Pulsar-DTS-i 200cc A

Identification Contents
Contents
Identification 1
Salient Features 2
Technical Specifications 4
FAQ’s 6
PDI Checklist 9
PDI SOP 11
Periodic Maintenance and Lubrication Chart 13
Periodic Service SOP 15
Service Wise Part Kit 18
All information contained in this Note is based on the latest
Scheduled Maintenance 20
product information at the time of publication. Bajaj Auto
Limited accepts no liability for any inaccuracies or omissions Standard Checking Procedure 30
in this publication, although every possible care has been Special Tools 34
taken to make it as complete and accurate as possible. All Carburettor and Fuel System 39
procedures and specifications subject to change without
Digital Twin Spark Ignition System 48
prior notice. The right is reserved to make such changes at
any time without prior notice. Important Points to Remember 50
Removal of Engine from Frame 52
Removal of Engine from Frame
Dismantling 55
DOC. NO.: 71 1103 69 REV. 00, FEB. 07
Dismantling Engine Sub Assembly 64
Parts Inspection Parameters 69
Service Data - Engine / Frame 74
Parts Identification 79
Tightening Torque - Engine/Chassis 91
Assembling Engine 95
Dismantling & Assembling Front Fork 111
Front Disc Brake 114
Tubeless Tyre and its Repair Procedure 119
Maintenance Electricals 126
Main Electrical Diagram & Individual Circuit Diagrams 135
Pulsar DTS-i 200 Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i 200 Training Notes
Identification Salient Features
Identification Salient Features

The Engine and Frame serial numbers are used
to register the vehicles. They are the only
STYLE :
means of identifying your particular vehicle
from the other of the same model and type.
These serial numbers may be needed by your
Features :
dealer when ordering the parts. In the event of Brawny Masculine Looks:Split Seats, anti scratch
theft, the investigating authorities will require tank Pad, two piece grab rail, Stylish Petrol tank
both these numbers in addition to the model,
flaps, Chiseled rear looks, Wolf-eyed Head lamp,
type and any special features of your vehicle
that can help identifications.
LED tail Lamp, black Styling
Advantages :
Location of Parts A bold assertive stance, Neat looks. Brains, brawn
and definitely male.
9 1 2 3 Benefit :
• The styling and looks that let you break free
POWER & PERFORMANCE :
4 Features :
Engine :
• 4 stroke, DTS-i 200cc - 18ps ( 13.25 Kw)
• State-of-the-art features at the heart of digital
biking : Digital Twin Spark Ignition, digital CDI
5
unit, TRICS III, CV Carburetor
• First Oil Cooled Engine
Advantages :
• New and more powerful DTS-i engine with no
precedence in industry
• Optimum ignition timing for any engine rpm, better
throttle response and reduced emissions
6 • Optimum Engine cooling and Maintains Lube oil
viscosity at high temperatures and extreme stress
for optimum performance.
Benefit :
• Crisp Throttle response for consistent engine
output for varying load and speed conditions at
7 different levels of acceleration. More power, more
8
mileage, ultimate refinement
• High performance under every possible load
condition
1. Control Switch RH 4. Body Control Unit 7. ExhausTEC
(Placed inside Head Light Fairing)
2. LCD Speedo Console 8. Oil Cooler
5. Hall Sensor for Indicator
3. Control Switch LH 6. Vehicle Speed Sensor 9. Tail Light LED display
Pulsar DTS-i 200 Training Notes 1 Dealer Development Center Dealer Development Center 2 Pulsar DTS-i 200 Training Notes
Salient Features Technical Specifications
COMFORT & CONVENIENCE : Engine and Transmission

Type : Four stroke DTS-i, Natural air cooled.
Features :
• LCD Speedo Console No. of cylinders : One
• Self cancelling indicators Bore : 67.00 mm.
• Smoother bump free ride pleasure. Stroke : 56.40 mm.
Advantages : Engine displacement : 198.8 cc.
• Easy to read & understand digital speedo, odometer
Compression ratio : 9.5 + 0.5:1
display with two trip meters having resetting facility &
warning signals. Idling Speed : 1400 + 100 rpm.
• Switching OFF the indicators automatically after Max. net power : 13.25 kW (18.0 Ps)
completion of turn.
Max. net torque : 17.17 Nm / 1.75 Kg.
• The telescophic front suspension with 130mm travel
and supported with Nitrox shock absorber on rear. Ignition System : Microprocessor controlled digital C.D.I.
Benefit : Ignition Timing : 100 BTDC at 1400 rpm.
• Excellent riding pleasure. : 280 BTDC at 3500 rpm.
Fuel : Unleaded petrol
MANEUVERABILITY & STABILITY : Carburettor : UCAl-MIKUNI BS29, Side Drought, CV Type.
Spark Plug : 2 Nos. Champion RG4HC (Resistive)
Features :
Spark Plug Gap : 0.6 to 0.8 mm.
• First Bike in India to employ wide tubeless tyres.
Lubrication : Wet sump, Forced.
Front 90/90 & rear 120/ 80
• Beefy frame with longer wheel base of 1350 mm Starting : Electric start.
Advantages : Clutch : Wet, Multidisc type.
• More strength with Superior high-speed dynamics Transmission : 5 speed constant mesh.
• Tubeless tyres do not deflate suddenly in case of Primary Reduction : 3.47 : 1 (66/19)
a puncture and help in reducing unsprung mass. Gear Ratios: 1st gear : 26.04 : 1 (36/13)
Less rolling resistence ensures complete road 2nd gear : 17.67 : 1 (32/17)
stability 3rd gear : 12.97 : 1 (29/21)
Benefit : 4th gear : 10.15 : 1 (26/24)
• High stability and exceptionally tight turning radius 5th gear : 8.65 : 1 (24/26)
Final drive ratio : 2.71 : 1 (38/14)
SAFETY : CHASSIS & BODY
Frame Type : Double cradle.
Features : Suspension Front : Telescopic front fork with DU bush (Stroke 130 mm)
• Front ~ large ventilated disc brake (260 mm) Rear : Trailing arm with coaxial hydraulic cum gas filled
• Rear ~ Drum Brake (130 mm) adjustable shock absorbers, and triple rate coil springs.
Advantages : Brakes Front : Hydraulically operated disc type.
• Larger front Disc brake ensures effective braking
Comes to an Instant Halt Rear : Mechanically expanding shoe and drum type.
Benefit : Tyres Front : 90 x 90 x 17, 49 P (Tubeless)

Enhances safety and handling. Rear : 120 / 80 x 17, 61 P (Tubeless)
Tyre Pressure Front : 2.00 kg/cm2 (28.4 Psi)
Rear Solo : 2.00 kg/cm2 (28.4 Psi)
Rear Pillion : 2.15 kg/cm2 (30.5 Psi)
Rims (Alloy Wheels) Front : 1.85 x 17
Rear : 2.50 x 17
Technical Specifications Frequently Asked Questions (FAQ’s)
Fuel Tank Capacity : 15 liters Full Ï Why one more model with ‘Pulsar DTS-i 200 cc’ name is introduced when ‘Pulsar DTSi 180 cc’
: 3.2 liters Reserve is already available?
: 2.0 liters Usable reserve B In case of Premium segment Brand of vehicle, we can have two or more categories to meet
aspirations of all customers.
CONTROLS
Steering : Handle Bar B With Best Style and Looks in common, the customers of this segment expect different Performance
Parameters. Customers want to keep on upgrading themselves to Higher Power with Advanced
Accelerator : Twist grip type on RH side of handle bar Features.
Gears : Left foot pedal operated
B To make One Brand to address these aspirations, new ‘Pulsar DTS-i 200 cc’ has been introduced as
Clutch : Lever operated on LH side of handle bar on a Higher Performance level than existing ‘Pulsar DTS-i 180 cc’.
Choke : Push-Pull knob on carburettor
Brakes Front : Lever operated on RH side of handle bar Ï When ‘Pulsar DTS-i 200 cc’ is a different model with more Power & Performance, why the
looks are kept same as ‘Pulsar DTS-i 180 cc’?
Rear : Pedal operated by right foot
B It is One Brand with different Hearts.
ELECTRICALS
B Nothing wrong to have two different models having similar looks. But key performance parameters
System : 12 V (AC + DC) could be different.
Battery : 12V 9 Ah MF type.
Head Lamp : 35/35 W-HS1 B We have Pulsar Twins since beginning as an example, which are well accepted by our customers
and are doing fantastic in their performance.
Pilot Lamp : 5W - 2 Nos.
Tail/Stop lamp : LED / LED Ï How both these models deliver the expected performance? And what are their Performance
Turn signal lamp : 10 W (2 Nos.) Parameters?
Turn signal pilot lamp : LED
B It can be understood clearly from the following.
Side stand indicator lamp : LED
• The new ‘Pulsar DTS-i 200 cc’ : High Power with Advanced Features
Hi beam indicator lamp : LED
Neutral indicator lamp : LED
Speedometer lamp : LCD display Technical Features Performance Parameters
Rear number plate lamp : 5 W
• 198.80 cc DTS-i Engine. • Horse Power of 18.00 Ps.
Horn : 12V DC
• Reduced Friction & Mass design of key engine • Greater Torque of 17.17 N-m
DIMENSIONS parts with pressurised lubrication system. • Max. Speed of 130 Kmph.
Length : 2035 mm. • Oil cooled engine. • Maintain controlled engine oil temperature to
Width : 750 mm. achieve optimum engine performance.
Height : 1165 mm.
Wheel base : 1350 mm.
Turning circle radius : 2500 mm. (Minimum) • The new ‘Pulsar DTS-i 180 cc’ : Powerful & well accepted features.
Ground clearance : 165 mm. (Minimum)
WEIGHTS Technical Features Performance Parameters
Vehicle kerb weight : 145 kg. • 178.60 cc DTS-i Engine. • Horse Power of 16.51 Ps.
Gross vehicle weight : 280 Kg.
• Max. Torque of 15.22 N-m
PERFORMANCE • Max. Speed of 125 Kmph.
Maximum speed : 130 km/hr with single rider (68kg) • LCD speedo console with self cancelling
• Stylish digital controls. indicators, sensor type self lighting switches,
Climbing ability : 28% (160 Maximum)
LED tail lamp..
Notes:
• Values given above are nominal and for guidance only, 15% variations is allowed to cater for
production and measurement variation. B As far as Style / Look and Comfort features are concerned, both the model have by and large
• All dimensions are under UNLADEN condition. common features.
• Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
• Specifications are subject to change without notice.
Frequently Asked Questions (FAQ's) Frequently Asked Questions (FAQ's)
Ï What are other key features of new ‘Pulsar DTSi 200 cc’ motorcycle in comparison with ‘Pulsar Ï What is Oil Cooled Engine? And what are its Advantages?
DTSi 180 cc’?
B The ‘Pulsar DTS-i 200cc’ Engine is natural air cooled engine & is further supported by a oil cooler
B Following are the overall features in comparison at a Glance. which maintains the engine oil temperature so that the viscosity of the engine oil is maintained (high
speed riding causes rise in engine temperature & adversely affects on the oil viscosity) at various
Features Pulsar DTS-i 200 cc Pulsar DTS-i 180 cc engine speed conditions & optimum engine performance can be achieved.
Cubic Capacity 198.80 cc 178.60 cc New Pulsar DTS-i 200 cc : - Ï What is a tubeless tyre? And what are its Advantages?
High Power with
Horse Power 18.00 Ps 16.51 Ps B The name ‘Tubeless’ it self speaks that the tyre is without tube. In this tyre there is a inner tube
Advanced Features.
which is a integral part of the tyre known as inner liner. The air is held between the rim and the tyre.
Torque 17.17 N-m 15.22 N-m The air filling valve is fixed air tightly on the wheel rim.
Max. Speed 130 Kmph 125 Kmph Advantages:
Pulsar DTS-i 180 cc : -
Oil Cooled Engine YES NO • Slow air leak.
Powerful and well accepted
Starting Mechanism Self Start Only Self & Kick Start features. • Better fuel efficiency.
• Less chance of damage in case of flat running.
Tubeless Tyre YES NO
• Better heat dissipation.
Intelligent Digital CDI YES YES
• Cost saving on tube.
ExhausTEC YES YES • No tube related problems.
Speedo featuring warning
indicators like, Choked Air Ï Is tubeless tyre repairable?
Digital Control YES NO Filter Element, High Oil Temp., B YES, Tubeless tyres can be repaired locally. There are various methods like
Low Battery Voltage, Low
Engine Oil Level 1. Filler Method.
Wheel Base 1350 mm 1320 mm Better Road Holding 2. Plug (Mushroom) Method.
Front Suspension 130 mm 135 mm 3. Patch Method.
Pleasant &
Rear Suspension with Comfortable ride
YES YES But Bajaj Auto Limited recommends only 2nd method i.e. Plug (Mushroom) Method since it is more
Nitrox Shockers
effective & safe.
Brighter illumination & low
LED Tail Lamp YES YES current consumption.
Split Type Seat YES NO Adds sporty look & supports
good riding posture
Easy maneuverability
Wheel Size (17") YES YES & light handling
Wolf eyed lamp which matches
Head Lamp Fairing Head Lamp Fairing Head Lamp Fairing
with the character of the bike
Graphics Gorgeous Graphics to match to the profile Attractive Style

of the vehicle & Looks
Ï What do the 4 icons at the topmost portion of the Speedometer Display?

B The 4 icons displays :-
1. The 1st icon from the left indicates a
Choked Air Filter Element, when displayed.
2. The 2nd icon from left indicates a

High Oil Temperature, when displayed.
3. The 3rd icon from left indicates +
Low Battery Voltage, when displayed.
4. The 4th icon from left indicates

Low Engine Oil Level, when displayed.
PDI Checklist PDI Checklist
SL CHECK POINTS FOR PDI Check PDI done by BAL/ Service Engg. PDI Done by dealer SL CHECK POINTS FOR PDI Check PDI done by BAL/ Service Engg. PDI Done by dealer
1 LOCK OPERATION 18 ENGINE OIL LEAKAGE
STEERING LOCK NOT WORKING/JAM DRAIN BOLT
SIDE COVER LOCK NOT WORKING MAGNETO COVER
Seat locks Front and rear. CRANKCASE JOINT
2 PAINT FINISH - OVER FLOW (Samples / photographs) OIL FILLING PLUG
3 FUEL TANK DEFECTS OHC COVER
LEAKAGE TAPPET COVER
BLISTERS BENJO BOLT
RUSTY CHAIN TENSIONER 'O' RING
OTHERS (Specify) OIL LEVEL INDICATOR WINDOW
4 FUEL COCK OPERATION - HARD / LEAKAGE OIL FILTER COVER
5 FRONT / REAR WHEEL OFFSET Oil cooler banjo bolts joints.
6 WHEEL 19 CLUTCH OPERATION
FR. WHEEL rotation. Easy operation
FRONT WHEEL RUNOUT (SPECIFY) 20 PLATING DEFECTS
REAR WHEEL RUN OUT (SPECIFY) HANDLE BAR
7 SILENCER - BAFFLE NOISE 21 ENGINE OPENING DURING PDI (If any)
8 SWITCHES (Give engine no & reason for engine opening)
RH switch operations 22 FRAME OPENING DURING PDI (If any)
LH Switch operations (Give chassis no & reason for chassis opening)
IGNITION SWITCH SHORT 23 OTHER DEFECTS :
9 LIGHTS:- MINOR ADJUSTMENTS
Side indicator blinking. 24 TRANSIT DAMAGES (Send photographs )
HEAD LIGHT [ Mark in check column for the point found ok
TAIL/BRAKE LED # Mention about FFR/EER
10 HORN :- DISTORTED/WEAK SOUND(DO NOT SET)
11 Speedo :
Tripmeter - 1/2 working -Resetting
Fuel level indication
Reserve indication (by red lamp)
Red lamp blinking after crossing Engine RPM 9000
Auto-switch off of Ind lamps (H bar straight for > 2 sec)
Head light / tail light illumination after 3 seconds
LED functioning - Speedounit - Both side indication, Side
stand, Neutral, Hi beam, RES ind lamp
12 FLAT SPOT (GIVE CO %)
13 DRIVE CHAIN slack (mention amont of play)
14 BRAKE OPERATION - FRONT/REAR
FRONT BRAKE
REAR BRAKE EFFECTIVENESS
BRAKE LIGHT REMAINING ON CONTINUOUSLY.
15 GAP AT THE REED SWITCH AND MAGNETO.
16 LOOSE PARTS
ENGINE MOUNTING BOLT
17 ENGINE NOISE
TAPPET NOISE
CHAIN TENSIONER / TIMING CHAIN
PDI SOP PDI SOP
Sr. Special PNR & its M & T / Service Sr. Special PNR & its M & T / Service
Description Position SMM GP Tools Consumables Shop Equipments Description Position SMM GP Tools Consumables Shop Equipments
No. Tools Attachment No. Tools Attachment
Identify & Park Vehicle on Lifter Bay Check the following and
1 0.80
Work Bay lubricate if necessary
Remove the Thermocol and • Rear brake lever Oil,
2 additional packing if any. Study 0.50 • Rear brake pedal / cam RH/LH Multipurpose
PDI card and Work content. 20 • Pillion foot rest FRONT 1.00 Oil Can Grease,
Open Petrol tank cap Petrol Petrol, Waste • Center stand REAR SAE 20W40
3 0.50 Oil
& pour petrol Dispenser Cloth • Side stand
Check for smooth operation of • Kick lever boss
4 0.10 • Clutch lever
fuel cock lever
Check & top up engine oil level, Nose Plier, OE accessories fitment - OE Spanner
5 RH 0.30 Cloth 21 LH/RH 1.15
if required. Oil Can, Funnel Mirrors RH & LH Set
Check clutch cable operation & OE Spanner Set,
6 RH 0.10
Adjust if required. Spanner Set Tommy Bar,
Check front brakes for efficient OE accessories fitment - Screw Driver, Dial Type
7 Front 0.10 Ring Spanner Suction Pump 22 LH/RH 3.25
working & Adjust if required. Leg guard, Saree Guard Plier, Nylon Torque Wrench
Hammer,
Check and correct tyre inflation Air Pressure Pedaled Allen Key
8 Front 0.20
pressure - Front Wheel Gauge Air Pump
Check electrical couplers of all
Check Battery voltage, fill / top-up Cotton Waste, Multi Meter, sensors
electrolyte, apply petroleum jelly, OE Spanner Set, Petroleum Jelly, Hydrometer,
9 LH 0.60
Screw Driver 23 • Engine Temperature LH/RH 0.35 Nose Plier
connect terminals properly. Electrolyte Battery Charger • Oil level & Temperature
Inspect Rear Shock Absorber Shocker • Air filter clogged
10 RH/LH 0.10
setting & Correct if necessary. Adjustment
Start vehicle, Check operation of
Check Rear brakes for efficient Opened electrical like- Head light, Tail light,
11 Rear 0.10
working & adjust if required. Spanner Set Brake light, Side stand indicator,
+ ve
24 Horn, Speedometer, Odometer, LH/RH 0.70
Check and Correct tyre inflation Air Pressure Pedaled Screw Driver
12 Rear 0.20 Side indicators, Parking, Pass light
pressure - Rear Wheel. Gauge Air Pump
Malfunction indicators and
Ring Spanner Fuel indicator working
Lubricate chain and Check / Set, OE Spanner Cloth,
13 LH 0.40 Check working of all
Adjust chain slackness if required. Set, Oil Can SAE 90 Oil 25 LH/RH 0.40
electrical switches
OE Spanner
14 Check Accelerator cable free play LH 0.05
Set CO-HC Analyzer;
26 Check Idling and CO%. LH/RH 0.60 12" Connector
Tachometer
OE Spanner
15 Check & Adjust TPS LH 0.10
Set Check RPM meter, Speedometer,
OE Spanner 27 Odometer & Trip meter for proper Front 0.50 OE Spanner
16 Check gear shifter lever operation LH 0.05 functioning and Correct if required
Set
Check & Adjust steering and RH / Ring Spanner 28 Check all locks for proper operation LH/RH 0.50
17 0.20
Handle bar for free movement. Front Set
Test drive the vehicle, check digital
Check front mudguard alignment OE Spanner
18 Front 0.05 speedometer working. Study the OE Spanner,
wrt Front Wheel Set 29 1.30
job card and verify work done. Ring Spanner
Check all important nut bolts for Take vehicle out and park.
torque and tightness,
30 Clean/Wash the veh. before delivery 1.00
• Handle bar mounting bolt
• Stem lower & upper bracket bolts Torque Wrench, Repair for any other defects seen
31
• Stem of bolts Socket Set, or observed during test drive.
19 • Front axle nut LH/RH 4.00 Ring Spanner
Total SMM 19.20
• Cylinder head nuts Set, OE
• Engine foundation bolts Spanner Set
Total time taken for PDI SOP 19 Minutes approximately.
• Trailing arm bolts
• Silencer cover shield bolts
• Both LH/RH engine mtg. bolts In a shift of 480 minutes, One technician can do 25 Vehicles PDI SOP comfortably.
Periodic Maintenance Periodic Maintenance
& Lubrication Chart & Lubrication Chart
Whichever RECOMMENDED FREQUENCY Whichever RECOMMENDED FREQUENCY

comes first comes first
Sr. Initial Subsequent Sr. Initial Subsequent
Operation Operation
No. Kms. 750 2,500 5,000 7,500 Every 2,500km No. Kms. 750 2,500 5,000 7,500 Every 2,500km
OR OR
Days 30~45 105~120 195~210 285~300 Every 90 days Days 30~45 105~120 195~210 285~300 Every 90 days
1. Servicing l l l l l 28. Steering stem bearing L,R 1 year Every 10000 kms
2. Idle speed / CO% C,A l l l l l 29. Wheel bearing C,L 1 year Every 10000 kms
3. Valve tappet clearance A l Every 5000 kms 30. Master cylinder cup and Dust seal R Every 2 years
4. Engine oil (SAE 20W50 of API SJ+JASO MA) R l l Every 5000 kms 31. Caliper piston seal and Dust seal R Every 2 years
5. Oil strainer / Centrifugal filter CL Every 10000 kms 32. Swing arm pivot pin L l Every 5000 kms.
6. Air cleaner element V CL l l l l l 33. Front fork C,L l l l
7. Air cleaner element R Every 10000 kms 34. Front fork oil R Every 10000 kms
8. Carburettor CL,A l l l l l 35. Front brake hose C,R 2 years
9. Fuel system leakages C,R l l l l l 36. Check nitrox gas pressure

7.0+0.5 Kg/cm2 Every 10000 kms
10. Fuel pipes R Every Year
37. Drive chain L Every 500 kms.
11. Spark plug / gap CL,A l l l l l
38. Drive chain slack n A l Every 1000 kms.
12. Spark plugs (2 Nos.) R Every 10000 kms
39. Drive chain wear. Remove & lubricate C,R l Every 5000 kms.
13. Battery electrolyte level C,A l l l l Every Year
40. Engine compression pressure C Every 10000 kms
14. Brake light switch C,A l l l l l
41. Cylinder head de-carbonising &
15. Oil cooler pipes C,R l l l l l Valve lapping CL Every 30000 kms
16. High pressure fuel filter C,R l l l l l 42. Valve oil seals R Every 30000 kms
17. Clutch play C,A l l l l l 43. Lubrication of Gear starter clutch 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 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 A - Adjust • CL - Clean • C - Check • L - Lubricate • T - Tighten • R - Replace
23. Steering play C,A l l l l l Note : Parts / Lubricants to be replaced as per Periodic Maintenance & Lubrication Chart are
mandatory 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
27. General lubrication L l l l l l
Periodic Service SOP Periodic Service SOP
Position Position Position Position

of Tech. of Tech. M & T / of Tech. of Tech. M & T /
Sr. Description Sp. PNR & its Sr. Description Sp. PNR & its
w.r.t. SMM w.r.t. SMM GP Tools PNR Consumables Serv. Shop w.r.t. SMM w.r.t. SMM GP Tools PNR Consumables Serv. Shop
No. Tools Attachment Equipments No. Tools Attachment Equipments
Vehicle Vehicle Vehicle Vehicle
LH RH LH RH
Washing 6" Comb. Measuring

1 Wash vehicle thoroughly. Clean oil strainer. (Replace
boy Pliers, Oil 20W50, jar 1 liter,
17 if required) After 1 year or RH Funnel
Ring Cloth
2 Identify the vehicle. 0.30 10000km whichever is later Oil dispenser
Spanner Set
Bring vehicle and OE Spanner

3 0.50 18 Check clutch & adjust RH 0.30
position on bay. Set
4 Raise the lift. 0.30 Ring

Cloth Oil disposer,
19 Fill engine oil (1150 ml) RH 1.35 Spanner Set
Pistol 20W50 Oil Air gun
Start vehicle and Warm up. Plier
Remove RH/LH side covers grip
5 RH 0.70 PNR Filler Gauge
Seat, Petrol tank and
keep properly Socket Clean, Check & adjust Spark Spark Plug
set Ring
20 RH Spark Plug RH 2.40 Plug Cloth Cleaning
Spanner Set
(Replace - if required) Spanner Machine
Pistol Air Gun
grip
Drain engine oil. Oil Disposer,
6 LH 1.30 PNR Cloth Screw Driver
Air Gun Check & Top-up Piston Suction
Socket 21 FRONT 1.00 Ring
brake fluid level Ring Pump
set Spanner Set
Pistol Pencil Type

Filter Check / Adjust front brake
Clean air filter. grip 22 FRONT 0.50 Pressure
Cleaning & wheel freeness
7 (Replace - if necessary) RH 3.00 PNR Gauge
Stand, Cloth,
Socket
20W 40 Oil Pencil type
set Check / Adjust front tyre
23 FRONT 0.40 Pressure
air pressure
-ve Head Gauge
Drain carburettor Screw Driver Float Cloth,
8 LH 1.30 RH Ring
(Overhaul if required) Nylon Brush Gauge Kerosene 24 Check & adjust steering RH 0.80 Spanner Set
Plastic Tray
Check RH side important
Check accelerator & adjust OE spanner fasteners and tight
9 LH 0.40
set
a. Engine foundation bolts
Clean, Check & adjust Spark Spark Plug b. Front axle nut
Ring Fine Polish Pistol
LH Spark Plug Plug Cleaning
10 LH 2.40 Spanner c. Side bolts of Front fork OE Spanner Grip,
Paper Machine,
(Replace - if necessary) Set Spanner 25 d. Handle bar bolts RH 1.30 Set, Ring PNR
Air Gun
Spanner set Socket
e. RSA top & bottom nuts
Check & adjust tappet Set
clearance. (if required) Ring Cloth, f. Swing arm axle nut
LH, Tappet Filler Gauge,
11 During 4 th Servicing or Spanner SAE 90 Oil, g. Silencer protective cover
REAR holder Air Gun
after 5000 Km whichever Set Diesel screws / bolts
is later. h. Rear view mirror
Check LH side important Lubricate as per
fasteners and tight Pistol lubrication schedule
OE
a. Side bolts of front fork spanner set, grip
a. Clutch lever 20W50 Oil,
12 LH 0.60 Ring PNR
b. Engine foundation bolts b. Rear brake pedal Graphite,
spanner set Socket 26 LH RH 0.80 Oil can
c. Side stand set c. Brake cam Grease,
d. RSA top & bottom nuts d. Pillion foot rest Cloth
e. Center stand
OE Pistol f. Side stand
Adjust chain slackness & grip Cloth,
REAR spanner set, Chain
13 Lubricate. Remove and 3.90 PNR 20W90 oil, Pistol
LH Ring Cleaning
clean, If required. Socket Diesel Grip,
spanner set Refit RH, LH side covers,
set 27 LH RH 0.50 PNR
Seats, Petrol tank assly.
Check & Adjust rear brake OE Spanner Socket
14 RH 0.50 Set
& wheel freeness SEt
Pencil Type Check & Clean fuel line
Check and Adjust REAR 28 LH 0.50
15 0.40 Air gun Pressure and clean petrol tank cover
rear tyre air pressure RH Gauge
Check Battery, top up with Check electrical couplers

Distilled Water. Clean Electrolyte, Multi Meter, of all sensors
terminals & apply Petroleum OE spanner, Petroleum Hydrometer,
16 Jelly. Rout cables properly RH 1.80 Battery 29 a. Engine temperature LH 0.35
Screw driver jelly, Cotton
& fit terminal caps properly. waste Charger b. Oil level & temperature
Recharge battery if required c. Air filter clog
Periodic Service SOP Service Wise Parts Kit
Position Position
of Tech. of Tech. M & T / Periodic Parts Replacement Kit for Free & Paid Services
Sr. Description Sp. PNR & its
w.r.t. SMM w.r.t. SMM GP Tools PNR Consumables Serv. Shop
No. Tools Attachment
Vehicle Vehicle Equipments Service Days Kms. Limit Part Name Quantity
LH RH
Engine oil 1150 ml.
Check RPM meter,
Speedometer, Odometer 1st Free 30~45 500~750
30 & Trip meter for proper FRONT 0.50 Clutch cover gasket 1
functioning & Correct if
required 2nd Free 105~120 2000~2500 NIL NIL
Start vehicle, Check 3rd Free 195~210 4500~5000 Engine oil 1150 ml.
operation of electrical like -
a. Check all electrical 4th Free 285~300 7000~7500 NIL NIL
RH
switches
Engine oil 1150 ml.
b. Head light FRONT
Philips Clutch cover gasket 1
c. Tail light REAR
Screw
d. Brake light RH/RR Driver
31 0.95 Ring Air filter foam element 1
e. Horn FRONT Spanner Set
Comb. Spark plug 2
f. Speedometer, Odometer, FRONT
Pass, Parking light Pliers
Fork oil 330 ml.
g. Side indicators, Front RH/LH
and Rear both sides 5th Free 375~390 9500~10000 Drive chain lock & link set 1
h. Side stand indicator
High pressure fuel filter 1
i. Fuel indicator
8" Small Starter clutch bush 1

32 Tune engine & carburettor LH 2.00
connector
Fork oil seal 2
33 Study job card & verify work 1.00
Cylinder head gasket (If required) 1
34 Lower the lift. 0.30
Front disc pad inspect / replace (If worn out) 2 + 2
35 Take out & park the vehicle 0.50
1st Paid 465~480 12000~12500 NIL NIL
SUB TOTAL 16.3 16.55
Engine oil 1150 ml.
Carry out any additional
36 work as indicated by the 5.0 5.0
customer or as required 2nd Paid 555~570 14500~15000 Drive chain lock & link set 1
TOTAL TIME 21.3 21.55 Steering cone kit 1
37
Test ride of the vehicle - To be done 3rd Paid 615~630 17000~17500 NIL NIL
if required and park 1.5 by Expert
Engine oil 1150 ml.
To be done
Clean the vehicle at the
38 1.0 by Delivery
time of delivery
boy
Clutch cover gasket 1
Air filter foam element 1
Total time taken for Periodic SOP 33 Minutes approximately.
Spark plug 2
In a shift of 480 minutes, One technician can do 15 Vehicles Periodic SOP comfortably. 4th Paid 705~720 19500~20000 Front disc pad inspect / replace (If worn out) 2 + 2
In a shift of 480 minutes, 23 Vehicles per Bay per Day can be achieved comfortable with Fork oil 330 ml.
1 Bay, 2 Technician working. Clutch plate 1
Rear brake damper 1
Drive chain lock & link set 1
5th Paid 795~810 22000~22500 NIL NIL
6th Paid 885~900 24500~25000 Chain sprocket kit 1
7th Paid 975~990 27000~27500 NIL NIL
Service Wise Parts Kit Schedule Maintenance
Periodic Parts Replacement Kit for Free & Paid Services Cleaning
The vehicle must be cleaned periodically using pressurized water.
Service Days Kms. Limit Part Name Quantity
Before cleaning the vehicle cover the important parts like Ignition
Engine oil 1150 ml. switch, Silencer Tail end, CDI unit, H.T. coil with plastic bags. Don’t
apply the jet of water directly on electrical parts such as Switches,
Clutch cover gasket 1 Ignition unit, Coils etc. otherwise they may get damaged.
Air filter foam element 1 Brushing with kerosene and wiping dry with clean rag is advisable for
external cleaning of the engine. All painted surfaces should be washed
Spark plug 2 with water. Do not use kerosene or hard detergent soap on painted
surfaces as it damages the paint and turns it dull.
Valve oil kit 1
After washing, dry the vehicle with compressed air and carry out the
8th Paid 1065~1080 29500~30000 Cylinder head gasket 1 lubrication as recommended
Cylinder head stud copper plated steel washer 4
Caution : Water may enter on the brake liners during washing & brake
Front disc pad inspect / Replace (If worn out) 2 + 2 slippage may occur. Ensure that brake liners are dry before driving the
vehicle.
Steering cone kit 1
Fork oil 330 ml. Periodic Maintenance
Drive chain lock & link set 1 Periodic maintenance (in accordance with the periodic maintenance
chart) of a vehicle is most important to prolong vehicle life, trouble
Use always Genuine Bajaj Auto parts & recommended lubricants. free running and ensure your safety while driving.
(Engine oil: SAE 20W50 API ‘SJ’ + JASO ‘MA’ grade)
Engine Oil Level Checking
• Park the vehicle on level surface on center stand to check the oil
level.
Notes : • Inspect the oil level through oil inspection window
• It should be in between upper and lower mark
• Top up if required
Recommended Oil Grade and Qty

Grade SAE 20W50 of API ‘SJ’ + JASO ‘MA’
Quantity Drain & Refill 1150 ml.
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.
• Clutch cover B
• Oil cooler banjo bolts & gaskets

• Oil pump mounting bolts (A) (3 Nos)
A
• Pump with strainer.
• Clip (B) and take out ‘Oil Strainer’ from oil
pump.
Schedule Maintenance Schedule Maintenance
Remove : Air Filter Cleaning

• Clean oil strainer with Kerosene / Diesel blow compressed air and
then refit it. Clean Air filter element adhering to standard SOP
• Replace oil strainer if found damaged.
3rd Stage:
1st Stage:
Dip into
Clean with Kerosene Engine Oil (20W40)
Centrifugal Oil Filter Cleaning:
Remove :
• Centrifugal oil filter cover mounting screws
(C) 3 Nos.
• The cover with gasket
• Replace gasket if damaged
Squeeze and Remove
• Clean centrifugal oil filter using Nylon Squeeze Excess Oil
brush/kerosene or Diesel
Air Filter
Air Cleaner Element Removal
Remove :
2nd Stage:
• RH side panel by unlocking it with key
Clean with Dry with Cotton Cloth
Kerosene Again
Remove :
• 2 bolts (A).
Blow Low Pressure
• Air filter cover (B). Compressed Air
B
A
Remove : Air Filter Element Cleaning and Inspection
• Air filter element assembly along with catrej Note : In dusty areas, the element should be cleaned more frequently
• Seperate foam filter from the catrej than the recommended interval.
After riding 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 if there is a brakage in the element material or any other damage
to the element replace the element with a new one.
Note :
• No need of removing flame arrestor
Warning : Clean the element in a well-ventilated area, and make sure
• White colour filter portion towards carburettor side that there are no sparks or flames anywhere near the working area.
• Ensure beading placed properly when fitting cover Because of the danger of highly flammable liquid, do not use
gasoline/petrol or a low-flash point solvent to clean the element.
Spark Plug Position 1 2 3 4 5

Spring Action Stronger
Recommended Spark Plug Champion RG4HC
Electrode Gap 0.6 ~ 0.8 mm If the Shock Absorber sleeves on both sides are not adjusted to
Replace Spark Plug After every 10000 Kms. the same position, an unsafe riding condition may result.
Note : Std setting is done in 2nd notch
Battery - 12V - 9 Ah Nitrox Air Filling

• Battery is located inside LH cover Procedure for gas checking and Refilling
• Check the electrolyte level in each cell and ensure that the level is • Remove the Phillips-headed small screw and ‘O’ ring.
between the upper and lower level lines. • Clamp the cylindrical guide clamp on to the canister keeping the
• Remove the battery filler caps and fill with distilled water until the rubber plug in the center to support the syringe needle insertion and
electrolyte level in each cell reaches the upper level line if required. keeping in position.
• Hold the pump as shown and pierce the syringe needle into the
Note : Add only distilled water to the battery. Tap water is not a center of rubber plug.
substitute for distilled water and will shorten the life of the battery. • The molded needle adaptor will rest into the clamped cylindrical
guide
• Apply petroleum jelly on to the terminals • Read the gas pressure on the dial gauge. If the gas pressure is
below 6.5 Kg/cm2 refill the air by pumping, keeping the needle in as
it is condition without removal. As the natural air consists of 71% of
Front Brake Fluid Level nitrogen it will serve the purpose.
Front Brake Fluid Level • To fill the air into the canister, apply full stroke of pump as shown;
otherwise air will not get inflated into the pump.
• Front brake fluid master cylinder reservior is located near RH switch
on handle bar. • Keep on pumping the air unless you get 7.5 kg/cm2 on the gauge
• To check oil level, park the vehicle on Main / Center stand with • Pull out the air pump along with needle carefully and take out the
handle bar in straight position. guide clamp
• Always ensure that brake fluid level is above ‘MIN’ mark given on • Finally fix the phillips headed screw with ‘O’ ring.
inspection window.
• Use only DOT-3 or DOT-4 brake fluid (from sealed container) to top
up if required.
Note : It is advisable that brake fluid should be replenished once in

a year.
Drive Chain Slack / Lubrication
• Set the motorcycle upon its center stand.
Rear Shock Absorber
• Rotate the rear wheel to find the position where the chain is tightest
The rear shock absorbers can be adjusted to one of five positions to & measure the vertical movement midway between the sprockets.
suit riding conditions. Using special tool adjust the required position
you desire. They can be left soft for average road riding condition • If the drive chain is too tight or too loose, adjust it so that the
but should be adjusted harder for rough road condition. chain slack will be within the standard value.
Shock Absorbers adjusted either too soft or too hard adversely affect • Check drive chain slackness at every 1000 kms.
riding comfort and stability. Drive Chain Slackness : 25 ~ 35 mm
To adjust the Rear Shock Absorbers Service Limit 40 ~ 50 mm
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 Tyre Air Pressure

1st Stage: • Keep appropriate tyre pressure as mentioned below to increase life
of this tyre and for better fuel consumption.
Clean with SAE 90 Grade oil.
2
Front 2.00 Kg/cm (28.4 PSI)
2
Rear - with Solo 2.00 Kg/cm (28.4 PSI)
Rear - with Pillion 2.15 Kg/cm2 (30.5 PSI)
2nd Stage:
Clean with Cleaner
SAE 90 Grade oil again Important Adjustments and Checking Procedures
Idling Speed Adjustment
Whenever the idling adjustment is disturbed
follow the procedure given below for setting
Blow Compressed Air proper engine idling.
• Start engine & drive it for at least 5 kms.
or warm the engine till the oil temp
reaches 600C.
• Remove the Bolt/Plug near Exhaus TEC

• Connect the probe of CO analyser. Set the CO between1.75~2.25 %
by adjusting volume control screw.
3rd Stage: • Then set the engine idling r.p.m. by rotating the idle adjustment
screw clockwise or anticlockwise by hand.
Dip into SAE 90 Oil
• For the precise adjustment of idling speed, use of tachometer is
recommended.
• Rotate the throttle a few times to make sure that the idling speed
does not change. Readjust if necessary.
• Do not attempt to compensate for faults in other systems by
adjusting the idle speed.
Idling Sped : 1400 + 100 rpm
Soak into SAE 90 Oil Tappet Clearance Setting

• Ensure that the engine is cold.
• Ensure the ‘T’ mark on the ‘Rotor’ match
with the mark on the ‘Crankcase LH’. At
this stage the ‘Piston’ is at TDC and both
the ‘Tappets’ are free.
• Holding tappet screw firmly with special
tool loosen the tappet screw nut.
• Put the feeler gauge, measure and adjust
Final Stage: the clearance.
• Lock the nut holding screw with special tool after getting desired
Hook Chain for
clearance.
dripping of excess oil
• Again check the tappet clearance with gauge. The gauge should
slide with slight resistance between tappet and valve stem head
feeler and tighten the check nut with a spanner.
• Inlet Valve : 0.05 mm • Exhaust Valve : 0.1 mm
Special Tools : Feeler Gauge - 69 7502 51 & Valve Adjusting
Screw Holder - 37 1031 53
Ignition Timing Inspection Reed Switch Setting and Checking

Connect cable of stroboscope to one of the H. T. Coil carrying Check throttle lever movement by rotating it with hand. It should not
current to spark plug. be sticky in operation and should return back it self on releasing.
Start the engine. bracket Multimeter should show continuity.
• Magnet should not touch with reed switch.
Aim the stroboscope light at Magneto cover glass window. Gap
2.5mm max.
• Gap between Magnet & Reed Switch should not be more than 2.5mm.
- At idling speed the ‘F’ marked line on the rotor coincide with the
line mark on magneto side c’case. (100 BTDC @ 1400 rpm). • Movement of throttle lever with magnet assembly and Reed Switch
fitted should be free.
- As the engine rpm is increased the ‘A’ marked on the rotor
coincide with the line mark on magneto side c’case. (280 BTDC @
3500 rpm). Reed Switch : Setting
- This indicates the advance timing is functioning correctly. • Accelerator cable play: 2-3 mm by adjusting the Adjuster
- Remember the ‘T’ marked line is a reference line for TDC position • Protude stopper of the throttle lever bracket must on idling screw tip.
of the piston and is not for Ignition timing.
Clutch Lever Free Play Adjustment

A • Slide the dust cover at lever yoke end.
• Check that the clutch cable outer end is fully seated in the adjuster.
0.00 Reed Switch : Checking
• Turn the adjuster (A) until the proper amount of free play can be
obtained. • Keep throttle at zero position.
B • Tighten the lock nut (B) against the adjuster. If the clutch free play • On connecting multimeter to Reed Switch coupler it should show
cannot be adjusted with the adjuster at the handle bar end, use the continuity.
adjuster at the lower ends of the clutch cable situated on clutch
cover.
• 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 clutch cable bracket by holding one nut and
tightening the other, after the required free play.
C Clutch Lever Free Play : 2 ~ 3 mm 1
• When throttle is open and Reed Switch magnet crosses to straight

edge of fix bracket of Reed Switch multimeter should show
discontinuity.
Accelerator Free Play Adjustment

• Turn the adjuster (A) until the proper amount of free play can be
obtained.
• Tighten the lock nut (B) against the adjuster.
• 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 0.00
B
Accelerator cable situated on carburettor.
A • Loosen the 2 lock nuts (C) on accelerator cable bracket end adjust • On De-acceleration, when of Reed Switch magnet re-coinsides with
by adjuster (D) provided on the cable. straight edge of fix bracket of Reed Switch Multimeter should show
continuity.
D • Tighten both the lock nuts on bracket by holding one nut and
tightening the other, after ensuring the required free play.
C Accelerator Grip Free Play : 2 ~ 3 mm
Schedule Maintenance Standard Checking Procedure
Front Brake Free Play Adjustment Compression Pressure Testing

There is no need for free play adjustment, since the pistons in caliper For testing the compression pressure first warm up the engine.
assembly will move towards the pads and take new positions in order Remove the spark plug. LH side.
to automatically compensate for pad wear. The free play will be
approximately 2 ~ 3 mm.
Caution : Disconnect H. T. lead cable from second spark plug i.e. RH side.
Front Brake Lever Play : 2 ~ 3 mm.
Rear Brake Pedal Adjustment Fit the compression gauge with adapter in the Spark plug hole.
Check the rear brake pedal play as stated below. If it is more or less Open the throttle fully & crank the engine.
than the standard, adjust the rear brake. Note the reading in the compression gauge.
• Depress the rear brake pedal lightly by hand. This is free play. Release the pressure by pressing the release valve on hose pipe.
• If the rear brake pedal free play is incorrect, adjusting the rear brake Take average of 3 such readings for noting actual compression
shoe adjuster nut (A). pressure.
• Operate the pedal (B) for few times to see that it returns to its rest Confirm the compression pressure is between 11 to 13 Kg/cm2
position immediately upon release.
Wet Compression Test :
• Rotate rear wheels to check for brake drag.
If the compression pressure is found below lower limit than
• Check braking effectiveness. specified, put few drops of engine oil through the spark plug hole
• If there is any doubt as to the conditions of the brake, check the and again check compression pressure.
brake parts for wear or damage. If you find considerable increase this time, then cause for the low
• Turn the adjuster until the rear brake pedal have the correct amount compression pressure lies in Cylinder / Piston assembly.
of play. If compression pressure remains the same, then the cause for low
Rear Brake Pedal Play : 25 ~ 30 mm. compression pressure lies in Cylinder / Head assembly.
Rear Brake Pedal Position Adjustment Caution : If wet compression is done, remove second spark plug and clean
thoroughly to avoid oil fouling before fitment.
To suit rider foot comfort / operating style the angle of the rear brake
pedal can be adjusted by loosening the lock nut (A) and adjusting the
A bolt (B). Chain Slack Adjustment :
Ensure free play by turning the adjuster clockwise or anticlockwise to
B achieve specified free play.
• Set the motorcycle upon its centre stand.
• Rotate the rear wheel to find the position where the chain is tightest
Note : After pedal position adjustment, it is necessary to set the free play.
and measure the vertical movement midway between the sprockets.
• If the drive chain is too tight or too loose, adjust it so that the
Petrol Cock Bowl Cleaning chain slack will be within the standard value i.e. 25-35 mm.
Put off the fuel cock. • Loosen the rear torque link nut (A) & rear brake adjusting nut (F).
Remove the bowl with open ended spanner. • Loosen the left and right chain adjuster lock nuts (B).
• Clean the bowl and refit. • Loosen the axle nut (C).
• If the chain is too tight, back out the left & right chain adjusting
nuts evenly & kick the wheel forward until the chain is too loose.
• Turn both chain adjusting nuts evenly until the drive chain has the
correct amount of slack. To keep the chain and wheel properly
B Tie Rod Adjustment aligned, the notch (E) on the left
Lubricate the ball joints. C chain adjuster should align with the
F A same swing arm mark that the right
• Adjust the Tie rod nut (A) and (B) to achieve desired position of chain adjuster notch (E) aligns with.
gear pedal position.
A Warning : Misalignment of the wheel will result in abnormal wear, and may E
result in unsafe riding condition.
Standard Checking Procedure Standard Checking Procedure
• Tighten both chain adjuster lock nuts. Air Bleeding of Disc Brake System :
For air bleeding from front Hydraulic brake system first top up the
master cylinder with hydraulic oil.
Operate the brake lever slowly in order to get filled the oil in the
circuit.
Connect transparent tube to the bleeder screw at caliper
Operate the brake lever and keeping in pressed position loosens the
bleeder screw so that some oil escapes with the air bubbles.
• Center the brake panel assembly in the brake drum. This is done by Keep on operating the brake lever till the air bubble escape out
tightening the axle nut lightly, spinning the wheel, and depressing completely through bleeder screw, and top up the master cylinder if
the brake pedal forcefully. The partially tightened axle nut allows the required.
brake panel assembly to center itself within the brake drum.
Once the air escapes out from the hose pipe the brake lever meets
• Tighten the Axle Nut resistance, which indicates completion of air bleeding
• Tighten the torque link nut After completing the bleeding, top up the master cylinder up to the
• Fix the snap ring maximum level mark.
• Adjust the correct brake play
Note : This procedure can prevent a soft or spongy feeling brake.

Nitrox Air Filling
• Remove the Phillips head screw & small ‘O’ ring fitted on air valve
Piston Ring Fitment :
of Nitrox RSA.
• Piston rings must always be fitted with respect to exhaust mark on • Fix the guide to canister of Nitrox shocker in such a way that guide
the piston. hole is concentric with air filling valve.
• First place the bottom oil rail ring with end gap 280 towards left of • Insert the Nitrox air filling pumps needle end into the guide &
the exhaust mark in the last groove. carefully pierce the rubber pin fitted inside the air valve of Nitrox
• Place oil expander ring with butting end downward and end gap RSA.
facing opposite to the exhaust mark. • Note the pressure indicated by pressure gauge of Nitrox air pump.
• Now fit top oil rail ring on the expander ring with end gap 300 Refill the pressure.
towards right of the exhaust mark. • Once the pressure reaches upto 7.5 Kg/cm2, take out the needle
• Fit the second piston ring with ‘Top 2’ mark facing upward and end slowly from canister.
gap facing opposite to the exhaust mark. • Fit the Phillips head screw & small ‘O’ ring fitted on air valve of
• Finally fit the first ring with ‘Top 1’ mark upward and end gap Nitrox RSA.
facing towards the exhaust mark.
• Remember fitment of 2nd ring upside down may lead to passing of Power Up the Jig
oil above the piston and ultimately leading to smoky exhaust.
The Jig should carry out a self test, where first all Red LED; glow
sequentially and then all Green LED; flash twice.
Manual Testing
• Connect wiring harness to C1 connector.
• Through this harness the following testing can be carried out :
- Vehicle sensor speed.
- Hall sensor.
- Starter relay.
Standard Checking Procedure Special Tools
LCD Speedo Console Test : Details of Exclusive Special Tool

• Connect wiring harness number 2 to C2 connector. For carrying out repairs / overhauls, 2 new special tools for Pulsar DTS-i 200cc have been
• After connecting speedo console wait unitl console LCD goes blank. developed. Rest of the special tools required remains the same which were earlier required for
• Now press speedo console test switch to start the test. Pulsar and Pulsar DTSi and Pulsar DTSi UG III.
• Observe for working of speedo console till test ends.
Engine
Sprocket Catcher
Body Control Unit (BCU) Test :
Drawing No.:
• Connect wiring harness number 3 to C3, C4 and C5 connectors 37 10DH 36
respectively.
Application :
• Press the BCU test switch. For holding sprocket during removal
• At the end of complete test, Green colour glowing of ‘Result’ LED / refitting of Cam sprocket allen
indicates BCU test passed. bolt.
• At the end of complete test, Red glowing of ‘Result’ LED indicates
BCU test failed at respective Red indications.
Camshaft Big Bearing Puller
Drawing No.:
37 10DH 32
Application :
To remove bearing (Decompression
assembly side) of camshaft.
Camshaft Small Bearing Puller
Drawing No.:
37 10DH 31
Application :
To remove small bearing of
camshaft.
Rocker Pin Remover
Drawing No.:
37 10DH 35
Application :
To remove rocker pin from cylinder
head.
Silent Bush Puller
Drawing No.:
37 10DH 33
Application :
To remove silent bush from cylinder
head cover.
Special Tools Special Tools
Rotor Puller with Butt Pin Bearing Extractor
Drawing No.: Drawing No.:

37 10DJ 32 37 10DJ 76
Application : Application :
Used to pull out the rotor from Used to extract the input shaft
crankshaft assembly. bearing from crankcase LH.
Primary Gear Holder

Bearing Puller
Drawing No.:
37 10DJ 28 Drawing No.:
Application : 37 10DJ 77
Use to hold primary gear while Application :
loosening / tightening the clutch nut. Used to pull out the bearing for
body balancer from crankcase LH.
Balancer Gear Holder

Adaptor & Valve Spring compressor
Drawing No.:
37 10DJ 63 Adaptor - Drawing No.: 37 10DJ 78
Valve Spring Compressor - Drawing
Application : No.: 37 1031 07
Used to load the pre-tensioned scissor Application :
gears of Assly balancer Idler gear. Used for assembling / dismantling
inlet, exhaust valves by compressing
spring in cylinder head.
Special Nut
Rotor Holder
Drawing No.:
37 10DJ 43 Drawing No.:
Application : H6 0721 00
Used to remove / fit of centrifugal Application :
oil filter nut. To hold rotor while loosening bolt.
Dia. = 25.9+0.1
Note : Existing tool can be used by reducing diameter to 25.9 + 0.1 mm
Piston Ring Holder ew Drift
Drawing No.:----------- Drawing No.:

74 9309 89
Application :
Used for compressing the piston Application :
rings when assembly piston in the To remove piston pin.
cylinder block.
Bearing Race Extractor Thrust plate aligner/holder
Drawing No.: Drawing No.:

37 00DJ 01 T-1011168
Application : Application :
Used for removing the lower bearing To align the clutch hub concentricity
race from ‘T’ w.r.to clutch wheel, clutch housing
and thrust plate
Special Tools Special Tools
Crankshaft Bearing Extractor ew Chassis
Drawing No.: -------------

Fork oil seal fitment punch
Application : Drawing No.: 74 9310 13

To remove bearing from crankshaft
Application :
To fit fork oil seal on outer pipe
Output Sprocket Holder
Drawing No.:
37 1030 53 Rear Shock absorber adjuster
Application : Drawing No.:

To hold the output sprocket while 37 00DH 14
removing sprocket bolt Application :
For adjusting the notch position of
RSA to achieve hard or soft rear
Bearing Driver Set suspension
Drawing No.:
37 1030 61 Fork Inner & Outer Tube Extractor
Application : Drawing No.: 74 9310 15

Common bearing driver set for fitting
and removing bearings from
crankcase.
Application :
Used for removing front fork inner
tube from outer tube.
Notes : Notes :
Carburettor and Fuel System Carburettor and Fuel System
Carburettor Fuel Tank

Specifications : • Turn the fuel tap to the off position.
• Disconnect the fuel pipe connections from the petrol cock.
Item Pulsar 200cc
• Disconnect the fuel indicator wiring harness connection.
Make and Type Ucal-Mikuni BS29
Identification No. JC BS29
Idling Speed 1400 +100
VC Screw setting 2.5 +2 turns out
Main Jet 110
Jet needle mark 4EDY2 Remove :
JC Needle jet mark 922MP-3 • Side cover LH and RH by unlocking it with key.
BS29 Jet needle clip 1st from top
position Note : To remove the side covers LH and RH, unlock with the key then
Pilot Jet 17.5 hold the front end of the cover and pull the front end out then pull the
cover in forward direction to remove it from the lug.
Starter jet Fixed type
Throttle valve Fixed type
Chock Lever 2 stage with push pull type mechanism
Remove :
• Pull the cable from the cover LH to unlock the rider seat lock &
Notes : Pillion seat lock.
• Both seat assembly
Note : To remove the seat assembly individually hold the seat assembly
and lift it from the rear end and pull it back.
Remove :
• 1 bolt (A).
• Fuel gauge wiring connection.
• Drain pipe connection.
• Fuel pipe connection.
• Fuel tank assembly
Note : To remove the fuel tank assembly from the chassis lift the fuel tank
assembly by holding it at the rear end and pull it back.
Fuel Tank Inspection

Remove the hoses from the fuel tank, and open the tank cap. Check
to see if the breather pipe and water drain pipe in the tank for
clogging. If they are clogged, remove the tank and drain it, and then
blow pipes free with compressed air.
Fuel Tank Cleaning
Warning : Clean the tank in well ventilated area, and take care that there
are no smokes or flame anywhere near the working area. Because of the
danger of highly flammable liquids, do not use gasoline or low-flash point
solvents to clean the tank.
Carburettor and Fuel System Carburettor and Fuel System
• Remove the fuel tank and drain it. • Bowl

• Pour some high-flash point solvent into the fuel tank and shake the • Strainer
tank to remove dirt and fuel deposits. • Gasket
• Pour the solvent out of the tank. • Selector Body
• Dry the tank and the fuel tap with compresses air. • 2 hole subber seal
• Install the fuel tank.
Note : While installing the fuel tank on chassis make sure that the dampers
(A) on petrol tank are mounted on the chassis. Notes :
Fuel Tank Cap Dismantling

To unlock the Fuel tank cap, insert the key in the key slot and turn it
anticlockwise direction and lift open the tank cap.
A Now remove the anti theft screw and then remove the allen bolts (A)
and remove the fuel tank cap assembly from the fuel tank. Fitting is
the reverse procedure of dismantling. But take care that the vent hole
is free from any foreign particles that may clog the hole. To lock the
fuel tank cap, just press the cap without key.
Fuel Cock Removal

Remove :
• 2 bolts (A)
• Fuel cock assembly from the fuel tank.
A
Note :
• Always loosen the bowl of the fuel cock on vehicle itself
• Check the fuel cock strainer for any breaks or deterioration.
• If the fuel cock strainer have any breaks or are deteriorated,
they may allow dirt to reach the carburettor, causing poor
running. Replace the strainer.
• Clean the fuel cock strainer in a high-flash point solvent.

• Pour high flash point solvent through the cock in all lever positions.
• Dry the tank and the fuel cock with compressed air.
• Install the cock on the tank.
Working of Carburettor Working of Carburettor
Starter Circuit : Constant Velocity Carburettor Pilot Circuit : Constant Velocity Carburettor 1. Pilot Jet
2. Pilot Outlet Hole
Cut Section View
of Mixing Chamber 3. Butterfly Valve
4. Volume Control
Screw
5. Idling Adjustment
Screw
6. Fuel Inlet
Air inlet
for choke
Towards
Engine Towards
Engine
Air Inlet
1. Plunger Cap 1. Plunger
for pilot jet
2. Diaphragm Cap 2. Mixing Chamber Towards
3. Diaphragm Piston Valve 3. Starter Jet Engine
4. Piston Valve with Jet Needle
5. Float Chamber
Function Function
The function of starter circuit is to provide rich air fuel mixture on starting / cold starting. At cold engine The pilot circuit provides the air fuel mixture at idling when not enough air is being drawn through the
carburettor to cause the main circuit to operate.
condition the air is dense also the engine parts are cold enough this does not allow the petrol to
vaporize properly this leads to starting trouble.
Construction
The pilot circuit consists of pilot jet, pilot air jet and volume control screw. The pilot jet meters the fuel
Construction and the pilot air jet meters the air quantity. The volume control (VC) screw controls the amount of air fuel
The Starter Circuit consists of a starter jet and a plunger. The starter jet is used to meter the fuel and a
mixture flowing through the pilot outlet.
plunger that opens an air passage from the inlet of the carburettor (underneath the diaphragm) which
passes the mixture to the mainfold.
Working
As the air enters the pilot air inlet the fuel is metered by pilot jet and air quantity is metered by pilot air
Working jet. The atomized / vaporized mixture is discharged through the pilot outlet. The pilot outlet is located on
On pulling the choke lever the plunger is lifted by a cable. This uncovers the fuel passage that leads to the manifold side of the carburettor. Since the throttle valve is almost at fully closed position, air fuel
the starter jet, air inlet passage and the outlet passage towards the manifold. This creates enough mixture is supplied mainly by pilot outlet only. Air fuel mixture volume is adjusted by volume control (VC)
suction to draw fuel up from the bowl into the mixing chamber (below the plunger). Here the fuel is screw and mixture becomes lean when volume control (VC) screw turned clockwise and rich when it is
mixed with the air and the mixture is drawn into the engine through the outlet passage. turned Anticlockwise direction.
Working of Carburettor Working of Carburettor
Progression Circuit : Constant Velocity Carburettor 1. Pilot Jet

Main Circuit : Constant Velocity Carburettor
2. Pilot Outlet Hole
3. Bypass /
Progression Holes
1. Piston Valve
4. Butterfly Valve
2. Piston Valve Diaphragm
5. Volume Control
3. Jet Needle
Screw
4. Needle Jet
6. Throttle Lever
5. Jet Holder
6. Main Jet
Towards
Engine Air Inlet
for main jet
Function
The Main Circuit provides air fuel mixture by
Air Inlet lifting up the piston valve in direct proportion
Towards for pilot jet to the engine demand. This assures the
Engine correct venture size & air velocity throughout
the mid range operation of the engine.
Construction
This circuit consists of jet needle, needle jet
and main jet. To assist in atomization an air
bleed circuit is incorporated in the main
metering system and it aids fuel vaporization
by introducing the air into the fuel before it
enters the main air stream.
Function The piston valve movement is controlled by spring and carburettor venture vacuum which is generated
The progression circuit provides the air / fuel mixture at small throttle opening when pilot circuit is still below the piston valve diaphragm.
working but unable to meet the engine demands on small throttle opening.
Working
Construction When the butterfly valve is opened and air flow through the venturi increases, the air pressure in the
The progression circuit follows the path of pilot circuit and the construction is same as that of pilot venturi (and the upper chamber) decreases.
circuit. As the atmospheric pressure in the bottom chamber is greater than the venturi pressure above the
diaphragm, the piston valve along with jet needle is pushed up and more air fuel mixture is drawn into
Working the engine from main jet through needle jet into the main air stream.
As like pilot circuit the fuel is metered by pilot jet and air volume is metered by pilot air jet. This mixture When the butterfly valve is closed, air flow through the venturi decreases; air pressure in the venturi
in atomized form is discharged through the bypass ports when the butterfly valve is opened from idling increases and approaches atmospheric pressure, & the spring pushes the piston valve along with jet
further. needle down.
Working of Carburettor Digital Twin Spark Plug Ignition (DTS-i)
Pulsar DTSi is the first bike in the world (In small cc engine) to have twin spark ignition system.
Do’s Don’ts
1. The most obvious feature is the Twin Spark Plug configuration o f
Handling the Engine. The cylinder head has 2 spark plugs one on either
side. The spark plugs are of the smae Heat range (Champion
• Use appropriate screw • Never use oversize screw RG4HC (Resistive) and have similar electrode gaps. These also
drivers. drivers. spark simultaneuosly, This has been done to improve the
• Do not over tighten the jets combustion process by reducing the time of combustion. The end
and screws. results are low emissions, good fuel economy and good
• These will damage the jets driveability
and their seats. 2. To enable the sparking of the 2 spark plugs, a intelligent CDI
capable of handling this was developed. Further more, the ignition
Cleaning timing has been optimised to give the best output from engine
(100 BTDC @ 1400 rpm, 280 BTDC @ 3500 rpm). To enable
• For cleaning always use • Never clean the carburettor optimum igntion timing for part throttle loads and full throttle
carburettor cleaner like with water. loads, there are separate igntion maps stored in the memory of
- Acetone the CDI. These are activated depending on the throttle opening
- Carbon Tetra chloride • Jets & air passages will get
and engine speed. The Digital CDI has a bit Microprocessor which
- Aerosol clogged due to sediments if
handles all these inputs and gives out the required and correct
- CVC spray cleaned by water.
spark advance. The intelligent CDI can be easily indentified by 2
green dots marked on CDI case.
Maintenance 3. To enable switching the required igntion maps, a magnetically
operated need switch is incorporated on the carburettor throttle
Ensure Replace shaft and carburettor body. This is known as TRICS. Throttle
• Jets • Jets Responsive Igntion Control System.
- Holes are clean. - Worn out jet.
- Holes are not worn out. - Incorrect size jet. 4. These engines are capable of of reviving very high, quite easily.
- Size as per specification. To keep them mechanically safe, a engine rpm limiter has been
incorporated in the Digital CDI. This curtails the sparks to the
spark plugs thereby limiting the engine rpm Max upto 10500 and
• Float is in good condition. - Punctured, Squeezed and thus keeps the engine mechanically safe. There are 2 spark plugs.
distorted float. LH spark plug fires at 350 rpm and then continues to give spark
till at 10500 rpm of engine. The spark is cut off from LH plug
10500 rpm to protect engine from excessively high speed.
RH spark plug gives spark at 750 rpm and then continues to give
till 6000 rpm of engine. If engine rpm exceeds 6000 rpm then RH
plug is cut off. This is done to reduce combustion noise created
• Float Pin - Worn out tip.
in engine.
- Tip having no wear mark. - If spring loaded pin is
- Spring loaded pin is free sticky. 5. This engine has been extensively tuned for more Power and
in movement. Torque.
6. The DTSi technology has enabled the Pulsar to meet 2007 norms
without any Secondary air injection devices.
• Needle Jet - Needle worn out at taper
- No wear at taper portion. portion. Troubleshooting :
- Circlip position is in
specified groove. • Malfunctioning of the Reed switch assly will not harm the engine, neither it will give any physical
indicators like starting trouble or misfiring.
However checking of proper functioning of Reed Switch Assly at PDI and at every service
is essential.
• Piston valve - Piston valve worn out.
- No wear mark. Scoring marks. • Following symptoms may indicate as malfunctioning of Reed Switch Assly as one of the cause.
- Diaphragm condition. - Diaphragm punctured.
Symptom Cause Remedy
Sudden drop in mileage & power The igntion systems is working only Replacement of Reed Switch Assly
lack in mid range rpm in 2nd map due to reed switch is
stuck in open circuit
Overhaul carburettor at every 10,000 kms. and insepct the parts.
Digital Twin Spark Plug Ignition (DTS-i) Important Points to Remember
Customer Eductaion Tips : Valve timing • When splitting crankcase

• While starting the engine in any case throttle should not be rotated more. Even if this happens, • Ensure the sprocket marks always remove 1 long bolt
engine will start, but the engine rpm will shoot uo too much (due to too high throttle opening) (A) are aligned horizontally fitted from clutch side
with cylinder head top first.
• Whenever there is a sudden subtantial drop in mileage, customer should report to Bajaj Auto’s machined face and the
Authorised Service Centres. piston is at TDC.
A A
CO % Checking and Tune Up (To ensure betten mileage) :

Check following before CO % checking / Tune up - • Secure the ‘Cam Chain • Remove long bolt
• Air filter connections, intake manifold, insulator fitment, connecting tube fitment. Sprocket’ in the Spl. tool immediately after removal
• Spark Plug gap (0.6 to 0.8 mm) firmly & then tighten the of long bolt clutch side.
• All pipes and connections of fuel system for any cracks, leakage, plucking, pinching and loose sprocket allen bolt (A). • Ensure proper fitment of
0
connections.
• Ensure that the ‘O’ mark bolt with copper washer to
• Ensure Tappet Clearance :
on washer always faces avoid oil leakage.
Inlet : 0.05 mm A outwards when tightening
Exhaust : 0.1 mm
the allen bolt.
• Ensure compression pressure inside the cylinder (11 to 13 Kg/cm2)
• Check the ignition timing (100 BTDC at 1400 rpm and 280 BTDC at 3500 rpm)
CO % checking and carburettor VC screw setting • Rocker arm has 20 rollers • Shifter fork is having a
• Start and warm up the engine inside the outer cage. roller. These rollers are
• The oil temperature should be above 600 C. This can be achieved by running vehicle in top gear • NR bearing doesn’t have having one side tapered
at the speed of minimum 40 Kmph for 5 ~ 6 Kms. inner cage. inner dia.
• Adjust the engine speed to 1400 + 100 rpm with idling adjustment screw of carburettor. • Take utmost care while • Taper portion of roller
• Adjust the CO with the VC screw. It should be in between 1.75 to 2.25 % dismantling. Rollers should should face towards fork
• Confirm the engine speed whether it is within 1400 + 100 rpm or not. When setting Idle CO %, not fall inside engine. gear shift.
idle rpm and VCS have to be adjusted together to achieve 2 % CO and 1400 + 100 engine • Apply grease to fix needle
rpm. rollers inside rocker arm.
Item Pulsar 200cc Ensure • Load the assly balancer

Belleville • While assembling hub idler gear with 2 teeths
Make Ucal-Mikuni BS 29 Washer
clutch place plain washer from either side using the
Plain
Washer first & then place Belleville special tool.
Identification No JCBS29 washer. Concave face
Clutch
Hub should be upwards i.e.
Type CV Type towards technician.
Idling Speed 1400+100

A • After placing Belleville, fit • Fit primary gear drive (A).
B
VC Screw Setting 2.5+2 turns out clutch plate with 48 • The mark teeth of the
friction material cubs (A) primary gear should match
Main Jet 110 with more I.D. with the line mark on the
• 4 Nos. of clutch plates crankcase. This indicated
Jet needle mark 4EDY2 with 36 fiction material that the piston is at TDC
cubs (B) alternatively along position.
Needle jet mark 922MP-3 C
with steel plates. This procedure should be
• Fit top clutch plate with carried before fitting the
Jet needle clip position 1st from top 40 friction material cubs ‘Clutch Housing’ and this
(C). position should not be
Pilot Jet 17.5 disturbed while fitting the
• Input shaft has special ‘Clutch Housing’.
Starter Jet Fixed type nut.
Throttle valve Fixed type • Thick spacer tapered I.D.
should be placed on
Chock lever 2 stage with push tapered portion of Input
pull type mechanism Shaft.
• Input Shaft has left hand
threads.
Important Points to Remember Removal of Engine from Frame
• Take ‘Assembly Balancer Always ensure piston ring Removal of Engine from Frame :
Idler Gear’ along with position.
Thrust Washer which is Remove :
• Top Ring :
pre-loaded and is held in • Put OFF the fuel cock
Open end facing towards
special tool, Slide down
exhaust. • Side panel LH
the special tool with ‘Gear’
to engage the bottom half • Second Ring : • Side panel RH
of the ‘Assembly Balancer Open end facing towards
Idler Gear’ with the ‘Body inlet.
Balancer Gear Assembly’
• Upper Rail :
• Fit ‘Thrust washer’ on the
Open end 300 facing
other side.
towards exhaust. Remove :
• On assembly of ‘Assembly
Balancer Idler Gear’ the • Bottom Rail : • Both Seat assembly by pulling the cable for seat lock release
itched / Dot mark of Body Open end 300 facing located on LH side.
Balancer Gear Assembly’ towards inlet. • Disconnect the negative terminal of the battery.
should match with the line
mark on the ‘Crankcase’. • Expander : • Disconnect the wiring harness socket for fuel level Indicator.
Open ends at center and • Fuel pipe connections and moisture drain pipe from fuel tank.
joints butting together
• Holding the ‘Assembly facing down. • Disconnect stator plate harness
Balancer Gear’ in special • Disconnect neutral switch coupler
tool now slide inside the
‘Clutch Housing’ so that When tightening the special
the ‘Clutch Housing’ nut for centrifugal filter the
Remove :
smoothly engages with the Primary gear holder should
top half of ‘Assembly hold between the ‘Primary • Engine oil temp sensor screw (B) and disconnect the wire
Balancer Idler Gear’. Gear’ and ‘Clutch Housing’ • Remove sensor and gasket
from bottom side. (Note that
• Remove Spl. tool gently. • Drain bolt (A) and drain out the oil from engine.
oil pump assly is removed).
• Fit 2 dowels and Assly • Refit the drain bolt with gasket & tighten it.
B A
Balancer Idler Gear Cover
• Ensure perfect marking of When loosening the special Recommended oil Grade SAE 20W50 of API ‘SJ’ + JASO ‘MA’
gear marks with respect to nut for ‘Centrifugal Filter’ the
crankcase mark. Primary gear holder should Recommended Quantity Drain & Refill 1150 ml
Engine Overhaul 1300 ml
be hold between the
• Always prime a new oil ‘Primary Gear’ and Clutch
cooler by starting the Housing’ from upper side.
Remove :
engine and loosening the A
return line banjo (A) on the • Bolt (A)
clutch cover to remove • Petrol tank assembly.
trapped air. Never rest the Rotor holder
A against Gear change pedal
lever.
• Do not let the oil cooler

hang by itself, supported
only by the oil pipes,
Remove :
when assembling onto or
dis-assembling from the • Bolts (A)
chassis. The existing special nut • Gear shift pedal (B)
puller for Pulsar can be use • Drive sprocket cover LH.
for Pulsar UG-III and Pulsar
200 cc by reducing its
• Do not dismantle the cam diameter to 25.9 + 0.1 mm.
chain tensioner assembly.
Removal of Engine from Frame Removal of Engine from Frame
Using Special Tool : Sprocket Holder - Remove :

37 1030 53 • Disconnect the reed switch coupler.
A Remove : • Spark plug cap LH
• Bolts (A) • PCV pipe from breather
• Plate drive sprocket
B • Drive sprocket along with the chain.
• Neutral switch coupler (B).
Remove :
Remove : • While removing engine foundation bolts, first remove the topmost bolt and
• 2 nuts (B) for silencer flange then go down progressively.
Note : Bolts (A) holding the engine to the chassis. (4 bolts of 12 mm and
Note : Always remove the flange mounting first and then rear mounting to
B 1 bolt needs deep socket for removing it).
avoid misalignment of studs.
Remove :
• Bolt (A) of silencer bracket mounted on pillion RH side footstep.
• Silencer assembly.
A
Remove :
• Starter motor connection (A)
• Lift up the engine off the chassis and place it on engine stand.
A
Note : After disconnecting all the sub assemblies and control cables from
the engine lift up the engine and remove it from RHS of the vehicle.
Remove :
• Banjo bolt and gasket of oil cooler pipe (Intake) (A)
• Banjo bolt and gasket of oil cooler (Outlet) (B)
• Bolt (C)
C
A&B
Remove :
• Air filter mounting bolts to facilitate the removal of carburettor with
reed switch.
• Clamps of carburettor and disconnect carburettor along with
insulator and dismantle cables from it.
• Bracket bolts securing clutch cable on clutch cover.
• Spark plug cap RH
Dismantling Engine Dismantling Engine
Engine Top End Dismantling : Remove :

• Magneto cover 5 bolts
Engine Top End Dismantling : • Disconnect neutral switch coupler
Remove : • Magneto cover
• Pull out the cover on the spark plug cap RH and the spark plug • Rotate crankshaft to get piston at TDC.
cap itself • Ensure both tappets are at free state (i.e.
at the end of compression stroke)
• Using a plug spanner, loosen the spark plug and remove the spark
plug RH
• Loosen & unscrew the allen head grub screw of the sleeve spark Remove :
plug RH. • Loosen 2 dummy plug (A)
A
Note : Wrap a piece of cloth around the protruding edge of the
sleeve spark plug and using a plier, pull out the sleeve.
Remove :
• Cylinder head securing head cover 2 bolts (A)
• Cylinder head securing head cover 4 bolts (B)
Remove : A C B • Cylinder head securing head cover 4 domed cap nuts (C)
• There are 2 ‘O’ rings fitted in the cylinder head, one on the cam • 4 copper plated steel washers
chain wall and the other near the spark plug threading
• Using a thin, sharp pointed tool pierce the ‘O’ rings and remove Note : Improper tightening sequence may cause warpage in cylinder
them. (If required only) head cover and it can be damaged permanently.
Note : Remove these only if the ‘O’ ring protrusim in the bore is
non-existant (which means that the ‘O’ ring has set and it has lost Remove :
its compression or sealing ability.) • Cylinder head cover complete
• Cam shaft cap
• 2 Dummy plugs
Remove :
• Dummy plug gasket
• Loosen bolt (A) and unscrew chain tensioner plunger
• Cam chain tensioner assembly 2 bolts (B)
B • Cam chain tensioner assembly
A • Gasket
Using Special Tool : Sprocket Catcher -
3710 DH 36
Remove :
• Allen bolt (A)
Remove : • Spacer
• Both tappet caps A
• Cam sprocket
• Collar
• Cam shaft assly
Note : Hold the cam chain up right using soft copper wire or
thread. Do not use cotton waste for holding the cam chain.
Remove : Engine LH : (Magneto Side)

• Cylinder head assembly
Using Sp. Tool : Rotor Holder - H6 0721 00
• 2 Dowels
• Hold the rotor assembly
• Gasket cylinder head
A Remove :
• Rotor bolt (A)
• Washer
Remove : Using Special Tool - Rotor Puller with butt pin :

• 2 Banjo bolts (A) 37 10DJ 32
• Copper gasket Remove :
• Bolt (B) • Rotor assembly
A • Oil Pipe • Woodruff key
Remove : Note :
• Non tensioner side chain guide Holding the gear complete starter clutch rotate the rotor and pull it out
• Cylinder block assembly in Anticlockwise direction to prevent rollers and springs coming out.
Note : Holding the gear complete starter clutch rotate the rotor and
pull it out in Anticlockwise direction to prevent rollers and springs
coming out.
Warning :
Using Special Tool : Drift - 74 9309 89 • These components remain hot for a long time especially if removed from
Remove : a hot engine. Wear suitable hand protection to prevent burns.
• Rotor puller has left hand threads
• Piston pin lock LH & RH side
• Piston pin
• Piston assembly Remove :
• Gasket
B • Bolt (A)
Note : Place a piece of clean cloth above hallow portion of
• Plate starter clutch gear return (B)
cranckcase to arrest piston pin circlip if it falls during fitment.
• Gear starter clutch
A
Warning : When tapping the drift for removal of piston pin, confirm that
the connecting rod is held firmly against the direction of tapping to avoid
damage to big end bearing connecting rod of crankshaft.
Remove :
• Collar (A)
Remove : • Shaft
• Block gasket A • Gear comp. starter counter assly
A • 2 Dowels (A)
Note : Tie the cam chain firmly using soft copper wire/thread firmly
to avoid slipping down into crankcase.
Remove : Using Sp Tool : Special Nut Puller - 37 10DJ43

• 3 Screw (A) Using Sp Tool : Primary Gear Holder - 3710 DJ28
• Guide starter assembly along with oil seal. Remove :
• Centrifugal oil filter special nut
Note : Removal of guide starter assembly is to be removed only if • Belleville washer
required.
• Body centrifugal oil filter assly
Caution : Ensure that the woodruff key of rotor is removed prior to the
removal of guide starter assembly. The lips of magneto oil seal housed in
guide starter assembly will get damaged if not done so. Remove :
• Bearing with plunger
A Engine RH : Clutch Side

Remove :
• 1 screw - (A)
• Starter motor cover
Using Sp Tool : Special Nut Puller - 37 10DJ 43

Note : The rod clutch lifter, plunger oil, plate plunger oil and spring
joint may fall out of their respective places into the oil collection Using Sp Tool : Primary Gear Holder - 3710DJ28
tray. If so, ensure that these are collected & accounted for before Remove :
proceeding. • Input shaft special nut
• Belleville washer
Remove : • Clutch assly comp
• 12 Clutch cover bolts (B) • Spacer
• Bracket clutch cable (C)

Note : The existing Special Nut Puller 37 10DJ 43 can be used by
Note : The rod clutch lifter, plunger oil, plate plunger oil and spring grinding the tool OD to 25.9 + 0.1 mm
joint may fall out of their respective places into the oil collection
C B tray. If so, ensure that these are collected & accounted for before
proceeding.
Remove : Dia. = 25.9+0.1
• 2 Dowels
Remove :
• Clutch cover gasket
A • 3 Assly balancer Idler gear cover bolts (A)
• Starter Motor (B)
• Cover
• Washer
B • 2 Dowel
Using Sp. Tool : Primary Gear Holder 37 10DJ 28

A Remove : Remove :
• 3 phillips head screws (A) • Clutch housing
• Centrifugal oil filter cover
• Gasket
Note : Some amount of oil is trapped in cover and body of

centrifugal oil filter, this oil should be drained into the oil tray. Note : For ease in removal of clutch house insert special tool (P.
No.-37 10DJ 63) in Assly Balancer Idler Gear.
Remove : Remove :
• Assly balancer idler gear • Gear change lever
• 2 Washer
Remove : Remove :
• Bolt (A) • Spring
A • Locking plate • Allen bolt (A)
• Body balancer gear assly A • Guide gear
• Spacer
• Parallel Pin
Note : Check and inspect the drum change arm stopper for free
movement always.
Remove :
• Primary gear
• square key Engine Central Part :
Remove :
Note : Take care that square key does not fall inside the crankcase
A • Bolt (A) on RH side crankcase (Clutch side)
hollow portion while removing.
Remove :
• Cam chain
• Cam chain sprocket Remove :
• Parallel Pin • Bolt (B) on LH side crankcase (Magneto side)
Remove :
• 3 Bolts (A)
• Oil pump assembly Remove :
• 8 bolts on LH side crankcase
• 2 Dowels
• Split the Crankcase halves.
Warning : The oil pump may be hot, hence use suitable hand
A Note : Before separating crankcase halves confirm that all the
protection. Also, since the oil pump houses the oil strainer / mesh
also, it may retain some quantity of oil. This oil may be hot. Hence crankcase joining bolts are removed and the sprocket cam drive
proper care should be taken to drain it. with parallel pin on crankshaft assembly is removed.
Note : The oil which is in the oil pump housing should also be
drained out into the oil drain tray for measuring drained oil.
Dismantling Engine
Remove :
• 2 Shafts (A) & (B) of gear shifter fork.
• 3 fork shifts (1 small for input 2 big for output shaft.
• 3 Rollers
• Drum change
B A
Remove :
• Crankcase gasket
• 2 dowels
• Crankshaft assly
Pulsar DTS-i 200 Training Notes 63 Dealer Development Center

Pulsar-DTS-i 200cc A

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Identification Contents

Identification Salient Features

POWER & PERFORMANCE :

COMFORT & CONVENIENCE : Engine and Transmission

Advantages : Clutch : Wet, Multidisc type.

Benefit : Tyres Front : 90 x 90 x 17, 49 P (Tubeless)

WEIGHTS Technical Features Performance Parameters

Graphics Gorgeous Graphics to match to the profile Attractive Style

Ï What do the 4 icons at the topmost portion of the Speedometer Display?

2. The 2nd icon from left indicates a

3. The 3rd icon from left indicates +

Low Battery Voltage, when displayed.

4. The 4th icon from left indicates

Whichever RECOMMENDED FREQUENCY Whichever RECOMMENDED FREQUENCY

6. Air cleaner element V CL l l l l l 33. Front fork C,L l l l

8. Carburettor CL,A l l l l l 35. Front brake hose C,R 2 years

9. Fuel system leakages C,R l l l l l 36. Check nitrox gas pressure

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

19. Rear brake pedal play C,A 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

27. General lubrication L l l l l l

Position Position Position Position

Washing 6" Comb. Measuring

Bring vehicle and OE Spanner

4 Raise the lift. 0.30 Ring

Pistol Pencil Type

Check Battery, top up with Check electrical couplers

8" Small Starter clutch bush 1

TOTAL TIME 21.3 21.55 Steering cone kit 1

Recommended Oil Grade and Qty

Note : It is most vital to adhere to recommended frequency of oil change for

Oil Strainer Cleaning

• Oil cooler banjo bolts & gaskets

Remove : Air Filter Cleaning

Remove : Air Filter Element Cleaning and Inspection

Spark Plug Position 1 2 3 4 5

Note : Std setting is done in 2nd notch

Battery - 12V - 9 Ah Nitrox Air Filling

Note : It is advisable that brake fluid should be replenished once in

Drive Chain Cleaning / Lubrication Tyre Air Pressure

• Remove the Bolt/Plug near Exhaus TEC

Soak into SAE 90 Oil Tappet Clearance Setting

Ignition Timing Inspection Reed Switch Setting and Checking

Clutch Lever Free Play Adjustment

• When throttle is open and Reed Switch magnet crosses to straight

Accelerator Free Play Adjustment

Front Brake Free Play Adjustment Compression Pressure Testing

Note : This procedure can prevent a soft or spongy feeling brake.

LCD Speedo Console Test : Details of Exclusive Special Tool

Camshaft Small Bearing Puller

Rocker Pin Remover

Silent Bush Puller

Rotor Puller with Butt Pin Bearing Extractor

Drawing No.: Drawing No.:

Primary Gear Holder

Balancer Gear Holder

Piston Ring Holder ew Drift

Drawing No.:----------- Drawing No.:

Bearing Race Extractor Thrust plate aligner/holder

Drawing No.: Drawing No.:

Crankshaft Bearing Extractor ew Chassis

Drawing No.: -------------