Bajaj Electricals Pulsar 135 LS Owner`s manual

Dear Customer,
Congratulations on becoming the proud owner of a “Bajaj Pulsar 135 LS” motorcycle, one of the finest motorcycles in
the country.
Your safety and the safety of others is extremely important. Hence, before you ride the bike, please read this Owner's
Manual carefully and familiarize yourself with the operating mechanism, controls and maintenance requirements. This will
ensure you a long and trouble free ownership experience.
To keep your bike in perfect running condition and deliver consistent performance, we have specially programmed the
periodic maintenance services which includes 3 Free and 4 Paid services. We earnestly advise you to avail all these
services at any of our Vehicle Dealers or Authorised Service Centres as per the schedule contained in this booklet
Your “Bajaj Pulsar 135 LS” comes with a warranty of 2 Years or 30,000 Kms. whichever occurs earlier from the date
of sale. For details please refer to “Warranty : Scope & Limits” given in this manual.
We urge you to entrust all your service needs to a Bajaj Dealer or Authorised Service Centre only. They are well
equipped with all necessary facilities / genuine parts / oil and trained manpower will ensure the best care for your bike.
Should you require any additional information or wish to convey any grievance you may contact us on our toll free no.
/ e-mail mentioned on front cover inner page of this manual.
Thank you for choosing a Bajaj and wish you unlimited miles of happy riding!!
SERVICE DEPARTMENT
BAJAJ AUTO LIMITED
Table of Contents
Description
Identification Data..........................................................................................................................................................................1
Technical Specifications................................................................................................................................................................ 2
Location of Parts........................................................................................................................................................................... 3
How to Ride your Bike................................................................................................................................................................12
• Running In....................................................................................................................................................................... 12
• Riding the Bike................................................................................................................................................................12
• Fuel Saving Tips............................................................................................................................................................. 14
Safe Riding Tips.......................................................................................................................................................................... 15
General Maintenance Information...............................................................................................................................................16
• Engine Oil........................................................................................................................................................................16
• Battery..............................................................................................................................................................................18
• Monsoon Care................................................................................................................................................................ 19
Daily Safety Checks.....................................................................................................................................................................20
Non-use Maintenance................................................................................................................................................................. 21
Periodic Maintenance / Lubrication Chart................................................................................................................................. 22
Schedule for Periodic Part Replacement...................................................................................................................................25
Warranty : Scope & Limits......................................................................................................................................................... 29
Service Records...........................................................................................................................................................................32
Battery Warranty Card.....................................................................................................................................................................
Service Coupons
DOC. NO.: 71110943
REV. 00, DEC. 09
Safety and Warning Information
Warning
This indicates that a potential hazard or injury to you or other persons and to the vehicle can
happen, if the advise provided is not followed.
Caution
This indicates that a potential hazard that could result in vehicle damage. Follow the advise
provided with the caution.
Notice
The description and illustration in this booklet are not to be taken as binding on the manufacturers.
The essential features of the type described and illustrated herein remaining unaltered.
Bajaj Auto Limited reserves the right to carry out at any moment without being obliged to bring this
booklet upto-date.
Modifications on the vehicle, parts or accessories as may be convenient and necessary.
Identification Data
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 :
On the LH side of steering tube.
(Alpha-Numeric - 17 digits).
Engine Number Location :
On LH side crankcase near gear change lever
(Alpha-Numeric - 11 digits)
1
Technical Specifications
Engine
Bore x Stroke
Eng. Displacement
Compression Ratio
Idling Speed
Max. Net Power
Max. Net Torque
Ignition System
Spark Plug (2 Nos)
Spark Plug Gap
Lubrication
Transmission
Front Brake
Rear Brake
Fuel Tank Capacity
Full
Reserve
Usable
Dimensions
Length
Width
Height
Wheel base
Ground clearance
: 4 stroke DTS-i, Single cylinder
Natural air cooled.
: 54.0 mm x 58.8 mm
: 134.66 cc
: 9.8:1
: 1400 rpm
: 13.5 Ps @ 9000 rpm
: 11.4 Nm @ 7500 rpm
: DC, Micro controller based digital
CDI with Trics
: CHAMPION, BOSCH
: 0.6~0.7 mm
: Wet sump, Forced.
: 5 speed constant mesh.
: Hydraulic operated 240 mm disc
brake
: Mech. expanding shoe 130 mm
:
: 8 liters
: 2.5 liters
: 1.6 liters
:
: 1995 mm
: 765 mm
: 1045 mm
: 1325 mm
: 170 mm
Tyre Size
Front
Rear
Tyre Pressure Front
Rear (Solo)
Rear (Pillion)
Electrical System
Head Lamp
Pilot lamp
Neutral
Reserve Indicator
Tail / Stop Lamp
Turn Signal Indicator
Side indicator Lamp
Hi Beam Indi. Lamp
Speedometer Lamp
Fuel Gauge
Horn
Battery
Rear No. Plate Lamp
Vehicle Kerb Weight
Gross Vehicle Weight
Max. Speed
Climbing Ability
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
2.75 X 17”, 41 P
100/90 X 17”, 55 P
1.75 kg/cm2 (25 psi)
2.00 kg/cm2 (28 psi)
2.25 kg/cm2 (32 psi)
12 Volts DC
35/35W
5W (2 nos.)
LED
LED
LED
LED (inside cluster)
LED
LED
LED
LED bar display
12 V DC 2A
12 V 5 Ah MF
5W
122 kg.
252 kg.
115 km/hr.
(With single rider 68 kg)
: 26% max.
}
Note : All dimensions are under UNLADEN condition.
Above information is subject to change without any notice.
2
Location of Parts
1
5
6
7
2
8
3
9
10
11
12
4
1.
Speedometer : The vehicle speed is displayed in digit.
2.
Fuel Level Indicator : It shows available fuel in fuel tank.
3.
Tachometer : It shows the engine speed in RPM.
4.
Steering cum Ignition Switch : Key operated switch for Ignition
‘ON’/‘OFF’ & locking handle bar.
5.
Odometer : The Odometer shows cumulative reading of total
distance covered by vehicle in Km.
6.
Turn Signal Indicator (LH & RH) : When Turn signal switch is
turned to Left or Right, Turn pilot indicator - LH or RH will flash.
7.
Hi Beam Indicator : When Headlight is ‘ON’ & Hi beam is
selected with engine running, Hi beam indicator will be lit.
3
8.
Reserve Indicator : It shows reserve position when petrol left in
the petrol tank is 2.5 ltr. Approx.
9. Neutral Indicator : When the transmission is in Neutral and
Ignition switch ‘ON’, the Neutral indicator is lit.
10. Trip Meter Reset Button : Trip meter can be reset to zero by
pressing the button.
11. Trip Meter : The Trip meter shows the distance travelled since it
was last reset to zero.
12. Battery Indicator : It shows battery charge condition.
Continuous display of this icon means battery is in charged condition.
LOW
Pop-up of this indication means battery is in low charged condition.
Location of Parts
Steering cum Ignition Lock :
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 the 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’ and ‘Side cover lock’.
4
Location of Parts
Fuel Tap
Fuel Tank
Cap
OFF
RES
ON
Fuel Tank Cap
•
To open the fuel tank cap, open the flap. Insert the
key in the lock and turn it clockwise and lift fuel
tank cap.
•
‘Fuel Tank Cap’ gets locked when pushed back into
the place.
5
Fuel Tap
Fuel tap lever has following positions.
ON
: When fuel level is above Reserve position.
RES : When fuel level is below Reserve position.
OFF : When fuel supply is to be cut off.
Location of Parts
A
D
B
C
Left Handle Bar Switches
A. Dipper Switch : When headlight is ON, High or Low
beam can be 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
C. Horn Button : (
horn.
) Press horn button for sounding
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.
B. Turn Signal Switch : When the turn signal switch is
turned to Left ( ) or Right ( ), the corresponding
turn signals flash on and off. To stop flashing, push
the switch in and release.
6
Location of Parts
F. Starter Button :
Starter button operates the electric starter when
clutch lever is depressed with transmission in any
gear.
G
E
F
Right Handle Bar Switches
E. Head Light Switch : It has 3 positions.
: All lamps 'OFF'.
: While engine running, Tail lamp, Meter lamp
and Pilot lamp/s ‘ON’.
: While engine running, Head lamp, Pilot lamp/s,
Tail lamp and Meter lamps ‘ON’.
7
It is recommended to start the engine with the
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.
Location of Parts
C
C
B
B
A
Removal of Side Cover LH
• Insert the key into the cover lock (A) and turn the key
clockwise.
• Hold the cover with both hands and pull front side
first (B). Slide (C) forward. Take out ‘Side cover’.
Fitment of Side Cover LH
• Match lug provided on rear side (C) of ‘Side Cover’
with bracket located on chassis & Slide (C) backward.
• Match Lug (B) provided on front side of ‘Side Cover’
with hole provided on ‘Fuel Tank’. Press the cover.
• Match the ‘Side Cover’ properly lock with bracket
provided on ‘Holder step LH’ & Lock (A) the ‘Side
Cover’.
CAUTION : Remove cover as described above,
otherwise the lugs may break.
A
Removal of Side Cover RH
• Remove the screw (A) given on ‘Side Cover’.
• Hold the cover with both hands and pull front side
first (B) . Slide (C) forward. Take out ‘Side cover’.
Fitment of Side Cover RH
• Match rear side (C) of ‘Side Cover’ lug with Bracket
located on chassis and slide (C) backward.
• Match Lug provided on front side (B) of ‘Side Cover’
with hole provided on ‘Fuel Tank’ and press ‘Side
Cover’ inside.
• Match ‘Side Cover’ properly with bracket provided on
‘Air filter assly’ and fix it with Screw (A).
CAUTION : Fit cover as described above to ensure
proper fitment.
8
Location of Parts
BATTERY
TOOL KIT
Battery
Tool Kit Location
•
•
•
It is located inside the ‘Side Cover’ LH.
Always maintain electrolyte level in each cell
between max and min level lines.
Always keep a watch on battery charge level
indicating icon, if it flashes (indicates battery is in
low charged condition), show the vehicle to
authorised BAL dealer.
•
9
It is located below the battery.
CAUTION : Insert tool kit properly in compartment
provided on air filter assembly for proper fitment of
‘LH’ side cover.
Location of Parts
A
B
Fig. 1 Seat Release Cable
Fig. 2 Seat Mounting Bolt
Removal of Seat - Rear
Removal of Seat - Front
•
•
•
•
•
Remove ‘Side Cover’ LH.
To remove Seat Rear, pull the ‘Seat Release Cable’
(A) shown in fig. 1 to release seat lock. Keeping
cable pulled, tap the center of seat, lift the seat
from rear end and slide it towards tail lamp to
remove seat.
•
Remove ‘Side Cover’ LH.
Remove ‘Seat Rear’.
To remove Seat Front, remove bolt (B) shown in fig.
2.
Lift the seat from rear end and slide it towards tail
lamp to remove seat.
CAUTION : Always remove Rear Seat first.
10
Location of Parts
3
4
6
2
1
Fig. A
5
Fig. B
Fig. C
Fitment of Seat - Front
Fitment of Seat - Rear
•
•
•
•
For fitment of Seat Front, match & insert the bracket
(‘1’ of Fig. ‘A’) of seat with slot (‘2’ of Fig. ‘A’)
provided below fuel tank rear mounting on chassis.
Push seat towards fuel tank.
Then press the seat at rear from top to align lock
bolt (‘3’ of Fig. ‘B’) .
Tighten the lock bolt.
CAUTION : Always fit Front Seat first.
11
7
•
•
For fitment of Seat Rear, match & insert the bracket
(‘4’ of Fig. ‘C’) of seat with bracket (‘5’ of Fig. ‘C’)
provided on chassis.
Push seat towards fuel tank and align lock rod (‘6’
of Fig. ‘C’) & seat lock (‘7’ of Fig. ‘C’).
Then press the seat in middle from top to lock the
seat.
How to Ride your Bike
Running IN
Starting the Engine :
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
0 - 1000
14
22
31
38
45
1000 - 2000
19
31
43
52
62
•
•
•
5th
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 workup into the
engine.
Riding the Bike
Before starting the vehicle and with the ignition key off,
adhere to the following first thing in the morning or after
a long period of non-use (whichever is the case).
Depress the clutch lever completely. Kick the kick lever
all the way down to its stop, briskly a couple of times.
Release the clutch lever.
Keep the fuel tap to ON or RES position.
Turn ignition switch to ON position.
Turn Kill switch to (
) ON position.
Confirm that the vehicle (transmission) is in neutral.
Keep the throttle completely closed, push the starter
button (
) or kick the engine with kick starter lever.
CAUTION : Do not operate the starter continuously
for more than 5 sec. Wait for 15 sec. before you restart.
NOTE : The motorcycle is equipped with a starter
lockout switch. The vehicle can start in any gear when
clutch lever is depressed.
It is recommended to start the engine with the
transmission in neutral.
Moving Off :
•
•
•
•
•
Check that Center/Side stand is up.
Depress the clutch lever.
Shift into 1st gear.
Open the throttle and release the clutch lever slowly
and simultaneously.
As the clutch starts to engage, open the throttle a
little more, giving the engine just enough rpm to
keep it from stalling.
12
How to Ride your Bike
Shifting Gears :
•
•
•
Close throttle & depress the clutch.
Shift into next higher or lower gear.
Open the throttle and release the clutch lever slowly
and simultaneously.
•
•
•
Shift down one gear at a time so that you are in
Neutral when you come to a complete stop.
When stopping, always apply both brakes at the
same time. De-clutch as necessary to keep the
engine from stalling.
Never lock the brakes, or it will cause the tyres to
skid. When cornering, use brakes judiciously and do
not de-clutch. Reduce your speed before you get
into the corner. For emergency braking, disregard
downshifting, and concentrate on applying the
brakes as hard as possible without skidding.
Stopping the Vehicle :
Gear Shifting Lever & Gear Shifting Sequence
WARNING : When shifting down to lower gear, do
not shift at such a high speed that the engine rpm
rises excessively and which may cause the rear
wheel to skid.
Braking :
•
Close the throttle completely, leaving the clutch
engaged (except where shifting gears) so that the
engine braking will help slow down the motorcycle.
13
•
•
•
•
Close the throttle completely.
Shift the transmission into neutral.
Bring the vehicle to complete stop.
Turn the ignition switch off.
Parking :
•
•
Shift the transmission into neutral and turn the
ignition switch OFF.
Support the motorcycle on a firm level surface with
the center or side stand.
CAUTION : Do not park on a soft or steeply
inclined surface or the motorcycle may fall over.
How to Ride your Bike
Fuel Saving Tips
• Ensure Following Vehicle Maintenance.
•
Drive smoothly and steadily at speed between 40
and 50 km/h .
Vehicle Maintenance (Ensure Following)
•
Drive at constant speed; avoid sudden accelerations
& harsh braking as far as possible. Plan your trips
properly with minimum start-stops.
•
Change the gear judiciously according to the speed
requirements. Drive as far possible in highest gear.
•
Travel as light as possible; do not overload the
vehicle above the specified payload.
•
Stop the engine quickly at the end of the journey.
Avoid excessive idling. For intermediate stoppages,
cut-off the engine if you want to stop for more than
two minutes.
Fuel
Check fuel lines and connections for
leakage.
Spark plug
Inspect and clean spark plug. Adjust
electrode gap.
Air filter
Clean air filter element periodically.
Engine oil
Check level. Use “Bajaj DTS-i
10000” high performance engine oil
for top up or refill.
Brakes
Ensure that the brakes are not
dragging / binding.
Clutch
Ensure correct clutch lever play.
Tyre pressure
Always maintain the recommended
tyre pressure.
Carburettor
Adjust idling speed.
14
Safe Riding Tips
• Always wear
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.
• Familiarise yourself well with starting, acceleration and
braking of the vehicle.
• When applying the brakes, use both front and rear
brakes simultaneously. Applying only one brake may
cause the vehicle to loose control.
• Riding at proper speed and avoiding unnecessary
acceleration and braking are important not only for
safety and low fuel consumption, but also for longer
life of the vehicle.
• During monsoon drive the vehicle more cautiously.
Remember vehicles skid more easily during light
showers.
• Drive cautiously. Start early & reach your destination
safely.
15
• Always carry vehicle registration & insurance papers,
and a valid driving licence with you.
• Avoid driving on loose sand or stones where vehicle
is likely to skid.
• Properly wrap-up loose clothes while driving or riding
to avoid entangling in wheel or other objects on road.
• Always concentrate on riding for safety.
General Maintenance Information
Engine Oil
• Check engine oil level every day before starting the
vehicle.
• Always maintain engine oil level between upper &
lower mark provided on cover RH.
Engine Oil Level Checking :
• Park the vehicle on level surface on center stand.
• Check oil level through oil inspection gauge as shown
in photograph.
• Always maintain engine oil level between the upper
(C) and lower (D) mark provided on Cover RH.
Engine Oil Capacity :
• 1000 ml for refill and 1100 ml on engine overhaul.
A
A : Oil Filler
Cap
B : Oil Level
Inspection
Window
C
B
D
Recommended Oil :
“Bajaj DTS-i 10000” a high performance
engine oil developed by Bajaj auto,
specially formulated for vehicles with DTS-i
engine.
Bajaj Auto recommends “Bajaj DTS-i 10000” engine oil
for 10,000 kms drain interval, better performance of
engine components & warranty benefits.
Bajaj DTS-i
10000
SAE 20W50 of API ‘SL’, JASO
MA Grade
Replacement
Frequency*
1st replacement at 750 Kms. / 1st
service. Thereafter at every
10,000 Kms.
*For any other branded oil of equivalent grade
replacement frequency will be 5000 Kms.
CAUTION :
• It is most important to adhere to recommended
grade & frequency of oil change for the purpose
of long life of critical engine components. For
details refer periodic maintenance chart.
• Do not reuse drained oil.
16
General Maintenance Information
Wheel Puncture :
Drive Chain Slackness
Use the recommended levers while removing the Tyre /
Tube for puncture work. This will avoid any damages to
the edges / scratches on paint of the wheel.
•
Chain top edge to be kept between the two marks
during chain slackness adjustment.
•
Care should be taken, that the chain should never
run dry.
•
Lubricate chain from outside with SAE 90 oil at
every 500 kms.
•
Chain slackness will have to be adjusted whenever
required.
Tyre Pressure :
Keep appropriate tyre pressure as mentioned below to
increase life of the tyre & for better fuel consumption.
Front
1.75 Kg/Cm2 (25.0 psi)
Rear (Solo)
2.00 Kg/Cm2 (28.5 psi)
Rear (with Pillion)
2.25 Kg/Cm2 (32.0 psi)
17
General Maintenance Information
CAUTION : Do not drive/run vehicle in battery
disconnected condition. It may lead to damage of
electrical /electronic components.
• Warranty on battery is 18 months from the date of
purchase of vehicle.
Spark Plug
•
•
•
Battery : 12V - 5 Ah, MF
• Battery is located inside ‘Side Cover’ LH.
• Always ensure that battery electrolyte level is in
between max & min level marks.
• Check & top up battery by distilled water if
electrolyte level is below min level mark.
• Battery life would get adversely affected if top up
with ‘Tap Water’.
• Environment care must be taken to dispose off the
used battery. It is always recommended to hand over
the same to the Authorised battery / Bajaj dealer for
proper disposal of the same.
• When battery is found discharged, it is advised to get
it charged immediately.
Remove spark plugs by using plug spanner.
Clean the spark plugs.
Adjust the gaps if incorrect by bending outer
electrode carefully.
Spark Plug Gap
: 0.6~0.7 mm.
Spark Plug Make
: BOSCH (2 Nos.) Or
CHAMPION (2 Nos.)
18
General Maintenance Information
Monsoon Care :
Front Brake Fluid Level
•
Front brake fluid master cylinder reservoir is located
near RH switch on handle bar.
•
To check oil level, keep the vehicle on Centre stand
with handle bar in straight ahead position.
•
Always ensure that brake fluid level is above ‘MIN’
mark given on inspection window.
•
Use only DOT 3 or DOT 4 brake fluid (from sealed
container) to top up if required.
It is advisable that brake fluid should be replenished at
evert 30,000 Kms or once in two years which ever
occurs earlier.
19
•
It is suggested to customer to take appropriate care
in area of heavy monsoon or high rainfall area. The
appropriate surface preventive coat to avoid rusting /
poor surface finish on account of adverse
atmospheric conditions.
•
Vehicle cleaning to be done with soft & clean wet
cloth to avoid scratches on painted parts.
•
Clean & lubricate all the important parts as detailed
in a periodic maintenance chart.
•
Do not apply direct water jet on painted, electrical /
electronic parts.
•
Do not obstruct engine cooling by adding mud
protection sheet from front.
Daily Safety Checks
Before riding the motorcycle be sure to check the
following items. Please give proper importance to these
checks and perform all of them before riding the
motorcycle. If any irregularities are found during these
checks, refer to the Maintenance chapter and see
Authorised Dealer / Service center 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 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.
What to check
Check for
Brakes
1. Correct pedal play (20~25 mm).
2. Brake lining wear indicator within
‘USABLE RANGE’.
3. No dragging.
Drive chain
1. Proper slack (25~30 mm).
2. Adequate lubrication.
Lighting
Operation of all lights.
Horn
Correct functions.
Steering
1. Smoothness.
2. No restriction of movement.
3. Not Loose / Tight.
Clutch
1. Correct lever play. (2 to 3 mm).
2. Smooth operation of lever.
Side and
Centre Stand
Return to their fully up position.
Tyres
1. Correct pressure.
2. Adequate tread depth.
3. No cracks or cuts.
Mirrors
Correct position.
20
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. Make sure that the
storage area is well ventilated and free from any
source of flames or spark.
•
Fill 10% excess air pressure in both wheels.
21
** 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 (applicable to certain
models).
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.
Periodic Maintenance / Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation
No.
1.
Servicing
Kms
1st
2nd
750
5000 10000 15000 20000 25000 30000
3rd
4th
5th
6th
7th
3
3
3
3
3
3
3
1st - 750 Kms / 30 Days
2nd onward @5000 Kms
Servicing
2.
Engine idling speed / CO%
A
A
A
A
A
A
A
A
3.
Valve tappet clearance
A
A
A
A
A
A
A
A
4.
Engine oil* - Bajaj DTS-i 10000
R
R
R
R
R
Replace at 10000 Kms*
5.
Oil strainer / Centrifugal filter
CL
CL
CL
CL
CL
Clean at 10000 Kms
6.
Engine oil filter / Paper oil filter
R
R
R
R
R
Replace at every
oil change
C, A, R
C, A
C, A
C, A
R
C, A
C, A
R
Replace at every 15000 Kms
CL, R
CL
CL
CL
R
CL
CL
R
Clean at every 5000 Kms
Replace at every 15000 Kms
CL
CL
CL
CL
CL
CL
7.
Spark plugs functioning / Gap (If applicable)
8.
Air cleaner element Clean / Replace
V
V
9.
Air filter cover ‘O’ Ring
R
10.
Fuel cock sediment bowl cleaning
CL
R
11.
Carburettor float bowl cleaning
12.
Carburettor rubber duct
C, R
CL
CL
13.
Fuel pipes
C, R
C
C
C
C
R
14.
Battery electrolyte level
C, A
C, A
C, A
C, A
C, A
C, A
C
C
C
Replace at every 20000 Kms
CL
C
R
CL
Clean at every 10000 Kms
C
Replace at every 20000 kms
C
C
Replace at every 20000 kms
C, A
C, A
C
15.
Clutch lever free play
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
16.
Throttle grip play
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
*For any other brand of oil (SAE 20W50 API ‘SL’ JASO MA grade) drain interval is 5000 kms.
V
V
More frequent cleaning may be required when driving in dusty condition.
22
Periodic Maintenance / Lubrication Chart
Sr. Operation
No.
RECOMMENDED FREQUENCY
Servicing
Kms
1st
2nd
750
5000 10000 15000 20000 25000 30000
C, A
C, A
C, A
C, A
C, A
C, A
C, A
CL
CL
CL, R
CL
CL
CL, R
Replace at every 15000 kms
C, A
C, A
C, A
C, A
C, A
R
Replace at every 30000 kms
17.
Rear brake pedal free play
C, A
18.
Brake lining or pad wear
CL, R
19.
Brake fluid level / Top up / Replace (If applicable)
C, A, R
C, A
3rd
4th
5th
6th
7th
20.
Master cylinder cup and dust seal (If applicable)
R
R
Replace at every 30000 kms
21.
Caliper piston seal and dust seal (If applicable)
R
R
Replace at every 30000 kms
C, R
Replace at every 30000 kms
22.
Brake hose pipe (If applicable)
23.
Brake cam & pedal pivot pin
24.
Steering play
25.
Steering stem bearing
C, R
L
C, A
L
C, A
C, A
C, L, R
C, A
C, A
C,L,R
L
C, A
C, A
C,L,R
C, A
C,L,R
26.
All fasteners tightness
C, T
C, T
C, T
C, T
C, T
C, T
C, T
C, T
27.
Rear sprocket fasteners
C, T
C, T
C, T
C, T
C, T
C, T
C, T
C, T
28.
Rear wheel rubber shock damper
C, R
29.
Silencer drain hole cleaning
CL
30.
Cylinder head de-carbonising, valve lapping &
Replace valve oil seals
CL
31.
Engine air breather tube
32.
Drive chain slackness adjustment & lubrication
23
R
C, A, L
C, R
CL
CL
CL
C, R
CL
CL
CL
C, R
CL
Replace at every 10000 kms
CL
Clean at every 5000 Kms
CL
Clean at every 15000 Kms
R
C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L C,A,L
Replace at every 20000 Kms
Lubricate at every 500 kms.
A- slackness whenever reqd.
Periodic Maintenance / Lubrication Chart
Sr. Operation
No.
33.
Drive chain ‘O’ ring type (If applicable)
34.
Drive chain remove, clean, insp. & lubricate (O/H)
35.
Drive chain link lock
RECOMMENDED FREQUENCY
Servicing
Kms
1st
2nd
750
5000 10000 15000 20000 25000 30000
L
3rd
4th
5th
6th
7th
At every 500 Kms
CL, L
CL, L
CL, L
CL, L
R
R
R
R
Replace at every 10000 Kms
C, R
At every 5000 kms i.e. at
every service after 2nd service
36.
Wheel bearing (for non sealed bearings only)
C, L
37.
Tyre tread wear (replace if worn out till TWI limit)
C, R
38.
Front fork oil
C, L
C, R
C, R
R
C, R
At every 10000 Kms
At every 20000 Kms
C, R
R
Replace at every 20000 Kms
39.
Auto choke, Thermal sensor (If applicable)
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
At every 5000 Kms
40.
TPS (If applicable)
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
At every 5000 Kms
41.
RSA - Check gas pressure (If applicable)
C, A
42.
Starter clutch bush kit (If applicable)
CL, R
43.
Clutch switch cleaning (If applicable)
CL
44.
General lubrication
L
45.
Swing arm pivot pin lubrication
L
46.
Engine foundation silent bush (If applicable)
R
C, A
At every 20000 Kms.
CL, R
CL
L
L
L
CL, R
CL
L
L
CL
L
L
L
R
Lubricate at every 20000 Kms
R
Replace at every 15000 Kms
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note : Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to
customer.
24
Schedule for Periodic Part Replacement
Bajaj Auto recommends the following periodic parts replacement for optimum performance of your vehicle as per the
schedule.
Type of Service
Kms limit
Days
1st Free
500 ~ 750
30 - 45
2nd Free
4500 ~ 5000
240 Days
Item Description
Engine Oil
Engine Oil Filter / Paper Oil Filter
NIL
Engine Oil
3rd Free
9500 ~ 10000
240 Days
1st Paid
25
14500 ~ 15000
1000 ml
1
NIL
1000 ml
Engine Oil Filter / Paper Oil Filter
1
Steering Stem Bearing Cone Set (If Required)
1
Rear Wheel Rubber Damper (If Required)
1
Drive Chain Link Lock
Spark Plug
Air Cleaner Element
120 Days
from the
last service
Qty
1
2 Nos.
Brake Pad / Shoe (If Required)
1
Valve Oil Seals
4
Cylinder Head Gasket
1
Starter Clutch Bush Kit (If applicable)
1
Engine foundation silent bush (If applicable)
2
Schedule for Periodic Part Replacement
Type of Service
Kms limit
Days
Item Description
Engine Oil
2nd Paid
19500 ~ 20000
120 Days
from last
service
24500 ~ 25000
1
Air Filter Cover ‘O’ Ring
1
Carburettor Rubber Duct
1
Fuel Pipes
1
Steering Stem Bearing Cone Set (If Required)
1
Rear Wheel Rubber Dampers (If Required)
1
Engine Air Breather Tube
1
Drive Chain Link Lock
1
NIL
Engine Oil
4th Paid
29500 ~ 30000
1000 ml
Engine Oil Filter / Paper Oil Filter
Front Fork Oil
3rd Paid
Qty
Engine Oil Filter / Paper Oil Filter
Spark Plugs
300 ml
NIL
1000 ml
1
2 Nos.
26
Schedule for Periodic Part Replacement
Type of Service
Kms limit
Days
Item Description
Air Cleaner Element
1
Brake Pad / Shoe
1
Brake Fluid (If applicable)
4th Paid
27
29500 ~ 30000
120 Days
from last
service
Qty
75 ml
Brake Hose Pipe (If applicable)
1
Master Cylinder Cup & Dust Seal (If applicable)
1
Caliper Piston Seal & Dust Seal (If applicable)
1
Steering Stem Bearing Cone Set (If Required)
1
Rear Wheel Rubber Damper (If Required)
1
Drive chain Lock
1
Valve Oil Seals
4
Cylinder Head Gasket
1
Starter Clutch Bush Kit (If applicable)
1
Engine foundation silent bush (If applicable)
2
Warranty : Scopes and Limits
Bajaj Auto Limited gives the following warranty in
respect of the “Bajaj Pulsar 135 LS” motorcycle
manufactured by them.
Every possible care and precaution has been taken to
ensure quality in respect of the material & workmanship
in the vehicles manufactured by us. Bajaj Auto Limited
will repair or replace at their Authorised Workshops, free
of charge, part or parts there of as may be found, on
examination, to have manufacturing defect within a
period of 2 Years or 30,000 Kms., whichever occurs
earlier from the date of sale subject to fulfillment of
condition stipulated in part A, B & C given here under
Warranty is applicable for only first owner of vehicle.
Part A:
Warranty claims in respect of such items like shock
absorbers, speedometers etc. though claimed through
us, are subject to the acceptance of the respective
manufacturers. In all such cases the decision of the
respective manufacturer will be final and binding.
Proprietory parts like tyres, tubes, battery and spark
plugs are warranted by their respective manufacturers
(Only one year warranty from the date of purchase/as
applicable) and should be claimed on them directly by
the customer. Bajaj Auto Limited shall not be liable in
any manner to replace them though their dealers will
29
give full assistance in preferring such claims on
respective manufacturers.
Bajaj Auto Limited undertake no liability in the matter of
consequential loss or damage caused due to the failure
of the parts. Delay, if any, at the repairing workshop in
carrying out repair to vehicle shall not be a ground for
extending the warranty period, nor shall it give any right
to the customer for claiming any compensation for
damages.
Bajaj Auto Limited reserves the right either to repair or
replace the defective parts.
Where a defective part can be replaced by part/s of
alternative brand/s, which are normally used by Bajaj
Auto Limited in the course of manufacture, Bajaj Auto
Limited reserves the right to carry out the replacement
by a part or parts of any such alternative brand/s.
This warranty and any claim arising there from is subject
to Pune jurisdiction only.
Part B:
No claim for exchange or repair can be considered
unless the customer :
a. Ensures that immediately upon detection of the
defect, he approaches any nearest Authorised Bajaj
Vehicle Dealers and Recommended Authorised
Service Centers with the concerned vehicle and
Warranty : Scopes and Limits
enables him to remove and despatch the part/parts
attributing to the manufacturing defect to the
Company.
b. Produces the Owner's Manual, in original, to enable
that dealer to verify the details.
It must be expressly understood that claims forwarded
directly to us by the owner / customers will not be
entertained at all and such defective part/parts thus
forwarded by them will lie at our factory at their own
risk, and this warranty shall not be enforceable.
To avail the benefits of warranty, the following are
mandatory •
Availing of Initial 3 Free Services without lapse.
•
Availing 4 paid services at every 5000 kms. or 120
days whichever occurs first without any lapse.
•
Availing of all above services at the Authorised
Vehicle Dealers & Recommended Authorised Service
Centers.
•
Maintaining all service records duly signed and
stamped by dealers.
•
Usage of only recommended engine
frequency - “Bajaj DTS-i 10000” for
10000 Kms (or equivalent grade of
SL + JASO MA for 5,000 Kms. drain
oil at specified
drain interval of
SAE20W50 API
interval).
Part C :
Further this warranty is NOT applicable to :
1. Normal maintenance operations like brake & clutch
adjustments, cleaning of fuel system, engine tune-up
or such other adjustments.
2. Parts subjected to normal wear & tear like Clutch
Plates, Brake Shoes, Chain, Sprockets, Fork Oil
Seal, Spark Plug, Control Cables, Brake Pad..
3. Replacement of electrical items like self-start’s wear
and tear items (if fitted), bulbs & rubber components
like grommets, ‘O’ rings, bellows as well as filters,
packings, gaskets, fasteners etc.
4. Painted parts. Only blistering or peeling off of paint
film are covered under warranty. Any defect arising
out of external damages or due to usage of
protective covers / additional protective coatings
adverse atmospheric condition etc. is not allow like
under warranty.
5. All consumables like Engine oil, Fork oil, Brake Oil,
Grease etc. are chargeable to customer.
6. Any defect arising due to above consumables not
changed as per scheduled or if used other than the
recommended one.
30
Warranty : Scopes and Limits
7.
All chrome plated parts are prone to rust or
corrosion in coastal area or in acidic environment or
due to neglected cleaning etc. However chrome film
peeling is covered under warranty in general
atmospheric conditions. Blue/ Yellow colouration of
silencer near exhaust port is permissible and hence
not covered under warranty.
8.
Oxidation of unpainted/painted crankcase, cylinder
block, cylinder head etc. in acidic environment or in
a coastal area.
9.
Valve lapping (De-carbonizing) required to be done
at 15,000 kms, which is normal servicing
requirement.
10.
Parts of the vehicle that have been subjected to
misuse, accident, negligent treatment OR which
have been used in conjunction with parts & an
equipment not manufactured or recommended for
use by Bajaj Auto Limited, if in the sole judgement
of Bajaj Auto Limited, such use prematurely affects
the performance and reliability of the vehicle.
11.
31
Parts of the vehicle that have been altered and
modified or replaced in unauthorised 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.
12.
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.
13.
Vehicles used for any competition or race and/or for
attempting to set up any kind of record.
14.
Any failure arising due to use of adulterated or bad
quality fuel.
Parts affected due to bad fuel quality are not
covered Under warranty.
Bajaj Auto Limited reserves the right to make any
changes in design or to add any improvements on the
vehicle at any time without incurring any obligation to
install the same on a vehicle previously supplied and
sold. Also, the conditions of this warranty are subject to
alteration without any notice.
This warranty is the entire written warranty given by Bajaj
Auto Limited for “Bajaj Pulsar 135 LS” motorcycle’ and
no other person, including the Bajaj dealer or its or his
agent or employee is authorised to extend or enlarge this
warranty.
Service Record Chart
Free/Paid Services
* Kms. / Days
Range
1st Free Service **Oil change
500~750
or 30~45
days
2nd Free Service
4500~5000
or
240 days
3rd Free Service **Oil change
9500~10000
or
240 days
1st Paid Service
14500~15000
or 120 days
from last service
2nd Paid Service **Oil change
19500~20000
or 120 days
from last service
3rd Paid Service
24500~25000
or 120 days
from last service
4th Paid Service **Oil change
29500~30000
or 120 days
from last service
* Whichever occurs earlier.
Job Card No.
K.M. Reading
Date
CO %
Servicing Dealer (Sign & Stamp)
**Use ‘Bajaj DTS-i 10000’ engine oil for 10000 kms drain interval or SAE 20W50 API ‘SL’ JASO MA grade for 5000 kms drain interval.
(Any oil change during Free/Paid service are chargeable to customer).
32
Use only Bajaj Genuine Parts
For optimum performance
of vehicle
For prolonged life of
components & vehicle
Always
For economical
maintenance cost
Insist
on
For rider's safety
Genuinity Test
Scratch Hologram to find ‘Genuine’
Patrial transparent Hologram
Genuine
Bajaj Auto Limited
Akurdi Pune 411 035 India
03100802
CLUTCH BOX
P0001
PACKAGING MONTH
MAY 2003
QTY. 1 NO.
M.R.P. (Incl. of All Taxes) in Rs. for Qty. packed
IN ASSAM, KARNATAKA, MANIPUR, M.P.,
NAGALAND, U.P.,
& UTTARANCHAL IN OTHER STATES
57.43
55.58
Golden Hologram
Price Label
parts