WARRANTY MANUAL

AND MAINTENANCE
Dear customer.
Congratulations on choosing Rouser135 LS, one of the finest vehicles in the world.
Before driving, please read this owner's manual carefully to familiarize yourself with the mechanisms and
vehicle controls. To keep your motorcycle in perfect condition and achieve consistent performance, you
We strongly suggest doing periodic maintenance services. You can trust the Bajaj-Guerrero dealers.
who are well equipped and have trained personnel to maintain and repair your Rouser 135 LS. If you have the need
When taking the vehicle to a local workshop, always insist on Genuine Bajaj parts to ensure your safety on one hand.
Performance and long life of your vehicle. If you require additional information, please contact the Bajaj Dealer.
Nearest warrior. If necessary, mentioning the registration number, chassis, engine, mileage, and phone number.
where you can contact him. Finally, we ask you to give your vehicle the appropriate care and regular maintenance such as
It is described in this manual. We are sure that this will provide you with a satisfactory experience, free of inconveniences during its use.
We wish you to enjoy driving for many kilometers.
 TableofContents
• Motor Oil
Description
Data from •Battery
Identification.................................................................................................................................... 1
Care in Rainy Season
Specifications
Techniques 2
Daily Safety Review.....................................................................................................................................................20
Location of
Parts 3 Warehouse Maintenance...................................................................................................................................................21
How to handle the
Motorcycle..................................................................................................................................... 12 Periodic Maintenance and Lubrication Table
•
Settlement................................................................................................................................. 12 Periodic Parts Replacement Calendar..............................................................................................................................25
•
Pre-Delivery Inspection......................................................................................................................................................28
Driving
Tips for Saving Applicable to All Paid Services
Combustible 14
Safety Tips for Use only Genuine Parts
To handle Safety and Precautionary Information
Maintenance Information Caution
General..................................................................................................................................... 16
This indicates that there is a potential risk or harm to you or others and to the vehicle if
this notice made is not taken into consideration.
DOC. NO.: 71110943 REV.00, DEC. 09 Care
This indicates a potential risk that may result in damage to the vehicle. Follow the advice
expected with due care.
 Datos de Identificación Technical Specifications
The Frame and Engine numbers are used to register the motorcycle. They are alphanumeric codes that Motor 4 Times DTS-i, One cylinder Front Tires: 2.75 X 17”, 41 P
they identify their particular vehicle from others of the same make and model. Air cooled. Rear:100/90X17”,55P
Diameter and Stroke: 54.0 mm x 58.8 mm Pressure Forward: 1.75 kg/cm2(25 psi)
Location of the Frame Number (NIV): Desplazamiento : 134.66 cc Rear(Solo):2.00kg/cm2(28 psi)
On the left side of the steering tube. Relationship of comp. 9.8:1 Rear (Passenger): 2.25 kg/cm230 psi
(17 alphanumeric digits). Idle 1400 rpm Electrical System 12 Volts DC
NIV: Vehicle Identification Number Max Power 13.5 Ps @ 9000 rpm Lighthouse 35/35W
MaxTorque 11.4 Nm @ 7500 rpm Pilots 5W (2 pieces)
Ignition System CD, microcontrolled CDI Neutralwitness LED
with TRICS Witnessreservation LED
Spark plug (2 Nos) CHAMPION, BOSCH Skull LED
Spark Plug Gap 0.6~0.7 mm Directionalwitness LED
Lubrication Wet sump, forced Neutralwitness LED
Transmission 5 speeds Highbeamwitness LED
Front Brake Hydraulically operated, disc Speedometer light : LED
of 240 mm Fuel level LED bars
RearBrake 130 mm drum Horn 12 V DC 2A
Tank Cap : Battery 12 V 5 Ah MF
Full 8 liters Focus for plate 5W
Reservation 2.5 liters Net weight : 122 kg.
Utilizable 1.6 liters Total weight 252 kg. (C/conductor and passenger)
Dimensions : Max Speed 115 km/hr.
Length 1995 mm (With a driver weighing 68kg)
Wide 765 mm Earrings 26% max.
Location of Engine Number: Height 1045 mm
On the left side of the engine near the Distance between axles: 1325 mm Note: All dimensions are in no-load condition.
gear shift pedal Distance to the floor 170 mm The information above may change without notice.
(11 alphanumeric digits)

2
 Localization of Parts Parts Localization
1
5
6

2 7
8
3
9
10
4 11
12

1. Speedometer: The speed of the vehicle is displayed in 8. Reserve Indicator: When it lights up. It shows that the To put on the lock:
digits. fuel level in the tank is approximately 2.5
liters. It has three positions Turn the handle completely to the left side or
2. Indicador de Nivel de Combustible : Combustible disponible right. Press and release the key. Turn the key to the
9.Neutral Witness: When the transmission is in neutral,
3. Tachometer: Displays the engine speed in rpm the witness lights up. LOCK Locked address, on position "LOCK" and remove the key.
4. Power Switch: Operates the 'ON'/'OFF' switch 10. Trip Reset Button: The trip meter can off
& the address lock. To remove the lock:
be readjusted to zero by pressing the button.
5. Odometer: Displays the accumulated kilometers that the vehicle 11. Travel Meter : The odometer show the kilometers
Insert the key and turn counterclockwise.
has traveled. trips since it was readjusted to zero. OFF Free direction, turned on clock to the 'OFF' or 'ON' position.
6. Turn Signal Indicators: When the switch of 12. Battery Indicator: Shows the condition of the battery. off
Key :
turn signals are activated, the indicator and turn signals
they blink. If it is displayed continuously, it means that the battery ON Free direction, turned on A common key is used for the switch of
is in good condition ignition, tank cap and cover lock
7.High Light Witness: When the lighthouse is on and lit turned on
the witness lights up. LOW When this symbol is displayed, the battery is lateral.
downloaded.
 Parts Location Parts Localization
A
D

Valve of
Stopperof Combustible
tank
RES B
C
ON

Left Hand Switches C. Horn Button: Press the button to ring

the horn.
• To open the tank cap, lift the lid. It has three positions A. High Beam Switch: When the front headlight is
Insert the key and turn it clockwise. on, the high or low beam can be selected D. Interruptor de Sobrepaso : Presione el interruptor
ON The fuel level is above the with the switch. The high beam indicator is located to turn on the high beam and alert vehicles
watch and lift the cap.
reservation. in the instrument console. This turns on at against their intention to surpass.
• The stopper closes by pushing it to its position. select the high beam.
RES: The fuel level is below the
Close. The key cannot be removed while the
reservation. High Beam Low beam
this cap is open.
OFF: The fuel delivery is closed. B. Turn Signal Switch: When the switch
It is stopped on the left. ) or right ( ), the
the corresponding directional blinks. The indicator in
the console blinks the same way. To stop
the blink press the switch.
 Parts Location Localization of Parts
:hct tS
w
i racS
ti r tcelE.F
The switch operates the electric drive when the
G the clutch lever is applied and with C
C
the transmission at any speed.
B B
It is recommended to start the engine in neutral.

E G. Engine Stop Switch :

The switch is for emergency use. During A
F A
an emergency, press the switch to ( ) for
turn off the engine.

Right-Hand Switches WARNING: While starting the engine, ensure

that the Stop switch is located in the
Removal of Left Side Cover Removal of Right Side Cover
E. Interruptor de Luces : Tiene tres posiciones. Insert the key into the lock (A) and turn clockwise. Remove screw (A).
ON position ) . If it remains in the
the clock hands. Hold the cover with both hands and pull from the front.
Position OFF the engine will not start.
All the lights off. Hold the cover with both hands and pull from the front first (B). Slide (C) forward. Remove the
first (B). Slide (C) forward. Remove the cover.
Whiletheengineisrunning,the cover. Installation of DER Roof
skull, dashboard, and pilot lights, remain Installation of Left Cover Match the back clip (C) of the cover with
enclosed. • Match the back clip (C) of the cover with the chassis support and slide (C) backward.
the chassis support and slide (C) backwards. • Match (B) from the front of the cover in the hole
While the engine is running. The headlight • Pair (B) from the front of the cover in the hole in the tank and press the cover.
forward, Skull and instruments will be previous in the tank and press the cover. Match the cover appropriately with the support
lit Properly match the lock and turn the key remove the air filter and install the screw (A).
in the lock (A) to finish.
WARNING: Install the cover as shown
WARNING: Remove the cover as described to ensure its installation.
above, otherwise it may damage it.
 Parts Location Parts Localization

BATTERY

Tool

Fig. 1 Seat Release Cable Fig. 2 Seat fastening screw

Battery Tool Game Removal of the Rear Seat Removal of Front Seat
• It is located behind the left side cover. • It is located beneath the battery. • Remove the left side cover • Remove the left side cover.
• Always keep the electrolyte level between the • To remove the back seat, pull the cable from • Remove the rear seat.
lower and upper levels. CAUTION: Insert the tool set release of seat (A) shown in figure 1. • To remove the front seat. Remove the
• Always keep an eye on the load condition of appropriately for the side cover Keep the cable pulled, and press lightly the screw (B) shown in figure 2.
the battery with the icon indicator on the dashboard, yes left can be installed correctly. back seat, lift the back seat of the
• Lift the back part of the seat and slide it towards
blinks (indicates that the battery is in a the back part and slide it back to the same
back to remove it.
discharge condition), take the vehicle to a time.
authorized service center B for them to review it.
WARNING: Always remove the seat in this manner
indicated.
 Parts Localization How to Handle the Motorcycle
Settlement Engine Start:
An appropriate settlement is important for improvement. • Put the fuel valve in ON or RES.
the performance and a problem-free life of the vehicle. • Turn the ignition key to ON.
• During the first 2000 Kms. Do not exceed the • The Stop switch must be in position ( )
speed limits following. • Confirm that the transmission is in neutral.
Kms 1a 2a 3a 4a 5a • Keep the accelerator closed, and press the button.
of march ) or kick to turn on.
0 - 1000 14 22 31 38 45
1000 - 2000 19 31 43 52 62 CAUTION: Do not operate the starter motor for more
of 5 seconds. Wait about 15 seconds before
• Always keep the speed below the restart the electric drive.
limits indicated in the table.
• Do not rev the engine excessively. NOTE: The motorcycle is equipped with a switch
Installation of Front Seat Rear Seat Installation • Do not start to move or accelerate the engine gear lock. The motorcycle can start
• To install the rear seat, pair and insert immediately after starting. Heat the in any shift when the clutch is engaged.
• Match and insert tab (1) into support (2)
the support (4 of figure C) of the seat with the idle engine for one minute to give However, we recommend starting the engine in
provided below the tank and shown in the figure
support (5 of figure C) provided in the chassis. opportunity for the oil to lubricate the entire engine. neutral transmission position.
And push the seat forward ensuring
that the tongue (1) fits with the support (2). • Push the seat forward and align the pin Starting to Move:
• Press the seat at the back to (6 of figure C) and the seat lock (7 of • Check that the lateral and central triples are up.
align the fastening screw. the figure C ) . • Actuate the drunkenness lever.
• Press the seat in the center until it fits in. • Change to 1 to Speed.
• Tighten the fastening screw.
lock ensuring that the seat does not • Open the throttle and release the clutch lever
levante5 again. slowly and simultaneously.
CAUTION: Always install the front seat
• Upon starting to get drunk, open a little more the
first
accelerator taking the revolutions enough to
that the engine does not turn off.
 How to Handle the Motorcycle How to Handle the Motorcycle
Making Changes : • I lower one gear at a time until
I reach neutral when you stop.
• Close the throttle and engage the clutch. • Drive smoothly and consistently at a speed
• When stopping, always apply both brakes.
• Switch to the following high or low speed. between 40 and 50 km/h.
at the same time. Engage the clutch to
• Open the throttle and release the clutch lever keep the engine running. • Drive at a constant speed; avoid acceleration. Combustible Inspect fuel hoses and
slowly and simultaneously. sudden or abrupt braking as much as possible. Plan. connections due to leaks
• Never tie the brakes, it can cause the
tires skid. When in a curve, apply the your trip appropriately with minimal starts and
stops. Spark plugs Inspect and clean the spark plugs.
brakes with care and I did not apply the clutch.
Adjust your calibration.
Slow down when taking a turn. In a • Make the changes with judgment according to the
emergency, do not lower your guard and focus on speed requirements. Drive as much as possible Air Filter Clean the filter periodically.
apply the brakes as best as possible without reaching in high changes.
skid the tires. Motor Oil Check level. Use grade oil.
• Travel as light as possible; do not overload it.
vehicle above its specified load. and quality specified in the
Stopping the Vehicle: maintenance chapter
• Close the throttle completely. • Stop the motor quickly at the end of its run.
Avoid excessive idling. If there are continuous stops, Brakes Ensure that the brakes are not
• Put the transmission in neutral. turn off the engine if it stops for more than two dragging or failing
CAUTION: When changing to a speed • Pare el vehículo completamente. minutes.
inferior, do not change when revolutions • Turn the power switch to the OFF position. • Ensure the following Vehicle Maintenance. Clutch Ensure the correct game.
they are on high as this can still rise
plus the revolutions and cause a skid Parked: Tires Always maintain pressure
causing the motorcycle to lose control and • Put it in neutral and turn off the engine. adequate.
to cause an accident.
• Stop the motorcycle on level ground with
Carburetor Adjust the idle speed.
either of the two tripods.
Braking
• Completely close the throttle without acting on the WARNING: Do not park in sloping areas
clutch so that the engine stops the vehicle. the smooth terrain to avoid vehicle falls.
 Tips for Safe Handling General Maintenance Information
Always wear a helmet. Always carry the registration papers in the vehicle. Recommended Oil:
when driving. The helmet must insurance and valid license. Check the engine oil level every day The use of multigrade motor oil SAE 20W50 with
comply with regulations and before starting the vehicle. SL API specifications and JASO MA since you are
Avoid handling in sand or gravel where the
appropriate standards. specifications comply for the use of oil
the vehicle is more prone to skid. Always keep the engine oil level between
Read the instructions of the the upper and lower marks located in the formulated for motorcycles.
Do not wear loose clothing that may get caught in the
manual y s i g a l a s right cover.
wheels of the vehicle.
cautiously It is recommended to change the oil at intervals of
Engine Oil Level Check:
Always focus on driving safely. 5,000 kms, for better performance of the
• Avoid unnecessary accessories that involve the Park the vehicle on the central tripod in a engine components.
safety of you, the passenger, and other vehicles. level surface.
Familiarize yourself and follow the rules and regulations of Check the level through the peephole Motor Oil Grade SAE 20W50 API 'SL'
Traffic is like this as well as the signs Keep the level between C and D
traffic regulations.
Engine Oil Capacity: Frequency of 1erreplacement at 750 Km. / 1er
Familiarize yourself with starting, accelerating, and braking. 1000 ml when filling and 1100 ml when reconditioning. Replacement* service. Henceforth each
of the vehicle. 5,000 Km.
When applying the brakes, use both front and rear. For any brand of oil, the replacement must be
simultaneously apply. Only apply one every 5000 km.
It can cause you to lose control of the vehicle.
Drive at a proper speed and avoid
CAUTION:
unnecessary acceleration and braking. This is
important for your safety, consumption of It is of utmost importance to use the degree and
fuel and vehicle lifespan. recommended oil change frequencies
with the purpose of lengthening the life of the
During the rainy season, drive with components. See maintenance table.
Caution. Remember that it is more slippery. Do not reuse used oil.
• Drive carefully. Leave early and arrive at your
safe destination.
 General Maintenance Information General Maintenance Information
WARNING: Do not drive the vehicle with the battery
disconnected. This can lead to damage in the
electrical and electronic components of the vehicle.

Spark plug
• Remove the spark plugs using the appropriate tool.
• Clean the spark plugs properly.
• Adjust the calibration if it is incorrect by bending.
the grounding electrode very carefully.
Battery: 12V - 5 Ah, MF
Flat Tire Chain Game Calibration 0.6~0.7 mm.
The battery is located behind the side cover.
Use the recommended tools to remove the • The top of the chain must be maintained left. Brands BOSCH UR4AC (2 Nos.) O
tire and the inner tube and avoid damaging the rim and paint between the two brands during the game adjustment of Always ensure that the electrolyte level is CHAMPION PRZ9HC (2 Nos.)
of the same. the same. always between the upper and lower levels.
• Becarefulthatthechainshouldnevergetstuck • Check and fill the battery with distilled water if the
Tire Pressure: without lubrication. electrolyte level is below the
Maintain the tire pressure mentioned inferior brand.
down to increase its lifespan and save fuel. • Lubricate the chain with specification oil.
The life of the battery can be compromised if it
SAE 90 every 500 km.
use running water.
Forward 1.75 Kg/Cm2(25.0 psi) • The review and adjustment of the chain game must Taknig caer of hte envorinmen,t when
to be done whenever required. if you need to dispose of batteries, you should take them to a recycling center.
Back(Solo) 2.00 Kg/Cm2(28.5 psi) specialized collection for battery recycling
Back(withpassenger) 2.25 Kg/Cm232.0 psi used or with its distributor. If you notice that the battery
It is downloaded, upload it immediately.
 General Maintenance Information Daily Security Review
Beware during the Rainy Season: Before riding the motorcycle, make sure to check What to Review Review
the following points. Please of the importance
• The user is advised to take appropriate care. Brakes Correct fit (20~25 mm).
appropriate to this review and perform it before driving
durante la temporada de lluvias. Utilice una capa 2. Wear indicator within the
the motorcycle. If it finds irregularities during the
appropriate protector to prevent oxidation USABLE RANGE.
review, refer to the maintenance chapter and see
during adverse atmospheric conditions.
your authorized distributor or service center for 3. Without dragging.
• The cleaning of the vehicle should be done with cloths. return the motorcycle to a condition of operation
soft and clean to avoid damaging the parts safe. Chain 1. Correct fit (25~30 mm).
painted.
2. Adequate lubrication.
• Clean and lubricate all important parts CAUTION: The lack of carrying out this
detailed in the maintenance periodic table. review every day before driving the Lights Operation of all.
motorcycle can result in serious harm or
• Do not apply pressurized water to painted parts, Honk Correct operation.
Front Brake Fluid Level accident or a severe accident.
electrical or electronic.
Address softness
• The front brake fluid reservoir is located • Do not obstruct the engine ventilation, using
on the handlebar near the switches of What to Review Revise 2. Without restriction to movement.
protectors for water or mud at the front of it
Right handlebar. motes. Neither loose nor tight.
Combustible Sufficient amount for the distance
• To check the level, position the vehicle in the planned, without leaks in the ducts. Clutch Correct fit. (2 to 3 mm).
central tripie on a level surface. Check
Motor Oil Engine oil level between the 2. Smooth lever operation.
that the cover of the reserve is horizontal
completely. upper and lower marks Tripies Complete return position above.
• Always ensure that the front brake level Accelerator Correct cable game of Lateral and Center
be above the minimum shown accelerator (2 to 3 mm) Tires Correct pressure.
• Use only DOT 3 or DOT 4 brake fluid Smooth operation and positive return
Depth of the floor.
brake fluid (from a closed bottle). to the accelerator position
automatically closed. 3. No cuts or slashes.
It is recommended that the brake fluid be changed every
30,000 Km or once every two years the first thing that Lock Address. Proper operation of the lock Mirrors Correct position.
it happens.
 Storage Maintenance PeriodicMaintenanceandLubricationTable
Storage maintenance is necessary if the ** Batería :
vehicle remains out of use for a long period a. Remove the battery and place it on top of a Sr. Operation
(more than 15 days). The proper maintenance of No. Service 1st 2o 30 40 50 60 7o
wood table in a ventilated area.
storage done with care before storage Kms 750 5000 10000 15000 20000 25000 30000
it will prevent the oxidation of the vehicle as well as dangers
b. Before using the vehicle.
• Charge the battery at a Service Center 1. Service n n n n n 1st n- 750
n Km / 30 Days
from fire due to not being used. Every 5000 km forward 20
• Clean the vehicle completely. Authorized.
2. Idle and %CO A A A A A A A A
• I emptied the fuel from the tank and the carburetor (if • Revise and correct the electrolyte level and apply.
petrolatum in terminals. (Applicable to certain 3. Valve Clearance A A A A A A A A
the fuel is left over time, the
combustible degrades and turns into a models). 4. Motor Oil* R R R R R R R R Replace every 5,000 Km*
gum-like substance that can clog the carburetor. 5. Sieve CL CL CL CL CL Clean every 10,000 km
Preparation after storage:
• Remove one of the spark plugs and add a few drops of 6. Oil Filter R R R R R R R R Replace each change of
• Completely clean the vehicle.
two-stroke oil in the cylinder. Operate the Oil
kick slowly sometimes so that this • Make sure the spark plugs are tight.
7. Spark plugs C, A, R C, A C, A C, A R C, A C, A R Replace every 15,000 Km
cover the walls of the cylinder and reinstall them • Put fuel in the tank. V V
spark plugs. 8. Air Filter Element CL, R CL CL CL R CL CL R Clean every 5,000 km
• Change the engine oil. Replace every 15,000 Km
• Place the vehicle on a box or stand to • Review all the points listed in the section of
that the two wheels do not touch the ground and are in the 9. Arosello Cover Air Filter R R Replace every 20,000 km
daily safety review.
both air. 10. Fuel Valve Cover CL CL CL CL CL CL CL
• Revise and inflate the tires to their pressure.
• Add a little oil to all the parts appropriate. 11. Carburetor Drainage CL CL CL CL Clean every 10,000 km
unpainted metal objects to prevent 12. Rubber Duct of the Carburetor C, R C C C C R C C Replace every 20,000 km
oxidation. Avoid oiling rubber parts and brake pads.
brake. 13. Fuel Hoses C, R C C C C R C C Replace every 20,000 km
• Lubricate the control cables. 14. Battery Electrolyte Level C, A C, A C, A C, A C, A C, A C, A C, A
• Cover the vehicle. Ensure good ventilation and 15. Clutch Lever Game C, A C, A C, A C, A C, A C, A C, A C, A
that this is out of the reach of sparks or fire. 16. Throttle Control Game C, A C, A C, A C, A C, A C, A C, A C, A
Motor oil grade (SAE 20W50 API 'SL' JASO MA) intervals of 5,000 kms.
V V
Cleaning more frequently in dusty conditions.
PeriodicMaintenanceandLubricationTable PeriodicMaintenanceandLubricationTable

Mr. Operation Mr. Operation

No. Service 1st 2nd 3rd 4th 5th 6th 7th No. Service 1st 2o 30 4o 50 60 70
Kms 750 5000 10000 15000 20000 25000 30000 Kms 750 5000 10000 15000 20000 25000 30000

17. Rear Brake Pedal Game C, A C, A C, A C, A C, A C, A C, A C, A 33. Aerocello Chain (If applicable) L Every 500 Kms
18. Brake Pad Wear CL, R CL CL CL, R CLCL CL, R Replace every 15,000 km 34. Remove, clean, inspect & lubricate chain
CL, L (O/H) CL, L CL, L CL, L Every 10,000 km
19. Brake Fluid (If applicable) C, A, R C, A C, A C, A C, A C, A C, A R Replace every 30,000 km Chain Lock and Bolt R R R R Replace every 10,000 km
20. Retain and dust cover Master Cylinder R(If applicable) R Replace every 30,000 km 36. Wheel Bearings (non-sealed only) L C, L Every 20,000 km
21. Clutch and Brake Clamp Dust Cover R R Replace every 30,000 km 37. Tire Wear (replace if needed) C, R C, R C, R C, R C, R C, R Every 5,000 km example
each service after the 2nd
Brake Hose C, R C, R Replace every 30,000 km
Front Fork Oil R R Replace every 20,000 Km
23. Brake Lever and Brake Pin Pivot L L L
Automatic drowner and temperature sensor C, A C, A C, A C, A C, A C, A C, A C, A Every 5,000 Km
24. Direction Game C, A C, A C, A C, A C, A C, A C, A C, A
40. TPS C, A C, A C, A C, A C, A C, A C, A C, A Every 5,000 Km
25. Steering Bearings C, L, R C,L,R C,L,R C,L,R
41. Gas Pressure of Rear Dampers C, A C, A Every 20,000 Kms
26. Tightening of Fasteners C, T C, T C, T C, T C, T C, T C, T C, T
42. Clutch Drive Bushing Game CL, R CL, R CL, R
27. Rear Gear Screws C, T C, T C, T C, T C, T C, T C, T C, T
Clutch Switch CL CL CL CL
28. Rear Gear Dampening Bushings C, R C, R C, R C, R Replace every 10,000 km
General Lubrication L L L L L L L L
29. Muffler Drain Hole CL CL CL CL CL CL CL CL Clean every 5,000 km
45. Rear Fork Pivot Pin L L Lubricate every 20,000 km
30. Decarbonization of Head, Settling of
Valves and Valve Seal Replacement CL CL CL Clean every 15,000 km 46. Hule Head Support Bushing R R R Replace every 15,000 Km

31. Engine Breathing Tube R R Replace every 20,000 km

C : Revise, A : Ajuste, CL : Limpie, R : Remplace, T : Apriete, L : Lubrique
32. Chain Play and Lubrication C, A, L Lube every 500 km.
A- Adjust when required. Parts and lubricants for periodic maintenance are mandatory and paid for by the motorcycle user.
 Maintenance Parts Replacement Schedule Maintenance Parts Replacement Schedule
Bajaj Auto recommends replacing the following parts for your vehicle to achieve optimal performance. Limit of Kms Days Description Quantity

Motor Oil 1000 ml

Limit of Kms Days Description Quantity
Oil Filter 1
Motor Oil 1000 ml
500 ~ 750 30 - 45 Arosello Filter Cover 1
Oil Filter 1
Rubber Duct of the Carburetor 1
4500 ~ 5000 240 Days Motor Oil 1000 ml
Fuel Hoses 1
Motor Oil 1000 ml 19500 ~ 20000
Steering Bearings 1
Oil Filter 1
120 Days Shock Absorber Bushings Rear Gear 1
9500 ~ 10000 240 Days Steering Bearings 1
since
Shock Absorber Bushings Rear Gear 1 the last Engine Breathing Tube 1
service
Chain Lock and Bolt 1 Chain Lock and Shackle 1
Spark plugs 2 Nos.
Front Fork Oil 300 ml
Air Filter Element 1
24500 ~ 25000 Motor Oil 1000 ml
Motor Oil and Oil Filter 1000 ml and 1
120 Days
Motor Oil 1000 ml
14500 ~ 15000 since the Valve Seals 4
last Head Packaging 29500 ~ 30000 Oil Filter 1
1
service
Clutch Release Bearing Set 1 Spark plugs 2 Nos.
Head Shock Absorber Hole 2
Maintenance Parts Replacement Calendar Pre-Delivery Inspection
Limit of Kms Days Description Quantity Fill the tank with the appropriate fuel and check the flow to the carburetor. q
2. Check all lock plates, tank cap, ignition, steering, side cover. q
Air Filter Element 1 3. Check the smooth operation of the fuel valve. q
Brake Pads 1 4. Check the oil level and refill if necessary. q
5. Check all controls, game and operation: - Accelerator, Clutch, brake lever,
Brake Fluid 75 ml Rear brake pedal. q
6. Check the operation and position of the gear pedal. q
Brake Hose 1
7. Inspect the rear shocks and their proper adjustment. q
Master Cylinder Dust Cover and Retaining Ring 1 8. Revise and adjust the chain game. Lubricate if necessary. q
9. Check the brakes and adjust if necessary. q
120 Days Packaging and Dust Cover Jaw Game 1
29500 ~ 30000 since 10. Check and fill the brake fluid level. q
the last Steering Bearings 1 11. Check and adjust the tire pressure to the recommended value. q
service 12. Check the voltage at the battery terminals, specific gravity, electrolyte level. Charge if required.
Hules de Amortiguación EngraneTrasero 1 Check the connection at the terminal, relay switch, and apply petroleum jelly to the terminals. q
Chain Lock and Shackle 1 13. Review and adjust the game in the direction. q
14. Check the alignment of the front cover with respect to the front rim. q
Valve Retainers 4 15. Check the torque of all important nuts and bolts. q
1 16. Install original accessories such as mirrors, bumpers, etc. q
Head Packaging
17. Start the engine and check the idle and % of CO. q
Clutch Hub Kit 1 18. Check all switches, gauges, horn, and lights to ensure they are working properly. q
Head Shock Absorber Bushings 2 19. Perform a driving test of the vehicle. q
20. Check for oil leaks and correct if any exist. q
21. Repair any other defects seen or observed during the test drive and clean the vehicle. q
22. Wash and detail the vehicle before delivering it. q
 Applicable to All Services Use Only Original Parts
Wash the vehicle.
2. Change or fill with motor oil according to the periodic maintenance schedule. For Optimal Performance
3. Clean the air filter element. (Replace every 15,000 km). of the Vehicle
4. Check the fuel hoses. (Replace the hoses every 20,000 km).
5. Clean the sieve according to the periodic maintenance schedule. (Replace if necessary).
6. Clean the fuel valve bowl.
To Prolong Life of
7. Drain the carburetor / Clean the bowl according to the periodic maintenance schedule. the Components and Vehicle
8. Clean, Check and Adjust the Spark Plug Calibration. (Replace every 15,000 km).
9. Replace the rubber duct of the carburetor and the air filter aerosol every 20,000 km.
10. Revise and adjust the valve clearance if required. Decarbure the head every 15,000 km.
To Save on
11. Adjust the chain set. Lubricate. Replace the lock and pin every 10,000 km. the Maintenance
12. Replace rear gear shock oils every 10,000 km. (If needed)
Replace the engine breathing tube every 20,000 km.
14. Clean the drain hole of the muffler every 5,000 km. For the Driver's Safety
15. Check the wear of brake pads and adjust. Replace every 15,000 km. (If needed)
Lubricate the brake lever and pin every 15,000 km.
17. Remplace el reten y cubre polvos del cilindro maestro, sello y cubre polvo de la mordaza, manguera de freno cada 30,000 Kms.
18. Check and fill brake fluid. Replace brake fluid every 30,000 km. Originality Test
19. Revise and adjust the steering. Replace the steering bearings every 10,000 km.
20. Replace the front fork oil every 20,000 km.
21. Clean the clutch switch every 10,000 km. Scratch the hologram 'Genuine'
22. Revise and adjust the clutch and accelerator.
Partially Transparent Hologram
23. Replace the clutch gear bushings every 15,000 km.
24. Replace the head cushioning rubber every 15,000 km.
25. Check and tighten nuts, bolts, and fasteners to their recommended torque.
26. Lubricate specific points according to the lubrication schedule, rear fork pivot bolt every 20,000 km.
27. Check battery voltage, electrolyte level and fill with distilled water if required. Guide the cables and install the caps. Ba ja j Au to LIm ite d
Aku rd i P u ne 4 1 1 035 India
03100802 CLUTCH BO X
P 0001

properly terminals, clean the terminals and add petroleum jelly.

P ACKAGING MONTH
MAY 2 0 0 3
M.R.P. (Incl. of All Ta xe s ) in Rs . for Qty. pa cke d QTY. 1 NO.
IN AS S AM, KARNATAKA, MANIP UR, M.P., 57.43
NAG ALAND, U.P.,
& UTTAR ANCHAL IN OTHER S TATES 55.58

28. Start the engine, check and adjust the horn, all lights, TPS, automatic choke, thermal sensor.
29. Check the idle and the % of CO. Tune the engine and carburetor if needed.
30. Review and adjust the pressure of the rear shock absorbers if necessary every 20,000 km.
31. Carry out any other additional work if required.
32. Check tire wear and inflate to the recommended pressure.
33. Take a driving test.
34. Wash and detail the vehicle before delivery. Golden Hologram