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Bajaj Auto RE 4-stroke User Manual
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Bajaj Auto RE 4-stroke User Manual

Petrol, cng, lpg
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Petrol, CNG, LPG
User's Guide
1
WORLD'S NO.
Three Wheeler

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Summary of Contents for Bajaj Auto RE 4-stroke

  • Page 1 Petrol, CNG, LPG User’s Guide WORLD’S NO. Three Wheeler...

  • Page 2: Parts View

    Identification Identification Clutch lever Mobile Charger socket Hazard switch Stereo switch Selector Switch Switch LH On - off parking switch Switch RH Accelerator Grip Tell Tale Indicators Choke lever Speedometer and odometer Petrol Vehicle LH turn pilot indicator RH turn pilot indicator Hi beam indicator Neutral Indicator Gas Vehicle...
  • Page 3 Dear Customer, RE 4-STROKE We Thank you for choosing the “ ”, which would give you ‘Value for Money, For Years’. We are sure that you will be happy with its performance. The salient features of this vehicle are DTSI Engine (Twin Spark Plug), bigger oil filter, magnetic strainer, stronger chassis &...
  • Page 4 IMPORTANT NOTE WARNING / CAUTION / NOTE Indicates special information to make Please read this manual and follow its maintenance easier or instruction clear. instruction carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special MODIFICATION WARNING meaning.

  • Page 5: Table Of Contents

    Index Index Before Driving.............. 1 Operating your vehicle..........41 Preventive maintenance..........53 Pre Delivery Inspection check points...... 72 Notice ............... 74 Delivery Certificate ........... 76...

  • Page 6: Before Driving

    1. Before Driving Locks Mirrors Handle bar and Dashboard Other controls Other Important parts location Identification data Technical Specifications...

  • Page 7: Steering Lock

    1.1 Locks Locking Un-Locking Steering Lock Steering Lock Steering Lock • Steering lock is below dashboard. Steering lock operation : • Locking : Turn the Handle bar to LH side, rotate the 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.
  • Page 8 Lock Lock Unlock Unlock Glove Box Lock Tool Box Lock Glove box lock: • To Unlock or lock glove box 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.
  • Page 9 Unlock Lock Lock Unlock Lock Unlock Side Filling Door Lock(Petrol veh.) Rear Door Lock Side 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 door insert the key & rotate it clockwise. Rear door lock: A lock is given for locking rear door.
  • Page 10 Unlock Lock A. Gas Filling Door Lock A.Gas filling 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.
  • Page 11 1.2 Mirrors Mirrors Outside Rear View Mirror: • Adjust the outside rear view mirror so that you can see the rear sides of your vehicle in the mirrors. WARNING Be careful when judging the size or distance of a vehicle or other object seen in the side convex mirror.
  • Page 12 1.3 Handle Bar and Dashboard Petrol 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 Selector Switch J.
  • Page 13 1.3 A & B. Speedometer & Indicators Petrol 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 indicator...
  • Page 14 2 & 3 Battery Charging Indicator : This light will glow when the Ignition switch is switched “ON” and will go off after starting of the vehicle. If this indicator glows continuously even after starting of vehicle, then battery is not getting charged.
  • Page 15 4. Headlamp Hi-beam : When the Headlamp Hi-beam is on this indicator will glow and give indication to the driver. 5. Neutral : Indicator light will glow as the Ignition switch is switched “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.
  • Page 16 7.Gas mode indicator 8..Gas Level Indicator 7.Gas mode indicator (CNG) (LPG) 7. Gas mode indicator: This indicator glows when ignition key is turned “ON” and gas selector switch is at CNG/LPG mode as applicable. 8. Gas Level Indicator : LED lamps in tell tale indicator shows the gas level in tank. Whenever tank is full all LED lamps will glow.
  • Page 17 1.3 C. Switch LH Switch L.H. A. Side indicator switch : It has 3 positions. Center : All side indicator lights remain “OFF”. : Front and Rear, LH side indicator lamps and LH turn pilot indicator will flash simultaneously. : Front and Rear, RH side indicator lamps and RH turn pilot indicator will flash simultaneously.
  • Page 18 1.3 D. Switch RH Wiper blade Self Parking Position Switch R.H. • With ON/OFF switch ON Position A. Light switch : It has following positions Head and Pilot lights “OFF”. Parking, & Tail lamps will be “ON”. Head, Tail, and Parking lamps will be “ON” Hi beam indication will be “ON”, if switch is in High Beam position.
  • Page 19 1.3 E. Ignition Parking Switch IGNITION PARKING SWITCH Ignition Parking Switch • It is located on the dash board. • Insert the key & rotate it clockwise to make it on. • It has 4 positions : OFF : All electrical circuits “OFF”. ON : All Electrical circuits “ON”...
  • Page 20 1.3 F & G. Hazard & Stereo Switch A)Hazard Warning switch Stereo Switch A. Hazard Warning Switch: In case of emergency , this switch is to be operated. It will switch on all 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.
  • Page 21 1.3 H. Selector Switch For Gas Vehicle Selector Switch Selector Switch : It is mounted on Dashboard. Selector switch has been provided 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.
  • Page 22 1.4 Other Controls Other Controls 1.4 A. Parking Brake 1.4 B. Brake Pedal 1.4 C. Clutch Lever 1.4 D. Reverse Lever...
  • Page 23 1.4 A. Parking Brake Pull the lever to apply Press the button to release A. Parking Brake • It is located below dashboard. To apply the parking brake, pull the parking brake lever all the way up. To release the parking brake push the button "B" in middle of the Lever and lower to its original position.
  • Page 24 Pull the lever to apply Press the button to release CAUTION Always apply parking brakes fully before leaving your vehicle or it may move causing injury or damage , especially on gradients. When parking, shift the vehicle into first gear (when vehicle is parked on uphill) &...
  • Page 25 1.4 B. Brake Pedal Brake Pedal : Vehicle is provided with hydraulic brake system. Brake is operated by pedal mounted on RH side of scudo. CAUTION If brake squeal is excessive and occurs each time the brakes are applied, you should have the brakes checked by distributor / dealer.
  • Page 26 CAUTION If water gets into the brake drums, brake performance may become poor and unpredictable. After driving through water or 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 repeatedly applying the brakes while driving slowly until the brakes have regained their normal effectiveness.
  • Page 27 1.4C- Clutch Lever Clutch Lever: Clutch 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 braking and drop in fuel efficiency.
  • Page 28 1.4D- Reverse Lever Reverse Gear Lever Reverse Gear Engaged Reverse Gear disengaged Reverse Gear : For engaging reverse gear - • Change to neutral, stop the vehicle with engine idling. • Pull the reverse gear lever. • Press clutch lever. •...
  • Page 29 1.5 Other Important Parts Location 1.5 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.
  • Page 30 1.5 A. Fuel Tank B. Fuel Tank A. Fuel Tank For Gas Vehicle For petrol Vehicle A. Fuel Tank (Petrol Vehicle) • Fuel tank is mounted on rear RH side. • Fuel tank capacity is 8 litres including Reserve of 1.5 litres. B.
  • Page 31 1.5 A1. Fuel Cock PETROL VEHICLE Fuel Cock: 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.
  • Page 32 1.5 B Battery Battery (12V ,32Ah) Battery (12V ,32Ah) • It is located on RH side of driver seat. WARNING Batteries produce flammable hydrogen gas. Keep flames and sparks 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.
  • Page 33 1.5 C Spare 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 spare wheel...
  • Page 34 1.5 D Mobile Charger, Water Bottle Holder Mobile Charger Socket Water Bottle Holder 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.
  • Page 35 1.5 E Air Filter Air Filter Air Filter: Air filter is used to provide clean air to engine. It is located on body near engine.
  • Page 36 1.5 F Fuel Filter Fuel Filter (Gas Vehicle) Fuel Filter (Petrol Vehicle) Fuel Filter : 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.
  • Page 37 1.5 G Fuse Box Battery fuse Fuse Box : A) Main fuse box : Fuse box is mounted on electrical unit plate below dashboard at LH side 2 Spare fuses (one of 10A & another of 30 A) is provided in a fuse box cover. B)Battery fuse box : Mounted on battery mounting bracket.
  • 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.
  • Page 39 I Cylinder Refueling LPG A. LPG Cylinder : It is mounted below passenger seat. B. Multifunction Valve : It is mounted on LPG cylinder. It is an assembly, mounted on LPG tank for filling tank and withdrawal of LPG along with safety devices. C.
  • Page 40 1.5 I Cylinder Refueling D. Refilling Valve : To refill the cylinder with LPG, 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 switch is in Gas mode.
  • Page 41 J Cylinder & Refueling CNG A. CNG Cylinder : It is mounted below passenger seat. B. Pressure Gauge : It is mounted on remote filling valve which indicates pressure inside the cylinder . C. Dust Plug : It is mounted on remote filling valve and is used for refilling the gas. Please ensure that dust plug is properly fitted.
  • Page 42 J Cylinder & Refueling Refueling : Refueling is done via remote filler valve A Dust plug is provided in this unit. When only 'R' lamp glow on gas level indicator refueling should be done. To refill the cylinder with CNG gas, open the lockable door provided at RH side of body as shown in fig.

  • Page 43: Identification Data

    1.6 Identification Data The Chassis and Engine serial numbers are used to register the vehicle. They are the only means of identifying your particular vehicle from others of the same model and type. Chassis Number Location - At Front on Dashboard . Sample No.
  • Page 44 1.7 Technical Specification Engine 4Stroke, Spark Petrol Tank Capacity Ignition, Forced air Petrol Vehicle : Full: 8 Litres, cooled. Reserve : 1.5 Litres Bore X Stroke 63.5 mm x 62.8 mm Gas Vehicle : 3.0 Litres (Limphome) Engine Displacement :198.88 cm L.P.G.
  • Page 45 1.7 Technical Specification Electrical System 12 V DC Battery 12V 32 Ah Head Lamp 35/35 W Pilot Lamp Tail / Stop Lamp 5/21 W or 5/18 W Side Indicator Lamp 10 W Horn 12V DC Reverse Lamp 10 W Pilot Lamp Vehicle Weight Petrol Kerb Wt...

  • Page 46: Operating Your Vehicle

    2. Operating Your Vehicle Daily Safety Checks Safe Driving Tips Fuel Saving Tips Running In Starting and Driving...

  • Page 47: Daily Safety Checks

    2.1 Daily Safety Checks Before starting the vehicle, it is recommended to do following checks.: Make sure that mirrors, lights and reflectors are clean and 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.

  • Page 48: Safe Driving Tips

    2.2 Safe Driving Tips WARNING Never drive while under the influence of alcohol or other drugs. Alcohol and drugs can seriously impair your ability to drive safely. You should also avoid driving when you are tired, sick, irritated, or under stress.

  • Page 49: Fuel Saving Tips

    2.3 Fuel Saving Tips Ride smoothly and steadily at an optimum speed of 30 40 kmph Change the gear judiciously according to the speed requirement. Avoid following • Sudden acceleration and frequent / sudden braking. • Driving with foot on brake pedal. •...

  • Page 50: Running In

    2.4 Running - In • During first 2000 km running-in period do not exceed following speed limits. Gear Speed km/hr • 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 a minute at idle speed to give the oil a chance to work up into the engine.
  • Page 51 2.5 Starting & Driving Starting the Engine • Turn ignition switch key ON • Ensure that vehicle is in Neutral gear, by confirming the neutral lamp in tell tale indicator is lit. • Check Tell tale lights for Battery charging indicator in tell tale indicator is lit. •...
  • Page 52 Moving On : • When the engine has started battery charging, indicator should 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. •...
  • 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.
  • Page 54 Reverse Gear Lever Normal position Engaged position Reverse Gear : For engaging reverse gear - • Change to neutral, stop the vehicle with engine in idling condition. • Pull the reverse gear lever. • Press clutch . • Engage transmission into first gear. •...
  • Page 55 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 switch on ‘Gas’ mode. Bajaj Auto has provided a limphome facility to run the vehicle on petrol in case the ‘Gas’ is...
  • Page 56 To run vehicle on Petrol mode : • Put Selector switch in Petrol mode. • Wait for some time for filling of the Carburettor bowl. • Crank the engine. CAUTION While switching from petrol to gas mode, put the Selector switch in OFF position. Run the vehicle till the petrol in Carburettor is consumed.
  • Page 57 Ignition / Parking Switch Stopping the engine : • Close the throttle completely. • Shift the gear to neutral. • Turn the ignition switch to “OFF” position.

  • Page 58: Preventive Maintenance

    3. Preventive Maintenance Index Periodic Maintenance Chart Periodic Lubrication Chart Engine Box Oil - Checking / Replacement Differential Oil - Checking / Replacement Recommended Oil Grade and Quantity Air Filter Cleaning Procedure Battery Wiper Motor Drive Shaft Slider Block 3.10 Brake Oil 3.11 Free Play 3.12 Tyre Rotation...

  • Page 59: Periodic Maintenance Chart

    3.1 Periodic Maintenance Chart RECOMMENDED ODOMETER READING km Operation 20K 25K 30K 35K 1. Vehicle washing & Cleaning CL CL 2. Clean/replace Air filter element CL CL CL Replace after every 40,000 km 3. Clean/Replace breather tube filter CL Replace After every 10,000 km 4.
  • Page 60 3.1 Periodic Maintenance Chart GAS Kit Related RECOMMENDED ODOMETER READING km Operation 20K 25K 30K 35K 1. Check gas leakages C,A,R C,A,R C,A,R C,A,R 2. Replace gas filter element solenoid CNG Replace after every 10,000 km Replace if required Check gas filter HPR CNG, replace if required 4.

  • Page 61: Lubrication Chart

    3.2 Lubrication Chart RECOMMENDED ODOMETER READING km Operation 20K 25K 30K 35K 1. Replace/top up Gear Box oil replace* Replace After every 10,000 km. Top up at every 1000 km 2. Replace/top up Differential oil Replace After every 10,000 km 3.
  • Page 62 3.3 Engine Oil-Checking/Replacement Face ‘R’ A. Oil filler hole/dipstick B. Oil level dipstick C. Upper level (Max level) D. Lower level (Min level) Engine Oil level checking procedure : • Park the vehicle on level surface to check the oil level. •...
  • Page 63 3.3 Engine Oil-Checking/Replacement A. Oil filler hole B. Oil drain plug Oil replacement : Replace oil as per Lubrication Chart. For Replacing Engine Oil : • Run the engine for about 10 minutes to warm up the oil • Place the vehicle on a level ground so that the oil settles down •...
  • Page 64 3.3 Engine Oil-Checking / Replacement A. Location of Oil strainer B. Oil filter A. Oil Strainer Cleaning • Oil Strainer is situated inside the plug as shown in the figure. • Oil Strainer should be cleaned in accordance with periodic maintenance chart. B.
  • Page 65 3.4 Differential Oil-Checking & Replacement Differential Oil level bolt Differential Oil level checking procedure: – Place the vehicle on a level ground. – Let the oil settle for a few minutes. – 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 starts flowing out.
  • Page 66 3.4 Differential Oil-Checking & Replacement B Oil drain bolt C Oil filler plug Oil replacement : Replace oil as per Lubrication Chart. For replacing Differential oil : • Run the engine for about 10 minutes to warm up the oil. •...

  • Page 67: Recommended Oil Grade And Quantity

    3.5 Recommended Oil Grade and Quantity Recommended Engine Oil: Always insist on Bajaj Genuine Engine Oil for optimum engine performance. It is a specially formulated oil for vehicles with DTS-i engines. Lubrication Replace the oil in accordance with periodic maintenance chart. Recommended oil grade Quantity Engine Oil...

  • Page 68: Air Filter Cleaning

    3.6 Air Filter Cleaning Air Filter Cleaning : • Open clips of air filter assembly. • Remove air filter element. • Clean the air filter element by blowing air jet from inside & tapping the element on ground. • Clean air filter housing by air jet and wipe it clean. •...
  • Page 69 3.7 Battery Battery (12V 32Ah) • Check and ensure that the electrolyte level is between the upper (Max) and lower (Min) level in each cell. • If electrolyte level is below lower level in any cell, top up to upper level with distilled water only. WARNING Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.

  • Page 70: Wiper Motor

    3.8 Wiper Motor Wiper Motor Wiper Motor : • Self parking feature is provided in the wiper motor. Wiper blade will rest in extreme left position. (When viewed from inside the cabin). WARNING Before washing vehicle, wrap the wiper motor with polythene sheet to prevent water entry.

  • Page 71: Drive Shaft Slider Block

    3.9 Drive Shaft Slider Block Propeller Shaft Greasing Do the Propeller shaft greasing at every 5000 kms. Use only following recommended grease for greasing the propeller shaft. Hindustan petroleum - AP3 Or equivalent Castro/ volvotine - NLGI-3 Indian Oil - Servo RR3 Bellows of propeller shaft should be kept in good condition and replaced immediately if torn.

  • Page 72: Brake Oil

    3.10 Brake Oil Brake Oil container : Brake oil container is located on Master Cylinder near brake pedal. Check the brake fluid level by looking at the reservoir. Check that the fluid level 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.
  • Page 73 Brake Oil • it is advisable that the brake fluid should be replenished at least once in a year. We recommend following brake fluids. Marketed by Type of oil Hindustan Petroleum Hp Super Duty brake fluid DOT-3 Indian Oil Corporation Servo brake fluid super HD Bharat Petroleum...

  • Page 74: Free Play

    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...
  • Page 75 3.12 Tyre Rotation Sequence -2 Sequence -1 FRONT FRONT SPARE REAR REAR REAR REAR Tyre rotation : The wheels are interchangeable provided they are correctly inflated. To even out tyre tread wear it is recommended to rotate it after every 5,000 km and inflate it to the specified pressure. The best tyres should always be kept at the rear wheels which are driving wheels, thereafter follow the sequence of rotation.
  • Page 76 3.12 Tyre Rotation Correct Traction Danger:Poor Grip Danger: Poor Handling Optimum Handling Insufficient Traction Poor Economy Optimum Tyre Life Rapid Wear(Center) Rapid Wear(Edge) Properly inflated Properly inflated Over Inflated Over Inflated Under inflated Under inflated Tyre Pressure : Keep appropriate tyre pressure as mentioned below to increase life of the tyre and for better fuel consumption.

  • Page 77: Pre Delivery Inspection

    4. Pre Delivery Inspection Transit Damage : Check the vehicle for any transit damages. Performance: Check engine oil & differential oil level and top up if necessary. Check gear shifting and clutch for proper adjustment and working. Check and adjust engine idling if necessary. Check for drivability, hesitation.
  • Page 78 No., Make and Purchase Date) • Selling/Servicing Distributors / Dealers • Nature of Complaint in Brief For any additional Information or Assistance Please Contact : Bajaj Auto Limited Export Service International Business Akurdi, Pune 411 035 India Phone : +91 20 27406278 Fax : +91 20 27407385 E-mail : customerservice@bajajauto.co.in...

  • Page 79: 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 up-to-date, modifications on the vehicle, parts or accessories as may be convenient and necessary.
  • Page 80 Delivery Certificate Chassis No.: Engine No.: • 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. Place : Date Customer's Signature (TO BE RETAINED BY SELLING DEALER)

  • Page 81: Delivery Certificate

    Delivery Certificate Date of Sale Customer’s Name : Address Phone No. Dealer’s Name Address...
  • Page 82 Use only Bajaj Genuine Parts For optimum performance of vehicle For prolonged life of components & vehicle Always For economical Insist parts maintenance cost For rider's safety Genuinity Test Scratch Hologram to find ‘Genuine’ Partial transparent Hologram Golden Hologram...
  • Page 83 E-MAIL www.bajajauto.com WEB-SITE Export Service, International Business Bajaj Auto Limited WORLD’S NO. Akurdi, Pune 411 035 India. Three Wheeler Mileage Safety Trust Benefit Bajaj Auto Limited Registered & Head Office Akurdi, Pune - 411 035, India. Tel. : +91 20 27472851,...

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