Pulsar DTS-i 220 User manual

Notice: The description and illustration in this booklet are not to be taken as binding on
the manufacturers. The essential features of the type described and illustrated herein
remaining unaltered, Bajaj Auto Limited reserves the right to carry out at any moment
without being obliged to bring this booklet upto-date, Modifications on the vehicle, parts
or accessories as may be convenient and necessary.
Safety and Warning Information :
Warning : This indicates that a potential hazard or injury to you or other persons & to the
vehicle can happen if advice provided is not followed
Caution : This indicates that a potential hazard that could result in vehicle damage.
Follow the Advice provided with the caution.
Description
1. Technical Specifications................. 1
2. Location of Parts............................ 2
3. How to Ride Motorcycle................ 10
4. Safe Riding Tips..............................11
5. Running In Instruction.....................11
6. Daily Safety Checks........................12
7. Periodic Maintenance Information......... 13
8. Periodic Maintenance/ Service Record. 16
9. Periodic Part Replacement Schedule....18
10. Applicable to all services 19
11. Non-use Maintenance.............................20
Table of Contents

Location of Parts : Speedometer Indicators Technical Specifications
Engine : 4 Stroke, Single Cyl.,
Natural air/ Oil cooled
Bore x Stroke : 67.00mm x 62.4mm
Engine Displacement : 220 cc
Compression Ratio : 9.5 + 0.5 : 1
Idling Speed : 1400 + 100
Max. Net Power :21 PS at 8500 rpm.
Max. Net Torque :19.12 Nm at 7000 rpm.
Ignition System : Digital CDI
Spark Plug : 2 Nos. Champion
RG6HCC
Spark Plug Gap : 0.8 to 0.9 mm
Lubrication : Wet sump, Forced
Transmission : 5 speed constant mesh
Brakes (Frt. & Rr.) : Hydraulic operated disc
brakes
Fuel Tank Capacity :
Full : 15.0 liters
Reserve : 3.2 liters
Usable Reserve : 2.0 liters
Tubeless Tyre Size :
Front : 90/90 x 17,49P
Rear : 120/80 x 17, 61P
Tyre Pressure :
Front : 2kg / cm2 (28 PSI)
Rear (solo) : 2 kg / cm2 (28 PSI)
Rear (pillion) : 2.25 kg / cm2 (32 PSI)
Dimensions :
Length : 2035 mm
Width : 750 mm
Height : 1165 mm
Wheel base : 1350 mm
Min. Turning Radius : 2500 mm
Ground Clearance : 165 mm (Min.)
Electrical System : 12 Volts DC
Head Lamp : 55/55 W-H7 (for F)
: 35/35 W (for S)
Pilot Lamp : 5 W Each 2 Nos.
Tail /Stop : LED/LED
Turn Signal Indi. : 10 W - 12 V
Neutral Indicator : LED
Hi Beam Indicator : LED
Turn Pilot Indicator : LED
Side Stand Indi. : LED
Speedometer : LCD Display
Rear No. Plate : 5 W
Horn : 12 V DC (2 Nos.)
Battery : 12V - 9 Ah
Vehicle Kerb Wt. : 152 kg. (for F)
: 148 kg. (for S)
Gross Vehicle Wt. : 282 kg. (for F)
: 278 kg. (for S)
Climbing Ability : 28% (160max)
Note : All dimensions are under UNLADEN condition. Above information is subject to change.
1. Side stand indicator : When Side stand is ‘ON’, the Side stand indicator will be lit.
2. Turn signal indicator : When turn signal switch is turned to LH/RH, pilot indicator flash.
3. Trip meter : It shows the distance travelled since it was last reset to zero.
4. Trip meter knob : Reset trip meter to zero by pressing the trip meter knob.
5. Speedometer : The vehicle speed is displayed digitally.
6. Odometer : The Odometer shows the total distance that the vehicle has accumulated.
7. Fuel level indicator : Fuel level indicator shows available fuel in fuel tank.
8. Tachometer : It shows the engine speed in RPM.
9. Neutral indicator : When the transmission is in neutral, the neutral indicator light will lit.
10. Hi beam indicator : When the H/L is on high beam, the hi beam indicator light will lit.
5
1
6
3
10
9
2
4
8
7
12

Location of Parts (220 F) Location of Parts (220 S)
Front Fork
Clutch Lever
Fuel
Tank Rear
Shock Absorber
Grab
Handle
Pillion
Foot Rest
Gear Change
Lever
Side
Stand
Center
Stand
Accelerator
Grip
Front Brake
Lever
Rear Brake
Pedal
Center Stand
Silencer
Accelerator
Grip
Fuel
Tank
Rear
Shock
Absorber Front Fork
Grab
Handle
34

To Lock the Steering :
To lock the steering, turn the handle bar to
left or right. Push down & turn key to
“LOCK” position and remove key.
To Unlock the Steering :
To unlock the steering, insert key in steering
cum ignition lock & turn it clockwise to
“OFF” or “ON” position.
Other Keys :
A common key is used for ‘Steering cum
Ignition lock’, ‘Fuel tank cap’ and ‘Side
cover lock’.
Key can not be removed with ignition
switch in ON position.
Location of Parts
Fuel Tap
Fuel tap lever has following positions.
ON : When fuel level is above reserve .
RES : When fuel level is below reserve.
OFF : When fuel supply is to be cut off.
Fuel Tank Cap
• To open the fuel tank cap, lift the flap
(A), insert the key in the lock and turn it
clockwise.
• To lock ‘Fuel Tank Cap’ gently press
the cap.
L
L
E
R
-
H
S
U
P
FUEL
TAP
OFF
ON
RES
Identification Data / Location of Parts
These icons flash whenever their limits
are exceeded.
Take you vehicle to service station for
maintenance of required item, if any of the
above indicating icon flickers continuously.
The chassis / Engine serial numbers are
used for registration. These are the unique
alpha-numeric codes to identify your vehicle
from others of the same model and type.
Engine
Number
Chassis
Number
Chassis No.
1. 220 F - RH side of steering tube
2. 220 S - LH side of steering tube
4 Icons On Speedo Display At The Top
+
Low Engine
Oil Level
Low
Battery
Voltage
High
Engine
Temperature
Air Filter
Choked
+
FUEL TANK
CAP
A
56

Location of Parts
Removal of Left / Right Side Cover
• Access to battery is by removing LH cover.
• Insert ignition key & turn it clock wise.
• Pullout the cover from fuel tank knob.
• Slide the cover towards left direction.
• Direction of removal is important to avoid
breakage of cover locking lug.
Tool Kit Location
• It is loc ated bel ow Rr. s eat. For
removing seat please refer procedure
given on page number 9.
• 2 rubber straps are provided to hold the
tool kit.
Battery (12V - 9Ah)
• Battery is located inside LH side cover.
• Check electrolyte level in each cell &
ensure that it is between upper & lower
level lines.
• Remove battery filler caps and fill with
distilled water until electrolyte level in each
cell reaches upper level line.
• Add only distilled water to battery. Tap
water is not a substitute for distilled water
and will shorten the life of battery.
• Environment care is to be taken to dispose
off used battery. It is always recommended
to handover same to Authorised Battery /
Bajaj Dealer for proper disposal of same.
• Warranty on battery is 18 months from the
date of purchase of vehicle.
Location of Parts
A) Dipper switch : When headlight is ON, High
or Low beam can be selected with the dipper
switch. : High Beam : Low beam
B) Turn signal switch : When the turn signal
switch is turned to Left ( ) or Right ( ),
the corresponding turn signals flash on and
off. To stop flashing, push the switch in
opposite direction of indicator.
Auto Cancellation of Indicators
• After having turned to LH or RH directions,
the indicators would switch off itself when
the handle bar is straightened.
• If one forgets to take a turn, but has
selected the turn signal it will be switched
off automatically after approx. 1 min.
C) Horn button : ( ) Press for sounding horn.
Battery
Left Handle Bar Switches
C
B
A
D
G
E
F
Right Handle Bar Switches
D) Pass Switch : Press the switch to flash the
head light. It should be used to give signals
to on coming vehicles while overtaking.
: All lamps 'OFF'.
: Tail, Meter, Pilot lamp/s ‘ON’.
: Head, Pilot, Tail, Meter lamps ‘ON’.
E. Head Light Switch : It has 3 positions.
F. Starter Button : Push start button to start the
engine with transmission in neutral position.
In geared condition pressing clutch lever
would be required.
G. Engine Kill Switch : During emergency move
engine kill switch to the OFF ( ).
Caution : While starting ensure that engine
Kill switch is in on ( ) position. Engine will not
Start if the kill switch in OFF ( ) position.
78

Removal of Seat - Front & Rear
• Remove ‘Side Cover’ LH.
• To remove Seat Front, pull the ‘Seat
Release Cable’ (A) to release seat lock.
Keeping cable pulled, tap the center of
seat, lift the seat from rear end and slide it
back to remove seat.
• To remove Seat Rear, pull the ‘Seat
Release Cable’ (B) to release seat lock.
Keeping cable pulled, tap the center of
seat, lift the seat from rear end and slide it
towards tail lamp to remove seat.
Caution : Always remove Rear Seat first.
Fitment of Seat - Front & Rear
• For fitment of Seat Front, match & insert
the bracket (‘1’ of Fig. ‘B’),
of seat with slot (‘2’ of Fig. ‘B’) provided
below fuel tank rear mounting on chassis.
Push seat towards fuel tank and align lock
rod (‘3’ of Fig. ‘B’) & seat lock (‘4’ of Fig.
‘B’). Then press the seat in middle from top
to lock the seat.
• For fitment of Seat Rear, match & insert the
bracket (‘5’ of Fig. ‘C’) of seat with slot (‘6’
of Fig. ‘C’) provided below fuel tank rear
mounting on chassis. Push seat towards fuel
tank and align lock rod (‘7’ of Fig. ‘C’) &
seat lock (‘8’ of Fig. ‘C’). Then press the
seat in middle from top to lock the seat.
Caution : Always fit Front Seat first.
Fig. B
1
2
3
4
Fig. C
5
8
6
Seat Release Cable
A
B
How to Ride Your Bike
Location of Parts
th th
From 5 to 4
th rd
From 4 to 3
rd nd
From 3 to 2
nd st
From 2 to 1
50 km/h
40 km/h
30 km/h
20 km/h
Braking :
• Close throttle completely, leaving clutch
engaged so that engine braking will help slow
down motorcycle. Shift down one gear at a
time so that you are in Neutral when you
come to a complete stop.
• When stopping, always apply both brakes at
same time. De-clutch as necessary to keep
engine from stalling.
• Never lock brakes, it will cause tyres to skid.
When cornering, use brakes judiciously & do
not de-clutch. Reduce speed before you get
into the corner. For emergency braking,
disregard downshifting, & concentrate on
applying brakes as hard as possible.
not shift at such high speed that the engine rpm
jumps excessively. This may cause engine
damage, and rear wheel may skid. Downshifting
should be done at recommended speeds.
Gear Shifting Lever
Caution : Do not operate starter continuously
for more than 5 sec. Wait for 15 seconds
before re-start.
Note : The motorcycle is equipped with a
starter lockout switch. The starter switch will
operate only when transmission is in neutral
or clutch lever depressed.
Moving Off :
• Check that Center/Side stand is up.
st
• Depress clutch lever, shift into 1 gear.
• Open throttle and release the clutch lever
slowly and simultaneously, as the clutch start
to engage, open throttle a little more, giving
engine just enough rpm to keep running.
Shifting Gears :
• Close throttle & depress clutch lever.
• Shift into next higher or lower gear.
• Open the throttle and release the clutch lever
slowly and simultaneously.
Warning : When shifting down to lower gear, do
Starting the Engine :
1. Turn /
2. Turn ignition/ kill switch to ON position.
3. Confirm that transmission is in neutral.
4. Keep the throttle completely closed.
5. Push starter button until the engine starts.
fuel tap to ON RES position.
7
910

Running In / Safe Riding Tips Safe Riding Tips / Daily Safety Checks
• Do not race the engine excessively.
• Do not run at constant speed. Vary the
engine speed.
Fuel Saving Tips :
A well maintained vehicle and good driving
can contribute a lot to the saving of petrol.
Following are a few simple fuel saving tips.
Good Riding Habits :
• Ride smoothly and steadily at an optimum
driving speed of 40 to 50 Km/h.
• Avoid harsh braking.
• Change the gear judiciously according to
the speed and load requirement.
• Don’t overload the vehicle above the
specified payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for
more than two minutes.
Safe Riding Tips
•Always wear a helmet while riding. Your
helmet should conform to appropriate
Indian standards i.e. ISI mark.
•Read thoroughly the instructions in this
manual and follow them carefully.
•Avoid unnecessary accessories for the
safety of both rider and other motorists.
•Get familiar with traffic rules & regulations in
your states & general traffic signs.
Familiarise yourself well with starting,
acceleration and braking of the vehicle.
•When applying the brakes, use both, the
front and rear brakes. Applying only one
brake may cause the rider to loose control,
use more of the front than rear judiciously
depending on road surface conditions.
•During monsoon ride the vehicle more
cautiously. Remember vehicles skid more
easily during light showers.
•Drive cautiously. Start early and reach your
destination safely.
•Always carry vehicle registration papers,
insurance and a valid driving licence with
you.
•Riding at proper speed and avoiding
unnecessary acceleration and braking are
important not only for safety and low fuel
consumption, but also for longer life of the
vehicle and smooth operation.
If any irregularities are found during these
checks, refer to the Maintenance chapter and
see your dealer for the action required to return
the motorcycle to a safe operating condition.
Warning : Failure to perform these checks every
day before you ride may result in serious damage
or severe accident.
• Enough fuel level for planned distance of
journey. No fuel leakage in fuel lines.
n
•Engine oil level (bet upper - lower level mark)
•Throttle cable play of 2 - 3 mm. Smooth
operation & positive return to closed position,
•Steering Lock lever not fouling.
•Brake Pedal Play - 20 to 30 mm.
•Wear lining Indicator within usable range.
no brake dragging.
•Drive Chain slack of 25 to 35 mm,/ adequately
lubricated.
• Function of all lights & horn
• Sm oot h steer ing movem ent w ithout
restriction
•Clutch lever play - 2 to 3 mm
•Both stands return to their fully up position.
• Correct inflation pressure in both tyres
adequate tread depth - no cracks / cuts.
• Correct rear viewing mirror span adjustment.
Daily Safety Checks :
Before riding a motorcycle be sure to check
everyday following items.
Please give importance to these checks and
perform all of them.
Stopping the vehicle :
• Close the throttle completely, Shift the
transmission into neutral. Bring the vehicle to
complete stop, Turn the ignition switch off.
Parking :
• Support motorcycle on a firm level surface with
the center or side stand. Lock the steering.
Caution : Do not park on a soft or steeply
inclined surface otherwise motorcycle may fall
over.
Proper running-in is important for the better life
and trouble free performance of the vehicle.
• During first 2000 kms running-in period do
not exceed following speed limits.
Kms 1st 2nd 3rd 4th 5th
0 - 1000 15 30 45 55 65
1000 - 2000 20 40 55 65 75
• Always keep the speed below the limits
mentioned in the table.
• Do not start moving or race the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to work up into the engine.
Running In
11 12

Periodic Maintenance Information
Drive Chain
• Chain with ‘O’ rings is fitted on your
vehicle.
• ‘O’ rings must always run in wet condition
to ensure better chain life.
• Adjust chain slack every 1000 kilometers.
• Lubricate chain every 500 kilometers with
SAE 90 oil.
Method of chain lubrication :
• Place the bike on centre stand.
• Start rolling rear wheel in reverse direction.
• Clean the chain with nylon brush by using
mixture of oil / kerosene.
• Lubricate chain with SAE 90 oil. For better
retention “chain lube. spray” can be used.
• Spray the lubricant inside chain between
plates, rollers and bush completely.
• Wipe out excess lubricant by using lint
free cloth.
Tyre Pressure :
• Keep appropriate tyre pressure to increase
tyre life and for better fuel consumption.
2
Front 2.00 Kg/Cm (28.5 psi)
2
Rear (Solo) 2.00 Kg/Cm (28.5 psi)
2
Rear (with Pillion) 2.25 Kg/Cm (32 psi)
Drive Chain
Periodic Maintenance Information
Chain lube spray
13 14
Engine Oil
• Check the engine oil level every day.
• Maintain oil level between upper and lower mark
provided at oil window.
• Vehicle should be parked at level ground while
checking oil level.
• Top up with specified grade of oil if the oil l e v e l i s
below lower level mark.
• Completely screw in dipstick after oil filling is over.
Oil Quantity: Refill during servicing - 1150 ml.
Filling post overhaul - 1300 ml.
Recommended Engine Oil : Bajaj DTSi 10000Engine
Oil Grade : SAE 20W50 API ‘SL’ or JASO ‘MA’ Grade
Spark Plug
• Remove spark plug by using plug spanner
(Box 16 m.m)
• Clean both the spark plugs.
• Adjust the gap if incorrect by bending outer
electrode carefully.
Spark plug gap : 0.8 to 0.9 m.m
Recommended : Champion RG6HCC
Spark Plug (Resistive)
B : Oil Level
Inspection
Window
Caution :
•It is most important to adhere with the
recommended grade & frequency of oil
change for the purpose of long life of
critical engine components. For details refer
periodic maintenance chart.
• Do not reuse drained oil.
A
B
Recommended Engine Oil:
Always insist on Bajaj Genuine Engine
Oil for optimum engine performance
and warranty benefits. It is a specially
formulated oil for vehicles with DTS-i
engines.
A : Oil Filler
Cap
st
• Engine oil replacement frequency : 1 service & then every
1 0 , 0 0 0 K m . I n c a s e a n y o t h e r e n g i n e o i l o f
same specifications is used, the frequency of Oil replacement
will be every 5000 Kms.

Periodic Maintenance Chart & Service Record
Front Brake Fluid Level :
• Front brake fluid master cylinder reservoir is located
near RH switch on handle bar.
• To check oil level, keep vehicle on Center stand with
handle bar in straight position.
• Always ensure that brake fluid level is above ‘MIN’
mark given on inspection window.
• Use only DOT 3 or DOT 4 brake fluid (from sealed
container) to top up if required.
It is advisable that brake fluid should be replenished
at every 30,000 Kms or once in two years which ever
occurs earlier.
Wheel Puncture : Advisable to visit tyre dealer if
possible, or known tubeless tyre repair shops.
Usage of a wheel removal / fitment machine strangle
recommended.
If at all, tyre levers have to be used, they should be
having no sharp edges and the procedure of removal /
fitment should not nick / dent the wheel or tyre in any
manner.
Caution : Tubeless tyres are used on motorcycle. The
side walls of the tyres in contact with the wheel rim
should not be damaged in any way during fitment /
removal of tyre in case of punctures. The tyre side walls
in contact with the wheel rim seals air.
Periodic Maintenance Information
1. Servicing 3 3 3 3 3 3 3
2. Engine idling speed / CO% A A A A A A A A
3. Valve tappet clearance A A A A A A A A
4. Engine oil (Bajaj DTSI 10000 oil)* C,A R Top-up R Top-up R Top-up R Replace at 5000 Kms
Replace in 1st service & at
every 10000 Kms
5. Oil strainer / Centrifugal filter CL CL CL CL CL CL CL CL Clean at 5000 Kms
6. Spark plugs functioning / Gap C, A, R C, A C, A C, A R C, A C, A R Replace at every 15000
7. Air cleaner element Clean / Replace VV CL, R CL CL CL R CL CL R Cl- 5000 Kms. R-15000
8. Fuel cock sediment bowl cleaning CL CL CL CL CL CL CL
9. Carburetor float bowl cleaning CL CL CL CL Clean at every 10000 Kms
10. Battery electrolyte level C, A C, A C, A C, A C, A C, A C, A C, A
11. Clutch lever free play C, A C, A C, A C, A C, A C, A C, A C, A
12. Throttle grip play C, A C, A C, A C, A C, A C, A C, A C, A
13. Rear brake pedal free play C, A C, A C, A C, A C, A C, A C, A C, A
14. Brake fluid level / Top up / Replace C, A, R C, A C, A C, A C, A C, A C, A R Replace at every 30000
15. Brake cam & pedal pivot pin L L L
16. Steering play C, A C, A C, A C, A C, A C, A C, A C, A
17. All fasteners tightness C, T C, T C, T C, T C, T C, T C, T C, T
18. Rear Shock Absorber - Gas pressure C, A C, A Every 20000 Kms
Recommended Frequency
Servicing
Sr.
No. Operation 1st
750
2nd
5000
3rd
10000
4th
15000
5th
20000
6th
25000
7th
30000
Kms
Note - More frequent cleaning may required when driving in dusty condition. C : Check, A : Adjust, CL : Clean,
R : Replace, T : Tighten, L : Lubricate.
Note : Incase the motorcycle is fitted with imported
tyres, compliance to respective Indian standard & central
motor vehicle rules has been ensured.
MIN.
15 16

Periodic Maintenance Chart & Service Record Periodic Part Replacement Schedule
19. Rear sprocket fasteners C, T C, T C, T C, T C, T C, T C, T C, T
20. Silencer drain hole cleaning CL CL CL CL CL CL CL CL CL every 5000 Kms
21. Cylinder head de-carbonising, CL CL CL R- oil seals & valve lapping
22. Drive chain ‘O’ ring type - Clean / lubricate C, L At every 500 Kms
23. Drive chain slack (O/H) CL, L CL, L CL, L CL, L Every 10000 Kms
24. Wheel bearing C, L C, L Every 20000 Kms
25. Tyre tread wear C, R C, R C, R C, R C, R C, R Every 5000 kms
26. Front fork oil R R Replace at every 20000
27. TPS / Auto choke, Thermal sensor C, A C, A C, A C, A C, A C, A C, A C, A At every 5000 Kms
28. Starter clutch bush kit for dry type CL, R CL,R CL, R
29. General lubrication L L L L L L L L
30. Swing arm pivot pin lubrication L L Lubricate at every 20000
31. Clutch switch cleaning CL CL CL CL
RECOMMENDED FREQUENCYSr.
No. Operation
Servicing 1st
750
2nd
5000
3rd
10000
4th
15000
5th
20000
6th
25000
7th
30000
Kms
Ist Free
500~750
2nd Free
4500~5000
3rd Free
9500-10000
Ist Paid
14500~15000
2nd Paid
19500~20000
3rd Paid
24500~25000
30~45 240 240 120 Days 120 Days 120 Days
Type of service, Kms limits
& No of Days
Steering Stem Bearing Cone Set 1√ √
Rear Wheel Rubber Damper 1√ √
Drive Chain Link Lock 1√ √
Spark Plug 2 Nos. √ √
Air Cleaner Element 1√ √
Brake Pad 1√ √
Valve Oil Seals 2√ √
Cylinder Head Gasket 1√ √
Starter Clutch Kit 1√ √
Engine Silent Bush 2√ √
Air Filter Cover ‘O’ Ring 1√
Carb. Rubber Duct / Fuel Pipes 1√
1
Item Description Qty.
Engine Air Breather Tube 1√
Brake Hose Pipe 1√
Master Cylinder Cup & Dust Seal 1√
Caliper Piston Seal & Dust Seal 1√
Days
Note : Replacement of Parts at periodic interval is mandetary and on chargeable basis.
17 18
Note : Periodic parts / lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are
chargeable to customer.
* It is strongly recommended to use only “Bajaj DTS-i 10000” Genuine engine oil. In case any other engine oil of same
specifications is used, the frequency of Sr. No. 4, 5 & 6 will be every 5000 Kms.