Bajaj Discover Ownership Thread

[Discover Tourer]

help of in changing my bike's clutch plates and oil seal

I've bajaj discover 125 2006 model it is DTS-i I want to change the clutch plates and the faulty timing chain please help me in changing them and tell me the tools and it's size that needed for the work

[sarada06884]

Re: Bajaj Discover Ownership Thread

I've bajaj discover 125 2006 model it is DTS-i I want to change the clutch plates and the faulty timing chain please help me in changing them and tell me the tools and it's size that needed for the work

Yes you can change the clutch plates yourself provided you have all the requisite tools. You need to have a number 10 T spanner to open the clutch case. You have to open the kick lever to get the clutch out. You need to inspect the clutch by the number of holes it has. Some clutch plates have four holes and some five holes. Also you need special tools to open the bolts on the clutch Bell and plates. It's quite impossible to open without these special tools. If you have all these tools then it can be done. Removing and replacing a timing chain is a job which needs high precision. You need to open the head cap and align the engine at TDC. Then you need to remove the rocker arm assembly and the head. It can also be done at home provided you have expertise

[TunaFish]

Discover 100 Lose Rubber Sprocket

Hello Forum,

Sorry if you see another post with same title. I tried to post earlier but I am not sure if it went through or not due to internet problem. So I am posting again.
I want to know about the cushion rubber inside the sprocket of rear wheel. The mechanic told me it is faulty so I replaced it on his advice but I don't feel any difference while riding. I can still hear a " Thud " sound and a slight jolt when I twist or release the throttle. He told me that it happens when the cram rubber inside the sprocket wears out.
I will take it back to him next week. or Should I see another mechanic ?

I have Discover 100M.

[anirudh.88]

Bajaj Discover Wiring Issue

Hi,
I am having a strange electrical problem with my Bajaj Discover old model ( 2005 ).
I dont have much knowledge about motorbikes wiring so maybe you guys can help.
1) My bike neutral ( green light),high/low beam (blue light) and indicators lights (green light) on the dash (next to key lock) are not working.
2) Indicators and horn are not working as well.
3) But the Headlight , parking bulbs (2 of them above headlight) and the speedometer,fuel meter illumination lights are working.




2-3 days back I was getting a cracking /sparking sound from the black colored Relay which is underneath the petrol tank.
( I went to mechanic when i heard that sound and he checked it ).
When that sparking sound was coming all the above mentioned lights (points 1 & 2) were also flickering.
The mechanic told me that relay is bad. But after he did some digging there was water in one of the connector behind the Headlight.
He removed the water and everything worked fine. But now again this problem started.

I went to mechanic today he told me that the battery charger is spoiled.
Maybe by charger he means Regulator rectifier, I am not sure. It looks like he doesn't know much and says anything when he cant find the fault.

Also looks like my battery has also died becoz of this, but the lights used to work even without the battery when i start the bike
without the battery. Can anyone help regarding this.
Also is there a way I can test charger and the relay. I have a Digital multimeter with me.


Also another mechanic tried testing with a new battery. But that caused all the wires heat up so he quickly removed it.

Thanks in Advance for your help.

[TunaFish]

Re: Bajaj Discover Ownership Thread

Mine is red and black in color with 4 gears. Mileage is awesome. Done 5160 KMs on it so far. Longest ride was 92 kms once. mostly ride within city.

[babybiker125]

Need toe only shifter for Bajaj Discover 125 (2015 model)

Hello Members,

I have been riding my discover for a year now. I like everything of the bike except only one thing, the heel and toe shifter. Is there any way to install the toe only shifter that is used in pulsar 135? Many times my size 9 shoes gets stuck between the shifter and accidentally hit neutral. It's the only thing I hate about the bike. I don't get it! Why does only the Pulsar models have the toe shifter, and the discovers have to do with the stupid heel and toe one? Does it cost so much? Please help me.

Thank you,
Subhasis.

[babybiker125]

Re: Bajaj Discover Ownership Thread

How to replace heel and toe shifter with toe only ????

[anirudh.88]

Bajaj Discover 2005 (1st model) Self Start in gear mode Issue..

Hello xbhpians,

I am having an unusual issue with the self start in my bajaj discover 125cc 2005 model..
I recently put a new exide 9ah battery on my bike.

So the thing is the self start on my bike works fine when i use it on neutral. Bike starts in an instant.
The problem comes when i use it on any gear. Like 1st gear or 2nd gear or when sometimes bike turns off while driving on the middle of road.

First the bike self start works even without the cluth held on any gear.. The self start tries to start the bike on all gears without the clutch held which gives a jerk and then stops. I think it should not happen.

Secondly, Today i tried starting the bike on 1st gear with the clutch held.. What happen was initially the bike was not starting, after some time the bike started with very low power like the petrol tank is about to get empty...( I had to keep giving accelerator , felt like engine was not getting petrol ).. So i pulled the choke which started the bike properly...

After which I again tried Self start on neutral which worked fine.

Then again i tried to check self start on 1st gear with clutch held which gave me the same problem..
When ever i use self with clutch held on any gear the engine dosent start properly..

I checked the petrol which is about half tank full..

I tried local mechanics shops to rectify but none of them are able to help much..

Any help would be appreciated guys..

[The Monk]

Re: Bajaj Discover 2005 (1st model) Self Start in gear mode Issue..

Hello xbhpians,



Any help would be appreciated guys..

It sounds less like a fuelling issue and more of an electrical issue. The Pulsars often used to face this. There is a clutch switch, which gets activated when you pull in the clutch lever which allows the motorcycle to be started in gear.

If that switch gets carbon deposits then this problem occurs. I say this since your bike starts perfectly in neutral.

Check this out and hopefully your problem should be solved. Cheers

[anirudh.88]

Re: Bajaj Discover Ownership Thread

Thanks to The Monk...


Today I went to the mechanic and asked them to look the clutch switch...
They said its working fine infact what it was doing was totally opposite...

When the clutch is applied it disconnects the two wire coming out of it...
and when the clutch lever is left it connects them...

I searched for the clutch switch at 5-6 different shops but no luck.. as all of them had for pulsar which had smaller bearing and wont fit in my bike...

Atlast i bought the pulsar one and removed the internal socket of it into my clutch switch...

Worked like a charm.....

One more thing I want to ask if anyone knows how to repair the reciever unit of fuel gauge (the one at the front which shows fuel reading ).
Mechanics are asking to replace this as it is not repaired..

Mine always shows full tank when the sender unit wire is connected.. and 3/4 tank full when the wire is disconnected..

I have checked the two wire in the socket coming from petrol tank with a multimeter and they show a resistance of 40 ohms...So i guess the sender unit ( float and stuff ) are working properly ..


Also I want to know if my bike has DC wiring or AC wiring... as i want to change the headlight and parking bulbs with LEDs...

[Ajit Datta]

bajaj discover 112 cc troubleshooting.

hello,
I'm new to xbhp and I have a bajaj discover 112cc 2007th bike, after a long time in 2015 my bike stop automatically on road when accelerate, and milege comes to 45kmpl, then I contact a good mechanic and a new bore, piston clutch plate new valves new exhaust pipe I have changed.
After 1.5 year i mean now I heard tappet sound and he just tighten the tappet after that my bikes engine sound become 'kdak kdak' when I accelerate.
After that I contact that mechanic, he told me that the roker arm's rollers are damaged have change it, I said okay then he changed that rokerarm new set genuine parts. He cost me 800
600/- for rokerarm
200/- for labour charge
but after that I heard that "kdak kdak" sound more, he told me that it's my bikes connecting rod sound, my bikes connecting rod free play sound,
he said totally engine work to be done, he estimated 8000/- for engine work, I didn't give him my bike till now.
Please help me guys, what's the problem in my bike and what will I do.?
I'm requesting you to please help me.
Thank you in advance.

[Ajit Datta]

Re: Bajaj Discover Ownership Thread

Any experts....Please help me..

[sarada06884]

Re: Bajaj Discover Ownership Thread

Hi to all the members of the forum,

I am again facing a strange problem with my discover 100 cc DTSi motorcycle (04 year old and run for 72000 km). Of late it has been consuming engine oil at approximately 200-250 ml for every 500-600 km. on hard revving it is emitting a little or faint black smoke from the exhaust. This bike had been consuming oil as I have posted earlier. Ironically this had come down I the winter as the temperatures are shooting Up I have observed that the bike is gulping oil. I use Castrol 20W-40 in my Bike. The pickup and mileage are absolutely normal (70 Kmpl) i city traffic. I am not facing any other problems like starting or stalling. Also examined the spark plugs they are in good coke colour. All the periodic maintenance is done by me and is done promptly. (Oil change at 2000 km, air filter change, spark plug adjustment and timely replacement of required parts ) The air filter was changed only some 600 km ago. As usual the mechanic is of the opinion that the vehicle needs to be re-bored to get rid of this oil consumption issue. isn't 72000 too early for a rebuild. Kindly suggest what might have gone wrong.

Since the pickup and mileage are absolutely normal (70 Kmpl) in city traffic, I am not convinced with the mechanics opinion. I suspect that several things like Oil seals, valves, valve guides have gone wrong or may be only the piston rings. Oil seals, valves, valve guides if found defective will be replaced. In case of strip down of the top end I am in two minds:

• Suppose it is only the piston rings that have gone wrong and the entire block and piston is ok can I go with replacement of only the piston rings?
• In case it needs a rebuild, I want to go for a new block piston kit instead of reboring. Now I would like to know the cost of the components

1. New Block Piston Kit.
2. New Valves
3. Oil Seals
4. Any other parts that are to be replaced.

I request the knowledgeable members of this forum to throw some light o this issue and also about the cost of these spares.
Thanks in advance

Regards

P.S.Srinivas