Bajaj Auto Pulsar 135 LS Owner's Manual

Foreword

Welcome to the Pulsar family!

You are now the proud owner of the next generation Pulsar 135 LS , India's No.1 sports bike. By

No.1 we are talking about unparalleled performance, superior technology and incredible market leadership that Pulsar today enjoys. This makes the Pulsar you ride, unbeatable and unchallenged both on and off the road.

Before you ride out, please read this Owner's Manual carefully and familiarize yourself with the operating mechanism, controls and maintenance requirements of your Pulsar. This will ensure you a safe and trouble free ownership experience.

To keep your bike in perfect running condition and deliver consistent performance, we have specially programmed the periodic maintenance services which includes 3 free services and subsequent paid services, as per the schedule contained in this booklet. We earnestly advise you to avail all these services at any of our Bajaj Dealers or Authorised Service Centres, who are well equipped with all necessary facilities / genuine parts / oil and trained manpower to ensure the best care for your Pulsar. Your ‘Pulsar 135 LS’ comes with a warranty of 2 Years or 30,000 Kms whichever occurs earlier from the date of sale. For details please refer to “Warranty : Scope &

Limits” given in this manual.

Should you require any additional information feel free to contact us on our toll free no.:

1800 233 2453 or e-mail us at: [email protected] or visit the Bajaj Auto website www.bajajauto.com

To be a part of the Pulsarmania, visit www.mypulsar.com and join the Pulsar fanpage on facebook: www.facebook.com/mypulsar

Rev up, shift gears and enjoy the Pulsar experience…

SERVICE DEPARTMENT

BAJAJ AUTO LIMITED

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. Control Switches

8. Removal & Fitment of Side Covers

9. Removal & Fitment Seat

10. Battery / Tool kit

11. Daily Safety Checks

12. How to ride your Bike

13. Safe Riding Tips

14. Engine Oil

15. Wheels - Tyre

16. Periodic Maintenance Information

17. Free Service Guidelines

18. Periodic Maintenance & Lubrication Chart

19. Non Use Maintenance

20. Delivery Certificate

21. Warranty Scope & Limit

22. Battery Warranty Card

14

15

19

20

10

12

13

21

22

26

27

32

34

35

4

5

6

1

3

7

8

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

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

Technical Specifications

Engine

Bore x Stroke

: 4 stroke DTS-i, Single cylinder 4 valve

Natural air cooled.

: 54.0 mm x 58.8 mm

Eng. Displacement : 134.60 cc

Compression Ratio : 9.8 +/- 0.5 :1

Idling Speed

Max. Net Power

Max. Net Torque

Ignition System :

:

:

: 1400 +/- 100 RPM

13.5 PS @ 9000 RPM

11.4 Nm @ 7500 RPM

DC CDI

Spark Plug (2 Nos) : CHAMPION, PRZ9HC

& BOSCH UR4AC

Spark Plug Gap

Lubrication

Transmission

Starting Aid

: 0.7~0.8 mm

: Wet sump, Forced.

: 5 speed constant mesh. (1 down 4 up)

: Self & Kick

1

Front Brake

Rear Brake

: Hydraulic operated disc brake

: Mech. expanding drum brake

Fuel Tank Capacity :

Full : 8.0 liters

Reserve

Usable

Dimensions

Length

:

:

:

: 2.5 liters

1.6 liters

1995 mm

Width

Height

: 765 mm

: 1075 mm

Wheel base : 1325 mm

Ground clearance : 165 mm

Tyre Size

Front

Rear

: 2.75 X 17”, 41 P

: 100/90 X 17”, 55 P

Technical Specifications

Tyre Pressure Front : 1.75 kg/cm 2

Rear (Solo) : 2.00 kg/cm 2

Electrical System

Battery

Rear (Pillion) : 2.25 kg/cm 2

Head Lamp

: 12 Volts DC

: 12V 5Ah MF

: 35/35W

Pilot lamp

Tail / Stop Lamp

: 5W (2 nos.)

: LED

Side indicator Lamp : Bulb 10W

Neutral : LED Green

Reserve Indicator : LCD

Turn Signal Indicator : LED Green

Hi-Beam Indicator : LED Blue

Speedometer Illumination : LED

Fuel Gauge : LCD bar display

Horn : 12V DC 2A

Rear No. Plate Lamp : 5W

Vehicle Kerb Weight : 122 kg.

Gross Vehicle Weight : 252 kg.

Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without any notice.

• This vehicle complies to BS IV standards.

• AHO is government regulation.

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 Side of Steering Tube

(Alpha-Numeric - 17 Digits)

3

Location of Parts

Grab Handle

Nitrox Rear

Shock Absorber

Fuel Tank Cap

Speedometer

LED Tail

Lamp

Brake Lever

Front Fork

Pillion

Foot Rest

Manual Choke

4

Engine Oil

Inspection Window

Disc Brake

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.

5

To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push

& release the key. Turn the key to “LOCK” position and remove the key.

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

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

Fuel Tank Cap / Fuel Tap

Fuel Tank

Cap

Fuel Tap

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.

• To lock the ‘Fuel Tank Cap’ insert the key in the lock and turn it clockwise and press

fuel tank cap. ‘Click’ sound ensures cap is fully locked.

Precaution :

Dont attach metallic ‘Key chain’ as it may damage paint of petrol tank cover.

6

Fuel Tap

Fuel tap lever has following positions.

OFF : When fuel supply is to be cut off.

ON : When fuel level is above reserve position.

RES : When fuel level is below reserve position.

Speedometer Details

5

6

1

2 7

3 8

4 9

10/11

Speedometer display will get on when ignition switch is made ‘ON’.

1. Speedometer : The vehicle speed is displayed in digits Km/hr.

2. Fuel Level Indicator : Shows available fuel in tank.

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

4. Reserve Indicator : It blinks when fuel level drops to reserve.

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

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

7. Battery Indicator :

Battery icon glow on when battery needs charging.

8. Neutral Indicator : and Ignition switch ‘ON’, the Neutral indicator will glow

9. Trip Meter Reset Button : to zero by pressing the button.

10. Trip Meter :

11. Odometer :

The Trip meter shows the distance travelled since it was last reset to zero.

It

Shows battery charge condition.

When transmission is in Neutral

Trip meter can be reset shows cumulative reading of total distance covered by vehicle in Km.

7

Control Switches

D

A

B

C

Left Handle Bar Switches

A. Dipper Switch : When headlight is ON,

High or Low beam can be selected with the dipper switch. Hi beam indicator light located on Speedo console will light up when high beam is selected.

: High Beam : Low beam

B. Turn Signal Switch : When the turn signal knob is turned to Left ( ) or Right ( ) respective indicator will start blinking, to stop blinking push the knob in & release.

8

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

F

AHO Feature

(Automatic Headlight ‘ON’)

There is no ‘Light switch’ on RH control switch.

E

Right Handle Bar Switches

E. Starter Button :

Starter button operates the electric starter.

It is recommended to start the engine with the transmission in neutral.

Vehicle in Gear - Press clutch lever & operate starter button to start the engine.

F. Engine Kill Switch :

The engine kill switch is used for switching

ON & OFF the engine.

: Engine OFF

: Engine ON

9

Ignition switch ‘ON’ Speedometer illumination

Engine ‘OFF’ Tail lamp, Number

Plate Lamp, Pilot

Lamp & Control Switches

Effect of pressing In addition to above

‘Pass Switch’

Illumination will get ‘ON’

Hi-beam will get ‘ON’

Ignition switch ‘ON’ & Engine Running

Speedometer illumination, Tail lamp, Number Plate

Lamp, Pilot Lamp & Control Switches Illumination will get ‘ON’ in addition to above, headlamp will get on as given below.

Hi/Low beam Headlamp

Switch Status

Effect of

Pass Switch

Low beam Low beam ‘ON’ Hi beam ‘ON’

Hi beam Hi beam

‘ON’

No change

Removal & Fitment of Side Cover LH / RH

Rubber

Grommet

B C

A

Bracket

Removal of Side Cover LH

• Insert the key into the ‘LH cover lock’ (A) and turn the key clockwise.

• Hold the cover with both the hands and pull front portion (B) of the cover. Slide rear portion (C) forward. Take out ‘LH Side cover’.

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

10

Fitment of Side Cover LH

• Match slot provided on rear portion (C) of

‘Side Cover LH’ with the bracket located on chassis & Slide (C) backward.

• Match Lug (B) provided on front portion of

‘Side Cover’ with the rubber grommet hole provided on ‘Fuel Tank’. Press in the cover.

• Match the ‘Side Cover Lock’ (A) properly with the bracket provided on ‘Holder step

LH’ and Lock the ‘Side Cover’.

Removal & Fitment of Side Cover LH / RH

C

B Rubber

Grommet

Bracket

A

Removal of Side Cover RH

• Remove the screw (A) securing the ‘Side

Cover RH’.

• Hold the cover with both the hands and pull front portion (B) first. Slide (C) forward.

Take out ‘Side cover RH’.

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

11

Fitment of Side Cover RH

• Match slot provided on rear portion (C) of

‘Side Cover LH’ with the bracket located on chassis and slide (C) backward.

• Match Lug provided on front side (B) of

‘Side Cover’ with rubber grommet hole provided on ‘Fuel Tank’ and press in ‘Side

Cover RH’.

• Match ‘Side Cover’ properly with bracket provided on ‘Air filter assly’ and fix it with

Screw (A).

Removal & Fitment of Seat

D

B

A

E

C

Fig. 1 Seat release cable

Removal of Seat

Fig. 2

• Remove ‘Side Cover’ LH.

• Pull the ‘Seat Release Cable’ (A) to release seat lock. Keeping cable pulled, lift the seat from rear end and slide it towards tail lamp to remove seat assembly. Fig.1

Fig. 3

Fitment of Seat

• Match & insert the seat lug (B) in frame bracket (C) provided below fuel tank rear mounting (Fig.2).

• Match seat locking rod (D) with seat lock

(E) (Fig.3).

• Press the rear portion of seat from top to lock the seat.

12

Battery / Tool Kit

BATTERY TOOL KIT

Battery

• It is located inside the ‘Side Cover’ LH.

• Always maintain electrolyte level in each cell between max and min level lines.

• Always keep a watch on battery charge level indicating icon, if it flashes (indicates battery is in low charged condition), show the vehicle to authorised BAL dealer.

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

13

Tool Kit Location

• It is located below the battery.

First Aid Kit Location

• First aid kit is to be stored in side seat cowl.

CAUTION : Insert tool kit properly in compartment provided on air filter assembly for proper fitment of ‘LH’ side cover.

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 level 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 Pedal Play - 20 to 30 mm.

• Wear lining Indicator within usable range.

No brake dragging, applicable to drum brake vehicles.

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

• Drive Chain slack of 25 to 30 mm adequately lubricated.

• Function of all lights & horn

• Clutch lever play - 2 to 3 mm

• Smooth steering movement without restriction.

• Both stand return to their fully up position.

• Correct inflation pressure in both tyres

Adequate tyre tread depth - no cracks / cuts.

• Correct rear viewing span adjustment of mirror.

14

How to Ride Your Bike

Starting The Engine :

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

• Switch ‘ON’ ignition & ‘Kill Switch’

• Confirm that transmission is in neutral.

• Fold R.H side rider footrest.

• Keep throttle completely closed, press starter button “ ” / apply kick to start the engine.

• Release starter button / kick lever as soon as engine starts.

• Open R.H side rider footrest back to its position.

• If the engine is cold or when starting for first time, use choke ‘ ’ for quick starting.

OFF

ON

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

Manual Choke

Referance Image.

15

Warning : During kick starting if rider footrest is not folded, kick lever hits the footrest and severe jerk would get experienced at foot. Also rider step holder would get damaged due to impact.

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 : Do not let the engine idle longer than 3 minuets otherwise it will overheat.

Note : The motorcycle is equipped with a clutch switch.

The engine can be started by self starter in any gear if the clutch lever is pressed.


Note : Before starting the engine, in ignition key off condition, press the clutch lever & operate kick starter lever all the way down for 5-6 times. Then release the clutch lever.

This practice ensures lubrication of clutch components for their longer life.

Moving Off :

• Check that Center/Side stand is up.

• Depress the clutch lever.

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

• As the clutch starts to engage, open the throttle a little more, giving the engine just enough rpm to keep it from stalling.

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.

Gear

Shifting

Lever

5

4

3

2

N

1

Gear Shifting

Pattern

16

Recommended Speed for Shifting Down th rd nd

45 km/h

35 km/h

25 km/h st 15 km/h

Optimum Shifting Speeds for best mileage

1st gear : 0 km/h

2nd gear : 15 ~ 18 km/h

3rd gear : 24 ~ 27 km/h

4th gear : 33 ~ 36 km/h

5th gear : 41 ~ 44 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 recommended speeds as shown in table.


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 & 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.

Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

Parking the Vehicle :

• Support the 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 or the motorcycle may fall over.

Whenever vehicle is falls down, remove plug of 'Y connecter drain tube' & drain out accumulated petrol

Location - Near Main Stand

17

'Y connecter drain tube plug’

Running IN

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

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

Kms 1st 2nd 3rd 4th 5th

0 - 1000 14 22 30 37 44

1000 - 2000 18 28 38 46 55


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

• Do not race the engine excessively.

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

Fuel Saving Tips :

A well maintained vehicle and good driving can contribute a lot to the saving of petrol. Following are a few simple fuel saving tips.

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.

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, probably with same fuel dispenser.

• Divide kilometer run / fuel quantity filled.

Ensure following maintenance points to get optimum fuel efficiency from your bike.

18

Fuel Check fuel lines & connections for leakage.

Spark plugs Inspect and clean spark plugs.

Adjust electrode gap.

Air filter C l e a n a i r f i l t e r e l e m e n t periodically.

Engine oil Check level. Use recommended grade and quantity.

Brakes Ensure that the brakes are not dragging / binding.

Clutch

Tyre

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 driving or riding. Your helmet should conform to appropriate Indian standards.

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

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

• Get familiar and follow traffic rules & 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 vehicle to loose control.

• Riding at proper speed and avoiding unnecessary acceleration and braking are important not only for safety and low fuel consumption, but also for longer life of the vehicle.

• During monsoon drive the vehicle more cautiously.

Remember vehicles skid more easily during light showers.

19

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

• Always concentrate on riding for safety.

Monsoon Care :

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

• Vehicle cleaning to be done with soft & clean wet cloth to avoid scratches on painted parts.

• Clean & lubricate all the important parts as detailed in a periodic maintenance chart.

• Do not apply direct water jet on painted, electrical / electronic parts.

• Do not obstruct engine cooling by adding mud protection sheet from front.

Engine Oil

A : Oil Filler

Cap

B : Oil Level

Gauge

B

A

C

D

Engine Oil Level Checking :

• Check engine oil level every day. Park vehicle on level surface on center stand.

• Check oil level through oil level gauge ‘B’.

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

Cover RH. Top up with specified grade of oil if the oil level is below lower level mark.

Engine Oil Capacity :

• Refill at servicing : 1000 ml.

• During engine overhaul : 1100 ml.

20

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 SAE 20W50 API

135 LS 10000 ‘SL’ or JASO ‘MA’ st • Engine oil replacement frequency : 1 service & then every 10,000 Km.

• Engine oil level top-up frequency : Every 5000 km.

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.

Wheels - Tyre

Front Wheel

Use the recommended levers while removing the Tyre / Tube for puncture work. This will avoid any damages to the edges / scratches on paint of the wheel.

Tyre Pressure :

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

Pulsar 135 LS

Front

Rear (Solo)

1.75 kg/cm

2.00 kg/cm

Rear(with Pillion) 2.25 kg/cm 2

2

2

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

21

Periodic Maintenance Information

Min. Level

Max

Min

Front Brake Fluid Level :

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

• To check oil level, keep the vehicle on center stand with handle bar in straight ahead condition.

• Always ensure that brake fluid level is above ‘MIN’ mark given on inspection

Window.

22

Battery

• Battery type : 12V 5Ah

• Battery Warranty : 18 months from date of purchase.

• Add only distilled water to the battery if battery electrolyte level is below min. level mark.

CAUTION : Tap water is not a substitute for distilled water and will shorten the life of the battery.


• When battery is found discharged, it is advised to get it charged immediately.

• Environment care must be taken to dispose off the used battery. It is always recommended to hand over the same to the Authorised battery / Bajaj dealer for proper disposal of the same.

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

• If vehicle is to be stored for more than 2 weeks disconnect battery to avoids self discharge.

23

CAUTION :

• While disconnecting always disconnect negative (-ve) cable first.

• While refitting always connect positive

(+ve) cable first.


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.) : BOSCH OR

: CHAMPION

Drive Chain Slackness

• Chain top edge to be kept between the two marks during chain slackness adjustment.

• Chain slackness will have to be adjusted whenever required.

• Std. Chain slackness 25 ~ 30 mm.

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

Std. Chain slackness : 25~30 mm

0.7 to

0.8 mm

24


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 Kms

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

Can’ available with Bajaj dealers.

25

Method of O-ring Chain Lubrication :

• Place the bike on centre stand.

• 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.

Free Service Guidelines

Customer ID :

Instruction to avail Free Service through

Digitized Free Service Coupon

Please follow following procedure : -

• Please provide your mobile number to Dealer at the time of buying of new Bajaj Vehicle.

• In case of change in mobile number, please update to Dealer / ASC.

• You will receive the Customer ID through SMS at the time of buying of new vehicle.

• Please note the Customer ID in Owner’s

Manual for your reference.

• During Free Service, please provide your

Customer ID to Dealer / ASC workshop.

• When you are at Dealership / ASC workshop for Free Service, you will receive the ‘Unique

Coupon Number’ (UCN) through SMS in your mobile.

• Please inform the UCN to Dealer / ASC at the time of Free Service.

Service

1st Free

Service

2nd Free

Service

3rd Free

Service

1st Paid

Service

2nd Paid

Service

3rd Paid

Service

4th Paid

Service

Periodic Service Criteria

Days Kms

30~45

240

360

500~750

4500~5000

9500~10000

120 Days from last Service

Every

5000 Km after previous service

Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.

26

Periodic Maintenance & Lubrication Chart

Sr.

No.

Operation

1. Water wash & dry the vehicle completely

2. Engine oil (Bajaj DTSi 10000 oil)

3. Engine oil filter

4. Oil strainer

5. Body centrifugal filter**

6. Starter Clutch (Dry Type)**

7. Spark plug

8. Air cleaner element ***

Servicing st

1 Free

Kms

500

~

750



RECOMMENDED FREQUENCY

4500

~

5000



9500

~

10000

 

Every

5000 Km after

Previous Service

 

Subsequent

Ensure to prevent water

 entry in Petrol tank,

Silencer & electrical

Parts. Use caustic free detergent for washing.

C,R

C,R

R Top R Top R Top R BGO DTSi 10W30 for

Up Up Up 100cc models.

BGO DTSi 20W50 for

Models above 125cc.

R R R R

CL

CL

L

CL

CL

L

CL,A,R CL,A

CL,R CL CL CL

CL

L L

CL

CL

L L

CL,A

R CL CL

CL

CL

L

R

R

Use recommended

Molycote grease.

 Tick in the box after replacing the periodic parts.

27


Sr.

No.

Operation

9. Air filter cover ‘O’ ring

10. In line paper filter

11. Fuel cock paper filter.

12. Fuel cock sediment bowl cleaning

13. Carburettor rubber duct

14. Fuel pipe

15. Valve tappet clearance

16. Non-Sealed drive chain cleaning & lubrication

17. Sealed drive chain cleaning & lubrication

18. Engine air breather tube

19. Silencer drain hole cleaning

 Tick in the box


Servicing st

1 Free

Kms

500

~

750

4500

~

5000

9500

~

10000

CL,R CL CL CL R

Every

5000 Km after


CL CL

R R

R

CL

C,R

R

CL

C,R

R

CL

R

R

C,R C C C R C C R

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

CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A

Subsequent

CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A Customer to apply OKS chain lub spray at every

500 kms.

C

CL

C C

CL

C

CL

C

CL

C

CL

C

CL

C

CL after replacing the periodic parts.

28


Sr.

No.

Operation

20. Silencer tail pipe cleaning**

21. Brake cam & brake pedal pivot pin

Servicing st

1 Free

Kms

500

~

750

CL


4500

~

5000

9500

~

10000

Every

5000 Km after


CL CL CL CL CL CL

Subsequent

C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use AP grease.

22. Brake lining or pad -

Check wear indicator

23. Brake fluid level **- top up / replace C,A,R

C,R C,R C,R R

C,A

C,R C,R R

24. Disc brake assly -- Check functionality, C leakage or any other damage.

C C C

25. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A

R Use recommended brake fluid

(DOT3/DOT4)

26. Battery electrolyte level, specific gravity C,A C,A C,A C,A C,A C,A C,A C,A Not applicable for

VRLA battery

27. Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T routing, tie bands & clamps tightness.

28. Ignition switch barrel cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray


29


Sr.

No.

Operation

29. Handle bar control switches contacts cleaning

30. Steering play

31. Steering stem bearing*** &

Cap steering bearing (Plastic)**

32. Main stand & side stand pin**

33. Swing arm pivot pin

(for non silent bush)**

34. All fasteners tightness

35. Engine foundation silent bushes**

36. General lubrication-Clutch lever, front brake lever, kick lever.

37. Idle speed / CO%


Servicing st

1 Free

Kms

500

~

750

Every

5000 Km after


Subsequent

4500

~

5000

9500

~

10000

C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray


C,CL,L,R

CL,L

L

C,CL, C,CL, C,CL, Check & replace if

L,R L,R L,R Damaged. Use HP

L

CL,L

L L

CL,L

L L

CL,L

L

Lithon RR3 grease for lubrication.

Use AP grease.

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

C

L L L L

C

L L L

C

L


Use AP grease.


30


Sr.

No.

Operation

Servicing st

1 Free

Kms

500

~

750

38. Coolant level in expansion tank**

39. Coolant hose damage/clamps/leakage** C


C C C

Every

5000 Km after


C C C

Subsequent

4500

~

5000

9500

~

10000

C,A C,A C,A C,A C,A C,A C,A C,A Use recommended

'Ready to use coolant'.

40. Radiator fins**

41. Spoke tightening**-Front & Rear

C C C C C C C

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

42. Front fork dust seal & Rubber bellow CL CL CL CL CL CL CL

43. SAI, EVAP hoses - Check functionality, C,R C,R C,R C,R C,R C,R C,R C,R Replace if cut / damaged leakage or any other damage**

44. EVAP drain tube cleaning** CL CL CL CL CL CL CL CL


** As applicable to model

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

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

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

31

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 back 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

32 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

• 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.

33

Delivery Certificate

FRAME NO.

ENGINE NO.

:

:

Customer’s Name Mr/Mrs/Miss :

Sold on.:

Address : Contact No. :

I have taken possesion of motorcycle along with the following items.

1. Owner's Manual

2. 2 nos of key

3. Set of tools

4. First Aid Kit

5. Standard Accessories

6. Battery Make ___________ Sr. No. ____________

7. Tyre Fr Make ___________ Sr. No. ____________

Rr Make ___________ Sr. No. ____________

The Vehicle has been delivered to my satisfaction & I have understood all terms and conditions of warranty, service schedules & maintenance tips and shall abide by them.

Customer's Signature (To be filled in by the dealer)

Important - "Do not detach this page from Owner's Manual"

34

Dealer Code :

Dealer Name :

Address

Contact No. :

:

Warranty : Scope & Limit

Bajaj Auto Limited gives the following warranty in respect of the

“Pulsar 135 LS”

motorcycle manufactured by them.

Every possible care and precaution has been taken to ensure quality in respect of the material & workmanship in the vehicles manufactured by us. Bajaj Auto Limited will repair or replace at their Authorised Workshops, free of charge, part or parts there of as may be found, on examination, to have manufacturing defect within a period of 2 Years or 30,000 Kms., whichever occurs earlier from the date of sale subject to fulfillment of condition stipulated in part A, B & C given here under

Warranty is applicable for only first owner of vehicle.

Part A:

Warranty claims in respect of such items like shock absorbers, speedometers etc. though claimed through us, are subject to acceptance of the respective manufacturers.

In all such cases the decision of the respective manufacturer will be final and binding.

Proprietory parts like tyres, tubes, battery and spark plugs are warranted by their respective manufacturers (Only one year warranty from the date of purchase/as applicable) and should be claimed on them directly by the customer.

Bajaj Auto Limited shall not be Liable to replace them

35 though their dealer will give full assistance in preferring such claims.

Bajaj Auto Limited undertake no liability in the matter of consequential loss or damage caused due to the failure of the parts. Delay, if any, at the repairing workshop in carrying out repair to vehicle shall not be a ground for extending the warranty period, nor shall it give any right to the customer for claiming any compensation for damages.

Bajaj Auto Limited reserves the right either to repair or replace the defective parts.

Where a defective part can be replaced by part/s of alternative brand/s, which are normally used by Bajaj

Auto Limited in the course of manufacture, Bajaj Auto

Limited reserves the right to carry out the replacement by a part or parts of any such alternative brand/s.

This warranty and any claim arising there from is subject to Pune jurisdiction only.

Part B:

No claim for exchange or repair can be considered unless the customer : a. Ensures that immediately upon detection of the defect, he approaches any nearest Authorised Bajaj

Vehicle Dealers & Recommended Authorised Service

Centers with the concerned vehicle and enables him


to remove and despatch the part / parts attributing to the manufacturing defect to the Company.

b. Produces the Owner's Manual, in original, to enable that dealer to verify the details.

It must be expressly understood that claims forwarded directly to us by the owner / customers will not be entertained at all and such defective part/parts thus forwarded by them will lie at our factory at their own risk, and this warranty shall not be enforceable.

To avail benefits of warranty, following are mandatory

1. Availing of Initial 3 Free Services without lapse.

2. Availing 4 paid services at every 5000 kms. or 120 days whichever occurs first without any lapse.

3. Availing of all above services at the Authorised

Vehicle Dealers & Recommended Authorised Service

Centers.

4. Maintaining all service records duly signed and stamped by dealers.

5. Usage of only recommended engine oil

“Bajaj DTS-i 10000” at specified frequency for drain interval of 10,000 kms . & engine oil level top-up at

5000 kms.

6. Replacing mandatory periodic parts such as air filter, oil filter etc. as per periodic maintenance schedule.

36

Part C :

Further this warranty is NOT applicable to :

1. Normal maintenance operations like brake & clutch adjustments, cleaning of fuel system, engine tune-up or such other adjustments.

2. Parts subjected to normal wear & tear like Clutch

Plates, Brake Shoes, Chain, Sprockets, Fork Oil

Seal, Spark Plug, Control Cables, Brake Pads.

3. Replacement of electrical items like self-start’s wear and tear items (if fitted), bulbs & rubber components like grommets, ‘O’ rings, bellows as well as filters, packings, gaskets, fasteners etc.

4. Painted parts. Only blistering or peeling off of paint film are covered under warranty. Any defect arising out of external damages or due to usage of protective covers /additional protective coatings adverse atmospheric condition etc. is not allow like under warranty.

5. All consumables like Engine oil, Fork oil, Brake Oil,

Grease etc. are chargeable to customer.

6. Any defect arising due to above consumables not changed as per scheduled or if used other than the recommended one.


7. All chrome plated parts are prone to rust or corrosion in coastal area or in acidic environment or due to neglected cleaning etc. However chrome film peeling is covered under warranty in general atmospheric conditions. Blue/ Yellow colouration of silencer near exhaust port is permissible and hence not covered under warranty.

8. Oxidation of unpainted/painted crankcase, cylinder block, cylinder head etc. in acidic environment or in a coastal area.

9. Valve lapping (De-carbonizing) is to be carried out if required.

10. Parts of the vehicle that have been subjected to misuse, accident, negligent treatment OR which have been used in conjunction with parts & an equipment not manufactured or recommended for use by Bajaj

Auto Limited, if in the sole judgement of Bajaj Auto

Limited, such use prematurely affects the performance and reliability of the vehicle.

11. Parts of the vehicle that have been altered and modified or replaced in unauthorized manner like use of wider tyres, loud silencers etc and which in the sole judgement of the Bajaj Auto Limited affects its performance and reliability.

37

12. Vehicles which are not being serviced at recommended dealers as per the service schedule described or which have not been operated or maintained in accordance with the instructions maintained in the Owner’s Manual.

13. Vehicles used for any competition or race and/or for attempting to set up any kind of record.

14. Any failure arising due to use of adulterated or bad quality fuel.

Parts affected due to bad fuel quality are not covered

Under warranty.

15. If additional electrical accessories such as -

Remote, Bigger horn, Musical brake light etc. fitted on vehicle.

16. If the vehicle has been used for commercial purpose like Taxi or any other means of commercial transportation.

Bajaj Auto Limited reserves the right to make any changes in design or to add any improvements on the vehicle at any time without incurring any obligation to install the same on a vehicle previously supplied and sold. Also, the conditions of this warranty are subject to alteration without any notice.

This warranty is the entire written warranty given by Bajaj

Auto Limited for

“Pulsar 135 LS”

motorcycle’ and no other dealer or its or his agent or employee is authorised to extend or enlarge this warranty.

BATTERY WARRANTY CARD

MAKE OF BATTERY : ........................

BATTERY SR. NO.

:

TYPE OF BATTERY :

NAME OF OWNER AND ADDRESS :

MFG. CODE OF BATTERY :

BATTERY CHARGING DATE :

VEHICLE SALE DATE :

TYPE OF VEHICLE :

FRAME NO.

:

REG. NO.

:

ENGINE NO.

:

2

3

4

5

6

SERVICE RECORD

Sr.

No.

Date

Age

Mths.

1

Specific

Gravity

Voltage Remarks

Dealer’s Stamp

& Signature

* Code

* Code For Remarks:

LL : Low electrolyte level.

AE : Electrical system needs attention.

IR : Insufficient running of vehicle.

CB : Cover broken.

BC : Broken Container.

PM : Poor maintenance.

BA : Battery abused.

Note : Customer should insist that “Service Record" must be filled by respective authorised battery dealer as proof of specified maintenance for easy settlement of claim, if any.

TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS

IN CASE OF CLAIM

Name of Dealer & Code :__________________________________________________________________

__________________________________________________________________________________________

Date of claim :________________________________________________Battery Type :_______________

Serial No. :__________________________________________________Date of Fitment :______________

Failure Mode (Please tick as applicable)

• Loose connection

• Internal Short

• Plate Shedding

• Intercell Connection

• Does not Hold Charge

• Wrong Assembly

• Wrong Application

• Terminal Corroded

• Overcharge / Undercharge

• Reverse Charge

• High Specific Gravity Electrolyte

• Electrolyte Contamination

• Electrolyte Level not Maintained

• Left Lying Idle

# Claim Accepted ## Claim Rejected

Details of Repair, if any____________________________________________________________________________

Note:

Please contact nearest respective authorised battery dealer for details immediately after purchase of vehicle.

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