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Dealer Development Center

Dia. = 25.9+0.1

Using Special Tool :
Special Nut Puller 37 10DJ43
Primary Gear Holder 3710 DJ28

Remove :

• Centrifugal oil filter special

nut

• Belleville washer
• Body centrifugal oil filter

assly

Remove :

• Bearing with plunger

Using Special Tool : Special

Nut Puller 37 10DJ 43
Primary Gear Holder 3710DJ28
Remove :

• Input shaft special nut
• Belleville washer
• Clutch assly comp
• Spacer

Note :

The existing Special Nut Puller 37 10DJ 43 can be used by

grinding the tool OD to 25.9 + 0.1 mm

Using Special Tool :

Primary

Gear Holder 37 10DJ 28

Remove :

• 3 phillips head screws (A)
• Centrifugal oil 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 be drained into the oil tray.

Pulsar DTS-i UG-III-180cc

Training Notes

Pulsar DTS-i UG-III-180cc

Training Notes

Remove :

• Assly Bal. idler gear
• 2 Washer

Note :

Take case that square key does not fall inside the crankcase

hollow portion while removing.

Remove :

• Bolt (A)
• Locking plate
• Body balancer gear assly

Remove :

• Primary gear
• Square key

Remove :

• Cam chain
• Cam chain sprocket
• Parallel Pin

Remove :

• 3 Assly balancer Idler gear cover bolts (A)
• Cover
• Washer
• 2 Dowel

Remove :

• Clutch housing

Note :

For ease in removal of clutch house insert special tool

(P. No.-37 10DJ 63) in Assly Balancer Idler Gear.

Dismantling Engine

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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Pulsar DTS-i 180 UG III, Руководство по обучению

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Содержание DTS-i 180 UG III

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