Bajaj Auto Boxer BM 150, User Manual

Page 1: ...User s Guide User s Guide Export Export...

Page 2: ...epairs 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 addit...

Page 3: ...s 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 necessa...

Page 4: ...ug 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 Br...

Page 5: ...ilot 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 Ba...

Page 6: ...ique 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...

Page 7: ...ock 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 Loc...

Page 8: ...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...

Page 9: ...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 S...

Page 10: ...se 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 lev...

Page 11: ...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 show...

Page 12: ...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...

Page 13: ...ode 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 cab...

Page 14: ...th 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 firs...

Page 15: ...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 Remo...

Page 16: ...ey 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 to...

Page 17: ...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...

Page 18: ...s 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 faci...

Page 19: ...hift 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 ge...

Page 20: ...ycle 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 fo...

Page 21: ...mileage is by following the full tank to full tank method Fill way tank full up to small mouth brim Run the bike for say 100 km Fill the tank full again in same fuel filling station probably with sam...

Page 22: ...while driving or riding Your helmets should conform to appropriate Indian standards Read thoroughly the instructions in this manual and follow them carefully A v o i d u n n e c e s s a r y accessorie...

Page 23: ...required to return the motorcycle to a safe operating condition Warning Failure to perform these checks every day before you ride may result in serious damage or severe accident Enough fuel level for...

Page 24: ...n Cover RH Top up with specified grade of oil if the oil level is below lower level mark Engine Oil Capacity Refill at Servicing 1000 ml During engine overhaul 1100 ml Engine Oil Level Checking Recomm...

Page 25: ...t Do not reuse drained oil Use the recommended levers while removing the Tyre Tube for puncture work This will avoid any damages to the edges scratches on paint of the wheel Tyre Pressure Keep appropr...

Page 26: ...p vehicle on center stand with handle bar in straight ahead position Always ensure that brake fluid level is above MIN mark Use only DOT 3 or DOT 4 brake fluid from sealed container to top up if requi...

Page 27: ...ff used battery It is always recommended to hand over the same to Authorised battery Bajaj Dealer for proper disposal How to keep battery healthy Switch Off ignition when engine is not running Get bat...

Page 28: ...pion PRZ9HC or Bosch UR4AC 0 7 to 0 8 mm Drive Chain Slackness Chain top edge to be kept between the two marks during chain slackness adjustment Care should be taken that the chain should never run dr...

Page 29: ...drive chain at every 5 000 kilometers Clean the chain with nylon brush by using kerosene with the help of chain cleaning machine After cleaning dip chain in SAE 90 oil lubricate in molten grease of c...

Page 30: ...er cover O Ring Clean 5000 kms C A R R R R R Engine idling speed CO SAE 20W50 API SL JASO MA2 Replace 5000 kms A A A A A A A A Valve tappet clearance A A A A A A A A CL CL CL C A C A R C A Replace eve...

Page 31: ...ssly Check funtionality leakage or any other damage Replace every 15000 kms C Clutch lever free play C A C A C A C A C A C A C A C A Throttle grip play CL CL R CL Master cylinder cup dust seal Caliper...

Page 32: ...C A C A C A C A C A C A C L R C L R C L R C T C T C T C T C T C T C T C T C T C T C T C T C T C T C T Cylinder hear decarbonizing valve lapping Replace valve oil seals CL Clean every 15000 kms 28 CL...

Page 33: ...ion L L 34 35 36 37 38 C R C R C R C R C R R CL CL CL L L L L L L L Lubricate every 20000 kms 30 It is strongly recommended to use only recommended grade of oil As applicable to model More frequent cl...

Page 34: ...ls are raised off the ground Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or brake liners Lubricate the control cables Cover entire vehicle neatly Mak...

Page 35: ...Use only Bajaj Genuine Parts...

Page 36: ...Bajaj Auto Limited Akurdi Pune 411 035 India Tel 91 20 27472851 Fax 91 20 27407385 www bajajauto com...