Professional Documents
Culture Documents
Pulsar 150 1805
Pulsar 150 1805
REV.06,
09,MAY
AUG18
18
To keep your bike in perfect running condition and deliver consistent performance, we have
specially programmed the periodic maintenance services which includes 3 Free and subsequent
Paid services, as per the schedule contained in this booklet. We earnestly advise you to avail all
these services at any of our Bajaj Dealers or Authorised Service Dealers, who are well equipped
with all necessary facilities / genuine parts / oil and trained manpower to ensure the best care for
your Pulsar. Your Pulsar comes with a warranty of 5 Years or 75,000 Kms whichever occurs earlier
from the date of sale. For details please refer to “Warranty : Scope & Limits” given in this manual.
Should you require any additional information feel free to contact us on our helpline numbers or e-
mail us at: customerservice@bajajauto.co.in or visit the Bajaj Auto website www.bajajauto.com
To be a part of the Pulsarmania, visit www.mypulsar.com and join the Pulsar fanpage on
facebook: www.facebook.com/mypulsar
Rev up, shift gears and enjoy the Pulsar experience…
SERVICE DEPARTMENT
BAJAJ AUTO LIMITED
7. Control Switches 8 Caution : This indicates that a potential
8. Removal & Fitment of Side Covers 10 hazard that could result in vehicle
9. Removal & Fitment Seat 12 damage. Follow the Advice provided with
10. Battery / Tool kit 13 the caution.
11. Daily Safety Checks 14
12. How to ride your Bike 15
Notice:
13. Safe Riding Tips 19
14. Engine Oil 20 The description and illustration in this booklet
15. Wheels - Tyre 21 are not to be taken as binding on the
manufacturers. The essential features of the
16. Periodic Maintenance Information 22
type described and illustrated herein remaining
17. Periodic Maintenance & Lubrication Chart 26
unaltered. Bajaj Auto Limited reserves the
18. Free Service Guidelines 31
right to carry out at any moment without
19. Non Use Maintenance 32 being obliged to bring this booklet upto-date
18. Delivery Certificate 33 & to do modifications on the vehicle, parts or
19. Warranty Scope & Limit 34 accessories as may be convenient and
20. Battery Warranty Card necessary.
13.4 Nm at 6000 RPM 14.22 Nm at 6500 RPM
Ignition System : DC CDI DC CDI DC CDI
Spark Plug : Champion RG4HC, 2 Nos. Champion RG4HC, 2 Nos. Champion RG4HC, 2 Nos.
Spark Plug Gap : 0.7 to 0.8 mm 0.7 to 0.8 mm 0.7 to 0.8 mm
Transmission : 5 speed constant mesh. 5 speed constant mesh. 5 speed constant mesh.
Front Brake : Disc Brake Disc Brake Disc Brake
Rear Brake : Drum Brake Disc Brake Disc Brake
Fuel Tank Capacity
Full : 15 litres 15 litres 15 litres
Reserve : 3.2 litres 3.2 litres 3.2 litres
Usable Reserve : 2.0 litres 2.0 litres 2.0 litres
Dimensions :
Length : 2055 mm 2035 mm 2035 mm
Width : 755 mm 765 mm 765 mm
Height : 1060 mm 1115 mm 1115 mm
Wheel base : 1320 mm 1345 mm 1345 mm
Ground clearance : 165 mm 165 mm 165 mm
Note : • All dimensions are under UNLADEN condition. 1 • This vehicle complies to BS IV standards.
• Above information is subject to change without any notice. • AHO is government regulation.
Battery : 12V - 4Ah VRLA 12V - 4 Ah VRLA 12V - 9 Ah MF
Head Lamp : 35/35W, HS1 35/35W, HS1 35/35W, HS1
Pilot Lamp : 5W Each 2 Nos. 5W Each 2 Nos. 5W Each 2 Nos.
Tail /Stop Lamp : LED LED LED
Turn Signal Lamp : 10W (4 nos.) 10W (4 Nos.) 10W (4 Nos.)
Neutral Indicator : LED LED LED
Hi Beam Indicator : LED LED LED
Turn Indicator : LED LED LED
Side Stand Indicator : LCD LCD LCD
Speedometer Illumination : LCD Amber LCD Blue LCD Blue
Low battery indicator : LED LED for Non ABS, LCD for ABS LED for Non ABS, LCD for ABS
ABS Indicator : Not applicable LED LED
Rear No. Plate Lamp : 3W 3W 3W
Horn : 12V DC 12V DC 12V DC
Vehicle Kerb Weight : Non ABS ABS Non ABS ABS Non ABS ABS
: 144 kg. Not applicable 144 kg. 146 kg.
Gross Vehicle Weight : 274 kg. Not applicable 274 kg. 276 kg.
2
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)
3
Front Fork
Pillion
Foot Rest
OFF: Steering unlock. Ignition OFF. RES : When fuel level is below
Fuel Tapposition.
reserve
ON: Steering unlock. Ignition ON.
5
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.
When you apply Front brake under conditions which
Fuel Tank Cap
may lock the wheels, you feel a corresponding
• To open the fuel tank cap, open the flap. sensation (pulsation) in Front brake lever. This is
Insert the key in the lock and turn it
clockwise and lift fuel tank cap. normal and it means your ABS is active.
Also it is recommended to use both front & rear brakes
• To lock the ‘Fuel Tank Cap’ insert the key
simultaneously.
in the lock and turn it clockwise and press
Always slow down when cornering. The anti-lock brake
fuel tank cap. ‘Click’ sound ensures cap is
system cannot prevent accidents resulting from
fully locked.
excessive speeds.
Precaution :
Dont attach metallic ‘Key chain’ as it may damage
paint of petrol tank.
6
5 10
14
6 11
12
1. Side Stand Indicator : It glows when Side stand is reset to zero by pressing the button.
down & igntion switch is ‘ON’. 9. Trip Meter : The Trip meter shows the distance
2. Fuel Level Indicator : Fuel level indicator shows traveled since it was last reset to zero.
available fuel in fuel tank. Tank symbol glows when 10. Battery Indicator : It shows battery needs charging
petrol level in tank reaches reserve level 11. Hi Beam Indicator : It glows when Headlight is ‘ON’
3. Engine Rev Indicator :It blinks when engine RPM & Hi beam is selected with engine running.
cross 9000 RPM mark. 12. Neutral Indicator : It glows when transmission is in
4. Tachometer Dial : It shows engine speed in RPM. Neutral & Ignition switch ‘ON’.
5. Odometer : The Odometer shows the total distance 13. Bajaj Logo : Bajaj logo flying ‘B’ glows.
that the vehicle has accumulated. 14. ABS Indicator ( ): With Ignition switch ON the
6. Turn Indicator (LH & RH) : When Turn signal switch ABS indicator glows. When vehicle speed is more than
is turned to L/R, Turn indicator - LH or RH will flash. 5 Km/h the ABS indicator goes off, if this indicator
7. Speedometer:Vehicle speed will be displayed digitally glows while vehicle is running, it means there is
8. Trip Meter Reset Button : Both trip meters can be problem in ABS unit.
7
B
Removal of Seat- Front & Rear Fitment of Seat- Front & Rear
(Pulsar 150 Twin Disc / 180) (Pulsar 150 Twin Disc / 180)
• Remove ‘Side Cover’ LH. • Both the seats can be fitted by matching their lug
• Pull rear seat lock cable (A) & remove ‘Rear Seat’ with the respective lock & pressing down the lug into
• Similarly pull the front seat lock cable (B) & remove lock.
‘Front Seat’.
CAUTION: Always remove Rear seat first. CAUTION : Always fit Front seat first.
For Pulsar 150 follow procedure as given below For Pulsar 150 follow procedure as given below
Removal of Seat assembly complete Fitment of Seat assembly complete
• Remove ‘Side Cover’ LH. • The seat assembly can be fitted by matching its lug
• Pull seat lock cable (A) & remove the seat complete. with the lock & pressing down the lug into the lock.
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Pulsar 180 Pulsar 150 / 150 Twin Disc
Battery Tool Kit Location
• It is located inside the ‘Side Cover’ LH. • It is located below the battery.
• Always maintain electrolyte level in each
• 2 rubber straps are provided to hold the
cell between max and min level lines.
tool kit.
• Always keep a watch on battery charge
level indicating icon, if it flashes (indicates
battery is in low charged condition), show First Aid Kit Location
the vehicle to authorised BAL dealer.
• First aid kit is to be stored in seat cowl.
CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may
lead to damage of electrical / electronic CAUTION : Always fit rubber strap for
components. locking tool kit.
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return the motorcycle to a safe operating brake vehicle.
condition.
• Drive Chain slack of 20 to 30 mm
Warning : Failure to perform these adequately lubricated.
checks every day before you ride may • Function of all lights & horn
result in serious damage or severe
accident. • Clutch lever play - 2 to 3 mm
• Smooth steering movement without
• Enough fuel level for planned distance of restriction.
journey. No fuel leakage in fuel lines.
• Both stand return to their fully up position.
• Engine oil level (between upper and lower
level mark) • Correct inflation pressure in both tyres
Adequate tyre tread depth - no cracks /
• Throttle cable play of 2 ~ 3 mm. Smooth cuts.
operation and positive return to closed
position, • Correct rear viewing span adjustment of
mirror.
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button “ ” to start the engine. Note : The motorcycle is equipped with a clutch
• Release starter button as soon as engine switch. This switch ensures that engine does not
starts. start if the transmission is in gear.
Note : Do not let the engine idle longer than 3 However, the engine can be started in any
minuets otherwise it will overheat. gear if the clutch lever is pressed.
• If the engine is cold or when starting for first
time, use choke ‘ ’for quick starting. Moving Off :
• Check that Center/Side stand is up.
• When the engine is • Depress the clutch lever.
OFF warmed up enough to st
• Shift into 1 gear.
idle without using • Open the throttle and release the clutch
ON choke, return the
choke to OFF lever slowly and simultaneously.
position. • As the clutch starts to engage, open the
throttle a little more, giving the engine just
Manual Choke
enough rpm to keep it from stalling.
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Braking :
• Close throttle completely, leaving clutch
engaged (except where shifting gears) so
that engine braking will help slow down
motorcycle.
• Shift down one gear at a time so that you
Gear Shifting are in Neutral when you come to a complete
Pattern stop.
Gear Shifting Lever • Front brake is to be used to get maximum
braking performance.
Recommended Speed for Shifting Down • Rear brake is to be used when more de
45 km/h celeration is required.
From 5th to 4th Gear
• When stopping, always apply both brakes at
th rd
From 4 to 3 Gear 35 km/h the same time. De-clutch as necessary to
From 3rd to 2nd Gear 25 km/h avoid engine stalling.
A : Oil Filler Cap, B : Oil Level Gauge Pulsar Bajaj DTS-i SAE 20W50 API
150/180 10000 ‘SL’ or JASO ‘MA’
Engine Oil Level Checking : 150 Twin Disc
• Check engine oil level every day. Park
vehicle on level surface on centre stand. • Engine oil replacement frequency : 1st service &
then every 10,000 Km.
• Check oil level through oil level gauge ‘B’.
• Engine oil level top-up frequency : Every 5000 km.
• Always maintain engine oil level between
upper (C) and lower (D) mark provided on CAUTION :
Cover RH. Top up with specified grade of • It is most important to adhere to
oil if the oil level is below lower level mark. recommended grade & frequency of oil
change for the purpose of long life of
Engine Oil Capacity : critical engine components. For details
• Refill at servicing : 1000 ml. refer periodic maintenance chart.
• During engine overhaul : 1100 ml. • Do not reuse drained oil.
20
Tyre Pressure :
Keep appropriate tyre pressure as mentioned
below to increase life of the tyre & for better
Tubeless Tyre : fuel consumption.
Front Brake Fluid Level : Battery : 12V-9 Ah MF, For Pulsar 180
• Front brake fluid reservior is located on RH • Battery is located inside ‘Side Cover’ LH.
side of Handle bar. • Always ensure that battery electrolyte level
is in between max & min level marks.
• To check oil level, keep the vehicle on
• Check & top up battery by distilled water if
center stand with handle bar in straight
electrolyte level is below min level mark.
ahead condition.
• Battery life would get adversely affected if
• Always ensure that brake fluid level is top up with ‘Tap Water’.
above ‘MIN’ mark given on inspection
Window.
CAUTION : Tap water is not a substitute
for distilled water and will shorten the life
of the battery.
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discharge of electrolyte through vent tube. 15-20 sec. for battery to recover.
• Do not add extra electrical accessories
• Environment care must be taken to such as - Remote, Bigger horn, Musical
dispose off the used battery. It is always brake light etc. This will reduce life of
recommended to hand over the same to battery
the Authorised battery / Bajaj dealer for • If vehicle is to be stored for more than 2
proper disposal of the same. weeks disconnect battery to avoids self
• When battery is found discharged, it is discharge.
advised to get it charged immediately.
Std. Chain
slackness : 20~30 mm
0.7 to
0.8 mm Top edge
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Drive Drive
Chain Chain
Cleaning Lubrication
Drive chain must be cleaned & lubricated as Method of O-ring Chain Lubrication :
per periodic maintenance schedule. • Place the bike on centre stand.
a. Drive chain (Non O-ring type) • Clean the chain by using lint free cloth (If
• Non O-ring type chain should be removed & excessive mud / slush found approach Bajaj
cleaned by Nylon brush & Kerosene or in Service Center for proper cleaning)
Chain Cleaning Machine. • Shake the can vigorously by holding
• It should be lubricated by SAE 90 grade oil. vertically upright till the noise of steel ball
b. Drive chain (O-ring type) inside heard uniformly.
• ‘O’ rings must always be kept wet for best • Hold spray can at the back of rear sprocket
performance hence lubricate every 500 Kms with extension tube nose at 5~10 cm.
• O-ring chain lubrication can easily be done • Rotate the wheel in reverse direction &
by owners using Bajaj ‘Chain Lube Spray spray the lube on middle portion of the
Can’ available with Bajaj dealers. chain up to full length of the chain.
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Parts. Use caustic free
detergent for washing.
2. Engine oil (Bajaj DTSi 10000 oil) C,R R Top R Top R Top R BGO DTSi 10W30 for
Up Up Up 100cc models.
BGO DTSi 20W50 for
Models above 125cc.
4. Oil strainer CL CL CL CL CL
16. Non-Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
cleaning & lubrication**
17. Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A Customer to apply OKS
cleaning & lubrication** chain lub spray at every
500 kms.
23. Brake fluid level **- top up / replace C,A,R C,A R Use recommended
brake fluid
(DOT3/DOT4)
25. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A
26. Battery electrolyte level, specific gravity C,A C,A C,A C,A C,A C,A C,A C,A Not applicable for
VRLA battery
27. Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness.
28. Ignition switch barrel cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray
31. Steering stem bearing*** & C,CL,L,R C,CL, C,CL, C,CL, Check & replace if
Cap steering bearing (Plastic)** L,R L,R L,R Damaged. Use HP
Lithon RR3 grease for
lubrication.
32. Main stand & side stand pin** CL,L CL,L CL,L CL,L Use AP grease.
34. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
37. Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
41. Spoke tightening**-Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
43. SAI, EVAP hoses - Check functionality, C,R C,R C,R C,R C,R C,R C,R C,R Replace if cut / damaged
leakage or any other damage**
44. EVAP drain tube cleaning** CL CL CL CL CL CL CL CL
Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.
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** For Battery :
• Empty the fuel from the fuel tank and a. Remove battery and keep it on wooden
carburettor float bowl (if fuel is left in for a plank, in properly ventilated area.
longer time, the fuel will break and gummy b. Before taking the vehicle for use.
substance could clog the carburettor). • Get the battery recharged from the
• Remove spark plug & put several drops of Authorised Service Center / Battery Dealer.
engine oil into the cylinder. Kick engine • Apply petroleum jelly on battery terminals.
over slowly a few times to coat cylinder
wall with oil & install back spark plug. Preparation for regular use after storage :
• Set the vehicle on a box or a stand so that • Follow daily safety checks.
both wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to
prevent rusting. Avoid getting oil on rubber
parts or brake liners.
• Cover entire vehicle neatly. Make sure that
storage area is well ventilated & free from
any source of flames or spark.
• Fill 10% excess air pressure in both
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I have taken possesion of motorcycle along with the following items.
Dealer Code :
Dealer Name :
Address :
Customer's Signature (To be filled in by the dealer) Contact No. :
SERVICE RECORD
Sr. Age Specific Dealer’s Stamp * Code For Remarks:
Date Gravity Voltage Remarks & Signature * Code
No. Mths. LL : Low electrolyte level.
1 AE : Electrical system needs attention.
2 IR : Insufficient running of vehicle.
3 CB : Cover broken.
4 BC : Broken Container.
5 PM : Poor maintenance.
6 BA : Battery abused.
Note : Customer should insist that “Service Record" must be filled by respective authorised battery dealer as proof of specified
maintenance for easy settlement of claim, if any.
• Loose connection • Overcharge / Undercharge
• Internal Short • Reverse Charge
• Plate Shedding • High Specific Gravity Electrolyte
• Intercell Connection • Electrolyte Contamination
• Does not Hold Charge • Electrolyte Level not Maintained
• Wrong Assembly • Left Lying Idle
• Wrong Application
• Terminal Corroded
CIN : L65993PN2007PLC130076