Bajaj service

ACKNOWLEDGEMENT

To make a report of this magnitude is impossible without a dedicated effort and perfect
guidance.

We would like to express feeling of gratitude to the under mentioned officials for their
assistant, guidance and inspiration before and throughout the project.

Special thanks to Mr .vishwanath patel, our project faculty, for showing us a proper way to
walk on, for providing help and guidance throughout the report; he has always been the
source of encouragement. He has ceaselessly guided us in all the aspects of the project, with
his abundance amount of experience and finer ideas.

We would like to thank Mr .Puneeth G, for his guidance whenever we called for. We have
always been welcomed with very pleasant smile and full co-operation by him.

Working on the project is hard, need hard work and concentration. What made it possible is
the support we received from those around us. We thank to all the faculties of our college for
giving us guidance. Encouragement and right path to work on. We thank everybody who has
directly or indirectly helped us in this report to make it success full.

ABHILASH B E (524ME16301)

CHINTHAN B E (524ME16307)

ABISHEK B D (524ME16302)

CHETHANA D R (524ME16306)

CHETHAN M B (524ME16305)

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 1

Bajaj service

TABLE OF CONTENT

1. INTRODUCTION........................................................... 03
2. HISTORY……………………………………………… 04
3. TECHNICAL SPECIFICATION ……………………… 05
4. FIRST SERVICE ……………………………………… 06
5. FUEL TANK CAP……………………………………. 08
6. BRAKING …………………………………………….. 09
7. FUEL SAVING TIPS ………………………………….. 10
8. BATTERY : 12V-9 AH MF…………………………… 11
9. TUBELESS TYRE ................................................................ 12
10. SPARK PLUG………………………………………… 13
11. TOOLS USED IN WORKSHOP....................................... 15
12. ENGINE ASSEMBLY....................................................... 25
13. ENGINE OIL CHECKING................................................ 28
14. HEAD LIGHT ADJUSTMENT ........................................ 31
15. NON USE MAINTAINANCE........................................... 33
16. ACTICITY......................................................................... 36
17. FREE DELIVERY INSPECTION .................................... 40
18. CONCLUSION................................................................... 41
19. REFRENCE........................................................................ 42

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 2

Bajaj service

INTRODUCTION

COMPANY OVERVIEW

Bajaj Auto Limited is a global two-wheeler and three-wheeler Indian manufacturing

company.[3] Bajaj Auto manufactures and sells motorcycles, scooters and auto rickshaws.
Bajaj Auto is a part of the Bajaj Group. It was founded by Jamnalal Bajaj in Rajasthan in the
1940s. It is based in Pune,

Mumbai, with plants in Chakan (Pune), Waluj (near Aurangabad) and Pantnagar in
Uttarakhand.[4] The oldest plant at Akurdi (Pune) now houses the R&D centre 'Ahead'. Bajaj
Auto is the world's sixth-largest manufacturer of motorcycles and the second-largest in
India.[5] It is the world's largest three-wheeler manufacturer.[6] On May 2015, its market
capitalisation was ₹640 billion (US$9.8 billion), making it India's 23rd largest publicly traded
company by market value.[7] The Forbes Global 2000 list for the year 2012 ranked Bajaj
Auto at 1,416.[4]

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 3

Bajaj service

HISTORY

Bajaj scooter built under license from Vespa license from the Government of India to
manufacture two-wheelers and three wheelers[ 8] and obtained Licence from Piaggio to
manufacture Vespa Brand Scooters in India and started making Vespa 150 scooters. It
became a public limited company in 1960.[9] In 1970, it rolled out its 100,000th vehicle.[9]
In 1977, it sold 100,000 vehicles in a financial year.[9] In 1985, it started producing at Waluj
near Aurangabad.[9] In 1986, it sold 500,000 vehicles in a financial year.[9] In 1995, it rolled
out its ten millionth vehicle and produced and sold one million vehicles in a year.[10] With
the launch of motorcycles in 1986, the company has changed its image from a scooter
manufacturer to a two-wheeler manufacturer. In 2017 it was announced that Bajaj Auto and
Triumph Motorcycles Ltd would form an alliance to build mid-capacity motorcycles[11].
According to the authors of Globality: Competing with veryone from Everywhere for
Everything, Bajaj has operations in 50 countries creating a line of bikes targeted to the
preferences of entry-level buyers.[12]

speedometer

Head lamp
Back Rest.

Fuel tank
Rear shock Absorber

Brake Lever

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 4

Bajaj service

Identification Data and Vehicle Identification Number #

0
Engine Number………… Chassis Number………. VIN Number………………..
2
2
8
There are three unique numbers assigned to your scooter. The engine and 0chassis serial
9
numbers are used by the factory to identify the exact model. Please cite 08both of these
2
numbers whenever you are ordering replacement parts. The vehicle identification A number is
D
used to register your vehicle with the Department of Motor Vehicles in your7 state. It is a
2
2
3
crime in all states to alter the vehicle identification number. Also, the alteration
3
of any of
these numbers will immediately void your warranty. #

TECHNICAL SPECIFICATIONS

Engine : 4stroke,singlecylinder,forcedaircooled,sparkignition

Engine Displacement : 145.45cm3

Max.Net Power : 9.00HPat6000r/minofengine

Ignition System : Electronic ignition(C.D.I.)

Spark Plug : Champion:PL7YC(Tobe used with resistor spark plug cap)

Lubrication : Wet sump forced lubrication

Transmission : 4 speed gearbox

Front &Rear Brakes : Mechanical expanding shoe type

Fuel Tank Capacity : 1.32 Gal. (5.00litres)

Electrical System : 12VD.C.

: Head lamp:35/35W Tail/Stop lamp :5/21W Side indicator lamp:10W Horn :

12VD.C.

Curb Weight : 253 lbs/115kg

Max Speed : 55MPH/90km/h with single rider

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 5

Bajaj service

FIRST SERVICE

(1) Check and correct tire pressure. Flush and refill engine oil.

(2) Check & clean oil strainer. Check & adjust valve clearance. Clean & adjust spark plug

gap.

(3) Check & adjust all control cables.

(4) Carry out lubrication as per lubrication chart. Check front/rear brakes for effective

operation.

(5) Check all lights, horn and switch operations for satisfactory working. Air filter element to

be cleaned, if frequently used in dusty area.

(6) Clean the vehicle before delivery

SECOND SERVICE

(1) Clean & adjust spark plug gap.

(2) Checkandtightennutsforfront/rearshockabsorberbolts,enginefoundationbolts,

(3) Check & adjust all control cables.

(4) Carry out lubrication as per lubrication chart. Check front/rear brakes for effective

operation.

(5) Check all lights, horn and switch operations for satisfactory working. Air filter

element to be cleaned, if frequently used in dusty area.

(6) Test drive the vehicle before delivery.

(7) Clean the vehicle before delivery.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 6

Bajaj service

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. Bajaj must warrant the emission control system on your
motorcycle for the periods of time listed below provided there has been no abuse, neglector

Your emission control system may include parts such as the carburetor or fuel-injection
system, the ignition system, catalytic converter and engine computer. Also included may be
hoses, belts, connectors and other emission- related assemblies.

Manufacturer’s Warranty Coverage

• Class I motorcycle(50-169cc) for a period of five (5) years or 12,000 kilometers (7,456
miles), whichever first occurs.

• Class II motorcycles(170to279cc) for a period of use of five (5) years or 18,000

kilometers (11,185 miles), whichever first occurs.

• Class III motorcycles(280ccandlarger) for a period of use of five (5) years or 30,000
kilometers (18,641 miles), whichever first occurs.

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.

Every possible care and precaution has been taken to ensure quality in respect of material and
workmanship in the vehicles manufactured by Bajaj Auto Ltd.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 7

Bajaj service

TIRE CHANGE

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 re- assembly.
Tighten the nuts diagonally and evenly

Fuel Tank Cap

• To open the fuel tank cap, open the flap. Insert the key in the lock and turn it clockwise
and lift fuel tank cap.

• To lock the ‘Fuel Tank Cap’ insert the key in the lock and turn it clockwise and press
fuel tank cap. ‘Click’ sound ensures cap is fully locked.

Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position.

1. Speedometer : The speedometer needle shows the speed of the vehicle in Km/Hr.

2. Odometer : It shows the total distance that the vehicle has covered.

3. Trip Meter : It shows the distance traveled since it was last reset to zero.

4. Trip Meter Knob : Reset trip meter to zero by turning reset knob anticlockwise.

5. Bajaj Logo : Bajaj logo flying‘B’.

Safe Riding Tips

• Always wear Helmet while driving or riding. Your helmet should conform to
appropriate Indian standards.

• Read thoroughly the instructions given in this manual and follow them carefully.

• Avoid unnecessary accessories for the safety of both rider and other motorists.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 8

Bajaj service

• Familia rise yourself well with starting, acceleration and braking of the vehicle.

• When applying the brakes, use both front & rear brakes simultaneously. Applying
only one brake may cause the vehicle to lose control.

• Riding at proper speed and avoiding unnecessary acceleration and braking are
important not only for safety and low fuel consumption, but also for longer life of the
vehicle.

• During monsoon drive the vehicle more cautiously. Remember vehicles skid more
easily during light showers.

BRAKING :

• Close the throttle completely, leaving the clutch engaged (except where shifting gears) so
that the engine braking will help slow down the motorcycle.

• Shift down one gear at a time so that you are in Neutral when you come to a complete
stop.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 9

Bajaj service

• When stopping, always apply both brakes at the same time. De-clutch as necessary to
avoid engine stalling.

• Never lock the brakes, or it will cause the tyres to skid. When cornering, use brakes
judiciously & do not de-clutch. Reduce your speed before you get into the corner. For
emergency braking, disregard downshifting, and concentrate on applying brakes as hard
as possible with out skidding.

FUEL SAVING TIPS:

A well maintained vehicle and good driving can contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips.

Good Riding Habits :

• Ride smoothly and steadily at an optimum drivingspeedof40to50Km/h

• Avoid harsh braking.

• Change the gear judiciously according to the speed and load requirement.

• Don’t overload the vehicle above the specified payload.

• Use the accelerator judiciously.

• Cut off the engine if you want to stop for more than two minutes.

How to check mileage (Fuel efficiency)

Best way to calculate mileage is by following the full tank to full tank method.

• Fill way tank full up to small mouth(brim).

• Runthebikeforsay100km.

• Fill the tank full again in same fuel filling station, probably with same fuel dispenser.

Divide kilometer run / fuel quantity filled

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 10

Bajaj service

Monsoon Care :

• It is suggested to customer to take appropriate care in area of heavy monsoon or high

rainfall area. The appropriate surface preventive coat to avoid rusting / poor surface finish
on account of adverse atmospheric conditions.

BATTERY : 12V-9 AH MF

• Always ensure that battery electrolyte level is in between max & min level marks.

• Check & top up battery by distilled water if electrolyte level is below min level mark.

CAUTION : Tap water is not a substitute for distilled water and will shorten the life of the
battery.

• Environment care must be taken to dispose off the used battery. It is always
recommended to hand over the same to the Authorised battery / Bajaj dealer for proper
disposal of the same.

• When battery is found discharged, it is advised to get it charged immediately.

TUBELESS TYRE :

The main advantage of tubeless tyres is in case of puncture the rate of air leak isvery
slow, hence customer can easily drive the vehicle upto nearest puncture repair shop for
removing puncture.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 11

Bajaj service

Front Brake Fluid Level

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 12

Bajaj service

• Front brake fluid master cylinder reservoir is located near RHs witch on handlebar.
• To check oil level, keep the vehicle on Centre stand with handle bar in straight position.
• Always ensure that brake fluid level is above ‘MIN’ mark given on inspection window.
• Use only DOT 4 brake fluid (from sealed container) to top up if required.
• Change the brake fluid as per periodic maintenance schedule.

SPARK PLUG

• Remove spark plugs by using plugs panner.

• Clean the sparkplugs.

• Adjust the gaps if incorrect by bending outer electrode carefully.

Spark Plug Gap : 0.8 to 0.9mm.

Spark Plug (2 Nos.) : CHAMPION P-RG6HCC

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 13

Bajaj service

Drive Chain Slackness

• Chain slackness will have to be adjusted when ever required.

• Std.Chainslackness25~35mm.

• Marking on chain adjusters should be identically positioned on both sides.

Matte finish painted parts cleaning Do’s :

∙ Use Colin or dish washing detergent solution for cleaning.(1 spoon in ½bucket)

Remove foreign substances like insect remains, road debris using a soft brush.

∙ Use microfiber cleaning cloths Ex.- Muslin cloth for painted parts cleaning.

Don’ts :

∙ Do not use wax/spray/products made for normal glossy paint for cleaning.

∙ Do not use products that are even mildly abrasive, such as polishes, glazes, or rubbing
compounds.

∙ Do not use mechanical cleaners/polishers.

∙ Do not use terrycloth or paper towels or shine enhan cement products.

∙ Do not rub the finish vigorously, this will burnish the paint finish, causing a permanent
shiny spot. Shiny spots cannot be removed.

∙ No Polishing/Teflon coating on painted parts.

Bajaj Auto Limited gives the following warranty in respect of the “Avenger 220 DTS-i”
motorcycle manufactured by them.

Every possible care and precaution has been taken to ensure quality in respect of the material
& workmanship in the vehicles manufactured by us. Bajaj Auto Limited will repair or replace
at their Authorised Workshops, free of charge, part or parts there of as may be found, on
examination, to have manufacturing defect within a period of 2 Years or 30,000 Kms.,

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 14

Bajaj service

whichever occurs earlier from the date of sale subject to fulfillment of condition stipulated
inpartA B&C given here under

Warranty is applicable for only first owner of vehicle.

Part A:

Warranty claims in respect of such items like shock absorbers, speedometers etc. though
claimed through us, are subject to acceptance of the respective manufacturers. In all such
cases the decision of the respective manufacturer will be final and binding.

Safety and Warning information:

Caution : This indicates that a potential hazard that could result in vehicle damage. Follow
the Advice provided with the caution. Warning : This indicates that a potential hazard or
injury to you or other persons & to the vehicle can happen if advice provided is not followed.

TOOLS USED IN WORKSHOP:

Evaluation The tool was employed at the man Truck & Bus AG Salzgitter plant. Its assembly
is structured into a main multi model assembly line and pre-assembly areas for modules.
Preassemblies are located close to the main line, which enables a just-in-sequence delivery of

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 15

Bajaj service

modules. The modules are demanded by different customers, namely the main assembly line
and a completely knocked down (CKD) production. In contrast to the main assembly, the
CKD production does not assemble complete trucks. Modules are packed into containers
being shipped abroad. The trucks are assembled afterwards. The existence of two internal
customers leads to specific complexity for capacity planning in pre-assembly areas.

Our hand tools section covers a vast range suitable for many applications. Most hand tools
can be supplied by mail order meaning you can often get hand tools online with next day
delivery UK. Many of our tools are from popular automotive brands such as Sealey, Draper,
Laser, Tool Connection, however we also import our own range of tools which are
competitively priced. Our range covers everything suitable for the automotive workshop,
both car and commercial.

In a workshop environment, you are sure to come across a variety of different workshop tools
that are necessary for different operations. With such a range of different equipment, you may
wonder what certain pieces of equipment are for. To save this confusion, we've put together a
handy guide for you about the less straightforward workshop tools and their uses.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 16

Bajaj service

Though not technically a tool, when working at a height, tool lanyards are a tool which helps
prevent heavier workshop tools falling from your belt. It also absorbs shock force which
occurs when an item is dropped, which stops the worker being pulled down at the same time.

Adjustable Wrench;

What adjustable wrenches are used for;

Wrenches are typically used to provide grip when turning objects, such as nuts and bolts.
This adjustable wrench is a workshop tool which will allow you to adjust the wrench to the
size needed for the operation.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 17

Bajaj service

Hand Riveter;

What hand riveters are used for:

Hand riveters are a workshop tool which uses a pre-drilled hole to join two pieces of
metal/plastic together. The hand riveter presses the rivet against the hole and the buckling
bar, causing the rivet to deform and flatten to secure the pieces together.

Farm Jack;

What farm jacks are used for:

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 18

Bajaj service

Farm road jacks are an ideal workshop tool used for lifting and pulling/pushing items in off-
road environments. This farm jack is also a perfect tool for a 4x4 recovery kit.

Hydraulic Wedge Spreader;

What a hydraulic wedge spreader is used for: This hydraulic wedge is a perfect workshop
tool for separating stubborn joints, even those with fitted ring grooves. Friction free, unlike
hammers and lever bars, this hydraulic wedge limits any damage to the joints.

Screwdrivers and Fasteners

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 19

Bajaj service

I will need a good collection of screwdrivers so that you can open all the screws you can find
around your house. Household E-waste is extremely useful, learn to hoard it and harvest it for
free motors, power electronics, and other such things. Also, try to curate an assortment of
nuts and bolts from all these things that you unscrew. They can be extremely helpful at time.

ENGINE ASSEMBLY:

Fig: disassemble the IC engine parts

Ignition Lock : It is located at right side of the frame below ‘Fuel Tank’. It has three
positions. The key can be removed from switch only in ‘OFF’ position.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 20

Bajaj service

Key position Function

OFF Engine off.

All Electrical circuits off

ON Engine can be started in this

Position by starter button.

P (Park) Engine & all electrical off. Only

Tail & Pilot lamp ‘ON’.

Warning : If you leave the P (Park) position on for a long time (@1 hour), the

battery may get discharged.

Steering Lock :

To lock the steering : Turn the handle bar to the left. Slide open key hole cover clockwise.
Insert key in lock. Turn the key anti-clockwise and push key in while turning the handle bar
slightly to ‘Right’, and turn the key clockwise (Original position). Pull the key out.

To unlock the steering : Insert key in lock and turn anti-clockwise. Hold the key in this
position & move the handle bar to ‘Right’ to release the lock. Pull the key out.

Key : A common key is used for Ignition lock, Steering lock, Fuel tank cap and Side cover
lock.

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:

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 21

Bajaj service

1. Neveroperateyourscooterwithleadedgasoline.Evenasmallamountofnormallead
edgasolinewill
damagethecatalystandmakethecatalyticconvertercompletelyineffective.

2. Nevertamperwiththecatalyticconverter,whichisinstalledinsidethesilencerassem
bly.

3. Never turn off the engine when the scooter is in motion. Likewise, never try
to start your scooter by pushing it, towing it, or coasting it down a hill. Failure
to observe this precaution will damage the catalytic converter, and can lead to
a serious over temperature event, or even a fire, If the engine misfires or
appears to have any loss of performance, immediately take your scooter to
your local Bajaj Dealer.

Fuel Tank Cap

• To open the fuel tank cap, open the flap. Insert the key in the lock and turn it clockwise
and lift fuel tank cap.

• To lock the ‘Fuel Tank Cap’ insert the key in the lock and turn it clockwise and press
fuel tank cap. ‘Click’ sound ensures cap is fully locked.

Left Handle Bar Switches

A. Dipper Switch: When headlight is ON, High or Low beam can be selected with the
dipper switch.

: High Beam : Low beam

B. Turn Signal Switch : When the turn signal switch is turned to Left ( ) or Right ( ) the
corresponding turn signals flash on and off. To stop blinking push the switch in &
release.

A. Horn Button: ( ) Press button for sounding horn.

B. Pass Switch: Press the switch to flash the head light. It is used to give signal to
vehicles coming from opposite side while overtaking.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 22

Bajaj service

Right Handle Bar Switches

A. Starter Button :
Starter button operates the electric starter. It is recommended to start the engine with the
transmission in neutral.
Vehicle in Gear - Press clutch lever & operate starter button to start the engine.
B. Engine Kill Switch :
The engine kill switch is used for switching ON & OFF the engine.
: Engine OFF
: Engine ON

TOOL KIT LOCATION

• Tool kit is located in tool kit compartment.

• Lid is provided inside RH side cover.

FIRST AID KIT LOCATION

• First aid kit is to be stored along with tool kit in the slot provided near battery.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 23

Bajaj service

• Before riding motorcycle be sure to check following items. Please give proper importance
to these checks and perform all of them before riding motorcycle.
• If any irregularities are found during these checks, refer to the Maintenance chapter &
see your dealer for the action required to return the motorcycle to a safe operating
condition.

• Enough fuel level for planned distance of journey. No fuel leakage in fuel lines.

• Engine oil level (between upper and lower level mark)

• Throttle cable play of 2 ~ 3 mm. Smooth operation and positive return to closed position,

• Brake Pedal Play - 20 to 30 mm.

• Wear lining Indicator within usable range. No brake dragging.

• Brake Fluid level above MIN mark provided on reservoir, applicable to disc brake
vehicle.

• Drive Chain slack of 25 to 35 mm adequately lubricated.

• Function of all lights & horn

• Clutch lever play - 2 to 3 mm

• Smooth steering movement without restriction.

• Both stand return to their fully up position.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 24

Bajaj service

• Correct inflation pressure in both tyres Adequate tyre tread depth - no cracks / cuts.

• Correct rear viewing span adjustment of mirror.

Starting The Engine :

• Keep fuel tap to ON or RES position.

• Turn ignition / kill switch to ON position.

• Confirm that transmission is in neutral.

• If the engine is cold or when starting for first time, use choke for quick starting.

• Keep throttle completely closed, press starter button “ ”.

• When the engine is warmed up enough to idle without using choke, return the choke to
“OFF” position.

Note : When the engine is already warm on hot days (Higher than 350C), open the
throttle part away instead of using the choke, and then start the engine.
Caution: Do not operate the starter
Continuously for more than 5 seconds. Wait for 15 seconds before you recrank.
Note : The motorcycle is equipped with a starter lockout switch. The starter switch will
operate only when transmission is in neutral or clutch lever depressed.
Moving Off :

• Check that Center/Side stand is up.

• Depress clutch lever, Shift into 1st gear.

• Open the throttle and release the clutch lever slowly and simultaneously.

• As the clutch starts to engage, open the throttle a little more, giving the engine just
enough rpm to keep running.

Shifting Gears :

• Close throttle & depress the clutch.

• Shift into next higher or lower gear.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 25

Bajaj service

• Open the throttle and release the clutch lever slowly and simultaneously.

Braking :

• Close the throttle completely, leaving the clutch engaged (except where shifting gears) so
that the engine braking will help slow down the motorcycle.

• Shift down one gear at a time so that you are in Neutral when you come to a complete
stop.

• When stopping, always apply both brakes at the same time. De-clutch as necessary to
avoid engine stalling.

• Never lock the brakes, or it will cause the tyres to skid. When cornering, use brakes
judiciously & do not de-clutch. Reduce your speed before you get into the corner. For
emergency braking, disregard downshifting, and concentrate on applying brakes as hard
as possible without skidding.

Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

Parking the Vehicle :

• Support the motorcycle on a firm level surface with the center or side stand.

• Lock the steering.

Running IN

Proper running-in is important for the better life & trouble free performance of the vehicle.

• During first 2000 kms running-in period do not exceed following speed limits.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 26

Bajaj service

Kms 1st 2nd 3rd 4th 5th

0 - 1000 15 30 45 55 65

1000 - 20 40 55 65 75
2000

• Always keep the speed below the limits mentioned in the table.

• 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

Fuel Saving Tips :

A well maintained vehicle and good driving can contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips.

Good Riding Habits :

• Ride smoothly and steadily at an optimum driving speed of 40 to 50 Km/h

• Avoid harsh braking.

• Change the gear judiciously according to the speed and load requirement.

• Don’t overload the vehicle above the specified payload.

• Use the accelerator judiciously.

• Cut off the engine if you want to stop for more than two minutes.

How to check mileage (Fuel efficiency)

Best way to calculate mileage is by following the full tank to full tank method.

• Fill way tank full up to small mouth (brim).

• Run the bike for say 100 km.

• Fill the tank full again in same fuel filling station, probably with same fuel dispenser.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 27

Bajaj service

Divide kilometer run / fuel quantity filled

Engine Oil Level Checking

: B
CD

• Check engine oil level every day. Park vehicle on level surface.

• Check oil level through oil level gauge ‘B’.

• Always maintain engine oil level between upper (C) and lower (D) mark provided on
Cover RH. Top up with specified grade of oil if the oil level is below lower level mark.

• Completely screw in the dipstick after oil filling is over.

Engine Oil Capacity :

• Refill at servicing : 1150 ml.

• During engine overhaul : 1200 ml.

Recommended Engine Oil:

Always insist on Bajaj Genuine Engine Oil for optimum engine performance and warranty
benefits. It is a specially formulated oil for vehicles with DTS-i engines.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 28

Bajaj service

Battery : 12V-9 Ah MF

• Always ensure that battery electrolyte level is in between max & min level marks.

• Check & top up battery by distilled water if electrolyte level is below min level mark.

CAUTION : Tap water is not a substitute for distilled water and will shorten the life of the
battery.

• Environment care must be taken to dispose off the used battery. It is always
recommended to hand over the same to the Authorised battery / Bajaj dealer for proper
disposal of the same.

• When battery is found discharged, it is advised to get it charged immediately.

CAUTION : Do not drive/run vehicle in battery disconnected condition. It may lead to

damage of electrical /electronic components.

• Warranty on battery is 18 months from the date of purchase of vehicle.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 29

Bajaj service

How to keep battery healthy ?

• Switch ‘Off’ ignition if engine is not running.

• Do not press starter button for more than 5 sec. After 3 successive cranking, wait for
15-20 sec. for battery to recover.

• Do not add extra electrical accessories such as - Remote, Bigger horn, Musical brake
light etc. This will reduce life of battery

• If vehicle is to be stored for more than 2 weeks disconnect battery to avoids self
discharge.

CAUTION :

• While disconnecting always disconnect negative (-ve) cable first.

• While refitting always connect positive (+ve) cable first.

Head Light Beam Adjustment

The Head light beam can be adjusted Vertically and Horizontally. If adjusted too low, neither
low nor high beam will illuminate the road adequately. If adjusted too high, the high beam
will fail to illuminate the road.

A. Horizontal Adjustment screw : Turn the horizontal adjuster on the headlight with a screw
driver in or out unit the beam points straight ahead.

Turn the horizontal adjuster clockwise to face the headlight left.

B. Vertical Adjustment screw : Turn the Vertical adjuster on the headlight in or out to adjust
vertically.

Turn the Vertical adjuster clockwise to face the headlight up.

Drive Chain Cleaning

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 30

Bajaj service

Drive chain must be cleaned & lubricated as per periodic maintenance schedule.
Drive Chain (O-ring type)
• ‘O’ rings must always be kept wet for best performance hence lubricate every 500
Km.
• O-ring chain lubrication can easily be done by owners using Bajaj ‘Chain Lube Spray
Can’ available with Bajaj dealers.

Method of O-ring Chain Lubrication :

• Park vehicle perpendicular to the ground on level surface. Clean the chain by using lint
free cloth (If excessive mud / slush found approach Bajaj Service Center for proper
cleaning)

• Shake the can vigorously by holding vertically upright till the noise of steel ball inside
heard uniformly.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 31

Bajaj service

• Hold spray can at the back of rear sprocket with extension tube nose at 5~10 cm.

• Rotate the wheel in reverse direction & spray the lube on middle portion of the chain up to
full length of the chain.

NON-USE MAINTENANCE

Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more
than 15 days**). The correct and careful non- use maintenance carried out before storing the
vehicle will prevent the vehicle from rusting and from such other non-operational damages
like fire hazards.

• Clean the entire vehicle thoroughly.

• Empty the fuel from the fuel tank and carburettor float bowl (if fuel is left in for a longer
time, the fuel will break and gummy substance could clog the carburettor).

• Remove spark plug & put several drops of 2T oil into the cylinder. Crank the engine
over slowly a few time to coat cylinder wall with oil & install back sparkplug.

• Set the vehicle on a box or a stand so that both wheels are raised off the ground.

• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber
parts or brake liners.

• Cover entire vehicle neatly. Make sure that storage area is well ventilated & free from any
source of flames or spark.

• Fill 10% excess air pressure in both wheels.

• Make sure the spark plugs are fitted tightly.

• Fill the fuel tank with fuel.

• Change the engine oil.

• Check all the points listed in the Daily Safety Checks section.

• Check and inflate tyres to proper tyre pressure.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 32

Bajaj service

Scope:-

Bajaj Auto Limited gives the following warranty in respect of the “Avenger 220 DTS-i”
motorcycle manufactured by them.

Every possible care and precaution has been taken to ensure quality in respect of the material
& workmanship in the vehicles manufactured by us. Bajaj Auto Limited will repair or replace
at their Authorized Workshops, free of charge, part or parts there of as may be found, on
examination, to have manufacturing defect within a period of 2 Years or 30,000 Kms.,
whichever occurs earlier from the date of sale subject to fulfillment of condition stipulated in
part A, B & C given here under

Warranty is applicable for only first owner of vehicle.

Part A:

Warranty claims in respect of such items like shock absorbers, speedometers etc. though
claimed through us, are subject to acceptance of the respective manufacturers. In all such
cases the decision of the respective manufacturer will be final and binding.

Proprietory parts like tyres, tubes, battery and

spark plugs are warranted by their respective manufacturers (Only one year warranty from
the date of purchase/as applicable) and should be claimed on them directly by the customer.
Bajaj Auto Limited shall not be Liable to replace them

though their dealer will give full assistance in preferring such claims.

Bajaj Auto Limited undertake no liability in the matter of consequential loss or damage
caused due to the failure of the parts. Delay, if any, at the repairing workshop in carrying out
repair to vehicle shall not be a ground for extending the warranty period, nor shall it give any
right to the customer for claiming any compensation for damages.

Bajaj Auto Limited reserves the right either to repair or replace the defective parts.

Where a defective part can be replaced by part/s of alternative brand/s, which are normally
used by Bajaj Auto Limited in the course of manufacture, Bajaj Auto Limited reserves the
right to carry out the replacement by a part or parts of any such alternative brand/s.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 33

Bajaj service

This warranty and any claim arising there from is subject to Pune jurisdiction only

to remove and dispatch the part / parts attributing to the manufacturing defect to the
Company.

a. Produces the Owner's Manual, in original, to enable that dealer to verify the details.

It must be expressly understood that claims forwarded directly to us by the owner / customers
will not be entertained at all and such defective part/parts thus forwarded by them will lie at
our factory at their own risk, and this warranty shall not be enforceable.

To avail benefits of warranty, following are mandatory

1. Availing of Initial 3 Free Services without lapse.

2. Availing 4 paid services at every 5000 kms. or 120 days whichever occurs first without
any lapse.

3. Availing of all above services at the Authorised Vehicle Dealers & Recommended
Authorised Service Centers.

4. Maintaining all service records duly signed and stamped by dealers.

5. Usage of only recommended engine oil

“Bajaj DTS-i 10000” at specified frequency

for drain interval of 10,000 kms. & engine oil level top-up at 5000 kms.

Replacing mandatory periodic parts such as air filter, oil filter etc. as per periodic
maintenance schedule

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 34

Bajaj service

ACTICITY:-

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 35

Bajaj service

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 36

Bajaj service

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 37

Bajaj service

TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS IN CASE OF

CLAIM

Name of Dealer & Code :

Date of claim : Battery Type : Serial No. : Date of Fitment :

Failure Mode (Please tick as applicable)

• Loose connection • Overcharge / Undercharge

• Internal Short • Reverse Charge

• Plate Shedding • High Specific Gravity Electrolyte

• Intercell Connection • Electrolyte Contamination

• Does not Hold Charge • Electrolyte Level not Maintained

• Wrong Assembly • Left Lying Idle

• Wrong Application

• Terminal Corroded

Details of Repair, if any Note:

Please contact nearest respective authorised battery dealer for details immediately after

purchase of vehicle.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 38

 Bajaj service

ARPITHA BAJAJ
SERVICE
HASSAN

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 39

Bajaj service

Pre Delivery Inspection

1. Check and correct tire pressure including that of Spare Wheel.

2. Check and tighten nuts for front/rear shock absorber bolts, engine foundation bolts,
handle bar lock bolt and front/rear wheel nuts.
3. Check steering/ignition lock, luggage box lock, seat lock, and tool box lock for proper
operation.
4. Check all lights, horn, switch, speedometer and fuel gauge operations for satisfactory
working condition.
5. Check for smooth operation of fuel cock lever.
6. Check front/rear brakes for effective working condition. Test drive the vehicle.
7. Repair any other defects seen or observed during test drive. Clean the vehicle before
delivery.
8. Recommendations for safe and proper operation of vehicle
9. 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
10. Do not hang anything from your scooter’s handlebars, fenders or forks because this
will upset the handling of your scooter and could prevent you from avoiding an

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 40

Bajaj service

4. CONCLUSION

In general, the workshop appears to have been highly successful. While some tentative
recommendations might be made for future training programs of this type – e.g. make
available more computers to allow smaller user groups, gain a better idea of the computer
access and computing experience of participants – it would seem desirable to retain flexibility
to meet the needs of the audience and adapt presentations as suits the progress of the group. It
was to be expected that some problems would arise, but overall the workshop appears to have
been highly successful in achieving its objectives. Lasting benefits are expected for the
ACIAR research project in terms of a shared research methodology and vision, and progress
in planning of specific activities. This engenders confidence for conducting such a training
program as a capacity-building exercise in other locations. There was clear enthusiasm for the
modelling activities and hands-on computing in relation to the simulation modelling package
Simile, development of financial analysis spreadsheets with MicroSoft Excel and linear
programming using the Solver facility. The modules on research administration and
publication strategy also appeared to be of high interest.

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 41

Bajaj service

REFRENCE

Website:

 www.business-standard.com/.
 https://www.youtube.com/watch?v=DyTCAsX06R4
 https://www.youtube.com/watch?v=pYWOdrszCxg
 https://www.youtube.com/watch?v=cfmpLnVcdH
 www.bajaj motors.com
 www.information google.com
 www.bajaj

DEPT. OF MECHANICAL ENGG. RAJEEV POLYTECHNIC HASSANPAGE 42