Bajaj Discover 100M Service Station Manual Download

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SOP OF ENGINE DISMANTLING

Discover DTS-Si
Service Station Manual

122

Dealer Development Center

Akurdi Pune

•

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,

then fit the crankshaft assembly.

Ensure crankshaft fitment in crankcase by hand pressure only.

Mallet can be used for tapping crankshaft.

Do not use hammer for crankshaft fitment

heat the clutch side crankcase

with heater at 150 C

Note :

Crankshaft Removal & fitment

Summary of Contents for Discover 100M

Page 1: ...Service Station Manual Service Station Manual...

Page 2: ...inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible All procedures and specifications subject to change without p...

Page 3: ...ightening Torques Special Tools Engine SOP for Engine Dismantling Gear Transmission Power Flow Part Identification Service Limit Removal of Engine from Frame Engine Assembling Important Skill Tips Eng...

Page 4: ...Electrical Circuit Diagrams 227 222 248 220 238 Supplementary SSM for Discover 100 4G 249 12 Supplementary SSM for Discover 125 2Valve 267 13 Supplementary SSM for Discover 125M 273 14 Diagnosis Trou...

Page 5: ...Foreword 1 1 Dealer Development Center Akurdi Pune Discover 100 M Service Station Manual fi rvD...

Page 6: ...nual carefully Don t take shortcuts Remember to keep complete records of maintenance and repair with dates and any new parts installed In this manual the produce is divided into its major systems and...

Page 7: ...n s siT n an sri p i l m tYi SDy al vgr aivti m T n sY sivc t rhi j y n b j mi Tr siykl piT s an p i pr T sni j upyi g kri b j mi Tr siykl s v s krt vKt s v s m y almi aip l Ap S yl T s g Js an T ATrs...

Page 8: ...Workshop Safety 3 vk Si p s fT...

Page 9: ...sin YS T AT dr yin pi tin Si t riKi a lT miT a j r C vihnn ri lrn v c ni Bigmi cQivi fy al piep vihnni grm Yiy t vi Bign ADk nh t n yin riKv aim YviY aig lig Sk C T AT cil krt vKt a r li vr cil kri j...

Page 10: ...ourself cool while taking tests It is very necessary to be alert Mount the vehicle in the center of the rollers Fuel pipe should not touch heated part of the vehicle it may cause fire Make sure to put...

Page 11: ...p srmi Y g di piT k s AP Dmi psir Yiy C j Y t ai Ki n n ksin kr Sk C Bir dbiNviL grm hvi li h mi Bl ti m Ry Ye Sk C y m T k T sni a r aiuTl Tmi v nh b k an klcni piT sn hvi mir n sif krvi nh j ni piT...

Page 12: ...It is advisable to fit a pressure regulator FRL Filter Regulator Lubricator in the pneumatic line which supplies air pressure to the air tool It regulates the outlet pressure to 6 5 Kg cm This avoids...

Page 13: ...lift Don t put leg hand in between while raising lowering the lifter Bay Do not lower the lifter bay table without unlocking the mechanical lift lock Do not keep your leg between the top and bottom fr...

Page 14: ...upr Ti p an bi Tmn v c riKvi nh lfTr b pr kim krt vKt Q li kpDi ph rvi nh hieD il k e Tsn Qli m kSi nh lfTr b cil krvin hi y Ryir lfTr b upr b upr uBi rh v nh pivr p k pia s F aig jt b F riKv kim kij...

Page 15: ...General Information Before Servicing 7 jnrl e fi rm Sn s v s g ph li...

Page 16: ...tery then the negative cable to the negative terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Cleaning Vehicle before Disassemb...

Page 17: ...kri s v s p r Yyi bid ph li k bl an Ryir bid k bl Y k bl b Tr Tm nl siY Di piT s n a jD mi Ti tYi Bir piT sn vhn krt vKt piT sn GirY Yt e ai Y bcvi mi ph rvi vihn Ds bl krti ph lin sfie vihnn Ds krti...

Page 18: ...embly order is provided in this Service Manual follow the procedures given Replacement Parts Replacement parts must be BAJAJ genuine or recommended by BAJAJ Gaskets O rings Oil seals Grease seals Circ...

Page 19: ...akAmit ni tr Sk C kiQ li piT sn njr vd ki ri zn DAklh Sn an b ki e n kSin miT ckiSi dr k piT sn alg alg s v s lm T Nvi miT m y almi aip l a kAnn mddli ki e piT s n kSin kirk vi mL aYvi t s v s lm Tn...

Page 20: ...sembly and assembly excessive force can cause expensive or hard to repair damage When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced...

Page 21: ...Ti Ti k Y bi T nT an Ak n Ki lviY g B r n kSin Ye Sk C sir g Nvtin Ti c r cni upyi g viri nkk kr l Ti k Y j fiATns TieT krvi fi s tikit Ds bl an a s bl dr yin i y e p kT Ak D iyvrni upyi gY Ak ni ni...

Page 22: ...essure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Press inner race when bearing is to be fitted o...

Page 23: ...N b r g ris pr dbiN aiv t n j yia dbivi Ki T j yia r s pr dbiN krviY b r g Krib Ye Sk C a drn r sn dbivi jyir sifT pr b r g f T krvin hi y bhirn r sn dbivi jyir b r g bi rmi fT krvin hi y ai el s l g...

Page 24: ...olour wire is identified first by the primary colour and then the stripe colour Unless instructed otherwise electrical wires must be connected to those of the same colour Instrument Use a meter that h...

Page 25: ...Y vD f rvvimi aiv f rvvin dSimi aiv l f l a DjATm Tn asr kr Sk C k k sifTn pi z T dSimi f rvi w DyiL p miN klc kvrn bij Y el kT kl viyr b klr Y viyr ai LKiyC ph li pi Emr klr an b ji ATi ep klr n hti...

Page 26: ...cessively spread open circlips with tool during installing to prevent deformation Always use appropriate special tool for opening assembling parts to avoid damages To avoid dust muck entry inside the...

Page 27: ...m SnY bcvi srkl p lgivt vKt t T sY vFir K l n Ye y t n kiLJ riKv n ksin Yt aTkivvi piT sni ai pn g an a s bl vKt hm si n kr l Ap Syl T sni j upyi g kri F L an mD a Jnmi jti aTkivvi a Jn lgt ki epN r p...

Page 28: ...NOTES Discover 100 M Service Station Manual 14 Dealer Development Center Akurdi Pune...

Page 29: ...ty Checks Running In Fuel Saving Tips Non Use Maintenance Customer Awareness Bajaj Genuine Parts Maintenance Tips 15 g ihkn mi ht s f ried g T s drri jni s fT c k rn g en fy al bcivvin T s ni n y z m...

Page 30: ...ds Read thoroughly the instructions in this manual and follow them carefully Avoid unnecessary accessories for the safety of both rider and other motorists Get familiar and follow traffic rules and re...

Page 31: ...kiT aTkivviY srf s Big pr p v T v ki T lgivi vihnni mhRvni bFij piT s p r yi D k m T n smi v gtvir aip l C t m jb sif kri an l b k T kri vihnni aigLni Bigmi mD p i T kSn s T lgiv n a Jnn k l g s ATmmi...

Page 32: ...ange the gear judiciously according to the speed requirement Don t overload the vehicle above the specified payload Use the accelerator judiciously Cut off the engine if you want to stop for more than...

Page 33: ...p Ym 200 k m rn g en smy giLi drm yin n c m jbn Ap D l m T upr jv nh k m 1st 2 nd 3 rd 4 th 0 1000 13 23 33 43 1000 2000 18 32 45 60 ki OTkmi jNivyi m jb Ap D l m T n c Ap D riKv a Jnn vFir r s krv n...

Page 34: ...els are raised off the ground Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or brake liners Lubricate the control cables Cover the entire vehicle neatl...

Page 35: ...ili ai el vD ki T Ye y Ryirbid Apik lg piCi f T kr di vihnn bi ks pr aYvi AT D pr m ki j Y b n h l jm n upr rh kiTY bcivvi miT klr vgrni bFi m Tl sf s upr ai elni Ap kri rbr piT s an b k lienr pr ai e...

Page 36: ...lgiv nh j v k r mi T hi n bj r vg r b Tr Tm nl Ki l niKi vihn li bi smy s F upyi gmi n l vin hi y ti b aqviD yiY vFir s f ATiT bTn stt dbiv nh pi c s k D rih v dr k ATiT r v c j b Tr r kvr krvimi mdd...

Page 37: ...hicle by keeping brake pedal pressed Always ensure tyres are inflated to specified air pressure Do not add extra electrical accessories e g remote horn buzzer etc Disconnect battery terminals if vehic...

Page 38: ...ot fit accessories to carry extra load Warranty is applicable for manufacturing defects with in a period of 2years or 30 000 kms whichever occurs earlier Warranty is not applicable to Parts subjected...

Page 39: ...f Tm T an vh kl m T n s PM S Dy l p miN vi r T 2 vP aYvi 30 000 k m b mi Y j vh l aiv t smy giLi dr yin m y f kcr g D f kT miT lig pD C vi r T lig pDt nY piT sni an s Finmi v yr an T yr j vi k klc l...

Page 40: ...rts Carry out all free paid services as per recommendations Follow Running in instructions other riding tips for proper riding habits Insist on replacement of periodic parts as recommended in Schedule...

Page 41: ...NOTES Discover 100 M Service Station Manual 22 Dealer Development Center Akurdi Pune...

Page 42: ...Technical Specifications Technical Specifications Carburettor Specification 23 T kn kl Ap S f k Sn T kn kl Ap S f k Sn kir y r Tr Ap S f k Sn...

Page 43: ...Drum Disc Rear Drum Brake Size Front 130 mm Drum 200 mm Disc Rear 110 mm Drum brake Tyres Front 2 75 x 17 41 P Unidirectional Rear 3 0 x 17 50 P Unidirectional Tyre Pressure Front 1 75 Kg Cm Rear Solo...

Page 44: ...cifications are subject to change without notice Steering Handlebar Accelerator On handle bar RH grip Gears Left foot pedal operated Step shift Brakes Front Lever operated RH hand Rear Pedal operated...

Page 45: ...bility of DOT 3 completely drain old brake fluid replace with DOT 4 Hydraulic Brake Quantity Service 1 L Eng O H 1 1 L Quantity fork leg Service 140 2 5 ml Front fork 2 3 Grease Silicon Caliper anchor...

Page 46: ...Discover 100 M Service Station Manual 27 Dealer Development Center Akurdi Pune Grease All purpose Fr rear wheel axle Swing arm shaft Brake pedal pivot pin Center stand shaft Side stand U bracket Gear...

Page 47: ...NOTES Discover 100 M Service Station Manual 28 Dealer Development Center Akurdi Pune...

Page 48: ...ith Competitors Vehicles PM Schedule Importance of overall parts cleanliness storage Importance of PM schedule execution Salient Features 29 h vic S h S K S vihnn ai LK an k T i s siyl T fcs f kv Tl p...

Page 49: ...ter 2 Speedometer 3 Neutral Indicator 4 Turn Signal Indicator LH RH It shows the total distance that the vehicle has been ridden The Speedometer pointer shows the speed of the vehicle It illuminates w...

Page 50: ...DJT Ap Di m Trn f kSn 1 ai Di m Tr j vihnn cil l a tr btiv c 2 Ap Di m Tr Ap Di m Trni ki Ti vihnn g t btiv C 3 y T l e D k Tr j T i Am Sn y T l avAYimi hi y an e n Sn Av c cil hi y Ryir btiv C 4 Tn s...

Page 51: ...starter when clutch lever is depressed with transmission in any gear It is recommended to start engine with transmission in neutral All lamps OFF While engine running Tail lamp Pilot lamp s ON While e...

Page 52: ...l p ai n YS jyir a Jn cil hi y h D l p pieli T l p T l l p an m Tr l p ON YS ATiT r bTn ai bTn el kT k ATiT rn ai pr T kr C jyir klc l vr dbiv l hi y an T i Am Sn ki epN gyrmi hi y T i Am Sn y T lmi...

Page 53: ...n Quick easy starting High power pick up More power at all loads conditions better torque at low RPM less emissions STYLE Athletic Muscular petrol tank side covers seat cowling New head lamp with attr...

Page 54: ...mi vFir pivr vFir Ti k ai Ci rpm pr ai C p d PN ATiel a Tl T k an mAky lr p T i l T k sieD kvs an S T kiul G aikP k f r g an Tv n piyli T l p siY n nv h D l p eni v T v an D AT kT D kl nvi d Kivin Ap...

Page 55: ...ueling For easy inspection of oil level More convenience Easy monitoring of oil level SAFETY ATTRIBUTE KEY FEATURES ADVANTAGES BENEFITS Drum Brake 130 mm drum brake at front 110 mm rear drum brake Hig...

Page 56: ...l vln srL r t yin riK Skiy C s fT slimt 130 mm D m b k aigL an 1100 mm piCLn D m b k DAk b k aigL 200 mm DAk b k an piCL 110 mm D m b k vFir mjb t s m Dbr k Dl j c s s t ni srKimN ni mi Slmi vwir lib...

Page 57: ...ique style and amazing combination of power and mileage It gives an opportunity to the whole not of new customers to experience the superior benefits of the new Discover offering versus any other comp...

Page 58: ...a kz AT g pivr an Ki i p v kn miel j aipt b rmi sfLti m Lv c k l C nv DAkvr 100m t n i N mi b krti vwir fiydi m d C an k mt pN Kc Skiy t v C Aki p nv DAkvr 100m t n i N mi y n k ATiel pivr an miel jn...

Page 59: ...onal Conventional Yes 102 00 9 3 PS 7500 RPM 9 02 Nm 6000 rpm 95 Kmph 82 10 Kmph 4 Speed constant mesh 4 Speed constant mesh 4 Speed constant mesh Electric Kick Start 113 kg 82 3 PS Ton AC DC Availabl...

Page 60: ...double cradle Frame Tubular double cradle Frame Light weight robust Excellent vehicle dynamics road grip stability Front 2 75X17 41P Rear 3 00 X 17 50P Rear 3 00X18 6PR 52P Front 2 75X18 4PR 42P Rear...

Page 61: ...Kms 20 Brake fluid level top up replace C A R C A R Use recommended brake fluid DOT3 DOT4 21 Disc brake assly Check functionality C C C C leakage or any other damage 22 All cables rear brake pedal fre...

Page 62: ...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 C Ch...

Page 63: ...ncies found through testing inspection a Training programs encourage appreciates for abnormality identification prevention b Audit review to assure quality performance c For better understanding show...

Page 64: ...s ky Sn an ki p T s n Ki i k v r t krv a sj gt ai LKvi an bcivvi T n g p i g im a nkr j an a p S y Sn kri b kvi l T prfi rm sn Ki i krvi ai D T kri an r y kri c T kn Synn smjdir miT t mn ai tr k smy p...

Page 65: ...olyte specific gravity checking Battery charge condition checking by battery tester Charging of battery on BAL recommended battery charger Clutch free play setting Accelerator free play setting Front...

Page 66: ...b Tr cij pr j krv srL s f ATiT DC sATmn Am Y f kSn klc f l c k g a ks l Tr f l s T krv aigLn b kn f l s T krv D m b k miT lig DAk b k s ATm c k krv srL g yr SfT g ef kT v b k g vihn upr D iev c en ni...

Page 67: ...on 60 C Adjust if required 1400 100 RPM 0 Kick operation Smooth operation Gear shifting Smooth operation Engine noise No abnormal noise Silencer noise No abnormal noise from silencer shi elds Fastener...

Page 68: ...5 5 5 Kgm Rider footrest mounting bolt 2 0 2 2 Kgm Stay LH RH mounting bolt 1 8 2 2 Kgm ELECTRICAL Battery Terminal voltage 12 4 V DC Charge status using load tester Electrolyte level Tightness of ba...

Page 69: ...nt to measure oil quantity after draining This is important to understand the oil consumption pattern be more than During the interval from one oil change to the next oil change engine oil quantity sh...

Page 70: ...ng jar level marking to be verified by transferring oil from Borosil measuring jar Warm up engine ensure engine oil temp 60 C Run vehicle on MRTB for 3 mins 50 kmph speed 0 rkmi D D g D m jbn fkt b j...

Page 71: ...to collected in measuring jar Ensure no oil spillage while draining Wait till last drop of oil to be drained About 10 mins Measure engine oil drain qty While measurement jar to be kept on flat surface...

Page 72: ...last drop In case oil top up is required add required qty of fresh to match 1000 ml volume refill in engine Remove LH Side panel by using vehicle key Air Filter Element Removal and cleaning ai el D e...

Page 73: ...sing 10 mm spanner Remove the seat assembly by pulling seat lock cable IMPORTANCE OF PM SCHEDULE EXECUTION Discover 100 M Service Station Manual 47 Dealer Development Center Akurdi Pune sT li k viyr K...

Page 74: ...towards rear side Clean the paper filter element as per the SOP Use low pressure point 1 75 Bar for paper filter cleaning IMPORTANCE OF PM SCHEDULE EXECUTION Discover 100 M Service Station Manual 48...

Page 75: ...filter cover by holding air filter element towards front side IMPORTANCE OF PM SCHEDULE EXECUTION Discover 100 M Service Station Manual 49 Dealer Development Center Akurdi Pune a r f Tr a l m Tn an f...

Page 76: ...e 5 Do not use abrasive material tool to clean IMPORTANCE OF PM SCHEDULE EXECUTION Discover 100 M Service Station Manual 50 Dealer Development Center Akurdi Pune ai el AT nr sif krvi miT n SOP ph l s...

Page 77: ...10000 Kms Remove 3 bolts 8 mm A F Take out Cover oil filter with O ring IMPORTANCE OF PM SCHEDULE EXECUTION Discover 100 M Service Station Manual 51 Dealer Development Center Akurdi Pune a Jn ai el f...

Page 78: ...nner Visually check spark plug electrode for color erosion crack breakage Clean the spark plug on spark plug cleaning machine Check and adjust spark plug gap by wire gauge Api k lg sif krvi an g p c k...

Page 79: ...g pre fitment manually thereafter use spanner for tightening Ensure spark plug cap is firmly fitted Replace spark plug as per the interval given in the Periodic Maintenance Schedule p r yi D k m T n s...

Page 80: ...nd the bowl Remove strainer from petrol cock body Clean the bowl and the strainer with the help of petrol and nylon brush Put fuel cock knob in ON Res position confirm no fuel leakage fy al ki k s D m...

Page 81: ...Nitrile rubber hand gloves while topping up battery electrolyte level checking of specific gravity Clean the battery battery terminal Inspect battery for damage leakage Open the all 6 caps b Tr el kT...

Page 82: ...vehicle stability LH RH RSA spring adjuster cams must be adjusted equally to the same position otherwise vehicle may wobble become in stable Note Standard setting is done in 1st notch Notch Position...

Page 83: ...cap It must be 60 c 0 Check set engine idling RPM with the use of digital tachometer to 1400 100 by adjusting idling screw Remove bolt washer fitted to the silencer nozzle near to ExhausTEC Connect s...

Page 84: ...are within specified limit For getting better engine performance optimum fuel efficiency achieve CO as recommended in specification matrix SOP for Battery Electrolyte Level Specific Gravity Checking a...

Page 85: ...hould have specific gravity of 1 240 Add distilled water maintain level in between Min Max level Use Nitrile rubber hand gloves while topping up battery electrolyte level checking of specific gravity...

Page 86: ...y Checking Adjustment Check for smooth rotation of accelerator grip Check accelerator free play by scale ruler Adjust accelerator free play 2 3 mm Recommended free play is 2 3 mm Yi Tl k bl f l c k kr...

Page 87: ...Measure rear brake pedal free play by using steel scale Adjust rear brake pedal free play as per specification Recommended free play Y X 25 30 mm Note Brake free play adjustment is possible in drum br...

Page 88: ...the tappet screw nut Put the feeler gauge measure and adjust the clearance Lock the nut holding screw with special tool after getting required clearance Again check the tappet clearance with gauge The...

Page 89: ...l kri flr g j m ki an kl yr S mip n a djAT kri j r kl yr S m L yi bid Ap S yl T s vD Ak pkD riK nTn li kkri g j vD fr a kvir T p T kl yr S c kkri T p T Ak l p an vi v AT m h D sh j flr g j Ks Di an Ap...

Page 90: ...e chain with SAE 90 oil Ensure oil is directed on to the ends of the bushes links on either side Rotate the rear wheel for proper lubrication of entire chain Wipe off excess oil or dripping oil adjust...

Page 91: ...e chain In second stage clean the drive chain in chain cleaning stand 2nd pot containing Diesel Kerosene Lock open end direction Chain slackness 20 25 mm In first stage clean the drive chain in chain...

Page 92: ...ubricate SEALED drive chain in greasing unit as this will damage the drive chain 3 After 2 minutes take out the drive chain with the help of hook hang it on chain hanging stand to allow dripping off e...

Page 93: ...ki c tvN s D Di ev c nn g sg y nT mi l b k t krv nh t m krviY Di ev c nn n ksin Ye Sk C 3 b m nT bid h k vD Di ev v nn bhir kiQi an t n h g g AT D upr lTkivi j Y vwirin g s Tpk n nkL y 4 hiY vD ri lrn...

Page 94: ...ut fuel cock knob position OFF Fuel Cock Filter Replacement Take out fuel cock sediment bowl Clean sediment bowl thoroughly with low pressure compressed air nylon brush fy al ki k f Tr bdlv ki kn ni b...

Page 95: ...as shown in photograph Clamp wiring harness near air filter using PVC clamp Clamp wiring harness above battery using PVC clamp Clamp wiring harness near LHS H T coil using PVC clamp viyr g hirn s ni T...

Page 96: ...hrough button clamp located near LHS petrol tank rubber damper Route wiring harness beneath the rod joining lamp shade through LHS Replace broken PVC cable tie clamps Note viyr g hirn sn p T i l T kn...

Page 97: ...Fuel System CO Checking and Setting Engine Standard Operating Procedure Tune up Carburettor Circuits 69 fy al s ATm CO c k krv an s T krv a Jn Ty n ap ATinDD ai pr T g p i s zr kir y r Tr srk T...

Page 98: ...achieve values given below The ideal CO is between 1 75 to 2 25 at idling RPM 1400 100 Note Remember the Air Screw should not be taken out more than the recommended position Every time Air Screw setti...

Page 99: ...d NOT BE any continuity Input supply voltage check Standard value 12 5 0 4 volts Battery voltage SOP Connect TPS coupler Switch ON ignition key Check voltage between Brown and Black Yellow wires of TP...

Page 100: ......

Page 101: ...n D l IAYt mi m ki Ki i kri k a Jn POT mi Dmi cilt hi y Y i Tl Ki l l POT IAYt mi y an l k y li viyr v c ni vi T j c k kri ATi D vi T j 1 vi TY ai Ci Y i Tl K l l IAYt mi WOT IAYt mi vi T j c k krvi S...

Page 102: ...5 2 25 m Lvvi miT b n j r c k pi e T a fy al ki k k fy al lienmi Y fy al lk j n Yt hi y t n Ki i kri b aigL piCLnii b n h l f frti hi y t n Ki i kri c Ki i kri sic Tiyr p Sr aigLn h l 25 psi piCLn h l...

Page 103: ...ge and sediment from Carburetor bowl Clean the Carburetor bowl by petrol soft nylon brush STANDARD OPERATING PROCEDURE Discover 100 M Service Station Manual 72 Dealer Development Center Akurdi Pune ki...

Page 104: ...ipe put fuel cock knob position to ON RES as per availability of fuel in fuel tank confirm no leakage from joints STANDARD OPERATING PROCEDURE Discover 100 M Service Station Manual 73 Dealer Developme...

Page 105: ...CAT Ensure CO between 1 75 2 25 Air Screw Setting STANDARD OPERATING PROCEDURE Discover 100 M Service Station Manual 74 Dealer Development Center Akurdi Pune a r Ak s T g ni F sieD kvr kiQyi bid kir y...

Page 106: ...Vent 1 14 Solenoid Assembly 1 15 O Ring Solenoid 1 16 Screw Washer 1 17 Sensor Throttle Position 1 18 O Ring TPS 1 STANDARD OPERATING PROCEDURE Discover 100 M Service Station Manual 75 Dealer Develop...

Page 107: ...n Starter Circuit Tube Starter Jet Fuel Well Plunger O Ring Solenoid Operated Choke Plunger Mixing Chamber CARBURETTOR CIRCUITS Discover 100 M Service Station Manual 76 Dealer Development Center Akurd...

Page 108: ...engine side of the carburettor STARTER SYSTEM AUTO CHOKE B Throttle Valve In closed Position Float Chamber Bowl Fuel Well Starter Circuit Tube Mixing Chamber Plunger In Lifted Condition Solenoid Oper...

Page 109: ...raised opening throttle pilot outlet is fully exposed to the manifold vacuum and supplies fuel to its full extent which is sufficient to meet the engine requirement at slow speed Air fuel mixture beco...

Page 110: ...the total air fuel mixture is relatively less The jet needle is a tapered needle attached to the throttle valve which points downward through the centre of carburettor venturi The tapered end of the j...

Page 111: ...NOTES Discover 100 M Service Station Manual 80 Dealer Development Center Akurdi Pune...

Page 112: ...Dismantling Engine Assembling Important Skill Tips Gear Transmission Power Flow Engine Lubrication low Of Oil Part Identification a Jn an T i Sm Sn TieTn g Ti k s v s l m T Ap S yl T s f mmiY a Jn kiQ...

Page 113: ...3 5 Kgm Silencer Bracket Bolt Cylinder Head Bolts 12 mm 2 2 2 5 Kgm Rotor Mounting Nut 5 0 5 5 Kgm Cam Sprocket Allen Bolt 1 6 1 8 Kgm Clutch Cover Bolts 0 9 1 1 Kgm Engine Mounting Rear Nut M8 1 8 2...

Page 114: ...Screws 0 9 1 1 Kgm 0 9 1 1 Kgm 0 5 0 7 Kgm Stator Plate Bolts Kick Guide Bolts 0 9 1 1 Kgm 0 9 1 1 Kgm Crankcase Joining Bolts RH 0 9 1 1 Kgm Crankcase Joining Bolts LH Output Sprocket Bolts 0 9 1 1...

Page 115: ...nside Diameter Std Limit Ser Limit Piston Ring Groove Clearance Std Limit Ser Limit Valve Spring Free Length Std Limit Ser Limit Valve Stem Bent Std Limit Ser Limit Piston Diameter Std Limit Ser Limit...

Page 116: ...Std Limit Ser Limit 1 6 1 7 mm 1 55 mm Gear Shift Drum Groove Width Std Limit Ser Limit 4 55 4 7 mm 4 75 mm Shaft Fork OD Std Limit Ser Limit 9 972 9 987 mm 9 96 mm Cam Chain 20 Links Length Std Limi...

Page 117: ...of Cam sprocket allen bolt Magneto Rotor Holder Part No F41ZJZ44 Application To hold rotor while loosening tightening its nut Magneto Rotor Puller Part No F41ZJZ46 Application To pull out the rotor fr...

Page 118: ...ch Dismantling Tool Part No F41AJA58 Application To dismantle assembled clutch of Discover DTS Si kick start as well as self start vehicle Spark Plug Spanner Part No 37 1040 51 Application For removin...

Page 119: ...ft Piston Pin Part No 37 1010 06 Application To remove refit piston pin Output Sprocket Holder Part No 37 1030 53 Application To h o l d t h e o u t p u t sprocket while removing sprocket allen bolts...

Page 120: ...Si Service Station Manual 89 Dealer Development Center Akurdi Pune Crankcase Heater Part No 37 2040 21 Application To heat the crankcase RH for easy fitment of crankshaft NOTES Ap S yl T s a J n k en...

Page 121: ...from cock E gauge ap Oil Strainer 18mm A F trainer Drain Engine Oil Measure drained oil quantity Remove C A Remove oil s Pull seat lock cable to open the lock seat Take out seat assembly complete Rem...

Page 122: ...wire D Stator plate wiring coupler F Auto choke Yellow coupler E TPS coupler Remove Starter Motor Red wire G Remove engine breather tube H Disconnect Disconnect Disconnect E G C A B Remove Gear chang...

Page 123: ...of cylinder head silencer mtg studs due to silencer weight Loosen clamp intake manifold A Loosen clamp air filter duct B Take out carburettor assembly C Loosen 2 nuts A of adjuster clutch cable 12mm A...

Page 124: ...from front engine foundation bracket A CAUTION While taking down engine from c h a s s i s f r a m e t a ke d u e precaution for safety Take down engine assembly complete a s smi Y a J n bhir kiQv bh...

Page 125: ...r Akurdi Pune 2 4 2 1 3 6 5 8 7 S N Description Qty 1 Cylinder Head Cover Comp 1 2 Bolt 4 3 Gasket Head Cover 1 4 Plate Cylinder Head 1 5 Bolt Head Mounting 4 S N Description Qty 6 Flanged Bolt M8X1 2...

Page 126: ...8 10 9 11 12 S N Description Qty 1 Kit Assly Cylinder Head 1 2 Sleeve Spark Plug 1 3 Screw Grub M5X0 8X7 1 4 Ring O 3 5 O Ring 1 6 Stud M8X1 25X451 2 S N Description Qty 7 Gasket Cylinder Head 1 8 In...

Page 127: ...nter Akurdi Pune 3 8 4 1 2 7 5 6 10 9 10 S N Description Qty 1 Valve Intake 2 2 Valve Exhaust 2 3 Seal Oil 4 4 Collet 8 5 Assly Rocker Arm Inlet 1 S N Description Qty 6 Assly Rocker Arm Exhaust 1 7 Sh...

Page 128: ...ft Assly 1 2 Circlip Internal 1 3 Bolt Tensioner 1 4 Spacer Cam Sprocket 1 5 Sprocket Cam Driven 32 Teeth 1 6 Washer Special Camshaft 1 7 Bolt Hex Socket Head Cap 1 S N Description Qty 8 Cam Chain Str...

Page 129: ...l 98 Dealer Development Center Akurdi Pune 2 3 2 7 5 1 6 6 4 S N Description Qty 1 Kit Block Piston 1 2 Pin Hollow Dowel 2 3 Gasket Cylinder Block 1 4 Thermal Sensor 1 5 Kit Piston Ring 1 6 Circlip Pi...

Page 130: ...Rotate chain tensioner s screw in clockwise direction to take plunger backward lock it Two bolts B 8mm A F Take out tensioner Take out gasket chain tensioner Check TDC Position Remove Align rotor mar...

Page 131: ...plug RH Skill Tip Rotate sleeve before pulling out Cover sleeve portion by cotton cloth then pull out by plier Remove Spark plug RH CAUTION Do not pull out sleeve directly by plier otherwise it would...

Page 132: ...nently Remove Using Piston Pin Drift special tool Remove Piston pin B Piston Assembly C Circlip A by using small screw driver Circlip A Skill Tip Cover crankcase bore by clean lint free cloth while di...

Page 133: ...SOP OF ENGINE DISMANTLING Discover DTS Si Service Station Manual 102 Dealer Development Center Akurdi Pune Remove Gasket cylinder block 2 Dowels A A kiQi Di v l 2 n br a giAk T sl Dr li k...

Page 134: ...Pune 1 2 4 5 1 3 7 9 6 8 10 S N Description Qty 1 Washer Thickness 0 4 mm 2 2 Drive Assly 1 3 Gear Starter Clutch 1 4 Starter Motor Assly 1 5 Bolt Flange 2 S N Description Qty 6 Body starter Clutch 1...

Page 135: ...ace plastic cap on one way clutch rollers CAUTION If magneto rotor is removed without placing plastic cap roller would fall down Using Rotor Holder F41AJA09 Rotor Puller F41AJA10 Remove Nut 19mm A F B...

Page 136: ...F E B C D 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 Stopper gear starter clutch Removal of...

Page 137: ...Clutch Release Assly 1 3 Bracket Clutch Cable 1 4 Bolt Flange M5 8 5 Bolt 3 6 Decal Clutch Cover 1 6A Ring O 1 7 Cap Filter 1 8 Element Oil Filter 1 9 Rod Push 1 S N Description Qty 10 Seal Oil 1 11...

Page 138: ...Qty 1 Assembly Clutch 1 2 Collar Clutch 1 3 Kit Primary Drive Driven 1 3A Washer Plain 1 4 Wheel Clutch 1 5 Plate Cutch 4 6 Kit Friction Plate 1 7 Hub Clutch 1 S N Description Qty 8 Clutch Holder 1 9...

Page 139: ...s 8mm A F Clutch Cable Bracket Cover clutch 8 bolts 8mm A F Clutch Cable Bracket Cover clutch Remove Spring A Plain Washer B Lever clutch release C Remove Gasket A 2 Dowels B Bearing C A B B A C B C A...

Page 140: ...Socket for clutch nut F41ZJA54 Remove Special nut for clutch B Belleville washer C Plain washer D Skill Tip Clutch Nut must be removed by rotating it in clockwise direction Skill Tip Lock Special too...

Page 141: ...58 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 Remove Primary Gear A Square Key Spacer Crankshaft B A E C...

Page 142: ...Description Qty 1 Kick Shaft 1 2 Washer Thrust 1 3 Circlip 2 4 Spring Kick Starter Ratchet 1 5 Ratchet 1 6 Washer Plain 3 7 Assly Gear Starter Pinion 1 S N Description Qty 8 External Circlip 1 9 Spri...

Page 143: ...une 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 B A k k sifT Ki lvi miT n p k yi ki...

Page 144: ...ent Center Akurdi Pune 5 1 3 4 2 S N Description Qty 1 Assembly Oil Pump 1 2 Screw Pan Cross 3 3 Gasket Case Oil Pump 1 4 Pin Dowel 2 5 Gear Oil Pump Driven 1 Oil Pump ai el p p n br vgt kvi TT 1 ai e...

Page 145: ...Remove Allen bolt Chain Guide Tensioner Side Cam Timing Chain SOP OF ENGINE DISMANTLING Discover DTS Si Service Station Manual 114 Dealer Development Center Akurdi Pune a Jn Ki lvin p Ft p miN SOP l b...

Page 146: ...nual 115 Dealer Development Center Akurdi Pune 4 2 2 3 1 6 5 7 S N Description Qty 1 Assly Drum Gear Shift 1 2 Shaft Gear Fork Shift 2 3 Fork Gear Shift Output 2 4 Fork Input Disco H 1 5 Cam Drum Chan...

Page 147: ...5 4 10 11 12 S N Description Qty 1 Lever Comp Gear Shift 1 2 Extension Spring 1 3 Spring Gear Shift Return 1 4 Nut Hexagon 1 5 Washer Spring Steel 1 6 Inhibitor Comp Gear Shift 1 7 Step Washer 1 8 Spr...

Page 148: ...shift lever C Collar Washer D Spring E Remove Special bolt A 5mm A F Cam gear Guide Gear change drum B 4 Rollers Lever gear change shaft C B A C B D E Remove 2 Bolts 8mm A F Starter Motor C A gyr s fT...

Page 149: ...LH 1 2 Ball Bearing 1 3 Seal Oil 1 4 Bearing Needle Roller 1 5 Bush Bendix 1 6 Seal Oil 1 7 Switch Neutral 1 8 Neutral Switch AL Washer 1 9 Stopper Gear Starter 1 S N Description Qty 10 Screw Pan Cro...

Page 150: ...3 4 S N Description Qty 1 Engine Assly 1 1A Assly C Case RH 1 2 Bushing Drum 1 3 Needle Roller Bearing 1 4 Bearing Ball 6203 HN3 C3 1 5 Stopper plate input bearing 1 S N Description Qty 6 Screw Pan Pr...

Page 151: ...6 Short Bolt B from LH Magneto Side A Remove Shaft Fork Shift A Gear Change Drum B Washer Input C Shift Fork Input D Output E Input shaft assembly F Output shaft assly G F G E D Dismantling Crankcase...

Page 152: ...061 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 Kick Guide By using Bearing driver set 371030...

Page 153: ...mbly Remove block piston assembly Spit the crankcase remove crankshaft assembly Before re fitment of crankshaft assembly then fit the crankshaft assembly Ensure crankshaft fitment in crankcase by hand...

Page 154: ...shifter shaft Clutch lever Oil seals lip Fork Bushes Rollers Molybdenum Di Sulphide grease Grease Application while Assembling Engine Name of fastener nut bolt Type of loctite Cam sprocket allen bolt...

Page 155: ...ring surface is 0 5 mm below crankcase surface Crankcase Oil Passages Always blow high pressure compressed air through the oil passage holes of crankcase clutch cover in reserve direction of flow of o...

Page 156: ...IMPORTANT SKILL TIPS Discover DTS Si Service Station Manual 125 Dealer Development Center Akurdi Pune Assembly of 1 gear O P Collar Bush st Assemble collar bush for 1st Gear Output in correct directio...

Page 157: ...n ball bearing seats to 150 c by electric heater to facilitate easy insertion of main bearing into their crankcase seats 0 Keep heater on crankcase main ball bearing setting area switch ON heater LED...

Page 158: ...aft Fork G Fork Shift Output H Bush Roller Assembly of I P O P shaft thrust washers Ensure fitment of one washer Thrust Part no JA551008 on top face of 1st Gear output One washer thrust JA551004 below...

Page 159: ...of crankshaft Perfect centering of crankshaft Transmission Neutral Position Before joining crankcase LH RH halves ensure that transmission gears are in neutral position Crankcase Joining Before joini...

Page 160: ...s before assembling Piston Ring Fitment Piston rings must always be fitted with respect to exhaust mark on the piston First place the bottom oil rail ring with end gap 30 towards left of the exhaust m...

Page 161: ...Kick Ratchet with respect to the dot mark on Shaft Kick Assemble kick shaft washers as shown in the exploded view 1 Kick Shaft 2 Washer Thrust 3 Circlip 4 Spring Kick Starter Ratchet 5 Ratchet 6 Wash...

Page 162: ...tor complete gear Shift one Plain washer 10mm A F nut Always apply loctite 243 to threads of nut before fitment After tightening nut ensure free movement of In Com Gr Shift 4 Nut Hexagon 5 Washer Spri...

Page 163: ...serted otherwise assly of Cam Gear Guide would not be possible Cut portion of Cam must be in line of neutral pin Blank hole Press fit pin for neutral position Cam guide cut portion Guide Gear Cam Fitm...

Page 164: ...h Hsg is punched on the spacer for identification JD mark ClutchAssemblySequence 4 Wheel Clutch 5 PlateCutch 6 KitFrictionPlate 7 HubClutch 8 ClutchHolder 9 CompressionSpring 10 FlangeBolt 11 SpacerCl...

Page 165: ...itment of a plain Belleville washer before special nut Belleville washer s bigger contactcircle diameter must face towards clutch smaller contact circle diameter touching with special nut Apply loctit...

Page 166: ...TIPS Discover DTS Si Service Station Manual 135 Dealer Development Center Akurdi Pune Starter Clutch Assembly Ensure proper fitment of spring retainer its lugs to be matched with plate holes spring p...

Page 167: ...Cover Breather Passage Before assembling cylinder head cover check confirm that engine breather passage is clear by blowing light pressure compressed air A B Cylinder Head Bolts Tightening Sequence A...

Page 168: ...of lapping stick Check the condition of valve seat and valve face Valve Lapping A Carry out valve leakage test for intake and exhaust valves Position the camshaft in such way that both the valves are...

Page 169: ...3 Spline Washer 3 4 Ring Snap 5 5 Gear 3rd Drive 1 6 Gear 2nd Drive 1 7 Washer Thrust 2nd Drive 1 8 Shaft Output 1 9 Gear 2nd Driven 1 10 Washer Gear 2nd Driven 1 S N Description Qty 11 Gear 3rd Drive...

Page 170: ...respective gears is explained as below 2ND GEAR INPUT 3RD GEAR INPUT 4TH GEAR INPUT 1ST GEAR INPUT INPUT SHAFT SPECIAL WASHER COLLAR BUSH SPECIAL WASHER OUTPUT SHAFT 2ND GEAR OUTPUT 3RD GEAR OUTPUT 4...

Page 171: ...3rd gear Clutch Input Shaft 3rd Gear Input 4th Gear Input 4th Gear Output Power Flow in 4th gear 1 1 4 3 3 2 2 4 1 1 4 3 3 2 2 4 Clutch Input Shaft 1st Gear Input 1st Gear Output 4th Gear Output 1 1...

Page 172: ...Station Manual 141 Dealer Development Center Akurdi Pune ENGINE LUBRICATION FLOW OF OIL Lubrication Circuit l b k Sn sk T h D trf kn kT g ri D k k sif T ai el AT nr k p f Tr p pr f Tr a l m T ai el p...

Page 173: ...side crankcase hole INLET continued PASSAGE OUTLET ENGINE LUBRICATION FLOW OF OIL Discover DTS Si Service Station Manual 142 Dealer Development Center Akurdi Pune a J n l b k Sn ai elni fli ai el AT...

Page 174: ...ap between bolt and cylinder block cylinder head Cylinder head hole Small oil sump for lubricating various cylinder head parts L H Crankcase passage towards nozzle Nozzle oil jet RH sieDmi k k sifT up...

Page 175: ...ump oil through L H crankcase oil passage leading to Nozzle Oil Jet and check whether oil comes out from hole provided on the Nozzle Oil Jet Nozzle Oil Jet Remove clean orifice oil jet by blowing comp...

Page 176: ...Discover DTS Si Service Station Manual 145 Dealer Development Center Akurdi Pune NOTES...

Page 177: ...escription Identification Mark Part No Gear 4 Drive th PA 5512 07 No of Teeth 22 Outer Diameter is 46 6 mm Visual Part Name Description Identification Mark Part No DISCOVER 100 M Part Name Description...

Page 178: ...on Identification Mark Part No Gear 4 Drive th JZ 5512 02 No of Teeth 23 Outer Diameter is 45 7 mm Visual Part Name Description Identification Mark Part No DISCOVER 100 T Part Name Description Identif...

Page 179: ...art No Intake Manifold PA 5814 07 Extra Boss is provided Visual Part No PA 5814 07 provided on intake manifold Part Name Description Identification Mark Part No DISCOVER 100 M Part Name Description Id...

Page 180: ...Name Description Identification Mark Part No Intake Manifold PA 5814 03 Extra Boss is not provided Visual D102 mark provided on intake manifold Part Name Description Identification Mark Part No DISCO...

Page 181: ...Service Station Manual 150 Dealer Development Center Akurdi Pune DISCOVER 100 M Part Name Description Identification Mark Part No Engine Output Sprocket JB 5510 00 Teeth profile is different than Disc...

Page 182: ...rvice Station Manual 151 Dealer Development Center Akurdi Pune DISCOVER 100 T Part Name Description Identification Mark Part No Engine Output Sprocket JZ 5510 04 Teeth profile is different than Discov...

Page 183: ...Discover DTS Si Service Station Manual 152 Dealer Development Center Akurdi Pune NOTES...

Page 184: ...f m an sAp nSn TieTn g Ti k s v s l m T Ap Syl T s piT s vOi n vgt k Ti l k bl T g SOP...

Page 185: ...a kS i nT piCLni Ap i k Tn nT AT ar g AT m nT Kici viL RSA miu T g nT uprn piCLn a ksln nT h Dl bir hi Dr bi T fi k piep Ti p bi T Av g aim SifT Ti k ri D nT p nl upr fi k s Tr nT fi k a Dr b k T bi...

Page 186: ...TieTn g Ti k f m f T f Dr miu T g bi T piCLni h l kpl g nT f T k l pr aiu T g bi T rieDr f T r AT aiu T g RHAT bi T LH AT bi Ts D Ak miu T g bi T...

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Page 207: ...piT s ke r t Kbr pD D Akvr 100m D Akvr100m...

Page 208: ...D Akvr 100T ni w...

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Page 213: ...D Akvr100M ni w...

Page 214: ...D Akvr 100 4G ni w...

Page 215: ...k T i l k bl T g a ks l Tr k bln T g...

Page 216: ...k Ti l k bl T g k c k bl T g...

Page 217: ...k Ti l k bl T g f T b k k bl T g aigLni mD giD ni Dib0 bij mi aip l kl pmiY aigLni b k viyrn f T kri aigLni b k k bln Ap Di m Trni k bl siY Ap Di m Tr s w siY le v Ap Di m Tr k bl T g...

Page 218: ...ATiT D ai pr T g pi s zr D Akvr 100 M...

Page 219: ...ksln 17 ni r g Ap nr iri Ki l a ksln bhir kiQi mm f T b k k bln nT 14 n Q l kr aigLni h ln p nln bhir kiQi mmaf aigLni h ln bhirkiQi f T a ksl aiuTr Ty bmi f C k nh t c k kri f T fi k bi D ni uprni 17...

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Page 250: ...D Akvr 100m el kT k s b Tr kri an ni kri el kT kl c k krvin p wt el kT kl srk T Diyigi m SOP...

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Page 279: ...ATiT D ai pr T g pi s zr D Akvr 100 M...

Page 280: ...D Akvr 100 vFirin D Akvr ssm 100 4G T kn kl vgt TieTn g Ti k s kib r Tr n vgt piT sn vgt el kT kl srk T Diyigi m...

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Page 293: ...piT s n vgt D Akvr 100 4Ap D g ar piT sn nim piT n br vgt Tiep AC DC ke r t Kbr pD...

Page 294: ...el kT kl srk T Diyigi m E n aSn srk T...

Page 295: ...el kT kl srk T Diyigi m e n aSn srk T...

Page 296: ...el kT kl srk T Diyigi m b Tr ciJ g srk T...

Page 297: ...el kT kl srk T Diyigi m lieT s ATm srk T...

Page 298: ...D Akvr 125 vFirin D Akvr vi v ssm 125 2 T kn kl mih t siyl T fy cr kib r Tr Ap s f k Sn TieTn g Ti k...

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Page 304: ...vFirin D Akvr miT ssn 125m T kn kl vgt siyl T fy cr kib r Tr Ap S f k Sn piT s n vgt a r f Trn sfie TieTn g Ti k s sop...

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Page 316: ...p ibl m Si Fvi an t n nrikrN...

Page 317: ...T b l S T g a n Aiiekli p D yi...

Page 318: ...D Akvr 100m b j ai Ti l m T D aik D p ni 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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