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Table of Contents

Description Safety and Warning information :


1. Technical Specifications 1
2. Identification Data 3
Warning : This indicates that a potential
3. Location of Parts 4
hazard or injury to you or other persons &
4. Steering cum Ignition lock 5
5. Fuel Tank Cap 6
to the vehicle can happen, if advice
6. Speedometer Details 7 provided is not followed.
7. Speedometer Setting 10
8. Control Switches 12
Caution : This indicates that a potential
9. Rear seat / Tool kit 14
hazard which could result in vehicle
10. Front Seat / Battery 15
11. Fitment of Front & Rear Seat 16
damage, if advice provided is not
12. Daily Safety Checks 17 followed.
13. How to ride your Bike 18
14. Safe Riding Tips 22
Notice:
15. Engine Oil 23
16. Wheels - Tube less Tyre 24 The description and illustration in this booklet
17. Battery 25 are not to be taken as binding on the
18. Engine Cooling System / Coolant 26 manufacturers. The essential features of the
19. Periodic Maintenance Information 28 type described and illustrated herein remaining
20. Brake Fluid 30 unaltered. Bajaj Auto Limited reserves the
21. Periodic Maintenance & Lubrication Chart 31 right to carry out at any moment without
22. Non Use Maintenance being obliged to bring this booklet upto-date
& to do modifications on the vehicle, parts or
accessories as may be convenient and
necessary.
Technical Specifications
Engine : 4 Stroke, Single Cyl. Front & Rear Brake : Disc Brake
Bore x Stroke : 72.0 mm x 49.0 mm Fuel Tank Capacity
Engine Displacement : 199.5 cc Full : 13 liters
Compression Ratio : 11 + 0.5 : 1
Dimensions :
Idling Speed : 1400 + 100 RPM
Length : 1999 mm
Max. Net Power : 18 KW at 9750 RPM
Width : 765 mm
Max. Net Torque : 18.3 Nm at 8000 RPM
Height : 1114 mm
Ignition System : 12V ,DC
Wheel base : 1363 mm
FI System : Single Point Injection
Ground clearance : 157 mm
into manifold - BOSCH
Tyre Size
Spark Plug : 3 Nos
Front : 100/80-17,52P tubeless
Spark Plug Gap : 0.7 ~ 0.9 mm
Rear : 130/70-17,61P tubeless
Transmission : 6 speed constant
mesh Tyre Pressure
Gear Shifting Pattern : 1 Down 5 Up Front : 1.75 kgf/cm2 (25 PSI)
Engine Lubrication : Pressurized oil supply Rear (Solo) : 2.00 kgf/cm2 (28 PSI)
Engine Cooling : Liquid cooling Rear (with pillion) : 2.25 kgf/cm2 (32 PSI)

Starting Aid : Electric starter


1
Technical Specifications
Electrical System : 12 Volts DC Side Stand Indicator : LCD
Head Lamp : Twin Projector ABS Indicator : LED - Yellow
55W - Low Beam Rear No. Plate Lamp : LED
65W - High Beam Horn : 12V DC
Position Lamp : LED Battery : 12V , 8Ah VRLA
Tail /Stop Lamp : LED
Side Indicator lamp : LED (4 nos) Vehicle Kerb Weight : 165 kg.
Neutral Indicator : Green LED
Hi Beam Indicator : Blue LED Gross Vehicle weight : 295 kg.
Turn Signal Indicator : Green LED
Speedometer Back Light : LCD , Amber Max. Speed : 135 km/hr
Fuel Level Indicator : LCD Bar
Low Oil Pr. Indicator : LED- Red
Malfunction Indicator : LED - Yellow
Coolant Temp. Indicator : LED - Red
Low Battery Indicator : LED - Red Note :
Bajaj Logo : LED - Blue All dimensions are under UNLADEN condition.
Rev Indicator : LED - Yellow Above information is subject to change without
Service Reminder : LCD any notice.

2
Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.

Engine Number Location


On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

Frame Number Location


On Seal Lock Mounting Bracket
(Alpha-Numeric - 17 Digits)

3
Location of Parts
Grab
Pillion Seat Rider Seat Front Brake Digital Speedometer
Handle
Lever

Front Number
Rear Plate
Number
Plate

Front Fork

Nitrox
Rear
Shock
Absorber

Rear Disc Brake Rear Brake Front Disc Brake


Pedal

4
Steering cum Ignition Lock

Steering cum Ignition Lock : To Lock the Steering : To lock the steering,
turn the handle bar to the left side. Push &
It has three positions.
release the key. Turn the key to LOCK
position and remove the key. Steering lock
LOCK: Steering locked. Ignition OFF. can be done on left side only.
To Unlock the Steering : To unlock steering,
OFF: Steering unlock. Ignition OFF. insert the key in steering cum ignition lock &
turn it clockwise to OFF or ON position.
Key : A common key is used for Steering
ON: Steering unlock. Ignition ON. cum Ignition lock, Fuel tank cap & Rear
Seat.
5
Fuel Tank Cap / Fuel Tap

Fuel Tank Cap

Fuel Tank Cap


To open the fuel tank cap, open the flap.
Insert the key in the lock and turn it
clockwise and lift fuel tank cap.
Fuel Tank Cap gets locked when pushed
back into place.

6
Speedometer Details
1
2
3

4
5

6
7
8
9
Speedometer display will work when, only both 6. Low Battery Indicator : It indicates battery needs
Ignition switch & kill switch are in ON position. charging.
1. Fuel Level Indicator: It shows fuel level in fuel tank. 7. Malfunction Indicator ( ) :It blinks whenever any
2. Tachometer Dial: It shows engine speed in RPM. abnormality is noticed in fuctioning of FI system
3. Turn Signal Indicator (LH & RH): When Turn signal related componenets
switch is turned to Left or Right, Turn pilot Indicator - 8. Low Oil Pressure Indicator ( ) : It blinks when
LH or RH will flash. engine oil pressure is low.
4. Neutral Indicator: When the transmission is in 9. Coolant Temperature Indicator ( ) : It blinks when
Neutral, Neutral indicator will glow. engine coolant Temperature is more than 1150
5. Hi Beam Indicator: When Headlight is ON & Hi centigrade.
beam is selected with engine running, Hi beam
indicator will glow.
7
Speedometer Details
12
13
14

15
16

17
10
18
M
S

11

10. Bajaj Logo : Bajaj logo flying B continuously glows. and subsequently at each 5000 kms. Icon will
11. Mode Button : Mode button used for changing the continue to glow till it is reset. This icon is to be
mode while selecting & setting Trip1, Trip2, ODO, reset after service is carried out.
Clock & Service reminder. 14. Side Stand Indicator : When side stand is ON .
12. Engine Over Rev Indicator : It glows when engine 15. Digital Clock : It indicates time in HR : M (AM/PM)
RPM crosses 9500 RPM. 16. Speedometer: Vehicle speed will be displayed in
13. Service Reminder ( ): Spanner symbol glows digital form in Km / Hr.
when ODO meter reading reaches set Kms. for 17. Odometer : The Odometer shows the total distance
service. This Icon will flash at - that the vehicle has covered. Odometer can't be
1st : 450 km 2nd : 4950 km, reset to Zero.
rd
3 : 9950 km, 4th : 14950 km 18. Trip Meter : Trip 1 & Trip 2 shows the distance
Side Stand Indicator will light. traveled since it was last reset to zero.

8
Speedometer Details

21

20
M
S 19

19. Set Button : Set button used for setting Clock & Coolant Temperature Indicator
Service reminder. Low Battery Indicator
20 ABS Indicator (Yellow) ( ABS ) : With ignition switch Low Oil Pressure
ON & Kill switch ON the ABS indicator glows. Malfunction Indicator
When vehicle speed is more than 10 km/hr the ABS
indicator goes off, if this indicator glows while vehicle Instructions :
is running, it means there is problem in ABS unit. Incase, Malfunction indicator / ABS indicator gets ON
21 Low Fuel Level Indicator : It blinks incase of low during vehicle running, bring the vehicle to the nearest
fuel level (1 bar or less) BAL dealership for inspection / repair

Note : After switching ON the ignition switch & kill ABS System
switch, the following indications will remain ON till Always maintain a safe distance between you and
engine is started. objects ahead.
9
Speedometer Setting
Vehicle speed should always be reduced during extreme road 1. Trip Meter Reset :
conditions. The braking distance for motorcycle equipped with an
anti-lock braking system may be longer than for those without it Mode & Set push button is provided for selecting &
on rough road conditions. During these conditions the vehicle resetting ODO/TRIP1/TRIP2. LHS part of speedo
should be driven at reduced speeds. console.

When you apply front brake under conditions which may lock the 1. Press 'Mode' button Mode changes from
wheels, you feel a corresponding sensation (pulsation) in Front for less than 2 sec. ODO/TRIP1/TRIP2
brake lever. This is normal & it means your ABS is active.

Also it is recommended to use both front & rear brakes 2. Press 'Mode' button Selected mode
simultaneously. for more than 15 sec. TRIP1/TRIP2 will get reset.
Other TRIP mode will
Always slow down when cornering. the anti-lock brake system
cannot prevent accidents resulting from excessive speeds continue updating.

2. Service Reminder Reset ( ) :


Wrench symbol glows when ODO meter reading
reached to set Kms.
Service Reminder
This icon will glow at-
1st : 450 Kms 2nd : 4450 Kms
rd
TRIP1/2 3 : 9450 Kms 4th : 14450Kms
& subsequently at each 5000 Kms.
Note : Engine & motorcycle speed should be zero.

10
Speedometer Setting

1. Press 'Mode' push button TRIP1 Mode selected


for less than 2 sec.
2. Press 'Mode' & 'Set' : stops blinking
push button together Digits start blinking
for more than 2 sec.
TRIP1/2 3. Press 'Mode' button for Hour digits will
less than 1 sec. increase by one.
Mode
Set
M 4. Press 'Set' button for Minute digits will
S
less than 1 sec. increase. If Mode/Set
button is pressed
continuously then digits
3. Clock Reset : will stop blinking.
Digital clock indicates time in HR & MM separated 5. Press 'Mode' & 'Set' Set value will be saved
by colon : button together for Exit clock setting mode
It is a 12 hour clock. more than 2 sec. Digits stop blinking
Initially : will be blinking : start blinking
Clock setting is possible in TRIP 1 mode only. 6. Clock set 'Mode' is Auto exit without saving
selected & no editing set value.
is carried out for
more than 5 sec.

11
Control Switches

A D

Left Handle Bar Switches C. Horn Button : ( ) Press button for


A. High/Low Switch : When headlight is ON, sounding horn.
High or Low beam can be selected with D. Pass Switch : Press the switch to flash
this switch. Hi beam indicator light located the head light. It is used to give signal to
on Speedo console will light up when high vehicles coming from opposite side while
beam is selected. overtaking.

: High Beam : Low beam


B. Turn Signal Switch : When the turn signal
knob is pushed to Left ( ) or Right ( )
respective indicator will start blinking, to
exit push the knob in & release.
12
Control Switches
F. Starter Button :
G Starter button operates the electric starter
when clutch lever is depressed with
transmission in any gear.
It is recommended to start the engine
with the transmission in neutral.
E
G. Engine Kill Switch :
F The engine kill switch is for emergency
use. During emergency move the engine
kill switch to the OFF ( ) position.
Right Handle Bar Switches
Speedometer display will work when both Ignition
E. Head Light Switch : It has 3 positions.
switch & kill switch are in ON position.

: All lamps 'OFF'.


CAUTION : While starting ensure that
engine kill switch is in ON ( ) position.
: With engine running, Tail lamp,
Meter lamp, Pilot lamp/s, number Engine will not start if the kill switch
plate lamp will glow. is in OFF position
: With engine running, Head lamp,
Pilot lamp/s, Tail lamp ,Meter lamps
and number plate lamp will glow.

13
Rear Seat / Tool Kit

Tool Kit

Removal of Rear Seat Tool Kit Location


Insert Key into lock (A) It is located below the Rear seat.
Turn the key clock wise. 2 rubber straps are provided to hold the
Pull front end of Rear seat tool kit.
Take out Rear seat
CAUTION : Always ensure rubber strap
is fitted for securing tool kit.

14
Front Seat / Battery

Battery

Removal of Front Seat Battery


First remove Rear seat. It is located below Front seat.
Remove Front seat mounting bolts (B).
Pull back rear end of Front seat.
Take out Front seat.

15
Fitment of Front & Rear Seat
Front seat lug & bracket

C F
A H
E

I
B D
G

Fitment of Front Seat Fitment of Rear Seat


Match the lugs of Front seat (A) with First make sure Front seat is fitted
chassis bracket (B). properly.
Push Front seat toward petrol tank. Place Rear seat in fitment location.
Match Front seat rear brackets (C) with Insert bracket (H) of seat into hook (I).
the holes provided on chassis (D). Match the rod of Front seat (F) with seat
Tighten the bolts (E). lock (G).
Press front portion of seat.

16
Daily Safety Checks
Before riding motorcycle be sure to check Brake Fluid level above MIN mark
following items. Please give proper importance provided on reservior, applicable to disc
to these checks and perform all of them brake vehicle.
before riding motorcycle.
Drive Chain slack of 15 to 25 mm
If any irregularities are found during these adequately lubricated.
checks, refer to the Maintenance chapter &
see your dealer for the action required to Function of all lights & horn
return the motorcycle to a safe operating Clutch lever play - 2 to 3 mm
condition.
Check Coolant level between MIN and
Warning : Failure to perform these MAX mark in coolant reservoir tank.
checks every day before you ride, may Smooth steering movement without
result in serious damage or severe restriction.
accident.
Side stand return to its retracted position.
Enough fuel for planned distance of Correct inflation pressure in both tyres
journey. No fuel leakage in fuel lines. Adequate tyre tread depth - no cracks /
cuts.
Engine oil level (between upper and lower
level mark) Correct rear viewing span adjustment of
mirror.
Throttle cable play of 2 ~ 3 mm. Smooth
operation and positive return to closed
position,

17
How to Ride Your Bike
1. Starting The Engine : 2. Shifting Gears :
Turn ignition switch key to ? position. Close throttle & depress the clutch.
Keep kill switch in position. Shift into next higher or lower gear.
Confirm that transmission is in neutral / Open the throttle and release the clutch
press the clutch lever. lever slowly and simultaneously.
Keep throttle completely closed, press
starter button,
Release starter button as soon as engine 3. Moving Off :
starts. Check that side stand is up / retracted.
Depress the clutch lever.
Shift into 1st gear.
Caution : Do not operate the starter
Open the throttle and release the clutch
continuously for more than 5 seconds
lever slowly and simultaneously.
otherwise battery would get discharged.
As the clutch starts to engage, open the
Wait 15 sec. between each operation of the throttle a little more, giving the engine just
starter which will facilitate battery to recover. enough rpm to prevent it from stalling.
Note : The motorcycle is equipped with a starter
lockout switch. This switch ensures that engine
does not start if the transmission is in gear.
However, the engine can be started in any
gear if the clutch lever is pressed.
Note : Incase of battery discharged condition,
vehicle can be started by pushing it.

18
How to Ride Your Bike
6 4. Braking :
5
4 Close the throttle completely, leaving the
3 clutch engaged (except where shifting gears)
2
N so that the engine braking will help slow
1 down the motorcycle.
Shift down one gear at a time so that you
Gear shifting are in Neutral when you come to a complete
Gear shifting Lever pattern stop.
When stopping, always apply both brakes at
Recommended Speed for Shifting Down the same time. De-clutch as necessary to
From 6th to 5th Gear 54 km/h avoid engine stalling.
45 km/h Never lock the brakes, or it will cause the
From 5th to 4th Gear
tyres to skid. When cornering, use brakes
From 4th to 3rd Gear 35 km/h judiciously and do not de-clutch. Reduce
From 3rd to 2nd Gear 25 km/h your speed before you get into the corner.
For emergency braking, disregard
From 2 nd st
to 1 Gear 15 km/h downshifting, and concentrate on applying
brakes as hard as possible without skidding.
Warning : When shifting down to lower
gear, do not shift at such high speed 5. Stopping the Vehicle :
that engine rpm jumps excessively. This Close the throttle completely.
may cause engine damage, & rear wheel
Shift the transmission into neutral.
may skid. Downshifting should be done
at speeds as recommended in table Bring the vehicle to complete stop.
above. Turn the ignition switch off.
19
How to Ride Your Bike
6. Parking the Vehicle : 7. Running IN
Proper running-in is important for better life &
trouble free performance of the vehicle.
Parking using side stand.
During first 2000 kms running-in period do
Support the motorcycle on a firm level not exceed following speed limits.
surface with the side stand.
Lock the steering on LHS. Kms 1st 2nd 3rd 4th 5th 6th
0 - 1000 10 18 24 32 40 48
1000 - 2000 16 24 30 38 46 54

Always keep the speed below the limits


mentioned in the table.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle Do not rev the engine excessively.
may fall over. Do not start moving or rev the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to workup into the engine.

20
How to Ride Your Bike
Fuel Saving Tips : Ensure following maintenance points to get
A well maintained vehicle and good driving optimum performance from your bike.
can contribute a lot to the saving of feul.
Following are a few simple fuel saving tips. Fuel Check fuel lines & connections
for leakage.
Good Riding Habits :
Ride smoothly and steadily at a reasonable Spark Plugs Inspect and clean spark plugs.
speed. Adjust electrode gap. Replace
Avoid harsh braking. spark plugs as per P.M. Chart.
Change the gear judiciously according to Air Filter Clean the air filter element
the speed and load requirement. periodically. Replace as per
Dont overload the vehicle above the Periodic Maintenance Chart.
specified payload. Engine Oil Check engine oil level. Always
Use the accelerator judiciously. use recommended grade and
Cut off the engine if you want to stop for quantity.
more than two minutes.
Brakes Ensure that the brakes are not
How to check mileage (Fuel efficiency) dragging / binding.
Best way to calculate mileage is by following
the full tank to full tank method. Clutch Ensure correct clutch lever
Fill way tank full up to small mouth (brim). play.
Run the bike for say 100 km. Tyre Air Always maintain recommended
Fill the tank full again in same fuel filling Pressure tyre pressure.
station, preferably from same fuel
dispenser.
Divide kilometers run / fuel quantity filled.
21
Safe Riding Tips
Safe Riding Tips Drive cautiously. Start early & reach your destination
Always wear Helmet while riding. Your helmet should safely.
conform to appropriate Safety standards. Always carry vehicle registration & insurance papers,
Thoroughly read the and a valid driving licence with you.
instructions given in this manual Avoid driving on loose sand or stones where vehicle
and follow them carefully. is likely to skid.
Avoid unnecessary accessories Properly wrap-up loose clothes while riding to avoid
for the safety of both rider and entangling in wheel or other objects on road.
other motorists. Always concentrate on Safe riding.
Get familiar with and follow
traffic rules & regulations in your states as well as Rainy Season Care :
general traffic signs. It is suggested to customer to take appropriate care
Familiarise yourself well with starting, acceleration and in area of high rainfall area. Appropriate surface
braking of the vehicle. preventive coat to avoid rusting on account of
When applying the brakes, use both front & rear adverse atmospheric conditions.
brakes simultaneously. Applying only one brake may Vehicle cleaning to be done with soft & clean wet
cause the rider to loose control. cloth to avoid scratches on painted parts.
Riding at proper speed and avoiding unnecessary Clean & lubricate all the important parts as detailed in
acceleration and braking are important not only for a periodic maintenance chart.
safety and low fuel consumption, but also for long life Do not apply direct water jet on painted, electrical /
of the vehicle. electronic parts.
During monsoon drive the vehicle more cautiously. Do not obstruct engine cooling by adding mud
Remember vehicles skid more easily during light protection sheet from front.
showers.
22
Engine Oil
Recommended Engine Oil:
Model Recommended Engine oil Grade
A

Pulsar SAE 20W50 API SL, or JASO MA


200 RS
C
A : Oil Filler Engine oil replacement frequency : 1st service & then
Cap B
every 5,000 Km.
B : Oil Level D Engine oil level top-up frequency : Every 2500 km.
Window

Engine Oil Level Checking :


Check engine oil level every day in the morning.
Park vehicle perpendicular to the ground on level
surface as mentioned in page no. 21 (6.1)
Check oil level through oil level window B. CAUTION :
Always maintain engine oil level between upper It is most important to adhere to
(C) and lower (D) mark provided on Clutch cover recommended grade & frequency of oil
RHS. Top up with specified grade of oil, if the oil change for the purpose of long life of
level is below lower level mark.
critical engine components. For details
Engine Oil Capacity : refer periodic maintenance chart.
Refill at servicing : 1200 ml. Do not reuse drained oil.
During engine overhaul : 1400 ml. Contact your Dealer for proper
disposal of drained engine oil.
23
Wheels - Tube Less Tyre
Wheel Puncture :
Visit nearest known tubeless tyre repair
shop to remove puncture.
Remove puncture by Filler or Plug method
only.
Do not use patch method to remove
puncture of tubeless tyre.

Tyre Pressure :
Front Wheel
Keep appropriate tyre pressure as mentioned
CAUTION : Tubeless tyres are fitted in this below to increase life of the tyre & for better
motorcycle. The walls of the tyres in fuel consumption.
contact with the wheel rim should not be
damaged in any way during fitment / Front 25 PSI
removal of tyre. The tyre side walls in
contact with wheel rim seals air. Pulsar RS 200 Rear (Solo) 28 PSI
Removing Front Wheel :
Rear (with Pillion) 32 PSI
Park vehicle perpendicular to the ground on
level surface as mentioned in page no. 21
(6.1)
Remove speed sensor cable from case meter Note : Ensure tyres fitted comply with local
assembly. rules and regulations governing tyres.
Loosen front axle nut.
Remove front wheel assembly from fork.
24
Battery
It is always recommended to hand over
the same to an Authorised battery / Bajaj
dealer for proper disposal.
When low battery icon pops-up on
speedometer display, it is advised to get in
touch with Bajaj dealer & get it charged
immediately.

How to keep battery healthy ?


Battery : 12V - 8 Ah VRLA Switch Off ignition when engine is not
Battery is located below front seat. running.
Get battery checked/ charged during
Battery Features :
periodic services.
No topping-up is required
Do not press starter button for more than
Reduced self discharge, Enhances safety. 5 sec. After 3 successive cranking, wait for
No vent tube open to atmosphere hence no 15-20 sec. for battery to recover.
discharge of electrolyte through vent tube. Do not add extra electrical accessories
such as - Remote, Bigger Horn, Musical
CAUTION : Do not drive / run vehicle in
brake light etc. This will reduce life of
battery disconnected condition. It may
battery
lead to damage of electrical / electronic
components. Disconnect battery +ve & -ve wires if
vehicle is to be stored for more than 2
Environment care must be taken to weeks. This avoids self discharge.
dispose off the used battery.
25
Engine Cooling System
Radiator Assembly
A

Expansion
Tank

Radiator
Cooling Fan

Coolant is provided for cooling of engine. Note :


Water pump in the engine circulates the coolant Fan will start at temperature 980 C and stops at
in cooling system. 920 C. This is normal condition and it indicates
The pressure resulting from the heating of the that cooling system is functioning well
cooling system is regulated by a valve in radiator
cap (A). Warning : During motorcycle operation, the
Heat expansion causes excess coolant to flow coolant gets very hot & is under pressure.
into compensating coolant tank. Do not remove the radiator cap, radiator hose
When the temperature falls, this surplus coolant or other cooling system components when the
is sucked back into the cooling system. engine is hot.
Cooling fan is provided for cooling of coolant Allow the engine & cooling system to cool
circulated through radiator fins down. In case of exposure to hot coolant,
rinse immediately with lukewarm water.

26
Coolant
Coolant Specifications :
Antifreeze ready mix (Recommended Brand-
Coolant level
Motul : Moto cool expert,
inspection window Max Castrol : Radicool
Total coolant quantity : 1000 ml. (750~780 ml
Min in radiator & 220~230 ml expansion tank).
Coolant Top up
Park vehicle perpendicular to the ground on
level surface by using side stand.
Check coolant level in engine cold condition
only.
Ensure coolant level is between Min & Max
mark.
Warning : Coolant is poisonous and is a Always top up coolant through reservoir cap.
health hazard. Always replace coolant with recommended
Avoid skin, eye and clothing caontact brand only. (Radicool from Castrol, Moto
with coolant. If it gets into your eyes, cool expert from Motul) or equivalent.
rinse immediately with water and contact Use nitrile rubber hand glows while draining
a doctor. & topping up coolant.
Do not top up coolant through radiator cap.
Wash affected skin areas immediately Where pre-mixed coolant is not available
with soap and water. If coolant is coolant concentrate and distilled water
swallowed, contact a doctor should be mixed separately in a clean jar in a
immediately. Change clothes that have proportion of 1:1
come into contact with coolants. Keep
coolant out of the reach of children
27
Periodic Maintenance Information
Spark Plug Drive Chain Slackness
Remove spark plugs by using plug Chain slackness will have to be adjusted
spanner. whenever required.
Clean the spark plugs. Std. Chain slackness 15 ~ 25 mm.
Adjust the gaps if incorrect by bending Marking on chain adjusters should be
outer electrode carefully. identically positioned on both sides.

Spark Plug Gap : 0.7 to 0.8 mm.


Spark Plug (2 Nos.) : BOSCH(UR6CE)
(LH A + RH B)
(1 No. ) : BOSCH - YR5NEO
(Center C)

A C

0.7 to
0.8 mm

28
Periodic Maintenance Information

Drive Drive
Chain Chain
Cleaning Lubrication

Drive chain must be cleaned & lubricated as Method of O-ring Chain Lubrication :
per periodic maintenance schedule. Park vehicle perpendicular to the ground on level
Drive Chain (O-ring type) surface. Clean the chain by using lint free cloth (If
excessive mud / slush found approach Bajaj
O rings must always be kept wet for Service Center for proper cleaning)
best performance hence lubricate every Shake the can vigorously by holding vertically
500 Km. upright till the noise of steel ball inside heard
uniformly.
O-ring chain lubrication can easily be
Hold spray can at the back of rear sprocket with
done by owners using Bajaj Chain Lube extension tube nose at 5~10 cm.
Spray Can available with Bajaj dealers, Rotate the wheel in reverse direction & spray the
or equivalent. Ensure that the lubricant lube on middle portion of the chain up to full
length of the chain.
does not damage the rubber 'O' rings.
29
Brake Fluid

Front Rear
Brake Brake
Fluid Fluid
Reservior Reservior

Front & Rear Brake Fluid Level Brake Fluid Replacement.


Front brake fluid reservior is located on RH Change the brake fluid of the front & rear
side of Handle bar. brake according to service schedule.
Rear brake fluid reservior is located behind Use only DOT-3 ro DOT-4 brake fluid (from
RH pillion holder bracket. sealed container) for top up & replacement.
To check oil level, Park vehicle
perpendicular to the ground on level surface
with handle bar in straight ahead condition
Always ensure that brake fluid level is above
MIN mark given on inspection Window.

30
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

1 Clean the vehicle with water wash & dry Ensure to prevent water entry in
Petrol tank, Silencer & electrical
completely
parts.Use caustic free detergent for
washing.

2 Engine oil & engine oil C,R R R R R R R R SAE 20W50 "API SJ" Grade
filter* Replace at every 5000kms. And
top-up at every 2500 Kms (If
required)..

3 Oil strainer CL CL CL CL CL Oil strainer cleaning at the time of


oil change.

CL,C,A CL,A C & A at 20000 kms. Replace


4 Spark plug after 40000 kms.
R R Cleaning not required . replace
5 Air cleaner element & cover 'O' ring
after every 20000 kms

6 In line fuel filter R R Replace after evrey 20000 kms

7 Fuel pipe C,R C,R Replace if required

8 Valve tappet clearance C,A C,A Check & adjust at every 20000
kms
9 Sealed drive chain cleaning & lubrication CL,L,A CL,L CL,L CL,L CL,L CL,L CL,L CL,L Customer to apply OKS chain lube
A A A A A A A spray at every 500 kms

31
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

10 Air filter drain tube CL CL Clean at every 2000 kms

11 Silencer drain hole cleaning CL CL CL CL CL CL CL

12 Brake pedal pivot pin C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use recommended AP grease.
13 Brake lining or pad -Check wear indicator C,R C,R C,R C,R R C,R C,R R Replace brake shoes /brake
pad at every15000 Kms
14 Brake fluid level - top up / replace C,A,R C,A R Use recommended brake
fluid (DOT3/DOT4).
15 Disc brake assly -- Check functionality, C C C C
leakage or any other damage.

16 All cables & rear brake pedal -free play C,A C,A C,A C,A C,A C,A C,A C,A

17 Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness.

32
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

18 Steering play C,A C,A C,A C,A C,A C,A C,A C,A

19 Ignition switch barrel cleaning & handle bar C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use recommended WD40
control switches contacts cleaning, spray

20 Steering stem bearing & Cap steering C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Check & replace if damaged.
bearing(Plastic) L,R L,R L,R L,R L,R L,R L,R L,R Use HP Lithon RR3 grease
for lubrication.

21 Side stand pin CL,L CL,L CL,L CL,L Use recommended AP


grease.

22 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T

23 General lubrication-Clutch lever, front brake L L L L L L L L Use recommended AP


lever, kick lever. grease.

24 Coolant level in expansion tank C,A C,A C,A C,A C,A C,A C,A C,A Use recommended Ready
to use coolant

33
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Subsequent
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
25 Coolant hose damage/clamps/leakage C C C C C C C
26 Radiator fins C C C C C C C

* It is strongly recommended to use specified grade only , In case of any other engine oil of same specifications is
used the frequency would be every 5000 kms

C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate

Note: periodic parts / lubricants as per periodic maintenance & chart are mandatory & the same is chargeable to customer.

34
Non-Use Maintenance
Non-use maintenance is necessary if a vehicle with soap water. The rust will go off
remains off road for a longer duration (more automatically during first few application of
than 15 days**). The correct and careful non- brake.
use maintenance carried out before storing ** For Battery :
a. Remove battery and keep it on wooden
the vehicle will prevent the vehicle from
plank, in properly ventilated area.
rusting and from such other non-operational b. Before taking the vehicle for use.
damages like fire hazards. Get the battery recharged from the
Clean the entire vehicle thoroughly. Authorised Service Center / Battery Dealer.
Remove spark plug & put several drops of Apply petroleum jelly on terminals.
engine oil into the cylinder. Kick engine (applicable to certain models).
over slowly a few times to coat cylinder Preparation for regular use after storage :
wall with oil & install spark plug. Clean the vehicle
Set the vehicle on a box or a stand so that Fit the battery after recharging.
both wheels are raised off the ground. Make sure the spark plug is tight.
Spray oil on all unpainted metal surfaces to Fill the fuel tank with fuel.
prevent rusting. Avoid getting oil on rubber Change the engine oil.
parts or brake liners. Check all the points listed in the Daily Safety
Cover entire vehicle neatly. Make sure that Checks section.
storage area is well ventilated & free from Check and inflate tyres to proper tyre
any source of flames or spark. pressure.
Fill 10% excess air pressure in both wheels.
Do not apply oil on front brake disc, to
prevent rusting. If the front brake disc rusts
during storage, do not attempt to clean it