Pulsar 125 Fi TRG Note
Pulsar 125 Fi TRG Note
Pulsar 125 Fi TRG Note
Pulsar 125 Fi
The Training No tes are a comp rehensive
training guide on ser vice and
main tenance ope rations and procedures
to be followed by se rvice personnel
at authorised se rvice cent res and
dealerships whilst at tending to the Bajaj
Pulsar 125 Fi.
The Training Note covers standard
workshop producers,
simplified for easy learning and
understanding for service technicians
worldwide.
NOTICE Copyright
All information contained in this Training Note is based on All Intellectual Property Rights, including but not limited
the latest product information at the time of publication. to 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. No part of this drawing may be copied or
care has been taken to make it as complete and accurate reproduced, either in part or in full by any means, whether
as possible. All procedures and specifications subject to mechanical or electronic, without prior written permission
change without prior notice. The right is reserved to make of the authorized signatory of Bajaj Auto Limited. Bajaj
such changes at any time without prior notice. reserves all rights to deal with violations of this clause in
accordance with applicable laws.
DOC. NO.: 71112877, REV. 00, OCT 2018
CIN L65993PN2007PLC130076 © Bajaj Auto Limited, 11 th SEPT 2012.
Contents
I Read... I Learn 1
CHAPTER 1
Identification...........................................................................................................2
Salient Features......................................................................................................5
Technical Specifications.........................................................................................7
Pre-Delivery Inspection Checklist..........................................................................9
Periodic Maintenance & Lubrication Chart..........................................................11
Fuel System 13
CHAPTER 2 Wiring Harness routing........................................................................................14
Working of Systems ............................................................................................20
Fuel Injection - Advantages Over Carburetion.....................................................30
EMS Sensor & Actuators......................................................................................31
Malfunction Indication...........................................................................................35
Tune up for Optimum Mileage..............................................................................37
CHAPTER 3
Engine & Transmission 39
Tightening Torques...............................................................................................40
Service Limits.......................................................................................................42
Special Tools.........................................................................................................44
Engine Dismantling...............................................................................................47
Frame 60
CHAPTER 4
Tightening Torques...............................................................................................61
Service Limits.......................................................................................................62
Special Tools.........................................................................................................63
Combi Brake System-SOP....................................................................................66
Standard Operating Procedures...........................................................................69
Electricals 82
CHAPTER 5
Battery..................................................................................................................83
VRLA Battery Initial Filling..................................................................................83
Do's & Don'ts......................................................................................................85
Electrical Checking Procedure.............................................................................89
Standard Operating Procedure..........................................................................105
Key LearningPoints
CHAPTER 1
Salient Features
Technical Specifications
Identification
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric
codes to identify your particular vehicle from others of the same model and type.
Control Switches
Identification
RH Control Switch
E. Starter Button :
F
Starter button operates the electric starter when clutch lever is
depressed with transmission in any gear.
It is recommended to start the engine with the transmission in neutral.
F. Engine Kill Switch :
E
The engine kill switch is for emergency use. During emergency move
the engine kill switch to the ‘OFF’ ( ) position.
Speedometer display will work when both Ignition switch & kill switch are
in ‘ON’ position.
To Lock the Steering : To lock the steering, turn the handle bar to the left
side. Push & release the key. Turn the key to “LOCK” position and remove
the key. Steering lock can be done on left handle position only.
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’.
Identification
Instrument Cluster Information
7 6
3
2 5
1
11
4
9
10
8
Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position.
Salient Features
PERFORMANCE
Key Features Advantages
All new 4 valve 125cc Optimum power • Refined Engine with
delivery without proprietary DTS-I
DTSi Engine
sacrificing low end technology that
Engine power: 12 Ps at torque delivers a balanced
Better drivability &
8500 RPM mix of power &
knock free performance.
Engine torque: 10.78 Nm Steady & Stable efficiency.
performance. • More power in all load
at 6500 RPM
Reduced of bore friction
DC ignition system. – Long life for the conditions, Better torque
Piston. delivery at lower RPM
Molycote piston
Better Heat Disputation • Eco Friendly - Lower
Oil jet for cooling piston -Improved life of engine
components. emissions & high fuel
Heavy duty gear box. efficiency
H i g h S p e e d
Viscous type air filter performance. • Smooth gear shifts for
element. Optimum utilization of start stop traffic
engine torque.
Paper element type oil
conditions
More effective filtration
filtration system. • Quick starts in wintry
Paper type oil filtration conditions.
Advanced Engine system filters out micro
level dirt/dust particles • Minimal wear & tear of
Management System
from engine oil. engine parts, thus
incorporated in ECU Adaptive ignition maps lower maintenance &
(EPM 44 type) for Optimum Engine longer life.
Performance.
STYLE
Key Features Advantages Benefits
• LED tail lamp • Classic & Efficient LED • Premium looks with
Tail Lamp. enhanced battery life
• Fuel tank • Streamlined Fuel tank
with a capacity of
10.5L.
• Imposing Front Fascia
• Open chested handle
bar position with a • Sleek & aggressive
symmetrical head light stance with a trendy
and a dual tone color dual tone colour
scheme palette for a modern &
trendy appearance
Salient Features
CONVENIENCE
Key Features Advantages Benefits
• MIL indicator. (Applicable • FI & related system errors • Information easily
to Fi variant only) are indicated by blinking available at a glance.
patterns
SAFETY
Key Features Advantages Benefits
• Powerful DC lighting • Intensity & illumination • Bright & even visibility
system with AHO of the head light does at all speeds & driving
not change with change conditions.
in engine/ Vehicle
• Tubular frame chassis speed.
with 1325 mm wheel- • Long life of chassis,
base & 5 spoke alloy • Strong chassis with good stability &
wheel. superior handling manoeuvrability
• Disc brake at Front & • 240mm ventilated disc • Safe & effective
Drum at Rear (With CBS) brake at front & 130 braking
mm Drum at rear
Technical Specifications
Engine & Transmission
Type : 4 stroke, single cylinder air cooled
No. of cylinders : One
Bore : 52 mm
Stroke : 58.6 mm
Engine displacement : 124.4 cc
Idling Speed : 1400 ± 100 rpm
Compression ratio : 9.8 ± 0.5 : 1
Max. net power : 12 Ps @ 8500 rpm
Max. net torque : 10.78 Nm (1.1Kg-m) @ 6500 rpm
Ignition System : Inductive DC ignition
Ignition Timing : Variable as per map in ECU
Spark Plug : 2 plugs
Spark Plug Gap : 0.7 ~ 0.8 mm
Lubrication : Wet sump, Forced lubrication
Transmission : 5 speed constant mesh
Primary reduction : 3.57
Gear shifting : 1 down 4 up
Primary reduction : 3.57
Gear Ratios 1st Gear : 2.833
2nd Gear : 1.823
3rd Gear : 1.333
4th Gear : 1.086
5th Gear : 0.909
Final Drive Ratio : 3.071:1(43/14)
Technical Specifications
Controls
Steering : Handlebar
Accelerator : On handle bar, RH grip
Gears : Left foot pedal operated, Step shift
Brakes Front : On handle bar, RH lever
Rear : Pedal operated by RH foot lever (CBS)
Clutch : Lever operated, left hand
Electricals
System : 12 V (DC)
Battery : 12V 6 Ah VRLA (Valve Regulated Lead Acid)
Head Lamp : 12V 35/35W
Position Lamp : 12V 5 W (2 nos.)
Rear number plate lamp : 12V 3 W
Tail / Stop Lamp : LED Type
Side Indicator Lamp : 12V 10W (4 nos. - Amber bulbs)
Neutral Indicator : LED - Green
High Beam Indicator : LED Type
Turn Signal Indicator : LED Type
Side Stand Indicator : LCD
Speedometer Lamp : LCD
Low battery indicator : 12V, 2W
Rear number plate lamp : 12V 3W
Horn : 12V DC, Type 2A (70 mm dia.) X 2
Dimensions
Length : 1995 mm
Width : 765 mm
Height : 1045 mm
Wheel Base : 1325 mm
Ground Clearance : 170 mm
Weights
Vehicle Kerb Weight : 125 kg
Gross Vehicle Weight : 200 kg
Performance
Maximum Speed, km/h : 95 Kmph
Climbing Ability : 26%
Notes :
• 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.
Recommended Oil SAE 20W50 of API 'SL', JASO MA Grade. Bajaj DTS-i Oil.
Recommended Quantity Drain & Refill 1000 ml., Engine Overhaul 1100 ml.
3 Engine oil & Oil filter R R R R R R R R 20W50API SL JASO MA Grade. Bajaj DTS-i Oil
6 Spark plug functioning / Gap CL, A, R CL, A CL, A R Replace at every 30000Kms
7 Air cleaner element Clean / Replace CL,R CL CL CL R CL CL R Clean at every 5000Kms Replace @ every 15000Kms
11 Clutch lever free play C,A C,A C,A C,A C,A C,A C,A C,A
12 Throttle grip play C,A C,A C,A C,A C,A C,A C,A C,A
14 Brake lining or pad wear CL,R CL CL CL,R CL CL CL,R Replace at every 15000 kms
15 Brake fluid level**- top up / replace C,A,R CL,L C,A CL,L CL,L Use recommended brake fluid (DOT3/DOT4)
17 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
19 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
20 Rear sprocket fasteners C,T C,T C,T C,T C,T C,T C,T C,T
21 Main stand & side stand pin** CL,L C,R C,R C,R
25 Wiring Harness & Battery Connections C,T C,T C,T C,T C,T C,T C,T C,T
Routine, tie bands & clamps tightness
26 General Lubrication L L L L L L L L
28 EVAP drain tube cleaning** C,L C,L C,L C,L C,L C,L C,L C,L
30 Force distribution unit drain hole C,L C,L C,L C,L C,L C,L C,L C,L
* More frequent cleaning may be required when driving in dusty condition. A - Adjust C- Check CL- Clean L- Lubricate T- Tighten R- Replace
** As applicable to model
Bajaj Pulsar 125 Fi Training Notes
11
1 I Read ..... I Learn
Notes
CHAPTER 2
Fuel System
Speedometer
Head lamp
HT coil-1
Lambda Sensor
Starter relay
LH Horn
Battery Positive
Battery Negative
Fuse Box
Side stand switch
Starter Relay
Purge valve
EVAP
TPS Front-rear
T Map harness connection
Regulator
Purge valve HT coil 2
IACV RH Horn
Rear Brake
switch Starter Motor
Chassis Engine earth
earth
TPS
Front-rear Assembly
harness reference
connection point
ECU Magneto
Front-rear
harness
connection
ECU Earth
Regulator earth
Tail lamp
Number plate lamp
Rear blinker RH
Rea blinker LH
CAN interface
CAN Termination
unit
18
125 Fi
Fuel System & EMS
It Supplies air to the Throttle body via It measures the temperature of the
a nozzle as per the duty cycle decided engine. The readings from this sensor are
by RPM , Temp of the engine . Thermal
then fed back to the ECU, which uses
In other words, it helps in providing Sensor
Purge Valve this data to adjust the fuel injection
additional air during cold starting
(Just like stepper motor) and also and ignition timing.
stabilizes the idle rpm by adjusting
the air supply
Thermal Sensor
Purge Valve
Indicator
Thermal Sensor
Working
Upon acceleration the throttle valve position changes. The wiper type
blades moves over the coil winding as it is pivoted directly on the
throttle valve shaft.
Working
The moving weights are suspended freely. When the vehicle
leans down on either of the LH I RH side the position of these
weights changes. The change of position of the weights is
sensed by the sensor. If the inclination angle exceeds beyond
60° to the vertical the sensor will give signal to ECU to cut off
the ignition system.
Working
As the rotor rotates the notched square blocks on the rotor periphery causes
voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts
the number of pulses per second and understands at what RPM the engine is
operating and accordingly precise fuel metering and ignition spark advance is
controlled.
There are 23 square notches I square blocks on the rotor outer periphery and are
placed equidistance.
At a particular location there is wide gap seen between 2 square notches I square
blocks. This can also be determined as square notch missing.
This missing square notch area represents the BTDC position. At this BTDC
position voltage pulse is sensed by the crank angle sensor and is communicated
to ECU.
When certain troubles are develop in the electronic control system, the
ECU stores the same in its memory & turns ON Malfunction Indicator
Light ( ) on the speedometer.
This alerts the driver that there is some problem and repair / service in
needed.
If a single sensor or its harness part fails the ECU may substitute a value
for failed sensor. This allows the engine to appear to run normal. A fault
that turns on the malfunction indicator light may also put the engine into
its limp-in mode. This means that limited operation strategy (LOS) chip in
the ECU has taken over. It provides basic instructions to the
microprocessor if a part of the electronic system fails. The engine runs
but with fixed ignition timing and air fuel ratio. The injector pulse width
does not change. This allows the vehicle to be driven but with greatly
reduced performance. The benefit of this is the vehicle can be limp-in for
service instead of being towed or transported into a cargo.
The technician can retrieve the stored trouble code from ECU memory
using the diagnostic tool. To use the code the technician can refer the
Diagnostic Chart or the Flash Code. This chart explains where lies the
problem and its probable cause.
Engine
THERMAL
PERGE
VALVE
Glows
Limitations of Carburettor :
• Restricted air flow due to venture design causes power
loss (volumetric efficiency is limited).
• As intake manifold contains combustible mixture,
danger of back fire from the cylinder into the manifold
is always there.
• At high altitude or in warm weather, possibility of
vapour lock.
• After burning noise in silencer on sudden deceleration.
• Does not support sudden acceleration.
• Difficult cold starting and requires choke for starting.
• In cold conditions, fuel wets the wall of the induction
manifold causing running difficulties.
• Difficult cold starting and requires choke for starting.
• Inconsistence in fuel efficiency. Maintenance cost is
reasonably more. High emission level.
30
125 Fi
Fuel System & EMS
Mail Relay
Purge Valve
The Sensors are located on Vehicle & Engine. But, most of the sensors are
located on the throttle body. The throttle body has a butterfly valve & is
located between the air filter and the intake manifold. It regulates how much
air can go to the engine, based on riders input through the opening &
closing of Throttle.
Don'ts:
• Do not adjust the Throttle Stop screw located on the throttle body.
This has been factory adjusted.
• Do not pull out the sensor couplers of the throttle body forcefully. It
has self-locking lugs which might break
• Do not dismantle/Open the throttle body.
• Do not clean the carbon soot deposited at the interface of the blade &
bore.
• Do not tamper with the throttle body in any manner.
5 Purge valve
Spark Plug :-
BOSCH / Champion
Spark plug gap : 0.7 ~ 0.8 mm
0.7 ~ 0.8 mm
Replace at every : 30,000 Kms
Compression Pressure :-
Standard : 12 to 13 Kg/cm2
Service Limit : 9.5 Kg / cm2
Tappet Clearance :-
Intake Valve : 0.05 mm
Exhaust Valve : 0.08 mm
Notes
CHAPTER 3
Service Limits
Special Tools
Engine Dismantling
Tightening Torques
Spark Plug (2 Numbers) Oil Strainer Cap (18 mm A/F) Cap Oil Filter Cover Bolt
Tightening Torques
Nut Securing Clutch Assembly Magneto Rotor Mounting Nut Starter Motor Mounting Nut
Service Limits
Compression Pressure Valve Clearance Clutch Spring Free Length
Intake Exhaust
2
Std. Limit 12.0 ~ 13.0 kg/cm Std. Limit 0.05 mm 0.08 mm Std. Limit 25.5 mm
Ser. Limit 9.5 kg/cm 2
Ser. Limit — — Ser. Limit 24.9 mm
Intake Exhaust
Std. Limit 7.994 mm Std. Limit 30.49 mm 30.44 mm
Std. Limit 59.91~60.11 mm
Ser. Limit – Ser. Limit 30.29 mm 30.24 mm
Cam Lobe Width Valve Spring Free Length Valve Stem Diameter
Intake Exhaust
Std. Limit 8.9 ~ 9.1 mm Std. Limit 37.92 mm Std. Limit 4.475~4.490mm 4.455~4.470mm
Valve Stem Bend Valve Stem to Guide Clearance Cylinder Head Warp
Intake Exhaust
Std. Limit 0.01 mm Std. Limit 0.01~0.037 0.03~0.057 Std. Limit 0.03 mm
Ser. Limit 0.015 mm Ser. Limit 0.047 mm 0.067 mm Ser. Limit 0.05 mm
Piston Cylinder Clearance Piston Ring Groove Clearance (mm) Steel Plate Warp
Piston Ring End Gap (mm) Friction Plate Warp Gear Shift Fork Guide Pin Dia
Shaft Fork Shift O.D Rocker Arm I.D Steel Plate Thickness
Std. Limit 9.972 ~ 9.987 mm Std. Limit 10 ~ 10.022 mm Std. Limit 1.6~1.7 mm
Ser. Limit 9.96 mm Ser. Limit 10.03 mm Ser. Limit 1.5 mm
Special Tools
Cam Sprocket Holder
Part No : 37 1043 07
Part No : 37 1043 06
Part No : 37 0043 69
Tappet Adjuster
Part No : 37 1043 55
Application : To loosen / tighten tappet
adjuster
Special Tools
Socket clutch nut
Part No : 37 1043 16
Part No : 37 1043 58
Part No : 37 1043 56
Part No : 37 10CS 22
Bearing Extractor
Part No : 37 1030 48
Special Tools
Adaptor & Valve Spring Compressor
Part No : 37 1010 06
Part No : 37 1030 53
Part No E6101100
Part No : 37 1030 61
Engine Dismantling
Top Side Dismantling
Remove
• Cylinder head cover bolts
• Take out cylinder head cover &
gasket.
Note - Always loosen cylinder Head
mounting bolts in criss - cross
pattern
Remove
• TDC finder cap
• Check the cam sprocket T mark.
Note - Align the rotor mark w.r.t
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
Engine Dismantling
Remove
• Cam sprocket bolt
Remove
• Cam sprocket
• Cam Sprocket Collar
Remove
• RH & LH side spark plug by using
spark plug removing tool.
Spark plug removal tool
Special Tool Part no. 37 1040 51
Remove
• Spark plug sleeve using
Engine Dismantling
Remove
• Cylinder Head Bolt.
Remove
• Cam sprocket Circlip
• Circlip of rocker arm shaft (Inlet &
Exhaust)
Remove
• Rocker arm shaft (Intake &
Exhaust) by using rocker shaft
removing tool
• Take out rocker arm & rocker arm
shaft.
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.
Engine Dismantling
Take Out
• Camshaft Assembly.
Remove
• Dowels on cylinder block.
• Cylinder head gasket.
Remove
• Chain guide
• Cylinder block.
Remove
• Dowels
• Cylinder block gasket.
Engine Dismantling
Remove
• Piston pin locking clip
• Piston pin
• Take out piston.
Note - Cover the crankcase bore with
clean cloth before removing piston pin
locking clip.
Remove
• Clutch cover mounting
Remove
• Clutch thrust bearing
• Primary gear nut with by using
clutch nut removing special tool.
• 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
Engine Dismantling
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.
Engine Dismantling
• Using clutch dismantling tool
Remove
• 4 bolts
• 4 springs
• Clutch holder
• Clutch hub
• Friction plates
• Steel / pressure plates (4 Nos)
• Wheel clutch
Clutch Dismantling tool
Special Tool Part no. : F4 1AJA 58
Remove
• Inhibitor Assembly
• Guide gear shift
• Take out guide gear shift
Remove
• Oil pump driven gear
Remove
• Primary gear nut
• Take out
• Belleville washer
• Plain washer
• Primary gear
Engine Dismantling
Remove
• Timing chain from sprocket
• Starter motor bolt
• Take out starter motor
Remove
• Stator plate
• Pick up coil screws
Remove
• Dowels
• Take out magneto cover gasket.
Engine Dismantling
Remove
• Gear starter clutch locking plate
screw
• Rotor bolt
• Plain washer
Remove
• Rotor
• Gear Starter Clutch
Remove
• Magneto rotor key.
• Starter counter gear assembly.
Magneto rotor puller
Special Tool Part no. : 37 0042 76
Remove
• LH crankcase bolts
• RH crankcase bolts
Engine Dismantling
Remove
• RH crankcase
Remove
• Crankshaft
• Fork shaft
• Input & output fork shaft
Remove
• Gear change drum
• Input fork & output forks
Remove
• Input & output gear shaft assembly
• washer plain of input gear shaft.
Engine Dismantling
Remove
• Crankshaft damper from crankcase
LH.
Remove
• Input shaft bearing locking plate
• Kick shaft locking plate bolts
Remove
• Input shaft bearing using bearing driver set.
Remove
• Bolt gear shift change
• Gear change drum bush using
bearing driver set.
Engine Dismantling
Remove
• Output shaft oil seal
• Gear change lever oil seal
Remove
• Output shaft bearing using bearing
driver set
• Neutral switch
Notes
CHAPTER 4
Service Limits
Special Tools
Tightening Torques
Front Axle Nut Rear Axle Nut RSA Lower Bolt
Service Limits
Brake Pad Thickness-Front Front Disc Run Out Axle Wheel Run Out
Radial Wheel Run Out Tyre Tread Depth Rear Sprocket Warp
Front Rear
Std. Limit TIR 0.5 mm or less Std. Limit 5 mm 1 mm Std. Limit TIR 0.4 mm or Less
Ser. Limit TIR 0.2 mm Ser. Limit 6.8 mm 1.5 mm Ser. Limit TIR 0.5 mm
Drive Chain Slack Front Fork Oil Grade & Capacity Drive chain Length
Grade : 20 Link Length
Fork Oil Level
SAE 10W20
Bajaj Genuine
Fork Oil
Quantity :
O/H: 140 + 2.5ml
Drain & Refill:
(Per Fork Leg 1st 2nd 20th
Assly)
MEASURE THIS LENGTH
Std. Limit 25 ~ 30 mm Std. Limit N/A Std. Limit 254.0~254.6 (20 links)
Ser. Limit 40 mm Ser. Limit N/A Ser. Limit 260 (20 links)
100 mm
Special Tools
Fork Oil Seal Driver
Part No : 37 1830 07
Application :
To fit fork oil seal in its seat
provided at outer pipe ID.
Special Tools
Bearing Race Extractor
Part No. : 37 00DJ 01
Application :
To Pull out steering race from
Fork Under Holder Bracket.
Tube Spanner
Part No. : 37 1043 57
Application :
For oil pressure sensor removal
& fitment on vehicle.
Special Tools
1.1. Purpose of SOP: The purpose of this SOP is to describe the procedure for brake free play setting for Motorcycle
having front disc and rear drum brake configuration. This SOP would assist technician to set Motorcycle brake free play as
per CBS system design to ensure satisfactory performance of vehicle brake system.
1.1. Front disc brake free play setting: Check front brake lever operation for smooth working. Ensure front wheel
for free rotation / freeness (Front brake lever travel should be in the range of 10-20 mm. Front brake play may not be
necessary to check as brake bleeding already been done and system is self compensatory)
Note: Ensure brake bleeding has been done if wheel rotation is not free. Brake lever should return completely in non
operating state after brake bleeding done.
Front brake
CBS cable
CBS brake pedal
assembly
Main lever
Sub lever
CBS front
brake cable
Knob on setting
tool for adjustment
• As this will be done at road side garage where special tools / measuring instrument / free play setting guideline may
not be known. As free play may not be in the specified range the optimum braking efficiency can not be achieved.
• Hence, it is recommended to do setting as per SOP / guideline after any front / rear wheel repairs (puncture / brake
shoe replacement / CBS cable replacement, any brake free play adjustment / drive chain repair, replacement,
adjustment).
• Clean master cylinder & caliper thoroughly by low pressure water spray
before opening master cylinder top cover & caliper bleeder screw.
• Drain the brake fluid from caliper assembly by removing rubber cap of 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.
• Remove front brake hose caliper end banjo bolt with 14 mm spanner.
Note :
Keep the plastic jar below caliper assembly.
• 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.
- Fit a proper tube which fits snugly tight on the bleeder screw nipple.
- Insert ring spanner through the pipe fitted on the bleeder screw nipple.
- Connect the tube siphon pump’s pipe and loosen the bleeder screw by the
ring spanner.
- Press the bellow of the Siphon pump in its valve open position. Then close
the valve of the pump and release the bellow. Simultaneously press the
brake lever to take out air trapped in the system. Carry out the same
procedure until the entire air trapped in the system gets removed.
- During this process continuously monitor and maintain the brake fluid level
in the master cylinder reservoir slightly above the minimum mark.
MIN
• Clean master cylinder & caliper thoroughly by keeping nozzle in spray mode
before opening master cylinder top cover & caliper bleeder screw.
• 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.
• Remove front brake hose master cylinder end banjo bolt with 14 mm
spanner.
• Smear silicon grease on new piston seals of master cylinder piston kit.
• Insert the piston assembly in master cylinder from front brake lever side.
• Fit the circlip
• Fit actuating shaft & grommet
• Fit master cylinder on handle bar & tighten 8 mm 2 bolts with T spanner.
• Fit front brake lever & connect front brake switch terminals.
• 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.
• Cut the cable tie tied to front brake at master cylinder end & take put front
brake hose.
• Refit the new brake hose pipe & replace copper washers fitted at both ends
with new one.
• Route the front brake hose as shown in front brake hose routing given in
control cable routing section & tighten master cylinder & caliper end banjo
bolts.
• 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.
• Remove master cylinder reservoir cover mounting screws with phillips head
screw driver & take out -
- Master cylinder reservoir cover
- PVC cap &
- Rubber diaphragm
• Refit the rubber diaphragm, PVC cap & master cylinder reservoir cap &
tighten the mounting screws.
• Drive the vehicle & check the brake effectiveness.
• Use DOT-3 / DOT-4 brake fluid from a sealed container.
MIN • Ensure no leakage of brake fluid through brake hose / benjo bolts / caliper
assembly.
• Carry out air bleeding if required.
• 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.
Notes
CHAPTER 5
Electrical
Battery
Battery
Battery Technical Specification
• Make Exide
• Terminal Voltage 12.8 Volt
• Type VRLA Battery
• Capacity 8 Ah
• Charging Current Specification 4.0 Amp
• Charging Voltage Specification 14.5 + 0.1 V
• Battery Charger Metafab / Apple Energy Make
Seal
Battery
Step 3: Fill the battery
Hold the electrolyte container upside down.
Place the container upright on battery. Match the 6
seals with the respective filler ports.
Note: Ensure the container is upright and not tilled. If
tilled the electrolyte might fail to flow.
Now force the container down until seals get pierced,
and electrolyte flows into the battery.
Battery
Dos & Don’ts
Dos Don’ts
• Apply petroleum jelly • Do not apply grease to
to battery terminals.
poles / terminals.
• Always charge the • Do not use any other
battery with the help battery charger for
of BAL recommended charging VRLA battery.
VRLA battery charger.
• Always use Midtronics • Do not fit extra
battery tester for
electrical accessories.
checking condition of This will result in
VRLA battery. wiring getting short &
battery would get
discharged. This will
shorten life of battery.
Ensure that horn is free from Never adjust nut on horn cap
dust and mud accumulation. side & bracket end (back side)
as it will result in horn
malfunctioning & failure.
Ensure that horn switch button
is operating freely.
Ignition System
Dos
• Always install recommended capacity of battery on the bike.
• Always replace spark plug by correct heat range plug.
• Check and adjust spark plug gap periodically. Adjust it to 0.7~0.9 mm b y wire
gauge.
• Replace spark plug at every 40,000 kms.
• Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3 ~
1.5 Kgm.
• Ensure H.T. cable secondary connection is firmly fitted in spark plug cap and H.T.
coil.
• Ensure that magneto coupler is firmly fitted.
• Always use a right size socket during removal and re-installation of spark plug.
• During periodic service make use of spark plug cleaning machine to clean spark
plug electrodes & check proper functioning of all spark plugs.
Don’ts
• 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.
Don’ts
• Do not install a lower / higher capacity battery than what is recommended.
• While washing vehicle do not direct pressurized water jet on Head Light, Tail
Light, Indicators.
• Do not drive the vehicle by keeping brake pedal pressed.
• Do not start Vehicle with light control switch in ON condition.
Switches
Dos
• Always clean switch assembly with soft cloth.
• After washing the vehicle ensure to apply dry air on switches before operation.
• Ensure that rear brake switch is free from dust, dirt &mud Accumulation.
• Always ensure that grommets provided on clutch switch, front brake switch and
rear brake switch are intact.
• Always apply WD-40 electrical contact cleaning spray to sticky switches.
Don’ts
• Do not apply direct pressurized water jet on control switches.
• Do not lubricate electrical switches by oil or grease.
• Do not over tighten the switches.
• 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.
OR
2. On vehicle
Check the continuity of fuse with Digital multi meter
Continuity shown – Fuse ok
No Continuity – Fuse blown off
If it is blown off, replace by new one of same capacity.
SOP :
• Switch OFF Ignition key.
• Disconnect Ignition switch’s coupler.
• Check continuity between wires in ‘ON’ & ‘OFF’ position.
Standard Value :
• Beep Sound & Continuity in ‘ON’ position. No continuity in ‘OFF’
position.
SOP :
• Turn ‘ON’ the ignition switch.
• The brake light should glow brightly when the front brake lever /
rear brake pedal is pressed.
• If it does not, check the front brake switch.
Clutch Switch
Meter Range Yellow / Green Black / Yellow
OFF – Clutch lever not Pressed
Horn
Clamp Meter Range Connections Standard Value
Encircle clamp meter jaws 2.2 Amps
200 DC A
around Brown wire of horn
2.2
Standard Valve :
ON Resistance OFF Resistance
Full
Of Bars Displayed
(Ω) with tolerance of + 2 Ω (Ω) with tolerance of + 2 Ω
1st Bar 62 71
3rd Bar 44 48
4th Bar 37 40
Full Tank 5th Bar 24 30
6th Bar 14 20
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.
SOP :
• Switch OFF engine.
• Disconnect coupler from Relay.
• Connect multi meter to Starter Relay coil terminals.
• Check resistance.
SOP :
• 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.
SOP :
• 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.
Connections Standard
Sr. Meter Range
Meter +ve Meter -ve Resistance Value
1 Y1 Y2
2 200 Ohm Y2 Y3 0.5 + 1 Ohm
3 Y3 Y1
SOP :
• Remove lower fairing LH & RH by removing 6 nos. each Philips screws.
• Disconnect all 3 spark plug caps (care to be taken so that spark plug
does not jump to metal part)
• Switch ‘ON’ Ignition switch & kill switch.
• Select range & set clamp meter zero reading.
80
Wire Connections
Standard
Sr.No. Parameter Vehicle position Meter
Meter -ve Reading
+ve
Red/ Yellow/
1 Input voltage NA 5 VDC
Blue Black
Brown/G Yellow/
Normal position 4.8~4.9 VDC
reen Black
2 Output voltage
Tilled position Brown/G Yellow/
2~2.2VDC
(> 600) reen Black
SOP :
• Switch ON ignition switch & kill switch.
• Set Multimeter to 20 VDC.
• Connect Multimeter as shown.
Wire Connections
Meter Range Standard Reading
Meter +ve Meter -ve
Pin no. 1 Pin no. 2 9 ~ 10 Ohm @ 250C
200 Ohms Meter displays 1 on LHS
Pin no. 3 Pin no. 4
@ 250C (open circuit)
SOP :
• Ensure ignition switch is OFF.
• Remove the harness side lambda sensor coupler.
• Set Multimeter on 200 Ohm range & connect as per table.
• Set Multimeter on 200 Ohm range & connect as per table.
Wire Connections
Sr.No . Component meter range Standard Value Results
Meter + ve Meter -ve
Crank angle Resistance Black/
1 White/ Red 345 ~ 385 Ohms OK
sensor 2 K Ohms Yellow
Black/ Beep sound Ok
2 Neutral switch Continuity Green
Yellow No Beep sound Defective
SOP :
• Switch OFF ignition switch & kill switch.
• Connect Multimeter as shown.
Wire Connections
Sr.No. Parameter Meter Range StandardReading
Meter +ve Meter -ve
1 Resistance 20 K Ohms Pin no. 1 Pin no. 2 1.5 ~ 2.5KOhm
2 Input voltage 20 VDC Pink / Black Pink / Blue 5 VDC
White/
3 Output voltage 20 VDC Orange
Pink / Blue 3.15 ~ 4.45 VDC
Note :
For resistance checking remove coupler of TMAP sensor &
connect the Multimeter prob to Pin 1 & Pin 2 as shown.
T MAP Sensor
Input Voltage Checking Note :
For input & output voltage checking connect coupler of TMAP
sensor.
SOP :
• Remove petrol tank cover & petrol tank.
• Remove air filter cover along with paper filter element.
• Connect Multimeter as shown in table given below.
Wire connection
Sr.No. Parameter Magnet Position Meter - Std. Reading
Meter +ve
ve
Input voltage (Side stand Red/ Yellow/
1 N.A. 5 VDC
position- any) Blue Bl ack
SOP :
• Switch ON ignition switch & kill switch.
• Set Multimeter to 20 VDC.
• Connect Multimeter as shown in table given below.
Fuel Pump
Measuring & Testing Equipment : Multimeter
Note :
• Battery should be fully charged.
• Fuse and ignition switch should be OK.
• Audible sound will be heard which will confirm fuel is working.
• Check main relay first if fuel pump is not working.
Wire Connections
Sr.No Parameter Meter Range Standard Reading
Meter + ve Meter -ve
12 +0.6 Ohms @
1 Resistance 2K Ohms Pin no. 1 Pin no. 2 0
25 C
Note :
• Remove petrol tank cover & petrol tank .
• Remove air filter cover along with paper filter element.
• Disconnect the injector coupler.
• Connect Multimeter to Pin 1 & Pin 2 of injector.
H.T. Coil
Measuring & Testing Equipment : Multimeter
Primary Winding Resistance Checking
Continuity
Meter Range Wire Connections
Check
Meter +ve Meter –ve
200 Ohms Relay coil Relay coil 80 ~ 140 Ohms
Terminal 1 Terminal 2
Note :
• Switch off the engine.
• Remove relay from coupler.
• Connect the digital multi meter to relay coil terminals and
check resistance.
Note :
• Connect external 12DC supply to relay coil terminals.
• “TUK” sound will be heard.
• Set digital Multimeter on continuity mode & connect the
digital multimeter to relay contacts terminals & check
continuity.
• Continuity (beep sound) indicated relay is Ok.
Remove
• ECU mounting bracket nut .
Take Out
• ECU bracket.
• Battery case.
Remove
• Pull ECU lock.
Fit
• ECU in coupler completely.
• Apply lock.
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