Bajaj PULSAR NS200 Manual Download

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Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

Servicing

Sr.

No.

Operation

1st

500

750

2nd

4500

5000

3rd

9500

10000

4th

14500

15000

5th

19500

20000

6th

24500

25000

7th

29500

30000

Kms

Remarks

Clean the vehicle with water wash & dry
completely

Ensure to prevent water entry in
Petrol tank, Silencer & electrical
parts.Use caustic free detergent for
washing.

Engine oil & engine oil
filter*

SAE 20W50 "API SJ" Grade

Replace at every 5000kms. And
top-up at every 2500 Kms (If
required).

Oil strainer

Oil strainer cleaning at the time of
oil change.

Spark plug

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

In line Paper filter or Fuel Cock paper filter

Fuel cock sediment bowl cleaning

Carburetor rubber duct

C,R

CL,C,R

CL,A

C,R

Fuel pipe

Valve tappet clearance

C,A

Summary of Contents for PULSAR NS200

Page 1: ...ke Fluid 32 22 Periodic Maintenance Lubrication Chart 33 23 Non Use Maintenance Notice The description and illustration in this booklet are not to be taken as binding on the manufacturers The essential features of the type described and illustrated herein remaining unaltered Bajaj Auto Limited reserves the right to carry out at any moment without being obliged to bring this booklet upto date to do...

Page 2: ...upply Engine Cooling Liquid cooling Starting Aid Electric starter Front Brake Hydraulic Disc type Rear Brake Hydraulic Disc type Fuel Tank Capacity Full 12 liters Usable Reserve 2 4 liters Unusable Reserve 0 2 liters Dimensions Pulsar NS Pulsar AS Length 2017 mm 2070 mm Width 804 mm 804 mm Height 1195 mm 1205 mm Wheel base 1363 mm 1363 mm Ground clearance 167 mm 167 mm Tyre Size Front 100 80 17 52...

Page 3: ...ype Side Indicator lamp 10W Neutral Indicator Green LED Hi Beam Indicator Blue LED Turn Signal Indicator Green LED Side Stand Indicator LED Speedometer Lamp LED Rear No Plate Lamp 3W Horn 12V DC Battery 12V 8 Ah VRLA Vehicle Kerb Weight 145 kg For NS 200 153 Kg For AS 200 Gross Vehicle Weight 275 kg For NS 200 283 kg For AS 200 Including rider pillion Max Speed 136 km hr 2 Technical Specifications...

Page 4: ...s to identify your particular vehicle from others of the same model and type Engine Number Location On LH Side Crankcase Near Gear Change Lever Alpha Numeric 11 Digits 3 Frame Number Location For NS 200 On RH Side of Steering Tube Alpha Numeric 17 Digits On LH Side of Steering Tube Alpha Numeric 17 Digits for applicable countries ...

Page 5: ...cycle They are the unique alpha numeric codes to identify your particular vehicle from others of the same model and type Engine Number Location On LH Side Crankcase Near Gear Change Lever Alpha Numeric 11 Digits 4 Frame Number Location For AS200 Below Pillion Seat Alpha Numeric 17 Digits ...

Page 6: ...Location of Parts Pulsar NS 200 Front Fork Clutch Lever Fuel Tank Cap Manual Choke Lever Pillion Foot Rest Side Stand Gear Change Lever Digital Speedometer Disc Brake LED Tail Lamp 5 OFF ON ...

Page 7: ...ulsar NS 200 Grab Handle Pillion Seat Rider Seat Rear Disc Brake Radiator Coolant Level Indicator Coolant Tank Cap Rear Brake Pedal Paper oil Filter Front Brake Lever Rear Number Plate 6 MAX MIN Nitrox Rear Shock Absorber ...

Page 8: ... Parts Pulsar AS 200 Grab Handle Pillion Seat Rider Seat Rear Disc Brake Radiator Coolant Level Indicator Coolant Tank Cap Rear Brake Pedal Paper oil Filter Front Brake Lever Rear Number Plate 7 Nitrox Rear Shock Absorber ...

Page 9: ...ck can be done on left side only To Unlock the Steering To unlock steering insert the key in steering cum ignition lock turn it clockwise to OFF or ON position Key A common key is used for Steering cum Ignition lock Fuel tank cap Rear Seat Steering cum Ignition Lock It has three positions LOCK Steering locked Ignition OFF OFF Steering unlock Ignition OFF ON Steering unlock Ignition ON 8 ...

Page 10: ...wise and lift fuel tank cap Fuel Tank Cap gets locked when pushed back into place Fuel Tank Cap Fuel Tap Fuel Tank Cap 9 Fuel Tap Fuel tap has following positions Fuel Tap ON When fuel level is above Reserve position RES When fuel level is below Reserve position OFF When fuel supply is to be cut off ...

Page 11: ...r When the transmission is in Neutral Neutral indicator will glow 5 Hi Beam Indicator When Headlight is ON Hi beam is selected with engine running Hi beam indicator will glow 6 charging 7 Low Oil Pressure Indicator It blinks when engine oil pressure is low 8 Coolant Temperature Indicator It blinks when 0 engine coolant Temperature is more than 115 centigrade 9 Bajaj Logo Bajaj logo flying B contin...

Page 12: ...It blinks continuously when petrol level in tank reaches reserve level 1 bar or less 11 RPM crosses 9500 RPM 12 Service Reminder Spanner symbol glows when ODO meter reading reaches set Kms for service This Icon will flash at st nd 1 450 km 2 4950 km rd th 3 9950 km 4 14950 km and subsequently at each 5000 kms Icon will continue to glow till it is reset This icon is to be reset after service is car...

Page 13: ...ter Reset Mode Set push button is provided for selecting resetting ODO TRIP1 TRIP2 LHS part of speedo console 1 Press Mode button for less than 2 sec Press Mode button for more than 15 sec Mode changes from ODO TRIP1 TRIP2 Selected mode TRIP1 TRIP2 will get reset Other TRIP mode will continue updating 2 Note Engine motorcycle speed should be zero Speedometer Setting 12 Mode Service Reminder TRIP1 ...

Page 14: ... than 1 sec Press Set button for less than 1 sec Press Mode Set button together for more than 2 sec Clock set Mode is selected no editing is carried out for more than 5 sec or Vehicle is started stops blinking Digits start blinking Hour digits will increase by one Minute digits will increase If Mode Set button is pressed continuously then digits will stop blinking Set value will be saved Exit cloc...

Page 15: ...while overtaking Left Handle Bar Switches A High Low Switch When headlight is ON High or Low beam can be selected with this switch Hi beam indicator light located on Speedo console will light up when high beam is selected High Beam Low beam B Turn Signal Switch When the turn signal knob is pushed to Left or Right respective indicator will start blinking to exit push the knob in release 14 ...

Page 16: ...starter when clutch lever is depressed with transmission in any gear It is recommended to start the engine with the transmission in neutral G Engine Kill Switch The engine kill switch is for emergency use During emergency move the engine kill switch to the OFF position Speedometer display will work when both Ignition switch kill switch are in ON position CAUTION While starting ensure that engine k...

Page 17: ...ated below the Rear seat 2 rubber straps are provided to hold the tool kit Removal of Rear Seat Insert Key into lock A Turn the key clock wise Pull front end of Rear seat Take out Rear seat CAUTION Always ensure rubber strap is fitted for securing tool kit 16 ...

Page 18: ...It is located below Front seat Battery details are given in Battery Maintenance page no 28 Removal of Front Seat First remove Rear seat Remove Front seat mounting bolts B Pull back rear end of Front seat Take out Front seat B 17 ...

Page 19: ...tch Front seat rear brackets C with the holes provided on chassis Tighten the bolts D Fitment of Rear Seat First make sure Front seat is fitted properly Place Rear seat in fitment location Insert bracket E of seat into hook F Match the rod of Front seat G with seat lock H Press front portion of seat Front seat lug bracket B A E F G H C D 18 ...

Page 20: ... cover as described above Otherwise the lugs may break Fitment of Side Cover LH or RH Match Lug D provided on front portion of Side Cover with hole C provided on Chassis and press Side Cover inside Match Lug E provided on rear portion of Side Cover with hole F provided on Chassis and press Side Cover inside Tighten the upper A lower B screw with screw driver Fit pillion rider seat CAUTION Fit cove...

Page 21: ...an adjustment of mirror Before riding motorcycle be sure to check following items Please give proper importance to these checks and perform all of them before riding motorcycle If any irregularities are found during these checks refer to the Maintenance chapter see your dealer for the action required to return the motorcycle to a safe operating condition Warning Failure to perform these checks eve...

Page 22: ...o next higher or lower gear Open the throttle and release the clutch lever slowly and simultaneously 3 Moving Off Check that side stand is up retracted Depress the clutch lever st Shift into 1 gear Open the throttle and release the clutch lever slowly and simultaneously As the clutch starts to engage open the throttle a little more giving the engine just enough rpm to prevent it from stalling Caut...

Page 23: ...sregard downshifting and concentrate on applying brakes as hard as possible without skidding 5 Stopping the Vehicle Close the throttle completely Shift the transmission into neutral Bring the vehicle to complete stop Turn the ignition switch off th th From 5 to 4 Gear th th From 6 to 5 Gear th rd From 4 to 3 Gear rd nd From 3 to 2 Gear nd st From 2 to 1 Gear 45 km h 54 km h 35 km h 25 km h 15 km h...

Page 24: ... free performance of the vehicle During first 2000 kms running in period do not exceed following speed limits Always keep the speed below the limits mentioned in the table Do not rev the engine excessively Do not start moving or rev the engine immediately after starting Run the engine for a minute at idle speed to give the oil a chance to workup into the engine Kms 1st 2nd 3rd 4th 5th 6th 0 1000 1...

Page 25: ... tank full up to small mouth brim Run the bike for say 100 km Fill the tank full again in same fuel filling station preferably from same fuel dispenser Divide kilometers run fuel quantity filled Ensure following maintenance points to get optimum performance from your bike Fuel Check fuel lines connections for leakage Spark Plugs Inspect and clean spark plugs Adjust electrode gap Replace spark plug...

Page 26: ...inted electrical electronic parts Do not obstruct engine cooling by adding mud protection sheet from front Safe Riding Tips Always wear Helmet while riding Your helmet should conform to appropriate Safety standards T h o r o u g h l y r e a d t h e instructions given in this manual and follow them carefully Avoid unnecessary accessories for the safety of both rider and other motorists Get familiar...

Page 27: ... level mark Engine Oil Capacity Refill at servicing 1200 ml During engine overhaul 1400 ml A B C D 26 Engine Oil Model Recommended Grade Pulsar SAE 20W50 API SL 200 NS AS Engine oil or JASO MA CAUTION It is most important to adhere to recommended grade frequency of oil change for the purpose of long life of critical engine components For details refer periodic maintenance chart Do not reuse draine...

Page 28: ...ly Do not use patch method to remove puncture of tubeless tyre Tyre Pressure Keep appropriate tyre pressure as mentioned below to increase life of the tyre for better fuel consumption Note Ensure tyres fitted comply with local rules and regulations governing tyres Front 25 PSI Pulsar 200 NS AS Rear Solo 28 PSI Rear with Pillion 32 PSI Front Wheel Removing Front Wheel Park vehicle perpendicular to ...

Page 29: ...How to keep battery healthy Switch Off ignition when engine is not running Get battery checked charged during periodic services Do not press starter button for more than 5 sec After 3 successive cranking wait for 15 20 sec for battery to recover Do not add extra electrical accessories such as Remote Bigger Horn Musical brake light etc This will reduce life of battery Disconnect battery ve ve wires...

Page 30: ...ow into compensating coolant tank C When the temperature falls this surplus coolant is sucked back into the cooling system Warning During motorcycle operation the coolant gets very hot is under pressure Do not remove the radiator cap radiator h o s e o r o t h e r c o o l i n g s y s t e m components when the engine is hot Allow the engine cooling system to cool down In case of exposure to hot coo...

Page 31: ...oto cool expert Castrol Radicool Total coolant quantity 1000 ml 750 780 ml in radiator 220 230 ml expansion tank Coolant Top up Park vehicle perpendicular to the ground on level surface as mentioned in page no 21 6 1 Check coolant level in engine cold condition only Ensure coolant level is between Min Max mark Always top up coolant through reservoir cap Always replace coolant with recommended bran...

Page 32: ...ct by bending outer electrode carefully Spark Plug Gap 0 7 to 0 8 mm Spark Plug 2 Nos RG 6HCC LH A RH B 1 No BOSCH VR5NE Center C 0 7 to 0 8 mm Drive Chain Slackness Chain slackness will have to be adjusted whenever required Std Chain slackness 15 25 mm Marking on chain adjusters should be identically positioned on both sides 30 C A ...

Page 33: ... rings Method of O ring Chain Lubrication Park vehicle perpendicular to the ground on level surface as mentioned in page no 21 6 1 Clean the chain by using lint free cloth If excessive mud slush found approach Bajaj Service Center for proper cleaning Shake the can vigorously by holding vertically upright till the noise of steel ball inside heard uniformly Hold spray can at the back of rear sprocke...

Page 34: ...face as mentioned in page no 21 6 1 with handle bar in straight ahead condition Always ensure that brake fluid level is above MIN mark given on inspection Window Brake Fluid Replacement Check Adjust brake fluid level in every service Change the brake fluid of the front rear brake according to service schedule Use only DOT 3 ro DOT 4 brake fluid from sealed container for top up replacement Front Br...

Page 35: ...s Use caustic free detergent for washing Engine oil engine oil filter SAE 20W50 API SJ Grade Replace at every 5000kms And top up at every 2500 Kms If required Oil strainer Oil strainer cleaning at the time of oil change Spark plug Air cleaner element cover O ring In line Paper filter or Fuel Cock paper filter Fuel cock sediment bowl cleaning Carburetor rubber duct C R R R R R R R R CL CL CL CL CL ...

Page 36: ...very15000 Kms Brake fluid level top up replace Use recommended brake fluid DOT3 DOT4 Disc brake assly Check functionality leakage or any other damage Replace if damaged All cables rear brake pedal free play CL L A CL L CL L CL L CL L CL L CL L Cl L A A A A A A A C R C R C R C L R C C L R C L R C L R C L R C L R C L R C R C R C R C R R C R C R R C A R C A R C C C C C A C A C A C A C A C A C A C A C...

Page 37: ...stand side stand pin Use recommended AP grease All fasteners tightness Engine foundation silent bushes General lubrication Clutch lever front brake lever Use recommended AP grease C A C A C A C A C A C A C A C A CL L CL L CL L CL L C C C L L L L L L L L C A C A C A C A C A C A C A C A C A C A C A C A C A C A C A C A C C C C C C C C T C T C T C T C T C T C T C T C CL C CL C CL C CL L R L R L R L R ...

Page 38: ...ommended to use specified grade only In case of any other engine oil of same specifications is used the frequency would be every 5000 kms As applicable to model More frequent cleaning is required while driving in dusty environment C Check A Adjust CL Clean R Replace T Tighten L Lubricate Note periodic parts lubricants as per periodic maintenance chart are mandatory the same is chargeable to custom...

Page 39: ...prevent rusting Avoid getting oil on rubber parts or brake liners Cover entire vehicle neatly Make sure that storage area is well ventilated free from any source of flames or spark Fill 10 excess air pressure in both wheels Do not apply oil on front brake disc to prevent rusting If the front brake disc rusts during storage do not attempt to clean it with soap water The rust will go off automatical...

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