Professional Documents
Culture Documents
2
Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.
3
Location of Parts
Grab Rear Speedometer
Handle Shock Absorber
Kick
Lever Fuel
Tank Accelerator
Grip
Front Fork
Pillion
Foot Rest
Front
Sensor
Disc
Brake Padel
2 7
8
3
4
9
5 14
ABS
6 11
15 12
1. Side Stand Indicator : It glows when Side stand is down & 8. Trip Meter Reset Button : Both trip meters can be
ignition switch is ‘ON’. Ignition system will be cut off if reset to zero by pressing the button.
vehicle is attempted to be driven in side stand down 9. Trip Meter : The Trip meter shows the distance traveled
condition. since it was last reset to zero.
2. Fuel Level Indicator : Fuel level indicator shows available 10. Battery Indicator : It shows battery needs charging
fuel in fuel tank. Tank symbol glows when petrol level in tank 11. Hi Beam Indicator : It glows when Headlight is ‘ON’ & Hi
reaches reserve level beam is selected with engine running.
3. Engine Rev Indicator :It blinks when engine RPM cross 12. Neutral Indicator : It glows when transmission is in Neutral
9000 RPM mark. & Ignition switch ‘ON’.
4. Tachometer Dial : It shows engine speed in RPM. 13. Bajaj Logo : Bajaj logo flying ‘B’ glows.
5. Odometer : The Odometer shows the total distance that the 14. ABS Indicator ( ): With Ignition switch ON the ABS
vehicle has accumulated. indicator glows. When vehicle speed is more than 5 Km/h the
6. Turn Indicator (LH & RH) : When Turn signal switch is ABS indicator goes off, if this indicator glows while vehicle is
turned to L/R, Turn indicator - LH or RH will flash. running, it means there is problem in ABS unit.
7. Speedometer:Vehicle speed will be displayed digitally 15. Malfunction Indicator ( ) : It glows whenever any
abnormality is noticed in functioning of FI related components.
6
Fuel Tank & Instructions for customer
Fuel Tank • There is no fuel cock.
Cap
• Always maintain minimum 3 Liter petrol in
fuel tank.
• Do not rev engine in standstill condition.
• Don’t use adulterated fuel or fuel additives
as it will result in rusting & clogging of
Injector, Fuel pump module & catalytic
convertor.
• If vehicle is tiled beyond 60 Deg, then Roll
over sensor cuts off Ignition system as a
Fuel Tank Cap safety feature.
• To open the fuel tank cap, open the flap. • Never drive by disconnecting wheel speed
Insert the key in the lock and turn it sensor as ABS unit will not function.
clockwise and lift fuel tank cap. • Cleaning cloth to be
• To lock the ‘Fuel Tank Cap’ insert the key strapped along with
in the lock and turn it clockwise and press toolkit under pillion seat
fuel tank cap. ‘Click’ sound ensures cap is assy as shown in image.
fully locked. • Do not keep the cleaning cloth in the
vicinity of high temperature zone e.g.
Precaution : Engine, Silencer assy, Catalytic convertor,
Dont attach metallic ‘Key chain’ as it may damage Starter motor, etc.
paint of petrol tank.
7
Control Switches
D
A
C
A
A B
Lug
A
Lock
Removal of Seat- Front & Rear Fitment of Seat- Front & Rear
(Pulsar 150 Twin Disc) (Pulsar 150 Twin Disc)
• Remove ‘Side Cover’ LH. • Both the seats can be fitted by matching their lug
• Pull rear seat lock cable (A) & remove ‘Rear Seat’ with the respective lock & pressing down the lug into
• Similarly pull the front seat lock cable (B) & remove lock.
‘Front Seat’.
CAUTION: Always remove Rear seat first. CAUTION : Always fit Front seat first.
For Pulsar 150 follow procedure as given below For Pulsar 150 follow procedure as given below
Removal of Seat assembly complete Fitment of Seat assembly complete
• Remove ‘Side Cover’ LH. • The seat assembly can be fitted by matching its lug
• Pull seat lock cable (A) & remove the seat complete. with the lock & pressing down the lug into the lock.
12
Battery / Tool Kit
Tool kit
Location
First Aid
kit Location
14
How to Ride Your Bike
Starting The Engine : • As the clutch starts to engage, open the
• Switch ‘ON’ ignition & ‘Kill Switch’ throttle a little more, giving the engine just
enough rpm to keep it from stalling.
• Confirm that transmission is in neutral.
• Keep throttle completely closed, press starter Shifting Gears :
button “ ” to start the engine. • Close throttle & depress the clutch.
• Release starter button as soon as engine • Shift into next higher or lower gear.
starts. • Open the throttle and release the clutch
Note : Do not let the engine idle longer than 3
lever slowly and simultaneously.
minuets otherwise it will overheat.
Note : The motorcycle is equipped with a clutch switch. This Gear Shifting Lever Gear Shifting Pattern
switch ensures that the engine can be started in any gear if the
clutch lever is pressed. Recommended Speed for Shifting Down
Moving Off : From 5th to 4th Gear 45 km/h
• Check that Center/Side stand is up.
• Depress the clutch lever.
th rd
From 4 to 3 Gear 35 km/h
• Shift into 1st gear. rd nd
From 3 to 2 Gear 25 km/h
• Open the throttle and release the clutch lever
slowly and simultaneously. From 2 nd st
to 1 Gear 15 km/h
15
How to Ride Your Bike
Warning : When shifting down to lower gear, Parking the Vehicle :
do not shift at such high speed that engine RPM • Support the motorcycle on a firm level
jumps excessively. This may cause engine
surface with the center or side stand.
damage, & rear wheel may skid. Downshifting
should be done at recommended speeds as • Lock the steering.
shown in table. CAUTION : Do not park on a soft or steeply
inclined surface or the motorcycle may fall over.
Braking :
• Close the throttle completely, leaving the clutch Running IN
engaged (except where shifting gears) so that the Proper running-in is important for the better
engine braking will help slow down the motorcycle.
life & trouble free performance of the vehicle.
• Shift down one gear at a time so that you are in
Neutral when you come to a complete stop. • During first 2000 kms running-in period do
• When stopping, always apply both brakes at the not exceed following speed limits.
same time. De-clutch as necessary to avoid engine
stalling. Kms 1st 2nd 3rd 4th 5th
• Never lock the brakes, or it will cause the tyres to
0 - 1000 10 20 30 35 45
skid. When cornering, use brakes judiciously & do
not de-clutch. Reduce your speed before you get 1000 - 2000 15 30 40 45 55
into the corner. For emergency braking, disregard
downshifting, and concentrate on applying brakes • Always keep the speed below the limits
as hard as possible without skidding. mentioned in the table.
Stopping the Vehicle : • Do not race the engine excessively.
• Close the throttle completely. • Do not start moving or race the engine
immediately after starting. Run the engine for a
• Shift the transmission into neutral.
minute at idle speed to give the oil a chance to
• Bring the vehicle to complete stop. workup into the engine.
• Turn the ignition switch off.
16
How to Ride Your Bike
Fuel Saving Tips : Ensure following maintenance points to get
A well maintained vehicle and good driving optimum performance from your bike.
can contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips. Fuel Check fuel lines & connections
for leakage.
Good Riding Habits :
Spark Plugs Inspect and clean spark plugs.
• Ride smoothly and steadily at an optimum
Adjust electrode gap. Replace
driving speed of 40 to 50 Km/h
spark plugs as per P.M. Chart.
• Avoid harsh braking.
• Change the gear judiciously according to Air Filter Clean the air filter element
the speed and load requirement. periodically. Replace as per
• Don’t overload the vehicle above the Periodic Maintenance Chart.
specified payload. Engine Oil Check engine oil level. Always
• Use the accelerator judiciously. use recommended grade and
• Cut off the engine if you want to stop for quantity.
more than two minutes. Brakes Ensure that the brakes are not
How to check mileage (Fuel efficiency) dragging / binding.
Best way to calculate mileage is by following Clutch Ensure correct clutch lever
the full tank to full tank method. play.
• Fill way tank full up to small mouth (brim). Tyre Air Always maintain recommended
• Run the bike for say 100 km.
• Fill the tank full again in same fuel filling Pressure tyre pressure.
station, probably with same fuel dispenser. Brake Fluid Always maintain brake fluid
• Divide kilometer run / fuel quantity filled. level above minimum mark
17
Safe Riding Tips
Safe Riding Tips • It is suggested to customer to take appropriate care
• Always wear Helmet while driving or riding. Your in area of heavy monsoon or high rainfall area. The
helmet should conform to appropriate Indian appropriate surface preventive coat to avoid rusting /
standards. poor surface finish on account of adverse atmospheric
• Read thoroughly the instructions conditions.
given in this manual and follow • Always carry vehicle registration & insurance papers,
them carefully. and a valid driving licence with you.
• Avoid unnecessary accessories General Maintenance Tips :
for the safety of both rider and • Vehicle cleaning to be done with soft & clean wet
other motorists. cloth to avoid scratches on painted parts.
• Get familiar and follow traffic rules & regulations in • Clean & lubricate all the important parts as detailed in
your states as well as general traffic signs. a periodic maintenance chart.
• Familiarise yourself well with starting, acceleration and • Do not apply direct water jet on painted, electrical /
braking of the vehicle. electronic parts.
• When applying the brakes, use both front & rear • Do not obstruct engine cooling by adding mud
brakes simultaneously. Applying only one brake may protection sheet from front
cause the vehicle to loose control. • Drive cautiously. Start early & reach your destination
• Riding at proper speed and avoiding unnecessary safely.
acceleration and braking are important not only for • Avoid driving on loose sand or stones where vehicle
safety and low fuel consumption, but also for longer is likely to skid.
life of the vehicle. • Properly wrap-up loose clothes while driving or riding
• During monsoon, drive the vehicle more cautiously. to avoid entangling in wheel or other objects on road.
Remember vehicle skid more easily during light • Always concentrate on riding for safety.
showers.
18
Engine Oil
Recommended Engine Oil:
Always insist on Bajaj Genuine
Engine Oil for optimum engine
performance and warranty
A benefits. It is a specially
formulated oil for vehicles with
DTS-i engines.
B
C Model Recommended Grade
Engine oil
D Pulsar Bajaj DTS-i SAE 20W50
150 & 10000 ‘JASO ‘MA2’ API SN
A : Oil Filler Cap, B : Oil Level Gauge 150 Twin Disc BS6 Compliant
Engine Oil Level Checking : • Engine oil replacement frequency : 1st service &
• Check engine oil level every day. Park then every 10,000 Km.
vehicle on level surface on centre stand. • Engine oil level top-up frequency : Every 5000 km.
• For all BS VI Vehicles, above BS VI compliant
• Check oil level through oil level gauge ‘B’.
engine oil is to be used only. Use of BS 6 engine
• Always maintain engine oil level between
oil will give prolonged life of catalytic convertor.
upper (C) and lower (D) mark provided on
Cover RH. Top up with specified grade of CAUTION :
oil if the oil level is below lower level mark. • It is most important to adhere to
recommended grade & frequency of oil
Engine Oil Capacity : change for the purpose of long life of
critical engine components. For details
• Refill at servicing : 1000 ml. refer periodic maintenance chart.
• During engine overhaul : 1100 ml. • Do not reuse drained oil.
19
Wheels - Tyre
Wheel Puncture:
• Visit nearest known tubeless tyre repair shop
to remove puncture.
• Remove puncture by Filler or Plug method
only.
• Do not use patch method to remove puncture
of tubeless tyre.
Tyre Pressure :
Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
fuel consumption.
Tubeless Tyre : Front 1.75 Kgf/cm2 (25 PSI)
The main advantage of tubeless tyres is in Rear (Solo) 2 Kgf/cm2 (28.4 PSI)
case of puncture the rate of air leak is very
slow, hence customer can easily drive the Rear (with Pillion) 2.25 Kgf/cm2 (32 PSI)
vehicle upto nearest puncture repair shop for Note : Incase the motorcycle is fitted with imported
removing puncture. tyres. compliance to respective indian standard &
central motor vehicle rules has been ensured.
CAUTION : Tubeless tyres are fitted in this • Tyre warranty is settled by tyre manufacturer.
motorcycle. The walls of the tyres in contact • Decision is taken based on tyre wear and
with the wheel rim should not be damaged running of vehicle.
in any way during fitment / removal of tyre. • BAL settles tyre warranty only for imported
The tyre side walls in contact with wheel rim tyres.
seals air.
20
Periodic Maintenance Information
MIN.
MIN.
Front Brake Fluid Level : Rear Brake Fluid Level : Applicable for Twin Disc
• Front brake fluid master cylinder reservoir is located • Rear brake fluid master cylinder reservoir is located
near RH switch on handle bar. below seat assembly.
• To check oil level, keep vehicle on Center stand with • To check oil level, Remove seat & keep vehicle on
handle bar in straight position. Center stand with handle bar in straight position.
• Always ensure that brake fluid level is above ‘MIN’ • Always ensure that brake fluid level is above ‘MIN’
mark given on inspection window. mark given on inspection window.
• Use only DOT 4 brake fluid (from sealed container) • Use only DOT 4 brake fluid (from sealed container)
to top up if required. to top up if required.
It is advisable that brake fluid should be replenished It is advisable that brake fluid should be replenished
at every 30,000 Kms. at every 30,000 Kms.
21
Periodic Maintenance Information
CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may
lead to damage of electrical /electronic
components.
How to keep battery healthy ?
• Switch ‘Off’ ignition when engine is not
running.
• Get battery checked / charged during
Battery : 12V, 4 Ah VRLA periodic services.
• Do not press starter button for more than 5
Battery Features :
sec. After 3 successive cranking, wait for 15-
• No topping-up is required 20 sec. for battery to recover.
• Reduced self discharge, Enhance safety. • Do not add extra electrical accessories
• No vent tube open to atmosphere hence no such as - Remote, Bigger horn, Musical
discharge of electrolyte through vent tube. brake light etc. This will reduce life of
• Environment care must be taken to battery
dispose off the used battery. It is always • If vehicle is to be stored for more than 2
recommended to hand over the same to weeks disconnect battery to avoids self
the Authorised battery / Bajaj dealer for discharge.
proper disposal of the same. CAUTION :
• When battery is found discharged, it is • While disconnecting always disconnect
advised to get it charged immediately. negative (-ve) cable first.
• Warranty on battery is 18 months from the • While refitting always connect positive
date of purchase of vehicle. (+ve) cable first.
22
Periodic Maintenance Information
Spark Plug Drive Chain Slackness
• Remove spark plugs by using plug • Chain top edge to be kept between the
spanner. two marks during chain slackness
• Clean the spark plugs. adjustment.
• Adjust the gaps if incorrect by bending • Chain slackness will have to be adjusted
outer electrode carefully. whenever required.
• Std. Chain slackness 20 ~ 30 mm.
Spark Plug Gap : 0.7 to 0.8 mm.
• Marking on chain adjusters should be
Spark Plug (2 Nos.) : CHAMPION RG4HC identically positioned on both sides.
Std. Chain
slackness : 20~30 mm
0.7 to
0.8 mm
Top edge
23
Periodic Maintenance Information
Drive
Chain
Cleaning
24
Free Service Guidelines Customer ID :
Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.
25
Periodic Maintenance & Lubrication Chart
3. Oil strainer CL CL CL CL CL
7. Inline fuel filter nylon hoses with quick connector C,R C,R
C, A C, A C, A C, A
C, R C, R C, R C, R C, R C, R C, R C, R C, R Replace if required.
27
Periodic Maintenance & Lubrication Chart
11. Engine breather tube for cracks. C,R C,R C,R C,R C,R C,R
12. EVAP system Hoses- check for cracks C,R C,R C,R C,R C,R C,R C,R
13. Engine foundation silent bushes for cracks C,R C,R C,R C,R
Wiring harness connections, routine & Conduit C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
16. / PVC sleeve inspection.
Battery connections & health by load tester. +ve C,A,L,T C,A,L, C,A,L, C,A,L, C,A,L, C,A,L, C,A,L, C,A,L,
17. T T T T T T
terminal cap fitment. T
18. Ignition switch contacts cleaning CL,L CL,L CL,L CL,L CL,L CL,L
19. HT coil connections (Primary and Secondary) C,T C,T C,T C,T C,T C,T C,T
20. Starter motor & starter relay connections C,T C,T C,T C,T C,T C,T C,T
28
Periodic Maintenance & Lubrication Chart
C,R C,R C,R C,R C,R C,R C,R C,R C,R Replace if required.
CL CL CL CL CL CL CL CL CL
CL CL CL CL
CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L CL,L Use recommended WD40 spray
29
Periodic Maintenance & Lubrication Chart
25. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
26. Steering stem bearing & Cap steering bearing C,CL,L C,CL,L C,CL,L C,CL,L
(Plastic)*
27. Front fork oil & seals C,R C,R C,R C,R C,R C,R C,R C,R
29. Rear Brake shoes and Front pads for wear limit. C,R C,R C,R C,R R C,R C,R R
30. Rear brake cam CL.L CL.L CL.L CL.L CL.L CL.L CL.L
30
Periodic Maintenance & Lubrication Chart
C C C C C C C C C
During 1st Free Service :Use lint free cloth for cleaning & SAE 90 oil for lubrication
CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A without removing from vehicle. During all other services: Remove, Clean by Diesel
& Lubricate using molten chain grease.
C,R C,R R C,R C,R R C,R C,R R Replace at every 15000 Kms
CL.L CL.L CL.L CL.L CL.L CL.L CL.L CL.L CL.L Use AP grease.
31
Periodic Maintenance & Lubrication Chart
32. Rear sprocket fasteners for looseness. C,T C,T C,T C,T C,T
34. Fairing & windshield well nuts for rubber crack C,R C,R C,R C,R C,R C,R
35. Clutch & Throttle cable free play adjustment C,A C,A C,A C,A C,A C,A C,A C,A
36. Head light focus adjustment C,A C,A C,A C,A C,A C,A C,A C,A
37. Check & confirm all bulbs / switches working. C,A C,A C,A C,A C,A C,A C,A C,A
32
Periodic Maintenance & Lubrication Chart
C,A,R C,A,R C,A,R C,A,R C,A,R R C,A,R C,A,R C,A,R Replace brake oil & Master / Caliper seals at every
30000kms
C,R C,R C,R C,R Replace rear wheel rubber shock damper if required
C,R C,R C,R C,T C,R C,R C,R C,R C,R Replace if rubber found hard..
C,A C,A C,A C,A C,A C,A C,A C,A C,A Replace cables if operation found hard.
33
Periodic Maintenance & Lubrication Chart
39. Tyre air pressure. C,A C,A C,A C,A C,A C,A C,A C,A
40. Mirror position & joint firmness. C,A C,A C,A C,A C,A C,A C,A C,A
34
Periodic Maintenance & Lubrication Chart
C,A C,A C,A C,A C,A C,A C,A C,A C,A Ensure model wise tyre air pressure.
C,T C,T C,T C,T C,T C,T C,T C,T C,T Use model wise torque values.
35
Non-Use Maintenance
Non-use maintenance is necessary if a vehicle wheels.
remains off road for a longer duration (more • Do not apply oil on front brake disc, to
than 15 days**). The correct and careful non- prevent rusting. If the front brake disc rusts
use maintenance carried out before storing during storage, do not attempt to clean it
the vehicle will prevent the vehicle from with soap water. The rust will go off
rusting and from such other non-operational automatically during first few application of
damages like fire hazards. brake.
• Clean the entire vehicle thoroughly. ** For Battery :
• Empty the fuel from the fuel tank and a. Remove battery and keep it on wooden
carburettor float bowl (if fuel is left in for a plank, in properly ventilated area.
longer time, the fuel will break and gummy b. Before taking the vehicle for use.
substance could clog the carburettor). • Get the battery recharged from the
• Remove spark plug & put several drops of Authorised Service Center / Battery Dealer.
engine oil into the cylinder. Kick engine • Apply petroleum jelly on battery terminals.
over slowly a few times to coat cylinder
wall with oil & install back spark plug. Preparation for regular use after storage :
• Set the vehicle on a box or a stand so that • Follow daily safety checks.
both wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to
prevent rusting. Avoid getting oil on rubber
parts or brake liners.
• Cover entire vehicle neatly. Make sure that
storage area is well ventilated & free from
any source of flames or spark.
• Fill 10% excess air pressure in both
36
Delivery Certificate
FRAME NO. :
Dealer Code :
Dealer Name :
Address :
Customer's Signature (To be filled in by the dealer) Contact No. :
SERVICE RECORD
Sr. Age Specific Dealer’s Stamp * Code For Remarks:
Date Gravity Voltage Remarks & Signature * Code
No. Mths. LL : Low electrolyte level.
1 AE : Electrical system needs attention.
2 IR : Insufficient running of vehicle.
3 CB : Cover broken.
4 BC : Broken Container.
5 PM : Poor maintenance.
6 BA : Battery abused.
Note : Customer should insist that “Service Record" must be filled by respective authorised battery dealer as proof of specified
maintenance for easy settlement of claim, if any.
TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS
IN CASE OF CLAIM
Name of Dealer & Code :__________________________________________________________________
__________________________________________________________________________________________
Date of claim :________________________________________________Battery Type :_______________
Serial No. :__________________________________________________Date of Fitment :______________