 kms.



Every 5000 kms. Every 10000 kms.











Every 10000 kms.

Every 1 Year

1 Year

CL,A R



Every 10000 kms. 15 Days

 

PERIODIC MAINTENANCE AND LUBRICATION CHART : Indicates operation to be performed. : More frequent cleaning may be required when driving in dusty condition. A - Adjust ust CL- Clean C - Check Check L - Lubricate T - Tighten Tighten R - Replace Replace

Note: Parts/Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.

RECOMMENDED FREQUENCY

Whichever comes first

Sr. No. Operation

OR

Initial

Subsequent

Kms. 750 2,500 5,0 5,000 00 7,500 Days 3 0

90

1 50

Every Eve ry 2,5 2,500k 00km m

2 25 25

E ve ry ry 75 d ay ay s

21.

Engine mounting silent blocks

R

22.

Tyre tread w ear

C,R

23.

General lubrication

L

24.

Steering stem bearing

L

1 Year

25.

Wheel bearing

L

1 Year

26.

Sw ing arm mounting bush

R

27.

Front fork

C

28.

F ront fork oil Fr

R

29.

Spoke tightness and ririm runout

C,A











30.

Rear shock absorber

C,R











31.

Drive chain Dr

32.

Drive chain slack

33.. 33

Driv Dr ivee cha chain in we wear ar / Rem Remov ovee and and Lu Lubr bric icat atee

34. Gap between w een Reed Reed switch t ch and and TPS mag magnet net

Every 20000 kms. 

















Every 10000 kms. Every 10000 kms. 

Every 20000 kms.





Every 10000 kms.

L

Every 500 km

A

Every 2500 km

C,R C, R C,A



Every 5000 kms

 









 

: Indicates operation to be performed. : More frequent cleaning may be required when driving in dusty condition. A - Adjust Adjust CL- Clea Clean n C - Check Check L - Lubricate Lubricate T - Tighte Tighten n R - Replace Replace

Note: Parts/Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.


PARTS IDENTIFICATION - PULSAR 150 DTSi

PARTS IDENTIFICATION - DISCOVER

Part Name

Cylinder Head with Cover

Part Name


Part No.

DH 1015 29

Part No.

DS 1011 09

Description

-----

Description

-----

Identification Mark

Rubberised silent bush fitted in head cover.

Identification Mark

Steel bush fitted in head cover.

Part Name


Part Name


Part No.

DH 1015 29

Part No.

DS 1011 09

Description

Bigger combustion chamber cavity.

Description

Smaller combustion chamber cavity.

Identification Mark

DH mark is embossed on casting.

Identification Mark

DS mark is embossed on casting.

Part Name

Cylinder Complete

Part Name

Cylinder Complete

Part No.

DH 1015 27

Part No.

DS 1012 54

Description

Bigger bore.

Description

Smaller bore.

Identification Mark

-----

Identification Mark

-----

Part Name

Piston Assembly

Part Name

Piston Assembly

Part No.

DH 1015 30

Part No.

DS 1010 13

Description

Large in diameter.

Description

Smaller in diameter.

Identification Mark

DHU mark is embossed on piston crown.

Identification Mark

Two valve relieve grooves are provided on piston crown.




Part Name

Piston Pin

Part Name

Piston Pin

Part No.

DH 1012 70

Part No.

DS 1010 86

Description

Wall thickness is more.

Description

Wall thickness is less.

Identification Mark

No chamfer.

Identification Mark

Chamfer is provided.

Part Name

Cam Chain

Part Name

Cam Chain

Part No.

DH 1010 50

Part No.

DS 1010 36

Description

More in length 313 mm.

Description

Less in length 300 mm.

Identification Mark

One chain link mark with white paint.

Identification Mark Part Name

Chain Guide

Part Name

Chain Guide

Part No.

DH 1010 10

Part No.

DS 1010 11

Description

Length is more.

Description

Length is less.

Identification Mark

Length is 178 mm.

Identification Mark

Length is 168 mm.

Part Name

Guide Chain (Tight)

Part Name

Guide Chain (Tight)

Part No.

DH 1010 17

Part No.

DS 1010 12

Description Identification Mark

Description No curvature at bottom location.

Identification Mark

Curvature at bottom location.




Part Name

Crankshaft Assembly

Part Name

Crankshaft Assembly

Part No.

DH 1010 57

Part No.

DS 1011 84

Description

Web shape is different.

Description

Web shape is different.

Identification Mark

DH mark is embossed on con-rod.

Identification Mark

Groove for square key cotter on clutch side shaft.

Part Name

Clutch Spring

Part Name

Clutch Spring

Part No.

DH 1014 83

Part No.

DS 1011 16

Description

Spring has 5 coil turns.

Description

Spring has 4 coil turns.

Identification Mark

Spring is marked with Yellow colour paint.

Identification Mark

Spring is marked with Red colour paint.

Part Name

Clutch Hub

Part Name

Clutch Hub

Part No.

DH 1014 34

Part No.

DH 1013 46

Description

Height is more.

Description

Height is less.

Identification Mark

Height is 22.5 mm.

Identification Mark

Height is 20.5 mm.

Part Name

Guide Split

Part Name

Guide Split

Part No.

DH 1013 74

Part No.

DS 1011 06


Description Splines on ID

Identification Mark

No splines on ID.




Part Name

Gear Change Lever

Part Name

Gear Change Lever

Part No.

DH 1011 34

Part No.

DS 1011 34

Description

18.53mm.

Description

Identification Mark

Open end welding dimension is 38.2.

Identification Mark

Open end welding dimension is 36.53

Part Name

Guide Gear Shift

Part Name

Guide Gear Shift

Part No.

DH 1014 95

Part No.

DS 1010 79

Description

More wide.

Description

Small in size and shape.

Identification Mark

Have 5 pins.

Identification Mark

Have 4 pins.

Part Name

Rotor Assembly

Part Name

Rotor Assembly

Part No.

DS 1110 08

Part No.

DS 1110 08

Description

Pick up coil sensor is less in length.

Description

Pick up coil sensor is more in length.

Identification Mark

Pick up coil sensor projection length is 18.13 mm.

Identification Mark

Pick up coil sensor projection length is 20.00 mm.

Part Name

Wiring Harness

Part Name

Wiring Harness

Part No.

DH 2010 29

Part No.

DS 2010 01 For KS Version and DS 2010 32 For ES Version.


20.00mm.

Description Yellow colour insulation tape fitted on harness.

Identification Mark

Red colour insulation tape fitted on harness.




Part Name

CDI

Part Name

CDI

Part No.

DH 1110 19

Part No.

DS 1110 03

Description

Description

Identification Mark

DH mark is embossed on body.

Identification Mark

DS mark is embossed on body.

Part Name

Rear Wheel Sprocket

Part Name

Rear Wheel Sprocket

Part No.

DJ 1510 18

Part No.

DS 1510 59

Description

Has 42 teeths.

Description

Has 45 teeths.

Identification Mark

42 ‘T’ mark and yellow passivated.

Identification Mark

45 ‘TALS’ mark and black in colour.


ENGINE EXPLODED VIEW

T I G H T E N I N G T O R Q U E S - E N G I N E CYL. HEAD BKT. MTG. BOLTS

ENGINE MOUNTING BOLTS

ENGINE MOUNTING NUTS

CHAIN TENSIONER MTG. BOLTS

2.0 to 2.2 kgm.

3.0 to 3.2 kgm.

2.0 to 2.2 kgm.

1.1 kgm.

OUTPUT SPROCKET BOLTS

SILENCER MOUNTING BOLT

SILENCER MOUNTING NUTS

GUIDE GEAR ALLEN BOLT

1.1 kgm.

3.5 kgm.

2.5 kgm.

1.5 kgm.

STARTER COUNTER BOLT

CRANKCASE JOINING BOLTS

CRANKCASE JOINING BOLT

CLUTCH COVER BOLTS

1.1 kgm.

1.1 kgm.

1.1 kgm.

1.1 kgm.

CYLINDER BLOCK / PISTON CYLINDER HEAD ASSEMBLY SILENCER CLUTCHMECHANISM OIL PUMP & FILTER CLUTCHCOVER CHAIN TENSIONER & CHAIN GUIDE CRANKSHAFT KICKMECHANISM CRANKCASE & COVERS TRANSMISSION STATOR & ROTOR ASSEMB LY STARTER MECHANISM (ELECTRIC)


T I G H T E N I N G T O R Q U E S - E N G I N E

T I G H T E N I N G T O R Q U E S - F R A M E

OIL PUMP MOUNTING BOLTS

CENTRIFUGAL OIL FILTER NUT

GENERATOR COVER BOLTS

CLUTCH NUT (L.H. THREADS)

1.1 kgm.

5.5 kgm.

1.1 kgm.

5.5 kgm.

CYLINDER HEAD COVER NUTS

CYLI CY LIND NDER ER HE HEAD AD CO COVE VER R BO BOLT LTS S

CAM CA M S PRO PROCK CKET ET ALL ALLEN EN BOL BOLT T

STARTER MOTOR BOLTS

3.5 kgm.

1.1 kgm.

1.4 kgm.

1.1 kgm.

FRONT AXLE NUT

REAR AXLE NUT

TORQUE ROD NUT

SLEEVE NUT

4.0 to 5.0 kgm.

HANDLE HANDL E BAR BAR HOLDER HOLDER BOLTS

8.0 to 10.0 kgm.

3.0 to 4.0 kgm.

8.0 kgm.

1.8 to 2.5 kgm.

STEERING STE ERING TOP BOLT

STG. STEM NUT (SLOTTED)

UPPER CLAMP BOLT

LOWER CLAMP BOLTS

2.0 kgm.

4.5 to 5.0 kgm.

0.5 kgm.

3.0 to 3.2 kgm.

3.0 to 3.2 kgm.

SWING ARM PIVOT NUT

4.5 to 5.5 kgm.

ROTOR MOUNTING BOLT

KICK GUIDE BKT. HOLDER BOLTS

SPARK PLUGS (2 NOS.)

DRAIN CAP

R.S.A. MTG. NUTS/BOLTS

4.5 kgm.

1.1 kgm.

1.4 kgm.

3.0 kgm.

UPPER - 3.5 to 4.0 kgm. LOWER - 2.5 kgm.

REAR SPROCKET MTG. NUT


SERVICE DATA - ENGINE COMP. PRESSURE

Standard Service Limit

VALVE CLEARANCE

2

12-14 kg/cm 9.1-14 kg/cm2

CAM HEIGHT

Standard S er er vi vi ce ce L im im it

Inlet 0.05 0.05


Exhaust 0.10 0.10

VALVE SPRING FREE LENGTH

Inlet 30.80 3 0. 0. 5

Ex. 30.4 3 0. 0. 00 00

CYLINDER HEAD WARP

Outer 41.6 40.6


SERVICE DATA - ENGINE ROCKER ARM SHAFT DIA.

Inner 37.9 36. 9

CAM SHAFT CHAIN 20 LINKS

ROCKER ARM INSIDE DIA.

CAM SPROCKET DIAMETER

PISTON RING/GROOVE CLEARANCE

Top


9.97 - 9.98 9.92

VALVE STEM DIAMETER


I nl nl et et 4.46 4.40

E xh xh au st st 4.46 4.40

CYLINDER INSIDE DIA.


10.00 - 10.01 10.04

VALVE STEM BEND



61.4 61.3

VALVE HEAD THICKNESS

TIR 0.01 TIR 0.03

PISTON DIAMETER


I nl nl et 0.5 0.3

E xh au st 0.8 0.6

PISTON/CYL. CLEARANCE

Second

0.02-0.06 0.01-0.05 Standard 0.16 0. 15 Service Limit

PRESSURE PLATE WARP


PISTON RING END GAP

0.15 0.25

CRANK SHAFT RUN OUT


Top 0.15-0.30 0.55

Second 0.30-0.45 0.70

SHIFT FORK GUIDE PIN DIA.

Standard Service Li Limit

4.97 4.90

CONROD BIG END AXIAL CLEARANCE

20-link length

CLUTCH SPRING FREE LTH


30.4 29.4

SHIFT FORK PAD THICKNESS


4.97 4.90

FRICTION PLATE THICKNESS



2 nd

21s t 7mm

MEASURE THIS LENGTH

Standard S erv ice L im imi t

0. 00 0. 05


127 - 127.2 128


57.010-57.017 57.017-57.024


56.978-56.900 56.988-56.998


0.019 - 0.039 0.05


TIR 0.02 max. TIR 0.05

Standard Service Li Limit

0.1-0. 35 0 45

14000 + 100 140 100

VC sc sc re re w

2 .5 + 1 .0 Turn

J et et n ee ee dl dl e clip pos positi ition on

F ix ed ed , No clip provision.

Main jet

#128

Pilot jet 5.05-5.15 5.25

#35

CO%

1.75-2.25

ENGINE OIL SPECIFICAT SPECIFICATIONS IONS

40mm

1st

Idling i ng spee speedd SHIFT DRUM GROOVE WIDTH

Grade

10mm 20mm

2.9-3.1 2.75

CARBURETTOR SPECIFICATIONS Item DISCOVER Makee & type Mak type NCV 24 Keihin Side Draught, CV

: SAE 20W40 of API ‘SG’ + JASO ‘MA’ grade or superior.

Quantity

: 1000 ml (Drain and Refill)

Oil Change Frequency

: Every 2,500 km. Check and Top-up if required.

Oil Stra Strainer iner Clea Cleaning ning : Every 10,000 km.


SERVICE DATA - FRAME BR. PANEL CAM HOLE DIA.

BRAKE CAM DIAMETER

ELECTRICAL WIRING DIAGRAM - (ELECTRIC START) FR. BRAKE PAD THICKNESS

BR. SHOE LINING THICKNESS

BRAKE DRUM INDISE DIA. SIGNAL LAMP FRONT RH LAMP 12V-10W

Gr

Gr

B/Y

B/Y

B/R

SWITCH ASSY.

FUEL METER **

METER ASSY.

S ta ta nd ar d

1 2. 0- 12 12 .0 3

S er vi ce Li Li mi mi t

1 2. 15


11.95-11.98 11.88

Standard

7.4

Standard

Service Limit

3.8

Service Limit

3.85-4.15 2.0

Standard

130.00 - 130.16

Service Limit

130.75

* LAMP 12V, 1.7W (QTY. 4)

NEUTRAL LAMP * TURN SIGNAL INDICATOR LAMP * (FRONT LH )

Br

Br

B/Y

B/Y

W/Y

W/Y

Lg

Lg

Gr

Gr

G

G

R/B

R/B

R/W

R

C.D.I. ASSY. CONTROL SWITCH RH

LIGHT SWITCH

FRONT BRAKE SWITCH F F O

AXIAL WHEEL RUN OUT

RADIAL WHEEL RUN OUT

DRIVE CHAIN SLACK

P

TURN SIGNAL RELAY

NC

H.T.COIL

NO

DRIVE CHAIN LENGTH

B / / r Y B R

r B L

G / Y r / g / W L Y B B G

r B

L / Y Y R

B / / r Y B R

Y / Y / W B Y / B

r B L r B L

H.T.COIL

Y / B

Y Y / B W

SPARK PLUG

Br

TIR 0.1

Standard

TIR 0.8

Standard

TIR 0.8

Standard

25 - 35

Standard

Service Limit

TIR 0.2

Service Limit

TIR 2.0

Service Limit

TIR 2.0

Service Limit

35 - 45

Service Limit

Gr

B/Y

B/Y

SIGNAL LAMP REAR RH

IGNITION SWITCH

TAIL LAMP ASSY

Br

W

W

B/W

B/W

B/Y

B/Y R/W

Standard

Gr

O O N F F

21st

MEASURE THIS LENGTH

r B L

O

Y / R W / W / Y / B W L L Y

20-linklength

1st 2 nd

REAR BRAKE SWITCH

Y / W / B B B

B

FUEL LEVEL GUAGE

TURN SIGNAL INDICATOR LAMP * (FRONT RH)

100 mm

SPARK PLUG

REGULATOR

ILLUMINATION LAMP ** L / Y Y R

AXLE RUN OUT

RELAY (FOR INTERLOCKING)

PO ON

HIGH BEAM INDICATOR LAMP * ** LAMP 12V, 3.4W (QTY. 2)

STARTER SWITCH

L

L

B/Y

B/Y

R/W

R

254 - 254.6 B/Y

REAR SPROCKET WARP

REAR TYRE TREAD DEPTH

FR. TYRE TREAD DEPTH

FR. FORK SPRING FREE LTH.

FRONT FORK OIL Grade : SAE 10W20

Free Length

Standard

TIR 0.4

Standard

6.6

Standard

5.0

Standard

420

Service Limit

TIR 0.5

Service Limit

1.5

Service Limit

1.0

Service Limit

416

TAIL/STOP LAMP 12V-5/21 W

259

Capacity : 145 + 2.5 ml (per leg) Oil change frequency : After every 10,000 Kms.

G Y / B

R/B HEAD LAMP ASSY/LAMP 12V-35/35W HS1

B/Y R/Y

EARTH-FRAME

R POSITION LAMP 12V-5W- 2 Nos.

B/Y

B r / R G

Y

R

G

g L

Y / B B

R W / W R / / / / Y R L L Y W B

R

STARTER MOTOR W

B /Y SIGNAL LAMP FRONT LH

B

G

G

Y / B / Y R R

r B

g L

FUSE (15 Amps.)

R Y R / W / W / / / R L L Y W B

L / B r Y / / Y R G O G B B

B / W

R/Y LO

G/W G/W CLUTCH SWITCH

PASS SWITCH

DIMMER SWITCH

HI

R

B/Y B/Y

O

CONTROL SWITCH LH

HORN SWITCH

CABLE ASSY. EARTH

R

L

TURN SIGNAL SWITCH

B HORN (P.NO. DS 20 1016)

STARTER RELAY WITH DAMPER NEUTRAL SWITCH

COIL PULSING

B

BATTERY 12V-9Ah CABLE ASSY. RED

G

SIGNAL LAMP REAR LH


ELECTRICAL WIRING DIAGRAM - (KICK START) SIGNAL LAMP FRONT RH LAMP 12V-10W

Gr

Gr

B/ Y

B/ Y

INDIVIDUAL CIRCUIT DIAGRAM (ES)

AC LIGHTING CIRCUIT CONTROLSWITCH RH

B/Y

PO B/R

INDICATOR LAMP HIGHBEAM 12V1.4W

SWITCH ASSY. C.D.I.ASSY. FUEL METER

*LAMP 12V,1.4W (QTY.5)

NEUTRAL LAMP * TURN SIGNAL INDICATOR LAMP * (FRONT LH )

W/G Br B/Y W/Y

W/G Br B/Y W/Y

Lg

Lg

Gr G R/B R/W

Gr G R/B R

R.R.UNIT

OFF Y / B

R B/Y

FRONT BRAKE SWITCH CONTROL SWITCH RH

TURN SIGNAL RELAY H.T.COIL

FUEL LEVEL GUAGE

SPARK PLUG

REGULATOR

HIGH BEAM INDICATOR LAMP * **LAMP 12V,3W (QTY.3)

R

ON

B/Y

CAPACITOR

LIGHT SWITCH

ILLUMINATION LAMP **

ON

F F O

r B L

r B

O

r B L

ILLUMINATION LAMP FUELMETER 12V3W

R/W

ILLUMINATION LAMP SPEEDOMETER 12V3W

R/W

Y / B

Y

R / Y

B/Y

TURN SIGNAL INDICATOR LAMP * (FRONT RH)

Y / Y B W Y / B

R

R

Y / / Y W B

R

Y

W / R

B/Y

PO

L / Y Y

L / Y R/W

B

ILLUMINATION LAMP ** ILLUMINATION LAMP **

ILLUMINATION LAMP TACHOMETER 12V3W

REAR BRAKE SWITCH

R R W Y / / / / B B B R W B

r B L

W

r B L

H.T.COIL

SPARK PLUG

Gr

Gr

B/Y

B/Y

L B/Y R

L B/Y R

R / B

TAIL/STOP LAMP 12V-5/21W

Y

SIGNAL LAMP REAR RH

B/Y

O O N F F IGNITION SWITCH

Br W B/ W B/ Y

R

Br W B/ W B/ Y R


B/Y Y / B

G

R/ B

HEAD LAMP ASSY/LAMP

B/ Y

12V-60/55W POSITION LAMP12V-4W

Y / B

R / Y W / / R L Y W B

R/ Y

EARTH-FRAME

B/ Y

B/Y

Br/W

R

B / R

B r L / Y / R G O G Y

g L

Y / B B

B/ Y G

r B B

Y

SIGNAL LAMP REAR LH

POSITION LAMP 12V-5W

B/Y

R

B/R

HEAD LAMP ASSY/ LAMP 12V-35/ 35WHS1

Y / B B/Y

L / Y R/Y

POSITION LAMP 12V-5W

B Y / / W B

g L

R / B

R

L / B r / G O G Y R

LO

HI

DIMMER SWITCH

R / B

Y / R

B / R

PASS SWITCH

R / Y

Y

G

Y / B Y / R R

R

B/R

FUSE (15A)

W / r Y / / R R L Y G B

SIGNAL LAMP FRONT LH

G

R/W

TAIL LAMP ASSY

Y / B B

R O L TURN SIGNAL HORN SWITCH SWITCH

CONTROL SWITCH LH

R

HORN

NEUTRAL SWITCH MAGNETO

MAGNETO

G

L G I N O S I C L U P

LO

BATTERY 12V 2.5AH

PASSSWITCH

HI

DIMMERSWITCH

Y / B

B/Y


INDIVIDUAL CIRCUIT DIAGRAM (ES) CONTROL SWITCH RH


INTERLOCKRELAY

STARTER SWITCH

Lg

STARTER MOTOR AND BATTERY CHARGING CIRCUIT

IGNITION CIRCUIT

B/R

Lg NC

REED SWITCH ASSY.

B

C.D.I. ASSY.

P

G / Y

Br NEUTRAL LAMP

NO

SPARK PLUG

H.T.COIL W / r B

g L

R.R.UNIT

Y / R

B Y / B

r B

R

W / G Y / B

O N

W

W / L

W / L

Y / B

Br/W

O F F

W / B

R / W

Y

B Y / B

Br IGNITION SWITCH

B

SPARK PLUG

H.T.COIL W

B

W O N

Y / B

W

Y/G

O F F

g L

EARTH-FRAME

Lg

B

R/Y Y / R

W / G

W / L

R

W / L

B/Y

G / Y

R

IGNITION SWITCH

FUSE (15 Amps.)

NEUTRAL SWITCH

B/W

STARTER MOTOR

R R

R G/W

Y / B

B/Y

Y / B

B

R/Y BATTERY 12V 9Ah

B

MAGNETO CLUTCH SWITCH

MAGNETO W/R

STARTER RELAY COIL PULSING B/Y B/Y

R / B

G

B


INDIVIDUAL CIRCUIT DIAGRAM (ES) Gr

SIGNAL LAMP FRONT RH 12V 10W

SIDE INDICATOR AND HORN CIRCUIT


Gr

FUEL GAUGE AND BRAKE LIGHT CIRCUIT

Br

B/Y W/Y

r G

LHTURN SIGNAL INDICATOR LAMP 12V 1.4W

FUEL METER

FRONT BRAKE SWITCH

TURNSIGNAL RELAY

Y / B

REAR BRAKE SWITCH

FUELLEVEL GUAGE

r B

B/Y

G

RH TURN SIGNAL INDICATOR LAMP 12V 1.4W

Y / B

r B

r B

B/Y

SIGNAL LAMP REAR RH 12V 10W

O

G

Gr O O N F F

r B

L

IGNITION SWITCH W/Y

O O N F F

L

L

Br

Br

IGNITION SWITCH

Y / B

W

W

W B/Y

B/Y TAILLAMP ASSY

Gr

Y / B

B/Y

G

G

O

r G

B/Y SIGNAL LAMP FRONT LH 12V 10W

O

B

MAGNETO

Y / B

FUSE (15 Amps.)

STARTER MOTOR

B / W

G

R

O

L

TURN SIGNAL SWITCH

W

STARTER MOTOR

MAGNETO

FUSE (15 Amps.) B / W

B

R HI

SIGNAL LAMP REARLH 12V 10W

W

r B

B


R

B

+ HORN SWITCH

HORN

STARTER RELAY

BATTERY 12V-9Ah

B/Y BATTERY 12V-9Ah


STANDARD PROCEDURE FOR CO CHECKING AND SETTING Readiness of CO Gas Analyzer: Warm up the CO Gas Analyzer for 10 to 15 minutes before proceeding further. Warming up is essential every time machine is put on to purge out any gases left in side. Carry out Span Check as per manufacturer's recommendation to confirm the OK condition of the Equipment (If Span Check does not confirm the reading, then carry out Gas Calibration as per manufacturers recommendation). Set the Equipment display to Zero before taking the reading.

Readiness of the Vehicle: Before checking the CO emission, prepare the vehicle for checking the CO >>> • Warm up the engine to its normal operating temperature by riding 5 to 6 Kms. The Clutch cover should be warm enough by feel. • Ensure the Choke is in OFF position.

• Screw in Volume Control Screw completely. Engine should die down in this condition. Note: If engine does not go off, then attend to the additional air supply problem in the carburetor circuit & intake system. After solving the problem once again confirm that engine should die down on closing the Volume Control Screw.

• Confirm the Volume Control Screw Screw to it recommended recommended position of 2.5 turns. • Set Idling speed speed to specified Idling Idling to 1400 + 100 rpm of respective engines. Raise the engine to moderate speed at no load condition for about 15 seconds. Then bring back to specified idling RPM.

Taking the Reading: • Insert 'Special 'Special Probe' in the Silencer tail end pipe properly. Use right mouth piece of the probe to suit with tail end pipe of respective vehicle. The special probe is a combination of adaptor and probe. It comes with adjustable stand.

STANDARD PROCEDURE FOR CO CHECKING AND SETTING Precaution: Always ensure rubberised taper portion is intact with the tail end of the silencer and adaptor is mounted on the stand at suitable height such that ingression of fresh air does not take place. The probe and silencer should be held in same axis.

• Note the CO / HC Readings when the reading display display stabilizes. • As per Emission Norms the recommended recommended CO% for 2 Wheelers is 4.5% at Idling RPM. But CO% for Bajaj Vehicles, for best results in terms of fuel efficiency are different for different models. For Discover the ideal CO% is between 1.75 to 2.25% at Idling rpm with Volume Control Screw between 0.5 to 4.5 turns out. • If the reading is shown excess excess or less than BAL Specifications for respective model, then try to achieve by adjusting Volume Control Screw. - Turning out Volume Control Screw will lead to more CO% & turning in will lead to less CO%. Note: Remember the Volume Control Screw should not be taken out more than the recommended position. Every time Volume Control Screw setting is changed specified Idling RPM must be restored and then reading should be considered.

• If the CO% is not falling with in recommended recommended % in spite of adjusting the Volume Control Screw then find out the cause and rectify the same.

• After rectifying ng the problem confirm the CO% CO% in the same way as mentioned above. Imp: For Better Mileage and Performance, achieve CO% as recommended. In Discover for better mileage and performance achieve values given below.

Recommended CO% value w.r.t. Volume Control Screw and Idling RPM for Better Fuel Efficiency Model D is is c ov ov er er

Recommended Volume Control Screw Recommended Idling RPM CO% Position 1 .7 .7 5% 5% – 2. 2. 25 25 %

0.5 to 4.5

1400 + 100


T U N E - U P F O R O P T I M U M M I L E A G E Reed Switch : Maintenance Check throttle lever movement by rotating it with hand. It should not be sticky in operation and should return back it self on releasing.

T U N E - U P F O R O P T I M U M M I L E A G E Reed Switch : Checking • K e e p t h r ot ot t l e position. (Fig. 1).

1

Gap 2.5mm max.

0.00

zero

SPARK PLUG: RG 4 HC.

0.6 to 0.7MM

• When throttle throttle is open and and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switch (Fig. 2) multimeter should show discontinuity.

Replace at every : 10,000 Kms.

AIR FILTER: • Clean at every every 2,500 Kms. Kms. • Replac Replace e at every every 10,000 Kms.

1

• On De-acceleration, De-acceleration, when of Reed Switch magnet recoinsides with straight edge of fix bracket of Reed Switch (Fig. 3) Multimeter should show continuity.

• Protude Protude stopper (B) of the throttle lever bracket must on idling screw (C) tip. C B

Fig. 3

CARBURATTOR • Idling : 1400 1400 + 100 rpm. • V o l u m e C o nt nt r o l s c r e w setting : 2.5 + 2.0 turns. • CO % : 1.75 to to 2.25 %.

Other Mandatory Checks

Fig. 2

A

TAPPET CLEARANCE • Inlet valve: valve: 0.05 0.05 mm • Exhau Exhaust st valve: valve: 0.1 mm

Spark Plug Gap : Gap : 0.6 to 0.7 mm.

Fig. 1

Reed Switch : Setting • Accelerator Accelerator cable play: play: 2-3 mm by adjusting the Adjuster (A).

at

• On connecting connecting multimeter multimeter to Reed Switch coupler it should show continuity.

• Magnet should should not touch with reed switch. • Gap between between Magnet & Reed Switch should not be more than 2.5 mm. • Movement Movement of throttle lever lever with magnet assembly and Reed Switch fitted should be free.

Engine Maintenance

COMPRESSION PRESSURE • Sta Standa ndard rd : 2 12 to 14 Kg/cm • Service Service Limit: Limit: 2 9.1 to 14 Kg/cm

a. Ensure Ensure no fuel leakage through through fuel cock, fuel fuel lines. b. Ensu Ensure re free rotation rotation of both the wheels. wheels. c. Ensu Ensure re correct correct tyre pressure pressure Front wheel : 28 PSI, Rear wheel : 32 PSI d. Set control control cable cable free play: play: • Clutch lever lever 2-3 mm. mm. • Front brake brake lever 2-3 2-3 mm. • Rear brake brake pedal 25-30 mm. mm. e. Chain slackn slackness ess : 25 to to 35 mm.


WARRANTY AND SERVICES Sr.. No. Sr No. Se Serv rvic icee Type Type

Kms. Km s./d /day ayss *

1

0 0, 0, 50 50 0 - 00 00, 75 750 Km Kms . o r 30 da da ys ys .

2 3 4 5 6 7 8 9 10 11 12 13

1s t F re re e w it h Oil change 2nd Free 3r d F re re e w it h Oil change 4th Free 1s t Pa id wi wi th Oil change 2nd Paid 3r d Pa id wi wi th Oil change 4th Paid 5t h P aiai d w it h Oil change 6th Pai d 7 th Pa Pa id wi wi th th Oil change 8th Pai d 9 th Pa Pa id wi wi th th Oil change

02,000 - 02,500 Kms. or 90 days. 0 4, 4, 50 50 0 - 05 05, 00 000 Km Kms . o r 15 0 da ys ys . 07,000 - 07,500 Kms. or 225 days. 0 9, 9, 50 50 0 - 10 10, 00 000 Km Kms . o r 30 0 da ys ys . 12,000 - 1122,500 Kms. or 37 375 days. 1 4, 4, 50 50 0 - 15 15, 00000 Km Kms . o r 45 0 da ys ys . 17,000 - 17,500 Kms. or 525 days. 1 9, 9, 50 50 0 - 20 20, 00 000 Km Kms . o r 60 0 da ys ys . 22,000 - 22,500 Kms. or 675 days. 2 4, 4, 50 50 0 - 25 25 ,0 00 00 Km Km s.s. or or 67 67 5 d ay ay s. s. 27,000 - 27,500 Kms. or 675 days. 2 9, 9, 50 50 0 - 30 30 ,0 00 00 Km Km s.s. or or 67 67 5 d ay ay s. s.

Warranty 2 Years Or 30,000 30,000 Kms. Kms. whichever occurs earlier.

RESISTANCES PICKUP COIL : Range (Ohms)

Connections Meter +ve Meter -ve White/Red Black/Yellow

Reading (Ohms) 200 + 30

CHARGING COIL Range Connections (Ohms) Meter +ve Meter -ve X1 Red Black/Yellow

Reading (Ohms) 15 + 3

X 10

LOCTITES

IMPORTANT ENGINE ASSEMBLY TIPS

Apply before assembly: 638 (Colour - Green)

Engine Mounting Bolt Tighten Sequence

• • • •

BATTERY CHARGING COIL(KS) Range Connections (Ohms) Meter +ve Meter -ve Bl ue ue /Whi te te Bl ac ac k/ k/ Ye Yel low X1

Reading (Ohms) 1.0 + 0.3

BATTERY CHARGING COIL(ES) Range Connections (Ohms) Meter +ve Meter -ve X1 Blue/White Blue/White


• • •

Apply before assembly : 243 (Colour - Blue) • • • •

243

•

•

LIGHTING COIL (KS) Range Connections (Ohms) Meter +ve Meter -ve X1 Ye l ow ow /Re d B la ck ck/ Ye Ye l ow ow


LIGHTING COIL (ES) Connections Range (Ohms) Meter +ve Meter -ve X1 Ye l ow ow /Re d B la ck ck/ Ye Ye l ow ow


Guide gear allen bolt. Kick guide bolts. Drum stopper arm bolt. Starter counter one way clutch allen bolts. Oil separator plate screws. Bolt holding spring for stopper arm. Stopper bolt - changer lever spring.

• • • • • •

•

Bolt for Plate stopper bearing. Screw for Pick up mounting on cover. Screw for Stator mounting on cover. Allen bolt for Sprocket fitment on cam shaft. Flanged bolt for Oil pump fitment on crankcase RH. Allen bolt for Chain tensioner to crankcase RH. Flanged bolt for Assembly of crankcase LH & RH. Allen bolt for Sprocket fitment on output shaft. Screw for Kick lever. Flanged bolt for Starter motor fitment on cover RH. Screw for Starter motor cover. Flanged bolt for Stopper for plate starter clutch gear return. Clutch nut.

Whenever engine is mounted on the frame or during periodic services always tighten engine mounting bolts in the sequence shown in the figure. This will ensure proper mounting of the engine and will reduce the vibrations and also increase the life of mounting rubber bushes.

6 7 5

3 2 8

4

9 10

1


IMPORTANT ENGINE ASSEMBLY TIPS • • • • •

•

•

A

‘Input Shaft’ has special nut. ‘Input Shaft’ has Left hand threads. No need of applying Loctite 243. Washer for Input shaft nut is same as of primary gear. The special nut has ring mark for identification. Secure the cam chain sprocket by the tool given below firmly and then tighten the sprocket allen bolt (A). Ensure that the ‘O’ mark on washer always faces outwards when tightening the allen bolt (A).

PRECAUTIONARY MEASURES •

Chain top edge to be kept between the two marks during chain slackness adjustment.

Precautions to be taken while dismantling of engine •

•

•

•

Remove the allen head grub screw before removing the sleeve spark plug. Before fitting the sleeve spark plug apply thin layer or molybdenum di-sulphide grease on the entry chamfers for the ‘O’ rings.

•

•

•

Valve timing Ensure the sprocket marks (A) are aligned horizontally with cylinder head top machined face. Ensure the piston is at TDC. Ensure ‘T’ mark on rotor matching t he c’case mark.

•

•

Always blow compressed air through the oil passages in reverse direction of oil flow and ensure the passages are clear.

•

•

A

A

•

•

•

The clutch collar having hole is to be slided into the clutch housing for effective lubrication.

•

Apply a thin layer of liquid gasket on body of the starter cover.

•

•

While removing engine foundation bolts, first remove the topmost and then go down progressively. After removing all the engine connections lift up and remove the engine from RHS of the vehicle. Improper loosening sequence may cause warpage in cylinder head cover and it can be damage permanently.

Precautions to be taken while assembling of engine •

•

•

•

Drain the engine oil into a clean tray by loosening and removing strainer cap located on LH side of crankcase.

•

As fas as possible do not let oil to wet the top of the piston, or the combustion chamber in the cylinder.

•

If cylinder block is tight in dowels, lightly tap with hands in upward direction. If still tight use a plastic or woodem rod and pry it upwards. When taping the drift for removal of gudgeon pin, confirm that the connecting rod is held firmly against the direction of tapping to avoid damage to big end bearing of crank shaft. Starter cover base is fitted on the crankcase with liquid gasket application hence tap gently for easy detachment. Clutch nut have left hand threads.

•

•

•

•

• •

Bigger gear to be assembled facing the dust cap side while assembling the starter counter gear.

•

When splitting crankcase always remove. First Fir st : 1 longe longest st bolt bolt fitted e d from r om clu clutch tch sid side. e. Secondd : 1 long bolt fitted Secon t ted from from magneto magneto side and and then remove all bolts from magneto side.

•

•

Confirm the free rotation; shifting of gears after assembling. Always align the gear box into neutral gear position and then assemble both the crank cases. Bolt sizes are different. Ensure 1 longest bolt is fitting in clutch side crankcase and 1 long bolt is fitting towards breather side cranckase. Confirm the free rotation of crank shaft and centering of crankshaft. While fitting kick spring, make sure that spring sharp edge does not scratch against crankcase surface and damage the surface finish. Special nut has left hand threads and round cut mark around the nut. Do not lock the rotor holder special tool against the pickup coil sensor on rotor and gear change shaft. Always lubricate the needle roller bearing when over hauled. Incorrect bolt size fitment on body starter may result in locking of rotor or gear counter assembly. Place a piece of clean cloth above hollow portion of crank case to arrest piston pin circlip if it falls during fitment. Before fitting the sleeve spark plug apply thin layer of molybdenum disulphide grease on the entry chamfers for the ‘ O’ rings. Ensure that the ‘O’ mark on washer always faces upwards. Ensure the sprocket marks are aligned horizontally with cylinder head top machined face and the piston is at TDC. Improper tightening sequence may cause warpage in cylinder head cover and it can be damage permanently.


FREQUENTLY ASKED QUESTIONS - FAQ’S


 What are the features of ‘Di scover DTS-i’ motorcycle?

 Placing another Spark plug opposite to the original one enables the sparks to occur simultaneously, thus reducing the time for combustion to take place, thereby increasing combustion efficiency and its speed with tremendous benefits.

 ‘Discover DTS-i’ has many Unique; Advanced & Contemporary features as mentioned below. Unique Features: • • • • •

High Power of____________ 11.51 Ps. Greater Torque of_________ 10.80 N-m. Max. Speed of____________1 of____________100 00 Kmph. Least emission of CO, so great environment friendly vehicle. Unique and cute Headlamp fairing with twin pilot lamps and option of Round Headlamp as well that matches to the profile of the vehicle.

Advanced Features: Digital Twin Spark Ignition System (DTS-i) with Twin Map for accurate ignition timing. Throttle Responsive Ignition Control System (TRICS). Optimized engine combustion characteristics to provide ultimate performance. •

• •

Contemporary Features: Contemporary Strongest & Sturdier frame & stiffer rectangular cross-sectioned swing arm to with stand twists and all kind of road tortures. Longest wheel base in its class for better road holding characteristics. Highest rear wheel travel to ensure most comfortable ride in all terrain. Longest fr. suspension travel in its class to provide pleasant ride. •

•

•

•

•

Brightest Headlamp with 60 / 55 Watt Halogen bulb for safer night ride.

In fact ‘Discover DTS-i’ delivers power & performance of 125 cc engine and economy of 100 cc engine. More over the Comfort, Convenient & Safety are ultimate to any motorcycle on Indian road with the capacity of of 100 to 135 cc engine. engine.  What is ‘DTS - i’ ?

Technology  DTS-i stands for Digital Twin Spark Ignition - an Advanced Technology which will be the heart of a new breed of high performance engines from Bajaj.  What is the Advanced Technology in DTS-i ?

 DTS-i engines incorporate Two Spark Plugs (hence called Twin Spark) in the cylinder head, a Microprocessor controlled (like computers) Digitally operated CDI which accurately controls the Ignition Timing and ‘TRICS’ or Throttle Responsive Ignition Control System, which is a non-contact switch on the Carburetor body and this changes the Ignition Map based on Throttle position.  Combined actions of these technological breakthroughs enhances the Overall Performance likes Power, Pick-up, and Mileage etc.  Why Twin Spark Plugs ?

 Conventionally in a 4-stroke engine the spark plug is at one end of the combustion chamber. It means the Air fuel mixture combustion is better around the sparkplug, rather than the opposite side of the combustion chamber. Because of the longer time needed for the combustion to take place on the far side (opposite (opposite side of the spark plug) overall combustion is slow, leading to poor combustion efficiency.

 What is the ‘DIGITAL’ in Digital Twin Spark ignition ?

 Conventional Analogue type CDI’s work in a very constricted manner. They are unable/constrained to control the ignition advance or retard for specific points in the entire engine rpm range. They could either advance or retard but not do both for specific points in the engine rpm range.  The Ignition System of ‘DTS-i’ is Digitally operated. An 8 bit Microprocessor is programmed to decide and control the Ignition Advance or Retard at any point in the entire engine rpm range. It is like a computer being programmed to run in a specific way. There is tremendous consistency and accuracy in the Ignition Timing, which enhances the overall Performance.  This Digital CDI has also been programmed to cut the sparks to the spark plugs at high rpm’s thereby preventing anybody from damaging the engine. All these advantages are only possible with Digital Chips.  What is ‘TRICS’ and what is so special about it ?

 A non-contact type switch is mounted on the cable pulley shaft of the Digital CDI to change change the Ignition Advance/Retard map. The amount of angular movement of the cable pulley shaft depends on the speed and load demands of the Rider.  With the adaptation of TRICS, the engine also becomes highly Knock resistant.

 ‘Throttle Responsive Ignition Control System’ activates and swaps between two different Ignition Ignition Maps for getting an optimum Ignition Advance/Retard Timing, for different speed an load conditions. The switching over of the Ignition maps is Seamless and the switch itself is completely maintenance free for the life of the Vehicle.  What are the benefits of ‘DTS-i’ in a nutshell ?

 Digitally managed Optimum Ignition Timing over the entire engine rpm range formore accuracyand accuracyand efficiency. And faster & complete combustion process – leading to complete utilization of air-fuel mixture and thereby results in – Enhanced Power. Enhanced Pick-up. Enhanced Mileage. Enhanced Drivability in all engine operating conditions. Less Emission of CO. that meets ‘2005 Emission norms’. • • • • •

 Can existing non DTS-i 2 Wheelers be converted into DTS-i

technology ?  No, the ‘DTS-i’ technology demands major technological changes in the engine and vehicle, hence it is almost impossible to convert an existing 2-wheeler to accept ‘DTS-i’ technology.The conversion is not economically viable, as it means almost a complete replacement of the vehicle/engine.  Does ‘DTS-i’ costs more in Maintenance ?

 No. The ‘DTS-i’ technology is tried and tested under extreme conditions by Bajaj Auto Limited. The systems/parts of ‘DTS-i’ are virtually maintenance free.


FREQUENTLY ASKED QUESTIONS - FAQ’S  How ‘DTS-i’ is different from VT-I in TVS Centra and AMI in Hero

 Why Dual Oil Filtration system is not given in ‘Discover DTS-i’

Honda Ambition ?  VT-I of TVS Centra and AMI of Hero Honda Ambition only have swithchable Ignition timing maps and Digital CDI’s. The switch of TVS Centra is not Maintenance free and the switch of Hero Honda Ambition is a contact type, which means problems or wear and tear.

where as this feature feature is given given in Wind 125? 125?  ‘Discover DTS-i’ engine too has dual oil filtration system. The first stage filtration is done by extra extra large strainer with fine mesh. And the second stage filtration is taken care by in built Centrifugal Oil filter mounted on crankshaft.

“DTS-i technology from Bajaj Auto Limited is the future of bikes”.  Why the Tyre size is of 17" where as normally all other

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motorcycles traditionally traditionally have 18" tyres? ‘Discover DTS-i’ motorcycl ‘Discover orcycle has some special special geometry geometry as far as Ride Comfort & Pleasure is concerned. The Specialties are The longest Wheel Base >>> 1305 mm. Lowest Center of Gravity. Longest Front Suspension Travel >>> 135 mm. Wider distance between both Front fork tubes. Rear Shock Absorber having Triple Rating Spring & longer stroke. >>> 85 mm. Longest Rear Wheel Travel. >>> 110 mm. • • •

 Being 125 cc and having higher power, why ‘Discover DTS-i’ has

not been incorprated with 5-speed gear transmission ?  Considering utilization of power produced by this engine, to achieve better low-end torque, torque, pick up and and to obtain maximum mileage gear ratios have been uniformly spread across all gears appropriately. With this 4-speed transmission is enough enough to perform the task. task.

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 When ‘Discover DTS-i’ has so advanced engine, then how come

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SAI system & BS Valve is not provided in this?  That is one of the speciality of ‘DTS-i’ engine. The optimized combustion combu stion process process because because of two Spark plugs, plugs, Digitallyma Digitallyma na ge d accurate Ignition and TRICS all together address the advantages of low emission, better cold startability, enhanced drivability delivered by SAI System and B S Valve.

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All these things are enabling ‘Discover DTS-i’ to deliver Excellent Road holding, Better Balancing and Extra ordinary High speed Stability. With this, there is absolutely no need of 18" tyre. B

 With extra large strainer and Centrifugal Oil filter, the level of filtration would be similar to the engine engine having Primary Strainer and Paper Oil filter.

Rather here, the 17" tyre, tyre, due to reduced weight and lesser road contact area, it will contribute in enhancing the mileage as compared to 18" tyre.

 That means, again lesser the components, more the benefits.  Why primary kick mechanism isn’t provided in ‘Discover DTS-i’

engine?  To reduce engine components which minimizes the engine weight as

FREQUENTLY ASKED QUESTIONS - FAQ’S well, the kick mechanism is provided is similar to ‘Caliber’ & ‘Boxer’ range of motorcycles.

 Minimized weight contributes in enhancing the mileage and lesser the components contribute to cost benefits, which we can pass on to our valued customers.

 Still such noise will always be heard on high performance engines. So to achieve more from the limited capacity engines we need to accept the facts. Of course this fact is not harmful and will not effect on the performance of the engine.

 Why ‘De-compression’ mechanism like in Pulsar engines is not

 Why 4-Plate clutch on this engine, where as ‘Wind 125’ and

provided in ‘Discover DTS-i’ engine?  Normally ‘De-compression’ mechanism is required in higher capacity engines where one would feel resistance in operating the kick while starting the engine. ‘Discover DTS-i’ engine does not require this.

Pulsar engines have 5-Plate clutch ?  The clutch of ‘Discover DTS-i’ engine is bigger so the plates (friction plates) are wider in size. Due to this, the more contact area in line with 5-Plate clutch is obtained. With this, 4-Plate clutch is big enough to handle power transmission characteristics.

 Why Aircraft Type Fuel Tank Cap similar to Pulsar Fuel Tank Cap

is not provided ?  Petrol tank caps are designed considering shape of Petrol Tanks. The cap provided on Discover Petrol tank goes well with its shape.  Why the engine noise level is towards higher side in ‘Discover

DTS-i’?  As we have seen that the ‘Discover DTS-i’ engine is designed and developed to achieve optimized combustion process. This is achieved by having higher compression ratio and so many other design parameters related to Intake and combustion process.

 This complete combustion process will generate some combustion noise. This noise will be a characteristic of high performance engines like ‘DTS-i’ engines. To minimize this noise, & control vibrations as well, rubber dampers have been incorporated in the clutch cover & magneto cover.

 Why Crankshaft Balancer is not provided in ‘Discover DTS-i’

engine?  The Crankshaft design and geometry is optimized and the Static & Dynamic balancing factors factors are well taken care by this crankshaft with respect to relative rotating components. Thus the crankshaft of ‘Discover DTS-i’ engine does not need balancer.  How come 'Discover DTS-i' is expected to give better mileage in

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spite of higher capacity 125cc engine? So many parameters aspects aspects are incorporated incorporated in ‘Discover DTS-i' to enable it deliver better mileage. On technological front, as we have seen so far the package package of DTS-i like Twin Spark Plugs, Digital CDI, T win Ignition Maps & TRICS in this ‘Lean Burn’ engine, all together have improved combustion process that is leading to • Complete ete combustio combustionn of air - fuel mixture. ure.


FREQUENTLY ASKED QUESTIONS - FAQ’S •

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Altering of Ignition timing depending upon different throttle positions.

As these activities consistently take place, the fuel efficiency is bound happen in ‘Discover DTS-i' engine. Moreover, other certain virtual elements are there to support this engine for delivering better mileage. The other virtual elements are Lesser weight of the engine as compared to other 125 CC engines. Lesser road resistance due to lesser road contact area on account of 17" tyres. Virtual Instructor to the Rider in the form of ‘Ride Control Switch' to ride the vehicle in ‘Fuel Efficiency Zone'.

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Truly speaking, if ‘Discover DTS-i' is ridden within 'Fuel Efficiency Zone' as per instruction of Ride Control Switch, it can put all other 125 CC engined vehicles on shame and even able to compete shoulder to shoulder with other 100 CC engined vehicles.  What is ‘Exhaust TEC'?

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Exhaust ‘TEC’ is a device incorporated in exhaust system of ‘Discover DTS-i’ engine. ‘TEC’ stands for ‘Torque ‘Torque Expansion Chamber’. Chamber’. It improves ‘Scavenging’ process. The exhaust system has this revolutionary feature, which drastically improves engine torque at low revs without compromising anything at mid or high engine revs. It has been extensively optimized to get the maximum possible performance out of the engine. The Silencer also has a characteristic tonal quality to it. It gives out a pleasant sounding

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0

D is co co ve ve r

C T 1 00 00

Power

11.51

8

7.5

7.5

V ic ic to to r 1 25 25

F az az er er

92

81.86

86.4

96.39

 Is Power & Pick-up of ‘Discover DTS-i’ marginally or substantially

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better than current 100 cc popular bikes or there's a substantial improvement? No. The Power & Pick up of of ‘Discover DTS-i’ is far.. far… better than the popular 100 CC bikes and even much better than any other 125 CC bike on the road.

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The Power Power & Torque compari comparison son is follows. lows.

Crux 7.7

Freedom 8

Torque

2

0.98

0.9

0.9

0.82

0.92

10

You can very well see that how the ‘DTS-i’ technology technology has enabled enabled ‘Discover DTS-i' to be close to its Big Brother Brother Pulsar 150 cc.

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‘Discover DTS-i' almost equal to Regular Regular Pulsar 150 cc and close to Pulsar 150 cc with ‘DTS-i’ engine. The table below indicates the comparison.

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0 Discover

Fazer

Fredom 125

More over over it even looks looks like mini mini Pulsar Pulsar as well.

Victor 125

Power

11.51

10.8

10.7

9.66

Torque

2

1.06

1.07

0.97

Vehicle Pulsar DTS-i 150 cc

 Will 125 cc bikes become standard on the road as against current

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‘Discover DTS-i' different than in Pulsar? The ‘DTS-i’ technology technology as such from Bajaj is the same on Pulsar as well as D iscover. The package of ‘DTS-i’ that comprises Twin Spark Plugs, Digital CDI, Twin Ignition Maps and TRICS are very much there and function similar as in case of Pulsar. But the values of performance are as per the respective engine requirements.

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The Power to Weight Weight Ratio that means the Power Power produced per ton on weight of the vehicle in comparison comparison with other vehicle is given below. D is is co co ve ve r

P as as si si on on + Splendor

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On one side it was successful to make the engine deliver more power and on the other side it has tried to reduce the engine weight by simplifying the design as compared to other 125 CC engines.

Freedom Prima 125

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Discover? ‘Higher the Power Power Heavier the Engine’ has become now a vintage story (or has become a old proverb) Bajaj R & D with its capability has engineered and developed ‘Discover DTS-i’ engine with Higher Power to Weight Ratio as compared to other 125 CC engines.

Power to Weight Ratio i.e. Power per Ton weight of the vehicle

 Does Discover has all the technologies of Pulsar? OR Is ‘DTS-i’ in

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 Normally higher power bikes are heavier in weights. How about

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low frequency ‘boom’, which many people associate with the typical 'Bullet' kind of silencer sound. While meeting the mandatory current Noise norms, it gives the vehicle an identity, which is different from any other bike, so as to make it very unique.

Combustion at accurate timing with respect to engine rpm at different speeds and loads on the engine.

100cc bikes? 100 cc bikes are plying on Indian roads now for over a decade. It's a normal tendency of a person that when he plans to change the vehicle, he always look for better better power, better capacity, better pick up. And when because of advancement in engine technology, if better capacity, say 125 cc engines offers similar economy of 100 cc, then it influences the trend. We strongly feel 125cc bikes wil become standard on the Indian road and 100cc bikes will go the way mopeds have gone.

Pulsar 150 cc Regular ‘Discover DTS-i’

Power

Torque

Maximum Speed

13.02 Ps

11.68 N-mm (1.19 Kg-m)

120 Kmph

12 Ps

10.8 N-m (1.1 Kg-m)

100 Kmph

11.51 Ps

10.8 N-m (1.1 Kg-m)

> 100 Kmph

 Is 125cc ‘Discover DTS-i' is poor man's Pulsar?

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Yes. Why not? It not not only resembles resembles Pulsar in masculine masculine physique but also it is quite sturdier and rigid in built. The Frame, the square box swing arm all makes it as strong as Pulsar. So it is a mini Pulsar with economy.

Discover Dts i Srr

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