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Foreword: Pulsar Comes With A Warranty of 2 Years or 30,000 Kms Whichever Occurs Earlier
Foreword: Pulsar Comes With A Warranty of 2 Years or 30,000 Kms Whichever Occurs Earlier
2
Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.
3
Location of Parts
Grab Rear
Handle Shock Absorber
Fuel
Tank Accelerator
Manual Grip
Choke
Front Fork
Pillion
Foot Rest
Steering cum Ignition Lock : To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Push
It has three positions.
& release the key. Turn the key to “LOCK”
position and remove the key.
LOCK: Steering locked. Ignition OFF.
To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
OFF: Steering unlock. Ignition OFF. turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering
cum Ignition lock’, ‘Fuel tank cap’ & ‘Side
ON: Steering unlock. Ignition ON. cover lock’.
5
Fuel Tank Cap / Fuel Tap
Fuel Tank
Cap Fuel Tap
1 7
2
8
3
4
9
5 10
6 11
12
Speedometer display will get on when ignition switch is made ‘ON’.
1. Side Stand Indicator : When Side stand is down, 7. Speedometer:Vehicle speed will be displayed digitally
then Side stand indicator will glow. 8. Trip Meter Reset Button : Both trip meters can be
2. Fuel Level Indicator : Fuel level indicator shows reset to zero by pressing the button.
available fuel in fuel tank. Tank symbol glows when 9. Trip Meter : The Trip meter shows the distance
petrol level in tank reaches reserve level traveled since it was last reset to zero.
3. Engine Rev Indicator :It blinks when engine RPM 10. Battery Indicator : It indicates battery needs
cross 9000 RPM mark. charging
4. Tachometer Dial : It shows engine speed in RPM. 11. Hi Beam Indicator : When Headlight is ‘ON’ & Hi
5. Odometer : The Odometer shows the total distance beam is selected with engine running, Hi beam
that the vehicle has accumulated. indicator will glow.
6. Turn Signal Indicator (LH & RH) : When Turn signal 12. Neutral Indicator : When transmission is in Neutral
switch is turned to Left or Right, Turn pilot indicator - & Ignition switch ‘ON’, Neutral indicator will glow.
LH or RH will flash.
7
Control Switches
D
A
C
A
A Lug
Lug
B Lock
Lock
Removal of Seat- Front & Rear (P 180) Fitment of Seat- Front & Rear (P 180)
• Remove ‘Side Cover’ LH. • Both the seats can be fitted by matching their lug
• Pull rear seat lock cable (A) & remove ‘Rear Seat’ with the respective lock & pressing down the lug into
• Similarly pull the front seat lock cable (B) & remove lock.
‘Front Seat’.
CAUTION: Always remove Rear seat first. CAUTION : Always fit Front seat first.
For Pulsar 150 follow procedure as given below For Pulsar 150 follow procedure as given below
Removal of Seat assembly complete Fitment of Seat assembly complete
• Remove ‘Side Cover’ LH. • The seat assembly can be fitted by matching its lug
• Pull seat lock cable (A) & remove the seat complete. with the lock & pressing down the lug into the lock.
12
Battery / Tool Kit
Tool Kit
Battery
14
How to Ride Your Bike
Starting The Engine : Caution : Do not operate the starter
• Turn the fuel tap knob to ‘ON’ or ‘RES’ continuously for more than 5 seconds
position. otherwise battery would get discharged.
• Switch ‘ON’ ignition & ‘Kill Switch’ Wait 15 sec. between each operation of
• Confirm that transmission is in neutral. the starter which will facilitate battery to
recover.
• Keep throttle completely closed, press starter
button “ ” to start the engine. Note : The motorcycle is equipped with a clutch
• Release starter button as soon as engine switch. This switch ensures that engine does not
starts. start if the transmission is in gear.
Note : Do not let the engine idle longer than 3 However, the engine can be started in any
minuets otherwise it will overheat. gear if the clutch lever is pressed.
• If the engine is cold or when starting for first
time, use choke ‘ ’for quick starting. Moving Off :
• Check that Center/Side stand is up.
• When the engine is • Depress the clutch lever.
OFF warmed up enough to • Shift into 1st gear.
idle without using • Open the throttle and release the clutch
ON choke, return the
choke to OFF lever slowly and simultaneously.
position. • As the clutch starts to engage, open the
throttle a little more, giving the engine just
Manual Choke
enough rpm to keep it from stalling.
15
How to Ride Your Bike
Shifting Gears : Warning : When shifting down to lower
• Close throttle & depress the clutch. gear, do not shift at such high speed that
engine rpm jumps excessively. This may
• Shift into next higher or lower gear. cause engine damage, & rear wheel may
• Open the throttle and release the clutch skid. Downshifting should be done at
lever slowly and simultaneously. recommended speeds as shown in table.
Braking :
• Close the throttle completely, leaving the
clutch engaged (except where shifting gears)
so that the engine braking will help slow
down the motorcycle.
• Shift down one gear at a time so that you
are in Neutral when you come to a complete
Gear Shifting stop.
Pattern • When stopping, always apply both brakes at
Gear Shifting Lever the same time. De-clutch as necessary to
avoid engine stalling.
Recommended Speed for Shifting Down • Never lock the brakes, or it will cause the
tyres to skid. When cornering, use brakes
From 5th to 4th Gear 45 km/h
judiciously & do not de-clutch. Reduce your
th
From 4 to 3 Gear rd
35 km/h speed before you get into the corner. For
emergency braking, disregard downshifting,
rd
From 3 to 2 Gear nd
25 km/h
and concentrate on applying brakes as hard
From 2 nd st
to 1 Gear 15 km/h as possible without skidding.
16
How to Ride Your Bike
Stopping the Vehicle : Running IN
• Close the throttle completely. Proper running-in is important for the better
• Shift the transmission into neutral. life & trouble free performance of the vehicle.
• Bring the vehicle to complete stop. • During first 2000 kms running-in period do
not exceed following speed limits.
• Turn the ignition switch off.
Parking the Vehicle : Kms 1st 2nd 3rd 4th 5th
• Support the motorcycle on a firm level 0 - 1000 14 22 30 37 44
surface with the center or side stand. 1000 - 2000 18 28 38 46 55
• Lock the steering.
• Always keep the speed below the limits
CAUTION : Do not park on a soft or steeply mentioned in the table.
inclined surface or the motorcycle may fall over. • Do not race the engine excessively.
Whenever vehicle is falls down, remove plug of 'Y • Do not start moving or race the engine
connecter drain tube' & drain out accumulated immediately after starting. Run the engine
petrol for a minute at idle speed to give the oil a
Location - Near Main Stand chance to workup into the engine.
A : Oil Filler Cap, B : Oil Level Gauge Pulsar Bajaj DTS-i SAE 20W50 API
150/180 10000 ‘SL’ or JASO ‘MA’
Engine Oil Level Checking :
• Check engine oil level every day. Park • Engine oil replacement frequency : 1st service &
vehicle on level surface on centre stand. then every 10,000 Km.
• Check oil level through oil level gauge ‘B’. • Engine oil level top-up frequency : Every 5000 km.
• Always maintain engine oil level between
CAUTION :
upper (C) and lower (D) mark provided on
• It is most important to adhere to
Cover RH. Top up with specified grade of
recommended grade & frequency of oil
oil if the oil level is below lower level mark.
change for the purpose of long life of
Engine Oil Capacity : critical engine components. For details
• Refill at servicing : 1000 ml. refer periodic maintenance chart.
• During engine overhaul : 1100 ml. • Do not reuse drained oil.
20
Wheels - Tyre
Wheel Puncture:
• Visit nearest known tubeless tyre repair shop
to remove puncture.
• Remove puncture by Filler or Plug method
only.
• Do not use patch method to remove puncture
of tubeless tyre.
Tyre Pressure :
Tubeless Tyre : Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
The main advantage of tubeless tyres is in fuel consumption.
case of puncture the rate of air leak is very
slow, hence customer can easily drive the Pulsar 150 Pulsar 180
vehicle upto nearest puncture repair shop for
removing puncture. Front 25 PSI 28.4 PSI
Rear (Solo) 28.4 PSI 30 PSI
CAUTION : Tubeless tyres are fitted in this Rear (with Pillion) 32 PSI 32 PSI
motorcycle. The walls of the tyres in contact
with the wheel rim should not be damaged Note : Incase the motorcycle is fitted with
in any way during fitment / removal of tyre. imported tyres. compliance to respective indian
The tyre side walls in contact with wheel rim standard & central motor vehicle rules has been
seals air. ensured.
21
Periodic Maintenance Information
Max
Min
Min. Level
Front Brake Fluid Level : Battery : 12V-9 Ah MF, For Pulsar 180
• Front brake fluid reservior is located on RH • Battery is located inside ‘Side Cover’ LH.
side of Handle bar. • Always ensure that battery electrolyte level
is in between max & min level marks.
• To check oil level, keep the vehicle on
• Check & top up battery by distilled water if
center stand with handle bar in straight
electrolyte level is below min level mark.
ahead condition.
• Battery life would get adversely affected if
• Always ensure that brake fluid level is top up with ‘Tap Water’.
above ‘MIN’ mark given on inspection
Window.
CAUTION : Tap water is not a substitute
for distilled water and will shorten the life
of the battery.
22
Periodic Maintenance Information
Battery : 12V, 4 Ah VRLA For Pulsar 150 How to keep battery healthy ?
• Switch ‘Off’ ignition when engine is not
running.
Battery Features :
• Get battery checked / charged during
• No topping-up is required periodic services.
• Reduced self discharge, Enhance safety. • Do not press starter button for more than
• No vent tube open to atmosphere hence no 5 sec. After 3 successive cranking, wait for
discharge of electrolyte through vent tube. 15-20 sec. for battery to recover.
• Do not add extra electrical accessories
• Environment care must be taken to such as - Remote, Bigger horn, Musical
dispose off the used battery. It is always brake light etc. This will reduce life of
recommended to hand over the same to battery
the Authorised battery / Bajaj dealer for • If vehicle is to be stored for more than 2
proper disposal of the same. weeks disconnect battery to avoids self
• When battery is found discharged, it is discharge.
advised to get it charged immediately.
Std. Chain
slackness : 25~30 mm
0.7 to
0.8 mm Top edge
24
Periodic Maintenance Information
Drive Drive
Chain Chain
Cleaning Lubrication
Drive chain must be cleaned & lubricated as Method of O-ring Chain Lubrication :
per periodic maintenance schedule. • Place the bike on centre stand.
a. Drive chain (Non O-ring type) • Clean the chain by using lint free cloth (If
• Non O-ring type chain should be removed & excessive mud / slush found approach Bajaj
cleaned by Nylon brush & Kerosene or in Service Center for proper cleaning)
Chain Cleaning Machine. • Shake the can vigorously by holding
• It should be lubricated by SAE 90 grade oil. vertically upright till the noise of steel ball
b. Drive chain (O-ring type) inside heard uniformly.
• ‘O’ rings must always be kept wet for best • Hold spray can at the back of rear sprocket
performance hence lubricate every 500 Kms with extension tube nose at 5~10 cm.
• O-ring chain lubrication can easily be done • Rotate the wheel in reverse direction &
by owners using Bajaj ‘Chain Lube Spray spray the lube on middle portion of the
Can’ available with Bajaj dealers. chain up to full length of the chain.
25
Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation
st nd rd
Servicing 1 Free 2 Free 3 Free Every Subsequent
No. 500 4500 9500 5000 Km after
Kms ~ ~ ~ Previous Service
750 5000 10000
1. Water wash & dry the vehicle Ensure to prevent water
completely entry in Petrol tank,
Silencer & electrical
Parts. Use caustic free
detergent for washing.
2. Engine oil (Bajaj DTSi 10000 oil) C,R R Top R Top R Top R BGO DTSi 10W30 for
Up Up Up 100cc models.
BGO DTSi 20W50 for
Models above 125cc.
4. Oil strainer CL CL CL CL CL
16. Non-Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
cleaning & lubrication
17. Sealed drive chain 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
cleaning & lubrication chain lub spray at every
500 kms.
21. Brake cam & brake pedal pivot pin 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.
23. Brake fluid level **- top up / replace C,A,R C,A R Use recommended
brake fluid
(DOT3/DOT4)
25. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A
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
30. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
31. Steering stem bearing*** & C,CL,L,R C,CL, C,CL, C,CL, Check & replace if
Cap steering bearing (Plastic)** L,R L,R L,R Damaged. Use HP
Lithon RR3 grease for
lubrication.
32. Main stand & side stand pin** CL,L CL,L CL,L CL,L Use AP grease.
34. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
37. Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
41. Spoke tightening**-Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
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
Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.
31
Non-Use Maintenance
Non-use maintenance is necessary if a vehicle wheels.
remains off road for a longer duration (more • Do not apply oil on front brake disc, to
than 15 days**). The correct and careful non- prevent rusting. If the front brake disc rusts
use maintenance carried out before storing during storage, do not attempt to clean it
the vehicle will prevent the vehicle from with soap water. The rust will go off
rusting and from such other non-operational automatically during first few application of
damages like fire hazards. brake.
• Clean the entire vehicle thoroughly. ** For Battery :
• Empty the fuel from the fuel tank and a. Remove battery and keep it on wooden
carburettor float bowl (if fuel is left in for a plank, in properly ventilated area.
longer time, the fuel will break and gummy b. Before taking the vehicle for use.
substance could clog the carburettor). • Get the battery recharged from the
• Remove spark plug & put several drops of Authorised Service Center / Battery Dealer.
engine oil into the cylinder. Kick engine • Apply petroleum jelly on terminals.
over slowly a few times to coat cylinder (applicable to certain models).
wall with oil & install back spark plug. Preparation for regular use after storage :
• Set the vehicle on a box or a stand so that • Clean the vehicle
both wheels are raised off the ground. • Make sure the spark plug is tight.
• Spray oil on all unpainted metal surfaces to • Fill the fuel tank with fuel.
prevent rusting. Avoid getting oil on rubber • Change the engine oil.
parts or brake liners. • Check all the points listed in the Daily
• Cover entire vehicle neatly. Make sure that Safety Checks section.
storage area is well ventilated & free from • Check and inflate tyres to proper tyre
any source of flames or spark. pressure.
• Fill 10% excess air pressure in both
32
Delivery Certificate
FRAME NO. :
Dealer Code :
Dealer Name :
Address :
Customer's Signature (To be filled in by the dealer) Contact No. :
SERVICE RECORD
Sr. Age Specific Dealer’s Stamp * Code For Remarks:
Date Gravity Voltage Remarks & Signature * Code
No. Mths. LL : Low electrolyte level.
1 AE : Electrical system needs attention.
2 IR : Insufficient running of vehicle.
3 CB : Cover broken.
4 BC : Broken Container.
5 PM : Poor maintenance.
6 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 :______________