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in the country. Your safety and the safety of others is extremely important. Hence, before you ride the bike, please read this Owner's Manual carefully and familiarize yourself with the operating mechanism, controls and maintenance requirements. This will ensure you a long and trouble free ownership experience. To keep your bike in perfect running condition and deliver consistent performance, we have specially programmed the periodic maintenance services which includes 3 Free and 4 Paid services. We earnestly advise you to avail all these services at any of our Vehicle Dealers or Authorised Service Centres as per the schedule contained in this booklet Your Bajaj Pulsar 135 LS comes with a warranty of 2 Years or 30,000 Kms. whichever occurs earlier from the date of sale. For details please refer to Warranty : Scope & Limits given in this manual. We urge you to entrust all your service needs to a Bajaj Dealer or Authorised Service Centre only. They are well equipped with all necessary facilities / genuine parts / oil and trained manpower will ensure the best care for your bike. Should you require any additional information or wish to convey any grievance you may contact us on our toll free no. / e-mail mentioned on front cover inner page of this manual. Thank you for choosing a Bajaj and wish you unlimited miles of happy riding!!
Table of Contents
Description Identification Data..........................................................................................................................................................................1 Technical Specifications................................................................................................................................................................ 2 Location of Parts........................................................................................................................................................................... 3 How to Ride your Bike................................................................................................................................................................12 Running In....................................................................................................................................................................... 12 Riding the Bike................................................................................................................................................................12 Fuel Saving Tips............................................................................................................................................................. 14 Safe Riding Tips.......................................................................................................................................................................... 15 General Maintenance Information...............................................................................................................................................16 Engine Oil........................................................................................................................................................................16 Battery..............................................................................................................................................................................18 Monsoon Care................................................................................................................................................................ 19 Daily Safety Checks.....................................................................................................................................................................20 Non-use Maintenance................................................................................................................................................................. 21 Periodic Maintenance / Lubrication Chart................................................................................................................................. 22 Schedule for Periodic Part Replacement...................................................................................................................................25 Warranty : Scope & Limits......................................................................................................................................................... 29 Service Records...........................................................................................................................................................................32 Battery Warranty Card..................................................................................................................................................................... Service Coupons DOC. NO.: 71110943 REV. 00, DEC. 09
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.
Identification Data
The Frame and Engine serial numbers are used to register the motorcycle. They are the unique alpha-numeric codes to identify your particular vehicle from others of the same model and type.
Engine Number Location : On LH side crankcase near gear change lever (Alpha-Numeric - 11 digits)
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Technical Specifications
Engine Bore x Stroke Eng. Displacement Compression Ratio Idling Speed Max. Net Power Max. Net Torque Ignition System Spark Plug (2 Nos) Spark Plug Gap Lubrication Transmission Front Brake Rear Brake Fuel Tank Capacity Full Reserve Usable Dimensions Length Width Height Wheel base Ground clearance : 4 stroke DTS-i, Single cylinder Natural air cooled. : 54.0 mm x 58.8 mm : 134.66 cc : 9.8:1 : 1400 rpm : 13.5 Ps @ 9000 rpm : 11.4 Nm @ 7500 rpm : DC, Micro controller based digital CDI with Trics : CHAMPION, BOSCH : 0.6~0.7 mm : Wet sump, Forced. : 5 speed constant mesh. : Hydraulic operated 240 mm disc brake : Mech. expanding shoe 130 mm : : 8 liters : 2.5 liters : 1.6 liters : : 1995 mm : 765 mm : 1045 mm : 1325 mm : 170 mm Front Rear Tyre Pressure Front Rear (Solo) Rear (Pillion) Electrical System Head Lamp Pilot lamp Neutral Reserve Indicator Tail / Stop Lamp Turn Signal Indicator Side indicator Lamp Hi Beam Indi. Lamp Speedometer Lamp Fuel Gauge Horn Battery Rear No. Plate Lamp Vehicle Kerb Weight Gross Vehicle Weight Max. Speed Climbing Ability Tyre Size 2.75 X 17, 41 P 100/90 X 17, 55 P 1.75 kg/cm2 (25 psi) 2.00 kg/cm2 (28 psi) 2.25 kg/cm2 (32 psi) 12 Volts DC 35/35W 5W (2 nos.) LED LED LED LED (inside cluster) LED LED LED LED bar display 12 V DC 2A 12 V 5 Ah MF 5W 122 kg. 252 kg. 115 km/hr. (With single rider 68 kg) : 26% max. : : : : : : : : : : : : : : : : : : : : : :
Note : All dimensions are under UNLADEN condition. Above information is subject to change without any notice.
Location of Parts
1 5 6 2 3 7 8 9 10 11 12
Reserve Indicator : It shows reserve position when petrol left in the petrol tank is 2.5 ltr. Approx. 9. Neutral Indicator : When the transmission is in Neutral and Ignition switch ON, the Neutral indicator is lit. 10. Trip Meter Reset Button : Trip meter can be reset to zero by pressing the button. 11. Trip Meter : The Trip meter shows the distance travelled since it was last reset to zero. 12. Battery Indicator : It shows battery charge condition.
Continuous display of this icon means battery is in charged condition.
LOW
1. 2. 3. 4. 5. 6. 7.
Speedometer : The vehicle speed is displayed in digit. Fuel Level Indicator : It shows available fuel in fuel tank. Tachometer : It shows the engine speed in RPM. Steering cum Ignition Switch : Key operated switch for Ignition ON/OFF & locking handle bar. Odometer : The Odometer shows cumulative reading of total distance covered by vehicle in Km. Turn Signal Indicator (LH & RH) : When Turn signal switch is turned to Left or Right, Turn pilot indicator - LH or RH will flash. Hi Beam Indicator : When Headlight is ON & Hi beam is selected with engine running, Hi beam indicator will be lit.
8.
Location of Parts
To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push & release the key. Turn the key to LOCK position and remove the key. To Unlock the Steering : To unlock the steering, insert the key in steering cum ignition lock & turn it clockwise to OFF or ON position. Key : A common key is used for Steering cum Ignition lock, Fuel tank cap and Side cover lock.
Location of Parts
Fuel Tap
ON
Fuel Tap
Fuel tap lever has following positions. ON : When fuel level is above Reserve position. RES : When fuel level is below Reserve position. OFF : When fuel supply is to be cut off.
Location of Parts
A D
B C
D. Pass Switch : Press the switch to flash the head light. It is used to give signal to vehicles coming from opposite side while overtaking.
Location of Parts
G F. Starter Button : Starter button operates the electric starter when clutch lever is depressed with transmission in any gear. It is recommended to start the engine with the transmission in neutral. G. Engine Kill Switch : The engine kill switch is for emergency use. During emergency move the engine kill switch to the OFF ( ) position. CAUTION : While starting ensure that engine kill switch is in ON ( ) position. Keeping the kill switch in OFF position Engine will not start.
E F
Location of Parts
C B
C B
Match lug provided on rear side (C) of Side Cover with bracket located on chassis & Slide (C) backward. Match Lug (B) provided on front side of Side Cover with hole provided on Fuel Tank. Press the cover. Match the Side Cover properly lock with bracket provided on Holder step LH & Lock (A) the Side Cover. CAUTION : Remove cover as described above, otherwise the lugs may break.
Insert the key into the cover lock (A) and turn the key clockwise. Hold the cover with both hands and pull front side first (B). Slide (C) forward. Take out Side cover.
Remove the screw (A) given on Side Cover. Hold the cover with both hands and pull front side first (B) . Slide (C) forward. Take out Side cover. Match rear side (C) of Side Cover lug with Bracket located on chassis and slide (C) backward. Match Lug provided on front side (B) of Side Cover with hole provided on Fuel Tank and press Side Cover inside. Match Side Cover properly with bracket provided on Air filter assly and fix it with Screw (A). CAUTION : Fit cover as described above to ensure proper fitment.
Location of Parts
Battery
It is located inside the Side Cover LH. Always maintain electrolyte level in each cell between max and min level lines. Always keep a watch on battery charge level indicating icon, if it flashes (indicates battery is in low charged condition), show the vehicle to authorised BAL dealer.
Location of Parts
10
Location of Parts
3
1
4 6
Fig. A
Fig. B
Fig. C
11
Always keep the speed below the limits mentioned in the table. Do not race the engine excessively. 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 workup into the engine.
Moving Off :
Check that Center/Side stand is up. Depress the clutch lever. Shift into 1st gear. Open the throttle and release the clutch lever slowly and simultaneously. As the clutch starts to engage, open the throttle a little more, giving the engine just enough rpm to keep it from stalling.
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Parking :
Shift the transmission into neutral and turn the ignition switch OFF. Support the motorcycle on a firm level surface with the center or side stand. CAUTION : Do not park on a soft or steeply inclined surface or the motorcycle may fall over.
Braking :
Close the throttle completely, leaving the clutch engaged (except where shifting gears) so that the engine braking will help slow down the motorcycle.
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14
15
Bajaj Auto recommends Bajaj DTS-i 10000 engine oil for 10,000 kms drain interval, better performance of engine components & warranty benefits. Bajaj DTS-i 10000 Replacement Frequency* SAE 20W50 of API SL, JASO MA Grade 1st replacement at 750 Kms. / 1st service. Thereafter at every 10,000 Kms.
*For any other branded oil of equivalent grade replacement frequency will be 5000 Kms. CAUTION : It is most important to adhere to recommended grade & frequency of oil change for the purpose of long life of critical engine components. For details refer periodic maintenance chart. Do not reuse drained oil.
C B D
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Wheel Puncture :
Use the recommended levers while removing the Tyre / Tube for puncture work. This will avoid any damages to the edges / scratches on paint of the wheel.
Tyre Pressure :
Keep appropriate tyre pressure as mentioned below to increase life of the tyre & for better fuel consumption. Front Rear (Solo) Rear (with Pillion) 1.75 Kg/Cm2 (25.0 psi) 2.00 Kg/Cm2 (28.5 psi) 2.25 Kg/Cm2 (32.0 psi)
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Spark Plug
Remove spark plugs by using plug spanner. Clean the spark plugs. Adjust the gaps if incorrect by bending outer electrode carefully. : 0.6~0.7 mm. : BOSCH (2 Nos.) Or CHAMPION (2 Nos.)
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It is advisable that brake fluid should be replenished at evert 30,000 Kms or once in two years which ever occurs earlier.
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Drive chain
Steering Lock
Mirrors
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Non-Use Maintenance
Non-use maintenance is necessary if a vehicle remains off road for a longer duration (more than 15 days**). The correct and careful non-use maintenance carried out before storing the vehicle will prevent the vehicle from rusting and from such other non-operational damages like fire hazards. Clean the entire vehicle thoroughly. Empty the fuel from the fuel tank and carburettor float bowl (if fuel is left in for a longer time, the fuel will break and gummy substance could clog the carburettor). Remove the spark plug and put several drops of 2T oil into the cylinder. Kick the engine over slowly a few times to coat the cylinder wall with oil and install back the spark plug. Set the vehicle on a box or a stand so that both the wheels are raised off the ground. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or brake liners. Lubricate the control cables. Cover the entire vehicle neatly. Make sure that the storage area is well ventilated and free from any source of flames or spark. Fill 10% excess air pressure in both wheels. ** For Battery : a. Remove battery and keep it on wooden plank, in properly ventilated area. b. Before taking the vehicle for use. Get the battery recharged from the Authorised Service Center / Battery Dealer. Check and correct the electrolyte level and apply petroleum jelly on terminals (applicable to certain models).
Preparation for regular use after storage : Clean the vehicle Make sure the spark plug is tight. Fill the fuel tank with fuel. Change the engine oil. Check all the points listed in the Daily Safety Checks section. Check and inflate tyres to the proper tyre pressure.
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RECOMMENDED FREQUENCY
Servicing Kms 1st 750 2nd 3rd 4th 5th 6th 7th 5000 10000 15000 20000 25000 30000
Servicing Engine idling speed / CO% Valve tappet clearance Engine oil* - Bajaj DTS-i 10000 Oil strainer / Centrifugal filter Engine oil filter / Paper oil filter Spark plugs functioning / Gap (If applicable) Air cleaner element Clean / Replace Air filter cover O Ring Fuel cock sediment bowl cleaning Carburettor float bowl cleaning Carburettor rubber duct Fuel pipes Battery electrolyte level Clutch lever free play Throttle grip play
V V
3 3 3 3 750 Kms / 30 Days 3 3 3 1st 2nd onward @5000 Kms A A R CL R C, A, R CL, R R CL CL C, R C, R C, A C, A C, A C C C, A C, A C, A C C C, A C, A C, A CL CL CL C C C, A C, A C, A C C C, A C, A C, A CL A A R CL R C, A CL C, A CL A A A A R CL R C, A CL R R A A A A R CL R C, A CL R CL CL R R C, A C, A C, A C C C, A C, A C, A CL CL CL C C C, A C, A C, A Clean at every 10000 Kms Replace at every 20000 kms Replace at every 20000 kms C, A CL A A A A R CL R R R Replace at 10000 Kms* Clean at 10000 Kms Replace at every oil change Replace at every 15000 Kms Clean at every 5000 Kms Replace at every 15000 Kms Replace at every 20000 Kms
*For any other brand of oil (SAE 20W50 API SL JASO MA grade) drain interval is 5000 kms. More frequent cleaning may be required when driving in dusty condition.
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RECOMMENDED FREQUENCY
Servicing Kms C, A CL, R C, A, R R R C, R L C, A C, L, R C, T C, T C, T C, T C, T C, T C, A C, A C, A C,L,R C, T C, T C, T C, T L C, A C, A C,L,R C, T C, T C, T C, T C, A C, A 1st 750 C, A 2nd C, A CL C, A 3rd C, A CL C, A 4th C, A CL, R C, A 5th C, A CL C, A 6th C, A CL C, A 7th C, A CL, R R R R C, R L C, A C,L,R C, T C, T Replace at every 15000 kms Replace at every 30000 kms Replace at every 30000 kms Replace at every 30000 kms Replace at every 30000 kms 5000 10000 15000 20000 25000 30000
Rear wheel rubber shock damper Silencer drain hole cleaning Cylinder head de-carbonising, valve lapping & Replace valve oil seals Engine air breather tube Drive chain slackness adjustment & lubrication
C, R CL CL R C, A, L CL CL
C, R CL CL CL
C, R CL CL
C, R CL CL
Replace at every 10000 kms Clean at every 5000 Kms Clean at every 15000 Kms Replace at every 20000 Kms Lubricate at every 500 kms. A- slackness whenever reqd.
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RECOMMENDED FREQUENCY
Servicing Kms L CL, L R C, L C, R R C, A C, A C, A CL, R CL L L R R L L CL L L CL, R CL L L R L C, A C, A C, A C, A C, A C, A C, A C, A C, R C, R 1st 750 2nd 3rd 4th 5th 6th 7th 5000 10000 15000 20000 25000 30000 At every 500 Kms CL, L R CL, L R C, L C, R R C, A C, A C, A CL, R CL L Lubricate at every 20000 Kms Replace at every 15000 Kms C, A C, A C, A C, A C, R C, R CL, L R At every 10000 Kms Replace at every 10000 Kms At every 20000 Kms At every 5000 kms i.e. at every service after 2nd service Replace at every 20000 Kms At every 5000 Kms At every 5000 Kms At every 20000 Kms.
C : Check, A : Adjust, CL : Clean, R : Replace, T : Tighten, L : Lubricate Note : Parts / Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer.
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26
27
29
30
13. 14.
8.
9.
10.
11.
31
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Always
Insist
on
parts
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