Bajaj GT 125X Guide

Service Station Manual

SPECIFICATION INFORMATION
Service Support - M/C
Service Station Manual
All information contained in this service station manual is based on the latest product information at the time of
publication. Bajaj Auto Limited accepts no liability for any 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 prior notice. The right is reserved to make such changes at any time without prior notice.
Doc. No . :71120187 Rev. No . : 00 AUG. 2022

REVISION MATRIX
Service Support - M/C
Service Station Manual
Sr. No Rev No Date Reason for change
1
2
3
3

INDEX
Service Support - M/C
Service Station Manual
1. Technical Information................................................................................................. 1
Technical Information.................................................................................. 2
Preventive Maintenance Chart................................................................... 4
PDI Checklist............................................................................................... 7
Speedometer Information............................................................................ 11
6. Engine ........................................................................................................................ 14
Torque Value ............................................................................................. 15
Service Limit............................................................................................... 18
Special Tools.............................................................................................. 20
Important SOP............................................................................................ 24
Engine Oil Flow path.................................................................................. 58
Part Identification....................................................................................... 62
7. Frame ........................................................................................................................ 84
Torque Value............................................................................................. 85
Service Limit............................................................................................. 87
Special Tools............................................................................................. 88
Important SOP.......................................................................................... 91
Hose/Cable Routing.................................................................................. 123
Part Identification...................................................................................... 128
8. Electrical .................................................................................................................... 140
Important SOP........................................................................................... 141
Wiring Harness Routing............................................................................. 161
Part Identification....................................................................................... 166
Circuit Diagrams........................................................................................ 167
INDEX

1
Technical Information
• Technical Specifications
• Preventive Maintenance Chart
• PDI check sheet
• Speedometer Information

2Service Support - M/C
Service Station Manual
Parameter CT 110X ES Drum Drum
Type Single cylinder, 4 stroke, Air cooled
Bore 50 mm
Stroke 58.8 mm 58.6 mm
Displacement 115.45 cc 124.45 cc
Idling speed 1300 ± 100 rpm 1300 ± 100 rpm
Max.Net Power 8.60 PS @ 7500 rpm 10.87 PS @ 8000 rpm
Max. Net Torque 9.81 Nm @ 5000 rpm 11Nm @ 5500 rpm
Ignition system DC DC
Spark plugs Qty 2 Nos 2 Nos
Spark plug gap 0.8 - 0.9 mm 0.8 - 0.9 mm
Lubrication Splash Splash
Transmission 4 speed constant mesh 5 Speed constant mesh
Gear shifting pattern All Down All Down
Engine oil Grade BAJAJ DTSi 10000 BS6 Compliant Engine
oil. Grade – SAE 10W30 API SL MIN
BAJAJ DTSi 10000 BS6 Compliant Engine oil
Grade – SAE 20W50 API SL MIN
Engine oil Drain & Refill quantity 1000 ml 1000 ml
Overhaul quantity 1100 ml 1100 ml
Frame Square tube, single down tube with lower cradle
Suspension
Front Telescopic suspension, Ø 30 mm dia fork
Rear Twin suspension with spring in spring (SNS) type
Brakes
Front Drum, Ø 130 mm
Rear Drum, Ø 110 mm
Tyres
Front 2.75 X 17”, 41 P – Tube Type,
Rear 3 X 17”, 50 P – Tube Type 100/90-17, 55P, Tubeless tyre
80/100-17, 46P, Tubeless tyre
Tyre Pressure
Front 2 Kgf/cm² (28 PSI)
Rear (Solo) 2 Kgf/cm² (28 PSI)
Rear (Pillion) 2.25 Kgf/cm² (32 PSI)
Fuel Tank Capacity Full 11 Litres
Fork oil Grade SAE 10W20 Bajaj Genuine Fork oil
Fork oil Quantity / leg 146 ml
Frame
Engine
TECHNICAL SPECIFICATIONS
CT 125X ES Disc Drum / 125X Drum Drum
Single cylinder, 4 stroke, Air cooled
52 mm
Drum, Ø 130 mm
Disc, Ø 240 mm / Drum, Ø 130 mm

3Service Support - M/C
Service Station Manual
Parameter
Length 1998 mm
Width 753 mm 810 mm
Height 1098 mm 1102 mm
Wheelbase 1285 mm 1285 mm
Ground Clearance 170 mm 170 mm
Vehicle Kerb Weight 127 Kg Drum – 130 Kg / Disc – 131.5 Kg
Drum – 260 Kg / Disc – 261.5 KgVehicle Gross Weight 257 Kg
System
Battery
Head Lamp
Position Lamp
Tail / Stop Lamp
Side Indicator Lamp
Neutral Indicator Icon Lamp
Hi Beam Indicator Icon Lamp
Turn Signal Indicator Icon Lamp
Speedometer back light
Fuel Level Indicator
Malfunction Indicator Icon Lamp
Rear Number Plate Lamp
Horn
12V DC
3Ah, VRLA
35W/35W
12V 10W/5W
LED
12V 10W
12V 2W
12V 2W
12V 2W
12V 2W12V 2W
12V 2W
12V 2A
Analogue
Part of Tail lamp
Electrical
Always maintain minimum 3 litres fuel in fuel tank for smooth functioning of vehicle.
NOTE • All dimensions are under UNLADEN Condition. • Above information is subject to change without any notice.• This vehicle complies to BS VI standards • AHO is government regulation.
2000 mm
TECHNICAL SPECIFICATIONS
CT 110X ES Drum Drum CT 125X ES Disc Drum / 125X Drum Drum

PREVENTIVE MAINTENANCE CHART
4Service Support - M/C
Service Station Manual
PREVENTIVE MAINTENANCE CHART
Sr.
No. Activities / Check points
Recommended frequency -- Service interval & Kms
Remarks
Servicing 1st
(Free)
2nd
(Free)
3rd
(Free) 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th
Kms
500 - 750
4500 -
5000
9500 -
10000
14500 -
15000
19500 -
20000
24500 -
25000
29500 -
30000
34500 -
35000
39500 -
40000
44500 -
45000
49500 -
50000
54500 -
55000
59500 -
60000
64500 -
65000
69500 -
70000
74500 -
75000
1Servicing with water wash √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
Ensure to prevent water entry in Petrol tank, Silencer & electrical parts. Use caustic free detergent for washing.
2Engine oil (Bajaj DTSI 10000 oil) Top up, R R Top-up R Top-up R Top-up R Top-up R Top -up R Top-up R Top-up R Top-up
Use BGO 20W50 BS6 Oil level window cleaning at every 10000 kms by petrol spray & nylon brush.
3Engine oil Filter R R R R R R R R R Replace oil filter in 1st service &
at every 10000 Kms
4Oil strainer CL CL CL CL CL CL CL CL CL Oil strainer cleaning at the time of
oil change.
5Air cleaner element** & air filter cover ‘O’ ring.
Drain tube cleaning. CL,R CL CL CL R CL CL R CL CL R CL CL R CL CL R
Replace air cleaner element at every 15000 Kms. Replace air filter cover O ring along with filter.
6Fuel pipes for cracks. C,R C C C R C C R C C R C C R C C R Replace at every 15000kms 7Spark plug clean & check gap CL,A,R CL,A CL,A R CL,A CL,A R CL,A Replace at every 30000 kms 8Valve tappet clearance C,A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A C, A 9Carburettor float chamber cleaning** CL CL CL CL CL CL
10 Carburettor rubber duct (Sleeve) for hard
resulting in loose fitment. C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R Replace if required
11 Engine breather tube for cracks. C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R Replace if required 12 EVAP system Hoses- check for cracks C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R
Drain EVAP "Y" connection drain tube.Replace if found cut / damaged
13 Silencer drain hole cleaning CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL 14 Wiring harness connections, routine &
Conduit / PVC sleeve inspection. C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
Damaged conduit / PVC sleeves protection by applying electrical tape film.
15 Battery connections & health by load tester.
+ve terminal cap fitment. C,A,L,T C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
C,A,L,
T
Apply Petroleum jelly on battery terminals. Use Midtronics battery tester.
16 Ignition switch contacts cleaning CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L Use recommended WD40 spray 17 HT coil connections (Primary and Secondary) C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T 18 Starter motor & starter relay connections C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T

PREVENTIVE MAINTENANCE CHART
5Service Support - M/C
Service Station Manual
PREVENTIVE MAINTENANCE CHART
Sr.
No. Activities / Check points
Recommended frequency -- Service interval & Kms
Remarks
Servicing 1st
(Free)
2nd
(Free)
3rd
(Free) 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th
Kms
500 - 750
4500 - 5000
9500 -
10000
14500 -
15000
19500 -
20000
24500 -
25000
29500 -
30000
34500 -
35000
39500 -
40000
44500 -
45000
49500 -
50000
54500 -
55000
59500 -
60000
64500 -
65000
69500 -
70000
74500 -
75000
19
Check fault code, Clear fault history, Update latest hex file if applicable
C C C C C C C C C C C C C C C C C
20
Non- sealed Drive chain wear**- Clean, Lubricate & adjust. Replace if required
CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
During 1st Free Service :Use lint free cloth for cleaning & SAE 90 oil for lubrication without removing from vehicle .During all other services: Remove, Clean by Diesel & Lubricate using molten chain grease.
21 Drive chain link lock R R R R Replace at every 20000kms 22 Main stand & side stand both pivot
pin C,L C,L C,L C,L Use recommended AP grease.
23 Steering play C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A 24 Steering stem bearing & Cap
steering bearing (Plastic)** C,CL,L C,CL,L C,CL,L C,CL,L C,CL,L C,CL,L C,CL,L C,CL,L Replace if required. Use Limaplex
grease for lubrication
25 Front fork oil & seal C,R C,R C,R C,R C,R C,R C,R R C,R C,R C,R C,R C,R R C,R C,R C,R Replace oil and oil seal + dust seal in
pair at every 30000 kms
26 Brake shoe / Pad for wear limit C,R C,R C,R C,R R C,R C,R R C,R C,R R C,R C,R R C,R C,R R Replace at every 15000 Kms 27 Brake cam cleaning & lubrication CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L Use AP grease. 28
1. Check source of leakages if
any in the brake system.
2. Check Front brake hose
condition.
3. Check Brake fluid level and
top up, if needed.
C,A,R C,A C,A C,A C,A C,A C,A R C,A C,A C,A C,A C,A R C,A C,A C,A
Check & Top up DOT4 brake oil in every service. Replace brake oil & Master / Caliper seals at every 30000kms
29 Rear sprocket fasteners for
looseness. C,T C,T C,T C,T C,T C,T C,T C,T C,T 3.2 - 3.8 Kgf-m
30 Rear wheel rubber shock dampers
for excess play. C,R C,R C,R C,R C,R C,R C,R C,R Replace rear wheel rubber shock
damper if required

Sr.
No. Acivities / Check points
Recommended frequency -- Service interval & Kms
Remarks
Servici
ng
1st
(Free)
2nd
(Free)
3rd
(Free) 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th 16th
Kms
500 - 750
4500 - 5000
9500 - 10000
14500 -
15000
19500 -
20000
24500 -
25000
29500 -
30000
34500 -
35000
39500 -
40000
44500 -
45000
49500 -
50000
54500 -
55000
59500 -
60000
64500 -
65000
69500 -
70000
74500 -
75000
31 All cables free play adjustment C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A Replace cables if operation found
hard.
32 Head light focus adjustment C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A 33 Check & confirm all bulbs / switches working. C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A
Contact type switches if found sticky then use recommended WD40 spray
34 General lubrication – Clutch lever / front brake
lever & kick lever, rear brake lever L L L L L L L L L L L L L L L L L Use recommended AP grease.
35 Tyre air pressure. C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A
Front : 2 Kgf/cm² (28 PSI) Rear (Solo) : 2 Kgf/cm² (28 PSI) Rear (Pillion) : 2.25 Kgf/cm² (32 PSI)
36 Mirror position & joint firmness. C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A C,A 37 Mobile USB port C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R C,R
Charging OK to be checked in engine start condition using LED USB light
38
All fasteners tightness
C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T C,T
Front axle 4.5 - 5.5 Kgf-m Rear axle 8 - 10 Kgf-m Swing arm axle 4.5 – 5.5 Kgf-m Rider foot rest. LH : 2.8 – 3.2 Kgf-m
RH : 1.8 – 2.2 Kgf-m
Engine foundation front & top 1.8 – 2.2 Kgf-m Engine foundation Rear. 2.8 - 3.2 Kgf-m
** More frequent cleaning may be required while driving in dusty environment. C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate Note : Periodic parts, Oil, Filters, All types of greases, Cleaning agents, Cables, Wear & tear parts, Rubber ‘O’ rings / oil seals / pipes, Gaskets to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.
PREVENTIVE MAINTENANCE CHART
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Service Station Manual
PREVENTIVE MAINTENANCE CHART

7Service Support - M/C
Service Station Manual
PDI CHECK SHEET - CT 125X DRUM
Battery
Battery charge condition As per SOP
Green LED-Battery fully
charged.
Yellow LED -Battery
partially discharged.
Red LED-Battery deep
discharged.
1. Midtronics battery
tester,
2. Battery charger
3. Petroleum jelly
Battery terminals tightness &
Petroleum jelly application. Carry out cable connections.
Ensure firm connection of
+ve & -ve terminals, apply
petroleum jelly & ensure
protection cap fitment on
+ve terminal
Tyre Pressure Air pressure in Front & Rear
tyre
Check air pressure in both
tyres using tyre pressure
gauge.
Front- 2 Kgf/cm² (28 PSI)
Rear Solo-2 Kgf/cm² (28
PSI)
Rear Pillion-2.25 Kgf/cm²
(32 PSI)
Tyre pressure gauge.
Brakes
Front brake free play
Use free play checking
gauge. 2-3 mm
Free play checking
gauge.
Free play of rear brake pedal Use free play checking
gauge.
Brake pedal free play
20 - 30 mm
Brake pedal play
/chain slackness
checking gauge
Clutch Lever /
Throttle
Free play of Clutch lever &
Throttle. Use free play gauge. Free play 2 ~ 3 mm Free play gauge
Drive Chain Slackness Use chain slackness
checking gauge Slackness 20 - 30 mm
Brake pedal play
/chain slackness
checking gauge
PDI Check sheet
Dealer's Name Dealer's code:
Model City
Frame No. Date of PDI
Engine No. PDI done by
1. Check Points before starting the vehicle
Check Point What to check How to check Recommendation /
Reference
Workshop
Observation
Tools , equipment &
consumables required
Engine Oil
1. Engine oil level.
2. Oil leakages, if any.
Vehicle to be parked on center
stand.
1. Engine cold condition -- Oil
level should be in between
lower & upper mark of oil level
window.
2. Check this point after test
ride on road.
1. Engine oil filling
funnel.
2. BGO 20W50
BS VI Compliant
Fuel Pipe 1.Pipe & Circlip fitting
2.Fuel leakage Visual _
Mirror 1.Fitment.
2.Adjustment.
Mirror adjustment as per user's
requirement.
Clear rear view setting on
vehicle.
Leg & Saree
guard Ease of fitment _ Hardware fully tightened.
Lock Operation
Smooth operation of Steering
cum Ignition lock, LHS cover
lock, Petrol Tank cap lock
By using vehicle key.
Insert vehicle key in lock &
check operation of respective
lock.
Fasteners
Torque values
Front Axle
Using dial torque wrench
4.5 - 5.5 Kgf-m
Dial torque
wrench 20 Kgf-m
Rear Axle 8 - 10 Kgf-m
Swing arm Shaft 4.5 - 5.5 Kgf-m
Rider foot rest. LH : 2.8 – 3.2 Kgf-m
RH :1.8 – 2.2 Kgf-m
Engine foundation front 1.8 – 2.2 Kgf-m
Engine foundation Rear. 2.8 - 3.2 Kgf-m

8Service Support - M/C
Service Station Manual
PDI CHECK SHEET - CT 125X DRUM
Check Point What to check How to check Recommendation /
Reference
Workshop
Observation
Tools , equipment &
consumables required
Switch Operation RH & LH control switch,
ignition switch, clutch switch
& brake switches
Check for smooth
operation & functioning
_
Horn Coupler connection,Horn
sound.
By hearing _
All Bulbs Working Head lamp, Tail / stop lamp,
Side indicators, Speedo bulb,
DRL
Check functioning. _
Speedometer
Working of speedometer,
Fuel gauge
Fuel gauge-By filling fuel. Speedometer, working to be
checked during / after test
ride
Working of all signal
indicators icons (N, Turn
signal, High beam, MIL & B
Logo)
By observing speedo
Indications after switching
ON ignition switch.
Funnel for filling petrol
& measuring jar
2. Check Points during / after starting the vehicle
Headlamp checking SOP.
Refer head light focus values
chart.
Focus to be checked with rider
& from a distance of 5 meters.
Head light Focus display
chart with 5m mark.
3. Check Points during Test Ride
Gear shifting Smooth operation In case of any issue during
test ride, vehicle to be
attended in workshop.
A.P.Grease,Feeler
gauge,Multimeter.
Driveability Throttle response, Brakes
effectiveness- Front & Rear
Engine noise No abnormal noise
4. Visual inspection for dent, scratches, rust etc
5. Clean the vehicle thoroughly before delivery to customer.
Note-
Vehicle FIFO system required with monitoring system.
Vehicles to be dispatched to network only after carrying out PDI activity at Dealership.
Do not drive vehicle in speed sensor dis connected condition & same to be instructed to customer.

9Service Support - M/C
Service Station Manual
PDI CHECK SHEET - CT 125X DISC
PDI Check sheet
Dealer's Name Dealer's code:
Model City
Frame No. Date of PDI
Engine No. PDI done by
1. Check Points before starting the vehicle
Check Point What to check How to check Recommendation /
Reference
Workshop
Observation
Tools , equipment &
consumables required
Engine Oil
1. Engine oil level.
2. Oil leakages, if any.
Vehicle to be parked on center
stand.
1. Engine cold condition -- Oil
level should be in between
lower & upper mark of oil level
window.
2. Check this point after test
ride on road.
1. Engine oil filling
funnel.
2. BGO 20W50
BS VI Compliant
Fuel Pipe 1.Pipe & Circlip fitting
2.Fuel leakage Visual _
Mirror 1.Fitment.
2.Adjustment.
Mirror adjustment as per user's
requirement.
Clear rear view setting on
vehicle.
Leg & Saree
guard Ease of fitment _ Hardware fully tightened.
Brake Fluid
1. Level in Front reservoir.
2. Brake Fluid leakage if any.
Visual 1. Brake fluid level above MIN
mark, top up if required.
2. Check this point after test
ride on road.
DOT 4 brake fluid.
Syphon pump for air
bleeding.
Lock Operation
Smooth operation of Steering
cum Ignition lock, LHS cover
lock, Petrol Tank cap lock
By using vehicle key.
Insert vehicle key in lock &
check operation of respective
lock.
Battery
Battery charge condition As per SOP
Green LED Battery fully
charged.
Yellow LED -Battery
partially discharged.
Red LED-Battery deep
discharged.
1. Midtronics battery
tester,
2. Battery charger
3. Petroleum jelly
Battery terminals tightness &
Petroleum jelly application. Carry out cable connections.
Ensure firm connection of
+ve & -ve terminals, apply
petroleum jelly & ensure
protection cap fitment on
+ve terminal
Tyre Pressure Air pressure in Front & Rear
tyre
Check air pressure in both
tyres using tyre pressure
gauge.
Front- 2 Kgf/cm² (28 PSI)
Rear Solo-2 Kgf/cm² (28
PSI)
Rear Pillion-2.25 Kgf/cm²
(32 PSI)
Tyre pressure gauge.
Brakes Free play of rear brake pedal Use free play checking
gauge.
Brake pedal free play 20 –
30 mm
Brake pedal play
/chain slackness
checking gauge
Clutch Lever /
Throttle
Free play of Clutch lever &
Throttle. Use free play gauge. Free play 2 ~ 3 mm Free play gauge
Drive Chain Slackness Use chain slackness
checking gauge Slackness 20 - 30 mm
Brake pedal play
/chain slackness
checking gauge
Fasteners
Torque values
Front Axle
Using dial torque wrench
4.5 - 5.5 Kgf-m
Dial torque wrench 20
Kgf-m
Rear Axle 8 - 10 Kgf-m
Swing arm Shaft 4.5 - 5.5 Kgf-m
Rider foot rest. LH : 2.8 – 3.2 Kgf-m
RH :1.8 – 2.2 Kgf-m
Engine foundation front 1.8 – 2.2 Kgf-m
Engine foundation Rear. 2.8 - 3.2 Kgf-m

10 Service Support - M/C
Service Station Manual
PDI CHECK SHEET - CT 125X DISC
Check Point What to check How to check Recommendation /
Reference
Workshop
Observation
Tools , equipment &
consumables required
2. Check Points during / after starting the vehicle
Switch Operation
RH & LH control switch,
ignition switch, clutch switch
& brake switches
Check for smooth
operation & functioning _
Horn Coupler connection,Horn
sound. By hearing _
All Bulbs Working
Head lamp, Tail / stop lamp,
Side indicators, Speedo bulb,
DRL
Check functioning. _
Speedometer
Working of speedometer,
Fuel gauge
Fuel gauge-By filling fuel. Speedometer, working to be
checked during / after test
ride
Working of all signal
indicators icons (N, Turn
signal, High beam, MIL & B
Logo)
By observing speedo
Indications after switching
ON ignition switch.
Funnel for filling petrol
& measuring jar
Headlamp checking SOP.
Refer head light focus values
chart.
Focus to be checked with rider
& from a distance of 5 meters.
Head light Focus display
chart with 5m mark.
3. Check Points during Test Ride
Gear shifting Smooth operation In case of any issue during
test ride, vehicle to be
attended in workshop.
A.P.Grease,Feeler
gauge,Multimeter.
Driveability Throttle response, Brakes
effectiveness- Front & Rear
Engine noise No abnormal noise
4. Visual inspection for dent, scratches, rust etc
5. Clean the vehicle thoroughly before delivery to customer.
Note-
Vehicle FIFO system required with monitoring system.
Vehicles to be dispatched to network only after carrying out PDI activity at Dealership.
Do not drive vehicle in speed sensor dis connected condition & same to be instructed to customer.

11 Service Support - M/C
Service Station Manual
SPEEDOMETER INFORMATION
Mobile Charger
• Mobile charging socket has been provided on handle bar (handle bar upper holder).
• The charger socket has been provided with cap to protect charger socket from dust & water entry during washing / during rain.
• Always ensure charger cap is firmly fitted on socket when charger socket is not in use.
• The mobile charger will supply output voltage only in engine running condition.
• Customer to use suitable USB cable for mobile charging.
Caution:
Do not use mobile phone while driving. Momentary lapse in concentration might result in an accident.
Charger Cap
Charging Socket
1. Odometer : The Odometer shows the total distance that the vehicle has accumulated.
2. Speedometer : The Speedometer pointer shows the speed of vehicle.
3. Fuel Level Indicator : Fuel level indicator shows approximate available fuel in fuel tank.
4. Turn Signal Indicator (Green) : When Turn signal switch is turned to Left or Right, Turn pilot indicator LH or RH will flash.
5. Neutral Indicator (Green) : When the transmission is in Neutral & Ignition switch ‘ON’, the Neutral indicator will get ‘ON’.
6. Hi Beam Indicator (Blue) : When Headlight is ‘ON’ & Hi beam is selected, Hi beam indicator will get ‘ON’.
7. Malfunction Indicator ( ) : It glows (Amber color) whenever any abnormality is noticed in functioning of Ignition / BS VI
carburettor components.
13
4
6
5
7
2

12 Service Support - M/C
Service Station Manual
SPEEDOMETER INFORMATION
SOP to prevent fuel stains on Fuel tank
• After fuel refilling & before shutting the cap wipe the spilled fuel from the
painted areas around the cap, wipe by soft dry cotton cloth.
• Shut and lock the cap fully.
• This practice needs to be followed to maintain the shine of color on fuel tank.
Matte Finish Painted Parts Cleaning
Do’s :
1. Use Colin or caustic free solution for cleaning. (1 spoon in ½ bucket water) Remove foreign substances like insect
remains, road debris using a soft brush.
2. Use microfiber cleaning cloths Ex.- Muslin cloth for painted parts cleaning.
• In case fuel is spilled out on fuel tank, it is to be immediately cleaned with clean soft cotton cloth to prevent
permanent stain marks on fuel tank.
Don’ts :
• Do not use any gloss enhancement products / wax / sprays.
• Do not use products that are even mildly abrasive, such as polishes, glazes, or rubbing compounds.
• Do not use mechanical cleaners/polishers.
• Do not use terrycloth or paper towels or shine enhancement products.
• Do not rub the finish vigorously, this will burnish the paint finish, causing a permanent shiny spot. Shiny spots cannot
be removed.
• No Polishing/Teflon coating on painted parts.
Fuel Tank Cap
Frame Grip
Purpose of Frame Grip
• Holding Grip for Pillion rider .
• Small luggage carrier.
Note : Maximum Allowable load on Frame Grip is 7 Kg.
• Do not hang any item on frame grip which may damage near by parts.
• Luggage should not have an overhang from Frame Grip.
• Ensure luggage is secured & will not shift while riding.
• Loosely secured luggage may affect riding & stability of motorcycle.
• Do not carry excessively heavy or huge luggage on the motorcycle.
Warning :
Please exercise utmost caution while carrying luggage on the motorcycle. Failure to
adhere to above precaution can cause loss of control on the motorcycle leading to
potential accident resulting in serious injury to both rider & other road users besides
causing severe damage to motorcycle.

13 Service Support - M/C
Service Station Manual
SPEEDOMETER INFORMATION
Side stand condition
Side stand
Indication in
speedometer
Gear position Remark
Down
No Neutral Self start / kick start possible
No Gear is applied in vehicle start
condition by pressing clutch lever Engine will get cut off.
Down No Gear Engine will not start by self / kick
Side Stand Switch Interlocking
Ignition
switch Light switch Engine OFF / Running High / Low beam selector switch Result
ON OFF or ON Engine OFF Any DRL with high intensity , Taillamp ON
ON OFF or ON Engine OFF Any + Pass switch is
pressed
Headlight High beam gets ON &
DRL with intensity low
ON OFF Engine running Any
DRL with high intensity , Taillamp ON. MIL
gets disappear(only if no any abnormality
is noticed in functioning of Ignition / BS VI
carburetor components)
ON ON Engine running Low beam Headlight low beam gets ON &
DRL with intensity low
ON ON Engine running High beam Headlight high beam gets ON &
DRL with intensity low
ON ON Engine running Low beam + Pass switch
is pressed
Headlight high beam gets ON &
DRL with intensity low
ON ON Engine running High beam + Pass
switch is pressed
Headlight high beam gets ON &
DRL with intensity low, No effect of pass
switch pressing
Lights & DRL Working

14
Engine
• Torque Value
• Service Limit
• Special Tools
• Important SOP
• Engine Oil Flow Path
• Engine Oil / Loctite /
Grease Application Matrix
• Part Identification

15 Service Support - M/C
Service Station Manual
TORQUE VALUE
Sr. No. Parameter Torque value
(Kgf-m)
1 Cover cylinder head bolts 1 - 1.1
2 Cylinder head tower bolts 2.3 - 2.5
3 Intake Pipe moutning screw 0.9 - 1
4 Camshaft sprocket mounting bolt 1.8
5 Chain tensioner mounting bolt 1 - 1.1
6 Chain guide moutning bolt 1 - 1.1
7 Primary gear nut 6.5 - 7
8 Clutch nut 5 - 5.5
9 Rotor bolt 6.5 - 7
10 Lock plate on Output sprocket mounting 0.6 - 0.8
11 Cam drum change moutning bolt 1 - 1.1
12 Gear change lever bolt 0.8 - 1.2
13 Cap oil filter moutning bolt 1 - 1.1
14 Inhibitor nut 1 - 1.1
15 Oil stariner cap (oil Drain) 1 - 1.1
16 Oil pump mounting screw 0.5 - 0.7
17 Clutch cover mounting bolts 1 - 1.1
18 Magneto cover mounting bolts 1 - 1.1
19 Cover LH RR moutning bolts 0.6 - 0.8
20 Air filter mountings on frame 0.5 - 0.8
21 Silencer mounting nut on cylinder head 2 - 2.2
22 Silencer mounting bolt on RH Stay 2.8 - 3.2

16 Service Support - M/C
Service Station Manual
TORQUE VALUE
Sr. No. Parameter Torque value
(Kgf-m)
23 One way clutch bolts on rotor 1.4 - 1.5
24 Starter Motor bolts 1 - 1.1
25 Kick lever bolt 2.3 - 2.5