background image

Dealer  Development  Center,  Pune

10

Pulsar  DTS-i  150/180  Training  Notes

Frequently  Asked  Questions  (FAQ’s)

Dealer  Development  Center,  Pune

11

Pulsar  DTS-i  150/180  Training  Notes

Read  Before  You  Ride

Function
To  show  display  &
analogue  display  of.....

• Warning  Indicators  : A 

digital  display  through 
i c o n   o f   k e y  
maintenance  factors  -

Digital  LCD
Speedo  Console

+

Drop  in  battery  voltage

• Tachometer

A  analogue  display  tachometer  showing  0~12  x 
1000  rpm  display  for  understanding  the  engine 
rpm.

• Fuel  Gauge

A  vertical  12  bar  equally  segmented  graphical 
indicator  indicates  fuel  level  inside  the  fuel  tank.

• Low  Fuel  Level  Indicator

A  red  colour  LED  bulb  will  glow  continuously 
when  the  fuel  level  drops  below  3.5  liters  thus 
reminding  the  rider  for  refueling.

• Easy  to  read  Digital  Speedo  Display  showing

- Vehicle  speed  -  Km/Hr.
- Odometer  -  Kms  covered.
- Resetting  trip  meter  -  for  recording  distance 

covered  in  trip  with  resetting  provision.

• Various  Indicator  Lamps  Showing

Side  indicators,  Neutral  position,  High  beam 
‘ON’  &  Side  stand  ‘ON’  indicator  functioning.

How  to  Operate
• Put  ‘ON’  ignition  key.  The  battery  voltage  icon 

on  top  will  pop-up  and  will  vanish  away 
automatically.  All  other  will  show  static  display 
until  the  vehicle  moves  on  road.

Benefits
• When  the  battery  voltage  drops  below  11.9  V, 

the  low  battery  icon  will  pop-up  and  will  start 
blinking  stating  that  the  needs  to  be  charged  / 
needs  maintenance.  Thus  rider  is  cautioned  & 
can  get  necessary  repairs  done.

• Easy  to  read  speedo  console  displaying  the 

digits.

yourbike

know

Function
• C r a n k s   e n g i n e   j u s t   b y  

feather  touch.

How  to  Operate
• Switch  ‘ON’  ignition  &  kill  switch.  Put  vehicle 

into  neutral  or  declutch  if  in  gear.

• Press  self  start  button  (0.2  second).

Do  not  open  throttle  (accelerator)  while  starting.  Once 
engine  starts  do  not  rev  up  engine  while  vehicle  is 
parked  on  the  stand.

Benefits
• Comfort.
• Hassle  free  starting.

Soft  Self  Start

Function
• For  easy  starting  of  engine

during  cold  condition.

How  to  Operate
• 2  stage  pull  /  push  type.  Manual  operation.

Do  not  open  throttle  (accelerator)  while  starting.

Benefits
• Smooth  &  easy  start.

Choke

Starting  the  Bike

Function
On  starting  the  engine  by  self  starter  button,  if 
engine  doesn’t  start  &  starter  button  is  operated 
for  more  than  3  times  at  one  go,  then,  the  power 
supply  to  starter  motor  is  disabled  and  would  be 
possible  to  crank  only  after  a  lapse  of  20  seconds 
or  you  switch  ‘OFF’  &  then  ‘ON’  the  ignition  key.

Benefits
• Protects  starter  motor.
• Safe  guards  battery  from  getting  drained.
• Enhances  battery  life.

Protection  Against  Over  Cranking

What  is  the  benefit  /  advantage  of  having  DC  system?

Constant  &  Consistent  high  intensity  current  is  available  even  at  low  engine  rpm  which  gives 
improved  combustion  &  better  startability.

No  head  light  voltage  fluctuations  resulting  into  brighter  head  light  illumination  consistently.  It  is  the 
same  existing  battery  i.e.  MF  battery  (A  low  maintenance  battery)

The  main  features  of  this  MF  battery  are  :-
•   Electrolyte  level  checking  is  not  required   frequent.
•   The  unique  vent  mechanism  provided  that  do  not  allow  loss  of  electrolyte.
•   No  drain  pipe  unlike  in  conventional  type  battery  so  no  chances  of  spillage  of  electrolyte.

Does  DC  system  vehicle  cost  more  in  maintenance?

No.  It  is  important  to  ensure  Good  health  of  Battery  that's  all  !  Care  should  be  that,  adding  extra 
accessories  will  lead  to  faster  draining  of  battery.

What  is  the  warranty  limit  for  this  MF  Battery?

The  warranty  for  the  MF  battery  is  18  months  from  the  date  of  vehicle  sold  against  any 
manufacturing  defect  observed.

Why  is  there  no  Kick  starter  provision  in  Pulsar  DTSi  180cc?

Normally  sports  bike  having  larger  CC  engine,  do  not  have  kick-starters  for  the  reason  that  riders 
footrest  comes  in  the  way  of  kick  operation  necessitating  folding  of  the  footrest  etc.  Even  if  battery  is 
discharged  to  the  level  of  not  able  crank  the  engine  through  self  start,  Engine  can  be  started  by 
push  start.  (Min  voltage  required  for  ignition  system  i.e.  7.8  V  where  as  self  start  needs  11.5  V).

Since  this  vehicle  is  with  DC  lighting  system,  will  it  be  having  headlamp  control  unit?

No.  It  will  have  a  BCU  (Body  Control  Unit)  as  like  earlier  Pulsar  DTSi.

Can  the  spoilers  of  New  Pulsar  DTSi  be  fitted  on  old  Pulsar  DTSi?

No,  it  is  not  possible  as  the  mounting  brackets  for  fixing  the  spoilers  are  welded  on  petrol  tank  at 
precise  location  only.

Is   the  tube  less  tyre  used  in  both  Pulsar   DTSi  150cc  &  Pulsar  DTSi  180cc?

The  tube  less  tyres  are  used  only  in  Pulsar  DTSi  180cc  only.

What  is  a  tubeless  tyre  &   What  are  its  advantages?

The  name  'Tubeless'  it  self  indicates  that  the  tyre  is  without  tube.  In  this  tyre  there  is  inner  tube 
which  is  a  integral  part  of  the  tyre  known  as  inner.  The  air  is  held  between  the  rim  &  the  tyre.  The 
air  filling  valve  is  fixed  air  tightly  on  wheel  rim.

Advantages  :
•   Better  fuel  efficiency.
•   Better  heat  dissipation. 
•   Less  chance  of  damage  in  case  of  flat  running.
•   Slow  air  leak.
•   No  tube  related  problems.
•   Cost  saving  on  tube.

Is   the  tubeless  tyre  repairable  if  get  punctured?

YES.  Puncture  of  Tubeless  tyres  can  be  repaired  locally.  There  are  various  methods  like  -

1.   Filter  Method

2.   Plug  (Mushroom)  Method

3.   Patch  Method

But  Bajaj  Auto  Limited  recommends.  Plug  (Mushroom)  method  since  it  is  more  effective  &  safe.

+

Summary of Contents for Pulsar 150 DTS-i

Page 1: ...uel Supply System Dismantling Assembling Fuel Cock Working of Various CV Carburettor Circuits Dos Don ts Carburettor Specifications Tune up for Getting Optimum Mileage 26 27 Engine Transmission 29 Imp...

Page 2: ...39 Service Limits 42 Tubeless Tyre Its Puncture Repair Procedure SOP for Tubeless Tyre Removal Dismantling Assembling Front Fork Front Disc Brake 44 49 51 40 Electricals 57 Digital Twin Spark Ignition...

Page 3: ...sh split seats 2 piece grab rail Tank spoiler Wolf eyed head lamp LED tail Lamp Black styling Clip on handlebar Thicker and pinched clamped fork Naked chain Advantages A bold assertive stance Neat loo...

Page 4: ...Plug 2 Nos Champion RG4HC Resistive Spark Plug Gap 0 6 to 0 8 mm Lubrication Wet sump Forced Starting Kick start Electric start Clutch Wet Multidisc type Transmission 5 speed constant mesh Primary Red...

Page 5: ...ear Mechanically expanding shoe and drum type Tyres Front 90 x 90 x 17 49 P Tubeless Rear 120 80 x 17 61 P Tubeless 2 Tyre Pressure Front 2 00 kg cm 28 4 Psi 2 Rear Solo 2 00 kg cm 28 4 Psi 2 Rear Pil...

Page 6: ...D Turn signal lamp 10 W 2 Nos Turn signal pilot lamp LED Side stand indicator lamp LED Hi beam indicator lamp LED Neutral indicator lamp LED Speedometer lamp LCD display Rear number plate lamp 5 W Hor...

Page 7: ...on Against Over Cranking What is the benefit advantage of having DC system Constant Consistent high intensity current is available even at low engine rpm which gives improved combustion better startab...

Page 8: ...ion when engine is not running Do not press brake pedal brake lever while running otherwise brake light would glow continuously drain the battery Do not switch ON OFF ignition switch un necessarily Ge...

Page 9: ...Training Notes PDI SOP PDI Checklist Periodic Maintenance Lubrication Periodic Service SOP Service wise Part Kit Scheduled Maintenance Standard Checking Procedure Special Tools I Check I Maintain All...

Page 10: ...old Start Warm Start Idling Speed warm Condition 1400 100 rpm Throttle response Brakes Front Rear Digital speedometer Odometer Trip meters Fuel gauge Fuel indicator red lamp CO should be 2 in engine w...

Page 11: ...0000 kms 27 Air breather tube C C C C R Every 1 year 28 Drive chain lubrication Slackness adjustment C A L C A L C A L C A L L Every 500 kms Adj slack 2500 kms 29 Drive chain remove Clean Inspect Lubr...

Page 12: ...Chain Lock and Link Set Engine Air Breather Tube Clutch cover gasket Engine Oil NIL Air Filter O ring Drive Chain lock and link set Spark Plug Starter clutch bush set Chain sprocket kit If required N...

Page 13: ...older Drift Thrust Plate Aligner Holder Output Sprocket Holder Bearing Driver Set Rear Shock Absorber Adjuster Piston Ring Holder 37 10DH 36 37 10DH 32 37 10DH 31 37 10DH 35 37 10DH 33 37 10DJ 32 37 1...

Page 14: ...Training Notes Fuel Supply System Dismantling Assembling Fuel Cock Working of Various CV Carburettor Circuits Dos Don ts Carburettor Specifications Tune up for Getting Optimum Mileage Fuel System All...

Page 15: ...ttle at zero position Fig 1 On connecting multimeter to Reed Switch coupler it should show continuity When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switc...

Page 16: ...ng Engine Overhauling Removal of Engine from Frame Dismantling of Engine Dismantling Engine Sub Assembly Part Inspection Parameters Assembling Engine Service Data Tightening Torque CAT Converter Contr...

Page 17: ...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 Inl...

Page 18: ...c 180 cc Cyl Head Bkt Mtg Bolts M8 2 2 Kg m Engine Mounting Bolts M8 2 2 Kg m M10 2 4 Kg m Output Sprocket Bolts 1 1 Kg m Loctite 243 Silencer Mounting Nuts 1 4 1 9 Kg m Balancer Gear Cover Bolts 1 0...

Page 19: ...oid thread damage Always use wire gauge for setting spark plug electrode gap Use feeler gauge for setting valve clearance Always follow loosening tightening sequence of cylinder head bolts otherwise i...

Page 20: ...ter the ExhausTEC port and consist of 4 main parts 1 The substrate or the support which is of honeycomb ceramic type or metallic type 2 The wash coat or intermediate layer such as alumina which provid...

Page 21: ...lled supply of oil to clutch Clutch housing has been modified to closed type to retain required quantity of oil consistently Advantages 1 Smoother gear shift feel 2 Controlled clutch lubrication Passa...

Page 22: ...Overhaul 320 ml Brake Shoe Lining Thickness 3 85 4 15 3 85 4 15 Standard Limit 2 0 2 0 Service Limit Pulsar 150 cc Pulsar 180 cc Brake Cam Diameter 11 95 11 98 13 95 13 98 Standard Limit 11 88 13 88...

Page 23: ...ne 43 Pulsar DTS i 150 180 Training Notes Tightening Torque For 150 cc 180 cc Tightening Torque For 150 cc 180 cc Front Axle Nut 4 0 5 0 8 0 10 0 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc Rear...

Page 24: ...inner liner The valve is permanently fixed to the rim The assly is airtight Components Tyre Tube with Valve and Rim Loss of air is very slow after getting punctured because a i r c a n e s c a p e thr...

Page 25: ...advantages Stiff ridges are formed on the inner liner of the tyre due to hardening of the repair compound which prohibits use of tubes with the tyre If tube has to be used then proper grinding of tyre...

Page 26: ...ended below Damage Chance To avoid scratches on the paint damages to wheel rim portion it is essential to take certain care precautions while carrying out puncture repair job Following steps must be f...

Page 27: ...yre bead portion with crowbar to fit the bead portion in the wheel rim Inflate the tyre to little more pressure than specification You will hear a noise that indicates that the bead portion has taken...

Page 28: ...Allen bolt Copper platted washer Note Mount the special tool firmly on the bench vice and insert the fork pipe In special tool for firm locking Note Ensure that the snap ring and the bottom allen bol...

Page 29: ...ork assly in the fork holder Bolt A Fit Allen bolt Handle bar 2 Allen bolts B Fit Bracket with wheel sensor case complete Bolt A Wheel sensor harness coupler Fit Mudguard Brace fender 4 bolts A Fit Wh...

Page 30: ...g Procedure Electricals Information on Digital Speedo Console Vehicle Speed Sensor LED Tail Lamp Backlit Non Contact Type Switches Working of Indicator Auto Cancellation Working of BCU etc Individual...

Page 31: ...ing of new battery Initial charging duration 10 15 hrs Initial charging current 0 9 to 1 Amp Initial Charging Procedure 1 Fill each cell with battery grade sulfuric acid of the correct Sp gravity 1 24...

Page 32: ...e and direct sunlight How to Determine Condition of Battery Specific gravity check Whether battery is fully charged or partially charged it will always show same no load voltage of 12 volts or more un...

Page 33: ...ls Measure the secondary winding resistance as follows Remove the plug cap by turning it counter clockwise Connect the tester between the spark plug leads Measure primary winding resistance Measure se...

Page 34: ...B 14 3 Dealer Development Center Pune 65 Pulsar DTS i 150 180 Training Notes Measuring Testing Equipment Multimeter Fuel Gauge Tank Unit 200 Ohms Meter Range As per chart given below White Yellow Met...

Page 35: ...s check cranking current displayed on clamp meter LCD display Dealer Development Center Pune 67 Pulsar DTS i 150 180 Training Notes Dos Don ts HORN Dos 3 Ensure that resonator is not pressed by any po...

Page 36: ...tery life Do not add extra electrical load on battery as it will draw more current will reduce battery life Do not cover vent mechanism of battery by cloth paper or any other object Don ts 7 Dealer De...

Page 37: ...od do not dismantle control switches Do not add extra electrical loads e g musical horns additional horns buzzers as it will reduce switch contact life battery life b a t t e r y life Do not operate s...

Page 38: ...B R B Y R B O F F O N B Y R Y W W Br HEAD LAMP ASSY LAMP 12V 35 35W HS1 IGNITION SWITCH EARTH FRAME R R B R PIN NO 3 HIGH BEAM INDICATOR PIN NO 13 POSITION LAMP ON INPUT SWITCH BODY CONTROL UNIT FROM...

Page 39: ...Y Lg Lg SWITCH BODY CONTROL UNIT FROM LH SWITCH R W W R Br R B Y Br W RELAY KILL SWITCH CONTROL Br L B Y Br L Br L Br L Br L W G Br L Br W NC NO P W B STARTER MOTOR R FUSE 10 Amps R W B STARTER RELAY...

Page 40: ...Keep off direct fire near the power pack Avoid oil spillage around the working area for safety reasons Dealer Development Center Pune 76 Pulsar DTS i 150 180 Training Notes Dealer Development Center P...

Page 41: ...Air supply system Observe the following safety related precautions when using an air tool It is advisable to fit a pressure regulator FRL Filter Regulator Lubricator in the pneumatic line which suppli...

Reviews: