Professional Documents
Culture Documents
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.
Key Learning Points
Testing guidelines
CHAPTER 1
Workshop Safety &
Procedures
Workshop Safety
uu Technicians must always be wearing shoes and
dressed in clothing that is not too loose.
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 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 Electrical Wiring
Ensure that the points and switches are easily
accessible and conduct periodic checks and repairs.
CHAPTER 2
Customized Bajaj Auto Tools /
Special Tools, Equipment & Gadgets
Special Tools (Engine & Frame)
Standard Tools
Other Gadgets
Notes
Standard Tools
Equipment: Equipment:
External and Internal Star Bit Set
Circlip Pliers
Specs / Range:
Specs / Range: Standard size
Equipment: Equipment:
Combination Plier Component Handling
Crate
Specs / Range:
Specs / Range:
Qty Required:
Plastic with partition
CH64120 (2x2)
Qty Required:
One for each bay
Equipment: Equipment:
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
Equipment: Equipment:
Electrician Screw 5 Pcs Phillips Screw Driver
driver Sets
Specs / Range: Specs / Range:
3 mm Flat 861, 862 L, 863
Qty Required: Qty Required:
One for each bay One set for each bay
Equipment: Equipment:
Allen Key set 5 Pcs Screw Driver Sets
Equipment:
T-Handle Box Wrench Equipment:
Spark Plug Cleaner
Spes / Range:
8 mm, 10 mm, 11 mm, Specs:
12 mm 2 Gas
Equipment: Equipment:
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
Equipment: Equipment:
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
Other Gadgets
New D&F Tool
Part No. :
Application : For checking
diagnostic and troubleshooting
codes of EMS.
Notes
CHAPTER 3
Understanding the Bike
Identity
Distinguishing Features
Salient Features
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
Distinguishing Features
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.
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.
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.
Salient Features
Performance
Key Features Advantages Benefits
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
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
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
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?
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
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.
Bajaj Pulsar 200NS FI Training Notes
29
3 Understanding the Bike
CHAPTER 4
Preliminary Checks &
Maintenance Operations
PDI Checklist
Lubrication Matrix
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.
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.
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
20 Steering play C,A C,A C,A C,A C,A C,A C,A C,A
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
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.
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
A
uu Remove:
Drain Bolt - A
Oil Strainer - B
B
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
Note:
The standard oil consumption per 1000
kms is 30 to 80 ml
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
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
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
uu Fit
Washer
Drain bolt.
uu Remove
Coolant from the expansion tank
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.
Note:
Ensure that the vent pipe is routed correctly
Stage 2
450 uu Position pressure gun at a 45 degree angle and at a
distance of 50 mm from paper filter.
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
distance of 50 mm from paper filter.
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
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
Compression Pressure
Details Kg/cm2 PSI Bar
Std 11-13 156.4~185.0 10.78~12.74
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
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.
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
CHAPTER 5
Fuel System & EMS
DTSi – Fi Engine Management Systems / EMS Layout
Working of Systems
Fuel Injection
Regulator connectors Coolant temp. sensor Engine earth Chassis earth Side stand switch
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
Regulator magneto Fuel Fuel level Stepper Regulator Main relay & EMS ECU
connection pump sensor motor Fuel pump relay
TPS
Oil pressure
sensor
CTS
TMAP
Oil
Pressure
CTS
Starter
Motor
Aux. starter
relays 1,2 & 3
Earth chassis
CAN Application
2
AUX Starter Relay 2
Its function is to isolate starter circuit from ECU. If this relay fails engine
1 can not be crank.
Notes
Coolant Fuel
temperature Injector
sensor.
Throttle
position Malfunction
sensor indicator
(TPS)
Diagnostic
Side stand sensor coupler
1 - MPRD (Relay)
P4
P3
4 P2
2 3 P1
6 - Fuel Pump
7 8
10
10 - Diagnostic Coupler
11
11 - Radiator Fan
Construction
Fuel pump module assembly
Fuel Pump
Fuel Strainer
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
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
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.
Construction
It consists of a micro computer A - D Convertor (Analog to Digital) and I - O Unit (Input - Output).
Sensors Actuators
Vehicle Speed Sensor MPRD (Relay)
Analogue to Digital - (A-D)
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.
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.
Notes
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.
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
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
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.
Notes
Working of Systems
Malfunction Indicator Light
List of Diagnostic Trouble Codes
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.
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.
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
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
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.
Bajaj Pulsar 200NS FI Training Notes
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.
uu Remove
2 bolts
uu Remove
Grommet
Slide out accelerator
cable
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.
SOP’s
Injector Removal
Note: Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal.
uu Remove
Injector
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
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.
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).
CHAPTER 6
Engine & Transmission
4 2
Intake Valve
Tappet clearance: 0.05 mm
Exhaust valve
Tappet clearance: 0.08 mm
a b
B
A
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.
Remove
• 4 Bolts (10mm A/F)
Skill Tip : Always loosen cylinder head cover bolts in criss - cross
pattern.
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
• 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.
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.
Remove
• Gasket cylinder block (A)
• 2 Dowels (B)
Oil Filter
Remove
• 2 flanged bolts (8mm A/F) M5 x
16
• ‘O’ ring.
• Cap oil filter.
• Oil filter.
Remove
• Clutch lifter bearing.
Remove
• Special nut for clutch
• Belleville washer
Remove
• Allen bolt (A).
• Gear shift guide (B).
• Spacer (C).
C A
B
LUBRICATION SYSTEM
DISMANTLING
OIL PUMP
Remove
• Circlip (A).
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
• Magneto Cover
Remove
• Starter counter gear 1.
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
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.
uu Put OFF the ignition switch. uu Re-fit air filter cover and petrol tank and start the
engine.
uu Remove uu Remove
Magneto cover Bolt
Gasket Stopper for gear starter clutch
2 dowels
Bajaj Pulsar 200NS FI Training Notes
77
6 Engine & Transmission
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 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
Std. Limit 21.0 ~ 21.2 mm Std. Limit 22.17 ~ 21.57 mm Std. Limit 0.02 mm
Std. Limit 1.6 mm Std. Limit 2.92 ~ 3.08 mm Std. Limit 0.1 mm
Steel Plate Wrap Rocker Arm Shaft Diameter Cam Sprocket Diameter
20 Link Length
Valve Stem Diameter Valve Stem Bend Valve Stem to Guide Clearance
10mm
20mm
40mm
Piston Diameter Piston Ring End Gap Piston Ring Groove Clearance
Std. Limit 11.966 ~ 11.984 mm Std. Limit 12.0 mm Std. Limit 4.55 ~ 4.70 mm
Notes
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
Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 1.0 ~ 1.2 kgm
Stator Plate Mtg. Bolts Eng. Mtg. Rr. Upper/Lower Bolts Clutch Cover Bolts
Tightening torque - 0.7 ~ 0.8 kgm Tightening torque - 2.5 ~ 3.0 kgm Tightening torque - 1.0 ~ 1.2 kgm
Oil Pump Mounting Bolts Coolant Temperature Sensor Magneto Cover Bolts
Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 1.2 ~ 1.4 kgm Tightening torque - 1.0 ~ 1.2 kgm
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
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
Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 1.0 ~ 1.1 kgm Tightening torque - 2.5 ~ 2.7 kgm
LH/RH Engine Stay Lower Bolts Silencer Joining Nut Injector Mounting Bolt
Tightening torque - 2.5 ~ 3.0 kgm Tightening torque - 1.0 ~ 1.1 kgm Tightening torque - 0.8 ~ 1.0 kgm
Oil Pressure Sensor Nut Bal. Driver Gear Mounting Bal. Driven Gear Mounting (Allen)
Tightening torque - 1.1 ~ 1.5 kgm Tightening torque - 5.9 ~ 6.0 kgm Tightening torque - 2.2 ~ 2.5 kgm
Tightening torque - 1.0 ~ 1.2 kgm Tightening torque - 4.4 ~ 4.6 kgm
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.
CHAPTER 7
Frame & Suspension
Service Limits
Tightening Torque
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
19 Link Length
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
Rear Sprocket Mounting Nut Handle Bar Holder Bolts Fork Center Nut
Steering Stem Nut Slotted Fork Upper Bracket Bolts Fork Under Bracket Bolts
RSA Mounting Bolt (Upper) RSA Mounting Bolt (Lower) Disc Mounting Bolts (Front)
Brace Fender Mounting Bolt Rear Brake Pedal Mtg. Bolt Bracket Rear Number Plate
Side Stand Mounting Bolt Handlebar End Weight Bolt Tank Mounting Bolt
Tightening torque
1.6 ~ 1.8 kgm
2 nos
• Take out -
- Spacer tube
- Washer &
- Fork Main spring.
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.
Bajaj Auto International Business
Frame & Suspension
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.
CHAPTER 8
Electricals
VRLA Battery Initial Filling
Seal
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)
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 -
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.
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.
uu SOP :
Pi Y/B R/L
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
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..
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
Measuring & Testing Equipment : Multimeter
+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.
Checking Procedure
Light Control Module (LCM) uu SOP :
Switch ON ignition switch Br
V
1
Set multimeter to 20 VDC.
2
1
Connect multimeter as
V W
PIN4
PIN3
PIN2
PIN1
below. V W
LIGHT_CONTROL_MODULE
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.
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
coupler.
Set multimeter at 200
Ohm range.
Connect multimeter
as shown and note
reading.
Y Y Y
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.
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.
Measuring & Testing Equipment : Multimeter
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
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.
2
connect as shown.
STEEPER_MOTOR
uu SOP : B/Y
Y Y Y
Checking Procedure
Starter Relay Coil R/Y B/Y
1
uu SOP :
Switch OFF engine.
1
Disconnect coupler from Relay.
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
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
32 7 93 1
42 6 110 0
52 5
63 4
73 3
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.
Note:
Capacitor is very important for ECU functioning, so
ensure capacitor coupler is always firmly connected.
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
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.
uu SOP :
Br/G
Switch ON ignition switch and kill switch. Br/G
1 1
Br/G
4 4
Checking Procedure
Coolant Temperature Sensor uu SOP :
Ensure engine is off. Pi/L B/W
1
mm tube spanner.
Connect multimeter as
shown and check resistance
value.
ENGINE_TEMP_SENSOR
uu SOP :
Ensure ignition switch is
OFF.
Remove the harness side
lambda sensor coupler.
Set multimeter on 200 W W Gr B
4
2
4
1
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
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.
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.
Note :
1. No checking method using multimeter is recommended
for checking this unit
2. Checking by replacement method only.
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.
Checking Procedure
Twin H. T. Coil
Measuring & Testing Equipment : Multimeter Primary Winding Resistance Checking
Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
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.
uu Remove
Battery terminal
caps
Battery +ve and
then -ve terminal
Lift out battery
uu Remove
Battery
uu Remove
Disconnect the
coupler
2 Bolts
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
uu Remove uu Remove
Rubber cap Head light
holder
uu Remove uu Remove
Wire clip lock Head light lamp
uu DON’T Short
circuit the
terminal post
uu DO – Use
proper
equipment for
testing
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.
OIL PRESSURE SWITCH CIRCUIT RADIATOR FAN MOTOR CIRCUIT SIDE INDICATOR CIRCUIT
SIDE STAND INDICATOR CIRCUIT TACHOMETER CIRCUIT VEHICLE SPEED SENSOR CIRCUIT
Key Learning Points
CHAPTER 1
Technical Specifications
Pre-delivery Inspection Checklist
Periodic Maintenance & Lubrication Chart
AHO (Automatic Headlamp ON)
ECM Removal & Fitment
Partial BS IV Related Changes
Special Tool
D&T Codes
New Color & Graphics
EVAP - Evaporative Emission System
Evap Circuit (For Fuel Injection)
ABS - Anti Lock Braking System
Technical Specifications
ENGINE & TRANSMISSION
Engine : 4 Stroke, Single Cylinder
Bore : 72.0 mm
Stroke : 49.0 mm
Engine displacement : 199.5 cc
Idling Speed : 1400 + 100 RPM
Max. net power : 24.5 PS (18 KW) @ 9750 RPM
Max. net torque : 18.6 N.m @ 8000 RPM
Ignition System : DC
Spark Plug : 3 nos
Spark Plug Gap : 0.7 ~ 0.9 mm
Lubrication : Wet sump forced Lubrication
Transmission : 6 Speed constant mesh
Gear shifting pattern : 1 Down 5 Up
Engine oil grade : SAE 20W50 API ‘SL’ or JASO ‘MA’)
Drain & Refill quantity : 1200 ml
Overhaul quantity : 1400 ml
Technical Specifications
ELECTRICALS
System : 12 V (DC)
Head Lamp : H4, 55/60W
Position Lamp : 3W (2 nos.)
Tail / Stop Lamp : LED Type
Side Indicator Lamp : 10 W
Neutral Indicator : LED, Green
Hi Beam Indicator : LED, Blue
Turn Signal Indicator : LED, Green
Side Stand Indicator : LED, Green
Speedometer Illumination : LCD, Blue
Fuel Level Indicator : LCD Bar
Low Oil Pressure Indicator : LED, Red
Coolant Temperature Indicator : LED, Red
Low Battery Indicator : LED, Red
Bajaj Logo : LED, Blue
Rear Number Plate Lamp : 3W
Horn : 12V, DC
Battery : 12V - 8Ah VRLA
DIMENSIONS
Length : 2017 mm
Width : 804 mm
Height : 1075 mm
Wheel Base : 1363 mm
Ground Clearance : 169 mm
WEIGHTS ABS
Vehicle Kerb Weight : 154 Kg
Gross Vehicle Weight : 284 Kg
Note :
• Values given above are nominal & for guidance only, 15% variations is allowed to center for production &
measurement.
• All dimensions are under un-laden condition.
• Definitions of terminologies wherever applicable are as per relevant IS / ISO Standards.
• Specifications are subject to change without notice.
PDI Check sheet common for all models (Torque values given for Pulsar RS 200 Partial BS-IV )
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
Oil level between lower & upper mark / Top up if required
Engine oil
(In both wheel touched to ground condition)
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
Coolant cold condition (In both wheel touched to ground condition)
Ensure no leakage
Steering cum Ignition lock, Seat lock, LH side cover lock, Petrol
Lock Operation
tank cap lock.
Terminal voltage 12.8 V DC for VRLA Battery using battery tester
Battery Tightness of battery terminals / cables / Petroleum Jelly
application
Front: 25 PSI (1.75 Kg / cm2 )
Tyre Pressure
Rear (with pillion): 32 PSI (2.25 Kg / cm2 )
Clutch/ throttle cable Free play 2 ~3 mm
Slackness 15 ~ 25 mm
Drive chain Equal marking of chain adjusters on both side
No touching to chain case
Engine foundation bolts
Fasteners (Check torque)
Recommended torque wrench Front mounting bolts – 2.6 ~ 4.5 Kg.m (25.5 ~ 44.1 N.m)
to be used for applying torque Rear mounting bolts – 4.5 Kg.m (44.1 N.m)
on nut -bolts as mentioned in
PDI check sheet using reference Front axle nut – 10.0 Kg.m (98.1 N.m)
torque chart .
However if any major parts Rear axle nut - 10.0 Kg.m (98.1 N.m)
are required to be removed
(Except side cover & seat) for Swing arm shaft nut - 14.0 Kg.m (137.34 N.m)
accessibility of torque wrench ,
in those cases the tightnes s RSA Mounting nut top / bottom nut - 3.2 ~ 3.8 Kg.m (31.4 ~ 37.3 N.m)
can be ensure d using open end Upper bracket / handle holder side bolts – 1.8 ~ 2.2 Kg.m (17.6 ~ 21.5 N.m)
/ ring spanner / bo x typ e
spanne r a s applicable without Front fork under bracket bolts – 2.5 ~ 3.0 Kg.m (24.5 ~ 29.4 N.m)
removing those major parts
Rider footrest bolts – 1.8 ~ 2.2 Kg.m (17.6 ~ 21.5 N.m)
** As applicable to model
*** More frequent cleaning is required while driving in dusty env ironment.
BS III BS IV / EU IV
Ignition Switch - ON Speedometer Lamp, Tail lamp, Parts Changed due to AHO feature
Engine - OFF number plate Lamp, Pilot Lamp Control switch RH Light switch deleted
in headlamp will get “ON”
Wiring harness • No branch for light switch
Ignition Switch - ON Headlamp will get “ON” • Connections for light
Engine - Running as per Low / High beam selector control module.
switch position. Flasher Deleted
High Beam Low Beam
Light control Module New Part added :
• It will sense magneto is
running & will give input for
head light filaments.
• Flasher circuit is inbuilt
in this module.
BS III BS IV / EU IV
ECU Fitment :-
• Ensure that dampers on ECU mounting brackets are in good
condition. Replace if found damaged.
• Ensure that coupler & ECU "Top“ written face should be towards
upside.
Push Press
• Separate fuel pump module & fuel gauge. • Combined fuel pump module & fuel gauge.
• 2 pole coupler. • 4 pole coupler.
Not Applicable
• Without plate fuel pump mounting • Without plate fuel pump mounting.
THROTTLE BODY
• Without evaporate fuel supply pipe. • With evaporate fuel supply pipe.
• Bigger in size. • Smaller in size.
ECU
• Profile is different than Pulsar RS 200 BS IV • Profile is different than Pulsar RS 200
BATTERY CASE
Not Applicable
Not Applicable
Not Applicable
Not Applicable
CAMSHAFT ASSLY
MUFFLER ASSY
CAMSHAFT
• Groove added.
Special Tool
4 Pole to 2 Pole Converter Pigtail
Notes
D&T Codes
- Drivability is affected. -
Short circuit to battery Throttle Position Sensor connections,
Load on engine (In tool, group1,
1 P0123 voltage, short to wiring harness. Replace Throttle body and
entry5 is engine load which is
Sensor/Switch “A” sensor supply +5V check.
equivalent to volumetric
efficiency) is calculated based
on Manifold Air Pressure sensor.
Circuit High
- Drivability is affected. -
Throttle Position Sensor connections,
Short circuit to Load on engine (In tool, group1,
2 P0122 wiring harness. Replace Throttle body and
Ground; open Circuit entry5 is engine load which is
Sensor/Switch “A” check.
equivalent to volumetric
efficiency) is calculated based
on Manifold Air Pressure sensor.
Circuit Low
Idle Air Control
System Intake manifold
3 P0507 Check for intake manifold leakage.
RPM Higher Than leakage
Expected
Limited engine speed
Idle Air Control
System Check for any damage to engine (Damage
Torque loss of engine
4 P0506 inside engine - valve, piston, crank shaft
RPM Lower Than is too high
etc).
Expected
Manifold Short Circuit to battery Deactivation of manifold
Absolute voltage; pressure diagnosis
Pressure/Barome - Cold Start and after
5 P0108 Short Circuit to sensor
tric start is affected.
Pressure Circuit - Altitude adaptation
supply; Open Circuit
High doesn’t happen.
- Secondary Load sensor
Manifold i.e. Throttle Position Sensor is
Absolute used for sensing load.
- Drivability is affected. - Vehicle
running in group injection mode
(In ok case 1 injection happens Temperature Manifold Air Pressure
Pressure/Barome Short Circuit to
6 P0107 in one cycle, but in case of this connections, wiring harness. Replace
tric Ground
error 2 injections happen in one Throttle body and check.
cycle and that is called group
injection).
Pressure Circuit
Low
D&T Codes
Sr. No. P-Code DTC meaning DTC cause Symptoms To Check
HO2S Heater
Control
Short Circuit to battery
14 P0032
voltage
Circuit High Bank 1 - Lambda control activation is
delayed. - Lambda sensor
Sensor 1 signal diagnosis is switched off. Check for lambda sensor connections,
HO2S Heater - Drivability may get affected. replace lambda sensor and check.
Control - Exhaust emissions are affected.
Short Circuit to Ground
15 P0031 Circuit Low
Bank 1
Sensor 1
HO2S Heater
16 P0030 Control Circuit Open Circuit
Bank 1 Sensor 1
Radiator Fan
Short Circuit to battery
17 P0692 Control Circuit High
voltage
Radiator Fan - Fan is not running. - Engine will
Short Circuit to Ground Check for fan connections. Replace fan
18 P0691 Control Circuit heat up and seize and may cause
damage to components. and check.
Low
Radiator Fan
19 P0480 Relay Control Open Circuit
Circuit fault
D&T Codes
Sr. No. P-Code DTC meaning DTC cause Symptoms To Check
O2 Sensor Circuit
Short Circuit to battery - Lambda control is deactivated.
20 P0132 High Voltage
voltage
Bank 1 Sensor 1
O2 Sensor Circuit
Short Circuit to - Drivability could be affected.
21 P0131 Low Voltage Bank
Ground
1 Sensor 1
Heater encoupling to
sensor signal (In
lambda (O2) sensor
Check for lambda sensor connections,
cable there are 4
replace lambda sensor and check.
O2 Sensor Circuit wires. 2 for sensor - Exhaust emissions are affected.
22 P0130
Bank 1 Sensor 1 and 2 for heater. If
heater cable gets
shorted to sensor
cable, then this error
pops up).
O2 Sensor Circuit
No
Open Circuit signal or
23 P0134 Activity Detected
open Circuit Ground
Bank
1 Sensor 1
Malfunction
Indicator
Short Circuit to battery
24 P1605 Lamp (MIL)
voltage
Control
Circuit
Malfunction
Indicator
Short Circuit to Check for MIL connections. Replace
25 P1604 Lamp (MIL)
Ground Speedometer console and check.
Control
Circuit
Malfunction
Indicator
26 P0650 Lamp (MIL) Open Circuit
Control
Circuit
- No fuel pump safety shut-off,
Side stand sensor
Short Circuit to battery ignition cut-off or injection cut-
27 P1504 Short Circuit to Check for side stand sensor
voltage off can happen in case of vehicle
battery
tilted/fall down.
Side stand sensor & roll over sensor connections. Replace
Short Circuit to
28 P1503 Short Circuit to side stand sensor or roll over sensor and
Ground
Ground check.
Side stand sensor
No valid sensor signal
29 P1501 Circuit signal
is present
nonplausible
D&T Codes
Side Stand sensor
Short Circuit to battery
31 P1508
Short Circuit to voltage
battery
Side Stand sensor
Short Circuit to
32 P1507
Short Circuit to Ground
Safety fuel cut-off is active when Check for side stand sensor connections.
Ground
vehicle is not in neutral gear Replace side stand sensor and check.
Side Stand sensor
No valid sensor signal
33 P1505 Circuit signal
is present
nonplausible
Engine Speed
45 P1606 Signal Circuit open Open Circuit
D&T Codes
- No effect on drivability. -
May affect Idle as IACV is closed.
System Voltage Short Circuit to battery
46 P0563 - May damage ECU and
High voltage
other components if voltage is
too high and Voltage remaining Check RR unit connections. Replace RR
high for longer time. unit and check.
- No effect on drivability
System Voltage Short Circuit to but engine may hunt/stop
47 P0562
Low Ground if battery is fully discharged as
ECU will stop functioning.
System Voltage
Battery voltage is Battery voltage is switched to fix
48 P1510 sensing failure in Replace ECU and check.
measured incorrectly value
ECU
Vehicle Speed
Sensor Check for vehicle speed sensor
49 P0501 “A” Open Circuit Vehicle speed not displayed. connections. Replace vehicle speed
Range/Performan sensor and check.
ce
This is related to pin 3 of
ECU which give power to
Coolant Temperature
Sensor Reference Sensor, Manifold Air
Short Circuit to battery
50 P0641 Voltage “A” -
voltage Pressure and Manifold Air Temperature .
Circuit error
Replace ECU and check. Check
connections and replace Coolant
Temperature Sensor, Throttle body and
check.
This is related to pin 27 of
ECU which give power to
Sensor Reference Throttle Position Sensor, roll over sensor,
Short Circuit to
51 P0651 Voltage “B” - side stand sensor. Replace ECU and check.
Ground
Circuit error Check connections and replace Throttle
body, roll over sensor, side stand sensor
and check.
Engine speed limited to lower
Engine Speed RPM.
limited (limp If temp reaches 120°C then
Engine coolant temp Check coolant level, check oil level, check
52 P0217 home mode)due engine is shut down; If temp
overheating functioning of fan.
to engine coolant reduces to 110°C then there is no
temp overheating error anymore and P code is not
active
EVAP System
Short Circuit to battery
53 P0459 Purge control
voltage
valve circuit high
EVAP System
Short Circuit to
54 P0458 Purge control
Ground Check for purge valve connections.
valve circuit low Purging will not happen
Replace purge valve and check.
EVAP System
Purge
55 P0444 control valve Open Circuit
circuit
open
D&T Codes
Sr. No. P-Code DTC meaning DTC cause Symptoms To Check
Temperature
Short Circuit to battery
58 P0655 Warning
voltage
Lamp circuit high
Temperature Overheat indication on Check for connections to temperature
Short Circuit to
59 P0656 Warning Lamp speedometer console will not warning lamp. Replace speedometer
Ground
circuit low function if engine overheats. console and check.
Temperature
60 P0657 Warning Lamp Open Circuit
circuit open
PETROL
TANK
-- -- -- -- --
-- -- --
-- -- -- -- --
-- -- --
Breather
ENGINE
THROTTLE BODY
ASSEMBLY
Drain
PURGE
CANISTER VALVE
Y Y Connector
Drain tube
Y Connector
Plug
Working of EVAP :
1. Petrol vapours from petrol tank reaches canister assembly through Y connector
2. Vapours are absorbed in canister & while engine running vapours are sucked in engine through purge valve (one way
type)
connector to canister )
( canister )
( tube canister to
Purge valve )
( tube connector
to throttle body )
Purge valve
Drain Tube
BS IV / EURO IV UPDATES
ABS Unit
ABS ECU
Wheel
speed
Motor Pump sensor
Control
unit
Solenoid
valve OUT
Reservoir
Gripped Gripped
strongly strongly
(small (small
vibration) vibration)
Solenoid valve IN Brake caliper
Solenoid valve IN
Brake caliper
Wheel
Wheel
speed
speed Motor Pump
Motor
Control sensor
Control sensor
unit
unit
Solenoid
Solenoid valve OUT
valve OUT
Reservoir
Reservoir
Y Y Y
B B
R R Y Y Y
B
B
Y Y Y
BS IV / EURO IV UPDATES
W/B W/B Y Y Y
SPEEDOMETER
Electrical Circuit Diagrams
Gr/R Br
IGNITION SUPPLY PIN 2
B/Y W/B W Br
GROUND PIN 13
W
Battery Charging & Low Battery Indication Circuit
W FUSE O/P
BATTERY +VE PIN 20
30A 7.5 A 7.5 A
MAIN
FUSE
BOX
F1 F2 F6
FUSE I/P
R W/B Br/L
IGNITION SWITCH
ONOFF
Br BR/L
W W/B
R B
+ -
ON
Ignition Circuit
Br/WR/W R/WL/G
B/Y O/W B/R
Ignition Driver 24
B
Power Ground 2 23
B/Y
Pi Y/B R/L
Y/B R/L G/Y
B/Y B O/W
R B
Pi/L Y/W
+ -
Pi Y R
COOLANT TEMP SENSOR H.T. COIL 1 SIDE STAND SWITCH TPS VRLA BATTERY - 8Ah
Horn Circuit
W/B Br
IGNITION SWITCH
FUSE O/P
ONOFF 30A 15A
MAIN
W BR/L FUSE
BOX
F1 F6
Br W/B
FUSE I/P
R Br/L
BS IV / EURO IV UPDATES
B B/Y
R B
Br B
B B/Y
+ -
HORN SWITCH
HORN (CONTROL SWITCH LH) VRLA BATTERY - 8Ah
IGNITION SWITCH
Electrical Circuit Diagrams
FUSE O/P
ONOFF 30A 15A
MAIN
W BR/L FUSE
BOX
F1 F6
Br W/B
FUSE I/P
R Br/L
Tail Lamp
B/Y L
R B
B/Y L
+ -
ON
Gr/R Gr/Pi
Br/G Y/B R/L
Fuel Pump Circuit
BS IV / EURO IV UPDATES
ECU
L/G Br/G W/B R/W O/W Gr/R
IGNITION SWITCH 11 Main Relay Driver Roll Over Switch 39
FUSE O/P
Electrical Circuit Diagrams
W/Br Y/B
14 Fuel Pump Relay Sensor Ground 2 38 30A 15A 15A 7.5A
ONOFF MAIN
Ignition Keys 33
Gr/Pi
Br BR/L FUSE
Sensor Supply 2 27
R/L BOX
F1 F3 F4 F7
W W/B Br/W
Power Supply After Main Relay 25 FUSE I/P
Power Ground 2 23
B/Y R W/B Br/L Br/L
O/L B/Y
R B
+ -
B/Y B/Y
GROUND PIN 13
W W
BATTERY PIN 20 W/B W R/W Br Gr/R
FUSE O/P
30A 7.5A 15A 15A 7.5A
MAIN
FUSE
BOX
F1 F2 F3 F6 F7
ECU FUSE I/P
R/G Y/G R W/B W/B Br/L Br/L
10 Starter Relay Clutch Switch I/P 42
L/G Gr/Pi
11 Main Relay Driver Ignition Keys 33
R/G Br/W
Power Supply After Main Relay 25
LG B/Y
22 Neutral Switch Power Ground 2 23
IGNITION SWITCH
ONOFF
Br BR/L
W W/B
R R/Y B/Y
R B
R/Y B
M + -
R R
STARTER MOTOR STARTER RELAY VRLA BATTERY - 8Ah
KILL SWITCH MAIN RELAY
(CONTROL SWITCH RH)
OFF
ON
Br/L Gr/R
Gr/R Gr/Pi
BS IV / EURO IV UPDATES
SPEEDOMETER
Gr/R Br
IGNITION SUPPLY PIN 2
O/Br O/Br
SIDE STAND INDICATION PIN 4
B/Y B/Y
GROUND PIN 13
W W
BATTERY +VE PIN 20
ECU
Electrical Circuit Diagrams
ONOFF
Br BR/L
W W/B
Pi Y/B R/L
R B
+ -
Pi Y R
ON
Br/L Gr/R
Br/WR/W R/WL/G
Gr/R Gr/Pi
SPEEDOMETER
Radiator Fan Motor Circuit
Gr/R Br
IGNITION SUPPLY PIN 2
B/Y B/Y
Gr/Y R
B/Y B
ECU
BS IV / EURO IV UPDATES
W W/B
W/B W R/W O Br Gr/R
FUSE O/P
30A 7.5A15A 7.5A 7.5A 7.5A
MAIN
FUSE
BOX
F1 F2 F3 F5 F6 F7
FUSE I/P
R W/B W/B W/B Br/L Br/L
R B
Pi/L Y/W
+ -
Br O B/Y
BS IV / EURO IV UPDATES
SPEEDOMETER
Gr/R Br
IGNITION SUPPLY PIN 2
Gr Gr
RIGHT TURN IND PIN 7
G G
LEFT TURN IND PIN 8
B/Y B/Y
GROUND PIN 13
W W
BATTERY +VE PIN 20
Electrical Circuit Diagrams
W/B W Br
FUSE O/P
30A 7.5A 15A
MAIN
FUSE
IGNITION SWITCH BOX
F1 F2 F6
ONOFF FUSE I/P
Br BR/L R W/B Br/L
W W/B
Gr O G
R B
Gr O G
+ -
R OFF L
W/B W Br
FUSE O/P
30A 7.5A 7.5A
IGNITION SWITCH
BS IV / EURO IV UPDATES
ONOFF
Br BR/L
W W/B
W/Y G/W
G/R Pi/R
R B
+ -
ON
ECU
W/R Y/B W/B R/W Gr/R
4 Crankshaft Input (+) Sensor Ground 2 38
Electrical Circuit Diagrams
+ -
ON
Br/L Gr/R
G/B
Br/W
BS IV / EURO IV UPDATES
Pi/L Y/W
+ -
ON
Br/L Gr/R
Gr/R Gr/Pi
MIL Indication Circuit
BS IV / EURO IV UPDATES
SPEEDOMETER
Gr/R Br
IGNITION SUPPLY PIN 2
Br/R Br/R
MIL INDICATION PIN 10
B/Y B/Y
GROUND PIN 13
W W
BATTERY PIN 20
ECU
Electrical Circuit Diagrams
Gr/Pi
Ignition Keys 33
Br/R Br/W
8 MIL Power Supply After Main Relay 25
L/G B/Y
11 Main Relay Driver Power Ground 2 23
IGNITION SWITCH
ONOFF
Br BR/L
W W/B
W/B W R/W Br Gr/R
FUSE O/P
30A7.5A 15A 15A 7.5A
MAIN
FUSE
BOX
F1 F2 F3 F6 F7
FUSE I/P
R W/B W/B Br/L Br/L
R B
+ -
SPEEDOMETER
Gr/R Br
IGNITION SUPPLY PIN 2
B/Y B/Y
GROUND PIN 13
L/R Br/Pi
OIL PRESSURE PIN 19
W W
BATTERY +VE PIN 20
W/B W Br
FUSE O/P
30A 7.5A 7.5A
FUSE I/P
IGNITION SWITCH R W/B Br/L
ONOFF
Br BR/L
W W/B
BS IV / EURO IV UPDATES
Br/Pi
R B
+ -
ON
Br/WR/W R/WL/G
B/Y O/W B/R
SPEEDOMETER ECU
Gr/R Br B/R Br/G
IGNITION SUPPLY PIN 2 2 Ignition Driver 2 Rool Over Switch 39
V/B V/B W/R Y/B W/B W R/W O/W Br Gr/R
ENGINE RPM PIN 12 4 Crankshaft Input (+) Sensor Ground 2 38
Electrical Circuit Diagrams
IGNITION SWITCH
ONOFF
Br BR/L
W W/B
B/Y B O/W
R B
+ -
ON B/Y Y L Gr/G
ABS Circuit
Br/L Gr/R
B W W B
Br/WR/W R/WL/G
W W R/W
Electrical Circuit Diagrams
IGNITION SWITCH
ONOFF
Br BR/L ECU
L/G Gr/Pi
11 Main Relay Driver Ignition Keys 33
W W/B Br/W
W/B W/L Power Supply After Main Relay 25
Power Ground 2 23
B/Y
25A 10A
ABS W/B W R/W Br Gr/R Gr/G
BOX FUSE O/P
F1 F2 30A 7.5A 15A 15A 7.5A 7.5A
MAIN
FUSE
R R/W BOX
F1 F2 F3 F6 F7 F9
FUSE I/P
R W/B W/B Br/L Br/L Br/L
R B
+ -
ON
L Br
Br
MAIN_RELAY
2
1
2
1
3
4
6
5
2
1
3
4
5
4
3
1
2
1
3
4
6
5
2
1
2
1
3
4
L Br Y/R B/Y Br/W Gr/R Gr/Pi B/Y W /R LG Br/W R/W R/W L/G
Lighting Circuit
R/W
R/W
R/W
S P13
BS IV / EURO IV UPDATES
SPEEDOMETER
NC
P I N1
Gr/R Br
IGNI TION_S UPPLY 1
P I N2 1
1
R/B
HI GH_BEAM P I N3
O/BR O/BR
S IDE_STAND P I N4 2 2
W /Y W/Y
FUEL_INPUT P I N5 3 3 4 C r a n k s h a f tI n p u t +
V EHICLE_S PEED_SENSOR P I N6
LG LG
NEUTRAL _INDI CATION P I N11 6
6
B B/V
ENGINE_RPM P I N12 7
7
B/Y G/W
Electrical Circuit Diagrams
GROUND 8 I g n i t i o n K e y 33
P I N13
8
Y/W Pi/R
COOLANT_ TEM P_S ENS OR P I N14 10 10
R R
BACKLIGHT P I N15 Br 9
9
NC P I N17
V SS_48_INPUT P I N18
Br/G Br/Pi
OIL_PRES SURE P I N19 11 11
W W W
BATTERY_POS ITIV E P I N20
12 12
G/R G/R L L L
DIR_IND_FRONT_LH 1 1
ASSEMBLY
HEAD_LAMP_ASSEMBLY Gr Gr Br R R
1 1 1
R/B R/B B/Y 1 B/Y B/Y NUMBER_PLATE
3 3 2
2
G G
2 2
4
LAMP
4
R/B R/B R/Y R/Y
R/B 1 5 5
1
B/Y B/Y B/Y
B/Y B/Y 3
6 6
3
R/Y R/Y 2
R/Y 2
R R
R 4 4
ON O FF
Br Br BR/L
1
1
IGNITION_SWITCH
W W W/B
2
2
W/B W/B
W/B
S P30 R/W
W/B W/B W O/W Br
O
W/B
TO FUS E O/P
2
F U S E _ B O X AS S EM B LY
F2
F3
F6
F7
F8
F9
F5
F4
TO FUS E I/P
Br/L
S P32
BR/L
Br/L
Br/L
Br/L
9
2
3
6
4
5
7
8
1
W/B
W/B
2
1
B B S P33
1
9
2
3
6
5
7
8
1
1
2
B
1
1
2
1
V W O
R/Y Br Y/L R/B Gr G B B/Y Br/W R/Y B
Br B/V O B/Y
R TO_ENGINE_
3
2
4
V W B/Y Br/W R/Y B B CHASSIS GROUND
R/Y Br Y/L R/B Gr O G B
1
1
GROUND
OUTPUT
GROUND
ENGINE RPM
+12V S UP PLY
+12V S UP PLY
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