Manual de Taller Bajaj Pulsar 220S

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

TO: Selected Dealers / Authorized Service Centers - 2 Wh Spare Parts Dealers & Distributors

Product Category CC Group Bulletin No.

Sub:

Introduction of “Pulsar 220 DTSi“

Date

Motorcycle 220 NP: 12 23/06/2009

Dear Sirs: We are pleased to introduce ‘Bajaj Pulsar 220 DTSi’ DTSi’. This bike offers a gre at package of Style, Power & Technology in its class of bikes. We enclose herewith following information of this new bike, which gives you insight 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 placing order Initial kit.

Annex – 11

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 Manager (Service-Probiking)

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

Page 1 of 32

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

Annex-1

Salie nt F F e ea tur e es

Attribute

Key Features

Advantages & Benefits

Style • • • • • •

• • • • • • •

Performance

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 clamp ed 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.

•

•

Bold assertive stance, Sporty looks. Brains, brawn and definitely bold. The style that lets you break f ree.

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 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

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.

• • • • • • • • • • • • • •

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.

Page 2 of 32


Annex-1

Salie nt F F e ea tur e es

Attribute

Key Features

Advantages & Benefits

Style • • • • • •

• • • • • • •

Performance

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 clamp ed 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.

•

•

Bold assertive stance, Sporty looks. Brains, brawn and definitely bold. The style that lets you break f ree.

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 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

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.

• • • • • • • • • • • • • •

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.

Page 2 of 32


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.

•

• • • •

• • • • • • •

•

• • •

• •

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.

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

• • •

• • • • • • •

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.

Page 3 of 32


A nne x -- 2 2

Te c Spe cif ic ations ch nic al S

ENGINE & TRANSMISSION

CONTROLS Steering Accelerator

Type No. of cylinders Bore Stroke

: Four stroke, Natural air cooled. : One. : 67 mm : 62.4 mm

Engine displacement Compression ratio Idling Speed Maximum net power Maximum net torque Ignition system Ignition Timing

: : : : : : :

Fuel Fuel Feed Spark Plug

: : :

Spark plug gap Lubrication Starting Clutch Transmission Primary reduction Gear Ratios 1st Gear

: : : : : :

220 cc 9.5 + 0.5 : 1 1400 +100 rpm. 21 Ps @ 8500 rpm 19 Nm @ 7000 rpm Microprocessor controlled digital C.D.I. 10° BTDC 1000 rpm 26 ° bTDC at 2500 RPM Unleaded Petrol Carbureted 2Nos. Champion P -RG6HCC 0.8 to 0.9 mm Wet sump, Forced Electric Start only Wet, multidisc type. 5 speed constant mesh. 3.47 : 1 (66/19)

: 24.736 : 1 (36/13)

2nd Gear 3rd Gear

: 16.814 : 1 (32/17)

4th Gear 5th Gear Final Drive Ratio

: 9.677 : 1 (26/24)

: 12.335 : 1 (29/21) : 7.939 : 1 (24/26) : 2.57 : 1 (37/14)

CHASSIS & BODY Frame type Suspension: Front Rear

: Double cradle type. : : Telescopic with Guide & Slide bush (Stroke - 130 mm.) : Trailing arm with coaxial gas assisted Hydraulic shock absorbers and coil springs.

: Handle bar : Twist grip type on right hand of handle bar : Left foot pedal operated : Lever operated on left side of handle bar : Auto choke

Gears Clutch Choke Brakes : Front Rear

: Lever operated on right side of handle bar : Pedal operated by right foot.

ELECTRICALS System Battery Head lamp Pilot lamp( Tail/stop lamp Turn signal lamp Turn signal pilot lamp Side stand indicator lamp Hi beam indicator lamp Neutral indicator lamp Speedometer lamp Rear No. plate Lamp Horn DIMENSIONS

:12 Volts (D.C.) :12V 9Ah MF :12V , 55 W H7 (Main) 12V, 55 W H7 (Passing) :12V , 5W 2 Nos : LED/LED : 12V , 10 W : LED : LED : LED : LED : LED Display : 12V, 5 W : 12 V DC , 2 nos

Length Width Height Wheel base Turning circle radius Ground Clearance WEIGHTS

:2035 mm. : 750 mm. :1165 mm. :1350 mm. : 2500 mm. :165mm.

Vehicle kerb weight Max. total weight

: 152 Kg. : 282 Kg.

PERFORMANCE Climbing ability

0

: 28 % (16 )

Page 4 of 32

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

NOTES :Front Rear

Front Rear Tyre pressure: Front Rear Pillion - Rear Rims : Front Rear

: Hydraulically operated disc brake : Hydraulically operate d disc brake Tyres: : 90x90 X 17, 49P, Tubeless : 120/80 X 17, 61P, Tubeless

Values given above are nominal and for guidance only, 15% variation is allowed to cater for production and measurement variation. All dimensions are under unladen condition. • Definitions of terminologies wherever applicable are as • per relevant IS / ISO standards. Specifications are subject to change without notice. • •

: 2.00 kg/cm 2 (28.0 Psi) (Solo &Pillion) : 2.00 kg/cm 2 (28.0 Psi)(Solo) : 2.25 kg/cm 2 (32.0 Psi) : 1.85 x 17 : 2.50 x 17

A nne x -- 3 3

Comparison with Competition Vehicles

DESCRIPTION Manufacturer Colours

Ex-showroom price

On-road price (Mumbai)

COMPARISION WITH COMPETITOR PRODUCTS HERO HONDA YAMAHA KARIZMA YFZ R 15 Hero Honda Motors Limited Sport red / Vibrant Blue / Moon yellow / Force Silver / Black with option of Black / Red Alloys Black alloy wheel - Rs. 75471 (Mumbai) Red alloy wheel - Rs. 76206 (Mumbai) Black alloy wheel - Rs. 83638 (Mumbai) Red alloy wheel - Rs. 84435 (Mumbai)

ENGINE & TRANSMISSION Air cooled, 4 stroke Single Engine cylinder OHC Displacement 223 cm³ Engine horse 17ps @ 7000 rpm power Engine Torque 18.35 N-m@ 6000 rpm Gear box 5 Speed Constant Mesh Carburetor - VE, Constant Fuel supply Vacuum Carburetor with CCVI system (Carb controlled variable ignition)

BAJAJ 220 DTSi

India Yamaha Motor Pvt. Ltd.

Bajaj Auto Ltd.

Yamaha Blue / Graphite / Blazing Red

Midnight Black, Plasma Blue, Wine Red, Grey Silver

Rs. 97, 425 (Chennai)

Rs. 1,08,600 (Chennai)

Liquid cooled, 4 stroke Single cylinder SOHC 4 valve 149.8 cm³

4 Stroke, DTSi, Air cooled /with an Oil Cooled 220 cm³

17 ps @ 8500 rpm

21 ps @ 8500 rpm

15 N-m @ 7500 rpm 6 Speed Constant mesh

19 Nm @7000 rpm 5 Speed Constant Mesh

Electronic Fuel Injection

Carburetor - CV

Page 5 of 32


CHASSIS & BODY Frame type Suspension Front Suspension Rear Brakes Front Brakes Rear

Tubular single cradle, Diamond type Telescopic Hydraulic shock absorbers Swing arm with 5 step adjustable type Hydraulic shock absorber Disc Dia 276 (non asbestos type) Internal expanding shoe type Dia 130mm (non asbestos type)

Delta Box Frame

Double Cradle type

Telescopic Hydraulic shock absorbers

Telescopic front fork

Linked monocross suspension with spring/shock absorber Single Disc Single Disc

Trailing Arm with coaxial gas assisted hydraulic shock absorbers & coil springs Hydraulically operated disc brake Hydraulically operated disc brake

ELECTRICALS Ignition System Battery Spark Plug Head Lamp Tail / Stop Lamp Number plate Turn Signal Lamp

Advanced Microprocessor Ignition (AMI) 12V - 7 Ah NGK - DPR8 EA 9 CHAMPION - PRA 7 HC 12V - 35/35 W Halogen (Multi reflector - DC) 12V - 5W / 21W X 2 nos. (Multi reflector) 12V - 5W 12V - 21W X 4 nos. (Multi reflector)

DIMENSIONS Length 2125 mm Width 755 mm Height 1160 mm Wheel Base 1355 mm Ground clearance 150 mm Kerb Weight 150 Kgs. PERFORMANCE Max. Speed 125 kmph STYLING DIFFERENTIATOR

Styling

1. Bold new graphics 2. Speedo dials in bright yellow for clear day time visibility 3. Muffler cover with chrome finish

TCI

Microprocessor controlled digital CDI

12V - 3.5 AH

12 V, 9 AH MF

NGK/CR8E

Champion P -RG6HCC

TWIN - Low beam - 12V-35W High beam - 12V - 35W

12 V, 55 W H7

12V - 5W / 21W

LED/LED

12V - 5W

12 V, 5 W

12V - 10W X 4 nos.

12 V, 10 W

1995 mm 670 mm 1070 mm 1290 mm 160 mm 131 Kgs.

2035 mm 750 mm 1165 mm 1350 mm 165 mm 152 Kg

140 kmph 1. Liquid cooled - 4 valves - Fuel injected 2. Delta Box frame 3. Linked type monocross suspension

1. Brawny masculine looks. 2. Wolf eyes head lamp 3. 3 D Metallic decals on petrol tank.

Page 6 of 32


A nne x -- 4

DC Ignition System Advantages Quick/ easy start.

Easy Cold starting.

No starting Trouble after Washing.

No start – Water entry post monsoon.

Battery life

Trigger start rpm down to 200 from 350. 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. Auto choke – Engine temperature Sensor provided to give rich mixture At winter mornings.

Sealed couplers everywhere to arrest water entry.

Sealed Starter relay – potting type to avoid water entry.

Better battery charging current at lower rpm and throughout the rpm range. (At 20 kmph speed 1.25 Amps 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.

Page 7 of 32


A nne x -- 5 5

Read Before You Ride A 1

Starting the vehicle : 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 :

1

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. Choked air filter indicator.

2

High engine oil temperature indicator.

3

Low battery charge level indicator.

4

Less engine oil level indicator.

C 1 2 3 4 5

6

7 8 9

Maintaining Battery charge level is very essential, for starting of vehicle. Important Does and Don'ts : The powerful engine with quick throttle response would make the driver to open the accelerator with caution. Do not open the throttle suddenly. 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. As soon as "fuel res" red indicator light is ON, fill up the fuel at the nearby filling station. 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. 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. 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. Do not add any additional electrical / electronic gadgets on the vehicle, as they would disturb functioning of engine management system. 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. 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".

Page 8 of 32


A nne x -- 6 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 By

Dealer Name Please ensure that following checks are carried out during PDI before Delivery of vehicle To Check

Check For

 If OK X If Not OK

Observati ons Remarks

Engine

Engine Oil: SAE 20W50API SJ or SL+ JASO MA Idling rpm( Warm Up)

Oil Level OK/Top up if required Oil leakage if any- specify source of oil leakage

Fasteners ( Check torque)

Engine Mounting Bolts ( M- 8 2.2 Kgm , M-10 2.4 Kgm)

Check/Adjust if reqd( 1400+- 100 rpm) with tachometer 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

Page 9 of 32

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

Lock operation

Front Axle nut - 8~ 9 Kgm Rear Axle nut 8~10 Kgm Handle Bar bolts 2~2.2 Kgm Fasteners ( Check Torque)

Steering Cap bolt 5Kgm 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- terminal s/ 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, Ne utral 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

Page 10 of 32


A nne x -- 7 7

Pre-Delivery Inspection - SOP

Sr. No 1 2 3 4 5 6 7 8

9

10 11 12

Description

Posit ion

Identify & Park Vehicle on Work Bay Remove the Thermocol and additional packing if any. Study PDI card and Work content. Open Petrol tank cap & pour petrol Check for smooth operation of fuel cock lever Check & top up engine oil level, if required. Check clutch cable operation & Adjust if required. Check front brakes for efficient working & Adjust if required. Check and correct tyre inflation pressure - Front Wheel Check Battery voltage, check up electrolyte level, ensure petroleum jelly presence, and connect terminals properly. Inspect Rear Shock Absorber setting & Correct if necessary. Check Rear brakes for efficient working & adjust if required. Check and Correct tyre inflation pressure - Rear Wheel.

SMM

0.50

Lifter Bay

Petrol Dispenser

Petrol, Waste Cloth

Nose Plier, Oil Can, Funnel OE Spanner Set

RH

0.30

RH

0.10

Front

0.10

Ring Spanner

Suction Pump

Front

0.20

Air Pressure Gauge

Pedaled Air Pump

LH

0.60

OE Spanner Set, Screw Driver

RH/L H

0.10

Rear

0.10

Rear

0.20

0.40

14

Check Accelerator cable free play

LH

0.05

15

Check & Adjust TPS

LH

0.10

LH

0.05

RH / Front

0.20

Front

0.05

18

M&T/ Service Shop Equipments

Consumables

0.10

LH

17

PNR & its Attach

0.50

13

Check gear shifter lever operation Check & Adjust steering and Handle bar for free movement. Check front mudguard alignment wrt Front Wheel

Special Tools

0.80

Lubricate chain and Check / Adjust chain slackness if required.

16

GP Tools

Cloth

Cotton Waste, Petroleum Jelly, Electrolyte

Multi Meter, Hydrometer, Battery Charger

Shocke r Adjust Opened Spanner Set Air Pressure Gauge Ring Spanner Set, OE Spanner, Set, Oil Can

Pedaled Air Pump

Cloth,SAE 90 Oil

OE Spanner Set OE Spanner Set OE Spanner Set Ring Spanner Set OE Spanner Set

Page 11 of 32

Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. No

19

20

21

22

23

24

25

Description

Posit ion

Check all important nut bolts for torque and tightness, LH/R • Handle bar mounting bolt H • Stem lower & upper bracket bolts • Stem of bolts • 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 RH/L • Rear brake lever H • Pillion foot rest FRON • Center stand T, • Side stand REAR • Clutch lever OE accessories fitment -Mirrors RH & LH

OE accessories fitment Leg guard, Saree Guard

Check electrical couplers of all sensors • Engine Temperature sensor • Oil level & Temperature sensor • Air filter IR sensor Start vehicle, Check operation of electrical like- Head light, Tail light, Brake light, Side stand indicator, Horn, Speedometer, Odometer, Side indicators, Parking, Pass light indicators and Fuel indicator working Check working of all electrical switches

SMM

4.00

GP Tools

Oil Can

1.15

OE Spanner Set

LH/R H

3.25

Spanner Set, Tommy Bar, Screw Driver,Plier, Nylon,Ham mer,Allen Key

LH/R H

0.35

Nose Plier

LH/R H

0.70

+ ve , Screw Driver

LH/R H

0.40

26

Check Idling and CO%.

LH/R H

27

Check RPM meter, Speedometer, Odometer & Trip meter for proper functioning and Correct if required

Front

0.50

28

Check all locks for proper operation

LH/R H

0.50

PNR & its Attach

Consumables


Torque Wrench, Socket Set, Ring Spanner , Spanner Set

1.00

LH/R H

Special Tools

0.60

12" Connector

OE Spanner

Oil, Multipurpose Grease, SAE 20W40 Oil

Dial Type, Torque Wrench

CO-HC Analyzer; Tachometer

Page 12 of 32

Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 Sr. No

29

30 31

Posit ion

Description Test drive the vehicle, check digital speedometer working. Study the PDI job card and verify work done. Take vehicle out and park. Clean/Wash the veh. before delivery Repair for any other defects seen or observed during test drive.

PNR & its Attach

Special Tools

SMM

GP Tools

1.30

OE Spanner, Ring Spanner

Consumables


1.00

19.20 Total time taken for PDI SOP 19 Minutes approximately.

Total SMM

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

A nne x -- 8 8

Periodic Service SOP

Sr. No.

Description

Position of Tech. w.r.t. Vehicle LH

SM M

Position of Tech. w.r.t. Vehicle RH

SMM

GP Tools

Sp. Tol.

PNR

PNR & its Attac

Consumables

M&T/ Serv. Shop Equipments

Cloth

Oil Disposer, Air Gun

Washing boy

1

Wash vehicle thoroughly.

2

Identify the vehicle.

0.3

3

Bring vehicle and position on bay.

0.5

4

Raise the lift.

5

Start vehicle and Warm up. Remove RH/LH side covers Seat, Petrol tank and keep properly

6

Remove rear seat. Clean Portion Below seat by brush

7

Drain engine oil. Confirm Qty / Quality OR eng Oil

0.3

LH

RH

0.2

LH

1.3

0.7

Pistol grip PNR Socket set

Brush Pistol grip PNR Socket set

Page 13 of 32


Sr. No.

Description


Take Clean marked vessel to measure oil drain. Start bike for 8-10 seconds & 8 switch Off. Drain oil removing drain plug Refer to SA if less than 900 ml.

9

SM M


SMM

GP Tools

Sp. Tol.

PNR

PNR & its Attac

Consuma bles


0..5

Clean air filter. (Replace - if necessary)

RH

10

Drain carburettor (Overhaul if required)

LH

11

Check accelerator & adjust

LH

12

Remove RHS plug cap & remove water inside sleeve by Compressed air. Remove both plugs & set Gap (every Service) Replace Spark Plugs at interval of 20,000kms

13

Check & Adjust Tappet clearance.

14

Check LH side important fasteners and tight a. Side bolts of front fork b. Engine foundation bolts c. Side stand d. RSA top & bottom nuts

LH

15

Remove Front Sprocket cover. Clean inside of cover by pressurized water. Dry the cover by compressed air, Remove the dust/dirt surrounding small sprocket by Screw drive/Blade & clean to specs.

LH

LH

1.3

3

Head Screw Driver Nylon Brush Plastic Tray

RH

0.4

0.5

RH


0.5

Float Gauge

Filter Cleaning Stand, Cloth, 20W 40 Oil

Cloth, Kerosene

OE spanner set

Plug Spanner


OE spanner set, Ring spanner set


10.4

0.6

3.0

Brush G. P. tool

kerosene

Page 14 of 32


Sr. No.

16

17 18

19

Description


SM M

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

3.0

Check & adjust rear brake for smooth working

0.5

Check for mud on caliper pads ,clean. Check for rear damper play by rotating rear wheel. Remove wheel, replace damper if play observed.

20

Check and Adjust rear tyre air pressure

21

Checks for play in rear sprocket Nut- Re tighten if required.


SMM

GP Tools

Sp. Tol.

PNR

PNR & its Attac

Brush

Consumables


Kerosene

0.1

0.1

Fr Rh.

LH

0.4

REAR RH

0.4

0.2

Check Battery, top up with Distilled Water. Clean terminals & apply Petroleum 22 Jelly. Rout cables properly & fit terminal caps properly. Recharge battery if required

Spanner

RH

23

Check Air pressure-10k Pump in nitrox to space (7.5kg/cm2) with help of pump.

24

Clean oil strainer. (Replace if required) After 1 year or 10000km whichever is later, clean centrifugal filter at 10.000 kms

RH

25

Check clutch & adjust

RH

LH

1

RH

1.8

Pencil Type Pressure Gauge

Air gun Pistol grip PNR Socket set

OE spanner, Screw driver

Electrolyte , Petroleum jelly, Cotton waste

Multi Meter, Hydrometer, Battery Charger

6" Comb. Pliers, Ring Spanner Set

Oil 20W50, Cloth

Measuring jar 1 liter, Funnel Oil dispenser

1

0.3

OE Spanner Set

Page 15 of 32


Sr. No.

Description

26

Fill engine oil (1150 ml)

27

Clean, Check & adjust RH Spark Plug (Replace - if required)


SM M

1

Position of Tech. w.r.t. Vehicle RH RH

RH

SMM

GP Tools

1.35

Ring Spanner Set Plier

2.4

Ring Spanner Set

1

Screw Driver Ring Spanner Set

28

Check & Top-up brake fluid level

29

Check & Replace the parts if necessary.

30

Check & Adjust play. Check pads - Replaced if required.

0.2

31

Check for leakage, spongy feeling. Replace kit if required.

0.2

32

Remove fork pipe tubes, drain oil Clean pipe inner with kerosene & then refill new oil from Company supplied bottle (320ml/tube).

32

33

Check / Adjust front tyre air pressure

FRONT

0.4

34

Check & adjust steering

RH

0.8

Ring Spanner Set

35

Check RH side important fasteners and tight A. Engine foundation bolts B. Front axle nut C. Side bolts of Front fork D. Handle bar bolts E. RSA top & bottom nuts F. Swing arm axle nut G. Silencer protective cover screws / bolts H. Rear view mirror

1.3

OE Spanner Set, Ring Spanner set

2

FRONT

RH

Sp. Tol.

PNR

Spark Plug Spanner

Piston Ring

PNR & its Attac

Consumables


Cloth 20W50 Oil

Oil disposer, Air gun

Cloth

Filler Gauge Spark Plug Cleaning Machine Air Gun

Suction Pump

Pencil type Pressure Gauge

Pistol Grip, PNR Socket Set

Page 16 of 32


Sr. No.

36

Description

Lubricate as per lubrication Chart a. Clutch lever b. Pillion foot rest c. Center stand d. Side stand.


SM M

LH

RH

37

Refit RH, LH side covers, Seats, Petrol tank assly.

38

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

2.0

39

Ensure all lubrication points are Covered as per lubrication chart.

0.3

40

Check electrical couplers of all sensors a. Engine temperature sensor b. Oil level & temperature

LH

LH


SMM

0.8

RH

0.5

FRONT

0.5

GP Tools

Sp. Tol.

PNR

PNR & its Attac

Consumables


20W50 Oil, Graphite, Grease, Cloth

Oil can

Pistol Grip, PNR Socket Set

0.35

sensor c. Air filter IR sensor

41

Check RPM meter, Speedometer, Odometer & Trip meter for proper functioning & Correct if required

42

Start vehicle, Check operation of electrical like -a. Check all electrical switches b. Head light c. Tail light d. Brake light e. Horn f. Speedometer, Odometer, Pass, Parking light g. Side indicators, Front and Rear both sides h. Side stand indicator i. Fuel indicator

RH REAR RH/RR FRONT RH/LH

0.95

Philips Screw Driver Ring Spanner Set Comb. Pliers

Page 17 of 32


Description


SM M

43

Tune engine & carburettor

LH

2

44

Study job card & verify work

Sr. No.

45


SMM

Consumables


1

16.3

16.55

5

5

49

TOTAL TIME

21.3

21.55

50

Test ride of the vehicle if required and park

Clean the vehicle at the time of delivery

PNR

PNR & its Attac

8" Small connector

Lower the lift. Take out & park the 46 vehicle 47 SUB TOTAL Carry out any additional 48 work as indicated by the customer or as required

51

GP Tools

Sp. Tol.

0.3 0.5

1.5

To be done by Expert

1

To be done by 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 P eriodic SOP comfortably. In a shift of 480 minutes, 23 Vehi cles per Bay per Day can be achieved comfortable with 1 Bay, 2 Technician working.

Page 18 of 32


A nne x -- 9 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 comes first SN

Operation

RECOMMENDED FREQUENCY Initial

KMS.

500750

Day

30-45

OR

Subsequent

2,500 kms.

Every 2,500km

240 days from date of sale P P P C,A C,A C,A R C,A

Every 75 days

1 2 3 4 5 6 7 8

Servicing Idle speed / CO % Engine oil (SAE 20W50 of API SJ or SL+JASO MA) Valve tappet clearance Oil strainer / Centrifugal filter Air cleaner element Air cleaner element* Carburetor draining

9

Carburetor O/H cleaning, adjustment

10

Fuel system leakage

11

Fuel pipes

12 13 14 15 16 17 18 19 20 21

Air breather tube Spark plug gap Battery electrolyte level Brake light switch Clutch play Throttle play Rear brake pedal free movement Brake pads wear (front & rear) Steering play All fasteners tightness including eng. mtg bolt

22

Engine mtg. silent bush

23 24

Tyre thread wear General lubrication

25

Steering stem bearing

26

Wheel bearings

27 28

Swing arm pivot pin Front fork

29

Front fork oil

R -Every 10,000 kms.

30

Fork oil seal and dust seal kit

C - Every 10,000 kms. R If reqd.

P C,A R C,A CL CL

CL

CL

CL

D

D

D

D

C

C

C

C

CL,A,C C C,A C,A C,A C,A C C,A T




L

L

L

L

C,A Every 5000 kms Every 5000 kms Every 10000 kms CL R -Every 15000 kms D -Every Service Every 10000 kms if required. C, R - if required R - Every two years./20000kms R - Every one year R - Every 15000 km. Every service C,A C,A C,A C,A Replace if required C,A T C -Every 20,000 kms R-if required. C -Every service L L -Every 10000 kms. R -if required L -Every 15,000 kms.

C,A

L C,A

Every 5,000 kms. C,A

Page 19 of 32

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

Operation

RECOMMENDED FREQUENCY Initial

Subsequent

KMS.

500750

2,500 kms.

Every 2,500km

Day

30-45

240 days from date of sale

Every 75 days

OR

31

Rear shock absorbers

C - Every 10,000 kms.

32

L -Every 500 kms.

34

Drive chain Drive chain wear/Remove/Clean/Inspect/Lubricate Drive chain lock

35

Engine compression pressure

C -Every 15,000 kms.

36 37

Cylinder block piston and head de-carbonizing Cylinder head - Valve lapping

38

Valve oil seal

39

Swing arm mtg. bush / bearing

40

Gap between reed switch & TPS magnet

41

Clutch plate

42

Carburetor rubber duct

43 44 45 46 47 48 49 50 51 52 53 54

Silencer drain hole cleaning Air filter cover "O" ring Rear wheel rubber shock damper Rear sprocket fasteners Auto choke functioning Front brake lever play Oil cooler pipes Lubrication of gear starter clutch Clutch, Accelerator cable Master cylinder cup and dust seal Caliper piston and dust seal Front brake hose

Every 15,000 kms. Every 30,000 kms. C- Every 15000 R -Every 30,000 kms. C -Every 20,000 kms. Rif required C - Every Service C -Every 20000 kms. Rif required C -Every year R -If required CL -Every Service Every 15,000 kms. R -Every 10,000 kms. T -Every 5,000 kms. C - Every service

55 56

Starter clutch bush kit Clutch switch cleaning

57

Brake fluid change

33

A - Adjust ;

CL-Clean ;

Every 5,000 kms.

C,CL,L R

Every 5,000 kms.

C

C

C

C

CL

CL

CL

CL

C C,A C,R

C C,A C,R

T C C,A C,R L

C C,A C,R

C-Every service L-Every 5,000 kms. R -Every two years R -Every two years R -Every two years R -Every two years

R -Every 15000 kms. Every 5000 kms. C C - Every Month, R-Every 20000 kms. or once in a year

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.

Model Pulsar 220-F CC

Engine Oil Grade SAE 20W40 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ Grade or Superior

Quantity Drain & Refill = 1000 ml. 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


A nne x -- 1 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. No 1 2 3 4 5 6 7 8 9 10 11 12 13

Description

Min lev el 2 2 5 5 2 2 2 2 2 1 1 1 10

P-220

SR.No

DK101607 DJ101373 DK101326 DK101327 DK101625 DK101567 DK151066 DK151068 DK101565 DK101634 DK101630 DK101631 DK101236

54 55 56 57 58 59 60 61 62 63 64 65 66

20 10 2 1

DK101279 DK121009 DK101482 52DH0169

67 68 69 70

14 15 16 17

Cylinder head Camshaft assly Valve kit Valve repair kit Block piston assly Clutch Friction Disk -C. Clutch Friction Disk. Clutch Friction Disk -B Plate Clutch Oil cooler Oil cooler pipe inlet Oil cooler pipe outlet Banjo bolts for oil cooler Banjo bolts washer for oil cooler Element air filter Silencer Oil pump assly

18

Rotor Assly - F

1

JC111027

71

19

Stator plate - F

1

JC111026

72

20

HT coil RH

1

JC111023

73

21 22

HT coil LH Spark plug LH / RH

1 5

JC111022 DG111008

74 75

23

Regulator voltage

1

DK201001

76

24

2

JC111007

77

25 26 27 28 29 30

Starter motor Body complete starter clutch Gear starter clutch Holder step LH Holder step RH Wheel rim front Wheel rim rear

3 2 2 2 1 1

DK101595 JC101112 DK161137 DK161138 JC151013 DK151050

78 79 80 81 82 83

31

Chain sprocket kit

2

84

Description

Min level

P-220

Headlight Assembly Blinker Fr LH Blinker Fr RH Blinker Rr LH Blinker Rr RH Petrol Tank- Red Petrol Tank- Black Petrol Tank - Blue Petrol Tank - Silver Front Fender- Red Front Fender- Black Front Fender - Silver Front Fender - Blue

2 2 2 2 2 1 1 1 1 1 1 1 1

DK201056 DJ201208 DJ201209 DJ201206 DJ201207 DK71032V DK71034M DK71034K DK71034L DK74032V DK74034M DK74034L DK74034K

Speedo Cable Assly Fork Inner Pipe Front Disc Decals - Petrol Tank "B" monogram on Tank LH - RED,BLUE, BLACK "B" monogram on Tank LH - SILVER "B" monogram on Tank RH - RED,BLUE, BLACK "B" monogram on Tank RH - SILVER Decals seat - Cowl - Red Decals seat - Cowl Plasma Blue Decals seat - Cowl Silver Grey Decals seat - Cowl Midnight Black Fairing - Red Fairing - Silver Fairing Blue Fairing - Black Gasket Cylinder Block Master Kit - Major ( Front Brake)

2 2 1 2

DK201098 DK181070 DK151027 36DK0026

1

JC141049

1

JC141053

1

JC141050

1 2

JC141054 DH73032V

2

DH73034K

2

DH73034L

2 2 2 2 2 5

DH73034M DK74012V DK74014L DK74014K DK74014M DK101063

5

DE191043

Page 21 of 32

Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 SR. No 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

Description

Disc pad set front Rear caliper pad with shims Brake pedal / tie rod Lock set Switch RH Fork oil seal Tube fuel Main relay Fuse Wiring Harness - F Engine temp sensor Camshaft sprocket Camshaft bolt Speedometer Assly -S Speedometer Assly - SF Handle bar - LH Handle bar - LH Handle bar - RH Handle bar - RH Clutch Cable Tail Light Assembly Wind Shield

Min lev el 5

P-220

SR.No

DE151037

85

10 2 2 2 5 10 1 5 1 1 2 5 1 1 1 1 1 1 5 2 2

DK151038 DK191012 DK181034 DK201034 DK181019 DJ141006 AL201012 30201085 JC201041 DK101577 DS101276 DK101386 JC191014 JC191018 DK181046 DK181059 DK181047 DK181062 JC191004 DK201003 DK161069

86 87 88 89 90 91 92 93 94 95 96 97

Description

Min level

P-220

Magnet Assly SCB

3

DK201039

Cylinder head Gasket Switch LH Steering Cone kit Cap Camshaft Capacitor Fuel Gauge Starter Relay(solenoid) Clutch switch (6AMP) Gasket Cover RHS Gasket Crankcase Gasket cover Magneto Lever comp gear shifter

2 2 3 5 1 2 2 2 10 2 2 2

DK101003 DK201033 36DV0007 DS101096 DK201036 DK201065 DK201078 DK201083 DH101154 DH101006 JC101137 DH101705

A nne x -- 1 11

Initial K Kit List

Sr.No.

Partno.

Description

Qty / Initial Kit

MRP

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

R EGULATOR

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


A nne x -- 1 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

A nne x -- 1 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 fu el/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 co mpletely 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


‘ L Labour Schedule ’ ffor jjobs e eligible u under warranty ::

SN

Replacement under warranty at dealership

U/W job completion time for Pulsar 220 DTS-i

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Oil Cooler replacement. Replacement of Rear Disc brakes. Replacement of rear Disc Pads ( within 1000 kms) Master Cylinder Major replacement Caliper Assembly – Major Kit replacement Front Wheel Drum Bearing replacement Brake Disc replacement Disc holder plate on Wheel Drum replacement Master Cylinder replacement Rear Brake Hose replacement Fairing/fairing frame replacement Air filter Box Assembly replacement Coupler / Hub Bearing / Hub replacement Steering Lock / Key replacement Disc holder plate on Wheel Drum replacement Rear Fender / Mudguard replacement Speedo case/cable replacement Rider Seat Cowling replacement Windshield/ Fairing replacement Complete Lock Set replacement Fuel Tank replacement Replacement of front Disc Pads ( within 1000 kms) Brake Disc replacement Front Brake Hose replacement Front Fork Oil Seal one side Front Fork, Bearing Races, Cones & Steel Balls replacement Fork Inner Tube one side replacement Fork Outer Tube one side replacement Front Fork Upper Holder replacement Front Fork Lower Holder replacement Fork Spring one side replacement Trailing Arm Bush/dust covers replacement Trailing (Swing Arm) replacement Master Cylinder Major Kit replacement Caliper Assembly – Major Kit replacement Master Cylinder replacement Magneto Rotor replacement Stator Plate Assembly replacement Chassis / Frame replacement Replacing handle bar Replacement of Chain sprocket kit Engine Foundation Bush Kit replacement

30.00 30.00 15.00 45.00 60.00 30.00 45.00 45.00 60.00 45.00 75.00 30.00 45.00 30.00 30.00 45.00 15.00 15.00 45.00 30.00 30 30 75 90 60 120 60 60 120 120 60 120 120 120 120 120 60 60 480 60 60 60.00

A nne x -- 1 1 4

Labour hours to be claimed in units 2 2 1 3 4 2 3 3 4 3 5 2 3 2 2 3 1 1 3 2 2 2 5 6 4 8 4 4 8 8 4 8 8 8 8 8 4 4 32 4 4 4

Page 26 of 32

Enclosure to Service New Product Bulletin ‘NP : 12 ’ dated 23nd June 2009 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93

Fuel cock replacement. Magneto Cover replacement Centrifugal Filter Cover/Gasket replacement Crank Case (LH) Gear Shifter Shaft Oil Seal replacement Clutch Centrifugal Change Gear Shifter Lever Mechanism replacement Gear Return Spring / Shaft Pawl / Spring replacement Carb Assembly replacement Starter Counter Gear/Bush/NRB replacement Guide Starter 'O' ring / Oil seal replacement Guide Starter Assly / Gear Inner Bush replacement Clutch Cover replacement Shaft Release Clutch / Oil Seal replacement Oil Pump Assembly replacement Clutch (Friction / Steel) Plates replacement Cylinder Head Assembly replacement Valve/Springs/Seal replacement Rocker / Shaft Rocker Arm replacement Valve/Valve Guide replacement Timing Chain / Sprocket replacement Cam Shaft Both Bearings replacement Cam Shaft assly. Replacement Set Primary Gear (Driver & Driven) / replacement Body Balancer Assembly replacement Cylinder Block/Piston Assembly replacement Piston Rings replacement Crank Shaft Assembly replacement Crank Shaft Bearings replacement Crank Case Assembly replacement Crank Case (RH) replacement Crank Case (LH) replacement Input Shaft and Out Put Shaft/Speed Gears replacement G.S. Drum replacement G.S. Forks replacement Replacement of Balancer Idler gear Replacement of starter clutch Complete Wiring Harness replacement Replacement of BCU. Starter motor replacement Speedometer Assembly replacement SPM Console Upper Cover replacement Head Lamp Assembly replacement H.T. Coil Single replacement A/C Regulator (Voltage) replacement Ignition Switch Assembly replacement Rear Brake Light Switch replacement Head Lamp Bulb replacement Park Lamp Bulb replacement Tail Lamp Assembly replacement Rectifier / RR unit replacement Fuel Gauge Float Unit replacement

15.00 15.00 30.00 30.00 30.00 45.00 45.00 30.00 30.00 30.00 30.00 60 60 75 90 120 120 120 120 165 120 120 165 165 180 180 330 330 330 330 330 330 330 330 210 75 135 75.00 45.00 45.00 45.00 75.00 15.00 15.00 30.00 15.00 30.00 45.00 15.00 15.00 30.00

1 1 2 2 2 3 3 2 2 2 2 4 4 5 6 8 8 8 8 11 8 8 11 11 12 12 22 22 22 22 22 22 22 22 14 5 9 5 3 3 3 5 1 1 2 1 2 3 1 1 2

Page 27 of 32


A nne x --15

Electrical Circuit Diagram

1. Starter Motor Circuit

2. D.C. Ignition Circuit

Page 28 of 32


3. Battery Charging Circuit

4. Brake Lamp Circuit

Page 29 of 32


5. Horn Circuit

6. Side Indicator Circuit

Page 30 of 32


7. Lighting Circuit

Page 31 of 32

Manual de Taller Bajaj Pulsar 220S

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