Bajaj GT 125X Service Station Manual
  1. Manuals
  2. Brands
  3. Bajaj Manuals
  4. Motorcycle
  5. GT 125X
  6. Service station manual

Bajaj GT 125X Service Station Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Service Station Manual

Advertisement

Table of Contents
loading

Related Manuals for Bajaj GT 125X

Summary of Contents for Bajaj GT 125X

  • Page 1 Service Station Manual...
  • Page 2 All information contained in this service station manual 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.
  • Page 3 REVISION MATRIX Rev No Date Reason for change Sr. No Service Support - M/C Service Station Manual...

  • Page 4: Table Of Contents

    INDEX INDEX 1. Technical Information....................1 Technical Information.................. 2 Preventive Maintenance Chart..............4 PDI Checklist....................7 Speedometer Information................11 6. Engine ........................14 Torque Value ..................... 15 Service Limit....................18 Special Tools....................20 Important SOP.................... 24 Engine Oil Flow path.................. 58 Part Identification..................

  • Page 5: Technical Information

    Technical Information • Technical Specifications • Preventive Maintenance Chart • PDI check sheet • Speedometer Information...
  • Page 6 Gear shifting pattern All Down All Down BAJAJ DTSi 10000 BS6 Compliant Engine BAJAJ DTSi 10000 BS6 Compliant Engine oil Engine oil Grade oil. Grade – SAE 10W30 API SL MIN Grade – SAE 20W50 API SL MIN Engine oil Drain & Refill quantity...
  • Page 7 TECHNICAL SPECIFICATIONS Parameter CT 110X ES Drum Drum CT 125X ES Disc Drum / 125X Drum Drum Length 1998 mm 2000 mm Width 753 mm 810 mm Height 1098 mm 1102 mm Wheelbase 1285 mm 1285 mm Ground Clearance 170 mm 170 mm Vehicle Kerb Weight 127 Kg...

  • Page 8: Preventive Maintenance Chart

    PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 9 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 10 PREVENTIVE MAINTENANCE CHART PREVENTIVE MAINTENANCE CHART Service Support - M/C Service Station Manual...
  • Page 11 PDI CHECK SHEET - CT 125X DRUM 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...
  • Page 12 PDI CHECK SHEET - CT 125X DRUM Recommendation / Workshop Tools , equipment & Check Point What to check How to check Reference Observation consumables required 2. Check Points during / after starting the vehicle RH & LH control switch, Check for smooth Switch Operation ignition switch, clutch switch...
  • Page 13 PDI CHECK SHEET - CT 125X DISC 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...
  • Page 14 PDI CHECK SHEET - CT 125X DISC Recommendation / Workshop Tools , equipment & Check Point What to check How to check Reference Observation consumables required 2. Check Points during / after starting the vehicle RH & LH control switch, Check for smooth Switch Operation ignition switch, clutch switch...

  • Page 15: Speedometer Information

    SPEEDOMETER INFORMATION 1. Odometer : The Odometer shows the total distance that the vehicle has accumulated. 2. Speedometer : The Speedometer pointer shows the speed of vehicle. 3. Fuel Level Indicator : Fuel level indicator shows approximate available fuel in fuel tank. 4.
  • Page 16 SPEEDOMETER INFORMATION SOP to prevent fuel stains on Fuel tank Fuel Tank Cap • After fuel refilling & before shutting the cap wipe the spilled fuel from the painted areas around the cap, wipe by soft dry cotton cloth. • Shut and lock the cap fully. •...
  • Page 17 SPEEDOMETER INFORMATION Side Stand Switch Interlocking Side stand Side stand condition Indication in Gear position Remark speedometer Neutral Self start / kick start possible Down Gear is applied in vehicle start Engine will get cut off. condition by pressing clutch lever Down Gear Engine will not start by self / kick...

  • Page 18: Engine

    Engine • Torque Value • Service Limit • Special Tools • Important SOP • Engine Oil Flow Path • Engine Oil / Loctite / Grease Application Matrix • Part Identification...

  • Page 19: Torque Value

    TORQUE VALUE Torque value Sr. No. Parameter (Kgf-m) Cover cylinder head bolts 1 - 1.1 Cylinder head tower bolts 2.3 - 2.5 Intake Pipe moutning screw 0.9 - 1 Camshaft sprocket mounting bolt Chain tensioner mounting bolt 1 - 1.1 Chain guide moutning bolt 1 - 1.1 Primary gear nut...
  • Page 20 TORQUE VALUE Torque value Sr. No. Parameter (Kgf-m) One way clutch bolts on rotor 1.4 - 1.5 Starter Motor bolts 1 - 1.1 Kick lever bolt 2.3 - 2.5 Service Support - M/C Service Station Manual...
  • Page 21 TIGHTENING SEQUENCE Clutch Cover Mounting bolts Magneto Cover Mounting bolts RH Crankcase Mounting bolts LH Crankcase Mounting bolts Engine Mounting bolts Service Support - M/C Service Station Manual...

  • Page 22: Service Limit

    SERVICE LIMIT Standard Service Limit Parameter (in mm) (in mm) Min : 9.5 Engine compression pressure 12- 13 kgf/cm kgf/cm Valve tappet clearance Intake 0.05 - 0.07 Not Applicable Valve tappet clearance Exhaust 0.1 - 0.12 Not Applicable Rocker arm shaft diameter 9.97 - 9.98 9.965 Cam sprocket root diameter...
  • Page 23 SERVICE LIMIT Standard Service Limit Parameter (in mm) (in mm) Gear shift fork guide pin diameter 4.45 - 4.49 4.43 Gear shift drum groove width 4.6 - 4.7 4.75 Crankshaft runout 0.02 0.05 Cam lobe width 6.9 - 7.1 Not Applicable Shaft fork shift outer diameter 9.97 - 9.98 9.96...
  • Page 24 SPECIAL TOOLS Tappet setting tool Part No. : 37104355 Usage : For adjusting tappet clearance Free Play Gauge & Tappet Feeler Gauge Part No. : 37104390 Usage : For checking tappet clearance Cam sprocket Holder Part No. : 37104396 Usage : For holding cam sprocket during tightening &...

  • Page 25: Special Tools

    SPECIAL TOOLS Spark plug sleeve removal tool Part No. : 37104309 Usage : For removing RH side spark plug sleeve. Temperature Sensor Removal & Fitment Tool Part No. : 37104388 Usage : For removal & fitment of temperature sensor Chain Tensioner adjustment tool Part No.
  • Page 26 SPECIAL TOOLS Adaptor - Valve spring compressor Valve Spring Compressor Part No. : 37103107 Usage : For compressing valve spring. Valve spring compressor Adaptor Valve Spring Compressor Part No. : 37103108 Usage : This adaptor is to be used with Valve Spring Compressor. Primary gear Holder Part No.
  • Page 27 SPECIAL TOOLS Magneto rotor puller Part No. : 37104369 Usage : For pulling rotor assembly from crankshaft. Bearing driver set Part No. : 37103061 Usage : For removing & fitment of bearing from crankcase. Adaptor Output shaft bearing extractor from RH crankcase Adaptor Input &...
  • Page 28 IMPORTANT SOP Magneto Side All Part Removal Side cover LH. • Insert the key into the cover lock (A) and turn the key clockwise. • Hold cover with both hands & pull front side first (B) & Slide rear side (C) towards front wheel side.
  • Page 29 IMPORTANT SOP • Shift Fuel tap assembly knob to OFF position. • Pull out Fuel pipe clamp. • Take out Fuel pipe from Fuel tap assembly • Remove Circlip of Fuel tank mounting. • Remove metal Washer. Lift Fuel tank and remove: •...
  • Page 30 IMPORTANT SOP • Remove cover rear LH mounting bolts(2 Nos) using 8 mm spanner & take out cover LH rear • Remove Stator Assembly coupler connection • Remove Neutral Switch connection • Remove Magneto cover mounting bolts (7 nos) with 8 mm T Spanner in cris-cross pattern.
  • Page 31 IMPORTANT SOP • Remove Dowels (2 nos) & magnet cover gasket • Remove gear starter clutch stopper plate mounting screw with Phillips head Screwdriver. • Take out gear starter clutch stopper plate. • Using magneto rotor holder, remove magneto rotor nut with 19 mm socket. •...
  • Page 32 IMPORTANT SOP • Take out Woodruff key. • Remove Gear drive starter Cam Chain / Clutch Cover Side All Parts Removal On Vehicle • Remove Fuel tank, drain engine oil as explained in “Magneto Side All Part Removal on Vehicle SOP”. •...
  • Page 33 IMPORTANT SOP • Disconnect RH H.T. coil connection. • Remove RH H.T. coil mounting bolts (02 nos) with 8 mm Spanner & take out RH H.T. Coil. • Disconnect LH H.T. coil connection. • Remove LH H.T. coil mounting bolts (02 nos) with 8 mm Spanner &...
  • Page 34 IMPORTANT SOP • Remove cylinder head cover mounting bolts (04 nos) with 8 mm spanner. • Take out cylinder head cover. Check TDC position. • Align magneto rotor mark with respect to crankcase LH mark. • Check cam sprocket marks from RH side. •...
  • Page 35 IMPORTANT SOP • Remove clutch cable bracket mounting bolts (2 nos) with 8 mm T Spanner • Remove clutch cable connected to clutch release shaft. • Remove Rider RH footrest (Stay RH) mounting bolts (02 nos) with 12 mm spanner for ease of clutch cover removal.
  • Page 36 IMPORTANT SOP • Remove plunger from Crankshaft • Remove Clutch bearing. • Using primary gear holder special tool, loosen Primary gear drive nut with 19 mm spanner. • Using primary gear holder & clutch nut special nut, remove clutch nut (LH type threading). Take out: •...
  • Page 37 IMPORTANT SOP • Take out clutch stack complete • Take out washer & Clutch housing complete • Take out clutch spacer & washer. • Take out Primary gear nut & washer. • Take out Primary gear. Service Support - M/C Service Station Manual...
  • Page 38 IMPORTANT SOP • Take out key & spacer. • Take out Cam chain • Remove oil pump driven gear. • Remove oil pump mounting screws (3 nos) with Philips head screwdriver & take out pump. • Remove oil pump dowels (02 nos) & gasket •...
  • Page 39 IMPORTANT SOP • Remove kick shaft spring from spring mounting rod & take out kick shaft. • Take out washer • Remove inhibitor complete gear shift mounting nut with 10 mm T Spanner. Take out inhibitor complete gear shift assembly. •...
  • Page 40 IMPORTANT SOP • Remove cam drum change mounting bolt with 5 mm allen key & take out cam drum change with 4 pins. Cylinder Head/ Block-Piston Removal on Vehicle • Remove Fuel tank as explained in “Magneto Side all parts removal SOP” •...
  • Page 41 IMPORTANT SOP • Remove Auto choke coupler connection. • Remove TPS coupler connection. • Loosen both clamps of carburetor using 3 mm allen key. • Take out carburetor assembly. • Remove cylinder head mounting bolt (A) using 12 mm spanner. •...
  • Page 42 IMPORTANT SOP • Remove cylinder head mounting bolts (4Nos) with 12 mm spanner in criss-cross pattern. Skill tip: While removing Cylinder head mounting bolt H (RH side rear bolt) as shown in photograph, tilt bolt H slightly towards RH side and remove the bolt.
  • Page 43 IMPORTANT SOP • Take out dowels (02 nos). • Remove engine temperature sensor coupler connection. • Remove engine temperature sensor with washer using special tool. • Take out chain guide (exhaust side) • Take out Cylinder block. • Take out cylinder block gasket. •...
  • Page 44 IMPORTANT SOP • Remove chain guide (inlet side) mounting bolt by using 5 mm allen key and take out guide. Crankcase (Engine) Assembly Removal from Vehicle • Remove Magneto side & Clutch side parts “Magneto Side all parts removal SOP”. •...
  • Page 45 IMPORTANT SOP • Remove belly pan mounting bolts (2 nos) by using 5 mm allen key & take out belly pan. • Remove Leg guard lower mounting bolt by using 12 mm spanner • Remove Engine front mounting bolts (3 Nos) (hold head and remove nut) using 12 mm spanner.
  • Page 46 IMPORTANT SOP • Remove LH crankcase joining bolts (6 nos) using 8 mm spanner. • All LH side bolts (7 nos) are of same length. Remove RH crankcase joining bolts: • Inner side bolt (2 nos) using 8 mm spanner. •...
  • Page 47 IMPORTANT SOP • Take out crankshaft & damper. • Remove shaft input fork gear shift. • Remove shaft output fork gear shift • Separate out fork gear shift from gear change drum and take out drum gear shift.. • Take out input fork gear shift. •...
  • Page 48 IMPORTANT SOP • Take out output shaft washer (thick). • Takeout input shaft & output shaft assembly together. • Takeout input shaft bottom side washer (thin). • Remove oil seal output shaft. • Remove output shaft bearing (LH crankcase) using bearing driver set. •...
  • Page 49 IMPORTANT SOP • Remove output shaft bearing from RH crankcase using bearing extractor tool. Engine Assembly Skill tips before crankcase assembly : • Engine oil passages: - Ensure that oil passages are clear by pumping engine oil into passage. - Apply low compressed air through the oil passage in reverse direction of oil flow for cleaning.
  • Page 50 IMPORTANT SOP Crankcase Assembly • Fit all the bearings in both crankcase using Bearing Driver set. • Prefit input shaft bearing lock plate mounting bolt & tighten to recommended torque. • Assemble input & output shaft assembly with gears in LH crankcase Skill Tip: •...
  • Page 51 IMPORTANT SOP Assemble output & input fork gear shifts: • Input fork gear shift: 1 Nos • Output fork gear shift: 2 Nos. Skill Tip: • Input & Output fork gear shift fitment as shown in photograph: - Input fork gear shift: rib facing downward - Output fork gear shift: ribs facing towards each other.
  • Page 52 IMPORTANT SOP • Fit dowels (2 nos) on crankcase. • Fit new crankcase gasket. Ensure crankcase face is clean before application of new gasket. • Fit RH Crankcase on LH crankcase. Prefit RH crankcase mounting bolts (5 nos) as shown in photograph & tighten to recommended torque.
  • Page 53 IMPORTANT SOP • Fit output shaft oil seal. • Fit clutch cover and magneto cover on crankcase assembly to avoid any dust entry and cover crankcase bore with clean lint free cotton cloth. Note: - Only pre-fit both covers bolts(2 Nos per cover in crisscross pattern).
  • Page 54 IMPORTANT SOP • Remove clutch cover & magneto cover from crankcase assembly. • Assemble piston assembly, piston pin & new circlips. • Take out cloth. • Assemble dowels (2 nos) & new cylinder block gasket. • Ensure that no any foreign particles are fallen in crankcase bore. •...
  • Page 55 IMPORTANT SOP • Assemble rotor key, rotor assembly with one way clutch & gear starter clutch on crankshaft assembly. • Apply Loctite 243 to rotor mounting nut. Using rotor holder, prefit rotor mounting nut with thick spacer & tighten to recommended torque(5 – 5.5 Kgf-m).
  • Page 56 IMPORTANT SOP • Assemble guide gear. Apply Loctite 243 to guide gear bolt. Prefit guide gear mounting bolt & tighten to recommended torque (1 – 1.1 Kgf- • Assemble lever complete gear shift(LCGS). • Assemble spring inhibitor, washer & inhibitor. Prefit inhibitor mounting bolt &...
  • Page 57 IMPORTANT SOP • Fit Chain guide exhaust side. • Insert cam chain. • Tie cam chain using copper wire. • Assemble spacer for primary gear. • Apply Loctite 243 to primary gear nut & assemble key, primary gear, washer & it’s mounting nut.
  • Page 58 IMPORTANT SOP • Assemble clutch thrust bearing. Top side assembly • Remove cotton cloth from block cylinder. • Assemble dowels (2 nos) and new cylinder head gasket. • Assemble head cylinder assembly. • Fit camshaft assembly & camshaft circlip. • Assemble rocker arm & rocker arm shaft of both inlet & outlet side. Service Support - M/C Service Station Manual...
  • Page 59 IMPORTANT SOP • Pre fit cylinder head mounting bolts (4 nos) & tighten as per recommended torque. Skill tip: While fitting Cylinder head mounting bolt H, tilt bolt H slightly towards RH side and fit the bolt. • Prefit & tighten cylinder head 5th bolt as per recommended torque.
  • Page 60 IMPORTANT SOP • Assemble cover head cylinder. Prefit it’s mounting bolts (4 nos) & tighten to recommended torque. • Assemble breather pipe in cylinder head cover and fit breather pipe clamp. • Assemble engine top mounting bracket. Prefit it’s bolts (03 nos) & tighten to recommended torque. •...
  • Page 61 IMPORTANT SOP • Assemble clutch cover, bracket clutch cable with cable clutch. • Prefit clutch cover mounting bolts & tighten to recommended torque. • Assemble dowels (2 Nos) & new gasket magneto cover • Prefit magneto cover mounting bolts & tighten to recommended torque. •...
  • Page 62 ENGINE OIL FLOW PATH Oil Strainer Oil pump Inlet Oil pump outlet Oil pump outlet to RH Crankcase hole Inlet hole of engine oil filter chamber Entry in engine oil filter chamber Oil filtration through engine oil filter Filtered Oil Entry hole in clutch cover Clutch cover inlet hole Towards Crankshaft through Exit from jet for clutch lubrication...
  • Page 63 ENGINE OIL FLOW PATH Exit from con rod slots for piston lubrication From clutch cover to RH crankcase RH crankcase Inner oil gallery From RH crankcase to LH Crankcase From LH Crankcase to Top face Service Support - M/C Service Station Manual...
  • Page 64 ENGINE OIL FLOW PATH Entry in head-block mounting bolt hole Cylinder Block In & out from Cylinder Head Out Cylinder Head In block Service Support - M/C Service Station Manual...
  • Page 65 ENGINE OIL / LOCTITE / GREASE APPLICATION MATRIX Loctite Application Part Name Type of Loctite Cam sprocket allen bolt Loctite 243 Pickup coil screws Loctite 243 Gear stopper screw (gear starter Loctite 243 clutch) Kick guide bolts Loctite 243 Output sprocket bolts Loctite 243 Oil pump screw Loctite 243...
  • Page 66 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Valve Intake Part Name Identification mark location Outer diameter Photograph Length Part Number JE511267, Qty : 2 Nos DH102535, Qty : 1 NOS 36JH0028, Qty : 1 Nos •...
  • Page 67 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Cylinder Head Part Name Provision for plate cylinder head fitment Photograph Part Number JE511160 DH102533 JZ511122 • 4 valve design • 2 Valve design •...
  • Page 68 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Rocker Arm Assembly Part Name Photograph Part Number JE511269 Dk101755 JH511210 Description Compatible for 4 valve Compatible for 2 valve Compatible for 2 valve design design.
  • Page 69 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Spring Valve Part Name Photograph Part Number JE511216, Qty – 4 Nos JF511217, Qty – 2 Nos JZ511202, Qty – 2 Nos Length : 36.18 mm Length : 38.9 mm Length : 38.74 mm Description...
  • Page 70 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Camshaft Assembly Part Name Ø 15 Photograph Ø 14.6 Ø 15 Identification Identification Part Number JE511265 PD511256 Jz511226 • Diameter : Ø 14.6 mm •...
  • Page 71 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Cam Chain Part Name BorgWarner make Photograph LGB make PD511084 – BorgWarner make Part Number JE511233 DY511208 DH103758 – LGB make Description Number of links : 102 Number of links : 100 Number of links : 96 Gasket Cylinder Head...
  • Page 72 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Plate Cylinder Head Part Name Photograph Part Number PA511039 Description With plate cylinder head Block cylinder (Sub part of Kit Block piston) Part Name Photograph 36DH4262 Part Number...
  • Page 73 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Gasket Block Cylinder Part Name Photograph Ø 63 Ø 75 Ø 64 Part Number JE521030 DK101063 JH521007 Description • Diameter : Ø 64 mm •...
  • Page 74 PART IDENTIFICATION Model Pulsar NS125 Pulsar 125 CT 125X ES Disc & CT 125X ES Drum Sprocket Crankshaft Part Name BorgWarner make Photograph LGB make Identification : Groove DK101068 - BorgWarner make Part Number JE531033 PF531057 DK102019 – LGB Make Description Number of teeth : 18 Number of teeth : 17...
  • Page 75 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Lever Brake Cam Part Name Photograph Part Number PF541029 PF541066 Description Without nozzle oil jet With nozzle oil jet Crankcase RH Part Name Photograph Part Number JH541007...
  • Page 76 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Shaft Assembly Clutch release Part Name Photograph Part Number JV541208 DY541213 Description Design is different than CT 110X Bracket Clutch Cable Part Name Photograph Part Number DY541215...
  • Page 77 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Input Shaft Part Name Photograph 170.3 mm 159.3 mm Part Number PA551002 JZ551010 Description Total Length : 159.3 mm Total Length : 170.3 mm Gear 4th Drive Part Name Photograph...
  • Page 78 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear 3rd Drive Part Name Photograph Part Number PF551201 JE551209 • Number of teeth : 22 • Number of teeth : 18 Description •...
  • Page 79 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear 5th Drive Part Name Photograph Part Number JZ551213 Description Number of teeth : 22 Output shaft Part Name Part Number PF551003 JZ551008 Description Total Length : 132.2 mm Total Length : 123.2 mm...
  • Page 80 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear 3rd Driven Part Name Photograph Part Number PF551204 JE551210 Description Number of teeth : 27 Number of teeth : 24 Gear 1st Driven Part Name Photograph Part Number...
  • Page 81 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear 5th Driven Part Name Photograph Part Number JZ551211 Description Number of teeth : 20 Gear 2nd Driven Part Name Photograph Part Number JE551205 PF551203 •...
  • Page 82 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Shaft Assembly Gear Shift (LCGS) Part Name Photograph Groove 195 mm 184 mm Part Number PF561200 JK561200 • Total Length : 184 mm •...
  • Page 83 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear Change Drum Part Name Photograph Part Number PF561001 PA561001 Description Design is different than CT 110X Cam Drum Change Part Name Photograph Part Number JE561005 JA561002...
  • Page 84 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Shaft Fork Gear Shift Part Name Groove Photograph 83 mm 74 mm Part Number PF561002 JD561006 • Total length : 74 mm • Total length : 83 mm Description •...
  • Page 85 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gear Kick Pinion Part Name Photograph Part Number PF621004 PA621008 Description Number of teeth : 19 Number of teeth : 21 Intake Pipe Part Name Slot Photograph...
  • Page 86 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Air Filter Assembly Part Name Photograph Carburettor fitment side Carburettor fitment side Part Number DY581046 DY581056 Description Connecting tube is bigger than CT 110X Rotor Assembly Part Name Photograph...
  • Page 87 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Gasket Cover cylinder head Part Name Photograph Part Number JV511012 JD511010 Description Design is different than CT 110X Carburetor Part Name Part Number DY581215 DY581236 Throttle position sensor - JD351800 (Flash make)

  • Page 88: Important Sop

    Frame • Torque Value • Service Limit • Special Tools • Important SOP • Hose / Cable Routing • Part Identification...
  • Page 89 TORQUE VALUE Torque Value (Kgf -m) Sr.No. Parameter RR Unit bolts 0.6 - 0.7 HT Coil bolts 0.8 - 1.2 Front seat rear bolts Engine mounting bolt top 1.8 - 2.2 Engine mounting bolt front 1.8 - 2.2 Engine mounting bolt rear 2.8 - 3.2 Steering slotted nut RSA Top nut...
  • Page 90 TORQUE VALUE Torque Value (Kgf -m) Sr.No. Parameter Fork underbracket bolt 2.5 - 3.0 Upper Bracket center nut (Big) 4.5 - 5 Fuel gauge bolt 0.35 - 0.5 Fuel cock bolt 1.2 - 1.6 Speedometer mtg nuts 0.6 - 0.8 Headlight mtg nuts / bolts (Focus 0.6 - 0.8 adjustment bolt &...
  • Page 91 SERVICE LIMIT Standard (mm) Service Limit (mm) Sr.No. Parameter Front 12 - 12.03 12.15 Brake Panel cam hole diameter Rear 12 - 12.03 12.15 Front 11.95 - 11.98 11.88 Brake cam diameter Rear 11.95 - 11.98 11.88 Brake disc run out Not Applicable Brake disc thickness 3.8 - 4.2...
  • Page 92 SPECIAL TOOLS Balancer lock nut loosening & tightening tool for steering slotted nut Part No. : 37004160 Usage : For tightening & loosening of steering slotted nut. Fork seal cleaner Part No. : 37004362 Usage : For cleaning dust seal & oil seal.
  • Page 93 SPECIAL TOOLS Oil seal removing tool Part No. : 37174029 Usage : For removing oil seal from outer tube Underbracket cone removal tool Part No. : 37004479 & 37004480 Usage : For removing underbracket cone. Underbracket cone fitment tool Part No. : 37004480 Usage : For fitment of underbracket...
  • Page 94 SPECIAL TOOLS CBS brake adjustment tool(Disc version) Part No. : 37004354 Usage : For adjusting CBS front brake. Service Support - M/C Service Station Manual...
  • Page 95 IMPORTANT SOP Front Fork Overhaul • Remove front axle nut with washer using 17 mm spanner, holding front axle head with 14 mm spanner. • Hold wheel assembly & take out front axle. • Take out brake panel assembly from wheel. •...
  • Page 96 IMPORTANT SOP • Remove front fender mounting bolts (2 Nos) using 12 mm spanner. • Remove front fork top bolt using 17 mm spanner. • Remove under bracket bolt using 14 mm spanner. • Take out fork leg assembly from vehicle. •...
  • Page 97 IMPORTANT SOP • Remove rubber bellow from outer tube groove & take out rubber bellow. • Remove fork top bolt using 27 mm spanner. • Take out fork top bolt with o ring & spacer tube. NOTE: Take care while removing fork top bolt, as bolt & spacer tube may fly off causing injury to person.
  • Page 98 IMPORTANT SOP • Remove outer tube bottom bolt using 6 mm allen key & take out allen bolt with copper washer. • Hold the fork leg assembly as shown in photograph & take out seat pipe holder. • Take out fork inner pipe from outer tube. •...
  • Page 99 IMPORTANT SOP • Using small flat head screwdriver, remove dust seal. • Ensure no dent/damage to outer tube while using small flat head screwdriver. • Take out lock oil seal using small flat head screwdriver. • Insert oil seal removal tool (Part No : 37174029) as shown in photograph. •...
  • Page 100 IMPORTANT SOP • Hold oil seal removing tool central stud with 15 mm spanner & tighten nut with 30 mm spanner to extract oil seal from outer tube. • Take out oil seal removing tool with oil seal as shown in photograph. •...
  • Page 101 IMPORTANT SOP • Take out oil seal as shown in photograph. Assembly : • Clean fork inner pipe & outer tube with clean lint free cotton cloth. • Pour diesel in fork inner pipe & outer tube by closing other end with hand. •...
  • Page 102 IMPORTANT SOP • Insert fork inner pipe, cap oil lock & outer tube. • Fit new copper washer. Pre-fit outer tube bottom bolt & tighten using 6 mm allen key. Torque value : 1.5 – 2.5 Kgf-m • Hold fork leg assembly with seat pipe holder as shown in photograph & take out seat pipe holder.
  • Page 103 IMPORTANT SOP • Insert lock oil seal & fit lock oil seal. • Insert new dust seal. • Insert main spring & spacer tube. • Refill recommended fork oil (SAE 10W20,qty : 146 ml per leg). • Pre-fit fork top bolt & tighten using 27 mm spanner. •...
  • Page 104 IMPORTANT SOP • Insert the rubber bellow with clamp. Fit rubber bellow in groove on outer tube. Tighten rubber bellow mounting clamp screw with phillips head screwdriver. • Fit fork leg assembly on vehicle • Prefit fork top bolt, under bracket bolt & tighten to recommended torque.
  • Page 105 IMPORTANT SOP • Fit front wheel with brake panel assembly & insert axle. • Fit washer. Prefit axle nut & tighten to recommended torque. Torque value : 4.5 – 5.5 Kgf-m Trim Frame Grip Replacement • Remove trim frame grip mounting bolts (2 nos) using 4 mm allen key. •...
  • Page 106 IMPORTANT SOP • Remove holder taillamp mounting bolts (4 Nos) using 10 mm spanner. • Lift holder tail lamp & keep Holder taillamp with taillamp assembly & indicators as shown in photograph. • Remove frame grip mounting bolts (2 Nos) using 12 mm spanner. •...
  • Page 107 IMPORTANT SOP • Prefit frame grip mounting bolts & tighten to recommended torque (2 – 2.2 Kgf-m) • Fit holder tail lamp on frame grip as explained in “Wire Holder / Housing Taillamp / Holder Taillamp Replacement SOP”. • Prefit frame grip (RSA) mounting bolts & tighten to recommended torque (3.2 – 3.8 Kgf- Trim Leg Guard Replacement •...
  • Page 108 IMPORTANT SOP Fitment Orientation of trim leg guard : Textured portion is towards rider side when seated on vehicle. Textured portion is towards rider side when seated on vehicle. • Prefit trim leg guard on leg guard to achieve it’s correct fitment as explained in “Orientation of trim leg guard”.
  • Page 109 IMPORTANT SOP • Position Bottom Bolt and Apply Force to downward & Position the Bolt and pre fit. • In few cases can be positioned by loosening the stay top bolt as it has oblong hole for free float & alignment. Steering Overhaul •...
  • Page 110 IMPORTANT SOP • Remove speedometer couplers. • Take out speedometer. • Remove fork center nut using 32 mm spanner & take out handle bar assembly. • Hold underbracket assembly & Using Balancer lock nut tool (Part Number : 37004160), remove steering slotted nut. •...
  • Page 111 IMPORTANT SOP • Take out upper & lower bearing cage. • Using nylon brush, clean steering cone kit by diesel & kerosine. • Apply limaplex HTX3 grease on cone, races & bearing cage. For removal of races from frame, petrol tank is to be removed. •...
  • Page 112 IMPORTANT SOP • Press torque rod mounting bolt & take out torque rod mounting bolt. • Remove brake rod mounting nut using 14 mm spanner. • Press rear brake pedal & remove brake rod from rear lever brake cam. • Insert screwdriver in axle head hole & remove rear axle nut with washer using 22 mm spanner.
  • Page 113 IMPORTANT SOP • Take out brake panel assembly from rear wheel. • Take out cover LH RR mounting bolts (2 nos) using 8 mm spanner and take out cover LH • Remove chain cover mounting bolts (5 nos) using 10 mm spanner. Note : Hold lower chain cover while removing it’s mounting bolts (shown by pink arrow) to avoid falling of lower chain cover.
  • Page 114 IMPORTANT SOP • Take out lower & upper chain cover. • Remove drive chain link lock using plier. • Take out lock plate. • Take out drive chain locking link & drive chain • Take out coupling sleeve nut with washer using 27 mm spanner. Service Support - M/C Service Station Manual...
  • Page 115 IMPORTANT SOP • Take out coupling assembly. • Remove LH & RH Rear shock absorber mounting bolts using 12 mm spanner. • Take out LH & RH Chain adjusters. • Remove brake return spring connected to torque rod using plier. •...
  • Page 116 IMPORTANT SOP • Hold swing arm assembly & take out swing arm shaft. • Take out swing arm assembly. • Swing arm hardware details : RH Stay LH Stay RH Stay LH Stay Washer Washer • Clean swing arm shaft using diesel/kerosine. •...
  • Page 117 IMPORTANT SOP • Remove chain slider mounting screws (2 nos) with washer using phillips head screwdriver. • Take out chain slider. • Refit all the parts in reverse order of removal. • Adjust chain slackness & CBS free play. Brake Cam Replacement •...
  • Page 118 IMPORTANT SOP • Hold lever brake cam mounting bolt using 8 mm spanner & remove using 10 mm spanner. Take out nut, washer & lever brake cam mounting bolt • Take out lever brake cam. • Take out wear indicator. •...
  • Page 119 IMPORTANT SOP • Apply AP grease to brake cam. • Refit all the parts in reverse order of removal. • Adjust chain slackness & CBS free play. Coupling Replacement • Remove coupling assembly from swing arm as explained in “Swing arm replacement SOP”.
  • Page 120 IMPORTANT SOP • Using flat head screwdriver & hammer, open lock plate. • Remove coupling sprocket mounting nuts (4 Nos) using 17 mm spanner. • Take out coupling sprocket & lock plates (2 nos). • Refit all the parts in reverse order of removal. •...
  • Page 121 IMPORTANT SOP • Adjust rear brake free play by adjusting rear Rear brake pedal Free play brake pedal free play adjuster nut (A). Use rear brake pedal free play gauge Part No : 37004307 Specification : 20 - 30 mm. Ensure rear wheel freeness after setting.
  • Page 122 IMPORTANT SOP • Do not adjust CBS front brake cable at rear brake Cover pedal end as shown in photograph. Adjuster nut CBS front brake cable • Do not open cover at rear brake pedal mounting as shown in photograph during CBS Free play setting.
  • Page 123 IMPORTANT SOP • Put “CBS Front brake adjustment tool (Part No – 37004354)” between lever front brake slot & master cylinder slot as shown in photograph. • If tool moves freely in the slots, take out tool & adjust tool length by rotating adjuster knob provided on CBS Front brake adjustment tool till it tightly fits between two slots.
  • Page 124 IMPORTANT SOP CBS Free Play Setting (Disc version) - Precautions • Do not overtighten adjuster nut on CBS cable (brake pedal to master cylinder) by any tool. • Do not set / adjust rear brake pedal free play adjuster nut after CBS front brake setting. •...
  • Page 125 IMPORTANT SOP Bracket USB Charger / USB Charger Replacement • Remove handlebar upper holder mounting bolts (4 Nos) using 10 mm spanner. Take out handle holder upper. • Keep cloth on fuel tank & keep handlebar assembly on fuel tank. •...
  • Page 126 IMPORTANT SOP • Take out USB charger slotted nut & spacer. • Take out USB charger from bracket USB charger. Assembly : • Insert USB charger in bracket USB charger. • Fit spacer as shown in photograph. • Prefit USB charger slotted nut & tighten using flathead screwdriver.
  • Page 127 CONTROL CABLES / HOSE ROUTING Brake hose Routing • Route brake hose from master cylinder as shown in photograph. • Fit rubber grommet on hose in clamp fitted on underbracket (as shown by yellow circle). • Fit rubber grommet on hose in clamp hose fitted on underbracket (as shown by blue circle) &...
  • Page 128 CONTROL CABLES / HOSE ROUTING • Route speedometer cable as shown in photograph & connect to speedometer. CBS Cable – Pedal to Master cylinder Routing • Route the CBS brake cable from master cylinder actuating link as shown in photograph. •...
  • Page 129 CONTROL CABLES / HOSE ROUTING CBS Cable – Pedal to Front Brake panel Routing • Route the CBS brake cable from metal bracket as shown by blue circle in photograph. CBS Cable • Route the CBS brake cable from metal hook as shown by blue circle in photograph.
  • Page 130 CONTROL CABLES / HOSE ROUTING • Route the front brake cable as shown in photograph & connect to front brake lever. Speedometer Cable Routing-Drum version • Route speedometer cable through metal clamp as shown by yellow circle in photograph. • Route speedometer cable through metal hook near underbracket as shown by blue circle in photograph.
  • Page 131 CONTROL CABLES / HOSE ROUTING • Route the throttle cable through harness clamp fitted in frame hole as shown by pink circle in photograph. • Route the throttle cable through metal hook as shown by blue circle in photograph. • Route throttle cable through bracket throttle cable fitted on carburettor & connect to Bracket throttle Cable throttle drum as shown in photograph.
  • Page 132 PART IDENTIFICATION - CT 125X ES DISC - 00DY07ZZ NOTE : For Part numbers, Always Refer Spare Parts Catalogue Available on E-SSM Model CT 110X ES Drum CT 125X ES Disc FRONT FORK Part Name Part Number DY121015 DY121020 Description Without provision for caliper mounting on outer With provision for caliper mounting on outer tube tube.
  • Page 133 PART IDENTIFICATION - CT 125X ES DISC - 00DY07ZZ Model CT 125X ES Disc CT 110X ES Drum BRAKE SYSTEM FRONT Part Name Part Number Drum brake with CBS Disc brake with CBS Service Support - M/C Service Station Manual...
  • Page 134 PART IDENTIFICATION - CT 125X ES DRUM -00DY06ZZ NOTE : For Part numbers, Always Refer Spare Parts Catalogue Available on E-SSM Model CT 110X ES Drum CT 125X ES Disc Wheel Front Part Name Part Number JZ131042 JK131046 Description Size : 1.40 x 17 Size : 1.85 x 17 CBS Cable –Rear brake pedal to Lever brake cam front Part Name...

  • Page 135: Part Identification

    PART IDENTIFICATION Common for – CT 125X ES Disc -00DY07ZZ & CT 125X ES Drum -00DY06ZZ NOTE : For part numbers, always refer spare parts catalogue available on e-ssm. Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Engine Hanger LH Part Name Part Number...
  • Page 136 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Assembly swing arm Part Name 12.3 mm 15.5 mm 42.5 mm 47.5 mm Part Number DY122020 DY122050 Axle fitment slot dimensions : 15.5 mm x 47.5 mm Description Axle fitment slot dimensions : 12.3 mm x 42.5 mm Axle Rear...
  • Page 137 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Damper Coupling Part Name Part Number 31151021, Qty : 4 Nos DK151094 Description Design is different than CT 110X Wheel Rear Part Name Part Number DU151078 DH151144 Description...
  • Page 138 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Kit chain sprocket Part Name Kit Part No. 36DY0020 36DY0040 Output sprocket Coupling sprocket Output sprocket Coupling sprocket Drive chain Drive chain Part Name Kit sub parts JZ551004 PF141003...
  • Page 139 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Lever Brake Cam Part Name Ø 14.2 mm Ø 12.2 mm Photograph Part Number DU151046 31151037 Description Inner diameter : Ø 14.2 mm Inner diameter : Ø 12.2 mm Bracket Assembly Socket Charger Part Name Photograph...
  • Page 140 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Socket Charger Part Name Photograph Part Number PF403400 Description With socket charger Seat Assembly Part Name Photograph Part Number DY191014 DY191005 Description Design is different than CT 110X Service Support - M/C Service Station Manual...
  • Page 141 PART IDENTIFICATION Model CT 110X ES Drum CT 125X ES Disc & CT 125X ES Drum Stand Center Part Name Photograph Part Number DY113206 PF113202 • Center stand base dimension : 293.5 mm • Center stand base dimension : 298 mm Description •...
  • Page 142 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Handlebar Part Name Photograph Part Number DU181155 DY151011 Description Without provision for weight handle bar fitment With provision for weight handle bar fitment Kick Lever Assembly Part Name Photograph...
  • Page 143 PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Assembly grip RH Part Name Photograph Part Number PF151032 JH151003 Description Design is different than CT 110X Weight Handlebar Part Name Photograph Part Number DH181022 With weight handle bar Description...

  • Page 144: Electrical

    Electrical • Important SOP • Wiring Harness Routine • Part Identification • Circuit Diagram...
  • Page 145 IMPORTANT SOP Bulb - Headlamp Replacement • Remove headlamp assembly mounting bolts (4 Nos) with metal washers using 10 mm spanner. • Hold the assembly as shown in photograph. • Pull out dust cap of headlamp harness. Service Support - M/C Service Station Manual...
  • Page 146 IMPORTANT SOP • Remove headlamp coupler. • Remove bulb holding clip. • Take out bulb. Assembly • Fit bulb in reflector. • Fit bulb holding clip. Service Support - M/C Service Station Manual...
  • Page 147 IMPORTANT SOP • Fit headlamp coupler. • Fit dust cap properly to avoid any dust/water entry. • Pre-fit headlamp mounting bolts & tighten to recommended torque(0.6 - 0.8 Kgf-m). Harness Headlamp Replacement • Remove headlamp coupler as explained in “Bulb - Headlamp Replacement SOP”. Service Support - M/C Service Station Manual...
  • Page 148 IMPORTANT SOP • Pull out the rubber bellow. • Remove headlamp harness coupler from wiring harness. • Take out headlamp harness. Assembly • Fit headlamp harness coupler to its mating coupler in wiring harness. • Fit rubber bellow properly to avoid any dust/water entry. All the couplers should be inside rubber bellow.
  • Page 149 IMPORTANT SOP • Fit headlamp coupler, dust cap & headlamp assembly on lampshade as explained in “Bulb - Headlamp Replacement SOP”. Headlamp Assembly / Fairing Headlamp/ DRL Unit / Speedo Flap / Headlamp Mounting Brackets Replacement • Remove bulb headlamp & harness headlamp coupler as explained in “Bulb - Headlamp Replacement SOP”...
  • Page 150 IMPORTANT SOP • Remove speedo flap mounting screws (3 nos) using phillips head screwdriver & take out speedo flap. • Remove DRL unit mounting screws (4 nos) using phillips head screwdriver & take out DRL unit. • Remove fairing headlamp mounting screws (5 nos) using phillips head screwdriver. •...
  • Page 151 IMPORTANT SOP • Ensure foams on fairing & DRL unit are intact and in good condition. Replace with new one if found cut / torn / peel off. • Remove bracket headlamp upper & bracket headlamp lower mounting bolts (2 Nos each) using 10 mm spanner.
  • Page 152 IMPORTANT SOP Assembly Lock on rim Rim lock & Lug on Housing headlamp details Lock on rim should get lock beneath lug on housing Lug on housing • Fit reflector with rim in housing headlamp. • Rotate reflector with rim holding housing in the direction of yellow arrow.
  • Page 153 IMPORTANT SOP • Prefit bracket front number plate mounting screws (2 Nos) with metal washers & then tighten them using phillips head screwdriver. • Prefit DRL unit mounting screws (4 Nos) & then tighten them using phillips head screwdriver. • Fit speedo flap on headlamp assembly. Prefit speedo flap mounting screws (3 Nos) & then tighten them using phillips head screwdriver.
  • Page 154 IMPORTANT SOP • Fit 2 nos cable ties. • Prefit headlamp mounting bolts (4 Nos) & tighten them to recommended torque (0.6 – 0.8 Kgf-m) Headlamp Focus Adjustment • Adjust headlamp focus as per following chart- LH Side RH Side Low beam &...
  • Page 155 IMPORTANT SOP • Pull out the rubber bellow. • Remove speedometer couplers. • Remove speedometer mounting nuts(2 Nos) using 10 mm spanner & take out speedometer assembly. • For assembly on vehicle, follow the reverse steps of removal SOP. Front Indicator Replacement •...
  • Page 156 IMPORTANT SOP • Insert 14 mm spanner as shown in photograph & remove indicator mounting nut with washer. • Remove indicator mounting nut & washer from indicator harness branch. Take out indicator. • For assembly on vehicle, follow the reverse steps of removal SOP.
  • Page 157 IMPORTANT SOP Bulb Taillamp / Lense with gasket / Reflector Replacement • Remove Lense mounting screws (2 Nos) using phillips head screw driver & Take out lense. • Hold the reflector as shown in photograph to avoid falling of reflector, take out bulb taillamp.
  • Page 158 IMPORTANT SOP • Hold the reflector as shown in photograph, fit bulb taillamp. • Fit lense, prefit lense mounting screws & tighten them using using phillips head screw driver. Wire Holder / Housing Taillamp / Holder Taillamp Replacement • Remove seat assembly mounting bolts (2 Nos) LH side RH side with metal washers using 5 mm allen key.
  • Page 159 IMPORTANT SOP • Cut the cable tie as shown in photograph. • Remove rear indicator couplers. • Pull out the harness branches near CU & remove wire holder taillamp coupler. • Remove holder taillamp mounting bolts (4 Nos) using 10 mm spanner. •...
  • Page 160 IMPORTANT SOP • Remove Lense, Gasket, Bulb taillamp & reflector as explained in “Bulb Taillamp / Lense with gasket / Reflector Replacement SOP”. • Insert 15 mm spanner through indicator harness branch & remove indicator mounting nuts. • Remove nut from indicator harness branch & take out indicator.
  • Page 161 IMPORTANT SOP • Remove wire holder from housing taillamp. • Replace 2 nos foams on housing taillamp if found peel off / damaged with new one. • Take out boot from holder taillamp. Assembly • Fit boot in holder taillamp. •...
  • Page 162 IMPORTANT SOP Fit wire holder in Housing taillamp. • Fit 2 nos metal washer on housing taillamp studs as shown in photograph. • Fit housing taillamp in holder taillamp. • Fit 2 nos metal washer on housing taillamp studs as shown in photograph. •...
  • Page 163 IMPORTANT SOP • Hold reflector with one hand & fit bulb taillamp. • Prefit lense screws & tighten them using phillips head screw driver. • Fit bracket indicator mounting & indicators. • Fit taillamp assembly on frame. Fit holder taillamp holes on collar. •...
  • Page 164 IMPORTANT SOP • Fit indicator couplers, wire holder couplers. Wire holder coupler Indicator coupler • Fit cable tie. • Fit indicators & wire holder branches in space between CU & Frame rod as shown in photograph. Service Support - M/C Service Station Manual...

  • Page 165: Wiring Harness Routing

    WIRING HARNESS ROUTING • Route the wiring harness as shown in photograph. Service Support - M/C Service Station Manual...
  • Page 166 WIRING HARNESS ROUTING • Route the wiring harness as shown in photograph. • Route the wiring harness as shown in photograph. Service Support - M/C Service Station Manual...
  • Page 167 WIRING HARNESS ROUTING • Route the wiring harness as shown in photograph. • Route the wiring harness as shown in photograph. Service Support - M/C Service Station Manual...
  • Page 168 WIRING HARNESS ROUTING • Route the wiring harness as shown in photograph. • Route the wiring harness as shown in photograph. Service Support - M/C Service Station Manual...
  • Page 169 WIRING HARNESS ROUTING • Route the wiring harness as shown in photograph. • Route the wiring harness as shown in photograph. Service Support - M/C Service Station Manual...

  • Page 170: Part Identification

    PART IDENTIFICATION Model CT 110X ES Drum Drum CT 125X ES Disc & CT 125X ES Drum Light control Module / DC Flasher Part Name Part Number DS201025 JL402004 Description With light control module With DC flasher Wiring Harness Part Name Part Number DY402214 JL402004...
  • Page 171 ELECTRICAL CIRCUIT DIAGRAM SPEEDOMETER PIN DETAILS SPEEDOMETER SIDE STAND INDICATOR FUEL GAUGE TURN SIGNAL LH SUPPLY (+VE) GEN ILLUMINATION TURN SIGNAL RH EARTH (-VE) HIGH BEAM NEUTRAL Br/R Br/R Service Support - M/C Service Station Manual...
  • Page 172 ELECTRICAL CIRCUIT DIAGRAM CONTROL UNIT PIN DETAILS H.T. COIL 1 Br/B AIR INJECTOR Br/R STR INTERLOCK RELAY O/Br AUTO CHOKE CAN HIGH CAN LOW Br/L IGNITION KEY H.T. COIL 2 V. BATTERY XDRG (GROUND) XDRP (SUPPLY) SIDE STAND INPUT NEUTRAL SWITCH INPUT LAMBDA SENSOR CRANK POSITION SENSOR -ve CRANK POSITION SENSOR +ve...
  • Page 173 ELECTRICAL CIRCUIT DIAGRAM STARTER MOTOR CIRCUIT CUM SIDE STAND INDICATION FUSE BOX STR INTERLOCK RELAY Br/L IGNITION KEY XDRG 12 SIDE STAND INPUT 14 NEUTRAL SWITCH INPUT 16 GROUND 20 Service Support - M/C Service Station Manual...
  • Page 174 ELECTRICAL CIRCUIT DIAGRAM IGNITION CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...
  • Page 175 ELECTRICAL CIRCUIT DIAGRAM BATTERY CHARGING CIRCUIT REGULATOR UNIT CAPACITOR MAGNETO ASSEMBLY VRLA BATTERY Service Support - M/C Service Station Manual...
  • Page 176 ELECTRICAL CIRCUIT DIAGRAM CAN CIRCUIT CAN INTERFACE FRAME EARTH Br/L IGNITION SWITCH VRLA BATTERY CONTROL UNIT Service Station Manual Service Station Manual...
  • Page 177 ELECTRICAL CIRCUIT DIAGRAM MIL CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...
  • Page 178 ELECTRICAL CIRCUIT DIAGRAM AIR SOLENOID VALVE CIRCUIT Service Support - M/C Service Station Manual...
  • Page 179 ELECTRICAL CIRCUIT DIAGRAM LIGHTING WITH DRL CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...
  • Page 180 ELECTRICAL CIRCUIT DIAGRAM USB CHARGER CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...
  • Page 181 ELECTRICAL CIRCUIT DIAGRAM BRAKE LAMP CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...
  • Page 182 ELECTRICAL CIRCUIT DIAGRAM SIDE INDICATOR CIRCUIT FUSE BOX Service Support - M/C Service Station Manual...

Table of Contents