Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

New Product Bulletin

Product Category Motorcycle

TO:
Selected Dealers / Authorized Service Centers - 2 Wh CC Group 220
Spare Parts Dealers & Distributors
Bulletin No. NP: 12
Sub: Introduction of “Pulsar 220 DTSi“
Date 23/06/2009

Dear Sirs:
We are pleased to introduce ‘Bajaj Pulsar 220 DTSi’. This bike offers a great package of Style, Power & Technology
in its class of bikes. We enclose herewith following information of this new bike, which gives you insight on product
features, maintenance details etc.
Product related information
1. Salient Features Annex – 1
2. Technical Specifications Annex – 2
3. Comparison With Competition Vehicles Annex – 3
4. DC Ignition System Annex – 4
5. Read before you ride Annex – 5
6. Pre-Delivery Inspection Checklist Annex – 6

Maintenance related information

7. Pre-Delivery Inspection - SOP Annex – 7
8. Periodic Service SOP Annex – 8
9. Periodic Maintenance & Lubrication Chart Annex – 9
10. Critical Part List Annex – 10
11. Initial Kit List-Vehicle billing would start after dealer Annex – 11
placing order Initial kit.
12. Frequently Asked Questions Annex – 12
13. Frequently Asked Questions related to Warranty Annex – 13
14. Reimbursement of warranty Jobs Annex – 14
15. Electrical Circuit Annex – 15

Note:-
1. The existing Pulsar 220 DTS-Fi is not opened for non pro-biking dealers. Hence this model will be sold &
serviced by probiking dealers only.
2. In view of above policy, the warranty & FSC of Pulsar 220 DTS-Fi will be claimed by probiking dealers as
usual.
Please go through above information. Ask your workshop & spare parts managers to share the same
with all staff and act upon the action points as per action matrix enclosed.
Thanking You,
Yours faithfully,

Prashant G. Pingle Cc to: Field Service Team/RTC team/RMs (Ser.)/RSMs/Technical

Manager (Service-Probiking) Service Team

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009
Salient Features
Attribute Key Features
Style
• Brawny masculine looks
• Stylish split seats
• 2 piece grab rail
• Tank spoiler
• Wolf-eyed head lamp
• Clip on - split type handle bar. Black
styling
• Thicker and pinched clamped fork
• Naked chain with O ring.
• New colours.
• 3 D metallic decals on petrol tank.
• All black painting.
• Stylish stainless steel silencer.
• Clear lens blinkers.
Performance Performance
• 4 stroke DTSi 220 cc air cooled
engine with an oil cooler. Engine
generating21 Ps @ 8500 rpm.
• Digital twin spark ignition.
• Digital DC CDI with TPS control
• DC ignition system.
• CV carburetor
• New starter clutch.
• Controlled lubrication system for
clutch.
• Bigger Exhaus-TEC.
• Bigger catalytic converter.
DTSi Engine
Comfort
• Large 37 dia front fork with more
stroke length.
• Nitrox shockers at the rear.
• Bigger suspension travel at rear due
to smaller wheel dia.
• Swing arm with needle roller
bearings at pivot
• Pinch clamp fork.
• Wide tyres at front (90/90/17)and
rear(120/80/17).
• Clip on type handle bar.
Annex-1
Advantages & Benefits
• Bold assertive stance, Sporty looks. Brains,
brawn and definitely bold.
• The style that lets you break free.
• DTSi technology advantages :
1. Good power and pick up.
2. Better fuel efficiency.
3. Lesser emissions.
• DC Ignition system advantages :
1. Easy to start due to low trigger start RPM.
2. Cold startability improved due to auto choke.
• Better engine performance
• Ride that can be enjoyed due to
1. Razor sharp response to throttle inputs.
2. More power at all load conditions, better torque
at low rpm, less emissions.
3. Ease of startability during winter mornings too.
4. Environment friendly bike.
5. Smooth gear shift
• More stroke length to absorb shocks.
• Better dampening during high speed drives.
• More stroke length to absorb shocks.
• Low friction and high rigidity.
• Smooth - parallel fork sliding action.
• Better grip available.
• Isolation of vibrations due to rubber dampening.
• Smooth ride at any terrian.
• Smooth ride at any speeds/terrian.
• Comfort on country roads too.
• Excellent drive
• No sticktion at front fork.
• Excellent Road holding characteristics.
• No vibrations.
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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009
Convenience
• Self cancelling indicators.
• LCD Speedo console.
1 .Low Battery level indicator.
2. Filter foam clogging indicator.
3. Engine oil temp sensor.
4. Low Engine oil level indication
sensor.
5. Day - night mode
6. Digital speed indication.
7. Tripmeter to record two trips.
8. Reserve indicator warning LED
lamp.
9. Engine Over speed limiter.
10. Digital fuel gauge.
11. Tachometer for engine speeds.
• Intelligent battery saves function
during excess cranking.
• Intelligent battery saves function
during continuous head lamp ON
condition.
• illuminated handle bar switches.
• Low maintenance battery.
• High capacity O ring chain.
• Anti scratch tank pad.
Safety
• Bigger front disc brake.
• Bigger rear disc brake.
• Tubeless tyres.
• High strength chassis.
• DC head lamp
• Auto switch over to in tact head light
filament in case of fusing.
• 3000 combination ignition lock -
twin track key
• No need to push back the button after turns.
• Get the warning before battery conks off.
• Clean filter to keep engine healthy.
• Save oil related damages.
• Save oil related damages.
Easy on eyes during night drive, can see during
day time.
• Easy of reading
• Better to claim conveyance bills.
• Better fill up quickly.
• Protects the engine from excess raving.
• Easy to read.
• Monitor and maintain engine speeds.
• Disables cranking after three cranks, thus
saving battery drain.
• Shuts off within 3.5 seconds, thus saving
continuous battery drain.
• Delight to watch during night.
• Do not worry to fill up electrolyte level.
• Dust would not enter inside chain.
• Tank protected from scratches.
• Easy to ride without any
driving/operating/maintenance hassles.
• Confidence inspiring brakes.
• Confidence inspiring brakes.
• Would deflate slowly allowing you to reach
safely.
• Better strength and stability on drive.
• Better illumination during low idling speeds too.
• Lights are always ON.
• Pilfer proof.
• Safety on drive by better braking/lights.
• Lights are always present.
• Safe even when not being driven.
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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 2
Technical Specifications

ENGINE & TRANSMISSION CONTROLS

Steering : Handle bar
Accelerator : Twist grip type on right hand
Type : Four stroke, Natural air cooled. of handle bar
No. of cylinders : One. Gears : Left foot pedal operated
Bore : 67 mm Clutch : Lever operated on left side of
Stroke : 62.4 mm handle bar
Choke : Auto choke
Engine displacement : 220 cc Brakes :
Compression ratio : 9.5 + 0.5 : 1 Front : Lever operated on right
Idling Speed : 1400 +100 rpm. side of handle bar
Maximum net power : 21 Ps @ 8500 rpm Rear : Pedal operated by right foot.
Maximum net torque : 19 Nm @ 7000 rpm
Ignition system : Microprocessor controlled digital C.D.I. ELECTRICALS
Ignition Timing : 10° BTDC 1000 rpm System :12 Volts (D.C.)
26 ° bTDC at 2500 RPM Battery :12V 9Ah MF
Fuel : Unleaded Petrol Head lamp :12V , 55 W H7 (Main)
Fuel Feed : Carbureted 12V, 55 W H7 (Passing)
Spark Plug : 2Nos. Champion Pilot lamp( :12V , 5W 2 Nos
P -RG6HCC Tail/stop lamp : LED/LED
Spark plug gap : 0.8 to 0.9 mm Turn signal lamp : 12V , 10 W
Lubrication : Wet sump, Forced Turn signal pilot lamp : LED
Starting : Electric Start only Side stand indicator lamp : LED
Clutch : Wet, multidisc type. Hi beam indicator lamp : LED
Transmission : 5 speed constant mesh. Neutral indicator lamp : LED
Primary reduction : 3.47 : 1 (66/19) Speedometer lamp : LED Display
Gear Ratios Rear No. plate Lamp : 12V, 5 W
1st Gear : 24.736 : 1 (36/13) Horn : 12 V DC , 2 nos
2nd Gear : 16.814 : 1 (32/17) DIMENSIONS
3rd Gear : 12.335 : 1 (29/21) Length :2035 mm.
4th Gear : 9.677 : 1 (26/24) Width : 750 mm.
5th Gear : 7.939 : 1 (24/26) Height :1165 mm.
Final Drive Ratio : 2.57 : 1 (37/14) Wheel base :1350 mm.
Turning circle radius : 2500 mm.
Ground Clearance :165mm.
CHASSIS & BODY WEIGHTS

Frame type : Double cradle type. Vehicle kerb weight : 152 Kg.
Suspension: : Max. total weight : 282 Kg.
Front : Telescopic with Guide & Slide bush PERFORMANCE
(Stroke - 130 mm.)
Rear : Trailing arm with coaxial gas assisted 0
Hydraulic shock absorbers and coil Climbing ability : 28 % (16 )
springs.

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Brakes: NOTES :-
Front : Hydraulically operated disc brake
Rear : Hydraulically operated disc brake • Values given above are nominal and for guidance only,
Tyres: 15% variation is allowed to cater for production and
Front : 90x90 X 17, 49P, Tubeless measurement variation.
Rear : 120/80 X 17, 61P, Tubeless • All dimensions are under unladen condition.
Tyre pressure: • Definitions of terminologies wherever applicable are as
per relevant IS / ISO standards.
Front : 2.00 kg/cm2 (28.0 Psi) (Solo &Pillion)
• Specifications are subject to change without notice.
Rear : 2.00 kg/cm2 (28.0 Psi)(Solo)
Pillion - Rear : 2.25 kg/cm2 (32.0 Psi)
Rims :
Front : 1.85 x 17
Rear : 2.50 x 17

Annex - 3
Comparison with Competition Vehicles
COMPARISION WITH COMPETITOR PRODUCTS
HERO HONDA YAMAHA BAJAJ 220
DESCRIPTION
KARIZMA YFZ R 15 DTSi
Manufacturer Hero Honda Motors Limited India Yamaha Motor Pvt. Ltd. Bajaj Auto Ltd.
Sport red / Vibrant Blue / Moon
Yamaha Blue / Graphite / Midnight Black, Plasma Blue,
Colours yellow / Force Silver / Black with
Blazing Red Wine Red, Grey Silver
option of Black / Red Alloys
Black alloy wheel - Rs. 75471
Ex-showroom (Mumbai)
Rs. 97, 425 (Chennai)
price Red alloy wheel - Rs. 76206
(Mumbai)
Black alloy wheel - Rs. 83638
On-road price (Mumbai)
Rs. 1,08,600 (Chennai)
(Mumbai) Red alloy wheel - Rs. 84435
(Mumbai)
ENGINE & TRANSMISSION
Air cooled, 4 stroke Single Liquid cooled, 4 stroke Single 4 Stroke, DTSi, Air cooled /with
Engine
cylinder OHC cylinder SOHC 4 valve an Oil Cooled
Displacement 223 cm³ 149.8 cm³ 220 cm³
Engine horse
17ps @ 7000 rpm 17 ps @ 8500 rpm 21 ps @ 8500 rpm
power
Engine Torque 18.35 N-m@ 6000 rpm 15 N-m @ 7500 rpm 19 Nm @7000 rpm
Gear box 5 Speed Constant Mesh 6 Speed Constant mesh 5 Speed Constant Mesh
Carburetor - VE, Constant
Fuel supply Vacuum Carburetor with CCVI
Electronic Fuel Injection Carburetor - CV
system (Carb controlled variable
ignition)

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

CHASSIS & BODY

Tubular single cradle, Diamond
Frame type Delta Box Frame Double Cradle type
type
Telescopic Hydraulic shock Telescopic Hydraulic shock
Suspension Front Telescopic front fork
absorbers absorbers
Swing arm with 5 step Trailing Arm with coaxial gas
Linked monocross suspension
Suspension Rear adjustable type Hydraulic shock assisted hydraulic shock
with spring/shock absorber
absorber absorbers & coil springs
Disc Dia 276 (non asbestos Hydraulically operated disc
Brakes Front Single Disc
type) brake
Internal expanding shoe type - Hydraulically operated disc
Brakes Rear Single Disc
Dia 130mm (non asbestos type) brake
ELECTRICALS
Advanced Microprocessor
Microprocessor controlled
Ignition System Ignition TCI
digital CDI
(AMI)
Battery 12V - 7 Ah 12V - 3.5 AH 12 V, 9 AH MF
NGK - DPR8 EA 9
Spark Plug NGK/CR8E Champion P -RG6HCC
CHAMPION - PRA 7 HC
12V - 35/35 W Halogen TWIN - Low beam - 12V-35W
Head Lamp 12 V, 55 W H7
(Multi reflector - DC) High beam - 12V - 35W
12V - 5W / 21W X 2 nos.
Tail / Stop Lamp 12V - 5W / 21W LED/LED
(Multi reflector)
Number plate 12V - 5W 12V - 5W 12 V, 5 W
12V - 21W X 4 nos.
Turn Signal Lamp 12V - 10W X 4 nos. 12 V, 10 W
(Multi reflector)
DIMENSIONS
Length 2125 mm 1995 mm 2035 mm
Width 755 mm 670 mm 750 mm
Height 1160 mm 1070 mm 1165 mm
Wheel Base 1355 mm 1290 mm 1350 mm
Ground clearance 150 mm 160 mm 165 mm
Kerb Weight 150 Kgs. 131 Kgs. 152 Kg
PERFORMANCE
Max. Speed 125 kmph 140 kmph
STYLING DIFFERENTIATOR
1. Bold new graphics 1. Liquid cooled - 4 valves - Fuel
1. Brawny masculine looks.
2. Speedo dials in bright yellow injected
2. Wolf eyes head lamp
Styling for clear day time visibility 2. Delta Box frame
3. 3 D Metallic decals on petrol
3. Muffler cover with chrome 3. Linked type monocross
tank.
finish suspension

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 4

DC Ignition System Advantages

Quick/ Trigger start rpm down to 200

from 350.
easy start. Hi spark intensity at lo rpm due
to DC input.
Lower starting current drawn by
Starter motor.38 Amps (46)
Better brush life due to low
current carry.
Easy Cold
starting. Auto choke – Engine temperature
Sensor provided to give rich mixture
At winter mornings.

No starting
Trouble after Sealed couplers everywhere to
Washing. arrest water entry.

No start – Sealed Starter relay –

potting type to avoid water
Water entry post entry.
monsoon.

Better battery charging current at lower rpm and

throughout the rpm range. (At 20 kmph speed 1.25 Amps
Battery life more charging current). Thus no issues even on vehicles
running at slow speeds in city.

Battery warranty period matched with vehicle warranty

period.

HRD tester for better health check.

Portable booster battery charger.

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 5

Read Before You Ride

A Starting the vehicle :
1 Put the Ignition and Kill switch in ON position.
2 Confirm that the vehicle is in neutral.
3 Button starts the engine without opening throttle.
B Warning indicators on Speedometer :
There are 4 indicators which would start flashing, indicating the need of maintenance for that part.
Customer should visit authorized service station whenever these warning indicators start flashing.
1 Choked air filter indicator.
2 High engine oil temperature indicator.
3 Low battery charge level indicator.
4 Less engine oil level indicator.
Maintaining Battery charge level is very essential, for starting of vehicle.
C Important Does and Don'ts :
1 The powerful engine with quick throttle response would make the driver to open the accelerator with
caution. Do not open the throttle suddenly.
2 Use both the brakes at a time. Use of front brake for dead stop would give better control. Since the front
axle weight is more, the rear brake has been deliberately toned down to avoid skidding.
3 As soon as "fuel res" red indicator light is ON, fill up the fuel at the nearby filling station.
4 Use better quality fuel only. Anything above 87 octane rating. Do not use any additives with the petrol. Since
this is a precision machine, adulterated fuel should never be used.
5 Tyres fitted on this vehicle are tubeless tyres.Do not allow anybody to open them by using wrong tools. Go
to authorized MRF tyre dealers who are equipped with necessary tools, so as to avoid possible damage to
wheel rim.
6 Chain with built in O ring is fitted on this vehicle. The lubrication at every 500 kms with SAE 90 oil and
adjustment at every 1000 kms would be essential.Pl see to it that the chain never runs dry.

7 Do not add any additional electrical / electronic gadgets on the vehicle, as they would disturb functioning of
engine management system.
8 During washing of the vehicles, pl does take care of different sensors fitted on engine. Do not direct the jet
of water towards electrical parts and sensors.
9 For stainless steel silencer, care will have to be taken to avoid oil contact. Otherwise stain marks would be
seen, thus damaging aesthetics. The silencer would turn slightly chromish after initial use, which is a natural
phenomenon.
" Wishing you a Pulsating ride "…………. "Happy Riding".

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 6

Pre-Delivery Inspection Checklist (PDI)

Following is the checklist for carrying out PDI of “Pulsar DTS i220- motorcycle. While next annexure (no. 6) gives
detailed Standard Operating Procedure for PDI, this checklist is to understand various check points those are to
be checked / inspected before delivery of the new vehicle.

Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as
per the points given below. This ensures trouble free vehicle delivery to the customer

PDI Check List Pulsar 220cc- DTSi

Chassis No
Date :
Engine No
PDI Done
Dealer Name
By
Please ensure that following checks are carried out during PDI before Delivery of vehicle

If OK Observati
To Check Check For X If Not ons
OK Remarks
Engine
Engine Oil: Oil Level OK/Top up if required
SAE 20W50API SJ or SL+ Oil leakage if any- specify source of oil leakage
JASO MA
Idling rpm( Warm Up) Check/Adjust if reqd( 1400+- 100 rpm) with tachometer
Fasteners ( Check torque) Engine Mounting Bolts ( M- 8 2.2 Kgm , M-10 2.4 Kgm)
Silencer Mounting Bolts( 3.5~4.0Kgm)
Drain Bolt (2.5 Kgm)
Rocker Arm Bolts( 2.5-3 kgm)
FUEL SYSTEM
Fuel Tank/ Pipes No leakage/ Correct Fitment
Carburettor No leakage/ Correct Fitment
Fuel Cock Smooth Operation
FRAME
Tyre Pressure Front 2.00Kg/cm ( 28.4 PSI)
Rear Solo 2.00 Kg/cm ( 28.4 PSI)
Rear Pillion 2.00 Kg/cm ( 30.5 PSI)
CONTROLS
Brakes Front Brake lever free play (2~3 mm)
Rear Brake pedal free play(25~30mm)
Throttle Grip Free play (2~3 mm) & smooth operation
Clutch Smooth operation, no juddering, Free play 2~3 mm
Clutch cable Routing thru the bracket located near lower 'T' on vehicle RH side
Drive Chain Slackness standard: 25~ 35 mm
SUSPENSION
Front Fork No leakage/ smooth working(wipe out if any seepage

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Rear Shock Absorber Spring Adjuster notch position: 1st notch ( Standard)
Steering Smooth Operation ( No play/ Sticky movement)
Steering cum ignition , rider seat ( pillion+rider),LH/RH side cover
Lock operation
lock
Front Axle nut - 8~ 9 Kgm
Rear Axle nut 8~10 Kgm
Handle Bar bolts 2~2.2 Kgm
Steering Cap bolt 5Kgm
Fasteners
( Check Torque) RSA Mtg Dome nut - 3.5~ 4.0 Kgm
Swing Arm Pivot nut - 8~ 10Kgm
Caliper install bolts (Front & Rear) - 2.2 ~ 2.8 Kgm
Brake Disc Allen bolts - 2.6 ~ 3.2 Kgm
Fork Pinch Clamp bolt - 2.0 ~ 2.2 Kgm
ELECTRICAL
Charge Status ( 12.5V open circuit terminal voltage)
HRD test (To show Green light only)
Battery Tightness of battery- terminals/ Cables. Petroleum jelly
Position of fuse box ( 2 nos)

All Bulbs Working Head light (both bulbs working).

Headlight tail light illumination switch off after 3 seconds
Pilot lights (2), LED Tail/ Stop, Side Indicator, Speedometer LEDS,
Number plate lamps
Auto switch "OFF" of Indicators(by moving Handle Bar
Turn Pilot, High beam, Neutral Indicator, Tell tale icons on, switch
LH/RH,
Switch operation LH & RH control, Ignition, Fr& Rr brake & Kill switch
Starter Motor Proper working/ Engagement
TEST DRIVE
Starting Cold Start & Warm Start
Working off Auto Choke( Click sound when ignition is turned "ON")
Idling Speed ( Warm condition) ( 1400+/- 100 rpm) with
tachometer
Drive Ability Throttle response
Brakes ( Front & Rear)
Digital Speedometer, Odometer, Trip meters, Fuel guage & Fuel
Indicator red lamp
CO% Check CO should be 2% in engine warm condition at idling rpm
Cleaning Wash & Clean vehicle properly

IMPORTANT NOTE
Look for any external damages in transit: Please check, record & rectify send report with photos.
 Moisture / Oil collecting tube of Air filter should be properly fitted and routed correctly.
 Both LH & RH side spark plug caps must be tightly secured and ensure proper functioning of Spark Plugs.
 TPS on carburetor for functioning’s

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 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 7
Pre-Delivery Inspection - SOP

PNR & M&T/

Sr. Posit Special
Description SMM GP Tools its Consumables Service Shop
No ion Tools
Attach Equipments
Identify & Park Vehicle on Work
1 0.80 Lifter Bay
Bay
Remove the Thermocol and
2 additional packing if any. Study 0.50
PDI card and Work content.
Open Petrol tank cap & pour Petrol Petrol,
3 0.50
petrol Dispenser Waste Cloth
Check for smooth operation
4 0.10
of fuel cock lever
Nose Plier,
Check & top up engine oil
5 RH 0.30 Oil Can, Cloth
level, if required.
Funnel
Check clutch cable operation OE Spanner
6 RH 0.10
& Adjust if required. Set
Check front brakes for
Ring
7 efficient working & Adjust if Front 0.10 Suction Pump
Spanner
required.
Check and correct tyre Air Pressure Pedaled Air
8 Front 0.20
inflation pressure - Front Wheel Gauge Pump
Check Battery voltage, check up
OE Spanner Cotton Waste, Multi Meter,
electrolyte level, ensure
9 LH 0.60 Set, Screw Petroleum Jelly, Hydrometer,
petroleum jelly presence, and
Driver Electrolyte Battery Charger
connect terminals properly.
Shocke
Inspect Rear Shock Absorber RH/L
10 0.10 r
setting & Correct if necessary. H
Adjust
Check Rear brakes for efficient Opened
11 Rear 0.10
working & adjust if required. Spanner Set
Check and Correct tyre inflation Air Pressure Pedaled
12 Rear 0.20
pressure - Rear Wheel. Gauge Air Pump

Ring
Lubricate chain and Check /
Spanner Set,
13 Adjust chain slackness if LH 0.40 Cloth,SAE 90 Oil
OE Spanner,
required.
Set, Oil Can

OE Spanner
14 Check Accelerator cable free play LH 0.05
Set
OE Spanner
15 Check & Adjust TPS LH 0.10
Set
Check gear shifter lever OE Spanner
16 LH 0.05
operation Set
Check & Adjust steering and RH / Ring
17 0.20
Handle bar for free movement. Front Spanner Set
Check front mudguard OE Spanner
18 Front 0.05
alignment wrt Front Wheel Set

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 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

PNR & M&T/

Sr. Posit Special
Description SMM GP Tools its Consumables Service Shop
No ion Tools
Attach Equipments
Check all important nut bolts
Torque
for torque and tightness, LH/R
4.00 Wrench,
• Handle bar mounting bolt H
Socket Set,
• Stem lower & upper bracket
Ring
bolts
Spanner ,
• Stem of bolts
Spanner Set
19 • Front axle nut
• Cylinder head nuts
• Engine foundation bolts
• Trailing arm bolts
• Silencer cover shield bolts
• Both LH/RH engine mtg. bolts
• Rear Caliper bolts.
Check the following and lubricate
if necessary Oil,
RH/L
• Rear brake lever Multipurpose
H
• Pillion foot rest Grease,
20 FRON 1.00 Oil Can
• Center stand SAE 20W40
T,
• Side stand Oil
REAR
• Clutch lever

OE accessories fitment LH/R OE Spanner

21 1.15
-Mirrors RH & LH H Set
Spanner Set,
Tommy Bar,
Screw
OE accessories fitment - LH/R Dial Type,
22 3.25 Driver,Plier,
Leg guard, Saree Guard H Torque Wrench
Nylon,Ham
mer,Allen
Key
Check electrical couplers of all
sensors
LH/R
23 • Engine Temperature sensor 0.35 Nose Plier
H
• Oil level & Temperature sensor
• Air filter IR sensor
Start vehicle, Check operation of
electrical like- Head light, Tail
light, Brake light, Side stand
LH/R + ve , Screw
24 indicator, Horn, Speedometer, 0.70
H Driver
Odometer, Side indicators,
Parking, Pass light indicators and
Fuel indicator working
Check working of all electrical LH/R
25 0.40
switches H
CO-HC
LH/R 12"
26 Check Idling and CO%. 0.60 Analyzer;
H Connector
Tachometer
Check RPM meter, Speedometer,
Odometer & Trip meter for
27 Front 0.50 OE Spanner
proper functioning and Correct if
required
Check all locks for proper LH/R
28 0.50
operation H

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 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

PNR & M&T/

Sr. Posit Special
Description SMM GP Tools its Consumables Service Shop
No ion Tools
Attach Equipments
Test drive the vehicle, check
digital OE Spanner,
29 speedometer working. Study the 1.30 Ring
PDI job card and verify work Spanner
done. Take vehicle out and park.
Clean/Wash the veh. before
30 1.00
delivery
Repair for any other defects seen
31
or observed during test drive.

Total SMM 19.20

Total time taken for PDI SOP 19 Minutes approximately.

In a shift of 480 minutes, One technician can do 25 Vehicles PDI SOP comfortably.

Annex - 8

Periodic Service SOP

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consu-
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. mables
Vehicle Vehicle Attac Equipments
LH RH

Washing
1 Wash vehicle thoroughly.
boy

2 Identify the vehicle. 0.3

Bring vehicle and
3 0.5
position on bay.
4 Raise the lift. 0.3
Pistol
Start vehicle and Warm
grip
up. Remove RH/LH side
5 LH RH 0.7 PNR
covers Seat, Petrol tank
Socket
and keep properly
set

Remove rear seat.

6 Clean Portion Below seat 0.2 Brush
by brush

Pistol
Drain engine oil. grip
Oil Disposer,
7 Confirm Qty / Quality OR LH 1.3 PNR Cloth
Air Gun
eng Oil Socket
set

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 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consuma
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. bles
Vehicle Vehicle Attac Equipments
LH RH

Take Clean marked vessel

to measure oil drain. Start
bike for 8-10 seconds &
8 0..5
switch Off. Drain oil
removing drain plug Refer
to SA if less than 900 ml.
Filter
Pistol
Cleaning
grip
Clean air filter. Stand,
9 RH 3 PNR
(Replace - if necessary) Cloth,
Socket
20W 40
set
Oil
Head
Screw
Driver
Drain carburettor Float Cloth,
10 LH 1.3 RH Nylon
(Overhaul if required) Gauge Kerosene
Brush
Plastic
Tray

OE
Check accelerator &
11 LH 0.4 spanner
adjust
set

Remove RHS plug cap &

remove water inside Pistol
sleeve by Compressed grip
Plug
12 air. Remove both plugs & LH 0.5 RH 0.5 PNR
Spanner
set Gap (every Service) Socket
Replace Spark Plugs at set
interval of 20,000kms

Check & Adjust Tappet

13 10.4
clearance.

Check LH side important OE

Pistol
fasteners and tight a. Side spanner
grip
bolts of front fork set,
14 LH 0.6 PNR
b. Engine foundation bolts Ring
Socket
c. Side stand spanner
set
d. RSA top & bottom nuts set

Remove Front Sprocket

cover. Clean inside of
cover by pressurized
water. Dry the cover by
Brush
15 compressed air, Remove LH 3.0 kerosene
G. P. tool
the dust/dirt surrounding
small sprocket by Screw
drive/Blade & clean to
specs.

Page 14 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consu-
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. mables
Vehicle Vehicle Attac Equipments
LH RH

Clean Chain with

kerosene/Oil by nylon
brush. Dry the
16 chain.lubricate with 90 3.0 Brush Kerosene
grade oil .Spray "OKS" on
chain. Adjust the Chain to
specs.

Check & adjust rear brake

17 0.5
for smooth working
Check for mud on caliper
18 0.1
pads ,clean.
Check for rear damper
play by rotating rear
19 wheel. Remove wheel, 0.1
replace damper if play
observed.
Pencil Type
Check and Adjust REAR
20 Fr Rh. 0.4 0.4 Air gun Pressure
rear tyre air pressure RH
Gauge
Pistol
Checks for play in rear grip
21 sprocket Nut- Re tighten if LH 0.2 Spanner PNR
required. Socket
set

Check Battery, top up with

Distilled Water. Clean
Electrolyte
terminals & apply
OE , Multi Meter,
Petroleum
spanner, Petroleum Hydrometer,
22 Jelly. Rout cables properly RH 1.8
Screw jelly, Battery
& fit terminal caps
driver Cotton Charger
properly.
waste
Recharge battery if
required

Check Air pressure-10k

Pump in nitrox to space
23 LH 1 RH 1
(7.5kg/cm2) with help of
pump.
Clean oil strainer.
6" Comb.
(Replace Measuring
Pliers, Oil
if required) After 1 year or jar 1 liter,
24 RH Ring 20W50,
10000km whichever is Funnel
Spanner Cloth
later, clean centrifugal Oil dispenser
Set
filter at 10.000 kms

OE
25 Check clutch & adjust RH 0.3 Spanner
Set

Page 15 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consu-
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. mables
Vehicle Vehicle Attac Equipments
LH RH
Ring
Spanner Cloth Oil disposer,
26 Fill engine oil (1150 ml) 1 RH 1.35
Set 20W50 Oil Air gun
Plier

Filler Gauge
Clean, Check & adjust Ring Spark Spark Plug
27 RH Spark Plug RH 2.4 Spanner Plug Cloth Cleaning
(Replace - if required) Set Spanner Machine
Air Gun

Screw
Driver
Check & Top-up Piston Suction
28 2 FRONT 1 Ring
brake fluid level Ring Pump
Spanner
Set

Check & Replace the parts

29
if necessary.
Check & Adjust play.
30 Check pads - Replaced if 0.2
required.
Check for leakage,
31 spongy feeling. Replace 0.2
kit if required.
Remove fork pipe tubes,
drain oil Clean pipe inner
with kerosene & then refill
32 32
new oil from Company
supplied bottle
(320ml/tube).
Pencil type
Check / Adjust front tyre
33 FRONT 0.4 Pressure
air pressure
Gauge
Ring
34 Check & adjust steering RH 0.8 Spanner
Set

Check RH side important

fasteners and tight A.
Engine foundation bolts
B. Front axle nut C. Side OE Pistol
bolts of Front fork D. Spanner Grip,
35 Handle bar bolts E. RSA RH 1.3 Set, Ring PNR
top & bottom nuts F. Spanner Socket
Swing arm axle nut G. set Set
Silencer protective cover
screws / bolts H. Rear
view mirror

Page 16 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consu-
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. mables
Vehicle Vehicle Attac Equipments
LH RH

Lubricate as per
20W50
lubrication Chart
Oil,
a. Clutch lever
36 LH RH 0.8 Oil can Graphite,
b. Pillion foot rest
Grease,
c. Center stand
Cloth
d. Side stand.

Pistol
Grip,
Refit RH, LH side covers,
37 LH RH 0.5 PNR
Seats, Petrol tank assly.
Socket
Set

Blow Compressed air in

petrol tank drain pipe.if
water traces found in pipe
Remove tank. Check drain
38 pipe pinching & Check 2.0
spring position. Refit the
pipe properly. Clean the
Cavity below. Cap with
clean cloth.

Ensure all lubrication

39 points are Covered as per 0.3
lubrication chart.
Check electrical couplers
of all sensors a. Engine
temperature sensor
40 LH 0.35
b. Oil level & temperature
sensor
c. Air filter IR sensor
Check RPM meter,
Speedometer, Odometer
41 & Trip meter for proper FRONT 0.5
functioning & Correct if
required

Start vehicle, Check

operation of electrical like
Philips
-a. Check all electrical
Screw
switches b. Head light RH
Driver
c. Tail light d. Brake light e. REAR
Ring
42 Horn f. Speedometer, RH/RR 0.95
Spanner
Odometer, Pass, Parking FRONT
Set
light g. Side indicators, RH/LH
Comb.
Front and Rear both sides
Pliers
h. Side stand indicator i.
Fuel indicator

Page 17 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Position Position
of Tech. of Tech. PNR M&T/
Sr. SM Sp. Consu-
Description w.r.t. w.r.t. SMM GP Tools PNR & its Serv. Shop
No. M Tol. mables
Vehicle Vehicle Attac Equipments
LH RH

8" Small
43 Tune engine & carburettor LH 2
connector

Study job card & verify

44 1
work
45 Lower the lift. 0.3
Take out & park the
46 0.5
vehicle
47 SUB TOTAL 16.3 16.55
Carry out any additional
48 work as indicated by the 5 5
customer or as required
49 TOTAL TIME 21.3 21.55

To be
Test ride of the vehicle -
50 1.5 done
if required and park
by Expert

To be
done
Clean the vehicle at the
51 1 by
time of delivery
Delivery
boy
Total time taken for Periodic SOP 33 Minutes approximately.( except major maintenance jobs)

In a shift of 480 minutes, One technician can do 15 Vehicles Periodic SOP comfortably.

In a shift of 480 minutes, 23 Vehicles per Bay per Day can be achieved comfortable with
1 Bay, 2 Technician working.

Page 18 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 9
Periodic Maintenance & Lubrication Chart
During scheduled
periodic services & after warranty period while customer avail services, one should follow the given below
maintenance chart for carrying out recommended job elements. Attending specific element at specific period/kms
and enable consistent performance of the vehicle. SAs should explain & educate customers on this.

Whichever RECOMMENDED FREQUENCY

comes
Initial Subsequent
first
SN Operation 500-
KMS. 2,500 kms. Every 2,500km
750
OR
240 days from date
Day 30-45 Every 75 days
of sale
1 Servicing P P P P
2 Idle speed / CO % C,A C,A C,A C,A C,A
3 Engine oil (SAE 20W50 of API SJ or SL+JASO MA) R R Every 5000 kms
4 Valve tappet clearance C,A C,A Every 5000 kms
5 Oil strainer / Centrifugal filter CL Every 10000 kms
6 Air cleaner element CL CL CL CL CL
7 Air cleaner element* R -Every 15000 kms
8 Carburetor draining D D D D D -Every Service
Every 10000 kms if
9 Carburetor O/H cleaning, adjustment
required.
10 Fuel system leakage C C C C C, R - if required
R - Every two
11 Fuel pipes
years./20000kms
12 Air breather tube R - Every one year
13 Spark plug gap CL,A,C CL,A,C CL,A,C CL,A,C R - Every 15000 km.
14 Battery electrolyte level C C C C Every service
15 Brake light switch C,A C,A C,A C,A C,A
16 Clutch play C,A C,A C,A C,A C,A
17 Throttle play C,A C,A C,A C,A C,A
18 Rear brake pedal free movement C,A C,A C,A C,A C,A
19 Brake pads wear (front & rear) C C C C Replace if required
20 Steering play C,A C,A C,A C,A C,A
21 All fasteners tightness including eng. mtg bolt T T T T T
C -Every 20,000 kms R-if
22 Engine mtg. silent bush
required.
23 Tyre thread wear C -Every service
24 General lubrication L L L L L
L -Every 10000 kms. R -if
25 Steering stem bearing
required

26 Wheel bearings L -Every 15,000 kms.

27 Swing arm pivot pin L Every 5,000 kms.
28 Front fork C,A C,A C,A
29 Front fork oil R -Every 10,000 kms.

C - Every 10,000 kms. R -

30 Fork oil seal and dust seal kit
If reqd.

Page 19 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Whichever RECOMMENDED FREQUENCY

comes
first Initial Subsequent
SN Operation 500-
KMS. 2,500 kms. Every 2,500km
750
OR
240 days from date of
Day 30-45 Every 75 days
sale
31 Rear shock absorbers C - Every 10,000 kms.
32 Drive chain L -Every 500 kms.
Drive chain
33 Every 5,000 kms.
wear/Remove/Clean/Inspect/Lubricate C,CL,L
34 Drive chain lock R Every 5,000 kms.
35 Engine compression pressure C -Every 15,000 kms.
36 Cylinder block piston and head de-carbonizing Every 15,000 kms.
37 Cylinder head - Valve lapping Every 30,000 kms.
C- Every 15000 R -Every
38 Valve oil seal
30,000 kms.
C -Every 20,000 kms. R-
39 Swing arm mtg. bush / bearing
if required
40 Gap between reed switch & TPS magnet C C C C C - Every Service
C -Every 20000 kms. R-
41 Clutch plate
if required
C -Every year R -If
42 Carburetor rubber duct
required
43 Silencer drain hole cleaning CL CL CL CL CL -Every Service
44 Air filter cover "O" ring Every 15,000 kms.
45 Rear wheel rubber shock damper R -Every 10,000 kms.
46 Rear sprocket fasteners T T -Every 5,000 kms.
47 Auto choke functioning C C C C C - Every service
48 Front brake lever play C,A C,A C,A C,A
49 Oil cooler pipes C,R C,R C,R C,R C-Every service
50 Lubrication of gear starter clutch L L-Every 5,000 kms.
51 Clutch, Accelerator cable R -Every two years
52 Master cylinder cup and dust seal R -Every two years
53 Caliper piston and dust seal R -Every two years
54 Front brake hose R -Every two years
55 Starter clutch bush kit R -Every 15000 kms.
56 Clutch switch cleaning C Every 5000 kms.
C - Every Month, R-Every 20000 kms. or once in a
57 Brake fluid change
year

A - Adjust ; CL-Clean ; C - Check L - Lubricate; T – Tighten ; R- Replace

Note: Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory
and the same are chargeable to customer.
Engine Oil
Model Grade Quantity
Drain & Refill = 1000 ml.
Pulsar 220-F CC SAE 20W40 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ Grade or Superior
Engine Overhaul = 1100 ml.

Note:-Warranty limit:- 2 years or 30,000 kms.( Whichever occurs earlier).

4 Free Services & 9 Paid Services for warranty remains valid.

Page 20 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 10

Critical Parts List

Critical parts list for maintaining customer satisfaction : WM to review the stocks every month start/mid
month.Maintaining bare minimum level of all these parts is very essential from customer satisfaction point of
view. Service engineer to audit few parts from the list updated by spares manager.

SR. Description Min P-220 SR.No Description Min P-220

No lev level
el
1 Cylinder head 2 DK101607 54 Headlight Assembly 2 DK201056
2 Camshaft assly 2 DJ101373 55 Blinker Fr LH 2 DJ201208
3 Valve kit 5 DK101326 56 Blinker Fr RH 2 DJ201209
4 Valve repair kit 5 DK101327 57 Blinker Rr LH 2 DJ201206
5 Block piston assly 2 DK101625 58 Blinker Rr RH 2 DJ201207
6 Clutch Friction Disk -C. 2 DK101567 59 Petrol Tank- Red 1 DK71032V
7 Clutch Friction Disk. 2 DK151066 60 Petrol Tank- Black 1 DK71034M
8 Clutch Friction Disk -B 2 DK151068 61 Petrol Tank - Blue 1 DK71034K
9 Plate Clutch 2 DK101565 62 Petrol Tank - Silver 1 DK71034L
10 Oil cooler 1 DK101634 63 Front Fender- Red 1 DK74032V
11 Oil cooler pipe inlet 1 DK101630 64 Front Fender- Black 1 DK74034M
12 Oil cooler pipe outlet 1 DK101631 65 Front Fender - Silver 1 DK74034L
13 Banjo bolts for oil cooler 10 DK101236 66 Front Fender - Blue 1 DK74034K
Banjo bolts washer for
14 oil cooler 20 DK101279 67 Speedo Cable Assly 2 DK201098
15 Element air filter 10 DK121009 68 Fork Inner Pipe 2 DK181070
16 Silencer 2 DK101482 69 Front Disc 1 DK151027
17 Oil pump assly 1 52DH0169 70 Decals - Petrol Tank 2 36DK0026
"B" monogram on Tank -
18 Rotor Assly - F 1 JC111027 71 LH - RED,BLUE, BLACK 1 JC141049
"B" monogram on Tank -
19 Stator plate - F 1 JC111026 72 LH - SILVER 1 JC141053
"B" monogram on Tank -
20 HT coil RH 1 JC111023 73 RH - RED,BLUE, BLACK 1 JC141050
"B" monogram on Tank -
21 HT coil LH 1 JC111022 74 RH - SILVER 1 JC141054
22 Spark plug LH / RH 5 DG111008 75 Decals seat - Cowl - Red 2 DH73032V
Decals seat - Cowl -
23 Regulator voltage 1 DK201001 76 Plasma Blue 2 DH73034K
Decals seat - Cowl -
24 Starter motor 2 JC111007 77 Silver Grey 2 DH73034L
Body complete starter Decals seat - Cowl -
25 clutch 3 DK101595 78 Midnight Black 2 DH73034M
26 Gear starter clutch 2 JC101112 79 Fairing - Red 2 DK74012V
27 Holder step LH 2 DK161137 80 Fairing - Silver 2 DK74014L
28 Holder step RH 2 DK161138 81 Fairing Blue 2 DK74014K
29 Wheel rim front 1 JC151013 82 Fairing - Black 2 DK74014M
30 Wheel rim rear 1 DK151050 83 Gasket Cylinder Block 5 DK101063
Master Kit - Major ( Front
31 Chain sprocket kit 2 84 Brake) 5 DE191043

Page 21 of 32
 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

SR. Description Min P-220 SR.No Description Min P-220

No lev level
el
32 Disc pad set front 5 DE151037 85 Magnet Assly SCB 3 DK201039
Rear caliper pad with
33 shims 10 DK151038 86 Cylinder head Gasket 2 DK101003
34 Brake pedal / tie rod 2 DK191012 87 Switch LH 2 DK201033
35 Lock set 2 DK181034 88 Steering Cone kit 3 36DV0007
36 Switch RH 2 DK201034 89 Cap Camshaft 5 DS101096
37 Fork oil seal 5 DK181019 90 Capacitor 1 DK201036
38 Tube fuel 10 DJ141006 91 Fuel Gauge 2 DK201065
39 Main relay 1 AL201012 92 Starter Relay(solenoid) 2 DK201078
40 Fuse 5 30201085 93 Clutch switch (6AMP) 2 DK201083
41 Wiring Harness - F 1 JC201041 94 Gasket Cover RHS 10 DH101154
42 Engine temp sensor 1 DK101577 95 Gasket Crankcase 2 DH101006
43 Camshaft sprocket 2 DS101276 96 Gasket cover Magneto 2 JC101137
44 Camshaft bolt 5 DK101386 97 Lever comp gear shifter 2 DH101705
45 Speedometer Assly -S 1 JC191014
46 Speedometer Assly - SF 1 JC191018
47 Handle bar - LH 1 DK181046
48 Handle bar - LH 1 DK181059
49 Handle bar - RH 1 DK181047
50 Handle bar - RH 1 DK181062
51 Clutch Cable 5 JC191004
52 Tail Light Assembly 2 DK201003
53 Wind Shield 2 DK161069

Annex - 11
Initial Kit List

Qty / Initial
Sr.No. Partno. Description MRP
Kit
1 DK101630 OIL PIPE INLET 1 228
2 DK101631 OIL PIPE OUTLET 1 211
3 JC111022 IGNITION COIL WITH CABLE LH 1 114
4 JC111023 IGNITION COIL WITH CABLE RH 1 114
5 JC191019 CABLE ACCELERATER 1 73.5
6 JC191004 CABLE-CLUTCH 1 101
7 DK111071 CDI UNIT 1 830
8 DK201001 REGULATOR 1 879
9 DK201033 CONTROL SWITCH LH 1 625
10 DK201034 CONTROL SWITCH RH 1 624
11 DK101503 ENGINE TEMP SENSOR 1 123
12 DK181019 OIL SEAL 2 54.95
13 DK151038 REAR BRAKE PAD 2 194

Page 22 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 12

Frequently Asked Questions

Frequently asked questions by customers at service reception :

These questions are posed by customers at the service stations. Everybody from your dealership need
to give the same answer.Pl read these answers carefully and start speaking in one language.

Engine is overheating? - heat being felt at legs.

The engine mounting orientation on Pulsar DTS-i is vertical.

When vehicle is running, the cooling air draught is getting directed from front side.
That cool air picks up the heat from engine and cools it down. Then it flows on driver's legs.
The more the hot air the driver feels, more heat has been picked up by air, thus giving better engine cooling.
Nothing to worry about this, Engine is having additional oil cooling too. If the engine is really overheating you
would get an indicator on speedometer. You would just get check spark plug colour which would indicate us
safely about engine health. Nothing would happen to engine once that confirmation is over.
Do not worry; we are here to take care of any issue.

Rear brake not urgent on Pulsar 220,inspite of having disc brakes.

Both the brakes are to be used while braking for perfect and safe braking..
The front disc brake is urgent and can be used for dead stopping during emergency.
If bajaj auto can make the front brake that urgent, the rear one can as well be made easily that way.
However it would result in to skidding of the vehicle, as rear wheel is having traction.
Hence rear brake has been toned down slightly as a safety precaution.
(Mechanic has to confirm that the brake disc pads are not worn out, do not carry oil, water, tyres are not worn out
and the braking effectiveness is as like any other new vehicle)

Engine noise level is going up after a long drive of 35 + kms.

To increase fuel efficiency, one has to reduce friction inside the engine.
Pulsar engines have been provided with roller rocker arrangement inside cylinder head to reduce friction. After
long drive, when metallic parts expand, the noise level too goes up.
While the film of lubrication oil takes care of friction, noise level builds up slightly.
Hence nothing to worry about noise level post prolonged drives. No harm would happen to your engine.

Gear shifting neutral finding is difficult when standing in standstill position at signals.

Since this is a constant mesh gear box, without moving the wheels slightly -the gear dogs may not get
engaged. Hence it is important to rock the wheels slightly to facilitate shifting down to neutral.
(technician has to confirm himself that the gear shifting is not hard, do not have clutch drag etc before explaining
this to customer. use check list for confirming all parameters)

Fuel gauge is not accurate ? Does not show litre by litre.

The reading which gauge is suppose to show is in three stages Behalf and Full.(details given in O&M)
Its an indicator and can not be as precise as is expected.

Can I use higher- better grade of oil ?

As long as it meets the specification as given by BAJAJ auto. (API JASO MA)
20 W50/SG-SL grade. Anything above this can be used.

Page 23 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

There is a peculiar noise from engine told by mechanic as Knocking ?

The Pulsar engine employees DTSi technolodgy.The two spark waves from spark plugs collides with each other
and that crates a noise ,being perceived as combustion noise. This noise level do not have any effect whatsoever
on engine performance and noise.Just

Can I use accessories like remote control, imported air filters, add on horns etc?

All the parts related to engine and electrical parts are designed to certain specs. Changing/modifying any part
would affect the performance. Hence we do not advise fitment of such parts and warranty would also stand
negated in all such cases. Hence its better

Annex - 13
Frequently Asked Questions Questions related to Warranty

Why parts like clutch plates, chain-sprockets, steering races, timing chain, brake shoes etc are not
covered under warranty ?

These are the parts which are prone to wear and tear due to vehicle usage, external factors. The very fact
that they have lasted long up to 10000 kms + do suggest that there was no manufacturing defect to start
with. If they had failed now it is something to

Why only block piston and crankshaft given under fuel adulteration claims?

1. Component failure due to adulterated fuel is not a manufacturing defect.

2. Engine manufactured for sustaining adulterated fuels would cost too heavy on customer's products.
3. Since this is not a manufacturing defect, can not be covered under warranty.
4. However since this is an accident (use of an adulterated fuel), Bajaj auto and its dealers are ready to contribute
and help out customer. All the parties should share the cost of repairs.
Bajaj auto would give 40 % cost. Customer would give 33 % and dealer would charge 50 % labour and forego
his spare parts discounts. The dealer is supposed to save and reuse certain components to reduce cost of repairs.
Thus earlier burden of Rs 7000 to customer would go down to @ 3000.
Since this is not a genuine manufacturing defect it would not be covered at the time of a second time failure.
Entire automobile fraternity to raise this issue with concerned Government officials.
The calculation details of reimbursement are given in the sheet attached.
Create the awareness amongst customers regarding proper use of fuel/fuel additives and consequences of bad
fuel quality.

Why Battery/tyres are not given by selling dealer under warranty?

World over the policy of warranty of proprietary parts is the same. They are warranted by respective
manufacturers. They are experts in analyzing the failures and have special equipments for checking the parts.
Further the Batteries can not be transported due to environmental factors.

Why the alloy wheel breakage is not covered under warranty ?

Alloy wheels which are die casted have been designed and certified by ARAI for all normal usage conditions.
They would crack under extreme operating conditions like heavy impacts.
Since heavy impacts are an accident, this will have to be covered under insurance.
The run out also can not get developed after usage as like spoked wheels.
Hence only paint defect can be covered under warranty - by completely repainting the part. No replacement is
required here too.

Page 24 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Why the part as failed on my vehicle so early - why cant you replace complete vehicle ?

The vehicle is manufactured by using 4 Ms.men.machine,material and method. Something can go wrong in rare
case. The automobile is not a stationary machine like many other consumer durables. To cover up any
manufacturing lapse the warranty is given by Bajaj auto. We sincerely apologies for this to have happened on
your vehicle. But the faulty part replacement would restore the vehicle performance. We are equipped with,
trained to carry out those repairs. Since the vehicle is an assly of so many parts, complete replacement is not a
logical solution for this defect removal. Further the change of vehicle is not permitted by RTO,once registered.
However we guarantee the optimum performance of your vehicle and we are committed for that.

I should get all modified parts fitted on my old vehicle - why not ?

Products are being continuously modified by BAJA auto for enhancing performance. This is a way of life.
However this does not mean that all the modifications need to be passed on to all consumers. Neither has it
happened in any other industry.

Why the warranty is not extended and applicable for the part replaced now ?

When the vehicle was sold to you the contract of warranty was for 2 years post sale of the vehicle. The warranty is
not individually specified for individual parts. Hence it’s not possible to extend the warranty. However if failure
happens on same part again

Why warranty seizes if all free/paid service schedules is not maintained ?

Periodic maintenance care is extremely important for a moving machine line an automobile. If vehicle is not
maintained/serviced prudently as specified by manufacturer, the performance would go down drastically. That
may cause few premature failures which c

Why the life of a component is so less ? (Sprocket - 13000 kms ?,clutch plates - 17000 kms,Drive chain -
16000 kms ?)

Apart from material strength, the life of wear and tear items is dependant upon the maintenance care/driving
pattern in which the vehicle is running. A prudently maintained/driven vehicle would give thrice the life of a part as
compared to badly driven,bad

Page 25 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex - 14
‘ Labour Schedule’ for jobs eligible under warranty :
Remboursement of Warranty Jobs

U/W job
Labour hours to
completion
SN Replacement under warranty at dealership be claimed in
time for Pulsar
units
220 DTS-i
1 Oil Cooler replacement. 30.00 2
2 Replacement of Rear Disc brakes. 30.00 2
3 Replacement of rear Disc Pads ( within 1000 kms) 15.00 1
4 Master Cylinder Major replacement 45.00 3
5 Caliper Assembly – Major Kit replacement 60.00 4
6 Front Wheel Drum Bearing replacement 30.00 2
7 Brake Disc replacement 45.00 3
8 Disc holder plate on Wheel Drum replacement 45.00 3
9 Master Cylinder replacement 60.00 4
10 Rear Brake Hose replacement 45.00 3
11 Fairing/fairing frame replacement 75.00 5
12 Air filter Box Assembly replacement 30.00 2
13 Coupler / Hub Bearing / Hub replacement 45.00 3
14 Steering Lock / Key replacement 30.00 2
15 Disc holder plate on Wheel Drum replacement 30.00 2
16 Rear Fender / Mudguard replacement 45.00 3
17 Speedo case/cable replacement 15.00 1
18 Rider Seat Cowling replacement 15.00 1
19 Windshield/ Fairing replacement 45.00 3
20 Complete Lock Set replacement 30.00 2
21 Fuel Tank replacement 30 2
22 Replacement of front Disc Pads ( within 1000 kms) 30 2
23 Brake Disc replacement 75 5
24 Front Brake Hose replacement 90 6
25 Front Fork Oil Seal one side 60 4
26 Front Fork, Bearing Races, Cones & Steel Balls replacement 120 8
27 Fork Inner Tube one side replacement 60 4
28 Fork Outer Tube one side replacement 60 4
29 Front Fork Upper Holder replacement 120 8
30 Front Fork Lower Holder replacement 120 8
31 Fork Spring one side replacement 60 4
32 Trailing Arm Bush/dust covers replacement 120 8
33 Trailing (Swing Arm) replacement 120 8
34 Master Cylinder Major Kit replacement 120 8
35 Caliper Assembly – Major Kit replacement 120 8
36 Master Cylinder replacement 120 8
37 Magneto Rotor replacement 60 4
38 Stator Plate Assembly replacement 60 4
39 Chassis / Frame replacement 480 32
40 Replacing handle bar 60 4
41 Replacement of Chain sprocket kit 60 4
42 Engine Foundation Bush Kit replacement 60.00 4

Page 26 of 32
Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

43 Fuel cock replacement. 15.00 1

44 Magneto Cover replacement 15.00 1
45 Centrifugal Filter Cover/Gasket replacement 30.00 2
46 Crank Case (LH) Gear Shifter Shaft Oil Seal replacement 30.00 2
47 Clutch Centrifugal 30.00 2
48 Change Gear Shifter Lever Mechanism replacement 45.00 3
49 Gear Return Spring / Shaft Pawl / Spring replacement 45.00 3
50 Carb Assembly replacement 30.00 2
51 Starter Counter Gear/Bush/NRB replacement 30.00 2
52 Guide Starter 'O' ring / Oil seal replacement 30.00 2
53 Guide Starter Assly / Gear Inner Bush replacement 30.00 2
54 Clutch Cover replacement 60 4
55 Shaft Release Clutch / Oil Seal replacement 60 4
56 Oil Pump Assembly replacement 75 5
57 Clutch (Friction / Steel) Plates replacement 90 6
58 Cylinder Head Assembly replacement 120 8
59 Valve/Springs/Seal replacement 120 8
60 Rocker / Shaft Rocker Arm replacement 120 8
61 Valve/Valve Guide replacement 120 8
62 Timing Chain / Sprocket replacement 165 11
63 Cam Shaft Both Bearings replacement 120 8
64 Cam Shaft assly. Replacement 120 8
65 Set Primary Gear (Driver & Driven) / replacement 165 11
66 Body Balancer Assembly replacement 165 11
67 Cylinder Block/Piston Assembly replacement 180 12
68 Piston Rings replacement 180 12
69 Crank Shaft Assembly replacement 330 22
70 Crank Shaft Bearings replacement 330 22
71 Crank Case Assembly replacement 330 22
72 Crank Case (RH) replacement 330 22
73 Crank Case (LH) replacement 330 22
74 Input Shaft and Out Put Shaft/Speed Gears replacement 330 22
75 G.S. Drum replacement 330 22
76 G.S. Forks replacement 330 22
77 Replacement of Balancer Idler gear 210 14
78 Replacement of starter clutch 75 5
79 Complete Wiring Harness replacement 135 9
80 Replacement of BCU. 75.00 5
81 Starter motor replacement 45.00 3
82 Speedometer Assembly replacement 45.00 3
83 SPM Console Upper Cover replacement 45.00 3
84 Head Lamp Assembly replacement 75.00 5
85 H.T. Coil Single replacement 15.00 1
86 A/C Regulator (Voltage) replacement 15.00 1
87 Ignition Switch Assembly replacement 30.00 2
88 Rear Brake Light Switch replacement 15.00 1
89 Head Lamp Bulb replacement 30.00 2
90 Park Lamp Bulb replacement 45.00 3
91 Tail Lamp Assembly replacement 15.00 1
92 Rectifier / RR unit replacement 15.00 1
93 Fuel Gauge Float Unit replacement 30.00 2

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Annex -15
Electrical Circuit Diagram

1. Starter Motor Circuit

2. D.C. Ignition Circuit

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

3. Battery Charging Circuit

4. Brake Lamp Circuit

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

5. Horn Circuit

6. Side Indicator Circuit

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Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

7. Lighting Circuit

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 Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009

Action Matrix:

Works PDI In Service Floor

SL Key Information Sales In charge
Manager/DSE charge Advisor In charge
1 Salient Features Understand
features of this
Update Update
new variant and Update Technicians
2 Technical Specification
share with the
sales team
Caparison with
3
competitive
4 D C Ignition Share with Sales
5 Read before you ride /Service /PDI
6 PDI Checklist teams
7 PDI SOP & Time Chart Share with Sales
Periodic Service SOP /Service /PDI
8 team
Chart
Periodic Maintenance
9 & Lubrication Update
Chart
10 Critical Part List Update Update Technicians
Share with Sales
11 Initial Kit part list Update team & ASC/RSO Update
/YES channels
Frequently asked
12 Update Update Technicians
questions
Frequently asked
13 questions-related to Update Update Technicians
warranty
Reimbursement of
14
warranty Jobs
15 Electrical Circuits
Initials
Date

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