Training Note

RE 4S Petrol/LPG/CNG

The Training Notes are a

comprehensive training guide on

service and maintenance operations

and procedures to be followed by

service personnel at authorised service

centres and dealerships whilst attending

to the RE 4S Petrol/LPG/CNG. The

Training Note covers standard

workshop procedures, simplified for

easy learning and understanding for

service technicians worldwide.

NOTICE

All information contained in this Training Note

is based on the latest product information at

the time of publication. Bajaj Auto Limited

accepts no liability for any inaccuracies or

omissions in this publication, although every

possible care has been taken to make it as

complete and accurate as possible. All

procedures and specifications subject to

change without prior notice. The right is

reserved to make such changes at any time

without prior notice.

DOC. NO.: 71112611 REV. 00, NOV 2016

CIN L65993PN2007PLC130076

Copyright

All Intellectual Property Rights, including but

not limited to Copyright, applying to this

drawing and the information contained therein

vest solely and exclusively with Bajaj Auto

Limited. No part of this drawing may be

copied or reproduced, either in part or in full

by any means, whether mechanical or

electronic, without prior written permission of

the authorized signatory of Bajaj Auto Limited.

Bajaj reserves all rights to deal with violations

of this clause in accordance with applicable

laws.

CHAPTER

1

CHAPTER

2

CHAPTER

3

Know Your Vehicle

I Check .... I Maintain

Contents

01

15

24

Vehicle Identification

Location of Parts

Salient Features

Technical Specifications

Pre-Delivery Inspection Checklist

Periodic Maintenance Schedule

Lubrication Chart

Schedule Maintenance

Procedure for Fitment of Oil Filter on the Engine

Tools & Gadgets

Special Tools with Application

02

03

06

13

16

17

18

19

22

25

CHAPTER

Fuel System - Petrol

30

Carburetor Specifications

Working & Functions of Carburetor

Engine Tuning Procedure

- SOP Engine idle rpm setting

- SOP Carburettor tuning with CO gas analyser

Carburetor Do’s & Don’ts

4

31

32

36

37

38

CHAPTER

Fuel System - LPG

40

Carburetor Specifications

SOP Engine idle rpm setting & tuning procedure

LPG System - Working Principle

5

41

42

43

Contents

CHAPTER

Fuel System - CNG

46

Carburetor Specifications

SOP Engine idle rpm setting & tuning procedure

CNG System - Working Principle

6

47

48

49

CHAPTER

Chassis & Suspension

93

Front Suspension Dismantling & Assembling

Rear Suspension Dismantling & Assembling

Steering System Maintenance

Brake System

Precautions Tips

8

94

96

98

99

109

CHAPTER

Electricals

111

Maintenance Electrical

Electrical Checking Procedure

Electrical Circuit Diagrams

9

112

116

119

CHAPTER

7

Engine & Transmission 54

Lubrication System

SOP of Engine Dismantling

SOP of Engine Assembling

Service Limits - Engine

Tightening Torques - Engine

55

57

70

88

90

Know Your Vehicle

CHAPTER 1

Vehicle Identification

Location of Parts

Salient Features

Technical Specifications

01

RE 4S Petrol/LPG/CNG

Key Learning Points

Understanding the complete anatomy of

Vehicle

Technical Specifications and Performance

Parameter

Vehicle Salient features

02

Bajaj Auto International Business

Vehicle Identification - Maxima

Know Your Vehicle

The Engine & Chassis serial numbers

are used to register the vehicles. They

are the only means of identifying your

particular vehicle from the other of the

same model & type. These serial

numbers may be needed by your dealer

when ordering the parts. In the event

of theft, the investigating authorities will require both these numbers in addition to the model, type & any

special features of your vehicle that can help identification.

Chassis Number System

1-3 represents : World Manufacturer index

4-6 represents : Type & Variant code (TV code)

7 represents : Power code

8 represents : Production quantity code

9 represents : Check digit

10 represents : Year code

11 represents : Plant code

12 represents : Month code

13-17 represents : Chassis progressive number

MD2 A45 A Z 0 G W D 15565

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

World manufacture index

TV code

Power

code

Check

digit

Year

code

Month

code

Chassis progressive number

Plant code

Production

quantity code

Engine Number System

1-2 represents : Product code

3 represents : Production quantity code

4 represents : Plant code

5 represents : Calender year code

6 represents : Month code

7-11 represents : Engine progressive number

AZ Z W C A 00234

1 2 3 4 5 6 7 8 9 10 11

Product code

Production

quantity code

Calender

Year

code

Plant

code

Month

digit

Engine progressive number

Know Your Vehicle

1

2

1

7 8

4

2 3 9 10

5

6

1. Battery charging indicator

2. Neutral indicator

3. Oil pressure indicator

4. Petrol mode indicator

5. Gas mode indicator

Instrument Cluster

For Petrol For LPG & CNG Gas

1. Gear change twist grip

2. Clutch lever

3. Switch LH

4. Ignition switch

5. Switch RH

6. Accelerator grip

7. Stereo Switch

8. Hazard switch

9. Speedometer

10. Tell Tale Indicator Assly.

Location of Parts

4

5

3

03

RE 4S Petrol/LPG/CNG

04

Bajaj Auto International Business

Brake Pedal

• Brake operating pedal is located on right side of floor

Board as shown in figure.

Brake oil container

• It is located on chassis near & brake pedal.

• Always maintain brake oil level between upper (Max) and

lower (Min) level.

• Always use recommended brake fluid (DOT3)

Steering Lock

• Locked and unlocked positions are as shown in the

above figure.

• Steering is locked only when handle bar is in extreme left

position.

• After confirming the locking of the handle bar take out the

Key from the lock barrel.

Parking Brake

• It is located on right hand side of driver seat.

• Pull the lever in upward position so that the reverse gear

lever is “ON”

Clutch Lever

• Clutch operating Lever is located on left side of handle

as shown in the figure.

• Do not keep clutch lever in pressed condition always in

engine running condition, it will shorten the life of clutch

parts .

• Maintain correct clutch lever free play of 4~5mm.

Location of Parts

Spare Wheel

• It is located below driver’s seat.

Know Your Vehicle

Location of Parts

Reverse Gear Lever

• It is located below dashboard

• To apply the reverse gear, pull the reverse gear lever

all the way up. To release the reverse gear push the

button “B” in middle of the Lever and lower to its original

Position.

Battery

• High power, heavy duty 12V, 32 Ah battery.

• Ensure electrolyte level in each cells to be between min and max level,

as indicated on battery.

05

RE 4S Petrol/LPG/CNG

02

Salient Features

PERFORMANCE

Features

• DTS-i engine.

Advantages

• Complete combustion.

• Better throttle response.

• Less pollution.

• More mileage.

Benefits

• Powerful engine with more mileage.

Features

• Optimized air intake.

Advantages

• Maximized air passage for duct.

• Minimized dirt and dust entry.

• Minimize possibility of piston scuffing and cylinder

scoring.

Benefits

• Improve engine components life & less engine repair

cost.

Features

• Dual oil filtration system.

Advantages

• Micro level oil filtration.

• Better lubrication to engine components.

• Reduced oil drain interval.

Benefits

• Low operating cost & no brake down.

Features

• Anti judder clutch.

Advantages

• Smooth clutch operation.

• Reduce clutch burning.

• Smooth gear shifting.

Benefits

• Jerk free ride with ease in gear shifting.

Features

• Oil cooler.

Advantages

• Retains the viscosity of oil.

• Enhanced oil flow.

• Optimum engine cooling and cleaning.

Benefits

• High performance with low downtime.

Know Your Vehicle

06

Bajaj Auto International Business

Features

• Solid post spark plug

Advantages

• E nsures higher retention of the plug cap on the

spark plug, preventing it from coming off or

loosening.

• Provides a positive & distinctly fellable

click during plug cap fitment.

Benefits

• Repeated removal & fitment of plug cap does

not deteriorate its locking and retention ability.

Features

• CDI incorporates new proprietary software

optimizing engine performance in all speed and

load conditions.

Advantages

• Easy starting

• Reduced Misfiring and enhanced complete

combustion

• More Mileage.

Benefits

• Hassle free starting at all engine operating

conditions.

Features

• Revised camshaft/valve timing

Advantages

• The new revised camshaft ensures better

drivability.

Benefits

• Better low end torque enables the engine to

accelerate quickly and avoid frequent gear

changes.

To reduce the Engine oil consumption :

 ‘J’ groove added on piston skirt top

 End gap of piston ring top and ring bottom

reduced.

Salient Features

PERFORMANCE

Know Your Vehicle

07

RE 4S Petrol/LPG/CNG

02

Features

• High strength ‘Y’ frame

Advantages

• Withstand Heavy Load.

• No sagging of chassis.

Benefits

• Long life chassis resulting in low repair &

maintenance cost.

Features

• Muscular scudo

Advantages

• Aerodynamic shape.

• More leg space.

• Clean cabin look.

• Trendy exterior look.

Benefits

• A strong muscular look with more leg space.

Features

• Heightened wind shield

Advantages

• Good Visibility.

• Stylish Appearance

Benefits

• Comfortable driving with good visibility.

 Oil pressure indicator is Provided on Instrument

console for Petrol Vehicles.

 In the event of oil pressure drop or low engine

oil level the indicator glows continuously. Thus

indicating the driver to stop the vehicle and

check the cause.

Heat radiated from exhaust system is reduced by

 Double tube (pipe in pipe) construction of

complete header tube outside muffler improved

durability of entire silencer assembly .

Salient Features

PERFORMANCE

Know Your Vehicle

08

Bajaj Auto International Business

Features

• New turn indicator position

Advantages

• Reduce the Possibilities of Breakage during

Turning

• Stylish look.

Benefits

• Stylish vehicle with less repair cost.

Features

• Body flushed tail lamps

Advantages

• Compact Rear View look

Benefits

• Stylish vehicle as per customer demand.

Linear Side

Profile

Features

• Linear side profile

Advantages

• Elegant Side View look.

Benefits

• Stylish vehicle as per customer demand.

Features

• Ergonomic switches & controls

Advantages

• Ergonomic placement of Switches and Knobs.

• No interference of knobs / key with knee.

Benefits

• Comfortable driving & easy operation of the

knobs.

COMFORT & STYLE

Features

• Ergonomic handlebar position

Advantages

• Better reach to Handle bar.

• More knee clearance.

• No obstruction while turning the vehicle.

Benefits

• Fatigue reduced, can drive for more hours.

Know Your Vehicle

Salient Features

09

RE 4S Petrol/LPG/CNG

02

Features

• Quick reach brake pedal

Advantages

• No heel rest required.

• Easy accessing of Brake Pedal.

• Comfortable Sitting Posture

Benefits

• Fatigue reduced, can drive for more hours.

 Equalizer bracket welded on right hand side

main member.

 Hand lever on right side member.

 Reverse gear lever shifted to front side on Y

member (LH Side).

COMFORT & STYLE

Features

• Heightened hood pipe

Advantages

• Enhanced Head room space.

Benefits

• Stylish vehicle as per customer demand.

Know Your Vehicle

Salient Features

10

Bajaj Auto International Business

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