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Bajaj Platina 100 BS VI Supplementary Service Manual
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Bajaj Platina 100 BS VI Supplementary Service Manual

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Supplementary Service Station Manual - Platina 100 BS VI
Product code
Platina 100 ES BS VI CBS : PF20
Platina 100 KS BS VI CBS : PF25

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Summary of Contents for Bajaj Platina 100 BS VI

  • Page 1 Supplementary Service Station Manual - Platina 100 BS VI Product code Platina 100 ES BS VI CBS : PF20 Platina 100 KS BS VI CBS : PF25...
  • Page 2 Index Sr No Parameter Technical Specifications Preventive Maintenance Chart PDI check sheet Torque Value & Service Limit Part identification Wiring Harness Routing...

  • Page 3: Technical Specifications

    Technical Specifications...
  • Page 4 4 Speed Stroke 58.8 mm Gear shifting pattern All Down Displacement 102 cc BAJAJ DTSi 10000 BS6 Engine oil Grade Compliant Engine oil 10W30 API SN JASO MA2’ Idling speed 1300 +/- 100 rpm Engine oil Drain & Refill 1000 ml quantity Max.Net Power...
  • Page 5 Rear (Pillion) 2.25 Kgf/cm² (32 PSI) Fuel Tank Capacity Full 11 Litres Fuel Tank Usable Reserve 1.5 Litres Fuel Tank Un-Usable Reserve 0.5 Litres Fork oil Grade Bajaj fork oil ,SAE 10W20 Fork oil Quantity / leg 150 +/- 2.5 ml...
  • Page 6 Electrical Parameters Specification Fuel Gauge Values System Fuel Quantity Fuel Level Standard Value(Ω) (Litres) Battery 12V 3Ah VRLA Empty Tank Head Lamp 12V 35W/35W Half Tank Part of Daytime Running Position Lamp Light (DRL) Full Tank Tail / Stop Lamp 12V 5/10W Side Indicator icon lamp 12V 10W...

  • Page 7: Preventive Maintenance Chart

    Preventive Maintenance Chart...
  • Page 8 √ √ √ √ √ √ Servicing with water wash tank, Silencer & electrical parts.Use caustic free detergent for washing. Use BGO 10W30 Engine oil (Bajaj DTSI 10000 oil) Top up, R Top-up Top-up Top-up Top-up Top-up Top-up Top-up Top-up Oil level window cleaning at every 10000 kms by petrol spray &...
  • Page 9 Recommended frequency -- Service interval & Kms Servicing 10th 11th 12th 13th 14th 15th 16th (Free) (Free) (Free) Sr No Activities / Check points Remarks Check fault code, Clear fault history, Update latest hex file if applicable During 1st Free Service :Use lint free cloth for cleaning &...
  • Page 10 Recommended frequency -- Service interval & Kms Servici 10th 11th 12th 13th 14th 15th 16th (Free) (Free) (Free) Sr No Activities / Check points Remarks General lubrication – Clutch lever / front brake Use recommended AP grease. lever & kick lever. Front : 1.75 Kgf/cm²...
  • Page 11 PDI Check sheet...
  • Page 12 PDI Check sheet Dealer's Name Dealer's code: Model City Frame No. Date of PDI Engine No. PDI done by 1. Check Points before starting the vehicle Recommendation / Workshop Tools , equipment & Check Point What to check How to check Reference Observation consumables required...
  • Page 13 Tools , equipment & Recommendation / Workshop Check Point What to check How to check consumables Reference Observation required Green LED-Battery fully charged. Yellow LED -Battery Battery charge condition As per SOP partially discharged. 1. Midtronics battery Red LED-Battery deep Battery tester, discharged.
  • Page 14 Worksho Tools , equipment & Check Point What to check How to check Recommendation / Reference consumables Observati required Front Axle 4.5 - 5.5 Kgf-m Rear Axle 5.5 - 6.5 Kgf-m 5.2 – 5.8 Kgf-m Swing arm Shaft Fasteners Torque values Using dial torque Dial torque wrench wrench...
  • Page 15 Tools , equipment & Recommendation / Workshop Check Point What to check How to check consumables Reference Observation required Funnel for filling Speedometer working to Working of speedometer, Fuel gauge-By filling fuel. petrol & measuring be checked during / , Fuel gauge after test ride Speedometer Working of all signal...
  • Page 16 Torque Values & Service Limits...
  • Page 17 Torque Value - Engine Torque value Torque value Sr. No. Parameter Sr. No. Parameter (Kgf-m) (Kgf-m) Cover cylinder head bolts 1 - 1.1 Oil strainer cap 1 - 1.1 Cylinder head bolts 2.2 - 2.5 Oil pump mounting screw 0.5 - 0.7 Intake Manifold fitted on head bolts 1 - 1.1 Clutch cover bolts...
  • Page 18 Torque Value - Frame Torque Value (Kgf- Torque Value (Kgf- Sr.No. Parameter Sr.No. Parameter ECU Mtg bracket nuts 0.8 - 1.2 Rear coupling sleeve nut 6.2 - 6.8 Torque rod nut 2.8 - 3.2 RR Unit bolts 0.8 - 1.2 HT Coil bolts 0.8 - 1.2 Rear brake pedal bolt...
  • Page 19 Service Limit - Engine Sr. No Parameter Standard (mm) Service Limit (mm) Sr. No Parameter Standard (mm) Service Limit (mm) Engine compression Piston Ring end 12 - 13 Kgf/cm² Min 9.5 Kgf/cm² 0.20 - 0.40 0.65 pressure gap (second ring) Piston Ring end Valve tappet clearance 0.20 - 0.70...
  • Page 20 Service Limit - Frame Sr.No Parameter Standard Specification (mm) Service Limit (mm) Front 12 - 12.03 12.15 Brake Panel cam hole diameter Rear 12 - 12.03 12.15 Front 11.95 - 11.98 11.83 Brake cam diameter Rear 11.95 - 11.98 11.88 Front 3.9 - 4.5 Brake Shoe lining thickness...
  • Page 21 Part Identification –for Platina 100 ES BS VI(00PF20ZZ)

  • Page 22: Wiring Harness

    Wiring Harness Model Platina 100 ES BS VI (00PF27ZZ) Platina 100 ES BS VI (00PF20ZZ) Part No PF402265 PF402257 Harness routing is different than Platina 100 ES BS VI Description (00PF27ZZ) & Platina 100 KS BS VI (00PF26ZZ)
  • Page 23 Part Identification –for Platina 100 KS BS VI (00PF25ZZ)
  • Page 24 Wiring Harness Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Part No PF402267 PF402263 Harness routing is different than Platina 100 ES BS VI Description (00PF27ZZ) & Platina 100 KS BS VI (00PF26ZZ)
  • Page 25 Part Identification – Common Platina 100 BS VI(00PF20ZZ) Platina 100 BS VI (00PF25ZZ)

  • Page 26: Rear Shock Absorber

    Rear Shock Absorber Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK122021 PF122025 • Spring on Spring type • Spring in Spring type Description •...
  • Page 27 Lever Holder Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) M8X1.25P Ø 8 mm Photograph Part No LH - JL161014, RH - DS191033 LH - PF161010, RH - PF161012 Description With threading Without threading...
  • Page 28 Hand Grip Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No LH - JK151018, RH (Assembly) - JK151019 LH - PF161005, RH(Assembly)- PF161007 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 29 Clutch Cable /Front Brake Cable Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Clutch cable - PA161209 Clutch cable - PF161226 Part No Front brake cable - JK161215 Front brake cable - PF161234 Description Without lever rubber boot...
  • Page 30 Daytime Running Light (DRL) unit Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK401025 Description With separate DRL unit...
  • Page 31 Lamp Head Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No PF401022 JK401023 Description With integrated DRL Unit Without integrated DRL Unit...
  • Page 32 Fairing Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK181265 JK181256 Description Without provision for DRL unit fitment With provision for DRL unit fitment...
  • Page 33 Indicator Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph JK401028 - INDICATOR FRONT LH-REAR RH Front LH - DJ201208, Front RH - DJ201209 Part No JK401029 - INDICATOR FRONT RH-REAR LH Rear LH - DJ201206, Rear RH - DJ201207...
  • Page 34 Bracket Fairing Lower Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK181277 PF181264 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 35 Structure Indicator Front Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK181279 PF181237 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 36 Flap Speedometer Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK181267 JK181247 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 37 Bracket Fairing Upper Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK181278 JK181246 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 38 Tail Lamp Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK401027 DZ201016 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...

  • Page 39: Seat Assembly

    Seat Assembly Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK191006 PF191011 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...
  • Page 40 Saree Guard Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK231206 PF231206 Design is different than Platina 100 ES BS VI Description (00PF27ZZ) &...

  • Page 41: Control Switch Lh

    Control Switch LH Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No JK401410 JB401400 Description Length : 650 mm Length : 420 mm...

  • Page 42: Hand Guard

    Hand Guard Platina 100 ES BS VI(00PF20ZZ) Platina 100 ES BS VI (00PF27ZZ) Model Platina 100 KS BS VI (00PF26ZZ) Platina 100 KS BS VI (00PF25ZZ) Photograph Part No Refer SPC Description With hand guard...

  • Page 43: Wiring Harness Routing

    Wiring Harness Routing...
  • Page 44 Platina 100ES BS VI (00PF20ZZ) Top Side LH Side...
  • Page 45 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 46 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 47 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 48 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 49 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 50 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 51 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 52 Platina 100ES BS VI (00PF20ZZ) • Route the harness as shown in photograph.
  • Page 53 Platina 100KS BS VI (00PF25ZZ) Top Side LH Side...
  • Page 54 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 55 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 56 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 57 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 58 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 59 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 60 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 61 Platina 100KS BS VI (00PF25ZZ) • Route the harness as shown in photograph.
  • Page 62 Electrical Parts Values Sr.No Part Standard Value 3.9Ω±10% Starter Relay Coil 0.7Ω ±10% Battery Charging Coil Pick Up Coil 215±20Ω DC Charging Voltage 14.5 ± 0.1V DC Charging Current 8.3A ±0.5 @ 4000 RPM Horn 12V 2A Input voltage 5 V ±0.1 Throttle Position Sensor Output voltage 4.7 V...