Bajaj GT 125X, Service Station Manual

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

Page 2: ...e 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 p...

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

Page 4: ...n 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 Importan...

Page 5: ...1 Technical Information Technical Specifications Preventive Maintenance Chart PDI check sheet Speedometer Information...

Page 6: ...Si 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 Sus...

Page 7: ...gnal 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...

Page 8: ...Replace at every 30000 kms 8 Valve 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 9 Carburettor float chamber cleaning CL CL CL CL CL CL 10 Carburettor rubber du...

Page 9: ...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 P...

Page 10: ...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 cm 28 PSI Rear Solo 2 Kgf cm 28 PSI Rear Pillion 2 25 Kgf cm 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...

Page 11: ...ss 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...

Page 12: ...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 check...

Page 13: ...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 dischar...

Page 14: ...gh 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 chec...

Page 15: ...r 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 lev...

Page 16: ...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 bu...

Page 17: ...illamp 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...

Page 18: ...14 Engine Torque Value Service Limit Special Tools Important SOP Engine Oil Flow Path Engine Oil Loctite Grease Application Matrix Part Identification...

Page 19: ...lutch 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 I...

Page 20: ...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...

Page 21: ...ice Support M C Service Station Manual TIGHTENING SEQUENCE Clutch Cover Mounting bolts Magneto Cover Mounting bolts RH Crankcase Mounting bolts LH Crankcase Mounting bolts Engine Mounting bolts 1 6 3...

Page 22: ...t Intake 30 04 29 99 8 Valve spring free length Inner 38 74 37 53 10 Valve stem diameter Intake 4 96 4 98 4 95 11 Valve stem diameter Exhaust 4 94 4 96 4 93 12 Valve stem bent 0 01 0 015 14 Cylinder h...

Page 23: ...mm Service Limit in mm 25 Gear shift fork guide pin diameter 4 45 4 49 4 43 26 Gear shift drum groove width 4 6 4 7 4 75 27 Crankshaft runout 0 02 0 05 28 Cam lobe width 6 9 7 1 Not Applicable 29 Sha...

Page 24: ...For checking tappet clearance Cam sprocket Holder Part No 37104396 Usage For holding cam sprocket during tightening loosening of cam sprocket mounting bolt 3 8 Universal joint for central spark plug...

Page 25: ...e Temperature Sensor Removal Fitment Tool Part No 37104388 Usage For removal fitment of temperature sensor Chain Tensioner adjustment tool Part No 37104387 Usage For adjusting chain tension Drift Pist...

Page 26: ...mpressor Part No 37103108 Usage This adaptor is to be used with Valve Spring Compressor Primary gear Holder Part No F41AJA11 Usage For holding primary drive driven gears during clutch nut Primary gear...

Page 27: ...age For removing fitment of bearing from crankcase Adaptor Output shaft bearing extractor from RH crankcase Part No 37104410 Usage For removal of output shaft bearing from RH crankcase only NOTE This...

Page 28: ...ut Seat assembly by sliding towards rear Wheel side A B C LH side RH side SideCoverRH RemoveSideCovermountingScrew A withScrewdriver Hold cover with both hands pull front side first B Slide rear side...

Page 29: ...FueltankEVAPpipe RemoveFueltank Usingengineoildrainfunnel removedrainboltwith18mmSpanner Vehicleshouldbein warmupconditionbeforedrainingengineoil RemoveCirclipofFueltankmounting RemovemetalWasher Shif...

Page 30: ...T SOP RemoveNeutralSwitchconnection Remove Magneto cover mounting bolts 7 nos with 8 mm T Spanner in cris cross pattern RemoveStatorAssemblycouplerconnection Remove cover rear LH mounting bolts 2 Nos...

Page 31: ...ornutwith19mmsocket Takeoutmagnetorotornut washer RemovegearstarterclutchstopperplatemountingscrewwithPhillipsheadScrewdriver Takeoutgearstarterclutchstopperplate RemoveDowels 2nos magnetcovergasket U...

Page 32: ...holding bolts head using 12 mm spanner TakeoutEnginetopmountingbracket TakeoutWoodruffkey RemoveGeardrivestarter Pull out breather pipe clamp and take out breatherpipefromcylinderheadcover RemoveRHspa...

Page 33: ...LHH T coilmountingbolts 02nos with 8mmSpanner takeoutLHH T Coil DisconnectRHH T coilconnection Remove RH H T coil mounting bolts 02 nos with8mmSpanner takeoutRHH T Coil Removechaintensionercentreboltu...

Page 34: ...boltalongwithwasher TakeoutCamsprocketandcollarcamsprocket Tiecamchainwithsoftcopperwire CheckTDCposition Align magneto rotor mark with respect to crankcaseLHmark CheckcamsprocketmarksfromRHside Remov...

Page 35: ...tclutchcover Remove dowels 2 nos and clutch cover gasket Remove Rider RH footrest Stay RH mounting bolts 02 nos with 12 mm spanner for easeofclutchcoverremoval Remove clutch cable bracket mounting bol...

Page 36: ...SOP Usingprimarygearholder clutchnutspecialnut removeclutchnut LHtypethreading Takeout Clutchnut Plainwasher Bellevillewasher RemoveClutchbearing Using primary gear holder special tool loosen Primary...

Page 37: ...Service Support M C Service Station Manual 33 IMPORTANT SOP Takeoutclutchspacer washer TakeoutPrimarygearnut washer Takeoutwasher Clutchhousingcomplete Takeoutclutchstackcomplete TakeoutPrimarygear...

Page 38: ...Station Manual 34 IMPORTANT SOP Remove oil pump mounting screws 3 nos with Philipsheadscrewdriver takeoutpump Removeoilpumpdowels 02nos gasket TakeoutCamchain Removeoilpumpdrivengear Takeoutkey space...

Page 39: ...nutwith10mmTSpanner Takeoutinhibitorcompletegearshiftassembly Inhibitorbolt Inhibitor Washer Spring Remove lever gear shift mounting bolt with 8 mm spanner take out lever gear shift assembly Takeoutwa...

Page 40: ...Removecamsprocketasexplainedin Clutchsidepartsallparts CamchainRemovalon VehicleSOP Remove grommet from throttle cable bracket takeoutthrottlecablefromthrottledrum Remove cam drum change mounting bolt...

Page 41: ...ontmountingnuts Skilltip Only Silencer mounting nuts to be removed Silencer mouth to be pulled slightly but not to be removed This skill tip is applicable during cam shaft Rocker arm removal on vehicl...

Page 42: ...cerassembly Usingrockerarmshaftremovingtool removerockerarmshaftofbothinlet outletside Takeoutrockerarm 2nos Remove cylinder head mounting bolts 4Nos with12mmspannerincriss crosspattern Skilltip While...

Page 43: ...eoutcylinderblockgasket Takeoutdowels 02nos Remove engine temperature sensor coupler connection Remove engine temperature sensor with washerusingspecialtool Takeoutdowels 02nos Covercrankcaseborewithc...

Page 44: ...d take out starter motor ring terminal by removing it s nut using 10 mmspanner Remove chain guide inlet side mounting bolt by using 5 mm allen key and take out guide Remove starter motor mounting bolt...

Page 45: ...ve Engine front mounting bolts 3 Nos hold head and remove nut using 12 mm spanner Rear Engine rear top mounting nut holding bolt head with 14 mm spanner Take out earthing cable Remove belly pan mounti...

Page 46: ...tsarelongerinlength while sideboltisofshortlength TakeoutCrankcaseRH RemoveRHcrankcasejoiningbolts Innersidebolt 2nos using8mmspanner RHcrankcasejoiningbolts 3nos using8mmspanner Note Innersidebolts 0...

Page 47: ...veshaftoutputforkgearshift Separate out fork gear shift from gear change drumandtakeoutdrumgearshift Takeoutinputforkgearshift Takeoutoutputforkgearshift 2nos Removeshaftinputforkgearshift Takeoutcran...

Page 48: ...g LHcrankcase usingbearingdriverset Takeoutinputshaftbottomsidewasher thin Takeoutoutputshaftwasher thick Takeout input shaft output shaft assembly together Remove input shaft bearing lock plate using...

Page 49: ...rhaul always clean all jets in engine by applying low pressure are in directionoppositetoengineoilflow RemoveoutputshaftbearingfromRHcrankcaseusingbearingextractortool Gaskets ORings Oilsealsreplaceme...

Page 50: ...ckplatemountingbolt tightentorecommendedtorque Assembleinput outputshaftassemblywithgearsinLHcrankcase Fit all the bearings in both crankcase using BearingDriverset SkillTip WhenfittedoncrankcaseLH Th...

Page 51: ...gcrankcaseLH RH ensurethattransmissiongearsareinneutralposition SkillTip Input Outputforkgearshiftfitmentasshowninphotograph Inputforkgearshift ribfacingdownward Outputforkgearshift ribsfacingtowardse...

Page 52: ...color 1nos shortbolt Outerside shownbyBluecolor Change crankcase assembly position so that LH crankcaseisontopside Prefit LH crankcase mounting bolts 7 nos as shown in photograph and tighten to recom...

Page 53: ...nginefrontmountingbolts 03nos asshowninphotograph Place crankcase assembly on jack and align as showninphotograph Lifttheengineassemblyandplaceoncradle Fitoutputshaftoilseal Fit clutch cover and magne...

Page 54: ...it with clean lintfreecottoncloth Assembledowels 2nos newcylinderblockgasket Ensurethatnoanyforeignparticlesarefallenincrankcasebore Removeclutchcover magnetocoverfromcrankcaseassembly Assemblepistona...

Page 55: ...arter motor mounting bolts tighten to recommended torque Assemblerotorkey rotorassemblywithoneway clutch gear starter clutch on crankshaft assembly Apply Loctite 243 to rotor mounting nut Using rotor...

Page 56: ...pump Prefit oil pump mounting bolts tightentorecommendedtorque Assemble spring inhibitor washer inhibitor Prefit inhibitor mounting bolt tighten to recommendedtorque Assemble guide gear Apply Loctite...

Page 57: ...3 to primary gear nut assemble key primary gear washer it s mountingnut FitChainguideexhaustside Insertcamchain Tiecamchainusingcopperwire Assemble clutch washer Apply Loctite 243 toclutchnut prefitcl...

Page 58: ...SOP Removecottonclothfromblockcylinder Assemble dowels 2 nos and new cylinder headgasket Assembleheadcylinderassembly Fitcamshaftassembly camshaftcirclip Assembleclutchthrustbearing Assemblerockerarm...

Page 59: ...1 8 Kgf m using camsprocketholdertool TDCConfirmation Ensurecamsprocketmarkarealigned Ensurerotormarkisalignedwithmarkoncrankcase Prefit tighten cylinder head 5th bolt as per recommendedtorque Pre fi...

Page 60: ...it sgrubscrew Usingspecialtool fitLH RHsidesparkplugs Fitbothcapssparkplug Assembletemperaturesensorusingspecialtool Fittemperaturesensorcoupler Assembleenginetopmountingbracket Prefitit s bolts 03nos...

Page 61: ...covermountingbolts tightentorecommendedtorque Assemble dowels 2 Nos new gasket magnetocover Assembleclutchcover bracketclutchcablewithcableclutch Prefitclutchcovermountingbolts tightentorecommendedtor...

Page 62: ...Oil pump outlet to RH Crankcase hole Inlet hole of engine oil filter chamber Entry in engine oil filter chamber Oil filtration through engine oil filter Filtered Oil Entry hole in clutch cover Clutch...

Page 63: ...C Service Station Manual ENGINE OIL FLOW PATH Exit from con rod slots for piston lubrication From clutch cover to RH crankcase RH crankcase Inner oil gallery From RH crankcase to LH Crankcase From LH...

Page 64: ...60 Service Support M C Service Station Manual ENGINE OIL FLOW PATH Entry in head block mounting bolt hole Cylinder Block In out from block Cylinder Head In Cylinder Head Out In Out In Out...

Page 65: ...ing bolts Loctite 243 Stator harness bracket screw Loctite 243 Engine oil application Part Name Engine oil All ball bearings needle roller bearing SAE 20W50 Crank shaft big end bearing SAE 20W50 Trans...

Page 66: ...ntification mark 2BE Outer diameter 22 5 mm Length 91 05 mm Identification mark DS Outer diameter 24 mm Length 79 63 mm Identification mark B5A Part Name Valve Exhaust Pulsar 125 Identification mark l...

Page 67: ...vision for plate cylinder head fitment 2 Valve design Straight fins Without provision for plate cylinder head fitment 4 valve design Curved fins Without provision for plate cylinder head fitment Part...

Page 68: ...Name Rocker Arm Assembly Photograph JE511269 Pulsar 125 Dk101755 JH511210 Compatible for 2 valve design Compatible for 2 valve design Compatible for 4 valve design Part Number DK101751 Qty 2 Nos DK102...

Page 69: ...Inner diameter 15 5 mm Wire diameter 3 2 mm Identification mark Yellow dot over coils Length 36 18 mm Inner diameter 14 7 mm Wire diameter 3 mm Identification mark Yellow dot over coils Part Number J...

Page 70: ...iameter 15 mm Identification mark Groove Diameter 15 mm Identification mark Groove at 3 places Diameter 14 6 mm Identification mark Not present Part Number JE511234 JE511237 BorgWarner make PF511258 L...

Page 71: ...Cam Chain Photograph JE511233 Pulsar 125 PD511084 BorgWarner make DH103758 LGB make DY511208 Number of links 102 Number of links 100 Number of links 96 Part Number JE511170 DH102230 PA511098 Descripti...

Page 72: ...me Plate Cylinder Head Photograph NA NA NA NA Pulsar 125 PA511039 With plate cylinder head Part Number 36JF0226 36DH4262 36DY0032 Description Without ribs Without hole for oil pipe fitment Without rib...

Page 73: ...Name Gasket Block Cylinder Photograph JE521030 DK101063 Diameter 64 mm Diameter 75 mm Pulsar 125 JH521007 Diameter 63 mm Part Number 36JF0226 36DH4262 36DY0032 Description 4 Valve cut out Identificati...

Page 74: ...t Crankshaft Photograph JE531033 DK101068 BorgWarner make DK102019 LGB Make Number of teeth 18 Number of teeth 17 Pulsar 125 PF531057 Number of teeth 17 Part Number JE531054 Dh102540 BorgWarner DH1025...

Page 75: ...110X ES Drum Drum CT 125X ES Disc CT 125X ES Drum Part Number PF541029 PF541066 Description Without nozzle oil jet With nozzle oil jet Part Name Lever Brake Cam Part Number JH541007 Description Shorte...

Page 76: ...Drum CT 125X ES Disc CT 125X ES Drum Part Number JV541208 DY541213 Description NA Design is different than CT 110X Part Name Shaft Assembly Clutch release Part Number DY541215 Description NA Design i...

Page 77: ...rum CT 125X ES Disc CT 125X ES Drum Part Number PA551002 JZ551010 Description Total Length 159 3 mm Total Length 170 3 mm Part Name Input Shaft Part Number JZ551202 Description Number of teeth 22 Numb...

Page 78: ...ES Disc CT 125X ES Drum Part Number PF551201 JE551209 Description Number of teeth 22 Without groove on teeth Number of teeth 18 With groove on teeth Part Name Gear 3rd Drive Part Number JE551200 Descr...

Page 79: ...Z551213 Description NA Number of teeth 22 Part Name Gear 5th Drive Part Number JH551211 Description Number of teeth 20 Number of lugs 3 Number of teeth 25 Number of lugs 5 Part Name Gear 4th Driven Ph...

Page 80: ...25X ES Disc CT 125X ES Drum Part Number PF551204 JE551210 Description Number of teeth 27 Number of teeth 24 Part Name Gear 3rd Driven Part Number JE551215 Description Number of teeth 31 Number of slot...

Page 81: ...um Drum CT 125X ES Disc CT 125X ES Drum Part Number JZ551211 Description NA NA NA Number of teeth 20 Part Name Gear 5th Driven Part Number JE551205 Description Number of teeth 26 Without slots Number...

Page 82: ...25X ES Drum Part Number JK561200 Description Total Length 184 mm With groove PF561200 Total Length 195 mm Without groove Part Name Shaft Assembly Gear Shift LCGS Part Number PA561209 Description NA De...

Page 83: ...X ES Drum Drum CT 125X ES Disc CT 125X ES Drum Part Number PA561001 Description NA PF561001 Design is different than CT 110X Part Name Gear Change Drum Part Number JE561005 Description NA Design is di...

Page 84: ...X ES Drum Part Number JD561006 Description Total length 74 mm With groove PF561002 Total length 83 mm Without groove Part Name Shaft Fork Gear Shift Part Number PA621007 Description Total length 148 8...

Page 85: ...m CT 125X ES Disc CT 125X ES Drum Part Number PA621008 Description Number of teeth 19 PF621004 Number of teeth 21 Part Name Gear Kick Pinion Part Number DY581415 Description NA Rib slot position is di...

Page 86: ...S Drum Part Number DY581056 Description NA DY581046 Connecting tube is bigger than CT 110X Part Name Air Filter Assembly Photograph Carburettor fitment side Carburettor fitment side Part Number JZ3510...

Page 87: ...s different than CT 110X Part Name Gasket Cover cylinder head Photograph Part Number DY581236 Description Throttle position sensor JB351800 CTS Make DY581215 Throttle position sensor JD351800 Flash ma...

Page 88: ...84 Frame Torque Value Service Limit Special Tools Important SOP Hose Cable Routing Part Identification...

Page 89: ...Swing arm shaft nut 4 5 5 5 11 LH Stay bolt 2 2 2 5 12 RH Stay bolt 2 2 2 5 13 Rider footrest bolt LH 2 8 3 2 14 Rider footrest bolt RH 1 8 2 2 15 Brace fender bolts 1 8 2 16 Side stand bolt 3 3 2 17...

Page 90: ...3 0 29 Upper Bracket center nut Big 4 5 5 30 Fuel gauge bolt 0 35 0 5 31 Fuel cock bolt 1 2 1 6 32 Speedometer mtg nuts 0 6 0 8 33 Headlight mtg nuts bolts Focus adjustment bolt pivot bolt 0 6 0 8 34...

Page 91: ...8 4 2 3 5 5 Brake pad thickness Front 5 1 6 Brake Shoe lining thickness Front 4 2 Rear 4 2 7 Brake drum inside diameter Front 130 130 16 130 75 Rear 130 130 16 130 75 8 Axle run out 0 1 0 2 9 Axial w...

Page 92: ...o 37004362 Usage For cleaning dust seal oil seal Fork seat pipe holder 11 mm Part No 37004320 Usage For holding seat pipe during tightening loosening of outer tube bottom bolt LED USB Light Part No 37...

Page 93: ...e Underbracket cone removal tool Part No 37004479 37004480 Usage For removing underbracket cone Underbracket cone fitment tool Part No 37004480 Usage For fitment of underbracket cone Bearing Race Fitm...

Page 94: ...90 Service Support M C Service Station Manual SPECIAL TOOLS CBS brake adjustment tool Disc version Part No 37004354 Usage For adjusting CBS front brake...

Page 95: ...ation Manual IMPORTANT SOP Front Fork Overhaul Remove front axle nut with washer using 17 mm spanner holding front axle head with 14 mmspanner Holdwheelassembly takeoutfrontaxle Takeoutbrakepanelassem...

Page 96: ...IMPORTANT SOP Removefrontfendermountingbolts 2Nos using12mmspanner Removefrontforktopboltusing17mmspanner Removeunderbracketboltusing14mmspanner Takeoutforklegassemblyfromvehicle Removerubberbellowmo...

Page 97: ...egroove takeoutrubberbellow Removeforktopboltusing27mmspanner Takeoutforktopboltwithoring spacertube NOTE Take care while removing fork top bolt as bolt spacer tube may fly off causing injury to perso...

Page 98: ...pring Holdtheforklegassemblyasshowninphotograph takeoutseatpipeholder Remove outer tube bottom bolt using 6 mm allen key take out allen bolt with copper washer Takeoutforkinnerpipefromoutertube Takeou...

Page 99: ...Usingsmallflatheadscrewdriver removedustseal Ensurenodent damagetooutertubewhileusingsmallflatheadscrewdriver Insertoilsealremovaltool PartNo 37174029 asshowninphotograph Insertlockingpininoilsealrem...

Page 100: ...asshowninphotograph Hold oil seal removing tool central stud with 15 mm spanner tighten nut with 30 mm spannertoextractoilsealfromoutertube Hold oil seal removing tool central stud with 15 mm spanner...

Page 101: ...otograph Pourdieselinforkinnerpipe outertubebyclosingotherendwithhand After pouring diesel close both ends of fork inner pipe with hands then shake inner pipe Repeatthisstepforoutertube Nylonbrushcanb...

Page 102: ...k outertube Hold fork leg assembly with seat pipe holder as shown in photograph take out seat pipe holder Assemblenewoilsealasshowninphotograph Notesaboutoilseal Neverreuseoilseal Alwaysreplacethefork...

Page 103: ...eal Insertlockoilseal fitlockoilseal Insertmainspring spacertube Refillrecommendedforkoil SAE10W20 qty 146mlperleg Pre fitforktopbolt tightenusing27mmspanner Check the working of leg assembly by press...

Page 104: ...crew with phillips head screwdriver Prefit fork top bolt under bracket bolt tighten to recommendedtorque Torquevalue Forktopbolt 3 3 5Kgf m Underbracketbolt 2 5 3Kgf m Insert front axle through both l...

Page 105: ...ervice Station Manual IMPORTANT SOP Fitfrontwheelwithbrakepanelassembly insertaxle Fitwasher Prefitaxlenut tightentorecommendedtorque Torquevalue 4 5 5 5Kgf m Removetrimframegripmountingbolts 2nos usi...

Page 106: ...holder tail lamp keep Holder taillamp with taillamp assembly indicators as shown inphotograph Removeholdertaillampmountingbolts 4Nos using10mmspanner Removeframegripmountingbolts 2Nos using12mmspanne...

Page 107: ...der TaillampReplacementSOP Prefit frame grip RSA mounting bolts tighten to recommended torque 3 2 3 8 Kgf m Prefitframegripmountingbolts tightentorecommendedtorque 2 2 2Kgf m Removetrimlegguardmountin...

Page 108: ...Prefit trim leg guard mounting screws collars Tighten trim leg guard mounting screws usingphillipsheadscrewdriver Fitment Orientationoftrimlegguard Texturedportionistowardsridersidewhenseatedonvehicl...

Page 109: ...float alignment PositionBottomBoltandApplyForcetodownward PositiontheBoltandprefit Removebothforklegassembly frontfender Removeheadlampassembly Frontindicatorcouplers Remove Speedo cable from speedom...

Page 110: ...edometercouplers Removeforkcenternutusing32mmspanner takeouthandlebarassembly Hold underbracket assembly Using Balancer lock nut tool Part Number 37004160 removesteeringslottednut Holding underbracket...

Page 111: ...Takeoutupper lowerbearingcage ApplylimaplexHTX3greaseoncone races bearingcage Forremovalofracesfromframe petroltankistoberemoved Refitallthepartsinreverseorderofremoval Removetorquerodmountingnutlock...

Page 112: ...brakerodmountingnutusing14mmspanner Presstorquerodmountingbolt takeouttorquerodmountingbolt Pressrearbrakepedal removebrakerodfromrearleverbrakecam Insert screwdriver in axle head hole remove rear axl...

Page 113: ...8 mm spanner and take out cover LH RR Takeoutbrakepanelassemblyfromrearwheel Removechaincovermountingbolts 5nos using10mmspanner Note Hold lower chain cover while removing it s mounting bolts shown by...

Page 114: ...ort M C Service Station Manual IMPORTANT SOP Removedrivechainlinklockusingplier Takeoutlower upperchaincover Takeoutlockplate Takeoutdrivechainlockinglink drivechain Takeoutcouplingsleevenutwithwasher...

Page 115: ...SOP Remove LH RH Rear shock absorber mountingboltsusing12mmspanner Takeoutcouplingassembly TakeoutLH RHChainadjusters Removebrakereturnspringconnectedtotorquerodusingplier Remove swing arm shaft nut...

Page 116: ...Station Manual IMPORTANT SOP Swingarmhardwaredetails Holdswingarmassembly takeoutswingarmshaft Takeoutswingarmassembly Cleanswingarmshaftusingdiesel kerosine ApplyAPgreasetoswingarmshaft RH Stay LH St...

Page 117: ...artsinreverseorderofremoval Adjustchainslackness CBSfreeplay Remove chain slider mounting screws 2 nos withwasherusingphillipsheadscrewdriver Remove rear brake panel assembly from wheel as explained i...

Page 118: ...Manual IMPORTANT SOP Takeoutleverbrakecam Holdleverbrakecammountingboltusing8mmspanner removeusing10mmspanner Takeoutnut washer leverbrakecammountingbolt Takeoutwearindicator Takeoutbrakecam oringbra...

Page 119: ...tallthepartsinreverseorderofremoval Adjustchainslackness CBSfreeplay Remove coupling assembly from swing arm as explained in Swing arm replacement SOP Removespacerfromcoupling Removesleevefromcoupling...

Page 120: ...iver hammer openlockplate Ensure following adjusters are completely loose A Rearbrakepedalfreeplayadjusternut B Adjuster nut CBS cable brake pedal to panel front C Adjusternutfrontbrakecable Adjust fr...

Page 121: ...o 37004333 in such a way that both wheels areliftedfromgroundlevel Rotatebothrear frontwheelsbyhand applyonlyrearbrake ensure Withnormalforce rearwheelgetslockedbutfrontwheelstillrotates Furtherincrea...

Page 122: ...edalendasshowninphotograph Do not open cover at rear brake pedal mounting as shown in photograph during CBS Free play setting Frequency Check Adjustateveryservice Ensurefrontdiscbrakebleedingisdone fr...

Page 123: ...CBSFrontbrakeadjustmenttool Press brake pedal 2 3 times Check front wheel freeness If wheel is not free loosen adjuster nut B on CBS cable brake pedal to master cylinder in stepofhalf threadtillfrontw...

Page 124: ...ork like wheel rim replacement tyre replacementetc Drivechain sprocketsetreplacement AnyoftheCBSpartremoved replaced Do not adjust CBS brake cable at rear brake pedalendasshowninphotograph Do not open...

Page 125: ...Take out handleholderupper Keepclothonfueltank keephandlebarassemblyonfueltank Remove headlamp mounting bolts 4 Nos using10mmspanner Hold headlamp assembly remove USB chargercouplerconnection Take out...

Page 126: ...B charger slotted nut tighten using flatheadscrewdriver Assemble USB Charger with bracket USB chargerasshowninphotograph Connect USB charger coupler to it s mating coupler Hold handlebar assembly in i...

Page 127: ...bracket asshownbyyellowcircle Fit rubber grommet on hose in clamp hose fitted on underbracket as shown by blue circle furtherconnecttocaliperassembly Routespeedometercablethroughmetalclampasshownbyyel...

Page 128: ...tograph Route the CBS brake cable as shown in photograph Route the CBS brake cable through metal clamp asshownbybluecircleinphotograph Route the CBS brake cable as shown in photograph Route the CBS br...

Page 129: ...e CBS brake cable from metal hook as shownbybluecircleinphotograph Route the CBS brake cable as shown in photograph Connect the CBS brake cable to secondary linkofbrakepedalasshowninphotograph Front b...

Page 130: ...w circle in photograph Route speedometer cable through metal hook near underbracket as shown by blue circleinphotograph Routespeedometercableasshowninphotograph connecttospeedometer Routethethrottleca...

Page 131: ...tedinframeholeasshownbypinkcircle inphotograph Routethethrottlecablethroughmetalhookasshownbybluecircleinphotograph Routetheclutchcableasshowninphotograph Route the clutch cable through metal clamp as...

Page 132: ...Disc Part Number DY121015 DY121020 Description Without provision for caliper mounting on outer tube With provision for caliper mounting on outer tube Part Name FRONT FORK Part Number NA JK131815 Desc...

Page 133: ...IDENTIFICATION CT 125X ES DISC 00DY07ZZ 129 Service Support M C Service Station Manual Model CT 110X ES Drum CT 125X ES Disc Part Number Drum brake with CBS Disc brake with CBS Part Name BRAKE SYSTEM...

Page 134: ...Part Number JZ131042 JK131046 Description Size 1 40 x 17 Size 1 85 x 17 Part Name Wheel Front Part Number NA JK131815 Description NA Outer diameter 240 mm Part Name CBS Cable Rear brake pedal to Lever...

Page 135: ...catalogue available on e ssm Model CT 110X ES Drum CT 125X ES Disc CT 125X ES Drum Part Number DY113406 PF113402 Description Center distance 99 2 mm Center distance 94 3 mm Part Name Engine Hanger LH...

Page 136: ...art Name Assembly swing arm 15 5 mm 47 5 mm 12 3 mm 42 5 mm Part Number PA131239 PF131208 Description Outer Diameter 12 mm Outer Diameter 15 mm Part Name Axle Rear Part Number Tyre Front JV131024 Rear...

Page 137: ...um Part Number 31151021 Qty 4 Nos DK151094 Description NA Design is different than CT 110X Part Name Damper Coupling Part Number DU151078 DH151144 Description Size 1 85 x 17 Size 2 15 x 17 Part Name W...

Page 138: ...l Rear Photograph Kit Part No 36DY0020 36DY0040 Output sprocket Drive chain Coupling sprocket Part Name Kit sub parts Part Number Not serviceable JZ551004 PF141003 PA131278 Same for CT 110X CT 125X Nu...

Page 139: ...S Disc CT 125X ES Drum Part Number DU151046 31151037 Description Inner diameter 14 2 mm Inner diameter 12 2 mm Part Name Lever Brake Cam Part Number DY403400 Description NA With bracket for socket cha...

Page 140: ...Model CT 110X ES Drum CT 125X ES Disc CT 125X ES Drum Part Number PF403400 Description With socket charger Part Name Socket Charger Part Number DY191014 Description NA Design is different than CT 110...

Page 141: ...S Drum Part Number DY113206 Description Center stand base dimension 298 mm Twin holes on bracket Part Name Stand Center Photograph Center stand base dimension 293 5 mm Single hole on bracket PF113202...

Page 142: ...Disc CT 125X ES Drum Part Number DY151011 Description Without provision for weight handle bar fitment DU181155 With provision for weight handle bar fitment Part Name Handlebar Photograph Part Number D...

Page 143: ...CT 110X ES Drum Drum CT 125X ES Disc CT 125X ES Drum Part Number JH151003 Description NA PF151032 Design is different than CT 110X Part Name Assembly grip RH Photograph Part Number DH181022 Descripti...

Page 144: ...140 Electrical Important SOP Wiring Harness Routine Part Identification Circuit Diagram...

Page 145: ...ort M C Service Station Manual IMPORTANT SOP Remove headlamp assembly mounting bolts 4 Nos withmetalwashersusing10mmspanner Holdtheassemblyasshowninphotograph Pulloutdustcapofheadlampharness Bulb Head...

Page 146: ...142 Service Support M C Service Station Manual IMPORTANT SOP Takeoutbulb Removebulbholdingclip Assembly Fitbulbinreflector Fitbulbholdingclip Removeheadlampcoupler...

Page 147: ...nual IMPORTANT SOP Pre fitheadlampmountingbolts tightentorecommendedtorque 0 6 0 8Kgf m Fitdustcapproperlytoavoidanydust waterentry Fitheadlampcoupler Harness Headlamp Replacement Removeheadlampcouple...

Page 148: ...emoveheadlampharnesscouplerfromwiringharness Pullouttherubberbellow Takeoutheadlampharness Assembly Fitheadlampharnesscouplertoitsmatingcouplerinwiringharness Fit rubber bellow properly to avoid any d...

Page 149: ...lacementSOP Remove bulb headlamp harness headlamp coupler as explained in Bulb Headlamp ReplacementSOP HarnessHeadlampReplacement SOP Cutcabletielock 2nos fittedonupperbracket RemoveDRLunitcoupler Rem...

Page 150: ...ting screws 3 nos using phillips head screwdriver take out speedoflap Removefairingheadlampmountingscrews 5nos usingphillipsheadscrewdriver Takeoutheadlampassemblyfromfairingheadlamp Remove bracket fr...

Page 151: ...racketheadlamplowermountingbolts 2Noseach using10mmspanner Ensure foams on fairing DRL unit are intact and in good condition Replace with new one if foundcut torn peeloff Takeoutbracketheadlampupper b...

Page 152: ...fyellowarrow Assembly Rimlock LugonHousingheadlampdetails Lockonrimshouldgetlockbeneathlugonhousing Pre fithousingheadlampscrews tightenthemusingphillipsheadscrewdriver Prefit bracket headlamp upper b...

Page 153: ...htenthemusingphillipsheadscrewdriver Fit speedo flap on headlamp assembly Prefit speedo flap mounting screws 3 Nos thentightenthemusingphillipsheadscrewdriver Fit bulb in headlamp lock clip harness he...

Page 154: ...cableties Adjustheadlampfocusasperfollowingchart Remove headlamp assembly with fairing from vehicle as explained in Headlamp Assembly Fairing Headlamp DRL Unit Speedo Flap Headlamp Mounting Brackets R...

Page 155: ...e out speedometer assembly For assembly on vehicle follow the reverse stepsofremovalSOP Pullouttherubberbellow Remove headlamp assembly with fairing from vehicle as explained in Headlamp Assembly Fair...

Page 156: ...IMPORTANT SOP Remove indicator mounting nut washer from indicator harness branch Take out indicator For assembly on vehicle follow the reverse stepsofremovalSOP Insert 14 mm spanner as shown in photog...

Page 157: ...tor as shown in photograph to avoid falling of reflector take out bulb taillamp Takeoutreflector Remove Lense mounting screws 2 Nos using phillips head screw driver Take out lense TakeoutLensegasket A...

Page 158: ...sing using phillips head screw driver Holdthereflectorasshowninphotograph fitbulbtaillamp Removeseatassemblymountingbolts 2Nos withmetalwashersusing5mmallenkey Lift the seat assembly from rear side sl...

Page 159: ...Cutthecabletieasshowninphotograph Pull out the harness branches near CU removewireholdertaillampcoupler Removeholdertaillampmountingbolts 4Nos using10mmspanner Liftholdertaillampfromcollars takeouthol...

Page 160: ...emove Lense Gasket Bulb taillamp reflector as explained in Bulb Taillamp Lense withgasket ReflectorReplacementSOP Insert 15 mm spanner through indicator harness branch remove indicator mounting nuts T...

Page 161: ...l IMPORTANT SOP Replace2nosfoamsonhousingtaillampiffoundpeeloff damagedwithnewone Removewireholderfromhousingtaillamp Takeoutbootfromholdertaillamp Assembly Fitbootinholdertaillamp Boot fitted in hold...

Page 162: ...OP Fit2nosmetalwasheronhousingtaillampstudsasshowninphotograph FitwireholderinHousingtaillamp Fithousingtaillampinholdertaillamp Fit2nosmetalwasheronhousingtaillampstudsasshowninphotograph Prefithousi...

Page 163: ...rews tightenthemusingphillipsheadscrewdriver Holdreflectorwithonehand fitbulbtaillamp Fitbracketindicatormounting indicators Fittaillampassemblyonframe Fitholdertaillampholesoncollar 0 4 0 5 Kgf m 0 8...

Page 164: ...M C Service Station Manual IMPORTANT SOP Fitcabletie Fitindicatorcouplers wireholdercouplers Fit indicators wire holder branches in space between CU Frame rod as shown in photograph Wire holder couple...

Page 165: ...WIRING HARNESS ROUTING Route the wiring harness as shown in photograph 161 Service Support M C Service Station Manual...

Page 166: ...WIRING HARNESS ROUTING Route the wiring harness as shown in photograph 162 Service Support M C Service Station Manual Route the wiring harness as shown in photograph...

Page 167: ...WIRING HARNESS ROUTING Route the wiring harness as shown in photograph 163 Service Support M C Service Station Manual Route the wiring harness as shown in photograph...

Page 168: ...WIRING HARNESS ROUTING Route the wiring harness as shown in photograph 164 Service Support M C Service Station Manual Route the wiring harness as shown in photograph...

Page 169: ...WIRING HARNESS ROUTING Route the wiring harness as shown in photograph 165 Service Support M C Service Station Manual Route the wiring harness as shown in photograph...

Page 170: ...e DC Flasher Part Number DY402214 JL402004 Description With provision for fitment of DC Flasher With provision for fitment of Socket charger Light control module Part Name Wiring Harness Model CT 110X...

Page 171: ...METER PIN DETAILS SPEEDOMETER 2 1 SIDE STAND INDICATOR 3 TURN SIGNAL LH TURN SIGNAL RH GEN ILLUMINATION SUPPLY VE FUEL GAUGE 8 HIGH BEAM NEUTRAL MIL 7 EARTH VE 9 10 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7...

Page 172: ...OSITION SENSOR ve CRANK POSITION SENSOR ve 19 GROUND 20 O Br G L Y L B W Br L B R W R L G Y L Y W R B Y H T COIL 1 1 B AIR INJECTOR 2 Br B MIL 3 Br R STR INTERLOCK RELAY 4 R G XDRG GROUND 12 Y B SIDE...

Page 173: ...E BOX IGNITION SWITCH Br L W OFF Br W SUPPLY VE EARTH VE SPEEDOMETER Br B Y 4 7 NEUTRAL 2 L G Br B Y L G 1 2 1 2 1 3 1 3 2 Pi L Pi 3 2 1 OUTPUT SV GROUND SIDE STAND SWITCH IGNITION KEY 9 Br L STR INTE...

Page 174: ...G L Br L 1 3 6 2 CONTROL UNIT AUTO CHOKE CAN_HIGH 5 6 CAN_LOW 7 ETS 8 IGNITION KEY 9 H T COIL 2 10 XDRP XDRG 13 12 TPS 15 LAMBDA SENSOR 17 CRANK POSITION SENSOR 19 GROUND 20 O Br G L Y L B W Br L B R...

Page 175: ...1 Service Support M C Service Station Manual BATTERY CHARGING CIRCUIT CAPACITOR REGULATOR UNIT L W L R MAGNETO ASSEMBLY L W L W W B Y VRLA BATTERY B W B L W L W B Y L R L W W B Y F1 W 15A W B 5 6 4 3...

Page 176: ...Service Station Manual CAN CIRCUIT VRLA BATTERY W B IGNITION SWITCH Br L W CAN INTERFACE Y L B Y G L Br L 1 3 6 2 CONTROL UNIT CAN_HIGH 6 CAN_LOW 7 IGNITION KEY 9 V BATTERY 11 GROUND 20 G L Y L Br L...

Page 177: ...TH VE SPEEDOMETER Br B Y 4 7 MIL 1 Br R Br B Y Br R IGNITION SWITCH Br L W BATTERY W B 10A Br F2 F1 W 15A Br L W B FUSE BOX CAN INTERFACE Y L B Y G L Br L 1 3 6 2 FRAME EARTH CONTROL UNIT MIL CAN_HIGH...

Page 178: ...OLENOID VALVE CIRCUIT IGNITION SWITCH Br L W BATTERY W B CAN INTERFACE Y L B Y G L Br L 1 3 6 2 CONTROL UNIT AIR_S CAN_HIGH 2 6 CAN_LOW 7 IGNITION KEY 9 V BATTERY 11 GROUND 20 Br B G L Y L Br L W B Y...

Page 179: ...W B Y BATTERY W B Br F1 W 15A Br L W B B Y Y R Y Y L R B SUPPLY VE GENERAL ILLUMINATION SPEEDOMETER Br Y L 4 5 Br R EARTH VE B Y 7 B Y HIGH BEAM R B 8 R B 1 2 1 2 3 1 2 3 2 9 3 6 3 1 4 2 10A F2 2 1 2...

Page 180: ...r G F1 W 15A Br L W B 1 2 10A F2 2 1 2 5 1 3 4 6 B Y O L W Br Br V W V LIGHT CONTROL MODULE L W MAGNETO ASSEMBLY L W 5 6 Br W OFF ON B FUSE BOX 10A F3 V 2 1 Gr G Br B Y USB CHARGER B Y ELECTRICAL CIRC...

Page 181: ...e Support M C Service Station Manual BRAKE LAMP CIRCUIT IGNITION SWITCH Br L W L B Y TAIL LAMP BATTERY W B F1 W 15A Br L W B 1 2 2 1 Br L REAR BRAKE SWITCH 2 1 L Br Br L FRONT BRAKE SWITCH 2 1 L Br Br...

Page 182: ...B F1 W 15A Br L W B O G 1 2 5 7 3 TURN SIGNAL LH TURN SIGNAL RH SUPPLY VE 7 EARTH VE 4 6 4 5 7 8 4 5 7 8 G Br Gr B Y G Br Gr B Y L OFF 4 Gr Gr B Y Gr INDICATOR REAR RH 2 1 B Y Gr B Y Gr INDICATOR FRO...