Question about Bajaj Pulsar 150 Motorcycles

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Whats wrong mechanic or my bike ???????

I have been riding this pulsar 150 for past 2yrs totally 38,000kms . 2months back bajaj service mechanic told me that i have to change the battery since i had problem with selfstart and poor horn sound. so day before yest i have bought new "amaron battery" fixed up. i used the self start button, it has started my engine very smooth, i was very happy :P but today again i got a self starter problem. whenever i use selfstart, sound comes from the engine and starter motor just like old battery tried to run the starter motor then it dies. so i went to bajaj service center, 1. they have checked my battery, voltage reading showed 12.5vlts so they said battery is ok . 2. they have checked the ""small box with 2 little fuses in it. it was ok but supply comes even if the ignition is ""off"" this could be a problem. 3. they checked the relay by shorting relay terminals with long screw driver. it start the starter motor but unsuccessful to start up the engine. 4. they have checked little black colour box (they said its rectifier) . it was ok. 5. finally they have connected long thick wire, one terminal on battery and another terminal on started motor connection. nothing happened . "FINALLY THEY SAID I GOTTA CHANGE MY STARTER MOTOR " :( :( :( i said ok will come on saturday to fix it up. when i retured home i tried to use self start again THIS TIME no sign of anything no old battery starting sound from engine or starter motor, my speedometer dead if i stop the engine, click sound from relay whenever i push self start button ..... I DONT KNOW WHATS HAPPENING :((( CAN ANY ONE HELP ME OUT PLZZZZZZZZZZZZ

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  • Bajaj Master
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Hi Shakthi, it should be noted that in order to "PROPERLY" diagnosis any electric starter issue it is "IMPERATIVE" that you begin with a fully charged battery 12.5 volts or better and be able to pass a proper load test, and the usual suspects are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, 12.5 volts or better,to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid has dropped more than 1/2 volt.
4. With a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 8-9 volts.
If a lower voltage is produced a proper battery load test should be performed with a load tester to validate battery integrity or battery replacement.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohm-meter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buy a new one.
For more information about your issue, please visit the websites below. Good luck and have a nice day.

Btw, I’m available to help over the phone in case u need at

Posted on Nov 18, 2015


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SOURCE: Headlight

I think u can replace it by 220's headlight and any bajaj authorised service center can do this job but just to tell u that the 220's headlight works out well in terms of design because it goes well with the fairing on the tank. If u try to put it on 150 then probably it would not go with the tank of 150 in terms of flowlines and it will also look big and bulky.Do remember that the headlight assembly unit of 220 have a different wiring mechanism as the headlight comes with a Xenon projected lamps. U will have to change the wiring system of your 150 by 220's one and will cost u big bucks. But if money is not a constraint for u then u can always go ahead and do this job on your bike.

Posted on Nov 10, 2008

  • 55 Answers

SOURCE: wont start on button


Posted on Nov 26, 2008

  • 404 Answers

SOURCE: push starter button and no start

Evansville! Nice part of the World.
Bud's Harley Shop still there?
O.k. daft thing is the off run switch on the handlebars turned to off?
Failing this will the bike start and run off bumping (Push start).
If it does take a look at the battery (Maybe Dead cell/s) or Starter solenoid wire/fuse.
Solenoid is located near the battery it is the cylindrical item with the main pos+ wire from battery going to it.
Good Luck! could do with a new Bud's Harley 'T' shirt as mines worn out.
Paul 'W'
Onyer~EDson(:0 {#><U.K.
Oh! please remember to politely rate my effort!

Posted on Jan 21, 2009

  • 216 Answers

SOURCE: custom bike....starter "clunks" and does not turn over

Sounds like your jack shaft isnt engaging into the bushing in your outer primary... you should pull off the outer primary and try carefully filing the edges off the bushing... Also check that the jack shaft has been properly installed.... This problem is common on customs

Posted on Jun 21, 2009

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