Owner’s Manual & Service Records
Owner’s Record All correspondence relating to service problems may be addressed to: SERVICE DEPARTMENT, BAJAJ USA 525 ECCLES AVENUE SOUTH SAN FRANCISCO, CA 94080 Notice: The description and illustration in this booklet are not to be taken as binding on the manufacturers.
Delivery Certificate To REMOVE - TEAR HERE Customer’s Name : Address : Date Purchased : Dealer : To be removed & retained by dealer.
Delivery Certificate Vin # : • 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. • A copy of the owner’s manual containing service requirements, five service record pages, and a warranty statement was given to me along with the vehicle.
Pre Delivery Inspection l Check and correct tire pressure including that of Spare Wheel. l Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. l Check transmission and engine oil level and top up if necessary. l Check for smooth operation of accelerator and choke operation. l Check and adjust Steering column for loose/tight. l Initial charging of battery, Install, connect and apply petroleum jelly on terminals.
Important Precautions The following precautions must be observed if your vehicle is fit with a catalytic converter. If you are unsure whether your scooter has a catalytic converter or not, check with your dealer. The catalytic converter, which is installed inside the silencer, reduces the exhaust emissions and is required in some states. Caution: 1. Never operate your scooter with leaded gasoline.
Hello ! Dear Customer, We wish to congratulate you for choosing The “Bajaj Chetak 4 Stroke”, coming from Bajaj Auto the world’s largest manufacturer of scooters. “Chetak 4 Stroke” will give you value for your money, for years! We are sure that you will be proud of its performance. Please read this Owner’s Manual before riding to familiarize yourself with the mechanism and controls of the vehicle.
Table of Contents Description Identification Data 1 Technical Specifications 2 Location of Controls and Components 3 General Information 10 Running In 15 Periodic Maintenance Chart 17 Lubrication Chart 18 Changing Tires 19 Safety Recommendation 22 Service Records
Identification Data and Vehicle Identification Number # 022809082AD72233 # Engine Number Chassis Number VIN Number There are three unique numbers assigned to your scooter. The engine and chassis serial numbers are used by the factory to identify the exact model. Please cite both of these numbers whenever you are ordering replacement parts. The vehicle identification number is used to register your vehicle with the Department of Motor Vehicles in your state.
Technical Specifications Engine Engine Displacement Max. Net Power Ignition System Spark Plug Lubrication Transmission Front & Rear Brakes Fuel Tank Capacity Electrical System : : : : : : : : : : : Curb Weight Max Speed : : 4 stroke, single cylinder, forced air cooled, spark ignition 145.45 cm3 9.00 HP at 6000 r/min of engine Electronic ignition (C.D.I.) Champion : PL 7 YC (To be used with resistor spark plug cap) Wet sump forced lubrication 4 speed gear box Mechanical expanding shoe type 1.32 Gal. (5.
Location Of Controls / Speedometer / Rear View Mirrors 2 3 4 6 1 11 ENGINE STOP 10 7 8 9 5 1. 2. 3. 4. 5. 6. 7. 8. 9. Clutch Lever Mirror LH Speedometer Mirror RH Luggage box lock Fr. Brake Lever RH Switch Steering Lock / Ignition Switch LH Switch 1. 2. 3. 4. 5. 6. Hi-Beam Indicator Turn Signal Indicator Speedometer Odometer Fuel Gauge Neutral Indicator 10. Accelerator 11.
The Steering Lock / Ignition Switch is located on the right hand side below the handle bar. It has three positions. Steering Lock / Ignition Switch Key Position Function LOCK Steering locked Ignition OFF OFF Steering unlock Ignition OFF ON Ignition ON Key Removal Key can be removed Key can not be removed To Lock the Steering • Turn the handle bar to the left. (Steering will be locked only when handle bar is in left position.
Fuel Tank • It has capacity of 1.32 gal. • Location of fuel tank is as shown in the figure. Fuel Gauge The fuel level gauge is provided in the speedometer console to indicate the fuel quantity in the fuel tank. Fuel level is indicated as follows: • “E” mark indicates approx. Empty. • Mid mark indicates approx. 0.66 gal. • “F” mark indicates approx. 1.32 gal. Fuel Tank RES OFF ON Fuel Cock Position Fuel Cock It has the following three positions On : When fuel level is above 0.26 gal.
RES OFF ON Off On A Choke Lever A : Seat Lock A : Tool Box Lock • It is located near the fuel cock lever. • Choke is required especially for cold starting. • The ‘On’ and ‘Off’ positions of choke lever are as shown in figure. Seat Lock : • It is located on left hand side of the seat. • The lock ensures the security of the fuel tank. • Turn the key clockwise to unlock seat. • For locking, gently press the seat from top. Tool Box Lock : • It is located as shown in the figure A.
OFF Right Hand Switch A Starter switch : Press the button to start the engine. B Supplementary engine stop switch : Move to the ‘Run’ position before starting engine. Move to the ‘Off’ position to stop engine. RUN STOP ENGINE B A Right Hand Switch B Left Hand Switch A C Left Hand Switch This scooter is equipped with lights that illuminate whenever the ignition is turned on. A Turn signal switch : Move the knob left or right to activate turn signal.
A : Spare Wheel B :Wheel Cover A B A : Took Kit B : Jack 8 Spare Wheel : Spare wheel is located behind seat on bracket. For removing the wheel : • Remove the wheel cap. • Remove the spare wheel mounting bolts. (Ref. Fig. A) Wheel Cover The wheel covers are fitted to all wheels. B : Wheel Cover Warning: Proper tire pressure is very important to the handling of your scooter, and to your safety. Never ride your scooter with tires either over or under-inflated. See the specifications table on page 12.
Battery Battery (12V - 9Ah) • Battery is located at LH side inside the Cowl. • Check & ensure that the electrolyte level is between the upper and lower level lines in each cell. • If the electrolyte level is below the lower level in any cell, fill to upper level with distilled water only. • Inspect the terminals. Clean if corroded. Tighten the battery clamps, then apply a little petroleum jelly. • Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery.
General Information A : Oil Filler Location B : Oil Level Indicator C : Upper Level D : Lower Level C B D Engine Oil A 10 A : Cap Engine Oil: Check engine oil level daily. For proper functioning of cylinder block/piston, crankshaft, tappets, clutch and transmission, the oil should be maintained at an appropriate level. • Place the vehicle on center stand, on a level ground. • Clean the surface area around the oil filler opening. • Unscrew the dipstick from oil filler opening hole and wipe it dry.
Lubrication of the antidive front suspension A grease nipple is provided on Brake panel at location “A” (Ref. fig.) for lubrication of Brass bushes fitted inside Front brake panel assly. These Bushes are recommended to be greased after every 2000 miles. To lubricate Bush inner fitted inside Antidive link assly at location “B” (Ref. fig.), you will have to dismantle and remove the Bush inner and then lubricate with Grease. The Bush inner are recommended to be greased after every 3000 miles.
Spark Plug • Using compressed air, blow any loose dirt away from around the spark plug. • Remove the spark plug using the special spark plug wrench, clean the spark plug using a wire brush, or a proprietary spark plug cleaner. • Adjust the gap if incorrect by bending the outer electrode carefully. Caution Never try to bend the center electrode of the spark plug. This will surely destroy your spark plug. Spark Plug Gap 0.6 to 0.
Starting Procedure (Kick Start) • Ensure the transmission is in neutral. (Neutral lamp in speedometer console should be illuminated) • Ensure the Steering/Ignition lock is in the ‘ON’ position. • Ensure the Engine stop switch is in the ‘RUN’ position. How to operate the kick starter : Move the kick-starter slowly. Make sure that the ratchet is engaged, then depress smartly. A) Normal Starting: Do not open throttle while starting.
• Moving from ‘Stand Still Position’ Pull the clutch lever to its full travel and twist the shift lever tube upwards in one smooth motion to put the vehicle in 1st gear. Release clutch gradually and simultaneously, open the throttle gradually to move away from stand still position. • Do not run the vehicle with the clutch partially engaged. Do not slip the clutch to overtake or to climb on a gradient. This will damage the clutch. • Downshifting of gears i.e.
Running In Running In • First 500 miles is designated as a running in period. The maximum vehicle speed recommended during running in: Distance in miles 0 - 500 Max. vehicle speed in gears (mph) 1st 10 2nd 20 3rd 30 4th 40 • Never exceed the specified running in speed. • Do not over-rev the engine. • 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.
Safety and Maintenance Tips Vehicle Condition: • Warning: There is a serious danger of fire if gasoline is leaking from any portion of your vehicle. Never ride your vehicle if you smell gasoline. Have your vehicle repaired immediately by your authorized Bajaj Dealer. Failure to heed this warning can lead to a serious fire, with subsequent serious injury or even death. • Check all fuel lines and connections whenever your vehicle smells of gasoline. • Never fill with gasoline up to the filler cap.
Periodic Maintenance Chart Recommended Odometer Reading in miles Operation Service Intervals 300 1200 3000 6000 9000 12000 15000 Air filter element cleaning Spark plug : Cleaning & gap setting : Replacement Check and adjust valve clearance Clean inline fuel filter l Indicates operation to be performed. * To be cleaned more frequently in dusty areas. ** Must be performed to maintain emissions warranty.
Lubrication Chart Operation Engine oil replacement Oil filter cleaning Lubricant to be used Recommended Odometer Reading in miles 300 1200 3000 6000 9000 12000 15000 SAE 15W50 Every 3000 miles Fire Proof Solvent Every 3000 miles Replace oil filter Brake, clutch lever Speedo flex drive, pinion Steering races Stand pin Gear shifter assly l Indicates operation to be performed.
Front Wheel Removal • Put the vehicle on stand. • Remove nuts securing wheel to the axle flange by using box spanner, while loosening these nuts hold the wheel by hand or apply front brake. • Take out spring washers. • Pull the wheel from axle flange studs. Front Wheel Installation Rear Wheel Installation Front Wheel Installation • Reverse the above sequence. • Tighten the wheel nuts securely. Rear Wheel Removal The procedure for using the jack is as follows.
3) Dismantle/Assemble the rear wheel. Engage the wheel nuts by hand (Do not tighten). 4) Remove the jack . 5) Put the vehicle in 1st gear and tighten the wheel nuts. Rear Wheel Installation • Reverse the above sequence. • Tighten the nuts securely. • Check for free rotation, brake effectiveness and engine starting. Warning Do not forget to install the spring washer before Installing the wheel nuts, tighten the wheel nuts securely. While removing the rear wheel protect your hand from the hot silencer.
Tire Change Tire Change For replacing a flat tire, unscrew the nuts, which secure the wheel to brake drum and slide off the wheel. Repair the tube or fit on the spare wheel. In case of rear wheel, use the jack as described in previous page. For removing a tire & tube first deflate the tube and unscrew the nuts on the wheel so that the two halves of the rim fall apart. (Refer fig.) Do not forget to put spring washers before tightening the nuts at the time of reassembly.
Recommendations for safe and proper operation of vehicle Warning: Do not overload your scooter. Attach luggage or packages as close as possible to the center of your scooter and distribute the load from side to side as evenly as possible to keep imbalance to a minimum. Remember that loads tend to loosen with riding. So frequently check the security of your load. Do not carry packages that protrude from the luggage rack or which cover any of the signal lights, the headlight, or the horn.
Recommendations for safe and proper functioning of vehicle • Continued use of original Bajaj replacement parts by an authorized Bajaj Dealer.
Service Record 1 To maintain your vehicle’s warranty, regular inspection and maintenance by your authorized Bajaj Dealer is required. Owner’s Name : Vin # : Date of Sale : Date of Service : Mileage : Service Dealer’s Signature : The first service interval should be performed between 300 and 500 miles or the first 30 days whichever comes first. See reverse for required service.
First Service l l l l l l l l l l l l l l Check and correct tire pressure. Flush and refill engine oil. Check & clean oil strainer. Check & adjust valve clearance. Clean & adjust spark plug gap. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. Check & adjust all control cables. Carry out lubrication as per lubrication chart. Check front/rear brakes for effective operation.
Service Record 2 To maintain your vehicle’s warranty, regular inspection and maintenance by your authorized Bajaj Dealer is required. Owner’s Name : Vin # : Date of Sale : Date of Service : Mileage : Service Dealer’s Signature : The second service interval should be performed between 1200 and 1500 miles. See reverse for required service.
Second Service l l l l l l l l l l l l l Check and correct tire pressure. Check engine oil level, top up if necessary. Check & adjust valve clearance. Clean & adjust spark plug gap. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. Check & adjust all control cables. Carry out lubrication as per lubrication chart. Check front/rear brakes for effective operation.
Service Record 3 To maintain your vehicle’s warranty, regular inspection and maintenance by your authorized Bajaj Dealer is required. Owner’s Name : Vin # : Date of Sale : Date of Service : Mileage : Service Dealer’s Signature : The third service interval should be performed between 2800 and 3100 miles. See reverse for required service.
Third Service l l l l l l l l l l l l l l l l Check and correct tire pressure. Flush and refill engine oil. Check & clean oil strainer & inline fuel filter. Check & adjust valve clearance. Clean & adjust spark plug gap. Clean the air filter. Clean the carburetor and adjust idling. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. Check & adjust all control cables. Carry out lubrication as per lubrication chart.
Service Record 4 To maintain your vehicle’s warranty, regular inspection and maintenance by your authorized Bajaj Dealer is required. Owner’s Name : Vin # : Date of Sale : Date of Service : Mileage : Service Dealer’s Signature : The fourth service interval should be performed between 6000 and 6300 miles. See reverse for required service.
Fourth Service l l l l l l l l l l l l l l l l Check and correct tire pressure. Flush and refill engine oil. Check & clean oil strainer & in-line fuel filter. Replace if required. Check & adjust valve clearance. Clean & adjust spark plug gap. Replace if required. Clean the air filter. Clean the carburetor and adjust idling. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. Check & adjust all control cables.
Service Record 5 To maintain your vehicle’s warranty, regular inspection and maintenance by your authorized Bajaj Dealer is required. Owner’s Name : Vin # : Date of Sale : Date of Service : Mileage : Service Dealer’s Signature : The fifth service interval should be performed between 9000 and 9300 miles. See reverse for required service.
Fifth Service l l l l l l l l l l l l l l l l Check and correct tire pressure. Flush and refill engine oil. Check & clean oil strainer & in-line fuel filter. Check & adjust valve clearance. Clean & adjust spark plug gap. Clean the air filter. Clean the carburetor and adjust idling. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock bolt and front/rear wheel nuts. Check & adjust all control cables. Carry out lubrication as per lubrication chart.
Bajaj Auto Ltd. - Emission Control System Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Bajaj Auto Ltd. (hereinafter Bajaj) are pleased to explain the emission control system warranty on your 2002 and later motorcycle. In California new motor vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards.
Owner’s Warranty Responsibilities • As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Bajaj recommends that you retain all receipts covering maintenance on your motorcycle, but Bajaj cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. • You are responsible for presenting your motorcycle to a Bajaj dealer as soon as a problem exists.
Bajaj USA - Limited Warranty on Emission Control System Bajaj USA, 526 Eccles Avenue, South San Francisco, CA 94080 (hereinafter Bajaj) warrants that each new 2002 and later Bajaj motorcycle, that includes as standard equipment a headlight, taillight and stoplight, and is street legal: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and B.
In the State of California only, emission related warranted parts are specifically defined by the state’s Emission Warranty Parts List.
II. Limitations: This Emission Control System warranty shall not cover any of the following: A. Repair or replacement required as a result of • accident, • misuse, • repairs improperly performed or replacements improperly installed, • use of replacement parts or accessories not conforming to Bajaj specification which adversely affect performance and or • use in competitive racing or related events B. Inspections, replacement of parts and other services and adjustments required for required maintenance. C.
Bajaj shall not be liable for any other expenses, loss or damage, whether direct, incidental, consequential or exemplary arising in connection with the sale or use of or inability to use the Bajaj motorcycle for any purpose. Some states do not allow the exclusion or limitation of any incidental or consequential damages, so the above limitations may not apply to you. B. No express emission control system warranty is given by Bajaj except as specifically set forth herein.
VI. Additional Information: Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, Bajaj is not liable for these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser. Manufacturer: Bajaj Auto Ltd.
Owner’s Manual Notice - ‘Reporting of Safety Defects’ If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying (manufacturer). If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Noise Emission Warranty: Bajaj Auto Ltd. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to: Bajaj USA, 526 Eccles Avenue, South San Francisco, CA 94080 Tampering Warning: Tampering with Noise Control System Prohibited.
Among those acts presumed to constitute tampering are the acts listed below: (1) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. (2) Removal or puncturing of any part of the intake system. (3) Lack of proper maintenance. (4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
Warranty Statement The following warranty applies to Bajaj scooters distributed by Bajaj USA. The warranty is the only warranty on these products, other than the emission control system, and noise emission control system set out elsewhere. No express warranty is given by Bajaj USA except as specifically set forth herein. Any warranty implied by law, including any warranty of merchantability or of fitness for a particular purpose, or for any purpose, is limited to the express terms stated in this warranty.
Auto Ltd. in the course of manufacture, Bajaj USA reserves the right to carry out the replacement by a part or parts of any such alternative brand/s. This warranty and any claim arising there from are subject to United States of America jurisdiction only. No claim for exchange or repair will be considered unless the customer: (a) Ensures that immediately upon discovery of the defect, he/she approaches any nearest Authorized Bajaj Vehicle dealer.
been used in conjunction with parts and equipment not manufactured or recommended for use by Bajaj USA. (4) Parts of the vehicle that been altered and modified or replaced in an unauthorized manner. (5) Vehicles which are not being serviced by Authorized Bajaj vehicle dealers as per the service schedule described in the owner’s manual or which have not been operated or maintained in accordance with the instructions mentioned in the owner’s manual. (6) Vehicles used for any competition.
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