Bajaj pulsar DTS-i Service Station Manual Download

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Pulsar 150/180 DTS-i

Service Station Manual

Dealer Development Center

Akurdi Pune

Frame & Suspension

157

Tightening Torques

Special Tools

Working of Nitrox Suspension

Service Limits

Control Cable Routing

SOP for Front Fork Dust Seal & Oil Seal Replacement

160

164

169

158

162

167

Electrical

213

Battery

Battery Dos & Don'ts

Starter Motor

Electrical Checking Procedures

SOP for Checking Charge Condition of Battery

230

218

234

214

232

Diagnosis & Troubleshooting

247

SOP for Steering Overhaul

SOP for Swing Arm Replacement

SOP for Caliper Piston Seal and Dust Seal Replacement

SOP for Dismantling & Assembling Front Fairing

Wiring Harness Routing

Sop for Master Cylinder Piston Kit Replacement

181

195

202

176

186

197

SOP for Front Brake Hose Replacement

SOP for Brake Fluid Replacement

209

207

Dos & Don'ts

Electrical Circuit Diagrams

240

237

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Summary of Contents for pulsar DTS-i

Page 1: ...Service Station Manual Service Station Manual...

Page 2: ...dures and specifications subject to change without prior notice The right is reserved to make such changes at any time without prior notice DOC NO 71110987 REV 01 MAR 14 Dealer Development Center Serv...

Page 3: ...mission 85 8 Tightening Torques Special Tools Engine Dismantling Part Inspection Parameters Engine Lubrication Flow of Oil Gear Transmission Power Flow Service Data Engine Removal from Frame Engine Su...

Page 4: ...Checking Procedures SOP for Checking Charge Condition of Battery 230 218 234 214 232 Diagnosis Troubleshooting 247 11 SOP for Steering Overhaul SOP for Swing Arm Replacement SOP for Caliper Piston Se...

Page 5: ...Foreword 1 sm pt...

Page 6: ...l carefully Don t take shortcuts Remember to keep complete records of maintenance and repair with dates and any new parts installed In this manual the produce is divided into its major systems and the...

Page 7: ...Workshop Safety 3 vk Si p s fT...

Page 8: ...p yourself cool while taking tests It is very necessary to be alert Mount the vehicle in the center of the rollers Fuel pipe should not touch heated part of the vehicle it may cause fire Make sure to...

Page 9: ...is advisable to fit a pressure regulator FRL Filter Regulator Lubricator in the pneumatic line which supplies air pressure to the air tool It regulates the outlet pressure to 6 5 Kg cm This avoids the...

Page 10: ...t Don t put leg hand in between while raising lowering the lifter Bay Safety Tips Do not lower the lifter bay table without unlocking the mechanical lift lock Do not keep your leg between the top and...

Page 11: ...General Information Before Servicing 7 jnrl vgt s v s ph li...

Page 12: ...battery then the negative cable to the negative terminal Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Cleaning Vehicle before Disass...

Page 13: ...assembly order is provided in this Service Manual follow the procedures given Replacement Parts Replacement parts must be BAJAJ genuine or recommended by BAJAJ Gaskets O rings Oil seals Grease seals C...

Page 14: ...ssembly and assembly excessive force can cause expensive or hard to repair damage When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic face...

Page 15: ...pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Press inner race when bearing is to be fitte...

Page 16: ...o colour wire is identified first by the primary colour and then the stripe colour Unless instructed otherwise electrical wires must be connected to those of the same colour Instrument Use a meter tha...

Page 17: ...excessively spread open circlips with tool during installing to prevent deformation Always use appropriate special tool for opening assembling parts to avoid damages To avoid dust muck entry inside t...

Page 18: ...NOTES Pulsar 150 180 DTS i Service Station Manual 14 Dealer Development Center Akurdi Pune...

Page 19: ...Fuel Saving Tips Non Use Maintenance Customer Awareness Bajaj Genuine Parts Maintenance Tips 15 gi hk miT n vgt sivc t Y vihn clivvin r t drri jni s fT c k vihn clivvi dr yinni pi e T p Ti l bcivvi mi...

Page 20: ...ds Read thoroughly the instructions in this manual and follow them carefully Avoid unnecessary accessories for the safety of both rider and other motorists Get familiar and follow traffic rules and re...

Page 21: ...le free performance of the vehicle During first 2000 kms running in period do not exceed following speed limits Kms 1st 2nd 3rd 4th 5th 0 1000 14 22 30 37 44 1000 2000 18 28 38 46 55 Always keep the s...

Page 22: ...ke liners Lubricate the control cables Cover the entire vehicle neatly Ensure that the storage area is well ventilated free from any source of flames or spark Fill 10 excess air pressure in both wheel...

Page 23: ...Do not add extra electrical accessories e g remote horn buzzer etc Disconnect battery terminals if vehicle is not being used for long time more than 2 weeks Do not press self start button continuously...

Page 24: ...nt vehicle maintenance as per PM schedule Warranty is applicable for manufacturing defects with in a period of 2years or 30 000 kms whichever occurs earlier Warranty is not applicable to Parts subject...

Page 25: ...AGING MONTH MAY 2003 JA551421 PLATE JUDDER Bajaj Auto Limited Akurdi Pune 411 035 India M R P Incl of All Taxes in Rs for Qty packed Pkg MTH OCT 06 48 29 QTY 1 No NF 143 B Hologram Scratch Hologram to...

Page 26: ...NOTES Pulsar 150 180 DTS i Service Station Manual 22 Dealer Development Center Akurdi Pune...

Page 27: ...ical Specifications Technical Specifications Carburettor Specification Oil Grease Loctite application matrix 23 p sr i dts T kn kl mih t T kn kl vgt kib r Tr Ap S f k Sn ai el g s li klieT kyi viprvin...

Page 28: ...mm Lubrication Wet sump Forced Starting Kick start Electric start Clutch Wet Multidisc type Transmission 5 speed constant mesh Primary Reduction 3 47 1 66 19 Gear Ratios 1st gear 28 20 1 36 13 2nd ge...

Page 29: ...Tail Stop lamp LED LED 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 numb...

Page 30: ...mm Lubrication Wet sump Forced Starting Electric start Clutch Wet Multidisc type Transmission 5 speed constant mesh Primary Reduction 3 47 1 66 19 Gear Ratios 1st gear 26 93 1 36 13 2nd gear 18 31 1 3...

Page 31: ...n 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 Horn 12V...

Page 32: ...Position 2nd from top Pilot Jet 17 5 Starter jet Fixed type Throttle valve Fixed type Choke Lever 2 stage with push pull type mechanism ON OFF DJ U4 BS29 9321 B Carburettor Specifications of Pulsar 15...

Page 33: ...rvice 1 L Eng O H 1 1 L For Pulsar 150 cc Quantity fork leg Service 145 2 5 ml For Pulsar 180 cc Quantity fork leg Service 295 2 5 ml Front fork 2 3 Grease Silicon Caliper assembly Front disc brake Gr...

Page 34: ...Oil pump mounting bolt Allen bolt securing guide gear on shift drum Screw securing stopper for input shaft bearing Special bolt guide chain slack side Nut inhibitor mounting Nut clutch mounting Damper...

Page 35: ...controls Frequently Asked Questions FAQs PM Schedule PDI Check Sheet Importance of PM schedule execution Salient Features 31 h vi c h S K v h kl vOi n vgt an k Ti ls s l y T f cr S Dy al c k s T Dy a...

Page 36: ...unique alpha numeric codes to identify your particular vehicle from others of the same model and type Frame Number Location On LH Side of Steering Tube Alpha Numeric 17 Digits Engine Number Location...

Page 37: ...total distance that the vehicle has accumulated 6 Neutral Indicator When transmission is in Neutral Ignition switch ON Neutral indicator will glow 7 Speedometer Vehicle speed will be displayed digital...

Page 38: ...turn signal knob is turned to Left or Right respective indicator will start blinking to stop blinking push the knob in release Right Handle Bar Switches E Head Light Switch It has 3 positions All lamp...

Page 39: ...the key to LOCK position and remove the key To Unlock the Steering To unlock steering insert the key in steering cum ignition lock turn it clockwise to OFF or ON position Key A common key is used for...

Page 40: ...d speed conditions at different levels of acceleration More power more mileage ultimate refinement Well refined engine and Optimum performance with more power STYLE Brawny masculine looks Stylish spli...

Page 41: ...YES YES YES YES Head Lamp Fairing New decals to match to the profile of the vehicle YES YES What are other distinguish features of new Pulsar DTS i 180 cc motorcycle in comparison with New Pulsar DTS...

Page 42: ...arters 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...

Page 43: ...CL L A CL L A cleaning lubrication 14 Sealed drive chain CL L A CL L A CL L A CL L A CL L A CL L A CL L A CL L A Customer to apply OKS cleaning lubrication chain lub spray at every 500 kms 15 Engine...

Page 44: ...dy to use coolant 35 Coolant hose damage clamps leakage C C C C C C C 36 Radiator fins C C C C C C C 37 Spoke tightening Front Rear C T C T C T C T C T C T C T C T Pulsar 150 180 DTS i Service Station...

Page 45: ...ew to assure quality performance c For better understanding show Periodic Service DVD to technicians at suitable interval 5 How to promote compliance to PM schedule a Work shop side 1 Ensure adherence...

Page 46: ...ondition 60 C Adjust if required 1400 100 RPM 0 Kick operation Smooth operation Gear shifting Smooth operation Engine noise No abnormal noise Silencer noise No abnormal noise from silencer shields Fas...

Page 47: ...ut 150 cc 180cc 8 10 Kgm Brake disc allen bolts 150 cc 180cc 2 6 3 2 Kgm Pinch clamp bolt 180cc 2 0 2 2 Kgm ELECTRICAL Battery Terminal voltage 12 4 V DC Charge status using load tester Electrolyte le...

Page 48: ...vity checking Battery charge condition checking by battery tester Charging of battery on BAL recommended battery charger Clutch free play setting Accelerator free play setting Front brake free play se...

Page 49: ...5 bar max s washer et the nozzle in spray mode 5 Wash the vehicle by keeping nozzle 2 meters away from parts 3 Clean the exterior surface of engine metal parts by diesel or kerosene with soft nylon br...

Page 50: ...r mudguards to remove the mud dirt 7 Clean painted parts by gently rubbing their surface with sponge soft cloth dampened with solution of mild car shampoo liquid solution 8 Rub the front and rear tyre...

Page 51: ...essure gauge on washing machine Spray gun adjustable spray jet Silencer tail end cap 11 Vehicle should be wiped off by cotton cloth immediately after washing 12 To avoid water entry paper filter do no...

Page 52: ...hly clean 4 Measure the quantity of drained oil 2 Ensure the engine is in warm condition before opening engine oil drain bolt 3 Drain engine oil in a clean container IMPORTANCE OF PM SCHEDULE EXECUTIO...

Page 53: ...re oil quantity after draining This is important to understand the oil consumption pattern 9 During the interval from one oil change to the next oil change engine oil quantity should not be more than...

Page 54: ...nter Akurdi Pune 14 Ensure oil filler cap O ring as in good condition 15 Ensure oil filler cap is fully tight Required Special Tools Equipment Measuring Jar Funnel Cleaning brush ai el f Tr k p r g br...

Page 55: ...y using box spanner and handle 2 Drain engine oil in a clean container 3 Remove two bolts securing right hand side foot rest take out the foot rest 4 Remove bolt securing kick lever take out kick leve...

Page 56: ...ng Bracket Clutch Cable take out the clutch cable end terminal from Lever Clutch 7 Loosen remove clutch cover bolts in crisscross pattern take out clutch cover 8 Remove the bolts securing Oil Pump Ass...

Page 57: ...ar on the strainer mesh in the direction opposite to flow of oil 12 Pump the engine oil by Oil can through the input passage hole of oil pump body simultaneously rotate the oil pump shaft nylon gear i...

Page 58: ...Cleaning 1 Remove two bolts securing right hand side foot rest 2 Take out the foot rest 3 Remove bolt securing kick lever 4 Take out kick lever from kick shaft 5 Remove phillips screw securing Cover...

Page 59: ...pment Center Akurdi Pune 8 Loosen remove clutch cover bolts in crisscross pattern 9 Take out clutch cover 10 Remove centrifugal oil filter cover mounting screws 11 Clean centrifugal oil filter by nylo...

Page 60: ...ne 13 Apply 0 5 Kgm torque while refitting 14 Replace clutch cover gasket by new one Required Special Tools Equipment Phillips Screw Driver Nylon Brush Torque Wrench T Spanner 15 Tighten clutch cover...

Page 61: ...l 57 Dealer Development Center Akurdi Pune 2 Visually check spark plug electrode for color erosion crack breakage 3 Clean the spark plug on spark plug cleaning machine 4 Check and adjust spark plug ga...

Page 62: ...ULE EXECUTION 6 Replace spark plug as per the interval given in the Periodic Maintenance Schedule 7 Refit spark plugs by doing pre fitment manually thereafter use spanner for tightening 8 Ensure spark...

Page 63: ...Center Akurdi Pune 2 Remove the petrol cock sediment bowl by using a ring spanner 3 Pour out the petrol to remove sludge and sediment from Petrol Cock Sediment Bowl 4 Remove strainer from petrol cock...

Page 64: ...stepped adjuster cam to suit individual requirement as per load road conditions Turn the adjuster cam on each shock absorber to same required position Setting the adjuster cam to higher notch position...

Page 65: ...est oxygen censor test etc 2 Readiness of the Vehicle a Warm up the engine Run the vehicle on MRTB or drive the vehicle for about 3 4 kms on road b After warm up check the engine oil temperature by di...

Page 66: ...he air or VC screw to get CO value between 1 5 2 5 at idling RPM or 1400 100 8 Reconfirm the engine idling RPM CO are within specified limit 9 For getting better engine performance optimum fuel effici...

Page 67: ...IMPORTANCE OF PM SCHEDULE EXECUTION Battery Electrolyte Level Specific Gravity Checking 1 Open the side cover panel 2 Clean the battery battery terminal 3 Inspect battery for damage leakage 4 Open all...

Page 68: ...ter maintain level in between Min Max level Required Special Tools Equipment Hand Gloves Distilled Water Bottle with Dropper Hydrometer 8 Use Nitrile rubber hand gloves while topping up battery electr...

Page 69: ...Press and release the clutch lever to confirm the smooth operation of clutch 2 If clutch operation is jammed or sticky replace clutch cable 3 Check the clutch lever free play by steel rule 4 If free p...

Page 70: ...ent Center Akurdi Pune IMPORTANCE OF PM SCHEDULE EXECUTION Throttle Cable Free Play Checking Adjustment 1 Check for smooth rotation of accelerator grip 2 Check accelerator free play by scale ruler 3 A...

Page 71: ...y Checking Adjustment 1 Check for smooth operation of rear brake pedal 2 Measure rear brake pedal free play by using a steel scale 3 Adjust rear brake pedal free play as per specification 4 Recommende...

Page 72: ...age the Piston is at TDC and both the Tappets are free 4 Put the feeler gauge measure and adjust the clearance 5 Lock the nut holding screw with special tool after getting desired clearance 6 Again ch...

Page 73: ...in rotation and keep the nose of the extension tube at about 5 10 cms away from the chain 4 Rotate the wheel in reverse direction spray the lube on the middle portion of the chain so that lubricant wi...

Page 74: ...e for 1st Free service 2 Lubricate chain with SAE 90 oil Ensure oil is directed on to the ends of the bushes links on either side 3 Rotate the rear wheel for proper lubrication of entire chain 4 Wipe...

Page 75: ...the chain cover Sealed Type Chain Non Sealed Type Chain 3 7 3 3 3 3 Diesel SAE90 Oil in 1 1 proportion Diesel Kerosene 2 Open the drive chain link lock As applicable to model 3 Take out the chain 4 I...

Page 76: ...hain on vehicle Adjust chain slackness as per specification 6 Hook the chain for dripping off 7 8 Dip the chain in greasilator containing molten grease IOC servo compound for 2 minutes 7 7 3 3 9 Hook...

Page 77: ...Fuel System CO Checking and Setting Engine Standard Operating Procedure Tune up Carburettor Circuits 73 fy al s ATm co SOP c k g an t n s T g a Jn Ty n ap kib r Tr srk T...

Page 78: ...CO as recommended In Pulsar motorcycle for better mileage and performance achieve values given below Note Remember the VC Screw should not be taken out more than the recommended position Every time V...

Page 79: ...peration and should return back it self on releasing bracket Multimeter should show continuity Magnet should not touch with reed switch Gap between Magnet Reed Switch should not be more than 2 5mm Mov...

Page 80: ...UNE UP When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switch multimeter should show discontinuity On De acceleration when of Reed Switch magnet re coinsid...

Page 81: ...w Loosen clamps of rubber duct Remove intake manifold bolts and take out carburetor Remove Philips screws securing the Carburetor bowl to the Carburetor body Take out Carburetor bowl Pour out sludge a...

Page 82: ...arburetor bowl Refit carburettor on vehicle confirm no fuel leakage STANDARD OPERATING PROCEDURE Pulsar 150 180 DTS i Service Station Manual 78 Dealer Development Center Akurdi Pune SOP kib r Trni j T...

Page 83: ...Pulsar 150 180 DTS i Service Station Manual 79 Dealer Development Center Akurdi Pune CARBURETTOR CIRCUITS kib r Tr srk T...

Page 84: ...properly this leads to starting trouble Construction Working 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 passa...

Page 85: ...air quantity The volume control VC screw controls the amount of air fuel mixture flowing through the pilot outlet As the air enters the pilot air inlet the fuel is metered by pilot jet and air quanti...

Page 86: ...des 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 The progression circuit follows the path of pilot...

Page 87: ...t 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 b...

Page 88: ...Notes Pulsar 150 180 DTS i Service Station Manual 84 Dealer Development Center Akurdi Pune...

Page 89: ...emblies Dismantling Parts Inspection Parameters Assembly of Engine Gear Transmission Power Flow Engine Lubrication Flow of Oil 85 a Jn an T i sm Sn TieTn g Ti k s vs D Ti Ap S yl T s yid riKvi miT ni...

Page 90: ...er Bolts 1 0 1 1 Kg m Loctite 243 Crankcase Joining Bolts 1 1 Kg m Loctite 243 Crankcase Joining Bolt 1 1 Kg m Loctite 243 Engine Mounting Nuts M8 2 2 M10 2 4 Kg m Kg m Silencer Mounting Bolt 3 5 4 0...

Page 91: ...m 0 Camshaft Sprocket Allen Bolt 1 4 Kg m Loctite 243 Kick Guide Allen Bolts 1 2 Kg m Starter Motor Mtg Bolts 1 1 Kg m Cylinder Head Cover Bolts 3 5 Kg m Spark Plugs 2 Nos 1 4 Kg m 4 5 Kg m Rotor Mou...

Page 92: ...15 Inlet 0 03 Exhaust 0 08 7 98 7 98 61 1 61 1 Service Limit Service Limit Service Limit Pulsar 150 cc Pulsar 150 cc Pulsar 150 cc Pulsar 180 cc Pulsar 180 cc Pulsar 180 cc 7 994 8 0 7 994 8 0 Valve...

Page 93: ...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 Cylinder Inside Diameter Group A 58 010 58 025 Group A 63 50 63 508 Standard Limit Group B...

Page 94: ...econd 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 Pulsar 150 cc Pulsar 150 cc Pulsar 180 cc...

Page 95: ...emoval 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 Drawin...

Page 96: ...Butt Pin Drawing No 37 10DJ 32 Application Used to pull out rotor from crankshaft assembly Primary Gear Holder Drawing No 37 10DJ 28 Application Use to hold primary gear while loosening tightening the...

Page 97: ...oil filter nut Note Existing tool can be used by reducing diameter to 25 9 0 1 mm Dia 25 9 0 1 Bearing Extractor Drawing No 37 10DJ 76 Application Used to extract the input shaft brg from crankcase LH...

Page 98: ...ication 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 7...

Page 99: ...lutch place plain washer first then place Belleville washer Concave face should be upwards i e towards technician After placing Belleville fit clutch plate with 40 friction material cubs A with more I...

Page 100: ...l tool Input shaft has special nut Thick spacer tapered I D should be placed on tapered portion of Input Shaft Input Shaft has left hand threads Fit primary gear drive A The mark teeth of the primary...

Page 101: ...th the line mark on the Crankcase Holding the Assembly Balancer Gear in special tool now slide inside the Clutch Housing so that the Clutch Housing smoothly engages with the top half of Assembly Balan...

Page 102: ...the special nut for centrifugal filter the Primary gear holder should hold between the Primary Gear and Clutch Housing from bottom side Note that oil pump assly is removed When loosening the special n...

Page 103: ...m fuel tank Disconnect stator plate harness Disconnect neutral switch coupler Remove Engine oil temp sensor screw B and disconnect the wire Remove sensor and gasket Drain bolt and drain out the oil fr...

Page 104: ...ove 2 nuts for silencer flange B Note Always remove the flange mounting first and then rear mounting to avoid misalignment of studs Using Special Tool Sprocket Holder 37 1030 53 Remove Bolts A Plate d...

Page 105: ...t needs deep socket for removing it 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 engin...

Page 106: ...t Asly Cyl Head with Cover 1 2 Cover Tappet 2 3 O Ring Kit for Cover Cyl Head 1 4 Silent Bush 1 5 Camshaft Cap 1 6 Domed Cap Nut 4 S N Description Qty 7 Copper Washer 4 8 Hex Bolt with Flange 2 9 Hex...

Page 107: ...er Head 1 4 Damper Cylinder Head 5 5 Intake Pipe 1 6 O Ring Intake Pipe 1 S N Description Qty 7 Carburettor Insulator 1 8 Clamp for Insulator 2 9 Hex Bolt Flange 2 10 Sleeve Spark Plug 1 11 Grub Screw...

Page 108: ...2 Rocker Arm Shaft Exhaust 1 Rocker Arm Shaft Exhaust OD 10 mm 1 3 Rocker Arm with roller 2 Rocker Arm without roller 2 S N Description Qty 4 Cotter valve 4 5 Seal valve stem 2 6 Valve Repair Kit 1 7...

Page 109: ...Driven 32 T 1 7 Collar cam Sprocket 1 8 Special camshaft washer 1 S N Description Qty 9 Hex Soc Head cap Bolt 1 10 Cam Chain 1 11 Cam chain Tensioner pivot Bolt 1 12 Tensioner Assly 1 13 Hex Bolt Flan...

Page 110: ...iston Assly Std 1 4 Ring Set Piston 1 5 Ring Snap 2 6 Cylinder Block Piston Assly 1 S N Description Qty 7 Oil Pipe Assly 1 8 Bolt Special 2 9 Gasket 4 10 Damper 6 11 Bolt dummy for Temp sensor 1 12 Wa...

Page 111: ...one on the cam chain wall and the other near the spark plug threading Using a thin sharp pointed tool pierce the O rings and remove them If required only Note Remove these only if the O ring protrusim...

Page 112: ...g A Remove Cylinder head securing head cover 2 bolts A B C Cylinder head securing head cover 4 bolts Cylinder head securing head cover 4 domed cap nuts 4 copper plated steel washers Note Improper tigh...

Page 113: ...Remove Allen bolt Spacer Cam sprocket Collar Cam shaft assly A Note Hold the cam chain up right using soft copper wire or thread Do not use cotton waste for holding the cam chain Remove Cylinder head...

Page 114: ...ing fitment Warning 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 o...

Page 115: ...er clutch 1 3 Gear starter clutch 1 4 Plate starter clutch gear return 1 5 Bolt 1 6 Shaft starter counter 1 7 Collar starter counter 1 8 Gear comp starter counter assly 1 9 Bolt socket 3 S N Descripti...

Page 116: ...21 00 Remove Hold the rotor assembly Rotor bolt Washer A Engine LH Magneto Side Using Special Tool Rotor Puller with butt pin 37 10DJ 32 Remove Rotor assembly Woodruff key A Pulsar 150 180 DTS i Servi...

Page 117: ...A Shaft Gear comp starter counter assly A B A Warning These components remain hot for a long time especially if removed from a hot engine Wear suitable hand protection to prevent burns Rotor puller ha...

Page 118: ...ick with O ring 1 7 Parallel pin 1 8 Gauge 1 9 Wire circlip 1 10 Bolt 10 11 Pin Dowel 2 12 Bracket Clutch Cable 1 S N Description Qty 13 Gasket cover RH 1 14 Plunger Oil 1 15 Plate Plunger Oil 1 16 Sp...

Page 119: ...ial Nut 1 2 Spring judder 1 3 Clutch Assly Complete 1 4 Clutch Center 1 5 Plate Clutch Pressure 1 6 Friction Plate Kit 1 7 Plate Clutch 5 8 Spring Clutch Capacity 4 9 Bolt 5 S N Description Qty 10 Bea...

Page 120: ...l out of their respective places into the oil collection tray If so ensure that these are collected accounted for before proceeding Remove 2 Dowels Clutch cover gasket Starter Motor B A Remove 1 screw...

Page 121: ...cial nut Belleville washer Body centrifugal oil filter assly Remove Bearing with plunger Using Sp Tool Special Nut Puller 37 10DJ 43 Using Sp Tool Primary Gear Holder 3710DJ28 Remove Input shaft speci...

Page 122: ...move Assly balancer idler gear 2 Washer Remove Bolt A Locking plate Body balancer gear assly A Remove Primary gear Square key Note Take care that square key does not fall inside the crankcase hollow p...

Page 123: ...iner 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 oi...

Page 124: ...hat all the crankcase joining bolts are removed and the sprocket cam drive with parallel pin on crankshaft assembly is removed B Remove 2 Shafts of gear shifter fork A B 3 fork shifts 1 small for inpu...

Page 125: ...Bearing Extractor 37 1030 68 Remove Needle roller bearing for output shaft assembly from crankcase RH B Crankcase Clutch Side Using Sp Tool Bearing Extractor 37 1030 72 Remove Bearing for drum change...

Page 126: ...aring stopper Bearing for gear change drum from crankcase A Magneto Cover Remove 2 phillips head screws A of Pulsar coil E mounting Bolts B of stator assembly 1 phillips head screws C of stopper Stato...

Page 127: ...ch friction Plate clutch Plate clutch pressure Wheel clutch Clutch housing Thrust washer conical from inner ID A B C D E F G Cylinder Head U s i n g S p T o o l V a l v e S p r i n g Compressor 37 103...

Page 128: ...r gear completely A C B D E C B A D Gear Complete Starter Counter Assembly Remove Place the gear comp starter counter assly on the arbor press as shown in the figure Using Bearing driver set P No 37 1...

Page 129: ...3 gear on output shaft Remove circlip and collect the washer Remove gear 2 driven mounted on bush with shoulder ring Slide out gear 5th driven A B C D E F G H I J K L N M st rd rd nd A B C D E F G H...

Page 130: ...aring 39 1880 20 Bigger Bearing using sp tool from camshaft assembly Small Bearing Washer A B C Gear Starter Clutch Remove Remove Place the gear starter clutch on arbor press as shown in photo Using B...

Page 131: ...em oil seals on valve guide Valve guide for crack if any Silencer mounting studs threads Ok No damage Oil gallery free from deposits Dummy plug threads intact Placement of shims between rocker arm and...

Page 132: ...mark Top Ring TOP 1 Second Ring TOP 2 Big end axial radial play As per Service data Run out As per Service data Threading condition Ok No damages Key way condition Ok No damages Big end bearing Free r...

Page 133: ...mbedded Colour change Signs of overheating if any No uneven wear pattern Conical face machining for spacer clutch Bearings Clutch No Wear marks on slots Clearance between clutch plate tangs and slot i...

Page 134: ...l 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...

Page 135: ...body threads intact Front free movement of push rod Push rod forward end cap rivet intact loose Groove for circlip fitment Free rotation of internal screw Rotor Chain Tensioner Carburettor Float Needl...

Page 136: ...sembly Use Bearing Driver set P No 37 1030 68 Fit Needle roller Bearing for Output Shaft Assembly Use Bearing Driver set P No 37 1030 74 Fit Bearing for drum change Crankcase LH Magneto Side Fit Use B...

Page 137: ...fitting the bearing for Input Shaft in Crankcase LH as this will damage the protruding lug of crankcase casting Sealed bearings must face crankcase side protruding lug side Use Bearing Driver set P No...

Page 138: ...es Magneto Cover 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 Pin...

Page 139: ...te Repeat the same procedure for fitment of other roller rocker A B C Cylinder Head Fit Valve steam seals Slide the valve from below Place the Valve Springs C D Inner Outer closed coiled ends placed a...

Page 140: ...Center Clutch Hub Belleville Washer Clutch Plate A 1 Nos Pressure Plate 5 Nos Clutch Plate B 4 Nos Clutch Plate C 1 Nos Wheel Clutch Springs 4 Nos Thrust Plate Bolt A B C Note Ensure concentricity of...

Page 141: ...other end of spring should but against the lug on Scissor Gear A C B D E CB A D Loading the assembly Balancer Idler Gear Using Sp Tool Balancer Gear Holder 3710DJ63 Using Special Tool Slide the Assemb...

Page 142: ...elease Washer Spring torsion clutch lever External lever Bolt Spring joint A F Plunger Plate E Plunger Plate E Plunger oil D 2 Dowel Pins Grommet M Oil feeler plug G Note Ensure fitment of set of damp...

Page 143: ...haft Gear 3 driven Spline washer Circlip Gear 4th driven Steel bush with shoulder ring Gear1st driven Thrust washer M J Gear 5th driven Circlip nd rd rd B C D E F G H J I K A A B C D E F G H I J K L M...

Page 144: ...to cut off any protruding Gasket This is very important for preventing any oil leakage from Crankcase and Cylinder Block Joint Don t apply grease any adhesive to Crankcase Gasket as these Gasket when...

Page 145: ...kurdi Pune Fit Spring Note a Apply Loctite 638 at Bolt Shift Change B if removed b Ensure free movement on Stopper Gear Shift in Bolt Shift Change Fit Body Balancer Gear Lock Bolt A Use Loctite 243 Fi...

Page 146: ...ody balancer assembly mark w r t crankcase mark Fit Clutch housing Note Ensure perfect matching of gear alignment marks w r to crankcase marks Refer the skill tips section for understanding procedure...

Page 147: ...Nut 37 10DJ 43 Fit Spacer Clutch Assembly Complete Washer Special Nut Note Special nut for input shaft has LH threads Fit Bearing with plunger Using Special Tool Primary Gear Holder 37 10DJ 28 and Cen...

Page 148: ...and reduces sealing efficiency Magneto Side Fit Shaft Starter Counter Gear complete starter counter assly Collar Note Always apply a thin layer of grease on to the roller bearing of gear complete sta...

Page 149: ...Dealer Development Center Akurdi Pune Fit Plate starter clutch return A Bolt Use loctite 243 B A B Using Special Tool Rotor Holder H6 0721 00 Washer Bolt Fit Top End Fit 2 Dowels Block Base Gasket Us...

Page 150: ...ide the piston assembly into cylinder Fit Note Apply thin layer of oil in cylinder bore and piston assly when sliding inside for ease in fitment Fit Head gasket 2 Dowels A Chain Guide Non tensioner si...

Page 151: ...e on the entry chambers for the O rings Fit Cam Shaft Collar Using Sp Tool 37 10DH 36 Cam Sprocket Special Washer Allen Bolt Fit Note Ensure the sprocket marks A are aligned horizontally with cylinder...

Page 152: ...permanently Fit Cam Shaft Cap 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 mor...

Page 153: ...pment Center Akurdi Pune Fit Tappet cap with O ring Fit 2 Dowel Gasket Note Always ensure that the piston is at the end of compression stroke and T mark on rotor is in line with the crankcase mark Whe...

Page 154: ...tput Sprocket holder 37 1030 53 Bush Sprocket Plate drive sprocket 2 bolts Use loctite 243 Fit Fit Oil pipe Copper gasket Banjo bolt A Bolt B A B Notes Pulsar 150 180 DTS i Service Station Manual 150...

Page 155: ...ip 4 6 Gear 3rd drive 1 7 Gear 5th drive 1 8 Gear 2nd drive 1 9 Plain washer 1 10 Shaft output transmission 1 11 Washer thrust 2 12 Gear 3rd driven 1 S N Description Qty 13 Plain washer 1 14 Gear 4th...

Page 156: ...ed between first gear and Output shaft Third gear is freely rotating on Output splines Forth gear is fixed but sliding on Output Shaft splines Fifth gear is fixed but sliding on Output Shaft splines F...

Page 157: ...utch Input Shaft Output Shaft Final Drive to the Rear Wheel 2 Gear Input 2 Gear Output 5 Gear Output nd nd th 1 4 5 3 3 2 1 4 2 5 Third Gear Position When Third Gear is engaged power from clutch flows...

Page 158: ...the Rear Wheel Clutch 3 Gear Input 5 Gear Input 5 Gear Output rd th th Forth Gear Position When Forth Gear is engaged power from clutch flows as follows Input Shaft Output Shaft Final Drive to the Re...

Page 159: ...Pune ENGINE LUBRICATION FLOW OF OIL OIL STRAINER OIL PUMP CLUTCH COVER INLET CENTRIFUGAL FILTER CRANKSHAFT CLUTCH COVER OUTLET RHS CRANKCASE TOP RHS C CASE THROUGH HAAD STUD CAMSHAFT ROCKER ARM CYLIND...

Page 160: ...Pulsar 150 180 DTS i Service Station Manual 156 Dealer Development Center Akurdi Pune Notes...

Page 161: ...spension SOP for Front Fork Dust Seal Oil Seal Replacement SOP for Steering O H Dismantling Assembling Front Fairing SOP for Swing Arm Replacement SOP for Caliper Piston Seal Dust Seal Replacement SOP...

Page 162: ...cc Pulsar 180 cc 1 8 2 0 1 8 2 0 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc 7 0 8 0 NA Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc 2 0 2 2 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc...

Page 163: ...r 180 cc 2 2 2 8 2 2 2 8 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc RSA Mounting Dome Nut 3 5 4 0 3 5 4 0 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc Brake Disc Allen Bolts 2 6 3 2 Loctite...

Page 164: ...d Limit 3 8 3 8 Service Limit Pulsar 150 cc Pulsar 180 cc Axial Wheel Run Out Standard Limit TIR 2 0 TIR 2 0 Service Limit Pulsar 150 cc Pulsar 180 cc TIR 1 0 or Less TIR 1 0 or Less Radial Wheel Run...

Page 165: ...ree Length Free Length Tyre Tread Depth Front 5 0 Rear 6 8 Front 5 0 Rear 7 3 Standard Limit Front 1 0 Rear 1 5 Front 1 0 Rear 2 0 Service Limit Pulsar 150 cc Pulsar 180 cc Fork Oil Level For 150 CC 2...

Page 166: ...Pulsar DTSi UG III Drawing No Application 37 1740 05 Used for holding the fork piston from inside Fork Holder Drawing No Application 37 1740 03 To fit fork oil seal on outer pipe Fork Oil Seal Fitmen...

Page 167: ...earing race from T Common bearing driver set for fitting and removing bearings from crankcase For adjusting the notch position of RSA to achieve hard or soft rear suspension Application Notes Pulsar 1...

Page 168: ...er Clamp the speed sensor cable s in a grommet of the metallic bracket Speed Sensor Cable Pulsar 150 180 DTS i Service Station Manual 164 Dealer Development Center Akurdi Pune k Ti l k bln T g Ap D s...

Page 169: ...clip Pass the clutch cable through clutch cover bracket adjuster Clutch Cable Pulsar 150 180 DTS i Service Station Manual 165 Dealer Development Center Akurdi Pune k c k bl klc k bln r T g fi Ti gi f...

Page 170: ...able through the engine top end inserted in foundation bracket clamp Accelerator Cable Pulsar 150 180 DTS i Service Station Manual 166 Dealer Development Center Akurdi Pune a ks l Tr k bl a ks l Tr k...

Page 171: ...s Cap Circlip Piston Ring Piston Rebound Spring Piston Rod Inner Tube Cover Cap Air Hose Valve Assly Outer Spring Oil Seal Rod Guide Bump Stopper Adjuster Canister Upper Chamber Lower Chamber Working...

Page 172: ...s shown and pierce the syringe needle into the center of rubber plug The molded needle adaptor will rest into the clamped cylindrical guide Read the gas pressure on the dial gauge If the gas pressure...

Page 173: ...der Comp Fork 2 9 Pipe Comp Suspension Inner 2 10 Slide Bush 2 11 Spring Washer 2 12 Bolt 2 13 Spring Front Fork 2 14 Grommet Top 2 S N Description Qty 15 Bolt Fork 2 16 O Ring 2 17 Seat Fork Spring 2...

Page 174: ...g spanner b Remove bolt holding front axle firmly on outer tube by 13mm ring spanner c Take out front axle Pulsar 150 180 DTS i Service Station Manual 170 Dealer Development Center Akurdi Pune f T b k...

Page 175: ...LH RH side securing front fender by 12mm ring spanner take out front fender assembly Remove allen bolt of upper bracket by 6mm allen key under bracket bolt by 17 mm ring spanner Take out the front fo...

Page 176: ...bush oil seal extraction special tool on fork inner pipe as per sequence shown in photograph Pulsar 150 180 DTS i Service Station Manual 172 Dealer Development Center Akurdi Pune Ap Sr Ty b vi Sr an...

Page 177: ...len bolt by 6mm allen key Remove outer tube by rotating special tool in clock wise direction Remove fork inner pipe from under bracket take out the special tool as shown in photograph Pulsar 150 180 D...

Page 178: ...Hold fork leg assembly assemble anti friction bush washer oil seal as shown in photographs Assembling Pulsar 150 180 DTS i Service Station Manual 174 Dealer Development Center Akurdi Pune f T fi k ai...

Page 179: ...ool and insert the snap ring and dust seal Fill recommended quantity of fork oil 320 2 5ml and insert spring washer spacer tube Initially hand tighten the fork bolt by pressing it and then fully tight...

Page 180: ...rvice Station Manual 176 Dealer Development Center Akurdi Pune S N Description Qty 1 Frame Assly Comp 1 2 Cup Rear 2 3 Nut 1 4 Cup Steering 1 5 Bearing Cone Kit 1 Kit St Cone with RR3 Grease 1 6 Ball...

Page 181: ...L assembly with speedometer Remove harness brake hose clamping bracket Pulsar 150 180 DTS i Service Station Manual 177 Dealer Development Center Akurdi Pune SOP AT yr g ai vrai l p T i l T k kvr kiQ...

Page 182: ...caliper assembly Remove Front Axle Remove front fender Remove center bolt Pulsar 150 180 DTS i Service Station Manual 178 Dealer Development Center Akurdi Pune f T k l pr a s blk n Ki li aigLn a ksl...

Page 183: ...Carry out greasing steering ball replacement activity Upper race 19 balls Lower race 20 balls Pulsar 150 180 DTS i Service Station Manual 179 Dealer Development Center Akurdi Pune fi k ni s T l bi Tn...

Page 184: ...OVERHAUL Fit the upper lower cones by using special tools Notes Pulsar 150 180 DTS i Service Station Manual 180 Dealer Development Center Akurdi Pune AT ar g ai vr ai l SOP upr an n c n ki nn Ap Syl...

Page 185: ...1 3 Wind Shield 1 4 Bolt M 5 4 5 Non Metallic Washer 4 6 Well Nut 4 7 Decal Wind Shield 1 8 M5 X 15 Mushroom HD 2 9 Packing Fairing 1 S N Description Qty 10 Fairing Mounting Upper Bracket 1 11 Kit Har...

Page 186: ...ber Remove 2 bolts 2 washer Remove 6 screws B CAUTION Keep the visor at good location to avoid scratches A B Pulsar 150 180 DTS i Service Station Manual 182 Dealer Development Center Akurdi Pune D sm...

Page 187: ...ad light fairing assembly Remove Couplers for speedometer Couplers indicator Speedometer complete Pulsar 150 180 DTS i Service Station Manual 183 Dealer Development Center Akurdi Pune kiQi an bi T Ki...

Page 188: ...the speedometer coupler Fairing assembly Fit 2 bolts Holding with lamp shade LH RH Fit 6 screws Pulsar 150 180 DTS i Service Station Manual 184 Dealer Development Center Akurdi Pune f T krv f T kri l...

Page 189: ...s Fit 2 Number plate holding bolts Number plate with damper rubber Fit Visor 4 screws Pulsar 150 180 DTS i Service Station Manual 185 Dealer Development Center Akurdi Pune f T kri 2 bi T 2 vi Sr f T k...

Page 190: ...r Shock Absorber 2 2 Bolt Pre coated 2 3 Kit Bush Rear Shock 1 4 Swing Arm Assly 1 5 Bush Swing Arm 4 6 Collar Swing Arm 2 7 Dust Seal Swing Arm 4 8 U Nut Swing Arm 1 9 Shaft Swing Arm 1 S N Descripti...

Page 191: ...Holder LH Step 1 2 Holder RH Step 1 3 Pillion Step Assly Comp LH 1 4 Pillion Step Assly Comp RH 1 5 Rubber Pillion Step 2 6 Kit Hardware Pillion 2 7 Hexagonal Head Screw 2 8 Nut 1 S N Description Qty...

Page 192: ...condition or else may cause injury burn Remove Circlip Nut Torque link rod Remove Brake rod nut Brake rod Distance piece Spring Pulsar 150 180 DTS i Service Station Manual 188 Dealer Development Cente...

Page 193: ...emove Bolt Remove Swing arm RH side nut Remove Step holder RH complete Pulsar 150 180 DTS i Service Station Manual 189 Dealer Development Center Akurdi Pune SOP Av g aim bdlvi miT kiQi r ar b k Av c k...

Page 194: ...e Bolt Gear pedal yoke Remove 2 bolt Chain cover Remove Bolt Remove Allen bolt Pulsar 150 180 DTS i Service Station Manual 190 Dealer Development Center Akurdi Pune kiQi bi T g ar p Dl ci k kiQi 2 bi...

Page 195: ...hain adjuster assembly from LH RH side Rear sprocket Distance central Distance LH Pulsar 150 180 DTS i Service Station Manual 191 Dealer Development Center Akurdi Pune SOP Av g aim bdlvi miT kiQi c en...

Page 196: ...arm Step holder LH Remove Guide the chain out Swing arm Bush LH RH Pulsar 150 180 DTS i Service Station Manual 192 Dealer Development Center Akurdi Pune SOP Av g aim bdlvi miT kiQi bi T RSA LH RH kiQ...

Page 197: ...Clamp the wiring harness at the lamp shade clamp for both side wiring harness respectively as shown in the photograph Pulsar 150 180 DTS i Service Station Manual 193 Dealer Development Center Akurdi P...

Page 198: ...LH side long member of frame at two locations shown Clamp the fuse box as shown in photograph Pulsar 150 180 DTS i Service Station Manual 194 Dealer Development Center Akurdi Pune SOP Av g aim bdlvi m...

Page 199: ...aph Position of main fuse box Body earthing of starter motor DC electrical system Pulsar 150 180 DTS i Service Station Manual 195 Dealer Development Center Akurdi Pune viyrn s hirn s T g AT Tr l T viy...

Page 200: ...er motor cable clamp it with the band as shown in the photograph Notes Pulsar 150 180 DTS i Service Station Manual 196 Dealer Development Center Akurdi Pune viyr g hirn s T g ATiT r mi Tr k bln fi Ti...

Page 201: ...g banjo bolt then remove caliper assembly from fork mounting location Remove the allen bolt of LH caliper Remove both brake pads Pulsar 150 180 DTS i Service Station Manual 197 Dealer Development Cent...

Page 202: ...essure 2 bar This could cause piston to fly out from caliper body causing damage to it any one in the vicinity Pulsar 150 180 DTS i Service Station Manual 198 Dealer Development Center Akurdi Pune SOP...

Page 203: ...s Insert piston into caliper bore Clean the anchor pin holder bracket thoroughly Pulsar 150 180 DTS i Service Station Manual 199 Dealer Development Center Akurdi Pune k l pr a s bl ni mi Ti nini piT s...

Page 204: ...brake pads by smooth emery paper Fit brake pads allen bolt into the LH caliper RH caliper Pulsar 150 180 DTS i Service Station Manual 200 Dealer Development Center Akurdi Pune a kr p n upr s l ki n g...

Page 205: ...tain oil level above MIN mark Re fit rubber diaphragm reservoir cap Check brake effectiveness Drive the vehicle confirm brake effectiveness Pulsar 150 180 DTS i Service Station Manual 201 Dealer Devel...

Page 206: ...ake fluid from caliper assembly by loosening air bleeder screw using transparent PVC tube which will avoid spillage of brake fluid on caliper body disc pads also powder coating peel off inefficient br...

Page 207: ...master cylinder by loosening banjo bolt Insert blunt tipped screw driver or steel spoke from banjo bolt side push piston towards brake lever Ensure master cylinder does not get damaged due to screw d...

Page 208: ...ke fluid Dry master cylinder by compressed air Fit master cylinder on handle bar Smear silicon grease on new piston seals of master piston kit Insert piston assembly from brake lever side into master...

Page 209: ...nsert protection boot correctly so that dust will not enter Refit the brake lever front brake switch Use new copper washers fit hose pipe by tightening banjo bolt Pulsar 150 180 DTS i Service Station...

Page 210: ...t rubber diaphragm reservoir cap Check brake effectiveness Drive the vehicle confirm brake effectiveness Note Use DOT 3 brake fluid from a sealed container Ensure no leakage of brake fluid through bra...

Page 211: ...fluid from caliper assembly by opening air bleeder screw Remove the hose pipe fitment banjo bolt from both ends master cylinder caliper assembly Replace the hose pipe as well as copper washers fitted...

Page 212: ...OR FRONT BRAKE HOSE REPLACEMENT Route the front brake hose as shown in photographs Conduct the brake bleeding procedure Pulsar 150 180 DTS i Service Station Manual 208 Dealer Development Center Akurdi...

Page 213: ...rain brake fluid from caliper air bleeder bolt Tighten the air bleeder bolt on caliper assembly Remove reservoir cover by removing 2 nos phillips head screws Remove PVC cap rubber diaphragm Pulsar 150...

Page 214: ...loosen the bleeder screw by the ring spanner e Press the bellow of the Siphon pump in its valve open position Then close the valve of the pump and release the bellow Simultaneously press the brake lev...

Page 215: ...slightly above the minimum mark For drum brake vehicles check and adjust front brake lever free play It should be 4 5 mm for all motorcycles Ensure front wheel is rotating freely Note Use DOT 3 brake...

Page 216: ...Pulsar 150 180 DTS i Service Station Manual 212 Dealer Development Center Akurdi Pune Notes...

Page 217: ...edure Starter Motor Battery Dos Don ts SOP for Checking Battery Charge Condition Dos Don ts Electrical Circuit Diagrams 213 el kT kl b Tr el kT kl c k g p Ft ATiT r mi Tr b Tr kri ni kri b Tr ciJ g k...

Page 218: ...ndividual cell can be checked by measuring Sp gravity of electrolyte in that cell The specific gravity of electrolyte can be checked by using Hydrometer having small diameter spout For measuring the S...

Page 219: ...battery on load conditions Top up level with distilled water to max level when the electrolyte level is less than half of min max level Connect battery to charge ensure respective terminal are connec...

Page 220: ...tteries 2 5Ah 5Ah 7Ah 9Ah Constant current type having 0 25 Amp 0 5 Amp 0 7 Amp 0 9 Amp current settings 6 Channel Battery Charger Pulsar 150 180 DTS i Service Station Manual 216 Dealer Development Ce...

Page 221: ...harging and scrap the battery If there is no bad battery indication then continue charging till charging is over Again test battery condition using PBT 50 load tester If result is OK then put the batt...

Page 222: ...ar brake light switch by depressing the brake pedal If it does not operate as specified adjust the brake light switch or check the switch Pedal Pressed Pedal Released Brown Blue Ignition Switch OFF ON...

Page 223: ...e does not match as per specifications replace the coil If the meter reads as specified the ignition coil windings are probably good However if the ignition system still does not perform then check sp...

Page 224: ...spect the fuse element If it is blown out replace the fuse If a fuse fails during operation the electrical system to determine the cause and then replace it with a new fuse of proper amperage Clutch S...

Page 225: ...tions Starter Relay Coil Black Wire Meter ve Standard Value SOP Switch OFF engine Connect multimeter to Starter Relay coil terminals Check resistance Disconnect coupler from Relay Measuring Testing Eq...

Page 226: ...ries with the circuit while conducting above test DC Charging Voltage Measurement Use fully charged battery while measuring To measure the DC voltage set the meter at 20VDC range Connect the meter ve...

Page 227: ...2 8 Liter 67 77 Ohm 2 Bars Just Above Reserve 3 5 Liter 58 62 Ohm 3 Bars Half Tank 4 5 Liter 36 44 Ohm 4 Bars Full Tank 8 5 Liter 6 10 Ohm 6 Bars Full Tank Note Before checking the above please confi...

Page 228: ...ignal Side stand on indication Additional battery charge status indication system is provided The glowing of this icon indicates as drops during cranking Low Battery Voltage Please ignore battery icon...

Page 229: ...ut is equivalent to that of a bulb With this tail LED lamp battery discharge possibility is very minimum in case of a brake switch short condition When you operate light control switch to glow the int...

Page 230: ...CDI H T Coil Checking Hang the unit on leg guard of the vehicle Remove Spark Plug cap connect to suitable terminal S1 S2 on the unit Connect Red probe of the unit to HT coil primary terminal Connect B...

Page 231: ...B Y Br Violet Light Control Module Y Br Or B Y Br Violet I P from magneto Earthing Flasher circuit Flasher circuit 12VDC from battery I P to H L switch Measuring Testing Equipment Multimeter SOP Switc...

Page 232: ...eed sensor magnetic ring must be max 4 mm min 0 5 mm Ensure intact condition of O Ring for speed sensor Use correct size O Ring in case of replacement Vehicle Speed Sensor 1 Set multimeter to 20 VDC 2...

Page 233: ...e Adjacent segment on commutator Meter Range Continuity is shown Any segment on commutator Connections Meter ve Meter ve Standard Value Measuring Testing Equipment DC Clamp Meter Starter Motor Current...

Page 234: ...mutator slots Clean commutator segments Lubricate brass bush by 2 3 drops of Servo 32 oil NR Bearing by high temperature high speed OKS410 grease Check as per SOP the continuity between 2 adjacent seg...

Page 235: ...er Remove carbon particles from commutator slots by sharp blade knife Clean commutator segments by soft cloth Lubricate brass bush by 2 3 drops of Servo 32 oil NR Bearing by high temperature high spee...

Page 236: ...er battery terminals Do not increase the level of electrolyte beyond maximum level mark otherwise it would over flow through Vent Mechanism damage other parts Battery Pulsar 150 180 DTS i Service Stat...

Page 237: ...ity 3 Use midtronics battery tester for checking battery charge condition 3 7 Do not short circuits the poles 7 Do not fit extra electrical accessories Tampering of wiring for fitting buzzer etc other...

Page 238: ...ct polarities Connect ve ve wire clamps of Battery to ve ve terminals of the Battery tester SOP for Checking Charge Condition of Battery Pulsar 150 180 DTS i Service Station Manual 234 Dealer Developm...

Page 239: ...Push TEST button for checking condition of battery tester Voltage indication Green LED is glowing Battery is OK can be used on vehicle Pulsar 150 180 DTS i Service Station Manual 235 Dealer Developme...

Page 240: ...arger Voltage indication red LED is glowing Battery is deep discharged Charge battery on Metafab VRLA battery charger for 30 minutes If battery can not be charged BAD battery indication will be displa...

Page 241: ...fully charged Ensure that horn switch button is operating freely Ensure that horn wires are intact Don ts 7 Do not hit by mallet screw driver on horn resonator Never remove resonator cap as it could r...

Page 242: ...removal and re installation of spark plug During periodic service make use of spark plug cleaning machine to clean spark plug electrodes check proper functioning of both the spark plugs Dos 3 Do not r...

Page 243: ...s 3 Don ts 7 SWITCHES After washing the vehicle ensure to apply dry air on switches before operation Always ensure that grommets provided on clutch switch front brake switch and rear brake switch are...

Page 244: ...L KILL SWITCH Br L Gr R Y G STARTER MOTOR CABLE ASSY RELAY TO STARTER MOTOR R W ENGINE OFF ON TRANSIL DIODE Lg R W Lg Lg Y G Horn Circuit O F F O N Br L W W Br IGNITION SWITCH W HORN B Br FUSE 1 15 A...

Page 245: ...WITCH REAR BRAKE SWITCH TAIL LAMP ASSLY Stop LED Battery Charging Circuit L W L W B Y W L W L W BATTERY MF 9Ah W L W L W B Y R R UNIT EARTH FRAME B Y FUSE 15 Amps CAPACITOR B W B W B W MAGNETO ASSLY B...

Page 246: ...FUSE 1 15 Amps O F F O N Br L W W Br IGNITION SWITCH R W L W VEHICLE SPEED SENSOR B Y Br L W W B BATTERY MF 9Ah DIGITAL SPEEDOMETER Gr R R W L W W Br L Gr R KILL SWITCH Br L Gr R W Br L L W W Br R W O...

Page 247: ...OMMON GROUND SEALED COUPLER TWIN BOX ASSY Gr R B Y W Y BATTERY MF 9Ah ENG OFF ENG ON Ignition Circuit ELECTRICAL CIRCUIT DIAGRAMS LHS SPARK PLUG DC C D I ASSY B B H T COIL 1 H T COIL 2 B R TPS B Y B R...

Page 248: ...Br G G Br L W W Br Gr Gr TURN SIGNAL SWITCH SIGNAL LAMP REAR LH LAMP 12V 10W SIGNAL LAMP REAR RH LAMP 12V 10W LIGHT CONTROL MODULE SIGNAL LAMP FRONT LH LAMP 12V 10W IGNITION SWITCH SIGNAL LAMP FRONT...

Page 249: ...MODULE V Br B Y L W B Y L W Br V Br L Gr R Gr R KILL SWITCH B Y Br W R LED CONTROL Br L Gr R B Y Br W MAGNETO W W Br L V R R ON R W ENG OFF Gr R L W L W B Y W W L W L W CAPACITOR W W DC REGULATOR ASS...

Page 250: ...Pulsar 150 180 DTS i Service Station Manual 246 Dealer Development Center Akurdi Pune Notes...

Page 251: ...Diagnosis Troubleshooting 247 p iblm Si Fvi an t n nrikrN...

Page 252: ...rouble shooting refer trouble shooting encyclopedia uploaded on portal Troubleshooting Encyclopedia DIAGNOSIS AND TROUBLESHOOTING Pulsar 150 180 DTS i Service Station Manual 248 Dealer Development Cen...

Page 253: ...Bajaj Auto Limited Akurdi Pune 411 035 India Tel 91 20 2 Fax 91 20 2 7472851 7407385 b j ai Ti l m T D aik D p ni 4110 035 Birt...

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