Pulsar DTS-i 180 UG III Training Manual Download Page 3

Frequently Asked Questions (FAQ’s)

Dealer Development Center

6

Technical Specifications

Dealer Development Center

5

Fuel Tank Capacity

: 15 liters Full
: 3.2 liters Reserve
: 2.0 liters Usable reserve

CONTROLS

Steering

: Handle Bar

Accelerator

: Twist grip type on RH side of handle bar

Gears

: Left foot pedal operated

Clutch

: Lever operated on LH side of handle bar

Brakes

Front

: Lever operated on RH side of handle bar

Rear

: Pedal operated by right foot

ELECTRICALS

System

: 12 V (AC+DC)

Battery

: 12V 9Ah

Head Lamp

: 35/35 W-HS1

Pilot Lamp

: 5W - 2 Nos.

Tail/Stop lamp

: 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

: LED display

Rear number plate lamp

: 5 W

Horn

: 12V DC

DIMENSIONS

Length

: 1990 mm.

Width

:      750  mm.

Height

: 1090 mm.

Wheel base

: 1320 mm.

Turning circle radius

: 2180 mm. (Minimum)

Ground  clearance

:      165  mm.  (Minimum)

WEIGHTS

Vehicle kerb weight

: 143 kg.

Gross vehicle weight

: 273 Kg.

PERFORMANCE

Maximum speed

: 125 km/h with single rider (68kg)

0

Climbing ability

: 28% (16  Maximum)

Notes:

Values given babove are nominal and for guidance only, 15% variations is allowed to cater for 
production and measurement variation.

All dimensions are under UNLADEN condition.

Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.

Specifications are subject to change without notice.

Pulsar DTS-i UG-III-180cc 

Training Notes

Pulsar DTS-i UG-III-180cc 

Training Notes

Ï

What are the special features of 'PULSAR DTS-i 180 UG III '? OR

Ï

What is so special in this 'PULSAR DTS-i 180 UG III '?

B

Pulsar UGIII is next version of Pulsar breed. It is loaded with lots of unique & 
contemporary features and that distinguishes the Pulsar not only in the category of Power, 
Performance & Style but also for Comfort, Convenience & Safety from the competition.

B

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 / features are

Œ

Enhanced Performance 

• Refined engine power delivery by optimization of ExhausTEC location, bigger & twin 

Air Filter element, optimized valve timing, reduced engine friction etc.

• Stainless steel silencer that lasts long & overcomes rusting.
• All sensor type electrical switches  that function for the life of the bike. Absolutely no 

maintenance in absence of mechanical contacts.

Œ

Enhanced Style

 

• Stylish fairing & Headlamp assembly with owl eye, new black mask to separate 

headlamp from parking lights 

• New age, sharp & attractive 2 Row Tail lamp with LED lights
• Louver type LH & RH covers with wire mesh gives sturdy look.
• Ergonomically designed  self-letting switches
• Absolutely no maintenance in absence of mechanical contacts.

Œ

Enhanced Comfort & Convenience 

• Loaded with Digital Technology like  LCD Speed/Odo display, digital fuel meter, Digital 

trip meter that enables to count two trips.  

• Car like self canceling indicator switches that keeps rider free from switching off the 

indicators after turn.

• Apart from digital fuel meter, warning light for low fuel level is provided. 
• Self check provision for tachometer to ensure proper functioning.
• Oil level inspection window that indicates oils level at a glance.

Œ

Enhanced Safety

• Engine cut-off at 10000 RPM  Spark gets cut-off at 10000 RPM
• High RPM warning lamp  when engine reaches to 9000 RPM automatically Red LED 

bulb starts blinking.

• Day night mode of Speedo console, LED illumination for tell-tale icons on electrical 

switches that glows in the night for positive access.

Ï

How does the digital Speedo work?

B

Front wheel of the bike has a sensor & magnet unit. The sensor counts no. of pulses w.r.t. 

wheel rotation & logically calculates number of wheel rotation & gives input to the display 

unit in the speedo console and the LCD display indicates accurate speed, odo reading & 

trip meter readings.

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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