Periodic Maintenance & Lubrication Chart
Dealer Development Center
14
PDI SOP
Dealer Development Center
13
Description
Position
SMM
GP Tools
Special
Tools
PNR & its
Attachment
Consumables
M & T / Service
Shop Equipments
Sr.
No.
20
Check all important nut bolts for
torque and tightness,
• Handle bar mounting bolt
• Stem lower & upper bracket bolts
• Stem of bolts
• Front axle nut
• Cylinder head nuts
• Engine foundation bolts
• Trailing arm bolts
• Silencer cover shield bolts
• Both LH/RH engine mtg. bolts
LH/RH
4.00
12-13, 14-15,
16-17, 20-22
Ring Spanner,
22 mm Box
Spanner with
Handle Ratchet
Pistol Grip
PNR
21
Check the following and
lubricate if necessary
• Rear brake lever
• Rear brake pedal / cam
• Pillion foot rest
• Center stand
• Side stand
• Kick lever boss
• Clutch lever
RH/LH
FRONT
REAR
1.00
Oil Can
SAE
20W40 Oil
22
OE accessories fitment -
Mirrors RH & LH
LH/RH
1.15
17mm
OE Spanner
23
OE accessories fitment -
Leg guard
LH/RH
3.25
10-12 No.
OE Spanner
and 12 No.
Box Spanner
Pistol Grip
PNR
24
Start vehicle, Check operation of
electrical like- Head light, Tail light,
Brake light, Side stand indicator,
Horn, Speedometer, Odometer,
Side indicators, Parking and
Pass light working.
LH/RH
0.35
25
Check Idling and CO%.
LH/RH
0.60
Small
Screw driver
CO-HC Analyzer;
Tachometer,
Proper Exhaust
Sealing
Arrangement
of Silencer
26
Trip meter working
LH/RH
0.10
27
Check all locks for proper operation
LH/RH
0.50
28
Test drive the vehicle, check digital
speedometer working. Study the
job card and verify work done.
Take vehicle out and park.
1.30
29
Clean/Wash the veh. before delivery
1.00
17.75
Total SMM
30
Repair for any other defects seen
or observed during test drive.
Expected Output in 480 Minutes / Man / 27 Vehicles
Pulsar DTS-i UG-III-180cc
Training Notes
Pulsar DTS-i UG-III-180cc
Training Notes
1.
Servicing
l
l
l
l
l
2.
Idle speed / CO%
C,A
l
l
l
l
l
3.
Valve tappet clearance
A
l
Every 5000 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
8.
Carburettor
CL,A
l
l
l
l
l
9.
Fuel system leakages
C,R
l
l
l
l
l
10.
Fuel pipes
R
Every Year
11.
Spark plug / gap
CL,A
l
l
l
l
l
12.
Spark plugs (2 Nos.)
R
Every 10000 kms
13.
Battery electrolyte level
C,A
l
l
l
l
Every Year
14.
Brake light switch
C,A
l
l
l
l
l
15.
Clutch play
C,A
l
l
l
l
l
16.
Throttle play
C,A
l
l
l
l
l
17.
Rear brake pedal play
C,A
l
l
l
l
l
18.
Brake lining or pad wear
C,R
l
l
l
l
l
19.
Brake fluid level / top up
C
1 Month
l
l
l
l
l
20.
Brake fluid change
R
Every 10,000 kms.
21.
Steering play
C,A
l
l
l
l
l
22.
All fasteners tightness
C,T
l
l
l
l
l
23.
Engine mounting silent blocks
R
Every 20,000 kms.
24.
Tyre tread wear
C,R
l
l
l
l
25.
General lubrication
L
l
l
l
l
l
26.
Steering stem bearing
L,R
1 year
Every 10000kms
27.
Wheel bearing
C,L
1 year
Every 10000kms
28.
Master cylinder cup and Dust seal
R
Every 2 years
29.
Caliper piston seal and Dust seal
R
Every 2 years
30.
Swing arm pivot pin
L
l
Every 5000kms.
31.
Front fork
C,L
l
l
l
32.
Front fork oil
R
Every 10000kms
33.
Front brake hose
C,R
2 years
2
34.
Rr. Shock Absorber-
Check gas pressure 7.0+0.5 Kg/cm
Every 10000kms
35.
Drive chain
L
Every 500 kms.
36.
Drive chain slack
A
l
Every 2500 kms.
37.
Drive chain wear / Remove & Lubricate
C,R
l
Every 5000kms.
38.
Engine compression pressure
C
Every 10000kms
39.
Cylinder head de-carbonising & valve lapping
CL
Every 30000kms
40.
Valve oil seals
R
Every 30000kms
Sr.
No.
Operation
Whichever
comes first
750 2,500
RECOMMENDED FREQUENCY
Initial
Subsequent
5,000 7,500 Every 2,500km
Kms.
Days
OR
30~45 105~120 195~210 285~300
Every 90 days
l
:
Indicates operation to be performed.
«
:
More frequent cleaning may be required when driving in dusty condition.
Note:
Parts / Lubricants to be replaced as per Periodic Maintenance and
Lubrication Chart are mandatory and the same are chargeable to customer.
A -
Adjust
CL -
Clean
C -
Check
L
-
Lubricate
T
-
Tighten
R -
Replace
