background image

Dealer  Development  Center,  Pune

78

Pulsar  DTS-i  150/180  Training  Notes

Workshop  Safety

o Hand  Tools

-

Do  not  use  worn  out  hand  tools.

o Calibration  of  Workshop  Equipment

-

Calibrate  all  Workshop  and  M  &  T  Equipment  once  in  a  year.

o Avoid  direct  body  contact  with  Petrol,  Kerosene.

Caution  :  Prolonged  contact  of  used  oil  may  cause  cancer. 

  o Waste  Oil  Disposal

-

Sell  used  oil  to  Government  approved  re-cycle  agencies.

-

Collect  used  oil  in  oil  disposer  /  barrel.

-

Don’t  throw  oil  into  sewage  line.

-

Don’t  spill  oil  on  the  floor.

o Safety  Precautions  while  Operating Air  Tools

Air  tools  operate  on  compressed  air  supplied  by  the  shop  air  system 
(Compressor  & Air  supply  system). 

Observe  the  following    safety  related  precautions  when  using  an  air  
tool.

 

It  is  advisable  to  fit  a  pressure  regulator  (FRL:-  Filter  Regulator

 

Lubricator)  in  the  pneumatic  line  which  supplies  air  pressure  to the 

2  

air  tool.  It  regulates  the  outlet  pressure  to  @6.5  Kg/cm . This 
avoids  the  risk  of  personal  injury.

Never  use  the  blow  gun  to  blow  dust  off  your  clothes  and  never 
point  it  at  anyone.  The  air  pressure  can  drive  dust  particles  at 
high  speed.  These  particles  can  penetrate  into  the  flesh  or  eyes. 
High  pressure  air  hitting  on  open  wound  can  force  air  into  the 
blood  stream.  This  can  result  in  death.

Never  look  into  the  air  outlet  of  a  pneumatic  tool.

Never  blow-clean  brake  or  clutch  parts.  This  could  put  asbestos 
dust  particles  into  the  air  which  are  harmful  to  inhale.  (These 
particles  are  cancerous  -  can  lead  to  Cancer).

Содержание Pulsar 150 DTS-i

Страница 1: ...uel Supply System Dismantling Assembling Fuel Cock Working of Various CV Carburettor Circuits Dos Don ts Carburettor Specifications Tune up for Getting Optimum Mileage 26 27 Engine Transmission 29 Imp...

Страница 2: ...39 Service Limits 42 Tubeless Tyre Its Puncture Repair Procedure SOP for Tubeless Tyre Removal Dismantling Assembling Front Fork Front Disc Brake 44 49 51 40 Electricals 57 Digital Twin Spark Ignition...

Страница 3: ...sh split seats 2 piece grab rail Tank spoiler Wolf eyed head lamp LED tail Lamp Black styling Clip on handlebar Thicker and pinched clamped fork Naked chain Advantages A bold assertive stance Neat loo...

Страница 4: ...Plug 2 Nos Champion RG4HC Resistive Spark Plug Gap 0 6 to 0 8 mm Lubrication Wet sump Forced Starting Kick start Electric start Clutch Wet Multidisc type Transmission 5 speed constant mesh Primary Red...

Страница 5: ...ear Mechanically expanding shoe and drum type Tyres Front 90 x 90 x 17 49 P Tubeless Rear 120 80 x 17 61 P Tubeless 2 Tyre Pressure Front 2 00 kg cm 28 4 Psi 2 Rear Solo 2 00 kg cm 28 4 Psi 2 Rear Pil...

Страница 6: ...D 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 LCD display Rear number plate lamp 5 W Hor...

Страница 7: ...on Against Over Cranking What is the benefit advantage of having DC system Constant Consistent high intensity current is available even at low engine rpm which gives improved combustion better startab...

Страница 8: ...ion when engine is not running Do not press brake pedal brake lever while running otherwise brake light would glow continuously drain the battery Do not switch ON OFF ignition switch un necessarily Ge...

Страница 9: ...Training Notes PDI SOP PDI Checklist Periodic Maintenance Lubrication Periodic Service SOP Service wise Part Kit Scheduled Maintenance Standard Checking Procedure Special Tools I Check I Maintain All...

Страница 10: ...old 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 w...

Страница 11: ...0000 kms 27 Air breather tube C C C C R Every 1 year 28 Drive chain lubrication Slackness adjustment C A L C A L C A L C A L L Every 500 kms Adj slack 2500 kms 29 Drive chain remove Clean Inspect Lubr...

Страница 12: ...Chain Lock and Link Set Engine Air Breather Tube Clutch cover gasket Engine Oil NIL Air Filter O ring Drive Chain lock and link set Spark Plug Starter clutch bush set Chain sprocket kit If required N...

Страница 13: ...older Drift Thrust Plate Aligner Holder Output Sprocket Holder Bearing Driver Set Rear Shock Absorber Adjuster Piston Ring Holder 37 10DH 36 37 10DH 32 37 10DH 31 37 10DH 35 37 10DH 33 37 10DJ 32 37 1...

Страница 14: ...Training Notes Fuel Supply System Dismantling Assembling Fuel Cock Working of Various CV Carburettor Circuits Dos Don ts Carburettor Specifications Tune up for Getting Optimum Mileage Fuel System All...

Страница 15: ...ttle at zero position Fig 1 On connecting multimeter to Reed Switch coupler it should show continuity When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switc...

Страница 16: ...ng Engine Overhauling Removal of Engine from Frame Dismantling of Engine Dismantling Engine Sub Assembly Part Inspection Parameters Assembling Engine Service Data Tightening Torque CAT Converter Contr...

Страница 17: ...Service Limit Service Limit Service Limit Pulsar 150 cc Pulsar 150 cc Pulsar 150 cc Pulsar 150 cc Pulsar 180 cc Pulsar 180 cc Pulsar 180 cc Pulsar 180 cc TIR 0 01 TIR 0 01 Inlet 4 40 Exhaust 4 41 Inl...

Страница 18: ...c 180 cc Cyl Head Bkt Mtg Bolts M8 2 2 Kg m Engine Mounting Bolts M8 2 2 Kg m M10 2 4 Kg m Output Sprocket Bolts 1 1 Kg m Loctite 243 Silencer Mounting Nuts 1 4 1 9 Kg m Balancer Gear Cover Bolts 1 0...

Страница 19: ...oid thread damage Always use wire gauge for setting spark plug electrode gap Use feeler gauge for setting valve clearance Always follow loosening tightening sequence of cylinder head bolts otherwise i...

Страница 20: ...ter the ExhausTEC port and consist of 4 main parts 1 The substrate or the support which is of honeycomb ceramic type or metallic type 2 The wash coat or intermediate layer such as alumina which provid...

Страница 21: ...lled supply of oil to clutch Clutch housing has been modified to closed type to retain required quantity of oil consistently Advantages 1 Smoother gear shift feel 2 Controlled clutch lubrication Passa...

Страница 22: ...Overhaul 320 ml Brake Shoe Lining Thickness 3 85 4 15 3 85 4 15 Standard Limit 2 0 2 0 Service Limit Pulsar 150 cc Pulsar 180 cc Brake Cam Diameter 11 95 11 98 13 95 13 98 Standard Limit 11 88 13 88...

Страница 23: ...ne 43 Pulsar DTS i 150 180 Training Notes Tightening Torque For 150 cc 180 cc Tightening Torque For 150 cc 180 cc Front Axle Nut 4 0 5 0 8 0 10 0 Torque Value in Kg m Pulsar 150 cc Pulsar 180 cc Rear...

Страница 24: ...inner liner The valve is permanently fixed to the rim The assly is airtight Components Tyre Tube with Valve and Rim Loss of air is very slow after getting punctured because a i r c a n e s c a p e thr...

Страница 25: ...advantages Stiff ridges are formed on the inner liner of the tyre due to hardening of the repair compound which prohibits use of tubes with the tyre If tube has to be used then proper grinding of tyre...

Страница 26: ...ended below Damage Chance To avoid scratches on the paint damages to wheel rim portion it is essential to take certain care precautions while carrying out puncture repair job Following steps must be f...

Страница 27: ...yre bead portion with crowbar to fit the bead portion in the wheel rim Inflate the tyre to little more pressure than specification You will hear a noise that indicates that the bead portion has taken...

Страница 28: ...Allen bolt Copper platted washer Note Mount the special tool firmly on the bench vice and insert the fork pipe In special tool for firm locking Note Ensure that the snap ring and the bottom allen bol...

Страница 29: ...ork assly in the fork holder Bolt A Fit Allen bolt Handle bar 2 Allen bolts B Fit Bracket with wheel sensor case complete Bolt A Wheel sensor harness coupler Fit Mudguard Brace fender 4 bolts A Fit Wh...

Страница 30: ...g Procedure Electricals Information on Digital Speedo Console Vehicle Speed Sensor LED Tail Lamp Backlit Non Contact Type Switches Working of Indicator Auto Cancellation Working of BCU etc Individual...

Страница 31: ...ing of new battery Initial charging duration 10 15 hrs Initial charging current 0 9 to 1 Amp Initial Charging Procedure 1 Fill each cell with battery grade sulfuric acid of the correct Sp gravity 1 24...

Страница 32: ...e and direct sunlight How to Determine Condition of Battery Specific gravity check Whether battery is fully charged or partially charged it will always show same no load voltage of 12 volts or more un...

Страница 33: ...ls Measure the secondary winding resistance as follows Remove the plug cap by turning it counter clockwise Connect the tester between the spark plug leads Measure primary winding resistance Measure se...

Страница 34: ...B 14 3 Dealer Development Center Pune 65 Pulsar DTS i 150 180 Training Notes Measuring Testing Equipment Multimeter Fuel Gauge Tank Unit 200 Ohms Meter Range As per chart given below White Yellow Met...

Страница 35: ...s check cranking current displayed on clamp meter LCD display Dealer Development Center Pune 67 Pulsar DTS i 150 180 Training Notes Dos Don ts HORN Dos 3 Ensure that resonator is not pressed by any po...

Страница 36: ...tery life Do not add extra electrical load on battery as it will draw more current will reduce battery life Do not cover vent mechanism of battery by cloth paper or any other object Don ts 7 Dealer De...

Страница 37: ...od do not dismantle control switches Do not add extra electrical loads e g musical horns additional horns buzzers as it will reduce switch contact life battery life b a t t e r y life Do not operate s...

Страница 38: ...B R B Y R B O F F O N B Y R Y W W Br HEAD LAMP ASSY LAMP 12V 35 35W HS1 IGNITION SWITCH EARTH FRAME R R B R PIN NO 3 HIGH BEAM INDICATOR PIN NO 13 POSITION LAMP ON INPUT SWITCH BODY CONTROL UNIT FROM...

Страница 39: ...Y Lg Lg SWITCH BODY CONTROL UNIT FROM LH SWITCH R W W R Br R B Y Br W RELAY KILL SWITCH CONTROL Br L B Y Br L Br L Br L Br L W G Br L Br W NC NO P W B STARTER MOTOR R FUSE 10 Amps R W B STARTER RELAY...

Страница 40: ...Keep off direct fire near the power pack Avoid oil spillage around the working area for safety reasons Dealer Development Center Pune 76 Pulsar DTS i 150 180 Training Notes Dealer Development Center P...

Страница 41: ...Air supply system Observe the following safety related precautions when using an air tool It is advisable to fit a pressure regulator FRL Filter Regulator Lubricator in the pneumatic line which suppli...

Отзывы: