Pulsar 135 LS User Manual

Foreword

Welcome to the Pulsar family! You are now the proud owner of the next generation Pulsar 135 LS, India's No.1 sports bike. By

No.1 we are talking about unparalleled performance, superior technology and incredible market leadership that Pulsar today enjoys. This makes the Pulsar you ride, unbeatable and unchallenged both on and off the road.

Before you ride out, please read this Owner's Manual carefully and familiarize yourself with the operating mechanism, controls and maintenance requirements of your Pulsar. This will ensure you a safe and trouble free ownership experience.

To keep your bike in perfect running condition and deliver consistent performance, we have specially programmed the periodic maintenance services which includes 3 free services and subsequent paid services, as per the schedule contained in this booklet. We earnestly advise you to avail all these services at any of our Bajaj Dealers or Authorised Service Centres, who are well equipped with all necessary facilities / genuine parts / oil and trained manpower to ensure the best care for your Pulsar. Your ‘Pulsar 135 LS’ comes with a warranty of 2 Years or 30,000 Kms whichever occurs earlier from the date of sale. For details please refer to “Warranty : Scope & Limits” given in this manual.

Should you require any additional information feel free to contact us on our toll free no.:

1800 233 2453 or e-mail us at: customerservice@bajajauto.co.in or visit the Bajaj Auto website www.bajajauto.com

To be a part of the Pulsarmania, visit www.mypulsar.com and join the Pulsar fanpage on facebook:

www.facebook.com/mypulsar

Rev up, shift gears and enjoy the Pulsar experience…

SERVICE DEPARTMENT BAJAJ AUTO LIMITED

Description

1. Technical Specifications 1

2. Identification Data 3

3. Location of Parts 4

4. Steering cum Ignition lock 6

5. Fuel Tank Cap / Fuel Tap 7

6. Speedometer Details 8

7. Control Switches 9

8. Removal & Fitment of Side Covers 11

9. Removal & Fitment Seat 13

10. Battery / Tool kit 14

11. Daily Safety Checks 15

12. How to ride your Bike 16

13. Safe Riding Tips 20

14. Engine Oil 21

15. Wheels - Tyre 22

16. Periodic Maintenance Information 23

17. Periodic Maintenance & Lubrication Chart 27

18. Warranty Certificate 32

19. Warranty Scope & Limit 33

21. Service Coupons & Non Use Maintenance

20 Battery Warranty Card

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 modifications on the vehicle, parts or accessories as may be co nvenient and necessary.

Safety and Warning information :

Table of Contents

Caution : This indicates that a potential ha zard th at co ul d re sult in vehicl e damage. Follow the Advice provided with the caution.

Warning : This indicates that a potential hazard or injury to you or other persons & to the vehicle can happen if advice provided is not followed.

Engine : 4 stroke DTS-i, Single

cylinder 4 valve (2 Intake & 2 Exhaust)

Natural air cooled.

Bore x Stroke : 54.0 mm x 58.8 mm

Eng. Displacement : 134.66 cc

Compression Ratio : 9.8:1

Idling Speed : 1400 RPM

Max. Net Power : 13.5 PS @ 9000 RPM

Max. Net Torque : 11.4 Nm @ 7500 RPM

Ignition System : DC, Digital CDI with

TRICS

Spark Plug (2 Nos) : CHAMPION, PRZ9HC

& BOSCH UR4AC

Spark Plug Gap : 0.6~0.7 mm

Lubrication : Wet sump, Forced.

Transmission : 5 speed constant

mesh.

Front Brake : Hydraulic operated 240

mm disc brake

Rear Brake : Mech. expanding shoe

130 mm dia. Drum

Fuel Tank Capacity :

Full : 8.0 liters

Reserve : 2.5 liters

Usable : 1.6 liters

Dimensions :

Length : 1995 mm

Width : 765 mm

Height : 1045 mm

Wheel base : 1325 mm

Ground clearance : 170 mm

Technical Specifications

Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without any notice.

Tyre Size Front : 2.75 X 17”, 41 P

Rear : 100/90 X 17”, 55 P

Tyre Pressure Front : 1.75 kg/cm

Rear (Solo) : 2.00 kg/cm

Rear (Pillion) : 2.25 kg/cm

Electrical System : 12 Volts DC Head Lamp : 35/35W Pilot lamp : 5W (2 nos.) Neutral : LED Reserve Indicator : LED Tail / Stop Lamp : LED Turn Signal Indicator : LED Side indicator Lamp : LED Hi Beam Indi. Lamp : LED Speedometer Lamp : LED Fuel Gauge : LED bar display Horn : 12V DC 2A Battery : 12V 5Ah MF

Technical Specifications

}

(inside cluster)

Rear No. Plate Lamp : 5W

Vehicle Kerb Weight : 122 kg.

Gross Vehicle Weight : 252 kg.

Max. Speed : 115 km /hr. (Wi th

single rider 68kg)

Identification Data

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

Frame Number Location

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

Engine Number Location

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

Location of Parts

Front Fork

Clutch Lever

Fuel Tank Cap

Nitrox Rear

Shock Absorber

Pillion Foot Rest

Side

Stand

Gear Change

Lever

Speedometer

Disc Brake

LED Tail

Lamp

Grab Handle

Centre Stand

Steering cum Ignition Lock

To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push & release the key. Turn the key to “LOCK” position and remove the key.

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’ & ‘Side cover lock’.

Steering cum Ignition Lock :

It has three positions.

LOCK: Steering locked. Ignition OFF.

OFF: Steering unlock. Ignition OFF.

ON: Steering unlock. Ignition ON.

Fuel Tank Cap

• To open the fuel tank cap, open the flap. Insert the key in the lock and turn it clockwise and lift fuel tank cap.

• ‘Fuel Tank Cap’ gets locked when pushed back into the place.

Fuel Tap

Fuel tap lever has following positions. 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.

Fuel Tank Cap / Fuel Tap

Fuel Tank

Cap

OFF

RES

FUEL

Fuel Tap

7. Reserve Indicator : It shows reserve position when

petrol left in the petrol tank is 2.5 ltr. Approx.

8. Neutral Indicator : When transmission is in Neutral

and Ignition switch ‘ON’, the Neutral indicator is lit.

9. Trip Meter Reset Button : Trip meter can be reset

to zero by pressing the button.

10. Trip Meter : The Trip meter shows the distance

travelled since it was last reset to zero.

11. Battery Indicator : Shows battery charge condition.

This icon means battery is in charged condition. Pop-up of this iocon means battery is in low charged

condition.

LOWLOW

Speedometer Details

1. Speedometer : The vehicle speed is displayed in

digit.

2. Fuel Level Indicator : Shows available fuel in tank.

3. Tachometer : It shows the engine speed in RPM.

4. Odometer : It shows cumulative reading of total

distance covered by vehicle in Km.

5. Turn Signal Indicator (LH & RH) : When Turn signal

switch’s knob is turned to Left or Right, Turn pilot indicator - LH or RH will flash.

6. Hi Beam Indicator : When Headlight is ‘ON’ & Hi

beam is selected with engine running, Hi beam indicator will be lit.

Control Switches

C. Horn Button : ( ) Press button for

sounding horn.

D. Pass Switch : Press the switch to flash

the head light. It is used to give signal to vehicles coming from opposite side while overtaking.

Left Handle Bar Switches

A. Dipper Switch : When headlight is ON,

High or Low beam can be selected with the dipper 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 turned to Left ( ) or Right ( ) respective indicator will start blinking, to stop blinking push the knob in & release.

Right Handle Bar Switches

E. Head Light Switch : It has 3 positions.

: All lamps 'OFF'.

: While engine running, Tail lamp and

Pilot lamps ‘ON’.

: While engine running, Headlamp, Pilot

lamp, Tail lamp, Meter lamps ‘ON’.

transmission in any gear. It is recommended to start engine with 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.

Control Switches

F. Starter Button : It operates the electric

starter when clutch lever is depressed with

CAUTION : While starting ensure that engine kill switch is in ON ( ) position. Keeping the kill switch in OFF position Engine will not start.

Removal & Fitment of Side Cover LH / RH

CAUTION : Remove cover as described above, Otherwise the lugs may break.

Fitment of Side Cover LH

• Match slot provided on rear portion (C) of ‘Side Cover LH’ with the bracket located on chassis & Slide (C) backward.

• Match Lug (B) provided on front portion of ‘Side Cover’ with the rubber grommet hole provided on ‘Fuel Tank’. Press in the cover.

• Match the ‘Side Cover Lock’ (A) properly with the bracket provided on ‘Holder step LH’ and Lock the ‘Side Cover’.

Removal of Side Cover LH

• Insert the key into the ‘LH cover lock’ (A) and turn the key clockwise.

• Hold the cover with both the hands and pull front portion (B) of the cover. Slide rear portion (C) forward. Take out ‘LH Side cover’.

Rubber Grommet

Bracket

Removal & Fitment of Side Cover LH / RH

Fitment of Side Cover RH

• Match slot provided on rear portion (C) of ‘Side Cover LH’ with the bracket located on chassis and slide (C) backward.

• Match Lug provided on front side (B) of ‘Side Cover’ with rubber grommet hole provided on ‘Fuel Tank’ and press in ‘Side Cover RH’.

• Match ‘Side Cover’ properly with bracket provided on ‘Air filter assly’ and fix it with Screw (A).

Removal of Side Cover RH

• Remove the screw (A) securing the ‘Side Cover RH’.

• Hold the cover with both the hands and pull front portion (B) first. Slide (C) forward. Take out ‘Side cover RH’.

CAUTION : Fit cover as described above to ensure proper fitment.

Rubber Grommet

Bracket

Removal & Fitment of Seat

Removal of Seat - Rear

• Remove ‘Side Cover’ LH.

• To remove Seat Rear, pull the ‘Seat Release Cable’ (A) shown in fig. 1 to release seat lock. Keeping cable pulled, tap the center of seat, lift the seat from rear end and slide it towards tail lamp to remove seat.

Fig. 1 Seat release cable

Fig. 2 Seat mounting bolt

Removal of Seat - Front

• Remove ‘Side Cover’ LH.

• Remove ‘Seat Rear’.

• To remove Seat Front, remove bolt (B) shown in fig. 2

• Lift the seat from rear end and slide it towards tail lamp to remove seat.

CAUTION : Always remove Rear seat first.

Removal & Fitment of Seat

Fitment of Seat - Front

• For fitment of Seat Front, match & insert the bracket (‘1’ of Fig. ‘A’) of seat with slot (‘2’ of Fig. ‘A’) provided below fuel tank rear mounting on chassis. Push seat towards fuel tank.

• Then press the seat at rear from top to align lock bolt (‘3’ of Fig. ‘B’).

• Tighten the lock bolt.

Fitment of Seat - Rear

• For fitment of Seat Rear, match & insert bracket (‘4’ of Fig. ‘C’) of seat with bracket (‘5’ of Fig. ‘C’) provided on chassis.

• Push seat towards fuel tank & align lock rod (‘6’ of Fig. ‘C’) & seat lock (‘7’ of Fig. ‘C’).

• Then press the seat in middle from top to lock the seat.

Fig. A Fig. B Fig. C

CAUTION : Always fit Front seat first.

Battery / Tool Kit

Tool Kit Location

• It is located below the battery.

Battery

• It is located inside the ‘Side Cover’ LH.

• Always maintain electrolyte level in each

cell between max and min level lines.

• Always keep a watch on battery charge level indicating icon, if it flashes (indicates battery is in low charged condition), show the vehicle to authorised BAL dealer.

CAUTION : Do not drive/run vehicle in battery disconnected condition. It may lead to damage of electrical / electronic components.

CAUTION : Insert tool kit properly in compart ment p ro vided on air filte r assembly for proper fitment of ‘LH’ side cover.

TOOL KIT

BATTERY

Daily Safety Checks

• Brake Pedal Play - 20 to 30 mm.

• Wear lining Indicator within usable range. No brake dragging, applicable to drum brake vehicles.

• Bra ke Flu id lev el abo ve MIN m ark provided on reservoir, applicable to disc brake vehicle.

• Drive Chain slack of 25 to 30 mm adequately lubricated.

• Function of all lights & horn

• Clutch lever play - 2 to 3 mm

• Smoot h st eerin g mo vemen t wi thout restriction.

• Both stand return to their fully up position.

• Correct inflation pressure in both tyres Adequate tyre tread depth - no cracks / cuts.

• Correct rear viewing span 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 every day before you ride may result in serious damage or severe accident.

• Enough fuel level for planned distance of journey. No fuel leakage in fuel lines.

• Engine oil level (between upper and lower level mark)

• Throttle cable play of 2 ~ 3 mm. Smooth operation and positive return to closed position,

How to Ride Your Bike

Starting The Engine :

• Turn the fuel tap knob to ‘ON’ or ‘RES’

position.

• Switch ‘ON’ ignition & ‘Kill Switch’

• Confirm that transmission is in neutral.

• Fold R.H side rider footrest.

• Keep throttle completely closed, press

starter button “ ” / apply kick to start the engine.

• Release starter button / kick lever as soon as engine starts.

• Open R.H side rider footrest back to its position.

Warning : During kick starting if rider footrest is not folded, kick lever hits the footrest a nd severe jerk wou ld get experienced at foot. Also rider step holder would get damaged due to impact.

Moving Off :

• Check that Center/Side stand is up.

• Depress the clutch lever.

• 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 keep it from stalling.

Caution : Do not operate the starter continuously for more than 5 seconds otherwise battery would get discharged. Wait 15 sec. between each operation of the starter which will facilitate battery to recover.

Note : Do not let the engine idle longer than 3

minuets otherwise it will overheat.

Note : The motorcycle is equipped with a starter lockout switch. This switch ensures that engine does not start if the transmission is in

gear.

However, the engine can be started in any gear if the clutch lever is pressed.

Before starting the engine, in ignition key

off condition, press the clutch lever & operate kick starter lever all the way down for 5-6 times. Then release the clutch lever.

This practice ensures lubrication of clutch components for their longer life.

Note :

Braking :

• Close the throttle completely, leaving the

clutch engaged (except where shifting gears) so that the engine braking will help slow down the motorcycle.

• Shift down one gear at a time so that you

are in Neutral when you come to a complete stop.

• When stopping, always apply both brakes at

the same time. De-clutch as necessary to avoid engine stalling.

• Never lock the brakes, or it will cause the

tyres to skid. When cornering, use brakes judiciously & do not de-clutch. Reduce your speed before you get into the corner. For emergency braking, disregard downshifting, and concentrate on applying brakes as hard as possible without skidding.

th th

From 5 to 4 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

35 km/h

25 km/h

15 km/h

Recommended Speed for Shifting Down

Warning : When shifting down to lower

gear, do not shift at such high speed that engine rpm jumps excessively. This may cause engine damage, & rear wheel may skid. Downshifting should be done at recommended speeds as shown in table.

How to Ride Your Bike

Shifting Gears :

• Close throttle & depress the clutch.

• Shift into next higher or lower gear.

• Open the throttle and release the clutch lever slowly and simultaneously.

Gear Shifting

Pattern

Gear Shifting Lever

Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

Parking the Vehicle :

• Support the motorcycle on a firm level surface with the center or side stand.

• Lock the steering.

Running IN

Proper running-in is important for the better life & trouble 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 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 workup into the engine.

How to Ride Your Bike

CAUTION : Do not park on a soft or steeply inclined surface or the motorcycle may fall over.

Kms 1st 2nd 3rd 4th 5th

0 - 1000 14 22 31 38 45 1000 - 2000 19 31 43 52 62

How to Ride Your Bike

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.

Good Riding Habits :

• Ride smoothly and steadily at an optimum driving speed of 40 to 50 Km/h

• Avoid harsh braking.

• Change the gear judiciously according to the speed and load 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.

How to check mileage (Fuel efficiency)

Best way to calculate mileage is by following the full tank to full tank method.

• Fill way tank full up to small mouth (brim).

• Run the bike for say 100 km.

• Fill the tank full again in same fuel filling station, probably with same fuel dispenser.

• Divide kilometer run / fuel quantity filled.

Fuel Check fuel lines & connections

for leakage.

Spark plugs Inspect and clean spark plugs.

Adjust electrode gap.

Air filter C l ea n a i r f i lt e r e l e m en t

periodically.

Engine oil Check level. Use recommended

grade and quantity.

Brakes Ensure that the brakes are not

dragging / binding.

Clutch Ensure correct clutch lever play.

Tyre Always maintain recommended

Pressure. tyre pressure.

Carburettor Clean & adjust the carburettor.

Adjust idling speed.

Ensure following maintenance points to get optimum fuel efficiency from your bike.

Optimum Shifting Speeds for best mileage

1st gear : 0 km/h 2nd gear : 15 ~ 18 km/h 3rd gear : 24 ~ 27 km/h 4th gear : 33 ~ 36 km/h 5th gear : 41 ~ 44 km/h

Safe Riding Tips

• Drive cautiously. Start early & reach your destination

safely.

• Always carry vehicle registration & insurance papers,

and a valid driving licence with you.

• Avoid driving on loose sand or stones where vehicle

is likely to skid.

• Properly wrap-up loose clothes while driving or riding

to avoid entangling in wheel or other objects on road.

• Always concentrate on riding for safety.

Monsoon Care :

• It is suggested to customer to take appropriate care

in area of heavy monsoon or high rainfall area. The appropriate surface preventive coat to avoid rusting / poor surface finish on account of adverse atmospheric conditions.

• Vehicle cleaning to be done with soft & clean wet

cloth to avoid scratches on painted parts.

• Clean & lubricate all the important parts as detailed in

a periodic maintenance chart.

• Do not apply direct water jet on painted, electrical /

electronic parts.

• Do not obstruct engine cooling by adding mud

protection sheet from front.

Safe Riding Tips

• Always wear Helmet while driving or riding. Your

he lmet should conform to appropriate In di an standards.

• Read thoroughly the instructions

given 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 & regulations in

your states as well as general traffic signs.

• Familiarise yourself well with starting, acceleration and

braking of the vehicle.

• When applying the brakes, use both front & rear

brakes simultaneously. Applying only one brake may cause the vehicle to loose control.

• Riding at proper speed and avoiding unnecessary

acceleration and braking are important not only for safety and low fuel consumption, but also for longer life of the vehicle.

• During monsoon drive the vehicle more cautiously.

Remember vehicles skid more easily during light showers.

Engine Oil

A : Oil Filler Cap B : Oil Level Gauge

Engine Oil Level Checking :

• Check engine oil level every day. Park vehicle on level surface on center stand.

• Check oil level through oil level gauge ‘B’.

• Always maintain engine oil level between upper (C) and lower (D) mark provided on Cover RH. Top up with specified grade of oil if the oil level is below lower level mark.

Engine Oil Capacity :

• Refill at servicing : 1000 ml.

• During engine overhaul : 1100 ml.

Recommended Engine Oil:

Always insist on Bajaj Genuine Engine Oil for optimum engine perf orma nce a nd warr anty ben efit s. It is a spec iall y formulated oil for vehicles with DTS-i engines.

Model Recommended Grade

Engine oil

Pulsar Bajaj DTS-i SAE 20W50 API 135 LS 10000 ‘SL’ or JASO ‘MA’

• Engine oil replacement frequency : 1 service & then every 10,000 Km.

• Engine oil level top-up frequency : Every 5000 km.

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 drained oil.

Wheels - Tyre

Use the recommended levers while removing the Tyre / Tube for puncture work. This will avoid any damages to the edges / scratches on paint of the wheel.

Tyre Pressure :

Keep appropriate tyre pressure as mentioned below to increase life of the tyre & for better fuel consumption.

Note : Incase the motorcycle is fitted with imported tyres. compliance to respective indian standard & central motor vehicle rules has been ensured.

Front 1.75 kg/cm

Rear (Solo) 2.00 kg/cm

Rear(with Pillion) 2.25 kg/cm

Front Wheel

Pulsar 135 LS

Periodic Maintenance Information

Front Brake Fluid Level :

• Front brake fluid reservior is located on RH side of Handle bar.

• To check oil level, keep the vehicle on center stand with handle bar in straight ahead condition.

• Always ensure that brake fluid level is above ‘MIN’ mark given on inspection Window.

Battery

• Battery type : 12V 5Ah

• Battery Warranty : 18 months from date of purchase.

• Add only distilled water to the battery if battery electrolyte level is below min. level mark.

Max

Min

CAUTION : Tap water is not a substitute for distilled water and will shorten the life of the battery.

Min. Level

Periodic Maintenance Information

• When battery is found discharged, it is advised to get it charged immediately.

• Environ ment c are mu st be taken to dispose off the used battery. It is always recommended to hand over the same to the Authorised battery / Bajaj dealer for proper disposal of the same.

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

• If vehicle is to be stored for more than 2 weeks disconnect battery to avoids self discharge.

CAUTION :

• While disconnecting always disconnect negative (-ve) cable first.

• While refitting always connect positive (+ve) cable first.

Periodic Maintenance Information

Spark Plug

• Rem ove spa rk plu gs b y using p lug spanner.

• Clean the spark plugs.

• Adjust the gaps if incorrect by bending outer electrode carefully.

Spark Plug Gap : 0.6 to 0.7 mm.

Spark Plug (2 Nos.) : BOSCH OR

: CHAMPION

0.6 to

0.7 mm

Drive Chain Slackness

• Chain top edge to be kept between the two mark s d u r i ng chain s l a c kness adjustment.

• Chain slackness will have to be adjusted whenever required.

• Std. Chain slackness 25 ~ 35 mm.

• Marking on chain adjusters should be identically positioned on both sides.

Std. Chain slackness : 25~35 mm

Periodic Maintenance Information

Drive chain must be cleaned & lubricated as

per periodic maintenance schedule.

a. Drive chain (Non O-ring type)

• Non O-ring type chain should be removed & cleaned by Nylon brush & Kerosene or in Chain Cleaning Machine.

• It should be lubricated by SAE 90 grade oil.

b. Drive chain (O-ring type)

• ‘O’ rings must always be kept wet for best performance hence lubricate every 500 Kms

• O-ring chain lubrication can easily be done by owners using Bajaj ‘Chain Lube Spray Can’ available with Bajaj dealers.

Method of O-ring Chain Lubrication :

• Place the bike on centre stand.

• Clean the chain by using lint free cloth (If excessive mud / slush found approach Bajaj Service Center for proper cleaning)

• Shake the can vi go ro us ly by holding vertically upright till the noise of steel ball inside heard uniformly.

• Hold spray can at the back of rear sprocket with extension tube nose at 5~10 cm.

• Rotate the wheel in reverse direction & spray the lube on middle portion of the chain up to full length of the chain.

Drive Chain Cleaning

Drive Chain Lubrication

Periodic Maintenance & Lubrication Chart

1st - 500~750 Kms / 30~45

1. Servicing 3 3 3 3 3 3 3 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 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

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

Subsequent

Periodic Maintenance & Lubrication Chart

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,A C,A C,A C,A C,A C,A C,A

24. Battery electrolyte level & specific gravity** C 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

500

750

4500

5000

9500

10000

14500

15000

19500

20000

24500

25000

29500

30000

RECOMMENDED FREQUENCY

Servicing

Sr.

No.

Operation

1st

2nd

3rd

4th

5th 6th

7th

Kms

Subsequent

Periodic Maintenance & Lubrication Chart

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

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

500

750

4500

5000

9500

10000

14500

15000

19500

20000

24500

25000

29500

30000

RECOMMENDED FREQUENCY

Servicing

Sr.

No.

Operation

1st

2nd

3rd

4th

5th 6th

7th

Kms

Subsequent

Periodic Maintenance & Lubrication Chart

500

750

4500

5000

9500

10000

14500

15000

19500

20000

24500

25000

29500

30000

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

RECOMMENDED FREQUENCY

Servicing

Sr.

No.

Operation

1st

2nd

3rd

4th

5th 6th

7th

Kms

Subsequent

Periodic Maintenance & Lubrication Chart

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

* 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

500

750

4500

5000

9500

10000

14500

15000

19500

20000

24500

25000

29500

30000

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

RECOMMENDED FREQUENCY

Servicing

Sr.

No.

Operation

1st

2nd

3rd

4th

5th 6th

7th

Kms

Subsequent

Warranty Certificate

FRAME NO. :

ENGINE NO. :

Registration No. :

Sold on (DD / MM / YY)

To the Customer’s Mr/Mrs/Miss :

Address :

Contact No.:

By the Dealer M/s :

Address :

Contact No.:

SAP Code :

The vehicle is warranted for 2 Years or 30,000 Kms. whichever occur earlier from the date of sale as per terms & conditions given in Warranty : Scopes and Limits.

SERVICE DEPARTMENT

BAJAJ AUTO LIMITED

Warranty : Scope & Limit

Bajaj Auto Limited gives the following warranty in respect of the motorcycle manufactured by them.

Every possible care and precaution has been taken to ensure quality in respect of the material & workmanship in the vehicles manufactured by us. Bajaj Auto Limited will repair or replace at their Authorised Workshops, free of charge, part or parts there of as may be found, on examination, to have manufacturing defect within a period of 2 Years or 30,000 Kms., whichever occurs earlier from the date of sale subject to fulfillment of condition stipulated in part A, B & C given here under

Warranty is applicable for only first owner of vehicle.

Part A:

Warranty claims in respect of such items like shock absorbers, speedometers etc. though claimed through us, are subject to acceptance of the respective manufacturers. In all such cases the decision of the respective manufacturer will be final and binding.

Proprietory parts like tyres, tubes, battery and spark plugs are warranted by their respective manufacturers (Only one year warranty from the date of purchase/as applicable) and should be claimed on them directly by the customer. Bajaj Auto Limited shall not be Liable to replace them

“Pulsar 135 LS”

though their dealer will give full assistance in preferring such claims.

Bajaj Auto Limited undertake no liability in the matter of consequential loss or damage caused due to the failure of the parts. Delay, if any, at the repairing workshop in carrying out repair to vehicle shall not be a ground for extending the warranty period, nor shall it give any right to the customer for claiming any compensation for damages.

Bajaj Auto Limited reserves the right either to repair or replace the defective parts.

Where a defective part can be replaced by part/s of alternative brand/s, which are normally used by Bajaj Auto Limited in the course of manufacture, Bajaj Auto Limited reserves the right to carry out the replacement by a part or parts of any such alternative brand/s.

This warranty and any claim arising there from is subject to Pune jurisdiction only.

Part B:

No claim for exchange or repair can be considered unless the customer :

a. Ensures that immediately upon detection of the

defect, he approaches any nearest Authorised Bajaj Vehicle Dealers & Recommended Authorised Service Centers with the concerned vehicle and enables him

to remove and despatch the part / parts attributing to the manufacturing defect to the Company.

b. Produces the Owner's Manual, in original, to enable

that dealer to verify the details. It must be expressly understood that claims forwarded directly to us by the owner / customers will not be entertained at all and such defective part/parts thus forwarded by them will lie at our factory at their own risk, and this warranty shall not be enforceable.

To avail benefits of warranty, following are mandatory

1. Availing of Initial 3 Free Services without lapse.

2. Availing 4 paid services at every 5000 kms. or 120

days whichever occurs first without any lapse.

3. Availing of all above services at the Authorised

Vehicle Dealers & Recommended Authorised Service

Centers.

4. Maintaining all service records duly signed and

stamped by dealers.

Usage of only recommended engine oil

at specified frequency for drain

interval of 10,000 kms. & engine oil level top-up at

5000 kms.

6. Replacing mandatory periodic parts such as air filter,

oil filter etc. as per periodic maintenance schedule.

“Bajaj DTS-i 10000”

Part C :

Further this warranty is NOT applicable to :

1. Normal maintenance operations like brake & clutch adjustments, cleaning of fuel system, engine tune-up or such other adjustments.

2. Parts subjected to normal wear & tear like Clutch Plates, Brake Shoes, Chain, Sprockets, Fork Oil Seal, Spark Plug, Control Cables, Brake Pads.

3. Replacement of electrical items like self-start’s wear and tear items (if fitted), bulbs & rubber components like grommets, ‘O’ rings, bellows as well as filters, packings, gaskets, fasteners etc.

4. Painted parts. Only blistering or peeling off of paint film are covered under warranty. Any defect arising out of external damages or due to usage of protective covers /additional protective coatings adverse atmospheric condition etc. is not allow like under warranty.

5. All consumables like Engine oil, Fork oil, Brake Oil, Grease etc. are chargeable to customer.

6. Any defect arising due to above consumables not changed as per scheduled or if used other than the recommended one.

Warranty : Scope & Limit

7. All chrome plated parts are prone to rust or corrosion in coastal area or in acidic environment or due to neglected cleaning etc. However chrome film peeling is covered under warranty in general atmospheric conditions. Blue/ Yellow colouration of silencer near exhaust port is permissible and hence not covered under warranty.

8. Oxidation of unpainted/painted crankcase, cylinder block, cylinder head etc. in acidic environment or in a coastal area.

9. Valve lapping (De-carbonizing) if required to be done at 20,000 km, which is normal servicing requirement.

10. Parts of the vehicle that have been subjected to misuse, accident, negligent treatment OR which have been used in conjunction with parts & an equipment not manufactured or recommended for use by Bajaj Auto Limited, if in the sole judgement of Bajaj Auto Lim ited , suc h use p rema tur ely af fect s the performance and reliability of the vehicle.

11. Parts of the vehicle that have been altered and modified or replaced in unauthorized manner like use

of wider tyres, loud silencers etc and which in the sole judgement of the Bajaj Auto Limited affects its performance and reliability.

12. Vehicles which are not being serviced at

recommend ed dea lers a s p er the servi ce schedule described or which have not been operated or maintained in accordance with the instructions maintained in the Owner’s Manual.

13. Vehicles used for any competition or race and/or for attempting to set up any kind of record.

14. Any failure arising due to use of adulterated or bad quality fuel.

Parts affected due to bad fuel quality are not covered Under warranty.

15. If additional electrical accessories such as - Remote, Bigger horn, Musical brake light etc. fitted on vehicle.

Bajaj Auto Limited reserves the right to make any changes in design or to add any improvements on the vehicle at any time without incurring any obligation to install the same on a vehicle previously supplied and sold. Also, the conditions of this warranty are subject to alteration without any notice.

This warranty is the entire written warranty given by Bajaj Auto Limited for motorcycle’ and no other ealer or its or his agent or employee is authorised to extend or enlarge this warranty.

“Pulsar 135 LS”

Warranty : Scope & Limit

SERVICE RECORD

Sr.

No.

Date

Age

Mths.

Specific

Gravity

Voltage

Remarks

Dealer’s Stamp

& Signature

* Code

BATTERY WARRANTY CARD

MAKE OF BATTERY : ........................

MFG. CODE OF BATTERY : SR.NO.:

TYPE OF BATTERY : DATE OF SALE :

NAME OF OWNER AND ADDRESS :

TYPE OF VEHICLE : REG. NO.:

FRAME NO.: ENGINE NO.:

* Code For Remarks: LL : Low electrolyte level. AE : Electrical system needs attention. IR : Insufficient running of vehicle. CB : Cover broken. BC : Broken Container. PM : Poor maintenance. BA : Battery abused.

Note : Customer should insist that “Service Record" must be filled by respective authorised battery dealer as proof of specified maintenance for easy settlement of claim, if any.

Details of Repair, if any____________________________________________________________________________ Note: Please contact nearest respective authorised battery dealer for details immediately after purchase of

vehicle.

Name of Dealer & Code :__________________________________________________________________

__________________________________________________________________________________________

Date of claim :________________________________________________Battery Type :_______________

Serial No. :__________________________________________________Date of Fitment :______________

TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS

IN CASE OF CLAIM

# Claim Accepted

## Claim Rejected

Failure Mode (Please tick as applicable)

• Loose connection • Overcharge / Undercharge

• Internal Short • Reverse Charge

• Plate Shedding • High Specific Gravity Electrolyte

• Intercell Connection • Electrolyte Contamination

• Does not Hold Charge • Electrolyte Level not Maintained

• Wrong Assembly • Left Lying Idle

• Wrong Application

• Terminal Corroded

Free Service

Owner's Name :

Frame No. :

Engine No. :

Date of Date of Kms. Sale : Service : Run :

Periodic Part Replacement : Paper oil filter *

Oil used for Replacement / Top Up: Bajaj Genuine oil Servicing Dealer

(Dealer’s name & Code no.)

Valid for 500 to 750 Kms or 30-45 Days.

(From the Date of Sale whichever occurs earlier)

Availing all Free / Paid Services, replacing mandatory

periodic parts & engine oil will entitle warranty eligibility.

This coupon entitles for jobs as per list overleaf. (Refer Periodic Maintenance Chart) IMPORTANT: Replace Engine oil (Qty 1000 ml.) ‘Bajaj DTS-i 10000’ oil for drain interval of 10000 Kms Cost of Engine oil, consumables & Periodic Parts are chargeable to Customer.

FREE

* if applicable* if applicable

Servicing Dealer

Date ----------------------------------

Kms. ----------------------------------

• Bajaj Genuine Oil used for Replacement Yes No

Mandatory Periodic Part Replacement

• Paper oil filter*

Warranty : Continued

Warranty : Terminated

Warranty is null or void

if Bajaj Genuine Oil &

Mandatory periodic

parts are not replaced

Free Service

1st Free Service (500-750 Kms.)

1. Wash the vehicle.

2. Replace engine oil (Bajaj DTS-i 10000)

3. Replace engine oil filter.

4. Clean oil strainer / Body centrifugal filter.*

5. Clean air filter element.

6. Check all fuel pipes.

7. Clean & adjust spark plugs gap.

8. Check & adjust valve tappet clearance.

9. Check and top up coolant level in expansion tank.*

10. Check and adjust chain slackness. Lubricate drive chain ('O' ring chain* at every 500 Km)

11. Check brake linings* or pad wear*, replace if required.

12. Check & top up brake fluid level.*

13. Check & adjust clutch, accelerator, brake free play*, steering play.

14. Check & adjust rear brake switch.

15. Check & tighten the front & rear spokes*

16. Check & tight Nuts, Bolts, Fasteners & Rear wheel sprocket to the recommended torque.

17. Lubricate specific points.

WORK IS CARRIED OUT TO MY SATISFACTION.

Owner’s SignatureWorkshop Incharge

18. Check Battery voltage, route cables & fit terminal caps properly, clean terminals & apply Petroleum Jelly.

19. Check electrolyte level and top up if required with distilled water.*

20. Start engine, check & adjust horn & all lights for proper functioning.

21. Check oil pressure indicator on speedo console.*

22. Check & clean ignition switch contacts.

23. Check & adjust gap between reed switch & TPS magnet.*

24. Check & adjust idling and CO%. Tune engine & carburettor if required.

25. Carry out any additional work if required.

26. Check & Adjust air pressures in the tyres.

27. Test ride the Vehicle.

28. Clean the vehicle at the time of delivery.

Owner's Name :

Frame No. :

Engine No. :

Date of Date of Kms. Sale : Service : Run :

Periodic Part Replacement :

Drive chain link lock

Oil used for Replacement / Top Up: Bajaj Genuine oil Servicing Dealer

(Dealer’s name & Code no.)

FREE

Valid for 4500 to 5000 Kms or 240 Days.

(From the Date of Sale whichever occurs earlier)

Availing all Free / Paid Services, replacing mandatory

periodic parts & engine oil will entitle warranty eligibility.

Date ----------------------------------

Kms. ----------------------------------

• Bajaj Genuine Oil used for top up Yes No

Warranty is null or void

if Bajaj Genuine Oil &

Mandatory periodic

parts are not replaced

Periodic Part Replacement

• Drive chain link lock

Warranty : Continued

Warranty : Terminated

Free Service

Servicing Dealer

* if applicable * if applicable

2nd Free Service (4500-5000 Kms.)

1. Wash the vehicle.

2. Check & top up engine oil (Bajaj DTS-i

10000)

3. Clean air filter element

4. Clean fuel cock sediment bowl.

5. Check all fuel pipes.

6. Clean & adjust spark plugs gap.

7. Check & adjust valve tappet clearance.

8. Clean silencer drain hole.

9. Clean silencer tail pipe.*

10. Check & top up coolant level in expansion tank.*.

11. Check coolant hose & clamps, replace if required.*

12. Check & adjust radiator fins.*

13. Remove & Lubricate drive chain ('O' ring chain* at every 500 Km)

14. Replace chain link lock & adjust chain slackness.

15. Check brake linings* or pad wear*, replace if required.

16. Check & top up brake fluid level.*

17. Check & adjust clutch, accelerator, brake free play*, steering play.

18. Check & adjust rear brake switch.

19. Check & tighten the front & rear spokes*

20. Check & tight Nuts, Bolts, Fasteners & Rear wheel sprocket to the recommended torque.

WORK IS CARRIED OUT TO MY SATISFACTION.

Owner’s SignatureWorkshop Incharge

21. Lubricate specific points.(Starter clutch / Swing arm pivot pin / Brake cam* & pedal pivot pin)

22. Check & Clean Step-Pillion LH & RH (ball and plate)*

23. Check Battery voltage, route cables & fit terminal caps properly, clean terminals & apply Petroleum Jelly

24. Check electrolyte level & top up if required with distilled water.*

25. Check wiring harness for removal / cut of plastic band / cable tie, metal clamp from chassis, rubbing of harness proper & routing.

26. Start engine, check & adjust horn & all lights, auto choke* for proper functioning.

27. Check & Tighten St. Motor, St. Relay & H.T. coil connections.

28. Check oil pressure indicator on speedo console.*

29. Check & clean ignition switch contacts.

30. Check & adjust gap between reed switch & TPS magnet.*

31. Check & adjust idling and CO%. Tune engine & carburettor if required.

32. Carry out any additional work if required.

33. Check & Adjust air pressures in the tyres.

34. Test ride the Vehicle & Clean the vehicle at the time of delivery.

Valid for 9500 to 10000 Kms or 240 Days.

(From the Date of Sale whichever occurs earlier)

Date ----------------------------------

Kms. ----------------------------------

Owner's Name :

Frame No. :

Engine No. :

Date of Date of Kms. Sale : Service : Run :

Periodic Part Replacement : Paper oil filter* Drive chain link lock Fork oil Fork oil seal

Oil used for Replacement / Top Up: Bajaj Genuine oil Servicing Dealer (Dealer’s name & Code no.)

FREE

Availing all Free / Paid Services, replacing mandatory

periodic parts & engine oil will entitle warranty eligibility.

• Bajaj Genuine Oil used for Replacement Yes No

Warranty is null or void

if Bajaj Genuine Oil &

Mandatory periodic

parts are not replaced

Mandatory Periodic Part Replacement

• Paper oil filter*

• Drive chain link lock

• Fork oil

• Fork oil seal

Warranty : Continued

Warranty : Terminated

Free Service

Servicing Dealer

* if applicable * if applicable

3rd Free Service (9500-10000 Kms.)

1. Wash the vehicle.

2. Replace engine oil (Bajaj DTS-i 10000)

3. Replace engine oil filter.

4. Clean oil strainer, air filter element, fuel cock sediment bowl & carburettor float chamber.

5. Check all fuel pipes.

6. Clean & adjust spark plugs gap.

7. Check & adjust valve tappet clearance.

8. Clean silencer drain hole & tail pipe.*

9. Check & top up coolant level in expansion tank.*.

10. Check coolant hose & clamps, replace if required, Check & adjust radiator fins.*

11. Check rear wheel damper & wheel bearings, replace if required.

12. Drive chain remove & lubricate, replace chain link lock & adjust slackness.

13. Replace front fork oil & oil seals.

14. Check brake linings* or pad wear*, replace if required.

15. Check & top up brake fluid level. Check brake hose pipe, replace if required.*

16. Check & adjust clutch, accelerator, brake free play*, steering play.

17. Check Cap steering bearing(Plastic), replace if required.

18. Check & adjust rear brake switch.

19. Check & tighten the front & rear spokes*

20. Check & tight Nuts, Bolts, Fasteners & Rear wheel sprocket to the recommended torque.

WORK IS CARRIED OUT TO MY SATISFACTION.

Owner’s SignatureWorkshop Incharge

21. Check & Clean Step-Pillion LH & RH (ball and plate)*

22. Check Battery voltage, route cables & fit terminal caps properly, clean terminals & apply Petroleum Jelly.

23. Check electrolyte level & top up if required with distilled water.*

24. Start engine, check & adjust horn & all lights, auto choke* for proper functioning.

25. Lubricate specific points.(Starter clutch / Steering stem bearing/ Swing arm pivot pin / Brake cam* & pedal pivot pin / main & side stand pin)

26. Check oil pressure indicator on speedo console.*

27. Check & clean ignition switch contacts if operation sticky.

28. Check, Clean & lubricate Clutch switch & brake switch (Horizontal base) contacts.*

29. Check & replace clutch switch-vertical base.*

30. Check & adjust gap between reed switch & TPS magnet.*

31. Check & Tighten St. Motor , St. Relay & H.T. coil connections.

32. Check & adjust idling and CO%. Tune engine & carburettor if required..

33. Carry out any additional work if required.

34. Check tyre wear & inflate air pressures in the tyres.

34. Test ride the Vehicle & Clean the vehicle at the time of delivery. .

PAID

1 Paid Service

2 Paid Service

Valid for 19500 to 20000 Kms or 120 days from the last service (whichever occurs earlier)

Availing all Free & Paid Services as per S ch edule will enti tle Warranty eligibility.

This coupon entitles paid labour jobs as per Periodic Maintenance Schedule.

Owner’s Name: -------------------------

-------------------------------------------

Frame No.:------------------------------

Engine No.:------------------------------

Kilometers :-----------------------------

Service Dealer: -------------------------

-------------------------------------------

Sold on: ---------------------------------

Valid for 14500 to 15000 Kms or 120 days from the last service (whichever occurs earlier)

Availing all Free & Paid Services as per S ch edule will enti tle Warranty eligibility.

This coupon entitles paid labour jobs as per Periodic Maintenance Schedule.

Owner’s Name: -------------------------

-------------------------------------------

Frame No.:------------------------------

Engine No.:------------------------------

Kilometers :-----------------------------

Service Dealer: -------------------------

-------------------------------------------

Sold on: ---------------------------------

DATE

-----------------------------------

KMS

-----------------------------------

JOB NO-----------------------

SERVICING DEALER

DATE

-----------------------------------

KMS

-----------------------------------

JOB NO-----------------------

SERVICING DEALER

Note : For periodic part replacement turn overleaf Note : For periodic part replacement turn overleaf

Note : For periodic part replacement turn overleaf

• Bajaj Genuine Oil used for Top up Yes No

Mandatory Periodic Part Replacement Done

Yes No

• Bajaj Genuine Oil used for Replacement Yes No

Mandatory Periodic Part Replacement Done

Yes No

1 Paid Service

IMPORTANT: Replace or Top Up Engine oil as per Periodic Maintenance Schedule.

Cost of L abour, engine oi l & periodic parts on chargeable basis.

Job elements as p er P er iodic Maintenance Schedule.

2 Paid Service

IMPORTANT: Replace or Top Up Engine oil as per Periodic Maintenance Schedule.

Cost of L abour, engine oi l &

periodic parts on chargeable basis.

Job elements as p er P er iodic Maintenance Schedule.

Periodic Part Replacement

• Air filter cover ‘O’ ring

• Air cleaner element

• Inline paper filter*

• Fuel cock paper filter element*

• Fuel pipes

• Drive chain link lock

Periodic Part Replacement

• Paper oil filter*

• Spark Plug

• Fork oil

• Front fork oil

• Engine breather tube

• Drive chain link lock

* if applicable * if applicable

• Air filter cover ‘O’ ring

• Air cleaner element

• Inline paper filter*

• Fuel cock paper filter

element*

• Fuel pipes

• Drive chain link lock

1 Paid Service Periodic Part Replacement

2 Paid Service Periodic Part Replacement

• Paper oil filter*

• Spark Plug

• Fork oil

• Front fork oil

• Engine breather tube

• Drive chain link lock

* if applicable

PAID

DATE

-----------------------------------

KMS

-----------------------------------

JOB NO-----------------------

SERVICING DEALER

DATE

-----------------------------------

KMS

-----------------------------------

JOB NO-----------------------

SERVICING DEALER

4 Paid Service

Valid for 29500 to 30000 Kms or 120 days from the last service (whichever occurs earlier)

Availing all Free & Paid Services as per S ch edule will enti tle Warranty eligibility.

This coupon entitles paid labour jobs as per Periodic Maintenance Schedule.

Owner’s Name: -------------------------

-------------------------------------------

Frame No.:------------------------------

Engine No.:------------------------------

Kilometers :-----------------------------

Service Dealer: -------------------------

-------------------------------------------

Sold on: ---------------------------------

3 Paid Service

Valid for 24500 to 25000 Kms or 120 days from the last service (whichever occurs earlier)

Availing all Free & Paid Services as per S ch edule will enti tle Warranty eligibility.

This coupon entitles paid labour jobs as per Periodic Maintenance Schedule.

Owner’s Name: -------------------------

-------------------------------------------

Frame No.:------------------------------

Engine No.:------------------------------

Kilometers :-----------------------------

Service Dealer: -------------------------

-------------------------------------------

Sold on: ---------------------------------

Note : For periodic part replacement turn overleaf Note : For periodic part replacement turn overleaf

Note : For periodic part replacement turn overleaf

• Bajaj Genuine Oil used for Replacement Yes No

Mandatory Periodic Part Replacement Done

Yes No

• Bajaj Genuine Oil used for Top up Yes No

Mandatory Periodic Part Replacement Done

Yes No

4 Paid Service

IMPORTANT: Replace or Top Up Engine oil as per Periodic Maintenance Schedule.

Cost of L abour, engine oi l &

periodic parts on chargeable basis.

Job elements as p er P er iodic Maintenance Schedule.

3 Paid Service

IMPORTANT: Replace or Top Up Engine oil as per Periodic Maintenance Schedule.

Cost of L abour, engine oi l & periodic parts on chargeable basis.

Job elements as p er P er iodic Maintenance Schedule.

Periodic Part Replacement

• Drive chain link lock

* if applicable * if applicable * if applicable

Periodic Part Replacement

• Paper oil filter*

• Air cleaner cover ‘O’ring

• Air cleaner element

• Inline paper filter*

• Drive chain link lock

• Fuel cock paper filter element*

• Brake fluid*

• Brake hose pipe*

Other parts as per PM schedule

3 Paid Service Periodic Part Replacement

• Drive chain link lock

• Paper oil filter*

• Air cleaner cover ‘O’ring

• Air cleaner element

• Inline paper filter*

• Drive chain link lock

• Fuel cock paper filter element

• Brake fluid

• Brake hose pipe

• Fuel pipes

• Coolant*

• Fork oil & oil seal

• Master cylinder piston kit

• Caliper piston seal kit

• Engine foundation bush

4 Paid Service Periodic Part Replacement

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

Applicable to all Paid Services

Sr No. Jobs to be carried out 1st Paid 2nd Paid 3rd Paid 4th Paid

14500~15000 19500~20000 24500~25000 29500~30000

1 Wash the vehicle. • • • •

2 Replace engine oil (Bajaj DTS-i 10000) • •

3 Replace engine oil filter • •

4 Clean Oil strainer (Bajaj DTS-i 10000) • •

5 Top up engine oil (Bajaj DTS-i 10000). • •

6 Clean body centrifugal oil filter** •

7 Clean fuel cock sediment bowl. • • • •

8 Clean & adjust carburettor • •

9 Clean air filter element. • •

10 Replace air filter element • •

11 Replace air filter cover 'O' ring • •

12 Replace engine air breather tube •

13 Clean carburettor float chamber • •

14 Replace fuel cock paper filter along with seal & in line paper • •

filter along with hose**

15 Check all fuel pipes. • •

16 Replace fuel pipes. • •

17 Clean & adjust spark plugs gap. • • •

Servicing

Kms

Applicable to all Paid Services

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

Sr No. Jobs to be carried out 1st Paid 2nd Paid 3rd Paid 4th Paid

14500~15000 19500~20000 24500~25000 29500~30000

18 Replace spark plugs. •

19 Check & adjust valve tappet clearance. • • • •

20 De-carbonise cylinder head •

21 Check engine compression pressure. • •

22 Clean silencer drain hole & tail pipe**. • • • •

23 Check carburettor rubber duct, replace if required. •

24 Check & top up coolant level in expansion tank.** • • •

25 Replace coolant in expansion tank** •

26 Check coolant hose & clamps, replace if required, • • • •

Check & adjust radiator fins.**

27 Replace coolant hose & clamps.** Replace at every 3 years or 36,000 Kms

28 Check wheel bearings, replace if required. • • • •

29 Check rear wheel damper, replace if required. • •

30 Check & adjust drive chain slackness. • • • •

31 Drive chain remove & lubricate, replace chain link lock • • • •

32 Replace front fork oil & oil seals. • •

33 Check brake linings** or pad wear**, replace if required. • • • •

34 Check & top up brake fluid level. • • •

35 Check brake hose pipe, replace if required.** •

Servicing

Kms

Applicable to all Paid Services

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

Sr No. Jobs to be carried out 1st Paid 2nd Paid 3rd Paid 4th Paid

14500~15000 19500~20000 24500~25000 29500~30000

36 Replace brake hose, brake fluid, master cylinder piston kit, •

Caliper piston seal kit**

37 Check & adj. clutch, accelerator, brake free play**, steering play • • • •

38 Check & replace clutch plates. •

39 Check & adjust rear brake switch. • • • •

40 Check & tighten the front & rear spokes** • • • •

41 Check & adjust Rr. Shock absorber gas pressure** •

42 Check & tight Nuts, Bolts, Fasteners & Rear wheel. • • • •

sprocket to the recommended torque

43 General lubrication • • • •

44 Lubricate-Swing arm pivot pin / Brake cam** & pedal pivot pin • • • •

45 Lubricate-Starter clutch-Dry application • • • •

46 Lubricate-Steering stem bearing, main stand & side stand pin • •

47 Replace Engine foundation silent bushes • •

48 Check Battery voltage, route cables & fit terminal caps properly • • • •

Clean terminals & apply Petroleum Jelly

49 Check wiring harness for removal/cut of plastic band/cable tie, • •

metal clamp from chassis, rubbing of harness proper & routing.

50 Check electrolyte level & top up if reqd with distilled water.** • • • •

Servicing

Kms

Applicable to all Paid Services

Note : Above jobs are applicable as per Periodic Maintenance Schedule.

Servicing

Kms

* 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. 2, 3 & 4 will be every 5000 Kms.

Sr No. Jobs to be carried out 1st Paid 2nd Paid 3rd Paid 4th Paid

14500~15000 19500~20000 24500~25000 29500~30000

51 • •

52 • • • •

53 Start engine, check & adjust horn & all lights, auto choke** • • • •

for proper functioning

52 Check oil pressure indicator on speedo console.** • • • •

53 Check & clean ignition switch contacts if operation sticky. • • • •

54 Check, Clean & lubricate Clutch switch & brake switch • •

(Horizontal base) contacts.**

55 Check clutch switch (vertical base)-replace if required** • •

56 Check & adjust gap between reed switch & TPS magnet.** • • • •

57 Check & Tighten St. Motor , St. Relay & H.T. coil connections. • • • •

58 Check & adjust idling and CO%. Tune engine • • • •

& carburettor if required.

59 Carry out any additional work if required. • • • •

60 Check tyre wear & inflate air pressures in the tyres. • • • •

61 Test ride the Vehicle & Clean vehicle at the time of delivery. • • • •

Check Cap steering bearing(Plastic), replace if required.

Check & Clean Step-Pillion LH & RH (ball and plate)*

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 nonuse 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 spark plug & put several drops of 2T oil into the cylinder. Kick engine over slowly a few times to coat cylinder wall with oil & install back spark plug.

• Set the vehicle on a box or a stand so that both 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.

• 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 automatically during first few application of brake.

** For Battery :

a. Remove battery and keep it on wooden

plank, in properly ventilated area.

b. Before taking the vehicle for use.

• Get t he bat ter y rec har ged f rom the Authorised Service Center / Battery Dealer.

• A pply p e t role u m j elly o n t e rmin a l s. (applicable to certain models).

Preparation for regular use after storage :

• Clean the vehicle

• Make sure the spark plug is tight.

• Fill the fuel tank with fuel.

• Change the engine oil.

• Check all the points listed in the Daily

Safety Checks section.

• Check and inflate tyres to proper tyre pressure.

Pulsar 135 LS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual