Pulsar 220 DTS-i Owner's Manual

Foreword

Welcome to the Pulsar family!
You are now the proud owner of 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 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 Dealers (ASD), who are well
equipped with all necessary facilities / genuine parts / oil and trained manpower to ensure the best
care for your Pulsar. Your Pulsar comes with a warranty of 5 Years or 75,000 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 helpline numbers or e-mail
us at: [e-mail] 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

Table of Contents

Description

1. Technical Specifications 1

2. Identification Data 3

3. Location of Parts 4

4. Steering cum Ignition lock & Control Switches 5

5. Speedometer Non ABS 7

6. Speedometer ABS & ABS System Information 8

7. Fuel Tank Cap / Fuel Tap 9

8. Removal & Fitment of Side Covers 10

9. Removal & Fitment Seat 11

10. Battery / Tool kit 12

11. Daily Safety Checks 13

12. How to ride your Bike 14

13. Safe Riding Tips 18

14. Engine Oil 19

15. Wheels - Tyre 20

16. Periodic Maintenance Information 21

17. Free Service Guidelines 25

18. Periodic Maintenance & Lubrication Chart 26

19. Non Use Maintenance 31

20. Delivery Certificate 33

21. Warranty Scope & Limit 34

22. Battery Warranty Card

Safety and Warning information :

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.

Caution : This indicates that a potential
ha za rd t ha t could result in vehic le
damage. Follow the Advice provided with
the caution.

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
acces sories a s m ay be c onvenient a nd
necessary.

Technical Specifications

Engine : 4 Stroke, Oil cooled

Bore x Stroke : 67.00mm x 62.4mm

Eng. Displacement : 220 cc

Compression Ratio : 9.5 +/- 0.5 : 1

Idling Speed : 1400 + 100

Max. Net Power : 20.93 PS at 8500 RPM

Max. Net Torque : 18.55 Nm at 7000 RPM

Ignition System : DC CDI

Spark Plug (2 Nos.) : Champion RG6HCC

Spark Plug Gap : 0.7 to 0.8 mm

Lubrication : Wet sump, Forced

Transmission : 5 speed constant mesh

Gear Shifting : 1 Down 4 Up

Brakes (Fr. & Rr.) : Hydraulic operated disc

brakes

Starting Aid : Electric Starter

Fuel Tank Capacity :

Full : 15 liters

Reserve : 3.2 liters / 3.5 liters-ABS

Usable Reserve : 2 liters / 2.5 liters-ABS

Tubeless Tyre Size :

Front : 90/90 x 17, 49P

Rear : 120/80 x 17, 61P

Tyre Pressure :

Front : 2 kg/cm (28.4 PSI)

Rear (solo) : 2.1 kg/cm (30 PSI)

Rear (pillion) : 2.25 kg/cm (32 PSI)

2

2

2

Dimensions :

Length : 2035 mm

Width : 750 mm

Height : 1165 mm

Wheel base : 1350 mm

Ground Clearance : 165 mm

1

Technical Specifications

Electrical System : 12 Volts DC

Battery : 12V - 9 Ah

Head Lamp : 55W (Low Beam )

: 55W (High Beam )

Pilot Lamp : 5W (2 Nos)

Tail /Stop : LED

Side Indicator : 10W (4 nos)

Neutral Indicator : LED

Hi Beam Indicator : LED

Turn Pilot Indicator : LED

Side Stand Indicator : LCD

Speedometer : LCD Display

ABS Indicator : LED (Yellow)

Low Battery : LED Red (Non ABS)

: LCD (ABS)

Rear No. Plate : 5W

Horn : 12V DC (2 Nos.)

Kerb Weight : 155 Kg (Non ABS)

: 158 Kg (ABS)

Gross Weight : 285 Kg (Non ABS)

: 288 Kg (ABS)

Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without
any notice.

• This vehicle complies to BS IV standards.

• AHO is government regulation.

2

Identification Data

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

Engine Number Location

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

Chassis Number Location

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

3

Location of Parts

Grab

Handle

Pillion
Foot Rest

Rear

Disc Brake

Note: Photograph is of Pulsar 220 Non ABS vehicle.

Rear

Shock Absorber

Engine Oil Level

Inspection Window

Manual

Choke

Accelerator

Grip

Fuel

Tank

Front Fork

Front Disc Brake

4

Steering cum Ignition Lock & Control Switches

D

A

B

C

Left Handle Bar Switches

A. Dipper Switch : When headlight is ON,

High or Low beam can be selected with

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’.

the dipper switch.

: High Beam : Low beam
B. Turn Signal Switch : When the turn signal

knob is turned to Left ( ) or Right ( ) the
corresponding turn signals start flashing.
To stop flashing, push the switch in &
release.

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.

5

Steering cum Ignition Lock & Control Switches

AHO Feature (Automatic Headlight ‘ON’)

F

E

Right Handle Bar Switches

E. Starter Button :

Starter button operates the electric starter.

It is recommended to start the engine with
the transmission in neutral.

Vehicle in Gear - Press clutch lever &

operate starter button to start the engine.

F. Engine Kill Switch :

The engine kill switch is used for switching

ON & OFF the engine.
: Engine OFF
: Engine ON

There is no ‘Light switch’ on RH control
switch.

Ignition switch ‘ON’ Speedometer illumination
Engine ‘OFF’ Tail lamp, Number
Plate Lamp, Pilot
Lamp & Control Switches
Illumination will get ‘ON’
Effect of pressing In addition to above
‘Pass Switch’ Hi-beam will get ‘ON’

Ignition switch ‘ON’ & Engine Running

Speedometer illumination, Tail lamp, Number Plate
Lamp, Pilot Lamp & Control Switches Illumination will
get ‘ON’
in addition to above, headlamp will get on as given
below.

Hi/Low beam Headlamp Effect of
Switch Status Pass Switch

Low beam Low beam ‘ON’ Low+Hi
beam ‘ON’
Hi beam Hi beam No change
‘ON’

6

Speedometer Non ABS

1

2
3

4

5

Speedometer display will get on when ignition switch is made ‘ON’.

1. Fuel level indicator : Fuel level indicator shows

approx available fuel in fuel tank.( ) Symbol blinks
continuously when petrol level reaches reserve level.

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

3. Odometer : The Odometer shows the total distance

that the vehicle has accumulated.

4. Turn signal indicator : When ignition switch is ‘ON’

& turn signal switch is turned to LH/RH, Side
indicator will flash.

5. Neutral indicator : When ignition switch is ‘ON’ &

the transmission is in neutral, the neutral indicator
light will glow.

6

7

8

9

Air Filter

10

Choked

These icons glows whenever their limits are exceeded.

11

Take your vehicle to service station for maintenance of
required item, if any of the above items glows continuously.

Low Engine

Oil Level

6. Side stand indicator : When ignition switch is ‘ON’

& side stand is down, side stand indicator will glow.

7. Speedometer : The vehicle speed i s displayed

digitally in Km/h.

8. Trip meter knob : Reset trip meter to zero by

pressing the trip meter knob.

9. Trip meter : It shows the distance travelled since it

was last reset to zero.

10. Hi beam indicator : When ignition switch is ‘ON’ &

the H/L is on high beam, the hi beam indicator light
will glow.

11. Low Battery Indicator : It indicates battery needs

charging.

High Engine
Temperature

7

Speedometer ABS

1

ABS

2

1. Low Battery Indicator : It indicates battery needs

charging.

2. ABS Indicator ( ): With Ignition switch ON the

ABS indicator glows. When vehicle speed is more

than 5 Km/h the ABS indicator goes off, if this
indicator glows while vehicle is running, it means
there is problem in ABS unit.

Other icons & information is same as of Non ABS
Speedometer.

ABS System Information:

 Always maintain a safe distance between you and

objects ahead. Vehicle speeds should always be
reduced during extreme road conditions. The braking
distance for motorcycle equipped with an anti-lock
braking system may be longer than for those without it
on rough road conditions. During these conditions the
vehicle should be driven at reduced speeds.

 When you apply Front brake under conditions which

may lock the wheels, you feel a corresponding
sensation (pulsation) in Front brake lever. This is normal
and it means your ABS is active.

 Also it is recommended to use both front & rear brakes

simultaneously.

 Always slow down when cornering. The anti-lock brake

system cannot prevent accidents resulting from
excessive speeds.

8

Fuel Tank Cap / Fuel Tap

A

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.

• To lock the ‘Fuel Tank Cap’ insert the key
in the lock and turn it clockwise and press

fuel tank cap. ‘Click’ sound ensures cap is

fully locked.

Precaution :
Dont attach metallic ‘Key chain’ as it may damage
paint of petrol tank.

Fuel Tap

Fuel Tap

Fuel tap lever has following positions.

OFF : When fuel supply is to be

cut off.

ON : When fuel level is above

reserve position.

RES : When fuel level is below

reserve position.

9

Removal & Fitment of Side Cover LH

B

C

A

A

Removal of Side Cover LH

• Access to battery is by removing LH
cover.

• Insert ignition key (A)& turn it clock wise.

• Pullout the cover (B) from fuel tank knob.

• Slide the cover (C) towards left direction .

• Direction of removal is important to avoid
breakage of cover locking lug.

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

B

Fitment of Side Cover LH

• Match slot provided on rear end of ‘Side

Co ve r’ with b ra ck et (A) pr ov ided on
‘Chassis’ and slide ‘Side Cover’ backward
(towards Tail lamp).

• Match Lug provided on front portion of
‘Side Cover’ with hole (B) provided on ‘Fuel
Tank’ and press ‘Side Cover’ inside.

• Match the lock plate of ‘Side Cover’
properly with bracket on ‘Chassis’ and
rotate key in clockwise direction to lock.

10

Removal & Fitment of Seat

B

1

A

Fig. B

Removal of Seat - Front & Rear

• Remove ‘Side Cover’ LH.

• To remove Seat Front, pull the ‘Seat Release
Cable’ (A) to release seat lock. Keeping cable
pulled, tap the center of seat, lift the seat
from rear end & slide it back to remove seat.

• To remove Seat Rear, pull the ‘Seat Release
Cable’ (B) 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.

Caution : Always remove Rear Seat first.

Fitment of Seat - Front & Rear

• For fitment of Seat Front, match & insert the

3

2

4

5

6

Fig. CSeat Release Cable

bracket (‘1’ of Fig. ‘B’), of seat with slot (‘2’ of

Fig. ‘B’) p ro vided below fu el tank rear
mounting on chassis. Push seat towards fuel
tank and align lock rod (‘3’ of Fig. ‘B’) & seat
lock (‘4’ of Fig. ‘B’). Then press the seat in
middle from top to lock the seat.

• For fitment of Seat Rear, match & insert the
bracket (‘5’ of Fig. ‘C’) of seat with slot (‘6’ of
Fig. ‘C’) p rovided b elow fuel t ank re ar
mounting on chassis. Push seat towards fuel
tank and align lock rod (‘7’ of Fig. ‘C’) & seat
lock (‘8’ of Fig. ‘C’). Then press the seat in
middle from top to lock the seat.

Caution : Always fit Front Seat first.

11

7

8

Battery / Tool Kit

Tool kit
Location

First Aid
kit Location

Battery (12V - 9Ah)

• Battery is located inside LH side cover.

• Make of battery may differ from vehicle to
vehicle.

Tool Kit Location

• It is located below Rear seat.

• Tool kit to be tight by 2 nos rubber bands.

First Aid Kit Location

• First aid kit is to be stored in seat cowl.

CAUTION : Ensure tool kit is fitted

properly with rubber bands.

12

Daily Safety Checks

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 &
visit BAL 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.

• Brake Pedal Play - Fixed, Not to be

adjusted for rear disc brake version.

• B rak e F lui d le vel abo ve MI N mark

provided on reservoir.

• Drive Chai n slack of 20 to 30 mm

adequately lubricated.

• Function of all lights & horn.

• Clutch lever play - 2 to 3 mm.

• S mooth steer ing mo vemen t w ithou t

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.

13

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.

• Keep throttle completely closed, press starter

button “ ” to start the engine.

• Release starter button as soon as engine
starts.

Note : Do not let the engine idle longer than 3
minuets otherwise it will overheat.

• If the engine is cold or when starting for first

time, use choke ‘ ’for quick starting.

OFF

ON

Referance photo

• When the engine is
warmed up enough to
idle without using
choke, return the
choke to OFF
position.

Manual Choke

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 : The motorcycle is equipped with a clutch
switch. This switch ensures that the engine can

be started in any gear if the clutch lever is
pressed.

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.

st

14

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 Lever Gear Shifting

Recommended Speed for Shifting Down

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

Pattern

50 km/h

40 km/h

30 km/h

20 km/h

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.

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.

15

How to Ride Your Bike

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.

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

Whenever vehicle is falls down, remove plug of 'Y
connecter drain tube' & drain out accumulated
petrol

Location - Near Main Stand

'Y connecter drain
tube plug’

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.

Kms 1st 2nd 3rd 4th 5th
0 - 1000 10 20 30 35 45
1000 - 2000 15 30 40 45 55

• 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.

16

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.

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 plugs as per P.M. Chart.

Air Filter Clean the air filter element

periodically. Replace as per
Periodic Maintenance Chart.

Engine Oil Check engine oil level. Always

use recommended grade and
quantity.

Brakes Ensure that the brakes are not

dragging / binding.

Clutch Ensure correct clutch lever

play.

Tyre Air Always maintain recommended

Pressure tyre pressure.

Carburettor Clean & adjust the carburettor.

Adjust idling speed.

17

Safe Riding Tips

Safe Riding Tips

• Always wear Helmet while driving or riding. Your

he lm et sh ou ld conform to appropriate Indian
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.

• 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.

18

Engine Oil

Recommended Engine Oil:

Always insist on Bajaj DTS-i Engine Oil for

A

optimum engine performance and warranty
benefits. It is a specially formulated oil for
vehicles with DTS-i engines.

Model Recommended Engine oil

B

A: Oil Filler Cap, B: Oil Level Inspection Window

Engine Oil Level Checking :

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

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

• Always maintain engine oil level between
upper and lower 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 : 1150 ml.

• During engine overhaul : 1300 ml.

Pulsar 220 Bajaj DTS-i 20W50
OR
Bajaj DTS-i 10W50 Synthetic

• 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.

st

19

Wheels - Tyre

Tubeless Tyre :

The main advantage of tubeless tyres is in
case of puncture the rate of air leak is very
slow, hence customer can easily drive the
vehicle upto nearest puncture repair shop for
removing puncture.

CAUTION : Tubeless tyres are fitted in this
motorcycle. The walls of the tyres in contact
with the wheel rim should not be damaged
in any way during fitment / removal of tyre.
The tyre side walls in contact with wheel rim
seals air.

Wheel Puncture:

• Visit nearest known tubeless tyre repair shop
to remove puncture.

• Remove puncture by Filler or Plug method
only.

• Do not use patch method to remove puncture
of tubeless tyre.

Tyre Pressure :

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

Front 28 PSI

Rear (Solo) 28 PSI

Pulsar 220

Rear (with Pillion) 32 PSI

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

20

Periodic Maintenance Information

MIN.

Front Brake Fluid Level :

• Front brake fluid master cylinder reservoir is located
near RH switch on handle bar.

• To check oil level, keep vehicle on Center stand with
handle bar in straight position.

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

• Use only DOT 3 or DOT 4 brake fluid (from sealed
container) to top up if required.

It is advisable that brake fluid should be replenished

at every 30,000 Kms.

21

Periodic Maintenance Information

Battery : 12V-9 Ah MF

• B att ery is l oca ted

inside ‘Side Cover’
LH.

• Always ensure that

bat ter y elec tro l yte
level is in between
m a x & m i n l e ve l
marks.

• C hec k & t op u p

battery by distilled water if electrolyte level
is below min level mark.

• Battery life would get adversely affected if

top up with ‘Tap Water’.

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

• E nv ironment c ar e m us t b e ta ke n t o

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.

• When battery is found discharged, it is

advised to get it charged immediately.

Max

Min

CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may lead
to da m age o f ele ctr i cal / ele ctro nic
components.

• Warranty on battery is 18 months from the
date of purchase of vehicle.

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.

22

Periodic Maintenance Information

Spark Plug

• R emo ve s park p lug s b y us ing plu g
spanner.

• Clean the spark plugs.

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

Spark Plug Gap : 0.7 to 0.8 mm.

Spark Plug (2 Nos.) : CHAMPION RG6HCC

0.7 to

0.8 mm

Drive Chain Slackness

• Chain slackness will have to be adjusted
whenever required.

• Std. Chain slackness 20 ~ 30 mm.

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

23

Periodic Maintenance Information

Drive Chain

Drive
Chain
Lubrication

Drive chain must be cleaned & lubricated as
per periodic maintenance schedule.

Drive Chain (O-ring type)

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

• 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 :

• Park vehicle perpendicular to the ground on level

surface. 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 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.

24

Free Service Guidelines

Customer ID :

Instruction to avail Free Service through
Digitized Free Service Coupon

Please follow following procedure : -

• Please provide your mobile number to Dealer at
the time of buying of new Bajaj Vehicle.

• In case of change in mobile number, please
update to Dealer / ASD.

• You will receive the Customer ID through SMS
at the time of buying of new vehicle.

• Please note th e Customer ID in Owner’s
Manual for your reference.

• During F ree Servi ce, please pro vide your
Customer ID to Dealer / ASD workshop.

• When you are at Dealership / ASD workshop for
Free Service, you will receive the ‘Unique
Coupon Number’ (UCN) through SMS in your
mobile.

• Please inform the UCN to Dealer / ASD at the
time of Free Service.

(ASD-Authorised Service Dealer)

Availing all Free / Paid Services, replacing mandatory periodic parts & engine oil will entitle warranty eligibility.

Subsequent

Paid services

Periodic Service Criteria

Service

1st Free

Service

2nd Free

Service

3rd Free

Service

Days

30~45

240

360

120 Days

from

last Service

Kms

500~750

4500~5000

9500~10000

Every

5000 Km

after previous

service

25

whichever occurs earlier

Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

st

nd

2 Free

4500

~

5000

rd

3 Free

9500

~

10000

Every

5000 Km after

Previous Service

Subsequent

1 Free

Sr.

No.

Operation

Servicing

Kms

500

750

~

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

2. Engine oil (Bajaj DTSi 10000 oil) C,R R Top R Top R Top R BGO DTSi 10W30 for
Up Up Up 100cc models.
BGO DTSi 20W50 for
Models above 125cc.

3. Engine oil filter** C,R R R R R

4. Oil strainer CL CL CL CL CL

5. Body centrifugal filter** CL CL CL CL

6. Starter Clutch (Dry Type)** L L L L L L L Use recommended
Molycote grease.

7. Spark plug CL,A,R CL,A CL,A R

8. Air cleaner element *** CL,R CL CL CL R CL CL R

 Tick in the box  after replacing the periodic parts.

26

Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

st

nd

2 Free

4500

~

5000

rd

3 Free

9500

~

10000

Every

5000 Km after

Previous Service

Subsequent

1 Free

Sr.

No.

Operation

Servicing

Kms

500

750

~

9. Air filter cover ‘O’ ring CL,R CL CL CL R CL CL R

10. In line paper filter R R R

11. Fuel cock paper filter. R R R

12. Fuel cock sediment bowl cleaning CL CL CL

13. Carburettor rubber duct C,R C,R

14. Fuel pipe C,R C C C R C C R

15. Valve tappet clearance C,A C,A C,A C,A

16. Non-Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A
cleaning & lubrication

17. Sealed drive chain CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A CL,L,A Customer to apply OKS
cleaning & lubrication chain lub spray at every
500 kms.

18. Engine air breather tube C C C C C C C C

19. Silencer drain hole cleaning CL CL CL CL CL CL CL

 Tick in the box  after replacing the periodic parts.

27

Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

st

nd

2 Free

4500

~

5000

rd

3 Free

9500

~

10000

Every

5000 Km after

Previous Service

Subsequent

1 Free

Sr.

No.

Operation

Servicing

Kms

500

750

~

20. Silencer tail pipe cleaning** CL CL CL CL CL CL CL

21. Brake cam & brake pedal pivot pin C,L,R C C,L,R C,L,R C,L,R C,L,R C,L,R C,L,R Use AP grease.

22. Brake lining or pad - C,R C,R C,R R C,R C,R R
Check wear indicator

23. Brake fluid level **- top up / replace C,A,R C,A R Use recommended
brake fluid
(DOT3/DOT4)

24. Disc brake assly -- Check functionality, C C C C
leakage or any other damage.

25. All cables & rear brake pedal-free play C,A C,A C,A C,A C,A C,A C,A C,A

26. Battery electrolyte level, specific gravity C,A C,A C,A C,A C,A C,A C,A C,A Not applicable for
VRLA battery

27. Wiring harness & Battery connections- C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T C,A,T
routing, tie bands & clamps tightness.

28. Ignition switch barrel cleaning C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray

 Tick in the box  after replacing the periodic parts.

28

Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

st

nd

2 Free

4500

~

5000

rd

3 Free

9500

~

10000

Every

5000 Km after

Previous Service

Subsequent

1 Free

Sr.

No.

Operation

Servicing

Kms

500

750

~

29. Handle bar control switches C,CL C,CL C,CL C,CL C,CL C,CL C,CL C,CL Use WD40 spray
contacts cleaning

30. Steering play C,A C,A C,A C,A C,A C,A C,A C,A

31. Steering stem bearing*** & C,CL,L,R C,CL, C,CL, C,CL, Check & replace if
Cap steering bearing (Plastic)** L,R L,R L,R Damaged. Use HP
Lithon RR3 grease for
lubrication.

32. Main stand & side stand pin** CL,L CL,L CL,L CL,L Use AP grease.

33. Swing arm pivot pin L L L L L L L
(for non silent bush)**

34. All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T

35. Engine foundation silent bushes** C C C

36. General lubrication-Clutch lever, L L L L L L L L Use AP grease.
front brake lever, kick lever.

37. Idle speed / CO% C,A C,A C,A C,A C,A C,A C,A C,A

 Tick in the box  after replacing the periodic parts.

29

Periodic Maintenance & Lubrication Chart

RECOMMENDED FREQUENCY

st

nd

2 Free

4500

~

5000

30

rd

3 Free

9500

~

10000

Every

5000 Km after

Previous Service

Subsequent

1 Free

Sr.

No.

Operation

Servicing

Kms

500

750

~

38. Coolant level in expansion tank** C,A C,A C,A C,A C,A C,A C,A C,A Use recommended
'Ready to use coolant'.

39. Coolant hose damage/clamps/leakage** C C C C C C C

40. Radiator fins** C C C C C C C

41. Spoke tightening**-Front & Rear C,T C,T C,T C,T C,T C,T C,T C,T

42. Front fork dust seal & Rubber bellow CL CL CL CL CL CL CL

43. SAI, EVAP hoses - Check functionality, C,R C,R C,R C,R C,R C,R C,R C,R Replace if cut / damaged
leakage or any other damage**

44. EVAP drain tube cleaning** CL CL CL CL CL CL CL CL

 Tick in the box  after replacing the periodic parts.

** As applicable to model
*** More frequent cleaning may be required while driving in dusty environment.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate
Note : Periodic parts, Oil, Coolant, Filters, All types of greases, Cleaning agents, Cables, Wear & tear parts, Rubber

‘O’ rings / oil seals / pipes, Gaskets to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory
and the same are chargeable to customer.

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

engine 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 pressur e 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 the bat ter y r ech arg ed f rom the

Authorised Service Center / Battery Dealer.

• Apply petroleum jelly on battery terminals.

Preparation for regular use after storage :

• Follow daily safety checks.

31

32

Delivery Certificate

FRAME NO. :

ENGINE NO. : Sold on.:

Customer’s Name Mr/Mrs/Miss :

Address : Contact No. :

I have taken possesion of motorcycle along with the following items.

1. Owner's Manual 5. Standard Accessories

2. 2 nos of key 6. Battery Make ___________ Sr. No. ____________

3. Set of tools 7. Tyre Fr Make ___________ Sr. No. ____________

4. First Aid Kit Rr Make ___________ Sr. No. ____________

The Vehicle has been delivered to my satisfaction & I have understood all terms and conditions of
warranty, service schedules & maintenance tips and shall abide by them.

Dealer Code :
Dealer Name :
Address :

Customer's Signature (To be filled in by the dealer)

Important - "Do not detach this page from Owner's Manual"

33

Contact No. :

Warranty : Scope & Limit

Bajaj Auto Limited gives the following warranty in respect
of the motorcycle manufactured “Pulsar 220 DTS-i”
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 ., whichever occurs earlier 5 Years or 75,000 Kms
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 re spective
manufacturer will be final and binding.

Proprietory parts like tyres, tubes, battery and spark plugs
are warranted by their respective manufacturers and
should be claimed on them directly by the customer. Bajaj
Auto Limited shall not be Liable to replace them

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
Dealers with the concerned vehicle and enables him

34

Warranty : Scope & Limit

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 / customer 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 paid services at subsequent 5000 kms. or

120 days from last service whichever occurs first

without any lapse.

3. Availing of all above services at the Authorised

Vehicle Dealers & Recommended Authorised Service

Dealers.

4. Usage of only recommended engine oil
“Bajaj DTS-i 10000” at specified frequency for drain

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

5000 kms.

5. Replacing mandatory periodic parts such as air filter,

oil filter etc. as per periodic maintenance schedule.

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 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
/non-recommended 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.

7. Never drive your bike through flooded roads or a
flooded patch, damage to the engine parts due to
water entry is not covered under warranty.

35

Warranty : Scope & Limit

8. 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.

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

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 ite d, s uch u se p rema ture ly a ffec ts t he
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. Ve hicl es whi ch ar e n ot be ing s er vic ed at

recommended dealers as per the service 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 ad dition al e lec trical a cce ssorie s su ch a s -
Remote, Bigger horn, Musical brake light etc. fitted on
vehicle.

16. If the vehicle has been used for commercial purpose
li ke Taxi o r any o th er means of co mm er ci al
transportation.

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 “Pulsar 220 DTS-i” motorcycle’ and no
other dealer or its or his agent or employee is authorised to
extend or enlarge this warranty.

36

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.:

SERVICE RECORD

Sr.

Date

No.

1

2

3

4

5

6

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.

Age

Mths.

Specific

Gravity

Voltage

Remarks

Dealer’s Stamp

& Signature

* Code

* 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.

TO BE FILLED IN BY BATTERY DEALERS / DISTRIBUTORS

IN CASE OF CLAIM

Name of Dealer & Code :__________________________________________________________________

__________________________________________________________________________________________

Date of claim :________________________________________________Battery Type :_______________

Serial No. :__________________________________________________Date of Fitment :______________

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

# Claim Accepted

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

vehicle.

## Claim Rejected

Use only Bajaj Genuine Parts

50

10W

synthetic

We are committed to provide the best of sales & service experience,
however should you require any additional assistance, please call
our Call centre on the number given below.

State Phone Number State Phone Number

A.P. / Telangana 040 33992453 N.Delhi / Haryana 011 33992453
Bihar 0612 33992453 Odisha 0674 33992453
Chattisgarh 0771 33992453 Punjab / H.P. / 0172 33992453
Gujarat 079 33992453 Chandigarh / J & K
Jharkhand 0651 33992453 Rajasthan 0141 33992453
Karnataka 080 33992453 T.N. / Pondicherry 044 33992453
Kerala 0484 33992453 U.P. / Uttarakhand 0522 33992453
Madhya Pradesh 0755 33992453 W.Bengal / North East 033 33992453
Maharashtra 020 33992453

Call charges are as applicable

Call centre timings :- Monday to Saturday (09.30 - 18.30 IST)

Please download customer care app from ‘Google play store’
and ‘Apple store’ and book the vehicles for servicing and more on
your phone.

E-mail : [e-mail]

Web Site : www.bajajauto.com

CIN : L65993PN2007PLC130076