Pulsar DTS-i 220 Owner's Manual

Table of Contents

Description

1. Technical Specifications................. 1

2. Location of Parts............................ 2

3. How to Ride Motorcycle................ 10

4. Safe Riding Tips..............................11

5. Running In Instruction.....................11

6. Daily Safety Checks........................12

7. Periodic Maintenance Information......... 13

8. Periodic Maintenance/ Service Record. 16

9. Periodic Part Replacement Schedule....18

10. Applicable to all services 19

11. Non-use Maintenance.............................20

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 that could result in vehicle damage.

Follow the Advice 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.

1

Technical Specifications

Engine

: 4 Stroke, Single Cyl.,

Natural air/ Oil cooled

Bore x Stroke : 67.00mm x 62.4mm

Engine Displacement : 220 cc

Compression Ratio

Idling Speed

Max. Net Power

Max. Net Torque

Ignition System

Spark Plug

Spark Plug Gap

Lubrication

Transmission

Brakes (Frt. & Rr.)

Fuel Tank Capacity

Full

Reserve

Usable Reserve

Tubeless Tyre Size

Front

Rear

Tyre Pressure

Front

Rear (solo)

Rear (pillion)

: 9.5 + 0.5 : 1

: 1400 + 100

: 21 PS at 8500 rpm.

: 19.12 Nm at 7000 rpm.

: Digital CDI

: 2 Nos. Champion

RG6HCC

: 0.8 to 0.9 mm

: Wet sump, Forced

: 5 speed constant mesh

: Hydraulic operated disc brakes

:

: 15.0 liters

: 3.2 liters

: 2.0 liters

:

: 90/90 x 17,49P

:

: 120/80 x 17, 61P

: 2kg / cm2 (28 PSI)

: 2 kg / cm2 (28 PSI)

: 2.25 kg / cm2 (32 PSI)

Dimensions :

Length

Width

Height

Wheel base

Pilot Lamp

Tail /Stop

Turn Signal Indi.

Neutral Indicator

Hi Beam Indicator : LED

Turn Pilot Indicator : LED

Side Stand Indi.

Speedometer

Rear No. Plate

Horn

Battery

Vehicle Kerb Wt.

Gross Vehicle Wt.

Climbing Ability

: 2035 mm

: 750 mm

: 1165 mm

: 1350 mm

Min. Turning Radius : 2500 mm

Ground Clearance

Electrical System

Head Lamp

: 165 mm (Min.)

: 12 Volts DC

: 55/55 W-H7 (for F)

: 35/35 W (for S)

: 5 W Each 2 Nos.

: LED/LED

: 10 W - 12 V

: LED

: LED

: LCD Display

: 5 W

: 12 V DC (2 Nos.)

: 12V - 9 Ah

: 152 kg. (for F)

: 148 kg. (for S)

: 282 kg. (for F)

: 278 kg. (for S)

: 28% (160max)

Note : All dimensions are under UNLADEN condition. Above information is subject to change.

Location of Parts : Speedometer Indicators

4

2

9

7

8

5

3

6

1

10

1. Side stand indicator : When Side stand is ‘ON’, the Side stand indicator will be lit.

2. Turn signal indicator : When turn signal switch is turned to LH/RH, pilot indicator flash.

3. Trip meter : It shows the distance travelled since it was last reset to zero.

4. Trip meter knob : Reset trip meter to zero by pressing the trip meter knob.

5. Speedometer : The vehicle speed is displayed digitally.

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

7. Fuel level indicator : Fuel level indicator shows available fuel in fuel tank.

8. Tachometer : It shows the engine speed in RPM.

9. Neutral indicator : When the transmission is in neutral, the neutral indicator light will lit.

10. Hi beam indicator : When the H/L is on high beam, the hi beam indicator light will lit.

2

3

Location of Parts (220 F)

Accelerator

Grip

Fuel

Tank

Rear

Shock Absorber

Grab

Handle

Clutch Lever

Front Fork

Pillion

Foot Rest

Side

Stand

Gear Change

Lever

Center

Stand

Location of Parts (220 S)

Grab

Handle

Fuel

Tank

Accelerator

Grip

Rear

Shock

Absorber

Silencer

Center Stand

Rear Brake

Pedal

Front Brake

Lever

Front Fork

4

5

Identification Data / Location of Parts

The chassis / Engine serial numbers are used for registration. These are the unique alpha-numeric codes to identify your vehicle from others of the same model and type.

Chassis No.

1. 220 F - RH side of steering tube

2. 220 S - LH side of steering tube

4 Icons On Speedo Display At The Top

+

Chassis

Number

Engine

Number

Air Filter

Choked

High

Engine

Temperature

Low

Battery

Voltage

+

Low Engine

Oil Level

These icons flash whenever their limits are exceeded.

Take you vehicle to service station for maintenance of required item, if any of the above indicating icon flickers continuously.

Location of Parts

FUEL

TAP

R-

E

L

L

A

RES

To Lock the Steering :

To lock the steering, turn the handle bar to left or right. Push down & turn key to

“LOCK” position and remove key.

To Unlock the Steering :

To unlock the steering, insert key in steering cum ignition lock & turn it clockwise to

“OFF” or “ON” position.

Other Keys :

A common key is used for ‘Steering cum

Ignition lock’, ‘Fuel tank cap’ and ‘Side cover lock’.

Key can not be removed with ignition switch in ON position.

ON

Fuel Tap

FUEL TANK

CAP

Fuel tap lever has following positions.

ON : When fuel level is above reserve .

RES : When fuel level is below reserve.

OFF : When fuel supply is to be cut off.

Fuel Tank Cap

• To open the fuel tank cap, lift the flap

(A), insert the key in the lock and turn it clockwise.

• To lock ‘Fuel Tank Cap’ gently press the cap.

6

Location of Parts

D

A

G

B

C

E

F

7

Left Handle Bar Switches

A) Dipper switch : When headlight is ON, High or Low beam can be selected with the dipper switch. : High Beam : Low beam

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 opposite direction of indicator.

Auto Cancellation of Indicators

• After having turned to LH or RH directions, the indicators would switch off itself when the handle bar is straightened.

• If one forgets to take a turn, but has selected the turn signal it will be switched off automatically after approx. 1 min.

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

Right Handle Bar Switches

D) Pass Switch : Press the switch to flash the head light. It should be used to give signals to on coming vehicles while overtaking.

E. Head Light Switch : It has 3 positions.

: All lamps 'OFF'.

: Tail, Meter, Pilot lamp/s ‘ON’.

: Head, Pilot, Tail, Meter lamps ‘ON’.

F. Starter Button : Push start button to start the engine with transmission in neutral position.

In geared condition pressing clutch lever would be required.

G. Engine Kill Switch : During emergency move engine kill switch to the OFF ( ).

Caution : While starting ensure that engine

Kill switch is in on ( ) position. Engine will not

Start if the kill switch in OFF ( ) position.

Location of Parts

Battery

Removal of Left / Right Side Cover

• Access to battery is by removing LH cover.

• Insert ignition key & turn it clock wise.

• Pullout the cover from fuel tank knob.

• Slide the cover towards left direction.

• Direction of removal is important to avoid breakage of cover locking lug.

Tool Kit Location

• It is located below Rr. seat. For removing seat please refer procedure given on page number 9.

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

Battery (12V - 9Ah)

• Battery is located inside LH side cover.

• Check electrolyte level in each cell & ensure that it is between upper & lower level lines.

• Remove battery filler caps and fill with distilled water until electrolyte level in each cell reaches upper level line.

• Add only distilled water to battery. Tap water is not a substitute for distilled water and will shorten the life of battery.

• Environment care is to be taken to dispose off used battery. It is always recommended to handover same to Authorised Battery /

Bajaj Dealer for proper disposal of same.

• Warranty on battery is 18 months from the date of purchase of vehicle.

8

Location of Parts

B

1

3

5

7

A

2

8

4

6

9

Seat Release Cable

Fig. B

Removal of Seat - Front & Rear

• Remove ‘Side Cover’ LH.

• To remove Seat Front, pull the ‘Seat

Release Cable’ (A) to release seat lock.

Keeping cable pulled, tap the center of seat, lift the seat from rear end and slide it back to remove seat.

• To remove Seat Rear, pull the ‘Seat

Release Cable’ (B) 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.

Caution : Always remove Rear Seat first.

Fitment of Seat - Front & Rear

• For fitment of Seat Front, match & insert the bracket (‘1’ of Fig. ‘B’),

Fig. C

of seat with slot (‘2’ of Fig. ‘B’) provided below fuel tank rear mounting on chassis.

Push seat towards fuel tank and align lock rod (‘3’ of Fig. ‘B’) & seat lock (‘4’ of Fig.

‘B’). Then press the seat in middle from top to lock the seat.

• For fitment of Seat Rear, match & insert the bracket (‘5’ of Fig. ‘C’) of seat with slot (‘6’ of Fig. ‘C’) provided below fuel tank rear mounting on chassis. Push seat towards fuel tank and align lock rod (‘7’ of Fig. ‘C’) & seat lock (‘8’ of Fig. ‘C’). Then press the seat in middle from top to lock the seat.

Caution : Always fit Front Seat first.

How to Ride Your Bike

Starting the Engine :

1. Turn fuel tap to ON RES position.

2. Turn ignition/ kill switch to ON position.

3. Confirm that transmission is in neutral.

4. Keep the throttle completely closed.

5. Push starter button until the engine starts.

Caution : Do not operate starter continuously for more than 5 sec. Wait for 15 seconds before re-start.

Note : The motorcycle is equipped with a starter lockout switch. The starter switch will operate only when transmission is in neutral or clutch lever depressed.

Moving Off :

• Check that Center/Side stand is up.

• Depress clutch lever, shift into 1 gear.

• Open throttle and release the clutch lever slowly and simultaneously, as the clutch start to engage, open throttle a little more, giving engine just enough rpm to keep running.

Shifting Gears :

• Close throttle & depress clutch lever.

• Shift into next higher or lower gear.

• Open the throttle and release the clutch lever slowly and simultaneously.

Warning : When shifting down to lower gear, do th rd nd st

50 km/h

40 km/h

30 km/h

20 km/h

Gear Shifting Lever

not shift at such high speed that the engine rpm jumps excessively. This may cause engine damage, and rear wheel may skid. Downshifting should be done at recommended speeds.

Braking :

• Close throttle completely, leaving clutch engaged so that engine braking will help slow down 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 same time. De-clutch as necessary to keep engine from stalling.

• Never lock brakes, it will cause tyres to skid.

When cornering, use brakes judiciously & do not de-clutch. Reduce speed before you get into the corner. For emergency braking, disregard downshifting, & concentrate on applying brakes as hard as possible.

10

Running In / Safe Riding Tips

11

Stopping the vehicle :

• Close the throttle completely, Shift the transmission into neutral. Bring the vehicle to complete stop, Turn the ignition switch off.

Parking :

• Support motorcycle on a firm level surface with the center or side stand. Lock the steering.

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

Running In

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

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

Kms 1st 2nd 3rd 4th 5th

0 - 1000 15 30

1000 - 2000 20 40

45

55

55

65

65

75

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

• Do not start moving or race the engine immediately after starting. Run the engine for a minute at idle speed to give the oil a chance to work up into the engine.

• Do not race the engine excessively.

• Do not run at constant speed. Vary the engine speed.

Fuel Saving Tips :

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

Following are a few simple fuel saving tips.

Good Riding Habits :

• Ride smoothly and steadily at an optimum driving speed of 40 to 50 Km/h.

• 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.

Safe Riding Tips

•

Always wear a helmet while riding. Your helmet should conform to appropriate

Indian standards i.e. ISI mark.

•

Read thoroughly the instructions in this manual and follow them carefully.

•

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

Safe Riding Tips / Daily Safety Checks

• Get familiar with traffic rules & regulations in your states & general traffic signs.

Familiarise yourself well with starting, acceleration and braking of the vehicle.

• When applying the brakes, use both, the front and rear brakes. Applying only one brake may cause the rider to loose control, use more of the front than rear judiciously depending on road surface conditions.

• During monsoon ride the vehicle more cautiously. Remember vehicles skid more easily during light showers.

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

• Always carry vehicle registration papers, insurance and a valid driving licence with you.

• 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 and smooth operation.

Daily Safety Checks :

Before riding a motorcycle be sure to check everyday following items.

Please give importance to these checks and perform all of them.

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

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

• Enough

fuel level for planned distance of journey. No fuel leakage in fuel lines.

• Engine oil level (bet upper - lower level mark)

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

• Steering Lock lever not fouling.

• Brake Pedal Play - 20 to 30 mm.

• Wear lining Indicator within usable range.

no brake dragging.

•

Drive Chain slack of 25 to 35 mm,/ adequately lubricated.

• Function of all lights & horn

• Smooth steering movement without restriction

• Clutch lever play - 2 to 3 mm

• Both stands return to their fully up position.

• Correct inflation pressure in both tyres adequate tread depth - no cracks / cuts.

• Correct

rear viewing mirror span adjustment.

12

Periodic Maintenance Information

A

A : Oil Filler

Cap

B : Oil Level

Inspection

Window

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.

13

B

Engine Oil

• Check the engine oil level every day.

• Maintain oil level between upper and lower mark provided at oil window.

• Vehicle should be parked at level ground while checking oil level.

• Top up with specified grade of oil if the oil l e v e l i s below lower level mark.

• Completely screw in dipstick after oil filling is over.

Oil Quantity:

Refill during servicing - 1150 ml.

Filling post overhaul - 1300 ml.

Recommended Engine Oil : Bajaj DTSi 10000Engine

Oil Grade : SAE 20W50 API ‘SL’ or JASO ‘MA’ Grade

1 0 , 0 0 0 K m . I n c a s e a n y o t h e r e n g i n e o i l o f same specifications is used, the frequency of Oil replacement will be every 5000 Kms.

Caution :

• It is most important to adhere with the 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.

Spark Plug

• Remove spark plug by using plug spanner

(Box 16 m.m)

• Clean both the spark plugs.

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

Spark plug gap : 0.8 to 0.9 m.m

Recommended : Champion RG6HCC

Spark Plug (Resistive)

Periodic Maintenance Information

Drive Chain

Drive Chain

• Chain with ‘O’ rings is fitted on your vehicle.

• ‘O’ rings must always run in wet condition to ensure better chain life.

• Adjust chain slack every 1000 kilometers.

• Lubricate chain every 500 kilometers with

SAE 90 oil.

Method of chain lubrication :

• Place the bike on centre stand.

• Start rolling rear wheel in reverse direction.

• Clean the chain with nylon brush by using mixture of oil / kerosene.

Chain lube spray

• Lubricate chain with SAE 90 oil. For better retention “chain lube. spray” can be used.

• Spray the lubricant inside chain between plates, rollers and bush completely.

• Wipe out excess lubricant by using lint free cloth.

Tyre Pressure :

• Keep appropriate tyre pressure to increase tyre life and for better fuel consumption.

Front

Rear (Solo)

14

Periodic Maintenance Information

MIN.

15

Front Brake Fluid Level :

• Front brake fluid master cylinder reservoir is located near RH switch on handle bar.

• To check oil level, keep vehicle on Center stand with handle bar in straight 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 every 30,000 Kms or once in two years which ever occurs earlier.

Wheel Puncture : Advisable to visit tyre dealer if possible, or known tubeless tyre repair shops.

Usage of a wheel removal / fitment machine strangle recommended.

If at all, tyre levers have to be used, they should be having no sharp edges and the procedure of removal / fitment should not nick / dent the wheel or tyre in any manner.

Caution : Tubeless tyres are used on motorcycle. The side walls of the tyres in contact with the wheel rim should not be damaged in any way during fitment / removal of tyre in case of punctures. The tyre side walls in contact with the wheel rim seals air.

Note : Incase the motorcycle is fitted with imported tyres, compliance to respective Indian standard & central motor vehicle rules has been ensured.

Periodic Maintenance Chart & Service Record

Sr.

No.

Operation

1.

Servicing

2.

Engine idling speed / CO%

3.

Valve tappet clearance

4.

Engine oil (Bajaj DTSI 10000 oil)*

Servicing

Kms

A

A

1st

750

3

A

A

Recommended Frequency

2nd

5000

3

A

A

3rd

10000

3

A

A

4th

15000

3

A

A

5th

20000

3

A

A

6th

25000

3

A

A

7th

30000

3

A

A

5.

Oil strainer / Centrifugal filter

6.

Spark plugs functioning / Gap

7.

Air cleaner element Clean / Replace

VV

8.

Fuel cock sediment bowl cleaning

9.

Carburetor float bowl cleaning

10.

Battery electrolyte level

C,A R Top-up R Top-up R Top-up R Replace at 5000 Kms

Replace in 1st service & at every 10000 Kms

CL CL CL CL

C, A, R C, A C, A C, A

CL, R

CL

CL CL

CL

CL

CL

CL

C, A

CL

R

R

CL

CL

CL

CL

CL

C, A C, A

CL

CL

CL Clean at 5000 Kms

R

R

CL

Replace at every 15000

Cl- 5000 Kms. R-15000

CL CL CL Clean at every 10000 Kms

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

11.

Clutch lever free play

12.

Throttle grip play

13.

Rear brake pedal free play

14.

Brake fluid level / Top up / Replace

15.

Brake cam & pedal pivot pin

16.

Steering play

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

C, A, R C, A C, A C, A C, A C, A C, A R

L

C, A

L L

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

Replace at every 30000

17.

All fasteners tightness

18.

Rear Shock Absorber - Gas pressure

C, T

C, A

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

Note - More frequent cleaning may required when driving in dusty condition.

C, A Every 20000 Kms

C : Check, A : Adjust, CL : Clean,

R : Replace, T : Tighten, L : Lubricate.

16

Periodic Maintenance Chart & Service Record

Sr.

RECOMMENDED FREQUENCY

No. Operation

19. Rear sprocket fasteners

Servicing 1st

Kms 750

2nd

5000

3rd

10000

4th

15000

5th

20000

6th

25000

7th

30000

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

20. Silencer drain hole cleaning

21. Cylinder head de-carbonising,

CL

CL

22. Drive chain ‘O’ ring type - Clean / lubricate C, L

23. Drive chain slack

24. Wheel bearing

CL

(O/H) CL, L

C, L

25. Tyre tread wear

26. Front fork oil

27. TPS / Auto choke, Thermal sensor

28. Starter clutch bush kit for dry type

29. General lubrication

30. Swing arm pivot pin lubrication

31. Clutch switch cleaning

CL CL CL CL CL CL CL every 5000 Kms

CL CL R- oil seals & valve lapping

At every 500 Kms

CL, L

C, L

CL, L CL, L Every 10000 Kms

Every 20000 Kms

C, R C, R C, R C, R C, R C, R

R R

Every 5000 kms

Replace at every 20000

C, A C, A C, A C, A C, A C, A C, A C, A At every 5000 Kms

CL, R

L

L

CL

L L L

CL

CL,R

L L

L

CL

L

CL, R

L

CL

Lubricate at every 20000

* 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.

17

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

Periodic Part Replacement Schedule

Type of service, Kms limits

& No of Days

Days

Ist Free

500~750

30~45

2nd Free

4500~5000

3rd Free

9500-10000

Ist Paid

14500~15000

240 240

120 Days

2nd Paid

19500~20000

120 Days

3rd Paid

24500~25000

120 Days

Item Description

Steering Stem Bearing Cone Set

Rear Wheel Rubber Damper

Drive Chain Link Lock

Spark Plug

Air Cleaner Element

Brake Pad

Valve Oil Seals

Cylinder Head Gasket

Starter Clutch Kit

Engine Silent Bush

Air Filter Cover ‘O’ Ring

Carb. Rubber Duct / Fuel Pipes

Qty.

1

1

1

2 Nos.

2

1

1

1

1

2

1

1

√

√

√

Engine Air Breather Tube

Brake Hose Pipe

Master Cylinder Cup & Dust Seal

1

1

Caliper Piston Seal & Dust Seal

1

Note : Replacement of Parts at periodic interval is mandetary and on chargeable basis.

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

18

Applicable to All Services

1. Wash the vehicle.

2. Change / Top up engine oil as per periodic maintenance schedule.

3. Clean air filter element. (Replace element at every 15,000 kms).

4. Check all fuel lines. (Replace fuel pipes at every 20,000 kms).

5. Clean oil strainer / centrifugal filter as per periodic maintenance schedule. (Replace, if required).

6. Clean fuel cock sediment bowl.

7. Drain carburettor / clean float bowl as per periodic maintenance schedule.

8. Clean, Check & Adjust spark plug gap. (Replace at every 15,000 kms).

9. Replace carburetor duct, & Air filter ‘O’ ring at every 20,000 kms.

10. Check & adjust valve clearance (if required). Decarbonize cylinder head at every 15,000 kms.

11. Adjust chain slackness. Lubricate chain. Replace kit chain lock at every 10,000 kms.

12. Replace rear wheel rubber damper at every 10,000 kms. (if required)

13. Replace engine air breather tube at every 20,000 kms.

14. Clean silencer drain hole at every 5,000 kms.

15. Check brake pad wear.

16. Replace master cylinder cup & dust seal, caliper piston seal & dust seal, brake hose pipe at every 30,000 Kms.

17. Check and top up brake fluid level. Replace brake fluid at every 30000 kms.

18. Check and adjust steering freeness. Replace steering cone kit at 10000 kms.

19. Replace fork oil at every 20000 kms.

20. Clean clutch switch at every 10000 kms.

21. Check & adjust clutch, accelerator.

22. Lubricate gear starter clutch as per periodic maintenance schedule.

23. Replace starter clutch kit at every 15000 kms.

24. Replace engine foundation silent bush at every 15000 kms.

25. Check & tight fasteners to the recommended torque.

26. Lubricate specific points as per lubrication schedule, swing arm pivot pin at 20,000 Kms.

27. Check battery voltage with HRD tester, electrolyte level & top up. Clean terminals & apply petroleum jelly.

28. Start the vehicle, check & adjust horn & all lights, TPS, auto choke, thermal sensor.

29. Check idling and CO%. Tune engine & carburetor if required.

30. Rear shocker gas pressure at every 20,000 kms. for proper functioning.

31. Check tyre wear & inflate air pressure in the tyre.

32. Test ride, Clean the vehicle at the time of delivery.

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

19

Non-Use Maintenance

Non-use maintenance is necessary if a vehicle remains off road for longer duration. Correct & careful non-use maintenance carried out before storing vehicle will prevent it from rusting & such other non-operational damages like fire hazards.

• Clean the entire vehicle thoroughly.

• Empty fuel from fuel tank & carburettor float bowl (if fuel is left in for a longer time, fuel will break & gummy substance could clog carburettor).

• Remove spark plug & put several drops of 2T oil into the cylinder. Kick engine over slowly a few times to coat cylinder wall with oil & install back spark plug.

• Set vehicle on a box or a stand so that both the wheels are raised off ground.

• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or brake liners.

• Lubricate control cables.

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

• Remove battery from vehicle. Maintain electrolyte level at “Upper Level”. Ensure that it is fully charged. Check once in a month.

• Keep Battery away from rain, dew moisture & direct sunlight.

• 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.

Preparation for regular use after storage :

• Clean the vehicle

• Check the electrolyte level in the battery, charge if necessary, and install it in the motorcycle. Be careful that the battery vent hose is not pinched and that it is routed properly.

• Make sure the spark plug is tight.

• Fill the fuel tank with fuel, Change engine oil.

• Check all the points listed in the Daily Safety

Checks section.

• Check and inflate tyres.

Rainy Season Care : Fit & Finish Parts

It is suggested to customer to take appropriate care in high rainfall area. The appropriate surface preventive coat to avoid rusting / poor surface finish on account of adverse atmospheric conditions.

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