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Copyright, applying to this drawing and the information Bajaj Auto Limited accepts no liability for any inaccuracies contained therein vest solely and exclusively with Bajaj or omissions in this publication, although every possible Auto Limited.
C. Horn Button : ( ) Press button for sounding horn. D. Pass Switch : Press the switch to flash the head light. It is used to give signal to vehicles coming from opposite side while overtaking. Bajaj Auto International Business...
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To Unlock the Steering : To unlock steering, insert the key in steering cum ignition lock & turn it clockwise to “OFF” or “ON” position. Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear Seat’. Bajaj Pulsar 125 Carburetor Training Notes...
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7. Odometer : The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to ‘Zero’. 8. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero. 9. Set Button : Set button used for setting Clock & Service reminder. Bajaj Auto International Business...
& scheme trendy appearance Bajaj Pulsar 125 Carburetor Training Notes...
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• Disc brake at Front & • S a f e & e f f e c t i v e brake at front & 130 Drum at Rear (With CBS) braking mm Drum at rear Bajaj Auto International Business...
Rear (with Pillion) 2.25 kg/cm² (32.0 PSI) Rims Front 1.4 X 17” Spoke alloy wheel Rear 2.15 X 17” Spoke alloy wheel Fuel Tank Capacity 10.5 Litters Usable Reserve 2.5 Litters Unusable Reserve 2 Litters Bajaj Pulsar 125 Carburetor Training Notes...
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Values given above are nominal & for guidance only, 15% variation is allowed to cater for production & measurement. • All dimensions are under un-laden conditions. • Definitions of terminologies wherever applicable are as per relevant IS/ISO standards. • Specifications are subject to change without notice. Bajaj Auto International Business...
/ ring spanner / Front fork under bracket bolts - 2.5 ~ 3.0 Kg.m box type spanner as applicable without removing those major Rider foot rest bolts – 1.8 ~ 2.2 Kg.m parts. Bajaj Pulsar 125 Carburetor Training Notes...
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4. Visual inspection for dent, scratches, rust… 5. Clean the vehicle thoroughly before delivery to customer. Recommended Oil SAE 20W50 of API 'SL', JASO MA Grade. Bajaj DTS-i Oil. Replacement Frequency* 1st replacement at 500-750 Kms./ 1st service. Thereafter at every 5000 Kms.
Key Learning Points Understanding of Carburettor specs. Understanding of Secondary Air Injection system Understanding of Tune-up for Optimum Mileage CHAPTER 2 Fuel System Carburettor Specifications Secondary Air Injection (SAI) Tune-Up for Optimum Mileage Bajaj Pulsar 125 Carburetor Training Notes...
Fuel System Carburettor Specification Specification Item Make UCAL Type BS 24 Idling speed 1400 ± 100 rpm Main Jet Jet needle marking U-5EDR Needle jet mark Pilot jet 12.5 Throttle valve mark Choke Manual Bajaj Auto International Business...
Vaccum In • Connected to air filter assembly, exhaust valve passage in the cylinder head and intake manifold. Air outlet ON Acceleration Air Inlet No fresh air supply Air outlet to Exhaust manifold ON De-acceleration Bajaj Pulsar 125 Carburetor Training Notes...
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• This pulls the diaphragm against the spring tension and restricts the air flow. • Once the vacuum reduces the diaphragm opens due to spring tension and air starts flowing. Advantages : • Reduced emission of Carbon Monoxide & Hydro Carbons. • Environment friendly vehicle. Bajaj Auto International Business...
• Disconnect the hose connection of air filter to SAI from the filter side. • Firmly fit the nylon plug. • Use Nylon Plug (Part No: 37104331) for plugging the hose. Bajaj Pulsar 125 Carburetor Training Notes...
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10. Refit RH side cover. 11. Drive the vehicle & confirm the performance for good drivability & startability. Note: For vehicles without CAT & SAI system. CO% 2 + 0.5 & Idling rpm: 1400 ± 100 Bajaj Auto International Business...
• Rear brake pedal 15 ~ 20 mm. e. Chain slackness : 25~30 mm. Check & confirm proper functioning of spark plug. g. Use of recommended grade of bajaj genuine oil and ensure oil level between MIN & MAX level. Bajaj Pulsar 125 Carburetor Training Notes...
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Fuel System Notes Bajaj Auto International Business...
Appropriate Torque Application for Various Engine Components Engine Dismantling procedure Understanding of Standard Limits and Service Limits for all Engine Components CHAPTER 3 Engine & Transmission Tightening Torques Service Limits Special Tools Engine Dismantling Bajaj Pulsar 125 Carburetor Training Notes...
Valve Stem to Guide Clearance Cylinder Head Warp Intake Exhaust Std. Limit 0.01 mm 0.01~0.037 0.03~0.057 0.03 mm Std. Limit Std. Limit Ser. Limit 0.015 mm Ser. Limit 0.052 mm 0.072 mm Ser. Limit 0.05 mm Bajaj Auto International Business...
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Rocker Arm I.D Steel Plate Friction Plate Std. Limit 9.972 ~ 9.987 mm Std. Limit 10 ~ 10.022 mm Std. Limit 1.55~1.65mm 2.95~3.05mm Ser. Limit 9.96 mm Ser. Limit 10.03 mm Ser. Limit 2.75 mm Bajaj Pulsar 125 Carburetor Training Notes...
: F4 1AJA 11 Application : To hold primary and secondary gear loosening /tightening the primary gear nut & special nut securing clutch. Tappet Adjuster Part No : 37 1043 55 Application : To loosen / tighten tappet adjuster Bajaj Auto International Business...
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Rocker Shaft Remover Part No : 37 10CS 22 Application : To remove Rocker Shaft from cylinder head. Bearing Extractor Part No : 37 1030 48 Application : To Pull out main ball bearing from crankshaft. Bajaj Pulsar 125 Carburetor Training Notes...
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Application : To assemble “Bushing with PTFE Lining” at parent hole of crankcase RH for “Gear Shift Drum” mounting. Bearing Driver Set Part No : 37 1030 61 Application : Common bearing driver set for fitting & removing bearings from crankcase. Bajaj Auto International Business...
Crankcase marking. Remove • Cam chain tensioner bolt • Rotate chain tensioner screw in clockwise direction to take plunger backwards and lock it. Remove • Chain tensioner • Take out chain tensioner along with gasket Bajaj Pulsar 125 Carburetor Training Notes...
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Spark plug removal tool Special Tool Part no. 37 1040 51 Remove • Spark plug sleeve using Note : Do not pull spark plug sleeve by plier, to avoid any damage on it. Bajaj Auto International Business...
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Rocker Shaft Remover Tool Special Tool Part no. : 37 10DH 35 Remove • Intake & Exhaust valves along with- • Retainer • Valve spring • Oil seal • Valve spring seat using valve spring compressor. Bajaj Pulsar 125 Carburetor Training Notes...
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Adaptor & Valve Spring Compressor Compressor - 37 1031 07 Adaptor - 37 1031 08 Remove • Dowels on cylinder block. • Cylinder head gasket. Remove • Chain guide • Cylinder block. Remove • Dowels • Cylinder block gasket. Bajaj Auto International Business...
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• Clutch nut by holding the primary gear Note - Lock the special tool between primary gear teeth & clutch housing gear from top. Primary Gear holder - F41AJA11 Clutch nut Removing tool - 37104316 Bajaj Pulsar 125 Carburetor Training Notes...
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Take Out • Clutch nut • Belleville washer • Plain washer Remove • Clutch stack complete • Plain washer. Remove • Kick return spring • Take out kick shaft assembly. Remove • lever comp gear shift. Bajaj Auto International Business...
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• Take out guide gear shift Remove • Oil pump driven gear • Oil pump screws • Take out the oil pump Remove • Primary gear nut • Take out • Belleville washer • Plain washer • Primary gear Bajaj Pulsar 125 Carburetor Training Notes...
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• Timing chain from sprocket • Starter motor bolt • Take out starter motor Magneto Side Dismantling Remove • Magneto cover bolts Remove • Stator plate • Pick up coil screws Remove • Dowels • Take out magneto cover gasket. Bajaj Auto International Business...
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Engine & Transmission Engine Dismantling Remove • Output shaft oil seal • Gear change lever oil seal Remove • Output shaft bearing using bearing driver set • Neutral switch Bajaj Auto International Business...
Appropriate Torque Application for Various Frame Components Understanding of Standard Operating Procedure Understanding of Standard Limits and Service Limits for all Frame Components CHAPTER 4 Frame & Suspension Tightening Torques Service Limits Special Tools Standard Operating Procedure Bajaj Pulsar 125 Carburetor Training Notes...
25 ~ 30 mm Std. Limit Std. Limit 254.0~254.6 (20 links) 260 (20 links) Ser. Limit 40 mm Ser. Limit Ser. Limit Axle Run Out 100 mm Std. Limit TIR 0.05 mm Ser. Limit TIR 0.2 mm Bajaj Pulsar 125 Carburetor Training Notes...
/ tightening fork allen head bolt at bottom. Installer Upper & Lower Bearing Race Frame Part No : 37 1801 06 Application : To install upper & lower steering races / cones into their seats inside frame. Bajaj Auto International Business...
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Part No. : 37 1043 57 Application : For oil pressure sensor removal & fitment on vehicle. Fork Special Bolt Tightening Tool Part No. : 37 0043 40 Application : For tightening & loosening fork bolt Bajaj Pulsar 125 Carburetor Training Notes...
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Frame & Suspension Special Tools Combi Brake Adjustment Tool Part No. : 37 0043 54 Application : For Adjusting Brake free play. Bajaj Auto International Business...
CBS front brake delay should be in the range of 5- 10 mm measured at brake pedal foot resting pad. Fig 1: CBS disc drum Layout Front brake Master Cylinder assembly Front brake CBS cable CBS brake pedal assembly Rear Brake Rod Bajaj Pulsar 125 Carburetor Training Notes...
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CBS - Combi Brake System-SOP Fig 2: Front brake MC assembly Main lever Sub lever Fig 3: CBS brake pedal assembly Free play measured at foot resting pad CBS front brake cable Adjuster Nut (A) Adjuster Nut (B) Bajaj Auto International Business...
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/ CBS cable replacement, any brake free play adjustment / drive chain repair, replacement, adjustment). 2.5. CBS free play setting values CBS front brake delay Individual front brake Rear brake free play (mm) (mm) free play (mm) 10-20 15-20 5-10 Bajaj Pulsar 125 Carburetor Training Notes...
/ disc pads & also powder coating peel off / inefficient braking. • Remove front brake hose caliper end banjo bolt with 14 mm spanner. Note : Keep the plastic jar below caliper assembly. Bajaj Auto International Business...
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125 Carb. Frame & Suspension Standard Operating Procedure • Remove caliper pin holder bracket as shown in photograph. • Clean the anchor pins thoroughly. • Remove pad spring. Bajaj Pulsar 125 Carburetor Training Notes...
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Replace caliper assembly major / minor kit. Caliper Minor Kit • Smear silicon grease on piston Caliper Major Kit OD & rubber parts. • Fit oil seals & dust seals. • Fit pistons in caliper body. Bajaj Auto International Business...
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Clean the brake pads by smooth emery paper. • Fit caliper assembly on front fork mounting & tighten mounting bolts with 12 mm spanner. • Fit brake hose caliper end banjo bolt with 14 mm spanner. Bajaj Pulsar 125 Carburetor Training Notes...
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Frame & Suspension Standard Operating Procedure • Fill the brake fluid above MIN level. Bajaj Auto International Business...
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Drain the brake fluid from caliper assembly by loosening air bleeder screw & using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking. Bajaj Pulsar 125 Carburetor Training Notes...
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Frame & Suspension Standard Operating Procedure • Remove front brake switch terminals. • Remove front brake hose master cylinder end banjo bolt with 14 mm spanner. Bajaj Auto International Business...
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- Master cylinder reservoir cover - PVC cap & - Rubber diaphragm • Remove actuating shaft & grommet. • Remove circlip & take out piston assembly. • Clean master cylinder using brake fluid & apply low compressed air. Bajaj Pulsar 125 Carburetor Training Notes...
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Fit front brake hose & tighten banjo bolt. • Fill brake fluid into master cylinder reservoir just above MIN level & carry out air bleeding. • Fit diaphragm & master cylinder reservoir cap. • Drive the vehicle and confirm brake effectiveness. Bajaj Auto International Business...
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Remove master cylinder reservoir cover, PVC cap & take out rubber diaphragm. • Fill the brake fluid in master cylinder reservoir & carry out bleeding operation. • Fit rubber diaphragm, PVC cap & master cylinder reservoir cover. Bajaj Pulsar 125 Carburetor Training Notes...
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Drive the vehicle & check the brake effectiveness. • Use DOT-3 / DOT-4 brake fluid from a sealed container. • Ensure no leakage of brake fluid through brake hose / benjo bolts / caliper assembly. • Carry out air bleeding if required. Bajaj Auto International Business...
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Turn the adjuster cam on shock absorber to same required position. Setting the adjuster cam to higher notch position increases the spring stiffness & vice as versa. • Shock absorber adjusted either too soft or too stiff could adversely affect riding comfort & vehicle stability. Bajaj Pulsar 125 Carburetor Training Notes...
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Frame & Suspension Notes Bajaj Auto International Business...
Check specific gravity of each cell & voltage after 1 hour it should be 12.5 volt & specific gravity 1.24 for the fully charged battery. • Disconnect the battery from the changer. • Fit vent / filler plug strip firmly. • Reconnect battery terminals • Apply petroleum jelly to the battery terminals. Bajaj Auto International Business...
voltage by multimeter. the poles to check battery condition. • Use only distilled water • Do not use mineral to top up battery. water, drinking water to top up battery. Bajaj Pulsar 125 Carburetor Training Notes...
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Ensure that horn switch button is operating freely. Ensure that battery is fully Do not hit by mallet / screw charged. driver on horn resonator. Bajaj Auto International Business...
Do not replace spark plug by non recommended one (different heat range). • Never short circuit H.T. coil primary wire to ground. It could lead to ECU failure. • Do not adjust spark plug gap with any instruments like screw driver, pliers etc. Bajaj Pulsar 125 Carburetor Training Notes...
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Do not add extra electrical loads e.g. musical horns, additional horns, buzzers as it will reduce switch contact life & battery life & battery life. • Do not tamper / alter rear brake switch spring. • Do not operate switch immediately after water servicing. Bajaj Auto International Business...
Electrical Checking Procedure Checking Procedure Fuse 10A, 10A are located inside the fuse box as shown in photograph. To open fuse box cover unlock the cover & open the fuse box. Remove the fuse check continuity. Bajaj Pulsar 125 Carburetor Training Notes...
No continuity Brown/Blue Mode Measuring & Testing Equipment : Multimeter SOP : • Put ignition switch OFF. • Put kill switch OFF. • Set multimetr at continuity range. • Connect multimeter as shown in the table. Bajaj Auto International Business...
• If it does not, check the front brake switch. Clutch Switch Meter Range Yellow / Green Black / Yellow OFF – Clutch lever not Pressed ON – Clutch lever Pressed Measuring & Testing Equipment : Multimeter Bajaj Pulsar 125 Carburetor Training Notes...
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3rd Bar 4th Bar 5th Bar 6th Bar Note: If display in speedo console is not proper then please check following - • Battery Voltage • Speedometer coupler & fuel gauge tank unit coupler connection is firm. Bajaj Auto International Business...
• Connect external 12V DC supply to starter relay coil terminals. • ‘Tuk’ sound will be heard. • Set multi meter on continuity mode. • Connect multi meter at relay contact terminals. • Continuity (beep sound) indicates starter relay is OK. Bajaj Pulsar 125 Carburetor Training Notes...
• Remove spark plug cap from HT coil cable. • Set multi meter on 2 K Ohm range. • Connect multi meter probes as shown in photograph. • Standard value, 1 K Ohm + 150 Ohm. Bajaj Auto International Business...
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Measuring & Testing Equipment : Multimeter Use fully charged battery while measuring At 4500 RPM with Meter Range Connections Heal Light ON Meter +ve Meter -ve 20 K Ohms 14.4 + 0.2 Volts Battery +ve Battery -ve Terminal Terminal Bajaj Pulsar 125 Carburetor Training Notes...
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OK coil. • Visually inspect the secondary winding lead. • If it shows any damage, replace the coil. Primary Winding 0.45±10% W at 25 C Secondary Winding 5.0±10% K W at 25 C Bajaj Auto International Business...
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SWITCH Br/L Br/L Br/L Br/L PIN NO. 8 IGNITION SUPPLY TAIL STOP PIN NO. 9 LAMP BATTERY POSITIVE PIN NO. 10 HIGH BEAM NUMBER Br/L PLATE LAMP Br/W Br/W LIGHT CONTROL MODULE BATTERY CONTROL SWITCH LH Bajaj Auto International Business...
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PIN NO. 9 BATTERY POSITIVE PIN NO. 11 Br/L RIGHT TURN INDICATOR PIN NO. 14 LEFT TURN INDICATOR SINGLE LAMP REAR LH SIGNAL LAMP FRONT BATTERY indicator switch CONTROL SWITCH LH LIGHT CONTROL MODULE Bajaj Pulsar 125 Carburetor Training Notes...
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Electrical Notes Bajaj Auto International Business...
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Bajaj Auto Limited Akurdi Pune 411 035 India Tel | +91 20 27472851 Fax | +91 20 27407385 www.bajajau t o.com CIN number : CIN L65993PN2007PLC130076...
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