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Pulsar DTS I UG III TRG Notes B PDF
Pulsar DTS I UG III TRG Notes B PDF
A Dismantling of Subassemblies :
B Using Special Tool : Bearing C Magneto Cover
Extractor - 37 10DJ 77 B
A Remove :
Remove: • 2 Phillips head screws (A) of pulsar coil (E) mounting.
• Bearing (B) for output shaft E • Bolts (B) of stator assembly.
assembly from crankcase RH • 1 Phillips head screw (C) of stopper.
D
• Stator coil assembly (D) along with pulsar coil.
A
Remove :
A Using Special Tool : Bearing • Rocker shaft (A)
Extractor - 37 10DJ 77 • Rocker arm
C
Remove : • Set of washers (1 wave and
• Bearing (A) for output shaft 2 plane) (B)
assembly from crankcase LH • Rollers 20 nos. (C)
Note : Similarly remove the other Rocker shaft & Rocker Arm from
head over
Using Special Tool : Bearing
Extractor - 37 10DJ 77
Remove :
A Top End :
B
A
• Bearing (A) for body balancer Cylinder Head
D
gear bearing from crankcase Using Sp. Tool Valve Spring Compressor 37 1031 07 & Adapter
LH 37 10DJ 78
C
Remove :
• 2 Cotter valve (A)
F
• Valve spring retainer (B)
Using Special Tool : Bearing • Springs inner (D)
Extractor - 37 10DJ 76 E
• Spring outer (C)
Remove :
A • Valve from below (E)
• Bearing (A) for input shaft
assembly from crankcase LH • Washer (F)
• Valve steam seal (G)
Similarly carry out the same
procedure to dismantle the other
valve from the cylinder head
assembly.
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Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Dismantling - Engine Sub Assemblies Dismantling - Engine Sub Assemblies
A Chain Tensioner Assembly Bearing Removal from Assly Balancer Idler Gear Cover and
B
Remove : Crankcase RH
C
D • Circlip (A) from the body (I) Using Sp. Tool : Bearing Extractor - 37 10CD 30
E • Cap (B) along with screw internal and screw external (C) Remove :
F
• Spring (D) • Needle roller bearing from RH crankcase.
I • Thrust washer (E)
H
G • ‘O' ring (F)
• Bolt (G) and ‘O’ ring (H)
Assembly Balancer Idler Gear
6
Clutch Assembly A C D Remove :
2
6
7
4 Remove : • Thrust washers (A)
6
7
• 4 bolts (A) • Circlip (B) from any one side of the gear
7
12
8
• Holder clutch (B) • Scissor gear (C)
10
5
1
9 • 4 springs (C) • Torsion Spring (D)
• Clutch center (D) Similarly carry out the same procedure on other side of the gear
14
6
3 17 13
16
B D E CB A
15
11
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Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Dismantling - Engine Sub Assemblies
Crankcase Magneto Side
Remove :
• 3 Screws (A)
• Guide starter assembly (B) on which oil seal is mounted.
C
• Oil seal (C)
A D
• Damper (D)
B
Clutch Cover
G A Remove :
B
• Parallel Pin (A)
• Clutch shaft release completely (B) by slightly rotating it so,
• Rack (C)
H • Plunger oil (D)
• Plate plunger oil (E)
• Spring joint ‘A’ (F)
C
• Oil filler plug (G)
• Oil seal kick shaft (H)
K • Wire clip (I)
F • Oil inspection window
J E
L D • Flanged bolt (8 Nos.) (J)
• Set of damper (K)
• Set of plate (L)
• Grommet (M)
Camshaft Dismantling
Using Special Tool :
Bearing Pullers :
3710DJ 74 for Bearing 39227020
A
B 3710DJ75 for Bearing 39148520
C Remove :
F
• Bigger Bearing using sp. tool
from camshaft assembly(A)
E
• Collar de-comp (B)
D
• Decompression unit (C)
• Small Bearing (E)
• Lock washer (D)
• Parallel pin (F)
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Parts Inspection Parameters Parts Inspection Parameters
Spark Plug : Crankshaft :
• Type / Heat value - RG 4 HC/Bosh UR3DC (Resistive) • Big end axial/radial play : As per Service data.
• Gap between electrodes - 0.7 to 0.8 mm • Runout : As per Service data.
• Electrode condition - No errosion • Threading condition : Ok / No damages.
• Colour at the electrodes tip - Brownish • Key way condition : Ok / No damages.
• Threads of reach portion - Ok / No damage • Big end bearing : Free rotation / Jam
• Con-rod : No bending / twisting
• Oil passage : No blockage.
Cylinder Head : • Square slot key way for primary gear
• Mating surface : No warpage / No scratches (Service limit for
warpage: 0.05mm) Crankcase :
• Identification mark - DJ mark embossed on casting • Mating surface : Smooth / No scratches.
• No fins breakage • No Cracks, damages, breakage.
• Spark plug hole threads - Ok / No damage • Bearing seat, oil seal seat & proper pressing / positioning of oil
• Carbon built up in combustion chamber cavity- Clean it seals, needle roller, ball bearings freely rotating
• Valve seat : No pitting / No carbon deposition • No Blow holes in casting
• Proper fitment of Dampers (4 Nos)
• Breather pipe / hole : No clogging
• Proper fitment of ‘O’rings
• Proper fitment of valve stem oil seals on valve guide • Oil passage : Clean / No clogging
• Valve guide for crack if any • Threads of holes & studs : Ok / No damages
• Silencer mounting studs threads - Ok / No damage • Visible number punching on LH Crank Case
Cylinder Block :
• No fins breakage Bearings :
• No Scoring marks • Axial play : Ok / Not excessive
• No Seizure marks • Radial play : Ok / Not excessive
• Ok Seating – mating surfaces • Bearing Seat : No sign of high spot on seating area.
• Smooth Honing pattern
• Bearing class & code : As per specification numbers
• Correct / Same grouping mark w.r.t. piston (A & B group)
• Inner diameter of block as mentioned in service data. • Bearing Rotation : Free Rotation
• Ovality - Not more then 0.05 mm.
• 3 Nos. of damper rubbers Properly fitted on fins
• Proper fitment of ‘O’ ring on bottom side Clutch :
• Clutch plates / Steel plates - Thickness as per service data
Piston : • Warpage as per service data
• Grouping mark with respect to cylinder block must be same. • No Seizure / Damaged bonding of friction material
• Diameter of the piston - As mentioned in service data
• Tangs (Lugs) / Teeth - No wearing
• No scoring marks on the skirt
• Thrust plate cracked
• No blow by marks
• No Foreign material embedded
• No seizure marks.
• Manufacturing / Identification code and date code • Colour change / Signs of overheating if any
• Piston pin - scratches dent marks • No uneven wear pattern
• Steel plates planishing
Rings : • Conical face machining for spacer clutch
• No uneven wear around circumference / breakage.
• Discoloration at working face. Clutch Housing :
• Carbon built up on inner face if any. • No Wear marks on slots.
• Piston ring end gap - As per Service data • Clearance between clutch plate tangs and slot in the clutch
housing should not be excessive
• Piston ring width (thickness) - As per Service data
• Free movement of plates in clutch housing slots.
• Free rotation of Rings in Piston grooves - No stickyness.
• Rivets of clutch housing should not be loose.
• Piton ring identification mark
Top Ring : TOP 1, Second Ring : TOP 2 • Free rotation of housing on Input shaft
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Parts Inspection Parameters Parts Inspection Parameters
Clutch Hub / Clutch Wheel : Guide Kick :
• Contact surface for friction plates-should not be worn out • No presence of any burr & flashes
excessively • Face to face fitment on Crankcase after tightening.
• Pressure Plate free movement in clutch hub splines • Application of loctite 638 to securing allen bolts
• Holes for lubrication
• Clutch hub height
• Smoothness in ID of clutch wheel
• Spacer free movement on clutch wheel
Camshaft :
• Presence of plain and wave washer in 1st clutch plate
• Presence of locating washer
• Free rotation of bearing
Transmission :
• Lobe height - as per Service Data
• No Teeth breakage or crack
• No cut / wear marks on cam
• No Wear pattern on teeth
• De-comp mechanism stickyness
• No Wear of dog teeth & dog holes on gear
• No Seizure mark on gear seat.
• Free movement of gears on the shaft (1st Output, 2nd Output, 3rd
Notes :
Output, 4th Input and 5th input gears are free on the respective
shaft)
• Free movement of Fork shift on the fork shaft
• Gear shift drum groove profile - Ok / No damage - Wear
• Free movement of Fork shift guide roller in the drum groove
Drum :
• Presence of Neutral rivet on the Drum
• Free rotation of Drum in LH crankcase parent hole.
• Inner hollow portion must be free from casting dust / burr
• Groove profile width as per Service Data
• Hole available for parallel pin
• Drum profile free from Hi-Spot for free sliding of bush
Carburettor :
• Float
- No puncture
- Alignment w.r.t float pin - Ok
- Not touching to bowl walls
• Needle Valve
- No groove formation on the tip
- Smooth action of spring loaded pin,
- Smooth movement in its seat.
• Volume Control Screw
- Not bent / Threads OK. / Not jammed / Presence of Spring
Washer and ‘O’ ring.
• Jets
- Correct size, No wear of jet hole, No clogging
• Piston Valve
- Smooth free sliding, clearance in its seat, no excess wear mark.
• Choke Operation - Smooth (Push and pull type)
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Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Service Data - Engine Service Data - Engine
Compression Pressure Valve Clearance Rocker Arm Shaft Dia. Piston Diameter Piston / Cylinder Clearance Piston Ring / Groove Clearn.
7mm
Std. Limit 6.0 ~ 10.0 Kg/cm2 Inlet Exhaust Std. Limit 7.994 ~ 8.0 Std. Limit 63.478 ~ 63.488 Std. Limit 0.012 ~ 0.030 TOP SECOND
Std. Limit 0.05 0.10 Std. Limit 0.02~0.06 0.01~0.05
Serv. Limit 5.0 ~ 10.0 Kg/cm2 Serv. Limit 0.05 0.15 Serv. Limit 7.98 Serv. Limit 63.488 ~ 63.498 Serv. Limit —
Serv. Limit 0.16 0.15
Cam Sprocket Diameter Cam Height Valve Spring Free Length Piston Ring End Gap Clutch Spring Free Length Friction Plate Thickness
Std. Limit 61.48 ~ 61.36 Inlet Exhaust Inner Outer TOP SECOND Std. Limit 30.0 Std. Limit 2.9 ~ 3.1
Std. Limit 31.0 30.4 Std. Limit 39.10 43.6 Std. Limit 0.15~0.30 0.30~0.45
Serv. Limit 61.30 Serv. Limit 29.0 Serv. Limit 2.75
Serv. Limit 30.8 30.2 Serv. Limit 39.00 42.6 Serv. Limit 0.55 0.70
Valve Stem Diameter Valve Stem Bend Valve Head Thickness Pressure Plate Warp Shift Fork Guide Pin Dia. Shift Drum Groove Width
Cylinder Head Warp Camshaft Chain Lth. 20 Links Cylinder Inside Diameter Crankshaft Run Out
20-link length
10mm
20mm
40mm
Std. Limit 127.00 ~ 127.20 Std. Limit 63.50 ~ 63.508 Std. Limit 0.02 Max.
Serv. Limit 0.05
Serv. Limit 128.0 Serv. Limit 63.508 ~ 63.515 Serv. Limit 0.05
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Service Data - Frame Service Data - Frame
Brake Panel Cam Hole Dia. Brake Cam Diameter Front Brake Pad Thickness Front Fork Spring Free Length Front Fork Oil
Std. Limit 12.00 ~ 12.03 Std. Limit 11.95 ~ 11.98 Std. Limit 7.4 Std. Limit 398.50 Quantity :165 ml / Fork Pipe
(Drain & Refill)
Serv. Limit 12.15 Serv. Limit 11.88 Serv. Limit 3.8 Serv. Limit 391.00
Brake Shoe Lining Thickness Brake Drum Inside Diameter Axle Run Out
Notes :
100 mm
Std. Limit 3.85 ~ 4.15 Std. Limit 130 .0 ~ 130.16 Std. Limit TIR 0.1 or Less
Serv. Limit 2.0 Serv. Limit 130.75 Serv. Limit TIR 0.2
Axial Wheel Run Out Radial Wheel Run Out Drive Chain Slack
Std. Limit TIR 1.0 or Less Std. Limit TIR 0.8 or Less Std. Limit 25 ~ 35
Serv. Limit TIR 2.0 Serv. Limit TIR 2.0 Serv. Limit 40 ~ 50
20-link length
Std. Limit 254.0 ~ 254.6 Std. Limit 0.4 or Less Std. Limit Front: 5.0 Rear: 6.8
Serv. Limit 259.0 Serv. Limit 0.5 Serv. Limit Front: 1.0 Rear: 1.5
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Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Part Name Shaft Input Transmission Part Name Shaft Input Transmission
Better clamping of clutch assly is ensured on Effective clamping of clutch assembly is ensured on
Description Input Shaft for effective torque transmission with Description Input Shaft by using guide plate clutch in between
this new clutch mechanism. shaft & clutch assembly.
Part Name Guide Gear Shift Part Name Guide Gear Shift
Guide Gear with 6 pins is meshed with gear Guide Gear with 4 pins is meshed with gear change
Description change lever & transmits reciprocating motion into Description lever & transmits reciprocating motion into rotary
rotary motion & thus rotates drum change. motion & thus rotates drum change.
Identification Mark Guide Gear is having 6 pins. Identification Mark Guide Gear is having 4 pins.
Part Name Fork Gear Shift (Input & Output) Part Name Fork Gear Shift (Input & Output)
Part No. Input : DK 1011 33 Output : DK 1011 34 Part No. DH 1011 30 - Input DH 1011 32 - Output
The roller in fork gear shift roll in the drum profile smoothly The fork gear shift pin slides in the drum profile as
Description as & when drum rotates & guides to transmit To & Fro Description & when drum rotates & guides to transmit To & Fro
motion to fork gear shift for matching respective gears. motion to fork gear shift for matching respective gear.
Ø 5 mm
4
Ø 4. Pin dia. = 5 mm. I/P shaft fork mark = S 32.
Identification Mark • Pin diameter is 4.4 mm • ‘U’ mark on fork shift. Identification Mark O/P shaft fork mark = S 95 & S 92 respectively.
Part Name Gear Drum Change Assembly Part Name Gear Drum Change Assembly
Part Name Lever Comp Gear Shift Part Name Lever Comp Gear Shift
Selector lever operates radially. Selector lever is Selector lever operates To & Fro. Selector lever
Identification Mark short in length. Identification Mark is more in length.
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Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Description It houses the entrire clutch side assemblies. Description It houses the entire clutch side assemblies.
Part Name Holder Clutch (Thrust Plate) Part Name Holder Clutch (Thrust Plate)
Description Holder clutch holds the clutch bearing & plunger. Description Holder clutch holds the clutch bearing & plunger.
Identification Mark Holder clutch has 4 holes for mounting. Identification Mark Holder clutch has 6 holes for mounting.
Clutch spring helps smooth engaging & disengaging Clutch spring helps smooth engaging & disengaging
Description Description the clutch mechanism.
the clutch mechanism.
Identification Mark Clutch spring height is 30.8 mm. Identification Mark Clutch spring height is 29.3 mm.
Clutch wheel holds the set of clutch plate & Clutch wheel holds the set of clutch plate &
Description Description
pressure plate. pressure plate.
Clutch wheel has 4 legs for mounting Clutch wheel has 6 legs for mounting
Identification Mark clutch springs. Identification Mark clutch springs.
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Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Part Name Clutch Plate Pressure Part Name Clutch Plate Pressure (6 Clutch Plates)
New part added. This plate is fitted facing the Total 6 clutch plates of same specifications are
Description Description
clutch wheel side. housed in clutch assembly for torque transmission.
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Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Part Name Plate Clutch (Pressure Plate) Part Name Plate Clutch (Pressure Plate)
Description Pressure plate are housed in between clutch plates. Description Pressure plate are housed in between clutch plates.
Pressure plate is more wide. Pressure plate Pressure plate is not wide as compared with regular.
Identification Mark width = 17 mm. Identification Mark Width = 14 mm.
Identification Mark Slots provided in clutch housing. Identification Mark No slots in clutch housing.
Part No. Cylinder head cover is a part of Cylinder Head Comp Part No. Cylinder head cover is a part of Cylinder Head Comp
Description Head cover houses the complete OHC system. Description Head cover houses the complete OHC system.
Identification Mark ‘U’ mark embossed in casting. Identification Mark ‘DJ’ mark embossed in casting.
Part Name Cylinder Head Comp Part Name Cylinder Head Comp
Cylinder head comp houses the complete OHC Cylinder head comp houses the complete
Description Description
system with valve train. OHC system with valve train.
‘DJ’ mark along with ‘U’ mark embossed in casting. ‘DJ’ mark embossed in casting. Valve springs
Identification Mark Valve springs fitment groove is deep. Identification Mark fitment groove is not deep.
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Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Camshaft assly is housed in between cylinder head Camshaft assly is housed in between cylinder head
Description cover & cyl. head comp. It drives the entire valve Description cover & cyl. head comp. It drives the entire
train assly as per enhanced valve timing. valve train assly.
9.6 mm 12.6 mm
Identification Mark Cam (track) width is less. Track width = 9.6 mm. Identification Mark Cam (track) width is more. Track width = 12.6 mm.
Part Name Valve Spring Outer Part Name Valve Spring Outer
Valve spring helps in smooth closing of valves Valve spring helps in smooth closing of valves
Description Description
without any noise as per enhanced valve timing. without any noise.
It is more in length. Length = 43.6 mm. Spring is It is short in length. Length = 42 mm. Spring is
Identification Mark Identification Mark
marked with White oil paint. marked with Blue oil paint.
Part Name Valve Spring Inner Part Name Valve Spring Inner
Valve spring helps in smooth closing of valves Valve spring helps in smooth closing of valves
Description Description
without any noise as per enhanced valve timing. without any noise.
It is more in length. Length = 39.1 mm. Spring is It is short in length. Length = 38 mm. Spring is
Identification Mark Identification Mark
marked with White oil paint. marked with Blue oil paint.
Stator plate harness neutral coupler is having Stator plate harness neutral coupler is having bullet
Identification Mark square shape. Identification Mark type terminal.
Part Name Magneto Assembly (Rotor) Part Name Magneto Assembly (Rotor)
Magneto assembly rotor is having analog ignition Magneto assly rotor is having only Digital Ignition
Description Description
timing for initial starting for avoiding back kicking. Timing.
UG-3 mark embossed on the body viewed ‘E’ & ‘M’ mark embossed on the body viewed from
Identification Mark Identification Mark
from tail side. tail side.
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Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Part Name Centrifugal Oil Filter Part Name Centrifugal Oil Filter
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Parts Identification Parts Identification
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
With enhanced valve timing & to achieve better To meet the requirement of UG-II engine
Description engine performance the carburettor assembly Description specifications the carburettor is tuned.
is retuned.
On RH side of Carburettor body BS-29, DJ-U3 On RH side of Carburettor body BS-29, DJ-U2
Identification Mark Identification Mark mark is embossed.
mark is embossed.
Part Name Air Filter Assembly Part Name Air Filter Assembly
The new large volume air filter with fine & corse
A large volume air filter is introduced to provide
Description filter foam is incorporated to provide torque on Description
torque on demand with optimised intake system.
Drain demand with optimised intake system.
Tube
Drain tube is provided on bottom side to discharge No drain tube is provided on bottom side to
Identification Mark Identification Mark
the condensed engine oil. discharge the condensed eng. oil.
The silencer has been further optimised to match The silencer has been optimised to meet the
Description the changes done incorporating the new camshaft Description performance of Pulsar UG-II with ExhausTEC
& air filter assembly. introduction.
Part Name Head Light Assembly Part Name Head Light Assembly
The parking lamps are projected out with a new aggressive The parking lamps are in line with the head light
Description look & together with the mask that gives a real ‘Phantom’ Description
look. H/L facing has been lowered to give balanced looks.
body line.
Parking lamps are projected out. Provision for Parking lamps are inline with head light body.
Identification Mark mask fitment. Identification Mark No provision for mask fitment.
Part Name Handle Holder Assembly Part Name Handle Holder Assembly
Handle holder assembly height has been increased Handle holder assembly height is been designed
Description Description
to accommodate new speedo console. H low to accommodate twin pod speedo console.
H
Identification Mark Height of handle holder is more i.e. 31.5 mm. Identification Mark Height of handle holder is less i.e. 18.5 mm.
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Parts Identification Parts Identification
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
Part Name Holder Fork Upper Part Name Holder Fork Upper
Description Holder fork upper cover clamps the fork pipes & Description Holder fork upper cover clamps the fork pipes,
handle holder. handle holder & twin pod speedometer assembly.
Brace fender gives reinforcement to mud guard & Brace fender gives reinforcement to mud guard &
Description also guides the wire / hose going to wheel sensor Description also guides the brake hose going towards
& caliper assembly respectively. caliper assembly.
2 nos. of brackets provided for No bracket provided for disc brake hose /
Identification Mark a) Speedometer wire. b) For disc brake hose. Identification Mark speedo cable.
Part Name Front Number Plate Bracket Part Name Front Number Plate Bracket
The front number plate bracket holds the number The front number plate bracket holds the number
Description Description
plate & for firm fitment 3 point mounting is given. plate & is mounted with 2 point mounting.
Easy to read digital speedometer displaying speed in Twin pod analogue type speedometer displaying
Description kmph, odometer displaying distance covered & trip meter Description vehicle speed, engine rpm, odometer & trip meter.
displaying distance covered per trip with resetting facility. With trip meter adjustment facility.
Identification Mark Digital speedometer with analogue type tachometer. Identification Mark Twin pod analogue type speedometer.
New part added. It is a sensor sensing the vehicle Case meter assly houses the speedometer worm
Description Description
speed and is a non contact type wheel sensor. gear & the pinion gear assly to drive speedometer.
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Parts Identification Parts Identification
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
Identification Mark Coupler colour is White. Identification Mark Coupler colour is Red.
Identification Mark Provision of engine kill switch. Identification Mark No engine kill switch available.
A low maintenance battery with a unique vent Conventional type of battery with overflow tube
mechanism that allows only gas / vapours to
Description Description mechanism. Electrolyte level inspection interval is
escape & not the electrolyte. Hence electrolyte level
inspection interval is less. more as compared to low maintenance battery.
Battery top side mould has orange colour. Battery top side mould has black colour.
Identification Mark Identification Mark
Battery has vent valve on RH side. Battery have a vent plug on RH side.
Identification Mark Two green colour dot marks on CDI unit. Identification Mark One green colour dot marks on CDI unit.
Part Name Side Stand Switch Part Name Side Stand Switch
Identification Mark Side stand switch cable length is more. Identification Mark Side stand switch cable length is less.
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Parts Identification Parts Identification
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
Part Name Side Stand Magnet Part Name Side Stand Magnet
Identification Mark Side stand magnet body has green passivation. Identification Mark Side stand magnet body is black in colour.
No rib at tool kit mounting area. Seat locking stud Rib at tool kit mounting area. Seat locking stud is
Identification Mark Identification Mark located in central part of seat assly.
is located at extreme tail end.
Part Name Seat Lock Assembly Part Name Seat Lock Assembly
Description Since seat lock is shifted to tail end of the seat. Description The seat lock is located at center of the seat.
Part Name Gear Change Pedal Part Name Gear Change Pedal
Identification Mark Gear pedal has more curved shape. Identification Mark Gear pedal has less curved shape.
Part Name Holder RH Step & LH Step Part Name Holder RH Step & LH Step
Part No. DJ 1612 57 & DJ 1612 56 Part No. DJ 1611 12 & DJ 1611 11
Description Holder step provided for resting pillion rider's foot. Description Holder step provided for resting pillion rider's foot.
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Parts Identification Parts Identification
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
The rear fender is located below the rider seat for The rear fender is located below the rider seat for
Description Description
arresting dust / dirt & water splashing on. arresting dust / dirt & washer splashing on.
Saree guard is mounted on chassis as a safety Saree guard is mounted on chassis as a safety
Description feature for arresting the possibility of saree getting Description feature for arresting the possibility of saree getting
entangled into rear wheel while riding the bike. entangled into rear wheel while riding the bike.
Saree guard has a less curve shape near ladies Saree guard has more curve shape near ladies foot
Identification Mark Identification Mark
foot step as compared to UG-II. Saree guard step as compared with Pulsar UG-III. Saree guard
mounting allen bolt is short in length. mounting allen bolt is more in length.
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Tightening Torque - Engine
Cyl. Head Bkt. Mtg. Bolts Engine Mounting Bolts Engine Mounting Nuts
M8: 2.2 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m
Chain Tensioner Mtg. Bolts Output Sprocket Bolts Silencer Mounting Bolt
Silencer Mounting Nuts Balancer Gear Cover Bolts Crankcase Joining Bolt
1.4 ~ 1.9 Kg.m 1.0 ~ 1.1 Kg.m (Loctite 243) 1.2 Kg.m (Loctite 243)
1.1 Kg.m (Loctite 243) 1.1 Kg.m (Loctite 243) 1.1 Kg.m
Oil Pump Mounting Bolts Centrifugal Oil Filter Nut Rotor Cover Bolts
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Tightening Torque - Engine Tightening Torque - Frame
Clutch Nut (LH Threads) Cylinder Head Cover Bolts Cylinder Head Cover Nuts Front Axle Nut Rear Axle Nut Torque Rod Nut
5.0 Kg.m 3.5 Kg.m 1.0 ~ 1.5 Kg.m 4.0 ~ 5.0 Kg.m 8.0 ~ 10.0 Kg.m 3.0 ~ 4.0 Kg.m
Camshaft Sprocket Allen Bolt Starter Motor Mounting Bolts Rotor Mounting Bolt Sleeve Nut Rear Sprocket Mtg. Nut Handle Bar Holder Bolts
1.4 Kg.m (Loctite 243) 1.1 Kg.m 4.5 Kg.m 7.0 ~ 8.0 Kg.m 1.8 ~ 2.5 Kg.m (Loctite 243) 2.0 ~ 2.2 Kg.m
Kick Guide Allen Bolts Spark Plugs (2 Nos.) Drain Bolt Steering Top Cap Bolt Stg. Stem Nut (slotted) Upper Clamp Allen Bolt
1.2 Kg.m 1.4 Kg.m 2.5 Kg.m 3.5 Kg.m 0.5 Kg.m 1.8 ~ 2.0 Kg.m
Lower Clamp Bolt RSA Mounting Dome Nut Swing Arm Pivot Nut
Caliper Install Bolts Brake Disc Allen Bolts Banjo Bolt Caliper
2.2 ~ 2.8 Kg.m 0.9 ~ 1.1 (Loctite 243) 2.2 ~ 2.8 Kg.m
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Assembly - Engine Assembly - Engine
Note : Do not use inner guide while fitting the bearing for ‘Input Shaft’
in ‘Crankcase LH’ as this will damage the protruding lug of crankcase
casting. Shield of brg. must be on crankcase side/protruding lug side.
Use Bearing Driver set (P. No. 37 1030 61) Assembly of Sub assemblies :
Fit :
Magneto Cover
• Bearing for ‘Body Balancer gear Assembly’
Fit :
• ‘Harness’ in the ‘Cover’
• ‘Stopper’ and tighten the ‘Screw’ (Use Loctite 243)
• ‘Pulsar Coil’ and tighten 2 ‘Screws’ (Use Loctite 243)
• ‘Stator Assembly’ and tighten 2 ‘Bolts’ (Use Loctite 243)
• 2 ‘Dowel Pins’
Use Bearing Driver set (P. No. 37 1030 61)
Camshaft Assembly
Fit : F Fit :
• Oil seal on ‘Guide Starter Assembly’ C
B • Parallel Pin (A)
• ‘O’ ring on ‘Guide Starter Assembly’.
A • De-compression Mechanism (B)
• Damper
• ‘Washer’ (C)
D
• Washer (D)
E
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Assembly - Engine Assembly - Engine
• Using Arbour Press Similarly carry out the same procedure to assemble the other
Fit : ‘Valve’ in the ‘Cylinder Head’.
• ‘Bigger Bearing’ (E)
• ‘Small Bearing’ (F) Note : Ensure that there is no valve leakage. If required pour
the petrol in intake and Exhaust manifold and observe leakage
at valve head.
Note : Apply thin layer of oil on sliding surfaces of parts for smooth
fitting.
Fit : 5
10
• ‘Plain Washer’ in ‘Clutch Center’ / ‘Clutch Hub’
9
1
16
• ‘Bellivelli Washer’
6
A
17
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Assembly - Engine Assembly - Engine
Oil Pump Loading the assembly Balancer
Fit : Idler Gear
• ‘O’ ring (A) on the ‘Oil Strainer’ (B) Using Special Tool - Balancer
A • ‘Clip’ (C) Gear Holder 37 10DJ 63
• Slide the ‘Assembly Balancer
B
Idler Gear’ in special tool (A)
C • Rotate the ‘Scissor Gear’
anticlockwise till the lug contacts
the torsion spring.
Kick Shaft Assembly • Using a marker, mark the ‘Balancer Idler Gear’ and ‘Scissor
Fit : Gear Tooth’
H
A E G B • ‘Pinion Complete Kick Starter’ (I) Using Special Tool
• ‘Washer’ (H) • Turn the ‘Scissor Gear’ anticlockwise such that 2 teeth pre-load
is achieved. This can be confirmed by the markings done
• ‘Circlip’ (G)
previously.
• ‘Ratchet Kick Starter’ (F)
• Holding the ‘Scissor Gear’ pre-loaded in the above position
I slide the ‘Scissor Gear’ into the special tool completely.
Note : Match the dot mark of ‘Ratchet Kick Start’ with respect to
C D F ‘Spindle Kick Start Assembly’ and then slide ‘Ratchet Kick Starter’ (F) Repeat the same procedure for loading the other ‘Scissor Gear’.
on ‘Spindle Kick Start’
Note : Keep this Assembly balancer idler gear in loaded condition with
special tool.
• ‘Spring Kick Starter Ratchet’ (E)
• ‘Washer Thrust’ (D)
• ‘Circlip’ (C) Gear Complete Starter Counter Assembly
• ‘Washer Thrust’ (B) Using Arbour Press
• ‘Thrust Washer’ (A) Fit :
• ‘Needle Roller Bearing’
Assembly Balancer Idler Gear Bearing
Using Bearing Driver set (P. No.: 37 1030 61)
Fit :
• Needle roller bearings in crankcase RH and Cover
Crankcase LH (Magneto Side)
Note : Apply oil on bearing OD before pressing bearings for smooth Fit :
bearing • ‘Guide Starter Assembly’
• 3 ‘Screws’ (A) (Use loctite 243)
Fit :
A C D • ‘Springs’ (D) A
• ‘Scissor Gears’ (C)
• ‘Circlip’ (B)
Clutch Cover
• Thrust washer
G A Fit :
Similarly carry out the same procedure on other side of the gear B
• Kick shaft oil seal (H)
to assemble the ‘Balancer Idler Gear’ completely.
• Oil inspection window
B D E CB A
• Wire clip (I)
Note : Ensure that one spring end butts against spring dowel in H
• Set dampers (K)
‘Balancer Idler Gear’ & the other end of spring should butt • Set of plates (L)
against the lug on ‘Scissor Gear’
C • Bolts (J)
• ‘Rack’ (C)
• ‘Shaft Clutch Release’ (B) in ‘Clutch Cover’ by rotating it slightly
K to match the teeth.
F
J E • ‘Parallel Pin’ (A) to lock the ‘Shaft Clutch Release’
L D
• Washer
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Assembly - Engine Assembly - Engine
• ‘Spring’ torsion clutch lever Engine Assembling
• External lever
• ‘Bolt’ Engine Central Part
• Spring joint ‘A’ (F)
Fit : (In Magneto side Crankcase)
• ‘Plunger Plate’ (E)
• ‘Input and Output Shaft Assembly’ simultaneously.
• ‘Plunger oil (D)
• ‘Fork shifts’ along with rollers on ‘Input and Output Shaft
• 2 ‘Dowel Pins’
Assembly’ (2 bigger fork shifts on output shaft and 1 smaller on
• ‘Grommet (M) input shaft).
• Oil feeler plug (G)
Apply loctite 243 to all damper fitment bolts. Note : For ease of assembly of gears, remove gear 1st driven and
insert both the input and output shaft assemblies with gears in mesh
into their respective bearings. The gear box should be in neutral gear
Note : Ensure fitment of set of dampers and plate before fitting the before ‘RH Crankcase’ is assembled on to ‘LH Crankcase’.
above.
Fit :
A
• ‘Drum Change’
Input Shaft Assembly
• ‘Shaft Gear Shift’
B C EF I K Fit : From LH side of shaft (A)
• ‘Kick Spring’ (A)
• Thrust washer (K)
• 2 Dowels
• Gear 4th (J)
• ‘Gasket’
• Splined washer (I)
• Circlip (H)
• Gear 3rd drive (G) Caution : Use a sharp blade or knife to cut off any protruding
D G H J A
• Circlip (F) ‘Gasket’. This is very important for preventing any oil leakage from
‘Crankcase’ and ‘Cylinder Block Joint’. Don't apply grease / any
• Splined washer (E)
adhesive to ‘Crankcase Gasket’ as these ‘Gasket’ when comes in
• Gear 5th drive (D) contact with oil expands and seals hidden cavities.
• Gear 2nd drive (C)
• Thrust washer (B) Fit :
• Crankshaft
L M H FE CB A Output Shaft Assembly
Fit : from LH side of shaft Caution : Check oil supply to big end bearing by pumping oil in the
clutch side end of crankshaft and lets oil dribble out of con-rod big
• Gear 5th driven (M)
end sides.
• Bush (N) with shoulder ring
• Gear 2nd driven (L)
• washer (K)
Fit :
• Circlip (J)
• Crankcase RH
Fit : from RH side of shaft
• Bolts (LH & RH Side)
JK N I G D • Thrust washer (H) behind the 3rd gear on output shaft
• Gear 3rd driven (G)
• Spline washer (F).
• Circlip (E)
• Gear 4th driven (D) Clutch Side
• Steel bush (C) with shoulder ring Fit :
• Gear1st driven (B) • ‘Parallel Pin’.
• Thrust washer (A) • ‘Sprocket Cam Drive’
• ‘Cam Chain’
Note : Hold the cam chain upright using a soft copper wire or a
thread.
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Assembly - Engine Assembly - Engine
Fit : Fit :
• ‘Square Key • Washer
• ‘Primary Gear’. • ‘Kick Shaft Assembly’
• Washer
Note :
Note : Ensure fitment of 2 ‘Plain Washers’ on either side of ‘Kick Shaft
Assembly’. 1. Ensure fitment of 2 ‘Plain Washers’ on either side of ‘Kick Shaft
Assembly’
2. Refer Skill tip for fitment procedure on page no....
Fit :
• ‘Body Balancer Gear’. Fit :
A • ‘Lock’. • ‘Thrust Washer’
• ‘Bolt’ (A) (Use Loctite 243) • ‘Assly Balancer Idler Gear’ with Special Tool
• Thrust washer
Fit :
Fit :
• ‘Parallel Pin’.
Align gear timing marks of ..
• ‘Spacer’
A • ‘Guide gear shifter’ • Primary gear mark w.r.t
crankcase mark
• ‘Allen Bolt’ (A)
• Body balancer assly mark
w.r.t crankcase mark
Fit :
Fit :
• ‘Spring’ (A)
• Clutch housing
A
Note : Note :
a. Apply Loctite 638 at ‘Bolt Shift Change’ (B) if removed. 1. Ensure perfect matching of gear alignment marks w.r.to crankcase
b. Ensure free movement on ‘Stopper Gear Shift’ in ‘Bolt Shift marks.
B Change’. 2. Refer the skill tips section for understanding procedure for gear
alignment marks given on page no 52.
Fit : Fit :
• ‘Gear change lever assly’ • 2 ‘Dowels’
• ‘Assly Balancer Idler Gear Cover’
• 3 ‘Bolt’
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Assembly - Engine Assembly - Engine
Fit :
Fit :
• 2 Dowels
• ‘Woodruff key’
• ‘Oil Pump Assembly’
• ‘Magnet along with gear starter clutch’.
• 3 ‘Bolts’
Note :
• Always apply a thin layer of grease to the roller bearing of gear
starter clutch.
• Add few drops of oil on OD of gear starter clutch for lubrication.
Fit :
Fit :
• ‘Starter Motor’
• ‘Plate starter clutch return (A)
• Clutch cover gasket’
• ‘Bolt’ (Use loctite 243) (B)
• ‘2 Dowels’
A
B
Note : Do not apply any grease to stick ‘Gaskets’ to the
‘Clutch Cover / Magneto Cover’ or ‘Crankcase’. As grease
deteriorates the gasket material and reduces sealing
effeciency.
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Assembly - Engine Assembly - Engine
Using Special Tool : Rotor Note : Place clean piece of cloth on the ‘Crankcase’ bottom end
Holder H6 0721 00 because their is chance of ring snap falling down while fitment.
Fit :
• ‘Washer’
• ‘Bolt’
Fit : Note : Apply thin layer of oil in cylinder bore and piston assly
when sliding inside for ease in fitment.
• ‘Magneto Cover’
• 5 ‘Bolts’
Fit :
• Neutral switch coupler
• Head gasket
• 2 ‘Dowels (A)
A
• ‘Chain Guide’ (Non tensioner side)
Using Special Tool : Output Note : Holding the chain firmly bring the piston assly to TDC position
and Ensure ‘T’ mark on the rotor is matching with generator cover
sprocket holder 37 1030 53
mark.
Fit :
• ‘Bush’. Fit :
• ‘Sprocket’. • ‘Cylinder Head Assly’.
• 2 Dowels
• ‘Plate drive Sprocket’.
• 2 ‘Bolts’ (Use loctite 243).
Top End
Fit :
• 2 ‘Dowels’
• Block Base Gasket Fit :
• ‘Spark Plug Sleeve’.
• ‘Grub Screw’.
• ‘Spark Plug’
Using Special Tool : Drift Note : Before fitting the sleeve spark plug apply thin layer of
74 9309 89 molybdenum disulphide grease on the entry chambers for the ‘O’ rings.
Fit :
• ‘Piston’
• ‘Piston Pin’
• ‘Circlip’
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Assembly - Engine Assembly - Engine
Fit : Fit :
• ‘Cam Shaft’. • ‘Cam Chain Tensioner’
• ‘Collar’. • 2 ‘Bolt’
• Release the tensioner plunger bolt
• ‘Dust cap’ and ‘O’ ring’
Adjust :
Using Sp. Tool - 37 10DH 36
• Check and adjust the tappet
Fit :
clearance
• ‘Cam Sprocket’.
• ‘Special Washer’.
• ‘Allen Bolt’ Inlet Valve : 0.05 mm
Exhaust Valve : 0.1 mm
Fit :
Fit :
• Tappet cap with ‘O’ ring
• ‘Cam Shaft Cap’. • Cap magneto cover
• Apply thin layer of liquid
gasket to head cover
• ‘Head Cover’
Note :
• Do not apply liquid gasket on to the cam shaft cap and other
inside mounting areas.
• Refer Skill Tip for more details
II Fit :
• ‘Copper Plated Washer’
• Tighten bolts as per sequence
Ist : 4 Domed cap nut
III
I IInd : 4 Long bolts of Head Cover
IIIrd : 2 Longest bolts of Head cover
II
Note : Improper tightening sequence of bolts may cause permanent
warpage in cylinder head cover and it can get damaged permanently.
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Dismantling Front Fork Dismantling Front Fork
Remove : C Remove :
• Speedometer sensor cable from wheel (A) and from fender • Bellow clamp (A)
B clamp (B) • Bellow (B)
Skill Tip : Keep it aside safely
• Bolt fork (C) from the top of front fork assembly along with the ‘O’
ring
A
A B
Remove : Remove :
• Caliper assembly front mounting bolt (A) • Seat fork spring (8 Allen bolt)
• Spacer tube
A • Washer
Skill Tip : Place wedge between pads. Remove front brake lever.
• Spring
• Fork oil in a container
• The dust seal and the snap ring over the oil seal
Remove :
C D Remove :
• Loosen bolt (C)
• Inner tube (B) of front fork with DU bush
• Pull down fork leg assembly by slowly rotating it
• Oil seal (C) for outer tube
• Similarly carry out the same procedure to take out other side
fork leg • Guide bush washer (D)
• Spacer
C • Bushing
B
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Assembling Front Fork Front Disc Brake
Using Sp. Tool : Fork for cylinder holder adapter - 37 1830 08/11 Master Cylinder
Fit :
Working:
• Place Fork cylinder set in the inner tube, cylinder base & place
it in outer tube. Hold the piston with the help of special tool. When the brake lever is in idle condition, there is no pressure inside
the cylinder. The feed & compensation aperture are open & connect
• Bolt it from lower side of outer tube with Allen key. the pressure chamber & compensation chamber to reservoir.
• Guide bush, washer When the brake lever is operated, the push rod pushes the piston
• Oil seal using special tool (A) inside the cylinder. A small quantity of fluid returns from pressure
• Snap Ring chamber to reservoir before primary seal completely blocks the feed
aperture. Once this condition is achieved, any force exerted on the
• Dust seal lever is transformed into pressure in the brake circuit.
A • Spring and fill oil.
Air Vent
Feed aperature
Cover
Diaphragm When the brake lever is released, the piston is pressed back quickly
• Seat fork spring and Collar fork. Compensation operature
Secondary seal
Reservoir
Master cylinder by the return spring to its idle position. Due to this, a vacuum is
generated in the pressure chamber & the fluid in the compensation
body
• Bolt
chamber flows to pressure chamber through the primary seal, the
Similarly carry out the same procedure to assemble the other fork. Brake Lever Piston Outlet Port
Compensattion
Chamber
Pressure
Chamber
external edges of which flex approximately to allow fluid to pass to
Skill Tip : The Part Name & No written on oil seal should face up side Primary seal
pressure chamber. After return of the master cyl. piston, the caliper
i.e. towards technician while fitting. Spring retracts (after some relative time delay). This causes the fluid in the
pressure chamber to return to the reservoir through feed aperture.
Fit : Master Cylinder Dismantling and Assembling
• Slide the front fork assly in the fork holder Dismantling :
• Allen bolts • Remove front brake switch and its connection (A)
• Bolt fork at the top end
Similarly carry out the same procedure for fitment of the other
shock absorber.
Fit :
• Remove front brake lever by removing the nut and pivot bolt (B)
• Front fender
• The push rod boot (One end of the boot is held in a groove in
• 2 Allen bolts (A) (2 on either side) the push rod and its other (larger) end is held in a groove in the
cylinder body).
A B
Fit :
• Top cover by removing 2 screws (C)
• Front wheel assembly.
• Front axle (A)
• Tighten self lock nut
A • Calliper assembly and
tighten 2 bolts
• Speedometer sensor cable C
connection.
• Nylon Cap (D)
Caution : Don’t apply excess grease or any other lubricant on the
wheel sensor case. • Rubber diaphragm (E)
D E
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Front Disc Brake Front Disc Brake
• Brake fluid from the reservoir with the help of syringe/syphon Caliper Assembly
pump
Working :
In the brake released condition, the brake fluid inside the caliper is at
atmospheric pressure and the disc rotates freely as the pads do not
press against it.
When the brake lever is operated, the pressure generated in the
hydraulic circuit acts on the caliper pistons. The caliper in turn push
the friction pad on the side of the caliper body against the rotating
disc. The friction pad on the other side of the disc also presses against
• Master cylinder along with hose assembly from handle bar by the disc due to reaction force on caliper body. Thus both the friction
removing the 2 flanged 8 bolts (F) on the clamp. Hose pads press against the disc, thereby generating braking torque.
• Brake hose from master cylinder outer by removing banjo bolt (G)
When the lever is released, the pressure in the hydraulic circuit return
• Wipe out clearly the outer surface of master cylinder. Bleeder to atmospheric level. The friction pads return to idle position due to
F Screw
return of the caliper pistons which is due to the spring action of the
Banjo seals.
G Skill Tip : Bolt
• Ensure that there should not be any spillage of brake fluid on When the pads wear, the pistons move further towards the Disc during
painted parts brake application, but after release of pressure they retract only to the
extent allowed by the spring action of the seal. The pistons therefore
take up new positions in idle condition, and thus provide automatic
adjustment to compensate for pad wear. Due to this reason, there is
Safety Tip :
no need for free play adjustment in the Brake Lever in Master Cylinder.
• Take care of your eyes while working with brake fluid. Pin
Piston
Disc
• Hold the master cylinder in a soft jaw vice. Pad
Disc
• Remove circlip with the help of a plier, by pressing the piston Pad
slightly inside the bore, with a nylon or wooden rod. Piston
Seal
• Take out the piston assembly along with the Return spring by
pulling it out. Caliper
Body
If transparent window in the cylinder body for level indication
needs replacement (due to damage, etc.) proceed as follows:- Carrier
Bracket
• Remove Lock Ring on the window with screw driver Disc
Dust Seal
• Remove window and ‘O’ ring.
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Front Disc Brake Front Disc Brake
Warning : Do not apply high pressure compressed air, which will cause Inspection and Maintenance Frequency
the piston to jump out of the cylinder. The piston should be taken out
gradually with moderately compressed air. Care to be taken not to Check Points Frequency
damage the sealing surface of the inlet port while applying air pressure.
Brake Fluid Level / Leakage Inspect during every service /
• Do not place your finger in front of the piston while applying every 2500 Km refil up to upper
compressed air to push it out. limit (till step on the inner side of
the reservoir) if level is low.
• Remove piston seal using a thin part like a thickness gauge, etc.
Replace brake fluid every two years.
Caution : Be careful not to damage inside (bore side) of the cylinder. (In severe operating conditions,
replace in a year.)
Skill Tip : While assembling use loctite paste 243 on allen bolt for
mounting LH pad retainer case. Brake Lever Operation Inspect during every service/every
2500 Km
• Assemble the caliper assly in reverse order of dismantling
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Maintenance - Electricals Maintenance - Electricals
Battery • Remove vent plug strip happens, the chemical reactions within the battery
• Top up level with distilled water in between are affected and results in loss of capacity. Mostly
Technical Specification : the causes of sulphation are as under :
Min and Max. level
• Type & Capacity 12V - 9 AH • Connect battery to charge and ensure a. Undercharging.
respective terminal are connected properly
b. Standing in a partially or completely discharge
• Specific gravity of electrolyte 1.24 for use above 100C • Set charging current at 0.9 A DC condition for long time.
for initial filling of new battery
• Charge battery for 3/4 hrs., then check c. Low electrolyte level : If electrolyte level is
• Specific gravity of electrolyte 1.28 for use above 100C voltage and special gravity. permitted to fall below the top of the battery
for initial filling of new battery • Voltage should be 12.5 volts and special plates, then the exposed surfaces will harden
gravity in all 6 cells should be 1.240. This is a and will become sulphated.
• Initial charging duration 10 ~ 15 hrs
confirmation check for a fully charged battery.
d. Adding acid : If acid is added to a cell in which
• Initial charging current 0.9 to 1 Amp • Disconnect the battery from the changer. sulphation exists the condition will be
• Fit vent plug strip firmly. aggravated.
Initial Charging Procedure
Hydrometer • Connect battery on to vehicle. e. High specific gravity : If specific gravity is higher
1. Fill each cell with battery grade sulfuric acid • Apply petroleum jelly on to the battery than the recommended value, then sulphation
of the correct Sp. gravity (1.24 at room temp. terminal. may occur.
for use above 100C and 1.28 at room temp. Read f. High temp.: High temperature accelerates
for use below100C). Here Battery Maintenance sulphation, particularly of an idle, partially
2. Allow the battery to stand for 30 min. after discharged battery.
For the optimum performance and longer battery
filling. life the maintenance of battery is important. Voltage of the sulphated battery : -
3. Keep vent plugs open. Connect battery to a. Always keep the battery clean and dry. Cells of the sulphated battery will show low
charger and charge at 0.9 Amp.
specific gravity. Follow the procedure given below.
b. Visually inspect the surface of the battery
4. Charge continuously for 10~15 hours taking container. If there are any signs of cracking or • Check voltage before charging.
Sp. gravity readings every hour. Fully charged electrolyte leakage from battery, replace the
condition is indicated when all cells are • Charge for 2 hours
battery inside the box provided on floor board. battery.
gassing freely and evenly and show no rise in • Check voltage every 1 hour. If voltage increases
Fasten the battery firmly with bracket & allied
specific gravity over 3 successive readings. Never add acid or ordinary tap water for then continue charging. But if voltage does not
fasteners.
topping up since this will shorten Battery life. increase, discontinue charging. Otherwise
5. After charging push vent plugs strip firmly into
place and wash off acid spillage with water c. Connect cables to the positive and negative battery charger will get permanently damaged. If
and dry the battery. terminals properly. Reverse connections will Non Use Maintenance battery is not badly sulphated (i.e. voltage more
damage the charging system permanently. than 9 volts), then battery can be revived by
Checking the Specific Gravity When the vehicle is likely to remain off-road for special treatment. In such case it is advisable to
d. Always connect the “negative (earthling) longer, time (say more than a month) then Non give sulphated battery to authorised dealer of
The charge condition of the individual cell can be terminal” at Iast. Use Maintenance should be carried out as battery manufacturer for necessary special
checked by measuring Sp. gravity of electrolyte in e. Clean the battery terminals and cable follows otherwise the battery may get sulphated treatment.
that cell. The specific gravity of electrolyte can be connections. Smear them with petroleum jelly and permanently damaged.
checked by using Hydrometer having small to avoid corrosion How to Determine Condition of Battery
a. Remove the battery from vehicle.
diameter spout.
g. Check that the battery cable connections are b. Maintain electrolyte at ‘Upper Level’. Specific gravity check: - Whether battery is fully
For measuring the Sp. gravity bring the electrolyte firm and cables do not rub against any metal charged or partially charged, it will always show
in the Hydrometer to eye level, and read the components. c. During off service period, battery should be same “no load voltage” of 12 volts or more
graduations on the float scale bordering on the charged once a month. (unless battery cells are damaged due to
lower meniscus (i.e. curved down portion of sulphation etc). But specific gravity of the fully
electrolyte surface) as shown in the figure. After Battery Charging Procedure : d. Keep the battery fully charged.
charged battery and partially charged battery will
charging is over, fit the filling caps strip, wash This is a M.F (Maintenance Free) battery. This e. Store the battery in cool, dry place. be different. Fully charged battery will show Sp.
acid spillage with water. Dry the battery. Ensure battery is not having any exhaust tube instead it gravity of 1.240 while partially charged battery
terminals are clean. f. Keep the battery away from rain, dew,
has a unique vent mechanism. will show less specific gravity. Therefore, specific
moisture and direct sunlight.
gravity check is very important to know condition
Battery Installation: The electrolyte level in this M.F. battery needs to
of the battery.
be topped up with distilled water once in a year. Battery Sulphation
Install the battery on vehicle as described below In case battery in discharged and needs to be
charged using battery changed procedure is as A sulphated battery is one which has been left
a. Ensure that in all six cells the level of standing in a discharged condition or
follows :
electrolyte is near the maximum level mark. undercharged to the point where abnormal lead
• Remove battery from vehicle
b. To clean and dry the surface wipe the top of sulphate has formed on the plates (Sulphate cells
• Clean battery throughly looks like white crystal like sugar). Where this
the battery with a clean cloth. Install the
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Maintenance - Electricals Maintenance - Electricals
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Maintenance - Electricals Maintenance - Electricals
Rectifier & Regulator Assembly : REGULATOR RECTIFIER UNIT DC Charging Voltage Measurement :
(Use fully charged battery while
AC Voltage Measurement : measuring)
To measure AC voltage, open the headlight housing. Start the engine and set it at 4000+25 RPM. Ensure To measure the DC voltage; set the meter at
that the headlight, tail light, Speedometer light are ‘ON’ and the dipper switch is at ‘Hi beam’ position. 20VDC range. Connect the meter +ve lead to
L/W
L/W
white from RR unit and meter -ve lead to
W
Connect AC voltmeter in parallel across the AC circuit load by connecting the +ve meter lead to
red/black lead from the dipper switch and the -ve meter lead to ground. ground. Start the engine and set it at 4000+25
RPM. Measure the voltage with and without
Measure AC lighting voltage at 4000+25 RPM. The voltage should be 13.5+0.5 V. Stop the engine. headlight switch to the ON position. Stop the
Disconnect the meter leads. Reassemble the headlight housing. engine disconnect the meter leads.
Meter Range Specification at 4000+25 RPM Multimeter connected in
Parrallel with Battery for Meter Range Specification at 4000+25 RPM
AC 2o Volt 13.7 + 0.3 V checking DC charging
L/W
L/W
DC 20 Volt 14 ~ 15 V
W
voltage
AC Lighting Circuit : 14.2
FUSE
(10 Amps.)
W/B
L/W
L/W
B
CONTROL
20 PIN COUPLER WITH DUST COVER
SWITCH RH R
PIN NO.3 R/B R/B
HIGH BEAM INDICATOR BATTERY
INSTRUMENT CLUSTER
PIN NO.20 W
Y
O
R
Y
Y/R
O
Y
F
N
F
Br Br To measure the DC charging current, set the
IGNITION
13.5
SWITCH meter at 20ADC. Connect meter+ve lead to
W W
TAIL/
White/black lead from RR Unit and meter -ve
R R STOP lead to battery +ve lead.
L/W
L/W
LED
W
ASSLY
- Start the engine and set it at 4000+25 RPM.
W
R
+
NO.
PLATE
Multimeter connected Measure the DC charging current. The DC
R
FUSE LAMP
10 Amps
R/B R/B
5 W
in Series with Battery charging current should be 2 A max stop the
W/B
ASSY/LAMP LIGHTING
B/Y B/Y COIL the RR unit and battery
12V-35/35W HS1
R/Y R/Y R
B
charging Current
POSITION LAMP
12V-5W- 2 NOS.
STARTER RELAY
BATTERY
12V-9Ah
0.9 Meter Range Connection Specification
70A RATING
L/W
L/W
W
DC10A Meter +ve Meter -ve 2 A max at
R
White/Black Battery (+) 4000+25 RPM
MAGNETO
terminal of lead (White)
R/R
FUSE
(10 Amps.)
W/B
L/W
L/W
B
R
BATTERY
12V-9Ah
STARTER RELAY
WITH DAMPER
MAGNETO
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Maintenance - Electricals Maintenance - Electricals
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`
137
•
•
•
•
•
•
•
•
Notes :
inverted
problems.
rubber cover.
circumstances.
on console cover
L/W
Br/B
R/W
Y
R
R/Y
R/B
W/R
TACHOMETER
L
Br
B/ Y
L/W
L/W
PIN NO.20
L
Br
B/ Y
L/W
L/W
O
O
F
N
F
Br Br
IGNITION TAIL
W W
SWITCH LAMP
B/W B/W L L ASSY
B/Y B/Y B/ Y B/ Y
R/W R /W R TAIL/
STOP
LED
R
B/Y
B/ Y SIGNAL
G G LAMP
O/Br
B/Y
Lg
POSITION LAMP
B/Y
O/Br
12V-5W- 2 Nos. R
R STARTER
MOTOR
W
SIDE STAND
Lg
B/Y SWITCH
B/Y
Br/B
B/Y
Br/B
FUSE
Y/G
R/W
Y/R
R
L/W
L/W
W/R
B/Y
B
G G CABLE
ASSEMBLY
Lg EARTH
R
Lg BATTERY
B/Y 12V-9Ah
B/Y HORN (LH) HORN (RH)
CLUTCH STARTER RELAY
SWITCH 70A RATING
ING
C
Y/G
LS
NEUTRAL
PU OIL
H.T. COIL
No. 2 SPARK C.D.I. ASSY.
(For PLUG
Secondary
Spark Plug)
Br
Br
G
L
B/W
W/R
B/R
B/Y
R
B
Y
H.T. COIL
Br
Br
L
L
No. 1 SPARK
B/W
W/R
B/Y
R
(For PLUG O
Primary O F
O Spark Plug)
N F
O
F
N Br
F
IGNITION B/W B/W IGNITION
SWITCH SWITCH
B/Y B/Y L STOP
W
LAMP
LED
BANK
R
W/R B/Y
B/Y
Kill Switch
W
FUSE
10 Amps
W/R
R
B/Y
W/B
EXCITER COIL
B
R
STARTER RELAY
IN G
PU OIL
12V-9Ah
MAGNETO
CONTROL
REGULATOR SWITCH LH
RECTIFIER UNIT
L/W
B/Y
Br/B
B/Y
Br
O
O
F
N
F
Br Br
IGNITION
B/Y SWITCH
W W
B/Y
W
Br/B
W
B/Y
FUSE EARTH-FRAME
L/W
L/W
10 Amps
W/B
FUSE
10 Amps
B
W/B
BATTERY R
CHARGING COIL
Br/B
Br/B
B/Y
B/Y
BATTERY B
R
STARTER RELAY 12V-9Ah
70A RATING
STARTER RELAY BATTERY
70A RATING 12V-9Ah
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Individual Circuit Diagrams Individual Circuit Diagrams
AC Lighting Circuit : Side Indicator Circuit :
CONTROL
POSITIVE SUPPLY
TURN SIGNAL
PIN NO.11 B/Y B/Y
B/Y
BODY CONTROL UNIT UNIT
COMMON GROUND
PIN NO.7 Gr Gr
PIN NO.13 R R AC INPUT
& OUTPUT TALE-TELL BLINKER- RH INPUT Gr
POSITION LAMP ON- INPUT
Y/R
PIN NO.20 W
Y
PIN NO.8 G G G
PERMANENT BATTERY + INPUT
R/B
TALE-TELL BLINKER- LH INPUT
R/Y
B/Y
Br
O
R
Y
COMMON GROUND
Y/R
O
Y
F
N
F
Br Br PIN NO.20 W
Br
IGNITION PERMANENT BATTERY + INPUT
SWITCH
Gr
TAIL/
W W STOP
B/Y
SIGNAL
W
LED Gr Gr
Assly O O LAMP
R R N F REAR
F B/Y
Br Br RH
IGNITION
W
R
B/Y
NO. SWITCH W W
PLATE
R
W
W/B
HEAD LAMP SIGNAL
Y/R
ASSY/LAMP LIGHTING SIGNAL LAMP LAMP
B/Y B/Y COIL FRONT LH REAR
12V-35/35W HS1 B
G G G G LH
R/Y R/Y R
POSITION LAMP FUSE
B/Y
12V-5W- 2 NOS. BATTERY 10 Amps
W/B
STARTER RELAY 12V-9Ah BATTERY
70A RATING
12V-9Ah
STARTER B
R
R RELAY
EARTH-FRAME 70A RATING
MAGNETO
SPEEDOMETER COUPLER
INSTRUMENT CLUSTER
INSTRUMENT CLUSTER + INPUT SENSOR PIN NO.2 Br Br
INSTRUMENT CLUSTER + INPUT
INSTRUMENT CLUSTER
W/Y
PIN NO.11 B/Y B/Y
PIN NO.10 B B COMMON GROUND
TACHOMETER C.D.I. ASSY.
W/Y
B/Y B/Y W
B/Y
PIN NO.11 PIN NO.20
COMMON GROUND PERMANENT BATTERY + INPUT
B/Y
B
B/Y
PIN NO.20 W
PERMANENT BATTERY + INPUT
O
O F
N
O O B
F Br Br
N F IGNITION
F
Br Br SWITCH W W
IGNITION
SWITCH
W
B/Y
W W FUSE
W
10 Amps
W/B
FUSE
10 Amps
W/B
BATTERY B
R
12V-9Ah
B EARTH-FRAME
R STARTER BATTERY
RELAY 12V-9Ah
70A RATING
STARTER RELAY
70A RATING
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Individual Circuit Diagrams Individual Circuit Diagrams
Stator Motor Circuit : Side Stand Indication Circuit :
PIN NO.2 Br Br
INSTRUMENT CLUSTER + INPUT
SPEEDOMETER COUPLER
INSTRUMENT CLUSTER
PIN NO.2 Br Br
PIN NO.11 Please note that INSTRUMENT CLUSTER + INPUT
COMMON GROUND BODY CONTROL UNIT Starter Switch is enable only
if Kill Switch is in
DC INPUT ‘OFF’ condition.
PIN NO.20 W
& OUTPUT
O/Br
PERMANENT BATTERY + INPUT PIN NO.11 B/Y B/Y
COMMON GROUND
B/Y
O O
N F
F W
PIN NO.20
Br
IGNITION Br Br
SWITCH PERMANANT BATTERY + INPUT
W W
Y/G
O O
W
N FF
R Br Br
IGNITION
STARTER SWITCH
B/Y
R/W
W W
W
MOTOR
W
FUSE
B/Y
B/Y
10 Amps
EARTH-FRAME
FUSE
W/B
10 Amps
Lg Lg
Lg
W/B
R/W B
R
B/Y B/Y
B
O/Br
EARTH-FRAME
B/Y
R
STARTER BATTERY
RELAY 12V-9Ah
70A RATING
Y/G Y/G STARTER RELAY BATTERY
NEUTRAL SIDE STAND SWITCH 70A RATING 12V-9Ah
SWITCH
PIN NO.9 Lg Lg
TALE-TELL NEUTRAL INDICATOR
INSTRUMENT CLUSTER
PIN NO.2 Br Br
INSTRUMENT CLUSTER + INPUT
W
PIN NO.20
PERMANENT BATTERY + INPUT
Lg
Br
O
O F
W
N F
Br Br
IGNITION
SWITCH W W
W
FUSE
Lg
10 Amps
W/B
B
R
STARTER
RELAY
NEUTRAL SWITCH 70A RATING BATTERY
12V-9Ah
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DTSi Trouble Shooting DTSi Trouble Shooting
2nd Step : Air Induction Related 5th Step : Front Wheel Rotation Related
Check air filter foam Not Clean air filter foam element (fine & corse) as per Not Adjust front brake lever free play
element for OK SOP if clogged / excess oil soaked OK if less than specified
Check front wheel
no clogging / for free rotation
correct oil soaking
If OK Front Brake Lever Free Play
Continued.....
Continued.....
145 146
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DTSi Trouble Shooting DTSi Trouble Shooting
OK
OK
6th Step : Rear Wheel Rotation Related 8th Step : Spark Plug Related
Not Adjust rear brake free play if Check spark plug Not Clean & adjust spark plug gap
Check rear wheel OK less than specified for no fouling / OK as per specification
for free rotation correct heat range
& gap. Check both
If OK
Rear Brake Pedal Free Play spark plug for
If OK DTS-i engine
25 ~ 30 mm Replace spark plug by recommended
one if incorrect heat range
If OK
Continued..... Continued.....
147 148
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DTSi Trouble Shooting DTSi Trouble Shooting
OK
OK
10th Step : TPS Related 12th Step: Engine Compression Pressure Related
Check
Check TPS for Not Adjust gap between magnet & reed compression
correct gap / free OK switch as per specification if found more pressure.
movement / magnet Perform dry If compression pressure If compression pressure
presence / continuity & wet in wet test is NOT OK in wet test is OK
If OK compression
Check & Rectify Check & Rectify
test cylinder head cylinder block
Clean TPS switch related reasons related reasons
Standard Gap
Between Magnet & if stuck up / sticky operation
Reed Switch
2.5 mm If OK
Correct valve timing Clean compression
if mark on cam ring & piston groove
Replace magnet if missing sprocket not aligning if sticky / jam
with cyl. head when
OK rotor ‘T’ mark is
If OK aligned with
crankcase L.H. mark
Replace cylinder
If OK piston assembly
if partially seized
Replace H.T. coil for malfunctioning Rectify valve seat and valve
face by lapping if pitted /
OK worn out / excess carbon
deposition Inspect De-comp *Standard Inlet Exhaust
mechanism for stickness Tappet
Clearance 0.05 mm 0.10 mm
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DTSi Trouble Shooting DTSi Trouble Shooting
Clean compression
OK ring & piston ring
Reset valve tappet
3rd Step : Carburettor Related if sticky / jam
clearance if not
Not as per specifications
Check carburettor Re-adjust V.C. screw as per specifications
for correct OK
air fuel mixture
with the help of If OK Replace piston ring set
CO gas analyser if compression
Tighten cylinder head
Correct ‘e’ clip position ring worn out
bolts if loose
as per specification
Continued..... Continued.....
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DTSi Trouble Shooting DTSi Trouble Shooting
OK
Inspect De-compression
4th Step : Fork Inner Pipe Related
mechanism for stickyness
Not
Replace fork inner pipes if bent
OK
Check fork inner pipe
Piston Standard Diameter Cylinder Standard Diameter & under holder If OK
bracket for alignment
‘A’ Group ‘B’ Group ‘A’ Group ‘B’ Group
63.478~63.488 63.488~63.498 63.50~63.508 63.508~63.515 Replace fork under holder bracket ‘T’ if bent
OK
Continued.....
153 154
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DTSi Trouble Shooting DTSi Trouble Shooting
OK 6th Step : Frame Alignment Related Replace kick lever if bent / kick boss
Not resting area worn out / not flat
Replace frame if misaligned at
OK steering tube area
Check frame for If OK
alignment
If OK
OK Replace kick boss if splines /
serrations worn out
Replace frame if mounting hole of
swing arm is oblonged
OK
4th Step : Crankcase L.H. Related
Check crankcase RH
Not Replace crankcase RH if cracked at
kick boss area
for intact condition OK kick boss area
155 156
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DTSi Trouble Shooting DTSi Trouble Shooting
Clutch slippage
OK 5th Step : Clutch Assembly Related
1st Step : Clutch Lever Free Play Related Not
Replace clutch springs if free length
OK is less than standard
Check clutch lever Not Set clutch lever free play Dismantle clutch &
free play OK as per specifications
check all
components for If OK
Std. Free Play correct dimensions
for Clutch Lever & no abnormal wear Replace friction plates
if worn out /
2~3 mm OK 2nd Step : Clutch Cable Related
burnt / friction bonding given away
Not Dismantle, rectify & refit
OK clutch lever if sticky
If OK
Check clutch lever
operation for If OK
Replace steel plates
smooth working if worn out / burnt / glazy
Replace clutch cable if sticky / jam
If OK
OK
4th Step : Clutch Release Mech. Related
Not
Replace clutch release lever
OK if bent / O.D. oversize
Check clutch release
mechanism for
smooth operation If OK
If OK
OK
Replace rack & ‘Clutch Release Shaft’
if teeth worn out / damaged
Continued.....
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DTSi Trouble Shooting DTSi Trouble Shooting
If OK
OK
Correct alignment of swing arm
brackets if bent
OK
4th Step : Engine Sprocket Collar Related
OK
Continued.....
159 160
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DTSi Trouble Shooting DTSi Trouble Shooting
Silencer noise OK
5th Step : Muffler Related
1st Step : Mounting Nuts Related
Check silencer for Not Replace silencer if baffle plate /
Check silencer intact baffle plates OK plates are loose
Not
mouth securing nuts Tighten silencer mouth nuts if loose
for tightness OK
OK
Tightening Torque = 1.4~1.9 Kgm 6th Step : Torque Expansion chamber Related
If OK
2nd Step : Gasket Related
Check silencer Replace silencer mouth gasket Replace silencer if noise in ExhausTEC
Not chamber due to paint solidified from inside
mouth gasket (gasket exhaust) if pressed
for intact condition OK
OK
3rd Step : Silencer Guard Related
OK
4th Step : Footrest Fouling Related
OK
Continued.....
161 162
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DTSi Trouble Shooting DTSi Trouble Shooting
1st Step : Steering Ring Nut Related 1st Step : Master Cylinder Related
Not Top-up master cylinder by using
Check steering ring Loosen steering center nut / bolt,
nut & center fork side clamp bolts and OK DOT-3/DOT-4 brake fluid if fluid
nut / bolt for Not fork top bolts, steering ring nut Check brake fluid level is below minimum mark
correct tightness OK & tighten them in sequence as per S.O.P. in master cylinder
(No over tightening) to specified torque for correct level
If OK
2nd Step: Steering Races Fitment Related Disc Pad Lining Thickness
Standard Limit Service Limit
Not 7.4 mm 3.8 mm
Check steering races Refit steering races as per S.O.P. OK
for correct fitment OK if fitted in tilted condition 7.4 mm 3.8 mm
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DTSi Trouble Shooting
OK
2nd Step : Brake Fluid leakage Related
Check brake hose,
Caliper and Identify source of leakage, rectify &
Not
Master cylinder top-up if brake fluid level is below
OK minimum mark
for no leakages.
OK
3rd Step : Air Trapping Related
Check Disc Brake
system free Not Carry out air bleeding of
from air trapping. OK disc brake system as per SOP
OK
4th Step : Master Cylinder Related
Check master Clean master cylinder cover &
cylinder vent holes Not
vent holes if clogged
for no clogging. OK due to oxidation / dust.
OK
OK
Check master
Not Replace primary seal of
cylinder primary seal
OK master cylinder if worn out.
for no wear.
OK
4th Step : Caliper Related
Check for free
floating movement Not Clean & Lubricate caliper pins by
of Caliper. OK silicon grease / brake fluid if jam.
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Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center