Bajaj QUTE User Manual
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Bajaj QUTE User Manual

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Summary of Contents for Bajaj QUTE

  • Page 2 For this reason, it may be necessary to inspect or replace parts before the next scheduled service. It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your Qute.
  • Page 3 IMPORTANT NOTES Bajaj Qute is designed and constructed to meet the normal demands of regular road operation but not Ø for use on race courses or offroad. The vehicle must only be used as intended. Ø Dangers can arise for people, property and the environment through use not as intended.

  • Page 4: Table Of Contents

    CONTENTS Introduction............1 Part locations..........10 Driving controls..........28 Operational.............49 Maintenance...........58 1. INTRODUCTION 1-A. Foreword...............2 1-B. To protect environment..........3 Identification Data..........4 Technical Specifications........5...

  • Page 5: 1-A. Foreword

    1A. FOREWORD Dear Customer, We thank you for choosing the ‘QUTE’ which would give you ‘Value for Money, for Years’. We are sure that you will be happy with its performance. Small, Stylish, comfortable last mile transportation, very fuel efficient, very low tail pipe emissions, low cost of running.These are some of the unique features of the vehicle.

  • Page 6: 1-B. To Protect Environment

    1B. TO PROTECT ENVIRONMENT BAL is committed to produce Bajaj Qute using environmentally sustainable technology. Many features have been incorporated in this vehicle which have been designed to ensure environmental compatibility throughout the life cycle of the vehicle. We would like to inform you that this vehicle meets emission norms and this is being regularly validated at the manufacturing stages.

  • Page 7: Identification Data

    1C. 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. BFZWHM00058 Engine Number Location Chassis Number Location - On B pillar on Front RH door On Crankcase between head Example:...

  • Page 8: Technical Specifications

    1D. TECHNICAL SPECIFICATIONS Description Sr.No. NON EU BS IV Four stroke, Twin spark-ignition, Single cylinder engine, liquid cooled ENGINE Bore/Stroke 63.5 mm x 68.4 mm. Capacity 216.6 cm3 Compression Ratio 11:01 2.2 Litre (Green Engine) Engine Oil Capacity 1.65 Litre (Without Oil Filter/1,000Kms Service) 1.8 Litre (With Oil Filter/Every 5,000Kms Service) Spark Plug CHAMPION RER6YCA...
  • Page 9 1D. TECHNICAL SPECIFICATIONS Description BS IV Sr.No. NON EU Suspension Independent Suspension with Twin leading arm, coil over shock absorber & anti roll bar Front Independent suspension with Semi trailing arm and coil over shock absorber Rear Steering Manual ( Rack & Pinion) Hydraulic with H-split.
  • Page 10 1D. TECHNICAL SPECIFICATIONS Description BS IV Sr.No. NON EU Body Steel monocoque body made in high strength steel Weights (kg) 449 Kgs Unladen Mass 446 Kgs 464 Kgs Gross vehicle weight 749 Kgs 746 Kgs 764 Kgs Payload 300 Kgs Seating capacity 4, including driver Electrical systems...
  • Page 11 1D. TECHNICAL SPECIFICATIONS Description Sr.No. Compression Ratio 12:1 10.7:1 Max. Engine Output 8.08 Kw at 5500 rpm 8.72 Kw at 5500 rpm Max. Torque 16.1 Nm at 4000 rpm 17.1 Nm at 4000 rpm Fuel Tank (water capacity) 35 Lit. (Water Capicity) 20.6 Lit.
  • Page 12 1D. TECHNICAL SPECIFICATIONS Discription S.No. Non EU BS IV Main chassis dimensions (In mm) Overall height (Unladen) 1652 Overall length 2752 2796 2752 Wheel Base 1925 Rear overhang Overall Width 1312 Wheel track 1143 Lowest Hard Point from flat surface 180 mm - Unladen Turning circle radius 3.5 meters...

  • Page 13: Part Locations

    2. PART LOCATIONS 2A. Doors Operation 2A-1. Main doors............11 2A-2. Engine bay cover & Fuel filling flap....12 2B. Storage space 2B-1. Luggage storage space........13 2B-2. Utility storage space........14 2C. Weather protection.............15 2D. Mirrors...............16 2E. Seats: 2E-1. Front seats............17 2E-2. Rear seats (Foldable 60:40)......18 2E-3.

  • Page 14: 1. Main Doors

    2A-1. MAIN DOORS: MANUAL DOOR & LOCKS • All 4 doors can be opened from inside/outside by pulling the door latch as shown in Figure: a. • All the doors can also be locked or unlocked independently from inside by rotating the knob in anticlockwise and clockwise as shown in Figure: c and d.

  • Page 15: 2. Engine Bay Cover & Fuel Filling Flap

    2A-2. ENGINE BAY COVER & FUEL FILLING FLAP a. Engine bay cover with lock : Engine is mounted in engine bay at the rear of the vehicle underneath rear passenger seat. An engine bay cover with locking provision is provided to cover the engine. To access engine, open engine bay cover.

  • Page 16: 1. Luggage Storage Space

    2B-1. LUGGAGE STORAGE SPACE: a. Luggage carrier: It is located on the roof of the vehicle. The load carrying capacity is 30 kg max. Danger: Never carry objects longer or wider than your roof carrier. b. Front luggage box: The front luggage box is located underneath the front hood. The load carrying capacity is 20 kg max. Use key to unlock the front bonnet.

  • Page 17: 2. Utility Storage Space

    2B-2. UTILITY STORAGE SPACE: a. Utility storage: A small storage area is below front seat (fig.a) & more storage area behind rear seat (fig.b). Additional storage space can created by folding rear seat (60:40) as per requirement b. Glove box LH: It is located on LH side of dashboard.

  • Page 18: Weather Protection

    2C. WEATHER PROTECTION a. Rear Windshield: Rear Windshield is at rear end of vehicle. It is having a fixed toughened transparent glass for clear visibility, safety of the Occupants and weather protection. b. Front Windshield: Large Windshield is provided at front of vehicle. It is laminated for safety and good visibility. Warning: Do not use cleaning solvents like Gasoline, Kerosene, Paint Thinners or Silicone-based chemicals on front windshield or rear wind shield as it can result in impaired visibility.

  • Page 19: Mirrors

    2D. MIRRORS Mirrors: a. IRVM- Inner rear view mirror is provided inside the cabin and fitted to windshield. It can be manually adjusted to suit Driver’s convenience. Warning: Angling the IRVM to reduce rear vehicle headlamp glare will hamper rear visibility. b.

  • Page 20: 1. Front Seats

    2E-1. FRONT SEATS a. Front seats: Two front seats are provided, Driver Seat & Co- driver seat. Driver seat is adjustable in forward & backward directions. b. Moving the Driver seat forward & backward: To adjust the driver seat position, lift the track lever (1) under the front driver seat cushion, then slide the seat (forward/backward) to the desired position.

  • Page 21: 2. Rear Seats (Foldable 60:40)

    2E-2. REAR SEATS c. Rear seats: A cushioned seat is provided for the rear passengers. Seat Back rest can be split in a 60:40 ratio for folding down individually as required. Positions that can be achieved are - Complete open - 40 % fold (Ensure central latch is locked towards 60% seat) - 60% fold (Ensure central latch is locked towards 40% seat) - Completely folded...
  • Page 22 2E-2. REAR SEATS d. Folding of rear seats: - For folding the rear seat to desired position, press the button of central latch (Figure: a) & move the latch laterally to the opposite side i.e. if 40% fold is desired, move the central latch towards 60% side seat.

  • Page 23: 3. Seat Belts

    Driver seat Safety Belts: Occupants safety is of utmost importance. Your Qute is equipped with ELR (Emergency Locking Retractor) type seat belts, both front and rear as a part of occupant restraint system. Why Safety Belts: Wearing seat belts properly can protect you from being ejected out of the vehicle, impacting the steering wheel or against other occupants in case of an accident or sudden braking.
  • Page 24 2E-3. SEAT BELTS Driver seat Warning: - Using one seat belt for more than one person at a time is dangerous. - For expectant Mothers, we recommend the use of auxiliary seat-belt. Kindly consult your doctor for specific recommendations. - Ensure there is no twisting of seat belt as twisted seat belts can result in injury to the occupants incase of sudden braking/collisions.

  • Page 25: Siding Glass Windows

    Latch Spring operated release lever Qute is equipped with sliding glass windows on front and rear doors for more wind flow in to passenger cabin. d. Opening and Closing of sliding windows: - Just slide either the front or rear glass along the sliding channel by holding the lock sliding glass as per requirement.

  • Page 26: Engine Cabin Parts

    2G. ENGINE CABIN PARTS Important part location 1. Main fuse 40 A 5. Central spark plug 09. Diagnostic tool socket 2. Thermostat cap 6. Spark Plug 10. Air filter 3. Battery 7. Cabin lamp 11. Throttle body Assly. 4. Coolant tank 8.

  • Page 27: Cylinder & Refueling (Lpg)

    2H. Cylinder & Refueling (LPG): a. LPG Cylinder: It is mounted below driver seat. b. Multifunction Valve : It is mounted on LPG cylinder. It is an assembly, mounted on LPG tank for filling tank & withdrawal of LPG along with safety devices. c.
  • Page 28 2H. Cylinder & Refueling (LPG): Filling valve Dust cap d. Refilling Valve: To refill the cylinder with LPG, open dust cap & insert the LPG filling gun inside refilling unit, Fill the LPG into cylinder. Dust Cap : It is mounted on LPG filling valve & is used for refilling the gas. Please ensure that dust cap is properly fitted.

  • Page 29: Cylinder & Refueling (Cng)

    2I. Cylinder & Refueling (CNG): a. CNG Cylinder: It is mounted below driver seat. b. CNG Valve (Shut Off) : It controls (ON-OFF) supply of CNG gas as indicated. It should be closed, while carrying out servicing, maintenance & when vehicle is parked overnight. Also in case of any leakage, Shut off valve should be closed immediately.
  • Page 30 2I. Cylinder & Refueling (CNG): Filling valve Dust cap Refueling: Refueling is done via CNG filler valve A Dust cap is provided in this unit. Refueling should be done when CNG symbol blinks at the instrument cluster. To refill the cylinder with CNG gas, open the lockable door provided at RH side of body as shown in Fig.

  • Page 31: Driving Controls

    3. DRIVING CONTROLS 3A.Electrical..............29 3A-1. Instrument cluster..........30 3A-2. Combination switch..........36 3A-3. Ignition Switch .............38 3A-4. Hazard switch & mobile charger......39 3A-5. Heater Blower Switch...........40 3A-6. Lamps..............41 3A-7. Fuses & relays.............43 3B. Mechanical...............44 3B-1. Steering wheel.............45 3B-2. Gear shifter lever..........46 3B-3.

  • Page 32: Electrical

    3A. ELECTRICAL   Right Hand Drive (RHD) Vehicle Left Hand Drive (LHD) Vehicle 1. Instrument cluster 2. Combination switch 3. Ignition Switch 4. Mobile charger 5. Provision for FM Radio fitment / Utility Box 6. Hazard switch Heater Blower *Accessories shown may not be a part of standard fitment.

  • Page 33: 1. Instrument Cluster

    3A-1. INSTRUMENT CLUSTER It is located on dashboard 1) LH turn indicator 2) High beam indicator 3) Fuel level indicator 4) Parking brake / Brake fluid check indicator 5) RH turn indicator 6) Low oil pressure indicator 7) Engine coolant High temperature indicator 8) Battery charging indicator 9) MIL indicator (Malfunction Indicator light) 10) Neutral indicator...
  • Page 34 3A-1. INSTRUMENT CLUSTER 1&5. Turn signal indicator : Turn signal indicators can be operated only when ignition is ‘ON’. They can be operated by using the turn indicator switch on the combination switch. The direction indicator arrow (Left) and (Right) on the instrument cluster flashes along with external indicators lights as per selection.
  • Page 35 3A-1. INSTRUMENT CLUSTER 4. Brake fluid level warning light : This lights comes on when the ignition switch is turned to the “ON” position & switches off when the engine is started. If this light glows when engine is running then it indicates that either brake fluid level in reservoir is low or parking brake is engaged .
  • Page 36 3A-1. INSTRUMENT CLUSTER 8. Battery charging indicator : This Symbol lights up when the ignition is turned ‘ON’ and goes ‘OFF‘ after the engine starts .If this symbol glows while engine is running, it indicates that battery is not getting charged. 9.
  • Page 37 3A-1. INSTRUMENT CLUSTER 11. Speedometer: The speedometer indicates vehicle speed in km/h. Speedometer console has readings up to 100 km/h, but Max speed of vehicle is limited to 70 Km/h. 12. LCD display function: It has following readings a. Odometer Reading :The odometer records the total distance, the vehicle has been driven. b.
  • Page 38 3A-1. INSTRUMENT CLUSTER MODE Push Buttons Function – (MODE & SET) a ◘ŕ ś Function Button Time duration Activity Enters Clock set mode.All the digits start blinking & ":" stops Mode & Set >5 sec blinking. By pressing Mode & (simultaneously) Set buttons the clock time can be changed.

  • Page 39: 2. Combination Switch

    3A-2. COMBINATION SWITCH Light stalk :(RH):Outer rotary switch on the stalk is provided for selecting Position (Parking) or Head lamp. Position (parking) lamp works in ignition OFF condition also, but head lamp works only when ignition switch is in ON position. For selecting Position lamps or Head lights, twist the outer rotary switch to the desired position.
  • Page 40 3A-2. COMBINATION SWITCH D) Side indicator : Push the stalk upwards for changing lane or turning to Left and downwards for changing lane or turning to Right according to requirement. It has three positions. - Side indicator OFF - Lane change for Left or Right Turn (Light pressing has a self- return) - Lane change for Left or Right Turn (Full pressing has a self cancellation after the left or right turn) E) STALK WIPERS(LH):...

  • Page 41: 3. Ignition Switch

    3A-3. IGNITION SWITCH The ignition switch is located on the right side of the steering column. The switch has four positions. LOCK :You can insert or remove the key only in this position. The steering column gets locked when the key is removed. ACC : By turning key to ACC (key in) position, all accessories including music system will be ‘ON’.

  • Page 42: 4. Hazard Switch & Mobile Charger

    3A-4. HAZARD SWITCH & MOBILE CHARGER a. Hazard Warning Switch: Hazard switch can be switched on (Irrespective of Ignition Key in On/Off position) : Both front and rear LH and RH blinkers will blink simultaneously along with Turn pilot indicators in Instrument cluster. Hazard switch is self illuminating for aiding operation at night.

  • Page 43: 5. Heater Blower Switch

    3A-5. HEATER BLOWER SWITCH a. Heater Blower: Heater Blower is mounted below dashboard with its air exit behind Instrument cluster on dash board. It can be operated by switching “ON” the heater blower switch located besides hazard switch on dashboard. Heater Blower switch is self illuminating for aiding operation at night.

  • Page 44: 6. Lamps

    3A-6. LAMPS a. Head lamps: Head lamps are clear lens type having multi focal reflector and are provided with halogen bulb with double filament for providing illumination of the road. It also incorporates side indicator lamp and a parking lamp. 1) High / Low Beam 2) Position / Parking Lamp 3) Front Direction Indicator...
  • Page 45 3A-6. LAMPS a. Engine cabin light: Engine cabin light is provided on top, inside the engine cabin. Its switch has two positions, on lamp itself. ON - The lamp will come ‘ON’ when switch is in this position. OFF -The lamp will be turned ‘OFF’ when switch is in this position. b.

  • Page 46: 7. Fuses & Relays

    3A-7. FUSES & RELAYS Fuse & relays are located in two locations, 1. Below dashboard: Horn Relay b. Parking Lamp Relay c. Fuse wiper motor 15A d. Head Lamp Relay e. Hi/ Low beam f. Fuse Box Assembly 2. Inside Engine cabin: a.

  • Page 47: Mechanical

    3B. MECHANICAL  1. Steering wheel 2. Gear shifting lever 3. Accelerator pedal 4. Brake Pedal 5. Clutch Pedal 6. Parking Brake *Accessories shown may not be a part of standard fitment.

  • Page 48: 1. Steering Wheel

    3B-1. STEERING WHEEL Left Hand Drive (LHD) Right Hand Drive (RHD) Steering wheel : — It is used to steer the vehicle to any desired direction. — Steering wheel is mounted on Steering column & linked to front wheel through rack & pinion mechanism.

  • Page 49: 2. Gear Shifter Lever

    3B-2. GEAR SHIFTER LEVER Lift the knob ‘b’ and shift downward to engage into Reverse Gear shifter lever: Gearshift lever is mounted on the dashboard. a. Forward gear: The gearshift pattern is shown on the gear shift lever knob. For up shifting, push the gear shifter knob upwards &...

  • Page 50: 3. Control Pedals

    3B-3. CONTROL PEDALS ABC Pedals : These are mounted below dashboard , in front of driver. a. Accelerator Pedal : This pedal controls the speed of the engine. Depressing the accelerator pedal increases engine speed. b. Brake Pedal : Vehicle is equipped with front and rear drum brakes. Depressing the brake pedal applies both front &...

  • Page 51: 4. Parking Brake

    3B-4. PARKING BRAKE To release Parking Parking brake lever: It is located on left hand side of driver seat on Left Hand drive vehicles & it is located on right hand side of driver seat on Right Hand drive vehicles. a.

  • Page 52: Operational

    4. OPERATIONAL 4A. Pre driving checks..........50 4B. Safe driving tips............. 51 4C. Fuel saving tips............52 4D. Starting engine............53 4E. Shifting gears............54 4F. Stopping engine and parking......... 55 4G. Driving in adverse conditions......... 56...

  • Page 53: Pre Driving Checks

    4A. PRE DRIVING CHECKS: Please ensure to check (Refer maintenance) - Visually check the tyres for damage or improper inflation pressure. Inflate if required to recommended specs. - Coolant level in expansion tank. Coolant should be in between Max. & Min. marks. - Engine oil level on dipstick should be between Max.

  • Page 54: Safe Driving Tips

    4B. SAFE DRIVING TIPS Never drive the vehicle under the influence of Alcohol. ü Don’t drive when you’re tired ü Get as much supervised driving practice when new to vehicle. ü Maintain a safe distance. ü Make sure you are familiar with your vehicle & its controls. ü...

  • Page 55: Fuel Saving Tips

    4C. FUEL SAVING TIPS Vehicle fuel economy is mainly dependent on A. Vehicle maintenance. • Service vehicle regularly as per recommended service schedule & use genuine parts only. • Always maintain clean air-filter. • Maintain correct tyre pressures. B. Style of driving •...

  • Page 56: Starting Engine

    4D. STARTING ENGINE Starting: - Apply Parking brake. - Insert the key in steering cum ignition lock and turn it to ‘ON’ position. - Ensure all indicators in cluster are ON. - Confirm that gear indicator is in ‘N’ position in Instrument cluster. - Press the clutch pedal fully.

  • Page 57: Shifting Gears

    4E. SHIFTING GEARS The gearshift pattern is shown on the gear shift lever knob. Gear shifting is in sequential form, in a “I” pattern Forward Gears: For engaging forward gears • Release the throttle while pressing the clutch pedal. • Shift into the next higher or lower gear. •...

  • Page 58: Stopping Engine And Parking

    4F. STOPPING ENGINE AND PARKING Running-in Period: Avoid full-throttle starts Avoid rapid acceleration and prolonged high speed running of the engine while using new vehicle for the first 1000 km of operation. Do not exceed the following road speeds during running in period. Gear - Km/hr: Do not tow any other vehicle during running in period.

  • Page 59: Driving In Adverse Conditions

    4G. DRIVING IN ADVERSE CONDITIONS: Caution : Driving Through Water : Never attempt to drive vehicle through deep water logged roads, If at all the situation demands that you have to drive through water then adopt the following measures. - Keep engine at high revs and drive the vehicle in low gear. - Avoid stopping/switching “OFF”...
  • Page 60 4G. DRIVING IN ADVERSE CONDITIONS: Caution : Climbing Sharp Gradients on Loose Surfaces : - Start off smoothly in any suitable gear (preferably lower gears) so that gear changing in the middle of the climb is not required. - Accelerate smoothly. Shifting of gears has to be done cautiously to avoid loss of control. - If the wheels start to slip on loose surface, motion can be maintained by steering the wheels to left and right, thereby providing increased grip.

  • Page 61: Maintenance

    5. MAINTENANCE 5A. Routine Maintenance...................59 5B. Periodic Maintenance Chart.................60 5C. Recommended Oil Grade and Quantity............65 5D. Engine oil level check & top up..............66 5E. Engine oil replacement.................67 5F. Oil & Fuel Filter..................... 68 5G. Air filter element & spark plug cleaning............69 5H.

  • Page 62: Routine Maintenance

    5A. ROUTINE MAINTENANCE Inspection and maintenance of the vehicle should be entrusted to trained professionals only. Please be careful while personally inspecting / maintaining the vehicle as it may cause damage to the vehicle or may cause injury. The ignition and fuel systems are highly important in view of emission control and for efficient engine operation.

  • Page 63: Periodic Maintenance Chart

    5B. PERIODIC MAINTENANCE CHART Sr.no Service Activities 1000 5000 10000 15000 20000 25000 30000 35000 Remark General Wash & Clean the vehicle All checks as per job card SAE 10W30 Replace / top up Engine oil* (API SL JASO MA2) Replace at 30000 Kms Check , top up / Replace coolant or 2 years...
  • Page 64 5B. PERIODIC MAINTENANCE CHART Sr.no Service Activities 1000 5000 10000 15000 20000 25000 30000 35000 Remark Power train Clean /Adjust/Replace Spark Plug Adjust gap if required Clean/ Replace Air filter Element Replace at 40000 Kms Clean/Replace breather tube filter Replace at 40000 Kms Clean / replace oil strainer Replace at 10000 kms Check &...
  • Page 65 5B. PERIODIC MAINTENANCE CHART Sr.no Service Activities 1000 5000 10000 15000 20000 25000 30000 35000 Remark Suspension First 5000, 10000 Kms & thereafter at every Check & adjust Wheel Geometry (alignment) 10000 Kms Check Front & Rear shock absorber for leakage/bent rod, physical damage &...
  • Page 66 5B. PERIODIC MAINTENANCE CHART Sr.no Service Activities 1000 5000 10000 15000 20000 25000 30000 35000 Remark TRIMS & SEATS Door Striker mounting First at 1000 km & then Door latch hardware after every 20000 km Lubrication Points Greasing Door latches Greasing door stricker Clutch pedal cable holder pivot Grease if required...
  • Page 67 5B. PERIODIC MAINTENANCE CHART Sr.no Service Activities 1000 5000 10000 15000 20000 25000 30000 35000 Remark CNG and LPG System Tighten if leak Check gas joints for leak or smell noticed Replace after every Replace all rubber components and 3 years flexible CNG/LPG hoses Replace if crack or Check Steel pipe and flexible hoses for gas supply...

  • Page 68: Recommended Oil Grade And Quantity

    5C. RECOMMENDED OIL GRADE AND QUANTITY Lubrication Replace the oil in accordance with Periodic Maintenance chart. Quantity Consumable Recommended 1650 ml (first 1000kms service-without oil filter) SAE 10W30 1800 ml (Subsequent 5,000Kms services-with oil filter) Engine Oil (API SL JASO MA2) 2200 ml (During engine overhauling) Top up (as required) Ethylene Glycol :...

  • Page 69: Engine Oil Level Check & Top Up

    5D. ENGINE OIL LEVEL CHECK & TOP UP Engine oil level check: • Park vehicle on a level ground. • To be done early in the morning before engine has been started. • For checking engine oil level use dipstick •...

  • Page 70: Engine Oil Replacement

    5E. ENGINE OIL REPLACEMENT Replace engine oil as per Periodic Maintenance schedule For replacing Engine Oil: Run engine for about 10 min to warm up oil. • Place the vehicle on a level ground for oil to settle down. • Oil Drain : •...

  • Page 71: Oil & Fuel Filter

    5F. OIL & FUEL FILTER a. Oil strainer cleaning/replacement: • Oil strainer is located inside the Oil drain nut • Replace as per PM Schedule b. Replace Oil filter: • Located as shown in picture, • Replace Oil filter as per PM schedule •...

  • Page 72: Air Filter Element & Spark Plug Cleaning

    5G. AIR FILTER ELEMENT & SPARK PLUG CLEANING Clamps AIR FILTER ELEMENT CLEANING: Air filter assly is mounted inside the Engine cabin • Unlock 2 nos. of air filter Box clamps as shown in fig. • Rotate the box in downward direction using very little force •...
  • Page 73 5G. AIR FILTER ELEMENT & SPARK PLUG CLEANING Insulator 0.8 to 0.9mm Central Spark plug Side Spark plug Spark plug cleaning & replacement: Ensure engine is in cold condition. Disconnect the spark plug caps Ÿ Using spark plug spanner, remove the spark plugs Ÿ...

  • Page 74: Radiator

    5H. RADIATOR Radiator Cleaning: Visually get the radiator fins checked for dirt/dust accumulation by Authorized Distributor/Dealer. Get it cleaned from authorised Distributor/Dealer Do not use High pressure water spray for radiator as it can damage the fins. Note: Check coolant level in expansion tank only. If coolant level is seen below the Min. mark then top up specified coolant.

  • Page 75: Fluids Top Up - Coolant, Brake Oil & Wiper Washer

    5I. FLUIDS TOP UP - LHD VEHICLE a. Coolant : Check coolant level is in between max.& min. marks of expansion tank as shown in fig. Add recommended coolant between the min & max mark. b. Brake fluid: Brake fluid reservoir is located on front LH side of the vehicle underneath the front hood. Ensure brake oil level is in between Min.
  • Page 76 5I. FLUIDS TOP UP - RHD VEHICLE a. Coolant : Check coolant level is in between max.& min. marks of expansion tank as shown in fig. Add recommended coolant between the min & max mark. b. Brake fluid: Brake fluid reservoir is located on front RH side of the vehicle underneath the front hood. Ensure brake oil level is in between Min.

  • Page 77: Wiper Care

    5J. WIPER CARE For Chattering, Noisy problems & line generation Wiper care: Check the condition of Wiper blade regularly. If the wiper blade is not wiping properly, lift the blade over the glass & clean the windshield glass & blades with mild detergent & rinse with water. If thin lines of water are observed after the wiper blade sweep then check the gap between arm strip and glass.

  • Page 78: Adjusting Free Play

    5K. ADJUST FREE PLAY Free play & travel of Controls: a. Brake Pedal Play (at pedal) 10mm(Max) b. Accelerator Pedal Play (at pedal) 3~5mm (EU vehicle are equipped with ETB-Electronic Throttle Body & hence no adjustment required). c. Clutch Pedal play (at pedal) 10~15mm d.

  • Page 79: Battery

    5L. BATTERY: Check battery for correct electrolyte level and corrosion on the terminals. 1. Check battery terminals for corrosion (a white or yellowish powder). To remove it, clean the terminals with a solution of baking soda. 2. Wash the solution off with plain water. Dry off the battery with a cloth or paper towel. 3.

  • Page 80: Fuses

    5M. FUSES If any electrical unit in the vehicle is not functioning, check the fuses first. To check and replace them - • Turn the ignition key to the 'LOCK' position. • Identify the defective fuse from it’s melted wire i.e. if the silver-colored band inside the fuse is broken or melted. •...
  • Page 81 5M. FUSES 3. (15A) 6. (5A) FUSE 40A 5. (15A) 2. (15A) 1. (30A) 4. (15A) 0. (10A,15A) 0. 10A,15A – Spare fuses 9. 5A - Spare fuse 1. 30A - Head Lamp 10. 30A - Spare Fuse 2. 15A - HT coil, Reverse Lamp, Blower, Aux •...

  • Page 82: Tyre Maintenance

    5N. TYRE MAINTENANCE 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 WITH ALLOY WHEEL TYRE WITH STEEL WHEEL TYRES: Vehicle is fitted with tubeless tyres.
  • Page 83 5N. TYRE MAINTENANCE Front Front When used When spare without wheel is also SpareTyre used from accessory list TYRE ROTATION : To avoid uneven wear of tyres and to prolong their life, rotate the tyres as illustrated. Tyres should be rotated as recommended in the periodic maintenance schedule.

  • Page 84: Wheel Alignment

    5O. WHEEL ALIGNMENT To ensure driving stability and higher tyre life, check wheel alignment at specified intervals Wheel Alignment : Alignment Values Data (Unladen). Front Wheel : • Total Toe - in to be set to : In deg - min In mm 1 18' to 1 06' 6.9 to 5.85...

  • Page 85: Wheel Replacement

    5P. WHEEL REPLACEMENT Flat Tyre Replacement : If a tyre goes flat, observe the following safety precautions before you change the tyre • Turn on the Hazard flasher. • Pull the vehicle off the road to a safe place so that there is no hindrance to the traffic. •...
  • Page 86 5P. WHEEL REPLACEMENT Removing flat Tyre: • Using a flat head screw driver, pry off the axle nut cap. • Loosen the wheel mounting bolts by 2-3 turns. • Engage the jack properly at correct jacking point (at front & rear sides). There are 2 notches at front & rear underneath the doors.
  • Page 87 5P. WHEEL REPLACEMENT Caution: During Tyre replacement: - Do not attempt to raise vehicle until the jack is in proper position. - As the jack begins to lift the vehicle pause to make sure jack is not misaligned, so that it does not have a chance to slip.

  • Page 88: Starting With Jump Leads

    5Q. STARTING WITH JUMP LEADS engine block OR unpainted metal (Engine) part which is away from the discharged battery. • Crank and start the engine. • While disconnecting follow reverse order i.e. disconnect Negative (-ve) lead followed by Positive (+ve) lead. Caution: - Do not connect negative (-ve ) terminal of charged battery to the negative (-ve ) terminal of discharged...

  • Page 89: Vehicle Washing

    5R. VEHICLE WASHING Vehicle Washing: Always wash the vehicle in shade. Spray the vehicle thoroughly with cold water. Mix shampoo in the wash water, Do not mix solvent (fuel, thinners). Make sure to rinse all soap and cleaners completely off the surface.

  • Page 90: Towing The Vehicle

    5S. TOWING THE VEHICLE : Towing Vehicle: In case of break down & vehicle is not in a condition to be driven on road, arrange for towing of Ÿ the vehicle • For towing a vehicle, the best way is to use a professional Tow truck only. •...
  • Page 91 Care to be taken while parking the vehicle for long periods: Park the vehicle in covered, dry and if possible well ventilated premises, Shift into lower gear. Ÿ • Remove the battery terminal cables (first remove the cable from the negative terminal). •...
  • Page 92 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 remain 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 93 USE ONLY BAJAJ GENUINE PARTS...

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