Manual de Taller Bajaj Pulsar 220S

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

Page 1 of 32

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

Sub: Introduction of “Pulsar 220 DTSi“

Dear Sirs: We are pleased to introduce ‘Bajaj Pulsar 220 DTSi’. This bike offers a great package of Style, Power & Technology in its class of bikes. We enclose herewith following information of this new bike, which gives you insight on product features, maintenance details etc.

Product related information

1. Salient Features Annex – 1

2. Technical Specifications Annex – 2

3. Comparison With Competition Vehicles Annex – 3

4. DC Ignition System Annex – 4

5. Read before you ride Annex – 5

6. Pre-Delivery Inspection Checklist Annex – 6

Maintenance related information

7. Pre-Delivery Inspection - SOP Annex – 7

8. Periodic Service SOP Annex – 8

9. Periodic Maintenance & Lubrication Chart

Annex – 9

10. Critical Part List Annex – 10

11. Initial Kit List-Vehicle billing would start after dealer

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)

New Product Bulletin

Product Category Motorcycle

CC Group 220

Bulletin No. NP: 12

Date 23/06/2009

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


Page 2 of 32

Annex-1

Attribute Key Features Advantages & Benefits

Style • Brawny masculine looks

• Stylish split seats • 2 piece grab rail • Tank spoiler • Wolf-eyed head lamp • Clip on - split type handle bar. Black

styling • Thicker and pinched clamped fork • Naked chain with O ring. • New colours. • 3 D metallic decals on petrol tank. • All black painting. • Stylish stainless steel silencer. • Clear lens blinkers.

• Bold assertive stance, Sporty looks. Brains, brawn and definitely bold.

• The style that lets you break free.

Performance Performance

DTSi Engine

• 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

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.

SSaalliieenntt FFeeaattuurreess


Page 3 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.


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AAnnnneexx -- 22

ENGINE & TRANSMISSION CONTROLS

Steering : Handle bar

Accelerator : Twist grip type on right hand

of handle bar

Gears : Left foot pedal operated

Clutch : Lever operated on left side of

handle bar

Choke : Auto choke

Brakes :

Front : Lever operated on right

side of handle bar

Rear : Pedal operated by right foot.

ELECTRICALS

System :12 Volts (D.C.)

Battery :12V 9Ah MF

Head lamp :12V , 55 W H7 (Main)

12V, 55 W H7 (Passing)

Pilot lamp( :12V , 5W 2 Nos

Tail/stop lamp : LED/LED

Turn signal lamp : 12V , 10 W

Turn signal pilot lamp : LED

Side stand indicator lamp : LED

Hi beam indicator lamp : LED

Neutral indicator lamp : LED

Speedometer lamp : LED Display

Rear No. plate Lamp : 12V, 5 W Horn : 12 V DC , 2 nos DIMENSIONS

Type : Four stroke, Natural air cooled.

No. of cylinders : One.

Bore : 67 mm

Stroke : 62.4 mm

Engine displacement : 220 cc

Compression ratio : 9.5 + 0.5 : 1

Idling Speed : 1400 +100 rpm.

Maximum net power : 21 Ps @ 8500 rpm

Maximum net torque : 19 Nm @ 7000 rpm

Ignition system : Microprocessor controlled digital C.D.I.

Ignition Timing : 10° BTDC 1000 rpm

26 ° bTDC at 2500 RPM

Fuel : Unleaded Petrol

Fuel Feed : Carbureted

Spark Plug : 2Nos. Champion

P -RG6HCC

Spark plug gap : 0.8 to 0.9 mm

Lubrication : Wet sump, Forced

Starting : Electric Start only

Clutch : Wet, multidisc type.

Transmission : 5 speed constant mesh.

Primary reduction : 3.47 : 1 (66/19)

Gear Ratios

1st Gear : 24.736 : 1 (36/13)

2nd Gear : 16.814 : 1 (32/17)

3rd Gear : 12.335 : 1 (29/21)

4th Gear : 9.677 : 1 (26/24)

5th Gear : 7.939 : 1 (24/26) Final Drive Ratio : 2.57 : 1 (37/14)

Length :2035 mm.

Width : 750 mm.

Height :1165 mm.

Wheel base :1350 mm.

Turning circle radius : 2500 mm. Ground Clearance :165mm.

CHASSIS & BODY WEIGHTS

Vehicle kerb weight : 152 Kg.

Max. total weight : 282 Kg.

PERFORMANCE

Frame type : Double cradle type.

Suspension: :

Front : Telescopic with Guide & Slide bush

(Stroke - 130 mm.) Rear : Trailing arm with coaxial gas assisted

Hydraulic shock absorbers and coil springs.

Climbing ability : 28 % (160)

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Page 5 of 32

AAnnnneexx -- 33

Brakes:

Front : Hydraulically operated disc brake

Rear : Hydraulically operated disc brake

Tyres:

Front : 90x90 X 17, 49P, Tubeless

Rear : 120/80 X 17, 61P, Tubeless

Tyre pressure:

Front : 2.00 kg/cm2 (28.0 Psi) (Solo &Pillion)

Rear : 2.00 kg/cm2 (28.0 Psi)(Solo)

Pillion - Rear : 2.25 kg/cm2 (32.0 Psi)

Rims :

Front : 1.85 x 17

Rear : 2.50 x 17

NOTES :-

• 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.

COMPARISION WITH COMPETITOR PRODUCTS

DESCRIPTION HERO HONDA KARIZMA

YAMAHA YFZ R 15

BAJAJ 220 DTSi

Manufacturer Hero Honda Motors Limited India Yamaha Motor Pvt. Ltd. Bajaj Auto Ltd.

Colours Sport red / Vibrant Blue / Moon yellow / Force Silver / Black with option of Black / Red Alloys

Yamaha Blue / Graphite / Blazing Red

Midnight Black, Plasma Blue, Wine Red, Grey Silver

Ex-showroom price

Black alloy wheel - Rs. 75471 (Mumbai) Red alloy wheel - Rs. 76206 (Mumbai)

Rs. 97, 425 (Chennai)

On-road price (Mumbai)

Black alloy wheel - Rs. 83638 (Mumbai) Red alloy wheel - Rs. 84435 (Mumbai)

Rs. 1,08,600 (Chennai)

ENGINE & TRANSMISSION

Engine Air cooled, 4 stroke Single cylinder OHC

Liquid cooled, 4 stroke Single cylinder SOHC 4 valve

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

Displacement 223 cm³ 149.8 cm³ 220 cm³

Engine horse power

17ps @ 7000 rpm 17 ps @ 8500 rpm 21 ps @ 8500 rpm

Engine Torque 18.35 N-m@ 6000 rpm 15 N-m @ 7500 rpm 19 Nm @7000 rpm

Gear box 5 Speed Constant Mesh 6 Speed Constant mesh 5 Speed Constant Mesh

Fuel supply system

Carburetor - VE, Constant Vacuum Carburetor with CCVI (Carb controlled variable ignition)

Electronic Fuel Injection Carburetor - CV

Comparison with Competition Vehicles


Page 6 of 32

CHASSIS & BODY

Frame type Tubular single cradle, Diamond type

Delta Box Frame Double Cradle type

Suspension Front Telescopic Hydraulic shock absorbers

Telescopic Hydraulic shock absorbers

Telescopic front fork

Suspension Rear Swing arm with 5 step adjustable type Hydraulic shock absorber

Linked monocross suspension with spring/shock absorber

Trailing Arm with coaxial gas assisted hydraulic shock absorbers & coil springs

Brakes Front Disc Dia 276 (non asbestos type)

Single Disc Hydraulically operated disc brake

Brakes Rear Internal expanding shoe type - Dia 130mm (non asbestos type)

Single Disc Hydraulically operated disc brake

ELECTRICALS

Ignition System Advanced Microprocessor Ignition (AMI)

TCI Microprocessor controlled digital CDI

Battery 12V - 7 Ah 12V - 3.5 AH 12 V, 9 AH MF

Spark Plug NGK - DPR8 EA 9 CHAMPION - PRA 7 HC

NGK/CR8E Champion P -RG6HCC

Head Lamp 12V - 35/35 W Halogen (Multi reflector - DC)

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

12 V, 55 W H7

Tail / Stop Lamp 12V - 5W / 21W X 2 nos. (Multi reflector)

12V - 5W / 21W LED/LED

Number plate 12V - 5W 12V - 5W 12 V, 5 W

Turn Signal Lamp 12V - 21W X 4 nos. (Multi reflector)

12V - 10W X 4 nos. 12 V, 10 W

DIMENSIONS

Length 2125 mm 1995 mm 2035 mm

Width 755 mm 670 mm 750 mm

Height 1160 mm 1070 mm 1165 mm

Wheel Base 1355 mm 1290 mm 1350 mm

Ground clearance 150 mm 160 mm 165 mm

Kerb Weight 150 Kgs. 131 Kgs. 152 Kg

PERFORMANCE

Max. Speed 125 kmph 140 kmph

STYLING DIFFERENTIATOR

Styling

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

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 7 of 32

Battery life

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.

Quick/ easy start.

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.

Easy Cold starting. Auto choke – Engine temperature

Sensor provided to give rich mixture At winter mornings.

No starting Trouble after Washing.

Sealed couplers everywhere to arrest water entry.

Sealed Starter relay – potting type to avoid water entry.

No start – Water entry post

monsoon.

DC Ignition System Advantages

AAnnnneexx -- 44


Page 8 of 32

A Starting the vehicle : 1 Put the Ignition and Kill switch in ON position.

2 Confirm that the vehicle is in neutral.

3 Button starts the engine without opening throttle.

B Warning indicators on Speedometer :

There are 4 indicators which would start flashing, indicating the need of maintenance for that part. Customer should visit authorized service station whenever these warning indicators start flashing.

1 Choked air filter indicator.

2 High engine oil temperature indicator.

3 Low battery charge level indicator.

4 Less engine oil level indicator.

Maintaining Battery charge level is very essential, for starting of vehicle.

C Important Does and Don'ts : 1 The powerful engine with quick throttle response would make the driver to open the accelerator with

caution. Do not open the throttle suddenly. 2 Use both the brakes at a time. Use of front brake for dead stop would give better control. Since the front

axle weight is more, the rear brake has been deliberately toned down to avoid skidding.

3 As soon as "fuel res" red indicator light is ON, fill up the fuel at the nearby filling station.

4 Use better quality fuel only. Anything above 87 octane rating. Do not use any additives with the petrol. Since this is a precision machine, adulterated fuel should never be used.

5 Tyres fitted on this vehicle are tubeless tyres.Do not allow anybody to open them by using wrong tools. Go to authorized MRF tyre dealers who are equipped with necessary tools, so as to avoid possible damage to wheel rim.

6 Chain with built in O ring is fitted on this vehicle. The lubrication at every 500 kms with SAE 90 oil and adjustment at every 1000 kms would be essential.Pl see to it that the chain never runs dry.

7 Do not add any additional electrical / electronic gadgets on the vehicle, as they would disturb functioning of engine management system.

8 During washing of the vehicles, pl does take care of different sensors fitted on engine. Do not direct the jet of water towards electrical parts and sensors.

9 For stainless steel silencer, care will have to be taken to avoid oil contact. Otherwise stain marks would be seen, thus damaging aesthetics. The silencer would turn slightly chromish after initial use, which is a natural phenomenon.

" Wishing you a Pulsating ride "…………. "Happy Riding".

Read Before You Ride

AAnnnneexx -- 55


Page 9 of 32

AAnnnneexx -- 66

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

Engine No Date :

Dealer Name

PDI Done By

Please ensure that following checks are carried out during PDI before Delivery of vehicle

To Check Check For �� If OK X If Not

OK

Observations

Remarks

Engine

Engine Oil: Oil Level OK/Top up if required

SAE 20W50API SJ or SL+ JASO MA

Oil leakage if any- specify source of oil leakage

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

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

Silencer Mounting Bolts( 3.5~4.0Kgm)

Drain Bolt (2.5 Kgm)

Rocker Arm Bolts( 2.5-3 kgm)

FUEL SYSTEM

Fuel Tank/ Pipes No leakage/ Correct Fitment

Carburettor No leakage/ Correct Fitment

Fuel Cock Smooth Operation

FRAME

Tyre Pressure Front 2.00Kg/cm ( 28.4 PSI)

Rear Solo 2.00 Kg/cm ( 28.4 PSI)

Rear Pillion 2.00 Kg/cm ( 30.5 PSI)

CONTROLS

Brakes Front Brake lever free play (2~3 mm)

Rear Brake pedal free play(25~30mm)

Throttle Grip Free play (2~3 mm) & smooth operation

Clutch Smooth operation, no juddering, Free play 2~3 mm

Clutch cable Routing thru the bracket located near lower 'T' on vehicle RH side

Drive Chain Slackness standard: 25~ 35 mm

SUSPENSION

Front Fork No leakage/ smooth working(wipe out if any seepage

Pre-Delivery Inspection Checklist (PDI)


Page 10 of 32

Rear Shock Absorber Spring Adjuster notch position: 1st notch ( Standard)

Steering Smooth Operation ( No play/ Sticky movement)

Lock operation Steering cum ignition , rider seat ( pillion+rider),LH/RH side cover lock

Front Axle nut - 8~ 9 Kgm

Rear Axle nut 8~10 Kgm

Handle Bar bolts 2~2.2 Kgm

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

Fasteners ( Check Torque)

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)

Tightness of battery- terminals/ Cables. Petroleum jelly

Position of fuse box ( 2 nos)

Battery

All Bulbs Working Head light (both bulbs working).

Headlight tail light illumination switch off after 3 seconds

Pilot lights (2), LED Tail/ Stop, Side Indicator, Speedometer LEDS, Number plate lamps

Auto switch "OFF" of Indicators(by moving Handle Bar

Turn Pilot, High beam, Neutral Indicator, Tell tale icons on, switch LH/RH,

Switch operation LH & RH control, Ignition, Fr& Rr brake & Kill switch

Starter Motor Proper working/ Engagement

TEST DRIVE

Starting Cold Start & Warm Start

Working off Auto Choke( Click sound when ignition is turned "ON")

Idling Speed ( Warm condition) ( 1400+/- 100 rpm) with tachometer

Drive Ability Throttle response

Brakes ( Front & Rear)

Digital Speedometer, Odometer, Trip meters, Fuel guage & Fuel Indicator red lamp

CO% Check CO should be 2% in engine warm condition at idling rpm

Cleaning Wash & Clean vehicle properly

IMPORTANT NOTE

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


Page 11 of 32

AAnnnneexx -- 77

Sr.No

Description Position

SMM GP Tools Special Tools

PNR & its Attach

Consumables M & T / Service Shop Equipments

1 Identify & Park Vehicle on Work Bay

0.80 Lifter Bay

2 Remove the Thermocol and additional packing if any. Study PDI card and Work content.

0.50

3 Open Petrol tank cap & pour petrol

0.50 Petrol Dispenser

Petrol, Waste Cloth

4 Check for smooth operation of fuel cock lever

0.10

5 Check & top up engine oil level, if required.

RH 0.30 Nose Plier, Oil Can, Funnel

Cloth

6 Check clutch cable operation & Adjust if required.

RH 0.10 OE Spanner Set

7 Check front brakes for efficient working & Adjust if required.

Front 0.10 Ring Spanner

Suction Pump

8 Check and correct tyre inflation pressure - Front Wheel

Front 0.20 Air Pressure Gauge

Pedaled Air Pump

9

Check Battery voltage, check up electrolyte level, ensure petroleum jelly presence, and connect terminals properly.

LH 0.60 OE Spanner Set, Screw Driver

Cotton Waste, Petroleum Jelly, Electrolyte

Multi Meter, Hydrometer, Battery Charger

10 Inspect Rear Shock Absorber setting & Correct if necessary.

RH/LH

0.10 Shocker Adjust

11 Check Rear brakes for efficient working & adjust if required.

Rear 0.10 Opened Spanner Set

12 Check and Correct tyre inflation pressure - Rear Wheel.

Rear 0.20 Air Pressure Gauge

Pedaled Air Pump

13 Lubricate chain and Check / Adjust chain slackness if required.

LH 0.40

Ring Spanner Set, OE Spanner, Set, Oil Can

Cloth,SAE 90 Oil

14 Check Accelerator cable free play LH 0.05 OE Spanner Set

15 Check & Adjust TPS LH 0.10 OE Spanner Set

16 Check gear shifter lever operation

LH 0.05 OE Spanner Set

17 Check & Adjust steering and Handle bar for free movement.

RH / Front

0.20 Ring Spanner Set

18 Check front mudguard alignment wrt Front Wheel

Front 0.05 OE Spanner Set

Pre-Delivery Inspection - SOP


Page 12 of 32

Sr.No



PNR & its Attach


19

Check all important nut bolts for torque and tightness, • Handle bar mounting bolt • 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.

LH/RH

4.00

Torque Wrench, Socket Set, Ring Spanner , Spanner Set

20

Check the following and lubricate if necessary • Rear brake lever • Pillion foot rest • Center stand • Side stand • Clutch lever

RH/LH FRONT, REAR

1.00 Oil Can

Oil, Multipurpose Grease, SAE 20W40 Oil

21 OE accessories fitment -Mirrors RH & LH

LH/RH

1.15 OE Spanner Set

22 OE accessories fitment - Leg guard, Saree Guard

LH/RH

3.25

Spanner Set, Tommy Bar, Screw Driver,Plier, Nylon,Hammer,Allen Key

Dial Type, Torque Wrench

23

Check electrical couplers of all sensors • Engine Temperature sensor • Oil level & Temperature sensor • Air filter IR sensor

LH/RH

0.35 Nose Plier

24

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

LH/RH

0.70 + ve , Screw Driver

25 Check working of all electrical switches

LH/RH

0.40

26 Check Idling and CO%. LH/RH

0.60 12" Connector

CO-HC Analyzer; Tachometer

27

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

Front 0.50 OE Spanner

28 Check all locks for proper operation

LH/RH

0.50


Page 13 of 32

AAnnnneexx -- 88

Sr.No



PNR & its Attach


29

Test drive the vehicle, check digital speedometer working. Study the PDI job card and verify work done. Take vehicle out and park.

1.30 OE Spanner, Ring Spanner

30 Clean/Wash the veh. before delivery

1.00

31 Repair for any other defects seen or observed during test drive.

Total SMM 19.20

Total time taken for PDI SOP 19 Minutes approximately.

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

Sr. No.

Description

Position of Tech. w.r.t.

Vehicle LH

SMM


Vehicle RH

SMM GP Tools Sp. Tol.

PNR PNR & its Attac

Consu-mables

M & T / Serv. Shop Equipments

1 Wash vehicle thoroughly. Washing boy

2 Identify the vehicle. 0.3

3 Bring vehicle and position on bay.

0.5

4 Raise the lift. 0.3

5

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

LH RH 0.7

Pistol grip PNR Socket set

6 Remove rear seat. Clean Portion Below seat by brush

0.2 Brush

7 Drain engine oil. Confirm Qty / Quality OR eng Oil

LH 1.3


Cloth Oil Disposer, Air Gun

Periodic Service SOP


Page 14 of 32

Sr. No.

Description

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

SMM

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


PNR

PNR & its Attac

Consumables


8

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

0..5

9 Clean air filter. (Replace - if necessary)

RH 3


Filter Cleaning Stand, Cloth, 20W 40 Oil

10 Drain carburettor (Overhaul if required)

LH 1.3 RH

Head Screw Driver Nylon Brush Plastic Tray

Float Gauge

Cloth, Kerosene

11 Check accelerator & adjust

LH 0.4 OE spanner set

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

LH 0.5 RH 0.5 Plug Spanner


13 Check & Adjust Tappet clearance.

10.4

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 0.6

OE spanner set, Ring spanner set


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 3.0 Brush G. P. tool

kerosene


Page 15 of 32

Sr. No.

Description


Vehicle LH

SMM


Vehicle RH


PNR PNR & its Attac

Consu-mables


16

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 Brush Kerosene

17 Check & adjust rear brake for smooth working

0.5

18 Check for mud on caliper pads ,clean.

0.1

19

Check for rear damper play by rotating rear wheel. Remove wheel, replace damper if play observed.

0.1

20 Check and Adjust rear tyre air pressure

Fr Rh. 0.4 REAR RH

0.4 Air gun Pencil Type Pressure Gauge

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

LH 0.2 Spanner


22

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

RH 1.8

OE spanner, Screw driver

Electrolyte, Petroleum jelly, Cotton waste

Multi Meter, Hydrometer, Battery Charger

23

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

LH 1 RH 1

24

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

RH

6" Comb. Pliers, Ring Spanner Set

Oil 20W50, Cloth

Measuring jar 1 liter, Funnel Oil dispenser

25 Check clutch & adjust RH 0.3 OE Spanner Set


Page 16 of 32

Sr. No.

Description


Vehicle LH

SMM


Vehicle RH


PNR PNR & its Attac

Consu-mables


26 Fill engine oil (1150 ml) 1 RH 1.35

Ring Spanner Set Plier

Cloth 20W50 Oil

Oil disposer, Air gun

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

RH 2.4 Ring Spanner Set

Spark Plug Spanner

Cloth

Filler Gauge Spark Plug Cleaning Machine Air Gun

28 Check & Top-up brake fluid level

2 FRONT 1

Screw Driver Ring Spanner Set

Piston Ring

Suction Pump

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 Pencil type Pressure Gauge

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

RH 1.3

OE Spanner Set, Ring Spanner set

Pistol Grip, PNR Socket Set


Page 17 of 32

Sr. No.

Description


Vehicle LH

SMM


Vehicle RH


PNR PNR & its Attac

Consu-mables


36

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

LH RH 0.8 Oil can

20W50 Oil, Graphite, Grease, Cloth

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

LH RH 0.5

Pistol Grip, PNR Socket Set

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

sensor c. Air filter IR sensor

LH 0.35

41

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

FRONT 0.5

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 18 of 32

Sr. No.

Description


Vehicle LH

SMM


Vehicle RH


PNR PNR & its Attac

Consu-mables


43 Tune engine & carburettor LH 2 8" Small connector

44 Study job card & verify work

1

45 Lower the lift. 0.3

46 Take out & park the vehicle

0.5

47 SUB TOTAL 16.3 16.55

48

Carry out any additional work as indicated by the customer or as required

5 5

49 TOTAL TIME 21.3 21.55

50 Test ride of the vehicle - if required and park

1.5 To be done

by Expert

51 Clean the vehicle at the time of delivery

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 Periodic SOP comfortably.

In a shift of 480 minutes, 23 Vehicles per Bay per Day can be achieved comfortable with

1 Bay, 2 Technician working.


Page 19 of 32

AAnnnneexx -- 99

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.

RECOMMENDED FREQUENCY Whichever comes first

Initial Subsequent

KMS. 500-750

2,500 kms. Every 2,500km SN Operation

OR

Day 30-45 240 days from date

of sale Every 75 days

1 Servicing P P P P

2 Idle speed / CO % C,A C,A C,A C,A C,A

3 Engine oil (SAE 20W50 of API SJ or SL+JASO MA) R R Every 5000 kms

4 Valve tappet clearance C,A C,A Every 5000 kms

5 Oil strainer / Centrifugal filter CL Every 10000 kms

6 Air cleaner element CL CL CL CL CL

7 Air cleaner element* R -Every 15000 kms

8 Carburetor draining D D D D D -Every Service

9 Carburetor O/H cleaning, adjustment

Every 10000 kms if required.

10 Fuel system leakage C C C C C, R - if required

11 Fuel pipes

R - Every two years./20000kms

12 Air breather tube R - Every one year

13 Spark plug gap CL,A,C CL,A,C CL,A,C CL,A,C R - Every 15000 km.

14 Battery electrolyte level C C C C Every service

15 Brake light switch C,A C,A C,A C,A C,A

16 Clutch play C,A C,A C,A C,A C,A

17 Throttle play C,A C,A C,A C,A C,A

18 Rear brake pedal free movement C,A C,A C,A C,A C,A

19 Brake pads wear (front & rear) C C C C Replace if required

20 Steering play C,A C,A C,A C,A C,A

21 All fasteners tightness including eng. mtg bolt T T T T T

22 Engine mtg. silent bush

C -Every 20,000 kms R-if required.

23 Tyre thread wear C -Every service

24 General lubrication L L L L L

25 Steering stem bearing

L -Every 10000 kms. R -if required

26 Wheel bearings

L -Every 15,000 kms.

27 Swing arm pivot pin L Every 5,000 kms.

28 Front fork C,A C,A C,A

29 Front fork oil R -Every 10,000 kms.

30 Fork oil seal and dust seal kit

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

Periodic Maintenance & Lubrication Chart


Page 20 of 32

RECOMMENDED FREQUENCY Whichever comes first Initial Subsequent

KMS. 500-750

2,500 kms. Every 2,500km SN Operation

OR

Day 30-45 240 days from date of

sale Every 75 days

31 Rear shock absorbers

C - Every 10,000 kms.

32 Drive chain L -Every 500 kms.

33 Drive chain wear/Remove/Clean/Inspect/Lubricate C,CL,L

Every 5,000 kms.

34 Drive chain lock R Every 5,000 kms.

35 Engine compression pressure

C -Every 15,000 kms.

36 Cylinder block piston and head de-carbonizing Every 15,000 kms.

37 Cylinder head - Valve lapping Every 30,000 kms.

38 Valve oil seal

C- Every 15000 R -Every 30,000 kms.

39 Swing arm mtg. bush / bearing

C -Every 20,000 kms. R-if required

40 Gap between reed switch & TPS magnet C C C C C - Every Service

41 Clutch plate

C -Every 20000 kms. R- if required

42 Carburetor rubber duct

C -Every year R -If required

43 Silencer drain hole cleaning CL CL CL CL CL -Every Service

44 Air filter cover "O" ring Every 15,000 kms.

45 Rear wheel rubber shock damper R -Every 10,000 kms.

46 Rear sprocket fasteners T T -Every 5,000 kms.

47 Auto choke functioning C C C C C - Every service

48 Front brake lever play C,A C,A C,A C,A

49 Oil cooler pipes C,R C,R C,R C,R C-Every service

50 Lubrication of gear starter clutch L L-Every 5,000 kms.

51 Clutch, Accelerator cable R -Every two years

52 Master cylinder cup and dust seal R -Every two years

53 Caliper piston and dust seal R -Every two years

54 Front brake hose R -Every two years

55 Starter clutch bush kit R -Every 15000 kms.

56 Clutch switch cleaning C Every 5000 kms.

57 Brake fluid change C - Every Month, R-Every 20000 kms. or once in a

year

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

Note: Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.

Engine Oil

Model Grade Quantity

Pulsar 220-F CC SAE 20W40 of API ‘SJ’ or ‘SL’ + JASO ‘MA’ Grade or Superior 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 21 of 32

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

Description Min level

P-220 SR.No Description Min level

P-220

1 Cylinder head 2 DK101607 54 Headlight Assembly 2 DK201056

2 Camshaft assly 2 DJ101373 55 Blinker Fr LH 2 DJ201208

3 Valve kit 5 DK101326 56 Blinker Fr RH 2 DJ201209

4 Valve repair kit 5 DK101327 57 Blinker Rr LH 2 DJ201206

5 Block piston assly 2 DK101625 58 Blinker Rr RH 2 DJ201207

6 Clutch Friction Disk -C. 2 DK101567 59 Petrol Tank- Red 1 DK71032V

7 Clutch Friction Disk. 2 DK151066 60 Petrol Tank- Black 1 DK71034M

8 Clutch Friction Disk -B 2 DK151068 61 Petrol Tank - Blue 1 DK71034K

9 Plate Clutch 2 DK101565 62 Petrol Tank - Silver 1 DK71034L

10 Oil cooler 1 DK101634 63 Front Fender- Red 1 DK74032V

11 Oil cooler pipe inlet 1 DK101630 64 Front Fender- Black 1 DK74034M

12 Oil cooler pipe outlet 1 DK101631 65 Front Fender - Silver 1 DK74034L

13 Banjo bolts for oil cooler 10 DK101236 66 Front Fender - Blue 1 DK74034K

14 Banjo bolts washer for oil cooler 20 DK101279 67 Speedo Cable Assly 2 DK201098

15 Element air filter 10 DK121009 68 Fork Inner Pipe 2 DK181070

16 Silencer 2 DK101482 69 Front Disc 1 DK151027

17 Oil pump assly 1 52DH0169 70 Decals - Petrol Tank 2 36DK0026

18 Rotor Assly - F 1 JC111027 71 "B" monogram on Tank - LH - RED,BLUE, BLACK 1 JC141049

19 Stator plate - F 1 JC111026 72 "B" monogram on Tank - LH - SILVER 1 JC141053

20 HT coil RH 1 JC111023 73 "B" monogram on Tank -RH - RED,BLUE, BLACK 1 JC141050

21 HT coil LH 1 JC111022 74 "B" monogram on Tank - RH - SILVER 1 JC141054

22 Spark plug LH / RH 5 DG111008 75 Decals seat - Cowl - Red 2 DH73032V

23 Regulator voltage 1 DK201001 76 Decals seat - Cowl - Plasma Blue 2 DH73034K

24 Starter motor 2 JC111007 77 Decals seat - Cowl - Silver Grey 2 DH73034L

25 Body complete starter clutch 3 DK101595 78

Decals seat - Cowl - Midnight Black 2 DH73034M

26 Gear starter clutch 2 JC101112 79 Fairing - Red 2 DK74012V

27 Holder step LH 2 DK161137 80 Fairing - Silver 2 DK74014L

28 Holder step RH 2 DK161138 81 Fairing Blue 2 DK74014K

29 Wheel rim front 1 JC151013 82 Fairing - Black 2 DK74014M

30 Wheel rim rear 1 DK151050 83 Gasket Cylinder Block 5 DK101063

31 Chain sprocket kit 2

84 Master Kit - Major ( Front Brake) 5 DE191043

AAnnnneexx -- 1100

CCrriittiiccaall PPaarrttss LLiisstt


Page 22 of 32

SR.No

Description Min level

P-220 SR.No Description Min level

P-220

32 Disc pad set front 5 DE151037 85 Magnet Assly SCB 3 DK201039

33 Rear caliper pad with shims 10 DK151038 86 Cylinder head Gasket 2 DK101003

34 Brake pedal / tie rod 2 DK191012 87 Switch LH 2 DK201033

35 Lock set 2 DK181034 88 Steering Cone kit 3 36DV0007

36 Switch RH 2 DK201034 89 Cap Camshaft 5 DS101096

37 Fork oil seal 5 DK181019 90 Capacitor 1 DK201036

38 Tube fuel 10 DJ141006 91 Fuel Gauge 2 DK201065

39 Main relay 1 AL201012 92 Starter Relay(solenoid) 2 DK201078

40 Fuse 5 30201085 93 Clutch switch (6AMP) 2 DK201083

41 Wiring Harness - F 1 JC201041 94 Gasket Cover RHS 10 DH101154

42 Engine temp sensor 1 DK101577 95 Gasket Crankcase 2 DH101006

43 Camshaft sprocket 2 DS101276 96 Gasket cover Magneto 2 JC101137

44 Camshaft bolt 5 DK101386 97 Lever comp gear shifter 2 DH101705

45 Speedometer Assly -S 1 JC191014

46 Speedometer Assly - SF 1 JC191018

47 Handle bar - LH 1 DK181046

48 Handle bar - LH 1 DK181059

49 Handle bar - RH 1 DK181047

50 Handle bar - RH 1 DK181062

51 Clutch Cable 5 JC191004

52 Tail Light Assembly 2 DK201003

53 Wind Shield 2 DK161069

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 REGULATOR 1 879

9 DK201033 CONTROL SWITCH LH 1 625

10 DK201034 CONTROL SWITCH RH 1 624

11 DK101503 ENGINE TEMP SENSOR 1 123

12 DK181019 OIL SEAL 2 54.95

13 DK151038 REAR BRAKE PAD 2 194

AAnnnneexx -- 1111

IInniittiiaall KKiitt LLiisstt


Page 23 of 32

AAnnnneexx -- 1122

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.

Frequently Asked Questions


Page 24 of 32

AAnnnneexx -- 1133

�� 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

Frequently Asked Questions Questions related to Warranty

�� Why parts like clutch plates, chain-sprockets, steering races, timing chain, brake shoes etc are not

covered under warranty ? � These are the parts which are prone to wear and tear due to vehicle usage, external factors. The very fact

that they have lasted long up to 10000 kms + do suggest that there was no manufacturing defect to start with. If they had failed now it is something to

�� Why only block piston and crankshaft given under fuel adulteration claims? � 1. Component failure due to adulterated fuel is not a manufacturing defect.

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

�� Why Battery/tyres are not given by selling dealer under warranty? � World over the policy of warranty of proprietary parts is the same. They are warranted by respective

manufacturers. They are experts in analyzing the failures and have special equipments for checking the parts. Further the Batteries can not be transported due to environmental factors. �� Why the alloy wheel breakage is not covered under warranty ? � Alloy wheels which are die casted have been designed and certified by ARAI for all normal usage conditions. They would crack under extreme operating conditions like heavy impacts. Since heavy impacts are an accident, this will have to be covered under insurance. The run out also can not get developed after usage as like spoked wheels.

Hence only paint defect can be covered under warranty - by completely repainting the part. No replacement is required here too.


Page 25 of 32

�� 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 26 of 32

AAnnnneexx -- 1144 ‘‘ LLaabboouurr SScchheedduullee’’ ffoorr jjoobbss eelliiggiibbllee uunnddeerr wwaarrrraannttyy ::

RReemmbboouurrsseemmeenntt ooff WWaarrrraannttyy JJoobbss

SN Replacement under warranty at dealership

U/W job completion

time for Pulsar 220 DTS-i

Labour hours to be claimed in

units

1 Oil Cooler replacement. 30.00 2

2 Replacement of Rear Disc brakes. 30.00 2

3 Replacement of rear Disc Pads ( within 1000 kms) 15.00 1

4 Master Cylinder Major replacement 45.00 3

5 Caliper Assembly – Major Kit replacement 60.00 4

6 Front Wheel Drum Bearing replacement 30.00 2

7 Brake Disc replacement 45.00 3

8 Disc holder plate on Wheel Drum replacement 45.00 3

9 Master Cylinder replacement 60.00 4

10 Rear Brake Hose replacement 45.00 3

11 Fairing/fairing frame replacement 75.00 5

12 Air filter Box Assembly replacement 30.00 2

13 Coupler / Hub Bearing / Hub replacement 45.00 3

14 Steering Lock / Key replacement 30.00 2

15 Disc holder plate on Wheel Drum replacement 30.00 2

16 Rear Fender / Mudguard replacement 45.00 3

17 Speedo case/cable replacement 15.00 1

18 Rider Seat Cowling replacement 15.00 1

19 Windshield/ Fairing replacement 45.00 3

20 Complete Lock Set replacement 30.00 2

21 Fuel Tank replacement 30 2

22 Replacement of front Disc Pads ( within 1000 kms) 30 2

23 Brake Disc replacement 75 5

24 Front Brake Hose replacement 90 6

25 Front Fork Oil Seal one side 60 4

26 Front Fork, Bearing Races, Cones & Steel Balls replacement 120 8

27 Fork Inner Tube one side replacement 60 4

28 Fork Outer Tube one side replacement 60 4

29 Front Fork Upper Holder replacement 120 8

30 Front Fork Lower Holder replacement 120 8

31 Fork Spring one side replacement 60 4

32 Trailing Arm Bush/dust covers replacement 120 8

33 Trailing (Swing Arm) replacement 120 8

34 Master Cylinder Major Kit replacement 120 8

35 Caliper Assembly – Major Kit replacement 120 8

36 Master Cylinder replacement 120 8

37 Magneto Rotor replacement 60 4

38 Stator Plate Assembly replacement 60 4

39 Chassis / Frame replacement 480 32

40 Replacing handle bar 60 4

41 Replacement of Chain sprocket kit 60 4

42 Engine Foundation Bush Kit replacement 60.00 4


Page 27 of 32

43 Fuel cock replacement. 15.00 1

44 Magneto Cover replacement 15.00 1

45 Centrifugal Filter Cover/Gasket replacement 30.00 2

46 Crank Case (LH) Gear Shifter Shaft Oil Seal replacement 30.00 2

47 Clutch Centrifugal 30.00 2

48 Change Gear Shifter Lever Mechanism replacement 45.00 3

49 Gear Return Spring / Shaft Pawl / Spring replacement 45.00 3

50 Carb Assembly replacement 30.00 2

51 Starter Counter Gear/Bush/NRB replacement 30.00 2

52 Guide Starter 'O' ring / Oil seal replacement 30.00 2

53 Guide Starter Assly / Gear Inner Bush replacement 30.00 2

54 Clutch Cover replacement 60 4

55 Shaft Release Clutch / Oil Seal replacement 60 4

56 Oil Pump Assembly replacement 75 5

57 Clutch (Friction / Steel) Plates replacement 90 6

58 Cylinder Head Assembly replacement 120 8

59 Valve/Springs/Seal replacement 120 8

60 Rocker / Shaft Rocker Arm replacement 120 8

61 Valve/Valve Guide replacement 120 8

62 Timing Chain / Sprocket replacement 165 11

63 Cam Shaft Both Bearings replacement 120 8

64 Cam Shaft assly. Replacement 120 8

65 Set Primary Gear (Driver & Driven) / replacement 165 11

66 Body Balancer Assembly replacement 165 11

67 Cylinder Block/Piston Assembly replacement 180 12

68 Piston Rings replacement 180 12

69 Crank Shaft Assembly replacement 330 22

70 Crank Shaft Bearings replacement 330 22

71 Crank Case Assembly replacement 330 22

72 Crank Case (RH) replacement 330 22

73 Crank Case (LH) replacement 330 22

74 Input Shaft and Out Put Shaft/Speed Gears replacement 330 22

75 G.S. Drum replacement 330 22

76 G.S. Forks replacement 330 22

77 Replacement of Balancer Idler gear 210 14

78 Replacement of starter clutch 75 5

79 Complete Wiring Harness replacement 135 9

80 Replacement of BCU. 75.00 5

81 Starter motor replacement 45.00 3

82 Speedometer Assembly replacement 45.00 3

83 SPM Console Upper Cover replacement 45.00 3

84 Head Lamp Assembly replacement 75.00 5

85 H.T. Coil Single replacement 15.00 1

86 A/C Regulator (Voltage) replacement 15.00 1

87 Ignition Switch Assembly replacement 30.00 2

88 Rear Brake Light Switch replacement 15.00 1

89 Head Lamp Bulb replacement 30.00 2

90 Park Lamp Bulb replacement 45.00 3

91 Tail Lamp Assembly replacement 15.00 1

92 Rectifier / RR unit replacement 15.00 1

93 Fuel Gauge Float Unit replacement 30.00 2


Page 28 of 32

AAnnnneexx --1155 Electrical Circuit Diagram

1. Starter Motor Circuit

2. D.C. Ignition Circuit


Page 29 of 32

3. Battery Charging Circuit

4. Brake Lamp Circuit


Page 30 of 32

5. Horn Circuit

6. Side Indicator Circuit


Page 31 of 32

7. Lighting Circuit


Page 32 of 32

Action Matrix:

SL Key Information Works

Manager/DSE PDI In charge

Sales In charge Service Advisor

Floor In charge

1 Salient Features

2 Technical Specification Update

Understand features of this new variant and share with the sales team

Update

Update Technicians

3 Caparison with competitive

4 D C Ignition 5 Read before you ride 6 PDI Checklist

7 PDI SOP & Time Chart

8 Periodic Service SOP Chart

9 Periodic Maintenance & Lubrication Chart

Update

10 Critical Part List Update Update Technicians

11 Initial Kit part list Update Share with Sales team & ASC/RSO /YES channels

Update

12 Frequently asked questions

Share with Sales /Service /PDI teams Share with Sales /Service /PDI team

Update Update Technicians

13 Frequently asked questions-related to warranty

Update Update Technicians

14 Reimbursement of warranty Jobs

15 Electrical Circuits

Initials

Date

Documents

Manual de Taller Bajaj Pulsar 220S