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 13. Daily Safety Checks 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 23. Non Use Maintenance 1 3 5 8 9 10 12 14 16 17 18 19 20 21 25 26 27 28 29 30 32 33 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 : 4 Stroke, Single Cyl. Fuel Tank Capacity Bore x Stroke : 72.0 mm x 49.0 mm Full : 12 liters Usable Reserve : 2.4 liters Unusable Reserve : 0.2 liters Engine Displacement : 199.5 cc Compression Ratio : 11 : 1 Idling Speed : 1350 ~ 1450 RPM Dimensions : Pulsar NS Pulsar AS Max. Net Power : 23.5 PS at 9500 RPM Length : 2017 mm 2070 mm Max. Net Torque : 18.3 Nm at 8000 RPM Width : 804 mm 804 mm Ignition System : DC Height : 1195 mm 1205 mm Spark Plug : 3 Nos Wheel base : 1363 mm 1363 mm : 167 mm 167 mm Spark Plug Gap : 0.7 ~ 0.8 mm Ground clearance Transmission : 6 speed constant mesh Tyre Size Gear Shifting Pattern : 1 Down 5 Up Front : 100/80-17,52P tubeless Rear : 130/70-17,61P tubeless Engine Lubrication : Pressurized oil supply Engine Cooling : Liquid cooling : Electric starter Front : 1.75 kgf/cm2 (25 PSI) Starting Aid Rear (Solo) : 2.00 kgf/cm2 (28 PSI) Front Brake : Hydraulic Disc type Rear (with pillion) : 2.25 kgf/cm2 (32 PSI) Rear Brake : Hydraulic Disc type Tyre Pressure 1 Technical Specifications Electrical System Head Lamp Position Lamp Tail /Stop Lamp Side Indicator lamp Neutral Indicator Hi Beam Indicator Turn Signal Indicator Side Stand Indicator Speedometer Lamp Rear No. Plate Lamp Horn Battery : : : : : : : : : : : : : 12 Volts DC H4, 55/60W 3W (2 nos.) LED type 10W Green LED Blue LED Green LED LED LED 3W 12V DC 12V - 8 Ah VRLA Note : • All dimensions are under UNLADEN condition. • Above information is subject to change without any notice. Vehicle Kerb Weight : 145 kg.(For NS 200) 153 Kg.(For AS 200) Gross Vehicle Weight : 275 kg. (For NS 200) 283 kg. (For AS 200) (Including rider & pillion) Max. Speed : 136 km/hr. 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 (For NS 200) On RH Side of Steering Tube (Alpha-Numeric - 17 Digits) On LH Side of Steering Tube (Alpha-Numeric - 17 Digits) [for applicable countries) 3 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 ( For AS200) Below Pillion Seat (Alpha-Numeric - 17 Digits) 4 Location of Parts (Pulsar NS 200) Digital Speedometer Fuel Tank Cap OFF ON Manual Choke Lever Clutch Lever LED Tail Lamp Front Fork Pillion Foot Rest Disc Brake Side Stand Gear Change Lever 5 Location of Parts ( Pulsar NS 200) Grab Handle Pillion Seat Rider Seat Front Brake Lever MAX MIN Rear Number Plate Coolant Coolant Level Tank Cap Indicator Nitrox Rear Shock Absorber Rear Disc Brake Rear Brake Pedal Paper oil Filter 6 Radiator Location of Parts (Pulsar AS 200) Grab Handle Pillion Seat Rider Seat Front Brake Lever MAX. MIN. Rear Number Plate Coolant Coolant Level Tank Cap Indicator Nitrox Rear Shock Absorber Rear Disc Brake Rear Brake Pedal Paper oil Filter 7 Radiator Steering cum Ignition Lock 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. Steering cum Ignition Lock : It has three positions. LOCK: Steering locked. Ignition OFF. OFF: Steering unlock. Ignition OFF. To Unlock the Steering : To unlock steering, insert the key in steering cum ignition lock & turn it clockwise to “OFF” or “ON” position. ON: Steering unlock. Ignition ON. Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear Seat’. 8 Fuel Tank Cap / Fuel Tap Fuel Tap Fuel Tank Cap Fuel Tank Cap Fuel Tap • 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 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. 9 Speedometer Details 1 2 3 4 5 6 7 8 M S 9 10 6. Low Battery Indicator : It indicates battery needs charging. 7. Low Oil Pressure Indicator ( ) : It blinks when engine oil pressure is low. 8. Coolant Temperature Indicator ( ) : It blinks when engine coolant Temperature is more than 1150 centigrade. 9. Bajaj Logo : Bajaj logo flying ‘B’ continuously glows. 10. Mode Button : Mode button used for changing the mode while selecting & setting Trip1, Trip2, ODO, Clock & Service reminder. 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. 10 Speedometer Details 11 12 13 14 15 16 17 M 18 19 S 11. Engine Over Rev Indicator : It glows when engine RPM crosses 9500 RPM. 12. Service Reminder ( ): ‘Spanner’ symbol glows when ODO meter reading reaches set Kms. for service. This Icon will flash at 1st : 450 km 2nd : 4950 km, rd 3 : 9950 km, 4th : 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. 13. Side Stand Indicator : When side stand is ‘ON’ . Side Stand Indicator will light. 14. Digital Clock : It indicates time in HR : M (AM/PM) 15. Speedometer: Vehicle speed will be displayed in digital form in Km / Hr. 16. Odometer : The Odometer shows the total distance that the vehicle has covered. Odometer can't be reset to ‘Zero’. 17. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero. 18. Set Button : Set button used for setting Clock & Service reminder. 19 Reserve Indicator : It blinks continuously when petrol level in tank reaches reserve level ( 1 bar or less) 11 Speedometer Setting Service Reminder TRIP1/2 Mode 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. Mode changes from ‘ODO/TRIP1/TRIP2’ 2. Press 'Mode' button for more than 15 sec. Selected mode 2. Service Reminder Reset ( ) : • ‘Wrench’ symbol glows when ODO meter reading reached to set Kms. This icon will glow at1st : 450 Kms 2nd : 4450 Kms rd 3 : 9450 Kms 4th : 14450Kms & subsequently at each 5000 Kms. ‘TRIP1/TRIP2’ will get reset. Note : Engine & motorcycle speed should be zero. Other TRIP mode will continue updating. 12 Speedometer Setting 1. Press 'Mode' push button TRIP1 Mode selected for less than 2 sec. 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. Hour digits will increase by one. 4. Press 'Set' button for less than 1 sec. Minute digits will increase. If Mode/Set button is pressed continuously then digits will stop blinking. 5. Press 'Mode' & 'Set' button together for more than 2 sec. 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. 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. 13 Control Switches A D B 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. 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. 14 Control Switches F. Starter Button : Starter button operates the electric starter when clutch lever is depressed with transmission in any gear. G It is recommended to start the engine with the transmission in neutral. E G. Engine Kill Switch : The engine kill switch is for emergency use. During emergency move the engine kill switch to the ‘OFF’ ( ) position. F Right Handle Bar Switches Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position. E. Head Light Switch : It has 3 positions. : All lamps 'OFF'. CAUTION : While starting ensure that engine kill switch is in ON ( ) position. : With engine running, Tail lamp, Meter lamp and Pilot lamp/s ‘ON’. Engine will not start if the kill switch is in OFF position : With engine running, Head lamp, Pilot lamp/s, Tail lamp and Meter lamps ‘ON’. 15 Rear Seat / Tool Kit Tool Kit A Removal of Rear Seat Tool Kit Location • • • • • It is located below the ‘Rear seat’. • 2 rubber straps are provided to hold the tool kit. Insert Key into lock (A) Turn the key clock wise. Pull front end of ‘Rear seat’ Take out ‘Rear seat’ CAUTION : Always ensure rubber strap is fitted for securing tool kit. 16 Front Seat / Battery B Removal of Front Seat Battery • • • • • It is located below ‘Front seat’. First remove ‘Rear seat’. Remove ‘Front seat’ mounting bolts (B). Pull back rear end of ‘Front seat’. Take out ‘Front seat’. Battery details are given in ‘Battery Maintenance’ page no. 28. 17 Fitment of Front & Rear Seat Front seat lug & bracket C E D A F G B H Fitment of ‘Front Seat’ Fitment of ‘Rear 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). • 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. 18 Removal & Fitment of Side Cover LH / RH A D C F E B Removal of Side Cover LH or RH Fitment 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’. • 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. CAUTION : Remove cover as described above, Otherwise the lugs may break. 19 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. • Brake Fluid level above MIN mark provided on reservior, applicable to disc brake vehicle. • Drive Chain slack of 15 to 25 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. Warning : Failure to perform these checks every day before you ride, may result in serious damage or severe accident. • 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. • Enough fuel for planned distance of journey. No fuel leakage in fuel lines. • Engine oil level (between upper and lower level mark) • Correct rear viewing span adjustment of mirror. • Throttle cable play of 2 ~ 3 mm. Smooth operation and positive return to closed position, 20 How to Ride Your Bike 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. 1. Starting The Engine : • Turn the fuel tap knob to ‘ ’ or ‘ ’ position. • Turn ignition switch key to ‘ ? ’ position. • Keep kill switch in ‘ ’ 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. 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. 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 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 prevent it from stalling. Caution : Do not operate the starter continuously for more than 5 seconds otherwise battery would get discharged. 21 How to Ride Your Bike 4. Braking : 6 5 4 3 2 N 1 Gear shifting Lever • 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. For emergency braking, disregard downshifting, and concentrate on applying brakes as hard as possible without skidding. Gear shifting pattern Recommended Speed for Shifting Down From 6th to 5th Gear 54 km/h From 5th to 4th Gear 45 km/h From 4th to 3rd Gear 35 km/h From 3rd to 2nd Gear 25 km/h From 2 nd st to 1 Gear 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. 5. Stopping the Vehicle : • • • • 22 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. • • 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. 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. Kms 1st 2nd 3rd 4th 5th 6th 0 - 1000 1000 - 2000 10 16 40 46 18 24 24 30 32 38 48 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. CAUTION : Do not park on a soft or steeply inclined surface or the motorcycle may fall over. 23 How to Ride Your Bike Fuel Saving Tips : Ensure following maintenance points to get optimum performance from your bike. 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. 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. 24 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 Ensure correct clutch lever play. Tyre Air 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. • Thoroughly read the 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. • 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. 25 Engine Oil Recommended Engine Oil: A Recommended Engine oil Grade Pulsar SAE 20W50 API ‘SL’, or JASO ‘MA’ 200 NS/AS C A : Oil Filler Cap B : Oil Level Window Model • Engine oil replacement frequency : 1st service & then every 5,000 Km. • Engine oil level top-up frequency : Every 2500 km. 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. Engine Oil Capacity : • Refill at servicing : 1200 ml. • During engine overhaul : 1400 ml. 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. 26 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. Tyre Pressure : Front Wheel Keep appropriate tyre pressure as mentioned below to increase life of the tyre & for better fuel consumption. 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. Pulsar 200 NS/AS 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. Front 25 PSI Rear (Solo) 28 PSI Rear (with Pillion) 32 PSI Note : Ensure tyres fitted comply with local rules and regulations governing tyres. 27 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. 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. 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. 28 Engine Cooling System B C Radiator Cap Expansion Tank A • 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. Warning : During motorcycle operation, the coolant gets very hot & is under pressure. Do not remove the radiator cap, radiator hose or other cooling system 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. 29 Coolant Coolant Specifications : Antifreeze ready mix (Recommended BrandMotul : 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 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 swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children 29 Periodic Maintenance Information Spark Plug Drive Chain Slackness • Remove spark plugs by using plug spanner. • Chain slackness will have to be adjusted whenever required. • Std. Chain slackness 15 ~ 25 mm. • Marking on chain adjusters should be identically positioned on both sides. • Clean the spark plugs. • Adjust the gaps if incorrect by bending outer electrode carefully. Spark Plug Gap : Spark Plug (2 Nos.) : 0.7 to 0.8 mm. RG-6HCC (LH ‘A’ + RH ‘B’) (1 No. ) : BOSCH - VR5NE (Center ‘C’) A C 0.7 to 0.8 mm 30 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. 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. 31 Brake Fluid Front Brake Fluid Reservior Rear Brake Fluid Reservior Front & Rear Brake Fluid Level Brake Fluid Replacement • 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. • 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. 32 Periodic Maintenance & Lubrication Chart Sr. Operation No. RECOMMENDED FREQUENCY Servicing 1st 2nd Kms 500 ~ 750 4500 9500 14500 19500 24500 29500 ~ ~ ~ ~ ~ ~ 5000 10000 15000 20000 25000 30000 3rd 4th 5th 6th 7th Ensure to prevent water entry in Petrol tank, Silencer & electrical parts.Use caustic free detergent for washing. 1 Clean the vehicle with water wash & dry completely C,R R 3 Oil strainer CL CL 4 Spark plug CL,C,R 2 Engine oil & engine oil filter* Remarks R R R CL R R R SAE 20W50 "API SJ" Grade Replace at every 5000kms. And top-up at every 2500 Kms (If required).. CL Oil strainer cleaning at the time of CL oil change. CL,A R R R R R CL R CL R CL 5 Air cleaner element*** & cover 'O' ring 6 In line Paper filter or Fuel Cock paper filter 7 Fuel cock sediment bowl cleaning 8 Carburetor rubber duct C,R 9 Fuel pipe C,R 10 Valve tappet clearance C,A C,R C C C R C,A 33 C C R C,A Periodic Maintenance & Lubrication Chart Sr. Operation No. 11 Sealed drive chain cleaning & lubrication 12 Engine air breather tube 13 Brake cam & brake pedal pivot pin 14 Brake lining or pad -Check wear indicator 15 Brake fluid level **- top up / replace RECOMMENDED FREQUENCY Servicing 1st 2nd Kms 500 ~ 750 4500 9500 14500 19500 24500 29500 ~ ~ ~ ~ ~ ~ 5000 10000 15000 20000 25000 30000 3rd CL,L,A CL,L CL,L CL,L A A A C,R C,L,R C,R C 17 All cables & rear brake pedal -free play C,A 5th 6th 7th Remarks CL,L CL,L CL,L Cl,L (Customer to apply OKS chain A A A A lube spray at every 500 kms) C,R C,R Check & replace if required C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use recommended AP grease. Replace brake shoes /brake C,R C,R C,R R C,R C,R R pad at every15000 Kms C,A,R 16 Disc brake assly -- Check functionality, leakage or any other damage. 4th C,A C C,A C,A C,A C C,A C,A C,A R Use recommended brake fluid (DOT3/DOT4). C Replace if damaged C,A 18 Wiring harness & Battery connectionsrouting, tie bands & clamps tightness. C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T 19 Ignition switch barrel cleaning & handle bar control switches contacts cleaning, C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use recommended WD40 spray 34 Periodic Maintenance & Lubrication Chart Sr. Operation No. RECOMMENDED FREQUENCY Remarks Kms 1st 500 ~ 750 3rd 5th 6th 2nd 4th 7th 4500 9500 14500 19500 24500 29500 ~ ~ ~ ~ ~ ~ 5000 10000 15000 20000 25000 30000 20 Steering play C,A C,A C,A Steering stem bearing*** & Cap steering 21 bearing(Plastic)** C,CL L,R C,CL L,R C,CL L,R C,CL Check & replace if damaged. Use L,R HP Lithon RR3 grease for 22 Main stand & side stand pin** CL,L CL,L CL,L CL,L Use recommended AP grease. 23 All fasteners tightness C,T 24 Engine foundation silent bushes ** C 25 General lubrication-Clutch lever, front brake lever. 26 Idle speed / CO% L L L L L C,A C,A C,A C,A C,A C,A C,A C,A 27 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'. C C C 28 Coolant hose damage/clamps/leakage Servicing C C,T C,T C,A C,T C,A C,T C,A C,T C,A lubrication. C,T C 35 C,A C,T C L C L C L C Use recommended AP grease. Periodic Maintenance & Lubrication Chart Sr. Operation No. RECOMMENDED FREQUENCY Servicing Kms 29 Radiator fins C,T 1st 500 ~ 750 3rd 5th 6th 2nd 4th 7th 4500 9500 14500 19500 24500 29500 ~ ~ ~ ~ ~ ~ 5000 10000 15000 20000 25000 30000 C,T C,T C,T C,T C,T C,T Remarks C,T * It is strongly recommended to use specified grade only , 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 is required while driving in dusty environment. C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate Note: periodic parts / lubricants as per periodic maintenance & chart are mandatory & the same is chargeable to customer. 36 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. • Apply petroleum jelly on terminals. (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.