AHO AND BSIV

Dear Biker,

Congratulation on choosing the Mojo, a magnificent machine by Mahindra And

Mahindra Ltd. (Two Wheelers Division). What you own is not just another motorcycle
but one that represents the true spirit of the road - the magic of possibility, the lure of
freedom, the excitement of adventure and the power of untold tales.The roads are now
truely yours to explore.

Mojo is engineered for versatility and consistently delivers a superb riding experience,
whether you are on a long trip, cruising down an endless highway or a short ride
through the city streets.

Now that you are a proud owner of this motorcycle, you must be making plans to head
out on the roads on your Mojo. It is important to comprehensively understand your
machine and this Onwer’s Manual will be the best guide for you to do that.

So, get set to chase down the endless horizon and blow the wind out of your way. Gear
up to feel the engine pounding with power and your heart beat with joy. You will truly
enjoy cruising down the roads and highways and make heads turn in admiration and
envy.

We are always there to support you in your journeys with a toll free number:

1800 233 8883 exclusively for you.

 NOTE :-
Information contained in this owner's manual is based on the latest product
information available at time of printing. Mahindra And Mahindra Ltd. (Two
Wheelers Division) reserves the right to make changes at any time without
notice and /or without incurring any obligation.
Accessories shown in the illustration may not be part of the standard equipment.
This Owner Manual can be referred for Mojo and all its variants for functional,
operational and maintenance information.
No part of this publication may be reproduced without prior written consent of
Mahindra And Mahindra Ltd. (Two Wheelers Division).
All copyrights reserved with the company.

© Mahindra And Mahindra Ltd. (Two Wheelers Division)

OWNER IDENTIFICATION

Owner's Name :

Address :

City : State : Country :

Mobile No.: Tel. No. :

E-mail :

Frame No.: Colour :

(Stamped on the left side of the steering stem of the chassis.)

Engine No.:

(Stamped on the lower side of the LH crankcase.)

Key No.: Battery Make :

Battery Sr. No.: Battery Mfg. Code/Date :

Date of Regn.: Dealer Code :

STAMP OF AUTHORIZED DEALER

MAINTAINING YOUR MOJO
Warranty :
Quality of your Mojo motorcycle is guaranteed through a comprehensive warranty
policy that covers a period of 2 years or running of 32,000 km, whichever is earlier from
the date of sale. Details of warranty terms and conditions and warranty registration card
are included in this owner's manual.
Maintenance :
The ownership experience of any automotive product is strongly correlated to usage and
maintenance. A motorcycle is a machine and is subject to wear and tear during use as
well as is subject to damage resulting from untoward incidents, adulterated fuel etc. We
strongly advise you to read this owner's manual carefully and follow the maintenance
schedules to ensure optimum performance of the machine.
Mahindra And Mahindra Ltd. (Two Wheelers Division) recommended servicing
schedules :
We offer 4 free services for your motorcycle over a period of 18 months. After free
servicing a periodic program of paid services is specially designed to keep your Mojo in
perfect running condition during daily use. This owner's manual includes instructions
and coupons for availing the company recommended service schedule. The coupons
will be accepted at all Authorized Mahindra And Mahindra Ltd. (Two Wheelers
Division) dealers and service centers.
It is a constant endeavor from Mahindra And Mahindra Ltd. (Two Wheelers Division)
to provide the best care and service for your motorcycle. Remember that your
Mahindra And Mahindra Ltd. (Two Wheelers Division) dealer is just a call away. The
Technicians at the Mahindra And Mahindra Ltd. (Two Wheelers Division) dealer are
thoroughly trained and our workshops have'State of Art' equipment to take care of your
Mojo.

So make sure to take your Mojo to the nearest Mahindra And Mahindra Ltd. (Two
Wheelers Division) dealer for regular service and check- ups. Nobody understands your
motorcycle better than we do..

We strongly urge you to practice safe riding and please do remember to wear a helmet at
all times while riding. Don’t forget a helmet for the pillion rider as well.

Wishing you a happy and safe ride.

Thank you.

Warm Regards,
Customer Care
Mahindra And Mahindra Ltd. (Two Wheelers Division),
D-1 Block, Plot No. 18/2(Part) M.I.D.C.,
Chinchwad, Pune - 411 019.
E-mail Id : care.customer@mahindra.com
Help Line No.: 1800 233 8883 (Toll Free)
CONTENTS :
DESCRIPTION PAGE NO.
MOTORCYCLE IDENTIFICATION 1
TECHNICAL SPECIFICATION 3
SAFETY GUIDELINES 5
SAFE LOADING AND ACCESSORIES 7
DAILY SAFETY CHECKLIST 8
RECOMMENDED USAGE GUIDELINES 9
PART LOCATION 11
PART FUNCTION 14
INSTRUMENTS AND INDICATORS 15
MULTI- FUNCTION DISPLAY 18
BRAKES 24
CLUTCH 26
COOLANT 28
FUEL 30
ENGINE OIL 33
TUBELESS TYRES 34
ESSENTIAL INDIVIDUAL COMPONENTS 38
RIGHT HANDLEBAR CONTROLS 39
LEFT HANDLEBAR CONTROLS 40
FEATURES 41
SEAT 42
DOCUMENT BAG 42
STARTING THE ENGINE 44
RIDING 46
BRAKING 47
CONTENTS :
DESCRIPTION PAGE NO.

PARKING 48
ANTI-THEFT TIPS 48
MAINTENANCE 49
• SAFETY PRECAUTIONS 51
• MAINTENANCE SCHEDULE 52
• TOOL KIT 55
• AIR CLEANER 56
• ENGINE OIL 57
• THROTTLE OPERATION 60
• COOLANT 61
• DRIVE CHAIN 62
• FRONT AND REAR SUSPENSION INSPECTION 68
• SIDE STAND 68
• WHEEL REMOVAL 69
• BRAKE PAD WEAR 73
BATTERY 75
FUSE REPLACEMENT 77
CLEANING 79
STORAGE GUIDE 81
TAKING CARE OF THE UNEXPECTED IF YOU CRASH 82
CATALYTIC CONVERTER 83
BASIC TROUBLE SHOOTING 84
WARRANTY 100
MOTORCYCLE IDENTIFICATION
Frame No. (Alpha Numeric 17 digit)

xxx
xxx x
xxx
xxx
xxx
xxx
FRAME xx

NUMBER

Frame No. is stamped on the left side of the steering stem of the chassis.

VIN NUMBER - 17 DIGIT

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
M C D K E 1 C 1 6 F 1 J 0 0 0 0 1
WMI Code Model Code Drive Engine Transmission Year Code Plant Code Month Code Production Serial No
VIN - Vehicle Identification Number
1
Engine No. (Alpha Numeric 11 digit)

xxxx
xxxxxxxxxxxx

ENGINE
NUMBER

Engine No. is stamped on the lower side of the LH crankcase .

Electric start
1 2 3 4 5 6 7 8 9 10 11
U F E F J 0 0 0 0 0 1
Model Code Engine Year Code Month Code Serial No

2
TECHNICAL SPECIFICATIONS
Dimensions Overall Length : 2100 mm
Overall Width : 800 mm
Overall Height : 1165.5 mm
Wheelbase : 1465 mm
Minimum Ground Clearance : 173.5 mm
Weight Kerb Weight (With 90% Fuel, : 182 kg
Tools etc.)
: 1500 ml
Capacities Engine Oil - Overhauling
Engine Oil - Service Fill : 1250 ml [ CASTROL - SAE 10W-50
API SL JASO MA-2 [
Fuel Tank : 21 Liters

Engine Max Torque : 30 N.m @ 5500 rpm

Bore And Stroke : 76 x 65 mm
Compression Ratio : 11:1
Displacement : 294.72 cm3
Spark Plug (Standard) : Bosch UR 3CP30
Spark Plug Gap : 0.7 mm
Valve Clearance (Cold ) : Intake : 0.080 ~ 0.100 mm
Exhaust : 0.150 ~ 0.180 mm
Idle Speed : 1500 ± 100 rpm

3
Chassis And Suspension
Chassis Type : Tubular
Front Suspension : USD FORK
Rear Suspension : Gas charged Mono shock with IFP (Internal Floating Piston)
Power Transmission
Primary Reduction : 2.346
Final Ratio : 3.46
st
Gear Ratio, 1 : 2.846
nd
2 : 1.813
rd
3 : 1.389
th
4 : 1.143
th
5 : 0.957
th
6 : 0.833
Electrical Alternator Output : 90W -5th, 6th, 110W-Electric start
Lights Head Lamp : 12V 35/35W
Tail / Brake light : LED
Turn Signal Indicator : 12V, 10W
Number Plate Bulb : 12V, 5W
Fuse Capacity : 5A, 10A, 15A & 30A
ITEM SPECIFICATION
Starting System Electric
Speedometer Digital
Wheels Alloy Wheel
Battery 12V 11.2Ah, VRLA / 9Ah, VRLA
Tyre Size - Front 110/70R17 M/C 54W
Rear 150/60R17 M/C 66W
4
SAFETY GUIDELINES :
Importance of Safety :
Your motorcycle will provide many years of service and pleasure if you take
responsibility for your own safety and understand the challenges that you can meet on
the road.
There is much that you can do to protect yourself while riding the vehicle. You will find
many helpful recommendations throughout this manual. The most important are -
a) Always wear a Helmet
b) Make yourself visible for other road user to see
c) Ride within your limits.
Mahindra And Mahindra Ltd. (Two Wheelers Division) urges you to practice safe
riding. Here are few tips :
 Familiarize yourself thoroughly with your motorcycle by reading this Owner's
Manual and follow operating instructions especially with regard to starting,
accelerating and applying brakes on your vehicle.
 Initially, before riding in regular traffic practice riding in an uncongested area to
familiarize yourself with your Mojo motorcycle.
 Stay within speed limits as dictated by road, weather and traffic conditions. Riding
at a proper speed and avoiding unnecessary acceleration is important for your
safety. It also improved fuel consumption and increases longevity of your vehicle.
Helmets & Eye Protection :
Wearing a proper motorcycle helmet is most important because it offers, the best
protection against head injuries in the event of an accident. The helmet should fit your
head comfortably and securely. Always wear eye protection when riding your
motorcycle.
5
Additional Riding Safety Tips :
Always wear sturdy footwear with non slip soles to help protect your feet and ankles.
Leather gloves, when worn will keep your hands warm and will help to prevent blisters,
cuts and burns in the unfortunate event of an accident.
A motorcycle riding suit or jacket will go a long way in preventing road rash .
l If you must ride through the rain, exercise greater caution to avoid skidding. Make
sure your throttle and brake inputs are gentle and smooth when riding on wet
surfaces.
l To avoid head injury in accidents, always wear a helmet (conforming to
appropriate specified standards).
l We also recommend wearing other protective apparel such as gloves, footwear etc.
l When faced with speed breakers and potholes, slow down your
vehicle to avoid loss of control and mechanical damage to your motorcycle.
l During braking, use both front and rear brakes simultaneously.
l Always follow the traffic rules.
l Always carry original documents of motorcycle’s registration, insurance, PUC
Certificate and a valid driving license with you.

WARNING : Wearing a helmet safeguards for any serious injury. Be sure you and
your pillion rider also always wears a helmet and preferable eye protection with other
protective apparel while riding.

6
SAFE LOADING AND ACCESSORIES :
General guidelines to help you to decide how to equip your motorcycle and how to
load it safely :

l Check that both tyres are properly inflated, with recommended air tyre pressure.
l Ensure all luggage and accessories are secure for stable handling of the vehicle.
l Do not carry items that protrude beyond the width and length of motorcycle that
may affect the performance and operation of the vehicle.
l Do not carry children or pets on the petrol tank or between the rider and the petrol
tank.
l Do not modify the motorcycle. It has been designed carefully by our experts and
any modification may adversely impact its safety and performance and may even
be illegal.

Loading Guidelines :
Your motorcycle is primarily intended for transporting you and a pillion. If you wish to
carry cargo, check with your Mahindra Two Wheelers dealer for advice. Improper
loading of your motorcycle can affect its stability and handling. Even if your motorcycle
is properly loaded with cargo, you should always ride at a reduced speed.

7
DAILY SAFETY CHECKLIST :
Enjoy safe & trouble free ride, ensure following pre-ride checks :-
Ÿ There is enough fuel in the tank to cover your planned journey and there is no
fuel leakage.
Ÿ Engine oil level is adequate.
Ÿ Coolant level is adequate.
Ÿ Throttle operation and its return is smooth.
Ÿ Steering lock is operating well.
Ÿ Brakes are not dragging.
Ÿ Check the functioning of electrical equipment.
Ÿ Side stand is at fully retracted position.
Ÿ Tyres have correct air pressure, adequate tread depth and there are no
cracks/cuts on them.
Ÿ Rear view mirrors are positioned to give good rear visibility.
Ÿ MIL should not glow on speedometer.
Ÿ Check side stand indicator on speedometer.

8
RECOMMENDED USAGE GUIDELINES :
Running-In Procedure :
It is important to ride your motorcycle properly during the initial 1000 kms to ensure
longevity and hassle free running.
Please follow the instructions mentioned below during the course of the "Running-In"
period :
l Avoid full throttle operation and rapid acceleration.
l After you start the engine, run it at idle for a minute to enable the oil and coolant to
circulate within entire the engine and cooling system.
l After ignition is on, do not crank till speedo self check completion (time-5sec).

Cleaning Procedure :
l Avoid spraying water under high pressure on following areas :
t Silencer outlet, decals, switches and speedometer
t Ignition switch, handlebar switches and other electrical parts.
t Throttle body & intake manifold.
t Under seat storage.
t Radiator fins.
l After cleaning, rinse the motorcycle thoroughly with plenty of clean water.
l Dry the motorcycle, start the engine and let it run for few minutes in idling.
l Test the brakes before riding in traffic. Applications of brakes several times may be
necessary to restore normal braking performance.
Note:- Do not give throttle while starting the bike.

CAUTION :
Immediately after washing the motorcycle braking performance may be impaired.

9
General Tips for Maximizing Fuel Efficiency :
While your Mojo has been designed to give maximum fuel efficiency, it is important to
understand that fuel efficiency is affected by several extraneous factors i.e. rider usage
habits, road conditions, traffic, wind direction etc.
l Ensure tyre pressure is maintained as per manufacturer’s recommended
specifications.
Different tyre pressures are recommended for single seat and double seat riding.
observe them carefully.
l Front and Rear brakes should have the right amount of free play.
l Engine oil should be changed diligently as recommended in the maintenance
schedule.
l Total weight loaded on to the two wheeler makes a big difference to mileage,
therefore avoid unnecessary overloading.
l Petrol expands during daytime when atmospheric temperature is relatively
higher, hence it is recommended to refill the tank preferably early in the
morning or late in the evening when outside ambient temperature is relatively low.
l Keep your Mojo clean and dust free.
l Do not fill fuel to the brim of the tank as there can be spillage as petrol can expand
and consequently overflow.
l Fill petrol from busy and well known petrol stations where quality and quantity are
assured.
l Do not rev the engine unnecessarily.
l Try and avoid congested roads as far as possible, even if it means you have to take a
slightly longer route.
l Go gentle on the throttle.
l Use Recommended chain play setting.

10
 PART LOCATION
6
14

7 8

4
5 11
9

10

3 2 1 12
13

1. Horn switch 6. Rear view mirror 11. Engine kill switch

2. Turn signal switch 7. Instrument panel 12. Self-start switch
3. Head light dimmer switch 8. Ignition switch 13. Fuel tank lid
4. Pass light switch 9. Front brake lever 14. Front brake fluid reservoir
5. Clutch lever 10. Throttle grip

11
LEFT SIDE VIEW

5
6

1
3 4
2

1. Gear shift pedal 3. Side stand 5. Grab Rail

2. LH Side cover 4. Pillion foot rest 6. Seat Lock

12
RIGHT SIDE VIEW

6 8
3 7

2 5
1
4

1. Pillion foot rest 4. RH Side cover 7. Seat

2. Rider foot rest 5. Rear brake pedal 8. Fuse Location
3. Battery 6. Tool kit

13
PART FUNCTION 1
IGNITION SWITCH 2

1. Ignition switch N
O

2. Ignition key

OFF
SH
PU
3. Steering lock position
3

Key Position Function Key Removal

ON The engine can be started. Turn signal lights, Key cannot be removed.
Horn, Stop light and fuel indicator can be
operated.
OFF Engine cannot be started. Lights and Key can be removed.
indicators cannot be operated.

LOCK Steering is locked. Key can be removed.

Note:- Ignition will perform after kill switch in ON condition

14
INSTRUMENTS AND
INDICATORS
The indicators are contained in the instrument panel. Their 1
functions are described in the tables on the following pages. 2
3
(1)Multi-function display
(2) Tachometer
16
(3) Engine Over-speed indicator
15
(4) Digital Clock
14
(5) Fuel Indicator
(6) Speedometer 13 4
SIDE
STAND

(7) Odometer 12 TRIP

5
(8) Right Push Button (Reset button) 11 6
(9) Engine coolant temperature indication
7
(Red Light ON) 9
10
(10) Left Push Button (Mode Button) 8
(11) Right Turn Indicator (Green Light Blinking)
(12) Side Stand Indicator (Red Light ON)
(13) MIL (malfunction Indication light) (Amber Light ON)
(14) Neutral Indication (Green Light ON)
(15) High Beam Indication (Blue Light ON)
(16) Left Turn Indicator (Green Light Blinking)

15
 Description Sign Function
1. Multi-function display The display includes the following
functions.
This display shows the initial display.
(a) Speedometer Shows riding speed.
(b) Odometer Shows accumulated mileage.
(c) Tripmeter (Trip 1/Trip 2) Shows mileage per trip.
(e) Fuel gauge Shows approximate fuel available.
(f) Digital clock Shows hour and minute.
2. Tachometer Shows engine revolutions per minute The
tachometer needle will swing to the
maximum scale on the dial once when the
ignition switch is turned ON
3. Limp Home If coolant lamp warning light is ON & MIL
lamp also ON & if engine rpm is not going
beyond 5000 rpm, then please take the
vehicle to dealership immediately. In this
condition, engine will not run beyond 5000
rpm. This function is for safety of engine &
vehicle preventing from damages.
4. Neutral indicator (green) Lights when the transmission is in neutral.

16
 Description
5. Right turn signal indicator
(Green)
6. High beam indicator (blue)
7. Right push button (Reset)
8. Left push button (Mode)
9. EFI malfunction(Amber MIL)
10. Left turn signal indicator
(Green)
11. Engine over speed Indication
12. Coolant temp warning
indicator
13. Side stand
STAND
Sign Function
Flashes when the right turn signal operates.
Lights when the headlight is on high beam.
This button is used to reset the tripmeter
or to set the digital clock.
This button is used to select the odometer
and tripmeter or to set the digital clock.
Lights when there is any abnormality in the
system. If it comes on at any other time,
reduce speed and take the motorcycle to
your dealer as soon as possible.
Flashes when the left turn signal operates
Indication ON when engine RPM crosses
8500 (Tachometer warning light) rpm
When coolant temperature is at a high of
1150 C. It is a warning signal to the user
SIDE
Flash when side stand ON.
17
Multi-function Display 1
2
Multi-function display (1) includes the
following functions:
(a) Odometer/Tripmeter
(b) Fuel gauge
(c) Digital clock
6
SIDE
STAND

TRIP

3
4

(1) Multi-function display

(2) Tachometer
(3) Odometer/Tripmeter
(4) High coolant temperature indicator
(5) Fuel gauge
(6) Digital clock

18
Speedometer
Shows riding speed. 1
Odometer/Tripmeter
2
The odometer (2) shows accumulated
mileage. TRIP

The tripmeter (3) shows mileage per trip.

There are two trip meter available Trip 1,
Trip 2.Push the MODE button (4) to select
the odometer and tripmeter.
To reset the tripmeter, push and hold the 3
RESET button (5) for more than 2 seconds 4
when the display is in the trip meter.
Push the Mode button (4) for 3 second to
check Max speed in trip. To reset the Max
speed push the reset button (5).
5
Coolant Temperature
(1) Speedometer (4) MODE button
Overheating Indicator or Coolant
Temperature warning : (2) Odometer (5) RESET button
When the coolant is over specified (3) Tripmeter
temperature , the red indication lights on .
Your Mojo is protected with limp home
mode. If the coolant temperature reaches
above specified limit, engine rpm is
automatically limited up to 5000 rpm. This
is done to protect the engine safety.
Note:- Engine rpm limited up to 5000 rpm
in limp home mode.
19
Fuel Gauge 2
The fuel gauge liquid crystal display (1)
shows the approximate available fuel in a
graduated display. When all segments up
to F (2) are on, the fuel tank is full.
The fuel tank capacity is: 21.0 Lt.
When there is only one segment (3) left, fuel
will be low and you should refuel as soon as
possible.
The amount of fuel left in the tank with the
vehicle set upright is approximately: 2.5 Lt.
This segment flashes when the fuel 1
decreases further.

(1) Fuel gauge

(2) Segment F
(3) Segment E
20
Digital Clock 3. To set the hour, push the RESET
button until the desired hour is
Shows hour and minute. To set the digital displayed.
clock, proceed as follows:
The time is advanced by one hour,
each time the button is pushed.
1. Turn the ignition switch ON.
2. Push and hold both the MODE button (2)
and RESET button (3) for more than 3
seconds. The clock will be set in the adjust
mode with the hour (1) display flashing

Push the MODE button. The 1st digit of

minute display will start flashing.
2 3

(1) Digital clock

(2) MODE button
(3) RESET button

21
1st digit in minute mode start blinking. Press the MODE button to complete the clock
setting.
Press the RESET button to set the 1st digit of
minute until the desired digit of minute.
Press the MODE button to set the 2nd digit of
minute.
Press the RESET button to set the 2nd digit of
minute until the desired digit of minute.

Note:-The clock will be reset if the battery

is disconnected.

22
MAJOR COMPONENTS
(Information you need to operate
this motorcycle)
SUSPENSION
The rear shock absorber (1)has infinitesimal
positions for different load or riding
conditions.
Use spanner set (holding & adjusting
spanner) with extension bar to adjust the
spring pre-load.
Ensure to lock the adjustment nut after pre-
load adjustment.
Moving the adjustment nut clockwise will 1
increase spring pre-load & anti-clockwise
will reduce spring pre-load. 2

(1) Rear shock absorber

(2), (3) Spanner

23
BRAKES
1
Both the front and rear brakes are the LOWER

hydraulic disc type. As the brake pads wear,

the brake fluid level drops. There are no
adjustments to perform, but fluid level and
pad wear must be inspected periodically.
The system must be inspected frequently to
ensure there are no fluid leaks. If the brake
lever or pedal free travel becomes excessive
and the brake pads are not worn beyond the
recommended limit, there is probably air in (1) LOWER level mark
the brake system and it must be bled. Contact
your dealer to get this serviced.
Front Brake Fluid Level:
With the motorcycle in an upright position,
check the fluid level. It should be above the
LOWER level mark (1). If the level is at or
below the LOWER level mark, check the
brake pads for wear (page 73 ).
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid to be used is
DOT 4 from a sealed container.

24
Rear Brake Fluid Level:
With the motorcycle in an upright position,
check the fluid level. It should be between the
UPPER(1) and LOWER(2) level marks. If the
level is at or below the LOWER level mark, 1
check the brake pads for wear (page 73 ). UPPER

LOWER
2
Worn pads should be replaced. If the pads
are not worn, have your brake system
inspected for leaks.
The recommended brake fluid to be used is
DOT 4 from a sealed container.
(1) UPPER level mark
Other Checks: Make sure there are no fluid (2) LOWER level mark
leaks. Check for deterioration or cracks in the
hoses and fittings.

25
CLUTCH
Clutch adjustment may be required if the
motorcycle stalls when shifting into gear or 2
tends to creep; or if the clutch slips, causing
acceleration to lag behind engine speed.
Minor adjustments can be made with the
clutch cable adjuster (1 ) at the clutch lever
(2).
Normal clutch lever free play is:
(10 ~ 12.5 mm (2.5~3 mm at pivot end)
4
1. Pull back the rubber dust cover (3). 3
2. Loosen the lock nut (4) and turn the clutch
cable adjuster. Tighten the lock nut and check
the adjustment.
3. If the adjuster is threaded out near its limit
or if the correct freeplay cannot be obtained, 1
using the clutch cable adjuster, loosen the
locknut and turn the clutch cable adjuster
completely. Tighten the lock nut and install
the rubber dust cover. (1) Clutch cable adjuster
(2) Clutch lever
(3) Rubber dust cover
(4) Lock nut

26
4. Loosen the lock nut (5) at the lower end of 5
the cable. Turn the adjusting nut (6) to obtain
the specified freeplay. Tighten the lock nut
and check the adjustment.
5. Start the engine, pull in the clutch lever and
shift into gear. Make sure the engine does not A
stall and the motorcycle does not creep.
Gradually release the clutch lever and open B
the throttle. The motorcycle should begin to
move smoothly and accelerate gradually.
If proper adjustment cannot be obtained or
the clutch does not work correctly, see your
dealer. 6
Other Checks:
Check the clutch cable for links or signs of (5) Lock nut
wear that could cause sticking or failure.
Lub ricate t he clut ch cable wit h a (6) Adjusting nut
commercially available cable lubricant to
prevent premature wear and corrosion.
(A) Increase freeplay
(B) Decrease freeplay

27
COOLANT
Coolant Recommendation
Use only genuine COOLANT containing corrosion inhibitors, specifically recommended
for aluminum engines when adding or replacing the coolant.

The coolant should be inspected and replaced properly by following the maintenance
schedule (page 52 ).
Coolant Specification :-
Castrol Radicool SF-0 Premix

Qty - 1400 ml.

Note:- Do not use non-ethylene glycol coolant, tap water, nor mineral water when

adding or replacing the coolant. Use of improper coolant may cause damage, such as

corrosions in the engine, blockage of the cooling passage or radiator and premature

wear of the water pump seal. Use any genuine COOLANT without diluting with water.

28
Inspection 4
3
The reserve tank is located on the right side of
the crankcase under RH radiator cowl. Check
the coolant level in the reserve tank (1) while
the engine is at the normal operating
temperature with the motorcycle in an
upright position. If the coolant level is below 2 1
the LOWER level mark, add coolant mixture
until it reaches the UPPER level mark (3).
(1) Reserve tank
Always add coolant to the reserve tank. Do
(2) LOWER level mark
not attempt to add coolant by removing the
(3) UPPER level mark
radiator cap.
(4) Reserve tank cap

If the reserve tank is empty, or if coolant loss

is excessive, check for leaks and see your
dealer for repair.

29
FUEL
Fuel Tank
The fuel tank capacity including the reserve
supply is: 21 lt.
To open the fuel fill cap, open the lock 1 cover,
insert the ignition key and turn it clockwise. The
fuel fill cap will pop up and can be lifted off. Do not
overfill the tank. There should be no fuel above the
level plate.
After refueling, to close the fuel fill cap, align the
latch in the cap with the slot in the filler neck. Push
the fuel fill cap into the filler neck until it snaps
closed and locks. Remove the key and close the
lock cover. Key must be inserted in cap to close it.
Petrol is highly flammable and explosive. You can
be burned or seriously injured when handling fuel.
Stop the engine and keep heat, sparks, and flame
away. Refuel only outdoors. Wipe up spills
immediately.

Warning :- Petrol is highly flammable and explosive. You can be burned or seriously
injured when handling fuel.Stop the engine and keep heat, sparks, and flame away.
Refuel only outdoors. Wipe up spills immediately.

30
Use unleaded petrol with a research octane
3
number of 91 or higher.

The use of leaded petrol will cause

premature damage to the catalytic converter.

2
1
Notice
(1) Fuel fill cap
If ‘‘spark knock’’ or ‘‘pinking’’ occurs at a (2) Lock cover
steady engine speed under normal load, (3) Ignition key
change brands of petrol. If spark knock or
pinking persists, consult your dealer.

Failure to do so is considered misuse, and

damage caused by misuse is not covered by
Warranty.

31
Petrol Containing Alcohol

If you decide to use a petrol containing alcohol (gasohol), be sure its octane rating is at
least as high as that recommended. There are two types of ‘‘gasohol’’: one containing
ethanol, and the other containing methanol. Do not use petrol that contains more than 10
% ethanol. Do not use petrol containing methanol (methyl or wood alcohol) that does
not also contain co solvents and corrosion inhibitors for methanol. Never use petrol
containing more than 5 % methanol, even if it has co solvents and corrosion inhibitors.

The use of petrol containing more than 10 % ethanol (or more than 5 % methanol) may:

Damage the painting of the fuel tank.

Damage the rubber tubes of the fuel line.

Cause corrosion of the fuel tank.

Cause poor drivability.

Before buying fuel from an unfamiliar station, try to find out if the fuel contains alcohol.
If it does, confirm the type and percentage of alcohol used. If you notice any undesirable
operating symptoms while using a petrol that contains alcohol, or one that you think
contains alcohol, switch to a petrol that you know does not contain alcohol.

Note: This bike is equipped with Electronic fuel injection. It is recommended to use
RON 91 octane petrol.

32
ENGINE OIL
Engine Oil Level Check
Check the engine oil level each day
before riding the motorcycle.
The level must be maintained between 4
the upper (1) and lower (2) level marks.
1. Start the engine and let it idle for 3~5
minutes. 1
Upper level mark
2. Stop the engine and hold the Lower level mark
2
motorcycle in an upright position on
3
firm, level ground.
3. After 2~3 minutes, check the oil level (1) Upper level mark
is between the upper and lower level
marks in the dipstick (4). (2) Lower level mark
4. If required, remove the oil fill cap (3) (3) Oil fill cap
and add the specified oil up to the (4) Dipstick
upper level mark. Do not overfill.
5. Reinstall the oil fill cap. Check for oil
leaks.
Notice
Running the engine with insufficient
oil pressure may cause serious engine
damage.

33
TUBELESS TYRES
To safely operate your motorcycle, your tyres must be the proper type and size,
in good condition with adequate tread, and correctly inflated for the load you
are carrying. The following pages give more detailed information on how and
when to check your air pressure, how to inspect your tyres for damage, and
what to do when your tyres need to be repaired or replaced.
Note: The tyres fitted in Mojo vehicle meets the requirements of Bureau of
Indian Standards and Central Motor Vehicle Rules
Warning
Using tyres that are excessively worn or improperly inflated can cause a crash
in which you can be seriously hurt. Follow all instructions in this owner’s
manual regarding tyre inflation and maintenance.
Air Pressure
Keeping your tyres properly inflated provides the best combination of
handling, tread life and riding comfort. Generally, underinflated tyres wear
unevenly, adversely affect handling, and are more likely to fail from being
overheated. Overinflated tyres make your motorcycle ride harshly, are more
prone to damage from road hazards, and wear unevenly. We recommend that
you visually check your tyres before every ride and use a gauge to measure air
pressure at least once a month or any time you think the tyres might be low.
Tubeless tyres have some self-sealing ability if they are punctured. However,
because leakage is often very slow, you should look closely for punctures
whenever a tyre is not fully inflated.

34
Always check air pressure when your
tyres are ‘‘cold’’ when the motorcycle
has been parked for at least three
hours. If you check air pressure when
your tyres are ‘‘warm’’ when the
motorcycle has been ridden for even a
few miles the readings will be higher
than if the tyres were ‘‘cold’’. This is
normal, so do not let air out of the tyres
to match the recommended cold air
pressures given below. If you do, the
tyres will be underinflated.
The recommended ‘‘cold’’ tyre
pressures are:
kPa (kgf/cm , psi)
Rider only
Front - 200 (29)
Rear - 225 (33)
Solo with Pillion rider
Front - 200 (29)
Rear - 250 (36)
35
Inspection
Whenever you check the tyre
pressures, you should also examine
the tyre treads and sidewalls for
wear, damage, and foreign objects:
Look for:
Bumps or bulges in the side of the
tyre or the tread. Replace the tyre if
you find any bumps or bulges.
Cuts, splits or cracks in the tyre.
Replace the tyre if you can see fabric
or cord.
Excessive tread wear.
Also, if you hit a pothole or hard
object, pull to the side of the road as
soon as you can safely and carefully
inspect the tyres for Front damage.
Tread Wear

Replace tyres before tread depth at the

2
center of the tyre reaches the
following limit:
1
Minimum tread depth (TWI)

Front: 1.0 ± 0.1 mm (1) Wear indicator

(2)Wear indicator location mark
Rear: 1.0 ± 0.1 mm

36
Tyre Repair
If a tubeless tyre is punctured or damaged, please visit nearest tyre
manufacture dealer and follow his recommendation for repair or replacement.
Caution :-
Repair/Replacement of tubeless tyre by unauthorized person may render the
tyre useless or tyre can fail while driving.
Tyre Replacement
The tyres that came on your motorcycle were designed to match the
performance capabilities of your motorcycle and provide the best combination
of handling, braking, durability and comfort.
Warning
Installing improper tyres on your motorcycle can affect handling and stability.
This can cause a crash in which you can be seriously hurt or killed.
Always use the size and type of tyres recommended in this owner’s manual.
The recommended tyres for your motorcycle are:
Front: 110/70R 17 M/C 54 W
Rear: 150/60R 17 M/C 66 W
Type: Radial, tubeless
Whenever you replace a tyre, use one that is equivalent to the original.

Important Safety Reminders

Do not install a tube inside a tubeless tyre on this motorcycle. Excessive heat
buildup can cause the tube to burst. Use only tubeless tyres on this motorcycle.
The rims are designed for tubeless tyres, and during hard acceleration or
braking, a tube-type tyre could slip on the rim and cause the tyre to rapidly
deflate.
37
ESSENTIAL INDIVIDUAL
ON
COMPONENTS OFF

IGNITION SWITCH

The ignition switch (1) is at the front

side of the fuel tank. The headlight, LOCK
position lights, taillight and license
light will come on whenever you
turn the ignition switch ON. If your 1
motorcycle is stopped with the
ignition switch ON and the engine is (1) Ignition switch
not running, the position lights,
taillight and license light will still be
on, resulting in battery discharge.

Note : Engine kill switch should be

ON while ignition switch or key is
ON (Engine kill switch)

38
RIGHT HANDLEBAR CONTROLS
1
Engine Kill Switch
The engine kill switch (1) is next to the throttle
grip. When the switch is in the ( ) position, the
engine will operate. When the switch is in the
(OFF) position, the engine will not operate. This
switch is intended primarily as an emergency
switch and should normally remain in the ( ) 2
position.
If your motorcycle is stopped with the ignition
(1) Engine stop switch
switch ON and the engine kill switch ( ),
position lights, taillight and license light will (2) Start button
still be on, resulting in battery discharge.
Start Button
Always operate clutch lever to start the engine.
The start button (2) is below the Headlight ON switch.
The start button is used for starting the engine. Pushing the button starts the engine. See
Starting Procedure, page 44.
When the start button is pushed, the starter motor will crank the engine and the
headlight, position lights, taillight and license light will stay on.
Note : Always need to operate clutch to start engines.
Headlight ON (Head lamp turns ON as soon as engine is started)
Vehicle which are manufactured from April 20017 onwards having “Automatic Head
Lamp ON” system.

39
LEFT HANDLEBAR CONTROLS
1 2
Headlight Dimmer Switch (1)

Push the headlight dimmer switch to (HI) to

select high beam or to (LO) to select low
beam.
3
Passing Light Control Switch (2) 4

When this switch is pressed, the headlight

flashes on to signal approaching cars or
when passing.

Turn Signal Switch (3)

(1) Headlight dimmer switch
Move to (L) to signal a left turn, (R) to signal
(2) Passing light control switch
a right turn. Press to turn signal off.
(3) Turn signal switch
(4) Horn button
Horn Button (4)

Press the button to sound the horn.

40
 To lock
FEATURES
(A)

(Not required for operation)

STEERING LOCK (B)

To lock the steering, turn the handlebar all (C)

the way to the left, turn the ignition key (1) to (A)
LOCK while pushing in. Remove the key. To To unlock
1
unlock the steering, turn the key to OFF.

Do not turn the key to LOCK while riding

the motorcycle; loss of vehicle control will
(1) Ignition key
result. (A) Push in
(B) Turn to LOCK
(C) Turn to OFF

41
SEAT
Rear seat 1

To remove the rear seat (1), insert the

ignition key (2) into the seat lock (3) and
tounge (4). Turn it clockwise, then pull the
rear seat up and back.
To install the rear seat, insert the Tounge 4
into the below fuel tank, and then push
down on the rear of the rear seat.
Be sure the seat is locked securely in position
after installation.
3 2
(1) Rear seat (2) Ignition key
(3) Seat lock (4) Tounge
DOCUMENT BAG
1
The document compartment (1) is under the
rear seat.
This owner’s manual and other documents
should be stored in the document bag.
When washing your motorcycle, be careful
not to flood this area with water.

(1) Document compartment

42
OPERATION
PRE-RIDE INSPECTION
For your safety, it is very important to take a few moments before each ride to walk
around your motorcycle and check its condition. If you detect any problem, be sure
you take care of it, or have it corrected by your dealer.
Warning
Improperly maintaining this motorcycle or failing to correct a problem before riding
can cause a crash in which you can be seriously hurt .
Always perform a pre-ride inspection before every ride and correct any problems.
Engine oil level: Add engine oil if required. Check for leaks.
Fuel level: Fill fuel tank when necessary. Check for leaks.
Coolant level: Add coolant if required. Check for leaks.
Front and rear brakes: Check operation; make sure there is no brake fluid leakage.
Check tyres condition and pressure.
Drive chain: Check condition and slack. Adjust and lubricate if necessary.
Throttle check: For smooth opening and full closing in all steering positions .
Lights and horn: Check that headlight, brake/tail light, position lights, license light,
turn signals, indicators and horn function properly.
Engine kill switch check: For proper function.

43
STARTING THE ENGINE
Always follow the proper starting procedure described below.
Your motorcycle’s exhaust contains poisonous carbon monoxide gas. High levels of
carbon monoxide can collect rapidly in enclosed areas such as a garage.
Do not run the engine with the garage door closed. Even with the door open, run the
engine only long enough to move your motorcycle out of the garage.
To protect the catalytic converter in your motorcycle’s exhaust system, avoid extending
idling and the use of leaded petrol.
Do not use the electric starter for more than 5 seconds at a time. Release the start button
for approximately 10 seconds before pressing it again.

Preparation
Before starting, insert the key, turn the ignition switch ON and confirm the following:
The transmission is in neutral (neutral indicator is ON).
The engine kill switch is at ( ).
The EFI malfunction indicator lamp (MIL) is OFF.
Starting Procedure
This motorcycle has a fuel-injected engine with an automatic choke. Follow the
procedure indicated below.
With the throttle completely closed, press the start button.
The engine will not start if the throttle is fully open (because the electronic control
module cuts off the fuel supply).

44
Flooded Engine

Press the start button for 5 seconds.

Follow the normal starting procedure.

If the engine starts with unstable idle, open the throttle slightly.

If the engine does not start, wait for 10 seconds, then follow steps again.

Ignition Cut Off

Your motorcycle is designed to automatically stop the engine and fuel pump if the
motorcycle is over-turned (a rollover sensor cuts off the ignition system). Before
restarting the engine, you must turn the ignition switch to the OFF position and then
back to ON.

RUNNING-IN

Help assure your motorcycle’s future reliability and performance by paying extra
attention to how you ride during the first 1000 kms.

During this period, avoid full-throttle starts and rapid acceleration.

45
RIDING
Review Motorcycle Safety before you ride.
Make sure the side stand is fully retracted before riding the motorcycle. If the stand is
extended, it may interfere with control during a left turn.
Make sure flammable materials such as dry grass or leaves do not come in contact with
the exhaust system when riding, idling, or parking your motorcycle.
1. After the engine has been warmed up, the motorcycle is ready for riding.
2. While the engine is idling, pull in the clutch lever and depress the shift lever to
shift into 1st (low) gear.
3. Slowly release the clutch lever and at the same time gradually increase engine
speed by opening the throttle. Coordination of the throttle and clutch lever will
assure a smooth positive start.
4. When the motorcycle attains a moderate speed, close the throttle, pull in the
clutch lever and shift to 2nd gear by raising the shift lever.
This sequence is repeated to progressively shift to 3rd, 4th, 5th and 6th (top) gear.
5. Coordinate the throttle and brakes for smooth deceleration.
6. Both front and rear brakes should be used at the same time and should not be
applied strongly enough to lock the wheel, or braking effectiveness will be reduced
and control of the motorcycle will be difficult.

46
BRAKING
For normal braking, apply both the brake pedal and lever while down-shifting to match
your road speed. For maximum braking, close the throttle and firmly apply the pedal
and lever; pull in the clutch lever before coming to a complete stop to prevent stalling of
the engine.

Important Safety Reminders:

• Independent operation of only the brake lever or brake pedal reduces stopping
performance.
• Extreme application of the brake controls may cause wheel lock, reducing control of
the motorcycle.
• Whenever possible, reduce speed or brake before entering a turn; closing the throttle
or braking in mid-turn may cause wheel slip. Wheel slip will reduce
control of the motorcycle.
• When riding in wet or rainy conditions, or on loose surfaces, the ability to maneuver
and stop will be reduced. All of your actions should be smooth under these
conditions. Rapid acceleration, braking or turning may cause loss of control. For
your safety, exercise extreme caution when braking, accelerating or turning.
• When descending a long, steep grade, use engine compression braking by
downshifting, with intermittent use of both brakes. Continuous brake application
can overheat the brakes and reduce their effectiveness.
• Riding with your foot resting on the brake pedal or your hand on the brake lever
may actuate the brakelight, giving a false indication to other drivers. It may also
overheat the brakes, reducing effectiveness.

47
PARKING
1. After stopping the motorcycle, shift the transmission into neutral, turn the
handlebar fully to the left, turn the ignition switch OFF and remove the key.
2. Use the side stand to support the motorcycle for parking.
Park the motorcycle on firm, level ground to prevent it from falling over. If you must
park on a slight incline, aim the front of the motorcycle uphill to reduce the possibility of
rolling off the side stand or overturning.
3. Lock the steering to prevent theft .
The exhaust pipe and muffler become very hot during operation and remain sufficiently
hot to inflict burns if touched even after shutting off the engine.
Make sure flammable materials such as dry grass or leaves do not come in contact with
the exhaust system when parking your motorcycle.
ANTI-THEFT TIPS
1. Always lock the steering and never leave the key in the ignition switch. This sounds
simple but people do forget.
2. Be sure the registration information for your motorcycle is accurate and current.
3. Park your motorcycle in a locked garage whenever possible.
4. Put your name, address, and phone number in this Owner’s Manual and keep it
with your motorcycles at all times. Many times stolen motorcycles are identified by
information in the Owner’s Manuals that are still with them.
NAME :.........................................................................................................................................
ADDRESS : ..................................................................................................................................
PHONE NO :...............................................................................................................................

48
MAINTENANCE

THE IMPORTANCE OF MAINTENANCE

A well-maintained motorcycle is essential for safe, economical and trouble-free riding. It

will also help reduce air pollution.

To help you properly care for your motorcycle, the following pages 52-54 include a
Maintenance Schedule and a Maintenance Record for regularly scheduled maintenance.

These instructions are based on the assumption that the motorcycle will be used
exclusively for its designed purpose. Sustained high speed operation or operation in
unusually wet or dusty conditions will require more frequent service than specified in
the Maintenance Schedule. Consult your dealer for recommendations applicable to
your individual needs and use.

WARNING
If your motorcycle overturns or becomes involved in a crash, be sure your dealer
inspects all major parts, even if you are able to make some repairs. Improperly
maintaining this motorcycle or failing to correct a problem before you ride can cause
a crash in which you can be seriously hurt. Always follow the inspection and
maintenance recommendations and schedules in this owner’s manual.

49
MAINTENANCE SAFETY

This section includes instructions on some important maintenance tasks. You can
perform some of these tasks with the tools provided if you have basic mechanical skills.

Other tasks that are more difficult and require special tools are best performed by
professionals. Wheel removal should normally be handled only by a Mahindra
technician or other qualified mechanic; instructions are included in this manual only to
assist in emergency service.

Some of the most important safety precautions follow. However, we cannot warn you of
every conceivable hazard that can arise in performing maintenance. Only you can
decide whether or not you should perform a given task.

WARNING
Failure to properly follow maintenance instructions and precautions can cause you to
be seriously hurt .

Always follow the procedures and precautions in this owner’s manual.

50
SAFETY PRECAUTIONS
• Make sure the engine is off before you begin any maintenance or repairs. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust.
Be sure there is adequate ventilation whenever you operate the engine.
• Burns from hot parts.
Let the engine and exhaust system cool before touching.
• Injury from moving parts.
Do not run the engine unless instructed to do so.
• Read the instructions before you begin, and make sure you have the
tools and skills required.
• To help prevent the motorcycle from falling over, park it on a firm, level surface,
using the side stand or a maintenance stand to provide support.
• To reduce the possibility of a fire or explosion, be careful when working around
fuel or batteries. Use only nonflammable solvent, not petrol, to clean parts. Keep
cigarettes, sparks and flames away from the battery and all fuel-related parts.
Remember that your Mahindra Two Wheelers dealer knows your motorcycle best and is
fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new Mahindra Genuine Parts or their
equivalents for repair and replacement.

51
 SERVICE SCHEDULE
SERVICES 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th
MONTHS 1 6 12 18 24 30 36
KM 1000 6000 12000 18000 24000 30000 36000

I = EVERY 24000 KMS R=EVERY 48000 KMS

I/R*

(Adjust if Required)

I/R I/R I/R I/R I/R

52
 SERVICE SCHEDULE
SERVICES 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th
MONTHS 1 6 12 18 24 30 36
KM 1000 6000 12000 18000 24000 30000 36000

53
 SERVICE SCHEDULE
SERVICES 1 st 2 nd 3 rd 4 th 5 th 6 th 7 th
MONTHS 1 6 12 18 24 30 36
KM 1000 6000 12000 18000 24000 30000 36000

AS & WHEN MIL FLASHES

Note:- I/R*: First check the fuel flow rate as per the SOP, If the flow rate is not as per specification, you need to
check the fuel pump filter and if required, replace it.

1) Service more frequently when riding in dusty area

2) For higher odometer reading, repeat at the frequency.
3) The vehicle must be serviced at every 6000 km or within 6 month (whichever is earlier)
from the date of previous service. Engine oil drain period 6000 kms applicable only on
CASTROL - SAE 10W-50 API SL JASO MA-2
Can be done by the customer himself.
We recommend that these items are to be attended by Authorized Mahindra
Two Wheelers service center.
These items must be attended only by Authorized Mahindra Two Wheelers
service center as they require special tools/Expertise/lubricants.

54
TOOL KIT
The tool kit ( 1) is in the tool kit compartment (2 ) under the seat.
Some roadside repairs, minor adjustments and parts replacement can be performed
with the tools available in the kit.

• SCREW DRIVER PLUS MINUS

• HOLDER DRIVE
• OPEN SPANNER 8 X 10 MM

TOOL KIT
• ALLEN KEY 6 MM
• ALLEN KEY 4 MM
• ALLEN KEY 5 MM
• SPARE FUSE KIT ASSY
• TOOL BAG 2
1
• SPARK PLUG REMOVER
1) Tool kit
• FUSE PULLER
2) Tool kit compartment

55
AIR CLEANER
Refer to the Safety Precautions on page 51.
Your Mojo is fitted with dry Paper Filter. The air cleaner should be serviced at regular
intervals (page 52). Service more frequently when riding in unusually wet or dusty
areas.
1. Remove the seat.
2. Remove the fuel tank.
3. Remove the air cleaner case cover (1) by removing the screws .
4. Remove the air cleaner element.
5. Install the new air cleaner element. Make sure the air cleaner element is fixed. Use
the Mahindra Genuine air cleaner element specified for your model. Using the
non-Mahindra air cleaner element which is not of equivalent quality may cause
premature engine wear or performance variations.
6. Install the removed parts in reverse order of removal.
This motorcycle is equipped with a paper type air cleaner element.
Note:- Do not apply any type of oil on it. 1

(1) Air cleaner case cover

56
ENGINE OIL
Refer to the Safety Precautions on page 51.
Your motorcycle does not need oil additives. Use the recommended oil.
RECOMMEDE ENGINE OIL : CASTROL - SAE 10W-50 API SL JASO MA-2
Do not use oils with graphite or molybdenum additives. They may adversely affect
clutch operation.
Engine Oil and Filter
Engine oil quality is the main factor affecting engine service life. Change the engine oil as
specified in the maintenance schedule .
When running in very dusty conditions, oil changes should be performed more
frequently than specified in the maintenance schedule.
Please dispose of used engine oil in a manner that is compatible with the environment.
We suggest you take it in a sealed container to your local recycling center or service
station for reclamation. Do not throw it in the trash or pour it on the ground or down a
drain.
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for
prolonged periods. Although this is unlikely unless you handle used oil on a daily basis,
it still advisable to thoroughly wash your hands with soap and water as soon as possible
after handling used oil.
Changing the oil filter requires a torque wrench. If you do not have it and the necessary
skill, we recommend that you have your dealer perform this service.
If a torque wrench is not used for this installation, see your dealer as soon as possible to
verify proper assembly.
Change the engine oil with the engine at normal operating temperature and the
motorcycle on its side stand to assure complete and rapid draining.

57
Engine Oil Filter Replacement Procedure

1. Place a drain pan under the crankcase.

2. To drain the oil, remove the oil filler cap, oil drain bolt (1) and sealing washer (2).

3. Remove the oil filter cover (3), oil filter (4 ) by removing the oil filter cover bolt ( 5).

4. Install the new oil filter. Use only the Mahindra Genuine oil filter specified for your
model. Using the non-Mahindra filter which is not of equivalent quality may cause
engine damage.

2
5 3

1 4

(1) Oil drain bolt (3) Oil filter cover (5) Oil filter cover bolt
(2) Sealing washer (4) Oil filter

58
5. Install the oil filter spring into the oil filter cover. Then, install the O-ring and oil
filter cover. Make sure the oil filter cover bolts are tightened securely to the specified
torque. Oil filter cover bolts torque:- 11 N.m

6. Check that the sealing washer (As per recommended maintenance schedule) on the
drain bolt is in good condition and install the bolt. Replace the sealing washer
every other time the oil is changed, or each time if necessary. Engine oil drain bolt
torque: - 20 N.m

7. Fill with recommended grade oil; approximately:- 1250 ml

8. Install the oil fill cap.

9. Start the engine and let it idle for 3 ~5 minutes.

10. After engine is shut off wait for 2~3 minutes. Then, use the dipstick to check the oil
level with the motorcycle upright on firm, level ground. Make sure there are no oil
leaks.

NOTICE

Improper installation of the oil filter can cause serious engine damage.

59
THROTTLE OPERATION
Refer to the Safety Precautions on page 51.
1. Check for smooth rotation of the throttle grip from the fully open to the fully closed
position at both full steering positions.
2. Measure the throttle grip freeplay at the throttle grip flange. The standard freeplay
should be approximately: 3~5 mm
To adjust the freeplay, slide the throttle cable boot (1), then loosen the lock nut (2) and
turn the adjuster (3).
After adjustment, tighten the lock nut and return the throttle cable boot securely.

2
(B )
1

(A )

(1) Throttle cable boot (A) Increase

(2) Lock nut (B) Decrease
(3) Adjuster

60
COOLANT

Refer to the Safety Precautions on page 51.

Coolant Replacement

Coolant should be replaced by your dealer, unless the owner has proper tools and
service data and is mechanically qualified.

Always add coolant to the reserve tank. Do not attempt to add coolant by removing the
radiator cap.

WARNING
Removing the radiator cap while the engine is hot can cause the coolant to spray out,
seriously scalding you.

Always let the engine and radiator cool down before removing the radiator cap.

61
DRIVE CHAIN
Refer to the Safety Precautions. The service life of
the drive chain (1) is dependent upon proper
lubrication and adjustment. Poor maintenance
can cause premature wear or damage to the drive
chain and sprockets.
The drive chain should be checked, adjusted and
lubricated as part of the periodic inspection.
Under severe usage, or when the motorcycle is
ridden in unusually dusty or muddy areas, more
frequent maintenance will be necessary.
Inspection:
1. Turn the engine off, place the motorcycle on
its side stand and shift the transmission into 1
neutral.
2. Check slack in the lower drive chain run
midway between the sprockets. Drive chain
slack should be adjusted to allow the
following vertical movement by hand:
3. Roll the motorcycle forward. Stop. Check the
drive chain slack. Repeat this procedure (1) Drive chain
several times. Drive chain slack should
remain constant. If the chain is slack only in Chain Slackness :- 30~35 mm
certain sections, some links are kinked and
binding. Binding and kinking can frequently
be eliminated by lubrication.

62
4. Roll the motorcycle forward. Stop
and place it on its side stand. Inspect
the drive chain and sprockets for any
of the following conditions:
DRIVE CHAIN Damaged Sprocket Worn Sprocket
Teeth Teeth
*Damaged Rollers
*Loose Pins REPLACE REPLACE
*Dry or Rusted Links
*Kinked or Binding Links
*Excessive Wear
*Improper Adjustment
*Damaged or Missing O-rings
SPROCKETS
*Excessively Worn Teeth Normal Sprocket Teeth

*Broken or Damaged Teeth GOOD

CAUTION
A drive chain with damaged rollers, loose pins, or missing O-rings must be replaced.
A chain which appears dry, or shows signs of rust, requires supplementary
lubrication. Kinked or binding links should be thoroughly lubricated and worked
free. If links cannot be freed, the chain must be replaced.

63
Adjustment:
Drive chain slack should be checked and adjusted, if necessary, every 1,000 km. When
operated at sustained high speeds or under conditions of frequent rapid acceleration,
the chain may require more frequent adjustment.
If the drive chain requires adjustment, the procedure is as follows:
1. Place the motorcycle on its side stand on a firm, level surface with the transmission
in neutral and the ignition switch OFF.
2. Loosen the rear axle nut (1).
3. Loosen the drive chain lock nuts on both sides of the swing arm.
4. Turn both drive chain adjusting nuts (2) an equal number of turns until the correct
drive chain slack is obtained. Turn the drive chain adjusting nuts clockwise to
tighten the chain, or counterclockwise to provide more slack. Adjust the chain slack
at a point midway between the drive sprocket and the rear wheel
sprocket. Roll the motorcycle forward. Stop and place it on its side stand. Recheck
chain slack.
Chain slack should be: 30~35 mm

(1) Rear axle nut

(2) Drive chain adjusting nut
(3) Chain adjuster index mark
1 2 (4) Rear edge of adjusting slot

64
5. Check rear axle alignment by making sure the chain adjuster index marks (4) align
with the rear edge (5) of the adjusting slots.

Both left and right marks should correspond. If the axle is misaligned, turn the left or
right adjusting nut until the marks correspond on the rear edge of the adjusting slots
and recheck chain slack.

6. Tighten the rear axle nut to the specified torque.

Rear axle nut torque: 70~80 N·m

If a torque wrench is not used for this installation, see your dealer as soon as possible
to verify proper assembly.

7. Tighten the drive chain adjusting nuts lightly, then tighten the drive chain lock nuts
by holding the drive chain adjusting nuts with a spanner.

8. Recheck drive chain slack.

65
Wear Inspection:

Check the chain wear label when adjusting the chain. If the red zone (6) on the label
aligns with the arrow mark (7 ) on the chain

adjuster plates after the chain has been adjusted to the proper slack, the chain is
excessively worn and must be replaced. The proper slack is: 30 ~ 35 mm

Damage to the bottom part of the frame may be caused by excessive drive chain slack of
more than: 50 mm(2.0 in) Chain: RS20HNXR (110 Links)

If necessary, have the drive chain replaced by your dealer.

(6) Red zone

(7) Arrow mark

66
Lubrication and Cleaning :
Lubricate every 1,000 km or sooner if chain appears dry.
After inspecting the slack, clean the chain and sprockets while rotating the rear wheel.
Use dry cloth with chain cleaner designed specifically for O-ring chains, or neutral
detergent. Use a soft brush if the chain is dirty.
After cleaning, wipe dry and lubricate with drive chain lubricant designed specifically
for X-Ring. If not available, use MOTUL C1 chain cleaner and C2 chain lube
Do not use a steam cleaner, a high pressure cleaner, wire brush, volatile solvent such as
gasoline and benzene, abrasive cleaner, chain cleaner or lubricant not designed
specifically for O-ring chains as these can damage the rubber O-ring seals.
Avoid getting lubricant on the brakes or tyres. Avoid applying excess chain lubricant to
prevent spray onto your clothes and the motorcycle.
L
TU
MO

67
FRONT AND REAR SUSPENSION INSPECTION
Refer to the Safety Precautions on page 51.
1. Check the front fork assembly by locking the front brake and pumping the fork up
and down vigorously. Suspension action should be smooth and there must be no oil
leakage.
2. Carefully inspect all front and rear suspension fasteners for tightness.

SIDE STAND
Refer to the Safety Precautions on page 51. Check the side stand spring (1) for damage
and loss of tension, and the side stand assembly for freedom of movement. If the side
stand is squeaky or stiff, clean the pivot area and lubricate the pivot bolt with clean
engine oil.

1) Side stand spring

68
WHEEL REMOVAL
Refer to the Safety Precautions on page 51 .
This motorcycle is equipped with a side
stand only. Therefore, if front or rear wheel
removal is required, it will be necessary to
2
raise the center of the motorcycle with a jack
or other firm support. If none is available, see
your dealer for this service.
Front Wheel Removal
1. Support the motorcycle securely and
raise the front wheel off the ground using
a safety stand or a hoist.
2. Remove the front axle nut (1).
3. Remove the front axle shaft (2), front
1
wheel and side collar.
Avoid getting grease, oil, or dirt on the disc
or pad surfaces. Any contamination can (1) Front axle nut
cause poor brake performance or rapid pad
(2) Front axle shaft
wear after reassembly.
Do not apply grease oil lubricant on wheel
seals. Seal may damage.

Do not depress the brake lever when the wheel is off the motorcycle. The caliper pistons
will be forced out of the cylinders with subsequent loss of brake fluid. If this occurs,
servicing of the brake system will be necessary. See your dealer for this service.

69
Front Wheel Installation
1. Install the side collars into the left side wheel hub.
2. Position the wheel between the fork legs and insert the front axle shaft from the right
fork side, to the left fork leg and wheel hub.
To avoid damaging the brake pads while installing the wheel, carefully fit the brake
disc between the pads.
3. Tighten the front axle nut to the specified torque. Front axle nut torque: 70 ~ 80 N.m
4. Tighten the axle pinch bolt on the left fork leg to the specified torque. Axle pinch bolt
torque : 25 N.m
5. After installing the wheel, apply the brake several times and then check if the wheel
rotates freely. Recheck the wheel assembly if the brake drags or if the wheel does not
rotate freely.
If a torque wrench is not used for installation, see your dealer as soon as possible to
verify proper assembly. Improper assembly may lead to loss of braking capacity.
NOTES:
Ÿ Always protect the disc, after removing wheel assembly from vehicle. Do not
support wheel on disc while working on removed wheel assembly. This may
damage disc.
Ÿ Protect disc from oil & grease. Oil /Grease on disc may reduce braking. Panic
braking can cause accident.
Ÿ Check wheel bearing for any damage or wear, Change if worn or damaged.
Ÿ Clean thread of shaft before assembly. Use new nut every time.

70
Rear Wheel Removal
1. Support the motorcycle securely and raise the rear wheel off the ground.
2. Loosen the drive chain adjusting nuts (1).
3. Remove the rear axle nut (2).
4. Remove the drive chain (3) from the driven sprocket by pushing the rear wheel
forward.
5. Remove the rear axle shaft (4), side collars and rear wheel from the swing arm.
Do not depress the brake pedal while the wheel is off the motorcycle. The caliper piston
will be forced out of the cylinder with subsequent loss of brake fluid. If this occurs,
servicing of the brake system will be necessary. See your dealer for this service.

2 1 4

(1) Drive chain adjusting nuts

(2) Rear axle nut
(3) Drive chain
(4) Rear axle shaft

71
Rear Wheel Installation 2
To install the rear wheel, reverse the removal
procedure.
1. Install the rear axle shaft and rear wheel
to the swing arm.
2. Install the drive chain over the driven
sprocket.
3. Install the rear axle nut.
1
4. Adjust the drive chain (page 62).
5. Tighten the rear axle nut to the specified (1) Rear Axle Shaft
torque: 70 ~ 80 N.m (2) Drive Chain

When installing the wheel, carefully fit the brake disc between the brake pads to avoid
damaging the pads.
After installing the wheel, apply the brake several times and then check if the wheel
rotates freely. Recheck the wheel if the brake drags or if the wheel does not rotate freely.
If a torque wrench is not used for installation, see your dealer as soon as possible to verify
proper assembly. Improper assembly may lead to loss of braking capacity.
NOTES:
Ÿ Protect cush drive (Rubber damper) from oil/grease, it may damage rubber.
Ÿ Install the (rubber damper) cush drive correctly into its place. Apply soap solution
for easy assembly. Press flange coupling assembly into cush drive while doing so
protect rear brake disc by supporting wheel assembly correctly.

72
BRAKE PAD WEAR
Refer to the Safety Precautions on page 51.
Brake pad wear depends upon the severity of
usage, the type of riding, and road conditions. 2 1
(Generally, the pads will wear faster on wet and
dirty roads.) Inspect the pads at each regular
maintenance interval.
Front Brake
Check the wear indicator grooves (1) in each pad.
If either pad is worn to the bottom of the grooves,
replace both pads as a set. See your dealer for this
service.
Checking & Monitoring of Disc:-
Disc wear
Check the thickness of front & rear brake disc at
several places.
Thickness should be more than (1) Wear indicator grooves
(2) Cut outs
Front 3.5 mm
Rear 4.0 mm
If disc thickness is less than above values, do
change disc.
Also, check disc for damage, cracking and
deformation. If it shows the above defects,
change disc.

73
Rear Brake
If the brake pad friction material is less than 1 mm, then replace pad.
If either pad is worn to the bottom of the grooves, replace both pads as a set. See your
dealer for this service.
Checking front & rear brake fluid level :-
1) If the brake disc fluid falls below ‘Min’ mark, this indicates the leakage in brake system
or worn out brake lining. Check brake system and do not continue riding. Get it
inspected form Mahindra Two Wheelers authorized dealer.
2) Reduced braking effect caused by old brake fluid.
Ÿ Change the brake fluid of front & rear brake every 2 years (people living in high
humidity areas should consider changing brake fluid every year).
Ÿ Do not keep reservoir cap open for longer duration.
Ÿ Fill and replace brake fluid from new sealed clean container only.

3) Use only DOT 4 oil. DO NOT mix different oil grades.

(1)Wear indicator grooves

74
BATTERY

Refer to the Safety Precautions on page 51.

It is not necessary to check the battery electrolyte level or to add distilled water as the
battery is a maintenance-free (sealed) type. If your battery seems weak (causing hard
starting or other electrical troubles), contact your dealer.

NOTICE

Your battery is a maintenance-free type and can be permanently damaged if the cap strip
is removed.

WARNING
The battery gives off explosive hydrogen gas during normal operation. A spark or
flame can cause the battery to explode with enough force to seriously hurt you. Wear
protective clothing and a face shield, or have a skilled mechanic do the battery
maintenance.

75
The battery (1) is in the battery box under the
seat. 4 1

Removal:

1. Make sure the ignition switch is OFF.

2. Remove the seat.

3. Remove the battery holder (2) by

removing the bolt .

4. Disconnect the negative (-) terminal lead

(3) from the battery first, then disconnect
the positive (+) terminal lead (4). 3 2
5. Pull out the battery from the battery box.
Installation: (1) Battery
(2) Battery holder
1. Reinstall in the reverse order of removal. (3) Negative (-) terminal lead
Be sure to connect the positive (+) (4) Positive (+) terminal lead
terminal first, then the negative (-)
terminal.

2. Check that all bolts and other fasteners

are secure.

76
FUSE REPLACEMENT

Refer to the Safety Precautions. When Blown fuse

frequent fuse failure occurs, it usually

indicates a short circuit or an overload in
the electrical system. See your dealer for
repair.

NOTICE
OK fuse
Never use a fuse with a different rating
from that specified. Serious damage to the
electrical system or a fire may result,
causing a dangerous loss of lights or
engine power.

77
Fuse Boxes:

The fuse box ( 1) are located under the seat.

The specified fuses are: 5A (2), 10A (3), 15A (4)

4
and 30A (5).
5
1. Remove the seat.

2. Open the fuse box covers.

1 3 2
3. Pull out the old fuse. If the fuse is blown,
install a spare fuse.
(1) Fuse box
The spare fuses are located in the fuse (2) Fuse 5A
boxes. (3) Fuse 10A
(4) Fuse 15A
4. Close the fuse box covers and install the
(5) Fuse 30A
seat.

78
CLEANING
Clean your motorcycle regularly to protect the surface finishes and inspect for damage,
wear, and oil, coolant or brake fluid leakage.
Avoid cleaning with products that are not specifically designed for motorcycle or
automobile surfaces.
They may contain harsh detergents or chemical solvents that could damage the metal,
paint, and plastic on your motorcycle.
If your motorcycle is still warm from recent operation, give the engine and exhaust
system time to cool off.
We recommend avoiding the use of high pressure water spray.
NOTICE :
High pressure water (or air) can damage certain parts of the motorcycle.
Washing the Motorcycle
1. Rinse the motorcycle thoroughly with cool water to remove loose dirt.
2. Clean the motorcycle with a sponge or soft cloth using cool water.
Avoid directing water to muffler outlets and electrical parts, radiator fins and
throttle body.
3. Clean the plastic parts using a cloth or sponge dampened with a solution of mild
detergent and water. Rub the soiled area gently rinse it frequently with fresh water.
Take care to keep brake fluid or chemical solvents off the motorcycle. They will
damage the plastic and painted surfaces.
The inside of the headlight lens may be clouded immediately after washing the
motorcycle. Moisture condensation inside the headlight lens will disappear gradually
by lighting the headlight in high beam. Run the engine while keeping the headlight on

79
4. After cleaning, rinse the motorcycle thoroughly with plenty of clean water. Strong
detergent residue can corrode alloy parts.

5. Dry the motorcycle, start the engine, and let it run for several minutes.

6. Test the brakes before riding the motorcycle. Several applications may be necessary
to restore normal braking performance.

7. Lubricate the drive chain immediately after washing and drying the motorcycle.

Braking efficiency may be temporarily impaired immediately after washing the

motorcycle. Anticipate longer stopping distance to avoid a possible accident.

Finishing Touches

After washing your motorcycle, consider using a commercially-available spray

cleaner/polish or quality liquid or paste wax to finish the job. Use only a non-abrasive
polish or wax made specifically for motorcycles or automobiles. Apply the polish or wax
according to the instructions on the container.

80
STORAGE GUIDE
Extended storage, requires that you take certain steps to reduce the effects of
deterioration from non-use of the motorcycle. In addition, necessary repairs should be
made before storing the motorcycle; otherwise, these repairs may be forgotten by the
time the motorcycle is removed from storage.
STORAGE
1. Make sure the tank is as empty as possible so that you can fill up fresh fuel when you
put the motorcycle back into operation.
2. Make sure the cooling system is filled with a genuine Castrol Radicool SF-0 PREMIX
3. Change the engine oil.
4. Remove the battery. Store in an area protected from freezing temperatures and
direct sunlight.
5. Lubricate the drive chain (page 62).
6. Inflate the tyres to their recommended pressures.
7. Store the vehicle in a dry location that is not subject to large fluctuations in
temperature.

WARNING
Petrol is highly flammable and explosive. You can be burned or seriously injured
when handling fuel.
• Stop the engine and keep heat, sparks, and flame away.
• Refuel only outdoors.
• Wipe up spills immediately.

81
REMOVAL FROM STORAGE
1. Uncover and clean the motorcycle.
2. Change the engine oil.
3. Charge the battery as required. Install the battery.
4. Perform all Pre-ride Inspection checks.
Test ride the motorcycle at low speeds in a safe riding area away from traffic.
TAKING CARE OF THE UNEXPECTED
IF YOU CRASH
Personal safety is your first priority after a crash. If you or anyone else has been injured,
take time to assess the severity of the injuries and whether it is safe to continue riding.
Call for emergency assistance if needed. Also follow applicable laws and regulations if
another person or vehicle is involved in the crash.
If you decide that you are capable of riding safely, first evaluate the condition of your
motorcycle. If the engine is still running, turn it off and look it over carefully; inspect it
for fluid leaks, check the tightness of critical nuts and bolts, and secure such parts as the
handlebar, control levers, brakes, and wheels.
If there is minor damage, or you are unsure about possible damage, ride slowly and
cautiously. Sometimes, crash damage is hidden or not immediately apparent, so you
should have your motorcycle thoroughly checked at a qualified service facility as soon
as possible. Also, be sure to have your dealer check the frame and suspension after any
serious crash.

82
CATALYTIC CONVERTER

This motorcycle is equipped with a catalytic converter.

The catalytic converter contains precious metals that serve as catalysts, promoting
chemical reactions to convert the exhaust gasses without affecting the metals. The
catalytic converter acts on HC, CO, and NOx. A replacement unit must be an original
Mahindra part or its equivalent.

The catalytic converter must operate at a high temperature for the chemical reactions to
take place. It can set on fire any combustible materials that come near it. Park your
motorcycle away from high grasses, dry leaves, or other flammables.

A defective catalytic converter contributes to air pollution, and can impair your engine’s
performance. Follow these guidelines to protect your motorcycle’s catalytic converter.

• Always use unleaded petrol. Even a small amount of leaded petrol can contaminate
the catalyst metals, making the catalytic converter ineffective.

• Keep the engine in good running condition.

• A poorly running engine can cause the catalytic converter to overheat causing
damage to the converter or the motorcycle.

• If your engine is misfiring, backfiring, stalling, or otherwise not running properly,

stop riding and turn off the engine. Have your motorcycle serviced as soon as
possible.

83
BASIC TROUBLESHOOTING
FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Ignition switch in "OFF" position Switch on ignition
Engine kill switch in "OFF" position Push stop switch to "ON" position
Vehicle Clogged fuel line/pipe Clean the fuel line/pipe
not
starting Vent hole clogged in fuel tank cap Clean vent hole
(does not
crank) Auto decompression not Ensure free motion of flyweight
working in exhaust cam assembly
Loose spark plug Tighten spark plug
Clutch slipping Adjust clutch cable free play
Starter motor not working Check and replace if faulty

84
 FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Loose connection and /or
Starter relay not working Check & replace, if necessary
Malfunctioning of clutch/
Vehicle starter switch & battery discharge Check & replace, if necessary
not
starting If vehicle is without neutral indicator Press the clutch lever & start
(does not
crank) switch together
Starter Motor not working &
Battery not fully charged Check & replace, if necessary
Failure of spark plug Check & replace, if necessary
Oil leakage Check & rectify
Oil level incorrect Check & adjust as per service manual
High oil
consumption Breather system leakage Check & rectify
Worn out Cyl-Piston parts Change service limit exceeded parts

85
 FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Water in petrol tank/Fuel Line Clean throttle body/petrol tank.
Fill tank with fresh petrol
Loose/Leak through intake Tighten rubber hose / line suitably,
Vehicle hose/line Replace if necessary
cranks
but does Loose spark plug Fix cap/lead firmly
not start Spark plug fouled/insulation broken Clean/reset gap or replace
(Engine
Misfiring) Poor compression Auto decompression sticky
or not working
White/Blue smoke due to excess
oil in sump above max level Check and drain excess oil

86
 FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Faulty fuel supply Clean the fuel line/pipes/vent hole
Clutch Cable free play excessive &
clutch slipping Adjust cable free play
Choked air filter Clean/Replace air filter
Engine Loose/Leak in Intake line / Tighten rubber hose / Intake
lacks
power Throttle body mounting Suitably, Replace if necessary
Rear chain adjusted too tight Re-adjust properly
Under inflated tyres Inflate to correct Tyre pressures as
recommended
TPS setting Adjust Zero setting

87
 FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Transmission Clutch slipping Check and correct
Suction/Intake System/parts leakage Check and correct
Incorrect Fueling & Ignition
Timing adjustments Check and correct
Engine TPS setting Adjust Zero setting
overheating Cylinder fins/casting not clean /

clogged with mud, dirt Clean the Cylinder fins/casting area

Silencer/Exhaust System /
parts leakage Check and correct
Cooling System / Parts leakage Check and correct

88
 FAULTS /
POSSIBLE CAUSES ACTION TO BE TAKEN
CONCERNS
Faulty fuel supply Clean the fuel line/tap/vent hole
Very low idling speed Increase idling speed
Transmission Clutch slipping Check and correct
Vehicle Suction/Intake System /
getting
off in parts leakage Check and correct
running
(Engine Incorrect Fueling & Ignition
Starts, Timing adjustments Check and correct
But Runs
Irregularly TPS setting (Too Lean or Rich) Adjust Zero setting
&
Stop/stall) Silencer/Exhaust System /
parts leakage Check and correct
Cooling System / Parts leakage/
blockage Check and correct

89
PROBLEM POSSIBLE CAUSES ACTIONS
Ignition Key is OFF Keep Ignition Key in ON condition
Kill Switch OFF Keep Kill Switch in ON condition
Battery discharge It should be more than 12.4 V, Charge if
required.
Fuse Blown Replace if found blown
Starter
motor Loose connection Ensure the all the connectors are firmly
does not connected with wiring
work
DTC showing on speedometer Check the error code on Diagnostic tool
Auxillary relay failed Check the Relay Operation
Wiring harness defective Check the Continuity of wiring harness
starting circuit
Starter switch not working Check the Continuity
Clutch switch not working Check the Continuity
Starter relay is defective Check the starter relay operation

90
PROBLEM POSSIBLE CAUSES ACTIONS
Check engine clutch -
Check engine starter gear -
Starter
motor Ignition system defective Check spark by removing spark plug,
operates If no spark then check the electrical system.
but
Spark plug gap adjustment Ensure the proper gap in spark plug
engine
doesn’t start Fuel pump not working or Check fuel pump & measure the fuel
Low fuel pressure volume by using diagnostic tool
DTC showing on speedometer Check the error code on Diagnostic tool
Battery discharge / Weak Ensure the Battery voltage is more
than 12.4 Volt
Starter Battery cells are weak During cranking it should not be
motor
struggles below 6 Volt
to crank Loose connection Ensure the all the connectors are firmly
connected with wiring
Starter Motor defective Check starter motor for any obstruction

91
PROBLEM POSSIBLE CAUSES ACTIONS
Ignition Key is OFF Keep Ignition Key in ON condition
Battery discharge It should be more than 12.4 V,
Charge if required.
Lights are Fuse Blown Replace if found blown
not Control switch not working Check the Continuity
illuminating
Bulb/ LED has fused Replace if fused
Loose connection Ensure the all the connectors are firmly
connected with wiring
Wiring harness defective Check the Continuity of Lighting circuit in
wiring harness
Headlight Setting disturbed Follow the SOP for Head lamp setting
Reflector dirty / damage Check for any damage or dark spots inside
Head Lamp headlamp reflector area, replace if required
illumination Battery discharge It should be more than 12.4 V,
not proper
Charge if required.
Regulator output voltage is Check the RR unit output voltage.
low for charging battery i.e. >13.5 V. Replace if found faulty
92
PROBLEM POSSIBLE CAUSES ACTIONS
Hi/Lo switch faulty Check the Continuity
Unable to
switch Headlamp Controller Replace if found defective
HI LO unit defective
beams
Wiring harness defective Check the Continuity of wiring harness
Gap between disc & sensor is Ensure the gap between disc and sensor,
Not more adjust if required.
showing
proper Loose connection Ensure the all the connectors are firmly
vehicle connected with wiring
speed
Speed sensor defective Replace if found defective
Battery discharge It should be more than 12.4 V,
Clock in Charge if required.
speedometer Loose connection Ensure the all the connectors are firmly
not proper
connected with wiring
Incorrect setting of Clock Ensure the proper setting for clock

93
PROBLEM POSSIBLE CAUSES ACTIONS
Ignition Key is OFF Keep Ignition Key in ON condition
Speedometer Loose connection Ensure the all the connectors are firmly
tell-tales
connected with wiring
Not
visible/ Speedometer Defective Replaced if found defective
not working
Battery discharge It should be more than 12.4 V,
Charge if required.
Ignition Key is OFF Keep Ignition Key in ON condition
Battery discharge It should be more than 12.4 V,
Side Charge if required.
stand Loose connection Ensure the all the connectors are firmly
Indication
Not connected with wiring
working Magnet missing Installed new magnet if required
or
continuous More gap between switch Maintain the proper gap between
ON & magnet switch & magnet
Switch defective Replaced if found defective

94
PROBLEM POSSIBLE CAUSES ACTIONS
Ignition Key is OFF Keep Ignition Key in ON condition
Battery discharge It should be more than 12.4 V,
Horn not Charge if required.
working Loose connection Ensure the all the connectors are firmly
connected with wiring
Fuse Blown Replace if found blown
Control switch not working Check the Continuity
Ignition Key is OFF Keep Ignition Key in ON condition
Battery discharge It should be more than 12.4 V,
Horn Sound Charge if required.
not proper
Loose connection Ensure the all the connectors are firmly
connected with wiring
Incorrect screw adjustment Set the horn by adjusting screw

95
PROBLEM POSSIBLE CAUSES ACTIONS
Ignition Key is OFF Keep Ignition Key in ON condition
Battery discharge It should be more than 12.4 V,
No Fuel
Indication / Charge if required.
Improper Loose connection Ensure the all the connectors are firmly
fuel
Indication connected with wiring
Fuel sensor defective Check the resistance of Fuel level sensor,
replaced if found faulty
Engine MIL indication on speedometer Use the diagnostic tool to rectify
Cranks but
doesn’t start / the Error code
Engine
misfire / Loose connection in Ignition Ensure the connections
Engine
power Loss coil & suppressor cap

96
PROBLEM POSSIBLE CAUSES ACTIONS
Fuse Blown Replace if found blown
Loose connection / dust Remove, clean and then connect Negative
accumulation on negative / Earth terminal again.
terminal
Battery defective Check the VRLA battery separately
Battery is
not getting using a VRLA battery charger
charged Regulator unit defective Crank the engine and check for regulator
/ low output voltage output voltage : >14V @ 2000 RPM
Magneto coil defective Confirm the magneto all coil resistances
are within specifications, replace if required.
Magneto coil short with ground Confirm that there is no short circuit
between ground and phases of coil

97
PROBLEM POSSIBLE CAUSES ACTIONS
IACV defective Check IACV valve for its operation,
replace if required
Incorrect fitment of IACV Ensure the proper fitment of IACV
Engine is
running, Battery discharge It should be more than 12.4 V,
but Idling Charge if required.
is not proper
MIL indication on speedometer Use the diagnostic tool to rectify the
Error code
Reverse polarity of Pulsar coil Ensure the correct polarity of wires for
Pulsar coil

98
PROBLEM POSSIBLE CAUSES ACTIONS
MIL indication on speedometer Use the diagnostic tool to rectify the
Error code
Temperature sensor failure / Check the Temperature indication
High temperature on speedometer
Engine
Over heat Radiator Fan faulty Check for Fan operation through
diagnostic tool
Reverse direction of fan Check Fan air flow direction
Low coolant Check the coolant level
Coolant pump not working Ensure the operation of coolant pump
Thermostat not working Ensure the thermostat operation

99
WARRANTY
Scope :
This warranty is given only to the Mojo motorcycles manufactured by Mahindra And
Mahindra Ltd. (Two Wheelers Division) and sold by their Authorized dealers, after pre-
delivery inspection , to be free from any defect in manufacturing or fitment of part /
parts.
Terms And Conditions :
1) Mahindra And Mahindra Ltd. (Two Wheelers Division) undertakes either to repair
or replace (whichever is necessary) only such parts (not the entire assembly), if it is
revealed upon their inspection , that they have failed due to manufacturing defect
through their Authorized outlets “ Free of charge “ during a period of 2 years or
running of 32,000 kms, whichever is earlier from the date of sale.
2) Customer must produce the motorcycle along with this manual to any of the
Authorized service outlet, enabling them to verify and furnish proper details.
3) Mahindra And Mahindra Ltd. (Two Wheelers Division) reserves the right to make
any modification or improvement in design or to add any improvement on
motorcycle at any time, without prior notice and without obligation to install the
same on vehicle previously supplied or sold. Replacement of the motorcycle is not
warrantied. Also, condition of this warranty is subjected to alteration without any
notice.
4) Battery Warranty - Applicable as per the warranty terms of Battery Manufacturer.
Customer can directly claim battery warranty from local battery dealer by
presenting the owner’s manual.
104
The warranty becomes void in the following cases:
1. Free services are not availed as per specified schedule.
2. Subsequent paid services are not followed as per the recommended schedule.
The warranty is not applicable to:
1. Normal maintenance operations like brake and clutch adjustments , cleaning of fuel
systems , engine tune-up or such other adjustments.
2. Vehicle failure due to misuse , improper lubrication , overloading , lack of
maintenance and accidents.
3. Parts subjected to normal wear and tear like brake shoes, spark plug, clutch
plates, drive chain and sprocket .
4. Replacement of electrical items like bulbs and rubber components , ‘O’ ring , bellows
filters , gasket etc.
5. In case of front and rear shock absorbers , subjective feeling of hard/ soft operation of
shock absorbers is not covered under warranty.
6. Painted Parts: Only blistering, chipping or flaking of the color is covered under
warranty. However, the final authority for decision will be the company.
7. Chrome plated parts as they are likely to catch rust in coastal areas or acidic
environment or due to neglect. Only peel off of the chrome film will be accepted
under warranty.
8. Oxidation of crankcase and cylinder head , surface rusting of cylinder block etc.
9. Vehicles repaired by “unauthorized workshop “

105
10. Use of non genuine spare parts, engine oil and fitment of accessories not
recommended by company.
11. Vehicle used for any competition or race etc.
12. Damages occurred in riots , strikes and natural calamities.
13. The proprietary items like tyres , tubes , battery or spark plug since they are directly
handled by respective manufacturers and are subjected to their respective warranty
terms and conditions . In all such cases , the decision of the respective manufacturer
will be final and binding on all concerned.
14. This warranty is given by Mahindra And Mahindra Ltd. (Two Wheelers Division)
for Mojo and no other person, including the dealer or his agent or employee is
authorized to extend or enlarge its scope.
15. Decision regarding warranty settlement shall be taken by Mahindra And Mahindra
Ltd. (Two Wheelers Division). and shall be final and binding on all concerned ,
subject to Pune jurisdiction only.

106
 COUPON NO. : CM
MODEL : MO J O
WARRANTY REGISTRATION CARD

CUSTOMER'S NAME :
ADDRESS :
PIN :
PHONE. NO. : MOBILE NO. :
E-mail :
FRAME NO. : ENGINE NO. :
BATTERY MAKE : BATTERY SR. NO. :
DATE OF SALE : REGN. NO. :
DEALER CODE : DEALER NAME & CITY :

(CUSTOMER'S SIGNATURE) (DEALER’S STAMP AND SIGNATURE)

1) MAIL TO : WARRANTY MANAGEMENT CELL, Mahindra And Mahindra Ltd. (Two Wheelers Division) LIMITED, PLOT NO. 2, INDUSTRIAL
AREA NO. 1, PITHAMPUR, DIST. DHAR - 454775 (M.P.)
FUEL SYSTEM-CHECK FUEL LINES FOR LEAKAGE

(1500 RPM ± 100)

CHECK REAR BRAKE PLAY

HORN FUNCTION / SOUND DRIVE CHAIN SLACKNESS
BATTERY VOLTAGE
DIGITAL CLOCK SETTING
HEAD LAMP HIGH BEAM & LOW BEAM WORKING AT ENGINE RPM >1000
 COUPON NO. : CM
MODEL : MO J O
WARRANTY REGISTRATION CARD

CUSTOMER'S NAME :
ADDRESS :
PIN :
PHONE. NO. : MOBILE NO. :
E-mail :
FRAME NO. : ENGINE NO. :
BATTERY MAKE : BATTERY SR. NO. :
DATE OF SALE : REGN. NO. :
DEALER CODE : DEALER NAME & CITY :

(CUSTOMER'S SIGNATURE) (DEALER’S STAMP AND SIGNATURE)

2) DEALER COPY :
 COUPON NO. : CM
MODEL : MO J O
WARRANTY REGISTRATION CARD

CUSTOMER'S NAME :
ADDRESS :
PIN :
PHONE. NO. : MOBILE NO. :
E-mail :
FRAME NO. : ENGINE NO. :
BATTERY MAKE : BATTERY SR. NO. :
DATE OF SALE : REGN. NO. :
DEALER CODE : DEALER NAME & CITY :

(CUSTOMER'S SIGNATURE) (DEALER’S STAMP AND SIGNATURE)

3) CUSTOMER COPY :
 km km

1000

6000

12000

18000

PAID 24000

PAID 30000

PAID 36000

6 month
DELIVERY CERTIFICATE :

Frame No. :

Engine No.:

Above motorcycle was inspected / test driven by me / my representative at the time of

delivery and found to be acceptable and free from any operational/visual defects

A copy of owner’s manual containing 4 free service coupons, warranty certificate

and a tool kit was given to me along with the motorcycle.

I understand that my warranty claims if any, will be considered by the manufacturer

in accordance with the specified scope and limit of the warranty.

Place:

Date:
Customer Signature

Date of sale : Dealer Name & Address :

Customer name :
Address :

(To be retained by selling dealer)

1st SERVICE - FREE

1 Test drive the motorcycle, if required for reported trouble

2 Wash and clean the motorcycle
3 Inspect valve clearance, adjust if required
4 Replace engine oil
5 Replace engine oil filter
6 Replace magnetic drain bolt washer
7 Clean Engine oil strainer
8 Clean air cleaner
9 Check engine idle speed
10 Check radiator coolant level & top up, if required
11 Inspect the slackness of drive chain , if required clean and lubricated
12 Inspect the clutch free play, adjust if required
13 Check all cables for damage, routing and sharp bends
14 Inspect the brake fluid, top up if required
15 Check and tighten all nuts, bolts and fasteners
16 Check side stand operation
17 Check the free rotation of wheels
18 Check the correct tyre pressure
19 Inspect the steering for smooth movement
20 Battery voltage checking & application of petroleum jelly on battery terminals
21 Check all light , horn and electrical switches
22 In case of MIL indication read out the fault memory using the Mojo diagnostics tool
23 Reconfirm the trouble rectification by taking test ride
24 Clean the vehicle
2nd SERVICE - FREE

1 Test drive the motorcycle, if required for reported trouble

2 Wash and clean the motorcycle
3 Clean & Replace washer of Magnetic drain bolt
4 Replace engine oil
5 Clean air cleaner
6 Check engine idle speed
7 Check radiator coolant level & top up, if required
8 Replace magnetic drain bolt washer
9 Inspect the slackness of drive chain , if required clean and lubricated
10 Inspect the clutch free play, adjust if required
11 Check all cables for damage, routing and sharp bends
12 Inspect the brake fluid, top up if required
13 Check front and rear brake pad wear
14 Check and tighten all nuts, bolts and fasteners
15 Check side stand operation
16 Inspect head light focusing and adjust if required
17 Check the free rotation of wheels
18 Check the correct tyre pressure
19 Inspect the steering for smooth movement
20 Battery voltage checking & application of petroleum jelly on battery terminals
21 Check all light , horn and electrical switches
22 In case of MIL indication read out the fault memory using the Mojo diagnostics tool
23 Reconfirm the trouble rectification by taking test ride
24 Clean the vehicle
3rd SERVICE - FREE
1 Test drive the motorcycle, if required for reported trouble
2 Wash and clean the motorcycle
3 Inspect the fuel line for any leakages
4 Clean fuel filter
5 Inspect the throttle free play, throttle operation, lubricate if necessary
6 Clean & Replace washer of Magnetic drain bolt
7 Replace engine oil
8 Replace engine oil filter
9 Replace magnetic drain bolt washer
10 Replace air cleaner
11 Check engine idle speed
12 Check radiator coolant level & top up, if required
13 Inspect the slackness of drive chain , if required clean and lubricated
14 Inspect drive chain slider
15 Check cooling system for any leakages
16 Inspect the clutch free play, adjust if required
17 Check all cables for damage, routing and sharp bends
18 Inspect the brake fluid, top up if required
19 Check front and rear brake pad wear
20 Check and tighten all nuts, bolts and fasteners
21 Check side stand operation
22 Inspect head light focusing and adjust if required
23 Check the free rotation of wheels
24 Check the correct tyre pressure
25 Inspect the steering for smooth movement
26 Battery voltage checking & application of petroleum jelly on battery terminals
27 Check all light , horn and electrical switches
28 In case of MIL indication read out the fault memory using the Mojo diagnostics tool
29 Reconfirm the trouble rectification by taking test ride
30 Clean the vehicle
4th SERVICE - FREE

1 Test drive the motorcycle, if required for reported trouble

2 Wash and clean the motorcycle
3 Inspect the fuel line for any leakages
4 Inspect the throttle free play, throttle operation, lubricate if necessary
5 Clean & Replace washer of Magnetic drain bolt
6 Replace engine oil
7 Clean air cleaner
8 Check engine idle speed
9 Check radiator coolant level & top up, if required
10 Replace magnetic drain bolt washer
11 Inspect the slackness of drive chain , if required clean and lubricated
12 Inspect the clutch free play, adjust if required
13 Check all cables for damage, routing and sharp bends
14 Replace the brake fluid
15 Check front and rear brake pad wear
16 Check and tighten all nuts, bolts and fasteners
17 Check side stand operation
18 Inspect head light focusing and adjust if required
19 Check the free rotation of wheels
20 Check the correct tyre pressure
21 Inspect the steering for smooth movement
22 Battery voltage checking & application of petroleum jelly on battery terminals
23 Check all light , horn and electrical switches
24 In case of MIL indication read out the fault memory using the Mojo diagnostics tool
25 Reconfirm the trouble rectification by taking test ride
26 Clean the vehicle