Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

New Product Bulletin

Product Category Motorcycle
TO: CC Group 200 to 220 cc
Bulletin No. NP:3
All Pro-Biking Dealers Date 18/09/2007

Sub: New Avenger DTS-i with 200cc engine

Dear Sirs:
We are pleased to introduce the new Avenger DTS-i with 200cc engine. Apart from upgrading the engine
from 180 cc to 200 cc this bike also has other features added to it. This increased power of the engine makes
this cruiser bike further enjoyable to ride.

The key features are as follows.

Proven 200cc DTS-i Engine.
Oil cooled engine
Fuel gauge.
Windshield (as an accessory)
We enclose following information for your reference.
Know the Technical Specifications
1. Technical Specifications Annex – 1

Understand PDI check points Periodic Maintenance related information

2. Pre Delivery Inspection Checklist Annex – 2
3. Pre Delivery Inspection - SOP Annex- 3
4. Periodic Service - SOP Annex- 4
5. Periodic Service wise – Part Kit Annex – 5
6. Periodic Maintenance & Lubrication Chart Annex – 6
7. Skill tips for Windshield Annex – 7

Know exclusive Spare Parts

8. Exclusive Spare Parts list Annex – 8

Please go through the complete information. Ask your workshop & spare parts managers to share the same
with all staff and act up on the action points as per action matrix enclosed.
Thanking You,
Yours faithfully,

Dhiraj Mullick,
Senior Manager (Service Support)
Cc to: Field Service Team / RTC team / RMs (Service) / RSMs / NSMs / Technical Service Team

Page 1 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 1
Technical Specifications No. of Pages - 1

ENGINE & TRANSMISSION CONTROLS

Type : Four stroke Natural & Oil cooled Steering : Handlebar
No. of Cylinders : One Accelerator :Twist grip on RHS of handle bar
Bore / Stroke : 67.00 mm / 56.40 mm Gears : Left foot pedal operated
Eng. Displacement : 198.80cc Clutch : Lever on LHS of H’ bar
Compression Ratio : 9.5 + 0.5 :1 Brakes: Front : Lever on RHS of H’ bar
Idling Speed : 1400 +100 rpm Rear : Pedal operated by Right foot
Max. net Power : 17.51PS @ 8000 rpm ELECTRICALS
Max. net Torque : 16.78 Nm @ 6000 rpm System : 12 Volts (AC +DC)
Ignition System : Microprocessor controlled Battery : 12 Volts 9Ah
Digital CDI Head lamp : 12 V 60/65 W ,
Ignition Timing : 100 BTDC at 1500r/min Tail / Stop lamp : 5/21W
280 BTDC at 3500r/ min Turn signal lamp : 21W
Fuel : Unleaded Petrol Turn signal pilot lamp : 3 W
Carburettor : Side Draught, Speedometer lamp : 3 W
UCAL- MIKUNI BS 29 Hi-beam indicator lamp: 1.7 W
Spark Plug : 2 nos. Champion Horn : 12 V DC
RG4HC (Resistive) Fuel gauge : 2W
Spark Plug Gap : 0.7 to 0.8 mm Fuel gauge lamp : 1.7 W
Lubrication : Wet sump, forced lubrication
DIMENSIONS
Clutch : Wet, Multi Disc Type
Length : 2195 mm
Transmission : 5 Speed Constant Mesh
Width : 750 mm
Primary reduction : 3.47 : 1 (66/19)
Gear Ratios: Height : 1070 mm
1st Gear : 26.04 : 1 (36/13) Wheel base : 1475 mm
2nd Gear : 17.67 : 1 (32/17) Ground clearance : 169 mm
3rd Gear : 12.97 : 1 (29/21) Turning circle dia : 2540 mm
4th Gear : 10.15 : 1 (26/24) Weights
5th Gear : 8.65 : 1 (24/26) Vehicle kerb weight : 154 Kg (Without windshield)
Final Drive Ratio : 2.71 : 1 (38/14) Gross vehicle weight : 286 Kg.
CHASSIS & BODY PERFORMANCE
Frame Type : Double cradle type Maximum speed : 110 Kmph
Suspension: (with single rider 68 Kg)
Front : Telescopic (140 mm Travel) Climbing ability : 28% (160 Max)
Rear : Swing arm with 5 step adjustable
SAs with triple rated spring (90mm Notes
travel) • Values given above are nominal & for guidance
Brakes: Front : Hydraulically operated disc only, 15% variation is allowed to cater for
Rear : Mech. expanding shoe & drum type production & measurement
Tyres Size: Front : 90/90 - 17, 49 P
Rear : 130/90 - 15,M/C 66 P • All dimensions are under un-laden conditions
Tyres Pressure:
Front : 1.5 Kg/cm2 (21.0 PSI) • Definitions of terminologies wherever applicable
Rear (Solo) : 1.5 Kg/cm2 (21.0 PSI) are as per Relevant IS/ISO standards
Rear (with Pillion) : 1.75 Kg/cm2 (25.0 PSI)
Rims: Front : 1.85 x 17” • Specifications are subject to change without
Rear : 2.75 x 15” notice
Fuel Tank Capacity : 14 Liters
Reserve : 3.4 Liters

Page 2 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 2

Pre-Delivery Inspection Checklist No. of Pages - 2

Following is the checklist for carrying out PDI of “Avenger DTS-i 1200cc” motorcycle. It is important to carry
out PDI checks for ensured delivery of trouble free vehicle to the customer.

Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as
per the points given below. This ensures healthy vehicle delivery to the customer

Page 3 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Page 4 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 3
Pre-Delivery Inspection - SOP No. of Pages - 3

This section of information gives clear idea on what is the right sequence for checking the vehicle before delivery.
This also indicates the time required to complete each checkpoints and overall time required to complete the PDI.

Each 'Avenger DTS-I 200cc‘motorcycle can be inspected and kept ready for delivery in 20 minutes appx. That
means 24 motorcycles can be inspected in a shift.

Checking all elements with right sequence as mentioned below will ensure trouble free delivery of new 'Avenger
DTS-i 200cc’ The objective of defect free delivery is that vehicle should not come back till first free service with any
kind of problems

Position
GP Tools, Spl. Tools,
of the Std.
Activities / Inspection points / PNR & PNR-A
SL technician Man Consumables
Job elements M & T Instruments,
w.r.t Minutes
Equipment
vehicle
1 Identify & Park Vehicle on Work Bay 0.80
2 Remove the Thermocol and additional 0.06
packing if any
3 Open Petrol tank cap & pour petrol 0.40 Measuring Jar, Funnel Petrol,Waste Cloth
4 Check for smooth operation of fuel 0.12
cock lever
5 Raise the Lift study PDI card and work 0.57
content.
6 Check clutch play and adjust if required RH 0.11 10-11 OE spanner
7 Check Battery voltage,fill/top up RH 0.77 6" comb. Pliers, 8" screw Cloth, fine polish
electrolyte, apply petroleum jelly, driver, distilled water filler, paper, Petroleum Jelly,
connect terminals. 10mm T spanner, RSD Distilled water
Hydrometer, Battery
Charger, Battery Tester
8 Check Rear brakes for efficient working. Rr/RH 0.31 10-11, 14-15, 16-17, 20- Cloth, Graphite
22 ring spanner, 10-11, Grease, Fine polish
14-15 OE spanner 6" paper
9 Check Rear wheel Spokes for any Loose Rr/RH 0.13 comb. pliers, Mallet
hammer, 12" screw driver
spoke Spanner, RSD Pistol
10 Rear wheel run out check & adjust Rr. 0.14 grip PNR socket set
11 Check and correct tyre inflation Rr. 0.24 Pencil type Pressure Analogous/Digital type
pressure- Rear Wheel gauge Pressure gauge, Air
filling Valve
12 Adjustment 2.5mm LH 0.31 8, 10mm T spanner, 14- Cloth, SAE 90 oil,
Lubricate chain and check/adjust chain 15, 12-13, 24-27 ring Diesel Air gun, Spark
slackness. spanner, 10-11 OE plug cleaning M/c
spanner, Mallet hammer,
6" comb. Pliers, torque
wrench, socket set, RSD
13 Check gear shifter lever operation LH 0.29 10-11 OE spanner

Page 5 of 19
 Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Position
GP Tools, Spl. Tools,
of the Std.
Activities / Inspection points / PNR & PNR-A
SL technician Man Consumables
Job elements M & T Instruments,
w.r.t Minutes
Equipment
vehicle
14 Check All controls LH
Choke 0.13 12-13 OE spanner 6"
combination plier
Accelerator cable 0.11 10-11 OE spanner
15 Check front brakes for efficient working. Fr/LH 0.13 10-11, 12-13, ring Brake fluid , Cloth,
spanner, 6" comb. Pliers
Pistol grip PNR Socket set
16 Check Front wheel Spokes for any Loose Fr. 0.12
17 Front wheel run out check & adjust Fr. 0.08
18 Check and correct tyre inflation pressure- Fr 0.24 Pencil type Pressure Analogous/Digital type
FRONT gauge Pressure gauge, Air
filling Valve
19 Check & Adjust steering and Handle bar Fr. 0.23 14-15, 16-17 ring
for free Movement spanner

20 Check front mudguard alignment wrt Fr 0.04

front wheel (specific models)

21 Check all important nut bolts for torque LH/RH 3.99 10-11, 12-13, 14-15,
and tightness, 16-17, 20-22 ring
a. Handle bar mounting bolt spanner, 22 mm box
b. Stem under & upper bracket bolts spanner with Handle
c. Stem of bolts Ratchet, 6" comb. pliers,
d. Front axle nut RSD , Allen key 6 No.
e. Cylinder head nuts Pistol grip PNR Socket
f. Engine foundation bolts set
g. Tralling arm bolts
h. Silencer cover shield bolts
i. Both LH/RH mounting bolts
j. Check & tight any other fasteners if
reqd.
22 Check-up for oil leakage and rectify if any LH/RH 0.50
(especially from oil cooler, engine crank
case etc.)

23 Check the following and lubricate if RH/LH 1.10

necessary FRONT
a. Front brake lever / cam REAR
b. Rear brake lever
c. Rear brake pedal / cam
d. Pillion foot rest
e. Center stand
f. Side stand
g. Kick lever boss
h. Clutch lever

Page 6 of 19
 Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Position
GP Tools, Spl. Tools,
of the Std.
Activities / Inspection points / PNR & PNR-A
SL technician Man Consumables
Job elements M & T Instruments,
w.r.t Minutes
Equipment
vehicle
24 OE accessories fitment like LH/RH
a OE-accessories- Mirrors- Right 0.35 17mm spanner
b OE-accessories- Mirrors- Left 0.36
c OE-accessories-Leg guard 3.24 10-12mm spanner
d OE-acessories-Saree guard 1.01 Allen key No.4
e Wind shield (optional)
29 Start vehicle,Check operation of LH/RH 0.46
electricalsa. Head lightb. Tail lightc. Brake
lightd. Horne. Speedo meter,
Odometerf. Pass, Parking lightg. Side
indicatorsh. Fuel meter
30 Check Idling and CO%. LH/RH 0.64 8" connector CO-HC analyzer;
Tachometer, Proper
exhaust sealing
arrangement of Silencer
31 Trip meter working LH/RH 0.18

32 Check all locks for proper operation LH/RH 0.58

33 Test Drive the vehicle and study the job 1.23

card and verify work done.
Take vehicle out and park
34 Clean/wash the vehicle before delivery 1.0

Total 19.94

35 Rectify other defects, if any, observed

during test drive.

Abbreviations:
GPT: General Purpose Tools; SPT: Spl. Tools; PNR: Pneumatic Nut Runner,
RSD = Ratchet Screw Driver; PNR-A: Pneumatic Nut Runner Attachments;
M&T: Measuring & Testing Equipments

Summary:

1. Total time taken for carrying out PDI of one “'Avenger DTS-I 200cc motorcycle is within 20 minutes
approximately.
2. In a shift of 480 minutes, one technician can do 24 vehicles PDI comfortably.

Page 7 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 4
Periodic Service – SOP No. of Pages - 4

This section explains how to carry out Periodic Service in right sequence. Following right sequence of job elements plays
an important role to achieve higher Productivity per bay per technician.
The time calculated is excludes washing time and some periodic maintenance related points like tappet clearance setting
and oil strainer cleaning etc which falls under specific coupon services.
On an average, for normal periodic service total time taken by ‘1B 1T’ on the bay would be 53 minutes approx & with
‘1B 2T’ on the bay it would be 27 minutes. That means in a shift of 480 minutes, ‘1B 1T’ can do 9 vehicles and
‘1B 2T’ can do 17-18 vehicles.

Techn. Techn.
Std. Std. GP/Spl. Tools, PNR & PNR-A ,
position position
SL Man Job Elements to be carried out Man Equipments, Consumables
w.r.t w.r.t
Mts Mts M & T instruments
vehicle vehicle
1 Wash Vehicle thoroughly. To be done by Washing boy
2 0.30
Identify the vehicle
3 0.50
Bring vehicle and position on bay
4 0.30
Raise the Lift
5 Start Veh. and Warm up. Remove
GPT: Spanner Set
RH, LH side covers, seat, Petrol
RH & LH 1.70 1.8 PNR: Pistol Grip, PNR-A: Socket
tank along with fuel gauge and
Set
keep properly
6 LH 1.3 Drain Engine Oil GPT: Spanner Set, plastic tray Cloth
PNR: Pistol Grip PNR-A: Sckt Set
EQPT: Oil Dispor., Air Gun
7 LH 5.5 Clean Air filter. (Replace - if PNR: Pistol grip Cloth, 20W 40 oil,
necessary) PNR-A: Socket Set Diesel, Air filter
EQPT: Filter clg stand, air gun element
8 LH 0.25 Drain Carburetor. (Overhaul - if GPT: 6" Cheese head and 8" Cloth, 20W 40 oil,
required) Phillips head Screwdriver, Diesel
Nylon brush 10mm, plastic tray,
Spanner Set, 6" comb. Pliers
EQPT: Air Gun
M&T: Float Gauge RSD:
9 LH 0.45 Tighten the carburetor. Air Duct GPT: Philips Head Screw Driver
mounting
10 LH 0.5 Check Accelerator and adjust GPT: Spnr Set, 6" comb. Pliers
11 LH 2.2 Clean, Check & adjust LH Spark GPT: Wire brush Cloth, fine polish
Plug (Replace - if necessary) SPT: Spark plug spanner paper, Spark Plug
EQPT: Plug cleaner, Air gun
M&T: Filler gauge 0.01 to 1 mm
12 Check & adjust tappet clearance. GPT: Spanner Set, 8mm 'T' Cloth
(if required) spanner, Spark plug spanner
During 4 th Servicing or after PNR : Pistol grip;PNR-A: Sckt Set
5000 Km whichever is later SPT: Tappet holder
M&T: Filler gauge 0.01to1 mm,
13 LH 1.2 Check LH Side Important GPT: Spanner Set, Combination
Fasteners and tight pliers, (+ & - screw drivers)
a Side bolts of Front fork PNR: Pistol grip
PNR-A: Socket Set
b Engine foundation bolts
c RSA top and bottom nuts

Page 8 of 19
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Techn. Techn.
Std. Std. GP/Spl. Tools, PNR & PNR-A ,
position position
SL Man Job Elements to be carried out Man Equipments, Consumables
w.r.t w.r.t
Mts Mts M & T instruments
vehicle vehicle
14 Rr 2.5 Adjust chain slackness & GPT: Spanner Set, Nylon Cloth, SAE 90 oil,
Lubricate. Remove and clean , If hammer, 6" combination plier Diesel
required PNR: Pistol grip
PNR-A: Sckt Set; EQPT: CCM
15 Check/ Adjust Rear Brake, wheel Rr 0.65 GPT: 6" comb. pliers, Mallet Cloth, Graphite
freeness and run out hammer, Spnr Set, (-) Sr Driver Grease, Fine polish
PNR: Pistol grip; PNR-A: Sckt Set paper
16 Check & adjust Rr. tyre air Rr. 0.3 EQPT: Analogous/Digital type Pr.
pressure gauge, Air filling Valve, air gun
17 Check Battery, top up Distilled RH 1.1 GPT: 8mm 'T' Spanner, (-) Cloth, fine polish
Water. Clean terminals & apply Screw Driver paper, Petroleum
Petroleum Jelly. Rout cables M & T: Multimeter, Hydrometer Jelly, Distilled water
properly and fit terminal caps EQPT: Batt. Charger & Tester
properly. Recharge battery if
required (Applicable to certain
models)
18 Clean oil strainer. (Replace - if RH GPT: Spanner Set, Plastic tray Diesel, cloth, Clutch
required) After 1 Year or 10000 PNR: Pstiol grip; PNR-A: Sckt Set Cover Gasket, Oil
Km whichever is later EQPT: Filter clg stand, air gun Strainer
19 Check Clutch and adjust RH 0.4 GPT: 6" comb. Pliers, Spnr Set
PNR: Pistol grip; PNR-A: Sckt Set
20 Fill Engine Oil RH 1.15 GPT: 6" comb. Pliers, Funnel Oil 20W50, Cloth
Eqpt: Oil Disposer., Air Gun
M&T: Measuring Jar 1 Ltr.
21 Clean, Check & adjust RH Spark RH 2.0 GPT: Wire brush Cloth, fine polish
Plug (Applicable to certain SPT: Spark plug spanner paper, Spark Plug
models only) (Replace - if EQPT: Plug cleaner, Air gun
required) M&T: Filler gauge 0.01 to 1 mm
Clean/replace oil filter RH 1.91 GPT: 8mm 'T' Spanner Oil filter,
PNR: Pistol Grip; PR-A-Sckt 8m kerosene/diesel,
EQPT: Filter cleaning Stand brush, cloth
19 Fill Engine Oil (1000 ml) RH 1.35 GPT: 6" comb. Pliers, Funnel Oil 20W40 API SJ
Eqpt: Oil Disposer., Air Gun + JASO MA, Cloth
M&T: Measuring Jar 1Ltr.
20 Clean, Check & adjust Spark Plug RH 2.40 GPT: Spark plug spanner, wire Cloth, fine polish
Exhaust side brush, PNR : Pistol grip paper, Spark Plug
Eqpt: Air gun, Plug cleaner,
M&T: Feeler Gauge
21 Check/ Adjust Front Brake & GPT: 14,15 OE spanner, Cloth, fine polish
wheel freeness 14,15,16,17 Ring spanner paper
Eqpt: Air gun
22 Check Choke and adjust RH 0.2 GPT: Spanner Set

23 Check and top up brake fluid Fr 1 GPT: Spanner Set, 6" comb. Cloth, fine polish
level Pliers, (+) screw driver paper
PNR: Pistol grip
PNR-A: Socket Set

Page 9 of 19
 Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Techn. Techn.
Std. Std. GP/Spl. Tools, PNR & PNR-A ,
position position
SL Man Job Elements to be carried out Man Equipments, Consumables
w.r.t w.r.t
Mts Mts M & T instruments
vehicle vehicle
24 Check/ Adjust Fr. Brake, wheel Fr. 0.45 GPT: Spanner Set, Comb. pliers Cloth, fine polish
freeness and run out PNR: Pistol grip; PNR-A: Sckt Set paper
EQPT: Air Gun
25 Check & adjust Fr. tyre air Fr. 0.35 EQPT: Analogous/Digital type
pressure Pr. gauge, Air flg Valve, air gun
26 Check and adjust steering. Fr 1.05 GPT: Spanner Set
PNR: Pistol grip; PNR-A: Sckt Set
SPT: Fork Spanner
27 Check RH Side Important RH 3.5 GPT: Spanner Set, Combination
Fasteners and tight pliers,
a Engine foundation bolts (+ & - screw drivers)
b Front axle nut PNR: Pistol grip
c Side bolts of Front fork PNR-A: Socket Set
d Handle bar bolts
e RSA top and bottom nuts
f Rear view mirror
g Silencer & protective cover
h Swing arm axle not
28 LH/RH 1.7 Lubricate as per Lubrication Eqpt: Oil Can, Grease gun 20W40 oil, Graphite
Schedule Grease, cloth
a Fr. Brake lever
b Clutch lever
c Fr. Brake cam
d Rr. Brake pedal
e Rr. Brake Cam
f Pillion Foot Rest
g Center Stand
h Kick lever boss pin
29 Check & correct oil cooler LH/RH 5.9 GPT: Spanner Set
leakages if any. Refit RH, LH side PNR: Pistol grip
covers, seat, Petrol tank along PNR-A: Socket Set
with fuel gauge
30 LH 0.5 Check and Clean fuel line and EQPT: Air Gun
clean PT cover. (Replace filter - if
required)
31 Check Speedometer, odometer, Fr 0.15
fuel meter for proper functioning
& correct, if required.
Start vehicle, check & adjust the
32
following.
a Head light.
b Tail light.
GPT: (+ & -) screwdriver, 6"
c 0.72 LH Brake light.
comb. Pliers, Spanner Set
d Horn
Speedometer, pass & parking
e
lights (If applicable)
f Side Indicators.
32 LH 2 Tune Engine & Carburetor. GPT: 8" connector CO-HC analyzer;
(-ve) Tachometer, Proper
exhaust sealing
arrangement of
Silencer

Page 10 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

33 Study Job Card & verify work 1.00

34 Lower the Lift 0.3

35 0.5 Take out and park the vehicle

21.40 Sub Total 21.30

36 5.00 Carry out any additional work as 5.0

indicated by the Customer or as
required.
Total 26.40 Total 26.30
Time Time
37 Test Drive the vehicle, check 1.5 To be done by Expert
digital speedometer working.
Study the job card and verify
work done. Take vehicle out &
park
38 Clean the vehicle at the time of 1.0 To be done by Delivery boy
delivery

Abbreviations: GPT: General Purpose Tools; SPT: Spl. Tools; PNR: Pneumatic Nut Runner, RSD = Ratchet Screw Driver;
PNR-A: Pneumatic Nut Runner Attachments; M&T: Measuring & Testing Equipments
Summary:
1. Total time taken for carrying out PS by ‘1B 1T’ on the bay would be 53 minutes approx & with ‘1B 2T’ on the
bay it would be 27 minutes
2. In a shift of 480 minutes, ‘1B 1T’ can do 9 vehicles and ‘1B 2T’ can do 17-18 vehicles

Page 11 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 5
Periodic Service wise Parts kit No. of Pages - 2

For optimum & consistent performance form the engine/vehicle, replacement of periodic parts during respective
periodic service as recommended below is very important. Following table gives service wise parts that are
required to be replaced.

Service Type Days Kms limit

Part name Qty

Engine Oil 1200 ml

1st Free 30 - 45 days 500 - 750
Clutch cover gasket 1
2nd Free 105 - 120 days 2000 - 2500 NIL NIL
3rd Free 195 - 210 days 4500 - 5000 Engine Oil 1200 ml
4th Free 195 - 210 days 7000 - 7500 NIL NIL
Engine Oil 1200 ml
Spark Plug, 2
Air Filter Foam element 1
Starter clutch bush 1
Fork Oil 300 ml
5th Free 375 - 390 days 9500 - 10000
Front fork dust seal & Oil seal (If required) 2 each
Cylinder head gasket (If required) 1
Drive Chain lock and link set 1
Front disc pad inspect (If worn out) 1
Fork oil seal 4
st
1 Paid 465 - 480 days 12000 - 12500 NIL NIL
Engine Oil 1000 ml
nd
2 Paid 555 - 575 days 14500 - 15000 Drive Chain lock and link set 1
Steering races & ball kit 1
3rd Paid 615 - 630 days 17000 - 17500 NIL NIL
Engine Oil 1000 ml
Spark Plug 2
Air Filter Foam element 1
Air Filter cover O ring 1
Engine Breather pipe 1
Carburettor Rubber duct 1
Fork Oil 300 ml
4th Paid 705 -720 days 19500 - 20000 Front fork Oil seal (If required) 2
Front fork Dust seal (If required) 2
Cylinder head gasket ( If required ) 1
Drive Chain lock and link set 1
Brake shoes (If worn out ) 1
Rear wheel damper rubber 4
Starter Clutch bush set 1
Starter motor brushes with spring 1

Page 12 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Service Type Days Kms limit

Part name Qty

5th 795 -810 days 22000 - 22500 NIL NIL

Paid
6h Paid 885 - 900 days 24500 - 25000 Chain sprocket kit 1
7th Paid 975 - 990 days 27000 - 27500 NIL NIL

Engine Oil 1200 ml

Spark Plug 2
Air Filter Foam element 1
Carburettor rubber duct 1
Fork Oil 300 ml
8th Paid 1065- 1080 days 29500 - 30000 Front fork oil seal (If required) 2
Cylinder head gasket ( If required ) 1
Drive Chain lock and link set 1
Brake shoes / disc pad ( If worn out ) 1
Valve Oil seal 2
Cylinder head stud copper washers 4

Note:
1. Always use Bajaj genuine parts & recommended lubricants
2. Engine oil grade - SAE 20 W50 API SJ + JASO MA GRADE

Page 13 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 6
Periodic Maintenance & Lubrication Chart No. of Pages - 2

During scheduled periodic services & after warranty period while customer avail services, one should follow the
given below maintenance chart for carrying out recommended job elements. Attending specific element at specific
period/kms enable consistent performance of the vehicle. SAs should explain & educate customers on this.

Page 14 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Page 15 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 7
Skill tips for Windshield
Windshield is supplied as an accessory not part of standard fitment. Windshield adds to aesthetics. The tilt of
the shield is adjustable. Following is customer information & right procedure for fitting the Windshield.

Customer Information:
As the Windshield is an accessory item, while selling, following information must be clearly communicated to all
customers who intend to buy.
The windshield is available as an accessory. This is to add aesthetics & style statement.
It will not completely stop airflow from front and hence full-face helmet would still be necessary.
Windshield can be adjusted forward or backward as per the requirement of driver's height.
The control on road would still be based on driver's vision from above the windshield.
Curvature on the windshield can sometimes distort the image if looked from a specific angle.

Windshield Assly. & fitment procedure:

A. Windshield is available in a Kit form (P.No. 52 JM0018).

Nut
B. Fitment Procedure:
Remove holder handle bar lower stud cap nuts Plate
( 2 nos ) & plate .
Disconnect speedometer cable from speedometer.
Route speedometer cable top end through windshield &
frame bracket as shown. Tighten speedometer cable top nut.
Locate "windshield with its mounting bracket" on to Frame
Bracket
holder handle bar lower mounting stud & tighten the
cap nuts ( 2 nos) with holding the handle bar.
Do not fit plate (DV181018) over or below windshield
frame bracket. It will reduce holding area for nut.
Check for proper fitment of the windshield.

Based on the user requirement angular position of windshield

can be adjusted by + 5 Degrees.

The procedure for adjustment is given below: -

Loosen RH side 2 bolts of windshield frame.
Loosen LH side 1 nut & 1 bolt of windshield frame.

Adjust windshield forward or backward as per requirement

& tighten these nut / bolts after adjustment is over.
The tighteninthese nut/bolts is 2.5 Kg.m

Page 16 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Annex - 8

Exclusive Spare Parts List Frame

We give below spare parts details for ‘Avenger DTS-i 200 cc’. You are requested to place order accordingly

SL Added parts Description BAL MRP in Rs. Deleted parts Qty

1 JM100001 Engine assembly complete with 28317.00
starter motor DV101001 1
2 JM100042 Head cylinder with cover 3389.00 DV101062 1
3 JM100043 Cylinder block / Piston assly. 1936.00 DJ101155 1
4 JM100012 Crankcase LH 1760.00 DH101582 1
5 DK101057 Crankcase RH 2084.00 DH101586 1
6 JM100006 Manifold (Intake pipe) 77.10 DV101028 1
7 DK101076 Assembly cover RH 1316.00 DH101149 1
8 52JM0008 Oil cooler assembly 1,263.00 NA 1
9 JM100020 Assembly pipe inlet oil cooler 179.00 NA 1
10 JM100021 Assembly pipe outlet oil cooler 179.00 NA 1
11 DK101366 Bolt special banjo oil cooler 9.95 NA 1
12 JM100038 Assembly cover magneto 314.00 DH101155 1
13 JM100039 Cover LH RR 290.00 DV101002 1
14 36JM0001 Set damper 78.40 36DH1006 1
15 36JM0002 Set plate 20.34 36DH1007 1
16 DV101065 Lever complete gear shift 169.00 DH101699 1
17 JM100033 Silencer assembly 3340.00 DV101003 1
18 JM111003 Magneto assembly 1712.00 DV111004 1
19 JM111002 Stator assembly 534.00 DV111005 1
20 JM120002 Assembly air filter 1027.00 DV121002 1
21 JM120001 Connecting tube 48.93 DG121016 1
22 JM120003 Carburettor assembly 1945.00 DV121009 1
23 JM161026 Frame assembly complete 5875.00 DV161001 1
24 JM161004 Bracket engine rear 161.00 DV161014 1
25 59040043 Bolt Allen M8x150L 14.99 39241404 1
26 JM161002 Engine mtg. bracket front LH 24.08 DV161042 1
27 JM161003 Engine mtg. Bracket front RH 25.52 DV161043 1
28 JM161005 Bracket engine HD LH 9.65 DV161015 1
29 JM161006 Bracket engine HD RH 9.9 DV161016 1
30 DK161081 Rubber (Oil cooler mtg.) 2.46 NA 2
31 JM161020 Sleeve (Oil cooler mtg.) 8.81 NA 2
32 39150711 Washer (Oil cooler mtg.) 0.72 NA 2
33 39231004 Bolt (Oil cooler mtg.) 3.37 NA 2

Page 17 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

34 JM171001 Arm complete Swing 982.00 DV171002 1

35 JM141004 Cover assembly fuel tank 1120.00 52DV0011 1
36 DD141027 Flange assembly fuel gauge 15.98 NA 1
37 30141028 Gasket fuel gauge 11.97 NA 1
38 30141032 Bolt 2.52 NA 4
39 JM161015 Holder step RH 171.00 DV101026 1
40 52JM0015 Coupling assembly 897.00 DV151004 1
41 36JM0003 Chain sprocket kit 1,012.00 36DV0006 1
42 JM181003 Lock set ( 5 in 1) 678.00 DV181004 1
43 52JM0018 Frame wind shield assembly 2050.00 NA 1
44 DD201011 Damper 1.94 NA 4
45 JM191001 Lever brake 167.00 DG191043 1
46 JM191005 Cable brake 84.94 DV191001 1
47 JM201001 Wiring harness 1043.00 DV201025 1
48 JM191006 Spring rear brake switch 1.92 DG201025 1
49 JM201003 Housing assembly control (LH) 392.00 DV201003 1
50 JM201002 Horn 224.00 DG201020 1
51 AP201029 Starter relay 139.00 DV201016 1
52 JM161017 Guard front bumper 194.00 DG221034 2
Painted Parts Remarks
1 JM7101X3 Fuel tank with decal 2864.00 Ebony black 1
2 JM71012T Fuel tank with decal 2792.00 Titanium silver 1
3 JM71012V Fuel tank with decal 2910.00 Cocktail wine red 1
4 JM71013A Fuel tank with decal 2934.00 Long beach blue 1
5 JM7301X3 Side cover LH 223.00 Ebony black 1
6 JM73012T Side cover LH 255.00 Titanium silver 1
7 JM73012V Side cover LH 265.00 Cocktail wine red 1
8 JM73013A Side cover LH 256.00 Long beach blue 1
9 JM7302X3 Side cover RH 205.00 Ebony black 1
10 JM73022T Side cover RH 237.00 Titanium silver 1
11 JM73022V Side cover RH 247.00 Cocktail wine red 1
12 JM73023A Side cover RH 238.00 Long beach blue 1

Page 18 of
Enclosure to Service New Product Bulletin ‘NP :3 dated 18th September 2007

Action Matrix:

Works Manager/ PDI Service Floor

SL Key Information Sales In charge
DSE In charge Advisor In charge
Understand
thoroughly
along with Understand thoroughly
Understand
Share with Sales team to along with workshop team
Technical along with PDI
1 Sales/Service/PDI enable the
Specification team
Team team to deliver Create product confidence
to customers in them
with great
confidence
2 PDI Check list Share with
Understand &
Service/PDI Understand & get updated
implement
3 PDI - SOP Team
Periodic
4
Service SOP
Periodic Service Share with
5
wise Parts Kit Service Team
Understand & get updated
Periodic Monitor
Percolate in detail to all
Maintenance & adherence
6 concerned technician
Lubrication
Chart
Implement & ensure
Share with
Skill tips for adherence
7 Service & PDI
Windshield
Team
Exclusive Spare
8 Spare Part team to update. Service team to understand
Parts list
Date of Actions:
Initials of concern official

Page 19 of