BS-VI Training Module

Electrical System & Checking Procedure

 BS VI Vehicles: Below 150 CC

Relation with vehicle

BS VI Carburettor Application
performance
Below 150 CC model Defective Carburettor may affect vehicle
Platina-series/CT-series/Pulsar125 idling rpm, Driving performance, vehicle
emission level & startability issue.

1
Air Basic operation will be same as the existing CV
Solenoid
3 carburettor.
Auto Choke BS VI Carburettor have following 3 new parts:

1. Air Solenoid
2
2. Throttle position sensor (TPS)
TPS
3. Auto Choke
BS VI Carburettor System: Sensors & Actuators

Precautions to be taken during Carburettor handling:

❑ Ensure mounting clamps are fully tightened.

❑ Ensure no gap / inclined fitment of carburettor.

❑ Use recommended carburettor cleaning spray (Part no:- 36001956) for carburettor cleaning or
removing any gummy substances.

❑ Sensors & Actuators test must be carried out using Bosch diagnostic tool, before individual part
checking.

❑ During Wash, do not apply pressurised water jets on sensors & actuators.

❑ Do not set/adjust “Idling adjusting screw/volume control (VC) screw” in BS VI Carburettor.

Note: Auto Choke and Air Control Solenoid Valve are separately serviceable.
BS VI Carburettor System: Sensors & Actuators

Input to control unit Output from control unit

AIR SOLENOID
OXYGEN SENSOR

AUTO CHOKE

ENGINE TEMP SENSOR

HT COILS

ELECTRONIC CONTROL UNIT

THROTTLE POSITION SENSOR

SPEEDOMETER ASSEMBLY

CRANK ANGLE SENSOR DIAGNOSTIC TOOL

CONNECTOR
BS VI Carburettor System: Sensors & Actuators

Part Name Or Images Function Application

Electronic Control unit (ECU), which
controls series of actuators based on
Electronic the input from sensors. It is like a *Below 150 CC Model
Control Unit computer hard disk, programmed with CT-series/Platina-series/
(ECU) special software. Pulsar 125

Sensor A sensor is a device that detects and

(Oxygen sensor, Engine Temp., responds to some type of input from
Crank angle sensor. TPS etc.) the physical environment. The specific
All BS VI models
input could be light, heat, motion,
moisture, pressure, or any other
environmental phenomena.
Actuators An actuator is something that
(Air solenoid, Auto choke, H.T. coil, converts energy into motion. It also
MIL etc.) can be used to apply a force.
An actuator typically is a mechanical
All BS VI Models
device that takes energy — usually
energy that is created by air, electricity
or liquid — and converts it into some
kind of motion or indications.
BS VI Carburettor System: Sensors (Input to ECU )

Sensor Name and Images Function Benefits Application

The O2 or lambda or Oxygen

sensor is mounted in the exhaust
manifold to monitor how much
oxygen is there in the exhaust gases
OXYGEN coming out from engine.
Better
SENSOR Monitoring oxygen levels in the
emission
exhaust is a way of gauging the fuel *Below 150
control
air mixture. It tells the ECU if the fuel CC Model
mixture is burning rich (less oxygen) CT-series/
or lean (more oxygen). Platina-
It assist the ECU to adjust the series/
amount of fuel to be injected. Pulsar125
Engine temperature sensor is fitted
ENGINE
TEMP on engine head assembly which
Maintains
SENSOR sense the engine temperature and
Optimum
inform to ECU. It assist ECU to adjust
Temperature
the ignition timing & Auto choke
operation.
BS VI Carburettor System: Sensors (Input to ECU )

Sensor Name and

Function Benefits Application
Images

The throttle position sensor (TPS) is

part of fuel management system
and helps ensure that the correct
mixture of air and fuel is delivered
THROTTLE to your engine. It Detect the throttle Torque on
POSITION position & assist ECU to control fuel
SENSOR
demand *Below 150
supply for optimum performance of CC Model
vehicle CT-series/
Platina-
series/
It Measures the position of Pulsar125
CRANK crankshaft and its rotational speed
ANGLE & assist ECU to determine injection Optimum
SENSOR
& Ignition timing Performance
of Engine
BS VI Carburetor System: Actuators (Output from ECU)

Actuators Name and

Function Benefits Application
Images
Solenoid valve is incorporated in the Optimum
secondary air circuit to control the Air Performance
Air Fuel Ratio. Solenoid is being operated of Engine for
Solenoid with the help of Engine Control unit cleaner
(ECU) By operating the solenoid , the engine
air flow will be controlled so that the air exhaust.
fuel ratio is maintained at the required *Below
level. 150 CC
Model
Auto Auto choke mainly used in CV
CT-series/
Choke carburetor starter circuit, to supply rich For better Platina-
mixture, while engine is in cold cold start series
condition.
Pulsar 125
High tension coil transform low voltage
H.T. Coil into high voltage. It has two coils one High voltage
is primary takes current from CDI or for better fuel
ECU and another is secondary which consumption
is steps up voltage & sends to Sp plug
BS VI Carburettor System: Actuators (Output from ECU)

Actuators Name and

Function Benefits Application
Images

Malfunction indication lamp blinks if

there any malfunctioning in fuel
Speedometer injection system
assembly Improve the
(MIL) ride’s safety *Below 150
CC Model
CT-series/
Platina-
It is used to connect the BOSCH D&F Easy to series
Diagnostic tool if MIL light blinking in speedometer diagnose
tool Pulsar 125
assembly, due to any defect observed issues
connector
in CU related parts in vehicle. related to
input &
output
devices
Carburettor Parts checking procedure
BS VI Carburettor System: Sensors & Actuators

Precautions to be taken before parts checking:

1. First diagnose issue using BOSCH D& F tool.

2. Check fuse condition.

3. Check wiring harness cut/short/opened.

4. Check related part coupler wire pin loosed or its fitment.

5. Check ECU connection with defective or suspected part.

BS VI Carburettor: Air solenoid valve checking

Relation with vehicle

Actuator-Air Solenoid valve Application
performance
*Below 150 CC Model There will be performance issues
CT-series/Platina-series/Pulsar125 like-
Unstable idling RPM, low mileage,
misfiring, low pick up issue.

Wire Connections
Sr. Multimet Standard
No. er Meter Meter - Reading
+ve ve
48.6 to
1 200 Ω Pin no. 1 Pin no. 2 59.4 Ω
(ohms)
 BS VI Carburettor: Air solenoid valve checking

Sr No. Checking SOP- Images

Air solenoid resistance checking

1 Take out air solenoid valve from carburettor

Set multimeter on 200Ω mode and check

2 resistance in the range of 48.6 to 59.4 Ω in
Pin 1 & Pin 2

Air solenoid functionality

Connect 12V DC supply to air solenoid

3
valve using battery.

Tik- Tik sound will be heard indicating OK

4
condition

If resistance within range and plunger Tik-

5 Tik sound comes then part is ok, if not-
replace the part.
 BS VI Carburettor: TPS Sensor checking

Relation with vehicle

Sensor- Throttle position Sensor Application
performance
*Below 150 CC Model There will be performance issues
CT-series/Platina-series/Pulsar125 like-
Unstable idling RPM, low mileage,
misfiring, low pick up issue.

Sr. Wire Connections Standard

Parameter
No. Meter +ve Meter -ve Reading

4.9-5.1
1 Input voltage Red/Blue Yellow/Black
VDC
Output voltage
Less than 1
2 partial open Green/Yellow Yellow/Black
VDC
throttle (POT)
Output voltage
4 ~ 4.5
3 wide open Green/Yellow Yellow/Black
VDC
throttle(WOT)
 BS VI Carburettor: TPS Sensor checking

Sr
Checking SOP Images
No.
Input Voltage
1 Set Multimeter on 20V DC mode
2 Put the +Ve probe in red/blue and –Ve probe in
Yellow/black wire

3 Check voltage up to 4.9 to 5.1 V

Out put voltage
1 Set Multimeter on 20V DC mode
2 Put the +Ve probe in Green/Yellow wire and –Ve probe in
Yellow/black wire

3 (A) Check voltage less than 1V in partial open throttle

(POT)
4 (B) Check voltage in the range of 4 to 4.5 V in wide open
throttle. (WOT)

If input, output voltage is within range then part is OK if not

then change the part
BS VI Carburettor: Engine Temperature Sensor Checking

Sensor-Engine Temperature Application Relation with vehicle

Sensor performance
*Below 150 CC Model Unstable Idling rpm & driving
CT-series/Platina-series/Pulsar125 performance will be affected

Meter Wire
Standard Value
Range Connections
Temperatur
Meter Meter – Resistance
e in Degree
+ve ve in K Ohms
Centigrade
0 27.01~29.03
10 17.63~18.79
20 / 200
K Ohms 20 11.81~12.46
Pin
Pin no 2 25 9.73~10.27
no 1
30 8.05~8.50
40 5.59~5.94
50 3.95~4.24
 BS VI Carburettor: Engine Temperature Sensor Checking

Sr No. Checking SOP- ETS resistance Images

1 Set Multimeter on 20/200KΩ mode

2 Put the +Ve probe in Pin1 and –Ve in Pin 2

Check the resistance in the range of 3.9 to

3 29.03 KΩ as per temperature given in the
chart
Take the two values of engine temperature
sensor
a) While engine in hot condition and
measure the temperature by
4
thermometer
b) While engine in cold condition also
measure cold temperature of engine
by thermometer

If resistance values is within range then part is ok

if not replace the part
BS VI Carburettor: Crank angle Sensor and neutral switch

Sensor- Crank angle & Neutral Switch Application Relation with vehicle
performance
*Below 150 CC Model Engine RPM indication & Ignition
CT-series/Platina- system will be affected
series/Pulsar125

Wire
Connections Stand
Sr. Compo meter
ard Results
No. nent range
Meter Meter Value
+ve -ve

Crank 215 +
Resistance White/ Black/
1 angle 20 OK
2 K Ohms Red Yellow
sensor Ohms

Beep
Ok
sound
Neutral Light Black/
2 Continuity
switch Green Yellow No
Defectiv
Beep
e
sound
BS VI Carburettor: Crank angle Sensor and Neutral switch

Sr
Checking SOP Images
No.
Crank angle Sensor

1 Set Multimeter on 2kΩ mode

2 Put the +Ve probe in white/red and –Ve probe in

black/yellow wire
3 Check resistance in the range of 215±20Ω
(195 to 235 K ohm)
Neutral Switch

1 Set Multimeter on continuity mode

2 Put the +Ve probe in light green wire and touch the –Ve
probe to vehicle chassis (body earthing)
3 While vehicle in neutral condition beep sound comes, if
vehicle in gear beep sound will not come.

If resistance values are within range then part is ok if not

replace the part
 BS VI Carburettor- H.T. Coil

Actuator- H.T. Coil Application Relation with vehicle

performance
*Below 150 CC Model Vehicle hesitation issue, starting
CT-series/Platina-series/Pulsar125 problem & Misfiring

Resistance Checking –Primary Coil

Meter Standar
Wire Connections
Range d Value
Meter +ve Meter –ve 0.3 to
200
Pin- 0.9
Ohms Pin - Black
Black/Yellow Ohms

Resistance Checking –Secondary Coil

Meter Standard
Wire Connections
Range Value

20k Meter +ve Meter –ve 4.5 to 6.5

Ohms Thick Wire Core K Ohms
 BS VI Carburettor- H.T. Coil

Sr
Checking SOP Images
No.
Primary coil-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-Black and –Ve probe touch to

coil body
3 Check resistance in the range of 0.3 to 0.9 Ω

Secondary coil-Resistance

1 Set Multimeter on 20KΩ mode

2 Put the +Ve probe in plug cap cord (Thick wire) and –Ve
probe touch to coil body

3 Check resistance- Value should be in the range of 4.5 to

6.5 KΩ
If resistance values is within range then part is ok if not
replace the part.
 BS VI Carburettor:
Oxygen Sensor (O2 or Lambda Sensor)
Relation with vehicle
Sensor-Oxygen sensor Application
performance
*Below 150 CC Model Malfunctioning of Oxygen sensor
CT-series/Platina-series/Pulsar125 will result in either rich mixture
causing black smoke or lean
mixture with poor drivability.

Sr. Wire Connections

Standard Reading
No. Meter +ve Meter -ve

Meter displays 1
1 Pin no. 1 Pin no. 2 (Infinity) @ 25⁰C
(open circuit)
 BS VI Carburettor:
Oxygen Sensor (O2 or Lambda Sensor)

Sr
Checking SOP Images
No.

Oxygen Sensor-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-1 and –Ve probe Pin-2

Meter displays 1 (Infinity) @ 25⁰C

3
(open circuit)

If resistance values is within range then part is ok if

4 not replace the part.
 BS VI Carburettor: Auto Choke Checking

Actuator- Auto Choke Application Relation with vehicle

performance
*Below 150 CC Model Malfunctioning of auto choke will
CT-series/Platina-series/Pulsar125 result in to Starting issue in cold
weather & unstable Idling RPM

Multime Wire Connections

ter
Standard Reading
Setting
Meter +ve Meter -ve
Range
200
Wire-1 Wire-2 11 ~13 Ohms
Ohm
 BS VI Carburettor: Auto Choke Checking

Sr No. Checking SOP Images

Auto choke resistance check by multimeter

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-1 and –Ve probe in Pin-2

3 Check resistance in the range of 11 to 13 Ω

Auto choke functionality check with Battery

1 Connect the auto choke with 12 V DC battery supply

2 Confirm the working of auto choke

3 Check whether solenoid operated choke gets 'ON' i.e.

plunger remaining lifted as long as the external supply is
given to it.

If resistance values is within range then part is ok if

not replace the part.
 BS VI Vehicle: Cold Starting SOP

Vehicle startability

CT & Platina 100 / 110, Pulsar 125 BS6 vehicles are equipped with Auto Choke.
System is designed in such a way to take care of cold starting without customer
intervention.
However, there could be a situation where vehicle is parked for few days, choke
may not get ON due to ambient temp being on border line and hence trouble may
arise in engine starting.
Is such situation, to assist the engine start, follow the procedure given in the next
slide to activate the choke.

(Ensure fuel in tank & as per the quantity ensure fuel cock position “ON / RESERVE” &
ignition off before starting this procedure)
 BS VI: Cold Starting SOP

1. ENSURE IGN OFF

2. THROTTLE WIDE OPEN. (Hold the position)
3. DO IGN ON & IGN OFF (1st time )
4. DO IGN ON & IGN OFF (2nd time )
5. DO IGN ON & IGN OFF (3rd time )
6. RELEASE THROTTLE TO CLOSE CONDITION. (Remove hand from throttle grip)
7. DO IGN ON
8. CRANK ENGINE TO START.

IGN OFF THROTTLE WIDE OPEN IGN ON

 Wiring Diagram of
BSVI Carburettor Model
Circuit Diagram- Air Solenoid Valve

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
Circuit Diagram- CAN

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
Circuit Diagram- Ignition

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
Circuit Diagram-Auto Choke

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
Circuit Diagram- MIL

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
Circuit Diagram- Starter Motor

Colour Code
Green/Yellow G/Y
Black/Yellow B/Y
White/Red W/R
Black/Yellow B/Y
Blue/white B/W
Green G
Green/white G/W
Red/Blue R/L
Brown Br
White W
Red R
FI System
Motorcycle above 150 CC
 FI System Sensors & Actuators
(150 CC & above vehicle)

Applicable in Input to ECU Output from

ECU

Air cooled engine

ENGINE
Pulsar 150/180/220 TEMP FUEL
SENSOR PUMP
Avenger 160/220
SIDE FUEL
STAND INJECTOR
SWITCH

ROLLOVER HT COIL
SENSOR

IACV
STEPPER/
OXYGEN
SOLENOID
SENSOR

IACV
PURGE
CRANK
VALVE
ANGLE
SENSOR MALFUNCTION
INDICATOR

POSITION/
PRESSURE/ DIAGNOSTIC
TEMP TOOL
SENSOR COUPLER
 FI System Sensors & Actuators
(150 CC & above vehicle)
Input to ECU Output from
ECU
Applicable in
ENGINE FUEL PUMP
Liquid cooled TEMP
SENSOR
engine
SIDE STAND
NS200/RS200 SWITCH FUEL
INJECTOR
D400/D250
ROLLOVER
SENSOR HT COIL

IACV
OXYGEN STEPPER
SENSOR

CRANK ANGLE PURGE

SENSOR VALVE

MALFUNCTION
INDICATOR
TEMPERATURE/
MANIFOLD
PRESSURE SENSOR
DIAGNOSTIC TOOL
COUPLER

THROTTLE
POSITION
SENSOR
RADIATOR FAN
BS VI Fuel injection System Sensors & Actuators

Part Name Or Images Function Application

Electronic control unit (ECU) *Above 150 CC Model
commonly known as engine control unit Pulsar 150/180/220
Electronic or engine control module (EGM) Avenger 160/220
Control Unit which controls series of actuators base Ns200/RS200/D400/D250
(ECU) on the input from sensors. It is like a
computer hard disk ,programmed with
special software.

Sensor A sensor is a device that detects and All BS VI model

(Oxygen sensor, engine temp. responds to some type of input from the
crank angle sensor. TPS etc.) physical environment. The specific input
could be light, heat, motion, moisture,
pressure, or any one of a great number
of other environmental phenomena.

Actuators An actuator is something that converts All BS VI Models

(Fuel pump, injector, stepper energy into motion. It also can be used
motor, H.T. coil. Purge valve etc.) to apply a force. An actuator typically is
a mechanical device that takes energy
— usually energy that is created by air,
electricity or liquid — and converts it
into some kind of motion
 BS VI Fuel injection System
Sensors (Input to ECU)
Sensor Name and Images Function Benefits Application

ENGINE Engine temperature sensor is fitted on engine Measure the Engine block Pulsar
TEMP head assembly which sense the engine Temperature & assist ECU 150/180/220
SENSOR temperature and inform to ECU. It measure to adjust the fuel injection Avenger 160/180
the Engine block Temperature & assist volume *Air cooled
engine
ECU to adjust the ignition timing.

Coolant temperature sensor is fitted on Based on input fan motor NS200/RS200/D

Coolant engine head assembly which sense the automatically switched 400/D250
TEMP engine coolant temperature and inform to ON and OFF, maintains
SENSOR ECU engine optimum temp *Liquid cooled
engine
It is located on side stand and inform position Improve the rider’s safety Pulsar
of side stand to ECU. If the stand position is 150/180/220
Side Stand ON, ECU stops the engine, if stand is in OFF Avenger 160/220
Switch condition ECU allows the vehicle to move. Ns200/RS200/D4
00/D250
*Above 150 CC
Model
This sensor sense the vehicle tilt position if Improve the rider’s safety Pulsar
vehicle tilt is more than 60 degree it gives If vehicle falls 150/180/220
Roll over signal to ECU and ECU cuts the actuators Avenger 160/220
sensor power supply to stop the engine. Ns200/RS200/D4
00/D250
*Above 150 CC
Model
 BS VI Fuel injection System
Sensors (Input to ECU)

Sensor Name and Images Function Benefits Application

Measures the position of crankshaft and its Optimum Pulsar 150/180/220

rotational speed & assist ECU to determine performance of Avenger 160/220
CRANK
injection & Ignition timing engine Ns200/RS200/D400/
ANGLE
D250
SENSOR
*Above 150 CC
Model

Measures the intake air temperature and Better acceleration Pulsar 150/180/220
POSITION/ pressure and assist the ECU to adjust the and smooth driving Avenger 160/180
PRESSURE/ fuel injection volume and detect the throttle experience *Air cooled engine
TEMP position
SENSOR

Temperature manifold absolute pressure Better acceleration NS200/RS200/D400/

sensor and smooth driving D250
The ECU uses the data to calculate density experience
TMAP and determine the engine's air mass flow *Liquid cooled
sensor rate, which helps the ECU determine the engine
amount of fuel needed to create optimum
combustion
 BS VI Fuel injection System
Sensors (Input to ECU)

Sensor Name and Images Function Benefits Application

Detect the throttle position Better acceleration NS200/RS200/D4

and smooth 00/D250
TPS driving experience
sensor *Liquid cooled
engine

The O2 or lambda or Oxygen sensor is Better Emission Pulsar

mounted in the exhaust manifold to control 150/180/220
monitor how much oxygen is there in Avenger 160/220
the exhaust gases coming out from Ns200/RS200/D40
Oxygen
engine. Monitoring oxygen levels in the 0/D250
sensor
exhaust is a way of gauging the fuel air *Above 150 CC
mixture. It tells the ECU if the fuel Model
mixture is burning rich (less oxygen) or
lean (more oxygen).
It assist the ECU to adjust the amount
of fuel to be injected
 BS VI Fuel injection System
Actuators (Output from ECU)
Actuators Name and
Function Benefits Application
Images
Fuel pump pumps the fuel from the vehicle’s fuel High fuel pressure for Pulsar 150/180/220
tank to the fuel injector under high pressure. better combustion Avenger 160/220
Fuel Pump
Always ensure there should be minimum 3 litre Ns200/RS200/D400/D2
petrol in the fuel tank. 50
*Above 150 CC Model

Fuel injector injects the precise amount of More power and better Pulsar 150/180/220
Injector atomized fuel in the engine combustion chamber mileage Avenger 160/220
based on the ECU data. Ns200/RS200/D400/D2
50
*Above 150 CC Model

High tension coil transform low voltage into high Improve in vehicle Pulsar 150/180/220
voltage. It has two coils one is primary takes performance Avenger 160/220
H.T. Coil supply from ECU and another is secondary which Ns200/RS200/D400/D2
steps up voltage & supplies to Sp Plug 50
*Above 150 CC Model

The stepper motor is a device that converts digital Better atomization of Pulsar 150/180/220
Stepper pulses into mechanical shaft rotation which fuel for better cold- Avenger 160/220
Motor adjusts the idle speed of engine based on input start & cleaner Ns200/RS200/D400/D2
from ECU emission. 50
*Above 150 CC Model
 BS VI Fuel injection System
Actuators (Output from ECU)
Actuators Name and
Function Benefits Application
Images
Malfunction indication lamp blinks if there any Improve the rider’s Pulsar 150/180/220
malfunctioning in fuel injection system safety Avenger 160/220
Speedometer Ns200/RS200/D400/
assembly D250
(MIL) *Above 150 CC
Model
It is useful for connecting BOSCH D & F tool Easy to diagnose FI Pulsar 150/180/220
Diagnostic if MIL light is blinking in instrument cluster or system related Avenger 160/220
tool any defect observed in vehicle. issues Ns200/RS200/D400/
connector D250
*Above 150 CC
Model
Its purpose is to cool the engine coolant. It Better cooling effect Ns200/RS200/D400/
Radiator starts when coolant temperature reaches 98c for engine D250
Fan and stops at 88c
*Liquid cooled
engine
The purge valve is the part of the vehicle Improve the emission Pulsar 150/180/220
Purge Evaporative Emission Control (EVAP) system Avenger 160/220
Valve system. The EVAP system prevents fuel Ns200/RS200/D400/D2
vapours in the fuel tank from escaping into 50
the atmosphere. The purge valve precisely *Above 150 CC Model
controls the amount of fuel vapour that is
purged from the charcoal canister.
 Various relays used in FI models

1. Main Relay :
This is used in Battery supply to EMS loads. Main relay is switched ON by ECU giving GND signal to main
relay for completing coil circuit. Main relay contacts output is used for -
- ECU battery supply input.
- Fuel injector.
- Heater of oxygen sensor.
- Headlamp relay coil
- Starter relay coil
If this relay fails, then the vehicle will not start
2. Headlamp Relay : (RS-200)
This relay is used for switching ON & OFF head lamp Hi beam filament. Low beam filament power is 55 W &
when Hi
beam filament is switched ON another 65W load comes on the system. Conditions when Hi-beam filament gets
ON-
Hence total load becomes 120W i.e. 10ADC current would flow through wiring harness.
To reduce wire size the Hi beam relay is introduced This relay is used for switching ON head lamp after Engine
rpm is achieved .Low beam or high beam ON depends on Dipper switch status in Switch control LH.
3. Fuel pump Relay :
This relay is used for switching ON / OFF Fuel pump based on GND signal from ECU.
4. Intermediate Starter relay :
This relay is used for switching ON starter relay based on GND signal from ECU
5. Radiator fan Relay :
This relay is used for switching ON / OFF radiator fan motor. The fan motor power is 30W & hence to avoid 2.5 A
current flowing through wiring harness, radiator relay is fitted
 BS VI Fuel Injection System
Sensors & Actuators

Precautions to be taken before parts checking:

1. First diagnose vehicle by BOSCH D& F tool

2. Check fuse condition

3. Check wiring harness cut/short/opened

4. Check related part coupler wire pin loosed or its fitment

5. Check ECU connection with defective or suspected part

FI System Position/Pressure/Temperature Sensor

Relation with vehicle

Sensor- PPTS Application
performance
Pulsar 150/180/220 Start-ability, Fuel consumption &
Avenger 160/220 power- pickup will be affected.

*All above 150 CC air cooled

engine.
Wire Connections
Sr. Meter
Parameter Meter - Standard Reading
No. Range Meter +ve
ve

Temperature
1 20 K Ohms Pin no 4 Pin no 5 2000 Ohms @ 25⁰C
Resistance

2 Input voltage 20 VDC Pin no 1 Pin no 5 5 VDC

Input throttle Idle : 0.45

Throttle Output
3 20 VDC Pin no 2 Pin no 5 V
Voltage

Throttle Output Wide open throttle: 4.2

4 20 VDC Pin no 2 Pin no 5
Voltage V
FI System Position/Pressure/Temperature Sensor

Sr
Checking SOP Images
No.
Input Voltage
1 Set Multimeter on 20V DC mode

2 Put the +Ve probe in Pink/Black (Pin-1) and –Ve probe in

Pink/blue (Pin-5) wire
3 Check voltage in the range of 4.9 to 5.1 V

Out put voltage

1 Set Multimeter on 20V DC mode

2 Put the+Ve probe in Green/Yellow (pin-2) wire and –Ve probe in

Pink/blue(Pin-5) wire
3 Check voltage less than 1 V in partial open throttle

4 Check voltage in the range 4 to 4.5 v in wide open throttle.

Coil Resistance
1 Set Multimeter on 20kΩ mode
2 Put the +Ve probe in Pin4 and –Ve probe in Pin 5

3 Check resistance up to 2kΩ

If input voltage, output voltage and resistance are within range then
part is ok , if not replace the part
 FI System: Throttle Position Sensor

Relation with vehicle

Sensor- Throttle position Sensor Application
performance
NS200/RS200/D400/D250 Start-ability, Fuel consumption &
power- pickup will be affected.
*Liquid cooled engine.

Sr. Connect Multimeter probe

Standard
No Parameter
Meter +ve Meter -ve Reading
.

1 Input voltage Red/Black Black/Green 3.3 VDC

2 Output voltage idle throttle Green/Yellow Black/Green 0.35~0.65 VDC

Output voltage wide open

3 Green/Yellow Black/Green 2.9~3.0 VDC
throttle

1.6 ~ 2.4
4 Coil Resistance Pin 2 Pin 3
KOhms
 FI System: Throttle Position Sensor

Sr
Checking SOP Images
No.
Input Voltage

1 Set Multimeter on 20V DC mode

2 Put the +Ve probe in red/blue and –Ve probe in black/green wire

3 Check voltage in the range of 3.3 to 4 V

Out put voltage

1 Set Multimeter on 20V DC mode

2 Put the +Ve probe in Green/Yellow and –Ve probe in black/green

wire

3 Check voltage less than 1 V in partial open throttle

4 Check the voltage in the range of 4 to 4.5 v in wide open throttle.

Coil Resistance

1 Set Multimeter on 20kΩ mode

2 Put the +Ve probe in Pin2 and –Ve Pin 3

3 Check resistance in the range of 1.6 to 2.4 ohm

If input voltage, output voltage and resistance are within range then
part is ok , if not replace the part
 FI System:
Temperature manifold absolute pressure Sensor
Relation with vehicle
Sensor- TMAP Application
performance
NS200/RS200/D400/D250 Start ability, Fuel consumption &
power- pickup will be affected.
*Liquid cooled engine.

Set Connect Multimeter

Sr. Multimet probe Standard
Parameter
No. er Meter Meter - Reading
Range +ve ve
20 K 2 + 0.5 K Ohms
1 Resistance Pin no. 2 Pin no. 1
Ohms @ 25⁰C
TMAP Circuit Input
2 20 VDC Pin no.3 Pin no. 1 5 VDC
voltage
Output
3 20 VDC Pin no.4 Pin no. 1 3.8 + 0.65 VDC
voltage

4 3

4 3
 FI System:
Temperature manifold absolute pressure Sensor
Sr
Checking SOP Images
No.
TMAP Resistance
1 Set Multimeter on 20kΩ mode
2 Put the +Ve probe in Pin 1 and –Ve probe in
Pin 2
3 Check resistance in the range of 1.5 to 2.5
KΩ at 25 ⁰C
TMAP Input voltage
1 Set Multimeter on 20V DC
2 Put the +Ve probe in Red/blue and –Ve probe
in yellow/black
3 Check voltage up to 5V
TMAP Out put voltage
1 Set Multimeter on 20 V DC
2 Put the +Ve probe in white/red and –Ve probe
in yellow/black
3 Check voltage in the range of 3.8 ± 0.65 V
If values are not within range replace the part
 FI Sensor- Engine Temperature

Sensor-Engine Temperature Relation with vehicle

Application
Sensor performance
Pulsar 150/180/220 Start ability, fuel consumption &
Avenger 160/220 power- pickup will be affected
*All above 150 CC air cooled
engine.
Meter
Wire Connections Standard Value
Range

Temperature in
Meter Resistance in K
Meter –ve Degree
+ve Ohms
Centigrade

0 27.01~29.03
10 17.63~18.79
20 / 200 K
Ohms 20 11.81~12.46
Pin no
Pin no 2 25 9.73~10.27
1
30 8.05~8.50
40 5.59~5.94
50 3.95~4.24
 FI Sensor: Engine Temperature Sensor

Sr No. Checking SOP- ETS resistance Images

1 Set Multimeter on 20/200KΩ mode

2 Put the +Ve probe in Pin1 and –Ve in Pin 2

Check the resistance in the range of 3.9 to

3 29.03 KΩ as per temperature given in the
chart
Take the two values of engine temperature
sensor
a) While engine is in hot condition,
measure the engine temperature by
thermometer and measure the sensor
4
resistance by multimeter
b) While engine in cold condition also
measure cold temperature of engine
by thermometer and measure the
resistance by multimeter

If resistance values is within range then part is ok

if not replace the part
 FI Sensor: Coolant Temperature Sensor

Relation with vehicle

Sensor-Coolant Temperature Sensor Application
performance
NS200/RS200/D400/D250 1. Radiator fan will not work & coolant temperature
*Liquid cooled engine. may shoot up affecting engine performance.
2. High coolant temperature icon may not blink.
3. start ability, fuel consumption & power- pickup
will be affected.

Set
Multimeter Connect Multimeter probe Standard Value
Range

Temperature in
Meter Resistance in K
Meter –ve Degree
+ve Ohms
Centigrade

0 5.30~6.11

2 / 20 K 10 3.44~3.92
Ohms
Coupler 20 2.28~2.58
Coupler Pin 2
Pin 1 25 1.88~2.12
30 1.55~1.75

40 1.06~1.21

50 0.75~0.86
 FI Sensor: Coolant Temperature Sensor

Sr No. Checking SOP- ECT resistance Images

1 Set Multimeter on 20 KΩ mode

2 Put the +Ve probe in Pin1 and –Ve in Pin 2

Check the resistance in the range of 0 to 5

3
KΩ as per temperature given in the chart

Take the two values of engine temperature

sensor
a) When the engine is hot measure the
temperature by thermometer and
4 measure the resistance by multimeter
b) While in cold condition also measure
cold temperature of engine by
thermometer and measure the
resistance by multimeter

If resistance values is within range then part is ok

if not replace the part
 FI Sensor: Side Stand Sensor

Sensor-Side Stand Switch Application Relation with vehicle

performance
NS200/RS200/D400/D250 Interlocking with vehicle running in gear
Pulsar 150/180/220
Avenger 160/220

*All above150 CC model

Wire connection
Sr.
Parameter Magnet Position Std. Reading
No.
Meter Meter
+ve -ve

Input voltage (Side Pin no Pin no

1 N.A. 5 VDC
stand position - any) 2 3

Output voltage (Side Magnet in front of Pin no Pin no

0.34 ± 0.2 VDC
stand position - OFF) side stand switch 1 3
2
Side stand Magnet away from Pin no Pin no
3.61 ± 0.1 V DC
position-ON side stand switch 1 3
 FI Sensor: Side Stand Sensor

Sr
Checking SOP Images
No.
Input voltage

1 Set Multimeter on 20 V DC

2 Put the +Ve probe in red/blue (Pin 2) and –Ve

probe in Pink/blue (Pin 3) or yellow/black

3 Check voltage up to 5V

Output voltage side stand position OFF

1 Set Multimeter on 20 V DC

2 Put the +Ve probe in Pink (Pin 1) and –Ve probe in

Pink/blue (Pin 3) or yellow/black
3 Check voltage in the range 0.34 ± 0.2 VDC

Output voltage side stand position ON

1 Set Multimeter on 20 V DV

2 Put the +Ve probe in Pink (Pin 1) and –Ve probe in

Pink/blue (Pin 3) or yellow/black
3 Check voltage in the range 3.6 ± 0.1 V
 FI Sensor: Oxygen Sensor

Relation with vehicle

Sensor-Oxygen sensor Application
performance
Pulsar 150/180/220 Malfunctioning of Oxygen sensor will
Avenger 160/220 result in either rich mixture causing black
*All above 150 CC (air cooled engine) smoke or lean mixture resulting in poor
vehicle drive ability.

Wire Connections
Sr.No. Standard Reading
Meter +ve Meter -ve
Heater Resistance: less
1 Pin no. 1 Pin no. 2
than 14 Ohm @ 25⁰C
Meter displays 1 (infinity)
2 Pin no. 3 Pin no. 4 @ 25⁰C
 FI Sensor: Oxygen Sensor

Sr
Checking SOP Images
No.

Oxygen Sensor-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-1 and –Ve probe Pin-2

3 Check Heater Resistance: less than 14 Ohm @ 25⁰C

4 Put the +Ve probe in Pin-3 and –Ve probe Pin-4

5 Check Meter displays 1 (infinity) @ 25⁰C

 FI Sensor: Oxygen Sensor

Relation with vehicle

Sensor-Oxygen sensor Application
performance
NS200/RS200/D400/D250 Malfunctioning of Oxygen sensor will
*Liquid cooled engine. result in either rich mixture causing black
smoke or lean mixture resulting in vehicle
drive ability.

Sr.No Wire Connections

Standard Reading
. Meter +ve Meter -ve
Heater Resistance:
1 Pin no. 1 Pin no. 2
Ohm 9 + 1 @ 25⁰C
Meter displays 1
2 Pin no. 3 Pin no. 4 (infinity) @ 25⁰C
 FI Sensor: Oxygen Sensor

Sr
Checking SOP Images
No.

Oxygen Sensor-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-1 and –Ve probe Pin-2

3 Check Heater Resistance: 9 + 1 Ohm @ 25⁰C

4 Put the +Ve probe in Pin-3 and –Ve probe Pin-4

5 Check Meter displays 1 (Infinity) @ 25⁰C

(open circuit)
If resistance value is within range then part is ok, if not
replace the part
 FI Sensor: Roll Over sensor
Relation with vehicle
Sensor- Roll over Sensor Application
performance
NS200/RS200/D400/D250 Ignition cut off incase of Vehicle topple
Pulsar 150/180/220 more than 60 deg.
Avenger 160/220

*All above150 CC model

Wire Connections
Sr.No Vehicle Standard
Parameter Meter
. position Meter -ve Reading
+ve

Pin no
1 Input voltage NA Pin no 3 5 VDC
2
Normal Pin no
Pin no 3 3.60 VDC
position 1
Output
2 Tilled
voltage Pin no
position Pin no 3 0.4 VDC
1
(> 60⁰)
 FI Sensor: Roll Over sensor
Sr
Checking SOP Images
No.
Input voltage
1 Set Multimeter on 20 V DC mode
2 Put the +Ve probe in Red/blue and –Ve probe
in Yellow/black wire
3 Check voltage up to 5V
Output voltage-Normal Position
1 Set Multimeter on 20 V DC mode
2 Put the +Ve probe in Brown/green and –Ve
probe in Yellow/black wire
3 Check voltage up to 3.60 VDC
Output voltage-voltage-Tilted position
(> 60⁰)
1 Set Multimeter on 20 V DC mode
2 Put the +Ve probe in Grey and –Ve probe in
Black/Yellow wire
3 Check voltage up to 0.4 VDC
If value is within range then part is ok, if
not replace the part
 FI Sensor:
Crank angle sensor & Neutral switch
Sensor- Crank angle & Neutral Switch Application Relation with vehicle
performance
NS200/RS200/D400/D250 Wrong indication of Engine RPM in
Pulsar 150/180/220 speedo.
Avenger 160/220 Malfunction in Ignition system.
No start situation in case of open circuit.
*All above150 CC model

Wire
Sr. Compone meter Connections Standard Resul
No. nt range Meter Meter Value ts
+ve -ve

Resista
Crank
nce Pin no Pin no 390 + 10
1 angle OK
2K 1 2 Ohms
sensor
Ohms

Body Beep sound Ok

Neutral Continui Pin no
2 groun No Beep Defect
switch ty 3
d sound ive
 FI Sensor:
Crank angle sensor & Neutral switch
Sr
Checking SOP Images
No.
Crank angle Sensor-Resistance

1 Set Multimeter on 2kΩ mode

2 Put the +Ve probe in white/red and –Ve probe in

black/yellow wire
3 Check in the range of 390±10Ω (380 to 400 ohm)

Neutral Switch-continuity

1 Set Multimeter on continuity mode

2 Put the +Ve probe in light green wire and –Ve probe on
body earthing
3 While vehicle in neutral condition beep sound comes, if
vehicle in gear position beep sound not come.

If resistance value is within range then part is ok, if

not replace the part
 FI Actuator: H.T. Coil

Relation with vehicle

Actuator- H.T. Coil Application
performance
Pulsar 150/180/220 Misfiring or hesitation problems.
Avenger 160/220 No spark resulting in no start.
*All above 150 CC (air cooled
engine)
Resistance Checking –Primary Coil
Meter Standard
Wire Connections
Range Value

vvv vvv Meter +ve Meter –ve 2.3 ±

200
10%
Ohms Pin no 1 Pin no 2 Ohms
Resistance Checking –Secondary Coil
Meter Standard
Wire Connections
Range Value
Meter +ve Meter –ve
HT coil 13 ± 20% K
20 K Ohms
Pin no 1 secondary Ohms
O/P
 FI Actuator: H.T. Coil

Sr
Checking
Checking SOP
SOP Images
No.
Primary coil-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-Black and –Ve probe touch to

coil body.
3 Check resistance in the range of 2.3 ±10%Ω (2.07 to
2.53 ohm)
Secondary coil-Resistance

1 Set Multimeter on 20KΩ mode

2 Put the +Ve probe in plug cap cord (Thick wire) and –Ve
probe touch to coil body
3 Check the resistance in the range of 13±20%KΩ (10.4 to
15.6 ohm)

If resistance value is within range then part is ok, if not

replace the part
 FI Actuator: H.T. Coil

Relation with vehicle

Actuator- H.T. Coil Application
performance
NS200/RS200/D400 Misfiring or hesitation problems.
*Liquid cooled engine No spark resulting in no start.

Resistance Checking –Primary Coil

Meter Standar
Wire Connections
Range d Value
v v
Meter +ve Meter –ve
0.3 to
200 Pin- 0.9
Ohms Pin - Black Black/Yello Ohms
w
Resistance Checking –Secondary Coil

Meter Standar
Wire Connections
Range d Value

Meter +ve Meter –ve 4.5 to

20k
6.5 K
Ohms
Thick Wire Core Ohms
 FI Actuator: H.T. Coil

Sr
Checking SOP Images
No.
Primary coil-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-Black and –Ve probe touch to

coil body
3 Check resistance in the range of 0.3 to 0.9 Ω

Secondary coil-Resistance

1 Set Multimeter on 20KΩ mode

2 Put the +Ve probe in plug cap cord (Thick wire) and –Ve
probe touch to coil body
3 Check in the range of 4.5 to 6.5 KΩ

If resistance value is within range then part is ok, if not

replace the part
 FI Actuator: H.T. Coil

Relation with vehicle

Actuator- H.T. Coil twin cord Application
performance
NS200/RS200/D400 Misfiring or hesitation problems.
*Liquid cooled engine No spark resulting in no start.

Resistance Checking –Primary Coil

Set
Standard
Multimeter Connect Multimeter probe
Value
v v range
Meter +ve Meter –ve
0.513 ~
200 Ohms Pin of 0.627
Pin of Black
Orange / Ohms
/ Red- pin1
White- pin2

Resistance Checking –Secondary Coil

Set
Connect Standar Remar
Multimeter
Multimeter probe d Value k
range
Meter Meter – To be
+ve ve measur
11.0 ~ e
20 K Ohms 16.2 betwee
HT HT K Ohms n to
output output 2 H.T.
outputs
 FI Actuator: H.T. Coil

Sr
Checking SOP Images
No.
Primary coil-Resistance

1 Set Multimeter on 200 Ω mode

2 Put the +Ve probe in Pin-1 and –Ve probe to pin-2 in red
colour coupler
3 Check resistance in the range of0.51 to 0.62 Ω

Secondary coil-Resistance

1 Set Multimeter on 20KΩ mode

2 Put the +Ve probe in plug cap cord-1 (Thick wire) and –
Ve probe in cord-2 (Thick wire)
3 Check the resistance in the range of 11 to 16.2 KΩ

If resistance value is within range then part is ok, if not

replace the part
 FI Actuator: Injector

Relation with vehicle

Actuator-Injector Application
performance
NS200/RS200/D400/D250 Malfunctioning of fuel Injector will
Pulsar 150/180/220 result in either rich or lean mixture
Avenger 160/220 causing Smokey exhaust /misfiring
*All above 150CC problems.
Knocking/Combustion noise.

Wire
v Sr. Meter Connections Standard
Parameter
No. Range Mete Mete Reading
r +ve r -ve
12 + 0.6
200 Pin Pin
1 Resistance Ohms @
Ohms no. 1 no. 2
20⁰C
 FI Actuator: Injector

Sr
Checking SOP Images
No.

Fuel Injector-Resistance

Set Multimeter on 200 Ω mode

1

Put the +Ve probe in Pin-1 and –Ve probe

2 Pin-2

Check resistance 12 + 0.6 Ohms (11.4

to12.06 ohm) @ 20⁰Cas per temperature
3 given in the chart.

If resistance value is within range then part is ok, if

not replace the part
 Air Flow through Connector Purge Valve
(Pulsar 150 Models Only )

Connection to
Connector purge valve

Purge valve

Expansion tank.
To eliminate the air flow
noise
 Air Flow through Connector Purge Valve
(Pulsar 150 Models Only )

From Air filter to

expansion tank

From expansion
tank to Purge valve

From Purge valve

to connector purge
valve
 Air Flow through Connector Purge Valve
(Pulsar 150 Models Only )

Air flow through Pipe connection is

connector purge blocked (Not in
valve to throttle use)
body chamber

From throttle body

chamber to engine
This rubber grommet is
blocking the air flow coming
from throttle body(Inflow
from intake side)
 FI Actuator: IACV solenoid

Relation with vehicle

Actuator-IACV solenoid Application
performance
Pulsar 150/180/220 If IACV solenoid not working idling
Avenger 160/220 RPM will be affected.
*All above 150CC

Standard
Sr.No. Wire Connections
Value
Meter
Meter -ve
+ve
1 24 +3Ω
Pin no.
Pin no. 2
1
 FI Actuator: IACV solenoid

Sr
Checking SOP Images
No.

IACV solenoid-Resistance

1 Set Multimeter on 200 Ω mode

Put the +Ve probe in Pin-1 and –Ve probe

2
Pin-2

Check resistance 24 ±3Ohms

3

If resistance value is within range then part is

ok, if not replace the part
 FI Actuator: Purge Valve

Relation with vehicle

Actuator-Purge valve Application
performance
Pulsar 150/180/220 If IACV solenoid not working idling
Avenger 160/220 RPM & vehicle start ability will be
NS200/RS200/D400/D250 affected.
*All above 150CC

Sr.No Standard
Wire Connections
. Value
Meter
Meter -ve
1 +ve 24 +3Ω
v Pin no. 1 Pin no. 2
 FI Actuator: Purge Valve

Sr
Checking SOP Images
No.

Purge Valve-Resistance

1 Set Multimeter on 200 Ω mode

Put the +Ve probe in Pin-1 and –Ve probe

2
Pin-2

Check resistance 24 ±3Ohms

3

If resistance value is within range then part is

ok, if not replace the part.
 FI Actuator: Stepper Motor

Relation with vehicle

Actuator-Stepper Motor Application
performance
Pulsar 180/220 Unstable idling RPM.
Avenger 160/220 Start ability will be affected.
NS200/RS200/D400/D250
*All above 150CC

Sr.No. Wire Connections Standard Value

Meter +ve Meter -ve
1 51Ω +10%
Pin no. 1 Pin no. 4
2 Pin no. 2 Pin no. 3 51Ω +10%

vvv
 Fuel Pump Delivery Checking

Relation with vehicle

Actuator-Fuel Pump Application
performance
Pulsar 150/180/220 Malfunctioning of fuel pump will
Avenger 160/220 result in intermittent fuel supply
NS200/RS200/D400/D250 causing hesitation /misfiring, no
*All above 150CC start.

Sr
Checking SOP Images
No.

1 Remove petrol tank.

Keep the petrol tank on flat surface in such a way that no

2
pressure is applied on fuel pipes.

Connect the fuel pump delivery checking pigtail coupler

3
to fuel pump coupler.

Connect the fuel pump delivery checking pigtail crocodile

4
to the 12V battery supply.

5 Check fuel pump delivery as per given specification

 Fuel Pump Delivery Checking

Sr
Checking SOP Images
No.

Hold the clean & calibrated Borosil jar near inline

1 fuel filter outlet for collecting fuel & press the
button of pigtail.

Keep the jar on plane surface & Check the fuel

2 quantity collected in Borosil jar as per below
specification.

Fuel pump delivery 10 per sec

Sr.No. BS norms Model Specification

1 BS III RS 200 180 ml
2 BS IV RS 200/D400 220 ml
3 BS VI D400/250 195±10 ml
4 BS VI RS200/NS200 135±10 ml
5 BS VI Pulsar150/180/220 & Avenger 160/220 80-90 ml
 Fuel Pump Pressure Checking

Relation with vehicle

Actuator-Fuel Pump Application
performance
Pulsar 150/180/220 Malfunctioning of fuel pump will
Avenger 160/220 result in intermittent fuel supply
NS200/RS200/D400/D250 causing hesitation /misfiring, no
*All above 150CC start.

Sr
Checking SOP Images
No.

Remove petrol Tank mounting bolts & disconnect fuel

1
gauge & pump couplers

2 Disconnect the Injector pipe quick connector.

Assemble the fuel pump pressure checking unit as

3
shown. Connect this unit to the pump outlet.
Quick connector
connection to
pump
4 Make the fuel pump coupler connection.
 Fuel Pump Pressure Checking

Sr
Checking SOP Images
No.

1 Check the value as per given in the chart

Disconnect the fuel pump coupler connection &

2
hose pipe quick connector.

Fuel pump delivery 10 per sec

Sr.No. BS norms Model Specification

1 BS III RS 200 2.4 - 2.8 bar (2.44 – 2.85 Kgf/cm²)
2 BS IV RS 200/D400 3.1 to 3.6 bar (3.46 to 3.67 Kgf/cm²)
3 BS VI D400/250 3.4 to 3.6 bar (3.46 to 3.67 Kgf/cm²)
4 BS VI RS200/NS200 2.4 - 2.8 bar (2.44 – 2.85 Kgf/cm²)
Pulsar150/180/220 & Avenger
5 BS VI 2.4 - 2.6 bar (2.44 – 2.65 Kgf/cm²)
160/220
Note:- If quick coupler is hard to remove wait for 5 min.
 Transil Unit

Relation with vehicle

Transil Unit Application
performance
Pulsar 150/180/220 Fuel pump issue, vehicle start
ability

Function :
Connections
Multimeter Multimeter Standard Transil unit is provided to protect Fuel
Range Positive Negative Value pump circuit from high voltage
(Red (Black transients generated during electrical
Probe) Probe) functioning of vehicle
Diode range (2K)
Black Red 0.2 – 0.7 V It is connected in wiring harness such
that fuel pump relay supply goes to
fuel pump through Transil unit. Only
Reverse Open
diode can be checked using
Multimeter.
 Transil Unit

Sr
Checking SOP Images
No.

Set multimeter on diode range (2kΩ)

1
mode

Put the + Ve probe in black wire and

2
–Ve probe in red wire

3 Check voltage in the range 0.2 to 0.7 V

Put the + Ve probe in red wire and –Ve

4
probe in black wire .

5 It’s showing open circuit

If value is within range then part is ok ,if not

replace the part.
 Fuel Flow Circuit (Aisan Make)

Strainer (Inlet to pump)

FSM Body

Fuel pump (pressurize the

fuel) the fuel)
Fuel Back to tank

If(Inline
YES
pressure> Relief valve
2.5 bar)

NO

Injector
 Fuel Lines- Overview

Strainer (Inlet to
pump)

Fuel pump
(pressurize the fuel)
* Fuel Back to
FSM Body tank
If(Inline
YES Relief
pressure
valve
>P# bar)

NO

Injector

Applicable models : PULSAR 150 / PULSAR 180 /PULSAR 220 /AVENGER 160/AVENGER 220
*Refer Next slide
 Fuel Supply Circuit

Relief valve Fuel Pump

Inlet to pump
1*

Fuel back to
tank Strainer
Pump Outlet Through
relief valve Quick connector (size - 6.30 – 1/4")
(IF pressure JL171843
more than
2.5 bar)
Applicable models : PULSAR 150 / PULSAR 180 /PULSAR 220 /AVENGER 160/AVENGER 220
 Fuel Supply System

Pump Strainer (Inlet to

delivery pump)

Fuel pump
(pressurize the fuel) Relief Fuel Back to
* valve tank

Inline fuel filter

If(Inline YES
pressure
> P# bar)
NO
Towards Regulator Injector

*Refer Next slide

Applicable models- NS160 / NS200 / RS200 / DOMINAR 400
 Fuel Supply Circuit

To Injector

Fuel Pump

Strainer

1
2

2 1

Fuel back to tank Relief valve Pump Outlet Quick connector Inline fuel filter

Applicable models- NS160 / NS200 / RS200 / DOMINAR 400

Electrical Circuit Diagrams
Pulsar 150/ Pulsar 180/ Pulsar 220
Models

NOTE : For better clarity, refer BS VI Supplementary SSM available on e-ssm.

Battery Charging

Code Wire colour

W White
Br/L Brown/Blue
Br Brown
L/W Blue/white
B/Y Black/Yellow
B Black
R Red
Ignition

Code Wire colour

W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
Horn

Code Wire colour

W White
Br/L Brown/Blue
Br Brown
B/Y Black/Yellow
B Black
R Red
Brake Lamp

Code Wire colour

W White
Br/L Brown/Blue
Br Brown
B/Y Black/Yellow
L Blue
R Red
Fuel Pump
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Starter Motor
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Side Stand Indication
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Side Indicator
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Fuel Meter
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Fuel Injector
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
EVAP Purge Valve
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
MIL Indication
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Engine RPM Indication
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
ABS
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
Lighting
Code Wire colour
W White
Br/L Brown/Blue
Br Brown
B Black
B/Y Black/Yellow
Y/L Yellow/Blue
Gr Grey
R/L Red/Blue
W/R White/red
Y/B Yellow /Black
G/Y Green/Yellow
L/G Blue/Green
O/W Orange/White

Pi/L Pink/Blue
L/Y Green/Yellow
G/B Green/Black
R Red
THANK YOU