Bajaj Auto Boxer BM 150 User manual

User's GuideUser's Guide
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Dear Customer,
Congratulations on choosing “Boxer BM 150” motorcycle, one of the finest motorcycles in the
country brought to you by Bajaj Auto Limited.
Before you prepare for riding, please read this User's Guide carefully to familiarize yourself with the
mechanism and the controls of the vehicle.
To maintain your bike in perfect running condition to deliver consistent performance, we earnestly
advise you to avail periodic services, at Bajaj Dealers.
You can entrust Bajaj Dealers, who are well equipped with all necessary facilities, skill sets and
trained manpower for servicing and repairs of your “Boxer BM 150”. In the rare event of going to a
local garage, always insist on Genuine Bajaj Spares to ensure safety, performance and longer life of
your vehicle.
Should you require any additional information, please approach Bajaj Dealers. If necessary, you may
also write to selling dealers, with relevant details like Registration no. Chassis no., Engine no., Date
of purchase, Kms. run and your contact number.
Finally, may we request you to give your motorcycle a proper care and regular maintenance, as
described in this manual. We are sure this will offer you a long trouble-free ownership experience.
Wishing you unlimited miles of happiness!
International Marketing
BAJAJ AUTO LIMITED
Akurdi Pune - 411 035 India
CIN L65993PN2007PLC130076
DOC. NO. 71111331
REV. 03, FEB. 2019
Foreword

Description
1. Technical Specifications 1
2. Identification Data 3
3. Location of Parts 4
4. How to Ride Your Bike 15
5. Safe Riding Tips 19
6. Daily Safety Checks 19
7. Periodic Maintenance Information 21
8. Periodic Maintenance & Lub. Chart 27
9. Non-use Maintenance 31
Notice: The description and illustration in this booklet are not to be taken as binding on
the manufacturers. The essential features of the type described and illustrated herein
remaining unaltered. Bajaj Auto Limited reserves the right to carry out modifications on
the vehicle, parts or accessories as may be convenient and necessary at any moment
without being obliged to bring this booklet upto-date.
Safety and Warning information :
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.
Caution : This indicates that a potential hazard that could result in vehicle damage.
Follow the advice provided with the caution.
Table of Contents

Engine : 4 stroke, single cylinder
Natural air cooled,
Spark ignition
Bore x Stroke : 56.0 mm x 58.8 mm
Eng. Displacement : 144.8 cc
Compression Ratio : 9.8 : 1
Idling Speed : 1400 rpm + 100
Max. Net Power : 12 PS @ 7500 rpm
Max. Net Torque : 12.55 Nm @ 5500 rpm
Ignition System : DC
Spark Plug (1 Nos) : CHAMPION PRZ9HC or
BOSCH UR4AC
Spark Plug Gap : 0.7~0.8 mm
Lubrication : Wet sump, Forced.
Transmission : 5 speed constant mesh.
Front Brake : Mech. expanding shoe
130 mm dia. Drum
240 mm dia. Disc
Rear Brake : Mech. expanding shoe
130 mm dia. Drum
Fuel Tank Capacity :
Full : 11 liters
Reserve : 2.5 liters
Usable : 1 liters
Dimensions :
Length : 2016 mm
Width : 740 mm
Height : 1055 mm
Wheel base : 1285 mm
Ground clearance : 190 mm
Turning circle radius : 2100 mm
1
Technical Specifications

Tyre Size : BM 150
Front : 3.00 X 17”, 45 P RIB
Rear : 100/90X17”,55 P STUD
Tyre Size : BM 150 X
Front : 3.00X17”,SEMI KNOBBY
Rear : 100/90X17”,SEMI KNOBBY
Tyre Pressure
2
Front : 1.75 kg/cm (25 PSI)
2
Rear (Solo) : 2.00 kg/cm (28 PSI)
2
Rear (Pillion) : 2.25 kg/cm (32 PSI)
Electrical System : 12 Volts (DC)
Head Lamp
(w/o Pilot lamp) : 12V, 35/35W HS1
Neutral : 12V, 2W
Tail / Stop Lamp : 12V, 5/21W
Turn Signal Indicator : 12, 2W
Side indicator Lamp : 12V, 10W (4 nos.)
Hi Beam Indi. Lamp : 12V, 2W
Speedometer Lamp : 12V, 2W (2 nos.)
Horn : 12 V 2A, DC
Battery : 12 V 4 Ah VRLA
Vehicle Kerb Weight : 125 kg.
Gross Vehicle Weight : 255 kg.
Max. Speed : 1 0 0 k m / h r . ( W i t h
single rider 68kg)
0
Climbing Ability : 25% max. (14 )
Note : All dimensions are under UNLADEN
condition. Above information is subject to change
without any notice.
Technical Specifications
2

The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.
Frame Number Location
On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)
Identification Data
3

Headlamp
Rear
Shock Absorber
Carburettor with
Manual choke
Brake Pedal
Engine Oil
Inspection Window
Fuel Tank
Rider
Foot Rest
Pillion Foot Rest
Rear Number
Plate
Silencer
Front Brake
Lever
Speedometer
Grab Handle
Location of Parts
4

Front Fork
Clutch Lever
Fuel Tank Cap
Rear
Shock Absorber
Pillion
Foot Rest
Side
Stand
Gear Change
Lever
Speedometer
Tail
Lamp
Grab Handle
Location of Parts
5

To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Push &
release the key. Turn the key to “LOCK” position
and remove the key.
To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering cum
Ignition lock’, ‘Fuel tank cap’ & ‘Side cover
lock’.
Steering cum Ignition Lock :
It has three positions.
LOCK : Steering locked. Ignition OFF.
OFF : Steering unlock. Ignition OFF.
ON : Steering unlock. Ignition ON.
Location of Parts
6

Location of Parts
7
Fuel Tank Cap
• To open the fuel tank cap, insert the key in
the lock and turn it clockwise and lift fuel
tank cap.
• ‘Fuel Tank Cap’ is locked when pushed /
pressed back into the place.
Fuel Tap
Fuel tap lever has following positions.
ON : When fuel level is above Reserve
position.
RES : When fuel level is below Reserve
position.
OFF : When fuel supply is to be cut off.
OFF
ON
RES
FUEL
Fuel Tap
Fuel Tank Cap

Location of Parts
8
1. Odometer : It shows the total distance that the vehicle
has been ridden.
2. Speedometer : The Speedometer pointer shows the
speed of the vehicle.
3. Turn Signal Indicator (LH & RH) : When Turn signal
switch is turned to Left or Right, Turn pilot indicator LH
or RH will flash.
4. Hi Beam Indicator : When Headlight is ‘ON’ & Hi beam
is selected with engine running, Hi beam indicator will be
lit.
5. Fuel Level Indicator : It shows available fuel in fuel
tank.
6. Neutral Indicator : It illuminates when transmission is
in Neutral & Ignition switch is ‘ON’.
7. Steering cum Ignition Switch : Key operated switch
for Ignition ‘ON’/‘OFF’ & locking handle bar.
1
2
3
4
5
6
3
7

Location of Parts
9
Left Handle Bar Switches
A. Dipper Switch : When headlight is ON, High
or Low beam can be selected with the dipper
switch. Hi beam indicator light located on
Speedo console will light up when high beam is
selected.
: 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 flashing, push the switch in and release.
C. Horn Button : ( ) Press horn button for
sounding horn.
D. Pass Switch : Press the switch to flash the
head light. It is used to give signal to
vehicles coming from opposite side while
overtaking.
A
B
C
D

Location of Parts
10
F. Starter Button : Electric starter operates
only when the vehicle is in neutral position. Self
start is not possible in gear engaged mode.
Right Handle Bar Switches
E. Head Light Switch : It has 2 positions.
: All lamps 'OFF’.
: While engine running, Head lamp,
Tail lamp & Meter lamps ‘ON’.
E
F
USB Mobile Charger
• Mobile charging facility using USB cable
CAUTION : Do not charge mobile in
engine-off condition. This may lead to
Battery getting d ischarged.
Mobile should be charged in engine
running condition.

Location of Parts
11
Fitment of Side Cover LH
• Match & insert the Lug C (rear side) in
bracket mounted on chassis & slide ‘Side
Cover’ LH toward rear side.
• Match ‘B’ lug provided on front side of side
cover with hole provided on fuel tank & press
side cover inside.
Removal of Side Cover LH
• Insert the key into the cover lock (A) and
turn the key clockwise.
• Hold the cover with both hands and pull
front side (B) first & slide rear side (C)
toward front side. Take out ‘Side cover LH’.
CAUTION : Remove cover as described
above, otherwise cover lugs may break.
A
B
C
CAUTION : Ensure tool kit is fully
inserted in tool kit slot.

Location of Parts
12
Fitment of Side Cover RH
• Match rear side (C) of ‘Side Cover’ lug with
hole located on chassis & press the cover.
• Match the Lug provided on front side (B) of
‘Side Cover’ with hole provided on ‘Fuel Tank’
& press ‘Side Cover’ inside.
• Match ‘Side Cover’ properly with bracket
provided on ‘Chassis’ & fix it with Screw (A).
CAUTION : Fit cover as described above
to ensure proper fitment.
Removal of Side Cover RH
• Remove the screw (A) given on ‘Side Cover’.
• Hold the cover with both hands and pull
front side (B) first & rear side (C) later. Take
out ‘Side cover’.
CAUTION : Remove cover as described
above, otherwise the lugs may break.
A
B
C

Location of Parts
13
Removal of Seat
• Remove 2 nos. M5 Allen bolts provided for
fixing of seat on LH & RH sided with M5
allen key.
• Lift the seat from rear side & pull it toward
rear side.
Fitment of Seat
• Match & insert the bracket ('1' of Fig. 'B') of
seat with slot ('2' of Fig. 'B') provided below
fuel tank rear mounting on chassis.
• Push seat towards fuel tank and align lugs
('3’ & ‘4’ of Fig. ‘B') with bracket on chassis
& tighten 2 nos m5 Allen bolts in LH/RH
side.
Fig. B
Fig. A

Location of Parts
14
Tool Kit Location
Make of Battery may differ from vehicle to vehicle
Tool Kit Location
• It is located below the battery box.
• If tool kit is not inserted properly, then it
may obstructs LH cover fitment.
Battery
• It is located inside the ‘Side Cover’ LH.
• Always maintain electrolyte level in each cell
between Max. & Min. level marks.
CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may lead
to damage of electrical / electronic
components.
CAUTION : Ensure tool kit is fully
inserted in tool kit slot.

15
• Keep throttle completely closed, press
starter button “ ” / apply kick to start the
engine.
Starting The Engine :
• Turn the fuel tap knob to ‘ON’ or ‘RES’
position.
• Turn ignition switch key to ‘ON’ position.
• Confirm that transmission is in neutral.
• If the engine is cold or when starting for
first time, use manual choke for quick
starting. Choke lever is located on RH side
of Carburettor.
Caution : Do not operate the starter
continuously for more than 5 seconds
otherwise battery would get discharged.
Wait 15 sec. after successive 3 cranks,
which will facilitate battery to recover.
• Release starter button / kick lever as soon
as engine starts.
• When the engine is warmed up enough to
idle without using choke, return the manual
choke lever to OFF position.
Note : Do not let the engine idle longer than 3
minuets otherwise it will overheat.
Manual Choke
OFF Position ON Position
How to Ride Your Bike

16
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.
Warning : When shifting down to lower gear,
do not shift at such high speed that engine
rpm jumps excessively. This may cause
engine damage, and rear wheel may skid.
Moving Off :
• Check that Center/Side stand is up.
• Depress the clutch lever.
st
• Shift into 1 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 it from stalling.
Gear shifting
pattern
Shifting Gears :
• Close throttle & depress the clutch.
• Shift into next higher or lower gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
How to Ride Your Bike

17
• Never lock the brakes, or it will cause the
tyres to skid. When cornering, use brakes
judiciously and do not de-clutch. Reduce
your speed before you get into the corner.
F o r e m e r g e n c y b r a k i n g , d i s r e g a r d
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.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle
may fall over.
Proper running-in is important for the better life
and trouble free performance of the vehicle.
• During first 2000 kms running-in period do
not exceed following speed limits.
• 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 workup into the engine.
Kms 1st 2nd 3rd 4th 5th
0 - 1000 10 20 30 35 45
1000 - 2000 15 30 40 45 55
Running IN
How to Ride Your Bike