Table of Contents
Description
1. Technical Specifications 1
2. Identification Data 3
3. Location of Parts 5
4. Steering cum Ignition lock 7
5. Fuel Tank Cap / Fuel Tap 8
6. Speedometer Details 9
7. Speedometer Setting 11
8. Control Switches 13
9. Rear seat / Tool kit 15
10. Front Seat / Battery 16
11. Fitment of Front & Rear Seat 17
12. Daily Safety Checks 18
13. How to ride your Bike 19
14. Safe Riding Tips 23
15. Engine Oil 24
16. Wheels - Tube less Tyre 25
17. Battery 26
18. Periodic Maintenance Information 27
19. Brake Fluid 29
20. Periodic Maintenance & Lubrication Chart 30
21. Non Use Maintenance
Notice:
The description and illustration in this booklet
are not to be taken as binding on the
manufacturers. The essential features of the
type described and illustrated herein remaining
unaltered. Bajaj Auto Limited reserves the
right to carry out at any moment without
being obliged to bring this booklet upto-date
& to do modifications on the vehicle, parts or
accessories as may be convenient and
necessary.
Safety and Warning information :
Caution : This indicates that a potential
hazard which could result in vehicle
damag e, i f ad vice provided is not
followed.
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.
Engine : 4 Stroke, Single Cyl.
Bore x Stroke : 56.0 mm x 60.7 mm
Engine Displacement : 149.5 cc
Compression Ratio : 9.8 + 0.5 : 1
Idling Speed : 1400 + 100 RPM
Max. Net Power : 17 PS at 9500 RPM
Max. Net Torque : 13 Nm at 7000 RPM
Ignition System : DC
Spark Plug : 2 Nos
Spark Plug Gap : 0.7 ~ 0.8 mm
Transmission : 5 speed constant
mesh
Gear Shifting Pattern : 1 Down 4 Up
Engine Lubrication : Forced Lubrication
Starting Aid : Electric / Kick start
Front Brake : Petal Disc type
Rear Brake : Drum type
Fuel Tank Capacity
Full : 12 liters
Usable Reserve : 2.4 liters
Unusable Reserve : 0.2 liters
Dimensions : NS 150 AS 150
Length : 2017 mm 2070 mm
Width : 803.5 mm 803.5 mm
Height : 1075 mm 1205 mm
Wheel base : 1363 mm 1363 mm
Ground clearance : 176 mm 170 mm
Tyre Size
Front : 80/100-17,46P tubeless
Rear : 110/80-17,57P tubeless
Tyre Pressure
2
Front : 1.75 kgf/cm (25 PSI)
2
Rear (Solo) : 2.00 kgf/cm (28 PSI)
2
Rear (with pillion) : 2.25 kgf/cm (32 PSI)
Technical Specifications
1
Note :
• All dimensions are under UNLADEN condition.
• Above information is subject to change without
any notice.
Vehicle Kerb Weight : 140 kg.(For )
143 Kg.(For AS 150)
Gross Vehicle Weight : 270 kg. (For NS 150)
273 kg. (For AS 150)
NS 150
Electrical System : 12 Volts DC
Head Lamp : High Beam - 12V 55W
Low Beam - 12V 55W
Position Lamp : 3W (2 nos.)
Tail /Stop Lamp : LED type
Side Indicator lamp : 10W (4 nos.)
Neutral Indicator : Green LED
Hi Beam Indicator : Blue LED
Turn Signal Indicator : Green LED
Side Stand Indicator : LCD
Speedometer Lamp : LCD
Low Battery Indicator : Red LED
Low Oil Pressure : Red LED
Service Reminder : LCD
Bajaj Logo : Blue LED
Rear No. Plate Lamp : 3W
Horn : 12V DC
Battery : 12V - 4 Ah VRLA
2
Technical Specifications
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.
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)
3
Frame Number Location (For NS 150)
On RH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
[for applicable countries)
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.
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)
4
Frame Number Location ( For AS 150)
Below Pillion Seat
(Alpha-Numeric - 17 Digits)
Location of Parts (Pulsar NS 150)
5
Grab Handle Pillion Seat Rider Seat
Front
Disc
Brake
Rear Brake
Pedal
Paper oil
Filter
Front Brake Lever
Rear
Number
Plate
Nitrox
Rear
Shock
Absorber
Location of Parts (Pulsar AS 150)
Grab Handle Pillion Seat Rider Seat
Front
Disc
Brake
Rear Brake
Pedal
Paper oil
Filter
Front Brake Lever
Rear
Number
Plate
6
Nitrox
Rear
Shock
Absorber
Steering cum Ignition Lock
To Lock the Steering : To lock the steering,
turn the handle bar to the left side. Push &
release the key. Turn the key to “LOCK”
position and remove the key. Steering lock
can be done on left side only.
To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering
cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear
Seat’.
Steering cum Ignition Lock :
It has three positions.
LOCK: Steering locked. Ignition OFF.
OFF: Steering unlock. Ignition OFF.
ON: Steering unlock. Ignition ON.
7
Fuel Tank Cap
• To open the fuel tank cap, open the flap.
Insert the key in the lock and turn it
clockwise and lift fuel tank cap.
• ‘Fuel Tank Cap’ gets locked when pushed
back into place.
Fuel Tank Cap / Fuel Tap
Fuel Tank Cap
8
Fuel Tap
Fuel tap has following positions.
Fuel Tap
ON : When fuel level is above
Reserve position.
RES: When fuel level is below
Reserve position.
OFF: When fuel supply is to be cut
off.
2
7
9
3
4
6
5
8
1
M
S
Speedometer Details
Speedometer display will work when, only both
Ignition switch & kill switch are in ‘ON’ position.
1. Fuel Level Indicator: It shows fuel level in fuel tank.
2. Tachometer Dial: It shows engine speed in RPM.
3. Turn Signal Indicator (LH & RH): When Turn signal
switch is turned to Left or Right, Turn pilot Indicator LH or RH will flash.
4. Neutral Indicator: When the transmission is in
Neutral, Neutral indicator will glow.
5. Hi Beam Indicator: When Headlight is ‘ON’ & Hi
beam is selected with engine running, Hi beam
indicator will glow.
6.
charging.
7. Low Oil Pressure Indicator ( ) : It blinks when
engine oil pressure is low.
8. Bajaj Logo : Bajaj logo flying ‘B’ continuously glows.
9. Mode Button : Mode button used for changing the
mode while selecting & setting Trip1, Trip2, ODO,
Clock & Service reminder.
Low Battery Indicator : It indicates battery needs
9
13. Digital Clock : It indicates time in HR : M (AM/PM)
14. Speedometer: Vehicle speed will be displayed in
digital form in Km / Hr.
15. Odometer : The Odometer shows the total distance
that the vehicle has covered. Odometer can't be
reset to ‘Zero’.
16. Trip Meter : Trip 1 & Trip 2 shows the distance
traveled since it was last reset to zero.
17. Set Button : Set button used for setting Clock &
Service reminder.
18. Reserve Indicator : It blinks continuously when
petrol level in tank reaches reserve level ( 1 bar or
less)
10.
RPM crosses 9500 RPM.
11. Service Reminder ( ): ‘Spanner’ symbol glows
when ODO meter reading reaches set Kms. for
service. This Icon will flash at -
st nd
1 : 450 km 2 : 4950 km,
rd th
3 : 9950 km, 4 : 14950 km
and subsequently at each 5000 kms. Icon will
continue to glow till it is reset. This icon is to be
reset after service is carried out.
12. Side Stand Indicator : When side stand is ‘ON’ .
Side Stand Indicator will light.
Engine Over Rev Indicator : It glows when engine
Speedometer Details
10
S
M
Speedometer Details
11
16
17
18
12
13
15
14
10
2. Service Reminder Reset ( ) :
• ‘Wrench’ symbol glows when ODO meter reading
reached to set Kms.
This icon will glow at-
st nd
1 : 450 Kms 2 : 4450 Kms
rd th
3 : 9450 Kms 4 : 14450Kms
& subsequently at each 5000 Kms.
1. Trip Meter Reset :
• Mode & Set push button is provided for selecting &
resetting ‘ODO/TRIP1/TRIP2’. LHS part of speedo
console.
1.
Press 'Mode' button
for less than 2 sec.
Press 'Mode' button
for more than 15 sec.
Mode changes from
‘ODO/TRIP1/TRIP2’
Selected mode
‘TRIP1/TRIP2’ will get reset.
Other TRIP mode will
continue updating.
2.
Note : Engine & motorcycle speed should be zero.
Speedometer Setting
11
M
S
Mode
Service Reminder
TRIP1/2
Set
3. Clock Reset :
• Digital clock indicates time in HR & MM separated
by colon ‘:’
• It is a 12 hour clock.
• Initially ‘:’ will be blinking
• Clock setting is possible in TRIP 1 mode only.
1.
Press 'Mode' push button
for less than 2 sec.
TRIP1 Mode selected
2.
Press 'Mode' & 'Set'
push button together
for more than 2 sec.
Press 'Mode' button for
less than 1 sec.
Press 'Set' button for
less than 1 sec.
Press 'Mode' & 'Set'
button together for
more than 2 sec.
Clock set 'Mode' is
selected & no editing
is carried out for
more than 5 sec.
or
Vehicle is started.
‘:’ stops blinking
Digits start blinking
Hour digits will
increase by one.
Minute digits will
increase. If Mode/Set
button is pressed
continuously then digits
will stop blinking.
Set value will be saved
Exit clock setting mode
Digits stop blinking
‘:’ start blinking
Auto exit without saving
set value.
3.
4.
5.
6.
Speedometer Setting
12
M
S
Mode
TRIP1/2
Set
Control Switches
A
B
C
D
C. Horn Button : ( ) Press button for
sounding horn.
D. Pass Switch : Press the switch to flash
the head light. It is used to give signal to
vehicles coming from opposite side while
overtaking.
Left Handle Bar Switches
A. High/Low Switch : When headlight is ON,
High or Low beam can be selected with
this switch. Hi beam indicator light located
on Speedo console will light up when high
beam is selected.
: High Beam : Low beam
B. Turn Signal Switch : When the turn signal
knob is pushed to Left ( ) or Right ( )
respective indicator will start blinking, to
exit push the knob in & release.
13
E
G
F
Control Switches
Right Handle Bar Switches
E. Head Light Switch : It has 3 positions.
: All lamps 'OFF'.
: With engine running, Tail lamp,
Meter lamp and Pilot lamp/s ‘ON’.
: With engine running, Head lamp,
Pilot lamp/s, Tail lamp and Meter
lamps ‘ON’.
F. Starter Button :
Starter button operates the electric starter
when clutch lever is depressed with
transmission in any gear.
It is recommended to start the engine
with the transmission in neutral.
G. Engine Kill Switch :
The engine kill switch is for emergency
use. During emergency move the engine
kill switch to the ‘OFF’ ( ) position.
Speedometer display will work when both Ignition
switch & kill switch are in ‘ON’ position.
CAUTION : While starting ensure that
engine kill switch is in ON ( ) position.
Engine will not start if the kill switch
is in OFF position
14
Rear Seat / Tool Kit
A
Tool Kit Location
• It is located below the ‘Rear seat’.
• 2 rubber straps are provided to hold the
tool kit.
Removal of Rear Seat
• Insert Key into lock (A)
• Turn the key clock wise.
• Pull front end of ‘Rear seat’
• Take out ‘Rear seat’
CAUTION : Always ensure rubber strap
is fitted for securing tool kit.
15
Tool Kit
Front Seat / Battery
Battery
• It is located below ‘Front seat’.
Battery details are given in ‘Battery
Maintenance’ page no. 25.
Removal of Front Seat
• First remove ‘Rear seat’.
• Remove ‘Front seat’ mounting bolts (B).
• Pull back rear end of ‘Front seat’.
• Take out ‘Front seat’.
B
16
Fitment of Front & Rear Seat
Fitment of ‘Front Seat’
• Match the lugs of ‘Front seat’ (A) with
chassis bracket (B).
• Push ‘Front seat’ toward petrol tank.
• Match ‘Front seat’ rear brackets (C) with
the holes provided on chassis.
• Tighten the bolts (D).
Fitment of ‘Rear Seat’
• First make sure ‘Front seat’ is fitted
properly.
• Place ‘Rear seat’ in fitment location.
• Insert bracket (E) of seat into hook (F).
• Match the rod of ‘Front seat’ (G) with seat
lock (H).
• Press front portion of seat.
Front seat lug & bracket
B
A
E
F
G
H
C
D
17
Daily Safety Checks
• B rake F luid l evel a bove MIN mark
provided on reservior, applicable to disc
brake vehicle.
• Drive Chain slack of 20 to 25 mm
adequately lubricated.
• Function of all lights & horn
• Clutch lever play - 2 to 3 mm
• Check Coolant level between MIN and
MAX mark in coolant reservoir tank.
• Smoo th ste eri ng movem ent without
restriction.
• Side stand return to its retracted position.
• Correct inflation pressure in both tyres
Adequate tyre tread depth - no cracks /
cuts.
• Correct rear viewing span adjustment of
mirror.
Before riding motorcycle be sure to check
following items. Please give proper importance
to these checks and perform all of them
before riding motorcycle.
If any irregularities are found during these
checks, refer to the Maintenance chapter &
see your dealer for the action required to
return the motorcycle to a safe operating
condition.
Warning : Failure to perform these
checks every day before you ride, may
result in serious damage or severe
accident.
• Enough fuel for planned distance of
journey. No fuel leakage in fuel lines.
• Engine oil level (between upper and lower
level mark)
• Throttle cable play of 2 ~ 3 mm. Smooth
operation and positive return to closed
position,
18
How to Ride Your Bike
1. Starting The Engine :
• Turn the fuel tap knob to ‘ ’ or ‘ ’
position.
• Turn ignition switch key to ‘ ’ position.
• Keep kill switch in ‘ ’ position.
• Confirm that transmission is in neutral /
press the clutch lever.
• If the engine is cold or when starting for
first time, use manual choke ( ) for quick
starting. Choke lever is located on LH side
of carburettor.
• Keep throttle completely closed, press
starter button,
• Release starter button as soon as engine
starts.
• When the engine is warmed up enough to
idle without using choke, return the manual
choke to OFF position.
Note : Do not let the engine idle longer than 3
minutes otherwise it will overheat.
2. Shifting Gears :
• Close throttle & depress the clutch.
• Shift into next higher or lower gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
3. Moving Off :
• Check that side stand is up / retracted.
• Depress the clutch lever.
st
• Shift into 1 gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
• As the clutch starts to engage, open the
throttle a little more, giving the engine just
enough rpm to prevent it from stalling.
Caution : Do not operate the starter
continuously for more than 5 seconds
otherwise battery would get discharged.
Wait 15 sec. between each operation of the
starter which will facilitate battery to recover.
Note : The motorcycle is equipped with a starter
lockout switch. This switch ensures that engine
does not start if the transmission is in gear.
However, the engine can be started in any
gear if the clutch lever is pressed.
Note : Incase of battery discharged condition,
vehicle can be started by pushing it.
19
?
4. Braking :
• Close the throttle completely, leaving the
clutch engaged (except where shifting gears)
so that the engine braking will help slow
down the motorcycle.
• Shift down one gear at a time so that you
are in Neutral when you come to a complete
stop.
• When stopping, always apply both brakes at
the same time. De-clutch as necessary to
avoid engine stalling.
• Never lock the brakes, or it will cause the
tyres to skid. When cornering, use brakes
judiciously and do not de-clutch. Reduce
your speed before you get into the corner.
F o r e m e r g e n c y b r a k i n g , d i s r e g a r d
downshifting, and concentrate on applying
brakes as hard as possible without skidding.
5. Stopping the Vehicle :
• Close the throttle completely.
• Shift the transmission into neutral.
• Bring the vehicle to complete stop.
• Turn the ignition switch off.
th th
From 5 to 4 Gear
th rd
From 4 to 3 Gear
rd nd
From 3 to 2 Gear
nd st
From 2 to 1 Gear
45 km/h
35 km/h
25 km/h
15 km/h
Recommended Speed for Shifting Down
Gear shifting
pattern
Gear shifting Lever
1
N
2
3
4
5
How to Ride Your Bike
Warning : When shifting down to lower
gear, do not shift at such high speed
that engine rpm jumps excessively. This
may cause engine damage, & rear wheel
may skid. Downshifting should be done
at speeds as recommended in table
above.
20
6. Parking the Vehicle :
6.1 Parking using center stand.
• Support the motorcycle on a firm level
surface with the center stand.
6.2 Parking using side stand.
• Support the motorcycle on a firm level
surface with the side stand.
• Lock the steering.
7. Running IN
Proper running-in is important for better life &
trouble free performance of the vehicle.
• During first 2000 kms running-in period do
not exceed following speed limits.
• Always keep the speed below the limits
mentioned in the table.
• Do not rev the engine excessively.
• Do not start moving or rev the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to workup into the engine.
Kms 1st 2nd 3rd 4th 5th
0 - 1000 14 22 30 38 44
1000 - 2000 19 30 42 52 61
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle
may fall over.
How to Ride Your Bike
21
How to Ride Your Bike
Fuel Saving Tips :
A well maintained vehicle and good driving
can contribute a lot to the saving of feul.
Following are a few simple fuel saving tips.
Good Riding Habits :
• Ride smoothly and steadily at a reasonable
speed.
• Avoid harsh braking.
• Change the gear judiciously according to
the speed and load requirement.
• Don’t overload the vehicle above the
specified payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for
more than two minutes.
How to check mileage (Fuel efficiency)
Best way to calculate mileage is by following
the full tank to full tank method.
• 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, preferably from same f u el
dispenser.
• Divide kilometers run / fuel quantity filled.
Ensure following maintenance points to get
optimum performance from your bike.
Fuel Check fuel lines & connections
for leakage.
Spark Plugs Inspect and clean spark plugs.
Adjust electrode gap. Replace
spark plugs as per P.M. Chart.
Air Filter Clean the air filter element
periodically. Replace as per
Periodic Maintenance Chart.
Engine Oil Check engine oil level. Always
use recommended grade and
quantity.
Brakes Ensure that the brakes are not
dragging / binding.
Clutch Ensure correct clutch lever
play.
Tyre Air Always maintain recommended
Pressure tyre pressure.
Carburettor Clean & adjust the carburettor.
Adjust idling speed.
22
Safe Riding Tips
• Drive cautiously. Start early & reach your destination
safely.
• Always carry vehicle registration & insurance papers,
and a valid driving licence with you.
• Avoid driving on loose sand or stones where vehicle
is likely to skid.
• Properly wrap-up loose clothes while riding to avoid
entangling in wheel or other objects on road.
• Always concentrate on Safe riding.
Rainy Season Care :
• It is suggested to customer to take appropriate care
in area of high rainfall area. Appropriate surface
preventive coat to avoid rusting on account of
adverse atmospheric conditions.
• Vehicle cleaning to be done with soft & clean wet
cloth to avoid scratches on painted parts.
• Clean & lubricate all the important parts as detailed in
a periodic maintenance chart.
• Do not apply direct water jet on painted, electrical /
electronic parts.
• Do not obstruct engine cooling by adding mud
protection sheet from front.
Safe Riding Tips
• Always wear Helmet while riding. Your helmet should
conform to appropriate Safety standards.
• T h o r o u g h l y r e a d t h e
instructions given in this manual
and follow them carefully.
• Avoid unnecessary accessories
for the safety of both rider and
other motorists.
• Get familiar with and follow
traffic rules & regulations in your states as well as
general traffic signs.
• Familiarise yourself well with starting, acceleration and
braking of the vehicle.
• When applying the brakes, use both front & rear
brakes simultaneously. Applying only one brake may
cause the rider to loose control.
• Riding at proper speed and avoiding unnecessary
acceleration and braking are important not only for
safety and low fuel consumption, but also for long life
of the vehicle.
• During monsoon drive the vehicle more cautiously.
Remember vehicles skid more easily during light
showers.
23
A : Oil Filler
Cap
B : Oil Level
Window
Engine Oil Level Checking :
• Check engine oil level every day in the morning.
Park vehicle perpendicular to the ground on level
surface as mentioned in page no. 21 (6.1)
• Check oil level through oil level window ‘B’.
• Always maintain engine oil level between upper
(C) and lower (D) mark provided on Clutch cover
RHS. Top up with specified grade of oil, if the oil
level is below lower level mark.
Engine Oil Capacity :
• Refill at servicing : 1200 ml.
• During engine overhaul : 1400 ml.
24
Engine Oil
Model Recommended Grade
Pulsar SAE 20W50 API ‘SL’, or JASO ‘MA’
150NS/AS
Engine oil
CAUTION :
• It is most important to adhere to
recommended grade & frequency of oil
change for the purpose of long life of
critical engine components. For details
refer periodic maintenance chart.
• Do not reuse drained oil.
• C ontact your Dealer for proper
disposal of drained engine oil.
Recommended Engine Oil:
st
• Engine oil replacement frequency : 1 service & then
every 5,000 Km.
• Engine oil level top-up frequency : Every 2500 km.
Wheels - Tube Less Tyre
CAUTION : Tubeless tyres are fitted in this
motorcycle. The walls of the tyres in
contact with the wheel rim should not be
damaged in any way during fitment /
removal of tyre. The tyre side walls in
contact with wheel rim seals air.
Wheel Puncture :
• Visit nearest known tubeless tyre repair
shop to remove puncture.
• Remove puncture by Filler or Plug method
only.
• Do not use patch method to remove
puncture of tubeless tyre.
Tyre Pressure :
Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
fuel consumption.
Note : Ensure tyres fitted comply with local
rules and regulations governing tyres.
Front 25 PSI
Pulsar 150 NS/AS Rear (Solo) 28 PSI
Rear (with Pillion) 32 PSI
Front Wheel
Removing Front Wheel :
• Park vehicle perpendicular to the ground on
level surface
• Remove speed sensor cable from case meter
assembly.
• Loosen front axle nut.
• Remove front wheel assembly from fork.
25
Battery
Battery : 12V - 4 Ah VRLA
• Battery is located below front seat.
Battery Features :
• No topping-up is required
• Reduced self discharge, Enhances safety.
• No vent tube open to atmosphere hence no
discharge of electrolyte through vent tube.
• It is always recommended to hand over
the same to an Authorised battery / Bajaj
dealer for proper disposal.
• W hen l ow batter y icon pops -up o n
speedometer display, it is advised to get in
touch with Bajaj dealer & get it charged
immediately.
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 cranking, 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 life of
battery
• Disconnect battery +ve & -ve wires if
vehicle is to be stored for more than 2
weeks. This avoids self discharge.
CAUTION : Do not drive / run vehicle in
battery disconnected condition. It may
lead to damage of electrical / electronic
components.
• Environment care must b e taken to
dispose off the used battery.
26
Periodic Maintenance Information
Spark Plug
• R emove spa rk plugs by us ing plu g
spanner.
• Clean the spark plugs.
• Adjust the gaps if incorrect by bending
outer electrode carefully.
Spark Plug Gap : 0.7 to 0.8 mm.
Spark Plug (2 Nos.) : BOSCH UR4AC
Champion PRZ9HC
0.7 to
0.8 mm
Drive Chain Slackness
• Chain slackness will have to be adjusted
whenever required.
• Std. Chain slackness 20 ~ 25 mm.
• Marking on chain adjusters should be
identically positioned on both sides.
27
Periodic Maintenance Information
Drive chain must be cleaned & lubricated as
per periodic maintenance schedule.
Drive Chain (O-ring type)
• ‘O’ rings must always be kept wet for
best performance hence lubricate every
500 Km.
• O-ring chain lubrication can easily be
done by owners using Bajaj ‘Chain Lube
Spray Can’ available with Bajaj dealers,
or equivalent. Ensure that the lubricant
does not damage the rubber 'O' rings.
Method of O-ring Chain Lubrication :
• Park vehicle perpendicular to the ground on level
surface as mentioned in page no. 21 (6.1). Clean
the chain by using lint free cloth (If excessive
mud / slush found approach Bajaj Service Center
for proper cleaning)
• Shake the can vigorously by holding vertically
upright till the noise of steel ball inside heard
uniformly.
• Hold spray can at the back of rear sprocket with
extension tube nose at 5~10 cm.
• Rotate the wheel in reverse direction & spray the
lube on middle portion of the chain up to full
length of the chain.
Drive
Chain
Cleaning
Drive
Chain
Lubrication
28
Brake Fluid
Front & Rear Brake Fluid Level
• Front brake fluid reservior is located on RH
side of Handle bar.
• Rear brake fluid reservior is located behind
RH pillion holder bracket.
• To check oil level, Park vehicle
perpendicular to the ground on level surface
as mentioned in page no. 21 (6.1) with
handle bar in straight ahead condition
• Always ensure that brake fluid level is above
‘MIN’ mark given on inspection Window.
Brake Fluid Replacement
• Check & Adjust brake fluid level in every
service.
• Change the brake fluid of the front & rear
brake according to service schedule.
Use only DOT-3 ro DOT-4 brake fluid (from
sealed container) for top up & replacement.
Front
Brake
Fluid
Reservior
29
Periodic Maintenance & Lubrication Chart
30
RECOMMENDED FREQUENCY
Servicing
Sr.
No.
Operation
1st
500
~
750
2nd
4500
~
5000
3rd
9500
~
10000
4th
14500
~
15000
5th
19500
~
20000
6th
24500
~
25000
7th
29500
~
30000
Kms
Remarks
Clean the vehicle with water wash & dry
completely
Ensure to prevent water entry in
Petrol tank, Silencer & electrical
parts.Use caustic free detergent for
washing.
Engine oil & engine oil
filter*
SAE 20W50 "API SJ" Grade
Replace at every 5000kms. And
top-up at every 2500 Kms (If
required)..
Oil strainer
Oil strainer cleaning at the time of
oil change.
Spark plug
Air cleaner element & cover 'O' ring
In line Paper filter or fuel cock paper filter
Check & replace if required
Fuel cock sediment bowl cleaning
Carburetor rubber duct
C,R R R R R R R R
CL CL CL CL CL
CL,A,R CL,A CL,A R
CL,R R R
R R R
CL CL CL
C,R C,R
C,R R R
Fuel Pipe
1
2
3
4
5
6
7
8
9
C,A C,A C,A
Valve tappet clearance
10
Periodic Maintenance & Lubrication Chart
31
500
~
750
4500
~
5000
9500
~
10000
14500
~
15000
19500
~
20000
24500
~
25000
29500
~
30000
RECOMMENDED FREQUENCY
Servicing
Sr.
No.
Operation
1st
2nd
3rd
4th
5th 6th
7th
Kms
Remarks
Check & replace if required
Customer to apply OKS chain
lube spray @ every 500 kms
Engine Air Breather Tube
Brake cam & brake pedal pivot pin Use recommended AP grease.
Brake lining or pad -Check wear indicator
Replace brake shoes /brake
pad at every15000 Kms
Brake fluid level** - top up / replace
Use recommended brake
fluid (DOT3/DOT4).
Replace if damaged
Disc brake assly -- Check functionality,
leakage or any other damage.
All cables & rear brake pedal -free play
C,R C,R C,R
C,L,R C C,L,R C,L,R C,L,RC,L,R C,L,R C,L,R
C,R C,R C,R C,R R C,R C,R R
C,A,R C,A R
C C C C
C,A C,A C,A C,A C,A C,A C,A C,A
C,A,T C,A,T C,A,T C,A,T C,A,TC,A,T C,A,T C,A,T
Wiring harness & Battery connectionsrouting, tie bands & clamps tightness.
12
13
14
15
16
17
18
Sealed Drive chain cleaning & lubrication
CL,L,A
A A A A A A A
CL,L CL,L CL,L CL,L CL,L CL,L CL,L
11
Periodic Maintenance & Lubrication Chart
32
500
~
750
4500
~
5000
9500
~
10000
14500
~
15000
19500
~
20000
24500
~
25000
29500
~
30000
RECOMMENDED FREQUENCY
Servicing
Sr.
No.
Operation
1st
2nd
3rd
4th
5th 6th
7th
Kms
Remarks
Ignition switch barrel cleaning & handle bar
control switches contacts cleaning,
Use recommended WD40
spray
Steering play
Steering stem bearing*** & Cap steering
bearing(Plastic)**
Check & replace if damaged.
Use HP Lithon RR3 grease
for lubrication.
Main Stand & Side stand pin
Use recommended AP
grease.
All fasteners tightness
General lubrication-Clutch lever, front brake
lever, kick lever.
Engine Foundation silent bushes**
Use recommended AP
grease.
C,A C,A C,A C,A C,A C,A C,A C,A
C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL
CL,L CL,L CL,L CL,L
C,T C,T C,T C,T C,T C,T C,T C,T
L L L L L L L L
C C C
C,CL
L,R L,R L,R L,R L,R L,R L,R L,R
C,CL C,CL C,CL C,CL C,CL C,CL C,CL
19
20
21
22
23
24
25
Periodic Maintenance & Lubrication Chart
33
500
~
750
4500
~
5000
9500
~
10000
14500
~
15000
19500
~
20000
24500
~
25000
29500
~
30000
RECOMMENDED FREQUENCY
Servicing
Sr.
No.
Operation
1st
2nd
3rd
4th
5th 6th
7th
Kms
Subsequent
Ideal Speed / CO %
* It is strongly recommended to use specified grade only , In case of any other engine oil of same specifications is
used the frequency would be every 5000 kms
** As applicable to model .
*** More frequent cleaning is required while driving in dusty environment.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note: periodic parts / lubricants as per periodic maintenance & chart are mandatory & the same is chargeable to customer.
C,A C,A C,A C,A C,A C,A C,A C,A
26
Non-Use Maintenance
Non-use maintenance is necessary if a vehicle
remains off road for a longer duration (more
than 15 days**). The correct and careful nonuse 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 float bowl (if fuel is left in for a
longer time, the fuel will break and gummy
substance could clog the carburettor).
• Remove spark plug & put several drops of
engine oil into the cylinder. Kick engine
over slowly a few times to coat cylinder
wall with oil & install spark plug.
• Set the vehicle on a box or a stand so that
both wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to
prevent rusting. Avoid getting oil on rubber
parts or brake liners.
• 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.
• Do not apply oil on front brake disc, to
prevent rusting. If the front brake disc rusts
during storage, do not attempt to clean it
with soap water. The rust will go off
automatically during first few application of
brake.
** For Battery :
a. Remove battery and keep it on wooden
plank, in properly ventilated area.
b. Before taking the vehicle for use.
• G e t the batter y r e c harged fro m t h e
Authorised Service Center / Battery Dealer.
• A p p l y p e t r o l e u m j e l l y o n t e r m i n a l s .
(applicable to certain models).
Preparation for regular use after storage :
• Clean the vehicle
• Fit the battery after recharging.
• Make sure the spark plug is tight.
• Fill the fuel tank with fuel.
• Change the engine oil.
• Check all the points listed in the Daily Safety
Checks section.
• Check and inflate tyres to proper tyre
pressure.
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