Power Up the Jig
The Jig should carry out a self test, where first all Red LED; glow
sequentially and then all Green LED; flash twice.
Manual Testing
• Connect wiring harness to C1 connector.
• Through this harness the following testing can be carried out :
- Vehicle sensor speed.
- Hall sensor.
- Starter relay.
Dealer Development Center
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Dealer Development Center
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Piston Ring Fitment :
• Piston rings must always be fitted with respect to exhaust mark on the
piston.
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• First place the bottom oil rail ring with end gap 28 towards left of the
exhaustmark in the last groove.
• Place oil expander ring with butting end downward and end gap facing
opposite to the exhaust mark.
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• Now fit top oil rail ring on the expander ring with end gap 30 towards
right of the exhaust mark.
• Fit the second piston ring with ‘Top 2’ mark facing upward and end gap
facing opposite to the exhaust mark.
• Finally fit the first ring with ‘Top 1’ mark upward and end gap facing
towards the exhaust mark.
• Remember fitment of 2nd ring upside down may lead to passing of oil
above the piston and ultimately leading to smoky exhaust.
• Tighten both chain adjuster lock
nuts.
• Tighten the sleeve nuts securely.
• Center the brake panel assembly in the brake drum. This is done by
tightening the axle nut lightly, spinning the wheel, and depressing the
brake pedal forcefully. The partially tightened axle nut allows the
brake panel assembly to center itself within the brake drum.
• Tighten the Axle Nut
• Tighten the torque link nut
• Fix the snap ring
• Adjust the correct brake play
Note :
This procedure can prevent a soft 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.
This may cause misalingment of the
wheels and result in loss of control.
Pulsar DTS-i UG-III-180cc
Training Notes
Pulsar DTS-i UG-III-180cc
Training Notes
Nitrox Air Filling
• Remove the Phillips head screw & small ‘O’ ring fitted on air valve
of Nitrox RSA.
• Fix the guide to canister of Nitrox shocker in such a way that
guide hole is concentric with air filling valve.
• Insert the Nitrox air filling pumps needle end into the guide &
carefully pierce the rubber pin fitted inside the air valve of Nitrox
RSA.
• Note the pressure indicated by pressure gauge of Nitrox air pump.
Refill the pressure.
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• Once the pressure reaches upto 7.5 Kg/cm , take out the needle
slowly from canister.
• Fit the Phillips head screw & small ‘O’ ring fitted on air valve of
Nitrox RSA.
Air Bleeding of Disc Brake System :
For air bleeding from front Hydraulic brake system first top up the
master cylinder with hydraulic oil.
Operate the brake lever slowly in order to get filled the oil in the
circuit.
Connect transparent tube to the bleeder screw at caliper
Operate the brake lever and keeping in pressed position loosens
the bleeder screw so that some oil escapes with the air bubbles.
Keep on operating the brake lever till the air bubble escape out
completely through bleeder screw, and top up the master cylinder
if required.
Once the air escapes out from the hose pipe the brake lever meets
resistance, which indicates completion of air bleeding
After completing the bleeding, top up the master cylinder up to the
maximum level mark.
Standard Checking Procedure
Standard Checking Procedure
