Common F : 21 23/11/20111

Sub: RATIONALISATION OF WIRING HARNESS: MODEL DISCOVER 100, 125 & 150 Dear Sir, Rationalisation of wiring harnesses have been carried out on Discover 100, 125 & 150. The part no. details are as given below
SN 1 2 3 4 5 6 7 8 Model Discover 100 KS Discover 100 KS (Spoke wheels) Discover 125 KS Discover 100 ES Discover 125 ES Discover 150 Discover All Old Part No PA402201 PA402212 -------PA402200 JZ402209 JZ402200 NA Cable Tie Lock (Fairing Mtg Bkt) Clip Positive Lock (Frame Gusset 60111415 60111417 Harness Wiring (SS) PA402211 Description Harness Wiring KS-With Clamps Harness Wiring KS-With Clamps Harness wiring KS New Part No PA402213 PA402214 JZ402213 Qty 1 1 1 1 1 1 3 1 MRP is being updated in system 1279.00 MRP (in Rs.) 1143.00 872.00 1157.50

Note : Hence forth only new wiring harness will be supplied through spare parts with clamps. Implementation cut off details are given below.
SN 1 2 3 4 5 6 Model Discover 100 KS Discover 100 ES (Spoke wheels) Discover 100 ES Discover 125 ES Discover 125 KS Discover 150 Waluj Plant Date 22.08.2011 23.08.2011 21.08.2011 08.08.2011 From day 1 06.08.2011 Pantnagar 31.08.2011 01.09.2011 Plant Date

Modification details are given below. A) For commonization of wiring harness, coupler colours are changed.
Discover 100 Coupler Existing CDI coupler Starter Relay Gray KS New Natural Existing Gray Natural ES New Natural Blue Existing Natural KS New No change Existing Natural Natural Discover 125 ES New No change Blue Discover 150 ES Existing New Green Natural Natural Blue

Not applicable

Not applicable

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B) While doing rationalisation of wiring harnesses modified clamps (clip positive lock) are provided with wiring harness on vehicle at following three locations for proper routing & to avoid pinching. Location 1. Fairing mounting bracket Existing clamping New clamping

Harness branch clamped by metallic Harness branch clamped on fairing clamp of fairing mounting bracket mounting bracket by Cable tie lock (P. No. 60111415. Qty-2) Note : 1.No change in part no. of fairing mounting bracket. 2. Henceforth only modified bracket will be supplied through spare parts.

2.Frame gusset below fuel tank

Harness clamped on frame gusset by Harness clamped on frame gusset by clip. (P. No. DK201049) Clip positive lock (P No. 60111417. Qty-1) 3. Rear fender

Harness clamped on frame by metalic Harness clamped on frame by metalic clamp near rear fender clamp & on rear fender by Clip positive lock (P No. 60111415. Qty-1)

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C) Fitment Procedure:

Fitment of new wiring harness on earlier produced vehicle (before cut off)
6 ~ 8 mm

10 ~ 12 mm

1. Remove seat cowl assembly 2. Remove tool kit from tool kit location 3. Make marking on rear fender (as shown in photograph) 4. Drill 7 mm hole on rear fender. (as shown in photograph) 5. Remove flashes from drilled hole.

7 mm drilled hole

6. Insert Cable tie lock in the drilled hole. (P. No. 60111415. Qty-1) 7. Clamp wiring harness by metalic clamp.

Cable tie lock Metalic clamp

8. Remove existing clamp from frame. (P. No.DK201049) 9. Press clip positive loc (provided with wiring harness) (P. No.60111417) on frame gusset properly as shown in photograph.

10. Remove 2 nos. Cable tie lock from wiring harness. (P. No. 60111415) 11. Clamp wiring harness with metalic clamps on fairing mounting bracket (as shown in photograph)

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Fitment of old wiring harness (stock available with dealer) on earlier produced vehicles. (before cut off)
6 ~ 8 mm 10 ~ 12 mm

1. Remove seat cowl assembly 2. Remove tool kit from tool kit location 3. Make marking on rear fender (as shown in photograph) 4. Drill 7 mm hole on rear fender. (as shown in photograph) 5. Remove flashes from drilled hole.

7 mm drilled hole

Cable tie lock

Metalic clamp

6. Fit Cable Tie Lock on wiring harness- qty1 (part no. 60111415 available in spare parts) for exact positon refer new wiring harness available in spare parts. 7. Insert cable tie lock in the hole provided on rear fender 8. Clamp wiring harness with metalic clamp near rear fender on frame

9. Fit clip positive lock on wiring harness- qty1 (Part no. 60111417 available in spare part) 10.Press clip positive lock on frame gusset properly as shown in photograph-for exact positon refer new wiring harness available in spare parts.

11. Clamp harness by metallic clamp of fairing mounting bracket.

Note : Old wiring harness cannot get fitted on new vehicles due to fairing mounting bracket change.

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Precautions to be taken in field to avoid wiring harness failures. 1. Ensure wiring harness is properly routed & clamped. 2. Ensure firm connections of all couplers. 3. Ensure wiring harness couplers are placed properly in bellows provided at head lamp fairing & tail lamp side. 4. Ensure correct routing of wiring harness which will avoid pinching of wires. 5. Do not apply pressurized water jet on wiring harness. 6. Do not fit extra electrical accessories. Such as Remote Extra & bigger horns Musical brake light Buzzer Higher wattage Headlamp bulb. Flasher operating all 4 side indicators simultaneously 7. Do not replace fuse with higher capacity fuse. 8. Do not cut wiring conduit / wires midway. 9. Never remove conduit from wiring harness 10. Never bypass fuse. 11. Do not repair wiring harness instead replace for safety. 12. Do not ground any wire for checking current-spark. Wiring harness failure due any one of the reason mentioned above should not be covered under warranty replacement. Please share this information with your concerned service staff and all secondary channel technicians. Thanking You, Yours faithfully, For BAJAJ AUTO LIMITED

Subrat Kumar Mishra Senior Manager-Service Support (2Wh) Cc to: 1. Field Service Team (to update dealers & ASCs as applicable) 2. RTC team 3. CQA Action matrix:
SN Key Information Works Manager / DSE Understand & ensure conformance at all level Command Area manager Make additional copy for ASC distribution Spares In charge Update SPC, Order new parts Service Adviser Floor In charge

Rationalisation of wiring harness : Model Discover 100, 125 & 150

Understand thoroughly along with workshop team & update all technicians

Date of Actions: Initials of concern official

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