Pulsar DTS-i 180 UG III Training Manual Download Page 5

Pre Delivery Inspection Checklist

Dealer Development Center

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Dealer Development Center

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Pulsar DTS-i UG-III-180cc 

Training Notes

Pulsar DTS-i UG-III-180cc 

Training Notes

Ï

What is that disabling of cranking after 3 successive attempts?

B

A protective device has been incorporated in the system that allows rider to attempt self-
start option (pressing of self-start button) for starting only three times at times. After third 
attempt the battery power supply gets cut-off to the self-starter motor, thus avoid rider 
from further cranking of engine by self-start.

B

This is mainly to protect the battery from over draining by excess attempts of pressing of 

self-start button to start the engine.

B

However, one can again use the self-start option after 15 seconds after third attempt.

Ï

How come so many features are managed accurately & what is the guarantee of no 
malfunctioning of these features?

B

It is needless to say that the digital technology that works with sensors & chips works 

accurately. To control all the functions of these electronics features, an intelligent device 

has been installed in the electrical system. This is called BCU (Body Control Unit) 

Ï

What exactly is BCU (Body Control Unit)? How it controls all these functioning?

B

BCU (Body Control Unit) is a device that integrates & controls major of all electrical / 

electronic functions on the vehicle. It is an intelligent device that works on microchip base. 

B

In the eventuality of electrical overloads or short circuits, the built in intelligent protection 

circuit takes the control of the situation & prevent future damages on other electronic 

parts. For example:- During night, suppose 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 beam automatically 

without manual shifting of any switches.

B

It also checks & inspects the fused circuit religiously for any corrections and thus riders' 

safety is ensured.

Ï

Are these type of product features available in Pulsar150cc also?

B

Presently not. But as in all sphere of life, technology also proliferates. When that happens 
you may find similar features in Pulsar 150cc also.

Ï

Can one alter the current Pulsar model & incorporate these features?

B

` No. It is not possible. Physically lot of changes are there that are not easily 

accommodated in the existing Pulsar.

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Check

PDI done by BAL/ 

Service Engg.

PDI Done by 

Dealer

Check Points for PDI

LOCK OPERATION                     
STEERING LOCK NOT WORKING/JAM
SIDE COVER LOCK NOT WORKING
PAINT FINISH -  OVER FLOW  (Samples / photographs)
FUEL TANK DEFECTS           
LEAKAGE                                       
BLISTERS                                    
RUSTY
OTHERS  (Specify)
FUEL COCK OPERATION -  HARD / LEAKAGE 
FRONT / REAR WHEEL OFFSET           
WHEEL                                       
FR. WHEEL TYRE -Free rotation.
FRONT WHEEL RUNOUT (SPECIFY)   
REAR WHEEL RUN OUT (SPECIFY)   

SILENCER - BAFFLE NOISE   
SWITCHES 
RH switch operations
LH Switch operations

IGNITION SWITCH SHORT
LIGHTS:-
Side indicator blinking.                               

HEAD LIGHT                             

HORN  :- DISTORTED/WEAK SOUND(DO NOT SET)

Tripmeter - 1/2 working -Resetting 
Odometer working

Auto - Calibration of RPM meter
Fuel level indication
Reserve indication (by red lamp)
Red lamp blinking after crossing Engine RPM 9000
Auto-switch off of Ind lamps(H bar straight for > 2 sec)
Head light / tail light illumination after 3 seconds 

SPEEDO  Needle flickering.

LED functioning - Speedounit - Both side indication, 
Side stand, Neutral, Hi beam, RES ind lamp

TAIL/BRAKE LED         

Speedo :

SPEEDO  NOT SENSING. 

Frequently Asked Questions (FAQ’s)

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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