Guide 3 Basas Dear Customer, Congratulations on choosing “Bajaj Discover (135) DTS-I", one of the tinast vehi you by Bajaj Auto Limited, In the country brought to Before you prepare for riding, please read this User's Guide and the controls of the vehicle, votully to familarize yourself with the med To maintain your bike in perfect running condition to deliver consistent performance, we earnestly advise you to avail periodic servic You can entrust our Bajaj Dealers, who are well equi sssary facilities, skill sats and trained manpower for servicing and repairs of your “Bajaj Discover (135) DTS-i". In the rare event af going to a local garage, always insist on Genuine Bajaj Spares to ensure safety, performance and longer lfe of your vehicle. Should you require any addtional information, please approach our Bajaj Dealers. If necessary, you may also write to seling dealers, with relevant details like Rogstration no. Chassis no., Engine no., Date of purchase, Kms. un, name of selling dealer and your contact numbers. Finally, may we request you to give your vehicle @ 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 BAJAS AUTO LIMITED AAkurdi Pune 411 036 IndiaDescription Identification Data 1 Technical Specifications Location of Parts How to Ride 2 Motorcycle . 10 Sate Riding Tips 12 Daily Safety Checks . 13 Running In . - 14 Fuel Saving - 14 General Information a 15 Periodic Maintenance / Lubrication Chart 7 Schedule For Service Wise Part List 2 ‘Non-use Maintenance 3 Identification Data Discover ee The Frame and Engine seal numbers aro used to register the motoreye to resister the metoreyce. Thy are te unique alpha-numaric codes to identify your particular vehicle from others of the same model and type. = Frame Number Location On the LH side of steering tube. (Alpha-Numaric - 17 digits), Engine Number Location : (On LH side crankcase near gear change lover (Aipna-Numeric - 11 dighs).Technical Specifications ae Engine + 4 stroke DTS, Single evlinder [Natural air cooled, Bore x Stroke = 58,0 mmx 508 mmm Eng. Displacement = 754.21 ce Compression Ratio : 95 + 05:1 {ating Speed £1400 + 100 mpm ‘Max. Not Power = 9.64 (13.10Ps) at 8500 rpm Ignition System Mero controler based digital CO! ‘Spark Plug Champion RG 4 HG 2 Nos. ‘Spark Plug Gap: 0.7 to. 1.8mm Lubrication Wet sump, Forced Transmission 4 speed constant mesh, Front Brake Hydraulic operated disc brake. Rear Brake + Moch. expanding shoe & draen ‘ype, 3000 tes 23 tives Dimensions: Lengtn 2030 mm win 760 mm Hegnt 1065 mm Whee! base 3305 mm Min. Turing radius + 2100 mm Ground clearance: 173 mm (Min) Piscorers Bs Tyre Size Front 2.7817, 42 eer : 100/90 X17, 62 P Tyre Pressure Front: 1.75 kg/cm” (25 ps) Rear (Solo) : 2.00 kg” (28 ps) Rear (Pillon) : 2.25 ka/em’ (32 ps) Eloctrical Systom 42 Vote AC + DC Head Lamp 35/05 W HSI HA Position Pilot Lamp: 5 W i Nos.) For ES Version Stop Lamp/Tail Lamp: 5W/21W Turn Signal Lamp #10 @ Nos) Neuttal Indicator Lamp: 1.7 W HiBieam indi. Lamp 17 Tum Pit incl. Lamp: 1.7 W Nos) Speedometer Lamp: 34W Fuel Gauge saw Hom 212vDC Batery #12V-5 Ah Vehicle Kerb Weight: 185 ka. Gross Vahicle Weight: 263 ka, Max. Speod +108 kr. (With snl rider 68 kg) Climbing Ability + 25% (14) max Note : All dimensions are under UNLADEN condition, Above information is subject to change. Location of Parts 41. Hi beam indicator : When Headlight is ‘ON’ & Hi beam Is selected witn engine running, Hi bean ineatar wal be I 2, Turn signal indicator (LH & RH) : When Turn signal snitch is turned to Left or Right, Tum pilot incicator ~ Hor BH wil fash, 3, Trip meter reset knob : The trip metor can be reset to zero by tuming the Trip mater reset knob anticlockwise. 4, Trip meter : The Trip meter shows the distance travelled since it was last reset to zero, 5. Speedometer : The Speedometer pointer shows the ‘speed of vehicle 6. Odometer : The Odometer shows the total distance thatthe vehicle has accumulated. Be 7. Fuel level indicator : valaole fue in fuel tank. '& Neutral indicator : When the transmission ie in ‘Neutral & Ignition switch ‘ON’, the Neutral indicator is i 8. Steering cum Ignition switch : Key operated switch ‘or Ignition "ON'OFF” & locking handle bar. Steering cum Ignition Lock : It has three positions, Fual level indicator shows LOCK : Stosring locked Ignition OFF. OFF: Steoring unlock. Ignition OFF. ON = Steering unlock. Ignition ON. To lock the steering : To look the steering, turn the hhandie bar to the left or night. Tur the key to “LOCK” postion and remove the key. To unlock the steering : To uniock the steering, insort the kay in stoering cum ignition lock & turn it clockwise 10 "OFF" or "ON" position. Key : A common key Is used for ‘Steering cum Ignition lock’, Fuel tank cap’ and 'Side cover lockLocation of Parts Fuel Tank Cap Fuel Tank Cap * To open the fuel tank cap, insert the Key in the lock and tum it clockwise ard lift fuel tark cap, ‘+ Fuel Tank Cap! is locked when pushed back into the place, Fuel Tap has following positions. (ON : When fual level is above Reserve position RES : When fuol level is below Reserve position. OFF : When fuel supply is to be cut off Location of Parts oe Left Handle Bar Switches |A. Dipper switch : When headlight is ON, High or ‘Low beem ean be selected with the dipper switch. Hibeam ingicator ight locatad on Speedo console will ight up whon high beam is selected. 3D : High Beam — gO: Low beam B. Tum Signal Switch : When the tum signal switch fis tumed to Left (2) or Right (o>), the coresponding turn signals flash on and off. To stop flashing, push the switch in and release. ©. Horn Button : ( fox) Press hom button for sounding hom, D. Pase Switch : Press the switch to flash the head light. is used to give signal to venicles coming from opposite side while overtakingLocation of Parts Right Handle Bar Switches E. Head Light Switch : It has 3 positions © =: Allamps OFF. S00: While engine running, Tail lamp, Meter lamp and Pit lamps ‘ON’ While ene anna, Head * Pilot lamp/s, Tail lamp and Mair ap “ON Be F. Starter Button : Only applicable for vehicle with ‘Self lectie) Statt’ provision. Starter bution operates the ‘lectrc starter when clutch lever is depressed with trangmission in any gear. It is recommended to start the engine with the transmission in neutral @. Ride Control Switch : The function of 'Ride Control is to make the rider to sense the Economy zone of the throttle fer better fuel efficiency. When "Ride Control's in ON pposttion, on opening the throttle, at parkour position one will foo! slight resistance to the rotation of the throttle. This indicates the end of tual Economy zone. However throttle can be rotated further to get higher speed, When the switch is in OFF position, the resistance to the theattla rotation 's not sensed. Thus there wil be ‘no indication of fuel Economy zone. Location of Parts Removal of Side Cover LH ‘Insert the key into the cover lock (A) and tum the key clockwise ‘+ Hold the cover with both hands and pul front sie frst (B) roar side itor (6). Take out ‘Side cover Fitment of Side Cover LH Match rear side (C) of ‘Side Cover lug with hole located ‘on chassis and press the ‘Side Cove! + Match Lug (B} provided on front side of ‘Side Cover vith hole provided on ‘Fuel Tank’ and press ‘Side Cover inside + Match the ‘Side Cover’ properly ath bracket provided con ‘Chassis! and Lock (A the ‘Side Cover CAUTION : Remove cover as described above, otherwise ‘the lugs may break. Removal of Side Cover RH + Remove the screw (A) given on ‘Side Cover Hold the cover with beth hands anc pull front sie fst (@)& rear side later (©), Take out ‘Side cover Fitment of Side Cover RH Match rear sie (©) of 'Side Cover" lug with hole located fon chassis and press the cover. ‘+ Match Lug (B) provided on front sido of ‘Side Cover’ ‘wih ole provided on “Fuel Tank’ and press “Side Cover inside. ‘+ Match ‘Side Cover’ propery with bracket provided on "Chassis! an fx it wth Sere CAUTION : Fit cover as described above to ensure proper fitmentLocation of Parts é BATTERY} Battery + It Is located inside the ‘Side Cover’ LH. For + removing ‘Side Cover’ LH, please reler procedure given on page number 7. * Always maintain electrolyte level in each cell * between upper and lower level lines. ss [root xr Tool Kit Location It is located below the seat on rear mudguard, For removing seat please refer procedure given on page number 9. ‘A rubber strap is provided to hold the toolkit Location of Parts A: Seat Release Cable Removal of Seat + Remove ‘Side Cover" LH. a + Pull the “Seat Rolaase Cable (A) to rolease saat lock. Keeping cable pulled. tap the rear of seat, it the seat ftom rear end and slide it towards tal lamp to remove seat Fitment of Seat Match & insert the bracket ('1' of Fig. ‘B}) of seat with slot (2! of Fig, 'B') provided below fuel tank rear mounting on chassis. Push seat towards fuel tank and align.lack rod (3° of Fig.'C}) & seat lock ('4' of Fig, ‘C’). Then press the Goat in middle from top to lock the soat.How to Ride Motorcycle Before starting the vehicle and with the ignition key off, adhere 10 the following fist thing in the moming for ‘after a long period of non-use (whichever is the case) + Depress the clutch lever completly. Kick the kick lever all the way down to is stop, briskly a couple of tmes, Release the clutch lever. Storing the engin Koop the fuol ‘ap to ON or RES position. ‘+ Tur lgnton ewten to ON postion. + Gontiem that the vehicia. (transmission) nut 1+ Ifthe engine Is cold or when starting for frst time, use choke for quick stating. Choke lever (A) is located on LH sie switch + Keep the throtile competely closed, push. the starter button ( @) ) oF kick the engine with kick starter lever. + When the engine is warmed up enough to idle without using choke, retum the choke to. OFF [se = ae NOTE : When the engine is already warm on hot days (Highor than 35°C), open the throttle partly instead of using the choke, and then start tho engine. CAUTION : Do not operate the starter continuously for more than 5 soconds. Walt for 15 seconds before you re-start. NOTE : The motorcycle is equipped with a starter Jockout switch. The vohicio can stant in any goar when clutch lever is depressed, It is recommended to start the engina with the ‘ranemission in neutral, postion ‘A: Choke “OFF” B: Choke “ON” m7 How to Ride Motorcycle mM Pisco, Moving Om: Braking 1 Chock that Center/Side stand is up + Depress the clutch ever. + shit into 1 gear + Open the throttie and release the clutch lever slowly ‘and simultaneoualy + As the clutch starts to engage, open the throttle a litle ‘mor, giving the engine ust enough rpm to keep i from stating ‘Shitting Gea + Close throite & depress the clutch, + Shitioto next higher or lower gear + Open the throtie and release the clutch lever siowiy and simultaneously. Gear Shifting Sequence & Gear Shifting Lever WARNING : When shiting down to lower gear, do not Shin at such a high speed that the engine “pm rises ‘excessively and which may cause the rear wheel to skid + "Cee the throttle completly, losuing the. clutch ngaged foxcopt hare ann gear) so thatthe sngne bracing wil hap stow sown tre metoreyes + Sot down one qoor atm eo tha you orem Novia waren year comet a complete stp. + Yen stopping, abays apply bath bakes atte same mo, De-eknch as naseseary t9 koap the soins hom stag . Nae ba ‘the brakes, or it will cause the tyres to skid. When carrenng. ise brakes jist ad do nt d= un Reduce your speed before yur get ito the Comer. For emergency bang, deregarc dowsing, core Fat au a, eee Sosciin wins seine Stopping the vehicle: lose te trots completly Shin the wansmssion io noua Bing te vette to corte ston {J Turnthe gnton stent Suppor the metoxeyto on a ied aurora sth tom color rend wel Took the steering Parking : ‘+ Shift the transmission ito poutral and turn the igrition switch OFF. + Support the motoreycle on a fm level surtace with the canter or side sian CAUTION : Do not park on a soft oF steeply inclined Se speed oe aad‘Safe Riding Tips + WEAR A HELMET : Always woar a hoimot wile driving. Your helmet should confirm 2s. per your county standards, © Read thoroughly the instructions in this. manual ‘and follow them carefully + Avoid unnecessary accessories for the safaly of both rider and other motorists, © Get familar with traffic rules and regulations in your states as well as general trafic signs. = Do not averioad your vehicle ‘= Famiiarise yourself well with staring, acceleration ‘and braking of the vehicle ‘= When applying the brakes, use both, the front ‘and rear brakes. Applying only one brake may cause the vehicle to loose contro, ‘+ Riding at proper speed and avoiding unnecessary fscceleration and braking are important not only for safety and low fuel consumption, but also for longer life of the vahicle and smooth aperation, + During rainy season drive the vehicle more ‘cautiously. Remember vehicles skid more easily uring light showers. Drive cautiously. Start early and reach your destination safely ‘Always cary vehicle registration papers, insurance ‘and a valid driving licence with you. RAINY SEASON CARE : Fit & Finish Parts ft Is suggested to customer to take appropnate care in area of heavy rainfall area. The appropriate surface preventive coat to avoid fusting / poor surface finish on account of adverse atmospheric conditions, Clean & lubricate all the important parts as dolailed in a periodic maintenance chart. Do not obstruct engine cooling by adding protection sheet from front. a Daily Safety Checks Belore riding the motorcycle be sute to cheok the following items. Please give proper importance to these checks and perform all of thom before. riding the motorcycle. If any irregularities ara found during these checks, refer to the Maintenance chaoter ang see your dealer for the action required to retum the motorcycle to a safe operating condition, BS ‘What to check] Check for Brakes 1. Correct pedal play (15-20 mm) 2. Brake lining wear indicator Within ‘USABLE RANGE” 3..No dragging Drive chain 1. Proper slack (30-38 mm). WARNING : Fallure to perform these checks every 2. Adequate Lbrication, day betore you ride may result m serious damage [Tsing | Operation of al ahs Horn ‘Corectfunetions What to check | Cheok for Steering | 1. Sroatiress Fue! Enough fuel for the plannad| distance of operation, no leaks ‘| the fue lines, Engine OW | Oil level between upper and lower marks, Throttle 1. Correct play in the throttle cabia| @toamm) 2. Smooth operation and_ postive return of tho throtte grip to the| closed position. Steering Lack | Correct operation 2. No restriction of movement. 3. Loose oF Tight ‘Gluten 1. Correct lever play. (2 to 8 mm) 2. Smooth operation of lever: ‘Side and Return to thei fly up position Contre Stand Tyres: 1. Comect pressure. 2. Adequate tread depth 3, No cracks or cuts. Mirrors Correct positionRunning IN Proper running-in is important for the better life and trouble free performance of the vehicle © During fist 2000 ms runningsin period do. not fexo8ed following speed limits, Kine ist [2nd] oed_| ath 0 - 1000 15 |_30 [45 [56 1000 - 2000 | 20 | 40 | 55 | 5 * 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 apeed to give the all a chance to workup into the engine. = Do not run at constant speed. Vary the engine speed. Fuel Saving Tips : ‘A wall maintained vehicle and good driving can Contribute a lot fo the eaving of petrol Fallowing are a few simple fuel saving tips Good Riding Habits = + Rice smoothiy and steadily at an optimum driving speed of 40 to $0 Krrvh or within the ride control selector band in ‘ON’ postion. ane ee Avoid harsh braking, * Change the gear ludiciously according to the ‘speed requirement, + Don't overioad the vehicle above the specified payload. + Use the accelerator judiciously + Cut off the engine If you want to stop for more ‘han two minutes. Vehicle Maintenance (Ensure Following) Fu Gheck fuel Ines and connections for leakage. ‘Spark plug | hepect and clean spark plug. Adjust sectrode gap. ‘irfiter | Clean the air ter earnent periodically Engine of | Chack level Use recommended grade ‘and quantity, Brakes [Ensure thatthe brakes are not dragging Finding Clutch Ensure correct elich lover play, Tyre pressure| Always maintain the recommended te] prossura Carburettor | Glean and adjust the carburetor Adjust iding epee. General Information A: Oil Filler Hole B : Oil Level Inspection Window Engine Oil : Check every week * Always maintain engine oil level between the upper land lower mark provided on Cover RH. + Replace the ol in accordance with periodic ‘maintenance chart Recommended | SAE 20w40 of oi APL 'SJ'+JASO "MA ‘grade or Superior. Oil Capacity | 1100 mi ‘Refit: 1000 mi. Discover se ‘is most vital to adhere to recommended frequency of oll change for the purpose of long lie of critical ‘engine components. For details refer periodic maintenance chert, Wheel Puncture Use the recommended levers. wile removing the Tyre / Tube for puncture work This wi avoid ary damages to the edges / soratenes on paint of the weak ‘Tyre Pressure | + Keep appropriato tyre pressure as mentioned below 10 increase fe of the tire and for etter fuel ‘consumption. Front 1.75 kglon (25 ps Rear (Solo) 2.00 kg/cm’ (28 psi) Rear (With Pilion) | 2.25 kg/em’ (32 gs) Spark Plug +” Remove spark plugs by using plug spanner. * Glean the spark plugs. + Adjust the gaps if incorrect by bending outer electrode carol ‘Spark plug gap: 0.7 to 0.8 mm, Spark Plug, # Champion RG 4 HC (2 Nos.) mis)General Information Battery (12V - 5 Ah) Battary is located inside ‘Side Cover! LH. Check the electrolyte loval in each cell and ensure that is between the upper and lower level lines. Hf electrolyte is below lower level remove the battery filer caps and fil with cistiled water until the electrolyte level in each cell reaches the upper level lin. ‘Add only distiled water to the battery. Tap water is nol a substitute for cistiled water and wil shorten the life of the battery, Environment care must be taken to dispose off the Used battery. It is always, recommenced to hand lover the same to the Baja, dealer for propor disposal of the same, Front Brake Fluid Level = Front brake fad master cyinder reservoir is located nar RH ste cn handle ba. ‘+ To check ol lavel, Keon the vehicle on Centre stand with nana barn straight ahead pasion. Always ensure that brake fuid level i above “MIN mark jjven on irepection window. + Use only DOT 3 or DOT 4 brake uid (hem sealed containen to top up required tis advisable that brake fuid should be replenished once in year. Drive Chain Drive. chain fted on your vehicle © special chain with “0 fing aoa, Core should be taken, that the chaln should never run ony ‘Lubricate chain tom eutslde with SAE 90 cl ‘© Chain slack wil have to be adjusted at every 1000 kms Periodic Maintenance and Lubrication Chart zi Bs ae ‘RECOMMENDED FREQUENCY ©: Ingcates se amar Sperone Na | Operation 1 rr Subsequent pera ins [0759] 2500s. [every 2500 fr Me even Days] 30-48 [2d dys rom date asa Evry 75 ays fevered | Sena viv p? ys sone 2 | He speed OOH tA [A [CA] CA ICA a 3 | Enpne of SAE arnad AST SOT R Eve Ss [Wate tnpet ocarance Ey oA Eve 200 rs ioe 3. [Of rarer’ Cental gar cL Eve 1000 kn © Check 6._| ‘Air cleaner element cafe aya fa i Ail 7-| carer eran Every 1000 me i nee 8. | Carburettor drahing: D o > D |B -Every Service co 3. | cobuetor OF ceanag aaret sry 1000 i Teed 70-| Fel aye stage Ce CST) sew: 1. | Fuel pipes. R- Every two years: eee 12 | arteareriaie Eve on year Fee tna 13. | Spark plug gap GAC |AAC | CLAC| CLAC| R- Every 15000 km. art Lalsioaton Chat 14 | ater electro evel i eT ootone 15. | Brake ight switch GA | ca | cA | ca [oa sawn. 16 | Ouch ca [ca [ca] ca [ea 17] Tt ca [ca [ca [ca fea 18 | Rear ore efi ca Lea [ca Tea toa iy Dovey 1 a na,Periodic Maintenance and Lubrication Chart Be = nes eel RECONNENDED FREQUENCY or, Sr a ‘nia Subsequent pera | Operation Meet ic) Sa ‘Kins. |500-750| 2,500 kms. Every 2,500 ‘coaning may Days| 20 45 [240 days from date of ale| Every 75 days in 7E | rate ing or pas wear (rom & rear T ]0 JC | C | Rashooifreqired cael 26, | Soong ay 7 oraten esoreeiaoen mange meter | T | T | 1 [1 [t age ee CeaynaoeRTeane| 41M = C-Every 10,000 hens © + Check Be Tre benno tite | everalicten ro a ee 25 | Se se ot Cee ores Reet] aie ‘26. | Wheel bearings Leaps > T Ere 500s 2 Sangam etn HR cx cA se | Fenton Parsubrcanstobe a Reve WOODS eats es Every FOOD ks erode Memtenaroe | Foro oa and a San Fa ee 131, | Rear shock absorbers c c c EB _[O-Qasrgennse TATE are mandatory and he [Dre he Levey Sire som ve oenpate aL Evy 5.00 4s feeusoner | Dacron Ra com oe 34 _| Drive chain lock E Eur SM ng “35, | Engine compression pressure Seve ts nepioms. 36. | Gytnderbicek piston and Need de-carbonising ay na m By ROK ay Tea aR Periodic Maintenance and Lubrication Chart es nae RECOMMENDED FREQUENCY © nakatos se eames reac ibe Raby 1 Ina Subseauent feemet on Ms [s00730] 2001s | Every 25008 — Days] 30-45 [20 day am dat fea] Every 78 ays Serna | Cabarete are ver 30000 sauein 22, | Voveoiseaonone GE ISRO Ey SOON wns] Con 29.| swing am ig bush Borg C-eyaygOvIne Ruma] 40. | Gan between reed uth & TPS ape ee Te Te fo evry sence aie a1[ Cuerpo Evy 20000 re Roa] CSch 2. | cataeetr aber Eve eo reed = ate 15, | Sor an tel ean TY 1 Thin 4 | Arter cove Ong Ev 15.0 a | for wee! uber too gee Every 100001 | Rr spake otras T Eve 5,000 faa | en noat ca [ea | ca | cx Parstubrean toe 7H. Fr bake er pap ca | ca [ca] ca ‘pues opt 48. | Citch, Front brake and Acoderaor calle R Bey woyears a | Mate inde cu and dst tl Even Hoye be ranay sho Si-| Caer pson ag tet R-Evey ho yee Save areca ‘52. | Frontbrake hose R-Evory two years — | Storer eh bust Evy 000 ane | Cucnsnieiceanng c ery SI 3, | Bake nusctange Era Non RE 200 a, roca ar Fey Bain oroen capeSchediile For Service Wise Pat List Bajaj Auto recommends the following periodic parts replacement for optimum performance of your vehicle as per the schedule. Ks limit Days | tem Description oy Engine Oil Clutch Gover Gasket 500-750 30-45 7000 mt_| 1 2000 - 2500 Nit NIL Engine Of 1000 mil #800 - S000 aa Drive Chain lock and tink set 1000 mi 7000 - 7500 Ni NIL Engine oil 1000 mi (Glutoh Cover Gasket Fork Ol Fork Oil Seal and Dust Seal Kit 300 mi £9500 - 10,000 | 75 days trom | Air Breather Tube thelast Air Filter Foam eloment service [air Fiter Gover "O" Ring ‘Rear Wheel Damper Drive Chain Lock and Link Set Starter Clutch Bush Kit 12000 - 12500 NiL EY Schedule For Service Wise Part List as ‘Ks tit Days | item Deseription ty Engine Oil 1000 (rive Chain lock and link sei 1 Brake Shoos / Front Disc Pads (F worn out) asod.-13000 ‘Stesring stom bearing (required) ‘Spark Plug 1 71 2 1 [Cylinder head gasket {required } 17000 = 17500, Nil Nil Engine O7 ‘Clutch Cover Gaskat 1000 mi 1 Fok i 75 days from, — 00 Henec™ |" Fork Oil Seal and Dust Seal Kit 1 covice Al Filter Foam element Air Filter Cover *O" Ring — Drive Chain fock and fink sat (Clutch plate (if required} |TRear wheel rubber shock damper 1 i i 1 i Brake fluid ‘Starter Clutch Bush Kit 22000 - 22500 | NIL 1 1 T Nik Bieri - S600 ‘Chain sprocket kit (If required) Engine Oi 7000 mi, | 27000 - 27500) NIL NIL HiSchedule For Service Wise Part List ‘aaa | — tae — mer = j Engine Oi 1000 mi ae Cor Sas ; Air Filter Foam element Air fier cover O ring 29500 - 30000 Airbreather tube ‘Spark Plug Fork Ol Fork Oil Seal and Dust Seal Kit ‘Drive Chain lock and lnk set Brake shoes / Front Disc Pads (if worn out) 76 days tom | C¥inder head gasket (required) {the last service|_ Valve oil seal Steering stem bearing (required) ‘Starter Clutch Bush Kit ear wheel rubber shock damper Front brake cable ‘Acclerator cable Clutch cable ‘Carburetor duct Fue! pipes Master Cylinder Cup and Dust Seal Caliper Piston Cup and Dust Seal Front Brake Hose ‘Brake Fluid Non-Use Maintenance Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 ‘days”). The comrect and 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 the fuel tank and carburettor ficat bow! (if fuel is left in for a longer time, the fuel will break and gummy substance could clog the carburettor) Remove the spark plug and put several drops of 2T ill into the cylinder. Kick the engine over slowly a few times to coat the oylinder wall with Oil and install back the spark plug, Set the vohicle on a box or a stand so that both the wheels are raised off the ground. Spray oll on all unpainted metal surfaces to Prevent rusting, Avoid getting cil 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 trom any source of flames or spark. ee Proparation for regular use after storage: Clean the vehicle Make sure the spark plug is tight. Fill the fuol tank with fue) Ghange the engine oil Check all the points listed in the Dally Safety ‘Checks section, Check and inflate tyres to the proper tyre pressure. For Battery: ‘a. Remove battery and keep it on wooden plank, in properiy ventilated ares. b. Botore taking the vehicle for us + Get the battery recharged from the Battery Dealer ‘+ Check and corect the electrolyte level and apply petroleum jelly on terminals {applicable to certain maces).Pre Delivery Inspection + askqusts pk ino pao tink tor Ope How opto te earbuer ‘Check ee, PT. co, gnten snitch, stewing ork MAL. cover (AS applicable to cetin mode “Gh engine ov and ea Check ersmsion i ni ana op irq. e appeabe to certain mode. 18 a 22 i (Check a corto fr prope ie pty at ncn Boose, ch ve, Hon ako or, fear bake pal nr. chal ve (AB apteabe fe certain mos ‘Sheek ot tar er or pope stn and wrtng. 1 pect rea shock absoter fr proper Ettng and cones ice. (At applicable to certain moded 8 Check whol ru Out nd geen eos rege (he appcat to cain rade (hk | et chan sknass azote. Lubrict raqurea As apical to certain mode, (ho ues and aes aque Check at Up ke Fuld ol, Hi appeabe to certain mde (Chock ae ad a reser othe recommenced ue cocuce {Check tery seal vag, spi ray, waco eve. Charge the try # requ [Check caoracton a erin. fly and 3p) perm jay on tris Weare, (Greck and aint tring ear. Check font musa agement wrt ont hc {Grace rponart rears ba tor pope tora ae tare. Fal OE. acoso ihe miro. og gus muller gut ate, (Aeeppiabl to een mod ‘aan veel, cb ding ana CO% Cenc al antes, mar, hom aa lah or proper iting eat ove me vetie, Check or 0 kage ad vey ay. Fir er ay oer detects sean or cost oir he tat ve ets aang he velo. (Chan he vel / washing etre aay, cecooccucen 24 Applicable to Periodic Services 2. 8. 7. 8. +8 BERS lash the vehi, Fush & change Engio ol / Top up Of Level ee per Sehedie}, on charge basis ‘lean air ar (Rapa, A per Sebel). chook ana ean fut tina, Replace ft, required ~F Applicable {Gtoan Fite. Replace, As por Sdbedule - # Agpeabs). Clean of strainer As per Schedule. (Replace, Il eer - I Aca (lean & Drain Carburotr. (vem, rere. (lean, Check & Aas spark pug gop Replace Ae per Secu) (check 8 Correct Whee! Rur-out ff Aepicabie Chock & Aust ar prosoues n te Ye. (Chick & aut if requeec valve doaanee. (Me per Schedule - i Anpcae ‘Adjust chain slciess. Clean & Lubreale Chath reed (sper Schedule -W Appel) (Check 8 ast brakes (Check ard top up brake fui ov Apes Cec and adjust steering, (Chock / Replace Fork OX As per Sree 6 Appese (Chuck Chatch, Gear, Choke, Acceaator& TPS Of Aenlesle & sus i requed on charge bass (Gheck & taht Nuts, Hots & Fasteners to the recommended torave Refer SSM. Lubricate seccfe pens a8 per Lubreation Sched (Srock Battery, top up Oiseg Water, Route the cables and Rt trina caps Prepsny Clean terminals & apolyPetrolsum Jely ‘opleatia, Check all Metors fo proper tuner, Start vehicle, check & acs Hom & Al Lights or proper toncnonng | Stat veils, check ing ard CO%, Tune Engine & Carburetor requred. (amy ext ary ational wore # requred “Tost Rds he Venice 1 roqured isan te vehicle at the tne of deliveryBs Notice The description and illustration in this booklet are not to be taken as binding on the manufacturers, The essential features of the type desorbed and illustrated herein remaining unaltered; Bajaj Auto Limited reserve the night 10 carry out at any moment without being obliged to bring this booklet up-to-date, modifications on the vericle, parts lr accessories as may be convenient and necessary. DOC. NO. 71110537 REV. 00, DEC., 2007 Balas LUCHA TS as Bajaj Auto Limited Akurd) Pune 411 035 India Tol +91 2027472851 Fax +91 2027407305 w-bajajauto.com