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Table of Contents

Description Safety and Warning information :


1. Technical Specifications 1
2. Identification Data 3
Warning : This indicates that a potential
3. Location of Parts 5
hazard or injury to you or other persons &
4. Steering cum Ignition lock 8
5. Fuel Tank Cap / Fuel Tap 9
to the vehicle can happen, if advice
6. Speedometer Details 10 provided is not followed.
7. Speedometer Setting 12
8. Control Switches 14
Caution : This indicates that a potential
9. Rear seat / Tool kit 16
hazard which could result in vehicle
10. Front Seat / Battery 17
11. Fitment of Front & Rear Seat 18
damage, if advice provided is not
12. Removal & Fitment of Side Cover LH & RH 19 followed.
13. Daily Safety Checks 20
14. How to ride your Bike 21
Notice:
15. Safe Riding Tips 25
16. Engine Oil 26 The description and illustration in this booklet
17. Wheels - Tube less Tyre 27 are not to be taken as binding on the
18. Battery 28 manufacturers. The essential features of the
19. Engine Cooling System / Coolant 29 type described and illustrated herein remaining
20. Periodic Maintenance Information 30 unaltered. Bajaj Auto Limited reserves the
21. Brake Fluid 32 right to carry out at any moment without
22. Periodic Maintenance & Lubrication Chart 33 being obliged to bring this booklet upto-date
23. Non Use Maintenance & to do modifications on the vehicle, parts or
accessories as may be convenient and
necessary.

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Technical Specifications
Engine : 4 Stroke, Single Cyl. Fuel Tank Capacity
Bore x Stroke : 72.0 mm x 49.0 mm Full : 12 liters
Engine Displacement : 199.5 cc Usable Reserve : 2.4 liters
Compression Ratio : 11 : 1 Unusable Reserve : 0.2 liters

Idling Speed : 1350 ~ 1450 RPM Dimensions : Pulsar NS Pulsar AS


Max. Net Power : 23.5 PS at 9500 RPM Length : 2017 mm 2070 mm
Max. Net Torque : 18.3 Nm at 8000 RPM Width : 804 mm 804 mm
Ignition System : DC Height : 1195 mm 1205 mm
Spark Plug : 3 Nos Wheel base : 1363 mm 1363 mm
Ground clearance : 167 mm 167 mm
Spark Plug Gap : 0.7 ~ 0.8 mm
Transmission : 6 speed constant Tyre Size
mesh Front : 100/80-17,52P tubeless
Gear Shifting Pattern : 1 Down 5 Up Rear : 130/70-17,61P tubeless
Engine Lubrication : Pressurized oil supply
Tyre Pressure
Engine Cooling : Liquid cooling Front : 1.75 kgf/cm2 (25 PSI)
Starting Aid : Electric starter Rear (Solo) : 2.00 kgf/cm2 (28 PSI)
Front Brake : Hydraulic Disc type Rear (with pillion) : 2.25 kgf/cm2 (32 PSI)
Rear Brake : Hydraulic Disc type
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Technical Specifications
Electrical System : 12 Volts DC Note :
Head Lamp : H4, 55/60W • All dimensions are under UNLADEN condition.
Position Lamp : 3W (2 nos.) • Above information is subject to change without
Tail /Stop Lamp : LED type any notice.
Side Indicator lamp : 10W
Neutral Indicator : Green LED
Hi Beam Indicator : Blue LED
Turn Signal Indicator : Green LED
Side Stand Indicator : LED
Speedometer Lamp : LED
Rear No. Plate Lamp : 3W
Horn : 12V DC
Battery : 12V - 8 Ah VRLA

Vehicle Kerb Weight : 145 kg.(For NS 200)

153 Kg.(For AS 200)

Gross Vehicle Weight : 275 kg. (For NS 200)


283 kg. (For AS 200)
(Including rider & pillion)
Max. Speed : 136 km/hr.

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Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.

Engine Number Location


On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

Frame Number Location (For NS 200)


On RH Side of Steering Tube
(Alpha-Numeric - 17 Digits)

On LH Side of Steering Tube


(Alpha-Numeric - 17 Digits)
[for applicable countries)
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Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.

Engine Number Location


On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)

Frame Number Location ( For AS200)


Below Pillion Seat
(Alpha-Numeric - 17 Digits)

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Location of Parts (Pulsar NS 200)
Digital Fuel Tank Cap OFF ON
Speedometer

Manual Choke
Lever
Clutch Lever
LED
Tail
Lamp

Front Fork

Pillion
Foot
Rest

Disc
Brake

Gear Change Side


Lever Stand

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Location of Parts ( Pulsar NS 200)
Grab Handle Pillion Seat Rider Seat Front Brake Lever

MAX

MIN

Rear
Number
Plate Coolant Coolant
Level Tank Cap
Indicator
Nitrox Rear
Shock Absorber

Rear Brake Paper oil Radiator


Rear Disc Brake
Pedal Filter

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Location of Parts (Pulsar AS 200)

Grab Handle Pillion Seat Rider Seat Front Brake Lever

MAX.

MIN.

Rear
Number Coolant Coolant
Plate Level Tank Cap
Indicator

Nitrox Rear
Shock
Absorber

Rear Brake Paper oil Radiator


Rear Disc Brake
Pedal Filter

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Steering cum Ignition Lock

Steering cum Ignition Lock : To Lock the Steering : To lock the steering,
turn the handle bar to the left side. Push &
It has three positions.
release the key. Turn the key to “LOCK”
position and remove the key. Steering lock
LOCK: Steering locked. Ignition OFF. can be done on left side only.
To Unlock the Steering : To unlock steering,
OFF: Steering unlock. Ignition OFF. insert the key in steering cum ignition lock &
turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering
ON: Steering unlock. Ignition ON. cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear
Seat’.
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Fuel Tank Cap / Fuel Tap

Fuel Tap

Fuel Tank Cap

Fuel Tank Cap Fuel Tap


• To open the fuel tank cap, open the flap. Fuel tap has following positions.
Insert the key in the lock and turn it
clockwise and lift fuel tank cap. ON : When fuel level is above
• ‘Fuel Tank Cap’ gets locked when pushed Reserve position.
back into place.
RES: When fuel level is below
Reserve position.

OFF: When fuel supply is to be cut


off.

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Speedometer Details
1
2
3

4
5

6
7
M

8 S

9 10
Speedometer display will work when, only both 6. Low Battery Indicator : It indicates battery needs
Ignition switch & kill switch are in ‘ON’ position. charging.
1. Fuel Level Indicator: It shows fuel level in fuel tank. 7. Low Oil Pressure Indicator ( ) : It blinks when
2. Tachometer Dial: It shows engine speed in RPM. engine oil pressure is low.
3. Turn Signal Indicator (LH & RH): When Turn signal 8. Coolant Temperature Indicator ( ) : It blinks when
0
switch is turned to Left or Right, Turn pilot Indicator - engine coolant Temperature is more than 115
LH or RH will flash. centigrade.
4. Neutral Indicator: When the transmission is in 9. Bajaj Logo : Bajaj logo flying ‘B’ continuously glows.
Neutral, Neutral indicator will glow. 10. Mode Button : Mode button used for changing the
5. Hi Beam Indicator: When Headlight is ‘ON’ & Hi mode while selecting & setting Trip1, Trip2, ODO,
beam is selected with engine running, Hi beam Clock & Service reminder.
indicator will glow.
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Speedometer Details
11
12
13

14
15

16
17
M
S
18
19

11. Engine Over Rev Indicator : It glows when engine 14. Digital Clock : It indicates time in HR : M (AM/PM)
RPM crosses 9500 RPM. 15. Speedometer: Vehicle speed will be displayed in
12. Service Reminder ( ): ‘Spanner’ symbol glows digital form in Km / Hr.
when ODO meter reading reaches set Kms. for 16. Odometer : The Odometer shows the total distance
service. This Icon will flash at - that the vehicle has covered. Odometer can't be
1st : 450 km 2nd : 4950 km, reset to ‘Zero’.
rd
3 : 9950 km, 4th : 14950 km 17. Trip Meter : Trip 1 & Trip 2 shows the distance
and subsequently at each 5000 kms. Icon will traveled since it was last reset to zero.
continue to glow till it is reset. This icon is to be 18. Set Button : Set button used for setting Clock &
reset after service is carried out. Service reminder.
13. Side Stand Indicator : When side stand is ‘ON’ . 19 Reserve Indicator : It blinks continuously when
Side Stand Indicator will light. petrol level in tank reaches reserve level ( 1 bar or
less)
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Speedometer Setting

Service Reminder

TRIP1/2

Mode
Set

1. Trip Meter Reset : 2. Service Reminder Reset ( ) :


• Mode & Set push button is provided for selecting & • ‘Wrench’ symbol glows when ODO meter reading
resetting ‘ODO/TRIP1/TRIP2’. LHS part of speedo reached to set Kms.
console.
This icon will glow at-
1. Press 'Mode' button Mode changes from
for less than 2 sec. ‘ODO/TRIP1/TRIP2’ 1st : 450 Kms 2nd : 4450 Kms
3rd : 9450 Kms 4th : 14450Kms
2. Press 'Mode' button Selected mode & subsequently at each 5000 Kms.
for more than 15 sec. ‘TRIP1/TRIP2’ will get reset.
Other TRIP mode will Note : Engine & motorcycle speed should be zero.
continue updating.
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Speedometer Setting

1. Press 'Mode' push button TRIP1 Mode selected


for less than 2 sec.
2. Press 'Mode' & 'Set' ‘:’ stops blinking
push button together Digits start blinking
for more than 2 sec.
3. Press 'Mode' button for Hour digits will
less than 1 sec. increase by one.
4. Press 'Set' button for Minute digits will
less than 1 sec. increase. If Mode/Set
button is pressed
continuously then digits
3. Clock Reset : will stop blinking.
• Digital clock indicates time in HR & MM separated 5. Press 'Mode' & 'Set' Set value will be saved
by colon ‘:’ button together for Exit clock setting mode
• It is a 12 hour clock. more than 2 sec. Digits stop blinking
• Initially ‘:’ will be blinking ‘:’ start blinking
• Clock setting is possible in TRIP 1 mode only. 6. Clock set 'Mode' is Auto exit without saving
selected & no editing set value.
is carried out for
more than 5 sec.
or
Vehicle is started.
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Control Switches

D
B

Left Handle Bar Switches C. Horn Button : ( ) Press button for


A. High/Low Switch : When headlight is ON, sounding horn.
High or Low beam can be selected with D. Pass Switch : Press the switch to flash
this switch. Hi beam indicator light located the head light. It is used to give signal to
on Speedo console will light up when high vehicles coming from opposite side while
beam is selected. overtaking.

: High Beam : Low beam


B. Turn Signal Switch : When the turn signal
knob is pushed to Left ( ) or Right ( )
respective indicator will start blinking, to
exit push the knob in & release.
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Control Switches
F. Starter Button :
G Starter button operates the electric starter
when clutch lever is depressed with
transmission in any gear.
It is recommended to start the engine
E with the transmission in neutral.

F G. Engine Kill Switch :


The engine kill switch is for emergency
use. During emergency move the engine
kill switch to the ‘OFF’ ( ) position.
Right Handle Bar Switches
Speedometer display will work when both Ignition
E. Head Light Switch : It has 3 positions.
switch & kill switch are in ‘ON’ position.

: All lamps 'OFF'.


CAUTION : While starting ensure that
engine kill switch is in ON ( ) position.
: With engine running, Tail lamp,
Meter lamp and Pilot lamp/s ‘ON’. Engine will not start if the kill switch
is in OFF position
: With engine running, Head lamp,
Pilot lamp/s, Tail lamp and Meter
lamps ‘ON’.
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Rear Seat / Tool Kit

Tool Kit

Removal of Rear Seat Tool Kit Location


• Insert Key into lock (A) • It is located below the ‘Rear seat’.
• Turn the key clock wise. • 2 rubber straps are provided to hold the
• Pull front end of ‘Rear seat’ tool kit.
• Take out ‘Rear seat’
CAUTION : Always ensure rubber strap
is fitted for securing tool kit.

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Front Seat / Battery

Removal of Front Seat Battery


• First remove ‘Rear seat’. • It is located below ‘Front seat’.
• Remove ‘Front seat’ mounting bolts (B).
Battery details are given in ‘Battery
• Pull back rear end of ‘Front seat’.
Maintenance’ page no. 28.
• Take out ‘Front seat’.

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Fitment of Front & Rear Seat
Front seat lug & bracket

C D E
A
G F

B
H

Fitment of ‘Front Seat’ Fitment of ‘Rear Seat’


• Match the lugs of ‘Front seat’ (A) with • First make sure ‘Front seat’ is fitted
chassis bracket (B). properly.
• Push ‘Front seat’ toward petrol tank. • Place ‘Rear seat’ in fitment location.
• Match ‘Front seat’ rear brackets (C) with • Insert bracket (E) of seat into hook (F).
the holes provided on chassis. • Match the rod of ‘Front seat’ (G) with seat
• Tighten the bolts (D). lock (H).
• Press front portion of seat.

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Removal & Fitment of Side Cover LH / RH

A
D C

E
B

Removal of Side Cover LH or RH Fitment of Side Cover LH or RH


• Remove pillion & rider seat. • Match Lug (D) provided on front portion of
• Remove screw (A) upper & (B) lower of side ‘Side Cover’ with hole (C) provided on
cover mounting. ‘Chassis’ and press ‘Side Cover’ inside.
• Pull front portion of ‘Side Cover’ to release • Match Lug (E) provided on rear portion of
its lug from hole (C) provided on ‘Fuel Tank’. ‘Side Cover’ with hole (F) provided on
• Pull rear portion of ‘Side Cover’ to release ‘Chassis’ and press ‘Side Cover’ inside.
its Lug (E) from hole (F) provided on • Tighten the upper (A) & lower (B) screw with
‘Chassis’. screw driver.
• Fit pillion & rider seat.
CAUTION : Remove cover as described CAUTION : Fit cover as described above
above, Otherwise the lugs may break. to ensure proper fitment.
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Daily Safety Checks
Before riding motorcycle be sure to check • Brake Fluid level above MIN mark
following items. Please give proper importance provided on reservior, applicable to disc
to these checks and perform all of them brake vehicle.
before riding motorcycle.
• Drive Chain slack of 15 to 25 mm
If any irregularities are found during these adequately lubricated.
checks, refer to the Maintenance chapter &
see your dealer for the action required to • Function of all lights & horn
return the motorcycle to a safe operating • Clutch lever play - 2 to 3 mm
condition.
• Check Coolant level between MIN and
Warning : Failure to perform these MAX mark in coolant reservoir tank.
checks every day before you ride, may • Smooth steering movement without
result in serious damage or severe restriction.
accident.
• Side stand return to its retracted position.
• Enough fuel for planned distance of • Correct inflation pressure in both tyres
journey. No fuel leakage in fuel lines. Adequate tyre tread depth - no cracks /
cuts.
• Engine oil level (between upper and lower
level mark) • Correct rear viewing span adjustment of
mirror.
• Throttle cable play of 2 ~ 3 mm. Smooth
operation and positive return to closed
position,

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How to Ride Your Bike
1. Starting The Engine : Wait 15 sec. between each operation of the
• Turn the fuel tap knob to ‘ ’ or ‘ ’ starter which will facilitate battery to recover.
position. Note : The motorcycle is equipped with a starter
• Turn ignition switch key to ‘ ? ’ position. lockout switch. This switch ensures that engine
• Keep kill switch in ‘ ’ position. does not start if the transmission is in gear.
• Confirm that transmission is in neutral / However, the engine can be started in any
press the clutch lever. gear if the clutch lever is pressed.
• If the engine is cold or when starting for
Note : Incase of battery discharged condition,
first time, use manual choke ( ) for quick
vehicle can be started by pushing it.
starting. Choke lever is located on LH side
of carburettor.
• Keep throttle completely closed, press 2. Shifting Gears :
starter button, • Close throttle & depress the clutch.
• Release starter button as soon as engine • Shift into next higher or lower gear.
starts. • Open the throttle and release the clutch
• When the engine is warmed up enough to lever slowly and simultaneously.
idle without using choke, return the manual 3. Moving Off :
choke to OFF position. • Check that side stand is up / retracted.
Note : Do not let the engine idle longer than 3 • Depress the clutch lever.
minutes otherwise it will overheat. • Shift into 1st gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
Caution : Do not operate the starter
• As the clutch starts to engage, open the
continuously for more than 5 seconds throttle a little more, giving the engine just
otherwise battery would get discharged. enough rpm to prevent it from stalling.
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How to Ride Your Bike
6 4. Braking :
5
4 • Close the throttle completely, leaving the
3 clutch engaged (except where shifting gears)
2
N so that the engine braking will help slow
1 down the motorcycle.
• Shift down one gear at a time so that you
Gear shifting are in Neutral when you come to a complete
Gear shifting Lever pattern stop.
• When stopping, always apply both brakes at
Recommended Speed for Shifting Down the same time. De-clutch as necessary to
From 6th to 5th Gear 54 km/h avoid engine stalling.
th th
45 km/h • Never lock the brakes, or it will cause the
From 5 to 4 Gear
tyres to skid. When cornering, use brakes
From 4th to 3rd Gear 35 km/h judiciously and do not de-clutch. Reduce
From 3rd to 2nd Gear 25 km/h your speed before you get into the corner.
For emergency braking, disregard
From 2nd to 1st Gear 15 km/h downshifting, and concentrate on applying
brakes as hard as possible without skidding.
Warning : When shifting down to lower
gear, do not shift at such high speed 5. Stopping the Vehicle :
that engine rpm jumps excessively. This • Close the throttle completely.
may cause engine damage, & rear wheel
• Shift the transmission into neutral.
may skid. Downshifting should be done
at speeds as recommended in table • Bring the vehicle to complete stop.
above. • Turn the ignition switch off.
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How to Ride Your Bike
6. Parking the Vehicle : 7. Running IN
6.1 Parking using center stand. Proper running-in is important for better life &
trouble free performance of the vehicle.
• Center stand is available as accessories
at dealership. • During first 2000 kms running-in period do
not exceed following speed limits.
• Support the motorcycle on a firm level
surface with the center stand.
Kms 1st 2nd 3rd 4th 5th 6th
6.2 Parking using side stand. 0 - 1000 10 18 24 32 40 48
• Support the motorcycle on a firm level 1000 - 2000 16 24 30 38 46 54
surface with the side stand.
• Lock the steering.
• Always keep the speed below the limits
mentioned in the table.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle • Do not rev the engine excessively.
may fall over. • Do not start moving or rev the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to workup into the engine.

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How to Ride Your Bike
Fuel Saving Tips : Ensure following maintenance points to get
A well maintained vehicle and good driving optimum performance from your bike.
can contribute a lot to the saving of feul.
Following are a few simple fuel saving tips. Fuel Check fuel lines & connections
for leakage.
Good Riding Habits :
• Ride smoothly and steadily at a reasonable Spark Plugs Inspect and clean spark plugs.
speed. Adjust electrode gap. Replace
• Avoid harsh braking. spark plugs as per P.M. Chart.
• Change the gear judiciously according to Air Filter Clean the air filter element
the speed and load requirement. periodically. Replace as per
• Don’t overload the vehicle above the Periodic Maintenance Chart.
specified payload. Engine Oil Check engine oil level. Always
• Use the accelerator judiciously. use recommended grade and
• Cut off the engine if you want to stop for quantity.
more than two minutes.
Brakes Ensure that the brakes are not
How to check mileage (Fuel efficiency) dragging / binding.
Best way to calculate mileage is by following
the full tank to full tank method. Clutch Ensure correct clutch lever
• Fill way tank full up to small mouth (brim). play.
• Run the bike for say 100 km. Tyre Air Always maintain recommended
• Fill the tank full again in same fuel filling Pressure tyre pressure.
station, preferably from same fuel
dispenser. Carburettor Clean & adjust the carburettor.
Adjust idling speed.
• Divide kilometers run / fuel quantity filled.
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Safe Riding Tips
Safe Riding Tips • Drive cautiously. Start early & reach your destination
• Always wear Helmet while riding. Your helmet should safely.
conform to appropriate Safety standards. • Always carry vehicle registration & insurance papers,
• Thoroughly read the and a valid driving licence with you.
instructions given in this manual • Avoid driving on loose sand or stones where vehicle
and follow them carefully. is likely to skid.
• Avoid unnecessary accessories • Properly wrap-up loose clothes while riding to avoid
for the safety of both rider and entangling in wheel or other objects on road.
other motorists. • Always concentrate on Safe riding.
• Get familiar with and follow
traffic rules & regulations in your states as well as Rainy Season Care :
general traffic signs. • It is suggested to customer to take appropriate care
• Familiarise yourself well with starting, acceleration and in area of high rainfall area. Appropriate surface
braking of the vehicle. preventive coat to avoid rusting on account of
• When applying the brakes, use both front & rear adverse atmospheric conditions.
brakes simultaneously. Applying only one brake may • Vehicle cleaning to be done with soft & clean wet
cause the rider to loose control. cloth to avoid scratches on painted parts.
• Riding at proper speed and avoiding unnecessary • Clean & lubricate all the important parts as detailed in
acceleration and braking are important not only for a periodic maintenance chart.
safety and low fuel consumption, but also for long life • Do not apply direct water jet on painted, electrical /
of the vehicle. electronic parts.
• During monsoon drive the vehicle more cautiously. • Do not obstruct engine cooling by adding mud
Remember vehicles skid more easily during light protection sheet from front.
showers.
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Engine Oil
Recommended Engine Oil:
A
Model Recommended Engine oil Grade

Pulsar SAE 20W50 API ‘SL’, or JASO ‘MA’


200 NS/AS
C
A : Oil Filler • Engine oil replacement frequency : 1st service & then
B
Cap every 5,000 Km.
B : Oil Level D • Engine oil level top-up frequency : Every 2500 km.
Window

Engine Oil Level Checking :


• Check engine oil level every day in the morning.
Park vehicle perpendicular to the ground on level
surface as mentioned in page no. 21 (6.1)
• Check oil level through oil level window ‘B’. CAUTION :
• Always maintain engine oil level between upper • It is most important to adhere to
(C) and lower (D) mark provided on Clutch cover recommended grade & frequency of oil
RHS. Top up with specified grade of oil, if the oil change for the purpose of long life of
level is below lower level mark.
critical engine components. For details
Engine Oil Capacity : refer periodic maintenance chart.
• Refill at servicing : 1200 ml. • Do not reuse drained oil.
• During engine overhaul : 1400 ml. • Contact your Dealer for proper
disposal of drained engine oil.
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Wheels - Tube Less Tyre
Wheel Puncture :
• Visit nearest known tubeless tyre repair
shop to remove puncture.
• Remove puncture by Filler or Plug method
only.
• Do not use patch method to remove
puncture of tubeless tyre.

Tyre Pressure :
Front Wheel
Keep appropriate tyre pressure as mentioned
CAUTION : Tubeless tyres are fitted in this below to increase life of the tyre & for better
motorcycle. The walls of the tyres in fuel consumption.
contact with the wheel rim should not be
damaged in any way during fitment / Front 25 PSI
removal of tyre. The tyre side walls in
contact with wheel rim seals air. Pulsar 200 NS/AS Rear (Solo) 28 PSI
Removing Front Wheel :
Rear (with Pillion) 32 PSI
• Park vehicle perpendicular to the ground on
level surface as mentioned in page no. 21
(6.1)
• Remove speed sensor cable from case meter Note : Ensure tyres fitted comply with local
assembly. rules and regulations governing tyres.
• Loosen front axle nut.
• Remove front wheel assembly from fork.
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Battery
• It is always recommended to hand over
the same to an Authorised battery / Bajaj
dealer for proper disposal.
• When low battery icon pops-up on
speedometer display, it is advised to get in
touch with Bajaj dealer & get it charged
immediately.

How to keep battery healthy ?


Battery : 12V - 8 Ah VRLA • Switch ‘Off’ ignition when engine is not
• Battery is located below front seat. running.
• Get battery checked/ charged during
Battery Features :
periodic services.
• No topping-up is required
• Do not press starter button for more than
• Reduced self discharge, Enhances safety. 5 sec. After 3 successive cranking, wait for
• No vent tube open to atmosphere hence no 15-20 sec. for battery to recover.
discharge of electrolyte through vent tube. • Do not add extra electrical accessories
such as - Remote, Bigger Horn, Musical
CAUTION : Do not drive / run vehicle in
brake light etc. This will reduce life of
battery disconnected condition. It may
battery
lead to damage of electrical / electronic
components. • Disconnect battery +ve & -ve wires if
vehicle is to be stored for more than 2
• Environment care must be taken to weeks. This avoids self discharge.
dispose off the used battery.
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Engine Cooling System

C B
Radiator Cap

A Expansion Tank

• Coolant is provided for cooling of engine. Warning : During motorcycle operation,


• Water pump (A) in the engine circulates the coolant gets very hot & is under
the coolant in cooling system. pressure.
• The pressure resulting from the heating of Do not remove the radiator cap, radiator
the cooling system is regulated by a valve hose or other cooling system
in radiator cap (B). components when the engine is hot.
• Heat expansion causes excess coolant to Allow the engine & cooling system to
flow into compensating coolant tank (C). cool down. In case of exposure to hot
coolant, rinse immediately with lukewarm
• When the temperature falls, this surplus
water.
coolant is sucked back into the cooling
system.

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Coolant
Coolant Specifications :
Antifreeze ready mix (Recommended Brand-
Reservoir cap Motul : Moto cool expert,
(for coolant top up)
Castrol : Radicool
Total coolant quantity : 1000 ml. (750~780 ml
MAX in radiator & 220~230 ml expansion tank).
Coolant Top up
MIN • Park vehicle perpendicular to the ground on
level surface as mentioned in page no. 21
(6.1)
• Check coolant level in engine cold condition
only.
• Ensure coolant level is between Min & Max
Warning : Coolant is poisonous and is a mark.
health hazard. • Always top up coolant through reservoir cap.
Avoid skin, eye and clothing caontact • Always replace coolant with recommended
with coolant. If it gets into your eyes, brand only. (Radicool from Castrol, Moto
rinse immediately with water and contact cool expert from Motul) or equivalent.
a doctor. • Use nitrile rubber hand glows while draining
& topping up coolant.
Wash affected skin areas immediately • Do not top up coolant through radiator cap.
with soap and water. If coolant is Where pre-mixed coolant is not available
swallowed, contact a doctor coolant concentrate and distilled water
immediately. Change clothes that have should be mixed separately in a clean jar in a
come into contact with coolants. Keep proportion of 1:1
coolant out of the reach of children
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Periodic Maintenance Information
Spark Plug Drive Chain Slackness
• Remove spark plugs by using plug • Chain slackness will have to be adjusted
spanner. whenever required.
• Clean the spark plugs. • Std. Chain slackness 15 ~ 25 mm.
• Adjust the gaps if incorrect by bending • Marking on chain adjusters should be
outer electrode carefully. identically positioned on both sides.

Spark Plug Gap : 0.7 to 0.8 mm.


Spark Plug (2 Nos.) : RG-6HCC
(LH ‘A’ + RH ‘B’)
(1 No. ) : BOSCH - VR5NE
(Center ‘C’)

A C

0.7 to
0.8 mm

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Periodic Maintenance Information

Drive Drive
Chain Chain
Cleaning Lubrication

Drive chain must be cleaned & lubricated as Method of O-ring Chain Lubrication :
per periodic maintenance schedule. • Park vehicle perpendicular to the ground on level
Drive Chain (O-ring type) surface as mentioned in page no. 21 (6.1). Clean
the chain by using lint free cloth (If excessive
• ‘O’ rings must always be kept wet for mud / slush found approach Bajaj Service Center
best performance hence lubricate every for proper cleaning)
500 Km. • Shake the can vigorously by holding vertically
upright till the noise of steel ball inside heard
• O-ring chain lubrication can easily be
uniformly.
done by owners using Bajaj ‘Chain Lube • Hold spray can at the back of rear sprocket with
Spray Can’ available with Bajaj dealers, extension tube nose at 5~10 cm.
or equivalent. Ensure that the lubricant • Rotate the wheel in reverse direction & spray the
lube on middle portion of the chain up to full
does not damage the rubber 'O' rings. length of the chain.
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Brake Fluid

Front Rear
Brake Brake
Fluid Fluid
Reservior Reservior

Front & Rear Brake Fluid Level Brake Fluid Replacement


• Front brake fluid reservior is located on RH • Check & Adjust brake fluid level in every
side of Handle bar. service.
• Rear brake fluid reservior is located behind • Change the brake fluid of the front & rear
RH pillion holder bracket. brake according to service schedule.
• To check oil level, Park vehicle Use only DOT-3 ro DOT-4 brake fluid (from
perpendicular to the ground on level surface sealed container) for top up & replacement.
as mentioned in page no. 21 (6.1) with
handle bar in straight ahead condition
• Always ensure that brake fluid level is above
‘MIN’ mark given on inspection Window.
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Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

1 Clean the vehicle with water wash & dry Ensure to prevent water entry in
Petrol tank, Silencer & electrical
completely
parts.Use caustic free detergent for
washing.

2 Engine oil & engine oil C,R R R R R R R R SAE 20W50 "API SJ" Grade
filter* Replace at every 5000kms. And
top-up at every 2500 Kms (If
required)..

3 Oil strainer CL CL CL CL CL Oil strainer cleaning at the time of


oil change.

4 Spark plug CL,C,R CL,A R

5 Air cleaner element*** & cover 'O' ring R R R


6 In line Paper filter or Fuel Cock paper filter R R R
7 Fuel cock sediment bowl cleaning CL CL CL
8 Carburetor rubber duct C,R C,R
9 Fuel pipe C,R C C C R C C R
10 Valve tappet clearance C,A C,A C,A

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Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
11 Sealed drive chain cleaning & lubrication CL,L,A CL,L CL,L CL,L CL,L CL,L CL,L Cl,L (Customer to apply OKS chain
A A A A A A A lube spray at every 500 kms)

12 Engine air breather tube C,R C,R C,R Check & replace if required

13 Brake cam & brake pedal pivot pin C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use recommended AP grease.
14 Brake lining or pad -Check wear indicator Replace brake shoes /brake
C,R C,R C,R C,R R C,R C,R R pad at every15000 Kms

15 Brake fluid level **- top up / replace Use recommended brake


C,A,R C,A R fluid (DOT3/DOT4).
16 Disc brake assly -- Check functionality, C C C C Replace if damaged
leakage or any other damage.
17 All cables & rear brake pedal -free play
C,A C,A C,A C,A C,A C,A C,A C,A

18 Wiring harness & Battery connections-


routing, tie bands & clamps tightness. C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T

19 Ignition switch barrel cleaning & handle bar C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use recommended WD40
control switches contacts cleaning, spray

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Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000

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

Steering stem bearing*** & Cap steering C,CL C,CL C,CL C,CL Check & replace if damaged. Use
21 bearing(Plastic)** L,R L,R L,R L,R HP Lithon RR3 grease for
lubrication.
22 Main stand & side stand pin** CL,L CL,L CL,L CL,L Use recommended AP grease.
23 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T

24 Engine foundation silent bushes ** C C C

25 General lubrication-Clutch lever, front brake L L L L L L L L Use recommended AP


lever. grease.
26 Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
27 Coolant level in expansion tank C,A C,A C,A C,A C,A C,A C,A C,A Use recommended 'Ready to
use coolant'.

28 Coolant hose damage/clamps/leakage C C C C C C C

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Periodic Maintenance & Lubrication Chart
RECOMMENDED FREQUENCY
Sr. Operation Remarks
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
29 Radiator fins C,T C,T C,T C,T C,T C,T C,T C,T

* It is strongly recommended to use specified grade only , In case of any other engine oil of same specifications is
used the frequency would be every 5000 kms
** As applicable to model
*** More frequent cleaning is required while driving in dusty environment.

C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate

Note: periodic parts / lubricants as per periodic maintenance & chart are mandatory & the same is chargeable to customer.

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Non-Use Maintenance
Non-use maintenance is necessary if a vehicle • Fill 10% excess air pressure in both wheels.
remains off road for a longer duration (more • Do not apply oil on front brake disc, to
than 15 days**). The correct and careful non- prevent rusting. If the front brake disc rusts
use maintenance carried out before storing during storage, do not attempt to clean it
with soap water. The rust will go off
the vehicle will prevent the vehicle from
automatically during first few application of
rusting and from such other non-operational brake.
damages like fire hazards. ** For Battery :
• Clean the entire vehicle thoroughly. a. Remove battery and keep it on wooden
• Empty the fuel from the fuel tank and plank, in properly ventilated area.
carburettor float bowl (if fuel is left in for a b. Before taking the vehicle for use.
longer time, the fuel will break and gummy • Get the battery recharged from the
substance could clog the carburettor). Authorised Service Center / Battery Dealer.
• Remove spark plug & put several drops of • Apply petroleum jelly on terminals.
engine oil into the cylinder. Kick engine (applicable to certain models).
over slowly a few times to coat cylinder Preparation for regular use after storage :
wall with oil & install spark plug. • Clean the vehicle
• Set the vehicle on a box or a stand so that • Fit the battery after recharging.
both wheels are raised off the ground. • Make sure the spark plug is tight.
• Spray oil on all unpainted metal surfaces to • Fill the fuel tank with fuel.
prevent rusting. Avoid getting oil on rubber • Change the engine oil.
parts or brake liners. • Check all the points listed in the Daily Safety
• Cover entire vehicle neatly. Make sure that Checks section.
storage area is well ventilated & free from • Check and inflate tyres to proper tyre
any source of flames or spark. pressure.

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