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TO: Selected Dealers / Authorized Service Centers - 2 Wh Spare Parts Dealers & Distributors Sub: Introduction of “Pulsar 220 DTSi“
Product Category CC Group Bulletin No. Date
Motorcycle 220 NP: 12 23/06/2009
Dear Sirs: We are pleased to introduce ‘Bajaj Pulsar 220 DTSi’. This bike offers a great package of Style, Power & Technology in its class of bikes. We enclose herewith following information of this new bike, which gives you insight on product features, maintenance details etc.
Product related information
1. Salient Features 2. Technical Specifications 3. Comparison With Competition Vehicles 4. DC Ignition System 5. Read before you ride 6. Pre-Delivery Inspection Checklist
Maintenance related information
Annex – 1 Annex – 2 Annex – 3 Annex – 4 Annex – 5 Annex – 6
7. Pre-Delivery Inspection - SOP 8. Periodic Service SOP 9. Periodic Maintenance & Lubrication Chart 10. Critical Part List 11. Initial Kit List-Vehicle billing would start after dealer placing order Initial kit. 12. Frequently Asked Questions 13. Frequently Asked Questions related to Warranty 14. Reimbursement of warranty Jobs 15. Electrical Circuit
Annex – 7 Annex – 8 Annex – 9 Annex – 10 Annex – 11 Annex – 12 Annex – 13 Annex – 14 Annex – 15
Note:1. The existing Pulsar 220 DTS-Fi is not opened for non pro-biking dealers. Hence this model will be sold & serviced by probiking dealers only. 2. In view of above policy, the warranty & FSC of Pulsar 220 DTS-Fi will be claimed by probiking dealers as usual. Please go through above information. Ask your workshop & spare parts managers to share the same with all staff and act upon the action points as per action matrix enclosed. Thanking You, Yours faithfully,
Prashant G. Pingle Manager (Service-Probiking)
Cc to: Field Service Team/RTC team/RMs (Ser.)/RSMs/Technical Service Team
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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009
• • • • • • • • • • • • • Brawny masculine looks Stylish split seats 2 piece grab rail Tank spoiler Wolf-eyed head lamp Clip on - split type handle bar. Black styling Thicker and pinched clamped fork Naked chain with O ring. New colours. 3 D metallic decals on petrol tank. All black painting. Stylish stainless steel silencer. Clear lens blinkers. • •
Advantages & Benefits
Bold assertive stance, Sporty looks. Brains, brawn and definitely bold. The style that lets you break free.
• 4 stroke DTSi 220 cc air cooled engine with an oil cooler. Engine generating21 Ps @ 8500 rpm. • Digital twin spark ignition. • Digital DC CDI with TPS control • DC ignition system. • CV carburetor • New starter clutch. • Controlled lubrication system for clutch. • Bigger Exhaus-TEC. • Bigger catalytic converter. • DTSi technology advantages : 1. Good power and pick up. 2. Better fuel efficiency. 3. Lesser emissions. • DC Ignition system advantages : 1. Easy to start due to low trigger start RPM. 2. Cold startability improved due to auto choke. • Better engine performance • Ride that can be enjoyed due to 1. Razor sharp response to throttle inputs. 2. More power at all load conditions, better torque at low rpm, less emissions. 3. Ease of startability during winter mornings too. 4. Environment friendly bike. 5. Smooth gear shift
• Large 37 dia front fork with more stroke length. • Nitrox shockers at the rear. • Bigger suspension travel at rear due to smaller wheel dia. • Swing arm with needle roller bearings at pivot • Pinch clamp fork. • Wide tyres at front (90/90/17)and rear(120/80/17). • Clip on type handle bar. • • • • • • • • • • • • • • More stroke length to absorb shocks. Better dampening during high speed drives. More stroke length to absorb shocks. Low friction and high rigidity. Smooth - parallel fork sliding action. Better grip available. Isolation of vibrations due to rubber dampening. Smooth ride at any terrian. Smooth ride at any speeds/terrian. Comfort on country roads too. Excellent drive No sticktion at front fork. Excellent Road holding characteristics. No vibrations.
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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009
• Self cancelling indicators. • LCD Speedo console. 1 .Low Battery level indicator. 2. Filter foam clogging indicator. 3. Engine oil temp sensor. 4. Low Engine oil level indication sensor. 5. Day - night mode 6. Digital speed indication. 7. Tripmeter to record two trips. 8. Reserve indicator warning LED lamp. 9. Engine Over speed limiter. 10. Digital fuel gauge. 11. Tachometer for engine speeds. • Intelligent battery saves function during excess cranking. • Intelligent battery saves function during continuous head lamp ON condition. • illuminated handle bar switches. • Low maintenance battery. • High capacity O ring chain. • Anti scratch tank pad. • • • • • No need to push back the button after turns. Get the warning before battery conks off. Clean filter to keep engine healthy. Save oil related damages. Save oil related damages. Easy on eyes during night drive, can see during day time. Easy of reading Better to claim conveyance bills. Better fill up quickly. Protects the engine from excess raving. Easy to read. Monitor and maintain engine speeds. Disables cranking after three cranks, thus saving battery drain. Shuts off within 3.5 seconds, thus saving continuous battery drain. Delight to watch during night. Do not worry to fill up electrolyte level. Dust would not enter inside chain. Tank protected from scratches. Easy to ride without any driving/operating/maintenance hassles.
• • • • • • • • • • •
Bigger front disc brake. Bigger rear disc brake. Tubeless tyres. High strength chassis. DC head lamp Auto switch over to in tact head light filament in case of fusing. • 3000 combination ignition lock twin track key • • • • • • • Confidence inspiring brakes. • Confidence inspiring brakes. • Would deflate slowly allowing you to reach safely. • Better strength and stability on drive. • Better illumination during low idling speeds too. • Lights are always ON. • Pilfer proof. • Safety on drive by better braking/lights. • Lights are always present. • Safe even when not being driven.
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4 mm : : : : : : : : : : : : : : : : 220 cc 9. 21 Ps @ 8500 rpm 19 Nm @ 7000 rpm Microprocessor controlled digital C. multidisc type. : One. Natural air cooled. 3.I.9 mm Wet sump.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex . 5 W : 12 V DC .677 : 1 (26/24) : 7.) :12V 9Ah MF :12V . total weight PERFORMANCE Climbing ability : 28 % (16 ) 0 Type No. 10 W : LED : LED : LED : LED : LED Display : 12V.130 mm.814 : 1 (32/17) : 12. : : Telescopic with Guide & Slide bush (Stroke . :165mm. 10° BTDC 1000 rpm 26 ° bTDC at 2500 RPM Unleaded Petrol Carbureted 2Nos.2 Technical Specifications ENGINE & TRANSMISSION CONTROLS Steering Accelerator : Handle bar : Twist grip type on right hand of handle bar : Left foot pedal operated : Lever operated on left side of handle bar : Auto choke Front Rear ELECTRICALS System Battery Head lamp Pilot lamp( Tail/stop lamp Turn signal lamp Turn signal pilot lamp Side stand indicator lamp Hi beam indicator lamp Neutral indicator lamp Speedometer lamp Rear No. of cylinders Bore Stroke Engine displacement Compression ratio Idling Speed Maximum net power Maximum net torque Ignition system Ignition Timing Fuel Fuel Feed Spark Plug Spark plug gap Lubrication Starting Clutch Transmission Primary reduction Gear Ratios 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Final Drive Ratio : Four stroke.D. 5 speed constant mesh. 55 W H7 (Passing) :12V .335 : 1 (29/21) : 9.5 : 1 1400 +100 rpm. Forced Electric Start only Wet. :1350 mm. : 67 mm : 62.57 : 1 (37/14) :12 Volts (D.939 : 1 (24/26) : 2.5 + 0. : 282 Kg.) : Trailing arm with coaxial gas assisted Hydraulic shock absorbers and coil springs. 55 W H7 (Main) 12V. :1165 mm. : 750 mm. 2 nos :2035 mm. Champion P -RG6HCC 0.C. : 2500 mm. 5W 2 Nos : LED/LED : 12V .736 : 1 (36/13) : 16. : 24. : 152 Kg.47 : 1 (66/19) Gears Clutch Choke Brakes : : Lever operated on right side of handle bar : Pedal operated by right foot. CHASSIS & BODY Frame type Suspension: Front Rear : Double cradle type. plate Lamp Horn DIMENSIONS Length Width Height Wheel base Turning circle radius Ground Clearance WEIGHTS Vehicle kerb weight Max. Page 4 of 32 .8 to 0.
Rs. Ltd. 15% variation is allowed to cater for production and measurement variation.0 Psi) (Solo &Pillion) : 2.CV Page 5 of 32 . • Definitions of terminologies wherever applicable are as per relevant IS / ISO standards. Annex . 84435 (Mumbai) YAMAHA YFZ R 15 India Yamaha Motor Pvt. 425 (Chennai) On-road price (Mumbai) Rs.85 x 17 : 2. Midnight Black.Rs.00 kg/cm2 (28. 97.Rear Rims : Front Rear : Hydraulically operated disc brake : Hydraulically operated disc brake Tyres: : 90x90 X 17. DTSi.600 (Chennai) ENGINE & TRANSMISSION Air cooled. Yamaha Blue / Graphite / Blazing Red BAJAJ 220 DTSi Bajaj Auto Ltd. 49P. Tubeless : 120/80 X 17. Wine Red. 83638 (Mumbai) Red alloy wheel .25 kg/cm2 (32. 4 stroke Single Engine cylinder OHC Displacement 223 cm³ Engine horse 17ps @ 7000 rpm power Engine Torque 18. 76206 (Mumbai) Black alloy wheel . 61P. Grey Silver Ex-showroom price Rs.3 Comparison with Competition Vehicles COMPARISION WITH COMPETITOR PRODUCTS DESCRIPTION Manufacturer Colours HERO HONDA KARIZMA Hero Honda Motors Limited Sport red / Vibrant Blue / Moon yellow / Force Silver / Black with option of Black / Red Alloys Black alloy wheel . Tubeless : 2. 75471 (Mumbai) Red alloy wheel . 4 stroke Single cylinder SOHC 4 valve 149.0 Psi) : 1.00 kg/cm2 (28. Plasma Blue. 1. Constant Fuel supply Vacuum Carburetor with CCVI system (Carb controlled variable ignition) Liquid cooled. Air cooled /with an Oil Cooled 220 cm³ 21 ps @ 8500 rpm 19 Nm @7000 rpm 5 Speed Constant Mesh Carburetor . • Specifications are subject to change without notice.8 cm³ 17 ps @ 8500 rpm 15 N-m @ 7500 rpm 6 Speed Constant mesh Electronic Fuel Injection 4 Stroke.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Brakes: Front Rear Front Rear Tyre pressure: Front Rear Pillion .VE.35 N-m@ 6000 rpm Gear box 5 Speed Constant Mesh Carburetor . • All dimensions are under unladen condition.0 Psi)(Solo) : 2.50 x 17 NOTES :• Values given above are nominal and for guidance only.Rs.08.Rs.
2. 9 AH MF Champion P -RG6HCC 12 V.5W / 21W 12V . 10 W 2035 mm 750 mm 1165 mm 1350 mm 165 mm 152 Kg Tubular single cradle.Low beam .DC) 12V .5W / 21W X 2 nos.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 CHASSIS & BODY Frame type Suspension Front Suspension Rear Brakes Front Brakes Rear ELECTRICALS Ignition System Battery Spark Plug Head Lamp Tail / Stop Lamp Number plate Turn Signal Lamp Advanced Microprocessor Ignition (AMI) 12V .PRA 7 HC 12V . 3 D Metallic decals on petrol tank. (Multi reflector) TCI 12V .5W 12V . 1995 mm 670 mm 1070 mm 1290 mm 160 mm 131 Kgs. Delta Box frame 3. Diamond type Telescopic Hydraulic shock absorbers Swing arm with 5 step adjustable type Hydraulic shock absorber Disc Dia 276 (non asbestos type) Internal expanding shoe type Dia 130mm (non asbestos type) Delta Box Frame Telescopic Hydraulic shock absorbers Linked monocross suspension with spring/shock absorber Single Disc Single Disc Double Cradle type Telescopic front fork Trailing Arm with coaxial gas assisted hydraulic shock absorbers & coil springs Hydraulically operated disc brake Hydraulically operated disc brake DIMENSIONS Length 2125 mm Width 755 mm Height 1160 mm Wheel Base 1355 mm Ground clearance 150 mm Kerb Weight 150 Kgs. Brawny masculine looks.5W 12V . Bold new graphics 2.3. PERFORMANCE Max.35/35 W Halogen (Multi reflector .21W X 4 nos.DPR8 EA 9 CHAMPION . Linked type monocross suspension Microprocessor controlled digital CDI 12 V. Page 6 of 32 .35W 12V . 140 kmph 1.5 AH NGK/CR8E TWIN . 5 W 12 V.12V-35W High beam . 55 W H7 LED/LED 12 V.10W X 4 nos. Wolf eyes head lamp 3. (Multi reflector) 12V .12V .7 Ah NGK .4 valves .Fuel injected 2. Speedo dials in bright yellow for clear day time visibility 3. Speed 125 kmph STYLING DIFFERENTIATOR 1. Muffler cover with chrome finish Styling 1. Liquid cooled .
Sealed Starter relay – potting type to avoid water entry. Hi spark intensity at lo rpm due to DC input. Portable booster battery charger. No start – Water entry post monsoon.4 DC Ignition System Advantages Quick/ easy start. Trigger start rpm down to 200 from 350.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex . Page 7 of 32 . No starting Trouble after Washing. Sealed couplers everywhere to arrest water entry. Lower starting current drawn by Starter motor. Thus no issues even on vehicles running at slow speeds in city.38 Amps (46) Better brush life due to low current carry. Battery warranty period matched with vehicle warranty period. Easy Cold starting. Auto choke – Engine temperature Sensor provided to give rich mixture At winter mornings. HRD tester for better health check.25 Amps more charging current). (At 20 kmph speed 1. Battery life Better battery charging current at lower rpm and throughout the rpm range.
Do not direct the jet of water towards electrical parts and sensors. Do not use any additives with the petrol.Do not allow anybody to open them by using wrong tools. so as to avoid possible damage to wheel rim. Customer should visit authorized service station whenever these warning indicators start flashing. pl does take care of different sensors fitted on engine. "Happy Riding". Choked air filter indicator.Pl see to it that the chain never runs dry. Otherwise stain marks would be seen. Confirm that the vehicle is in neutral. The lubrication at every 500 kms with SAE 90 oil and adjustment at every 1000 kms would be essential. thus damaging aesthetics. The silencer would turn slightly chromish after initial use. Chain with built in O ring is fitted on this vehicle. Use better quality fuel only. indicating the need of maintenance for that part. Low battery charge level indicator. Anything above 87 octane rating. which is a natural phenomenon. Tyres fitted on this vehicle are tubeless tyres. Use both the brakes at a time. For stainless steel silencer. Go to authorized MRF tyre dealers who are equipped with necessary tools. Less engine oil level indicator. Do not add any additional electrical / electronic gadgets on the vehicle. Important Does and Don'ts : The powerful engine with quick throttle response would make the driver to open the accelerator with caution. Since the front axle weight is more. adulterated fuel should never be used. 1 2 3 4 C 1 2 3 4 5 6 7 8 9 Page 8 of 32 . Button starts the engine without opening throttle. Warning indicators on Speedometer : There are 4 indicators which would start flashing. Since this is a precision machine. Use of front brake for dead stop would give better control. Maintaining Battery charge level is very essential. care will have to be taken to avoid oil contact. " Wishing you a Pulsating ride "…………. as they would disturb functioning of engine management system. for starting of vehicle. High engine oil temperature indicator. the rear brake has been deliberately toned down to avoid skidding.5 Read Before You Ride A 1 2 3 B Starting the vehicle : Put the Ignition and Kill switch in ON position. Do not open the throttle suddenly.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex . fill up the fuel at the nearby filling station. As soon as "fuel res" red indicator light is ON. During washing of the vehicles.
specify source of oil leakage Check/Adjust if reqd( 1400+. M-10 2. Whether BAL Service Executive carries out sample PDI or Dealer staff does.5-3 kgm) FUEL SYSTEM Fuel Tank/ Pipes Carburettor Fuel Cock FRAME Tyre Pressure Front 2.6 Pre-Delivery Inspection Checklist (PDI) Following is the checklist for carrying out PDI of “Pulsar DTS i220. 6) gives detailed Standard Operating Procedure for PDI.5 PSI) CONTROLS Brakes Throttle Clutch Clutch cable Drive Chain SUSPENSION Front Fork No leakage/ smooth working(wipe out if any seepage Front Brake lever free play (2~3 mm) Rear Brake pedal free play(25~30mm) Grip Free play (2~3 mm) & smooth operation Smooth operation.00 Kg/cm ( 30.4 PSI) Rear Solo 2. each vehicle should be checked as per the points given below.5 Kgm) Rocker Arm Bolts( 2.00Kg/cm ( 28.DTSi Chassis No Engine No Dealer Name Date : PDI Done By Please ensure that following checks are carried out during PDI before Delivery of vehicle If OK To Check Check For X If Not OK Engine Engine Oil: SAE 20W50API SJ or SL+ JASO MA Idling rpm( Warm Up) Fasteners ( Check torque) Oil Level OK/Top up if required Oil leakage if any.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex .00 Kg/cm ( 28.4 PSI) Rear Pillion 2. no juddering.5~4.0Kgm) Drain Bolt (2.2 Kgm . This ensures trouble free vehicle delivery to the customer PDI Check List Pulsar 220cc.motorcycle. this checklist is to understand various check points those are to be checked / inspected before delivery of the new vehicle.8 2.100 rpm) with tachometer Engine Mounting Bolts ( M. While next annexure (no. Free play 2~3 mm Routing thru the bracket located near lower 'T' on vehicle RH side Slackness standard: 25~ 35 mm No leakage/ Correct Fitment No leakage/ Correct Fitment Smooth Operation Observati ons Remarks Page 9 of 32 .4 Kgm) Silencer Mounting Bolts( 3.
LH/RH side cover lock Front Axle nut . Petroleum jelly Position of fuse box ( 2 nos) All Bulbs Working Head light (both bulbs working). rider seat ( pillion+rider).terminals/ Cables.5~ 4.0 ~ 2. Trip meters.2 ~ 2.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Rear Shock Absorber Steering Lock operation Spring Adjuster notch position: 1st notch ( Standard) Smooth Operation ( No play/ Sticky movement) Steering cum ignition .8~ 9 Kgm Rear Axle nut 8~10 Kgm Handle Bar bolts 2~2. Odometer.2 Kgm ELECTRICAL Charge Status ( 12.2 Kgm Fasteners ( Check Torque) Steering Cap bolt 5Kgm RSA Mtg Dome nut .2. Headlight tail light illumination switch off after 3 seconds Pilot lights (2). High beam. Neutral Indicator.2.8 Kgm Brake Disc Allen bolts .2. Both LH & RH side spark plug caps must be tightly secured and ensure proper functioning of Spark Plugs. Fuel guage & Fuel Indicator red lamp CO% Check Cleaning CO should be 2% in engine warm condition at idling rpm Wash & Clean vehicle properly IMPORTANT NOTE Look for any external damages in transit: Please check.3. Tell tale icons on. Speedometer LEDS. Number plate lamps Auto switch "OFF" of Indicators(by moving Handle Bar Turn Pilot.6 ~ 3.8~ 10Kgm Caliper install bolts (Front & Rear) .2 Kgm Fork Pinch Clamp bolt . Side Indicator. LED Tail/ Stop.5V open circuit terminal voltage) HRD test (To show Green light only) Battery Tightness of battery. switch LH/RH. TPS on carburetor for functioning’s Page 10 of 32 .0 Kgm Swing Arm Pivot nut . Ignition.100 rpm) with tachometer Drive Ability Throttle response Brakes ( Front & Rear) Digital Speedometer. record & rectify send report with photos. Moisture / Oil collecting tube of Air filter should be properly fitted and routed correctly. Switch operation Starter Motor TEST DRIVE Starting LH & RH control. Fr& Rr brake & Kill switch Proper working/ Engagement Cold Start & Warm Start Working off Auto Choke( Click sound when ignition is turned "ON") Idling Speed ( Warm condition) ( 1400+/.
10 0. if required.05 0. Check front brakes for efficient working & Adjust if required.10 GP Tools Special Tools Consumables Petrol Dispenser Petrol.7 Pre-Delivery Inspection . ensure petroleum jelly presence. Waste Cloth RH RH Front Front 0.SAE 90 Oil 14 15 16 17 18 LH LH LH RH / Front Front 0.Rear Wheel. Petroleum Jelly. Set. Oil Can.05 Page 11 of 32 .05 0.10 0. OE Spanner. Check and correct tyre inflation pressure . Funnel OE Spanner Set Ring Spanner Air Pressure Gauge OE Spanner Set.10 0. Electrolyte Multi Meter. Oil Can OE Spanner Set OE Spanner Set OE Spanner Set Ring Spanner Set OE Spanner Set Cloth Suction Pump Pedaled Air Pump Cotton Waste.10 0.80 0. Check Rear brakes for efficient working & adjust if required.60 10 11 12 RH/L H Rear Rear 0. Study PDI card and Work content.SOP PNR & its Attach M&T/ Service Shop Equipments Lifter Bay Sr.20 Nose Plier. Check Accelerator cable free play Check & Adjust TPS Check gear shifter lever operation Check & Adjust steering and Handle bar for free movement.40 Cloth. Check clutch cable operation & Adjust if required.30 0. Check and Correct tyre inflation pressure . Battery Charger 9 LH 0.10 0.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex .20 Pedaled Air Pump 13 LH 0. and connect terminals properly. Inspect Rear Shock Absorber setting & Correct if necessary. Lubricate chain and Check / Adjust chain slackness if required. No 1 2 3 4 5 6 7 8 Description Identify & Park Vehicle on Work Bay Remove the Thermocol and additional packing if any.Front Wheel Check Battery voltage. Check front mudguard alignment wrt Front Wheel Posit ion SMM 0. check up electrolyte level.50 0. Hydrometer.50 0. Open Petrol tank cap & pour petrol Check for smooth operation of fuel cock lever Check & top up engine oil level. Screw Driver Shocke r Adjust Opened Spanner Set Air Pressure Gauge Ring Spanner Set.20 0.
Screw Driver. Spanner Set PNR & its Attach Consumables M&T/ Service Shop Equipments 4.00 Oil Can Oil.Allen Key 22 OE accessories fitment Leg guard. Check the following and lubricate if necessary • Rear brake lever • Pillion foot rest • Center stand • Side stand • Clutch lever OE accessories fitment -Mirrors RH & LH SMM GP Tools Torque Wrench. Odometer.15 OE Spanner Set Spanner Set. Nylon. Ring Spanner .70 + ve . Tail light. Socket Set. Speedometer.50 OE Spanner 28 LH/R H 0.50 Page 12 of 32 . Pass light indicators and Fuel indicator working Check working of all electrical switches Check Idling and CO%.35 Nose Plier LH/R H 0.Plier. Check operation of electrical like.25 Dial Type. Tommy Bar. Multipurpose Grease. Side stand indicator. Torque Wrench 23 24 25 26 Check electrical couplers of all sensors • Engine Temperature sensor • Oil level & Temperature sensor • Air filter IR sensor Start vehicle.40 0. SAE 20W40 Oil 21 1. Screw Driver LH/R H LH/R H 0. • Handle bar mounting bolt • Stem lower & upper bracket bolts • Stem of bolts • Front axle nut • Cylinder head nuts • Engine foundation bolts • Trailing arm bolts • Silencer cover shield bolts • Both LH/RH engine mtg. Parking.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. Check RPM meter.Ham mer. Side indicators. bolts • Rear Caliper bolts. REAR LH/R H 1. Brake light.60 12" Connector CO-HC Analyzer.Head light. No Posit ion LH/R H Special Tools Description Check all important nut bolts for torque and tightness. Tachometer 27 Front 0.00 19 20 RH/L H FRON T. Speedometer. Horn. Saree Guard LH/R H 3. Odometer & Trip meter for proper functioning and Correct if required Check all locks for proper operation LH/R H 0.
3 0. before delivery Repair for any other defects seen or observed during test drive. Clean Portion Below seat by brush Drain engine oil.3 0. Total SMM SMM GP Tools PNR & its Attach Consumables M&T/ Service Shop Equipments 29 1. Tol. Shop Equipments 1 2 3 4 Wash vehicle thoroughly. One technician can do 25 Vehicles PDI SOP comfortably. PNR PNR & its Attac Consumables M&T/ Serv.r. Annex .t. Start vehicle and Warm up.00 19. Identify the vehicle. Vehicle LH SM M Position of Tech. Vehicle RH SMM GP Tools Sp. In a shift of 480 minutes.7 Pistol grip PNR Socket set 6 0.r. No Posit ion Special Tools Description Test drive the vehicle.8 Periodic Service SOP Sr. Confirm Qty / Quality OR eng Oil 0.5 Washing boy 5 LH RH 0. w.30 OE Spanner.3 Cloth Oil Disposer. Description Position of Tech.2 Brush Pistol grip PNR Socket set 7 LH 1. Petrol tank and keep properly Remove rear seat. Air Gun Page 13 of 32 . Bring vehicle and position on bay.t. No.20 Total time taken for PDI SOP 19 Minutes approximately. check digital speedometer working. Clean/Wash the veh. Ring Spanner 30 31 1. Study the PDI job card and verify work done. w. Take vehicle out and park. Raise the lift.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. Remove RH/LH side covers Seat.
Start bike for 8-10 seconds & switch Off. RSA top & bottom nuts Remove Front Sprocket cover. Tol. 20W 40 Oil 10 Drain carburettor (Overhaul if required) LH 1. Dry the cover by compressed air. P. Clean inside of cover by pressurized water.. w. PNR PNR & its Attac Consuma bles M&T/ Serv.0 Brush G. (Replace .5 Plug Spanner 13 10. 0.r. Engine foundation bolts c.4 OE spanner set.t. Kerosene 11 Check accelerator & adjust Remove RHS plug cap & remove water inside sleeve by Compressed air. Check LH side important fasteners and tight a.t. Vehicle RH Sr.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Position of Tech. Vehicle LH Position of Tech. Shop Equipments 8 Take Clean marked vessel to measure oil drain. No.if necessary) RH 3 Pistol grip PNR Socket set Head Screw Driver Nylon Brush Plastic Tray Filter Cleaning Stand. Drain oil removing drain plug Refer to SA if less than 900 ml.6 15 LH 3. Remove the dust/dirt surrounding small sprocket by Screw drive/Blade & clean to specs. Side stand d.r. Cloth. Ring spanner set Pistol grip PNR Socket set 14 LH 0. Description SM M SMM GP Tools Sp.4 OE spanner set Pistol grip PNR Socket set 12 LH 0.3 RH Float Gauge Cloth. LH 0.000kms Check & Adjust Tappet clearance. Side bolts of front fork b.5 RH 0. Remove both plugs & set Gap (every Service) Replace Spark Plugs at interval of 20. tool kerosene Page 14 of 32 .5 9 Clean air filter. w.
Shop Equipments 16 Clean Chain with kerosene/Oil by nylon brush. Check & adjust rear brake for smooth working Check for mud on caliper pads .clean. (Replace if required) After 1 year or 10000km whichever is later. Clean terminals & apply Petroleum Jelly. replace damper if play observed. w. Dry the chain.5 0.Spray "OKS" on chain.t. Recharge battery if required Check Air pressure-10k Pump in nitrox to space (7. Clean oil strainer.r. Pliers. PNR PNR & its Attac Consumables M&T/ Serv. Remove wheel. clean centrifugal filter at 10. Rout cables properly & fit terminal caps properly.1 19 0.t.3 OE Spanner Set Page 15 of 32 .lubricate with 90 grade oil . Funnel Oil dispenser 25 Check clutch & adjust RH 0. Cloth Measuring jar 1 liter. Vehicle RH SMM GP Tools Sp.Re tighten if required. top up with Distilled Water.2 Spanner 22 RH 1. Cotton waste Multi Meter. Tol.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr.0 Brush Kerosene 17 18 0. No. Check Battery. Hydrometer.4 REAR RH 0. Screw driver Electrolyte . Check and Adjust rear tyre air pressure Checks for play in rear sprocket Nut. Petroleum jelly.5kg/cm2) with help of pump. Vehicle LH SM M Position of Tech. Adjust the Chain to specs. Ring Spanner Set Oil 20W50.r. Description Position of Tech. Check for rear damper play by rotating rear wheel.8 OE spanner.000 kms Fr Rh.1 20 0. Battery Charger 23 LH 1 RH 1 24 RH 6" Comb. w. 3.4 Air gun Pistol grip PNR Socket set Pencil Type Pressure Gauge 21 LH 0.
t. Shop Equipments 26 Fill engine oil (1150 ml) 1 1. Swing arm axle nut G. Vehicle LH Position of Tech. w. No. Replace kit if required.2 30 31 0. Ring Spanner set Pistol Grip.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Position of Tech. Silencer protective cover screws / bolts H.r. Handle bar bolts E. Check pads . Air gun Filler Gauge Spark Plug Cleaning Machine Air Gun 27 Clean. w. spongy feeling. Side bolts of Front fork D. Rear view mirror RH 1.3 OE Spanner Set. Check & adjust RH Spark Plug (Replace . Remove fork pipe tubes. Check & Adjust play.2 32 32 33 FRONT 0. Vehicle RH RH Sr. Front axle nut C.t. Check for leakage.if required) RH 2. RSA top & bottom nuts F. Check / Adjust front tyre air pressure 0. PNR Socket Set Page 16 of 32 . Engine foundation bolts B.4 Cloth 28 Check & Top-up brake fluid level 2 FRONT 1 Screw Driver Ring Spanner Set Piston Ring Suction Pump 29 Check & Replace the parts if necessary.r.4 Ring Spanner Set Pencil type Pressure Gauge 34 Check & adjust steering RH 0.Replaced if required. Tol.8 35 Check RH side important fasteners and tight A. drain oil Clean pipe inner with kerosene & then refill new oil from Company supplied bottle (320ml/tube). Description SM M SMM GP Tools Sp.35 Ring Spanner Set Plier Ring Spanner Set Spark Plug Spanner Cloth 20W50 Oil Oil disposer. PNR PNR & its Attac Consumables M&T/ Serv.
Tol.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. Air filter IR sensor Check RPM meter. Check electrical couplers of all sensors a. Clutch lever b. Check drain pipe pinching & Check spring position. Seats. Front and Rear both sides h.r. Grease. Description Position of Tech. Ensure all lubrication points are Covered as per lubrication chart. Speedometer. Check all electrical switches b. Clean the Cavity below. Cloth 37 Refit RH. LH RH 0. Shop Equipments 36 Lubricate as per lubrication Chart a. LH RH 0. Brake light e.0 39 0. Cap with clean cloth. Pillion foot rest c.t. Pliers Page 17 of 32 . Head light c.r. w.35 sensor c. Side indicators. Engine temperature sensor b. Pass. Oil level & temperature 2.if water traces found in pipe Remove tank. Check operation of electrical like -a. Fuel indicator 41 FRONT 0.5 42 RH REAR RH/RR FRONT RH/LH 0.3 40 LH 0. PNR Socket Set 38 Blow Compressed air in petrol tank drain pipe. Tail light d. Petrol tank assly. PNR PNR & its Attac Consumables M&T/ Serv. Parking light g.8 Oil can 20W50 Oil. Graphite. No.5 Pistol Grip. LH side covers. w. Speedometer. Center stand d.95 Philips Screw Driver Ring Spanner Set Comb. Odometer. Side stand.t. Horn f. Vehicle RH SMM GP Tools Sp. Vehicle LH SM M Position of Tech. Odometer & Trip meter for proper functioning & Correct if required Start vehicle. Side stand indicator i. Refit the pipe properly.
3 0. No. In a shift of 480 minutes. Tol.t. Vehicle RH SMM GP Tools Sp. 2 Technician working. w. Shop Equipments 43 Tune engine & carburettor Study job card & verify work Lower the lift. w.3 5 21. Page 18 of 32 .( except major maintenance jobs) In a shift of 480 minutes.5 51 Clean the vehicle at the time of delivery 1 Total time taken for Periodic SOP 33 Minutes approximately.3 16. Vehicle LH SM M Position of Tech. Take out & park the vehicle SUB TOTAL Carry out any additional work as indicated by the customer or as required TOTAL TIME Test ride of the vehicle if required and park LH 2 8" Small connector 44 45 46 47 48 49 1 0.55 5 21.r.t.r. One technician can do 15 Vehicles Periodic SOP comfortably.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. 23 Vehicles per Bay per Day can be achieved comfortable with 1 Bay.5 16. PNR PNR & its Attac Consumables M&T/ Serv. Description Position of Tech.55 To be done by Expert To be done by Delivery boy 50 1.
A C.A T CL. 500750 30-45 P C.000 kms.Every one year R .Every two years.A C. adjustment Fuel system leakage Fuel pipes Air breather tube Spark plug gap Battery electrolyte level Brake light switch Clutch play Throttle play Rear brake pedal free movement Brake pads wear (front & rear) Steering play All fasteners tightness including eng.C C C.A C.A C.A C C. Whichever comes first SN Operation OR Day 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Servicing Idle speed / CO % Engine oil (SAE 20W50 of API SJ or SL+JASO MA) Valve tappet clearance Oil strainer / Centrifugal filter Air cleaner element Air cleaner element* Carburetor draining Carburetor O/H cleaning.A T CL.500km Every 75 days C.A.C C C.A C C.A C. C.if required R .000 kms.500 kms. R If reqd. Every service C.A C.A. SAs should explain & educate customers on this.A L C.Every 15000 km.A C.C C C.A T CL.A R C. Attending specific element at specific period/kms and enable consistent performance of the vehicle.A CL D CL D CL D Subsequent Every 2.A C.A C. R -if required L -Every 15.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex .C C C.A R -Every 10. C. Every 5.A Replace if required C. mtg bolt Engine mtg.9 Periodic Maintenance & Lubrication Chart During scheduled periodic services & after warranty period while customer avail services. C -Every service L L -Every 10000 kms.000 kms.A C.A T C C C C KMS. one should follow the given below maintenance chart for carrying out recommended job elements.A C.A R C.A T C -Every 20.A.A C. silent bush Tyre thread wear General lubrication Steering stem bearing Wheel bearings Swing arm pivot pin Front fork Front fork oil Fork oil seal and dust seal kit C.000 kms.A CL CL D RECOMMENDED FREQUENCY Initial 2.A.000 kms R-if required. R . C . 240 days from date of sale P P P C.A C.A C.A C C.A C.A C.A C C.A Every 5000 kms Every 5000 kms Every 10000 kms CL R -Every 15000 kms D -Every Service Every 10000 kms if required. Page 19 of 32 ./20000kms R .A L L L L CL.A C.Every 10.
Every 10.000 kms. Page 20 of 32 .A C. CL-Clean .Every 15000 R -Every 30. C .2 years or 30. Rif required C -Every year R -If required CL -Every Service Every 15.000 kms.000 kms. Every 30.000 kms. Rif required C .R L C C. C .Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Whichever comes first SN Operation OR Day 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Rear shock absorbers Drive chain Drive chain wear/Remove/Clean/Inspect/Lubricate Drive chain lock Engine compression pressure Cylinder block piston and head de-carbonizing Cylinder head .Valve lapping Valve oil seal Swing arm mtg.A C.500 kms.Every service C-Every service L-Every 5.Replace Note: Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.000 kms. Every 15.Every Service C -Every 20000 kms. R -Every 10. T -Every 5. Note:-Warranty limit:. C.R C C.000 kms. bush / bearing Gap between reed switch & TPS magnet Clutch plate Carburetor rubber duct Silencer drain hole cleaning Air filter cover "O" ring Rear wheel rubber shock damper Rear sprocket fasteners Auto choke functioning Front brake lever play Oil cooler pipes Lubrication of gear starter clutch Clutch.Lubricate. Every 5.000 kms. R-Every 20000 kms. Engine Overhaul = 1100 ml.000 kms. Every 5000 kms.L R Every 5. R. R -Every two years R -Every two years R -Every two years R -Every two years C C. Accelerator cable Master cylinder cup and dust seal Caliper piston and dust seal Front brake hose Starter clutch bush kit Clutch switch cleaning Brake fluid change CL CL CL CL C C C C KMS. C C .000 kms.A C.A C. C -Every 15.CL. 500750 30-45 RECOMMENDED FREQUENCY Initial 2. L -Every 500 kms.000 kms.Check L . Model Pulsar 220-F CC Engine Oil Grade SAE 20W40 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ Grade or Superior Quantity Drain & Refill = 1000 ml.000 kms.Adjust .000 kms. T – Tighten .Every Month. 240 days from date of sale Subsequent Every 2. 4 Free Services & 9 Paid Services for warranty remains valid. or once in a year A . C.( Whichever occurs earlier).R T C C.000 kms. C -Every 20.R R -Every 15000 kms.500km Every 75 days C .
SILVER "B" monogram on Tank RH .Black Gasket Cylinder Block Master Kit .10 Critical Parts List Critical parts list for maintaining customer satisfaction : WM to review the stocks every month start/mid month.SILVER Decals seat .Red Front Fender. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Description Cylinder head Camshaft assly Valve kit Valve repair kit Block piston assly Clutch Friction Disk -C.BLUE.Cowl . BLACK "B" monogram on Tank LH . Clutch Friction Disk -B Plate Clutch Oil cooler Oil cooler pipe inlet Oil cooler pipe outlet Banjo bolts for oil cooler Banjo bolts washer for oil cooler Element air filter Silencer Oil pump assly Rotor Assly .Black Front Fender .RED.Blue Speedo Cable Assly Fork Inner Pipe Front Disc Decals .Silver Front Fender .F Stator plate .Red Decals seat .Silver Front Fender.BLUE.Cowl Midnight Black Fairing .Red Petrol Tank.Cowl Silver Grey Decals seat .No Description Min level 2 2 2 2 2 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 2 2 2 2 2 2 2 2 5 5 P-220 DK101607 DJ101373 DK101326 DK101327 DK101625 DK101567 DK151066 DK151068 DK101565 DK101634 DK101630 DK101631 DK101236 DK101279 DK121009 DK101482 52DH0169 JC111027 JC111026 JC111023 JC111022 DG111008 DK201001 JC111007 DK101595 JC101112 DK161137 DK161138 JC151013 DK151050 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 Headlight Assembly Blinker Fr LH Blinker Fr RH Blinker Rr LH Blinker Rr RH Petrol Tank.Blue Petrol Tank .Maintaining bare minimum level of all these parts is very essential from customer satisfaction point of view.Petrol Tank "B" monogram on Tank LH .Black Petrol Tank . BLACK "B" monogram on Tank RH . Service engineer to audit few parts from the list updated by spares manager. SR.Silver Fairing Blue Fairing .Red Fairing .Cowl Plasma Blue Decals seat .Major ( Front Brake) DK201056 DJ201208 DJ201209 DJ201206 DJ201207 DK71032V DK71034M DK71034K DK71034L DK74032V DK74034M DK74034L DK74034K DK201098 DK181070 DK151027 36DK0026 JC141049 JC141053 JC141050 JC141054 DH73032V DH73034K DH73034L DH73034M DK74012V DK74014L DK74014K DK74014M DK101063 DE191043 Page 21 of 32 . Clutch Friction Disk.RED.F HT coil RH HT coil LH Spark plug LH / RH Regulator voltage Starter motor Body complete starter clutch Gear starter clutch Holder step LH Holder step RH Wheel rim front Wheel rim rear Chain sprocket kit Min lev el 2 2 5 5 2 2 2 2 2 1 1 1 10 20 10 2 1 1 1 1 1 5 1 2 3 2 2 2 1 1 2 P-220 SR.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex .
LH Handle bar .11 Initial Kit List Sr.No Description Min level 3 2 2 3 5 1 2 2 2 10 2 2 2 P-220 Disc pad set front Rear caliper pad with shims Brake pedal / tie rod Lock set Switch RH Fork oil seal Tube fuel Main relay Fuse Wiring Harness .RH Handle bar .Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 SR.No.95 194 Page 22 of 32 .F Engine temp sensor Camshaft sprocket Camshaft bolt Speedometer Assly -S Speedometer Assly .5 101 830 879 625 624 123 54. 1 2 3 4 5 6 7 8 9 10 11 12 13 Partno. No 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Description Min lev el 5 10 2 2 2 5 10 1 5 1 1 2 5 1 1 1 1 1 1 5 2 2 P-220 SR. DK101630 DK101631 JC111022 JC111023 JC191019 JC191004 DK111071 DK201001 DK201033 DK201034 DK101503 DK181019 DK151038 Description OIL PIPE INLET OIL PIPE OUTLET IGNITION COIL WITH CABLE LH IGNITION COIL WITH CABLE RH CABLE ACCELERATER CABLE-CLUTCH CDI UNIT REGULATOR CONTROL SWITCH LH CONTROL SWITCH RH ENGINE TEMP SENSOR OIL SEAL REAR BRAKE PAD Qty / Initial Kit 1 1 1 1 1 1 1 1 1 1 1 2 2 MRP 228 211 114 114 73.SF Handle bar .LH Handle bar .RH Clutch Cable Tail Light Assembly Wind Shield DE151037 DK151038 DK191012 DK181034 DK201034 DK181019 DJ141006 AL201012 30201085 JC201041 DK101577 DS101276 DK101386 JC191014 JC191018 DK181046 DK181059 DK181047 DK181062 JC191004 DK201003 DK161069 85 86 87 88 89 90 91 92 93 94 95 96 97 Magnet Assly SCB Cylinder head Gasket Switch LH Steering Cone kit Cap Camshaft Capacitor Fuel Gauge Starter Relay(solenoid) Clutch switch (6AMP) Gasket Cover RHS Gasket Crankcase Gasket cover Magneto Lever comp gear shifter DK201039 DK101003 DK201033 36DV0007 DS101096 DK201036 DK201065 DK201078 DK201083 DH101154 DH101006 JC101137 DH101705 Annex .
heat being felt at legs. do not carry oil. the rear one can as well be made easily that way. Nothing would happen to engine once that confirmation is over. Gear shifting neutral finding is difficult when standing in standstill position at signals. The front disc brake is urgent and can be used for dead stopping during emergency. the noise level too goes up. When vehicle is running.(details given in O&M) Its an indicator and can not be as precise as is expected. You would just get check spark plug colour which would indicate us safely about engine health. The more the hot air the driver feels. While the film of lubrication oil takes care of friction.12 Frequently Asked Questions Frequently asked questions by customers at service reception : These questions are posed by customers at the service stations. The engine mounting orientation on Pulsar DTS-i is vertical. Hence nothing to worry about noise level post prolonged drives. use check list for confirming all parameters) Fuel gauge is not accurate ? Does not show litre by litre. If bajaj auto can make the front brake that urgent. (API JASO MA) 20 W50/SG-SL grade. Do not worry. After long drive. (technician has to confirm himself that the gear shifting is not hard. Since this is a constant mesh gear box. thus giving better engine cooling. Both the brakes are to be used while braking for perfect and safe braking. No harm would happen to your engine. Can I use higher.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex . the cooling air draught is getting directed from front side. as rear wheel is having traction. we are here to take care of any issue. when metallic parts expand. That cool air picks up the heat from engine and cools it down. (Mechanic has to confirm that the brake disc pads are not worn out. one has to reduce friction inside the engine. To increase fuel efficiency. Pulsar engines have been provided with roller rocker arrangement inside cylinder head to reduce friction. tyres are not worn out and the braking effectiveness is as like any other new vehicle) Engine noise level is going up after a long drive of 35 + kms. Nothing to worry about this. The reading which gauge is suppose to show is in three stages Behalf and Full. do not have clutch drag etc before explaining this to customer. Engine is overheating? . Page 23 of 32 . Then it flows on driver's legs. more heat has been picked up by air. Everybody from your dealership need to give the same answer. Anything above this can be used.Pl read these answers carefully and start speaking in one language.. water. If the engine is really overheating you would get an indicator on speedometer. without moving the wheels slightly -the gear dogs may not get engaged.better grade of oil ? As long as it meets the specification as given by BAJAJ auto.inspite of having disc brakes. Hence rear brake has been toned down slightly as a safety precaution. Engine is having additional oil cooling too. However it would result in to skidding of the vehicle. noise level builds up slightly. Rear brake not urgent on Pulsar 220. Hence it is important to rock the wheels slightly to facilitate shifting down to neutral.
Just Can I use accessories like remote control. Customer would give 33 % and dealer would charge 50 % labour and forego his spare parts discounts. Since heavy impacts are an accident. Component failure due to adulterated fuel is not a manufacturing defect. They would crack under extreme operating conditions like heavy impacts. Thus earlier burden of Rs 7000 to customer would go down to @ 3000. can not be covered under warranty.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 There is a peculiar noise from engine told by mechanic as Knocking ? The Pulsar engine employees DTSi technolodgy. Bajaj auto and its dealers are ready to contribute and help out customer. imported air filters. Why the alloy wheel breakage is not covered under warranty ? Alloy wheels which are die casted have been designed and certified by ARAI for all normal usage conditions. No replacement is required here too. Page 24 of 32 . Engine manufactured for sustaining adulterated fuels would cost too heavy on customer's products. chain-sprockets.by completely repainting the part. add on horns etc? All the parts related to engine and electrical parts are designed to certain specs. However since this is an accident (use of an adulterated fuel). All the parties should share the cost of repairs. 3. Entire automobile fraternity to raise this issue with concerned Government officials. external factors. The calculation details of reimbursement are given in the sheet attached.being perceived as combustion noise.The two spark waves from spark plugs collides with each other and that crates a noise . Since this is not a genuine manufacturing defect it would not be covered at the time of a second time failure. 2. brake shoes etc are not covered under warranty ? These are the parts which are prone to wear and tear due to vehicle usage. Hence only paint defect can be covered under warranty . this will have to be covered under insurance. Why Battery/tyres are not given by selling dealer under warranty? World over the policy of warranty of proprietary parts is the same. Changing/modifying any part would affect the performance. They are experts in analyzing the failures and have special equipments for checking the parts. They are warranted by respective manufacturers. Bajaj auto would give 40 % cost. The very fact that they have lasted long up to 10000 kms + do suggest that there was no manufacturing defect to start with. The dealer is supposed to save and reuse certain components to reduce cost of repairs. Further the Batteries can not be transported due to environmental factors. This noise level do not have any effect whatsoever on engine performance and noise. If they had failed now it is something to Why only block piston and crankshaft given under fuel adulteration claims? 1.13 Frequently Asked Questions Questions related to Warranty Why parts like clutch plates. Hence we do not advise fitment of such parts and warranty would also stand negated in all such cases. The run out also can not get developed after usage as like spoked wheels. Create the awareness amongst customers regarding proper use of fuel/fuel additives and consequences of bad fuel quality. Hence its better Annex . 4. steering races. timing chain. Since this is not a manufacturing defect.
The warranty is not individually specified for individual parts. Hence it’s not possible to extend the warranty.men.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Why the part as failed on my vehicle so early .17000 kms.13000 kms ?. Since the vehicle is an assly of so many parts. complete replacement is not a logical solution for this defect removal. This is a way of life.once registered. That may cause few premature failures which c Why the life of a component is so less ? (Sprocket . To cover up any manufacturing lapse the warranty is given by Bajaj auto. Neither has it happened in any other industry.bad Page 25 of 32 . Something can go wrong in rare case. trained to carry out those repairs. But the faulty part replacement would restore the vehicle performance.machine.material and method. Why the warranty is not extended and applicable for the part replaced now ? When the vehicle was sold to you the contract of warranty was for 2 years post sale of the vehicle. the performance would go down drastically. The automobile is not a stationary machine like many other consumer durables. However if failure happens on same part again Why warranty seizes if all free/paid service schedules is not maintained ? Periodic maintenance care is extremely important for a moving machine line an automobile. We sincerely apologies for this to have happened on your vehicle. A prudently maintained/driven vehicle would give thrice the life of a part as compared to badly driven. the life of wear and tear items is dependant upon the maintenance care/driving pattern in which the vehicle is running.clutch plates .why cant you replace complete vehicle ? The vehicle is manufactured by using 4 Ms.Drive chain 16000 kms ?) Apart from material strength. However we guarantee the optimum performance of your vehicle and we are committed for that. We are equipped with. Further the change of vehicle is not permitted by RTO. If vehicle is not maintained/serviced prudently as specified by manufacturer.why not ? Products are being continuously modified by BAJA auto for enhancing performance. However this does not mean that all the modifications need to be passed on to all consumers. I should get all modified parts fitted on my old vehicle .
Replacement of rear Disc Pads ( within 1000 kms) Master Cylinder Major replacement Caliper Assembly – Major Kit replacement Front Wheel Drum Bearing replacement Brake Disc replacement Disc holder plate on Wheel Drum replacement Master Cylinder replacement Rear Brake Hose replacement Fairing/fairing frame replacement Air filter Box Assembly replacement Coupler / Hub Bearing / Hub replacement Steering Lock / Key replacement Disc holder plate on Wheel Drum replacement Rear Fender / Mudguard replacement Speedo case/cable replacement Rider Seat Cowling replacement Windshield/ Fairing replacement Complete Lock Set replacement Fuel Tank replacement Replacement of front Disc Pads ( within 1000 kms) Brake Disc replacement Front Brake Hose replacement Front Fork Oil Seal one side Front Fork.00 30.00 30.00 30.00 30.00 45.14 SN Replacement under warranty at dealership Oil Cooler replacement. Replacement of Rear Disc brakes.00 45.00 30 30 75 90 60 120 60 60 120 120 60 120 120 120 120 120 60 60 480 60 60 60.00 45.00 15.00 75.00 45.00 60.00 30. Cones & Steel Balls replacement Fork Inner Tube one side replacement Fork Outer Tube one side replacement Front Fork Upper Holder replacement Front Fork Lower Holder replacement Fork Spring one side replacement Trailing Arm Bush/dust covers replacement Trailing (Swing Arm) replacement Master Cylinder Major Kit replacement Caliper Assembly – Major Kit replacement Master Cylinder replacement Magneto Rotor replacement Stator Plate Assembly replacement Chassis / Frame replacement Replacing handle bar Replacement of Chain sprocket kit Engine Foundation Bush Kit replacement Labour hours to be claimed in units 2 2 1 3 4 2 3 3 4 3 5 2 3 2 2 3 1 1 3 2 2 2 5 6 4 8 4 4 8 8 4 8 8 8 8 8 4 4 32 4 4 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Page 26 of 32 .00 45.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 ‘ Labour Schedule’ for jobs eligible under warranty : Remboursement of Warranty Jobs U/W job completion time for Pulsar 220 DTS-i 30.00 15. Bearing Races.00 30.00 60.00 Annex .00 45.00 15.00 45.
00 45. Starter motor replacement Speedometer Assembly replacement SPM Console Upper Cover replacement Head Lamp Assembly replacement H.00 30.00 75.00 30.00 30.Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Fuel cock replacement.00 45.00 15.00 60 60 75 90 120 120 120 120 165 120 120 165 165 180 180 330 330 330 330 330 330 330 330 210 75 135 75.00 30. Magneto Cover replacement Centrifugal Filter Cover/Gasket replacement Crank Case (LH) Gear Shifter Shaft Oil Seal replacement Clutch Centrifugal Change Gear Shifter Lever Mechanism replacement Gear Return Spring / Shaft Pawl / Spring replacement Carb Assembly replacement Starter Counter Gear/Bush/NRB replacement Guide Starter 'O' ring / Oil seal replacement Guide Starter Assly / Gear Inner Bush replacement Clutch Cover replacement Shaft Release Clutch / Oil Seal replacement Oil Pump Assembly replacement Clutch (Friction / Steel) Plates replacement Cylinder Head Assembly replacement Valve/Springs/Seal replacement Rocker / Shaft Rocker Arm replacement Valve/Valve Guide replacement Timing Chain / Sprocket replacement Cam Shaft Both Bearings replacement Cam Shaft assly.T.00 45.00 15.00 30.00 30.S.00 45. Coil Single replacement A/C Regulator (Voltage) replacement Ignition Switch Assembly replacement Rear Brake Light Switch replacement Head Lamp Bulb replacement Park Lamp Bulb replacement Tail Lamp Assembly replacement Rectifier / RR unit replacement Fuel Gauge Float Unit replacement 15. Drum replacement G.00 15.00 15.00 30. Replacement Set Primary Gear (Driver & Driven) / replacement Body Balancer Assembly replacement Cylinder Block/Piston Assembly replacement Piston Rings replacement Crank Shaft Assembly replacement Crank Shaft Bearings replacement Crank Case Assembly replacement Crank Case (RH) replacement Crank Case (LH) replacement Input Shaft and Out Put Shaft/Speed Gears replacement G. Forks replacement Replacement of Balancer Idler gear Replacement of starter clutch Complete Wiring Harness replacement Replacement of BCU.00 30.00 30.00 15.00 1 1 2 2 2 3 3 2 2 2 2 4 4 5 6 8 8 8 8 11 8 8 11 11 12 12 22 22 22 22 22 22 22 22 14 5 9 5 3 3 3 5 1 1 2 1 2 3 1 1 2 Page 27 of 32 .S.00 45.00 15.00 45.00 30.
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Annex -15 Electrical Circuit Diagram 1.C. Ignition Circuit Page 28 of 32 . D. Starter Motor Circuit 2.
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 3. Brake Lamp Circuit Page 29 of 32 . Battery Charging Circuit 4.
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 5. Horn Circuit 6. Side Indicator Circuit Page 30 of 32 .
Lighting Circuit Page 31 of 32 .Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 7.
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Action Matrix: SL 1 2 Key Information Salient Features Update Technical Specification Caparison with competitive D C Ignition Read before you ride PDI Checklist PDI SOP & Time Chart Periodic Service SOP Chart Periodic Maintenance & Lubrication Chart Critical Part List Initial Kit part list Frequently asked questions Frequently asked questions-related to warranty Reimbursement of warranty Jobs Electrical Circuits Works Manager/DSE PDI In charge Sales In charge Understand features of this new variant and share with the sales team Service Advisor Update Floor In charge Update Technicians 3 4 5 6 7 8 9 10 11 12 13 14 15 Initials Date Share with Sales /Service /PDI teams Share with Sales /Service /PDI team Update Update Update Update Update Share with Sales team & ASC/RSO /YES channels Update Update Technicians Update Technicians Update Technicians Page 32 of 32 .
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