Bajaj Auto RE 4-stroke User Manual Download Page 58

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3. Preventive Maintenance

Index

3.1

Periodic Maintenance Chart

3.2

Periodic Lubrication Chart

3.3

Engine Box Oil - Checking / Replacement

3.4

Differential Oil - Checking / Replacement

3.5

Recommended Oil Grade and Quantity

3.6

Air Filter Cleaning Procedure

3.7

Battery

3.8

Wiper Motor

3.9

Drive Shaft Slider Block

3.10 Brake Oil

3.11 Free Play

3.12 Tyre Rotation

Summary of Contents for RE 4-stroke

Page 1: ...User s Guide Petrol CNG LPG WORLD S NO 1 Three Wheeler...

Page 2: ...icator G Petrol mode indicator E Battery charging indicator D Neutral Indicator C Hi beam indicator B RH turn pilot indicator A LH turn pilot indicator 7 On off parking switch 3 Hazard switch 6 Switch...

Page 3: ...equipped with all necessary facilities skill sets and trained manpower for servicing and repairs of your RE 4 STROKE In the event of going to a local garage always insist on Genuine Bajaj Spares to en...

Page 4: ...l hazard that could result in death or injury WARNING CAUTION Indicates a potential hazard that could result in vehicle damage NOTE Indicates special information to make maintenance easier or instruct...

Page 5: ...Index Index 1 Before Driving 1 2 Operating your vehicle 41 3 Preventive maintenance 53 4 Pre Delivery Inspection check points 72 5 Notice 74 6 Delivery Certificate 76...

Page 6: ...1 Before Driving 1 1 1 Locks 1 2 Mirrors 1 3 Handle bar and Dashboard 1 4 Other controls 1 5 Other Important parts location 1 6 Identification data 1 7 Technical Specifications...

Page 7: ...key in anti clockwise direction to align the lock position push in and rotate clockwise After confirming the locking of handle bar take out the key from barrel Un locking Turn the key anti clockwise...

Page 8: ...lock insert the key and rotate it clockwise or anticlockwise respectively Tool Box Lock To Unlock or lock Tool box lock insert the key and rotate it clockwise or anticlockwise respectively Glove Box L...

Page 9: ...r properly with body and rotate key clockwise Filling Door Locks Petrol vehicle For filling petrol in tank open the lockable cover To open the lock insert the key rotate it anticlockwise To lock the d...

Page 10: ...ling door lock For filling gas in tank open the lockable cover To open the lock insert the key rotate it Anticlockwise To lock the door insert the key rotate it clockwise A Gas Filling Door Lock Unloc...

Page 11: ...mirror so that you can see the rear sides of your vehicle in the mirrors Be careful when judging the size or distance of a vehicle or other object seen in the side convex mirror Be aware that object l...

Page 12: ...etrol Vehicle Gas Vehicle A Speedometer and odometer B Tell Tale Indicators C Switch LH D Switch RH E On off parking switch F Mobile Charger socket G Hazard switch H Stereo switch I Selector Switch J...

Page 13: ...cators Petrol Gas 1 Battery charging indicator 2 LH turn pilot indicator 3 RH turn pilot indicator 4 Hi beam indicator 5 Neutral Indicator 6 Petrol mode indicator 7 Gas mode indicator 8 Gas level indi...

Page 14: ...icle then battery is not getting charged In this case immediately take the vehicle to Distributor Dealer 2 3 Turn Pilot indicators LH RH When you turn on the left or right turn signals the correspondi...

Page 15: ...itched ON provided the vehicle is in Neutral gear The light will go off as soon as the gear is engaged This helps the driver to confirm Neutral position while starting and stopping the vehicle Note St...

Page 16: ...Indicator LED lamps in tell tale indicator shows the gas level in tank Whenever tank is full all LED lamps will glow One by one lights will go off as the gas level in tank drops Whenever only R light...

Page 17: ...de indicator lights remain OFF LH Front and Rear LH side indicator lamps and LH turn pilot indicator will flash simultaneously RH Front and Rear RH side indicator lamps and RH turn pilot indicator wil...

Page 18: ...Head Tail and Parking lamps will be ON Hi beam indication will be ON if switch is in High Beam position B Wiper Motor switch It has 2 positions ON Wiper motor ON OFF Wiper motor OFF Wiper blade shoul...

Page 19: ...parking hazard circuit PARKING Parking light and hazard operation will come on when respective switches on switch board are ON and key is in parking position START starter motor will start After holdi...

Page 20: ...ll 4 indicator lights simultaneously and both turn pilot indicators will blink simultaneously Key switch should be in ON or Parking position to operate hazard switch B Stereo Switch A switch is provid...

Page 21: ...ded on the front face which controls gas and petrol supply It has 3 positions 1 Gas The vehicle will run on gas i e LPG CNG 2 Off Both gas and petrol solenoids will be off 3 Petrol The vehicle will ru...

Page 22: ...1 4 Other Controls 17 Other Controls 1 4 A Parking Brake 1 4 B Brake Pedal 1 4 C Clutch Lever 1 4 D Reverse Lever...

Page 23: ...securely or does not fully release have your vehicle inspected immediately by an authorized distributor dealer 1 4 A Parking Brake A Parking Brake It is located below dashboard To apply the parking b...

Page 24: ...gear when vehicle is parked on uphill Remember that even if transmission is in gear you must apply the parking brake fully Shift the vehicle into Reverse Gear When Vehicle is parked on Downhill When p...

Page 25: ...the brakes are applied you should have the brakes checked by an authorized distributor dealer Do not ride the brakes by applying them continuously or resting your foot on the pedal This will result i...

Page 26: ...washing the underside of the vehicle test the brakes while driving at a slow speed to see if they have maintained their normal effectiveness If the brakes are less affective than normal dry them by re...

Page 27: ...tch is operated by hand lever located on LH side of handle bar CAUTION Do not drive with clutch lever in pressed condition It could result in excessive clutch wear clutch damage or loss of engine brak...

Page 28: ...neutral stop the vehicle with engine idling Pull the reverse gear lever Press clutch lever Engage transmission into first gear Release the clutch lever slowly and open throttle to set the vehicle in...

Page 29: ...5 A Petrol Tank 1 5 A1 Fuel Cock 1 5 B Battery0 1 5 C Spare Wheel 1 5 D Mobile Charger Socket water bottle holder 1 5 E Air Filter 1 5 F Fuel Filter 1 5 G Fuse Box 1 5 H Oil Cooler 1 5 I Cylinder Ref...

Page 30: ...rear RH side Fuel tank capacity is 8 litres including Reserve of 1 5 litres B Petrol Tank limphome facility for Gaseous vehicles Petrol tank is mounted on rear RH side Petrol tank capacity is 3 0 lit...

Page 31: ...ock Fuel cock knob is located near driver seat Fuel cock is operated by this knob It has 3 position ON fuel level is above 1 5 litre RES fuel level drops below 1 5 litre OFF fuel supply cut off ON OFF...

Page 32: ...ks away from the battery or an explosion may occur Never smoke when working in the vicinity of the battery When checking or servicing the battery disconnect the negative cable Be careful not to cause...

Page 33: ...Wheel Spare Wheel Location of spare wheel is under driver seat Remove 2 bolts of driver seat frame Tilt the driver seat frame to handle bar side To remove spare wheel remove the 2 nuts securing the sp...

Page 34: ...le Holder B B A A Mobile Charger Socket Mobile charger socket is on dashboard Mobile can be charged in Key OFF condition key ON position and Parking position B Water Bottle Holder Water bottle holder...

Page 35: ...Air Filter Air filter is used to provide clean air to engine It is located on body near engine 1 5 E Air Filter Air Filter 30...

Page 36: ...lter Fuel filter is given to provide clean fuel to the engine It is in between fuel pipes from fuel tank i to Carburetor in Petrol vehicles ii to solenoid in Gas vehicles Fuel Filter Petrol Vehicle Fu...

Page 37: ...ttery fuse box Mounted on battery mounting bracket WARNING Battery fuse A B Always be sure to replace a blown fuse with a fuse of the correct ampere Never use a substitute such as aluminum foil or wir...

Page 38: ...1 5 H Oil Cooler Oil Cooler Engine is fitted with oil cooler which helps to control the engine temperature and subsequently enhance the life of engine parts 33...

Page 39: ...nk for filling tank and withdrawal of LPG along with safety devices C Shut Off Valve This shut off valve is to be closed when vehicle is parked for longtime or overnight Also in case of any leakage ob...

Page 40: ...open the valve D and insert the LPG filling gun inside refilling unit Fill the LPG into cylinder E LPG Solenoid Valve This valve gets operated when ignition switch is in ON position and selector swit...

Page 41: ...ling the gas Please ensure that dust plug is properly fitted Ensure that after removing dust plug all electrical supply is in OFF condition D Shut Off Valve It controls ON OFF supply of CNG gas as ind...

Page 42: ...with CNG gas open the lockable door provided at RH side of body as shown in fig Remove Dust plug and fill the gas into cylinder till the pressure in cylinder reaches 200 bar Close the refueling unit b...

Page 43: ...They are the only means of identifying your particular vehicle from others of the same model and type 1 6 Identification Data Chassis Number Location At Front on Dashboard Engine Number Location On R...

Page 44: ...on RG6HCC BOSCH UR6CC Lubrication Pressurized lubrication by separate oil pump Transmission gears 4 Forward 1 Reverse Spark 39 Petrol Tank Capacity Petrol Vehicle Full 8 Litres Reserve 1 5 Litres Gas...

Page 45: ...Indicator Lamp 10 W Horn 12V DC Reverse Lamp 10 W Pilot Lamp 5 W Vehicle Weight Petrol LPG CNG Kerb Wt 348 kg 368 kg 389 kg Max Wt 678 kg 698 kg 719 kg Max Speed Petrol 65 km h LPG 65 km h CNG 63 km h...

Page 46: ...2 Operating Your Vehicle 41 2 1 Daily Safety Checks 2 2 Safe Driving Tips 2 3 Fuel Saving Tips 2 4 Running In 2 5 Starting and Driving...

Page 47: ...d unobstructed Fuel Enough fuel in tank Check fuel pipes for cracks leakage Replace if found defective Electrical Operating of all tell tale lights switches horn etc Brakes Effectiveness lever play dr...

Page 48: ...Driving down a Hill When driving down a hill the engine should be used for braking by shifting to next Lower gear Never drive while under the influence of alcohol or other drugs Alcohol and drugs can...

Page 49: ...irement 3 Avoid following Sudden acceleration and frequent sudden braking Driving with foot on brake pedal Driving with partial disengaging of clutch half clutch Overloading Driving at high speeds Ove...

Page 50: ...4th Speed km hr 10 15 25 35 Always keep within the specified running in speeds Do not race the engine excessively Do not start moving or race the engine immediately after starting Run the engine for...

Page 51: ...onfirming the neutral lamp in tell tale indicator is lit Check Tell tale lights for Battery charging indicator in tell tale indicator is lit Use ignition switch key to start the vehicle Wait for about...

Page 52: ...ould go off Release parking brake Press the clutch Shift into first gear Open the throttle a little and start to release the clutch very slowly As clutch starts to engage open the throttle a little mo...

Page 53: ...Shifting Gears Close the throttle while pressing the clutch Shift into the next higher or lower gear Open the throttle partially while releasing the clutch 48...

Page 54: ...top the vehicle with engine in idling condition Pull the reverse gear lever Press clutch Engage transmission into first gear Release the clutch pedal lever and open throttle to set the vehicle in moti...

Page 55: ...uired to open the throttle slightly Still vehicle if does not start it is likely that vehicle is flooded with Gas Put the switch in OFF position Crank the engine as soon as the vehicle starts put swit...

Page 56: ...engine On starting the engine release the choke immediately 3 Warm up the engine and run the vehicle on petrol for 2 to 4 minutes i e For 3 to 5 kms 4 To switch over engine to GAS put the selector sw...

Page 57: ...Stopping the engine Close the throttle completely Shift the gear to neutral Turn the ignition switch to OFF position Ignition Parking Switch 52...

Page 58: ...Lubrication Chart 3 3 Engine Box Oil Checking Replacement 3 4 Differential Oil Checking Replacement 3 5 Recommended Oil Grade and Quantity 3 6 Air Filter Cleaning Procedure 3 7 Battery 3 8 Wiper Motor...

Page 59: ...A C A C A C A Adjust if required 10 Check Replace fuel pipes C R C R C R C R 11 Check Battery electrolyte level top up C T C T C T C T 12 Do Tyre rotation seq 1 seq 2 A A A A A A A Seq 1 at 5k 15k 25k...

Page 60: ...ilter HPR CNG replace if required C R Replace if required 4 Clean Gas regulator CL Open Power valve 5 Replace all rubber components of gas kit After every three 3 years 6 Gas cylinder retesting After...

Page 61: ...meter drive L L L L L L L L 9 Speedometer inner greasing L L L Every 10 000 km 10 Apply petroleum jelly on Battery terminals L L L L L L L L RECOMMENDED ODOMETER READING km 10K 5K 1K 15K 20K 25K 30K 3...

Page 62: ...tely on the seating face of clutch cover Remove the dipstick check the oil level This should be between the two marks C and D as shown A Oil filler hole dipstick B Oil level dipstick C Upper level Max...

Page 63: ...ound so that the oil settles down Remove oil drain plug Let the oil drain completely Tighten the drain plug Remove oil filling plug and pour the correct quantity of recommended oil Ensure oil level at...

Page 64: ...cleaned in accordance with periodic maintenance chart B Oil Filter Replace the oil filter element assembly at every 10 000 Kms Ensure Engine oil level confirms to maximum level indicated of dipstick o...

Page 65: ...Remove differential oil level bolt The oil level is correct if oil just starts flowing out when bolt is removed If oil is not flowing out i e Less oil level top up with specified oil till the oil star...

Page 66: ...n a level ground so that the oil settles down Remove oil drain plug Let the oil drain completely Tighten the drain plug Remove oil filling plug and pour the correct quantity of recommended oil Check t...

Page 67: ...efer periodic maintenance chart Do not reuse drained oil Dispose of drained oil properly Two different grade and brands of oil should not be mixed Ensure Engine oil level confirms to maximum level ind...

Page 68: ...ir jet from inside tapping the element on ground Clean air filter housing by air jet and wipe it clean Assemble the air filter element in the housing fix the clips 3 6 Air Filter Cleaning Position fil...

Page 69: ...lower level in any cell top up to upper level with distilled water only Check battery terminal voltage and Sp gravity Charge the battery if required Check connections of battery terminals and starter...

Page 70: ...king feature is provided in the wiper motor Wiper blade will rest in extreme left position When viewed from inside the cabin Wiper Motor Before washing vehicle wrap the wiper motor with polythene shee...

Page 71: ...the propeller shaft Hindustan petroleum AP3 Castro volvotine NLGI 3 Indian Oil Servo RR3 Bellows of propeller shaft should be kept in good condition and replaced immediately if torn Torn bellows will...

Page 72: ...evel is between the Max and Min lines If the brake fluid level is near the Min line fill it up to the MAX line with recommended brake fluid CAUTION A rapid fluid loss indicates a leak in the brake sys...

Page 73: ...luids Marketed by Type of oil Hindustan Petroleum Hp Super Duty brake fluid DOT 3 Indian Oil Corporation Servo brake fluid super HD Bharat Petroleum Bharat Heavy Duty brake fluid Castrol India Ltd Cas...

Page 74: ...3 11 Free Play Free play for a At brake pedal 10 15 mm b At clutch Lever 4 5 mm c Accelerator grip 2 3 mm d Choke cable 2 3 mm at engine end e Spark plug gap 0 6 0 8 mm 69...

Page 75: ...cified pressure The best tyres should always be kept at the rear wheels which are driving wheels thereafter follow the sequence of rotation Sequence 1 After 5 000 15 000 km Change front tyre face inte...

Page 76: ...2 Front 2 1 kg cm 30 PSI 2 Rear 2 4 kg cm 34 PSI Tyre Size 4 00 8 4 6 PR All four tyres Correct Traction Optimum Handling Optimum Tyre Life Danger Poor Handling Poor Economy Rapid Wear Edge Danger Poo...

Page 77: ...k for drivability hesitation Check Play Adjustment Cable Check and adjust all control cables Check and correct tyre inflation pressure including that of Spare wheel Electrical related Check all lights...

Page 78: ...Details Engine No Chassis No Registration No Make and Purchase Date Selling Servicing Distributors Dealers Nature of Complaint in Brief For any additional Information or Assistance Please Contact Baj...

Page 79: ...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 up...

Page 80: ...ected 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 Place Date Customer s Signature TO BE RETAINE...

Page 81: ...Delivery Certificate Date of Sale Customer s Name Address Phone No Dealer s Name Address 77...

Page 82: ...lways Insist on For optimum performance of vehicle For prolonged life of components vehicle For economical maintenance cost Genuinity Test For rider s safety Scratch Hologram to find Genuine Partial t...

Page 83: ...onal Business Bajaj Auto Limited Akurdi Pune 411 035 India www bajajauto com E MAIL WEB SITE customerservice bajajauto co in WORLD S NO 1 Three Wheeler Bajaj Auto Limited Registered Head Office Akurdi...

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