Pulsar DTS-i 180 UG III Training Manual Download Page 12

Dealer Development Center

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Dealer Development Center

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Note :

 

It is advisable that brake fluid should be replenished 

once 

in a year.

 Spark Plug

Recommended Spark Plug

Champion RG4HC / Bosch UR3DC

Electrode Gap

0.7 ~ 0.8 mm

Replace Spark Plug

After every 10000 Kms.

 Battery - 12V - 9 Ah

• Battery is located inside LH cover
• Check the electrolyte level in each cell and ensure that the level is 

between the upper and lower level lines.

• Remove the battery filler caps and fill with distilled water until the 

electrolyte level in each cell  reaches the upper level line if 

required.

• Apply petroleum jelly on to the terminals

 Front Brake Fluid Level

• Front brake fluid master cylinder reservior is located near RH 

switch on handle bar.

• To check oil level, park the vehicle on Main / Center stand with 

handle bar in straight position.

• Always ensure that brake fluid level is above ‘MIN’ mark given on 

inspection window.

• Use only DOT-3 or DOT-4 brake fluid (from sealed container) to 

top up if required. 

Note :

 

Add only distilled water to the battery. Tap water is not a 

substitute for distilled water and will shorten the life of the 

battery.

 Rear Shock Absorber

The rear shock absorbers can be adjusted to one of five positions to 

suit riding conditions. Using special tool adjust the required position 

you desire. They can be left soft for average road riding condition 

but should be adjusted harder for rough road condition.
Shock Absorbers adjusted either too soft or too hard adversely affect 

riding comfort and stability.

To adjust the Rear Shock Absorbers

Turn the adjusting sleeve on each shock absorber to the desired 
position. The higher the adjuster sleeve is positioned, the stronger 
the spring tension, and the harder the ride.
Check to see that both sleeves are turned to the same relative 

position.

Pulsar DTS-i UG-III-180cc 

Training Notes

Pulsar DTS-i UG-III-180cc 

Training Notes

 Nitrox Air Filling

Procedure for gas checking and Refilling
• Remove the Phillips-headed small screw and ‘O’ ring.

• Clamp the cylindrical guide clamp on to the canister keeping the 

rubber plug in the center to support the syringe needle insertion 

and keeping in position.

• Hold the pump as 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 is 

below 6.5 Kg/cm2 refill the air by pumping, keeping the needle in 

as it is condition without removal. As the natural air consists of 

71% of nitrogen it will serve the purpose.

• To fill the air into the canister, apply full stroke of pump as 

shown; otherwise air will not get inflated into the pump.

• Keep on pumping the air unless you get 7.5 kg/cm2 on the gauge

• Pull out the air pump along with needle carefully and take out the 

guide clamp

• Finally fix the phillips headed screw with ‘O’ ring.

 Drive Chain Slack / Lubrication

• Set the motorcycle upon its center stand.
• Rotate the rear wheel to find the position where the chain is 

tightest & measure the vertical movement midway between the 

sprockets.

• If the drive chain is too tight or too loose, adjust it so that the 

chain slack will be within the standard value.

• Check drive chain slackness at every 1000 kms.

Drive Chain Slackness : 25 ~ 30 mm

Service Limit 35 ~ 45 mm

If the Shock Absorber sleeves on both sides are not adjusted 

to the same position, an unsafe riding condition may result.

Position
Spring Action

1

2

3

4

5

Stronger

Note :

 Std setting is done in 

 notch

2nd

Schedule Maintenance

Schedule Maintenance

Summary of Contents for DTS-i 180 UG III

Page 1: ...g and Roller rocker with NR bearing for friction reduction that improves drivability LED tail lamp that consumes negligible power require zero maintenance Stainless steel silencer that overcomes rusti...

Page 2: ...5 kW 16 51 Ps at 8000 rpm Max net torque 15 22 Nm at 6000 rpm Ignition System Microprocessor controlled digital C D I 0 Ignition Timing 10 BTDC at 1500 rpm 0 28 BTDC at 3500 rpm Fuel Unleaded petrol C...

Page 3: ...Apart from refining the power delivery it is loaded with the features that are meant for cars So here is the Comfort Convenience Safety of the 4 wheels cars available on 2 wheels B The major changes f...

Page 4: ...turn Will it work in such situation B Yes Of course When the rider selects a right or left turn indicator but changes his mind and physically do not take a turn the indicators turn OFF automatically...

Page 5: ...one of the Head light filament blows OFF then there is a possibility of an accident due to sudden darkness To rescue here the BSU plays an important role It switches over the Headlight to the other b...

Page 6: ...smooth operation of fuel cock lever Check and correct tyre inflation pressure Front Wheel Check front brakes for efficient working Adjust if required Check clutch cable operation Adjust if required Ch...

Page 7: ...000 kms 4 Engine oil SAE 20W50 of API SG JASO MA R l l Every 5000 kms 5 Oil strainer Centrifugal filter CL Every 10000 kms 6 Air cleaner element V CL l l l l l 7 Air cleaner element R Every 10000 kms...

Page 8: ...22 24 27 Ring Spanner 10 11 14 15 OE Spanner Cloth Graphite Grease Fine Polish Paper Air Gun Periodic Service SOP Periodic Service SOP Description LH RH Side SMM GP Tools Special Tools Consumables M...

Page 9: ...as required 10 00 42 50 Total SMM Expected Production 480 minutes Man 11 35 Test Ride of the Vehicle if required and park 1 5 To be Carried out by Expert 36 Clean the vehicle at the time of delivery 1...

Page 10: ...vehicle life trouble free running and ensure your safety while driving Engine Oil Level Checking Park the vehicle on level surface on center stand to check the oil level Inspect the oil level through...

Page 11: ...i UG III 180cc Training Notes 1st Stage Clean with Kerosene Squeeze Clean with Kerosene Again Blow Low Pressure Compressed Air 3rd Stage Dip into Engine Oil 20W40 Squeeze and Remove Excess Oil Dry wit...

Page 12: ...oned the stronger the spring tension and the harder the ride Check to see that both sleeves are turned to the same relative position Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc...

Page 13: ...th the mark on the Crankcase LH At this stage the Piston is at TDC and both the Tappets are free Holding tappet screw firmly with special tool loosen the tappet Remove the Bolt Plug near Exhaus TEC Co...

Page 14: ...ount of free play can be obtained Tighten the lock nut B against the adjuster If the accelerator free play can not be adjusted with the adjuster at the handle bar end use the adjuster at the lower end...

Page 15: ...until the rear brake pedal have the correct amount of play Rear Brake Pedal Play 25 30 mm B A B A Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes Compression Pressur...

Page 16: ...t or spongy feeling brake C D Warning Tighten the bearing carrier nut before tightening the axle nut If the nut tightening order is reversed the rear axle will not be securely mounted on the swing arm...

Page 17: ...Training Notes Pulsar DTS i UG III 180cc Training Notes Camshaft Big Bearing Puller Drawing No 37 10DH 32 Application To remove bearing Decompression assembly side of camshaft Camshaft Small Bearing P...

Page 18: ...aring race from T Note Existing tool can be used by reducing diameter to 25 9 0 1 mm Dia 25 9 0 1 Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes Bearing Extractor Dr...

Page 19: ...or fitting and removing bearings from crankcase 37 1030 61 Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes Chassis Fork oil seal fitment punch Drawing No 37 0040 03 A...

Page 20: ...rward direction to remove it from the lug Remove Side cover LH and RH by unlocking it with key Remove Pull the cable from the cover LH to unlock the seat lock Seat assembly Note To remove the seat ass...

Page 21: ...re of dismantling But take care that the vent hole is free from any foreign particles that may clog the hole To lock the fuel tank cap just press the cap without key Fuel Cock Removal Remove 2 bolts A...

Page 22: ...Chamber Towards Engine 1 Plunger 2 Mixing Chamber 3 Starter Jet Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes 1 Pilot Jet 2 Pilot Outlet Hole 3 Butterfly Valve 4 V...

Page 23: ...by lifting up the piston valve in direct proportion to the engine demand This assures the correct venture size air velocity throughout the mid range operation of the engine Construction This circuit c...

Page 24: ...igntion timing for part throttle loads and full throttle loads there are separate igntion maps stored in the memory of the CDI These are activated depending on the throttle opening and engine speed Th...

Page 25: ...1400 100 engine rpm Item Pulsar 180cc Make Ucal Mikuni BS 26 Identification No DJ U3 Type CV Type Idling Speed 1400 100 VC Screw Setting 2 5 2 turns out Main Jet 117 5 Jet needle mark 4DHL42 Needle je...

Page 26: ...ville Washer Plain Washer Clutch Hub Fit primary gear drive A The mark teeth of the primary gear should match with the line mark on the c case This indicated that the piston is at TDC position This pr...

Page 27: ...t B Drive sprocket cover LH Using Special Tool Sprocket Holder 37 1030 53 Remove Bolts A Plate drive sprocket Drive sprocket along with the chain Neutral switch coupler B A A B A Recommended Oil Grade...

Page 28: ...Loosen and unscrew the allen head grub screw of the sleeve spark plug Remove Loosen bolt A and unscrew chain tensioner plunger Cam chain tensioner assembly 2 bolts B Cam chain tensioner assembly Remov...

Page 29: ...in Remove Cylinder head assembly 2 dowels Gasket cylinder head Remove Non tensioner side chain guide Cylinder block assembly Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training...

Page 30: ...Screw A Guide starter assembly along with oil seal Engine RH Clutch Side Remove Kick starter bolt Kick starter Warning The oil pump may be hot hence use suitable hand protection Also since the oil pum...

Page 31: ...filter cover Gasket Warning These parts may be hot if removed from a hot engine Use gloves for protection Note Some amount of oil is trapped in cover and body of centrifugal oil filter this oil should...

Page 32: ...move Gear change lever A A Pulsar DTS i UG III 180cc Training Notes Pulsar DTS i UG III 180cc Training Notes Remove Bolt B on LH side crankcase Magneto side Remove Kick spring 2 Shafts A B of gear shi...

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