Service Technical Bulletin

To:
Product Category Commercial Vehicle
Distributors Model RE2S FL
Bulletin No. IB / 3WH / 317
Date 06 / 01 / 2021
Sub: Introduction of RE2S Facelift

Sirs,

We are glad to introduce new model “RE2S Facelift”

Please find following information for service preparedness at your Distributors end

1. Technical Specification - Annx.1

2. Special Features / Improvements - Annx.2

3. Periodic Maintenance Chart - Annx.3

4. Exclusive Part List - Annx.4

Please share this information with your Service and Spares Staff

Thanking You,
Yours faithfully,
For BAJAJ AUTO LIMITED

Udaya S Malireddi
Div. Manager-Field Support
(International Business)
 Annexure 1 : Technical Specifications
RE2S Facelift
Parameters Petrol LPG
Engine
Engine Two stroke, force air cooled, Spark Ignition engine Two stroke, force air cooled Spark Ignition engine
Bore x Stroke (mm) 57x57 57x57
Engine Displacement (cc) 145.45 145.45
Compression Ratio 10 ± 0.7: 1 10 ± 0.7: 1
Idling Speed 1400 ± 300 1400 ± 300
Max. Net Power 6.3 kW @ 4000 (± 250) rpm at Crank Shaft 6.4 kW @ 5000 (± 250) rpm at Crank Shaft
Max. Net Torque 17 Nm @ 3000(± 250)rpm at Crankshaft 15 Nm @ 3300(± 250)rpm at Crankshaft
Ignition System Spark Ignition Spark Ignition
Spark Plug Champion RL82C Champion RL82C
Spark Plug Gap 0.7 to 0.8 mm 0.7 to 0.8 mm
Lubrication of piston, cylinder, gudgeon pin, Lubrication of piston, cylinder, gudgeon pin,
connecting rod, crank shaft main bearing is by 2T oil connecting rod, crank shaft main bearing is by 2T
Lubrication
mixed with fuel through oil pump & oil injected into oil mixed with fuel through oil pump & oil injected
the cylinder block. into the cylinder block.
Transmission 4 Forward + 1 Reverse 4 Forward + 1 Reverse
Fuel Tank Capacity
Full 8L 20.6L
2T oil tank capacity 1.5 L 1.5 L
Tyre pressure
Front 34 psi (2.4 kg/cm2) 34 psi (2.4 kg/cm2)
Rear 34 psi (2.4 kg/cm2) 34 psi (2.4 kg/cm2)
Brake Front / Rear
Tyre Size
Front 4.00 - 8,6 P.R. 4.00 - 8,6 P.R.
Rear 4.00 - 8,6 P.R. 4.00 - 8,6 P.R.
Electrical
System 12V DC 12V DC
Head Lamp 35/35W 35/35 W
Position Pilot Lamp 3W/ 5W 3W/ 5W
Stop Lamp/Tail Lamp 21/5W 21/5W
Turn Signal Lamp 10 W 10 W
Neutral Indicator Lamp 1.7 W 1.7 W
Hi Beam Indicator Lamp 1.7 W 1.7 W
Turn Pilot Indicator Lamp 1.7 W 1.7 W
Speedometer Lamp 1.7 W 1.7 W
Fuel Meter lamp 1.7 W 1.7 W
Horn 12V DC, Type 2A 12V DC, Type 2A
Battery 32Ah (Electric Start)/ 7 Ah (NonElectric Start) 32Ah (ES)
Dimensions :
Length 2658 mm 2658 mm
Width 1300 mm 1300 mm
Height 1700 mm 1700 mm
Wheel base 2000 mm 2000 mm
Ground clearance 170 mm 170 mm
Min. Turning radius 2880 mm 2880 mm
Weight:
Vehicle Kerb Weight 340 kg 365 kg
Gross Vehicle Weight 643 kg 668 kg
Performance
Max. Speed 60 km/h 60 km/h
Climbing ability 18% (10.2°) max. 16 % (9.1°) max
Annexure 2: Special Features / Improvements

RE2S Existing
Vehicle Front view
Before After

Vehicle Rear view

Before After
 RE2S Facelift new features (without Side Door)

Single piece Windshield

Hood with
Transparent Window

MFR Head Lamp New Styled Fit and

Finish Pax body

New Bigger ORVM

New EAC with

hidden hinge
Air Intake grill flushed
with body

New Styled Bumper

RE2S Facelift new features (with Side Door)

Single piece Windshield Hood with

Transparent Window

MFR Head Lamp New Styled Fit and

Finish body
 New Bigger ORVM

New EAC with

hidden hinge

Air Intake grill flushed

with body

New Styled Bumper

Dashboard

Speakers Speakers

New Interiors with MP3/FM Unit

Fit and Finish Body

Before After

REAR DOOR
EXISTING BODY REAR DOOR
FIT AND FINISH BODY
EXISTING BUMPER WITH GRILL
NEW STYLING BUMPER
 Hood with Side Transparent Window
Before After

PRESENT HOOD HOOD WITH SIDE TRANSPARANT WINDOW

Dashboard with FM Radio provision

Before After
METAL DASHBOARD PLASTIC DASHBOARD WITH FM RADIO PROVISION

MFR Headlamp
Before After
SINGLE HEADLAMP DUAL MFR HEADLAMPS
 Single Piece windshield with new styling OVRM
Before After

Round ORVM 3-piece windshield New styling Bigger ORVM Single piece windshield

Big Wiper Motor

Before After

Existing wiper motor Big wiper motor

Parking Brake at Driver RH similar to RE4S

Before After

Reverse lever Parking brake Parking brake Reverse lever

 Driver Seat with new Backrest
Before After

New Driver
backrest
suitable for Fit
& Finish body.
Back Support
increased for
Driver
Comfort. Back
rest angle
changed for
better Driver
comfort

Driver Seat with new Backrest

Before After
Reinforcement assembly
added below Driver seat
cushion to avoid sagging issue

DRIVER SEAT
DRIVER SEAT

Support bkts in
Seat frame.
FRAME DRIVER
SEAT

FRAME DRIVER
SEAT

RE2S Facelift: Features and improvements in Engine

Horizontal Deployment of few improvements in RE4S facelift engine in RE2S facelift are as follows:
• Foam strip added on air filter element for improvement in air filter efficiency.
• Slicker grill intake air matching to fit and finish improved body.
• Boot, adjuster for accelerator and choke of carburetor improved to protect engine from dust.

Except for above changes, the engine is similar as that of BSIV configuration with Twin Head Lamp.
 Foam added on air filer element to improve filter efficiency
Before After

Foam strip
all round,
5 mm thick,
30 ppi

ID Mark Section A-A

AL AF 01

▪ Filter element ϕ91.1 was ϕ101.1 for accommodating additional foam.

▪ Filter element changes and ID mark (ALAF01) also same for the both filters.

New Grill intake air

Slick air intake grill is added to suit new fit & finish body.
Before After

New Grill Intake Air

(AA121370)
Boot and adjuster for accelerator/choke cable improvement to arrest dust entry into engine.
Before After
Clamp positioning lug
Moulded rubber

Wire Clip (DG121040) Increased Clamping land

❑ Boot & adjustor assembly on throttle & choke cable modified

to restrict dust entry in to engine. Clamp provided to fix Bellow
position on adjustor.

Details of changes:
• Wedged shape ‘’O’’ ring is premolded inside the adjuster.
• Boot interference width on Adjuster increased and Boot
modified accordingly.
• Provision for wire clip location on OD of Boot added.
• Adjuster for accelerator and choke cables shifted from
carburetor end to near handle bar similar to gear control
cables.
 Annexure 3 : Periodic Maintenance Chart & Lubrication Chart

Periodic Maintenance Chart – RE 2S - Petrol

Sr. Recommended Odometer Reading km

Activity Remarks
No. 1K 5K 10K 15K 20K 25K 30K 35K
1 Vehicle washing & Cleaning CL CL CL CL CL CL CL CL
2 Clean Air filter element Replace after every 40K km. Do not
CL CL CL CL CL CL CL CL
remove foam during cleaning
3 Check all lights for working C,A C,A C,A C,A C,A C,A C,A C,A cleaning
Switches, indicators etc.
4 Check Battery electrolyte level
C,T C,T C,T C,T
& top up
5 Adjust Idling speed & CO% C,A C,A C,A C,A Idling RPM 1400+300
6 Clean & adjust Spark plug gap C,A C,A R C,A Gap 6.0 ~ 0.8mm
7 Check/adjust steering column C,A C,A C,A C,A Lock nut torque 4.5 ~ 5.0 kg
8 Check/adjust fuel pipes /
C,A C,A C,A C,A
replace
9 Do tyre rotation (seq.1 & RT RT RT RT RT RT RT “seq 1 at 5k,15k,25k….km
seq.2) seq1 seq2 seq1 seq2 seq1 seq seq seq2 at 10k,20k,30k….km
Replace prop. Shaft rubber 2 1
10 R With RR3 grease
buffers
Check front/rear sh. abs. for
11 C C C
any defect
12 Replace Fuel filter R R R
13 Replace 2T Oil filter R R R
14 Check and adjust control
C,A C,A C,A
cables
15 Check & top up brake fluid C,T C,T C,T Replace after every 40k km
16 De-carbonize engine & silencer CL
17 Check br. Liner wear, replace if C R
required
18 Passenger body & Hood Frame
T T T T T T T
mounting bolts
19 Check and tighten all
C,A C,A C,A After every 10K
Suspension joint
 Periodic Maintenance Chart – RE 2S – LPG

Sr. Recommended Odometer Reading km

Activity Remarks
No. 1K 5K 10K 15K 20K 25K 30K 35K
1 Vehicle washing & Cleaning CL CL CL CL CL CL CL CL
2 Clean Air filter element Replace after every 40K km. Do not
CL CL CL CL CL CL CL CL remove foam during cleaning
3 Check all lights for working C,A C,A C,A C,A C,A C,A C,A C,A Switches, indicators etc.
4 Check Battery electrolyte level
C,T C,T C,T C,T
& top up
5 Adjust Idling speed & CO% C,A C,A C,A C,A Idling RPM 1400+ 300
6 Clean & adjust Spark plug gap C,A C,A R C,A Gap 6.0 ~ 0.8mm
7 Check/adjust steering column C,A C,A C,A C,A Lock nut torque 4.5 ~ 5.0 kg
8 Check/adjust fuel pipes /
C,A C,A C,A C,A
replace
9 Do tyre rotation (seq.1 & RT RT RT RT RT RT RT “seq 1 at 5k,15k,25k….km
seq.2) seq1 seq2 seq1 seq2 seq1 seq seq seq2 at 10k,20k,30k….km
Replace prop. Shaft rubber 2 1
10 R With RR3 grease
buffers
Check front/rear sh. abs. for
11 C C C
any defect
12 Replace Fuel filter R R R
13 Replace 2T Oil filter R R R
14 Check and adjust control
C,A C,A C,A
cables
15 Check & top up brake fluid C,T C,T C,T Replace after every 40K km
16 De-carbonize engine & silencer CL
17 Check br. Liner wear, replace if
C R
required
18 Check system/joints for gas C.A
C.A.R C.A.R C.A.R C.A.R C.A.R C.A.R C.A.R After every 5K km or if smell
leakages .R
19 Check Electrical connection C.A C.A C.A C.A C.A C.A C.A C.A After every 5K km
20 Check Low pressure hose C Replace yearly once or if cracks
C C C C C C C found
21 Check Flexible hose assly C C C C C C C C After every 10K km
22 Clean Gas air mixer After every 30K km or yearly once
Replace rubber parts, if damaged
CL CL CL

23 Service Two stage regulator CL Replace yearly once or if failure

24 Clean dip tube filter – multi Replace yearly once or if failure
CL CL CL
function valve
25 Clean magnet lever – multi
CL CL CL After every 10K km
function valve
26 Service – multi function valve CL After every 30K km
27 Passenger body & Hood Frame
mounting bolts T T T T T T T

28 Check and tighten all

C,A C,A C,A After every 10K
suspension joints
29 Replace Solenoid filter element R R R Replace every 10K km
Lubrication Chart

Sr. Recommended Odometer Reading km

Activity
No. 1K 5K 10K 15K 20K 25K 30K 35K Remarks
1 Replace/top up Gear Box Oil replace R T R T R T R T BGO “performance plus”
Oil Quantity : 820ml- Gear Box
2 Replace/top up Differential oil T R T R T R T Oil Quantity : 220ml- Differential
3 Grease steering column races, balls L L L
4 Grease Front & Rear axles (Gr. nipple) L L L L L L L L
5 Grease Propeller Shaft flanges L With RR3 grease
6 Grease Gear shifter sector L L L L L L L L
7 Grease Speedo meter drive L L L L L L L L
8 Grease speedo meter inner greasing L L L
9 Battery terminals Lubrication L L L L L L L L Apply petroleum jelly
10 Clutch lever Greasing L L L L L L L L After every 20K km
11 Brake Pedal Pivot tube greasing L L L

CL - clean CR - clean R - Replace A - Adjust RT - Rotation L - Lubrication T - Top-up

Annexure 4 : Exclusive Part List

Qty QTY QTY QTY Peru

Sr No Part No. Description
Peru Sudan Haiti LPG
1 24165383 ASSEMBLY CHASSIS BARE 1 1 1 0
2 AG161037 ASSEMBLY CHASSIS BARE 0 0 0 1
3 24165384 FRAME ASSEMBLY CHASSIS 1 1 1 0
4 AG161038 FRAME ASSEMBLY CHASSIS 0 0 0 1
5 52AA1505 ASSEMBLY BODY WITH FRONT MUDGUARD 1 1 1 0
6 52AM0241 ASSEMBLY BODY WITH FRONT MUDGUARD 0 0 0 1
7 52AM0253 ASSEMBLY BODY 0 0 0 1
8 52AA1394 LATERAL ASSEMBLY RH WITH BOLT 1 1 1 1
9 KEBB4017 CIRCLIP INTERNAL 1 1 1 1
10 KADD0522 BOLT FLANGED 3 3 3 3
11 LAD00033 BOLT FLANGE M6x1-35L, PRE COATED 0 3 3 3
12 AP101282 GASKET COVER BENDIX 0 1 1 1
13 52244076 ASSEMBLY-FAN COVER PETROL 145FL 1 1 1 1
14 31201021 CLAMP 1 1 1 1
15 24101946 SHIFTER ASSEMBLY GEAR 0 1 1 1
16 AP101071 ASSEMBLY COVER BENDIX 0 1 1 1
17 52240643 CLUTCH COVER SUB ASSEMBLY 1 1 1 1
18 52240716 ASSEMBLY DIFFERENTIAL COVER RE 145 1 1 1 1
19 AS101017 ASSEMBLY BLOCK CYLINDER 0 0 0 1
20 52240717 ASSEMBLY - CRANKCASE CLUTCH SIDE FL145 1 1 1 1
21 52240712 ASSEMBLY CYLINDER HEAD DAMPER 1 1 1 1
22 52240656 CRANKCASE MAGNETO SIDE ES SUB ASSEMBLY 0 1 1 1
23 52240637 CRANKCASE MAGNETO SIDE NES SUB ASSEMBLY 1 0 0 0
24 AP101043 BEARING NEEDLE BENDIX 0 1 1 1
25 24116167 MAGNETO ASSEMBLY RE COMPACT ES 0 1 1 1
26 AP111007 MOTOR STARTER 0 1 1 1
27 AP101032 DRIVE BENDIX 0 1 1 1
28 52AA4035 ASSEMBLY-FAREMETER 205FL 1 1 1 1
29 52AP0542 CARBURETTOR 2S PET TWIN HEADLAMP 1 1 1 0
30 52AG0079 CARBURETTOR 2S PET TWIN HEADLAMP 0 0 0 1
31 24116173 MAGNETO ASSEMBLY 1 0 0 0
32 AG121072 ASSEMBLY COMP. INTEGRAL DUCT 0 0 0 1
33 AG121096 ASSEMBLY HOSE COMPLETE INTEGRAL 0 0 0 1
34 AA201445 ASSEMBLY PLATE ELECTRICAL FRONT 0 1 1 0
35 AM201144 ASSEMBLY PLATE ELECTRICAL 0 0 0 1
36 24201664 ASSEMBLY PLATE ELECTRICAL FRONT 1 0 0 0
37 24201663 HARNESS WIRING REAR 1 0 0 0
38 24201660 HARNESS WIRING FRONT 1 0 0 0
39 24201656 HARNESS WIRING REAR 0 1 1 0
40 24201666 HARNESS WIRING FRONT 0 1 1 0
41 AG201096 HARNESS WIRING REAR 0 0 0 1
ASSLY BATTERY HARNESS POSITIVE WITH STARTER
42 52AG0078 0 0 0 1
RELAY
43 24201661 HARNESS WIRING BODY 1 1 1 1
44 AG201095 HARNESS WIRING FRONT 0 0 0 1
45 52AG0043 REAR ELECTRIC PLATE & CDI 0 0 0 1
46 52241340 REAR ELECTRIC PLATE & CDI 0 1 1 0
47 52241750 REAR ELECTRIC PLATE &CDI COMP 1 0 0 0
48 52AM0216 ASSEMBLY BOLTABLE TMC MODULE COMPACT 1 1 1 1
49 KDDA1018 WASHER SP THN-ID10.2XOD18.1XT2.2 0 0 0 1
50 KAEA0612 BOLT-FLANGED-SMALL 0 0 0 2
51 LCK00002 NUT NYLOC FL-M10X1.25XH13XCL4XBR 2 2 2 2
52 24102028 SILENCER ASSEMBLY 0 1 1 0
53 24231899 DECAL 2 STROKE 1 1 1 1
54 24231898 DECAL 2 STROKE 1 1 1 1
ASSEMBLY MIDDLE COVER DASHBOARD ( MUDDY
55 52AA1701 1 1 1 1
BROWN Colour)
COVER ASSEMBLY DASHBOARD( MUDDY BROWN
56 52AA1702 1 1 1 1
Colour)
57 24121756 FILTER ASSEMBLY AIR 1 0 0 0
58 52AF0595 COVER PANEL BODY LH ( MUDDY BROWN Colour) 1 1 1 1
59 52AF0596 COVER PANEL BODY RH ( MUDDY BROWN Colour) 1 1 1 1
60 52240491 TUBE-CONECTING ASLY WITH ST HANDLE LEVER 1 1 1 1
61 52AA1445 ASSEMBLY KNOB MTG BKT WITH CONTROL CABL 1 1 1 1
62 AN161074 CLAMP ASSEMBLY BATTERY 0 1 1 1
63 AN161075 ROD TIE BATTERY 0 1 1 1
64 AS160028 ASSEMBLY CROSS MBR WITH DAMPERFL 0 0 0 1
65 52244061 ASSEMBLY oil tube of oil pump 1 1 1 1
66 52244060 ASSEMBLY OIL FILTER WITH HOSE 1 1 1 1
67 52AA0342 ASSEMBLY OIL TANK MOUNTING BRACKET REFL 1 1 1 1
68 52AM0214 ASSEMBLY TRIM LH& RH 1 1 1 1
69 52AU0117 Hood Assembly 1 1 1 0
70 52BA0822 ASSEMBLY BUMPER COMPACT BSVI _YELLOW 1 1 1 1
71 AA201391 CABLE BATTERY NEGATIVE 0 1 1 1
72 AF231661 FOAM 0 0 0 1
73 AF161100 PACKING LOWER FOR GAS CYLINDER 0 0 0 2
74 AF161098 ASSEMBLY STRAP 0 0 0 2
75 AA141067 CLIP SWIVEL SPACER 0 0 0 1
76 52AF0490 HOOD ASSEMBLY BLACK 0 0 0 1
ASSEMBLY WINDSHIELD COMPACT BSVI _YELLOW
77 52AU0106 1 1 1 1
EXPORT
78 52AM0212 ASSEMBLY DASHBOARD PLASTIC 1 1 1 1
79 AA121397 FILTER ASSEMBLY AIR 0 1 1 1
80 RA401400 SWITCH FUEL LPG VERTICAL 0 0 0 1
81 52AA1504 ASSEMBLY LOCKSETS WITH HARDWARES EXPORT 0 1 1 0
82 24221044 LABEL 2T OIL 1 1 1 1
83 AP231024 LABEL OPERATING INSTRUCTIONS 1 1 1 0
ASSEMBLY POWDER COATED WINDSHIELD COMPACT
84 52BA0828 1 1 1 1
BSVI _YELLOW
85 AG101039 ASSEMBLY SILENCER 0 0 0 1
86 52240663 ASSEMBLY FUEL TANK WITH FUEL COCK RE2S 1 1 1 0
87 LCB00005 NUT HEX M10X1.25 2 2 2 2
88 KADF08A0 BOLT FLANGED 1 1 1 1
89 39154011 WASHER PLAIN 4 4 4 4
90 LDB00015 WASHER PLAIN-ID 6.5XOD 20XT 2XBR 3 3 3 3
91 BA201067 BATTERY DRY 32AH 0 1 1 1
92 KCAC0605 NUT HEX THICK 0 1 1 1
93 KDBA0613 WASHER_PLAIN 0 1 1 1
94 KCGD1010 NUT HEX FLANGED 0 0 0 2
95 AF161059 PIN CLEVIS DIA 10 0 0 0 2
96 24141091 CLIP SPRING 0 0 0 2
97 KADA0822 BOLT FLANGED 0 0 0 3
98 52AA0445 ASSEMBLY HANDLEBAR REFL205 1 1 1 1
99 52AA0450 ASSEMBLY STEERING COLUMN WITHOUT CABLE 1 1 1 1
100 52241337 ASSEMBLY WHEEL COMPLETE COMPACT (ROLLED) 4 4 4 4
101 52BA0479 TRAILING ARM ASSLY LH COMPACT 1 1 1 1
102 52BA0478 TRAILING ARM ASSLY RH COMPACT 1 1 1 1
103 52AA0828 ASSEMBLY PROPELLAR SHAFT WITH SLIDER 1 1 1 1
104 SETAAC64 SET OF HARDWARE 1 0 0 0
105 24191219 INDICATOR ASSEMBLY RH 0 1 1 0
106 AG201069 INDICATOR ASSEMBLY 0 0 0 1
107 BF172116 CYLINDER LPG 0 0 0 1
108 SETAMS64 SET OF HARDWARE 0 0 0 1
109 SETAU024 SET OF HARDWARE 0 1 1 0
110 24191220 SPEEDOMETER 1 1 1 1
111 24191213 CABLE REVERSE 1 1 1 1
112 52241749 ASSEMBLY CONTROL CABLE SET 1 1 1 1
113 52AM0228 ASSEMBLY LPG / CNG KIT( BLG) COMPACT 2S 0 0 0 1
114 52241748 ASSEMBLY LOCKSETS WITH HARDWARES EXPORT 1 0 0 0
115 52AG0076 ASSEMBLY LPG / CNG KIT FOR COMPACT 2S (BAL) 0 0 0 1
116 52240727 ASSEMBLY SAI UNIT REFL 145 1 0 0 0
117 52241751 ASSEMBLY AIR FILTER RE 145 FL 1 0 0 0
118 52241747 ASSEMBLY DASHBORD COMPLETE RE 145 1 0 0 0
119 52AG0072 ASSEMBLY AIR FILTER RE 145 FL 0 0 0 1
ASSEMBLY DASHBORD COMPLETE RE 145 (MUDDY
120 52AG0074 1
BROWN COLOUR) 0 0 0
SET OF PLASTIC PARTS( Black Colour)_WITHOUT SIDE
121 52AU0174 1 1 1 1
DOOR
SET OF PLASTIC PARTS( MUDDY BROWN
122 52AU0173 1 1 1 1
Colour)_WITHOUT SIDE DOOR
123 52241755 ASSEMBLY AIR FILTER RE 145 FL 0 1 1 0
ASSEMBLY DASHBORD COMPLETE RE 145 (BEIGE
124 52241753 0 1 0
COLOUR) 1
125 52AG0077 ASSEMBLY LPG / CNG CYLINDER COMPACT 2S 0 0 0 1