Manual de Taller BAJAJ PULSAR 150 - 180 MANUAL TALLER 2017

Service Station Manual

’’’

All information contained in this Note 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.: 71110987 REV. 05, AUG. 17

Dealer

Development

Center

Service Station

Manual

N O T I C E

Service Support - M/C

Akurdi Pune

REVISION MATRIX

Pulsar RS 200

Service Station Manual

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

1 00 Aug / 2013 SSM developed for Pulsar 150 & Pulsar 180

2 01 Oct. / 2016 Addition of Supplementary SSM for Pulsar 135LS BS IV

Nov. / 2016

3 02

Dec. / 2016

Addition of Supplementary SSM for Pulsar 180 BS IV

Addition of Supplementary SSM for Pulsar 220 BS IV

March. / 2017

Addition of Supplementary SSM for Pulsar 150 BS IV

6 05

Aug. / 2017

SOP for Pulsar 220 BS IV :-

• Addition of SOP for checking magneto rotor on vehicle.

• Addition of Bajaj DTS-i 10W50 Synthetic oil as an alternate option.



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  

 

  

  

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 

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   

 ! "

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 %" &

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  !





! !'

" !

 ()

& " &)

 *+ , -  %

. !) &- -

/ (

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 +,)+ ()

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4

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2

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!"" ""

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#

& 6  *+ 

&,/1 " 

)"  &6  7

+ 

3

Pulsar 150/180 DTS-i

Service Station Manual

Dealer Development Center

Akurdi Pune

Frame & Suspension

157

Tightening Torques

Special Tools

Working of Nitrox Suspension

Service Limits

Control Cable Routing

SOP for Front Fork Dust Seal & Oil Seal Replacement

160

164

169

158

162

167

Electrical

213

Battery

Battery Dos & Don'ts

Starter Motor

Electrical Checking Procedures

SOP for Checking Charge Condition of Battery

230

218

234

214

232

Diagnosis & Troubleshooting

247

SOP for Steering Overhaul

SOP for Swing Arm Replacement

SOP for Caliper Piston Seal and Dust Seal Replacement

SOP for Dismantling & Assembling Front Fairing

Wiring Harness Routing

Sop for Master Cylinder Piston Kit Replacement

181

195

202

176

186

197

SOP for Front Brake Hose Replacement

SOP for Brake Fluid Replacement

209

207

Dos & Don'ts

Electrical Circuit Diagrams

240

237

Supplementary Service Station Manual -

Pulsar 135 UG + BS IV

249

Supplementary Service Station Manual -

Pulsar 150 UG + BS IV

285

Supplementary Service Station Manual -

Pulsar 180 UG + BS IV

324

Supplementary Service Station Manual -

Pulsar 220 UG + BS IV

360





       !"  #  $

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! "$"'

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'

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2  " $""   355 "$"% % $'

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$( "$%$'

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9") $"   

  $ * $ "%  , $" $ 5"

 $  $  $ (  $ 8

%$'  %"$$ : -  ") "  "!

$ "%$8  $  $  "%$ $

%$' % %$  $  $ ") %"4

, $# "! %"$$'

 1" -* ! " )$ %#$$" !"$"* $"

"%$ $ 1  $ $'

 0, "  $ 06  

 #"*  $ $%$"; )  !"") !

"$  $% %$%'



     

      

        



 %$"  #" $! % $%$" "

"% )%* ! "$ $%$  "#,* %" $

  $" " $%$" "! &$'

   !"

      

     

 %$  %"$" $ " )$ %$" $" $(

# " $ $ "! $ $$ " %$"  $

"% $ " #4$ $ !"")'

 "$ %$  -" ,) $$" "! $

 $ %""$  %""$'

 $ $$" " ) ! $ $%$"

%$ )% $ & %! $$ $"&*

"*  "  "%( $  # '

  

  



  

 

 



 

  

  

  

 

" %% $ $ " " +  " "$ # ,  ""'

" %% $  " "$%$, &$ <= ( 4 9

6",

 4 (

 4 !$  6"

 4  

" 0 $ ## 9 6", )  $"%% (

$"* * >" $%'

" %$" $" # $( )  3 $

 4 ( % $$ $ ,%  "  %  $ %

,%* "$) $   " #%( )$  !"%  % 5 $

'

 4 > "! %"" ) $( $$' $  ,  %  $" # $'

 4 "$ $ ,%  $ %$ "! $ "'

 4 1  " "$ $"% $ $ "! $ ,%* $   %

!'

 4 (  $" $ "  #") ) %"%$ $$ $" ," 

",$'

 4 "%( $ !"$ ) " 

 4  $$ -$ #")  '

 4 0 9$

 4 0  

"  %$" $" # $( )   6  

 4   ", !" "$%$" !" "$ %'

 4  ( !" "$%$" !" -$ '

 4  " ,$$"'

" 1 -$

 4 $ ?@ ",' 1 -$ 4    % '



 4 !   #!" $  -'



 4 $ "   %  $ "$ % " $$ $  "

 

"#$%$" : "" %%#$ '

" 9 ""

 4 7" "$  )" "$  $""'

" #$" "! 0"(" &$

 4 #$  0"("   +  &$ "%   '

" ," %$ #"  %"$%$ )$ $"* >"'

 $" A "" %"$%$ "!  "   % %%'

 " 0$ 7"

 4   " $" 6",$ ", 4% % %'

 4 "%$  "  " " : #'

 4 7"@$ $") " $" ) '

 4 7"@$  " " $ !""'

" !$  %$" ) $  ""

  $"" "$ " %"   #  $ "   $

<"" +     $='

 #, $ !"") !$  $ %$" )    $""'

 

2 $  ,# $" !$   $" <1A4 1$ $"



#%$"=  $ $%  )%    $" $ 



$""' $ $ $ "$$  $" BC'D >:% '  ," $

( "! " 5 '

 2 ,  $ #")  $" #") $ "!! " %"$  , "$

$ $  "'    % , $ $% $  '

 $% % $$ $" $ ! " ' 9  

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$  $'

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 2 , #")4% #( " %$% $'  %" $ #$" $

$% $" $  )%  ! $" ' < $% 

%%" 4 %  $" %='

 

  

  

  

 

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 4 ," %"$%$ "! #( ! )$ ('

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" %$% 0

 4   "$ "% %%( + 

 4 %$% #" + )$% $ # "%$ % $$

  $     %%#'

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" $ !$ #  $" ," %%$'

 4 !$  $ !$ # * "%( $ !$'

 4 7"@$ $ :  #$) )  : ") $!$ 3 '

 #  

 4 7" "$ ") $ !$ #  $# )$"$ "%( $ %% !$

"%('

 4 7" "$ ( "  #$) $ $"  #"$$" ! )

") $ !$ # '

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 4 7" "$ (  % 5"$ ""'

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 4 % %  $" # "$ $" ," 5 ! $  "  

$ #$)'

 4 > "!! %$ !  $ ") %('

 4 ," "  " $ )"(  !" !$  "'

 

  

  



  

 

 

2 3!" ,%



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  

  

  

 

 

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#$$  %# !" $ #$$  $" ,$ $  !" %%$ 

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<E=' 0 %"$ )$ $ ,%* !$ %"%$ $ "$, <E= %#

$" $ "$, <E= $ "! $ #$$  $ $ $, <4= %# $"

$ $, $'

  

 !$  " ,  $ ) ", $" ,$ 5  !" "#

  " $ $'

   

  $ ,% $""  #!" # ' 7$ " "$ !"

$ $ $"    ,% #  % %

-%, )  % !"% "! $ ,%'

    ! 

   $  $  !" $" "!  $'

"$" ,

!" !%

"

    ! "# $% & $ ' $ ( $ )



  

  

  

 

"  ! 

 !$  $ $ % ##  $ , # %*

$" $ $   % ' $  % %"$ " $% $ ",

$ $ $" "$%$ !"   !" $ $$   %"%$ #!"

# '

 #

  "$ % #  "  $ , "! # *

"),* ! #  "  ",  $ ,% * !"") $

"% ,'

! 

 %$ $ $ # 3FF  " %" # 

3FF' 6($* 4*  * 6 * % " "$$ 

$ # % )$ ) " ), #'

$

  "! )" "  $    $" " %%$'

  %$ ", $ !" %"""* %""$"* " "$

' ! $" $ "$ %$" "! $  !" ,%

$ " , $' % $ $ !     #

!" " ! $ $  # " $ ,% $'

$   %& 

 

  

  

  

 

 "%

 6 * ) $  $ )$ , #"$* $* " %)*

$$ $   $ "  $$ $ $"   !$'  $$

$ %%" $" $ %! &% $" ,$ % ) "

!"$" )% %  $" !%$"' ",  ) ""

$ #"$* $ " %)* !$ ""  "! $ #  #"$  &$ $

 $ ", $'

 %

 %"%$ $"&  $"  #"$* $* " %)    $" "

' $ !$ $" $ %! $"&   "" &$ 

$"& )%'

&

  %""   #   # * -%, !"%

% % -, "  $"  ' 0 % * ",

%) $$ ,  "4$ "%( $    %$

,'   $%4!% $ ), $  % '

'( #)

 9* (* "  "! #"$ ($  4 !$

#  % %  !"%' ", " ($ 

% $  !% $"  " $$ " ($ $ " "$

$ ' $ $ ) ($  % $  4

) 4#'

*% '( +) *' 

 1" %$" $$ & & ($ "  "4$ "%(

$* % $ !% " $$ " "   #!"  

& ($ " "4$ "%( $' 7" "$   $

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" '

(

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