Service Station

Manual
NOTICE

ni[T)s
a>dr aip[l dr[k (vgti[ jyir[ Cipvimi> aiv[l Ryir[ vihnn) bw) j nv) (vgti[ C[.
bÔj ai[Ti[ l)m)T[D ki[e pN jvibdir) l[v) nY0 pN dr[k j³yia[ ¹yin an[ s>BiL
riK[lC[. Ap[S)f)k[Sn an[ p¹wt) gm[ Ryir[ bdlie Sk[C[ j[mi> ph[li kh[vin) j$rnY)
an[ ki[e pN c[ºj krvi miT[ bÔj ai[Ti[ kr) Sk[C[ j[n) ÔN krvin) j$r nY)

All information contained in this Note is based on the latest

product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions
in this publication, although every possible care has been
taken to make it as complete and accurate as possible. All
procedures and specifications subject to change without prior
notice. The right is reserved to make such changes at any
time without prior notice.

DOC. NO.: 71110987 REV. 01, MAR. 14

Service Station Dealer

Manual Development
Center
 CONTENTS

1 Foreword sm<(pt 1

2 Workshop Safety vk< Si[p s[fT) 3

3 General Information jnrl enfi[rm[Sn 7

4 Customer Information gi\hk miT[n) (vgt 15

5 Technical Specifications T[kn)kl Ap[S)f)kSn 23

6 I Read ..... I Learn h&> vi>>c&.. h&> S)K)S 31

Vehicle Identification & Controls 32
Salient Features 36
FAQ's 37
Periodic Maintenance & Lubrication Chart 39
Pre-delivery Inspection Checklist 42
Importance of PM Schedule Execution 44

7 Fuel System fy&al s)ATm 73

Co Checking & Setting 74
Engine Tune up 75
Standard Operating Procedure 77
Carburettor Circuits 79

8 Engine & Transmission a[>Jn an[ Ti^ºsm)Sn 85

Tightening Torques 86
Service Data 88
Special Tools 91
Important Points to Remember 95
Engine Removal from Frame 99
Engine Dismantling 102
Engine Sub-Assemblies Dismantling 122
Part Inspection Parameters 127
Assembly of Engine 132
Gear Transmission Power Flow 151
Engine Lubrication - Flow of Oil 155

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PULSAR 200 NS
Service Station SERVICE STATION MANUAL
Manual Akurdi Pune
 9 Frame & Suspension f[m an[ sAp[nSn 157
Tightening Torques 158
Service Limits 160
Special Tools 162
Control Cable Routing 164
Working of Nitrox Suspension 167
SOP for Front Fork Dust Seal & Oil Seal Replacement 169
SOP for Steering Overhaul 176
SOP for Dismantling & Assembling Front Fairing 181
SOP for Swing Arm Replacement 186
Wiring Harness Routing 195
SOP for Caliper Piston Seal and Dust Seal Replacement 197
Sop for Master Cylinder Piston Kit Replacement 202
SOP for Front Brake Hose Replacement 207
SOP for Brake Fluid Replacement 209

10 Electrical el[kT)^kls 213

Battery 214
Electrical Checking Procedures 218
Starter Motor 230
Battery Dos & Don'ts 232
SOP for Checking Charge Condition of Battery 234
Dos & Don'ts 237
Electrical Circuit Diagrams 240

11 Diagnosis & Troubleshooting 247

p\i[\bl[m Si[wvi an[ t[n&> (nrikrN

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Service Station Manual Akurdi Pune
Foreword
sm<(pt....

1
 FOREWORD

This manual is designed primarily for use by trained Whenever you see these WARNINGS and CAUTION
mechanics in a properly equipped shop. symbols, heed their instructions! Always follow safe
operating and maintenance practices.
A basic knowledge of mechanics, the proper use of
tools, & workshop procedures must be understood in
order to carry out maintenance & repair satisfactorily. WARNING
In order to perform the work efficiently and to avoid This manual symbol identifies special instructions or
costly mistakes, read the text, throughly; familiarize procedures which, if not correctly followed, could
yourself with the procedures before starting work, and result in personal injury, or loss of life.
then do the work carefully in a clean area. Whenever
special tools or equipment are specified, do not use
makeshift tools or equipment. Precision measurements
can only be made if the proper instruments are used, CAUTION
and the use of substitute tools may adversely affect
safe operation. This caution symbol identifies special instructions or
procedures which, if not strictly observed, could result
For the duration of the warranty period, we in damage to or destruction of equipment.
recommend that all repairs & scheduled maintenance be
performed in accordance with this service manual. Any
repair procedure not performed in accordance with this
manual may void the warranty. SKILL TIP / NOTE
This symbol indicates points of particular interest for
To get the longest life out the vehicle. more efficient and convenient operation.
• Follow the Periodic Maintenance Chart in the Service H Indicates a conditional step or what action to take
Manual. based on the results of the test or inspection in the
• Be alert for problems & non-scheduled maintenance. procedural step or sub-step it follows.

• Use proper tools and genuine Bajaj motorcycle parts. In most chapters an exploded view illustration of the
Special tools, gauges, and testers that are necessary system components are incorporated.
when servicing Bajaj motorcycles are introduced by In these illustrations you will find the instructions
the Service Manual. Genuine parts provided as spare indicating which parts require specified tightening torque,
parts are listed in the Parts Catalogue. oil, grease or a locking agent during assembly.
• Follow the procedures in this manual carefully. Don't
take shortcuts.
• Remember to keep complete records of maintenance
and repair with dates and any new parts installed.

How to Use This Manual

In this manual, the produce is divided into its major
systems and these systems make up the manual's
chapters. The contents / index guide shows you all of
the product's system and assists in locating their
chapters. Each chapter in turn has its own comp-
rehensive table of contents.
For example, if you want carburettor information, to
locate the Fuel System Chapter.

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Service Station Manual 2 Akurdi Pune
vk<Si[p s[fT)
Workshop Safety

3
WORKSHOP SAFETY

o Technicians must put on shoes & dressing should not be very loose.
o Technicians must use Personnel Protective Equipment (PPE) like - Hand
Gloves
- Mask
- Safety Goggle
- Ear Plug
o Wear Nitrile Rubber Hand Gloves while handling petrochemicals like
petrol, Oil, Kerosene etc.

o Precautions to be taken while handling MRTB Test

- Take care that the vehicle is properly clamped in the clamping device,
otherwise it may go back with a force and can injure the rider.
- Keep yourself cool while taking tests. It is very necessary to be alert.
- Mount the vehicle in the center of the rollers.
- Fuel pipe should not touch heated part of the vehicle, it may cause
fire.
- Make sure to put on air blower while conducting test to avoid engine
overheating.
- Lock the front wheel properly
- Ensure that exhaust blower is running.
- Wear Helmet
- Wear ear plugs

o Precautions to be taken while handling CO Gas Analyser

- Use hand gloves for protection from hot silencer.
- Use mask for protection from exhaust gases.
- Ensure proper ventilation.

o Fire Extinguisher
- Install ‘ISI’ approved. Fire extinguishers - CO2 gas cylinders.
- Refill CO2 before the gas expires.
- Install Co2 gas cylinder at appropriate place so that there is no
obstruction / good accessability.

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WORKSHOP SAFETY

o Safety Precautions while Operating Air Tools

Air tools operate on compressed air supplied by the shop air system
(Compressor & Air supply system).
Observe the following safety related precautions when using an air tool.
• It is advisable to fit a pressure regulator (FRL:- Filter Regulator
Lubricator) in the pneumatic line which supplies air pressure to the air
2
tool. It regulates the outlet pressure to @6.5 Kg/cm . This avoids the
risk of personal injury.
• Never use the blow gun to blow dust off your clothes and never point
it at anyone. The air pressure can drive dust particles at high speed.
These particles can penetrate into the flesh or eyes. High pressure air
hitting on open wound can force air into the blood stream. This can
result in death.
• Never look into the air outlet of a pneumatic tool.
• Never blow-clean brake or clutch parts. This could put asbestos dust
particles into the air which are harmful to inhale. (These particles are
cancerous - can lead to Cancer).

o Hand Tools
- Do not use worn out hand tools.

o Calibration of Workshop Equipment

- Calibrate all Workshop and M & T Equipment once in a year.

o Avoid direct body contact with Petrol, Kerosene.

Caution : Prolonged contact of used oil may cause cancer.

o Waste Oil Disposal

- Sell used oil to Government approved re-cycle agencies.
- Collect used oil in oil disposer / barrel.
- Don’t throw oil into sewage line.
- Don’t spill oil on the floor.

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WORKSHOP SAFETY

o Precautions to be taken while handling Hydro-Electric Lift

- While raising / lowering the lifter bay ensure that vehicle is firmly hold
on the lifter bay to avoid accident.
- After raising the lifter bay, lock the lift.
- Don’t put leg/hand in between while raising / lowering the lifter Bay.

• Safety Tips
- Do not lower the lifter bay table without unlocking the mechanical lift
lock.
- Do not keep your leg between the top and bottom frame while
lowering the lifter bay.
- Do not work with loose clothing while working on the lifter bay.
- Do not keep hydraulic joints loose.
- Do not stand on the lifter bay’s top, when it is being operated.
- Special care is to be adopted to avoid injuries if either leg or hand is
entagled between.
- Keep off direct fire near the power pack.
- Avoid oil spillage around the working area for safety reasons.

o Brake Fluid Handling

- Store brake fluid in sealed container
- Avoid contact of brake fluid with skin.
- Don’t spill the brake fluid on painted components

o Electrical Wiring
- Carry out periodic checks & repairs
- Electrical board & Main Switch must be located such that
they are easily accessible.

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jnrl (vgt
General Information
• Before Servicing
s(<v<s ph[li

7
 GENERAL INFORMATION

General precautions to be taken while opening, assembling & storage of engine parts.

Battery Ground
Before completing any service on the motorcycle, disconnect the
battery cables from the battery to prevent the engine from accidentally
turning over. Disconnect the ground cable (-) first and then the positive
(+). When completed with the service, first connect the positive (+) cable
to the positive (+) terminal of the battery then the negative (-) cable to
the negative terminal.

Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from possible
sharp edges on the parts.

Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign
materials entering into sealed areas during vehicle disassembly can cause
excessive wear and decrease performance of the vehicle.
Photo given
for reference
only

Arrangement and Cleaning of Removed Parts

Use engine parts handling trays for storage of engine parts.

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GENERAL INFORMATION

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned,
store the parts in a clean area. Put a clean cloth or plastic sheet over
the parts to protect from any foreign materials that may collect before
reassembly.

Inspection Visual Inspection of Removed Parts

Reuse of worn or damaged parts may lead to serious accident.
Visually inspect removed parts for corrosion, discoloration, or other
damage. Refer to the appropriate sections of this manual for service
limits on individual parts. Replace the parts if any damage has been
found or if the part is beyond its service limit.

Replacement Parts
Replacement parts must be BAJAJ genuine or recommended by
BAJAJ. Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter pins
must be replaced with new ones whenever disassembled.

Assembly Order
In most cases assembly order is the reverse of disassembly, however,
if assembly order is provided in this Service Manual, follow the
procedures given.

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GENERAL INFORMATION

Tightening Sequence Tightening

Sequence
Generally, when installing a part with several bolts, nuts, or screws,
start them all in their holes and tighten them to a snug fit. Then tighten
2
3
them according to the specified sequence to prevent case warpage or 2
deformation which can lead to malfunction. Conversely when loosening
the bolts, nuts or screws, first loosen all of them by about a quarter turn 1
and then remove them.

Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to serious
damage. Tighten fasteners to the specified torque using a good quality
torque wrench.

Force
Use common sense during disassembly and assembly, excessive force
can cause expensive or hard to repair damage. When necessary, remove
screws that have a non-permanent locking agent applied using an impact
driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings after
disassembly can reduce sealing performance. Remove old gaskets and
clean the sealing surfaces throughly so that no gasket material or other
material remains. Install the new gaskets and replace the used O-rings
when re-assembling.

Liquid Gasket, Non-permanent Locking Agent

For applications that require liquid gasket or a non-permanent locking
agent, clean the surfaces so that so oil residue remains before applying
liquid gasket or non-permanent locking agent. Do not apply them
excessively. Excessive application can clog oil passages and cause
serious damage.

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GENERAL INFORMATION

Press
For items such as bearings or oil seals that must be pressed into
place, apply small amount of oil to the contact area. Be sure to maintain
proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely
necessary. Replace with new ones whenever removed. Press bearings
with the manufacturer and size marks facing out. Press the bearing into
place by putting pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between the inner
and outer race and result in bearing damage.
Press inner race - when bearing is to be fitted on shaft.
Press outer race - when bearing is to be fitted in the bore.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is
necessary. Replace with new ones whenever removed. Press new oil
seals with manufacture and size marks facing out. Make sure the seal is
aligned properly when installing.

Apply specified grease to the lip of seal before installing the seal.

Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with new ones.
Take care not to open the clip excessively when installing to prevent
deformation.

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GENERAL INFORMATION

Lubrication
It is most important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Apply the specific oil
or grease as specified.

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of
rotating direction will affect the adjustment. Rotate the crankshaft to
positive direction (clockwise viewed from clutch cover side).

Electrical Wires
A two-colour wire is identified first by the primary colour and then
the stripe colour. Unless instructed otherwise, electrical wires must be
connected to those of the same colour.

Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacturer's instructions throughly before
using the meter. Incorrect values may lead to improper adjustments.

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GENERAL INFORMATION

General Precautions
• To avoid damage to head of fasteners do not use over size or worn out tools.

• To avoid damage to painted parts, prevent spillage of battery acid & brake fluid.

• To avoid damage of machined face & color of the components store the parts in a clean plastic bin having
compartments to avoid components touching to each other.

• To avoid warpage of mating / sealing faces, mounting bolts should be tightened in a criss-cross pattern.

• To avoid slippage of threads leading to components damage, do not over torque bolts, nuts or screws.

• Always install new gasket & O rings when reassembling.

• Always apply grease to the lip of seal before installing.

• Always replace circlips / cotter pins & radiator hose clamps with new ones.

• Take care not to excessively spread open circlips with tool during installing to prevent deformation.

• Always use appropriate special tool for opening & assembling parts to avoid damages.

• To avoid dust / muck entry inside the engine wash vehicle throughly before executing any repair work related to
engine or otherwise this may lead to early failure of parts.

• Always use lint free cloth while handling engine parts.

• Always apply few oil drops between two moving parts to avoid dry run.

• Always blow high pressure compressed air through oil passage holes in reverse direction of flow of oil & ensure that
the passages are clear.

• Always apply loctite to bolts, screws or nuts wherever recommended to avoid loosening & subsequent break down.

• Confirm proper seating of circlips by rotating them to avoid it from coming out.

• Do not tap engine components by hammer in order to avoid damage. Engine components are precisely machined.

• Do not fit extra electrical accessories otherwise wiring would get short & battery would get discharged.

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NOTES

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Service Station Manual 14 Akurdi Pune
gi\hk miT[n) (vgt
Customer Information
-sivc[t)Y) vihn clivvin) r)t•Safe Riding Tips
-drri[jni s[fT) c[k •Daily Safety Checks
-vihn clivvi drÀyinni pi[eºT
•Running In
•Fuel Saving Tips
-p[Ti[^l bcivvi miT[n) kLi
-ni[n y^z m[enT[ºTns
-gi\hk (vOi[ ÔNkir) •Non Use Maintenance
-bÔj j[ºy&en piT<s •Customer Awareness
-m[nT[ºs T)¼s •Bajaj Genuine Parts
• Maintenance Tips

15
 CUSTOMER INFORMATION

Safe Riding Tips

• Always wear ISI helmets while driving or riding. Your helmets should conform to appropriate
Indian standards.
• Read thoroughly the instructions in this manual and follow them carefully.
• Avoid unnecessary accessories for the safety of both rider and other motorists.
• Get familiar and follow traffic rules and regulations in your states as well as general traffic
signs.
• Do not overload your vehicle.
• Familiarise yourself well with starting, acceleration and braking of the vehicle.
• When applying the brakes, use both, the front and rear brakes. Applying only one brake may cause the vehicle to
loose control.
• During monsoon drive the vehicle more cautiously. Remember vehicles skid more easily during light showers.
• Always carry vehicle registration papers, insurance and a valid driving licence with you.

MONSOON CARE : Fit & Finish Parts

• The appropriate surface preventive coat to be applied to avoid rusting on account of adverse atmospheric conditions.
• Clean & lubricate all the important parts as detailed in a periodic maintenance chart.
• Do not obstruct engine cooling by adding mud protection sheet from front.
• Vehicle cleaning to be done with soft & clean wet cloth to avoid scratches on painted parts.
• Do not apply direct water jet on painted, electrical / electronic parts.

Daily Safety Checks

Before riding the motorcycle be sure to check the following items. If any irregularities are found during these checks, refer
to the Maintenance chapter and see your dealer for the action required to return the motorcycle to a safe operating
condition.

WARNING
Failure to perform these checks every day before
you ride may result in serious damage or severe
accident.

What to check Check for

Fuel Enough fuel for the planned distance of operation, no leaks in the fuel lines.
Engine Oil Oil level between upper and lower marks.
Throttle 1. Correct free play in the throttle cable (2 to 3 mm)
2. Smooth operation and positive return of the throttle grip to the closed position.
Steering Lock Correct operation.

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CUSTOMER INFORMATION

What to check Check for

Brakes 1. Correct rear brake pedal play (25~30 mm) Applicable to 150 cc.
2. Brake lining wear indicator within ‘USABLE RANGE’.
3. No dragging.
Drive chain 1. Proper slack (25~35 mm).
2. Adequate lubrication.
Lighting Operation of all lights.
Horn Correct functions.
Steering 1. Smoothness.
2. No restriction of movement.
3. Loose or Tight.
Clutch 1. Correct lever play. (2 to 3 mm).
2. Smooth operation of lever.
Side and Center Stand Return to their fully up position.
Tyres 1. Correct pressure.
2. Adequate tread depth.
3. No cracks or cuts.
Mirrors Correct position.

Running In
Proper running-in is important for the better life and trouble free performance of the vehicle.
• During first 2000 kms running-in period do not exceed following speed limits.
Kms 1st 2nd 3rd 4th 5th
0 - 1000 14 22 30 37 44
1000 - 2000 18 28 38 46 55

• Always keep the speed below the limits mentioned in the table.
• Do not race the engine excessively.
• Do not start moving or race the engine immediately after starting. Run the engine for a minute at idle speed to give
the oil a chance to work up into the engine.

FUEL SAVING TIPS

A well maintained vehicle and good driving can contribute a lot to the saving of petrol. Following are a few simple fuel
saving tips.
• Ride smoothly and steadily at an optimum driving speed of 40 to 45 km/hr or within the economy band position.
• Avoid harsh braking.
• Change the gear judiciously according to the speed requirement.
• Don’t overload the vehicle above the specified payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for more than two minutes.

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CUSTOMER INFORMATION

Non-Use Maintenance
Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct
and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from
such other non-operational damages like fire hazards.
• Clean the entire vehicle thoroughly.
• Empty the fuel from the fuel tank and carburettor float bowl (if fuel is left in for a longer time, the fuel will break and
gummy substance could clog the carburettor).
• Remove the spark plug and put several drops of 2T oil into the cylinder. Kick the engine over slowly a few times to
coat the cylinder wall with oil and install back the spark plug.
• Set the vehicle on a box or a stand so that both the wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or brake liners.
• Lubricate the control cables.
• Cover the entire vehicle neatly. Ensure that the storage area is well ventilated & free from any source of flames or
spark.
• Fill 10% excess air pressure in both wheels.

** For Battery:
a. Remove battery and keep it on wooden plank, in properly ventilated area.
b. Before taking the vehicle for use.
• Get the battery recharged from the Authorised Service Center / Battery Dealer.
• Check and correct the electrolyte level and apply petroleum jelly on terminals.

Preparation for regular use after storage :

• Clean the vehicle
• Make sure the spark plug is tight.
• Fill the fuel tank with fuel.
• Change the engine oil.
• Check all the points listed in the Daily Safety Checks section.
• Check and inflate tyres to the proper tyre pressure.

Customer Education Points

Educate customers' during vehicle delivery on following points.
• Not to fit extra electrical accessories by cutting wiring harness. This will avoid short-circuiting & unnecessary load on
the battery.
• Not to rectify wiring / electrical system related performance issues at local mechanic garages.
• In case of main / wiring fuse blowing of problem, bring vehicle to authorized Bajaj dealer by starting engine with the
help of kick.

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CUSTOMER INFORMATION

Customer Awareness Points

Customer awareness to be developed on following points for trouble free performance of vehicle :
1) Regular Checks :
• Ensure battery electrolyte level between max - min. mark.
• Always ensure tyres are inflated to specified air pressure.
• Keep vehicle clean regularly.
• Ensure engine oil level between MAX. - MIN. mark.
• Ensure brake fluid level above MIN. mark.
• Do not apply front disc brakes on turning, & on slippery, muddy roads.
• Use both brakes simultaneously while braking.
• Do not ignore brake & engine oil leakage.
• Do not ignore worn out / cut tyre condition, if found replace immediately.
• Do not ignore fuel leakage.
• Ensure specified brake free play.
2) Vehicle usage :
• Gear shifting pattern is all up.
• Auto choke is located on RH side.
• During running in period, do not exceed speed limits mentioned in owners manual. It may lead to failure of engine
components.
• Do not drive vehicle above its rated payload.
• Do not drive vehicle with brake pedal partially pressed.
• Do not drive vehicle with clutch lever half pressed.
• Avoid harsh braking & do not drive the vehicle by keeping brake pedal pressed.
• Always ensure tyres are inflated to specified air pressure.
• Do not add extra electrical accessories e.g remote, horn, buzzer etc.
• Disconnect battery terminals, if vehicle is not being used for long time (more than 2 weeks)
• Do not press self start button continuously, wait for 5 secs. after each crank, this will help battery to recover.
• To take help of BAJAJ authorized workshop to bring vehicle to the workshop for repair if coolant leakage is noticed
through coolant system.
• Do not drive vehicle & bring the vehicle to BAJAJ authorized workshop if coolant level in expansion tank or engine oil
level is found below MIN. mark. Take help of authorized service station to take vehicle in workshop for repair.
3) Vehicle maintenance (PM schedule / service at authorized locations) :
• During periodic service replace mandatory periodic parts as per PM schedule given in owners manual.
• Follow periodic service schedule strictly for optimum engine & vehicle performance.
• Carry out any service/repairs at Bajaj authorized service centers only for quality service & genuine parts.
• Always insist on Bajaj Genuine Spare Parts in case of replacement.
• Always insist on Bajaj Genuine Oil (Bajaj DTSi 10000) for optimum engine performance & warranty benefits.
• Do not repair front fork inner pipe for bend removal & rear suspension for oil leakages in local workshop.
• Always fill fuel from reputed petrol pumps.
• Use DOT-3 / DOT-4 brake fluid for top up.
• Do not add additives in engine oil / petrol.

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CUSTOMER INFORMATION

4) Accessories :
• Do not fit extra electrical accessories, otherwise wiring would get short & battery would get discharged. Few e.g. -
- Remote / central locking system.
- Extra & bigger size horns.
- Musical brake light.
- Buzzer.
- Higher wattage Headlamp bulb.
- Flasher operating all 4 side indicators simultaneously
• Do not replace fuse with higher capacity fuse.
• Never bypass fuse.
• Do not cut wiring conduit / wires midway.
• Never remove conduit from wiring harness.
• Do not repair wiring harness instead replace for safety.
• Do not ground any wire for checking current-spark.
• Wiring harness failure due any one of the reason mentioned above is not covered under warranty replacement.
• Do not fit splash guard in front of the engine.
• Do not fit accessories to carry extra load.
5) BAL warranty policy - (Fuel adulteration / local accessories fitment & vehicle maintenance as per PM schedule) :
Warranty is applicable for manufacturing defects with in a period of 2years or 30,000 kms whichever occurs earlier.
Warranty is not applicable to -
• Parts subjected to normal wear & tear like Clutch Plates, Brake Shoes, Chain, Sprockets, Fork Oil Seal, Spark Plug,
Control Cables, Brake Pads.
• Replacement of bulbs, rubber components like grommets, ‘O’ rings, bellows & filters, packings, gaskets, fasteners etc.
• Parts of the vehicle that have been altered and modified or replaced in unauthorized manner like use of wider tyres,
loud silencers etc and which in the sole judgement of the Bajaj Auto Limited affects its performance and reliability.
• Vehicles which are not being serviced at recommended dealers as per the service schedule described or which have
not been operated or maintained in accordance with the instructions maintained in the Owner’s Manual.
• Vehicles used for any competition or race and/or for attempting to set up any kind of record.

• Any failure arising due to use of adulterated or bad quality fuel. Parts affected due to bad
fuel quality are not covered Under warranty.

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CUSTOMER INFORMATION

Bajaj Genuine Parts

For optimum performance of vehicle

For prolonged life of

components & vehicle Always
Insist
For economical maintenance cost

For rider's safety

on
parts
Genuinity Test

Scratch Hologram to find ‘Genuine’

Bajaj Auto Limited

Akurdi Pune 411 035 India
JA551421 QTY 1 No.
Bajaj Auto Limited
Akurdi Pune 411 035 India
Genuine

03100802 CLUTCH BOX

P0001
PACKAGING MONTH
MAY 2003
M.R.P. (Incl. of All Taxes) in Rs. for Qty. packed
IN ASSAM, KARNATAKA, MANIPUR, M.P.,
NAGALAND, U.P.,
QTY. 1 NO.
57.43
PLATE JUDDER NF-143-B
& UTTARANCHAL IN OTHER STATES 55.58

Pkg. MTH.
OCT 06.
M.R.P. (Incl.of All Taxes)
in Rs. for Qty. packed 48.29

Hologram Price Label

Maintenance Tips
Carry out all free & paid services as per recommendations.

Follow ‘Running-in’ instructions & other riding tips for proper riding habits.

Insist on replacement of periodic parts as recommended in ‘Scheduled for Periodic Part

Replacement.

Follow Periodic Maintenance & Lubrication Chart for specific repairs / parts replacements &
lubrication.

Always use engine oil of recommended grade in specified quantity.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 21 Akurdi Pune
NOTES

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 22 Akurdi Pune
 pÃsr dts-i

T[kn)kl mih)t)
Technical Specifications
-T[kn)kl (vgt
• Technical Specifications
-kib&<r[Tr Ap[S)f)k[Sn
-ai[el/g)\s/ li[klieT
• Carburettor Specification
-kyi< viprvin) (vgt • Oil / Grease / Loctite
application matrix

23
 TECHNICAL SPECIFICATIONS - 150 CC

Engine and Transmission

Type : Four stroke DTS-i, Natural air cooled.
No. of cylinders : One
Bore : 58.00 mm.
Stroke : 56.40 mm.
Engine displacement : 149.01 cc
Compression ratio : 9.5 + 0.5:1
Idling Speed : 1400 + 100 rpm.
Max. net power : 10.37 KW (14.09 Ps) @ 8500 RPM
Max. net torque : 12.76 Nm @ 6500 RPM
Ignition System : Microprocessor controlled digital C.D.I.
0 0
Ignition Timing : 10 BTDC at 1400 rpm, 25 BTDC at 3000 rpm.
Fuel : Unleaded petrol
Carburettor : UCAl-MIKUNI BS26, Side Drought, CV Type.
Spark Plug : 2 Nos. Champion RG4HC (Resistive)
Spark Plug Gap : 0.6 to 0.8 mm.
Lubrication : Wet sump, Forced.
Starting : Kick start / Electric start.
Clutch : Wet, Multidisc type.
Transmission : 5 speed constant mesh.
Primary Reduction : 3.47 : 1 (66/19)
Gear Ratios: 1st gear : 28.20 : 1 (36/13)
2nd gear : 19.17 : 1 (32/17)
3rd gear : 14.05 : 1 (29/21)
4th gear : 11.03 : 1 (26/24)
5th gear : 9.40 : 1 (24/26)
Final drive ratio : 2.93 : 1 (44/15)
CHASSIS & BODY
Frame Type : Double cradle.
Suspension Front : Telescopic Fr. fork with Antifriction bush (Stroke 135mm)
Rear : Trailing arm with coaxial hydraulic cum gas filled adjustable shock
absorbers, and triple rate coil springs.
Brakes Front : Hydraulically operated disc type.
Rear : Mechanically expanding shoe and drum type.
Tyres Front : 2.75 x 17, 41 P
Rear : 100 / 90 x 17, 55 P
Tyre Pressure Front : 1.75 kg/cm2 (25.0 Psi)
Rear Solo : 2.00 kg/cm2 (28.4 Psi)
Rear Pillion : 2.25 kg/cm2 (32.0 Psi)
Rims (Alloy Wheels) Front : 1.60 x 17
Rear : 2.15 x 17

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 24 Akurdi Pune
TECHNICAL SPECIFICATIONS - 150 CC

Fuel Tank Capacity : 15 liters Full

: 3.2 liters Reserve
: 2.0 liters Usable reserve
CONTROLS
Steering : Clip-on type handle bar
Accelerator : Twist grip type on RH side of handle bar
Gears : Left foot pedal operated
Clutch : Lever operated on LH side of handle bar
Choke : Push-Pull knob on carburettor
Brakes Front : Lever operated on RH side of handle bar
Rear : Pedal operated by right foot
ELECTRICALS
System : 12 V (DC)
Battery : 12V 7 Ah MF type.
Head Lamp : 35/35 W-HS1
Pilot Lamp : 5W - 2 Nos.
Tail/Stop lamp : LED / LED
Turn signal lamp : 10 W (2 Nos.)
Turn signal pilot lamp : LED
Side stand indicator lamp : LED
Hi beam indicator lamp : LED
Neutral indicator lamp : LED
Speedometer lamp : LCD display
Rear number plate lamp : 5W
Horn : 12V DC

DIMENSIONS
Length : 2055 mm.
Width : 790 mm.
Height : 1100 mm.
Wheel base : 1320 mm.
Turning circle radius : 2320 mm. (Minimum)
Ground clearance : 165 mm. (Minimum)

WEIGHTS
Vehicle kerb weight : 143 Kg.
Gross vehicle weight : 273 Kg.

PERFORMANCE
0
Climbing ability : 28% (16 Maximum)

Notes :
• Values given above are nominal and for guidance only, 15% variations is allowed to cater for production
and measurement variation.
• All dimensions are under UNLADEN condition.
• Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 25 Akurdi Pune
 TECHNICAL SPECIFICATIONS - 180 CC

Engine and Transmission

Type : Four stroke DTS-i, Natural air cooled.
No. of cylinders : One
Bore : 63.50 mm.
Stroke : 56.40 mm.
Engine displacement : 178.60 cc
Compression ratio : 9.5 + 0.5:1
Idling Speed : 1400 + 100 rpm.
Max. net power : 12.52 KW (17.02 Ps) @ 8500 RPM
Max. net torque : 14.22 Nm / 1.45 Kgm @ 6500 RPM
Ignition System : Microprocessor controlled digital C.D.I.
0 0
Ignition Timing : 10 BTDC at 1400 rpm, 25 BTDC at 3000 rpm.
Fuel : Unleaded petrol
Carburettor : UCAl-MIKUNI BS29, Side Drought, CV Type.
Spark Plug : 2 Nos. Champion RG4HC (Resistive)
Spark Plug Gap : 0.6 to 0.8 mm.
Lubrication : Wet sump, Forced.
Starting : Electric start.
Clutch : Wet, Multidisc type.
Transmission : 5 speed constant mesh.
Primary Reduction : 3.47 : 1 (66/19)
Gear Ratios: 1st gear : 26.93 : 1 (36/13)
2nd gear : 18.31 : 1 (32/17)
3rd gear : 13.43 : 1 (29/21)
4th gear : 10.54 : 1 (26/24)
5th gear : 8.98 : 1 (24/26)

Final drive ratio : 2.78 : 1 (39/14)

CHASSIS & BODY
Frame Type : Double cradle.
Suspension Front : Telescopic Fr. fork with Antifriction bush (Stroke 130mm)
Rear : Trailing arm with coaxial hydraulic cum gas filled adjustable shock
absorbers, and triple rate coil springs.
Brakes Front : Hydraulically operated disc type.
Rear : Mechanically expanding shoe and drum type.
Tyres Front : 90 x 90 x 17, 49 P (Tubeless)
Rear : 120 / 80 x 17, 61 P (Tubeless)
Tyre Pressure Front : 2.00 kg/cm2 (28.4 Psi)
Rear Solo : 2.00 kg/cm2 (28.4 Psi)
Rear Pillion : 2.15 kg/cm2 (30.5 Psi)
Rims (Alloy Wheels) Front : 1.85 x 17
Rear : 2.50 x 17

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 26 Akurdi Pune
TECHNICAL SPECIFICATIONS - 180 CC

Fuel Tank Capacity : 15 liters Full

: 3.2 liters Reserve
: 2.0 liters Usable reserve
CONTROLS
Steering : Clip-on type handle bar
Accelerator : Twist grip type on RH side of handle bar
Gears : Left foot pedal operated
Clutch : Lever operated on LH side of handle bar
Choke : Push-Pull knob on carburettor
Brakes Front : Lever operated on RH side of handle bar
Rear : Pedal operated by right foot
ELECTRICALS
System : 12 V (DC)
Battery : 12V 9 Ah MF type.
Head Lamp : 35/35 W-HS1
Pilot Lamp : 5W - 2 Nos.
Tail/Stop lamp : LED / LED
Turn signal lamp : 10 W (2 Nos.)
Turn signal pilot lamp : LED
Side stand indicator lamp : LED
Hi beam indicator lamp : LED
Neutral indicator lamp : LED
Speedometer lamp : LCD display
Rear number plate lamp : 5W
Horn : 12V DC

DIMENSIONS
Length : 2035 mm.
Width : 750 mm.
Height : 1165 mm.
Wheel base : 1350 mm.
Turning circle radius : 2500 mm. (Minimum)
Ground clearance : 165 mm. (Minimum)

WEIGHTS
Vehicle kerb weight : 147 kg.
Gross vehicle weight : 280 Kg.

PERFORMANCE
0
Climbing ability : 28% (16 Maximum)

Notes :
• Values given above are nominal and for guidance only, 15% variations is allowed to cater for production and measurement
variation.
• All dimensions are under UNLADEN condition.
• Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
• Specifications are subject to change without notice.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 27 Akurdi Pune
CARBURETTOR SPECIFICATIONS

Carburettor

Carburettor Specifications of Pulsar 150 cc :

Make and Type Ucal-Mikuni BS26, CV type

Identification No. DH - U3
Idling Speed 1400 +100
VC Screw setting 2.5 + 2 turns out
Main Jet 107.5
Jet needle mark 4DMP23
Needle jet mark P-1
Jet needle clip Position 2nd from top
Pilot Jet 12.5
B DH-U3
BS26 6X27 Starter jet Fixed type
Throttle valve Fixed type
Choke Lever 2 stage with push pull type
mechanism (ON / OFF)

Carburettor Specifications of Pulsar 180 cc :

Make and Type Ucal-Mikuni BS26, CV type

Identification No. DJ - U4
Idling Speed 1400 + 100
VC Screw setting 2.5 + 2 turns out
Main Jet 112.5
Jet needle mark 4078
Needle jet mark P-1
Jet needle clip Position 2nd from top
Pilot Jet 17.5
DJ-
BS29 U4
9321
B Starter jet Fixed type
Throttle valve Fixed type
Choke Lever 2 stage with push pull type
mechanism (ON / OFF)

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 28 Akurdi Pune
OIL / GREASE / LOCTITE APPLICATION MATRIX

Sr. Lubricant /
Grade Application Remark
No. Loctite

DTSi 10000, Quantity :

1. Engine oil SAE 20W50 API ‘SL’ Engine Service - 1 L
OR JASO ‘MA’ Eng. O/H - 1.1 L

For Pulsar 150 cc

Quantity / fork leg :
Service - 145 + 2.5 ml
2. Fork oil SAE 10W20 Front fork
For Pulsar 180 cc
Quantity / fork leg :
Service - 295 + 2.5 ml

3. Brake fluid DOT-3 / DOT-4 Hydraulic Brake • Brake fluid top up-
DOT 3 brake fluid
only.
• In case of non
availability of
DOT 3, completely
drain old brake
fluid & replace
with DOT 4.

4. Grease Lithon RR-3 Steering races & balls HP make

Starter clutch dry

5. Grease Molycote 7325 Magneto is dry
application

6. Grease Silicon Caliper assembly Front disc brake

• Fr. & rear wheel axle.

• Swing arm shaft
• Brake pedal pivot pin
7. Grease All purpose • Center stand shaft
• Side stand U bracket
• Gear shifter pivot
• Clutch & fr brake lever

Pulsar 180
8. Chain spray OKS - Chain lube spray ‘O’ ring drive chain
@ every 500 km

Oil for drive • Non ‘O’ ring type During all services
9. SAE 90
chain drive chain

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 29 Akurdi Pune
OIL / GREASE / LOCTITE APPLICATION MATRIX

Sr. Lubricant /
Grade Application Remark
No. Loctite

Electrical contact • Ignition switch

10. WD-40 Spray • Brake & clutch switch All services
cleaning spray
• LH/RH control switch

Rear fender bottom

11. Loctite Thread locker 243 mounting.
• Cam sprocket allen
bolt
• Pickup coil screws
• Stopper plate screws
(gear starter clutch)
• Kick guide bolts
• Output sprocket bolts
• Oil pump mounting
bolt.
• Allen bolt securing
guide gear on shift
drum.
• Screw securing
stopper for input
shaft bearing.
• Special bolt guide
chain slack side.
• Nut inhibitor mounting
• Nut clutch mounting
• Damper plate bolts
clutch cover.
• Damper plate bolts
magneto cover.
• Stator mounting bolts
• Stator harness clamp
plate screw.

Liquid gasket • Crankcase joining

12. Loctite L 5702
surface.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 30 Akurdi Pune
 h&> vi>c&>, h&. S)K&
I Read... I learn
v[h)kl (vOi[n) (vgt an[ k>ºTi[^ls • Vehicle identification &
s[l)yºT f)cr controls
PM S[Dy&al • Salient Features
PDI c[k s)T • Frequently Asked
PM {Dy&al p\miN[ kim krvi miT[n) (vgti[}
Questions (FAQs)
• PM Schedule
• PDI Check Sheet
• Importance of PM
schedule execution.

31
VEHICLE IDENTIFICATION & CONTROLS
vihn (vOi[n) mih)t) an[ k>ºTi[^l
c[s)s n>br an[ a[J>n n>brn&> li[k[Sn
Chassis Number & Engine Number Location

The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric codes to
identify your particular vehicle from others of the same model and type.

Frame Number Location f[m n>br li[k[Sn

On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)

Engine Number Location a[>Jn n>br li[k[Sn

On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 32 Akurdi Pune
VEHICLE IDENTIFICATION & CONTROLS

speedometer Icons function

1 6 Green
7
2
8
Red 3

4
9
5 N - + 10 Red
11 Blue
12 Green

1. Side Stand Indicator : When Side stand is ‘ON’, the Side stand indicator will glow.

2. Fuel Level Indicator : Fuel level indicator shows available fuel in fuel tank.

3. Reserve/ Engine Rev Indicator : It glows when petrol level in tank reaches reserve level. It also
blinks when engine RPM cross 9000 RPM mark.

4. Tachometer Dial : It shows engine speed in RPM.

5. Odometer : The Odometer shows the total distance that the vehicle has
accumulated.

6. Neutral Indicator : When transmission is in Neutral & Ignition switch ‘ON’, Neutral
indicator will glow.

7. Speedometer : Vehicle speed will be displayed digitally

8. Trip Meter Reset Button : Both trip meters can be reset to zero by pressing the button.

9. Trip Meter : The Trip meter shows the distance traveled since it was last reset
to zero.

10. Battery Indicator : It indicates battery needs charging

11. Hi Beam Indicator : When Headlight is ‘ON’ & Hi beam is selected with engine running,
Hi beam indicator will glow.

12. Turn Signal Indicator (LH & RH) : When Turn signal switch is turned to Left or Right, Turn pilot
indicator - LH or RH will flash.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 33 Akurdi Pune
VEHICLE IDENTIFICATION & CONTROLS

Left Handle Bar Switches

A. Dipper Switch : When headlight is ON, High or Low beam can be
A
selected with the dipper switch. Hi beam indicator light located on
Speedo console will light up when high beam is selected.
: High Beam : Low beam
B. Turn Signal Switch : When the turn signal knob is turned to Left (
B ) or Right ( ) respective indicator will start blinking, to stop blinking
push the knob in & release.
C

C. Horn Button : ( ) Press button for sounding horn.

D. Pass Switch : Press the switch to flash the head light. It is used to
give signal to vehicles coming from opposite side while overtaking.

Right Handle Bar Switches

E. Head Light Switch : It has 3 positions.

E : All lamps 'OFF'.

: While engine running, Tail lamp and Pilot

lamps ‘ON’.
F
: While engine running, Headlamp, Pilot lamp,
G Tail lamp, Meter lamps ‘ON’.

F. Starter Button : It operates the electric starter when clutch lever is

depressed with transmission in any gear. It is recommended to start
engine with transmission in neutral.

G. Engine Kill Switch : The engine kill switch is for emergency use.
During emergency move the engine kill switch to the ‘OFF’ ( )
position.

CAUTION : While starting ensure that engine kill

switch is in ON ( ) position. Keeping the kill switch
in OFF position Engine will not start.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 34 Akurdi Pune
VEHICLE IDENTIFICATION & CONTROLS

Steering cum Ignition Lock :

Apply spray inside
It has three positions.

LOCK : Steering locked. Ignition OFF.

OFF : Steering unlock. Ignition OFF.

ON : Steering unlock. Ignition ON.

To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push & release the key. Turn the
key to “LOCK” position and remove the key.

To Unlock the Steering : To unlock steering, insert the key in steering cum ignition lock & turn it clockwise to “OFF” or
“ON” position.

Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ & ‘Side cover lock’.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 35 Akurdi Pune
SALIENT FEATURES

PERFORMANCE

ATTRIBUTE KEY FEATURES ADVANTAGES BENEFITS

• 4 stroke, DTS-i 150cc - 14.09 • Legendary DTS-i engine • Crisp Throttle response for
Ps unmatched in industry. consistent engine output for
• 4 stroke, DTS-i 180cc - 17.02 • Optimum ignition timing for any varying load and speed
Ps engine rpm, better throttle conditions at different levels
response and reduced of acceleration. More power,
• State-of-the-art features at
emissions. more mileage, ultimate
the heart of digital biking:
refinement
Digital Twin Spark Ignition, • Ease in starting the bike at all
Digital DC CDI unit, TRICS-III, conditions. • Well refined engine and
CV Carburetor Optimum performance with
• Optimum transmission cooling more power.
• Controlled lubrication system.
system & smoother feel of
• DC ignition system gear shift.
• Bigger ExhausTEC.
• Bigger catalytic converter

STYLE

• Brawny masculine looks • A bold assertive stance, Neat • The styling and looks that let
• Stylish split seats looks. Brains, brawn & you break free.
definitely male.
• 2 piece grab rail
• Tank spoiler
• Wolf-eyed head lamp
• LED tail Lamp
• Black styling
• Clip-on handlebar
• Thicker and pinched clamped
fork
• Naked chain

COMFORT

• LCD Speedo Console • Easy to read & understand • Excellent riding pleasure.
• Self cancelling indicators digital speedo, odometer • Feather touch self start.
display with 2 trip meters
• Thicker front fork and swing having resetting facility & • Safe night riding.
arm with needle roller bearing. warning signal.
• DC ignition system. • Self cancellation indicators
• Telescopic front suspension
with anti friction bush &
supported with Nitrox shock
absorber on rear.
• Easy starting.
• No head light fluctuations
even at lower engine rpm.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 36 Akurdi Pune
FREQUENTLY ASKED QUESTIONS - FAQ'S

Ï What are other distinguish features of new ‘Pulsar DTS-i 180 cc’ motorcycle in comparison with ‘New Pulsar DTS-i
150 cc’?
B Following are the overall features in comparison at a Glance.

Features Pulsar DTS-i 180 cc Pulsar DTS-i 150 cc

Cubic Capacity 178.60 cc 149.01 cc
Horse Power 17.02 PS 14.09 PS
Torque 14.22 Nm 12.76

DC Ignition YES YES

Starting Mechanism Self Start Only Self & Kick Start
Tubeless Tyre YES NO
Intelligent Digital CDI YES YES
ExhausTEC YES YES
Controlled Lubrication YES YES
Digital Control YES NO
Wheel Base 1350 mm 1320 mm
Front Suspension with
YES YES
anti friction Bush
Rear Suspension with
YES YES
Nitrox Shockers
LED Tail Lamp YES YES
Split Type Seat YES NO
Wheel Size (17") YES YES
Head Lamp Fairing Head Lamp Fairing Head Lamp Fairing
Decals New decals to match to the profile of the vehicle
Clip on type Handle Bar YES NO
Elliptical type swing arm with
YES NO
needle roller bearing

Ï What is the function of Battery icon popping up in speedometer?

B The icon provided in the speedometer console indicates the status of battery. When the battery voltage drops down
bellow 11.9 volts then only it will pop up & warns the rider that battery needs charging.

Ï What is DC Ignition & lighting system?

B System works on DC electrical energy of battery. For Ignition system, supply comes from battery instead of exciter
coil located inside magneto. The vehicle battery is always kept charged by the magneto.

Ï Can we ride the bike by removing the battery?

B No, not at all. Disconnecting the battery from the vehicle will disable the starting / Ignition system & vehicle cannot
be started.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 37 Akurdi Pune
FREQUENTLY ASKED QUESTIONS - FAQ'S

Ï What is the benefit / advantage of having DC system?

B Constant & Consistent high intensity current is available even at low engine rpm which gives improved combustion
& better startability.
B No head light voltage fluctuations resulting into brighter head light illumination consistently. It is the same existing
battery i.e. MF battery (A low maintenance battery)
B The main features of this MF battery are :-
• Electrolyte level checking is not required frequent.
• The unique vent mechanism provided that do not allow loss of electrolyte.
• No drain pipe unlike in conventional type battery so no chances of spillage of electrolyte.
Ï Does DC system vehicle cost more in maintenance?
B No. It is important to ensure Good health of Battery that's all ! Care should be that, adding extra accessories will
lead to faster draining of battery.
Ï What is the warranty limit for this MF Battery?
B The warranty for MF battery is 18 months from the date of vehicle sold against any manufacturing defect observed.
Ï Why is there no Kick starter provision in Pulsar DTSi 180cc?
B Normally sports bike having larger CC engine, do not have kick-starters for the reason that riders footrest comes in
the way of kick operation necessitating folding of the footrest etc. Even if battery is discharged to the level of not
able crank the engine through self start, Engine can be started by push start. (Min voltage required for ignition
system i.e. 7.8 V where as self start needs 11.5 V).
Ï Can the spoilers of New Pulsar DTSi be fitted on old Pulsar DTSi?
B No, it is not possible as the mounting brackets for fixing the spoilers are welded on petrol tank at precise location
only.
Ï Is the tube less tyre used in both Pulsar DTSi 150cc & Pulsar DTSi 180cc?
B The tube less tyres are used only in Pulsar DTSi 180cc only.
Ï What is a tubeless tyre & What are its advantages?
B The name 'Tubeless' it self indicates that the tyre is without tube. In this tyre there is inner tube which is a integral
part of the tyre known as inner. The air is held between the rim & the tyre. The air filling valve is fixed air tightly
on wheel rim.
B Advantages :
• Better fuel efficiency.
• Better heat dissipation.
• Less chance of damage in case of flat running.
• Slow air leak.
• No tube related problems.
• Cost saving on tube.

Ï Is the tubeless tyre repairable if get punctured?

B YES. Puncture of Tubeless tyres can be repaired locally. There are various methods like -
1. Filter Method
2. Plug (Mushroom) Method
3. Patch Method
But Bajaj Auto Limited recommends. Plug (Mushroom) method since it is more effective & safe.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 38 Akurdi Pune
PERIODIC MAINTENANCE & LUBRICATION CHART

RECOMMENDED FREQUENCY
Sr. Operation Servicing 1st 2nd 3rd 4th 5th 6th 7th
Subsequent
No. 500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
1. Clean the vehicle with water wash Ensure to prevent water
& dry completely 3 3 3 3 3 3 3 entry in Petrol tank,
Silencer & electrical
Parts. Use caustic free
detergent for washing.
2. Engine oil (Bajaj DTSi 10000 oil) C,R R Top R Top R Top R BGO DTSi 20W40 for
& engine oil filter* Up Up Up 100cc models.
BGO DTSi 20W50 for
Models above 125cc.
3. Oil strainer CL CL CL CL CL Oil strainer cleaning at
the time of oil change.
4. Body centrifugal filter** CL CL CL CL
5. Starter Clutch (Dry Type)** L L L L L L L Use recommended
Molycote grease.
6. Spark plug CL,A,R CL,A CL,A R
7. Air cleaner element ***& cover ‘O’ ring CL,R CL CL CL R CL CL R
8. In line paper filter or R R R
Fuel cock paper filter.
9. Fuel cock sediment bowl cleaning CL CL CL
10. Carburettor rubber duct C,R C,R
11. Fuel pipe C,R C C C R C C R
12. Valve tappet clearance C,A C,A C,A C,A C,A C,A C,A C,A
13. Non-Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
cleaning & lubrication
14. Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A Customer to apply OKS
cleaning & lubrication chain lub spray at every
500 kms.
15. Engine air breather tube C C C C C C C C
16. Silencer drain hole cleaning CL CL CL CL CL CL CL
17. Silencer tail pipe cleaning** CL CL CL CL CL CL CL
18. Brake cam & brake pedal pivot pin C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use recommended
AP grease.
19. Brake lining or pad - C,R C,R C,R R C,R C,R R Replace brake shoes
Check wear indicator / brake pad at every
15000 Kms.
20. Brake fluid level **- top up / replace C,A,R C,A R Use recommended
brake fluid (DOT3/DOT4)
21. Disc brake assly -- Check functionality, C C C C
leakage or any other damage.
22. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A
23. Battery electrolyte level, specific gravity C,A C,A C,A C,A C,A C,A C,A C,A Not applicable for
VRLA battery
24. Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 39 Akurdi Pune
PERIODIC MAINTENANCE & LUBRICATION CHART

RECOMMENDED FREQUENCY
Sr. Operation Servicing 1st 2nd 3rd 4th 5th 6th 7th
Subsequent
No. 500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
25. Ignition switch barrel cleaning & C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use recommended
handle bar control switches Wd40 spray
contacts cleaning.
26. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
27. Steering stem bearing*** & C,CL,L,R C,CL, C,CL, C,CL, Check & replace if
Cap steering bearing (Plastic)** L,R L,R L,R Damaged. Use HP
Lithon RR3 grease for
lubrication.
28. Main stand & side stand pin** CL,L CL,L CL,L CL,L Use recommended
AP grease.
29. Swing arm pivot pin L L L L L L L
(for non silent bush)**
30. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
31. Engine foundation silent bushes** C C C
32. General lubrication-Clutch lever, L L L L L L L L Use recommended
front brake lever, kick lever. AP grease.
33. Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
34. Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A C,A Use recommended
'Ready to use coolant'.
35. Coolant hose damage/clamps/leakage** C C C C C C C
36. Radiator fins** C C C C C C C
37. Spoke tightening**-Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T

* It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be
every 5000 kms.

** As applicable to model

*** More frequent cleaning may be required while driving in dusty environment.

C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate

Note : Periodic parts, Oil, Coolant, Filters, All types of greases, Cleaning agents, Cables, Wear & tear parts, Rubber ‘O’ rings / oil seals / pipes,
Gaskets to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 40 Akurdi Pune
PERIODIC MAINTENANCE & LUBRICATION CHART

Why Periodic Maintenance

1. What is Preventive Maintenance ?
Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures.
The primary goal of PM is to up keep health of product through out it's life.

2. Why Preventive Maintenance ?

Preventive Maintenance is predetermined work to -
a. Ensure safe functioning of product with intended reliability.
b. Reduce cost of repairs & replacement.
c. Protect assets & prolong the useful life of component / product.

3. How to perform ?
a. Clean / Inspect / Lubricate / Adjust / Replace as per the PM chart & encyclopedia guidelines.
b. To correct deficiencies found through testing & inspection.

4. How to ensure execution & competency ?

a. Training programs, encourage & appreciates for abnormality identification & prevention.
b. Audit & review to assure quality performance.
c. For better understanding show “Periodic Service DVD” to technicians at suitable interval.

5. How to promote compliance to PM schedule ?

a. Work shop side -
1. Ensure adherence to S.O.P. while carrying out repairs through stage wise, service wise check sheet
deployment.
2. Monitor effectiveness of technicians through final inspection.
3. Monitor consumption of Periodic parts vis a vis vehicle serviced month wise.
b. Customer side -
1. Display periodic parts replacement chart in customer interaction explaining adverse effects, if not done.

6. Preventive Maintenance effectiveness - Indicators to be monitor by WM at service station

a. Reduction in repeat complaint.
b. Parts, components performing to intended life.
c. Reduction in brake down.
d. Increase in service volume through AMC engagement.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 41 Akurdi Pune
PRE-DELIVERY INSPECTION CHECKLIST

Following is the checklist for carrying out PDI of “Pulsar 150/180” motorcycle. This checklist is to understand various
check points those are to be checked / inspected before delivery of the new vehicle.
Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as per the
points given below. This ensures trouble free vehicle delivery to the customer.

Dealer's Name Dealer's code:

PDI check sheet - Pulsar 150/180
Frame No. Date of PDI
Engine No. PDI done by
Please unsure that following checks are carried out during PDI before delivery of vehicle.

3 if OK Observation /
To Check Check for
7 if NOT OK Remarks
ENGINE
Engine Oil "BAJAJ Oil level between lower & upper mark / Top up if required
DTS-i 10000" 20W50 Oil leakage if any, Specify source of oil leakage
Check in warm up condition 600C / Adjust if required
Idling RPM
(1400+100 RPM)
Kick operation Smooth operation
Gear shifting Smooth operation
Engine noise No abnormal noise
Silencer noise No abnormal noise from silencer & shields
Magneto cover bolts, - 0.9 ~ 1.1 Kgm
Clutch & Oil filter cover bolts - 0.9 ~ 1.1 Kgm
Engine foundation bolts
a) Front mounting bolts (Kg.m) - M8 : 2.2, M10 : 2.4
b) Rear mounting bolts (Kg.m) - M8 : 2.2, M10 : 2.4
Fasteners (Check
c) Top mounting bolts (Kg.m) - 2.2
torque)
Silencer mounting bolt
a) Silencer mouth flange nut - 1.4 ~ 1.9 Kgm
b) Silencer bracket bolts - 3.5 ~4.0 Kgm

FUEL SYSTEM
Fuel Tank / Pipes No leakage / Correct fitment
Fuel Cock Smooth operation
FRAME
Front : 1.75 Kg / Cm2 (25PSI)
Tyre Pressure
Rear (solo): 2.00 Kg/Cm2 (28.4PSI), (with Pillion): 2.25 Kg/Cm2 (32PSI)
Front & Rear Wheel Free rotation
Side & Center stand Smooth operation
Proper fitment
Mirror
Clear rear view
Head lamp Focus adjustment
CONTROLS

Brakes Rear - Brake pedal free play 25 ~ 30 mm

Throttle Grip free play - 2 ~ 3 mm. Smooth operation

Smooth operation, Free play - 2 ~ 3 mm
Clutch Cable
Standard routine (From Inside leg guard)
Speedo cable Standard routine

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 42 Akurdi Pune
PRE-DELIVERY INSPECTION CHECKLIST

Speedo cable Standard routine

Slackness standard - 25 ~ 35 mm
Drive chain lock position & standard fitment
Drive Chain
Equal marking of chain adjuster on both side
No touching to chain case
SUSPENSION
Front Fork No leakage. Smooth working
Rear Shock Absorber Spring adjuster notch position : 1st notch (Standard)
Steering Smooth operation (No play / No Sticky movement)
Steering cum Ignition lock, Seat lock, LH side cover lock,
Lock Operation
Petrol tank cap lock
Front axle nut (150cc - 4~5 Kgm, 180cc - 8~10 Kgm)
Rear axle nut (150cc - 8~10 Kgm, 180cc - 8~10 Kgm)
Torque rod nut (150 cc & 180cc - 3~4 Kgm)
Steering cap bolt (150cc - 3.5 Kgm, 180cc - 5 Kgm)
Handle bar bolts (150cc - 2~2.2 Kgm, 180cc - 2~2.2 Kgm)
Fasteners
(Check torque) Caliper install bolts (150 cc & 180cc - 2.2~2.8 Kgm)
RSA mounting dome nut (150 cc & 180cc - 3.5~4.0 Kgm)
Swing arm pivot nut (150 cc & 180cc - 8~10 Kgm)
Brake disc allen bolts (150 cc & 180cc - 2.6~3.2 Kgm)
Pinch clamp bolt (180cc - 2.0~2.2 Kgm)
ELECTRICAL
Terminal voltage 12.4 V DC & Charge status using load tester.
Electrolyte level.
Battery
Tightness of battery terminals / cables/ petroleum jelly application
Proper routine of overflow pipe
Fuse Position of fuse box
Head light, Tail / stop lamp, Side indicators, Speedo bulb,
All Bulbs Working
Number plate lamp
RH & LH control switch, Ignition switch & Brake switch
Switch Operation
(Front & Rear)
Working / Engagement in gear & neutral
Starter Motor
No abnormal noise
Working of Speedometer, Odometer
Speedometer Working of all signal indicators icons (Neutral, Turn signal High beam,
& Bajaj logo)
Headlamp assembly No excess gap & Uneven gap
Horn Ensure no distorted sound
Visual inspection No dent / damages / scratches

TEST DRIVE
Cold start & Warm start
Starting
Idling speed (Warm condition) (1400 + 100 RPM)
Throttle response
Drive ability
Brakes effectiveness - Front & Rear

CO % Check CO should be 1.5 ~ 2.5 % in engine warm condition at idling RPM

Cleaning Wash & Clean vehicle.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 43 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Importance of PM schedule execution

Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The
primary goal of PM is to up keep health of product through out it's life.

PM Activity Benefits
• Engine oil replacement / top up.
Better lubrication of engine components.
• Engine oil filter replacement.
Smooth functioning of engine parts.
• Oil strainer cleaning.

• Idle speed & CO% setting.

• Spark plug cleaning.
Better drive ability.
• Air filter cleaning.
consistancy in mileage.
• Fuel cock bowl cleaning.
• Carburettor cleaning.

• Battery electrolyte level checking

• Petroleum jelly application on battery terminals
• Battery terminals connection tightening
• Electrolyte specific gravity checking Easy self start smooth functioning of DC system.
• Battery charge / condition checking by battery tester
• Charging of battery on BAL recommended battery
charger

• Clutch free play setting

• Accelerator free play setting
Smooth gear shifting, effective braking
• Front brake free play setting (applicable to drum brake)
• Disc brake system checking

• Drive chain (non 'O' ring) lubrication on vehicle

• Drive chain ('O' ring) lubrication on vehicle
No chain noise issues.
• Drive chain (non 'O' ring) overhaul
Optimum performance of drive chain.
• Drive chain ('O' ring) overhaul
• Drive chain slackness checking & adjustment

• Wiring harness checking

• Ignition switch contacts cleaning checking & cleaning
• Clutch switch & brake switch contacts cleaning Smooth functioning of electrical controls.
• Clutch switch & replace
• Rear brake switch check & adjust

• General lubrication / greasing. No noise / wear & tear of parts.

• Fasteners tightening by torque wrench. No vibration related issues.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 44 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Servicing with Water Wash

1. Cover tail end of silencer with PVC cap to avoid water entry in silencer.

Caution :
Vehicle washing without covering silencer tail end will result in water entry
into silencer causing rusting of silencer.

2. Set water washer pressure for vehicle washing is 25 bar max & set the
nozzle in spray mode.

3. Clean the exterior surface of engine metal parts by diesel or kerosene

with soft nylon brush.

4. Dismantle the small chain cover & clean the area between magneto
cover and engine sprocket by using nylon brush and kerosene or diesel.

5. Wash the vehicle by keeping nozzle 2 meters away from parts.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 45 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

6. Adjust nozzle to jet mode & wash under the front and rear mudguards to
remove the mud & dirt.

7. Clean painted parts by gently rubbing their surface with sponge / soft
cloth dampened with solution of mild car shampoo / liquid solution.

8. Rub the front and rear tyres by nylon brush to remove dirt & mud.

9. Water wash the vehicle with nozzle in spray mode & clean all soap &
shampoo foam.

10. Dry the vehicle by using low pressure (2 bar) compressed air.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 46 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

11. Vehicle should be wiped off by cotton cloth immediately after washing.

12. To avoid water entry & paper filter, do not apply water on area beneath
seat. (applicable to Pulsar 200NS, Discover 125ST & Discover 100T).

Required Special Tools & Equipment

Water pressure gauge Spray gun Silencer tail

on washing machine adjustable spray jet end cap

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 47 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Engine Oil Replacement a[>Jnai[el bdlv&

1. Ensure vehicle is thoroughly clean.

vihnn[ sp*>N< sif krv&>

2. Ensure the engine is in warm condition before opening engine oil drain
bolt.
vihnn[ grm kyi< bid D[^en bi[ÃT Ki[l) j&n&> ai[el bhir kiQv&.

3. Drain engine oil in a clean container.

a[>Jn ai[el n[ sif Ôrmi kiQi[

4. Measure the quantity of drained oil.

ai[eln) mi#ii c[k kri[

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 48 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

5. Inspect oil quality.

6. Clean ferrous burr accumulated on the tip of magnetic drain plug and
then refit.

7. Tighten drain plug to recommended torque by torque wrench.

8. It is important to measure oil quantity after draining. This is important to

understand the oil consumption pattern.

9. During the interval- from one oil change to the next oil change, engine
oil quantity should not be more than 50 ml. per 1000 Kms. If oil drop is
more check for external oil leakage, smokey exhaust & piston ring wear.

10. Clean centrifugal oil filter (applicable for Pulsar 150 / 180 / 220 /
Avenger 220).

13. Use Bajaj Genuine oil only as per the recommended grade.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 49 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

14. Ensure oil filler cap ‘O’ ring as in good condition.

ai[el f)ÃTr k[p O r)>g bribr f)T C[ k[ nh) t[ ¹yin riKv&>

15. Ensure oil filler cap is fully tight.

ai[el D)^ÃTr k[p TieT C[ t[ c[k krv&.

j$r) T&Ãs an[ siwni[

Required Special Tools & Equipment

Measuring Jar Funnel Cleaning brush

m[zr)>g zir fn[l kl)p)g b\S

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 50 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Oil Strainer Cleaning

1. Remove the engine drain plug by using box spanner and handle.

2. Drain engine oil in a clean container.

3. Remove two bolts securing right hand side foot rest & take out the foot
rest.

4. Remove bolt securing kick lever & take out kick lever from kick shaft.

5. Remove phillips screw securing ‘Cover Starter Motor’. Take out the
‘Cover Starter Motor’.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 51 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

6. Remove 2 bolts securing ‘Bracket Clutch Cable’ & take out the clutch
cable end terminal from ‘Lever Clutch’.

7. Loosen & remove clutch cover bolts in crisscross pattern & take out
clutch cover.

8. Remove the bolts securing ‘Oil Pump Assembly’. Take out the ‘Oil Pump
Assembly’.

9. Remove the wire clip securing ‘Oil Strainer’ from the bottom end of ‘Oil
Pump Assembly’ & take out ‘Oil strainer’.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 52 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

10. Clean the ‘Oil Strainer’ by kerosene / diesel & nylon brush.

11. Blow low pressure air (2 bar) on the strainer mesh in the direction
opposite to flow of oil.

12. Pump the engine oil by 'Oil can' through the input passage hole of oil
pump body & simultaneously rotate the oil pump shaft nylon gear in
clockwise direction to ensure clear oil passage & working of oil pump.

13. Check condition of 'O' ring of 'Oil Strainer'. Re-install the oil strainer on
oil pump body. Refit the clamp securing 'Oil Strainer'.

Required Special Tools & Equipment

T Spanner Nylon Brush Air Gun

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 53 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Centrifugal Oil Filter Cleaning

1. Remove two bolts securing right hand side foot rest.

2. Take out the foot rest.

3. Remove bolt securing kick lever.

4. Take out kick lever from kick shaft.

5. Remove phillips screw securing ‘Cover Starter Motor’ & take out the
cover.

6. Remove 2 bolts securing ‘Bracket for Clutch Cable’.

7. Take out the clutch cable end terminal from ‘Lever Clutch’.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 54 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

8. Loosen & remove clutch cover bolts in crisscross pattern.

9. Take out clutch cover.

10. Remove centrifugal oil filter cover mounting screws.

11. Clean centrifugal oil filter by nylon brush & kerosene / diesel.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 55 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

12. Replace gasket by new one.

13. Apply 0.5 Kgm torque while refitting.

14. Replace clutch cover gasket by new one.

15. Tighten clutch cover bolts in crisscross sequence.

16. Apply specific torque to clutch cover bolts.

Required Special Tools & Equipment

Phillips Screw Driver Nylon Brush Torque Wrench

T-Spanner

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 56 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Spark Plug Gap Checking

1. Remove spark plugs using plug spanner.

2. Visually check spark plug electrode for color, erosion, crack & breakage.

3. Clean the spark plug on

spark plug cleaning machine.

4. Check and adjust spark plug gap by wire gauge.

5. Check spark plug on spark plug testing machine for intensity of spark &
its color. It should be blue spark with good intensity.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 57 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

6. Replace spark plug as per the interval given in the Periodic Maintenance
Schedule.

7. Refit spark plugs by doing pre-fitment manually & thereafter use spanner
for tightening.

8. Ensure spark plug cap is firmly fitted.

Note : Replace spark plug at every 20000 Kms.

Required Special Tools & Equipment

Wire Gauge Spark Plug

Spanner Regular

Spark Plug Spark Plug

Cleaning Machine Cleaning Gun

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 58 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Fuel Cock Sediment Bowl Cleaning

1. Put the petrol cock knob to OFF position.

2. Remove the petrol cock sediment bowl by using a ring spanner.

3. Pour out the petrol to remove sludge and sediment from Petrol Cock
Sediment Bowl.

4. Remove strainer from petrol cock body.

5. Clean the bowl and the strainer with the help of petrol and nylon brush.

6. Refit the strainer and the bowl.

7. Put fuel cock knob in ON / Res position & confirm no fuel leakage.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 59 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Silencer Drain Hole Cleaning

Clean the silencer drain hole by using
silencer drain hole cleaning tool as
shown in photograph.

Nitrox Rear Shock Absorber

Adjusting Spring Tension
• RSA spring tension can be adjusted with the help of 5 stepped adjuster
cam to suit individual requirement as per load & road conditions.
• Turn the adjuster cam on each shock absorber to same required position.
Setting the adjuster cam to higher notch position increases the spring
stiffness & vice-versa.
• Shock absorbers adjusted either too soft or too stiff could adversely
affect riding comfort & vehicle stability.

Position 1 2 3 4 5
Spring Action Stronger

If the Shock Absorber sleeves on both sides are not adjusted to the same
position, an unsafe riding condition may result.

Note : Std setting is done in 1st notch

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 60 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

CO% Setting
1. Readiness of CO gas analyzer
a. Ensure the machine is in well calibrated condition & calibration
certificate is available.
b. Switch ON & warm up the CO gas analyzer for its recommended
time.
c. Then carry out various tests such as leakage test, HC residue test,
IR zero test, oxygen censor test etc.

2. Readiness of the Vehicle

a. Warm up the engine. Run the vehicle on MRTB or drive the vehicle
for about 3 ~ 4 kms on road.

b. After warm up, check the engine oil temperature by dipping the probe of
temperature indicator in the oil through oil filler cap.
It must be 600c.

3. Check & set engine idling RPM with the use of digital tachometer to
1400 + 100 by adjusting idling screw.

4. Remove bolt & washer fitted to the silencer nozzle near to ExhausTEC.

5. Connect silicon tube of CO gas analyzer probe to the nozzle.

6. Note the CO when reading on LCD screen of the analyzer stabilizes.

Pulsar 150/180 DTS-i Dealer Development Center

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IMPORTANCE OF PM SCHEDULE EXECUTION

7. Set the air or VC screw to get CO value between 1.5 ~ 2.5 % at idling
RPM or 1400 + 100.

8. Reconfirm the engine idling RPM & CO are within specified limit.

9. For getting better engine performance & optimum fuel efficiency, achieve
CO% as recommended.

Required Special Tools & Equipment

Tachometer CO Gas Analyzer Thermometer

Screw Driver Silicon Tube

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 62 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Battery Electrolyte Level & Specific Gravity Checking

1. Open the side cover panel.

2. Clean the battery & battery terminal.

3. Inspect battery for damage / leakage.

4. Open all the 6 caps.

5. Check specific gravity by using hydrometer in all six cells one by one.

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IMPORTANCE OF PM SCHEDULE EXECUTION

6. Each cell should have specific gravity of 1.240.

7. Add distilled water & maintain level in between Min & Max level.

8. Use Nitrile rubber hand gloves while topping up battery electrolyte level &
checking of specific gravity.

Note :
- Dry battery (PDI) - Initial filling by electrolyte with charging for 10 ~ 12
hours.
- Wet battery (PDI / Servicing) - Add only distilled water & maintain level.

Required Special Tools & Equipment

Hand Gloves Distilled Water Bottle Hydrometer

with Dropper

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 64 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Clutch Cable Free Play Checking & Adjustment

1. Press and release the clutch lever to confirm the smooth operation of
clutch.

2. If clutch operation is jammed or sticky, replace clutch cable.

3. Check the clutch lever free play by steel rule.

4. If free play is less or more than standard, set it by using the adjuster
provided at the clutch lever end.

5. The free play can also be set by using the clutch cover end adjuster.

Pulsar 150/180 DTS-i Dealer Development Center

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IMPORTANCE OF PM SCHEDULE EXECUTION

Throttle Cable Free Play Checking & Adjustment

1. Check for smooth rotation of accelerator grip.

2. Check accelerator free play by scale / ruler.

3. Adjust accelerator free play.

4. Recommended free play is 2 ~ 3 mm.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 66 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Rear Brake Pedal Free Play Checking & Adjustment

1. Check for smooth operation of rear brake pedal.

2. Measure rear brake pedal

free play by using a steel
scale.

3. Adjust rear brake pedal free play as per specification.

4. Recommended free play (Y-X) - 25 ~ 30 mm.

Note :
Brake free play adjustment is possible in drum brake variants only.

Required Special Tools & Equipment

Measuring Scale

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 67 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Tappet Clearance Setting

1. Do tappet setting at engine cold condition.

2. Ensure the ‘T’ mark on the ‘Rotor’ match with the mark on the
‘Crankcase LH’. At this stage the ‘Piston’ is at TDC and both the
‘Tappets’ are free.

4. Put the feeler gauge, measure and adjust the clearance.

5. Lock the nut holding screw with special tool after getting desired
clearance.
6. Again check the tappet clearance with gauge. The gauge should slide
with slight resistance between tappet and valve stem head feeler and
tighten the check nut with a spanner.
Inlet Valve : 0.05 mm • Exhaust Valve : 0.1 mm

Required Special Tools & Equipment

Filler Gauge Tappet Adjusting Tool

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 68 Akurdi Pune
IMPORTANCE OF PM SCHEDULE EXECUTION

Sealed Type Drive Chain Lubrication on Vehicle

1. Put vehicle on center stand. Normal dust should be wiped clean using a
lint free cloth.

2. Hold the Chain Lube Spray Can (OKS Spray) vertically upright & shake it
vigorously till the noise of steel ball inside the can is heard uniformly. Fix
the extension tube (red pipe provided with the can).

3. Hold the can at the back of the rear sprocket in line with chain rotation
and keep the nose of the extension tube at about 5~10 cms away from
the chain.

4. Rotate the wheel in reverse direction & spray the lube on the middle
portion of the chain so that lubricant will get spread on roller & bushes
and on both sides of the chain. Spray the lube on full length of chain by
rotating the wheel to a complete rotation.

5. Rotate the wheel 3 ~ 4 times so that the lubricant spreads & settles for
5~6 times.
Wipe out any excess lubricant if it has dripped down or sprayed on the
wheel / tyre.

6. Adjust chain slackness as per specification.

Note :-
If drive chain is excessively dirty, then drive chain has to be removed &
cleaned using mixture of chain cleaning & lubricating spray, Diesel & SAE90
oil in 1:1 ratio.

Pulsar 150/180 DTS-i Dealer Development Center

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IMPORTANCE OF PM SCHEDULE EXECUTION

Non Sealed Type Drive Chain Lubrication on Vehicle

1. Put vehicle on center stand. Normal dust should be wiped clean using a
lint free cloth (applicable for 1st Free service).

2. Lubricate chain with SAE 90 oil. Ensure oil is directed on to the ends of
the bushes & links on either side.

3. Rotate the rear wheel for proper lubrication of entire chain.

4. Wipe off excess oil or dripping oil & closed the window cover.

5. Adjust chain slackness as per specification.

Note :-
If drive chain is excessively dirty, then drive chain has to be removed &
cleaned using diesel & lubricated in greasilator using molten (IOC Servo
compound) chain grease.

Pulsar 150/180 DTS-i Dealer Development Center

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IMPORTANCE OF PM SCHEDULE EXECUTION

Sealed & Non Sealed Type Drive Chain Lubrication by Removing from Vehicle
1. Remove the chain cover.
Sealed Non Sealed
Type Chain Type Chain

7 3

2. Open the drive chain link lock.

(As applicable to model).

3 3

3. Take out the chain.

3 3

4. In first stage clean the chain in

st
chain cleaning stand 1 pot
containing. Diesel +
SAE90 Oil Diesel /
in 1:1 Kerosene
proportion

5. In 2nd stage clean the chain in chain

nd
cleaning stand 2 pot containing
cleaner. Diesel +
SAE90 Oil
Diesel
in 1:1
proportion

Pulsar 150/180 DTS-i Dealer Development Center

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IMPORTANCE OF PM SCHEDULE EXECUTION

Sealed Non Sealed

Type Chain Type Chain
6. Hook the chain for dripping off.
3 3

7. Refit chain on vehicle & Adjust

chain slackness as per specification. 3 7
Non Sealed Lubrication :

8. D i p t h e c h a i n i n g r e a s i l a t o r
containing molten grease (IOC servo
compound) for 2 minutes
7 3

9. Hook the chain for dripping off

excess grease and refit chain on
vehicle.
7 3
10. Adjust the chain slackness as per
specification. 7 3

Required Special Tools & Equipment

T Spanner Chain Cleaning Stand Greasilator

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 72 Akurdi Pune
 fy&al s)ATm
Fuel System
co c[k)g an[ t[n&> s[T)g
a[>Jn Ty&n ap
• CO Checking and Setting
SOP
• Engine Tune-up
kib&<r[Tr srk)T • Standard Operating
Procedure
• Carburettor Circuits

73
CO CHECKING & SETTING

Readiness of CO Gas Analyser Taking the Reading

Warm up the CO Gas Analyzer • Remove M-5 bolt & aluminum
for 10~15 minutes before washer fitted to the nozzle
proceeding further. Warming up (12mm OD) shown in figure,
is essential every time machine of the connecting tube welded
is put on to purge out any to silencer pipe before CAT
gases left in side. converter.
Carry out Span Check as per • Use a Silicon Rubber tube of
manufacturer's Recommendation approximately 300 mm to fit
to confirm the OK condition of onto the nozzle. Only a
the Equipment (If Span Check Silicon rubber tube should be
does not confirm the reading, used, as it has better high
then carry out Gas Calibration as per mfgrs. temp. resistance & will not
recommendation). Set the Equipment display to Zero deform / melt due to high temp. at the nozzle.
before taking the reading. • Connect the other end of the Silicon Rubber tube to
the flexible probe pipe of machine. Ensure that the
inner diameter of Silicon tube perfectly matches with
Readiness of the Vehicle outer diameter of flexible probe pipe of Gas Analyzer.
• The Silicon rubber tube must fit snugly onto the
Before checking CO emission, prepare the vehicle for nozzle to prevent any air / exhaust gas leakage.
checking the CO. • Note the CO / HC readings when the reading display
stabilizes.
• Warm up the engine to its normal operating temp. by
• As per Emission Norms the recommended CO% for 2
riding 5~6 Kms. The crankcase cover should be
Wheelers is 3.5% at idling RPM. But CO% for Bajaj
warm enough by feel. (Engine Oil Temp. = 600C).
Vehicles, for best results in terms of fuel efficiency are
different for different models. The ideal CO% is
Caution: In choke ‘ON’ condition CO % is high : 9~10%.
between 1.5 to 2.5% at idling RPM = 1400 + 100.
Hence warming up of engine is a must.
• If the reading is shown excess or less than BAL
• Set CO to 1.5 ~ 2.5 %. specifications, try to achieve by adjusting VC Screw.
• Turning in VC Screw will lead to less CO% and
Note: If engine does not go off, then attend to the turning out will lead to more CO%.
additional air supply problem in the carburetor circuit & Note: Remember the VC Screw should not be taken out more
intake system. After solving the problem once again than the recommended position. Every time VC Screw setting is
confirm that engine should die down on closing the VC changed specified Idling RPM must be restored & then reading
Screw. should be considered.
• If the CO% is not falling within recommended % in
• Set CO to 1.5 ~ 2.5 %. spite of adjusting the VC Screw then find out the
• Set Idling speed to specified cause & rectify. After rectifying the problem confirm
Idling 1400+100 rpm. Raise the CO% in the same way as mentioned above.
the engine to moderate Important: For better mileage & performance, achieve
speed at no load condition CO% as recommended.
for about 15 seconds. Then
In Pulsar motorcycle for better mileage and performance
bring back to specified idling
achieve values given below.
RPM.

Recommended CO% value w.r.t. VC Screw

and Idling RPM for Better Fuel Efficiency
Recommended Recommended
CO% VC Screw Position Idling RPM
2.5 + 2 1400 + 100 rpm
1.5% ~ 2.5% turns out

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Service Station Manual 74 Akurdi Pune
ENGINE TUNE UP

Reed Switch Setting & Checking

Check throttle lever movement by rotating it with hand. It should not
be sticky in operation and should return back it self on releasing.
bracket Multimeter should show continuity.
• Magnet should not touch with reed switch.
• Gap between Magnet & Reed Switch should not be more than
2.5mm.
Gap
• Movement of throttle lever with magnet assembly and Reed
2.5mm max. Switch fitted should be free.

Reed Switch : Setting

• Accelerator cable play: 2-3 mm by adjusting the Adjuster
• Protude stopper of the throttle lever bracket must on idling screw
tip.

Reed Switch : Checking

0.00
• Keep throttle at zero position.
• On connecting multi meter to Reed Switch coupler it should show
continuity.

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Service Station Manual 75 Akurdi Pune
ENGINE TUNE UP

• When throttle is open and Reed Switch magnet crosses to straight

edge of fix bracket of Reed Switch multimeter should show
discontinuity.

0.00

• On De-acceleration, when of Reed Switch magnet re-coinsides

with straight edge of fix bracket of Reed Switch Multimeter should
show continuity.

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Service Station Manual 76 Akurdi Pune
STANDARD OPERATING PROCEDURE

SOP for Carburettor cleaning

• Ensure fuel cock knob at 'OFF'

position.
• Remove fuel pipe from fuel cock
side.
• Loosen drain screw and flush
out petrol from the “Carburetor
bowl”.
• Then re-tighten the drain screw.

• Loosen clamps of rubber duct.

• Remove intake manifold bolts and take out carburetor.

• Remove Philips screws securing the “Carburetor bowl” to the Carburetor body.
• Take out “Carburetor bowl”
• Pour out sludge and sediment from “Carburetor bowl”

• Clean the “Carburetor bowl” by petrol & soft nylon brush.

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Service Station Manual 77 Akurdi Pune
STANDARD OPERATING PROCEDURE SOP

• Clean the carburettor jets by low pressure compressed air.

kib&<r[Trni j[Tn[ li[ p[|Sr Wiri sif krv&>

• Clean the carburettor passages by low pressure compressed air.

kir¾y&r[Trni p[s[jn[ li[ p\[sr Wiri sif krv&>

• Refit carburettor bowl.

kib&<r[Tr biuln[ f)T kri[

• Tighten the screws of “Carburetor bowl”

• Refit carburettor on vehicle & confirm no fuel leakage.
kib&<r[Trni Ak*n[ TiET kri[
kib&<r[Tr n[ vihn upr f)T kr) c[k kri[ k[ p[\Ti[l l)k[j nY)n[

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Service Station Manual 78 Akurdi Pune
CARBURETTOR CIRCUITS kib&<r[Tr srk)T

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Service Station Manual 79 Akurdi Pune
CARBURETTOR CIRCUITS

Starter Circuit : Constant Velocity Carburettor

Cut Section View

of Mixing Chamber

Air inlet
for choke

Towards
Engine Towards
Engine

1. Plunger Cap 1. Plunger

2. Diaphragm Cap 2. Mixing Chamber
3. Diaphragm Piston Valve
4. Piston Valve with Jet Needle

Function
The function of starter circuit is to provide rich air fuel mixture on starting / cold starting. At cold engine
condition the air is dense also the engine parts are cold enough this does not allow the petrol to vaporize
properly this leads to starting trouble.

Construction
The Starter Circuit consists of a starter jet and a plunger. The starter jet is used to meter the fuel and a
plunger that opens an air passage from the inlet of the carburettor (underneath the diaphragm) which passes
the mixture to the manifold.

Working
On pulling the choke lever the plunger is lifted by a cable. This uncovers the fuel passage that leads to the
starter jet, air inlet passage and the outlet passage towards the manifold. This creates enough suction to
draw fuel up from the bowl into the mixing chamber (below the plunger). Here the fuel is mixed with the air

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Service Station Manual 80 Akurdi Pune
CARBURETTOR CIRCUITS

Pilot Circuit : Constant Velocity Carburettor 1. Pilot Jet

2. Pilot Outlet Hole
3. Butterfly Valve
4. Volume Control
Screw
5. Idling Adjustment
Screw

Air Inlet
Towards for pilot jet
Engine

Function
The pilot circuit provides the air fuel mixture at idling when not enough air is being drawn through the
carburettor to cause the main circuit to operate.

Construction
The pilot circuit consists of pilot jet, pilot air jet and volume control screw. The pilot jet meters the fuel and
the pilot air jet meters the air quantity. The volume control (VC) screw controls the amount of air fuel mixture
flowing through the pilot outlet.

Working
As the air enters the pilot air inlet the fuel is metered by pilot jet and air quantity is metered by pilot air jet.
The atomized / vaporized mixture is discharged through the pilot outlet. The pilot outlet is located on the
manifold side of the carburettor. Since the throttle valve is almost at fully closed position, air fuel mixture is
supplied mainly by pilot outlet only. Air fuel mixture volume is adjusted by volume control (VC) screw and
mixture becomes lean when volume control (VC) screw turned clockwise and rich when it is turned

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Service Station Manual 81 Akurdi Pune
CARBURETTOR CIRCUITS

Progression Circuit : Constant Velocity Carburettor 1. Pilot Jet

2. Pilot Outlet Hole
3. Bypass /
Progression Holes
4. Butterfly Valve
5. Volume Control
Screw

Air Inlet
Towards
for pilot jet
Engine

Function
The progression circuit provides the air / fuel mixture at small throttle opening when pilot circuit is still
working but unable to meet the engine demands on small throttle opening.

Construction
The progression circuit follows the path of pilot circuit and the construction is same as that of pilot circuit.

Working
As like pilot circuit the fuel is metered by pilot jet and air volume is metered by pilot air jet. This mixture in

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Service Station Manual 82 Akurdi Pune
CARBURETTOR CIRCUITS

Main Circuit : Constant Velocity Carburettor

1. Piston Valve
2. Piston Valve Diaphragm
3. Jet Needle
4. Needle Jet
5. Jet Holder

Towards
Engine Air Inlet
for main jet
Function
The Main Circuit provides air fuel mixture by lifting
up the piston valve in direct proportion to the
engine demand. This assures the correct venture
size & air velocity throughout the mid range
operation of the engine.

Construction
This circuit consists of jet needle, needle jet and
main jet. To assist in atomization an air bleed circuit
is incorporated in the main metering system and it
aids fuel vaporization by introducing the air into the
fuel before it enters the main air stream.
The piston valve movement is controlled by spring and carburettor venture vacuum which is generated below
the piston valve diaphragm.

Working
When the butterfly valve is opened and air flow through the venturi increases, the air pressure in the venturi
(and the upper chamber) decreases.
As the atmospheric pressure in the bottom chamber is greater than the venturi pressure above the
diaphragm, the piston valve along with jet needle is pushed up and more air fuel mixture is drawn into the
engine from main jet through needle jet into the main air stream.
When the butterfly valve is closed, air flow through the venturi decreases; air pressure in the venturi
increases and approaches atmospheric pressure, & the spring pushes the piston valve along with jet needle
down.

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Service Station Manual 83 Akurdi Pune
Notes

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 84 Akurdi Pune
 a[>Jn an[ T^iºsm)Sn
Engine & Transmission
-TieTn)g Ti[k<, • Tightening Torques
• Service Data
-s(<<vs D[Ti
-Ap[S)yl T&Ãs
-yid riKvi miT[ni pi[eºT
• Special Tools
-c[s)s uprY0 a[>Jn bhir kiQv&> • Important Points
-a[>Jn Ki[lv&> to Remember
-a[>Jnni b)Ô piT<s Ki[lvi an[ f)T krvi • Engine Removal from
-piT<s c[k)g/ p[rim)Tr Frame
-a[>Jn a[s[Àbl krv&> g)yr T^iºsm)Sn pivr fli[ • Engine Dismantling
-a[>Jn l&b)|k[Sn • Engine Sub-assemblies
Dismantling
• Parts Inspection
Parameters
• Assembly of Engine
• Gear Transmission
Power Flow
• Engine Lubrication -
Flow of Oil

85
TIGHTENING TORQUES

Cyl. Head Bkt. Mtg. Bolts Engine Mounting Bolts Engine Mounting Nuts

M8: 2.2 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m

Chain Tensioner Mtg. Bolts Output Sprocket Bolts Silencer Mounting Bolt

1.1 Kg.m 1.1 Kg.m (Loctite 243) 3.5 ~ 4.0 Kg.m

Silencer Mounting Nuts Balancer Gear Cover Bolts Crankcase Joining Bolt

1.4 ~ 1.9 Kg.m 1.0 ~ 1.1 Kg.m (Loctite 243) 1.2 Kg.m (Loctite 243)

Crankcase Joining Bolts Crankcase Joining Bolt Clutch Cover Bolts

1.1 Kg.m (Loctite 243) 1.1 Kg.m (Loctite 243) 1.1 Kg.m

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Service Station Manual 86 Akurdi Pune
TIGHTENING TORQUES

Oil Pump Mounting Bolts Centrifugal Oil Filter Nut Rotor Cover Bolts

1.1 Kg.m (Loctite 243) 5.5 Kg.m 1.1 Kg.m

Clutch Nut (LH Threads) Cylinder Head Cover Bolts Cylinder Head Cover Nuts

7.0 Kg.m 3.5 Kg.m 1.0 ~ 1.5 Kg.m

Camshaft Sprocket Allen Bolt Starter Motor Mtg. Bolts Rotor Mounting Bolt

1.4 Kg.m (Loctite 243) 1.1 Kg.m 4.5 Kg.m

Kick Guide Allen Bolts Spark Plugs (2 Nos.) Drain Bolt

1.2 Kg.m 1.4 Kg.m 2.5 Kg.m

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Service Station Manual 87 Akurdi Pune
SERVICE DATA

Compression Pressure Valve Spring Free Length

Standard Service Standard Service
Limit Limit Limit Limit
Inner Inner
Pulsar 6.0~10.0 5.0~10.0 Pulsar 39.10 39.0
2 2
150 cc Kg/Cm Kg/Cm 150 cc Outer Outer
43.6 42.6
Inner Inner
Pulsar 11.0~13.0 9.0~10.0 Pulsar 38.6 37.6
180 cc Kg/Cm2 Kg/Cm
2
180 cc Outer Outer
41.4 40.4

Valve Clearance Valve Stem Diameter

Standard Service Standard Service
Limit Limit Limit Limit
Inlet Inlet Inlet Inlet
Pulsar 0.05 0.05 Pulsar 4.48 4.40
150 cc Exhaust Exhaust 150 cc Exhaust Exhaust
0.10 0.15 4.46 4.41
Inlet Inlet Inlet Inlet
Pulsar 0.05 0.03 Pulsar 4.483 4.63
180 cc Exhaust Exhaust 180 cc Exhaust Exhaust
0.10 0.08 4.464 4.444

Rocker Arm Shaft Dia. Valve Stem Bend

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar
7.994~8.0 7.98 TIR 0.01 TIR 0.03
150 cc 150 cc

Pulsar Pulsar
7.994~8.0 7.98 TIR 0.01 TIR 0.03
180 cc 180 cc

Cam Sprocket Diameter Valve Head Thickness

Standard Service Standard Service
Limit Limit Limit Limit
Inlet Inlet
Pulsar 61.285 ~ Pulsar 0.05 0.3
61.1
150 cc 61.165 150 cc Exhaust Exhaust
0.8 0.6
Inlet Inlet
Pulsar 61.165 ~ Pulsar 0.05 0.3
61.1
180 cc 61.285 180 cc Exhaust Exhaust
0.8 0.6

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Service Station Manual 88 Akurdi Pune
SERVICE DATA

Cam Height Cylinder Head Warp

Standard Service Standard Service
Limit Limit Limit Limit
Inlet Inlet
Pulsar 31.0 30.8 Pulsar --
0.05
150 cc Exhaust Exhaust 150 cc
30.4 30.2
Inlet Inlet
Pulsar 31.3 31.1 Pulsar --
0.05
180 cc Exhaust Exhaust 180 cc
31.0 30.8

Camshaft Chain Length 20 Links Piston Ring End Gap

Standard Service Standard Service
Limit Limit Limit Limit
20-link length Top Top
Pulsar 127.00 ~ Pulsar 0.15~0.30 0.55
128.0
150 cc 127.20 150 cc Second Second
0.30~0.45 0.70
1st 2nd 21st
Top Top
MEASURE THIS LENGTH
Pulsar 127.00 ~ Pulsar 0.15~0.30 0.55
128.0
180 cc 127.20 180 cc Second Second
0.30~0.45 0.70

Cylinder Inside Diameter Clutch Spring Free Length

Standard Standard Service
Limit Limit Limit

Group A Group B
10mm
Pulsar Pulsar
20mm 58.010 ~ 58.017 ~ 37.00 35.00
150 cc 150 cc
40mm
58.025 58.033

Group A Group B
Pulsar Pulsar
63.50 ~ 63.508 ~ 37.00 35.00
180 cc 180 cc
63.508 63.515

Piston Diameter Friction Plate Thickness

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar 58.000 ~ 57.975 ~ Pulsar

2.9 ~ 3.1 2.75
150 cc 58.008 57.981 150 cc

Pulsar 63.500 ~ 63.475 ~ Pulsar

7mm 180 cc 2.9 ~ 3.1 2.75
63.508 63.481 180 cc

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Service Station Manual 89 Akurdi Pune
SERVICE DATA

Piston / Cylinder Clearance Pressure Plate Warp

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar
0.019 0.039 0.2 0.3
150 cc 150 cc

Pulsar Pulsar
0.019 0.039 0.2 0.3
180 cc 180 cc

Piston Ring / Groove Clearance Shift Fork Guide Pin Diameter

Standard Service Standard Service
Limit Limit Limit Limit
Top 0.025 Top
Pulsar ~ 0.065 0.16 Pulsar
4.49 4.40
150 cc Second Second 150 cc
0.02~0.06 0.15
Top 0.02 Top
Pulsar ~ 0.06 0.16 Pulsar
4.49 4.40
180 cc Second Second 180 cc
0.01~0.05 0.15

Shift Drum Groove Width Crankshaft Run Out

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar
7.5 7.65 0.02 Max 0.05
150 cc 150 cc

Pulsar Pulsar
7.5 7.35 0.02 Max 0.05
180 cc 180 cc

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Service Station Manual 90 Akurdi Pune
SPECIAL TOOLS

Details of Engine Related Special Tool

For carrying out repairs / overhauls, various special tools are required. Some are commonly shared
with other models also.

Crankshaft Bearing Extractor

Drawing No : JC 1010 01

Application : To r e m o v e
bearing from crankshaft

Sprocket Catcher
Drawing No : 37 10DH 36

Application : For holding sprocket

during removal / refitting of Cam
sprocket allen bolt.

Camshaft Big Bearing Puller

Drawing No : 37 10DH 32

Application : To remove bearing

(Decompression assembly side) of
camshaft.

Camshaft Small Bearing

Puller
Drawing No : 37 10DH 31

Application : To remove small

bearing of camshaft.

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Service Station Manual 91 Akurdi Pune
SPECIAL TOOLS

Rocker Pin Remover

Drawing No : 37 10DH 35

Application : To remove rocker pin

from cylinder head.

Silent Bush Puller

Drawing No : 37 10DH 33

Application : To remove silent

bush from cylinder head cover.

Rotor Puller with Butt Pin

Drawing No : 37 10DJ 32

Application : Used to pull out rotor

from crankshaft assembly.

Primary Gear Holder

Drawing No : 37 10DJ 28

Application : Use to hold primary

gear while loosening / tightening
the clutch nut.

Balancer Gear Holder

Drawing No : 37 10DJ 63

Application : Used to load the

pre-tensioned scissor gears of
Assly balancer Idler gear.

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Service Station Manual 92 Akurdi Pune
SPECIAL TOOLS

Special Nut
Drawing No : 37 10DJ 43

Application : Used to remove / fit

of centrifugal oil filter nut.

Note : Existing tool can be used by

reducing diameter to 25.9 + 0.1 mm
Dia. = 25.9+0.1

Bearing Race Extractor

Drawing No : 37 00DJ 01

Application : Used for removing

the lower bearing race from ‘T’

Bearing Extractor
Drawing No : 37 10DJ 76

Application : Used to extract the

input shaft brg. from crankcase
LH.

Bearing Puller
Drawing No : 37 10DJ 77

Application : Used to pull out the

bearing for body balancer from
crankcase LH.

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Service Station Manual 93 Akurdi Pune
SPECIAL TOOLS

Adaptor and Valve Spring

compressor
Adaptor Drawing No : 3710DJ78
Valve Spring Compressor Drawing
No.: 37 1031 07

Application : Used for assembling

/ dismantling inlet, exhaust valves
by compressing spring in cylinder
head.

Rotor Holder
Drawing No : H6 0721 00

Application : To hold rotor while

loosening bolt.

Drift
Drawing No : 74 9309 89

Application : To remove piston pin.

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Service Station Manual 94 Akurdi Pune
IMPORTANT POINTS TO REMEMBER

Valve timing
• Ensure the sprocket marks (A) are aligned horizontally with cylinder head
top machined face and the piston is at TDC.

A A

• Secure the ‘Cam Chain Sprocket’ in the Spl. tool firmly & then tighten the
sprocket allen bolt (A).
• Ensure that the ‘O’ mark on washer always faces outwards when tightening
the allen bolt.
0

• Take utmost care while assembling.

• Fit Belleville washer in between 2 plain washers.

Ensure
Belleville • While assembling hub clutch place plain washer first & then place Belleville
Washer washer. Concave face should be upwards i.e. towards technician.

Plain
Washer

Clutch
Hub

• After placing Belleville, fit clutch plate with 40 friction material cubs (A) with
B A more I.D.
• 3 Nos. / 4 Nos. of clutch plates with 48 fiction material cubs (B)
alternatively along with steel plates.
• Fit top clutch plate with 40 friction material cubs (C).

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Service Station Manual 95 Akurdi Pune
IMPORTANT POINTS TO REMEMBER

• Input shaft has special nut.

• Thick spacer tapered I.D. should be placed on tapered portion of Input
Shaft.
• Input Shaft has left hand threads.

• When splitting crankcase always remove 1 long bolt fitted from clutch side
first.

• Remove long bolt immediately after removal of long bolt clutch side.
• Ensure proper fitment of bolt with copper washer to avoid oil leakage.

• Load the assly balancer idler gear with 2 teeths from either side using the
special tool.

• Fit primary gear drive (A).

• The mark teeth of the primary gear should match with the line mark on the
crankcase. This indicated that the piston is at TDC position.
This procedure should be carried before fitting the ‘Clutch Housing’ and this
position should not be disturbed while fitting the ‘Clutch Housing’.

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Service Station Manual 96 Akurdi Pune
IMPORTANT POINTS TO REMEMBER

• Take ‘Assembly Balancer Idler Gear’ along with Thrust Washer which is
pre-loaded and is held in special tool, Slide down the special tool with
‘Gear’ to engage the bottom half of the ‘Assembly Balancer Idler Gear’ with
the ‘Body Balancer Gear Assembly’
• Fit ‘Thrust washer’ on the other side.
• On assembly of ‘Assembly Balancer Idler Gear’ the itched / Dot mark of
Body Balancer Gear Assembly’ should match with the line mark on the
‘Crankcase’.

• Holding the ‘Assembly Balancer Gear’ in special tool now slide inside the
‘Clutch Housing’ so that the ‘Clutch Housing’ smoothly engages with the
top half of ‘Assembly Balancer Idler Gear’.
• Remove Spl. tool gently.
• Fit 2 dowels and Assly Balancer Idler Gear Cover
• Ensure perfect marking of gear marks with respect to crankcase mark.

• Do not dismantle the cam chain tensioner assembly.

The existing special nut puller for Pulsar can be use for Pulsar UG-III and
Pulsar 200 cc by reducing its diameter to 25.9 + 0.1 mm.

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Service Station Manual 97 Akurdi Pune
IMPORTANT POINTS TO REMEMBER

Always ensure piston ring position.

• Top Ring :
Open end facing towards exhaust.

• Second Ring :
Open end facing towards inlet.

• Upper Rail :
0
Open end 30 facing towards exhaust.

• Bottom Rail :
0
Open end 30 facing towards inlet.

• Expander :
Open ends at center and joints butting together facing down.

When tightening the special nut for centrifugal filter the Primary gear holder
should hold between the ‘Primary Gear’ and ‘Clutch Housing’ from bottom
side. (Note that oil pump assly is removed).

When loosening the special nut for ‘Centrifugal Filter’ the Primary gear holder
should be hold between the ‘Primary Gear’ and Clutch Housing’ from upper
side.

Never rest the Rotor holder against Gear change pedal lever.

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Service Station Manual 98 Akurdi Pune
REMOVAL OF ENGINE FROM FRAME

Remove :
• Put OFF the fuel cock
• Side panel LH
• Side panel RH

Remove :
• Both Seat assembly by pulling the cable for seat lock release
located on LH side.
• Disconnect the negative terminal of the battery.
• Disconnect the wiring harness socket for fuel level Indicator.
• Fuel pipe connections and moisture drain pipe from fuel tank.
• Disconnect stator plate harness
• Disconnect neutral switch coupler

Remove :
• Engine oil temp sensor screw (B) and disconnect the wire
• Remove sensor and gasket
• Drain bolt (A) and drain out the oil from engine.
• Refit the drain bolt with gasket & tighten it.
Engine Oil
Model Grade Quantity
B A Pulsar 150 CC
SAE 20W50 of API ‘SJ’ or ‘SL’ + JASO ‘MA’
Grade or Superior Drain & Refill = 1000 ml.
SAE 20W50 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ Engine Overhaul = 1100 ml.
Pulsar 180 CC
Grade or Superior

Remove :
A • Bolt (A)
• Petrol tank assembly.

Remove :
• Bolts (A)
• Gear shift pedal (B)
• Drive sprocket cover LH.

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Service Station Manual 99 Akurdi Pune
REMOVAL OF ENGINE FROM FRAME

Using Special Tool : Sprocket Holder -

37 1030 53
Remove :
A
• Bolts (A)
• Plate drive sprocket
• Drive sprocket along with the chain.
• Neutral switch coupler (B).
B

Remove :
• 2 nuts (B) for silencer flange

Note : Always remove the flange mounting first and then rear mounting to avoid
misalignment of studs.
B

Remove :
• Bolt (A) of silencer bracket mounted on pillion RH side footstep.
• Silencer assembly.
A

Remove :
• Starter motor connection (A)

Remove :
• Air filter mounting bolts to facilitate the removal of carburettor with
reed switch.
• Clamps of carburettor and disconnect carburettor along with
insulator and dismantle cables from it.
• Bracket bolts securing clutch cable on clutch cover.
• Spark plug cap RH

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Service Station Manual 100 Akurdi Pune
REMOVAL OF ENGINE FROM FRAME

Remove :
• Disconnect the reed switch coupler.
• Spark plug cap LH
• PCV pipe from breather

Remove :
• While removing engine foundation bolts, first remove the topmost bolt and
then go down progressively.

Note : Bolts (A) holding the engine to the chassis. (4 bolts of 12 mm and 1 bolt
needs deep socket for removing it).

• Lift up the engine off the chassis and place it on engine stand.

Note : After disconnecting all the sub assemblies and control cables from the engine
lift up the engine and remove it from RHS of the vehicle.

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Service Station Manual 101 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Cover Cylinder Head kvr s)l)ºDr

6 8

2 4
9 7

11 2

10 3

10

11 1

S.N. Description Qty S.N. Description Qty

1 Head Cylinder with Cover 1 7 Copper Washer 4
Kit Asly Cyl Head with Cover 1 8 Hex. Bolt with Flange 2
2 Cover Tappet 2 9 Hex. Bolt / Flange 4
3 ‘O’ Ring Kit for Cover Cyl. Head 1 10 Plug 2
4 Silent Bush 1 11 Gasket 2
5 Camshaft Cap 1
6 Domed Cap Nut 4

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Service Station Manual 102 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Cylinder Head
s)l)ºDr h[D

10

11

6 9
5

3 8
7
8

S.N. Description Qty S.N. Description Qty

1 ‘O’ Ring Kit for Cover Cyl. Head 1 7 Carburettor Insulator 1
2 Stud (Exhaust) 2 8 Clamp for Insulator 2
3 Gasket Cylinder Head 1 9 Hex. Bolt / Flange 2
4 Damper Cylinder Head 5 10 Sleeve - Spark Plug 1
5 Intake Pipe 1 11 Grub Screw 1
6 ‘O’ Ring (Intake Pipe) 1

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Service Station Manual 103 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Valve
9
viÃv
4 8

3
6

S.N. Description Qty S.N. Description Qty

1 Rocker Arm Shaft - Intake 1 4 Cotter valve 4
Rocker Arm Shaft - 5 Seal valve stem 2
Intake (OD 10 mm) 1
6 Valve Repair Kit 1
2 Rocker Arm Shaft - Exhaust 1
7 Valve Kit 1
Rocker Arm Shaft -
Exhaust (OD 10 mm) 1 8 Wave washer 2
3 Rocker Arm with roller 2 9 Plain washer 4
Rocker Arm without roller 2

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Service Station Manual 104 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Camshaft & tensioner

k[\m SifT an[T[ºSnr

3 7 6 8 9

15
5

10 12
14

11
13

S.N. Description Qty S.N. Description Qty

1 Ring ‘O’ 1 9 Hex. Soc. Head cap Bolt 1
2 Camshaft Assembly 1 10 Cam Chain 1
3 Bearing cam RH side 1 11 Cam chain Tensioner pivot Bolt 1
4 Bearing cam LH side 1 12 Tensioner Assly 1
5 Guide chain Kit 1 13 Hex Bolt / Flange 2
6 Sprocket cam Driven (32 T) 1 14 Tensioner assly. gasket 1
7 Collar cam Sprocket 1 15 Bolt 1
8 Special camshaft washer 1

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Service Station Manual 105 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Cylinder & Piston s)lºDr an[ p)ATn

2
6

12
3
11

10 2

1
4
8
7
9
5

S.N. Description Qty S.N. Description Qty

1 Gasket Cylinder 1 7 Oil Pipe Assly 1
2 Pin dowel 4 8 Bolt Special 2
3 Piston Assly. Std. 1 9 Gasket 4
4 Ring Set Piston 1 10 Damper 6
5 Ring Snap 2 11 Bolt (dummy for Temp sensor) 1
6 Cylinder Block / Piston Assly 1 12 Washer (dummy for Temp sensor) 1

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Service Station Manual 106 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Engine Top End Dismantling : a[>Jn T[ip a[ºDD)sm[ºTl)g kiQi[

Remove :
• Pull out the cover on the spark plug cap RH and the spark plug
cap itself
• Using a plug spanner, loosen the spark plug and remove the
spark plug RH
• Loosen & unscrew the allen head grub screw of the sleeve spark
plug RH.
Apik< ¼k[p kvrn[ {rh} K[c) ¼lg k[p bhir kiQi[
RH Apik< ¼lgn[, ¼lg Ap[nr Wiri Ki[l) ¼lg bhir kiQi[

Note : Wrap a piece of cloth around the protruding edge of the sleeve spark plug
and using a plier, pull out the sleeve.
ni[>w: Apik< ¼lg Al)v n[ kiQvi miT[ cir[ bij& kpD&> m*k) Ryir bid ¼liyr Y) kiQi[

Remove : kiQi[
• There are 2 ‘O’ rings fitted in the cylinder head, one on the cam
chain wall and the other near the spark plug threading
• Using a thin, sharp pointed tool pierce the ‘O’ rings and remove
them. (If required only)

Note : Remove these only if the ‘O’ ring protrusim in the bore is non-existant (which
means that the ‘O’ ring has set and it has lost its compression or sealing ability.)

Remove : kiQi[
• Loosen bolt (A) and unscrew chain tensioner plunger
• Cam chain tensioner assembly 2 bolts (B)
• Cam chain tensioner assembly
B • Gasket
A
{a} bi[ÃTn[ l&z kri[ c[en T[ºSnr ¼lnzrn[ an[Ak* kri[
c[en T[ºsarni b[ bi[ÃTn[ Ki[li[
c[en T[ºsnr a[s[Àbl)
giAk[T

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Service Station Manual 107 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Remove :
• Both tappet caps

Remove :
• Magneto cover 5 bolts
• Disconnect neutral switch coupler
• Magneto cover
• Rotate crankshaft to get piston at
TDC.
• Ensure both tappets are at free state
(i.e. at the end of compression
stroke)

Remove :
A • Loosen 2 dummy plug (A)

Remove :
• Cylinder head securing head cover 2 bolts (A)
• Cylinder head securing head cover 4 bolts (B)
A C • Cylinder head securing head cover 4 domed cap nuts (C)
B
• 4 copper plated steel washers

Note : Improper tightening sequence may cause warpage in cylinder head cover and
it can be damaged permanently.

Remove :
• Cylinder head cover complete
• Cam shaft cap
• 2 Dummy plugs
• Dummy plug gasket

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Service Station Manual 108 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Using Special Tool : Sprocket Catcher

- 3710 DH 36
Remove :
• Allen bolt (A)
• Spacer
• Cam sprocket
• Collar
A • Cam shaft assly

Note : Hold the cam chain up right using soft copper wire or thread. Do not use
cotton waste for holding the cam chain.

Remove :
• Cylinder head assembly
• 2 Dowels
• Gasket cylinder head

Remove :
• 2 Banjo bolts (A)
• Copper gasket
• Bolt (B)
• Oil Pipe
A

Remove :
• Non tensioner side chain guide
• Cylinder block assembly

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Service Station Manual 109 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Using Special Tool : Drift - 74 9309

89
Remove :
• Piston pin lock LH & RH side
• Piston pin
• Piston assembly

Note : Place a piece of clean cloth above hallow portion of cranckcase to arrest
piston pin circlip if it falls during fitment.

Warning : When tapping the drift for removal of piston pin, confirm
that the connecting rod is held firmly against the direction of tapping to
avoid damage to big end bearing connecting rod of crankshaft.

Remove :
• Block gasket
• 2 Dowels (A)

Note : Tie the cam chain firmly using soft copper wire/thread firmly to avoid slipping
down into crankcase.

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Service Station Manual 110 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Starter Clutch ATiT<r kÃc

11

10
13

12

7 1

2
6
9

4
8

14

15
5

S.N. Description Qty S.N. Description Qty

1 Body comp. starter clutch 1 10 Motor assly. starter clutch 1
2 Plate roller clutch 1 11 Bolt 2
3 Gear starter clutch 1 12 Cover starter motor 1
4 Plate starter clutch gear return 1 Cover starter motor moonlight silver 1
5 Bolt 1 13 Slotted c’sunk screw 1
6 Shaft starter counter 1 14 Spring 5
7 Collar starter counter 1 15 Roller 5
8 Gear comp. starter counter assly. 1 16 Needle Roller Bearing
9 Bolt socket 3 (For Gear Starter Clutch) 1

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Service Station Manual 111 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Engine LH : (Magneto Side)

Using Sp. Tool : Rotor Holder - H6 0721
00

• Hold the rotor assembly

A Remove :
• Rotor bolt (A)
• Washer

Using Special Tool - Rotor Puller with

butt pin : 37 10DJ 32
Remove :
• Rotor assembly
• Woodruff key

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Service Station Manual 112 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Note :
Holding the gear complete starter clutch rotate the rotor and pull it out in
Anticlockwise direction to prevent rollers and springs coming out.

Warning :
• These components remain hot for a long time especially if removed from a
hot engine. Wear suitable hand protection to prevent burns.
• Rotor puller has left hand threads

Remove :
• Gasket
• Bolt (A)
B • Plate starter clutch gear return (B)
• Gear starter clutch

Remove :
• Collar (A)
• Shaft
• Gear comp. starter counter assly
A

Remove :
• 3 Screw (A)
• Guide starter assembly along with oil seal.

Note : Removal of guide starter assembly is to be removed only if required.

Caution : Ensure that the woodruff key of rotor is removed prior to the
removal of guide starter assembly. The lips of magneto oil seal housed in
guide starter assembly will get damaged if not done so.

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Service Station Manual 113 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Clutch Cover

17
18
12 4
9 3
7
8 22
23
19
20

2
8

13 11
5

1
10

21

16
15
14

S.N. Description Qty S.N. Description Qty

1 Cover comp RH 1 13 Gasket cover RH 1
Cover comp RH-Flower Type 1 14 Plunger Oil 1
Kit Asly Cl Cover-Moonlight Silver 1 15 Plate Plunger Oil 1
2 Grommet Breather 1 16 Spring Joint ‘A’ 1
3 Shaft clutch release 1 17 Spring torsion clutch lever 1
4 Seal clutch lever 1 18 Washer 1
5 Rack 1 19 Set damper 1
6 Dip stick with ‘O’ ring 1 20 Flanged Bolt 5
7 Parallel pin 1 21 ‘Bajaj’ Decal / Decal DTS-i 1
8 Gauge 1 22 Bushing 1
9 Wire circlip 1 23 Set of Plate 1
10 Bolt 10 24 Plate Damper Integral 1
11 Pin Dowel 2 25 Damper Integral 1
12 Bracket Clutch Cable 1

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Service Station Manual 114 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Clutch

7
6

4
7 17

7 8
11
9

5 9
1

13

15
3 16 12
10

14

S.N. Description Qty S.N. Description Qty

1 Special Nut 1 10 Bearing Clutch lifter thrust 1
2 Spring judder 1 11 Holder Clutch 1
3 Clutch Assly. Complete 1 12 Rod Clutch lifter 1
4 Clutch Center 1 13 Spacer clutch 1
5 Plate Clutch Pressure 1 14 Nut Primary drive lock 1
6 Friction Plate Kit 1 15 Lever Assly. Clutch 1
7 Plate Clutch 5 16 Washer Primary Drive Gear 1
8 Spring Clutch Capacity 4 17 Seat judder spring
9 Bolt 5

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Service Station Manual 115 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Engine RH : Clutch Side

Remove :
A • 1 screw - (A)
• Starter motor cover

Note : The rod clutch lifter, plunger oil, plate plunger oil and spring
joint may fall out of their respective places into the oil collection tray.
If so, ensure that these are collected & accounted for before
proceeding.

Remove :
• 12 Clutch cover bolts (B)
• Bracket clutch cable (C)

Note : The rod clutch lifter, plunger oil, plate plunger oil and spring joint may fall out
B of their respective places into the oil collection tray. If so, ensure that these are
C collected & accounted for before proceeding.

Remove :
• 2 Dowels
• Clutch cover gasket
• Starter Motor (B)

Using Sp. Tool : Primary Gear Holder 37

10DJ 28
Remove :
A • 3 phillips head screws (A)
• Centrifugal oil filter cover
• Gasket

Note : Some amount of oil is trapped in cover

and body of centrifugal oil filter, this oil should be drained into the oil tray.

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Service Station Manual 116 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Using Sp Tool : Special Nut Puller - 37

10DJ43
Using Sp Tool : Primary Gear Holder - 3710
DJ28
Remove :
• Centrifugal oil filter special nut
• Belleville washer
• Body centrifugal oil filter assly

Remove :
• Bearing with plunger

Using Sp Tool : Special Nut Puller - 37 10DJ

43
Using Sp Tool : Primary Gear Holder -
3710DJ28
Remove :
• Input shaft special nut
• Belleville washer
• Clutch assly comp
• Spacer

Note : The existing Special Nut Puller 37 10DJ 43 can be used by grinding the tool
OD to 25.9 + 0.1 mm

Dia. = 25.9+0.1

Remove :
• 3 Assly balancer Idler gear cover bolts (A)
A • Cover
• Washer
• 2 Dowel

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Service Station Manual 117 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Remove :
• Clutch housing

Note : For ease in removal of clutch house insert

special tool (P. No.-37 10DJ 63) in Assly
Balancer Idler Gear.

Remove :
• Assly balancer idler gear
• 2 Washer

Remove :
• Bolt (A)
• Locking plate
A • Body balancer gear assly

Remove :
• Primary gear
• Square key

Note : Take care that square key does not fall inside the crankcase hollow portion
while removing.

Remove :
• Cam chain
• Cam chain sprocket
• Parallel Pin

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Service Station Manual 118 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Remove :
• 3 Bolts (A)
• Oil pump assembly
• 2 Dowels

Warning : The oil pump may be hot, hence use suitable hand
protection. Also, since the oil pump houses the oil strainer / mesh also,
A it may retain some quantity of oil. This oil may be hot. Hence proper
care should be taken to drain it.

Note : The oil which is in the oil pump housing should also be drained out into the
oil drain tray for measuring drained oil.

Remove :
• Gear change lever

Remove :
• Spring
• Allen bolt (A)
• Guide gear
A • Spacer
• Parallel Pin

Note : Check and inspect the drum change arm stopper for free movement always.

Engine Central Part :

Remove :

• Bolt (A) on RH side crankcase (Clutch side)

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Service Station Manual 119 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Remove :
• Bolt (B) on LH side crankcase (Magneto side)

Remove :
• 8 bolts on LH side crankcase
• Split the Crankcase halves.

Note : Before separating crankcase halves confirm that all the crankcase joining
bolts are removed and the sprocket cam drive with parallel pin on crankshaft
assembly is removed.

Remove :
• 2 Shafts (A) & (B) of gear shifter fork.
• 3 fork shifts (1 small for input 2 big for output shaft.
• 3 Rollers
• Drum change

B A

Remove :
• Crankcase gasket
• 2 dowels
• Crankshaft assly

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Service Station Manual 120 Akurdi Pune
SOP FOR DISMANTLING ENGINE

Air Filter
Crankcase Clutch Side :
Using Sp. Tool : Bearing Driver set-37
1030 61
Remove :
• Bearing (A) for input shaft assembly
from crankcase RH

Using Sp. Tool : Bearing Extractor 37

1030 68
Remove :
• Needle roller bearing (B) for output
A shaft assembly from crankcase RH
B

Crankcase Clutch Side :

Using Sp. Tool : Bearing Extractor 37
1030 72
Remove :
• Bearing (C) for drum change

Crankcase Magneto Side :

Remove :
• Oil Seal
Using Sp. Tool : Bearing Extractor 37
1030 72
A Remove :
• Bearing (A) for output shaft assembly
from crankcase LH

Using Sp. Tool : Bearing Extractor - 37

10DJ 77
Remove :
• Bearing (A) for body balancer gear
bearing from crankcase LH
A

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Service Station Manual 121 Akurdi Pune
DISMANTLING ENGINE SUB ASSEMBLIES

Using Sp. Tool : Bearing Extractor - 37

10DJ 76
Remove :
• Bearing (A) for input shaft assembly
A from crankcase LH

Remove :
• Bolt (A)
• Bearing stopper
Using Sp. Tool : Bearing Driver set
371030 74
Remove :
• Bearing for gear change drum from
crankcase
A

Magneto Cover :
Remove :
C • 2 phillips head screws (A) of Pulsar
B coil (E) mounting.
A
• Bolts (B) of stator assembly.
• 1 phillips head screws (C) of stopper
E • Stator coil assembly (D) along with
Pulsar coil.
D

Cylinder Head Cover :

Using Sp. Tool : Rocker pin remover - 37
10DH35
Remove :
B
• Rocker shaft (A)
A

• Rocker arm (C)

• Set of washers (1 wave & 2 plain)
C (B)

Note : Similarly remove the other Rocker shaft &

Rocker Arm from head over.

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Service Station Manual 122 Akurdi Pune
DISMANTLING ENGINE SUB ASSEMBLIES

Top End
A Cylinder Head :
B
Using Sp. Tool : Valve Spring
D Compressor - 37 1031 07
Using Sp. Tool : Adapter - 37 10DJ 78
C
Remove :
• 2 Cotter valve (A)
F • Valve spring retainer (B)
• Springs inner (D)
E • Spring outer (C)
• Valve from below (E)
• Washer (F)
• Valve steam seal (G)
Similarly carry out the same procedure
to dismantle the other valve from the
cylinder head assembly.

Chain Tensioner Assembly :

It is not recommended to Dismantled Chain Tensioner Assly.

Clutch Assembly :
E
6
Remove :
F
7
4
• 4 bolts (A)
D
• Holder clutch (B)
6

6 • 4 springs (C)
8 C
• Clutch center (D)
7
12
B
10
A
G
5
• Plain washer
14
• Belleville washer
6
3 • Disc clutch friction (E)
• Plate clutch (F)
• Plate clutch pressure (G) (Wheel
clutch)
• Clutch housing
• Thrust washer - conical from inner ID

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Service Station Manual 123 Akurdi Pune
DISMANTLING ENGINE SUB ASSEMBLIES

Oil Pump :
Remove :
• Clip (A)
• Oil strainer element (B) with 'O' ring
C (C)

Bearing Removal from Assly Balancer Idler Gear Cover and Crankcase
RH
Using Sp. Tool : Bearing Extractor - 37 10CD 30
Remove :
• Needle roller bearing from RH crankcase.

Assembly Balancer Idler Gear

Remove :
A C D • Thrust washers (A)
• Circlip (B) from any one side of the gear
• Scissor gear (C)
• Torsion Spring (D)
B D E C B A
Similarly carry out the same procedure on other side of the gear to
dismantle the idler gear completely.

Gear Complete Starter Counter Assembly

• Place the gear comp. starter counter assly on the arbor press as
shown in the figure.
• Using Bearing driver set (P. No. 37 1030 61)
Remove :
• Needle roller bearing.

Input Shaft Assembly

B C EF I K
• 1st gear is integral with the shaft (A)
• Remove thrust washer (B) and slide out gear 2nd drive (C)
• Remove gear 5th drive (D) and collect the splined washer (E)
behind it.
• Remove circlip (F) and remove gear 3rd drive (G)
• Remove circlip (H) and collect the splined washer (I)
D G H J A • Remove gear 4th (J) and collect the thrust washer (K) behind it.

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Service Station Manual 124 Akurdi Pune
DISMANTLING ENGINE SUB ASSEMBLIES

L M H FE CB A Output Shaft Assembly

• There are no integral gears on output shaft.
• Remove thrust washer (A) and slide off the gear 1st driven (B)
st
and collect the steel bush (1 driven gear is mounted on steel
bush (C) with shoulder ring
• Slide off the gear 4th driven (D).
• Remove circlip (E) and spline washer (F). Remove the gear 3
rd

driven (G).
• Collect the thrust washer (H) behind the 3 gear on output shaft (I)
rd

• Remove circlip (J) and collect the washer (K)

• Remove gear 2 driven (L) mounted on bush (N) with shoulder
nd

JK N I G D
ring
• Slide out gear 5th driven (M)

Crankcase Magneto Side

Remove :
• 3 Screws (A)
• Guide starter assembly (B) on which oil seal is mounted.
• Oil seal (C)
C
A • Damper (D)
D

Clutch Cover
A Remove :
G
B • Parallel Pin (A)
• Clutch shaft release completely (B) by slightly rotating it so,
• Rack (C)
• Plunger oil (D)
• Plate plunger oil (E)
H
• Spring joint ‘A’ (F)
• Oil filler plug (G)
C • Circlip & Valve assembly (H)
• Wire clip (I)
• Oil inspection window
• Flanged bolt (8 Nos.) (J)
K
F • Set of damper (K)
J E • Set of plate (L)
L D
• Grommet (M)

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Service Station Manual 125 Akurdi Pune
DISMANTLING ENGINE SUB ASSEMBLIES

Camshaft Dismantling
Using Special Tool : Bearing Pullers - 37
A 10DJ 74 for Bearing 39 2542 20, 37
10DJ 75 for Bearing 39 1880 20
Remove :
• Bigger Bearing (A) using sp. tool from
C
camshaft assembly
B
• Small Bearing (B)
• Washer (C)

Gear Starter Clutch

Remove :
• Place the gear starter clutch on arbor press as shown in photo
• Using Bearing Driver Set (P. No.: 37 1030 61)
Remove :
• Needle roller bearing

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Service Station Manual 126 Akurdi Pune
PARTS INSPECTION PARAMETERS

Spark Plug :
• Type / Heat value - RG 4 HC
• Gap between electrodes - 0.6 to 0.8 mm
• Electrode condition - No erosion
• Colour at the electrodes tip - Brownish
• Threads of reach portion - Ok / No damage

Cylinder Head & Head Cover :

• Mating surface : No warpage/No scratches (Service limit for
warpage :0.05 mm)
• No fins breakage
• Spark plug hole threads - Ok / No damage
• Carbon built up in combustion chamber cavity- Clean it
• Valve seat : No pitting / No carbon deposition
• Proper fitment of Dampers (6 Nos)
• Proper fitment of ‘O’ rings
• Proper fitment of valve stem oil seals on valve guide
• Valve guide for crack if any
• Silencer mounting studs threads - Ok / No damage
• Oil gallery free from deposits
• Dummy plug threads intact
• Placement of shims between rocker arm and head cover.
• Presence of 20 rollers in each outer cage of rocker arm
• Tappet screw worn out / threads damaged
• Axial play in rollers.

Cylinder Block :
• No fins breakage
• No Scoring marks
• No Seizure marks
• Ok Seating – mating surfaces
• Smooth Honing pattern
• Correct / Same grouping mark w.r.t. piston (A & B group)
• Inner diameter of block as mentioned in service data.
• Ovality - Not more then 0.05 mm.
• 5 Nos. of damper rubbers Properly fitted on fins
• Proper fitment of ‘O’ ring on bottom side
• Identification mark 'DK' on casting

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Service Station Manual 127 Akurdi Pune
PARTS INSPECTION PARAMETERS

Piston :
• Grouping mark with respect to cylinder block must be same.
• Diameter of the piston - As mentioned in service data
• No scoring marks on the skirt
• No blow by marks
• No seizure marks.
• Manufacturing / Identification code and date code
• Piston pin - scratches dent marks
• Groove for piston pin lock

Rings :
• No uneven wear around circumference / breakage.
• Discoloration at working face.
• Carbon built up on inner face if any.
• Piston ring end gap - As per Service data
• Piston ring width (thickness) - As per Service data
• Free rotation of Rings in Piston grooves - No stickyness.
• Piton ring identification mark

Top Ring : TOP 1, Second Ring : TOP 2

Crankshaft :
• Big end axial/radial play : As per Service data.
• Run out : As per Service data.
• Threading condition : Ok / No damages.
• Key way condition : Ok / No damages.
• Big end bearing : Free rotation / Jam
• Con-rod : No bending / twisting
• Oil passage : No blockage.
• Square slot key way for primary gear
• Identification mark 'DK' on connecting rod

Crankcase :
• Mating surface:Smooth / No scratches.
• No Cracks, damages, breakage.
• Bearing seat, oil seal seat and proper pressing/positioning of oil
seals, needle roller, ball bearings freely rotating
• No Blow holes in casting
• Breather pipe / hole:No clogging
• Oil passage:Clean / No clogging
• Threads of holes & studs:Ok / No damages
• Visible number punching on LH Crank Case

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Service Station Manual 128 Akurdi Pune
PARTS INSPECTION PARAMETERS

Bearings :
• Axial play : Ok / Not excessive
• Radial play : Ok / Not excessive
• Bearing Seat : No sign of high spot on seating
area.
• Bearing class & code : As per specification numbers
• Bearing Rotation : Free Rotation

Clutch :
• Clutch plates / Steel plates - Thickness as per service data
• Warpage as per service data
• No Seizure / Damaged bonding of friction material
• Tangs (Lugs) / Teeth - No wearing
• Thrust plate cracked
• No Foreign material embedded
• Colour change / Signs of overheating if any
• No uneven wear pattern
• Conical face machining for spacer clutch

Clutch Housing :
• No Wear marks on slots.
• Clearance between clutch plate tangs and slot in the clutch
housing should not be excessive
• Free movement of plates in clutch housing slots.
• Rivets of clutch housing should not be loose.
• Free rotation of housing on Input shaft

Clutch Hub / Clutch Wheel :

• Contact surface for friction plates-should not be worn out
excessively
• Pressure Plate free movement in clutch hub splines
• Holes for lubrication
• Clutch hub height
• Smoothness in ID of clutch wheel
• Spacer free movement on clutch wheel
• Presence of plain and wave washer in 1st clutch plate

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Service Station Manual 129 Akurdi Pune
PARTS INSPECTION PARAMETERS

Transmission :
• No Teeth breakage or crack
• No Wear pattern on teeth
• No Wear of dog teeth & dog holes on gear
• No Seizure mark on gear seat.
st nd rd
• Free movement of gears on the shaft (1 Output, 2 Output, 3
th th
Output, 4 Input and 5 input gears are free on the respective
shaft)
• Free movement of Fork shift on the fork shaft
• Gear shift drum groove profile - Ok / No damage - Wear
• Free movement of Fork shift guide roller in the drum groove

Drum :
• Presence of Neutral rivet on the Drum
• Free rotation of Drum in LH crankcase parent hole.
• Inner hollow portion must be free from casting dust / burr
• Groove profile width as per Service Data
• Hole available for parallel pin
• Drum profile free from Hi-Spot for free sliding of bush

Camshaft :
• Presence of locating washer
• Free rotation of bearing
• Lobe height - as per Service Data
• No cut / wear marks on cam

Assembly Balancer Idler Gear :

• Nylon scissor gears worn out
• Circlip on either side
• Torsion spring sustaining adequate tension
• Torsion spring locking groove / hole oblonged or damaged.

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Service Station Manual 130 Akurdi Pune
PARTS INSPECTION PARAMETERS

Rotor :
• Smoothly key way machined
• Threading for holding rotor puller
• 'T' mark / line mark punched on rotor periphery
• Body threads for allen bolt fixing intact
• One way clutch body groove profile - Ok / No wear signs
• Proper seating of rollers, springs, bush in one way clutch.

Chain Tensioner :
• Sealing bolt body threads intact
• Front free movement of push rod
• Push rod forward end cap rivet intact / loose
• Groove for circlip fitment
• Free rotation of internal screw

Carburettor
• Float
- No Puncture
- Alignment w.r.t. float pin - OK
- Not touching to bowl walls

• Needle Valve
- No groove formation on the tip
- Smooth action of spring loaded pin
- Smooth movement in its seat.

• Volume Control Screw

- Not bent/threads OK / Not jammed / Presence of spring
washer and 'O' ring

• Jets
- Correct size, No wear of jet hole, No clogging

• Piston Valve
- Smooth free sliding, clearance in its seat, no excess wear
mark.

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ASSEMBLY - ENGINE

Fitting of Oil Seals

and Bearings :
Crankcase RH (Clutch Side)
Use Bearing Driver set (P. No. 37 1030 74)
Fit :
• Bearing for Input Shaft Assembly

Use Bearing Driver set (P. No. 37 1030 68)

Fit :
• Needle roller Bearing for Output Shaft Assembly

Use Bearing Driver set (P. No. 37 1030 74)

Fit :
• Bearing for drum change

Crankcase LH (Magneto Side)

Use Bearing Driver set (P. No. 37 1030 74)
Fit :
• Bearing for Output Shaft

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ASSEMBLY - ENGINE

Use Bearing Driver set (P. No. 37 1030 73)

Fit :
• Bearing for Input Shaft

Note : Do not use inner guide while fitting the bearing for ‘Input Shaft’ in ‘Crankcase
LH’ as this will damage the protruding lug of crankcase casting. Sealed bearings
must face crankcase side / protruding lug side.

Use Bearing Driver set (P. No. 37 1030 74)

Fit :
• Bearing for Body Balancer Gear Assembly

Use Bearing Driver set (P. No. 37 1030 61)

Fit :
• Oil seal on Guide Starter Assembly
• 'O' ring on Guide Starter Assembly
• Damper

Fit :
• Oil seal for Output Shaft

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ASSEMBLY - ENGINE

Fit :
• Oil seal for Gear Changer Lever

Clutch Cover
Fit :
• Oil seal for Clutch Lever on Clutch Cover

Assembly of
Sub assemblies :
Magneto Cover

C Fit :
B • Harness in the Cover
A
• 'Stopper' and tighten the 'Screw' (Use Loctite 243)
• 'Pulsar Coil' and tighten 2 'Screws' (Use Loctite 243)
E
• 'Stator Assembly' and tighten 2 bolts (Use Loctite 243)
D • 2 'Dowel Pins'

Camshaft Assembly
Fit :
C • Washer (B)

B
D

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ASSEMBLY - ENGINE

• Using Arbour Press

Fit :
• Small Bearing (D)
• Bigger Bearing (C)

Note : Apply thin layer of oil on sliding surfaces of shaft for smooth sliding of
bearing.

Assembling Head Cover

Fit :
• Roller rocker arm
• Tappet screw
• Tappet nut

Assembling Head Cover

Fit :
• Roller rocker arm (C)
• Set of 2 plan & 1 wave washer (B)
B
A

• Rocker arm shaft (A)

• Gaskets
• Dummy plugs
C Note : Repeat the same procedure for fitment of
other roller rocker.

A Cylinder Head
B Fit :
• Valve steam seals
D • Slide the valve from below
• Place the Valve Springs (C&D) (Inner
& Outer closed coiled ends placed at
C the bottom side)
• Valve spring retainer (B)
Using the Sp. Tool Valve Spring Compressor 37 1031 07 and Adaptor
37 10DJ 78
F • Press the valve springs
• Fit the cotter valves (A) and release the special tool
Similarly carry out the same procedure to assemble the other Valve
in the Cylinder head.
E
Note : Ensure that there is no valve leakage. If required pour the petrol in intake
and exhaust manifold & observe leakage at the valve head.

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ASSEMBLY - ENGINE

Clutch Assembly
Assemble the clutch plates and friction plates in clutch center / clutch
A hub.
Fit :
B • Plain Washer in Clutch Center / Clutch Hub
• Belleville Washer
• Clutch Plate (A) 1 Nos
C • Pressure Plate 5 Nos
• Clutch Plate (B) 4 Nos
• Clutch Plate (C) 1 Nos
• Wheel Clutch
• Springs 4 Nos.
• Thrust Plate
• Bolt

Align the Clutch Assembly into Clutch Housing

Fit :
• Spacer
• Clutch Assly

Note :
• Ensure concentricity of Thrust Plate w.r.to Clutch Wheel, Clutch Center, Clutch
Housing.

Oil Pump
Fit :
• 'O' ring (A) on the Oil Strainer (B)
A • Clip (C)

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ASSEMBLY - ENGINE

Assembly Balancer Idler Gear Bearing

Using Bearing Driver set (P. No.: 37 1030 61)
Fit :
• Needle roller bearings in crankcase RH and Cover

Note :
Apply oil on bearing OD before pressing bearings for smooth bearing fitment.

Fit :
A C D • Springs (D)
• Scissor Gears (C)
• Circlip (B)
• Thrust washer
Similarly carry out the same procedure on other side of the gear to
assemble the Balancer Idler Gear completely.
B D E CB A
Note :
Ensure that one spring end butts against spring dowel in Balancer Idler Gear and
the other end of spring should but against the lug on Scissor Gear.

Loading the assembly Balancer Idler Gear

Using Sp. Tool : Balancer Gear Holder
3710DJ63
• Slide the Assembly Balancer Idler
Gear in special tool (A)
• Rotate the Scissor Gear anti-
clockwise till the lug contacts the
torsion spring.
• Using a marker, mark the Balancer
Idler Gear & Scissor Gear Tooth

Using Special Tool

• Turn the Scissor Gear anticlockwise
such that 2 teeth pre-load is
achieved. This can be confirmed by
the markings done previously.
• Holding the Scissor Gear pre-loaded
in the above position slide the
Scissor Gear into the special tool
completely.
Repeat the same procedure for loading
the other Scissor Gear.

Note :
Keep this Assembly balancer idler gear in loaded
condition with special tool.

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ASSEMBLY - ENGINE

Gear Complete Starter Counter Assembly

Using Arbour Press
Fit :
• Needle Roller Bearing

Crankcase LH (Magneto Side)

Fit :
• Guide Starter Assembly
• 3 Screws (A) (Use loctite 243)

Clutch Cover
Fit :
G A
B • Valve assembly and circlip (H)
• Oil inspection window
• Wire clip (I)
• Set dampers (K)
H • Set of plates (L)
• Bolts (J)
• Rack (C)
C • Shaft Clutch Release (B) in Clutch Cover by rotating it slightly to
match the teeth.
• Parallel Pin (A) to lock the Shaft Clutch Release
K • Washer
F • Spring torsion clutch lever
J E • External lever
L D
• Bolt
• Spring joint ‘A’ (F)
• Plunger Plate (E)
• Plunger Plate (E)
• Plunger oil (D)
• 2 Dowel Pins
• Grommet (M)
• Oil feeler plug (G)

Apply loctite 243 to all damper fitment bolts.

Note : Ensure fitment of set of dampers and plate before fitting the above.

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ASSEMBLY - ENGINE

Input Shaft Assembly

B C EF I K Fit : From LH side of shaft (A)
• Thrust washer (K)
• Gear 4th (J)
• Splined washer (I)
• Circlip (H)
• Gear 3rd drive (G)
D
• Circlip (F)
G H J A
• Splined washer (E)
• Gear 5th drive (D)
• Gear 2nd drive (C)
• Thrust washer (B)

L M H FE CB A Output Shaft Assembly

Fit : from LH side of shaft
• Gear 5th driven (M)
• Bush (N) with shoulder ring
• Gear 2nd driven (L)
• Washer (K)
• Circlip (J)
Fit : from RH side of shaft
JK N I G D • Thrust washer (H) behind the 3rd gear on output shaft
• Gear 3 driven (G)
rd

• Spline washer (F).

• Circlip (E)
• Gear 4th driven (D)
• Steel bush (C) with shoulder ring
• Gear1st driven (B)
• Thrust washer (A)

Engine Assembling
Fit : (In Magneto side Crankcase)
• Input and Output Shaft Assembly simultaneously.
• Fork shifts along with rollers on Input and Output Shaft Assembly
(2 bigger fork shifts on output shaft and 1 smaller on input
shaft).

Note :
For ease of assembly of gears, remove gear 1st driven and insert both the input
and output shaft assemblies with gears in mesh into their respective bearings. The
gear box should be in neutral gear before ‘RH Crankcase’ is assembled on to ‘LH
Crankcase’.

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ASSEMBLY - ENGINE

Fit :
• Drum Change
• Shaft Gear Shift
• 2 Dowels
• Gasket

Fit :
• Crankshaft

Caution : Use a sharp blade or knife to cut off any protruding ‘Gasket’.
This is very important for preventing any oil leakage from ‘Crankcase’
and ‘Cylinder Block Joint’. Don't apply grease / any adhesive to
‘Crankcase Gasket’ as these ‘Gasket’ when comes in contact with oil
expands and seals hidden cavities.

Fit :
• Crankcase RH
• Bolts (LH & RH Side)

Caution : Check oil supply to big end bearing by pumping oil in the
clutch side end of crankshaft and let oil come out of con-rod big end
sides.

Fit :
• Parallel Pin.
• Sprocket Cam Drive
• Cam Chain

Note : Hold the cam chain upright using a soft copper wire or a thread.

Fit :
• ‘Square Key
• ‘Primary Gear’.

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ASSEMBLY - ENGINE

Fit :
A
• Body Balancer Gear
• Lock
• Bolt (A) (Use Loctite 243)

Fit :
• Parallel Pin
• Spacer
A • Guide gear shifter
• Allen Bolt (A)

Fit :
• Spring
B
Note :
a. Apply Loctite 638 at ‘Bolt Shift Change’ (B) if removed.
b. Ensure free movement on ‘Stopper Gear Shift’ in ‘Bolt Shift Change’.

Fit :
• Gear change lever assembly

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ASSEMBLY - ENGINE

Fit :
• Thrust Washer
• Assly Balancer Idler Gear with Special Tool
• Thrust washer

Fit :
Align gear timing marks of ..
• Primary gear mark w.r.t crankcase
mark
• Body balancer assembly mark w.r.t
crankcase mark

Fit :
• Clutch housing

Note :
• Ensure perfect matching of gear alignment marks w.r.to crankcase marks.
• Refer the skill tips section for understanding procedure for gear alignment
marks.

Fit :
• 2 Dowels
• Assly Balancer Idler Gear Cover
• 3 Bolt

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ASSEMBLY - ENGINE

Using Spl Tool - Primary gear holder : 37

10DJ 28 & Special Nut : 37 10DJ 43
Fit :
• Spacer
• Clutch Assembly Complete
• Washer
• Special Nut

Note : Special nut for input shaft has LH threads.

Fit :
• Bearing with plunger

Using Special Tool : Primary Gear Holder

- 37 10DJ 28 and Centrifugal Oil Filter
Nut - 37 10DJ 43
Fit :
• Centrifugal Oil Filter
• Washer
• Special Nut

Using Special tool : Primary gear holder

37 10DJ 28
Fit :
• Gasket
• 3 screws
• Cover

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ASSEMBLY - ENGINE

Fit :
• 2 Dowels
• Oil Pump Assembly
• 3 Bolts

Fit :
• Starter Motor
• Clutch cover gasket
• 2 Dowels

Note : Do not apply any grease to stick ‘Gaskets’ to the ‘Clutch Cover / Magneto
Cover’ or ‘Crankcase’. As grease deteriorates the gasket material and reduces
sealing efficiency.
• Clutch Cover
• 10 bolts
• Bracket Clutch Cable
• Starter Motor Cap
• Screw’

Magneto Side
Fit :
• Shaft Starter Counter
• Gear complete starter counter assly
• Collar

Note : Always apply a thin layer of grease on to the roller bearing of gear complete
starter counter assembly.

Fit :
• Woodruff key
• Magnet along with gear starter clutch
Note :
• Always apply a thin layer of grease to the roller bearing of gear starter clutch.
• Lubricate the one way clutch using the Molikote grease.

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ASSEMBLY - ENGINE

Fit :
• Plate starter clutch return (A)
• Bolt (Use loctite 243) (B)

A B

Using Special Tool : Rotor Holder H6

0721 00
Fit :
• Washer
• Bolt

Top End
Fit :
• 2 Dowels
• Block Base Gasket

Using Special Tool : Drift 74 9309 89

Fit :
• Piston
• Piston Pin
• Circlip

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ASSEMBLY - ENGINE

Note : Place clean piece of cloth on the ‘Crankcase’ bottom end because their is
chance of ring snap falling down while fitment.

Using Special Tool : Piston Ring Holder 37 10DJ 30

Fit :
• Slide the Cam Chain upright with soft copper wire / Thread into
cylinder
• Slide the piston assembly into cylinder

Note : Apply thin layer of oil in cylinder bore and piston assly when sliding inside
for ease in fitment.

Fit :
• Head gasket
• 2 Dowels (A)
• Chain Guide (Non tensioner side)

Note : Holding the chain firmly bring the piston assly to TDC position and Ensure
A

‘T’ mark on the rotor is matching with generator cover mark.

Fit :
• Cylinder Head Assly
• 2 Dowels

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ASSEMBLY - ENGINE

Fit :
• Spark Plug Sleeve
• Grub Screw
• Spark Plug

Note : Before fitting the sleeve spark plug apply thin layer of molybdenum disulfide
grease on the entry chambers for the ‘O’ rings

Fit :
• Cam Shaft
• Collar

Using Sp. Tool - 37 10DH 36

Fit :
• Cam Sprocket
• Special Washer
• Allen Bolt

Note :
• Ensure the sprocket marks (A) are aligned horizontally with cylinder head top
machined face and the piston is at TDC.
• Secure the ‘Cam Chain Sprocket’ in the special tool firmly and then tighten the
sprocket allen bolt.
• Ensure that the ‘O’ mark on washer always faces outwards when tightening the
allen bolt.

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ASSEMBLY - ENGINE

Fit :
• Cam Shaft Cap
• Apply thin layer of liquid gasket to
head cover
• Head Cover

Note :
• Do not apply liquid gasket on to the cam
shaft cap and other inside mounting areas.
• Refer Skill Tip for more details

II Fit :
• Copper Plated Washer
• Tighten bolts as per sequence
I Ist : 4 Domed cap nut
III
IInd : 4 Long bolts of Head Cover
IIIrd : 2 Longest bolts of Head cover

Note : Improper tightening sequence of bolts may cause permanent warpage in

II cylinder head cover and it can get damaged permanently.

Fit :
• Cam Chain Tensioner
• 2 bolt
• Release the tensioner plunger bolt
• Dust cap and ‘O’ ring’

Adjust :
• C h e c k a n d a d j u s t t h e ta p p e t
clearance

Inlet Valve Exhaust Valve

0.05 mm 0.1 mm

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ASSEMBLY - ENGINE

Note :
Always ensure that the piston is at the end of compression stroke and ‘T’ mark on
rotor is in line with the crankcase mark. When adjusting tappet clearance.

Fit :
• Tappet cap with ‘O’ ring

Fit :
• 2 Dowel
• Gasket

Fit :
• Magneto cover
• 5 Bolts
• Neutral switch coupler

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ASSEMBLY - ENGINE

Using Special Tool - Output Sprocket

holder - 37 1030 53
Fit :
• Bush
• Sprocket
• Plate drive sprocket
• 2 bolts (Use loctite 243)

Fit :
• Oil pipe
A
• Copper gasket
• Banjo bolt (A)
• Bolt (B)

Notes

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Service Station Manual 150 Akurdi Pune
GEAR TRANSMISSION POWER FLOW

S.N. Description Qty S.N. Description Qty

1 Shaft input transmission 1 13 Plain washer 1
2 Plain washer 1 14 Gear 4th driven 1
3 Gear 4th drive 1 15 Bush 1st driven 1
4 Washer spline 3 16 Gear 1st driven 1
5 External circlip 4 17 Gear 5th driven 1
6 Gear 3rd drive 1 18 Bush 2nd driven 1
7 Gear 5th drive 1 19 Gear 2nd driven 1
8 Gear 2nd drive 1 20 Collar sprocket 1
9 Plain washer 1 21 O ring sprocket collar 1
10 Shaft output transmission 1 22 Sprocket drive 1
11 Washer thrust 2 23 Plate drive sprocket 1
12 Gear 3rd driven 1 24 Bolt drive sprocket 2

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GEAR TRANSMISSION POWER FLOW

Construction & Working

Input Shaft and its gears :

6 4 5
• First gear is integral with Input Shaft. 3
2
• Second gear is fixed on Input Shaft 1
splines.
• Third gear is fixed but sliding on Input
Shaft splines.
• Forth gear is a freely rotating gear on
Input Shaft. 7

• Fifth (top) gear is freely rotating on Input

splines.

Output Shaft and its gears :

• First gear is a freely rotating gear on
Output Shaft. A bush which is free inside 9
gear I.D. & shaft O.D. is fitted between 12 10 11 8
first gear and Output shaft.
• Second gear is a freely rotating gear on
Output Shaft. A bush which is free inside
gear I.D. & shaft O.D. is fitted between 1. Input shaft. 7. Output shaft
first gear and Output shaft. 2. First gear input. 8. First gear output.
• Third gear is freely rotating on Output 3. Second gear input. 9. Second gear output.
splines. 4. Third gear input. 10. Third gear output.
• Forth gear is fixed but sliding on Output 5. Fourth gear input. 11. Fourth gear output.
Shaft splines. 6. Fifth gear input. 12. Fifth gear output.
• Fifth gear is fixed but sliding on Output
Shaft splines.

First Gear Position : When First Gear is

engaged, Power from clutch flows as follows. 5
4
2 3
Clutch 1

Input Shaft

1st Gear Input

1st Gear Output

th
4 Gear Output
5
Output Shaft 4
3
2 1
Final Drive to the Rear Wheel

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GEAR TRANSMISSION POWER FLOW

Second Gear Position : When Second Gear

is engaged, power from clutch flows as
5
follows. 4
2 3
1
Clutch

Input Shaft

nd
2 Gear Input

nd
2 Gear Output

th
5 Gear Output
5
4
3
Output Shaft 2 1

Final Drive to the Rear Wheel

Third Gear Position : When Third Gear is

engaged, power from clutch flows as follows. 5
4
2 3
1
Clutch

Input Shaft

3rd Gear Input

rd
3 Gear Output

th
4 Gear Output
5
4
Output Shaft 3
2 1

Final Drive to the Rear Wheel

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GEAR TRANSMISSION POWER FLOW

Forth Gear Position : When Forth Gear is

engaged, power from clutch flows as follows. 5
4
2 3
Clutch 1

Input Shaft

rd
3 Gear Input

th
4 Gear Input

th
4 Gear Output
5
Output Shaft 4
3
2 1

Final Drive to the Rear Wheel

Fifth Gear Position : When Fifth Gear is

engaged, power from clutch flows as follows. 5
4
2 3
Clutch 1

Input Shaft

rd
3 Gear Input

th
5 Gear Input

th
5 Gear Output
5
Output Shaft 4
3
2 1

Final Drive to the Rear Wheel

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Service Station Manual 154 Akurdi Pune
ENGINE LUBRICATION - FLOW OF OIL

OIL STRAINER

OIL PUMP

CLUTCH COVER INLET CENTRIFUGAL FILTER

TOP -RHS C'CASE RHS CRANKCASE CLUTCH COVER OUTLET CRANKSHAFT

& THROUGH HAAD STUD

CAMSHAFT CYLINDER BLOCK OUTLET

CYLINDER BLOCK

CYLINDER BLOCK
ROCKER ARM

LHS C'CASE INLET INPUT & OUTPUT SHAFT

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Notes

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Service Station Manual 156 Akurdi Pune
Frame & Suspension
• Tightening Torques
• Service Data
• Special Tools
• Control Cable Routing
• Working of Nitrox
Rear Suspension
• SOP for Front Fork Dust
Seal & Oil Seal
Replacement
• SOP for Steering O/H
• Dismantling & Assembling
Front Fairing
• SOP for Swing Arm
Replacement
• SOP for Caliper Piston
Seal & Dust Seal
Replacement
• SOP for Master Cylinder
Piston Kit Replacement
• SOP for Brake Hose
Replacement
• SOP for Brake Fluid
Replacement

157
TIGHTENING TORQUES -
150 CC AND 180 CC

Front Axle Nut Handle Bar Holder Bolts

Torque Value Torque Value
in Kg.m in Kg.m

2.0 ~ 2.2
Pulsar Pulsar (150 cc Photo not
4.0 ~ 5.0
150 cc 150 cc illustrated)

Pulsar Pulsar
8.0 ~ 10.0 2.0 ~ 2.2
180 cc 180 cc

Rear Axle Nut Steering Top Cap Bolt

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar
8.0 ~ 10.0 3.5
150 cc 150 cc

Pulsar Pulsar
8.0 ~ 10.0 5.0
180 cc 180 cc

Torque Rod Nut Steering Stem Nut (Slotted)

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar
3.0 ~ 4.0 0.5
150 cc 150 cc

Pulsar Pulsar
3.0 ~ 4.0 0.5
180 cc 180 cc

Sleeve Nut Upper Clamp Allen Bolt

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar
7.0 ~ 8.0 1.8 ~ 2.0
150 cc 150 cc

Pulsar Pulsar
-- NA -- 1.8 ~ 2.0
180 cc 180 cc

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Service Station Manual 158 Akurdi Pune
TIGHTENING TORQUES -
150 CC AND 180 CC

Rear Sprocket Mounting Nut Lower Clamp Bolt

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar 1.8 ~ 2.5 Pulsar

2.5 ~ 3.5
150 cc (Loctite 243) 150 cc

Pulsar 3.0 ~ 3.2 Pulsar

2.5 ~ 3.5
180 cc (Loctite 243) 180 cc

RSA Mounting Dome Nut Brake Disc Allen Bolts

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar 2.6 ~ 3.2

3.5 ~ 4.0
150 cc 150 cc (Loctite 243)

Pulsar Pulsar 2.6 ~ 3.2

3.5 ~ 4.0
180 cc 180 cc (Loctite 243)

Swing Arm Pivot Nut Banjo Bolt Caliper

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar
8.0 ~ 10.0 2.2 ~ 2.8
150 cc 150 cc

Pulsar Pulsar
8.0 ~ 10.0 2.2 ~ 2.8
180 cc 180 cc

Caliper Install Bolts Fork Pinch Bolt

Torque Value Torque Value
in Kg.m in Kg.m

Pulsar Pulsar
2.2 ~ 2.8 2.0 ~ 2.2
150 cc 150 cc

Pulsar Pulsar
2.2 ~ 2.8 2.0 ~ 2.2
180 cc 180 cc

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Service Station Manual 159 Akurdi Pune
SERVICE DATA -
150 CC AND 180 CC

Brake Panel Cam Hole Diameter Axle Run Out

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar TIR 0.1

12.0~12.03 12.15 TIR 0.2
150 cc 150 cc or Less

Pulsar 100 mm Pulsar TIR 0.1

14.0~14.03 14.15 TIR 0.2
180 cc 180 cc or Less

Brake Cam Diameter Axial Wheel Run Out

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar 11.95 ~ Pulsar TIR 1.0

11.88 TIR 2.0
150 cc 11.98 150 cc or Less

Pulsar 13.95 ~ Pulsar TIR 1.0

13.88 TIR 2.0
180 cc 13.98 180 cc or Less

Front Brake Pad Thickness Radial Wheel Run Out

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar TIR 0.8

7.4 3.8 TIR 2.0
150 cc 150 cc or Less

Pulsar Pulsar TIR 0.8

7.4 3.8 TIR 2.0
180 cc 180 cc or Less

Brake Shoe Lining Thickness Drive Chain Slack

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar Pulsar
3.85~4.15 2.0 25 ~ 35 40 ~ 50
150 cc 150 cc

Pulsar Pulsar
3.85~4.15 2.0 25 ~ 35 40 ~ 50
180 cc 180 cc

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Service Station Manual 160 Akurdi Pune
SERVICE DATA -
150 CC AND 180 CC

Brake Drum Inside Diameter Drive Chain Length

Standard Service Standard Service
Limit Limit Limit Limit
20-link length

Pulsar 130.0 ~ Pulsar 254.0 ~

130.75 259.0
150 cc 130.16 150 cc 254.6

1st 2nd 21st

Pulsar 130.0 ~ MEASURE THIS LENGTH Pulsar 301.6 ~
130.75 307.0
180 cc 130.16 180 cc 302.1

Rear Sprocket Warp Front Fork Spring Free Length

Standard Service Standard Service
Limit Limit Limit Limit

Pulsar 0.4 Pulsar

0.5 398.50 391.0
150 cc or Less 150 cc

Free Length
Pulsar 0.4 Pulsar
0.5 373.0 368.0
180 cc or Less 180 cc

Tyre Tread Depth Front Fork Oil

Standard Service
Limit Grade Quantity
Limit
Fork Oil Level
Front Front Drain & Refill
Pulsar 5.0 1.0 (For 150 CC) Pulsar SAE - 145+2.5 ml
150 cc Rear Rear 218 + 2.0 mm 150 cc 10W20 Overhaul
6.8 1.5 - 165 ml
(For 180 CC)
Front Front 233 + 2.0 mm Drain & Refill
Pulsar 5.0 1.0 Pulsar SAE - 295+2.5 ml
180 cc Rear Rear 180 cc 10W20 Overhaul
7.3 2.0 - 320 ml

Grease Application Points

S.N. Vehicle Component Type of Grease
1. Bearing balls of steering HP Lithion RR3 grease
2. Swing arm shaft & Bushes
3. Front wheel axle
4. Rear wheel axle
AP grease
5. Brake pedal pivot
6. Center stand shaft
7. Side stand ‘U’ bracket

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Service Station Manual 161 Akurdi Pune
SPECIAL TOOLS

Details of Exclusive Special Tool

For carrying out repairs / overhauls, these 4 new special tools were developed earlier exclusively
for Pulsar DTS-i 200cc & Pulsar DTS-Fi 220cc & can be used for Pulsar UG-4 also. Rest of the
special tools required remains the same which were earlier used for Pulsar, Pulsar DTSi UG-II,
Pulsar DTSi UG III.

Fork Oil Seal

Fitment Punch :
Drawing No : 37 1740 03
Application :
To fit fork oil seal on outer pipe.

Fork Inner & Outer Tube

Extractor :
Drawing No : 37 1740 04
Application :
Used for removing front fork inner
tube from outer tube.

Fork Holder :
Drawing No : 37 1740 05
Application :
Used for holding the fork piston
from inside.

Needle Bearing Puller :

Drawing No : 74 9309 93
Application :
To remove & refit needle roller
bearing from swing arm.

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Service Station Manual 162 Akurdi Pune
SPECIAL TOOLS Ap[Ayl T&Ãs

ki[mn Ap[Syl T&Ãsn) (vgt

Details of Other Common Special Tool
Ap[Syl n[m Ap[S)yl T&l n>br kyi> lig[ C[ t[
Special Tool Name Special Tool No. Application
Bearing Race Extractor 37 10DH 36 Used for removing the lower bearing race from ‘T’
b[r)g r[s a[ks[rTr
37 1030 61 Common bearing driver set for fitting and removing bearings from
Bearing Driver Set
crankcase.
b[>r)g Di^evr s[T
For adjusting the notch position of RSA to achieve hard or soft rear
Rear Shock Absorber Adjuster 37 00DH 14
suspension.
r)ar Si[k a[bsi[br a[D(ATr

Notes ni[>w;

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Service Station Manual 163 Akurdi Pune
CONTROL CABLE ROUTING
kºTi[^l k[bln& $T)g

Speed Sensor Cable

• Clamp the speed sensor cable on case meter with a bracket &
screw.
Ap)D s[ºsr k[bln[ k[es m)Tr upr b[\k[T an[ Ak* Wir[ f)t kri[

• Pass both the cables through flexible clamp mounted on front

fender.
b>n[ k[bln[ mDgiD< upr aip[l kl[Àp miY) pis kri[

• Clamp the speed sensor cable’s in a grommet of the metallic

bracket.
Ap)D s[ºsr k[bln[ m[Til)k b[\k[Tni rbr gi\m[Tmi>Y) pis kr) f)T kri[

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Service Station Manual 164 Akurdi Pune
CONTROL CABLE ROUTING

Clutch Cable kÃc k[bl

• Route clutch cable as shown in the photograph.

klc k[bln&> r[T)g fi[Ti[gi\fs mi btiv[l p\miN[ f)T kri[

• Pass the cable through grommet fitted in wire clip.

k[bln[ gi[\m[T mi>Y) viyr kl)p Wiri f)T kri[

• Pass the clutch cable through clutch cover bracket & adjuster.

kÃc k[bln[ kÃc kvr b[\k[Tni a[SjATr mi>Y) f)T kri[

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Service Station Manual 165 Akurdi Pune
CONTROL CABLE ROUTING

Accelerator Cable a[ks)l[Tr k[bl

• Route the accelerator cable as shown in the photograph.

a[ks[l[Tr k[bln[ fi[Ti[ gi\fs p\miN[ $T)g kri[

• Route the accelerator cable through the engine top end inserted
in foundation bracket clamp.

a[ksl[Tr k[bln[ a[>Jn Ti[p a[ºD uprni fiuºD[Sn b[\k[Tni kl[Àp Wiri
$T)g kri[

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Service Station Manual 166 Akurdi Pune
WORKING OF
NITROX REAR SUSPENSION

Function
• To suspend rear wheel to the frame with the
help of swinging trailing arm.
• To allow rear wheel to travel up and down
Adjuster
by absorbing shocks while passing through
ditches / bumps (comfortable ride for the Membrane

rider and pillion rider).

Canister
• To provide stability while graduating turns.
Inner Tube
Gas Cap
Air Hose Upper Chamber
Valve Assly.
Advantage Circlip
Cover Cap
The gas filled shock absorber enhances the Piston
Piston Ring
dampening performance by eliminating the
Rebound Spring Lower Chamber
formation of foam. The foam formation is
Rod Guide
eliminated by the nitrogen gas filled inside the Oil Seal
Bump Stopper
canister. The nitrogen gas is filled in canister at
a pressure which is 8 times greater than Piston Rod
atmospheric pressure.

Outer Spring

Working : Gas Filled

Compression Stroke
In gas filled shock absorber, oil is completely filled in
inner, outer tube and canister. Nitrogen gas is filled in
2
membrane at a pressure of 6.5~7.5 Kg/cm .

During this stroke, oil flows freely from ‘Upper Chamber’

to ‘Lower Chamber’ through piston valve. Simultaneously
oil also flows to canister assembly through base valve
and compresses the membrane filled with nitrogen gas.

At the end of the compression stroke, bump stop rubber

takes load and avoids hitting of lower eyelet mounting
against outer tube.

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Service Station Manual 167 Akurdi Pune
WORKING OF
NITROX REAR SUSPENSION

Working : Gas Filled

Extension Stroke
During this stroke, oil in canister starts returning to upper
chamber through base valve without any resistance due
to expansion of membrane.

Simultaneously, oil from lower chamber will flow slowly

into upper chamber with resistance due to piston valve.

At the end of extension stroke, rebound spring avoids

hitting of piston rod assembly complete against rod guide.

Procedure for gas checking and Refilling

• Remove the Phillips-headed small screw and ‘O’ ring.
• Clamp the cylindrical guide clamp on to the canister keeping the
rubber plug in the center to support the syringe needle insertion
and keeping in position.
• Hold the pump as shown and pierce the syringe needle into the
center of rubber plug.
• The molded needle adaptor will rest into the clamped cylindrical
guide
• Read the gas pressure on the dial gauge. If the gas pressure is
below 6.5 Kg/cm2 refill the air by pumping, keeping the needle in
as it is condition without removal. As the natural air consists of
71% of nitrogen it will serve the purpose.
• To fill the air into the canister, apply full stroke of pump as
shown; otherwise air will not get inflated into the pump.
• Keep on pumping the air unless you get 7.5 kg/cm2 on the gauge
• Pull out the air pump along with needle carefully and take out the
guide clamp
• Finally fix the phillips headed screw with ‘O’ ring.

In current produced pulsars Nitrox RSA is at bottom side & Air filling
is not recommended in these rear shock absorbers.

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Service Station Manual 168 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

14 15
16 20
8
17
18
21
19
18
3 2

19 22 23
24
25

4/5 26

9 13
24
23
6 27
10
7 11
12
1

S.N. Description Qty S.N. Description Qty

1 Fork Front 1 15 Bolt Fork 2
2 Kit Outer Tube 1 16 ‘O’ Ring 2
3 Oil Seal 2 17 Seat Fork Spring 2
4 Outer Tube Lh 1 18 Spacer Tube 2
5 Outer Tube Rh 1 19 Washer 2
6 Gasket 2 20 Bolt 1
7 Bolt 2 21 Holder Fork Upper 1
8 Cylinder Comp. Fork 2 22 Socket Bolt 2
9 Pipe Comp. Suspension Inner 2 23 Cushion Rubber 2
10 Slide Bush 2
24 Cover Trail B 4
11 Spring Washer 2
25 Lamp Shade Assly. 1
12 Bolt 2
26 Bearing Cone 1
13 Spring Front Fork 2
14 Grommet Top 2 27 Holder Fork Under 1

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Service Station Manual 169 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

• Remove bolt securing front brake hose clamp by 8 mm T spanner

fºT b[\k his kl[Àpn[ 8mmni 't' Ap[nr Wiri Ki[li[

• Remove 2 nos bolts securing caliper assembly by 12mm ring spanner.

k[l)pr a[s[Àbl)n[ 12mmni r)>g Ap[nr Wiri b[bi[ÃTn[ Ki[li[

• Remove kiQi[
a. Axle nut by 22mm ring spanner.
a[ksln) 22n>brn) nTn[r)g Ap[nrn[Wiri

b. Remove bolt holding front axle firmly on outer tube by 13mm ring
spanner.
fºT a[ksl n[ pkDvi miT[n) nTn[ 13mm r)>g Ap[nr Wiri Ki[li[

c. Take out front axle.

aigLn) a[ks[ln[ bhir kiQi[

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Service Station Manual 170 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

• Remove speed sensor assembly & Take out front wheel assembly.

• Remove 4 no. bolts (2 nos.

on both LH & RH side)
securing front fender by
12mm ring spanner & take
out front fender assembly.

• Remove allen bolt of upper

bracket by 6mm allen key &
under bracket bolt by 17
mm ring spanner.

• Take out the front fork leg assembly.

• Remove fork top bolt by 14mm Allen key.

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Service Station Manual 171 Akurdi Pune
SOP DAT s)l ai[el s)l bdlvin) p¹Ft)
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

• Remove spacer tube, washer & Front fork spring.

Ap[Sr Ty&b, vi[Sr an[ f\ºT f\[m l[g Ap\)>gn[ bhir kiQi[.

• Remove front fork oil & collect in measuring jar.

aigLni fi[k<ni ai[el bhir kiQ) m[zr)>g Ôrmi> niKi[.

• Hold piston with cylinder piston holder special tool & remove Allen bolt
by 6mm allen key
s)l)ºDr p)ATn hi[ÃDr Ap[Syl T&Ãs oiri p)ATnn[ hi[ÃD kr) 6 mm
Allenkey oiri Ki[li[.

• Remove dust seal & oil seal lock (snap ring).

DAT s)l an[ ai[el s)l li[kn[ bhir kiQi[. {An[pr)>g}

• Insert the front fork anti-friction bush & oil seal extraction special tool on
fork inner pipe as per sequence shown in photograph.
f\ºT fi[k< a[ºT) (fkSn b&S an[ ai[el s)l p&lrn[ enr piep upr fi[Ti[g\ifs
p\miN[ m&ki[.

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Service Station Manual 172 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

• Remove handle bar holder by removing 2 nos allen bolts with 6mm allen
key.
h[ºDl bir hi[ÃDrni b[ bi[ÃTn[ 6 mm Allen Key Wiri Ki[li[.fi

• Insert fork inner pipe along with special tool in under bracket such that
special tool top portion touches to under bracket bottom edge.

• Tighten the fork upper bracket allen bolt by 6mm allen key.
fi[k< apr b\[k[Tn[ 6 mm Allen key bi[ÃT n[ TieT kri[.

• Remove outer tube by rotating special tool in clock wise direction

Ap[Syl T&Ãsn[ kli[k viez (dSimi> f[rv) aiuTr Ty&bn[ bhir kiQi[.

• Remove fork inner pipe from under bracket & take out the special tool as
shown in photograph.
aºDr b\[kTmi>Y) fi[k< enr piepn[ fi[Ti[g\ifsmi jNiv[l p\miN[ bhir kiQi[.

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Service Station Manual 173 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

• Take out front fork oil seal, washer & anti-friction bush.
f\ºT fi[k< ai[el s)l/vi[Sr an[ a[ºT) f)kSn b&Sn[ bhir kiQi[.

Assembling f)T krv&

• Hold fork cylinder on cylinder piston holder tool & insert spring and fork
inner pipe.
s)l)ºDr p)ATn hi[Ã|Dr T&l upr fi[k< s)l)ºDr n[ hi[ÃD kr) a>dr Ap\)>g an[
enr piep f)T kri[.

• Assemble oil lock cap & outer tube followed by tightening of allen bolt
(From bottom side of outer tube) by 6mm allen key.
ai[el ki[l k[p an[ aiuTr Ty&b Ryirbid 6 mm Allen key bi[ÃT Wiri
TieT kri. {aiuTr Ty&b n) n)c[n) trfY)}

• Hold fork leg assembly & assemble anti friction bush, washer & oil seal
as shown in photographs.
fi[k< l[g a[s[Àbl)n[ pkD)n[ a[ºT) f)kSn b&S/vi[Sr/an[ ai[el s)l f)T
kri[. fi[Ti[g\ifs p\miN[

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Service Station Manual 174 Akurdi Pune
SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT

Note :-
1. Never reuse oil seal.
2. Always replace the fork oil seal along with dust seal of same
manufacturer.
3. Front fork oil seal fitment direction should be as shown in photograph.

• Fit the oil seal by using oil seal fitment special tool and insert the snap
ring and dust seal.

• Fill recommended quantity

of fork oil (320 +2.5ml) and
insert spring, washer &
spacer tube.

• Initially hand tighten the fork bolt by pressing it and then fully tighten by
14 mm Allen key.

• Remove fork inner pipe from under bracket & take out the special tool as
shown in photograph.

Note:
For fitment of fork leg on vehicle follow the reverse order of removal steps.

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Service Station Manual 175 Akurdi Pune
SOP FOR STEERING OVERHAUL SOP AT)yr)>g ai[vrai[l

3
4

6 5

S.N. Description Qty

1 Frame Assly. Comp. 1
2 Cup Rear 2
3 Nut 1
4 Cup - Steering 1
5 Bearing Cone Kit 1
Kit St Cone with RR3 Grease 1
6 Ball Steel With Cage 2

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Service Station Manual 176 Akurdi Pune
SOP FOR STEERING OVERHAUL SOP AT)yr)>g ai[vrai[l

• Remove Petrol tank cover & petrol tank

p[T^i[l T[ºk kvr kiQ) p[T^i[l T[ºk bhir kiQi[

• Remove 4 screws from top of

speedometer and 2 bolts from
bottom side.
Ap)Di[m)Tr uprni j Ak\& an[
n)c[Y) b[ bi[ÃT Ki[li[.

• Pull out Head Lamp assembly & disconnect the couplers.

h[D lieT a[s[Àbl)n[ bhir trf kiQ) kplrni kn[kSn Ki[li[.

• Take out H/L assembly with speedometer

h[D lieT a[s[Àbl) n[ Ap)Di[m)Tr siY[ bhir kiQi[.

• Remove harness & brake hose clamping bracket

hirn[s an[ b\[k hi[s kl[mn[ bhir kiQi[.

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 177 Akurdi Pune
SOP FOR STEERING OVERHAUL

• Remove Front caliper assembly

f\ºT k[l)pr a[s[Àblk)n[ Ki[li[.

• Remove Front Axle

aigLn) a[ksl Ki[li[.

• Remove Front wheel assembly

aigLni Äh)ln[ bhir kiQi[.

• Remove front fender.

aigLni mDgiD<n[ Ki[li[.

• Remove center bolt.

s[ºTr bi[ÃTn[ Ki[li[.

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Service Station Manual 178 Akurdi Pune
SOP FOR STEERING OVERHAUL

• Remove fork central bolt.

• Lift handle bar assembly to right side

fi[k<ni s[ºT^l bi[ÃTn[ Ki[li[.
h[ºDl bir a[s[Àbl)n[ jmN) bij& m&ki[.

• Remove slotted nut

Ali[T[D nTn[ Ki[li[.

• Remove upper & lower steering ball cage.

upr an[ n)c[ni AT)ar)>g bi[ÃT k[jn[ bhir kiQi[.

• Remove upper & lower cones

by using Cone removal tool.
upr an[ n)c[n) ki[nn[ Ap[Syl
T&Ãs Wiri bhir n)kiLi[.

• Carry out greasing / steering ball replacement activity.

g\)s)>g/Cri bdlvin) p¹Ft)/p\i[m<sr
- Upper race 19 balls
upr 19 Cri
- Lower race 20 balls n)c[ 20 Cri

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Service Station Manual 179 Akurdi Pune
SOP FOR STEERING OVERHAUL AT)ar)>g ai[vr ai[l SOP

• Fit the upper & lower cones by using special tools.

upr an[ n)c[n) ki[nn[ Ap[Syl T&Ãs Wiri f)T kri[.

Notes

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Service Station Manual 180 Akurdi Pune
SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING

4 5

6
8
7 9
1
2
13
11
10 14
12

16

16

15

17

S.N. Description Qty S.N. Description Qty

1 Head Lamp Assly. Without Bulb 1 10 Fairing Mounting Upper Bracket 1
2 Back Cover 1 11 Kit Hardware Mtg. Bracket 1
3 Wind Shield 1 12 Clip Nut 4
4 Bolt M-5 4 13 Screw Pan Cross 2
5 Non Metallic Washer 4 14 Screw Pan Cross 2
6 Well Nut 4 15 Lamp 12V 35/35W-HS1 1
7 Decal Wind Shield 1 16 Amber Bulb 2
8 M5 X 15 Mushroom HD 2 17 Head Lamp Bulb Wiring Harness 1
9 Packing Fairing 1

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Service Station Manual 181 Akurdi Pune
SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING

Dismantling D)sm[ºTl)>g- Ki[lv&

Remove : kiQi[.
• 4 screws
• Visor

CAUTION c[tvN)
Keep the visor at good location to avoid scratches.

viezr upr Ak\[c pDti ri[kvi miT[ sir) j³yia[ m&ki[.

Remove :
• 2 Nos. of plate bolt (A).
• Number plate with damper rubber.
A
kiQi[
¼l[Tni b[ bi[ÃT
n>br ¼l[T rbr D[Àpr siY[.

Remove :
• 2 bolts
• 2 washer
kiQi[
2bi[ÃT
2vi[Sr

Remove :
• 6 screws (B).
B kiQi[
6 Ak&|

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Service Station Manual 182 Akurdi Pune
SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING

Remove :
• Bolt (Holding with lamp shade) LH & RH.
kiQi[
LH an[ RH bi[ÃT Ki[li[ {l[Àp S[D siY[}

Remove :
• Disconnect all couplers.
• Head light fairing assembly.
kiQi[
bFi kplrn[ C&ti kri[.
h[D lieT f[r)>g a[s[Àbl)

Remove :
• Couplers for speedometer.
• Couplers indicator.
• Speedometer complete.
kiQi[
Ap)Di[ m)Tr kplr
kplr eºD)k[|Tr
Ap)Di[m)Tr k>pl)T

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Service Station Manual 183 Akurdi Pune
SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING

Assembling f)T krv&>

Fit :
• Speedometer on lamp shade.
• Guide the couplers.
• Connect speedometer coupler.
f)T kri[
l[Àp S[D upr Ap)Di[m)Tr
gieD kplr
Ap)Di[m)Tr kplrn[ kn[kT kri[.

Fit :
• Connect the speedometer coupler.
• Fairing assembly.
f)T kri[
Ap)Di[m)Tr kplr
f[r)>g a[s[Àbl)

Fit :
• 2 bolts (Holding with lamp shade) LH & RH.
f)T kri[
LH an[ RH 2 bi[ÃT {l[Àp S[D siY[}

Fit :
• 6 screws.
f)T kri[
6 Ak\&

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Service Station Manual 184 Akurdi Pune
SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING

Fit :
• 2 bolts.
• 2 washers.
f)T kri[
2 bi[ÃT
2 vi[Sr

Fit :
• 2 Number plate holding bolts.
• Number plate with damper rubber.
f)T kri[
¼l[T hi[ÃD)>g bi[ÃT 2 n>br
n>br ¼l[T D[Àpr rbr siY[

Fit :
• Visor.
• 4 screws.
f)T kri[
viezr
4Ak\&

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 185 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

10
11
12
7 7 5 7 8 3
5 6
5

17
18 2

6 5
7 4 1
9

2 14
16
15
13
16
15

S.N. Description Qty S.N. Description Qty

1 Rear Shock Absorber 2 10 Chain Slider 1
2 Bolt Pre-coated 2 11 Screw 2
3 Kit Bush Rear Shock 1 12 Plain Washer 2
4 Swing Arm Assly. 1 13 Adjuster Chain LH 1
5 Bush Swing Arm 4 14 Adjuster Chain RH 1
6 Collar Swing Arm 2 15 Plate Chain Adjuster 2
7 Dust Seal Swing Arm 4 16 Hexagon Nut 4
8 ‘U’ Nut Swing Arm 1 17 Grease Nipple 2
9 Shaft Swing Arm 1 18 Plain Washer (nylon) 2

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Service Station Manual 186 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

4 5

10
1
11

8 7
9

5 3

S.N. Description Qty S.N. Description Qty

1 Holder LH Step 1 9 Flanged Bolt 2
2 Holder RH Step 1 10 Tube Silencer Mtg. 1
3 Pillion Step Assly. Comp. LH 1 11 Damper Silencer Mtg. 1
4 Pillion Step Assly. Comp. RH 1 12 Flange Bolt M10 1
5 Rubber Pillion Step 2 13 Washer Plain 1
6 Kit Hardware Pillion 2 14 U Nut M10 1
7 Hexagonal Head Screw 2 15 Grease Nipple Kit 1
8 Nut 1

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Service Station Manual 187 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

Remove :
• 2 flange nuts.
kiQi[
fl[ºj nT 2 n>br

Remove : kiQi[
• Allen bolt. a[ln bi[ÃT
• Nut. nT
• Silencer complete. siyl[nsr kÀpl)T

Note :
1. Slide down the flange of silencer for easy removal of silencer assembly.
2. Ensure that the silencer is not in hot condition or else may cause injury / burn.
ni[>F
1
2.siyl[nsr hi[T k>D)Snmi n hi[y t[ ¹yin riKv&>

Remove :
&>
• Circlip.
• Nut.
• Torque link rod.
kiQi[
srkl)p
nT
Ti[k l)ºD ri[D

Remove :
• Brake rod nut.
• Brake rod.
• Distance piece.
• Spring.

kiQi[
b\[k ri[D nT
b\[k ri[D
D)ATºs p)s
Ap\)>g

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Service Station Manual 188 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

Remove :
• Rear brake switch coupler.
kiQi[
r)ar b\[k Av)c kplr

Remove :
• Bolt.
kiQi[
bi[ÃT

Remove :
• Swing arm RH side nut.
kiQi[
Av)>g aim< RH sieD nT

Remove :
• Step holder RH complete.
kiQi[
At[p hi[ÃDr RH k>pl)T

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Service Station Manual 189 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT

Remove :
• Bolt
• Gear pedal yoke.
kiQi[
bi[[ÃT
g)ar p[Dl ci[k

Remove :
• 2 bolt.
• Chain cover.
kiQi[
2 bi[[ÃT
c[en kvr

Remove :
• Bolt.
kiQi[
bi[[ÃT

Remove :
• Allen bolt.
kiQi[
a[ln bi[[ÃT

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Service Station Manual 190 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

Remove :
• 2 bolts for chain cover.
• Chain cover.
kiQi[
c[en kvrni b[ bi[[ÃT
c[en kvr

Remove : kiQi[
• Axle nut a[ksl nT
• Washer vi[Sr
• Distance D)sTºs
• Axle a[ksl
• Washer vi[Sr

Remove :
• Drum panel plate
• Wheel
kiQi[
D^m p[nl ¼l[T
Äh)l

Remove :
• Chain adjuster assembly from LH / RH side.
• Rear sprocket.
• Distance central.
• Distance LH.
kiQi[
c[en a[DjATr a[s[Àbl) LH/RH sieD
piCLn&> Apik[T
D)ATºs s[ºT^l
D)ATºs LH

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Service Station Manual 191 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT

Remove :
• Bolt for RSA - LH & RH.
kiQi[
RSA bi[[ÃT- LH & RH

Remove :
• Axle swing arm.
• Step holder LH.
kiQi[
a[ksl Av)>g aim<
AT[p hi[ÃDr LH

Remove :
• Guide the chain out.
• Swing arm.
• Bush LH & RH.
kiQi[
c[en aiuT gieD
Av)>g aim<
LH an[ RH b&S

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Service Station Manual 192 Akurdi Pune
SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

• From RH side of frame’s steering tube area route the corrugated

wiring harness as shown in the photograph.
RH sieD f\[m AT)ar)>g Ty&b bij&Y) b[r)>g hirn[sn[ $T kri[ {fiTi[giifs p\miN[}

• Clamp the wiring harness at the lamp shade clamp & frame’s RH
side clip as shown in the photograph.
viyr)>g hirn[s n[ kl[Àp, l[Àp ri[Dni kl[Àp j[ f\[m upr RH sieD upr aip[l
C[ t[ p\miN[ kri[ {fi[Ti[g\ifs p\miN[}

• From LH side of frame’s steering tube area route the corrugated

wiring harness as shown in the photograph.
f\[mn) LH sieD kupr AT)ar)g Ty&b sieD upr AT)ar)>g Ty&b viyr)>g
hirn[s $T)>g kri[. fi[Ti[g\ifs p\miN

• Clamp the wiring harness at the lamp shade clamp for both side
wiring harness respectively as shown in the photograph.
l[Àp S[D upr viyr)>g hirn[sn[ kl[Àp kri[.{fi[Ti[g\ifs p\miN[}

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SOP FOR SWING ARM REPLACEMENT
SOP Av)>g aim< bdlvi miT[

• Clamp the wiring harness on main member of frame by band as

shown.
m[en m[Àbr upr {f\[m upr} viyr)>g hirn[sn[ kl[Àp kri[.

• Clamp the wiring harness on main member of frame (above the

battery) by band as shown.
f\[mni m[en m[Àbr upr viyr)>g hirn[s kl[Àp kri[. {b[Tr) upr}

• Clamp the wiring harness on LH side long member of frame at

two locations shown.
viyr)>g hirn[sn[ LH sieD f\[mni li[ºg m[Àbr upr b[ j³yia[ kl[Àp kri[.

• Clamp the fuse box as shown in photograph.

fy&z bi[ksn[ fi[Ti[g\ifsmi btiv[l p\miN[ kl[Àp kri[.

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WIRING HARNESS ROUTING
viyrn[s hirn[s $T)>g

• Route the stator plate wiring through the clamp provided on frame
as shown in the photograph.
AT[Tr ¼l[T viyr)>g n[ fi[Ti[g\ifsmi btiÄyi p[miN[ f\[m upr $T)>g kri[.

• Clamp the harness with the clamp on long member as shown in

the photograph.
viyr)>g hirn[sn[ f\[mni li[>g m[Àbr upr fi[Ti[g\ifsmi jNiv[l p\miN[ kl[Àp kri[.

• Position of main fuse box.

m[en fy&z biks pi[z)Sn

• Body earthing of starter motor & DC electrical system.

ATiT<r mi[Tr an[ DC el[kT^)kl s)ATm bi[D) aY)>g

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WIRING HARNESS ROUTING
viyr)>g hirn[s $T)>g

• Route the starter motor cable & clamp it with the band as shown
in the photograph.
ATiT<r mi[Tr k[bln[ fi[Ti[ g\ifsmi> jNiv[l p\miN[ kl[Àp b[ºD Wiri kri[.

Notes

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SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT
SOP k[l)pr p)ATn s)l an[ DAT s)l bdlvi miT[

• Clean master cylinder & caliper thoroughly by low pressure water spray
before opening master cylinder top cover & caliper bleeder screw.
miATr s)l)ºDr an[ k[l)prn[ kim krti ph[li li[ a[r p[\[srY) bribr sif
kr) Ryir bid j miATr s)l)ºDr Ti[p kvr an[ k[l)pr ¾l)Dr Ak\& Ki[lvi.

• Drain the brake fluid from caliper assembly by loosening air bleeder
screw & using transparent PVC tube which will avoid spillage of brake
fluid on caliper body / disc pads & also powder coating peel off /
inefficient braking.
b\[k ai[el n[ k[l)pr a[s[Àbl)miY) PVC piLi Wiri ¾l)Dr Ak\& Ki[l) bhir
kiQi[ j[Y) ai[el k[l)pr bi[D)/D)Ak vD[ upr ni pD[ an[ klr Krib ni Yiy

• First remove hose pipe by removing banjo bolt & then remove caliper
assembly from fork mounting location.
b[ºÔ[ bi[ÃTn[ Ki[l)n[ hi[s piep bhir kiQi[ Ryirbid k[l)pr a[s[Àbl)n[ fi[k<
uprY) Ki[li[.

• Remove the allen bolt of LH caliper.

LH k[l)prni Allen bi[ÃTn[ bhir kiQi[.

• Remove both brake pads.

b>n[ b\[k p[>Dn[ bhir kiQi[.

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SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT
SOP- k[l)pr p)ATn s)l an[ DAT s)l bdlvi miT[

• Remove holder bracket & pad spring.

hi[ÃDr b\[k[T an[ p[s Ap\)>gn[ bhir kiQi[

• Remove piston by applying compressed air through banjo bolt hole. Due
to compressed air pressure, the piston will be pushed out of caliper
body. b[ºÔ[ bi[ÃTmi hvini p\[srY) hvi mir) p)ATnn[ bhir kiQi[. hvini
p\[srn[ l)F[ p)ATn bhir aivri[.
Caution : c[tvN):
Do not apply high compressed air pressure >2 bar. This could
cause piston to fly out from caliper body, causing damage to it &
any one in the vicinity.
p)ATn an[ bFi rbr piT<sn[ bhir kiQ) k[l)pr bi[D)n[ D)zl/k[ri[s)n Wiri
sif kri[ an[ k[l)pr bi[D)n[ hvi Wiri sif kri[.
• Remove pistons & all rubber parts. Clean caliper body by Diesel /
Kerosene. Dry caliper body by applying compressed air.
2 birY) vF& hie a[r ki[Àp\[s a[rY) t[n[ sif ni krv&> nh)tr p)ATn k[l)pr
bi[D)mi>Y) bhir n)kL) jS[ an[ ki[en[ n&ksin Yvin) Skyti rh[ C[.

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SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT

• Replace caliper assembly major / minor kit.

k[l)pr a[s[Àbl) ni mi[Ti/nini piT<sn[ bhir kiQi[.

• Smear silicon grease on piston OD & rubber seals.

p)ATnn) bhir n) srf[s upr an[ rbr piT<s upr s)l)ki[n g\)s lgivi[

• Insert piston into caliper bore.

p)ATnn[ k[l)pr ni hi[lmi> m&ki[.

• Clean the anchor pin & holder bracket thoroughly.

a[>kr p)n an[ hi[ÃDr b\k[Tn[ bribr sif kri[.\

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SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT

• Smear silicon grease on anchor pins evenly.

a[ºkr p)n upr s)l)ki[n g\)s bribr lgivi[.

• Fit holder bracket on caliper assembly.

k[l)pr a[s[Àbl) upr hi[ÃDr b\[k[T f)T kri[.

• Clean brake pads by smooth emery paper.

b[k p[>Dn[ Am&Y a[r) p[pr Wiri sif kri[.

• Fit brake pads & allen bolt into the LH caliper & RH caliper.
LH/RH k[l)pr mi> b[\[k p[Dn[ f)T kri[ an[ a[ln bi[ÃTn[ f)T kri[.

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SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT

• Fit caliper assembly on fork mounting & fit the brake hose pipe by
tightening banjo bolt.
k[l)pr a[s[Àbl)n[ fi[k< upr f)T kr) b\[k hi[s piepn[ f)T kri[ b[ºÔ[ bi[ÃT
Wiri

• Remove reservoir cap & rubber diaphragm. Fill brake fluid up to max
level.
r)zvr k[p an[ rbr Diyifim< n[ bhir kiQ) b\[k ai[eln[ Max l[vl s&F)
um[ri[.

• Remove the air by bleeding process. Maintain oil level above MIN mark.
¾l)D)>g p\i[s[s kr) hvi bhir kiQi[ an[ ai[el l[vl Min s&F) j$r) C[.

• Re-fit rubber diaphragm & reservoir cap. Check brake effectiveness.

• Drive the vehicle & confirm brake effectiveness.

rbr Diyifim< an[ r)z<vr k[p f)T kri[ an[ b\[k)G c[k kri[.
vihn cliv) b\[k bribr lig[ C[ k[ nh) t[ c[k kri[.
Note :
• Use DOT-3 / DOT-4 brake fluid from a sealed container.
• Ensure no leakage of brake fluid through brake hose / benjo bolts /
caliper assembly.
ni[>F: h>m[Si DOT.3/DOT4 ai[el vipri[ • Carry out air bleeding if required.
¹yin riKv& k[ ai[el b\[k hi[s/b[ºÔ[ bi[ÃT/k[l)prmi>Y) ni hi[y
j$r) hi[y ti[ a[r ¾l)D)>g kri[.
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SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT

• Clean master cylinder & caliper thoroughly by keeping nozzle in spray

mode before opening master cylinder top cover & caliper bleeder screw.

• Drain the brake fluid from caliper assembly by loosening air bleeder
screw & using transparent PVC tube which will avoid spillage of brake
fluid on caliper body / disc pads & also powder coating peel off /
inefficient braking.

• Remove front brake switch & brake lever.

• Remove protection boot & remove the circlip with the help of plier.

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SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT

• Keep the container below the master cylinder for oil collection during
opening.

• Remove brake hose from master cylinder by loosening banjo bolt.

• Insert blunt tipped screw driver or steel spoke from banjo bolt side &
push piston towards brake lever. (Ensure master cylinder does not get
damaged due to screw driver or spoke)

• Take out piston assembly from brake lever side.

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SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT

• Remove master cylinder cap, remove master cylinder from handle bar &
clean internals by using brake fluid.

• Dry master cylinder by compressed air.

• Fit master cylinder on handle bar. Smear silicon grease on new piston
seals of master piston kit.

• Insert piston assembly from brake lever side into master cylinder bore.

• Insert the circlip with the help of plier.

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SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT

• Insert protection boot correctly so that dust will not enter.

• Refit the brake lever & front brake switch.

• Use new copper washers & fit hose pipe by tightening banjo bolt.

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SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT

• Fill brake fluid up to MAX level.

• Remove the air by bleeding process. Maintain oil level in between MAX
& MIN level.

• Re-fit rubber diaphragm & reservoir cap. Check brake effectiveness.

• Drive the vehicle & confirm brake effectiveness.

Note :
• Use DOT-3 / DOT-4 brake fluid from a sealed container.
• Ensure no leakage of brake fluid through brake hose / benjo bolts /
caliper assembly.
• Carry out air bleeding if required.

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SOP FOR FRONT BRAKE HOSE REPLACEMENT

• Clean brake system by keeping nozzle in spray mode.

• Drain brake fluid from caliper assembly by opening air bleeder screw.

• Remove the hose pipe fitment banjo bolt from both ends (master cylinder
& caliper assembly).

• Replace the hose pipe as well as copper washers fitted at both ends.

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SOP FOR FRONT BRAKE HOSE REPLACEMENT

• Route the front brake hose

as shown in photographs.

• Conduct the brake bleeding procedure.

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SOP FOR BRAKE FLUID REPLACEMENT

• Clean the surface area of master cylinder.

• Drain brake fluid from caliper air bleeder bolt.

• Tighten the air bleeder bolt on caliper assembly.

• Remove reservoir cover by removing 2 nos. phillips head screws.

• Remove PVC cap & rubber diaphragm.

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SOP FOR BRAKE FLUID REPLACEMENT

• Perform air bleeding of disc brake system if the brake operation is

spongy.
a. Remove rubber cap from caliper's bleeder screw.
b. Fit a proper tube which fits snugly tight on the bleeder screw nipple.
c. Insert ring spanner through the pipe fitted on the bleeder screw nipple.

d. Connect the tube to siphon pump's pipe and loosen the bleeder screw
by the ring spanner.

e. Press the bellow of the Siphon pump in its valve open position. Then
close the valve of the pump and release the bellow. Simultaneously
press the brake lever to take out air trapped in the system. Carry out
the same procedure until the entire air trapped in the system gets
removed.

• Fill the master cylinder reservoir by using DOT-3 / DOT-4 brake fluid.

• Fill the master cylinder reservoir by using DOT-3 / DOT-4 brake fluid.

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SOP FOR BRAKE FLUID REPLACEMENT

• Fit the master cylinder cover.

• Press the front brake lever and check the operation of disc brake.

f. During this process continuously monitor and maintain the brake fluid
level in the master cylinder reservoir slightly above the minimum mark.

• For drum brake vehicles, check and adjust front brake lever free play. It
should be 4 ~ 5 mm for all motorcycles.

• Ensure front wheel is rotating freely.

Note :
• Use DOT-3 / DOT-4 brake fluid from a sealed container.
• Ensure no leakage of brake fluid through brake hose / benjo bolts /
caliper assembly.
• Carry out air bleeding if required.

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Notes

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Service Station Manual 212 Akurdi Pune
el[kT^)kl
-b[Tr)
Electrical
-el[kT^)kl c[k)>g p¹Ft) • Battery
-ATiT<r mi[Tr • Electrical Checking
-b[Tr)-kri[/ni kri[ Procedure
-SOP b[Tr) ciJ<>g k>D)Sn • Starter Motor
-kri[ ni kri[
• Battery - Dos & Don'ts
-el[kT^)kl srk)T Diyig\im
• SOP for Checking
Battery Charge Condition
• Dos & Don'ts
• Electrical Circuit Diagrams

213
BATTERY

Battery
Technical Specification :
• Type & Capacity Pulsar 150 - 12V - 7 AH
Pulsar 180 - 12V - 9 AH
• Specific gravity of electrolyte 1.24 for use above 100C
for initial filling of new battery
• Specific gravity of electrolyte 1.28 for use below 100C
for initial filling of new battery
• Initial charging duration 10 ~ 15 hrs
• Initial charging current Pulsar 150 - 0.5 Amp, Pulsar 180 - 0.9 to 1 Amp

Initial Charging Procedure

1. Fill each cell with battery grade sulfuric acid of Hydrometer
the correct Sp. gravity (1.24 at room temp. for
0
use above 10 C and 1.28 at room temp. for use
0
below 10 C). Read
2. Allow the battery to stand for 30 min. after filling. Here
3. Keep vent plugs open. Connect battery to
charger and charge at 0.9 Amp.
4. Charge continuously for 10~15 hours taking Sp.
gravity readings every hour. Fully charged
condition is indicated when all cells are gassing
freely and evenly and show no rise in specific
gravity over 3 successive readings.
5. After charging push vent plugs strip firmly into
place and wash off acid spillage with water and inside the box provided on floor board. Fasten
dry the battery. the battery firmly with bracket & allied fasteners.
6. Using the battery load tester confirm for good c. Connect cables to the positive and negative
indication of state of charge of battery. terminals properly. Reverse connections will
damage the charging system permanently.
Checking the Specific Gravity d. Always connect “negative (earthling) terminal” at
The charge condition of the individual cell can be Iast.
checked by measuring Sp. gravity of electrolyte in e. Clean battery terminals and cable connections.
that cell. The specific gravity of electrolyte can be Smear them with petroleum jelly to avoid
checked by using Hydrometer having small diameter corrosion.
spout. g. Check that the battery cable connections are
For measuring the Sp. gravity bring the electrolyte in firm and cables do not rub against any metal
the Hydrometer to eye level, and read the components.
graduations on the float scale bordering on the
lower meniscus (i.e. curved down portion of Battery Charging Procedure :
electrolyte surface) as shown in the figure. After This is a M.F (Maintenance Free) battery. This
charging is over, fit the filling caps strip, wash acid battery is not having any exhaust tube instead it
spillage with water. Dry the battery. Ensure terminals has a unique vent mechanism.
are clean.
The electrolyte level in this M.F. battery needs to
Battery Installation: be topped up with distilled water not exceeding the
max level if found that the electrolyte level is below
Install the battery on vehicle as described below
min level / dropped down. In case battery in
a. Ensure that in all six cells the level of electrolyte discharged and needs to be charged using battery
is near the maximum level mark. changed procedure is as follows :
b. To clean and dry the surface wipe the top of the • Remove battery from vehicle
battery with a clean cloth. Install the battery
• Clean battery throughly
• Remove gang bar strip.

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BATTERY

• Top up level with distilled water to max level and results in loss of capacity. Mostly the causes of
when the electrolyte level is less than half of min sulphation are as under :
& max level. a. Undercharging.
• Connect battery to charge & ensure respective b. Standing in a partially or completely discharge
terminal are connected properly. condition for long time.
• Set charging current at 0.9 A DC. c. Low electrolyte level : If electrolyte level is
• Charge battery for 3/4 hrs., then check voltage permitted to fall below the top of the battery
and special gravity. plates, then the exposed surfaces will harden
• Battery open circuit voltage should be > 12.5 and will become sulphated.
volts (when disconnected from charger) & special d. Adding acid : If acid is added to a cell in which
gravity in all 6 cells should be 1.240. This is a sulphation exists the condition will be aggravated.
confirmation check for a fully charged battery. e. High specific gravity : If specific gravity is higher
• Disconnect the battery from the charger. than the recommended value, then sulphation
• Fit gang bar plug firmly. may occur.
• Using the battery load tester confirm for good f. High temp.: High temperature accelerates
indication of state of charge of battery. sulphation, particularly of an idle, partially
• Connect battery on to vehicle. discharged battery.
• Apply petroleum jelly on battery terminal.
Voltage of the Sulphated Battery : -
Battery Maintenance Cells of the sulphated battery will show low specific
For the optimum performance and longer battery life gravity. Follow the procedure given below.
the maintenance of battery is important. • Check voltage before charging.
a. Always keep the battery clean and dry. • Charge for 2 hours
b. Visually inspect the surface of the battery • Check voltage every 1 hour. If voltage increases
container. If there are any signs of cracking or then continue charging. But if voltage does not
electrolyte leakage from battery, replace the increase, discontinue charging. Otherwise battery
battery. charger will get permanently damaged. If battery
is not badly sulphated (i.e. voltage more than 9
Never add acid or ordinary tap water for topping up
volts), then battery can be revived by special
since this will shorten Battery life. treatment. In such case it is advisable to give
sulphated battery to authorised dealer of battery
Non Use Maintenance manufacturer for necessary special treatment.
When the vehicle is likely to remain off-road for
longer, time (say more than a month) then Non Use How to Determine Condition of Battery
Maintenance should be carried out as follows Specific gravity check: - Whether battery is fully
otherwise the battery may get sulphated and charged or partially charged, it will always show
permanently damaged. same “no load voltage” of 12 volts or more (unless
a. Remove the battery from vehicle. battery cells are damaged due to sulphation etc).
b. Maintain electrolyte at ‘Upper Level’. But specific gravity of the fully charged battery and
c. During off service period, battery should be partially charged battery will be different. Fully
charged once a month or if the battery DC charged battery will show Sp. gravity of 1.240 while
voltage drops below 12.3 V. partially charged battery will show less specific
gravity. Therefore, specific gravity check is very
d. Keep the battery fully charged. important to know condition of the battery.
e. Store the battery in cool, dry place.
f. Keep the battery away from rain, dew, moisture Note :
and direct sunlight. Use of battery load tester will give the correct indication of
state of charge of battery on load conditions.
Battery Sulphation
A sulphated battery is one which has been left
standing in a discharged condition or undercharged
to the point where abnormal lead sulphate has
formed on the plates (Sulphate cells looks like white
crystal like sugar). Where this happens, the
chemical reactions within the battery are affected

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BATTERY

6 Channel Battery Charger 6- c[nl b[Tr) cij<r

• Make m[ek Teknikraft T[kn)k\ifT

• Model m[iDl 12M6, with stand
Suitable for charging 6 batteries
(2.5Ah/5Ah/7Ah/9Ah)
Constant current type having 0.25 Amp.
/0.5 Amp./0.7 Amp./0.9 Amp. current
settings.

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BATTERY

Checking Condition of Battery

For checking condition of battery, load tester as per

following specifications is to be used :
Make Midtronics
Model PBT50

Procedure for checking battery condition

• Disconnect battery +ve & -ve terminals.
• Confirm battery type & reference no.
• Connect load tester's Red & Black cable to battery +ve & -ve terminal respectively.
• Press test button.

LED Indication Status Result Action

Green LED glowing OK Battery is fully charged Battery can be used on the
vehicle.

Green & Yellow LED OK / LOW Battery is partially discharged. Charge the battery on battery
glowing charger

Yellow LED glowing LOW Battery is discharged & needs charging Charge the battery on battery
charger

Red LED glowing 7 Not OK • Try charging on charger.

• Observe for half an hour if

charger gives indication of ‘bad
battery’, then discontinue
charging and scrap the battery.

• If there is no bad battery

indication then continue charging
till charging is over.

• Again test battery condition

using PBT 50 load tester. If
result is OK, then put the
battery on vehicle.

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ELECTRICAL CHECKING
PROCEDURES

Switches :
Front Brake Light Switch Inspection :
• Turn ON the ignition switch.
• The brake Light LED Blank should get on when the front
brake (Lever is pressed) is applied.
• If it does not, check the Front brake switch.

Brown Blue
Lever Pressed
Lever Released

Rear Brake Light Switch Timing Inspection :

• Turn ON the ignition switch.
• Check the operation of the rear brake light switch by
depressing the brake pedal
• If it does not operate as specified, adjust the brake light
switch or check the switch.

Brown Blue
Pedal Pressed
Pedal Released

Neutral Switch :
• The neutral switch will be in ON position only when the
engine is in neutral.
• The neutral light will not glow when vehicle is in gear.

Light Green Earthing

‘ON’ (Vehicle in neutral)
‘OFF’ (Vehicle in gear)

Ignition Switch :
Brown/Blue White
‘OFF’
‘ON’

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ELECTRICAL CHECKING
PROCEDURES

Stator Plate Coils Inspection :

• Disconnect stator plate coupler
• Set multi meter on ohm range. (Ohm Meter)

Pickup Coil Resistance :

Range Connections Reading
Meter +ve Meter -ve 215 + 20
2 K W ohm
White/Red Black/Yellow

Battery Charging Coil :

Range Meter +ve Meter -ve Reading
200 W Blue/White Blue/White 0.9~1.1 W at 250C

H. T. Coil H. T. Coil Resistance Checking

Primary
Measuring & Testing Equipment : Multimeter
• Measure the primary winding resistance as follows
Meter Range Connections Standard Value
Meter +ve Meter -ve
200 Ohms 0.3 ~ 0.5 Ohms at 25 C
0

White / Yellow Black / Yellow

• Measure the secondary winding resistance as follows

• Remove the plug cap by turning it counter clockwise.
H.T. Coil
Secondary Meter Range Connections Standard Value
Meter +ve Meter -ve
20 K Ohms 4.5 ~ 5.5 K Ohms at 25 C
0

White / Yellow Black / Yellow

• If the value does not match as per, specifications replace the coil.
• If the meter reads as specified, the ignition coil windings are probably
good. However, if the ignition system still does not perform then check
spark output of HT coil using CDI / HT coil tester.

H. T. Coil Spark Output Checking

S.N. LED Status Spark Status Conclusion

Continuous
1. Glows Ignition system is OK
Bluish Spark
HT Coil / Spark plug / Plug cap
2. Glows No Spark
may be defective
Intermittent HT Coil / Spark plug / Plug cap
3. Glows Spark may be defective

Does not Check pick up coil & Exciter coil

4. No Spark
Glow if found OK then replace CDI

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ELECTRICAL CHECKING
PROCEDURES

Fuse :
Main Fuse Inspection (Capacity = 15 Amp) / Secondary Fuse
Inspection (Capacity = 10 Amp)
• Inspect the fuse element
• If it is blown out, replace the fuse.
• If a fuse fails during operation, the electrical system to
determine the cause, and then replace it with a new fuse of
proper amperage.

Caution : When replacing a fuse be sure the new fuse matches the specified fuse rating for
that circuit. Installing of a fuse with a higher rating may cause damage to wiring and
components.

Relay :
Solenoid Relay (Inspection Using Multi meter)

Coil Resistance Meter +ve Meter -ve Reading

X 200 Ohm Red/Yellow Black 3.8 + 2.0 Ohm

Clutch Switch :
The clutch switch has 3 wires and it has contact configuration of
this vehicle is not having interlock relay Instead its working is taken
care of by clutch switches.

Meter Range Light Green Yellow / Green Black /Yellow

OFF - Clutch l l l
lever not pressed
ON - Clutch
l l l
lever pressed

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ELECTRICAL CHECKING
PROCEDURES

Starter Relay Coil Resistance Checking

Measuring & Testing Equipment : Multimeter

Meter Range Connections Standard Value

200 Ohms Meter +ve Meter -ve
Starter Relay Starter 3.9 Ohms + 10%
Coil Red - Relay Coil
Yellow Wire Black Wire

SOP :
• Switch OFF engine.
• Disconnect coupler from Relay.
• Connect multimeter to Starter Relay coil terminals.
• Check resistance.

Starter Relay Continuity Checking

Measuring & Testing Equipment : Multimeter

SOP :
• Connect external 12V DC supply to starter relay coil terminals.
• ‘Tuk’ sound will be heard.
• Set multimeter on continuity mode.
• Connect multimeter at to relay contact terminals.
• Continuity (beep sound) indicates starter relay is OK.

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Service Station Manual 221 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

CAPACITOR
REGULATOR
WITH CAPACITOR
DC Charging Voltage Measurement : (Use fully
charged battery while measuring)
W
To measure the DC voltage; set the meter at
20VDC range. Connect the meter +ve lead to white
W

from RR unit and meter -ve lead to ground. Start

the engine and set it at 4000+25 RPM. Measure
W

L/W

L/W
W

Multimeter connected in
the voltage with and without headlight switch to the
Parrallel with Battery for ON position. Stop the engine disconnect the meter
W
checking DC charging leads.
voltage
Meter Range Specification at 4500 RPM
W

DC 20 Volt 14.3 to 14.7 V

L/W

L/W

14.3
W

FUSE
L/W
L/W

(10 Amps.)
W/B

B
R
BATTERY
12V-9Ah
STARTER RELAY
MAGNETO 100A RATING

CAPACITOR
REGULATOR
WITH CAPACITOR
Battery DC Charging current : (Use fully charged
battery ensuring battery voltage = 12.5 + 0.3 V
W before measuring)
W

To measure the DC charging current, set the meter

at 20ADC. Connect meter+ve lead to White/black
W

lead from RR Unit and meter -ve lead to battery

L/W

L/W
W

Multimeter connected +ve lead.

W in Series with Battery Start the engine and set it at 4000+25 RPM.
for checking DC Measure the DC charging current. The DC charging
charging Current current should be 0.7 A max stop the engine and
disconnect meter leads. Connect the RR unit and
battery.
W

0.7
L/W

L/W

Meter
Connection Specification
W

Range
Meter +ve Meter -ve 0.7 A max
White/Black Battery (+)
DC10A at 4000+25
FUSE terminal of lead (White) RPM
L/W
L/W

(10 Amps.) R/R

W/B

Note :
B Connect multi meter in series with the circuit while
R conducting above test.
BATTERY
12V-9Ah
STARTER RELAY
MAGNETO 100A RATING

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Service Station Manual 222 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Empty Tank
Fuel Gauge - Tank Unit
Measuring & Testing Equipment : Multimeter

Meter Range Connections Standard Value

Meter +ve Meter -ve As per chart
200 Ohms
White / Yellow Black / Yellow given below

Standard Value : (For 150 CC & 180 CC)

Full Tank Fuel Level Fuel Quantity Standard value Graphical Bar on
Instrument cluster
Empty Tank 1.25+0.3 Liter 93~101 Ohm 0 Bar
Reserve 2.8 Liter 67~77 Ohm 2 Bars
Just Above Reserve 3.5 Liter 58~62 Ohm 3 Bars
Half Tank 4.5 Liter 36~44 Ohm 4 Bars
Full Tank 8.5 Liter 6~10 Ohm 6 Bars

Note: Before checking the above, please confirm

• Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is firm.

Note: Before checking the above, please confirm

• Battery Voltage
• Speedometer coupler & fuel gauge tank unit coupler connection is firm.

Horn
Measuring & Testing Equipment : DC Clamp Meter

Meter Range Connections Standard Value

Encircle clamp meter jaws 2.2 Amps

200 DC A
around Brown wire of horn

SOP :
• Encircle clamp meter jaws around Brown wire of Horn.
• Press horn switch & check instantaneous current drawn by horn.

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Service Station Manual 223 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Speedometer Console : The speedometer has a wide Digital LCD

screen with a orange backlit display mode for superb visibility of
display during night riding condition.

This entire speedo console houses following :

• A large analogue tachometer with self check mechanism.
• A red LED indicator showing low fuel level (Reserve-3.6 Lit)
inside the fuel tank.
• Digital Displays for - linear speed in Kmph.
- Odometer
- Trip meter (Unique facility of resetting the trip meter 1 and 2
respectively)
• A row of indication LED displaying functioning of
- Neutral Light
- High beam
- Turn signal
- Side stand on indication

+
Additional battery charge status indication system is provided.
The glowing of this icon indicates
Low Battery Voltage
+
Please ignore battery icon during cranking

as Battery Voltage drops < 11.9 V during cranking

A unique Day-Night mode functioning feature is provided it means the LED glows intensely in day time and
in evening and night time LED glows dim. This feature is provided for riders convenience and Safety.
Maintenance :
• Do not apply pressurized water jet on speedo console.
• Speedo console should not be kept inverted.
• Ensure no scratches / breakage of glass of speedo console
• Ensure Speedo console coupler is firmly fitted.
• Try to park the vehicle in shadow & avoid direct facing to sun rays.

Note :
The speedometer console has a unique built in memory logic function which stores on the data in its memory even if DC supply is
disconnected.

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Service Station Manual 224 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Tail LED Lamp :

The illumination for Tail lamp and Brake lamp are done through 2
rows of LED’s each. These are high intensity LED’s.
The main advantage of these LED’s is that;
• They consume very less power. i.e LED consumes 3W
power against 21 W power of a conventional brake lamp.
• Life of LED is infinite.
• Light output is equivalent to that of a bulb.
• With this tail LED lamp battery discharge possibility is very
minimum in case of a brake switch short condition.
When you operate light control switch to glow, the intensity is low. As
soon as you operate brake switch the brightness of LED increases to
show you bright light.
This changeover of intensity is maintained with the help of electronic
circuit placed inside Tail Lamp Console assly and is a totally sealed
unit.

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Service Station Manual 225 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

CDI Assembly

Identification :
• Case colour - Black for Pulsar 150
• Coupler - White 2 coupler with sealed
type.
• Case colour - Brown for Pulsar 180
• Coupler - Black 2 coupler with sealed
type.
• Make - Varroc
Measuring & Testing Equipment : CDI / HT
Coil Tester.

SOP for CDI/H.T. Coil Checking

Measuring & Testing Equipment : CDI / HT Coil tester.

• Hang the unit on leg guard of the vehicle.
• Remove Spark Plug cap & connect to suitable terminal S1/S2 on the unit.
• Connect 'Red' probe of the unit to HT coil primary terminal.
• Connect 'Black' probe to earth.
• Start the engine.
• Status of LED & Spark window indicates the result as below.

S.N. LED Status Spark Status Conclusion

Continuous
1. Glows Ignition system is OK
Bluish Spark

HT Coil / Spark plug / Plug cap

2. Glows No Spark
may be defective

Intermittent HT Coil / Spark plug / Plug cap

3. Glows Spark may be defective

Does not Check pick up coil & Exciter coil

4. No Spark
Glow if found OK then replace CDI

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Service Station Manual 226 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Light Control Module

Location : Mounted on bracket above high beam projector lamp.

This unit is a combination of head light controller & flasher unit.

Function :
The flasher circuit controls the flashing rate & operation of side indicators.
Light Control Module The light control module switches ON head light (Low beam & High beam)
only when engine is in running condition.

4 pin coupler 2 pin

coupler

Y Br Or B/Y Br Violet

I/P from magneto

Y

Flasher circuit 12VDC from battery

Br Br
Light Control
Flasher circuit Module I/P to H/L switch
Or Violet

Earthing
B/Y

Measuring & Testing Equipment : Multimeter.

SOP :
• Switch ON ignition switch & kill switch.
• Set multimeter to 20 VDC.
• Connect multimeter as shown in table given below.

Sr. Condition Wire connections Std Reading

1. Meter +ve Meter -ve
Ignition switch ON & kill switch
ON. Br (2 pin
coupler) B/Y 12 VDC

Engine is running - H/L switch

2. Violet B/Y 14.5 VDC
OFF.

Engine is running - H/L switch

3. Violet B/Y 13.5 VDC
ON.

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Service Station Manual 227 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Vehicle Speed Sensor

• Non contact Wheel Sensor - In LCD speedo console there are no moving
parts as wheel speed is sensed through a non contact hall effect sensor.
The hall sensor is an electronic switch which operates due to magnetic
field. The sensor has 3 wires - Supply, Earth & Output. This sensor
converts one rotation of front wheel into 8 pulses & these are transmitted
to digital speedometer through a sensor cable.

Do’s & Don’ts

• Do not apply pressurized water jet on vehicle speed sensor.
• Handle wheel sensor carefully while working on front brake drum related
repairs.
• Ensure sensor cable is intact & not fouling with any other part.
• Speed sensor should not physically touch to magnetic ring.

Note: Gap between speed sensor & magnetic ring must be : max 4 mm &
min - 0.5 mm. Ensure intact condition of ‘O’ Ring for speed sensor. Use
correct size ‘O’ Ring in case of replacement.

SOP for checking wheel sensor

Measuring & Testing Equipment : Multimeter
1. Set multimeter to 20 VDC
2. Connect multimter to 4 pole coupler of wheel sensor as per table given
below.
Multimeter +ve Blue-White wire
Multimeter -ve Black-Yellow wire
3. Switch ON ignition switch
4. Rotate front wheel slowly, mark on the tyre for identification and to
ensure that one rotation is complete.
5. In one rotation of front wheel, 8 pulses are generated per revolution.
The reading on multimeter will vary between 4~4.5 VDC & 0VDC 8
times.
6 Conclusion -
Wheel Sensor If 8 times reading on multimeter varies between
OK 4 ~ 4.5 VDC and 0 VDC in one rotation of front
wheel.
Wheel sensor If reading on multimeter does not vary & remains
Faulty continuously in the range of 4~4.5 VDC
If reading on multimeter does not vary & remains
continuously in the range of 0VDC.

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Service Station Manual 228 Akurdi Pune
ELECTRICAL CHECKING
PROCEDURES

Starter Motor - Current Drawn

Measuring & Testing Equipment : DC Clamp Meter
Meter Range Connections Standard Value
Encircle clamp meter 30 ~ 38 Amps Spark
200 DC A transformer jaws around Plug Caps removed
thick Red wire of starter motor (Measured at 270)

SOP :
• Switch ‘ON’ Ignition Key & disconnect both spark plug caps (care to be taken
so that spark plug does not jump to metal part)
• Select range & set clamp meter Zero reading.
• Encircle red input wire of starter motor by clamp meter jaws.
• Crank engine by pressing self starter button.
• Press self starter button 3 seconds & check cranking current displayed on
clamp meter LCD display.

Starter Motor Armature

Measuring & Testing Equipment : Multimeter

Meter Range Connections Standard Value

Continuity Meter +ve Meter -ve No continuity
mode is shown
Commutator segment Shaft

SOP :
• Dismantle starter motor & take out Armature.
• Check continuity between starter motor shaft & each segment on commutator.
• Replace armature if continuity is shown.

Measuring & Testing Equipment : Multimeter

Meter Range Connections Standard Value

Meter +ve Meter -ve
Continuity Continuity
Adjacent is shown
Mode Any segment
segment on
on commutator
commutator

SOP :
• Dismantle starter motor & take out armature
• Check continuity between each pair of adjacent segments on commutator.
• Replace armature if ‘No’ continuity is shown between any two adjacent pair of
commutator segments.

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Service Station Manual 229 Akurdi Pune
STARTER MOTOR

DE Bracket Assly. (Cover Front)

Yoke Assembly

‘O’ Ring for

1 Fiber & 1 Plain Washer
DE Bracket

“O’ Ring (2 nos.) Armature Assembly

Positive Brush
Tie Bolt (2 nos.) Holder Assly

CE Bracket
Assembly
Sealing Ring (Cover Rear)
(2 nos.)

Negative Brush
Holder Assly

‘O’Ring Inside
+Ve Terminal Assly Insulation Bush

Service Limit of Starter Motor Carbon Brush

Standard 6.0 mm Usable Limit 5.0 mm

Carbon Brush

2.5
Wire

1. Check for brush wear

2. Measure length of brush & replace if below usable limit

Periodic Maintenance (After warranty period)

• Check, Inspect & if required Replace carbon brushes, Springs at every 15,000 Kms
• Remove carbon particles from commutator slots.
• Clean commutator segments.
• Lubricate brass bush by 2 ~ 3 drops of Servo 32 oil & NR Bearing by high temperature-high speed
OKS410 grease
• Check as per SOP the continuity between 2 adjacent segments of commutator with the help of Multimeter.
• Replace Yoke Sealing Rings & tie bolt ‘O’ Rings whenever starter motor is dismantled.

Note : Do not dismantle starter motor within warranty period.

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Service Station Manual 230 Akurdi Pune
STARTER MOTOR

Shaft Permanent
Magnets

Brush Holder

Commutator

Bush

Brush Holder

Carbon Brushes
Armature Winding

3 Dos • Remove carbon particles from commutator slots by sharp

blade / knife.
• Clean commutator segments by soft cloth.
• Lubricate brass bush by 2~3 drops of Servo 32 oil & NR
Bearing by high temperature-high speed OKS410 grease .
• Clean the carbon particles deposited inside the rear end
cover.
• Remove all accumulated rust particles by paper.
• Ensure firm connection of Red wire of starter motor
• Replace the Yoke sealing Rings if worn out / broken.
• Ensure the +ve brush holder assly securing nut is fully tight.
• Use correct capacity and fully charged battery.
• Starter switch should be released immediately once the engine starts.
• Assemble Starter Motor front cover such that the mark on it matches with 2 marks on
body. Assemble rear cover such that mark on it matches w i t h 1 m a r k o n b o d y.
Otherwise motor will rotate in reverse direction due to reverse polarity of magnets. This
will give cranking trouble.
• Replace Yoke Sealing Rings & tie bolt ‘O’ Rings whenever starter motor is dismantled.
• Put few drops of oil on starter motor front cover ‘O’ ring before assembling starter
motor.

7 Don’ts •
•
Do not drop down the motor.
Don not Clean Commutator segments by polish paper.
• Do not wash or clean the armature and carbon with kerosene or petrol.
• Do not hit the motor body by hammer or screw driver as it will lead to magnet
breakage.
• Do not use worn out / broken sealing rings of Yoke assly as this would lead to water
entry.
• Do not direct pressurized water jet on motor body during washing.
• Do not crank the engine continuously in case the engine does not start. Analyze the
cause and correct. Otherwise battery will get drained and the starter motor will get
damaged.
• Do not energize the starter motor when the engine is running. Serious damages will
occur to the drive mechanism.
• Don’t press starter switch more than 3 seconds. After 3 successive cranking, if engine
doesn’t start, wait 15 ~ 20 seconds for battery to recover & then crank for next cycle.

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Service Station Manual 231 Akurdi Pune
DOS AND DON’TS

Battery

3 Dos 7 Don’ts

3 • Apply petroleum jelly to • Do not apply grease to

poles / terminals.
7 poles / terminals.

• Use proper tools. • Do not hammer battery

3 terminals.

• Use only distilled water • Do not use mineral water,

3 to top up battery.
7 drinking water to top up
battery.

• Always maintain • Do not increase the level of

3 electrolyte level between electrolyte beyond maximum
maximum & minimum level mark otherwise it
level marks. would over flow through
Vent Mechanism & damage
other parts.

• Always charge battery • Do not quick charge battery

3 by constant current
7 by current higher than
method with the help of specified current.
specified charger. • Constant voltage charging
method must be strictly
avoided.
• Do not use local make
battery charger.

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Service Station Manual 232 Akurdi Pune
DOS AND DON’TS

Battery

3 Dos 7 Don’ts
• Check open circuit • Do not short circuits the
3 voltage by multi meter. poles.

• Always maintain battery • Do not fit extra electrical

3 top cover clean and dry.
7 accessories (Tampering of
Always keep Vent wiring for fitting buzzer etc.)
Mechanism area clean & other wise wiring would get
clear. short & battery would get
discharged. This will shorten
the life of battery.

• Use hydrometer for

3 checking specific gravity

3 • Use midtronics battery

tester for checking
battery charge condition.

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Service Station Manual 233 Akurdi Pune
SOP FOR CHECKING CHARGE CONDITION OF BATTERY
SOP - b[Tr)n) cij< k>D)Sn c[k)>g

SOP - b[Tr)n) cij< k>D)Sn c[k)>g

SOP for Checking Charge Condition of Battery

• Ensure Ignition switch of the vehicle is in OFF position.

vihnn) e³n)Sn Av)c 'OFF' pi[z)Snmi> l[v) j$r) C[

• Disconnect battery terminals. Always remove negative wire

first, then remove positive wire
b[Tr) Tm)<nlni kn[kSnn[ Ki[li[. hm[Si -ve viyr ph[li Ki[li[ Ryirbid +ve
viyrn[ Ki[lci

• Confirm battery type,& check for reference no. printed on the back side of
the instrument
c[k b[Tr) an[ r[frºs n>br j[ piCLn) Big upr aip[l C[

Connect Battery tester clamps to battery terminals, observing correct

polarities.

• Connect + ve & - ve wire clamps of Battery to +ve & -ve terminals of the
Battery tester.
b[Tr) T[ATni kl[Àpn[ kn[kT kr) pi[l)s) bribr C[ k[ nh) t[ c[k kri[ +ve
an[ -ve viyr n[ b[Tr) T[ATr siY[ kn[kT kri[

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Service Station Manual 234 Akurdi Pune
SOP FOR CHECKING CHARGE CONDITION OF BATTERY

• Confirm display indication on LCD.

• Clamps connection is not firm, remove dirt, dust, rust if any from battery
terminals.

LCD D)A¼l[ cil& C[ k[ nh) t[ c[k kri[

b[Tr) Tm)<nln[ sif kr) kn[kSn n kri[

• Battery voltage is less than 8VDC.

• Internal disconnection of battery terminal

8 vdc krti vi[ÃT[j ai[Ci hi[y
b[Tr)ni eºTrnl kn[kSnn[ c[k kri[

• This is reference no. typed when used last time. Set correct reference no.
of battery to be tested using UP/DOWN keys & reference no. chart printed
on back side of the instrument.
ai agiuni r[frnsmi jyir[ vipr[l t[ p\miN[ b[Tr) T[ATr T[AT krvi
up/down k) vipri[ an[ r[frºs miT[ piCL ciT< aip[lC[

• Push “TEST” button for checking condition of battery tester

• Voltage indication & Green LED is glowing-Battery is OK & can be used

on vehicle.

b[Tr) T[ATr ni p&S bTnn[ dbivi[

Ô[ b[Tr) T[ATr upr g)\n lieT btiv[ ti[ b[Tr) ok C[

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Service Station Manual 235 Akurdi Pune
SOP FOR CHECKING CHARGE CONDITION OF BATTERY

• Voltage indication and green & yellow LED's are glowing-Battery is partially
charged. Charge the battery using Metafab make VRLA battery charger

• Voltage Indication & yellow LED is glowing-Battery is discharged. Charge

the battery using Metafab make VRLA battery charger

• Voltage indication & red LED is glowing-Battery is deep discharged.

Charge battery on Metafab VRLA battery charger for 30 minutes. If battery
can not be charged, BAD battery indication will be displayed on charger &
battery needs to be disposed off, If no such indication is displayed then
continue charging till charging is over.

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Service Station Manual 236 Akurdi Pune
DOS AND DON’TS

HORN

3 Dos 7 Don'ts
Ensure that horn is firmly fitted Never remove resonator
on frame cap as it could result in
water entry & subsequent
malfunctioning of horn

Ensure that horn is free from Do not apply pressurised

dust and mud accumulation. water jet directly on horn
resonator.

Ensure that horn wires are

Never adjust nut on horn
intact.
cap side & bracket end
(back side) as it will result
in horn malfunctioning &
failure.

Ensure that horn switch button

Do not remove silicon
is operating freely.
sealant from adjustment
screw as it will result in
water entry in horn.

Ensure that battery is fully

charged.

• Adjust horn by phillips screw

driver Do not hit by mallet /
- without removing silicon screw driver on horn
sealant from the adjustment resonator.
screw.
- by rotating the screw in the
direction of arrow provided
in the screw.

Ensure that resonator is not

pressed by any portion of
cables or wiring harness as it
will result in distorted sound.

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Service Station Manual 237 Akurdi Pune
DOS AND DON’TS

IGNITION SYSTEM

3 Dos • Always install recommended capacity of battery on the bike.

• Always replace spark plug by correct heat range plug.
• Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler
gauge.
• Replace spark plug at every 30,000 kms.
• Check for firm fitment of spark plug in cylinder head - Tightening torque 1.3
~ 1.5 Kgm.
• Ensure H.T. cable secondary connection is firmly fitted in spark plug cap a n d
H.T. coil.
• Check that CDI coupler is tightly fitted.
• Ensure that magneto coupler is firmly fitted.
• Always use a right size socket during removal and re-installation of spark
plug.
• During periodic service make use of spark plug cleaning machine to clean
spark plug electrodes & check proper functioning of both the spark plugs.

7 Don'ts • Do not replace spark plug by non recommended one (different heat range).
• Do not replace CDI by local make or different make.
• Never short circuit H.T. coil primary wire to ground. It could lead to CDI
failure.
• Do not adjust the spark plug gap with any instruments like screw Driver,
pliers etc.
• Do not drive the vehicle without battery. Driving motorcycle in battery
removed condition could cause damage to electrical components like voltage
regulator because of no load Condition.

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Service Station Manual 238 Akurdi Pune
DOS AND DON’TS

LIGHTS

• Check that all bulbs are firmly fitted in bulb holder.

3 Dos
• Ensure that all fixing screw of bulb housing are intact.
• Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side
indicator is intact.
• Check that couplers and wires of bulbs are in good condition.

7 Don'ts • Do not install a lower / higher capacity battery than what is

recommended.
• Do not use Higher / Lower wattage Bulbs.
• While washing Vehicle do not direct pressurized water jet on Head
Light, Tail Light,Indicators.
• Do not ride on brakes.
• Do not start Vehicle with light control switch in ON condition.

SWITCHES

• After washing the vehicle ensure to apply dry air on switches before
3 Dos operation.
• Always ensure that grommets provided on clutch switch, front brake
switch and rear brake switch are intact.
• Always apply WD-40 Rust Spray to sticky switches.

7 Don'ts • Do not apply direct pressurized water jet on control switches.

• Do not lubricate electrical switches by oil or grease.
• Do not over tighten the switches.
• During warranty period do not dismantle control switches.
• Do not add extra electrical loads e.g. musical horns, additional horns,
buzzers as it will reduce switch contact life & battery life &battery life.
• Do not operate switch immediately after water servicing.

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Service Station Manual 239 Akurdi Pune
ELECTRICAL CIRCUIT DIAGRAMS

START SWITCH ENGINE OFF Starter Motor Circuit

ON KILL
SWITCH ATiT<r mi[Tr srk)T

Gr/R

Gr/R
R/W

Br/L
O O
R/W

Br/L
N F
F
Br Br/L
IGNITION
SWITCH

W W
CABLE ASSY. RELAY

W
R/W R TO STARTER MOTOR

CABLE ASSY. RED

Y/G FUSE 1 STARTER
(15 Amps.) MOTOR

W/B
Lg

Lg

B
STARTER RELAY
Lg

BATTERY
Lg MF 9Ah CABLE
NEUTRAL ASSY
R
SWITCH R/W EARTH
B/Y
CLUTCH
SWITCH TRANSIL B/Y Y/G
ASSY Y/G DIODE Y/G

O
O
F
Horn Circuit
N F
hi[n< srk)T
Br Br/L
IGNITION
SWITCH

W W
W

Br
Br/L

B
B

TWIN BOX ASSY

FUSE 2 FUSE 1
(10 Amps.) (15 Amps.)
Br
B

W/B

Br
B

B/Y

HORN
SWITCH BATTERY
MF 9Ah
HORN

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Service Station Manual 240 Akurdi Pune
ELECTRICAL CIRCUIT DIAGRAMS

FRONT BRAKE REAR BRAKE

Brake Light Circuit
SWITCH SWITCH
b\[k lieT srk)T

Br

Br
L

L
L
TAIL LAMP ASSLY.
(Stop LED)
B/Y

O O
N F
F
Br Br/L
IGNITION
SWITCH

W W

Br/L
Br

W
TWIN BOX ASSY

FUSE 2 FUSE 1
(10 Amps.) (15 Amps.)

W/B
Br
Br

BATTERY
MF 9Ah

CAPACITOR
B Battery Charging Circuit
b[Tr) ciJ<g srk)T

R.R. UNIT
W

L/W

L/W
B/Y

L/W

L/W
B/Y

W
W

FUSE
B/Y

(15 Amps.)
L/W

L/W

W/B

EARTH-FRAME BATTERY
MF 9Ah

MAGNETO
ASSLY. (BATTERY
CHARGING COIL)

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Service Station Manual 241 Akurdi Pune
 ELECTRICAL CIRCUIT DIAGRAMS

PIN NO. 1
INSTRUMENT CLUSTER + INPUT
Neutral Lamp Circuit
Gr/R Gr/R ENG OFF
KILL
SWITCH ON ºy&T^l l[Àp srk)T
DIGITAL SPEEDOMETER

PIN NO. 6
B/Y
COMMON GROUND

Gr/R
Br/L
PIN NO. 7
COMMON GROUND

Lg Lg
PIN NO. 9
TALE-TELL NEUTRAL INDICATOR

Gr/R
Br/L
PIN NO. 16
PERMANENT BATTERY + INPUT SEALED Gr/R
COUPLER Lg

O O
N F

Br/L
IGNITION SWITCH

F
Br Br/L

W W W

FUSE 1
W/B (15 Amps.)

BATTERY
Lg

MF 9Ah

NEUTRAL
SWITCH

KILL SWITCH
PIN NO. 1
Br Gr/R VEHICLE ENG
Vehicle Speed Sensor Circuit
INSTRUMENT CLUSTER + INPUT SPEED OFF
PIN NO. 2 SENSOR ON
VEHICLE SPEED SENSOR + INPUT
R/W ENG
v[h)kl Ap)D s[ºsr srk)T
ON
R/W

L/W

B/Y

Gr/R
Br/L
DIGITAL SPEEDOMETER

PIN NO. 6
COMMON GROUND
PIN NO. 7 B/Y
COMMON GROUND

W
R/W

L/W

Gr/R
Br/L

PIN NO. 12 L/W L/W

VEHICLE SPEED SENSOR OUTPUT

R/W
Gr/R
W
PIN NO. 16
PERMANENT BATTERY + INPUT
SEALED
COUPLER
Br/L

O O
N F
F
Br Br/L Br/L
IGNITION
SWITCH
W W W
W

TWIN BOX ASSY

FUSE 1
(15 Amps.)
W/B

BATTERY
MF 9Ah

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Service Station Manual 242 Akurdi Pune
 ELECTRICAL CIRCUIT DIAGRAMS

PIN NO. 1
INSTRUMENT CLUSTER + INPUT
Fuel Gauge Circuit
Br Gr/R
fy&al g[j srk)T
KILL
SWITCH TFR
W/Y
TANK
UNIT
DIGITAL SPEEDOMETER

ENG OFF
ON
PIN NO. 6
COMMON GROUND ENG ON
PIN NO. 7 B/Y
COMMON GROUND

W/Y

B/Y
Gr/R
Br/L
PIN NO. 13 W/Y
FUEL GAUGE INDICATOR

Gr/R
Br/L

W/Y

B/Y
W
PIN NO. 16
PERMANENT BATTERY + INPUT SEALED
COUPLER
Gr/R

O W/Y
O
F
N
F
Br Br/L Br/L
IGNITION
SWITCH

W W W

W
TWIN BOX ASSY
FUSE 1
(15 Amps.)
W/B

BATTERY
MF 9Ah

DC C.D.I. ASSY.
B/R TPS
Ignition Circuit
e³n)Sn srk)T
KILL SWITCH
W/R

B/Y

B
Pi

ENG OFF
B/Y

ON
Pi

ENG ON

RHS
H.T.COIL 2 B/R
SPARK PLUG
Gr/R
Br/L

B
Gr/R
B/Y
Gr/R
Br/L

H.T.COIL 1 LHS SPARK

O O
N F PLUG
IGNITION SWITCH

F
Br Br/L

W
W W

Gr/R
W
W/R

FUSE
(15 Amps.)
W/B
W/R

R
OIL
PC

BATTERY
K-U

12V-7Ah
PIC

MAGNETO

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 243 Akurdi Pune
 ELECTRICAL CIRCUIT DIAGRAMS

Br Gr/R
PIN NO. 1
INSTRUMENT CLUSTER + INPUT KILL SWITCH
Tachometer Circuit

ON
ENG OFF T[ki[m)Tr srk)T
ENG ON
PIN NO. 6 DC C.D.I. ASSY.
COMMON GROUND B/Y
PIN NO. 7
DIGITAL SPEEDOMETER

COMMON GROUND

Gr/R
Br/L
B B

Gr/R
B/Y
PIN NO. 8

B
TACHOMETER

Gr/R
B
Gr/R
W
PIN NO. 16
PERMANENT BATTERY + INPUT SEALED
COUPLER

O O
N F
F
Br Br/L Br/L H.T.COIL 1 SPARK PLUG 1
IGNITION
SWITCH

W W W

W
B
FUSE 1
(15 Amps.)
Gr/R

W/B
BATTERY
MF 9Ah

Gr Gr
SIGNAL LAMP
FRONT RH
LAMP 12V-10W
Side Indicator Circuit
B/Y
KILL SWITCH

PIN NO. 1
INSTRUMENT CLUSTER + INPUT
Br Gr/R
ENG OFF sieD eºD)k[Tr srk)T
ON
ENG ON
Gr/R
Br/L
DIGITAL SPEEDOMETER

PIN NO. 6
COMMON GROUND
PIN NO. 7
B/Y
COMMON GROUND

LIGHT CONTROL
W
MODULE
Gr/R
Br/L

PIN NO. 10
TALE-TELL BLINKER - LH INPUT
PIN NO. 11
TALE-TELL BLINKER - RH INPUT

Gr/R
Br

W
PIN NO. 16
PERMANENT BATTERY + INPUT SEALED
SIGNAL LAMP
COUPLER
REAR RH
LAMP 12V-10W
Gr Gr
Br/L

O O
F B/Y B/Y
N F
Br Br/L Br/L Br
IGNITION
W
SWITCH
W
W W
Gr

G
SIGNAL LAMP
REAR LH
O LAMP 12V-10W
B/Y B/Y
Gr
O

Br/L

G G
G

Br
TWIN BOX ASSY
B/Y
SIGNAL LAMP
FRONT LH FUSE 2 FUSE 1
LAMP 12V-10W (15 Amps.) (20 Amps.)
G G
Gr

Br
O

W/B

BATTERY
R O L MF 9Ah
TURN SIGNAL
SWITCH

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Service Station Manual 244 Akurdi Pune
ELECTRICAL CIRCUIT DIAGRAMS el[kT^)kl srk)T Diyig\im

LIGHT SWITCH LED CONTROL KILL SWITCH

Kill Switch ON
Br Gr/R OFF
PO
ENG OFF
LIGHT CONTROL
MODULE Lighting Circuit
LO ENG ON
ON lieTn)>g srk)T

Br/W
Gr/R
R/W

Gr/R
B/Y
Y/L

Br/L
DC REGULATOR

R
R
V
ASSLY WITH

L/W
B/Y

Br
CAPACITOR

V
CAPACITOR
BACK LIGHT R

R
DIGITAL SPEEDOMETER

GROUND
B/Y

Br/W

Gr/R
B/Y
W

Y/L

L/W
B/Y
V

Br
R

L/W
L/W
B/Y
W
W
R

HIGH BEAM INDICATOR R/B

R/B Gr/R

L/W

L/W
W
W
BATTERY SEALED
COUPLER

Br/L
W
O O
F
N F
Br
Br Br/L Br/L
IGNITION TAIL LAMP ASSY
SWITCH W
W W W B/Y B/Y

R R R
R

R
B/Y W

R/B R/B

HEAD LAMP B/Y B/Y

ASSY/LAMP
12V-35/35W HS1 R/Y
R/Y
B/Y

POSITION R

L/W
L/W
LAMP
12V-5W- 2 Nos. R R

Br/L
NO. PLATE LAMP

W
Br/W
R/B

R
R/Y
Y/L
Br

L/W
L/W
FUSE FUSE
(10 Amps.) (15 Amps.)
R/B

Br

W/B
Br/W
B/Y
R/B

R/B
R/Y

Y/L
Br

BATTERY
LO HI MAGNETO 12V-7Ah
HI/LO BEAM LED'S
PASS
SWITCH SWITCH

CONTROL SWITCH LH

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Service Station Manual 245 Akurdi Pune
Notes

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 246 Akurdi Pune
p\[iblm Si[Fvi an[ t[n& (nrikrN
Diagnosis & Troubleshooting

247
DIAGNOSIS AND TROUBLESHOOTING

For Diagnosis & trouble shooting refer trouble shooting

encyclopedia uploaded on portal.
Troubleshooting
Encyclopedia

Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual 248 Akurdi Pune
Bajaj Auto Limited bÔj ai[Ti[ l)m)T[D
Akurdi Pune 411 035 India aik&D)< p&ni 4110 035, Birt
Tel +91 20 27472851
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