table of contents · r e no tbak s id g he manufacturers. the essential features of the type...

Table of Contents

Description

1. Technical Specifications 1

2. Identification Data 3

3. Location of Parts 4

4. Steering cum Ignition lock 5

5. Fuel Tank Cap / Fuel Tap 7

6. Speedometer Details 9

7. Speedometer Setting 11

8. Control Switches 15

9. Front / Rear seat 18

10. Fitment of Front & Rear Seat 19

11. Daily Safety Checks 20

12. How to ride your Bike 25

13. Safe Riding Tips 29

14. Engine Oil 30

15. Wheels - Tube less Tyre 31

16. Battery 34

17. Periodic Maintenance Information 36

18. Brake Fluid 39

19. Periodic Maintenance & Lubrication Chart 42

20. Non Use Maintenance

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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 modi f icat ions on the veh ic le , par ts or accessories as may be convenient and necessary.

Safety and Warning information :

Caution : This indicates that a potential hazard which could result in vehicle damage, if advice provided is not followed.

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.

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Degrees of risk and symbols:

Danger:Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning:Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution:Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.

Note:Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Tampering Warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1 The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or

2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Warning:Environmental Hazard

Improper handling of fluids like fuel, oil, coolant are danger to the environment.

- Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Warning:Indicates a danger that will lead to environmentaldamage if the appropriate measures are nottaken.

Engine : 4 Stroke, Single Cyl.

Bore x Stroke : 58.0 mm x 60.7 mm

Engine Displacement : 160.3 cc

Compression Ratio : 9.8 + 0.5 : 1

Idling Speed : 1500 + 100 RPM

Max. Net Power E-III : 11.05 kw @ 8500 RPM

E-IV : 11.00 kw @ 8500 RPM

Max.Net Torque E-III : 14.12 Nm @ 6000 RPM

E-IV : 13.99 Nm @ 6000 RPM

Ignition System : DC

Spark Plug : 2 Nos

Spark Plug Gap : 0.7 ~ 0.8 mm

Transmission : 5 speed constant mesh

Gear Shifting Pattern : 1 Down 4 Up

Engine Lubrication : Forced Lubrication

Starting Aid : Self Start / Kick start

Front Brake : Hydraulically operated Disc type

Rear Brake : Hydraulically operated Disc type

Fuel Tank Capacity

Full : 12 liters

Dimensions

Length : 2017 mm

Width : 803.5 mm

Height : 1060 mm

Wheel base : 1370 mm

Ground clearance : 167 mm

Tyre Size

Front : 90/90-17, 49 P tubeless

Rear : 120/80-17, 61 P tubeless

Tyre Pressure 2 Front : 1.75 kgf/cm (25 PSI) 2 Rear (Solo) : 2.00 kgf/cm (28 PSI)

2 Rear (with pillion) : 2.25 kgf/cm (32 PSI)

Technical Specifications

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Note :

• All dimensions are under UNLADEN condition.

• Above information is subject to change without any notice.

Electrical System : 12 Volts DC

Head Lamp : 55/60 W, (Halogen)

Position Lamp : 3W (2 nos.)

Tail /Stop Lamp : LED type

Side Indicator lamp : 10W (4 nos.)

Neutral Indicator : Green LED

Hi Beam Indicator : Blue LED

Turn Signal Indicator : Green LED

Side Stand Indicator : LCD

Speedometer Lamp : LCD

Low Battery Indicator : Red LED

Low Oil Pressure : Red LED

Service Reminder : LCD

Bajaj Logo : Blue LED

Rear No. Plate Lamp : 3W

Horn : 12V DC, Type 2A

(82mm dia.)

Battery : 12V - 8 Ah VRLA

Technical Specifications

Vehicle Kerb Weight : E-III E-IV

148 kg. 151 kg.

Gross Vehicle Weight : 223 kg. 233 kg.

(Vehicle kerb weight together with rider 75kg)

Max. Speed : 107 Kmph

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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)

Frame Number Location On RH Side of Steering Tube (Alpha-Numeric - 17 Digits)

On LH Side of Steering Tube (Alpha-Numeric - 17 Digits) (for applicable countries)

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Location of Parts

Grab Handle Pillion Seat Rider Seat

Front Disc

Brake

Rear BrakePedal

Paper oilFilter

Front Brake Lever

RearNumber Plate

Nitrox Rear ShockAbsorber

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Steering cum Ignition Lock

To Lock the Steering : To lock the steering, turn the handle bar to the left side. Push & release the key. Turn the key to “LOCK” position and remove the key. Steering lock can be done on left side only.

To Unlock the Steering : To unlock steering, insert the key in steering cum ignition lock & turn it clockwise to “OFF” or “ON” position.

Key : A common key is used for ‘Steering cum Ignition lock’, ‘Fuel tank cap’ & ‘Rear Seat’.

Steering cum Ignition Lock :

It has three positions.

LOCK: Steering locked. Ignition OFF.

OFF: Steering unlock. Ignition OFF.

ON: Steering unlock. Ignition ON.

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Steering cum Ignition Lock

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Unlocking the steering

– Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove the key.

P You can now steer the bike again.

Locking the steering

Note:Danger of damage

The parked vehicle can roll away or fall over.

- Park the vehicle on a firm and level surface.

- Turn the handlebar all the way to the left.

- Insert the key into the ignition/handlebar lock, press in, and turn to the left. Remove the key.

[ Steering is no longer possible.

Opening the filler cap

Danger:Fire hazard

Fuel is highly flammable.

The fuel in the fuel tank expands when warm and

can escape if overfilled.

- Do not refuel the vehicle in the vicinity of open

flames or lit cigarettes.

- Switch off the engine for refueling.

- Make sure that no fuel is spilled; particularly not

on hot parts of the vehicle.

- If any fuel is spilled, wipe it off immediately.

- Observe the specifications for refueling.

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 place.

Fuel Tank Cap / Fuel Tap

Fuel Tank Cap

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Fuel Tank Cap / Fuel Tap

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Fuel TapWarning:Danger of poisoning

Fuel is poisonous and a health hazard.

– Avoid skin, eye and clothing contact with fuel.

– Immediately consult a doctor if you swallow

fuel.

– Do not inhale fuel vapors.

– In case of skin contact, rinse the affected area

with plenty of water.

– Rinse the eyes thoroughly with water, and

consult a doctor in case of fuel contact with the

eyes.

– Change your clothing in case of fuel spills on

them.

– Keep fuels correctly in a suitable canister, and

out of the reach of children.

Warning:Environmental hazard

Improper handling of fluids like fuel, oil, coolant

are danger to the environment.

– Do not allow fuel to enter the groundwater, the

soil, or the sewage system.

Warning:Fire hazard

Fuel is highly flammable, toxic and a health

hazard.

– Check the filler cap is locked correctly after

closing.

– Change your clothing in case of fuel spills on

them.

– Rinse the affected area immediately with plenty

of water in the event of contact with the skin.

Speedometer Details

9

Speedometer display will work when, only both Ignition switch & kill switch are in ‘ON’ position.

1. Fuel Level Indicator: It shows fuel level in fuel tank.

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

3. Turn Signal Indicator (LH & RH): When Turn signal switch is pushed to Left or Right, turn signal indicator - LH or RH will flash.

4. Neutral Indicator: When the transmission is in Neutral, Neutral indicator will glow.

5. Hi Beam Indicator: When Headlight is ‘ON’ & Hi beam is selected with engine running, Hi beam indicator will glow.

6. Low Oil Pressure Indicator ( ) : It blinks when engine oil pressure is low.

7. Malfunction Indicator : It blinks whenever any abnormality is noticed in functioning of FI system related components.

8. Low Battery Indicator : It indicates battery needs charging.

9. Bajaj Logo : Bajaj logo flying ‘B’ glows continuously.

10. ABS Indicator : With Ignition switch ON the ABS indicator glows. When vehicle speed is more than 5 km/hr, the ABS indicator goes OFF, if this indicator glows while vehicle is running, it means there is problem in ABS unit.

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5

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Speedometer Details

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10. Mode Button : Mode button used for changing the mode while selecting & setting Trip1, Trip2, ODO, Clock & Service reminder.

11. Set Button : Set button used for setting Clock & Service reminder.

12. Reserve/Engine Rev Indicator: It glows continuously when petrol level in tank reaches reserve level. It also blinks when engine RPM cross 10000 RPM mark.

13. Service Reminder ( ) : ‘Wrench’ symbol glows when ODO meter reading reaches to set Kms. It indicates vehicle is due for periodic service.

This Icon will flash at - 1st : 450 km 2nd : 4450 km, 3rd : 9450 km, 4th : 14450 km

and subsequently at each 5000 kms. Icon will continue to glow till it is reset. This icon is to be reset after service is carried out.

14. Side Stand Indicator : When Side stand is ‘ON’, the Side stand indicator will lit.

15. D igital Clock : It indicates time in HR : MM (AM/PM)

16. Speedometer: Vehicle speed will be displayed in digital form in Km / Hr.

17. Odometer : The Odometer shows the total distance that the vehicle has covered. Odometer can not be reset to ‘Zero’.

18. Trip Meter : Trip 1 & Trip 2 shows the distance traveled since it was last reset to zero. Rolls over to zero after 999.9 km & continue updating.

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11S

M

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2. Service Reminder Reset ( ) :

• ‘Wrench’ symbol glows when ODO meter reading reached to set Kms.

This icon will glow at-st nd 1 : 450 Kms 2 : 4450 Kmsrd th 3 : 9450 Kms 4 : 14450Kms

& subsequently at each 5000 Kms.

1. Trip Meter Reset :

• Mode & Set push button is provided for selecting & resetting ‘ODO/TRIP1/TRIP2’. LHS part of speedo console.

1. Press 'Mode' buttonfor less than 2 sec.

Press 'Mode' buttonfor more than 15 sec.

Mode changes from ‘ODO/TRIP1/TRIP2’

Selected mode‘TRIP1/TRIP2’ will get reset. Other TRIP mode will continue updating.

2.Note : Engine & motorcycle speed should be zero.

Speedometer Setting

M

S

Mode

Service Reminder

TRIP1/2

Set

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3. Clock Reset :

• Digital clock indicates time in HR & MM separated by colon ‘:’

• It is a 12 hour clock.

• Initially ‘:’ will be blinking

• Clock setting is possible in TRIP 1 mode only.

1. Press 'Mode' push buttonfor less than 2 sec.

TRIP1 Mode selected

2. Press 'Mode' & 'Set'push button togetherfor more than 2 sec.

Press 'Mode' button for less than 1 sec.

Press 'Set' button for less than 1 sec.

Press 'Mode' & 'Set'button together formore than 2 sec.

Clock set 'Mode' is selected & no editingis carried out formore than 5 sec. or Vehicle is started.

‘:’ stops blinking Digits start blinking

Hour digits willincrease by one.

Minute digits will increase. If Mode/Set button is pressed continuously then digits will stop blinking.

Set value will be savedExit clock setting mode Digits stop blinking ‘:’ start blinking

Auto exit without saving set value.

3.

4.

5.

6.

Speedometer Setting

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M

S

Mode

TRIP1/2

Set

Speedometer Setting

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Warning:Danger of accidentsWhen visibility is poor, the daytime running light is not a substitute for the low beam.Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain.– Ensure that the appropriate type of lighting is

always selected.– Note the legal regulations regarding the daytime

running light.

Advice on first use

Danger:Danger of accidentsA rider who is not fit to ride poses a danger to him or herself and others.– Do not operate the vehicle if you are not fit to

ride due to alcohol, drugs or medication.– Do not operate the vehicle if you are physically

or mentally impaired.

Warning:Danger of accidentsNew tires have reduced road grip.– The contact surface on new tires is not yet

roughened.

Warning:Risk of injuryMissing or poor protective clothing presents an increased safety risk.– Wear appropriate protective clothing such as

helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

Warning:Danger of crashingDifferent tire tread patterns on the front and rear wheel impair the handling characteristic.Different tire tread patterns can make the vehicle significantly more difficult to control.– Make sure that only tires with a similar tire

tread pattern are fitted to the front and rear wheel.

Warning:Danger of accidentsNon-approved or non-recommended tires and wheels impact the handling characteristic.– Only use tires/wheels as recommended by OEM

with the corresponding speed index.

Speedometer Setting

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Warning:Danger of accidents

Total weight and axle loads influence the handling

characteristic. The overall weight consists of:

motorcycle ready for operation and with a full

tank, driver and passenger with protective clothing

and helmet, and luggage.

– Do not exceed the maximum permissible overall

weight or the axle loads.


Improper mounting of cases or the tank rucksack

impairs the handling characteristic.

– Mount and secure cases and tank rucksack

according to the manufacturer's instructions.

Warning:Danger of accidentsThe luggage system will be damaged if it is overloaded.– Read the manufacturer information on maximum

payload when mounting cases.


Luggage which has slipped impairs visibility.

If the tail light is covered, you are less visible to

traffic behind you, especially when it is dark.

– Check that your luggage is fixed properly at

regular intervals.


A high payload alters the handling characteristic

and increases the stopping distance.

– Adapt your speed to your payload.


Pieces of luggage which have slipped impair the

handling characteristic.

– Check that your luggage is fixed properly at

regular intervals.

Control Switches

A

B

C

D

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. High/Low Switch : When headlight is ON, High or Low beam can be selected with this switch. Hi beam indicator light located on Speedo console will light up when high beam is selected.

: High Beam : Low beam

B. Turn Signal Switch : When the turn signal knob is pushed to Left ( ) or Right ( ) respective indicator will start blinking, to exit push the knob in & release.

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Control Switches

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Right Handle Bar Switches

E. Starter Button :

Starter button operates the electric starter when clutch lever is depressed with transmission in any gear.

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

F. Engine Kill Switch :

The engine kill switch is for emergency use. In an emergency, move the engine kill switch to the ‘OFF’ ( ) position.

Speedometer display will work when both Ignition switch & kill switch are in ‘ON’ position.

CAUTION : While starting ensure that engine kill switch is in ON ( ) position.

Engine will not start if the kill switch is in OFF position

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Control Switches

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Automatic Headlamp ON (AHO)

Danger:Danger of accidentsWhen visibility is poor, the daytime running light is not a substitute for the low beam.Automatic switching between the daytime running light and low beam may only be partially available when visibility is significantly impaired due to fog, snow or rain.– Ensure that the appropriate type of lighting is

always selected.– Note the legal regulations regarding the AHO.

Front / Rear Seat

A

Tool Kit Location

• It is located below the ‘Rear seat’.

• 2 rubber straps are provided to hold the tool kit.

Removal of Rear Seat

• Insert Key into lock (A)

• Turn the key clock wise.

• Pull front end of ‘Rear seat’

• Take out ‘Rear seat’

CAUTION : Always ensure rubber strap is fitted for securing tool kit.

Tool Kit

B

Battery• It is located below ‘Front seat’.

Battery detai ls are given in ‘Battery Maintenance’.

Removal of Front Seat

• First remove ‘Rear seat’.

• Remove ‘Front seat’ mounting bolts (B).

• Pull back rear end of ‘Front seat’.

• Take out ‘Front seat’.

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Fitment of Front & Rear Seat

Fitment of ‘Front Seat’

• Match the lugs of ‘Front seat’ (A) with chassis bracket (B).

• Push ‘Front seat’ toward petrol tank.

• Match ‘Front seat’ rear brackets (C) with the holes provided on chassis.

• Tighten the bolts (D).

Fitment of ‘Rear Seat’

• First make sure ‘Front seat’ is fitted properly.

• Place ‘Rear seat’ in fitment location.

• Insert bracket (E) of seat into hook (F).

• Match the rod of ‘Front seat’ (G) with seat lock (H).

• Press front portion of seat.

Front seat lug & bracket

B

A

E

FG

H

CD

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Daily Safety Checks

• Brake Fluid level above MIN mark provided on reservior, applicable to disc brake vehicle.

• Drive Chain s lack of 20 to 25 mm adequately lubricated.

• Function of all lights & horn

• Clutch lever play - 2 to 3 mm

• Smooth steering movement without restriction.

• Side stand return to its retracted 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 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.

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Daily Safety Checks

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Starting

Danger:Danger of poisoningExhaust gases are toxic and inhaling them may result in unconsciousness and death.– Always make sure there is sufficient ventilation

when running the engine.– Use an effective exhaust extraction system

when starting or running the engine in an enclosed space.

Caution:Danger of accidentsElectronic components and safety devices will be damaged if the battery is discharged or missing.– Never operate the vehicle with a discharged

battery or without a battery.

Note:Engine damageUnfiltered intake air has a negative effect on the service life of the engine. Dust and dirt will enter the engine without an air filter.

– Never start to use the vehicle without an air filter.

Note:Engine damageHigh revving speed with a cold engine negatively impacts the lifespan of the engine.– Always run the engine warm at a low speed.

Shifting, Riding

Warning:Danger of accidentsAbrupt load alterations can cause the vehicle to get out of control.– Avoid abrupt load alterations and sudden

braking actions.– Adapt your speed to the road conditions.

Warning:Danger of accidentsIf you change down at high engine speed, the engine races.– Do not change into a low gear at high engine

speed.

Warning:Danger of accidentsAn incorrect ignition key position causes malfunctions.– Do not change the ignition key position while

driving.

Daily Safety Checks

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Warning:Danger of accidentsAdjustments to the vehicle distract attention from traffic activity.– Make all adjustments when the vehicle is at a

standstill.

Warning:Risk of injuryThe passenger may fall from the motorcycle if they conduct themselves incorrectly.– Ensure that the passenger sits correctly on the

passenger seat, places his or her feet on the passenger foot rest and holds on to the rider or the grab handles.

– Note the regulations governing the minimum age of passengers in your country.

Warning:Danger of accidentsA risky riding style constitutes a major risk.– Comply with traffic regulations and ride

defensively and with foresight to detect sources of danger as early as possible.

Warning:Danger of accidentsCold tires have reduced road grip.– Ride the first miles carefully on every journey at

moderate speed until the tires reach operating temperature.

Warning:Danger of accidentsNew tires have reduced road grip.The contact surface on new tires is not yet roughened.

Warning:Danger of accidentsPieces of luggage which have slipped impair the handling characteristic.– Check that your luggage is fixed properly at

regular intervals.

Warning:Danger of accidentsA fall can damage the vehicle more seriously than it may first appear.– Check the vehicle after a fall as you do when

preparing for use.

Applying the brakes

Warning:Danger of accidentsMoisture and dirt impair the brake system.– Brake carefully several times to dry out and

remove dirt from the brake linings and the brake discs.

Daily Safety Checks

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Warning:Danger of accidentsA spongy pressure point on the front or rear brake reduces braking efficiency.– Check the brake system and do not continue

riding until the problem is eliminated. (Your Authorized Bajaj Service Centers will be glad to help.)

Warning:Danger of accidentsThe brake system fails in the event of overheating. If the foot brake lever is not released, the brake linings drag continuously.– Take your foot off the foot brake lever when

you are not braking.

Warning:Danger of accidentsHigher total weight increases the stopping distance.– Take the longer stopping distance into account

when carrying a passenger or luggage with you.

Warning:Danger of accidentsSalt on the roads impairs the brake system.– Brake carefully several times to remove salt

from the brake linings and the brake discs.– When braking, release the throttle and apply the

front and rear brakes at the same time.

Warning:Danger of accidentsABS may increase the stopping distance in certain situations.– Adjust application of the brakes to the

respective riding situation and riding surface conditions.

Warning:Danger of accidentsThe rear wheel can lock due to the engine braking effect.– Pull in the clutch, if you perform emergency or

full braking, or if you brake on a slippery ground.

Warning:Danger of accidentsBanked or laterally sloping ground reduces the maximum possible delay.– If possible finish braking before going into a

bend.

Daily Safety Checks

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Stopping, Parking

Warning:Risk of injuryPeople who act without authorization endanger

themselves and others.– Do not leave the vehicle unattended if the

engine is running.– Protect the vehicle against access by

unauthorized persons.– Lock the steering and remove the ignition key if

you leave the vehicle unattended.

Warning:Danger of burnsSome vehicle components become very hot when the vehicle is operated.– Do not touch any parts such as the exhaust

system, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

Note:Material damage

The vehicle may be damaged by incorrect procedure

when parking. Significant damage may be caused if

the vehicle rolls away or falls over.

The components for parking the vehicle are designed

only for the weight of the vehicle.

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when the

vehicle is parked on a stand.

Note:Fire hazard

Hot vehicle components pose a fire hazard and

explosion risk.

– Do not park the vehicle near to materials which are

highly flammable or explosive.

– Allow the vehicle to cool down before covering it.

How to Ride Your Bike

1. Starting The Engine :

• Turn ignition switch key to ‘ ’ position.• Keep kill switch in ‘ ’ position.• Confirm that transmission is in neutral / press

the clutch lever.• Keep throttle completely closed, press starter

button,• Release starter button as soon as engine

starts.

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

2. 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.

3. Moving Off :• Check that side stand is up / retracted.• Depress the clutch lever.

st • Shift into 1 gear.• Open the throttle and release the clutch lever

slowly and simultaneously.• As the clutch starts to engage, open the

throttle a little more, giving the engine just enough rpm to prevent it from stalling.

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 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.

Note : Incase of battery discharged condition, vehicle can be started by pushing it.

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4. 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 and do not de-clutch. Reduce your speed before you get into the corner. For emergency brak ing , d is regard downsh i f t ing , and concentrate on applying brakes as hard as possible without skidding.

5. Stopping the Vehicle :

• Close the throttle completely.

• Shift the transmission into neutral.

• Bring the vehicle to complete stop.

• Turn the ignition switch off.

th th From 5 to 4 Gear

th 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

Gear shifting pattern Gear shifting Lever

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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 speeds as recommended in table above.

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6. Parking the Vehicle :

6.1 Parking using center stand.

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

6.2 Parking using side stand.

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

• Lock the steering.

7. Running IN

Proper running-in is important for 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 rev the engine excessively.

• Do not start moving or rev the engine immediately after starting. Run the engine for a minute at idle speed to give the oil a chance to workup into the engine.

Kms 1st 2nd 3rd 4th 5th

0 - 1000 14 22 30 38 44

1000 - 2000 19 30 42 52 61

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


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Fuel Saving Tips :A well maintained vehicle and good driving can contribute a lot to the saving of feul. Following are a few simple fuel saving tips.

Good Riding Habits :

• Ride smoothly and steadily at a reasonable speed.

• 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, preferably from same fuel dispenser.

• Divide kilometers run / fuel quantity filled.

Ensure following maintenance points to getoptimum 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.

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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 riding to avoid entangling in wheel or other objects on road.

• Always concentrate on Safe riding.

Rainy Season Care :

• It is suggested to customer to take appropriate care in area of high rainfall area. Appropriate surface preventive coat to avoid rusting 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 riding. Your helmet should conform to appropriate Safety standards.

• Thoroughly read the instructions given in this manual and follow them carefully.

• Avoid unnecessary accessories for the safety of both rider and other motorists.

• Get familiar with 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 rider 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 long life of the vehicle.

• During monsoon drive the vehicle more cautiously. Remember vehicles skid more easily during light showers.

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Engine Oil Level Checking :

• Check engine oil level every day in the morning. Park vehicle perpendicular to the ground on level surface as mentioned.

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

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

Engine Oil Capacity :

• Refill at servicing : 1350 ml.(1200ml.+150 ml.)

• During engine overhaul : 1550 ml.(1400ml.+150 ml.)

(additional 150 ml is for Oil Cooler)

A : Oil Filler CapB : Oil Level Window

Engine Oil

Model Recommended Engine oil Grade

Pulsar SAE 20W50 API ‘SL’, or JASO ‘MA’ NS160Fi

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.• Contact your Dealer for proper disposal

of drained engine oil.

Recommended Engine Oil:

st• Engine oil replacement frequency : 1 service & then every 5,000 Km.

• Engine oil level top-up frequency : Every 2500 km.

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Wheels - Tube Less Tyre

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.

Note : Ensure tyres fitted comply with local rules and regulations governing tyres.

Front 25 PSI

Pulsar NS 160 Fi Rear (Solo) 28 PSI

Rear (with Pillion) 32 PSI

Front Wheel

Removing Front Wheel :• Park vehicle perpendicular to the ground on level

surface • Remove speed sensor cable from case meter

assembly.• Loosen front axle nut.• Remove front wheel assembly from fork.

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Installing the Front and Rear wheel

Warning:Danger of accidentsOil or grease on the brake discs reduces the braking effect.– Always keep the brake discs free of oil and

grease.– Clean the brake discs with brake cleaner when

necessary.

Warning:Danger of accidentsReduced braking effect caused by damaged brake discs.– Always lay the wheel down in such a way that

the brake discs are not damaged.

Warning:Danger of accidentsThere is no braking effect to start with at the rear brake after installing the rear wheel.– Actuate the foot brake several times before

going on a ride until you can feel a firm pressure point.

Checking the tire condition

Warning:Danger of accidentsIf a tire bursts while riding, the vehicle becomesuncontrollable.– Ensure that damaged or worn tires are replaced

immediately.

Warning:Danger of crashingDifferent tire tread patterns on the front and rear wheel impair the handling characteristic.Different tire tread patterns can make the vehiclesignificantly more difficult to control.– Make sure that only tires with a similar tire

tread pattern are fitted to the front and rear wheel.

Warning:Danger of accidentsNon-approved or non-recommended tires and wheels impact the handling characteristic.


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Antilock braking system (ABS)

Warning:Danger of accidentsChanges to the vehicle impair the function of the ABS.– Do not make any changes to the suspension

travel.– Only use spare parts on the brake system

which have been approved and recommended by Bajaj.

– Maintain the specified tire air pressure.– Service work and repairs must be performed

professionally.

The ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.

Warning:Danger of accidentsDriving aids can only prevent a rollover within the physical limitations.It is not always possible to compensate for extreme riding situations, for example with luggage loaded with a high center of gravity, varying road surfaces, steep descents or full braking without disengaging the gear.– Adapt your riding style to the road conditions

and your driving ability.

Checking the brake discs

Warning:Danger of accidentsWorn-out brake discs reduce the braking effect.– Make sure that worn-out brake discs are

replaced immediately.

Battery

Battery : 12V - 8 Ah VRLA• Battery is located below front seat.

Battery Features :

• No topping-up is required

• Reduced self discharge, Enhances safety.

• No vent tube open to atmosphere hence no discharge of electrolyte through vent tube.

• It is always recommended to hand over t h e same to an Authorised battery / Bajaj dealer for proper disposal.

• When low bat te ry i con pops-up on speedometer display, it is advised to get in touch with Bajaj dealer & get it charged immediately.

How to keep battery healthy ?

• Switch ‘Off’ ignition when engine is not running.

• Get battery checked/ charged during periodic services.

• Do not press starter button for more than 5 sec. After 3 successive cranking, wait for 15-20 sec. for battery to recover.

• Do not add extra electrical accessories such as - Remote, Bigger Horn, Musical brake light etc. This will reduce life of battery

• Disconnect battery +ve & -ve wires if vehicle is to be stored for more than 2 weeks. This avoids self discharge.

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

• Environment care must be taken to dispose off the used battery.

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Battery

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Removing & Recharging the Battery

Warning:Risk of injury

Battery acid and battery gases cause serious

chemical burns.

– Keep batteries out of the reach of children.

– Wear suitable protective clothing and safety

glasses.

– Avoid contact with battery acid and battery

gases.

– Keep sparks or open flames away from the

battery.

– Only charge batteries in well-ventilated rooms.

– Rinse the affected area immediately with plenty

of water in the event of contact with the skin.

– Rinse eyes with water for at least 15 minutes

and consult a doctor immediately if battery acid

and battery gases get into the eyes.


Batteries contain environmentally-hazardous

materials.

– Do not dispose of batteries as household

waste.

– Dispose of batteries at a collection point for

used batteries.

Periodic Maintenance Information

Spark Plug

• Remove spark plugs by using plug 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.) : BOSCH UR4AC

Champion PRZ9HC

0.7 to 0.8 mm

Drive Chain Slackness

• Chain slackness will have to be adjusted whenever required.

• Std. Chain slackness 20 ~ 25 mm.

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

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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, or

equivalent. Ensure that the lubricant does

not damage the rubber 'O' rings.

Method of O-ring Chain Lubrication :• Park vehicle perpendicular to the ground on level

surface as Clean the chain by using lint mentioned. 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.

DriveChainCleaning

DriveChainLubrication

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Checking & Adjusting the chain tension


Incorrect chain tension damages components and

results in accidents.

If the chain is tensioned too much, the chain,

engine sprocket, rear sprocket, transmission and

rear wheel bearings wear more quickly. Some

components may break if overloaded.

If the chain is too loose, the chain may fall off the

engine sprocket or the rear sprocket. As a result,

the rear wheel locks or the engine will be damaged.

– Check the chain tension regularly.

– Set the chain tension in accordance with the

specification.

Brake Fluid

Front & Rear Brake Fluid Level

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

• Rear brake fluid reservior is located behind RH pillion holder bracket.

• To check oil level, Park vehicle perpendicular to the ground on level surface as mentioned with handle bar in straight ahead condition

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

Brake Fluid Replacement

• Check & Adjust brake fluid level in every service.

• Change the brake fluid of the front & rear brake according to service schedule.

Use only DOT-3 ro DOT-4 brake fluid (from sealed container) for top up & replacement.

Front Brake Fluid Reservoir

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Brake Fluid

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Checking & Adding the brake fluid level

of the front brake


An insufficient brake fluid level will cause the

brake system to fail.

If the brake fluid level drops below the MIN

marking, the brake system is leaking or the brake

linings are worn down.

– Check the brake system and do not continue

riding until the problem is eliminated.


Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear

brake is changed in accordance with the service

schedule.


Hazardous substances cause environmental

damage.

– Dispose of oils, grease, filters, fuel, cleaning

agents, brake fluid, etc., correctly and in

compliance with the applicable regulations.


An insufficient brake fluid level will cause the

brake system to fail.

If the brake fluid level drops below the MIN

marking, the brake system is leaking or the brake

linings are worn down.

– Check the brake system and do not continue

riding until the problem is eliminated.

Brake Fluid

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Warning:Skin Irritation

Brake fluid causes skin irritation.

– Keep brake fluid out of the reach of children.

– Wear suitable protective clothing and safety

glasses.

– Do not allow brake fluid to come into contact

with the skin, the eyes or clothing.

– Consult a Doctor immediately if brake fluid has

been swallowed.

– Rinse the affected area with plenty of water in

the event of contact with the skin.

– Rinse eyes thoroughly with water immediately

and consult a Doctor if brake fluid comes into

contact with the eyes.

– If brake fluid spills on to your clothing, change

the clothing.

Checking the front & rear brake linings


Worn-out brake linings reduce the braking effect.

– Ensure that worn-out brake linings are replaced

immediately.


Damaged brake discs reduce the braking effect.

If the brake linings are not changed in time, the

brake lining carriers grind against the brake disc.

As a consequence, the braking effect is greatly

reduced and the brake discs are destroyed.

– Check the brake linings regularly.

Checking & Adjusting the free travel of

foot brake lever


The brake system fails in the event of

overheating.

If there is no free travel on the foot brake lever,

pressure builds up in the brake system on the

rear brake.

– Set the free travel on the foot brake lever in

accordance with the specification.

Periodic Maintenance & Lubrication Chart

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Servicing

RECOMMENDED FREQUENCY

Servicing & Water Wash

Sr.No. Operation 1st

Take care that no water enters in Petrol tank, Silencer & in electrical Parts. Use caustic free detergent for washing.

Kms

Engine oil & Engine oil filter

Oil strainer

Spark Plug

Air cleaner element & cover O ring***

1.

2.

3.

4.

7.

5.

6.

CL,A,R CL,A

CL,R R

CL CL CL CL CL

R

ü ü ü ü ü ü ü

SAE 20W50 API SL JASO MA Grade C,R R R R R

2nd 3rd

500~

750

4500~

5000

9500~

10000

RemarksEvery 5000 Kmafter Previous Service

In line fuel filter

Oil strainer cleaning at every oil change

CL,A

Cleaning not required

Fuel pipe C,R

R

R R R

R

RR

RR


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RECOMMENDED FREQUENCYSr.No. Operation

Valve tappet clearance

Sealed drive chain cleaning & lubrication

Air filter drain tube

Silencer drain hole cleaning

9.

11.

13.

14.

15.

Customer to apply OKS chain lub spray at every 500 kms.

CL

C,A

CL,L,A

CL

8.

10.

12.

Servicing

Kms

CL,L,A

1st

500~

750

CL

CL,L,A

2nd

4500~

5000

CL

CL,L,A

3rd

9500~

10000

C,A

CL,L,A

CL CL

CL,L,A

CL

CL,L,A

CL

CL,L,A

Remarks

Silencer tail pipe cleaning** CL CL CL CL CL CL CL

Replace Brake shoe/pads at every 15,000 kms C,L,R C,R C,L,R C,L,R C,L,R C,L,R

Brake lining or pad wear & lubricate Brake cam / pivot pin** - Check pad wear indicator

Every 5000 Kmafter Previous Service

CL

Brake fluid level**-top up / replace

Use recommended brake fluid (DOT3/DOT4)

C,A,R C,A R

Disc brake assly - check functionality, leakage or any other rubber parts damage.

C C C CReplace rubber parts if found damaged

Clean at every 20000 kms.

C,L,R C,L,R

C,A


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wiring harness & Battery connections routine, tie bands & clamps tightness

Ignition switch barrel cleaning & Handle bar control switches contacts cleaning

17.

19.

22.

18.

21.

All cables & rear brake pedal-free play

20.

Use WD40 spray or equivalentC,CL

C,A

C,A,T

Servicing

Kms

C,A

C,A,T

C,CL

1st

500~

750

C,A

C,CL

C,A,T

2nd

4500~

5000

C,A

C,CL

C,A,T

3rd

9500~

10000

C,A

C,CL

C,A,T

C,A

C,CL

C,A,T

C,A

C,CL

C,A,T

C,A

C,CL

C,A,T

Remarks

Steering play C,A C,A C,A C,A C,A C,A C,A C,A

Steering stem bearing*** & Cap steering bearing (Plastic)**

Check & replace if damaged. Use Limaplex HTX3 or equivalent grease for lubrication.

C,CL,L,R

C,CL,L,R

C,CL,L,R

C,CL

Every 5000 Kmafter Previous Service

Main stand & side stand pin** Use AP greaseCL,L CL,L CL,L CL,L

16.

All fasteners tightness C,T C,T C,T C,T C,T C,T C,T C,T

General lubrication-Clutch level, front brake level, kick lever. L Use AP greaseL L L L L L L23.

C,CL,L,R

C,CL,L,R

C,CL,L,R

C,CL,L,R


24.

25.

Servicing 1st

500~

750

2nd

4500~

5000

3rd

9500~

10000

RemarksEvery 5000 Kmafter Previous Service

EVAP hoses- Check functionality leakage or any other damage ** C,R

EVAP drain tube cleaning** C,L C,L C,L C,L C,L C,L C,L C,L

Kms

* It is strongly recommended to use only recommended grade of oil.

** 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.

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Replace if cut / damaged. Applicable for product with EVAP system only

Applicable for product with EVAP system only

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Non-Use Maintenance

Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from such other non-operational damages like fire hazards.• Clean the entire vehicle thoroughly.• 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 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 the battery recharged from the Authorised Service

Center / Battery Dealer.• Apply petroleum jelly on terminals. (applicable to certain

models).

Preparation for regular use after storage :• Clean the vehicle• Fit the battery after recharging.• 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.• 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 the battery recharged from the Authorised Service

Center / Battery Dealer.• Apply petroleum jelly on terminals. (applicable to certain

models).Preparation for regular use after storage :• Clean the vehicle• Fit the battery after recharging.• 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.

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