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Issued by SERVICE DEPARTMENT

AKURDI, PUNE 411 035.

CIRCULARS
3 Wheelers

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CIRCULAR 3WH: 1 TH 15 JUNE, 2001 TO: ALL VEHICLE DEALERS ALL AUTHORISED SERVICE CENTRES ALL SPARE PART DEALERS Sub : Modifications in 3H RE (D),3WH FE 4S, 3WH RE 4Sand CNG . Dear Sirs,

3WH RE (D) :- Mod.in Stay Air Cleaner 3WH RE 4S & 3WH RE 4S with CNG : Introduction of Elbow 3WH FE4S : Grommets for Upper part of Chassis

1) Modification in Stay Air Cleaner of 3WH RE (D): Stay Air Cleaner (P.No. BA122148) is modified to overcome the problem of cracking of same. Additional ribs are added at the location shown in fig.1. The change is implemented from 4-6-2001. The starting engine no. is BAM BHC 02846. There is no change in part number BA122148 of Stay Air Cleaner and it is interchangeable with old one. In the case of cracking of Stay Air Cleaner, only modified Stay Air Cleaner should be fitted.

Rib added at this location

Stay Air cleaner ( P.No. BA122148)

2) Introduction of Elbow in 3WH RE 4S & 3WH RE 4S with CNG: A) Elbow (P.No.AA10322) Self tapping Screw (P.No.39102702) and Plain Washer (P.No. 39020911) are introduced to overcome the problem of Vehicle stops during heavy rain due to water entry. B) Spark plug cap get short due to splashing of water through Tyre LH side. Water enters through Fancover. C) This is avoided by introducing Elbow (P.No.AA101322) on Fancover which does not allow water to enter into Fancover.

D) The change is implemented from 6.6.01 on 3WH RE 4S with CNG & same will be introduced on 3WH RE in due course of time. E) The list of parts added is as under.

Sr. No 1 2 3

Part No. Added AA101322 39102702 39020911

Description

Part No. Deleted -------

Qty/ Veh. 1 3 3

Elbow Self Tapping Screw Plain Washer

Inter changeability ----

Refer S. P. C. Veh. Page Fig. Code No. No. AA 23 New Part AF AA 23 New Part AF AA 23 New Part AF

There is no change in part number AB 1010 47 of Fancover complete and it is interchangeable with old one. We are giving below fitment procedure of Elbow on Fancover for old vehicles operating in field. Remove the Fancover from vehicle. Align the Marking Marking marking given on Elbow and Fancover and on on Elbow insert the Elbow into Fancover. Fancover

Sharp pointed tool

i) Holes are required to be drilled on old Fancover for fixing Elbow on it by Self tapping screw. ii) After aligning Elbow with Fan Cover, insert sharp pointed tool through holes of Elbow to make the 3 holes on FanCover.

Elbow

Fit the Fancover on vehicle. Fit the Elbow on Fancover by aligning the marking and fix it with Self tapping screw and Plain washer.

Fancover

If you are using locally available PVC pipes, the Pipes should be fitted such that the bend open end faces towards Rear door. It should not be faced towards ground or vertically upwards. 3) Grommets for Upper part of Chassis of 3WH FE4S Antidive Suspension: Please refer our Circular A15 dated 27.05.01 in which we have given details of Antidive Suspension. Please add following parts which are now released. Sr. No Part No. Added Description Part No. Deleted Qty/ Veh. Inter changeability Veh. Code AB AB AB Refer S. P. C.

1 2 3

39237323 39237423 39237523

Grommet Grommet Grommet

-------

1 2 2

-----

Page No. 66 66 66

Fig. No. New Part New Part New Part

Please bring this information to notice of your concerned staff and update your spare part Catalogue and place your order of parts as per your requirement. Thanking you, Yours Faithfully, for BAJAJ AUTO LIMITED

P.R.AGARWAL DEPT. MANAGER (TRG & DU-3WH) CC : FIELD SERVICE ENGINEERS : ALL AREA SERVICE MANAGERS / ALL REGIONAL TRAINING HEADS : ALL PRODUCT ASSURANCE ENGINEERS : ALL REGIONAL SALES MANAGERS

CIRCULAR 3WH: 2 TH 14 JULY, 2001. TO: ALL VEHICLE DEALERS ALL AUTHORISED SERVICE CENTRES ALL SPARE PART DEALERS

3WH RE (D):- Introd. of Antidive Suspension & Hydraulic brake system at Front Wheel 3WH RE 2S :- New spring locking of system Parts received along with F.F.R.

Sub: - Introduction of Antidive Suspension & Hydraulic brake system at Front Wheel of 3WH RE (D), New spring locking system on 3WH RE 2S,Parts received along with FFR:Dear Sirs, We are partially introducing new Antidive Suspension & Hydraulic brake system at Front Wheel of 3WH Rear Engine (Diesel) in the market from July 2001. Annexure 1 Annexure 2 Annexure 3 Location of Parts Maintenance Added / Deleted part list

2) New Spring locking System on 3WH RE 2S New Spring locking System is introduced to overcome the problem of Spring coming out from its location causing damage to rear Tyre . Separate Bracket-II LH (P.No.24171091) and Bracket- II RH (P.No. 24171092) are introduced for locking the Spring. These Bracket-II LH & RH are bolted to Trailing arm by modifying the same. Refer Fig.1

Bracket-II LH (P.No 24171091) Trailing arm One end of the Spring is inserted in this slot of Bracket II

Fig.1 Location of Bracket II (P.No. 24171091)

The Change is implemented from 26-5-2001. The list of parts added is as under. 1

Sr. No 1 2 3 4

Part No. Added 24171091 24171092 22150435 39019711

Description

Part No. Deleted ---------

Qty/ Veh. 1 1 2 2

Bracket-II LH Bracket-II RH Bolt Plain Washer

Inter changeability ---------

Refer S. P. C. Veh. Page Fig. Code No. No. 24 43 New part 24 43 New part 24 43 New part 24 43 New part

There is no change in part number 24171084 of Trailing arm assly LH & part number 24171086 Trailing are assly RH. Compete set of Bracket-II LH & RH (P. No. 24171091 & 24171092),Bolt(P.No. 22150435) Plain Washer (P.No. 39019711) and modified Trailing arm assly LH & RH is interchangeable with unmodified Trailing arm assly LH & RH. 3) Parts received along with F.F.R. It has been reported to us by plant QA that most of the times the parts received along with F.F.R. report comes in badly rusted or damaged condition due to which proper analysis of the failure becomes difficult / not possible. In view of this , we request you to pack the failed parts properly and oil them wherever necessary to avoid rusting. The original signs of failure should be kept intact and your observation in details should be maintained in F.F.R. All dealers and BAL Service engineers should make a note of this and comply with the plant requirement. Please bring this information to the notice of your concerned staff, update your Spare Part Catalogue and place your order of parts as per your requirement. Thanking you,

Yours Faithfully, for BAJAJ AUTO LIMITED

P.R.AGARWAL DM (SERVICE SUPPORT)

CC : FIELD SERVICE ENGINEERS : ALL AREA SERVICE MANAGERS / ALL REGIONAL TRAINING HEADS. : ALL PRODUCT ASSURANCE ENGINEERS : ALL REGIONAL SALES MANAGERS

Annexure - 1

Location of Parts

Oil container with cap

Bracket assly master cylinder

Master cylinder

Antidive link assly

Front hub

Residual pressure valve assly

Annexure-2

MAINTENANCE

Lubrication of Brass bush fitted inside Front brake panel assly and Bush inner fitted inside Antidive link assly are recommended to be greased after every 5000 Kms.

Bush inner fitted inside Antidive link assly

Brass bush fitted inside Front brake panel assly

Annexure-3 LIST OF PARTS ADDED/DELETED FOR 3WH RE - DIESEL WITH ANTIDIVE SUSPENSION AND HYDRAULIC BRAKE FOR FRONT WHEEL

Sr

Part No.

Description

Part No. Deleted BA161003 22160234 22161051 22201087 22201086 22171046 --------22171039 ------------22171051 --------------------24170205

No Added 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. BA161026 Bare Chassis Compl. AB 161174 Steering Cover Assy. AB 161180 Reinforcement Fr Mudguard AB 161182 Check Plate Fr M-Guard AB 201065 Housing Head Light AB 171004 Front Wheel Hub 39205904 Flanged Bolt AB 171006 Grease Seal AB 171018 Spacer - Brake Panel 39235217 Circlip AB 171007 Fr Wheel Axle Assy AB 171009 Antidive Link Assly AB 171011 Bush Sintered 05171052 Bush (Inner) 39105411 Plain Washer 39098115 H.Sloted Nut 39063008 Split Pin AB 171019 Fr Shock Assy Comp AB 171013 Top Rubber Bush AB 171014 Locating Cup Rubber Bush 39072115 Hexagon Nut 39031015 Hexagon Nut AB 171015 Spacer Nut 39054311 Plain Washer 39145504 Shoulder Bolt 39105411 Plain Washer 39078912 Washer Spring 39029615 Hexagon Nut AB 171017 Fr Suspension Spring

Qty/ Inter Page changeVeh ability No. 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 2 4 1 1 1 1 1 1 1 1 1 No. No No No No No No ------No ------------No ------------------No 51 51 53 53 53 54 54 54 54 54 54

Fig. No. 1 4 2 17 16 1 New Part New Part --"---"-9

Remark

New Part New Part New Part ---"-----"-----"--56 1 New Part New Part ---"-----"-----"-----"-----"-----"-----"-----"--57 1 56

For Fr. Axle For Fr. Axle

For FSA Lower end For FSA Lower end For FSA Lower end For FSA Lower end

Sr

Part No.

Description

Part No. Deleted BA181004 ------07181006 01180124 07181009 07181004 01180125 21180107 07181007 01180128 01180129 01180130 --22151036 22151040 ------22151041 ----39114004 22151054 22151056 22151055 -------

No Added 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. AB 181002 Steering Column Assy AB 171020 Needle Bush 39235717 Internal Circlip AB 171021 Pivot Pin Fr Wheel Hub AB 181010 Dust Cover Bottom AB 181011 Bearing Race Low. Inner AB 181012 Steel Ball With Cage AB 181014 Bearing Race Low Outer AB 181015 Dust Cover Top Lower - Brg AB 181016 Bearing Race Up Inner AB 181017 Steel Ball with Nylon Cag Up AB 181019 Bearing Race Up Outer AB 181020 Spacer Washer AB 181021 Lock Ring Upper Race AB 151035 Shoe Hold Disc Compl. 22150235 Fr Br Shoe Assy Comp 22150240 Return Spring 22150241 Plain Washer 22150242 22150243 22150244 39000101 22151048 391113904 AB 151063 AB 151054 AB 151064 AB 151065 AB 151066 AB 151067 Spring Special Washer Front Brake Drum Slot CSK Hd Screw - M4 Central Part Assy Weld Bolt Tmc Comp With Oil Container Oil Container with Cap Tandom Mast. Cyl Body Primary Piston Compl Secondary Piston Comp Stopper Secondary Piston

Qty/ Inter Page changeVeh ability No. 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 1 4 1 1 1 1 1 1 No --60 60 60 60 60 60 60 60 60 60 60 60 61 61 42 42 42 42 42 42 42 42 42 42 45 45 45 45 45 45

Fig. No. 1 New Part --"---"-8 11 10 9 12 13 14 15 16 17 New Part 1 3 New Part --"----"--15 New Part --"--16 1 13 2 New Part New Part New Part

Remark

--No No No No No No No No No No --No ------No No ----No No No No -------

Sr

Part No.

Description

Part No. Deleted --21150418 --------22151060 ----22151071 21150220 -----------------------------------

No Added 60. AB 151068 Gasket 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. AB 151069 Push Rod Complete 39236017 Internal Circlip AB 151070 Boot AB 151071 Grommet Oil Reservoir 39076101 Screw Pan Cross AB 151072 Cap Br Oil Reservoir AB 151073 Kit - Major T. M. Cyl. AB 151074 Kit - Minor T. M. Cyl. AB 151041 Brake Pedal Assembly AB 151014 Spring Br Pedal AB 151052 Brake Pipe Assy Fr. AB 151053 Banjo Union AB 151050 Connector Br Pipe AB 151049 Banjo Bolt 21150422 Packing AB 151048 Flexible Br. Hose 39166311 Plain Washer 39175315 Hexagon Nut AB 151051 Lock Clip Banjo Bolt AB 151057 Wheel Cylinder AB 151080 Bleeder Cap AB 151058 Major Kit - Wheel Cylinder AB 151075 Piston Wheel Cyl. AB 151077 Cup Wheel Cylinder AB 151079 Bleeder Screw AB 151078 Boot Wheel Cylinder AB 151076 Spring

Qty/ Inter Page changeVeh ability No. 1 --45 1 1 1 1 1 1 1 1 1 1 1 2 5 3 2 1 2 1 1 1 1 1 2 2 1 2 1 No --------No ----No No No --------------------------------46 45 45 45 45 46 46 46 47 47 ------------------------------------

Fig. No. New Part 16 New Part ---------22 New Part New Part 1 2 New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part New Part

Remark

Sr

Part No.

Description

Part No. Deleted ------BA151001 --------BA191007 BA191009 BA191011 22191067 AB191001 BA161056 22161079 ---22160235 22160236 39021911 39026312 39029215 22151043 01101008 21170108 22171049 23161305 24170208 39011904 05101083 03170121 03170129 39006204 01170122 39021711 01170251 05171012 05171008 01170254 01170255 39026812 24171069

No Added 88. AB 151059 Minor Kit - Wheel Cylinder 89. 39084914 Lock Washer Toothed 90. 22150451 Screw 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. 120. 121. 122. 123. 124. 125. 126. 127. 128. AA151009 Brake Pipe Rear- I AB 151055 Residual Pressure Valve Assembly AB 151056 Kit - Residual Pressure Valve AB 161184 Clamp AB 161185 Sleeve BA191042 Cable Assy gear Gray BA191050 Cable Assy Black Gear BA191046 Inner Cable Gear BA191046 Tube assly. comp. Throttle AB 191033 Accel Cont. Cable Comp AB 161188 Front Mudguard Assly AB 161187 Bajaj Name Plate AB 161186 Spacer ---------------------------------------------------------------------------Rubber Beading Bolt/Plate Assy Plain Washer Spring Washer Hexagon Nut M6 X 1 Dust Cover Roller Distance Piece Trunion Grease Nipple Lower Plate Bolt Hexagon Adjuster With Nut Hub Pin 10mm Brake Plate Hexagon Hd screw "O"Ring Plain Washer Inner Bush Lower Rubber Bush Lower Inner Bush Upper Rubber Bush Upper Bolt Spring Washer Bolt

Qty/ Inter Page changeVeh ability No. 1 ----2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 2 2 1 36 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 ----No -----

Fig.

Remark

No. New Part --New Part --New Part 50 New Part New Part New Part New Part New Part 67 6 67 7 67 63 62 53 51 53 51 51 51 51 51 54 57 57 57 57 57 57 64 55 55 55 57 57 56 56 56 56 56 56 56 8 9 1 1 11 New Part 6 7 8 9 10 3 11 10 7 12 2 4 16 17 18 19 8 9 2 3 4 5 6 7 8

Yes Yes Yes No Yes No No ------------------------------------------------------------------------------

For FSA For FSA For FSA 8

Sr

Part No.

Description

Part No. Deleted 39025111 39020111 39026712 39029615 BA 171002 39029415 03180111 03180114 39177220 03180119 03180120 03180118 03180116 01170130 22151039 01150209 22151066 39077504 39079815 05151017 01150109 05151013 03150111 39015108 01150112 39029915 21150405 21150406 22150455 22150456 22150457 22150458 21150408 39020311 39033617 22151056 22151070 21150404 21150416 21150421 -----------

No Added 129. ---130. ---131. ---132. ---133. ---134. ---135. 136. ---137. ---138. ---139. ---140. ---141. ---142. ---143. ---144. ---145. ---146. 147. 148. 149. 150. 151. 152. 153. 154. 155. 156. 157. 158. 159. 160. 161. 162. 163. 164. 165. 166. 167. 168. 169. 170. 171. 172. 173.

Plain Washer Plain Washer Spring Washer Hexagon Nut - M-10 Plate Assy Support Hex Lock Nut - M8 Hub Pin 12 Mm Shoulder Washer Shell Brg Distance Piece Spacer Washer Bush "O" Ring Grease Nipple Wear Pad Spring Lock Brake Cam Assembly ---Hexagon Bolt - M6 X 1 ---Hex Nut/Flange- M6 ---Fr Br Actuatng Lever ---Front Brake Link ---Front Brake Link ---Pin ---Split Pin ---Bolt ---Hexagon Nut - M7 X 1 ---Outer Valve Packing ---Valve Body ---Spring ---Spacer ---Oil Seal ---Piston - Master Cyl ---Packing - Master Cyl ---Plain Washer ---Wire Circlip ---Oil Container assly ---Packing Oil Container Cap ---Inner valve Packing ---Dust Cover ---Ring Nut Master Cylinder AB161173 Bracket Assly Master Cylinder Mounting 39199304 Bolt upset 39019811 Plain Washer 39026312 Spring Washer 39029215 Hex Nut

Qty/ Inter Page changeVeh ability No. 1 ---56 1 ---56 1 ---56 1 ---56 1 ---57 1 ---57 1 60 1 ---60 2 ---60 1 ---52 2 ---52 2 ---60 2 ---60 1 ---60 2 ---42 1 ---42 1 ---42 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 2 1 -------------------------------------------------------------------------------42 42 42 42 42 42 42 42 42 45 45 45 45 45 45 45 45 45 45 45 45 45 47 51 53 53 53 53

Fig. No. 9 10 11 12 5 6 2 3 4 5 6 5 6 7 2 4 5 7 8 6 9 10 11 12 13 14 4 5 6 7 8 9 10 11 12 13 14 3 15 5 New Part New Part New Part New Part New

Remark

For For For For

FSA FSA FSA FSA

For Mudguard Top Mounting

For Mudguard Side mounting

Sr

Part No.

Description

Part No. Deleted ------39006204 39021111 39021911 39008504 39019711 39026212 39029115 22181016 ----22170119 ----24151049 ----------------21150420 --------------24151027 ---

No Added 174. 15141013 Grommet 175. 176. 177. 178. 179. 180. 181. 182. 183. 184. 185. 186. 187. 188. 189. 190. 191. 192. 193. 194. 195. 196. 197. 198. 199. 200. 201. 202. 203. 204. 205. 206. 207. 208. 39023911 Plain washer 39185604 Hex Bolt Hex Head Screw Plain Washer Plain Washer Bolt Hex Head Plain Washer Spring Washer Hex Nut BA181006 Handle bar with sleeve 39177004 Flanged bolt 39042215 Nyloc Nut AB171022 Greese cup nut AB171023 Cap front wheel hub AB161093 Guide flexible hose BA122044 Governor spring 39020011 Plain Washer 39026512 Spring washer 39031015 Hex Nut 39086604 Hex bolt 39122411 39078812 39029415 BA191029 39170207 AB151053 AB151050 39045004 39073212 39029215 AA151010 AB151050 AB151060 AB151061 Plain Washer Spring Washer Hex Nut Pad Clutch Pedal Clovis Pin with Head Banjo Union Connector BR. Pipe Hex Bolt Washer Spring Hex Nut Brake Pipe rear II Connector Br. Pipe Wheel cylinder Major kit wheel Cylinder -------------

Qty/ Inter Page changeVeh ability No. 1 --53 1 1 2 2 2 2 1 2 2 1 1 1 1 1 1 1 3 3 3 2 4 2 2 1 1 1 1 1 1 1 1 3 2 2 No ----------------No ----------------------------No ----No -------

Fig.

Remark

No. New Part 53 New Part 53 New Part 53 8 53 10 53 9 53 3 53 4 53 5 53 6 62 1 New Part New Part 54 13 54 New Part New Part

For Mudguard Side mounting

For Link mounting on Steering Column

51 51 51 46 46 46 46 47 46 50

For Mech. Br. switch For mounting BKT assly. Master Cylinder For Mounting Tandom master cylinder

New Pert 19

New Part 50 New Part New Part New Part New Part 50 New Part New Part 50 50 New Part New Part

For Mounting Residual pressure valve

10

Sr

Part No.

Description

Part No. Deleted --22151060 21150418 39031215 21150419 BA201065 06201334 AB201028 39055302 ----BA201033

No Added 209. AB151062 210. 211. 212. 213. 214. 215. 216. 217. 218. 219. 220. --------BA201072 AB201072 AB201074 39169801 39019711 39026212 AB201075

Minor kit wheel Filler cap for oil container Connecting Rod Hex Nut Fork Head Assly Wiring Harness Head Light compl. with lamp Horn Screw Plain Washer Spring washer Rear Br. Switch

Qty/ Inter Page changeVeh ability No. 2 ----1 1 1 1 1 1 1 2 2 2 1 --------No No No --------46 46 46 46 70 70 74 74 74

Fig. No. New Part 22 16 17 18 8 ---

Remark

10 11 New Part New Part 33 10

11

CIRCULAR 3WH: 3 RD 23 JULY, 2001 TO: ALL VEHICLE DEALERS ALL AUTHORISED SERVICE CENTRES ALL SPARE PART DEALERS Sub : Modifications in 3WH RE 4S & RE 4S CNG, RE 2S & 3WH FE 4S:Dear Sirs, 1) Introduction of Gasket for crankcase assly, in 3WH RE-CNG.

3WH RE 4S CNG: -Introd. of Gasket for Crank case. 3WH RE 2S: -Mod. in Gasket of Reed Valve 3WH FE 4S : - Mod. in Rear brake switch

A) Gasket (P.No. AA101328) for Crankcase joint is introduced to overcome the problem of oil leakage. B) Due to this change, application of liquid Gasket has been stopped. Also Crankcase assly.(P.No. AA101344) is introduced in place of Crankcase assly (P.No.AA101263).Mating surface of Crankcase magneto side is machined by 0.4 mm. C) 70 nos. of 3WH RE CNG has been manufactured & dispatched to Delhi. The details of engine no., chassis no. & dealer name is given in enclosed annexure-1. D) The list of parts added /deleted is as under. Sr. No 1 2 Part No. Added AA101344 AA101328 Description Part No. Deleted AA101263 --Qty/ Veh. 1 1 Inter changeability No --Refer S. P. C. Pag. Fig No. No. 2 24 2 New Part

Crankcase assly Gasket

Veh. Code AA AF AA AF

E) Complete set of Crankcase assly.(P.No.AA101344) & Gasket (P.No. AA101328) is interchangeable with old Crankcase assly.(P.No.AA101263) 2) Modification in Gasket of Reed Valve of 3WH RE 2S:A Gasket (P.No. AE121047) for Reed valve is introduced in place of Gasket (P.No. AE121003). The material of Gasket is changed from "GB5B" to "Armstrong GR S-207". The change is carried out for improving sealing. The modified gasket is blue in colour. The change is implemented from 8 July 2001. The starting engine no. is AEMBHD 19091. The list of part added/ deleted.
TH

B C D E

Sr. No 1

Part No. Added AE121047

Description

Part No. Deleted AE121003

Qty/ Veh. 1

Inter changeability Yes

Refer S.P.C. Veh. Page Fig.N Code No. o. Refer cir. TW 52 dt.27.4.99

Gasket Reed Valve

3) Modification in Rear brake Switch of 3WH FE 4S. A B C D Rear brake Switch (P.No. AB201075) is introduced in place of Switch (BA201033). Length of cable has been reduced from 250 mm to 100 mm. for Optimisation. The change is implemented from 10 July 2001. The list of part added/ deleted is as under. Part No. Added AB201075 Description Part No. Deleted BA201033 Qty/ Veh. 1 Inter changeability Yes Refer S. P. C. Page Fig. No. No. Refer cir. A15 Dt.21-5-2001
TH

Sr. No 1

Rear brake Switch

Veh. Code AB

Please bring this information to notice of your concerned staff and update your spare part Catalogue and place your order of parts as per your requirement. Thanking you, Yours Faithfully, for BAJAJ AUTO LIMITED

P.R.AGARWAL DEPT. MANAGER (SERVICE SUPPORT) CC : FIELD SERVICE ENGINEERS : ALL AREA SERVICE MANAGERS / ALL REGIONAL TRAINING HEADS : ALL PRODUCT ASSURANCE ENGINEERS : ALL REGIONAL SALES MANAGERS

Annuxure - 1 Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. Engine No. AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC 9601 9603 9606 9611 9613 9615 9616 9618 9621 9622 9629 9624 9602 9604 9605 9607 9608 9610 9612 9614 9620 9625 9627 9628 9661 9662 9664 9665 9666 9667 9668 9669 9671 9672 9673 9674 9675 9676 9677 9678 9679 9680 9681 9682 9683 9684 9685 9686 9687 9688 Chassis No AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC 71620 71623 71628 71634 71619 71632 71618 71638 71639 71636 71630 71652 71637 71695 71621 71626 71624 71617 71622 71631 71640 71653 71629 71633 71779 71811 71793 71782 71778 71790 71694 71692 71784 71787 71774 71785 71781 71791 71776 71780 71835 71814 71815 71808 71820 71836 71818 71819 71817 71816 Dealer Name Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Bagga link services Gautam motors P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises P. R. J. Enterprises Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Pvt. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd. Ltd.

51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69.

AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC AAMBHC

9689 9690 9691 9692 9693 9695 9696 9697 9698 9699 9700 9701 9702 9703 9704 9617 9619 9626 9630

AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC AFFBHC

71812 71813 71807 71838 71834 71841 71840 71843 71842 71837 71809 71839 71810 71821 4680 4683 4675 71648 71651

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CIRCULAR 3WH: 4 TH 28 JULY, 2001 TO: ALL VEHICLE DEALERS ALL AUTHORISED SERVICE CENTRES ALL SPARE PART DEALERS Sub : Modifications in 3H RE 4S,RE 4S with CNG RE-Diesel and RE-2S. Dear Sirs,

3WH RE 4S& 2SRE (D):Alternate P. No. for Flange assly. 3WH RE 4S & CNG :- Introd. of Cover 3WH RE 4S CNG: -Mod. in Detachable entry tube assly.

1) Alternate part number for Flange assly of RE 4S & RE 4S with CNG and 3WH RE 2S :We are releasing herewith alternate part number for Flange assly. (Satellite housing), Flange assly. (Differential Gear Side) and Flange assly. (Wheel Side) manufactured by forging process instead of machining & welding process. Please place your Spare part order on these new part numbers. The list of parts added is as under. Sr. No Part No. Added Description Part No. Deleted Qty/ Veh. Inter changeability Refer S. P. C.

1.

BA132171

Flange(satellite housing) Flange gear side) (Differential

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2.

BA132172

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3.

BA132173

Flange (Wheel Side)

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Veh. Code AA,AF BA 24 AA,AF BA 24 AA,AF BA 24

Page No. 38 32 38 38 32 38 38 32 38

Fig. No. 1 1 1 1 4 4 13 5 5

2) Introduction of Cover for Gear Shifter of RE 4S & RE 4S with CNG :We have received few complaints of "Starter motor not operating" from field. Observation: - Cover (P.No. AA101258) was not fitted on Gear Shifter flange assly (P.No. AA101259) & plunger of Neutral Switch was worn out. Reason :- Plunger of neutral switch was worn out due to dust entry which resulted in to incomplete circuit of Starter motor causing problem Starter motor do not crank. In this connection, please refer TH our Circular A9 dt. 4 April 2001 in which we have given details of introduction of Neutral Switch, Cover (P.No.AA101258), Screw (P.No. 39075801) and Plain washer (P.No.39019711) for Gear Shifter Flange assly to prevent dust entry & thereby to overcome the problem of faster wear of plunger of Neutral Switch. 1

Action to be taken in field:- Please ensure that Cover (P.No. AA101258) is fitted on vehicles where Neutral switch is fitted.

3) Modification in Detachable entry tube assly in 3WH RE with CNG. Flange of Detachable entry tube assly. (P.No.AA101311) has been modified to overcome the problem of cracking of the flange. Filler radius has been increase to R 7 mm from 4.5 mm Refer fig.1. The change is implemented from 12 July 2001. The starting chassis no. is AFFBHD 72672. There is no change in part number AA101311 of Detachable entry tube assly and it is interchangeable with old one.
th

Please bring this information to notice of your concerned staff and update your spare part Catalogue and place your order of parts as per your requirement. Thanking you, Yours Faithfully, for BAJAJ AUTO LIMITED

P.R.AGARWAL DEPT. MANAGER (SERVICE SUPPORT) CC : FIELD SERVICE ENGINEERS : ALL AREA SERVICE MANAGERS / ALL REGIONAL TRAINING HEADS : ALL PRODUCT ASSURANCE ENGINEERS : ALL REGIONAL SALES MANAGERS