Bajaj Pulsar 150 DTS-i, Maintenance Manual

Page: 17 / 41

Service Data (For 150 cc & 180 cc)
Dealer Development Center, Pune
30
Pulsar DTS-i 150/180 Training Notes Dealer Development Center, Pune
31
Pulsar DTS-i 150/180 Training Notes
Service Data (For 150 cc & 180 cc)
Compression Pressure
6.0~10.0
2
Kg/Cm
11.0~13.0
2
Kg/Cm
Standard
Limit
5.0~10.0
2
Kg/Cm
9.0~10.0
2
Kg/Cm
Service
Limit
Pulsar
150 cc
Pulsar
180 cc
Valve Clearance
Rocker Arm Shaft Dia.
Cam Sprocket Diameter
Cam Height
Inlet
0.05
Exhaust
0.10
Inlet
0.05
Exhaust
0.10
61.285 ~
61.165
61.165 ~
61.285
Inlet
31.0
Exhaust
30.4
Inlet
31.3
Exhaust
31.0
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
Inlet
0.05
Exhaust
0.15
Inlet
0.03
Exhaust
0.08
7.98
7.98
61.1
61.1
Inlet
30.8
Exhaust
30.2
Inlet
31.1
Exhaust
30.8
Service
Limit
Service
Limit
Service
Limit
Service
Limit
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
7.994~8.0
7.994~8.0
Valve Spring Free Length
Inner
39.10
Outer
43.6
Inner
38.6
Outer
41.4
Standard
Limit
Inner
39.0
Outer
42.6
Inner
37.6
Outer
40.4
Service
Limit
Pulsar
150 cc
Pulsar
180 cc
Valve Stem Diameter
Valve Stem Bend
Valve Head Thickness
Cylinder Head Warp
Inlet
4.48
Exhaust
4.46
Inlet
4.483
Exhaust
4.464
Inlet
0.05
Exhaust
0.8
Inlet
0.05
Exhaust
0.8
0.05
0.05
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
TIR 0.03
TIR 0.03
Inlet
0.3
Exhaust
0.6
Inlet
0.3
Exhaust
0.6
--
--
Service
Limit
Service
Limit
Service
Limit
Service
Limit
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
TIR 0.01
TIR 0.01
Inlet
4.40
Exhaust
4.41
Inlet
4.63
Exhaust
4.444
Camshaft Chain Length 20 Links
127.00 ~
127.20
127.00 ~
127.20
Standard
Limit
128.0
128.0
Service
Limit
Pulsar
150 cc
Pulsar
180 cc
Cylinder Inside Diameter
Piston Diameter
Piston / Cylinder Clearance
Piston Ring / Groove Clearance
0.019
0.019
Top 0.025
~ 0.065
Second
0.02~0.06
Top 0.02
~ 0.06
Second
0.01~0.05
Standard
Limit
Standard
Limit
0.039
0.039
Top
0.16
Second
0.15
Top
0.16
Second
0.15
Service
Limit
Service
Limit
Service
Limit
Pulsar
150 cc
Pulsar
150 cc
Group A
58.010 ~
58.025
Group A
63.50 ~
63.508
Standard
Limit
Group B
58.017 ~
58.033
Group B
63.508 ~
63.515
Pulsar
150 cc
Pulsar
180 cc
58.000 ~
58.008
63.500 ~
63.508
Standard
Limit
57.975 ~
57.981
63.475 ~
63.481
Pulsar
150 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
20-link length
1st 2nd 21st
MEASURE THIS LENGTH
10mm
20mm
40mm
7mm
Piston Ring End Gap
Top
0.15~0.30
Second
0.30~0.45
Top
0.15~0.30
Second
0.30~0.45
Standard
Limit
Top
0.55
Second
0.70
Top
0.55
Second
0.70
Service
Limit
Pulsar
150 cc
Pulsar
180 cc
Clutch Spring Free Length
Friction Plate Thickness
Pressure Plate Warp
Shift Fork Guide Pin Diameter
37.00
37.00
0.2
0.2
4.49
4.49
Standard
Limit
Standard
Limit
Standard
Limit
Standard
Limit
2.75
2.75
0.3
0.3
4.40
4.40
Service
Limit
Service
Limit
Service
Limit
Service
Limit
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
150 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
Pulsar
180 cc
2.9 ~ 3.1
2.9 ~ 3.1
35.00
35.00