Bajaj Discover 100M, Service Station Manual

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ENGINE TUNE UP
Discover 100 M
Service Station Manual
71
Dealer Development Center
Akurdi Pune
TPS - Hall Sensor : Checking
Engine Tune-up
SPARK PLUG :
• Spark Plug Gap :
0.7~0.8 mm.
• Replace at Every :
30,000 Kms
BOSCH UR4AC, Champion PRZ9HC
0.7 to
0.8MM
a.
b. Ensure free rotation of both wheels.
c. Ensure correct tyre pressure - Front wheel : 25 PSI,
Rear wheel : 32 PSI
d.
Ensure no fuel leakage through fuel cock, fuel
lines.
Set control cable free play:
• Clutch lever 2~3 mm.
• Front brake lever 4~5 mm.
• Rear brake pedal 15~20 mm.
e. Chain slackness : 20~25 mm.
f. Check & confirm proper functioning of spark
plug.
g. Use of recommended grade of bajaj genuine
oil & engine oil level between MIN & MAX level.
Other Mandatory Checks
C o n t i n u i t y c h e c k i n c o u p l e r
disconnected condition :
SOP :
• Disconnect TPS coupler
• Check Continuity between Blue
& Black / Yellow wire
• T h e r e s h o u l d N OT B E a n y
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 TPS
Hall Sensor.
+
Voltage check in POT condition:
• Standard value : < 1 volt in
Partial Open Throttle position.
SOP :
• TPS coupler is in connected
condition.
• Ensure engine is running in POT
mode.
• Check voltage between Blue &
Black / Yellow wire in Partial
Open Throttle (POT) condition.
Voltage check in WOT condition:
Ensure engine is running in WOT
mode.
• Standard value : 2.7 to 5.0
( 0 . 2 ) v o l t s i n W i d e O p e n
SOP :
• TPS coupler is in connected
condition.
•
• Check voltage between Blue &
Black / Yellow wire in Wide Open
Throttle (POT) condition.
+
PAPER FILTER:
• Clean at Every :
5000 Kms.
• Replace at Every :
15,000 Kms.
COMPRESSION PRESSURE
• Standard :
11 to 13 Kg/cm 2
• Service Limit :
9.5 Kg/cm 2
TAPPET CLEARANCE
• Inlet Valve :
0.05 mm
• Exhaust Valve :
0.1 mm
CARBURATTOR
• Jet Needle Clip Position:
2 groove from top
• Air Screw Setting : 1½
1.0 To achieve CO% 1.75
~ 2.25
• Idling : 1400 + 100 rpm.
nd
+