Bajaj Discover 100M Service Station Manual
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Bajaj Discover 100M Service Station Manual

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Summary of Contents for Bajaj Discover 100M

  • Page 1 Service Station Service Station Manual 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.

  • Page 3: Table Of Contents

    CONTENTS Foreword fi[ r vD< Workshop Safety vk< S i[ p s[ f T) General Information jnrl eºfi[ r m[ S n Customer Information kATmr eºfi[ r m[ S n Technical Specifications T[ k n)kl Ap[ S )f)k[ S n I Read ..
  • Page 4 Frame & Suspension f[ m an[ ssp[ º sn Tightening Torques TieTn)> g Ti[ k < Service Limits s(v< s l)m)T Special Tools Ap[ S )yl T& Ã s Part Identification piT< s n) ai[ L KiN Control Cable Routing k>...

  • Page 5: Foreword

    fi[ r vD< Foreword Discover 100 M Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 6 • Be alert for problems & non-scheduled maintenance. procedural step or sub-step it follows. • Use proper tools and genuine Bajaj motorcycle parts. In most chapters an exploded view illustration of the Special tools, gauges, and testers that are necessary system components are incorporated.
  • Page 7 ai m[ º y& a l Äyv(AYt siFn s> p ºn vk< S i[ p mi> tYi T[ e ºD {til)m pim[ l i} T[ k n)S)nni upyi[ g miT[ bnivvimi aiv[ l C[ m[ º T[ º ns drÀyin an[ r)p[ r )> g n) s> t i[ P kirk Ki#i) miT[ (mk[ ( nk[ l n[ b[ z )k ÔNkir), T& Ã sni[ upyi[ g an[ vk< S i[ p p\ [ i s)jr smÔvvi j$r) C[ .

  • Page 8: Workshop Safety

    vk< S i[ p s[ f T) Workshop Safety...
  • Page 9 T[ k n)S)yn[ h> m [ S i b& T ph[ r [ l i hi[ v i Ô[ e a[ an[ D^ [ s )> g vFir[ T)l> & n hi[ v & Ô[ e a[ T[ k n)S)ynn[ h> m [ S i ps< n l p\ [ i T[ k T)v ekv)pm[ º T {PPe} ni[ upyi[ g krvi[ j[ v i k[ hiYni mi[ Ô , miAk, s[ f T) gi[ g l, eyr ¼lg p[ T ^ i [ k [ m )kl j[ v i k[ p[ T ^ i [ l , ai[ e l, k[ r i[ s )n h[ º...
  • Page 10 WORKSHOP SAFETY o Technicians must put on shoes & dressing should not be very loose. o Technicians must use Personnel Protective Equipment (PPE) like - Hand Gloves - Mask - Safety Goggle - Ear Plug o Wear Nitrile Rubber Hand Gloves while handling petrochemicals like petrol, Oil, Kerosene etc.
  • Page 11 a[ r T& Ã sni upyi[ g vKt[ ¹yinmi> riKvini m& d di Si[ p a[ r (sATm Wiri k\ [ i Àp\ A D a[ r upr a[ r T& Ã sni[ upyi[ g Yiy C[ {k\ [ i Àp[ \ s r an[ a[ r s¼liy (sATm} -a[ r T&...
  • Page 12 WORKSHOP SAFETY o Safety Precautions while Operating Air Tools Air tools operate on compressed air supplied by the shop air system (Compressor & Air supply system). Observe the following safety related precautions when using an air tool. • It is advisable to fit a pressure regulator (FRL:- Filter Regulator Lubricator) in the pneumatic line which supplies air pressure to the air tool.
  • Page 13 WORKSHOP SAFETY Precautions to be taken while handling Hydro-Electric Lift - While raising / lowering the lifter bay ensure that vehicle is firmly hold on the lifter bay to avoid accident. - After raising the lifter bay, lock the lift. - Don’t put leg/hand in between while raising / lowering the lifter Bay.
  • Page 14 hieD^ i [ el[ k T^ ) kl l)fTni upyi[ g vKt[ sivc[ t )ni pgli akAmit Yti[ aTkivvi vihn (lfTr v[ pr (fT kr[ l & hi[ y t[ n ) Ki#i) kri[ (lfTr Ki[ Ã yi bid, (lfTn[ li[ k kri[ (lfTr b[ vµc[ hiY/pg m&...

  • Page 15: General Information

    jnrl eºfi[ r m[ S n s(v< s )> g ph[ l i. General Information • Before Servicing...
  • Page 16 GENERAL INFORMATION General precautions to be taken while opening, assembling & storage of engine parts. Battery Ground Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (-) first and then the positive (+).
  • Page 17 jnrl eºfi[ r m[ S n . a[ > j )nni piT< s Ki[ l vi, (ra[ s [ À bl krvi an[ ATi[ r [ j krt) vKt[ l[ v in) simiºy kiLJ. b[ r r) gi\ U ºD ki[ e pN mi[ T rsiykln) kÀpl)T s(<...
  • Page 18 Replacement Parts Replacement parts must be BAJAJ genuine or recommended by BAJAJ. Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter pins must be replaced with new ones whenever disassembled. Assembly Order...
  • Page 19 kiQ[ l i piT< s n& ATi[ r [ j {sicvN)} sba[ s [ À bl) siY[ n i bGij piT< s sÃf hi[ v i Ô[ e a[ an[ t[ n [ sif a[ r )yimi> {j³yia[ } Ati[ r krvi, piT< s upr sif kpr& > aYvi ¼liAT)kn) s)T m&...
  • Page 20 GENERAL INFORMATION Tightening Sequence Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction.
  • Page 21 Tien)g (skvºs {TieT krvin) k^ m )k krvin) p¹F(t} simiºy r)t[ jyir[ pN ki[ e piT< siY[ (fT krvimi aivti k[ T li bi[ Ã T ,nT an[ Ak* t [ n i hilmi> ni> K )n[ simiºy (fT krvimi aiv[ C [ .
  • Page 22 GENERAL INFORMATION Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 23 p\ [ s vAt& j[ v )k[ b[ r )g aYvi ai[ e ls)l miT[ t[ n ) j³y[ pr j dbivv) j$r)C[ . t[ n i ki[ º T[ k TviLi Bigmi Yi[ D & > ai[ e lm* k v& > . Ki#) krv) k[ t[ n &...
  • Page 24 GENERAL INFORMATION Lubrication It is most important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 25 l& b )\ k [ S n a[ K * b j mhRvn& > C[ k [ frti{ri[ T [ T )g} an[ Kst[ {AlieD)> g } piT< s n& > a[ s [ À bl) drÀyin l& b )\ k [ S n krvimi aiv[ j[ Y ) simiºy upyi[ g vKt[ t[ K* b j ai[ C i wsiy, Ap[ s )fie ai[ e l an[ g)\ s ni[ j upyi[ g kri[ .
  • Page 26 GENERAL INFORMATION General Precautions • To avoid damage to head of fasteners do not use over size or worn out tools. • To avoid damage to painted parts, prevent spillage of battery acid & brake fluid. • To avoid damage of machined face & color of the components store the parts in a clean plastic bin having compartments to avoid components touching to each other.
  • Page 27 simiºy {General} sivc[ t ) {kiLJ} h[ k ni fiATns< n [ D[ m [ j Yti aTkivvi miT[ ai[ v rsiez k[ Gsiy[ l i T& Ã sn& upyi[ g n krvi[ klrviLi piT< s n[ n& k sin Yti aTkivvi t[ n i pr b[ T r), a[ s )D k[ b\ [ k ai[ e l Fi[ L ivvi d[ v & > nh) mS)ºD f| [ S an[ kÀpi[ n [ º...
  • Page 28 NOTES Discover 100 M Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 29: Customer Information

    • Non Use Maintenance ni[ n y& z m[ º T[ n ºs • Customer Awareness kATmr av[ r n[ s • Bajaj Genuine Parts bÔj j[ º y& a n piT< s • Maintenance Tips m[ º T[ n ºs T)¼s...
  • Page 30 CUSTOMER INFORMATION Safe Riding Tips • Always wear ISI helmets while driving or riding. Your helmets should conform to appropriate Indian standards. • Read thoroughly the instructions in this manual and follow them carefully. • Avoid unnecessary accessories for the safety of both rider and other motorists. •...
  • Page 31 riyD)> g T)¼s D^ i ev)> g an[ rieD)> g vKt[ hm[ S i ISI miki< v iL& > h[ Ã m[ T ph[ r i[ . aipn& > h[ Ã m[ T irt)y ATiºDD< Fi[ r N m& j bn& > hi[ y t[ n ) Ki#i) kr) l[ v ) ai m[ º...
  • Page 32 CUSTOMER INFORMATION What to check Check for Brakes 1. No dragging. Drive chain 1. Proper slack (20~25 mm) 2. Adequate lubrication. Lighting Operation of all lights. Horn Correct functions. Steering 1. Smoothness. 2. No restriction of movement. 3. Loose or Tight. Clutch 1.
  • Page 33 S& > c[ k krv& > - Si miT[ c[ k krv& > b\ [ k s – D^ [ g )> g n Yt& hi[ y 1. bribr Al[ k hi[ y {20-25 mm} D^ i ev c[ e n 2.
  • Page 34 CUSTOMER INFORMATION Non-Use Maintenance Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from such other non-operational damages like fire hazards.
  • Page 35 ni[ n y& z m[ º T[ n ºs {vihn upyi[ g mi> n hi[ y Ryir[ krvin& > m[ º T[ n ºs} Ô[ vihnn[ li> b i smy giLi s& F ) {15 (dvsY) vFir[ * **} upyi[ g mi> n l[ v in& > hi[ y ti[ ni[ n – y& z m[ º T[ n ºs krv& > j$r) C[ . sic) r)t[ an[ kiLJp&...
  • Page 36 g\ i hkn) ÔgZ t tini m& d di – {kATmr av[ r n[ s pi[ e ºT} kATmr av[ r n[ s n)c[ n i m& d diai[ n [ ¹yinmi> riK)n[ vihnni Kim) m& k t prfi[ m < º s miT[ v)ksivimi> aiÄyi C[ . 1.
  • Page 37 • Do not drive vehicle & bring the vehicle to BAJAJ authorized workshop if coolant level in expansion tank or engine oil level is found below MIN. mark. Take help of authorized service station to take vehicle in workshop for repair.
  • Page 38 • Parts of the vehicle that have been altered and modified or replaced in unauthorized manner like use of wider tyres, loud silencers etc and which in the sole judgement of the Bajaj Auto Limited affects its performance and reliability.
  • Page 39 a[ s sr)z vFirin) ki[ e pN a[ s sr)z f)T kriv) nh)\ , nh) tiu[ viyr)> g Si[ T < YS[ aYvi b[ T r) D)Acij< Ye Sk[ C[ . di.t. -r)mi[ T / s[ º T^ l li[ k )> g s)ATm -vFirini an[ mi) siezni hi[ n <...
  • Page 40 CUSTOMER INFORMATION Bajaj Genuine Parts bÔj j[ º y& a n piT< s vihnni mhtm prfi[ m [ < º s miT[ For optimum performance of vehicle For prolonged life of Always components & vehicle k> p i[ n ºTn) tYi vihnn) li> b ) aivrdi miT[...
  • Page 41 NOTES Discover 100 M Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 42: Technical Specifications

    T[ k n)kl Ap[ S )f)k[ S n Technical Specifications • Technical Specifications T[ k n)kl Ap[ ] S )f)k[ S n • Carburettor Specification kir¾y& r [ T r Ap[ S )f)k[ S n...
  • Page 43 TECHNICAL SPECIFICATIONS Engine & Transmission a[ º Jn an[ T^ i ºAm)Sn p\ k ir Type : Four stroke fi[ r AT^ i [ k (sl)ºDrni p\ k ir No. of cylinders : One a[ k bi[ r Bore : 47.00 mm AT^ i [ k Stroke : 58.8 mm...
  • Page 44 ¼l[ T ni[ l[ À p Rear Number plate lamp : 12V, 3W hi[ n < Horn : 2A @ 12 V bÔj li[ g i[ Bajaj Logo : 12V, 2W (Blue) Dimensions Diym[ º sn Length : 1986 mm l> b ie...
  • Page 45 TECHNICAL SPECIFICATIONS Carburettor kir¾y& r [ T r Item Specification aieTm Make Keihin Fie bnivT Type PTE 19D Tiep Idling Speed 1400 + 100 rpm aieDl)> g Ap)D Air Screw Setting 1½ a[ r Ak| & s[ T )> g Main Jet m[ e n j[ T Needle Jet Marking...
  • Page 46 TECHNICAL SPECIFICATIONS l& b \ ) k[ k ºT / li[ k TieT Lubricant / Application Remark Grade g\ [ D (rmik< Loctite upyi[ g aigL piCL n) Äh)l a[ k sl Grease All purpose • Fr. & rear wheel axle. Av)>...
  • Page 47 NOTES Discover 100 M Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 48: I Read

    h& > vic)S h& > S)K)S I Read... I learn • Vehicle identification & -vihnn) ai[ L K an[ k> T ^ i [ Ã s controls -siylºT (fcs< • Salient Features -(f| k vºTl) p& C iti p\ Æ n •...

  • Page 49: Vehicle Identification & Controls

    2. Speedometer : The Speedometer pointer shows the 6. Bajaj Logo : Bajaj Logo flying ‘B’ continuously glow. speed of the vehicle. 7. Hi Beam Indicator : When Headlight is ‘ON’ & Hi 3. Neutral Indicator :...
  • Page 50 c[ s )s n> b r an[ a[ º Jn n> b rn) j³yi f| [ m an[ a[ º Jn (sr)yl n> b rni[ upyi[ g vihnn) ni[ > F N) miT[ krvimi> aiv[ C[ j[ n> b rni ai> k Di – S¾dni ki[ D tmi$ vihn (bÔ srKij mi[ d l tYi t[ v ij p\ k irni vihnY) alg ai[ L K btiv[ C[ . f| [ m n>...
  • Page 51 VEHICLE IDENTIFICATION & CONTROLS Left Handle Bar Switches A. Hi / Lo Beam Selector Switch : When headlight is ON, High or Low beam can be selected by Hi / Lo Beam Selector Switch . Hi beam indicator light located on Speedo console will light up when high beam is selected.
  • Page 52 Dib)bij& n ) h[ º Dlbir Av)c : hie li[ b)m eºD)k[ T r Av)c: jyir[ h[ D lieT ON hi[ y Ryir[ hie aYvi li[ b)m, hie/li[ b)m Av)c Úiri ps> d kri[ hieb)m eºD)k[ T r lieT Ap)Di[ kºSi[ l mi> aip[ l C[ j[ hie b)m ps> d krSi[ Ryir[ cil& YS[ . : pis Av)c: h[ D lieT fl[ s krvi ai Av)c dbivi[ .

  • Page 53: Salient Features

    SALIENT FEATURES PERFORMANCE ATTRIBUTE KEY FEATURES ADVANTAGES BENEFITS New generation technology 4 Valve Engine High power & pick up. engineered for high power, pick up & performance. Engine power: 9.3 PS More power at all loads @7500 RPM conditions, better torque at Wider range of gear ratios low RPM, less emissions.
  • Page 54 prfi[ r m[ º s a[ T ^ ) ¾y& T a[ D viºT[ j fiydiai[ -4 viÃv a[ º Jn -vFir[ tikit, p)k ap an[ prfi[ r mi[ º s miT[ -vFir[ tikit an[ p)kap 9.3 PS@7500 RPM -a[ º Jn pivr nv) p[ Q )ni a[ º...
  • Page 55 SALIENT FEATURES CONVENIENCE ATTRIBUTE KEY FEATURES ADVANTAGES BENEFITS Fuel Gauge Displays approx. petrol More convenience quantity remaining in petrol tank reminds rider for refueling. Engine oil level window For easy inspection of oil Easy monitoring of oil level. level Self Start SAFETY ATTRIBUTE KEY FEATURES...
  • Page 56 srLti {svlt} -fy& a l g[ j -p[ T i[ ^ l T[ º kmi> bik) Ak[ l a> d iJt p[ T i[ ^ l -vwir[ svlt -a[ J n ai[ e l l[ v l v)ºDi[ Brivvin& yid rh[ -ai[ e l l[ v ln[ srL r)t[ ¹yin -s[ Ã...
  • Page 57 Top Speed: - 95 Kmph. Electrical system AC-DC type. Ï What “M” stands for in the brand name of bike? In Discover 100M, “M” stands for Mileage Ï What is need & scope for New ‘Discover 100 M’? Need : The new range of Discovers powered by world’s first patented 4V DTS-i engine offer unique style, exciting power...
  • Page 58 100 mm svil: (DAkvr mi (DAT)kT Kis)yt S& > C [ ? 100 m dr[ k nv) (DAkvr n)c[ m& j bn) Kisyti[ C [ viÃv a[ J n 9.3ps 7500 rpm -a[ J n pivr: 902 Nm 600 rpm -a[ J n Ti[ k <...

  • Page 59: Comparison With Competitors

    BAJAJ Hero-Splendor Pro Description Hero-Passion Pro ‘Discover 100 M’ BAJAJ ‘Discover 100 M’ pivr an[ prfi[ r mºS pivr an[ prfi[ r mºS POWER AND PERFORMANCE d& ( nyin)si[ p\ Y m ni[ w N) kr[ l 4 viÃv 97.2 97.2...
  • Page 60 (vÅl[ P N (hri[ Apl[ º Dr pi\ [ Advantages of BAJAJ Hero-Splendor Pro Description Hero-Passion Pro ‘Discover 100 M’ BAJAJ ‘Discover 100 M’ COMFORT AND CONVENIENCE T[ l )Aki[ p )k T[ l )Aki[ p )k Telescopic Telescopic Front Telescopic, 125...

  • Page 61: Periodic Maintenance & Lubrication Chart

    > aTkivv& > , Fi[ v i s& k vi[ detergent for washing. miT[ ki[ A T)k (f| D)TrjºT viprv& > Engine oil (Bajaj DTSi 10000 oil) BGO DTSi 20W40 for & engine oil filter* 100cc models.
  • Page 62 Spoke tightening**-Front & Rear Api[ k TieT krvi {aigL-piCL} * It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be every 5000 kms. ** As applicable to model *** More frequent cleaning may be required while driving in dusty environment.
  • Page 63 PERIODIC MAINTENANCE & LUBRICATION CHART Why Periodic Maintenance 1. What is Preventive Maintenance ? Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to up keep health of product through out it's life. 2.
  • Page 64 p)r)yi[ D )k m[ º T[ n [ º s Si miT[ ? . (p\ v [ º T)v m[ º T[ n ºs S& > C[ ? (p\ v [ º T)v m[ º T[ n ºs a[ b\ [ k Diun an[ f[ Ã yi[ r {vihn bgDv& > } Y) bcvi miT[ smyi> t r[ krvimi> aivt) a[ k T)v)T) C[ . PM ni[ h[ t &...
  • Page 65 PERIODIC MAINTENANCE & LUBRICATION CHART PERIODIC MAINTENANCE & LUBRICATION CHART Importance of PM schedule execution Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to up keep health of product through out it's life. PM Activity Benefits •...
  • Page 66 S)Dy& l n& > mhRv a[ k T)v)T) fiydi -a[ > J n ai[ e l bdlv& > / um[ r v& > -a[ > J n kÀpi[ n [ º Tn[ siri l& b \ ) k[ S n Yiy C[ . -a[ >...

  • Page 67: Pre-Delivery Inspection Checklist

    NOT OK ENGINE Oil level between lower & upper mark / Top up if required Engine Oil "BAJAJ Oil leakage if any Specify source of o il leakage DTS -i 10000" 20W40 Check in warm up condition 60 C / Adjust if required...
  • Page 68 Starter Motor No abnormal noise Working of Speedometer, Odometer Speedometer Working of all signal indicators icons ( Neutral, Turn signal High beam, & Bajaj logo) Headlamp assembly No excess gap & Uneven gap Horn Ensure no distorted sound Visual inspection...

  • Page 69: Importance Of Pm Schedule Execution

    IMPORTANCE OF PM SCHEDULE EXECUTION Engine Oil Replacement a[ > J n ai[ e l bdlv& > • Ensure vehicle is parked on plain surface. • Ensure vehicle is thoroughly clean. • Ensure the engine is in warm condition before opening engine oil drain bolt. •...
  • Page 70 IMPORTANCE OF PM SCHEDULE EXECUTION • Use Bajaj Genuine oil only as per the recommended grade (20W40). • Ensure oil filler cap ‘O’ ring is in good condition • Ensure oil filler cap is fully tight. 20W 40 (rkmiºD[ D g\ [ D { } m&...
  • Page 71 IMPORTANCE OF PM SCHEDULE EXECUTION • Park vehicle on main stand, on plain surface. (Confirm stand is not bend & front wheel touching to ground) vihnn[ smtl j³yia[ m[ e n ST[ º D upr m& k i[ . {Ki#i) kri[ AT[ º D vL[ l & > n hi[ y an[ aigLn&...
  • Page 72 IMPORTANCE OF PM SCHEDULE EXECUTION • Refit oil drain bolt / cap strainer. ai[ e l D^ [ e n bi[ Ã T an[ AT^ [ n r k[ p n[ piCi f)T kri[ • Fresh oil 1000 ml to be measured in calibrated measuring jar & to be filled in engine with funnel till last drop.
  • Page 73 IMPORTANCE OF PM SCHEDULE EXECUTION • Remove the seat assembly by pulling seat lock cable. (sT li[ k viyr K[ > c n[ S)Tn[ bhir kiQi[ • Remove the Screw of RH Side panel and take out the panel. sieD kvrni[ Ak| & Ki[ l i[ an[ kvr bhir kiQi[ •...
  • Page 74 IMPORTANCE OF PM SCHEDULE EXECUTION • Remove the air filter cover rear side two bolts / screw by using the 10 mm T spanner. 10 mm T pinin) mddY) a[ r f)ÃTr kvrni piCLn) bij& n i b[ bi[ Ã T / Ak| & Ki[ l i[ •...
  • Page 75 IMPORTANCE OF PM SCHEDULE EXECUTION a[ r f)ÃTr a[ l )m[ º Tn[ an[ (fÃTr kvrn) • Locate the air filter element inside air filter cover & slide air a> d r m& k i[ an[ a[ r (fÃTr a[ l )m[ º Tn[ filter cover by holding air filter pkD)n[ apr f)ÃTr kvrn[ aigLn) element towards front side.
  • Page 76 IMPORTANCE OF PM SCHEDULE EXECUTION SOP for Oil Strainer Cleaning ai[ e l AT^ [ n r sif krvi miT[ n ) • Clean oil strainer element at 1st servicing & at the time of engine oil replacement. • Clean oil strainer by Kerosene / Diesel & blow air of 2 bar pressure from inside.
  • Page 77 IMPORTANCE OF PM SCHEDULE EXECUTION SOP for Engine Oil Filter Replacement a[ > J n ai[ e l (fÃTr bdlvin) r)t { • Remove 3 bolts 8 mm A/F. • Take out ‘Cover oil filter’ with ‘O’ ring, ni bi[ Ã T Ki[ l i[ kvr ai[ e l (fÃTr ai[ r)>...
  • Page 78 IMPORTANCE OF PM SCHEDULE EXECUTION SOP for Spark Plug Cleaning & Gap Checking Api< k ¼lg sif krvi an[ g[ p c[ k krvin) r)t { • Remove spark plugs using plug spanner. ¼lg pini vD[ Api< k ¼lg Ki[ l i[ •...
  • Page 79 IMPORTANCE OF PM SCHEDULE EXECUTION • Replace spark plug as per the interval given in the Periodic Maintenance Schedule. p)r)yi[ D )k m[ º T[ n ºs (SDy& l mi> jNiv[ l a> t r m& j b Apik< ¼lg bdli[ •...
  • Page 80 IMPORTANCE OF PM SCHEDULE EXECUTION SOP for Fuel Cock Sediment Bowl Cleaning fy& a l ki[ k s[ º D)m[ º T biul sif krvin) r)t { • Put the petrol cock knob to 'off' position. • Remove the petrol cock sediment bowl by using a ring spanner. •...
  • Page 81 IMPORTANCE OF PM SCHEDULE EXECUTION b[ T r) el[ k T^ i [ l ieT l[ v l an[ Ap[ s )f)k g\ [ v )T) c[ k krvin) p¹Ft) { SOP for Battery Electrolyte Level & Specific Gravity Checking •...
  • Page 82 IMPORTANCE OF PM SCHEDULE EXECUTION siel[ n sr D^ [ e n hi[ l sif krvin) p¹Ft) { SOP for Silencer Drain Hole cleaning • Clean the silencer drain hole by using silencer drain hole cleaning tool as shown in photograph.
  • Page 83 IMPORTANCE OF PM SCHEDULE EXECUTION SOP for CO% Setting % s[ T )> g krvin) p¹Ft) • Readiness of CO gas analyzer a. Ensure the machine is in well calibrated condition & calibration certificate is available. b. Switch 'ON' & warm up the CO gas analyzer for its recommended time. c.
  • Page 84 IMPORTANCE OF PM SCHEDULE EXECUTION • Note the CO when reading on LCD screen of the analyzer stabilizes. • Set the air screw to get CO value between 1.75~2.25 % at idling RPM of 1400 + 100. • Reconfirm the engine idling RPM & CO are within specified limit. •...
  • Page 85 IMPORTANCE OF PM SCHEDULE EXECUTION hieDi[ ^ m )Trni upyi[ g vD[ bwi6 s[ l n) [ k Ap\ [ S )(fk g[ \ v )T) c[ k kri[ • Check specific gravity by using hydrometer in all six cells one by one. •...
  • Page 86 IMPORTANCE OF PM SCHEDULE EXECUTION Yi[ \ T l k[ b l (f^ ¼l[ c[ k krvi an[ a[ D jAT krvin) p¹wt) {SOP) SOP for Throttle Cable Free Play Checking & Adjustment • Check for smooth rotation of accelerator grip. a[ k m)Tr g)\ p n&...
  • Page 87 IMPORTANCE OF PM SCHEDULE EXECUTION piCLni b[ \ k p[ D ln) (f^ ¼ l[ c[ k krv) an[ a[ D jAT krvin)p¹wt). SOP for Rear Brake Pedal Free Play Checking & Adjustment • Check the smooth operation of rear brake pedal. piCLni b[ \ k p[ D ln&...
  • Page 88 IMPORTANCE OF PM SCHEDULE EXECUTION aigLn) b[ \ k n) (f^ ¼ l[ c[ k krv) an[ a[ D jAT krvin) p¹wt) SOP for Front Brake Free Play Checking & Adjustment • Check the smooth operation of front brake lever. aigLni b[ \ k l)vrn&...
  • Page 89 a[ J n q> D ) (AY(tmi> hi[ y t[ n ) Ki#i) kri[ “ri[ T r” uprn& > ” ” ”uprni (nSin siY[ mL[ t[ n ) Ki#i) kri[ n& > ( nSin” k[ ^ º k[ S ai (A(Y(tmi> (pATn pr hi[ y C[ an[ b>...
  • Page 90 IMPORTANCE OF PM SCHEDULE EXECUTION ni[ n ai[ r )g Di^ e v c[ n kl)n0g {vihn upr} n) p¹wt)- fkt ph[ l ) s(v< s drÀyin Non O ring Drive Chain Cleaning SOP (on Vehicle) - For 1st service only •...
  • Page 91 IMPORTANCE OF PM SCHEDULE EXECUTION ni[ n ai[ r)g D^ v c[ n kl)n)g krvin) p¹wt) {2n) s(v< s Y)} Non O ring Drive Chain Cleaning SOP (By removing from vehicle) - 2nd service onwards • Remove chain cover. c[ n kvr kiqi[ •...
  • Page 92 IMPORTANCE OF PM SCHEDULE EXECUTION • Blow the low pressure compressed air on drive chain Di^ e v c[ n upr li[ p[ \ S r viL) ki[ À p[ \ A D hvi miri[ {SOP) ni[ T (sÃD Di^ e v c[ n n[ vihnmi> Y ) kiQ)n[ l& b )\ k [ S n krvin) p¹wt) SOP for Non Sealed Drive Chain Lubrication by removing from Vehicle 1.
  • Page 93 1.ni[ n (SÃD Di^ e vc[ n n[ (Dzl/k[ r i[ s )n an[ niyli[ n b\ S vD[ sifkri[ SER/GEN/A vw& (vgt miT[ s(v< s srky& l r tir)K25.03.14mi> a ip[ l aYvi (p\ v [ º T)v an[ s iykli[ p )D)yimi pini n> 1 66Y)174 mi j& a i[ 2.ni[ n (sÃD Di^ e v c[ n n[ h* k n) mddY) b[ (m(nT miT[ mi[ Ã...
  • Page 94 IMPORTANCE OF PM SCHEDULE EXECUTION fy& a l ki[ k (fÃTr bdlv& > Fuel Cock Filter Replacement • Put fuel cock knob position OFF. “off” ki[ k n) ni[ b n[ (A(Y(tmi> m& k i[ • Remove fuel cock sediment bowl by ring spanner. r)>...
  • Page 95 IMPORTANCE OF PM SCHEDULE EXECUTION viyr)> g hirn[ s ni[ $T Wiring Harness Routing Place couplers of tail lamp, number plate lamp, LH & RH rear side indicator in bellow as shown in photograph. fi[ T i[ g \ i gmi> dSi< Ä yi m& j b T[ l l[ À p, n> b r ¼l[ T l[ À p, sieD eºD)k[ T rni kplr n[ b[ l i[ m i>...
  • Page 96 IMPORTANCE OF PM SCHEDULE EXECUTION Route wiring harness through button clamp located near LHS petrol tank rubber damper. viyr)> g hirn[ s n[ p[ T ^ i [ l T[ º kn) Dib) bij& rbr D[ À pr pis[ an[ bTn kl[ À pY) psir kri[ viyr)>...

  • Page 97: Fuel System

    fy& a l s)ATm Fuel System c[ k krv& > an[ s[ T krv& > • CO Checking and Setting a[ > J n Ty& n ap • Engine Tune-up ATinDD< ai[ p r[ T )| > g p\ i [ s )zr •...

  • Page 98: Co Checking & Setting

    • enough by feel. (Engine Oil Temp. = 60 C). Wheelers is 3.5% at idling RPM. But CO% for Bajaj Vehicles, for best results in terms of fuel efficiency Caution: In choke ‘ON’ condition CO % is high : 9~10%.

  • Page 99: Engine Tune Up

    Chain slackness : 20~25 mm. Check & confirm proper functioning of spark plug. Engine Tune-up g. Use of recommended grade of bajaj genuine oil & engine oil level between MIN & MAX level. SPARK PLUG : BOSCH UR4AC, Champion PRZ9HC •...
  • Page 101 kplrn& > Ô[ D iN kiQ) ni> K i[ ¾ly& an[ ¾l[ k / y[ l i[ viyrn) kºT)ºy& n )T) c[ k kri[ t[ m i> ki[ e kºT)ºy& n )T) hi[ v ) Ô[ e a[ nh) enp& T s¼liyni vi[ Ã T[ j c[ krvi kplrn[ Ô[ D i[ e³n)Sn Av)c kri[...
  • Page 102 5000 (km) pr sif krv& > 15000 (km) pr sif krv& > ki[ À p\ [ S n p\ [ S r 11 to 13 kg/cm2 ATiºDD< : 9.5 kg/cm2 s(v< s l)m)T : T[ p [ T kl)yrºs 0.05 mm enl[ T viÃv : 0.1 mm a[ k zi[ T viÃv :...

  • Page 103: Standard Operating Procedure

    STANDARD OPERATING PROCEDURE kir¾y& r [ T r sif krvin) p´Ft) SOP for Carburettor cleaning • Ensure fuel cock knob at 'OFF' position. • Remove fuel pipe from fuel cock side. • Loosen drain screw and flush out petrol from the “Carburetor bowl”.
  • Page 104 STANDARD OPERATING PROCEDURE • Clean the carburettor jets by low pressure compressed air. li[ p\ [ S r ki[ À p\ [ A D hvi vD[ • Clean the carburettor passages by low pressure compressed air. li[ ki[ À p\ [ A D hvi vD[ kir¾y& r [ T r p[ s [ j sif kri[ •...
  • Page 105 STANDARD OPERATING PROCEDURE a[ r Ak| & s[ T )> g Air Screw Setting Note : Carburetor air screw & idling screw adjustment by removing LH side cover. • Remove LH Side panel by using vehicle key & take out panel. ni[ >...
  • Page 106 STANDARD OPERATING PROCEDURE kir¾y& r [ T r a[ s [ À bl) D^ [ e n Ak| & Assembly Carburetor Drain Screw kir¾y& r [ T r j[ T k)T Kit Carb Jet 12 Adjuster Cable a[ D jAT k[ b l kir¾y&...
  • Page 107 CARBURETTOR CIRCUITS STARTER SYSTEM - AUTO CHOKE - A ATi< T r (sATm ai[ T i[ ci[ k si[ l i[ n ieDY) cilt& > ci[ k ¼l> j r Solenoid Operated Choke Plunger ‘O’ Ring ai[ r)> g Plunger Y\ i [ T l viÃv b>...
  • Page 108 CARBURETTOR CIRCUITS STARTER SYSTEM - AUTO CHOKE - B si[ l i[ n ieDY) cilti[ ci[ k y& n )T Solenoid Operated Y\ i [ T l viÃv b> F IAYt)mi> Choke Unit Throttle Valve In closed Position l)fT[ D IAYt)mi> ¼l> j r Plunger hvi fy&...
  • Page 109 CARBURETTOR CIRCUITS PILOT SYSTEM - Slow Speed System pieli[ T s)ATm {Ali[ Ap)D s)ATm} Y\ i [ T l k[ p Cap Throttle m[ g n[ T { hi[ l s[ º Tr Magnet (TPS) (Hall Sensor) fy& a l enl[ T Side View Fuel Inlet sieDni[ d[ K iv...
  • Page 110 CARBURETTOR CIRCUITS m[ e n s)ATm hie Ap)D s)ATm MAIN SYSTEM - High Speed System kl)p\ E Clip Y\ i [ T l k[ p from Ap\ ) > g Top Notch Cap Throttle (Std.) Spring Side View v[ º c& r ) hi[ l s[ º...
  • Page 111 NOTES Discover 100 M Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 112: Engine & Transmission

    a[ > > J n an[ T^ i ºSm)Sn Engine & Transmission • Tightening Torque -TieTn)g Ti[ k < • Service Limit -s(v< s l)m)T • Special Tools -Ap[ S )yl T* Ã s • Removal Of Engine From Frame -f| [ m miY) a[ J n kiQv&...
  • Page 113 TIGHTENING TORQUE - ENGINE Spark Plug Cap Strainer (18 mm A/F Bolt) Cap Oil Filter 1.3 ~ 1.5 Kgm 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm Silencer Mounting Nuts Silencer Bracket Bolt Engine Mounting Nut - Top 2.0 ~ 2.2 Kgm 3.5 Kgm 1.8 ~ 2.2 Kgm Engine Mounting...
  • Page 114 TIGHTENING TORQUE - ENGINE Primary Gear Nut Clutch Nut (L.H. Thread) Clutch Spring Bolts 34 ~ 35 Kgm 1.0 ~ 1.1 Kgm 5.0 ~ 5.5 Kgm Drum / Cam Allen Bolt Stud Inhibitor Nut Oil Pump Mounting Screws 0.9 ~ 1.1 Kgm 0.9 ~ 1.1 Kgm 0.5 ~ 0.7 Kgm Output Sprocket Bolts...

  • Page 115: Service Limit S(V< S L)M)T

    SERVICE LIMIT Engine Compression Pressure Valve Tappet Clearance Rocker Arm Shaft Diameter Std. Limit 11.00 ~ 13.00 kg/cm2 Std. Limit In. 0.05, Ex. 0.1 Std. Limit 7.994 ~ 8.0 mm Ser. Limit Min. 9.5 mm Ser. Limit Ser. Limit 7.98 mm Valve Spring Free Length Valve Stem Diameter Intake Valve Stem Diameter Exhaust...
  • Page 116 SERVICE LIMIT Cylinder Piston Clearance Clutch Spring Free Length Friction Plate Thickness 28 ~ 52 micron Std. Limit Std. Limit 25.5mm Std. Limit 2.95 ~ 3.05 mm Ser. Limit Max 60 Micron Ser. Limit 24.5 mm Ser. Limit 2.7 mm Steel Plate Thickness Friction Plate Warp Steel Plate Warp...

  • Page 117: Special Tools - Engine

    SPECIAL TOOLS - ENGINE Special Tools Ap[ S )yl T& Ã s k| [ m Api[ k [ T hi[ Ã Dr Cam Sprocket Holder piT< n> Part No. : F41ZJZ47 Application : F o r h o l d i n g s p r o c k e t during removal / refitting of Cam sprocket allen bolt.
  • Page 118 SPECIAL TOOLS - ENGINE klc (Dsm[ º Tl T& l Clutch Dismantling Tool Part No. : F41AJA58 piT< n> Application : To dismantle & assembled clutch of Discover DTS-Si kick start as well as self start vehicle. DTS-SI upyi[ g : (DAkvr ni klcn[ (Dsm[ º...
  • Page 119 SPECIAL TOOLS - ENGINE Adaptor & Valve Spring Compressor Adaptor Part No. : 37 1031 08 Valve Spring Compressor : 37 1031 07 Application : To assemble / dismantle intake, exhaust valve by compressing spring in cylinder head. Drift Piston Pin Part No.
  • Page 120 Ap[ S )yl T& Ã s-a[ J > n SPECIAL TOOLS - ENGINE k| [ e n k[ s r)Tr Crankcase Heater Part No. : 37 2040 21 piT< n> Application : To heat the crankcase RH for easy fitment of crankshaft.

  • Page 121: Removal Of Engine From Frame

    REMOVAL OF ENGINE FROM FRAME a[ s )smi> Y ) a[ J > n bhir kiQv& • Remove C ap Oil Strainer (18mm A/F) • Remove oil s trainer • Drain Engine Oil. • Measure drained oil quantity. Remove • L. H. Side Cover (by opening side cover lock by key) •...
  • Page 122 REMOVAL OF ENGINE FROM FRAME Disconnect • L.H. & R.H. side spark plug caps (A) & (B) • Thermal sensor wire securing bolt (8 mm A/F) (C) • Battery -ve terminal wire (D) • Disconnect Stator plate wiring coupler (F) •...
  • Page 123 REMOVAL OF ENGINE FROM FRAME Remove • 2 Nuts (A) (12mm A/F) • One Bolt (B) (14mm A/F) & one nut (C) (17mm A/F) • Take out silencer assembly. Skill Tip : Always remove silencer mouth nuts first and then remove bracket bolt. CAUTION Dismantling bracket bolt first c o u l d c a u s e b e n d i n g o f...
  • Page 124 REMOVAL OF ENGINE FROM FRAME a[ s )smi> Y ) a[ J > n bhir kiQv& Remove bhir kiQi[ • 4 nut-bolts (A) (12 mm A/F) from front engine foundation bracket. 4 nT bi[ Ã T {a[ } {12 mma/f} n[ a[ J > n fiuºD[ S n b[ \ k r mi> Y ) Ki[ l i[ •...

  • Page 125: Sop For Engine Dismantling

    SOP OF ENGINE DISMANTLING a[ J > n Ki[ l vi miT[ Cover Cylinder Head kvr (sl)ºDr h[ D S.N. Description Qty. S.N. Description Qty. Cylinder Head Cover Comp Flanged Bolt M8X1.25X148L Bolt Tube Breather Gasket Head Cover Clamp Plate Cylinder Head Bolt Head Mounting Discover DTS-Si Dealer Development Center...
  • Page 126 SOP OF ENGINE DISMANTLING Cylinder Head (sl)ºDr h[ D S.N. Description Qty. S.N. Description Qty. Kit Assly Cylinder Head Gasket Cylinder Head Sleeve Spark Plug Insulator Manifold PTE 20 Screw - Grub - M5X0.8X7 Manifold Intake Ring - ‘O’ Bolt Flange M6X1X25L O-Ring Insulator Stud M8X1.25X451...
  • Page 127 SOP OF ENGINE DISMANTLING Valve viÃv S.N. Description Qty. S.N. Description Qty. Valve Intake Assly Rocker Arm Exhaust Valve Exhaust Shaft Rocker Arm Intake Seal - Oil Kit Valve Repair Collet Wave Washer Assly Rocker Arm Inlet Plain Washer Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 128 SOP OF ENGINE DISMANTLING Camshaft & tensioner k[ m sifT an[ T[ º snr S.N. Description Qty. S.N. Description Qty. Camshaft Assly Cam Chain (Straight) Circlip - Internal Kit Chain Guide (Straight) Bolt Tensioner Tensioner Pivot Bolt Spacer Cam Sprocket Gasket Sprocket - Cam Driven 32 Teeth Chain Tensioner...
  • Page 129 SOP OF ENGINE DISMANTLING Cylinder & Piston (sl)ºDr an[ (pATn S.N. Description Qty. Kit Block Piston Pin - Hollow Dowel Gasket Cylinder Block Thermal Sensor Kit Piston Ring Circlip Piston Grommet - Thermal sensor Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 130 SOP OF ENGINE DISMANTLING TOP END DISMANTLING Keep the engine which is removed from vehicle on engine holding fixture. Dismantling - Cover Cylinder Head Remove • 4 Bolts (8mm A/F) Skill Tip : Always loosen cylinder head cover bolts in criss - cross pattern. •...
  • Page 131 SOP OF ENGINE DISMANTLING Cam Sprocket Using Spl. tool F41AJA08 Cam Sprocket holder Remove • Allen bolt (6mm A/F) • ‘O’ Washer • Cam Sprocket • Collar cam sprocket Skill Tip : Tie chain by soft copper wire. Remove • Spark plug RH Remove •...
  • Page 132 SOP OF ENGINE DISMANTLING Cylinder Head Complete Using Special tool 3710CS22 for Rocker Shaft remover Remove • 2 Rocker shaft • 2 Rocker arms • Circlip • Cam Shaft Using Valve Spring compressor Remove • 2 nos. collets • 2 nos. retainers •...
  • Page 133 SOP OF ENGINE DISMANTLING Remove kiQi[ • Gasket cylinder block giAk[ T (sl)ºDr ¾li[ k • 2 Dowels (A) Di[ v [ l 2 n> b r {a[ } Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 134 SOP OF ENGINE DISMANTLING Starter Clutch ATi< T r klc S.N. Description Qty. S.N. Description Qty. Washer (Thickness 0.4 mm) Body starter Clutch Drive Assly. Bolt Gear Starter Clutch Plate Roller Clutch Starter Motor Assly. Starter Clutch Repair Kit Bolt Flange Washer Discover DTS-Si Dealer Development Center...
  • Page 135 SOP OF ENGINE DISMANTLING MAGNETO DISMANTLING Magneto Assembly Remove • Drive gear (A) (Counter Gear) with 2 washer. Thickness of washers is 0.4mm. • Gear Starter Clutch (B) by rotating in clockwise direction. • Place plastic cap on one way clutch rollers.
  • Page 136 SOP OF ENGINE DISMANTLING Remove • 2 Phillips screw (A). • Pick up coil • 2 Bolts (8mm A/F) (B) • One phillips screw (C). • Lock plate (D) • Neutral Switch connection (E) • Stator plate • 2 Phillips screw (F) •...
  • Page 137 SOP OF ENGINE DISMANTLING Clutch Cover klc kvr S.N. Description Qty. S.N. Description Qty. Kit Assly. Clutch Cover Seal - Oil Shaft Clutch Release Assly. Clip - Wire Bracket Clutch Cable Gauge Bolt - Flange : M5 O Ring Cap Oil Filler Bolt Cap Oil Filler Decal Clutch Cover...
  • Page 138 SOP OF ENGINE DISMANTLING Clutch S.N. Description Qty. S.N. Description Qty. Assembly Clutch Clutch Holder Collar Clutch Compression Spring Kit Primary Drive & Driven Flange Bolt Washer - Plain Spacer Clutch Assembly Wheel Clutch Washer Plain Plate Cutch Washer Belleville Kit Friction Plate Bearing - Ball Hub Clutch...
  • Page 139 SOP OF ENGINE DISMANTLING CLUTCH SIDE DISMANTLING klc bij& Y ) Ki[ l v& Cover Clutch kvr klc Remove • 3 Bolts (A) (8mm A/F) 3 bi[ Ã T { } {8 mm • Cap filter (B) k[ p (fÃTr { } •...
  • Page 140 SOP OF ENGINE DISMANTLING Using Primary Gear Holder Special Tool F41AJA11 Remove • Nut (19mm A/F) • Belleville washer • Plain washer Skill Tip : Lock Special tool between the teeth of primary gear & clutch housing gear from top. Using Special Socket for clutch Direction of nut F41ZJA54...
  • Page 141 SOP OF ENGINE DISMANTLING By using Clutch Dismantling Special Tool F41AJA58 Remove • 6 bolts (A) (10mm A/F) • Holder Clutch (B) • 6 springs (C) • Clutch Hub (D) • Friction Plates (E) • Steel Plates (F) • Wheel Clutch (G) Removal of Primary Gear Key way for square key...
  • Page 142 SOP OF ENGINE DISMANTLING Kick Starter Mechanism k)k ATi< T r m)k[ n )zm S.N. Description Qty. S.N. Description Qty. Kick Shaft External Circlip Washer Thrust Spring Kick Return Circlip Assembly Kick Lever Spring Kick Starter Ratchet Kit Boss Kick Lever Ratchet Damper Washer Plain...
  • Page 143 SOP OF ENGINE DISMANTLING KICK SHAFT DISMANTLING Remove • One plain washer (Big) (A) • Take out kick shaft assly by rotating it with kick lever in anti-clockwise direction. • One plain washer (Small). k)k sifT Ki[ l vi miT[ n ) p\ ( k\ y i kiQi[ a[ k ¼l[ n b[ S r {mi[ T &...
  • Page 144 SOP OF ENGINE DISMANTLING Oil Pump ai[ e l pÀp S.N. Description Qty. n> b r (vgt kvi[ º TT) ai[ e l pÀp a[ s [ À bl) Assembly Oil Pump Ak\ & pin Screw Pan Cross ai[ e l pÀp uprn& giAk[ T 1 Gasket Case Oil Pump D[ i v[ l p)n Pin Dowel...
  • Page 145 SOP OF ENGINE DISMANTLING a[ J n Ki[ l vin) p¹Ft) p\ m iN[ l& b \ ) k[ S n (sATm Ki[ l vin) p¹Ft) LUBRICATION SYSTEM DISMANTLING Oil Pump Remove • Shaft oil pump with nylon gear (A) •...
  • Page 146 SOP OF ENGINE DISMANTLING Gear Change Drum g)yr c[ º j D^ m S.N. Description Qty. Assly Drum Gear Shift Shaft Gear Fork Shift Fork Gear Shift Output Fork Input Disco-H Cam Drum Change Special bolt Dowl Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 147 SOP OF ENGINE DISMANTLING Gear Change Mechanism (gyr bdlvin) (mk[ n )sm S.N. Description Qty. Lever Comp Gear Shift Extension Spring Spring Gear Shift Return Nut - Hexagon Washer (Spring Steel) Inhibitor Comp. Gear Shift Step Washer Spring Inhibitor Bolt - Flange : M6 Gear Shift Lever Damper Damper...
  • Page 148 SOP OF ENGINE DISMANTLING (gyr s)fT)> < g (mk[ n )sm (sATm GEAR SHIFTING MECHANISM - DISMANTLING Remove kiQi[ • Nut Inhibitor Stud (A) (10mm A/F) nT en h[ b )Tr AT< D { } 10 mm { • Plain washer (B) ¼l[ n vi[ S r { } •...
  • Page 149 SOP OF ENGINE DISMANTLING Crankcase RH k\ [ > k k[ s S.N. Description Qty. S.N. Description Qty. Assly C' Case LH Screw Pan Cross - M6 Ball Bearing Pin - Hollow Dowel Seal - Oil 11A Bolt Flange Bearing - Needle Roller Bolt - M6 X 55 Bush Bendix Mesh Oil Filter Assy_G2...
  • Page 150 SOP OF ENGINE DISMANTLING Crankcase LH k\ [ > k k\ [ s S.N. Description Qty. S.N. Description Qty. Engine Assly Screw - Pan Pre-coated Assly C’Case RH Bolt Shift Change Bushing Drum Guide Kick Needle Roller Bearing Bolt Flange Bearing - Ball 6203 HN3 C3 Stud (JA541015) Pre-coated Stopper plate input bearing...
  • Page 151 SOP OF ENGINE DISMANTLING CRANKCASE SPLITTING Remove • 1 long bolt (A) • 6 Short Bolt (B) from LH / Magneto Side Skill Tips : Length of one Long bolt 60.7 mm Length of remaining 6 nos of Short Bolts = 41.3 mm Dismantling - Crankcase Remove •...
  • Page 152 SOP OF ENGINE DISMANTLING By using Bearing driver set 37103061 Remove from RH Crankcase • PTFE bushing (By using bearing driver set) • One phillips screw & bearing stopper plate • Ball Bearing (I/P shaft 6203) • 2 Bolts (8mm A/F) •...
  • Page 153 SOP OF ENGINE DISMANTLING Crankshaft Removal & fitment • Remove the engine from vehicle. • Remove cylinder head cover & cylinder head assembly. • Remove block & piston assembly. • Spit the crankcase & remove crankshaft assembly. • Before re-fitment of crankshaft assembly, heat the clutch side crankcase with heater at 150 C then fit the crankshaft assembly.
  • Page 154 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Engine Oil Application while Assembling Engine Name of Component Type of Lubricant All ball bearings & needle roller brg. Crank shaft big end bearing Transmission shaft & gear teeth Fork shaft Drum groove & cam drum change Block /piston skirt SAE 20-W40 Rocker assly.
  • Page 155 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Crankcase Oil Passages Always blow high pressure compressed air through the oil passage holes (of crankcase & clutch cover) in reserve direction of flow of oil & ensure that the Passages are clear. Bushing for Gear Shift Drum Use special tool no E6101100TE to fit ‘Bushing for Gear shift Drum’...
  • Page 156 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Washer & ‘O’ Ring Fitment on Output Shaft Ensure fitment of washer on output • shaft before fitment of O ring. • Ensure fitment of ‘O’ Ring on output shaft groove (near LH side spines for mounting Engine sprocket) before inserting it into the bearing fitted in crankcase LH.
  • Page 157 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Output Shaft Assembly Ensure that 1st, 2nd, 3rd gear output are freely rotating on Shaft Output. Assemble washers & circlip locks as shown in exploded view. 8 : Shaft Output 9 : Gear 2nd Driven 10 4 10 : Washer Gear 2nd Driven 11 : Gear 3rd Driven...
  • Page 158 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS LH Crankcase Assembly • Assemble Crankshaft, Gear Shift Drum & Transmission Shafts with Gears, Kick return spring into Crankcase LH. • Ensure that Gear Shift Drum rotates freely in Bushing. Important : Fit “Fork shift input” such that mark (QK) faces upward & ‘JD’ mark faces downward.
  • Page 159 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Washer Fitment OD = 25.7 mm OD = 25.1 mm • Washer of 2nd Gear Input is thin & having more diameter. (OD = 25.7 mm, ID = 13.3 mm, Thickness = 0.4mm). • Washer for 1st Gear Output is thick & having less diameter (OD = 25.1mm, ID = 13.3 mm ID = 12.3 mm ID = 12.3 mm, Thickness = 1.00 mm).
  • Page 160 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Intake & Exhaust Rocker Shaft Exhaust Rocker Shaft - 48 mm • Intake Rocker Shaft is short in length as compared to Exhaust Rocker Shaft. Length of Intake Rocker Shaft = 48 mm, • Length of exhaust Rocker Shaft = 48 mm Intake Rocker Shaft...
  • Page 161 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Aligning TDC Position marks for Valve Timing Align 'T' mark on Magneto Rotor with the mark on LH Crankcase to bring piston to TDC position at the end of compression stroke. Then align two marks (horizontal lines) on Cam Sprocket parallel to cylinder head top face and cam Sprocket’s ‘T’...
  • Page 162 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Kick Shaft Return Spring Tension Match the slot provided on kick shaft end w.r.t. spring end. Rotate kick shaft in anticlockwise direction for giving 1 turn tension to ‘kick shaft return spring’. Insert kick shaft into crankcase parent hole by gentle tapping & rest the kick ratchet lug on crankcase stopper.
  • Page 163 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Cam / Guide Gear & Special Bolt Insert 5 no. of pin dowels into the holes of Gear Shift Blank hole Drum. One hole is provided extra on the Drum. One pin is press fitted on the drum (which is less in height) for neutral position.
  • Page 164 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Clutch Assembly Sequence 4 : Wheel Clutch 5 : Plate Cutch 6 : Kit Friction Plate 7 : Hub Clutch 8 : Clutch Holder 9 : Compression Spring 10 : Flange Bolt 11 : Spacer ClutchAssembly Clutch Spacer Ensure fitment of 4 mm thick “Spacer Clutch”...
  • Page 165 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Clutch Washer Sequence Place one plain Spacer (JD551400) on ‘Input shaft Bearing’ before assembling ‘Collar Clutch’ (Ja551406). Place one plain washer (39260011) between ‘Clutch Housing’ & Clutch Stack. Plain Washer Collar Spacer - Clutch ‘JD’...
  • Page 166 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Clutch Cover oil jet cleaning • Remove & clean ‘Oil Jet’ by blowing compressed air whenever clutch friction plates are replaced. • Apply one drop of loctite 243 to threads of ‘orifice oil jet’ before refitting. •...
  • Page 167 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Cylinder Head Cover Breather Passage Before assembling cylinder head cover check & confirm that engine breather passage is clear by blowing light pressure compressed air. Cylinder Head Bolts Tightening Sequence Always first tighten cylinder head big bolts (4 nos) (12mm A/F) in crisscross pattern &...
  • Page 168 ENGINE ASSEMBLING - IMPORTANT SKILL TIPS Valve Lapping A. Carry out valve leakage test for intake and exhaust valves. • Position the camshaft in such way that both the valves are completely closed. • Fill some quantity of petrol inside intake port. •...
  • Page 169 GEAR TRANSMISSION POWER FLOW Gear Transmission (gyr T^ i ºsm)Sn S.N. Description Qty. S.N. Description Qty. Shaft Input Gear 3rd Driven Gear 4th Drive Gear 4th Driven Spline Washer Bush 1st Driven Ring - Snap Gear 1st Driven Washer Thrust Gear 3rd Drive Gear 2nd Drive Collar Sprocket Drive...
  • Page 170 GEAR TRANSMISSION POWER FLOW (gyr T^ i ºsm)Sn pivr fli[ When the slider gear is made to slide by means of gear shift fork it meshes with the corresponding gear and the required gear ratio can be obtained. The detail working of respective gears is explained as below. CIRCLIP 2ND GEAR 3RD GEAR...
  • Page 171 GEAR TRANSMISSION POWER FLOW Clutch Input Shaft enp& T sifT (gyr enp& T 1st Gear Input (gyr aiuTp& T 1st Gear Output (gyr aiuTp& T 4th Gear Output aiuTp& T sifT Clutch enp& T sifT Input Shaft (gyr enp& T 3rd Gear Input (gyr enp&...
  • Page 172 ENGINE LUBRICATION - FLOW OF OIL Lubrication Circuit l& b )\ k [ S n sk)< T h[ D trf kn[ k T)> g ri[ D k[ p (fÃTr k\ [ > k sif| T p[ p r (fÃTr a[ l )m[ º T ai[ e l pÀp a[ s [ À...
  • Page 173 ENGINE LUBRICATION - FLOW OF OIL ai[ e lni[ fli[ a[ J > n l& b \ ) k[ S n ai[ e l AT[ n r Oil strainer ai[ e l pÀp enl[ T Oil pump inlet ai[ e l pÀp aiuTl[ T INLET Oil pump outlet enl[ T...
  • Page 174 ENGINE LUBRICATION - FLOW OF OIL sieDmi k\ [ > k sifT upr hi[ l sieD k\ [ > k k[ s hi[ l \ Crankshaft drilled LH side hole - RH side crankcase hole ai[ r )f)s k\ [ > k b)g a[ º D p)ºk Crank big end pin Orifice k\ [ >...
  • Page 175 ENGINE LUBRICATION - FLOW OF OIL Oil passage checking Nozzle Oil Jet ‘Nozzle Oil Jet’ is press fitted in the crankcase L.H. and it is an important part of lubrication circuit. It sprays the oil, at pressure, on the piston ribs to take out heat. Thus keeps piston relatively cool & protects it from seizure. Checking &...
  • Page 176 NOTES Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 177 PART IDENTIFICATION DISCOVER 100 M (DAkvr 100 Part Name Crankshaft Assembly PA 5310 25 Part No. Description RH Side crank shaft length is 78.3 mm Identification Visual Mark Part Name Input Shaft Part No. PA 5510 02 Description • Total Length is 159.3 mm 159.3 mm Identification Visual...
  • Page 178 PART IDENTIFICATION DISCOVER 100 T (DAkvr 100 Part Name Crankshaft Assembly PA 5310 21 Part No. Description RH Side crank shaft length is 89.3 mm Identification “PA” mark on connecting rod Mark Part Name Input Shaft Part No. JZ 5510 10 Description Total Length is 170.3 mm 170.3 mm...
  • Page 179 PART IDENTIFICATION DISCOVER 100 M (DAkvr 100 Part Name Gear 1 Driven Part No. PA 5512 05 No of Teeth :- 31 Description 68 mm Outer Diameter is 68 mm Identification Visual Mark Part Name Drum Gear Shift Part No. PA 5610 04 Description Total Length is 87.2 mm...
  • Page 180 PART IDENTIFICATION DISCOVER 100 T (DAkvr 100 Part Name Gear 1 Driven Part No. JZ 5512 04 • No of Teeth :- 34 Description 66.5 mm • Outer Diameter is 66.5 mm Identification Visual Mark Part Name Drum Gear Shift Part No.
  • Page 181 PART IDENTIFICATION DISCOVER 100 M (DAkvr 100 Part Name Engine Output Sprocket Part No. JB 5510 00 Teeth profile is different than Discover 100 T. Description Identification Visual Mark NOTES Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 182 PART IDENTIFICATION DISCOVER 100 T (DAkvr 100 Part Name Engine Output Sprocket Part No. JZ 5510 04 Description Teeth profile is different than Discover 100 M. Identification Visual Mark NOTES ni[ > F Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 183 NOTES Discover DTS-Si Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 184 f[ | m an[ sAp[ n Sn TieTn)g Ti[ k < s(v< s l)m)T Ap[ S yl T& Ã s piT< s (vOi[ n ) (vgt k> º Ti[ ^ l k[ b l $T)g...
  • Page 185 TieTn)g Ti[ k < - f[ m fºT a[ k SÃi nT piCLn) a[ k sln) nT Ti[ k < ri[ D nT p[ n l upr piCLni Ap[ i \ k [ T n) nT h[ º Dl bir hi[ Ã Dr bi[ Ã T fi[ k <...
  • Page 186 TieTn)g Ti[ k < -f[ m LH AT[ bi[ Ã Ts f\ º T f[ º Dr miuºT)g bi[ Ã T rieDr f& T r[ A T aiuºT)g RHAT[ bi[ Ã T piCLni Äh)l kpl)g nT D)Ak miuºT)g bi[ Ã T fºT k[ l )pr aiuºT)g bi[ Ã...
  • Page 207 piT< s ke r)t[ Kbr pD[ D)Akvr100m D)Akvr 100m...
  • Page 208 D)Akvr 100T ni[ w :...
  • Page 213 D)Akvr100M ni[ w :...
  • Page 214 100 4G D)Akvr ni[ w :...
  • Page 215 kºT^ i [ l k[ b l $T)g a[ k s)l[ T r k[ b ln& > $T)g...
  • Page 216 k> º Ti[ ^ l k[ b l $T)g kÃc k[ b l $T)g...
  • Page 217 k> º Ti[ ^ l k[ b l $T)g f> º T b[ \ k k[ b l $T)g aigLni mD giD< ni Dib0 bij& mi> aip[ l kl[ À pmiY) aigLni b[ \ k viyrn[ f)T kri[ . aigLni b[ \ k k[ b ln[ Ap)Di[ m )Trni k[ b l siY[ Ap)Di[ m )Tr s& w ) siY[ le Ôv.
  • Page 218 D)Akvr 100 M ATiT< º D ai[ p r[ T )g pi[ \ s )zr...
  • Page 219 SOP-aigLni fi[ k < n ) DAT s)l an[ ai[ e l s)l bdlvin) p¹wt) aigLni Äh_ln) a[ k sln[ 17 ni r)> g Ap[ n r Ùiri Ki[ l ) a[ k sln[ bhir kiQi[ fºT b[ \ k k[ b ln) nT mmaf) n[ Q )l) kr) aigLni Äh)ln)
  • Page 250 D)Akvr 100m el[ k T)^ k Ãs b[ T r) kri[ a n[ ni kri[ el[ k T)^ k l c[ k krvin) p¹wt) el[ k T)^ k l srk)T Diyigi\ m...
  • Page 279 D)Akvr 100 M ATiT< º D ai[ p r[ T )g pi[ \ s )zr...
  • Page 280 D)Akvr 100{4G) vFirin& > D)Akvr T[ k n)kl (vgt TieTn)> g Ti[ k < s kib& < r [ T r n) (vgt piT< s n) (vgt el[ k T)^ k l srk)T Diyigi\ m...
  • Page 293 piT< s n) (vgt D)Akvr 100{4Ap)D g)ar)} piT< s n& nim piT< n> b r AC-DC (vgt Tiep ke r)t[ Kbr pD[ ?
  • Page 294 el[ k T)^ k l srk)T Diyigi\ m E³n)aSn srk)T...
  • Page 295 el[ k T)^ k l srk)T Diyigi\ m e³n)aSn srk)T...
  • Page 296 el[ k T)^ k l srk)T Diyigi\ m b[ T r) ciJ< g srk)T...
  • Page 297 el[ k T)^ k l srk)T Diyigi\ m lieT s)ATm srk)T...
  • Page 298 D)Akvr 125 2 vFirin& D)Akvr { viÃv} T[ k n)kl mih)t) siyl[ º T fy& c r kib& < r [ T r Ap[ s )f)k[ S n TieTn)g Ti[ k <...
  • Page 304 125m vFirin& > D)Akvr miT[ T[ k n)kl (vgt siyl[ º T fy& c r kib& ^ < r [ T r Ap[ S )f)k)Sn piT< s n) (vgt sop- a[ r (fÃTrn) sfie TieTn)g Ti[ k < s...
  • Page 316 p\ [ i bl[ m Si[ F vi an[ t[ n & > (nrikrN...
  • Page 318 D)Akvr 100m bÔj ai[ T i[ l)m)T[ D aik& < D ) p& n i-411035 Birt...
  • Page 319 Bajaj Auto Limited Akurdi Pune 411 035 India Tel +91 20 27472851 Fax +91 20 27407385 www.bajajauto.com...

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