Professional Documents
Culture Documents
TECHNICAL SPECIFICATIONS
P.D.I. CHECK LIST
PERIODIC MAINTENANCE AND LUBRICATION
ENGINE EXPLODED VIEW
TIGHTENING TORQUES
SERVICE DATA
WIRING DIAGRAM
CIRCUIT DIAGRAMS & RESISTANCES
WARRANTY AND SERVICES
WORKING OF BSV, SAI & PCV
TROUBLE SHOOTING FOR SAI & BSV SYSTEM
IMPORTANT ENGINE ASSEMBLY TIPS
CO% CHECKING & TUNE-UP
FREQUENTLY ASKED QUESTIONS (FAQs)
TECHNICAL SPECIFICATIONS
TECHNICAL SPECIFICATIONS
Type
Transmission
No. of cylinders
One
Bore
54.00 mm
Stroke
54.40 mm
Engine displacement
124.60 cc.
Compression ratio
Idling Speed
9.3 + 0.5 : 1
1400-1550 rpm (Warm condition with SAI)
Ignition system
Electronic ignition
Ignition Timing
Fuel
Unleaded Petrol
Carburettor
Spark Plug
0.6 to 0.7 mm
Lubrication
Starting
Kick start
Clutch
Wet, multidisc
st
1 Gear
2nd Gear
3rd Gear
4th Gear
5th Gear
33.09
20.22
14.90
11.95
10.11
03.14 : 1 (44/14)
03.21 : 1 (74/23)
:
:
:
:
:
1
1
1
1
1
(36/11)
(32/16)
(28/19)
(26/22)
(24/24)
Brakes Type
Front
Rear
Drum or Disc
Mech. expanding shoe & drum
Brake Size
Front
Rear
Tyre
Front
Rear
Tyre Pressure
Front
Rear
Rims
DIMENSIONS
Front
Rear
1.6 x 18
1.85 x 18
13 Litres
2.5 Litres
2.0 Litres
CONTROLS
Steering
Accelerator
Gear
Clutch
Brakes
Front
Rear
Handle bar
Twist grip on R.H.S. of handle bar
Left foot pedal operated
Lever operated on L.H.S. of handle bar
Lever operated on R.H.S. of handle bar
Right foot pedal operated
ELECTRICALS
System
Head lamp
Pilot lamp
Tail/stop lamp
Turn signal lamp
Neutral indicator lamp
Turn pilot ind. lamp
Speedometer lamp
Horn
Battery
12 Volts AC + DC
35/35 W-HS1
4W
5 / 10 W
10 W
3.4 W
3.4 W
3.4 W
12 V DC
12 V - 2.5 Ah
Length
Width
Height
Wheel base
Min. Turning circle radius
Min. Ground clearance
2025 mm.
740 mm.
1115 mm.
1260 mm.
2040 mm.
155 mm.
WEIGHTS
Vehicle kerb weight
Gross vehicle weight
121 kg.
251 kg.
PERFORMANCE
Maximum speed
Climbing ability
NOTES :
Values given above are nominal and for guidance only. 15%
variation is allowed to cater for production and measurement
variation.
All dimensions are under unladen condition.
Definitions of terminologies wherever applicable are as per
relevant IS / ISO standards.
Specifications are subject to change without notice.
P. D . I . C H E C K L I S T
TO CHECK
CHECK FOR
ENGINE :
P. D . I . C H E C K L I S T
TO CHECK
Idling Speed
Kick operation
Smooth Operation
Spokes
Drive chain
DIRECTION OF
CHAIN ROTATION
Leakages / Fitment
Fuel Tap
Smooth operation
Carburettor
FRAME :
A) WHEELS
Tyre Pressure
Front - 25 PSI
Rear - 28 PSI (Solo), 32 PSI (Double)
E) FASTENERS
B) CONTROLS
Brakes
Clutch
Throttle
ELECTRICAL
A) BATTERY
FUEL SYSTEM :
Fuel Tank / Pipes
TO CHECK
Choke
CHECK FOR
FRAME :
FRAME :
CHECK FOR
C) SUSPENSION
Front fork
Steering
D) LOCK OPERATION
TO CHECK
CHECK FOR
ELECTRICAL
(Check torque & correct if required)
Front axle nut (5.0 to 6.0 kgm.) Check split pin
Rear axle nut (6.9 to 7.1 kgm.) Check split pin
Fork lower clamping bolt (3.2 to 3.8 kgm.)
Trailing arm nut (5.5 to 6.5 kgm.)
Rear shock mounting nut (4.0 to 5.0 kgm.)
Steering top bolt (2.0 to 3.0 kgm.)
Holder handle upper bolts (4 Nos.)
(2.0 to 2.6 kgm.)
Holder handle nuts (2 Nos.) (3.5 kgm.)
Front brake disc install bolt (2.2 to 2.6 kgm.)
Caliper install bolt (2.2 to 2.8 kgm.)
C) HORN
Horn working
D) SWITCH OPERATION
B) DRIVE ABILITY
C) CO % CHECK
D) CLEANING
Frequency
Which
ever
comes
first
Operation
1.
Servicing
2.
Valve clearance
3.
4.
5.
Oil strainer
Cl
6.
Cl
7.
8.
Cl, A
9.
C, R
10.
Fuel pipes
11.
12.
Spark plug
13.
C, A
14.
C, Cl
15.
C, A
Top-up
Subsequent
6,000
Every 6,000 km
Every 6,000 km
Every 6,000 km
Every 6,000 km
Every 12,000 km
Every 6,000 km
l
4 Years
l
Cl, A
l
Every 12,000 km
15 days
l
l
l
l
16.
17.
18.
C, R
19.
Steering play
C, A
20.
Adjust
Clean
Check
Lubricate
Tighten
Replace
Sr.
No.
Frequency
Which
ever
comes
first
Operation
21.
22.
General lubrication
C, R
l
6,000
23.
2 Years
2 Years
25.
Wheel bearing
1 Year
l
l
26.
27.
Drive chain
Every 500 km
28.
Every 1000 km
29.
Cl, L
31.
33.
34.
Month
35.
4 Years
C, A
R
2 Years
C, A
36.
4 Years
37.
2 Years
32.
: Indicates operation to
be performed.
Subsequent
24.
30.
Adjust
Clean
Check
Lubricate
Tighten
Replace
BSV VALVE
DRAIN BOLT
SPARK PLUG
NEUTRAL SWITCH
10
STEERING NUT
11
12
S E R V I C E D A TA - E N G I N E
PISTON/CYL. CLEARANCE
0.018-0.042
Standard
--Service Limit
11.98-11.99
Standard
Service Limit 11.96
Standard
Service Limit
12.00 to 12.018
12.05
5.9-6.0
5.8
Standard
Service Limit
S E R V I C E D A TA - E N G I N E
Standard
Service Limit
TIR 0.01
TIR 0.05
0.4 or less
Standard
Service Limit TIR 0.1
VALVE CLEARANCE
CAM HEIGHT
CARBURETTOR SPECIFICATIONS
COMPRESSION PRESSURE
20-link length
10mm
20mm
40mm
1st
2nd
21st
41.50
39.70
PISTON DIAMETER
Service Limit
0.05
Standard
Service Limit
6.05-6.20
6.3
Standard
Service Limit
127.00 to 127.30
128.9
Standard
Service Limit
54.00-54.012
54.10
Standard
Service Limit
0.1-0.2
0.4
Standard
Ex. 0.08-0.12
Inlet 0.05-0.08
Standard
Service Limit
12.0-14.0 kg/cm
9.1-14.0 kg/cm2
13
Idling speed
VC screw
2.5 + 1 Turn
Jet needle
clip position
Main jet
#105
Pilot jet
#15
CO%
Grade
SAE20W40 OF API SG + JASO MA
Quantity
1100 ml (Newly assembled engine)
950 ml (Drain & Refill)
Oil change frequency
Every 6,000 km
Check & Top-up if required.
5mm
53.970-53.982
Standard
53.82
Service Limit
Wind 125
Standard
Service Limit
Item
TOP
SECOND
0.02-0.06 0.01-0.05
Std.
0.15
Ser. Limit 0.16
Standard
Service Limit
Exhaust
1.15-1.45
0.5
Inlet
0.85-1.15
0.5
Standard
Service Limit
Exhaust
4.958-4.973
4.94
Inlet
4.975-4.990
4.96
Standard
Service Limit
TOP
0.15-0.30
SECOND
0.30-0.45
0.6
0.7
Standard
Service Limit
3.5-3.6
3.2
Standard
Service Limit
2.9-3.0
2.6
Standard
Service Limit
0.2
0.3
14
WIRING DIAGRAM
FRONT BRAKE
SWITCH
TURN SIGNAL
RELAY
FUEL LEVEL
GAUGE
REAR BRAKE
SWITCH
PO
ON
OFF
Standard
Service Limit
7.4
3.8
Standard
Service Limit
4.3-4.7
2.3
Br
L/W
Br
Br
W/Y
B/Y
W/Y
B/Y
L
L
B/Y
FUSE 10A
W/R
Y
B/Y
W
Br
Br
R/W
R/W
B/Y
W/Y
Lg
Gr
G
R/B
NEUTRAL INDICATOR
LAMP 12V3.4W
W/B
11.96-11.98
Standard
Service Limit 11.88
B/Y
W/Y
Lg
Gr
G
R/B
12.0-12.027
Standard
12.15
Service Limit
B
Br
R/L
FUEL METER
100 mm
B
Br
BATTERY
12V2.5AH
W/R
REGULATOR
TACHOMETER
ILLUMINATION 12V3.4W
20-link length
B/Y
Br
IGNITION
SWITCH
2nd
OFF LOCK
1.2 or less
Standard
2.0
Service Limit
Standard
Service Limit
4.9
1.0
Standard
Service Limit
130-130.16
130.75
Standard
Service Limit
B/Y
B/Y
B/Y
21st
1.0 or less
Standard
2.0
Service Limit
SIGNAL
LAMP
REAR R.H.
12V10W
Br
W
ON
1st
Gr
254-254.5
259
SIGNAL LAMP
FRONT R.H.
12V10W
Gr
Gr
B/Y
B/Y
B/Y
B/Y
SIGNAL
LAMP
REAR L.H.
12V10W
R/B
HEAD LAMP
12V35/35W
B/Y
B/Y
Br
L/Y
B/Y
Y
Lg
L/Y
W/R
IGNITER
COIL
PULSING
B/Y
Br
SIGNAL LAMP
FRONT L.H.
12V10W
W
Y
G
L
B/Y
B/Y
Y
R/W
B/Y
B/Y
Y
Br/W
R/Y
R/L
R/B
Gr
O
G
POSITION
LAMP 12V5W
R/Y
R/W
R/B
Gr
O
G
B/Y
R/Y
B/Y
R/B
Standard
Service Limit
15
6.8
2.0
20 to 30
Standard
--Service Limit
Standard
Service Limit
--TIR 0.5
HI R
LO
DIMMER
SWITCH
TURN
SIGNAL HORN PASSING
SWITCH SWITCH SWITCH
SPARK
PLUG
HORN
12V2.5A
EARTH
FRAME
IGNITION
COIL
NEUTRAL
SWITCH
MAGNETO
16
W/R
BATTERY
12V2.5AH
TACHOMETER
B
B/Y
B/Y
Br
Br
B/Y
W/B
W/B
B/Y
FUSE 10A
R
FUSE 10A
W/R
B/Y
BATTERY
12V2.5AH
G
Br
REGULATOR
W/R
IGNITION
SWITCH
Br
OFF LOCK
Br
L/Y
B/Y
L/Y
W/R
ON
Br
EARTH FRAME
17
B/Y
B/Y
IGNITER
COIL
PULSING
IGNITION
COIL
SPARK
PLUG
MAGNETO
18
ON
Br
W/R
B/Y
B/Y
B/Y
B/Y
B/Y
B/Y
Br
B/Y
O
B/Y
ON
B/Y
OFF LOCK
Br
Br
W
B/Y
B/Y
SIGNAL LAMP
REAR L.H.
12V10W
B/Y
O
G
Gr
Gr
Gr
W/B
SIGNAL LAMP
REAR R.H.
12V10W
IGNITION
SWITCH
Gr
B/Y
FUSE 10A
Gr
B/Y
SIGNAL LAMP
FRONT L.H.
12V10W
W/Y
W/B
Br
Gr
OFF LOCK
SIGNAL LAMP
FRONT R.H.
12V10W
W/Y
FUEL METER
IGNITION
SWITCH
BATTERY
12V2.5AH
FUSE 10A
Br
B/Y
G
TURN SIGNAL INDICATOR
LAMP R.H.12V3.4W
Br
W/Y
Gr
B/Y
Gr
W/Y
B/Y
R
B/Y
BATTERY
12V2.5AH
G
W/R
EARTH FRAME
B/Y
EARTH
FRAME
19
20
L
L
BATTERY
12V2.5AH
W/B
B/Y
FUSE 10A
Br
Br
B/Y
R/B
R
R/B
R/W
R/W
B/Y
B/Y
R/L
REGULATOR
Br
OFF
L/W
W/R
POON
Br
B/Y
HI.BEAM INDICATOR
LAMP12V3.4W
ILLUMINATION 12V3.4W
ILLUMINATION 12V3.4W
ILLUMINATION 12V3.4W
B/Y
ON
Br
Br
OFF LOCK
B/Y
B/Y
B/Y
R/L
R/B
R/Y
B/Y
R/B
B/Y
B/Y
Y
R/W
B/Y
R/B
Br/W
R/Y
R/W
POSITION
LAMP 12V5W
R/Y
HEAD LAMP
12V35/35W
R/B
B/Y
IGNITION
SWITCH
MAGNETO
DIMMER
PASSING
SWITCH
SWITCH
GRIP SWITCH L.H.
21
EARTH
FRAME
EARTH FRAME
22
W/R
Br
Lg
FUSE 10A
FUSE 10A
Br
BATTERY
12V2.5AH
Lg
W/B
B/Y
W/B
NEUTRAL INDICATOR
LAMP 12V3.4W
Br
IGNITION
SWITCH
W
ON
Br
IGNITION
SWITCH
OFF LOCK
ON
Br
Br
OFF LOCK
B/Y
Lg
Br
B/Y
Lg
B/Y
Lg
HORN
12V2.5A
HORN SWITCH
GRIP SWITCH L.H.
23
EARTH
FRAME
NEUTRAL
SWITCH
24
RESISTANCES
Pickup coil :
Range
(Ohms)
Meter +ve
Meter -ve
Reading
(Ohms)
X 10
Blue
Black
108-132
Connections
Sr. No.
AC voltage measurement
Range
Meter +ve
Meter -ve
AC 25V
Yellow
Black/Yellow
Reading
13-14 Volts
at 4000 rpm
Meter +ve
Meter -ve
Reading
(Ohms)
X1
White
Black
0.6 + 0.2
Connections
Range
DC 25V
Range
Meter +ve
Meter -ve
Reading
(Ohms)
X1
Yellow
Black
0.5 + 0.2
Connections
Meter -ve
Battery -ve
terminal
Reading
13-15 Volts
at 4000 rpm
1 Free
750 - 1,000 km or 30
days.
2 Free
days.
3 Free
days.
4 Free
days.
5 Free
days.
6 Free
days.
Reading
1-2 Amp.
at 4000 rpm
Paid
days.
Paid
days.
Paid
days.
Lighting coil :
Range
(Ohms)
Meter +ve
White wire
of RR unit
20 A
Meter +ve
White wire
of RR unit
Range
X 1k ohms
Meter negative (-)
lead connection
3
4
2
1
Meter -ve
Battery +ve
terminal
100-500
20-200
3
4
20-500
20-200
ty
n
a
rr ars
a
W Ye
2 Or km
0 occurs
0
,0heverlier
0
4whic ear
20-200
25
26
W O R K I N G O F B S V, S A I & P C V
BSV is fitted on intake tappet cover. The overall function of this valve is to
enrich the air-fuel mixture during cold start condition for better driveability.
This valve is designed to do the above function till the engine reaches a
specified temperature i.e. 500 C. Till the specified temperature is achieved,
the BSValve remains closed. After the specified (500C) temperature is
reached the valve opens automatically allowing for air to flow through it &
restores the normal air fuel mixture. The effectiveness of BSV can be
checked by pinching tube from BSV to Carburettor, when Tube is pinched,
the CO value increases & vice versa. Please note that for above check
Engine temperature should be above 50 oC.
Due to exhaust gas pulses, the Reed valve inside the ASV assly opens &
the fresh air is inducted into exhaust port. This leads to dilution of Carbon
Monoxide due to oxidation.
ASV
SYMPTONS
PROBABLE CAUSES
REMEDIES
1.
Misfiring
2.
3.
4.
INTAKE MANIFOLD
TO ASV
BSV
SR.
NO.
ASV TO
CYLINDER HEAD
BSV OUT (BSV TO
CARBURETTOR)
Check for all air filter connections. There are two openings
Fit the plug on air filter.
provided on air filter. Pipe is fitted on one opening & the other
other opening is pluged with a plug. Check if this plug is missing.
AIR
FILTER
CARBURETTOR
27
PCV - FROM
BREATHER TO
AIR FILTER
BSV damaged.
Replace BSV.
28
I M P O R T A N T E N G I N E A S S E M B LY T I P S
I M P O R T A N T E N G I N E A S S E M B LY T I P S
BSV IN (AIR FILTER
TO BSV)
Piston
1st Ring
2nd Ring
Rail Upper
CARBURETTOR
Spacer
Rail Lower
These 4 Friction
Plates are same
(Small inside
diameter)
29
EX.
BSV OUT
(BSV TO
CARBURETTOR)
CLUTCH ASSEMBLY
BSV
2 Spacers : 1 before
& 1 after assembly of
Housing comp. Clutch
This Friction
Plate is different
(Large inside
diameter)
Position of O ring
Position of O ring
30
I M P O R T A N T E N G I N E A S S E M B LY T I P S
Oil Filter Assembly
While assembling Oil Filter,
ensure that Grommet (B) is
properly fitted on Oil Filter.
Grommet face to inside
as shown in figure.
Crankcase LH
Do not apply
Liquid Gasket
to this area.
Apply Liquid
Gasket to
area shown
in Grey Colour.
C O % C H E C K I N G & T U N E - U P ( To e n s u r e b e t t e r m i l e a g e )
Check following before CO% checking / Tune up
Air filter connections (check all pipes connected to BSV & SAI)
Spark plug gap (0.6 to 0.7 mm)
All pipes & connections of SAI & BSV for any cracks, leakage,
plucking, pinching & loose connections.
CO% checking & Carburettor VC screw setting
Start & warm up the engine.
The oil temperature should be above 500C. This can be
achieved by running vehicle in top gear at the speed of
minimum 40 kmph. for 4 - 5 km
Pinch the tube between Cylinder head & SAI.
Adjust the engine speed to 1200 to 1250 rpm with Idling
adjust screw of carburettor keeping tube (between Cylinder
& SAI) pinched.
Adjust the CO with the VC screw. It should be 2.0 to 3.0%
keeping tube (between Cylinder & SAI) pinched.
Confirm the engine speed whether it is within 1200 to 1250
rpm or not. If not O.K. adjust to 1200 to 1250 rpm by idling
adjust screw keeping tube (between Cylinder & SAI)
pinched. Do not disturb VC screw & Idling screw setting.
After the adjustment, remove pinch of tube between Cylinder Head
& SAI.
31
Tube between
Cylinder Head
and SAI
VC screw
32
F R E Q U E N T LY A S K E D Q U E S T I O N S ( F A Q S )
F R E Q U E N T LY A S K E D Q U E S T I O N S ( F A Q S )
How this higher capacity and higher power engine delivers good
mileage?
B The major contributors for good mileage are
CV carburettor
DC ignition system with digital controlled Igniter
The CV carburettor ensures accurate supply of air fuel mixture at all
the engine load and speed.
The digital controlled Igniter introduces spark at accurate timing in the
cylinder and the DC ignition delivers high intensity current to burn the
mixture effectively and completely.
33
How is it possible to kick start the engine even after pressing the
clutch lever?
B In Wind 125', the kick mechanism has a direct drive through a
separate path to the crankshaft and not through gear transmission
and clutch.
As the transmission and clutch plates are not in the drive flow. It can
be started inspite of pressing the clutch lever.
This is similar to Pulsar and Eliminator kick drive mechanisms.
34
35
36
37
38
39
40