User's Guide

(Export)
 Foreword
Dear Customer,
Congratulations on choosing “Boxer BM 150” motorcycle, one of the finest motorcycles in the
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 “Boxer BM 150”. 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 and your contact number.
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
DOC. NO. 71111331 Akurdi Pune - 411 035 India
REV. 03, FEB. 2019 CIN L65993PN2007PLC130076
Table of Contents

Description 7. Periodic Maintenance Information 21

1. Technical Specifications 1 8. Periodic Maintenance & Lub. Chart 27
2. Identification Data 3 9. Non-use Maintenance 31
3. Location of Parts 4
4. How to Ride Your Bike 15
5. Safe Riding Tips 19
6. Daily Safety Checks 19

Safety and Warning information :

Warning : This indicates that a potential hazard or injury to you or other persons & to
the vehicle can happen if advice provided is not followed.
Caution : This indicates that a potential hazard that could result in vehicle damage.
Follow the advice 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 modifications on
the vehicle, parts or accessories as may be convenient and necessary at any moment
without being obliged to bring this booklet upto-date.
 Technical Specifications
Engine : 4 stroke, single cylinder Front Brake : Mech. expanding shoe
130 mm dia. Drum
Natural air cooled,
240 mm dia. Disc
Spark ignition
Rear Brake : Mech. expanding shoe
Bore x Stroke : 56.0 mm x 58.8 mm
130 mm dia. Drum
Eng. Displacement : 144.8 cc
Fuel Tank Capacity :
Compression Ratio : 9.8 : 1
Full : 11 liters
Idling Speed : 1400 rpm + 100 Reserve : 2.5 liters
Max. Net Power : 12 PS @ 7500 rpm Usable : 1 liters
Max. Net Torque : 12.55 Nm @ 5500 rpm Dimensions :
Ignition System : DC Length : 2016 mm
Spark Plug (1 Nos) : CHAMPION PRZ9HC or Width : 740 mm
BOSCH UR4AC
Height : 1055 mm
Spark Plug Gap : 0.7~0.8 mm
Wheel base : 1285 mm
Lubrication : Wet sump, Forced.
Ground clearance : 190 mm
Transmission : 5 speed constant mesh.
Turning circle radius : 2100 mm

1
 Technical Specifications
Tyre Size : BM 150 Hi Beam Indi. Lamp : 12V, 2W
Front : 3.00 X 17”, 45 P RIB Speedometer Lamp : 12V, 2W (2 nos.)
Rear : 100/90X17”,55 P STUD Horn : 12 V 2A, DC
Tyre Size : BM 150 X Battery : 12 V 4 Ah VRLA
Front : 3.00X17”,SEMI KNOBBY
Rear :100/90X17”,SEMI KNOBBY Vehicle Kerb Weight : 125 kg.
Tyre Pressure Gross Vehicle Weight : 255 kg.
Front : 1.75 kg/cm2 (25 PSI) Max. Speed : 100 km/hr. (With
Rear (Solo) : 2.00 kg/cm2 (28 PSI) single rider 68kg)
Rear (Pillion) : 2.25 kg/cm2 (32 PSI) Climbing Ability : 25% max. (140)
Electrical System : 12 Volts (DC)
Note : All dimensions are under UNLADEN
Head Lamp
condition. Above information is subject to change
(w/o Pilot lamp) : 12V, 35/35W HS1 without any notice.
Neutral : 12V, 2W
Tail / Stop Lamp : 12V, 5/21W
Turn Signal Indicator : 12, 2W
Side indicator Lamp : 12V, 10W (4 nos.)

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 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)

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Location of Parts
Speedometer
Fuel Tank

Grab Handle Rear

Shock Absorber
Carburettor with Front Brake
Manual choke Lever

Headlamp

Rear Number
Plate

Silencer

Brake Pedal

Rider Engine Oil

Foot Rest Inspection Window
Pillion Foot Rest

4
Location of Parts

Speedometer Fuel Tank Cap Grab Handle

Clutch Lever
Rear
Shock Absorber

Tail
Lamp
Front Fork

Pillion
Foot Rest

Side
Gear Change Stand
Lever

5
 Location of Parts

Steering cum Ignition Lock : To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Push &
It has three positions.
release the key. Turn the key to “LOCK” position
and remove the key.
LOCK : Steering locked. Ignition OFF. To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
OFF : Steering unlock. Ignition OFF. turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering cum
Ignition lock’, ‘Fuel tank cap’ & ‘Side cover
ON : Steering unlock. Ignition ON. lock’.

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 Location of Parts
Fuel Tank Cap
Fuel Tap

RES

FUEL
OFF
ON

Fuel Tank Cap Fuel Tap

• To open the fuel tank cap, insert the key in Fuel tap lever has following positions.
the lock and turn it clockwise and lift fuel
ON : When fuel level is above Reserve
tank cap.
position.
• ‘Fuel Tank Cap’ is locked when pushed /
pressed back into the place. RES : When fuel level is below Reserve
position.
OFF : When fuel supply is to be cut off.

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 Location of Parts

1
5

6
3
3

4 7

1. Odometer : It shows the total distance that the vehicle 5. Fuel Level Indicator : It shows available fuel in fuel
has been ridden. tank.
2. Speedometer : The Speedometer pointer shows the 6. Neutral Indicator : It illuminates when transmission is
speed of the vehicle. in Neutral & Ignition switch is ‘ON’.
3. Turn Signal Indicator (LH & RH) : When Turn signal 7. Steering cum Ignition Switch : Key operated switch
switch is turned to Left or Right, Turn pilot indicator LH for Ignition ‘ON’/‘OFF’ & locking handle bar.
or RH will flash.
4. Hi Beam Indicator : When Headlight is ‘ON’ & Hi beam
is selected with engine running, Hi beam indicator will be
lit.

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 Location of Parts

B
D

Left Handle Bar Switches C. Horn Button : ( ) Press horn button for
sounding horn.
A. Dipper Switch : When headlight is ON, High
or Low beam can be selected with the dipper D. Pass Switch : Press the switch to flash the
switch. Hi beam indicator light located on
head light. It is used to give signal to
Speedo console will light up when high beam is
vehicles coming from opposite side while
selected.
overtaking.
: 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.

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 Location of Parts

Right Handle Bar Switches USB Mobile Charger

E. Head Light Switch : It has 2 positions. • Mobile charging facility using USB cable
: All lamps 'OFF’.
: While engine running, Head lamp, CAUTION : Do not charge mobile in
Tail lamp & Meter lamps ‘ON’. engine-off condition. This may lead to
Battery getting discharged.
F. Starter Button : Electric starter operates Mobile should be charged in engine
only when the vehicle is in neutral position. Self running condition.
start is not possible in gear engaged mode.

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 Location of Parts

C
B

Removal of Side Cover LH Fitment of Side Cover LH

• Insert the key into the cover lock (A) and • Match & insert the Lug C (rear side) in
turn the key clockwise. bracket mounted on chassis & slide ‘Side
Cover’ LH toward rear side.
• Hold the cover with both hands and pull
front side (B) first & slide rear side (C) • Match ‘B’ lug provided on front side of side
toward front side. Take out ‘Side cover LH’. cover with hole provided on fuel tank & press
side cover inside.

CAUTION : Remove cover as described CAUTION : Ensure tool kit is fully

above, otherwise cover lugs may break. inserted in tool kit slot.

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 Location of Parts

C
B

Removal of Side Cover RH Fitment of Side Cover RH

• Remove the screw (A) given on ‘Side Cover’. • Match rear side (C) of ‘Side Cover’ lug with
hole located on chassis & press the cover.
• Hold the cover with both hands and pull • Match the Lug provided on front side (B) of
front side (B) first & rear side (C) later. Take ‘Side Cover’ with hole provided on ‘Fuel Tank’
out ‘Side cover’. & press ‘Side Cover’ inside.
• Match ‘Side Cover’ properly with bracket
CAUTION : Remove cover as described provided on ‘Chassis’ & fix it with Screw (A).
above, otherwise the lugs may break.
CAUTION : Fit cover as described above
to ensure proper fitment.

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 Location of Parts

Fig. A Fig. B

Removal of Seat Fitment of Seat

• Remove 2 nos. M5 Allen bolts provided for • Match & insert the bracket ('1' of Fig. 'B') of
fixing of seat on LH & RH sided with M5 seat with slot ('2' of Fig. 'B') provided below
allen key. fuel tank rear mounting on chassis.
• Lift the seat from rear side & pull it toward • Push seat towards fuel tank and align lugs
rear side. ('3’ & ‘4’ of Fig. ‘B') with bracket on chassis
& tighten 2 nos m5 Allen bolts in LH/RH
side.

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 Location of Parts

Tool Kit Location

Make of Battery may differ from vehicle to vehicle

Battery Tool Kit Location

• It is located inside the ‘Side Cover’ LH. • It is located below the battery box.
• Always maintain electrolyte level in each cell
• If tool kit is not inserted properly, then it
between Max. & Min. level marks.
may obstructs LH cover fitment.

CAUTION : Do not drive/run vehicle in

battery disconnected condition. It may lead CAUTION : Ensure tool kit is fully
to damage of electrical / electronic inserted in tool kit slot.
components.

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 How to Ride Your Bike
Starting The Engine : • Release starter button / kick lever as soon
• Turn the fuel tap knob to ‘ON’ or ‘RES’ as engine starts.
position. • When the engine is warmed up enough to
• Turn ignition switch key to ‘ON’ position. idle without using choke, return the manual
• Confirm that transmission is in neutral. choke lever to OFF position.
• If the engine is cold or when starting for
first time, use manual choke for quick Note : Do not let the engine idle longer than 3
starting. Choke lever is located on RH side minuets otherwise it will overheat.
of Carburettor.
Caution : Do not operate the starter
Manual Choke continuously for more than 5 seconds
otherwise battery would get discharged.
OFF Position ON Position
Wait 15 sec. after successive 3 cranks,
which will facilitate battery to recover.

• Keep throttle completely closed, press

starter button “ ” / apply kick to start the
engine.

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 How to Ride Your Bike
Moving Off : Warning : When shifting down to lower gear,
• Check that Center/Side stand is up. do not shift at such high speed that engine
rpm jumps excessively. This may cause
• Depress the clutch lever.
engine damage, and rear wheel may skid.
• Shift into 1st 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 Braking :
enough rpm to keep it from stalling. • Close the throttle completely, leaving the
clutch engaged (except where shifting gears)
Shifting Gears : so that the engine braking will help slow
down the motorcycle.
• Close throttle & depress the clutch.
• Shift down one gear at a time so that you
• Shift into next higher or lower gear. are in Neutral when you come to a complete
• Open the throttle and release the clutch stop.
lever slowly and simultaneously. • When stopping, always apply both brakes at
the same time. De-clutch as necessary to
avoid engine stalling.

Gear shifting
pattern

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 How to Ride Your Bike
• Never lock the brakes, or it will cause the Running IN
tyres to skid. When cornering, use brakes
Proper running-in is important for the better life
judiciously and do not de-clutch. Reduce
and trouble free performance of the vehicle.
your speed before you get into the corner.
For emergency braking, disregard • During first 2000 kms running-in period do
downshifting, and concentrate on applying not exceed following speed limits.
brakes as hard as possible without skidding.

Stopping the Vehicle : Kms 1st 2nd 3rd 4th 5th

• Close the throttle completely. 0 - 1000 10 20 30 35 45
• Shift the transmission into neutral. 1000 - 2000 15 30 40 45 55
• Bring the vehicle to complete stop. • Always keep the speed below the limits
• Turn the ignition switch off. mentioned in the table.
• Do not race the engine excessively.
Parking the Vehicle : • Do not start moving or race the engine
immediately after starting. Run the engine for
• Support the motorcycle on a firm level
a minute at idle speed to give the oil a
surface with the center or side stand.
chance to workup into the engine.
• Lock the steering.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle
may fall over.

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 How to Ride Your Bike
Fuel Saving Tips : Ensure following maintenance points to get
optimum fuel efficiency from your bike.
A well maintained vehicle and good driving can
contribute a lot to the saving of petrol. Following Fuel Check fuel lines & connections
are a few simple fuel saving tips. for leakage.
Good Riding Habits :
• Ride smoothly and steadily at an optimum Spark plug Inspect and clean spark plug.
driving speed of 40 to 50 Km/h Adjust electrode gap.
• Avoid harsh braking. Air filter Clean air filter element
• Change the gear judiciously according to the periodically.
speed and load requirement. Engine oil Check level. Use recommended
• Don’t overload the vehicle above the grade and quantity.
specified payload.
• Use the accelerator judiciously. Brakes Ensure that the brakes are not
• Cut off the engine if you want to stop for dragging / binding.
more than two minutes. Clutch Ensure correct clutch lever play.
• Ensure choke lever is in ‘OFF’ condition after Tyre Always maintain recommended
engine get warm.
How to check mileage (Fuel efficiency) Pressure. tyre pressure.
Best way to calculate mileage is by following the Carburettor Clean & adjust the carburettor.
full tank to full tank method. Adjust idling speed.
• Fill way tank full up to small mouth (brim).
• Run the bike for say 100 km.
• Fill the tank full again in same fuel filling
station, probably with same fuel dispenser.
• Devide kilometer run / fuel quantity filled.

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 Safe Riding Tips
Safe Riding Tips braking are important not only for safety and
low fuel consumption, but also for longer life
• Always wear helmets while driving or riding.
of the vehicle.
Your helmets should conform to appropriate
Indian standards. • During monsoon drive the vehicle more
cautiously. Remember vehicles skid more
• Read thoroughly the
easily during light showers..
instructions in this
manual and follow them • Drive cautiously. Start early & reach your
carefully. destination safely.
• Avoid unnecessary • Always carry vehicle registration & insurance
accessories for the papers, and a valid driving licence with you.
safety of both rider and • Avoid driving on loose sand or stones where
other motorists. vehicle is likely to skid.
• Get familiar and follow traffic rules & • Properly wrap-up loose clothes while driving
regulations in your states as well as general or riding to avoid entangling in wheel or other
traffic signs. objects on road.
• Familiarise yourself well with starting, • Always concentrate on riding for safety.
acceleration and braking of the vehicle.
• When applying the brakes, use both front and
rear brakes simultaneously. Applying only one Daily Safety Checks :
brake may cause the vehicle to loose control. Before riding motorcycle be sure to check
• Riding at proper speed and avoiding following items. Please give proper importance
unnecessary acceleration and to these checks and perform all of them before
riding motorcycle.

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 Safe Riding Tips
If any irregularities are found during these • Smooth steering movement without
checks, refer to the Maintenance chapter & see restriction
your dealer for the action required to return the • Both stands return to their fully up position.
motorcycle to a safe operating condition. • Correct inflation pressure in both tyres
Warning : Failure to perform these checks Adequate tyre tread depth- no cracks / cuts.
every day before you ride may result in serious • Correct rear viewing span adjustment of
damage or severe accident. mirror.
• Enough fuel level for planned distance of
journey. No fuel leakage in fuel lines. Monsoon Care
• Take appropriate care in area of heavy
• Engine oil level (betn upper - lower level mark)
monsoon or high rainfall or high humidity. A
• Throttle cable play of 3 - 4 mm. Smooth
appropriate surface preventive coat to avoid
operation & positive return to closed position,
rusting on account of adverse atmospheric
• Steering Lock lever not fouling.
conditions is recommended.
• Brake Pedal Play 15 to 20. • Vehicle cleaning to be done with soft & clean
• Wear lining Indicator within usable range. No wet cloth to avoid scratches on painted parts.
brake dragging. • Clean & lubricate all the important parts as
• Drive Chain slack of 25 to 30 mm adequately detailed in a periodic maintenance chart.
lubricated. • Do not apply direct water jet on painted,
• Function of all lights & horn electrical / electronic parts.
• Clutch lever play - 2 to 3 mm • Do not obstruct engine cooling by adding mud
splash protection sheet at the front.

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 Periodic Maintenance Information
Recommended Engine Oil :
Always insist on Genuine Oil for optimum
engine performance.

Recommended SAE 20W50 API‘SL’ or

A
Oil Grade JASO‘MA2’
C

• Engine oil Replacement Frequency : 1st service &

B then every 5,000 Kms.
D

A : Oil Filler Cap B : Oil Level Gauge

Engine Oil Level Checking :

• Check engine oil level every day. Park vehicle
on level surface on center stand.
• Check oil level through oil level gauge ‘B’.
• Always maintain engine oil level between
upper (C) and lower (D) mark provided on
Cover RH. Top up with specified grade of oil
if the oil level is below lower level mark.
Engine Oil Capacity :
• Refill at Servicing : 1000 ml.
• During engine overhaul : 1100 ml.

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 Periodic Maintenance Information
CAUTION :
• It is most important to adhere to Tyre Pressure :
recommended grade & frequency of oil Keep appropriate tyre pressure as mentioned
change for the purpose of long life of critical below to increase life of the tyre & for better
fuel consumption.
engine components. For details refer
periodic maintenance chart. Front 1.75 Kg/Cm2 (25.0 psi)
• Do not reuse drained oil.
Rear (Solo) 2.00 Kg/Cm2 (28.0 psi)
Wheel Puncture : Rear (with Pillion) 2.25 Kg/Cm2 (32.0 psi)

Note : Incase the motorcycle is fitted with

imported tyres. compliance to respective
indian standard & central motor vehicle rules
has been ensured.

Use the recommended levers while removing the

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

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 Periodic Maintenance Information
Front Brake Fluid Level : (For Front Disc version)

evel
Min. L

Front brake fluid master cylinder reservoir is located near RH switch on handle bar.
• To check brake fluid level, keep vehicle on center stand with handle bar in straight ahead position.
• Always ensure that brake fluid level is above ‘MIN’ mark.
• Use only DOT 3 or DOT 4 brake fluid (from sealed container) to top up if required.

It is advisable that brake fluid should be replaced at every 30,000 Kms or once in two years whichever
occurs earlier.

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 Periodic Maintenance Information
Battery Maintenance : How to keep battery healthy ?
• Switch ‘Off’ ignition when engine is not
running. Get battery checked / charged during
periodic services.
• Do not press starter button for more than 5
sec. After 3 successive crankings, wait for 15-
20 sec. for battery to recover.
• Do not add extra electrical accessories such
as - Remote, Bigger horn, Musical brake
light etc. This will reduce the life of battery
Battery : • If vehicle is to be stored for more than 2
• Battery is located below seat assembly.
• 12V 4Ah VRLA (Valve Regulated Lead Acid type).
weeks disconnect battery to avoids self
Battery is sealed for life. discharge.
• Make of battery may differ from vehicle to vehicle.
Battery Features :
• No topping-up is required
• Reduced self discharge, Enhance safety. CAUTION : While disconnecting always
• No vent tube open to atmosphere hence no discharge of disconnect negative (-ve) cable first. While
electrolyte through vent tube. refitting always connect positive (+ve)
• When battery is found discharged, it is advised to get it cable first.
charged immediately.
• Environment care must be taken to dispose off used
battery. It is always recommended to hand over the same
to Authorised battery / Bajaj Dealer for proper disposal.

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 Periodic Maintenance Information
Spark Plug Drive Chain Slackness
• Remove spark plug by using plug spanner. • Chain top edge to be kept between the two
• Clean the spark plug. marks during chain slackness adjustment.
• Adjust the gap if incorrect by bending outer • Care should be taken, that the chain should
electrode carefully. never run dry. Lubricate chain from outside
Spark Plug Gap : 0.7 to 0.8 mm. with SAE 90 oil at every 500 kms.

Spark Plug : Champion PRZ9HC or • Chain slackness will have to be adjusted

Bosch UR4AC whenever required.

Std. Chain slackness :

25~30 mm

0.7 to
0.8 mm

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 Periodic Maintenance Information

Cleaning Chain Lubrication

Drive Chain • Clean the chain with nylon brush by using

• Lubricate chain every 500 kilometers with SAE kerosene/ with the help of chain cleaning
90 oil. machine.
• Check & if required adjust chain slackness • After cleaning, dip chain in SAE 90 oil /
(whenever required). lubricate in molten grease of chain cleaning
• Remove, clean, inspect and lubricate machine.
(overhaul) drive chain at every 5,000 • For effective lubrication recommended chain
kilometers. spray can be used. Spray the lubricant into
clearance between drive chain roller & bush.
Method of chain lubrication :
Wipe out excess lubricant by using lint free
• Remove chain covers & drive chain link lock cloth.
• Take out drive chain.

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 Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY
Sr. Servicing 1st
Operation 2nd 3rd
No. Every 5000 Km Remarks
500 4500 9500 after Previous Service
Kms ~ ~ ~
750 5000 10000
1st - 750 kms / 30 days
1. Servicing ü ü ü ü ü ü ü 2nd onward @ 5000 kms

2. Engine idling speed / CO% A A A A A A A A

3. Valve tappet clearance A A A A A A A A

SAE 20W50 API ‘SL’ /

4. Engine oil & Engine oil filter* R R R R R R R R JASO ‘MA2’
Replace @ 5000 kms

5. Oil strainer CL CL CL CL CL CL CL CL Clean @ 5000 kms

6. Spark plug functioning / Gap C,A,R C,A C,A C,A R C,A C,A R Replace @ every 15000 kms

Air cleaner element*** Clean @ every 5000 kms

7. Clean / Replace CL,R CL CL CL R CL CL R Replace @ every 15000 kms

8. Air filter cover ‘O’ Ring ** R R Replace @ every 15000 kms

9. Fuel cock sediment bowl cleaning CL CL CL CL CL CL CL Clean @ every 5000 kms

10. Carburetor float bowl cleaning CL CL CL CL Clean @ every 10000 kms

11. Carburetor rubber duct C, R C C C C R C C Replace @ every 20000 kms

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

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 Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY
Sr. Servicing 1st
Operation 2nd 3rd
No. Every 5000 Km Remarks
500 4500 9500 after Previous Service
Kms ~ ~ ~
750 5000 10000
12. Fuel pipes C,R C C C C R C C Replace @ every 20000 kms

13. Clutch lever free play C,A C,A C,A C,A C,A C,A C,A C,A

14. Throttle grip play C,A C,A C,A C,A C,A C,A C,A C,A

15. Rear brake pedal free play C,A C,A C,A C,A C,A C,A C,A C,A

Brake lining / pad wear / lubricate

16. brake cam / Brake pedal pivot pin CL,R CL CL CL,R CL CL CL,R Replace @ every 15000 kms
- check brake wear indicator
Use recommended brake fluid
17. Brake fluid level**-top up / replace C,A,R C,A R (DOT3 / DOT4). Replace at
every 30000 kms.
Disc brake assly - Check
18. funtionality, leakage or any other C C C C
damage

19. Master cylinder cup & dust seal R R Replace @ every 30000 kms

20. Caliper piston seal & dust seal R R Replace @ every 30000 kms

21. Brake pipe hose C,R C,R Replace @ every 30000 kms

28
Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY
Sr. Servicing 1st
Operation 2nd 3rd
No. Every 5000 Km Remarks
500 4500 9500 after Previous Service
Kms ~ ~ ~
750 5000 10000
22. Brake cam & pedal pivot pin L L L

23. Steering play C,A C,A C,A C,A C,A C,A C,A C,A

24. Steering stem bearing C,L,R C,L,R C,L,R C,L,R Replace @ every 10000 kms

25. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T

26. Rear sprocket fasteners C,T C,T C,T C,T C,T C,T C,T C,T

27. Rear wheel rubber shock damper C, R C,R C,R C,R Replace @ every 10000 kms

Cylinder hear decarbonizing, valve

28. CL CL CL Clean @ every 15000 kms
lapping & Replace valve oil seals

29. Engine air breather tube R R Replace @ every 20000 kms

Non-Sealed drive chain cleaning & Customer to apply OKS chain lube
30. CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
lubrication spray or equivalent @ every 500 kms.

Drive chain remove, clean, insp. &

31. CL,L CL,L CL,L CL,L CL,L CL,L CL,L
lub. (O/H)

32. Drive chain link lock R R R R R R R Replace @ every 5000 kms

Wheel bearing (for non-sealed

33. bearings only) C,L C,L

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 Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY
Sr. Servicing 1st
Operation 2nd 3rd
No. Every 5000 Km Remarks
500 4500 9500 after Previous Service
Kms ~ ~ ~
750 5000 10000
34. Tyre tread wear C,R C,R C,R C,R C,R C,R

35. Front fork oil R R Replace @ every 20000 kms

Clutch switch cleaning

36. CL CL CL CL
(if applicable)

37. General lubrication L L L L L L L L

38. Swing arm pivot pin lubrication L L Lubricate @ every 20000 kms

* It is strongly recommended to use only recommended grade of oil.

** As applicable to model
*** More frequent cleaning may be required while driving in dusty environment.

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

Note : Periodic parts, Oil, Filters, All types of greases, Cleaning agents, Cables, Wear & tear parts, Rubber ‘O’ rings / oil seals / pipes,
Gaskets to be replaced as per Periodic Maintenance and Lubrication Chart and is mandatory.

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 Non-Use Maintenance
Non-use maintenance is necessary if a vehicle ** For Battery :
remains off road for a longer duration (more a. Remove battery and keep it on wooden
than 15 days**). The correct and careful non-use
plank, in properly ventilated area.
maintenance carried out before storing the
vehicle will prevent the vehicle from rusting and b. Before taking the vehicle for use.
from such other non-operational damages like • Get the battery recharged from the Authorised
fire hazards. Service Center.
• Clean the entire vehicle thoroughly. • Check and correct the electrolyte level and
• Empty the fuel from the fuel tank and apply petroleum jelly on terminals (applicable
carburettor float bowl (if fuel is left in for a to certain models).
longer time, the fuel will break and gummy Preparation for regular use after storage :
substance could clog the carburettor). • Clean the vehicle
• Remove spark plug & put several drops of 2T
• Make sure the spark plug is tight.
oil into the cylinder. Kick engine over slowly a
few times to coat cylinder wall with oil & • Fill the fuel tank with fuel.
install back spark plug. • Change the engine oil.
• Set the vehicle on a box or a stand so that • Check all the points listed in the Daily Safety
both wheels are raised off the ground. Checks section.
• Spray oil on all unpainted metal surfaces to • Check and inflate tyres to proper tyre
prevent rusting. Avoid getting oil on rubber pressure.
parts or brake liners.
• Lubricate the control cables.
• Cover entire vehicle neatly. Make sure that
storage area is well ventilated & free from any
source of flames or spark.
• Fill 10% excess air pressure in both wheels.

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Use only Bajaj Genuine Parts
Bajaj Auto Limited
Akurdi Pune 411 035 India
Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com