Bajaj CT125X Service Station Manual PDF – DOWNLOAD

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Bajaj CT125X Service Station Manual PDF – DOWNLOAD

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Table of Contents for Bajaj CT125X Service Station Manual

Enhance your Bajaj motorcycle repairs with this SEO-friendly TOC, incorporating keywords like “CT125X engine SOP guide” and “Bajaj preventive maintenance chart” for targeted searches in two-wheeler servicing.

• Index (Page not specified | Overview)
  • 1. Technical Information (Page 1 | 13 Pages)
    • Technical Specifications (Page 2) – Detailed parameters for CT 110X ES Drum Drum and CT 125X ES Disc Drum / 125X Drum Drum models (e.g., engine displacement, power/torque, ignition, lubrication, transmission, frame, suspension, brakes, tyres, pressures, capacities, dimensions, weights, electrical components).
    • Preventive Maintenance Chart (Page 4) – Service intervals (1st Free at 500-750 kms up to 16th at 74500-75000 kms), activities/check points (e.g., engine oil/filter, air cleaner, spark plug, valve tappet, carburettor, hoses, chain, stands, steering, brakes, USB port), key symbols (C/Check, A/Adjust, etc.), and chargeable items.
    • PDI Checklist (Page 7) – Pre-Delivery Inspection sheet (dealer’s info, checks before/after starting, during test ride, visual inspection, cleaning; separate sheet for CT 125X DISC with brake fluid checks).
    • Speedometer Information (Page 11) – Indicators (odometer, speedometer, fuel level, turn signal, neutral, high beam, MIL), mobile USB charger, fuel tank cap care, matte finish cleaning, frame grip usage (max 7 kg load), side stand switch interlocking table.
• 6. Engine (Page 14 | 48 Pages)
  • Torque Value (Page 15) – Engine component torques (e.g., cylinder head bolts 1-1.1 Kgf-m, kick lever bolt 2.3-2.5 Kgf-m), tightening sequences (clutch/magneto covers, crankcase bolts, engine mounting).
  • Service Limit (Page 18) – Limits for compression pressure, tappet clearance, rocker arm, cam lobe, valve spring, stem, cylinder warp, cam chain, piston clearance, ring gap, clutch spring, plates, gear shift components, crankshaft runout.
  • Special Tools (Page 20) – Tools like tappet setting tool (37104355), cam sprocket holder (37104396), magneto rotor puller (37104369), bearing driver set (37103061).
  • Important SOP (Page 24) – Step-by-step procedures: magneto side removal, cam chain/clutch cover removal, cylinder head/block-piston removal, crankcase removal/splitting, skill tips before assembly, engine assembly (input shaft, gear drum, crankshaft, etc.), magneto/clutch/top side assembly, engine oil refill (1100 ml BS VI 20W50).
  • Engine Oil Flow Path (Page 58) – Detailed oil circulation (strainer to pump, filter, crankshaft, con rod, etc.).
  • Engine Oil/Loctite/Grease Application Matrix (Page 59) – Loctite (e.g., cam sprocket bolt 243), oil (bearings SAE 20W50), grease (valve stem AP Grease) applications.
  • Part Identification (Page 62) – Model comparisons (Pulsar NS125 vs. CT 125X), parts like valves, cylinder head, rocker arm, camshaft, gaskets, piston, sprockets, crankshaft, brake cam, crankcase, clutch, brackets, shafts, gears, drum, intake pipe, air filter, rotor, carburettor (with photos, numbers, descriptions).
• 7. Frame (Page 84 | 2 Pages)
  • Torque Value (Page 85) – Frame component torques (e.g., rear axle 8-10 Kgf-m, front axle 4.5-5.5 Kgf-m, handle bar holder 2.5-3 Kgf-m).
• Subsequent Sections (Inferred from Partial Content; Pages 142-178 | 37 Pages)
  • Bulb – Headlamp Replacement (Page 142) – Removal/assembly SOPs, torque specs.
  • Harness Headlamp Replacement (Page 144) – Removal/assembly SOPs.
  • Headlamp Assembly/Fairing Headlamp/DRL Unit/Speedo Flap/Headlamp Mounting Brackets Replacement (Pages 145-150) – Views, reflector/housing/lock details, assembly torques, headlamp focus adjustment (730-830 mm).
  • Speedometer Replacement (Page 151) – Removal/assembly SOPs.
  • Front Indicator Replacement (Pages 151-152) – Removal SOPs.
  • Bulb Taillamp/Lense with Gasket/Reflector Replacement (Pages 153-154) – Removal/assembly SOPs.
  • Wire Holder/Housing Taillamp/Holder Taillamp Replacement (Pages 154-160) – Views, removal/assembly, torques, wiring routing.
  • Wiring Harness Routing (Pages 161-165) – Photographic routing instructions.
  • Part Identification (Page 166) – Light control module/DC flasher, wiring harness (part numbers, descriptions for CT 110X/125X).
  • Electrical Circuit Diagrams (Pages 167-178) – Speedometer/control unit/starter motor/ignition/battery charging/CAN/MIL/air solenoid/lighting DRL/USB charger/brake lamp/side indicator pin details, components, diagrams.

(Attractively formatted with bold chapters, page references, and SEO keywords in descriptions; reconstructed from extraction for user navigation. Full manual focuses on specs, maintenance, engine, frame, electrical; partial content emphasizes electrical SOPs.)

SEO-Optimized WooCommerce Product Full Description

Master Bajaj motorcycle servicing with the official Bajaj CT125X service station manual PDF (Doc. No. 71120187, Rev. 00, August 2022) – an indispensable 182-page workshop resource for the rugged CT125X commuter bike. Powered by a 124.4 cc air-cooled single-cylinder DTSi engine (10.9 PS @ 8000 rpm, 11 Nm @ 5500 rpm), this BS VI compliant model, launched in 2022, features a tubular frame, telescopic suspension, USB charging, DRL, and disc/drum brakes for urban/rural reliability. Ideal for service stations handling 2022+ variants (ES Disc/Drum), it ensures precise repairs with torque specs and diagnostics.

From technical specs to electrical diagrams, this Bajaj CT125X repair manual equips technicians with illustrated SOPs, limits, and tools for optimal performance.

Why Choose This Bajaj CT125X Service Manual PDF?

• Comprehensive Specs & Limits: Engine details (bore 52 mm, stroke 58.6 mm), service limits (compression 12-13 kgf/cm² min 9.5), tyre pressures (front 28 PSI), dimensions (2002x765x1072 mm), weights (kerb 118 kg).
• Maintenance Mastery: Preventive chart (intervals up to 75000 kms), PDI checklist (battery charge, brakes, USB port), speedometer indicators (MIL, high beam, neutral).
• Engine Expertise: Torque values (head bolts 1-1.1 Kgf-m), special tools (tappet setter 37104355), SOPs (magneto removal, crankcase splitting, assembly, oil flow path).
• Frame & Electrical Repairs: Torques (rear axle 8-10 Kgf-m), headlamp/DRL replacement, wiring routing, part ID (harness DY402214), circuit diagrams (ignition, CAN, USB charger).
• Safety & Care Tips: Matte finish cleaning, frame grip usage (max 7 kg), side stand interlocking, fuel stain prevention.

Extracted Table of Contents for Quick Reference

Navigate repairs easily with this keyword-optimized TOC, ideal for “Bajaj CT125X engine torque guide” or “preventive maintenance chart PDF”.

• Index (Overview)
  • 1. Technical Information (Page 1): Specs, preventive chart (Page 4), PDI checklist (Page 7), speedometer info (Page 11).
• 6. Engine (Page 14): Torque (Page 15), service limit (Page 18), special tools (Page 20), important SOP (Page 24), oil flow (Page 58), application matrix (Page 59), part ID (Page 62).
• 7. Frame (Page 84): Torque (Page 85).
• Electrical & Lighting (Pages 142-178): Headlamp bulb/harness/assembly/DRL/speedo flap replacement (Pages 142-150), speedometer/front indicator (Page 151-152), taillamp bulb/lense/reflector/wire holder/housing (Pages 153-160), wiring routing (Pages 161-165), part ID (Page 166), circuit diagrams (Pages 167-178).

This digital PDF download is searchable and printable – perfect for Bajaj dealerships. Download now and tackle “CT125X electrical troubleshooting”!

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