12 Manual de Servicio PULSAR 200 NS Trainig Notes
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(Fuel Injection)
The Training Notes are a comprehensive training guide on service and maintenance operations and procedures to be followed by service personnel at authorised service centres and dealerships whilst attending to the Bajaj Pulsar 200NS FI. The Training Note covers standard workshop procedures, simplified for easy learning and understanding for service technicians worldwide.
NOTICE
Copyright
All information contained in this Training Note is based on the latest product information at the time of publication. Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice. The right is reserved to make such changes at any time without prior notice.
All Intellectual Property Rights, including but not limited to Copyright, applying to this drawing and the information contained therein vest solely and exclusively with Bajaj Auto Limited. No part of this drawing may be copied or reproduced, either in part or in full by any means, whether mechanical or electronic, without prior written permission of the authorized signatory of Bajaj Auto Limited. Bajaj reserves all rights to deal with violations of this clause in accordance with applicable laws.
DOC. NO.: REV. 00, OCT 2014
© Bajaj Auto Limited, 11th SEPT 2012.
Contents CHAPTER
1
Workshop Safety and Procedures
CHAPTER
2
The Tool Chest – Know Your Tools Special Tools (Engine & Frame) Standard Tools Other Gadgets
CHAPTER
3
Understanding the Bajaj Pulsar 200NS FI Identity Distinguishing Features Salient Features Technical Features & Specs Read Before Your Ride
CHAPTER
4
Preliminary Checks & Maintenance Operations PDI Checklist Perodic Maintenance Chart Lubrication Matrix Periodic Service SOP
CHAPTER
5
Fuel System & EMS DTSi – Fi Engine Management Systems / EMS Layout Working of Systems Fuel Injection Dos and Don’ts
Contents CHAPTER
6
Engine & Transmission Important Points to Remember During Engine Overhaul Dismantling the Engine Dismantling the Engine Sub Assembly Service Data Tightening Torque
CHAPTER
7
Frame & Suspension Service Limits Tightening Torque Dismantling & Assembling Front Fork Front Disc Brake
CHAPTER
8
Electricals VRLA Battery Initial Filling VRLA Battery Charger & its Charging SOP Dos and Don’ts for RLA Battery Electrical Checking Procedure Electrical Circuit Diagrams
Key Learning Points Understanding workshop discipline and safety guidelines Testing guidelines Precautions whilst handling tools and equipment
CHAPTER 1
Workshop Safety & Procedures
Bajaj Pulsar 200NS FI Training Notes
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1
Workshop Safety and Procedures
Workshop Safety uu Technicians must always be wearing shoes and dressed in clothing that is not too loose. uu Always use protective Equipment (PPE) like - Hand Gloves Mask Safety Goggle Ear Plugs
uu Wear Nitrite Rubber Hand Gloves while handling petrochemicals like petrol, oil, kerosene etc.
uu Fire Extinguisher Install ‘ISI’ approved. Fire extinguishers - CO2 gas cylinders. Refill CO2 before the gas expires.
Install Co2 gas cylinder at appropriate place so that there is no obstruction / good accessibility.
uu Safety Precautions whilst Operating Air Tools
Air pressure tools operate on compressed air supplied by the shop Compressor and Air supply system.
Observe the following safety related precautions when using an air tool. It is advised to fit a pressure regulator (FRL:- Filter Regulator Lubricator) in the pneumatic line which supplies air pressure to the air tool. It regulates the outlet pressure to 6.5 Kg/cm2. This avoids the risk of personal injury.
Warning
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Never use the blow gun to blow dust off your clothes and never point it at another person. The air pressure also thrusts dust particles at high velocity. These particles can penetrate into the flesh or eyes. If high pressure air hits on open wound, it can force air into the blood stream which at times can even result in instant death due to cardiac arrest.
Workshop Safety uu Hand Tools Do not use worn out hand tools. uu Calibration of Workshop Equipment Calibrate all Workshop and M and T Equipment once in a year. uu Avoid direct body contact with Petrol, Kerosene.
Caution
Prolonged contact of used oil can cause cancer.
uu Waste Oil Disposal Sell used oil only to Government approved re-cycle agencies. Collect used oil in oil disposer / barrel. Don’t throw oil into the sewage line. Don’t spill oil on the floor.
uu Precautions to be taken while handling Hydro-Electric Lift Whilst raising / lowering ensure the vehicle is firmly mounted After raising the lifter bay, lock the lift. Don’t put leg/hand in between while raising / lowering uu Safety Tips Do not lower the lifter bay table without unlocking the lift lock. Do not work with loose clothing whilst working on the lifter bay. Do not keep hydraulic joints loose. Do not stand on the lifter bay when in operation. Keep fire away from the power pack. Avoid oil spillage around the working area. uu Battery Acid Handling Use hand gloves, wear apron and safety glasses Avoid contact of battery acid with skin Use plastic trays to keep charging batteries and avoid battery acid spillage uu Brake Fluid Handling Store brake fluid in sealed container and avoid spillage. Avoid contact of brake fluid with skin. uu Electrical Wiring Ensure that the points and switches are easily accessible and conduct periodic checks and repairs. Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Key Learning Points Understanding workshop tools, applications and appropriate usage practices Usage of customized tools developed by BAL for Pulsar 200NS Fi
CHAPTER 2
Customized Bajaj Auto Tools / Special Tools, Equipment & Gadgets Special Tools (Engine & Frame) Standard Tools Other Gadgets
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Camshaft Big end bearing & Balancer bearing puller Part No.
: 37 1042 57
Application : For removing balancer and big bearing of cam shaft
uu Crank Shaft remover Part No.
: 37 1042 52
Application : Tool for splitting the crankcase
uu Spark Plug Spanner 3 in one Part No.
: 37 1042 55
Application : For removing LHS / RHS and Central spark plug from cylinder head when engine is mounted on vehicle
uu Primary gear holder+Balancer Drive / Driven gear holder Part No.
: 37 0041 59
Application : Special tool for holding Balancer drive and driven gears during tightening / loosening the nut Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Balancer lock nut tightening/ removing tool Part No.
: 37 0041 60
Application : Special tool for Balancer drive gear lock nut (tightening / loosening)
uu Output shaft oil seal fitment tool Part No.
: 37 1041 56
Application : For pressing oil seal on the output shaft
uu Balancer + Radiator pump oil seal fitment tool Part No.
: 37 0042 56
Application : For fitting 2 nos back to back oil seals for balancer and Radiator pump
uu Cam Sprocket Holder Part No.
: 37 1042 54
Application : For holding cam sprocket during removal and re-fitting of cam sprocket bolt.
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Magneto Rotor Puller Part No.
: 37 0041 55
Application : For pulling out magneto rotor from crank shaft
uu Rocker Shaft remover Part No.
: 37 10DH 35
Application : For removing rocker arm shaft
uu Drift Piston Pin Part No.
: 37 10DS 27
Application : For removing piston pin.
uu Clutch special nut remover Part No.
: 37 10DJ 43
Application : To remove and fit clutch nut. Rocker Shaft remover
Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Clutch Dismantling Tool Part No.
: T 10111 68
Application : For dismantling and assembly of clutch assembly.
uu Camshaft Small Bearing Puller Part No.
: 37 10DH 31
Application : For removing small bearing of cam shaft
uu Bearing Driver Set Part No.
: 37 1030 61
Application : For removing bearings from crank case.
uu Magneto Rotor Holder Part No.
: H6 0721 00
Application : For holding rotor assembly while loosening bolt.
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Tappet Setting Tool Part No.
: F4 1ZJW 33 / 37 1031 53
Application : For adjusting valve tappet clearance.
uu Valve Spring Compressor Part No.
: 37 1031 07
Application : For compressing valve springs for easy removal of intake and exhaust valves.
uu Adaptor for Valve Spring Compressor Part No.
: 37 1031 08
Application : For compressing valve springs for easy removal of intake and exhaust valves.
uu Output Sprocket Holder Part No.
: 37 1030 53
Application : To hold out put sprocket while removing sprocket bolt.
Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tools Application: for Frame Repairs uu Fork oil seal fitment punch Part No.
: 37 1740 03
Application : To remove antifriction and oil seal bush from front fork outer pipe.
uu Fork cylinder holder handle with adaptor Part No.
: 37 1740 05
Application : For holding cylinder piston
uu Installer Upper & Lower Bearing Race Frame Part No.
: 37 1801 06
Application : To install upper and lower steering races / cones into their seats inside frame.
Notes
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tools Application: for Frame Repairs uu Swing arm needle roller bearing extractor & fitment tool Part No.
: 74 9309 93
Application : For removal and fitting of needle roller bearing in swing arm
uu Steering Nut tightening tool Part No.
: 37 1801 01
Application : For tightening / loosening of steering nut
uu Rear Mono Suspension Adjuster Part No.
: 37 0041 70
Application : For adjustment of mono rear suspension setting
uu Stem Bearing Driver Part No.
: 37 1830 05
Application : To fit bearing race on fork under holder bracket
Bajaj Pulsar 200NS FI Training Notes
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The Tool Chest - Know Your Tools
Standard Tools Equipment: External and Internal Circlip Pliers Specs / Range:
Equipment: Star Bit Set Specs / Range: Standard size
Qty Required:
Qty Required: One set
Equipment: Combination Plier
Equipment: Component Handling Crate
Specs / Range: Qty Required:
Specs / Range: Plastic with partition CH64120 (2x2) Qty Required: One for each bay
Equipment: Cleaning Brush Specs / Range: 2 and 3 Inch Qty Required: One
Equipment: CVC Products: Battery coat, Viscolube, Carburetor cleaner, Multilube, Galvanizing spray Etc. Specs / Range: Aerosols Qty Required: As per Load
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Equipment: Electrician Screw driver
Equipment: 5 Pcs Phillips Screw Driver Sets
Specs / Range: 3 mm Flat
Specs / Range: 861, 862 L, 863
Qty Required: One for each bay
Qty Required: One set for each bay
Equipment: Allen Key set
Equipment: 5 Pcs Screw Driver Sets
Specs / Range: Set
Specs / Range: 827, 929, 912, 923, 825
Qty Required: One set
Qty Required: One set for each bay
Standard Tools Equipment: Tyre pressure gauge
Item: Tool Trolleys
Specs / Range: Dial Type / Pen Type
Specs: Regular with 4 Trays
Qty Required: One
Equipment: T-Handle Box Wrench Spes / Range: 8 mm, 10 mm, 11 mm, 12 mm
Qty: Each Per Bay
Equipment: Spark Plug Cleaner Specs: 2 Gas
Qty Required: One set for each bay
Qty Required: One
Equipment: Open End Spanner
Equipment: Work Table with Special Tool Display board
Spes / Range: 6 x 7 mm; 8 x 9 mm; 10 x 12 mm; 12 x 14 mm; 14 x 17 mm; 17 x 19 mm; 24 x 27 mm; 24 x 27 mm
Specs:
Qty Required: One
Qty Required: One set for each bay Equipment: Ring Spanner Specs / Range: 6 x 7 mm; 8 x 9 mm; 10 x12 mm; 12 x 14 mm; 14 x 17 mm; 17 x 19 mm; 24 x 27 mm; 24 x 27 mm
Equipment: Electric Plier, Cutters and Connectors Specs / Range: Multi Tech / Others Qty Required: One for each bay
Qty Required: One set for each bay Equipment: Long Nose Plier Specs / Range: Standard size Qty Required: One for each bay
Equipment : Socket set with Reversible Ratchet
Specs / Range : ½” SQ. DR. 8, 10, 12, 14, 17, 19,24 mm, Sockets; 3/8” Long Sockets 8,10 mm; ½” Extension 5” Long. ½” DR. Quick Release Ratchet; ½” DR. T Handle; ½” X 3/8” Adapter 3/8” X ½” Adapter with Tools Box Qty Required : One Set
Bajaj Pulsar 200NS FI Training Notes
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The Tool Chest - Know Your Tools
Other Gadgets New D&F Tool Part No. : Application : For checking diagnostic and troubleshooting codes of EMS.
Old D&F Tool Part No.
:
Application : For checking diagnostic and troubleshooting codes of EMS.
Multimeter Special Prob Part No.
:
Application : To establish the contact between multimeter and the inspecting electrical component.
Pressure Gauge for Engine Oil Part No.
:
Application : To measure the engine oil pressure in the lubrication system.
Pressure Gauge for Fuel Part No.
:
Application : To measure the fuel pressure in the fuel line.
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Other Gadgets VRLA Battery Charger Part No.
: 37004162
Application : To charge the new and used VRLA battery.
Battery Load Tester Part No.
: 37204020
Application : To inspect the battery charge holding ability of the new and used VRLA battery.
Pig Tail for Fuel Delivery Measurement Part No.
:
Application : To establish the electrical contact between battery and fuel pump through a operating ON/OFF switch.
Tuskun Screw Driver Part No.
:
Application : To remove and fit the tuskun screws for TMAP and TPS.
Notes
Bajaj Pulsar 200NS FI Training Notes
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1
Workshop Safety and Procedures
Key Learning Points Understanding the Complete Anatomy of the Vehicle Technical Specifications and Performance Parameters Briefing and Educating the Customer on Appropriate Riding and Usage Discipline, and Routine Maintenance
CHAPTER 3
Understanding the Bike Identity Distinguishing Features Salient Features Technical Features & Specs Read Before Your Ride
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Identity
CE JL Z
D91
543
The Engine Number, unique to each vehicle is engraved into the engine body, located below the sprocket cover.
The Frame Number, which is also unique to each vehicle, is engraved into the frame. This is located on the right hand side of the frame between the fork mountings.
Location of Parts 1 RH Control Switch
9 Cover Mud Rear
2 LH Control Switch
10 Assembly Chain Cover
3 Speedo Console
11 Nitrox Mono Suspension
4 Expansion Tank
12 Tail Lamp
5 Front & Rear Disc Brake
13 Grab Rail
6 DTSi 4-Valve Engine
14 Perimeter Frame
7 Clutch Cover
15 Exhaust TEC
2
1
8 Underbelly Exhaust with exhausTEC
3
13
14
12
10 11 9
4
6 5 8
7
5
15
Bajaj Pulsar 200NS FI Training Notes
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3
Understanding the Bike
Distinguishing Features Triple Spark Technology uu Triple Spark: Provides faster and more optimal combustion thereby increasing combustion performance and efficiency. Combustion is 27% faster than twin spark and 50% faster than a single spark engine. uu 4-valve Engine: 2 intake and 2 exhaust valves enables better breathing for the engine thus enhancing torque and power at all engine speeds. Enables engine to rev to high RPM levels without getting choked, thereby producing more power.
Fuel Injection
The fuel injection system delivers optimum volume of fuel which along with Triple spark plugs helps promote high combustion efficiency as compared to a single or dual spark plug carburetor model, thus creating a powerful , fuel efficient and low emission engine.
6-Speed Gearbox
Perfectly matched 6-speed gearbox ensures optimum utilization of the torque and power characteristics of the 4-valve triple spark engine.
Liquid Cooling
Ensures control on engine temperature despite high engine output and sports performance, thus enhancing engine life, negating power fade due to overheating, lowering engine noise and reducing emissions.
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Distinguishing Features Perimeter Frame
The frame provides 3 times the lateral stiffness of the Pulsar 220 frame thereby giving the Pulsar 200NS very good high speed handling and precise cornering abilities.
Rear Nitrox Mono Shock
Monoshock for identical damping characteristics on either side of the bike. Nitrox enhances high speed absorption of ripples on road , aiding straight line stability.
Exhaus TEC
Improves engine torque at low rpm and is optimized to get maximum engine performance. Thus, no frequent gear change is needed.
Underbelly Exhaust:
Provides the bike with a better mass centralization allowing higher lean angles without grounding of muffler.
Bajaj Pulsar 200NS FI Training Notes
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Understanding the Bike
Salient Features Performance Key Features uu Triple spark technology uu 4 Valve Engine uu Liquid cooling uu 6 speed gearbox
Advantages uu Superior Innovative technology engineered for optimum engine performance at any speed uu Enhanced power and performance uu Smooth engine run at any rpm uu Higher efficiency in both, mileage and emissions
Benefits uu Great performance across the entire rpm band and all gears giving the Pulsar 200NS a true sports bike character
Style
24
Key Features
Advantages
Benefits
uu Brawny masculine looks of a Naked Sports bike uu Muscular Perimeter frame uu Specially designed foot pegs and switches uu Stylish split seats uu 2-piece grab rail for better support uu Well styled head lamp uu Clip on type handle bars uu Sporty exposed drive chain uu New look alloy wheels uu Broad tyres and petal disc brakes uu Well concealed underbelly exhaust
uu Bold assertive stance and sporty riding position uu Aggressive and sporty looks
uu The Street Fighter look gives the Pulsar 200NS unmatched character on the road.
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Salient Features Comfort & Handling Key Features uu Perimeter frame with a special swing arm uu Underbelly exhaust uu Superior bike ergonomics and weight distribution uu Nitrox Mono Rear suspension uu Large 37 mm dia. front fork with single antifriction bush uu Broad front and rear tyres uu Clip on handle bar
Advantages uu Rigid chassis for excellent high speed handling uu Optimum centre of gravity for high stability uu Near perfect 50:50 front to rear ensures a very sporty ride uu Nitrox rear suspension enables a smoother ride over small undulations when at high speeds uu Large dia front forks ensures high rigidity for stable front braking and flicking around corners uu Broad tyres enhance the high speed handling characteristics uu Clip on type handlebars give a sporty feel to the riding posture
Benefits uu Optimized maneuverability for high speed cornering combined with flex-free front forks and broad tyres and a sporty riding position ensures a truly sporty ride.
Safety Key Features uu Front and Rear petal disc brakes uu Broad Tubeless tyres uu High strength chassis – Perimeter frame and swing arm uu Powerful DC head lamp
Advantages
Benefits
uu For sharp, precise fade free braking uu Reliability with a sporty grip. uu The tread pattern contributes to high Performance uu Superior structural strength uu High wattage DC head lamp provides Uniform strong beam spread at any rpm
uu Enhanced and reliable braking capability along with strong flicker free lights to match high performance capability of the bike
Bajaj Pulsar 200NS FI Training Notes
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Understanding the Bike
Technical Features & Specs Engine & Transmission uu Type
: 4 stroke, single cylinder water cooled,fuel injected
uu No. of Cylinder
: One
uu Bore
: 72.0 mm
uu Stroke
: 49.0 mm
uu Engine Displacement : 199.4 cc uu Compression Ratio
: 11:1
uu Idling Speed
: 1400 ± 50 rpm
uu Max.Net Power uu Max.net Torque
: 18 Kw @ 9750 rpm : 18.6 Nm @ 8000 rpm
uu Ignition System
: Inductive DC ignition
uu Ignition Timing
: Variable as per map in ECU
uu Fuel
: Unleaded petrol
uu Carburetor
: NA
uu Spark Plug
: 3 Plugs
uu Spark Plug gap
: 0.8 ~ 0.9 mm
uu Lubrication
: Wet sump, Forced lubrication
uu Starting
: Electric start
uu Clutch
: Mechanically actuated
uu Transmission
: 6 speed constant mesh
uu Primary reduction
: 3.272
Gear ratios uu 1st gear uu 2nd gear uu 3rd gear uu 4th gear uu 5th gear
: 26.49 : 19.32 : 14.54 : 11.58 : 9.77
uu 6th gear
: 8.57
uu Final drive ratio
: 40/14
EMS uu System
: 12V,DC
uu Ignition system
: Digitally controlled thru ECU
uu Fuel feed
: Port fuel injection
uu Malfunction indicator : LED lamp wattage
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Technical Features & Specs Frame
uu Frame Type uu Suspension Front Rear uu Brakes Front & Rear uu Brake Size Front Rear uu Tyres Front Rear uu Tyre Pressure Front Rear (Solo) Rear (with Pillion) uu Rims Front Rear uu Fuel Tank Capacity uu Usable Reserve uu Unusable Reserve
Dimensions
: Perimeter : 130 mm Fork travel, Telescopic, Single antifriction bush : 120 mm wheel travel, mono suspension with nitrox : Hydraulically operated disc type : 280 mm Disc brake : 230 mm Disc brake : : 100/80, 17, 52 P Tubeless : 130/70, 17, M/C 62P : 1.75 kg/cm² (25.0 PSI) : 2.00 kg/cm² (28.0 PSI) : 2.25 kg/cm² (32.0 PSI) : 2.5X17” 10 Spoke alloy wheel : 3.5X17” 10 Spoke alloy wheel : 12.0 liters : 2.4 liters : 0.2 liters
uu Length : uu Width : uu Height : uu Wheel base : uu Saddle height : uu Turning Circle Radius : uu Ground Clearance :
Performance
2017 mm 804 mm 1195 mm 1363 mm 807 mm 2500 mm (min) 167 mm
uu Maximum : 129 in sixth gear Speed, km/h (with single rider 68 Kg) uu Climbing ability : R & D
Electricals uu System uu Battery
uu Head Lamp uu Tail/Stop lamp uu Side Indicator lamp uu Position lamp uu Rear Number Plate lamp uu Speedometer back light uu Neutral indicator uu Turn signal indicator uu Hi-beam indicator uu Reserve indicator uu Horn uu Fuel gauge
: : : : :
12V,DC “12V 8Ah VRLA (Valve regulated lead acid)” 12V 55/60 W, (Halogen) LED type 12V 10W (4 nos. - Amber bulbs) : 12V 3 W (2 nos.) : 12V 3W : LCD back light : : : : : :
LED type LED type LED type LED type 12V DC, Type 2A (82 mm dia.) TFR Type
Weights
uu Vehicle kerb : 145.0 Kg weight, kg (Electric start) uu Gross vehicle : 275.0 Kg (Electric start) weight, kg
Controls
uu Steering uu Accelerator uu Gears uu Brakes Front Rear
: Handlebar : On handle bar, RH grip : Left foot pedal operated, 1 down 5 up, Step shift : On handle bar, RH lever : Pedal operated by RH foot
Notes :
Values given above are nominal and for guidance only, 15% variation is allowed to cater for production and measurement. All dimensions are under un-laden conditions. Definitions of terminologies wherever applicable are as per Relevant IS/ISO standards. Specifications are subject to change without notice.
Bajaj Pulsar 200NS FI Training Notes
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3
Understanding the Bike
Test Yourself 1.
On what side of the steering tube is the chassis no located? a) L/H
b) R/H
The Chassis no consists of how many digits? a) 16 2.
d) 19
b) 18.0PS
c) 16.51 PS
d) 19.0 PS
c) 120 / 80 X 17, 49 P
d) 120 X 90 X 17, 51P
What is the rear tyre size of the Pulsar 200 NS Fi? a) 90 X 90 X 17, 49 P
4.
c) 17
What is the minimum net power of the Pulsar 200 NS Fi? a) 20.0 PS
3.
b) 11
b) 12 / 80 X 17, 61 P
On what side of the engine is the spark plug fitted? a) L/H
b) R/H
Of what type is the spark plug used in the Pulsar 200 NS Fi? a) RG4HCC
b) RG6HCC
c) RG4HC
d) RG4H
5.
Which of the components listed below do not form a part of the fuel injection system?
6.
What do you understand by EMS?
7.
In the console, what does the icon on the RH side of the high beam indicate? a) System Malfunction
8.
b) Side stand OUT
c) Hi Beam ON
Name the icons on the console. (Pl illustrate the icons) a) b) c) d) e)
9.
What is the Max Net Torque for Pulsar 200 NS Fi? a) 17.17 Nm @ 6500 rpm
b) 19.12 Nm @ 6500 rpm
c) 15.22 Nm @ 6000 rpm
10 During PDI it is recommended to check the fuel cock operation for hardness/leakage a) True
b) False
11. The fuel pump is located inside the petrol tank. a) True
b) False
12. The fuel gauge is located inside the speedo console a) True
b) False
13. The Pulsar 200 NS Fi has a port injection system a) True
b) True
14. The Pulsar 200 NS Fi has an oil cooled engine. a) True
b) True
15. What is the handle bar on the the Pulsar 200 NS Fi referred to as? a) Clip on handle bar
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b) Split type handle bar
c) Both are correct
Read Before You Ride Digital LCD Speedo Console
Soft Self Start
Function: Display information on key important factors and alarm indications.
Function Cranks engine just by feather touch.
Neutral position of gear. Side indicator pilot indication. Hi beam indicator Drop in battery voltage Drop in engine oil pressure Engine overheating & rise in engine temp.>115°C Malfunction indication of EMS Tachometer: A analogue display tachometer showing 0~12 x 1000 RPM display for understanding the engine RPM. Engine RPM Limiter: A amber colour LED bulb starts blinking when the engine RPM reaches to 9500 RPM cautioning the rider crossing safety zone (However engine RPM curtails above 10500).
How to Operate Switch ‘ON’ ignition and kill switch. Put vehicle into neutral or declutch if in gear. Press self start button. Do not open throttle (accelerator) while starting. Once engine starts do not rev up engine while vehicle is parked on the stand. Benefits Comfort Hassle free starting
Malfunction Indicator Function It gives indication signal about error in Engine Management System.
Fuel Gauge: A vertical 9 bar equally segmented graphical indicator indicates fuel level inside the fuel tank.
How to Operate This operates automatically as and when the error is generated.
Low Fuel Level Indicator: Icon will blink continuously when the fuel level drops below 3.5 liters thus reminding the rider for refueling.
Visual Signal Amber colour icon on LH side in indicator will pop-up, this is an indication that EMS has an error.
Side Stand:A indication display of stand ON will appear when stand is put ON.
Immediately take the vehicle to a BAL authorised Service Station.
Easy to read Digital Speedo Display showing Vehicle speed - Km/Hr. Odometer - Kms covered. Resetting trip meter - for recording distance covered in trip with resetting provision (TRIP 1 & TRIP 2). Digital clock - displays time in HR:MM (AM/PM). Service Reminder: A service reminder will pop-up reminding you that vehicle is due for next service. How to Operate Put ‘ON’ ignition key and kill switch. All 4 icons on top will pop-up and few will vanish away automatically. All other will show static display until the vehicle moves on road. Other displays are dynamic which functions individually for respective applications.
Mode Selection Switch Function
Trip meter, Digital clock and Service reminder setting Advantage Facility to change Time as per local time. Reset trip meter to calculate the distance covered in a trip. Note : Service reminder setting is to be done by Bajaj Authorised Service Centers / Dealers only.
Head Light always ON Feature DC head light will glow on start of vehicle automatically. Advantage Continuous DC head light on facility. Benefits Brighter illumination throughout the ride. Road safety.
Benefits Great safety. Arrest consequential damages arising
Side Stand Riding Protection Feature Protection against side stand riding. Advantage The EMS systems senses the side stand on signal and does not allow the engine to run with side stand in ON position. Benefits Rider’s safety.
Liquid Cooled Engine Feature Liquid cooled engine. Advantage Maintains lubricating oil viscosity even at high temp. and extreme stress for optimum performance Benefits Effective cooling and lubrication helps to deliver the higher engine performance under every possible load condition.
VRLA Battery Feature Zero maintenance battery. Advantage No top up required. Benefits Effective cooling & lubrication helps to deliver the higher engine performance under every possible load condition.
Bajaj Pulsar 200NS FI Training Notes
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Understanding the Bike
Read Before You Ride Gear Shifting Pattern
Fuel Saving Tips
Feature 1 down 5 up shift mechanism.
Benefits Safe to drive at all speed conditions
Avoid following −− Sudden pick-up and frequent braking. −− Needless and excessive idling. −− Excessive high speed riding. Check and Inflate tyre pressure once in a week. Fill petrol at reputed petrol pumps. Use only branded fuel. Inspect the coolant and engine oil level. Top-up to MAX level
Disc Brakes - Front & Rear
Monsoon Care
Feature Hydraulic disc brakes.
Benefits Ease in stopping the vehicle at desired spot. Safely controlling the vehicle speed.
Fit and Finish Parts It is suggested to take proper care in heavy monsoon / high rainfall area. The appropriate surface preventive coat is to be applied to avoid rusting / poor surface finish on account of adverse atmospheric conditions. Clean and lubricate all the important parts as detailed in a Periodic Chart given in Owner’s Manual.
Tubeless Tyres
Additional Care
Advantage Bike will never be left into neutral condition.
Advantage Most efficient and safe braking.
Advantage If punctured do not deflate suddenly and helps in reducing unsprung mass. Less rolling resistance ensures complete road stability. Benefits High stability and less maintenance
Engine Oil : Check every week Park the vehicle on level surface to check the oil level. Always maintain engine oil level between the upper and lower level. Replace the oil in accordance with P.M. Chart.
Recommended Oil Grade and Qty
Battery
Grade
How to Keep Battery Healthy Switch ‘OFF’ ignition when engine is not running. Do not ride with the brake pedal / brake lever depressed. The brake light would remain active and drain the battery. Get your battery checked / charged during periodic services
SAE 20W50 of API ‘SL’ + JASO ‘MA’ grade or superior.
Quantity Drain and Refill 1200 ml. Engine Overhaul 1400 ml. Coolant Ensure coolant in expansion tank is between Min and Max level mark. Top up with recommended brands Recommended Coolant Brand Mfr. Castrol - Radicool, Motul - Motocool Expert Quantity Drain and Refill - 1000 ml.
Safe Riding Tips
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Always wear standard helmet while riding. Never use mobile phones while riding. Always keep rear view mirrors clean. Use both, front and rear disc brakes simultaneously. Applying only one brake may cause loss of control and skidding or diving. Do not apply front brake when cornering or at turns. Familiarise yourself well with seating posture, starting, acceleration and braking of the vehicle. Use side indicators before turning. Fuel pump inside the tank is lubricated and cooled by the fuel. Hence always maintain minimum 3 liter of fuel in fuel tank.
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Key Learning Points Understanding the standard procedure to be followed during Pre-Delivery Inspection of a new vehicle and entering PDI details as per checklist Important tightening torque applications with loctile recommendation Standard timelines for attending PDI operations and PDI productivity Things to be remembered and followed during PDI
CHAPTER 4
Preliminary Checks & Maintenance Operations PDI Checklist Perodic Maintenance Chart Lubrication Matrix Periodic Service SOP
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Preliminary Checks and Maintenance Operations
Pre-Delivery Inspection Checklist Following is the checklist for carrying out PDI of “Pulsar 200NS” motorcycle. This checklist is to understand various check points those are to be checked / inspected before delivery of the new vehicle. Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as per the points given below. This ensures trouble free vehicle delivery to the customer. Dealer's Name
Dealer's code:
PDI Check sheet-Pulsar 200 NS
Frame No.
Date of PDI
Engine No.
PDI done by
Please unsure that following checks are carried out during PDI before delivery of vehicle. To Check ENGINE
Check for
✔ if OK X if NOT
Engine Oil "BAJAJ DTS-i 10000" 20W50
Oil level between upper and lower mark of oil level gauge / Top up if required
Oil leakage if any - Specify source of leakage
Gear shifting
Smooth operation
Engine noise
No abnormal noise
Silencer noise
No abnormal noise
Fasteners (Check torque)
Assy pipe A exhaust band clip bolt – 1.8 ~ 2.0 Kgm
Assy end chamber band clip bolt- 1.8 ~ 2.0 Kgm
Gear shifter lever pivot bolts – 0.9 ~ 1.1 Kgm
Ensure level between MIN and MAX mark in Reservoir tank in engine cold condition
COOLING SYSTEM Coolant level
Coolant leakage if any - Specify source of leakage
Radiator fan FUEL SYSTEM Tank Cap
FRAME
Tyre Pressure
Working of radiator fan after coolant temperature reaches 98 C
Petrol tank cap bolt fitment
Front : 1.75 Kg / Cm2 (25.0 PSI)
Rear (with Pillion) : 2.25 Kg / Cm (32.0 PSI)
Freeness of front and rear wheel
2
Wheel
Steering movement Check for smooth operation.
Side stand
Smooth operation
Mirror
Proper fitment
Clear rear view
Head lamp
Focus adjustment
Brakes
Front / Rear: a) No oil leakage from master cylinder and caliper
CONTROLS
32
0
Steering cum ignition, Rear seat lock
b) Check oil level in master cylinder (Visual inspection)
Throttle
Grip free play - 2 ~ 3 mm. Smooth operation
Clutch Cable
Smooth operation, Free play - 2 ~ 3 mm
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Remarks
Pre-Delivery Inspection Checklist To Check
Check for
Speedo cable
Proper routing
Drive Chain
Slackness standard - 15 ~ 25 mm
Equal marking of chain adjuster on both side
Front Fork
No leakage(Visual inspection), Smooth working
Rear Shock Absorber
Spring adjuster notch position : 2nd notch (Standard)
Steering
Smooth operation (No excess play / No sticky movement)
Lock Operation
Steering lock operation(Only on LH side), Seat lock, Petrol tank lock
SUSPENSION
Fasteners (Check torque)
ELECTRICAL Battery
✔ if OK X if NOT
Front axle nut - 10 Kgm
Rear axle nut - 10.0 Kgm
Rear sprocket mounting bolts – 3.2 ~ 3.8 Kgm
Holder handle bar bolts - 1.8 ~ 2.0 Kgm
Fork center nut - 4.8 ~ 5.2 Kgm
Swing arm shaft - 14 Kgm
Front fender mounting bolt- 1.8 ~ 2 Kgm
Stay LH / RH mounting bolt - 1.6 ~ 1.8 Kgm
Check nut bolts, screws, split pins for tightness.
Open circuit voltage (13 to 13.2 V DC) and Charge status by VRLA battery tester
Tightness of battery terminals / cables
Fuse
Position of fuse box
Kill switch
In OFF position check for no Speedometer display and no self start working.
All Bulbs Working Switch Operation Starter Motor Speedometer
Horn
Head light, LED tail / stop, Side indicators, Number plate lamp
RH and LH control switch, Ignition switch and Brake switch (Front and Rear)
No abnormal noise
Working / Engagement in gear and neutral
No excess gap and uneven gap
Working of Speedometer, Odometer and Tripmeter, Clock setting
Working of all signal indicators icons (Turn pilot, Neutral, High beam, Side stand, Battery charge and Bajaj logo)
Ensure no distorted sound
Starting
Cold start and Warm start
Drive ability
Throttle response
Brakes effectiveness- Front and Rear
Wash and Clean vehicle properly
TEST DRIVE
Cleaning
Remarks
Important Note: Look for any external damages in transit, please check, record and rectify send report with photos.
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Preliminary Checks and Maintenance Operations
Periodic Maintenance Chart Recommended Frequency Sr No
1
PM check points
Service
1st
2nd
3rd
Kms
500 ~ 750
4500 ~ 5000
9500 ~ 10000
Clean the vehicle with water wash and dry completely
2
Engine oil (Bajaj DTSi 10000 oil) & engine oil filter*
3
√
√
√
4th
5th
6th
14500 19500 24500 ~ ~ ~ 15000 20000 25000
√
√
√
7th 29500 ~ 30000
√
Top-up
R
Top-up
Oil strainer cleaning at the time of oil change.
CL
CL
4
Spark plug
CL,A,R
5
Air cleaner element ***& cover ‘O’ ring
CL, R
6
In line fuel filter .
7
Fuel pipe
C,R
C
C
C
R
C
C
R
8
Valve tappet clearance
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
9
Sealed drive chain cleaning & lubrication
10
Air filter drain tube
C
11
Silencer drain hole cleaning
12
Silencer tail pipe cleaning**
13
Brake cam & brake pedal pivot pin
14
Brake lining or pad -Check wear indicator
15
Brake fluid level **- top up / replace
16
Disc brake assly -- Check functionality, leakage or any other damage.
C
17
All cables & rear brake pedal -free play
C,A
CL
R
BGO DTSi 20W50 for models above 125cc.
Oil strainer
CL
Top-up
R
R
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Ensure to prevent water entry in Petrol tank, Silencer and electrical parts. Use caustic free detergent for washing.
C, R
34
Remarks
CL
CL
CL
CL,A
CL,A
R
CL
R
R
CL
CL
R
CL,L,A CL,L,A CL,L,A
R
CL,L,A CL,L,A CL,L,A CL,L,A
Customer to apply OKS chain lub spray at every 500 kms.
C
C
C
C
C
C
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
C
C,L,R
C,L,R
C,L,R
C,L,R
C,L,R
C,L,R
Use recommended AP grease.
C,R
C,R
C,R
R
C,R
C,R
R
Replace brake shoes /brake pad at every15000 Kms
R
Use recommended brake fluid (DOT3/DOT4).
C,L,R
C
CL,L,A
R
C,A,R
C,A
C
C,A
C,A
C,A
C
C,A
C,A
C
C,A
C,A
Periodic Maintenance Chart Recommended Frequency Sr No
PM check points
Service
1st
2nd
3rd
4th
5th
6th
7th
Kms
500 ~ 750
4500 ~ 5000
9500 ~ 10000
14500 19500 24500 ~ ~ ~ 15000 20000 25000
29500 ~ 30000
18
Wiring harness & Battery connections- routing, tie bands & clamps tightness.
C,A,T
C,A,T C,A,T
C,A,T
C,A,T
C,A,T
C,A,T
C,A,T
19
Ignition switch barrel cleaning & handle bar control switches contacts cleaning,
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
20
Steering play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
21
Steering stem bearing*** & Cap steering bearing(Plastic)**
22
Remarks
Use recommended WD40 spray
Check and replace if damaged. C,CL,L,R Use HP Lithon RR3 grease for lubrication.
C,CL,L,R
C,CL,L,R
C,CL,L,R
Main stand & side stand pin**
CL,L
CL,L
CL,L
23
All fasteners tightness
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
24
General lubrication-Clutch lever, front brake lever, kick lever.
L
L
L
L
L
L
L
L
Use recommended AP grease.
25
Coolant level in expansion tank**
C,A
C,A
C,A
C,A
C,A
C,A
C,A
R
Use recommended 'Ready to use coolant'.
26
Coolant hose damage/clamps/ leakage**
C
C
C
C
C
C
C
27
Radiator fins**
C
C
C
C
C
C
C
CL,L
Use recommended AP grease.
* It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be every 5000 kms ** As applicable to model *** More frequent cleaning is required while driving in dusty environment.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate Following items are chargeable to Customer. Oil,Coolant,Filters,All types of greases,Cleaning agents,Cables,Wear and tear parts,Rubber O rings/oil seals/pipes , Gaskets etc.
Bajaj Pulsar 200NS FI Training Notes
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Preliminary Checks and Maintenance Operations
Lubrication Matrix Oil / Grease / Loctite application matrix Sr. Lubricant / Loctite No.
Grade
Application
Remark Quantity : Drain and Refill - 1200 ml Eng. O/h - 1400 ml
1
Engine oil
DTSi 10000, SAE 20W50 API SF/SG JASO MA
Engine
2
Fork oil
SAE 10W20
Front fork
3
Brake fluid
N.A
N.A
5
Grease
All purpose
Front and real wheel axle, Swing arm shaft, Brake pedal pivot pin, Center stand shaft, Side stand U bracket, Gear shifter pivot, Clutch and front brake lever
4
Grease
6
Chain spray
7
Oil for drive chain
8
Electrical contact cleaning spray
Lithon RR-3
OKS - Chain lube spray SAE 90
WD-40 Spray
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N.A
Steering races and balls HP make
N.A
Non ‘O’ ring type drive chain • Ignition switch
• Brake and clutch switch • LH/RH control switch
Notes
Quantity / fork leg : Drain and Refill - 295 ±2.5 ml Overhaul - 320 ml
During all services All services
Periodic Service SOP Engine Oil Replacement
uu Ride the Vehicle for 2-3 Km to warm the engine. uu Park the vehicle on levelled surface.
A
B
uu Remove: Drain Bolt - A Oil Strainer - B
uu Measure & Inspect: Quantity of the oil collected. uu Inspect: The quality of the oil collected. Note: The standard oil consumption per 1000 kms is 30 to 80 ml
uu Clean: Strainer using Kerosene / Diesel. Blow air of 2 bar pressure from inside to outside. Clean the ferrous burr deposited on the oil strainer. uu Inspect: The ‘O’ ring for firm fitment
A
uu Fit: Strainer and the strainer cap Tighten the strainer cap - A
Bajaj Pulsar 200NS FI Training Notes
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4
Preliminary Checks and Maintenance Operations
Periodic Service SOP uu Fill recommended quantity of engine oil. Grade SAE 20W50 API SF/SG, JASO MA
Drain and Refill
Engine Overhaul
1200 ml 1400 ml
Note: The standard oil consumption per 1000 kms is 30 to 80 ml
Engine Oil Filter Replacement A uu Remove 2 bolts - A
B
Filter cover - B
A
uu Remove Oil Filter Note: Do not clean or reuse the oil filter element. Replace the oil filter at the first service and thereafter at every oil change.
A
uu Fit Oil filter cover - A A
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2 bolts - B
Periodic Service SOP Spark Plug Gap Adjustment uu Remove & check spark plug for... 3. Errosion 1. Spark Plug type 4. Cracks / Breakge 2. Color Recommended Spark Plug
Central – BOSCH YR5NE
Electrode Gap
0.8 ~ 0.9 mm
LHS & RHS – CHAMPION – PRG6HCC
u Clean the spark plug u Check and adjust spark plug gap using wire gauge. u Spark plug gap should be - 0.8~ 0.9 mm Note: Cleaning every 10,000 Kms. Replacement every 30000 km.
uu Fit Screw in spark plugs first manually and thereafter use spanner for tightening it.
Notes
Bajaj Pulsar 200NS FI Training Notes
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Preliminary Checks and Maintenance Operations
Periodic Service SOP Coolant Replacement Drain the coolant uu During run, the coolant heats and is under pressure. Do not remove the radiator cap, radiator hoses or other any other component of the cooling system when the engine is in heated condition. Allow the engine and cooling system to cool down.
A
uu Park the vehicle on levelled surface. uu Remove Bleeder Screw - A
uu Remove Drain bolt - A Washer - B uu Drain the coolant A & B
Warning
Steam and overheated radiator fluid if comes in contact with skin, causes serious burns. Please therefore do not open the radiator cap or drain when the engine is heated.
Replacement of coolant : uu Use only the recommended brand (ready to use) of coolant. Make
Castrol - Radicool
Motul - Motocool expert
Qty 1000 ml
Note: Replace coolant every 30,000 Kms
uu Fit Washer Drain bolt.
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Periodic Service SOP Coolant Replacement
uu Remove Coolant from the expansion tank
Skill tips: Stop until the coolant with air bubbles emerges out from the bleeding screw.
uu Fit Radiator cap - A A Caution
Do not open the radiator cap in engine hot or during engine running condition.
uu Remove Cap for the expansion tank. Top up the coolant to maximum mark.
uu Refit the cap of the expansion tank. Note: Ensure that the vent pipe is routed correctly
Bajaj Pulsar 200NS FI Training Notes
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Preliminary Checks and Maintenance Operations
Periodic Service SOP Air Filter Cleaning Stage 1 uu Use compressed filtered air of pressure less than 2 bar. uu Position pressure gun at a 90 degree angle and at a distance of 50 mm from paper filter. uu Move the pressure gun along the lines of the folds.
900
Stage 2 450
uu Position pressure gun at a 45 degree angle and at a distance of 50 mm from paper filter. uu Twist the paper filter slightly. uu Move the pressure gun along the fold line.
Stage 3 900
Dos uu Clean paper filter at every 5000 Kms. uu Increase frequency of cleaning if the vehicle is being used in dusty conditions. uu Replace the paper filter at 15000 Kms. uu Hold filter element by its PU foam.
Notes
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uu Position pressure gun at a 90 degree angle and at a distance of 50 mm from paper filter. uu Blow out the remaining dust the pressure gun along the lines of the folds.
Don’ts uu Don’t use solvents such as petrol, Diesel, Kerosene or water to clean paper filter element. uu Don’t apply any oil on paper filter element. uu Don’t touch paper filter surface with soiled hand. uu Don’t wipe the paper filter with cloth, paper or any abrasive material.
Periodic Service SOP Tappet Setting
uu Ensure that the piston is at the end of the compression stroke. uu Both rockers are the free. uu Ensure that the cam sprocket marks are parallel to the cylinder head surface. uu Check and adjust clearance of both, inlet and exhaust valves
Note: Make one rotation of crankshaft and recheck the tappet clearance once again. If found incorrect adjust it again. Tappet Clearance Intake
Exhaust
0.05 mm
0.08 mm
SOP for compression pressure checking (Dry Test) uu Warm the engine by riding the vehicle for about 1 km. uu Park the vehicle on levelled surface uu Disconnect all spark plug caps. uu Remove the RH side spark plug. uu Connect the compression gauge adapter and fit it.
uu Open the throttle fully uu Crank the engine for 6 seconds uu Note the compression pressure
uu Take 3 readings and calculate the mean of the 3 readings Compression Pressure Details Std
Kg/cm2 11-13
Service limit 9.5
PSI
Bar
135.5
9.31
156.4~185.0 10.78~12.74
Bajaj Pulsar 200NS FI Training Notes
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Preliminary Checks and Maintenance Operations
Periodic Service SOP ‘O’ Ring Type Drive Chain Lubrication (On the vehicle) uu Park the vehicle on the service stand. uu Ensure free rotation of the rear wheel. uu Wipe / clean of dust using a lint free cloth.
uu Shake the chain lube spray thoroughly. uu Hold the spray at a distance of 5 – 10 cm from the chain uu Rotate the wheel in the reverse direction when spraying . Spray on the middle section of the chain.
‘O’ Ring Drive Chain Cleaning by Removing from Vehicle (Diesel + SAE 90 oil 1:1)
44
1st Stage : Clean with Diesel + oil 1:1
2nd Stage: Clean with Diesel + oil 1:1
Blow Low Pressure Compressed Air
Final Stage : Hook chain for dripping of excess oil
Soak into SAE 90 oil
3rd Stage: Dip into SAE 90 oil
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Periodic Service SOP Drive Chain Slackness Checking
uu Park the vehicle firmly on the service stand. uu Rotate the rear wheel uu Adjust slackness if found incorrect
Drive chain Slackness Std
Specs = Frame ppt
Ser limit
Specs = Frame ppt
Drive Chain Slackness Adjustment
uu Loosen Rear axle nut.
uu Adjust: LH chain adjuster RH chain adjuster Note: Ensure bolt LH/RH adjusters are adjusted equally.
uu Tighten: Rear axle nut. Ensure correct chain slackness.
Bajaj Pulsar 200NS FI Training Notes
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Preliminary Checks and Maintenance Operations
Why to & How to maintain your Vehicle? Why Periodic Maintenance is required? Components of vehicle & engine are subject to Continuous working. Rotation, Reciprocation, Swivel etc. Operational misuse.
Moreover, the vehicle get abused by Various driving habits. Bad road conditions. Dense traffic conditions. Different weather conditions.
All these call for regular Periodic Maintenance.
How to maintain the vehicle regularly?
By following the Service Schedule and Periodic Maintenance Schedule, one can maintain and keep the vehicle fit and healthy. Avail all the free services as per schedule. Avail all the paid services as per schedule. Follow Periodic Maintenance as per P.M. chart given in the Owner’s Manual.
Benefits :
Periodic Service / Maintenance ensures Consistent performance. Remote chances of breakdowns / accidents due to failure of parts. Enables safe riding. Economical in long run
Keep your vehicle fit and healthy by following Scheduled Services and Periodic Maintenance Schedule for trouble free performance
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Key Learning Points Understanding of EMS Layout Understanding the Function, Construction and Working of Sensors and Actuators Application and Usage of Diagnostic Tools Standard Operating Procedures for Fuel Pump Pressure Inspection and Fuel Pump Delivery Measurement
CHAPTER 5
Fuel System & EMS DTSi – Fi Engine Management Systems / EMS Layout Working of Systems Fuel Injection Dos and Don’ts
Bajaj Pulsar 200NS FI Training Notes
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5
Fuel System & EMS
DTS-Fi Engine Management System Location of parts Speedometer harness Tail and stop lamp, Rear blinker RH, Rear blinker LH, Number plate lamp, Fuse box assy., Aux. start relay 1,2,3. And CAN interface Ignition Switch Control Switch LH Control Switch RH Clutch Switch Kill Switch
Lambda (oxygen) sensor, crank sensor, stepper motor, Fuel injector, TMAP, TPS, CTS, Oil pressure sensor.
Lambda (oxygen) sensor, crank sensor, stepper motor, Fuel injector, TMAP, TPS, CTS, Oil pressure sensor.
HT coil 1
Roll over sensor
Photo
Part Name
Remark
H.T. Coil 2
For LH & RH spark plug
Roll Over Sensor
Sends ignition cut of signal to ECU when bike inclination angle > 68°
H.T. Coil 1
HT coil 2
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For Central spark plug
DTS-Fi Engine Management System Location of important parts / couplers Crank sensor & Lambda (oxygen) sensor
Regulator connectors
Photo
Fuel Pump Fuel Level Sensor
Coolant temp. sensor
Part Name Remark Crank Sensor
It monitor the position or rotational speed of the crankshaft
Lambda Sensor
Fuel Pump
Stepper motor
Engine earth
Photo
Light control module
Chassis earth
Regulator earth
Side stand switch
Part Name Remark
Light Control Module
It manages all the individual lights of the vehicle electric system.
Detects amount of oxygen in exhaust gas and sends signal to ECU which adjusts the air fuel mixture to the optimal level.
Regulator Earth
It has AC/DC voltage regulator & a rectifier. The RR unit regulates the electrical voltage & also helps in charging the battery.
To draw the fuel from fuel tank and push it along the fuel lines to injector and keep a constant pressure in the system.
Side Stand Switch
When the side stand is put ON the side stand sensor will send the information to ECU. ECU will thereafter not allow the engine to run in any gear.
Coolant temp. sensor
It measures the temperature of the coolant. The readings from this sensor are then fed back to the ECU, which uses this data to adjust the fuel injection and ignition timing.
Fuel Level Sensor
It senses the fuel level / quantity inside the fuel tank and communicates the same to fuel gauge.
Stepper Motor
Stepper motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor’s position can then be commanded to move and hold at one of these steps without any feedback sensor
Engine Earth
Chassis Earth
Common earthing for the electrical system
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
DTS-Fi Engine Management System Location of important parts / couplers Oil pressure sensor
TMAP TPS Termination Radiator fan unit relay
Regulator magneto Fuel Fuel level connection pump sensor
Photo
Stepper Regulator Main relay & EMS ECU motor Fuel pump relay
Part Name Remark Fuel Injector To inject the fuel into the intake manifold until the electric signal from solenoid is cut of by ECU. Oil pressure It measures the Sensor pressure of the engine oil flowing thru the internal oil galleries and communicates the signal to the speedometer. TMap
TPS
Termination Unit
50
It is a micromechanical sensor that measures the absolute pressure in the intake manifold and compares it with a reference vacuum, not with the ambient pressure. To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. It consist of a transil diode that filters the voltage surge thereby protects ECU from voltage fluctuation.
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Starter relay
Photo
Part Name Remark ECU
To collect information from various sensors & insure that correct quantity of fuel is injected into the intake manifold at precise timing at various engine load & speed condition
Main Relay
Fuel Pump Relay
Radiator Fan Relay
A relay is an electrically operated switch. Most relays use an electromagnetic to mechanically operate a switch. Relays are used where it is necessary to control a circuit by a lowpower signal
DTS-Fi Engine Management System Location of important parts / couplers Starter relay Starter relay coil Radiator fan relay
Termination unit
TMAP
TPS Oil pressure sensor
CTS Rear brake switch
Starter motor
TPS
Rear brake switch
TMAP Oil Pressure CTS Starter Motor
Battery positive
Battery negative
Main fuse
CAN Termination
Fuse Box Assembly Signal Lamp rear LH Signal Lamp rear RH Tail and Stop Lamp Number Plate Lamp And Can interface
Aux. starter relays 1,2 & 3
CAN Application
Earth chassis
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
DTS-Fi Engine Management System Photo
Part Name
Remark
CAN Termination
This unit is provided to have uninterrupted communication between diagnostic tool and ECU
Function of Aux Starter Relay AUX Starter Relay 3 Incorporated for clutch & neutral switch interlocking in starter circuit.
3 2
AUX Starter Relay 2 1
Its function is to isolate starter circuit from ECU. If this relay fails engine can not be crank.
AUX Starter Relay 1 It is grey in color. It has a diode that is provided for suppressing voltage surge. If vehicle is driven without this relay ECU may fail.
Notes
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Engine Management Systems Gives Input to ECU
Receive Output from ECU
Coolant temperature sensor.
Fuel Injector
Oxygen sensor (Lambda sensor)
Fuel pump
Crank angle sensor.
HT Coil
Throttle position sensor (TPS)
Temperature and Manifold pressure sensor (TMAP)
Roll over sensor.
Side stand sensor
Wheel speed sensor.
Malfunction indicator
ECU
Main power relay
Stepper Motor
Diagnostic coupler
Radiator Fan
Bajaj Pulsar 200NS FI Training Notes
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5
Fuel System & EMS
EMS Sensors and Actuators 1 1 - MPRD (Relay)
3
2
P4 P3 P2 P1
4
5 2 - Steeper Motor
3 - Injector
4 - T MAP Sensor
6
6 - Fuel Pump
7
8 7 - H. T. Coils (LH)
9 9 - Engine Malfunction Indicator (MIL)
10
10 - Diagnostic Coupler
11 11 - Radiator Fan
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8 - H. T. Coils (RH)
5 - TPS
Working of Systems Fuel Pump Function To draw the fuel from the fuel tank and push it along the fuel lines to the injector rail and keeping a constant pressure in the system. Also the fuel pump needs to ensure a high level of fuel flowing through the fuel line thus maintaining constant fuel delivery pressure.
Construction Fuel pump module assembly
Fuel Pump Mounting Bracket
Fuel Strainer
Fuel Pressure Regulator Fuel Pump
Rubber Gasket for Sealing on to Petrol Tank Pressurized Fuel out to Fuel Filter Fuel Filter to Injector
Regulator Connected in a ‘T’ Joint Fuel to Injector
Working The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the end of which is a fuel pressure regulator. In order to keep the injector pressure differential constant despite variations of inlet manifold depression with load, the fuel pressure regulator senses the difference between pumping pressure and that of the inlet manifold. Excess fuel is returned to the fuel tank, the continuous flushing keeps the fuel cool and avoids formation of pockets of fuel vapor. The fuel pump is lubricated and cooled by the fuel flowing through the motor, including the brushes and across the armature hence it is important that never run the pump without adequate fuel inside the fuel tank. The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pump, fuel injector nozzles from clogging. Fuel Pump Resistance = 2.7 + 0.1 Ohms Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Fuel Injector
Function To inject the fuel into the intake manifold until the electric signal from solenoids is cut off by ECU.
Construction
Fuel Supply
Electric Connection
Rail ‘O’ Ring Seal Integral Filter
Return Spring
Coil
Armature Valve Needle
Washer
Manifold ‘O’ Ring Pintle Protection Cap Pintle
Working The fuel injector supplies the fuel in the form of a spray from the injector pintle which is located on intake manifold. The injector have the nozzles which are opened and closed by solenoid wound (coil) in the injector body. When the windings are energized the armature is attracted due to magnetism and compresses the spring which lifts the needle valve. Thus pintle automises the fuel into a fine spray form with a pressure about 2.5 bars (36 lbf / in2) until the electric signal in the solenoid is cut off by the ECU. The injector internal movement is restricted just to < 0.1 mm. Also period that an injector remains open is very low (between 1.5 and 10 milliseconds). Thus the opening and closing time is critical for accurate fuel metering. The fuel spray mixes with the incoming air as both move towards the inlet valve giving a precisely metered combustion mixture.
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Working of Systems Engine Control Unit (ECU)
Introduction The automotive engine has two power generation systems named as ‘Carburetion System’ and ‘Ignition System’ respectively. The Carburettor supplies atomized / vaporized air fuel mixture to the engine maintaining the desired air fuel ratio as per engine requirement. The Ignition system supplies electric igniting spark at the spark plug tip as per precise engine demand (timing) to burn the compressed air fuel mixture inside the combustion chamber. However these 2 systems like Carburetion and Ignition has been dealt separately. In digital ignition circuits a microprocessor is used in the CDI unit. This microprocessor is capable of controlling various tasks. Hence it was logical to use this spare capacity for controlling fueling also. Thus then developed a digital electronic control system for fuel injection and combined it with the digital ignition control to form a single unit controller. This unit is named as “Electronic Control Unit”.
Function
It collects information from various sensors and ensure that a correct quantity fuel is injected into the intake manifold at precise time considering various engine load and speed conditions. It is brain of the engine and controls various devices. Also it controls / supports on vehicle diagnostic instrument for diagnosing the problem in fuel injection system.
Construction It consists of a micro computer A - D Convertor (Analog to Digital) and I - O Unit (Input - Output). Input signals are received from various set of Sensors
Signals given to operate following Actuators
Actuators
Side Stand Sensor Clutch Switch Engine Oil Pressure Sensor Roll Over Sensor Lambda Sensor Crank Angle Sensor and Neutral Switch T Map Sensor Throttle Position Sensor Coolant Temperature Sensor
Signal Processing (SP)
Vehicle Speed Sensor
Analogue to Digital - (A-D)
Sensors
MPRD (Relay) Steeper Motor
Engine Control Unit ECU
Injector Fuel Pump H.T. Coil (LH&RH) Engine Malfunction Speedo Icon Radiator Fan It also supports in Diagnostic trouble codes assessment. Bajaj Pulsar 200NS FI Training Notes
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Working of Systems Engine Control Unit (ECU) Working The ignition and fuel injection is controlled by a single control unit named as ‘ECU’. In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all outputs to the computer are in the form of digital pulses. These inputs received may be steady or slowly varying voltages. These are said to be in analogue form and which are converted into equivalent digital valves by an analogue to digital (AD) converter. The digital output are fed to the input I output rail for transporting to the main heart of the computer. Thus the ECU collects all signals, calculates them and process them to actuators to delivery precise ignition advance timing and fuel injection requirement for the engine at various load and speed conditions.
Set of Various Sensors A sensor is a device which detects or measures a quantity, usually in electrical form so that it may be used in measurement or control. The analogue signal processing is added to the sensor, this improves the resistance to interference.
Set of Various Actuators Actuators is a general term used to describe a control mechanism i.e. a device that converts electrical signals into mechanical movement e.g. Fuel injector Fuel pump Solenoid starter relay
Notes
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Working of Systems Throttle Position Sensor
Function To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU.
Construction The throttle body has a throttle valve mounted on the intake manifold. The throttle valve is connected by accelerator cable and its opening and closing is controlled by accelerator twist grip mounted on RH side of handle bar. The throttle position sensor mounted on the throttle valve continuously reports the throttle position to the ECU. This is a rotary throttle position sensor having a variable resistor also called as a potentiometer. Internally it has a coil resistance wire in the form of a half circle. One end connects to the ground and other end is connected to a 5 volt source from ECU. The wiper blade has a contact that rides on the coil and connects to the throttle valve shaft. Also the position of the throttle valve is important in controlling the idling rpm.
Working Upon acceleration the throttle valve position changes. The wiper type blades moves over the coil winding as it is pivoted directly on the throttle valve shaft. Throttle position at zero (closed} position When the throttle valve is closed, the blade is at the grounded end of the coil. A small voltage signal is send to ECU at this position which senses that the throttle position is at zero. Further movement of throttle position As the throttle valve moves towards the open position, the wiper type blade swings towards 5 volt end of the coil. This sends an increasing voltage signal to the ECU. Thus the continuously charging voltage regularly communicates the ECU the exact position of the throttle valve.
RESISTANCE COIL CLOSED THROTTLE
WIPER BLADE
PIVOT
WIDE OPEN THROTTLE
OUTPUT VOLTAGE TO ECU
5 VOLTS FROM ECU
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Fuel System & EMS
Working of Systems Engine Temperature Sensor Function
To measure the engine / engine oil temperature up to 200 0C.
Construction The principal methods of temperature measurement is are done by the thermistor. The thermistor is made from semi conductor material such as cobalt or nickel oxides and is encapsulated in a brass sleeve for mechanical protection.
Working The thermistors are semi conductor resistors which change their resistance valve with temperature. The resistance decreases with an increase in engine temperature as it has a negative temperature coefficient (NTC) and vice versa. The characteristic of engine temperature is represented graphically. (The values do not match exactly, it is just a representation for understanding). This NTC type thermistor is used to measure the engine temperature in engine management system.
200
Thermister Resistance (Ohm)
180 160 140 120 100 80 60 40 20 Temp. OC
0 0
10
20
30
40
50
60
70
80
NTC Thermistor Characteristic
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90 100
NTC Thermistor
Working of Systems Roll Over Sensor
Function To send the ignition cut off signal to ECU for shutting down the engine if the bike exceeds the inclination angle beyond 60° on either of the side.
Main Switch Sensor
Construction The roll over sensor is a sealed sensor unit and that contains moving weight which is suspended freely on a shaft. This is mounted below the air filter box onto the chassis. Please note, even if roll over sensor is not connected (coupler open) the vehicle does not start (to ensure safety) and the malfunction will be shown on speedometer.
Magnet
Working
x
O
60 O
60
The moving weights are suspended freely. When the vehicle leans down on either of the LH I RH side the position of these weights changes. The change of position of the weights is sensed by the sensor. If the inclination angle exceeds beyond 60° to the vertical the sensor will give signal to ECU to cut off the ignition system.
0
This is a useful safety feature because inclination angle exceeding 60° indicates that the rider has dropped the bike or is involved in an accident. Thus safety of the bike and rider is ensured. y
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Crank Angle Sensor Function To communicate the ECU how fast the crankshaft is rotating per minute and help ECU in delivering precise fuel metering and ignition spark advance.
Construction A magnetic sensor located in magneto cover facing towards square notched I square block on the rotor periphery.
Working As the rotor rotates the notched square blocks on the rotor periphery causes voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts the number of pulses per second and understands at what RPM the engine is operating and accordingly precise fuel metering and ignition spark advance is controlled. There are 23 square notches I square blocks on the rotor outer periphery and are placed equidistance. At a particular location there is wide gap seen between 2 square notches I square blocks. This can also be determined as square notch missing. This missing square notch area represents the BTDC position. At this BTDC position voltage pulse is sensed by the crank angle sensor and is communicated to ECU. ECU uses this information to control ignition spark advance.
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Working of Systems Malfunction Indicator Light Function When certain troubles develop in the electronic control system, the ECU stores in its memory or number or trouble code for each fault. This turns a Malfunction Red Indicator Light ( ) on the speedometer (next to Hi-beam light). This alerts the driver that there is some problem and repair / service in needed. If a single sensor or its harness part fails the ECU may substitute a value for failed sensor. This allows the engine to appear to run normal. A fault that turns on the malfunction indicator light may also put the engine into its limp-in mode. This means that limited operation strategy (LOS) chip in the ECU has taken over. It provides basic instructions to the microprocessor if a part of the electronic system fails. The engine runs but with fixed ignition timing and air fuel ratio. The injector pulse width does not change. This allows the vehicle to be driven but with greatly reduced performance. The benefit of this is the vehicle can be limpin for service instead of being towed or transported into a cargo. The technician can retrieve the stored trouble code from ECU memory using the diagnostic tool. To use the code the technician can refer the Diagnostic Chart or the Flash Code. This chart explains where lies the problem and its probable cause.
Notes
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Fuel System & EMS
Working of Systems Malfunction Indicator Light
List of Diagnostic Trouble Codes
64
SR No
P Codes
“Blink code”
“Drive Cycle”
1
P0123
3
Throttle/Pedal Position Sensor/Switch “A” Circuit High
2
P0122
06
3
Throttle/Pedal Position Sensor/Switch “A” Circuit Low
3
P0507
11
1
Idle Air Control System RPM Higher Than Expected
4
P0506
11
1
Idle Air Control System RPM Lower Than Expected
5
P0108
09
3
6
P0107
09
3
"Manifold Absolute Pressure/Barometric Pressure Circuit High”
7
P0629
41
1
8
P0628
41
1
Fuel Pump “A” Control Circuit Low
9
P0627
41
1
Fuel Pump “A” Control Circuit/Open
10
P0336
02
3
11
P0262
33
1
Crankshaft Position Sensor “A” Circuit Range/ Performance
12
P0261
33
1
Cylinder 1 Injector Circuit Low
13
P0201
33
1
Injector Circuit/Open – Cylinder 1
14
P1611
14
**
Fuel consumption signal output short to Battery
15
P1610
14
**
Fuel consumption signal output short to Ground
16
P1609
14
**
Fuel consumption signal output open
17
P0032
45
3
HO2S Heater Control Circuit High Bank 1 Sensor 1
18
P0031
45
3
HO2S Heater Control Circuit Low Bank 1 Sensor 1
19
P0030
45
3
HO2S Heater Control Circuit Bank 1 Sensor 1
20
P0692
16
1
Radiator Fan Control Circuit High
21
P0691
16
1
Radiator Fan Control Circuit Low
22
P0480
16
1
Radiator Fan Relay Control Circuit fault
23
P0132
17
3
O2 Sensor Circuit High Voltage Bank 1 Sensor 1
24
P0131
17
3
O2 Sensor Circuit Low Voltage Bank 1 Sensor 1
25
P0130
17
3
O2 Sensor Circuit Bank 1 Sensor 1
26
P0134
17
3
O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1
27
P1605
18
**
Malfunction Indicator Lamp (MIL) Control Circuit High
28
P1604
18
**
Malfunction Indicator Lamp (MIL) Control Circuit Low
29
P0650
18
**
Malfunction Indicator Lamp (MIL) Control Circuit
30
*P1504
15
1
Roll over sensor Short Circuit to battery
31
*P1503
15
1
Roll over sensor Short Circuit to Ground
32
*P1501
15
1
Roll over sensor circuit signal non-plausible
33
*P1502
15
1
Roll over sensor circuit open
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06
DTC meaning
Manifold Absolute Pressure/Barometric Pressure Circuit Low Fuel Pump “A” Control Circuit High
Cylinder 1 Injector Circuit High
Working of Systems Malfunction Indicator Light
List of Diagnostic Trouble Codes SR No
P Codes
“Blink code”
“Drive Cycle”
34
P1603
**
Rest tank Fuel Indicator Circuit High
35
P1602
19
**
Rest tank Fuel Indicator Circuit Low
36
P1601
19
**
Rest tank Fuel Indicator Circuit open
37
*P1508
25
1
Side Stand sensor Short Circuit to battery
38
*P1507
25
1
Side Stand sensor Short Circuit to Ground
39
*P1505
25
1
Side Stand sensor circuit signal non-plausible
40
*P1506
25
1
Side Stand sensor circuit open
41
P0509
49
3
Idle Air Control System Circuit High
42
P0508
49
3
Idle Air Control System Circuit Low
43
P0511
49
3
Idle Air Control Circuit
44
P0689
21
**
ECM/PCM Power Relay Sense Circuit Low
45
P0112
13
**
Intake Air Temperature Sensor 1 Circuit Low
46
P0113
13
**
Intake Air Temperature Sensor 1 Circuit High
47
P0117
12
3
Engine Coolant Temperature Sensor 1 Circuit Low
48
P0118
12
3
Engine Coolant Temperature Sensor 1 Circuit High
49
P1608
22
**
Engine Speed Signal Circuit High
50
P1607
22
**
Engine Speed Signal Circuit Low
51
P1606
22
**
Engine Speed Signal Circuit Open
52
P0563
24
**
System Voltage High
53
P0562
24
**
System Voltage Low
54
P1510
24
**
System Voltage sensing failure in ECU
55
P0501
23
3
Vehicle Speed Sensor “A” Range/Performance
56
P0643
26
3
Sensor Reference Voltage “A” Circuit Hig h
57
P0642
26
3
Sensor Reference Voltage “A” Circuit Low
58
P0653
27
1
Sensor Reference Voltage “B” Circuit High
59
P0652
27
1
Sensor Reference Voltage “B” Circuit Low
19
DTC meaning
Note: Actual description of DTC may vary to make it fit on Tool screen. * This fault codes are not applicable in case of RE 60. ** Blink Code getsON immediately. Healing for all DTC requires 3 driving cycle.
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Fuel Injection – Advantages over Carburetion : Advantages of Fuel Injection Increased power output per unit of displacement. Higher torque at low engine rpm. Improved cold start, warm up and sudden acceleration (No chance of wetting intake manifold). Lower fuel consumption. Overall superb drive-ability. Lower maintenance cost. Communicates malfunctioning of fuel injection system, if any. Low emission level.
Fuel Injection – Advantages over Carburetion : Limitations of Carburettor : Restricted air flow due to venture design causes power loss (volumetric efficiency is limited). As intake manifold contains combustible mixture, danger of back fire from the cylinder into the manifold is always there. At high altitude or in warm weather, possibility of vapour lock. After burning noise in silencer on sudden deceleration. Does not support sudden acceleration. Difficult cold starting and requires choke for starting. In cold conditions, fuel wets the wall of the induction manifold causing running difficulties. Difficult cold starting and requires choke for starting. Inconsistence in fuel efficiency. Maintenance cost is reasonably more. High emission level.
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SOP’s Petrol Tank Removal Insert Key and open the lock uu Remove Pillion seat
uu Remove 2 Bolts
uu Remove 2 Allen bolts 2 Nylon washers
uu Remove Rubber mesh
Rider seat
uu Remove Collared rubber washer Bush
uu Remove 2 Screws Side cover LH Side cover RH
Note: Similarly remove it for RH
uu Remove Allen bolt Washer Note: Similarly remove it for RH
uu Remove 2 Bolts 2 Nylon washers
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Fuel System & EMS
SOP’s Petrol Tank Removal uu Remove Flange bolt Collared washer Note: Similarly remove it for RH
uu Remove Carefully pull out the tank cover
A
B
uu Remove Disconnect the fuel gauge coupler (A) Disconnect the fuel pump coupler (B)
uu Remove Lift up the petrol tank
uu Remove Disconnect the clip and remove the hose pipe from filter side uu Remove 3 bolts (RL/RH/Front) 3 collared bush
Skill tip: Disconnect the fuel pipe carefully as the fuel line is filled with the pressurised fuel at 2.5 bars
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SOP’s Fuel Pump Delivery Inspection
Purpose of this test : To inspect correct quantity of fuel delivered through fuel pump for 10 seconds. uu Instruments required : Pig tail (BAL part no. : -------) Measuring jar Charged battery
Pigtail On Off Switch
Keep petrol tank on plain surface. Coupler Crocodile clips
Hold the clean jar at the fuel pipe outlet for collecting the fuel
Connect fuel pump delivery checking pigtail coupler to fuel pump coupler. Connect fuel pump delivery checking pigtail crocodile clips to 12V external battery source.
Quantity Unit
Put ON the “ON-OFF” switch of the pigtail.
180
Measure the fuel delivery for 10 seconds.
mililiters
Fuel Pump Pressure Inspection:
Purpose of this test : To measure the fuel pump delivery pressure. uu Instruments required :
uu Remove : Fuel pipe from fuel filter
Fuel pressure gauge
Connect to Fuel pipe (a)
Connect to Fuel filter (b)
uu Fit : The removed fuel pipe to the pressure gauge T joint. Other end of the pipe to the fuel filter. Bajaj Pulsar 200NS FI Training Notes
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SOP’s Fuel Pump Pressure Inspection Mount the petrol tank
Note: Ensure both the clamps are fully tighten. Switch “ON” the ignition key Observe the pressure that is displayed on the pressure gauge. Specification
Unit
36 to 42
PSI
2.5 to 2.9 2.4 to 2.8
Bar
Kg/cm2
Note : If the specification mention above is not achieved then confirm for no clogging of… 1. Tank air vent 2. Fuel line 3. Fuel filter Also confirm for proper functioning of fuel pump.
Throttle Body Removal
Note : Follow the earlier mentioned SOP’s till air filter case removal to proceed for Throttle Body removal. uu Remove 2 bolts
Loosen air filter side clamp
Note: Use long handle allen key
Loosen manifold side clamp
uu Remove Push up the circlip Hose pipe of PCV
uu Remove Push up the circlip Hose pipe of filter
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SOP’s Throttle Body Removal uu Remove Coupler for… Injector Steeper motor
uu Remove TPS coupler T map coupler
Skill tip: Before pulling the coupler first release the locking clip. Don’t pull the wire, pull the coupler firmly. uu Remove Grommet Slide out accelerator cable
uu Remove Pull out the filter box with throttle body
Skill tip: Cover the intake and engine breather bore using a soft clean cloth.
Injector Removal
Note : Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal. uu Remove Coupler
uu Remove Tusken screw Note: Use recommended Tusken screw driver.
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Fuel System & EMS
SOP’s Injector Removal
Note: Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal. uu Remove Injector
Skill tip: Cover the injector bore using soft clean cloth.
Engine Tune-up
Spark Plug Recommended Spark Plug
Central – BOSCH VR5NE
Electrode Gap
0.8 ~ 0.9 mm
Replace at every
LHS & RHS – CHAMPION – RG6HCC 30,000 kms
Air Filter
Note: Compressed air pressure should not be more than 2 bar
Clean at every: 5,000 Kms. Replace at every: 15,000 Kms
Cleaning frequency : Every 5000 Km. (increase freq. in dusty area) Replace Air Filter Foam at every 15,000 Km. uu Compression pressure checking
SOP : Warm up the engine. Park the vehicle Disconnect all plug caps. Remove LH spark plug and fit the compression gauge. With full throttle open crank the engine for 3 - 4 seconds. Take 3 readings and calculate the mean reading.
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SOP’s Tappet Clearance Adjustment Inlet Valve: 0.05 mm Exhaust Valve: 0.08 mm Tappet Clearance is to be check in engine cold condition.
Other Mandatory Checks Ensure no fuel leakage through fuel lines. Ensure free rotation of both wheels. Ensure correct tyre pressure - Front : 25 PSI, Rear : 32.0 PSI Set control cable free play: Clutch lever 2~3 mm. Rear brake pedal 20~25 mm. Accelerator free play 2~3 mm. Front brake free play 2~3 mm. Chain slackness : 15~25 mm. Check and confirm proper functioning of all 3 nos. spark plugs.
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Do’s & Don’ts Precautions while working on fuel injection system uu This fuel injection system is designed to be used with a 12V VRLA battery as its power source. Do not use any other local battery. uu Do not reverse the battery cable connections. This might damage the ECU. uu To prevent damage to the fuel injection parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running. uu Take care not to short circuit the leads that are directly connected to the battery positive (+) terminal to the chassis ground. uu Whenever the fuel injection electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (-) terminal. uu When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout the fuel hose. uu Do not operate the fuel pump if the pump is completely dry. The pump lubrication and cooling is done by the fuel itself. uu Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. uu Make sure all connectors in the circuit are clean and tight, and examine leads for signs of burning.
How to read MIL Code : uu The MI light will blink only when the vehicle is in idling or non running condition. In running condition the light would only glow. uu MIL codes are shown by a series of long and short blinks of the FI indicator light as shown below. uu Read long blink as 10 digits and small blink as a single unit digit. uu When there are a number of problems, all the MI codes can be stored and the display will begin starting from the lowest number blink code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open. uu For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed. (12 ---- 21) ---- (12 ---- 21) ---- (repeated).
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Key Learning Points Appropriate Torque Application for Various Engine Components Standard Operating Procedures for Oil Pressure Inspection Removal of Crank Angle Sensor Understanding of Standard Limits and Service Limits for all Engine Components
CHAPTER 6
Engine & Transmission
Bajaj Pulsar 200NS FI Training Notes
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Engine & Transmission
Important Skill Tips Cylinder Head Cover Dismantling
1
3
Always loosen 4 bolts in crisscross pattern. Tightening Torque : 1.0 ~ 1.2Kg.m
4
2
TDC Position for Valve Timing Check piston TDC position, Valve timing & Valve Tappet clearance before dismantling cylinder head. Intake Valve Tappet clearance: 0.05 mm Exhaust valve Tappet clearance: 0.08 mm
Cylinder Head Bolts Loosening Sequence Always loosen cylinder head short bolts (A) first and then loosen cylinder head long bolts (4 nos) in crisscross pattern.
A
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Important Skill Tips Piston Pin Circlip While removing / refitting piston pin circlip (snap ring), cover the crankcase bore with clean lint free cotton cloth to arrest circlip / snap ring falling inside the engine so as to avoid subsequent un- necessary opening of engine.
Primary Gear Holding While loosening ‘Primary Gear Nut’ & ‘Clutch Special Nut’, hold ‘Primary Gear’ and ‘Clutch Housing Gear’ by placing special tool from top.
Piston Ring Fitment 1
•
Piston rings must always be fitted with respect to exhaust mark on the piston
•
First place the bottom oil rail ring with end gap 30º towards left of the exhaust mark in the last groove.
•
Place oil expander ring with butting end downward & end gap facing opposite to the exhaust mark.
•
Now fit top oil rail ring on the expander ring with end gap 30º towards right of the exhaust mark.
•
Fit the second piston ring with ‘Top 2’ mark facing upward and end gap facing opposite to the exhaust mark.
•
Finally fit the first ring with ‘Top 1’ mark upward and end gap facing towards the exhaust mark.
•
Remember fitment of 2nd ring upside down may lead to passing of oil above the piston and ultimately leading to smoky exhaust.
2 3
Front
Top 1 Mark
Top ring
4 3 Top 2 Mark
Exhaust Arrow
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2nd ring
Engine & Transmission
Important Skill Tips Clutch Washer Sequence A : Special nut B : Belleville washer
A
C : Clutch stack D : Plain washer D
F
E : Clutch housing
B
F : Collar bush C
E
Counter Gear Washers a. When fitting spacer on allen bolt ensure that plain side of spacer face outside. b. When fitting ensure that bal. driven & driving gear collar side face inside.
a
b
Cylinder Head Bolts Loosening Sequence Always loosen cylinder head short bolts (A) first and then loosen cylinder head long bolts (4 nos) in crisscross pattern.
Ensure pin (A) & spring (B) is to be collected & carefully on removal of neutral switch.
B A Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Important Skill Tips When dismantling engine ..... Do not insert a sharp object in-between water pump rotor & crank case.
Tab the balancer shaft to remove rotor
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Engine & Transmission
Important Skill Tips Collect guide gear pin on removal of guide gear.
Ensure fitment of spacer when assembly guide gear
Remove input shaft bearing stopper on clutch side for fitment of crank case splitting tool.
Crank case splitting tool
Crank case splitting tool resting on bearing stopper location
Bajaj Pulsar 200NS FI Training Notes
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Engine & Transmission
Important Skill Tips Using engine heater heat the crank case clutch side for smooth & easy fitment of crankshaft bearing.
Ensure oil passages are not blocked.
- Ensure that the oil passage going towards orifice is cleared. - The orifice outlet is cleared.
Use grease to fix the springs when assembling. This is to avoid falling of the spring.
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Engine & Transmission
Important Skill Tips When aligning the marks for bal. driven & driver gear always ensure… - Piston is at TDC position. - Primary gear mark is align with crankcase mark.
Balancer driven & driver gear marks are inline with each other.
Close the bore of magnet side crank case using a lint free cloth when fitting the harness guide. This is to avoid bolt falling inside the crank case.
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Standard Operating Procedure Top Side Dismantling Dismantling - Cover Cylinder Head Remove • 4 Bolts (10mm A/F) Skill Tip : Always loosen cylinder head cover bolts in criss - cross pattern. • Cylinder head cover with gasket (rubber beading type)
Check TDC Position • Align rotor mark Crankcase LH.
w.r.t.
• Check cam sprocket marks from RH side.
Cam Chain Tensioner Remove • One Bolt (A) (10 mm A/F) • ‘O’ Ring • Rotate chain tensioner’s screw in clockwise direction to take plunger backward & lock it . • Two bolts (B) (8mm A/F) M6 • Take out tensioner. • Take out gasket chain tensioner.
Cam Sprocket Using Special tool 37 1042 54 Cam Sprocket holder Remove • Bolt special flanged (12mm A/F) • Cam Sprocket • Spacer cam shaft Skill Tip : Tie chain by soft copper wire.
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Engine & Transmission
Standard Operating Procedure Remove • Spark plug RH
Remove • •
Grub screw Sleeve spark plug RH.
Skill Tip : Rotate sleeve before pulling out Cover sleeve portion by cotton cloth & then pull out by plier.
CAUTION Do not pull out sleeve directly by plier otherwise it would get damaged.
Cylinder Head Bolts Remove • 2 Cylinder head short bolt (A) (8 mm A/F) M6 x 120 • 4 Cylinder head long bolts (B) (12 mm A/F) M10 x 147 • Take out cylinder head assembly complete
Skill Tip : Always loosen smaller bolts of cylinder head first & then loosen longer bolts in crisscross pattern to avoid cylinder head warpage.
Cylinder Head Complete Using Special tool 3710DH35 for Rocker Shaft remover Remove • 2 Rocker shaft (A) • 2 Rocker arms (B) • Circlip (C) • Cam Shaft (D)
B A B D C
Bajaj Pulsar 200NS FI Training Notes
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Engine & Transmission
Standard Operating Procedure Using Valve Spring Compressor Adaptor - 37103108 Remove • Collets (A) • 4 Retainers (B) • 4 Valve Springs (C) • 4 Valve Oil Seals (D) • Valve Spring Seats (E) • 2 Exhaust & 2 Intake Valves (F)
Cylinder Piston Assly. Remove • Gasket Cylinder Head • Chain Guide • 2 Dowels • Cylinder Block
Remove • Gasket cylinder block (A) • 2 Dowels (B)
Using Piston Pin Drift Part No: 37101006 Remove • Snap ring (Circlip) • Piston pin • Piston Assembly
Skill Tip : Cover crankcase bore by clean lint free cloth while dismantling piston circlip / snap ring.
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A B C D E F
Engine & Transmission
Standard Operating Procedure Clutch Side Dismantling Cover Clutch Remove • 11 Bolts (8mm A/F) M6 x 30. • Clutch Cable Bracket • Cover clutch • Clutch cover gasket. • 2 dowels.
Oil Filter Remove • 2 flanged bolts (8mm A/F) M5 x 16 • ‘O’ ring. • Cap oil filter. • Oil filter.
B C D E F
Shaft Clutch Release Remove • Push rod (A). • Shaft clutch release (B) • Spring (C) (lever clutch) • Plain washer (D). • Seal oil (E). • Needle bearing (F).
A
Remove • Clutch lifter bearing.
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Using Primary Gear Holder Special Tool 37004154 & Special Socket for Clutch Nut 3710DJ43 Remove • Nut sprocket drive lock.
Skill Tip : Lock Special tool between the teeth of primary gear & clutch housing gear from top.
• Remove Belleville washer.
Remove • Special nut for clutch
• Belleville washer
Bajaj Auto International Business
Engine & Transmission
Standard Operating Procedure Remove • Clutch stack complete • Plain washer • Timing chain • Clutch housing
Skill Tip : Clutch Nut must be removed by rotating it in clockwise direction.
•
Remove Collar bush.
By using Clutch Dismantling Special Tool Pulsar Remove • 4 bolts (A) (10mm A/F) • 4 springs (B) • Holder Clutch (C) • Clutch Hub (D) • Friction Plates (E) • Steel Plates (F) • Wheel Clutch (G)
C
B
A
D
G F
E
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Removal of Primary Gear Remove • Sprocket crankshaft. • Gear primary drive with wood ruff key. • Spacer crankshaft.
Gear Shift Mechanism Remove • Lever gear change shaft. • Stopper drum bolt ( mm A/F). • Washer (bigger dia). • Inhibitor gear shift lever. • Washer (smaller dia). • Drum stopper spring.
Remove • Allen bolt (A). • Gear shift guide (B). • Spacer (C).
C B
A
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Engine & Transmission
Standard Operating Procedure
LUBRICATION SYSTEM DISMANTLING OIL PUMP Remove • Circlip (A).
• Oil pump drive gear (B).
Remove • 3 flanged bolts (C) (8mm A/F) M6 x 30. • Oil pump body (D). • 2 Dowels (E) • Inner (F) & outer (G) rotor
C D
BA
E G
F
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Remove • Pivot bolt • Chain Guide (Slack Side) • Cam / Timing Chain
Magneto Side Dismantling Dismantling - Cover Magneto Remove • 9 bolts (8mm A/F) M6 X 30 • Magneto Cover Skill Tip : Loosen magneto cover bolts in criss-cross pattern.
Using Rotor Holder H6 0721 00 & Rotor Puller 37 0041 55 Remove • Hex flanged bolt (14 mm A/F) • Belleville washer (A) • Rotor (B) & its key.
Remove • Starter counter gear 1.
• Starter counter gear 2.
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Engine & Transmission
Standard Operating Procedure Balancer Drive & Driven Gear Remove • Nut balancer drive lock by using special tool. • Belleville washer. • Balancer drive gear. • Key wood ruff. • Allen bolt. • Special washer. • Gear balancer driven. • Square key.
Neutral Indicator Switch Remove • 2 bolts (A) (8 mm A/F) M5x10 • Bracket harness upper (B). • 1 bolt (C) (8 mm A/F) M5x10 • Bracket harness lower (D). • 2 bolts (E) (8 mm A/F) M5x16 • Neutral indicator switch (F).
A B
C D
E
F
Remove • 2 bolts (8 mm A/F) M5 x 13. • Pick up coil • 1 Bolt (8mm A/F) (B) M5 x 6 • Stopper plate (D). • Stator plate assembly 3 allen bolts (4 mm A/F) M5 x 0.8 x 35
WATER PUMP REMOVAL Remove • 5 bolts (A) (8mm A/F) M6x20 • Water pump cover (B). • ‘O’ ring (C). • Domed nut (D). • Washer (E). • Water pump rotor (F).
E F
D
C B A
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Crankcase Splitting Remove • 4 long bolt (A) (8mm A/F) M6 x 60 • 10 Short Bolt (B) Magneto Side (8mm A/F) M6 x 45
Dismantling - Crankcase By using Crankcase Splitting Special Tool Remove • Remove RH side crankcase. • Crankcase gasket. • 2 dowels (dia 14)
Crankshaft Removal Remove Crankshaft
Crankshaft Removal Remove • Shaft Fork Shift (A) Input & Output (B) with 2 springs. • Gear Change Drum (C) • Washer 1st Gear Output. • Washer below 2nd gear Input • Shift Fork - Input (D) / Output (E). • Input shaft assembly • Output shaft assly.
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E
C B D A
6
Engine & Transmission
SOP: Checking Engine Oil Pressure Purpose of this test : To measure oil pump delivery pressure checked at idle RPM at cylinder head.
uu Instruments required: Pressure gauge with adapter (BAL Part no. 37 0041 93)
uu Fit
uu Put OFF the ignition switch.
uu Re-fit air filter cover and petrol tank and start the engine.
uu Remove Rubber cap
uu Note the oil pressure on the oil pressure gauge at 1400 ± 50 RPM.
Disconnect Oil pressure switch cable connection Oil pressure switch
Note: Follow SOP of air filter removal to connect the oil pressure guage.
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Oil pressure gauge adapter and tighten it fully.
Specification
Unit
1.01
Kg/cm2
14.50
PSI
>1
bar
SOP: Crank Angle Sensor Removal Note: Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Crank Angle Sensor Removal.
uu Remove:
Using rotor holder special tool hold the rotor firmly uu Remove Flange Bolt
Stator plate socket
Washer
uu Remove: 13 bolts
Using rotor puller special tool pull the rotor firmly uu Remove Rotor Key
uu Remove Magneto cover Gasket
uu Remove Bolt Stopper for gear starter clutch
2 dowels Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
SOP: Crank Angle Sensor Removal
uu Remove: 2 bolts for crank angle sensor
Using Bal. gear holder special tool lock the balancer drive and driven gears firmly Bal. lock nut remover Loosen Special nut
uu Remove: Gear starter clutch
uu Remove Allen bolt Special washer uu Skill Tip Inspect for correct alignment marks for the balancer drive and driven gear.
uu Using Bal. gear holder special tool lock the balancer drive and driven gears firmly Loosen Allen bolt
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Skill tip : Ensure that the special washer with the cut mark is fitted facing the balancer driven gear.
uu Remove Special nut Belleville washer
SOP: Crank Angle Sensor Removal
uu Remove: Driver gear
uu Remove: Driver gear
Skill tip : Driver and driven gear with collar should face crankcase side.
uu Remove: Bolt keys (Driver and Driven)
uu Remove: All bolts securing the bracket
uu Remove: 2 bolts Neutral switch
uu Remove: Crank angle sensor with neutral switch
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Engine Service Data Compression Pressure
Std. Limit
11 ~ 13 kg/cm²
Ser. Limit
9.5 kg/cm²
Clutch Hub Height
Std. Limit Ser. Limit
Intake 0.05 mm -
Exhaust 0.08 mm -
Clutch Stackup Height
Clutch Spring Free Length
Std. Limit
38.4 mm
Ser. Limit
37.3 mm
Crankshaft Runout
Std. Limit
21.0 ~ 21.2 mm
Std. Limit
22.17 ~ 21.57 mm
Std. Limit
0.02 mm
Ser. Limit
21.4 mm
Ser. Limit
20.3 mm
Ser. Limit
-
Steel Plate Thickness
Friction Plate Thickness
Friction Plate Wrap
Std. Limit
1.6 mm
Std. Limit
2.92 ~ 3.08 mm
Std. Limit
0.1 mm
Ser. Limit
-
Ser. Limit
2.72 mm
Ser. Limit
-
Steel Plate Wrap
80
Valve Tappet Clearance
Rocker Arm Shaft Diameter
Cam Sprocket Diameter
Std. Limit
0.1 mm
Std. Limit
9.0 mm
Std. Limit
65.52 mm
Ser. Limit
-
Ser. Limit
-
Ser. Limit
65.22 mm
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Engine Service Data Cam Lobe Height
Camshaft Chain Length
Valve Spring free Length
20 Link Length
21st
1st 2nd
MEASURE THIS LENGTH
Intake Exhaust Std. Limit 30.34 mm 30.29 mm Ser. Limit 30.29 mm 30.24 mm
Std. Limit
129.4 mm
Std. Limit
38.9 mm
Ser. Limit
129.85 mm
Ser. Limit
37.9 mm
Valve Stem Diameter
Intake Exhaust Std. Limit 4.483 mm 4.463 mm Ser. Limit 4.465 mm 4.445 mm Cylinder Head Warp
Valve Stem Bend
Valve Stem to Guide Clearance
Intake
Std. Limit
TIR 0.01 mm
Ser. Limit
TIR 0.015 mm
Cylinder Inside Diameter
Exhaust
Std. Limit 0.01~0.037 mm 0.03~0.057 mm Ser. Limit
0.047 mm
0.067 mm
Cylinder Piston Clearance
10mm 20mm 40mm
Std. Limit
0.05 mm
Ser. Limit
-
Piston Diameter
Group A
71.964 ~ 71.976 mm
Group B
-
72.006 ~ 72.013 mm
Std. Limit
Piston Ring End Gap
Std. Limit
0.03 ~ 0.049 mm
Ser. Limit
0.09 mm
Piston Ring Groove Clearance
Top
Second
Oil Ring
Top
Second
Oil Ring
Std. Limit
0.015~ 0.030 mm
0.030~ 0.050 mm
0.20 ~ 0.70 mm
Std. Limit
0.020~ 0.055 mm
0.02~ 0.060 mm
0.035 ~ 0.110 mm
Ser. Limit
-
-
-
Ser. Limit
-
-
-
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Engine Service Data Shaft Fork Shift O.D
Gear Shift Drum Groove Width
Std. Limit 11.966 ~ 11.984 mm
Std. Limit
12.0 mm
Std. Limit
4.55 ~ 4.70 mm
Ser. Limit
Ser. Limit
-
Ser. Limit
4.75 mm
-
Gear Shift Fork Guide Pin Diameter
Std. Limit
4.45 ~ 4.49 mm
Ser. Limit
4.4 mm
Notes
82
Fork Shift I.D
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Engine Tightening Torque Spark Plug
Oil Strainer Cap (18 mm A/F)
Cap Oil Filter Cover Bolts
Tightening torque - 1.3 ~ 1.5 kgm
Tightening torque - 0.8 ~ 1.0 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Chain Tensioner Mounting Bolts
Cylinder Head Cover Bolts
Output Sprocket Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Stator Plate Mtg. Bolts
Eng. Mtg. Rr. Upper/Lower Bolts
Clutch Cover Bolts
Tightening torque - 0.7 ~ 0.8 kgm
Tightening torque - 2.5 ~ 3.0 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Oil Pump Mounting Bolts
Coolant Temperature Sensor
Magneto Cover Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.2 ~ 1.4 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Primary Gear Nut
Cam Shaft Sprocket Bolt
Nut Securing Clutch Assly.
Tightening torque - 5.9 ~ 6.1 kgm
Tightening torque - 2.5 kgm
Tightening torque - 7.0~7.1 kgm Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Engine Tightening Torque
84
Magneto Rotor Mounting Nut
Stator Motor Mounting Nut
Inhibitor Nut
Tightening torque - 5.9~6.1 kgm
Tightening torque - 1.0~1.2 kgm
Tightening torque - 1.0~1.2 kgm
Guide Gear Allen Bolt
Clutch Holder Bolts
LH/RH Engine Stay Upper Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.1 kgm
Tightening torque - 2.5 ~ 2.7 kgm
LH/RH Engine Stay Lower Bolts
Silencer Joining Nut
Injector Mounting Bolt
Tightening torque - 2.5 ~ 3.0 kgm
Tightening torque - 1.0 ~ 1.1 kgm
Tightening torque - 0.8 ~ 1.0 kgm
Oil Pressure Sensor Nut
Bal. Driver Gear Mounting
Bal. Driven Gear Mounting (Allen)
Tightening torque - 1.1 ~ 1.5 kgm
Tightening torque - 5.9 ~ 6.0 kgm
Tightening torque - 2.2 ~ 2.5 kgm
Cylinder Head Small Bolts
Cylinder Head Big Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 4.4 ~ 4.6 kgm
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Do’s & Don’ts Dos
uu Always replace gasket ‘O’ rings of engine If dismantled.
Don’ts
uu Don’t reuse ‘O’ rings, gasket, Oil seals, Circlip locks as they use their strength and properties, once they are opened.
Dos
uu Whenever installing Spark Plug, first screw by hand and then tighten to specified torque.
Don’ts
uu Don’t adjust spark plug electrode gap by hacksaw blade or with judgment of eye otherwise it will affect the engine performance.
Dos
uu Always below light pressure compressed air from inside while cleaning ‘Oil strainer’ that is opposite to the direction of flow of oil.
Don’ts
uu Don’t reuse torn ‘Oil strainer’ otherwise it will affect lubrication system of engine and subsequently would lead to seizure.
Bajaj Pulsar 200NS FI Training Notes
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7
Frame & Suspension
Key Learning Points Appropriate Torque Application for Various Frame Components Understanding of Standard Limits and Service Limits for all Frame Components
CHAPTER 7
Frame & Suspension Service Limits Tightening Torque Dismantling & Assembling Front Fork Front Disc Brake
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Frame Service Data Disc Pad Thickness
Rear Sprocket Warp
Axle Wheel Run Out
Std. Limit
Fr-7.4 mm
Rr-7.3 mm
Std. Limit
TRI 0.4 mm or Less
Std. Limit
TIR 1.0 mm or Less
Ser. Limit
Fr-3.8 mm
Rr-2.0 mm
Ser. Limit
TIR 0.5 mm
Ser. Limit
TIR 2.0 mm
Tyre Tread Depth
Front Fork Oil Grade & Capacity Grade : SAE 10W20 Bajaj Genuine Fork Oil
F o r k O il L e v el
Radial Wheel Run Out
Std. Limit
TIR 0.8 mm or Less
Ser. Limit
TIR 2.0 mm
Std. Limit
Front:5.0 mm
Ser. Limit
Upto TWI 1.0
Drive Chain Slack
Quantity Per Fork Leg : O/H: 320 ml Drain & Refill: 295+2.5ml
Rear:6.0 mm
Axle Run Out
Drive Chain Length 19 Link Length
1st 2nd 100 mm
19th
MEASURE THIS LENGTH
Std. Limit
15 ~ 25 mm
Std. Limit
TIR 1.0 mm or Less
Std. Limit
301.6 ~ 302.1 (19 link)
Ser. Limit
30 ~ 40 mm
Ser. Limit
TIR 2.0 mm
Ser. Limit
307
Notes
Bajaj Pulsar 200NS FI Training Notes
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7
Frame & Suspension
Frame Tightening Torque
88
Front Axle Nut
Rear Axle Nut
Swing Arm Shaft
Tightening torque 9.0 ~ 10.0 kgm
Tightening torque 10.0 ~ 12.0 kgm
Tightening torque 13.0 ~ 15.0 kgm
Rear Sprocket Mounting Nut
Handle Bar Holder Bolts
Fork Center Nut
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 1.8 ~ 2.0 kgm
Tightening torque 4.8 ~ 5.2 kgm
Steering Stem Nut Slotted
Fork Upper Bracket Bolts
Fork Under Bracket Bolts
Tightening torque 0.5 kgm
Tightening torque 1.8 ~ 2.0 kgm
Tightening torque 2.5 ~ 3.0 kgm
RSA Mounting Bolt (Upper)
RSA Mounting Bolt (Lower)
Disc Mounting Bolts (Front)
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 2.6 ~ 3.2 kgm
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Frame Tightening Torque Disc Mounting Bolts (Rear)
Front Caliper Mounting Bolt
Front Fender Mounting
Tightening torque 2.6 ~ 3.2 kgm
Tightening torque 4.0 ~ 5.0 kgm
Tightening torque 0.8 ~ 1.0 kgm
Brace Fender Mounting Bolt
Rear Brake Pedal Mtg. Bolt
Bracket Rear Number Plate
Tightening torque 2.0 ~ 2.2 kgm
Tightening torque 2.0 ~ 2.2 kgm
Tightening torque 1.8 ~ 2.2 kgm
Side Stand Mounting Bolt
Handlebar End Weight Bolt
Tank Mounting Bolt
Tightening torque 2.5 ~ 3.0 kgm
Tightening torque 0.8 ~ 1.2 kgm
Tightening torque 1.8 ~ 2.2 kgm
LH & RH Stay Bolts
Tightening torque 1.6 ~ 1.8 kgm Bajaj Pulsar 200NS FI Training Notes
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7
Frame & Suspension
Dismantling & Assembling Front Fork Front Fork Overhaul
Bajaj Auto International Business
•
Align overhead chain pulley structure as shown in photograph.
•
Insert belt below headlight fairing structure as shown in photograph.
•
Hook the belt as shown in photograph.
•
Lift the vehicle by pulling chain.
•
Remove caliper mounting bolts (2 nos) with 12 mm spanner & front wheel speed sensor cable mounting bolt with 10 mm spanner.
•
Take out caliper assembly.
•
Remove front brake hose & speed sensor cable mounting clamp bolts with 8 mm spanner.
•
Remove front axle nut with 22 mm spanner holding axle head with 17 mm spanner.
•
Take out front axle & front wheel.
Frame & Suspension
Dismantling & Assembling Front Fork •
Remove front fender mounting bolts (4 nos) with 12 mm spanner & side bolts (2 nos) with 5 mm allen key
•
Take out front fender.
•
Ensure availability of 2 nos spacers
2 nos •
Loosen upper bracket & side holder mounting bolts (3 nos) with 6 mm allen key.
•
Loosen under bracket assembly mounting bolt with 17 mm spanner holding fork leg assembly with hand to prevent falling of fork leg.
•
Take out fork leg assembly from vehicle.
•
Remove fork inner pipe cap bolt with 5 mm allen key & take out fork inner pipe cap bolt.
•
Insert fork inner pipe holder tool in fork inner pipe & tighten fork inner pipe holder tool with 6 mm allen key.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Dismantling & Assembling Front Fork •
Remove fork top bolt with 14 mm allen key & take out fork top bolt.
•
Take out - Spacer tube - Washer & - Fork Main spring.
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•
Take out fork oil in measuring jar.
•
Take out dust seal & oil seal lock.
•
Using cylinder piston holder (Hexagonal shaped), remove fork outer tube bottom bolt with copper washer by 6 mm allen key.
•
Take out cylinder piston holder along with piston.
•
Insert fork oil seal & antifriction bush extraction tool through fork inner pipe as shown in photograph.
•
Using fork inner pipe holder tool, rotate oil seal extractor tool handle for removal of fork inner pipe along with oil seal & anti-friction bush from
Frame & Suspension
Dismantling & Assembling Front Fork •
Take out oil seal extraction tool from fork inner pipe.
•
Take out - Oil seal - Washer - Anti-friction bush & - Cap oil lock.
Clean Fork Outer tube & Inner Pipe as given below before assembly. •
Clean the fork inner pipe & outer tube with
•
Pour diesel in fork inner pipe by closing other end with hand.
•
After pouring diesel, close both ends of fork inner pipe with hands & shake inner pipe.
•
Pour diesel, in fork outer tube by closing other end with hard.
•
After pouring diesel, close both ends of fork outer tube with hands & shake outer tube.
•
Nylon brush can be used for removing burr / muck particles for inner / outer tube.
•
Blow compressed air through from inner pipe & fork outer tubes.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Dismantling & Assembling Front Fork •
Hold cylinder piston along with spring on cylinder piston holder as shown in photograph.
•
Assemble fork inner pipe, cap oil lock & fork outer tube.
• Insert anti-friction bush & washer.
•
Insert the oil seal & fitment oil seal using oil seal fitment
Note :
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•
Never reuse the fork oil seal.
•
Always replace the front fork oil seal along with dust seal of same manufacturer.
•
Front fork oil seal fitment direction should be as shown in photograph.
•
Always replace oil seal fitment punch if nylon sleeve found damaged.
Oil Seal Fitment
Replace if , Nylon sleeve found damaged
Frame & Suspension
Dismantling & Assembling Front Fork •
Fit oil seal lock & dust seal.
•
Fit fork main spring & washer.
•
Fill the correct quantity (285 ± 5 ml) of recommended fork oil (SAE 10W20).
•
Insert spacer tube.
•
Fit front fork top bolt with 14 mm allen key.
•
Fit fork inner pipe cap & tighten bolt with 5 mm allen key.
•
Refit the fork leg on vehicle.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake Caliper Anchor Piston Seal & Dust Seal Replacement
Bajaj Auto International Business
•
Clean Caliper assembly thoroughly by low pressure water spray before opening caliper bleeding screw.
•
Remove bleeder nut rubber cap.
•
Drain the brake fluid from caliper assembly by loosening air bleeder nut with 8 mm spanner & using transparent PUC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking
•
Remove front brake hose and wheel speed sensor cable mounting bracket bolt with 8 mm spanner.
•
Remove front brake hose banjo bolt with 14 mm spanner.
•
Remove caliper mounting bolts (2 nos) with 12 mm spanner & take out caliper assembly.
•
Remove brake pedal mounting pin lock clips (2 nos) with plier.
•
Take out brake pad mounting pin & brake pads.
Frame & Suspension
Front Disc Brake •
Remove caliper anchor pin holder bracket.
•
Remove rubber parts from caliper body.
•
Remove brake pad spring.
•
Remove bleeder nut & it's cap.
•
Remove caliper pistons by applying low compressed pressurized air (> 2 bar) through banjo bolt hole. Note :- Don't apply high compressed air pressure > 2 bar. This could cause piston to fly out from caliper body causing damaged to it & any one in the vicinity.
•
Remove dust seals & oil seals.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
Bajaj Auto International Business
•
Clean caliper body by diesel / kerosine.
•
Dry caliper body by applying low pressure compressed air.
•
Clean the anchor pin and holder bracket thoroughly.
•
Smear silicon grease on anchor pins evenly.
•
Fit new dust seal and oil seal in caliper body.
•
Smear silicon grease on piston OD & rubber seals.
•
Fit caliper pistons.
Frame & Suspension
Front Disc Brake •
Fit all rubber parts.
•
Fit anchor pin holder bracket.
•
Fit brake pad spring.
•
Clean brake pads by sand / polish paper.
•
Fit brake pad, brake pad mounting pin & brake pad mounting pin lock.
•
Fit bleeder nut along with rubber cap with 8 mm spanner.
•
Fit caliper body on fork location Pre-fit caliper mounting bolt & tighten it to recommended torque by torque wrench.
•
Fit brake hose banjo bolt. Note :- Always replace banjo bolt / copper washer whenever opened with new one.
•
Tighten front brake hose speed sensor cable mounting clamp bolt with 8
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
Bajaj Auto International Business
• •
Pre-Fit air bleeder nut with 8 mm spanner.
•
Remove master cylinder cover mounting screws (2 nos) with phillips head screw driver & take out master cylinder cover.
•
Remove PVC cap & rubber diaphragm.
•
Fill the master cylinder reservoir by recommended brake fluid (DOT 4)
•
Fit a proper tube which fits slightly tight on bleeder screw nipple.
•
Insert 8 mm ring spanner through pipe fitted on bleeder screw nipple.
•
Connect tube to siphon pumps pipe and loosen bleeder nut by ring spanner.
Frame & Suspension
Front Disc Brake •
• • • •
Press bellow siphon pup in its valve open position then close the valve of pump & release the bellow, simultaneously press the brake lever to take out air trapped in the system. Carry out the same procedure until entire air trapped in the system gets removed. During this process continuously monitor & maintain the brake fluid level in master cylinder reservoir slightly above MIN mark. Ensure front wheel is rotating freely. Tighten bleeder nut. Route front wheel speed sensor cable inside bleeder rubber cap
Master Cylinder Piston Kitt Replacement •
Clean master cylinder thoroughly by keeping nozzle in spray mode before opening master cylinder top cover.
•
Remove bleeder nut rubber cap.
•
Drain the brake fluid from caliper assembly by loosening air bleeder screw & using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking.
•
Remove front brake switch terminal connectors.
•
Remove front brake lever mounting nut with 10 mm spanner holding with phillips head screw driver
•
Take out front brake lever.
•
Remove master cylinder reservoir cover, PVC cap & rubber diaphragm.
•
Remove actuating shaft.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
Bajaj Auto International Business
•
Remove front brake hose mounting bolt with 14 mm spanner from master cylinder end.
•
Take out front brake hose.
•
Remove master cylinder mounting bolts (2 nos) with 8 mm spanner & take out master cylinder.
•
Remove actuating shaft rubber boot.
•
Remove master cylinder piston air clip.
•
Insert blunt tipped screw driver from banjo bolt side and push piston towards brake lever side. ensure master cylinder does not get damaged due to screw driver
•
Take out piston assembly from brake lever side.
•
Clean master cylinder with brake fluid.
Frame & Suspension
Front Disc Brake •
Dry master cylinder with low compressed air pressure (> 2 bar)
•
Smear silicon grease on new piston seals of master piston kit.
•
Fit new master cylinder piston inside master cylinder from brake lever side.
•
Fit air clip actuating shaft rubber boot and actuating shaft.
•
Fit master cylinder on vehicle.
•
Fit brake hose replace copper washer with new one.
•
Fit front brake lever.
•
Fill brake fluid & carry out air bleeding.
•
Fit master cylinder diaphragm. PVC cap and cover.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Do’s & Don’ts Dos uu Replace front fork oil with SAE 10W20 grade fork oil.
Don’ts
uu Don’t add any other mineral based oil to front fork.
Dos uu Maintain correct tyre pressure as per specification.
Don’ts
uu Don’t over / under inflate the tyres.
Dismantling & Assembling Front Fork** Front Disc Brake** **Similar to the Pulsar 200 NS Training Notes. For more details refer Pulsar 200 NS Training Notes (Doc No. 71111472).
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Key Learning Points Understanding of VRLA Battery Charger VRLA Battery Charging Process Checking and Inspection of all Electrical Components Standard Operating Procedures for Headlight Assembly Dismantling Removal of Sensors and Actuators
CHAPTER 8
Electricals VRLA Battery Initial Filling VRLA Battery Charger & its Charging SOP Dos and Don’ts for RLA Battery Electrical Checking Procedure Electrical Circuit Diagrams
Bajaj Pulsar 200NS FI Training Notes
91
8
Electrical
VRLA Battery Initial Filling Filling Procedures
Step 1: Get the battery ready Place the battery on a flat leveled and preferably on a insulated surface. Remove the filler port seal of the battery. Filler port seal
Step 2: Get the electrolyte ready Remove electrolyte container from the packing. Remove the sealing cap plug strip. Keep the sealing cap plug strip aside as this is to be used as battery sealing plug strip later.
Note: Do not puncture the seals manually.
Plug cap strip
Seal
Step 3: Fill the battery Hold the electrolyte container upside down. Place the container upright on battery. Match the 6 seals with the respective filler ports.
Note: Ensure the container is upright and not tilled. If tilled the electrolyte might fail to flow. Now force the container down until seals get pierced, and electrolyte flows into the battery.
Step 4: Check the electrolyte flow Make sure that air bubbles are visible in the electrolyte and which is seen in all the 6 tubes of the container. Leave the container on the battery as it is for 30 minutes.
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VRLA Battery Initial Filling Step 5: Take away the bottles Be sure that the entire electrolyte has flown down inside the battery. Tap the bottom of the container and gently remove the empty container.
Step 6: Attach the sealing cap Fit the sealing cap plug strip tightly on the filler ports of the battery. Ensure by pressing firmly that the cap has become flush with the top surface of battery.
Step 7: Charge the battery Charge the battery on BAL recommended VRLA battery charger as per std. SOP.
Caution
Never use conducting materials like screw drivers which can produce the spark near battery terminals. Do not add any additional electrolyte.
Bajaj Pulsar 200NS FI Training Notes
93
8
Electrical
VRLA Battery Initial Filling Metafab VRLA Battery Charger Indication Display 2
3
4
5
6
7
8
9
10
11
1 12
1.
On / off Switch
2.
New battery / use battery switch
3.
2 Amp / 4 Amp current selection Switch
4.
Main power supply indication light (Green)
5.
Open circuit indication light (Red)
6.
Bad battery indication light (Red)
7.
Reverse polarity indication light (Red
8.
Boost indication light (White)
9.
New battery indication light (Yellow)
10. Use battery indication light (Blue 11. Charged indication light (Green) 12. -ve terminal (Black) 13. +ve terminal (Red)
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VRLA Battery Charger & its Charging SOP Battery Charging Procedure for Metafab make VRLA Battery Charger
Charging SOP
Refer Charger Photo
Remove battery from vehicle and Clean battery thoroughly.
-
Connect battery charger to 230 V AC single phase power supply and switch on the button of main supply.
-
"Connect battery charger leads to battery terminals. Red lead to +ve terminal and Black lead to-ve terminal."
13
12
Switch on the battery charger main switch. Green LED will glow.
4
If Red LED glows it indicates reverse polarity connection.
7
"Select charging current 2 Amps or 4 Amps.
3
(2 Amps for 3 Ah / 4 Ah / 5 Ah VRLA batteries, 4 Amps for 6 Ah / 8 Ah / 10 Ah VRLA batteries)."
Select and press the charging switch for new battery or use battery (Green and Blue LED glow for new and use battery)
2
If Red LED blinks it indicates open circuit situation.
5
Battery charger detects the battery voltage. If it is less than 5 volts it will switch over to Boost charging mode White LED below the “Boost” will glow
8
"Battery charger detects battery voltage after every 3 minutes. If voltage increases above 5 volts it switches over to selected charging mode ie NEW/ USED."
10
9
Charging duration in this mode is 30 minutes. If the battery voltage is less than 5 volts after 30 minutes a Red LED indicating a bad battery will glow. This indicates the battery is not suitable for charging.
6
After completion of battery charging a Green LED will glow to indicate completion of charging.
11
"If battery charger is switches to NEW/USED charging mode, the battery would undergo charging for 5 to 14 hours depending on battery condition."
10
4
-
Switch off the main switch and disconnect the battery from the charger
-
Reconnect the battery terminals on vehicle.
-
Apply petroleum jelly to battery terminals.
-
Note: During charging if the battery is disconnected, an audio indicator will beep for 2 minutes with a Red LED blinking to indicate open circuit situation. Bajaj Pulsar 200NS FI Training Notes
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Electrical
Checking Procedure Front & Rear Brake Light Switch Measuring & Testing Equipment : Multimeter
Brown
Blue
Continuity check by multimeter
Lever Pressed
Continuity is shown
Lever Released
No continuity
uu SOP : Turn ‘ON’ the ignition switch. The brake light should glow brightly when the front brake lever / rear brake pedal is pressed. If it does not, check the front brake switch. Wire connection Meter +ve
Meter -ve
Input voltage (Side stand position-any)
N.A.
Red/
Yellow/ Black
5 VDC
Output voltage (Side stand position-OFF)
Magnet in front of side stand switch
Pink
Yellow/ Black
2~2.2 VDC
Side stand position-ON
Magnet away from side stand switch
Pink
Yellow/ Black
5.0 VDC
Connect multimeter as shown in table given below.
Y/B
R/L
2
Set multimeter to 20 VDC.
Pi
4
Switch ON ignition switch and kill switch.
2
uu SOP :
3
Blue
Std. Reading
4
1
2
Magnet Position
1
Parameter
3
Measuring & Testing Equipment : Multimeter
Sr. No.
1
Side Stand Switch
Pi
Y
R
Pi
Y
R
SIDE_STAND_SWITCH
Clutch Switch Meter Range
OFF – Clutch lever not pressed ON – Clutch lever pressed
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Yellow / Green
Black / Yellow
Checking Procedure Ignition Switch
Measuring & Testing Equipment : Multimeter
Meter Range
Continuity Mode
Wire Connections
Continuity Check
Meter +ve Meter –ve
OFF – No Continuity
Brown
White wire
ON – Continuity
uu SOP : Switch OFF Ignition key. Disconnect Ignition switch’s coupler. Check continuity between wires in ‘ON’ and ‘OFF’ position. uu Standard Value : Beep Sound and Continuity in ‘ON’ position. No continuity in ‘OFF’ position..
Engine Kill Switch
Measuring & Testing Equipment : Multimeter
Meter Range
Wire Connections
Meter Continuity +ve Mode Gray / Red
Meter –ve
Condition
Result
Engine OFF condition
Continuity is shown
Brown / Engine ON No Blue condition Continuity
uu SOP : Put ignition switch OFF. Put kill switch OFF. Set multimeter at continuity range. Connect multimeter as shown in the table given below.
Light Control Module (LCM)
Sr. No. Parameter
Wire Connections Meter +ve
Meter –ve
Std. Reading
1
Violet
Yellow/ Black
00 VDC
Red/ Engine is running - H/L Black switch ON.
Yellow/ Black
13.5 VDC
Measuring & Testing Equipment : Multimeter
2
Engine is OFF (Pass light OFF)
This unit is a combination of head light controller and flasher unit. It switches on the head light only when engine is running. Bajaj Pulsar 200NS FI Training Notes
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Electrical
Checking Procedure uu SOP : Switch ON ignition switch and kill switch.
2
1
V
W
V
W
B/Y
PIN1
PIN2
L/W O
PIN3
PIN4
Br
1
Set multimeter to 20 VDC. Connect multimeter as shown in table given below.
Br
V
2
Light Control Module (LCM)
LIGHT_CONTROL_MODULE
DC Charging Voltage Measurement
Measuring & Testing Equipment : Multimeter & Battery Load Tester Meter Range
Wire Connections Meter +ve Meter –ve
20 V DC Battery +ve terminal
Battery +ve terminal
Specified at 4500 RPM 14.5 V + 0.2 V DC
uu SOP : SOP : Put Ignition switch ON. Put Kill switch ON. Set multimeter at 20 VDC. Connect multimeter as shown. Start engine and run at 4500 RPM. Note : 1. Before conducting this test ensure battery voltage is 13.1 ± 0.1 Volts (Fully charged battery) 2. For DC voltage measurement connect multimeter in parallel with circuit.
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Checking Procedure Stator Plate (Battery Charging Coil) Measuring & Testing Equipment : Multimeter
This is 3 phase starter winding (oil dipped type) Sr.No.
Y2 Y1
Y3
Meter Range
Wire Connections Meter +ve
Meter –ve
Y2
Y2
1
200 Ohm Y1
3
Y3
2
uu SOP : Disconnect magneto coupler.
Y3
Std. esistance Value
1 Ohm
Y1
B/Y W/R
Set multimeter at 200 Ohm range. Connect multimeter as shown and note reading.
Y
Y
Y
Starter Motor Current Drawn
Measuring & Testing Equipment : Clamp Meter Meter Range 200 DC A
Conditions
Standard Value
Encircle clamp meter transformer jaws around thick Red wire of starter motor
40~45 Ampere (Spark plug caps removed)
uu SOP : Disconnect all 3 spark plug caps Switch ‘ON’ Ignition switch and kill switch. Select range and set clamp meter zero reading. Encircle red input wire of starter motor into the clamp meter jaws. Crank the engine for 3 seconds . Observe the cranking current displayed on clamp meter.
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Electrical
Checking Procedure Starter Motor Armature Inspection (For Each Segment Checking)
Measuring & Testing Equipment : Multimeter & Battery Load Tester
Meter Range
Continuity Mod
Wire Connections
Continuity Check
Meter +ve
Meter –ve No continuity to be shown Commutator Shaft segment
uu SOP : Dismantle starter motor and take out the Armature. Check the continuity between starter motor shaft and each segment on Commutator. Replace armature if continuity is shown. Measuring & Testing Equipment : Multimeter Meter Range
Wire Connections
Continuity Meter +ve Mode Any Commutator on segment
Meter –ve
Continuity Check
Adjacent segment on Commutator
Continuity is shown
uu SOP : Dismantle starter motor and take out armature Check continuity between each pair of adjacent segments on Commutator. Replace armature if ‘No’ continuity is shown between any two adjacent pair of Commutator segments.
Steeper Motor
Measuring & Testing Equipment : Multimeter P1
P2
P3
P4
Sr. No.
Wire Connections
1
Meter +ve
Meter -ve
Pin no. 1
Pin no. 4
51 Ω
Pin no. 2
Pin no. 3
51 Ω
2
Standard Value
uu SOP : Ensure ignition switch and kill switch is OFF. Remove harness side coupler. Set multimeter on 200 Ohm range and connect as shown in above table.
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Checking Procedure
2
Gr/W G/R
3
G/Y L/B
4
Measuring & Testing Equipment : Multimeter
uu SOP : Ensure ignition switch and kill switch is OFF. Remove harness side coupler. Set multimeter on 200 Ohm range and connect as shown.
1
Steeper Motor
STEEPER_MOTOR
Crank Angle Sensor & Neutral Switch Measuring & Testing Equipment : Multimeter
Sr. Component No.
1 2
Meter range
Wire Connections
Crank angle Resistance sensor 2 K Ohms Neutral switch
uu SOP : Switch OFF ignition switch and kill switch. Connect multimeter as shown.
Continuity
Meter +ve
White/ Red Light Green
Meter -ve
Black/ Yellow Black/
Yellow
Standard Value
Results
365 + 20 Ohms
OK
Beep sound
OK
No Beep sound
Defective
B/Y W/R
Y
Y
Y
Starter Relay Coil
Measuring & Testing Equipment : Multimeter Meter Range 200 Ohms
Wire Connections Meter +ve
Meter Range
Meter -ve
Starter relay Starter coil Redrelay coil Yellow wire Black wire
3.51 ~ 4.29 Ohms
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Electrical
Checking Procedure Starter Relay Coil
R
2
1 1
B/Y
2
uu SOP : Switch OFF engine. Disconnect coupler from Relay. Connect multimeter to Starter Relay coil terminals. Check resistance.
R/Y
R/Y
B
R/Y
B
1
1
R
STARTER RELAY
Relay Coil
Measuring & Testing Equipment : Multimeter
Meter Range
200 Ohms
Wire Connections Meter +ve
Meter -ve
Relay coil terminal 1
Relay coil terminal 2
Continuity Check
89 ~110 Ohms
uu SOP : Switch OFF engine. Remove relay from coupler. Connect multimeter to relay coil terminals. Check resistance.
Fuel Pump
Measuring & Testing Equipment : Multimeter
Meter Range
200 Ohms
Note: 1. Battery should be fully charged. 2. Fuse and ignition switch should be OK. 3. Audible sound will be heard which will confirm fuel pump is working. 4. Check main relay first if fuel pump is not working.
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B/Y O/L
1 2
Wire Connections Meter +ve
Meter -ve
Orange/ Blue
Black/ Yellow
1 2
B/Y
B/Y
O/L
O/L
Continuity Check 2.1 Ohms
Checking Procedure Injector
Measuring & Testing Equipment : Multimeter Sr. No. 1
Parameter
Meter Range
Resistance
200 Ohms
Wire Connections Meter +ve Meter -ve Pin no. 1
Pin no. 2
Standard Reading 12 + 6 Ohms @ 20⁰C
FUEL_INJECTOR uu SOP : Remove petrol tank cover and petrol tank. Remove air filter cover along with paper filter element. Disconnect the injector coupler. Connect multimeter to Pin 1 and Pin 2 of injector as shown.
FUEL
1
2
INJECTOR
B/W
Br/W
Fuel Gauge – Tank Unit
Measuring & Testing Equipment : Multimeter Meter Range
200 Ohms
Standard Valve:
Wire Connections Meter +ve
Meter -ve
White/ Yellow
Black/ Yellow
Resistance Bars on (+ 2 Ohms) Speedometer
Continuity Check
As per chart
Resistance (+ 2 Ohms)
Bars on Speedometer
12
8
83
2
32
7
93
1
42
6
110
0
52
5
63
4
73
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Electrical
Checking Procedure Fuel Gauge – Tank Unit
Note:
If display in speedo console is not proper then please check following 1. Battery Voltage
Y/B G/R
1
1
2
2
B/Y
B/Y
W/Y
W/Y
2. Speedometer coupler and fuel gauge tank unit coupler connection is firm.
Capacitor
Measuring & Testing Equipment : Nil
uu Checking method : Touch +ve wire of capacitor to earth. Spark will occur. This indicates capacitor is OK. Note: Capacitor is very important for ECU functioning, so ensure capacitor coupler is always firmly connected.
Engine Oil Pressure Sensor
Measuring & Testing Equipment : Multimeter Meter Range
Wire Connections
Continuity Mode
Meter -ve
Brown-Blue
Black/ Yellow
Br/Pi
1
uu SOP : If engine oil pressure is OK (i.e if 0.9 to 1.1 bar pressure is shown on pressure gauge) then continuity will be shown on multimeter.
Meter +ve
Note: Oil pressure icon will blink if engine RPM greater than 3500 rpm, Coolant temperature in the range of 50 0C to 60 0C and oil pressure less than 0.9 bar for time greater than 20 seconds are meet.
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OIL_PREESURE_SENSOR
Continuity Check
Continuity will be shown
Checking Procedure Roll Over Sensor
Measuring & Testing Equipment : Multimeter Sr. No.
Parameter
1
Input voltage
2
uu SOP : Switch ON ignition switch and kill switch. Set multimeter to 20 VDC. Connect multimeter as shown.
Output voltage
Br/G Y/B R/L
Vehicle position
Wire Connections
NA
Red/Blue Yellow/ 5 VDC Black
Normal position
Tilled position (> 60⁰)
Meter +ve
Meter -ve
Brown/ Green
Yellow/ 4.8~4.9 Black VDC
Brown/ Green
Yellow/ 2~2.2 VDC Black
Br/G
Br/G
B/Y
B/Y
1
1
2
2
3
3 Gr
4
4
Standard Reading
ROLL_OVER_
Gr
Coolant Temperature Sensor
Measuring & Testing Equipment : Multimeter
Meter Range
Wire Connections Meter +ve
2K Ohms
Coupler Pin 1
Standard Reading Meter -ve
Coupler Pin 2
Temperature in Degree Centigrade
Resistance in Ohms
50
0.80 K Ohms
25
2 K Ohms
70
0.42 K Ohms
100 120 150
0.18 K Ohms
0.110 K Ohms 57 Ohms
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Electrical
Checking Procedure Pi/L
B/W
1
uu SOP : Ensure engine is off. Remove coupler of coolant temperature sensor using 18 mm tube spanner. Connect multimeter as shown and check resistance value.
2
Coolant Temperature Sensor
ENGINE_TEMP_SENSOR
Oxygen (Lambda) Sensor
Pin no. 2
2
Pin no. 3
Pin no. 4
uu SOP : Ensure ignition switch is OFF. Remove the harness side lambda sensor coupler. Set multimeter on 200 Ohm range and connect as per table.
9 + 1 Ohm @ 25⁰C Meter displays 1 @ 25⁰C (open circuit)
W
W
Gr
B
W
W
Gr
B
4
Pin no. 1
3
1
Continuity will be shown
4
Meter -ve
3
Meter +ve
2
Continuity Mode
Continuity Check
1
Wire Connections
2
Sr. No.
1
Measuring & Testing Equipment : Multimeter
Br/W L/R
B/G
L/Y
T MAP Sensor
Measuring & Testing Equipment : Multimeter
Sr. No.
Parameter
1 2 3
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Meter Range
Wire Connections
Resistance
20 K Ohms
Pin no. 1
Input voltage
20 VDC
Red/Blue
20 VDC
White/ Red
Output voltage
Meter +ve Meter -ve
Standard Reading
Pin no. 2 + 0.5 K 2 Ohms @ 25⁰C
Yellow/ 5 VDC Black
Yellow/ 3.8 + 0.65 Black VDC
Checking Procedure T MAP Sensor
G
R/L W/O
P4 P3
Input Voltage Checking
P2 P1
1 2
U
uu SOP : Remove petrol tank and air filter cover along with paper filter element. Connect multimeter as shown in table.
Y/B
TMAP_SENSOR
P
Measuring & Testing Equipment : Multimeter
3 4
Note: For resistance checking remove coupler of TMAP sensor and connect the multimeter prob to Pin 1 and Pin 2 as shown.
Output Voltage Checking Note: For input or output voltage checking connect coupler of TMAP sensor.
Spark Plug Cap
uu SOP : Remove spark plug cap from HT coil cable. Set multimeter on 2 K Ohms range. Connect multimeter probes as shown and measure the value. Standard value, 1 K Ohm ± 150 Ohm.
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Electrical
Checking Procedure CAN Termination Unit
This unit is provided to have uninterrupted communication between diagnostic tool and ECU Note : 1. No checking method using multimeter is recommended for checking this unit 2. Checking by replacement method only.
Termination Unit
Function: It has transil diode for filtration of voltage surge / ripple in mains supply line there by protect ECU from voltage fluctuations. It also consist two diodes that are used for clutch switch and neutral switch circuit. These diodes are called reverse protection diodes. Reverse protection diodes provide correct neutral indication in speedo console. Symptoms of malfunctioning : Glowing of neutral indication in speedo console when vehicle is in gear and on pressing of clutch lever. Note : 1. No checking method using multimeter is recommended for checking this unit 2. Checking by replacement method only.
Radiator Fan Motor
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uu SOP : Disconnect coupler of fan motor. Connect external 12 V DC supply to disconnected coupler of fan motor. Now the fan motor will start running. Observe the fan running smoothly.
Checking Procedure TPS
Measuring & Testing Equipment : Multimeter
G/Y R/B B/G
1 2 3
Sr. Parameter No.
Wire Connections Meter +ve
Meter -ve
1
Input voltage
Red/Black
Black/ Green
Output voltage wide open throttle
Red/Black
2 3
3
Output Red/Black voltage idle throttle
Coil Pin 2 Resistance
Standard Reading 3.3 VDC
Black/ Green
0.5 VDC
Black/ Green
4.35 VDC
Pin 3
1.6 ~ 2.4 Ohms
uu SOP : Remove petrol tank cover and petrol tank. Remove air filter cover along with paper filter element. Connect multimeter as shown in table given below. Input Voltage Checking
Central H. T. Coil
Measuring & Testing Equipment : Multimeter
Primary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
200 Ohms Orange/ White Pin-1
Meter -ve Black Pin-2
Standard Value 0.513 ~ 0.627 Ohms
Secondary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
Meter -ve
20 K Ohms
HT output
Pin of Orange / White
Standard Value 4.23 ~ 5.17 K Ohms
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Electrical
Checking Procedure Twin H. T. Coil
Measuring & Testing Equipment : Multimeter
Primary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
200 Ohms Black / Red
Meter -ve Pin of Orange / White
Standard Value 0.63 ~ 0.77 Ohms
Secondary Winding Resistance Checking Meter Range 20 K Ohms
Wire Connections Meter +ve
Meter -ve
HT output
HT output
Standard Value
Remark
11.0 ~ 16.2 K Ohms
To be measure between to H.T. outputs
Horn
Measuring & Testing Equipment : DC Clamp Meter
Meter Range 200 DC A
Wire Connections
Encircle clamp meter jaws around Brown wire of horn
Standard Value 2.2 Amps
uu SOP : Encircle clamp meter jaws around Brown wire of Horn. Press horn switch and check the current drawn by horn.
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Battery Replacement Insert Key and open the lock uu Remove
uu Remove 2 Bolts Rider seat
Pillion seat
uu Remove 2 Bolts 2 Collared bush
Slide away ECU from battery bracket
uu Remove Battery terminal caps Battery +ve and then -ve terminal Lift out battery
uu Remove Battery
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Electrical
Roll Over Sensor SOP Note : Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Roll over sensor removal. uu Remove Disconnect the coupler 2 Bolts
H. T. Coil (RH Side) SOP Note : Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Roll over sensor removal.
uu Remove 2 Bolts Earthing connection
uu Remove Disconnect cables from routine bracket
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uu Remove Disconnect coupler
uu Remove Plug cap LH and RH Take out HT coil
Head Lamp Removal SOP uu Remove 2 LH allen Bolts
uu Remove Pull out the head light assly
2 RH allen Bolts
uu Remove Rubber cap
uu Remove Wire clip lock
uu Remove Head light holder
uu Remove Head light lamp
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Electrical
Do’s & Don’ts Battery Dos
Don’ts uu DO Apply petroleum jelly to terminal post
uu DON’T Apply Grease to terminal post
uu DON’T Short circuit the terminal post
uu DO – Use proper equipment for testing
uu DO – Use correct tools
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uu DON’T – Use wrong tools
Do’s & Don’ts Horn
Dos uu Adjust horn sound by rotating the Phillips screw in the direction of arrow provided on horn.
Don’ts uu Never adjust the nut on horn cap side and bracket end (horn back side) as it will result in horn malfunctioning and failure. uu Do not remove silicon sealant from adjustment screw as it will result in water entry inside the horn.
Switches
Dos uu After washing the vehicle ensure to apply dry air on switches before operation. uu Ensure that grommets provided on clutch switch, front brake switch and rear brake switch are intact.
Don’ts uu Do not apply direct pressurized water jet on control switches. uu Do not lubricate electrical switches by oil or grease. uu Do not over tighten the switch mounting screw.
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Diagram BATTERY CHARGING CIRCUIT
BRAKE LIGHT CIRCUIT
EMS Part -1
EMS Part-2
FUEL GAUGE CIRCUIT
HORN CIRCUIT
OIL PRESSURE SWITCH CIRCUIT
RADIATOR FAN MOTOR CIRCUIT
SIDE INDICATOR CIRCUIT
SIDE STAND INDICATOR CIRCUIT
TACHOMETER CIRCUIT
VEHICLE SPEED SENSOR CIRCUIT
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Electrical
Bajaj Auto International Business
Bajaj Auto Limited Akurdi Pune 411 035 India Tel | +91 20 27472851 Fax | +91 20 27407385 www.bajajauto.com CIN number : CIN L65993PN2007PLC130076
The Training Notes are a comprehensive training guide on service and maintenance operations and procedures to be followed by service personnel at authorised service centres and dealerships whilst attending to the Bajaj Pulsar 200NS FI. The Training Note covers standard workshop procedures, simplified for easy learning and understanding for service technicians worldwide.
NOTICE
Copyright
All information contained in this Training Note is based on the latest product information at the time of publication. Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice. The right is reserved to make such changes at any time without prior notice.
All Intellectual Property Rights, including but not limited to Copyright, applying to this drawing and the information contained therein vest solely and exclusively with Bajaj Auto Limited. No part of this drawing may be copied or reproduced, either in part or in full by any means, whether mechanical or electronic, without prior written permission of the authorized signatory of Bajaj Auto Limited. Bajaj reserves all rights to deal with violations of this clause in accordance with applicable laws.
DOC. NO.: REV. 00, OCT 2014
© Bajaj Auto Limited, 11th SEPT 2012.
Contents CHAPTER
1
Workshop Safety and Procedures
CHAPTER
2
The Tool Chest – Know Your Tools Special Tools (Engine & Frame) Standard Tools Other Gadgets
CHAPTER
3
Understanding the Bajaj Pulsar 200NS FI Identity Distinguishing Features Salient Features Technical Features & Specs Read Before Your Ride
CHAPTER
4
Preliminary Checks & Maintenance Operations PDI Checklist Perodic Maintenance Chart Lubrication Matrix Periodic Service SOP
CHAPTER
5
Fuel System & EMS DTSi – Fi Engine Management Systems / EMS Layout Working of Systems Fuel Injection Dos and Don’ts
Contents CHAPTER
6
Engine & Transmission Important Points to Remember During Engine Overhaul Dismantling the Engine Dismantling the Engine Sub Assembly Service Data Tightening Torque
CHAPTER
7
Frame & Suspension Service Limits Tightening Torque Dismantling & Assembling Front Fork Front Disc Brake
CHAPTER
8
Electricals VRLA Battery Initial Filling VRLA Battery Charger & its Charging SOP Dos and Don’ts for RLA Battery Electrical Checking Procedure Electrical Circuit Diagrams
Key Learning Points Understanding workshop discipline and safety guidelines Testing guidelines Precautions whilst handling tools and equipment
CHAPTER 1
Workshop Safety & Procedures
Bajaj Pulsar 200NS FI Training Notes
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1
Workshop Safety and Procedures
Workshop Safety uu Technicians must always be wearing shoes and dressed in clothing that is not too loose. uu Always use protective Equipment (PPE) like - Hand Gloves Mask Safety Goggle Ear Plugs
uu Wear Nitrite Rubber Hand Gloves while handling petrochemicals like petrol, oil, kerosene etc.
uu Fire Extinguisher Install ‘ISI’ approved. Fire extinguishers - CO2 gas cylinders. Refill CO2 before the gas expires.
Install Co2 gas cylinder at appropriate place so that there is no obstruction / good accessibility.
uu Safety Precautions whilst Operating Air Tools
Air pressure tools operate on compressed air supplied by the shop Compressor and Air supply system.
Observe the following safety related precautions when using an air tool. It is advised to fit a pressure regulator (FRL:- Filter Regulator Lubricator) in the pneumatic line which supplies air pressure to the air tool. It regulates the outlet pressure to 6.5 Kg/cm2. This avoids the risk of personal injury.
Warning
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Bajaj Auto International Business
Never use the blow gun to blow dust off your clothes and never point it at another person. The air pressure also thrusts dust particles at high velocity. These particles can penetrate into the flesh or eyes. If high pressure air hits on open wound, it can force air into the blood stream which at times can even result in instant death due to cardiac arrest.
Workshop Safety uu Hand Tools Do not use worn out hand tools. uu Calibration of Workshop Equipment Calibrate all Workshop and M and T Equipment once in a year. uu Avoid direct body contact with Petrol, Kerosene.
Caution
Prolonged contact of used oil can cause cancer.
uu Waste Oil Disposal Sell used oil only to Government approved re-cycle agencies. Collect used oil in oil disposer / barrel. Don’t throw oil into the sewage line. Don’t spill oil on the floor.
uu Precautions to be taken while handling Hydro-Electric Lift Whilst raising / lowering ensure the vehicle is firmly mounted After raising the lifter bay, lock the lift. Don’t put leg/hand in between while raising / lowering uu Safety Tips Do not lower the lifter bay table without unlocking the lift lock. Do not work with loose clothing whilst working on the lifter bay. Do not keep hydraulic joints loose. Do not stand on the lifter bay when in operation. Keep fire away from the power pack. Avoid oil spillage around the working area. uu Battery Acid Handling Use hand gloves, wear apron and safety glasses Avoid contact of battery acid with skin Use plastic trays to keep charging batteries and avoid battery acid spillage uu Brake Fluid Handling Store brake fluid in sealed container and avoid spillage. Avoid contact of brake fluid with skin. uu Electrical Wiring Ensure that the points and switches are easily accessible and conduct periodic checks and repairs. Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Key Learning Points Understanding workshop tools, applications and appropriate usage practices Usage of customized tools developed by BAL for Pulsar 200NS Fi
CHAPTER 2
Customized Bajaj Auto Tools / Special Tools, Equipment & Gadgets Special Tools (Engine & Frame) Standard Tools Other Gadgets
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Camshaft Big end bearing & Balancer bearing puller Part No.
: 37 1042 57
Application : For removing balancer and big bearing of cam shaft
uu Crank Shaft remover Part No.
: 37 1042 52
Application : Tool for splitting the crankcase
uu Spark Plug Spanner 3 in one Part No.
: 37 1042 55
Application : For removing LHS / RHS and Central spark plug from cylinder head when engine is mounted on vehicle
uu Primary gear holder+Balancer Drive / Driven gear holder Part No.
: 37 0041 59
Application : Special tool for holding Balancer drive and driven gears during tightening / loosening the nut Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Balancer lock nut tightening/ removing tool Part No.
: 37 0041 60
Application : Special tool for Balancer drive gear lock nut (tightening / loosening)
uu Output shaft oil seal fitment tool Part No.
: 37 1041 56
Application : For pressing oil seal on the output shaft
uu Balancer + Radiator pump oil seal fitment tool Part No.
: 37 0042 56
Application : For fitting 2 nos back to back oil seals for balancer and Radiator pump
uu Cam Sprocket Holder Part No.
: 37 1042 54
Application : For holding cam sprocket during removal and re-fitting of cam sprocket bolt.
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Magneto Rotor Puller Part No.
: 37 0041 55
Application : For pulling out magneto rotor from crank shaft
uu Rocker Shaft remover Part No.
: 37 10DH 35
Application : For removing rocker arm shaft
uu Drift Piston Pin Part No.
: 37 10DS 27
Application : For removing piston pin.
uu Clutch special nut remover Part No.
: 37 10DJ 43
Application : To remove and fit clutch nut. Rocker Shaft remover
Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Clutch Dismantling Tool Part No.
: T 10111 68
Application : For dismantling and assembly of clutch assembly.
uu Camshaft Small Bearing Puller Part No.
: 37 10DH 31
Application : For removing small bearing of cam shaft
uu Bearing Driver Set Part No.
: 37 1030 61
Application : For removing bearings from crank case.
uu Magneto Rotor Holder Part No.
: H6 0721 00
Application : For holding rotor assembly while loosening bolt.
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tool Application: for Engine Repairs uu Tappet Setting Tool Part No.
: F4 1ZJW 33 / 37 1031 53
Application : For adjusting valve tappet clearance.
uu Valve Spring Compressor Part No.
: 37 1031 07
Application : For compressing valve springs for easy removal of intake and exhaust valves.
uu Adaptor for Valve Spring Compressor Part No.
: 37 1031 08
Application : For compressing valve springs for easy removal of intake and exhaust valves.
uu Output Sprocket Holder Part No.
: 37 1030 53
Application : To hold out put sprocket while removing sprocket bolt.
Bajaj Pulsar 200NS FI Training Notes
13
2
The Tool Chest - Know Your Tools
Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tools Application: for Frame Repairs uu Fork oil seal fitment punch Part No.
: 37 1740 03
Application : To remove antifriction and oil seal bush from front fork outer pipe.
uu Fork cylinder holder handle with adaptor Part No.
: 37 1740 05
Application : For holding cylinder piston
uu Installer Upper & Lower Bearing Race Frame Part No.
: 37 1801 06
Application : To install upper and lower steering races / cones into their seats inside frame.
Notes
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Customized Bajaj Auto Tools Special Tools, Equipment and Gadgets Special Tools Application: for Frame Repairs uu Swing arm needle roller bearing extractor & fitment tool Part No.
: 74 9309 93
Application : For removal and fitting of needle roller bearing in swing arm
uu Steering Nut tightening tool Part No.
: 37 1801 01
Application : For tightening / loosening of steering nut
uu Rear Mono Suspension Adjuster Part No.
: 37 0041 70
Application : For adjustment of mono rear suspension setting
uu Stem Bearing Driver Part No.
: 37 1830 05
Application : To fit bearing race on fork under holder bracket
Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Standard Tools Equipment: External and Internal Circlip Pliers Specs / Range:
Equipment: Star Bit Set Specs / Range: Standard size
Qty Required:
Qty Required: One set
Equipment: Combination Plier
Equipment: Component Handling Crate
Specs / Range: Qty Required:
Specs / Range: Plastic with partition CH64120 (2x2) Qty Required: One for each bay
Equipment: Cleaning Brush Specs / Range: 2 and 3 Inch Qty Required: One
Equipment: CVC Products: Battery coat, Viscolube, Carburetor cleaner, Multilube, Galvanizing spray Etc. Specs / Range: Aerosols Qty Required: As per Load
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Equipment: Electrician Screw driver
Equipment: 5 Pcs Phillips Screw Driver Sets
Specs / Range: 3 mm Flat
Specs / Range: 861, 862 L, 863
Qty Required: One for each bay
Qty Required: One set for each bay
Equipment: Allen Key set
Equipment: 5 Pcs Screw Driver Sets
Specs / Range: Set
Specs / Range: 827, 929, 912, 923, 825
Qty Required: One set
Qty Required: One set for each bay
Standard Tools Equipment: Tyre pressure gauge
Item: Tool Trolleys
Specs / Range: Dial Type / Pen Type
Specs: Regular with 4 Trays
Qty Required: One
Equipment: T-Handle Box Wrench Spes / Range: 8 mm, 10 mm, 11 mm, 12 mm
Qty: Each Per Bay
Equipment: Spark Plug Cleaner Specs: 2 Gas
Qty Required: One set for each bay
Qty Required: One
Equipment: Open End Spanner
Equipment: Work Table with Special Tool Display board
Spes / Range: 6 x 7 mm; 8 x 9 mm; 10 x 12 mm; 12 x 14 mm; 14 x 17 mm; 17 x 19 mm; 24 x 27 mm; 24 x 27 mm
Specs:
Qty Required: One
Qty Required: One set for each bay Equipment: Ring Spanner Specs / Range: 6 x 7 mm; 8 x 9 mm; 10 x12 mm; 12 x 14 mm; 14 x 17 mm; 17 x 19 mm; 24 x 27 mm; 24 x 27 mm
Equipment: Electric Plier, Cutters and Connectors Specs / Range: Multi Tech / Others Qty Required: One for each bay
Qty Required: One set for each bay Equipment: Long Nose Plier Specs / Range: Standard size Qty Required: One for each bay
Equipment : Socket set with Reversible Ratchet
Specs / Range : ½” SQ. DR. 8, 10, 12, 14, 17, 19,24 mm, Sockets; 3/8” Long Sockets 8,10 mm; ½” Extension 5” Long. ½” DR. Quick Release Ratchet; ½” DR. T Handle; ½” X 3/8” Adapter 3/8” X ½” Adapter with Tools Box Qty Required : One Set
Bajaj Pulsar 200NS FI Training Notes
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2
The Tool Chest - Know Your Tools
Other Gadgets New D&F Tool Part No. : Application : For checking diagnostic and troubleshooting codes of EMS.
Old D&F Tool Part No.
:
Application : For checking diagnostic and troubleshooting codes of EMS.
Multimeter Special Prob Part No.
:
Application : To establish the contact between multimeter and the inspecting electrical component.
Pressure Gauge for Engine Oil Part No.
:
Application : To measure the engine oil pressure in the lubrication system.
Pressure Gauge for Fuel Part No.
:
Application : To measure the fuel pressure in the fuel line.
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Other Gadgets VRLA Battery Charger Part No.
: 37004162
Application : To charge the new and used VRLA battery.
Battery Load Tester Part No.
: 37204020
Application : To inspect the battery charge holding ability of the new and used VRLA battery.
Pig Tail for Fuel Delivery Measurement Part No.
:
Application : To establish the electrical contact between battery and fuel pump through a operating ON/OFF switch.
Tuskun Screw Driver Part No.
:
Application : To remove and fit the tuskun screws for TMAP and TPS.
Notes
Bajaj Pulsar 200NS FI Training Notes
19
1
Workshop Safety and Procedures
Key Learning Points Understanding the Complete Anatomy of the Vehicle Technical Specifications and Performance Parameters Briefing and Educating the Customer on Appropriate Riding and Usage Discipline, and Routine Maintenance
CHAPTER 3
Understanding the Bike Identity Distinguishing Features Salient Features Technical Features & Specs Read Before Your Ride
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Identity
CE JL Z
D91
543
The Engine Number, unique to each vehicle is engraved into the engine body, located below the sprocket cover.
The Frame Number, which is also unique to each vehicle, is engraved into the frame. This is located on the right hand side of the frame between the fork mountings.
Location of Parts 1 RH Control Switch
9 Cover Mud Rear
2 LH Control Switch
10 Assembly Chain Cover
3 Speedo Console
11 Nitrox Mono Suspension
4 Expansion Tank
12 Tail Lamp
5 Front & Rear Disc Brake
13 Grab Rail
6 DTSi 4-Valve Engine
14 Perimeter Frame
7 Clutch Cover
15 Exhaust TEC
2
1
8 Underbelly Exhaust with exhausTEC
3
13
14
12
10 11 9
4
6 5 8
7
5
15
Bajaj Pulsar 200NS FI Training Notes
21
3
Understanding the Bike
Distinguishing Features Triple Spark Technology uu Triple Spark: Provides faster and more optimal combustion thereby increasing combustion performance and efficiency. Combustion is 27% faster than twin spark and 50% faster than a single spark engine. uu 4-valve Engine: 2 intake and 2 exhaust valves enables better breathing for the engine thus enhancing torque and power at all engine speeds. Enables engine to rev to high RPM levels without getting choked, thereby producing more power.
Fuel Injection
The fuel injection system delivers optimum volume of fuel which along with Triple spark plugs helps promote high combustion efficiency as compared to a single or dual spark plug carburetor model, thus creating a powerful , fuel efficient and low emission engine.
6-Speed Gearbox
Perfectly matched 6-speed gearbox ensures optimum utilization of the torque and power characteristics of the 4-valve triple spark engine.
Liquid Cooling
Ensures control on engine temperature despite high engine output and sports performance, thus enhancing engine life, negating power fade due to overheating, lowering engine noise and reducing emissions.
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Distinguishing Features Perimeter Frame
The frame provides 3 times the lateral stiffness of the Pulsar 220 frame thereby giving the Pulsar 200NS very good high speed handling and precise cornering abilities.
Rear Nitrox Mono Shock
Monoshock for identical damping characteristics on either side of the bike. Nitrox enhances high speed absorption of ripples on road , aiding straight line stability.
Exhaus TEC
Improves engine torque at low rpm and is optimized to get maximum engine performance. Thus, no frequent gear change is needed.
Underbelly Exhaust:
Provides the bike with a better mass centralization allowing higher lean angles without grounding of muffler.
Bajaj Pulsar 200NS FI Training Notes
23
3
Understanding the Bike
Salient Features Performance Key Features uu Triple spark technology uu 4 Valve Engine uu Liquid cooling uu 6 speed gearbox
Advantages uu Superior Innovative technology engineered for optimum engine performance at any speed uu Enhanced power and performance uu Smooth engine run at any rpm uu Higher efficiency in both, mileage and emissions
Benefits uu Great performance across the entire rpm band and all gears giving the Pulsar 200NS a true sports bike character
Style
24
Key Features
Advantages
Benefits
uu Brawny masculine looks of a Naked Sports bike uu Muscular Perimeter frame uu Specially designed foot pegs and switches uu Stylish split seats uu 2-piece grab rail for better support uu Well styled head lamp uu Clip on type handle bars uu Sporty exposed drive chain uu New look alloy wheels uu Broad tyres and petal disc brakes uu Well concealed underbelly exhaust
uu Bold assertive stance and sporty riding position uu Aggressive and sporty looks
uu The Street Fighter look gives the Pulsar 200NS unmatched character on the road.
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Salient Features Comfort & Handling Key Features uu Perimeter frame with a special swing arm uu Underbelly exhaust uu Superior bike ergonomics and weight distribution uu Nitrox Mono Rear suspension uu Large 37 mm dia. front fork with single antifriction bush uu Broad front and rear tyres uu Clip on handle bar
Advantages uu Rigid chassis for excellent high speed handling uu Optimum centre of gravity for high stability uu Near perfect 50:50 front to rear ensures a very sporty ride uu Nitrox rear suspension enables a smoother ride over small undulations when at high speeds uu Large dia front forks ensures high rigidity for stable front braking and flicking around corners uu Broad tyres enhance the high speed handling characteristics uu Clip on type handlebars give a sporty feel to the riding posture
Benefits uu Optimized maneuverability for high speed cornering combined with flex-free front forks and broad tyres and a sporty riding position ensures a truly sporty ride.
Safety Key Features uu Front and Rear petal disc brakes uu Broad Tubeless tyres uu High strength chassis – Perimeter frame and swing arm uu Powerful DC head lamp
Advantages
Benefits
uu For sharp, precise fade free braking uu Reliability with a sporty grip. uu The tread pattern contributes to high Performance uu Superior structural strength uu High wattage DC head lamp provides Uniform strong beam spread at any rpm
uu Enhanced and reliable braking capability along with strong flicker free lights to match high performance capability of the bike
Bajaj Pulsar 200NS FI Training Notes
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3
Understanding the Bike
Technical Features & Specs Engine & Transmission uu Type
: 4 stroke, single cylinder water cooled,fuel injected
uu No. of Cylinder
: One
uu Bore
: 72.0 mm
uu Stroke
: 49.0 mm
uu Engine Displacement : 199.4 cc uu Compression Ratio
: 11:1
uu Idling Speed
: 1400 ± 50 rpm
uu Max.Net Power uu Max.net Torque
: 18 Kw @ 9750 rpm : 18.6 Nm @ 8000 rpm
uu Ignition System
: Inductive DC ignition
uu Ignition Timing
: Variable as per map in ECU
uu Fuel
: Unleaded petrol
uu Carburetor
: NA
uu Spark Plug
: 3 Plugs
uu Spark Plug gap
: 0.8 ~ 0.9 mm
uu Lubrication
: Wet sump, Forced lubrication
uu Starting
: Electric start
uu Clutch
: Mechanically actuated
uu Transmission
: 6 speed constant mesh
uu Primary reduction
: 3.272
Gear ratios uu 1st gear uu 2nd gear uu 3rd gear uu 4th gear uu 5th gear
: 26.49 : 19.32 : 14.54 : 11.58 : 9.77
uu 6th gear
: 8.57
uu Final drive ratio
: 40/14
EMS uu System
: 12V,DC
uu Ignition system
: Digitally controlled thru ECU
uu Fuel feed
: Port fuel injection
uu Malfunction indicator : LED lamp wattage
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Technical Features & Specs Frame
uu Frame Type uu Suspension Front Rear uu Brakes Front & Rear uu Brake Size Front Rear uu Tyres Front Rear uu Tyre Pressure Front Rear (Solo) Rear (with Pillion) uu Rims Front Rear uu Fuel Tank Capacity uu Usable Reserve uu Unusable Reserve
Dimensions
: Perimeter : 130 mm Fork travel, Telescopic, Single antifriction bush : 120 mm wheel travel, mono suspension with nitrox : Hydraulically operated disc type : 280 mm Disc brake : 230 mm Disc brake : : 100/80, 17, 52 P Tubeless : 130/70, 17, M/C 62P : 1.75 kg/cm² (25.0 PSI) : 2.00 kg/cm² (28.0 PSI) : 2.25 kg/cm² (32.0 PSI) : 2.5X17” 10 Spoke alloy wheel : 3.5X17” 10 Spoke alloy wheel : 12.0 liters : 2.4 liters : 0.2 liters
uu Length : uu Width : uu Height : uu Wheel base : uu Saddle height : uu Turning Circle Radius : uu Ground Clearance :
Performance
2017 mm 804 mm 1195 mm 1363 mm 807 mm 2500 mm (min) 167 mm
uu Maximum : 129 in sixth gear Speed, km/h (with single rider 68 Kg) uu Climbing ability : R & D
Electricals uu System uu Battery
uu Head Lamp uu Tail/Stop lamp uu Side Indicator lamp uu Position lamp uu Rear Number Plate lamp uu Speedometer back light uu Neutral indicator uu Turn signal indicator uu Hi-beam indicator uu Reserve indicator uu Horn uu Fuel gauge
: : : : :
12V,DC “12V 8Ah VRLA (Valve regulated lead acid)” 12V 55/60 W, (Halogen) LED type 12V 10W (4 nos. - Amber bulbs) : 12V 3 W (2 nos.) : 12V 3W : LCD back light : : : : : :
LED type LED type LED type LED type 12V DC, Type 2A (82 mm dia.) TFR Type
Weights
uu Vehicle kerb : 145.0 Kg weight, kg (Electric start) uu Gross vehicle : 275.0 Kg (Electric start) weight, kg
Controls
uu Steering uu Accelerator uu Gears uu Brakes Front Rear
: Handlebar : On handle bar, RH grip : Left foot pedal operated, 1 down 5 up, Step shift : On handle bar, RH lever : Pedal operated by RH foot
Notes :
Values given above are nominal and for guidance only, 15% variation is allowed to cater for production and measurement. All dimensions are under un-laden conditions. Definitions of terminologies wherever applicable are as per Relevant IS/ISO standards. Specifications are subject to change without notice.
Bajaj Pulsar 200NS FI Training Notes
27
3
Understanding the Bike
Test Yourself 1.
On what side of the steering tube is the chassis no located? a) L/H
b) R/H
The Chassis no consists of how many digits? a) 16 2.
d) 19
b) 18.0PS
c) 16.51 PS
d) 19.0 PS
c) 120 / 80 X 17, 49 P
d) 120 X 90 X 17, 51P
What is the rear tyre size of the Pulsar 200 NS Fi? a) 90 X 90 X 17, 49 P
4.
c) 17
What is the minimum net power of the Pulsar 200 NS Fi? a) 20.0 PS
3.
b) 11
b) 12 / 80 X 17, 61 P
On what side of the engine is the spark plug fitted? a) L/H
b) R/H
Of what type is the spark plug used in the Pulsar 200 NS Fi? a) RG4HCC
b) RG6HCC
c) RG4HC
d) RG4H
5.
Which of the components listed below do not form a part of the fuel injection system?
6.
What do you understand by EMS?
7.
In the console, what does the icon on the RH side of the high beam indicate? a) System Malfunction
8.
b) Side stand OUT
c) Hi Beam ON
Name the icons on the console. (Pl illustrate the icons) a) b) c) d) e)
9.
What is the Max Net Torque for Pulsar 200 NS Fi? a) 17.17 Nm @ 6500 rpm
b) 19.12 Nm @ 6500 rpm
c) 15.22 Nm @ 6000 rpm
10 During PDI it is recommended to check the fuel cock operation for hardness/leakage a) True
b) False
11. The fuel pump is located inside the petrol tank. a) True
b) False
12. The fuel gauge is located inside the speedo console a) True
b) False
13. The Pulsar 200 NS Fi has a port injection system a) True
b) True
14. The Pulsar 200 NS Fi has an oil cooled engine. a) True
b) True
15. What is the handle bar on the the Pulsar 200 NS Fi referred to as? a) Clip on handle bar
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b) Split type handle bar
c) Both are correct
Read Before You Ride Digital LCD Speedo Console
Soft Self Start
Function: Display information on key important factors and alarm indications.
Function Cranks engine just by feather touch.
Neutral position of gear. Side indicator pilot indication. Hi beam indicator Drop in battery voltage Drop in engine oil pressure Engine overheating & rise in engine temp.>115°C Malfunction indication of EMS Tachometer: A analogue display tachometer showing 0~12 x 1000 RPM display for understanding the engine RPM. Engine RPM Limiter: A amber colour LED bulb starts blinking when the engine RPM reaches to 9500 RPM cautioning the rider crossing safety zone (However engine RPM curtails above 10500).
How to Operate Switch ‘ON’ ignition and kill switch. Put vehicle into neutral or declutch if in gear. Press self start button. Do not open throttle (accelerator) while starting. Once engine starts do not rev up engine while vehicle is parked on the stand. Benefits Comfort Hassle free starting
Malfunction Indicator Function It gives indication signal about error in Engine Management System.
Fuel Gauge: A vertical 9 bar equally segmented graphical indicator indicates fuel level inside the fuel tank.
How to Operate This operates automatically as and when the error is generated.
Low Fuel Level Indicator: Icon will blink continuously when the fuel level drops below 3.5 liters thus reminding the rider for refueling.
Visual Signal Amber colour icon on LH side in indicator will pop-up, this is an indication that EMS has an error.
Side Stand:A indication display of stand ON will appear when stand is put ON.
Immediately take the vehicle to a BAL authorised Service Station.
Easy to read Digital Speedo Display showing Vehicle speed - Km/Hr. Odometer - Kms covered. Resetting trip meter - for recording distance covered in trip with resetting provision (TRIP 1 & TRIP 2). Digital clock - displays time in HR:MM (AM/PM). Service Reminder: A service reminder will pop-up reminding you that vehicle is due for next service. How to Operate Put ‘ON’ ignition key and kill switch. All 4 icons on top will pop-up and few will vanish away automatically. All other will show static display until the vehicle moves on road. Other displays are dynamic which functions individually for respective applications.
Mode Selection Switch Function
Trip meter, Digital clock and Service reminder setting Advantage Facility to change Time as per local time. Reset trip meter to calculate the distance covered in a trip. Note : Service reminder setting is to be done by Bajaj Authorised Service Centers / Dealers only.
Head Light always ON Feature DC head light will glow on start of vehicle automatically. Advantage Continuous DC head light on facility. Benefits Brighter illumination throughout the ride. Road safety.
Benefits Great safety. Arrest consequential damages arising
Side Stand Riding Protection Feature Protection against side stand riding. Advantage The EMS systems senses the side stand on signal and does not allow the engine to run with side stand in ON position. Benefits Rider’s safety.
Liquid Cooled Engine Feature Liquid cooled engine. Advantage Maintains lubricating oil viscosity even at high temp. and extreme stress for optimum performance Benefits Effective cooling and lubrication helps to deliver the higher engine performance under every possible load condition.
VRLA Battery Feature Zero maintenance battery. Advantage No top up required. Benefits Effective cooling & lubrication helps to deliver the higher engine performance under every possible load condition.
Bajaj Pulsar 200NS FI Training Notes
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3
Understanding the Bike
Read Before You Ride Gear Shifting Pattern
Fuel Saving Tips
Feature 1 down 5 up shift mechanism.
Benefits Safe to drive at all speed conditions
Avoid following −− Sudden pick-up and frequent braking. −− Needless and excessive idling. −− Excessive high speed riding. Check and Inflate tyre pressure once in a week. Fill petrol at reputed petrol pumps. Use only branded fuel. Inspect the coolant and engine oil level. Top-up to MAX level
Disc Brakes - Front & Rear
Monsoon Care
Feature Hydraulic disc brakes.
Benefits Ease in stopping the vehicle at desired spot. Safely controlling the vehicle speed.
Fit and Finish Parts It is suggested to take proper care in heavy monsoon / high rainfall area. The appropriate surface preventive coat is to be applied to avoid rusting / poor surface finish on account of adverse atmospheric conditions. Clean and lubricate all the important parts as detailed in a Periodic Chart given in Owner’s Manual.
Tubeless Tyres
Additional Care
Advantage Bike will never be left into neutral condition.
Advantage Most efficient and safe braking.
Advantage If punctured do not deflate suddenly and helps in reducing unsprung mass. Less rolling resistance ensures complete road stability. Benefits High stability and less maintenance
Engine Oil : Check every week Park the vehicle on level surface to check the oil level. Always maintain engine oil level between the upper and lower level. Replace the oil in accordance with P.M. Chart.
Recommended Oil Grade and Qty
Battery
Grade
How to Keep Battery Healthy Switch ‘OFF’ ignition when engine is not running. Do not ride with the brake pedal / brake lever depressed. The brake light would remain active and drain the battery. Get your battery checked / charged during periodic services
SAE 20W50 of API ‘SL’ + JASO ‘MA’ grade or superior.
Quantity Drain and Refill 1200 ml. Engine Overhaul 1400 ml. Coolant Ensure coolant in expansion tank is between Min and Max level mark. Top up with recommended brands Recommended Coolant Brand Mfr. Castrol - Radicool, Motul - Motocool Expert Quantity Drain and Refill - 1000 ml.
Safe Riding Tips
30
Always wear standard helmet while riding. Never use mobile phones while riding. Always keep rear view mirrors clean. Use both, front and rear disc brakes simultaneously. Applying only one brake may cause loss of control and skidding or diving. Do not apply front brake when cornering or at turns. Familiarise yourself well with seating posture, starting, acceleration and braking of the vehicle. Use side indicators before turning. Fuel pump inside the tank is lubricated and cooled by the fuel. Hence always maintain minimum 3 liter of fuel in fuel tank.
Bajaj Auto International Business
Key Learning Points Understanding the standard procedure to be followed during Pre-Delivery Inspection of a new vehicle and entering PDI details as per checklist Important tightening torque applications with loctile recommendation Standard timelines for attending PDI operations and PDI productivity Things to be remembered and followed during PDI
CHAPTER 4
Preliminary Checks & Maintenance Operations PDI Checklist Perodic Maintenance Chart Lubrication Matrix Periodic Service SOP
Bajaj Pulsar 200NS FI Training Notes
31
4
Preliminary Checks and Maintenance Operations
Pre-Delivery Inspection Checklist Following is the checklist for carrying out PDI of “Pulsar 200NS” motorcycle. This checklist is to understand various check points those are to be checked / inspected before delivery of the new vehicle. Whether BAL Service Executive carries out sample PDI or Dealer staff does, each vehicle should be checked as per the points given below. This ensures trouble free vehicle delivery to the customer. Dealer's Name
Dealer's code:
PDI Check sheet-Pulsar 200 NS
Frame No.
Date of PDI
Engine No.
PDI done by
Please unsure that following checks are carried out during PDI before delivery of vehicle. To Check ENGINE
Check for
✔ if OK X if NOT
Engine Oil "BAJAJ DTS-i 10000" 20W50
Oil level between upper and lower mark of oil level gauge / Top up if required
Oil leakage if any - Specify source of leakage
Gear shifting
Smooth operation
Engine noise
No abnormal noise
Silencer noise
No abnormal noise
Fasteners (Check torque)
Assy pipe A exhaust band clip bolt – 1.8 ~ 2.0 Kgm
Assy end chamber band clip bolt- 1.8 ~ 2.0 Kgm
Gear shifter lever pivot bolts – 0.9 ~ 1.1 Kgm
Ensure level between MIN and MAX mark in Reservoir tank in engine cold condition
COOLING SYSTEM Coolant level
Coolant leakage if any - Specify source of leakage
Radiator fan FUEL SYSTEM Tank Cap
FRAME
Tyre Pressure
Working of radiator fan after coolant temperature reaches 98 C
Petrol tank cap bolt fitment
Front : 1.75 Kg / Cm2 (25.0 PSI)
Rear (with Pillion) : 2.25 Kg / Cm (32.0 PSI)
Freeness of front and rear wheel
2
Wheel
Steering movement Check for smooth operation.
Side stand
Smooth operation
Mirror
Proper fitment
Clear rear view
Head lamp
Focus adjustment
Brakes
Front / Rear: a) No oil leakage from master cylinder and caliper
CONTROLS
32
0
Steering cum ignition, Rear seat lock
b) Check oil level in master cylinder (Visual inspection)
Throttle
Grip free play - 2 ~ 3 mm. Smooth operation
Clutch Cable
Smooth operation, Free play - 2 ~ 3 mm
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Remarks
Pre-Delivery Inspection Checklist To Check
Check for
Speedo cable
Proper routing
Drive Chain
Slackness standard - 15 ~ 25 mm
Equal marking of chain adjuster on both side
Front Fork
No leakage(Visual inspection), Smooth working
Rear Shock Absorber
Spring adjuster notch position : 2nd notch (Standard)
Steering
Smooth operation (No excess play / No sticky movement)
Lock Operation
Steering lock operation(Only on LH side), Seat lock, Petrol tank lock
SUSPENSION
Fasteners (Check torque)
ELECTRICAL Battery
✔ if OK X if NOT
Front axle nut - 10 Kgm
Rear axle nut - 10.0 Kgm
Rear sprocket mounting bolts – 3.2 ~ 3.8 Kgm
Holder handle bar bolts - 1.8 ~ 2.0 Kgm
Fork center nut - 4.8 ~ 5.2 Kgm
Swing arm shaft - 14 Kgm
Front fender mounting bolt- 1.8 ~ 2 Kgm
Stay LH / RH mounting bolt - 1.6 ~ 1.8 Kgm
Check nut bolts, screws, split pins for tightness.
Open circuit voltage (13 to 13.2 V DC) and Charge status by VRLA battery tester
Tightness of battery terminals / cables
Fuse
Position of fuse box
Kill switch
In OFF position check for no Speedometer display and no self start working.
All Bulbs Working Switch Operation Starter Motor Speedometer
Horn
Head light, LED tail / stop, Side indicators, Number plate lamp
RH and LH control switch, Ignition switch and Brake switch (Front and Rear)
No abnormal noise
Working / Engagement in gear and neutral
No excess gap and uneven gap
Working of Speedometer, Odometer and Tripmeter, Clock setting
Working of all signal indicators icons (Turn pilot, Neutral, High beam, Side stand, Battery charge and Bajaj logo)
Ensure no distorted sound
Starting
Cold start and Warm start
Drive ability
Throttle response
Brakes effectiveness- Front and Rear
Wash and Clean vehicle properly
TEST DRIVE
Cleaning
Remarks
Important Note: Look for any external damages in transit, please check, record and rectify send report with photos.
Bajaj Pulsar 200NS FI Training Notes
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4
Preliminary Checks and Maintenance Operations
Periodic Maintenance Chart Recommended Frequency Sr No
1
PM check points
Service
1st
2nd
3rd
Kms
500 ~ 750
4500 ~ 5000
9500 ~ 10000
Clean the vehicle with water wash and dry completely
2
Engine oil (Bajaj DTSi 10000 oil) & engine oil filter*
3
√
√
√
4th
5th
6th
14500 19500 24500 ~ ~ ~ 15000 20000 25000
√
√
√
7th 29500 ~ 30000
√
Top-up
R
Top-up
Oil strainer cleaning at the time of oil change.
CL
CL
4
Spark plug
CL,A,R
5
Air cleaner element ***& cover ‘O’ ring
CL, R
6
In line fuel filter .
7
Fuel pipe
C,R
C
C
C
R
C
C
R
8
Valve tappet clearance
C, A
C, A
C, A
C, A
C, A
C, A
C, A
C, A
9
Sealed drive chain cleaning & lubrication
10
Air filter drain tube
C
11
Silencer drain hole cleaning
12
Silencer tail pipe cleaning**
13
Brake cam & brake pedal pivot pin
14
Brake lining or pad -Check wear indicator
15
Brake fluid level **- top up / replace
16
Disc brake assly -- Check functionality, leakage or any other damage.
C
17
All cables & rear brake pedal -free play
C,A
CL
R
BGO DTSi 20W50 for models above 125cc.
Oil strainer
CL
Top-up
R
R
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Ensure to prevent water entry in Petrol tank, Silencer and electrical parts. Use caustic free detergent for washing.
C, R
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Remarks
CL
CL
CL
CL,A
CL,A
R
CL
R
R
CL
CL
R
CL,L,A CL,L,A CL,L,A
R
CL,L,A CL,L,A CL,L,A CL,L,A
Customer to apply OKS chain lub spray at every 500 kms.
C
C
C
C
C
C
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
CL
C
C,L,R
C,L,R
C,L,R
C,L,R
C,L,R
C,L,R
Use recommended AP grease.
C,R
C,R
C,R
R
C,R
C,R
R
Replace brake shoes /brake pad at every15000 Kms
R
Use recommended brake fluid (DOT3/DOT4).
C,L,R
C
CL,L,A
R
C,A,R
C,A
C
C,A
C,A
C,A
C
C,A
C,A
C
C,A
C,A
Periodic Maintenance Chart Recommended Frequency Sr No
PM check points
Service
1st
2nd
3rd
4th
5th
6th
7th
Kms
500 ~ 750
4500 ~ 5000
9500 ~ 10000
14500 19500 24500 ~ ~ ~ 15000 20000 25000
29500 ~ 30000
18
Wiring harness & Battery connections- routing, tie bands & clamps tightness.
C,A,T
C,A,T C,A,T
C,A,T
C,A,T
C,A,T
C,A,T
C,A,T
19
Ignition switch barrel cleaning & handle bar control switches contacts cleaning,
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
C,CL
20
Steering play
C,A
C,A
C,A
C,A
C,A
C,A
C,A
C,A
21
Steering stem bearing*** & Cap steering bearing(Plastic)**
22
Remarks
Use recommended WD40 spray
Check and replace if damaged. C,CL,L,R Use HP Lithon RR3 grease for lubrication.
C,CL,L,R
C,CL,L,R
C,CL,L,R
Main stand & side stand pin**
CL,L
CL,L
CL,L
23
All fasteners tightness
C,T
C,T
C,T
C,T
C,T
C,T
C,T
C,T
24
General lubrication-Clutch lever, front brake lever, kick lever.
L
L
L
L
L
L
L
L
Use recommended AP grease.
25
Coolant level in expansion tank**
C,A
C,A
C,A
C,A
C,A
C,A
C,A
R
Use recommended 'Ready to use coolant'.
26
Coolant hose damage/clamps/ leakage**
C
C
C
C
C
C
C
27
Radiator fins**
C
C
C
C
C
C
C
CL,L
Use recommended AP grease.
* It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be every 5000 kms ** As applicable to model *** More frequent cleaning is required while driving in dusty environment.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate Following items are chargeable to Customer. Oil,Coolant,Filters,All types of greases,Cleaning agents,Cables,Wear and tear parts,Rubber O rings/oil seals/pipes , Gaskets etc.
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Preliminary Checks and Maintenance Operations
Lubrication Matrix Oil / Grease / Loctite application matrix Sr. Lubricant / Loctite No.
Grade
Application
Remark Quantity : Drain and Refill - 1200 ml Eng. O/h - 1400 ml
1
Engine oil
DTSi 10000, SAE 20W50 API SF/SG JASO MA
Engine
2
Fork oil
SAE 10W20
Front fork
3
Brake fluid
N.A
N.A
5
Grease
All purpose
Front and real wheel axle, Swing arm shaft, Brake pedal pivot pin, Center stand shaft, Side stand U bracket, Gear shifter pivot, Clutch and front brake lever
4
Grease
6
Chain spray
7
Oil for drive chain
8
Electrical contact cleaning spray
Lithon RR-3
OKS - Chain lube spray SAE 90
WD-40 Spray
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N.A
Steering races and balls HP make
N.A
Non ‘O’ ring type drive chain • Ignition switch
• Brake and clutch switch • LH/RH control switch
Notes
Quantity / fork leg : Drain and Refill - 295 ±2.5 ml Overhaul - 320 ml
During all services All services
Periodic Service SOP Engine Oil Replacement
uu Ride the Vehicle for 2-3 Km to warm the engine. uu Park the vehicle on levelled surface.
A
B
uu Remove: Drain Bolt - A Oil Strainer - B
uu Measure & Inspect: Quantity of the oil collected. uu Inspect: The quality of the oil collected. Note: The standard oil consumption per 1000 kms is 30 to 80 ml
uu Clean: Strainer using Kerosene / Diesel. Blow air of 2 bar pressure from inside to outside. Clean the ferrous burr deposited on the oil strainer. uu Inspect: The ‘O’ ring for firm fitment
A
uu Fit: Strainer and the strainer cap Tighten the strainer cap - A
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Preliminary Checks and Maintenance Operations
Periodic Service SOP uu Fill recommended quantity of engine oil. Grade SAE 20W50 API SF/SG, JASO MA
Drain and Refill
Engine Overhaul
1200 ml 1400 ml
Note: The standard oil consumption per 1000 kms is 30 to 80 ml
Engine Oil Filter Replacement A uu Remove 2 bolts - A
B
Filter cover - B
A
uu Remove Oil Filter Note: Do not clean or reuse the oil filter element. Replace the oil filter at the first service and thereafter at every oil change.
A
uu Fit Oil filter cover - A A
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2 bolts - B
Periodic Service SOP Spark Plug Gap Adjustment uu Remove & check spark plug for... 3. Errosion 1. Spark Plug type 4. Cracks / Breakge 2. Color Recommended Spark Plug
Central – BOSCH YR5NE
Electrode Gap
0.8 ~ 0.9 mm
LHS & RHS – CHAMPION – PRG6HCC
u Clean the spark plug u Check and adjust spark plug gap using wire gauge. u Spark plug gap should be - 0.8~ 0.9 mm Note: Cleaning every 10,000 Kms. Replacement every 30000 km.
uu Fit Screw in spark plugs first manually and thereafter use spanner for tightening it.
Notes
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Preliminary Checks and Maintenance Operations
Periodic Service SOP Coolant Replacement Drain the coolant uu During run, the coolant heats and is under pressure. Do not remove the radiator cap, radiator hoses or other any other component of the cooling system when the engine is in heated condition. Allow the engine and cooling system to cool down.
A
uu Park the vehicle on levelled surface. uu Remove Bleeder Screw - A
uu Remove Drain bolt - A Washer - B uu Drain the coolant A & B
Warning
Steam and overheated radiator fluid if comes in contact with skin, causes serious burns. Please therefore do not open the radiator cap or drain when the engine is heated.
Replacement of coolant : uu Use only the recommended brand (ready to use) of coolant. Make
Castrol - Radicool
Motul - Motocool expert
Qty 1000 ml
Note: Replace coolant every 30,000 Kms
uu Fit Washer Drain bolt.
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Periodic Service SOP Coolant Replacement
uu Remove Coolant from the expansion tank
Skill tips: Stop until the coolant with air bubbles emerges out from the bleeding screw.
uu Fit Radiator cap - A A Caution
Do not open the radiator cap in engine hot or during engine running condition.
uu Remove Cap for the expansion tank. Top up the coolant to maximum mark.
uu Refit the cap of the expansion tank. Note: Ensure that the vent pipe is routed correctly
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Preliminary Checks and Maintenance Operations
Periodic Service SOP Air Filter Cleaning Stage 1 uu Use compressed filtered air of pressure less than 2 bar. uu Position pressure gun at a 90 degree angle and at a distance of 50 mm from paper filter. uu Move the pressure gun along the lines of the folds.
900
Stage 2 450
uu Position pressure gun at a 45 degree angle and at a distance of 50 mm from paper filter. uu Twist the paper filter slightly. uu Move the pressure gun along the fold line.
Stage 3 900
Dos uu Clean paper filter at every 5000 Kms. uu Increase frequency of cleaning if the vehicle is being used in dusty conditions. uu Replace the paper filter at 15000 Kms. uu Hold filter element by its PU foam.
Notes
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uu Position pressure gun at a 90 degree angle and at a distance of 50 mm from paper filter. uu Blow out the remaining dust the pressure gun along the lines of the folds.
Don’ts uu Don’t use solvents such as petrol, Diesel, Kerosene or water to clean paper filter element. uu Don’t apply any oil on paper filter element. uu Don’t touch paper filter surface with soiled hand. uu Don’t wipe the paper filter with cloth, paper or any abrasive material.
Periodic Service SOP Tappet Setting
uu Ensure that the piston is at the end of the compression stroke. uu Both rockers are the free. uu Ensure that the cam sprocket marks are parallel to the cylinder head surface. uu Check and adjust clearance of both, inlet and exhaust valves
Note: Make one rotation of crankshaft and recheck the tappet clearance once again. If found incorrect adjust it again. Tappet Clearance Intake
Exhaust
0.05 mm
0.08 mm
SOP for compression pressure checking (Dry Test) uu Warm the engine by riding the vehicle for about 1 km. uu Park the vehicle on levelled surface uu Disconnect all spark plug caps. uu Remove the RH side spark plug. uu Connect the compression gauge adapter and fit it.
uu Open the throttle fully uu Crank the engine for 6 seconds uu Note the compression pressure
uu Take 3 readings and calculate the mean of the 3 readings Compression Pressure Details Std
Kg/cm2 11-13
Service limit 9.5
PSI
Bar
135.5
9.31
156.4~185.0 10.78~12.74
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Preliminary Checks and Maintenance Operations
Periodic Service SOP ‘O’ Ring Type Drive Chain Lubrication (On the vehicle) uu Park the vehicle on the service stand. uu Ensure free rotation of the rear wheel. uu Wipe / clean of dust using a lint free cloth.
uu Shake the chain lube spray thoroughly. uu Hold the spray at a distance of 5 – 10 cm from the chain uu Rotate the wheel in the reverse direction when spraying . Spray on the middle section of the chain.
‘O’ Ring Drive Chain Cleaning by Removing from Vehicle (Diesel + SAE 90 oil 1:1)
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1st Stage : Clean with Diesel + oil 1:1
2nd Stage: Clean with Diesel + oil 1:1
Blow Low Pressure Compressed Air
Final Stage : Hook chain for dripping of excess oil
Soak into SAE 90 oil
3rd Stage: Dip into SAE 90 oil
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Periodic Service SOP Drive Chain Slackness Checking
uu Park the vehicle firmly on the service stand. uu Rotate the rear wheel uu Adjust slackness if found incorrect
Drive chain Slackness Std
Specs = Frame ppt
Ser limit
Specs = Frame ppt
Drive Chain Slackness Adjustment
uu Loosen Rear axle nut.
uu Adjust: LH chain adjuster RH chain adjuster Note: Ensure bolt LH/RH adjusters are adjusted equally.
uu Tighten: Rear axle nut. Ensure correct chain slackness.
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Preliminary Checks and Maintenance Operations
Why to & How to maintain your Vehicle? Why Periodic Maintenance is required? Components of vehicle & engine are subject to Continuous working. Rotation, Reciprocation, Swivel etc. Operational misuse.
Moreover, the vehicle get abused by Various driving habits. Bad road conditions. Dense traffic conditions. Different weather conditions.
All these call for regular Periodic Maintenance.
How to maintain the vehicle regularly?
By following the Service Schedule and Periodic Maintenance Schedule, one can maintain and keep the vehicle fit and healthy. Avail all the free services as per schedule. Avail all the paid services as per schedule. Follow Periodic Maintenance as per P.M. chart given in the Owner’s Manual.
Benefits :
Periodic Service / Maintenance ensures Consistent performance. Remote chances of breakdowns / accidents due to failure of parts. Enables safe riding. Economical in long run
Keep your vehicle fit and healthy by following Scheduled Services and Periodic Maintenance Schedule for trouble free performance
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Key Learning Points Understanding of EMS Layout Understanding the Function, Construction and Working of Sensors and Actuators Application and Usage of Diagnostic Tools Standard Operating Procedures for Fuel Pump Pressure Inspection and Fuel Pump Delivery Measurement
CHAPTER 5
Fuel System & EMS DTSi – Fi Engine Management Systems / EMS Layout Working of Systems Fuel Injection Dos and Don’ts
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Fuel System & EMS
DTS-Fi Engine Management System Location of parts Speedometer harness Tail and stop lamp, Rear blinker RH, Rear blinker LH, Number plate lamp, Fuse box assy., Aux. start relay 1,2,3. And CAN interface Ignition Switch Control Switch LH Control Switch RH Clutch Switch Kill Switch
Lambda (oxygen) sensor, crank sensor, stepper motor, Fuel injector, TMAP, TPS, CTS, Oil pressure sensor.
Lambda (oxygen) sensor, crank sensor, stepper motor, Fuel injector, TMAP, TPS, CTS, Oil pressure sensor.
HT coil 1
Roll over sensor
Photo
Part Name
Remark
H.T. Coil 2
For LH & RH spark plug
Roll Over Sensor
Sends ignition cut of signal to ECU when bike inclination angle > 68°
H.T. Coil 1
HT coil 2
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For Central spark plug
DTS-Fi Engine Management System Location of important parts / couplers Crank sensor & Lambda (oxygen) sensor
Regulator connectors
Photo
Fuel Pump Fuel Level Sensor
Coolant temp. sensor
Part Name Remark Crank Sensor
It monitor the position or rotational speed of the crankshaft
Lambda Sensor
Fuel Pump
Stepper motor
Engine earth
Photo
Light control module
Chassis earth
Regulator earth
Side stand switch
Part Name Remark
Light Control Module
It manages all the individual lights of the vehicle electric system.
Detects amount of oxygen in exhaust gas and sends signal to ECU which adjusts the air fuel mixture to the optimal level.
Regulator Earth
It has AC/DC voltage regulator & a rectifier. The RR unit regulates the electrical voltage & also helps in charging the battery.
To draw the fuel from fuel tank and push it along the fuel lines to injector and keep a constant pressure in the system.
Side Stand Switch
When the side stand is put ON the side stand sensor will send the information to ECU. ECU will thereafter not allow the engine to run in any gear.
Coolant temp. sensor
It measures the temperature of the coolant. The readings from this sensor are then fed back to the ECU, which uses this data to adjust the fuel injection and ignition timing.
Fuel Level Sensor
It senses the fuel level / quantity inside the fuel tank and communicates the same to fuel gauge.
Stepper Motor
Stepper motor is a brushless DC electric motor that divides a full rotation into a number of equal steps. The motor’s position can then be commanded to move and hold at one of these steps without any feedback sensor
Engine Earth
Chassis Earth
Common earthing for the electrical system
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Fuel System & EMS
DTS-Fi Engine Management System Location of important parts / couplers Oil pressure sensor
TMAP TPS Termination Radiator fan unit relay
Regulator magneto Fuel Fuel level connection pump sensor
Photo
Stepper Regulator Main relay & EMS ECU motor Fuel pump relay
Part Name Remark Fuel Injector To inject the fuel into the intake manifold until the electric signal from solenoid is cut of by ECU. Oil pressure It measures the Sensor pressure of the engine oil flowing thru the internal oil galleries and communicates the signal to the speedometer. TMap
TPS
Termination Unit
50
It is a micromechanical sensor that measures the absolute pressure in the intake manifold and compares it with a reference vacuum, not with the ambient pressure. To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU. It consist of a transil diode that filters the voltage surge thereby protects ECU from voltage fluctuation.
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Starter relay
Photo
Part Name Remark ECU
To collect information from various sensors & insure that correct quantity of fuel is injected into the intake manifold at precise timing at various engine load & speed condition
Main Relay
Fuel Pump Relay
Radiator Fan Relay
A relay is an electrically operated switch. Most relays use an electromagnetic to mechanically operate a switch. Relays are used where it is necessary to control a circuit by a lowpower signal
DTS-Fi Engine Management System Location of important parts / couplers Starter relay Starter relay coil Radiator fan relay
Termination unit
TMAP
TPS Oil pressure sensor
CTS Rear brake switch
Starter motor
TPS
Rear brake switch
TMAP Oil Pressure CTS Starter Motor
Battery positive
Battery negative
Main fuse
CAN Termination
Fuse Box Assembly Signal Lamp rear LH Signal Lamp rear RH Tail and Stop Lamp Number Plate Lamp And Can interface
Aux. starter relays 1,2 & 3
CAN Application
Earth chassis
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Fuel System & EMS
DTS-Fi Engine Management System Photo
Part Name
Remark
CAN Termination
This unit is provided to have uninterrupted communication between diagnostic tool and ECU
Function of Aux Starter Relay AUX Starter Relay 3 Incorporated for clutch & neutral switch interlocking in starter circuit.
3 2
AUX Starter Relay 2 1
Its function is to isolate starter circuit from ECU. If this relay fails engine can not be crank.
AUX Starter Relay 1 It is grey in color. It has a diode that is provided for suppressing voltage surge. If vehicle is driven without this relay ECU may fail.
Notes
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Engine Management Systems Gives Input to ECU
Receive Output from ECU
Coolant temperature sensor.
Fuel Injector
Oxygen sensor (Lambda sensor)
Fuel pump
Crank angle sensor.
HT Coil
Throttle position sensor (TPS)
Temperature and Manifold pressure sensor (TMAP)
Roll over sensor.
Side stand sensor
Wheel speed sensor.
Malfunction indicator
ECU
Main power relay
Stepper Motor
Diagnostic coupler
Radiator Fan
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Fuel System & EMS
EMS Sensors and Actuators 1 1 - MPRD (Relay)
3
2
P4 P3 P2 P1
4
5 2 - Steeper Motor
3 - Injector
4 - T MAP Sensor
6
6 - Fuel Pump
7
8 7 - H. T. Coils (LH)
9 9 - Engine Malfunction Indicator (MIL)
10
10 - Diagnostic Coupler
11 11 - Radiator Fan
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8 - H. T. Coils (RH)
5 - TPS
Working of Systems Fuel Pump Function To draw the fuel from the fuel tank and push it along the fuel lines to the injector rail and keeping a constant pressure in the system. Also the fuel pump needs to ensure a high level of fuel flowing through the fuel line thus maintaining constant fuel delivery pressure.
Construction Fuel pump module assembly
Fuel Pump Mounting Bracket
Fuel Strainer
Fuel Pressure Regulator Fuel Pump
Rubber Gasket for Sealing on to Petrol Tank Pressurized Fuel out to Fuel Filter Fuel Filter to Injector
Regulator Connected in a ‘T’ Joint Fuel to Injector
Working The fuel is pumped from the fuel tank by a roller cell pump through a fuel filter into a fuel rail at the end of which is a fuel pressure regulator. In order to keep the injector pressure differential constant despite variations of inlet manifold depression with load, the fuel pressure regulator senses the difference between pumping pressure and that of the inlet manifold. Excess fuel is returned to the fuel tank, the continuous flushing keeps the fuel cool and avoids formation of pockets of fuel vapor. The fuel pump is lubricated and cooled by the fuel flowing through the motor, including the brushes and across the armature hence it is important that never run the pump without adequate fuel inside the fuel tank. The fuel filter strains impurities out of the fuel. This is an important measure in preventing the fuel pump, fuel injector nozzles from clogging. Fuel Pump Resistance = 2.7 + 0.1 Ohms Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Fuel Injector
Function To inject the fuel into the intake manifold until the electric signal from solenoids is cut off by ECU.
Construction
Fuel Supply
Electric Connection
Rail ‘O’ Ring Seal Integral Filter
Return Spring
Coil
Armature Valve Needle
Washer
Manifold ‘O’ Ring Pintle Protection Cap Pintle
Working The fuel injector supplies the fuel in the form of a spray from the injector pintle which is located on intake manifold. The injector have the nozzles which are opened and closed by solenoid wound (coil) in the injector body. When the windings are energized the armature is attracted due to magnetism and compresses the spring which lifts the needle valve. Thus pintle automises the fuel into a fine spray form with a pressure about 2.5 bars (36 lbf / in2) until the electric signal in the solenoid is cut off by the ECU. The injector internal movement is restricted just to < 0.1 mm. Also period that an injector remains open is very low (between 1.5 and 10 milliseconds). Thus the opening and closing time is critical for accurate fuel metering. The fuel spray mixes with the incoming air as both move towards the inlet valve giving a precisely metered combustion mixture.
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Working of Systems Engine Control Unit (ECU)
Introduction The automotive engine has two power generation systems named as ‘Carburetion System’ and ‘Ignition System’ respectively. The Carburettor supplies atomized / vaporized air fuel mixture to the engine maintaining the desired air fuel ratio as per engine requirement. The Ignition system supplies electric igniting spark at the spark plug tip as per precise engine demand (timing) to burn the compressed air fuel mixture inside the combustion chamber. However these 2 systems like Carburetion and Ignition has been dealt separately. In digital ignition circuits a microprocessor is used in the CDI unit. This microprocessor is capable of controlling various tasks. Hence it was logical to use this spare capacity for controlling fueling also. Thus then developed a digital electronic control system for fuel injection and combined it with the digital ignition control to form a single unit controller. This unit is named as “Electronic Control Unit”.
Function
It collects information from various sensors and ensure that a correct quantity fuel is injected into the intake manifold at precise time considering various engine load and speed conditions. It is brain of the engine and controls various devices. Also it controls / supports on vehicle diagnostic instrument for diagnosing the problem in fuel injection system.
Construction It consists of a micro computer A - D Convertor (Analog to Digital) and I - O Unit (Input - Output). Input signals are received from various set of Sensors
Signals given to operate following Actuators
Actuators
Side Stand Sensor Clutch Switch Engine Oil Pressure Sensor Roll Over Sensor Lambda Sensor Crank Angle Sensor and Neutral Switch T Map Sensor Throttle Position Sensor Coolant Temperature Sensor
Signal Processing (SP)
Vehicle Speed Sensor
Analogue to Digital - (A-D)
Sensors
MPRD (Relay) Steeper Motor
Engine Control Unit ECU
Injector Fuel Pump H.T. Coil (LH&RH) Engine Malfunction Speedo Icon Radiator Fan It also supports in Diagnostic trouble codes assessment. Bajaj Pulsar 200NS FI Training Notes
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Working of Systems Engine Control Unit (ECU) Working The ignition and fuel injection is controlled by a single control unit named as ‘ECU’. In ECU the inputs from various sensors are fed into a signal processor circuits to ensure that all outputs to the computer are in the form of digital pulses. These inputs received may be steady or slowly varying voltages. These are said to be in analogue form and which are converted into equivalent digital valves by an analogue to digital (AD) converter. The digital output are fed to the input I output rail for transporting to the main heart of the computer. Thus the ECU collects all signals, calculates them and process them to actuators to delivery precise ignition advance timing and fuel injection requirement for the engine at various load and speed conditions.
Set of Various Sensors A sensor is a device which detects or measures a quantity, usually in electrical form so that it may be used in measurement or control. The analogue signal processing is added to the sensor, this improves the resistance to interference.
Set of Various Actuators Actuators is a general term used to describe a control mechanism i.e. a device that converts electrical signals into mechanical movement e.g. Fuel injector Fuel pump Solenoid starter relay
Notes
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Working of Systems Throttle Position Sensor
Function To measure the exact position of the throttle valve opening and to send this measurement signal in voltage form to ECU.
Construction The throttle body has a throttle valve mounted on the intake manifold. The throttle valve is connected by accelerator cable and its opening and closing is controlled by accelerator twist grip mounted on RH side of handle bar. The throttle position sensor mounted on the throttle valve continuously reports the throttle position to the ECU. This is a rotary throttle position sensor having a variable resistor also called as a potentiometer. Internally it has a coil resistance wire in the form of a half circle. One end connects to the ground and other end is connected to a 5 volt source from ECU. The wiper blade has a contact that rides on the coil and connects to the throttle valve shaft. Also the position of the throttle valve is important in controlling the idling rpm.
Working Upon acceleration the throttle valve position changes. The wiper type blades moves over the coil winding as it is pivoted directly on the throttle valve shaft. Throttle position at zero (closed} position When the throttle valve is closed, the blade is at the grounded end of the coil. A small voltage signal is send to ECU at this position which senses that the throttle position is at zero. Further movement of throttle position As the throttle valve moves towards the open position, the wiper type blade swings towards 5 volt end of the coil. This sends an increasing voltage signal to the ECU. Thus the continuously charging voltage regularly communicates the ECU the exact position of the throttle valve.
RESISTANCE COIL CLOSED THROTTLE
WIPER BLADE
PIVOT
WIDE OPEN THROTTLE
OUTPUT VOLTAGE TO ECU
5 VOLTS FROM ECU
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Fuel System & EMS
Working of Systems Engine Temperature Sensor Function
To measure the engine / engine oil temperature up to 200 0C.
Construction The principal methods of temperature measurement is are done by the thermistor. The thermistor is made from semi conductor material such as cobalt or nickel oxides and is encapsulated in a brass sleeve for mechanical protection.
Working The thermistors are semi conductor resistors which change their resistance valve with temperature. The resistance decreases with an increase in engine temperature as it has a negative temperature coefficient (NTC) and vice versa. The characteristic of engine temperature is represented graphically. (The values do not match exactly, it is just a representation for understanding). This NTC type thermistor is used to measure the engine temperature in engine management system.
200
Thermister Resistance (Ohm)
180 160 140 120 100 80 60 40 20 Temp. OC
0 0
10
20
30
40
50
60
70
80
NTC Thermistor Characteristic
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90 100
NTC Thermistor
Working of Systems Roll Over Sensor
Function To send the ignition cut off signal to ECU for shutting down the engine if the bike exceeds the inclination angle beyond 60° on either of the side.
Main Switch Sensor
Construction The roll over sensor is a sealed sensor unit and that contains moving weight which is suspended freely on a shaft. This is mounted below the air filter box onto the chassis. Please note, even if roll over sensor is not connected (coupler open) the vehicle does not start (to ensure safety) and the malfunction will be shown on speedometer.
Magnet
Working
x
O
60 O
60
The moving weights are suspended freely. When the vehicle leans down on either of the LH I RH side the position of these weights changes. The change of position of the weights is sensed by the sensor. If the inclination angle exceeds beyond 60° to the vertical the sensor will give signal to ECU to cut off the ignition system.
0
This is a useful safety feature because inclination angle exceeding 60° indicates that the rider has dropped the bike or is involved in an accident. Thus safety of the bike and rider is ensured. y
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Fuel System & EMS
Working of Systems Crank Angle Sensor Function To communicate the ECU how fast the crankshaft is rotating per minute and help ECU in delivering precise fuel metering and ignition spark advance.
Construction A magnetic sensor located in magneto cover facing towards square notched I square block on the rotor periphery.
Working As the rotor rotates the notched square blocks on the rotor periphery causes voltage pulses in the sensor. These pulses are sent to the ECU. The ECU counts the number of pulses per second and understands at what RPM the engine is operating and accordingly precise fuel metering and ignition spark advance is controlled. There are 23 square notches I square blocks on the rotor outer periphery and are placed equidistance. At a particular location there is wide gap seen between 2 square notches I square blocks. This can also be determined as square notch missing. This missing square notch area represents the BTDC position. At this BTDC position voltage pulse is sensed by the crank angle sensor and is communicated to ECU. ECU uses this information to control ignition spark advance.
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Working of Systems Malfunction Indicator Light Function When certain troubles develop in the electronic control system, the ECU stores in its memory or number or trouble code for each fault. This turns a Malfunction Red Indicator Light ( ) on the speedometer (next to Hi-beam light). This alerts the driver that there is some problem and repair / service in needed. If a single sensor or its harness part fails the ECU may substitute a value for failed sensor. This allows the engine to appear to run normal. A fault that turns on the malfunction indicator light may also put the engine into its limp-in mode. This means that limited operation strategy (LOS) chip in the ECU has taken over. It provides basic instructions to the microprocessor if a part of the electronic system fails. The engine runs but with fixed ignition timing and air fuel ratio. The injector pulse width does not change. This allows the vehicle to be driven but with greatly reduced performance. The benefit of this is the vehicle can be limpin for service instead of being towed or transported into a cargo. The technician can retrieve the stored trouble code from ECU memory using the diagnostic tool. To use the code the technician can refer the Diagnostic Chart or the Flash Code. This chart explains where lies the problem and its probable cause.
Notes
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Malfunction Indicator Light
List of Diagnostic Trouble Codes
64
SR No
P Codes
“Blink code”
“Drive Cycle”
1
P0123
3
Throttle/Pedal Position Sensor/Switch “A” Circuit High
2
P0122
06
3
Throttle/Pedal Position Sensor/Switch “A” Circuit Low
3
P0507
11
1
Idle Air Control System RPM Higher Than Expected
4
P0506
11
1
Idle Air Control System RPM Lower Than Expected
5
P0108
09
3
6
P0107
09
3
"Manifold Absolute Pressure/Barometric Pressure Circuit High”
7
P0629
41
1
8
P0628
41
1
Fuel Pump “A” Control Circuit Low
9
P0627
41
1
Fuel Pump “A” Control Circuit/Open
10
P0336
02
3
11
P0262
33
1
Crankshaft Position Sensor “A” Circuit Range/ Performance
12
P0261
33
1
Cylinder 1 Injector Circuit Low
13
P0201
33
1
Injector Circuit/Open – Cylinder 1
14
P1611
14
**
Fuel consumption signal output short to Battery
15
P1610
14
**
Fuel consumption signal output short to Ground
16
P1609
14
**
Fuel consumption signal output open
17
P0032
45
3
HO2S Heater Control Circuit High Bank 1 Sensor 1
18
P0031
45
3
HO2S Heater Control Circuit Low Bank 1 Sensor 1
19
P0030
45
3
HO2S Heater Control Circuit Bank 1 Sensor 1
20
P0692
16
1
Radiator Fan Control Circuit High
21
P0691
16
1
Radiator Fan Control Circuit Low
22
P0480
16
1
Radiator Fan Relay Control Circuit fault
23
P0132
17
3
O2 Sensor Circuit High Voltage Bank 1 Sensor 1
24
P0131
17
3
O2 Sensor Circuit Low Voltage Bank 1 Sensor 1
25
P0130
17
3
O2 Sensor Circuit Bank 1 Sensor 1
26
P0134
17
3
O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1
27
P1605
18
**
Malfunction Indicator Lamp (MIL) Control Circuit High
28
P1604
18
**
Malfunction Indicator Lamp (MIL) Control Circuit Low
29
P0650
18
**
Malfunction Indicator Lamp (MIL) Control Circuit
30
*P1504
15
1
Roll over sensor Short Circuit to battery
31
*P1503
15
1
Roll over sensor Short Circuit to Ground
32
*P1501
15
1
Roll over sensor circuit signal non-plausible
33
*P1502
15
1
Roll over sensor circuit open
Bajaj Auto International Business
06
DTC meaning
Manifold Absolute Pressure/Barometric Pressure Circuit Low Fuel Pump “A” Control Circuit High
Cylinder 1 Injector Circuit High
Working of Systems Malfunction Indicator Light
List of Diagnostic Trouble Codes SR No
P Codes
“Blink code”
“Drive Cycle”
34
P1603
**
Rest tank Fuel Indicator Circuit High
35
P1602
19
**
Rest tank Fuel Indicator Circuit Low
36
P1601
19
**
Rest tank Fuel Indicator Circuit open
37
*P1508
25
1
Side Stand sensor Short Circuit to battery
38
*P1507
25
1
Side Stand sensor Short Circuit to Ground
39
*P1505
25
1
Side Stand sensor circuit signal non-plausible
40
*P1506
25
1
Side Stand sensor circuit open
41
P0509
49
3
Idle Air Control System Circuit High
42
P0508
49
3
Idle Air Control System Circuit Low
43
P0511
49
3
Idle Air Control Circuit
44
P0689
21
**
ECM/PCM Power Relay Sense Circuit Low
45
P0112
13
**
Intake Air Temperature Sensor 1 Circuit Low
46
P0113
13
**
Intake Air Temperature Sensor 1 Circuit High
47
P0117
12
3
Engine Coolant Temperature Sensor 1 Circuit Low
48
P0118
12
3
Engine Coolant Temperature Sensor 1 Circuit High
49
P1608
22
**
Engine Speed Signal Circuit High
50
P1607
22
**
Engine Speed Signal Circuit Low
51
P1606
22
**
Engine Speed Signal Circuit Open
52
P0563
24
**
System Voltage High
53
P0562
24
**
System Voltage Low
54
P1510
24
**
System Voltage sensing failure in ECU
55
P0501
23
3
Vehicle Speed Sensor “A” Range/Performance
56
P0643
26
3
Sensor Reference Voltage “A” Circuit Hig h
57
P0642
26
3
Sensor Reference Voltage “A” Circuit Low
58
P0653
27
1
Sensor Reference Voltage “B” Circuit High
59
P0652
27
1
Sensor Reference Voltage “B” Circuit Low
19
DTC meaning
Note: Actual description of DTC may vary to make it fit on Tool screen. * This fault codes are not applicable in case of RE 60. ** Blink Code getsON immediately. Healing for all DTC requires 3 driving cycle.
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Working of Systems Fuel Injection – Advantages over Carburetion : Advantages of Fuel Injection Increased power output per unit of displacement. Higher torque at low engine rpm. Improved cold start, warm up and sudden acceleration (No chance of wetting intake manifold). Lower fuel consumption. Overall superb drive-ability. Lower maintenance cost. Communicates malfunctioning of fuel injection system, if any. Low emission level.
Fuel Injection – Advantages over Carburetion : Limitations of Carburettor : Restricted air flow due to venture design causes power loss (volumetric efficiency is limited). As intake manifold contains combustible mixture, danger of back fire from the cylinder into the manifold is always there. At high altitude or in warm weather, possibility of vapour lock. After burning noise in silencer on sudden deceleration. Does not support sudden acceleration. Difficult cold starting and requires choke for starting. In cold conditions, fuel wets the wall of the induction manifold causing running difficulties. Difficult cold starting and requires choke for starting. Inconsistence in fuel efficiency. Maintenance cost is reasonably more. High emission level.
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SOP’s Petrol Tank Removal Insert Key and open the lock uu Remove Pillion seat
uu Remove 2 Bolts
uu Remove 2 Allen bolts 2 Nylon washers
uu Remove Rubber mesh
Rider seat
uu Remove Collared rubber washer Bush
uu Remove 2 Screws Side cover LH Side cover RH
Note: Similarly remove it for RH
uu Remove Allen bolt Washer Note: Similarly remove it for RH
uu Remove 2 Bolts 2 Nylon washers
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
SOP’s Petrol Tank Removal uu Remove Flange bolt Collared washer Note: Similarly remove it for RH
uu Remove Carefully pull out the tank cover
A
B
uu Remove Disconnect the fuel gauge coupler (A) Disconnect the fuel pump coupler (B)
uu Remove Lift up the petrol tank
uu Remove Disconnect the clip and remove the hose pipe from filter side uu Remove 3 bolts (RL/RH/Front) 3 collared bush
Skill tip: Disconnect the fuel pipe carefully as the fuel line is filled with the pressurised fuel at 2.5 bars
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SOP’s Fuel Pump Delivery Inspection
Purpose of this test : To inspect correct quantity of fuel delivered through fuel pump for 10 seconds. uu Instruments required : Pig tail (BAL part no. : -------) Measuring jar Charged battery
Pigtail On Off Switch
Keep petrol tank on plain surface. Coupler Crocodile clips
Hold the clean jar at the fuel pipe outlet for collecting the fuel
Connect fuel pump delivery checking pigtail coupler to fuel pump coupler. Connect fuel pump delivery checking pigtail crocodile clips to 12V external battery source.
Quantity Unit
Put ON the “ON-OFF” switch of the pigtail.
180
Measure the fuel delivery for 10 seconds.
mililiters
Fuel Pump Pressure Inspection:
Purpose of this test : To measure the fuel pump delivery pressure. uu Instruments required :
uu Remove : Fuel pipe from fuel filter
Fuel pressure gauge
Connect to Fuel pipe (a)
Connect to Fuel filter (b)
uu Fit : The removed fuel pipe to the pressure gauge T joint. Other end of the pipe to the fuel filter. Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
SOP’s Fuel Pump Pressure Inspection Mount the petrol tank
Note: Ensure both the clamps are fully tighten. Switch “ON” the ignition key Observe the pressure that is displayed on the pressure gauge. Specification
Unit
36 to 42
PSI
2.5 to 2.9 2.4 to 2.8
Bar
Kg/cm2
Note : If the specification mention above is not achieved then confirm for no clogging of… 1. Tank air vent 2. Fuel line 3. Fuel filter Also confirm for proper functioning of fuel pump.
Throttle Body Removal
Note : Follow the earlier mentioned SOP’s till air filter case removal to proceed for Throttle Body removal. uu Remove 2 bolts
Loosen air filter side clamp
Note: Use long handle allen key
Loosen manifold side clamp
uu Remove Push up the circlip Hose pipe of PCV
uu Remove Push up the circlip Hose pipe of filter
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SOP’s Throttle Body Removal uu Remove Coupler for… Injector Steeper motor
uu Remove TPS coupler T map coupler
Skill tip: Before pulling the coupler first release the locking clip. Don’t pull the wire, pull the coupler firmly. uu Remove Grommet Slide out accelerator cable
uu Remove Pull out the filter box with throttle body
Skill tip: Cover the intake and engine breather bore using a soft clean cloth.
Injector Removal
Note : Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal. uu Remove Coupler
uu Remove Tusken screw Note: Use recommended Tusken screw driver.
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
SOP’s Injector Removal
Note: Follow the earlier mentioned SOP’s till air filter case removal to proceed for Injector removal. uu Remove Injector
Skill tip: Cover the injector bore using soft clean cloth.
Engine Tune-up
Spark Plug Recommended Spark Plug
Central – BOSCH VR5NE
Electrode Gap
0.8 ~ 0.9 mm
Replace at every
LHS & RHS – CHAMPION – RG6HCC 30,000 kms
Air Filter
Note: Compressed air pressure should not be more than 2 bar
Clean at every: 5,000 Kms. Replace at every: 15,000 Kms
Cleaning frequency : Every 5000 Km. (increase freq. in dusty area) Replace Air Filter Foam at every 15,000 Km. uu Compression pressure checking
SOP : Warm up the engine. Park the vehicle Disconnect all plug caps. Remove LH spark plug and fit the compression gauge. With full throttle open crank the engine for 3 - 4 seconds. Take 3 readings and calculate the mean reading.
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SOP’s Tappet Clearance Adjustment Inlet Valve: 0.05 mm Exhaust Valve: 0.08 mm Tappet Clearance is to be check in engine cold condition.
Other Mandatory Checks Ensure no fuel leakage through fuel lines. Ensure free rotation of both wheels. Ensure correct tyre pressure - Front : 25 PSI, Rear : 32.0 PSI Set control cable free play: Clutch lever 2~3 mm. Rear brake pedal 20~25 mm. Accelerator free play 2~3 mm. Front brake free play 2~3 mm. Chain slackness : 15~25 mm. Check and confirm proper functioning of all 3 nos. spark plugs.
Bajaj Pulsar 200NS FI Training Notes
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Fuel System & EMS
Do’s & Don’ts Precautions while working on fuel injection system uu This fuel injection system is designed to be used with a 12V VRLA battery as its power source. Do not use any other local battery. uu Do not reverse the battery cable connections. This might damage the ECU. uu To prevent damage to the fuel injection parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is ON, or while the engine is running. uu Take care not to short circuit the leads that are directly connected to the battery positive (+) terminal to the chassis ground. uu Whenever the fuel injection electrical connections are to be disconnected, first turn off the ignition switch, and disconnect the battery (-) terminal. uu When any fuel hose is disconnected, do not turn on the ignition switch. Otherwise, the fuel pump will operate and fuel will spout the fuel hose. uu Do not operate the fuel pump if the pump is completely dry. The pump lubrication and cooling is done by the fuel itself. uu Before removing the fuel system parts, blow the outer surfaces of these parts clean with compressed air. uu Make sure all connectors in the circuit are clean and tight, and examine leads for signs of burning.
How to read MIL Code : uu The MI light will blink only when the vehicle is in idling or non running condition. In running condition the light would only glow. uu MIL codes are shown by a series of long and short blinks of the FI indicator light as shown below. uu Read long blink as 10 digits and small blink as a single unit digit. uu When there are a number of problems, all the MI codes can be stored and the display will begin starting from the lowest number blink code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open. uu For example, if two problems occurred in the order of 21, 12, the service codes are displayed from the lowest number in the order listed. (12 ---- 21) ---- (12 ---- 21) ---- (repeated).
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Key Learning Points Appropriate Torque Application for Various Engine Components Standard Operating Procedures for Oil Pressure Inspection Removal of Crank Angle Sensor Understanding of Standard Limits and Service Limits for all Engine Components
CHAPTER 6
Engine & Transmission
Bajaj Pulsar 200NS FI Training Notes
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Engine & Transmission
Important Skill Tips Cylinder Head Cover Dismantling
1
3
Always loosen 4 bolts in crisscross pattern. Tightening Torque : 1.0 ~ 1.2Kg.m
4
2
TDC Position for Valve Timing Check piston TDC position, Valve timing & Valve Tappet clearance before dismantling cylinder head. Intake Valve Tappet clearance: 0.05 mm Exhaust valve Tappet clearance: 0.08 mm
Cylinder Head Bolts Loosening Sequence Always loosen cylinder head short bolts (A) first and then loosen cylinder head long bolts (4 nos) in crisscross pattern.
A
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Important Skill Tips Piston Pin Circlip While removing / refitting piston pin circlip (snap ring), cover the crankcase bore with clean lint free cotton cloth to arrest circlip / snap ring falling inside the engine so as to avoid subsequent un- necessary opening of engine.
Primary Gear Holding While loosening ‘Primary Gear Nut’ & ‘Clutch Special Nut’, hold ‘Primary Gear’ and ‘Clutch Housing Gear’ by placing special tool from top.
Piston Ring Fitment 1
•
Piston rings must always be fitted with respect to exhaust mark on the piston
•
First place the bottom oil rail ring with end gap 30º towards left of the exhaust mark in the last groove.
•
Place oil expander ring with butting end downward & end gap facing opposite to the exhaust mark.
•
Now fit top oil rail ring on the expander ring with end gap 30º towards right of the exhaust mark.
•
Fit the second piston ring with ‘Top 2’ mark facing upward and end gap facing opposite to the exhaust mark.
•
Finally fit the first ring with ‘Top 1’ mark upward and end gap facing towards the exhaust mark.
•
Remember fitment of 2nd ring upside down may lead to passing of oil above the piston and ultimately leading to smoky exhaust.
2 3
Front
Top 1 Mark
Top ring
4 3 Top 2 Mark
Exhaust Arrow
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2nd ring
Engine & Transmission
Important Skill Tips Clutch Washer Sequence A : Special nut B : Belleville washer
A
C : Clutch stack D : Plain washer D
F
E : Clutch housing
B
F : Collar bush C
E
Counter Gear Washers a. When fitting spacer on allen bolt ensure that plain side of spacer face outside. b. When fitting ensure that bal. driven & driving gear collar side face inside.
a
b
Cylinder Head Bolts Loosening Sequence Always loosen cylinder head short bolts (A) first and then loosen cylinder head long bolts (4 nos) in crisscross pattern.
Ensure pin (A) & spring (B) is to be collected & carefully on removal of neutral switch.
B A Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Important Skill Tips When dismantling engine ..... Do not insert a sharp object in-between water pump rotor & crank case.
Tab the balancer shaft to remove rotor
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Engine & Transmission
Important Skill Tips Collect guide gear pin on removal of guide gear.
Ensure fitment of spacer when assembly guide gear
Remove input shaft bearing stopper on clutch side for fitment of crank case splitting tool.
Crank case splitting tool
Crank case splitting tool resting on bearing stopper location
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Important Skill Tips Using engine heater heat the crank case clutch side for smooth & easy fitment of crankshaft bearing.
Ensure oil passages are not blocked.
- Ensure that the oil passage going towards orifice is cleared. - The orifice outlet is cleared.
Use grease to fix the springs when assembling. This is to avoid falling of the spring.
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Engine & Transmission
Important Skill Tips When aligning the marks for bal. driven & driver gear always ensure… - Piston is at TDC position. - Primary gear mark is align with crankcase mark.
Balancer driven & driver gear marks are inline with each other.
Close the bore of magnet side crank case using a lint free cloth when fitting the harness guide. This is to avoid bolt falling inside the crank case.
Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Standard Operating Procedure Top Side Dismantling Dismantling - Cover Cylinder Head Remove • 4 Bolts (10mm A/F) Skill Tip : Always loosen cylinder head cover bolts in criss - cross pattern. • Cylinder head cover with gasket (rubber beading type)
Check TDC Position • Align rotor mark Crankcase LH.
w.r.t.
• Check cam sprocket marks from RH side.
Cam Chain Tensioner Remove • One Bolt (A) (10 mm A/F) • ‘O’ Ring • Rotate chain tensioner’s screw in clockwise direction to take plunger backward & lock it . • Two bolts (B) (8mm A/F) M6 • Take out tensioner. • Take out gasket chain tensioner.
Cam Sprocket Using Special tool 37 1042 54 Cam Sprocket holder Remove • Bolt special flanged (12mm A/F) • Cam Sprocket • Spacer cam shaft Skill Tip : Tie chain by soft copper wire.
Bajaj Auto International Business
Engine & Transmission
Standard Operating Procedure Remove • Spark plug RH
Remove • •
Grub screw Sleeve spark plug RH.
Skill Tip : Rotate sleeve before pulling out Cover sleeve portion by cotton cloth & then pull out by plier.
CAUTION Do not pull out sleeve directly by plier otherwise it would get damaged.
Cylinder Head Bolts Remove • 2 Cylinder head short bolt (A) (8 mm A/F) M6 x 120 • 4 Cylinder head long bolts (B) (12 mm A/F) M10 x 147 • Take out cylinder head assembly complete
Skill Tip : Always loosen smaller bolts of cylinder head first & then loosen longer bolts in crisscross pattern to avoid cylinder head warpage.
Cylinder Head Complete Using Special tool 3710DH35 for Rocker Shaft remover Remove • 2 Rocker shaft (A) • 2 Rocker arms (B) • Circlip (C) • Cam Shaft (D)
B A B D C
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Using Valve Spring Compressor Adaptor - 37103108 Remove • Collets (A) • 4 Retainers (B) • 4 Valve Springs (C) • 4 Valve Oil Seals (D) • Valve Spring Seats (E) • 2 Exhaust & 2 Intake Valves (F)
Cylinder Piston Assly. Remove • Gasket Cylinder Head • Chain Guide • 2 Dowels • Cylinder Block
Remove • Gasket cylinder block (A) • 2 Dowels (B)
Using Piston Pin Drift Part No: 37101006 Remove • Snap ring (Circlip) • Piston pin • Piston Assembly
Skill Tip : Cover crankcase bore by clean lint free cloth while dismantling piston circlip / snap ring.
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A B C D E F
Engine & Transmission
Standard Operating Procedure Clutch Side Dismantling Cover Clutch Remove • 11 Bolts (8mm A/F) M6 x 30. • Clutch Cable Bracket • Cover clutch • Clutch cover gasket. • 2 dowels.
Oil Filter Remove • 2 flanged bolts (8mm A/F) M5 x 16 • ‘O’ ring. • Cap oil filter. • Oil filter.
B C D E F
Shaft Clutch Release Remove • Push rod (A). • Shaft clutch release (B) • Spring (C) (lever clutch) • Plain washer (D). • Seal oil (E). • Needle bearing (F).
A
Remove • Clutch lifter bearing.
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Using Primary Gear Holder Special Tool 37004154 & Special Socket for Clutch Nut 3710DJ43 Remove • Nut sprocket drive lock.
Skill Tip : Lock Special tool between the teeth of primary gear & clutch housing gear from top.
• Remove Belleville washer.
Remove • Special nut for clutch
• Belleville washer
Bajaj Auto International Business
Engine & Transmission
Standard Operating Procedure Remove • Clutch stack complete • Plain washer • Timing chain • Clutch housing
Skill Tip : Clutch Nut must be removed by rotating it in clockwise direction.
•
Remove Collar bush.
By using Clutch Dismantling Special Tool Pulsar Remove • 4 bolts (A) (10mm A/F) • 4 springs (B) • Holder Clutch (C) • Clutch Hub (D) • Friction Plates (E) • Steel Plates (F) • Wheel Clutch (G)
C
B
A
D
G F
E
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Removal of Primary Gear Remove • Sprocket crankshaft. • Gear primary drive with wood ruff key. • Spacer crankshaft.
Gear Shift Mechanism Remove • Lever gear change shaft. • Stopper drum bolt ( mm A/F). • Washer (bigger dia). • Inhibitor gear shift lever. • Washer (smaller dia). • Drum stopper spring.
Remove • Allen bolt (A). • Gear shift guide (B). • Spacer (C).
C B
A
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Engine & Transmission
Standard Operating Procedure
LUBRICATION SYSTEM DISMANTLING OIL PUMP Remove • Circlip (A).
• Oil pump drive gear (B).
Remove • 3 flanged bolts (C) (8mm A/F) M6 x 30. • Oil pump body (D). • 2 Dowels (E) • Inner (F) & outer (G) rotor
C D
BA
E G
F
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Remove • Pivot bolt • Chain Guide (Slack Side) • Cam / Timing Chain
Magneto Side Dismantling Dismantling - Cover Magneto Remove • 9 bolts (8mm A/F) M6 X 30 • Magneto Cover Skill Tip : Loosen magneto cover bolts in criss-cross pattern.
Using Rotor Holder H6 0721 00 & Rotor Puller 37 0041 55 Remove • Hex flanged bolt (14 mm A/F) • Belleville washer (A) • Rotor (B) & its key.
Remove • Starter counter gear 1.
• Starter counter gear 2.
Bajaj Auto International Business
Engine & Transmission
Standard Operating Procedure Balancer Drive & Driven Gear Remove • Nut balancer drive lock by using special tool. • Belleville washer. • Balancer drive gear. • Key wood ruff. • Allen bolt. • Special washer. • Gear balancer driven. • Square key.
Neutral Indicator Switch Remove • 2 bolts (A) (8 mm A/F) M5x10 • Bracket harness upper (B). • 1 bolt (C) (8 mm A/F) M5x10 • Bracket harness lower (D). • 2 bolts (E) (8 mm A/F) M5x16 • Neutral indicator switch (F).
A B
C D
E
F
Remove • 2 bolts (8 mm A/F) M5 x 13. • Pick up coil • 1 Bolt (8mm A/F) (B) M5 x 6 • Stopper plate (D). • Stator plate assembly 3 allen bolts (4 mm A/F) M5 x 0.8 x 35
WATER PUMP REMOVAL Remove • 5 bolts (A) (8mm A/F) M6x20 • Water pump cover (B). • ‘O’ ring (C). • Domed nut (D). • Washer (E). • Water pump rotor (F).
E F
D
C B A
Bajaj Pulsar 200NS FI Training Notes
6
Engine & Transmission
Standard Operating Procedure Crankcase Splitting Remove • 4 long bolt (A) (8mm A/F) M6 x 60 • 10 Short Bolt (B) Magneto Side (8mm A/F) M6 x 45
Dismantling - Crankcase By using Crankcase Splitting Special Tool Remove • Remove RH side crankcase. • Crankcase gasket. • 2 dowels (dia 14)
Crankshaft Removal Remove Crankshaft
Crankshaft Removal Remove • Shaft Fork Shift (A) Input & Output (B) with 2 springs. • Gear Change Drum (C) • Washer 1st Gear Output. • Washer below 2nd gear Input • Shift Fork - Input (D) / Output (E). • Input shaft assembly • Output shaft assly.
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E
C B D A
6
Engine & Transmission
SOP: Checking Engine Oil Pressure Purpose of this test : To measure oil pump delivery pressure checked at idle RPM at cylinder head.
uu Instruments required: Pressure gauge with adapter (BAL Part no. 37 0041 93)
uu Fit
uu Put OFF the ignition switch.
uu Re-fit air filter cover and petrol tank and start the engine.
uu Remove Rubber cap
uu Note the oil pressure on the oil pressure gauge at 1400 ± 50 RPM.
Disconnect Oil pressure switch cable connection Oil pressure switch
Note: Follow SOP of air filter removal to connect the oil pressure guage.
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Oil pressure gauge adapter and tighten it fully.
Specification
Unit
1.01
Kg/cm2
14.50
PSI
>1
bar
SOP: Crank Angle Sensor Removal Note: Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Crank Angle Sensor Removal.
uu Remove:
Using rotor holder special tool hold the rotor firmly uu Remove Flange Bolt
Stator plate socket
Washer
uu Remove: 13 bolts
Using rotor puller special tool pull the rotor firmly uu Remove Rotor Key
uu Remove Magneto cover Gasket
uu Remove Bolt Stopper for gear starter clutch
2 dowels Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
SOP: Crank Angle Sensor Removal
uu Remove: 2 bolts for crank angle sensor
Using Bal. gear holder special tool lock the balancer drive and driven gears firmly Bal. lock nut remover Loosen Special nut
uu Remove: Gear starter clutch
uu Remove Allen bolt Special washer uu Skill Tip Inspect for correct alignment marks for the balancer drive and driven gear.
uu Using Bal. gear holder special tool lock the balancer drive and driven gears firmly Loosen Allen bolt
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Skill tip : Ensure that the special washer with the cut mark is fitted facing the balancer driven gear.
uu Remove Special nut Belleville washer
SOP: Crank Angle Sensor Removal
uu Remove: Driver gear
uu Remove: Driver gear
Skill tip : Driver and driven gear with collar should face crankcase side.
uu Remove: Bolt keys (Driver and Driven)
uu Remove: All bolts securing the bracket
uu Remove: 2 bolts Neutral switch
uu Remove: Crank angle sensor with neutral switch
Bajaj Pulsar 200NS FI Training Notes
79
6
Engine & Transmission
Engine Service Data Compression Pressure
Std. Limit
11 ~ 13 kg/cm²
Ser. Limit
9.5 kg/cm²
Clutch Hub Height
Std. Limit Ser. Limit
Intake 0.05 mm -
Exhaust 0.08 mm -
Clutch Stackup Height
Clutch Spring Free Length
Std. Limit
38.4 mm
Ser. Limit
37.3 mm
Crankshaft Runout
Std. Limit
21.0 ~ 21.2 mm
Std. Limit
22.17 ~ 21.57 mm
Std. Limit
0.02 mm
Ser. Limit
21.4 mm
Ser. Limit
20.3 mm
Ser. Limit
-
Steel Plate Thickness
Friction Plate Thickness
Friction Plate Wrap
Std. Limit
1.6 mm
Std. Limit
2.92 ~ 3.08 mm
Std. Limit
0.1 mm
Ser. Limit
-
Ser. Limit
2.72 mm
Ser. Limit
-
Steel Plate Wrap
80
Valve Tappet Clearance
Rocker Arm Shaft Diameter
Cam Sprocket Diameter
Std. Limit
0.1 mm
Std. Limit
9.0 mm
Std. Limit
65.52 mm
Ser. Limit
-
Ser. Limit
-
Ser. Limit
65.22 mm
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Engine Service Data Cam Lobe Height
Camshaft Chain Length
Valve Spring free Length
20 Link Length
21st
1st 2nd
MEASURE THIS LENGTH
Intake Exhaust Std. Limit 30.34 mm 30.29 mm Ser. Limit 30.29 mm 30.24 mm
Std. Limit
129.4 mm
Std. Limit
38.9 mm
Ser. Limit
129.85 mm
Ser. Limit
37.9 mm
Valve Stem Diameter
Intake Exhaust Std. Limit 4.483 mm 4.463 mm Ser. Limit 4.465 mm 4.445 mm Cylinder Head Warp
Valve Stem Bend
Valve Stem to Guide Clearance
Intake
Std. Limit
TIR 0.01 mm
Ser. Limit
TIR 0.015 mm
Cylinder Inside Diameter
Exhaust
Std. Limit 0.01~0.037 mm 0.03~0.057 mm Ser. Limit
0.047 mm
0.067 mm
Cylinder Piston Clearance
10mm 20mm 40mm
Std. Limit
0.05 mm
Ser. Limit
-
Piston Diameter
Group A
71.964 ~ 71.976 mm
Group B
-
72.006 ~ 72.013 mm
Std. Limit
Piston Ring End Gap
Std. Limit
0.03 ~ 0.049 mm
Ser. Limit
0.09 mm
Piston Ring Groove Clearance
Top
Second
Oil Ring
Top
Second
Oil Ring
Std. Limit
0.015~ 0.030 mm
0.030~ 0.050 mm
0.20 ~ 0.70 mm
Std. Limit
0.020~ 0.055 mm
0.02~ 0.060 mm
0.035 ~ 0.110 mm
Ser. Limit
-
-
-
Ser. Limit
-
-
-
Bajaj Pulsar 200NS FI Training Notes
81
6
Engine & Transmission
Engine Service Data Shaft Fork Shift O.D
Gear Shift Drum Groove Width
Std. Limit 11.966 ~ 11.984 mm
Std. Limit
12.0 mm
Std. Limit
4.55 ~ 4.70 mm
Ser. Limit
Ser. Limit
-
Ser. Limit
4.75 mm
-
Gear Shift Fork Guide Pin Diameter
Std. Limit
4.45 ~ 4.49 mm
Ser. Limit
4.4 mm
Notes
82
Fork Shift I.D
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Engine Tightening Torque Spark Plug
Oil Strainer Cap (18 mm A/F)
Cap Oil Filter Cover Bolts
Tightening torque - 1.3 ~ 1.5 kgm
Tightening torque - 0.8 ~ 1.0 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Chain Tensioner Mounting Bolts
Cylinder Head Cover Bolts
Output Sprocket Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Stator Plate Mtg. Bolts
Eng. Mtg. Rr. Upper/Lower Bolts
Clutch Cover Bolts
Tightening torque - 0.7 ~ 0.8 kgm
Tightening torque - 2.5 ~ 3.0 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Oil Pump Mounting Bolts
Coolant Temperature Sensor
Magneto Cover Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.2 ~ 1.4 kgm
Tightening torque - 1.0 ~ 1.2 kgm
Primary Gear Nut
Cam Shaft Sprocket Bolt
Nut Securing Clutch Assly.
Tightening torque - 5.9 ~ 6.1 kgm
Tightening torque - 2.5 kgm
Tightening torque - 7.0~7.1 kgm Bajaj Pulsar 200NS FI Training Notes
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6
Engine & Transmission
Engine Tightening Torque
84
Magneto Rotor Mounting Nut
Stator Motor Mounting Nut
Inhibitor Nut
Tightening torque - 5.9~6.1 kgm
Tightening torque - 1.0~1.2 kgm
Tightening torque - 1.0~1.2 kgm
Guide Gear Allen Bolt
Clutch Holder Bolts
LH/RH Engine Stay Upper Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 1.0 ~ 1.1 kgm
Tightening torque - 2.5 ~ 2.7 kgm
LH/RH Engine Stay Lower Bolts
Silencer Joining Nut
Injector Mounting Bolt
Tightening torque - 2.5 ~ 3.0 kgm
Tightening torque - 1.0 ~ 1.1 kgm
Tightening torque - 0.8 ~ 1.0 kgm
Oil Pressure Sensor Nut
Bal. Driver Gear Mounting
Bal. Driven Gear Mounting (Allen)
Tightening torque - 1.1 ~ 1.5 kgm
Tightening torque - 5.9 ~ 6.0 kgm
Tightening torque - 2.2 ~ 2.5 kgm
Cylinder Head Small Bolts
Cylinder Head Big Bolts
Tightening torque - 1.0 ~ 1.2 kgm
Tightening torque - 4.4 ~ 4.6 kgm
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Do’s & Don’ts Dos
uu Always replace gasket ‘O’ rings of engine If dismantled.
Don’ts
uu Don’t reuse ‘O’ rings, gasket, Oil seals, Circlip locks as they use their strength and properties, once they are opened.
Dos
uu Whenever installing Spark Plug, first screw by hand and then tighten to specified torque.
Don’ts
uu Don’t adjust spark plug electrode gap by hacksaw blade or with judgment of eye otherwise it will affect the engine performance.
Dos
uu Always below light pressure compressed air from inside while cleaning ‘Oil strainer’ that is opposite to the direction of flow of oil.
Don’ts
uu Don’t reuse torn ‘Oil strainer’ otherwise it will affect lubrication system of engine and subsequently would lead to seizure.
Bajaj Pulsar 200NS FI Training Notes
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7
Frame & Suspension
Key Learning Points Appropriate Torque Application for Various Frame Components Understanding of Standard Limits and Service Limits for all Frame Components
CHAPTER 7
Frame & Suspension Service Limits Tightening Torque Dismantling & Assembling Front Fork Front Disc Brake
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Frame Service Data Disc Pad Thickness
Rear Sprocket Warp
Axle Wheel Run Out
Std. Limit
Fr-7.4 mm
Rr-7.3 mm
Std. Limit
TRI 0.4 mm or Less
Std. Limit
TIR 1.0 mm or Less
Ser. Limit
Fr-3.8 mm
Rr-2.0 mm
Ser. Limit
TIR 0.5 mm
Ser. Limit
TIR 2.0 mm
Tyre Tread Depth
Front Fork Oil Grade & Capacity Grade : SAE 10W20 Bajaj Genuine Fork Oil
F o r k O il L e v el
Radial Wheel Run Out
Std. Limit
TIR 0.8 mm or Less
Ser. Limit
TIR 2.0 mm
Std. Limit
Front:5.0 mm
Ser. Limit
Upto TWI 1.0
Drive Chain Slack
Quantity Per Fork Leg : O/H: 320 ml Drain & Refill: 295+2.5ml
Rear:6.0 mm
Axle Run Out
Drive Chain Length 19 Link Length
1st 2nd 100 mm
19th
MEASURE THIS LENGTH
Std. Limit
15 ~ 25 mm
Std. Limit
TIR 1.0 mm or Less
Std. Limit
301.6 ~ 302.1 (19 link)
Ser. Limit
30 ~ 40 mm
Ser. Limit
TIR 2.0 mm
Ser. Limit
307
Notes
Bajaj Pulsar 200NS FI Training Notes
87
7
Frame & Suspension
Frame Tightening Torque
88
Front Axle Nut
Rear Axle Nut
Swing Arm Shaft
Tightening torque 9.0 ~ 10.0 kgm
Tightening torque 10.0 ~ 12.0 kgm
Tightening torque 13.0 ~ 15.0 kgm
Rear Sprocket Mounting Nut
Handle Bar Holder Bolts
Fork Center Nut
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 1.8 ~ 2.0 kgm
Tightening torque 4.8 ~ 5.2 kgm
Steering Stem Nut Slotted
Fork Upper Bracket Bolts
Fork Under Bracket Bolts
Tightening torque 0.5 kgm
Tightening torque 1.8 ~ 2.0 kgm
Tightening torque 2.5 ~ 3.0 kgm
RSA Mounting Bolt (Upper)
RSA Mounting Bolt (Lower)
Disc Mounting Bolts (Front)
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 3.2 ~ 3.8 kgm
Tightening torque 2.6 ~ 3.2 kgm
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Frame Tightening Torque Disc Mounting Bolts (Rear)
Front Caliper Mounting Bolt
Front Fender Mounting
Tightening torque 2.6 ~ 3.2 kgm
Tightening torque 4.0 ~ 5.0 kgm
Tightening torque 0.8 ~ 1.0 kgm
Brace Fender Mounting Bolt
Rear Brake Pedal Mtg. Bolt
Bracket Rear Number Plate
Tightening torque 2.0 ~ 2.2 kgm
Tightening torque 2.0 ~ 2.2 kgm
Tightening torque 1.8 ~ 2.2 kgm
Side Stand Mounting Bolt
Handlebar End Weight Bolt
Tank Mounting Bolt
Tightening torque 2.5 ~ 3.0 kgm
Tightening torque 0.8 ~ 1.2 kgm
Tightening torque 1.8 ~ 2.2 kgm
LH & RH Stay Bolts
Tightening torque 1.6 ~ 1.8 kgm Bajaj Pulsar 200NS FI Training Notes
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7
Frame & Suspension
Dismantling & Assembling Front Fork Front Fork Overhaul
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•
Align overhead chain pulley structure as shown in photograph.
•
Insert belt below headlight fairing structure as shown in photograph.
•
Hook the belt as shown in photograph.
•
Lift the vehicle by pulling chain.
•
Remove caliper mounting bolts (2 nos) with 12 mm spanner & front wheel speed sensor cable mounting bolt with 10 mm spanner.
•
Take out caliper assembly.
•
Remove front brake hose & speed sensor cable mounting clamp bolts with 8 mm spanner.
•
Remove front axle nut with 22 mm spanner holding axle head with 17 mm spanner.
•
Take out front axle & front wheel.
Frame & Suspension
Dismantling & Assembling Front Fork •
Remove front fender mounting bolts (4 nos) with 12 mm spanner & side bolts (2 nos) with 5 mm allen key
•
Take out front fender.
•
Ensure availability of 2 nos spacers
2 nos •
Loosen upper bracket & side holder mounting bolts (3 nos) with 6 mm allen key.
•
Loosen under bracket assembly mounting bolt with 17 mm spanner holding fork leg assembly with hand to prevent falling of fork leg.
•
Take out fork leg assembly from vehicle.
•
Remove fork inner pipe cap bolt with 5 mm allen key & take out fork inner pipe cap bolt.
•
Insert fork inner pipe holder tool in fork inner pipe & tighten fork inner pipe holder tool with 6 mm allen key.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Dismantling & Assembling Front Fork •
Remove fork top bolt with 14 mm allen key & take out fork top bolt.
•
Take out - Spacer tube - Washer & - Fork Main spring.
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•
Take out fork oil in measuring jar.
•
Take out dust seal & oil seal lock.
•
Using cylinder piston holder (Hexagonal shaped), remove fork outer tube bottom bolt with copper washer by 6 mm allen key.
•
Take out cylinder piston holder along with piston.
•
Insert fork oil seal & antifriction bush extraction tool through fork inner pipe as shown in photograph.
•
Using fork inner pipe holder tool, rotate oil seal extractor tool handle for removal of fork inner pipe along with oil seal & anti-friction bush from
Frame & Suspension
Dismantling & Assembling Front Fork •
Take out oil seal extraction tool from fork inner pipe.
•
Take out - Oil seal - Washer - Anti-friction bush & - Cap oil lock.
Clean Fork Outer tube & Inner Pipe as given below before assembly. •
Clean the fork inner pipe & outer tube with
•
Pour diesel in fork inner pipe by closing other end with hand.
•
After pouring diesel, close both ends of fork inner pipe with hands & shake inner pipe.
•
Pour diesel, in fork outer tube by closing other end with hard.
•
After pouring diesel, close both ends of fork outer tube with hands & shake outer tube.
•
Nylon brush can be used for removing burr / muck particles for inner / outer tube.
•
Blow compressed air through from inner pipe & fork outer tubes.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Dismantling & Assembling Front Fork •
Hold cylinder piston along with spring on cylinder piston holder as shown in photograph.
•
Assemble fork inner pipe, cap oil lock & fork outer tube.
• Insert anti-friction bush & washer.
•
Insert the oil seal & fitment oil seal using oil seal fitment
Note :
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•
Never reuse the fork oil seal.
•
Always replace the front fork oil seal along with dust seal of same manufacturer.
•
Front fork oil seal fitment direction should be as shown in photograph.
•
Always replace oil seal fitment punch if nylon sleeve found damaged.
Oil Seal Fitment
Replace if , Nylon sleeve found damaged
Frame & Suspension
Dismantling & Assembling Front Fork •
Fit oil seal lock & dust seal.
•
Fit fork main spring & washer.
•
Fill the correct quantity (285 ± 5 ml) of recommended fork oil (SAE 10W20).
•
Insert spacer tube.
•
Fit front fork top bolt with 14 mm allen key.
•
Fit fork inner pipe cap & tighten bolt with 5 mm allen key.
•
Refit the fork leg on vehicle.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake Caliper Anchor Piston Seal & Dust Seal Replacement
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•
Clean Caliper assembly thoroughly by low pressure water spray before opening caliper bleeding screw.
•
Remove bleeder nut rubber cap.
•
Drain the brake fluid from caliper assembly by loosening air bleeder nut with 8 mm spanner & using transparent PUC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking
•
Remove front brake hose and wheel speed sensor cable mounting bracket bolt with 8 mm spanner.
•
Remove front brake hose banjo bolt with 14 mm spanner.
•
Remove caliper mounting bolts (2 nos) with 12 mm spanner & take out caliper assembly.
•
Remove brake pedal mounting pin lock clips (2 nos) with plier.
•
Take out brake pad mounting pin & brake pads.
Frame & Suspension
Front Disc Brake •
Remove caliper anchor pin holder bracket.
•
Remove rubber parts from caliper body.
•
Remove brake pad spring.
•
Remove bleeder nut & it's cap.
•
Remove caliper pistons by applying low compressed pressurized air (> 2 bar) through banjo bolt hole. Note :- Don't apply high compressed air pressure > 2 bar. This could cause piston to fly out from caliper body causing damaged to it & any one in the vicinity.
•
Remove dust seals & oil seals.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
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•
Clean caliper body by diesel / kerosine.
•
Dry caliper body by applying low pressure compressed air.
•
Clean the anchor pin and holder bracket thoroughly.
•
Smear silicon grease on anchor pins evenly.
•
Fit new dust seal and oil seal in caliper body.
•
Smear silicon grease on piston OD & rubber seals.
•
Fit caliper pistons.
Frame & Suspension
Front Disc Brake •
Fit all rubber parts.
•
Fit anchor pin holder bracket.
•
Fit brake pad spring.
•
Clean brake pads by sand / polish paper.
•
Fit brake pad, brake pad mounting pin & brake pad mounting pin lock.
•
Fit bleeder nut along with rubber cap with 8 mm spanner.
•
Fit caliper body on fork location Pre-fit caliper mounting bolt & tighten it to recommended torque by torque wrench.
•
Fit brake hose banjo bolt. Note :- Always replace banjo bolt / copper washer whenever opened with new one.
•
Tighten front brake hose speed sensor cable mounting clamp bolt with 8
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
Bajaj Auto International Business
• •
Pre-Fit air bleeder nut with 8 mm spanner.
•
Remove master cylinder cover mounting screws (2 nos) with phillips head screw driver & take out master cylinder cover.
•
Remove PVC cap & rubber diaphragm.
•
Fill the master cylinder reservoir by recommended brake fluid (DOT 4)
•
Fit a proper tube which fits slightly tight on bleeder screw nipple.
•
Insert 8 mm ring spanner through pipe fitted on bleeder screw nipple.
•
Connect tube to siphon pumps pipe and loosen bleeder nut by ring spanner.
Frame & Suspension
Front Disc Brake •
• • • •
Press bellow siphon pup in its valve open position then close the valve of pump & release the bellow, simultaneously press the brake lever to take out air trapped in the system. Carry out the same procedure until entire air trapped in the system gets removed. During this process continuously monitor & maintain the brake fluid level in master cylinder reservoir slightly above MIN mark. Ensure front wheel is rotating freely. Tighten bleeder nut. Route front wheel speed sensor cable inside bleeder rubber cap
Master Cylinder Piston Kitt Replacement •
Clean master cylinder thoroughly by keeping nozzle in spray mode before opening master cylinder top cover.
•
Remove bleeder nut rubber cap.
•
Drain the brake fluid from caliper assembly by loosening air bleeder screw & using transparent PVC tube which will avoid spillage of brake fluid on caliper body / disc pads & also powder coating peel off / inefficient braking.
•
Remove front brake switch terminal connectors.
•
Remove front brake lever mounting nut with 10 mm spanner holding with phillips head screw driver
•
Take out front brake lever.
•
Remove master cylinder reservoir cover, PVC cap & rubber diaphragm.
•
Remove actuating shaft.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Front Disc Brake
Bajaj Auto International Business
•
Remove front brake hose mounting bolt with 14 mm spanner from master cylinder end.
•
Take out front brake hose.
•
Remove master cylinder mounting bolts (2 nos) with 8 mm spanner & take out master cylinder.
•
Remove actuating shaft rubber boot.
•
Remove master cylinder piston air clip.
•
Insert blunt tipped screw driver from banjo bolt side and push piston towards brake lever side. ensure master cylinder does not get damaged due to screw driver
•
Take out piston assembly from brake lever side.
•
Clean master cylinder with brake fluid.
Frame & Suspension
Front Disc Brake •
Dry master cylinder with low compressed air pressure (> 2 bar)
•
Smear silicon grease on new piston seals of master piston kit.
•
Fit new master cylinder piston inside master cylinder from brake lever side.
•
Fit air clip actuating shaft rubber boot and actuating shaft.
•
Fit master cylinder on vehicle.
•
Fit brake hose replace copper washer with new one.
•
Fit front brake lever.
•
Fill brake fluid & carry out air bleeding.
•
Fit master cylinder diaphragm. PVC cap and cover.
Bajaj Pulsar 200NS FI Training Notes
7
Frame & Suspension
Do’s & Don’ts Dos uu Replace front fork oil with SAE 10W20 grade fork oil.
Don’ts
uu Don’t add any other mineral based oil to front fork.
Dos uu Maintain correct tyre pressure as per specification.
Don’ts
uu Don’t over / under inflate the tyres.
Dismantling & Assembling Front Fork** Front Disc Brake** **Similar to the Pulsar 200 NS Training Notes. For more details refer Pulsar 200 NS Training Notes (Doc No. 71111472).
90
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Key Learning Points Understanding of VRLA Battery Charger VRLA Battery Charging Process Checking and Inspection of all Electrical Components Standard Operating Procedures for Headlight Assembly Dismantling Removal of Sensors and Actuators
CHAPTER 8
Electricals VRLA Battery Initial Filling VRLA Battery Charger & its Charging SOP Dos and Don’ts for RLA Battery Electrical Checking Procedure Electrical Circuit Diagrams
Bajaj Pulsar 200NS FI Training Notes
91
8
Electrical
VRLA Battery Initial Filling Filling Procedures
Step 1: Get the battery ready Place the battery on a flat leveled and preferably on a insulated surface. Remove the filler port seal of the battery. Filler port seal
Step 2: Get the electrolyte ready Remove electrolyte container from the packing. Remove the sealing cap plug strip. Keep the sealing cap plug strip aside as this is to be used as battery sealing plug strip later.
Note: Do not puncture the seals manually.
Plug cap strip
Seal
Step 3: Fill the battery Hold the electrolyte container upside down. Place the container upright on battery. Match the 6 seals with the respective filler ports.
Note: Ensure the container is upright and not tilled. If tilled the electrolyte might fail to flow. Now force the container down until seals get pierced, and electrolyte flows into the battery.
Step 4: Check the electrolyte flow Make sure that air bubbles are visible in the electrolyte and which is seen in all the 6 tubes of the container. Leave the container on the battery as it is for 30 minutes.
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VRLA Battery Initial Filling Step 5: Take away the bottles Be sure that the entire electrolyte has flown down inside the battery. Tap the bottom of the container and gently remove the empty container.
Step 6: Attach the sealing cap Fit the sealing cap plug strip tightly on the filler ports of the battery. Ensure by pressing firmly that the cap has become flush with the top surface of battery.
Step 7: Charge the battery Charge the battery on BAL recommended VRLA battery charger as per std. SOP.
Caution
Never use conducting materials like screw drivers which can produce the spark near battery terminals. Do not add any additional electrolyte.
Bajaj Pulsar 200NS FI Training Notes
93
8
Electrical
VRLA Battery Initial Filling Metafab VRLA Battery Charger Indication Display 2
3
4
5
6
7
8
9
10
11
1 12
1.
On / off Switch
2.
New battery / use battery switch
3.
2 Amp / 4 Amp current selection Switch
4.
Main power supply indication light (Green)
5.
Open circuit indication light (Red)
6.
Bad battery indication light (Red)
7.
Reverse polarity indication light (Red
8.
Boost indication light (White)
9.
New battery indication light (Yellow)
10. Use battery indication light (Blue 11. Charged indication light (Green) 12. -ve terminal (Black) 13. +ve terminal (Red)
94
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13
VRLA Battery Charger & its Charging SOP Battery Charging Procedure for Metafab make VRLA Battery Charger
Charging SOP
Refer Charger Photo
Remove battery from vehicle and Clean battery thoroughly.
-
Connect battery charger to 230 V AC single phase power supply and switch on the button of main supply.
-
"Connect battery charger leads to battery terminals. Red lead to +ve terminal and Black lead to-ve terminal."
13
12
Switch on the battery charger main switch. Green LED will glow.
4
If Red LED glows it indicates reverse polarity connection.
7
"Select charging current 2 Amps or 4 Amps.
3
(2 Amps for 3 Ah / 4 Ah / 5 Ah VRLA batteries, 4 Amps for 6 Ah / 8 Ah / 10 Ah VRLA batteries)."
Select and press the charging switch for new battery or use battery (Green and Blue LED glow for new and use battery)
2
If Red LED blinks it indicates open circuit situation.
5
Battery charger detects the battery voltage. If it is less than 5 volts it will switch over to Boost charging mode White LED below the “Boost” will glow
8
"Battery charger detects battery voltage after every 3 minutes. If voltage increases above 5 volts it switches over to selected charging mode ie NEW/ USED."
10
9
Charging duration in this mode is 30 minutes. If the battery voltage is less than 5 volts after 30 minutes a Red LED indicating a bad battery will glow. This indicates the battery is not suitable for charging.
6
After completion of battery charging a Green LED will glow to indicate completion of charging.
11
"If battery charger is switches to NEW/USED charging mode, the battery would undergo charging for 5 to 14 hours depending on battery condition."
10
4
-
Switch off the main switch and disconnect the battery from the charger
-
Reconnect the battery terminals on vehicle.
-
Apply petroleum jelly to battery terminals.
-
Note: During charging if the battery is disconnected, an audio indicator will beep for 2 minutes with a Red LED blinking to indicate open circuit situation. Bajaj Pulsar 200NS FI Training Notes
95
8
Electrical
Checking Procedure Front & Rear Brake Light Switch Measuring & Testing Equipment : Multimeter
Brown
Blue
Continuity check by multimeter
Lever Pressed
Continuity is shown
Lever Released
No continuity
uu SOP : Turn ‘ON’ the ignition switch. The brake light should glow brightly when the front brake lever / rear brake pedal is pressed. If it does not, check the front brake switch. Wire connection Meter +ve
Meter -ve
Input voltage (Side stand position-any)
N.A.
Red/
Yellow/ Black
5 VDC
Output voltage (Side stand position-OFF)
Magnet in front of side stand switch
Pink
Yellow/ Black
2~2.2 VDC
Side stand position-ON
Magnet away from side stand switch
Pink
Yellow/ Black
5.0 VDC
Connect multimeter as shown in table given below.
Y/B
R/L
2
Set multimeter to 20 VDC.
Pi
4
Switch ON ignition switch and kill switch.
2
uu SOP :
3
Blue
Std. Reading
4
1
2
Magnet Position
1
Parameter
3
Measuring & Testing Equipment : Multimeter
Sr. No.
1
Side Stand Switch
Pi
Y
R
Pi
Y
R
SIDE_STAND_SWITCH
Clutch Switch Meter Range
OFF – Clutch lever not pressed ON – Clutch lever pressed
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Yellow / Green
Black / Yellow
Checking Procedure Ignition Switch
Measuring & Testing Equipment : Multimeter
Meter Range
Continuity Mode
Wire Connections
Continuity Check
Meter +ve Meter –ve
OFF – No Continuity
Brown
White wire
ON – Continuity
uu SOP : Switch OFF Ignition key. Disconnect Ignition switch’s coupler. Check continuity between wires in ‘ON’ and ‘OFF’ position. uu Standard Value : Beep Sound and Continuity in ‘ON’ position. No continuity in ‘OFF’ position..
Engine Kill Switch
Measuring & Testing Equipment : Multimeter
Meter Range
Wire Connections
Meter Continuity +ve Mode Gray / Red
Meter –ve
Condition
Result
Engine OFF condition
Continuity is shown
Brown / Engine ON No Blue condition Continuity
uu SOP : Put ignition switch OFF. Put kill switch OFF. Set multimeter at continuity range. Connect multimeter as shown in the table given below.
Light Control Module (LCM)
Sr. No. Parameter
Wire Connections Meter +ve
Meter –ve
Std. Reading
1
Violet
Yellow/ Black
00 VDC
Red/ Engine is running - H/L Black switch ON.
Yellow/ Black
13.5 VDC
Measuring & Testing Equipment : Multimeter
2
Engine is OFF (Pass light OFF)
This unit is a combination of head light controller and flasher unit. It switches on the head light only when engine is running. Bajaj Pulsar 200NS FI Training Notes
97
8
Electrical
Checking Procedure uu SOP : Switch ON ignition switch and kill switch.
2
1
V
W
V
W
B/Y
PIN1
PIN2
L/W O
PIN3
PIN4
Br
1
Set multimeter to 20 VDC. Connect multimeter as shown in table given below.
Br
V
2
Light Control Module (LCM)
LIGHT_CONTROL_MODULE
DC Charging Voltage Measurement
Measuring & Testing Equipment : Multimeter & Battery Load Tester Meter Range
Wire Connections Meter +ve Meter –ve
20 V DC Battery +ve terminal
Battery +ve terminal
Specified at 4500 RPM 14.5 V + 0.2 V DC
uu SOP : SOP : Put Ignition switch ON. Put Kill switch ON. Set multimeter at 20 VDC. Connect multimeter as shown. Start engine and run at 4500 RPM. Note : 1. Before conducting this test ensure battery voltage is 13.1 ± 0.1 Volts (Fully charged battery) 2. For DC voltage measurement connect multimeter in parallel with circuit.
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Bajaj Auto International Business
Checking Procedure Stator Plate (Battery Charging Coil) Measuring & Testing Equipment : Multimeter
This is 3 phase starter winding (oil dipped type) Sr.No.
Y2 Y1
Y3
Meter Range
Wire Connections Meter +ve
Meter –ve
Y2
Y2
1
200 Ohm Y1
3
Y3
2
uu SOP : Disconnect magneto coupler.
Y3
Std. esistance Value
1 Ohm
Y1
B/Y W/R
Set multimeter at 200 Ohm range. Connect multimeter as shown and note reading.
Y
Y
Y
Starter Motor Current Drawn
Measuring & Testing Equipment : Clamp Meter Meter Range 200 DC A
Conditions
Standard Value
Encircle clamp meter transformer jaws around thick Red wire of starter motor
40~45 Ampere (Spark plug caps removed)
uu SOP : Disconnect all 3 spark plug caps Switch ‘ON’ Ignition switch and kill switch. Select range and set clamp meter zero reading. Encircle red input wire of starter motor into the clamp meter jaws. Crank the engine for 3 seconds . Observe the cranking current displayed on clamp meter.
Bajaj Pulsar 200NS FI Training Notes
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8
Electrical
Checking Procedure Starter Motor Armature Inspection (For Each Segment Checking)
Measuring & Testing Equipment : Multimeter & Battery Load Tester
Meter Range
Continuity Mod
Wire Connections
Continuity Check
Meter +ve
Meter –ve No continuity to be shown Commutator Shaft segment
uu SOP : Dismantle starter motor and take out the Armature. Check the continuity between starter motor shaft and each segment on Commutator. Replace armature if continuity is shown. Measuring & Testing Equipment : Multimeter Meter Range
Wire Connections
Continuity Meter +ve Mode Any Commutator on segment
Meter –ve
Continuity Check
Adjacent segment on Commutator
Continuity is shown
uu SOP : Dismantle starter motor and take out armature Check continuity between each pair of adjacent segments on Commutator. Replace armature if ‘No’ continuity is shown between any two adjacent pair of Commutator segments.
Steeper Motor
Measuring & Testing Equipment : Multimeter P1
P2
P3
P4
Sr. No.
Wire Connections
1
Meter +ve
Meter -ve
Pin no. 1
Pin no. 4
51 Ω
Pin no. 2
Pin no. 3
51 Ω
2
Standard Value
uu SOP : Ensure ignition switch and kill switch is OFF. Remove harness side coupler. Set multimeter on 200 Ohm range and connect as shown in above table.
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Bajaj Auto International Business
Checking Procedure
2
Gr/W G/R
3
G/Y L/B
4
Measuring & Testing Equipment : Multimeter
uu SOP : Ensure ignition switch and kill switch is OFF. Remove harness side coupler. Set multimeter on 200 Ohm range and connect as shown.
1
Steeper Motor
STEEPER_MOTOR
Crank Angle Sensor & Neutral Switch Measuring & Testing Equipment : Multimeter
Sr. Component No.
1 2
Meter range
Wire Connections
Crank angle Resistance sensor 2 K Ohms Neutral switch
uu SOP : Switch OFF ignition switch and kill switch. Connect multimeter as shown.
Continuity
Meter +ve
White/ Red Light Green
Meter -ve
Black/ Yellow Black/
Yellow
Standard Value
Results
365 + 20 Ohms
OK
Beep sound
OK
No Beep sound
Defective
B/Y W/R
Y
Y
Y
Starter Relay Coil
Measuring & Testing Equipment : Multimeter Meter Range 200 Ohms
Wire Connections Meter +ve
Meter Range
Meter -ve
Starter relay Starter coil Redrelay coil Yellow wire Black wire
3.51 ~ 4.29 Ohms
Bajaj Pulsar 200NS FI Training Notes
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8
Electrical
Checking Procedure Starter Relay Coil
R
2
1 1
B/Y
2
uu SOP : Switch OFF engine. Disconnect coupler from Relay. Connect multimeter to Starter Relay coil terminals. Check resistance.
R/Y
R/Y
B
R/Y
B
1
1
R
STARTER RELAY
Relay Coil
Measuring & Testing Equipment : Multimeter
Meter Range
200 Ohms
Wire Connections Meter +ve
Meter -ve
Relay coil terminal 1
Relay coil terminal 2
Continuity Check
89 ~110 Ohms
uu SOP : Switch OFF engine. Remove relay from coupler. Connect multimeter to relay coil terminals. Check resistance.
Fuel Pump
Measuring & Testing Equipment : Multimeter
Meter Range
200 Ohms
Note: 1. Battery should be fully charged. 2. Fuse and ignition switch should be OK. 3. Audible sound will be heard which will confirm fuel pump is working. 4. Check main relay first if fuel pump is not working.
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Bajaj Auto International Business
B/Y O/L
1 2
Wire Connections Meter +ve
Meter -ve
Orange/ Blue
Black/ Yellow
1 2
B/Y
B/Y
O/L
O/L
Continuity Check 2.1 Ohms
Checking Procedure Injector
Measuring & Testing Equipment : Multimeter Sr. No. 1
Parameter
Meter Range
Resistance
200 Ohms
Wire Connections Meter +ve Meter -ve Pin no. 1
Pin no. 2
Standard Reading 12 + 6 Ohms @ 20⁰C
FUEL_INJECTOR uu SOP : Remove petrol tank cover and petrol tank. Remove air filter cover along with paper filter element. Disconnect the injector coupler. Connect multimeter to Pin 1 and Pin 2 of injector as shown.
FUEL
1
2
INJECTOR
B/W
Br/W
Fuel Gauge – Tank Unit
Measuring & Testing Equipment : Multimeter Meter Range
200 Ohms
Standard Valve:
Wire Connections Meter +ve
Meter -ve
White/ Yellow
Black/ Yellow
Resistance Bars on (+ 2 Ohms) Speedometer
Continuity Check
As per chart
Resistance (+ 2 Ohms)
Bars on Speedometer
12
8
83
2
32
7
93
1
42
6
110
0
52
5
63
4
73
3 Bajaj Pulsar 200NS FI Training Notes
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8
Electrical
Checking Procedure Fuel Gauge – Tank Unit
Note:
If display in speedo console is not proper then please check following 1. Battery Voltage
Y/B G/R
1
1
2
2
B/Y
B/Y
W/Y
W/Y
2. Speedometer coupler and fuel gauge tank unit coupler connection is firm.
Capacitor
Measuring & Testing Equipment : Nil
uu Checking method : Touch +ve wire of capacitor to earth. Spark will occur. This indicates capacitor is OK. Note: Capacitor is very important for ECU functioning, so ensure capacitor coupler is always firmly connected.
Engine Oil Pressure Sensor
Measuring & Testing Equipment : Multimeter Meter Range
Wire Connections
Continuity Mode
Meter -ve
Brown-Blue
Black/ Yellow
Br/Pi
1
uu SOP : If engine oil pressure is OK (i.e if 0.9 to 1.1 bar pressure is shown on pressure gauge) then continuity will be shown on multimeter.
Meter +ve
Note: Oil pressure icon will blink if engine RPM greater than 3500 rpm, Coolant temperature in the range of 50 0C to 60 0C and oil pressure less than 0.9 bar for time greater than 20 seconds are meet.
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Bajaj Auto International Business
OIL_PREESURE_SENSOR
Continuity Check
Continuity will be shown
Checking Procedure Roll Over Sensor
Measuring & Testing Equipment : Multimeter Sr. No.
Parameter
1
Input voltage
2
uu SOP : Switch ON ignition switch and kill switch. Set multimeter to 20 VDC. Connect multimeter as shown.
Output voltage
Br/G Y/B R/L
Vehicle position
Wire Connections
NA
Red/Blue Yellow/ 5 VDC Black
Normal position
Tilled position (> 60⁰)
Meter +ve
Meter -ve
Brown/ Green
Yellow/ 4.8~4.9 Black VDC
Brown/ Green
Yellow/ 2~2.2 VDC Black
Br/G
Br/G
B/Y
B/Y
1
1
2
2
3
3 Gr
4
4
Standard Reading
ROLL_OVER_
Gr
Coolant Temperature Sensor
Measuring & Testing Equipment : Multimeter
Meter Range
Wire Connections Meter +ve
2K Ohms
Coupler Pin 1
Standard Reading Meter -ve
Coupler Pin 2
Temperature in Degree Centigrade
Resistance in Ohms
50
0.80 K Ohms
25
2 K Ohms
70
0.42 K Ohms
100 120 150
0.18 K Ohms
0.110 K Ohms 57 Ohms
Bajaj Pulsar 200NS FI Training Notes
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8
Electrical
Checking Procedure Pi/L
B/W
1
uu SOP : Ensure engine is off. Remove coupler of coolant temperature sensor using 18 mm tube spanner. Connect multimeter as shown and check resistance value.
2
Coolant Temperature Sensor
ENGINE_TEMP_SENSOR
Oxygen (Lambda) Sensor
Pin no. 2
2
Pin no. 3
Pin no. 4
uu SOP : Ensure ignition switch is OFF. Remove the harness side lambda sensor coupler. Set multimeter on 200 Ohm range and connect as per table.
9 + 1 Ohm @ 25⁰C Meter displays 1 @ 25⁰C (open circuit)
W
W
Gr
B
W
W
Gr
B
4
Pin no. 1
3
1
Continuity will be shown
4
Meter -ve
3
Meter +ve
2
Continuity Mode
Continuity Check
1
Wire Connections
2
Sr. No.
1
Measuring & Testing Equipment : Multimeter
Br/W L/R
B/G
L/Y
T MAP Sensor
Measuring & Testing Equipment : Multimeter
Sr. No.
Parameter
1 2 3
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Bajaj Auto International Business
Meter Range
Wire Connections
Resistance
20 K Ohms
Pin no. 1
Input voltage
20 VDC
Red/Blue
20 VDC
White/ Red
Output voltage
Meter +ve Meter -ve
Standard Reading
Pin no. 2 + 0.5 K 2 Ohms @ 25⁰C
Yellow/ 5 VDC Black
Yellow/ 3.8 + 0.65 Black VDC
Checking Procedure T MAP Sensor
G
R/L W/O
P4 P3
Input Voltage Checking
P2 P1
1 2
U
uu SOP : Remove petrol tank and air filter cover along with paper filter element. Connect multimeter as shown in table.
Y/B
TMAP_SENSOR
P
Measuring & Testing Equipment : Multimeter
3 4
Note: For resistance checking remove coupler of TMAP sensor and connect the multimeter prob to Pin 1 and Pin 2 as shown.
Output Voltage Checking Note: For input or output voltage checking connect coupler of TMAP sensor.
Spark Plug Cap
uu SOP : Remove spark plug cap from HT coil cable. Set multimeter on 2 K Ohms range. Connect multimeter probes as shown and measure the value. Standard value, 1 K Ohm ± 150 Ohm.
Bajaj Pulsar 200NS FI Training Notes
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Electrical
Checking Procedure CAN Termination Unit
This unit is provided to have uninterrupted communication between diagnostic tool and ECU Note : 1. No checking method using multimeter is recommended for checking this unit 2. Checking by replacement method only.
Termination Unit
Function: It has transil diode for filtration of voltage surge / ripple in mains supply line there by protect ECU from voltage fluctuations. It also consist two diodes that are used for clutch switch and neutral switch circuit. These diodes are called reverse protection diodes. Reverse protection diodes provide correct neutral indication in speedo console. Symptoms of malfunctioning : Glowing of neutral indication in speedo console when vehicle is in gear and on pressing of clutch lever. Note : 1. No checking method using multimeter is recommended for checking this unit 2. Checking by replacement method only.
Radiator Fan Motor
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Bajaj Auto International Business
uu SOP : Disconnect coupler of fan motor. Connect external 12 V DC supply to disconnected coupler of fan motor. Now the fan motor will start running. Observe the fan running smoothly.
Checking Procedure TPS
Measuring & Testing Equipment : Multimeter
G/Y R/B B/G
1 2 3
Sr. Parameter No.
Wire Connections Meter +ve
Meter -ve
1
Input voltage
Red/Black
Black/ Green
Output voltage wide open throttle
Red/Black
2 3
3
Output Red/Black voltage idle throttle
Coil Pin 2 Resistance
Standard Reading 3.3 VDC
Black/ Green
0.5 VDC
Black/ Green
4.35 VDC
Pin 3
1.6 ~ 2.4 Ohms
uu SOP : Remove petrol tank cover and petrol tank. Remove air filter cover along with paper filter element. Connect multimeter as shown in table given below. Input Voltage Checking
Central H. T. Coil
Measuring & Testing Equipment : Multimeter
Primary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
200 Ohms Orange/ White Pin-1
Meter -ve Black Pin-2
Standard Value 0.513 ~ 0.627 Ohms
Secondary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
Meter -ve
20 K Ohms
HT output
Pin of Orange / White
Standard Value 4.23 ~ 5.17 K Ohms
Bajaj Pulsar 200NS FI Training Notes
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8
Electrical
Checking Procedure Twin H. T. Coil
Measuring & Testing Equipment : Multimeter
Primary Winding Resistance Checking Meter Range
Wire Connections Meter +ve
200 Ohms Black / Red
Meter -ve Pin of Orange / White
Standard Value 0.63 ~ 0.77 Ohms
Secondary Winding Resistance Checking Meter Range 20 K Ohms
Wire Connections Meter +ve
Meter -ve
HT output
HT output
Standard Value
Remark
11.0 ~ 16.2 K Ohms
To be measure between to H.T. outputs
Horn
Measuring & Testing Equipment : DC Clamp Meter
Meter Range 200 DC A
Wire Connections
Encircle clamp meter jaws around Brown wire of horn
Standard Value 2.2 Amps
uu SOP : Encircle clamp meter jaws around Brown wire of Horn. Press horn switch and check the current drawn by horn.
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Bajaj Auto International Business
Battery Replacement Insert Key and open the lock uu Remove
uu Remove 2 Bolts Rider seat
Pillion seat
uu Remove 2 Bolts 2 Collared bush
Slide away ECU from battery bracket
uu Remove Battery terminal caps Battery +ve and then -ve terminal Lift out battery
uu Remove Battery
Bajaj Pulsar 200NS FI Training Notes
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Electrical
Roll Over Sensor SOP Note : Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Roll over sensor removal. uu Remove Disconnect the coupler 2 Bolts
H. T. Coil (RH Side) SOP Note : Follow the earlier mentioned SOP’s till petrol tank removal to proceed for Roll over sensor removal.
uu Remove 2 Bolts Earthing connection
uu Remove Disconnect cables from routine bracket
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Bajaj Auto International Business
uu Remove Disconnect coupler
uu Remove Plug cap LH and RH Take out HT coil
Head Lamp Removal SOP uu Remove 2 LH allen Bolts
uu Remove Pull out the head light assly
2 RH allen Bolts
uu Remove Rubber cap
uu Remove Wire clip lock
uu Remove Head light holder
uu Remove Head light lamp
Bajaj Pulsar 200NS FI Training Notes
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Electrical
Do’s & Don’ts Battery Dos
Don’ts uu DO Apply petroleum jelly to terminal post
uu DON’T Apply Grease to terminal post
uu DON’T Short circuit the terminal post
uu DO – Use proper equipment for testing
uu DO – Use correct tools
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Bajaj Auto International Business
uu DON’T – Use wrong tools
Do’s & Don’ts Horn
Dos uu Adjust horn sound by rotating the Phillips screw in the direction of arrow provided on horn.
Don’ts uu Never adjust the nut on horn cap side and bracket end (horn back side) as it will result in horn malfunctioning and failure. uu Do not remove silicon sealant from adjustment screw as it will result in water entry inside the horn.
Switches
Dos uu After washing the vehicle ensure to apply dry air on switches before operation. uu Ensure that grommets provided on clutch switch, front brake switch and rear brake switch are intact.
Don’ts uu Do not apply direct pressurized water jet on control switches. uu Do not lubricate electrical switches by oil or grease. uu Do not over tighten the switch mounting screw.
Bajaj Pulsar 200NS FI Training Notes
115
Diagram BATTERY CHARGING CIRCUIT
BRAKE LIGHT CIRCUIT
EMS Part -1
EMS Part-2
FUEL GAUGE CIRCUIT
HORN CIRCUIT
OIL PRESSURE SWITCH CIRCUIT
RADIATOR FAN MOTOR CIRCUIT
SIDE INDICATOR CIRCUIT
SIDE STAND INDICATOR CIRCUIT
TACHOMETER CIRCUIT
VEHICLE SPEED SENSOR CIRCUIT
8
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Electrical
Bajaj Auto International Business
Bajaj Auto Limited Akurdi Pune 411 035 India Tel | +91 20 27472851 Fax | +91 20 27407385 www.bajajauto.com CIN number : CIN L65993PN2007PLC130076
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