Pulsar Rs 200 TRG Note Ib Frame-Electricals

Frame & Suspension
Key Learning Points
Appropriate Torque Application for Various

Frame Components
Understanding of Standard Limits and

Service Limits for all Frame Components
CHAPTER 4
Frame & Suspension

Special Tools
Service Limits
Tightening Torques
Standard Operating Procedure
ABS - Anti Lock Braking System
Bajaj Pulsar RS 200 Training Notes

68
4 Vehicle (Frame)
Special Tools
Special Tools Application : for Frame Repairs
Fork oil seal tment punch

Part No. : 37 1740 03
Application : To remove anti-
friction and oil seal
bush from front fork
outer pipe.
Fork cylinder holder handle

with adaptor
Part No. : 37 1740 05
Application : For holding cylinder
piston
Installer Upper & Lower

Bearing Race Frame
Part No. : 37 1801 06
Application : To install upper and
lower steering races /
cones into their seats
inside frame.
Swing arm needle roller

bearing extractor & tment
tool
Part No. : 74 9309 93
Application : For removal and
fitting of needle roller
bearing in swing arm
Bajaj Auto International Business

69
Vehicle (Frame)
Special Tools
Special Tools Application : for Frame Repairs
Steering Nut tightening tool

Part No. : 37 1801 01
Application : For tightening /
loosening of steering
nut
Rear Mono Suspension

Adjuster
Part No. : 37 0041 70
Application : For adjustment of
mono rear
suspension setting
Stem Bearing Driver

Part No. : 37 1830 05
Application : To fit bearing race
on fork under holder
bracket
Notes

70
4 Vehicle (Frame)
Service Limits
Disc Pad Thickness Rear Sprocket Warp Axial Wheel Run Out
Std. Limit Fr -7.4mm Rr -7.3mm Std. Limit TIR 0.4 mm or Less Std. Limit TIR 1.0 mm or Less
Ser. Limit Fr -3.8mm Rr -2.0mm Ser. Limit TIR 0.5 mm Ser. Limit TIR 2.0 mm
Radial Wheel Run Out Tyre Tread Depth Front Fork Oil Grade & Capacity
Grade :
SAE 10W20 Bajaj
Fork Oil Level

Genuine Fork Oil
Quantity Per
Fork Leg :
O/H: 320 ml
Drain & Refill:
295+2.5ml
Std. Limit TIR 0.8 mm or Less Std. Limit Fr.: 5.0mm, Rr : 6.0mm Std. Limit -
Ser. Limit TIR 2.0 mm Ser. Limit Upto TWI 1.0 Ser. Limit -
Drive Chain Slack Axle Run Out Drive Chain Length

19 Link Length
1st 2nd 19th

MEASURE THIS LENGTH
100mm
Std. Limit 15 ~ 25 mm Std. Limit TIR 0.1mm or Less Std. Limit 301.6 ~ 302.1 (19 link)
Ser. Limit 30 ~ 40 mm Ser. Limit TIR 0.2 Ser. Limit 307

71
Vehicle (Frame)
Tightening Torques
Front Axle Nut Rear Axle Nut Rear Sprocket Mounting Nut
Tightening torque 9.0 ~ 10.0 kgm Tightening torque 10.0 ~ 12.0 kgm Tightening torque 3.2 ~ 3.8 kgm
Handle Bar Holder Bolts Fork Center Nut Steering Stem Nut Slotted
Tightening torque 1.8 ~ 2.0 kgm Tightening torque 4.8 ~ 5.2 kgm Tightening torque 0.5 kgm
Fork Upper Bracket Bolts Fork Under Bracket Bolts RSA Mounting Bolt (Upper)
RSA Mounting Bolt (Lower) Disc Mounting Bolts (Front) Disc Mounting Bolts (Rear)
Front Caliper Mounting Bolt Front Fender Mounting Brace Fender Mounting Bolt

72
4 Vehicle (Frame)
Tightening Torques
Rear Brake Pedal Mtg. Bolt Bracket Rear Number Plate Side Stand Mounting Bolt
Handlebar End Weight Bolt Tank Mounting Bolt LH & RH Stay Bolts
Swing Arm Shaft
Tightening torque 13.0 ~ 15.0 kgm

73
Vehicle (Frame)

Side Fairing Removal
Using Phillips set screw driver
Remove:
A
• RH & LH lower fairing mounting screws (5+5=10) & 8
metalic washers (A) & 2 plastic washers (C)
• Push pull plug (1+1=2) (B)
A
B
B
A
A C C
Using 4mm allen key

Remove:
• Speedo flap mounting 6 allen bolts (A) & 4 plastic
washers (B).
• Pull out the speedo flap with the help of speedo flap
removing tool. (C)
B B
Skill tips:
Ensure 3 clip snaps are available at its location.
B B
A
A

74
4 Vehicle (Frame)

Using 5mm allen key
Remove:
• Tank cover mounting top 2 allen bolts.
Using Phillips set

screw driver and
8mm Ring spanner
Remove:
• LH & RH Side
fairing under speedo
flap screws (2+2=4).
Using Phillips set screw driver & 8mm Ring

spanner
Remove:
• Flange bolt (1+1=2)(A) & 2 plastic washers
• Side fairing mounting below front fairing dome nut (1+1=2)

& 2 screws (1+1)(B)
B B
B
A
B

75
Vehicle (Frame)

• Pull out RH & LH
side fairing lugs
from petrol tank
cover.

76
4 Vehicle (Frame)

Front Fairing Removal
Using 4mm allen key
Remove:
washers (B).
removing tool. (C)
B B
Skill tips:
B B
A
A
Using Phillips set

screw driver and
8mm Ring spanner
Remove:
• LH & RH Side
fairing under speedo
flap screws (2+2=4).

77
Vehicle (Frame)

Using Phillips set screw driver & 8mm Ring
spanner
Remove:
• Flange bolt (1+1=2)(A) & 2 plastic washers
• Side fairing mounting below front fairing dome nut (1+1=2)

& 2 screws (1+1)(B)
A
B
A
B
Remove:
• 3 nos Philips head screws (A)
• 2 dome nuts (B)
• Lower cover located below projector lamps.

78
4 Vehicle (Frame)

• Disconnect RH
and LH indicator
coupler connection.
Using 4 mm allen key

Remove:
• RH & LH mirror rubber cap (A)
• RH & LH Mirror mounting allen bolt. (B)
B
A

Remove:
• RH & LH mirror rubber cap (A)
• RH & LH Mirror mounting allen bolt. (B)
• LH and RH mirror
base rubber
damper

79
Vehicle (Frame)

• Ta k e o u t f r o n t
fairing by pulling
RH and LH side
fairing.

80
4 Vehicle (Frame)

Seat Cowl Removal
Using vehicle key
Remove:
• Pillion seat.
Using 10 mm ‘T’ spanner

Remove:
• Rider seat mounting 2 bolts
• Pull the rider seat at back side
Using 6 mm allen
key
Remove:
• LH Pillion step
holder mounting 2
allen bolts
Disconnect tail lamp

coupler connections
using 12mm Box
spanner
Remove :
• Tail lamp mounting
3 flange bolts
• Tail lamp

81
Vehicle (Frame)

Seat Cowl Removal
A Using Phillips set
screw driver
Remove:
• Seat cowl inner
mounting 8
screws, 6 metal
washers and 2
plastic washers (A)
• Seat cowl inner
A
Using Phillips set

screw driver
Remove:
• Seat cowl center
top mounting
bottom 2 screws
• Seat cowl center
top by pulling
upside
Using 10 mm ‘T’ spanner

Remove:
• Seat lock mounting 2 bolts
• Seat lock bracket
Using Phillips set

screw driver
Remove :
• LH seat cowl
mounting bottom 4
screws & 1 plastic A
washer

82
4 Vehicle (Frame)

Seat Cowl Removal
Using Phillips set
screw driver
Remove:
• Seat cowl LH
mounting 2 screws
• Seat cowl
mounting upper 1
screw & 1 metal
washer
Using 6mm allen key

Remove:
• Grab handle mounting 2 allen bolts
• Take out LH seat cowl
Using 6mm Allen key

& 10 mm ‘T’ spanner
Remove :
• RH Pillion step
holder mounting 2
allen bolts
• R e a r b r a k e
reservoir mounting
1 bolt

83
Vehicle (Frame)

Seat Cowl Removal
Using Phillips set
screw driver
Remove:
• RH seat cowl
mounting bottom 4
screws, 3 metal
washers & 1
A
plastic washer (A).
Using Phillips set

screw driver
Remove:
• Seat cowl RH
mounting 2 screws
• S e a t c o w l
mounting upper 1
screw

Remove :
• Grab handle mounting 2 allen bolts
• Take out RH seat cowl

84
4 Vehicle (Frame)

Petrol Tank Cover & Tank Removal
Using vehicle key
Remove:
• Pillion seat
Using 10 mm ‘T’
spanner
Remove :
• R i d e r s e a t
mounting 2 bolts
• Pull the rider seat
at back side
Using 10 mm ‘T’
spanner
Remove :
• RH and LH seat
cowl mounting
screws (1+1=2)
• Petrol tank cover

rear mounting 2
screws

85
Vehicle (Frame)

Using Phillips set screw driver
Remove:
A
• RH & LH lower fairing mounting screws (5+5=10) & 8
metallic washers (A) & 2 plastic washers ©
• Push pull plug (1+1=2) (B)
A
B
B
A
A C C
Using 4mm allen key

Remove:
washers (B).
removing tool. (C)
B B
Skill tips:
B B
A
A

86
4 Vehicle (Frame)

Using 5mm allen
key
Remove:
• Ta n k c o v e r
mounting top 2
allen bolts.
mounting front 2
allen bolts
Using 10mm ‘T’

spanner
Remove:
• Pull out RH & LH
side fairing lugs
from petrol tank
cover
Using 10mm ‘T’

spanner
Remove:
mounting under
side fairing front 2
step bolts
Using 10mm ‘T’ spanner

Remove:
• Take out petrol tank cover

87
Vehicle (Frame)

Using 12mm box
spanner
Remove:
• Petrol tank
mounting 3 flange
bolts
• Disconnect the fuel gauge coupler and fuel pump coupler

connection.
• Pull up the petrol tank from front side
• Disconnect the Injector hose from inline fuel filter.
• Take out the petrol tank.

88
4 Vehicle (Frame)

Function :
To prevent the wheels of vehicle from sudden locking during braking situations .
Benets :
• Increase motorcycle stability & riding comfort.
• Best possible deceleration without wheel lock up.
• Reduced braking distance under many conditions.
Working :
In ABS system, the ABS unit detects the possibility of wheels getting locked by taking input
from speed sensor located at both wheels. When the wheels are about to lock, the hydro-
electrical controller controls brake caliper fluid pressure & thus prevent wheels from getting
locked, avoiding possibility of accident.
Components of the ABS System :

ABS unit is a combination of Electrical & hydraulic controls. The ABS ECU receives pulse
signal from both wheel speed sensors, accordingly it controls flow of brake fluid to caliper.
ABS unit is located below fuel tank. The master cylinder to caliper assembly hydraulic
connection of front wheel is routed through ABS unit. The signal from the wheel sensors
opens or closes the solenoid valves in ABS unit there by controls flow of hydraulic oil to
caliper assembly.
Solenoid Valve (Inlet) :

It allows flow of brake fluid to caliper while braking.
Solenoid Valve (Outlet) :

In case of wheel locking situation, it releases braking force applied on disc by allowing brake
fluid to flow back to temporary reservoir.
ABS Indication Lamp :

When ignition switch is turned ON, ABS Indicator will stay ON, until wheel speed is more than
10 km / hr, then ABS Indicator goes OFF. If there is any problem with ABS system, the ABS
Indicator will blink indicating the problem in ABS system.
Wheel Speed Sensors :

These are HALL effect type speed sensors. They sense the pulse from sensor disc mounted
on wheels & convey it to ABS Unit.
Pump :
To built the pressure whenever is required.
Note: In case of ABS system failure Brake system will work as a normal hydraulic
brake.

89
Vehicle (Frame)

Block Diagram :
ABS Unit
ABS ECU
Rear wheel speed Front wheel speed

sensor Signal Signal sensor
Signal
Solenoid valve &
Pump
Brake fluid flow

Front wheel with disc &
caliper
Brake fluid flow

Front Master cylinder
Front brake lever
Normal braking (ABS not activated) Brake master cylinder
When the ABS is not activated, the electric

signal from the control unit is off, the
solenoid valve IN is open, and the solenoid
valve OUT is closed. The fluid pressure in Solenoid valve IN Brake caliper
the master cylinder during braking is
transmitted directly to the caliper through the
solenoid valve IN. This is normal braking
and the rider directly controls braking with
the brake lever.
Wheel
speed
Motor Pump sensor
Control
unit
Solenoid
valve OUT
Reservoir

90
4 Vehicle (Frame)

When the ABS is activated Pressure increase
Pressure decrease
Brake master cylinder Brake master cylinder
Gripped Gripped
strongly strongly
(small (small
vibration) vibration)
Solenoid valve IN Brake caliper
Solenoid valve IN
Brake caliper
Wheel
Wheel
speed
speed Motor Pump
Motor
Control sensor
Control sensor
unit
unit
Solenoid
Solenoid valve OUT
valve OUT
Reservoir
Reservoir
Even though vehicle control is improved during emergency braking, always maintain a safe
distance between you and objects ahead. Vehicle speeds should always be reduced during
extreme road conditions. The braking distance for motorcycle equipped with an anti-lock
braking system may be longer than for those without it on rough road conditions. During these
conditions the vehicle should be driven at reduced speeds.
The ABS continuously senses the speed of the wheels. If the wheels are going to lock, the
ABS system repeatedly modulates the hydraulic brake pressure to the wheels.
When you apply Front brake under conditions which may lock the wheels, rider will feel a
corresponding sensation (pulsation) in the Front Brake Lever. This is normal and it means
your ABS is active.
ALSO IT IS RECOMMENDED TO USE BOTH FRONT & REAR BRAKES SIMULTANEOUSLY.
USING FRONT BRAKE WILL GIVE MAXIMUM EFFECTIVE BRAKING.
Always slow down when cornering. The anti-lock brake system cannot prevent accidents
resulting from excessive speeds. If the ABS warning light is on and stays on, you may have a
problem with the ABS. In this case, however, your regular brakes will work normally.

91
Key Learning Points
Understanding of VRLA Battery Charger
VRLA Battery Charging Process
Checking and Inspection of all Electrical

Components
Standard Operating Procedures for

Headlight Assembly Dismantling
Removal of Sensors and Actuators
CHAPTER 5
Electricals
Battery
Checking Procedure
Dos & Don'ts
Electrical Diagram

92
5 Electricals
VRLA Battery Initial Filling

Filling Procedures
Step 1: Get the battery ready
Place the battery on a at leveled and
preferably on a insulated surface.
Remove the ller port seal of the battery.
Filler port seal
Step 2: Get the electrolyte ready

Remove electrolyte container from the packing.
Remove the sealing cap plug strip.
Keep the sealing cap plug strip aside as this is
to be used as battery sealing plug strip later.
Note: Do not puncture the seals manually.
Plug cap strip
Seal
Step 3: Fill the battery

Hold the electrolyte container upside down.
Place the container upright on battery. Match
the 6 seals with the respective ller ports.
Note: Ensure the container is upright and not tilled.
If tilled the electrolyte might fail to flow.
Now force the container down until seals get
pierced, and electrolyte ows into the battery.
Step 4: Check the electrolyte ow

Make sure that air bubbles are visible in the
electrolyte and which is seen in all the 6 tubes
of the container.
Leave the container on the battery as it is for 30
minutes.

93
Electricals

Step 5: Take away the bottles
Be sure that the entire electrolyte has own
down inside the battery.
Tap the bottom of the container and gently
remove the empty container.
Step 6: Attach the sealing cap

Fit the sealing cap plug strip tightly on the ller
ports of the battery.
Ensure by pressing rmly that the cap has
become ush with the top surface of battery.
Step 7: Charge the battery

Charge the battery on BAL recommended VRLA
battery charger as per std. SOP.
Never use conducting materials like

screw drivers which can produce the
spark near battery terminals.
Caution
Do not add any additional electrolyte.

94
5 Electricals

Metafab VRLA Battery Charger Indication Display
2 4 5 6 7
8 9 10 11
3 1
12 13
1. On / o Switch
2. New battery / use battery switch
3. 2 Amp / 4 Amp current selection Switch
4. Main power supply indication light (Green)
5. Open circuit indication light (Red)
6. Bad battery indication light (Red)
7. Reverse polarity indication light (Red
8. Boost indication light (White)
9. New battery indication light (Yellow)
10. Use battery indication light (Blue
11. Charged indication light (Green)
12. -ve terminal (Black)
13. +ve terminal (Red)

95
Electricals
VRLA Battery Charger & Its Charging SOP

Battery Charging Procedure for Metafab make VRLA Battery Charger
Charging SOP Refer Charger Photo
Remove battery from vehicle and Clean battery thoroughly. -
Connect battery charger to 230 V AC single phase power supply and switch on -
the button of main supply.
"Connect battery charger leads to battery terminals. Red lead to +ve terminal
13 12
and Black lead to-ve terminal."
Switch on the battery charger main switch. Green LED will glow. 4
If Red LED glows it indicates reverse polarity connection. 7
"Select charging current 2 Amps or 4 Amps.
(2 Amps for 3 Ah / 4 Ah / 5 Ah VRLA batteries, 4 Amps for 6 Ah / 8 Ah / 10 3
Ah VRLA batteries)."
Select and press the charging switch for new battery or use battery (Green and
Blue LED glow for new and use battery) 2 4 10
If Red LED blinks it indicates open circuit situation. 5
Battery charger detects the battery voltage. If it is less than 5 volts it will switch
over to Boost charging mode White LED below the Boost will glow 8
"Battery charger detects battery voltage after every 3 minutes. If voltage
increases above 5 volts it switches over to selected charging mode ie NEW/ 9 10
USED."
Charging duration in this mode is 30 minutes. If the battery voltage is less than
5 volts after 30 minutes a Red LED indicating a bad battery will glow. This 6
indicates the battery is not suitable for charging.
"If battery charger is switches to NEW/USED charging mode, the battery would -
undergo charging for 5 to 14 hours depending on battery condition."
After completion of battery charging a Green LED will glow to indicate completion
of charging.
11
Switch off the main switch and disconnect the battery from the charger -
Reconnect the battery terminals on vehicle. -
Apply petroleum jelly to battery terminals. -
Note: During charging if the battery is disconnected, an audio indicator will beep for
2 minutes with a Red LED blinking to indicate open circuit situation.

96
5 Electricals
Checking Procedure
Relay Checking Procedure
Sr. No. Relays Location
1. Aux relay - 1
2. Aux relay - 2 Mounted on frame tube bracket
3. Aux relay - 3 inside seat cowling LHS
4. Main relay 3 2 1
5. Hi beam relay
6. Radiator relay Mounted on frame tube bracket
7. Fuel pump relay inside seat cowling RHS
7 6
5 4
Aux relay - 1 Aux relay - 2, Aux relay - 3

Main relay, Hi beam relay
Radiator relay, Fuel pump relay
Auxiliary Relays :
1. Auxiliary Starter Relay - 1 :
It is gray in colour. For identification purpose the relay base colour is also gray.
- Diode is provided for suppressing voltage surge.
- Its function is to provide earth connection for auxiliary relay 2.
- If vehicle is driven with relay 1 in disconnected condition, ECU may fail.
Its function is to isolate starter circuit from ECU i.e. even if ECU resets starter circuit will be unaffected. Relay
& relay base are brown in colour. If this relay fails engine can not be cranked.
For incorporating clutch & neutral switch interlocking in starter circuit. Relay & relay base are brown in colour.
4. Main Relay :
This is used in starter circuit & ignition circuit. Main relay is switched ON by ECU giving GND signal to main
relay for completing coil circuit. Main relay contacts output is used for -
• ECU battery supply input.
• Fuel injector.
• Fuel pump relay coil.
• Radiator fan relay coil.
• Heater of oxygen sensor.
If this relay fails, then the vehicle will not start.

97
Electricals
Checking Procedure
5. Hi beam Relay :
This relay is used for switching ON & OFF head lamp Hi beam filament. Low beam filament power is 55 W &
when Hi beam filament is switched ON another 65W load comes on the system. Conditions when Hi-beam
filament gets ON-
• Pass switch is pressed.
• Vehicle is driven with Hi / Lo beam switch in Hi beam mode.
Hence total load becomes 120W i.e. 10ADC current would flow through wiring harness.
To reduce wire size the Hi beam relay is introduced.
6. Radiator Relay :
This relay is used for switching ON / OFF radiator fan motor. The fan motor power is 30W & hence to avoid
2.5ADC current flowing through wiring harness, radiator relay is fitted.
Fuel Pump Relay :

Fuel pump motor power is 18W. This motor is of continuous duty type & as long as the vehicle is running the fuel
pump module will remain ON & 1.6A Max current will continuously flow through wiring harness. To avoid this fuel
pump relay is provided.

98
5 Electricals
Checking Procedure
Front & Rear Brake Light Switch Brown Blue Continuity check
by multimeter
Measuring & Testing Equipment : Multimeter
Lever Continuity is
Pressed shown
Lever No continuity
Released
u SOP :
Turn ON the ignition switch.
The brake light should glow brightly when the
front brake lever / rear brake pedal is pressed.
If it does not, check the front brake switch.
Side Stand Switch Sr. Parameter Magnet Wire connection Std.

No. Position Meter Meter Reading
+ve -ve
1 Input voltage N.A. Red/ Yellow/ 5 VDC
(Side stand Black
Blue
position-any)
2 Output voltage Magnet Pink Yellow/ 2~2.2

(Side stand in front of Black VDC
position-OFF) side stand
switch
Side stand Magnet Pink Yellow/ 5.0 VDC
position-ON away from Black
side stand
switch
u SOP :
Pi Y/B R/L
Switch ON ignition switch

and kill switch.
2
1
Set multimeter to 20 VDC.

1
Pi Y R
Connect multimeter as
shown in table given below.
Pi Y R
SIDE_STAND_SWITCH
Clutch Switch
Meter Range Yellow / Green Black / Yellow
OFF Clutch
lever not pressed
ON Clutch
lever pressed

99
Electricals
Checking Procedure
Ignition Switch Meter Wire Connections Continuity Check
Measuring & Testing Equipment : Multimeter Range
Continuity Meter +ve Meter –ve OFF No
Mode Continuity
Brown White wire ON Continuity
u SOP :
Switch OFF Ignition key.
Disconnect Ignition switch s coupler.
Check continuity between wires in ON and OFF
position.
u Standard Value :
Beep Sound and Continuity in ON position. No
continuity in OFF position..
Engine Kill Switch Meter

Wire Connections Condition Result
Measuring & Testing Equipment : Multimeter Range
Engine
Meter Meter Continuity
OFF
Continuity +ve –ve
condition
is shown
Mode
Gray / Brown / Engine ON No
Red Blue condition Continuity
u SOP :
Put ignition switch OFF.
Put kill switch OFF.
Set multimeter at continuity range.
Connect multimeter as shown in the table given
below.
Light Control Module (LCM) r. S No. Parameter Wire Connections Std.

Meter Meter Reading
+ve –ve
1 Engine is Violet Yellow/ 14.5 VDC
OFF (Pass Black
light OFF)
2 Engine is Red/ Yellow/ 13.5 VDC
running - H/L Black Black
switch ON.
This unit is a combination of head light controller and
asher unit. It switches on the head light only when
engine is running.

100
5 Electricals
Checking Procedure
Light Control Module (LCM) u SOP :
V Br
Switch ON ignition switch
and kill switch.
1
Set multimeter to 20 VDC.
2
1
V W
Connect multimeter as B/Y
Br L/W O
shown in table given
PIN4
PIN3
PIN2
PIN1
below. V W
DC Charging Voltage Measurement

Measuring & Testing Equipment : Multimeter & Battery Load Tester
Meter Wire Connections Speci ed at

Range 4500 RPM
Meter +ve Meter –ve
20 V DC Battery Battery 14.5 V + 0.2 V
+ve +ve DC
terminal terminal
u SOP :
SOP :
Put Ignition switch ON.
Put Kill switch ON.
Set multimeter at 20 VDC.
Connect multimeter as shown.
Start engine and run at 4500 RPM.
Note :
1. Before conducting this test ensure battery voltage is
13.1 ± 0.1 Volts (Fully charged battery)
2. For DC voltage measurement connect multimeter in
parallel with circuit.

101
Electricals
Checking Procedure
Stator Plate (Battery Charging Coil)
This is 3 phase starter winding (oil dipped type)
Y2 Sr.No. Meter Wire Std.

Range Connections esistance
Y1 Y3 Value
Meter Meter
+ve –ve
1 200 Ohm Y1 Y3 1 Ohm
Y1 Y2
Y2 Y3
u SOP : B/Y
Disconnect magneto W/R
coupler.
Set multimeter at 200
Ohm range.
Connect multimeter
as shown and note
Y Y Y
reading.
Starter Motor Current Drawn

Measuring & Testing Equipment : Clamp Meter
Meter Conditions Standard Value

Range
200 Encircle clamp 40~45 Ampere
DC A meter transformer (Spark plug caps
jaws around thick removed)
Red wire of starter
motor
u SOP :
Disconnect all 3 spark plug caps
Switch ON Ignition switch and kill switch.
Select range and set clamp meter zero reading.
Encircle red input wire of starter motor into the
clamp meter jaws.
Crank the engine for 3 seconds .
Observe the cranking current displayed on clamp
meter.

102
5 Electricals
Checking Procedure
Starter Motor Armature Inspection
(For Each Segment Checking)
Measuring & Testing Equipment : Multimeter &
Meter Wire Connections Continuity
Battery Load Tester
Range Check
Continuity Meter +ve Meter –ve No continuity
Mod Commutator Shaft to be shown
segment
u SOP :
Dismantle starter motor and take out the
Armature.
Check the continuity between starter motor shaft
and each segment on Commutator.
Replace armature if continuity is shown.

Range Check
Continuity Meter +ve Meter –ve Continuity
Mode Any Adjacent is shown
Commutator segment on
on segment Commutator
u SOP :
Dismantle starter motor and take out armature
Check continuity between each pair of adjacent
segments on Commutator.
Replace armature if No continuity is shown
between any two adjacent pair of Commutator
segments.
Steeper Motor
Measuring & Testing Equipment : Multimeter Sr. No. Wire Connections Standard
Value
P2 P3
1 Meter +ve Meter -ve
P1 P4
Pin no. 1 Pin no. 4 51
2 Pin no. 2 Pin no. 3 51
u SOP :
Ensure ignition switch and kill switch is OFF.
Remove harness side coupler.
Set multimeter on 200 Ohm range and connect
as shown in above table.

103
Electricals
Checking Procedure
Steeper Motor u SOP :
Ensure ignition switch
Measuring & Testing Equipment : Multimeter and kill switch is OFF.
Remove harness side
coupler.
G/Y L/B Gr/W G/R
200 Ohm range and
2
connect as shown.
STEEPER_MOTOR
Crank Angle Sensor & Neutral Switch

Sr. Component Meter Wire Standard Results
No. range Connections Value
Meter Meter
+ve -ve
1 Crank angle Resistance K
White/ Black/ 365 ~ 385 OK
sensor Red Ohms
2 Ohms Yellow
2 Neutral Continuity Light Black/ Beep OK
switch Green sound
Yellow
No Beep Defective
sound
u SOP : B/Y
Switch OFF ignition switch and kill switch. W/R
Connect multimeter as shown.
Y Y Y
Starter Relay Coil

Meter Wire Connections Meter Range

Range
Meter +ve Meter -ve
200 Starter relay Starter 3.9 Ohms + 10%
Ohms coil Red- relay coil
Yellow wire Black wire

104
5 Electricals
Checking Procedure
Starter Relay Coil R/Y B/Y
1
u SOP :
1
Switch OFF engine.
R/Y B B
Disconnect coupler from Relay. 1
R
Connect multimeter to Starter Relay coil R/Y

1
terminals.
Check resistance. R
Relay Coil
Measuring & Testing Equipment : Multimeter Meter Wire Connections Continuity
Range Check
200 Meter +ve Meter -ve 80 ~140 Ohms
Ohms
Relay coil Relay coil
terminal 1 terminal 2
u SOP :
Switch OFF engine.
Remove relay from coupler.
Connect multimeter to relay coil terminals.
Check resistance.
Fuel Pump
Range Check
200 Meter +ve Meter -ve 2.1 Ohms
Ohms
Orange/ Black/
Blue Yellow
Note:
1. Battery should be fully charged.
2. Fuse and ignition switch should
be OK.
B/Y O/L
3. Audible sound will be heard
B/Y B/Y
which will confirm fuel pump is 1 12
O/L O/L
working. 2
4. Check main relay first if fuel
pump is not working.

105
Electricals
Checking Procedure
Injector
Sr. Parameter Meter Wire Connections Standard
No. Range Reading
1 Resistance 200 Meter +ve Meter -ve 12 + 0.6
Ohms Ohms @
Pin no. 1 Pin no. 2 25 C
FUEL_INJECTOR
u SOP :
Remove petrol tank cover and petrol tank. FUEL
Remove air lter cover along with paper lter
element. INJECTOR
Disconnect the injector coupler.
2
Connect multimeter to Pin 1 and Pin 2 of

injector as shown.
B/W Br/W
Fuel Gauge – Tank Unit


Range Check
200 Meter +ve Meter -ve As per chart
Ohms
White/ Black/
Yellow Yellow
Standard Valve: Resistance Bars on Resistance Bars on

(+ 2 Ohms) Speedometer (+ 2 Ohms) Speedometer
18 8 87 2
38 7 97 1
48 6 100 0
57 5
67 4
77 3

106
5 Electricals
Checking Procedure
Fuel Gauge – Tank Unit
Note:
If display in speedo console is not proper
then please check following Y/B
1 1
B/Y B/Y
G/R W/Y W/Y

1. Battery Voltage 2 2
2. Speedometer coupler and fuel gauge
tank unit coupler connection is firm.
Capacitor u Checking method :

Touch +ve wire of capacitor to earth. Spark will occur.
Measuring & Testing Equipment : Nil
This indicates capacitor is OK.
Note:
Capacitor is very important for ECU functioning, so
ensure capacitor coupler is always firmly connected.
Engine Oil Pressure Sensor

Range Check
Continuity Meter +ve Meter -ve Continuity
Mode will be shown
Brown-Blue Black/
Yellow
u SOP : Br/Pi
1
If engine oil pressure is OK (i.e if 0.9 to 1.1

bar pressure is shown on pressure gauge)
then continuity will be shown on multimeter.
Note:
Oil pressure icon will blink if engine RPM greater
than 3500 rpm, Coolant temperature in the range
of 50 0C to 60 0C and oil pressure less than 0.9 bar
for time greater than 20 seconds are meet.

107
Electricals
Checking Procedure
Roll Over Sensor
Sr. Parameter Vehicle Wire Connections Standard

No. position Reading
Meter Meter
+ve -ve
1 Input NA Red/Blue Yellow/ 5 VDC
voltage Black
2 Output Normal Brown/ Yellow/ 4.8~4.9
voltage position Green Black VDC
Tilled Brown/ Yellow/ 2~2.2
position Green VDC
Black
(> 60 )
Br/G
u SOP : B/Y
Br/G Br/G
Switch ON ignition switch and kill switch. 1 1
Gr
Set multimeter to 20 VDC. Y/B B/Y
2 3 4 2
Connect multimeter as shown. R/L 3 Gr
Coolant Temperature Sensor

Meter Wire Standard Reading

Range Connections
Temperature
Resistance in
Meter +ve Meter -ve in Degree
Ohms
Centigrade
25 1.88~2.12
2K Coupler Coupler
Ohms Pin 1 Pin 2 50 0.75~0.86

108
5 Electricals
Checking Procedure
Coolant Temperature Sensor u SOP :
Pi/L B/W
Ensure engine is off.
Remove coupler of coolant
1
temperature sensor using 18
mm tube spanner.
Connect multimeter as
shown and check resistance
value.
Oxygen (Lambda) Sensor

Sr. No. Wire Connections Continuity
Check
Continuity Meter +ve Meter -ve Continuity
Mode will be shown
1 Pin no. 1 Pin no. 2 9 + 10 Ohm @
25 C
2 Pin no. 3 Pin no. 4 Meter
displays 1 @
25 C (open
circuit)
u SOP :
Ensure ignition switch is
OFF.
Remove the harness side
lambda sensor coupler.
Set multimeter on 200 W W Gr B
Ohm range and connect

W W Gr B
as per table.
1
2
3
4
2
4
1
Br/W L/R B/G L/Y
TMAP Sensor
Sr. Parameter Meter Wire Connections Standard
No. Range Reading
Meter +ve Meter
-ve
1 Resistance 20 K Pin no. 1 Pin no. 1.5 ~ 2.5
Ohms 2 Ohms @
25 C
2 Input 20 VDC Red/Blue Yellow/ 5 VDC
voltage Black
3 Output 20 VDC White/ Yellow/ 3.15 ~ 4.45
voltage Red Black VDC

109
Electricals
Checking Procedure
TMAP Sensor
Measuring & Testing Equipment : Multimeter Y/B
1
u SOP : G
2
Remove petrol tank and air lter cover along
with paper lter element. TMAP_SENSOR
U
R/L
P
Connect multimeter as shown in table. 3
W/O
4
P4 P3 P2 P1 Note:
For resistance checking remove coupler of TMAP
sensor and connect the multimeter prob to Pin 1
and Pin 2 as shown.
Input Voltage Checking Output Voltage Checking

Note:
For input or output voltage checking connect
coupler of TMAP sensor.
Spark Plug Cap

u SOP :
Remove spark plug cap from HT coil cable.
Set multimeter on 2 K Ohms range.
Connect multimeter probes as shown and
measure the value.
Standard value, 1 K Ohm ± 150 Ohm.

110
5 Electricals
Checking Procedure
Termination Unit Function:
It has transil diode for ltration of voltage surge / ripple
in mains supply line there by protect ECU from voltage
uctuations.
It also consist two diodes that are used for clutch switch
and neutral switch circuit.
These diodes are called reverse protection diodes.
Reverse protection diodes provide correct neutral
indication in speedo console.
Symptoms of malfunctioning : Glowing of neutral indication
in speedo console when vehicle is in gear and on pressing
of clutch lever.
Note :
1. No checking method using multimeter is recommended
for checking this unit
2. Checking by replacement method only.
u SOP :
Radiator Fan Motor
Disconnect coupler of fan motor.
Connect external 12 V DC supply to
disconnected coupler of fan motor.
Now the fan motor will start running.
Observe the fan running smoothly.

111
Electricals
Checking Procedure
TPS Sr. Parameter Wire Connections Standard
No. Reading
Meter +ve Meter -ve
1 Input Red/Black Black/ 3.3 VDC

G/Y voltage Green
1 /B
R 2 Output Red/Black Black/ 0.3 ~ 0.65
2 voltage Green VDC
B/G idle throttle
3
3 Output Red/Black Black/ 2.7 ~ 3.0
voltage Green VDC
wide open
throttle
3 Coil Pin 2 Pin 3 1.6 ~ 2.4
Resistance Ohms
u SOP :
Remove petrol tank cover and petrol tank.
Remove air lter cover along with paper lter
element.
Connect multimeter as shown in table given
below.
Input Voltage Checking
Central H. T. Coil Primary Winding Resistance Checking

Measuring & Testing Equipment : Multimeter Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
200 Ohms Orange/ Black 0.513 ~

White Pin-1 Pin-2 0.627 Ohms
Secondary Winding Resistance Checking

Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
20 K HT output Pin of 4.23 ~ 5.17 K

Ohms Orange / Ohms
White

112
5 Electricals
Checking Procedure
Twin H. T. Coil
Measuring & Testing Equipment : Multimeter Primary Winding Resistance Checking
Meter Wire Connections Standard
Range Value
Meter +ve Meter -ve
200 Ohms Black / Red Pin of 0.63 ~ 0.77

Orange / Ohms
White
Secondary Winding Resistance Checking

Meter Standard
Wire Connections Remark
Range Value
Meter Meter To be
+ve -ve 10.8 ~ 16.2 measure
20 K K Ohms between to
Ohms HT HT H.T. outputs
output output
Horn
Measuring & Testing Equipment : DC Clamp
Meter Range Wire Standard Value
Meter
Connections
200 DC A Encircle clamp 2.2 Amps
meter jaws
around Brown
wire of horn
u SOP :
Encircle clamp meter jaws around Brown wire of
Horn.
Press horn switch and check the current drawn
by horn.

113
Electricals
Battery Replacement SOP
Insert Key and u Remove

open the lock 2 Bolts
Rider seat
u Remove
Pillion seat
u Remove Slide away ECU

2 Bolts from battery
bracket
2 Collared bush
u Remove
Battery terminal
caps
Battery +ve and
then -ve terminal
Lift out battery
u Remove
Battery

114
5 Electricals
Roll Over Sensor SOP

Note : Follow the earlier mentioned SOP’s till petrol tank removal
to proceed for Roll over sensor removal.
u Remove
Disconnect the
coupler
2 Bolts
H. T. Coil (RH Side) SOP

Note : Follow the earlier mentioned SOP’s till petrol tank removal
to proceed for Roll over sensor removal.
u Remove u Remove
2 Bolts Disconnect
Earthing coupler
connection
u Remove
Plug cap LH and
RH
Take out HT coil

115
Electricals
RH Head Lamp Bulb Removal SOP

u Remove
Disconnect
coupler
connections
Rotate RH head
light bulb (Hi-beam)
at anti-clockwise
direction
Pull out the

head light bulb
Disconnect
coupler
connections
Rotate LH head
light bulb
(Low-beam)
at anti-clockwise
direction
Pull out the

head light bulb

116
5 Electricals
Dos & Don’ts

Battery
Dos Don’ts
u DO Apply u DON T Apply
petroleum jelly Grease to
to terminal post terminal post
u DON T Short
circuit the
terminal post
u DO Use
proper
equipment for
testing
u DO Use u DON T Use

correct tools wrong tools

117
Electricals
Dos & Don’ts

Horn
Dos Don’ts
u Adjust horn sound by rotating the Phillips u Never adjust the nut on horn cap side and
screw in the direction of arrow provided on bracket end (horn back side) as it will result in
horn. horn malfunctioning and failure.
u Do not remove silicon sealant from adjustment
screw as it will result in water entry inside the
horn.
Switches
Dos Don’ts
u After washing the vehicle ensure to apply dry air u Do not apply direct pressurized water jet on
on switches before operation. control switches.
u Ensure that grommets provided on clutch switch, u Do not lubricate electrical switches by oil or
front brake switch and rear brake switch are grease.
intact. u Do not over tighten the switch mounting screw.

118
119
5
REAR
WHEEL
SENSOR
ABS Circuit
W B
R/W L/O
DIGITAL W/B
SPEEDOMETER Pin 18 Pump Meter
B/W B/W
ABS INDICATOR Pin 17 ABS Indicator
Electricals
Pin 16 - NC
L/W
VSS 48 INPUT

Pin 15 - NC
L/O
W/B Pin 14 Rear Wheel Sensor I/P
R/W
Pin 13 Rear Wheel Sensor Supply
W W/R W/R
FRONT Pin 12 Front Wheel Sensor Supply
Electrical Diagrams
WHEEL Y
SENSOR Pin 11 CAN Low
B L/Pi
B/Y
L/Pi Pin 10 Chassis Earth
OFF Pin 9 Solenoid Valve

ON W/L
Pin 8 Optional Speed Sensor Output
L/W
Pin 48 Y
BR/L Gr/R Pin 7 - NC
Pin 6 - NC
Pin 36 L
ELECTRONIC CONTROL UNIT

Pin 5 - NC
O/W
Br/W
Pin 4 Kill Switch
L/Pi
W/B W/L Pin 3 Front Wheel Sensor Input
TO FUSE O/P L
Pin 2 CAN High
F4
F9
TO FUSE I/P Gr/R 25A 10A
Pin 1
B/Y
B/Y
IGNITION_SWITCH Br/L
ON Br
OFF R
B
LOCK W W/B
30A B
CHASSIS
GROUND
BATTERY
SW CTL RH
CLUTCH_SWITCH LED CONTROL
OFF LG
START
TERMINATION_UNIT
ON
AUX_STR_RELAY_2 MAIN_RLY
B/Y Y/G R/Y AUX_STR_RELAY_3 AUX_STR_RELAY_1
LG
BR/L Gr/R NEUTRAL_SWITCH
Electricals
B/Y Y/G Y/R Gr/R

Y/L LG
R/Y
Y/L R/W L/G
Starting Circuit
LG R/G
Gr/Pi
Y/R B/Y R/G
O/W
W/G
R/G Gr/Pi R/G
R/W
LG
Gr/Pi
W/G W/G Br/W
Br/W
Electrical Diagrams
Br/W
Y/G
Y/G Y/G Gr/Pi
L/G O/W Gr/Pi
R/G
Gr/Pi
Pin 46 R/G
Br/W

Gr/Pi
Pin 53
IGNITION
SWITCH
Br BR/L
On
Off BR/L R/W O/W Gr/Pi
Lock
W W/B W/B
TO FUSE O/P
W/B
30A 15A 15A 7.5A
F1
F3
F4
F7
TO FUSE I/P
R Gr/R
W/B
BR/L
BR/L
R/Y BR/L
B/Y
R
R
R/Y B B
STARTER_MOTOR R
R
B
STARTER_RELAY
BATTERY
CHASSIS_GROUND

120
121
5
OFF KILL ROLL
SWITCH IGNITION_COIL_2 OVER
ON MAGNETO
SPARK PLUG LH SENSOR
ASSEMBLY
BR/L Br/G Gr
SPARK PLUG RH
B/Y W/R
Gr/R
Ignition Circuit
B/Y B/R
Br/G
B/Y W/R O/W
O/W W/B
Gr/R
R/L
O/W
Electricals
Y/B

W/B
Gr/R
TO_ELECTRONIC_CLUSTER R/L Pi/L

IGN Gr/R Gr/Pi 30
SUPPLY R/B B/G
6 31
Electrical Diagrams
R/L R/L
7 G/R
Gr/Pi Gr/Pi 38
9 O/W
39
10 W/R
DIGITAL SPEEDOMETER G/Y Y/B
42
44
Br/G Y/W
23
Gr/Pi L/B G/Y Y/W

25 37
Gr/W B O/W O/W
26
55
27
B/Y 56
B/R
Gr/Pi
IGNITION_SWITCH
Br BR/L BR/L
ON
OFF
LOCK W W/B
B/G
G/Y
Gr/W
R/B W/B O/W Gr/Pi
TO FUSE O/P
30A 15A 7.5A
Gr/W F1 F4 F7
B BR/L
TO FUSE I/P
R
O/W R
Gr/R
G/Y B/G G/Y BR/L
G/R
O/W L/B Y/W
B/Y Pi/L
B
BATTERY
CHASSIS
IGNITION_COIL_1 GROUND
STEPPER_MOTOR TPS
SPARK PLUG CENTRAL
ENGINE_TEMP_SENSOR
KILL OFF TERMINATION_UNIT
SWITCH ON
LG
BR/L Gr/R
Electricals
Neutral Light Circuit

NEUTRAL
SWITCH
O/W Gr/R LG
LG
LG
DIGITAL
Electrical Diagrams
SPEEDOMETER
Gr/R Gr/Pi Gr/Pi 09
IGN SUPPLY
UNIT
LG LG
CONTROL
ELECTRONIC
NEUTRAL IND LG 28
W W
BATTERY +VE
Gr/Pi
IGNITION_SWITCH
W
Br BR/L
ON
OFF O/W Gr/Pi
W/B
W W/B
LOCK
W/B
TO FUSE O/P
R 30A 7.5A 15A 7.5A
F1 F2 F4 F7
BR/L TO FUSE I/P
B
W/B
Gr/R
BATTERY BR/L
CHASSIS
GROUND

122
123
5
Gr Gr
DIR
IND
FRONT B/Y B/Y
RH
Gr
B/Y
DIGITAL
Side Indicator Circuit
SPEEDOMETER
B/Y DIR
Electricals
Gr Gr Gr IND
RIGHT TURN IND REAR
LEFT TURN IND Gr

RH
G G G
G
B/Y B/Y
G DIR IND
B/Y REAR LH
B/Y G
Electrical Diagrams
DIR
IND
FRONT G G
LH
Gr
ON Br BR/L BR/L
OFF
LOCK W W/B
IGNITION SWITCH Br
W/B
O
G
Br
O Gr Br
BR/L
TO FUSE O/P
30A 15A
F6
F1
Br O Gr O G TO FUSE I/P
R
R L
OFF B
BR/L
LIGHT CONTROL MODULE BR/L
CONTROL SWITCH LH
B
BATTERY
CHASSIS
GROUND
FRONT
BRAKE
SWITCH
Electricals
L Br
Brake Light Circuit
L Br
Electrical Diagrams
L L
ON Br BR/L
OFF
Br Br
REAR BRAKE
LOCK W W/B SWITCH
W/B
IGNITION SWITCH
L L
Br
BR/L
B/Y
TO FUSE O/P TAIL LAMP
ASSEMBLY
R 30A 15A
F1 F6
R
TO FUSE I/P
B
R BR/L
B
BATTERY CHASSIS
GROUND

124
125
5
OFF MAIN
RELAY
ON
BR/L Gr/R
R/W
R/W
R/W
O/W Gr/R R/W

L/G
Electricals
Coolant Temperature and
Br/W
Radiator Fan Motor Circuit
O/W

GR/Y R
L/G Pi/L
DIGITAL
SPEEDOMETER B/Y
Electrical Diagrams
O/W B
IGNITION Gr/R Gr/Pi Y/W

SUPPLY RADIATOR
FAN MOTOR
ELECTRONIC
G/Pi
CONTROL UNIT
COOLANT Y/W
TEMP.
BATTERY
+VE
W W GR/Y
Gr/Pi
Y/W
IGNITION_SWITCH
Br BR/L
ON
OFF O
W W/B Br/W
LOCK
O
Y/W G/Pi
R W/B W Gr/Pi RADIATOR
FAN
Pi/L TO FUSE O/P
RELAY
30A 7.5A 15A 15A 7.5A 7.5A
F1 F2 F3 F4 F5 F7
BR/L
TO FUSE I/P
W/B
Gr/R
B
ENGINE
TEMP BR/L
SENSOR
BATTERY CHASSIS R
GROUND
OFF
KILL
FUEL
SWITCH ON
LEVEL
SENSOR
Electricals
BR/L Gr/R B/Y W/Y
Fuel Level Sensor Circuit
B/Y W/Y
O/W Gr/R
DIGITAL
SPEEDOMETER
Electrical Diagrams
Gr/Pi
Gr/R Gr/Pi
IGN. SUPPLY
W/Y W/Y
FUEL INPUT
W W
BATTERY +VE
O/W
ON Br BR/L W/B
OFF
LOCK W W/B
IGNITION W Gr/Pi
SWITCH BR/L W/B
TO FUSE O/P
30A 7.5A 15A 7.5A
W/B F1 F2 F4 F7
R TO FUSE I/P
B BR/L
Gr/R
BR/L
BATTERY CHASSIS
GROUND

126
127
5
OFF
KILL
SWITCH ON MAGNETO
ASSEMBLY
BR/L Gr/R
B/Y W/R
Tachometer Circuit
B/Y W/R
Electricals
O/W Gr/R

Electrical Diagrams
Gr/Pi Gr/Pi Gr/Pi W/R

IGN SUPPLY
B B B
ENGINE RPM
ELECTRONIC
CONTROL UNIT
W W B/Y
BATTERY +VE
DIGITAL SPEEDOMETER
Gr/R
W/B
ON Br BR/L
OFF
LOCK W W/B
IGNITION
SWITCH
W/B
W O/W Gr/Pi
BR/L
TO FUSE O/P
30A 7.5A 15A 7.5A
R F1 F2 F4 F7
TO FUSE I/P
B R
BR/L Gr/R
W/B
BATTERY
CHASSIS Gr/R
GROUND
OFF
KILL ON
SWITCH
Electricals
B W BR/L Gr/R
Circuit - For ABS

Vehicle Speed Sensor
L/Pi W/R W/R

Pin 12
Pin 3
L/Pi
Pin 9
W/L
Gr/R Gr/Pi 09 Pin 8
Electrical Diagrams
IGN SUPPLY
ELECTRONIC
Gr/R 45 W/L Pin 4
CONTROL UNIT
VEH. SPEED
SENSOR
W/L O/W Gr/R
Gr/Pi
VSS 8
OUTPUT
10A Gr/R
W/L
DIGITAL SPEEDOMETER
L/W O/W
VSS 48 I/P
W
BATT. +VE
W
ON Br BR/L W/B
IGNITION OFF
SWITCH W
Gr/Pi
W W/B
LOCK W/B
R
TO FUSE O/P
30A 7.5A 15A 7.5A 7.5A
F1 F2 F4 F7 F9
Gr/R TO FUSE I/P

R
B
BR/L R
W/B Gr/R
BR/L
B
BATTERY
CHASSIS Gr/R

GROUND
128
129
5
OFF
VEHICLE SPEED
SENSOR KILL ON
SWITCH
R/W R/W
B/Y
BR/L Gr/R
L/W L/W
Circuit - Non ABS

Vehicle Speed Sensor
Electricals
B/Y

SPEED SEN R/W
SUPPLY
Gr/R Gr/Pi
IGN SUPPLY O/W Gr/R
ELECTRONIC
Gr/R W/L
CONTROL UNIT
VEH. SPEED
SENSOR
Electrical Diagrams
L/W
Gr/Pi
GROUND
B/Y L/W W/L
DIGITAL SPEEDOMETER
BATTERY W O/W
+VE
W
ON Br BR/L
IGNITION OFF W/B
SWITCH W
Gr/Pi
W W/B R
LOCK
W/B
TO FUSE O/P
R 30A 7.5A 15A 7.5A
R F4 F7
B F1 F2
BR/L TO FUSE I/P
BR/L Gr/R
B W/B
BATTERY
CHASSIS BR/L
GROUND
OFF LED
ON
CONTROL
PO
FRONT
POSITION
LAMP RH B/Y
B/Y B/Y Y/L R Br/W
Electricals
Lighting Circuit
R R R
R
R/B 21
HL_HIGH
BEAM B/V ECU
B/Y B/Y
TO_ELECTRONIC_CLUSTER R/Y R Br/W
R/B R/B TAIL_LAMP

HIGH ASSEMBLY
BEAM
R/Y R/Y B/Y
B/V R/B
R R R
BACK R
LIGHT
W W R
Electrical Diagrams
DIGITAL SPEEDOMETER
BAT+VE
V
FRONT POSITION
LAMP LH V
R R R/Y R/Y R
B/V
B/Y B/Y Br
NUMBER
Br PLATE
LAMP
OFF ON Br BR/L BR/L
LOCK W W/B W/B

Y/L Y/L
IGNITION
B/Y R/Y
SWITCH Br
HL_LOW
Y W/B
BEAM
R/Y
R/B
L/B R/B
W Br Y/L
R W/B
B/V B/Y
Br Br Y/L Br L/B
V TO FUSE O/P
B/Y Br/W
B/Y
F1 30A
F6 15A
F8 15A
F2 7.5A
R BR/L
TO FUSE I/P
Br B/Y V W
R/Y
B/Y
Y/L
Br R/B Br/W B W/B BR/L
HIGH
LIGHT CONTROL
BEAM LED B BR/L W/B
MODULE
RELAY LO HI BATTERY CHASSIS
CONTROL_SWITCH_LH GROUND

130
131
5
Horn Circuit
IGNITION_SWITCH
ON Br Br/L
OFF
LOCK W W/B
Electricals
Br Br

Br/L
W/B
Br
R
Electrical Diagrams
Br
TO FUSE O/P
30A 15A
B R
F1
F6
Br B B
B/Y TO FUSE I/P
1
1
BR/L
B
8
1
CHASSIS_GROUND
B B/Y BATTERY
BR/L
HORN
SWITCH
CONTROL LH
HORN SWITCH
OFF
KILL
SWITCH ON
BR/L Gr/R
Electricals
Side Stand Circuit

O/W Gr/R
O/Br 01 32 Pi
Electrical Diagrams
O/W
R/L 07
Gr/R
IGN SUPPLY
ELECTRONIC
Gr/Pi 09
CONTROL UNIT
SIDE STAND
W
42 Y/B
O/W
O/Br
B/Y
DIGITAL
B/Y
SPEEDOMETER
Gr/Pi Gr/Pi
BATT +VE
W W
IGNITION
SWITCH
W/B
ON Br BR/L BR/L
OFF
W W/B
LOCK
Y/B
Pi R/L
W/B TO FUSE O/P
30A 7.5A 15A 7.5A
R
F1
F2
F4
F7
B
TO FUSE I/P
W/B
BR/L
Pi Y R
Gr/R
SIDE BATTERY CHASSIS

STAND GROUND
SWITCH

132
133
5
SWITCH OFF
CONTROL
RH ON
BR/L Gr/R
2
1
2
Electricals
Engine Oil Pressure Circuit

O/W
Gr/R
TO_ELECTRONIC_CLUSTER
IGNITION 2 Gr/R 2 Gr/Pi Gr/Pi

SUPPLY
B/Y 11 B/Y
Electrical Diagrams
13
OIL
PRESSURE
19 L/R 17 Br/Pi
20 18
BATTERY +VE
DIGITAL SPEEDOMETER
W W
O/W O/W
W O/W Gr/Pi
IGNITION_SWITCH W/B
TO FUSE O/P
Br BR/L BR/L
ON 30A 7.5A 15A 7.5A
1 1
F1
F2
F4
F7
OFF
2 2 TO FUSE I/P
LOCK W W/B
R
Br/Pi
R
W/B BR/L Gr/R
1
Gr/R R B
1
1
W/B
8 Ah VRLA CHASSIS
BATTERY GROUND
OIL_PRESSURE_SENSOR
Gr/R
Electricals
Electrical Diagrams
Battery Charging Circuit
REGULATOR
REGULATOR
GROUND
CAPACITOR
MAGNETO
R B ASSEMBLY
B
B
1
B 2
1
2
Y Y Y Y
B B/Y
R
R
1
1
2
3
2
1
2
3
1
2
1
2
3
1
2
3
W/B
W/B Y
Y Y
Y
Y
W/B
Y
W/B
W/B
R W/B
30A
R
B
1
B
1
CHASSIS
8 Ah VRLA GROUND
BATTERY

134

Pulsar Rs 200 TRG Note Ib Frame-Electricals

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Pulsar Rs 200 TRG Note Ib Frame-Electricals

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Frame & Suspension

Key Learning Points

Appropriate Torque Application for Various

Understanding of Standard Limits and

Frame & Suspension

Standard Operating Procedure

ABS - Anti Lock Braking System

Bajaj Pulsar RS 200 Training Notes

Fork oil seal tment punch

Fork cylinder holder handle

Installer Upper & Lower

Swing arm needle roller

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Steering Nut tightening tool

Rear Mono Suspension

Stem Bearing Driver

Bajaj Pulsar RS 200 Training Notes

Fork Oil Level

Drive Chain Slack Axle Run Out Drive Chain Length

1st 2nd 19th

Ser. Limit 30 ~ 40 mm Ser. Limit TIR 0.2 Ser. Limit 307

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Bajaj Pulsar RS 200 Training Notes

Swing Arm Shaft

Tightening torque 13.0 ~ 15.0 kgm

Bajaj Auto International Business

Standard Operating Procedure

Using 4mm allen key

Bajaj Pulsar RS 200 Training Notes

Standard Operating Procedure

Using Phillips set

Using Phillips set screw driver & 8mm Ring

• Side fairing mounting below front fairing dome nut (1+1=2)

Bajaj Auto International Business

Standard Operating Procedure

Bajaj Pulsar RS 200 Training Notes

Standard Operating Procedure

Using Phillips set

Bajaj Auto International Business

Standard Operating Procedure

• Side fairing mounting below front fairing dome nut (1+1=2)

• 2 dome nuts (B)

• Lower cover located below projector lamps.

Bajaj Pulsar RS 200 Training Notes

Standard Operating Procedure

Using 4 mm allen key

• RH & LH Mirror mounting allen bolt. (B)

Using 4 mm allen key

• RH & LH Mirror mounting allen bolt. (B)

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Standard Operating Procedure

Bajaj Pulsar RS 200 Training Notes

Standard Operating Procedure

Using 10 mm ‘T’ spanner

• Pull the rider seat at back side

Disconnect tail lamp

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