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TO: Selected Dealers / Authorized Service Centers - 2 Wh Spare Parts Dealers & Distributors Sub: Introduction of Pulsar 220 DTSi
Dear Sirs: We are pleased to introduce Bajaj Pulsar 220 DTSi. This bike offers a great package of Style, Power & Technology in its class of bikes. We enclose herewith following information of this new bike, which gives you insight on product features, maintenance details etc.
Product related information
1. Salient Features 2. Technical Specifications 3. Comparison With Competition Vehicles 4. DC Ignition System 5. Read before you ride 6. Pre-Delivery Inspection Checklist
Maintenance related information
7. Pre-Delivery Inspection - SOP 8. Periodic Service SOP 9. Periodic Maintenance & Lubrication Chart 10. Critical Part List 11. Initial Kit List-Vehicle billing would start after dealer placing order Initial kit. 12. Frequently Asked Questions 13. Frequently Asked Questions related to Warranty 14. Reimbursement of warranty Jobs 15. Electrical Circuit
Note:1. The existing Pulsar 220 DTS-Fi is not opened for non pro-biking dealers. Hence this model will be sold & serviced by probiking dealers only. 2. In view of above policy, the warranty & FSC of Pulsar 220 DTS-Fi will be claimed by probiking dealers as usual. Please go through above information. Ask your workshop & spare parts managers to share the same with all staff and act upon the action points as per action matrix enclosed. Thanking You, Yours faithfully,
Page 1 of 32
Annex-1
Salient Features
Attribute
Key Features
Brawny masculine looks Stylish split seats 2 piece grab rail Tank spoiler Wolf-eyed head lamp Clip on - split type handle bar. Black styling Thicker and pinched clamped fork Naked chain with O ring. New colours. 3 D metallic decals on petrol tank. All black painting. Stylish stainless steel silencer. Clear lens blinkers.
Style
Performance
Performance
4 stroke DTSi 220 cc air cooled engine with an oil cooler. Engine generating21 Ps @ 8500 rpm. Digital twin spark ignition. Digital DC CDI with TPS control DC ignition system. CV carburetor New starter clutch. Controlled lubrication system for clutch. Bigger Exhaus-TEC. Bigger catalytic converter. DTSi technology advantages : 1. Good power and pick up. 2. Better fuel efficiency. 3. Lesser emissions. DC Ignition system advantages : 1. Easy to start due to low trigger start RPM. 2. Cold startability improved due to auto choke. Better engine performance Ride that can be enjoyed due to 1. Razor sharp response to throttle inputs. 2. More power at all load conditions, better torque at low rpm, less emissions. 3. Ease of startability during winter mornings too. 4. Environment friendly bike. 5. Smooth gear shift
DTSi Engine
Comfort
Large 37 dia front fork with more stroke length. Nitrox shockers at the rear. Bigger suspension travel at rear due to smaller wheel dia. Swing arm with needle roller bearings at pivot Pinch clamp fork. Wide tyres at front (90/90/17)and rear(120/80/17). Clip on type handle bar. More stroke length to absorb shocks. Better dampening during high speed drives. More stroke length to absorb shocks. Low friction and high rigidity. Smooth - parallel fork sliding action. Better grip available. Isolation of vibrations due to rubber dampening. Smooth ride at any terrian. Smooth ride at any speeds/terrian. Comfort on country roads too. Excellent drive No sticktion at front fork. Excellent Road holding characteristics. No vibrations.
Page 2 of 32
Convenience
Self cancelling indicators. LCD Speedo console. 1 .Low Battery level indicator. 2. Filter foam clogging indicator. 3. Engine oil temp sensor. 4. Low Engine oil level indication sensor. 5. Day - night mode 6. Digital speed indication. 7. Tripmeter to record two trips. 8. Reserve indicator warning LED lamp. 9. Engine Over speed limiter. 10. Digital fuel gauge. 11. Tachometer for engine speeds. Intelligent battery saves function during excess cranking. Intelligent battery saves function during continuous head lamp ON condition. illuminated handle bar switches. Low maintenance battery. High capacity O ring chain. Anti scratch tank pad. No need to push back the button after turns. Get the warning before battery conks off. Clean filter to keep engine healthy. Save oil related damages. Save oil related damages. Easy on eyes during night drive, can see during day time. Easy of reading Better to claim conveyance bills. Better fill up quickly. Protects the engine from excess raving. Easy to read. Monitor and maintain engine speeds. Disables cranking after three cranks, thus saving battery drain. Shuts off within 3.5 seconds, thus saving continuous battery drain. Delight to watch during night. Do not worry to fill up electrolyte level. Dust would not enter inside chain. Tank protected from scratches. Easy to ride without any driving/operating/maintenance hassles.
Safety
Bigger front disc brake. Bigger rear disc brake. Tubeless tyres. High strength chassis. DC head lamp Auto switch over to in tact head light filament in case of fusing. 3000 combination ignition lock twin track key Confidence inspiring brakes. Confidence inspiring brakes. Would deflate slowly allowing you to reach safely. Better strength and stability on drive. Better illumination during low idling speeds too. Lights are always ON. Pilfer proof. Safety on drive by better braking/lights. Lights are always present. Safe even when not being driven.
Page 3 of 32
Annex - 2
Technical Specifications
CONTROLS Steering Accelerator : Handle bar : Twist grip type on right hand of handle bar : Left foot pedal operated : Lever operated on left side of handle bar : Auto choke Front Rear ELECTRICALS System Battery Head lamp Pilot lamp( Tail/stop lamp Turn signal lamp Turn signal pilot lamp Side stand indicator lamp Hi beam indicator lamp Neutral indicator lamp Speedometer lamp Rear No. plate Lamp Horn DIMENSIONS Length Width Height Wheel base Turning circle radius Ground Clearance WEIGHTS Vehicle kerb weight Max. total weight PERFORMANCE Climbing ability : 28 % (16 )
0
Type No. of cylinders Bore Stroke Engine displacement Compression ratio Idling Speed Maximum net power Maximum net torque Ignition system Ignition Timing Fuel Fuel Feed Spark Plug Spark plug gap Lubrication Starting Clutch Transmission Primary reduction Gear Ratios 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Final Drive Ratio
: Four stroke, Natural air cooled. : One. : 67 mm : 62.4 mm : : : : : : : : : : : : : : : : 220 cc 9.5 + 0.5 : 1 1400 +100 rpm. 21 Ps @ 8500 rpm 19 Nm @ 7000 rpm Microprocessor controlled digital C.D.I. 10 BTDC 1000 rpm 26 bTDC at 2500 RPM Unleaded Petrol Carbureted 2Nos. Champion P -RG6HCC 0.8 to 0.9 mm Wet sump, Forced Electric Start only Wet, multidisc type. 5 speed constant mesh. 3.47 : 1 (66/19)
: Lever operated on right side of handle bar : Pedal operated by right foot.
: 24.736 : 1 (36/13) : 16.814 : 1 (32/17) : 12.335 : 1 (29/21) : 9.677 : 1 (26/24) : 7.939 : 1 (24/26) : 2.57 : 1 (37/14)
:12 Volts (D.C.) :12V 9Ah MF :12V , 55 W H7 (Main) 12V, 55 W H7 (Passing) :12V , 5W 2 Nos : LED/LED : 12V , 10 W : LED : LED : LED : LED : LED Display : 12V, 5 W : 12 V DC , 2 nos :2035 mm. : 750 mm. :1165 mm. :1350 mm. : 2500 mm. :165mm.
CHASSIS & BODY Frame type Suspension: Front Rear : Double cradle type. : : Telescopic with Guide & Slide bush (Stroke - 130 mm.) : Trailing arm with coaxial gas assisted Hydraulic shock absorbers and coil springs.
Page 4 of 32
Annex - 3
YAMAHA YFZ R 15
India Yamaha Motor Pvt. Ltd. Yamaha Blue / Graphite / Blazing Red
Ex-showroom price
ENGINE & TRANSMISSION Air cooled, 4 stroke Single Engine cylinder OHC Displacement 223 cm Engine horse 17ps @ 7000 rpm power Engine Torque 18.35 N-m@ 6000 rpm Gear box 5 Speed Constant Mesh Carburetor - VE, Constant Fuel supply Vacuum Carburetor with CCVI system (Carb controlled variable ignition)
Liquid cooled, 4 stroke Single cylinder SOHC 4 valve 149.8 cm 17 ps @ 8500 rpm 15 N-m @ 7500 rpm 6 Speed Constant mesh Electronic Fuel Injection
4 Stroke, DTSi, Air cooled /with an Oil Cooled 220 cm 21 ps @ 8500 rpm 19 Nm @7000 rpm 5 Speed Constant Mesh Carburetor - CV
Page 5 of 32
CHASSIS & BODY Frame type Suspension Front Suspension Rear Brakes Front Brakes Rear ELECTRICALS Ignition System Battery Spark Plug Head Lamp Tail / Stop Lamp Number plate Turn Signal Lamp Advanced Microprocessor Ignition (AMI) 12V - 7 Ah NGK - DPR8 EA 9 CHAMPION - PRA 7 HC 12V - 35/35 W Halogen (Multi reflector - DC) 12V - 5W / 21W X 2 nos. (Multi reflector) 12V - 5W 12V - 21W X 4 nos. (Multi reflector) TCI 12V - 3.5 AH NGK/CR8E TWIN - Low beam - 12V-35W High beam - 12V - 35W 12V - 5W / 21W 12V - 5W 12V - 10W X 4 nos. 1995 mm 670 mm 1070 mm 1290 mm 160 mm 131 Kgs. 140 kmph 1. Liquid cooled - 4 valves - Fuel injected 2. Delta Box frame 3. Linked type monocross suspension Microprocessor controlled digital CDI 12 V, 9 AH MF Champion P -RG6HCC 12 V, 55 W H7 LED/LED 12 V, 5 W 12 V, 10 W 2035 mm 750 mm 1165 mm 1350 mm 165 mm 152 Kg Tubular single cradle, Diamond type Telescopic Hydraulic shock absorbers Swing arm with 5 step adjustable type Hydraulic shock absorber Disc Dia 276 (non asbestos type) Internal expanding shoe type Dia 130mm (non asbestos type) Delta Box Frame Telescopic Hydraulic shock absorbers Linked monocross suspension with spring/shock absorber Single Disc Single Disc Double Cradle type Telescopic front fork Trailing Arm with coaxial gas assisted hydraulic shock absorbers & coil springs Hydraulically operated disc brake Hydraulically operated disc brake
DIMENSIONS Length 2125 mm Width 755 mm Height 1160 mm Wheel Base 1355 mm Ground clearance 150 mm Kerb Weight 150 Kgs. PERFORMANCE Max. Speed 125 kmph STYLING DIFFERENTIATOR 1. Bold new graphics 2. Speedo dials in bright yellow for clear day time visibility 3. Muffler cover with chrome finish
Styling
1. Brawny masculine looks. 2. Wolf eyes head lamp 3. 3 D Metallic decals on petrol tank.
Page 6 of 32
Annex - 4
Battery life
Better battery charging current at lower rpm and throughout the rpm range. (At 20 kmph speed 1.25 Amps more charging current). Thus no issues even on vehicles running at slow speeds in city. Battery warranty period matched with vehicle warranty period. HRD tester for better health check. Portable booster battery charger.
Page 7 of 32
Annex - 5
1 2 3 4 C 1 2 3 4 5
7 8 9
Page 8 of 32
Annex - 6
Page 9 of 32
IMPORTANT NOTE
Look for any external damages in transit: Please check, record & rectify send report with photos. Moisture / Oil collecting tube of Air filter should be properly fitted and routed correctly. Both LH & RH side spark plug caps must be tightly secured and ensure proper functioning of Spark Plugs. TPS on carburetor for functionings
Page 10 of 32
Annex - 7
Sr. No 1 2 3 4 5 6 7 8
Description Identify & Park Vehicle on Work Bay Remove the Thermocol and additional packing if any. Study PDI card and Work content. Open Petrol tank cap & pour petrol Check for smooth operation of fuel cock lever Check & top up engine oil level, if required. Check clutch cable operation & Adjust if required. Check front brakes for efficient working & Adjust if required. Check and correct tyre inflation pressure - Front Wheel Check Battery voltage, check up electrolyte level, ensure petroleum jelly presence, and connect terminals properly. Inspect Rear Shock Absorber setting & Correct if necessary. Check Rear brakes for efficient working & adjust if required. Check and Correct tyre inflation pressure - Rear Wheel. Lubricate chain and Check / Adjust chain slackness if required. Check Accelerator cable free play Check & Adjust TPS Check gear shifter lever operation Check & Adjust steering and Handle bar for free movement. Check front mudguard alignment wrt Front Wheel
Posit ion
GP Tools
Special Tools
Consumables
Petrol Dispenser
RH RH Front Front
Nose Plier, Oil Can, Funnel OE Spanner Set Ring Spanner Air Pressure Gauge OE Spanner Set, Screw Driver Shocke r Adjust Opened Spanner Set Air Pressure Gauge Ring Spanner Set, OE Spanner, Set, Oil Can OE Spanner Set OE Spanner Set OE Spanner Set Ring Spanner Set OE Spanner Set
Cloth
Suction Pump Pedaled Air Pump Cotton Waste, Petroleum Jelly, Electrolyte Multi Meter, Hydrometer, Battery Charger
LH
0.60
10 11 12
13
LH
0.40
Cloth,SAE 90 Oil
14 15 16 17 18
LH LH LH RH / Front Front
Page 11 of 32
Description Check all important nut bolts for torque and tightness, Handle bar mounting bolt Stem lower & upper bracket bolts Stem of bolts Front axle nut Cylinder head nuts Engine foundation bolts Trailing arm bolts Silencer cover shield bolts Both LH/RH engine mtg. bolts Rear Caliper bolts. Check the following and lubricate if necessary Rear brake lever Pillion foot rest Center stand Side stand Clutch lever OE accessories fitment -Mirrors RH & LH
SMM
Consumables
4.00
19
20
1.00
Oil Can
21
1.15
OE Spanner Set Spanner Set, Tommy Bar, Screw Driver,Plier, Nylon,Ham mer,Allen Key
22
LH/R H
3.25
23
24
25 26
Check electrical couplers of all sensors Engine Temperature sensor Oil level & Temperature sensor Air filter IR sensor Start vehicle, Check operation of electrical like- Head light, Tail light, Brake light, Side stand indicator, Horn, Speedometer, Odometer, Side indicators, Parking, Pass light indicators and Fuel indicator working Check working of all electrical switches Check Idling and CO%. Check RPM meter, Speedometer, Odometer & Trip meter for proper functioning and Correct if required Check all locks for proper operation
LH/R H
0.35
Nose Plier
LH/R H
0.70
+ ve , Screw Driver
LH/R H LH/R H
27
Front
0.50
OE Spanner
28
LH/R H
0.50
Page 12 of 32
Description Test drive the vehicle, check digital speedometer working. Study the PDI job card and verify work done. Take vehicle out and park. Clean/Wash the veh. before delivery Repair for any other defects seen or observed during test drive. Total SMM
SMM
GP Tools
Consumables
29
1.30
30 31
1.00
19.20 Total time taken for PDI SOP 19 Minutes approximately. In a shift of 480 minutes, One technician can do 25 Vehicles PDI SOP comfortably.
Annex - 8
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consumables
1 2 3 4
Wash vehicle thoroughly. Identify the vehicle. Bring vehicle and position on bay. Raise the lift. Start vehicle and Warm up. Remove RH/LH side covers Seat, Petrol tank and keep properly Remove rear seat. Clean Portion Below seat by brush Drain engine oil. Confirm Qty / Quality OR eng Oil 0.3 0.3 0.5
Washing boy
LH
RH
0.7
0.2
LH
1.3
Cloth
Page 13 of 32
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consuma bles
Take Clean marked vessel to measure oil drain. Start bike for 8-10 seconds & switch Off. Drain oil removing drain plug Refer to SA if less than 900 ml.
0..5
RH
Pistol grip PNR Socket set Head Screw Driver Nylon Brush Plastic Tray
10
LH
1.3
RH
Float Gauge
Cloth, Kerosene
11
Check accelerator & adjust Remove RHS plug cap & remove water inside sleeve by Compressed air. Remove both plugs & set Gap (every Service) Replace Spark Plugs at interval of 20,000kms Check & Adjust Tappet clearance. Check LH side important fasteners and tight a. Side bolts of front fork b. Engine foundation bolts c. Side stand d. RSA top & bottom nuts Remove Front Sprocket cover. Clean inside of cover by pressurized water. Dry the cover by compressed air, Remove the dust/dirt surrounding small sprocket by Screw drive/Blade & clean to specs.
LH
0.4
12
LH
0.5
RH
0.5
Plug Spanner
13
10.4 OE spanner set, Ring spanner set Pistol grip PNR Socket set
14
LH
0.6
15
LH
3.0
Brush G. P. tool
kerosene
Page 14 of 32
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consumables
16
Clean Chain with kerosene/Oil by nylon brush. Dry the chain.lubricate with 90 grade oil .Spray "OKS" on chain. Adjust the Chain to specs. Check & adjust rear brake for smooth working Check for mud on caliper pads ,clean. Check for rear damper play by rotating rear wheel. Remove wheel, replace damper if play observed. Check and Adjust rear tyre air pressure Checks for play in rear sprocket Nut- Re tighten if required. Check Battery, top up with Distilled Water. Clean terminals & apply Petroleum Jelly. Rout cables properly & fit terminal caps properly. Recharge battery if required Check Air pressure-10k Pump in nitrox to space (7.5kg/cm2) with help of pump. Clean oil strainer. (Replace if required) After 1 year or 10000km whichever is later, clean centrifugal filter at 10.000 kms Fr Rh.
3.0
Brush
Kerosene
17 18
0.5 0.1
19
0.1
20
0.4
REAR RH
0.4
21
LH
0.2
Spanner
22
RH
1.8
23
LH
RH
24
RH
25
RH
0.3
OE Spanner Set
Page 15 of 32
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consumables
26
1.35
Ring Spanner Set Plier Ring Spanner Set Spark Plug Spanner
Oil disposer, Air gun Filler Gauge Spark Plug Cleaning Machine Air Gun
27
RH
2.4
Cloth
28
FRONT
Piston Ring
Suction Pump
29
Check & Replace the parts if necessary. Check & Adjust play. Check pads - Replaced if required. Check for leakage, spongy feeling. Replace kit if required. Remove fork pipe tubes, drain oil Clean pipe inner with kerosene & then refill new oil from Company supplied bottle (320ml/tube). Check / Adjust front tyre air pressure 0.2
30
31
0.2
32
32
33
FRONT
34
RH
0.8
35
Check RH side important fasteners and tight A. Engine foundation bolts B. Front axle nut C. Side bolts of Front fork D. Handle bar bolts E. RSA top & bottom nuts F. Swing arm axle nut G. Silencer protective cover screws / bolts H. Rear view mirror
RH
1.3
Page 16 of 32
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consumables
36
Lubricate as per lubrication Chart a. Clutch lever b. Pillion foot rest c. Center stand d. Side stand.
LH
RH
0.8
Oil can
37
LH
RH
0.5
38
Blow Compressed air in petrol tank drain pipe.if water traces found in pipe Remove tank. Check drain pipe pinching & Check spring position. Refit the pipe properly. Clean the Cavity below. Cap with clean cloth. Ensure all lubrication points are Covered as per lubrication chart. Check electrical couplers of all sensors a. Engine temperature sensor b. Oil level & temperature
2.0
39
0.3
40
LH
0.35
sensor
c. Air filter IR sensor Check RPM meter, Speedometer, Odometer & Trip meter for proper functioning & Correct if required Start vehicle, Check operation of electrical like -a. Check all electrical switches b. Head light c. Tail light d. Brake light e. Horn f. Speedometer, Odometer, Pass, Parking light g. Side indicators, Front and Rear both sides h. Side stand indicator i. Fuel indicator
41
FRONT
0.5
42
0.95
Page 17 of 32
Sr. No.
Description
SM M
SMM
GP Tools
Sp. Tol.
PNR
Consumables
43
Tune engine & carburettor Study job card & verify work Lower the lift. Take out & park the vehicle SUB TOTAL Carry out any additional work as indicated by the customer or as required TOTAL TIME Test ride of the vehicle if required and park
LH
44 45 46 47 48 49
1 0.3 0.5 16.3 5 21.3 16.55 5 21.55 To be done by Expert To be done by Delivery boy
50
1.5
51
Total time taken for Periodic SOP 33 Minutes approximately.( except major maintenance jobs) In a shift of 480 minutes, One technician can do 15 Vehicles Periodic SOP comfortably. In a shift of 480 minutes, 23 Vehicles per Bay per Day can be achieved comfortable with 1 Bay, 2 Technician working.
Page 18 of 32
Annex - 9
Page 19 of 32
C C,A C,R
C C,A C,R
T C C,A C,R L
C C,A C,R
R -Every 15000 kms. Every 5000 kms. C C - Every Month, R-Every 20000 kms. or once in a year
A - Adjust ;
CL-Clean ;
C - Check
L - Lubricate; T Tighten ;
R- Replace
Note: Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.
Model Pulsar 220-F CC
Quantity Drain & Refill = 1000 ml. Engine Overhaul = 1100 ml.
Note:-Warranty limit:- 2 years or 30,000 kms.( Whichever occurs earlier). 4 Free Services & 9 Paid Services for warranty remains valid.
Page 20 of 32
Annex - 10
SR. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Description
Cylinder head Camshaft assly Valve kit Valve repair kit Block piston assly Clutch Friction Disk -C. Clutch Friction Disk. Clutch Friction Disk -B Plate Clutch Oil cooler Oil cooler pipe inlet Oil cooler pipe outlet Banjo bolts for oil cooler Banjo bolts washer for oil cooler Element air filter Silencer Oil pump assly Rotor Assly - F Stator plate - F HT coil RH HT coil LH Spark plug LH / RH Regulator voltage Starter motor Body complete starter clutch Gear starter clutch Holder step LH Holder step RH Wheel rim front Wheel rim rear Chain sprocket kit
Min lev el 2 2 5 5 2 2 2 2 2 1 1 1 10 20 10 2 1 1 1 1 1 5 1 2 3 2 2 2 1 1 2
P-220
SR.No
Description
Min level 2 2 2 2 2 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 2 2 2 2 2 2 2 2 5 5
P-220
DK101607 DJ101373 DK101326 DK101327 DK101625 DK101567 DK151066 DK151068 DK101565 DK101634 DK101630 DK101631 DK101236 DK101279 DK121009 DK101482 52DH0169 JC111027 JC111026 JC111023 JC111022 DG111008 DK201001 JC111007 DK101595 JC101112 DK161137 DK161138 JC151013 DK151050
54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84
Headlight Assembly Blinker Fr LH Blinker Fr RH Blinker Rr LH Blinker Rr RH Petrol Tank- Red Petrol Tank- Black Petrol Tank - Blue Petrol Tank - Silver Front Fender- Red Front Fender- Black Front Fender - Silver Front Fender - Blue Speedo Cable Assly Fork Inner Pipe Front Disc Decals - Petrol Tank "B" monogram on Tank LH - RED,BLUE, BLACK "B" monogram on Tank LH - SILVER "B" monogram on Tank RH - RED,BLUE, BLACK "B" monogram on Tank RH - SILVER Decals seat - Cowl - Red Decals seat - Cowl Plasma Blue Decals seat - Cowl Silver Grey Decals seat - Cowl Midnight Black Fairing - Red Fairing - Silver Fairing Blue Fairing - Black Gasket Cylinder Block Master Kit - Major ( Front Brake)
DK201056 DJ201208 DJ201209 DJ201206 DJ201207 DK71032V DK71034M DK71034K DK71034L DK74032V DK74034M DK74034L DK74034K DK201098 DK181070 DK151027 36DK0026 JC141049 JC141053 JC141050 JC141054 DH73032V DH73034K DH73034L DH73034M DK74012V DK74014L DK74014K DK74014M DK101063 DE191043
Page 21 of 32
Disc pad set front Rear caliper pad with shims Brake pedal / tie rod Lock set Switch RH Fork oil seal Tube fuel Main relay Fuse Wiring Harness - F Engine temp sensor Camshaft sprocket Camshaft bolt Speedometer Assly -S Speedometer Assly - SF Handle bar - LH Handle bar - LH Handle bar - RH Handle bar - RH Clutch Cable Tail Light Assembly Wind Shield
DE151037 DK151038 DK191012 DK181034 DK201034 DK181019 DJ141006 AL201012 30201085 JC201041 DK101577 DS101276 DK101386 JC191014 JC191018 DK181046 DK181059 DK181047 DK181062 JC191004 DK201003 DK161069
85 86 87 88 89 90 91 92 93 94 95 96 97
Magnet Assly SCB Cylinder head Gasket Switch LH Steering Cone kit Cap Camshaft Capacitor Fuel Gauge Starter Relay(solenoid) Clutch switch (6AMP) Gasket Cover RHS Gasket Crankcase Gasket cover Magneto Lever comp gear shifter
DK201039 DK101003 DK201033 36DV0007 DS101096 DK201036 DK201065 DK201078 DK201083 DH101154 DH101006 JC101137 DH101705
Annex - 11
Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Partno. DK101630 DK101631 JC111022 JC111023 JC191019 JC191004 DK111071 DK201001 DK201033 DK201034 DK101503 DK181019 DK151038
Description OIL PIPE INLET OIL PIPE OUTLET IGNITION COIL WITH CABLE LH IGNITION COIL WITH CABLE RH CABLE ACCELERATER CABLE-CLUTCH CDI UNIT REGULATOR CONTROL SWITCH LH CONTROL SWITCH RH ENGINE TEMP SENSOR OIL SEAL REAR BRAKE PAD
MRP 228 211 114 114 73.5 101 830 879 625 624 123 54.95 194
Page 22 of 32
Annex - 12
Page 23 of 32
Enclosure to Service New Product Bulletin NP : 12 dated 23nd June 2009 There is a peculiar noise from engine told by mechanic as Knocking ? The Pulsar engine employees DTSi technolodgy.The two spark waves from spark plugs collides with each other and that crates a noise ,being perceived as combustion noise. This noise level do not have any effect whatsoever on engine performance and noise.Just Can I use accessories like remote control, imported air filters, add on horns etc? All the parts related to engine and electrical parts are designed to certain specs. Changing/modifying any part would affect the performance. Hence we do not advise fitment of such parts and warranty would also stand negated in all such cases. Hence its better
Annex - 13
These are the parts which are prone to wear and tear due to vehicle usage, external factors. The very fact that they have lasted long up to 10000 kms + do suggest that there was no manufacturing defect to start with. If they had failed now it is something to Why only block piston and crankshaft given under fuel adulteration claims?
1. Component failure due to adulterated fuel is not a manufacturing defect. 2. Engine manufactured for sustaining adulterated fuels would cost too heavy on customer's products. 3. Since this is not a manufacturing defect, can not be covered under warranty. 4. However since this is an accident (use of an adulterated fuel), Bajaj auto and its dealers are ready to contribute and help out customer. All the parties should share the cost of repairs. Bajaj auto would give 40 % cost. Customer would give 33 % and dealer would charge 50 % labour and forego his spare parts discounts. The dealer is supposed to save and reuse certain components to reduce cost of repairs. Thus earlier burden of Rs 7000 to customer would go down to @ 3000. Since this is not a genuine manufacturing defect it would not be covered at the time of a second time failure. Entire automobile fraternity to raise this issue with concerned Government officials. The calculation details of reimbursement are given in the sheet attached. Create the awareness amongst customers regarding proper use of fuel/fuel additives and consequences of bad fuel quality. Why Battery/tyres are not given by selling dealer under warranty? World over the policy of warranty of proprietary parts is the same. They are warranted by respective manufacturers. They are experts in analyzing the failures and have special equipments for checking the parts. Further the Batteries can not be transported due to environmental factors. Why the alloy wheel breakage is not covered under warranty ? Alloy wheels which are die casted have been designed and certified by ARAI for all normal usage conditions. They would crack under extreme operating conditions like heavy impacts. Since heavy impacts are an accident, this will have to be covered under insurance. The run out also can not get developed after usage as like spoked wheels. Hence only paint defect can be covered under warranty - by completely repainting the part. No replacement is required here too.
Page 24 of 32
Enclosure to Service New Product Bulletin NP : 12 dated 23nd June 2009 Why the part as failed on my vehicle so early - why cant you replace complete vehicle ? The vehicle is manufactured by using 4 Ms.men.machine,material and method. Something can go wrong in rare case. The automobile is not a stationary machine like many other consumer durables. To cover up any manufacturing lapse the warranty is given by Bajaj auto. We sincerely apologies for this to have happened on your vehicle. But the faulty part replacement would restore the vehicle performance. We are equipped with, trained to carry out those repairs. Since the vehicle is an assly of so many parts, complete replacement is not a logical solution for this defect removal. Further the change of vehicle is not permitted by RTO,once registered. However we guarantee the optimum performance of your vehicle and we are committed for that. I should get all modified parts fitted on my old vehicle - why not ? Products are being continuously modified by BAJA auto for enhancing performance. This is a way of life. However this does not mean that all the modifications need to be passed on to all consumers. Neither has it happened in any other industry. Why the warranty is not extended and applicable for the part replaced now ? When the vehicle was sold to you the contract of warranty was for 2 years post sale of the vehicle. The warranty is not individually specified for individual parts. Hence its not possible to extend the warranty. However if failure happens on same part again Why warranty seizes if all free/paid service schedules is not maintained ? Periodic maintenance care is extremely important for a moving machine line an automobile. If vehicle is not maintained/serviced prudently as specified by manufacturer, the performance would go down drastically. That may cause few premature failures which c Why the life of a component is so less ? (Sprocket - 13000 kms ?,clutch plates - 17000 kms,Drive chain 16000 kms ?) Apart from material strength, the life of wear and tear items is dependant upon the maintenance care/driving pattern in which the vehicle is running. A prudently maintained/driven vehicle would give thrice the life of a part as compared to badly driven,bad
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Labour Schedule for jobs eligible under warranty : Remboursement of Warranty Jobs
U/W job completion time for Pulsar 220 DTS-i 30.00 30.00 15.00 45.00 60.00 30.00 45.00 45.00 60.00 45.00 75.00 30.00 45.00 30.00 30.00 45.00 15.00 15.00 45.00 30.00 30 30 75 90 60 120 60 60 120 120 60 120 120 120 120 120 60 60 480 60 60 60.00
Annex - 14
SN
Replacement under warranty at dealership Oil Cooler replacement. Replacement of Rear Disc brakes. Replacement of rear Disc Pads ( within 1000 kms) Master Cylinder Major replacement Caliper Assembly Major Kit replacement Front Wheel Drum Bearing replacement Brake Disc replacement Disc holder plate on Wheel Drum replacement Master Cylinder replacement Rear Brake Hose replacement Fairing/fairing frame replacement Air filter Box Assembly replacement Coupler / Hub Bearing / Hub replacement Steering Lock / Key replacement Disc holder plate on Wheel Drum replacement Rear Fender / Mudguard replacement Speedo case/cable replacement Rider Seat Cowling replacement Windshield/ Fairing replacement Complete Lock Set replacement Fuel Tank replacement Replacement of front Disc Pads ( within 1000 kms) Brake Disc replacement Front Brake Hose replacement Front Fork Oil Seal one side Front Fork, Bearing Races, Cones & Steel Balls replacement Fork Inner Tube one side replacement Fork Outer Tube one side replacement Front Fork Upper Holder replacement Front Fork Lower Holder replacement Fork Spring one side replacement Trailing Arm Bush/dust covers replacement Trailing (Swing Arm) replacement Master Cylinder Major Kit replacement Caliper Assembly Major Kit replacement Master Cylinder replacement Magneto Rotor replacement Stator Plate Assembly replacement Chassis / Frame replacement Replacing handle bar Replacement of Chain sprocket kit Engine Foundation Bush Kit replacement
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
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Enclosure to Service New Product Bulletin NP : 12 dated 23nd June 2009 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Fuel cock replacement. Magneto Cover replacement Centrifugal Filter Cover/Gasket replacement Crank Case (LH) Gear Shifter Shaft Oil Seal replacement Clutch Centrifugal Change Gear Shifter Lever Mechanism replacement Gear Return Spring / Shaft Pawl / Spring replacement Carb Assembly replacement Starter Counter Gear/Bush/NRB replacement Guide Starter 'O' ring / Oil seal replacement Guide Starter Assly / Gear Inner Bush replacement Clutch Cover replacement Shaft Release Clutch / Oil Seal replacement Oil Pump Assembly replacement Clutch (Friction / Steel) Plates replacement Cylinder Head Assembly replacement Valve/Springs/Seal replacement Rocker / Shaft Rocker Arm replacement Valve/Valve Guide replacement Timing Chain / Sprocket replacement Cam Shaft Both Bearings replacement Cam Shaft assly. Replacement Set Primary Gear (Driver & Driven) / replacement Body Balancer Assembly replacement Cylinder Block/Piston Assembly replacement Piston Rings replacement Crank Shaft Assembly replacement Crank Shaft Bearings replacement Crank Case Assembly replacement Crank Case (RH) replacement Crank Case (LH) replacement Input Shaft and Out Put Shaft/Speed Gears replacement G.S. Drum replacement G.S. Forks replacement Replacement of Balancer Idler gear Replacement of starter clutch Complete Wiring Harness replacement Replacement of BCU. Starter motor replacement Speedometer Assembly replacement SPM Console Upper Cover replacement Head Lamp Assembly replacement H.T. Coil Single replacement A/C Regulator (Voltage) replacement Ignition Switch Assembly replacement Rear Brake Light Switch replacement Head Lamp Bulb replacement Park Lamp Bulb replacement Tail Lamp Assembly replacement Rectifier / RR unit replacement Fuel Gauge Float Unit replacement 15.00 15.00 30.00 30.00 30.00 45.00 45.00 30.00 30.00 30.00 30.00 60 60 75 90 120 120 120 120 165 120 120 165 165 180 180 330 330 330 330 330 330 330 330 210 75 135 75.00 45.00 45.00 45.00 75.00 15.00 15.00 30.00 15.00 30.00 45.00 15.00 15.00 30.00 1 1 2 2 2 3 3 2 2 2 2 4 4 5 6 8 8 8 8 11 8 8 11 11 12 12 22 22 22 22 22 22 22 22 14 5 9 5 3 3 3 5 1 1 2 1 2 3 1 1 2
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Annex -15
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5. Horn Circuit
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7. Lighting Circuit
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Action Matrix:
SL 1 2 Key Information Salient Features Update Technical Specification Caparison with competitive D C Ignition Read before you ride PDI Checklist PDI SOP & Time Chart Periodic Service SOP Chart Periodic Maintenance & Lubrication Chart Critical Part List Initial Kit part list Frequently asked questions Frequently asked questions-related to warranty Reimbursement of warranty Jobs Electrical Circuits Works Manager/DSE PDI In charge Sales In charge Understand features of this new variant and share with the sales team Service Advisor Update Floor In charge
Update Technicians
3 4 5 6 7 8 9 10 11 12 13 14 15 Initials Date
Share with Sales /Service /PDI teams Share with Sales /Service /PDI team Update Update Update Update Update Share with Sales team & ASC/RSO /YES channels Update Update Technicians Update Technicians Update Technicians
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