Bajaj Pulsar N160, Owner'S Manual

Page 1: ...Owner s Manual ...

Page 2: ...Doc No 71120183 REV 01 JUNE 2022 ...

Page 3: ...ch includes 3 free services and subsequent paid services as per the schedule contained in this booklet We earnestly advise you to avail all these services at any of our Bajaj Dealers who are well equipped with all necessary facilities genuine parts oil and trained manpower to ensure the best care for your Pulsar Your Pulsar N160 BS VI comes with a warranty of 5 Years or 75 000 Kms whichever occurs...

Page 4: ...tery Fitment Of Rider Pillion Seat 20 11 Antilock Braking System ABS 21 12 Daily Safety Checks 22 13 How to ride your Bike 23 14 Safe Riding Tips 27 15 Engine Oil 28 16 Tubeless Tyre Tyre Pressure 29 17 Battery 30 18 Periodic Maintenance Information 31 19 Brake Fluid 33 20 Free Service Guidelines 34 21 Periodic Maintenance Lubrication Chart 35 22 Non Use Maintenance 43 23 Delivery Certificate 44 2...

Page 5: ...Net Power 16 PS at 8750 RPM Max Net Torque 14 65 Nm at 6750 RPM Ignition System DC Fl System BOSCH Spark Plug 2 Nos Spark Plug Gap 0 8 0 9 mm Lubrication Wet sump forced Lubrication Transmission 5 speed constant mesh Gear Shifting Pattern 1 Down 4 Up Engine Cooling Oil cooled Starting Aid Electric Front Rear Brake Disc Brake Specifications Parameter 1 ...

Page 6: ...base 1358 mm Ground Clearance 165 mm Tyre Tyre Pressure Front Tyre 100 80 17 52P Tubeless Rear Tyre 130 70 17 62P Tubeless Front 1 75 Kgf cm 25 PSI 2 Rear Solo 2 Kgf 28 PSI 2 cm Rear with pillion 2 25 Kgf cm 32 PSI 2 Electrical System 12 Volts DC Battery 12V 4Ah VRLA Head Lamp LED Tail Stop Lamp LED Side Indicator Bulb Amber 4 Nos ...

Page 7: ...Indicator LED Yellow Service Reminder LCD Side Stand Indicator LED Red ABS Indicator LED Yellow Rear No Plate Lamp 12V 5W Bulb Horn 12V DC Vehicle Kerb Weight 153 kg Single Channel ABS 154 kg Dual Channel ABS Vehicle Gross Weight 303 kg Single Channel ABS 304 kg Dual Channel ABS 3 Specifications Note All dimensions are under UNLADEN condition Above information is subject to change without any noti...

Page 8: ...igits The frame 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 type Engine Number Location On LH Side Crankcase Near Change lever Alpha Numeric 11 Digits ...

Page 9: ...an Reflex Reflector Mobile Charging Socket LED Head Lamp Rear Disc Front Disc Front Fork Front Brake Lever Rider Seat Pillion Seat Grab Handle LED Tail Lamp Rear Shock Absorber Rear Brake Pedal Engine Oil Level Inspection Window ...

Page 10: ...g cycle continues Headlight control on rpm Headlamp will be turned ON only at Engine running condition Steering cum Ignition Lock It has three positions Lock Steering locked Ignition OFF OFF Steering unlock Ignition OFF ON Steering unlock Ignition ON To lock the steering Turn the handle bar to the left side Push Rotate the key to LOCK Position Remove the key Steering locking on handle position lef...

Page 11: ...gn substances like insect remains road debris using a soft brush Use microfiber cleaning cloths Ex Muslin cloth for painted parts cleaning Use recommended 3M polish Don ts Do not use products that are even mildly abrasive such as polishes glazes or rubbing compounds Do not use mechanical cleaners polishers Do not use terrycloth or paper towels or shine enhancement products Do not rub the finish vi...

Page 12: ...8 3 4 5 6 7 8 9 10 2 1 11 12 16 17 18 19 20 14 15 13 ...

Page 13: ...ine REV Indicator It glows when engine RPM exceed 9000 RPM It indicates customer Not to REV up engine beyond safe engine operating RPM 12 ABS Indicator With Ignition switch ON the ABS indicator glows When vehicle speed is more than 5 Km h the ABS indicator goes off if this indicator glows while vehicle is running it means there is problem in ABS 13 Neutral Indicator When the transmission is in Neu...

Page 14: ...450 km 3rd 9450 km 4th 14450 km and subsequently at each 5000 kms Icon will continue to glow till it is reset This icon is to be reset after service is carried out Service reminder reset is to be done at zero vehicle speed zero engine speed 18 Low Fuel Level Indicator It blinks incase of low fuel level 1 bar or less 19 Digital Clock It indicates time in HR MM AM PM 2O Speedometer Vehicle speed wil...

Page 15: ... than zero If vehicle speed is zero then IFE will be displayed km L 2 ODO The Odometer shows the total distance that the vehicle has travelled 3 Fuel Level Indicator Fuel level is shown by digital LCD bars with E empty F full fuel tank LCD symbol Low fuel level icon blinks if number of bars on the fuel gauge are less than 2 bars Note IFE Instantaneous fuel economy AFE Average fuel economy DTE Dist...

Page 16: ...he average fuel economy in km L in TRIP1 mode 2 TRIP1 The Trip meter shows the total distance that the vehicle has travelled in TRIP1 mode If TRIP1 is reset average fuel economy AFE1 will reset 3 AFE2 Average Fuel economy2 This will indicate the average fuel economy in km L in TRIP2 mode 4 TRIP2 The Trip meter shows the total distance that the vehicle has travelled in TRIP2 mode If TRIP2 is reset ...

Page 17: ... vehicle can travel under current fuel economy fuel level condition DTE calculation is independent of TRIP and based on AFE for distance covered for last 25 Kms Max count of DTE is 990 Km speedometer will display values in multiple of 10 TRIP Setting If Set button is pressed more than 3 sec in TRIP1 or TRIP 2 mode then respective AFE trip distance will reset to Zero while DTE will continue to show...

Page 18: ...ll continue updating 2 Service Reminder Reset Wrench symbol glows when ODO meter reading reached to set Kms This icon will glow at 1st 450 Kms 2nd 4450 Kms 3rd 9450 Kms 4th 14450 Kms subsequently at each 5000 Kms Note Bring the motorcycle at authorised BAL dealership for re setting the service reminder icon 3 Clock Reset Digital clock indicates time in HR MM separated by colon It is 12 hour clock ...

Page 19: ...e set button together for more than 3 sec stops blinking Digits HH starts blinking Press set button for 1 sec HH value will be stored while MM starts blinking HH value will be stored while MM starts blinking Press mode button for 1 sec Minute digits will increase Press set button for 1 sec HH and MM value will be stored AM starts blinking Charger Cap Charging Socket Hour digits will increase Set v...

Page 20: ...beam is selected High Beam Low beam B Turn Signal Switch When the turn signal knob is turned to Left or Right respective indicator will start blinking to stop blinking push the knob in release C Horn Button Press button for sounding horn 16 D Pass Switch Press the switch to put ON Hi Beam It is used to give signal to vehicles coming from opposite side while overtaking ...

Page 21: ...l switch is used for switching ON OFF the engine Engine OFF Engine ON Effect to Pass Switch Hi Beam ON No change Head Lamp Beam Status Low Beam ON Hi beam ON Hi Low Beam switch Low Beam Hi beam Ignition switch ON Engine Running Speedometer illumination tail lamp number plate lamp pilot lamp will get ON in addition to above head lamp will get ON as given below AHO Automatic Headlight ON There is no...

Page 22: ...itch turned to ON position After headlight is turned to ON position with engine running intensity of DRL LED s will get reduced Igntion Switch ON ON DRL ON High Intensity ON Low Intensity Light Switch OFF ON Head Light OFF ON Tail lamp will get ON DRL ON High Intensity G E Starter Button Starter button operates the electric starter It is recommended to start the engine with the transmission in neu...

Page 23: ...itted with tie band as shown in photograph 19 Removal of Pillion Seat Insert Key into lock A Turn the key clock wise Lift front end of Pillion seat Pull Pillion seat toward front side Take out Pillion seat First Aid kit Location It is located on RH side of Seat Cowl below the Pillion seat Screw Driver Location ...

Page 24: ...ated below rider seat Fitment of Rider Seat Match the mating part Al of Rider seat with slot B Push Rider seat towards petrol tank Match Rider seat rear Lugs C with the holes D provided on chassis Fitment of Pillion Seat First make sure Rider seat is fitted properly Match the bracket of Pillion seat H with Hook I Insert lock rod F of seat into hook G Press front portion of seat ...

Page 25: ...r than for those without it on rough road conditions During these conditions the vehicle should be driven at reduced speeds When you apply Front brake Rear brake by pressing Front brake lever Rear brake pedal under conditions which may lock the wheels you feel a corresponding sensation pulsation in Front brake lever Rear brake pedal as applicable to model This is normal and it means ABS is active ...

Page 26: ...ore riding motorcycle be sure to check following items Please give proper importance to these checks and perform all of them before riding motorcycle If any irregularities are found during these checks refer to the Maintenance chapter 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 ...

Page 27: ...3 Moving Off Check that 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 1 Starting The Engine Ensure minimum 3 liters petrol is available in fuel tank Turn ignition switch key to position Put...

Page 28: ...ing the clutch engaged except where shifting gears so that the engine braking will help slow down the 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 the same time 5 Parking Using Side Stand Support the motorcycle on a firm level surface with the side stand Lock the steering on LHS Caution Do not park on...

Page 29: ...to 40 Km h speed for about 15 minutes Time for evaporation will vary depending on the humidity of the ambient air 25 Always keep speed below the limits given in 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 work up into the engine Whenever vehicle is fallen down remove...

Page 30: ...peed 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 How to check mileage Fuel efficiency Best way to calculate mileage is by following the full tank to full tank method Fill fuel tank up to small mouth brim Run the bike for say 100 km Fill the tank again up to small mouth b...

Page 31: ...iding to avoid entangling in wheel or other objects on road Always concentrate on riding for safety Always wear Helmet while driving or riding Your helmet should conform to Indian standards Read thoroughly the instructions given in this manual and follow them carefully Avoid unnecessary accessories for the safety of both rider and other motorists Familiarise yourself well with starting acceleratio...

Page 32: ...ar N160 28 Engine Oil Level Checking Check engine oil level every day Park vehicle on center stand on level surface Check oil level through oil level gauge B Always maintain engine oil level between upper and lower mark provided on Cover RH Top up with specified grade of oil if the oil level is below lower level mark Engine Oil Capacity Refill at servicing 1250 ml During engine overhaul 1450 ml Ca...

Page 33: ...ture Visit nearest known tubeless tyre repair shop to remove puncture Remove puncture by Filler or Plug method only Do not use patch method to remove puncture of tubeless tyre Caution Tubeless tyres are fitted in this motorcycle The walls of the tyres in contact with the wheel rim should not be damaged in any way during fitment removal of tyre The tyre side walls in contact with wheel rim seals ai...

Page 34: ...hen engine is not running Get battery checked charged during periodic services Do not add extra electrical accessories such as Remote Bigger Horn Musical brake light etc This will reduce life of battery may damage ECU Disconnect battery ve ve wires if vehicle is to be stored for more than 2 weeks This avoids self discharge Battery 12V 4 Ah VRLA Battery is located below Pillion Seat Battery Feature...

Page 35: ...rrect by bending outer electrode carefully Spark Plug Gap 0 8 to 0 9 mm Drive Chain Slackness Chain slackness will have to be adjusted whenever required Std Chain slackness 20 30 mm in 1st gear or both wheels touching to ground Marking on chain adjusters should be identically positioned on both sides ...

Page 36: ...pray can at the back of rear sprocket with extension tube nose at 5 10 cm Rotate the wheel in reverse direction spray the lube on middle portion of the chain up to full length of the chain Drive chain must be cleaned lubricated as per periodic maintenance schedule Drive Chain Sealed type 0 rings must always be kept wet for best performance hence lubricate at every 500 Km Sealed chain lubrication c...

Page 37: ...To check brake fluid level Park the vehicle perpendicular to the ground on level surface with handle bar in straight ahead condition Always ensure that brake fluid level is above MIN mark given on inspection Window Incase of level drop use only DOT 4 brake fluid from sealed container for top up replacement It is advisable that brake fluid should be replaced at every 30 000 Kms ...

Page 38: ...aler at the time of buying of new Bajaj Vehicle In case of change in mobile number please update to Dealer ASD When you are at Dealership ASD workshop for availing Free Service you will receive the Unique Coupon Number UCN through SMS in your mobile Please inform the UCN to Dealer ASD at the time of Free Service ASD Authorised Service Dealer 34 ...

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Page 40: ...R Top up R Top up R 4 Engine oil filter R R R R Drain tube cleaning CL CL CL CL CL CL CL 6 Fuel Pump Nylon hoses with quick connector C R 7 Spark plug clean check gap CL A CL A R 8 Valve tappet clearance C A 9 Engine breather tube for cracks C R C R C R C R C R 10 EVAP system Hoses check for cracks C R 11 Engine oil cooler fins C R C R C R C R C R C R 12 Silencer drain hole cleaning CL CL CL CL CL...

Page 41: ...required CL A CL A R CL A Replace at every 30000 kms C A C A C R C R C R C R C R C R C R C R C R Replace if required Need to remove RH Side cover Breather Tube is visible with this cover removed C R C R Drain EVAP Y connection drain tube Replace if found cut damaged C R C R C R C R C R C R C R C R C R If found damaged replace it CL CL CL CL CL CL CL CL CL CL CL CL CL R R Replace Viscous air filter...

Page 42: ...ve terminal cap fitment C A L T C A L T C A L T C A L T C A L T C A L T C A L T 15 Ignition switch contacts cleaning CL L CL L CL L CL L CL L 16 HT coil connections Primary and Secondary C T 17 Starter motor starter relay connections C T C T C T C T C T C T 18 Oil pressure indicator check on console post ignition ON C R C R C R C R C R C R C R 19 Check fault code Clear fault history Update latest ...

Page 43: ...ics battery tester In case of Battery removal 1 Battery negative terminal to be disconnected first 2 Latch seat bracket to be removed CL L CL L CL L CL L CL L CL L CL L CL L CL L Use recommended WD40 spray C T C T C T C T C T C T C T C T C T C T C T C R C R C R C R C R C R C R C R C R Icon should disappear post engine ON After 4000 rpm icon should not be displayed C C C C C C C C C C During 1st fr...

Page 44: ...ing arm NRB for more play 26 Front Rear Brake pads for wear limit C R C R C R R C R C R R 1 Check source of leakages if any in the brake system 2 Check Front rear brake hose condition 3 Check Brake fluid level and top up if needed 27 C A R C A R C A R C A R C A R C A R R 28 Rear sprocket fasteners for looseness C T C T C T C T 29 Rear wheel rubber shock dampers for excess play C R C R C R 30 Clutc...

Page 45: ... seal in pair at every 30000kms L Lubricate NRB at every 40 000 kms Use AP grease C R C R R C R C R R C R C R R Replace at every 15000 Kms Check Top up DOT4 brake Fluid in every service Replace DOT 4 brake Fluid Master Caliper seals at every 30000 kms C A R C A R R C A R C A R C A R C A R C A R C A R C T C T C T C T Torque 3 5 to 3 8 Kgf m C R C R C R C R Replace rear wheel rubber shock damper if ...

Page 46: ...ndation 4 Rider foot rest 5 Pillion Stay 36 C T C T C T C T C T C T C T Recommended frequency Service interval Kms Activities Check Points 29500 30000 24500 25000 19500 20000 14500 15000 9500 10000 4500 5000 500 750 7th 6th 5th 4th 3rd Free 2nd Free 1st Free Sr No 37 Mobile USB port C R C R C R C R C R C R C R 38 Drain hole no blockage verification below starter motor C CL C CL C CL C CL C CL C CL...

Page 47: ...C A C A C A C A C A Recommended Torque values Front rear axle 8 to 10 Kgf m Swing arm axle 13 to 15 Kgf m Engine foundation Front bottom 4 to 4 2 Kgf m Front Top 2 8 to 3 Kgf m Rear 4 to 4 2 Kgf m Top 2 2 to 2 4 Kgf m Rider foot rest 1 8 to 2 2 Kgf m Pillion stay 1 8 to 2 2 Kgf m C T C T C T C T C T C T C T C T C L C A C A C T C R C R C R C R C R C R C R C R C R Charging OK to be checked at Engine...

Page 48: ... fuel from the fuel tank and if fuel is left in for a longer time the fuel will break and gummy substance could clog the carburettor Remove spark plug put several drops of Engine oil into the cylinder Crank engine over slowly a few times to coat cylinder wall with oil install back spark plug Set the vehicle on a box or a stand so that both wheels are raised off the ground Spray oil on all unpainte...

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Page 50: ... by the customer Bajaj Auto Limited shall not be Liable to replace them though their dealer however Bajaj Dealers will provide full assistance in referring such claims with respective manufacturer Bajaj Auto Limited undertake no liability in the matter of consequential loss or damage caused due to the failure of the parts Delay if any at the repairing workshop in carrying out repair to vehicle sha...

Page 51: ...odic parts such as air filter oil filter etc as per periodic maintenance schedule Part C Further this warranty is NOT applicable to 1 Normal maintenance operations like brake clutch adjustments cleaning of fuel system engine tune up or such other adjustments 2 Parts subjected to normal wear tear like Clutch Plates Brake Shoes Chain Sprockets Fork Oil Seal Spark Plug Control Cables Brake Pads 3 Rep...

Page 52: ...ance and reliability 12 Vehicles which are not being serviced at recommended dealers as per the service schedule described or which have not been operated or maintained in accordance with the instructions maintained in the Owner s Manual 13 Vehicles used for any competition or race and or for attempting to set up any kind of record 14 Any failure arising due to use of adulterated or bad quality fu...

Page 53: ...48 Age Months ...

Page 54: ...10W 40 Top up bottle 40 10W 10W 40 40 10W BS 6 BS 6 comp lian t comp lian t USE ONLY BAJAJ GENUINE PARTS ...

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