Re Maxima Diesel User Manual

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User's Guide

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WORLD'S NO.

Three Wheeler

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Page 1 User’s Guide cover WORLD’S NO. Three Wheeler...
Page 2 Identification Identification De compression knob Reverse knob Engine stop knob Speedometer & Odometer Switch LH Hazard switch Ignition parking switch Switch RH Tell Tale Indicator Mobile Charger Battery charge indicator Low oil pressure indicator LH & RH Turn indicator glow plug indicator High beam indicator Neutral indicator Fuel level indicator...
Page 3 Dear Customer, RE MAXIMA Diesel 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 5 speed gear box, dry clutch (car type), stronger chassis &...
Page 4 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 5: Delivery Certificate
Delivery Certificate Date of Sale Customer’s Name : Address Phone No. Dealer’s Name Address...
Page 6 IMPORTANT NOTE WARNING / CAUTION / NOTE Indicates special information to make Please read this manual and follow its maintenance easier or instruction clear. instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special WARNING meaning.
Page 7 Index Index 1. Before Driving 2. Operating your vehicle 3. Preventive maintenance 4. Pre Delivery Inspection Check Points 5. Notice...
Page 8: Before Driving
1. Before Driving Before Driving Index 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 Specification...
Page 9 1.1 Locks 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 10 Lock Lock Unlock Unlock Glove Box Lock Stereo Cover Lock Glove box lock: To Unlock or lock glove box lock insert the key and rotate it clockwise or anticlockwise respectively. Stereo Cover Lock: Lockable cover for stereo is provided on RH side of dashboard To Unlock or lock stereo cover lock insert the key and rotate it clockwise or anticlockwise respectively.
Page 11 Diesel Tank Cap lock : • For filling diesel, open tank cap lock. • To open the lock, insert the key & rotate it Clockwise. • To close the lock, insert the key & rotate it Anticlockwise. Note Never wrap a plastic or polythene cover on fuel tank mouth as this may lead to vaccum lock...
Page 12 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 objects seen in the side convex mirror.
Page 13 1.3 Handle Bar and Dashboard A. Instrument cluster B. Switch RH C. Switch LH D. Ignition parking switch E. Mobile charger F. De compression knob G. Engine stop knob H. Reverse knob Hazard switch J. Stereo switch...
Page 14: Instrument Cluster
1.3 A. Instrument Cluster 0 0 0 0 1 5 km/h 1. Battery charging indicator 2. Low oil pressure indicator 3. LH turn pilot indicator 4. Fuel gauge 5. Glow plug (heater) indicator 6. Hi beam indicator 7. Neutral indicator 8.
Page 15 1. Battery Charging Indicator : This light will glow when the Ignition switch is switched ON and will go off after engine is started. If this indicator glows continuously even after engine is started, it indicates that the battery is not getting charged.
Page 16 3 & 8 3&8. Turn Pilot indicators (LH & RH) : When you turn on the left or right turn signals, the corresponding green arrow in the instrument cluster will flash along with the turn signal lights. When you turn on the hazard warning switch, both arrows will flash along with all the turn signal lights.
Page 17 0 0 0 0 1 5 km/h 6. Headlamp Hi-beam : When the Headlamp Hi-beam is ON this indicator will glow and give indication to the driver. Neutral : Indicator light will glow as the Ignition switch is switched “ON” provided the vehicle is in Neutral gear.
Page 18 1.3 B. Switch RH Switch RH Switch R.H. It has 3 control switches for operating head lights, wiper and starting button • With ON/OFF switch ON Position A. Light switch : It has following positions Head and Pilot lights “OFF”. Parking, Tail and Tell Tale Indicators illumination lamps will be “ON”.
Page 19 1.3 C. Switch LH Switch LH Switch L.H. It has 3 control switches for operating indicator lights, dipper and horn button. 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.
Page 20 1.3 D. Ignition - Parking Switch Ignition - Parking Switch Ignition - Parking Switch • It is located on the dash board. • Insert the key and rotate it clockwise to make it on. • It has 3 positions : OFF : All electrical circuits OFF.
Page 21: Engine Stop Knob
1.3 F. Stop Knob Pull the knob to operate Engine Stop Knob • It is located on the dash board below wiper motor indicated by “S” • Pull the knob to cut off the engine. CAUTION Do not use De-compression lever for stopping the engine.
Page 22 1.3 G. Decompression Knob Pull the knob to operate De-compression Knob • De-compression knob is located on center of dashboard indicated by “D” • Use De-compression knob for starting only. Note Starter motor will not operate until De-compression knob is operated (pulled). After three consecutive cranks, if engine dose not start, wait for about 30 Sec.
Page 23 1.3 H. Reverse Gear Knob Pull the knob to operate Reverse Gear Knob • Reverse gear knob is located on Dashboard indicated by “R”. • To engage reverse gear, change to neutral, stop vehicle with engine idling, pull the reverse gear knob and shift the gear twist grip to “R”...
Page 24 1.3 I & J. Hazard Warning & Stereo Switch A. Hazard Warning switch B. Stereo switch A. Hazard Warning Switch: Hazard switch can be switched ON (Irrespective of On/Off key switch position) : Both front and rear LH and RH blinkers will blink simultaneously and both Turn pilot indicators in Instrument cluster will blink simultaneously.
Page 25 1.4 Other Controls Other Controls 1.4 A. Parking Brake 1.4 B. Brake Pedal 1.4 C. Clutch Lever...
Page 26 1.4 A.Parking Brake Parking Release Parking Brake • It is located on left side of driver seat. • 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 Parking Brake Lever and lower it to its original position.
Page 27 Parking 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) & Shift the vehicle into Reverse Gear (When Vehicle is parked on Downhill).
Page 28: Brake Pedal
1.4 B. Brake Pedal Brake Pedal Vehicle is provided with hydraulically operating brake system. Master cylinder and brake fluid reservoir is located on chassis on RH side of scudo. WARNING cao t avanaI If brake squeal is excessive and occurs each time the brakes are applied, you should have the brakes checked by an authorized Distributor or dealer.
Page 29 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 30: Clutch Pedal
1.4 C. Clutch Pedal Clutch Pedal Clutch operating pedal is located on left side of scudo near floor board as shown in the figure. CAUTION Do not drive with clutch lever in pressed condition or do not rest your foot on clutch pedal. It could result in excessive clutch wear, clutch damage, unexpected loss of engine braking or drop in fuel efficiency.
Page 31 1.5 Other Important Parts Location 1.5 A. Fuel Tank and Fuel Feed Pump 1.5 B. Spare Wheel 1.5 C. Battery 1.5 D. Fuse Box 1.5 E. Mobile Charger Socket / Water Bottle Holder. 1.5 F. Fuel Filter / Air Filter 1.5 G.
Page 32 1.5 A Fuel Tank, Fuel Feed Pump A. Fuel Tank • Fuel tank is mounted on LH side of vehicle behind rear wheel. Fuel tank capacity is 8 liters. • Location of fuel tank cap is as shown in the figure. •...
Page 33 1.5 B Spare Wheel B.Spare Wheel • Location of spare wheel is under driver seat. • Remove 2 bolts of driver seat frame • Tilt the driver seat frame towards handle bar side • To remove spare wheel, open the spare wheel lock & remove the 2 nuts securing the spare wheel.
Page 34 1.5 C Battery C Battery (12V 50Ah) • It is located on RH side of driver seat. • Check and ensure that the electrolyte level is between the upper (Max) and lower (Min) level in each cell. • If the electrolyte level is below the lower level in any cell, top up to upper level with distilled water. WARNING Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.
Page 35 1.5 D Fuse Box Fuse Box : A) Main fuse box : Fuse box is mounted on electrical unit plate below dashboard at LH side. 2 Spare fuses (one 10A & another 30 A) are provided in the fuse box cover. Fuse layout is given on fuse box cover B)Battery fuse box : Mounted on battery mounting bracket.
Page 36 1.5 E Mobile Charger Socket A. Mobile Charger Socket B. Water Bottle Socket A. Mobile Charger Socket : Mobile charger socket is on dashboard near instrument cluster. You can charge the mobile while driving the vehicle. B. Water Bottle Holder : Water bottle holder is provided for keeping water bottle.
Page 37 1.5 F Fuel Filter & Air Filter Fuel Filter : Fuel filter is used to provide clean fuel to the engine by filtering the impurities. It is located below passenger body near to the fuel tank. NOTE Ensure to drain water by opening drain nut once in a month . Do not over tighten drain nut as it may break.
Page 38 1.5 G Oil Filter Oil Filter : Oil filter is used to circulate clean oil inside the engine for lubrication. It is located on engine. Oil Cooler : It is located at the top of engine Engine is fitted with oil cooler which helps to control the engine temperature and ensures engine is operating at optimum temperature.
Page 39: 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 other vehicles of the same model and type. Chassis Number Location - At Front on Dashboard . Ú...
Page 40: Technical Specifications
1.7 Technical Specifications Engine : Four Stroke, Forced air & oil cooled, Compression Ignition Bore X Stroke : 86.00mm x 77.00mm Engine Displacement : 447.3 cc Compression ratio : 24 1 : 1 ± Max. Net Power : 6.62 kW at 3400 150 rpm.
Page 41 Tyre Size : 4.5-10, 8PR (All four tyres) Tyre Pressure Front : 2.4 kg/cm (34PSI) Rear : 3.2 kg/cm (45PSI) Electrical System : 12 V, DC Battery : 12V 50 Ah Head Lamp : 35/35 W Tail / Stop Lamp : 5/21 W Side Indicator Lamp : 10 W...
Page 42 2. Operating Vehicle Index Daily Safety Checks Safe Driving Tips Fuel Saving Tips Running In Starting And Driving...
Page 43: Daily Safety Checks
2.1 Daily Safety Checks Before starting the vehicle, it is recommended to do following checks. Make sure that mirrors, lights & reflectors are clean and unobstructed Fuel : Enough fuel in tank. Check fuel pipes for cracks/leakage. Replace if found defective. Engine Oil : Check oil level daily.
Page 44: 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. Avoid driving while talking or operating mobile phone next lower Driving down Hill : When driving down a hill, the engine should be used for braking by shifting to...
Page 45: Fuel Saving Tips
2.3 Fuel Saving Tips 1. Ride smoothly and steadily at an optimum speed of 30- 40 kmph in 5th Gear 2. Change the gear judiciously according to the speed requirement. Recommended speed for gear shifting Gear Speed 8-11 11-15 15-20 &...
Page 46 2.4 Running - In • During first 2000 km running-in period do not exceed following speed limits. Gear Speed • 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 in the morning or in cold conditions .
Page 47: Starting And Driving
2.5 Starting & Driving Starting the Engine • Turn ignition switch key to ON position. • Ensure that vehicle is in Neutral gear, by confirming the neutral indicator tell tale light on dashboard is lit. • Check Tell tale lights for Battery charging & Oil Pressure on dash board are lit. •...
Page 48 2.5 Starting & Driving Moving On : • When the engine has started, battery charging, oil pressure indicator lights should go off. • Release parking brake. Depress the clutch lever. • Shift into first gear, neutral indicator light in instrument cluster should go off. •...
Page 49 2.5 Starting & Driving A. Clutch Pedal B. Gear change twist grip Shifting Gears : • Close the throttle while pressing the clutch pedal. • Shift into the next higher or lower gear. • Open the throttle partly, while releasing the clutch lever. NOTE Do not rest your foot on clutch pedal in running.
Page 50: Reverse Gear
2.5 Starting & Driving Pull the knob to operate Reverse Gear Knob Reverse Gear : For engaging reverse gear - • Change to neutral, stop the vehicle with engine idling. • Pull the reverse gear knob. • Depress clutch Pedal. •...
Page 51: Stopping The Engine
2.5 Starting & Driving Engine Stop Knob Pull the knob Pull the knob to operate to operate Stopping the engine : • Close the throttle completely. • Shift the gear to neutral. • Pull engine cut off knob, and release after engine dies down completely. •...
Page 52: Preventive Maintenance
3. Preventive Maintenance Index Periodic Maintenance Chart Periodic Lubrication Chart Engine Oil - Checking/replacement Oil Filter Replacement Gear Box Oil - Checking/replacement Differential Oil - Checking/replacement Recommended Oil Grade and Quantity Air Filter Cleaning Procedure Fuel Filter 3.10 Battery 3.11 Wiper Motor 3.12 Propeller Shaft 3.13 Brake Oil 3.14 Free Play...
Page 53: Periodic Maintenance Chart
3.1 Periodic Maintenance Chart RECOMMENDED ODOMETER READING km Operation Vehicle washing & Cleaning Clean/Replace air filter element & ‘O’ ring Replace after every 20K km Check all lights for working Switches, indicators etc Clean oil strainer Clean after every 20k km Check/adjust st.
Page 54: Lubrication Chart
3.2 Lubrication Chart RECOMMENDED ODOMETER READING km Operation Replace /top up Engine oil Replace /top up gear box & differential oil every 20K km Grease Steering races, balls, Lubricate at every 10K km Grease Gear shifter- sector Grease Fare meter drive, fr. suspension Grease Rear hub bearing every 60K km (kluber grease) Speedometer inner greasing...
Page 55 3.3 Engine Oil Checking / Replacement C. Drain Plug B. Oil Filling Plug A. Dip stick Engine Oil : For proper functioning of Engine, oil level inside the engine should be maintained between the max / min. levels marked on dip stick. Oil Level Inspection : •...
Page 56 • Remove the dip stick carefully. • Wipe off the dip stick clean. • Re-insert the dip stick fully (screw in fully) and take out to note the oil level. • In case the oil level is below the lower mark, top it up to the upper mark.
Page 57: Oil Filter Replacement
3.4 Oil Filter Replacement OIL FILTER Oil Filter Element Replacement: • Replace oil filter at every 10000 kms. • Remove cartridge by rotating it in anticlockwise direction. CAUTION To prevent oil leakage, make sure that the oil filter is tight, but do not over-tighten it.
Page 58 3.5 Gear Box Oil Checking Oil Level Check Bolt (Gear Box) Gear Box Oil : Oil level in Gear box is checked with the help of check bolt provided on Gear box cover. Oil level inspection : • Place the vehicle on a level ground. •...
Page 59 3.5 Gear Box Oil Replacement Drain Bolt Oil Filling Plug Gear Box Oil replacement : Replace oil as per Lubrication chart. For replacing gear box 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 60 3.6 Differential Oil Top up Oil Level Check Bolt Differential Oil : Oil level in Differential is checked with the help of check bolt provided in Main housing. Oil level inspection : • Place the vehicle on a level ground. •...
Page 61 3.6 Differential Oil Replacement Oil replacement : Replace oil as per Lubrication chart. For replacing differential 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 62 3.7 Recommended Oil Grade And Quantity Lubrication Replace the oil in accordance with periodic maintenance chart. Recommended Quantity At every Lubrication oil grade Fare meter drive 5000 Engine Oil refill 1450 ml. Gear shifter sector 5000 Clutch & Brake Pedal W/O oil filter 5000 SAE 15W40 of API...
Page 63: Air Filter Cleaning Replacement
3.8 Air Filter Cleaning Replacement Air Filter Air Filter Cleaning: • Open clips of air filter assembly. • Remove air filter element. • Clean the air filter element by blowing air jet from inside. • Clean air filter housing by air jet and wipe it clean. Please ensure that air pressure while cleaning air filter should not be more than 2kg/cm .
Page 64: Fuel Filter
3.9 Fuel Filter Water Drain Screw Draining of water from fuel filter housing: Water gets accumulated at the bottom of fuel filter housing. To drain water : • Loosen the drain bolt located at bottom of fuel filter housing. • Allow the water to drain completely •...
Page 65 Air bleeding Screw Ö Air bleeding from fuel lines : For bleeding air from fuel line: • Loosen the bolt located on top cover of fuel filter housing. • Switch on ignition and ensure feed pump is running. • Allow the fuel with air bubbles to flow from bolt. •...
Page 66 3.10 Battery A. Battery (12V 50Ah) • It is located on RH side of driver seat. • 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. WARNING •...
Page 67: Wiper Motor
3.11 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 68 3.12 Drive Shaft CV Drive Shaft CV Drive Shaft CV Differential Side Trailing arm side Drive Shaft CV : Rubber Bellows • Bellows should be kept in good condition & to be replaced immediately if torn. • Torn bellows will allow dust & water entry into the Drive Shaft flanges which will cause damage to Drive Shaft.
Page 69: Brake Oil
3.13 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 70 Brake Oil • it is advisable that the brake fluid should be replaced at least once in a year. We recommend following brake fluids. Marketed by Name of brake fluid Hindustan Petroleum Hp Super Duty brake fluid DOT-3 Indian Oil Corporation Servo brake fluid super HD Bharat Petroleum...
Page 71 3.14 Free Play Free play for : At brake pedal : 10-15 mm At clutch Pedal : 10-15 mm Accelerator grip : 2-3 mm Decompression cable : 3-4 mm (at engine end) Engine stop cable 3-4 mm (at engine end)
Page 72 3.15 Wheel Changing Fig. A Fig. B Changing wheel and tyres : Pull the parking brake and loosen the wheel retaining nuts. Place the jack as shown in Fig. ‘A’ (For removing Front wheel) and Fig. ‘B’ (For removing Rear wheel) then jack up the vehicle until the wheel clears the ground.
Page 73: Tyre Rotation
3.16 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 74: Tyre Pressure
3.16 Tyre Pressure Correct Traction Danger:Poor Grip Danger: Poor Handling Optimum Handling Insufficient Traction Poor Economy Optimum Tyre Life Rapid Wear(Center) Rapid Wear(Edge) Over Inflated Over Inflated Properly inflated Properly 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 75: Pre-Delivery Inspection
4. Pre Delivery Inspection Transit Damage : Check the vehicle for any transit damages. Performance: Check engine , gear box and differential oil levels 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 76 For faster response, please furnish the following details in e-mail / written communication to our Distributor. • Contact Details (Customer Name & Add. Ph./Mob. No) • Vehicle Details (Engine No., Chassis No., Registration No., Make and Purchase Date) • Selling/Servicing Distributors / Dealers •...
Page 77 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 78 Use only Bajaj Genuine Parts For optimum performance of vehicle For prolonged life of components & vehicle Always Insist For economical parts maintenance cost For rider's safety Genuinity Test Scratch Hologram to find ‘Genuine’ Partial transparent Hologram Golden Hologram...
Page 79 To Enable us to provide you faster response 1800 233 2453 (Week days) customerservice@bajajauto.co.in Please use our TOLL FREE E-MAIL Customer Care 'Toll Free No.' customerservice@bajajauto.co.in www.bajajauto.com WEB-SITE E-MAIL www.bajajauto.com Export Service, International Business Bajaj Auto Limited WEB-SITE WORLD’S NO. Akurdi, Pune 411 035 India.