2023-04 15/03/2023

To:
All Motorcycle Dealers Service Process
All Motorcycle ASDs
CT, Platina & Pulsar
• Take printout.
• Display on shop floor notice board for 2 weeks. CT 100, 110, 110X, 125X,
• Explain to relevant staff members & ensure conformance at all levels. Platina 100, 110, Pulsar 125, NS125
• Soft copy of service bulletin & updated SPC is available on e-SSM

Sub: BS VI E-Carburettor cleaning SOP.

BS VI E-Carburettor cleaning SOP to be followed if functional issues of the vehicles are reported
i.e.

• Starting trouble
• Unstable idle RPM
• Poor throttle response

(Carburettor cleaning is not a routine PM activity. Carburettor opening not to be carried

out unless it is necessary)

Pre checks before carburettor cleaning:

• Check the air solenoid and choke solenoid initialization after key ON. Replace in case of
no initialization noise. Faulty solenoid may cause the issues related to idle.
• Check purge pipe connection at carburettor end & carburettor fitment in rubber sleeve, if
found loose correct it.
• Check the carburettor breather pipe for any pinching, if found loose correct it.

After ensuring all the above points check vehicle performance, if issue persist then remove
the carburettor for cleaning. (Switch off the ignition key before removing the carburettor to
avoid unnecessary faults on MIL)

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SOP for BS VI E-Carburettor cleaning:

Step 1:

• Remove the FCB (Float chamber

bowl).
• Remove the carburettor cap,
vacuum piston assembly.
• Remove Pilot jet and Main jet with
jet holder.
• Tighten VCS. (While tightening,
measure nos of turns required to
fully tighten the VCS. Note down
the turns e.g. 2.5 turns)
• Now remove VCS.
• Remove air solenoid.
• Remove float assembly.

Step 2:

• Clean all the removed jets with

carburettor cleaning spray &
pressurised air (2 Bar).
• Replace the jets in case found
damaged / clogged (cleaning not
possible).

Step 3:

• Clean the slow circuit passages with

carburettor cleaning spray &
pressurised air (2 Bar) as shown in
images.

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Step 4:

• Clean the main circuit passages with

carburettor cleaning spray &
pressurised air (2 Bar) as shown in
images.

Step 5:

• Re-assemble all the child parts correctly.

• Assemble VCS & tight completely thereafter restore the VCS position to
original turns (As checked before dismantling it – in this case 2.5 turns).
• Check float chamber bowl ‘O’ Ring (Part No – PF581330), replace if found damaged
(on chargeable basis) and assemble the float chamber bowl. Ensure correct fitment
of the O’ ring to avoid leakages.
• Assemble the carburettor properly on vehicle. Connect all the couplers before
turning ON the ignition key.
• Ensure the carburettor breather not pinched.
• Turn ON the fuel cock and check the carburettor for any leakages / overflow.

Step 6:

• Warm up the engine up to 60°C oil temperature.

• Check Engine idle RPM (standard values: 1400 + 100)
• Adjust Engine RPM if not in range to standard specifications. Remove CAP (idle
adjuster) to access Adjuster screw for RPM adjustment
• Keep the engine in idle and check air solenoid Pulse Width Modulation (PWM) value
with help of D&F tool (refer SOP in Annex 1)
• Ensure the PWM values in the range of 50% to 80% in idle.
• Take VCS out in case if the PWM values are lower than 50%
• Take VCS IN in case if the PWM values are higher than 80%
• Replace CAP (idle adjuster) with new part (Part no PF581329)

Note:
• Checking of VCS turns before dismantling VCS & refitting of VCS at same nos
of turns is very important.

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Carburettor cleaning – DO’s & Don’ts:

DO’s Don’ts

Jet cleaning by carburettor cleaning spray Do not use steel wire for carburettor jet
& compressed air (2 bar). cleaning.

Check for source of water/ dust, if water / Do not ignore checking of fuel tank for
dust found in float chamber (Carburettor presence of water, clean if so.
duct, O-Rings, Fuel pipes) Do not ignore other locations of water entry.

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 Do not use worn out / damaged/ wrong parts.
• Ensure Float chamber bowl O-Ring
fitment in groove.

• If Float chamber bowl O-Ring found

damaged, to be replaced with new
O-Ring.

• Ensure float chamber mounting

screws tightening & confirm no
petrol leakage.

Above E-Carburettor cleaning SOP to be followed for all vehicles reported with above mentioned
issues in vehicle.

Please disseminate this information to all concerned.

Thanking You,
Yours faithfully,

For BAJAJ AUTO LIMITED

Ajay Sharma
Vice President – Service (Motorcycle Business)

Cc to: Field Service Team / RTC team / CQA

This Circular is pursuant to and in accordance with the STANDARD TERMS of DEALERSHIP AGREEMENT (“Agreement”) executed by and between BAJAJ AUTO LTD and You (the
“DEALER”) including in particular Articles 4.12, 6.4 and 9.6 thereof. For legal purposes, this Circular is being sent by BAJAJ AUTO LTD. through electronic mode, the contents of which are
deemed to be accepted by You. This Circular, unless revised by BAJAJ in writing, shall always be deemed to be an integral part of the Agreement and shall be read along with the Agreement.

Page 5 of 7
 Annexure 1: Air Solenoid PWM Checking SOP

Step 1

• Start the vehicle and Warm up the

engine up to 60°C oil temperature

• Connect D&F tool with vehicle.

• Go to Vehicle Diagnostic and select

appropriate model & year.

• Select “View data” & press Enter

• Select “LID2” and press Enter

• Select “Entire Data List” and press

Enter

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• Check “Air Solenoid Duty (%)”
values, it should be in the range of
50% to 80% in idle.

(It may take some time to stabilize

the values)

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