DTS-Fi TRG NOTE A

Notice Contents
Contents
Chapter 1
A
Know Your Bike
Vehicle Identification
1
B Location of Parts
C Salient Features
D Technical Specifications
E FAQ's (Frequently Asked Questions)
F Read Before ‘U’ Ride
G Evaluate Yourself
All information contained in this Note is based on the latest

Chapter 2
A
Pre-Delivery Care
PDI Check List
15
product information at the time of publication. Bajaj Auto B PDI SOP

C Tightening Torque - Engine
Limited accepts no liability for any inaccuracies or omissions D Tightening Torque - Frame
in this publication, although every possible care has been E Evaluate Yourself
3
taken to make it as complete and accurate as possible. All
procedures and specifications subject to change without Chapter Vehicle Maintenance 25
prior notice. The right is reserved to make such changes at
A Periodic Maintenance & Lubrication
any time without prior notice. B Periodic Service SOP
C Service Wise Part Kit
D Schedule Maintenance
E Standard Checking Procedures
DOC. NO.: 71 1104 33 REV. 00, MAY 07 F Know It On Your Finger Tip
G Evaluate Yourself
Chapter 4
A
Tools & Gadgets
Special Tools
53
B Know It On Your Finger Tip

C Evaluate Yourself
Chapter 5 A
Fuel System
DTS-Fi Engine Management System
61
B EMS Layout
C Working of System
D Fuel Injection - Advantages over Carburetion
E Part Inspection Parameters
F Engine Tune-Up
G Dos & Don'ts
H Know It On Your Finger Tip
I Evaluate Yourself
Pulsar DTS-Fi Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-Fi Training Notes
Contents
6
Chapter
A
B
C
D
E
F
G
Engine & Transmission
Removal of Engine from Frame
Dismantling Engine
Dismantling of Sub Assemblies
Parts Inspection Parameters
Service Data - Engine
Assembling of Sub Assemblies
Assembling Engine
93
Chapter 1 A
Know Your Bike
Vehicle Identification 2
H Know It On Your Finger Tip
I Evaluate Yourself B Location of Parts 2
Chapter 7
A
Frame & Suspension
Service Data - Frame
133
C
D
Salient Features
Technical Specifications
3
B Dismantling & Assembling Front Fork FAQ's (Frequently Asked Questions)

E 9
C Dismantling & Assembling of Front Fairing /
Head Light Assembly
D Dismantling & Assembling of Rear Seat Cover F Read Before ‘U’ Ride 11
/ LED Tail Lamp Assembly
E Parts Inspection Parameters G Evaluate Yourself 14
F Know It On Your Finger Tip
G Evaluate Yourself
Chapter 8
A
Brakes & Wheels
Dismantling & Assembling Rear Disc Brake
147
B Tubeless Tyres
C Parts Inspection Parameters
D Know It On Your Finger Tip
E Evaluate Yourself
Chapter 9
A
Electrical
Maintenance Electrical
169
Key Learning Points
B Parts Inspection Parameters After reading this chapter you should be able to understand..
C Know It On Your Finger Tip
D Evaluate Yourself
• Identification of important parts located on vehicle.
• The technical specifications & the performance parameters.
• How to educate the customer on first ride and inform simple tips on bike
maintenance.
Pulsar DTS-Fi Training Notes Dealer Development Center Dealer Development Center 1 Pulsar DTS-Fi Training Notes
Chapter 1 Know Your Bike Know Your Bike 1 Chapter
A Identification C Salient Features

The Engine & Frame serial numbers are used to
register the vehicles. They are the only means of Performance
identifying your particular vehicle from the other of
the same model & type. These serial numbers
may be needed by your dealer when ordering the
First bike
parts. In the event of theft, the investigating
authorities will require both these numbers in
addition to the model, type & any special features
of your vehicle that can help identification.
in India..... having following Unique Features
• Natural air-cooled 4 stroke engine employing a Oil cooler.
• High capacity bike engine to employ Rollers at the rocker arm
B Location of Parts pivots and camshaft interfaces for low friction.
9 1 2 3
and Other
Features are...
• New gear shifting mechanism for a positive / smooth shift feel with
low friction shift drum.
4 • New, large capacity clutch incorporating anti-judder mechanism for
superior clutch performance in all conditions.
• Highest power to weight ratio of 133 Ps to a tonne.
• All stainless steel exhaust, with a sporty aluminum clad canister.
• High flow intake and exhaust ports.
5 • Large capacity main bearings for transmitting high outputs, reliably.
• Large capacity output shaft bearing to handle high loads.
• Beefed-up transmission to handle the high power and torque
outputs of the engine.
• DTS Fi system is optimised for razor sharp response to throttle
inputs.
• DTS Fi ensures best in class fuel economy, with low variability and
6
least tail pipe emissions.
• New high strength chassis designed to handle the high engine
outputs and making possible precise handling traits with arrow like
straight line stability.
• Bike equipped with a high capacity ‘O’ ring chain for the final drive
- for smooth operation and long life in harsh operating conditions.
8 7
• High output 200 watt, 3 phase magneto.
• DC ignition and lighting quicker engine startups and constant
1. Control Switch RH 5. Sensor for Indicator illumination at any vehicle speed, even standstill conditions.
2. LCD Speedo Console 6. Vehicle Speed Sensor
7. ExhausTEC
• Bike equipped with a low maintenance battery to reduce frequent
3. Control Switch LH
electrolyte topping up.
4. Body Control Unit 8. Oil Cooler
(Placed inside Head Light Fairing) 9. Tail Light LED display
Pulsar DTS-Fi Training Notes 2 Dealer Development Center Dealer Development Center 3 Pulsar DTS-Fi Training Notes
Comfort & Convenience

and Other
First bike Features are...
in India..... having following Unique Features • Swing arm equipped with needle bearings at the pivot, for low
friction and high rigidity, giving excellent vehicle dynamics.
• To have electric start as the sole means of cranking. • Rear end equipped with Nitrox shock absorbers employing
• To employ the widest tyres, front 90/90 x17 & rear 120/80 x17. optimised spring and damper characteristics for all riding
conditions.
• To employ the use of large 37 mm diameter Forks for the front
suspension. • A red malfunction indication lamp in the speedo console gives
the error codes in order to identify any malfunctioning fuel
• To employ a non-contact type speedo drive for accuracy, simplicity injection components.
and long life.
Split seat design for easy access to the tool kit and first aid.
• To incorporate a pinch clamp for the front axle, thus ensuring
smooth, parallel fork sliding action to eliminate fork stiction. • 'Twin - slash' high intensity LED equipped, clear lens tail lamp,
requiring zero maintenance.
• To employ unique illuminated handlebar switches.
• To employ non-contact type of Handlebar switches, for that soft-
touch feel and zero-maintainance.
• To employ non-contact type ‘Intelligent’ self cancelling turn signals.
• To employ a large, free-form orange backlit LCD speedo panel,
displaying among other things the vehicle speed, odometer, 2 trip
loggers, graphic fuel level indicator and other information icons.
• To employ a stepper motor driven tachometer needle for quick
undamped response.
• To have a electronic speedo console, which, when keyed on, goes
through a self-diagnostic check.
• Incorporates a warning light for low fuel level in the speedo console
to draw the attention of the rider.
• To employ a ‘Intelligent’, battery save function which gets enabled
on continuous cranking and limits no of cranks.
• To employ a ‘Intelligent’, battery save function which disables the
headlamp from lighting up (if the headlamp switch is kept ‘ON’) to
divert battery resources for cranking.
• To employ a 'Intelligent' battery save function which disables the
headlamp, after a few seconds, if kept ‘ON’, without the engine
being run.
• To display
a warning icon for low battery voltage
a warning icon for a choked air filter element
a warning icon for low lube oil level
a warning icon for high engine temperature
Safety
and Other
First bike Features are...
in India..... having following Unique Features • Large 260 mm diameter Front disc for precise and progressive
braking.
• To employ the use of 'Tubeless' tyres, for superior performance • Elliptical section swing arm for extra rigidity combined with
and safety. good looks.
• To employ the use of a hydraulically actuated 230 mm diameter • Bike equipped with a Roll-over sensor to cut-off fuel supply in
Rear disc brake. case of a vehicle fall.
• To employ a pure sports style riding position with no compromises. • Sculpted looking Top clamp with pinch bolts for high rigidity.
• To employ clip-on type handle bar and having a unique damping • Sculpted, compact, fairing mounted rear view mirrors with good
method employed in the clip-on handlebars for isolating high rear visibility.
frequency vibrations (patent applied for).
• Sporty, sculpted 2 piece grab for the sleek big bike looks.
• To use a 3000 combination Ignition cum steering lock employing a
twin track, pilfer-proof key. • Crystal finished clear lens blinkers to compliment the bejewelled
clear lens tail lamp.
• To employ 'Black mask', twin headlamps in a vertical stack
configuration. • Aggressive and stylish anti-scratch tank pad to prevent damage
to the petrol tank paintwork due to zippers.
• To employ a high wattage (H7,55 watts) Elipsoidal Projector lamp
for 'White light' Low beam illumination.
• To employ a high wattage (H7,55 watts) compact clear lens
Parabolic lamp for 'White light' High beam illumination.
• To employ 'White light' pilot lamp bulbs.
• To incorporate a 'Day-Night' mode for the Speedo console and the
row of indicating lights including, Turn indicator, Neutral, High beam
and Malfunction indicator. In Day mode, these indicating lights are
brighter, for clear visibility in ambient sunlight. In Night mode these
indicating lights reduce their brightness to prevent glare to the
rider.
• To incorporate a flashing over-rev warning light in the speedo
console.
• To employ a 'Intelligent' safety feature, wherein, if the Low beam
fails it automatically switches over to the High beam and vice
versa.
D Technical Specifications E FAQ's (Frequently Asked Questions)
ENGINE & TRANSMISSION Rims Front : 1.85 x 17 Ï What is the difference between EMS & Fuel Injection?
Type : 4 Stroke, Rear : 2.50 x 17
B EMS stands for Engine Management System. Fuel Injection is a subset of the Engine Management
Natural air cooled Fuel Tank Capacity : 15 liters System. The EMS controls critical operations of various elements of the engine, such as, fuel metering,
No. of Cylinders : One mixture preparation and computation of optimum ignition advance for varying conditions of engine rpm,
CONTROLS load, engine temperature, ambient temperature and ambient pressure.
Bore : 67.00 mm
Steering : Handle bar
Stroke : 62.40 mm Accelerator : Twist grip type on right Ï What is the difference in DTS-Fi as compared to standard Fuel Injection Systems?
Engine Displacement : 220 cc side of handle bar B DTS-Fi stands for Digital Twin Spark Fuel Injection. The ECU of the DTS-Fi can independently compute
Compression Ratio : 9.5 + 0.5 : 1 Gears : Left foot pedal operated and control the ignition advance of each plug in order to give the best fuel economy, highest output and
Idling Speed : 1400 + 100 rpm Clutch : Lever operated on left lowest emissions.
side of handle bar
Maximum Net Power : 20 Ps Brakes Front : Lever operated on right Ï What is Port Fuel Injection and Direct Fuel Injection?
Maximum Net Torque : 19.12 Nm @ 6500 rpm side of handle bar
B Port Fuel Injection, as the name implies, means the Fuel is injected into the intake port. Direct Fuel
Ignition System : Digitally controlled Rear : Pedal operated by right
Injection, as the name implies, means the Fuel is injected directly into the combustion chamber.
through ECU foot.
Fuel : Unleaded petrol Ï What are the advantages of Fuel Injection?
ELECTRICAL
Fuel Feed : Port fuel injection B The advantages of Fuel Injection are :-
System : 12 Volts (D.C.)
Spark Plug : LH Side - 1 No.: Battery : 12V 9Ah • Low variability as a total system.
Champion RG4HCC Head lamp : 55/55 W H7 • High precision in Fuel delivery.
RH Side - 1 No.: Pilot lamp : 2 Nos. 5W each • Optimum usage of Spark timing.
Champion RG6HCC Tail/stop lamp : LED/LED
Turn signal lamp : 10 W • Caters to extreme conditions of hot and cold starting on its own.
Spark Plug Gap : 0.8 to 0.9 mm
Turn signal pilot lamp : LED • Intelligent adjustment of Fuel and Spark timing based on ambient and engine temperature conditions.
Lubrication : Wet sump, Forced
Malfunction indi. lamp : LED
Starting : Electric start only Hi beam indicator lamp : LED Ï What are basic components in a Fuel Injection System?
Clutch : Wet, multidisc type Neutral indicator lamp : LED B Fuel pump, Pressure regulator, Injector, Throttle body, Throttle position sensor, Intake air temperature
Transmission : 5 speed constant mesh Speedometer lamp : LCD Display sensor, Manifold pressure sensor, Engine temperature sensor, Engine rpm sensor and the Electronic
Primary Reduction : 3.47 : 1 (66/19) Rear No. plate Lamp : 5 W control unit.
Horn : 12 V DC
Gear Ratios Ï What is the role of Fuel Pump?
1st Gear : 25.42 : 1 (36/13) DIMENSIONS
2nd Gear : 17.28 : 1 (32/17) B The fuel pump picks up fuel from the fuel tank through the strainer, pressurizes it, for delivery to the
Length : 2035 mm. Injector. The fuel pump is located inside the vehicle fuel tank.
3rd Gear : 12.67 : 1 (29/21)
Width : 750 mm.
4th Gear : 9.94 : 1 (26/24)
Height : 1165 mm. Ï What is the role of the Pressure Regulator?
5th Gear : 8.47 : 1 (24/26)
Wheel base : 1350 mm.
Final Drive Ratio : 2.64 : 1 (37/14) B The Pressure Regulator regulates and maintains a constant line pressure. The pressure regulator is
Turning circle radius : 2500 mm.
integrated with the fuel pump module / assembly.
Ground Clearance : 165 mm. (Min)
CHASSIS & BODY
Ï What is the role of the Injector?
Frame Type : Double cradle type. WEIGHTS
Vehicle kerb weight : 150 Kg. B The Injector is responsible for delivering the fuel, in a spray form, into the intake manifold on the
Suspension Front : Telescopic (Stroke :
Max. total weight : 280 Kg. instructions of the ECU. The injector is mounted on the intake manifold ahead of the throttle body.
130mm)
Rear : Trailing arm with coaxial Ï What is the role of the Throttle Body?
PERFORMANCE
gas assisted hydraulic
Maximum speed : 130 km/h with single B The Throttle Body regulates the flow of air via a butterfly valve into the engine. The throttle body is
shock absorbers & coil
rider (68 kg) located between the air filter and intake manifold.
springs.
Brakes Front & Rear : Hydraulically operated Climbing ability : 28 % (160 Max.)
Ï What is the role of the Throttle Position Sensor?
disc brake
Notes B The Throttle Position Sensor senses the amount of opening or position of the butterfly valve in the throttle
Tyres (Tubeless) Front : 90 x 90 X 17, 49 P body and communicates this information to the ECU. The throttle position sensor is mounted on the left
• Values given above are nominal and for guidance
Rear : 120 / 80 X 17, 61 P only, 15% variation is allowed to cater for production side of the throttle body & is coupled to one end of the butterfly valve shaft.
Tyre Pressure : and measurement variation.
Front (Solo & Pinion) : 2.00 kg/cm2 (28.0 Psi) • All dimensions are under unladen condition. Ï What is the role of the Intake Air Temperature Sensor?
Rear (Solo) : 2.00 kg/cm2 (28.0 Psi) • Definitions of terminologies wherever applicable are B The Intake Air Temperature Sensor measures the temperature of air entering the engine and
Rear (Pillion) : 2.25 kg/cm2 (32.0 Psi) as per relevant IS / ISO standards. communicates this information to the ECU. The intake air temperature sensor is mounted on top of the
• Specifications are subject to change without notice. connecting tube, near the throttle body end.
Ï What is the role of the Manifold Pressure Sensor?

F Read Before ‘U’ Ride
B The Manifold Pressure Sensor measures the pressure variations in the intake manifold and communicates
this information to the ECU. The manifold pressure sensor is integrated in the ECU.
Starting the Bike
Ï What is the role of the Engine Temperature Sensor?
The Engine Temperature Sensor measures the changes in cylinder head temperature and communicates
know
B
this information to the ECU. The engine temperature sensor is threaded onto the cylinder head. yourbike Soft Self Start
Ï What is the role of the Engine RPM Sensor?
B The Engine RPM Sensor measures precise crankshaft rpm and position of the crank at any given instant Function
& communicates this information to the ECU. The timing wheel is incorporated into the rotor & together Digital LCD
Speedo Console • Cranks engine just by feather touch.
with the pick up unit forms the engine rpm sensor mechanism and is located in the magneto cover.
How to Operate
Ï What is the role of the Electronic Control Unit? • Switch ‘ON’ ignition & kill switch. Put vehicle into
Function
B The Electronic Control Unit is the brain of the entire fuel injection system. It digests information sent by To show display & neutral or declutch if in gear.
various sensors and determines fueling and spark timing to be delivered, for all unique conditions, analogue display of..... • Press self start button.
instantly. The ECU contains detailed information of the engine’s characteristics, from which it picks the • Warning Indicators : A digital display through icons of Do not open throttle (accelerator) while starting. Once
necessary data for commanding fueling and spark timing, Quantitatively and Qualitatively. The ECU is key maintenance factors - engine starts do not rev up engine while vehicle is parked
located behind the air filter. on the stand.
1. Air filter needs cleaning Benefits
Ï Why is there a hum from the petrol tank whenever the Ignition Key is turned to ‘ON’ position?
• Comfort.
B This hum is the initial priming noise of the fuel pump. • Hassle free starting.
2. Engine over heating & rise
Ï What does the icon on the RH side of the High beam icon indicate? in engine oil temperature
B The icon represents a System Malfunction which is in Red color.

3. Drop in battery voltage + Protection Against Over Cranking
Ï When does this red malfunction icon, light up?
Function
B This red malfunction icon lights up during initial Ignition Key ‘ON’ and stays on till the engine is cranked 4. Drop in engine oil level
On starting the engine by self starter button, if engine
up and made to idle. Whenever the engine shuts off or if there is any malfunction in the system this red doesn’t start & starter button is operated for more than 3
light remains continuously ‘ON’. • Tachometer : A analogue display tachometer showing
times at one go, then, the power supply to starter motor is
0~12 x 1000 rpm display for understanding the engine
disabled & would be possible to crank only after a lapse of
Ï What is the meaning of the red light located in the Tachometer region remaining continuously ‘ON’? rpm.
20 seconds or you switch ‘OFF’ & then ‘ON’ the ignition
B This means that the fuel level is low and one should immediately fill fuel at the nearest fuel pump to • Engine RPM Limiter : A red colour LED bulb starts key.
blinking when the engine rpm reaches to 10500 rpm
prevent dry running of the pump and cavitation of the system. Benefits
cautioning the rider crossing safety zone (However
engine rpm curtails above 10500). • Protects starter motor.
Ï What is the meaning of the red light located in the Tachometer region flashing ON & OFF? • Safe guards battery from getting drained.
• Fuel Gauge : A vertical 12 bar equally segmented
B This ‘ON’ & ‘OFF’ flashing of the red light indicates engine rpm exceeding 9000 rpm & is a warning light. graphical indicator indicates fuel level inside the fuel • Enhances battery life.
tank.
Ï What do the 4 icons at the topmost portion of the Speedometer Display?
• Low Fuel Level Indicator : A red colour LED bulb will
B The 4 icons displays :- glow continuously when the fuel level drops below 3.5 Malfunction Indicator Lamp
1. The 1st icon from the left indicates a Choked Air Filter Element, when displayed. liters thus reminding the rider for refueling.
2. The 2nd icon from left indicates a High Oil Temperature, when displayed. • Easy to read Digital Speedo Display showing
3. The 3rd icon from left indicates Low Battery Voltage, when displayed. - Vehicle speed - Km/Hr. Function
- Odometer - Kms covered. • It gives indication signal about
4. The 4th icon from left indicates Low Engine Oil Level, when displayed. - Resetting trip meter - for recording distance covered error in Engine Management
in trip with resetting provision. System (EMS).
Ï Why is there a small movement in each of the Clip-on handlebars?
• Various Indicator Lamps Showing : Side indicators,
B The Clip-on handlebars are rubber mounted which create the small movement. Neutral position, High beam ‘ON’ & Side stand ‘ON’ How to Operate
indicator functioning. • This operates automatically as & when the error
Ï Why is there no Kick starter provision? is generated & is seen when ignition is ‘ON’.
• Malfunction Indicator Lamp : A red colour LED will
B All sporty large displacement motorcycles do not use kick-starters for the reason that the rider’s footrest glow continuously when there is any error occurred in • Visual Signal :
comes in the way of kick operation, necessitating folding of the footrest etc. As the Electric Start System the EMS. Red lamp in speedometer will glow, this is an
is of an advanced nature, starting the bike even if the battery is dead can be done by the push-start indication that EMS has an error.
method. How to Operate
• Put ‘ON’ ignition key. All 4 icons on top will pop-up & Immediately take vehicle to a BAL Service Station.
Ï How will the engine start if the battery is completely dead? will vanish away automatically. All other will show
static display until the vehicle moves on road. Benefits
B The system has been designed such that even at low rotor rotations, when push starting / bump starting, • Other displays are dynamic which functions individually • Great safety.
enough energy to enable and start the Fuel Injection System is generated. for respective applications. • Arrest consequential damages arising.
Benefits • Do not switch ‘ON’ & ‘OFF’ ignition switch un- Tyre Pressure Front : 2.00 kg/cm2 (28 Psi)
Head Light necessarily as head light operates on battery.
Effective lubrication helps to deliver the higher engine Rear Solo : 2.00 kg/cm2 (28 Psi)
performance under every possible load condition. • Get your battery checked / charged during periodic
Feature services. Rear Pillion : 2.25 kg/cm2 (32 Psi)
• Car type DC head light.
Tubeless Tyre • Follow only recommended puncture repair procedure
Advantage Monsoon Care for removing puncture.
• Better illumination of light. • As far as possible use tyre mounting machine for tyre
Advantage fitting & removal of tyre from rim to avoid damage to
Benefits Tubeless Tyre do not deflate suddenly in case of Fit and Finish Parts
• No voltage fluctuation resulting into brighter alloy wheels.
puncture & helps in reducing unsprung mass. Less rolling • It is suggested to take proper care in heavy monsoon
illumination throughout the ride. resistance ensures complete road stability. / high rainfall area. The appropriate surface preventive
• Low chances of bulb failure. coat is to be applied to avoid rusting / poor surface
Benefits finish on account of adverse atmospheric conditions.
Oil Cooler
• High stability. • Clean and lubricate all the important parts as detailed
• Ease of puncture repair. Can be done by self. in a Periodic Chart given in O&M.
Side Indicator What Additional Care should I Take?
• Less maintenance. • Do not obstruct engine & engine oil cooler by adding
Engine Oil : Check every week
protection sheet from front otherwise engine cooling
Feature system gets affected. • Park the vehicle on level surface on center stand to
• Car type self cancelling indicators. check the oil level.
Advantage ride • Always maintain engine oil
yourbike level between the upper UPPER

• No manual operation for putting ‘OFF’ the indicators. Tubeless Tyre LEVEL
After completing the turn when the rider positions & lower level.
• Replace the oil in accordance
handle bar straight ahead the indicators are put ‘OFF’ Puncture Repair Method (Filler Type) LOWER
automatically. with Periodic Maintenance LEVEL
Fuel Saving Tips Tools & Material Used : Chart.
Benefits • Drive in economy zone i.e. driving at a constant speed Repairing Tool (Wrench) - Used for
• Convenience & comfort. @ 40~50 kmph in top gear. placing or piercing the repair compound Wrench
• Avoid following :- in place perfectly. Recommended Oil Grade and Qty
- Sudden pick-up & frequent braking. Repair Compound - Used for filling the
Disc Brakes - Needless & excessive idling. puncture. It forms bond with the tyre Grade SAE 20W50 of API ‘SG / SJ’ + JASO ‘MA’
- Excessive high speed riding. compound after application. grade or superior.
Feature • Check & Refill tyre pressure once in a week.
Solution - Adhesive used for applying Quantity Drain & Refill 1200 ml.
Hydraulic disc brakes. • Fill petrol at reputed petrol pumps.
the filler material (Few compounds come Needle Wrench
• Use only branded fuel. Engine Overhaul 1300 ml.
with self adhesive material also).
Advantage
Most efficient & safe braking. Safe Riding Tips Blades - Used for trimming the extra
• Always wear an ISI std. helmet while driving. compound above puncture surface, Filler
Check For
Benefits • Never use mobile phones while driving. outside the tyre. • Any leakage in oil cooler pipe.
• Stopping of vehicle at the desired destination with • Always keep rear view mirrors clean.
• Displaying of icons for low engine oil level / engine
minimum effort. • Use both, front and rear disc brakes simultaneously. Process : over heating.
• Safely controlling the vehicle speed. Applying only one brake may cause loss of control &
skidding or diving. Wrench
• Do not apply front brake when cornering or at turns. Step 1 : Identify the puncture hole and
Battery • Familiarise yourself well with seating posture, starting, Pierce the wrench.
acceleration & braking of the vehicle. Repair Compound in Tyre
• Use side indicators before turning.
Feature Step 2 : Pierce the repair compound
• Fuel pump inside the tank is lubricated & cooled by
• Low maintenance battery. into the puncture hole with needle type
the fuel. Hence always maintain minimum 3 liter of
wrench & pull out the wrench.
Advantage fuel in fuel tank.
Cut Excess Compound
• No frequent charging. No frequent top up.
Step 3 : Cut the excess compound with
Benefits blade.
• Low maintenance cost.
care
Oil Cooler
yourbike Care and Maintenance of Tyre
• Ensure correct tyre pressure.
• Rim should be free from dirt, rust and should not
Feature have any dents.
Oil cooled engine system Battery • Clean the tyre & rim interiors before placing the tyre
through forced lubrication on rim.
in addition to normal natural air cooling. • Lubricate tyre beads with mild soap solution before
How to Keep Battery Healthy
Advantage assembling & removing the tyre from rim.
• Switch ‘OFF’ ign. when eng. is not running.
Optimum engine cooling & maintains lubricating oil • Do not press brake pedal / brake lever while running
viscosity even at higher temperature and extreme stress otherwise brake light would glow continuously & drain
for optimum performance. the battery.
Chapter 1 Know Your Bike
2
G Evaluate Yourself
Evaluate yourself
1. The chassis no is located on RH side of the steering tube and has -
Chapter Pre-Delivery Care
a. 16 Digits b. 17 Digits c. 11 Digits
2. Maximum net power for Pulsar DTS Fi is A PDI Check List 16
a. 20 PS b. 18.0 PS c. 16.51 PS
B PDI SOP 18
3. The Rear tyre size of Pulsar DTS Fi is
a. 90 X 90 X 17, 49 P b. 12 / 80 X 17, 61 P c. 120 / 80 X 17, 49 P
C Tightening Torque - Engine 20
4. The spark plug fitted on RH side of Engine is -
a. RG4HCC b. RG4HC c. RG6HCC
D Tightening Torque - Frame 22
5. EMS stands for -
a. Engine management system b. Engine modular system c. Engine maintenance system E Evaluate Yourself 24
6. Following are not basic components of fuel injection system -
a. Fuel pump, Pressure Regulator, Injector, Throttle body, Sensors, Engine Control Unit
b. Oil pump, Pressure Regulator, Injector, Throttle body, Sensors, Engine Control Unit
c. All above are incorrect
7. In Speedo Console the icon on the RH side of the high beam indicates -
a. System Malfunction b. Side stand ON c. Hi-beam ON
8. Speedometer display has 4 icons which displays -
a. • Use Ist from Left indicates low engine oil level.
• Use IInd from left indicates low battery voltage.
• Use IIIrd from left indicates a high oil temperature.
• Use IVth from left indicates a checked air filter element.
b. • Use Ist from left indicates a chocked Air filter element.
• Use IInd from left indicates high oil temperature.
• Use IIIrd from left indicates low battery voltage.
• Use IVth from left indicates low engine oil level.
9. Max net torque for Pulsar DTS Fi is -
a. 17.17 Nm @ 6500 rpm b. 19.12 Nm @ 6500 rpm c. 15.22 Nm @ 6000 rpm
10. During PDI it recommended to check the fuel cock operation for-Hard/ Leakage -
a. True b. False
Key Leaning Points
After reading this chapter you should be able to understand..
11. The fuel pump is located inside the petrol tank
a. True b. False • The standard procedure to be followed during Pre-Delivery Inspection of new
12. The fuel gauge is located inside the Speedo console
vehicle & filling up the PDI check list.
a. True b. False • Important tightening torque applications with loctite recommendation.
13. Pulsar DTS Fi has a Port Injection System
• Standard time required for attending the PDI jobs & PDI productivity.
a. True b. False
14. Pulsar DTS Fi is a oil cooled Engine • Important specifications to be remembers during PDI.
a. True b. False
15. The handle bas used on Pulsar DTS Fi is named as
a. Clip on handle bar b. Split type handle bar c. All are correct
Chapter 2 Pre Delivery Care Pre Delivery Care 2 Chapter
A PDI Check List SL CHECK POINTS FOR PDI Check PDI done by BAL/ Service Advisor PDI Done by dealer
15 LOOSE PARTS
ENGINE MOUNTING BOLT
SL CHECK POINTS FOR PDI Check PDI done by BAL/ Service Advisor PDI Done by dealer
16 ENGINE NOISE
1 LOCK OPERATION
TAPPET NOISE
STEERING LOCK NOT WORKING / JAM / STICK
CHAIN TENSIONER / TIMING CHAIN
SIDE COVER LOCK NOT WORKING
17 ENGINE OIL LEAKAGE
SEAT LOCKS FRONT AND REAR
DRAIN BOLT
2 PAINT FINISH - OVER FLOW (Samples / photographs)
MAGNETO COVER
3 FUEL TANK DEFECTS
LEAKAGE CRANKCASE JOINT
BLISTER FORMATION OIL FILLING PLUG
RUSTY TAPPET COVER
OTHERS (Specify) BANJO BOLT

CHAIN TENSIONER 'O' RING
4 FRONT / REAR WHEEL OFFSET OIL LEVEL INSPECTION WINDOW
5 WHEEL OIL COOLER BANJO BOLTS JOINTS
FR. WHEEL TYRE FREE ROTATION OIL PRESSURE SWITCH
FRONT WHEEL RUNOUT (SPECIFY) OIL TEMPERATURE SENSOR
REAR WHEEL RUN OUT (SPECIFY) 18 CLUTCH OPERATION
6 SILENCER - BAFFLE NOISE, HEAT SHIELD, WIRE SHIELD LOOSE EASY OPERATION
7 SWITCHES 19 PLATING DEFECTS IF ANY
RH SWITCH OPERATIONS 20 ENGINE OPENING DURING PDI (If any)
LH SWITCH OPERATIONS (Give engine no & reason for engine opening)
IGNITION SWITCH OPERATION 21 FRAME OPENING DURING PDI (If any)
8 LIGHTS:- (Give chassis no & reason for chassis opening)
SIDE INDICATOR 22 OTHER DEFECTS :
HEAD LIGHT
TAIL/BRAKE LED MINOR ADJUSTMENTS
9 HORN:- DISTORTED / WEAK SOUND (DO NOT SET) 23 TRANSIT DAMAGES (Send photographs )
10 SPEEDO:- [ Mark in check column for the point found ok
Speedo sensing # Mention about FFR / EER
Speedo flicking needle
Trip meter 1/2 working - Resetting
Auto calibration of RPM meter
Fuel level indication
Reserve indication (by red lamp)
Red lamp blinking after crossing engine RPM 9000
Auto-switch off of indi. lamps (H'bar straight for > 2 sec.)
Head light / tail light illumination after 3 seconds
LED functioning - Speedo unit - Both side indication, Side
stand, Neutral, Hi-beam, Reserve indicator lamp
11 FLAT SPOT (GIVE CO %)
12 DRIVE CHAIN SLACK (MENTION AMONT OF PLAY)
13 BRAKE OPERATION - FRONT / REAR
FRONT BRAKE
REAR BRAKE EFFECTIVENESS
BRAKE LIGHT REMAINING ‘ON’ CONTINUOUSLY
14 GAP AT THE REED SWITCH AND MAGNETO
B PDI SOP Sr. Description

No.
Position SMM GP Tools
Special
Tools
PNR & its
Attachment
Consumables
M & T / Service
Shop Equipments
Ring spanner
Sr. Description Special PNR & its M & T / Service 22 Fit saree guard LH 0.85 set, 8mm
Position SMM GP Tools Consumables Shop Equipments
No. Tools Attachment Allen key
1 Identify & Park vehicle on bay. 0.60 Lifter Bay 23 Check all important nut-bolts for
torque and tightness,
Remove the Thermocol and
2 0.50 a. Handle bar mounting bolt
additional packing if any.
b. Stem under & upper bkt. bolts
Open Petrol tank cap Funnel, Petrol,
3 RH / LH 0.50 c. Stem of bolts Spanner set,
& pour petrol. Measuring jar Cotton waste
d. Front axle nut Tommy bar,
Funnel, Screw driver, Dial type
Check & top up engine oil level Engine oil, e. Cylinder head nuts RH / LH 4.00
4 RH 0.30 Nose plier, Plier, Nylon torque wrench
if required. Cloth f. Engine foundation bolts hammer,
Measuring jar
g. Trailing arm bolts Socket set
OE spanner h. Silencer cover shield bolts
Check clutch cable operation &
5 RH 0.10 set & -ve i. LH/RH engine mounting bolts
adjust if required.
Screw driver
24 Check the following and lubricate
Check accelerator cable free play OE spanner if necessary
6 RH 0.05
set
a. Rear brake pedal / cam
Check front brakes for efficient Plier, +ve Screw b. Pillion foot rest Oil 20W40,
working & adjust if required FRONT driver, Ring Suction pump RH / LH Cloth,
7 0.50 Brake oil c. Center stand
(Top up brake fluid, if required) RH spanner set FRONT 1.00 Oil can Multi-
d. Side stand & REAR -purpose
Check & correct tyre inflation Pencil type Pedaled e. Kick lever boss grease
8 pressure - Front wheel FRONT 0.20 pressure gauge air pump
f. Clutch lever
Check for operational noise of 25 Check electrical couplers of
9 fuel pump RH / LH 0.10
all sensors
Inspect rear shock absorber Ring spanner a. Engine temperature (Cyl. head)
10 setting and correct if necessary RH / LH 0.10 set b. Oil temperature (LH Crankcase)
c. Air filter clogged (Air Filter) RH / LH 0.35 Nose plier
Check rear brakes for efficient Plier, +ve
REAR Screw driver, d. Vehicle roll over (Below air filter)
11 working & adjust if required. 0.50 Brake oil
RH Ring spanner e. TPS (On throttle body)
(Top up brake fluid, if required)
set
Check working of all
26 RH / LH 0.40
Pencil electrical switches
Check and correct tyre inflation Pedaled
12 REAR 0.20 type pressure
pressure - Rear wheel air pump Start vehicle, check operation
gauge
of electricals like -
OE accessories fitment - Ring spanner Head light, Tail light, Brake light,
13 Leg guard RH 1.10
set 27 Side stand indicator, Horn, RH / LH 0.70
Speedometer, Odometer,
14 OE accessories fitment - Mirrors RH RH 0.50 6mm Allen key Side indicators, Parking and
Pass light, Malfunction indicators
Check battery voltage. Electrolyte, & Fuel indicator
OE spanner Multimeter,
Fill / Top-up electrolyte. Apply Petroleum
15 LH 0.60 set, Screw Hydrometer,
petroleum jelly. Connect jelly, Cotton Check & Correct working of
driver Charger
terminals properly. waste 28 all meters like - RH / LH 0.50
RPM, Speedometer & Trip
Ring spanner
set, OE Check all locks for proper
spanner set, Oil operation like - Steering lock,
Lubricate chain and Check/Adjust 29 RH / LH 1.30
16 LH 0.40 Tommy bar, 20W90, Both side cover locks, Seat lock,
chain slackness if required.
Nylon hammer, Cloth Petrol tank lock etc.
Comb. plier
Test drive the vehicle, Check digital
Check gear shifter lever OE speedometer working. Study the
17 operation LH 0.80 spanner set 30 1.30
job card and verify work done.
Take vehicle out and park.
6mm Allen
Check & Adjust steering and FRONT key, Ring Clean and Wash the vehicle
18 0.20 31 1.00
handle bar for free movement RH / LH spanner set before delivery.
Ring spanner Repair for any other defects seen

Check front mudguard alignment 32
19 FRONT 0.05 or observed during test drive.
w.r.t. front wheel set
20 OE accessories fitment - Mirrors LH LH 0.50 6mm Allen key TOTAL TIME 20.50
OE accessories fitment - Ring

21
Leg guard
LH 1.10
spanner set
As per SOP PDI Time : 20.50 minutes per Vehicle Productivity : 23 Vehicles / 8 Hours / Technician
Clutch Nut (LH Threads) Cylinder Head Cover Bolts Cylinder Head Cover Nuts
C Tightening Torque - Engine
Cyl. Head Bkt. Mtg. Bolts Engine Mounting Bolts Engine Mounting Nuts
7.0 Kg.m 1.0 ~ 1.2 Kg.m 4.0 Kg.m
Camshaft Spckt. Allen Bolt Starter Motor Mtg. Bolts Rotor Mounting Bolt
M8: 2.2 Kg.m M8: 2.2Kg.m M10: 2.4Kg.m M8: 2.2Kg.m M10: 2.4Kg.m
Chain Tensioner Mtg. Bolts Output Sprocket Bolts Silencer Mounting Bolt
1.4 Kg.m (Loctite 243) 1.1 Kg.m 4.5 Kg.m
Oil Cooler Banjo Bolts Spark Plug (2 Nos.) EOT Sensor Bolt
1.1 Kg.m 1.1 Kg.m (Loctite 243) 3.5 ~ 4.0 Kg.m
Silencer Mounting Nuts Balancer Gear Cover Bolts Crankcase Joining Bolt
1.6 ~ 1.8 Kg.m 1.4 Kg.m 1.0 ~ 1.2 Kg.m
ET Sensor Bolt Injector Mounting Bolt Oil Cooler Bracket Bolt

1.4 ~ 1.9 Kg.m 1.0 ~ 1.1 Kg.m (Loctite 243) 1.2 Kg.m (Loctite 243)
Crankcase Joining Bolts Crankcase Joining Bolt Clutch Cover Bolts
1.2 ~ 1.4 Kg.m 0.8 ~ 1.0 Kg.m 0.8 ~ 1.0 Kg.m
Oil Pressure Switch Bolt

1.1 Kg.m (Loctite 243) 1.1 Kg.m (Loctite 243) 1.1 Kg.m
Oil Pump Mounting Bolts Centrifugal Oil Filter Nut Rotor Cover Bolts
1.2 ~ 1.5 Kg.m
1.1 Kg.m (Loctite 243) 7.0 Kg.m 1.1 Kg.m
Oil Cooler Pipe Bolts Oil Pressure Sensor Fork Pinch Bolt
D Tightening Torque - Frame
Front Axle Nut Rear Axle Nut Rear Sprocket Mtg. Nut
1.0 ~ 1.2 Kg.m 1.2 ~ 1.5 Kg.m 2.0 ~ 2.2 Kg.m
4.0 ~ 5.0 Kg.m 8.0 ~ 10.0 Kg.m 1.8 ~ 2.5 Kg.m (Loctite 243)
Handle Bar Holder Bolts Steering Top Cap Bolt Stg. Stem Nut (Slotted) Notes :
2.0 ~ 2.2 Kg.m 3.5 Kg.m 0.5 Kg.m
Upper Clamp Allen Bolt Lower Clamp Bolt RSA Mounting Dome Nut
1.8 ~ 2.0 Kg.m 2.5 ~ 3.5 Kg.m 3.5 ~ 4.0 Kg.m
Swing Arm Pivot Nut FR. Caliper Install Bolts FR. Brake Disc Allen Bolts
8.0 ~ 10.0 Kg.m 2.2 ~ 2.8 Kg.m (Loctite 243) 0.9 ~ 1.1 Kg.m (Loctite 243)
FR. Brake Banjo Bolt Caliper RR. Caliper Install Bolts RR. Banjo Bolt Caliper
2.2 ~ 2.8 Kg.m 2.2 ~ 2.8 Kg.m (Loctite 243) 2.2 ~ 2.8 Kg.m
Chapter 2 Pre Delivery Care
3
E Evaluate Yourself
Evaluate yourself
1. The recommend oil grade for Pulsar DTS Fi is -
Chapter Vehicle Maintenance
a. SEA 20W50 of API “SJ” + JASO ‘MA’ b. SAE 20W50 of API “SG’ / ‘SJ” + JASO ‘MA’
C. SAE 20W50 of API “SG” + JASO ‘MA’ A Periodic Maintenance & Lubrication 26
2. What is the recommended oil qty for Pulsar DTS Fi-
a. 1200 ml for Drain & Refill; 1300 ml for Engine overhaul B Periodic Service SOP 28
b. 1250 ml for Drain & Refill; 1350 ml for Engine overhaul
c. All above are incorrect C Service Wise Part Kit 31
3. Following in the reshuffled / mismatched torque specification and torque application. You are advised to
match the following by putting appropriate Sr. No. in front of the respective empty block. D Schedule Maintenance 33
TORQUE VALUES Match the Sequence

E Standard Checking Procedures 43
Sr. No. Description Torque Value Sr. No.
1 CYL. HEAD BKT. MTG. BOLTS A 1.1 Kg.m 1
F Know It On Your Finger Tip 51
2 ENGINE MOUNTING BOLTS B 1.2 Kg.m (Loctite 243) 2
3 ENGINE MOUNTING NUTS C 1.1 Kg.m (Loctite 243) 3
G Evaluate Yourself 52
4 CHAIN TENSIONER MTG. BOLTS D 4.5 Kg.m 4
5 OUTPUT SPROCKET BOLTS E 1.1 Kg.m (Loctite 243) 5
6 SILENCER MOUNTING BOLT F 1.0 ~ 1.2 Kg.m 6
7 SILENCER MOUNTING NUTS G 1.4 Kg.m (Loctite 243) 7
8 BALANCER GEAR COVER BOLTS H 1.0 ~ 1.1 Kg.m (Loctite 243) 8
9 CRANKCASE JOINING BOLT I M8: 2.2 Kg.m M10: 2.4 Kg.m 9
10 CRANKCASE JOINING BOLTS J M8: 2.2 Kg.m M10: 2.4 Kg.m 10
11 CRANKCASE JOINING BOLT K 4.0 Kg.m 11
12 CLUTCH COVER BOLTS L 6.5 Kg.m 12
13 OIL PUMP MOUNTING BOLTS M 1.6 ~ 1.8 Kg.m 13
14 CENTRIFUGAL OIL FILTER NUT N 5.5 Kg.m 14
15 ROTOR COVER BOLTS O M8: 2.2 Kg.m 15
16
17
CLUTCH NUT (LH THREADS)
CYLINDER HEAD COVER BOLTS
P
Q
1.1 Kg.m
1.0 ~ 1.2 Kg.m
16
17
Key Leaning Points
18 CYLINDER HEAD COVER NUTS R 1.1 Kg.m (Loctite 243) 18 After reading this chapter you should be able to understand..
CAMSHAFT SPROCKET ALLEN BOLT
19 S 1.4 ~ 1.9 Kg.m 19
• Nature of jobs to be attended under maintenance & standard operation
STARTER MOTOR MOUNTING BOLTS
20 T 1.1 Kg.m 20
procedure for various jobs.
21 ROTOR MOUNTING BOLT U 1.1 Kg.m 21
22 OIL COOLER BANJO BOLTS V 1.1 Kg.m (Loctite 243) 22 • Importance of schedule maintenance & how to carry out schedule
23 SPARK PLUGS (2 NOS.) W 1.4 Kg.m 23 maintenance.
24 EOT SENSOR BOLT X 1.0 ~ 1.2 Kg.m 24 • Standard checking procedure for inspecting the various components.
25 ET SENSOR BOLT Y 1.2 ~ 1.4 Kg.m 25
26 INJECTOR MOUNTING BOLT Z 0.8 ~ 1.0 Kg.m 26
Chapter 3 Vehicle Maintenance Vehicle Maintenance 3 Chapter
A Periodic Maintenance & Lubrication Chart Whichever RECOMMENDED FREQUENCY

comes first
Sr. Initial Subsequent
Operation
Whichever RECOMMENDED FREQUENCY No. Kms. 750 2,500 5,000 7,500 Every 2,500km
comes first OR
Sr. Initial Subsequent Days 30~45 105~120 195~210 285~300 Every 90 days
Operation
No. Kms. 750 2,500 5,000 7,500 Every 2,500km 27. General lubrication L l l l l l
OR
Days 30~45 105~120 195~210 285~300 Every 90 days
28. Steering stem bearing L,R 1 year Every 10000 kms
1. Servicing l l l l l
29. Wheel bearing C,L 1 year Every 10000 kms
2. Idle speed / CO% C,A l l Every 5000 kms
30. Master cylinder cup and Dust seal R Every 2 years
3. Valve tappet clearance A l Every 5000 kms
31. Caliper piston seal and Dust seal R Every 2 years
4. Engine oil (SAE 20W50 of API SG / SJ + JASO MA) R l l Every 5000 kms
32. Swing arm pivot pin L l Every 5000 kms.
5. Oil strainer / Centrifugal filter CL Every 10000 kms
33. Front fork C,L l l l
6. Air cleaner element V CL l l l l l
34. Front fork oil R Every 10000 kms
7. Air cleaner element R Every 10000 kms
35. Front brake hose C,R 2 years
8. Fuel Injector C Every 10000 kms
36. Check gas pressure 7.0 + 0.5 Kg/cm2 Every 10000 kms
9. Fuel system leakages C,R l l l l l
37. Drive chain L Every 500 kms.
10. Fuel pipes R Every Year
38. Drive chain slack n A l Every 1000 kms.
11. Spark plug / gap CL,A l l l l l
39. Drive chain wear. Remove & lubricate C,R l Every 5000 kms.
12. Spark plugs (2 Nos.) R Every 30000 kms
40. Engine compression pressure C Every 10000 kms
13. Battery electrolyte level (Only if required) C,A l l l l Every Year
41. Cylinder head de-carbonising &
14. Brake light switch C,A l l l l l Valve lapping CL Every 30000 kms
15. Oil cooler pipes C,R l l l l l 42. Valve oil seals R Every 30000 kms
16. High pressure fuel filter C,R l l l l l 43. Rear brake hose C,R Every 2 years
17. Clutch play C,A l l l l l 44. Lubrication of Gear starter switch L Every 500 kms.
18. Throttle play C,A l l l l l
19. Rear brake pedal play C,A l l l l l l : Indicates operation to be performed.
20. Brake lining or pad wear C,R l l l l l « : More frequent cleaning may be required when driving in dusty condition & if the warning sign on
speedo console starts flashing.
21. Brake fluid level / top up (Front & Rear) C 1 Month l l l l l n : More frequent adjustment may be required if riding conditions are severe.
22. Brake fluid change R Every 10,000 kms or Once in a Year A - Adjust • CL - Clean • C - Check • L - Lubricate • T - Tighten • R - Replace
Note : Parts / Lubricants to be replaced as per Periodic Maintenance & Lubrication Chart are mandatory
23. Steering play C,A l l l l l
and the same are chargeable to customer.
24. All fasteners tightness C,T l l l l l
25. Engine mounting silent blocks R Every 20,000 kms
26. Tyre tread wear C,R l l l l
B Periodic Service SOP Position Position

of Tech. of Tech. M & T / Service
Sr. Description Sp. PNR & its
w.r.t. w.r.t. SMM GP Tools PNR Consumables Shop Equipments
No. Tools Attachment
Vehicle Vehicle
Position Position LH RH
Sr. Description Sp. PNR & its 6" Comb. Pistol
w.r.t. w.r.t. SMM GP Tools PNR Consumables Shop Equipments Clean oil strainer. (Replace Measuring jar
No. Tools Attachment pliers, Ring grip, Oil 20W50,
Vehicle Vehicle 16 if required) After 1 year or RH 1 liter,
LH RH spanner Socket Cloth
10000km whichever is later Oil dispenser
set, Funnel set
Washing
1 Wash vehicle thoroughly.
boy Check clutch and OE spanner
17 RH 0.30
adjust clutch lever play set
2 Identify the vehicle. 0.30
Ring Oil disposer,
Bring vehicle and 18 Fill engine oil (1200 ml) RH 1.35 spanner set, Cloth
3 position on bay. 0.50 Air gun
Plier
4 Raise the lift. 0.30 Clean, Check & adjust Spark plug Air gun,
Pistol
19 RH Spark Plug RH 2.40 spanner, Cloth Plug cleaner,
Pistol grip
Start vehicle and Warm up. (Replace - if required) Wire brush Filler gauge
Remove RH/LH side covers grip
5 LH RH 1.70 PNR Check / Adjust front brake Ring spanner
Front & Rear seats,
Petrol tank & keep properly Socket 20 & wheel freeness (Top up FRONT 1.50 set & +ve
set brake fluid, if required) screw driver
Socket Oil disposer, Check / Adjust front tyre Pencil type
6 Drain engine oil. LH 1.30 21 FRONT 0.40 Air gun
set Air gun air pressure pressure gauge
Pistol Pistol
Clean air filter. grip Cloth, Ring spanner grip,
7 RH 2.60 PNR 20W50 oil, Filter cleaning 22 Check & adjust steering RH 0.80
(Replace - if necessary) set, Socket
Socket Diesel set
set
Check RH side important
Check accelerator & adjust OE spanner fasteners and tight
8 RH 0.40
set
a. Engine foundation bolts
Clean, Check & adjust Spark plug Pistol Filler gauge, b. Front axle nut
9 LH Spark Plug LH 2.40 spanner, grip Air gun, Pistol
(Replace - if necessary) Plug cleaner c. Side bolts of Front fork OE spanner
Wire brush PNR grip,
23 d. Handle bar bolts RH 1.20 set, Ring
spanner set Socket
Check & adjust tappet Spark plug Pistol e. RSA top & bottom nuts set
clearance. (if required) spanner, grip
LH, Tappet Filler gauge f. Swing arm axle nut
10 During 4 th Servicing or 2.40 Ring PNR
REAR holder
after 5000 Km whichever Socket g. Silencer protective cover
spanner set
is later. set screws / bolts
h. Rear view mirror
Check LH side important
fasteners and tight Pistol Lubricate as per
OE
a. Side bolts of front fork spanner set, grip lubrication schedule
11 LH 0.60 Ring PNR
b. Engine foundation bolts a. Clutch lever 20W50 oil,
spanner set Socket
c. Side stand set Graphite,
24 b. Rear brake pedal LH RH 0.80 Oil can
d. RSA top & bottom nuts Grease,
c. Pillion foot rest Cloth
Pistol Cloth, d. Center stand
OE
Adjust chain slackness & grip 20W50 oil, e. Side stand
REAR spanner set, Chain
12 Lubricate. Remove and 3.90 PNR Diesel,
LH Ring cleaning stand
clean, If required. Socket Air filter Pistol
spanner set
set element grip,
Refit RH, LH side covers,
25 Seats, Petrol tank assly. LH 2.80 PNR
Check Rear brakes for Plier, -ve Socket
efficient working & adjust screw driver, set
13 RH 0.50 Brake oil Suction pump
if required (Top up brake Ring
fluid, if required) spanner set Check and clean
26 LH RH 0.50 Air gun
petrol tank lid.
Check and Adjust REAR Pencil type
14 0.40 Air gun
rear tyre air pressure RH pressure gauge Check electrical couplers
of all sensors
Check Battery, top up with
distilled water (Only if reqd). Electrolyte, a. Engine temperature
Multimeter,
Clean terminals & apply OE spanner, Petroleum 27 b. Oil temperature LH 0.35
15 RH 1.80 Hydrometer,
petroleum jelly. Rout cables Screw driver jelly, Cotton Battery charger c. Air filter clogged
properly & fit terminal caps waste
properly. Recharge battery d. Vehicle roll over
if required. e. TPS
Position Position
C Service Wise Part Kit
Sr. Description Sp. PNR & its
w.r.t. w.r.t. SMM GP Tools PNR Consumables Shop Equipments
No. Tools Attachment
Vehicle Vehicle
LH RH
Periodic Part Replacement Kit for Free & Paid Services
Check RPM Meter,
Speedometer, Odometer & Type of Service Days Kms. Limit Part Name Quantity
28 Trip meter for proper FRONT 0.50
functioning and correct, Engine oil 1200 ml.
if required.
1st Free 30~45 500~750
Clutch cover gasket 1
Start vehicle, Check 2nd Free 105~120 2000~2500 NIL NIL
operation of electricals like-
a. Check all electrical LH RH 3rd Free 195~210 4500~5000 Engine oil 1200 ml.
switches
1st Paid 285~300 7000~7500 NIL NIL
b. Head light. FRONT
Philips
c. Tail light. REAR screw driver, Engine oil 1200 ml.
Pistol
d. Brake light. RH/Rr Ring grip, Clutch cover gasket
29 0.95 1
e. Horn FRONT spanner set, Socket
Combination set Air filter foam element 1
f. Speedometer, Odometer, plier
Pass, Parking light FRONT
Spark plug 2
g. Side indicators
LH RH
Front & Rear both sides Fork oil 320 ml.
h. Malfunction indicator
2nd Paid 375~390 9500~10000 Drive chain lock & link set 1
i. Fuel indicator
High pressure fuel filter 1
Study job card & 0.5 0.50
30 verify work Starter clutch bush 1
31 Lower the lift. 0.30 Fork oil seal 2
32 Take out & park the vehicle 0.50 Cylinder head gasket (If required) 1
Sub Total 16.05 15.80 Front disc pad inspect / replace (If worn out) 2 + 2
Carry out any additional 3rd Paid 465~480 12000~12500 NIL NIL
33 work as indicated by the 5.0 5.0
customer or as required. Engine oil 1200 ml.
Total Time 21.05 20.8 4th Free 555~570 14500~15000 Drive chain lock & link set 1
Test drive the vehicle, check Steering cone kit 1
To be
digital speedometer working.
34 1.5 done by 4th Paid 615~630 17000~17500 NIL NIL
Study the job card and
expert
verify work done.
Engine oil 1200 ml.
To be
Clean the vehicle at the done by Clutch cover gasket 1
35 time of delivery. 1.0 delivery
boy
Air filter foam element 1
Spark plug 2
Total time taken for carrying out Periodic Service is approximately 42.0 minutes
5th Paid 705~720 19500~20000 Front disc pad inspect / replace (If worn out) 2 + 2
As per Periodic Service SOP Time : 42.0 minutes per Vehicle Fork oil 320 ml.
• Productivity : 11 Vehicles / 8 Hours / Technician • Productivity : 23 Vehicles / 8 Hours / 1 Bay, 2 Technician Clutch plate 1
Rear brake damper 1
Drive chain lock & link set 1
6th Paid 795~810 22000~22500 NIL NIL
Throttle body insulator 1
7th Paid 885~900 24500~25000
Chain sprocket kit 1
Periodic Part Replacement Kit for Free & Paid Services D Schedule Maintenance
Type of Service Days Kms. Limit Part Name Quantity
8th Paid 975~990 27000~27500 NIL NIL Periodic Maintenance :
Engine oil 1200 ml. Cleaning : The vehicle must be cleaned periodically using pressurized water. Before
Clutch cover gasket 1
cleaning the vehicle cover the important parts like Ignition switch, Silencer Tail end,
and H.T. coil with plastic bags. Don’t apply the jet of water directly on electrical
Air filter foam element 1 parts such as Switches, ECU, Ignition unit, Coils etc. otherwise they may get
Spark plug 2 damaged.
Valve oil kit 1 Brushing with kerosene and wiping dry with clean rag is advisable for external
cleaning of the engine. All painted surfaces should be washed with water. Do not
9th Paid 1065~1080 29500~30000 Cylinder head gasket 1
use kerosene or hard detergent soap on painted surfaces as it damages the paint
Cylinder head stud copper plated steel washer 4 and turns it dull.
Front disc pad inspect / replace (If worn out) 2 + 2 After washing, dry the vehicle carefully with low compressed air taking all
Steering cone kit 1 precautions similar to cleaning with pressurised water and carry out the lubrication
as recommended
Fork oil 320 ml.
Drive chain lock & link set 1 Periodic Maintenance :
Periodic maintenance (in accordance with the periodic maintenance chart) of a
Use always Genuine Bajaj Auto parts & recommended lubricants.
vehicle is most important to prolong vehicle life, trouble free running and ensure
(Engine oil: SAE 20W50 API ‘SG / SJ’ + JASO ‘MA’ grade)
your safety while driving.
Engine Oil Level Checking :

Notes : Upper Level
Lower Level
• Park the vehicle on level surface on center stand to check the oil level.
• Inspect the oil level through oil inspection window
• It should be in between upper and lower mark
• Top up if required
Recommended oil Grade & Qty SAE 20W50 of API ‘SG / SJ’ + JASO ‘MA’
Drain & Refill 1200 ml
Recommended Quantity
Engine Overhaul 1300 ml
Note :
It is most vital to adhere to recommended frequency of oil change for the purpose of
long life of critical engine components for details refer Periodic Maintenance Chart.
Oil Strainer Cleaning :

Remove :
• Drain engine oil.
A • Clutch cover
• Oil cooler banjo bolts & gaskets
• Oil pump mounting bolts (A) (3 Nos)
• Pump with strainer.
B
• Clip (B) and take out ‘Oil Strainer’ from oil pump.
Remove : Air Filter Cleaning :

• Clean oil strainer with Kerosene / Diesel and carefully blow low compressed Clean Air filter element adhering to standard SOP
air and then refit it.
• Replace oil strainer if found damaged. Ist Stage: IIIrd Stage:
Clean with Dip into engine oil

kerosene (20W50)
Centrifugal Oil Filter Cleaning :
Remove :
A • Centrifugal oil filter cover mounting screws (A)
• The cover with gasket
• Replace gasket if damaged
• Clean centrifugal oil filter using Nylon brush / Squeeze & remove
Squeeze
kerosene or Diesel excess oil
Air Filter :
Air Cleaner Element Removal : IInd Stage :
Remove :
• RH side panel by unlocking it with key Clean with Dry with lint free
kerosene again cotton cloth
Remove :
• 2 bolts (A)
A B • Air filter cover (B).
Blow low pressure

compressed air
Remove :
• Air filter element assembly along with cartridge
• Separate foam filter from the cartridge Air Filter Element Cleaning and Inspection :
Note :
In dusty areas, the element should be cleaned more frequently than the recommended interval. After riding
Note : through rain or on muddy roads, the element should be cleaned immediately. Since repeated cleaning opens the
pores of the foam element replace it with a new one in accordance with the Periodic Maintenance Chart. Also
• No need of removing flame arrester if there is a breakage in the element material or any other damage to the element replace the element with a
• White colour filter portion fitting towards throttle body side new one.
• Ensure rubber ‘O’ ring placed properly when fitting cover
Clean the element in a well-ventilated area, and make sure that there are no sparks or flames
anywhere near the working area. Because of the danger of highly flammable liquid, do not
Warning
use gasoline/petrol or a low-flash point solvent to clean the element.
Spark Plug : Position 1 2 3 4 5

Spring Action Stronger
Spark Plug Electrode Gap Replace Spark Plug
LH Side - Champion RG4HCC If the Shock Absorber sleeves on both sides are not adjusted to the same
0.8 mm ~ 0.9 mm After every 30000 Kms position, an unsafe riding condition may result.
RH Side - Champion RG6HCC
Note :
Battery - 12V - 9 Ah : Std setting is done in 2nd notch
• Battery is located inside LH cover
• Check the electrolyte level in each cell & ensure that the level is between the Nitrox Air Filling :
upper and lower level lines. Procedure for gas checking and Refilling
• Remove the battery filler caps and fill with distilled water until the electrolyte • Remove the Phillips-headed small screw and ‘O’ ring.
level in each cell reaches the upper level line if required.
• Clamp the cylindrical guide clamp on to the canister keeping the rubber plug
Note : in the center to support the syringe needle insertion and keeping in position.
Add only distilled water to the battery. Tap water is not a substitute for distilled • Hold the pump as shown and pierce the syringe needle into the center of
water and will shorten the life of the battery. rubber plug.
• The molded needle adaptor will rest into the clamped cylindrical guide
Front Brake Fluid Level : • Read the gas pressure on the dial gauge. If the gas pressure is below 6.5
• Front brake fluid master cylinder reservoir is located near RH switch on Kg/cm2 refill the air by pumping, keeping the needle in as it is condition
handle bar. without removal. As the natural air consists of 71% of nitrogen it will serve
the purpose.
• To check oil level, park the vehicle on Main / Center stand with handle bar in
straight position. • To fill the air into the canister, apply full stroke of pump as shown; otherwise
air will not get inflated into the pump.
• Keep on pumping the air unless you get 7.5 kg/cm2 on the gauge
Rear Brake Fluid Level :
• Rear brake fluid master cylinder is located on side below the Rider seat. • Pull out the air pump along with needle carefully and take out the guide
clamp
Max • To check oil level, park the vehicle on main stand.
• Always ensure that brake fluid level is above ‘MIN’ mark given on inspection • Finally fix the phillips headed screw with ‘O’ ring.
Min
container.
• Use only DOT-4 brake fluid (from sealed container) to top up if required. Drive Chain Slack / Lubrication :
• Rear brake fluid container is located below the rider seat.
• Set the motorcycle upon its center stand.
• To check oil level, park the vehicle on main stand.
Note : • Rotate the rear wheel to find the position where the chain is tightest and
It is advisable that the entire brake fluid should be replaced once in a year or every measure the vertical movement midway between the sprockets.
10000 ksm. • If the drive chain is too tight or too loose, adjust it so that the chain slack will
be within the standard value.
Rear Shock Absorber: • Check drive chain slackness at every 1000 kms.
The rear shock absorbers can be adjusted to one of five positions to suit riding
Drive Chain Slack / Lubrication
conditions. Using special tool adjust the required position you desire. They can be
left soft for average road riding condition but should be adjusted harder for rough Drive chain slackness Service Limit
road condition.
15 ~ 25 mm 30 ~ 40 mm
Shock Absorbers adjusted either too soft or too hard adversely affect riding
comfort and stability.
To adjust the Rear Shock Absorbers
Turn the adjusting sleeve on each shock absorber to the desired position. The
higher the adjuster sleeve is positioned, the stronger the spring tension, and the
harder the ride.
Check to see that both sleeves are turned to the same relative position.
Drive Chain Cleaning / Lubrication : Important Adjustment and Checking Procedure :

1st Stage: Idling speed adjustment :
• Warm up the vehicle
Clean with SAE 90 Oil
• Switch OFF the Ignition key and remove the pillion seat
• Connect the Diagnostic Tool coupler to the matching coupler (this coupler has
a rubber cap) provided in the wiring harness, properly
2nd Stage: • Switch ON the Ignition key of the vehicle to power the Diagnostic Tool
Clean with SAE 90 Oil again • Connect the CO pipe of the CO Analyser to the nozzle provided near
from a different tray ExhausTEC (Remove the bolt and washer) The CO Analyser should have
been warmed up properly prior to usage.
• Start the engine and let it Idle
• Punch in the relevant password and go to the Idle rpm adjust mode
• To enter into this mode the engine temperature (displayed as T_Oil Physical)
Blow Low Compressed Air should be greater than 800 C
• With the Diagnostic Tool attached, the Idling rpm rises in this mode, which is
normal
• Warm up the engine to a temperature of 930 C (T_Oil Physical). Unless this
3rd Stage: temperature is achieved one should not proceed further
Dip into SAE 90 Oil • After having achieved the temperature of 930 C, check the idling rpm
• The idling rpm should be between 1550 ~ 1600 (displayed on the Diagnostic
Tool screen)
• Adjust the Shipping Air screw at the bottom of the Throttle body to achieve
this rpm (Turn Out the screw for increasing rpm and Turn In the screw for
decreasing rpm)
• Note down the value of adjustment i.e. no of turns (could be 1/8th, 1/16th or
½ etc also)
Soak into SAE 90 Oil
• Go to the CO adjust mode
• The idle rpm will drop down (which is normal)
• Note the CO as displayed by the CO Analyser
Final Stage: • If the CO% is low, increase it by pressing on the Rich (UP) key, repeatedly
Hook Chain for and keep a note of the no of times the key is pressed.
dripping of excess oil • If the CO% is high, decrease it by pressing on the Lean (DOWN) key,
repeatedly and keep a note of the no of times the key is pressed.
• Exit the CO Adjust/Idle rpm check mode.
• Confirm the Idling rpm to be 1450+100 and Idling CO% to be 2+0.5%
Tyre Air Pressure : • Exit the Diagnostic Tool menu
Keep appropriate tyre pressure as mentioned below to increase life of this tyre and • Switch OFF the Ignition key
for better fuel consumption. • Remove the Diagnostic Tool coupler and assemble the rubber cap on the
coupler of the wiring harness
Tyre Air Pressure • Place this coupler in its intended location.
Front Rear (with Solo) Rear (with Pillion) • Fit the Pillion seat
2.00 Kg/cm2 2.00 Kg/cm2 2.25 Kg/cm2 • Remove the CO pipe and refit the bolt and washer of the nozzle at
(28 PSI) (28 PSI) (32 PSI) ExhausTEC.
• Take a Test ride and confirm Drive ability.
Tappet Clearance Setting : Front and Rear Brake Free Play Adjustment :
• Ensure that the engine is cold. There is no need for free play adjustment, since the pistons in caliper assembly will
• Ensure the ‘T’ mark on the ‘Rotor’ match with the mark on the ‘Crankcase move towards the pads and take new positions in order to automatically
LH’. At this stage the ‘Piston’ is at TDC and both the ‘Tappets’ are free. compensate for pad wear. The free play will be approximately 2 ~ 3 mm / 5~7 mm
• Holding tappet screw firmly with special tool loosen the tappet screwnut.
Front Brake Lever Play - 2 ~ 3 mm
• Put the feeler gauge, measure and adjust the clearance.
Rear Brake Lever Play - 5 ~ 7 mm
• Lock the nut holding screw with special tool after getting desired clearance.
• Again check the tappet clearance with gauge. The
gauge should slide with slight resistance between
Rear Brake Pedal Position Adjustment :
tappet and valve stem head feeler and tighten the A To suit rider foot comfort / operating style the angle of the rear brake pedal can be
check nut with a spanner. adjusted by loosening the lock nut (A) and adjusting the bolt (B).
Inlet Valve Exhaust Valve Ensure free play by turning the adjuster clockwise or anticlockwise to achieve
B specified free play. Fix the rubber sleeve on the bolt.
0.1 mm 0.05 mm
Special Tools
Rear Brake Light Switch Adjustment :
Feeler Gauge P. No. Valve adjusting screw holder P. No.
When either the front or rear brake is applied, the brake light glows on. The front
69 7502 51 37 1031 53 brake light switch requires no adjustment but the rear brake light switch should be
adjusted in accordance with the periodic maintenance chart.
B A Clutch Lever Free Play Adjustment : To be done only when engine is cold
Inspection :
• Slide the dust cover at lever yoke end. • Turn on the ignition switch. The brake light should go on wheel the front
• Check that the clutch cable outer end is fully seated in the adjuster. brake is applied.
• Turn the adjuster (A) until the proper amount of free play can be obtained. • If it does not, then inspect the front brake light switch.
A • Tighten the lock nut (B) against the adjuster. If the clutch free play cannot be • Check the operation of the rear brake light switch by depressing the brake
A
adjusted with the adjuster at the handle bar end, use the adjuster at the pedal. The brake light should glow after about 5 mm of pedal travel.
lower ends of the clutch cable situated on clutch cover.
• If it does not, adjust the rear brake light switch (A)
• Loosen the 2 lock nuts (C) on clutch cable bracket and adjust threading in
the adjuster provided on the clutch cover. Tighten both the lock nuts on Adjustment :
C
clutch cable bracket by holding one nut and tightening the other, after the • Adjust the rear brake light switch (A) by rotating the switch nut to create
required free play. adequate tension in spring to operate the switch.
Clutch Lever Free Play - 2 ~ 3 mm
B Tie Rod Adjustment :

Accelerator Free Play Adjustment : • Lubricate the ball joints
D
• Turn the adjuster (A) until the proper amount of free C
• Adjust the Tie rod nut (A) and (B) to achieve desired position of gear pedal
play can be obtained. position.
• Tighten the lock nut (B) against the adjuster. A
B A • If the accelerator free play can not be adjusted with

the adjuster at the handle bar end, use the adjuster
at the lower ends of the accelerator cable situated Petrol Filter :
on carburettor.
• Remove the petrol tank
• Loosen the 2 lock nuts (C) on accelerator cable
bracket end adjust by adjuster (D) provided on the • Disconnect the fuel pipe clips
cable. • Remove the high pressure strainer
• Tighten both the lock nuts on bracket by holding one Note :
nut & tightening the other, after ensuring the required
free play. Replace at every 5000 kms
Accelerator Grip Free Play - 2 ~ 3 mm
Throttle Body : E Standard Checking Procedure

• Remove throttle body from vehicle
• Cover the air passage on either side of throttle blade with self adhesive good Compression Pressure Testing :
quality tap.
— For testing the compression pressure first warm up the engine.
• Clean the accumulated soot / carbon deposited towards intake manifold and
— Remove the spark plug. LH side.
engine side with a lint free cloth dipped in petrol.
Note :
CAUTION
i. The soot formation / deposition at the interface of
throttle blade and blade matching bore is desired, Disconnect H. T. lead cable from second spark plug i.e. RH side.
hence should not be cleaned or wiped OFF
ii. Clean at every 20,000 km • Fit the compression gauge with adapter in the Spark plug hole.
• Open the throttle fully and crank the engine
Fuel Pipe and Manifold Pressure Sensor Pipe • Note the reading with the compression gauge.
• Remove the petrol tank • Release the pressure by pressing the release valve on hose pipe.
• Remove the high pressure filter. • Take average of 3 such readings for noting actual compression pressure.
• Check that the rubber pipes have not hardened • Confirm the compression pressure is between 11 to 13 Kg/cm2
Note : Wet Compression Test :
Replace the rubber pipe at every 30,000 Kms • If the compression pressure is found below lower limit than specified, put few
drops of engine oil through the spark plug hole and again check compression
Injector pressure.
• Clean the injector - Cleaning solvent (2 % of Petrol Plus) to be added in the • If you find considerable increase this time, then cause for the low
fuel tank and engine to be run. This needs to be done even after a long compression pressure lies in Cylinder / Piston assembly.
period of non running of vehicle also. • If compression pressure remains the same, then the cause for low
Note : compression pressure lies in Cylinder / Head assembly.
Cleaning at every 10,000 kms.

CAUTION
Oil Cooler If wet compression test is done, remove second spark plug and clean
• During regular engine oil replenish, ensure that the oil from oil cooler is also thoroughly to avoid oil fouling before fitment.
drained by removing the cover RH inner and outer banjo. Drain the oil in
slightly warm condition to ensure a quick and complete drain. After internal Chain Slack Adjustment :
servicing and assembling back the cover RH (Clutch Cover). Replace the
• Set the motorcycle upon its centre stand.
connections keeping the outer banjo slightly loose before filling the oil. New
copper washers needs to be used every time the banjo is opened. Fill • Rotate the rear wheel to find the position where the chain is tightest and
1200ml oil in engine. Run the engine and prime the cooler till slight seepage measure the vertical movement midway between the sprockets.
is seen from the banjo on crankcase LH. Tighten the Banjo thereafter. • If the drive chain is too tight or too loose, adjust it so that the chain slack
will be within the standard value i.e. 15-25 mm.
Note :
C • Loosen the axle nut (C)
Fill 1200 ml of oil in the engine. (Drain & refil) B B
• Loosen the left and right chain adjuster lock nuts
(B)
Starter Clutch and Rollers • If the chain is too tight, back out the left and right
• Remove the rotor assly from magneto cover chain adjusting nuts evenly and kick the wheel
E
forward until the chain is too loose.
• Clean the rollers and running track of starter clutch with a clean cloth and
lubricate the rollers and the track by lightly smearing SAE 20W50 oil. • Turn both chain adjusting nuts evenly until the drive
chain has the correct amount of slack. To keep the
Note : chain and wheel properly aligned, the notch (E) on
Clean and Lubricate at every 5000 kms. the left chain adjuster should align with the same
swing arm mark that the right chain adjuster notch Nitrox Air Filling :
(E) aligns with.
• Remove the Phillips head screw and small ‘O’ ring fitted on air valve of Nitrox
• Tighten both chain adjuster lock nuts RSA.
• Tighten the axle nut
• Fix the guide to canister of Nitrox shocker in such a way that guide hole is
• Tighten the axle nut concentric with air filling valve.
Note :
• Insert the Nitrox air filling pumps needle end into the guide and carefully pierce
Also visually check whether the front wheel & rear wheel are in the rubber pin fitted inside the air valve of Nitrox RSA.
alignment by viewing the vehicle ridden by someone at low
speed and handlebar kept straight. • Note the pressure indicated by pressure gauge of Nitrox air pump. Refill the
pressure.
• Once the pressure reaches upto 7.5 Kg/cm2, take out the needle slowly from
canister.
Misalignment of the wheel will result in abnormal chain wear, and may
• Fit the Phillips head screw & small ‘O’ ring fitted on air valve of Nitrox RSA.
result in unsafe riding condition.
Warning
Piston Ring Fitment :

• Piston rings must always be fitted with respect to exhaust mark on the
piston.
• First place the bottom oil rail ring with end gap 280 towards left of the
exhaust mark in the last groove.
• Place oil expander ring with butting end downward and end gap facing
opposite to the exhaust mark.
• Now fit top oil rail ring on the expander ring with end gap 300 towards right
of the exhaust mark.
• Fit the second piston ring with ‘Top 2’ mark facing upward and end gap
facing opposite to the exhaust mark.
• Finally fit the first ring with ‘Top 1’ mark upward and end gap facing towards
the exhaust mark.
• Remember fitment of 2nd ring upside down may lead to passing of oil above
the piston and ultimately leading to smoky exhaust.
Air Bleeding of Disc Brake System :

• For air bleeding from Front / Rear Hydraulic brake system first top up the
master cylinder / Reservoir with brake oil.
• Operate the brake lever / pedal slowly in order to get the oil filled in the
hose and oil passages
• Connect transparent tube or syphon pump to the bleeder screw / nipple at
caliper or syphon pump
• Operate the brake lever / pedal and keeping in pressed position loosens the
bleeder screw so that some oil escapes with the air bubbles.
• Keep on operating the brake lever / pedal till the air bubble escape out
completely through bleeder screw, and top up the master cylinder / reservoir
if required.
• Once the air escapes out from the hose pipe the brake lever / pedal meets
resistance, which indicates completion of air bleeding
• After completing the bleeding, top up the master cylinder / reservoir up to
the maximum level mark.
Note : Syphon pump can be used for air bleeding effectively.
Stator Assembly : Main Relay :

M & T : Multimeter M & T : Multimeter
Connections Standard Connections Standard

Range Range
Meter +ve Meter -ve Value Meter +ve Meter -ve Value
200 Ohms Red / Yellow Black / Yellow 0.9 Ohms 200 Ohms Main Relay Coil Main Relay Coil 80 ~ 150 Ohms
SOP : SOP :
• Switch OFF vehicle. • Remove relay from vehicle
• Disconnect stator plate coupler • Connect 12 V DC supply to coil terminals of main relay.
• Check continuity of contacts.
• Connect multimeter between yellow wires.
• If multimeter shows continuity then main relay is OK otherwise it is defective.
• Check resistance values between :
Note :
Y1 & Y2
i. If main relay is defective or malfunctioning then fuel pump and injector,
Y2 & Y3 ignition coil will not work.
Y1 & Y3 ii. This relay looks similar to interlock relay in Pulsar UG II vehicle but here
its function is different.
Crank Angle Sensor : Fuel Pump :

M & T : Multimeter M & T : Multimeter
Connections Standard Connections Standard

Range Range
Meter +ve Meter -ve Value Value
Meter +ve Meter -ve
200 Ohms Red / Red-White Green / White 380 Ohms 200 Ohms Orange Yellow 2.7 Ohms
• Ensure gap of 0.7mm between pole of crank sensor and rotor notch.
Note :
i. Battery should be fully charged.
ii. Fuse and Ignition switch should be OK
Starter Relay : iii. Audible sound will be heard which will confirm fuel pump is working.
M & T : Test jig of Pulsar UG III, Multimeter iv. Check main relay first if fuel pump is not working.
Connection :
Test Jig : Connect starter relay coupler to Test jig and it will show result as OK / Injector :
Defective.
M & T : Multimeter
Connections Standard
Range Connections Standard
Meter +ve Meter -ve Value Range
Meter +ve Meter -ve Value
Starter Relay Coil Starter Relay Coil
200 Ohms 55 ~ 60 Ohms *12 + 0.6 Ohms
Terminal Terminal 200 Ohms Orange Black-White
@ 200C
SOP : * Resistance may increase up to 20 Ohms as temperature rise.

• Remove relay from vehicle.
Note :
• Connect 12 V DC supply to coil terminals of starter relay. i. Battery should be fully charged.
• Check continuity of contacts. ii. Fuse and Ignition switch should be OK
• If multimeter shows continuity then starter relay is OK otherwise it is defective. iii. Check main relay first if fuel pump is not working.
Ignition Switch : Capacitor :

M & T : Multimeter M & T : Nil
Checking Method :
Range Touch +ve wire of capacitor to earth. Spark will occur. This indicates capacitor is
OK.
Continuity
Red Wire White Wire - NA - Note :
Mode
Capacitor is very important for ECU functioning, so ensure capacitor coupler is
always firmly connected.
Standard Value :
Beep sound & Continuity in ‘ON’ position. No continuity in ‘OFF’ position.
Note : Engine Oil Pressure Sensor :

i. Don't use duplicate or non-genuine key. M & T : Multimeter
ii Don't add oil in switch for lubrication.
Range
Engine Kill Switch :
Continuity
M & T : Multimeter Brown-Blue Black-Yellow - NA -
Mode
Connections Standard Standard Value :

Engine 'OFF' Mode Range If engine oil level is OK. Pressure developed will be 0.9 to 1.1 bar and continuity
will be shown on meter.
Continuity In case of a problem fault indication low oil indication icon on speedo console will
Brown Violet - NA -
Mode start blinking.
Standard Value :
Engine 'ON' Mode Continuity in Engine ‘ON’ condition. No continuity in Engine ‘OFF’ condition. Roll Over Sensor :
M & T : Multimeter
Note :
i. Avoid putting pressurised water jet on Engine Kill Switch. Connections Standard
Range
Fuel Gauge : Continuity

Green Black-Yellow - NA -
Mode
M & T : Multimeter
Checking Method :
Connections Standard i. Vehicle not tilted condition :
Range
Meter +ve Meter -ve Value Connect Gray and Brown / Green wires to multimeter. Multimeter will show
continuity.
As per chart
200 Ohms White-Yellow Black-Yellow given below ii. Vehicle tilted condition (> 600) :
Connect Brown-Green and Black-Yellow wires to multimeter. Multimeter will
Standard Value : show continuity but engine will go ‘OFF’ in 3.5 seconds.
Fuel Level Fuel Quantity Standard Value Graphical Bar on Speedo

Empty Tank 0.0 Liter 0.0 Ohm 0 Bar Intake Air Temperature Sensor :
Reserve 3.6 Liter 48 ~ 52 Ohm 2 Bars M & T : Multimeter
Half Tank 8.6 Liter 24 ~ 32 Ohm 6 Bars
Full Tank 12 Liter 6 ~ 14 Ohm 12 Bars Range
Note : If display in speedo console is not proper then please check following; 20K Ohms or
200 Ohms (Depending 2.7 K Ohms @ 280 C
i. Battery Voltage Green Black-Yellow
on Temperature) 46.09 Ohms @ 1500 C
ii. Speedometer coupler and wiring connections are firm.
Engine Temperature Sensor : F Know It On Your Finger Tip

M & T : Multimeter
• Remove the starter counter Top up the battery with

Connections Standard gear from one way clutch distilled water only. Ensure
Range
Meter +ve Meter -ve Value by rotating it anticlockwise that the level of electrolyte
and simultaneously pull it between upper & lower level
20K Ohms or outside to avoid bush only.
200 Ohms (Depending 10 K Ohms @ 250 C
Blue Black-Yellow spring / rollers flying off.
on Temperature) 62.62 Ohms @ 2000 C
• Clean and Lubricate with
SAE 20W50 oil.
Notes :
Cover the air passage of Replace the fuel filter if
throttle body with self blackish colour is seen on
adhesive good quality tape the body.
so that dust / carbon soot
does not enter inside while
cleaning.
Carry out priming of oil

cooler by loosening the LH
crankcase banjo.
Notes :
Chapter 3 Vehicle Maintenance
4
G Evaluate Yourself
Evaluate yourself
1. The recommended Engine oil is -
Chapter Tools & Gadgets
a. SAE 20W40 of API ‘SJ' + JASO 'MA'
b. SAE 20W50 of API ‘SG / SJ' + JASO 'MA' A Special Tools 54
c. SAE 20W50 of API ‘SJ' + JASO 'MB'
2. Warm up the engine to a temperature of 930 C is recommended before adjusting the Idling rpm. B Know It On Your Finger Tip 59
a. True b. False
C Evaluate Yourself 60
3. The Idling rpm can be adjusted by -
a. Adjusting the air screw which is located at the bottom of the throttle body.
b. Adjusting the shipping Air Screw which is located at the bottom of the throttle body.
c. Both above are correct
4. Turning out the Idling adjustment screw on the throttle body increases the Engine rpm
a. True b. False
5. Front brake lever free play and rear brake pedal free play is same -
a. True b. False
6. Tie rod free play is to be adjusted at every -

a. 5000 Kms b. 10,000 Kms c. All above are incorrect
7. Petrol filter is to be replaced at -

a. Every 5000 Kms b. Every 10,000 Kms c. Every 12,000 Kms
8. The soot formation / deposition at the interface of the throttle blade and blade matching bore is desired
and it should not be cleaned.
a. True b. False
9. Cleaning of injector is recommended at -

10. Cleaning of 1 way clutch rollers and running track of starter clutch is recommended at -
11. Fuel pipe & manifold pressure sensor pipe replacement is recommended at-
Key Leaning Points
a. Every 10,000 Kms b. Every 20,000 Kms c. Every 30,000 Kms After reading this chapter you should be able to understand..
12. Fuel pump strainer is to be replaced at - • The application of special tools for Engine / Chassis & its importance.
a. Every 10,000 Kms b. Every 20,000 Kms c. All above are incorrect
• Identification of exclusive special tools developed for Pulsar DTS-Fi.
13. Oil cooler assly needs to cleaned at -
a. Every 10,000 Kms b. Every 20,000 Kms c. All above are incorrect • Importance of diagnostic tools & its application.
14. What is the standard time recommended to carry out the periodic service as per standard SOP
a. 42.0 Minutes b. 52.0 Minutes c. 20.50 Minutes
15. In 5th Paid service it is recommended to replace drive chain lock and link set.
a. True b. False
Chapter 4 Tools & Gadgets Tools & Gadgets 4 Chapter
Rotor Puller with Butt Pin :

A Special Tools
Drawing No : 37 10DJ 32
Details of Exclusive Special Tool Application : Used to pull out the rotor from
For carrying out repairs / overhauls, 3 new special tools for Pulsar DTS Fi have been developed. crankshaft assembly.
Rest of the special tools required remains the same which were earlier required for Pulsar, Pulsar
DTSi UG-II, Pulsar DTSi UG III and Pulsar DTSi 200 CC (JC).
Engine : Primary Gear Holder :
Sprocket Catcher : Application : Use to hold primary gear while
loosening / tightening the clutch
Drawing No : 37 10DH 36 nut.
Application : For holding sprocket during
removal / refitting of Cam sprocket
allen bolt. Balancer Gear Holder :
Camshaft Big Bearing Puller : Application : Used to load the pre-tensioned
scissor gears of Assly balancer
Drawing No : 37 10DH 32 Idler gear.
Application : To remove bigger bearing
Special Nut :
Camshaft Small Bearing Puller : Application : Used to remove / fit of centrifugal
oil filter nut.
Drawing No : 37 10DH 31
Dia. = 25.9+0.1
Application : To remove small bearing of
camshaft. Note : Existing tool can be used by reducing diameter to 25.9 + 0.1 mm
Piston Ring Holder :

Rocker Shaft Remover : Drawing No : 37 10DK 03
Drawing No : 37 10DH 35 Application : Used for compressing the piston
Application : To remove rocker shaft from rings when assembling piston in
cylinder head cover. the cylinder block.
Bearing Race Extractor :

Silent Bush Puller : Drawing No : 37 00DJ 01
Drawing No : 37 10DH 33 Application : Used for removing the lower
Application : To remove silent bush from bearing race from ‘T’
cylinder head cover.
Bearing Extractor : Crankshaft Bearing Extractor :
Drawing No : 37 10DJ 76 Drawing No : JC1010 01

Application : Used to extract the input shaft Application : To remove bearing from
bearing from crankcase LH. crankshaft
Bearing Puller : Output Sprocket Holder :
Drawing No : 37 10DJ 77 Drawing No : 37 1030 53

Application : Used to pull out the bearing for Application : To hold the output sprocket while
body balancer from crankcase LH. removing sprocket bolt
Adaptor & Valve Spring compressor : Bearing Driver Set :
Adaptor : Drawing No : 37 1030 61

Application : Common bearing driver set for
Valve Spring Compressor : fitting and removing bearings from
Drawing No : 37 1031 07 crankcase.
Application : Used for assembling / dismantling
inlet, exhaust valves by
compressing spring in cylinder
Diagnostic Tool :
head. Drawing No : -----------------
Application : Used for diagnosing the electronic
Rotor Holder :
faults in the vehicle, CO% and
Drawing No : H6 0721 00 idle rpm setting.
Application : To hold rotor while loosening bolt.

Digital Diagnostic Instrument :
Drawing No : - NA -
Application : Used for various electronic parts
Drift : (Developed for like Wheel Sensor, Relay, Control
180 cc UG-III) Switches.
Drawing No : 74 9309 89
Application : To remove piston pin.
Thrust Plate Aligner / Holder :
Drawing No : T-1011168
Application : To align the clutch hub concentric
w.r.t clutch wheel, clutch housing
and thrust plate for assembly of
clutch.
Chassis : B Know It On Your Finger Tip

Fork oil seal fitment punch : New
When tightening the special Never rest the Rotor holder
Drawing No : 37 1740 03 nut for centrifugal filter the against Gear change pedal
Primary gear holder should lever.
Application : To fit fork oil seal on outer pipe held between the ‘Primary
Gear’ and ‘Clutch Housing’
from bottom side. (Note that
oil pump assly is removed).
Rear Shock absorber adjuster :

When loosening the special The existing special nut
Drawing No : 37 00DH 14
nut for ‘Centrifugal Filter’ the puller for Pulsar can be usee
Application : For adjusting the notch position of Primary gear holder should for Pulsar UG-III and DTS-Fi
RSA to achieve hard or soft rear be held between the ‘Primary by reducing its diameter to
Gear’ & Clutch Housing’ from 25.9 + 0.1 mm.
suspension
upper side.
Fork Inner & Outer Tube Extractor : New

Drawing No : 37 1740 04 Rotor Puller has LH threads. While removing Cam shaft
bearing hold the puller in
Application : Used for removing front fork inner
Bench vice and remove
tube from outer tube. bearing for easy or ease in
dismantling.
Fork Holder : New

Drawing No : 37 1740 05
Application : Used for holding the fork piston
from inside.
Notes :
Chapter 4 Tools & Gadgets
5
C Evaluate Yourself
Evaluate yourself
1. While removing the bigger cam sprocket the sprocket catcher Tool (P. No-37 10DH 36) can be rested on
Chapter Fuel System & EMS
either side of cylinder head ?
a. True b. False
A DTS-Fi Engine Management System 62
2. While dismantling cam shaft bearing using cam shaft bearing puller (P. No. 37 10DH 32) it is recommended to • Introduction / Various Sensors & Actuators
hold the special tool in bench vice
a. True b. False
B EMS Layout 65
3. Silent bush puller (P. No. 37 10DH 33) can be used fro removing and refitting bush from head cover ?
a. True b. False
C Working of System 66
4. What is the new outer diameter for Special Nut puller (P. No.37 10DJ 43)
a. 25.9 + 0.1 mm b. 29.5 + 0.1 mm c. 26.9 + 0.1 mm • Fuel Pump • ECU
• Fuel Injector • Various Sensors
5. Thrust plate aligner / holder (P. No. T-1 0111 68) is used to
a. Align clutch hub concentricity w.r.to clutch wheel, clutch housing and thrust plate
b. Align clutch hub concentricity w.r.to clutch wheel, Pressure plate and thrust plate D Fuel Injection - Advantages over Carburetion 77
c. All above are correct
E Part Inspection Parameters 78
6. Bearing Extractor (P. No. 37 10DJ 76) to remove Input Shaft bearing from Crankcase LH can be used to remove
Input Shaft bearing from crankcase RH
a. True b. False F Dos & Don'ts 82
7. To fit cam shaft bearings on cam shaft which of these will be used ?
a. Cam shaft small bearing puller b. Cam shaft big bearing puller c. Arbour Press G Know It On Your Finger Tip 91
8. To remove the piston rings from the Piston assly Piston ring holder is used -
H Evaluate Yourself 92
a. True b. False
9. Crankshaft brg. extractor P. No JC101001 can be use to remove the crankshaft bearing of Pulsar DTS-Fi
a. True b. False
10. Which of the following special tool is used to extract fork inner tube from outer
a. Fork inner & outer tube extractor (P. No. 74 9310 15)
b. Fork inner & outer tube extractor (P. No. 37 1740 04)
c. Both of the above tools can be used
11. Fork oil seal fitment punch P. No. 37 0040 03 for Pulsar UG III is common with Pulsar DTS Fi
a. True b. False
Key Learning Points
After reading this chapter you should be able to understand..
12. While loosening the centrifugal filter special nut the Primary gear holder should be placed on the bottom
(side near oil pump) in between clutch housing and Primary gear • Engine Management layout.
a. True b. False
• Function, Construction & Working of various sensors & actuators.
13. Idling rpm can be adjusted by using
a. Torque screw driver b. CO/HC Machine c. Diagnostic tool • The fuel injection advantages over carburetion.
14. While inspecting hall sensor unit for indicators when both LED lights of DDI glowing 'ON' indicates that
• How to tune-up the engine using the diagnostic tool.
a. Auto cancellation of indicator is working and steering
b. Auto cancellation of indicator is working and steering is at center • Inspection of various fuel system components, their standard & service limits.
c. All above is incorrect
15. CO% can be adjusted using diagnostic tool
a. True b. False

DTS-Fi TRG NOTE A

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DTS-Fi TRG NOTE A

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Notice Contents

All information contained in this Note is based on the latest

product information at the time of publication. Bajaj Auto B PDI SOP

B Know It On Your Finger Tip

B Dismantling & Assembling Front Fork FAQ's (Frequently Asked Questions)

A Identification C Salient Features

Comfort & Convenience

D Technical Specifications E FAQ's (Frequently Asked Questions)

Ï What is the role of the Manifold Pressure Sensor?

B The icon represents a System Malfunction which is in Red color.

yourbike level between the upper UPPER

BLISTER FORMATION OIL FILLING PLUG

RUSTY TAPPET COVER

OTHERS (Specify) BANJO BOLT

4 FRONT / REAR WHEEL OFFSET OIL LEVEL INSPECTION WINDOW

5 WHEEL OIL COOLER BANJO BOLTS JOINTS

FR. WHEEL TYRE FREE ROTATION OIL PRESSURE SWITCH

FRONT WHEEL RUNOUT (SPECIFY) OIL TEMPERATURE SENSOR

REAR WHEEL RUN OUT (SPECIFY) 18 CLUTCH OPERATION

7 SWITCHES 19 PLATING DEFECTS IF ANY

RH SWITCH OPERATIONS 20 ENGINE OPENING DURING PDI (If any)

LH SWITCH OPERATIONS (Give engine no & reason for engine opening)

IGNITION SWITCH OPERATION 21 FRAME OPENING DURING PDI (If any)

8 LIGHTS:- (Give chassis no & reason for chassis opening)

SIDE INDICATOR 22 OTHER DEFECTS :

B PDI SOP Sr. Description

Ring spanner Repair for any other defects seen

OE accessories fitment - Ring

7.0 Kg.m 1.0 ~ 1.2 Kg.m 4.0 Kg.m

1.4 Kg.m (Loctite 243) 1.1 Kg.m 4.5 Kg.m

1.6 ~ 1.8 Kg.m 1.4 Kg.m 1.0 ~ 1.2 Kg.m

ET Sensor Bolt Injector Mounting Bolt Oil Cooler Bracket Bolt

Crankcase Joining Bolts Crankcase Joining Bolt Clutch Cover Bolts

1.2 ~ 1.4 Kg.m 0.8 ~ 1.0 Kg.m 0.8 ~ 1.0 Kg.m

Oil Pressure Switch Bolt

1.2 ~ 1.5 Kg.m

1.1 Kg.m (Loctite 243) 7.0 Kg.m 1.1 Kg.m

1.0 ~ 1.2 Kg.m 1.2 ~ 1.5 Kg.m 2.0 ~ 2.2 Kg.m

2.0 ~ 2.2 Kg.m 3.5 Kg.m 0.5 Kg.m

1.8 ~ 2.0 Kg.m 2.5 ~ 3.5 Kg.m 3.5 ~ 4.0 Kg.m

TORQUE VALUES Match the Sequence

A Periodic Maintenance & Lubrication Chart Whichever RECOMMENDED FREQUENCY

18. Throttle play C,A l l l l l

19. Rear brake pedal play C,A l l l l l l : Indicates operation to be performed.

25. Engine mounting silent blocks R Every 20,000 kms

26. Tyre tread wear C,R l l l l

B Periodic Service SOP Position Position

Engine Oil Level Checking :

Oil Strainer Cleaning :

Remove : Air Filter Cleaning :

Clean with Dip into engine oil

Blow low pressure

Spark Plug : Position 1 2 3 4 5

Drive Chain Cleaning / Lubrication : Important Adjustment and Checking Procedure :

Clutch Lever Free Play - 2 ~ 3 mm

B Tie Rod Adjustment :

B A • If the accelerator free play can not be adjusted with

Accelerator Grip Free Play - 2 ~ 3 mm

Throttle Body : E Standard Checking Procedure

Cleaning at every 10,000 kms.

Piston Ring Fitment :

Air Bleeding of Disc Brake System :