UJJWAL MAURYA

Typewritten Text

By : UJJWAL MAURYA

-~-- ~·- ... - . . --

· aJ!qo{~RRESPONDE~CE RELA:fiNG ·· \ ~ 00 ~n wwmrr ;f; fuD: TC,I:t ~VICE ~1P:2~ '1EMS M.A. Y PLEASE

1 BATTERY WA RRANTY_CAnt) f MAKE OF BATtERY: EXIDE /AMCO/ GERMANIA -~

BE ADDRESSED TO :

SERVICE DEPARlMENT BAJAJ AUTO LIMITED

AKURDI, PUNE - 41 1 035 INDIA

NOTICE

The description and illustration in this booklet are not to be taken as binding on the manufacturers. The essenfRI features of the type descnbed and ill ustrated he rein remaining unaltered Raj. i auto lim ited reserve the right to carr{ out ~i anv moment without being obliged t~ br"o~J this booklet up-to-date, rnodifi ..::J tions on .~::: vchcle, parts or accessories as may bE" · : nvP ''3nt and necessary .

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'l MFG. CODE Or BATTERY: '-- - - ---- I Sll N! I I / TYPE OF BATT

!NAME OF OWN

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,1 CHASSIS NO

flY : .......

R AND Al llll ll SS:

,' SERVICE Rl COIUJ

DATL 0 1 t.AII

REG. NO.: ... .. .... ..

ENGINE NO. : ... .. .. .. ..

t~to I AIJU I t•tHu:ilh , .~ Mth:l umvlty

VollllfiO I Remarks Dealer's Stamp ·cotlu I I /'( II III '"' ,, .. ,,,,.,~.

& Signature 1 I. 111111 "'"' li11lyln luv"l

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iJOC NO. 36 02 01 43

NOTt;~ ? are ha~ been t.a l,~n \\ e t,: ·,s lating ~nglish version into Hindi version 1151 I I I I I I I BC : Hrukon t:onldtti!Jr

bu< st 11l m case 1f any dispute oout mteq::)rl!tatlon of any word/s or sentence/s 1

6 I arisc:!s, the English version shall prevail over the Hindi version. IL PM : Poor rnwnl cnance _ ___ _______ , _ _ __ ,_ 1:fl NOTE :"Service Record" must be filled b re . . BA: Baltery abused

REV.N O. 01 , FEB . 99 specified maintenance for easy s:ttl spectlvfe a~th~nsed battery dea ler as proof of ement o cla1m. 1f ''" V·

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TO BE FILLED IN BY BATTERY DEALERS I DISTRIBUTORS I BAL DEALERS( For Germania! IN CASE OF CLAIM

Name of dealer & code

Date of Claim .. ...... ... ....... ......... ...... .... ......... Battery

Serial No .. .. .. .... ..... ... ..... ... .... ...... ... ... ... .. ........ Date of fitment .. .............. ......... ... ... .. .... ......... ..... ....... .

Failure Mode (Please tick as applicable)

• Loose connection e Overcharge I Undercharge

• Internal Short • Sulphation

• Plate shedding • Reverse Charge

• lntercell connection • High sp. Gr. electrolyte

• Does not hold charge • Electrolyte Contamination

e Wrong Assembly • Electrolyte level not maintained

e Wrong Application • Left lying idle e Terminal corroded

\ # Claim Accepted \\## Claim Rejected j

NOTE: # If the customers claim is accepted by the dealer, the details for acceptance to be tick marked and warranty card to be sent to BAL alongwith warranty claim statement and battery duly electrolyte drained and thoroughly cleaned I rinsed by water.

## If the customers claim is rejected by the dealer the details for rejection to be tick marked and warranty card to be return to customer without detaching .

Detail of Repair, if NOTE: 1) Claims related to Germania battery will be Cleared by BAL dealers.

2) Claims related to other Brands will be Cleared by their respective dealers I distributors as per their ruling warranty terms & conditions.

3) Please contact nearest respective authorised Battery dealer for details

immediately after purchase of vehicle.

STATUTORY EMISSION REQUIREMENT

EMISSION SHOULD BE CHECKED AT GOVERNMENT

AU I ttORISEO STATIONS AT

PI ~ CIFIED FREOUENGIES .

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Dear Customer,

We wish to congratulate you for choosing "BAJAJ BRAVO". Coming from Bajaj Auto, the largest 2 & 3 Wh ee lers manufacturers of India and fourth lar9.est in the world, 'BRAVO' would give you 'value for money, for years! We are sure that yoo will be proud of its performance.

.Kindly read this Qwner's Manual before riding to familiarise yourself with th mechanism and controls of the vehicle.

We offer you 3 Coupon services and 6 Pt:ud services specially programmed to keop your vehicle in perfect condition. Kindly avoil these against the Coupons contained in th booklet at our authorised dealers. Bajaj Auto offers warranty on this vehicle for a period of 12 months or 12000 kms, whichever occurs first. For details please refer to "Warranty :Scope & Limit" towards the end of the Owner's Manual.

To ensure a long, tro.uble free life of your vehicle, give it proper care and maintenance described in this manual.

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ntrust the maintenance and repairs to the authorised bajaj dealers, who are well equipped with necessary focilities and are speciolly trorned on BAJI\.J n nAVO .

SERVICE DEPARTMENT BAJAJ AUTO LIMITED

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TABLE OF CONTENTS

Description

Identification data

Technical specifications

Location of parts " General information 11

Running In 16

Periodic Maintenance Chart . . . .. . 18

Lubrication Chart 19

Service coupons and Warranty

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IDENTIFICATION DATA

The on gino and chassis serial numbers are

used to roglster the vehlclo. They are lhe

only moons of identifying your particular

vehlclo from othors of tho snme model and

type .

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Engine number ~ ~ Chassis number

~~----------------------. 1 BRAVO

TECHNICAL SPECIFICATIONS

ENGINE :Two stroke,Single cylinder

Forced air cooled. ENGINE DISPLACEMENT: 145.45 cm

3

MAX. NET POWER

8.00"HP at 5500 rpm of engine

IGNITION SYSTEM

Electronic Ignition (C.D.I.)

SPARK PLUG ( Non-Resistive)

Mico : W 7 BC or Champion : PL 7 YC (To

be used with Resistive Spark plug cap )

LUBRICATION 2 % mixture of self mixing oil and petrol

TRANSMISSION : 4 speed gear box

FRONT & REAR BRAKES

Mechanical expanding shoe type.

FUEL TANK CAPACITY

6.0 litres (inclusive of 1.5 litres in reserve)

BRAVO -

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ELECTRICAL SYSTEM : 12V AC + DC

Head Lamp . .. .. . ... .. ... .. .. ... .. .... . .... 45/40W Tail/ Stop Lamp . . .. . . ... . . .. .. . .. . . . . ... 5 11 OW Side Indicator Lamp ...... .. .... ........... 10 W Horn ................. ... .... .......... .. ...... 12V DC Battery......... ..... .... ..... ... ..... . 12V- 2.5Ah

or 12V -9Ah (For self start)

KERB WEIGHT 103 Kg. 109 Kg. (For self start)

MAX. SPEED 85 km/ hr. with single rider (68 kg )

NOTE:

e Above information is subject to change, please contact Service Dept ., for latest information.

BRAVO 3

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LOCATION OF PARTS-~ Cfif ~ ~ 3 r""" ~

'1 2

k -~'II s . ...- l!!i ~1 ~~

1) Clutch Lever ~ \~ ~ 2) Instrument panel~ ~ ~ 3) Fr. Brake Lever~ ~~'fiT~ 4) RH Switch 't ~ ~ 5) Steering cum '"\ ~ ~ ~

Ignition switch ~ ~ 6) LH Switch "') mm ~

BRAVO

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SEEDOMETER

1) Hi-Beam Indicator

2) Turn Signal Display

3) Speedometer 4) Odometer 5) Fuel indicator

4

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STEERING CUM IGNITION LOCK e Steering will be locked only when

handle bar is in extreme left position.

Key Function Key position removal

LOCK Steering locked Ignition OFF

OFF Ignition OFF

ON Ignition ON

Key can be removed

Key can not be removed

BRAVO 5

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FUEL TANK Fuel tank ~ ~ ... e lthascapacityof6.0 • ~c:~ \~

lit res including 'i,. o l>,

reserve of about 1.5 ~i!~~ 1 ~ fu:rcf litres. ( < v !l) ~111>1(1 l1 I

e Location offuel tank ! ~~i:ffi1T]yrr ffl cap is as shown in ~ ~ 'fif~~m the figure. ~.~ ~ >1 l'<<al<ll lfllT ~ I

~K:.....&V ) ~ i'rtt

FUEL COCK 11~ ~ ~ / -/ I •. ~ i'rffi; ~ e It has ~~!lowing\ V~ '~~~~~~I

three pos1t1ons. v •

ON : When fuelleve is above 1.5 ltrs. 3TTif : ~ ~ m ~ . 4. ~ <h1R men ~I RES : When fuel level drops below 1.51trs. ~ : ~ ~ m ~. 4.~ ~ men ~I OFF: Fuel supply gets cut off. 3l]q) : ~ 'TefliJ GtG ~ ~ I Red mark indicates approximately 0.9 ± 0.31itres of fuel. ~ f.mr;r - ~'fiT m ~ 0.9 ± 0.3 M ~ I Reserve indicates approximately 2.0 ± 0.31itres of fuel. ~'fiT f.mr;r - ~'fiT m ~ 2.0 ± 0.3 M ~ I Mid mark indicates approximately 3.0 ± 0.31itres of fuel. <lN 'fiT f.mr;r -~ 'fiT m ~ 3.0 ± 0.3 ~ ~ I Full mark indicates approximately 5.0 litres min. of fuel. ~ 'fiT f.mr;r -~ 'fiT m ~ 5.0 M ~ I

FUEL INDICATOR : (For AC version only) This vehicle has Fuel indicator of new design. Even when the lgn~ion switch is "OFF" the needle will not return to "E" position but will show the reading.

BRAVO 6

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(~) "E"~ l\';:r ~~mllr~ I

0 Choke "OFF"

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CHOKE LEVER

e It is located near the fuol cock lever. e Choke is required especially for cold

starting.

e The "ON" and "OFF" positions of choke lever are as shown in figure.

TOOLKIT

e It can be kept inside the luggage box.

BRAVO 7

\ A: Fuel cock 8: Choke "ON"

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e ~ fBCR ~ t!Jfr !fi 'WI&~~ I • rrr§t ~ 'fi@ mm-~: vr.r ~ ~

m- q.r ~ tt arrcnm,RIT mar ~ 1 e ~ fBCR ~ emf (ON) am-~ (OFF)

<fit 31cm.rr \ffl' RP-r it~ ~ ~ I ~f<R ·~ ~~~*t ~ ~ I

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SWITCH LH

SWITCH LH e The switch is located on left side of

handle bar.

A) Dipper switch : It has 2 positions a: For high beam. b: For low beam.

B) Side Indicator switch : It has following 3 positions

N : All 4 side indicators will remain "OFF"in this position.

L.H. : Left hand side indicators will blink. R.H. : Right hand side indicators will blink.

C) Start button : (For self start version ) Press the button to start the engine.

IJnAVO

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SWITCH RH

SWITCH RH

• The switch is located on right side o.f handle bar.

A) : Light switch : It has 3 positions. OFF: All lights "OFF". Middle : With engine running,

speedometer lamp and tail lamp will be "ON".

ON : With engine running, head lamp, tail & speedometer lamp will be"ON".

B): Horn button

BRAVO 9

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ON : ~-~ ~\ U-f BT{c,m * am:~ <fi:Or ~ mrr 1

B) : ffl 'fir Oic.f

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SEATLOCK ~~ • lnwrt the key lntothelook ba<rel. Tum • ..,\\ <tlr"""'-"itsA\lll o;m\\'l>l oil <II the key In dockWise di,ectlon th'ough .. <!lim it '

0

W!l ""' ~ aitt fu>: about 90° and lift the seat from its rear ~ ~ <fit ~ ~ I end. e fu>;<tlr"" ..,;"! ij; ~"" ~ iiR'"'

e Fodooklng the seat pmss gently the ,ea' ""' ~ "" ""' i<R: "" ou\1 ""' I end of the seat from top until it locks. · ~ aih: q~ ofTcffi -

BATTERY & FUSE BOX e ~ ( ~'< - · '<.' Ah iN< F -· • Battery ( 12V, 2.5 Ah or 12V, 9Ah-For self ~ Ah -~ ~ ~ ~) 3lh: lf<f£ ;;{lcm

~ta~) & Fuse box ( 10 A) are located ( ~ o A) ~ <iRe: ~ m ~ ~ 1

tnstde LH bonnet. -----10---------------------------

SEAT LOCK

BRAVO

GENERAL INFORMATION

LUBRICATION : • The lubrication of engine parts is attained · by 2 % of 2T oil mixed into petrol.

Self mixing 2T Oil of JASO FC I API TC grade or equivalant should be used.

GEAR BOX OIL : • Replace the oil in accordance with

periodic maintenance chart.

Recommended oil

011 capacity

SAE 20W40 of API SC/CC grade.

300 mi.

STARTING: (For self start) e Turn the fuel cock to ON/RES. position

depending upon fuel level inside tank. e Confirm that the vehicle is in neutral gear

otherwise engine will not start. • Neutral switch is fitted on gear shifter

assly for this purpose as a safety feature. e Confirm that the light switch is OFF.

BJ;lAVO

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11 ------------------------

NUETRAL SWITCH

e Turn the 'Ignition switch' and 'Engine Cut­off switch' to ON position.

e Press the Start Button to start the engine. • Release start button as soon as engine

starts. When engine is cold : e Keep the choke lever in 'ON' position. e Press the Start Button with accelerator in

completely closed position. • Once the engine warms up, close (OFF)

choke lever without fail.

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(31'Mi) ~~I

When engine is warm : e While starting warm engine, open the

accelerator 1/Bth to 1/4th and press the Start Button.

BAITERV (12V-2. 5Ah OR 12V- 9 Ah For self start) • Check the electrolyte level in each cell is

between the upper and lower level lines. • Remove the battery filler caps and fill

with distilled water until the electrolyte level in each cell reaches the upper level line.

~

• Add only distilled water to the battery. Tap water is not a substitute for distilled • water and will shorten life of the battery.

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BRAVO 13 -------------

~

SEVENTH (B) PAID SERVICE

1. Front suspension overhaul and lubrication

2. Ensure trunion freeness.

WORK IS CARRIED OUT TO MY SATISFACTION

BRAVO

Owner's Signature

WAR.RANTY CERTIFICATE : BAJAJ BRAV~

Chassis No. Engine No.

I C-:b c_ 8 f-:1> ';)_e) /2-2- I pj&- 8 8> E S5S9 I sold on the __ day of {p /111 9r.'l q from which day this warranty is applicaJie. / 1 }

' J fu I , l lA ~ f Customer's Name < ("' rr dh ~ Y>-1 ~/Y&f r J I

~(c C h.~& q'-'fi,J fY'l_dlA~~ Address "lJ lfrh C~ ' ""w

rn orJJ!P r Dealer's Name ~--=-<;;Tr"'~

; : I 11 !\ 1-~ -v--( y-fl,T V\-F] / v '-""-.: 1 '-' , ..1

Address ,

.r<L.t, SERVICE DEPARTMENT BAJAJ AUTO LIMITED

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Fig'1' ~ '~' Fig'2'

LUBlCATlON OF FRONT SUSPENSION The locations of Grease nipples and recom­mended intervals for lubrication of Front suspension by grease (HP multipuporse or

:qiVi:i'"'"'l ~· _ ~ s under.

Refer Operation Recommeded

Interval Fig. No

1 Anlidive link bUshes Every 3000

&'O'rings kffiS.

2 Needle roller bearings

Every 6000

of Front brake panel kms.

3 Bushes & '0' rings of

Every 3000

Anlidive link & hub pin kffiS.

BRAVO

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14

SPARK PLUG e ·Cioan any dirt from around spark plug

bose. Romove spark plug by using plug panner (Box 21 m.m) and clean it.

• Adjust the gap if incorrect by bending outer electrode carefully

Spark plug gap : 0.7 to 0.8 m.m

Spark plug (Non-Resistive) l\lico : W 7 BC or Champion : PL 7 YC (To be used with Resistive Spark plug cap )

TYRE PRESSURE : Koop appropriate tyre pressure as ll10ntloned below to increase life of the lyre and for better fuel consumption.

TVRE SIZE : 3.50 -10, 4PR (All three tyres)

ront 1.25 kg/cm2 (18 psi)

Rear I solo 1.75 kg/cm2 (25 psi)

with pillion 2.50 kg/cm2 (36 psi)

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ORAVO 15 --------------

RECOMMENDATIONS FOR SAFE AND PROPER FUCTIONING OFVEHICLE

1) Continued fitment of following original

parts

a) Speedometer b) Rear Reflex Reflector c) Horn d) Brake liner e) Bulbs f) Fuel tank unit

2) Please ensure functioning of following before moving the vehicle :

a) Brakes b) Horn c) Lights

3) Ensure tighting of following fastners to specified T o.rques

a) Cylinder Head b) Handle bar c) Wheel nut d) Front axle Nut

: 1.5-1 .8 kg.m : 3.2-3.8 kg.m : 2.0-2.7 kg.m : 5.0-5.5 kg.m

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---------------------22--------------------BRAVO

nt I OMMENDED CARBURETORS

M il \11 1111d Type I ASIVCS setting from fully closed position.

•jllu;o Sl 2- 0-/2_0_0+1-1_1_/4 ± 3/4 turns

I11 IUX 20/20 BE

f I UO play for : 1) Front brake lever

l1) Rear brake pedal c) Clutch lever tl) Accelerator grip

± 1/2 turns

5 mm : 10 -15mm :3 -5 mm : 4 -5 mm

lm!rf.ld 'W•M••i\ ·

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111 1/\VO \ 23 --------------

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RUNNING IN e First 2000 kms run of vehicle is designated

as running in period. The maximum vehicle speed recommended during running in-

Distance in Kms

Max. vehicle speed in gears (Km/h)

1st I lind I lllrd I IVth

0-2000 20 30 45 60

e Always keep to the specified running in speed. ·

e Do not race the engine excessively. e 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.

FUEL SAVING TIPS : Following are a few simple tips for keeping your vehicle healthy and your pocket wealthy. Good riding habits : e Ride smoothly and steadily at an optimum

driving speed of 30 to 40 Kmph. e Avoid harsh braking.

~BRAVO 16

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am: flttR iT atfU'fi'OlPTclr ( t;ffif ~ .

<tr.~. ~ '('11 I ~ u I ~ u I ~ ~ o _ ~ o o o ~ o 1 ~ o 1 ~~ 1 "'o

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f.l\4bi•1C11?1 3l'R: ~ ~ ~ I e~iftiif~ I

-------

I nge the gear judiciously according to

tho speed requirement. (j ut off the engine if you want to stop for more than two minutos.

Vehicle condition : Check all fuel lines and connections whenever your vehiclo smells of petrol. Never fill the petrol right up to the filler cap.

• Always maintain tho recommended lyre pressure and check It every week.

• Ensure that the brakes are not dragging/ binding. ·

• For keeping the engine healthy : 0 Inspect and clean the spark plug,

adjust the gap as recommended. 0 Use only the recommended self

mixing 2T oil ( 2 %) for mixing with petrol.

0 Get the exhaust system cleaned at recommended intervals to avoid clogging.

0 If there is a power loss, then contact an authorised bajaj dealer and get

0

0

0

the vehicle properly tuned.

BRAVO 17 -------------

l

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• • • • • • • • • • !J • • • • • • • • • • ~ ~

• • • • • • • • • • ~ ~ ~ • • • • • • • • •• • -,$

f~

PERIODIC MAINTENANCE CHART

SR. OPERATION

NO.

1 Servicing

2 Air fi lter element cleaning * 3 Spark plug: cleaning & gap setting

replacement Every 7500kms

4 Carburettor cleaning/overhaul

5 Decarbonising engine, silencer Every 9000kms

6 Control r<>'"'

yourvenrc1e, ·- fCJ Good riding ffg~

--

• Ride smoothly a. driving speed of ~'-

1stment

'Its, fastners

front & rear brakes

>ck absorber

lumn Every 6000kms

'yte level - Every month

, to be performed

quently in dusty areas.

RECOMMENDED ODOMETER READING (KMS)

500 2000 3500 6000 9000 12000

• • • • • • • • • • • • • • • • • •

• • • • •

• • • • • • • • • • • • • • • • • • • • • • • •

• • • • • • • •

15000

• • • • • • • • •

I

• I

• Avoid harsh braking. ---- 18 -------------

BRAVO

LUBRICATION CHAn

OPERATION I lUBRICANT TOBE USED 500

lutch/gear box oil replacement SAE20W40 • I h nko, clutch lever GREASE • GREASE

cable I GREASE I • I • GREASE - -Wnnd pivot

SAE20W40 -· 'ear shifter assly

GREASE / e ./ • II I Control cables SAE20W40

Front wheel bearings GREASE

I 0. 1 Brake actuating shaft

GREASE j_ 1 I -! • 11. Battery terminal Every month Petroleum jelly 1 e J e e . I • J • ,. ·= Indicates operation to be performed

llllfiVO 19

SR.

NO.

• *

1

2

3

4

5

6

7

8

9

10

11

PERIODIC MAINTENANCE CHART RECOMMENDED ODOMETER

OPERATION READING (KMS) .

500 2000 3500 6000 9000 12000 15000

Servicing • • • • • • • Air filter element cleaning * • • • • • • • Spark plug: cleaning & gap setting • • • • • • •

replacement Every 7500kms • Carburettor clearting/overhaul • • • • • Decarbonising engine, silencer Every 9000kms • Control cable adjustment • • • • • • • Tightening nuts, bolts, fastners • • • • • • • Clean and adjust front & rear brakes • • • • • • • Check front/rear shock absorber • • • • • • • Check/adjust stg. column Every 6000kms • • Check battery electrolyte level - Every month • • • • • • • Indicates operation to be performed

To be cleaned more frequently in dusty areas.

~~--------------------- 18 --------------------------BRAVO

-~~==~===-=-~~----------~~~--------------

LUBRICATION CHAJlT

·=-· II

til l

• J.

OPERATION

Clutch/gear box oil replacement 1 SAE 20W40

Brake, clutch lever I GREASE

Front suspension GREASE

500

• •

III: G IIM~~ I I II i ll i IIIIOMETER Ill ~I •n~'ll~ M I)

oool :~I ' I' H IIII~~~ :, 12ooo 1:oo1

II . • • • • • •

I h11111 1'111 1" 1111 , l·l Speedo gear, pinion, cable GREASE e e Steering races, balls GREASE ~ • -

+6 - I • e l .~1-.- , .

I

. ,. Stand pivot SAE 20W40

1. ~Gear shifter assly 1 GREASE / • · / • _I • II. Control cables ' I SAE 20W40

), Front wheel bearings GREASE

/0. Brake actuating shaft GREASE / 1 I 1. Battery terminal Every month Petroleum jelly •

Indicates operation to be performed

IIIIAVO 19 --------------