Bajaj Auto Chetak User manual

Owner’s Manual & Service Records

Owner’s Record
Name :
Vin # :
Chassis # :
Engine # :
Date Purchased :
Dealer :
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. The essential features
of the type described and illustrations
herein remaining unaltered, Bajaj Auto
Limited reserves the right to carry out at
any moment, without being obliged to
bring this booklet up-to-date, modifications
on the vehicle, parts or accessories as
may be convenient and necessary.

Delivery Certificate
Customer’s Name :
Address :
Date Purchased :
Dealer :
To be removed & retained by dealer.
To REMOVE - TEAR HERE

Delivery Certificate
•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.
•I understand that my warranty claims, if any, will be
considered by the manufacturers only in accordance with
the scope & limits of the warranty as laid down in the
Warranty Statement.
Place :
Date : Customer’s Signature
Vin #:
Chassis #:
Engine #:
To be removed & retained by dealer.

Pre Delivery Inspection
lCheck and correct tire pressure including that of Spare Wheel.
lCheck and tighten nuts for front/rear shock absorber bolts, engine foundation bolts, handle bar lock
bolt and front/rear wheel nuts.
lCheck transmission and engine oil level and top up if necessary.
lCheck for smooth operation of accelerator and choke operation.
lCheck and adjust Steering column for loose/tight.
lInitial charging of battery, Install, connect and apply petroleum jelly on terminals.
lCheck and adjust engine idling.
lCheck steering/ignition lock, luggage box lock, seat lock, and tool box lock for proper operation.
lCheck all lights, horn, switch, speedometer and fuel gauge operations for satisfactory working
condition.
lCheck for smooth operation of fuel cock lever.
lCheck front/rear brakes for effective working condition.
lTest drive the vehicle.
lRepair any other defects seen or observed during test drive.
lClean the vehicle before delivery.

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. Even a small amount of normal leaded gasoline will
damage the catalyst and make the catalytic converter completely ineffective.
2. Never tamper with the catalytic converter, which is installed inside the silencer assembly.
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, with subsequent
serious injury to you and serious damage to your scooter.
4. If the engine misfires or appears to have any loss of performance, immediately take your scooter to
your local Bajaj Dealer.

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. To ensure a long, trouble free life of your vehicle, give it proper care and maintenance as
described in this manual.
It is important to regularly inspect and maintain your scooter for safe and optimum performance. Regular
inspection and service is required to maintain your warranty. The warranty period for this scooter is 12
months or 6,000 miles, whichever comes first. See the service record pages in this booklet for the required
service and inspection intervals.
Entrust the maintenance and repairs to the authorized Bajaj Dealers, who are well equipped with
necessary facilities and are specially trained on BAJAJ CHETAK 4 STROKE .
In case you need detailed information about your vehicle, the Service Station Manual is available from
authorized Bajaj Dealers. In the rare event of a problem with your vehicle, please write to Bajaj USA,
giving details like engine number, chassis number, date of purchase etc.
Hello !

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

Engine Number Chassis Number VIN Number
Identification Data and Vehicle Identification 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. It is a crime in all states to alter the
vehicle identification number. Also, the alteration of any of these numbers will
immediately void your warranty.
1
# 022809082AD72233 #

Technical Specifications
Engine : 4 stroke, single cylinder, forced air cooled, spark ignition
3
Engine Displacement : 145.45 cm
Max. Net Power : 9.00 HP at 6000 r/min of engine
Ignition System : Electronic ignition (C.D.I.)
Spark Plug : Champion : PL 7 YC (To be used with resistor spark plug cap)
Lubrication : Wet sump forced lubrication
Transmission : 4 speed gear box
Front & Rear Brakes : Mechanical expanding shoe type
Fuel Tank Capacity : 1.32 Gal. (5.00 litres)
Electrical System : 12V D.C.
:Head lamp : 35/35W Tail/Stop lamp : 5/21W
Side indicator lamp : 10W Horn : 12V D.C.
Curb Weight : 253 lbs/115 kg
Max Speed : 55 MPH/90km/h with single rider
Note: The above information is subject to change.
2

3
2 3 4
6
7
8
1
9
5
11
10
ENGINESTOP
5
6
3
4
1
2
R
F
20
30
4050 60 70 80
10
0
00111
MILES
MIPH
N
Location Of Controls / Speedometer / Rear View Mirrors
Handle Bar
Speedometer
1. Clutch Lever
2. Mirror LH
3. Speedometer
4. Mirror RH
5. Luggage box lock
6. Fr. Brake Lever
7. RH Switch
8. Steering Lock / Ignition Switch
9. LH Switch
10. Accelerator
11. Gear Shifter
1. Hi-Beam Indicator
2. Turn Signal Indicator
3. Speedometer
4. Odometer
5. Fuel Gauge
6. Neutral Indicator

4
The Steering Lock / Ignition Switch is located on the right hand
side below the handle bar. It has three positions.
To Lock the Steering
•Turn the handle bar to the left. (Steering will be locked only
when handle bar is in left position.)
•With the key in OFF position and turn it to the lock position.
•Take out the key.
Key Position
LOCK
OFF
ON
Function
Steering locked
Ignition OFF
Steering unlock
Ignition OFF
Ignition ON
Key Removal
Key can be removed
Key can not be removed
Steering Lock / Ignition Switch
Steering Lock

Fuel Tank
Fuel Cock Position
5
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 Cock
It has the following three positions
On : When fuel level is above 0.26 gal.
Res : When fuel level drops below 0.26 gal.
Off : Fuel supply is cut off.
Warning: Never mix oil in the
gasoline. To do so can lead to
engine failure and subsequent
accident with potentially
serious injury or even death.
Use only unleaded gasoline of
research octane number 87 or
higher.
There is 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.
OFF
ON
RES

Choke Lever
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.
A
A : Tool Box Lock
Tool Box Lock :
•It is located as shown in the figure A.
•Key can be removed after locking as
well as unlocking the Tool box.
•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.
A : Choke “OFF”
B : Choke “ON”
Choke Lever
6
A : Seat Lock
A
Off
On
OFF
ON
RES
AB

OFF
AB
RUN
ENGINESTOP
ENGINESTOP
B A C
7
Right Hand Switch
AStarter switch : Press the button to start
the engine.
BSupplementary engine stop switch :
Move to the ‘Run’ position before starting
engine. Move to the ‘Off’ position to stop
engine.
Left Hand Switch
This scooter is equipped with lights that
illuminate whenever the ignition is turned on.
ATurn signal switch : Move the knob left or
right to activate turn signal. Move back
the knob to center position to OFF turn
signal.
BHorn Switch : Press to activate horn.
CHeadlight High/Low beam switch. Press
the toggle upward for high beam, press
the toggle downward for low beam.
Right Hand Switch
Left Hand Switch

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
Note:
•Rear brake liner wear can be
inspected through window on
rear brake drum by unscrewing
the plug on it.
•Front brake liner wear can be
inspected by looking at the wear
indicator on front brake actuating
lever.
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.
Failure to observe this warning can
lead to instabilities in handling and
an upset with subsequent serious
accident, injury, or even death.
Tool Kit : Tool kit is strapped (by rubber
strap) inside the Luggage box. Unlock the
Luggage box, remove strap and take out
tool kit. Refer Fig. A
Jack : Jack is strapped (by rubber strap)
inside the Luggage box. Unlock the
Luggage box, remove strap and take out
jack. Refer Fig. B
A : Took Kit B : Jack
A
B
A : Spare Wheel B :Wheel Cover

9
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.
Battery
Location of Oil Filter and
Drain Bolt
Oil Filter Cleaning
•Oil filter is situated inside the bolt as shown in the figure.
•Oil filter should be cleaned in accordance with lubrication chart by an Authorized Bajaj
Dealer.
Warning : Failure to ensure that your engine has the proper amount of the appropriate
grade oil can lead to an engine seizure, with subsequent upset, serious injury, or even
death. Always ensure that your scooter has the proper amount and type of oil.

General Information
10
Engine Oil
BD
C
A : Oil Filler Location B : Oil Level Indicator C : Upper Level D : Lower Level
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
filleropening.
•Unscrew the dipstick from oil filler
opening hole and wipe it dry.
•Put the dip stick, on oil filler opening,
take out the dip stick and observe the
oil level o n i t .
•There are two marks engraved on it.
If the level is below the lower level
mark, remove the cap (A) & top up
with the appropriate quantity of
Recommended oil:
In summer :15W50 API SG +
JASO MA or
Superior
In winter :5W30 API SG +
JASO MA or
Superior
Oil capacity :1 Quart
recommende d oil up to upper level mark
If the oil level is too high i.e. Above the
upper level mark, drain some oil from
drain hole.
•Fit back the dipstick and tighten it
securely.
•Ensure that there is no oil leakage.
A
A : Cap