Foreword
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 email us at: customerservice@bajajauto.co.in 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
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
Safety and Warning information :
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.
Caution : This indicates that a potential
ha za rd th at could result in ve hicle
damage. Follow the Advice provided with
the caution.
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
acces sories as ma y be co nvenient and
necessary.
Technical Specifications
Discover 110 CBS Discover 125 CBS
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
1
Technical Specifications
Discover 110 CBS Discover 125 CBS
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
Front 1.75 Kg/cm (25 PSI) 1.75 Kg/cm (25 PSI)
Rear (Solo) 2.00 Kg/cm (28.5 PSI) 2.00 Kg/cm (28.5 PSI)
Rear (with Pillion) 2.25 Kg/cm (32 PSI) 2.25 Kg/cm (32 PSI)
2 2
2 2
2 2
2
Technical Specifications
Discover 110 CBS
Discover 125 CBS
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)
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.
3
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)
On LH Side Crankcase Near Gear
Engine Number Location
Change Lever (Alpha-Numeric - 11 Digits)
4
Location of Parts
Grab Handle
Nitrox Rear
Shock Absorber
Tail
Lamp
Pillion
Foot
Rest
CBS Force
Distribution
Unit
This photograph is of Discover 110 CBS.
Carburettor with
Manual choke
CBS
Mechanism
EVAP compatible
Fuel Tank
Engine Oil
Inspection
Window
Brake
Pedal
5
Speedometer
Headlamp
with DRL
CBS Cable
Distribution Unit
Front Fork
Steering Cum Ignition Lock
Steering cum Ignition Lock :
It has three positions.
LOCK : Steering locked. Ignition OFF.
OFF : Steering unlock. Ignition OFF.
ON : Steering unlock. Ignition ON.
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’.
6
Petrol Tank Cap & Fuel Tap
Fuel Tank
Cap
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.
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.
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.
7
Speedometer Details
1
Fuel Level Indications
2
3
7
4
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.
5
6
9
8
10
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’.
Fuel reserve level
8
Control Switch - LH
A
B
C
D
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.
D. Pass Switch : Press switch to flash the
head light. It is used to give signal to
vehicles coming from opposite side while
overtaking.
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’
9
Control Switch - RH
Day Time Running Light Feature:
F
• 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.
E
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.
: 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)
Day Time
Running Light
(DRL)
Igntion
Switch
ON
ON
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.
10
10
Light
Switch
OFF
ON
DRL
ON High Intensity
ON Low Intensity
Head
Light
OFF
ON
Removal & Fitment of Side Cover
B
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.
C
A
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.
11
Removal & Fitment of Side Cover
C
A
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.
B
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.
12
Battery & Tool Kit
Make of Battery may differ from vehicle to vehicle
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.
Tool Kit & First Aid Kit
Location
Tool Kit Location
• It is l oc ated bel ow the s eat o n r ea r
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.
13
Removal & Fitment of Seat
A
Fig. B
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.
1
3
2
4
Fig. CA : Seat Release Cable
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.
14
How to Ride Your Bike
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
OFF
ON
Note : Do not let the engine idle longer than 3 minu ets
otherwise it will overheat.
• When the engine is
warmed up enough to
idle without using
choke, return the
choke to OFF
position.
Manual Choke
C auti on : Do n ot op e rat e the s t art e r
co ntinu ou sly fo r m ore th an 5 sec on ds
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.
Th is pr ac ti ce ensures l ub ri ca tion 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.
15
How to Ride Your Bike
Note:
For maximum life of engine, never use hard
acceleration when engine is cold.
Moving Off :
• Check that Center/Side stand is up.
• Depress the clutch lever.
• 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.
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.
st
4
3
2
1
N
Gear shifting
pattern -
All Up-
Discover 110
5
4
3
2
N
1
Gear shifting
pattern -
1 Down 4 Up
-Discover 125 UG
Recommended Speed for Shifting Down
Gear Shifting
th th
From 5 to 4 Gear
th rd
From 4 to 3 Gear
rd nd
From 3 to 2 Gear
nd st
From 2 to 1 Gear
Discover 110
--
24~30 km/h
18~23 km/h
13~16 km/h
Discover 125 UG
45 km/h
35 km/h
25 km/h
15 km/h
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.
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.
16
How to Ride Your Bike
• 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 e m e r g e n cy b r a k i n g , d i s r e g a 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.
Running IN
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.
Discover 110
Kms 1st 2nd 3rd 4th
0 - 1000 10 20 30 40
1000 - 2000 15 30 40 45
Discover 125 UG
Kms 1st 2nd 3rd 4th 5th
0 - 1000 10 20 30 35 45
1000 - 2000 15 30 40 45 55
• 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.
17
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.
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
Ensure following maintenance points to get
optimum fuel efficiency from your bike.
Fuel Check fuel lines & connections
Spark plugs Inspect and clean spark plugs.
Air filter Clean the air filter element
Engine oil Check level. Use recommended
Brakes Ensure that the brakes are not
Clutch Ensure correct clutch lever play.
Tyre Always maintain recommended
Pressure. tyre pressure.
for leakage.
Adjust electrode gap.
periodically.
grade and quantity.
dragging / binding.
18
Safe Riding Tips
Safe Riding Tips
• Always wear helmets while driving or
riding. Your helmets should conform to
appr o p r iate Indi a n
standards.
• Read thoroughly the
in structi ons in th is
man ual a nd fo llo w
them carefully.
• Avoid u nnecessary
accessories for the safety of both rider and
other motorists.
• Get familiar and follow traffic rules &
regulations in your states as well as
general traffic signs.
• Familiarise yourself well with s tarting,
acceleration and braking of the vehicle.
• When applying the brakes, use both front
and rear brakes simultaneously. Applying
only one brake may cause the vehicle to
loose control.
• Riding at proper spee d and avoiding
unnecessary acceleration and
braking are important not only for safety
and low fuel consumption, but also for
longer life of the vehicle.
• During monsoon drive the vehicle more
cautiously. Remember vehicles skid more
easily during light showers..
• Drive cautiously. Start early & reach your
destination safely.
• Alw a ys carr y v e hicl e r e gis t rati o n &
insurance papers, and a valid driving
licence with you.
• Avoid driving on loose sand or stones
where vehicle is likely to skid.
• Properly wrap-up loose clothes whil e
driving or riding to avoid entangling in
wheel or other objects on road.
• Always concentrate on riding for safety.
Daily Safety Checks :
Before riding motorcycle be sure to check
following items. Please give proper importance
to these checks and perform all of them before
riding motorcycle.
19
Safe Riding Tips
If any irregularities are found during these
checks, refer to the Maintenance chapter &
see your dealer for the action required to return
the motorcycle to a safe operating condition.
Warning : Failure to perform these checks
every day before you ride may result in serious
damage or severe accident.
• Enough fuel level for planned distance of
journey. No fuel leakage in fuel lines.
• Engine oil level (bet upper - lower level mark)
n
• Throttle cable play of 2 - 3 mm. Smooth
operation & positive return to closed position,
• Steering Lock lever not fouling.
• Brake Pedal Play - 15 to 25 mm.
• Wear lining Indicator within usable range.
No brake dragging.
• Drive Chain slack of 25 to 35 mm adequately
lubricated.
• Function of all lights & horn
• Clutch lever play - 2 to 3 mm
• Front Brake lever play- 4 to 5 mm, 2 to 3 mm
for CBS vehicle. (Not applicable for Disc brake)
• Sm oot h s t eer ing mov emen t w ith out
restriction
• Both stands return to their fully up position.
• Correct inflation pressure in both tyres
Adequate tyre tread depth- no cracks / cuts.
• Correct rear viewing span adjustment of
mirror.
Monsoon Care :
• It is suggested to customer to take
appropriate care in area of heavy monsoon
or high rainfall area. The appropriate
surface preventive coat to avoid rusting /
poor surface finish on account of adverse
atmospheric conditions.
• Vehicle cleaning to be done with soft &
clean wet cloth to avoid scratches on
painted parts.
• Clean & lubricate all the important parts as
detailed in a periodic maintenance chart.
• Do not apply direct water jet on painted,
electrical / electronic parts.
• Do not obstruct engine cooling by adding
mud protection sheet from front.
20
Engine Oil
Recommended Engine Oil :
Always insist on Bajaj Genuine Oil for
A
optimum engine performance & warranty
benefits. It is a specially formulated oil for
Bajaj Bikes.
C
B
A : Oil Filler Cap B : Oil Level Gauge
D
Engine Oil Level Checking :
• Check engine oil level every day. Park
vehicle on level surface on center stand.
• Check oil level through oil level gauge ‘B’.
• Always maintain engine oil level between
upper (C) and lower (D) mark provided on
Cover RH. Top up with specified grade of
oil if the oil level is below lower level mark.
Engine Oil Capacity :
• Refill at Servicing : 1000 ml.
• During engine overhaul : 1100 ml.
Model Recommended eng. oil Grade
Discover 10W30
110 CBS
Discover 20W50
125 CBS
• Engine oil Replacement Frequency : 1st service &
then every 10,000 Kms.
• Engine oil level top-up Frequency : Every 5000 kms.
CAUTION :
• I t i s mos t i mpo rta nt to a dhe re to
recommended grade & frequency of oil
change for the purpose of long life of
critical engine components. For details
refer periodic maintenance chart.
• Do not reuse drained oil.
Bajaj DTS-i 10000
21
Wheels, Tyre Pressure & Front Brake Fluid Level
Wheels
Use the recommended levers while removing
the Tyre / Tube for puncture work. This will
avoid any damages to the edges / scratches
on paint of the wheel.
Motorcycle if fitted with spokes wheel ensure
spokes are always tight. Broken spoke should
be replaced immediately.
Note : Incase the motorcycle is fitted with
imported tyres. Compliance to respective
indian standard & central motor vehicle rules
has been ensured.
Tyre Pressure :
Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
fuel consumption.
Front 1.75 Kg/cm (25 PSI)
Rear (Solo) 2.00 Kg/cm (28.5 PSI)
Rear (with Pillion) 2.25 Kg/cm (32 PSI)
2
2
2
Front Brake Fluid
Level :
Front brake fluid master
cylinder reservoir is
located near RH switch
on handle bar.
• To check brake fluid level, keep vehicle on
Centre stand with handle bar in straight
ahead position.
• Always ensure that brake fluid level is
above ‘MIN’ mark.
• Use only DOT 3 or DOT 4 brake fluid (from
sealed container) to top up if required.
It is advisable that brake fluid should be
replenished at every 30,000 Kms or once in
two years which ever occurs earlier.
22
Min. Level
Periodic Maintenance Information
Battery Maintenance
Max
Min
Battery type :
12V 5Ah-Discover 110 CBS/125 CBS
Battery Warranty
Discover 110 CBS/125 CBS : 18 months from date
of purchase.
• Add only distilled water to the battery if
battery electrolyte level is below min. level
mark.
Make of Battery may differ from vehicle to vehicle
CAUTION : Tap water is not a substitute
for distilled water and will shorten the life
of the battery.
• When battery is found discharged, it is advised
to get it charged immediately.
• En vi ro nm ent care must be taken to
dispose off the used battery. It is always
recommended to hand over the same to
the Authorised battery / Bajaj dealer for
proper disposal of the same.
How to keep battery healthy ?
• Switch ‘Off’ ignition when e ng in e i s not
running.
• Get battery checked/ charged during periodic
services.
• Do not press starter button for more than 5
sec. After 3 successive cranking, wait for 1520 sec. for battery to recover.
• If vehicle is to be stored for more than 2
weeks disconnect battery to avoids self
discharge.
CAUTION :
• Always disconnect -ve cable first.
• While refitting always connect +ve cable first.
23
Periodic Maintenance Information
Spark Plug
• Remove spark plugs
by using plug spanner.
• Clean the spark plugs.
• Adjust the gaps if
incorrect by bending
outer electrode carefully.
Spark Plug Gap : 0.7 to 0.8 mm.
Spark Plug (2 Nos) : Champion PRZ9HC or
Bosch UR4AC
0.7 to
0.8 mm
Drive Chain Slackness
• Chain top edge to be kept between the
two marks during chain slackness
adjustment.
• Chain slackness will have to be adjusted
whenever required.
• Std. Chain slackness 25 ~ 35 mm.
• Marking on chain adjusters should be
identically positioned on both sides.
Top edge
Std. Chain
slackness
25~35 mm
Thoroughly clean
engine sprocket
Drive chain must be cleaned & lubricated as
per periodic maintenance schedule.
Drive Chain (Non sealed type)
• Non sealed type chain should be removed
& cleaned by Nylon brush & Kerosene /
diesel in chain cleaning stand.
• It should be lubricated by SAE 90 grade
oil.
24
Combined Braking system (CBS)
D
Lever brake cam
dot mark
A
Distance ‘C’
(should be 0-1 mm)
B
CBS Working :
• When front brake lever is pressed, then only front brake will get applied.
• When Rear brake pedal is pressed then both Rear and Front brake are applied, however it is
recommended to use both brakes simultaneously for best braking performance
Brake setting guideline in case rear wheel puncture and repair done at road side garage.
• Adjust rear brake free play by tightening force distribution unit ‘A’ (Similar procedure followed
for Non CBS vehicle). After adjustment ensure gap between CBS front brake cable 2 (B) sleeve
& cam lever slot (Distance C) and do not over tighten adjuster nut (D).
• It is recommended to do setting as per guideline mentioned at authorised dealership after rear /
front wheel puncture, rear / front brake shoe replacement, CBS cable replacement, higher brake
free play at rear / front, chain play adjustment, tyre refitting, etc.
• While fitment of lever brake cam, match dot mark of Lever brake cam with brake cam dot mark as
shown in fig (E).
25
Brake cam dot mark
Free Service Guidelines
Customer ID :
Instruction to avail Free Service through
Digitized Free Service Coupon
Please follow following procedure : -
• Please provide your mobile number to Dealer at
the time of buying of new Bajaj Vehicle.
• In case of change in mobile number, please
update to Dealer / ASD.
• You will receive the Customer ID through SMS
at the time of buying of new vehicle.
• Please note the Customer ID in Owner ’s
Manual for your reference.
• During Fre e Service, please prov ide your
Customer ID to Dealer / ASD workshop.
• When you are at Dealership / ASD workshop for
Free Service, you will receive the ‘Unique
Coupon Number’ (UCN) through SMS in your
mobile.
• Please inform the UCN to Dealer / ASD at the
time of Free Service.
(ASD-Authorised Service Dealer)
Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.
Subsequent
Paid services
Periodic Service Criteria
Service
1st Free
Service
2nd Free
Service
3rd Free
Service
Days
30~45
240
360
120 Days
from
last Service
Kms
500~750
4500~5000
9500~10000
Every
5000 Km
after previous
service
26
whichever occurs earlier
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
st
nd
2 Free
4500
~
5000
rd
3 Free
9500
~
10000
Every
5000 Km after
Previous Service
Subsequent
1 Free
Sr.
No.
Operation
Servicing
Kms
500
750
~
1. Water wash & dry the vehicle Ensure to prevent water
completely entry in Petrol tank,
Silencer & electrical
Parts. Use caustic free
detergent for washing.
2. Engine oil (Bajaj DTSi 10000 oil) C,R R Top R Top R Top R BGO DTSi 10W30 for
Up Up Up 100cc models.
BGO DTSi 20W50 for
Models above 125cc.
3. Engine oil filter C,R R R R R
4. Oil strainer CL CL CL CL CL
5. Body centrifugal filter** CL CL CL CL
6. Starter Clutch (Dry Type)** L L L L L L L Use recommended
Molycote grease.
7. Spark plug CL,A,R CL,A CL,A R
8. Air cleaner element / SAI Filter*** CL,R CL CL CL R CL CL R
Tick in the box after replacing the periodic parts.
27
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
st
nd
2 Free
4500
~
5000
rd
3 Free
9500
~
10000
Every
5000 Km after
Previous Service
Subsequent
1 Free
Sr.
No.
Operation
Servicing
Kms
500
750
~
9. Air filter cover ‘O’ ring CL,R CL CL CL R CL CL R
10. In line paper filter R R R
11. Fuel cock paper filter. R R R
12. Fuel cock sediment bowl cleaning CL CL CL
13. Carburettor rubber duct C,R C,R
14. Fuel pipe C,R C C C R C C R
15. Valve tappet clearance C,A C,A C,A C,A C,A C,A C,A C,A
16. Non-Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
cleaning & lubrication
17. Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A Customer to apply OKS
cleaning & lubrication chain lub spray at every
500 kms.
18. Engine air breather tube C C C C C C C C
19. Silencer drain hole cleaning CL CL CL CL CL CL CL
Tick in the box after replacing the periodic parts.
28
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
st
nd
2 Free
4500
~
5000
rd
3 Free
9500
~
10000
Every
5000 Km after
Previous Service
Subsequent
1 Free
Sr.
No.
Operation
Servicing
Kms
500
750
~
20. Silencer tail pipe cleaning** CL CL CL CL CL CL CL
21. Brake cam & brake pedal pivot pin C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use AP grease.
22. Brake lining or pad - C,R C,R C,R R C,R C,R R
Check wear indicator
23. Brake fluid level **- top up / replace C,A,R C,A R Use recommended
brake fluid
(DOT3/DOT4)
24. Disc brake assly -- Check functionality, C C C C
leakage or any other damage.
25. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A
26. Battery electrolyte level, specific gravity C,A C,A C,A C,A C,A C,A C,A C,A Not applicable for
VRLA battery
27. Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness.
28. Ignition switch barrel cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray
Tick in the box after replacing the periodic parts.
29
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
st
nd
2 Free
4500
~
5000
rd
3 Free
9500
~
10000
Every
5000 Km after
Previous Service
Subsequent
1 Free
Sr.
No.
Operation
Servicing
Kms
500
750
~
29. Handle bar control switches C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray
contacts cleaning
30. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
31. Steering stem bearing*** & C,CL,L,R C,CL, C,CL, C,CL, Check & replace if
Cap steering bearing (Plastic)** L,R L,R L,R Damaged. Use HP
Lithon RR3 grease for
lubrication.
32. Main stand & side stand pin** CL,L CL,L CL,L CL,L Use AP grease.
33. Swing arm pivot pin L L L L L L L
(for non silent bush)**
34. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
35. Engine foundation silent bushes** C C C
36. General lubrication-Clutch lever, L L L L L L L L Use AP grease.
front brake lever, kick lever.
37. Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
Tick in the box after replacing the periodic parts.
30
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
st
nd
2 Free
4500
~
5000
31
rd
3 Free
9500
~
10000
Every
5000 Km after
Previous Service
Subsequent
1 Free
Sr.
No.
Operation
Servicing
Kms
500
750
~
38. Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A C,A Use recommended
'Ready to use coolant'.
39. Coolant hose damage/clamps/leakage** C C C C C C C
40. Radiator fins** C C C C C C C
41. Spoke tightening**-Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
42. Front fork dust seal & Rubber bellow CL CL CL CL CL CL CL
43. SAI, EVAP hoses - Check functionality, C,R C,R C,R C,R C,R C,R C,R C,R Replace if cut / damaged
leakage or any other damage**
44. EVAP drain tube cleaning** CL CL CL CL CL CL CL CL
Tick in the box after replacing the periodic parts.
** As applicable to model
*** 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, Coolant, 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.
Non-Use Maintenance
Non-use maintenance is necessary if a vehicle
remains off road for a longer duration (more
than 15 days**). The correct and careful nonuse maintenance carried out before storing
the vehicle will prevent the vehicle from
rusting and from such other non-operational
damages like fire hazards.
• Clean the entire vehicle thoroughly.
• Empty the fuel from the fuel tank and
carburettor float bowl (if fuel is left in for a
longer time, the fuel will break and gummy
substance could clog the carburettor).
• Remove spark plug & put several drops of
engine oil into the cylinder. Kick engine
over slowly a few times to coat cylinder
wall with oil & install back spark plug.
• Set the vehicle on a box or a stand so that
both wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to
prevent rusting. Avoid getting oil on rubber
parts or brake liners.
• Cover entire vehicle neatly. Make sure that
storage area is well ventilated & free from
any source of flames or spark.
• Fill 10% excess air pressure in both
wheels.
• Do not apply oil on front brake disc, to
prevent rusting. If the front brake disc rusts
during storage, do not attempt to clean it
with soap water. The rust will go off
automatically during first few application of
brake.
** For Battery :
a. Remove battery and keep it on wooden
plank, in properly ventilated area.
b. Before taking the vehicle for use.
• Get t he ba tte ry re cha rge d fro m the
Authorised Service Center / Battery Dealer.
• Apply petroleum jelly on battery terminals.
Preparation for regular use after storage :
• Follow daily safety checks.
32
Delivery Certificate
FRAME NO. :
ENGINE NO. : Sold on.:
Customer’s Name Mr/Mrs/Miss :
Address : Contact No. :
I have taken possesion of motorcycle along with the following items.
1. Owner's Manual 5. Standard Accessories
2. 2 nos of key 6. Battery Make ___________ Sr. No. ____________
3. Set of tools 7. Tyre Fr Make ___________ Sr. No. ____________
4. First Aid Kit Rr Make ___________ Sr. No. ____________
The Vehicle has been delivered to my satisfaction & I have understood all terms and conditions of
warranty, service schedules & maintenance tips and shall abide by them.
Dealer Code :
Dealer Name :
Address :
Customer's Signature (To be filled in by the dealer)
Imp - "Do not detach this page from Owner's Manual"
33
Contact No. :
Warranty : Scope & Limit
Bajaj Auto Limited gives the following warranty in respect
of the “Bajaj Discover 110 / 125 UG” motorcycle
manufactured by them.
Every possible care and precaution has been taken to
ensure quality in respect of the material & workmanship in
the vehicles manufactured by us. Bajaj Auto Limited will
repair or replace at their Authorised Workshops, free of
charge, part or parts there of as may be found, on
examination, to have manufacturing defect within a period
of 5 Years or 75,000 Kms., whichever occurs earlier
from the date of sale subject to fulfillment of condition
stipulated in part A, B & C given here under
Warranty is applicable for only first owner of vehicle.
Part A:
Warranty claims in respect of such items like shock
absorbers, speedometers etc. though claimed through us,
are subject to acceptance of the respective manufacturers.
In all such cases the decis ion of the respective
manufacturer will be final and binding.
Proprietory parts like tyres, tubes, battery and spark plugs
are warranted by their respective manufacturers and
should be claimed on them directly by the customer. Bajaj
Auto Limited shall not be Liable to replace them
though their dealer will give full assistance in preferring
such claims.
Bajaj Auto Limited undertake no liability in the matter of
consequential loss or damage caused due to the failure of
the parts. Delay, if any, at the repairing workshop in
carrying out repair to vehicle shall not be a ground for
extending the warranty period, nor shall it give any right to
the customer for claiming any compensation for damages.
Bajaj Auto Limited reserves the right either to repair or
replace the defective parts.
Where a defective part can be replaced by part/s of
alternative brand/s, which are normally used by Bajaj
Auto Limited in the course of manufacture, Bajaj Auto
Limited reserves the right to carry out the replacement
by a part or parts of any such alternative brand/s.
This warranty and any claim arising there from is subject
to Pune jurisdiction only.
Part B:
No claim for exchange or repair can be considered
unless the customer :
a. Ensures that immediately upon detection of the
defect, he approaches any nearest Authorised Bajaj
Vehicle Dealers & Recommended Authorised Service
Dealers with the concerned vehicle and enables him
34
Warranty : Scope & Limit
to remove and despatch the part / parts attributing to
the manufacturing defect to the Company.
b. Produces the Owner's Manual, in original, to enable
that dealer to verify the details.
It must be expressly understood that claims forwarded
directly to us by the owner / customer will not be
entertained at all and such defective part/parts thus
forwarded by them will lie at our factory at their own risk,
and this warranty shall not be enforceable.
To avail benefits of warranty, following are mandatory
1. Availing of Initial 3 Free Services without lapse.
2. Availing paid services at subsequent 5000 kms. or
120 days from last service whichever occurs first
without any lapse.
3. Availing of all above services at the Authorised
Vehicle Dealers & Recommended Authorised Service
Dealers.
4. Usage of only recommended engine oil
“Bajaj DTS-i 10000” at specified frequency for drain
interval of 10,000 kms. & engine oil level top-up at
5000 kms.
5. Replacing mandatory periodic parts such as air filter,
oil filter etc. as per periodic maintenance schedule.
Part C :
Further this warranty is NOT applicable to :
1. Normal maintenance operations like brake & clutch
adjustments, cleaning of fuel system, engine tune-up or
such other adjustments.
2. Parts subjected to normal wear & tear like Clutch
Plates, Brake Shoes, Chain, Sprockets, Fork Oil Seal,
Spark Plug, Control Cables, Brake Pads.
3. Replacement of bulbs & rubber components like
grommets, ‘O’ rings, bellows as well as filters,
packings, gaskets, fasteners etc.
4. Painted parts. Only blistering or peeling off of paint film
are covered under warranty. Any defect arising out of
external damages or due to usage of protective covers
/n on-recomm ended pr otective c oa tings adver se
atmospheric condition etc. is not allow like under
warranty.
5. All consumables like Engine oil, Fork oil, Brake Oil,
Grease etc. are chargeable to customer.
6. Any defect arising due to above consumables not
changed as per scheduled or if used other than the
recommended one.
7. Never drive your bike through flooded roads or a
flooded patch, damage to the engine parts due to
water entry is not covered under warranty.
35
Warranty : Scope & Limit
8. All chrome plated parts are prone to rust or
corrosion in coastal area or in acidic environment or
due to neglected cleaning etc. However chrome film
peeling is covered under warranty in general
atmospheric conditions. Blue/ Yellow colouration of
silencer near exhaust port is permissible and hence
not covered under warranty.
9. Oxidation of unpainted/painted crankcase, cylinder
block, cylinder head etc. in acidic environment or in
a coastal area.
10. Parts of the vehicle that have been subjected to
misuse, accident, negligent treatment OR which have
been used in conjunction with parts & an equipment
not manufactured or recommended for use by Bajaj
Auto Limited, if in the sole judgement of Bajaj Auto
Lim ite d, suc h us e pr ema ture ly aff ects the
performance and reliability of the vehicle.
11. Parts of the vehicle that have been altered and
modified or replaced in unauthorized manner like use
of wider tyres, loud silencers etc and which in the
sole judgement of the Bajaj Auto Limited affects its
performance and reliability.
12. Ve hicl es w hich are n ot b eing ser vice d at
recommended dealers as per the service schedule
described or which have not been operated or
maintained in accordance with the instructions
maintained in the Owner’s Manual.
13. Vehicles used for any competition or race and/or for
attempting to set up any kind of record.
14. Any failure arising due to use of adulterated or bad
quality fuel.
Parts affected due to bad fuel quality are not covered
Under warranty.
15. If a ddi tio nal elect ric al a cc essori es s uc h a s -
Remote, Bigger horn, Musical brake light etc. fitted on
vehicle.
16. If the vehicle has been used for commercial purpose
li ke T ax i or a ny o th er means of commercial
transportation.
Bajaj Auto Limited reserves the right to make any changes in
design or to add any improvements on the vehicle at any
time without incurring any obligation to install the same on a
vehicle previously supplied and sold. Also, the conditions of
this warranty are subject to alteration without any notice.
This warranty is the entire written warranty given by Bajaj
Auto Limited for “Bajaj Discover 110 / 125 UG”
motorcycle’ and no other dealer or its or his agent or
employee is authorised to extend or enlarge this warranty.
36
BATTERY WARRANTY CARD
MAKE OF BATTERY : ........................ MFG. CODE OF BATTERY :
BATTERY SR. NO.: BATTERY CHARGING DATE :
TYPE OF BATTERY : VEHICLE SALE DATE :
NAME OF OWNER AND ADDRESS :
TYPE OF VEHICLE : REG. NO.:
FRAME NO.: ENGINE NO.:
SERVICE RECORD
Sr.
Date
No.
1
2
3
4
5
6
Note : Customer should insist that “Service Record" must be filled by respective authorised battery dealer as proof of specified
maintenance for easy settlement of claim, if any.
Age
Mths.
Specific
Gravity
Voltage
Remarks
Dealer’s Stamp
& Signature
* Code
* Code For Remarks:
LL : Low electrolyte level.
AE : Electrical system needs attention.
IR : Insufficient running of vehicle.
CB : Cover broken.
BC : Broken Container.
PM : Poor maintenance.
BA : Battery abused.
TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS
Name of Dealer & Code :__________________________________________________________________
__________________________________________________________________________________________
Date of claim :________________________________________________Battery Type :_______________
Serial No. :__________________________________________________Date of Fitment :______________
Failure Mode (Please tick as applicable)
• Loose connection • Overcharge / Undercharge
• Internal Short • Reverse Charge
• Plate Shedding • High Specific Gravity Electrolyte
• Intercell Connection • Electrolyte Contamination
• Does not Hold Charge • Electrolyte Level not Maintained
• Wrong Assembly • Left Lying Idle
• Wrong Application
• Terminal Corroded
IN CASE OF CLAIM
# Claim Accepted
Details of Repair, if any____________________________________________________________________________
Note:
Please contact nearest respective authorised battery dealer for details immediately after purchase of
vehicle.
## Claim Rejected
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