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 Model Old

Part No Description

New Part No

Qty MRP (in Rs.)

1 Discover 100 KS PA402201 Harness Wiring KS-With Clamps PA402213 1 1143.00

2 Discover 100 KS (Spoke wheels)

PA402212 Harness Wiring KS-With Clamps PA402214 1 872.00

3 Discover 125 KS -------- Harness wiring KS JZ402213 1 1157.50

4 Discover 100 ES PA402200

Harness Wiring (SS) PA402211

1

1279.00 5 Discover 125 ES JZ402209 1

6 Discover 150 JZ402200 1

7 Discover All NA

Cable Tie Lock (Fairing Mtg Bkt) 60111415 3 MRP is being updated in system 8 Clip Positive Lock (Frame Gusset 60111417 1

Note : Hence forth only new wiring harness will be supplied through spare parts with clamps.

Implementation cut off details are given below.

SN Model Plant Date Plant Date

1 Discover 100 KS

Waluj

22.08.2011

Pantnagar

01.09.2011 2 Discover 100 ES (Spoke wheels) 23.08.2011

3 Discover 100 ES 21.08.2011

4 Discover 125 ES 08.08.2011

31.08.2011 5 Discover 125 KS From day 1

6 Discover 150 06.08.2011 Modification details are given below.

A) For commonization of wiring harness, coupler colours are changed.

Coupler Discover 100 Discover 125 Discover 150

KS ES KS ES ES Existing New Existing New Existing New Existing New Existing New

CDI coupler

Gray Natural Gray Natural Natural No

change Natural

No change

Green Natural

Starter Relay

Not applicable Natural Blue Not applicable Natural Blue Natural Blue

Common

23/11/20111

F : 21

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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 Existing clamping New clamping

1. Fairing mounting bracket

Harness branch clamped by metallic clamp of fairing mounting bracket

Harness branch clamped on fairing 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 clip. (P. No. DK201049)

Harness clamped on frame gusset by ‘Clip positive lock’ (P No. 60111417. Qty-1)

3. Rear fender

Harness clamped on frame by metalic clamp near rear fender

Harness clamped on frame by metalic 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)

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.

6. Insert ‘Cable tie lock’ in the drilled hole. (P. No. 60111415. Qty-1)

7. Clamp wiring harness by 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)

‘Cable tie lock’

7 mm drilled hole

Metalic clamp

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6 ~ 8 mm

10 ~ 12 mm

Fitment of old wiring harness (stock available with dealer) on earlier produced vehicles. (before cut off)

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.

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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‘Cable tie lock’

7 mm drilled hole

Metalic clamp

10 ~ 12 mm

6 ~ 8 mm

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

Command Area

manager

Spares In charge

Service Adviser

Floor In charge

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

Understand & ensure conformance at all level

Make additional copy for ASC distribution

Update SPC, Order new parts

Understand thoroughly along with workshop team & update all technicians

Date of Actions:

Initials of concern official

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