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Dealer Development Center

42

Dealer Development Center

41

• Remove the fuel tank and drain it.
• Pour some high-flash point solvent into the fuel tank and shake 

the tank to remove dirt and fuel deposits.

• Pour the solvent out of the tank.
• Dry the tank and the fuel tap with compresses air.
• Install the fuel tank.

Note :

 While installing the fuel tank on chassis make sure that the 

dampers (A) on petrol tank are mounted on the chassis.

Fuel Tank Cap Dismantling

To unlock the Fuel tank cap, insert the key in the key slot and turn 
it anticlockwise direction and lift open the tank cap.
Now remove the anti theft screw and then remove the allen bolts (A) 
and remove the fuel tank cap assembly from the fuel tank. Fitting is 
the reverse procedure 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)
• Fuel cock assembly from the fuel tank.

• Clean the fuel cock strainer in a high-flash point solvent.
• Pour high flash point solvent through the cock in all lever positions.
• Dry the tank and the fuel cock with compressed air.
• Install the cock in the tank.

A

Note :

 

• Always loosen the bowl of the fuel cock on vehicle itself

• Check the fuel cock strainer for any breaks or deterioration.
• If the fuel cock strainer have any breaks or are deteriorated, 

they may allow dirt to reach the carburettor, causing poor 

running. Replace the strainer.

Pulsar DTS-i UG-III-180cc 

Training Notes

Pulsar DTS-i UG-III-180cc 

Training Notes

A

• Bowl
• Strainer
• Gasket
• Selector Body
• 2 hole subber seal

Notes :

Carburettor and Fuel System

Carburettor and Fuel System

Содержание DTS-i 180 UG III

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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