Bajaj Auto Pulsar 200 NS, Pulsar AS 200 Owner's Manual

Foreword

Welcome to the Pulsar family!

You are now the proud owner of the next generation Pulsar 200 NS / Pulsar AS 200, 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 200 NS / Pulsar AS 200’ 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. Speedometer Setting

8. Control Switches

9. Rear seat / Tool kit

10. Front Seat / Battery

12

14

16

17

11. Fitment of Front & Rear Seat 18

12. Removal & Fitment of Side Cover LH & RH 19

5

8

9

10

1

3

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. Free Service Guidelines

22. Periodic Maintenance & Lubrication Chart

26. Non Use Maintenance

23. Delivery Certificate

24. Warranty Scope & Limit

25. Battery Warranty Card

28

29

31

33

34

35

40

41

42

20

21

25

26

27

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, Single Cyl.

: 72.0 mm x 49.0 mm

Engine Displacement : 199.5 cc

Compression Ratio : 11 +/- 0.5 : 1

Idling Speed

Max. Net Power

Max. Net Torque

Ignition System

Spark Plug

Spark Plug Gap

: 1350 ~ 1450 RPM

: 23.5 PS at 9500 RPM

: 18.3 Nm at 8000 RPM

: DC

: 3 Nos

: 0.7 ~ 0.8 mm

Transmission : 6 speed constant mesh

Gear Shifting Pattern : 1 Down 5 Up

Engine Lubrication : Pressurized oil supply

Engine Cooling

Starting Aid

: Water cooling

: Electric starter

Front Brake

Rear Brake :

: Hydraulic Disc type

Hydraulic Disc type

1

Fuel Tank Capacity

Full

Usable Reserve :

: 12 liters

2.4 liters

Unusable Reserve : 0.2 liters

Dimensions

Length

Front

Rear

:

:

2017 mm

Width

Height

Wheel base : 1363 mm

Ground clearance : 169 mm

Tyre Size

: 804 mm

: 1075 mm

: 100/80-17,52P tubeless

: 130/70-17,62P tubeless

Tyre Pressure

Front

Rear (Solo)

Rear (with pillion)

:

:

:

1.75 kgf/cm (25 PSI)



Technical Specifications

Electrical System

Head Lamp

Position Lamp

Tail /Stop Lamp

Side Indicator lamp :

:

: 12 Volts DC

: H4, 55/60W

: 3W (2 nos.)

LED type

10W

Neutral Indicator

Hi Beam Indicator :

: Green LED

Blue LED

Turn Signal Indicator : Green LED

Side Stand Indicator : LCD

Speedometer Illumination : LCD Blue

Fuel Level Indicator : LCD Bar

Low Oil Pr. Indicator : LED-Red

Coolant Temp. Indicator : LED-Red

Low Battery Indicator : LED-Red

Bajaj Logo : LED-Blue

Rear No. Plate Lamp : 3W

Horn

Battery

: 12V DC

: 12V - 8 Ah VRLA

Vehicle Kerb Weight : 154 kg.

Gross Vehicle Weight : 284 kg.

2

Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without any notice.

• This vehicle complies to BS IV standards.

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 200 NS)

On RH Side of Steering Tube

(Alpha-Numeric - 17 Digits)

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 AS 200)

Below Pillion Seat

(Alpha-Numeric - 17 Digits)

4

Location of Parts

Digital

Speedometer

Fuel Tank Cap

Manual Choke

Lever ( )

Clutch Lever

Front Fork

Disc

Brake

Note: Photograph is of Pulsar 200NS.

Gear Change

Lever

5

Side

Stand

OFF ON

LED

Tail

Lamp

Pillion

Foot

Rest

Location of Parts

Grab Handle Pillion Seat Rider Seat

Rear

Number

Plate

Nitrox Rear

Shock Absorber

Front Brake Lever

MAX

MIN

Coolant

Level

Indicator

Radiator

Expansion

Tank Cap

Rear Disc Brake

Note: Photograph is of Pulsar 200NS.

Rear Brake

Pedal

6

Paper oil

Filter

Belly

Pan

Radiator

Location of Parts

Grab Handle Pillion Seat Rider Seat

Rear

Number

Plate

Nitrox

Rear Shock

Absorber

Rear Disc Brake

Note: Photograph is of Pulsar AS 200

Rear Brake

Pedal

Paper oil

Filter

7

Radiator

Front Brake Lever

MAX

MIN

Coolant

Level

Indicator

Radiator

Expansion

Tank Cap

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.

8

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 locking on handle position left hand side only.

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

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

Seat’.

Fuel Tank Cap / Fuel Tap

Fuel Tap

Fuel Tank Cap

Fuel Tank Cap

• To open the fuel tank cap, open the flap.

Insert the key in the lock and turn it clockwise and lift fuel tank cap.

• 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.

Caution :

In case petrol is spilled out on white colour petrol tank, it is to be immediately cleaned with clean soft cotton cloth to prevent permanent stain marks on petrol tank.

9

Precaution :

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

Fuel Tap

Fuel tap lever has following positions.

ON : When fuel level is above reserve position.

RES : When fuel level is below reserve position.

OFF : When fuel supply is to be cut off.

Speedometer Details

Green

Green

Blue

Red

Red

Red

Blue

1

2

3

4

5

6

7

8

9

Speedometer display will work when Ignition switch is at ‘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

10

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

7. Low Oil Pressure Indicator ( ) : It glows when engine oil pressure is low.

8. Coolant Temperature Indicator ( ) : It glows

0 when engine coolant Temperature is more than 115 centigrade.

9. Bajaj Logo : Bajaj logo flying ‘B’ continuously glow.

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

Clock & Service reminder.

Speedometer Details

19

11. Engine Rev Indicator : It blinks when engine RPM cross 10000 RPM mark. Remains continously ON at

RPM more than 10500.

12. Service Reminder ( ): ‘Wrench’ symbol glows when ODO meter reading reaches to set Kms. for service. This Icon will flash at st nd

1 : 450 km 2 : 4450 km, rd th 3 : 9450 km, 4 : 14450 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 down, the Side stand indicator will glow.

11

11

12

13

14

15

16

17

18

14.

Digital Clock: It indicates time in HR : MM (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 not 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).

Speedometer Setting

Service Reminder

TRIP 1/2

Mode M

S Set

1. Trip Meter Reset :

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

1. Press mode push button for less than 2 sec.

Mode changes from

‘ODO/TRIP1/TRIP2’

2.

Press set push button for more than 15 sec.

Selected mode

‘TRIP1/TRIP2’ will reset.

Other TRIP mode will continue updating.

12

2. Service Reminder Reset ( ) :

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

This icon will glow at-

1st : 450 Kms

3rd : 9450 Kms

2nd : 4450 Kms

4th : 14450 Kms

& subsequently at each 5000 Kms.

Note : Bring the motorcycle at authorised BAL dealership for re-setting the service reminder icon.

Speedometer Setting

Mode M

S Set

Clock

TRIP 1/2

3. Clock Reset :

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

• It is 12 hour clock.

• Initially ‘:’ will be blinking

• Clock setting is possible in TRIP 1 mode only.

13

1. Press mode push button for less than 2 sec.

2. Press mode & set push button together for more than 2 sec.

3.

Press mode button for less than 1 sec.

4.

Press set button for less than 1 sec.

5.

Press mode & set button together for more than 2 sec.

TRIP1 Mode selected

‘:’ stops blinking

Digits starts blinking

Hour digits will increases by one.

Minutes digits will increases. If mode/set button is pressed continuously then digits will stop blinking.

Set value will be saved

Exit clock setting mode

Digits stop blinking

‘:’ start blinking

6.

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

Auto exit without saving set value.

If engine/vehicle rpm is given then system will exit from clock set mode without saving set value.

Control Switches

A

C

B

D

Left Handle Bar Switches

A. Hi / Lo Beam Switch : Head lamp low or high beam can 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 stop blinking push the knob in & release.

14

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

D. Pass Switch : Press the switch to operate high beam filament in head light.

It is used to give signal to vehicles c o m i n g f r o m o p p o s i t e s i d e w h i l e overtaking.

Control Switches

F

AHO Feature

(Automatic Headlight ‘ON’)

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

E

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

15

Hi beam

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 lamp, 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

‘ON’

No change

Rear Seat / Tool Kit

A

Tool Kit

First Aid

Kit

Removal of Rear Seat

• Insert Key into lock (A)

• Turn the key clock wise.

• Pull upward front end of ‘Rear seat’

• Take out ‘Rear seat’

16

Tool Kit Location

• It is located below the ‘Rear seat’.

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

CAUTION : Always fit rubber strap for locking tool kit.

First Aid Kit Location

• It is kept inside seat cowl RH side.

Front Seat / Battery

B

Removal of Front Seat

• First remove ‘Rear seat’.

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

• Pull backward rear end of ‘Front seat’.

• Take out ‘Front seat’.

Battery

• It is located below ‘Front seat’.

17

Fitment of Front & Rear Seat

Front seat lug & bracket

C

A

B

D

G

E

F

H

Fitment of ‘Front Seat’

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

• Push ‘Front seat’ toward petrol tank.

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

• Tighten the bolts (D).

Fitment of ‘Rear Seat’

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

• Place ‘Rear seat’ on 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

E

G

B F

Removal of Side Cover LH or RH

• Remove pillion & rider seat first.

• 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 from hole provided on ‘Chassis’.

• Take out side cover .

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

19

Fitment of Side Cover LH or RH

• Match Lug (D) provided on front portion of

‘Side Cover’ with hole (E) provided on

‘Chassis’ and press ‘Side Cover’ inside.

• Match Lug (F) provided on rear portion of

‘Side Cover’ with hole (G) provided on

‘Chassis’ and press ‘Side Cover’ inside.

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

• Fit pillion & rider seat.

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

Daily Safety Checks

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

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

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

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

• Drive Chain slack of 15 ~ 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.

• Smooth steering movement without restriction.

• Side 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.

20

How to Ride Your Bike

1. Starting The Engine :

• Turn the fuel tap to ‘ ’ or ‘ ’ position.

• Turn ignition switch key to ‘ ’ position.

• Put 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 on LH side of carburettor.

• Keep throttle 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.

OFF

ON

Note : Do not let the engine idle longer than

3 minuets otherwise it will overheat.

21

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

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

Note : The motorcycle is equipped with a starter lockout switch. This switch ensures that engine does not start if the transmission is in gear. However, the engine can be started in any gear if the clutch lever is pressed.

Note : Incase of battery discharged condition, vehicle will start by push start.

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.

• Depress the clutch lever.

• Shift into 1 gear.

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

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


Gear shifting Lever

2

N

1

3

4

5

6

Gear shifting pattern

Recommended Speed for Shifting Down th th rd nd st

54 km/h

45 km/h

35 km/h

25 km/h

15 km/h

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

22

4. Braking :

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

• Shift down one gear at a time so that you are in Neutral when you come to a complete stop.

• When stopping, always apply both brakes at the same time. De-clutch as necessary to avoid engine stalling.

• Never lock the brakes, or it will cause the tyres to skid. When cornering, use brakes judiciously and do not de-clutch. Reduce your speed before you get into the corner.

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

5. Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.


6. Parking the Vehicle :

6.1 Parking using center stand.

• Center stand is available as accessories at dealership.

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

6.2 Parking using side stand.

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

•

Lock the steering.

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

Whenever vehicle is fallen down, remove plug of

' Y c o n n e c t e r d r a i n t u b e ' & d r a i n o u t accumulated petrol

Location - Near Main Stand

7. 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 6th

0 - 1000 10 18 24 32 40 48

1000 - 2000 16 24 30 38 46 54

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

• Do not 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.

'Y connecter drain tube plug’

23


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.

24

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

Fuel Check fuel lines & connections for leakage.

Spark Plugs Inspect and clean spark plugs.

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

Air Filter

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

Brakes

Clean the air filter element periodically. Replace as per

Periodic Maintenance Chart.

Clutch

Ensure that the brakes are not dragging / binding.

Ensure correct clutch lever play.

Tyre Air

Pressure

Always maintain recommended 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.

25

• 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

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.

C

A : Oil Filler

Cap

B : Oil Level

Gauge

B

D

Engine Oil Level Checking :

• Check engine oil level every day. Park vehicle perpendicular to the ground on level surface.

• 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 : 1200 ml.

• During engine overhaul : 1400 ml.

26

Model Recommended Grade

Engine oil

Pulsar Bajaj DTS-i SAE 20W50 API

NS/AS 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 - Tube Less Tyre

Wheel Puncture :

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

• Remove puncture by Filler or Plug method only.

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

Front Wheel

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

Removing Front Wheel :

• Park vehicle perpendicular to the ground on level surface.

• Remove speed sensor cable from case meter assembly.

• Remove front axle nut & take out.

• Remove front wheel assembly from fork.

Tyre Pressure :

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

Front

Pulsar NS/AS Rear (Solo)

25 PSI

28 PSI

Rear (with Pillion) 32 PSI

27

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

Battery

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

• When low battery icon pop-up on speedometer display, it is advised to reach

Bajaj dealer & get it charged immediately.

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

Battery : 12V - 8 Ah VRLA

• Battery is located below front seat.

Battery Features :

• No topping-up is required

• Reduced self discharge, Enhance 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

How to keep battery healthy ?

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

• Get battery checked/ charged during periodic services.

• Do not press starter button for more than

5 sec. After 3 successive cranking, wait for

15-20 sec. for battery to recover.

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

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

Engine Cooling System

C

B

A

Radiator

Cap

Expansion Tank

• Coolant is provided for cooling of engine.

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

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

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

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

29

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

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

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

Coolant

Coolant Level Inspection Window

Reservoir cap

(for coolant top up)

Coolant Specifications :

Use antifreeze ready to use

“Bajaj Koolex” coolant only.

MAX

Max

Min

MIN

Warning : Coolant is poisonous and causes health hazard.

Avoid contact between coolant & skin, eyes and clothing. 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

30

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 by using side stand.

• Check coolant level in engine cold condition only.

• Ensure coolant level is between Min & Max mark.

• Always top up coolant through expansion tank cap (A).

• Always replace coolant with “Bajaj Koolex” coolant only.

• Use nitrile rubber hand glows while draining

& topping up coolant.

• Do not top up coolant through radiator cap.

Periodic Maintenance Information

Spark Plug

• Remove spark plugs by using plug spanner.

• Clean the spark plugs.

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

Spark Plug Gap : 0.7 to 0.8 mm.

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

(LH ‘A’ + RH ‘B’) or UR6CC-BOSCH

(1 No. ) : RER6YCA-Champion

(Central ‘C’) or YR5NEO-BOSCH

A C

Drive Chain Slackness

• 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.

31

Periodic Maintenance Information

Drive

Chain

Cleaning

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 .

32

Drive

Chain

Lubrication

Method of O-ring Chain Lubrication :

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

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

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

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

Brake Fluid

Front

Brake

Fluid

Reservior

Front & Rear Brake Fluid Level

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

• Rear brake fluid reservior is located behind

RH pillion holder bracket.

• To check oil level, Park vehicle perpendicular to the ground on level surface with handle bar in straight ahead condition

• Always ensure that brake fluid level is above

‘MIN’ mark given on inspection Window.

33

Rear

Brake

Fluid

Reservior

Brake Fluid Replacement

• Check & Adjust brake fluid level in every service.

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

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

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.

34

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

CL

CL

L

CL,A,R

CL,R

CL

CL

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

L

CL

L L

CL,A

R

CL

CL

L L

CL

CL

L

R

R

Use recommended

Molycote grease.

 Tick in the box after replacing the periodic parts.

35


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

CL,R


4500

~

5000

9500

~

10000

R

Every

5000 Km after


R R

R

CL

C,R

R

CL

C,R

R

R

Subsequent

R

CL

Replace if required.

C,R

C,A

C C C R

C,A

C C R

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

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,R

CL CL CL

C,R

CL CL CL

C,R

CL

Replace if required.

after replacing the periodic parts.

36


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


37


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

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

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

Use AP grease.


38


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.

39

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.

40

• 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

• 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.

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"

41

Dealer Code :

Dealer Name :

Address

Contact No. :

:

Warranty : Scope & Limit

Bajaj Auto Limited gives the following warranty in respect of the

“Pulsar 200 NS / AS 200”

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

42 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.

43

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

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.

44

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.

F itted 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 200 NS / AS 200” 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

• Wrong Assembly

• Wrong Application

• Overcharge / Undercharge

• Reverse Charge

• Does not Hold Charge

• Left Lying Idle

• Terminal Corroded

# 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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