Bajaj Auto DTS-i Discover 110 CBS User manual

Dear Customer,
Congratulations on becoming the proud owner of a “DTS-i powered Bajaj Discover” motorcycle,
one of the finest motorcycles in the country.
Your safety and the safety of others is extremely important. Hence, before you ride the bike,
please read this Owner's Manual carefully and familiarize yourself with the operating mechanism,
controls and maintenance requirements. This will ensure you a long and trouble free ownership
experience.
To keep your bike in perfect running condition and deliver consistent performance, we have
specially programmed the periodic maintenance services which includes 3 Free and subsequent
paid services as per the schedule contained in this booklet. We earnestly advise you to avail all
these services at any of our Vehicle Dealers or Authorised Service Dealers (ASD).
Your “Bajaj Discover” comes with a warranty of 5 Years or 75,000 Kms. whichever occurs earlier
from the date of sale. For details please refer to “Warranty : Scope & Limits” given in this manual.
We urge you to entrust all your service needs to a Bajaj Dealer or Authorised Service Centers only.
They are well equipped with all necessary facilities / genuine parts / oil and trained manpower will
ensure the best care for your bike.
Should you require any additional information feel free to contact us on our helpline numbers or e-
mail us at: [email protected] or visit the Bajaj Auto website www.bajajauto.com
Thank you for choosing a Bajaj Discover and wish you unlimited miles of happy riding!!
SERVICE DEPARTMENT
BAJAJ AUTO LIMITED
Foreword

Table of Contents
Description
1. Technical Specifications 1
2. Identification Data 4
3. Location of Parts 5
4. Steering cum Ignition lock 6
5. Petrol Tank Cap / Fuel Tap 7
6. Speedometer Details 8
7. Control Switches 9
8. Removal & Fitment of Side Covers 11
9. Battery / Tool kit 13
10. Removal & Fitment Seat 14
11. How to ride your Bike 15
12. Safe Riding Tips 19
13. Engine Oil 21
14. Wheels - Tyre 22
15. Periodic Maintenance Information 23
16. Combined Braking system 25
17. Free Service Guidelines 26
18. Periodic Maintenance & Lubrication Chart 27
19. Non Use Maintenance 32
20. Delivery Certificate 33
21. Warranty Scope & Limit 34
22. Battery Warranty Card
Notice:
The description and illustration in this booklet
are not to be taken as binding on the
manufacturers. The essential features of the
type described and illustrated herein remaining
unaltered. Bajaj Auto Limited reserves the
right to carry out at any moment without
being obliged to bring this booklet upto-date
& to do modifications on the vehicle, parts or
accessories as may be convenient and
necessary.
Safety and Warning information :
Caution : This indicates that a potential
hazard that could result in vehicle
damage. Follow the Advice provided with
the caution.
Warning : This indicates that a potential
hazard or injury to you or other persons &
to the vehicle can happen if advice
provided is not followed.

Engine 4 stroke, 4 stroke,
Natural air cooled Natural air cooled
Bore x Stroke 50 mm x 58.8 mm 52 mm x 58.6 mm
Displacement 115.45 cc 124.45 cc
Idling Speed 1400 + 200 rpm 1400 + 100 rpm
Max. Net Power 8.6 PS @ 7000 rpm 11 PS @ 7500 rpm
Max. Net Torque 9.81 Nm @ 5000 rpm 11 Nm @ 5500 rpm
Ignition System DC CDI DC, Digital CDI
Starting Aid Kick / Self Kick / Self
Spark Plug Champion PRZ9HC or Champion PRZ9HC or
(2 Nos.) BOSCH UR4AC BOSCH UR4AC
Spark Plug Gap 0.7 to 0.8 mm 0.7 to 0.8 mm
Transmission 4 speed (Gear shifting-All Up) 1 Down 4 Up
Front Brake Drum Drum Brake / Disc Brake
Rear Brake Drum Drum
Technical Specifications
1
Discover 110 CBS Discover 125 CBS

Technical Specifications
Fuel Tank
Capacity
Full 8 liters 8 liters
Reserve 2.3 liters 2.3 liters
Usable Reserve 1.5 liters 1.5 liters
Dimensions
Length 2035 mm 2035 mm
Width 760 mm 760 mm
Height 1085 mm 1085 mm
Wheel Base 1305 mm 1305 mm
Ground Clearance 165 mm 165 mm
Tyre Size
Front 2.75 x 17, 41 P 2.75 x 17, 41 P
Rear 3.00 x 17, 50 P 3.00 x 17, 50 P (Drum Brake)
100/90-17 x 17, 55 P (Disc Brake)
Tyre Pressure
2 2
Front 1.75 Kg/cm (25 PSI) 1.75 Kg/cm (25 PSI)
2 2
Rear (Solo) 2.00 Kg/cm (28.5 PSI) 2.00 Kg/cm (28.5 PSI)
2 2
Rear (with Pillion) 2.25 Kg/cm (32 PSI) 2.25 Kg/cm (32 PSI)
Discover 110 CBS Discover 125 CBS
2

Technical Specifications
3
Electrical System 12V DC 12V DC
Battery 12V 5Ah 12V 5Ah
Head Lamp 12V, 35/35W 12V, 35/35 W
Position Lamp DRL DRL
Neutral LED LED
Tail / Stop Lamp 5/21W Bulb 5/21W Bulb
Turn Signal Indicator LED LED
Side Indicator Lamp 12V, 10W (4 nos.) 12V, 10W (4 nos.)
Hi Beam Indicator LED LED
Speedo Lamp LCD LCD
Horn 12V DC, 2A 12V DC
Low Battery Indicator LED LED
Rear No. Plate Lamp 12V, 3W 12V, 3 W
Vehicle Kerb Weight 117.5 Kg 123 Kg (Drum Brake)
125 Kg (Disc Brake)
Gross Vehicle Weight 247.5 Kg 253 Kg (Drum Brake)
255 Kg (Disc Brake)
Discover 110 CBS Discover 125 CBS
Note :
• All dimensions are under UNLADEN condition.
• Above information is subject to change without any notice.
• This vehicle complies to BS IV standards.
• Day Time Running Light (DRL) is a Government regulation.

4
Identification Data
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.
Frame Number Location
On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

5
Location of Parts
This photograph is of Discover 110 CBS.
Front Fork
CBS Cable
Distribution Unit
Headlamp
with DRL
EVAP compatible
Fuel Tank
Nitrox Rear
Shock Absorber
Carburettor with
Manual choke
Pillion
Foot
Rest
CBS Force
Distribution
Unit
Brake
Pedal
Engine Oil
Inspection
Window
CBS
Mechanism
Speedometer
Tail
Lamp
Grab Handle

Steering Cum Ignition Lock
6
To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Turn
the key to “LOCK” position and remove the
key.
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’ & ‘Side
cover lock’.
Steering cum Ignition Lock :
It has three positions.
LOCK : Steering locked. Ignition OFF.
OFF : Steering unlock. Ignition OFF.
ON : Steering unlock. Ignition ON.

7
Fuel Tank Cap
• To open the fuel tank cap, insert the key in
the lock and turn it clockwise and lift fuel
tank cap.
• ‘Fuel Tank Cap’ is locked when pushed /
pressed back into the place.
Fuel Tank
Cap
Petrol Tank Cap & Fuel Tap
Fuel Tap
Fuel Tap
Fuel tap lever has following positions.
ON : When fuel level is above
reserve position.
RES : When fuel level is below
reserve position.
OFF : When fuel supply is to be
cut off.
Precaution :
• Don’t attach metallic ‘Key chain’ as it may
damage paint/plating of petrol tank/tank cover.
• Don’t put PVC/Rexin cover on petrol tank.
Note : In case petrol spills on to tank, ensure
that tank is cleaned with a clean, dry cloth
immediately.

1. Odometer : It shows the total distance that the
vehicle has been ridden.
2. Speedometer : The Speedometer shows the speed
of the vehicle.
3. Tachometer : Its shows engine speed in RPM.
4. Trip Meter : Trip meter shows the distance travelled
since it was last reset to zero.
5. Turn Signal Indicator (LH & RH) : When Turn signal
switch is turned to Left or Right, Turn pilot indicator
LH or RH will flash.
6. Hi Beam Indicator : When Headlight is ‘ON’ & Hi
beam is selected, Hi beam indicator will glow.
7. Fuel Level Indicator : Shows available fuel in fuel
tank.
Fuel Reserve- last 2 bars blinks continuously.
-if level drops further, last bar blinks at faster rate.
8. Neutral Indicator : It illuminates when transmission
is in Neutral & Ignition switch is ‘ON’.
9. Low Battery Indicator : It gets ‘ON’ when Ignition
switch is ‘ON’. Once engine is started, it goes ‘OFF.
If it glows during running, this means low battery or
malfunctioning in charging system.
10. Trip Meter Reset Button : Press the reset button
for more than 3 sec. to reset Trip Meter reading to
‘zero’.
Speedometer Details
8
1
3
7
4
2Fuel Level Indications
Fuel reserve level
5
6
9
8
10

Control Switch - LH
9
D
D. Pass Switch : Press switch to flash the
head light. It is used to give signal to
vehicles coming from opposite side while
overtaking.
A. Dipper Switch : When headlight is ON,
High or Low beam can be selected with
the dipper switch.
: High Beam : Low beam
B. Turn Signal Switch : When the turn signal
switch is turned to Left ( ) or Right ( )
the corresponding turn signals flash on
and off. To stop blinking push the switch
in & release.
C. Horn Button : Press for sound horn.
Hi/Low beam Headlamp Effect of
Switch Status Pass Switch
Low beam Low beam ‘ON’ Hi beam ‘ON’
Hi beam Hi beam ‘ON’ No change
Any OFF Hi beam ‘ON’
A
B
C

Control Switch - RH
10
10
E. Starter Button : It operates the electric
starter when clutch lever is depressed
with transmission in any gear. It is
recommended to start engine with
transmission in neutral.
F. Light Switch : It has 2 positions. When
igntion switch is ‘ON’, lighting system will
work as per given table.
Day Time Running Light Feature:
• Day Time Running light is provided inside the
headlamp.
• Day Time Running light gets ON (High
intensity) when ignition switch turned to ON.
• After headlight is turned to ON position,
intensity of DRL LED’s will get reduced.
: Taillamp will get ON & DRL ON .
(High Intensity)
: Head lamp, Tail lamp, Number plate
lamp, Speedometer illumination will get
ON & DRL remains ON (Low intensity)
F
E
Igntion
Switch
ON
ON
DRL
ON High Intensity
ON Low Intensity
Light
Switch
OFF
ON
Head
Light
OFF
ON
Day Time
Running Light
(DRL)
Note: The inside of the lamp lens might fog up after
using the motorcycle in rain or after washing. Fog inside
the lamp lens will disappear gradually by switching on
the lamp while driving the motorcycle. The amount of
time it takes for the fog to disperse depends on the
humidity of the ambient air. Fog in non functional areas
other than reflector does not affect the lamp
performance.

Removal & Fitment of Side Cover
11
Fitment of Side Cover LH
• Match the Lug provided on rear side (C) of
‘Side Cover’ with the hole located on
chassis & press ‘Side Cover’.
• Match Lug provided on front side (B) of
‘Side Cover’ with hole provided on ‘Fuel
Tank’ and press ‘Side Cover’ inside.
• Match the ‘Side Cover’ properly with
bracket provided on ‘Chassis’ & rotate the
key in anticlockwise direction to lock it.
Removal of Side Cover LH
• Insert the key into the cover lock (A) and
turn the key clockwise.
• Hold the cover with both hands and pull
front side (B) first & rear side (C) later.
Take out ‘Side cover’.
CAUTION : Remove cover as described
above, otherwise cover lugs may break.
A
BC

Removal & Fitment of Side Cover
Fitment of Side Cover RH
• Match rear side (C) of ‘Side Cover’ lug with
hole located on air filter & press the cover.
• Match the Lug provided on front side (B) of
‘Side Cover’ with hole provided on ‘Fuel
Tank’ & press ‘Side Cover’ inside.
• Match ‘Side Cover’ properly with bracket
provided on ‘Chassis’ & fix it with Screw (A).
CAUTION : Fit cover as described
above to ensure proper fitment.
A
B
C
Removal of Side Cover RH
• Remove the screw (A) given on ‘Side
Cover’.
• Hold the cover with both hands and pull
front side (B) first & rear side (C) later.
Take out ‘Side cover’.
CAUTION : Remove cover as described
above, otherwise the lugs may break.
12

Battery & Tool Kit
13
Tool Kit & First Aid Kit
Location
Make of Battery may differ from vehicle to vehicle
Tool Kit Location
• It is located below the seat on rear
mudguard.
• A rubber strap is provided to hold tool kit.
First Aid Kit Location
• First aid kit is to be stored in between toolkit
and seat.
CAUTION : Always fit rubber strap to hold
the tool kit securely.
Loose tool kit would cause rattling noise.
Battery
• It is located inside the ‘Side Cover’ LH.
• Always maintain electrolyte level in each
cell between Max. & Min. level marks.
CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may lead
to damage of electronic components.
CAUTION : Do not keep head lamp ‘ON’
without the engine running.

Removal & Fitment of Seat
Removal of Seat
• Remove ‘Side Cover’ LH.
• Pull the ‘Seat Release Cable’ (A) to release
seat lock. Keeping cable pulled, lift the
seat from rear end and slide it towards tail
lamp to remove seat assembly.
Fitment of Seat
• Match & insert the bracket ('1' of Fig. 'B')
of seat with slot ('2' of Fig. 'B') provided
below fuel tank rear mounting on chassis.
• Push seat towards fuel tank and align lock
rod ('3’ of Fig. ‘C') & seat lock ('4' of Fig.
‘C'). Then press the rear portion of seat
from top to lock the seat.
Fig. CA : Seat Release Cable Fig. B
2
1
A
14
3
4

Caution : Do not ope rate th e s tart er
continuously for more than 5 seconds
otherwise battery would get discharged. Wait
15 sec. between each operation of the starter
which will facilitate battery to recover.
Note : The motorcycle is equipped with a starter
lockout switch. This switch ensures that
engine does not start if the transmission is
in gear. However, the engine can be started
in any gear if the clutch lever is pressed.
Note : Before starting the engine, in ignition key off
condition, press the clutch lever & operate kick
starter lever all the way down for 5-6 times. Then
release the clutch lever.
This practice ensures lubrication of clutch
components for their longer life.
Note:
1. If engine is not starting after multiple attempts, it
might be case of engine flooding.
In case of engine flooding, following to be tried:
a. Switch on the ignition switch.
b. Put off choke.
c. Open throttle completely & crank the engine for 5
sec
d. If engine starts, close the throttle. Observed idling, if
idling is unstable, give slight throttle.
e. If engine doesn't start, wait for 10 sec & repeat
above steps.
Note : Do not let the engine idle longer than 3 minuets
otherwise it will overheat.
How to Ride Your Bike
15
Starting The Engine :
• Turn the fuel tap knob to ‘ ’ or ‘ ’ position.
• Turn ignition switch key to ‘ ’ position.
• Confirm that transmission is in neutral / press
the clutch lever.
• Keep throttle completely closed, press starter
button “ ” /apply kick to start the engine.
• Release starter button / kick lever as soon as
engine starts.
• If the engine is cold or when starting for first
time, use choke ‘ ’ for quick starting.
Note: In cold condition, kick start to be preferred
for longer one way clutch life
• When the engine is
warmed up enough to
idle without using
choke, return the
choke to OFF
position.
Manual Choke
ON
OFF

How to Ride Your Bike
th th
From 5 to 4 Gear
Gear Shifting
th rd
From 4 to 3 Gear
rd nd
From 3 to 2 Gear
nd st
From 2 to 1 Gear
-- 45 km/h
Discover 110 Discover 125 UG
24~30 km/h 35 km/h
18~23 km/h 25 km/h
13~16 km/h 15 km/h
Braking :
• Close the throttle completely, leaving the
clutch engaged (except where shifting
gears) so that the engine braking will help
slow down the motorcycle.
• Shift down one gear at a time so that you
are in Neutral when you come to a
complete stop.
• When stopping, always apply both brakes
at the same time. De-clutch as necessary
to avoid engine stalling.
Warning : When shifting down to lower
gear, do not shift at such high speed that
engine rpm jumps excessively. This may
cause engine damage, and rear wheel may
skid. Downshifting should be done at
recommended speeds as shown in table.
Moving Off :
• Check that Center/Side stand is up.
• Depress the clutch lever.
st
• Shift into 1 gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
• As the clutch starts to engage, open the
throttle a little more, giving the engine just
enough rpm to keep it from stalling.
Gear shifting
pattern -
All Up-
Discover 110
Shifting Gears :
• Close throttle & depress the clutch.
• Shift into next higher or lower gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
16
4
3
2
1
N
Gear shifting
pattern -
1 Down 4 Up
-Discover 125 UG
4
3
5
2
N
1
Recommended Speed for Shifting Down
Note:
For maximum life of engine, never use hard
acceleration when engine is cold.

How to Ride Your Bike
17
• Never lock the brakes, or it will cause the
tyres to skid. When cornering, use brakes
judiciously and do not de-clutch. Reduce
your speed before you get into the corner.
For emer g e n cy b raki n g , d i srega r d
downshifting, and concentrate on applying
brakes as hard as possible without
skidding.
Stopping the Vehicle :
• Close the throttle completely.
• Shift the transmission into neutral.
• Bring the vehicle to complete stop.
• Turn the ignition switch off.
Parking the Vehicle :
• Support the motorcycle on a firm level
surface with the center or side stand.
• Lock the steering.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle
may fall over.
Kms 1st 2nd 3rd 4th
0 - 1000 10 20 30 40
1000 - 2000 15 30 40 45
Kms 1st 2nd 3rd 4th 5th
0 - 1000 10 20 30 35 45
1000 - 2000 15 30 40 45 55
Proper running-in is important for the better
life and trouble free performance of the
vehicle.
• During first 2000 kms running-in period do
not exceed following speed limits.
• Always keep the speed below the limits
mentioned in the table.
• Do not race the engine excessively.
• Do not start moving or race the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to workup into the engine.
Running IN
Discover 110
Discover 125 UG

How to Ride Your Bike
Fuel Saving Tips :
A well maintained vehicle and good driving can
contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips.
Good Riding Habits :
• Ride smoothly and steadily at an optimum
driving speed of 40 to 50 Km/h
• Avoid harsh braking.
• Change the gear judiciously according to
the speed and load 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 two minutes.
How to check mileage (Fuel efficiency)
Best way to calculate mileage is by following
the full tank to full tank method.
• Fill way tank full up to small mouth (brim).
• Run the bike for say 100 km.
• Fill the tank full again in same fuel filling
station, probably with same fuel dispenser.
• Devide kilometer run / fuel quantity filled.
Fuel Check fuel lines & connections
for leakage.
Spark plugs Inspect and clean spark plugs.
Adjust electrode gap.
Air filter Clean the air filter element
periodically.
Engine oil Check level. Use recommended
grade and quantity.
Brakes Ensure that the brakes are not
dragging / binding.
Clutch Ensure correct clutch lever play.
Tyre Always maintain recommended
Pressure. tyre pressure.
Ensure following maintenance points to get
optimum fuel efficiency from your bike.
Optimum Shifting Speeds for best mileage
Gear Discover 110 Discover 125 UG
1st gear 0 km/h 0 km/h
2nd gear 16 ~ 19 km/h 14 ~ 17 km/h
3rd gear 28 ~ 34 km/h 22 ~ 25 km/h
4th gear 40 ~ 48 km/h 31 ~ 34 km/h
5th gear Not applicable 38 ~ 42 km/h
18