Bajaj Auto RE 4-stroke User Manual

Manual is about: Petrol, CNG, LPG

Summary of RE 4-stroke

  • Page 1

    User’s guide petrol, cng, lpg world’s no. 1 three wheeler.

  • Page 2

    1 2 12 11 10 6 4 3 5 7 8 9 1 clutch lever 4 stereo switch 10 tell tale indicators 11 choke lever 12 speedometer and odometer h gas mode indicator f gas level indicator g petrol mode indicator e battery charging indicator d neutral indicator c hi beam indicator b rh turn pilot indicator a lh turn pil...

  • Page 3

    Dear customer, we thank you for choosing the “ re 4-stroke ”, which would give you ‘value for money, for years’. We are sure that you will be happy with its performance. The salient features of this vehicle are dtsi engine (twin spark plug), bigger oil filter, magnetic strainer, stronger chassis & b...

  • Page 4: Warning

    Important warning / caution / note please read this manual and follow its instruction carefully. To emphasize special information, the symbol and the words warning, caution and note have special meaning. These special meaning apply except when laws or regulations require that the single words be use...

  • Page 5

    Index index 1. Before driving.............................................................. 1 2. Operating your vehicle.............................................. 41 3. Preventive maintenance............................................ 53 4. Pre delivery inspection check points......................

  • Page 6

    1. Before driving 1 1.1 locks 1.2 mirrors 1.3 handle bar and dashboard 1.4 other controls 1.5 other important parts location 1.6 identification data 1.7 technical specifications.

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    1.1 locks steering lock • steering lock is below dashboard. Steering lock operation : • locking : turn the handle bar to lh side, rotate the key in anti-clockwise direction to align the lock position, push inand rotate clockwise.After confirming the locking of handle bar, take out the key from barre...

  • Page 8

    Glove box lock: • to unlock or lock glove box lock insert the key and rotate it clockwise or anticlockwise respectively. Tool box lock: • to unlock or lock tool box lock insert the key and rotate it clockwise or anticlockwise respectively. Glove box lock lock unlock tool box lock unlock lock 3.

  • Page 9

    Side a lock is given for locking rear door. To unlock the lock insert the key and rotate it anticlockwise. To lock the door, first match the door properly with body and rotate key clockwise. Filling door locks: (petrol vehicle) for filling petrol in tank, open the lockable cover. To open the lock in...

  • Page 10

    A.Gas filling door lock : • for filling gas in tank, open the lockable cover. • to open the lock insert the key & rotate it anticlockwise. • to lock the door insert the key & rotate it clockwise. A. Gas filling door lock unlock lock 5.

  • Page 11

    1.2 mirrors mirrors outside rear view mirror: • adjust the outside rear view mirror so that you can see the rear sides of your vehicle in the mirrors. Be careful when judging the size or distance of a vehicle or other object seen in the side convex mirror. Be aware that object look smaller & appear ...

  • Page 12

    1.3 handle bar and dashboard h g petrol vehicle gas vehicle a. Speedometer and odometer b. Tell tale indicators c. Switch lh d. Switch rh e. On - off parking switch f. Mobile charger socket g. Hazard switch h. Stereo switch i. Selector switch j. Choke lever h c i f d b j a e g 7.

  • Page 13

    1.3 a & b. Speedometer & indicators petrol gas 1. Battery charging indicator 2. Lh turn pilot indicator 3. Rh turn pilot indicator 4. Hi beam indicator 5. Neutral indicator 6. Petrol mode indicator 7. Gas mode indicator 8. Gas level indicator 6 8 3 4 2 5 1 7 8.

  • Page 14

    1 . Battery charging indicator : this light will glow when the ignition switch is switched “on” and will go off after starting of the vehicle. If this indicator glows continuously even after starting of vehicle, then battery is not getting charged. In this case immediately take the vehicle to distri...

  • Page 15

    5 n 6 4. Headlamp hi-beam : when the headlamp hi-beam is on this indicator will glow and give indication to the driver. 5. Neutral : indicator light will glow as the ignition switch is switched “on”, provided the vehicle is in neutral gear. The light willgo off as soon as the gear is engaged. This h...

  • Page 16

    7. Gas mode indicator: this indicator glows when ignition key is turned “on” and gas selector switch is at cng/lpg mode as applicable. 8. Gas level indicator : led lamps in tell tale indicator shows the gas level in tank. Whenever tank is full all led lamps will glow. One by one lights will go off a...

  • Page 17

    1.3 c. Switch lh switch l.H. A. Side indicator switch : it has 3 positions. Center : all side indicator lights remain “off”. Lh : front and rear, lh side indicator lamps and lh turn pilot indicator will flash simultaneously. Rh : front and rear, rh side indicator lamps and rh turn pilot indicator wi...

  • Page 18

    Switch r.H. • with on/off switch on position a. Light switch : it has following positions 0 : head and pilot lights “off”. 1 : parking, & tail lamps will be “on”. 2 : head, tail, and parking lamps will be “on” hi beam indication will be “on”, if switch is in high beam position. B. Wiper motor switch...

  • Page 19

    Ignition parking switch • it is located on the dash board. • insert the key & rotate it clockwise to make it on. • it has 4 positions : off : all electrical circuits “off”. On : all electrical circuits “on” except parking & hazard circuit. Parking : parking light and hazard operation willcome on (wh...

  • Page 20

    A. Hazard warning switch: in case of emergency , this switch is to be operated. It will switch on all 4 indicator lights simultaneously and both turn pilot indicators will blink simultaneously. Key switch should be in on or parking position to operate hazard switch. B. Stereo switch : a switch is pr...

  • Page 21

    Selector switch : it is mounted on dashboard. Selector switch has been provided on the front face which controls gas and petrol supply. It has 3 positions. 1. Gas : the vehicle will run on gas i.E. Lpg/cng 2. Off : both gas and petrol solenoids will be off. 3. Petrol : the vehicle will run on petrol...

  • Page 22

    1.4 other controls 17 other controls 1.4 a. Parking brake 1.4 b. Brake pedal 1.4 c. Clutch lever 1.4 d. Reverse lever.

  • Page 23

    Never drive your vehicle with the parking brake on, rear brake effectiveness can be reduced. Due to overheating, brake life may be shortened or permanent brake damage may result. If the parking brake does not hold the vehicle securely or does not fully release, have your vehicle inspected immediatel...

  • Page 24

    B a pull the lever to apply press the button to release always apply parking brakes fully before leaving your vehicle or it may move causing injury or damage , especially on gradients. When parking, shift the vehicle into first gear (when vehicle is parked on uphill) remember that even if transmissi...

  • Page 25

    Brake pedal : vehicle is provided with hydraulic brake system. Brake is operated by pedal mounted on rh side of scudo. If brake squeal is excessive and occurs each time the brakes are applied, you should have the brakes checked by an authorized distributor / dealer. Do not “ride” the brakes by apply...

  • Page 26

    If water gets into the brake drums, brake performance may become poor and unpredictable. After driving through water or washing the underside of the vehicle, test the brakes while driving at a slow speed to see if they have maintained their normal effectiveness. If the brakes are less affective than...

  • Page 27

    1.4c- clutch lever clutch lever: clutch is operated by hand lever located on lh side of handle bar. Caution do not drive with clutch lever in pressed condition. It could result in excessive clutch wear, clutch damage, or loss of engine braking and drop in fuel efficiency. 22.

  • Page 28

    1.4d- reverse lever 23 reverse gear : for engaging reverse gear - • change to neutral, stop the vehicle with engine idling. • pull the reverse gear lever. • press clutch lever. • engage transmission into first gear. • release the clutch lever slowly and open throttle to set the vehicle in motion. Re...

  • Page 29

    1.5 other important parts location 24 1.5 a. Petrol tank 1.5 a1. Fuel cock 1.5 b. Battery0. 1.5 c. Spare wheel 1.5 d. Mobile charger socket & water bottle holder 1.5 e. Air filter 1.5 f fuel filter 1.5 g. Fuse box 1.5 h. Oil cooler 1.5 i. Cylinder & refueling lpg 1.5 j. Cylinder & refueling cng.

  • Page 30

    1.5 a. Fuel tank a. Fuel tank (petrol vehicle) • fuel tank is mounted on rear rh side. • fuel tank capacity is 8 litres including reserve of 1.5 litres. B. Petrol tank (limphome facility) for gaseous vehicles • petrol tank is mounted on rear rh side. • petrol tank capacity is 3.0 litres. A. Fuel tan...

  • Page 31

    1.5 a1. Fuel cock fuel cock: fuel cock knob is located near driver seat. Fuel cock is operated by this knob. It has 3 position. On : fuel level is above 1.5 litre res : fuel level drops below 1.5 litre off : fuel supply cut off. On off res petrol vehicle 26.

  • Page 32

    1.5 b battery battery (12v ,32ah) • it is located on rh side of driver seat. Batteries produce flammable hydrogen gas. Keep flames and sparks away from the battery or an explosion may occur. Never smoke when working in the vicinity of the battery. When checking or servicing the battery, disconnect t...

  • Page 33

    1.5 c spare wheel spare wheel • location of spare wheel is under driver seat. • remove 2 bolts of driver seat frame • tilt the driver seat frame to handle bar side • to remove spare wheel, remove the 2 nuts securing the spare wheel 28.

  • Page 34

    1.5 d mobile charger, water bottle holder mobile charger socket waterbottle holder b b a a. Mobile charger socket : • mobile charger socket is on dashboard . Mobile can be charged in key off condition, key on position and parking position. B. Water bottle holder : • water bottle holder is provided f...

  • Page 35

    Air filter: air filter is used to provide clean air to engine. It is located on body near engine. 1.5 e air filter air filter 30

  • Page 36

    1.5 f fuel filter fuel filter : fuel filter is given to provide clean fuel to the engine. It is in between fuel pipes from fuel tank i) to carburetor in petrol vehicles. Ii) to solenoid in gas vehicles. Fuel filter (petrol vehicle) fuel filter (gas vehicle) 31.

  • Page 37

    1.5 g fuse box fuse box : a) main fuse box : fuse box is mounted on electrical unit plate below dashboard at lh side 2 spare fuses (one of 10a & another of 30 a) is provided in a fuse box cover. B)battery fuse box : mounted on battery mounting bracket. Warning battery fuse a b always be sure to repl...

  • Page 38

    1.5 h oil cooler oil cooler • engine is fitted with oil cooler which helps to control the engine temperature and subsequently enhance the life of engine parts. 33.

  • Page 39

    A. Lpg cylinder : it is mounted below passenger seat. B. Multifunction valve : it is mounted on lpg cylinder. It is an assembly, mounted on lpg tank for filling tank and withdrawal of lpg along with safety devices. C. Shut off valve : this shut off valve is to be closed when vehicle is parked for lo...

  • Page 40

    D. Refilling valve : to refill the cylinder with lpg, open the valve (d) and insert the lpg filling gun inside refilling unit. Fill the lpg into cylinder. E. Lpg solenoid valve : this valve gets operated when ignition switch is in ‘on’ position and selector switch is in gas mode. 1.5 i cylinder refu...

  • Page 41

    A. Cng cylinder : it is mounted below passenger seat. B. Pressure gauge : it is mounted on remote filling valve which indicates pressure inside the cylinder . C. Dust plug : it is mounted on remote filling valve and is used for refilling the gas. Please ensure that dust plug is properly fitted. Ensu...

  • Page 42

    Refueling : refueling isdone via remote filler valve a dust plug is provided in this unit. When only 'r' lamp glow on gas level indicator refueling should be done. To refill the cylinder with cng gas, open the lockable door provided at rh side of body as shown in fig. Remove dust plug and fill the g...

  • Page 43

    The chassis and engine serial numbers are used to register the vehicle. They are the only means of identifying your particular vehicle from others of the same model and type. 1.6 identification data chassis number location - at front on dashboard . Engine number location - on rh side crank case. 38 ...

  • Page 44

    1.7 technical specification engine : 4stroke, ignition, forced air cooled. Bore x stroke : 63.5 mm x 62.8 mm 3 engine displacement :198.88 cm max. Net power as per is:14599 petrol lpg cng 8.10 kw at 7.60 kw at 7.25 kw at 5000+250 rpm 5500+250 rpm 5500+250 rpm max. Net torque as per is:14599 petrol l...

  • Page 45

    1.7 technical specification 40 electrical system : 12 v dc battery : 12v 32 ah head lamp : 35/35 w pilot lamp : 5 w tail / stop lamp : 5/21 w or 5/18 w side indicator lamp : 10 w horn : 12v dc reverse lamp : 10 w pilot lamp : 5 w vehicle weight : petrol lpg cng kerb wt 348 kg. 368 kg. 389 kg. Max.Wt...

  • Page 46

    2. Operating your vehicle 41 2.1 daily safety checks 2.2 safe driving tips 2.3 fuel saving tips 2.4 running in 2.5 starting and driving.

  • Page 47

    2.1 daily safety checks before starting the vehicle, it is recommended to do following checks.: make sure that mirrors, lights and reflectors are clean and unobstructed fuel : enough fuel in tank. Check fuel pipes for cracks/leakage. Replace if found defective. Electrical : operating of all tell tal...

  • Page 48

    2.2 safe driving tips driving on slippery roads : on rainy days, "aquaplaning" can occur. It is loss of direct contact between road surface & vehicle tyres due to water film forming between them. Steering or braking during aquaplaning can be very difficult, & loss of control may occur. Maintain low ...

  • Page 49

    1 ride smoothly and steadily at an optimum speed of 30 40 kmph 2 change the gear judiciously according to the speed requirement. 3 avoid following • sudden acceleration and frequent / sudden braking. • driving with foot on brake pedal. • driving with partial disengaging of clutch (half clutch). • ov...

  • Page 50

    • during first 2000 km running-in period do not exceed following speed limits. Gear 1st 2nd 3rd 4th speed km/hr 10 15 25 35 • always keep within the specified running in speeds. • do not race the engine excessively. • do not start moving or race the engine immediately after starting. Run the engine ...

  • Page 51

    Starting the engine • turn ignition switch key on • ensure that vehicle is in neutral gear, by confirming the neutral lamp in tell tale indicator is lit. • check tell tale lights for battery charging indicator in tell tale indicator is lit. • use ignition switch key to start the vehicle. • wait for ...

  • Page 52

    Moving on : • when the engine has started battery charging, indicator should go off. • release parking brake. Press the clutch. • shift into first gear. • open the throttle a little, and start to release the clutch very slowly. • as clutch starts to engage, open the throttle a little more, giving th...

  • Page 53

    Shifting gears : • close the throttle while pressing the clutch. • shift into the next higher or lower gear. • open the throttle partially, while releasing the clutch. 48.

  • Page 54

    Reverse gear : for engaging reverse gear - • change to neutral, stop the vehicle with engine in idling condition. • pull the reverse gear lever. • press clutch . • engage transmission into first gear. • release the clutch pedal lever and open throttle to set the vehicle in motion. Reverse gear lever...

  • Page 55

    To run vehicle on gas mode : • put ignition switch to “on”. • put selector switch on gas mode. • crank the engine. • sometime it is required to open the throttle slightly. Still vehicle if does not start, it is likely that vehicle is flooded with gas. Put the switch in ‘off’ position. Crank the engi...

  • Page 56

    To run vehicle on petrol mode : • put selector switch in petrol mode. • wait for some time for filling of the carburettor bowl. • crank the engine. Important tips for ‘cold starting’ for easy ‘cold starting’ i.E first time in the morning or after 3 or 4 hours of parking when the engine becomes cold,...

  • Page 57

    Stopping the engine : • close the throttle completely. • shift the gear to neutral. • turn the ignition switch to “off” position. I gnition / parking switch 52.

  • Page 58

    3. Preventive maintenance 53 index 3.1 periodic maintenance chart 3.2 periodic lubrication chart 3.3 engine box oil - checking / replacement 3.4 differential oil - checking / replacement 3.5 recommended oil grade and quantity 3.6 air filter cleaning procedure 3.7 battery 3.8 wiper motor 3.9 drive sh...

  • Page 59

    3.1 periodic maintenance chart 1. Vehicle washing & cleaning cl cl cl cl cl cl cl cl 2. Clean/replace air filter element cl cl cl cl cl cl cl cl replace after every 40,000 km 3. Clean/replace breather tube filter cl cl r cl r cl r cl replace after every 10,000 km 4. Check all lights for working c,a ...

  • Page 60

    3.1 periodic maintenance chart 55 1. Check gas leakages c,a,r c,a,r c,a,r c,a,r 2. Replace gas filter element solenoid cng r r r replace after every 10,000 km 3. Check gas filter hpr cng, replace if required c,r replace if required 4. Clean gas regulator cl open power valve 5. Replace all rubber com...

  • Page 61

    3.2 lubrication chart 56 1. Replace/top up gear box oil replace* r t r t r t r t replace after every 10,000 km. Top up at every 1000 km 2. Replace/top up differential oil t r t r t r t replace after every 10,000 km 3. Grease steering races, balls l l l after every 10,000 km 4. Grease front suspensio...

  • Page 62

    Engine oil level checking procedure : • park the vehicle on level surface to check the oil level. • remove the dip stick & wipe it clean. • insert the dipstick tighten it till the face ‘r’ rest completely on the seating face of clutch cover. • remove the dipstick & check the oil level. • this should...

  • Page 63

    Oil replacement : replace oil as per lubrication chart. For replacing engine oil : • run the engine for about 10 minutes to warm up the oil • place the vehicle on a level ground so that the oil settles down • remove oil drain plug. Let the oil drain completely • tighten the drain plug • remove oil f...

  • Page 64

    A. Oil strainer cleaning • oil strainer is situated inside the plug as shown in the figure. • oil strainer should be cleaned in accordance with periodic maintenance chart. B. Oil filter • replace the oil filter element assembly at every 10, 000 kms. Ensure engine oil level confirms to maximum level ...

  • Page 65

    Differential oil level checking procedure: place the vehicle on a level ground. – let the oil settle for a few minutes. – remove differential oil level bolt. – the oil level is correct, if oil just starts flowing out when bolt is removed. If oil is not flowing out i.E. Less oil level top up with spe...

  • Page 66

    Oil replacement : replace oil as per lubrication chart. For replacing differential oil : • run the engine for about 10 minutes to warm up the oil. • place the vehicle on a level ground so that the oil settles down. • remove oil drain plug. Let the oil drain completely. • tighten the drain plug. • re...

  • Page 67

    3.5 recommended oil grade and quantity lubrication replace the oil in accordance with periodic maintenance chart. Recommended oil grade quantity engine oil bajaj dts-i 10000 4t premium engine oil 1600 ml. Differential oil bajaj dts-i 10000 4t premium engine oil 320 ml. Note • • it is most important ...

  • Page 68

    Air filter cleaning : • open clips of air filter assembly. • remove air filter element. • clean the air filter element by blowing air jet from inside & tapping the element on ground. • clean air filter housing by air jet and wipe it clean. • assemble the air filter element in the housing, fix the cl...

  • Page 69

    3.7 battery battery (12v 32ah) • check and ensure that the electrolyte level is between the upper (max) and lower (min) level in each cell. • if electrolyte level is below lower level in any cell, top up to upper level with distilled water only. • check battery terminal voltage and sp. Gravity. Char...

  • Page 70

    3.8 wiper motor wiper motor : • self parking feature is provided in the wiper motor. Wiper blade will rest in extreme left position. (when viewed from inside the cabin). Wiper motor before washing vehicle, wrap the wiper motor with polythene sheet to prevent water entry. Warning 65.

  • Page 71

    3.9 drive shaft slider block propeller shaft greasing do the propeller shaft greasing at every 5000 kms. Use only following recommended grease for greasing the propeller shaft. Hindustan petroleum - ap3 castro/ volvotine - nlgi-3 indian oil - servo rr3 bellows of propeller shaft should be kept in go...

  • Page 72

    3.10 brake oil brake oil container : brake oil container is located on master cylindernearbrakepedal. Check the brake fluid level by looking at the reservoir. Check that the fluid level is between the “max” and “min” lines. If the brake fluid level is near the “ min” line, fill it up to the “max” li...

  • Page 73

    Brake oil • it is advisable that the brake fluid should be replenished at least once in a year. We recommend following brake fluids. Marketed by type of oil hindustan petroleum hp super duty brake fluid dot-3 indian oil corporation servo brake fluid super hd bharat petroleum bharat heavy duty brake ...

  • Page 74

    3.11 free play free play for : a. At brake pedal : 10-15 mm b. At clutch lever : 4-5 mm c. Accelerator grip : 2-3 mm d. Choke cable : 2-3 mm (at engine end) e. Spark plug gap : 0.6-0.8 mm 69.

  • Page 75

    3.12 tyre rotation tyre rotation : the wheels are interchangeable provided they are correctly inflated. To even out tyre tread wear it is recommended to rotate it after every 5,000 km and inflate it to the specified pressure. The best tyres should always be kept at the rear wheels which are driving ...

  • Page 76

    3.12 tyre rotation tyre pressure : keep appropriate tyre pressure as mentioned below to increase life of the tyre and for better fuel consumption. 2 front 2.1 kg/cm (30 psi) 2 rear 2.4 kg/cm (34 psi) tyre size : 4.00 - 8, 4/6 pr (all four tyres) correct traction optimum handling optimum tyre life da...

  • Page 77

    4. Pre delivery inspection transit damage : check the vehicle for any transit damages. Performance: check engine oil & differential oil level and top up if necessary. Check gear shifting and clutch for proper adjustment and working. Check and adjust engine idling if necessary. Check for drivability,...

  • Page 78

    For faster response, please furnish the following details in e-mail / written communication to our distributor. • contact details (customer name & add. Ph./mob. No) • vehicle details (engine no., chassis no., registration no., make and purchase date) • selling/servicing distributors / dealers • natu...

  • Page 79

    Rev. 02, aug. 2014 doc. No. 71111882 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 at any moment without...

  • Page 80: Delivery  Certificate

    Chassis no.: engine no.: • 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. Place : date : customer's signature (to be retained by selling dealer) delivery certificate...

  • Page 81: Delivery  Certificate

    Delivery certificate date of sale : customer’s name : address : phone no. : dealer’s name : address : 77.

  • Page 82

    Use only bajaj genuine parts parts always insist on for optimum performance of vehicle for prolonged life of components & vehicle for economical maintenance cost genuinity test for rider's safety scratch hologram to find ‘genuine’ partial transparent hologram golden hologram.

  • Page 83

    Mileage safet y trust benefit export service, international business bajaj auto limited akurdi, pune 411 035 india. Www.Bajajauto.Com e-mail web-site customerservice@bajajauto.Co.In world’s no. 1 three wheeler bajaj auto limited registered & head office akurdi, pune - 411 035, india. Tel. : +91 20 2...