Baja Chetak 2002, Chetak 2003 Owner's manual

Owner’s Manual & Service Records

Owner’s Record

All correspondence relating to service
problems may be addressed to:

SERVICE DEPARTMENT, BAJAJ USA
525 ECCLES AVENUE
SOUTH SAN FRANCISCO,
CA
94080

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 illustrations
herein remaining unaltered, Bajaj Auto
Limited reserves the right to carry out at
any moment, without being obliged to
bring this booklet up-to-date, modifications
on the vehicle, parts or accessories as
may be convenient and necessary.

Name :

Vin # :

Chassis # :

Engine # :

Date Purchased :

Dealer :

Delivery Certificate

Customer’s Name :

Address :

Date Purchased :

Dealer :

To REMOVE - TEAR HERE

To be removed & retained by dealer.

Delivery Certificate

Vin #:

Chassis #:

Engine #:

• The above vehicle was inspected/test driven by me/my

representative at the time of taking delivery and it was
found to be acceptable and free from any operational or
visual defects.

• A copy of the owner’s manual containing service
requirements, five service record pages, and a warranty
statement was given to me along with the vehicle.

• I understand that my warranty claims, if any, will be
considered by the manufacturers only in accordance with
the scope & limits of the warranty as laid down in the
Warranty Statement.

Place :

Date : Customer’s Signature

To be removed & retained by dealer.

Pre Delivery Inspection

l Check and correct tire pressure including that of Spare Wheel.
l Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock

bolt and front/rear wheel nuts.

l Check transmission and engine oil level and top up if necessary.
l Check for smooth operation of accelerator and choke operation.
l Check and adjust Steering column for loose/tight.
l Initial charging of battery, Install, connect and apply petroleum jelly on terminals.
l Check and adjust engine idling.
l Check steering/ignition lock, luggage box lock, seat lock, and tool box lock for proper operation.
l Check all lights, horn, switch, speedometer and fuel gauge operations for satisfactory working

condition.

l Check for smooth operation of fuel cock lever.
l Check front/rear brakes for effective working condition.
l Test drive the vehicle.
l Repair any other defects seen or observed during test drive.
l Clean the vehicle before delivery.

Important Precautions

The following precautions must be observed if your vehicle is fit with a catalytic converter. If you are
unsure whether your scooter has a catalytic converter or not, check with your dealer. The catalytic
converter, which is installed inside the silencer, reduces the exhaust emissions and is required in some
states.

Caution:

1. Never operate your scooter with leaded gasoline. Even a small amount of normal leaded gasoline will

damage the catalyst and make the catalytic converter completely ineffective.

2. Never tamper with the catalytic converter, which is installed inside the silencer assembly.

3. Never turn off the engine when the scooter is in motion. Likewise, never try to start your scooter by

pushing it, towing it, or coasting it down a hill. Failure to observe this precaution will damage the
catalytic converter, and can lead to a serious over temperature event, or even a fire, with subsequent
serious injury to you and serious damage to your scooter.

4. If the engine misfires or appears to have any loss of performance, immediately take your scooter to
your local Bajaj Dealer.

Hello !

Dear Customer,
We wish to congratulate you for choosing The “Bajaj Chetak 4 Stroke”, coming from Bajaj Auto the world’s

largest manufacturer of scooters. “Chetak 4 Stroke” will give you value for your money, for years! We are
sure that you will be proud of its performance.

Please read this Owner’s Manual before riding to familiarize yourself with the mechanism and controls of
the vehicle. To ensure a long, trouble free life of your vehicle, give it proper care and maintenance as
described in this manual.

It is important to regularly inspect and maintain your scooter for safe and optimum performance. Regular
inspection and service is required to maintain your warranty. The warranty period for this scooter is 12
months or 6,000 miles, whichever comes first. See the service record pages in this booklet for the required
service and inspection intervals.

Entrust the maintenance and repairs to the authorized Bajaj Dealers, who are well equipped with
necessary facilities and are specially trained on BAJAJ CHETAK 4 STROKE .

In case you need detailed information about your vehicle, the Service Station Manual is available from
authorized Bajaj Dealers. In the rare event of a problem with your vehicle, please write to Bajaj USA,
giving details like engine number, chassis number, date of purchase etc.

Table of Contents

Description

Identification Data 1

Technical Specifications 2

Location of Controls and Components 3

General Information 10

Running In 15

Periodic Maintenance Chart 17

Lubrication Chart 18

Changing Tires 19

Safety Recommendation 22

Service Records

Identification Data and Vehicle Identification Number

# 022809082AD72233 #

Engine Number

Chassis Number VIN Number

There are three unique numbers assigned to your scooter. The engine and
chassis serial numbers are used by the factory to identify the exact model.
Please cite both of these numbers whenever you are ordering replacement
parts. The vehicle identification number is used to register your vehicle with the
Department of Motor Vehicles in your state. It is a crime in all states to alter the
vehicle identification number. Also, the alteration of any of these numbers will
immediately void your warranty.

1

Technical Specifications

Engine : 4 stroke, single cylinder, forced air cooled, spark ignition
Engine Displacement : 145.45 cm
Max. Net Power : 9.00 HP at 6000 r/min of engine
Ignition System : Electronic ignition (C.D.I.)
Spark Plug : Champion : PL 7 YC (To be used with resistor spark plug cap)
Lubrication : Wet sump forced lubrication
Transmission : 4 speed gear box
Front & Rear Brakes : Mechanical expanding shoe type
Fuel Tank Capacity : 1.32 Gal. (5.00 litres)
Electrical System : 12V D.C.

: Head lamp : 35/35W Tail/Stop lamp : 5/21W

Side indicator lamp : 10W Horn : 12V D.C.

Curb Weight : 253 lbs/115 kg
Max Speed : 55 MPH/90km/h with single rider

Note: The above information is subject to change.

2

3

Location Of Controls / Speedometer / Rear View Mirrors

2 3 4

EN
G

INE

S
TO

1

P

11

9

5

Handle Bar

5

6

3

4

R

F

N

MIPH

60

50

70

0

4

0

8

30

20

10

0

00111

MILES

Speedometer

1. Clutch Lever

2. Mirror LH

3. Speedometer

6

4. Mirror RH

5. Luggage box lock

10

6. Fr. Brake Lever

7. RH Switch

7

8. Steering Lock / Ignition Switch

8

9. LH Switch

1. Hi-Beam Indicator

1

2. Turn Signal Indicator

3. Speedometer

2

4. Odometer

5. Fuel Gauge

6. Neutral Indicator

10. Accelerator

11. Gear Shifter

3

The Steering Lock / Ignition Switch is located on the right hand
side below the handle bar. It has three positions.

Key Position

LOCK

OFF

Steering Lock / Ignition Switch

Steering Lock

4

ON

To Lock the Steering

• Turn the handle bar to the left. (Steering will be locked only

when handle bar is in left position.)

• With the key in OFF position and turn it to the lock position.

• Take out the key.

Function

Steering locked
Ignition OFF

Steering unlock
Ignition OFF

Ignition ON

Key Removal

Key can be removed

Key can not be removed

Fuel Tank

S

RE

F

OF

ON

Fuel Cock Position

Fuel Tank

• It has capacity of 1.32 gal.

• Location of fuel tank is as shown in the

figure.

Fuel Gauge
The fuel level gauge is provided in the
speedometer console to indicate the fuel
quantity in the fuel tank.

Fuel level is indicated as follows:

• “E” mark indicates approx. Empty.

• Mid mark indicates approx. 0.66 gal.

• “F” mark indicates approx. 1.32 gal.

Fuel Cock

It has the following three positions

On : When fuel level is above 0.26 gal.
Res : When fuel level drops below 0.26 gal.
Off : Fuel supply is cut off.

Warning: Never mix oil in the

gasoline. To do so can lead to
engine failure and subsequent
accident with potentially
serious injury or even death.
Use only unleaded gasoline of
research octane number 87 or
higher.

There is serious danger of fire
if gasoline is leaking from any
portion of your vehicle. Never
ride your vehicle if you smell
gasoline. Have your vehicle
repaired immediately by your
authorized Bajaj dealer.
Failure to heed this warning
can lead to a serious fire, with
subsequent serious injury or
even death.

5

S
E
R

F

F

O

N

O

Off

On

A

B

A

A

Choke Lever

Choke Lever

• It is located near the fuel cock lever.

• Choke is required especially for

cold starting.

• The ‘On’ and ‘Off’ positions of choke
lever are as shown in figure.

A : Choke “OFF”
B : Choke “ON”

A : Seat Lock

Seat Lock :

• It is located on left hand side of the

seat.

• The lock ensures the security of the
fuel tank.

• Turn the key clockwise to unlock
seat.

• For locking, gently press the seat

A : Tool Box Lock

Tool Box Lock :

• It is located as shown in the figure A.

• Key can be removed after locking as

well as unlocking the Tool box.

from top.

6

OFF

E

E

N

N

I

I

G

G

N

N

E

E

Right Hand Switch

Left Hand Switch

RUN

P

P

O

O

T

T

S

S

AB

B A C

Right Hand Switch
A Starter switch : Press the button to start

the engine.

B Supplementary engine stop switch :

Move to the ‘Run’ position before starting
engine. Move to the ‘Off’ position to stop
engine.

Left Hand Switch

This scooter is equipped with lights that
illuminate whenever the ignition is turned on.

A Turn signal switch : Move the knob left or

right to activate turn signal. Move back
the knob to center position to OFF turn
signal.

B Horn Switch : Press to activate horn.
C Headlight High/Low beam switch. Press

the toggle upward for high beam, press
the toggle downward for low beam.

7

A : Spare Wheel B :Wheel Cover

A

B

A : Took Kit B : Jack

8

Spare Wheel : Spare wheel is located

behind seat on bracket. For removing the
wheel :

• Remove the wheel cap.

• Remove the spare wheel mounting

bolts. (Ref. Fig. A)

Wheel Cover
The wheel covers are fitted to all wheels.

B: Wheel Cover

Tool Kit : Tool kit is strapped (by rubber

strap) inside the Luggage box. Unlock the
Luggage box, remove strap and take out
tool kit. Refer Fig. A

Jack : Jack is strapped (by rubber strap)
inside the Luggage box. Unlock the
Luggage box, remove strap and take out
jack. Refer Fig. B

Warning: Proper tire pressure is
very important to the handling of
your scooter, and to your safety.
Never ride your scooter with tires
either over or under-inflated. See
the specifications table on page 12.
Failure to observe this warning can
lead to instabilities in handling and
an upset with subsequent serious
accident, injury, or even death.

Note:

• Rear brake liner wear can be

inspected through window on
rear brake drum by unscrewing
the plug on it.

• Front brake liner wear can be
inspected by looking at the wear
indicator on front brake actuating
lever.