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Pulsar-DTS-i-UG-III-Trg-Notes-Final_1 TO 64

1. Enhanced Performance e Refined engine power delivery by optimization of ExhausTEC location bigger amp twin Air Filter element optimized valve timing reduced engine friction etc e Stainless steel silencer that lasts long amp overcomes rusting e All sensor type electrical switches that function for the life of the bike Absolutely no maintenance in absence of mechanical contacts amp Enhanced Style e Stylish fairing amp Headlamp assembly with owl eye new black mask to separate headlamp from parking lights e New age sharp amp attractive 2 Row Tail lamp with LED lights e Louver type LH amp RH covers with wire mesh gives sturdy look e Ergonomically designed self letting switches e Absolutely no maintenance in absence of mechanical contacts amp Enhanced Comfort amp Convenience e Loaded with Digital Technology like LCD Speed Odo display digital fuel meter Digital trip meter that enables to count two trips e Car like self canceling indicator switches that keeps rider free from switching off the indicators after turn e Apart from digital fuel meter warning light for low fuel level is provided e Self check provision for tachometer to ensure proper functioning e Oil level inspection window that indicates oils level at a glance amp Enhanced Safety e Engine cut off at 10000 RPM Spark gets cut off at 10000 RPM e High RPM warning lamp when engine reaches to 9000 RPM automatically Red LED bulb starts b
2. 0 7 to 0 8 mm Wet sump Forced Kick start Electric start Wet Multidisc type 5 speed constant mesh 3 47 1 66 19 26 93 1 36 13 18 31 1 32 17 13 43 1 29 21 10 54 1 26 24 8 98 1 24 26 24 26 2 80 1 43 15 Double cradle Telescopic front fork with DU bush Stroke 135mm Trailing arm with coaxial hydraulic cum gas filled adjustable shock absorbers and triple rate coil springs Mechanically expanding shoe and drum type Hydraulically operated disc type Mechanically expanding shoe and drum type 2 49 x 17 41 P 100 90 x 17 55 P 1 75 kg cm 24 5 Psi 2 00 kg cm 28 0 Psi 2 25 kg cm 32 0 Psi 1 60 x 17 2 15 x 17 4 Pulsar DTS i UG IIIl 180cc Training Notes Technical Specifications Fuel Tank Capacity CONTROLS Steering Accelerator Gears Clutch Brakes Front Rear ELECTRICALS System Battery Head Lamp Pilot Lamp Tail Stop lamp Turn signal lamp Turn signal pilot lamp Side stand indicator lamp Hi beam indicator lamp Neutral indicator lamp Speedometer lamp Rear number plate lamp Horn DIMENSIONS Length Width Height Wheel base Turning circle radius Ground clearance WEIGHTS Vehicle kerb weight Gross vehicle weight PERFORMANCE Maximum speed Climbing ability Notes 15 liters Full 3 2 liters Reserve 2 0 liters Usable reserve Handle Bar Twist grip type on RH side of handle bar Left foot pedal operated Lever operate
3. R Remove E e Assly Bal idler gear e Centrifugal oil filter special e 2 Washer nut e Belleville washer e Body centrifugal oil filter assly Remove Remove e Bearing with plunger e Bolt A e Locking plate e Body balancer gear assly Using Special Tool Special Nut Puller 37 10DJ 43 Primary Gear Holder 3710DJ28 Remove Remove e Primary gear e Square key e Input shaft special nut e Belleville washer Note Take case that square key does not fall inside the crankcase hollow portion while removing e Clutch assly comp e Spacer Remove e Cam chain e Cam chain sprocket e Parallel Pin Note The existing Special Nut Puller 37 10DJ 43 can be used by grinding the tool OD to 25 9 0 1 mm Dia 25 9 0 1 Os GF Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Dismantling Engine 63 Pulsar DTS i UG III 180cc Training Notes Remove e Gear change lever Remove e Spring e Allen bolt A e Guide gear e Spacer e Parallel Pin Note Check and inspect the drum change arm stopper for free movement always Using Kick starter lever Remove e Washer e Kick shaft assly comp Note Rotate the kick starter lever in Anticlockwise direction for removing the kick shaft assly Remove e Bolt A e Locking Plate e Kick idler gear Remove e Bolt A on RH side crankc
4. 33 Pulsar DTS i UG III 180cc Training Notes pubsacars LCD Speedo Console Test Connect wiring harness number 2 to C2 connector After connecting speedo console wait unitl console LCD goes blank Now press speedo console test switch to start the test Observe for working of speedo console till test ends Body Control Unit BCU Test Connect wiring harness number 3 to C3 C4 and C5 connectors respectively Press the BCU test switch At the end of complete test Green colour glowing of Result LED indicates BCU test passed At the end of complete test Red glowing of Result LED indicates BCU test failed at respective Red indications Dealer Development Center pulsar i For carrying out repairs overhauls 1 new special tools for Pulsar DTS i UG Ill have been developed Rest of the special tools required remains the same which were earlier required for Pulsar and Pulsar DTSi Special Tools Details of Exclusive Special Tool Eng ine Sprocket Catcher Drawing No 37 10DH 36 Application For holding sprocket during removal refitting of Cam sprocket allen bolt Camshaft Big Bearing Puller Drawing No 37 10DH 32 Application To remove bearing Decompression assembly side of camshaft Camshaft Small Bearing Puller Drawing No 37 10DH 31 Application To remove small bearing of camshaft Rocker Pin Remover Drawing No 37 10DH 35 Application To remove rock
5. Uploaded by lockhrt i Identification Data posken y Salient Features pakas The Engine and Frame serial numbers are used to register the vehicles They are the only means of identifying your particular vehicle from the other of the same model and type These serial numbers may be needed by your dealer when ordering the parts In the event of theft the investigating authorities will require both these numbers in addition to the model type and any special features of your vehicle that can help identifications Performance Refined engine power delivery by optimization of Exhaus TEC location and revised ignition timing with intelligent CDI New clutch amp revamped gear shifting mechanism that gives smooth positive virtually friction free gear shift feel New Bigger twin foam filter with an optimized intake system to provide better torque Optimized valve timing and Roller rocker with NR bearing for friction reduction that improves drivability LED tail lamp that consumes negligible power amp require zero Location of Parts maintenance Stainless steel silencer that overcomes rusting problem All sensor type electrical switches that enables switches to function for the life of the bike Absolutely no maintenance in absence of mechanical contacts Style Stylish fairing and head lamp assembly with owleye A new black mask that separates headlamp from parking lights adds to aesthetics Clear lens indicator with
6. Valve Adjusting Screw Holder 37 1031 53 inst ae 4 i Ap 2a E ee CO Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Schedule Maintenance 27 Pulsar DTS i UG III 180cc Training Notes Phsar Irssi Ignition Timing Inspection e Connect cable of stroboscope to one of the H T Coil carrying current to spark plug e Start the engine e Aim the stroboscope light at Magneto cover glass window At idling speed the F marked line on the rotor coincide with the line mark on magneto side c case 10 BTDC 1500 rpm As the engine rpm is increased the A marked on the rotor coincide with the line mark on magneto side c case 28 BTDC 3500 rpm This indicates the advance timing is functioning correctly Remember the T marked line is a reference line for TDC position of the piston and is not for Ignition timing Clutch Lever Free Play Adjustment e Slide the dust cover at lever yoke end e Check that the clutch cable outer end is fully seated in the adjuster e Turn the adjuster A until the proper amount of free play can be obtained e Tighten the lock nut B against the adjuster If the clutch free play cannot be adjusted with the adjuster at the handle bar end use the adjuster at the lower ends of the clutch cable situated on clutch cover e Loosen the 2 lock nuts C on clutch
7. NO FLAT SPOT GIVE CO DRIVE CHAIN slack mention amont of play RAKE OPERATION FRONT REAR RONT BRAKE EAR BRAKE EFFECTIVENESS BRAKE LIGHT REMAINING ON CONTINUOUSLY GAP AT THE REED SWITCH AND MAGNETO CHECK POINTS FOR PDI LOOSE PARTS KICK BOSS BOLT NGINE MOUNTING BOLT NGINE NOISE APPET NOISE HAIN TENSIONER TIMING CHAIN NGINE OIL LEAKAGE RAIN BOLT AGNETO COVER CRANKCASE JOINT OIL FILLING PLUG HC COVER APPET COVER ENJO BOLT HAIN TENSIONER O RING OIL LEVEL INDICATOR WINDOW OIL FILTER COVER LUTCH OPERATION UJ h a AIO Ol EN J J 6 17 m O 18 m 9 WD CD Se gt JU w LUTCH JUDDERING LATING DEFECTS ANDLE BAR 1 ENGINE OPENING DURING PDI If any Give engine no amp reason for engine opening RAME OPENING DURING PDI If any Give chassis no amp reason for chassis opening OTHER DEFECTS MINOR ADJUSTMENTS 4 TRANSIT DAMAGES Send photographs NO 0 L 2 3 v Marked if the ok observed hk Pulsar DTS i UG III 180cc Training Notes Dealer Development Center PDI SOP pubs Identify amp Park Vehicle on Work Bay Remove the Thermocol and 2 additional packing if any Study Special om ep PNR amp its Con bl M amp T Service Attachment 0nSUMAD ES Shop Equipments o fo titer Bay Bay Petrol Waste Cloth 1 PDI card and Work content Open Petrol tank cap 3 amp pour petrol Check
8. The rod clutch lifter plunger oil plate plunger oil and spring joint may fall out of their respective places into the oil collection tray If so ensure that these are collected amp accounted for before proceeding Remove 3 bolts A Oil pump assembly 2 Dowels Clutch cover gasket Starter Motor B Warning The oil pump may be hot hence use suitable hand protection Also since the oil pump houses the oil strainer mesh also it may retain some quantity of oil This oil may be hot Hence proper care should be taken to drain it Note The oil which is in the oil pump housing should also be drained out into the oil drain tray for measuring drained oil 60 Pulsar DTS i UG III 180cc Training Notes Dismantling Engine Dismantling Engine pubsacars7 Using Special Tool Primary Remove Gear Holder 37 10DJ 28 Remove e 3 Assly balancer Idler gear cover bolts A e Cover e 3 phillips head screws A e Washer e Centrifugal oil filter cover e 2 Dowel e Gasket Warning These parts may be hot if removed from a hot engine Use Remove gloves for protection e Clutch housing Note Some amount of oil is trapped in cover and body of centrifugal oil filter this oil should be drained into the oil tray Note For ease in removal of clutch house insert special tool P No 37 10DJ 63 in Assly Balancer Idler Gear Using Special Tool Special Nut Puller 37 10DJ43 Primary Gear Holder 3710 DJ28
9. Dealer Development Center Pulsar DTS i UG IIl 180cc Training Notes Schedule Maintenance Pulsar DTS i UG III 180cc Training Notes Spark Plug pubsaca Si Recommended Spark Plug Champion RG4HC Bosch UR3DC Electrode Gap 0 7 0 8 mm Replace Spark Plug After every 10000 Kms Battery 12V 9 Ah Battery is located inside LH cover Check the electrolyte level in each cell and ensure that the level is between the upper and lower level lines Remove the battery filler caps and fill with distilled water until the electrolyte level in each cell reaches the upper level line if required Note Add only distilled water to the battery Tap water is not a substitute for distilled water and will shorten the life of the battery Apply petroleum jelly on to the terminals Front Brake Fluid Level Front brake fluid master cylinder reservior is located near RH switch on handle bar To check oil level park the vehicle on Main Center stand with handle bar in straight position Always ensure that brake fluid level is above MIN mark given on inspection window Use only DOT 3 or DOT 4 brake fluid from sealed container to top up if required Note It is advisable that brake fluid should be replenished once in a year Rear Shock Absorber The rear shock absorbers can be adjusted to one of five positions to suit riding conditions Using special tool adjust the required position you desire They can be left s
10. Tighten the Axle Nut Tighten the torque link nut Fix the snap ring Adjust the correct brake play 31 Pulsar DTS i UG III 180cc Training Notes Note This procedure can prevent a soft or spongy feeling brake Piston Ring Fitment Piston rings must always be fitted with respect to exhaust mark on the piston First place the bottom oil rail ring with end gap 28 towards left of the exhaust mark in the last groove Place oil expander ring with butting end downward and end gap facing opposite to the exhaust mark Now fit top oil rail ring on the expander ring with end gap 30 towards right of the exhaust mark Fit the second piston ring with Top 2 mark facing upward and end gap facing opposite to the exhaust mark Finally fit the first ring with Top 1 mark upward and end gap facing towards the exhaust mark Remember fitment of 2nd ring upside down may lead to passing of oil above the piston and ultimately leading to smoky exhaust Dealer Development Center Dealer Development Center Standard Checking Procedure BRR Air Bleeding of Disc Brake System e For air bleeding from front Hydraulic brake system first top up the master cylinder with hydraulic oil e Operate the brake lever slowly in order to get filled the oil in the circuit e Connect transparent tube to the bleeder screw at caliper e Operate the brake lever and keeping in pressed position loosens the bleeder screw s
11. UG III 180cc Training Notes Dealer Development Center Removal of Engine from Frame Dealer Development Center Remove e 2 nuts B for silencer flange Note Always remove the flange mounting first and then rear mounting to avoid misalignment of studs Remove e Bolt A of silencer bracket mounted on pillion RH side footstep e Silencer assembly Remove e Starter motor connection A Remove e PCV pipe from breather Remove e Disconnect the reed switch coupler e Spark plug cap LH Remove e Air filter mounting bolts to facilitate the removal of carburettor with reed switch e Clamps of carburettor and disconnect carburettor along with insulator and dismantle cables from it e Bracket bolts securing clutch cable on clutch cover e Spark plug cap RH 54 Pulsar DTS i UG IIIl 180cc Training Notes Removal of Engine from Frame Pulsar DTS i UG III 180cc Training Notes Phsar Irssi Remove e While removing engine foundation bolts first remove the topmost bolt and then go down progressively Note Bolts A holding the engine to the chassis 4 bolts of 12 mm and 1 bolt needs deep socket for removing it e Lift up the engine off the chassis and place it on engine stand Note After disconnecting all the sub assemblies and control cables from the engine lift up the engine and remove it from RHS of the vehicle Dealer Development Center Dismantling Engine Dealer Devel
12. amber bulbs New age sharp and attractive 2 Row Tail lamp with LED lights New seat cowl to match stylish LED tail lamp Louver type LH amp RH covers with wire mesh gives sturdy look Ergonomically designed self letting switches Convenience and Comfort LCD Speedo Console with digital fuel gauge 12 level indicator Digital speed display odometer and two trip meter with resetting provision Self canceling indicators After completion of turn the indicator will be switched off automatically Engine oil level window for easy to monitor level Maintenance free battery once a year electrolyte top up In addition to Fuel gauge Reserve indicator bulb is provided that glows continuously till the petrol filled to main level Control Switch RH 1 Hall Sensor for Indicator 2 LCD Speedo Console 3 Control Switch LH 4 Body Control Unit Placed inside Head Light fairing Vehicle Speed Sensor ExhausTEC Tail Light LED display Self check provision for Tachometer for its functioning O M 9 pi Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes pubsacars Safety Day night mode of Speedo console The turn Indicator neutral high beam and side stand Indicator bulb glow brightly in the day for clarity and Intensity reduces during night to reduce irritance to the rider s eye High RP
13. brake liners are dry before driving the vehicle Periodic Maintenance Periodic maintenance in accordance with the periodic maintenance chart of a vehicle is most important to prolong vehicle life trouble free running and ensure your safety while driving Engine Oil Level Checking e Park the vehicle on level surface on center stand to check the oil level e Inspect the oil level through oil inspection window e t should be in between upper and lower mark e Top up if required Recommended Oil Grade and Qty Grade SAE 20W50 of API SG JASO MA Quantity Drain amp Refill 1000 ml Engine Overhaul 1100 ml Note It is most vital to adhere to recommended frequency of oil change for the purpose of long life of critical engine components for details refer Periodic Maintenance Chart Oil Strainer Cleaning Remove e Drain engine oil e Clutch cover e Oil pump mounting bolts A 3 Nos e Pump with strainer e Clip B and take out Oil Strainer from oil pump 20 Pulsar DTS i UG III 180cc Training Notes Remove e Clean oil strainer with Kerosene Diesel blow compressed air and then refit it e Replace oil strainer if found damaged Centrifugal Oil Filter Cleaning Remove e Centrifugal oil filter cover mounting screws C 3 Nos e The cover with gasket e Replace gasket if damaged e Clean centrifugal oil filter using Nylon brush kerosene or Diesel Air Cleaner Ele
14. for smooth operation of fuel cock lever 5 Check amp top up engine oil level if required l Check clutch cable operation amp R 10 12 13 OE Adjust if required l Spanner o Check front brakes for efficient Front 0 10 12 13 Ring working amp Adjust if required l Spanner 0 50 Measuring Jar Funnel O O O oe a gt O Analogous Digital type Pressure gauge Air filling Valve Check and correct tyre inflation pressure Front Wheel Pencil Type Front 0 20 Pressure Gauge Cloth Fine Check Battery voltage fill Screw Driver ke top up electrolyte apply Distilled water picnics ee petroleum jelly connect Filler 10mm Jelly Battery Tester terminals properly T Spanner Inspect Rear Shock Absorber RH LH setting amp correct if necessary Check Rear brakes for efficient Rear 14 15 No ee working amp adjust if required O E Spanner Fine Polish Paper Analogous Digital Check and Correct tyre inflation pressure Rear Wheel Distilled Water 1 1 Pencil Type Type Pressure Rear 0 20 Pressure Gauge Gauge Air Filling Valve 20 22 24 27 Ring Spanner Lubricate chain and Check U NOOO Cloth 0 40 Spanner Adjust chain slackness if required SAE 90 Oil Torque Wrench Socket Set Oil Can Check Choke lever operation 0 05 RH 12 13 16 17 Front Ring Spanner Check Accelerator cable free play Check amp Adjust TPS LH LH LH H Check gear shifter
15. is in specified groove Needle worn out at taper portion Piston valve worn out Scoring marks Diaphragm punctured e Piston valve No wear mark Diaphragm condition Overhaul carburettor at every 10 000 kms and insepct the parts 47 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center pulser i Pulsar DTSi is the first bike in the world In small cc engine to have twin spark ignition system Digital Twin Spark Plug Ignition DTS i 1 The most obvious feature is the Twin Spark Plug configuration o f the Engine The cylinder head has 2 spark plugs one on either side The spark plugs are of the smae Heat range Champion RG4HC Bosh UR3DC Resistive and have similar electrode gaps These also spark simultaneuosly This has been done to improve the combustion process by reducing the time of combustion The end results are low emissions good fuel economy and good driveability 2 To enable the sparking of the 2 spark plugs a intelligent CDI capable of handling this was developed Further more the ignition timing has been optimised to give the best output from engine 10 BTDC 1500 rpm 28 BTDC 3500 rpm To enable optimum igntion timing for part throttle loads and full throttle loads there are separate igntion maps stored in the memory of the CDI These are activated depending on the throttle opening and engine speed The Digital CDI has a bit Microprocessor which handles all
16. slack will be within the standard value i e 25 30 mm Loosen the rear torque link nut A amp rear brake adjusting nut F Loosen the left and right chain adjuster lock nuts B Loosen the axle nut C Loosen the bearing carrier nut D If the chain is too tight back out the left amp right chain adjusting nuts evenly amp kick the wheel forward until the chain is too loose Turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the notch E on the left chain adjuster should align with the same swing arm mark that the right chain adjuster notch E aligns with Warning Misalignment of the wheel will result in abnormal wear and may result in unsafe riding condition 30 Pulsar DTS i UG III 180cc Training Notes standard Checking Procedure Tighten both chain adjuster lock nuts Tighten the sleeve nuts securely Warning Tighten the bearing carrier nut before tightening the axle nut If the nut tightening order is reversed the rear axle will not be securely mounted on the swing arm This may cause misalingment of the wheels and result in loss of control Center the brake panel assembly in the brake drum This is done by tightening the axle nut lightly spinning the wheel and depressing the brake pedal forcefully The partially tightened axle nut allows the brake panel assembly to center itself within the brake drum
17. switches the indicator goes off automatically after the rider takes a turn amp brings the handle bar straight This feature is similar to cars That means rider do not have to press or turn the switch to cancel the indicators What if one switches ON the indicator and do not physically take a turn Will it work in such situation Yes Of course When the rider selects a right or left turn indicator but changes his mind and physically do not take a turn the indicators turn OFF automatically after pre set time For this a timer function is incorporated in the system And the timing for this timer is set around 80 seconds Dealer Development Center Frequently Asked Questions FAQ s S YD S D D YD amp Dealer Development Center pubsaears What does non contact Handlebar switches mean The control switches on both sides of the handlebar are conventional to look at in terms of switch operations amp knob position etc But the key amp distinguishing difference is the principle of functioning that means these switches do not function on the basis of physical contact for ON amp OFF These are on non contact sensor based This feature will have any wear and tear amp hence its life would be more than the life of the bike These are absolutely maintenance free as far as wear amp tear is concerned The other feature in these switches is the Illumination of the tell tale icons that is lit up with LEDs in
18. these inputs and gives out the required and correct spark advance The intelligent CDI can be easily indentified by 2 green dots marked on CDI case 3 To enable switching the required igntion maps a magnetically operated need switch is incorporated on the carburettor throttle shaft and carburettor body This is known as TRICS Throttle Responsive Igntion Control System 4 These engines are capable of of reviving very high quite easily To keep them mechanically safe a engine rpm limiter has been incorporated in the Digital CDI This curtails the sparks to the spark plugs thereby limiting the engine rom Max upto 9000 and thus keeps the engine mechanically safe There are 2 spark plugs LH spark plug fires at 350 rpm and then continues to give spark till at 9000 rom of engine The spark is cut off from LH plug 9000 rpm to protect engine from excessively high speed RH spark plug gives spark at 750 rpm and then continues to give till 6000 rom of engine If engine rom exceeds 6000 rpm then RH plug is cut off This is done to reduce combustion noise created in engine 5 This engine has been extensively tuned for more Power and Torque 6 The DTSi technology has enabled the Pulsar to meet 2006 norms without any Secondary air injection devices Troubleshooting e Malfunctioning of the Reed switch assly will not harm the engine neither it will give any physical indicators like starting trouble or misfiring However checking of pr
19. 0 Oil Spanner 10 11 OE Spanner 20 22 24 27 Ring Spanner 10 11 14 15 OE Spanner Periodic Service SOP a LH RH Special M amp T Service Analogous Digital Type 15 Check amp Adjust Rear tyre air pressure Pressure Gauge Air Filling Valve Pencil Type Pressure Gauge Check Battery Top up distilled water Clean terminals amp apply petroleum jelly Route cables properly and fit terminal caps properly Recharge battery if required Clean oil strainer Replace if required After 1 Year or 10000 Km whichever is later Screw Driver Distilled Water Filler 10mm T Spanner Cloth Fine Polish Paper Petroleum Jelly Distilled Water Diesel cloth Pistol Grip Clutch Cover PNR Gasket Oil Strainer Cloth Oil 20W50 of API SG Oil Dispenser JASO MA grade Cloth Fine Spark Plug Polish Paper Cleaner and Spark Plug Tester Air Gun Cloth Oil Dot 4 Cloth Fine Polish Paper Hydrometer Battery Charger Battery Tester T 8 No Box Spanner 12 13 OE Spanner 12 13 Ring Spanner 8mm T Spanner Plastic Tray Phillips Screw Driver J IT 12 13 OE Spanner Small Screw Driver 6 Combination Pliers Measuring Jar 1Liter Funnel Check clutch and Adjust Fill engine oil Spark Plug Spanner Plug Cleaner Wire Brush Clean Check amp Adjust RH spark plug J IT D D ma IT Check and Top up brake fluid level ER Fro
20. 10 12 No OE Spanner and 12 No Box Spanner Pistol Grip PNR NO Oo WM m Small Screw driver 0 10 Test drive the vehicle check digital speedometer working Study the job card and verify work done Take vehicle out and park Total SMM m Ty 17 B Repair for any other defects seen or observed during test drive Expected Output in 480 Minutes Man 27 Vehicles 13 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Periodic Maintenance amp Lubrication Chart ehee i Whichever RECOMMENDED FREQUENCY comes first Operation imiti Subsequent 760 200 500700 Evar 200m a fates ee a 4 Erare on SAE 2owso of aei saraso my R Je o Fs Ton svaner Convingal fer fol T e wroemereemenv Jol Te r wrar f fomm o a e re im e Every 5000 kms Every 5000 kms Every 10000 kms Every 10000 kms Co Fuer system eao fon ofras ooo fe E C fseek e n f ria Banery oectovte wer Jo Te Tia emeim oa eje fown oa ele ris Twotte pay foa eje e riz Pear vrake peca pey oa Je e e o o e Brake ining orpad wear oa Je e e e gt Tre Brake mua eve rop o imm e o o o o 20 weeman e s l O O eoo asems e eee e 22 mr esteners tomes or eje e o o 23 Ergne mounting sie oos R C l eooo ea tye tad wear fon elele e 28 Tenera woren i Jejel e l e 28 T Steerng stom veerg a iya l e oos 27 wne seng for aye O O very roos
21. 28 master eyinder cup ana busts R L l reys 20 camer piston seal ana Dust seal R L l eeey 20 swing empren M le O l ie soos alem o o e e dT 22 roma a s e O O 29 Front brake ose earl exs OCO 34 Fr Shock Absorber Crear oas messmo Toros raem J _ every ooo slowem o a i o oe Dive chain sack a e o a7 Drive chain wear 7 Remove amp turcas en Jo ieys 38 Erge compression pressure STC O eooo 30T Cylinder nead de carbonising amp vane repna oc _ Every soos wo vaesa SC PY very 00004 Indicates operation to be performed A Adjust L Lubricate More frequent cleaning may be required when driving in dusty condition Every Year Every 10000 kms Every Year 14 CL Clean T Tighten Note Parts Lubricants to be replaced as per Periodic Maintenance and Lubrication Chart are mandatory and the same are chargeable to customer C Check R Replace Dealer Development Center Pulsar DTS i UG III 180cc Training Notes 2 Identity the Vehicle a Bring vehicle amp position on bay a Start veh amp Warm up Remove RH LH side covers Seat Petrol Tank amp keep properly Drain Engine Oil Clean Air filter Replace if necessary Drain Carburetor Overhaul if required Check Accelerator and adjust Clean Check amp Adjust Replace if necessary Check amp Adjust tappet clearance if required During 4th Servicing or after 5000 Km whicheve
22. Chain Sprocket in the special tool firmly and then tighten the sprocket allen bolt A e Ensure that the O mark on washer always faces outwards when tightening the allen bolt e Inlet Rocker Arm Shaft is longer in length e Rocker arm has 20 Rollers inside the outer cage e Doesn t have inner cage e Take utmost care while dismantling Rollers should not fall inside engine e Apply grease for fixing needle rollers inside rocker arm e While removing refitting of piston pin circlip cover the crankcase chamber with clean cotton cloth to avoid falling of circlip inside the engine e Blow pressurised air to oil passages in reverse direction to that of oil flow 50 Dealer Development Center Pulsar DTS i UG IIl 180cc Training Notes Important Points to Remember Belleville Washer Plain Washer Clutch 51 Pulsar DTS i UG III 180cc Training Notes Ensure e While assembling hub clutch place plain washer first and then place belleville washer Concave face should be upwards i e toward technician e After placing Belleville fit clutch plate with 48 friction material cubs A with more I D e 4 Nos of clutch plates with 36 friction material cubs B alternatively along with steel plates e Fit top clutch plate with 40 friction material cubs C e Input shaft has special nut e Thick spacer washer tapered D it should be placed on tapped portion of Input Shaft e Input Shaft has left hand th
23. Chamber Function The function of starter circuit is to provide rich air fuel mixture on starting cold starting At cold engine condition the air is dense also the engine parts are cold enough this does not allow the petrol to vaporize properly this leads to starting trouble Construction The Starter Circuit consists of a starter jet and a plunger The starter jet is used to meter the fuel and a plunger that opens an air passage from the inlet of the carburettor underneath the diaphragm which passes the mixture to the mainfold Working On pulling the choke lever the plunger is lifted by a cable This uncovers the fuel passage that leads to the starter jet air inlet passage and the outlet passage towards the manifold This creates enough suction to draw fuel up from the bowl into the mixing chamber below the plunger Here the fuel is mixed with the air and the mixture is drawn into the engine through the outlet passage 43 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Working of Carburettor pubsacors7 Pilot Circuit Constant Velocity Carburettor Pilot Jet Pilot Outlet Hole Butterfly Valve Volume Control Screw 5 Idling Adjustment Screw A O N Fuel Inlet Air Inlet Towards for pilot jet Engine Function The pilot circuit provides the air fuel mixture at idling when not enough air is being drawn through the carburettor to cause the main circuit to operate Construct
24. DTS i UG IIl 180cc Training Notes Dismantling Engine 59 Pulsar DTS i UG IIl 180cc Training Notes Using Special Tool Rotor Holder H6 0721 00 e Hold the rotor assembly Remove e Rotor bolt A e Washer Using Special Tool Rotor Puller with butt pin 37 10DJ 32 Remove e Rotor assembly e Woodruff key Note Holding the gear complete starter clutch rotate the rotor and pull it out in Anticlockwise direction to prevent rollers and springs coming out Rotor puller has left hand threads Warning e These components remain hot for a long time especially if removed from a hot engine Wear suitable hand protection to prevent burns e Rotor puller has left hand threads Remove e Gasket e Bolt A e Plate starter clutch gear return B e Gear starter clutch Remove e Collar A e Shaft e Gear comp starter counter assly Dealer Development Center Dismantling Engine Dealer Development Center pubsacars Remove 3 Screw A Guide starter assembly along with oil seal Caution Ensure that the woodruff key of rotor is removed prior to the removal of guide starter assembly The lips of magneto oil seal housed in guide starter assembly will get damaged if not done so Engine RH Clutch Side Remove Kick starter bolt Kick starter Remove 1 screw A Starter motor cover Remove 12 Clutch cover bolts B Bracket clutch cable C Clutch cover Note
25. M warning lamp when engine reaches to 9000 RPM automatically Red LED bulb starts blinking This enables the rider to control the speed to avoid damages if any that may take place to engine components Engine cut off at 10000 RPM Spark gets cut off at 10000 RPM to bring down the engines RPM for safety LED illumination for tell tale icons on electrical switches that glows in the night for positive access of individual functions Dealer Development Center Technical Specifications Engine and Transmission Type No of cylinders Bore Stroke Engine displacement Compression ratio Idling Speed Max net power Max net torque Ignition System Ignition Timing Fuel Carburettor Spark Plug Spark Plug Gap Lubrication Starting Clutch Transmission Primary Reduction Gear Ratios 1st gear 2nd gear 3rd gear 4th gear oth gear Final drive ratio CHASSIS amp BODY Frame Type Suspension Front Rear Brakes Front Rear Tyres Front Rear Tyre Pressure Front Rear Solo Rear Pillion Rims Alloy Wheels Front Rear Dealer Development Center pulsar i Four stroke DTS i Natural air cooled One 63 50 mm 56 40 mm 178 60 cc 9 5 0 5 1 1400 100 rpm 12 15 kW 16 51 Ps at 8000 rpm 15 22 Nm at 6000 rpm Microprocessor controlled digital C D I 10 BTDC at 1500 rpm 28 BTDC at 3500 rpm Unleaded petrol UCAI MIKUNI BS29 Side Drought CV Type 2 Nos Champion RG4HC Bosch UR3DC Resistive
26. alve along with jet needle is pushed up and more air fuel mixture is drawn into the engine from main jet through needle jet into the main air stream When the butterfly valve is closed air flow through the venturi decreases air pressure in the venturi increases and approaches atmospheric pressure amp the spring pushes the piston valve along with jet needle down a5 gg ____ Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG IIIl 180cc Training Notes _ Working of Carburettor pulsacars7 r E Po A DoW Handling e Never use oversize screw drivers e Use appropriate screw drivers 4 T Ps a A e Do not over tighten the jets and screws e These will damage the jets and their seats e For cleaning always use e Never clean the carburettor carburettor cleaner like with water Acetone Carbon Tetra chloride e Jets amp air passages will get Aerosol clogged due to sediments if CVC spray cleaned by water Ensure Replace e Jets e Jets Holes are clean Holes are not worn out Size as per specification Worn out jet Incorrect size jet Punctured Squeezed and distorted float e Float is in good condition e Float Pin Worn out tip Tip having no wear mark If spring loaded pin is Spring loaded pin is free sticky in movement e Needle Jet No wear at taper portion Circlip position
27. anti theft screw and then remove the allen bolts A and remove the fuel tank cap assembly from the fuel tank Fitting is the reverse procedure of dismantling But take care that the vent hole is free from any foreign particles that may clog the hole To lock the fuel tank cap just press the cap without key Fuel Cock Removal Remove e 2 bolts A e Fuel cock assembly from the fuel tank Note e Always loosen the bowl of the fuel cock on vehicle itself e Check the fuel cock strainer for any breaks or deterioration e f the fuel cock strainer have any breaks or are deteriorated they may allow dirt to reach the carburettor causing poor running Replace the strainer e Clean the fuel cock strainer in a high flash point solvent e Pour high flash point solvent through the cock in all lever positions e Dry the tank and the fuel cock with compressed air e Install the cock in the tank AY NS 2 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Working of Carburettor prubsacaors7 Starter Circuit Constant Velocity Carburettor Cut Section View of Mixing Chamber a lt lt E Air inlet I for choke Towards Engine Towards Engine n he d Plunger Cap 1 Plunger Diaphragm Cap 2 Mixing Chamber Diaphragm Piston Valve 3 Starter Jet Piston Valve with Jet Needle Float
28. aph starts diminishing with corresponding drop in fuel level When the petrol level comes down to below four liters all the segments of the bar will vanish Apart from LCD graph bar a red warning light also has been provided in the console that glows continuously when the petrol level falls down to reserve And it will be ON till petrol is filled above reserve level When the digital fuel meter is available why the red warning light is provided While the LCD graphical bar segments indicates the petrol level in the fuel tank the red warning light continuously reminds the rider to fill the petrol Why two trip meter reading option is given How is it useful It is just to enable the rider to count reading for two different trips unlike only single trip in case of conventional type It is like this on selecting Trip1 its will indicate the distance covered in first trip that is set for In continuation on selecting Trip2 it will indicate the distance covered in the second trip Then if one wants to know the cumulative distance covered in first amp second trip it can be found in Trip1 mode For this one has to just press select Trip1 mode This is an added advantage taken from digital technology What do Self canceling Indicators switches means In conventional type of switches the rider has to manually depress or turn knob of indicator switch for putting OFF the indicator bulbs In case of this Self canceling
29. ase Clutch side Dealer Development Center Dismantling Engine Dealer Development Center pubsaears Remove e Bolt B on LH side crankcase Magneto side Remove e 8 bolts on LH side crankcase e Split the Crankcase halves Note Before separating crankcase halves confirm that all the crankcase joining bolts are removed and the sprocket cam drive with parallel pin on crankshaft assembly is removed Remove e Kick spring 2 Shafts A amp B of gear shifter fork 3 fork shifts 1 small for input 2 big for output shaft 3 Rollers e Drum change Remove e The entire gear box assembly together Remove e Crankcase gasket e 2 dowels e Crankshaft assly 64 Pulsar DTS i UG III 180cc Training Notes
30. cable bracket and adjust threading in the adjuster provided on the clutch cover Tighten both the lock nuts on clutch cable bracket by holding one nut and tightening the other after the required free play Clutch Lever Free Play 2 3 mm Accelerator Free Play Adjustment e Turn the adjuster A until the proper amount of free play can be obtained e Tighten the lock nut B against the adjuster e If the accelerator free play can not be adjusted with the adjuster at the handle bar end use the adjuster at the lower ends of the Accelerator cable situated on carburettor e Loosen the 2 lock nuts C on accelerator cable bracket end adjust by adjuster D provided on the cable e Tighten both the lock nuts on bracket by holding one nut and tightening the other after ensuring the required free play Accelerator Grip Free Play 2 3 mm Dealer Development Center pubsaears Schedule Maintenance Reed Switch Setting and Checking Check throttle lever movement by rotating it with hand It should not be sticky in operation and should return back it self on releasing bracket Multimeter should show continuity e Magnet should not touch with reed switch e Gap between Magnet amp Reed Switch should not be more than 2 5mm e Movement of throttle lever with magnet assembly and Reed Switch fitted should be free Reed Switch Setting e Accelerator cable play 2 3 mm by adjusting the Adjuster e Protude stopper of the th
31. cer Gear in special tool now slide inside the Clutch Housing so that the Clutch Housing smoothly engages with the top half of Assembly Balancer Idler Gear e Remove the special tool gently e Fit 2 dowels and Assly Balancer Idler Gear Cover e Ensure perfect marking of gear marks with respect to crankcase mark Pulsar DTS i UG IIIl 180cc Training Notes 52 53 Removal of Engine from Frame Removal of Engine from Frame Remove e Put OFF the fuel cock e Side panel LH e Side panel RH Remove e Seat assembly by pulling the cable for seat lock release located on RH side e Disconnect the negative terminal of the battery e Disconnect the wiring harness socket for fuel level Indicator e Fuel pipe connections and moisture drain pipe from fuel tank e Disconnect stator plate harness e Disconnect neutral switch coupler Remove e Drain bolt A and drain out the oil from engine e Refit the drain bolt with gasket amp tighten it Recommended Oil Grade and Qty Grade SAE 20W50 of API SG JASO MA Quantity Drain amp Refill 1000 ml Engine Overhaul 1100 ml Remove e Bolt A e Petrol tank assembly Remove Bolts A e Gear shift pedal bolt B e Drive sprocket cover LH Using Special Tool Sprocket Holder 37 1030 53 Remove e Bolts A e Plate drive sprocket e Drive sprocket along with the chain e Neutral switch coupler B Pulsar DTS i
32. ction 480 minutes Man Screw Driver 30 Tune Engine amp Carburetor A ol pubsacars 7 5 bI M amp T Service onsumabies Shop Equipments 20W40 Oil Graphite Grease Gun Grease Cloth Analyzer Tachometer Proper Exhaust Sealing Arrangement of Silencer 35 Test Ride of the Vehicle 15 To be Carried if required and park l out by Expert 36 Clean the vehicle at the i Will be done time of delivery by Delivery boy PNR Pneumatic Nut Runner 17 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center service Wise Part Kit Periodic Part Replacement Kit for Free Services Type of Service Days Kms Limit 1st Free 30 45 500 750 2nd Free 3rd Free 1st Paid 105 120 2000 2500 195 210 4500 5000 285 300 7000 7500 2nd Paid 375 390 9500 10000 465 480 12000 12500 955 5 0 14500 15000 615 630 17000 17500 3rd Paid 4th Free 4th Paid oth Paid 705 720 19500 20000 6th Paid 795 810 22000 22500 885 900 975 990 2 000 27500 7th Paid 24500 25000 8th Paid Dealer Development Center Part Name Quantity 1000 ml Clutch cover gasket 1 N NIL 1000 ml Engine oil Engine oil Steering cone kit IL Drive chain lock amp link set NIL NIL Engine oil 1000 ml Clutch cover gasket Air filter foam element Spark plug Brake shoes if worn out Front disc pad inspect replace If worn out Fork oil 330 ml Clutch plate Rear brake dampe
33. d on LH side of handle bar Lever operated on RH side of handle bar Pedal operated by right foot 12 V AC DC 12V 9Ah 35 35 W HS1 OW 2 Nos LED 10 W 2 Nos LED LED LED LED LED display 5 W 12V DC 1990 mm 750 mm 1090 mm 1320 mm 2180 mm Minimum 165 mm Minimum 143 kg 273 Kg 125 km h with single rider 68kg 28 16 Maximum e Values given babove are nominal and for guidance only 15 variations is allowed to cater for 5 Pulsar DTS i UG III 180cc Training Notes production and measurement variation All dimensions are under UNLADEN condition Definitions of terminologies wherever applicable are as per relevant IS ISO standards Specifications are subject to change without notice Dealer Development Center Frequently Asked Questions FAQ s YD amp Dealer Development Center What are the special features of PULSAR DTS i 180 UG Ill OR What is so special in this PULSAR DTS i 180 UG IlI Pulsar UGIIl is next version of Pulsar breed It is loaded with lots of unique amp contemporary features and that distinguishes the Pulsar not only in the category of Power Performance amp Style but also for Comfort Convenience amp Safety from the competition Apart from refining the power delivery it is loaded with the features that are meant for cars So here is the Comfort Convenience amp Safety of the 4 wheels cars available on 2 wheels The major changes features are
34. d the construction is same as that of pilot circuit Working As like pilot circuit the fuel is metered by pilot jet and air volume is metered by pilot air jet This mixture in vaporized atomized form is discharged through the bypass ports when the butterfly valve is opened from idling further Working of Carburettor pubsacars7 Main Circuit Constant Velocity Carburettor 1 Piston Valve 2 Piston Valve Diaphragm 3 Jet Needle 4 Needle Jet 5 Jet Holder 6 Main Jet gt 3 4 Towards Engine Air Inlet l for main jet Function The Main Circuit provides air fuel mixture by 5 lifting up the piston valve in direct proportion to the engine demand This assures the correct venture size amp air velocity throughout z the mid range operation of the engine Construction This circuit consists of jet needle needle jet and main jet To assist in atomization an air bleed circuit is incorporated in the main metering system and it aids fuel vaporization by introducing the air into the fuel before it enters the main air stream The piston valve movement is controlled by spring and carburettor venture vacuum which is generated below the piston valve diaphragm Working When the butterfly valve is opened and air flow through the venturi increases the air pressure in the venturi and the upper chamber decreases As the atmospheric pressure in the bottom chamber is greater than the venturi pressure above the diaphragm the piston v
35. doubt as to the conditions of the brake check the brake parts for wear or damage e Turn the adjuster until the rear brake pedal have the correct amount of play Rear Brake Pedal Play 25 30 mm Rear Brake Pedal Position Adjustment To suit rider foot comfort operating style the angle of the rear brake pedal can be adjusted by loosening the lock nut A and adjusting the bolt B Ensure free play by turning the adjuster clockwise or anticlockwise to achieve specified free play Fix the rubber sleeve on the bolt Note After pedal position adjustment it is necessary to set the free play Rear Brake Light Switch Adjustment When either the front or rear brake is applied the brake light glows on The front brake light switch requires no adjustment but the rear brake light switch should be adjusted in accordance with the periodic maintenance chart Inspection e Turn on the ignition switch The brake light should go on wheel the front brake is applied e If it does not then inspect the front brake light switch e Check the operation of the rear brake light switch by depressing the brake pedal The brake light should glow after about 15 mm of pedal travel e If it does not adjust the rear brake light switch Adjustment e Adjust the rear brake light switch A by rotating the switch nut to create adequate tension in spring to operate the switch Dealer Development Center standard Checking Dealer Developmen
36. er pin from cylinder head Silent Bush Puller Drawing No 37 10DH 33 Application To remove silent bush from cylinder head cover 34 Dealer Development Center Pulsar DTS i UG IIIl 180cc Training Notes Special Tools Dia 25 9 0 1 35 Pulsar DTS i UG III 180cc Training Notes Rotor Puller with Butt Pin Drawing No 37 10DJ 32 Application Used to pull out the rotor from crankshaft assembly Primary Gear Holder Drawing No 37 10DJ 28 Application Use to hold primary gear while loosening tightening the clutch nut Balancer Gear Holder Drawing No 37 10DJ 63 Application Used to load the pre tensioned scissor gears of Assly balancer Idler gear Special Nut Drawing No 37 10DJ 43 Application Used to remove fit of centrifugal oil filter nut Note Existing tool can be used by reducing diameter to 25 9 0 1 mm Piston Ring Holder Drawing No 37 10DJ 30 Application Used for compressing the piston rings when assembly piston in the cylinder block Bearing Race Extractor Drawing No 37 OODJ 01 Application Used for removing the lower bearing race from T Dealer Development Center Special Tools Dealer Development Center Bearing Extractor Drawing No 37 10DJ 76 Application Used to extract the input shaft bearing from crankcase LH Bearing Puller Drawing No 37 10DJ 77 Application Used to pull ou
37. hanges are there that are not easily accommodated in the existing Pulsar Dealer Development Center pulsar i a exom O O S steennetocknorwormnanay Oooo o se coven tocknorwormne ooo o 2 PANT FNSH OVER FLOW Samples photo O e memos ewe o fases oOo S o r a S fomes eee O S Fuet cock openanion maoriene O O 5 Fronr meanwmectorrser efwen S S o o waeren J ooo ooo FRONT WHEEL RUNOUT SPECIFY REAR WHEEL RUN OUT SPECIFY SILENCER BAFFLE NOISE SWITCHES ic tk A S a Pre Delivery Inspection Checklist T LH Switch operations IGNITION SWITCHSHORT fF o o 9p uiGHTS a _ Side indicator blinking o o S O HEADLIGHT o d l y O TAUBRAKELED o o d l y O HORN DISTORTED WEAK SOUND DO NOT SE fe 41 Speedo a a __ SPEEDO NOT SENSING SPEEDO Needle flickering fF Tripmeter 1 2 working Resetting fT Odometer working o d o Auto Calibration of RPM meter o Fuellevelindication d o Reserve indication by red lamp a Red lamp blinking after crossing Engine RPM 9000 fo Auto switch off of Ind lamps H bar straight for gt 2sec fo Head light tail light illumination after 3 seconds fF LED functioning Speedounit Both side indication Side stand Neutral Hi beam RES ind lamp 10 Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Ni Pre Delivery Inspection Checklist PDI done by BAL Service Engg PDI Done by S Dealer Check Points for PDI Check
38. ine till the oil temp reaches 60 C e Remove the Bolt Plug near Exhaus TEC e Connect the probe of CO analyser Set the CO between 1 75 2 25 by adjusting volume control screw e Then set the engine idling r p m by rotating the idle adjustment 3rd Stage screw clockwise or anticlockwise by hand Dip into SAE 90 Oil e For the precise adjustment of idling speed use of tachometer is recommended e Rotate the throttle a few times to make sure that the idling speed does not change Readjust if necessary e Do not attempt to compensate for faults in other systems by adjusting the idle speed Idling Sped 1400 100 rpm Tappet Clearance Setting Soak into SAE 90 Oil e Ensure that the engine is cold e Ensure the T mark on the Rotor match with the mark on the Crankcase LH At this stage the Piston is at TDC and both the Tappets are free e Holding tappet screw firmly with special tool loosen the tappet screw nut e Put the feeler gauge measure and adjust the clearance e Lock the nut holding screw with special tool after getting desired clearance Final Stage Hook Chain for dripping of excess oil e Again check the tappet clearance with gauge The gauge should slide with slight resistance between tappet and valve stem head feeler and tighten the check nut with a spanner e Inlet Valve 0 05 mm e Exhaust Valve 0 1 mm Special Tools Feeler Gauge 69 7502 51
39. ion The pilot circuit consists of pilot jet pilot air jet and volume control screw The pilot jet meters the fuel and the pilot air jet meters the air quantity The volume control VC screw controls the amount of air fuel mixture flowing through the pilot outlet Working As the air enters the pilot air inlet the fuel is metered by pilot jet and air quantity is metered by pilot air jet The atomized vaporized mixture is discharged through the pilot outlet The pilot outlet is located on the manifold side of the carburettor Since the throttle valve is almost at fully closed position air fuel mixture is supplied mainly by pilot outlet only Air fuel mixture volume is adjusted by volume control VC screw and mixture becomes lean when volume control VC screw turned clockwise and rich when it is turned Anticlockwise direction 44 Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Working of Carburettor pubsacaorss Progression Circuit Constant Velocity Carburettor 1 Pilot Jet 2 Pilot Outlet Hole 3 Bypass Progression Holes 4 Butterfly Valve 5 Volume Control Screw 6 Throttle Lever Air Inlet Towards for pilot jet Engine 2 Function The progression circuit provides the air fuel mixture at small throttle opening when pilot circuit is still working but unable to meet the engine demands on small throttle opening Construction The progression circuit follows the path of pilot circuit an
40. lever operation L O O NO O 0 1 12 13 14 15 16 17 18 Check amp Adjust steering and Handle bar for free movement 19 Check front mudguard alignment wrt Front Wheel J 2 Dealer Development Center Pulsar DTS i UG IIIl 180cc Training Notes PDI SOP PALAIDIS G omon Check all important nut bolts for torque and tightness O GP Tools Special PNR amp its onsimabies M amp T Service Tools Attachment Shop Equipments E 7 CO HC Analyzer Tachometer Proper Exhaust Sealing Arrangement of Silencer e Handle bar mounting bolt e Stem lower amp upper bracket bolts e Stem of bolts 20 Front axle nut 4 00 e Cylinder head nuts Engine foundation bolts e Trailing arm bolts e Silencer cover shield bolts e Both LH RH engine mtg bolts 12 13 14 15 16 17 20 22 Ring Spanner 22 mm Box Spanner with Handle Ratchet Oil Can ial Pistol Grip PNR Check the following and lubricate if necessary e Rear brake lever e Rear brake pedal cam e Pillion foot rest e Center stand e Side stand e Kick lever boss e Clutch lever OE accessories fitment Mirrors RH amp LH LHRH OE accessories fitment Leg guard Start vehicle Check operation of electrical like Head light Tail light Brake light Side stand indicator Horn Speedometer Odometer i Side indicators Parking and Pass light working Check Idling and CO LH RH NO NO NO NO NO 17mm OE Spanner
41. linking e Day night mode of Speedo console LED illumination for tell tale icons on electrical switches that glows in the night for positive access How does the digital Speedo work Front wheel of the bike has a sensor amp magnet unit The sensor counts no of pulses w r t wheel rotation amp logically calculates number of wheel rotation amp gives input to the display unit in the speedo console and the LCD display indicates accurate speed odo reading amp trip meter readings 6 Pulsar DTS i UG IIIl 180cc Training Notes Frequently Asked Questions FAQ s D amp amp D amp 1 Pulsar DTS i UG IIl 180cc Training Notes Phsar Irssi What are the advantages Benefits of the digital speedometer apart from giving accurate reading This system is totally contact less amp no mechanical transmission of drive from wheel to speedometer is available Thus this system is totally maintenance free amp lasts for the life of the bike How the digital fuel indicator meter works OR How one can understand the available fuel level in the fuel tank OR How to read the graphical bar of the fuel meter Graphic bar with 12 segment display is provided in the speedo console for indicating fuel level in the tank If the all the 12 segments of a bar graph are ON that indicates that the fuel tank is full As the float gauge in the tank starts lowering down due fuel level coming down the segments of the bar gr
42. ment Removal Remove e RH side panel by unlocking it with key Remove e 2 bolts A e Air filter cover B Remove e Air filter element assembly along with catre e Seperate foam filter from the catrej Note e No need of removing flame arrestor e White colour filter portion towards carburettor side e Ensure beading placed properly when fitting cover 21 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center 3rd Stage Dip into Engine Oil 20W40 1st Stage Clean with Kerosene Squeeze and Remove Squeeze Excess Oil 2nd Stage Clean with Kerosene Again Dry with Cotton Cloth Blow Low Pressure Compressed Air Air Filter Element Cleaning and Inspection Note In dusty areas the element should be cleaned more frequently than the recommended interval After riding through rain or on muddy roads the element should be cleaned immediately Since repeated cleaning opens the pores of the foam element replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a brakage in the element material or any other damage to the element replace the element with a new one Warning Clean the element in a well ventilated area and make sure that there are no sparks or flames anywhere near the working area Because of the danger of highly flammable liquid do not use gasoline petrol or a low flash point solvent to clean the element 22
43. nister apply full stroke of pump as shown otherwise air will not get inflated into the pump e Keep on pumping the air unless you get 7 5 kg cm2 on the gauge e Pull out the air pump along with needle carefully and take out the guide clamp e Finally fix the phillips headed screw with O ring Drive Chain Slack Lubrication e Set the motorcycle upon its center stand e Rotate the rear wheel to find the position where the chain is tightest amp measure the vertical movement midway between the sprockets e If the drive chain is too tight or too loose adjust it so that the chain slack will be within the standard value e Check drive chain slackness at every 1000 kms Drive Chain Slackness 25 30 mm Service Limit 35 45 mm 24 Pulsar DTS i UG IIIl 180cc Training Notes Drive Chain Cleaning Lubrication Tyre Air Pressure 1st Stage e Keep appropriate tyre pressure as mentioned below to increase Clean with Kerosene life of this tyre and for better fuel consumption Front 1 75 Kg cm 25 PSI Rear with Solo 2 00 Kg cm 28 PSI Rear with Pillion 2 25 Kg cm 32 PSI 2nd Stage Clean with Cleaner Important Adjustments and Kerosene again j Checking Procedures Idling Speed Adjustment Whenever the idling adjustment is disturbed follow the procedure Blow Compressed Air given below for setting proper engine idling e Start engine amp drive it for at least 5 kms or warm the eng
44. nt ER Driver 12 13 Ring Spanner 5 amp 10 mm Allen Key Check Adjust Front Analogous Digital Type Pressure Gauge Air filling Valve Check amp Adjust front tyre Pencil Type Front Pressure Gauge air pressure Check and Adjust steering Front Check Engine foundation bolts e Front axle nut e Side bolts of Front fork e Handle bar bolts e RSA top and bottom nuts 16 17 FA Fork Ring FA Spanner 10 11 12 13 14 15 16 17 20 22 No Ring Spanner 22 mm Box Spanner with Handle Ratchet e Swing arm axle nut e Silencer protective cover screws bolts e Rear view mirror 16 Dealer Development Center Pulsar DTS i UG IIIl 180cc Training Notes Periodic Service SOP iag LH RH Special Lubricate e Clutch lever e Rear Brake pedal e Rear Brake Cam Pillion Foot Rest LH RH 0 80 Oil Can e Center Stand e Side Stand e Kick lever boss pin 12 13 No LH RH 0 50 Ring Spanner 12mm Socket Pistol Grip Refit RH LH side covers Seat Petrol tank Check and Clean fuel line amp 28 Clean petrol tank Replace fuel pipe if required Check all Meters for proper functioning amp Correct if reqd Start vehicle Check amp Adjust the following m m on Small Screw Driver i sa wero vm efor fom a mememe foso w fe Carry out any additional work as indicated by the Customer 10 00 or as required E rau sam 2s Expected Produ
45. o that some oil escapes with the air bubbles e Keep on operating the brake lever till the air bubble escape out completely through bleeder screw and top up the master cylinder if required e Once the air escapes out from the hose pipe the brake lever meets resistance which indicates completion of air bleeding e After completing the bleeding top up the master cylinder up to the maximum level mark Nitrox Air Filling e Remove the Phillips head screw amp small O ring fitted on air valve of Nitrox RSA e Fix the guide to canister of Nitrox shocker in such a way that guide hole is concentric with air filling valve e Insert the Nitrox air filling pumps needle end into the guide amp carefully pierce the rubber pin fitted inside the air valve of Nitrox RSA e Note the pressure indicated by pressure gauge of Nitrox air pump Refill the pressure e Once the pressure reaches upto 7 5 Kg cm take out the needle slowly from canister e Fit the Phillips head screw amp small O ring fitted on air valve of Nitrox RSA Power Up the Jig The Jig should carry out a self test where first all Red LED glow sequentially and then all Green LED flash twice Manual Testing e Connect wiring harness to C1 connector e Through this harness the following testing can be carried out Vehicle sensor speed Hall sensor Starter relay 32 Pulsar DTS i UG IIl 180cc Training Notes standard Checking Procedure
46. oft for average road riding condition but should be adjusted harder for rough road condition Shock Absorbers adjusted either too soft or too hard adversely affect riding comfort and stability To adjust the Rear Shock Absorbers Turn the adjusting sleeve on each shock absorber to the desired position The higher the adjuster sleeve is positioned the stronger the spring tension and the harder the ride Check to see that both sleeves are turned to the same relative position Dealer Development Center Schedule Maintenance Dealer Development Center If the Shock Absorber sleeves on both sides are not adjusted to the same position an unsafe riding condition may result Note Std setting is done in 2nd notch Nitrox Air Filling Procedure for gas checking and Refilling e Remove the Phillips headed small screw and O ring e Clamp the cylindrical guide clamp on to the canister keeping the rubber plug in the center to support the syringe needle insertion and keeping in position e Hold the pump as shown and pierce the syringe needle into the center of rubber plug e The molded needle adaptor will rest into the clamped cylindrical guide e Read the gas pressure on the dial gauge If the gas pressure is below 6 5 Kg cm2 refill the air by pumping keeping the needle in as it is condition without removal As the natural air consists of 71 of nitrogen it will serve the purpose e To fill the air into the ca
47. omposition it is made up of The main features of this new battery are Electrolyte level checking is required at every one year instead of every fortnight The unique vent mechanism that do not allow loss of electrolyte No drainpipe unlike in conventional type battery So no chances of spillage of electrolyte So in all it is almost maintenance free battery Moreover the LED bulbs amp disable function of cranking after 3 successive self starts attempts will further only enhance the life of the battery 8 Pulsar DTS i UG III 180cc Training Notes Frequently Asked Questions FAQ s amp amp D D gt D Dy amp 9 Pulsar DTS i UG III 180cc Training Notes Phsar Irssi What is that disabling of cranking after 3 successive attempts A protective device has been incorporated in the system that allows rider to attempt self start option pressing of self start button for starting only three times at times After third attempt the battery power supply gets cut off to the self starter motor thus avoid rider from further cranking of engine by self start This is mainly to protect the battery from over draining by excess attempts of pressing of self start button to start the engine However one can again use the self start option after 15 seconds after third attempt How come so many features are managed accurately amp what is the guarantee of no malfunctioning of these features It is needle
48. oper functioning of Reed Switch Assly at PDI and at every service is essential e Following symptoms may indicate as malfunctioning of Reed Switch Assly as one of the cause Symptom Sudden drop in mileage amp power The igntion systems is working only Replacement of Reed Switch Assly lack in mid range rpm in 2nd map due to reed switch is stuck in open circuit 48 Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Digital Twin Spark Plug Ignition DTS i Phsar Irssi Customer Eductaion Tips e While starting the engine in any case throttle should not be rotated more Even if this happens engine will start but the engine rom will shoot uo too much due to too high throttle opening e Whenever there is a sudden subtantial drop in mileage customer should report to Bajaj Auto s Authorised Service Centres CO Checking and Tune Up To ensure betten mileage ener following before CO checking Tune up Air filter connections intake manifold insulator fitment connecting tube fitment e Spark Plug gap 0 7 to 0 8 mm e All pipes and connections of fuel system for any cracks leakage plucking pinching and loose connections e Ensure Tappet Clearance Inlet 0 05 mm Exhaust 0 1 mm e Ensure compression pressure inside the cylinder 6 to 10 Kg cm e Check the ignition timing 10 BTDC at 1500 rpm and 28 BTDC at 3500 rpm CO checking and carburettor VC screw setting e Start and warm u
49. opment Center Engine Top End Dismantling Remove e Pull out the cover on the spark plug cap RH and the spark plug cap itself e Using a plug spanner loosen and remove the spark plug RH e Loosen and unscrew the allen head grub screw of the sleeve spark plug Note Wrap a piece of cloth around the protruding edge of the sleeve spark plug and using a plier pull out the sleeve Remove e There are 2 O rings fitted in the cylinder head one on the cam chain wall and the other near the spark plug threading e Using a thin sharp pointed tool pierce the O rings and remove them If required Note Remove these only if the O ring protrusim in the bore is non existant which means that the O ring has set and it has lost its compression or sealing ability Remove e Loosen bolt A and unscrew chain tensioner plunger e Cam chain tensioner assembly 2 bolts B e Cam chain tensioner assembly Remove e Both tappet caps e Magneto cover cap seal and rotate crankshaft to get piston at TDC e Ensure both tappets are at free state i e at the end of compression stroke Remove e 2 dummy plug e 2 gaskets 56 Pulsar DTS i UG IIIl 180cc Training Notes Dismantling Engine pubsaraors Remove e Cylinder head securing head cover 2 bolts A e Cylinder head securing head cover 4 bolts B e Cylinder head securing head cover 4 domed cap nuts C e 4 copper plated steel washers Note Im
50. or soft rear suspension Fork Inner amp Outer Tube Extractor Drawing No 74 9310 15 Application Used for removing front fork inner tube from outer tube Pulsar DTS i UG IIIl 180cc Training Notes 38 Carburettor and Fuel System pulsar Carburettor and Fuel System pubsacars7 Fuel Tank e Turn the fuel tap to the off position Carburettor Specifications e Disconnect the fuel pipe connections from the petrol cock Item Pulsar 180cc Make and Type Ucal Mikuni BS29 identification No DJ U3 e Disconnect the fuel indicator wiring harness connection Remove i e Side cover LH and RH by unlocking it with key Needle jet mark 922MP 1 Jet needle clip 2nd from top position Pilot Jet 17 5 Starter jet Fixed type Throttle valve Fixed type Note To remove the side covers LH and RH unlock with the key then hold the front end of the cover and pull the front end out then pull the cover in forward direction to remove it from the lug Chock Lever 2 stage with push pull type mechanism Remove e Pull the cable from the cover LH to unlock the seat lock e Seat assembly Notes Note To remove the seat assembly hold the seat assembly and lift it from the rear end and pull it back Remove e 1 bolt A e Fuel gauge wiring connection e Drain pipe connection e Fuel pipe connection e Fuel tank assembly Note To remove the fuel tank assembly from the chassis lift the fuel
51. p the engine e The oil temperature should be above 60 C This can be achieved by running vehicle in top gear at the speed of minimum 40 Kmph for 5 6 Kms e Adjust the engine speed to 1400 100 rpm with idling adjustment screw of carburettor Adjust the CO with the VC screw It should be in between 1 75 to 2 25 Confirm the engine speed whether it is within 1400 100 rpm or not When setting Idle CO idle rom and VCS have to be adjusted together to achieve 2 CO and 1400 100 engine Make Ucal Mikuni BS 26 Identification No DJ U3 Type CV Type Idling Speed 1400 100 VC Screw Setting 2 5 2 turns out Main Jet 117 5 Jet needle mark 4DHL42 Needle jet mark 922MP 1 Jet needle clip position 2 from top Pilot Jet 17 5 Starter Jet Fixed type Throttle valve Fixed type Chock lever 2 stage with push pull type mechanism 49 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center pulser i e Remove the Allen Head Grub Screw before removing the Sleeve Spark Plug e Before fitting the Sleeve Spark Plug apply thin layer of molybdenum disulphite grease on the entry chamfers for the O rings for smooth sliding inside Important Points to Remember e Do not apply liquid gasket at location A which may block the lubrication passage Valve timing e Ensure the sprocket marks A are aligned horizontally with cylinder head top machined face and the piston is at TDC e Secure the Cam
52. proper tightening sequence may cause warpage in cylinder head cover and it can be damaged permanently Remove e Cylinder head cover complete e Cam shaft cap Using Special Tool Sprocket Catcher 3710 DH 36 Using Sp Tool Sprocket Catcher 3710 DH 36 Remove e Allen bolt e Spacer e Cam sprocket e Collar e Cam shaft assly Sprcoket Catcher Note Hold the cam chain up right using soft copper wire or thread Do not use cotton waste for holding the cam chain Remove e Cylinder head assembly e 2 dowels e Gasket cylinder head Remove e Non tensioner side chain guide e Cylinder block assembly 5 Pulsar DTS i UG IIl 180cc Training Notes Dealer Development Center Dismantling Engine Dealer Development Center Remove e Piston pin lock LH amp RH side Note Place a piece of clean cloth above hallow portion of crankcase to arrest piston pin circlip if it falls during fitment Using Special Tool Drift 74 9309 89 Remove e Remove piston pin e Piston assembly Caution When tapping the drift for removal of piston pin confirm that the connecting rod is held firmly against the direction of tapping to avoid damage to big end bearing connecting rod of crankshaft Remove e Block gasket e 2 dowels A Note Tie the cam chain firmly using soft copper wire thread firmly to avoid slipping down into crankcase Remove e 5 bolts A Remove e Cover magneto 58 Pulsar
53. r Drive chain lock amp link set NIL NIL Carburettor insulator Chain sprocket kit NIL NIL h Pulsar DTS i UG IIIl 180cc Training Notes 8 Service Wise Part Kit Periodic Part Replacement Kit for Free Services Type of Service Quantity 9th Paid 1065 1080 29500 30000 Use always Genuine Bajaj Auto parts amp recommended lubricants Engine oil SAE 20W50 API SG JASO MA grade Notes 19 Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Schedule Maintenance ia Upper _ Level Mark J t Lower ae Dealer Development Center s pulsar i The vehicle must be cleaned periodically using pressurized water Before cleaning the vehicle cover the important parts like Ignition switch Silencer Tail end CDI unit H T coil with plastic bags Don t apply the jet of water directly on electrical parts such as Switches Ignition unit Coils etc otherwise they may get damaged Cleaning Brushing with kerosene and wiping dry with clean rag is advisable for external cleaning of the engine All painted surfaces should be washed with water Do not use kerosene or hard detergent soap on painted surfaces as it damages the paint and turns it dull After washing dry the vehicle with compressed air and carry out the lubrication as recommended Caution Water may enter on the brake liners during washing amp brake slippage may occur Ensure that
54. r is later Check e Side bolts of Front fork Engine foundation bolts e Side stand e RSA top and bottom nuts Adjust chain slackness amp Lubricate Remove and Clean If required Check Adjust IS 15 LH RH LH RH LH Rear Rear Pulsar DTS i UG III 180cc Training Notes Periodic Service SOP n LH RH Special Wash vehicle thoroughly Both To be done by washing boy C w ofrene S o 8 9 10 11 OE spanner 5 bI M amp T Service onsumabies Shop Equipments 16mm Socket Extension Oil Draining Tommy Cloth Equipment amp Plastic Tray Cloth 8mm 20W40 Oil Filter Cleaning T Spanner Diesel Air Stand Air Gun Filter Element 12 13 No Ring Spanner a 12mm Socket Cloth Diesel Air gun Phillips Screw Driver Screw Driver 10mm Nylon Brush Float Plastic Tray Gauge 10 11 amp 14 15mm OE Spanner Cloth Fine Spark Plug Polish Paper Spark Plug Filler Spanner Plug Gauge Cleaner N Ves jo Cleaner and Spark Plug Tester Air Gun on Pistol Grip PNR Cloth Graphite Grease Fine Air Gun Polish Paper Dealer Development Center 8 9 No Ring Spanner 24 27 OE Spanner 14 mm Box Spanner with Handle Ratchet Spark Plug Spanner Filler Gauge 0 01 1mm Tappet Holder 14 15 16 17 20 22 Ring Spanner 12 mm Box Spanner with Handle Ratchet 12 13 No OE Spanner 10mm T Spanner 20 22 ia Cloth E g SAE 9
55. reads e When splitting crankcase always remove 1 long bolt fitted from clutch side first e Remove long bolt immediately after removal of long bolt clutch side e Ensure proper fitment of bolt with copper washer to avoid oil leakage e Shifter fork is having a roller These roller are one side tappered inner dia e Taper portion of roller should face towards fork gear shift e Ensure damper rubber fitment on magneto side guide plate e Fit primary gear drive A e The mark teeth of the primary gear should match with the line mark on the c case This indicated that the piston is at TDC position This procedure should be carried before fitting the Clutch Housing amp this position should not be disturbed while fitting the Clutch Housing Dealer Development Center Important Points to Remember Dealer Development Center e Load the assly balancer idler gear with 2 teeths from either side using the special tool e Take the Assembly Balancer Idler Gear along with Thrust Washer which is pre loaded and is held in special tool Slide down the special tool with Gear to engage the bottom half of the Assembly Balalncer Idler Gear with the Body Balancer Gear Assembly e Fit Thrust washer on the other side e On assembly of Assembly Balancer Idler Gear the itched Dot mark of Body Balancer Gear Assembly should match with the line mark on the Crankcase Holding the Assembly Balan
56. rottle lever bracket must on idling screw tip Reed Switch Checking e Keep throttle at zero position e On connecting multimeter to Reed Switch coupler it should show continuity e When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switch multimeter should show discontinuity e On De acceleration when of Reed Switch magnet re coinsides with straight edge of fix bracket of Reed Switch Multimeter should show continuity 28 Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Schedule Maintenance 29 Pulsar DTS i UG III 180cc Training Notes pubsacars Front Brake Free Play Adjustment There is no need for free play adjustment since the pistons in caliper assembly will move towards the pads and take new positions in order to automatically compensate for pad wear The free play will be approximately 2 3 mm Front Brake Lever Play 2 3 mm Rear Brake Pedal Adjustment Check the rear brake pedal play as stated below If it is more or less than the standard adjust the rear brake e Depress the rear brake pedal lightly by hand This is free play e f the rear brake pedal free play is incorrect adjusting the rear brake shoe adjuster nut A e Operate the pedal B for few times to see that it returns to its rest position immediately upon release e Rotate rear wheels to check for brake drag e Check braking effectiveness e f there is any
57. side the switch body This gives the icons a pleasant bluish white glow that can be seen in the night clearly amp coolly The tail lamp assembly seems to be too special What is so in that Yes The tail lamp is unique on this vehicle and no other competitor s vehicle has this feature It consists of 16 8 nos of LED bulbs with bi filaments The specialties of LED bulbs are Consume very low current Glow brightly Last far long Totally maintenance free So the LED tail lamp apart from delivering fantastic performance it adds to aesthetics What is this bi filament bulb Bi filament bulb means these LED bulbs have two filaments in each bulb One filament of lower wattage for parking lights amp another for brake lighting which is of little higher wattage If so much so electrical electronic appliances are loaded it may affect on Battery Absolutely not In fact all the bulbs amp backlit bulbs in the Speedo console except Head Lamp bulb amp pilot bulbs are of LED type Few of them works on AC amp few are on DC i e battery So there is hardly any drain on the battery as compared to conventional type of bulbs Moreover the Battery of this new Pulsar 180 is special amp maintenance free What is this maintenance free Battery The battery is new development in DC system on two wheelers in fact such batteries are introduced in cars earlier than bikes it is different than the conventional one in the material c
58. ss to say that the digital technology that works with sensors amp chips works accurately To control all the functions of these electronics features an intelligent device has been installed in the electrical system This is called BCU Body Control Unit What exactly is BCU Body Control Unit How it controls all these functioning BCU Body Control Unit is a device that integrates amp controls major of all electrical electronic functions on the vehicle It is an intelligent device that works on microchip base In the eventuality of electrical overloads or short circuits the built in intelligent protection circuit takes the control of the situation amp prevent future damages on other electronic parts For example During night suppose one of the Head light filament blows OFF then there is a possibility of an accident due to sudden darkness To rescue here the BSU plays an important role It switches over the Headlight to the other beam automatically without manual shifting of any switches It also checks amp inspects the fused circuit religiously for any corrections and thus riders safety is ensured Are these type of product features available in Pulsar150cc also Presently not But as in all sphere of life technology also proliferates When that happens you may find similar features in Pulsar 150cc also Can one alter the current Pulsar model amp incorporate these features No It is not possible Physically lot of c
59. t Center Procedure pulsar i For testing the compression pressure first warm up the engine Compression Pressure Testing Remove the spark plug LH side Caution Disconnect H T lead cable from second spark plug i e RH side Fit the compression gauge with adapter in the Spark plug hole Open the throttle fully then kick 5 times instantaneously Note the reading in the compression gauge Release the pressure by pressing the release valve on hose pipe Take average of 3 such readings for noting actual compression pressure Confirm the compression pressure is between 6 to 10 Kg cm Wet Compression Test lf the compression pressure is found below lower limit than specified put few drops of engine oil through the spark plug hole and again check compression pressure If you find considerable increase this time then cause for the low compression pressure lies in Cylinder Piston assembly lf compression pressure remains the same then the cause for low compression pressure lies in Cylinder Head assembly Caution If wet compression is done remove second spark plug and clean thoroughly to avoid oil fouling before fitment Chain Slack Adjustment Set the motorcycle upon its centre stand Rotate the rear wheel to find the position where the chain is tightest and measure the vertical movement midway between the sprockets lf the drive chain is too tight or too loose adjust it so that the chain
60. t the bearing for body balancer from crankcase LH Adaptor amp Valve Spring compressor Adaptor Drawing No 37 10DJ 78 Valve Spring Compressor Drawing No 37 1031 07 Application Used for assembling dismantling inlet exhaust valves by compressing spring in cylinder head Rotor Holder Drawing No H6 0721 00 Application To hold rotor while loosening bolt Drift Drawing No 74 9309 89 Application To remove piston pin Thrust plate aligner holder Drawing No T 1011168 Application To align the clutch hub concentricity w r to clutch wheel clutch housing and thrust plate Pulsar DTS i UG IIIl 180cc Training Notes 36 Special Tools 3 Crankshaft Bearing Extractor Drawing No 37 1001 14 Application To remove bearing from crankshaft Output Sprocket Holder Drawing No 37 1030 53 Application To hold the output sprocket while removing sprocket bolt Bearing Driver Set Drawing No 37 1030 61 Application Common bearing driver set for fitting and removing bearings from crankcase Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Special Tools Dealer Development Center Fork oil seal fitment punch Drawing No 37 0040 03 Application To fit fork oil seal on outer pipe Rear Shock absorber adjuster Drawing No 37 OODH 14 Application For adjusting the notch position of RSA to achieve hard
61. tank assembly by holding it at the rear end and pull it back Fuel Tank Inspection Remove the hoses from the fuel tank and open the tank cap Check to see if the breather pipe and water drain pipe in the tank for clogging If they are clogged remove the tank and drain it and then blow pipes free with compressed air Fuel Tank Cleaning Warning Clean the tank in well ventilated area and take care that there are no smokes or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents to clean the tank 39 p s A Pulsar DTS i UG III 180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS i UG III 180cc Training Notes Carburettor and Fuel System pubsacars Carburettor and Fuel System PALAIDIS e Remove the fuel tank and drain it e Bowl e Pour some high flash point solvent into the fuel tank and shake e Strainer the tank to remove dirt and fuel deposits Gasket e Pour the solvent out of the tank e Dry the tank and the fuel tap with compresses air e Install the fuel tank e Selector Body e 2 hole subber seal Note While installing the fuel tank on chassis make sure that the Notes dampers A on petrol tank are mounted on the chassis otes Fuel Tank Cap Dismantling To unlock the Fuel tank cap insert the key in the key slot and turn it anticlockwise direction and lift open the tank cap Now remove the

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