12 Manual de Servicio Platino y Boxer CT Trainig Notes PDF

(Fuel Injection)
The Training Notes are a comprehensive

training guide on service and
maintenance operations and procedures
to be followed by service personnel
at authorised service centres and
dealerships whilst attending to the Bajaj
Pulsar 200NS FI. The Training Note
covers standard workshop procedures,
simplified for easy learning and
understanding for service technicians
worldwide.
NOTICE Copyright
All information contained in this Training Note is based on All Intellectual Property Rights, including but not limited
the latest product information at the time of publication. to Copyright, applying to this drawing and the information
Bajaj Auto Limited accepts no liability for any inaccuracies contained therein vest solely and exclusively with Bajaj
or omissions in this publication, although every possible Auto Limited. No part of this drawing may be copied or
care has been taken to make it as complete and accurate reproduced, either in part or in full by any means, whether
as possible. All procedures and specifications subject to mechanical or electronic, without prior written permission
change without prior notice. The right is reserved to make of the authorized signatory of Bajaj Auto Limited. Bajaj
such changes at any time without prior notice. reserves all rights to deal with violations of this clause in
accordance with applicable laws.
DOC. NO.: REV. 00, OCT 2014
© Bajaj Auto Limited, 11th SEPT 2012.
Contents
1
Workshop Safety and Procedures
CHAPTER
2
The Tool Chest – Know Your Tools
CHAPTER
Special Tools (Engine & Frame)
Standard Tools
Other Gadgets
3
Understanding the Bajaj Pulsar 200NS FI
CHAPTER
Identity
Distinguishing Features
Salient Features
Technical Features & Specs
Read Before Your Ride
4
Preliminary Checks & Maintenance Operations
CHAPTER
PDI Checklist
Perodic Maintenance Chart
Lubrication Matrix
Periodic Service SOP
5
Fuel System & EMS
CHAPTER
DTSi – Fi Engine Management Systems / EMS Layout
Working of Systems
Fuel Injection
Dos and Don’ts
Contents
Engine & Transmission
CHAPTER 6 Important Points to Remember During Engine Overhaul
Dismantling the Engine
Dismantling the Engine Sub Assembly
Service Data
Tightening Torque
Frame & Suspension

CHAPTER 7 Service Limits
Tightening Torque
Dismantling & Assembling Front Fork
Front Disc Brake
8
Electricals
CHAPTER
VRLA Battery Initial Filling
VRLA Battery Charger & its Charging SOP
Dos and Don’ts for RLA Battery
Electrical Checking Procedure
Electrical Circuit Diagrams
Key Learning Points
Understanding workshop discipline

and safety guidelines
Testing guidelines
Precautions whilst handling tools and

equipment
CHAPTER 1
Workshop Safety &
Procedures
Bajaj Pulsar 200NS FI Training Notes

5
1 Workshop Safety and Procedures
Workshop Safety
uu Technicians must always be wearing shoes and
dressed in clothing that is not too loose.
uu Always use protective Equipment (PPE) like - Hand

Gloves
Mask
Safety Goggle
Ear Plugs
uu Wear Nitrite Rubber Hand Gloves while handling

petrochemicals like petrol, oil, kerosene etc.
uu Fire Extinguisher
Install ‘ISI’ approved. Fire extinguishers - CO2 gas
cylinders.
Refill CO2 before the gas expires.
Install Co2 gas cylinder at appropriate place so that
there is no obstruction / good accessibility.
uu Safety Precautions whilst Operating Air Tools
Air pressure tools operate on compressed air supplied

by the shop Compressor and Air supply system.
Observe the following safety related precautions when

using an air tool.
It is advised to fit a pressure regulator (FRL:- Filter
Regulator Lubricator) in the pneumatic line which
supplies air pressure to the air tool. It regulates the
outlet pressure to 6.5 Kg/cm2. This avoids the risk of
personal injury.
Never use the blow gun to blow dust off your

clothes and never point it at another person. The
air pressure also thrusts dust particles at high
velocity. These particles can penetrate into the
Warning
flesh or eyes. If high pressure air hits on open
wound, it can force air into the blood stream
which at times can even result in instant death
due to cardiac arrest.
Bajaj Auto International Business

6
Workshop Safety
uu Hand Tools
Do not use worn out hand tools.
uu Calibration of Workshop Equipment
Calibrate all Workshop and M and T Equipment
once in a year.
uu Avoid direct body contact with Petrol, Kerosene.
Prolonged contact of used oil can

Caution cause cancer.
uu Waste Oil Disposal

Sell used oil only to Government approved re-cycle
agencies.
Collect used oil in oil disposer / barrel.
Don’t throw oil into the sewage line.
Don’t spill oil on the floor.
uu Precautions to be taken while handling Hydro-Electric Lift

Whilst raising / lowering ensure the vehicle is firmly
mounted
After raising the lifter bay, lock the lift.
Don’t put leg/hand in between while raising / lowering
uu Safety Tips
Do not lower the lifter bay table without unlocking the lift
lock.
Do not work with loose clothing whilst working on the lifter
bay.
Do not keep hydraulic joints loose. Do not stand on the
lifter bay when in operation.
Keep fire away from the power pack. Avoid oil spillage
around the working area.
uu Battery Acid Handling

Use hand gloves, wear apron and safety glasses
Avoid contact of battery acid with skin
Use plastic trays to keep charging batteries and
avoid battery acid spillage
uu Brake Fluid Handling

Store brake fluid in sealed container and avoid
spillage.
Avoid contact of brake fluid with skin.
uu Electrical Wiring
Ensure that the points and switches are easily
accessible and conduct periodic checks and repairs.

7
2 The Tool Chest - Know Your Tools
Key Learning Points
Understanding workshop tools, applications

and appropriate usage practices
Usage of customized tools developed by

BAL for Pulsar 200NS Fi
CHAPTER 2
Customized Bajaj Auto Tools /
Special Tools, Equipment & Gadgets
Special Tools (Engine & Frame)
Standard Tools
Other Gadgets

8
Customized Bajaj Auto Tools
Special Tools, Equipment and Gadgets
Special Tool Application: for Engine Repairs
uu Camshaft Big end bearing &
Balancer bearing puller
Part No. : 37 1042 57
Application : For removing
balancer and big
bearing of cam shaft
uu Crank Shaft remover

Part No. : 37 1042 52
Application : Tool for splitting the
crankcase
uu Spark Plug Spanner 3 in one

Part No. : 37 1042 55
Application : For removing LHS
/ RHS and Central
spark plug from
cylinder head when
engine is mounted on
vehicle
uu Primary gear holder+Balancer

Drive / Driven gear holder
Part No. : 37 0041 59
Application : Special tool for
holding Balancer
drive and driven
gears during
tightening / loosening
the nut

9

uu Balancer lock nut tightening/
removing tool
Part No. : 37 0041 60
Application : Special tool for
Balancer drive gear
lock nut (tightening /
loosening)
uu Output shaft oil seal fitment

tool
Part No. : 37 1041 56
Application : For pressing oil seal
on the output shaft
uu Balancer + Radiator pump oil

seal fitment tool
Part No. : 37 0042 56
Application : For fitting 2 nos back
to back oil seals
for balancer and
Radiator pump
uu Cam Sprocket Holder

Part No. : 37 1042 54
Application : For holding cam
sprocket during
removal and re-fitting
of cam sprocket bolt.

10
uu Magneto Rotor Puller
Part No. : 37 0041 55
Application : For pulling out
magneto rotor from
crank shaft
uu Rocker Shaft remover

Part No. : 37 10DH 35
Application : For removing rocker
arm shaft
uu Drift Piston Pin

Part No. : 37 10DS 27
Application : For removing piston
pin.
uu Clutch special nut remover

Part No. : 37 10DJ 43
Application : To remove and fit
clutch nut. Rocker
Shaft remover

11

uu Clutch Dismantling Tool
Part No. : T 10111 68
Application : For dismantling and
assembly of clutch
assembly.
uu Camshaft Small Bearing Puller

Part No. : 37 10DH 31
Application : For removing small
bearing of cam shaft
uu Bearing Driver Set

Part No. : 37 1030 61
Application : For removing bearings
from crank case.
uu Magneto Rotor Holder

Part No. : H6 0721 00
Application : For holding rotor
assembly while
loosening bolt.

12
uu Tappet Setting Tool
Part No. : F4 1ZJW 33 /
37 1031 53
Application : For adjusting valve
tappet clearance.
uu Valve Spring Compressor

Part No. : 37 1031 07
Application : For compressing
valve springs for easy
removal of intake and
exhaust valves.
uu Adaptor for Valve Spring

Compressor
Part No. : 37 1031 08
Application : For compressing
valve springs for easy
removal of intake and
exhaust valves.
uu Output Sprocket Holder

Part No. : 37 1030 53
Application : To hold out put
sprocket while
removing sprocket
bolt.

13

Special Tools Application: for Frame Repairs
uu Fork oil seal fitment punch
Part No. : 37 1740 03
Application : To remove anti-
friction and oil seal
bush from front fork
outer pipe.
uu Fork cylinder holder handle

with adaptor
Part No. : 37 1740 05
Application : For holding cylinder
piston
uu Installer Upper & Lower

Bearing Race Frame
Part No. : 37 1801 06
Application : To install upper and
lower steering races /
cones into their seats
inside frame.
Notes

14
Special Tools Application: for Frame Repairs
uu Swing arm needle roller
bearing extractor & fitment
tool
Part No. : 74 9309 93
Application : For removal and
fitting of needle roller
bearing in swing arm
uu Steering Nut tightening tool

Part No. : 37 1801 01
Application : For tightening /
loosening of steering
nut
uu Rear Mono Suspension

Adjuster
Part No. : 37 0041 70
Application : For adjustment
of mono rear
suspension setting
uu Stem Bearing Driver

Part No. : 37 1830 05
Application : To fit bearing race
on fork under holder
bracket

15
Standard Tools
Equipment: Equipment:
External and Internal Star Bit Set
Circlip Pliers
Specs / Range:
Specs / Range: Standard size
Qty Required: Qty Required:

One set
Combination Plier Component Handling
Crate
Specs / Range:
Specs / Range:
Qty Required:
Plastic with partition
CH64120 (2x2)
Qty Required:
One for each bay
Cleaning Brush CVC Products: Battery
coat, Viscolube,
Specs / Range: Carburetor cleaner,
2 and 3 Inch Multilube, Galvanizing
spray Etc.
Qty Required:
One Specs / Range:
Aerosols
Qty Required:
As per Load
Electrician Screw 5 Pcs Phillips Screw Driver
driver Sets
Specs / Range: Specs / Range:
3 mm Flat 861, 862 L, 863
One for each bay One set for each bay
Allen Key set 5 Pcs Screw Driver Sets
Specs / Range: Specs / Range:

Set 827, 929, 912, 923, 825

One set One set for each bay

16
Standard Tools
Equipment: Item:
Tyre pressure gauge Tool Trolleys
Specs / Range: Specs:

Dial Type / Pen Type Regular with 4 Trays
Qty:
Qty Required:
Each Per Bay
One
Equipment:
T-Handle Box Wrench Equipment:
Spark Plug Cleaner
Spes / Range:
8 mm, 10 mm, 11 mm, Specs:
12 mm 2 Gas

One set for each bay One
Open End Spanner Work Table with Special
Tool Display board
Spes / Range:
6 x 7 mm; 8 x 9 mm; Specs:
10 x 12 mm; 12 x 14 Qty Required:
mm; 14 x 17 mm; One
17 x 19 mm; 24 x 27
mm; 24 x 27 mm
Qty Required:
One set for each bay
Ring Spanner Electric Plier, Cutters
and Connectors
Specs / Range:
6 x 7 mm; 8 x 9 mm; Specs / Range:
10 x12 mm; 12 x 14 Multi Tech / Others
mm; 14 x 17 mm;
17 x 19 mm; 24 x 27 Qty Required:
mm; 24 x 27 mm One for each bay
Qty Required:
One set for each bay
Equipment :
Equipment: Socket set with Reversible
Long Nose Plier Ratchet
Specs / Range :
Specs / Range: ½” SQ. DR. 8, 10, 12, 14, 17,
Standard size 19,24 mm, Sockets; 3/8” Long
Sockets 8,10 mm; ½” Extension
Qty Required:
5” Long. ½” DR. Quick Release
One for each bay
Ratchet; ½” DR. T Handle; ½” X
3/8” Adapter 3/8” X ½” Adapter
with Tools Box
Qty Required : One Set

17
Other Gadgets
New D&F Tool
Part No. :
Application : For checking
diagnostic and troubleshooting
codes of EMS.
Old D&F Tool

Part No. :
Application : For checking
diagnostic and troubleshooting
codes of EMS.
Multimeter Special Prob

Part No. :
Application : To establish the
contact between multimeter
and the inspecting electrical
component.
Pressure Gauge for

Engine Oil
Part No. :
Application : To measure the
engine oil pressure in the
lubrication system.
Pressure Gauge for

Fuel
Part No. :
Application : To measure
the fuel pressure in the
fuel line.

18
Other Gadgets
VRLA Battery Charger
Part No. : 37004162
Application : To charge the
new and used VRLA battery.
Battery Load Tester

Part No. : 37204020
Application : To inspect the
battery charge holding ability
of the new and used VRLA
battery.
Pig Tail for Fuel

Delivery Measurement
Part No. :
Application : To establish the
electrical contact between
battery and fuel pump
through a operating ON/OFF
switch.
Tuskun Screw Driver

Part No. :
Application : To remove
and fit the tuskun screws for
TMAP and TPS.
Notes

19
1 Workshop Safety and Procedures
Key Learning Points
Understanding the Complete Anatomy of

the Vehicle
Technical Specifications and Performance

Parameters
Briefing and Educating the Customer on

Appropriate Riding and Usage Discipline,
and Routine Maintenance
CHAPTER 3
Understanding the Bike
Identity
Salient Features
Read Before Your Ride

20
Identity
543
CE D91
JL Z
The Engine Number, unique to each vehicle is The Frame Number, which is also unique to each
engraved into the engine body, located below the vehicle, is engraved into the frame. This is located
sprocket cover. on the right hand side of the frame between the
fork mountings.
Location of Parts
1 RH Control Switch 9 Cover Mud Rear
2 LH Control Switch 10 Assembly Chain Cover
1 2
3 Speedo Console 11 Nitrox Mono Suspension
4 Expansion Tank 12 Tail Lamp
5 Front & Rear Disc Brake 13 Grab Rail
6 DTSi 4-Valve Engine 14 Perimeter Frame
7 Clutch Cover 15 Exhaust TEC
8 Underbelly Exhaust 3
with exhausTEC
13
14
12
10
11
9
4
6
5
5
7 15
8

21
3 Understanding the Bike
Triple Spark Technology
uu Triple Spark:
Provides faster and more optimal combustion
thereby increasing combustion performance and
efficiency. Combustion is 27% faster than twin spark
and 50% faster than a single spark engine.
uu 4-valve Engine:
2 intake and 2 exhaust valves enables better
breathing for the engine thus enhancing torque and
power at all engine speeds. Enables engine to rev
to high RPM levels without getting choked, thereby
producing more power.
Fuel Injection
The fuel injection system delivers optimum volume
of fuel which along with Triple spark plugs helps
promote high combustion efficiency as compared to
a single or dual spark plug carburetor model, thus
creating a powerful , fuel efficient and low emission
engine.
6-Speed Gearbox
Perfectly matched 6-speed gearbox ensures
optimum utilization of the torque and power
characteristics of the 4-valve triple spark engine.
Liquid Cooling
Ensures control on engine temperature despite
high engine output and sports performance, thus
enhancing engine life, negating power fade due to
overheating, lowering engine noise and reducing
emissions.

22
Perimeter Frame
The frame provides 3 times the lateral stiffness
of the Pulsar 220 frame thereby giving the Pulsar
200NS very good high speed handling and precise
cornering abilities.
Rear Nitrox Mono Shock

Monoshock for identical damping characteristics on
either side of the bike. Nitrox enhances high speed
absorption of ripples on road , aiding straight line
stability.
Exhaus TEC
Improves engine torque at low rpm and is optimized
to get maximum engine performance. Thus, no
frequent gear change is needed.
Underbelly Exhaust:
Provides the bike with a better mass centralization
allowing higher lean angles without grounding of
muffler.

23
Salient Features
Performance
Key Features Advantages Benefits
uu Triple spark technology uu Superior Innovative uu Great performance across

uu 4 Valve Engine technology engineered the entire rpm band and
for optimum engine all gears giving the Pulsar
uu Liquid cooling
performance at any speed 200NS a true sports bike
uu 6 speed gearbox character
uu Enhanced power and
performance
uu Smooth engine run at any
rpm
uu Higher efficiency in both,
mileage and emissions
Style
uu Brawny masculine looks of a uu Bold assertive stance and uu The Street Fighter look
Naked Sports bike sporty riding position gives the Pulsar 200NS
uu Muscular Perimeter frame uu Aggressive and sporty looks unmatched character on the
road.
uu Specially designed foot pegs
and switches
uu Stylish split seats
uu 2-piece grab rail for better
support
uu Well styled head lamp
uu Clip on type handle bars
uu Sporty exposed drive chain
uu New look alloy wheels
uu Broad tyres and petal disc
brakes
uu Well concealed underbelly
exhaust

24
Salient Features
Comfort & Handling
uu Perimeter frame with a uu Rigid chassis for excellent uu Optimized maneuverability

special swing arm high speed handling for high speed cornering
uu Underbelly exhaust uu Optimum centre of gravity for combined with flex-free
high stability front forks and broad tyres
uu Superior bike ergonomics
and a sporty riding position
and weight distribution uu Near perfect 50:50 front to
ensures a truly sporty ride.
uu Nitrox Mono Rear rear ensures a very sporty
suspension ride
uu Large 37 mm dia. front fork uu Nitrox rear suspension
with single antifriction bush enables a smoother ride
over small undulations when
uu Broad front and rear tyres
at high speeds
uu Clip on handle bar
uu Large dia front forks ensures
high rigidity for stable front
braking and flicking around
corners
uu Broad tyres enhance
the high speed handling
characteristics
uu Clip on type handlebars give
a sporty feel to the riding
posture
Safety
uu Front and Rear petal disc uu For sharp, precise fade free uu Enhanced and reliable
brakes braking braking capability along with
uu Broad Tubeless tyres uu Reliability with a sporty grip. strong flicker free lights to
match high performance
uu High strength chassis – uu The tread pattern contributes
capability of the bike
Perimeter frame and swing to high Performance
arm uu Superior structural strength
uu Powerful DC head lamp uu High wattage DC head lamp
provides Uniform strong
beam spread at any rpm

25

uu Type : 4 stroke, single cylinder
water cooled,fuel injected
uu No. of Cylinder : One
uu Bore : 72.0 mm
uu Stroke : 49.0 mm
uu Engine Displacement : 199.4 cc
uu Compression Ratio : 11:1
uu Idling Speed : 1400 ± 50 rpm
uu Max.Net Power : 18 Kw @ 9750 rpm
uu Max.net Torque : 18.6 Nm @ 8000 rpm
uu Ignition System : Inductive DC ignition
uu Ignition Timing : Variable as per map
in ECU
uu Fuel : Unleaded petrol
uu Carburetor : NA
uu Spark Plug : 3 Plugs
uu Spark Plug gap : 0.8 ~ 0.9 mm
uu Lubrication : Wet sump, Forced lubrication
uu Starting : Electric start
uu Clutch : Mechanically actuated
uu Transmission : 6 speed constant mesh
uu Primary reduction : 3.272
Gear ratios
uu 1st gear : 26.49
uu 2nd gear : 19.32
uu 3rd gear : 14.54
uu 4th gear : 11.58
uu 5th gear : 9.77
uu 6th gear : 8.57
uu Final drive ratio : 40/14
EMS
uu System : 12V,DC
uu Ignition system : Digitally controlled
thru ECU
uu Fuel feed : Port fuel injection
uu Malfunction indicator : LED
lamp wattage

26
Frame Electricals
uu Frame Type : Perimeter uu System : 12V,DC
uu Suspension uu Battery : “12V 8Ah VRLA
Front : 130 mm Fork travel, (Valve regulated lead acid)”
Telescopic, Single uu Head Lamp : 12V 55/60 W, (Halogen)
antifriction bush uu Tail/Stop lamp : LED type
Rear : 120 mm wheel travel, uu Side Indicator lamp : 12V 10W
mono suspension (4 nos. - Amber bulbs)
with nitrox
uu Position lamp : 12V 3 W (2 nos.)
uu Brakes
uu Rear Number : 12V 3W
Front & Rear : Hydraulically Plate lamp
operated disc type
uu Speedometer : LCD back light
uu Brake Size back light
Front : 280 mm Disc brake uu Neutral indicator : LED type
Rear : 230 mm Disc brake uu Turn signal indicator : LED type
uu Tyres : uu Hi-beam indicator : LED type
Front : 100/80, 17,
uu Reserve indicator : LED type
52 P Tubeless
uu Horn : 12V DC, Type 2A
Rear : 130/70, 17,
(82 mm dia.)
M/C 62P
uu Fuel gauge : TFR Type
uu Tyre Pressure
Front : 1.75 kg/cm² (25.0 PSI)
Rear (Solo) : 2.00 kg/cm² (28.0 PSI) Weights
Rear (with Pillion) : 2.25 kg/cm² (32.0 PSI) uu Vehicle kerb : 145.0 Kg
uu Rims weight, kg (Electric start)
Front : 2.5X17” 10 Spoke uu Gross vehicle : 275.0 Kg (Electric start)
alloy wheel weight, kg
Rear : 3.5X17” 10 Spoke
alloy wheel
uu Fuel Tank Capacity : 12.0 liters Controls
uu Usable Reserve : 2.4 liters uu Steering : Handlebar
uu Unusable Reserve : 0.2 liters uu Accelerator : On handle bar, RH grip
uu Gears : Left foot pedal operated,
1 down 5 up, Step shift
Dimensions uu Brakes
uu Length : 2017 mm Front : On handle bar, RH lever
uu Width : 804 mm Rear : Pedal operated by RH foot
uu Height : 1195 mm
uu Wheel base : 1363 mm
uu Saddle height : 807 mm
Notes :
uu Turning Circle Radius : 2500 mm (min)
Values given above are nominal and for guidance
uu Ground Clearance : 167 mm only, 15% variation is allowed to cater for production
and measurement.
Performance All dimensions are under un-laden conditions.

Definitions of terminologies wherever applicable are
uu Maximum : 129 in sixth gear as per Relevant IS/ISO standards.
Speed, km/h (with single rider 68 Kg)
Specifications are subject to change without notice.
uu Climbing ability : R & D

27
Test Yourself
1. On what side of the steering tube is the chassis no located?
a) L/H b) R/H
The Chassis no consists of how many digits?
a) 16 b) 11 c) 17 d) 19
2. What is the minimum net power of the Pulsar 200 NS Fi?
a) 20.0 PS b) 18.0PS c) 16.51 PS d) 19.0 PS
3. What is the rear tyre size of the Pulsar 200 NS Fi?
a) 90 X 90 X 17, 49 P b) 12 / 80 X 17, 61 P c) 120 / 80 X 17, 49 P d) 120 X 90 X 17, 51P
4. On what side of the engine is the spark plug fitted?
a) L/H b) R/H
Of what type is the spark plug used in the Pulsar 200 NS Fi?
a) RG4HCC b) RG6HCC c) RG4HC d) RG4H
5. Which of the components listed below do not form a part of the fuel injection system?
6. What do you understand by EMS?
7. In the console, what does the icon on the RH side of the high beam indicate?
a) System Malfunction b) Side stand OUT c) Hi Beam ON
8. Name the icons on the console. (Pl illustrate the icons)
a)
b)
c)
d)
e)
9. What is the Max Net Torque for Pulsar 200 NS Fi?
a) 17.17 Nm @ 6500 rpm b) 19.12 Nm @ 6500 rpm c) 15.22 Nm @ 6000 rpm
10 During PDI it is recommended to check the fuel cock operation for hardness/leakage
a) True b) False
11. The fuel pump is located inside the petrol tank.
a) True b) False
12. The fuel gauge is located inside the speedo console
a) True b) False
13. The Pulsar 200 NS Fi has a port injection system
a) True b) True
14. The Pulsar 200 NS Fi has an oil cooled engine.
a) True b) True
15. What is the handle bar on the the Pulsar 200 NS Fi referred to as?
a) Clip on handle bar b) Split type handle bar c) Both are correct

28
Read Before You Ride
Digital LCD Speedo Console Soft Self Start
Function: Display information on key important factors and alarm Function
indications. Cranks engine just by feather touch.
Neutral position of gear. How to Operate
Switch ‘ON’ ignition and kill switch.
Side indicator pilot indication.
Put vehicle into neutral or declutch if in
Hi beam indicator gear.
Drop in battery voltage Press self start button.
Drop in engine oil pressure Do not open throttle (accelerator) while starting. Once engine starts do
not rev up engine while vehicle is parked on the stand.
Engine overheating & rise in engine temp.>115°C
Benefits
Malfunction indication of EMS
Comfort
Tachometer: A analogue display tachometer Hassle free starting
showing 0~12 x 1000 RPM display for
understanding the engine RPM. Malfunction Indicator
Engine RPM Limiter: A amber colour LED bulb Function
starts blinking when the engine RPM reaches to It gives indication signal about error in
9500 RPM cautioning the rider crossing safety zone Engine Management System.
(However engine RPM curtails above 10500). How to Operate
Fuel Gauge: A vertical 9 bar equally segmented graphical indicator This operates automatically as and when
indicates fuel level inside the fuel tank. the error is generated.
Low Fuel Level Indicator: Icon will blink continuously Visual Signal
when the fuel level drops below 3.5 liters thus reminding Amber colour icon on LH side in indicator will pop-up, this is an
the rider for refueling. indication that EMS has an error.
Side Stand:A indication display of stand ON will appear
Immediately take the vehicle to a BAL authorised Service Station.
when stand is put ON.
Benefits
Easy to read Digital Speedo Display showing
Great safety.
Vehicle speed - Km/Hr.
Arrest consequential damages arising
Odometer - Kms covered.
Resetting trip meter - for recording distance covered in trip with Side Stand Riding Protection
resetting provision (TRIP 1 & TRIP 2).
Feature
Digital clock - displays time in HR:MM (AM/PM).
Protection against side stand riding.
Service Reminder: A service reminder will pop-up reminding you that
vehicle is due for next service. Advantage
The EMS systems senses the side stand on signal
How to Operate and does not allow the engine to run with side
Put ‘ON’ ignition key and kill switch. All 4 icons on top will pop-up and stand in ON position.
few will vanish away automatically. All other will show static display
until the vehicle moves on road. Benefits
Other displays are dynamic which functions individually for respective Rider’s safety.
applications. Liquid Cooled Engine
Feature
Mode Selection Switch
Liquid cooled engine.
Function
Trip meter, Digital clock and Service Advantage
reminder setting Maintains lubricating oil viscosity even at
high temp. and extreme stress for optimum
Advantage
performance
Facility to change -
Time as per local time. Benefits
Reset trip meter to calculate the distance covered in a trip. Effective cooling and lubrication helps to deliver the higher engine
performance under every possible load condition.
Note : Service reminder setting is to be done by Bajaj Authorised Service
Centers / Dealers only. VRLA Battery
Feature
Head Light always ON
Zero maintenance battery.
Feature
DC head light will glow on start of Advantage
vehicle automatically. No top up required.
Advantage Benefits
Continuous DC head light on facility. Effective cooling & lubrication helps
to deliver the higher engine performance under every possible load
Benefits condition.
Brighter illumination throughout the ride.
Road safety.
29
Read Before You Ride

Gear Shifting Pattern Fuel Saving Tips
Feature Avoid following
1 down 5 up shift mechanism. −− Sudden pick-up and frequent braking.
−− Needless and excessive idling.
Advantage
−− Excessive high speed riding.
Bike will never be left into neutral Check and Inflate tyre pressure once in a week.
condition.
Fill petrol at reputed petrol pumps.
Benefits Use only branded fuel.
Safe to drive at all speed conditions Inspect the coolant and engine oil level. Top-up to MAX level
Disc Brakes - Front & Rear Monsoon Care

Feature Fit and Finish Parts
Hydraulic disc brakes. It is suggested to take proper care in heavy
Advantage monsoon / high rainfall area. The appropriate
surface preventive coat is to be applied to avoid
Most efficient and safe braking.
rusting / poor surface finish on account of adverse
Benefits atmospheric conditions.
Ease in stopping the vehicle at desired spot. Clean and lubricate all the important parts as detailed in a Periodic
Safely controlling the vehicle speed. Chart given in Owner’s Manual.
Tubeless Tyres Additional Care

Advantage Engine Oil : Check every week
If punctured do not deflate suddenly and Park the vehicle on level surface to check
helps in reducing unsprung mass. Less the oil level.
rolling resistance ensures complete road
Always maintain engine oil level between
stability.
the upper and lower level.
Benefits Replace the oil in accordance with P.M.
High stability and less maintenance Chart.
Recommended Oil Grade and Qty Battery

Grade SAE 20W50 of API ‘SL’ + JASO ‘MA’ grade or superior. How to Keep Battery Healthy
Quantity Drain and Refill 1200 ml. Engine Overhaul 1400 ml. Switch ‘OFF’ ignition when engine is not running.
Do not ride with the brake pedal / brake lever depressed. The brake
Coolant light would remain active and drain the battery.
Ensure coolant in expansion tank is between Min and Max level mark. Get your battery checked / charged during periodic services
Top up with recommended brands
Recommended Coolant Brand

Mfr. Castrol - Radicool, Motul - Motocool Expert
Quantity Drain and Refill - 1000 ml.
Safe Riding Tips

Always wear standard helmet while riding.
Never use mobile phones while riding.
Always keep rear view mirrors clean.
Use both, front and rear disc brakes simultaneously. Applying only one
brake may cause loss of control and skidding or diving.
Do not apply front brake when cornering or at turns.
Familiarise yourself well with seating posture, starting, acceleration and
braking of the vehicle.
Use side indicators before turning.
Fuel pump inside the tank is lubricated and cooled by the fuel. Hence
always maintain minimum 3 liter of fuel in fuel tank.

30
Key Learning Points
Understanding the standard procedure to

be followed during Pre-Delivery Inspection
of a new vehicle and entering PDI details as
per checklist
Important tightening torque applications with

loctile recommendation
Standard timelines for attending PDI

operations and PDI productivity
Things to be remembered and followed

during PDI
CHAPTER 4
Preliminary Checks &
Maintenance Operations
PDI Checklist
Perodic Maintenance Chart
Lubrication Matrix

31
4 Preliminary Checks and Maintenance Operations
Pre-Delivery Inspection Checklist

Following is the checklist for carrying out PDI of “Pulsar 200NS” motorcycle. This checklist is to understand
various check points those are to be checked / inspected before delivery of the new vehicle.
Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked
as per the points given below. This ensures trouble free vehicle delivery to the customer.
Dealer's Name Dealer's

code:
PDI Check sheet-Pulsar 200 NS
Frame No. Date of PDI
Engine No. PDI done by
Please unsure that following checks are carried out during PDI before delivery of vehicle.
To Check Check for ✔ if OK Remarks
X if NOT
ENGINE
Engine Oil "BAJAJ Oil level between upper and lower mark of oil level gauge / Top 
DTS-i 10000" up if required
20W50
Oil leakage if any - Specify source of leakage 
Gear shifting Smooth operation 
Engine noise No abnormal noise 
Silencer noise No abnormal noise 
Fasteners (Check Assy pipe A exhaust band clip bolt – 1.8 ~ 2.0 Kgm 
torque) Assy end chamber band clip bolt- 1.8 ~ 2.0 Kgm 
Gear shifter lever pivot bolts – 0.9 ~ 1.1 Kgm 
COOLING SYSTEM
Coolant level Ensure level between MIN and MAX mark in Reservoir tank in 
engine cold condition
Coolant leakage if any - Specify source of leakage 
Radiator fan Working of radiator fan after coolant temperature reaches 98 C
0

FUEL SYSTEM
Tank Cap Petrol tank cap bolt fitment 
FRAME
Tyre Pressure Front : 1.75 Kg / Cm2 (25.0 PSI) 
Rear (with Pillion) : 2.25 Kg / Cm (32.0 PSI)
2

Wheel Freeness of front and rear wheel 
Steering movement Check for smooth operation. 
Side stand Smooth operation 
Mirror Proper fitment 
Clear rear view 
Head lamp Focus adjustment
CONTROLS Steering cum ignition, Rear seat lock
Brakes Front / Rear: 
a) No oil leakage from master cylinder and caliper
b) Check oil level in master cylinder (Visual inspection) 
Throttle Grip free play - 2 ~ 3 mm. Smooth operation 
Clutch Cable Smooth operation, Free play - 2 ~ 3 mm 

32
Pre-Delivery Inspection Checklist
To Check Check for ✔ if OK Remarks
X if NOT
Speedo cable Proper routing 
Drive Chain Slackness standard - 15 ~ 25 mm 
Equal marking of chain adjuster on both side 
SUSPENSION
Front Fork No leakage(Visual inspection), Smooth working 
Rear Shock Spring adjuster notch position : 2nd notch (Standard) 
Absorber
Steering Smooth operation (No excess play / No sticky movement) 
Lock Operation Steering lock operation(Only on LH side), Seat lock, Petrol 
tank lock
Fasteners (Check Front axle nut - 10 Kgm 
torque) Rear axle nut - 10.0 Kgm 
Rear sprocket mounting bolts – 3.2 ~ 3.8 Kgm 
Holder handle bar bolts - 1.8 ~ 2.0 Kgm 
Fork center nut - 4.8 ~ 5.2 Kgm 
Swing arm shaft - 14 Kgm 
Front fender mounting bolt- 1.8 ~ 2 Kgm 
Stay LH / RH mounting bolt - 1.6 ~ 1.8 Kgm 
Check nut bolts, screws, split pins for tightness. 
ELECTRICAL
Battery Open circuit voltage (13 to 13.2 V DC) and Charge status by 
VRLA battery tester
Tightness of battery terminals / cables 
Fuse Position of fuse box 
Kill switch In OFF position check for no Speedometer display and no self 
start working.
All Bulbs Working Head light, LED tail / stop, Side indicators, Number plate lamp 
Switch Operation RH and LH control switch, Ignition switch and Brake switch 
(Front and Rear)
Starter Motor No abnormal noise 
Working / Engagement in gear and neutral 
Speedometer No excess gap and uneven gap 
Working of Speedometer, Odometer and Tripmeter, Clock 
setting
Working of all signal indicators icons (Turn pilot, Neutral, High 
beam, Side stand, Battery charge and Bajaj logo)
Horn Ensure no distorted sound 
TEST DRIVE
Starting Cold start and Warm start 
Drive ability Throttle response 
Brakes effectiveness- Front and Rear 
Cleaning Wash and Clean vehicle properly 
Important Note: Look for any external damages in transit, please check, record and rectify send report with
photos.

33
Periodic Maintenance Chart

Recommended Frequency
Sr Service 1st 2nd 3rd 4th 5th 6th 7th

PM check points Remarks
No
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Ensure to prevent water entry in

Petrol tank, Silencer and electrical
Clean the vehicle with water wash parts.
1 √ √ √ √ √ √ √
and dry completely
Use caustic free detergent for
washing.
Engine oil (Bajaj DTSi 10000 oil) & BGO DTSi 20W50 for models
2 C, R R Top-up R Top-up R Top-up R
engine oil filter* above 125cc.
Oil strainer cleaning at the time of

3 Oil strainer CL CL CL CL CL
oil change.
4 Spark plug CL,A,R CL,A CL,A R
Air cleaner element ***& cover ‘O’

5 CL, R CL CL CL R CL CL R
ring
6 In line fuel filter . R R R
7 Fuel pipe C,R C C C R C C R
8 Valve tappet clearance C, A C, A C, A C, A C, A C, A C, A C, A
Sealed drive chain cleaning & Customer to apply OKS chain lub
9 CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
lubrication spray at every 500 kms.
10 Air filter drain tube C C C C C C C C
11 Silencer drain hole cleaning CL CL CL CL CL CL CL
12 Silencer tail pipe cleaning** CL CL CL CL CL CL CL
13 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 recommended AP grease.
Brake lining or pad -Check wear Replace brake shoes /brake pad
14 C,R C,R C,R R C,R C,R R
indicator at every15000 Kms
Use recommended brake fluid

15 Brake fluid level **- top up / replace C,A,R C,A R
(DOT3/DOT4).
Disc brake assly -- Check

16 functionality, leakage or any other C C C C
damage.
All cables & rear brake pedal -free

17 C,A C,A C,A C,A C,A C,A C,A C,A
play

34
Periodic Maintenance Chart
Recommended Frequency
Sr Service 1st 2nd 3rd 4th 5th 6th 7th

PM check points Remarks
No
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Wiring harness & Battery

18 connections- routing, tie bands & C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
clamps tightness.
Ignition switch barrel cleaning &

19 handle bar control switches contacts C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use recommended WD40 spray
cleaning,
20 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
Check and replace if damaged.

Steering stem bearing*** & Cap
21 C,CL,L,R C,CL,L,R C,CL,L,R C,CL,L,R Use HP Lithon RR3 grease for
steering bearing(Plastic)**
lubrication.
22 Main stand & side stand pin** CL,L CL,L CL,L CL,L Use recommended AP grease.
23 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
General lubrication-Clutch lever, front

24 L L L L L L L L Use recommended AP grease.
brake lever, kick lever.
Use recommended 'Ready to use

25 Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A R
coolant'.
Coolant hose damage/clamps/

26 C C C C C C C
leakage**
27 Radiator fins** C C C C C C C
* It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be every
5000 kms
** As applicable to model
*** More frequent cleaning is required while driving in dusty environment.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Following items are chargeable to Customer.
Oil,Coolant,Filters,All types of greases,Cleaning agents,Cables,Wear and tear parts,Rubber O rings/oil seals/pipes , Gaskets etc.

35
Lubrication Matrix
Oil / Grease / Loctite application matrix
Sr. Lubricant / Loctite Grade Application Remark
No.
1 Engine oil DTSi 10000, SAE Engine Quantity :
20W50 API SF/SG Drain and Refill - 1200 ml
JASO MA Eng. O/h - 1400 ml
2 Fork oil SAE 10W20 Front fork Quantity / fork leg :
Drain and Refill - 295 ±2.5 ml
Overhaul - 320 ml
3 Brake fluid N.A N.A N.A
4 Grease Lithon RR-3 Steering races and balls HP make
5 Grease All purpose Front and real wheel
axle, Swing arm shaft,
Brake pedal pivot pin,
Center stand shaft, Side
stand U bracket, Gear
shifter pivot, Clutch and
front brake lever
6 Chain spray OKS - Chain lube N.A
spray
7 Oil for drive chain SAE 90 Non ‘O’ ring type drive During all services
chain
8 Electrical contact WD-40 Spray • Ignition switch All services
cleaning spray
• Brake and clutch
switch
• LH/RH control switch
Notes

36
Engine Oil Replacement
uu Ride the Vehicle for 2-3 Km to warm the engine.

uu Park the vehicle on levelled surface.
A
uu Remove:
Drain Bolt - A
Oil Strainer - B
B
uu Measure & Inspect:

Quantity of the oil collected.
uu Inspect:
The quality of the oil collected.
Note:
The standard oil consumption per
1000 kms is 30 to 80 ml
uu Clean:
Strainer using Kerosene / Diesel.
Blow air of 2 bar pressure from inside to outside.
Clean the ferrous burr deposited on the oil strainer.
uu Inspect:
The ‘O’ ring for firm fitment
uu Fit:
Strainer and the strainer cap
Tighten the strainer cap - A
A

37
uu Fill recommended quantity of engine oil.
Grade SAE 20W50 API SF/SG, JASO MA

Drain and Refill 1200 ml
Engine Overhaul 1400 ml
Note:
The standard oil consumption per 1000
kms is 30 to 80 ml
Engine Oil Filter Replacement
A
uu Remove
B
2 bolts - A
A Filter cover - B
uu Remove
Oil Filter
Note:
Do not clean or reuse the oil filter element.
Replace the oil filter at the first service and
thereafter at every oil change.
A
uu Fit
Oil filter cover - A
2 bolts - B
A

38
Spark Plug Gap Adjustment
uu Remove & check spark plug for...
1. Spark Plug type 3. Errosion
2. Color 4. Cracks / Breakge
Recommended Central – BOSCH YR5NE

Spark Plug LHS & RHS – CHAMPION –
PRG6HCC
Electrode Gap 0.8 ~ 0.9 mm
u Clean the spark plug

u Check and adjust spark plug gap using wire gauge.
u Spark plug gap should be - 0.8~ 0.9 mm
Note:
Cleaning every 10,000 Kms. Replacement every
30000 km.
uu Fit
Screw in spark plugs first manually and thereafter
use spanner for tightening it.
Notes

39

Coolant Replacement
Drain the coolant
uu During run, the coolant heats and is under pressure.
Do not remove the radiator cap, radiator hoses or
other any other component of the cooling system
when the engine is in heated condition. Allow the
engine and cooling system to cool down.
A
uu Park the vehicle on levelled surface.
uu Remove
Bleeder Screw - A
uu Remove
Drain bolt - A
Washer - B
uu Drain the coolant
A Steam and overheated radiator fluid if comes
& in contact with skin, causes serious burns.
B Warning
Please therefore do not open the radiator cap
or drain when the engine is heated.
Replacement of coolant :
uu Use only the recommended brand
(ready to use) of coolant.
Make Qty
Castrol - Radicool
1000 ml
Motul - Motocool expert
Note: Replace coolant every 30,000 Kms
uu Fit
Washer
Drain bolt.

40
Coolant Replacement
uu Remove
Coolant from the expansion tank
Skill tips: Stop until the coolant with

air bubbles emerges out from the
bleeding screw.
uu Fit
Radiator cap - A
A
Do not open the radiator cap in engine
Caution
hot or during engine running condition.
uu Remove
Cap for the expansion tank.
Top up the coolant to maximum mark.
uu Refit the cap of the expansion tank.
Note:
Ensure that the vent pipe is routed correctly

41

Air Filter Cleaning
Stage 1
uu Use compressed filtered air of pressure less than
2 bar.
900 uu Position pressure gun at a 90 degree angle and at a
distance of 50 mm from paper filter.
uu Move the pressure gun along the lines of the folds.
Stage 2
450 uu Position pressure gun at a 45 degree angle and at a
uu Twist the paper filter slightly.
uu Move the pressure gun along the fold line.
Stage 3
uu Position pressure gun at a 90 degree angle and at a
900
uu Blow out the remaining dust the pressure gun along
the lines of the folds.
Dos Don’ts
uu Clean paper filter at every 5000 Kms. uu Don’t use solvents such as petrol, Diesel,
uu Increase frequency of cleaning if the vehicle is Kerosene or water to clean paper filter element.
being used in dusty conditions. uu Don’t apply any oil on paper filter element.
uu Replace the paper filter at 15000 Kms. uu Don’t touch paper filter surface with soiled hand.
uu Hold filter element by its PU foam. uu Don’t wipe the paper filter with cloth, paper or
any abrasive material.
Notes

42
Tappet Setting
uu Ensure that the piston is at the end of the
compression stroke.
uu Both rockers are the free.
uu Ensure that the cam sprocket marks are parallel to
the cylinder head surface.
uu Check and adjust clearance of both, inlet and
exhaust valves
Note:
Make one rotation of crankshaft and recheck the
tappet clearance once again.
If found incorrect adjust it again.
Tappet Clearance
Intake Exhaust
0.05 mm 0.08 mm
SOP for compression pressure checking (Dry Test)
uu Warm the engine by riding the vehicle for about 1 km.

uu Park the vehicle on levelled surface
uu Disconnect all spark plug caps.
uu Remove the RH side spark plug.
uu Connect the compression gauge adapter and fit it.
uu Open the throttle fully

uu Crank the engine for 6 seconds
uu Note the compression pressure
uu Take 3 readings and calculate the mean of

the 3 readings
Compression Pressure
Details Kg/cm2 PSI Bar
Std 11-13 156.4~185.0 10.78~12.74
Service limit 9.5 135.5 9.31

43

‘O’ Ring Type Drive Chain Lubrication (On the vehicle)
uu Park the vehicle on the service stand.

uu Ensure free rotation of the rear wheel.
uu Wipe / clean of dust using a lint free cloth.
uu Shake the chain lube spray thoroughly.

uu Hold the spray at a distance of 5 – 10 cm from the
chain
uu Rotate the wheel in the reverse direction when
spraying . Spray on the middle section of the chain.
‘O’ Ring Drive Chain Cleaning by Removing from Vehicle

(Diesel + SAE 90 oil 1:1)
1st Stage : 2nd Stage: Blow Low Pressure

Clean with Diesel + oil 1:1 Clean with Diesel + oil 1:1 Compressed Air
Final Stage : Soak into SAE 90 oil 3rd Stage:

Hook chain for dripping of Dip into SAE 90 oil
excess oil

44
Drive Chain Slackness Checking
uu Park the vehicle firmly on the service stand. Drive chain Slackness
uu Rotate the rear wheel
Std Specs = Frame ppt
uu Adjust slackness if found incorrect
Ser limit Specs = Frame ppt
Drive Chain Slackness Adjustment
uu Loosen
Rear axle nut.
uu Adjust:
LH chain adjuster
RH chain adjuster
Note:
Ensure bolt LH/RH adjusters are adjusted equally.
uu Tighten:
Rear axle nut.
Ensure correct chain slackness.

45
Why to & How to maintain your Vehicle?

Why Periodic Maintenance is required?
Components of vehicle & engine are subject to -
Continuous working.
Rotation, Reciprocation, Swivel etc.
Operational misuse.
Moreover, the vehicle get abused by

Various driving habits.
Bad road conditions.
Dense traffic conditions.
Different weather conditions.
All these call for regular Periodic Maintenance.
How to maintain the vehicle regularly?

By following the Service Schedule and Periodic Maintenance Schedule, one can
maintain and keep the vehicle fit and healthy.
Avail all the free services as per schedule.
Avail all the paid services as per schedule.
Follow Periodic Maintenance as per P.M. chart
given in the Owner’s Manual.
Benefits :
Periodic Service / Maintenance ensures -
Consistent performance.
Remote chances of breakdowns /
accidents due to failure of parts.
Enables safe riding.
Economical in long run
Keep your vehicle fit and healthy by following Scheduled Services and
Periodic Maintenance Schedule for trouble free performance

46
Key Learning Points
Understanding of EMS Layout
Understanding the Function, Construction

and Working of Sensors and Actuators
Application and Usage of Diagnostic Tools
Standard Operating Procedures for Fuel

Pump Pressure Inspection and Fuel Pump
Delivery Measurement
CHAPTER 5
Fuel System & EMS
DTSi – Fi Engine Management Systems / EMS Layout
Working of Systems
Fuel Injection
Dos and Don’ts

47
5 Fuel System & EMS
DTS-Fi Engine Management System

Location of parts
Speedometer
harness
Tail and stop lamp, Rear blinker

RH, Rear blinker LH, Number plate
lamp, Fuse box assy., Aux. start
relay 1,2,3. And CAN interface
Ignition Switch Lambda (oxygen) sensor, crank sensor,

Control Switch LH stepper motor, Fuel injector, TMAP, TPS,
Control Switch RH CTS, Oil pressure sensor.
Clutch Switch Kill Switch
Lambda (oxygen) sensor, crank

sensor, stepper motor, Fuel injector,
TMAP, TPS, CTS, Oil pressure sensor.
Roll over Photo Part Name Remark

HT coil 1
sensor H.T. Coil 1 For Central spark
plug
HT coil 2
H.T. Coil 2 For LH & RH spark

plug
Roll Over Sends ignition

Sensor cut of signal to
ECU when bike
inclination angle
> 68°

48
Location of important parts / couplers
Crank sensor & Lambda Fuel Pump Fuel Level Stepper Light control Regulator
(oxygen) sensor Sensor motor module earth
Regulator connectors Coolant temp. sensor Engine earth Chassis earth Side stand switch
Photo Part Name Remark Photo Part Name Remark

Crank It monitor the position Light It manages all the individual
Sensor or rotational speed of Control lights of the vehicle electric
the crankshaft Module system.
Lambda Detects amount of oxygen Regulator It has AC/DC voltage

Sensor in exhaust gas and sends Earth regulator & a rectifier. The RR
signal to ECU which adjusts unit regulates the electrical
the air fuel mixture to the voltage & also helps in
optimal level. charging the battery.
Fuel Pump To draw the fuel from fuel Side Stand When the side stand is put
tank and push it along the Switch ON the side stand sensor will
fuel lines to injector and send the information to ECU.
keep a constant pressure in ECU will thereafter not allow
the system. the engine to run in any gear.
Coolant It measures the temperature
temp. of the coolant. The readings
Fuel Level It senses the fuel level / sensor from this sensor are then fed
Sensor quantity inside the fuel tank back to the ECU, which uses
and communicates the this data to adjust the fuel
same to fuel gauge. injection and ignition timing.
Engine
Stepper Stepper motor is a Earth
Motor brushless DC electric motor
that divides a full rotation
into a number of equal
Common earthing for the
steps. The motor’s position
Chassis electrical system
can then be commanded
Earth
to move and hold at one
of these steps without any
feedback sensor

49
5 Fuel System & EMS

Oil pressure TMAP TPS Termination Radiator fan Starter
sensor unit relay relay
Regulator magneto Fuel Fuel level Stepper Regulator Main relay & EMS ECU
connection pump sensor motor Fuel pump relay
Photo Part Name Remark Photo Part Name Remark

Fuel Injector To inject the fuel into ECU To collect information
the intake manifold until from various sensors
the electric signal from & insure that correct
solenoid is cut of by ECU. quantity of fuel is
injected into the
Oil pressure It measures the intake manifold at
Sensor pressure of the engine precise timing at
oil flowing thru the various engine load &
internal oil galleries and speed condition
communicates the signal
to the speedometer. Main Relay
TMap It is a micromechanical
sensor that measures
the absolute pressure
in the intake manifold A relay is an
and compares it with electrically operated
a reference vacuum, Fuel Pump switch. Most
not with the ambient Relay relays use an
pressure. electromagnetic to
TPS To measure the exact mechanically operate
position of the throttle a switch. Relays
valve opening and to send are used where it is
this measurement signal necessary to control
in voltage form to ECU. Radiator a circuit by a low-
Fan Relay power signal
Termination It consist of a transil diode
Unit that filters the voltage
surge thereby protects
ECU from voltage
fluctuation.

50
Starter relay Starter relay coil Radiator fan relay Termination unit TMAP
TPS
Oil pressure
sensor
CTS
Rear brake switch Starter motor
TPS Rear brake switch
TMAP
Oil
Pressure
CTS
Starter
Motor
Battery positive Battery Main fuse CAN Fuse Box

negative Termination Assembly
Signal Lamp rear LH

Signal Lamp rear RH
Tail and Stop Lamp
Number Plate Lamp
And Can interface
Aux. starter
relays 1,2 & 3
Earth chassis
CAN Application

51
5 Fuel System & EMS

Photo Part Name Remark
This unit is provided to have

uninterrupted communication
CAN Termination
between diagnostic tool and
ECU
Function of Aux Starter Relay
AUX Starter Relay 3

Incorporated for clutch & neutral switch interlocking in starter circuit.
3
2
AUX Starter Relay 2
Its function is to isolate starter circuit from ECU. If this relay fails engine
1 can not be crank.
AUX Starter Relay 1

It is grey in color. It has a diode that is provided for suppressing voltage
surge. If vehicle is driven without this relay ECU may fail.
Notes

52
Engine Management Systems
Gives Input to ECU Receive Output from ECU
Coolant Fuel
temperature Injector
sensor.
Oxygen sensor Fuel

(Lambda sensor) pump
Crank angle HT Coil

sensor.
Throttle
position Malfunction
sensor indicator
(TPS)
Temperature and ECU Main power

Manifold pressure relay
sensor (TMAP)
Roll over Stepper

sensor. Motor
Diagnostic
Side stand sensor coupler
Wheel speed Radiator

sensor. Fan

53
5 Fuel System & EMS
EMS Sensors and Actuators
1 - MPRD (Relay)
P4
P3
4 P2
2 3 P1
2 - Steeper Motor 3 - Injector 4 - T MAP Sensor 5 - TPS
6 - Fuel Pump
7 8
7 - H. T. Coils (LH) 8 - H. T. Coils (RH)
9 - Engine Malfunction Indicator (MIL)
10
10 - Diagnostic Coupler
11
11 - Radiator Fan

54
Working of Systems
Fuel Pump
Function
To draw the fuel from the fuel tank and push it along the fuel
lines to the injector rail and keeping a constant pressure
in the system. Also the fuel pump needs to ensure a high
level of fuel flowing through the fuel line thus maintaining
constant fuel delivery pressure.
Construction
Fuel pump module assembly
Fuel Pump Mounting

Bracket Fuel Pressure Regulator
Fuel Pump
Fuel Strainer
Rubber Gasket for

Sealing on to Petrol Tank
Pressurized Fuel out to Regulator Connected

Fuel Filter in a ‘T’ Joint
Fuel Filter to Injector Fuel to Injector
Working
The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the end of which
is a fuel pressure regulator.
In order to keep the injector pressure differential constant despite variations of inlet manifold depression with
load, the fuel pressure regulator senses the difference between pumping pressure and that of the inlet manifold.
Excess fuel is returned to the fuel tank, the continuous flushing keeps the fuel cool and avoids formation of
pockets of fuel vapor.
The fuel pump is lubricated and cooled by the fuel flowing through the motor, including the brushes and across
the armature hence it is important that never run the pump without adequate fuel inside the fuel tank.
The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pump, fuel
injector nozzles from clogging.
Fuel Pump Resistance = 2.7 + 0.1 Ohms

55
5 Fuel System & EMS
Working of Systems
Fuel Injector
Function
To inject the fuel into the intake manifold until the electric
signal from solenoids is cut off by ECU.
Construction
Fuel Supply
Rail ‘O’ Ring Seal

Electric Connection
Integral Filter
Coil
Return Spring
Armature
Washer
Valve Needle
Manifold ‘O’ Ring
Pintle Protection Cap
Pintle
Working
The fuel injector supplies the fuel in the form of a spray from the injector pintle which is located on intake
manifold.
The injector have the nozzles which are opened and closed by solenoid wound (coil) in the injector body.
When the windings are energized the armature is attracted due to magnetism and compresses the spring
which lifts the needle valve. Thus pintle automises the fuel into a fine spray form with a pressure about 2.5 bars
(36 lbf / in2) until the electric signal in the solenoid is cut off by the ECU.
The injector internal movement is restricted just to < 0.1 mm. Also period that an injector remains open is very
low (between 1.5 and 10 milliseconds). Thus the opening and closing time is critical for accurate fuel metering.
The fuel spray mixes with the incoming air as both move towards the inlet valve giving a precisely metered
combustion mixture.

56
Working of Systems
Engine Control Unit (ECU)
Introduction
The automotive engine has two power generation systems
named as ‘Carburetion System’ and ‘Ignition System’
respectively.
The Carburettor supplies atomized / vaporized air fuel mixture
to the engine maintaining the desired air fuel ratio as per
engine requirement.
The Ignition system supplies electric igniting spark at the spark
plug tip as per precise engine demand (timing) to burn the
compressed air fuel mixture inside the combustion chamber.
However these 2 systems like Carburetion and Ignition has
been dealt separately.
In digital ignition circuits a microprocessor is used in the CDI
unit. This microprocessor is capable of controlling various
tasks. Hence it was logical to use this spare capacity for
controlling fueling also.
Thus then developed a digital electronic control system for
fuel injection and combined it with the digital ignition control to
form a single unit controller. This unit is named as “Electronic
Control Unit”.
Function
It collects information from various sensors and ensure that a correct quantity fuel is injected into the intake
manifold at precise time considering various engine load and speed conditions.
It is brain of the engine and controls various devices. Also it controls / supports on vehicle diagnostic instrument
for diagnosing the problem in fuel injection system.
Construction
It consists of a micro computer A - D Convertor (Analog to Digital) and I - O Unit (Input - Output).
Input signals are received Signals given to operate

from various set of Sensors following Actuators
Sensors Actuators
Vehicle Speed Sensor MPRD (Relay)
Analogue to Digital - (A-D)
Side Stand Sensor

Signal Processing (SP)
Steeper Motor
Clutch Switch Injector
Engine Oil Pressure Sensor Engine Fuel Pump
Roll Over Sensor H.T. Coil (LH&RH)
Control Unit
Lambda Sensor Engine Malfunction
Crank Angle Sensor and ECU
Speedo Icon
Neutral Switch
Radiator Fan
T Map Sensor
Throttle Position Sensor It also supports in
Coolant Temperature Diagnostic trouble
Sensor codes assessment.

57
5 Fuel System & EMS
Working of Systems
Engine Control Unit (ECU)
Working
The ignition and fuel injection is controlled by a single control unit named as ‘ECU’.
In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all outputs to the
computer are in the form of digital pulses.
These inputs received may be steady or slowly varying voltages. These are said to be in analogue form and
which are converted into equivalent digital valves by an analogue to digital (AD) converter.
The digital output are fed to the input I output rail for transporting to the main heart of the computer. Thus the
ECU collects all signals, calculates them and process them to actuators to delivery precise ignition advance
timing and fuel injection requirement for the engine at various load and speed conditions.
Set of Various Sensors

A sensor is a device which detects or measures a quantity, usually in electrical form so that it may be used in
measurement or control. The analogue signal processing is added to the sensor, this improves the resistance
to interference.
Set of Various Actuators

Actuators is a general term used to describe a control mechanism i.e. a device that converts electrical signals
into mechanical movement e.g. -
Fuel injector
Fuel pump
Solenoid starter relay
Notes

58
Working of Systems
Throttle Position Sensor
Function
To measure the exact position of the throttle valve open-
ing and to send this measurement signal in voltage form
to ECU.
Construction
The throttle body has a throttle valve mounted on the
intake manifold. The throttle valve is connected by
accelerator cable and its opening and closing is controlled
by accelerator twist grip mounted on RH side of handle
bar. The throttle position sensor mounted on the throttle
valve continuously reports the throttle position to the ECU.
This is a rotary throttle position sensor having a variable
resistor also called as a potentiometer. Internally it has a
coil resistance wire in the form of a half circle. One end
connects to the ground and other end is connected to a 5
volt source from ECU.
The wiper blade has a contact that rides on the coil and
connects to the throttle valve shaft.
Also the position of the throttle valve is important in
controlling the idling rpm.
Working
RESISTANCE COIL
Upon acceleration the throttle valve position changes.
The wiper type blades moves over the coil winding as CLOSED THROTTLE
it is pivoted directly on the throttle valve shaft.
Throttle position at zero (closed} position When the
throttle valve is closed, the blade is at the grounded
end of the coil. A small voltage signal is send to ECU
OUTPUT
at this position which senses that the throttle position VOLTAGE
is at zero. WIPER PIVOT
TO ECU
BLADE
Further movement of throttle position As the throttle
valve moves towards the open position, the wiper
type blade swings towards 5 volt end of the coil.
This sends an increasing voltage signal to the ECU. WIDE OPEN THROTTLE 5 VOLTS
Thus the continuously charging voltage regularly FROM ECU
communicates the ECU the exact position of the
throttle valve.

59
5 Fuel System & EMS
Working of Systems
Engine Temperature Sensor
Function
To measure the engine / engine oil temperature up
to 200 0C.
Construction
The principal methods of temperature measurement
is are done by the thermistor.
The thermistor is made from semi conductor material
such as cobalt or nickel oxides and is encapsulated
in a brass sleeve for mechanical protection.
Working
The thermistors are semi conductor resistors which change their resistance valve with temperature. The
resistance decreases with an increase in engine temperature as it has a negative temperature coefficient
(NTC) and vice versa.
The characteristic of engine temperature is represented graphically. (The values do not match exactly, it is just
a representation for understanding).
This NTC type thermistor is used to measure the engine temperature in engine management system.
200
180
Thermister Resistance (Ohm)
160
140
120
100
80
60
40
20
NTC
Thermistor
0 Temp. OC
0 10 20 30 40 50 60 70 80 90 100
NTC Thermistor Characteristic

60
Working of Systems
Roll Over Sensor
Function
To send the ignition cut off signal to ECU for shutting down
the engine if the bike exceeds the inclination angle beyond
60° on either of the side.
Construction
Main Switch
Sensor The roll over sensor is a sealed sensor unit and that
contains moving weight which is suspended freely on a
shaft. This is mounted below the air filter box onto the
chassis.
Please note, even if roll over sensor is not connected
(coupler open) the vehicle does not start (to ensure safety)
and the malfunction will be shown on speedometer.
Magnet
Working
The moving weights are suspended freely. When
the vehicle leans down on either of the LH I RH side
the position of these weights changes. The change
of position of the weights is sensed by the sensor.
60
60 O
If the inclination angle exceeds beyond 60° to the

O
vertical the sensor will give signal to ECU to cut off

the ignition system. x 0
This is a useful safety feature because inclination

angle exceeding 60° indicates that the rider has
dropped the bike or is involved in an accident. Thus
safety of the bike and rider is ensured.

61
5 Fuel System & EMS
Working of Systems
Crank Angle Sensor
Function
To communicate the ECU how fast the crankshaft
is rotating per minute and help ECU in delivering
precise fuel metering and ignition spark advance.
Construction
A magnetic sensor located in magneto cover facing towards
square notched I square block on the rotor periphery.
Working
As the rotor rotates the notched square blocks on
the rotor periphery causes voltage pulses in the
sensor. These pulses are sent to the ECU. The
ECU counts the number of pulses per second and
understands at what RPM the engine is operating
and accordingly precise fuel metering and ignition
spark advance is controlled.
There are 23 square notches I square blocks on the
rotor outer periphery and are placed equidistance.
At a particular location there is wide gap seen
between 2 square notches I square blocks. This
can also be determined as square notch missing.
This missing square notch area represents the
BTDC position. At this BTDC position voltage
pulse is sensed by the crank angle sensor and is
communicated to ECU.
ECU uses this information to control ignition spark
advance.

62
Working of Systems
Malfunction Indicator Light
Function
When certain troubles develop in the electronic control
system, the ECU stores in its memory or number or trouble
code for each fault. This turns a Malfunction Red Indicator
Light ( ) on the speedometer (next to Hi-beam light).
This alerts the driver that there is some problem and repair
/ service in needed.
If a single sensor or its harness part fails the ECU may
substitute a value for failed sensor. This allows the engine
to appear to run normal. A fault that turns on the malfunction
indicator light may also put the engine into its limp-in mode.
This means that limited operation strategy (LOS) chip in
the ECU has taken over. It provides basic instructions
to the microprocessor if a part of the electronic system
fails. The engine runs but with fixed ignition timing and air
fuel ratio. The injector pulse width does not change. This
allows the vehicle to be driven but with greatly reduced
performance. The benefit of this is the vehicle can be limp-
in for service instead of being towed or transported into a
cargo.
The technician can retrieve the stored trouble code from
ECU memory using the diagnostic tool. To use the code
the technician can refer the Diagnostic Chart or the Flash
Code. This chart explains where lies the problem and its
probable cause.
Notes

63
5 Fuel System & EMS
Working of Systems
List of Diagnostic Trouble Codes
SR No P Codes “Blink “Drive DTC meaning

code” Cycle”
1 P0123 06 3 Throttle/Pedal Position Sensor/Switch “A” Circuit High
2 P0122 06 3 Throttle/Pedal Position Sensor/Switch “A” Circuit Low
3 P0507 11 1 Idle Air Control System RPM Higher Than Expected
4 P0506 11 1 Idle Air Control System RPM Lower Than Expected
5 P0108 09 3 "Manifold Absolute Pressure/Barometric Pressure Circuit
High”
6 P0107 09 3 Manifold Absolute Pressure/Barometric Pressure Circuit
Low
7 P0629 41 1 Fuel Pump “A” Control Circuit High
8 P0628 41 1 Fuel Pump “A” Control Circuit Low
9 P0627 41 1 Fuel Pump “A” Control Circuit/Open
10 P0336 02 3 Crankshaft Position Sensor “A” Circuit Range/
Performance
11 P0262 33 1 Cylinder 1 Injector Circuit High
12 P0261 33 1 Cylinder 1 Injector Circuit Low
13 P0201 33 1 Injector Circuit/Open – Cylinder 1
14 P1611 14 ** Fuel consumption signal output short to Battery
15 P1610 14 ** Fuel consumption signal output short to Ground
16 P1609 14 ** Fuel consumption signal output open
17 P0032 45 3 HO2S Heater Control Circuit High Bank 1 Sensor 1
18 P0031 45 3 HO2S Heater Control Circuit Low Bank 1 Sensor 1
19 P0030 45 3 HO2S Heater Control Circuit Bank 1 Sensor 1
20 P0692 16 1 Radiator Fan Control Circuit High
21 P0691 16 1 Radiator Fan Control Circuit Low
22 P0480 16 1 Radiator Fan Relay Control Circuit fault
23 P0132 17 3 O2 Sensor Circuit High Voltage Bank 1 Sensor 1
24 P0131 17 3 O2 Sensor Circuit Low Voltage Bank 1 Sensor 1
25 P0130 17 3 O2 Sensor Circuit Bank 1 Sensor 1
26 P0134 17 3 O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1
27 P1605 18 ** Malfunction Indicator Lamp (MIL) Control Circuit High
28 P1604 18 ** Malfunction Indicator Lamp (MIL) Control Circuit Low
29 P0650 18 ** Malfunction Indicator Lamp (MIL) Control Circuit
30 *P1504 15 1 Roll over sensor Short Circuit to battery
31 *P1503 15 1 Roll over sensor Short Circuit to Ground
32 *P1501 15 1 Roll over sensor circuit signal non-plausible
33 *P1502 15 1 Roll over sensor circuit open

64
Working of Systems
List of Diagnostic Trouble Codes
SR No P Codes “Blink “Drive DTC meaning

code” Cycle”
34 P1603 19 ** Rest tank Fuel Indicator Circuit High
35 P1602 19 ** Rest tank Fuel Indicator Circuit Low
36 P1601 19 ** Rest tank Fuel Indicator Circuit open
37 *P1508 25 1 Side Stand sensor Short Circuit to battery
38 *P1507 25 1 Side Stand sensor Short Circuit to Ground
39 *P1505 25 1 Side Stand sensor circuit signal non-plausible
40 *P1506 25 1 Side Stand sensor circuit open

41 P0509 49 3 Idle Air Control System Circuit High
42 P0508 49 3 Idle Air Control System Circuit Low
43 P0511 49 3 Idle Air Control Circuit
44 P0689 21 ** ECM/PCM Power Relay Sense Circuit Low

45 P0112 13 ** Intake Air Temperature Sensor 1 Circuit Low
46 P0113 13 ** Intake Air Temperature Sensor 1 Circuit High
47 P0117 12 3 Engine Coolant Temperature Sensor 1 Circuit Low
48 P0118 12 3 Engine Coolant Temperature Sensor 1 Circuit High
49 P1608 22 ** Engine Speed Signal Circuit High
50 P1607 22 ** Engine Speed Signal Circuit Low
51 P1606 22 ** Engine Speed Signal Circuit Open
52 P0563 24 ** System Voltage High
53 P0562 24 ** System Voltage Low
54 P1510 24 ** System Voltage sensing failure in ECU
55 P0501 23 3 Vehicle Speed Sensor “A” Range/Performance
56 P0643 26 3 Sensor Reference Voltage “A” Circuit Hig h
57 P0642 26 3 Sensor Reference Voltage “A” Circuit Low
58 P0653 27 1 Sensor Reference Voltage “B” Circuit High
59 P0652 27 1 Sensor Reference Voltage “B” Circuit Low
Note:
Actual description of DTC may vary to make it fit on Tool screen.
* This fault codes are not applicable in case of RE 60.
** Blink Code getsON immediately.
Healing for all DTC requires 3 driving cycle.

65
5 Fuel System & EMS
Working of Systems
Fuel Injection – Advantages over Carburetion :
Advantages of Fuel Injection
Increased power output per unit of
displacement.
Higher torque at low engine rpm.
Improved cold start, warm up and sudden
acceleration (No chance of wetting intake
manifold).
Lower fuel consumption.
Overall superb drive-ability.
Lower maintenance cost.
Communicates malfunctioning of fuel injection
system, if any.
Low emission level.
Fuel Injection – Advantages over Carburetion :

Limitations of Carburettor :
Restricted air flow due to venture design causes
power loss (volumetric efficiency is limited).
As intake manifold contains combustible
mixture, danger of back fire from the cylinder
into the manifold is always there.
At high altitude or in warm weather, possibility of
vapour lock.
After burning noise in silencer on sudden
deceleration.
Does not support sudden acceleration.
Difficult cold starting and requires choke for
starting.
In cold conditions, fuel wets the wall of the
induction manifold causing running difficulties.
Difficult cold starting and requires choke for
starting.
Inconsistence in fuel efficiency.
Maintenance cost is reasonably more.
High emission level.

66
SOP’s
Petrol Tank Removal
Insert Key and open uu Remove
the lock 2 Allen bolts
uu Remove 2 Nylon washers
Pillion seat
uu Remove uu Remove
2 Bolts Rubber mesh
Rider seat
uu Remove
Collared rubber
washer
Bush
Note:
Similarly remove it
uu Remove for RH
2 Screws
Side cover LH
Side cover RH uu Remove
Allen bolt
Washer
Note:
Similarly remove it
for RH
uu Remove
2 Bolts
2 Nylon washers

67
5 Fuel System & EMS
SOP’s
Petrol Tank Removal
uu Remove uu Remove
Flange bolt Disconnect
Collared washer the fuel gauge
coupler (A)
Note: B
A Disconnect
Similarly remove it for RH
the fuel pump
coupler (B)
uu Remove uu Remove
Carefully pull out the Lift up the petrol
tank cover tank
uu Remove
Disconnect the
clip and remove
the hose pipe
from filter side
uu Remove
3 bolts
(RL/RH/Front)
3 collared bush
Skill tip:
Disconnect the fuel pipe carefully as the fuel line is
filled with the pressurised fuel at 2.5 bars

68
SOP’s
Fuel Pump Delivery Inspection
Purpose of this test : To inspect correct quantity of fuel delivered through fuel pump for 10 seconds.
uu Instruments
required :
Pig tail
(BAL part no. : -------)
Measuring jar
Charged battery
Pigtail
On Off Connect fuel pump

Switch delivery checking pigtail
coupler to fuel pump
Keep petrol tank on coupler.
plain surface. Connect fuel pump
Coupler delivery checking pigtail
crocodile clips to 12V
Crocodile clips external battery source.
Hold the clean jar at

the fuel pipe outlet for
collecting the fuel
Put ON the “ON-OFF” Quantity Unit
switch of the pigtail. 180 mililiters
Measure the fuel
delivery for 10 seconds.
Fuel Pump Pressure Inspection:

Purpose of this test : To measure the fuel pump delivery pressure.
uu Instruments uu Remove :
required : Fuel pipe from fuel
Fuel pressure gauge filter
Connect to
Fuel pipe (a) Connect to
Fuel filter (b)
uu Fit :
The removed fuel pipe to the pressure gauge T joint.
Other end of the pipe to the fuel filter.
69
5 Fuel System & EMS
SOP’s
Fuel Pump Pressure Inspection
Mount the petrol tank
Note:
Ensure both the clamps are fully tighten.
Switch “ON” the ignition key
Observe the pressure that is displayed on the pressure gauge.
Specification Unit
2.5 to 2.9 Bar
36 to 42 PSI
2.4 to 2.8 Kg/cm2
Note :
If the specification mention above is not achieved then confirm
for no clogging of…
1. Tank air vent
2. Fuel line
3. Fuel filter
Also confirm for proper functioning of fuel pump.
Throttle Body Removal

Note :
Follow the earlier mentioned SOP’s till air filter case removal to proceed for Throttle Body removal.
uu Remove
2 bolts
Loosen air filter

side clamp uu Remove
Note: Push up the circlip
Use long handle
Hose pipe of PCV
allen key
Loosen manifold uu Remove

side clamp Push up the circlip
Hose pipe of filter

70
SOP’s
Throttle Body Removal
uu Remove Coupler for… uu Remove
Injector TPS coupler
Steeper motor T map coupler
Skill tip: Before pulling

the coupler first release
the locking clip.
Don’t pull the wire, pull
the coupler firmly.
uu Remove
Grommet
Slide out accelerator
cable
Skill tip: Cover the intake and

uu Remove
engine breather bore using a
Pull out the filter box soft clean cloth.
with throttle body
Injector Removal
Note : Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal.
uu Remove uu Remove
Coupler Tusken screw
Note: Use
recommended Tusken
screw driver.

71
5 Fuel System & EMS
SOP’s
Injector Removal
Note: Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal.
uu Remove
Injector
Skill tip: Cover the

injector bore using
soft clean cloth.
Engine Tune-up
Spark Plug
Recommended Central – BOSCH VR5NE
Spark Plug LHS & RHS – CHAMPION –
RG6HCC
Electrode Gap 0.8 ~ 0.9 mm
Replace at every 30,000 kms
Air Filter Note: Compressed

air pressure should
Clean at every: not be more than 2
5,000 Kms. bar
Replace at every:
15,000 Kms
Cleaning frequency : Every 5000 Km.

(increase freq. in dusty area) Replace Air
Filter Foam at every 15,000 Km.
SOP :
uu Compression
pressure Warm up the engine.
checking Park the vehicle
Disconnect all plug caps.
Remove LH spark plug and fit the compression gauge.
With full throttle open crank the engine for 3 - 4 seconds.
Take 3 readings and calculate the mean reading.

72
SOP’s
Tappet Clearance Adjustment
Inlet Valve: 0.05 mm
Exhaust Valve: 0.08 mm
Tappet Clearance is to be check in

engine cold condition.
Other Mandatory Checks

Ensure no fuel leakage through fuel lines.
Ensure free rotation of both wheels.
Ensure correct tyre pressure - Front : 25 PSI, Rear : 32.0 PSI
Set control cable free play:
Clutch lever 2~3 mm.
Rear brake pedal 20~25 mm.
Accelerator free play 2~3 mm.
Front brake free play 2~3 mm.
Chain slackness : 15~25 mm.
Check and confirm proper functioning of all 3 nos. spark plugs.

73
5 Fuel System & EMS
Do’s & Don’ts

Precautions while working on fuel injection system
uu This fuel injection system is designed to be used with a 12V VRLA battery as its power source. Do not use
any other local battery.
uu Do not reverse the battery cable connections. This might damage the ECU.
uu To prevent damage to the fuel injection parts, do not disconnect the battery cables or any other electrical
connections when the ignition switch is ON, or while the engine is running.
uu Take care not to short circuit the leads that are directly connected to the battery positive (+) terminal to the
chassis ground.
uu Whenever the fuel injection electrical connections are to be disconnected, first turn off the ignition switch,
and disconnect the battery (-) terminal.
uu When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will
operate and fuel will spout the fuel hose.
uu Do not operate the fuel pump if the pump is completely dry. The pump lubrication and cooling is done by
the fuel itself.
uu Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air.
uu Make sure all connectors in the circuit are clean and tight, and examine leads for signs of burning.
How to read MIL Code :

uu The MI light will blink only when the vehicle is in idling or non running condition. In running condition the
light would only glow.
uu MIL codes are shown by a series of long and short blinks of the FI indicator light as shown below.
uu Read long blink as 10 digits and small blink as a single unit digit.
uu When there are a number of problems, all the MI codes can be stored and the display will begin starting
from the lowest number blink code in the numerical order. Then after completing all codes, the display is
repeated until the self-diagnosis indicator terminal is open.
uu For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the
lowest number in the order listed. (12 ---- 21) ---- (12 ---- 21) ---- (repeated).

74
Key Learning Points
Appropriate Torque Application for Various

Engine Components
Standard Operating Procedures for Oil

Pressure Inspection
Removal of Crank Angle Sensor
Understanding of Standard Limits and

Service Limits for all Engine Components
CHAPTER 6


75
Important Skill Tips

Cylinder Head Cover Dismantling
1 3 Always loosen 4 bolts in crisscross pattern.
Tightening Torque : 1.0 ~ 1.2Kg.m
4 2
TDC Position for Valve Timing

Check piston TDC position, Valve timing & Valve Tappet
clearance before dismantling cylinder head.
Intake Valve
Tappet clearance: 0.05 mm
Exhaust valve
Tappet clearance: 0.08 mm
Cylinder Head Bolts Loosening Sequence

Always loosen cylinder head short bolts (A) first and then
loosen cylinder head long bolts (4 nos) in crisscross pattern.

60
6 Engine & Transmission

Piston Pin Circlip
While removing / refitting piston pin circlip (snap ring), cover
the crankcase bore with clean lint free cotton cloth to arrest
circlip / snap ring falling inside the engine so as to avoid
subsequent un- necessary opening of engine.
Primary Gear Holding

While loosening ‘Primary Gear Nut’ & ‘Clutch Special Nut’,
hold ‘Primary Gear’ and ‘Clutch Housing Gear’ by placing
special tool from top.
Piston Ring Fitment

1 • Piston rings must always be fitted with respect to exhaust
2
mark on the piston
3 Front Top 1 Mark Top
ring
• First place the bottom oil rail ring with end gap 30º
4
towards left of the exhaust mark in the last groove.
3
Top 2 Mark 2nd
ring
Exhaust
Arrow
• Place oil expander ring with butting end downward & end
gap facing opposite to the exhaust mark.
• Now fit top oil rail ring on the expander ring with end gap
30º towards right of the exhaust mark.
• Fit the second piston ring with ‘Top 2’ mark facing upward
and end gap facing opposite to the exhaust mark.
• Finally fit the first ring with ‘Top 1’ mark upward and end
gap facing towards the exhaust mark.
• Remember fitment of 2nd ring upside down may lead to
passing of oil above the piston and ultimately leading to
smoky exhaust.

61

Clutch Washer Sequence
A : Special nut
A B : Belleville washer
C : Clutch stack
D : Plain washer
D
F
B E : Clutch housing
F : Collar bush
C
E
Counter Gear Washers

a. When fitting spacer on allen bolt ensure that plain side of
spacer face outside.
b. When fitting ensure that bal. driven & driving gear collar
side face inside.
a b
Cylinder Head Bolts Loosening Sequence

Always loosen cylinder head short bolts (A) first and then
loosen cylinder head long bolts (4 nos) in crisscross pattern.
Ensure pin (A) & spring (B) is to be collected & carefully on

removal of neutral switch.
B
A

62

When dismantling engine .....
Do not insert a sharp object in-between water pump rotor &
crank case.
Tab the balancer shaft to remove rotor

63

Collect guide gear pin on removal of guide gear.
Ensure fitment of spacer when assembly guide gear
Remove input shaft bearing stopper on clutch side for fitment

of crank case splitting tool.
Crank case splitting tool
Crank case splitting tool resting

on bearing stopper location

64

Using engine heater heat the crank case clutch side for
smooth & easy fitment of crankshaft bearing.
Ensure oil passages are not blocked.
- Ensure that the oil passage going towards orifice is cleared.

- The orifice outlet is cleared.
Use grease to fix the springs when assembling. This is to

avoid falling of the spring.

65

When aligning the marks for bal. driven & driver gear
always ensure…
- Piston is at TDC position.

- Primary gear mark is align with crankcase mark.
Balancer driven & driver gear marks are inline with each
other.
Close the bore of magnet side crank case using a lint free
cloth when fitting the harness guide. This is to avoid bolt
falling inside the crank case.

66
Standard Operating Procedure

Top Side Dismantling
Dismantling - Cover Cylinder Head
Remove
• 4 Bolts (10mm A/F)
Skill Tip : Always loosen cylinder head cover bolts in criss - cross
pattern.
• Cylinder head cover with gasket (rubber beading type)
Check TDC Position
• Align rotor mark w.r.t.

Crankcase LH.
• Check cam sprocket marks

from RH side.
Cam Chain Tensioner
Remove
• One Bolt (A) (10 mm A/F)
• ‘O’ Ring
• Rotate chain tensioner’s screw
in clockwise direction to take
plunger backward & lock it .
• Two bolts (B) (8mm A/F) M6
• Take out tensioner.
• Take out gasket chain
tensioner.
Cam Sprocket
Using Special tool 37 1042 54

Cam Sprocket holder
Remove
• Bolt special flanged (12mm
A/F)
• Cam Sprocket
• Spacer cam shaft
Skill Tip : Tie chain by soft

copper wire.


Remove
• Spark plug RH
Remove
• Grub screw
• Sleeve spark plug RH.
Skill Tip : Rotate sleeve before
pulling out Cover sleeve portion by
cotton cloth & then pull out by plier.
CAUTION
Do not pull out sleeve directly by
plier otherwise it would get
damaged.
Cylinder Head Bolts
Remove
• 2 Cylinder head short bolt (A) (8 mm A/F) M6 x 120
• 4 Cylinder head long bolts (B) (12 mm A/F) M10 x 147
• Take out cylinder head assembly complete
Skill Tip : Always loosen smaller bolts of cylinder head first & then
loosen longer bolts in crisscross pattern to avoid cylinder head
warpage.
Cylinder Head Complete

Using Special tool 3710DH35 for
B
Rocker Shaft remover A
Remove
• 2 Rocker shaft (A) B
D
• 2 Rocker arms (B)
C
• Circlip (C)
• Cam Shaft (D)


Using Valve Spring Compressor - A
Adaptor - 37103108 B
Remove C
• Collets (A)
• 4 Retainers (B) D
E
• 4 Valve Springs (C)
• 4 Valve Oil Seals (D) F
• Valve Spring Seats (E)
• 2 Exhaust & 2 Intake Valves
(F)
Cylinder Piston Assly.

Remove
• Gasket Cylinder Head
• Chain Guide
• 2 Dowels
• Cylinder Block
Remove
• Gasket cylinder block (A)
• 2 Dowels (B)
Using Piston Pin Drift

Part No: 37101006
Remove
• Snap ring (Circlip)
• Piston pin
• Piston Assembly
Skill Tip : Cover crankcase bore

by clean lint free cloth while
dismantling piston circlip / snap
ring.


Clutch Side Dismantling
Cover Clutch
Remove
• 11 Bolts (8mm A/F) M6 x 30.
• Clutch Cable Bracket
• Cover clutch
• Clutch cover gasket.
• 2 dowels.
Oil Filter
Remove
• 2 flanged bolts (8mm A/F) M5 x
16
• ‘O’ ring.
• Cap oil filter.
• Oil filter.
Shaft Clutch Release

B
Remove
C
• Push rod (A).
D • Shaft clutch release (B)
E
F
• Spring (C) (lever clutch)
• Plain washer (D). A
• Seal oil (E).
• Needle bearing (F).
Remove
• Clutch lifter bearing.


Using Primary Gear Holder
Special Tool 37004154 & Special
Socket for Clutch Nut 3710DJ43
Remove
• Nut sprocket drive lock.
Skill Tip : Lock Special tool

between the teeth of primary gear
& clutch housing gear from top.
• Remove Belleville washer.
Remove
• Special nut for clutch
• Belleville washer


Remove
• Clutch stack complete
• Plain washer
• Timing chain
• Clutch housing
Skill Tip : Clutch Nut must be

removed by rotating it in clockwise
direction.
• Remove Collar bush.
By using Clutch Dismantling A

Special Tool Pulsar B
C
Remove
• 4 bolts (A) (10mm A/F)
• 4 springs (B)
• Holder Clutch (C)
• Clutch Hub (D) D
• Friction Plates (E) G
E
• Steel Plates (F) F
• Wheel Clutch (G)


Removal of Primary Gear
Remove
• Sprocket crankshaft.
• Gear primary drive with wood
ruff key.
• Spacer crankshaft.
Gear Shift Mechanism

Remove
• Lever gear change shaft.
• Stopper drum bolt ( mm A/F).
• Washer (bigger dia).
• Inhibitor gear shift lever.
• Washer (smaller dia).
• Drum stopper spring.
Remove
• Allen bolt (A).
• Gear shift guide (B).
• Spacer (C).
C A
B

LUBRICATION SYSTEM
DISMANTLING
OIL PUMP
Remove
• Circlip (A).
• Oil pump drive gear (B).
Remove C
• 3 flanged bolts (C) (8mm A/F)
M6 x 30. D BA
E
• Oil pump body (D).
• 2 Dowels (E) G F
• Inner (F) & outer (G) rotor


Remove
• Pivot bolt
• Chain Guide (Slack Side)
• Cam / Timing Chain
Magneto Side Dismantling

Dismantling - Cover Magneto
Remove
• 9 bolts (8mm A/F) M6 X 30
• Magneto Cover
Skill Tip : Loosen magneto cover

bolts in criss-cross pattern.
Using Rotor Holder H6 0721 00 &

Rotor Puller 37 0041 55
Remove
• Hex flanged bolt (14 mm A/F)
• Belleville washer (A)
• Rotor (B) & its key.
Remove
• Starter counter gear 1.
• Starter counter gear 2.


Balancer Drive & Driven Gear
Remove
• Nut balancer drive lock by using
special tool.
• Belleville washer.
• Balancer drive gear.
• Key wood ruff.
• Allen bolt.
• Special washer.
• Gear balancer driven.
• Square key.
Neutral Indicator Switch

Remove
• 2 bolts (A) (8 mm A/F) M5x10 A B
• Bracket harness upper (B).
• 1 bolt (C) (8 mm A/F) M5x10
• Bracket harness lower (D).
• 2 bolts (E) (8 mm A/F) M5x16
• Neutral indicator switch (F).
C D E F
Remove
• 2 bolts (8 mm A/F) M5 x 13.
• Pick up coil
• 1 Bolt (8mm A/F) (B) M5 x 6
• Stopper plate (D).
• Stator plate assembly 3 allen
bolts (4 mm A/F) M5 x 0.8 x 35
WATER PUMP REMOVAL E

Remove D C
• 5 bolts (A) (8mm A/F) M6x20 B
F
• Water pump cover (B).
• ‘O’ ring (C). A
• Domed nut (D).
• Washer (E).
• Water pump rotor (F).


Crankcase Splitting
Remove
• 4 long bolt (A) (8mm A/F) M6
x 60
• 10 Short Bolt (B) Magneto Side
(8mm A/F) M6 x 45
Dismantling - Crankcase
By using Crankcase Splitting
Special Tool
Remove
• Remove RH side crankcase.
• Crankcase gasket.
• 2 dowels (dia 14)
Crankshaft Removal
Remove Crankshaft
Crankshaft Removal E
Remove
• Shaft Fork Shift (A) Input & C
Output (B) with 2 springs.
• Gear Change Drum (C)
B
• Washer 1st Gear Output.
• Washer below 2nd gear Input
• Shift Fork - Input (D) / Output D
(E).
A
• Input shaft assembly
• Output shaft assly.

SOP: Checking Engine Oil Pressure

Purpose of this test : To measure oil pump delivery
pressure checked at idle RPM at cylinder head.
uu Instruments required: uu Fit

Pressure gauge with adapter (BAL Part no. 37 Oil pressure gauge adapter and tighten it fully.
0041 93)
uu Put OFF the ignition switch. uu Re-fit air filter cover and petrol tank and start the
engine.
uu Remove uu Note the oil pressure on the oil pressure gauge

Rubber cap at 1400 ± 50 RPM.
Disconnect Oil pressure switch cable connection

Specification Unit
Oil pressure switch
>1 bar
1.01 Kg/cm2
Note: Follow SOP of air filter removal to connect 14.50 PSI

the oil pressure guage.

76
SOP: Crank Angle Sensor Removal
Note: Follow the earlier mentioned SOP’s till petrol tank removal to
proceed for Crank Angle Sensor Removal.
uu Remove: Using rotor holder special

Stator plate socket tool hold the rotor firmly
uu Remove
Flange Bolt
Washer
uu Remove: Using rotor puller special

tool pull the rotor firmly
13 bolts
uu Remove
Rotor
Key
uu Remove uu Remove
Magneto cover Bolt
Gasket Stopper for gear starter clutch
2 dowels
77
uu Remove:
Using
2 bolts for crank angle sensor
Bal. gear holder special tool lock the balancer
drive and driven gears firmly
Bal. lock nut remover
Loosen
Special nut
uu Remove:
Gear starter clutch
uu Remove
Allen bolt
Special washer
Skill tip : Ensure that the special washer
with the cut mark is fitted facing the
uu Skill Tip balancer driven gear.
Inspect for correct alignment marks for the
balancer drive and driven gear.
uu Using Bal. gear holder special tool lock the

balancer drive and driven gears firmly uu Remove
Loosen Special nut
Allen bolt Belleville washer

78
uu Remove: uu Remove: Skill tip : Driver and driven

Driver gear Driver gear gear with collar should
face crankcase side.
uu Remove:
Bolt keys (Driver and Driven)
uu Remove: uu Remove:
All bolts securing the bracket 2 bolts
Neutral switch
uu Remove:
Crank angle sensor with neutral switch

79
Engine Service Data

Compression Pressure Valve Tappet Clearance Clutch Spring Free Length
Std. Limit 11 ~ 13 kg/cm² Intake Exhaust Std. Limit 38.4 mm

Std. Limit 0.05 mm 0.08 mm
Ser. Limit 9.5 kg/cm² Ser. Limit - - Ser. Limit 37.3 mm
Clutch Hub Height Clutch Stackup Height Crankshaft Runout
Std. Limit 21.0 ~ 21.2 mm Std. Limit 22.17 ~ 21.57 mm Std. Limit 0.02 mm
Ser. Limit 21.4 mm Ser. Limit 20.3 mm Ser. Limit -
Steel Plate Thickness Friction Plate Thickness Friction Plate Wrap
Std. Limit 1.6 mm Std. Limit 2.92 ~ 3.08 mm Std. Limit 0.1 mm
Ser. Limit - Ser. Limit 2.72 mm Ser. Limit -
Steel Plate Wrap Rocker Arm Shaft Diameter Cam Sprocket Diameter
Std. Limit 0.1 mm Std. Limit 9.0 mm Std. Limit 65.52 mm
Ser. Limit - Ser. Limit - Ser. Limit 65.22 mm

80
Engine Service Data
Cam Lobe Height Camshaft Chain Length Valve Spring free Length
20 Link Length
1st 2nd 21st
MEASURE THIS LENGTH
Intake Exhaust Std. Limit 129.4 mm Std. Limit 38.9 mm

Std. Limit 30.34 mm 30.29 mm
Ser. Limit 30.29 mm 30.24 mm Ser. Limit 129.85 mm Ser. Limit 37.9 mm
Valve Stem Diameter Valve Stem Bend Valve Stem to Guide Clearance
Intake Exhaust Std. Limit TIR 0.01 mm Intake Exhaust

Std. Limit 4.483 mm 4.463 mm Std. Limit 0.01~0.037 mm 0.03~0.057 mm
Ser. Limit 4.465 mm 4.445 mm Ser. Limit TIR 0.015 mm Ser. Limit 0.047 mm 0.067 mm
Cylinder Head Warp Cylinder Inside Diameter Cylinder Piston Clearance
10mm
20mm
40mm
Std. Limit 0.05 mm 72.006 ~ 72.013 Std. Limit 0.03 ~ 0.049 mm

Std. Limit
Ser. Limit - mm Ser. Limit 0.09 mm
Piston Diameter Piston Ring End Gap Piston Ring Groove Clearance
Top Second Oil Ring Top Second Oil Ring

Group A 71.964 ~ 71.976 mm
0.015~ 0.030~ 0.20 ~ 0.020~ 0.02~ 0.035 ~
Std. Limit Std. Limit
0.030 mm 0.050 mm 0.70 mm 0.055 mm 0.060 mm 0.110 mm
Group B -
Ser. Limit - - - Ser. Limit - - -

81
Engine Service Data

Shaft Fork Shift O.D Fork Shift I.D Gear Shift Drum Groove Width
Std. Limit 11.966 ~ 11.984 mm Std. Limit 12.0 mm Std. Limit 4.55 ~ 4.70 mm
Ser. Limit - Ser. Limit - Ser. Limit 4.75 mm
Gear Shift Fork Guide Pin Diameter
Std. Limit 4.45 ~ 4.49 mm
Ser. Limit 4.4 mm
Notes

82
Engine Tightening Torque
Spark Plug Oil Strainer Cap (18 mm A/F) Cap Oil Filter Cover Bolts
Tightening torque - 1.3 ~ 1.5 kgm Tightening torque - 0.8 ~ 1.0 kgm Tightening torque - 1.0 ~ 1.2 kgm
Chain Tensioner Mounting Bolts Cylinder Head Cover Bolts Output Sprocket Bolts
Stator Plate Mtg. Bolts Eng. Mtg. Rr. Upper/Lower Bolts Clutch Cover Bolts
Oil Pump Mounting Bolts Coolant Temperature Sensor Magneto Cover Bolts
Primary Gear Nut Cam Shaft Sprocket Bolt Nut Securing Clutch Assly.
Tightening torque - 5.9 ~ 6.1 kgm Tightening torque - 2.5 kgm Tightening torque - 7.0~7.1 kgm

83
Engine Tightening Torque

Magneto Rotor Mounting Nut Stator Motor Mounting Nut Inhibitor Nut
Tightening torque - 5.9~6.1 kgm Tightening torque - 1.0~1.2 kgm Tightening torque - 1.0~1.2 kgm
Guide Gear Allen Bolt Clutch Holder Bolts LH/RH Engine Stay Upper Bolts
LH/RH Engine Stay Lower Bolts Silencer Joining Nut Injector Mounting Bolt
Oil Pressure Sensor Nut Bal. Driver Gear Mounting Bal. Driven Gear Mounting (Allen)
Cylinder Head Small Bolts Cylinder Head Big Bolts
Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 4.4 ~ 4.6 kgm

84
Do’s & Don’ts
Dos
uu Always replace gasket ‘O’ rings of engine If
dismantled.
Don’ts
uu Don’t reuse ‘O’ rings, gasket, Oil seals, Circlip
locks as they use their strength and properties,
once they are opened.
Dos
uu Whenever installing Spark Plug, first screw by
hand and then tighten to specified torque.
Don’ts
uu Don’t adjust spark plug electrode gap by
hacksaw blade or with judgment of eye
otherwise it will affect the engine performance.
Dos
uu Always below light pressure compressed air
from inside while cleaning ‘Oil strainer’ that is
opposite to the direction of flow of oil.
Don’ts
uu Don’t reuse torn ‘Oil strainer’ otherwise it
will affect lubrication system of engine and
subsequently would lead to seizure.

85
7 Frame & Suspension
Key Learning Points
Appropriate Torque Application for Various

Frame Components
Understanding of Standard Limits and

Service Limits for all Frame Components
CHAPTER 7
Frame & Suspension
Service Limits
Tightening Torque
Front Disc Brake

86
Frame Service Data
Disc Pad Thickness Rear Sprocket Warp Axle Wheel Run Out
Std. Limit Fr-7.4 mm Rr-7.3 mm Std. Limit TRI 0.4 mm or Less Std. Limit TIR 1.0 mm or Less
Ser. Limit Fr-3.8 mm Rr-2.0 mm Ser. Limit TIR 0.5 mm Ser. Limit TIR 2.0 mm
Radial Wheel Run Out Tyre Tread Depth Front Fork Oil Grade & Capacity
Grade :
SAE 10W20 Bajaj
F o r k O il L e v el
Genuine Fork Oil
Quantity Per Fork
Leg :
O/H: 320 ml
Drain & Refill:
295+2.5ml
Std. Limit TIR 0.8 mm or Less Std. Limit Front:5.0 mm Rear:6.0 mm
Ser. Limit TIR 2.0 mm Ser. Limit Upto TWI 1.0
Drive Chain Slack Axle Run Out Drive Chain Length
19 Link Length
1st 2nd 19th

MEASURE THIS LENGTH
100 mm
Std. Limit 15 ~ 25 mm Std. Limit TIR 1.0 mm or Less Std. Limit 301.6 ~ 302.1 (19 link)
Ser. Limit 30 ~ 40 mm Ser. Limit TIR 2.0 mm Ser. Limit 307
Notes

87
Frame Tightening Torque

Front Axle Nut Rear Axle Nut Swing Arm Shaft
Tightening torque Tightening torque Tightening torque

9.0 ~ 10.0 kgm 10.0 ~ 12.0 kgm 13.0 ~ 15.0 kgm
Rear Sprocket Mounting Nut Handle Bar Holder Bolts Fork Center Nut

3.2 ~ 3.8 kgm 1.8 ~ 2.0 kgm 4.8 ~ 5.2 kgm
Steering Stem Nut Slotted Fork Upper Bracket Bolts Fork Under Bracket Bolts

0.5 kgm 1.8 ~ 2.0 kgm 2.5 ~ 3.0 kgm
RSA Mounting Bolt (Upper) RSA Mounting Bolt (Lower) Disc Mounting Bolts (Front)

3.2 ~ 3.8 kgm 3.2 ~ 3.8 kgm 2.6 ~ 3.2 kgm

88
Frame Tightening Torque
Disc Mounting Bolts (Rear) Front Caliper Mounting Bolt Front Fender Mounting

2.6 ~ 3.2 kgm 4.0 ~ 5.0 kgm 0.8 ~ 1.0 kgm
Brace Fender Mounting Bolt Rear Brake Pedal Mtg. Bolt Bracket Rear Number Plate

2.0 ~ 2.2 kgm 2.0 ~ 2.2 kgm 1.8 ~ 2.2 kgm
Side Stand Mounting Bolt Handlebar End Weight Bolt Tank Mounting Bolt

2.5 ~ 3.0 kgm 0.8 ~ 1.2 kgm 1.8 ~ 2.2 kgm
LH & RH Stay Bolts
Tightening torque
1.6 ~ 1.8 kgm

89

Front Fork Overhaul
• Align overhead chain pulley
structure as shown in
photograph.
• Insert belt below headlight
fairing structure as shown in
photograph.
• Hook the belt as shown in

photograph.
• Lift the vehicle by pulling
chain.
• Remove caliper mounting

bolts (2 nos) with 12 mm
spanner & front wheel speed
sensor cable mounting bolt
with 10 mm spanner.
• Take out caliper assembly.

• Remove front brake hose &
speed sensor cable
mounting clamp bolts with 8
mm spanner.
• Remove front axle nut with

22 mm spanner holding axle
head with 17 mm spanner.
• Take out front axle & front
wheel.

Frame & Suspension

• Remove front fender
mounting bolts (4 nos) with
12 mm spanner & side bolts
(2 nos) with 5 mm allen key
• Take out front fender.

• Ensure availability of 2 nos
spacers
2 nos
• Loosen upper bracket & side

holder mounting bolts (3
nos) with 6 mm allen key.
• Loosen under bracket
assembly mounting bolt with
17 mm spanner holding fork
leg assembly with hand to
prevent falling of fork leg.
• Take out fork leg assembly

from vehicle.
• Remove fork inner pipe cap
bolt with 5 mm allen key &
take out fork inner pipe cap
bolt.
• Insert fork inner pipe holder

tool in fork inner pipe &
tighten fork inner pipe holder
tool with 6 mm allen key.


• Remove fork top bolt with 14
mm allen key & take out fork
top bolt.
• Take out -
- Spacer tube
- Washer &
- Fork Main spring.
• Take out fork oil in

measuring jar.
• Take out dust seal & oil seal
lock.
• Using cylinder piston holder

(Hexagonal shaped),
remove fork outer tube
bottom bolt with copper
washer by 6 mm allen key.
• Take out cylinder piston
holder along with piston.
• Insert fork oil seal & anti-

friction bush extraction tool
through fork inner pipe as
shown in photograph.
• Using fork inner pipe holder
tool, rotate oil seal extractor
tool handle for removal of
fork inner pipe along with oil
seal & anti-friction bush from

Frame & Suspension

• Take out oil seal extraction
tool from fork inner pipe.
• Take out -
- Oil seal
- Washer
- Anti-friction bush &
- Cap oil lock.
Clean Fork Outer tube & Inner

Pipe
as given below before
assembly.
• Clean the fork inner pipe &
outer tube with
• Pour diesel in fork inner pipe

by closing other end with
hand.
• After pouring diesel, close
both ends of fork inner pipe
with hands & shake inner
pipe.
• Pour diesel, in fork outer

tube by closing other end
with hard.
• After pouring diesel, close
both ends of fork outer tube
with hands & shake outer
tube.
• Nylon brush can be used for

removing burr / muck
particles for inner / outer
tube.
• Blow compressed air
through from inner pipe &
fork outer tubes.


• Hold cylinder piston along
with spring on cylinder piston
holder as shown in
photograph.
• Assemble fork inner pipe,
cap oil lock & fork outer
tube.
• Insert anti-friction bush &

washer.
• Insert the oil seal & fitment

oil seal using oil seal fitment
Note :
• Never reuse the fork oil seal.
Oil Seal Fitment
• Always replace the front fork
oil seal along with dust seal
of same manufacturer.
• Front fork oil seal fitment
direction should be as
shown in photograph.
• Always replace oil seal
Replace if , Nylon sleeve found damaged
fitment punch if nylon sleeve
found damaged.
Frame & Suspension

• Fit oil seal lock & dust seal.
• Fit fork main spring &

washer.
• Fill the correct quantity
(285 ± 5 ml) of
recommended fork oil (SAE
10W20).
• Insert spacer tube.

• Fit front fork top bolt with 14
mm allen key.
• Fit fork inner pipe cap &
tighten bolt with 5 mm allen
key.
• Refit the fork leg on vehicle.

Front Disc Brake

Caliper Anchor Piston Seal & Dust Seal Replacement
• Clean Caliper assembly thoroughly by low pressure water spray
before opening caliper bleeding screw.
• Remove bleeder nut rubber cap.
• Drain the brake fluid from caliper assembly by loosening air

bleeder nut with 8 mm spanner & using transparent PUC tube
which will avoid spillage of brake fluid on caliper body / disc pads
& also powder coating peel off / inefficient braking
• Remove front brake hose

and wheel speed sensor
cable mounting bracket bolt
with 8 mm spanner.
banjo bolt with 14 mm
spanner.
• Remove caliper mounting

bolts (2 nos) with 12 mm
spanner & take out caliper
assembly.
• Remove brake pedal

mounting pin lock clips (2
nos) with plier.
• Take out brake pad
mounting pin & brake pads.

Frame & Suspension
Front Disc Brake

• Remove caliper anchor pin holder bracket.
• Remove rubber parts from

caliper body.
• Remove brake pad spring.

• Remove bleeder nut & it's
cap.
• Remove caliper pistons by applying low compressed pressurized

air (> 2 bar) through banjo bolt hole.
Note :- Don't apply high compressed air pressure > 2 bar. This
could cause piston to fly out from caliper body causing damaged
to it & any one in the vicinity.
• Remove dust seals & oil

seals.

Front Disc Brake

• Clean caliper body by diesel
/ kerosine.
• Dry caliper body by applying
low pressure compressed
air.
• Clean the anchor pin and

holder bracket thoroughly.
• Smear silicon grease on

anchor pins evenly.
• Fit new dust seal and oil seal

in caliper body.
• Smear silicon grease on
piston OD & rubber seals.
• Fit caliper pistons.

Frame & Suspension
Front Disc Brake

• Fit all rubber parts.
• Fit anchor pin holder bracket.

• Fit brake pad spring.
• Clean brake pads by sand /

polish paper.
• Fit brake pad, brake pad

mounting pin & brake pad
mounting pin lock.
• Fit bleeder nut along with

rubber cap with 8 mm
spanner.
• Fit caliper body on fork
location Pre-fit caliper
mounting bolt & tighten it to
recommended torque by
torque wrench.
• Fit brake hose banjo bolt.

Note :- Always replace
banjo bolt / copper washer
whenever opened with new
one.
• Tighten front brake hose
speed sensor cable
mounting clamp bolt with 8

Front Disc Brake

• Pre-Fit air bleeder nut with 8 mm spanner.
•
• Remove master cylinder

cover mounting screws (2
nos) with phillips head screw
driver & take out master
cylinder cover.
• Remove PVC cap & rubber

diaphragm.
• Fill the master cylinder reservoir by recommended brake fluid

(DOT 4)
• Fit a proper tube which fits slightly tight on bleeder screw nipple.
• Insert 8 mm ring spanner through pipe fitted on bleeder screw

nipple.
• Connect tube to siphon pumps pipe and loosen bleeder nut by ring
spanner.

Frame & Suspension
Front Disc Brake

• Press bellow siphon pup in its valve open position then close the
valve of pump & release the bellow, simultaneously press the
brake lever to take out air trapped in the system. Carry out the
same procedure until entire air trapped in the system gets
removed.
• During this process continuously monitor & maintain the brake
fluid level in master cylinder reservoir slightly above MIN mark.
• Ensure front wheel is rotating freely.
• Tighten bleeder nut.
• Route front wheel speed sensor cable inside bleeder rubber cap
Master Cylinder Piston Kitt Replacement
• Clean master cylinder thoroughly by keeping nozzle in spray mode

before opening master cylinder top cover.
• Remove bleeder nut rubber cap.
• Drain the brake fluid from caliper assembly by loosening air

bleeder screw & using transparent PVC tube which will avoid
spillage of brake fluid on caliper body / disc pads & also powder
coating peel off / inefficient braking.
• Remove front brake switch

terminal connectors.
• Remove front brake lever
mounting nut with 10 mm
spanner holding with phillips
head screw driver
• Take out front brake lever.

reservoir cover, PVC cap &
rubber diaphragm.
• Remove actuating shaft.

Front Disc Brake

mounting bolt with 14 mm
spanner from master
cylinder end.
• Take out front brake hose.

mounting bolts (2 nos) with 8
mm spanner & take out
master cylinder.
• Remove actuating shaft

rubber boot.
piston air clip.
• Insert blunt tipped screw

driver from banjo bolt side
and push piston towards
brake lever side. ensure
master cylinder does not get
damaged due to screw
driver
• Take out piston assembly
from brake lever side.
• Clean master cylinder with brake fluid.

Frame & Suspension
Front Disc Brake

• Dry master cylinder with low
compressed air pressure (>
2 bar)
• Smear silicon grease on new piston seals of master piston kit.

• Fit new master cylinder piston inside master cylinder from brake
lever side.
• Fit air clip actuating shaft rubber boot and actuating shaft.
• Fit master cylinder on vehicle.
• Fit brake hose replace copper washer with new one.
• Fit front brake lever.
• Fill brake fluid & carry out air bleeding.
• Fit master cylinder diaphragm. PVC cap and cover.

Do’s & Don’ts

Dos
uu Replace front fork oil with SAE 10W20 grade
fork oil.
Don’ts
uu Don’t add any other mineral based oil to front
fork.
Dos
uu Maintain correct tyre pressure as per
specification.
Don’ts
uu Don’t over / under inflate the tyres.
Dismantling & Assembling Front Fork**

Front Disc Brake**
**Similar to the Pulsar 200 NS Training Notes. For
more details refer Pulsar 200 NS Training Notes
(Doc No. 71111472).

90
Key Learning Points
Understanding of VRLA Battery Charger
VRLA Battery Charging Process
Checking and Inspection of all Electrical

Components
Standard Operating Procedures for

Headlight Assembly Dismantling
Removal of Sensors and Actuators
CHAPTER 8
Electricals
Dos and Don’ts for RLA Battery
Electrical Checking Procedure
Electrical Circuit Diagrams

91
8 Electrical

Filling Procedures
Step 1: Get the battery ready
Place the battery on a flat leveled and
preferably on a insulated surface.
Remove the filler port seal of the battery.
Filler port seal
Step 2: Get the electrolyte ready

Remove electrolyte container from the packing.
Remove the sealing cap plug strip.
Keep the sealing cap plug strip aside as this is
to be used as battery sealing plug strip later.
Note: Do not puncture the seals manually.
Plug cap strip
Seal
Step 3: Fill the battery

Hold the electrolyte container upside down.
Place the container upright on battery. Match
the 6 seals with the respective filler ports.
Note: Ensure the container is upright and not tilled.
If tilled the electrolyte might fail to flow.
Now force the container down until seals get
pierced, and electrolyte flows into the battery.
Step 4: Check the electrolyte flow

Make sure that air bubbles are visible in the
electrolyte and which is seen in all the 6 tubes
of the container.
Leave the container on the battery as it is for 30
minutes.

92
Step 5: Take away the bottles
Be sure that the entire electrolyte has flown
down inside the battery.
Tap the bottom of the container and gently
remove the empty container.
Step 6: Attach the sealing cap

Fit the sealing cap plug strip tightly on the filler
ports of the battery.
Ensure by pressing firmly that the cap has
become flush with the top surface of battery.
Step 7: Charge the battery

Charge the battery on BAL recommended VRLA
battery charger as per std. SOP.
Never use conducting materials like

screw drivers which can produce the
spark near battery terminals.
Caution
Do not add any additional electrolyte.

93
8 Electrical

Metafab VRLA Battery Charger Indication Display
2 4 5 6 7
8 9 10 11
3
1
12 13
1. On / off Switch
2. New battery / use battery switch
3. 2 Amp / 4 Amp current selection Switch
4. Main power supply indication light (Green)
5. Open circuit indication light (Red)
6. Bad battery indication light (Red)
7. Reverse polarity indication light (Red
8. Boost indication light (White)
9. New battery indication light (Yellow)
10. Use battery indication light (Blue
11. Charged indication light (Green)
12. -ve terminal (Black)
13. +ve terminal (Red)

94
Battery Charging Procedure for Metafab make VRLA Battery Charger
Charging SOP Refer Charger Photo
Remove battery from vehicle and Clean battery thoroughly. -
Connect battery charger to 230 V AC single phase power supply and switch on -
the button of main supply.
"Connect battery charger leads to battery terminals. Red lead to +ve terminal
13 12
and Black lead to-ve terminal."
Switch on the battery charger main switch. Green LED will glow. 4
If Red LED glows it indicates reverse polarity connection. 7
"Select charging current 2 Amps or 4 Amps.
(2 Amps for 3 Ah / 4 Ah / 5 Ah VRLA batteries, 4 Amps for 6 Ah / 8 Ah / 10 3
Ah VRLA batteries)."
Select and press the charging switch for new battery or use battery (Green and
Blue LED glow for new and use battery) 2 4 10
If Red LED blinks it indicates open circuit situation. 5
Battery charger detects the battery voltage. If it is less than 5 volts it will switch
over to Boost charging mode White LED below the “Boost” will glow 8
"Battery charger detects battery voltage after every 3 minutes. If voltage
increases above 5 volts it switches over to selected charging mode ie NEW/ 9 10
USED."
Charging duration in this mode is 30 minutes. If the battery voltage is less than
5 volts after 30 minutes a Red LED indicating a bad battery will glow. This 6
indicates the battery is not suitable for charging.
"If battery charger is switches to NEW/USED charging mode, the battery would -
undergo charging for 5 to 14 hours depending on battery condition."
After completion of battery charging a Green LED will glow to indicate completion
of charging.
11
Switch off the main switch and disconnect the battery from the charger -
Reconnect the battery terminals on vehicle. -
Apply petroleum jelly to battery terminals. -
Note: During charging if the battery is disconnected, an audio indicator will beep for
2 minutes with a Red LED blinking to indicate open circuit situation.

95
8 Electrical
Checking Procedure
Front & Rear Brake Light Switch Brown Blue Continuity check
by multimeter
Measuring & Testing Equipment : Multimeter
Lever Continuity is
Pressed shown
Lever No continuity
Released
uu SOP :
Turn ‘ON’ the ignition switch.
The brake light should glow brightly when the
front brake lever / rear brake pedal is pressed.
If it does not, check the front brake switch.
Side Stand Switch Sr. Parameter Magnet Wire connection Std.

No. Position Meter Meter Reading
+ve -ve
1 Input voltage N.A. Red/ Yellow/ 5 VDC
(Side stand Black
Blue
position-any)
2 Output voltage Magnet Pink Yellow/ 2~2.2

(Side stand in front of Black VDC
position-OFF) side stand
switch
Side stand Magnet Pink Yellow/ 5.0 VDC
position-ON away from Black
side stand
switch
uu SOP :
Pi Y/B R/L
Switch ON ignition switch

and kill switch.
2
1
Set multimeter to 20 VDC.

1
Pi Y R
Connect multimeter as
shown in table given below.
Pi Y R
SIDE_STAND_SWITCH
Clutch Switch
Meter Range Yellow / Green Black / Yellow
OFF – Clutch
lever not pressed
ON – Clutch
lever pressed

96
Checking Procedure
Ignition Switch Meter Wire Connections Continuity Check
Measuring & Testing Equipment : Multimeter Range
Continuity Meter +ve Meter –ve OFF – No
Mode Continuity
Brown White wire ON – Continuity
uu SOP :
Switch OFF Ignition key.
Disconnect Ignition switch’s coupler.
Check continuity between wires in ‘ON’ and ‘OFF’
position.
uu Standard Value :
Beep Sound and Continuity in ‘ON’ position. No
continuity in ‘OFF’ position..
Engine Kill Switch Meter

Wire Connections Condition Result
Measuring & Testing Equipment : Multimeter Range
Engine
Meter Meter Continuity
OFF
Continuity +ve –ve
condition
is shown
Mode
Gray / Brown / Engine ON No
Red Blue condition Continuity
uu SOP :
Put ignition switch OFF.
Put kill switch OFF.
Set multimeter at continuity range.
Connect multimeter as shown in the table given
below.
Light Control Module (LCM) Sr. No. Parameter Wire Connections Std.
Meter Meter Reading
+ve –ve
1 Engine is Violet Yellow/ 00 VDC
OFF (Pass Black
light OFF)
2 Engine is Red/ Yellow/ 13.5 VDC
running - H/L Black Black
switch ON.
This unit is a combination of head light controller and
flasher unit. It switches on the head light only when
engine is running.

97
8 Electrical
Checking Procedure
Light Control Module (LCM) uu SOP :
Switch ON ignition switch Br
V
and kill switch.
1
Set multimeter to 20 VDC.
2
1
V W
shown in table given

Br L/W O B/Y
PIN4
PIN3
PIN2
PIN1
below. V W
LIGHT_CONTROL_MODULE
DC Charging Voltage Measurement

Measuring & Testing Equipment : Multimeter & Battery Load Tester
Meter Wire Connections Specified at

Range 4500 RPM
Meter +ve Meter –ve
20 V DC Battery Battery 14.5 V + 0.2 V
+ve +ve DC
terminal terminal
uu SOP :
SOP :
Put Ignition switch ON.
Put Kill switch ON.
Set multimeter at 20 VDC.
Connect multimeter as shown.
Start engine and run at 4500 RPM.
Note :
1. Before conducting this test ensure battery voltage is
13.1 ± 0.1 Volts (Fully charged battery)
2. For DC voltage measurement connect multimeter in
parallel with circuit.

98
Checking Procedure
Stator Plate (Battery Charging Coil)
This is 3 phase starter winding (oil dipped type)
Y2
Sr.No. Meter Wire Std.
Range Connections esistance
Y1 Y3 Value
Meter Meter
+ve –ve
1 200 Ohm Y1 Y3 1 Ohm
2 Y2 Y2
3 Y3 Y1
uu SOP : B/Y
Disconnect magneto W/R
coupler.
Set multimeter at 200
Ohm range.
Connect multimeter
as shown and note
reading.
Y Y Y
Starter Motor Current Drawn

Measuring & Testing Equipment : Clamp Meter
Meter Conditions Standard Value

Range
200 Encircle clamp 40~45 Ampere
DC A meter transformer (Spark plug caps
jaws around thick removed)
Red wire of starter
motor
uu SOP :
Disconnect all 3 spark plug caps
Switch ‘ON’ Ignition switch and kill switch.
Select range and set clamp meter zero reading.
Encircle red input wire of starter motor into the
clamp meter jaws.
Crank the engine for 3 seconds .
Observe the cranking current displayed on clamp
meter.

99
8 Electrical
Checking Procedure
Starter Motor Armature Inspection
(For Each Segment Checking)
Measuring & Testing Equipment : Multimeter &
Meter Wire Connections Continuity
Battery Load Tester
Range Check
Continuity Meter +ve Meter –ve No continuity
Mod Commutator Shaft to be shown
segment
uu SOP :
Dismantle starter motor and take out the
Armature.
Check the continuity between starter motor shaft
and each segment on Commutator.
Replace armature if continuity is shown.

Range Check
Continuity Meter +ve Meter –ve Continuity
Mode Any Adjacent is shown
Commutator segment on
on segment Commutator
uu SOP :
Dismantle starter motor and take out armature
Check continuity between each pair of adjacent
segments on Commutator.
Replace armature if ‘No’ continuity is shown
between any two adjacent pair of Commutator
segments.
Steeper Motor
Measuring & Testing Equipment : Multimeter Sr. No. Wire Connections Standard
Value
P2 P3
1 Meter +ve Meter -ve
P1 P4
Pin no. 1 Pin no. 4 51 Ω
2 Pin no. 2 Pin no. 3 51 Ω
uu SOP :
Ensure ignition switch and kill switch is OFF.
Remove harness side coupler.
Set multimeter on 200 Ohm range and connect
as shown in above table.

100
Checking Procedure
Steeper Motor uu SOP :
Ensure ignition switch
Measuring & Testing Equipment : Multimeter and kill switch is OFF.
Remove harness side
coupler.
G/Y L/B Gr/W G/R
Set multimeter on
200 Ohm range and
2
connect as shown.
STEEPER_MOTOR
Crank Angle Sensor & Neutral Switch

Sr. Component Meter Wire Standard Results
No. range Connections Value
Meter Meter
+ve -ve
1 Crank angle Resistance White/ Black/ 365 + 20 OK
sensor Red Ohms
2 K Ohms Yellow
2 Neutral Continuity Light Black/ Beep OK
switch Green sound
Yellow
No Beep Defective
sound
uu SOP : B/Y
Switch OFF ignition switch and kill switch. W/R
Connect multimeter as shown.
Y Y Y
Starter Relay Coil

Meter Wire Connections Meter Range

Range
Meter +ve Meter -ve
200 Starter relay Starter 3.51 ~ 4.29
Ohms coil Red- relay coil Ohms
Yellow wire Black wire

101
8 Electrical
Checking Procedure
Starter Relay Coil R/Y B/Y
1
uu SOP :
Switch OFF engine.
1
Disconnect coupler from Relay.
R/Y B
Connect multimeter to Starter Relay coil R/Y B
terminals.
Check resistance. R
1 1
R
STARTER RELAY
Relay Coil
Measuring & Testing Equipment : Multimeter Meter Wire Connections Continuity
Range Check
200 Meter +ve Meter -ve 89 ~110 Ohms
Ohms
Relay coil Relay coil
terminal 1 terminal 2
uu SOP :
Switch OFF engine.
Remove relay from coupler.
Connect multimeter to relay coil terminals.
Check resistance.
Fuel Pump
Measuring & Testing Equipment : Multimeter Meter Wire Connections Continuity
Range Check
200 Meter +ve Meter -ve 2.1 Ohms
Ohms
Orange/ Black/
Blue Yellow
Note:
1. Battery should be fully charged.
2. Fuse and ignition switch should
be OK.
3. Audible sound will be heard
B/Y B/Y B/Y
which will confirm fuel pump is 1 1
working. O/L
2 2
O/L O/L
4. Check main relay first if fuel

pump is not working.

102
Checking Procedure
Injector
Sr. Parameter Meter Wire Connections Standard
No. Range Reading
1 Resistance 200 Meter +ve Meter -ve 12 + 6
Ohms Ohms @
Pin no. 1 Pin no. 2 20⁰C
FUEL_INJECTOR
uu SOP :
Remove petrol tank cover and petrol tank. FUEL
Remove air filter cover along with paper filter
element. INJECTOR
Disconnect the injector coupler.
2
Connect multimeter to Pin 1 and Pin 2 of

injector as shown.
B/W Br/W
Fuel Gauge – Tank Unit


Range Check
200 Meter +ve Meter -ve As per chart
Ohms
White/ Black/
Yellow Yellow
Standard Valve: Resistance Bars on Resistance Bars on

(+ 2 Ohms) Speedometer (+ 2 Ohms) Speedometer
12 8 83 2
32 7 93 1
42 6 110 0
52 5
63 4
73 3

103
8 Electrical
Checking Procedure
Fuel Gauge – Tank Unit
Note:
If display in speedo console is not proper
then please check following Y/B
1 1
B/Y B/Y
G/R W/Y W/Y
1. Battery Voltage 2 2
2. Speedometer coupler and fuel gauge
tank unit coupler connection is firm.
Capacitor uu Checking method :

Touch +ve wire of capacitor to earth. Spark will occur.
Measuring & Testing Equipment : Nil
This indicates capacitor is OK.
Note:
Capacitor is very important for ECU functioning, so
ensure capacitor coupler is always firmly connected.
Engine Oil Pressure Sensor

Range Check
Continuity Meter +ve Meter -ve Continuity
Mode will be shown
Brown-Blue Black/
Yellow
uu SOP :
If engine oil pressure is OK (i.e if 0.9 to 1.1 Br/Pi
bar pressure is shown on pressure gauge)
1
then continuity will be shown on multimeter.
Note:
Oil pressure icon will blink if engine RPM greater
than 3500 rpm, Coolant temperature in the range
of 50 0C to 60 0C and oil pressure less than 0.9 bar
for time greater than 20 seconds are meet.
Bajaj Auto International Business OIL_PREESURE_SENSOR

104
Checking Procedure
Roll Over Sensor
Sr. Parameter Vehicle Wire Connections Standard

No. position Reading
Meter Meter
+ve -ve
1 Input NA Red/Blue Yellow/ 5 VDC
voltage Black
2 Output Normal Brown/ Yellow/ 4.8~4.9
voltage position Green Black VDC
Tilled Brown/ Yellow/ 2~2.2
position Green VDC
Black
(> 60⁰)
uu SOP :
Br/G
Switch ON ignition switch and kill switch. Br/G
1 1
Br/G
Set multimeter to 20 VDC. Y/B

2 2
B/Y B/Y
ROLL_OVER_
Connect multimeter as shown. R/L
3 3 Gr
Gr
4 4
Coolant Temperature Sensor

Meter Wire Standard Reading

Range Connections
Temperature
Resistance in
Meter +ve Meter -ve in Degree
Ohms
Centigrade
25 2 K Ohms
2K 50 0.80 K Ohms
Ohms
Coupler Coupler 70 0.42 K Ohms
Pin 1 Pin 2 100 0.18 K Ohms
120 0.110 K Ohms
150 57 Ohms

105
8 Electrical
Checking Procedure
Coolant Temperature Sensor uu SOP :
Ensure engine is off. Pi/L B/W
Remove coupler of coolant

temperature sensor using 18
1
mm tube spanner.
shown and check resistance
value.
ENGINE_TEMP_SENSOR
Oxygen (Lambda) Sensor

Measuring & Testing Equipment : Multimeter Sr. No. Wire Connections Continuity
Check
Continuity Meter +ve Meter -ve Continuity
Mode will be shown
1 Pin no. 1 Pin no. 2 9 + 1 Ohm @
25⁰C
2 Pin no. 3 Pin no. 4 Meter
displays 1 @
25⁰C (open
circuit)
uu SOP :
Ensure ignition switch is
OFF.
Remove the harness side
lambda sensor coupler.
Set multimeter on 200 W W Gr B
Ohm range and connect

as per table.
W W Gr B
1
4
2
4
1
Br/W L/R B/G L/Y
T MAP Sensor
Measuring & Testing Equipment : Multimeter Sr. Parameter Meter Wire Connections Standard
No. Range Reading
Meter +ve Meter
-ve
1 Resistance 20 K Pin no. 1 Pin no. 2 + 0.5 K
Ohms 2 Ohms @
25⁰C
2 Input 20 VDC Red/Blue Yellow/ 5 VDC
voltage Black
3 Output 20 VDC White/ Yellow/ 3.8 + 0.65
voltage Red Black VDC

106
Checking Procedure
T MAP Sensor
Measuring & Testing Equipment : Multimeter Y/B
1
uu SOP : G
2
Remove petrol tank and air filter cover along
with paper filter element. TMAP_SENSOR
U
Connect multimeter as shown in table. R/L
P
3
W/O
4
P4 P3 P2 P1 Note:
For resistance checking remove coupler of TMAP
sensor and connect the multimeter prob to Pin 1
and Pin 2 as shown.
Input Voltage Checking Output Voltage Checking

Note:
For input or output voltage checking connect
coupler of TMAP sensor.
Spark Plug Cap

uu SOP :
Remove spark plug cap from HT coil cable.
Set multimeter on 2 K Ohms range.
Connect multimeter probes as shown and
measure the value.
Standard value, 1 K Ohm ± 150 Ohm.

107
8 Electrical
Checking Procedure
CAN Termination Unit This unit is provided to have uninterrupted
communication between diagnostic tool and ECU
Note :
1. No checking method using multimeter is
recommended for checking this unit
2. Checking by replacement method only.
Termination Unit Function:

It has transil diode for filtration of voltage surge / ripple
in mains supply line there by protect ECU from voltage
fluctuations.
It also consist two diodes that are used for clutch switch
and neutral switch circuit.
These diodes are called reverse protection diodes.
Reverse protection diodes provide correct neutral
indication in speedo console.
Symptoms of malfunctioning : Glowing of neutral indication
in speedo console when vehicle is in gear and on pressing
of clutch lever.
Note :
1. No checking method using multimeter is recommended
for checking this unit
2. Checking by replacement method only.
Radiator Fan Motor uu SOP :

Disconnect coupler of fan motor.
Connect external 12 V DC supply to
disconnected coupler of fan motor.
Now the fan motor will start running.
Observe the fan running smoothly.

108
Checking Procedure
TPS Sr. Parameter Wire Connections Standard
No. Reading
Meter +ve Meter -ve
1 Input Red/Black Black/ 3.3 VDC

G/Y voltage Green
1
R/B 2 Output Red/Black Black/ 0.5 VDC
2 voltage Green
B/G
3 idle throttle
3 Output Red/Black Black/ 4.35 VDC
voltage Green
wide open
throttle
3 Coil Pin 2 Pin 3 1.6 ~ 2.4
Resistance Ohms
uu SOP :
Remove petrol tank cover and petrol tank.
Remove air filter cover along with paper filter
element.
Connect multimeter as shown in table given
below.
Input Voltage Checking
Central H. T. Coil Primary Winding Resistance Checking

Measuring & Testing Equipment : Multimeter Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
200 Ohms Orange/ Black 0.513 ~

White Pin-1 Pin-2 0.627 Ohms
Secondary Winding Resistance Checking

Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
20 K HT output Pin of 4.23 ~ 5.17 K

Ohms Orange / Ohms
White

109
8 Electrical
Checking Procedure
Twin H. T. Coil
Measuring & Testing Equipment : Multimeter Primary Winding Resistance Checking
Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
200 Ohms Black / Red Pin of 0.63 ~ 0.77

Orange / Ohms
White
Secondary Winding Resistance Checking

Meter Standard
Wire Connections Remark
Range Value
Meter Meter To be
+ve -ve 11.0 ~ 16.2 measure
20 K K Ohms between to
Ohms HT HT H.T. outputs
output output
Horn
Measuring & Testing Equipment : DC Clamp
Meter Range Wire Standard Value
Meter
Connections
200 DC A Encircle clamp 2.2 Amps
meter jaws
around Brown
wire of horn
uu SOP :
Encircle clamp meter jaws around Brown wire of
Horn.
Press horn switch and check the current drawn
by horn.

110
Battery Replacement
Insert Key and uu Remove

open the lock 2 Bolts
Rider seat
uu Remove
Pillion seat
uu Remove Slide away ECU

2 Bolts from battery
bracket
2 Collared bush
uu Remove
Battery terminal
caps
Battery +ve and
then -ve terminal
Lift out battery
uu Remove
Battery

111
8 Electrical
Roll Over Sensor SOP

Note : Follow the earlier mentioned SOP’s till petrol tank removal
to proceed for Roll over sensor removal.
uu Remove
Disconnect the
coupler
2 Bolts
H. T. Coil (RH Side) SOP

Note : Follow the earlier mentioned SOP’s till petrol tank removal
to proceed for Roll over sensor removal.
uu Remove uu Remove
2 Bolts Disconnect
Earthing coupler
connection
uu Remove uu Remove
Disconnect Plug cap LH and
cables from RH
routine bracket Take out HT coil

112
Head Lamp Removal SOP
uu Remove uu Remove
2 LH allen Pull out the
Bolts head light assly
2 RH allen
Bolts
uu Remove uu Remove
Rubber cap Head light
holder
uu Remove uu Remove
Wire clip lock Head light lamp

113
8 Electrical
Do’s & Don’ts

Battery
Dos Don’ts
uu DO Apply uu DON’T Apply
petroleum jelly Grease to
to terminal post terminal post
uu DON’T Short
circuit the
terminal post
uu DO – Use
proper
equipment for
testing
uu DO – Use uu DON’T – Use

correct tools wrong tools

114
Do’s & Don’ts
Horn
Dos Don’ts
uu Adjust horn sound by rotating the Phillips uu Never adjust the nut on horn cap side and
screw in the direction of arrow provided on bracket end (horn back side) as it will result in
horn. horn malfunctioning and failure.
uu Do not remove silicon sealant from adjustment
screw as it will result in water entry inside the
horn.
Switches
Dos Don’ts
uu After washing the vehicle ensure to apply dry air uu Do not apply direct pressurized water jet on
on switches before operation. control switches.
uu Ensure that grommets provided on clutch switch, uu Do not lubricate electrical switches by oil or
front brake switch and rear brake switch are grease.
intact. uu Do not over tighten the switch mounting screw.

115
Diagram
BATTERY CHARGING CIRCUIT BRAKE LIGHT CIRCUIT EMS Part -1
EMS Part-2 FUEL GAUGE CIRCUIT HORN CIRCUIT
OIL PRESSURE SWITCH CIRCUIT RADIATOR FAN MOTOR CIRCUIT SIDE INDICATOR CIRCUIT
SIDE STAND INDICATOR CIRCUIT TACHOMETER CIRCUIT VEHICLE SPEED SENSOR CIRCUIT
8 Electrical

116
Bajaj Auto Limited
Akurdi Pune 411 035 India
Tel | +91 20 27472851

Fax | +91 20 27407385
www.bajajauto.com
CIN number : CIN L65993PN2007PLC130076

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(Fuel Injection)

The Training Notes are a comprehensive

Frame & Suspension

Understanding workshop discipline

Precautions whilst handling tools and

Bajaj Pulsar 200NS FI Training Notes

uu Always use protective Equipment (PPE) like - Hand

uu Wear Nitrite Rubber Hand Gloves while handling

uu Safety Precautions whilst Operating Air Tools

Air pressure tools operate on compressed air supplied

Observe the following safety related precautions when

Never use the blow gun to blow dust off your

Bajaj Auto International Business

Prolonged contact of used oil can

uu Waste Oil Disposal

uu Precautions to be taken while handling Hydro-Electric Lift

uu Battery Acid Handling

uu Brake Fluid Handling

Bajaj Pulsar 200NS FI Training Notes

Key Learning Points

Understanding workshop tools, applications

Usage of customized tools developed by

Bajaj Auto International Business

uu Crank Shaft remover

uu Spark Plug Spanner 3 in one

uu Primary gear holder+Balancer

Bajaj Pulsar 200NS FI Training Notes

Customized Bajaj Auto Tools

uu Output shaft oil seal fitment

uu Balancer + Radiator pump oil

uu Cam Sprocket Holder

Bajaj Auto International Business

uu Rocker Shaft remover

uu Drift Piston Pin

uu Clutch special nut remover

Bajaj Pulsar 200NS FI Training Notes

Customized Bajaj Auto Tools

uu Camshaft Small Bearing Puller

uu Bearing Driver Set

uu Magneto Rotor Holder

Bajaj Auto International Business

uu Valve Spring Compressor

uu Adaptor for Valve Spring

uu Output Sprocket Holder

Bajaj Pulsar 200NS FI Training Notes

Customized Bajaj Auto Tools

uu Fork cylinder holder handle

uu Installer Upper & Lower

Bajaj Auto International Business

uu Steering Nut tightening tool

uu Rear Mono Suspension

uu Stem Bearing Driver

Bajaj Pulsar 200NS FI Training Notes

Qty Required: Qty Required:

Specs / Range: Specs / Range:

Qty Required: Qty Required:

Bajaj Auto International Business

Specs / Range: Specs:

Qty Required: Qty Required:

Bajaj Pulsar 200NS FI Training Notes

Old D&F Tool

Multimeter Special Prob

Pressure Gauge for