26 Manual de Servicios Pulsar 150 y 180 UG

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Service Station Manual

NOTICE
All information contained in this Note is based on the latest

product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions
in this publication, although every possible care has been
taken to make it as complete and accurate as possible. All
procedures and specifications subject to change without
prior notice. The right is reserved to make such changes at
any time without prior notice.
DOC. NO.: 71110987 REV. 05, AUG. 17
Service Station Dealer

Manual Development
Center
REVISION MATRIX
Sr. No. Rev. No. Date (MM/YY) Reason for Change

1 00 Aug / 2013 SSM developed for Pulsar 150 & Pulsar 180
2 01 Oct. / 2016 Addition of Supplementary SSM for Pulsar 135LS BS IV
3 02 Nov. / 2016 Addition of Supplementary SSM for Pulsar 180 BS IV
4 03 Dec. / 2016 Addition of Supplementary SSM for Pulsar 220 BS IV
5 04 March. / 2017 Addition of Supplementary SSM for Pulsar 150 BS IV
6 05 Aug. / 2017 SOP for Pulsar 220 BS IV :-

• Addition of SOP for checking magneto rotor on vehicle.
• Addition of Bajaj DTS-i 10W50 Synthetic oil as an alternate option.
Pulsar RS 200 Service Support - M/C

Service Station Manual Akurdi Pune

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9 Frame & Suspension 157
Tightening Torques 158
Service Limits 160
Special Tools 162
Control Cable Routing 164
Working of Nitrox Suspension 167
SOP for Front Fork Dust Seal & Oil Seal Replacement 169
SOP for Steering Overhaul 176
SOP for Dismantling & Assembling Front Fairing 181
SOP for Swing Arm Replacement 186
Wiring Harness Routing 195
SOP for Caliper Piston Seal and Dust Seal Replacement 197
Sop for Master Cylinder Piston Kit Replacement 202
SOP for Front Brake Hose Replacement 207
SOP for Brake Fluid Replacement 209
10 Electrical 213
Battery 214
Electrical Checking Procedures 218
Starter Motor 230
Battery Dos & Don'ts 232
SOP for Checking Charge Condition of Battery 234
Dos & Don'ts 237
Electrical Circuit Diagrams 240
11 Diagnosis & Troubleshooting 247
12 Supplementary Service Station Manual - 249

Pulsar 135 UG + BS IV



Pulsar 150/180 DTS-i Dealer Development Center

Service Station Manual Akurdi Pune

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Supplementary Service Station Manual
• Technical Specifications
• Revised Periodic
Maintenance &
Lubrication Chart
• Revised PDI Check Sheet
• Part Identification
• Electrical Circuit Diagrams
• New Updation
249
TECHNICAL SPECIFICATIONS
Engine & Transmission :-
Parameter Specification
Type 4 stroke DTS-I, Single cylinder 4 valve, Natural air cooled.
Bore 54.0 mm
Stroke 58.8 mm
Displacement 134.60 cc
Max.Net Power 13.5 PS @ 9000 RPM
Max. Net Torque 11.4 Nm @ 7500 RPM
Ignition system DC
Spark plugs Qty 2 Nos
Spark plug gap 0.7~0.8 mm
Lubrication Wet sump, Forced.
Transmission 5 speed constant mesh.
Gear shifting pattern 1 down 4 up
Engine Oil Details :-
Grade SAE 20W50 API ‘SL’ or JASO ‘MA’
Drain & Refill 1000 ml
Overhaul 1100 ml
Service Station Manual 250 Service Support MC

Chassis & Body :-
Frame Type Double cradle
Suspension Front : Telescopic suspension
Rear : Twin suspension with nitrox
Brakes Front : Hydraulic operated disc brakes
Rear : Mech. expanding drum brake
Tyres Front : 2.75 X 17”, 41 P
Rear : 100/90 X 17”, 55 P
Tyre Pressure Front : 1.75 Kg/Cm² (24.9 PSI)
Rear (Solo) : 2.00 Kg/Cm² (28.4 PSI)
Rear (Pillion) : 2.25 Kg/Cm² (32 PSI)
Fuel tank capacity :-
Full 8.0 Liters
Reserve 2.5 Liters
Usable Reserve 1.6 Liters
Fork Oil Details :-
Grade SAE 10W20
Quantity / leg 140 ml

Dimensions :-
Length 1995 mm
Width 765 mm
Height 1075 mm
Wheel Base 1325 mm
Ground Clearance 165 mm
Vehicle Kerb Weight 122 kg.
Vehicle Gross Weight 252 kg.
Electricals :-
System 12V DC
Battery 12V 5Ah, Flooded
Head Lamp 35/35W
Pilot lamp 5W (2 nos.)
Tail / Stop Lamp LED
Side indicator Lamp Bulb 10W
Neutral LED Green
Reserve Indicator LCD
Turn Signal Indicator LED Green
Hi-Beam Indicator LED Blue
Speedometer Illumination LED
Fuel Gauge LCD bar display
Horn 12V DC 2A

Carburetor Specification :-
Parameter Specification Photograph
Make UCAL
CO% - With SAI <1%
Idling RPM - With SAI 1350 – 1450 RPM
CO% - Without SAI 4.5 % - 5.5 %
Idling RPM - Without SAI 1300 – 1400 RPM
Choke Manual

REVISED PERIODIC MAINTENANCE & LUBRICATION CHART
Recommended Frequency
Service 1st 2nd 3rd 4th 5th 6th 7th
Sr
PM Check Point 500 4500 9500 14500 19500 24500 29500 Remark
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Ensure to prevent water

entry in Petrol tank,
1 Servicing with water wash Silencer & electrical parts.
     Use caustic free detergent
for washing.
"BGO DTS-i 10W30 for 100cc

Engine oil (Bajaj DTSi 10000 oil) & Top Top Top
2 C,R R R R R models. BGO DTS-i 20W50 for
engine oil filter* Up Up Up models above 125cc. "
3 Oil strainer, Body centrifugal filter** CL CL CL CL CL Oil Strainer Cleaning at the

time of oil Change
Clean body centrifugal flter at

750 Km & at 20K-Platina &
Pulsar
Use recommended molycote

4 Starter Clutch (Dry Type)** L L L L L L L grease
5 Spark plug CL,A,R CL,A CL,A R
Foam & Paper as applicable.O

6 Air Cleaner Element *** & Cover "O" Ring CL,R CL CL CL R CL CL R ring check at every service &
Replace if cut/damaged
7 In line paper filter or Fuel cock paper filter R R R
8 Fuel cock sediment bowl cleaning CL CL CL
9 Carburetor rubber duct C,R C,R Check & replace if required
10 Fuel pipe C,R C C C R C C R
11 Valve tappet clearance C,A C,A C,A C,A C,A C,A C,A C,A
CL,L,A CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • During 1st free service :
A A A A A A A Use lint free cloth for cleaning
& SAE 90 oil for lubrication
without removing from vehicle.
(If chain is excessiively dirty,
then chain has to to be
Non-Sealed drive chain cleaning & removed, cleaned using diesel
12 & lubricated using molten IOC
lubrication
servo compound chain
grease.)
• During all other services:
Remove, clean using diesel &
lubricated using molten IOC
servo compund chain grease.
CL,L,A CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • During regular service use
A A A A A A OKS spray for chain cleaning,
without removing chain from
vehicle.
13 Sealed drive chain cleaning & lubrication • If chain is excessiively dirty,
then chain has to be cleaned
by removing from vehicle.
(Customer to apply OKS chain
lube spray at every 500 Kms)
14 Engine air breather tube C C C C C C C C Replace if damaged
CL CL CL CL CL CL CL
15 Silencer drain hole cleaning
16 Silencer tail pipe cleaning ** CL CL CL CL CL CL CL
Brake lining or pad wear & lubricate brake C,L,R C C,L,R C,L,R R C,L,R C,L,R R Replace brake shoe/pads at
17 every 15,000 kms
cam & pivot pin** Check pad wear indicator

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Use recommended brake
18 Brake fluid level ** - top up / replace C,A,R C,A R fluid (DOT3 / DOT4)
Disc brake assembly–-check functionality,

19 C C C C Replace if damaged
leakage or any other damage
20 All cables & rear brake pedal - free play C,A C,A C,A C,A C,A C,A C,A C,A
Not applicable for VRLA
21 Battery electrolyte level , specific gravity C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T batteries
Wiring harness & battery connection -

22 C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness
Ignition switch barrel cleaning & handle bar Use recommended Wd40
23 C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL
control switches contacts cleaning spray
24 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
Steering stem bearing *** & cap steering C,CL, C,CL, C,CL, C,CL,L Check & replace if
25 damaged.Use HP Lithon
bearing (Plastic)** L,R L,R L,R ,R RR3 grease for lubrication
Use recommended AP
26 Main stand & side stand pin ** CL,L CL,L CL,L CL,L grease
Not applicable in case of

27 Swing arm pivot pin (For non silent bush)** L L L L L L L needle roller bearing
28 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
29 Engine foundation silent bushes ** C C C Replace if damaged
General lubrication - clutch lever, front Use recommended AP

30 L L L L L L L L
brake lever, kick lever grease
31 Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
Use recommended 'Ready

to Use coolant'.Replace at
32 Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A R every 30000 Kms or 2
years (Whichever occurs
earlier)
33 Coolant hose damage / clamps / leakage ** C C C C C C C Check & replace if required
34 Radiator fins ** C C C C C C C Check & replace if required
35 Spoke tightening ** - Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
Front fork dust seal area & inner pipe Applicable for front fork
36 CL CL CL CL CL CL CL
cleaning** with rubber bellow
SAI system / EVAP hoses - Check

37 C, R C, R C, R C, R C, R C, R C, R C, R Replace if cut / damaged
functionality, leakage or any other damage**
38 Pillion foot rest hinge lubrication** L L L L L L L L Use RR 3 Grease
39 EVAP Y connector drain tube ** CL CL CL CL CL CL CL CL
* It is strongly recommended to use only Bajaj genuine oil, in case of any other engine oil of same specification is used the 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
Note :- Periodic parts / lubricants as per periodic maintenance & Lubrication chart are mandatory & the same is chargeable to customer.

REVISED PRE-DELIVERY INSPECTION CHECKLIST
PDI Check sheet Common for all models (Torque Values given for Pulsar 135 BS IV)
Dealer's
Dealer's Name
code
Model City
Frame No Date of PDI
Engine No PDI done by
1. Check points before starting of the vehicle
Check & correct the below check points before starting the vehicle
If Ok
To Check Check for
X If Not Ok
Engine oil Oil level between lower & upper mark / Top up if required
Fuel tank / Pipes No leakage / Correct fitment
Mirror Fitment & adjustment to ensure clear rear view
Coolant level between MIN & MAX mark, top up if required in cold
Coolant condition
Ensure no leakage
Steering cum Ignition lock, Seat lock, LH side cover lock, Petrol tank
Lock Operation
cap lock
Terminal voltage 12.4 V D.C for MF battery & 12.8 V
DC for VRLA Battery using battery tester
Batterry
Tightness of battery terminals / cables / Petroleum
Jelly application
Front : 1.75 Kg/Cm² (24.9 PSI)
Tyre Pressure
Rear (with Pillion) : 2.25 Kg / cm2 (32 PSI)
Front : Brake lever free play 4 ~ 5 mm (For drum brake only)
Brakes
Rear : Brake pedal free play 20 – 30 mm
Clutch / throttle cable Free play 2 ~3 mm
Slackness 25 - 30 mm
Drive chain Equal marking of chain adjusters on both side
No touching to chain case

Engine foundation bolts
Front mounting bolts : 2.0 ~ 2.2 Kg.m (19.6 ~ 21.6 N.m)

Fasteners (Check torque)
Recommended torque wrench to Rear mounting bolts : 3.0 ~ 3.2 Kg.m (29.4 ~ 31.4 N.m)
be used for applying torque on
nut - bolts as mentioned in PDI
check sheet using reference Front axle nut : 4.0 ~ 5.0 Kg.m (39.2 ~ 49.1 N.m)
torque chart given in Annexure 4.
However if any major parts are Rear axle nut : 9.0 ~ 10.0 Kg.m (88.3 ~ 98.1 N.m)
required to be removed (Except
side cover & seat) for
accessibility of torque wrench, in Swing arm shaft nut : 8.0 ~ 10.0 Kg.m (78.5 ~ 98.1 N.m)
those cases the tightness can be
ensured using open end / ring
spanner / box type spanner as RSA Mounting nut Top : 2.8 ~ 3.2 Kg.m (27.5 ~ 31.4 N.m)
applicable without removing Bottom : 3.5 ~ 4.0 Kg.m (34.3 ~ 39.2 N.m)
those major parts
Front fork top bolts :
3.0 ~ 3.2 Kg.m (29.4 ~ 31.4 N.m)
Front fork under bracket bolts :

2.5 ~ 3.0 Kg.m (24.5 ~ 29.4 N.m)
2. Check points during / after starting the vehicle
Check & correct the below check points during / after starting the vehicle
Switch operation RH & LH control switch, ignition switch, clutch switch &
brake switch (Front & Rear)
Horn Ensure no distorted sound

Headlight, Tail / Stop lamp, Side indicators, Speedo bulbs, Number
All Bulbs working
plate lamp,
Working of speedometer, Odometer, Trip meter, Fuel gauge , Clock
Speedometer
Working of all signal indicators icons (Neutral, Turn signal, High
beam, Clock, Low battery indicator, Service reminder & Bajaj Logo)
Headlamps Focus confirmation
3. Check points during Test ride
Check & correct the below check points during Test ride
Gear shifting Smooth operation
Throttle response
Drive-ability
Brake effectiveness - Front & Rear

Engine noise No abnormal noise

Smooth working by pumping movement & smooth operation
Front fork / steering
(No play / No Sticky movement)
Oil / Coolant leakages Specify source of leakages
4. Idling RPM / CO%

Check & correct the below check points in engine warm condition
Idling RPM Check in warm up condition at 600 (SAI connected 1350 – 1450 RPM
& SAI disconnected 1300 – 1400 RPM)
CO Check in engine warm condition at idling RPM

CO % Check
(SAI connected < 1% & SAI disconnected 4.5 % – 5.5 % )
5. Visual inspection for dent, scratches, rust …
6. Clean the vehicle thoroughly before delivery to customer.
Note :- If performance related issue is observed in vehicle, then carry out Idling RPM & CO% Check activity.

PART IDENTIFICATION
Model Pulsar 135 Pulsar 135 BS IV
Photograph
Part Name Rear Fender Rear Fender EVAP
Part No JD181003 JD181412
Description • Profile is different than Pulsar 135 BS IV • Profile is different than Pulsar 135
Identification Visual Visual
Photograph
Part Name Petrol Tank Cap Petrol Tank Cap

PART IDENTIFICATION
Photograph
Part Name CDI CDI
Part No JE351200 JE351246
Description • 3 Nos couplers • 2 Nos couplers
Photograph
Part Name Carburetor Assembly Carburetor Assembly
• Without evaporated fuel supply pipe • With evaporated fuel supply pipe
Description • With Auto choke • With Manual Choke
• With TPS • Without TPS

PART IDENTIFICATION
Photograph
Part Name Air Filter Assembly Air Filter Assembly
Description • Without fresh air supply provision TO SAI unit • With fresh air supply provision TO SAI unit
Photograph
Bracket SAI mounting Guide hooks canister pipe
Part Name Frame Frame
Description • Without provision of bracket for SAI unit mounting • With provision of bracket for SAI unit mounting
• Without Provision of hooks for Canister pipe routing • With Provision of hooks for Canister pipe routing

PART IDENTIFICATION
252.9 mm
Photograph 240.8 mm
Part Name Wind Shield Wind Shield
• Profile is different than Pulsar 135 BS IV • Profile is different than Pulsar 135
Description
• Height is 240.8 mm • Height is 252.9 mm
Photograph
Part Name Speedometer Assembly Speedometer Assembly
Description • Speedometer artwork is different than • Speedometer artwork is different than

Pulsar 135 BS IV Pulsar 135

PART IDENTIFICATION
Front Seat
Photograph
Rear Seat
Part Name Seat Assembly Seat Assembly
Part No Front – JD191012, Rear – JD191003 JD191018
Description • Split type seat • One piece seat
LH
Photograph
RH
Part Name Grab Handle Grab Handle
Part No LH – JD231408, RH – JD231409 JD231413
Description • Split type • One piece

PART IDENTIFICATION
Photograph
Part Name Lever – Gear Change Lever – Gear Change
Photograph Ø 10 mm
Ø 9.0 mm
Part Name Inhibitor Inhibitor
Part No JD561203 PA561209
Description • Inner diameter is 9.0 mm • Inner diameter is 10 mm

PART IDENTIFICATION
Photograph
Part Name Shield Muffler Shield Muffler
Part No JD591026 JE591195
Description • With plating • Black in color
Photograph
Part Name Caliper Assembly Caliper Assembly
Part No JD131813 JF131806
Description • Black in color & Split type • Brass Gold Color & Integral type

PART IDENTIFICATION
Photograph
Part Name Brake Disc Brake Disc
Description • Silver Color • Black Color

SAI PARTS
12
5 5
11
8 9 8 10
13
2
2 14
3 6 15
2 14
16
1
11
S. N. Description S. N. Description
1 Unit SAI 9 Silencer For SAI
2 Band Clip SAI Hose Outlet Tube 10 Hose Pipe A/F To Silencer Unit
3 Tube Outlet SAI 11 Clamp
4 Gasket Sai Flange 12 Hose Pipe Intake Manifold
5 Bolt Flanged Small 13 Bolt Flanged
6 Hose Connector SAI 14 Sleeve SAI Unit
7 Hose Intake Silencer Unit To SAI 15 Grommet SAI Unit
8 CLAMP 16 Nut Hex Flanged

EVAP PARTS
2 1
3
4
4 17
10 9
5
16
15 14
7 4
11
4
12
8
9 13
S. N. Description S. N. Description
1 Canister 10 Tube Y Connector To Canister
2 Spring Band Clamp 15 x 10 11 Connector Y Shape
3 Tube Canister To Purge Valve 12 Tube Drain
4 Spring Band Clamp 13 x 12 13 Plug Fuel Drain
5 Grommet Purge Valve 14 Tube Tank To Y Connector
6 Valve Purge 15 Tube Canister Drain
7 Spring Band Clamp 11.5 X 8.4 16 Clamp - Canister Breather
8 Tube Purge Valve To Carburator 17 Tube Canister Breather
9 Spring Band Clamp 9 x 8.4

CONTROL SWITCH RH H.T. COIL 1 H.T. COIL 2 THERMAL SENSOR DC CDI
OFF
ON
KILL
SWITCH
LHS RHS
SPARK SPARK

Br/L Gr/R
PLUG PLUG
GROUND
H.T. COIL O/P 1
H.T. COIL O/P 2
THERMISTER INPUT
PICKUP COIL I/P
BATTERY +VE
B B/Y B/R B/Y
Br/L Gr/R B/W
ELECTRICAL CIRCUIT DIAGRAM
B/Y
B/R
B/W
W/R
Gr/R
Ignition Circuit + Tachometer Circuit
SPEEDOMETER
B/Y
269
GROUND PIN 1
Br/L FUSE
IGNITION SUPPLY PIN 8
W
BATTERY + VE PIN 9
B W W/B
ENGINE RPM PIN 16
10A
W/R B/Y
W/R B/Y
IGNITION SWITCH
ON OFF
W W
W/B B
Br Br/L
IL
L
+ -
PU
CO SING
Service Support MC
MAGNETO ASSEMBLY BATTERY - 5Ah
REGULATOR
CAPACITOR
GROUND
OUTPUT
INPUT
INPUT

B/Y W L/W L/W
Battery Charging Circuit
B/Y W L/W L/W
270
FUSE
W W/B
10A
L/W L/W
L/W L/W
W/B B
+ -
Service Support MC
FRONT INDICATOR LAMP RH DC-FLASHER REAR INDICATOR LAMP RH
12 V, 10 W 12 V, 10 W
B/Y B/Y Gr Gr
Gr Gr B/Y B/Y

Side Indicator Circuit
Br O
SPEEDOMETER
B/Y
GROUND PIN 1
Br/L
IGNITION SUPPLY PIN 8 REAR INDICATOR LAMP LH
W 12 V, 10 W
BATTERY + VE PIN 9
Gr G G
RIGHT TURN INDICATOR PIN 11
G
LEFT TURN INDICATOR PIN 14
B/Y B/Y
271
FUSE
IGNITION SWITCH
ON OFF Gr O G Br Br/L
W W 10A
Br Br/L FUSE
W W/B
10A
Gr O G
FRONT INDICATOR LAMP LH

12 V, 10 W
R OFF L W/B B
B/Y B/Y
+ -
SIDE INDICATOR SWITCH
Service Support MC
G G (CONTROL SWITCH LH) BATTERY - 5Ah
CLUTCH SWITCH CONTROL SWITCH RH NEUTRAL SWITCH
OFF
START ON KILL
SWITCH SWITCH

R/Y Br/L
Starter Motor Circuit
LG
Y/G B/Y LG
R/W Br/L
Y/G B/Y LG
272
SPEEDOMETER
GROUND PIN 1 B/Y
Br/L FUSE
W
BATTERY + VE PIN 9
LG W W/B
NEUTRAL INDICATOR PIN 15
10A
R R/W Y/G
R/Y B
IGNITION SWITCH M
ON OFF
W W W/B B
+ -
Br Br/L R R R
Service Support MC
STARTER MOTOR STARTER RELAY BATTERY - 5Ah
FUEL GAUGE LEVEL

Fuel Meter Circuit
B/Y W/Y
B/Y W/Y
SPEEDOMETER
B/Y
273
GROUND PIN 1
Br/L FUSE
W
BATTERY + VE PIN 9
W/Y W W/B
FUEL INPUT PIN 12
10A
IGNITION SWITCH
ON OFF
W W W/B B
+ -
Br Br/L
BATTERY - 5Ah
Service Support MC
VEHICLE SPEED SENSOR
R/W R/W
B/Y B/Y

L/W L/W
Vehicle Speed Sensor Circuit
SPEEDOMETER
B/Y FUSE 10A
GROUND PIN 1
R/W
SPEED SENSOR SUPPLY PIN 6
274
Br/L W W/B
W
BATTERY + VE PIN 9
L/W
VEHICLE SPEED SENSOR PIN 13
IGNITION SWITCH
ON OFF W/B B
W W
+ -
Br Br/L BATTERY - 5Ah
Service Support MC
CONTROL SWITCH RH
LIGHT SWITCH LED CONTROL
TAIL LAMP
OFF
ON PO
SPEEDOMETER
Lighting Circuit
B/Y B/Y

GROUND PIN 1 B/Y R R
R
BACK LIGHT PIN 3
Br/L Y/L V R B/Y Br/W
W
BATTERY + VE PIN 9
R/B
HIGH BEAM PIN 10
NUMBER PLATE LAMP

Y/L V R Br/W
B/Y B/Y
R R
IGNITION SWITCH
ON OFF
W W
275
Br Br/L
FUSE 10A
Br Br/L
R/Y Br Y/L R/B Br/W

9 2 3 6 1 FUSE 15A
9 2 3 6 1 W W/B
PILOT LAMP
3W
R/B
HEAD
LAMP LED
R/Y
LO HI
R
W/B B
PASS HI / LO
+ -
PILOT LAMP SWITCH SWITCH
Service Support MC
3W CONTROL SWITCH LH BATTERY - 5Ah
HORN RH
Horn Circuit

B Br
FUSE 10A
Br Br/L
IGNITION SWITCH
ON OFF
W W
276
FUSE 10A
Br Br/L
W W/B
B B/Y
B Br
B B/Y
W/B B
+ -
HORN SWITCH
Service Support MC
(CONTROL SWITCH LH) HORN LH BATTERY - 5Ah
FRONT BRAKE SWITCH
L L
L Br B/Y B/Y

Brake Lamp Circuit
BRAKE LAMP
L Br
FUSE 10A
IGNITION SWITCH Br Br/L
ON OFF
W W
277
FUSE 10A
Br Br/L
W W/B
L Br
W/B B
+ -
Service Support MC
REAR BRAKE SWITCH BATTERY - 5Ah
NEW UPDATION
• Petrol Tank Cap Locking
• AHO - Automatic Headlight
ON
• Part Identification (AHO)
• Electrical Circuit Diagram
(AHO related)
278
PETROL TANK CAP LOCKING
• Lock the petrol tank cap as follows -
• Insert the vehicle ignition key in petrol

tank cap lock.
• Turn the vehicle ignition key clockwise.
• Press the fuel tank cap as shown in

photograph. Ensure “TUK” sound to
confirm the proper locking of petrol tank
cap
• Take out vehicle ignition key clockwise.
• Press the flap of petrol tank cap lock.
• Do not attach metal key chain to vehicle

ignition key as it may cause scratch /
damage marks on painted part.
X

AHO - AUTOMATIC HEADLIGHT ON
New Feature :-
AHO (Automatic Headlight ON) feature is provided. There is no “Light switch” on RH control switch. AHO is
government regulation.
AHO improves safety as the bike becomes more visible to others on the road.
Before After
No Light switch
Light switch
Ignition switch - ON Speedometer lamp, Tail lamp, Parts changed due to AHO feature
Engine - OFF Number plate lamp, Pilot lamp in Control switch Light switch deleted.
headlamp will get “ON” RH
Wiring harness • No branch for light switch
Ignition switch - ON Headlamp will get “ON” as per
• Connections for light control
Engine - Running Low / High beam selector switch module
position.
Flasher Deleted
High Beam Low Beam
Light Control New part added :-
Module • It will sense magneto is running &
will give input for head light
filaments.
• Flasher circuit is inbuilt in this
module.

PART IDENTIFICATION
Model Pulsar 135 LS Pulsar 135 LS BS IV
Photograph
Part Name Flasher Light Control Module
Part No DS201025 JL402004
Description • With Flasher • With Light Control Module
Photograph
Part Name Wiring Harness Front Wiring Harness Front
Description • With Lighting Switch Connection • Without Lighting Switch Connection.

PART IDENTIFICATION
Photograph
Part Name Wiring Harness Rear Wiring Harness Rear
Description • Without Light Control Module Connection. • With Light Control Module Connection.
Photograph
Part Name Controls Switch RH Control Switch RH
Part No JF401401 Jd401400
Description • With Headlight Switch • Without Headlight Switch

FRONT INDICATOR LAMP RH LIGHT CONTROL MODULE REAR INDICATOR LAMP RH
12 V, 10 W 12 V, 10 W
B/Y B/Y Gr Gr
Gr Gr B/Y B/Y

Br O B/Y
Side Indicator Circuit (AHO)
SPEEDOMETER
B/Y
GROUND PIN 1
Br/L
IGNITION SUPPLY PIN 8 REAR INDICATOR LAMP LH
W 12 V, 10 W
BATTERY + VE PIN 9
Gr G G
G
B/Y B/Y
283
FUSE
IGNITION SWITCH
ON OFF Gr O G Br Br/L
W W 10A
Br Br/L FUSE
W W/B
10A
Gr O G

12 V, 10 W
R OFF L W/B B
B/Y B/Y
+ -
Service Support MC
CONTROL SWITCH RH REGULATOR UNIT MAGNETO ASSEMBLY
LED CONTROL
TAIL LAMP
SPEEDOMETER B/Y B/Y

GROUND PIN 1 B/Y Br R
Br L/W L/W
BACK LIGHT PIN 3
Lighting Circuit (AHO)
Br/L Br B/Y Br/W

W L/W L/W L/W
BATTERY + VE PIN 9
R/B
HIGH BEAM PIN 10
NUMBER PLATE LAMP

Br B/Y Br/W
L/W L/W L/W L/W L/W B/Y B/Y
Br R
IGNITION SWITCH
ON OFF
W W
284
Br Br/L
FUSE 10A
Br Br/L
R/Y Br V R/B Br/W

9 2 3 6 1 FUSE 15A
9 2 3 6 1 W W/B
PILOT LAMP
Y/L
3W V Br
Br L/W B/Y
R/B
HEAD
LAMP LED V W
R/Y
LO HI
Br
W/B B
PASS HI / LO
+ -
Service Support MC
3W CONTROL SWITCH LH LIGHT CONTROL MODULE BATTERY - 5Ah
ON
Maintenance & Lubrication
Chart
• Revised Pre - Delivery
Inspection Checklist
• Important SOP
285
Type 4 stroke, Single Cylinder, Natural air cooled
Bore 56 mm
Stroke 60.7 mm
Displacement 149.5 cc
Max.Net Power 10.3 KW (14 PS) at 8000 RPM
Max. Net Torque 13.4 Nm at 6000 RPM
Ignition system DC CDI
Spark plug gap 0.7 to 0.8 mm
Gear shifting pattern 1 DOWN, 4 UP
Grade Bajaj DTS-I 10,000 SAE 20W50 API ‘SL’ or JASO ‘MA’
Overhaul 1100 ml

Chassis & Body :-
Rear : Nitrox twin suspension
Brakes Front : Disc brake
Rear : Drum Brake
Front : 2.75 x 17”, 41P, Tubeless
Tyres 80/100 x 17”, 46P, Tubeless
Rear : 100/90 x 17”, 55P, Tubeless
Front : 1.75 kg/cm² (25 PSI)
Tyre Pressure Rear (Solo) : 2.00 kg/cm² (28.4 PSI)
Rear (Pillion) : 2.25 kg/cm² (32 PSI)
Full 15 Liters
Reserve 3.2 Liters
Fork Oil Details :-
Grade SAE 10W20

Dimensions :-
Length 2055 mm
Width 755 mm
Height 1060 mm
Wheel Base 1320 mm
Vehicle Kerb Weight 144 kg.
Vehicle Gross Weight 274 kg.
Electricals :-
Electrical System 12 Volts DC
Battery 12V - 4Ah VRLA
Head Lamp 35/35W, HS1
Pilot Lamp 5W Each 2 Nos
Tail /Stop Lamp LED
Turn Signal Lamp 10W (4 nos.)
Neutral Indicator LED
Hi Beam Indicator LED
Turn Pilot Indicator LED
Side Stand Indicator LCD
Speedometer Illumination LCD Blue
Rear No. Plate Lamp 5W
Horn 12V DC

Make UCAL
CO% - With SAI <1%
CO% - Without SAI 4.5 % - 5.5 %
Choke Manual

AHO - AUTOMATIC HEADLIGHT ON
New Feature :-
Before After
Light switch
No Light switch
Ignition switch - ON Speedometer illumination Parts changed due to AHO feature

Engine - OFF Engine ‘OFF’ Tail lamp, Number
Plate Lamp, Pilot Lamp & Control Control switch Light switch deleted.
RH
Switches Illumination will get ‘ON’
Effect of pressing In addition to above ‘Hi-beam will Wiring harness • No branch for light switch
get ‘ON’ • Connections for light control module
‘Pass Switch’
Flasher Deleted
Ignition switch - ON Speedometer illumination, Tail
Engine - Running lamp, Number Plate Lamp, Pilot Light Control New part added :-
Lamp & Control Switches
Illumination will get ‘ON’ in
filaments.
addition to above, headlamp will • Flasher circuit is inbuilt in this
get on as shown in table. module.
Hi / Low beam switch Headlamp status Effect of Pass switch Pressing

Low Beam
Low Beam ON High Beam ON
High Beam
High Beam ON No change

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

for washing.

3 Oil strainer, Body centrifugal filter** CL CL CL CL CL Oil Strainer Cleaning at the time
of oil Change
Clean body centrifugal filter at

1st free service & at 20,000
kms.


11 Valve tappet clearance C,A C,A C,A C,A
lubrication
grease.)
• During regular service use

OKS spray for chain cleaning,
vehicle.
CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • If chain is excessiively dirty,
13 Sealed drive chain cleaning & lubrication CL,L,A
A A A A A A A then chain has to be cleaned
17 every 15,000 kms

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000


Use recommended AP


30 L L L L L L L L

earlier)


Dealer's
Dealer's Name
code
Model City
If Ok
To Check Check for
X If Not Ok
Coolant condition
Ensure no leakage
Lock Operation
cap lock
Batterry
Jelly application
Front : 1.75 Kg / cm2 (25 PSI)
Tyre Pressure
Rear (with pillion) : 2.25 Kg / cm2 (32 PSI)
Brake lever free play 4 ~ 5 mm (For drum brake only)
Brakes
Rear- Brake pedal free play 15 ~ 20 mm
Clutch / throttle cable Free play 2 ~ 3 mm
Slackness 25 – 35 mm

Front & Rear mounting bolts :

Fasteners (Check torque) 2.0 ~ 2.2 Kg.m (19.6 ~ 21.6 N.m)
Recommended torque wrench to Front axle nut : 4.0 – 5.0 Kg.m (39.2 – 49.1 N.m)
check sheet using reference Rear axle nut : 8.0 ~ 10.0 Kg.m (78.5 ~ 98.1 N.m)
However if any major parts are Swing arm shaft nut : 8.0 ~ 10.0 Kg.m (78.5 ~ 98.1 N.m)
side cover & seat) for RSA Mounting :-
accessibility of torque wrench, in Top nut : 3.5 - 4.0 Kg.m (34.3 – 39.2 N.m)
those cases the tightness can be Bottom nut : 2.7 – 3.0 Kg.m (26.5 – 29.4 N.m)
spanner / box type spanner as Front fork top / side bolts : 1.8 – 2.2 Kg.m
applicable without removing (17.7 - 21.6 N.m)
those major parts
Front fork under bracket bolts : 3.0 ~ 3.2 Kg.m
(29.4 ~ 31.4 N.m)
LH / RH Step holder : 2.0 2.2 Kg.m (19.6 – 21.6 N.m)

All Bulbs working
plate lamp,
Speedometer
Throttle response
Drive-ability


4. Idling RPM / CO%


CO % Check

IMPORTANT SOP
Petrol tank cap locking


tank cap lock.

cap

X
Oil Pump Screw Tightening & Loosening Sequence
Loosening Tightening
1 1
3 3
2 2
1 - Slight Loose 1 - Loose 1- Pre-tight
2 - Slight Loose 2 - Loose 2- Tight
1- Tight

PART IDENTIFICATION
Photograph
Part Name Clutch Housing (FCC) Clutch Housing (FCC)
Part No DH101859 DH102207
Photograph
Part Name Hub Clutch Hub Clutch
Description • No of Holes – 5 • No of Holes – 4

• No of ribs - 5 • No of ribs - 4

PART IDENTIFICATION
Photograph
Part Name Wheel Clutch Wheel Clutch
Part No Dk101569 Dh102211
Description • No of mounting boss - 5 • No of mounting boss - 4
Photograph
Part Name Clutch Holder Clutch Holder
Part No DK101573 JG551443
Description
• No of mounting holes - 5 • No of mounting holes - 4

PART IDENTIFICATION
Photograph
Part Name Clutch Spring Clutch Spring
Description • No of springs - 5 • No of springs - 4
Photograph
Ø 110 mm
Part Name Plate Clutch Plate Clutch
Part No DK101565 PD551433
Description • Outer diameter is Ø 115 mm • Outer diameter is Ø 110 mm

PART IDENTIFICATION
Ø 91 mm
Photograph
Part Name Friction Plate Friction Plate

• No of petal – 40 • No of petal – 40 • No of petal – 48 • No of petal – 45
Description • No of lugs – 10 • No of lugs – 10 • No of lugs – 10 • No of lugs – 8
• Inner diameter is • Inner diameter is • Inner diameter is • Inner diameter is
Ø 101.5 mm Ø 95 mm Ø 95 mm Ø 91 mm
Photograph
Part Name Anti Judder Spring -
Part No DK101571 -
Description • With anti judder spring • Without anti judder spring

• Outer dimeter is Ø 100 mm
Identification Visual -

PART IDENTIFICATION
Photograph
Part Name Anti Judder Washer -
Part No DK101570 -
Description • With anti judder washer • Without anti judder washer

• Outer dimeter is Ø 100 mm
Identification Visual -
Ø 68 mm
Photograph Ø 62 mm
Part Name Crankshaft Assembly Crankshaft Assembly
Description • Outer diameter is Ø 62 mm • Outer diameter is Ø 68 mm

PART IDENTIFICATION
Photograph
Part Name Guide Gear Shift Guide Gear Shift
Part No DK101361 DH102189
Photograph
Part Name Guide Starter Guide Starter

PART IDENTIFICATION
Photograph
Description • No Provision for supply of evaporated fuel • Provision for supply of evaporated fuel
Photograph
• Without additional pipe for supply of fresh air to SAI • With additional pipe for supply of fresh air to SAI
Description
• Entry duct profile is different than Pulsar 150 BS IV • Entry duct profile is different than Pulsar 150

PART IDENTIFICATION
Ø 62 mm
Ø 68 mm
Photograph
Part Name Crankcase Crankcase
Part No LH - DJ101344, RH - DJ101213 LH - DH102164, RH - DH102165
Description • Main bearing hole dia is Ø 62 mm • Main bearing hole dia is Ø 68 mm
Photograph
Part Name Cap Cam Shaft Cap Cam Shaft
Part No DS101096 DH102201
Description • Cam shaft cap without threading • Cam shaft cap with threading

PART IDENTIFICATION
Photograph
Part Name Engine Mounting Bracket Top RH Engine Mounting Bracket Top RH
Part No DJ161089 DH161551
Description • Without Hook • With Hook
Photograph
Part Name Cam Shaft Assembly Cam Shaft Assembly
Part No DK101614 PD511224
Description • Identification groove near small bearing end • Identification groove away from small bearing end

PART IDENTIFICATION
Photograph
Part Name Petrol Tank Petrol Tank
Part No JC141031 DH141066
Description • No Additional provision for EVAP • Additional provision for EVAP
Breather
hole Breather
hole
Photograph
Part Name Cap Petrol Tank Cap Petrol Tank
Description • Without breather hole • With breather hole

PART IDENTIFICATION
SAI Mtg
SAI Mtg
bracket
bracket
Photograph
Purge Valve Mtg Purge Valve Mtg

bracket bracket
Hook
Hook
• Without SAI unit mounting bracket • With SAI unit mounting bracket
Description • Without bracket purge valve mounting • With bracket purge valve mounting
• Without hooks for SAI hose routing • With hooks for SAI hose routing
Photograph
Part Name Side Stand Side Stand
Part No DJ161218 DH161471

PART IDENTIFICATION
Photograph
Part Name Leg Guard Leg Guard
Part No DJ161226 LH - DH221012, RH - DH221013
Description • One piece leg guard • Split type leg guard
Photograph
Part Name Front Brake Disc Front Brake Disc
Part No JN131807 DH151081
Description • Silver color • Black color

PART IDENTIFICATION
Photograph
Part Name Flasher Light control Module
Description • With Flasher • With light control module
Photograph
Part Name Battery Battery
Part No JF401801 JF401803
Description • 7Ah Flooded Battery • 4Ah VRLA Battery

PART IDENTIFICATION
Photograph
Part Name CDI CDI
Description • Coupler color - Natural • Coupler color - Green
Photograph
Description • Dial graphics is different than Pulsar 150 BS IV • Dial graphics is different than Pulsar 150

PART IDENTIFICATION
Photograph
Part Name Switch Side Stand Switch Side Stand
Fuel Gauge
Pulsar 150 BS IV
Float Position Volume in Liters Resistance ( Ω )
Full 12 9.0 – 15.0
Half 8.4 28.0 – 38.0
Reserve 3.6 ± 0.2 74.0 – 84.0
Empty - 95.0 – 105.0

SAI PARTS
13
12
11
12
14
1 2
3 7 6
5
2
8
4
10
S. N. Description Qty. S. N. Description Qty.

1 SAI Unit 1 9 Gasket Metal Pipe 1
2 Clamp 3 10 Flanged Bolt 2
3 Clamp 1 11 Grommet SAI Unit 2
4 Clamp 1 12 Sleeve SAI Unit 4
5 Tube SAI Air Filter 1 13 Bolt Flanged 2
6 Hose SAI Unit To Manifold 1 14 Nut Hex Flanged 2
7 Metal Pipe SAI 1
8 Hose SAI Unit To SAI Pipe 1

EVAP PARTS
16 13 1
4
11
3 2
8
7 2 18
2 2
12
5 8
10
2 17
2
6 14
20 4
19
15
4

1 Canister 1 11 Tube Tank To Inline Connector 1
2 Spring Band Clamp 9 x 8.4 6 12 Tube Canister Breather 1
3 Tube T Connector To Canister 1 13 Spring Band Clamp 15 x 10 1
4 Spring Band Clamp 11.5 X 8.4 3 14 Valve Purge 1
5 Connector For Breather And Vapor Tube 2 15 Tube Purge Valve To Carburetor 1
6 Tube Inline Connector To T Connector 1 16 Tube Canister To Purge Valve 1
7 Tube Connector EVAP 1 17 Grommet Purge Valve 1
8 Spring Band Clamp 13 x 12 2 18 Clamp 1
9 Plug Fuel Drain 1 19 Tube Drain 1
10 Tube Canister Drain 1 20 Strap Canister 1

KILL SWITCH H.T. COIL 1 H.T. COIL 2 DC CDI
(CONTROL SWITCH RH)
OFF
KILL
ON
SWITCH
LHS RHS
SPARK SPARK

Br/L Gr/R
PLUG PLUG
H.T. COIL O/P 1

H.T. COIL O/P 2
PICKUP COIL I/P

BATTERY +VE
EARTH
B B/Y B/R B/Y
Br/L Gr/R
B/Y
B/R
W/R
Gr/R
SPEEDOMETER
Br Br
314
B B
ENGINE RPM PIN 10
B/Y W
GROUND PIN 11
W W Br
BATTERY PIN 20
W/R B/Y
15A
10A
FUSE
BOX
F1 F2
W/B Br/L
R B
W/R B/Y
IGNITION SWITCH
ON OFF + -
Br 1 Br/L
1
W 2 W
2 PICKUP
COIL
Service Support MC
MAGNETO ASSEMBLY VRLA BATTERY - 9Ah
SIDE STAND SWITCH
+5V GND

O/Br B/Y
Side Stand Indication Circuit
O/Br B/Y
W Br
15A
10A
FUSE
SPEEDOMETER BOX
F1 F2
Br Br
315
O/BR O/BR
SIDE STAND PIN 4
B/Y W W/B Br/L
GROUND PIN 11
W
BATTERY PIN 20
R B
IGNITION SWITCH
ON OFF + -
Br Br/L
W W
Service Support MC
VRLA BATTERY - 9Ah
REGULATOR UNIT
CAPACITOR

B/Y W
L/W
L/W
W
B/Y
SPEEDOMETER
B/Y W
GROUND PIN 11
W
W
BATTERY PIN 20
B/Y
L/W
L/W
316
MAIN FUSE
F1
W 15 A W/B
L/W L/W
R B
L/W L/W
+ -
Service Support MC
MAGNETO ASSEMBLY VRLA BATTERY - 9Ah
12 V, 10 W 12 V, 10 W
Gr Gr Gr Gr
B/Y B/Y B/Y B/Y

Br O B/Y
SPEEDOMETER
Br Br REAR INDICATOR LAMP LH

Gr Gr 12 V, 10 W
G G G G
B/Y W
GROUND PIN 11
W B/Y B/Y
BATTERY PIN 20
317
W Br
IGNITION SWITCH
15A
10A
ON OFF Gr O G FUSE
Br Br/L BOX
F1 F2
W W
W/B Br/L
R B
Gr O G
+ -
12 V, 10 W
R OFF L
G G
Service Support MC
B/Y B/Y (CONTROL SWITCH LH) VRLA BATTERY - 9Ah
OFF
START ON KILL
SWITCH SWITCH

R/Y Br/L
LG
Y/G B/Y LG
R/W Br/L
Y/G B/Y LG
318
SPEEDOMETER
W Br
Br Br
LG LG
B/Y W
GROUND PIN 11
15A
10A
FUSE
W BOX
BATTERY PIN 20 F1 F2
W/B Br/L
R R/W Y/G
R B
R/Y B
IGNITION SWITCH M + -
ON OFF
W/B
Br Br/L
W W R R
Service Support MC
STARTER MOTOR STARTER RELAY VRLA BATTERY - 9Ah
FUEL GAUGE LEVEL

Fuel Meter Circuit
B/Y W/Y
B/Y W/Y
SPEEDOMETER
Br Br
W/Y W
FUEL INPUT PIN 5
B/Y W/Y W Br
GROUND PIN 11
319
W
BATTERY PIN 20
15A
10A
FUSE
BOX
F1 F2
W/B Br/L
IGNITION SWITCH
R B
ON OFF
Br Br/L
W W + -
Service Support MC
VRLA BATTERY - 9Ah
R/W R/W
B/Y B/Y
L/W L/W

SPEEDOMETER
R/W Br
Br W
L/W W Br
SPEED SENSOR INPUT PIN 6
B/Y R/W
320
GROUND PIN 11
W
BATTERY PIN 20
L/W
15A
10A
FUSE
BOX
F1 F2
W/B Br/L
R B
IGNITION SWITCH
ON OFF
Br Br/L
+ -
W W
Service Support MC
VRLA BATTERY - 9Ah
LED CONTROL
TAIL LAMP
SPEEDOMETER B/Y B/Y

Br Br Br R
R/B R/B L/W L/W
HIGH BEAM PIN 3

B/Y Br Br B/Y Br/W
GROUND PIN 12
R W L/W
BACK LIGHT PIN 13 L/W L/W
W
BATTERY + VE PIN 20
NUMBER PLATE LAMP

Br B/Y Br/W
L/W L/W L/W Br R
L/W L/W
B/Y B/Y
IGNITION SWITCH
ON OFF
Br Br/L W Br
321
W W
15A
10A
FUSE
BOX
F1 F2
R/Y Br V R/B Br/W

9 2 3 6 1
W/B Br/L
9 2 3 6 1
PILOT LAMP
3W V Br
Br L/W B/Y R B
HEAD R/B
LAMP B/Y V W
LED + -
R/Y
LO HI
Br
PASS HI / LO
Service Support MC
3W CONTROL SWITCH LH LIGHT CONTROL MODULE VRLA BATTERY - 9Ah
HORN RH
SPEEDOMETER
Br
Horn Circuit
B/Y Br
GROUND PIN 11

W W
BATTERY PIN 20
B Br
W Br
IGNITION SWITCH
15A
10A
FUSE
ON OFF BOX
F1 F2
Br Br/L
322
W W
W/B Br/L
B B/Y
R B
B B Br
B/Y
+ -
HORN SWITCH
Service Support MC
(CONTROL SWITCH LH) HORN LH VRLA BATTERY - 9Ah
FRONT BRAKE SWITCH
L L
L Br B/Y B/Y

Brake Lamp Circuit
BRAKE LAMP
SPEEDOMETER
Br
B/Y Br L Br
GROUND PIN 11
W W
BATTERY PIN 20
IGNITION SWITCH
ON OFF
FUSE BOX
Br Br/L Br Br/L
323
10A F2
W W
W 15A F1 W/B
Br L
R B
+ -
REAR BRAKE SWITCH VRLA BATTERY - 9Ah
Service Support MC
• Revised Technical
Specifications
Maintenance & Lubrication
Chart
• Revised Pre - Delivery
Inspection Checklist
• Revised Torque Values
• Revised Service Limits
• New Updation
324
REVISED TECHNICAL SPECIFICATIONS
Specifications
Parameter
Pulsar 180 Pulsar 180 BS IV
Brake Rear – Drum Brake, dia 130 mm Rear – Disc Brake , 230 mm dia disc
Tyre Pressure – Rear Solo 28.4 PSI (2.000 Kg / cm2) 30 PSI (2.10 Kg / cm2)
Tyre Pressure – Rear Pillion 30.5 PSI (2.15 Kg / cm2) 32 PSI (2.25 Kg / cm2)
Width 750 mm 765 mm
Height 1165 mm 1115 mm
Wheelbase 1350 1345 mm
Choke Push-Pull type Lever type
TPS With TPS Without TPS
Make UCAL
CO% - With SAI <1%
CO% - Without SAI 4.5 % - 5.5 %
Choke Manual

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

for washing.


time of oil Change

Pulsar


lubrication
grease.)
CL,L,A CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • During regular service use
A A A A A A OKS spray for chain cleaning,
vehicle.
13 Sealed drive chain cleaning & lubrication • If chain is excessiively dirty,
then chain has to be cleaned
17 every 15,000 kms

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000


Use recommended AP


30 L L L L L L L L

earlier)


Dealer's
Dealer's Name
code
Model City
If Ok
To Check Check for
X If Not Ok
Coolant condition
Ensure no leakage
Lock Operation
cap lock
Batterry
Jelly application
Front : 1.75 Kg / cm2 (25 PSI)
Tyre Pressure
Rear (with pillion) : 2.25 Kg / cm2 (32 PSI)
Brake lever free play 4 ~ 5 mm (For drum brake only)
Brakes
Brake pedal free play (For drum brake only)
Slackness 20 ~ 25 mm


Recommended torque wrench to

Rear mounting bolts : 2.0 ~ 2.2 Kg.m (19.6 ~ 21.6 N.m)
check sheet using reference Front axle nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
However if any major parts are Rear axle nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
side cover & seat) for
accessibility of torque wrench, in Swing arm shaft nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
those cases the tightness can be
spanner / box type spanner as RSA Mounting nut Top / Bottom :
applicable without removing 3.2 – 3.5 Kg.m (31.4 – 34.3 N.m)
those major parts
Front fork top bolts :
2.0 – 2.2 Kg.m (19.6 – 21.6 N.m)

3.0 – 3.2 Kg.m (29.4 – 31.4 N.m)

All Bulbs working
plate lamp,
Speedometer
Throttle response
Drive-ability


4. Idling RPM / CO%


CO % Check

REVISED TORQUE VALUES & REVISED SERVICE LIMITS
Pulsar 180 BS IV
Parameter
Kg.m N.m
Rear Sprocket Mounting nuts 3.2 – 3.8 31.4 – 37.3
Handle Bar Holder bolts 2.2 – 2.5 21.6 – 24.5
Fork Center Nut 5.0 – 5.2 49.1 – 51.0
Fork Pipe Top side bolts 2.0 – 2.2 19.6 – 21.6
Fork underbracket Bolt 3.0 – 3.2 29.4 – 31.4
RSA Mounting Nut – Upper & Lower 3.2 – 3.5 31.4 – 34.3
Disc Mounting Bolts – Front & Rear 1.0 – 1.2 9.8 – 11.8
REVISED SERVICE LIMITS
Parameter Standard Specification Service Limit
Disc pad thickness – Rear 6.5 mm 3.3 mm
Brake disc thickness - Rear 4.0 mm 3.5 mm
Drive Chain Slackness 20.0 – 25.0 mm 30.0 – 35.0 mm
Drive Chain 20 Links length 314.4 mm 320.7 mm

PART IDENTIFICATION
Photograph
Part Name Engine Mounting Bracket Top Engine Mounting Bracket Top
Part No LH – JC161028, RH – JC161015 LH - DK161415, RH-DK161416
Description • Without Hook • With Hook

Photograph
Part Name Rear Fender Rear Fender
Part No DK161085 DK161338

PART IDENTIFICATION
Photograph
Part No Dh191065 Dh191066
Description • Dial graphics & LCD Artwork different than • Dial graphics & LCD Artwork different than
Pulsar 180 BS IV Pulsar 180
Photograph
Part Name Intake Pipe Intake Pipe
Part No DJ101215 DJ121090
Description • Without nipple connector • With nipple connector

PART IDENTIFICATION
Photograph
Description • Without provision for supply of evaporated fuel • With provision for supply of evaporated fuel
Photograph
Part Name Cam Shaft Cap Cam Shaft Cap
Part No DS101096 Dh102201
Description • Cam shaft cap without fins • Cam shaft cap with fins

PART IDENTIFICATION
Photograph
Description • Without provision for supply of fresh air to SAI • With provision for supply of fresh air to SAI
Photograph
Part Name Body Centrifugal Oil Filter Body Centrifugal Oil Filter
• Profile is different than Pulsar 180 With • Profile is different than Pulsar 180 BS IV
Description
mounting holes for cover fitment • Without mounting holes for cover fitment

PART IDENTIFICATION
Photograph
Part Name Cover Centrifugal Filter Cover Centrifugal Filter
• Without Slot • With Slot
Photograph
Part Name CDI CDI
• Brown color coupler • Natural color coupler

Description
• Part No "DJ111092" embossed on housing • Part No "DJ111097" embossed on housing

PART IDENTIFICATION
SAI Mtg bracket SAI Mtg bracket
Photograph
Purge Valve Mtg bracket Purge Valve Mtg bracket
Hook Hook
Part No JC161031 DJ161401
Photograph

PART IDENTIFICATION
Photograph
Part Name Gear Change Drum Gear Change Drum
Photograph
Part Name Petrol Tank Petrol Tank
Description • Without provision for supply of evaporated • With provision for supply of evaporated
fuel to canister fuel to canister

PART IDENTIFICATION
Photograph
Part Name Cap petrol Tank Cap petrol Tank
Front Front Rear
Photograph
Part No Front – DK151027, Rear – Not Applicable Front – DK151096, Rear – DK151097
Description • Without Black color • Black color disc

PART IDENTIFICATION
Photograph
Part Name Caliper Assembly Caliper Assembly
Part No DK151054 JF131806
Description • Gold color & Split type • Brass Gold color & Integral type
Fuel Gauge
Pulsar 180 Pulsar 180 BS IV
Float Position Volume in Liters Resistance ( Ω ) Float Position Volume in Liters Resistance ( Ω )
Full 8.5 6.0 – 10.0 Full 12 9.0 – 15.0
Half 4.5 36.0 – 44.0 Half 8.4 28.0 – 38.0
Reserve 2.8 67.0 – 77.0 Reserve 3.6 ± 0.2 74.0 – 84.0
Empty - 93.0 – 101.0 Empty - 95.0 – 105.0

SAI PARTS
13
12
11
12
14
1 2 7
3 6
5
4
8
4
9
3
10

1 SAI Unit 1 9 Gasket Metal Pipe With Flange SAI 1
2 Clamp SAI Pipe 2 10 Flanged Bolt 2
3 Clamp 2 11 Grommet SAI Unit 2
4 Clamp Hose SAI 2 12 Sleeve SAI Unit 4
5 Tube SAI Air Filter 1 14 Bolt Flanged 2
6 Hose SAI Unit To Manifold 1 15 Nut Hex Flanged 2
7 Metal Pipe With Flange SAI 1
8 Hose SAI Unit To SAI Pipe 1

EVAP PARTS
14 13 1
4
8
3 2
15
6 2 2 11
4 16
12
5 4
10
4 17
18
2
7
19
8

1 Canister 1 10 Tube Canister Drain 1
2 Spring Band Clamp 9 x 8.4 5 11 Clamp - Canister Breather 1
3 Tube T Connector To Canister 1 12 Tube Canister Breather 1
4 Spring Band Clamp 11.5 X 8.4 4 13 Spring Band Clamp 15 x 10 1
5 Connector For Breather And 14 Tube Canister To Connector 1
Vapor Tube 1 15 Connector Tube EVAP 2
6 Tube Tank To T Connector 1 16 Tube Connector To Purge Valve 1
7 Tube Condensate Fuel Drain 1 17 Grommet Purge Valve 1
8 Spring Band Clamp 13 x 12 2 18 Valve Purge 1
9 Plug Fuel Drain 1 19 Tube Purge Valve To Carburetor 1

CONTROL SWITCH RH H.T. COIL 1 H.T. COIL 2 DC CDI
OFF
ON
KILL
SWITCH
LHS RHS
SPARK SPARK

Br/L Gr/R
PLUG PLUG
H.T. COIL O/P 1

H.T. COIL O/P 2
PICKUP COIL I/P

BATTERY +VE
EARTH
B B/Y B/R B/Y

Br/L Gr/R
B/Y
B/R
W/R
Gr/R
SPEEDOMETER
Br Br
343
B B FUSE
ENGINE RPM PIN 10
B/Y W
GROUND PIN 12
W W W/B
BATTERY + VE PIN 20
15A
Br
W/R B/Y
10A
FUSE
W/R B/Y
R B
Br/L
IGNITION SWITCH
ON OFF + -
Br Br/L
W W
IL
L
PU
CO SING
Service Support MC
SIDE STAND SWITCH
+5V GND

O/Br B/Y
O/Br B/Y
SPEEDOMETER
Br Br
344
O/BR O/BR FUSE
SIDE STAND PIN 4
B/Y W
GROUND PIN 12
W W W/B
BATTERY + VE PIN 20
15A
Br
10A
FUSE
R B
Br/L
IGNITION SWITCH
ON OFF + -
Br Br/L
W W
Service Support MC
BATTERY - 9Ah
REGULATOR
CAPACITOR

L/W L/W W B/Y
L/W L/W W B/Y
345
FUSE
W W/B
15A
L/W L/W
L/W L/W
R B
+ -
Service Support MC
12 V, 10 W 12 V, 10 W
Gr Gr Gr Gr
B/Y B/Y B/Y B/Y

Br O
SPEEDOMETER
Br Br

Gr Gr
RIGHT TURN INDICATOR PIN 7 REAR INDICATOR LAMP LH
G G 12 V, 10 W
B/Y W G G
GROUND PIN 12
W
BATTERY + VE PIN 20
B/Y B/Y
346
FUSE
IGNITION SWITCH
ON OFF Gr O G Br/L Br
Br Br/L 10A
W W FUSE
W W/B
15A
R B
Gr O G
+ -
12 V, 10 W
R OFF L
G G
Service Support MC
B/Y B/Y (CONTROL SWITCH LH) BATTERY - 9Ah
OFF
START ON KILL
SWITCH SWITCH

R/Y Br/L
LG
Y/G B/Y LG
R/W Br/L
Y/G B/Y LG
347
SPEEDOMETER
Br Br FUSE
LG LG
B/Y W Br/L Br
GROUND PIN 12
W 10A
BATTERY + VE PIN 20
FUSE
W W/B
15A
R R/W Y/G
R B
R/Y B
IGNITION SWITCH M + -
ON OFF
W/B
Br Br/L
W W R R
Service Support MC
FUEL GAUGE LEVEL

Fuel Meter Circuit
B/Y W/Y
B/Y W/Y
SPEEDOMETER
Br Br
W/Y W
FUEL INPUT PIN 5
B/Y W/Y
GROUND PIN 12
348
W
BATTERY + VE PIN 20
FUSE
Br/L Br
10A
FUSE
W W/B
15A
IGNITION SWITCH
R B
ON OFF
Br Br/L
W W + -
Service Support MC
BATTERY - 9Ah
R/W R/W
B/Y B/Y
L/W L/W

SPEEDOMETER
R/W Br FUSE 10A
Br W
IGNITION SUPPLY PIN 2 Br/L Br
L/W
SPEED SENSOR INPUT PIN 6
B/Y
349
GROUND PIN 12 FUSE 15A
R/W
W
BATTERY + VE PIN 20
L/W
W W/B
R B
IGNITION SWITCH
ON OFF
Br Br/L
+ -
W W
Service Support MC
BATTERY - 9Ah
CONTROL SWITCH RH
TAIL LAMP
OFF
ON PO
SPEEDOMETER
Lighting Circuit
B/Y B/Y

Br Br R R
R/B R/B
HIGH BEAM PIN 3
B/Y R Y/L V R B/Y Br/W
GROUND PIN 12
R W
BACK LIGHT PIN 13
W
BATTERY + VE PIN 20
NUMBER PLATE LAMP

Y/L Br R Br/W
R R
B/Y B/Y
IGNITION SWITCH
ON OFF
Br Br/L
350
W W
FUSE 10A
Br/L
Br
R/Y Br Y/L R/B Br/W
9 2 3 6 1 FUSE 15A
9 2 3 6 1 W W/B
PILOT LAMP
3W
R B
R/B
HEAD
LAMP PASS
SWITCH LED + -
R/Y
LO HI
R
HI / LO
PILOT LAMP SWITCH
Service Support MC
HORN RH
Horn Circuit

B Br
FUSE 10A
IGNITION SWITCH Br/L
ON OFF Br
Br Br/L
351
FUSE 15A
W W
W W/B
B B/Y
R B
B Br
B B/Y
+ -
HORN SWITCH
Service Support MC
(CONTROL SWITCH LH) HORN LH BATTERY - 9Ah
FRONT BRAKE SWITCH
L L
L Br B/Y B/Y

Brake Lamp Circuit
BRAKE LAMP
L Br
FUSE 10A
IGNITION SWITCH Br/L
ON OFF Br
Br Br/L
352
FUSE 15A
W W
W W/B
Br L
R B
+ -
BATTERY - 9Ah
Service Support MC
REAR BRAKE SWITCH
NEW UPDATION
• Oil Pump Screw Tightening
& Loosening Sequence
ON
(AHO related)
353
NEW UPDATION


tank cap lock.

cap

X
1 1
3 3
2 2
1- Tight

NEW UPDATION
AHO - Automatic Headlight ON
New Feature :-
Before After
No Light switch
Light switch
position.
Flasher Deleted
High Beam Low Beam
filaments.
module.

PART IDENTIFICATION
Photograph
Photograph
Part No JF401401 JD401400

PART IDENTIFICATION
Part Name Wiring Harness Wiring Harness
• Without Light Control Module Connection. • With Light Control Module Connection.
Description
• With Lighting Switch Connection • Without Lighting Switch Connection

12 V, 10 W 12 V, 10 W
Gr Gr Gr Gr
B/Y B/Y B/Y B/Y

Br O B/Y
SPEEDOMETER
Br Br

Gr Gr
G G 12 V, 10 W
B/Y W G G
GROUND PIN 12
W
BATTERY + VE PIN 20
B/Y B/Y
358
FUSE
IGNITION SWITCH
ON OFF Gr O G Br/L Br
Br Br/L 10A
W W FUSE
W W/B
15A
R B
Gr O G
+ -
12 V, 10 W
R OFF L
G G
Service Support MC
B/Y B/Y (CONTROL SWITCH LH) BATTERY - 9Ah
LED CONTROL
TAIL LAMP
SPEEDOMETER B/Y B/Y

Br Br Br R
R/B R/B L/W L/W
HIGH BEAM PIN 3
B/Y Br Br B/Y Br/W

GROUND PIN 12
R W L/W
BACK LIGHT PIN 13 L/W L/W
W
BATTERY + VE PIN 20
NUMBER PLATE LAMP

Br B/Y Br/W
L/W L/W L/W Br R
L/W L/W
B/Y B/Y
IGNITION SWITCH
ON OFF
Br Br/L
FUSE 10A
359
W W Br/L
Br
FUSE 15A
R/Y Br V R/B Br/W
W W/B
9 2 3 6 1
9 2 3 6 1
PILOT LAMP
3W V Br
Br L/W B/Y R B
R/B
HEAD
LAMP PASS
LED V W
SWITCH + -
R/Y
LO HI
Br
HI / LO
PILOT LAMP SWITCH
Service Support MC
3W CONTROL SWITCH LH LIGHT CONTROL MODULE BATTERY - 9Ah
Maintenance &
Lubrication Chart
• Revised PDI Check Sheet
• Important SOP
• New Updation
360
Type 4 Stroke, Oil cooled
Bore 67.00 mm
Stroke 62.4 mm
Displacement 220 cc
Max. Net Power 20.93 PS at 8500 RPM
Max. Net Torque 18.55 Nm at 7000 RPM
Ignition system DC
Spark plug gap 0.7 ~ 0.8 mm
Lubrication Wet sump, Forced.
Gear shifting pattern 1 down 4 up
Grade SAE 20W50 API ‘SL’ OR Bajaj DTS-i 10W50 Synthetic oil
Overhaul 1300 ml

Chassis & Body :-
Rear : Twin suspension with nitrox
Brakes Front : Hydraulic operated disc brakes
Rear : Hydraulic operated disc brakes
Tyres Front : 90/90 x 17, 49P, Tubeless
Rear : 120/80 x 17, 61P, Tubeless
Tyre Pressure Front : 2.00 Kg/Cm² (28.4 PSI)
Rear (Solo) : 2.10 Kg/Cm² (30 PSI)
Rear (Pillion) : 2.25 Kg/Cm² (32 PSI)
Full 15.0 Liters
Reserve 3.2 Liters
Fork Oil Details :-
Grade SAE 10W20

Dimensions :-
Length 2035 mm
Width 750 mm
Height 1165 mm
Wheel Base 1350 mm
Vehicle Kerb Weight 155 kg
Vehicle Gross Weight 285 kg
Electricals :-
System 12V DC
Battery 12 V - 9 Ah
Head Lamp 55W (Low Beam) & 55W (High Beam )
Pilot lamp 5W (2 nos.)
Tail / Stop Lamp LED
Side indicator Lamp 10W (4 nos)
Neutral LED
Hi-Beam Indicator LED
Turn Signal Indicator LED
Side Stand Indicator LED
Speedometer LCD Display
Rear No. Plate lamp 5W
Horn 12V DC (2 Nos.)

Make UCAL
CO% - With SAI <1%
CO% - Without SAI 4.5 % - 5.5 %
Choke Manual

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

for washing.

models.
2 C,R R R R R BGO DTS-i 20W50 OR Bajaj
engine oil filter* Up Up Up
DTS-i 10W50 Synthetic oil

time of oil Change

Pulsar


• During 1st free service :

Use lint free cloth for cleaning
Non-Sealed drive chain cleaning & CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, removed, cleaned using diesel
12 CL,L,A & lubricated using molten IOC
lubrication A A A A A A A
grease.)
• During regular service use

OKS spray for chain cleaning,
vehicle.
CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • If chain is excessiively dirty,
13 Sealed drive chain cleaning & lubrication CL,L,A
A A A A A A then chain has to be cleaned
15 Silencer drain hole cleaning CL CL CL CL CL CL CL
17 every 15,000 kms

Sr
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000


Use recommended AP


30 L L L L L L L L

earlier)


Dealer's
Dealer's Name
code
Model City
If Ok
To Check Check for
X If Not Ok
Coolant condition
Ensure no leakage
Lock Operation
cap lock
Batterry
Jelly application
Front : 2.00 Kg / Cm² (28.4 PSI)
Tyre Pressure
Rear (with Pillion) : 2.25 Kg / Cm2 (32 PSI)
Front : Brake lever free play 4 ~ 5 mm (For drum brake only)
Brakes
Rear : Brake pedal free play (For drum brake only)
Slackness 20 ~ 25 mm


Recommended torque wrench to Rear mounting bolts : 1.8 ~ 2.2 Kg.m (17.7 ~ 21.6 N.m)
Front axle nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
check sheet using reference
Rear axle nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
However if any major parts are
s i d e c o v e r & s e a t ) f o r Swing arm shaft nut : 8.0 – 10.0 Kg.m (78.5 – 98.1 N.m)
accessibility of torque wrench, in
those cases the tightness can be RSA Mounting nut Top / Bottom :
ensured using open end / ring 3.2 – 3.5 Kg.m (31.4 – 34.3 N.m)
spanner / box type spanner as
applicable without removing Front fork top bolts :
2.0 – 2.2 Kg.m (19.6 – 21.6 N.m)
those major parts
3.0 – 3.2 Kg.m (29.4 – 31.4 N.m)
LH / RH Stay 2.2 - 2.5 Kg.m (21.6 – 24.5 N.m)

All Bulbs working
plate lamp,
Speedometer
Throttle response
Drive-ability


4. Idling RPM / CO%


CO % Check

IMPORTANT SOP
Procedure to check Magneto-rotor on vehicle
• Remove seat.
• Disconnect 2 pole white coupler –

connection from magneto to regulator.
• Insert digital multimeter probes into magneto coupler from cable side.
• Set the digital multimeter to read AC Voltage.
• Start the engine and rev up to 4000

RPM and hold the same constant for
25 seconds
• Note down the AC VOLTAGE reading
Should read Minimum 60 Volts AC.
Acceptance criteria : AC Voltage reading should be MINIMUM 60 Volts AC
Note :
1. After testing ,if AC voltage is not meeting the specification , replace the Rotor assembly with identified OK
rotor.
2. After replacement, above mentioned procedure to be repeated for confirmation.
Service Station Manual 369a Service Support MC

PART IDENTIFICATION
Photograph
Part Name CDI CDI
Description • With 2 Pole coupler • Without 2 Pole coupler

• Part No "DK111072" embossed on housing • Part No "DK111081" embossed on housing
Photograph
Description • Dial graphics & LCD Artwork different than • Dial graphics & LCD Artwork different than
Pulsar 220 UG Pulsar 220

PART IDENTIFICATION
Photograph
Part No JC120024 DK121092
Description • Without provision for supply of evaporated fuel • With provision for supply of evaporated fuel
• With Auto Choke • With Manual Choke
Photograph
Description • Without provision for supply of fresh air to SAI • With provision for supply of fresh air to SAI

PART IDENTIFICATION
SAI Mtg bracket SAI Mtg bracket
Purge Valve Mtg bracket Purge Valve Mtg bracket
Photograph
Hook Hook
Part Name Frame Assembly Frame Assembly
Part No JC161050 DK161409
Photograph

PART IDENTIFICATION
Photograph
Part Name Gear Change Drum Gear Change Drum
Photograph
Part Name Cap petrol Tank Cap petrol Tank
Part No DK141014 JY171601

PART IDENTIFICATION
Photograph
Part Name Body Centrifugal Oil Filter Body Centrifugal Oil Filter
Description
• With mounting holes for cover fitment • Without mounting holes for cover fitment
Photograph
Part Name Cover Centrifugal Filter Cover Centrifugal Filter
Description • Without Slot • With Slot
• With mounting holes • Without mounting holes

PART IDENTIFICATION
Front Rear Front Rear
Photograph
Part No Front – DK151027, Rear – DK151024 Front – DK151096, Rear – DK151097
Description • Without Black color • Black color disc
Photograph
Part Name Caliper Assembly - Front Caliper Assembly - Front
Part No DK151054 JF131806
Description • Gold color & Split type • Brass Gold color & Integral type

SAI PARTS
6
1 2 7
3
5
4
8
11
9
3
10
Sr. No. Description Sr. No. Description
1 SAI Unit 7 Metal Pipe With Flange SAI
2 Clamp SAI Pipe 8 Hose SAI Unit To Metal Pipe
3 Clamp 9 Gasket Metal Pipe With Flange SAI
4 Clamp Hose SAI 10 Flanged Bolt

5 Tube SAI Air Filter
11 Band Clip SAI Hose Outlet Tube
6 Hose SAI Unit To Manifold

EVAP PARTS
14 13 1
4
8
3 2
15
6 2 2 11
4 16
12
5 4
10
4 17
18
2
7
19
8
Sr. No. Description Sr. No. Description

1 Canister 11 Clamp - Canister Breather
2 Spring Band Clamp 9 x 8.4 12 Tube Canister Breather
3 Tube T Connector To Canister 13 Spring Band Clamp 15 x 10
4 Spring Band Clamp 11.5 X 8.4 14 Tube Canister To Connector
5 Connector For Breather And Vapor Tube 15 Connector Tube EVAP
6 Tube Tank To T Connector 16 Tube Connector To Purge Valve
7 Tube Condensate Fuel Drain 17 Grommet Purge Valve
8 Spring Band Clamp 13 x 12 18 Valve Purge
9 Plug Fuel Drain 19 Tube Purge Valve To Carburetor
10 Tube Canister Drain

MAGNETO ASSEMBLY
REGULATOR UNIT

CAPACITOR
L/W L/W
L/W L/W
R
L/W L/W
378
L/W L/W W
FUSE ASSEMBLY
F1
W W/B
15 A
R B
+ -
Service Support MC
BATTERY - 9Ah
FRONT BRAKE SWITCH
L L
L Br
B/Y B/Y

Brake Lamp Circuit
BRAKE LAMP
L Br
Br Br
L L
379
REAR BRAKE SWITCH
IGNITION SWITCH
ON OFF
W W
Br Br/L FUSE ASSEMBLY

Br 15A F2 Br/L
W 15A F1 W/B
R B
+ -
Service Support MC
BATTERY - 9Ah
IGNITION SWITCH
Horn Circuit
ON OFF FUSE ASSEMBLY

W W
Br 15A F2 Br/L
Br Br/L
W 15A F1 W/B
380
B B/Y
R B
B Br B Br
B B/Y
+ -
HORN SWITCH
(CONTROL SWITCH LH) HORN LH HORN RH BATTERY - 9Ah
Service Support MC
12 V, 10 W 12 V, 10 W
B/Y B/Y Gr Gr
Gr Gr B/Y B/Y

Br O
SPEEDOMETER
Br Br

Gr W
G G 12 V, 10 W
B/Y Gr G G
GROUND PIN11/12
W
BATTERY + VE PIN 20
B/Y B/Y
381
FUSE ASSEMBLY
IGNITION SWITCH
Br 15A F2 Br/L
ON OFF Gr O G
W W
W 15A F1 W/B
Br Br/L
R B
Gr O G
+ -
12 V, 10 W
R OFF L
B/Y B/Y
Service Support MC
FUEL LEVEL GUAGE

Fuel Meter Circuit
B/Y W/Y
B/Y W/Y
SPEEDOMETER
Br Br
W/Y W
FUEL INPUT PIN 5
B/Y W/Y
GROUND PIN 11/12
382
W
BATTERY + VE PIN 20
FUSE ASSEMBLY
Br 15A F2 Br/L
W 15A F1 W/B
IGNITION SWITCH
R B
ON OFF
W W
Br Br/L + -
Service Support MC
BATTERY - 9Ah
SPEEDOMETER
Br Br
O/Br O/Br
SIDE STAND PIN 4
B/Y
GROUND PIN 11/12
W W
BATTERY + VE PIN 20
IGNITION SWITCH FUSE ASSEMBLY
ON OFF Br 15A F2 Br/L

W W
W 15A F1 W/B
383
Br Br/L
B/Y O/Br
R B
B/Y O/Br
GND
+ -
SIDE STAND SWITCH BATTERY - 9Ah
Service Support MC
KILL SWITCH MAGNETO ASSEMBLY H.T. COIL 1 H.T. COIL 2 DC CDI
(CONTROL SWITCH RH) PICKUP
COIL
OFF
ON
LHS RHS
SPARK SPARK

Br/L Gr/R
PLUG PLUG
THERMISTER I/P
H.T. COIL O/P 1
H.T. COIL O/P 2
PICKUP COIL
BATTERY +VE
EARTH
B/Y W/R
B B/Y B/R B/Y

Br/L Gr/R
B/Y
B/R
B/W
W/R
Gr/R
B/Y W/R
Ignition Circuit & Engine RPM Indication
384
SPEEDOMETER
Br 1 Br
IGNITION SUPPLY PIN 2 1
B 5 W
TECHOMETER (ENGINE RPM) PIN 10 5
B/Y 12 B
GROUND PIN 11/12 12
W
BATTERY + VE PIN 20
FUSE ASSEMBLY
Br 15A F2 Br/L
W 15A F1 W/B
R B
B/Y B/W
IGNITION SWITCH
ON OFF + -
W W
Br Br/L
Service Support MC
ENGINE TEMPERATURE SENSOR BATTERY - 9Ah
SPEEDOMETER
Br Br
B/Y W
GROUND PIN 11/12
Br/L Br/R
OIL PRESSURE SENSOR PIN 18
W
BATTERY + VE PIN 20
Low Oil Pressure Indication Circuit
IGNITION SWITCH FUSE ASSEMBLY
ON OFF Br 15A F2 Br/L

W W
W 15A F1 W/B
385
Br Br/L
Br/R
B/Y
R B
+ -
OIL PRESSURE SENSOR BATTERY - 9Ah
Service Support MC
R/W R/W
B/Y B/Y
L/W L/W

SPEEDOMETER
R/W Br
Br W
L/W
VEHICLE SPEED SENSOR PIN 6
B/Y
386
GROUND PIN 11/12
R/W
W
BATTERY + VE PIN 20
L/W
FUSE ASSEMBLY
Br 15A F2 Br/L
W 15A F1 W/B
R B
IGNITION SWITCH
ON OFF
W W
+ -
Br Br/L
Service Support MC
BATTERY - 9Ah
THERMAL SENSOR

B/W
High Oil Temp Indication Circuit
SPEEDOMETER
Br Br
B/Y W
GROUND PIN 11/12
B/W
OIL TEMPERATURE SENSOR PIN 16
W B/W
BATTERY + VE PIN 20
387
FUSE ASSEMBLY
Br 15A F2 Br/L
W 15A F1 W/B
IGNITION SWITCH
ON OFF
W W R B
Br Br/L
+ -
Service Support MC
BATTERY - 9Ah
SPEEDOMETER
Br Gr/R
B/Y W
GROUND PIN 11/12
Gr/R
AIR FILTER SENSOR PIN 19
W Gr/R
BATTERY + VE PIN 20
388
Low Air Pressure Indication (Air Filter Choked Up) Circuit
FUSE ASSEMBLY
Br 15A F2 Br/L
4 3
2 1
W 15A F1 W/B
B/Y
Gr/R
Br
IGNITION SWITCH
ON OFF
W W R B
Br Br/L B/Y
Gr/R
Br
+ -
GROUND
I/P 12 VDC
O/P TO SPEEDO
AIR FILTER SENSOR BATTERY - 9Ah
Service Support MC
OFF
START ON KILL
SWITCH SWITCH

R/Y Br/L Gr/R
LG
Y/G
B/Y
LG
R/L Br/L Gr/R LG
LG
B/Y
Y/G
389
SPEEDOMETER
Br Br FUSE ASSEMBLY
LG LG Br 15A F2 Br/L
B/Y W
GROUND PIN 11/12
W W 15A F1 W/B
BATTERY + VE PIN 20
R/L Y/G
R B
IGNITION SWITCH R/Y B

M + -
ON OFF
W W W/B
Br Br/L R R
Service Support MC
CONTROL SWITCH RH
TAIL LAMP
OFF
ON PO
SPEEDOMETER
Lighting Circuit
B/Y B/Y

Br Br R R
R/B R/B
HIGH BEAM PIN 3
B/Y W Y/L V R B/Y Br/W
GROUND PIN 11/12
R R
BACK LIGHT PIN 13
W
BATTERY + VE PIN 20
NUMBER PLATE LAMP

Y/L Br R Br/W
B/Y B/Y
R R
IGNITION SWITCH
ON OFF
W W
390
Br Br/L
FUSE ASSEMBLY
Br 15A F2 Br/L
Br
R/Y
Y/L
R/B
Br/W
W 15A F1 W/B
2 9 3 6 1
2 9 3 6 1
PILOT LAMP
3W
R B
R/B
HEAD
LAMP PASS
SWITCH LED + -
R/Y
R LO HI
HI / LO
PILOT LAMP SWITCH
Service Support MC
NEW UPDATION
• Oil Pump Screw Tightening
& Loosening Sequence
ON
(AHO related)
391
NEW UPDATION


tank cap lock.

cap

X
1 1
3 3
2 2
1- Tight

NEW UPDATION
AHO - Automatic Headlight ON
New Feature :-
Before After
Light switch No Light switch
position.
Flasher Deleted
High Beam Low Beam
filaments.
module.

PART IDENTIFICATION
Photograph
Part No DS201025 DT402006
Photograph
Part Name Regulator Regulator
Description • ---- • ----

PART IDENTIFICATION
Photograph
Part No DT401404 DT401407
Part Name Wiring Harness Wiring Harness
• Without Light Control Module Connection. • With Light Control Module Connection.
Description
• With Lighting Switch Connection • Without Lighting Switch Connection

12 V, 10 W 12 V, 10 W
B/Y B/Y Gr Gr
Gr Gr B/Y B/Y

B/Y O Br
SPEEDOMETER
Br Br REAR INDICATOR LAMP LH
IGNITION SUPPLY
Gr Gr
12 V, 10 W
RIGHT TURN INDICATOR
G G G G
LEFT TURN INDICATOR
B/Y B/Y
GROUND B/Y B/Y
W W
BATTERY +VE
396
FUSE BOX
F2-10A
ON OFF
Br Br/L
W W Gr O G
W W/B
Br Br/L
F1-15A
IGNITION SWITCH
R B
Gr O G
+ -
12 V, 10 W
R OFF L
B/Y B/Y
Service Support MC
Gr Gr (CONTROL SWITCH LH) BATTERY - 9 Ah
CONTROL REGULATOR UNIT MAGNETO ASSEMBLY LIGHT CONTROL MODULE
SWITCH RH
LED CONTROL
SPEEDOMETER V W

Br Br
IGNITION SUPPLY
R/B R/B
HIGH BEAM L/W L/W
B/Y B/Y Br B/Y Br/W B/Y L/W Br

GROUND
R Br L/W
BACKLIGHT V Br
L/W L/W
W W
BATTERY +VE
Br B/Y Br/W
L/W L/W L/W
L/W L/W
ON OFF
397
W W
FUSE BOX
Br Br/L
F2-10A
IGNITION SWITCH Br Br/L
R/Y Br V R/B Br/W
W W/B
F1-15A
PILOT LAMP
3W
R/Y Br Y/L R/B
R/B R B
HEAD
LAMP
R/Y
+ -
Br LED
LO HI
PILOT LAMP
PASS HI / LO
3W SWITCH SWITCH
Service Support MC
CONTROL SWITCH LH BATTERY - 9 Ah
’
Bajaj Auto Limited

Akurdi Pune 411 035 India
Tel+91 20 27472851
Fax+91 20 27407385
www.bajajauto.com
CIN L65993PN2007PLC130076

26 Manual de Servicios Pulsar 150 y 180 UG

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26 Manual de Servicios Pulsar 150 y 180 UG

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’

Service Station Manual

All information contained in this Note is based on the latest

DOC. NO.: 71110987 REV. 05, AUG. 17

Service Station Dealer

Sr. No. Rev. No. Date (MM/YY) Reason for Change

6 05 Aug. / 2017 SOP for Pulsar 220 BS IV :-

Pulsar RS 200 Service Support - M/C

    

11 Diagnosis & Troubleshooting 247

12 Supplementary Service Station Manual - 249

13 Supplementary Service Station Manual - 285

14 Supplementary Service Station Manual - 324

15 Supplementary Service Station Manual - 360

Pulsar 150/180 DTS-i Dealer Development Center

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