Pulsar 125 Carb Advance

Advance Module 125 Carb.
125 Carb.
Engine & Brakes, Frame

Transmission & Suspension Electrical
 Engine Dismantling  Tightening Torques  Checking Procedure
 Engine Service Data  Service Limit  Do’s & Don’ts
 Engine Tightening Torque
 Important Skill Tips

Top side Dismantling 125 Carb.
Engine Dismantling
Remove:
• Cylinder head cover bolts
• Take out cylinder head cover & gasket.
Note - Always loosen cylinder Head mounting bolts in criss - cross

pattern
Remove:
• TDC finder cap
• Check the cam sprocket T mark.
Note - Align the rotor mark w.r.t Crankcase marking.
Remove:
• Cam chain tensioner bolt
• Rotate chain tensioner screw in clockwise
direction to take plunger backwards and lock it.
Engine Dismantling 125 Carb.
Remove :
• Chain tensioner
• Take out chain tensioner along with gasket.
Remove :
• Cam sprocket bolt
Special tool Part Number Application Photo
Cam sprocket To hold the cam

37 1043 07
holder sprocket
Remove :
• Cam sprocket
• Cam Sprocket Collar
Remove :
• RH & LH side spark plug by using spark
plug removing tool.
Spark plug To remove the

37 1043 56
removal tool RH spark plug
Remove :
• Spark plug sleeve using
Note : Do not pull spark plug sleeve by plier, to avoid any

damage on it.
Remove :
• Cylinder head bolt
1st
To remove the
Spark plug sleeve
37 1043 09 sleeve from
removing tool
cylinder head
Remove :
• Cam sprocket Circlip
• Circlip of rocker arm shaft (Inlet & Exhaust)
Remove :
• Rocker arm shaft (Intake & Exhaust) by using
rocker shaft removing tool
• Take out rocker arm & rocker arm shaft.
To remove the Rocker

Rocker Shaft Remover Tool 37 10CS 22
arm shaft
Remove :
• Intake & Exhaust valves along with -
 Retainer
 Valve spring
 Oil seal
 Valve spring seat using valve spring compressor.
Remove :
• Take out cam shaft assembly.
Adaptor & Valve Spring Compressor - 37 1031 07 To compress the

Compressor Adaptor - 37 1031 08 valve springs
Remove :
• Dowels on cylinder block.
• Cylinder head gasket.
Remove :
• Chain guide
• Cylinder block.
Remove :
• Dowels
• Cylinder block gasket.
Remove :
• Piston pin locking clip
• Piston pin
• Take out piston.
Note - Cover the crankcase bore with clean cloth
before removing piston pin locking clip .
Clutch Side Dismantling
Remove :
• Engine oil filter cover
• T spanner & take out engine oil filter
Remove :
• Clutch cover mounting
• Spanner & take clutch release shaft &
• Clutch cable bracket.
Remove :
• Clutch thrust bearing
• Primary gear nut with by using clutch nut
removing special tool.
• Clutch nut by holding the primary gear
Note - Lock the special tool between primary gear teeth &
clutch housing gear from top.
To hold the primary

Primary gear holder F4 1AJA 11
gear
To loosen / tighten
Clutch nut removing tool 37 1043 16 special nut
securing clutch
Take out :
• Clutch nut
• Belleville washer
• Plain washer
Remove :
• Clutch stack complete
• Plain washer.
Remove :
• Kick return spring
• Take out kick shaft assembly.
Remove :
• lever comp gear shift.
• Using clutch dismantling tool

Remove :
• 4 bolts
• 4 springs
• Clutch holder
• Clutch hub
• Friction plates
• Steel / pressure plates (4 Nos)
• Wheel clutch
To dismantle & assembled

Clutch dismantling tool 37 1043 58
clutch.
Remove :
• Inhibitor Assembly
• Guide gear shift
• Take out guide gear shift
Remove :
• Oil pump driven gear
• Oil pump screws
• Take out the oil pump
Remove :
• Primary gear nut
• Take out
 Belleville washer
 Plain washer
 Primary gear
Remove :
• Timing chain from sprocket
• Starter motor bolt
• Take out starter motor
Magneto Side Dismantling
Remove :
• Magneto cover bolts
Remove :
• Stator plate
• Pick up coil screws
Remove :
• Dowels
• Take out magneto cover gasket.
Remove :
• Gear starter clutch locking plate screw
• Rotor bolt
• Plain washer
Take out :
• Rotor
• Gear Starter Clutch
Remove :
• Magneto rotor key
• Starter counter gear assembly
To remove magneto
Magneto rotor puller 37 0043 69
rotor from crankshaft
Crankcase Splitting
Remove :
• LH crankcase bolts
• RH crankcase bolts
Put the engine on engine work

table
Remove :
• RH crankcase
Take out :
• Crankshaft
• Fork shaft
• Input & output fork shaft
Remove :
• Gear change drum
• Input fork & output forks
Remove :
• Input & output gear shaft assembly
• washer plain of input gear shaft.
Remove :
• Crankshaft damper from crankcase LH.
Crankcase RH Dismantling
Remove :
• Input shaft bearing locking plate
• Kick shaft locking plate bolts
Remove :
• Input shaft bearing using bearing driver set.
Remove
• Bolt gear shift change
• Gear change drum bush using bearing driver
set.
Crankcase LH parts removal :-
Remove
• Output shaft oil seal
• Gear change lever oil seal
Remove
• Output shaft bearing using bearing
driver set
• Neutral switch
Engine Service Data: 125 Carb.
Compression Pressure Valve Tappet Clearance
Std. Limit 12 ~ 13 kg/cm² Intake Exhaust

Std. Limit 0.05 mm 0.08 mm
Ser. Limit 9.5 kg/cm² Ser. Limit — —
Clutch Spring Free Length Friction Plate Thickness
Std. Limit 25.5 mm Std. Limit 2.9~3.0 mm

Ser. Limit 24.9 mm Ser. Limit 2.8 mm
Rocker Arm Shaft Diameter Cam Sprocket Diameter
Std. Limit 7.994 mm Std. Limit 59.91~60.11 mm
Ser. Limit — Ser. Limit —

Cam Lobe Height Cam Lobe Width
Intake Exhaust
Std. Limit 8.9~9.1 mm
Std. Limit 30.49 mm 30.44 mm
Ser. Limit 30.29 mm 30.24 mm Ser. Limit —

Valve Spring free Length Valve Stem Diameter
Intake Exhaust
Std. Limit 37.92 mm 4.475~4.490 4.455~4.470
Std. Limit
mm mm
Ser. Limit ----- Ser. Limit 4.465 mm 4.445 mm
Engine Service Data:
Valve Stem Bend

Valve Stem to Guide Clearance
Intake Exhaust
Std. Limit 0.01 mm
0.01 ~ 0.037 0.03 ~ 0.057
Std. Limit mm mm
Ser. Limit 0.015 mm 0.067 mm
Ser. Limit 0.047 mm
Cylinder Head Warp Camshaft Chain Length
Std. Limit 0.03 mm Std. Limit 127.00 ~ 127.05 mm

Cylinder Inside Diameter Piston Diameter
Group A 51.965 +0.007 mm

Std. Limit 52 ~ 52.010 mm
Group B —
Cylinder Piston Clearance Piston Ring Groove Clearance
Top Second Oil Ring

Std. Limit 0.028 ~ 0.052mm
Std.Limit 0.020 ~ 0.02 ~ 0.04 ~ 0.110
0.050 mm 0.055 mm mm
Ser. Limit 0.1 mm Ser.Limit 0.15 mm 0.15 mm 0.16 mm
Steel Plate Wrap Piston Ring End Gap
Top Second Oil Ring

Std. Limit 0.1 mm 0.1 ~ 0.25 0.15 ~ 0.3 0.2 ~
Std. Limit mm mm 0.7 mm
Ser. Limit 0.15 mm Ser. Limit 0.5 mm 0.7 mm 1 mm
Friction Plate Wrap Gear Shift Fork Guide Pin Diameter
Std. Limit 0.1 mm Std. Limit 4.45 ~ 4.49 mm

Shaft Fork Shift O.D Rocker Arm I.D
Std. Limit 9.972 ~ 9.987mm Std. Limit 10 ~ 10.022 mm

Steel Plate Thickness Gear Shift Drum Groove Width
Std. Limit 1.6 ~ 1.7 mm Std. Limit 4.55 ~ 4.7 mm

Engine Tightening Torque 125 Carb.
Spark Plug Oil Strainer Cap (18 mm A/F)
Tightening torque Tightening torque

1.3 ~ 1.5 kgm 0.7 ~ 0.8 kgm
Cap Oil Filter Cover Bolts Chain Tensioner Mounting Bolts

1.0 ~ 1.1 kgm 1.0 ~ 1.1 kgm
Cylinder Head Cover Bolts Output Sprocket Bolts

1.0 ~ 1.1 kgm 0.8 kgm
Clutch Cover Bolts Oil Pump Mounting Screws

1.0 ~ 1.1 kgm 0.8 ~ 0.9 kgm
Crankcase Joining Bolts Magneto Cover Bolts

1.0 ~ 1.1 kgm 1.0 ~ 1.1 kgm
Nut Securing Primary Gear Cam Shaft Sprocket Allen Bolt

6.0 ~ 6.5 kgm 1.6 ~ 1.8 kgm
Engine Tightening Torque
Nut Securing Clutch Assly. Magneto Rotor Mounting Nut

6.0~6.5 kgm 6.0~6.5 kgm
Stator Motor Mounting Nut Inhibitor Nut

0.7~0.8 kgm 1.0~1.1 kgm
Drum/Cam Allen Clutch Spring Bolts

Bolt

1.0~1.1 kgm 1.0~1.1 kgm
Manifold Mounting Bolts Cylinder Head Big Bolts

1.0~1.1 kgm 2.2~2.5 kgm
Important Skill Tips 125 Carb.
TDC Position for Valve Timing
Check piston TDC position, Valve timing & Valve

Tappet clearance before dismantling cylinder head.
Intake Valve
Tappet clearance: 0.05 mm
Exhaust valve
Tappet clearance: 0.08 mm
Cylinder Head Bolts loosening

sequence
Always loosen cylinder head

short bolts first & then loosen
cylinder head long bolts (4 no's)
in crisscross pattern.
Piston Pin Circlip
While removing / refitting piston pin Circlip

(snap ring), cover the crankcase bore with
clean lint free cotton cloth to arrest Circlip /
snap ring falling inside the engine so as to
avoid subsequent un- necessary opening of
engine.
Primary Gear Holding
While loosening ‘Primary Gear

Nut’ & ‘Clutch
Special Nut’, hold ‘Primary
Gear’ & ‘Clutch Housing Gear’
by placing special tool from top.
Piston Ring Fitment

1
• Piston rings must always be fitted with respect to exhaust
2 mark on the piston
3 Front Top 1 Mark Top
ring
• First place the bottom oil rail ring with end gap 30º towards
4
left of the exhaust mark in the last groove.
3
Exhaust
Top 2 Mark 2nd
ring • Place oil expander ring with butting end downward & end
Arrow
gap facing opposite to the exhaust mark.
• Now fit top oil rail ring on the expander ring with end gap 30º towards right of the exhaust mark.
• Fit the second piston ring with ‘Top 2’ mark facing upward and end gap facing opposite to the exhaust mark.
• Finally fit the first ring with ‘Top 1’ mark upward and end gap facing towards the exhaust mark.
• Remember fitment of 2nd ring upside down may lead to passing of oil above the piston and ultimately leading to smoky exhaust.
Clutch Washer Sequence

A A : Special nut
B : Belleville washer
C : Plain washer
D : Clutch stack
E : Clutch housing
B F
G
F : Clutch Spacer
C
G : Plain washer
D
E
When removing oil filter…
Use external expanding Circlip plier to pull out the oil filter.
Clutch Special Nut
• Special nut for clutch on Input shaft is having left hand

threading.
Loosening direction :Clockwise Tightening direction :
Counter-clockwise.
• Use special tool while loosening / tightening special nut.
Using engine heater heat the crank case clutch side

for smooth & easy fitment of crankshaft bearing.
Ensure oil passages are not blocked.

125 Carb.
Brakes frame &

Suspension
• Tightening Torques
• Service Limit
Tightening Torques 125 Carb.
Front Axle Nut RSA Lower Bolt
4.5 ~ 5.5 kgm 2.8 ~ 3.2 Kgm
Rear Axle Nut Rear Sleeve Nut
8 ~ 10 Kgm 3.0 ~ 4.0 Kgm

Rear Sprocket Mounting Nut Fork Centre Nut
3.2 ~ 3.8 Kgm 5 Kgm
Handle Bar Holder Bolts Steering Stem Nut Slotted
2.0 ~ 2.2 Kgm 0.5 Kgm

RSA Mounting Nut (Upper) Swing Arm Shaft
3 ~ 3.2 Kgm 4.5 ~ 5.5 Kgm
Disc Mounting Bolt (Front)
2.7 ~ 3.3 Kgm

Service Limits 125 Carb.
Brake Pad Thickness-Front Front Disc Run Out Axial Wheel Run Out
Std. Limit 5 mm
— Std. Limit — Std. Limit TIRTIR
0.80.5
mmororless
less
Ser. Limit 1 mm
— Ser. Limit 0.15 mm Ser. Limit TIR2.00.2mm
TIR
Service Limits
Radial Wheel Run Out Tyre Tread Depth Rear Sprocket Warp
Front Rear
Std. Limit TIRTIR
0.80.5
mmororless
less 5 mm 6.5+0.3mm
Std. Limit 5.3+0.3mm 1 mm Std. Limit TIRTIR
0.20.4
mmororless
Less
Ser. Limit TIR2.0
TIR 0.2mm 6.8 mm
Ser. Limit Upto 1.5 mm
TWI Upto TWI Ser. Limit TIR
TIR0.5
0.5 mm
Drive Chain Slack Front Fork Oil Grade & Capacity Drive chain Length
SAE 10W20
Grade : 20 Link Length
Fork Oil Level

SAE 10W20
Bajaj Genuine
Bajaj Genuine
Fork
ForkoilOil
Capacity
Quantity :
140O/H:
+/- 320 + 2.5ml
2.5 ml/
Drain & Refill:
leg295+2.5ml
assly (Drain 1st 2nd 20th
& (Per
Refill)
Fork Leg
Assly) MEASURE THIS LENGTH
Std. Limit 25
20–~30
25mm
mm Std. Limit N/A mm
36.186 Std. Limit 254.0
254- 254.6 (20 links)
(20 Links)
Ser. Limit 3540~mm
40 mm Ser. Limit N/A
35 mm Ser. Limit 259links)
260 (20
Service Limits
Axle Run Out
100 mm
TIR mm
Std. Limit TIR 0.1 0.05or
mmLess
Ser. Limit TIR 0.2
TIR 0.2 mm
mm
125 Carb.
Electrical
• Checking Procedure
• Do’s & Don’ts
Electrical Checking Procedure 125 Carb.
Battery Charging Coil
Measuring & Testing Equipment : Multimeter
Continuity
Meter Range Wire Connections
Check
Meter +ve Meter –ve
200 Ohms Blue-White or Blue-White or 0.5 + 0.1 Ohms
Yellow Yellow
SOP :
• Switch OFF engine.
• Disconnect stator plate coupler.
• Connect multimeter between two Blue / White wires.
• Check resistance value between Blue / White & Blue / White.
Pick-up Coil Resistance
Continuity
Check
200 Ohms 215 + 20 Ohms
White / Red Black / Yellow
SOP :
• Switch Off Ignition Key.
• Disconnect Stator Plate Coupler.
• Connect multimeter between White / Red & Black / Yellow wires.
• Measure resistance.
Battery Charging Voltage Measurement
Continuity
Check
20 K Ohms Battery +ve Battery -ve 14.4 + 0.2 Ohms
terminal terminal
Horn
Meter Range Connections Continuity Check
Encircle clamp meter jaws

200 DC A 2.2 Amp
around Brown wire of horn
SOP :
• Encircle clamp meter jaws around Brown wire of Horn.
• Press horn switch & check instantaneous current drawn by horn.
Fuel Gauge – Tank Unit
Continuity
Check
As per chart
20 K Ohms
White / Yellow Black / Yellow given below
ON Resistance OFF Resistance

Of Bar Displayed
(Ω) with tolerance of + 2 Ω (Ω) with tolerance of + 2 Ω
1st Bar 62 71
2nd Bar (Reserve zone) 52 57

3rd Bar 44 48
4th Bar 37 40
5th Bar 24 30
6th Bar 14 20
Note :
If display in speedo console is not proper then please check following -
• Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is firm.
Starter Relay
Continuity
Check
200 Ohms Starter relay coil Starter relay coil 3.1 Ohms + 10%
Red-Yellow wire Black wire
SOP :
• Switch OFF engine.
• Disconnect coupler from Relay.
• Connect multi meter to Starter Relay coil terminals.
• Check resistance.
Starter Relay Continuity Checking
Measuring & Testing Equipment : Multi meter

SOP :
• Connect external 12V DC supply to starter relay coil terminals.
• ‘Tuk’ sound will be heard.
• Set multi meter on continuity mode.
• Connect multi meter at relay contact terminals.
• Continuity (beep sound) indicates starter relay is OK.
Spark Plug
SOP :
• LHS & RHS spark plug - Make - BOSCH UR4AC or Champion -
Type - PRZ9HC
• Spark Plug Gap 0.7 ~ 0.8 mm
• Clean & adjust frequency - every 10,000 Kms.
• Replacement frequency 30,000 Kms.
Spark Plug Cap
SOP :
• Remove spark plug cap from HT coil cable.
• Set multi meter on 2 K Ohm range.
• Connect multi meter probes as shown in photograph.
• Standard value, 1 K Ohm + 150 Ohm.
DO’S & DON’TS 125 Carb.
Horn
Do’s: Don’ts:
• Adjust horn sound by rotating the • Never adjust the nut on horn cap side and bracket end
Philips screw in the direction of (horn back side) as it will result in horn
arrow provided on horn. malfunctioning & failure.
• Do not remove silicon sealant from adjustment screw
as it will result in water entry inside the horn.
DO’S & DON’TS 125 Carb.
Switches
Do’s: Don’ts:
• After washing the vehicle • Do not apply direct pressurized
ensure to apply dry air on water jet on control switches.
switches before operation.
• Do not lubricate electrical
• Ensure that grommets switches by oil or grease.
provided on clutch switch,
front brake switch and rear • Do not over tighten the
brake switch are intact. switch mounting screw.
125 Carb.
Thank you…!

Pulsar 125 Carb Advance

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Pulsar 125 Carb Advance

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Advance Module 125 Carb.

Engine & Brakes, Frame

 Engine Dismantling  Tightening Torques  Checking Procedure

 Engine Service Data  Service Limit  Do’s & Don’ts

 Engine Tightening Torque

 Important Skill Tips

Note - Always loosen cylinder Head mounting bolts in criss - cross

Special tool Part Number Application Photo

Cam sprocket To hold the cam

Special tool Part Number Application Photo

Spark plug To remove the

Note : Do not pull spark plug sleeve by plier, to avoid any

Special tool Part Number Application Photo

Special tool Part Number Application Photo

To remove the Rocker

Special tool Part Number Application Photo

Adaptor & Valve Spring Compressor - 37 1031 07 To compress the

Clutch Side Dismantling

Special tool Part Number Application Photo

To hold the primary

• Using clutch dismantling tool

Special tool Part Number Application Photo

To dismantle & assembled

Magneto Side Dismantling

Special tool Part Number Application Photo

Put the engine on engine work

Crankcase LH parts removal :-

Compression Pressure Valve Tappet Clearance

Std. Limit 12 ~ 13 kg/cm² Intake Exhaust

Clutch Spring Free Length Friction Plate Thickness

Std. Limit 25.5 mm Std. Limit 2.9~3.0 mm

Rocker Arm Shaft Diameter Cam Sprocket Diameter

Std. Limit 7.994 mm Std. Limit 59.91~60.11 mm

Ser. Limit — Ser. Limit —

Cam Lobe Height Cam Lobe Width

Ser. Limit 30.29 mm 30.24 mm Ser. Limit —

Valve Spring free Length Valve Stem Diameter

Engine Service Data:

Valve Stem Bend

Cylinder Head Warp Camshaft Chain Length

Std. Limit 0.03 mm Std. Limit 127.00 ~ 127.05 mm

Ser. Limit 0.05 mm Ser. Limit 127.254 mm

Cylinder Inside Diameter Piston Diameter

Group A 51.965 +0.007 mm

Cylinder Piston Clearance Piston Ring Groove Clearance

Top Second Oil Ring

Steel Plate Wrap Piston Ring End Gap

Top Second Oil Ring

Friction Plate Wrap Gear Shift Fork Guide Pin Diameter

Std. Limit 0.1 mm Std. Limit 4.45 ~ 4.49 mm

Ser. Limit 0.15 mm Ser. Limit 4.4 mm

Shaft Fork Shift O.D Rocker Arm I.D

Std. Limit 9.972 ~ 9.987mm Std. Limit 10 ~ 10.022 mm

Ser. Limit 9.96 mm Ser. Limit 10.03 mm

Steel Plate Thickness Gear Shift Drum Groove Width

Std. Limit 1.6 ~ 1.7 mm Std. Limit 4.55 ~ 4.7 mm

Ser. Limit 1.5 mm Ser. Limit 4.75 mm

Spark Plug Oil Strainer Cap (18 mm A/F)

Tightening torque Tightening torque

Cap Oil Filter Cover Bolts Chain Tensioner Mounting Bolts

Tightening torque Tightening torque

Cylinder Head Cover Bolts Output Sprocket Bolts

Tightening torque Tightening torque