Bajaj pulsar 125 User manual

1
Model :
Pulsar 125 Disc-Drum, Single seat: 00DH40ZZ
Pulsar 125 Drum-Drum, Single seat : 00DH36ZZ (Same as existing)
Pulsar 125 Disc-Drum, Split seat : 00DH34ZZ (Same as existing)
Pulsar 125 Drum-Drum, Split seat : 00DH38ZZ (Same as existing)
Supplementary Service Station Manual
Pulsar 125 BS VI
• Specification Information
- Technical Specifications
- Preventive Maintenance
Chart
- PDI Check Sheet
- Fuel Tank Cap &
Speedometer Related
Information
- Side Stand Switch
Interlocking
• Part Identification
• Wiring Harness Routing
• Circuit Diagram

SPECIFICATION INFORMATION
Service Support - M/C
Service Station Manual
All specification are same as existing
Pulsar 125 Disc-Drum, Single seat: 00DH32ZZ
Pulsar 125 Drum-Drum, Single seat : 00DH36ZZ
Pulsar 125 Disc-Drum, Split seat : 00DH34ZZ
Pulsar 125 Drum-Drum, Split seat : 00DH38ZZ
Refer supplementary SSM available on essm.
2
PM Chart & PDI check sheet are same as existing
Pulsar 125 Disc-Drum, Single seat: 00DH32ZZ
Pulsar 125 Drum-Drum, Single seat : 00DH36ZZ
Pulsar 125 Disc-Drum, Split seat : 00DH34ZZ
Pulsar 125 Drum-Drum, Split seat : 00DH38ZZ
Refer supplementary SSM available on essm.
• To open the fuel tank cap, open the flap. Insert the key in the lock
and turn it clockwise and lift fuel tank cap.
• To lock the ‘Fuel Tank Cap’ insert the keyin the lock and turn it
clockwise and press fuel tank cap. ‘Click’ sound ensures cap is
fully locked.
Precaution :
• Dont attach metallic ‘Key chain’ as it may damage paint of petrol
tank.
Fuel Tank Cap
Instructions for Customers
• Do not REV engine in standstill condition.
• Don't use adulterated fuel or fuel additives as it will result in rusting & clogging of engine parts.
• Never drive by disconnecting wheel speed sensor.
• Do not keep the cleaning cloth in the vicinity of high temperature zone e.g. Engine, Silencer assembly, catalytic convertor, starter
motor etc.
• While operating fuel tank cap do not apply pressure on tank cap
flap.
Fuel Tank Cap
Technical Specification
Preventive Maintenance Chart & PDI Check Sheet

SPECIFICATION INFORMATION
3Service Support - M/C
Service Station Manual
1. Side Stand Indicator: It glows when Side stand is down &
igntion switch is ‘ON’ and kill switch in ‘Engine ON’ position.
2. Fuel Level Indicator: Fuel level indicator shows available fuel
in fuel tank. Tank symbol glows when petrol level in tank
reaches reserve level
3. Engine Rev Indicator: It blinks when engine RPM cross
9500 RPM mark.
4. Tachometer Dial: It shows engine speed in RPM.
5. Odometer: The Odometer shows the total distance that the
vehicle has accumulated.
6. Turn Indicator (LH & RH): When Turn signal switch is
turned to L/R, Turn indicator - LH or RH will flash.
7. Speedometer: Vehicle speed will be displayed digitally
8. Trip Meter Reset Button: Both trip meters can be r e s e t t o
zero by pressing the button.
9. Trip Meter: The Trip meter shows the distance traveled
since it was last reset to zero.
10. Battery Indicator: It shows battery needs charging
11. Hi Beam Indicator: It glows when Headlight is ‘ON’ & Hi
beam is selected with engine running.
12. Neutral Indicator: It glows when transmission is in Neutral &
Ignition switch ‘ON’ and kill switch in ‘Engine ON’ position.
13. Malfunction Indicator ( ): It indicates malfunction in
sensors / actuators. It remains OFF while engine running.
8
9
10
11
13
7
12
2
5
6
4
3
1
Side stand switch interlocking
Side stand condition Side stand Indication
speedometer Gear position Remark
Down
Yes Neutral Self start / kick start possible
Yes Gear is applied in engine start
condition by pressing clutch lever Engine will get cut off
Down Yes Gear Engine will not start by self / kick.
Speedometer related information :

PART IDENTIFICATION
For Pulsar 125 Disc-Drum, Single seat: 00DH40ZZ, NOTE : For part numbers, always refer spare parts catalogue available
on e-ssm.
Part Number Dh201176 Dh201195
Description • Speedometer branch with two couplers :
12 Pin coupler & 2 pin coupler
• Light control module : 6 pin coupler & 2 pin coupler
• Speedometer branch with single coupler :
12 Pin coupler
• DC Flasher :2 pin coupler
Part Name WIRING HARNESS
4Service Support - M/C
Service Station Manual
Part Number Ds201025
Description With Light control module
Jl402004
With Flasher
Photograph
Part Name DC Flasher / Light Control Module
Model Pulsar 125 (00DH32ZZ) Pulsar 125 (00DH40ZZ)

PART IDENTIFICATION
Part Number Jl113818
Description NA
NA
NA
With cover switch side stand
Photograph
Part Name Cable guide & Nail cable guide
Model Pulsar 125 (00DH36ZZ) Existing Pulsar 125 (00DH36ZZ) New
Part Number Refer SPC Refer SPC
Description NA With tank flaps
Part Name Tank Flap
5Service Support - M/C
Service Station Manual
For Pulsar 125 Drum-Drum, Single seat : 00DH36ZZ (Same as existing)
NOTE : For part numbers, always refer spare parts catalogue available on e-ssm.
Cable Guide
Nail Cable guide
(Shown by pink color)
Part Number DH201093 JH401413
Description 2 Pin coupler 3 Pin coupler
Part Name Switch Side Stand

PART IDENTIFICATION
Part Number DH161825
Description NA
DH161719
Design is different than Pulsar 125 (00DH36ZZ)
Existing
Photograph
Part Name Holder Step Rider LH
Model Pulsar 125 (00DH36ZZ) Existing Pulsar 125 (00DH36ZZ) New
Part Number DH201162 DH201177
Description • Speedometer branch with two couplers :
12 Pin coupler & 2 pin coupler
• Side stand switch 2 pin coupler
• Speedometer branch with single coupler :
12 Pin coupler
• Side stand switch 3 pin coupler
Part Name Wiring Harness
6Service Support - M/C
Service Station Manual
Part Number Intake - DK102021 , Exhaust - DK102022
Description NA
Intake - DK101748, Exhaust - DK101751
Design is different than Pulsar 125 (00DH36ZZ)
Existing
Photograph
Part Name Rocker Arm
Intake
Exhaust
Intake
Exhaust

PART IDENTIFICATION
7Service Support - M/C
Service Station Manual
NOTE
For rocker arm shaft removal additional,
SCREW SET SOCKETs (as shown by blue circle)
is to be removed using 3 mm allen key.
This screw set Socket is Locking shaft Rocker arm
as shown in Photograph.
Part Number Refer SPC
Description Without holes for screw set socket fitment
Refer SPC
With holes for screw set socket fitment
Photograph
Part Name Cover Cylinder Head (Sub part of Kit Cover Head & Cylinder Head)
Model Pulsar 125 (00DH36ZZ) Existing Pulsar 125 (00DH36ZZ) New

PART IDENTIFICATION
8Service Support - M/C
Service Station Manual
Part Number Refer SPC
Description Without holes for screw set socket fitment
Refer SPC
With holes for screw set socket fitment
Photograph
Part Name Cover Cylinder Head (Sub part of Kit Cover Head & Cylinder Head)
Model Pulsar 125 (00DH36ZZ) Existing Pulsar 125 (00DH36ZZ) New
Cam Sprocket / Crankshaft assembly / Cam chain
Part Number PD511256
Description • NA
• Identification : With punch marks
DH102546
• Cam lobe design is different than Pulsar 125
(00DH36ZZ) Existing
• Identification : Without punch marks
Photograph
Part Name Camshaft Assembly
Model Part Description
LGB
Part number
Pulsar 125
Silent Timing Chain DH103758
Cam shaft sprocket PF511258
Crank shaft Assembly DH102565
For detailed information on cam sprocket /Crankshaft assembly & cam chain, refer service bulletin
2020-27 dated 11.08.2020 available on ESSM

PART IDENTIFICATION
9Service Support - M/C
Service Station Manual
Model Pulsar 125 (00DH36ZZ) Existing Pulsar 125 (00DH36ZZ) New
Part Number DH102528 DH103809 & DH102528
Description For DH103809 : Catalytic converter cell density more as compared to DH102528.After consumption of
DH102528, DH103809 will be implemented
Part Name Assembly Silencer

PART IDENTIFICATION
10 Service Support - M/C
Service Station Manual
Part Number Ds201025
Description With Light control module
Jl402004
With Flasher
Photograph
Part Name DC Flasher / Light Control Module
Model Pulsar 125 (00DH34ZZ) Existing Pulsar 125 (00DH34ZZ) New
Part Number DH201093 JH401413
Description 2 Pin coupler 3 Pin coupler
Part Name Switch Side Stand
Pulsar 125 Disc-Drum, Split seat : 00DH34ZZ (Same as existing)
NOTE : For part numbers, always refer spare parts catalogue available on e-ssm.
Part Number DH201168 DH201173
Description
• Speedometer branch with two couplers :
12 Pin coupler & 2 pin coupler
• Light control module : 6 pin coupler & 2 pin coupler
• Side stand switch : 2 pin coupler
• Speedometer branch with single coupler :
12 Pin coupler
• DC Flasher :2 pin coupler
• Side stand switch : 3 pin coupler
Part Name Wiring Harness

PART IDENTIFICATION
11 Service Support - M/C
Service Station Manual
Part Number DH161825
Description NA
DH161719
Design is different than Pulsar 125 (00DH34ZZ)
Existing
Photograph
Part Name Holder Step Rider LH
Model Pulsar 125 (00DH34ZZ) Existing Pulsar 125 (00DH34ZZ) New

PART IDENTIFICATION
12 Service Support - M/C
Service Station Manual
Part Number DS201025
Description With Light control module
JL402004
With Flasher
Photograph
Part Name DC Flasher / Light Control Module
Model Pulsar 125 (00DH38ZZ) Existing Pulsar 125 (00DH38ZZ) New
Part Number DH201093 Jh401413
Description 2 Pin coupler 3 Pin coupler
Part Name Switch Side Stand
Pulsar 125 Drum-Drum, Split seat : 00DH38ZZ (Same as existing)
NOTE : For part numbers, always refer spare parts catalogue available on E-SSM.
Part Number DH201180 DH201224
Description
• Speedometer branch with two couplers :
12 Pin coupler & 2 pin coupler
• Light control module : 6 pin coupler & 2 pin coupler
• Side stand switch : 2 pin coupler
• Speedometer branch with single coupler :
12 Pin coupler
• DC Flasher :2 pin coupler
• Side stand switch : 3 pin coupler
Part Name Wiring Harness

PART IDENTIFICATION
13 Service Support - M/C
Service Station Manual
Part Number DH161825
Description With Light control module
DH161719
Design is different than Pulsar 125 (00DH34ZZ)
Existing
Photograph
Part Name Holder Step Rider LH
Model Pulsar 125 (00DH38ZZ) Existing Pulsar 125 (00DH38ZZ) New
Part Number DH161752
Description NA
DH161680
Design is different than Pulsar 125 (00DH38ZZ)
Existing
Photograph
Part Name Bracket Assembly Number Plate Front

PART IDENTIFICATION
14 Service Support - M/C
Service Station Manual
Part Number DH191110
Description Regular speedometer (With more wires)
DH191089
CAN based speedometer (With less wires)
Photograph
Part Name Speedometer
Model Pulsar 125 Existing (All Variants) Pulsar 125 New (All Variants)
COMMON FOR
Pulsar 125 Disc-Drum, Single seat: 00DH40ZZ
Pulsar 125 Drum-Drum, Single seat : 00DH36ZZ (Same as existing)
Pulsar 125 Disc-Drum, Split seat : 00DH34ZZ (Same as existing)
Pulsar 125 Drum-Drum, Split seat : 00DH38ZZ (Same as existing)
NOTE : For part numbers, always refer spare parts catalogue available on e-ssm.
Part Number JF403000
Description NA
NA
With Relay Interlock
Photograph
Part Name Relay Interlock
NA

PART IDENTIFICATION
15 Service Support - M/C
Service Station Manual
Model Pulsar 125 Existing (All variants) Pulsar 125 New (All variants)
Part Number Refer SPC Refer SPC
Description NA Software is different than Pulsar 125 Existing
(All variants)
Part Name ECU EMS Assembly

WIRING HARNESS ROUTING
• Route the wiring harness as shown in photograph.
16 Service Support - M/C
Service Station Manual
Pulsar 125 Disc Drum Single seat (DH40)

• Route the wiring harness as shown in photograph.
• Route the wiring harness as shown in photograph.
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WIRING HARNESS ROUTING
Service Support - M/C
Service Station Manual

• Route the wiring harness as shown in photograph
• Route the wiring harness as shown in photograph
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WIRING HARNESS ROUTING
Service Support - M/C
Service Station Manual

• Route the wiring harness as shown in photograph.
• Route the wiring harness as shown in photograph.
19
WIRING HARNESS ROUTING
Service Support - M/C
Service Station Manual

• Route the wiring harness as shown in photograph
• Route the wiring harness as shown in photograph
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WIRING HARNESS ROUTING
Service Support - M/C
Service Station Manual