Пульсар нс 200 мануал

[Page 1] Kawasaki BAJAJ Pulsar 200 NS

Pulsar 200 NS Rouser 200 NS Motorcycle Service Manual
…

[Page 2] Kawasaki BAJAJ Pulsar 200 NS

…

[Page 3] Kawasaki BAJAJ Pulsar 200 NS

This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectio…

[Page 4] Kawasaki BAJAJ Pulsar 200 NS

…

[Page 5] Kawasaki BAJAJ Pulsar 200 NS

Pulsar 200 NS Rouser 200 NS Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or othe…

[Page 6] Kawasaki BAJAJ Pulsar 200 NS

LIST OF ABBREVIATIONS A ampere(s) km/h kilometers per hour ABDC after bottom dead center L liter(s) AC alternating current lb pound(s) Ah ampere hour LCD Liquid Crystal Display ATDC after top dead center LED Light Emitting Diode BBDC before bottom de…

[Page 7] Kawasaki BAJAJ Pulsar 200 NS

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repa…

[Page 8] Kawasaki BAJAJ Pulsar 200 NS

…

[Page 9] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-1 1 General Information Table of Contents Before Servicing ……………………………………………………………………………………………………… 1-2 Model Identification…………………………

[Page 10] Kawasaki BAJAJ Pulsar 200 NS

1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions…

[Page 11] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-3 Before Servicing Arrangement and Clea ning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage o…

[Page 12] Kawasaki BAJAJ Pulsar 200 NS

1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence …

[Page 13] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ba…

[Page 14] Kawasaki BAJAJ Pulsar 200 NS

1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil …

[Page 15] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-7 Model Identification BR200AD Left Side View BR200AD Right Side View Frame Number Engine Number
…

[Page 16] Kawasaki BAJAJ Pulsar 200 NS

1-8 GENERAL INFORMATION Model Identification BR200AE Left Side View BR200AE Right Side View
…

[Page 17] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-9 General Specifications Items BR200AD/AE Dimensions Overall Length 1 965 mm (77.36 in.) Overall Width 810 mm (31.9 in.) Overall Height 1 055 mm (41.54 in.) Wheelbase 1 360 mm (53.54 in.) Road Clearance 165 mm (6.50 in.) Seat He…

[Page 18] Kawasaki BAJAJ Pulsar 200 NS

1-10 GENERAL INFORMATION General Specifications Items BR200AD/AE Engine Oil: Type APISLwithJASOMA2 Viscosity SAE 20W-50 Capacity 1.4L(1.5USqt) Drive Train Primary Reduction System: Type Gear Reduction Ratio 3.273 (72/22) Clutch Type Wet multi disc Tr…

[Page 19] Kawasaki BAJAJ Pulsar 200 NS

GENERAL INFORMATION 1-11 General Specifications Items BR200AD/AE Electrical Equipment Battery 12 V 8 Ah Headlight: Type Semi-sealed beam Bulb: High Beam 12 V 60 W Low Beam 12 V 55 W Tail/Brake Light LED Alternator: Type Three-phase AC Maximum Output …

[Page 20] Kawasaki BAJAJ Pulsar 200 NS

1-12 GENERAL INFORMATION Unit Conversion Table Prefixes for Units: Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0.01 milli m × 0.001 micro µ × 0.000001 Units of Mass: kg × 2.205 = lb g × 0.03527 = oz Units of Volume: L × 0….

[Page 21] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance Table of Contents Periodic Maintenance Chart ……………………………………………………………………………………… 2-3 Torque and Locking Agent…………………………..

[Page 22] Kawasaki BAJAJ Pulsar 200 NS

2-2 P ERIODIC MAINTENANCE Caliper Rubber Parts Replacement ………………………………………………………………………. 2-36 Brake Pad Wear Inspection ……………………………………………………………………..

[Page 23] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart Servicing: 1st 500 ∼ 750 km/30 ∼ 45 days, 2nd onward at every 5 000 km C: Check, A: Adjust, CL: Clean, R: Replace, T: Tighten, L: Lubricate *: More frequent cleaning may be required when driving…

[Page 24] Kawasaki BAJAJ Pulsar 200 NS

2-4 P ERIODIC MAINTENANCE Periodic Maintenance Chart RECOMMENDED FREQUENCY Ser- vic- ing 1st 2nd 3rd 4th 5th 6th 7th Operation Km × 100 5 ∼ 7.5 45 ∼ 50 95 ∼ 100 145 ∼ 150 195 ∼ 200 245 ∼ 250 295 ∼ 300 Subse- quent See Page Wheel and ti…

[Page 25] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-5 Periodic Maintenance Chart RECOMMENDED FREQUENCY Ser- vic- ing 1st 2nd 3rd 4th 5th 6th 7th Operation Km × 100 5 ∼ 7.5 45 ∼ 50 95 ∼ 100 145 ∼ 150 195 ∼ 200 245 ∼ 250 295 ∼ 300 Subse- quent See Page Starter locko…

[Page 26] Kawasaki BAJAJ Pulsar 200 NS

2-6 P ERIODIC MAINTENANCE Torque and Locking Agent The following tables lists the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: L: Appl…

[Page 27] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks MufflerEndCoverScrews 6.9 0.70 61 in·lb L Clutch Clutch Cover Bolts 11 1.1 97 in·lb Clutch Hub Nut 69 7.0 51 L, Lh Clutch Stopper Bolts 11 1.1 97 in·lb Oi…

[Page 28] Kawasaki BAJAJ Pulsar 200 NS

2-8 P ERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Rear Sprocket Stud Bolts 34 3.5 25 L Brakes Front Caliper Mounting Bolts 25 2.5 18 L Front Brake Disc Mounting Bolts 28 2.9 21 L Rear Brake Disc Mounting Bo…

[Page 29] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-9 Torque and Locking Agent Torque Fastener N·m kgf·m ft·lb Remarks Rear Fender Bolts 4.9 0.50 43 in·lb Electrical System Spark Plugs 14 1.4 10 Alternator Rotor Bolt 58 5.9 43 L Stator Coil Bolts 7.4 0.75 65 in·lb L Water T…

[Page 30] Kawasaki BAJAJ Pulsar 200 NS

2-10 PERIODIC MAINTENANCE Torque and Locking Agent The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value….

[Page 31] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-11 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 350 ∼ 1 450 r/min (rpm) ––– Air Cleaner Element Dry paper type ––– Cooling Sy…

[Page 32] Kawasaki BAJAJ Pulsar 200 NS

2-12 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Brakes Brake Fluid: Grade DOT3 or DOT4 ––– Brake Pad Lining Thickness: Front 6.35 mm (0.250 in.) 1 mm (0.04 in.) Rear 6.0 mm (0.236 in.) 1 mm (0.04 in.) Brake Light Timing: Fr…

[Page 33] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-13 Special Tools Inside Circlip Pliers: 57001-143 Outside Circlip Pliers: 57001-144 Steering Stem Nut Wrench: 57001-1100 Valve Adjusting Screw Holder: 57001-1217 Jack: 57001-1238
…

[Page 34] Kawasaki BAJAJ Pulsar 200 NS

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Air Clean er Element Cleaning NOTE ○ In dusty areas, the element should be cleaned more frequently than the recommended interval. ○ After riding through rain or on muddy roads,…

[Page 35] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Push the air cleaner cover [A] forward [B] to clear the tabs [C], and remove the air cleaner cover. • Remove the air cleaner element [A] from the air cleaner cover [B]. • Replace the a…

[Page 36] Kawasaki BAJAJ Pulsar 200 NS

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make…

[Page 37] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Choke Operation Inspection • Check that the choke lever [A] moves smoothly. If the choke lever does not moves smoothly, inspect the choke plunger damage (see Carburetor Disassembly/As- sembl…

[Page 38] Kawasaki BAJAJ Pulsar 200 NS

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Hose Replacement WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated…

[Page 39] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Cooling System Coolant Level Inspection NOTE ○ Check the level when the engine is cold (room or ambi- ent temperature). • Check the coolant level in the reserve tank [A] with the motorcycl…

[Page 40] Kawasaki BAJAJ Pulsar 200 NS

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Fuel Tank Cover (see Fuel Tank Cover Removal in the Frame chapter) Radiator Cap [A] ○ Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop….

[Page 41] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures • When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions. NOTICE Soft or distilled water must be used with the an- tifreeze in the …

[Page 42] Kawasaki BAJAJ Pulsar 200 NS

2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove: Cylinder Head Cover (see Cylinder Head Cover Re- moval in the Engine Top End chapter) Timing Inspection Cap [A] • Turn the camshaft clockwise, and align the “T” mark [A] on t…

[Page 43] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Valve Clearance Adjustment • Loosen the valve adjusting screw locknut [A] and insert the thickness gauge [B] between the valve and adjusting screw [C], and turn the s crew until the adjustin…

[Page 44] Kawasaki BAJAJ Pulsar 200 NS

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Clutch Clutch Operation Inspection • Slide the dust cover [A]. • Pull the clutch lever just enough to take up the free play [A]. • Measure the gap between the lever [B] and the lever hol…

[Page 45] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures Engine Lubrication System Engine Oil Change • Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily. Then stop the engine. • Place an oil pan beneath the…

[Page 46] Kawasaki BAJAJ Pulsar 200 NS

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Oil Strainer Cleaning • Clean the screen [A] of the oil strainer with a high flash -point solvent and remove any particles stuck to them. NOTE ○ While cleaning the screen, check for any me…

[Page 47] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Replace the oil filter cap O-ring [A] with a new one. • Apply grease to the O-ring. • Install the oil filter cap [B]. • Tighten: Torque — Oil Filter Cap Bolts: 6.9 N·m (0.70 kgf·m,…

[Page 48] Kawasaki BAJAJ Pulsar 200 NS

2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Tread Depth Standard: Front 5.0 mm (0.20 in.) Rear 6.0 mm (0.24 in.) Service L imit: Front 1 mm (0.04 in.) Rear 1 mm (0.04 in.) WARNING Some replacement tires may adversely affect han- dling a…

[Page 49] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures Final Drive Drive Chain Lubrication Condition Inspection Lubrication is necessary after riding through rain or on wet roads, or any time that the chain appears dry. Use a lubricant for sealed …

[Page 50] Kawasaki BAJAJ Pulsar 200 NS

2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive C hain Slack A djustment • Loosen the rear axle nut [A]. • Turn both chain adjusters [B] evenly until the drive chain has the correct amount of slack. To keep the chain and wheel pro…

[Page 51] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures WARNING A chain that breaks or jumps off the sprockets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. Inspect t…

[Page 52] Kawasaki BAJAJ Pulsar 200 NS

2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Hose Installation Condition Inspection • Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. ○ The high pressure inside the brake line can cause flui…

[Page 53] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Check that the brake fluid level in the rear brake reservoir [A] is above the lower level line [B]. If the fluid level is lower than the lower level line, fill the reservoir to the upper l…

[Page 54] Kawasaki BAJAJ Pulsar 200 NS

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Remove the rubber cap [A] from the bleed valve on the caliper. • Attach a clear plastic hose [B] to the b leed valve, and run the other end of the hose into a c ontainer. • Fill the re…

[Page 55] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Brake Hose Replacement NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. • Remove: Headlight Assy (see Headlight Cove…

[Page 56] Kawasaki BAJAJ Pulsar 200 NS

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures Rear Master Cylinder Disassembly • Remove the rear master cylinder (see Rear Master Cylin- der Removal in the Brakes chapter). • Remove the piston assembly [A] as follows. ○ Remove the d…

[Page 57] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures • Using compressed air, remove the pistons. ○ Cover the caliper opening with a clean heavy cloth [A]. ○ Blow compressed air [B] into the hole for the banjo bolt to remove the piston. WAR…

[Page 58] Kawasaki BAJAJ Pulsar 200 NS

2-38 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Install the pad spring [A]. • Install the pads (see Front Brake Pad Installation in the Brakes chapter). • Wipe up any spilled brake fluid on the caliper with wet cloth. Rear Caliper D…

[Page 59] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-39 Periodic Maintenance Procedures • Replace the fluid seal [A] and the dust seal [B] with new ones. ○ Apply brake fluid to the seals, and install them into the cylinder by hand. NOTE ○ The fluid seal, dust seal and frict…

[Page 60] Kawasaki BAJAJ Pulsar 200 NS

2-40 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Light Switch Operation Inspection • Turn the ignition switch on. • The tail/brake light (LED) [A] should go on when the brake lever is applied or after the brake pedal is depressed a…

[Page 61] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-41 Periodic Maintenance Procedures • Pump the rear seat down and up [A] 4 or 5 times, and inspect the smooth stroke. If the shock absorber does not smoothly stroke or noise is found, inspect the oil leak (see Rear Shock Absor…

[Page 62] Kawasaki BAJAJ Pulsar 200 NS

2-42 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Play Adjustment • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) • Loosen the steering stem head bolt [A]. • Adjust the steering using the steering stem nu…

[Page 63] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-43 Periodic Maintenance Procedures Electrical System Lights and Switches Operation Inspection First Step • Set the gear position in the neutral position and side stand to down. • Turn the ignition switch on. • The followi…

[Page 64] Kawasaki BAJAJ Pulsar 200 NS

2-44 PERIODIC MAINTENANCE Periodic Maintenance Procedures Second Step • Turn the ignition switch on. • Turn on the turn signal switch [A] (left or right position). • The left or right turn signal lights [B] (front and rear) ac- cording to the s…

[Page 65] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-45 Periodic Maintenance Procedures Third Step • Set the dimmer switch [A] to low beam position. • Start the engine. • The following lights should go on according to below table. Low Beam Headlight [B] Goes on City Lights …

[Page 66] Kawasaki BAJAJ Pulsar 200 NS

2-46 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ On high beam, the brightest point [A] should be slightly below horizontal with the motorcycle on i ts wheels and the rider seated. Adjust the headlight to the proper an- gle according…

[Page 67] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-47 Periodic Maintenance Procedures • Insert the spark plug vertically into the spark plug hole with the spark plug installed in the plug wrench [A], and finger-tighten it first. NOTICE If tightening the spark plug with the wr…

[Page 68] Kawasaki BAJAJ Pulsar 200 NS

2-48 PERIODIC MAINTENANCE Periodic Maintenance Procedures Wiring Harness Inspection • Inspect the following to avoid wiring harness failures. 1. Ensure wiring harness is properly routed and clamped. 2. Ensure firm connections of all connectors. 3. …

[Page 69] Kawasaki BAJAJ Pulsar 200 NS

PERIODIC MAINTENANCE 2-49 Periodic Maintenance Procedures Chassis Parts Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with…

[Page 70] Kawasaki BAJAJ Pulsar 200 NS

2-50 PERIODIC MAINTENANCE Periodic Maintenance Procedures Condition of Bolts, Nuts and Fasteners Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition…

[Page 71] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-1 3 Fuel System Table of Contents Exploded View………………………………………………………………………………………………………… 3-2 Specifications …………………………………………….

[Page 72] Kawasaki BAJAJ Pulsar 200 NS

3-2 FUEL SYST EM Exploded View
…

[Page 73] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Throttle Sensor Mounting Bolt 5.0 0.51 44 in·lb R: Replacement Parts
…

[Page 74] Kawasaki BAJAJ Pulsar 200 NS

3-4 FUEL SYST EM Exploded View
…

[Page 75] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-5 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel Tap Mounting Bolts 3.9 0.40 35 in·lb 2 Fuel Tank Cap Bolts 4.9 0.50 43 in·lb 3 Fuel Tank Bolts 20 2.0 15 R: Replacement Parts
…

[Page 76] Kawasaki BAJAJ Pulsar 200 NS

3-6 FUEL SYST EM Specifications Item Standard Throttle Grip and Cable Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Carburetor Make/Type UCAL/UCD33 Idle Speed 1400±50r/min(rpm) Pilot Screw 2 turns out (for reference) Float Height 7.1 ±1 mm…

[Page 77] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-7 Throttle Grip and Cable Free Play Inspection • Refer to the Throttle Control System Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Control System Inspection in the Pe- riodic Mainten…

[Page 78] Kawasaki BAJAJ Pulsar 200 NS

3-8 FUEL SYST EM Throttle Grip and Cable • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System chapter) Plug [A] • Remove [A] the throttle cable [B]. • Rem…

[Page 79] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-9 Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Pilot Screw Adjustment …

[Page 80] Kawasaki BAJAJ Pulsar 200 NS

3-10 FUEL SYSTEM Carburetor • Measure the height [A] between the float bowl mating sur- face [B] and the float upper surface [C]. NOTE ○ Measure the height with the carburetor upside down. ○ Do not push the needle rod in during the float height…

[Page 81] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-11 Carburetor • Turn the fuel tap to “OFF.” • Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System chapter) Throttle C able Tip (Lower) (see…

[Page 82] Kawasaki BAJAJ Pulsar 200 NS

3-12 FUEL SYSTEM Carburetor Carburetor Installation • Installation is the reverse of removal. • Fit the carburetor projection [A] into the groove [B] of the carburetor holder [C]. • Check that the carburetor is installed horizontally. • Tight…

[Page 83] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-13 Carburetor Carburetor Disassembly • Remove the carburetor (see Carburetor Removal). • Remove the following parts from the carburetor body. • Remove the float bowl (see Float Height Inspection). NOTICE The pilot screw is set at …

[Page 84] Kawasaki BAJAJ Pulsar 200 NS

3-14 FUEL SYSTEM Carburetor • Install: Jet Needle Washer Spring Spring Seat [A] ○ Install the spring seat by turning it. • Fit the choke lever [A] to the choke plunger [B]. • Fit the groove [C] of the choke lever to the projection [D] of the …

[Page 85] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-15 Carburetor • Check the float valve needle [A]. It should be smooth with- out any grooves, s cratches, or tears. If the tip is damaged [B], replace the float valve needle. • Push the rod [C] in the float valve needle, then release…

[Page 86] Kawasaki BAJAJ Pulsar 200 NS

3-16 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion, it will prevent the engine from idling smoothly. Re- place it. Carburetor Cleanin…

[Page 87] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-17 Air Cleaner Air Cleaner Element Removal/Installation • Refer to the Air Cleaner Element Replacement in the Pe- riodic Maintenance chapter. Air Cleaner Element Cleaning and Inspection • Refer to the Air Cleaner Element Cleaning in…

[Page 88] Kawasaki BAJAJ Pulsar 200 NS

3-18 FUEL SYSTEM Air Cleaner Air Cleaner Drain C ap Inspection • Visually check the drain plug [A] if the water or oil accu- mulates. If any water or oil accumulates in the drain plug, remove the drain plug and drain it.
…

[Page 89] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-19 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be explo- sive under certain conditions, creating the potential for serious burns. Make sure the area is well venti- lated and free from any source of flame …

[Page 90] Kawasaki BAJAJ Pulsar 200 NS

3-20 FUEL SYSTEM Fuel Tank • Remove the fuel tank bolts [A]. • Slide the clamp [A]. • Disconnect the fuel hose [B]. • Slide the clamp [C]. • Disconnect the fuel tank drain hose [D]. • Remove the fuel tank [E]. • Drain the fuel. ○ Plac…

[Page 91] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-21 Fuel Tank Fuel Tank Installation • Installation is the reverse of removal. • Check that the dampers [A] and grommets [B] are in place on the flame and fuel tank. If the dampers and grommets are damaged or deterio- rated, replace …

[Page 92] Kawasaki BAJAJ Pulsar 200 NS

3-22 FUEL SYSTEM Fuel Tank Fuel Tap Removal • Remove the fuel tank (see Fuel Tank Removal). • Remove the snap pin [A] and knob [B]. • Remove the fuel tap mounting bolts [A] with nylon wash- ers and take out the fuel tap [B]. Fuel Tap Installati…

[Page 93] Kawasaki BAJAJ Pulsar 200 NS

FUEL SYSTEM 3-23 Fuel Tank Fuel Tap and Fuel Tank Cleaning WARNING Gasoline and low flash-point solvents can be flammable and/or explosive and cause severe burns. Clean the tank in a well-ventilated area, and take care that there are no sparks or fla…

[Page 94] Kawasaki BAJAJ Pulsar 200 NS

3-24 FUEL SYSTEM Fuel F ilter Fuel Filter Removal • Remove: Fuel Tank (see Fuel Tank Removal) Fuel Filter Screw [A] • Slide the clamp [A]. • Disconnect the fuel hose [B]. • Remove the fuel filter [C]. Fuel Filter Installation • Installation…

[Page 95] Kawasaki BAJAJ Pulsar 200 NS

COOLING SYSTEM 4-1 4 Cooling System Table of Contents Exploded View………………………………………………………………………………………………………… 4-2 Coolant Flow Chart…………………………………….

[Page 96] Kawasaki BAJAJ Pulsar 200 NS

4-2 COOLING SYSTEM Exploded View
…

[Page 97] Kawasaki BAJAJ Pulsar 200 NS

COOLING SYSTEM 4-3 Exploded View Torque No. Fastener N·m kgf·m ft·lb Remarks 1 Radiator Mounting Nuts 11 1.1 97 in·lb 2 Water Temperature Sensor 13 1.3 115 in·lb 3 Thermostat Cover Bolts 9.8 1.0 87 in·lb L 4 Radiator Fairing Bolts 8.8 0.90 78 i…

[Page 98] Kawasaki BAJAJ Pulsar 200 NS

4-4 COOLING SYSTEM Coolant Flow Chart
…

[Page 99] Kawasaki BAJAJ Pulsar 200 NS

COOLING SYSTEM 4-5 Specifications Item Standard Coolant Provided when Shipping Type (Recommended) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators) Color Green…

[Page 100] Kawasaki BAJAJ Pulsar 200 NS

4-6 COOLING SYSTEM Special Too l Box Wrench, 18 mm: 57001-E001
…