Bajaj Pulsar 200 NS motorcycle User guide

Table of Contents

Description

1. Technical Specifications

2. Identification Data

3. Location of Parts

4. Steering cum Ignition lock

5. Fuel Tank Cap / Fuel Tap

6. Speedometer Details

7. Speedometer Setting

8. Control Switches

9. Rear seat / Tool kit

10. Front Seat / Battery

11. Fitment of Front & Rear Seat

12. Removal & Fitment of Side Cover LH & RH 17

13. Daily Safety Checks 18

12

14

15

16

14. How to ride your Bike

15. Safe Riding Tips

16. Engine Oil

17. Wheels - Tube less Tyre

18. Battery

19. Engine Cooling System / Coolant

20. Periodic Maintenance Information

21. Brake Fluid

22. Periodic Maintenance & Lubrication Chart

26. Non Use Maintenance

29

31

32

19

23

24

25

26

27

7

8

4

6

10

1

3

Safety and Warning information :

Warning : This indicates that a potential hazard or injury to you or other persons & to the vehicle can happen, if advice provided is not followed.

Caution : This indicates that a potential hazard which could result in vehicle damage, if advice provided is not followed.

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

& to do modifications on the vehicle, parts or accessories as may be convenient and necessary.

Technical Specifications

Engine

Bore x Stroke

: 4 Stroke, Single Cyl.

: 72.0 mm x 49.0 mm

Engine Displacement : 199.5 cc

Compression Ratio : 11 : 1

Idling Speed

Max. Net Power

Max. Net Torque

Ignition System

: 1350 ~ 1450 RPM

: 23.5 PS at 9500 RPM

: 18.3 Nm at 8000 RPM

: DC

Spark Plug

Spark Plug Gap

: 3 Nos

: 0.7 ~ 0.8 mm

Transmission : 6 speed constant mesh

Gear Shifting Pattern : 1 Down 5 Up

Engine Lubrication : Pressurized oil supply

Engine Cooling : Liquid cooling

Starting Aid

Front Brake

Rear Brake

: Electric starter

: Hydraulic Disc type

: Hydraulic Disc type

1

Fuel Tank Capacity

Full : 12 liters

Usable Reserve : 2.4 liters

Unusable Reserve : 0.2 liters

Dimensions

Length

Width

:

: 2017 mm

: 804 mm

Height

Wheel base

: 1195 mm

: 1363 mm

Ground clearance : 167 mm

Tyre Size

Front

Rear

Tyre Pressure

Front

Rear (Solo)

Rear (with pillion)

: 100/80-17,52P tubeless

: 130/70-17,61P tubeless

Technical Specifications

Electrical System

Head Lamp

: 12 Volts DC

: H4, 55/60W

Position Lamp

Tail /Stop Lamp

: 3W (2 nos.)

: LED type

Side Indicator lamp

: 10W

Neutral Indicator

Hi Beam Indicator

: Green LED

: Blue LED

Turn Signal Indicator : Green LED

Side Stand Indicator : LED

Speedometer Lamp : LED

Rear No. Plate Lamp : 3W

Horn

Battery

: 12V DC

: 12V - 8 Ah VRLA

Vehicle Kerb Weight

: 145 kg.

Gross Vehicle Weight : 275 kg.

(Including rider & pillion)

Max. Speed

: 136 km/hr.

Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without any notice.

2

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.

Engine Number Location

On LH Side Crankcase Near Gear

Change Lever (Alpha-Numeric - 11 Digits)

Frame Number Location

On RH Side of Steering Tube

(Alpha-Numeric - 17 Digits)

On LH Side of Steering Tube

(Alpha-Numeric - 17 Digits)

[for applicable countries)

3

Location of Parts

Digital

Speedometer

Fuel Tank Cap

Manual Choke

Lever

Clutch Lever

Front Fork

Disc

Brake

Gear Change

Lever

4

Side

Stand

OFF ON

LED

Tail

Lamp

Pillion

Foot

Rest

Location of Parts

Grab Handle Pillion Seat Rider Seat

Rear

Number

Plate

Nitrox Rear

Shock Absorber

Front Brake Lever

MAX

MIN

Coolant

Level

Indicator

Coolant

Tank Cap

Rear Disc Brake

Rear Brake

Pedal

Paper oil

Filter

5

Radiator

Steering cum Ignition Lock

Steering cum Ignition Lock :

It has three positions.

LOCK: Steering locked. Ignition OFF.

OFF: Steering unlock. Ignition OFF.

ON: Steering unlock. Ignition ON.

6

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

Steering lock can be done on left side only.

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’ & ‘Rear

Seat’.

Fuel Tank Cap / Fuel Tap

Fuel Tap

Fuel Tank Cap

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 place.

Fuel Tap

Fuel tap 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.

7

Speedometer Details

4

5

1

2

3

6

7

10

9

Speedometer display will work when, only both

Ignition switch & kill switch are in ‘ON’ position.

1. Fuel Level Indicator: It shows fuel level in fuel tank.

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

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

LH or RH will flash.

4. Neutral Indicator: When the transmission is in

Neutral, Neutral indicator will glow.

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

8

8

6. Side Stand Indicator : When Side stand is ‘ON’, the

Side stand indicator will glow.

7. Bajaj Logo : Bajaj logo flying ‘B’ continuously glows.

8. Mode Button : Mode button used for changing the mode while selecting & setting Trip1, Trip2, ODO,

Clock & Service reminder.

9. Set Button : Set button used for setting Clock &

Service reminder.

10. Reserve/Engine Over Rev Indicator : It glows continuously when petrol level in tank reaches reserve level. It also blinks when engine RPM crosses 10,000 RPM.

Speedometer Details

11

17

18

12

15

13

14

16

11. Service Reminder ( ): ‘Spanner’ symbol glows when ODO meter reading reaches set Kms. for service. This Icon will flash at -

st nd

1 : 450 km 2 : 4950 km, rd th

3 : 9950 km, 4 : 14950 km

and subsequently at each 5000 kms. Icon will continue to glow till it is reset. This icon is to be

reset after service is carried out.

12. Low Oil Pressure Indicator ( ) : It blinks when engine oil pressure is low.

13. Speedometer: Vehicle speed will be displayed in digital form in Km / Hr.

9

14. Odometer : The Odometer shows the total distance that the vehicle has covered. Odometer can't be reset to ‘Zero’.

15. Digital Clock : It indicates time in HR : M (AM/PM)

16. Coolant Temperature Indicator ( ) : It blinks

0 when engine coolant Temperature is more than 115 centigrade.

17. Low Battery Indicator : It indicates battery needs charging.

18. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero.

Speedometer Setting

TRIP 1/2

Mode M

S Set

1. Trip Meter Reset :

• Mode & Set push button is provided for selecting & resetting ‘ODO/TRIP1/TRIP2’. LHS part of speedo console.

1. Press 'Mode' button for less than 2 sec.

2.

Press 'Mode' button for more than 15 sec.

2. Service Reminder Reset ( ) :

• ‘Spanner’ symbol glows when ODO meter reading reached to set Kms.

Mode changes from

‘ODO/TRIP1/TRIP2’

Selected mode

‘TRIP1/TRIP2’ will get reset.

Other TRIP mode will continue updating.

1. Press mode push button for less than 2 sec. & select Trip2.

2.

Press mode & set button for more than 5 sec.

Continuously.

Trip2 Mode selected

Service reminder icon will be reset.

10

Note : Engine & motorcycle speed should be zero.

Speedometer Setting

Mode M

S Set

TRIP 1/2

3. Clock Reset :

• Digital clock indicates time in HR & MM separated by colon ‘:’

• It is a 12 hour clock.

• Initially ‘:’ will be blinking

• Clock setting is possible in TRIP 1 mode only.

11

1. Press 'Mode' push button for less than 2 sec.

TRIP1 Mode selected

2. Press 'Mode' & 'Set' push button together for more than 2 sec.

‘:’ stops blinking

Digits start blinking

3.

Press 'Mode' button for less than 1 sec.

4.

Press 'Set' button for less than 1 sec.

5.

Press 'Mode' & 'Set' button together for more than 2 sec.

Hour digits will increase by one.

Minute digits will increase. If Mode/Set button is pressed continuously then digits will stop blinking.

Set value will be saved

Exit clock setting mode

Digits stop blinking

‘:’ start blinking

6.

Clock set 'Mode' is selected & no editing is carried out for more than 5 sec.

or

Vehicle is started.

Auto exit without saving set value.

Control Switches

A

C

B

D

Left Handle Bar Switches

A. High/Low Switch : When headlight is ON,

High or Low beam can be selected with this 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 pushed to Left ( ) or Right ( ) respective indicator will start blinking, to exit push the knob in & release.

12

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.

Control Switches

E

G

F

F. Starter Button :

Starter button operates the electric starter when clutch lever is depressed with transmission in any gear.

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.

Right Handle Bar Switches

E. Head Light Switch : It has 3 positions.

: All lamps 'OFF'.

: With engine running, Tail lamp,

Meter lamp and Pilot lamp/s ‘ON’.

: With engine running, Head lamp,

Pilot lamp/s, Tail lamp and Meter lamps ‘ON’.

13

Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position.

CAUTION : While starting ensure that engine kill switch is in ON ( ) position.

Engine will not start if the kill switch is in OFF position

Rear Seat / Tool Kit

A

Removal of Rear Seat

• Insert Key into lock (A)

• Turn the key clock wise.

• Pull front end of ‘Rear seat’

• Take out ‘Rear seat’

Tool Kit

14

Tool Kit Location

• It is located below the ‘Rear seat’.

• 2 rubber straps are provided to hold the tool kit.

CAUTION : Always ensure rubber strap is fitted for securing tool kit.

Front Seat / Battery

B

Removal of Front Seat

• First remove ‘Rear seat’.

• Remove ‘Front seat’ mounting bolts (B).

• Pull back rear end of ‘Front seat’.

• Take out ‘Front seat’.

Battery

• It is located below ‘Front seat’.

Battery details are given in ‘Battery

Maintenance’ page no. 26.

15

Fitment of Front & Rear Seat

Front seat lug & bracket

C

A

B

D

G

E

F

H

Fitment of ‘Front Seat’

• Match the lugs of ‘Front seat’ (A) with chassis bracket (B).

• Push ‘Front seat’ toward petrol tank.

• Match ‘Front seat’ rear brackets (C) with the holes provided on chassis.

• Tighten the bolts (D).

Fitment of ‘Rear Seat’

• First make sure ‘Front seat’ is fitted properly.

• Place ‘Rear seat’ in fitment location.

• Insert bracket (E) of seat into hook (F).

• Match the rod of ‘Front seat’ (G) with seat lock (H).

• Press front portion of seat.

16

Removal & Fitment of Side Cover LH / RH

A

D

C

F

B

E

Removal of Side Cover LH or RH

• Remove pillion & rider seat.

• Remove screw (A) upper & (B) lower of side cover mounting.

• Pull front portion of ‘Side Cover’ to release its lug from hole (C) provided on ‘Fuel Tank’.

• Pull rear portion of ‘Side Cover’ to release its Lug (E) from hole (F) provided on

‘Chassis’.

CAUTION : Remove cover as described above, Otherwise the lugs may break.

17

Fitment of Side Cover LH or RH

• Match Lug (D) provided on front portion of

‘Side Cover’ with hole (C) provided on

‘Chassis’ and press ‘Side Cover’ inside.

• Match Lug (E) provided on rear portion of

‘Side Cover’ with hole (F) provided on

‘Chassis’ and press ‘Side Cover’ inside.

• Tighten the upper (A) & lower (B) screw with screw driver.

• Fit pillion & rider seat.

CAUTION : Fit cover as described above to ensure proper fitment.

Daily Safety Checks

Before riding motorcycle be sure to check following items. Please give proper importance to these checks and perform all of them before riding motorcycle.

If any irregularities are found during these checks, refer to the Maintenance chapter & 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.

• Enough fuel for planned distance of journey. No fuel leakage in fuel lines.

• Engine oil level (between upper and lower level mark)

• Throttle cable play of 2 ~ 3 mm. Smooth operation and positive return to closed position,

• Brake Fluid level above MIN mark provided on reservior, applicable to disc brake vehicle.

• Drive Chain slack of 25 to 35 mm adequately lubricated.

• Function of all lights & horn

• Clutch lever play - 2 to 3 mm

• Check Coolant level between MIN and

MAX mark in coolant reservoir tank.

• Smooth steering movement without restriction.

• Side stand return to its retracted position.

• Correct inflation pressure in both tyres

Adequate tyre tread depth - no cracks / cuts.

• Correct rear viewing span adjustment of mirror.

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How to Ride Your Bike

1. Starting The Engine :

• Turn the fuel tap knob to ‘ON’ or ‘RES’ position.

• Turn ignition switch key to ‘ON’ position.

• Keep kill switch in ‘ON’ position.

• Confirm that transmission is in neutral / press the clutch lever.

• If the engine is cold or when starting for first time, use manual choke for quick starting. Choke lever is located on LH side of carburettor.

• Keep throttle completely closed, press starter button,

• Release starter button as soon as engine starts.

• When the engine is warmed up enough to idle without using choke, return the manual choke to OFF position.

Note : Do not let the engine idle longer than 3

minutes otherwise it will overheat.

Caution : Do not operate the starter continuously for more than 5 seconds otherwise battery would get discharged.

Wait 15 sec. between each operation of the starter which will facilitate battery to recover.

Note : The motorcycle is equipped with a starter

lockout switch. This switch ensures that engine does not start if the transmission is in gear.

However, the engine can be started in any gear if the clutch lever is pressed.

Note : Incase of battery discharged condition,

vehicle can be started by pushing it.

19

2. 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.

3. Moving Off :

• Check that side stand is up / retracted.

• Depress the clutch lever.

• Shift into 1 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 prevent it from stalling.

How to Ride Your Bike

Gear shifting Lever

2

N

1

3

4

5

6

Gear shifting pattern

Recommended Speed for Shifting Down

th th rd nd st

54 km/h

45 km/h

35 km/h

25 km/h

15 km/h

Warning : When shifting down to lower gear, do not shift at such high speed that engine rpm jumps excessively. This may cause engine damage, & rear wheel may skid. Downshifting should be done at speeds as recommended in table above.

20

4. Braking :

• Close the throttle completely, leaving the clutch engaged (except where shifting gears) so that the engine braking will help slow down the motorcycle.

• 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 avoid engine 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.

F o r e m e r g e n c y b r a k i n g , d i s r e g a r d downshifting, and concentrate on applying brakes as hard as possible without skidding.

5. Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

How to Ride Your Bike

6. Parking the Vehicle :

6.1 Parking using center stand.

• Center stand is available as accessories at dealership.

• Support the motorcycle on a firm level surface with the center stand.

6.2 Parking using side stand.

• Support the motorcycle on a firm level surface with the side stand.

• Lock the steering.

CAUTION : Do not park on a soft or steeply inclined surface or the motorcycle may fall over.

7. Running IN

Proper running-in is important for better life & trouble free performance of the vehicle.

• During first 2000 kms running-in period do not exceed following speed limits.

Kms

0 - 1000

1st 2nd 3rd 4th 5th 6th

10 18 24 32 40 48

1000 - 2000 16 24 30 38 46 54

• Always keep the speed below the limits mentioned in the table.

• Do not rev the engine excessively.

• Do not start moving or rev 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.

21

How to Ride Your Bike

Fuel Saving Tips :

A well maintained vehicle and good driving can contribute a lot to the saving of feul.

Following are a few simple fuel saving tips.

Good Riding Habits :

• Ride smoothly and steadily at a reasonable speed.

• Avoid harsh braking.

• Change the gear judiciously according to the speed and load 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.

How to check mileage (Fuel efficiency)

Best way to calculate mileage is by following the full tank to full tank method.

• Fill way tank full up to small mouth (brim).

• Run the bike for say 100 km.

• Fill the tank full again in same fuel filling station, preferably from same fuel dispenser.

• Divide kilometers run / fuel quantity filled.

22

Ensure following maintenance points to get optimum performance from your bike.

Fuel Check fuel lines & connections for leakage.

Spark Plugs Inspect and clean spark plugs.

Adjust electrode gap. Replace spark plugs as per P.M. Chart.

Air Filter Clean the air filter element periodically. Replace as per

Periodic Maintenance Chart.

Engine Oil Check engine oil level. Always use recommended grade and quantity.

Brakes Ensure that the brakes are not dragging / binding.

Clutch

Tyre Air

Ensure correct clutch lever play.

Always maintain recommended

Pressure tyre pressure.

Carburettor Clean & adjust the carburettor.

Adjust idling speed.

Safe Riding Tips

Safe Riding Tips

• Always wear Helmet while riding. Your helmet should conform to appropriate Safety standards.

• T h o r o u g h l y r e a d t h e instructions given in this manual and follow them carefully.

• Avoid unnecessary accessories for the safety of both rider and other motorists.

• Get familiar with and follow traffic rules & 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 & rear brakes simultaneously. Applying only one brake may cause the rider 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 long life of the vehicle.

• During monsoon drive the vehicle more cautiously.

Remember vehicles skid more easily during light showers.

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• Drive cautiously. Start early & reach your destination safely.

• 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 riding to avoid entangling in wheel or other objects on road.

• Always concentrate on Safe riding.

Rainy Season Care :

• It is suggested to customer to take appropriate care in area of high rainfall area. Appropriate surface preventive coat to avoid rusting 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.

Engine Oil

A

C

A : Oil Filler

Cap

B : Oil Level

Window

B

D

Engine Oil Level Checking :

• Check engine oil level every day in the morning. Park vehicle perpendicular to the ground on level surface as mentioned in page no. 21 (6.1)

• Check oil level through oil level window

‘B’.

• Always maintain engine oil level between upper (C) and lower (D) mark provided on

Clutch cover RHs. Top up with specified grade of oil, if the oil level is below lower level mark.

Recommended Engine Oil:

Always insist on Bajaj Genuine

Engine Oil for optimum engine performance and warranty benefits.

It is a specially formulated oil for vehicles with DTS-i engines.

Model Recommended Grade

Engine oil

Pulsar Bajaj DTS-i

200 NS 10000

SAE 20W50 API ‘SL’, or JASO ‘MA’ Grade

24

st

• Engine oil replacement frequency : 1 service & then every 10,000 Km. In case any other engine oil of same specifications is used, the frequency of Oil replacement will be every 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.

• Contact your Dealer for proper disposal of drained engine oil.

Wheels - Tube Less Tyre

Wheel Puncture :

• Visit nearest known tubeless tyre repair shop to remove puncture.

• Remove puncture by Filler or Plug method only.

• Do not use patch method to remove puncture of tubeless tyre.

Front Wheel

CAUTION : Tubeless tyres are fitted in this motorcycle. The walls of the tyres in contact with the wheel rim should not be damaged in any way during fitment / removal of tyre. The tyre side walls in contact with wheel rim seals air.

Removing Front Wheel :

• Park vehicle perpendicular to the ground on level surface as mentioned in page no. 21

(6.1)

• Remove speed sensor cable from case meter assembly.

• Loosen front axle nut.

• Remove front wheel assembly from fork.

25

Tyre Pressure :

Keep appropriate tyre pressure as mentioned below to increase life of the tyre & for better fuel consumption.

Front

Pulsar 200 NS Rear (Solo)

25 PSI

28 PSI

Rear (with Pillion) 32 PSI

Note : Ensure tyres fitted comply with local

rules and regulations governing tyres.

Battery

• It is always recommended to hand over the same to an Authorised battery / Bajaj dealer for proper disposal.

• When low battery icon pops-up on speedometer display, it is advised to get in touch with Bajaj dealer & get it charged immediately.

Battery : 12V - 8 Ah VRLA

• Battery is located below front seat.

Battery Features :

• No topping-up is required

• Reduced self discharge, Enhances safety.

• No vent tube open to atmosphere hence no discharge of electrolyte through vent tube.

CAUTION : Do not drive / run vehicle in battery disconnected condition. It may lead to damage of electrical / electronic components.

• Environment care must be taken to dispose off the used battery.

26

How to keep battery healthy ?

• Switch ‘Off’ ignition when engine is not running.

• Get battery checked/ charged during periodic services.

• Do not press starter button for more than

5 sec. After 3 successive cranking, wait for

15-20 sec. for battery to recover.

•

Do not add extra electrical accessories such as - Remote, Bigger Horn, Musical brake light etc. This will reduce life of battery

• Disconnect battery +ve & -ve wires if vehicle is to be stored for more than 2 weeks. This avoids self discharge.

Engine Cooling System

C

A

B

Cap

Radiator

Cooling Fan

• Coolant is provided for cooling of engine.

• Water pump (A) in the engine circulates the coolant in cooling system.

• The pressure resulting from the heating of the cooling system is regulated by a valve in radiator cap (B).

• Heat expansion causes excess coolant to flow into compensating coolant tank (C).

• When the temperature falls, this surplus coolant is sucked back into the cooling system.

27

Warning : During motorcycle operation, the coolant gets very hot & is under pressure.

Do not remove the radiator cap, radiator h o s e o r o t h e r c o o l i n g s y s t e m components when the engine is hot.

Allow the engine & cooling system to cool down. In case of exposure to hot coolant, rinse immediately with lukewarm water.

Coolant

Reservoir cap

(for coolant top up)

MAX

MIN

Warning : Coolant is poisonous and is a health hazard.

Avoid skin, eye and clothing caontact with coolant. If it gets into your eyes, rinse immediately with water and contact a doctor.

Wash affected skin areas immediately with soap and water. If coolant is s w a l l o w e d , c o n t a c t a d o c t o r immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children

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Coolant Specifications :

Antifreeze ready mix (Recommended Brand-

Motul : Moto cool expert,

Castrol : Radicool

Total coolant quantity : 1000 ml. (750~780 ml in radiator & 220~230 ml expansion tank).

Coolant Top up

• Park vehicle perpendicular to the ground on level surface as mentioned in page no. 21

(6.1)

• Check coolant level in engine cold condition only.

• Ensure coolant level is between Min & Max mark.

• Always top up coolant through reservoir cap.

• Always replace coolant with recommended brand only. (Radicool from Castrol, Moto cool expert from Motul) or equivalent.

• Use nitrile rubber hand glows while draining

& topping up coolant.

• Do not top up coolant through radiator cap.

Where pre-mixed coolant is not available coolant concentrate and distilled water should be mixed separately in a clean jar in a proportion of 1:1

Periodic Maintenance Information

Spark Plug

• Remove spark plugs by using plug spanner.

• Clean the spark plugs.

• Adjust the gaps if incorrect by bending outer electrode carefully.

Spark Plug Gap

: 0.7 to 0.8 mm.

Spark Plug (2 Nos.) : RG-6HCC

(LH ‘A’ + RH ‘B’)

(1 No. )

: BOSCH - VR5NE

(Center ‘C’)

A C

Drive Chain Slackness

• Chain slackness will have to be adjusted whenever required.

• Std. Chain slackness 25 ~ 35 mm.

• Marking on chain adjusters should be identically positioned on both sides.

0.7 to

0.8 mm

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Periodic Maintenance Information

Drive

Chain

Cleaning

Drive

Chain

Lubrication

Drive chain must be cleaned & lubricated as per periodic maintenance schedule.

Drive Chain (O-ring type

)

• ‘O’ rings must always be kept wet for best performance hence lubricate every

500 Km.

• O-ring chain lubrication can easily be done by owners using Bajaj ‘Chain Lube

Spray Can’ available with Bajaj dealers, or equivalent. Ensure that the lubricant does not damage the rubber 'O' rings.

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Method of O-ring Chain Lubrication :

•

Park vehicle perpendicular to the ground on level surface as mentioned in page no. 21 (6.1). Clean the chain by using lint free cloth (If excessive mud / slush found approach Bajaj Service Center for proper cleaning)

• Shake the can vigorously by holding vertically upright till the noise of steel ball inside heard uniformly.

• Hold spray can at the back of rear sprocket with extension tube nose at 5~10 cm.

• Rotate the wheel in reverse direction & spray the lube on middle portion of the chain up to full length of the chain.

Brake Fluid

Front

Brake

Fluid

Reservior

Rear

Brake

Fluid

Reservior

Front & Rear Brake Fluid Level

• Front brake fluid reservior is located on RH side of Handle bar.

• Rear brake fluid reservior is located behind

RH pillion holder bracket.

• To check oil level, Park vehicle perpendicular to the ground on level surface as mentioned in page no. 21 (6.1) with handle bar in straight ahead condition

• Always ensure that brake fluid level is above

‘MIN’ mark given on inspection Window.

31

Brake Fluid Replacement

• Check & Adjust brake fluid level in every service.

• Change the brake fluid of the front & rear brake according to service schedule.

Use only DOT-3 ro DOT-4 brake fluid (from sealed container) for top up & replacement.

Periodic Maintenance & Lubrication Chart

Sr.

No.

1.

2.

Operation

Servicing with water wash

Idle speed / CO%

3.

Valve tappet clearance

4.

Engine oil (Bajaj DTSI 10000 oil)*

5.

Oil strainer (Bajaj DTSi 10000 oil)*

6.

Engine oil filter (Bajaj DTSi 10000 oil)*

7.

Spark plug gap

8.

Spark plug

9.

Air cleaner element***

10. Air filter cover ‘O’ ring

11. In line paper filter along with hose & clamps**

12. Fuel cock sediment bowl cleaning

13. Fuel cock-Paper filter element & seal**

14.

Servicing

Kms

1st

500

~

750

RECOMMENDED FREQUENCY

2nd

4500

~

5000

3rd

9500

~

10000

4th

14500

~

15000

5th

19500

~

20000

6th

24500

~

25000

7th

29500

~

30000

Subsequent

3 3 3 3 3 3 3

1st - 500~750 Kms / 30~45 days,2nd onward@5000Kms

C, A C, A C, A C, A C, A C, A C, A C, A

C, A C, A C, A C, A C, A C, A C, A C, A

C, A R

Top-up

R

Top-up

R Top-up R Top-up @ every 5000 Kms.

Replace in 1st service & at every 10000 Kms

R

R

CL

R

CL

R

CL

R

CL

R

CL,A CL,A CL,A CL,A CL,A

R

CL, R CL CL CL

CL

R

R

R CL CL

CL

R Replace at every oil change

CL,A CL,A

R

Replace at every 20000kms

Replace at every 15000kms

R

R

R

R

R

CL CL CL CL CL CL

R

Replace at every 15000kms

Replace at every 15000kms

Replace at every 15000kms

32

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

15.

16.

17. Fuel pipes

18. Coolant level check in expansion tank**

19. Coolant in expansion tank**

20. Coolant hose damage/clamps/leakage**

21. Coolant hose damage/clamps/leakage**

22. Radiator fins**

23. Battery electrolyte level & specific gravity**

24. Battery connections

25. Clutch plate

26. Clutch play

27. Throttle play

28. Brake play

29. Brake lining or pad wear

30. Brake fluid level / top up**

Servicing

Kms

RECOMMENDED FREQUENCY

1st 2nd

500

~

750

4500

~

5000

3rd

9500

~

10000

4th

14500

~

15000

5th

19500

~

20000

6th

24500

~

25000

7th

29500

~

30000

C,R

C,A

R

C,R

R

C,A

C

C,T

C,R

C,A

C,A

C,A

C,R

C,A

C

C

C,A C,A C,A C,A C,A C,A C,A

C,A C,A C,A C,A C,A C,A C,A

C,A

C,R

C

C

C,T C,T C,T C,T C,T C,T

C,A

C,R

C

C

C,A

C,R

R

C

C,A

R

C

C

C,R

C,A

C

C

C,A

R

C

C,A

Subsequent

Replace at every 15000kms

C,A C,A C,A C,A C,A C,A At every service

Replacement at every 30000 Kms or 2 year (whichever occurs earlier)

C,R C,R C,R C,R C,R C,R Check & replace if required

Replacement at every 35000 Kms or 3 years (whichever occurs earlier)

C,A C,A C,A C,A C,A C,A

Check & replace if required

C,R C,R C,R Replace at every15000 Kms

C,A C,A C,A C,A C,A C,A Check & Top up if required in every service

33

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

31. Brake fluid

32. Front brake hose

33. Master cylinder piston kit

34. Caliper piston seal and Dust seal

35. Brake cam & pedal pivot pin**

36. Rear sprocket fasteners

37. Rear wheel rubber shock damper

38. Silencer drain hole cleaning

39. Engine compression pressure

40. Cylinder head de-carbonising

41. Engine air breather tube

42. Drive chain slackness

43. Drive chain lubrication on vehicle

4

4

. Drive chain link lock

45. Drive chain wear -- Remove & Lubricate

46. Drive chain ("O" ring design)**

47. Wheel bearing

CL

R

C,A

C,L

R

C,L

L

C,R

R

L

C,T

C,R

CL

C

R

R

R

Servicing

Kms

1st

500

~

750

RECOMMENDED FREQUENCY

2nd

4500

~

5000

3rd

9500

~

10000

4th

14500

~

15000

5th

19500

~

20000

6th

24500

~

25000

7th

29500

~

30000

R

R

R

Subsequent

L L L L L

R

L

C,T C,T C,T C,T C,T C,T C,T

C,R C,R

CL CL CL CL CL

C

C,R Check & replace if required

CL

C

CL

R

C,A C,A C,A C,A C,A C,A C,A

C,L

If required

Replace at 20000 Kms

R R R R R R

Whenever drive chain opened.

C,L C,L C,L C,L C,L C,L

Lubricate at every 500 km.(By customer)

C,R C,R C,R C,R C,R Check & replace if required

34

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

48. Tyre tread wear

49. Front fork oil

50. Front fork oil seal

51. Rr. Shock Absorber- Check gas pressure**

52. Wiring harness

53. Ignition switch contacts cleaning

54. Clutch switch & brake switch

(Horizontal base) contacts cleaning* *

55

. Clutch switch (Vertical base)**

Servicing

Kms

C,R

R

R

C,A

RECOMMENDED FREQUENCY

1st 2nd

500

~

750

4500

~

5000

4th

14500

~

15000

5th

19500

~

20000

6th

24500

~

25000

7th

29500

~

30000

Subsequent

3rd

9500

~

10000

C,R C,R C,R C,R C,R Check & replace if required

R

R

R

R

C,A

R Replace at every 10000kms

R Replace at every 10000kms

Not required for new design

(Filling from bottom)

C C C C

C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL

C,CL,L C,CL,L C,CL,L C,CL,L

Check & replace if required

56. Rear brake switch

57. Starter motor connections**

58. Starter relay connections**

C,R

C,A

C,T

C,T

C,R C,R C,R

C,A C,A C,A C,A C,A C,A C,A

C,T C,T C,T C,T C,T C,T

C,T C,T C,T C,T C,T C,T

59. HT coil connections

60. Oil pressure indicator check on console**

61. General lubrication

62. Main stand & side stand pin**

C,T

C

L

C,L

C

L

C,T C,T C,T C,T C,T C,T

C C C C C C

L L

C,L

L L

C,L

L L

C,L

35

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

63. Swing arm pivot pin (for non silent bush)**

64. Steering play

65

. Steering stem bearing

***

66. Cap steering bearing (Plastic)**

67. Step -Pillion LH & RH (Ball & Plate)**

68. All fasteners tightness

Servicing

Kms

L

C,A

C,CL,L,R

C,R

C,CL

C,T

RECOMMENDED FREQUENCY

1st 2nd

500

750

4500

5000

L

3rd

9500

~

10000

L

4th

14500

~

15000

L

5th

19500

~

20000

L

6th

24500

~

25000

L

7th

29500

~

30000

L

C,A C,A C,A C,A C,A C,A C,A

Subsequent

C,CL,L,R

C,R

C,CL,L,R

C,R

C,CL,L,R

Check & replace if required

C,R

C,CL C,CL C,CL C,CL C,CL C,CL

C,T C,T C,T C,T C,T C,T C,T

* It is strongly recommended to use only “Bajaj DTS-i 10000” Genuine engine oil. In case any other engine oil of same specifications is used, the frequency of Sr. No. 4, 5 & 6 will be every 5000 Kms.

** As applicable to model

*** More frequent cleaning may be required when riding in dusty condition.

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

Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.

36

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 nonuse 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 spark plug & put several drops of engine oil into the cylinder. Kick engine over slowly a few times to coat cylinder wall with oil & install spark plug.

• Set the vehicle on a box or a stand so that both 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.

• Cover entire vehicle neatly. Make sure that storage area is well ventilated & free from any source of flames or spark.

• Fill 10% excess air pressure in both wheels.

• Do not apply oil on front brake disc, to prevent rusting. If the front brake disc rusts during storage, do not attempt to clean it with soap water. The rust will go off automatically during first few application of brake.

** 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.

• A p p l y p e t r o l e u m j e l l y o n t e r m i n a l s .

(applicable to certain models).

Preparation for regular use after storage :

• Clean the vehicle

• Fit the battery after recharging.

• 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 proper tyre pressure.