Manual de Partes - Pulsar 150 Ug Iv
Manual de Partes - Pulsar 150 Ug Iv
Manual de Partes - Pulsar 150 Ug Iv
PULSAR 150 UG IV
GRUPO CROSLAND
Notice
All information contained in this manual 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 and without incurring an obligation to make such changes
to product manufactured previously. Contact your authorized
Bajaj Dealer for the latest information on product improvements
incorporated after this manual was issued.
Plate No. Description Page No. Plate No. Description Page No.
PLATE NO. : 1 PAGE NO. PLATE NO. : 2 PAGE NO. PLATE NO. : 5 PAGE NO. PLATE NO. : 6 PAGE NO.
COVER CYLINDER HEAD 1&2 CYLINDER HEAD 3&4 CYLINDER & PISTON 9 & 10 CRANKSHAFT 11 & 12
PLATE NO. : 3 PAGE NO. PLATE NO. : 4 PAGE NO. PLATE NO. : 7 PAGE NO. PLATE NO. : 8 PAGE NO.
VALVE 5&6 CAMSHAFT / TENSIONER 7&8 Balancer & Balancer Idler Gear 13 & 14 Transmission 15 & 16
Pictorial Index 150 Pictorial Index 150
PLATE NO. : 9 PAGE NO. PLATE NO. : 10 PAGE NO. PLATE NO. : 13 PAGE NO. PLATE NO. : 14 PAGE NO.
Change Drum / Shaft Fork 17 & 18 Gear Change Mechanism 19 & 20 Cover RH 25 & 26 Cover Magneto 27 & 28
PLATE NO. : 11 PAGE NO. PLATE NO. : 12 PAGE NO. PLATE NO. : 15 PAGE NO. PLATE NO. : 16 PAGE NO.
Engine Assly. & Crankcase RH 21 & 22 Crankcase LH 23 & 24 Clutch 29 & 30 Kick Starter Mechanism 31 & 32
Pictorial Index 150 Pictorial Index 150
PLATE NO. : 17 PAGE NO. PLATE NO. : 18 PAGE NO. PLATE NO. : 21 PAGE NO. PLATE NO. : 22 PAGE NO.
Carburettor 33 & 34 Air Cleaner Complete 35 & 36 Oil Pump 41 & 42 Magneto, CDI & H.T. Coil 43 & 44
PLATE NO. : 19 PAGE NO. PLATE NO. : 20 PAGE NO. PLATE NO. : 23 PAGE NO. PLATE NO. : 24 PAGE NO.
Silencer Assembly 37 & 38 Seat Assembly / Seat Lock 39 & 40 Starter Assembly (For Self Start) 45 & 46 Engine Mountings 47 & 48
Pictorial Index 150 Pictorial Index 150
PLATE NO. : 25 PAGE NO. PLATE NO. : 26 PAGE NO. PLATE NO. : 29 PAGE NO. PLATE NO. : 30 PAGE NO.
Frame and Frame Fittings 49 & 50 Swing Arm / Rear Shock Absorber 51 & 52 MUDGUARD FRONT & REAR 57 & 58 Stand Assembly 59 & 60
PLATE NO. : 27 PAGE NO. PLATE NO. : 28 PAGE NO. PLATE NO. : 31 PAGE NO. PLATE NO. : 32 PAGE NO.
Rider Foot Rest 53 & 54 Pillion Foot Rest / Holder 55 & 56 Tube / Tyre / Rim 61 & 62 FRONT HUB (FOR DRUM BRAKE) 63 & 64
Pictorial Index 150 Pictorial Index 150
PLATE NO. : 33 PAGE NO. PLATE NO. : 34 PAGE NO. PLATE NO. : 37 PAGE NO. PLATE NO. : 37A PAGE NO.
FR. Master Cylinder (For Disc Brake) 65 & 66 FRONT MASTER CYLINDER 67 & 68 Handle Bar 73 & 74 HANDLE BAR (Split Type) 75 to 78
PLATE NO. : 35 PAGE NO. PLATE NO. : 36 PAGE NO. PLATE NO. : 38 PAGE NO. PLATE NO. : 39 PAGE NO.
Rear Hub 69 & 70 REAR HUB 71 & 72 HANDLE BAR 79 & 80 Painted Parts & Decals 81/82/83/84
Pictorial Index 150 Pictorial Index 150
PLATE NO. : 40 PAGE NO. PLATE NO. : 41 PAGE NO. PLATE NO. : 44 PAGE NO. PLATE NO. : 45 PAGE NO.
Cap Tank & Gauge Fuel 85 & 86 Fittings P. Tank, Side Cover & Cover Seat 87 & 88 Chain Case 93 & 94 Head Lamp & Fairing 95 & 96
PLATE NO. : 42 PAGE NO. PLATE NO. : 43 PAGE NO. PLATE NO. : 46 PAGE NO. PLATE NO. : 47 PAGE NO.
Meter Assembly 89 & 90 Control Cables 91 & 92 Indicator Light Assembly 97 & 98 Tail Lamp Assly / FR & RR No. Plate 99 & 100
Pictorial Index 150
11 31 1011 06 Gasket 2
1 2
Front Wheel Direction
150 Plate No.: 2 Brand ID: 001MC606
Cylinder Head
12 36 DS10 01 ‘O’ Ring Kit For Cover Cyl. Head 1 Refer Page No.103
3 4
Front Wheel Direction
150 Plate No.: 3 Brand ID: 001MC606
Valve
5 6
Front Wheel Direction
150 Plate No.: 4 Brand ID: 001MC606
Camshaft / Tensioner
7 8
Front Wheel Direction
150 Plate No.: 5 Brand ID: 001MC606
9 10
Front Wheel Direction
150 Plate No.: 6 Brand ID: 001MC606
Crank shaft
11 12
Front Wheel Direction
150 Plate No.: 7 Brand ID: 001MC606
11 39 1674 04 Bolt 3
13 14
Front Wheel Direction
150 Plate No.: 8 Brand ID: 001MC606
Transmission
15 16
Front Wheel Direction
150 Plate No.: 9 Brand ID: 001MC606
10
2
2
3
17 18
Front Wheel Direction
150 Plate No.: 10 Brand ID: 001MC606
4
3
7
19 20
Front Wheel Direction
150 Plate No.: 11 Brand ID: 001MC606
8
6
9
7
10
4
21 22
Front Wheel Direction
150 Plate No.: 12 Brand ID: 001MC606
Crankcase LH
1 DJ 1013 44 Crankcase LH 1
2 39 2531 05 Stud 2
3 DH 1016 54 Guide Starter Assly 1
12 14 4 39 1715 19 Oil Seal 1
13 5 DH 1014 23 O’ Ring 1
2
2
24 6 39 0752 01 C’ Sunk Head Screw 3
21 7 39 2603 20 Bearing Ball (for Input Shaft) 1
8 39 2583 20 Bearing Ball (for Output Shaft) 1
9 39 2185 20 Balancer LH Bearing 1
9
20 10 39 2189 19 Oil Seal (For Output Shaft) 1
23 7
11 39 2190 19 Oil Seal (For Shift Lever) 1
12 DH 1012 03 Breather Pipe 1
5
4 13 DH 1012 46 Rubber Tube 1
24
14 28 1011 74 Spring Clip 1
6 8 15 DH1016 61 Plug (Drain Bolt) 1
16 10
16 31 1011 06 Gasket (For Drain Bolt) 1
15 19 17 DK 1013 80 Switch Comp.(Neutral) 1
18 18 DH 1017 84 Gasket Neutral Switch 1
1 19 DJ 2010 21 Cable Assly. (Battery To Earth) 1
3 17
20 39 2448 11 Plain Washer 1
11
25 21 39 1845 04 Flanged Bolt 1
22 39 1677 04 Bolt 8
22 23 39 2305 04 Bolt 1
24 DH 1014 22 Damper 1
25 DH 1011 69 Bush Starter Gear Inner 1
23 24
Front Wheel Direction
Plate No.: 13 Brand ID: 001MC606
150
Cover RH
1 52 DJ 01 96 Cover Comp RH 1
17 1A 36 DH40 31 Kit Assly. CL Cover K1 Flower Type 1 Ref. Cir. C-31
12 18 2 DH 1011 97 Grommet Breather 1
4
9 6 3 30 1011 42 Seal Kick Shaft 1
7
8 4 39 1041 19 Seal Clutch Lever 1
23 22
19 5 DH 1011 41 Rack 1
20
6 DH 1011 42 Shaft Clutch Release 1
2 3 7 39 2202 07 Parallel Pin 1
8 DG 1014 18 Gauge 1
13 11 9 DS 1012 15 Wire Circlip 1
5 10 DS 1013 53 Bolt 10
25 26
Front Wheel Direction
150 Plate No.: 14 Brand ID: 001MC606
Cover Magneto
12A
1A
27 28
Front Wheel Direction
150 Plate No.: 15 Brand ID: 001MC606
Clutch
29 30
Front Wheel Direction
150 Plate No.: 16 Brand ID: 001MC606
31 32
Front Wheel Direction
150 Plate No.: 17 Brand ID: 001MC606
Carburettor
6 DJ 1210 54 Screw 2
DH 1211 61 Screw (K1 UG4.5) 1 Ref. Cir. C-21
7 DJ 1210 55 Float Assly. 1
4
DH 1211 62 Float Assly. (K1 UG4.5) 1 Ref. Cir. C-21
12 8 36 DH12 03 Jet Holder Kit 1 Ref. Page No.105
3 DH 1211 66 Jet Kit (K1 UG4.5) 1 Ref. Cir. C-21
8 13
9 DH 1211 01 Magnet Assly. 1 TPS Assly.
7
5 10 DJ 1210 70 Reed Switch Assly. 1 Parts
2 1
11 39 1780 01 Pan Head Screw 2
6 9 12 DH 1210 93 Needle Assly. 1
11
6 13 DH 1211 50 Set Adjuster 1
14 DJ 1210 49 Set Plunger Assly. 1
10
33 34
Front Wheel Direction
150 Plate No.: 18 Brand ID: 001MC606
35 36
Front Wheel Direction
150 Plate No.: 19 Brand ID: 001MC606
Silencer Assembly
10
7 6
1
37 38
Front Wheel Direction
150 Plate No.: 20 Brand ID: 001MC606
39 40
Front Wheel Direction
150 Plate No.: 21 Brand ID: 001MC606
Oil Pump
6
1
41 42
Front Wheel Direction
150 Plate No.: 22 Brand ID: 001MC606
8
2
11
43 44
Front Wheel Direction
150 Plate No.: 23 Brand ID: 001MC606
45 46
Front Wheel Direction
150 Plate No.: 24 Brand ID: 001MC606
Engine Mountings
6
7 7
9
8 5
11
47 48
Front Wheel Direction
150 Plate No.: 25 Brand ID: 001MC606
8/9
2
2
49 50
Front Wheel Direction
150 Plate No.: 26 Brand ID: 001MC606
2 14
16
15
13
16
15
51 52
Front Wheel Direction
150 Plate No.: 27 Brand ID: 001MC606
2 2 5
2 3
1
4
9
8
6 7
53 54
Front Wheel Direction
150 Plate No.: 28 Brand ID: 001MC606
8 7
9
5 3
55 56
Front Wheel Direction
150 Plate No.: 29 Brand ID: 001MC606
7
8
11
10
57 58
Front Wheel Direction
150 Plate No.: 30 Brand ID: 001MC606
Stand Assembly
13
59 60
Front Wheel Direction
150 Plate No.: 31 Brand ID: 001MC606
4 5
61 62
Front Wheel Direction
150 Plate No.: 32 Brand ID: 001MC606
16
8
9
12
13
63 64
Front Wheel Direction
150 Plate No.: 33 Brand ID: 001MC606
TA
ON AP
13 10 DJ 1910 31 Screw 2
BR D C R C ING
1
LE E V
EA FILL MO
A S EAN E RE
L
C FO R
BE
15
11 DJ 1910 32 Cylinder Master 1
5 DE 1510 15 Cylinder Master 1 KBX
5 12 DJ 2011 00 Front Brake Switch 1
4 13 DJ 1910 34 Reservoir Cover 1
14 14 DJ 1910 35 Diaphragm 1
15 36 DH19 02 Oil Window Kit 1
7
7
2
11 6
12
5
4
65 66
Front Wheel Direction
150 Plate No.: 34 Brand ID: 001MC606
1
3
PAD SPRING
10
67 68
Front Wheel Direction
150 Plate No.: 35 Brand ID: 001MC606
Rear Hub
11 DJ 1510 34 Collar 1
18 4 12 39 2567 11 Plain Washer 1
13 DH 1710 19 ‘U’ Nut 1
13 14 39 0801 15 Nut 1
11 15 39 2566 11 Plain Washer 1
2 3
1 10
12 16 DJ 1510 35 Collar 1
17 36 DH40 13 Chain Sprocket Kit 1 Ref Page No.104
6
18 DS 1510 74 Lock Washer 3
5 19 30 1510 82 Seal Oil 1
7 8 20 39 2240 20 Bearing Ball 1
5 9
21 DS 1510 68 Coupling 1
22 DS 1510 73 ‘D’ Bolt 6
23 DJ 1510 33 Sleeve 1
24 39 0794 15 Hex. Lock Nut 6
25 DJ 1510 53 Drive Chain Lock 1
69 70
Front Wheel Direction
150 Plate No.: 36 Brand ID: 001MC606
6
2
10
5
7
7
71 72
Front Wheel Direction
150 Plate No.: 37 Brand ID: 001MC606
Handle Bar
I G N I T
FF O
E
K
O
H
C
L O
SS
E
-R
PA
N
R
U
T
20 12 DH 1910 07 Grip LH 1
4
13 DH 1910 08 Grip Assly. RH 1
9 14 14 DH 1910 19 Boot For Lever 1
15 DJ 1810 11 Handle Bar Weight 2
16
13 15
8 16 39 2427 04 Hex. Socket Head Cap Screw 2 Alt. 39 242704
7 17 DJ 1810 39 Pad Holder Handle 1
22 18 DJ 2210 03 Mirror Assly. LH 1
12
15 19 DJ 2210 04 Mirror Assly. RH 1
16 20 JB 4014 02 Switch Assly. Ignition 1
10 6 21 39 1943 04 Flange Bolt 2
11 22 DJ 2011 95 Clutch Switch 1
23 23 DJ 2012 11 Hall Sensor Assly. 1
24 24 39 2208 04 Flange Bolt 2
25 DH 1810 69 4 In 1 Lock Set With Key 1 N.I.
73 74
Front Wheel Direction
Brand ID: 001MC606
150 Plate No.: 37A
Handle Bar ( Split Type )
N 19
6 JC 2010 18 Control Switch RH 1
O
I
L OF ON
I G N I T
7 DJ 1910 54 Holder LH 1
F
E
-R
H LO
PUS CK
25
18 8 DJ 1910 55 Lever LH 1
23 9 DL 1910 14 Stud Lever Handle 1
29
10 30 1910 17 Self Locking Nut 1
26 27
28 6
14 4 11 DD 1911 47 Adjusting Screw 1
12 DH 1910 07 Grip LH 1
20 2
5 13 DH 1910 08 Grip assly. RH 1
9
14 DH 1910 19 Boot for lever LH 1
22 1 15 DJ 1810 11 Handle bar weight 2
8 3
11
16 39 2427 04 Hex. Soc. Hd. Cap Screw 2
12
15 7 17 DS 1910 52 Lever Boot for Clutch Switch 1 N.I.
16 18 JB 4014 02 Switch Assly. Ignition 1
10 21 19 38 1943 04 Flange Bolt 2
20 DK 1810 31 Bush Silent Handle Bar Tube 2
75 76
Front Wheel Direction
Brand ID: 001MC606
150 Plate No.: 37A
Handle Bar ( Split Type )
26 DK 1810 58 Bolt 2
N
O
19
I
L OF ON
I G N I T
27 39 1180 11 Washer 2
F
E
-R
H LO
PUS CK
25
18 28 DH 1810 99 Rubber Plug 2
23
29 DJ 2210 03 Mirror Assly. LH 1
29
30 DJ 2210 04 Mirror Assly. RH 1
26 27
28 6
14 4
20 2
5
9
22 1
8 3
11
12
15 7
16
10 21
77 78
Front Wheel Direction
150 Plate No.: 38 Brand ID: 001MC606
Front Fork
79 80
Front Wheel Direction
150 Plate No.: 39 Brand ID: 001MC606
81 82
Front Wheel Direction
150 Plate No.: 39 Brand ID: 001MC606
83 84
Front Wheel Direction
150 Plate No.: 40 Brand ID: 001MC606
11 30 1410 32 Bolt 4
12 DJ 1410 06 Tube Fuel 1
4
6 13 BA 1220 03 Pipe Clip 1
14 DH 1410 24 Drain Tube 1
15 DG 1410 28 Clamp 1
85 86
Front Wheel Direction
150 Plate No.: 41 Brand ID: 001MC606
1 36 DH16 01 Grommet Kit For Side Cover 1 Ref. Page No. 103
2 DH 1410 31 Tape Tank Inner 2
3 39 1606 01 Screw 2 Alt.DG161121
4 39 2424 11 Plain Washer 1
5 39 1556 04 Flange Bolt 1
6 DH 1410 23 Damper 1
7 DJ 1410 08 Damper Front 2
8 39 1902 04 Flanged Bolt 1
15
9 DK 1611 23 Cover Side Mesh LH 1
11 10 DK 1611 24 Cover Side Mesh RH 1
16 5
4
11 59 0200 01 Self Tap Screw 6
8 17 12 31 1610 18 Damper 2
13 13 JW 1710 07 Dual Tape 2
14 JD 1710 18 Special Tape 2
7
15 JC 1410 15 Grommet 2
2 6 3 16 JC 1410 17 Grommet II 2
1
17 JC 1410 16 Collar 2
11
9/10
12
87 88
Front Wheel Direction
150 Plate No.: 42 Brand ID: 001MC606
Meter Assembly
7
7
6
3 8
10
12
F
6
E km/h
4 x 1 0 0 rpm
2 SIDE
STAND
1
89 90
Front Wheel Direction
150 Plate No.: 43 Brand ID: 001MC606
Control Cables
91 92
Front Wheel Direction
150 Plate No.: 44 Brand ID: 001MC606
Chain Case
1
5
5 4
3 6
5
93 94
Front Wheel Direction
150 Plate No.: 45 Brand ID: 001MC606
17
95 96
Front Wheel Direction
150 Plate No.: 46 Brand ID: 001MC606
7/8
3/4
97 98
Front Wheel Direction
150 Plate No.: 47 Brand ID: 001MC606
4
3 2 6 39 1972 15 Bolt Flange 2
7 30 2010 29 Lamp 12V-4W 1
5 8 JW 4010 11 No. Plate Illumination 1
9 DJ 1610 72 Rear No. Plate Bkt. 1
10 DP 1611 45 Number Plate Rear 1
6
11 39 1680 04 Hex Flanged Bolt 2
12 39 1783 01 Truss Screw 2 For Front No. Plate
13 1
7 13 DP 1611 44 Number Plate Front 1
14 DH 1612 92 No. Plate Mounting Bracket 1
12 15 39 1074 04 Bolt Flange 2
8
14
15 10 11
99 100
Front Wheel Direction
150 Plate No.: 48 Brand ID: 001MC606
Electrical Equipments
13
101 102
Front Wheel Direction
150 Plate No.: 49 Brand ID: 001MC606
Tool Kit
1
2
103 104
Front Wheel Direction
150 Plate No.: 50 Brand ID: 001MC606
105 106
Front Wheel Direction
Kit List 150 Kit List 150
1 36DS1001 Cyl.Head O Ring Kit 39239121 O Ring (Cover tappet) 2 39071111 Plain washer 3
39128321 O ring 2 13 36DK0015 Kit element air filter DK121002 Element air filter fine 1
2 36DJ1004 Valve Kit DJ101124 Valve Intake 1 DK121003 Element air filter coarse 1
DJ101125 Valve Exhaust 1 14 36DH4011 Kit hardware shield DH101301 Seal shield muflar 2
DH101395 Trust screw 2
DH101481 Grommet shield 1
3 36DK0005 Valve Repair Kit DS101083 Retainer valve spring 2 15 36DK0009 Kit hardware silencer 39185004 Flange bolt 1
DH101731 Spring valve inner 2 39242511 Plain washer 1
DH101730 Spring valve outer 2 DD161071 U nut 1
DH101026 Seat valve spring 2 DH161155 Damper silencer 1
4 36DK0039 Guide Chain Kit DH101017 Guide chain (Tight) 1 DH161157 Tube silencer mounting 1
DK101059 Guide Chain (slack) 1
16 36DK0011 Kit hardware engine mounting 39231204 Bolt flange 4
5 36DH4009 Set primary drive & driven DH101628 Gear primary drive 1
39197015 Nut flange 8
DH101859 Clutch Housing com. 1
39241304 Bolt flange 1
6 36DH4019 Kit centrifugal oil filter 39220011 Washer 1
DH161245 U Nut 3
DH101234 Gasket centrifugal oil filter 1
17 36DS1802 Bearing cone kit DH181025 Bearing cone 1
Dh101640 Screw 1
DH181026 Bearing race 1
DH101066 Join oil dealivery 1
DH181024 Upper bearing race 1
DH101067 Spring oil delivery 1
39219908 Pin oil delivery joint 1 18 36DK0012 Kit bush rear shock absorber 39071411 Plain washer 8
7 36DH1004 Set Damper DH101284 Damper A 1 39071215 Dome cap nut 2
DH101286 Damper C 1 19 36DK0013 Kit hardware pillion DJ161186 Plait side pillion stape 2
DH101287 Damper D 1 DH161061 Pin pillion set 2
8 36DH1005 Set of Plate DH101288 Plate A 1 30141031 "O" ring 2
DH101289 Plate B 1 39104011 Plain washer 2
DH101290 Plate C 1 39078408 Split pin 2
DH101291 Plate D 1 20 36DH4012 Kit lever brake 30151038 "O" ring 1
9 36DH1006 Set Damper DH101282 Damper Cover Magneto 1 30101005 Indicator 1
DH101292 Damper A Cover LH RR 1 DJ151059 Lever brake 1
DH101294 Damper B Cover LH RR 1 39244704 Lever brake 1
10 36DH1007 Set of Plate DH101283 Plate Damper 1 39079815 Nut 1
DH101293 Plate Damper Cover LH RR 1 21 36DH4013 Chain sprocket kit DH151056 Sprocket (43 teeth) 1
11 36DH1008 Boss Kick Set DH101185 Spring Kick Starter Arm 1 Dh151051 Chain 1
DH101068 Ball steel 1 DH101117 Sprocket Drive 1
DH101547 Base kick lever 1 22 36DK0016 Kit hardware bracket pedal 39212104 Flange bolt 1
DH101548 Hex. bolt with flange 1 DH191013 Sprocket brake shifter assly 1
DH101320 Bolt 1 39153721 "O" ring 1
12 36DH4010 Kit Hardware Air Cleaner DH101320 Bracket lock 1 DH191023 Dust cap 1
1110609 Plain washer 1
39178001 Screw pan cross 1
39177304 Bolt flange 4
31121043 Coller 3
107 108
Front Wheel Direction
Kit List 150 Kit List 150
109 110
Front Wheel Direction
Parts Index 150 Parts Index 150
111 112
Parts Index 150 Parts Index 150
113 114
Parts Index 150 Parts Index 150
119 120
Parts Index 150 Parts Index 150
121 122