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 e-
mail 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 Safety and Warning information :
1. Technical Specifications 1
2. Identification Data 4 Warning : This indicates that a potential
3. Location of Parts 5 hazard or injury to you or other persons &
4. Steering cum Ignition lock 6 to the vehicle can happen if advice
5. Petrol Tank Cap / Fuel Tap 7 provided is not followed.
6. Speedometer Details 8
7. Control Switches 9 Caution : This indicates that a potential
8. Removal & Fitment of Side Covers 11 hazard that could result in vehicle
9. Battery / Tool kit 13 damage. Follow the Advice provided with
10. Removal & Fitment Seat 14 the caution.
11. How to ride your Bike 15
12. Safe Riding Tips 19
Notice:
13. Engine Oil 21
14. Wheels - Tyre 22 The description and illustration in this booklet
15. Periodic Maintenance Information 23 are not to be taken as binding on the
manufacturers. The essential features of the
16. Combined Braking system 25
type described and illustrated herein remaining
17. Free Service Guidelines 26
unaltered. Bajaj Auto Limited reserves the
18. Periodic Maintenance & Lubrication Chart 27
right to carry out at any moment without
19. Non Use Maintenance 32 being obliged to bring this booklet upto-date
20. Delivery Certificate 33 & to do modifications on the vehicle, parts or
21. Warranty Scope & Limit 34 accessories as may be convenient and
22. Battery Warranty Card 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/cm2 (25 PSI) 1.75 Kg/cm2 (25 PSI)
Rear (Solo) 2.00 Kg/cm2 (28.5 PSI) 2.00 Kg/cm2 (28.5 PSI)
Rear (with Pillion) 2.25 Kg/cm2 (32 PSI) 2.25 Kg/cm2 (32 PSI)

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. • This vehicle complies to BS IV standards.
• Above information is subject to change without any notice. • 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)

Engine Number Location

On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

4
 Location of Parts

EVAP compatible Speedometer

Fuel Tank

Grab Handle

Carburettor with
Nitrox Rear Manual choke Headlamp
Shock Absorber with DRL

Tail
Lamp CBS Cable
Distribution Unit
Front Fork

Pillion
Foot
Rest
CBS Force
Distribution
Unit
Engine Oil
CBS Inspection Brake
Mechanism Window Pedal

This photograph is of Discover 110 CBS. 5

 Steering Cum Ignition Lock

Steering cum Ignition Lock : To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Turn
It has three positions.
the key to “LOCK” position and remove the
key.
LOCK : Steering locked. Ignition OFF.
To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
OFF : Steering unlock. Ignition OFF. turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering
ON : Steering unlock. Ignition ON. cum Ignition lock’, ‘Fuel tank cap’ & ‘Side
cover lock’.

6
 Petrol Tank Cap & Fuel Tap

Fuel Tank
Cap Fuel Tap

Fuel Tank Cap Fuel Tap

• To open the fuel tank cap, insert the key in Fuel tap lever has following positions.
the lock and turn it clockwise and lift fuel
tank cap.
• ‘Fuel Tank Cap’ is locked when pushed / ON : When fuel level is above
pressed back into the place. reserve position.
Precaution : RES : When fuel level is below
• Don’t attach metallic ‘Key chain’ as it may reserve position.
damage paint/plating of petrol tank/tank cover.
• Don’t put PVC/Rexin cover on petrol tank. OFF : When fuel supply is to be
Note : In case petrol spills on to tank, ensure cut off.
that tank is cleaned with a clean, dry cloth
immediately.
7
 Speedometer Details
Fuel Level Indications
1 2

3 5
6

9
8
7 Fuel reserve level
10
4

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

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

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

C
B

Removal of Side Cover LH Fitment of Side Cover LH

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

11
 Removal & Fitment of Side Cover

C B

Removal of Side Cover RH Fitment of Side Cover RH

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

12
 Battery & Tool Kit

Tool Kit & First Aid Kit

Location

Make of Battery may differ from vehicle to vehicle

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

1
3

2
4
A

A : Seat Release Cable Fig. B Fig. C

Removal of Seat Fitment of Seat

• Remove ‘Side Cover’ LH. • Match & insert the bracket ('1' of Fig. 'B')
• Pull the ‘Seat Release Cable’ (A) to release of seat with slot ('2' of Fig. 'B') provided
seat lock. Keeping cable pulled, lift the below fuel tank rear mounting on chassis.
seat from rear end and slide it towards tail • Push seat towards fuel tank and align lock
lamp to remove seat assembly. 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 : Caution : Do not operate the starter
continuously for more than 5 seconds
• Turn the fuel tap knob to ‘ ’ or ‘ ’ position. otherwise battery would get discharged. Wait
• Turn ignition switch key to ‘ ’ position. 15 sec. between each operation of the starter
which will facilitate battery to recover.
• Confirm that transmission is in neutral / press
the clutch lever. Note : The motorcycle is equipped with a starter
lockout switch. This switch ensures that
• Keep throttle completely closed, press starter engine does not start if the transmission is
button “ ” /apply kick to start the engine. in gear. However, the engine can be started
• Release starter button / kick lever as soon as in any gear if the clutch lever is pressed.
engine starts. Note : Before starting the engine, in ignition key off
• If the engine is cold or when starting for first condition, press the clutch lever & operate kick
time, use choke ‘ ’ for quick starting. starter lever all the way down for 5-6 times. Then
release the clutch lever.
Note: In cold condition, kick start to be preferred
This practice ensures lubrication of clutch
for longer one way clutch life components for their longer life.
OFF • When the engine is Note:
warmed up enough to 1. If engine is not starting after multiple attempts, it
idle without using might be case of engine flooding.
choke, return the In case of engine flooding, following to be tried:
choke to OFF a. Switch on the ignition switch.
position. b. Put off choke.
ON c. Open throttle completely & crank the engine for 5
Manual Choke sec
d. If engine starts, close the throttle. Observed idling, if
Note : Do not let the engine idle longer than 3 minuets idling is unstable, give slight throttle.
otherwise it will overheat. e. If engine doesn't start, wait for 10 sec & repeat
above steps.

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

Gear shifting Gear shifting

• When stopping, always apply both brakes
pattern -
All Up-
pattern -
1 Down 4 Up
at the same time. De-clutch as necessary
Discover 110 -Discover 125 UG to avoid engine stalling.
16
 How to Ride Your Bike
• Never lock the brakes, or it will cause the Running IN
tyres to skid. When cornering, use brakes Proper running-in is important for the better
judiciously and do not de-clutch. Reduce life and trouble free performance of the
your speed before you get into the corner. vehicle.
For emergency braking, disregard
• During first 2000 kms running-in period do
downshifting, and concentrate on applying
not exceed following speed limits.
brakes as hard as possible without
skidding. Discover 110
Kms 1st 2nd 3rd 4th
Stopping the Vehicle :
0 - 1000 10 20 30 40
• Close the throttle completely.
1000 - 2000 15 30 40 45
• Shift the transmission into neutral.
Discover 125 UG
• Bring the vehicle to complete stop. Kms 1st 2nd 3rd 4th 5th
• Turn the ignition switch off. 0 - 1000 10 20 30 35 45
Parking the Vehicle : 1000 - 2000 15 30 40 45 55
• Support the motorcycle on a firm level
surface with the center or side stand. • Always keep the speed below the limits
• Lock the steering. mentioned in the table.
• Do not race the engine excessively.
CAUTION : Do not park on a soft or • Do not start moving or race the engine
steeply inclined surface or the motorcycle immediately after starting. Run the engine
may fall over. for a minute at idle speed to give the oil a
chance to workup into the engine.
17
 How to Ride Your Bike
Optimum Shifting Speeds for best mileage
Fuel Saving Tips :
A well maintained vehicle and good driving can Gear Discover 110 Discover 125 UG
contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips. 1st gear 0 km/h 0 km/h
2nd gear 16 ~ 19 km/h 14 ~ 17 km/h
Good Riding Habits : 3rd gear 28 ~ 34 km/h 22 ~ 25 km/h
• Ride smoothly and steadily at an optimum 4th gear 40 ~ 48 km/h 31 ~ 34 km/h
driving speed of 40 to 50 Km/h 5th gear Not applicable 38 ~ 42 km/h
• Avoid harsh braking. Ensure following maintenance points to get
• Change the gear judiciously according to optimum fuel efficiency from your bike.
the speed and load requirement.
Fuel Check fuel lines & connections
• Don’t overload the vehicle above the for leakage.
specified payload.
• Use the accelerator judiciously. Spark plugs Inspect and clean spark plugs.
Adjust electrode gap.
• Cut off the engine if you want to stop for
more than two minutes. Air filter Clean the air filter element
How to check mileage (Fuel efficiency) periodically.
Best way to calculate mileage is by following Engine oil Check level. Use recommended
the full tank to full tank method. grade and quantity.
• Fill way tank full up to small mouth (brim). Brakes Ensure that the brakes are not
• Run the bike for say 100 km. dragging / binding.
• Fill the tank full again in same fuel filling Clutch Ensure correct clutch lever play.
station, probably with same fuel dispenser.
Tyre Always maintain recommended
• Devide kilometer run / fuel quantity filled.
Pressure. tyre pressure.
18
 Safe Riding Tips

Safe Riding Tips braking are important not only for safety
and low fuel consumption, but also for
• Always wear helmets while driving or
longer life of the vehicle.
riding. Your helmets should conform to
appropriate Indian • During monsoon drive the vehicle more
standards. cautiously. Remember vehicles skid more
easily during light showers..
• Read thoroughly the
instructions in this • Drive cautiously. Start early & reach your
manual and follow destination safely.
them carefully. • Always carry vehicle registration &
• Avoid unnecessary insurance papers, and a valid driving
accessories for the safety of both rider and licence with you.
other motorists. • Avoid driving on loose sand or stones
• Get familiar and follow traffic rules & where vehicle is likely to skid.
regulations in your states as well as • Properly wrap-up loose clothes while
general traffic signs. driving or riding to avoid entangling in
• Familiarise yourself well with starting, wheel or other objects on road.
acceleration and braking of the vehicle. • Always concentrate on riding for safety.
• When applying the brakes, use both front
and rear brakes simultaneously. Applying Daily Safety Checks :
only one brake may cause the vehicle to Before riding motorcycle be sure to check
loose control. following items. Please give proper importance
• Riding at proper speed and avoiding to these checks and perform all of them before
unnecessary acceleration and riding motorcycle.
19
 Safe Riding Tips

If any irregularities are found during these • Smooth steering movement without
checks, refer to the Maintenance chapter & restriction
see your dealer for the action required to return • Both stands return to their fully up position.
the motorcycle to a safe operating condition. • Correct inflation pressure in both tyres
Warning : Failure to perform these checks Adequate tyre tread depth- no cracks / cuts.
every day before you ride may result in serious • Correct rear viewing span adjustment of
damage or severe accident. mirror.
• Enough fuel level for planned distance of
journey. No fuel leakage in fuel lines. Monsoon Care :
• Engine oil level (betn upper - lower level mark) • It is suggested to customer to take
• Throttle cable play of 2 - 3 mm. Smooth appropriate care in area of heavy monsoon
or high rainfall area. The appropriate
operation & positive return to closed position,
surface preventive coat to avoid rusting /
• Steering Lock lever not fouling. poor surface finish on account of adverse
• Brake Pedal Play - 15 to 25 mm. atmospheric conditions.
• Wear lining Indicator within usable range. • Vehicle cleaning to be done with soft &
No brake dragging. clean wet cloth to avoid scratches on
• Drive Chain slack of 25 to 35 mm adequately painted parts.
lubricated. • Clean & lubricate all the important parts as
• Function of all lights & horn detailed in a periodic maintenance chart.
• Do not apply direct water jet on painted,
• Clutch lever play - 2 to 3 mm electrical / electronic parts.
• Front Brake lever play- 4 to 5 mm, 2 to 3 mm • Do not obstruct engine cooling by adding
for CBS vehicle. (Not applicable for Disc brake) mud protection sheet from front.

20
 Engine Oil
Recommended Engine Oil :
Always insist on Bajaj Genuine Oil for
optimum engine performance & warranty
A
benefits. It is a specially formulated oil for
Bajaj Bikes.

Model Recommended eng. oil Grade

C
Discover Bajaj DTS-i 10000 10W30
110 CBS
B
D
Discover 20W50
A : Oil Filler Cap B : Oil Level Gauge 125 CBS
Engine Oil Level Checking :
• Check engine oil level every day. Park • Engine oil Replacement Frequency : 1st service &
vehicle on level surface on center stand. then every 10,000 Kms.
• Check oil level through oil level gauge ‘B’. • Engine oil level top-up Frequency : Every 5000 kms.
• Always maintain engine oil level between
upper (C) and lower (D) mark provided on CAUTION :
Cover RH. Top up with specified grade of • It is most important to adhere to
oil if the oil level is below lower level mark. recommended grade & frequency of oil
Engine Oil Capacity : change for the purpose of long life of
• Refill at Servicing : 1000 ml. critical engine components. For details
• During engine overhaul : 1100 ml. refer periodic maintenance chart.
• Do not reuse drained oil.
21
 Wheels, Tyre Pressure & Front Brake Fluid Level
Wheels Tyre Pressure :
Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
fuel consumption.
Front 1.75 Kg/cm2 (25 PSI)
Rear (Solo) 2.00 Kg/cm2 (28.5 PSI)
Rear (with Pillion) 2.25 Kg/cm2 (32 PSI)

Front Brake Fluid

Level :
Front brake fluid master
cylinder reservoir is Min. L
evel
Use the recommended levers while removing located near RH switch
the Tyre / Tube for puncture work. This will on handle bar.
avoid any damages to the edges / scratches
on paint of the wheel. • To check brake fluid level, keep vehicle on
Centre stand with handle bar in straight
Motorcycle if fitted with spokes wheel ensure ahead position.
spokes are always tight. Broken spoke should • Always ensure that brake fluid level is
be replaced immediately. above ‘MIN’ mark.
• Use only DOT 3 or DOT 4 brake fluid (from
Note : Incase the motorcycle is fitted with sealed container) to top up if required.
imported tyres. Compliance to respective It is advisable that brake fluid should be
indian standard & central motor vehicle rules replenished at every 30,000 Kms or once in
has been ensured. two years which ever occurs earlier.
22
 Periodic Maintenance Information
Battery Maintenance 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
Max
to get it charged immediately.
Min • Environment 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.
Battery type : How to keep battery healthy ?
12V 5Ah-Discover 110 CBS/125 CBS • Switch ‘Off’ ignition when engine is not
running.
Battery Warranty • Get battery checked/ charged during periodic
Discover 110 CBS/125 CBS : 18 months from date services.
of purchase. • Do not press starter button for more than 5
sec. After 3 successive cranking, wait for 15-
• Add only distilled water to the battery if 20 sec. for battery to recover.
battery electrolyte level is below min. level • If vehicle is to be stored for more than 2
mark. weeks disconnect battery to avoids self
discharge.
Make of Battery may differ from vehicle to vehicle CAUTION :
• Always disconnect -ve cable first.
• While refitting always connect +ve cable first.

23
 Periodic Maintenance Information

Spark Plug Top edge

• Remove spark plugs
by using plug spanner.
• Clean the spark plugs. 0.7 to
0.8 mm
• Adjust the gaps if
incorrect by bending Std. Chain
outer electrode carefully. slackness
Spark Plug Gap:0.7 to 0.8 mm. 25~35 mm
Spark Plug (2 Nos) : Champion PRZ9HC or Thoroughly clean
Bosch UR4AC engine sprocket

Drive Chain Slackness Drive chain must be cleaned & lubricated as

• Chain top edge to be kept between the per periodic maintenance schedule.
two marks during chain slackness Drive Chain (Non sealed type)
adjustment. • Non sealed type chain should be removed
• Chain slackness will have to be adjusted & cleaned by Nylon brush & Kerosene /
whenever required. diesel in chain cleaning stand.
• Std. Chain slackness 25 ~ 35 mm. • It should be lubricated by SAE 90 grade
• Marking on chain adjusters should be oil.
identically positioned on both sides.

24
 Combined Braking system (CBS)

D Lever brake cam

dot mark
A

Brake cam dot mark

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
Free Service Guidelines Customer ID :

Instruction to avail Free Service through

Digitized Free Service Coupon Periodic Service Criteria
Please follow following procedure : -
Service Days Kms
• Please provide your mobile number to Dealer at
the time of buying of new Bajaj Vehicle. 1st Free
• In case of change in mobile number, please Service 30~45 500~750
update to Dealer / ASD. 2nd Free

whichever occurs earlier

• You will receive the Customer ID through SMS Service 240 4500~5000
at the time of buying of new vehicle.
3rd Free
• Please note the Customer ID in Owner’s Service 360 9500~10000
Manual for your reference.
• During Free Service, please provide your
Customer ID to Dealer / ASD workshop.
• When you are at Dealership / ASD workshop for 120 Days Every
Subsequent
Free Service, you will receive the ‘Unique from 5000 Km
Paid services
Coupon Number’ (UCN) through SMS in your last Service after previous
mobile. service
• 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.

26
 Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
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
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
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
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
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
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
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
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
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.

31
 Non-Use Maintenance
Non-use maintenance is necessary if a vehicle wheels.
remains off road for a longer duration (more • Do not apply oil on front brake disc, to
than 15 days**). The correct and careful non- prevent rusting. If the front brake disc rusts
use maintenance carried out before storing during storage, do not attempt to clean it
the vehicle will prevent the vehicle from with soap water. The rust will go off
rusting and from such other non-operational automatically during first few application of
damages like fire hazards. brake.
• Clean the entire vehicle thoroughly. ** For Battery :
• Empty the fuel from the fuel tank and a. Remove battery and keep it on wooden
carburettor float bowl (if fuel is left in for a plank, in properly ventilated area.
longer time, the fuel will break and gummy b. Before taking the vehicle for use.
substance could clog the carburettor). • Get the battery recharged from the
• Remove spark plug & put several drops of Authorised Service Center / Battery Dealer.
engine oil into the cylinder. Kick engine • Apply petroleum jelly on battery terminals.
over slowly a few times to coat cylinder
wall with oil & install back spark plug. Preparation for regular use after storage :
• Set the vehicle on a box or a stand so that • Follow daily safety checks.
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
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) Contact No. :

Imp - "Do not detach this page from Owner's Manual"

33
 Warranty : Scope & Limit
Bajaj Auto Limited gives the following warranty in respect though their dealer will give full assistance in preferring
of the “Bajaj Discover 110 / 125 UG” motorcycle such claims.
manufactured by them. Bajaj Auto Limited undertake no liability in the matter of
Every possible care and precaution has been taken to consequential loss or damage caused due to the failure of
ensure quality in respect of the material & workmanship in the parts. Delay, if any, at the repairing workshop in
the vehicles manufactured by us. Bajaj Auto Limited will carrying out repair to vehicle shall not be a ground for
repair or replace at their Authorised Workshops, free of extending the warranty period, nor shall it give any right to
charge, part or parts there of as may be found, on the customer for claiming any compensation for damages.
examination, to have manufacturing defect within a period Bajaj Auto Limited reserves the right either to repair or
of 5 Years or 75,000 Kms., whichever occurs earlier replace the defective parts.
from the date of sale subject to fulfillment of condition Where a defective part can be replaced by part/s of
stipulated in part A, B & C given here under alternative brand/s, which are normally used by Bajaj
Warranty is applicable for only first owner of vehicle. Auto Limited in the course of manufacture, Bajaj Auto
Limited reserves the right to carry out the replacement
Part A:
by a part or parts of any such alternative brand/s.
Warranty claims in respect of such items like shock
This warranty and any claim arising there from is subject
absorbers, speedometers etc. though claimed through us,
to Pune jurisdiction only.
are subject to acceptance of the respective manufacturers.
In all such cases the decision of the respective Part B:
manufacturer will be final and binding. No claim for exchange or repair can be considered
Proprietory parts like tyres, tubes, battery and spark plugs unless the customer :
are warranted by their respective manufacturers and a. Ensures that immediately upon detection of the
should be claimed on them directly by the customer. Bajaj defect, he approaches any nearest Authorised Bajaj
Auto Limited shall not be Liable to replace them 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 Part C :
the manufacturing defect to the Company. Further this warranty is NOT applicable to :
b. Produces the Owner's Manual, in original, to enable 1. Normal maintenance operations like brake & clutch
that dealer to verify the details. adjustments, cleaning of fuel system, engine tune-up or
It must be expressly understood that claims forwarded such other adjustments.
directly to us by the owner / customer will not be
2. Parts subjected to normal wear & tear like Clutch
entertained at all and such defective part/parts thus
Plates, Brake Shoes, Chain, Sprockets, Fork Oil Seal,
forwarded by them will lie at our factory at their own risk, Spark Plug, Control Cables, Brake Pads.
and this warranty shall not be enforceable.
3. Replacement of bulbs & rubber components like
To avail benefits of warranty, following are mandatory
grommets, ‘O’ rings, bellows as well as filters,
1. Availing of Initial 3 Free Services without lapse.
packings, gaskets, fasteners etc.
2. Availing paid services at subsequent 5000 kms. or
120 days from last service whichever occurs first 4. Painted parts. Only blistering or peeling off of paint film
are covered under warranty. Any defect arising out of
without any lapse.
external damages or due to usage of protective covers
3. Availing of all above services at the Authorised
/non-recommended protective coatings adverse
Vehicle Dealers & Recommended Authorised Service
atmospheric condition etc. is not allow like under
Dealers.
warranty.
4. Usage of only recommended engine oil
5. All consumables like Engine oil, Fork oil, Brake Oil,
“Bajaj DTS-i 10000” at specified frequency for drain
Grease etc. are chargeable to customer.
interval of 10,000 kms. & engine oil level top-up at
5000 kms. 6. Any defect arising due to above consumables not
5. Replacing mandatory periodic parts such as air filter, changed as per scheduled or if used other than the
oil filter etc. as per periodic maintenance schedule. 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 12. Vehicles which are not being serviced at
corrosion in coastal area or in acidic environment or recommended dealers as per the service schedule
due to neglected cleaning etc. However chrome film described or which have not been operated or
peeling is covered under warranty in general maintained in accordance with the instructions
maintained in the Owner’s Manual.
atmospheric conditions. Blue/ Yellow colouration of
silencer near exhaust port is permissible and hence 13. Vehicles used for any competition or race and/or for
not covered under warranty. attempting to set up any kind of record.
9. Oxidation of unpainted/painted crankcase, cylinder 14. Any failure arising due to use of adulterated or bad
quality fuel.
block, cylinder head etc. in acidic environment or in
a coastal area. Parts affected due to bad fuel quality are not covered
Under warranty.
10. Parts of the vehicle that have been subjected to
15. If additional electrical accessories such as -
misuse, accident, negligent treatment OR which have Remote, Bigger horn, Musical brake light etc. fitted on
been used in conjunction with parts & an equipment vehicle.
not manufactured or recommended for use by Bajaj 16. If the vehicle has been used for commercial purpose
Auto Limited, if in the sole judgement of Bajaj Auto like Taxi or any other means of commercial
Limited, such use prematurely affects the transportation.
performance and reliability of the vehicle. Bajaj Auto Limited reserves the right to make any changes in
11. Parts of the vehicle that have been altered and design or to add any improvements on the vehicle at any
modified or replaced in unauthorized manner like use time without incurring any obligation to install the same on a
vehicle previously supplied and sold. Also, the conditions of
of wider tyres, loud silencers etc and which in the this warranty are subject to alteration without any notice.
sole judgement of the Bajaj Auto Limited affects its
This warranty is the entire written warranty given by Bajaj
performance and reliability. 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. Age Specific Dealer’s Stamp * Code For Remarks:
Date Gravity Voltage Remarks & Signature * Code
No. Mths. LL : Low electrolyte level.
1 AE : Electrical system needs attention.
2 IR : Insufficient running of vehicle.
3 CB : Cover broken.
4 BC : Broken Container.
5 PM : Poor maintenance.
6 BA : Battery abused.

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.
 TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS
IN CASE OF CLAIM
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

# Claim Accepted ## Claim Rejected

Details of Repair, if any____________________________________________________________________________

Note:
Please contact nearest respective authorised battery dealer for details immediately after purchase of
vehicle.