Pulsar DTS-i 180 UG III Training Manual Download Page 4

Dealer Development Center

8

Frequently Asked Questions (FAQ’s)

Frequently Asked Questions (FAQ’s)

Dealer Development Center

7

Pulsar DTS-i UG-III-180cc 

Training Notes

Pulsar DTS-i UG-III-180cc 

Training Notes

Ï

What are the advantages / Benefits of the digital speedometer apart from giving 
accurate reading?

B

This system is totally contact less & no mechanical transmission of drive from wheel to 
speedometer is available. Thus this system is totally maintenance free & lasts for the life of 
the bike.

Ï

How the digital fuel indicator meter works? OR How one can understand the available 
fuel level in the fuel tank? OR How to read the graphical bar of the fuel meter?

B

Graphic bar with 12-segment display is provided in the speedo console for indicating fuel 
level in the tank. If the all the 12 segments of a bar graph are 'ON', that indicates that the 
fuel tank is full. 

B

As the float gauge in the tank starts lowering down due fuel level coming down, the 

segments of the bar graph starts diminishing with corresponding drop in fuel level.

B

When the petrol level comes down to below four liters, all the segments of the bar will 
vanish.

B

Apart from LCD graph bar, a red warning light also has been provided in the console that 
glows continuously when the petrol level falls down to reserve. And it will be 'ON' till petrol 
is filled above reserve level.

Ï

When the digital fuel meter is available, why the red warning light is provided?

B

While the LCD graphical bar segments indicates the petrol level in the fuel tank, the red 

warning light continuously reminds the rider to fill the petrol.

Ï

Why two trip meter reading option is given? How is it useful? 

B

It is just to enable the rider to count reading for two different trips unlike only single trip in 

case of conventional type.

B

It is like this - on selecting 'Trip1' its will indicate the distance covered in first trip that is 
set for. In continuation, on selecting 'Trip2', it will indicate the distance covered in the 

second trip. Then if one wants to know the cumulative distance covered in first & second 
trip, it can be found in 'Trip1' mode. For this one has to just press/select 'Trip1' mode.

B

This is an added advantage taken from digital technology!

Ï

What do Self-canceling Indicators switches means?

B

In conventional type of switches, the rider has to manually depress or turn knob of 
indicator switch for putting 'OFF' the indicator bulbs. In case of this Self-canceling' 

switches the indicator goes off automatically after the rider takes a turn & brings the 
handle bar straight. This feature is similar to cars. That means, rider do not have to press 
or turn the switch to cancel the indicators.

Ï

What if one switches ON the indicator and do not physically take a 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 after pre-set time. 

For this a timer function is incorporated in the system. And the timing for this timer is set 

around 80 seconds.

Ï

What does non-contact Handlebar switches mean?

B

The control switches on both sides of the handlebar are conventional to look at, in terms 
of switch operations & knob position etc. But the key & distinguishing difference is the 
principle of functioning that means these switches do not function on the basis of physical 
contact for ON & OFF. These are on non-contact sensor based.

B

This feature will have any wear and tear & hence its life would be more than the life of the 

bike. These are absolutely maintenance free as far as wear & tear is concerned.

B

The other feature, in these switches is the Illumination of the tell-tale icons that is lit up 
with LEDs inside the switch body. This gives the icons a pleasant bluish white glow that 
can be seen in the night clearly & coolly.

Ï

The tail lamp assembly seems to be too special. What is so in that?

B

Yes. The tail lamp is unique on this vehicle and no other competitor's vehicle has this 

feature. It consists of 16 (8) nos. of LED bulbs with bi-filaments.  

B

The specialties of LED bulbs are 

-

  Consume very low current

-

  Glow  brightly

-

  Last  far  long

-

  Totally  maintenance  free

B

So, the LED tail lamp apart from delivering fantastic performance, it adds to aesthetics.

Ï

What is this bi-filament bulb?

B

Bi-filament bulb means these LED bulbs have two filaments in each bulb. One filament of 

lower wattage for parking lights & another for brake lighting, which is of little higher 
wattage.

Ï

If so much so electrical /electronic appliances are loaded, it may affect on Battery?

B

Absolutely not. In fact, all the bulbs & backlit bulbs in the Speedo console (except Head 

Lamp bulb & pilot bulbs) are of LED type. Few of them works on AC & few are on DC i.e. 

battery. So there is hardly any drain on the battery as compared to conventional type of 

bulbs.

B

Moreover, the Battery of this new Pulsar 180 is special & maintenance free.

Ï

What is this maintenance free Battery?

B

The battery is new development in DC system on two wheelers (in fact, such batteries are 
introduced in cars earlier than bikes) it is different than the conventional one in the material 
composition it is made up of. The main features of this new battery are
-  Electrolyte level checking is required at every one year instead of every fortnight 
-  The unique vent mechanism that do not allow loss of electrolyte
-  No drainpipe unlike in conventional type battery. So no chances of spillage of electrolyte.

B

So, in all it is almost maintenance free battery. Moreover, the LED bulbs, & disable 

function of cranking after 3 successive self starts attempts, will further only enhance the 
life of the battery.

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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