Serious coking from the bio-oil polymerisation is a bottle-neck challenge for bio-oil thermal upgrading. Probing the mechanism of bio-oil coking is the first step to achieve high carbon conversion efficiency. In this study, in-situ electron paramagnetic resonance (EPR) spectroscopy was used to characterise the stable free radical generation during bio-oil pyrolysis at 250–350 °C with reaction time of 2–10 min, which identify the coking process of bio-oil. The liquid and solid products were characterised using gas chromatography-mass spectrometer (GC–MS), ultraviolet fluorescence (UV-F) and Raman spectroscopy. The results indicate that the coking of bio-oil in pyrolysis can be divided into three stages of varied characteristics. The coke formation precedes with an initial induction period that lasts for 2–8 min and shortens with increasing pyrolysis temperature. In the period, light components polymerise into heavy ones, including polycyclic aromatics as the essential coke precursors. After the induction period, significant amounts of stable free radicals are generated with coke formation, and the content increases from 0.2 to 1.6–7.8 μmol/g bio-oil in the early stage of coking. Meanwhile, the coke precursors, polycyclic aromatics, are rapidly depleted. Afterwards, in the late stage, the nascent coke gradually condenses and the stable free radical content increases slowly.