SUSPENSION
PDI Check List
PDI Check List
Dealer’s Name
Dealer’s Code
Date of PDI
Please ensure that following checks are carried out during PDI before delivery of vehicle.
PDI done by
Frame No.
Engine No.
Dealer Development Center, Pune
16
Pulsar DTS-i 150/180 Training Notes
Dealer Development Center, Pune
17
Pulsar DTS-i 150/180 Training Notes
IMPORTANT NOTE : Look for any external damages in transit : Please check, record & rectify send report with photos.
•
Moisture / Oil collecting tube of Air filter should be properly fitted and routed correctly.
•
Both LH & RH side spark plug caps must be tightly secured and ensure proper functioning of Spark Plugs.
•
TPS on carburettor for functioning.
Rear Shock Absorber
Steering
Spring Adjuster notch position : 1st notch (Standard)
Smooth operation (No play / sticky movement)
To Check
Observations /
Remarks
3
if OK or
7
if NOT OK
Steering cum Ignition, Rider Seat (Pillion + Rider
for 180cc), LH / RH side cover lock
ELECTRICAL
TEST DRIVE
Lock Operation
Battery
All Bulbs Working
Switch Operation
Starter Motor
Starting
Drive ability
CO % Check
Cleaning
Fasteners
(Check Torque)
Front axle nut (150cc - 4~5 Kgm, 180cc - 8~9 Kgm)
Rear axle nut (150cc - 8~10 Kgm, 180cc - 8~10 Kgm)
Torque rod nut (150 cc & 180cc - 3~4 Kgm)
Handle bar bolts (150cc - 3.5Kgm, 180cc - 2~2.2Kgm)
Steering cap bolt (150cc - 3.5 Kgm, 180cc - 5 Kgm)
RSA mtg. dome nut (150 cc & 180cc - 3.5~4.0 Kgm)
Swing arm pivot nut (150 cc & 180cc - 8~10 Kgm)
Caliper install bolts (150 cc & 180cc - 2.2~2.8 Kgm)
Brake disc allen bolts (150 cc & 180cc - 2.6~3.2 Kgm)
Pinch clamp bolt (180cc - 2.0~2.2 Kgm)
LH & RH Control, Ignition, Fr & Rr brake & Kill switch
Proper working / Engagement
Cold Start & Warm Start
Idling Speed (warm Condition) (1400 + 100 rpm)
Throttle response
Brakes (Front & Rear)
Digital speedometer, Odometer, Trip meters, Fuel
gauge & Fuel indicator red lamp
CO should be 2% in engine warm condition at Idling rpm
Wash & Clean vehicle properly
Charge status (12.5V open circuit terminal Voltage)
Tightness of Battery - Terminals / Cables
Position of Fuse box (2 Nos.)
Head light, Pilot Lights (2), LED Tail /Stop, Side-
Indicator, Speedometer LEDs, Number plate lamp
Turn pilot, High beam, Neutral indicator, Tale tail icons
on switch LH/RH, Auto cancellation of indicators
Check For
Observations
/ Remarks
Front Fork
Silencer mounting nut (1.4 ~ 1.9 Kgm)
Drain bolt (2.5 Kgm)
Fasteners
(Check Torque)
Engine mounting bolts (M 8 2.2 Kgm, M 10 : 2.4 Kgm)
Silencer mounting bolt (3.5 ~ 4.0 Kgm)
Engine Oil :
For 150 cc
SAE 20W40 API SJ
or SL + JASO MA)
For 180 cc
SAE 20W50 API SJ
or SL + JASO MA)
Oil level OK / Top up if required
Oil Leakage if any - specify source of oil leakage
ENGINE:
To Check
Check For
3
if OK or
7
if NOT OK
Idling rpm (warm up)
Check / adjust if required (1400 + 100 rpm)
Smooth operation, Tightness of Kick boss bolt
Kick operation
(Applicable for 150 cc)
FUEL SYSTEM
FRAME
CONTROLS
Fuel Tank / Pipes
Carburettor
Fuel Cock
Tyre Pressure
Brakes
Throttle
Clutch
Clutch Cable
Drive Chain
No leakage / Correct Fitment
No leakage / Correct Fitment
Smooth Operation
Front
Rear Solo
Rear (Pillion)
Front Brake lever free play (2~3 mm)
Rear Brake Pedal free play (25~30 mm)
Grip free play (2~3mm) & smooth operation
Smooth operation, No juddering, Free play 2~3mm
Slackness standard : 25~35 mm
Routing through the bracket located near lower ‘T’
on vehicle RH side
No leakage / Smooth working
2
2.00 Kg/Cm (28.4 PSI)
2
2.00 Kg/Cm (28.4 PSI)
2
2.15 Kg/Cm (30.5 PSI)
2
1.75 Kg/Cm (25.0 PSI)
2
2.00 Kg/Cm (28.4 PSI)
2
2.25 Kg/Cm (32.0 PSI)
For 150 cc
For 150 cc
