Dear Customer,

Congratulations on choosing “ ” country brought to you by Bajaj Auto Limited.

Before you prepare for riding, please read this User's Guide carefully to familiarize yourself with the mechanism and the controls of the vehicle.

To maintain your bike in perfect running condition to deliver consistent performance, we earnestly advise you to avail periodic services, at Bajaj Dealers.

You can entrust Bajaj Dealers, who are well equipped with all necessary facilities, skill sets and trained manpower for servicing and repairs of your “ Bajaj CT-100 . In the rare event of going to a local garage, always insist on Genuine Bajaj Spares to ensure safety, performance and longer life of your vehicle.

Should you require any additional information, please approach Bajaj Dealers. If necessary, you may also write to selling dealers, with relevant details like Registration no. Chassis no., Engine no., Date of purchase, Kms. run, name of selling dealer and your contact numbers.

Finally, may we request you to give your motorcycle a proper care and regular maintenance, as described in this manual. We are sure this will offer you a long trouble-free ownership experience.

Wishing you unlimited miles of happiness!

International Marketing

BAJAJ AUTO LIMITED

Akurdi Pune - 411 035 India

Table of Contents

Description

Identification Data....................................................................................................................................1

Technical Specifications......................................................................................................................... 2

Location of Parts.....................................................................................................................................3

How to Ride your Bike.........................................................................................................................12

• Running In.................................................................................................................................12

• Riding the Bike..........................................................................................................................12

• Fuel Saving Tips.......................................................................................................................14

Safe Riding Tips....................................................................................................................................15

General Maintenance Information.........................................................................................................16

• Engine Oil..................................................................................................................................16

• Battery........................................................................................................................................18

• Rainy Season Care...................................................................................................................18

Daily Safety Checks...............................................................................................................................19

Non-use Maintenance............................................................................................................................20

Periodic Maintenance / Lubrication Chart........................................................................................... 21

Pre-Delivery Inspection..........................................................................................................................24

Applicable to All Periodic Services...................................................................................................... 25

Use Only Bajaj Genuine Parts..............................................................................................................26

DOC. NO. 71111342 REV. 01, July 11

Safety and Warning Information

Warning

This indicates that a potential hazard or injury to you or other persons and to the vehicle can happen, if the advise provided is not followed.

Caution

This indicates that a potential hazard that could result in vehicle damage.

Follow the advise provided with the caution.

Notice

The description and illustration in this booklet are not to be taken as binding on the manufacturers.

The essential features of the type described and illustrated herein remaining unaltered.

Bajaj Auto Limited reserves the right to carry out at any moment without being obliged to bring this booklet upto-date.

Modifications on the vehicle, parts or accessories as may be convenient and necessary.

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.

Frame Number Location

On LH Side of Steering Tube

(Alpha-Numeric - 17 Digits)

Engine Number Location

On LH Side Crankcase

Near Gear Change Lever

(Alpha-Numeric - 11 Digits)

1

Technical Specifications

Engine

Bore x Stroke

Eng. Displacement

Compression Ratio

Idling Speed

Max. Net Power

Ignition System

Spark Plug

Spark Plug Gap

: 4 stroke, Single cylinder, Natural air cooled, SI Engine.

: 53.0 mm x 45.0 mm

: 99.27 cc

: 9.5 + 0.5 : 1

: 1300 + 150 rpm

: 6.03kW (8.2Ps) at 7500 rpm

: C.D.I.

: Mico UR3AC or Champion PRZ9HC

: 0.6 to 0.7 mm

Lubrication

Transmission

Front Brake

Rear Brake

:

:

:

: Wet sump, Forced.

4 speed constant mesh.

Mech. expanding shoe type.

Mech. expanding shoe type.

Fuel Tank Capacity :

Full : 10.5 litres

Reserve : 2.4 Lit.

Un usable Reserve : 0.5 Lit.

Dimensions

Length

Width

Height

Wheel base

:

:

:

: 1970 mm for Round H.L.

: 1950 mm for Trapezoidal H.L.

: 770 mm

1065 mm

1235 mm

Min. Turning radius : 1900 mm

Ground clearance : 150 mm (Min.)

Tyre Size

Front : 2.75-17

Rear : 3.00-17

Tyre Pressure

Front : 1.75 kg/cm2 (24.5 psi)

Rear (Solo) : 2.00 kg/cm2 (28 psi)

Rear (Pillion) : 2.50 kg/cm2 (36 psi)

Electrical System : 12 Volts AC + DC

Head Lamp : 35/35 W

Stop Lamp/Tail Lamp

Turn Signal Lamp

: 21 W / 5 W

: 10 W

Neutral Indicator Lamp

Hi Beam Indicator Lamp

Turn Pilot Indicator Lamp

Speedometer Lamp

Horn

Battery

Vehicle Kerb Weight

Gross Vehicle Weight

Max. Speed

Climbing Ability

: 3 W

: 3 W

: 3 W

: 3 W (2 Nos.)

: 12 V DC

: 12 V-2.5 Ah

: 109 kg.

: 239 kg.

: 90 km/hr.

(With single rider 68 kg)

: 25% (140) max.

Note : All dimensions are under UNLADEN condition. Above information is subject to change.

2

Location of Parts

3

2

1

4

5

6

1. Speedometer :

The Speedometer pointer shows the speed of vehicle.

2. Odometer :

The Odometer shows the total distance that the vehicle has accumulated.

3. Neutral Indicator :

When the transmission is in Neutral and

Ignition switch ‘ON’, the Neutral indicator is lit. (Symbol is visible under lit condition).

4. Hi Beam Indicator :

When Headlight is ‘ON’ and Hi beam is

3 selected with engine running, Hi beam indicator will be lit. (Symbol is visible under lit condition).

5. Turn Signal Indicator (LH & RH) :

When Turn signal switch is turned to Left or Right, Turn pilot indicator will flash.

(Symbol is visible under lit condition).

6. Steering Lock cum Ignition Switch :

Key operated switch for Ignition ON/OFF

& locking handle bar.

Location of Parts

Steering cum Ignition Lock :

It has three positions.

LOCK

: Steering locked. Ignition

OFF.

OFF

ON

: Steering unlock. Ignition

OFF.

: Steering unlock. Ignition

ON.

To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push

& release the key. Turn the key to “LOCK” position and remove the key.

To Unlock the Steering : To unlock the steering, insert the key in steering cum ignition lock & turn it clockwise to “OFF” or

“ON” position.

Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ and ‘Side cover lock’.

4

Location of Parts

Fuel Tank

Cap

Fuel Tank Cap

• To open the fuel tank cap, insert the key in the lock and turn it clockwise and lift fuel tank cap.

• ‘Fuel Tank Cap’ is locked when pushed \ pressed back into the place.

RES

Fuel Tap

ON

Fuel Tap

Fuel tap lever has following positions.

ON : When fuel level is above Reserve position.

RES : When fuel level is below Reserve position.

OFF : When fuel supply is to be cut off.

5

Location of Parts

A

D

B

C

Left Handle Bar Switches

A. Dipper Switch : When headlight is ON,

High or Low beam can be selected with the dipper switch. Hi beam indicator light located on Speedo console will light up when high beam is selected.

: High Beam : Low beam

B. Turn Signal Switch : When the turn signal switch is turned to Left ( ) or

Right ( ), the corresponding turn signals flash on and off. To stop flashing, push the switch in and release.

6

C. Horn Button : ( ) Press horn button for sounding horn.

D. Pass Switch : Press the switch to flash the head light. It is used to give signal to vehicles coming from opposite side while overtaking.

Location of Parts

F

Right Handle Bar Switches

E. Head Light Switch : It has 3 positions.

All lamps 'OFF'.

While engine running, Tail lamp, Meter lamp and Pilot lamp/s ‘ON’.

While engine running, Head lamp, Pilot lamp, Tail lamp and Meter lamps ‘ON’.

7

E

F. Ride Control Switch :

The function of ‘Ride Control’ is to make rider to sense Economy zone of throttle for better fuel efficiency. When ‘Ride Control’ is in ‘ON’ position, on opening the throttle, at particular position one will feel slight resistance to the rotation of throttle grip.

This indicates the end of fuel Economy zone. However throttle can be rotated further to get higher speed. When switch is in ‘OFF’ position, the resistance to the throttle rotation is not sensed. Thus there will be no indication of fuel Economy zone.

Location of Parts

Side

Cover

RH

B

A

A

B

Side

Cover

RH

C

D

Removal of Side Cover LH & RH

• Insert the key into the cover lock (C) and turn the key clockwise & pull the ‘Side cover’ LH out from the bottom.

• Pull ‘Side cover’ from (A) to release Lug provided on ‘Side cover’ from hole provided on ‘Frame’.

• Slide the ‘Side Cover’ forward (towards the engine) from location (B) to release slot provided on front side of ‘Side cover’ from bracket with rubber cap provided on

‘Fuel Tank’. Take out ‘Side cover’.

• Similarly ‘Side cover’ RH can be removed after removing screw (D).

CAUTION : Remove cover as described above, otherwise the lugs may break.

8

Location of Parts

Side

Cover

RH

B

A

A

B

Side

Cover

RH

C

D

Fitment of Side Cover LH & RH

• Match slot (B) provided on front side of

‘Side Cover’ with bracket provided on

‘Fuel Tank’ and slide ‘Side cover’ backward (towards Tail lamp).

• Match Lug (A) provided on rear side of

‘Side cover’ with hole provided on ‘Frame’ and press ‘Side cover’ inside.

• Match the lock plate of ‘Side cover’ properly with bracket on ‘Chassis’ and

Lock. (For ‘Side cover’ LH).

• F o r ‘ S i d e c o v e r ’ R H a d o p t s a m e procedure and fit the screw (D) properly.

CAUTION : Fit cover as described above to ensure proper fitment.

9

Location of Parts

Battery

Tool Kit

Battery

•

It is located inside the ‘Side Cover’ LH.

•

Always maintain electrolyte level in each cell between upper and lower level lines by adding distilled water.

Tool Kit Location

•

It is located below the seat on rear mudguard.

•

A rubber strap is provided to hold the tool kit.

CAUTION : Always fit rubber strap to hold the tool kit.

10

Location of Parts

Front Brake

Adjuster

Rear Brake

Adjuster

Front Brake Adjustment

For safe riding the brakes must always be maintained in perfect condition. Brake is properly adjusted if -

• The wheel rotates freely when the control lever is in the resting position.

• The braking action starts after Front brake lever is pressed by 2-3 mm.

These conditions are obtained by adjusting the cables by means of adjuster shown in the figure & minor play adjustments can be done by adjuster provided near front brake lever.

11

Rear Brake Adjustment

Rear brake is properly adjusted if -

• The wheel rotates freely when the brake pedal is in the resting position.

• The braking action starts after Brake pedal is pressed by 20-30 mm.

These conditions are obtained by adjusting the cables by means of adjuster shown in figure.

WARNING : Both brakes, front and rear must be maintained in perfect condition, for road safety.

How to Ride Your Bike

Running IN

Proper running-in is important for the better life

& trouble free performance of the vehicle.

• During first 2000 kms running-in period do not exceed following speed limits.

Kms

0 - 1000

1000 - 2000

1st

15

20

2nd 3rd

30

40

45

60

4th

55

75

• Always keep the speed below the limits mentioned in the table.

• Do not race the engine excessively.

• Do not start moving or race the engine immediately after starting. Run the engine for a minute at idle speed to give the oil a chance to work-up into the engine.

Riding the Bike

Before starting the vehicle & with the ignition key ‘OFF’, adhere to the following first thing in the morning or after a long period of nonuse (whichever is the case).

12

Depress the clutch lever completely. Kick the kick lever all the way down to its stop, briskly a couple of times. Release the clutch lever.

Starting the Engine :

• Keep the fuel tap to ON or RES position.

• Turn ignition switch to ON position.

• Confirm that the vehicle (transmission) is in neutral.

• If the engine is cold or when starting for first time, use choke for quick starting. Choke lever (A) is located on LH side switch.

• Keep the

throttle completely closed, and kick the engine with kick starter lever.

• When the engine is warmed up enough to idle without using choke, return the choke to

OFF position.

A1

A

A1 : Choke “OFF”

A2 : Choke “ON”

A2

How to Ride Your Bike

NOTE: When the engine is already warm on

0 hot days (Higher than 30 c), open the throttle part away instead of using choke, & then start the engine.

Moving Off :

• Check that Center/Side stand is up.

• Depress the clutch lever.

• Shift into 1 gear.

• Open the throttle and release the clutch lever slowly and simultaneously.

• As the clutch starts to engage, open the throttle a little more, giving the engine just enough rpm to keep it from stalling.

Shifting Gears :

• Close throttle & depress the clutch.

• Shift into next higher or lower gear.

• Open the throttle and release the clutch lever slowly and simultaneously.

A. Gear Shifting Lever

WARNING : When shifting down to lower gear, do not shift at such a

N

1

2

A

high speed that engine rpm rises

3

4 excessively & which may cause rear wheel to skid.

Braking :

• Close the throttle completely, leaving the clutch engaged

(except where shifting gears) so that the engine braking will help slow down the motorcycle.

• Shift down one gear at a time so that you are in Neutral when you come to a complete stop.

• When stopping, always apply both brakes at the same time. De-clutch as necessary to keep engine from stalling.

• Never lock the brakes, or it will cause the tyres to skid.

When cornering, use brakes judiciously & do not declutch. Reduce your speed before you get into the corner.

For emergency braking, disregard downshifting, and concentrate on applying the brakes as hard as possible without skidding.

13

How to Ride Your Bike

Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

Parking :

• Shift the transmission into neutral and turn the ignition switch OFF.

• Support the motorcycle on a firm level surface with the center or side stand.

CAUTION: Do not park on a soft/steeply inclined surface or the motorcycle may fall over.

Fuel Saving Tips

• Drive smoothly & steadily at speed between

40 and 50 km/h .

• Drive at constant speed; avoid sudden accelerations & harsh braking as far as possible. Plan your trips properly with minimum start-stops.

• Change the gear judiciously according to the speed requirements. Drive as far as possible in highest gear.

14

• Travel as light as possible; do not overload the vehicle above the specified payload.

• Stop the engine quickly at the end of the journey. Avoid excessive idling. For intermediate stoppages, cut-off the engine if you want to stop for more than two minutes.

Vehicle Maintenance (Ensure Following)

Fuel

Spark plug

Check fuel lines and connections for leakage.

Inspect and clean spark plug. Adjust electrode gap.

Clean air filter element periodically.

Air filter

Engine oil

Brakes

Check level. Use recommended oil for top up or refill.

Ensure that the brakes are not dragging

/ binding.

Ensure correct clutch lever play.

Clutch

Tyre pressure Always maintain the recommended tyre pressure.

Carburettor Adjust idling speed.

Safe Riding Tips

• Always wear helmets while driving or riding.

Your helmets should confirm to appropriate standards.

• Read thoroughly the instructions in this manual and follow them carefully.

• Avoid unnecessary accessories for the safety of both rider and other motorists.

• Get familiar and follow traffic rules and regulations in your states as well as general traffic signs.

• Familiarize yourself well with starting, acceleration and braking of the vehicle.

• When applying the brakes, use both front and rear brakes simultaneously. Applying only one brake may cause the vehicle to loose control.

• Riding at proper speed and avoiding unnecessary acceleration and braking are important not only for safety and low fuel

15 consumption, but also for longer life of the vehicle.

• During rainy season drive the vehicle more cautiously. Remember vehicles skid more easily during light showers.

• Drive cautiously. Start early & reach your destination safely.

• Always carry vehicle registration and insurance papers, & a valid driving licence with you.

• Avoid driving on loose sand or stones where vehicle is likely to skid.

• Properly wrap-up loose clothes while driving or riding to avoid entangling in wheel or other objects on road.

• Always concentrate on riding for safety.

General Maintenance Information

Engine Oil

• Check engine oil level every day before starting the vehicle.

• Always maintain engine oil level between upper & lower mark provided on cover RH.

Engine Oil Level Checking :

• Park the vehicle on level surface on center stand.

• Check oil level through oil inspection gauge as shown in photograph. Always maintain engine oil level between the upper (C) and lower (D) mark provided on Cover RH.

Engine Oil Capacity :

For refill : 900 ml, For engine O/H 1000 ml.

A

A : Oil Filler Cap

B : Oil Level Gauge

C : Upper Level

D : Lower Level

B

C

D

Bajaj Auto recommends engine oil for 5,000 kms drain interval, for better performance of engine components.

Recommended SAE 20W40 of API ‘SL’, JASO

Oil MA Grade

Replacement 1st replacement at 750 Km / 1 st

Frequency* service. Thereafter at every 5000 Km

16

CAUTION : It is important to adhere to recommended grade & frequency of oil change for the purpose of long life of critical engine components. For details refer Periodic Maintenance chart. Do not reuse drained oil.

Oil Strainer

• Oil strainer is situated inside the clutch cover.

• Oil Strainer should be cleaned periodically at Vehicle Dealer/Authorised Service Center.

General Maintenance Information

Wheel Puncture :

Use recommended levers while removing the Tyre / Tube for puncture work. This will avoid any damages to the edges / scratches on paint of the wheel.

Tyre Pressure :

Keep appropriate tyre pressure as mentioned below to increase life of the tyre & for better fuel consumption.

Front

Rear (Solo)

Rear (with Pillion)

Drive Chain Slackness

• Chain top edge to be kept between two marks during chain slackness adjustment.

• Care should be taken, that the chain should never run dry.

• Lubricate chain from outside with SAE 90 oil at every 500 kms.

• Chain slackness will have to be adjusted whenever required.

17

General Maintenance Information

Battery : 12V 2.5Ah

• Battery is located inside ‘Side Cover’ LH.

• Always ensure that battery electrolyte level is in between max & min level marks.

Check & top up battery by distilled water if electrolyte level is below min level mark.

• Battery life would get adversely affected if top up with ‘Tap Water’.

• Environment care must be taken to dispose off used battery. It is always recommended to hand over the same to the Authorised battery / Bajaj dealer for proper disposal.

• When battery is found discharged, it is advised to get it charged immediately.

CAUTION : Do not drive/run vehicle in battery disconnected condition. It may lead to damage of electrical / electronic components.

18

Spark Plug

• Remove spark plugs by using plug spanner.

• Clean the spark plugs & adjust the gaps if incorrect by bending outer electrode carefully.

Spark Plug Gap : 0.6 to 0.7 mm.

Spark Plug (2 Nos) : Mico UR3AC, Champion

PRZ9HC

Rainy Season Care :

• It is suggested to customer to take appropriate care in area of high rainfall area.

The appropriate surface preventive coat to avoid rusting/poor surface finish on account of adverse atmospheric conditions.

• Vehicle cleaning to be done with soft & clean wet cloth to avoid scratches on painted parts.

• Clean & lubricate all the important parts as detailed in a periodic maintenance chart.

• Do not apply direct water jet on painted, electrical / electronic parts.

• Do not obstruct engine cooling by adding mud protection sheet from front.

Daily Safety Checks

Before riding the motorcycle be sure to check the following items. Please give proper importance to these checks and perform all of them before riding the motorcycle. If any irregularities are found during these checks, refer to the Maintenance chapter and see

Authorised Dealer / Service center for the action required to return the motorcycle to a safe operating condition.

WARNING : Failure to perform these checks every day before you ride may result in serious damage or severe accident.

What to check Check for

Fuel Enough fuel for the planned distance of operation, no leaks in the fuel lines.

Engine Oil

Throttle

Oil level between upper & lower marks.

1. Correct play in the throttle cable (2 to

3 mm)

2. Smooth operation & positive return of throttle grip to the closed position.

19

What to check Check for

Steering Lock Correct operation.

Brakes 1. Correct pedal play (20~30 mm).

2. Brake lining wear indicator within

‘USABLE RANGE’.

3. No dragging.

Drive chain

Lighting

Horn

Steering

Clutch

Side and

Center Stand

Tyres

1. Proper slack (30~35 mm).

2. Adequate lubrication.

Operation of all lights.

Correct functions.

1. Smoothness.

2. No restriction of movement.

3. Not Loose / Tight.

1. Correct lever play. (2 to 3 mm).

2. Smooth operation of lever.

Return to their fully up position.

Mirrors

1. Correct pressure.

2. Adequate tread depth.

3. No cracks or cuts.

Correct position.

Non-Use Maintenance

Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct & careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from such other non-operational damages like fire hazards.

• Clean the entire vehicle thoroughly.

• Empty the fuel from fuel tank & carburettor float bowl (if fuel is left in for a longer time, the fuel will break and gummy substance could clog the carburettor).

• Remove spark plug and put several drops of 2T oil into the cylinder. Kick the engine over slowly a few times to coat the cylinder wall with oil & install back the spark plug.

• Set the vehicle on a box or a stand so that both the wheels are raised off the ground.

• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or brake liners.

• Lubricate the control cables.

• Cover the entire vehicle neatly. Make sure that the storage area is well ventilated and free from any source of flames or spark.

• Fill 10% excess air pressure in both wheels.

** For Battery :

a. Remove battery & keep it on wooden plank, in properly ventilated area.

b. Before taking the vehicle for use.

• Get the battery recharged from Authorised

Service Center / Battery Dealer.

• Check & correct electrolyte level and apply petroleum jelly on terminals (applicable to certain models).

Preparation for regular use after storage :

•

Clean the vehicle

•

Make sure the spark plug is tight.

•

Fill the fuel tank with fuel.

•

Change the engine oil.

•

Check all the points listed in the Daily

Safety Checks section.

•

Check and inflate tyres to the proper tyre pressure.

20

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

1.

2.

3.

4.

5.

6.

Servicing

Engine idling speed / CO%

Valve tappet clearance

Engine oil

Oil strainer

Paper oil filter

7.

Spark plug functioning / Gap (2 nos.)

V

8.

Air cleaner element Clean / Replace

9.

Air filter cover ‘O’ Ring

10. Fuel cock sediment bowl cleaning

11. Carburettor float bowl cleaning

12. Carburettor rubber duct

13. Fuel pipes

14. Battery electrolyte level

15. Clutch lever free play

Servicing

Kms

R

CL

A

A

A

A

1st

750

3

RECOMMENDED FREQUENCY

2nd

5000

3

3rd

10000

4th

15000

3 3

5th

20000

3

6th

25000

3

7th

30000

3

1st - 750 Kms / 30 Days

2nd onward @5000 Kms

R

CL

A

A

R

CL

A

A

R

CL

A

A

R

CL

A

A

R

CL

A

A

R

CL

A

A

R

CL

Replace at 5000 Kms

Clean at 5000 Kms

R R R R R R R R Replace at every oil change

C, A, R C, A C, A C, A R C, A C, A R Replace at every 15000km

CL, R CL

R

CL

CL CL R CL CL

R

CL CL CL CL CL CL

R Clean at every 5000Km

Replace at every 15000km

Replace at every 20000km

CL

C, R

C, R

C

C

Note - More frequent cleaning may be required when driving in dusty condition.

C

C

CL

C

C

C

C

CL

R

R

C

C

CL

C

Clean at every 10000km

Replace at every 20000km

C Replace at every 20000km

C, A C, A C, A C, A C, A C, A C, A C, A

C, A C, A C, A C, A C, A C, A C, A C, A

21

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

30. Cylinder head de-carbonising, valve lapping & Replace valve oil seals

31. Engine air breather tube

32. Drive chain slackness adjustment

& lubrication

Servicing

Kms

16. Throttle grip play

17. Rear brake pedal free play

C, A C, A C, A C, A C, A C, A C, A C, A

C, A C, A C, A C, A C, A C, A C, A C, A

18. Brake lining or pad wear CL, R CL CL CL, R CL CL CL, R Replace at every 15000km

19. Brake fluid level/Top up/Repl. (If Appl) C, A, R C, A C, A C, A C, A C, A C, A R Replace at every 30000km

20. Master cyl. cup & dust seal (If Appl)

21. Caliper piston seal & dust seal (If Appl)

22. Brake hose pipe

23. Brake cam & pedal pivot pin

R

R

C, R

L L

R

R

C, R Replace at every 30000km

L

C, A C, A C, A C, A C, A C, A C, A C, A

Replace at every 30000km

Replace at every 30000km

24. Steering play

25. Steering stem bearing

26. All fasteners tightness

27. Rear sprocket fasteners

28. Rear wheel rubber shock damper

29. Silencer drain hole cleaning

C, L, R

C, T

C, T

C, R

CL

C, T

C, T

CL

C,L,R

C, T C, T C, T

C, T C, T C, T

C, R

C,L,R

C, T

C, T

C, R

C, T

C, T

CL CL CL CL CL

C,L,R

C, T

C, T

C, R Replace at every 10000km

CL Clean at every 5000km

CL

R

RECOMMENDED FREQUENCY

1st 2nd 3rd 4th 5th 6th 7th

750 5000 10000 15000 20000 25000 30000

CL

R

CL Clean at every 15000km

Replace at every 20000km

C, A, L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L Lubricate at every 500km

A-slackness whenever reqd.

22

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

Servicing

Kms

RECOMMENDED FREQUENCY

1st 2nd 3rd 4th 5th 6th 7th

750 5000 10000 15000 20000 25000 30000

33. Drive chain ‘O’ ring type (If applicable)

34. Drive chain remove, clean, inspect'

& lubricate (O/H)

35. Drive chain link lock

36. Wheel brg (for non sealed brgs only)

37. Tyre tread wear

38. Front fork oil

39. Auto choke, Thermal sensor (If Appl)

43. Clutch switch cleaning (If Appl)

44. General lubrication

45. Swing arm pivot pin lubrication

46. Eng foundation silent bush (If applicable)

L At every 500 Kms

CL, L

R

CL, L

R

CL, L

R

CL, L At every 10000km

R Replace at every 10000km

C, L

C, R

R

C, L

R

At every 20000km

C, R C, R C, R C, R C, R At every 5000kms i.e. at every service after 2nd ser.

Replace at every 20000km

C, A C, A C, A C, A C, A C, A C, A C, A At every 5000km

40. TPS (If Appl) C, A C, A C, A C, A C, A C, A C, A C, A C, A At every 5000km

41. RSA - Check gas pressure (If Appl) C, A

42. Starter cl. bush kit for dry type (If Appl) CL, R

C, A

CL, R

C, A At every 20000km

CL,R (If applicable)

CL

L

L

R

L L

CL

L L

R

CL

L

L

L

CL

L

R

Lubricate at every 20000km

Replace at every 15000km

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

Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.

23

Jobs to be Carried out during Pre-Delivery Inspection

1. Fill adequate petrol into petrol tank for proper flow of petrol to the carburettor.

2. Check all locks, P.T. cap, ignition switch, steering lock, Side cover.

3. Check for smooth operation for fuel cock.

4. Check engine oil level and top up if required.

5. Check all controls for proper free play and function :- Accelerator, clutch lever, front brake lever, rear brake pedal / lever, choke lever. (As applicable to certain model).

6. Check gear shifter lever for proper position and working.

7. Inspect rear shock absorber for proper setting & correct if required. (As applicable to certain model).

8. Check / Adjust chain slackness appropriately. Lubricate if required.

9. Check brakes and adjust if required.

10. Check and top up brake fluid level. (As applicable to certain model).

11. Check and adjust tyre air pressure to the recommended value.

12. Check battery terminal voltage, specific gravity, electrolyte level. Charge the battery if required.

Check connection at terminal, starter relay and apply petroleum jelly on terminals if required.

13. Check and adjust steering freeness.

14. Check front mudguard alignment w.r.t. front wheel.

15. Check all important nuts and bolts for proper torque and tightness.

16. Fit all O.E. accessories like mirror, leg guard etc. (As applicable to certain model).

17. Start vehicle, check idling and CO%.

18. Check all switches, meters, horn and lights for proper functioning.

19. Test drive the vehicle.

20. Check for oil leakage and rectify if any.

21. Repair for any other defects seen or observed during the test drive before cleaning the vehicle.

22. Clean the vehicle / washing before delivery.

24 q q q q q q q q q q q q q q q q q q q q q q

Applicable to All Paid Services

1.

Wash the vehicle.

2.

Change / Top up engine oil as per periodic maintenance schedule.

3.

Clean air filter element. (Replace element at every 15,000 kms).

4.

Check all fuel lines. (Replace fuel pipes at every 20,000 kms).

5.

Clean oil strainer / centrifugal filter as per periodic maintenance schedule. (Replace, if required).

6.

Clean fuel cock sediment bowl.

7.

Drain carburettor / clean float bowl as per periodic maintenance schedule.

8.

Clean, Check & Adjust spark plug gap. (Replace at every 15,000 kms).

9.

Replace carburetor duct, & Air filter ‘O’ ring at every 20,000 kms.

10.

Check & adjust valve clearance (if required). Decarbonize cylinder head at every 15,000 kms.

11.

Adjust chain slackness. Lubricate chain. Replace kit chain lock at every 10,000 kms.

12.

Replace rear wheel rubber damper at every 10,000 kms. (if required)

13.

Replace engine air breather tube at every 20,000 kms.

14.

Clean silencer drain hole at every 5,000 kms.

15.

Check brake lining & pad wear and adjust brakes. Replace at every 15,000 kms. (if required)

16.

Brake cam & pin lubricate at every 15,000 kms.

17.

Replace master cyl. cup & dust seal, caliper piston seal & dust seal, brake hose pipe at every 30,000km. (If applicable)

18.

Check and top up brake fluid level. Replace brake fluid at every 30000 kms. (If applicable)

19.

Check and adjust steering freeness. Replace steering cone kit at 10000 kms.

20.

Replace fork oil at every 20000 kms.

21.

Clean clutch switch at every 10000 kms. (If applicable)

22.

Check & adjust clutch, accelerator.

23.

Replace starter clutch bush kit at every 15000 kms. (If applicable)

24.

Replace engine foundation silent bush at every 15000 kms. (If applicable)

25.

Check & tight nuts, bolts & fasteners to the recommended torque.

26.

Lubricate specific points as per lubrication schedule, swing arm pivot pin at 20,000 Kms.

27.

Check batt. voltage, electrolyte level & top up if reqd. with distilled water. Route cables & fit terminal caps properly, Clean terminals & apply petroleum jelly.

28.

Start engine, check & adjust horn & all lights, TPS, auto choke, thermal sensor. (If applicable)

29.

Check idling and CO%. Tune engine & carburetor if required.

30.

Rear shocker gas pressure at every 20,000 kms. for proper functioning. (If applicable)

31.

Carry out any additional work if required.

32.

Check tyre wear & inflate air pressure in the tyre.

33.

Test ride the vehicle.

34.

Clean the vehicle at the time of delivery.

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

25

Use only Bajaj Genuine Parts

For optimum performance of vehicle

For prolonged life of components & vehicle

For economical maintenance cost

For rider's safety

Genuinity Test

Always

Insist

on

Scratch Hologram to find ‘Genuine’

Patrial transparent

Hologram

parts

Bajaj Auto Limited

Akurdi Pune 411 035 India

03100802 CLUTCH BOX

P0001

PACKAGING MONTH

MAY 2003

M.R.P. (Incl. of All Taxes) in Rs. for Qty. packed

IN ASSAM, KARNATAKA, MANIPUR, M.P.,

NAGALAND, U.P.,

& UTTARANCHAL IN OTHER STATES

QTY. 1 NO.

57.43

55.58

Golden Hologram

26

Price Label