Ssmpulsar 200ns-As200 & 200ns Bs IV Rev 03, Aug17

BS IV
Service Station
Manual
All information contained in this service station manual is based on the
latest product information at the time of publication. Bajaj Auto Limited
accepts no liability for any inaccuracies or omissions in this
publication, although every possible care has been taken to make it as
complete and accurate as possible. All procedures and specifications
subject to change without prior notice. The right is reserved to make
such changes at any time without prior notice.
DOC. NO. : 71111475 REV. 03 AUG, 2017
PULSAR 200 NS / AS 200 Service Support - M/C

Service Station Manual Akurdi Pune
REVISION MATRIX
Sr. No. Rev. No. Date (MM/YY) Reason for Change

1 00 March / 2012 SSM developed for Pulsar NS 200
2 01 Feb. / 2015 Addition of Supplementary SSM for Pulsar AS 200
3 02 March / 2017 Addition of Supplementary SSM for Pulsar 200 NS BS IV
• Addition of Bajaj DTS-i 10W50 Synthetic oil as an alternate option.
4 03 Aug. / 2017
• Camshaft sprocket mounting bolt torque value updated.
PULSAR 200 NS / AS 200 Service Support - M/C

Service Station Manual Akurdi Pune
CONTENTS
1 Foreword 1
2 Workshop Safety 3
3 General Information 7
4 Customer Information 13
5 I Read ..... I Learn 19
6 I Check ..... I Maintain 37
7 Fuel System 61
8 Engine & Transmission 67
9 Frame & Suspension 121
10 Electricals 150
11 Diagnosis & Troubleshooting 193
PULSAR 200 NS / AS 200 SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER

CONTENTS
12 Supplementary SSM - Pulsar 200 AS 217
12.1 Technical Specifications 218
12.2 Preventive Maintenance Schedule 220
12.3 Imporatant SOP’s 222
12.4 Control Cable routing 241
13 Supplementary Service Station Manual - 242

Pulsar 200 NS - BS IV
DEALER DEVELOPMENT CENTER PULSAR 200 NS / AS 200 SERVICE STATION MANUAL

Foreword
1
FOREWORD
This manual is designed primarily for use by trained Whenever you see these WARNINGS and CAUTION
mechanics in a properly equipped shop. symbols, heed their instructions! Always follow safe
operating and maintenance practices.
A basic knowledge of mechanics, the proper use of
tools, & workshop procedures must be understood in
order to carry out maintenance & repair satisfactorily. WARNING
In order to perform the work efficiently and to avoid This manual symbol identifies special
costly mistakes, read the text, throughly; familiarize instructions or procedures which, if not
yourself with the procedures before starting work, and correctly followed, could result in personal
then do the work carefully in a clean area. Whenever injury, or loss of life.
special tools or equipment are specified, do not use
makeshift tools or equipment. Precision measurements
can only be made if the proper instruments are used,
and the use of substitute tools may adversely affect CAUTION
safe operation.
This caution symbol identifies special instructions or
For the duration of the warranty period, we procedures which, if not strictly observed, could result
recommend that all repairs & scheduled maintenance be in damage to or destruction of equipment.
performed in accordance with this service manual. Any
repair procedure not performed in accordance with this
manual may void the warranty.
SKILL TIP / NOTE
To get the longest life out the vehicle. This symbol indicates points of particular interest for
• Follow the Periodic Maintenance Chart in the Service more efficient and convenient operation.
Manual.  Indicates a conditional step or what action to take
• Be alert for problems & non-scheduled maintenance. based on the results of the test or inspection in the
procedural step or sub-step it follows.
• Use proper tools and genuine Bajaj motorcycle parts.
Special tools, gauges, and testers that are necessary In most chapters an exploded view illustration of the
when servicing Bajaj motorcycles are introduced by system components are incorporated.
the Service Manual. Genuine parts provided as spare In these illustrations you will find the instructions
parts are listed in the Parts Catalogue. indicating which parts require specified tightening torque,
• Follow the procedures in this manual carefully. Don't oil, grease or a locking agent during assembly.
take shortcuts.
• Remember to keep complete records of maintenance
and repair with dates and any new parts installed.
How to Use This Manual

In this manual, the produce is divided into its major
systems and these systems make up the manual's
chapters. The contents / index guide shows you all of
the product's system and assists in locating their
chapters. Each chapter in turn has its own comp-
rehensive table of contents.
For example, if you want carburettor information, to
locate the Fuel System Chapter.
2 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

Workshop Safety
3
WORKSHOP SAFETY
o Technicians must put on shoes & dressing should not be very loose.
o Technicians must use Personnel Protective Equipment (PPE) like - Hand
Gloves
- Mask
- Safety Goggle
- Ear Plug
o Wear Nitrile Rubber Hand Gloves while handling petrochemicals like
petrol, Oil, Kerosene etc.
o Precautions to be taken while handling MRTB Test

- Take care that the vehicle is properly clamped in the clamping
device, otherwise it may go back with a force and can injure the
rider.
- Keep yourself cool while taking tests. It is very necessary to be alert.
- Mount the vehicle in the center of the rollers.
- Fuel pipe should not touch heated part of the vehicle, it may cause
fire.
- Make sure to put on air blower while conducting test to avoid engine
overheating.
- Lock The Front Wheel Properly
- Ensure that exhaust blower is running.
- Wear Helmet
- Wear ear plugs
o Precautions to be taken while handling CO Gas Analyser

- Use hand gloves for protection from hot silencer.
- Use mask for protection from exhaust gases.
- Ensure proper ventilation.
o Fire Extinguisher
- Install ‘ISI’ approved. Fire extinguishers - CO2 gas cylinders.
- Refill CO2 before the gas expires.
- Install Co2 gas cylinder at appropriate place so that there is no
obstruction / good accessability.

WORKSHOP SAFETY
o Safety Precautions while Operating Air Tools

Air tools operate on compressed air supplied by the shop air system
(Compressor & Air supply system).
Observe the following safety related precautions when using an air tool.
• It is advisable to fit a pressure regulator (FRL:- Filter Regulator
Lubricator) in the pneumatic line which supplies air pressure to the air
tool. It regulates the outlet pressure to @6.5 Kg/cm2. This avoids the
risk of personal injury.
• Never use the blow gun to blow dust off your clothes and never point
it at anyone. The air pressure can drive dust particles at high speed.
These particles can penetrate into the flesh or eyes. High pressure air
hitting on open wound can force air into the blood stream. This can
result in death.
• Never look into the air outlet of a pneumatic tool.
• Never blow-clean brake or clutch parts. This could put asbestos dust
particles into the air which are harmful to inhale. (These particles are
cancerous - can lead to Cancer).
o Hand Tools
- Do not use worn out hand tools.
o Calibration of Workshop Equipment

- Calibrate all Workshop and M & T Equipment once in a year.
o Avoid direct body contact with Petrol, Kerosene.

Caution : Prolonged contact of used oil may cause cancer.
o Waste Oil Disposal

- Sell used oil to Government approved re-cycle agencies.
- Collect used oil in oil disposer / barrel.
- Don’t throw oil into sewage line.
- Don’t spill oil on the floor.
PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 5

WORKSHOP SAFETY
o Precautions to be taken while handling Hydro-Electric Lift

- While raising / lowering the lifter bay ensure that vehicle is firmly hold
on the lifter bay to avoid accident.
- After raising the lifter bay, lock the lift.
- Don’t put leg/hand in between while raising / lowering the lifter Bay.
• Safety Tips
- Do not lower the lifter bay table without unlocking the mechanical lift
lock.
- Do not keep your leg between the top and bottom frame while
lowering the lifter bay.
- Do not work with loose clothing while working on the lifter bay.
- Do not keep hydraulic joints loose.
- Do not stand on the lifter bay’s top, when it is being operated.
- Special care is to be adopted to avoid injuries if either leg or hand is
entagled between.
- Keep off direct fire near the power pack.
- Avoid oil spillage around the working area for safety reasons.
o Brake Fluid Handling

- Store brake fluid in sealed container
- Avoid contact of brake fluid with skin.
- Don’t spill the brake fluid on painted components
o Electrical Wiring
- Carry out periodic checks & repairs
- Electrical board & Main Switch must be located such that
they are easily accessible.

General Information
• Before Servicing
7
GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a
motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions,
and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that
require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
Especially note the following.
Battery Ground
Before completing any service on the motorcycle, disconnect the
battery cables from the battery to prevent the engine from accidentally
turning over. Disconnect the ground cable (—) first and then the
positive (+). When completed with the service, first connect the
positive (+) cable to the positive (+) terminal of the battery then the
negative (—) cable to the negative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury from
possible sharp edges on the parts.
Solvent
Use a high-flush point solvent when cleaning parts. High flush
point solvent should be used according to directions of the solvent
manufacturer.
Cleaning Vehicle before Disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other
foreign materials entering into sealed areas during vehicle
disassembly can cause excessive wear and decrease performance of
the vehicle.

GENERAL INFORMATION
Arraignment and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts
according to the order the parts were disassembled and clean the
parts in order prior to assembly.
Storage of Removed Parts

After all the parts including subassembly parts have been cleaned,
store the parts in a clean area. Put a clean cloth or plastic sheet
over the parts to protect from any foreign materials that may collect
before reassembly.
Inspection
Reuse of worn or damaged parts may lead to serious accident.
Visually inspect removed parts for corrosion, discoloration, or other
damage. Refer to the appropriate sections of this manual for service
limits on individual parts. Replace the parts if any damage has been
found or if the part is beyond its service limit.
Replacement Parts
Replacement parts must be BAJAJ genuine or recommended by
BAJAJ. Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter
pins must be replaced with new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassembly,
however, if assembly order is provided in this Service Manual, follow
the procedures given.

GENERAL INFORMATION
Tightening Sequence Tightening

Sequence
Generally, when installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit.
Then tighten them according to the specified sequence to prevent
case warpage or deformation which can lead to malfunction. 1 2
Conversely when loosening the bolts, nuts or screws, first loosen all
of them by about a quarter turn and then remove them. If the
specified tightening sequence is not indicated, tighten the fasteners
alternating diagonally.
Tightening Torque
Incorrect torque applied to a bolt, nut, or screw may lead to
serious damage. Tighten fasteners to the specified torque using a
good quality torque wrench.
Force
Use common sense during disassembly and assembly, excessive
force can cause expensive or hard to repair damage. When
necessary, remove screws that have a non-permanent locking agent
applied using an impact driver. Use a plastic-faced mallet whenever
tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets and O-rings
after disassembly can reduce sealing performance. Remove old
gaskets and clean the sealing surfaces throughly so that no gasket
material or other material remains. Install the new gaskets and
replace the used O-rings when re-assembling.
Liquid Gasket, Non-permanent Locking Agent

For applications that require liquid gasket or a non-permanent
locking agent, clean the surfaces so that so oil residue remains
before applying liquid gasket or non-permanent locking agent. Do not
apply them excessively. Excessive application can clog oil passages
and cause serious damage.

GENERAL INFORMATION
Press
For items such as bearings or oil seals that must be pressed into
place, apply small amount of oil to the contact area. Be sure to
maintain proper alignment and use smooth movements when
installing.
Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is
absolutely necessary. Replace with new ones whenever removed.
Press bearings with the manufacturer and size marks facing out.
Press the bearing into place by putting pressure on the correct
bearing race as shown.
Pressing the incorrect race can cause pressure between the inner
and outer race and result in bearing damage.
Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is
necessary. Replace with new ones whenever removed. Press new oil
seals with manufacture and size marks facing out. Make sure the
seal is aligned properly when installing.
Apply specified grease to the lip of seal before installing the seal.
Circlips, Cotter Pins

Replace the circlips or cotter pins that were removed with new
ones. Take care not to open the clip excessively when installing to
prevent deformation.

GENERAL INFORMATION
Lubrication
It is most important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubrication points
are called out throughout this manual, apply the specific oil or grease
as specified.
Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of
rotating direction will affect the adjustment. Rotate the crankshaft to
positive direction (clockwise viewed from clutch cover side).
Electrical Wires
A two-colour wire is identified first by the primary colour and then
the stripe colour. Unless instructed otherwise, electrical wires must be
connected to those of the same colour.
Instrument
Use a meter that has enough accuracy for an accurate
measurement. Read the manufacturer's instructions throughly before
using the meter. Incorrect values may lead to improper adjustments.

Customer Information
• Safe Riding Tips
• Daily Safety Checks
• Running In
• General Information
• Non Use Maintenance
• DC Ignition System
• Bajaj Genuine Parts
• Maintenance Tips
13
CUSTOMER INFORMATION
Safe Riding Tips

• Always wear ISI helmets while driving or riding. Your helmets should conform to appropriate
Indian standards.
• Read thoroughly the instructions in this manual and follow them carefully.
• Avoid unnecessary accessories for the safety of both rider and other motorists.
• Get familiar and follow traffic rules and regulations in your states as well as general traffic
signs.
• Do not overload your vehicle.
• Familiarise yourself well with starting, acceleration and braking of the vehicle.
• When applying the brakes, use both, the front and rear brakes. Applying only one brake may cause the vehicle to
loose control.
• During monsoon drive the vehicle more cautiously. Remember vehicles skid more easily during light showers.
• Always carry vehicle registration papers, insurance and a valid driving licence with you.
MONSOON CARE : Fit & Finish Parts

• The appropriate surface preventive coat to be applied to avoid rusting on account of adverse atmospheric conditions.
• Clean & lubricate all the important parts as detailed in a periodic maintenance chart.
• Do not obstruct engine cooling by adding mud protection sheet from front.
• Vehicle cleaning to be done with soft & clean wet cloth to avoid scratches on painted parts.
• Do not apply direct water jet on painted, electrical / electronic parts.
Daily Safety Checks

Before riding the motorcycle be sure to check the following items. If any irregularities are found during these checks, refer
to the Maintenance chapter and see your dealer for the action required to return the motorcycle to a safe operating
condition.
WARNING
Failure to perform these checks every day
before you ride may result in serious
damage or severe accident.
What to check Check for

Fuel Enough fuel for the planned distance of operation, no leaks in the fuel lines.
Engine Oil Oil level between upper and lower marks.
Throttle 1. Correct free play in the throttle cable (2 to 3 mm)
2. Smooth operation and positive return of the throttle grip to the closed position.
Steering Lock Correct operation.

What to check Check for

Brakes 1. No dragging.
Drive chain 1. Proper slack (15~25 mm).

2. Adequate lubrication.
Lighting Operation of all lights.
Horn Correct functions.
Steering 1. Smoothness.
2. No restriction of movement.
3. Loose or Tight.
Clutch 1. Correct lever play. (2 to 3 mm).
2. Smooth operation of lever.
Side and Center Stand Return to their fully up position.
Tyres 1. Correct pressure.
2. Adequate tread depth.
3. No cracks or cuts.
Mirrors Correct position.
Coolant Coolant level between MAX & MIN mark.
Running In
Proper running-in is important for the better life and trouble free performance of the vehicle.
• During first 2000 kms running-in period do not exceed following speed limits.
Kms 1st 2nd 3rd 4th 5th 6th
0 - 1000 10 18 24 32 40 48
1000 - 2000 16 24 30 38 46 54
• Always keep the speed below the limits mentioned in the table.
• Do not race the engine excessively.
• Do not start moving or race the engine immediately after starting. Run the engine for a minute at idle speed to give
the oil a chance to work up into the engine.
FUEL SAVING TIPS

A well maintained vehicle and good driving can contribute a lot to the saving of petrol. Following are a few simple fuel
saving tips.
• Avoid harsh braking.
• Change the gear judiciously according to the speed requirement.
• Don’t overload the vehicle above the specified payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for more than two minutes.

Non-Use Maintenance
Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct
and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from
such other non-operational damages like fire hazards.
• Clean the entire vehicle thoroughly.
• Empty the fuel from the fuel tank and carburettor float bowl (if fuel is left in for a longer time, the fuel will break and
gummy substance could clog the carburettor).
• Remove the spark plug and put several drops of 2T oil into the cylinder. Self start the engine a few times to coat the
cylinder wall with oil and install back the spark plug.
• Set the vehicle on a box or a stand so that both the wheels are raised off the ground.
• Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or brake liners.
• Lubricate the control cables.
• Cover the entire vehicle neatly. Ensure that the storage area is well ventilated & free from any source of flames or
spark.
• Fill 10% excess air pressure in both wheels.
** For Battery:
a. Remove battery and keep it on wooden plank, in properly ventilated area.
b. Before taking the vehicle for use.
• Get the battery recharged from the Authorised Service Center / Battery Dealer.
• Apply petroleum jelly on terminals.
Preparation for regular use after storage :

• Clean the vehicle
• Make sure the spark plugs are tightly fitted.
• Fill the fuel tank with fuel.
• Change the engine oil & coolant level.
• Check all the points listed in the Daily Safety Checks section.
• Check and inflate tyres to the proper tyre pressure.
Customer Education Points

Vehicle :
• Steering handle can be locked only on LHS.
• Center stand is available as an accessory at dealership.
• Use both brakes simultaneously while braking.
• Do not apply front disc brakes on turning, & on slippery, muddy roads.
• The drive chain is ‘O’ ring type & it is to be lubricated by OKS spray which is available at dealership.
• Tubeless tyre are fitted in this vehicle. Maintain appropriate tyre pressure as given in owners manual.

General :
• Follow periodic service schedule strictly for optimum engine & vehicle performance.
• Carry out any service/repairs at Bajaj authorized service centers only for quality service & genuine parts.
• Always insist on Bajaj Genuine Spare Parts in case of replacement.
• During running in period, do not exceed speed limits mentioned in owners manual. It may lead to failure of engine
components.
• Avoid harsh braking & do not drive the vehicle by keeping brake pedal pressed.
• During periodic service replace mandatory periodic parts as per PM schedule given in owners manual.
Engine :
• Always insist on Bajaj Genuine Oil (Bajaj DTSi 10000) for optimum engine performance & warranty benefits.
• Silencer exhaust is located on RH side.
• Gear shifting pattern is one down 5 up.
• This engine is water cooled type. The coolant is poisonous & causes health hazard.
• Choke is manual lever operated & is located on LH side.
• Ensure coolant level between Min & Max mark.
• Use ready to use & recommended brand coolant as specified in owners manual.
• Do not open radiator cap in engine hot condition. Coolant is in hot condition & may splash out causing health hazard.
Electrical :
• Speedometer display will work when both ignition switch & kill switch are in ON position.
• Battery is sealed type & no electrolyte level top up is required.
• Do not drive vehicle in battery disconnected condition.
• Do not add extra electrical accessories e.g remote, horn, buzzer etc.
• In case battery icon starts glowing, bring the vehicle to workshop.
• Do not press self start button for more than 5 secs. continuously. This may lead to battery discharge. Wait for 15
secs, if vehicle does not start after 3 successive cranks.
• If coolant temp icon starts blinking, it is a alarm signal-Do not drive vehicle in such condition & bring the vehicle to
workshop.
• Service reminder icon will glow 50 kms before due kms for each service & subsequently at each 5000 kms it will
glow. After the respective service is carried out, then this icon is to be reset manually.
• Radiator fan motor will start if coolant temp reaches 980c.

NOTES
Bajaj Genuine Parts
For optimum performance of vehicle
For prolonged life of

components & vehicle Always
Insist
For economical maintenance cost
For rider's safety

on
parts
Genuinity Test
Scratch Hologram to find ‘Genuine’
Bajaj Auto Limited

Akurdi Pune 411 035 India
JA551421 QTY 1 No.
Bajaj Auto Limited
Genuine
03100802 CLUTCH BOX

P0001
PACKAGING MONTH
PLATE JUDDER
MAY 2003
M.R.P. (Incl. of All Taxes) in Rs. for Qty. packed
IN ASSAM, KARNATAKA, MANIPUR, M.P.,
NAGALAND, U.P.,
QTY. 1 NO.
57.43 NF-143-B
& UTTARANCHAL IN OTHER STATES 55.58
Pkg. MTH.
OCT 06.
M.R.P. (Incl.of All Taxes)
in Rs. for Qty. packed 48.29
Hologram Price Label
Maintenance Tips
Carry out all free & paid services as per recommendations.
Follow ‘Running-in’ instructions & other riding tips for proper riding habits.
Insist on replacement of periodic parts as recommended in ‘Scheduled for Periodic Part

Replacement.
Follow Periodic Maintenance & Lubrication Chart for specific repairs / parts replacements &
lubrication.
Always use engine oil of recommended grade in specified quantity.

I Read.... I Learn
• Identification
• Salient Features
• Technical Specifications
• Frequently Asked
Questions (FAQs)
• Comparison with
Competitors Vehicles
19
IDENTIFICATION & LOCATION OF PARTS
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.
Frame Number Location

On Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location

On LH Side Crankcase Near Gear Change Lever
(Alpha-Numeric - 11 Digits)
1
10
2 11 18
3 17
12
4 16
13
5 15
6 14
9
7
8
1. Fuel Level Indicator : Fuel level indicator shows 11. Service Reminder : ‘Wrench’ symbol glows
available fuel in fuel tank. when ODO meter reading reaches to set
2. Tachometer Dial : It shows engine speed in RPM. Kms. for service. This Icon will flash at -
3. Turn Signal Indicator (LH/RH) : When ignition 1st : 450 km. 2nd : 4950 km.
switch & kill switch is made on & Turn signal switch is 3rd : 9950 km. 4th : 14950 km.
turned to Left or Right, Turn pilot Indicator - LH/RH will and subsequently at each 5000 km. Icon will continue
flash. to glow till it is reset. This icon is to be reset after
4. Neutral Indicator : When ignition switch & kill service is carried out.
switch is made on & when the transmission is in 12. Low Battery Indicator : It indicates battery needs
Neutral & Ignition switch ‘ON’, Neutral indicator is lit. charging.
5. Hi Beam Indicator : When Headlight is ‘ON’ & Hi
13. Trip Meter : Trip 1 & Trip 2 shows the distance
beam is selected with engine running, Hi beam
traveled since it was last reset to zero.
indicator will lit.
6. Side Stand Indicator : When ignition switch & kill 14. Coolant Temperature Indicator : It blinks when
switch is made on & when Side stand is ‘ON’, the engine coolant temp. is more than 1150 centigrade.
Side stand indicator will lit. 15. Odometer : The Odometer shows the total distance
7. Logo : It indicates ‘Bajaj’ that the vehicle has covered. Odometer can not be
8. Mode Button : Mode button used for reset to ‘Zero’.
changing the mode while setting Trip1, Trip2 16. Speedometer : Vehicle speed will be displayed in
Clock & Service reminder. digital form in Km / Hr.
9. Set Button : Set button used for setting Trip 17. Digital Clock : It indicates time in HR : MM
1, Trip 2 Clock & Service reminder. (AM/PM)
10. Reserve/Engine Rev Indicator : It glows
continuously when petrol level in tank reaches reserve 18. Low Oil Pressure Indicator : It blinks when

IDENTIFICATION & LOCATION OF PARTS
Grab Handle Pillion Seat Rider Seat Front Brake Lever
Rear
Number
Plate
Rear Disc Brake Rear Brake Pedal Paper Oil Filter Caliper Assembly
Digital
Fuel Tank Cap
Speedometer
Nitrox Rear
Shock Absorber
Clutch Lever
LED
Tail
Lamp
Front Fork
Pillion
Foot
Rest
Front
Disc
Brake
Gear Change Side

Lever Stand

SALIENT FEATURES
PERFORMANCE
Molycote
Features Advantage Benefits
• 4 Valve Water cooled Engine having • More powerful Smooth engine beats Absolute joy to ride due to -
3 spark plugs Complete utilization of engine torque
• Razor sharp response to throttle
Better drive-ability & knock free
• Engine power : 23.5 PS at 9500 rpm. inputs.
performance Consistent engine
• Engine torque : 18.3 Nm at 8000 performance Power, Pick up & • More power at all load conditions,
rpm. Mileage better torque at low rpm, less
emissions. Smooth gear shifting
• Digital DC CDI with TPS control. • Seamless changes in ignition maps
Smooth gear shifting
• DC ignition system. for better engine performance.
• Cylinder block with coolant circulation • Frictionless operation of piston, better

passage cooling of piston crown
• Molycote piston • Better life of engine components
• Nozzle oil jet in lubrication circuit

• Heavy duty gear box • Suited for high speed driving.
• DC Lighting system • Constant bright beam from head light

even at low engine / vehicle speed.

SALIENT FEATURES
STYLE
• Stylish split seats.
• 2 piece grab rail.
• Wolf eyed head lamp.
• Clip on - split type handle bar.

• Bold assertive stance, Sporty looks.
• Thicker tube front fork. • The style that lets you break free.
Brains, brawn and definitely bold.
• Naked chain with O ring.
• New refreshing colors.
• Underbelly centrally located muffler.
• Clear lens blinkers.
• New look alloy wheels.

SALIENT FEATURES
COMFORT AND CONVENIENCE

• Large 37 mm dia front fork with single • Better life of front fork oil seal & other • Smooth ride at any terrian.
antifriction bush. parts of fork.
• Mono suspension with Nitrox at rear. • Better dampening during high speed • Plush ride comfort for rider as well as
drives. pillion on all road conditions.
• Swing arm with needle bearing. • Low friction and high rigidity. • Excellent drive ability
• Wide tyres at front & rear • Better grip available. • Excellent road holding characteristics.
• Clip on - Split type handle bar. • Isolation of vibrations due to rubber • No vibrations.
dampening.
1. LCD speedo console.

• Low Battery level indicator. • Get warning before battery conks off.
• Digital speed indication. • Easy of reading.
• Trip meter to record two trips. • Better to claim conveyance bills.
• Res indicator warning LED. • Reminder for fuel fill up.
• Engine over speed limiter. • Protects engine from excess raving.
• Digital fuel gauge. • Easy to read.
• Tachometer for engine speeds. • Monitor and maintain engine speeds.
• Service Reminder • Reminds customer about servicing. • Easy to ride without any driving /
• Bajaj Logo • Proud feeling operating / maintenance hassles.
• Real time clock • Displays time
2. Intelligent battery save function while • Head lamp controller switches on H/L
switching ON head lamp. only while eng. is in running condition.
3. Maintenance free sealed battery. • Topping up not required.
4. High capacity O ring chain. • Dust would not enter inside chain.

SALIENT FEATURES
SAFETY
• Disc brake at front & rear wheel. • Confidence inspiring brakes.
• Would deflate slowly allowing you to

• Tubeless tyres. • Safety on road in high speed driving.
reach safely.
• Perimeter frame with High strength • Better strength and stability on drive.
robust chassis.
• Better illumination during low idling

• Powerful DC head lamp • Lights are always present.
speeds too.
• Wider tyres & longest wheel base in
• Safe to drive on highway. • Highest stability & road grip.
its class of motorcycles.

TECHNICAL SPECIFICATIONS
Engine & Transmission

Type : Four stroke, water cooled
No. of cylinders : One
Bore : 72.0 mm
Stroke : 49.0 mm
Engine displacement : 199.5 cc
Compression ratio : 11:1
Idling Speed : 1400 + 50 rpm.
Max. net power : 23.5 PS @ 9500 rpm.
Max. net torque : 18.3 Nm @ 8000 rpm.
Ignition System : DC, Microprocessor controlled Digital CDI with TPS
Ignition Timing : Variable Timing with Multiple maps
Fuel : Unleaded Petrol
Carburettor : BS33, push pull choke with Continuous TPS
Spark Plug : 3 Plugs
Spark Plug Gap : 0.7 ~ 0.8 mm
Lubrication : Wet sump, Forced Lubrication
Starting : Electric Start
Clutch : Mechanically Actuated
Transmission : 6 Speed Constant Mesh
Primary reduction : 3.272
Gear Ratios 1st Gear : 2.83
2nd Gear : 2.07
3rd Gear : 1.56
4th Gear : 1.24
5th Gear : 1.05
6th Gear : 0.92
Final Drive Ratio : 2.6 : 1 (39/15)
Chassis & Body

Frame Type : Perimeter
Suspension Front : 130mm Fork travel, Telescopic, Single antifriction bush
Rear : 120mm wheel travel, Mono suspension with Nitrox
Brakes Front : Hydraulically operated disc type
Rear Hydraulically operated disc type
Brake Size Front : 280 mm Disc brake
Rear : 230 mm Disc brake
Tyres Front : 100/80, 17, 52 P Tubeless
Rear : 130/70, 17, 61 P Tubeless
Tyre Pressure Front : 1.75 Kg / Cm2 (25.0 PSI)
Rear (Solo) : 2.00 Kg / Cm2 (28.0 PSI)
Rear (with Pillion) : 2.25 Kg / Cm2 (32.0 PSI)
Rims Front : 2.5 x 17” 10 Spoke Alloy Wheel
Rear : 3.5 x 17” 10 Spoke Alloy Wheel
Fuel Tank Capacity : 12.0 Liters
Reserve : 2.4 Liters
Unusable Reserve : 0.2 Liter

Controls
Steering : Handlebar
Accelerator : On handle bar, RH grip
Gears : Left foot pedal operated, 1 down 5 up
Brakes Front : On handle bar, RH lever.
Rear : Pedal operated by RH foot
Electricals
System : 12 V (DC)
Battery : 12V 8Ah VRLA Type
Head Lamp : 12 V 55/60 W
Tail / Stop Lamp : LED Type
Side Indicator Lamp : 12 V 10 W (4 Nos. - Amber Bulbs )
Position Lamp : 12 V 3 W (2 Nos.)
Rear Number Plate Lamp : 12 V 3 W
Speedometer Back light : LCD Back light
Neutral Indicator : LED
Turn Signal Indicator : LED
Hi-beam Indicator : LED
Reserve Indicator : LED
Horn : 12 V DC, Type 2A
Fuel Gauge : TFR Type
Dimensions
Length : 2017 mm
Width : 804 mm
Height : 1195 mm
Wheel Base : 1363 mm
Saddle Height : 807 mm
Turning Circle Radius : 2500 mm
Ground Clearance : 167 mm
Weights
Vehicle Kerb Weight : 145.0 Kg
Gross Vehicle Weight : 275.0 Kg
Notes :
• Values given above are nominal & for guidance only, 15% variation is allowed to cater
for production & measurement.
• All dimensions are under un-laden conditions.
• Definitions of terminologies wherever applicable are as per Relevant IS/ISO standards.
• Specifications are subject to change without notice.

FREQUENTLY ASKED QUESTIONS - FAQ'S
 What are the key features of Pulsar 200 NS ?

 The new Pulsar 200 NS adopts Worlds first triple spark engine technology controlled by an advanced Electronic
Control Unit for an absolutely unmatched performance. To support this exhilarating heart pumping performance the
bike has following features :
• Water cooled engine
• 6 speed gear box
• 4 valve engine
• Cylinder block with molycote coated piston & coolant circulation passage
• Nozzle oil jet in lubrication circuit
• Underbelly centrally located silencer
• DC ignition & lighting system
• Stylish split seat
• Two piece grab rail.
• Wolf eyed head lamp
• Clip on split type handle bar
• Naked chain with 'O' ring
• New refreshing colors
• New look alloy wheels
• Large 37 dia front fork with single antifriction bush
• Mono suspension with Nitrox at rear
• Swing arm with needle bearings at pivot
• Wide tyres at front & rear
• LCD speedo console with icons, trip meter, Bajaj logo & real time clock.
• Maintenance free sealed battery
• Intelligent battery save function while switching ON head lamp
• Disc brake at front & rear wheel
• Wider & tubeless tyres
• Perimeter frame with high strength robustness.
 What NS stands for in the brand name of bike ?

 NS stands for Naked Sports genre.
 What are differences between old Pulsar 200 & New Pulsar 200 NS ?
 Differences between old Pulsar 200 & new Pulsar 200 NS are as follows :

Specifications Earlier Pulsar 200 Pulsar 200 NS
CC 198.8 199.5
HP 18 PS 23.5 PS
Torque 17.17 Nm 18.3 Nm
Silencer Regular Under belly type
Cylinder Head 2 Valve 4 Valve
Cylinder Block Regular With coolent circulation passage
Cooling Oil cooled Water cooled
Frame Double cradle Perimeter
Tyres Front - 90 x 90, 17 49 P Front - 100/80 - 17, 52 P, Tubeless

Rear - 120 x 80, 17 61 P Rear - 130/70 - 17, 61 P, Tubeless
Wheel Base 1350 1360
RSA Nitrox - Twin Nitrox - Mono
Gear Box 5 Speed 6 Speed
Max Speed 130 Km / Hr 136 Km / Hr
Battery 9 Ah, low maintenance 12V 8AH, VRLA Maintenance free

Front – Disc Front – Disc
Braking
Rear – Drum Rear – Disc
Electrical System AC – DC DC
Digital Speedometer No provision of real time clock Provision of real time clock
 What is water cooled engine & what are its benefits ?

 In water cooled engine coolant is used as a heat conductor instead of air
Benefits:
• Noise level of water cooled engine is less due to insulating properties of water jacket
• Engine operating temperature is regulated.
• Vehicle runs smoothly in extreme hot & cold weather conditions.
• No loss of power as engine will not get too hot due to coolant circulation system.
 What is triple spark? What are the benefits of triple spark ?

 Pulsar 200 NS has 3 spark plugs- LHS, RHS & Central. Pulsar 200 NS is world's first motorcycle to adopt Triple
Spark Engine Technology. Central plug fires first & LH / RH side plugs fire later. Firing of plugs in controlled by
intelligent CDI.
3 Spark plugs burn air fuel mixture completely & generates 23.5 PS power at 9500 RPM & high pick-up. Max
speed is 136 Km/Hr.

 What is a 4-valve engine and what are the benefits ?

 This engine has 2 Intake & 2 Exhaust valves compared to 1 Intake & 1 Exhaust valve of a 2 valve engine. These
valves are smaller & light weight compared to that of 2 valve engine.
4 valves (2 Intake & 2 Exhaust valves) are introduced to improve breathing i.e. Intake & Exhaust process of
engine. Flow area of Intake & Exhaust port / passages leading to valves gets increased. This facilitates induction of
more quantity of charge (air-fuel mixture) & also evacuation of all burnt gases inside the combustion chamber
Benefits:
• Increased engine performance-power, throttle response, pick-up at all engine speeds.
• Ensure faster, cleaner & more efficient combustion.
• Optimized volumetric efficiency & improved scavenging process
• Very less scavenging losses.
 What is the benefit of a 6 speed gear box ?

 • Less stress on engine at high speed.
• Optimum fuel economy at high speed
• Less noise at high speed
 How to refill coolant & how much quantity ?

 Coolant specifications :
• Antifreeze ready to mix (Recommended brand - Motul: Moto cool expert, Castrol Radicool)
• Total coolant quantity 1000 ml (750 ~ 780 ml in radiator & 220 ~ 230 ml expansion tank)
• Coolant required for refilling for 1000 ml.
Draining the coolant :
During motorcycle operation, the coolant gets very hot & is under pressure. Do not remove the radiator cap,
radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to
cool down.
• Stand the motorcycle upright.
• Place a suitable container under the engine.
• Remove screw.
• Take off the radiator cap.
• Completely drain the coolant.
• Mount screw with a new seal ring and tighten it.
Filling the cooling system :
• Remove radiator cap.
• Remove bleeder screw.
• Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten the bleeder screw
immediately.
• Fill the radiator completely with coolant. Mount the radiator cap.
• Rest the vehicle on the side stand.
• When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant.
• Remove the cap of compensating tank and add coolant until the coolant level is in between MIN & MAX mark.
• Mount the cap of the compensating tank.

 What is VRLA Battery ?

 This is totally sealed battery VRLA stands for Valve Regulated Lead Acid battery.
Battery features :
• Top-up not required
• Low self discharge
• Totally maintenance free.
• No possibility of spillage of electrolyte.
• Enhanced safety
• Compact design & High efficiency.
 Can I use regular 9Ah battery in place of VRLA battery ?

 NO, you can't use regular battery in this vehicle.
The VRLA battery is mounted at an angle. The regular battery has to be placed on horizontal surface. If it is
mounted on inclined surface, the battery acid may fall on vehicle parts & they will get damaged. This may lead to
serious problems in the vehicle. Hence, under no circumstances regular battery should be used in place of VRLA
battery.
 What are icons in speedometer display ?

 There are 4 icons which are displayed at RHS top cover of Digital speedometer.
Service Reminder - Wrench symbol glows when ODO meter reading reached to set Kms. for service.
This Icon will flash at -
1st : 450 km.
2nd : 4950 km.
3rd : 9950 km.
4th : 14950 km.
And subsequently at each 5000 kms. Icon will continue to glow till it is resetted. This icon is to be resetted after
service is carried out.
• Low oil pressure Indicator -

It blinks when engine oil pressure is low.
• Coolant Temperature Indicator -
It blinks when engine coolant Temperature is more than 1150 centigrade.
• Low Battery Indicator -
It indicates battery needs charging.

 What are other functions of speedometer?

 Apart from above icons digital speedometer has following features:
1. Fuel Level Indicator :

Fuel level indicator shows available fuel in fuel tank.
2. Tachometer Dial :
It shows engine RPM.
3. Turn Signal Indicator (LH & RH) :
When ignition switch & kill switch is made on & Turn signal switch is turned to Left or Right, Turn pilot Indicator -
LH or RH will flash.
4. Neutral Indicator :
When ignition switch, kill switch is made on & transmission is in Neutral then Neutral indicator will glow.
5. Hi Beam Indicator :
When ignition switch, kill switch & Headlight switch made on & Hi beam is selected with engine running, Hi b e a m
indicator will glow.
6. Side Stand Indicator :
When ignition switch & kill switch is made on Side stand is ‘ON’, the Side stand indicator will lit.
7. Bajaj Logo :
When ignition switch & kill switch is made on ‘B’ monogram will lit.
8. Mode Button / 9. Set Button :
Used for trip meter resetting, service icon resetting & clock setting.
10. Reserve / Engine Rev Indicator :
It glows continuously when petrol level in tank reaches reserve level. It also blinks when engine RPM cross 10000
RPM mark.
11. Speedometer :
Vehicle speed will be displayed in digital form in Km / Hr.
12. Odometer :
The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to 'Zero'.
13. Digital Clock :
It indicates time in HR: MM

 How to set clock in speedometer ?

 • Digital clock indicates time in HR : MM
• Initially ':' will be blinking
• Clock setting is possible in TRIP 1 mode only.
1. Press mode push button for less than 2 sec. TRIP 1 Mode selected
Press mode & set push button together for ‘:’ stops blinking. Digits starts blinking
2.
more than 2 sec.
3. Press mode button for less than 1 sec. Hour digits will increases by one.
Minutes digits will increases. If mode/set button is

4. Press set button for less than 1 sec. pressed continuously then digits will stop blinking.
Press mode & set button together for Set value will be saved Exit clock setting mode
5.
more than 2 sec. Digits stop blinking ‘:’ start blinking
Auto exit without saving set value.

Clock set mode is selected & no editing is If engine/vehicle rpm is given then system will exit
6.
carried out for more than 5 sec. from clock set mode without saving set value.
Note : Incase battery connection get disconnected you have to reset the clock.
 How to reset Service Reminder icon ?

 'Wrench' symbol glows when ODO meter reading reached to set Kms.
Press mode push button for less than

1. Trip 2 Mode selected
2 sec. & select Trip 2
Press mode & set button button for more
2. than 5 sec. continuously. Service reminder icon will be reset.
Note: Engine & motorcycle speed should be zero.
 How to reset Trip meter ?

 Mode push button is provided for selecting & resetting 'ODO / TRIP 1 / TRIP 2'. LHS part of speedo console.
1. Press mode push button for less than 2 sec. Mode changes from ‘ODO / TRIP 1 / TRIP 2’
Selected mode ‘TRIP1/TRIP2’ will reset.
2. Press set push button for more than 5 sec.
Other TRIP mode will continued to update.
 What is a perimeter frame? How is this frame different and better from other Pulsar frames ?
 The Pulsar 200 NS chassis comprises a pressed steel perimeter frame and a Rectangular tube section swing arm
delivering over three times the lateral stiffness of a P220 frame. This delivers outstanding high speed handling and
cornering stability.

FREQUENTLY ASKED QUESTIONS - FAQ’s
 What are advantages of Mono Suspension ?

 • Whenever you encounter a bump in a M/C with two shocks, both the shocks compress, but there is never a
situation when both of them compress for the equal length. This leads to downgraded dynamics when it comes
to stability. But with a single shock absorber, this problem is solved.
• They are also easier to adjust, since there's only one shock to adjust, and there is no worry about matching two
shocks.
• Nitrox gas filled mono suspension adds to the comfort of rider.
 What is a petal disc ?

 Shape of the disc is like a petal. It adds to the asethetics of the vehicle.
 What are colours available in this vehicle ?

 Pulsar will be available in Blue, Red, & Black colours.
In additions Pulsar 200 NS will also be made available in special colours like yellow.
 What are the benefits of an underbelly muffler? Why has the muffler been positioned there ?
 The weight of regular silencer is 7 Kg approx & due to side mounting, the vehicle balance is shifted to RHS which
affects vehicle handling & drive ability.
This underbelly type silencer weighs 4.2 kg approx & is located at centre of the vehicle hence centre of gravity is
at centre of vehicle & towards ground, therefore vehicle handling & drive ability is smooth as compared to all other
vehicles where silencer is mounted at RHS of vehicle.
 What is the advantage of Disc brake on both front and rear ?

 Advantage of disc brake is efficient braking with minimal effort by rider. Heating of alloy wheel is less as compared
to drum brake due to ventilated disc provided at front & rear wheels. Rider has to take precaution to apply both
brakes simultaneously.

COMPARISON WITH COMPETITORS VEHICLES
BAJAJ PULSAR Honda CBR Advantages of

Description Yamaha R15
200 NS 250R BAJAJ PULSAR 200 NS
POWER AND PERFORMANCE
Engine C.C 199.5 149.8 249.6

4 valve & world's first Triple spark
23.52 PS @ 17PS @ 25PS @ Patented technology engine engineered
Engine H.P
9500 rpm 8500 rpm 8500 rpm for the best performance
in its class of bikes.
Engine 18.3 Nm @ 15Nm @ 22.9 Nm @
Torque 8000 rpm 7500 rpm 7000 rpm
Transmission 6 Speed 6 Speed 6 Speed

• Utilization of high engine torque.
Max Speed 136 Kmph 125 Kmph 148 Kmph • Excellent drive–ability.
• Highest in its class
Starting • Soft & easy self start
Electric Start Electric Start Electric Start
Mechanism
Kerb
145 kg 136 kg 167 kg
Weight
Highest power to weight ratio
Power to 162.20 125 149.70 in its class
Weight PS/Ton PS/Ton PS/Ton
Ratio
Ignition Seamless changes in ignition maps
Digital CDI TCI Digital ECU Based
System according to change in vehicle load.
Quick & effort less engine starting.
Trics Available Not Available Available
ExhausTEC High engine torque & knock
System Available Not Available Not Available free engine.
STYLE
Twin
• Add to looks.
prismatic Yes Yes Eagle Eye
• Safe driving during dawn & dusk.
pilot Lamps
Tail Lamp • Minimal consumption battery energy &

LED LED LED long life.
LED
• No maintenance of bulb
Rear No.
Available Available Available Clear visibility even from long distance
Plate Lamp
Styling New age New age No
Graphics Innovative No No
• Sporty & eye catching looks.
Head Light • The best in its class of bikes.
With Fairing Yes Yes Yes

COMPARISON WITH COMPETITORS VEHICLES
COMFORT & CONVENIENCE
Front Telescopic front

Telescopic Telescopic Longest suspension travel in its
Suspension fork dia 37 with
Fork Fork class of bikes.
antifriction bush
Nitrox with Linked type Linked type

Rear The best ride comfort on any type
Mono monocross / monocross /
Suspension of road for any distance.
suspension prolink prolink
Battery 12V 8AH VRLA 12V, 5Ah 12V, 6Ah-MF Totally sealed & maintenance free battery
Low battery Reminds rider to charge battery

LED Available Not Available Not Available
Indicator in time.
For recording distance traveled
Trip Meter Available Available Available in km during a trip.
Rear Time YES No No Convenience to rider

Clock
Icon Available Not Available Not Available
Delta Box • Light weight & robust.

Pressed steel Twin spar • Excellent vehicle dynamics, road
Frame (perimeter frame)
Perimeter Frame type grip & stability.
10 Spoke 5 Spoke Alloy

Wheels 10 Spoke • Nimble handling & better agility.
Alloy Wheel Wheels
Front - 100/80 - 17, Front - 90/80 - Front-110/70 -

52 P, Tubeless 17 tubeless 17 tubeless • Excellent road grip.
Tyres
Rear - 130/70 - Rear - 130/70 - Rear-140/70 - • Wide tyres.
17, 61 P, Tubeless R17 tubeless 17 tubeless
Wheel Base 1360 mm 1345 mm 1367 mm • Long wheel base & Highest ground
clearance in its class.
• The best stability..
Ground • Most suitable for Indian driving
167 mm 160 mm 145 mm
Clearance conditions.
Fr. - Dia 280 Ft. - Dia 268 Ft. - Dia 296

mm Disc mm Disc mm Disc
Brakes • Excellent Braking efficiency.
Rr. - Dia 230 Rr. - Dia 220 mm Rr. - Dia 220
mm Disc mm Disc mm Disc

I Check.... I Maintain
• Periodic Maintenance
& Lubrication Chart
• Periodic Maintenance
Points
Max.
Min.
37
PERIODIC MAINTENANCE
MAINTENANCE &&LUBRICATION
LUBRICATIONCHART
RECOMMENDED FREQUENCY
Sr. Operation Subsequent
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
1st - 500~750 Kms / 30~45
1. Servicing       
days,2nd onward@5000Kms
2. Idle speed / CO% C, A C, A C, A C, A C, A C, A C, A C, A
3. Valve tappet clearance C, A C, A C, A C, A C, A C, A C, A C, A
4. Engine oil (Bajaj DTSI 10000 oil)* C, A, R R Top-up R Top-up R Top-up R Top-up@every 5000 Kms.
Replace in 1st service & at
every 10000 Kms
5. Oil strainer (Bajaj DTSi 10000 oil)* CL CL CL CL CL
6. Engine oil filter (Bajaj DTSi 10000 oil)* R R R R R Replace at every oil change
7. Body centrifugal filter -- Pulsar / Platina CL CL CL
8. Spark plug gap CL,A CL,A CL,A CL,A CL,A CL,A CL,A
9. Spark plug R R Replace at every 20000kms
10. Air cleaner element*** CL, R CL CL CL R CL CL R Replace at every 15000kms
11. Air filter cover ‘O’ ring R R R Replace at every 15000kms
12. In line paper filter along with hose & clamps** R R R Replace at every 15000kms
13. Fuel cock sediment bowl cleaning CL CL CL CL CL CL CL
14. Fuel cock-Paper filter element & seal** R R R Replace at every 15000kms
15. Carburettor CL,A CL,A CL,A
16. Carburettor float chamber cleaning CL CL CL CL
17. Carburettor rubber duct C,R C,R Check & replace if required
18. Fuel pipes C,R C C C R C C R Replace at every 15000kms
19. Coolant level check in expansion tank** C,A C,A C,A C,A C,A C,A C,A At every service
20. Coolant in expansion tank** R Replacement at every 30000 Kms or 2 year (whichever occurs earlier)
21. Coolant hose damage/clamps/leakage** C,R C,R C,R C,R C,R C,R C,R Check & replace if required
22. Coolant hose damage/clamps/leakage** R Replacement at every 35000 Kms or 3 years (whichever occurs earlier)
23. Radiator fins** C,CL C,A C,A C,A C,A C,A C,A
24. Battery electrolyte level & specific gravity** C.A C C C C C C C
25. Battery connections C,T C,T C,T C,T C,T C,T C,T
26. Clutch plate C,R C,R Check & replace if required
27. Clutch play C,A C,A C,A C,A C,A C,A C,A C,A
28. Throttle play C,A C,A C,A C,A C,A C,A C,A C,A
29. Brake play C,A C,A C,A C,A C,A C,A C,A C,A
30. Brake lining or pad wear C,R C,R C,R C,R R C,R C,R C,R Replace at every15000 Kms
31. Brake fluid level / top up** C,A C,A C,A C,A C,A C,A C,A Check & Top up if required
in every service
32. Brake fluid R R
33. Front brake hose R R
34. Master cylinder piston kit R R
35. Caliper piston seal and Dust seal R R
36. Brake cam & pedal pivot pin** L L L L L L L
37. Rear sprocket fasteners C,T C,T C,T C,T C,T C,T C,T C,T
38. Rear wheel rubber shock damper C,R C,R C,R C,R Check & replace if required
39. Silencer drain hole cleaning CL CL CL CL CL CL CL

PERIODIC MAINTENANCE & LUBRICATION
RECOMMENDED FREQUENCY
Sr. Operation
No. Servicing 1st 2nd 3rd 4th 5th 6th 7th Subsequent
500 4500 9500 14500 19500 24500 29500
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
40. Silencer tail pipe cleaning-Pulsar 150/180 CL CL CL CL CL CL CL
41. Engine compression pressure C C C
42. Cylinder head de-carbonising CL CL If required
43. Engine air breather tube R R Replace at 20000 Kms
44. Drive chain slackness C,A C,A C,A C,A C,A C,A C,A C,A
45. Drive chain lubrication on vehicle C,L C,L
46. Drive chain link lock R R R R R R R Whenever drive chain opened.
47. Drive chain wear -- Remove & Lubricate C,L C,L C,L C,L C,L C,L C,L
48. Drive chain ("O" ring design)** L Lubricate at every 500 km.(By customer)
49. Wheel bearing C,R C,R C,R C,R C,R C,R Check & replace if required
50. Spoke tightening-Front & Rear** C,T C,T C,T C,T C,T C,T C,T C,T
51. Tyre tread wear C,R C,R C,R C,R C,R C,R Check & replace if required
52. Front fork oil R R R R Replace at every 10000kms
53. Front fork oil seal R R R R Replace at every 10000kms
54. Auto choke** C C C C C C C
55. Gap betn Reed switch & TPS magnet** C,A C,A C,A C,A C,A C,A C,A C,A
56. Rr. Shock Absorber- Check gas pressure** C,A C,A Not required for new design
(Filling from bottom)
57. Starter Clutch** (Dry Application) L L L L L L L
58. Wiring harness C C C C
59. Ignition switch contacts cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL
60. Clutch switch & brake switch
(Horizontal base) contacts cleaning** C,CL,L C,CL,L C,CL,L C,CL,L
61. Clutch switch (Vertical base)** C,R C,R C,R C,R Check & replace if required
62. Rear brake switch C,A C,A C,A C,A C,A C,A C,A C,A
63. Starter motor connections** C,T C,T C,T C,T C,T C,T C,T
64. Starter relay connections** C,T C,T C,T C,T C,T C,T C,T
65. HT coil connections C,T C,T C,T C,T C,T C,T C,T
66. Oil pressure indicator check on console** C C C C C C C C
67. General lubrication L L L L L L L L
68. Main stand & side stand pin** C,L C,L C,L C,L
69. Swing arm pivot pin (for non silent bush)** L L L L L L L
70. Engine foundation silent bushes** R R R Replace at every 15000Kms
71. Steering play C,A C,A C,A C,A C,A C,A C,A C,A
72. Steering stem bearing*** C,CL,L,R C,CL,L,R C,CL,L,R C,CL,L,R Check & replace if required
73. Cap steering bearing (Plastic)** C,R C,R C,R C,R
74. Step -Pillion LH & RH (Ball & Plate)** C,CL C,CL C,CL C,CL C,CL C,CL C,CL
75. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
* It is strongly recommended to use only “Bajaj DTS-i 10000” Genuine engine oil. In case any other engine oil of same specifications is used, the frequency of Sr.
No. 4, 5 & 6 will be every 5000 Kms.
** As applicable to model
*** More frequent cleaning may be required when driving in dusty condition.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory & the same are chargeable to customer.

PERIODIC MAINTENANCE POINTS
Periodic Maintenance (in accordance with the periodic maintenance chart) of a vehicle it is utmost important to prolong
vehicle life, trouble free running & ensure safety while driving.
Washing (Water Servicing) - Dos & Don’ts
Do’s Don’ts
 Rinse the Bike thoroughly with water to remove  Do not direct pressurized water jet on head lamp
loose dirt and mud. glass, tail lamp glass, electrical components (H.T.
Coil, C.D.I., Flasher, Horn & all electrical digit
console switches) to avoid water entry & subsequent
damage.
 Clean the Bike with a Sponge or soft cloth using  Do not direct pressurized water jet on steering races
water. (cones) to avoid rusting & subsequent pitting of
steering balls & races.
 Clean the exterior surfaces of engine metal parts by  Do not direct high pressurized water jet on plastic,
kerosene / diesel spray & plastic / nylon brush. spark plug cap don’t direct jet on components
especially on decals.
 Cover silencer tail end by PVC cap.  Avoid directing water jet in to silencer muffler outlet.
 Clean the plastic parts using a soft cloth or sponge  Do not use detergent or strong solvent to clean
dampened with a solution of mild car shampoo / painted / plated parts. Avoid cleaning products that
liquid soap & water. Rub the soiled area gently are not specifically designed for automobile surfaces.
rinsing it frequently with fresh water. Strong detergent residues can corrode alloy parts
and also painted surfaces loose their shine / gloss.
Side Cover LH /RH Removal
• Insert vehicle key in pillion seat lock & rotate key clockwise to remove
pillion seat.
• Take out pillion seat from vehicle.

• Remove 2 Nos. M-10 Bolts Securing front seat.
• Take out front seat from vehicle
• Remove 2 nos. phillips head screws securing side cover LH.
• Hold the cover on both sides & pull out side cover LH.
• Remove 2 nos. phillips head screws

• Hold the cover on both sides & pull out side cover RH.
VRLA Battery Removal
• Take out front seat from vehicle.
• Remove 2 nos. PVC caps on battery terminals.
• Remove -ve terminal first by slightly lifting battery from its position.
• Remove +ve terminal by slightly lifting battery from its position.

• Take out battery from vehicle by removing the rubber band.
Spark Plug Cleaning SOP
• Remove LHS plug cap.
• Remove central plug cap which is located above LHS plug
• Remove RHS plug cap

• Using special plug spanner remove LHS plug
• Remove central plug using special plug spanner.
Note : Before removing central plug. It is mandatary to remove LHS plug.
• Remove RHS special plug using special plug spanner.
Remove :
• Clean spark plug with the help of spark plug cleaning machine.
Recommended Spark Plug Central- BOSCH YR5NE/Champion RER6YCA

LHS & RHS - Champion PRG6HCC
Electrode Gap 0.7 ~ 0.8 mm
Replace Spark Plug After every 20,000 Kms.

Coolant Level Inspection & Top up
• Park the vehicle on main stand while checking coolant level.

• Check coolant level in engine cold condition only.
• Ensure coolant level is between Min. & Max. mark.
• Always top up coolant through reservoir cap.
Max.
• Colour of coolant should be green.
Min. • Always replace coolant with recommended brand only. (Radicool from
Castrol, or Motul - Green colour ready to use).
• Use nitrile rubber hand glows while draining & refilling coolant
• Do not top up coolant through radiator cap.
Engine Oil Level Checking
• Park the vehicle on level surface on center stand to check the oil level.
• Inspect the oil level through oil inspection window.
• It should be in between Max and Min mark.
• Top up if required.
Recommended Oil :
“Bajaj DTS-i 10000” a high performance engine oil developed by Bajaj auto,
specially formulated for vehicles with DTS-i engine.
Bajaj Auto recommends “Bajaj DTS-i 10000” engine oil for 10,000 kms drain
interval, better performance of engine components & warranty benefits.
Bajaj DTS-i 10000 SAE 20W50 of API ‘SL’, JASO MA Grade.

OR Bajaj DTS-i 10W50 Synthetic oil
Replacement Frequency* 1st replacement at 750 Km/ 1st service.
Thereafter at every 10,000 Kms.
Recommended Quantity Drain & Refill 1200 ml., Engine O/H 1400 ml.
CAUTION :
• It is most important to adhere to recommended grade and frequency
of oil change for the purpose of long life of critical engine
components. For details refer P.M. chart.
• Do not reuse drained oil.

Engine Oil Drain / Strainer Cleaning SOP
• Warm up engine for 2-3 minutes.
• Remove drain plug located on LHS using 18 no. spanner.
• Check condition of 'o' ring.
• Pull out strainer.
Oil Filter Replacement SOP
• Oil filter is located on RHS just above exhaustech
• Remove 2 nos. M8 bolts of oil filter cover.
Note : Do not clean and re-use oil filter. Replace oil filter at every 10,000
Km.

• Using external circlip plier pull out oil filter.
• Collect oil in clean plastic jar

Drain & refill - 1200 ml.
Overhaul - 1400 ml.
Engine oil Grade - 20W50 BGO OR Bajaj DTS-i 10W50 Synthetic oil.
Air Filter Element Cleaning SOP
• Remove front seat & side cover LH & RH (Refer Side Cover LH/RH
Removal SOP, given on page no. 9).
• Remove 2 nos. M10 bolts of fuel tank cover located on either side of front
fork assembly.
• Remove 2 nos. M5 allen bolts located on top side near petrol tank cap
using 5 mm allen key.

• Remove tank cover grill rubber plug of LHS.
• Remove 2 nos. M5 allen bolt with 5 mm allen key from left hand side.
• Remove tank cover grill rubber plug of RHS.
• Remove 2 nos. M5 allen bolt with 5 mm allen key located on right hand
side of petrol tank cover.
• Remove 2 nos. phillips head screw with plastic washer located on rear
side of petrol tank cover.
• Pull cover side ways & lift it, simultaneously pull the cover towards rear
side & take out petrol tank cover.

• Remove 2 nos. M12 petrol tank mounting bolts from rear side.
• Remove 1 nos. M12 petrol tank mounting bolts from front side.
• Push breather pipe locking clip backwards & pull out breather pipe from
petrol tank.

• Put off petrol cock.
• Lift petrol tank upwards &

remove petrol pipe from petrol
cock.
• Remove fuel gauge coupler.
• Take out petrol tank assembly

complete along with 5 nos.
dampers & fuel gauge.
• Remove 4 nos. M10 bolts

securing air filter cover.
• Remove intake duct pipe from

locking clamp.
• Take out air intake duct cover

along with paper filter
• Take out paper filter element.

Paper Filter Element Cleaning
• Use filtered compressed air of pressure less than 2 bar.

• Position air gun straight at 90 Deg. angle & 50 mm away from paper
filter.
• Move the air gun along the fold line.
900
50 MM
• Positions air gun at 45 Deg. angle & 50 mm away from paper filter.
45
0
• Slightly twist the paper filter. Move the air gun along the fold line.
50 MM
• Keep air gun straight at 90 Deg. angle & 50 mm away from paper filter.
• Blow off remaining dust by moving air gun along the fold line.
900
50 MM
Do’s : Don’ts :
• Clean paper filter at every 5000 Kms. • Don't clean paper filter element with petrol / Diesel / Kerosene /
• Increase cleaning frequency in dusty area. water.
• Replace paper filter at 15000 Kms. • Don't apply oil on paper filter element.
• Hold filter element by its PU foam. • Don't touch paper filter surface by hand.
• Don't wipe paper filter by cloth, abrasive paper.
Post Cleaning Actions :

• Assemble filter element into the air filter box. Maintain tightening torque as per specification over the mounting bolts of
assembly cover side.
• Assemble back seat assembly in the vehicle after the complete assembly of air filter assembly.

Tappet Setting SOP
• Follow SOP till Air filter element removal, then refer steps given below.
Press Accelerator cable to RHS.
• Remove 4 Nos. M10 hex bolts of cylinder head cover in criss-cross

fashion
• Pull out cylinder head cover

• Remove nut securing magneto timing window & remove cap.
• Rotate engine with the cam sprocket special bolt till two line marks on
sprocket are parallel to cylinder head surface and ‘T’ mark is at top
position.
• Ensure the 'T' mark on rotor align with crankcase mark.
• Set intake & Exhaust valve clearance separately.

Intake - 0.05 mm
Exhaust - 0.08 mm
Note : Set tappet clearance in engine cold condition only.

Engine Compression Pressure
Dry Compression Test

• Start the engine & warm it up by driving vehicle for 2 ~ 3 Kms.
• Remove RHS & Central spark plug cap.
• Remove LHS spark plug cap & take out LHS spark plug.
• Thread in compression gauge with adapter into cyl. hd. LHS spark plug
hole.
• Switch ON ignition switch & kill switch.
• Open the throttle fully & press starter switch.
• Note reading displayed on compression gauge dial.
• Set compression gauge pointer to zero position by pressing release valve.
• Take such 3 readings. Calculate mean reading.
• Confirm that mean compression pressure is between 11 to 13 Kg/Cm2
Service limit is 9.5 Kg/Cm2
Wet Compression Test

• If the mean compression pressure reading is less than service limit
specified, put few drops of engine oil through the cylinder head spark plug
hole & crank the engine by pressing switch.
• Again conduct compression pressure test.
• If wet compression pressure reading is considerably greater than dry
compression pressure reading, this means there is compression leakage
past the rings. In this case check cylinder piston assembly as per visual &
dimensional inspection parameters.
• If Wet Compression pressure reading is same as dry compression
pressure reading then the cause could be pitted valve seat, bent valves or
torn cylinder head gasket etc.
Tyre Air Pressure
• Inflate tyres as per recommended pressure to get better tyre life &
optimum mileage.
• Check tyre pressure every week.
Front 1.75 Kg/ cm2 (25 PSI)

Rear - with Solo 2.00 Kg/ cm2 (28.0 PSI)
Rear - with Pillion 2.25 Kg/ cm2 (32.0 PSI)

Clutch Lever Free Play Adjustment
• Slide the dust cover at lever yoke end.

• Check that the clutch cable outer end is fully seated in the adjuster.
• Turn the adjuster until the proper amount of free play can be obtained.
• Tighten the lock nut against the adjuster. If the clutch free play cannot be
adjusted with the adjuster at the handle bar end, use the adjuster at the
lower ends of the clutch cable secured on clutch cover.
• Loosen the 2 lock nuts (12mm A/F) on clutch cable bracket and adjust
threading in the adjuster provided on the clutch cover. Tighten both the
lock nuts on clutch cable bracket by holding one nut and tightening the
other, after the required free play is set.
Clutch Lever Free Play : 2 ~ 3 mm
Accelerator Free Play Adjustment
• Turn the adjuster until the proper amount of free play can be obtained.
• Tighten the lock nut against the adjuster.
• If the accelerator free play can not be adjusted with the adjuster at the
handle bar end, use the adjuster at the lower ends of the accelerator
cable situated on carburettor.
• Loosen the 2 lock nuts on accelerator cable bracket end & adjust free
play by adjuster provided on the cable.
• Tighten both the lock nuts on bracket by holding one nut and tightening
the other, after ensuring the required free play.
Accelerator Grip Free Play : 2 ~ 3 mm
Drive Chain Slackness
• Park the motorcycle on its center stand.

• Rotate the rear wheel to find the position where the chain is tightest &
measure the vertical movement midway between the sprockets (from chain
inspection window).
• If the drive chain is too tight or too loose, adjust within the standard limit.
• Check drive chain slackness at every 1000 kms.
Drive Chain Slackness • Standard: 15~25 mm • Service Limit: 30~40 mm

Chain Slack Adjustment SOP
• Loosen the rear axle nut (M22).
• Adjust LH/RH chain adjuster

equally as per marking on
chain adjuster.
• Ensure drive chain slackness is in specified limit.
• Tighten the rear axle nut to specified torque.

O Ring Drive Chain Cleaning by removing from vehicle (Diesel + SAE 90 oil 1:1)
1st Stage:
Clean with
Diesel+ SAE 90
Oil 1:1
3rd Stage:
Dip into
SAE 90 oil
2nd Stage:
Clean with
Diesel+ SAE 90
Oil 1:1
again
Soak into
SAE 90 oil
Blow Low
Pressure
Compressed
Air
Final Stage :
Hook chain
for dripping
of excess oil
Note :
• During re-assembly of drive chain always use new link lock.
• Ensure ‘O’ ring fitment.

O Ring Drive Chain Lubrication
• Place the bike on center stand.

• Normal dust should be wiped clean using a lint free cloth.\
• Hold the Chain Lube Spray Can (OKS make) vertically upright & shake it
vigorously till the noise of steel ball inside the can is heard uniformly. Fix
the extension tube (red pipe provided with the can).
• Hold the can at the back of the rear sprocket in line with chain rotation
and keep the nose of the extension tube at about 5~10 cms away from
the chain.
• Rotate the wheel in reverse direction & spray the lube on the middle
portion of the chain so that lubricant will get spread on roller & bushes
and on both sides of the chain.
• Spray the lube on full length of chain by rotating the wheel to a complete
rotation.
• After completing this, rotate the wheel 3 ~ 4 times so that the lubricant
spreads & settles.
• Wipe out any excess lubricant if it has dripped down or sprayed on the
wheel / tyre.
Nitrox Mono Rear Shock Absorber
Adjusting Spring Tension

• RSA spring tension can be adjusted with the help of 6 stepped adjuster
cam to suit individual requirement as per load & road conditions.
• Turn the adjuster cam on each shock absorber to same required position.
Setting the adjuster cam to higher notch position increases the spring
Mono RSA stiffness & vice-versa Tool part no. 37 0041 70.
with Nitrox • Shock Absorbers adjusted either too soft or too stiff could adversely affect
riding comfort & vehicle stability.

Special Tool for Notch Position 1 2 3 4 5 6

Mono RSA adjuster
Spring Action Soft
Note: Standard setting is done in 2nd notch.
Notes

Notes

Fuel System
• Carburettor Specifications
• CO Checking and
Setting
• Tune-up for Optimum
Mileage
61
CARBURETTOR SPECIFICATIONS
UCAL
Item Specification
Make UCAL
Type BS33 with Continuous TPS
Idling Speed 1400 + 50 rpm
Main Jet 107.5
Jet Needle Mark U-4E0K1
Needle Jet Marking O-2M (971)
Jet Needle Position Fix
Pilot Jet 12.5
Throttle Valve Mark 125
Choke Manual Push Pull Choke with lever

CO CHECKING & SETTING
Readiness of CO Gas Analyser Taking the Reading

Warm up the CO Gas • Remove M-5 bolt & aluminum
Analyzer for 10~15 minutes washer fitted to the nozzle
before proceeding further. (12mm OD) shown in figure, of
Warming up is essential every the connecting tube welded to
time machine is put on to silencer pipe before CAT
purge out any gases left in converter.
side. • Use a Silicon Rubber tube of
Carry out Span Check as per approximately 300mm to fit onto
m a n u f a c t u r e r ' s the nozzle. Only a Silicon rubber
Recommendation to confirm tube should be used, as it has
the OK condition of the better high temp. resistance &
Equipment (If Span Check will not deform / melt due to
does not confirm the reading, then carry out Gas high temp. at the nozzle.
Calibration as per mfgrs. recommendation). Set the • Connect the other end of the Silicon Rubber tube to the
Equipment display to Zero before taking the reading. flexible probe pipe of machine. Ensure that the inner
diameter of Silicon tube perfectly matches with outer
diameter of flexible probe pipe of Gas Analyzer.
Readiness of the Vehicle • The Silicon rubber tube must fit snugly onto the nozzle
to prevent any air / exhaust gas leakage.
Before checking CO emission, • Note the CO / HC readings when the reading display
prepare the vehicle for stabilizes.
checking the CO. • As per Emission Norms the recommended CO% for 2
• Warm up the engine to its Wheelers is 3.5% at idling RPM. But CO% for Bajaj
normal operating temp. by Vehicles, for best results in terms of fuel efficiency are
riding 5~6 Kms. (Engine different for different models. The ideal CO% is
Oil Temp. = 600C). between 1.5 to 2.5% at idling RPM = 1400 +
50.
Caution: In choke ‘ON’ • If the reading is shown excess or less than BAL
condition CO % is high : specifications, try to achieve by adjusting VC Screw.
9~10%. Hence warming up of • Turning in VC Screw will lead to less CO% and turning
engine is a must. out will lead to more CO%.
• Screw in VC Screw completely. Engine should die Note: Remember the VC Screw should not be taken out
down in this condition. more than the recommended position. Every time VC Screw
setting is changed specified Idling RPM must be restored
Note: If engine does not go off, then attend to the and then reading should be considered.
additional air supply problem in the carburetor circuit & • If the CO% is not falling within recommended % in spite
intake system. After solving the problem once again of adjusting the VC Screw then find out the cause &
confirm that engine should die down on closing the VC rectify. After rectifying the problem confirm the CO% in
Screw. the same way as mentioned above.
Important: For Better Performance, achieve
• Confirm the VC Screw setting as per specification.
CO% as recommended.
• Set Idling speed to specified Idling 1400 + 50 rpm.
In Pulsar 200 NS motorcycle for better performance
Raise the engine to moderate speed at no load
condition for about 15 seconds. Then bring back to
Recommended CO% value w.r.t. VC Screw
specified idling RPM. and Idling RPM for Better Fuel Efficiency
Model Recommended CO% Recommended Idling RPM
Pulsar 1400 + 50 rpm
1.5% ~ 2.5%
200 NS

TUNE UP FOR OPTIMUM MILEAGE
Engine Tune-Up Other Mandatory Checks
SPARK PLUG : a. Ensure no fuel leakage through fuel cock,

Champion PRG6HCC, BOSCH fuel lines.
YR5NE b. Ensure free rotation of both wheels.
• Spark Plug Gap : c. Ensure correct tyre pressure -
0.7 ~ 0.8 mm. Front : 25 PSI, Rear : 32.0 PSI
0.6 to
0.7MM • Replace at Every : d. Set control cable free play:
20,000 Km • Clutch lever 2~3 mm.
• Rear brake pedal 20~25 mm.
e. Chain slackness : 15~25 mm.
f. Check and confirm proper functioning of all
AIR FILTER : 3 nos. spark plugs.
• Replace at Every :
15,000 Km.
COMPRESSION PRESSURE
• Standard :
11 to 13 Kg/cm2
• Service Limit :
9.5 Kg/cm2
TAPPET CLEARANCE
• Inlet Valve :
0.05 mm
• Exhaust Valve :
0.08 mm
CARBURATTOR
• Idling : 1400 + 50 rpm.

CARBURETTOR REMOVAL
Carburettor Removal
• Loosen carburettor rubber

hose clamps (3 mm allen key)
• Remove 2 nos. air filter assly

fitment bolts (10 mm T
spanner).
• Remove idling screw cable.
• Remove TPS connection
• Remove accelerator cable.
• Remove breather tube.
• Remove air filter drain tube.

CARBURETTOR REMOVAL
• Pull the air filter assly along with carburettor.
Carburettor Fitment
• Align the lug of carburettor

rubber hose with intake
manifold & hold the carburettor
vertically as shown.
• Match the air filter connecting

tube with carburettor intake
pipe & push the air filter assly
downward along with
carburettor.
• Align air filter connecting tube with carburettor intake side by using screw
driver.
• Tighten the clamps.
• Fit the breather tube, Drain tube, accelerator cable, idling screw cable &
TPS connection.
• Tighten the air filter assly bolts.

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TIGHTENING TORQUES - ENGINE
Rotor Mounting Nut Stator Plate Bolts Primary Gear Nut
5.9 ~ 6.1 kgm 0.7 ~ 0.8kgm 5.9~6.1 kgm
Clutch Nut Clutch Holder Bolts Guide Gear (Drum Cam) allen Bolt
7.0 ~ 7.1 kgm 1.1 ~ 1.0 Kgm 1.0 ~ 1.2 Kgm
Inhibitor bolt Coolant Temperature sensor Oil Pump Mounting Bolts
1.0 ~ 1.2 Kgm 1.2 ~ 1.4kgm 1.0 ~ 1.2 Kgm
Output Sprocket Bolts Chain Tensioner Mounting Bolts Cam Sprocket Hex Bolt
1.0 ~ 1.2 Kgm 1.0 ~ 1.2 Kgm 2.7 - 2.9 kgm

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Grade :-
SAE 10W20
Bajaj Genuine
Fork oil
Quantity :-
285 ± 2.5 ml
per leg

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BS IV
Supplementary Service Station Manual

Pulsar 200 NS BS IV
• Revised Technical
Specifications
• Revised Periodic
Maintenance &
Lubrication Chart
• AHO - Automatic Headlight
ON
• Revised PDI Check Sheet
• Important SOP
• Part Identification
• Electrical Circuit Diagrams
242
BS IV
Engine & Transmission :-
Parameter Specification
Type 4 stroke, Single Cylinder
Bore 72.0 mm
Stroke 49.0 mm
Displacement 199.5 cc
Max.Net Power 23.5 PS at 9500 RPM
Max. Net Torque 18.3 Nm at 8000 RPM
Ignition system DC
Spark plugs Qty 3 Nos
Spark plug gap 0.7 ~ 0.8 mm
Transmission 6 speed constant mesh
Gear shifting pattern 1 Down 5 Up
Engine Lubrication Pressurized oil supply
Engine Cooling Water cooling
Engine Oil Details :-
Grade Bajaj DTS-i 10000 SAE 20W50 API ‘SL’ or JASO ‘MA’ OR
Bajaj DTS-i 10W50 Synthetic oil
Drain & Refill 1200 ml
Overhaul 1400 ml
Service Station Manual 243 Service Support MC

BS IV
Chassis & Body :-
Frame Type Perimeter
Suspension Front : Telescopic suspension
Rear : Mono suspension with Nitrox
Brakes Front : Hydraulic Disc type
Rear : Hydraulic Disc type
Tyres Front : 100 / 80 - 17, 52P, Tubeless
Rear : 130 / 70 - 17,62P, Tubeless
Tyre Pressure Front : 1.75 kgf / cm² (25 PSI)
Rear (Solo) : 2.00 kgf / cm² (28 PSI)
Rear (Pillion) : 2.25 kgf / cm² (32 PSI)
Fuel tank capacity :-
Full 12.0 Liters
Usable Reserve 2.4 Liters
Unusable Reserve 0.2 Liters
Fork Oil Details :-
Grade SAE 10W20
Quantity / leg 285 ± 2.5 ml

BS IV
Dimensions :-
Length 2017 mm
Width 804 mm
Height 1075 mm
Wheel Base 1363 mm
Ground Clearance 169 mm
Vehicle Kerb Weight 154 kg.
Vehicle Gross Weight 284 kg.
Electricals :-
Electrical System 12 Volts DC
Head Lamp H4, 55/60W Blue Tinge
Position Lamp 3W (2 nos.) Blue Tinge
Tail / Stop Lamp LED type
Side Indicator lamp 10W
Neutral Indicator Green LED
Hi Beam Indicator Blue LED
Turn Signal Indicator Green LED
Side Stand Indicator LCD
Speedometer Illumination LCD Blue
Fuel Level Indicator LCD Bar
Low Oil Pr. Indicator LED-Red
Coolant Temp. Indicator LED-Red
Low Battery Indicator LED-Red
Bajaj Logo LED-Blue
Rear No. Plate Lamp 3W
Horn 12V DC
Battery 12V - 8 Ah VRLA

BS IV
Carburetor Specification :-
Parameter Specification Photograph
Make UCAL
CO% - With SAI <1%
Idling RPM - With SAI 1350 – 1450 RPM
CO% - Without SAI 4.5 % - 5.5 %
Idling RPM - Without SAI 1300 – 1400 RPM
Choke Manual

REVISED PERIODIC MAINTENANCE & LUBRICATION CHART
BS IV
Recommended Frequency
Service 1st 2nd 3rd 4th 5th 6th 7th
Sr
PM Check Point 500 4500 9500 14500 19500 24500 29500 Remark
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Ensure to prevent water

entry in Petrol tank,
1 Servicing with water wash Silencer & electrical parts.
     Use caustic free detergent
for washing.
BGO DTS-i 10W30 for 100cc

models. BGO DTS-I 20W50
Engine oil (Bajaj DTSi 10000 oil) & Top Top Top
2 C,R R R R R OR
engine oil filter* Up Up Up Bajaj DTS-i 10W50 Synthetic oil
3 Oil strainer, Body centrifugal filter** CL CL CL CL CL Oil Strainer Cleaning at the time
of oil Change.
Clean body centrifugal flter at

1st free service & at 20,000
kms.
Use recommended molycote

4 Starter Clutch (Dry Type)** L L L L L L L grease
5 Spark plug CL,A,R CL,A CL,A R

Foam & Paper as applicable.O
6 Air Cleaner Element *** & Cover "O" Ring CL,R CL CL CL R CL CL R ring check at every service &
Replace if cut/damaged
7 In line paper filter or Fuel cock paper filter R R R
8 Fuel cock sediment bowl cleaning CL CL CL
9 Carburetor rubber duct C,R C,R Check & replace if required
10 Fuel pipe C,R C C C R C C R
11 Valve tappet clearance C,A C,A C,A
CL,L,A CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • During 1st free service : Use
A A A A A A A lint free cloth for cleaning & SAE
90 oil for lubrication without
removing from vehicle.
(If chain is excessively dirty,
then chain has to be removed,
Non-Sealed drive chain cleaning & cleaned using diesel &
12 lubricated using molten IOC
lubrication
servo compound chain grease.)
• During all other services:

Remove, clean using diesel &
lubricated using molten IOC
servo compound chain grease.
• During regular service use

OKS spray for chain cleaning,
without removing chain from
vehicle.
CL,L, CL,L, CL,L, CL,L, CL,L, CL,L, • If chain is excessively dirty,
13 Sealed drive chain cleaning & lubrication CL,L,A
A A A A A A then chain has to be cleaned by
removing from vehicle.
(Customer to apply OKS chain
lube spray at every 500 Kms)
14 Engine air breather tube C C C C C C C C Replace if damaged
15 Silencer drain hole cleaning CL CL CL CL CL CL CL
16 Silencer tail pipe cleaning ** CL CL CL CL CL CL CL
Brake lining or pad wear & lubricate brake C,L,R C C,L,R C,L,R R C,L,R C,L,R R Replace brake shoe/pads at
17 every 15,000 kms
cam & pivot pin** Check pad wear indicator

REVISED PERIODIC MAINTENANCE & LUBRICATION CHART
BS IV
Recommended Frequency
Service 1st 2nd 3rd 4th 5th 6th 7th
Sr
PM Check Point 500 4500 9500 14500 19500 24500 29500 Remark
No
Kms ~ ~ ~ ~ ~ ~ ~
750 5000 10000 15000 20000 25000 30000
Use recommended brake
18 Brake fluid level ** - top up / replace C,A,R C,A R fluid (DOT3 / DOT4)
Disc brake assembly–-check functionality,

19 C C C C Replace if damaged
leakage or any other damage
20 All cables & rear brake pedal - free play C,A C,A C,A C,A C,A C,A C,A C,A
Not applicable for VRLA
21 Battery electrolyte level , specific gravity C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T batteries
Wiring harness & battery connection -

22 C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness
Ignition switch barrel cleaning & handle bar Use recommended Wd40
23 C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL
control switches contacts cleaning spray
24 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,L Check & replace if
25 damaged.Use HP Lithon
bearing (Plastic)** L,R L,R L,R ,R RR3 grease for lubrication
Use recommended AP
26 Main stand & side stand pin ** CL,L CL,L CL,L CL,L grease
Not applicable in case of

27 Swing arm pivot pin (For non silent bush)** L L L L L L L needle roller bearing
28 All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T
29 Engine foundation silent bushes ** C C C Replace if damaged
General lubrication - clutch lever, front Use recommended AP

30 L L L L L L L L
brake lever, kick lever grease
31 Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A
Use recommended 'Ready

to Use coolant'.Replace at
32 Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A R every 30000 Kms or 2
years (Whichever occurs
earlier)
33 Coolant hose damage / clamps / leakage ** C C C C C C C Check & replace if required
34 Radiator fins ** C C C C C C C Check & replace if required
35 Spoke tightening ** - Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T
Front fork dust seal area & inner pipe Applicable for front fork
36 CL CL CL CL CL CL CL
cleaning** with rubber bellow
SAI system / EVAP hoses - Check

37 C, R C, R C, R C, R C, R C, R C, R C, R Replace if cut / damaged
functionality, leakage or any other damage**
38 Pillion foot rest hinge lubrication** L L L L L L L L Use RR 3 Grease
39 EVAP Y connector drain tube ** CL CL CL CL CL CL CL CL
* It is strongly recommended to use only Bajaj genuine oil, in case of any other engine oil of same specification is used the 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 & Lubrication chart are mandatory & the same is chargeable to customer.

AHO - AUTOMATIC HEADLIGHT ON
BS IV
New Feature :-
AHO (Automatic Headlight ON) feature is provided. There is no “Light switch” on RH control switch. AHO is
government regulation.
AHO improves safety as the bike becomes more visible to others on the road.
Before After
Light switch No Light switch
Ignition switch - ON Speedometer illumination Parts changed due to AHO feature

Engine - OFF Tail lamp, Number Plate Lamp,
Pilot Lamp & Control Switches Control switch Light switch deleted.
RH
Illumination will get ‘ON’
Effect of pressing In addition to above ‘Hi-beam will Wiring harness • No branch for light switch
get ‘ON’ • Connections for light control module
‘Pass Switch’
Flasher Deleted
Ignition switch - ON Speedometer illumination, Tail
Engine - Running lamp, Number Plate Lamp, Pilot Light Control New part added :-
Module • It will sense magneto is running &
Lamp & Control Switches
will give input for head light
Illumination will get ‘ON’ in
filaments.
addition to above, headlamp will • Flasher circuit is inbuilt in this
get on as shown in table. module.
Hi / Low beam switch Headlamp status Effect of Pass switch Pressing

Low Beam
Low Beam ON High Beam ON
High Beam
High Beam ON No change

REVISED PRE-DELIVERY INSPECTION CHECKLIST
BS IV
PDI Check sheet Common for all models (Torque Values given for Pulsar 200 NS BS IV)
Dealer's
Dealer's Name
code
Model City
Frame No Date of PDI
Engine No PDI done by
1. Check points before starting of the vehicle
Check & correct the below check points before starting the vehicle
If Ok
To Check Check for
X If Not Ok
Engine oil Oil level between lower & upper mark / Top up if required
Fuel tank / Pipes No leakage / Correct fitment
Mirror Fitment & adjustment to ensure clear rear view
Coolant level between MIN & MAX mark, top up if required in cold
Coolant condition
Ensure no leakage
Steering cum Ignition lock, Seat lock, LH side cover lock, Petrol tank
Lock Operation
cap lock
Terminal voltage 12.4 V D.C for MF battery & 12.8 V
DC for VRLA Battery using battery tester
Batterry
Tightness of battery terminals / cables / Petroleum
Jelly application
Front : 25 PSI (1.75 Kg / cm2)
Tyre Pressure
Rear (with Pillion) : 32 PSI (2.25 Kg / cm2 )
Front- Brake lever free play 4 ~ 5 mm (For Drum brake only)
Brakes
Rear : Brake pedal free play (For drum brake only)
Clutch / throttle cable Free play 2 ~3 mm
Slackness 15 ~ 25 mm
Drive chain Equal marking of chain adjusters on both side
No touching to chain case

BS IV
Engine foundation bolts
Engine stay Upper bolts-2.4 – 2.6 Kg.m (23.5 – 25.5 N.m)

Engine stay Lower nuts-3.4 – 3.6 Kg.m (33.4 – 35.3 N.m)
Fasteners (Check torque)
Engine Rear mounting bolts : 2.5 – 3.0 Kg.m
Recommended torque wrench to (24.5 – 29.4 N.m)
be used for applying torque on
nut - bolts as mentioned in PDI Front axle nut : 9.0 ~ 11.0 Kg.m (88.3 – 107.9 N.m)
check sheet using reference
torque chart given in Annexure 4.
Rear axle nut : 10.0 - 12.0 Kg.m (98.1 – 117.7 N.m)
However if any major parts are
required to be removed (Except Swing arm shaft nut : 13.0 ~ 15.0 Kg.m
side cover & seat) for (127.5 ~ 147.2 N.m)
accessibility of torque wrench, in
those cases the tightness can be RSA Mounting top / bottom nut : 3.2 ~ 3.8 Kg.m
ensured using open end / ring (31.4 ~ 37.3 N.m)
spanner / box type spanner as
Front fork top / side bolts : 1.8 ~ 2.0 Kg.m
applicable without removing
(17.7 ~ 19.6 N.m)
those major parts
Front fork under bracket bolts : 2.5 ~ 3.0 Kg.m
(24.5 ~ 29.4 N.m)
LH / RH Stay bolts 1.8 ~ 2.2 Kg.m (17.7 ~ 21.6 N.m)
2. Check points during / after starting the vehicle
Check & correct the below check points during / after starting the vehicle
Switch operation RH & LH control switch, ignition switch, clutch switch &
brake switch (Front & Rear)
Horn Ensure no distorted sound

Headlight, Tail / Stop lamp, Side indicators, Speedo bulbs, Number
All Bulbs working
plate lamp,
Working of speedometer, Odometer, Trip meter, Fuel gauge , Clock
Speedometer
Working of all signal indicators icons (Neutral, Turn signal, High
beam, Clock, Low battery indicator, Service reminder & Bajaj Logo)
Headlamps Focus confirmation
3. Check points during Test ride
Check & correct the below check points during Test ride
Gear shifting Smooth operation
Throttle response
Drive-ability
Brake effectiveness - Front & Rear

BS IV
Engine noise No abnormal noise
Smooth working by pumping movement & smooth operation
Front fork / steering
(No play / No Sticky movement)
Oil / Coolant leakages Specify source of leakages
4. Idling RPM / CO%

Check & correct the below check points in engine warm condition
Idling RPM Check in warm up condition at 600 (SAI connected 1350 – 1450 RPM
& SAI disconnected 1300 – 1400 RPM)
CO Check in engine warm condition at idling RPM

CO % Check
(SAI connected < 1% & SAI disconnected 4.5 % – 5.5 % )
5. Visual inspection for dent, scratches, rust …
6. Clean the vehicle thoroughly before delivery to customer.
Note :- If performance related issue is observed in vehicle, then carry out Idling RPM & CO% Check activity.

IMPORTANT SOP
BS IV
Petrol tank cap locking
• Lock the petrol tank cap as follows -
• Insert the vehicle ignition key in petrol

tank cap lock.
• Turn the vehicle ignition key clockwise.
• Press the fuel tank cap as shown in

photograph. Ensure “TUK” sound to
confirm the proper locking of petrol tank
cap
• Take out vehicle ignition key clockwise.
• Press the flap of petrol tank cap lock.
• Do not attach metal key chain to vehicle

ignition key as it may cause scratch /
damage marks on painted part.
X
CO% Check & Adjust SOP
• CO% Check & Adjust SOP is same as
given in V15 & Avenger Service
Part No. : 37 0043 60
Station Manual except following
Changes in SOP
• Remove Rider Seat & LH side cover.
• Cut the clamp using cutter.
Oetiker clamp
Note : This clamp can be re-fitted
re-fitment using
using oetiker clamp crimping plier. special tool
• Pull the rubber hose.
• Plug air filter to SAI hose pipe by

nylon plug (Part No. - 37104331)

PART IDENTIFICATION
BS IV
Model Pulsar 200 NS Pulsar 200 NS BS IV
Photograph
Part Name Fuel Tank Fuel Tank
Part No JL171081 JL171810
Description • Without EVAP Tube • With EVAP Tube
Identification Visual Visual
Nut weld
Photograph
Hooks
Part Name Frame Frame
• Without 2 nos nut weld on pipe cross front for • With 2 nos nut weld on pipe cross front for
Description SAI Bracket mounting SAI Bracket mounting
• Without hooks for EVAP hose routing • With hooks for EVAP hose routing

PART IDENTIFICATION
BS IV
Photograph
Part Name Brace Fender Brace Fender
Description • Collar profile is different than Pulsar 200NS BS IV • Collar profile is different than Pulsar 200NS
10.5 mm 12 mm
Photograph
Part Name Shaft Assembly Brake Lever Shaft Assembly Brake Lever
Part No JL161010, REV-04 JL161010, REV - 05
Description • Brake switch spring bracket width – 10.5 mm • Brake switch spring bracket width – 12 mm

PART IDENTIFICATION
BS IV
Photograph
Part Name Expansion Tank Expansion Tank
Part No JL601226, REV-01 JL601226, REV - 02
Description • Without cut out • With cut out
Photograph
Part Name Step Holder LH Step Holder LH
Description • Profile is different than Pulsar 200NS BS IV • Profile is different than Pulsar 200NS

PART IDENTIFICATION
BS IV
LH
Photograph
RH
Part Name - Belly Pan
Part No - LH - JL181305, RH - JL181306
Description • Without belly pan • With belly pan
Identification - Visual
Photograph
Part Name - Bracket Belly Pan
Part No - JL181307
Description • Without Bracket belly pan • With Bracket belly pan
Identification - Visual

PART IDENTIFICATION
BS IV
Photograph
Fresh Air
Provision for
SAI
Part Name Air Filter Assembly Air Filter Assembly
Description • Without provision for supply of fresh air to SAI unit • With provision for supply of fresh air to SAI unit
• Profile is different than Pulsar 200NS BS IV • Profile is different than Pulsar 200NS
Photograph
Provision for
supply of
evaporated
fuel supply
Part Name Carburetor Assembly Carburetor Assembly
• Without provision for supply of evaporated • With Provision for supply of evaporated
Description fuel supply fuel supply
• With TPS • Without TPS

PART IDENTIFICATION
BS IV
Photograph
Part Name - Bracket SAI mounting
Part No - JL113827
Description • Without Bracket SAI mounting • With Bracket SAI mounting
Provision
Provision for supply
for supply of Vaccum
of fresh air to SAI
to cylinder head
Photograph
Part Name Assembly Cylinder head Assembly Cylinder head
Part No 36JL0010 JL511053
• Without provision for supply of fresh air from SAI • With provision for supply of fresh air from SAI
Description
• Without provision for supply of Vaccum to SAI • With provision for supply of Vaccum to SAI

PART IDENTIFICATION
BS IV
Photograph
Part Name Cam Shaft Assembly Cam Shaft Assembly
Part No JF511228 DT511239
Description • Without groove • With groove for identification
Photograph
Part Name Rocker Arm Rocker Arm
Part No In – JL511006, Ex – JL511007 In – DT511261, Ex – DT511262

• Tappet adjuster screw profile is different than • Tappet adjuster screw profile is different than
Pulsar 200 NS BS IV Pulsar 200 NS.
Description • Note :- • Note :-
- Tappet adjuster (P/N-37224015) to be used - Tappet adjuster (P/N-37104315) to be used
- Frequency at every service - Frequency at every 15,000 Kms.

PART IDENTIFICATION
BS IV
Photograph
Part Name Control Switch RH Control Switch RH
Description • With light switch • Without light switch
Photograph
Part Name CDI CDI
Description • Housing color - Brown • Housing Color - Red

PART IDENTIFICATION
BS IV
Photograph
Part Name Flasher Light Control Module
Part No DS201025 DT402006
Description • With Flasher • With Light control module
Photograph
Part Name Speedometer Assembly Speedometer Assembly
Description • With Yellow backlight • With blue backlight

PART IDENTIFICATION
BS IV
Ø 57.5 mm
Ø 70 mm
Photograph
Part Name Horn Horn
Part No JL401600 JG401601
• Mounting bracket profile is different than • Mounting bracket profile is different than
Description Pulsar 200NS BS IV Pulsar 200NS
• Outer diameter is Ø 57.5 mm • Outer diameter is Ø 70 mm
Photograph
Part Name Headlamp Assembly with bulb Headlamp Assembly with bulb

• Without blue tinge Headlamp & Position lamp •With blue tinge Headlamp & Position lamp
Description Note :- With bulb part number is given for Note :- With bulb part number is given for
demonstration purpose only. Use headlamp demonstration purpose only. Use headlamp
without bulb Y series part number for ordering without bulb Y series part number for ordering.

SAI PARTS
BS IV
18
19
16
15
14
17 6
7
4
3 10
12
8
9
5
1 7
13
11
2
Sr. No. Description Qty. Sr. No. Description Qty.

1 Assly SAI Pipe With Hose & Clamp 1 11 Hose SAI Unit To Airfilter 1
2 Bolt Flanged M6 x 16 1 12 Band Clip Sai Hose Outlet Tube 1
3 Bracket For SAI Pipe 1 13 Clamp Hose SAI 1
4 Bolt Flanged 2 14 Grommet Sai Unit 1
5 Unit SAI 1 15 Sleeve Sai Unit 1
6 Hose SAI Unit To Intake Manifold 1 16 Bolt Flanged 1
7 Clamp 1 17 Nut Hex Flanged 1
8 Clip Swivel Spacer 1 18 Bolt Flanged 2
9 Clamp SAI Pipe 1 19 Bracket SAI Unit Mtg - Loose 1
10 Hose Sai Unit To Exhaust Port 1

EVAP PARTS
BS IV
20 21
13
14 7
12
2
15
11
7
19
7
6
8 3 5 1
17
4
7
2
18 16
17 9
7
10
Sr. No. Description Qty. Sr. No. Description Qty.

1 Canister 1 12 Tube Canister To Connector 1
2 Strap Canister 1 13 Bracket Purge Valve Mounting 1
3 Bracket Canister Mounting 1 14 Grommet Purge Valve 1
4 Bolt - Flanged - Small 1 15 Valve Purge 1
5 Spring Band Clamp 9 x 8.4 2 16 Tube Canister Drain 1
6 Tube Y Connector To Canister 1 17 Spring Band Clamp 11.5 x 8.4 2
7 Spring Band Clamp 13 x 12 5 18 Tube Purge Valve To Carb. 1
8 Connector Y Shape 1 19 Tube Tank To Y Connector 1
9 Tube Connector To Plug 1 20 Evap Cap Rubber Bush Sealing 1
10 Plug Fuel Drain 1 21 Strap 1
11 Spring Band Clamp 15 x 10 1

CONTROL SWITCH RH H.T. COIL 1 H.T. COIL 2 COOLANT TEMP SENSOR DC CDI
OFF
ON
KILL
SWITCH
LHS RHS
SPARK SPARK
Service Station Manual

Br/L Gr/R
PLUG PLUG
B/W B/Y
H.T. COIL O/P 1
GROUND
PULSER INPUT
H.T. COIL O/P 2

BATTERY +VE
THERMISTER INPUT
B B/Y B/R B/Y

Br/L Gr/R
B
ELECTRICAL CIRCUIT DIAGRAMS
B/Y
B/R
B/W
W/R
Gr/R
Ignition Circuit + Tachometer Circuit
SPEEDOMETER
Gr/R Br
266
IGNITION SUPPLY PIN 2
B B 15A F2
ENGINE RPM PIN 12 Br Br/L
B/Y W
GROUND PIN 13
W W 20A F1 W/B
BATTERY + VE PIN 20
W/R B/Y
W/R B/Y
R B
IGNITION SWITCH
ON OFF + -
W W
Br Br/L
IL
L
PU
CO SING
Service Support MC
BS IV
MAGNETO ASSEMBLY VRLA BATTERY - 8Ah

SIDE STAND SWITCH

O/Br B/Y
Side Stand Indication Circuit
O/Br B/Y
SPEEDOMETER
Gr/R Br
267
O/BR O/BR 15A F2
SIDE STAND PIN 4 Br Br/L
B/Y W
GROUND PIN 13
W W 20A F1 W/B
BATTERY + VE PIN 20
R B
IGNITION SWITCH
ON OFF + -
W W
Br Br/L
Service Support MC
BS IV
VRLA BATTERY - 8Ah

BS IV
Battery Charging Circuit
VRLA BATTERY - 8Ah

B
-
R
+
W/B
FUSE
20A
W
CAPACITOR
L/W
L/W
REGULATOR UNIT
L/W
L/W
W
R
MAGNETO ASSEMBLY
L/W
Y
L/W

FRONT INDICATOR LAMP RH LIGHT CONTROL MODULE REAR INDICATOR LAMP RH
12 V, 10 W 12 V, 10 W
B/Y B/Y Gr Gr
Gr Gr B/Y B/Y

Side Indicator Circuit
B/Y O Br
SPEEDOMETER
Br Br
Gr Gr
RIGHT TURN INDICATOR PIN 7 REAR INDICATOR LAMP LH
G G 12 V, 10 W
LEFT TURN INDICATOR PIN 8
B/Y W G G
GROUND PIN 13
W
BATTERY + VE PIN 20
B/Y B/Y
269
IGNITION SWITCH
ON OFF Gr O G
Br 15A F2 Br/L
W W
Br Br/L W 20A F1 W/B
R B
Gr O G
+ -
FRONT INDICATOR LAMP LH
12 V, 10 W
R OFF L
B/Y B/Y
SIDE INDICATOR SWITCH
Service Support MC
G G
BS IV
(CONTROL SWITCH LH) VRLA BATTERY - 8Ah

CLUTCH SWITCH CONTROL SWITCH RH NEUTRAL SWITCH
OFF
START ON KILL
SWITCH SWITCH

R/Y Br/L
Starter Motor Circuit
LG
Y/G B/Y LG
R/W Br/L
Y/G B/Y LG
270
SPEEDOMETER
Br Br
LG LG Br 15A F2 Br/L
NEUTRAL INDICATOR PIN 11
B/Y W
GROUND PIN 13
W W 20A F1 W/B
BATTERY + VE PIN 20
R R/W Y/G
R B
R/Y B
IGNITION SWITCH M + -
ON OFF
W/B
W W
Br Br/L R R
Service Support MC
BS IV
STARTER MOTOR STARTER RELAY VRLA BATTERY - 8Ah

FUEL GAUGE LEVEL

Fuel Meter Circuit
B/Y W/Y
B/Y W/Y
SPEEDOMETER
Br Br
W/Y W
FUEL INPUT PIN 5
B/Y W/Y Br 15A F2 Br/L
GROUND PIN 13
271
W
BATTERY + VE PIN 20
W 20A F1 W/B
IGNITION SWITCH
R B
ON OFF
W W
Br Br/L + -
Service Support MC
BS IV
VRLA BATTERY - 8Ah

VEHICLE SPEED SENSOR
R/W R/W
B/Y B/Y
L/W L/W

Vehicle Speed Sensor Circuit
SPEEDOMETER
R/W
SPEED SENSOR SUPPLY PIN 1
Br
IGNITION SUPPLY PIN 2 Br Br 15A F2 Br/L
L/W
SPEED SENSOR INPUT PIN 6
B/Y W
272
GROUND PIN 13 W 20A F1 W/B
W
BATTERY + VE PIN 20
R B
IGNITION SWITCH
ON OFF
W W
+ -
Br Br/L
Service Support MC
BS IV
VRLA BATTERY - 8Ah

LIGHT CONTROL MODULE REGULATOR UNIT
TAIL LAMP
SPEEDOMETER
Lighting Circuit
B/Y B/Y

Gr/R Br R R
R/B R
HIGH BEAM PIN 3
B/Y W
GROUND PIN 13
R B/Y L/W Br L/W L/W
BACK LIGHT PIN 15
W Br V
BATTERY + VE PIN 20 L/W
R/Y
R/B NUMBER PLATE LAMP

B/Y B/Y
R R
L/W L/W L/W
IGNITION SWITCH
ON OFF
W W
273
Br Br/L
Br 15A F2 Br/L
R/Y Br V R/B
9 2 3 6
W 20A F1 W/B
L/W L/W
9 2 3 6
PILOT LAMP
Y/L
3W
R B
R/B
HEAD Y Y
LAMP PASS
SWITCH + -
R/Y
LO HI
R
HI / LO
PILOT LAMP SWITCH
Service Support MC
BS IV
3W CONTROL SWITCH LH MAGNETO ASSEMBLY VRLA BATTERY - 8Ah

Horn Circuit

IGNITION SWITCH
ON OFF
W W
Br 15A F2 Br/L
Br Br/L
W 20A F1 W/B
B B/Y
274
R B
B Br
B B/Y
+ -
HORN SWITCH
(CONTROL SWITCH LH) HORN LH VRLA BATTERY - 8Ah
Service Support MC
BS IV
FRONT BRAKE SWITCH
L L
L Br B/Y B/Y

Brake Lamp Circuit
BRAKE LAMP
L Br
IGNITION SWITCH
ON OFF Br 15A F2 Br/L
W W
275
W 20A F1 W/B
Br Br/L
Br L
R B
+ -
Service Support MC
BS IV
REAR BRAKE SWITCH VRLA BATTERY - 8Ah

SPEEDOMETER
Br Br
B/Y W
GROUND PIN 13
Br/G Br/G
OIL PRESSURE SENSOR PIN 19
W
BATTERY + VE PIN 20
Low Oil Pressure Indication Circuit
IGNITION SWITCH FUSE ASSEMBLY
ON OFF Br 15A F2 Br/L

W W
W 20A F1 W/B
276
Br Br/L
Br/G
B/Y
R B
+ -
OIL PRESSURE SENSOR VRLA BATTERY - 8Ah
Service Support MC
BS IV
CONTROL SWITCH RH DC CDI RADIATOR FAN RELAY
OFF
ON
KILL
SWITCH

Br/L Gr/R
GROUND
RAD. FAN RELAY O/P
BATTERY +VE
THERMISTER INPUT
RADIATOR
Gr/Y W Gr/R L/G FAN MOTOR
Radiator Fan Motor Circuit
Br/L Gr/R Gr/Y R

B/Y
L/G
B/W
Gr/R
B/Y B
SPEEDOMETER
Gr/R Br
277
B/Y B/W 15A F2 B/Y
GROUND PIN 13 Br Br/L
B/W W
COOLANT TEMP SENSOR PIN 17
W W 20A F1 W/B B/W
BATTERY + VE PIN 20
COOLANT TEMP SENSOR
R B
IGNITION SWITCH
ON OFF + -
W W
Br Br/L
Service Support MC
BS IV
VRLA BATTERY - 8Ah

BS IV
Bajaj Auto Limited

Tel +91 20 27472851
Fax +91 20 27407385
www.bajajauto.com

Ssmpulsar 200ns-As200 & 200ns Bs IV Rev 03, Aug17

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BS IV

DOC. NO. : 71111475 REV. 03 AUG, 2017

PULSAR 200 NS / AS 200 Service Support - M/C

Sr. No. Rev. No. Date (MM/YY) Reason for Change

PULSAR 200 NS / AS 200 Service Support - M/C

5 I Read ..... I Learn 19

6 I Check ..... I Maintain 37

8 Engine & Transmission 67

9 Frame & Suspension 121

11 Diagnosis & Troubleshooting 193

PULSAR 200 NS / AS 200 SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER

12 Supplementary SSM - Pulsar 200 AS 217

12.1 Technical Specifications 218

12.2 Preventive Maintenance Schedule 220

12.3 Imporatant SOP’s 222

12.4 Control Cable routing 241

13 Supplementary Service Station Manual - 242

DEALER DEVELOPMENT CENTER PULSAR 200 NS / AS 200 SERVICE STATION MANUAL

How to Use This Manual

2 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

o Precautions to be taken while handling MRTB Test

o Precautions to be taken while handling CO Gas Analyser

4 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

o Safety Precautions while Operating Air Tools

o Calibration of Workshop Equipment

o Avoid direct body contact with Petrol, Kerosene.

o Waste Oil Disposal

PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 5

o Precautions to be taken while handling Hydro-Electric Lift

o Brake Fluid Handling

6 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

Cleaning Vehicle before Disassembly

8 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

Arraignment and Cleaning of Removed Parts

Storage of Removed Parts

PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 9

Tightening Sequence Tightening

Liquid Gasket, Non-permanent Locking Agent

10 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

Ball Bearing and Needle Bearing

Oil Seal, Grease Seal

Circlips, Cotter Pins

PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 11

Direction of Engine Rotation

12 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

Safe Riding Tips

MONSOON CARE : Fit & Finish Parts

Daily Safety Checks

What to check Check for

14 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

What to check Check for

Drive chain 1. Proper slack (15~25 mm).

FUEL SAVING TIPS

PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 15

Preparation for regular use after storage :

Customer Education Points

16 DEALER DEVELOPMENT CENTER PULSAR 200 NS SERVICE STATION MANUAL

PULSAR 200 NS SERVICE STATION MANUAL DEALER DEVELOPMENT CENTER 17

Bajaj Genuine Parts

For optimum performance of vehicle