Bajaj pulsar DTS-i Service Station Manual
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Bajaj pulsar DTS-i Service Station Manual

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Summary of Contents for Bajaj pulsar DTS-i

  • Page 1 Service Station Service Station Manual Manual...
  • Page 2 º j krvi miT[ bÔj ai[ T i[ kr) Sk[ C [ j[ n ) ÔN krvin) j$r nY) All information contained in this Note is based on the latest product information at the time of publication. Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

  • Page 3: Table Of Contents

    CONTENTS Foreword sm< ( pt Workshop Safety vk< Si[ p s[ f T) jnrl enfi[ r m[ S n General Information Customer Information gi\ h k miT[ n ) (vgt Technical Specifications T[ k n)kl Ap[ S )f)kSn I Read ..I Learn h&...
  • Page 4 Frame & Suspension f[ m an[ sAp[ n Sn Tightening Torques Service Limits Special Tools Control Cable Routing Working of Nitrox Suspension SOP for Front Fork Dust Seal & Oil Seal Replacement SOP for Steering Overhaul SOP for Dismantling & Assembling Front Fairing SOP for Swing Arm Replacement Wiring Harness Routing SOP for Caliper Piston Seal and Dust Seal Replacement...

  • Page 5: Foreword

    Foreword sm< ( pt..
  • Page 6 • Be alert for problems & non-scheduled maintenance. In most chapters an exploded view illustration of the • Use proper tools and genuine Bajaj motorcycle parts. system components are incorporated. Special tools, gauges, and testers that are necessary...

  • Page 7: Workshop Safety

    vk< S i[ p s[ f T) Workshop Safety...
  • Page 8 WORKSHOP SAFETY o Technicians must put on shoes & dressing should not be very loose. o Technicians must use Personnel Protective Equipment (PPE) like - Hand Gloves - Mask - Safety Goggle - Ear Plug o Wear Nitrile Rubber Hand Gloves while handling petrochemicals like petrol, Oil, Kerosene etc.
  • Page 9 WORKSHOP SAFETY 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 air tool.
  • Page 10 WORKSHOP SAFETY Precautions to be taken while handling Hydro-Electric Lift - While raising / lowering the lifter bay ensure that vehicle is firmly hold on the lifter bay to avoid accident. - After raising the lifter bay, lock the lift. - Don’t put leg/hand in between while raising / lowering the lifter Bay.

  • Page 11: General Information

    jnrl (vgt General Information • Before Servicing s(< v < s ph[ l i...
  • Page 12 GENERAL INFORMATION General precautions to be taken while opening, assembling & storage of engine parts. Battery Ground Before completing any service on the motorcycle, disconnect the battery cables from the battery to prevent the engine from accidentally turning over. Disconnect the ground cable (-) first and then the positive (+).
  • Page 13 Replacement Parts Replacement parts must be BAJAJ genuine or recommended by BAJAJ. Gaskets, O-rings, Oil seals, Grease seals, Circlips or Cotter pins must be replaced with new ones whenever disassembled. Assembly Order...
  • Page 14 GENERAL INFORMATION Tightening Sequence Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified sequence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 GENERAL INFORMATION Lubrication It is most important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17 GENERAL INFORMATION General Precautions • To avoid damage to head of fasteners do not use over size or worn out tools. • To avoid damage to painted parts, prevent spillage of battery acid & brake fluid. • To avoid damage of machined face & color of the components store the parts in a clean plastic bin having compartments to avoid components touching to each other.
  • Page 18 NOTES Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 19: Customer Information

    -ni[ n y^ z m[ e nT[ º Tns • Non Use Maintenance -gi\ h k (vOi[ ÔNkir) • Customer Awareness -bÔj j[ º y& e n piT< s • Bajaj Genuine Parts -m[ n T[ º s T)¼s • Maintenance Tips...
  • Page 20 CUSTOMER INFORMATION Safe Riding Tips Always wear ISI helmets while driving or riding. Your helmets should conform to appropriate • Indian standards. Read thoroughly the instructions in this manual and follow them carefully. • Avoid unnecessary accessories for the safety of both rider and other motorists. •...
  • Page 21 CUSTOMER INFORMATION What to check Check for Brakes 1. Correct rear brake pedal play (25~30 mm) Applicable to 150 cc. 2. Brake lining wear indicator within ‘USABLE RANGE’. 3. No dragging. Drive chain 1. Proper slack (25~35 mm). 2. Adequate lubrication. Lighting Operation of all lights.
  • Page 22 Not to rectify wiring / electrical system related performance issues at local mechanic garages. • In case of main / wiring fuse blowing of problem, bring vehicle to authorized Bajaj dealer by starting engine with the • help of kick.
  • Page 23 • Do not drive vehicle & bring the vehicle to BAJAJ authorized workshop if coolant level in expansion tank or engine oil level is found below MIN. mark. Take help of authorized service station to take vehicle in workshop for repair.
  • Page 24 • Parts of the vehicle that have been altered and modified or replaced in unauthorized manner like use of wider tyres, loud silencers etc and which in the sole judgement of the Bajaj Auto Limited affects its performance and reliability.
  • Page 25 CUSTOMER INFORMATION Bajaj Genuine Parts For optimum performance of vehicle For prolonged life of Always components & vehicle Insist parts For economical maintenance cost For rider's safety Genuinity Test Scratch Hologram to find ‘Genuine’ Bajaj Auto Limited Akurdi Pune 411 035 India...
  • Page 26 NOTES Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...

  • Page 27: Technical Specifications

    pÃsr T[ k n)kl mih)t) Technical Specifications • Technical Specifications -T[ k n)kl (vgt -kib& < r [ T r Ap[ S )f)k[ S n • Carburettor Specification -ai[ e l/g)\ s / li[ k lieT • Oil / Grease / Loctite -kyi<...
  • Page 28 TECHNICAL SPECIFICATIONS - 150 CC Engine and Transmission Type Four stroke DTS-i, Natural air cooled. No. of cylinders Bore 58.00 mm. Stroke 56.40 mm. Engine displacement 149.01 cc Compression ratio 0.5:1 Idling Speed 1400 100 rpm. Max. net power 10.37 KW (14.09 Ps) @ 8500 RPM Max.
  • Page 29 TECHNICAL SPECIFICATIONS - 150 CC Fuel Tank Capacity 15 liters Full 3.2 liters Reserve 2.0 liters Usable reserve CONTROLS Steering Clip-on type handle bar Accelerator Twist grip type on RH side of handle bar Gears Left foot pedal operated Clutch Lever operated on LH side of handle bar Choke Push-Pull knob on carburettor...
  • Page 30 TECHNICAL SPECIFICATIONS - 180 CC Engine and Transmission Type Four stroke DTS-i, Natural air cooled. No. of cylinders Bore 63.50 mm. Stroke 56.40 mm. Engine displacement 178.60 cc Compression ratio 0.5:1 Idling Speed 1400 100 rpm. Max. net power 12.52 KW (17.02 Ps) @ 8500 RPM Max.
  • Page 31 TECHNICAL SPECIFICATIONS - 180 CC Fuel Tank Capacity 15 liters Full 3.2 liters Reserve 2.0 liters Usable reserve CONTROLS Steering Clip-on type handle bar Accelerator Twist grip type on RH side of handle bar Gears Left foot pedal operated Clutch Lever operated on LH side of handle bar Choke Push-Pull knob on carburettor...
  • Page 32 CARBURETTOR SPECIFICATIONS Carburettor Carburettor Specifications of Pulsar 150 cc : Make and Type Ucal-Mikuni BS26, CV type Identification No. DH - U3 Idling Speed 1400 100 VC Screw setting 2 turns out Main Jet 107.5 Jet needle mark 4DMP23 Needle jet mark Jet needle clip Position 2nd from top Pilot Jet...
  • Page 33 OIL / GREASE / LOCTITE APPLICATION MATRIX Lubricant / Application Grade Remark Loctite Quantity : DTSi 10000, Service - 1 L Engine oil Engine SAE 20W50 API ‘SL’ Eng. O/H - 1.1 L OR JASO ‘MA’ For Pulsar 150 cc Quantity / fork leg : Service - 145 2.5 ml Fork oil...
  • Page 34 OIL / GREASE / LOCTITE APPLICATION MATRIX Lubricant / Application Grade Remark Loctite • Ignition switch Electrical contact WD-40 Spray • Brake & clutch switch All services cleaning spray • LH/RH control switch Rear fender bottom Thread locker 243 Loctite mounting •...

  • Page 35: I Read

    h& > vi> c & > , h& . S)K& I Read... I learn • Vehicle identification & v[ h )kl (vOi[ n ) (vgt an[ k> º Ti[ ^ l s controls s[ l )yºT f)cr • Salient Features S[ D y&...

  • Page 36: Vehicle Identification & Controls

    VEHICLE IDENTIFICATION & CONTROLS vihn (vOi[ n ) mih)t) an[ k> º Ti[ ^ l c[ s )s n> b r an[ a[ J > n n> b rn& > li[ k [ S n Chassis Number & Engine Number Location The Frame and Engine serial numbers are used to register the motorcycle.
  • Page 37 VEHICLE IDENTIFICATION & CONTROLS speedometer Icons function Green Blue Green 1. Side Stand Indicator When Side stand is ‘ON’, the Side stand indicator will glow. 2. Fuel Level Indicator Fuel level indicator shows available fuel in fuel tank. 3. Reserve/ Engine Rev Indicator It glows when petrol level in tank reaches reserve level.
  • Page 38 VEHICLE IDENTIFICATION & CONTROLS Left Handle Bar Switches A. Dipper Switch : When headlight is ON, High or Low beam can be selected with the dipper switch. Hi beam indicator light located on Speedo console will light up when high beam is selected. : High Beam : Low beam B.
  • Page 39 VEHICLE IDENTIFICATION & CONTROLS Steering cum Ignition Lock : Apply spray inside It has three positions. LOCK : Steering locked. Ignition OFF. OFF : Steering unlock. Ignition OFF. : Steering unlock. Ignition ON. To Lock the Steering : To lock the steering, turn the handle bar to the left or right. Push & release the key. Turn the key to “LOCK”...

  • Page 40: Salient Features

    SALIENT FEATURES PERFORMANCE ATTRIBUTE KEY FEATURES ADVANTAGES BENEFITS • 4 stroke, DTS-i 150cc - 14.09 • L e g e n d a r y D T S - i e n g i n e • Crisp Throttle response for unmatched in industry.
  • Page 41 FREQUENTLY ASKED QUESTIONS - FAQ'S Ï What are other distinguish features of new ‘Pulsar DTS-i 180 cc’ motorcycle in comparison with ‘New Pulsar DTS-i 150 cc’? Following are the overall features in comparison at a Glance. Features Pulsar DTS-i 180 cc...
  • Page 42 YES. Puncture of Tubeless tyres can be repaired locally. There are various methods like - 1. Filter Method 2. Plug (Mushroom) Method 3. Patch Method But Bajaj Auto Limited recommends. Plug (Mushroom) method since it is more effective & safe. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual...

  • Page 43: Periodic Maintenance & Lubrication Chart

    & dry completely entry in Petrol tank, Silencer & electrical Parts. Use caustic free detergent for washing. Engine oil (Bajaj DTSi 10000 oil) BGO DTSi 20W40 for & engine oil filter* 100cc models. BGO DTSi 20W50 for Models above 125cc.
  • Page 44 Radiator fins** Spoke tightening**-Front & Rear * It is strongly recommended to use only Bajaj genuine oil,In case of any other engine oil of same specifications is used the frequency would be every 5000 kms. ** As applicable to model *** More frequent cleaning may be required while driving in dusty environment.
  • Page 45 PERIODIC MAINTENANCE & LUBRICATION CHART Why Periodic Maintenance 1. What is Preventive Maintenance ? Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to up keep health of product through out it's life. 2.

  • Page 46: Pre-Delivery Inspection Checklist

    NOT OK ENGINE Oil level between lower & upper mark / Top up if required Engine Oil "BAJAJ Oil leakage if any, Specify source of oil leakage 10000" 20W50 DTS-i Check in warm up condition 60 C / Adjust if required...
  • Page 47 Working / Engagement in gear & neutral Starter Motor No abnormal noise Working of Speedometer, Odometer Speedometer Working of all signal indicators icons (Neutral, Turn signal High beam, & Bajaj logo) Headlamp assembly No excess gap & Uneven gap Horn Ensure no distorted sound Visual inspection...

  • Page 48: Importance Of Pm Schedule Execution

    IMPORTANCE OF PM SCHEDULE EXECUTION Importance of PM schedule execution Preventive maintenance (PM) is scheduled maintenance activity aimed at the prevention of brake downs & failures. The primary goal of PM is to up keep health of product through out it's life. PM Activity Benefits •...
  • Page 49 IMPORTANCE OF PM SCHEDULE EXECUTION Servicing with Water Wash 1. Cover tail end of silencer with PVC cap to avoid water entry in silencer. Caution : Vehicle washing without covering silencer tail end will result in water entry into silencer causing rusting of silencer. 2.
  • Page 50 IMPORTANCE OF PM SCHEDULE EXECUTION 6. Adjust nozzle to jet mode & wash under the front and rear mudguards to remove the mud & dirt. 7. Clean painted parts by gently rubbing their surface with sponge / soft cloth dampened with solution of mild car shampoo / liquid solution. 8.
  • Page 51 IMPORTANCE OF PM SCHEDULE EXECUTION 11. Vehicle should be wiped off by cotton cloth immediately after washing. 12. To avoid water entry & paper filter, do not apply water on area beneath seat. (applicable to Pulsar 200NS, Discover 125ST & Discover 100T). Required Special Tools &...
  • Page 52 IMPORTANCE OF PM SCHEDULE EXECUTION Engine Oil Replacement a[ > J nai[ e l bdlv& 1. Ensure vehicle is thoroughly clean. vihnn[ sp* > N < sif krv& > 2. Ensure the engine is in warm condition before opening engine oil drain bolt.
  • Page 53 & piston ring wear. 10. Clean centrifugal oil filter (applicable for Pulsar 150 / 180 / 220 / Avenger 220). 13. Use Bajaj Genuine oil only as per the recommended grade. Pulsar 150/180 DTS-i Dealer Development Center...
  • Page 54 IMPORTANCE OF PM SCHEDULE EXECUTION 14. Ensure oil filler cap ‘O’ ring as in good condition. ai[ e l f)ÃTr k[ p r)> g bribr f)T C[ k[ nh) t[ ¹yin riKv& > 15. Ensure oil filler cap is fully tight. ai[ e l D)^ Ã...
  • Page 55 IMPORTANCE OF PM SCHEDULE EXECUTION Oil Strainer Cleaning 1. Remove the engine drain plug by using box spanner and handle. 2. Drain engine oil in a clean container. 3. Remove two bolts securing right hand side foot rest & take out the foot rest.
  • Page 56 IMPORTANCE OF PM SCHEDULE EXECUTION 6. Remove 2 bolts securing ‘Bracket Clutch Cable’ & take out the clutch cable end terminal from ‘Lever Clutch’. 7. Loosen & remove clutch cover bolts in crisscross pattern & take out clutch cover. 8. Remove the bolts securing ‘Oil Pump Assembly’. Take out the ‘Oil Pump Assembly’.
  • Page 57 IMPORTANCE OF PM SCHEDULE EXECUTION 10. Clean the ‘Oil Strainer’ by kerosene / diesel & nylon brush. 11. Blow low pressure air (2 bar) on the strainer mesh in the direction opposite to flow of oil. 12. Pump the engine oil by 'Oil can' through the input passage hole of oil pump body &...
  • Page 58 IMPORTANCE OF PM SCHEDULE EXECUTION Centrifugal Oil Filter Cleaning 1. Remove two bolts securing right hand side foot rest. 2. Take out the foot rest. 3. Remove bolt securing kick lever. 4. Take out kick lever from kick shaft. 5. Remove phillips screw securing ‘Cover Starter Motor’ & take out the cover.
  • Page 59 IMPORTANCE OF PM SCHEDULE EXECUTION 8. Loosen & remove clutch cover bolts in crisscross pattern. 9. Take out clutch cover. 10. Remove centrifugal oil filter cover mounting screws. 11. Clean centrifugal oil filter by nylon brush & kerosene / diesel. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual...
  • Page 60 IMPORTANCE OF PM SCHEDULE EXECUTION 12. Replace gasket by new one. 13. Apply 0.5 Kgm torque while refitting. 14. Replace clutch cover gasket by new one. 15. Tighten clutch cover bolts in crisscross sequence. 16. Apply specific torque to clutch cover bolts. Required Special Tools &...
  • Page 61 IMPORTANCE OF PM SCHEDULE EXECUTION Spark Plug Gap Checking 1. Remove spark plugs using plug spanner. 2. Visually check spark plug electrode for color, erosion, crack & breakage. 3. Clean the spark plug on spark plug cleaning machine. 4. Check and adjust spark plug gap by wire gauge. 5.
  • Page 62 IMPORTANCE OF PM SCHEDULE EXECUTION 6. Replace spark plug as per the interval given in the Periodic Maintenance Schedule. 7. Refit spark plugs by doing pre-fitment manually & thereafter use spanner for tightening. 8. Ensure spark plug cap is firmly fitted. Note : Replace spark plug at every 20000 Kms.
  • Page 63 IMPORTANCE OF PM SCHEDULE EXECUTION Fuel Cock Sediment Bowl Cleaning 1. Put the petrol cock knob to OFF position. 2. Remove the petrol cock sediment bowl by using a ring spanner. 3. Pour out the petrol to remove sludge and sediment from Petrol Cock Sediment Bowl.
  • Page 64 IMPORTANCE OF PM SCHEDULE EXECUTION Silencer Drain Hole Cleaning Clean the silencer drain hole by using silencer drain hole cleaning tool as shown in photograph. Nitrox Rear Shock Absorber Adjusting Spring Tension • RSA spring tension can be adjusted with the help of 5 stepped adjuster cam to suit individual requirement as per load &...
  • Page 65 IMPORTANCE OF PM SCHEDULE EXECUTION CO% Setting 1. Readiness of CO gas analyzer a. Ensure the machine is in well calibrated condition & calibration certificate is available. b. Switch ON & warm up the CO gas analyzer for its recommended time.
  • Page 66 IMPORTANCE OF PM SCHEDULE EXECUTION 7. Set the air or VC screw to get CO value between 1.5 ~ 2.5 % at idling RPM or 1400 100. 8. Reconfirm the engine idling RPM & CO are within specified limit. 9. For getting better engine performance & optimum fuel efficiency, achieve CO% as recommended.
  • Page 67 IMPORTANCE OF PM SCHEDULE EXECUTION Battery Electrolyte Level & Specific Gravity Checking 1. Open the side cover panel. 2. Clean the battery & battery terminal. 3. Inspect battery for damage / leakage. 4. Open all the 6 caps. 5. Check specific gravity by using hydrometer in all six cells one by one. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual...
  • Page 68 IMPORTANCE OF PM SCHEDULE EXECUTION 6. Each cell should have specific gravity of 1.240. 7. Add distilled water & maintain level in between Min & Max level. 8. Use Nitrile rubber hand gloves while topping up battery electrolyte level & checking of specific gravity.
  • Page 69 IMPORTANCE OF PM SCHEDULE EXECUTION Clutch Cable Free Play Checking & Adjustment 1. Press and release the clutch lever to confirm the smooth operation of clutch. 2. If clutch operation is jammed or sticky, replace clutch cable. 3. Check the clutch lever free play by steel rule. 4.
  • Page 70 IMPORTANCE OF PM SCHEDULE EXECUTION Throttle Cable Free Play Checking & Adjustment 1. Check for smooth rotation of accelerator grip. 2. Check accelerator free play by scale / ruler. 3. Adjust accelerator free play. 4. Recommended free play is 2 ~ 3 mm. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual...
  • Page 71 IMPORTANCE OF PM SCHEDULE EXECUTION Rear Brake Pedal Free Play Checking & Adjustment 1. Check for smooth operation of rear brake pedal. 2. Measure rear brake pedal free play by using a steel scale. 3. Adjust rear brake pedal free play as per specification. 4.
  • Page 72 IMPORTANCE OF PM SCHEDULE EXECUTION Tappet Clearance Setting 1. Do tappet setting at engine cold condition. 2. Ensure the ‘T’ mark on the ‘Rotor’ match with the mark on the ‘Crankcase LH’. At this stage the ‘Piston’ is at TDC and both the ‘Tappets’...
  • Page 73 IMPORTANCE OF PM SCHEDULE EXECUTION Sealed Type Drive Chain Lubrication on Vehicle 1. Put vehicle on center stand. Normal dust should be wiped clean using a lint free cloth. 2. Hold the Chain Lube Spray Can (OKS Spray) vertically upright & shake it vigorously till the noise of steel ball inside the can is heard uniformly.
  • Page 74 IMPORTANCE OF PM SCHEDULE EXECUTION Non Sealed Type Drive Chain Lubrication on Vehicle 1. Put vehicle on center stand. Normal dust should be wiped clean using a lint free cloth (applicable for 1st Free service). 2. Lubricate chain with SAE 90 oil. Ensure oil is directed on to the ends of the bushes &...
  • Page 75 IMPORTANCE OF PM SCHEDULE EXECUTION Sealed & Non Sealed Type Drive Chain Lubrication by Removing from Vehicle 1. Remove the chain cover. Sealed Non Sealed Type Chain Type Chain 2. Open the drive chain link lock. (As applicable to model). 3.
  • Page 76 IMPORTANCE OF PM SCHEDULE EXECUTION Sealed Non Sealed Type Chain Type Chain 6. Hook the chain for dripping off. 7. Refit chain on vehicle & Adjust chain slackness as per specification. Non Sealed Lubrication : 8. D i p t h e c h a i n i n g r e a s i l a t o r containing molten grease (IOC servo compound) for 2 minutes 9.

  • Page 77: Fuel System

    fy& a l s)ATm Fuel System c[ k )g an[ t[ n & > s[ T )g • CO Checking and Setting a[ > J n Ty& n ap • Engine Tune-up • Standard Operating kib& < r [ T r srk)T Procedure •...
  • Page 78 As per Emission Norms the recommended CO% for 2 • riding 5~6 Kms. The crankcase cover should be Wheelers is 3.5% at idling RPM. But CO% for Bajaj warm enough by feel. (Engine Oil Temp. = 60 C). Vehicles, for best results in terms of fuel efficiency are different for different models.
  • Page 79 ENGINE TUNE UP Reed Switch Setting & Checking Check throttle lever movement by rotating it with hand. It should not be sticky in operation and should return back it self on releasing. bracket Multimeter should show continuity. • Magnet should not touch with reed switch. •...
  • Page 80 ENGINE TUNE UP • When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switch multimeter should show discontinuity. • On De-acceleration, when of Reed Switch magnet re-coinsides with straight edge of fix bracket of Reed Switch Multimeter should show continuity.
  • Page 81 STANDARD OPERATING PROCEDURE SOP for Carburettor cleaning • Ensure fuel cock knob at 'OFF' position. • Remove fuel pipe from fuel cock side. • Loosen drain screw and flush out petrol from the “Carburetor bowl”. • Then re-tighten the drain screw. •...
  • Page 82 STANDARD OPERATING PROCEDURE • Clean the carburettor jets by low pressure compressed air. kib& < r [ T rni j[ T n[ li[ p[ | S r Wiri sif krv& > • Clean the carburettor passages by low pressure compressed air. kir¾y&...
  • Page 83 CARBURETTOR CIRCUITS kib& < r [ T r srk)T Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 84 CARBURETTOR CIRCUITS Starter Circuit : Constant Velocity Carburettor Cut Section View of Mixing Chamber Air inlet for choke Towards Towards Engine Engine 1. Plunger Cap 1. Plunger 2. Diaphragm Cap 2. Mixing Chamber 3. Diaphragm Piston Valve 4. Piston Valve with Jet Needle Function The function of starter circuit is to provide rich air fuel mixture on starting / cold starting.
  • Page 85 CARBURETTOR CIRCUITS Pilot Circuit : Constant Velocity Carburettor 1. Pilot Jet 2. Pilot Outlet Hole 3. Butterfly Valve 4. Volume Control Screw 5. Idling Adjustment Screw Air Inlet for pilot jet Towards Engine Function The pilot circuit provides the air fuel mixture at idling when not enough air is being drawn through the carburettor to cause the main circuit to operate.
  • Page 86 CARBURETTOR CIRCUITS Progression Circuit : Constant Velocity Carburettor 1. Pilot Jet 2. Pilot Outlet Hole 3. Bypass / Progression Holes 4. Butterfly Valve 5. Volume Control Screw Air Inlet Towards for pilot jet Engine Function The progression circuit provides the air / fuel mixture at small throttle opening when pilot circuit is still working but unable to meet the engine demands on small throttle opening.
  • Page 87 CARBURETTOR CIRCUITS Main Circuit : Constant Velocity Carburettor 1. Piston Valve 2. Piston Valve Diaphragm 3. Jet Needle 4. Needle Jet 5. Jet Holder Towards Engine Air Inlet for main jet Function The Main Circuit provides air fuel mixture by lifting up the piston valve in direct proportion to the engine demand.
  • Page 88 Notes Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 89 a[ > J n an[ T^ i ºsm)Sn Engine & Transmission • Tightening Torques -TieTn)g Ti[ k < , • Service Data s(< < v s D[ T i Ap[ S )yl T& Ã s • Special Tools yid riKvi miT[ n i pi[ e ºT •...
  • Page 90 TIGHTENING TORQUES Engine Mounting Bolts Engine Mounting Nuts Cyl. Head Bkt. Mtg. Bolts M8: 2.2 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m M8: 2.2 Kg.m M10: 2.4 Kg.m Chain Tensioner Mtg. Bolts Output Sprocket Bolts Silencer Mounting Bolt 1.1 Kg.m 1.1 Kg.m (Loctite 243) 3.5 ~ 4.0 Kg.m Silencer Mounting Nuts...
  • Page 91 TIGHTENING TORQUES Oil Pump Mounting Bolts Centrifugal Oil Filter Nut Rotor Cover Bolts 1.1 Kg.m (Loctite 243) 5.5 Kg.m 1.1 Kg.m Clutch Nut (LH Threads) Cylinder Head Cover Bolts Cylinder Head Cover Nuts Kg.m 3.5 Kg.m 1.0 ~ 1.5 Kg.m Camshaft Sprocket Allen Bolt Starter Motor Mtg.
  • Page 92 SERVICE DATA Compression Pressure Valve Spring Free Length Standard Standard Service Service Limit Limit Limit Limit Inner Inner Pulsar 6.0~10.0 5.0~10.0 Pulsar 39.10 39.0 150 cc 150 cc Outer Outer Kg/Cm Kg/Cm 43.6 42.6 Inner Inner Pulsar 11.0~13.0 9.0~10.0 Pulsar 38.6 37.6 180 cc...
  • Page 93 SERVICE DATA Cam Height Cylinder Head Warp Standard Service Standard Service Limit Limit Limit Limit Inlet Inlet Pulsar 31.0 30.8 Pulsar 0.05 150 cc Exhaust Exhaust 150 cc 30.4 30.2 Inlet Inlet Pulsar 31.3 31.1 Pulsar 0.05 180 cc Exhaust Exhaust 180 cc 31.0...
  • Page 94 SERVICE DATA Pressure Plate Warp Piston / Cylinder Clearance Standard Service Standard Service Limit Limit Limit Limit Pulsar Pulsar 0.019 0.039 150 cc 150 cc Pulsar Pulsar 0.019 0.039 180 cc 180 cc Piston Ring / Groove Clearance Shift Fork Guide Pin Diameter Standard Service Standard...
  • Page 95 SPECIAL TOOLS Details of Engine Related Special Tool For carrying out repairs / overhauls, various special tools are required. Some are commonly shared with other models also. Crankshaft Bearing Extractor Drawing No : JC 1010 01 Application : T o r e m o v e bearing from crankshaft Sprocket Catcher...
  • Page 96 SPECIAL TOOLS Rocker Pin Remover Drawing No : 37 10DH 35 Application : To remove rocker pin from cylinder head. Silent Bush Puller Drawing No : 37 10DH 33 Application : To remove silent bush from cylinder head cover. Rotor Puller with Butt Pin Drawing No : 37 10DJ 32 Application : Used to pull out rotor...
  • Page 97 SPECIAL TOOLS Special Nut Drawing No : 37 10DJ 43 Application : Used to remove / fit of centrifugal oil filter nut. Note : Existing tool can be used by reducing diameter to 25.9 + 0.1 mm Dia. = 25.9 0.1 Bearing Race Extractor Drawing No : 37 00DJ 01...
  • Page 98 SPECIAL TOOLS Adaptor and Valve Spring compressor Adaptor Drawing No : 3710DJ78 Valve Spring Compressor Drawing No.: 37 1031 07 Application : Used for assembling / dismantling inlet, exhaust valves by compressing spring in cylinder head. Rotor Holder Drawing No : H6 0721 00 Application : To hold rotor while loosening bolt.
  • Page 99 IMPORTANT POINTS TO REMEMBER Valve timing • Ensure the sprocket marks (A) are aligned horizontally with cylinder head top machined face and the piston is at TDC. • Secure the ‘Cam Chain Sprocket’ in the Spl. tool firmly & then tighten the sprocket allen bolt (A).
  • Page 100 IMPORTANT POINTS TO REMEMBER • Input shaft has special nut. • Thick spacer tapered I.D. should be placed on tapered portion of Input Shaft. • Input Shaft has left hand threads. • When splitting crankcase always remove 1 long bolt fitted from clutch side first.
  • Page 101 IMPORTANT POINTS TO REMEMBER • Take ‘Assembly Balancer Idler Gear’ along with Thrust Washer which is pre-loaded and is held in special tool, Slide down the special tool with ‘Gear’ to engage the bottom half of the ‘Assembly Balancer Idler Gear’ with the ‘Body Balancer Gear Assembly’...
  • Page 102 IMPORTANT POINTS TO REMEMBER Always ensure piston ring position. Top Ring : • Open end facing towards exhaust. Second Ring : • Open end facing towards inlet. Upper Rail : • Open end 30 facing towards exhaust. Bottom Rail : •...
  • Page 103 REMOVAL OF ENGINE FROM FRAME Remove : • Put OFF the fuel cock • Side panel LH • Side panel RH Remove : • Both Seat assembly by pulling the cable for seat lock release located on LH side. • Disconnect the negative terminal of the battery.
  • Page 104 REMOVAL OF ENGINE FROM FRAME Using Special Tool : Sprocket Holder - 37 1030 53 Remove : Bolts (A) • • Plate drive sprocket • Drive sprocket along with the chain. • Neutral switch coupler Remove : • 2 nuts for silencer flange Note : Always remove the flange mounting first and then rear mounting to avoid misalignment of studs.
  • Page 105 REMOVAL OF ENGINE FROM FRAME Remove : • Disconnect the reed switch coupler. • Spark plug cap LH • PCV pipe from breather Remove : • While removing engine foundation bolts, first remove the topmost bolt and then go down progressively. Note : Bolts (A) holding the engine to the chassis.
  • Page 106 SOP FOR DISMANTLING ENGINE Cover Cylinder Head kvr s)l)ºDr S.N. Description S.N. Description Head Cylinder with Cover Copper Washer Kit Asly Cyl Head with Cover Hex. Bolt with Flange Cover Tappet Hex. Bolt / Flange ‘O’ Ring Kit for Cover Cyl. Head Plug Silent Bush Gasket...
  • Page 107 SOP FOR DISMANTLING ENGINE Cylinder Head s)l)ºDr h[ D S.N. Description S.N. Description ‘O’ Ring Kit for Cover Cyl. Head Carburettor Insulator Stud (Exhaust) Clamp for Insulator Gasket Cylinder Head Hex. Bolt / Flange Damper Cylinder Head Sleeve - Spark Plug Intake Pipe Grub Screw ‘O’...
  • Page 108 SOP FOR DISMANTLING ENGINE Valve viÃv S.N. Description S.N. Description Rocker Arm Shaft - Intake Cotter valve Rocker Arm Shaft - Seal valve stem Intake (OD 10 mm) Valve Repair Kit Rocker Arm Shaft - Exhaust Valve Kit Rocker Arm Shaft - Wave washer Exhaust (OD 10 mm) Plain washer...
  • Page 109 SOP FOR DISMANTLING ENGINE Camshaft & tensioner k[ \ m SifT an[ T [ º Snr S.N. Description S.N. Description Ring ‘O’ Hex. Soc. Head cap Bolt Camshaft Assembly Cam Chain Bearing cam RH side Cam chain Tensioner pivot Bolt Bearing cam LH side Tensioner Assly Guide chain Kit...
  • Page 110 SOP FOR DISMANTLING ENGINE Cylinder & Piston s)lºDr an[ p)ATn S.N. Description S.N. Description Gasket Cylinder Oil Pipe Assly Pin dowel Bolt Special Piston Assly. Std. Gasket Ring Set Piston Damper Ring Snap Bolt (dummy for Temp sensor) Cylinder Block / Piston Assly Washer (dummy for Temp sensor) Pulsar 150/180 DTS-i Dealer Development Center...
  • Page 111 SOP FOR DISMANTLING ENGINE Engine Top End Dismantling : a[ > J n T[ i p a[ º DD)sm[ º Tl)g kiQi[ Remove : • Pull out the cover on the spark plug cap RH and the spark plug cap itself •...
  • Page 112 SOP FOR DISMANTLING ENGINE Remove : • Both tappet caps Remove : • Magneto cover 5 bolts • Disconnect neutral switch coupler • Magneto cover • Rotate crankshaft to get piston at TDC. • Ensure both tappets are at free state (i.e.
  • Page 113 SOP FOR DISMANTLING ENGINE Using Special Tool : Sprocket Catcher - 3710 DH 36 Remove : • Allen bolt • Spacer • Cam sprocket • Collar • Cam shaft assly Note : Hold the cam chain up right using soft copper wire or thread. Do not use cotton waste for holding the cam chain.
  • Page 114 SOP FOR DISMANTLING ENGINE Using Special Tool : Drift - 74 9309 Remove : • Piston pin lock LH & RH side • Piston pin • Piston assembly Note : Place a piece of clean cloth above hallow portion of cranckcase to arrest piston pin circlip if it falls during fitment.
  • Page 115 SOP FOR DISMANTLING ENGINE Starter Clutch ATiT< r kÃc S.N. Description S.N. Description Body comp. starter clutch Motor assly. starter clutch Plate roller clutch Bolt Gear starter clutch Cover starter motor Plate starter clutch gear return Cover starter motor moonlight silver Bolt Slotted c’sunk screw Shaft starter counter...
  • Page 116 SOP FOR DISMANTLING ENGINE Engine LH : (Magneto Side) Using Sp. Tool : Rotor Holder - H6 0721 • Hold the rotor assembly Remove : • Rotor bolt • Washer Using Special Tool - Rotor Puller with butt pin : 37 10DJ 32 Remove : •...
  • Page 117 SOP FOR DISMANTLING ENGINE Note : Holding the gear complete starter clutch rotate the rotor and pull it out in Anticlockwise direction to prevent rollers and springs coming out. Warning : • These components remain hot for a long time especially if removed from a hot engine.
  • Page 118 Spring torsion clutch lever Seal clutch lever Washer Rack Set damper Dip stick with ‘O’ ring Flanged Bolt Parallel pin ‘Bajaj’ Decal / Decal DTS-i Gauge Bushing Wire circlip Set of Plate Bolt Plate Damper Integral Pin Dowel Damper Integral...
  • Page 119 SOP FOR DISMANTLING ENGINE Clutch S.N. Description S.N. Description Special Nut Bearing Clutch lifter thrust Spring judder Holder Clutch Clutch Assly. Complete Rod Clutch lifter Clutch Center Spacer clutch Plate Clutch Pressure Nut Primary drive lock Friction Plate Kit Lever Assly. Clutch Plate Clutch Washer Primary Drive Gear Spring Clutch Capacity...
  • Page 120 SOP FOR DISMANTLING ENGINE Engine RH : Clutch Side Remove : • 1 screw - • Starter motor cover Note : The rod clutch lifter, plunger oil, plate plunger oil and spring joint may fall out of their respective places into the oil collection tray. If so, ensure that these are collected &...
  • Page 121 SOP FOR DISMANTLING ENGINE Using Sp Tool : Special Nut Puller - 37 10DJ43 Using Sp Tool : Primary Gear Holder - 3710 DJ28 Remove : • Centrifugal oil filter special nut • Belleville washer • Body centrifugal oil filter assly Remove : •...
  • Page 122 SOP FOR DISMANTLING ENGINE Remove : • Clutch housing Note : For ease in removal of clutch house insert special tool (P. No.-37 10DJ 63) in Assly Balancer Idler Gear. Remove : • Assly balancer idler gear • 2 Washer Remove : •...
  • Page 123 SOP FOR DISMANTLING ENGINE Remove : • 3 Bolts (A) • Oil pump assembly • 2 Dowels Warning : The oil pump may be hot, hence use suitable hand protection. Also, since the oil pump houses the oil strainer / mesh also, it may retain some quantity of oil.
  • Page 124 SOP FOR DISMANTLING ENGINE Remove : • Bolt on LH side crankcase (Magneto side) Remove : • 8 bolts on LH side crankcase • Split the Crankcase halves. Note : Before separating crankcase halves confirm that all the crankcase joining bolts are removed and the sprocket cam drive with parallel pin on crankshaft assembly is removed.
  • Page 125 SOP FOR DISMANTLING ENGINE Air Filter Crankcase Clutch Side : Using Sp. Tool : Bearing Driver set-37 1030 61 Remove : • Bearing for input shaft assembly from crankcase RH Using Sp. Tool : Bearing Extractor 37 1030 68 Remove : •...
  • Page 126 DISMANTLING ENGINE SUB ASSEMBLIES Using Sp. Tool : Bearing Extractor - 37 10DJ 76 Remove : • Bearing for input shaft assembly from crankcase LH Remove : • Bolt • Bearing stopper Using Sp. Tool : Bearing Driver set 371030 74 Remove : •...
  • Page 127 DISMANTLING ENGINE SUB ASSEMBLIES Top End Cylinder Head : U s i n g S p . T o o l : V a l v e S p r i n g Compressor - 37 1031 07 Using Sp. Tool : Adapter - 37 10DJ 78 Remove : •...
  • Page 128 DISMANTLING ENGINE SUB ASSEMBLIES Oil Pump : Remove : • Clip • Oil strainer element with 'O' ring Bearing Removal from Assly Balancer Idler Gear Cover and Crankcase Using Sp. Tool : Bearing Extractor - 37 10CD 30 Remove : •...
  • Page 129 DISMANTLING ENGINE SUB ASSEMBLIES Output Shaft Assembly • There are no integral gears on output shaft. • Remove thrust washer and slide off the gear 1st driven and collect the steel bush (1 driven gear is mounted on steel bush with shoulder ring (D).
  • Page 130 DISMANTLING ENGINE SUB ASSEMBLIES Camshaft Dismantling Using Special Tool : Bearing Pullers - 37 10DJ 74 for Bearing 39 2542 20, 37 10DJ 75 for Bearing 39 1880 20 Remove : • Bigger Bearing using sp. tool from camshaft assembly •...
  • Page 131 PARTS INSPECTION PARAMETERS Spark Plug : • Type / Heat value - RG 4 HC • Gap between electrodes - 0.6 to 0.8 mm • Electrode condition - No erosion • Colour at the electrodes tip - Brownish • Threads of reach portion - Ok / No damage Cylinder Head &...
  • Page 132 PARTS INSPECTION PARAMETERS Piston : • Grouping mark with respect to cylinder block must be same. • Diameter of the piston - As mentioned in service data • No scoring marks on the skirt • No blow by marks • No seizure marks.
  • Page 133 PARTS INSPECTION PARAMETERS Bearings : • Axial play Ok / Not excessive • Radial play Ok / Not excessive • Bearing Seat No sign of high spot on seating area. • Bearing class & code As per specification numbers • Bearing Rotation Free Rotation Clutch :...
  • Page 134 PARTS INSPECTION PARAMETERS Transmission : • No Teeth breakage or crack • No Wear pattern on teeth • No Wear of dog teeth & dog holes on gear • No Seizure mark on gear seat. • Free movement of gears on the shaft (1 Output, 2 Output, 3 Output, 4 Input and 5 input gears are free on the respective...
  • Page 135 PARTS INSPECTION PARAMETERS Rotor : • Smoothly key way machined • Threading for holding rotor puller • 'T' mark / line mark punched on rotor periphery • Body threads for allen bolt fixing intact • One way clutch body groove profile - Ok / No wear signs •...
  • Page 136 ASSEMBLY - ENGINE Fitting of Oil Seals and Bearings : Crankcase RH (Clutch Side) Use Bearing Driver set (P. No. 37 1030 74) Fit : • Bearing for Input Shaft Assembly Use Bearing Driver set (P. No. 37 1030 68) Fit : •...
  • Page 137 ASSEMBLY - ENGINE Use Bearing Driver set (P. No. 37 1030 73) Fit : • Bearing for Input Shaft Do not use inner guide while fitting the bearing for ‘Input Shaft’ in ‘Crankcase Note : LH’ as this will damage the protruding lug of crankcase casting. Sealed bearings must face crankcase side / protruding lug side.
  • Page 138 ASSEMBLY - ENGINE Fit : • Oil seal for Gear Changer Lever Clutch Cover Fit : • Oil seal for Clutch Lever on Clutch Cover Assembly of Sub assemblies : Magneto Cover Fit : • Harness in the Cover • 'Stopper' and tighten the 'Screw' (Use Loctite 243) •...
  • Page 139 ASSEMBLY - ENGINE • Using Arbour Press Fit : • Small Bearing (D) • Bigger Bearing (C) Note : Apply thin layer of oil on sliding surfaces of shaft for smooth sliding of bearing. Assembling Head Cover Fit : • Roller rocker arm •...
  • Page 140 ASSEMBLY - ENGINE Clutch Assembly Assemble the clutch plates and friction plates in clutch center / clutch hub. Fit : • Plain Washer in Clutch Center / Clutch Hub • Belleville Washer • Clutch Plate (A) 1 Nos • Pressure Plate 5 Nos •...
  • Page 141 ASSEMBLY - ENGINE Assembly Balancer Idler Gear Bearing Using Bearing Driver set (P. No.: 37 1030 61) Fit : • Needle roller bearings in crankcase RH and Cover Note : Apply oil on bearing OD before pressing bearings for smooth bearing fitment. Fit : •...
  • Page 142 ASSEMBLY - ENGINE Gear Complete Starter Counter Assembly Using Arbour Press Fit : • Needle Roller Bearing Crankcase LH (Magneto Side) Fit : • Guide Starter Assembly • 3 Screws (A) (Use loctite 243) Clutch Cover Fit : • Valve assembly and circlip (H) •...
  • Page 143 ASSEMBLY - ENGINE Input Shaft Assembly Fit : From LH side of shaft (A) • Thrust washer • Gear 4th • Splined washer • Circlip • Gear 3rd drive • Circlip • Splined washer • Gear 5th drive • Gear 2nd drive •...
  • Page 144 ASSEMBLY - ENGINE Fit : • Drum Change • Shaft Gear Shift • 2 Dowels • Gasket Fit : • Crankshaft Caution : Use a sharp blade or knife to cut off any protruding ‘Gasket’. This is very important for preventing any oil leakage from ‘Crankcase’ and ‘Cylinder Block Joint’.
  • Page 145 ASSEMBLY - ENGINE Fit : • Body Balancer Gear • Lock • Bolt (A) (Use Loctite 243) Fit : • Parallel Pin • Spacer • Guide gear shifter • Allen Bolt (A) Fit : • Spring Note : a. Apply Loctite 638 at ‘Bolt Shift Change’ (B) if removed. b.
  • Page 146 ASSEMBLY - ENGINE Fit : • Thrust Washer • Assly Balancer Idler Gear with Special Tool • Thrust washer Fit : Align gear timing marks of .. • Primary gear mark w.r.t crankcase mark • Body balancer assembly mark w.r.t crankcase mark Fit : •...
  • Page 147 ASSEMBLY - ENGINE Using Spl Tool - Primary gear holder : 37 10DJ 28 & Special Nut : 37 10DJ 43 Fit : • Spacer • Clutch Assembly Complete • Washer • Special Nut Note : Special nut for input shaft has LH threads. Fit : •...
  • Page 148 ASSEMBLY - ENGINE Fit : • 2 Dowels • Oil Pump Assembly • 3 Bolts Fit : • Starter Motor • Clutch cover gasket • 2 Dowels Note : Do not apply any grease to stick ‘Gaskets’ to the ‘Clutch Cover / Magneto Cover’...
  • Page 149 ASSEMBLY - ENGINE Fit : • Plate starter clutch return (A) • Bolt (Use loctite 243) (B) Using Special Tool : Rotor Holder H6 0721 00 Fit : • Washer • Bolt Top End Fit : • 2 Dowels • Block Base Gasket Using Special Tool : Drift 74 9309 89 Fit :...
  • Page 150 ASSEMBLY - ENGINE Note : Place clean piece of cloth on the ‘Crankcase’ bottom end because their is chance of ring snap falling down while fitment. Using Special Tool : Piston Ring Holder 37 10DJ 30 Fit : • Slide the Cam Chain upright with soft copper wire / Thread into cylinder •...
  • Page 151 ASSEMBLY - ENGINE Fit : • Spark Plug Sleeve • Grub Screw • Spark Plug Note : Before fitting the sleeve spark plug apply thin layer of molybdenum disulfide grease on the entry chambers for the ‘O’ rings Fit : •...
  • Page 152 ASSEMBLY - ENGINE Fit : • Cam Shaft Cap • Apply thin layer of liquid gasket to head cover • Head Cover Note : • Do not apply liquid gasket on to the cam shaft cap and other inside mounting areas. •...
  • Page 153 ASSEMBLY - ENGINE Note : Always ensure that the piston is at the end of compression stroke and ‘T’ mark on rotor is in line with the crankcase mark. When adjusting tappet clearance. Fit : • Tappet cap with ‘O’ ring Fit : •...
  • Page 154 ASSEMBLY - ENGINE Using Special Tool - Output Sprocket holder - 37 1030 53 Fit : • Bush • Sprocket • Plate drive sprocket • 2 bolts (Use loctite 243) Fit : • Oil pipe • Copper gasket • Banjo bolt (A) •...
  • Page 155 GEAR TRANSMISSION POWER FLOW S.N. Description S.N. Description Shaft input transmission Plain washer Plain washer Gear 4th driven Gear 4th drive Bush 1st driven Washer spline Gear 1st driven External circlip Gear 5th driven Gear 3rd drive Bush 2nd driven Gear 5th drive Gear 2nd driven Gear 2nd drive...
  • Page 156 GEAR TRANSMISSION POWER FLOW Construction & Working Input Shaft and its gears : • First gear is integral with Input Shaft. • Second gear is fixed on Input Shaft splines. • Third gear is fixed but sliding on Input Shaft splines. •...
  • Page 157 GEAR TRANSMISSION POWER FLOW Second Gear Position : When Second Gear is engaged, power from clutch flows as follows. Clutch Input Shaft 2 Gear Input 2 Gear Output 5 Gear Output Output Shaft Final Drive to the Rear Wheel Third Gear Position : When Third Gear is engaged, power from clutch flows as follows.
  • Page 158 GEAR TRANSMISSION POWER FLOW Forth Gear Position : When Forth Gear is engaged, power from clutch flows as follows. Clutch Input Shaft 3 Gear Input 4 Gear Input 4 Gear Output Output Shaft Final Drive to the Rear Wheel Fifth Gear Position : When Fifth Gear is engaged, power from clutch flows as follows.
  • Page 159 ENGINE LUBRICATION - FLOW OF OIL OIL STRAINER OIL PUMP CLUTCH COVER INLET CENTRIFUGAL FILTER TOP -RHS C'CASE RHS CRANKCASE CLUTCH COVER OUTLET CRANKSHAFT & THROUGH HAAD STUD CAMSHAFT CYLINDER BLOCK OUTLET CYLINDER BLOCK CYLINDER BLOCK ROCKER ARM LHS C'CASE INLET INPUT &...
  • Page 160 Notes Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 161 Frame & Suspension • Tightening Torques • Service Data • Special Tools • Control Cable Routing • Working of Nitrox Rear Suspension • SOP for Front Fork Dust Seal & Oil Seal Replacement • SOP for Steering O/H • Dismantling & Assembling Front Fairing •...
  • Page 162 TIGHTENING TORQUES - 150 CC AND 180 CC Front Axle Nut Handle Bar Holder Bolts Torque Value Torque Value in Kg.m in Kg.m 2.0 ~ 2.2 Pulsar Pulsar (150 cc Photo not 4.0 ~ 5.0 150 cc 150 cc illustrated) Pulsar Pulsar 8.0 ~ 10.0...
  • Page 163 TIGHTENING TORQUES - 150 CC AND 180 CC Rear Sprocket Mounting Nut Lower Clamp Bolt Torque Value Torque Value in Kg.m in Kg.m Pulsar 1.8 ~ 2.5 Pulsar 2.5 ~ 3.5 150 cc (Loctite 243) 150 cc Pulsar 3.0 ~ 3.2 Pulsar 2.5 ~ 3.5 180 cc...
  • Page 164 SERVICE DATA - 150 CC AND 180 CC Brake Panel Cam Hole Diameter Axle Run Out Standard Service Standard Service Limit Limit Limit Limit Pulsar Pulsar TIR 0.1 12.0~12.03 12.15 TIR 0.2 150 cc 150 cc or Less Pulsar Pulsar TIR 0.1 100 mm 14.0~14.03...
  • Page 165 SERVICE DATA - 150 CC AND 180 CC Drive Chain Length Brake Drum Inside Diameter Standard Service Standard Service Limit Limit Limit Limit 20-link length Pulsar 130.0 ~ Pulsar 254.0 ~ 130.75 259.0 150 cc 130.16 150 cc 254.6 1st 2nd 21st Pulsar 130.0 ~...
  • Page 166 For carrying out repairs / overhauls, these 4 new special tools were developed earlier exclusively for Pulsar DTS-i 200cc & Pulsar DTS-Fi 220cc & can be used for Pulsar UG-4 also. Rest of the special tools required remains the same which were earlier used for Pulsar, Pulsar DTSi UG-II, Pulsar DTSi UG III.
  • Page 167 SPECIAL TOOLS Ap[ A yl T& Ã s ki[ m n Ap[ S yl T& Ã sn) (vgt Details of Other Common Special Tool Ap[ S )yl T& l n> b r kyi> lig[ C[ t[ Ap[ S yl n[ m Special Tool Name Special Tool No.
  • Page 168 CONTROL CABLE ROUTING kºTi[ ^ l k[ b ln& $T)g Speed Sensor Cable • Clamp the speed sensor cable on case meter with a bracket & screw. Ap)D s[ º sr k[ b ln[ k[ e s m)Tr upr b[ \ k [ T an[ Ak* Wir[ f)t kri[ •...
  • Page 169 CONTROL CABLE ROUTING Clutch Cable kÃc k[ b l • Route clutch cable as shown in the photograph. klc k[ b ln& > r[ T )g fi[ T i[ g i\ f s mi btiv[ l p\ m iN[ f)T kri[ •...
  • Page 170 CONTROL CABLE ROUTING Accelerator Cable a[ k s)l[ T r k[ b l • Route the accelerator cable as shown in the photograph. a[ k s[ l [ T r k[ b ln[ fi[ T i[ gi\ f s p\ m iN[ $T)g kri[ •...
  • Page 171 WORKING OF NITROX REAR SUSPENSION Function • To suspend rear wheel to the frame with the help of swinging trailing arm. • To allow rear wheel to travel up and down Adjuster by absorbing shocks while passing through Membrane ditches / bumps (comfortable ride for the rider and pillion rider).
  • Page 172 WORKING OF NITROX REAR SUSPENSION Working : Gas Filled Extension Stroke During this stroke, oil in canister starts returning to upper chamber through base valve without any resistance due to expansion of membrane. Simultaneously, oil from lower chamber will flow slowly into upper chamber with resistance due to piston valve.
  • Page 173 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT S.N. Description S.N. Description Fork Front Bolt Fork Kit Outer Tube ‘O’ Ring Oil Seal Seat Fork Spring Outer Tube Lh Spacer Tube Outer Tube Rh Washer Gasket Bolt Bolt Holder Fork Upper Cylinder Comp.
  • Page 174 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT • Remove bolt securing front brake hose clamp by 8 mm T spanner fºT b[ \ k his kl[ À pn[ 8 Ap[ n r Wiri Ki[ l i[ • Remove 2 nos bolts securing caliper assembly by 12mm ring spanner. k[ l )pr a[ s [ À...
  • Page 175 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT • Remove speed sensor assembly & Take out front wheel assembly. • Remove 4 no. bolts (2 nos. on both LH & RH side) securing front fender by 12mm ring spanner & take out front fender assembly.
  • Page 176 DAT s)l ai[ e l s)l bdlvin) p¹Ft) SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT • Remove spacer tube, washer & Front fork spring. Ap[ S r Ty& b , vi[ S r an[ f\ º T f\ [ m l[ g Ap\ ) > g n[ bhir kiQi[ . •...
  • Page 177 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT • Remove handle bar holder by removing 2 nos allen bolts with 6mm allen key. mm Allen Key h[ º Dl bir hi[ Ã Drni b[ bi[ Ã Tn[ 6 Wiri Ki[ l i[ .
  • Page 178 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT • Take out front fork oil seal, washer & anti-friction bush. f\ º T fi[ k < ai[ e l s)l/vi[ S r an[ a[ º T) f)kSn b& S n[ bhir kiQi[ . Assembling f)T krv&...
  • Page 179 SOP FOR FRONT FORK DUST SEAL & OIL SEAL REPLACEMENT Note :- 1. Never reuse oil seal. 2. Always replace the fork oil seal along with dust seal of same manufacturer. 3. Front fork oil seal fitment direction should be as shown in photograph. •...
  • Page 180 SOP FOR STEERING OVERHAUL AT)yr)> g ai[ v rai[ l S.N. Description Frame Assly. Comp. Cup Rear Cup - Steering Bearing Cone Kit Kit St Cone with RR3 Grease Ball Steel With Cage Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 181 SOP FOR STEERING OVERHAUL AT)yr)> g ai[ v rai[ l • Remove Petrol tank cover & petrol tank p[ T ^ i [ l T[ º k kvr kiQ) p[ T ^ i [ l T[ º k bhir kiQi[ •...
  • Page 182 SOP FOR STEERING OVERHAUL • Remove Front caliper assembly f\ º T k[ l )pr a[ s [ À blk)n[ Ki[ l i[ . • Remove Front Axle aigLn) a[ k sl Ki[ l i[ . • Remove Front wheel assembly aigLni Äh)ln[ bhir kiQi[ .
  • Page 183 SOP FOR STEERING OVERHAUL • Remove fork central bolt. • Lift handle bar assembly to right side fi[ k < n i s[ º T^ l bi[ Ã Tn[ Ki[ l i[ . h[ º Dl bir a[ s [ À bl)n[ jmN) bij& m& k i[ . •...
  • Page 184 SOP FOR STEERING OVERHAUL AT)ar)> g ai[ v r ai[ l • Fit the upper & lower cones by using special tools. upr an[ n)c[ n ) ki[ n n[ Ap[ S yl T& Ã s Wiri f)T kri[ . Notes Pulsar 150/180 DTS-i Dealer Development Center...
  • Page 185 SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING S.N. Description S.N. Description Head Lamp Assly. Without Bulb Fairing Mounting Upper Bracket Back Cover Kit Hardware Mtg. Bracket Wind Shield Clip Nut Bolt M-5 Screw Pan Cross Non Metallic Washer Screw Pan Cross Well Nut Lamp 12V 35/35W-HS1 Decal Wind Shield...
  • Page 186 SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING Dismantling D)sm[ º Tl)> g - Ki[ l v& Remove : kiQi[ . • 4 screws • Visor CAUTION c[ t vN) Keep the visor at good location to avoid scratches. viezr upr Ak\ [ c pDti ri[ k vi miT[ sir) j³yia[ m& k i[ . Remove : •...
  • Page 187 SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING Remove : • Bolt (Holding with lamp shade) LH & RH. kiQi[ bi[ Ã T Ki[ l i[ {l[ À p S[ D siY[ } Remove : • Disconnect all couplers. • Head light fairing assembly. kiQi[ bFi kplrn[ C&...
  • Page 188 SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING Assembling f)T krv& > Fit : • Speedometer on lamp shade. • Guide the couplers. • Connect speedometer coupler. f)T kri[ l[ À p S[ D upr Ap)Di[ m )Tr gieD kplr Ap)Di[ m )Tr kplrn[ kn[ k T kri[ . Fit : •...
  • Page 189 SOP FOR DISMANTLING & ASSEMBLING FRONT FAIRING Fit : • 2 bolts. • 2 washers. f)T kri[ 2 bi[ Ã T 2 vi[ S r Fit : • 2 Number plate holding bolts. • Number plate with damper rubber. f)T kri[ ¼l[ T hi[ Ã...
  • Page 190 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ S.N. Description S.N. Description Rear Shock Absorber Chain Slider Bolt Pre-coated Screw Kit Bush Rear Shock Plain Washer Swing Arm Assly. Adjuster Chain LH Bush Swing Arm Adjuster Chain RH Collar Swing Arm Plate Chain Adjuster Dust Seal Swing Arm...
  • Page 191 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ S.N. Description S.N. Description Holder LH Step Flanged Bolt Holder RH Step Tube Silencer Mtg. Pillion Step Assly. Comp. LH Damper Silencer Mtg. Pillion Step Assly. Comp. RH Flange Bolt M10 Rubber Pillion Step Washer Plain Kit Hardware Pillion...
  • Page 192 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ Remove : • 2 flange nuts. kiQi[ fl[ º j nT 2 n> b r Remove : kiQi[ • Allen bolt. a[ l n bi[ Ã T • Nut. • Silencer complete.
  • Page 193 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ Remove : • Rear brake switch coupler. kiQi[ r)ar b\ [ k Av)c kplr Remove : • Bolt. kiQi[ bi[ Ã T Remove : • Swing arm RH side nut. kiQi[ Av)>...
  • Page 194 SOP FOR SWING ARM REPLACEMENT Remove : • Bolt • Gear pedal yoke. kiQi[ bi[ [ Ã T g)ar p[ D l ci[ k Remove : • 2 bolt. • Chain cover. kiQi[ 2 bi[ [ Ã T c[ e n kvr Remove : •...
  • Page 195 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ Remove : • 2 bolts for chain cover. • Chain cover. kiQi[ c[ e n kvrni b[ bi[ [ Ã T c[ e n kvr Remove : kiQi[ • Axle nut a[ k sl nT •...
  • Page 196 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT Remove : • Bolt for RSA - LH & RH. kiQi[ LH & RH bi[ [ Ã T- Remove : • Axle swing arm. • Step holder LH. kiQi[ a[ k sl Av)> g aim< AT[ p hi[ Ã...
  • Page 197 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ • From RH side of frame’s steering tube area route the corrugated wiring harness as shown in the photograph. RH sieD f\ [ m AT)ar)> g Ty& b bij& Y ) b[ r )> g hirn[ s n[ $T kri[ {fiTi[ g iifs p\ m iN[ } •...
  • Page 198 SOP FOR SWING ARM REPLACEMENT Av)> g aim< bdlvi miT[ • Clamp the wiring harness on main member of frame by band as shown. m[ e n m[ À br upr {f\ [ m upr} viyr)> g hirn[ s n[ kl[ À p kri[ . •...
  • Page 199 WIRING HARNESS ROUTING viyrn[ s hirn[ s $T)> g • Route the stator plate wiring through the clamp provided on frame as shown in the photograph. AT[ T r ¼l[ T viyr)> g n[ fi[ T i[ g \ i fsmi btiÄyi p[ m iN[ f\ [ m upr $T)> g kri[ . •...
  • Page 200 WIRING HARNESS ROUTING viyr)> g hirn[ s $T)> g • Route the starter motor cable & clamp it with the band as shown in the photograph. ATiT< r mi[ T r k[ b ln[ fi[ T i[ g\ i fsmi> jNiv[ l p\ m iN[ kl[ À p b[ º D Wiri kri[ . Notes Pulsar 150/180 DTS-i Dealer Development Center...
  • Page 201 SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT SOP k[ l )pr p)ATn s)l an[ DAT s)l bdlvi miT[ • Clean master cylinder & caliper thoroughly by low pressure water spray before opening master cylinder top cover & caliper bleeder screw. miATr s)l)ºDr an[ k[ l )prn[ kim krti ph[ l i li[ a[ r p[ \ [ s rY) bribr sif kr) Ryir bid j miATr s)l)ºDr Ti[ p kvr an[ k[ l )pr ¾l)Dr Ak\ &...
  • Page 202 SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT - k[ l )pr p)ATn s)l an[ DAT s)l bdlvi miT[ • Remove holder bracket & pad spring. hi[ Ã Dr b\ [ k [ T an[ p[ s Ap\ ) > g n[ bhir kiQi[ •...
  • Page 203 SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT • Replace caliper assembly major / minor kit. k[ l )pr a[ s [ À bl) ni mi[ T i/nini piT< s n[ bhir kiQi[ . • Smear silicon grease on piston OD & rubber seals. p)ATnn) bhir n) srf[ s upr an[ rbr piT<...
  • Page 204 SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT • Smear silicon grease on anchor pins evenly. a[ º kr p)n upr s)l)ki[ n g\ ) s bribr lgivi[ . • Fit holder bracket on caliper assembly. k[ l )pr a[ s [ À bl) upr hi[ Ã Dr b\ [ k [ T f)T kri[ . •...
  • Page 205 SOP FOR CALIPER PISTON SEAL AND DUST SEAL REPLACEMENT • Fit caliper assembly on fork mounting & fit the brake hose pipe by tightening banjo bolt. k[ l )pr a[ s [ À bl)n[ fi[ k < upr f)T kr) b\ [ k hi[ s piepn[ f)T kri[ b[ º Ô[ bi[ Ã T Wiri •...
  • Page 206 SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT • Clean master cylinder & caliper thoroughly by keeping nozzle in spray mode before opening master cylinder top cover & caliper bleeder screw. • Drain the brake fluid from caliper assembly by loosening air bleeder screw &...
  • Page 207 SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT • Keep the container below the master cylinder for oil collection during opening. • Remove brake hose from master cylinder by loosening banjo bolt. • Insert blunt tipped screw driver or steel spoke from banjo bolt side & push piston towards brake lever.
  • Page 208 SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT • Remove master cylinder cap, remove master cylinder from handle bar & clean internals by using brake fluid. • Dry master cylinder by compressed air. • Fit master cylinder on handle bar. Smear silicon grease on new piston seals of master piston kit.
  • Page 209 SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT • Insert protection boot correctly so that dust will not enter. • Refit the brake lever & front brake switch. • Use new copper washers & fit hose pipe by tightening banjo bolt. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual...
  • Page 210 SOP FOR MASTER CYLINDER PISTON KIT REPLACEMENT • Fill brake fluid up to MAX level. • Remove the air by bleeding process. Maintain oil level in between MAX & MIN level. • Re-fit rubber diaphragm & reservoir cap. Check brake effectiveness. •...
  • Page 211 SOP FOR FRONT BRAKE HOSE REPLACEMENT • Clean brake system by keeping nozzle in spray mode. • Drain brake fluid from caliper assembly by opening air bleeder screw. • Remove the hose pipe fitment banjo bolt from both ends (master cylinder &...
  • Page 212 SOP FOR FRONT BRAKE HOSE REPLACEMENT • Route the front brake hose as shown in photographs. • Conduct the brake bleeding procedure. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 213 SOP FOR BRAKE FLUID REPLACEMENT • Clean the surface area of master cylinder. • Drain brake fluid from caliper air bleeder bolt. • Tighten the air bleeder bolt on caliper assembly. • Remove reservoir cover by removing 2 nos. phillips head screws. •...
  • Page 214 SOP FOR BRAKE FLUID REPLACEMENT • Perform air bleeding of disc brake system if the brake operation is spongy. a. Remove rubber cap from caliper's bleeder screw. b. Fit a proper tube which fits snugly tight on the bleeder screw nipple. c.
  • Page 215 SOP FOR BRAKE FLUID REPLACEMENT • Fit the master cylinder cover. • Press the front brake lever and check the operation of disc brake. f. During this process continuously monitor and maintain the brake fluid level in the master cylinder reservoir slightly above the minimum mark. •...
  • Page 216 Notes Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 217 Electrical el[ k T^ ) kl -b[ T r) • Battery -el[ k T^ ) kl c[ k )> g p¹Ft) • Electrical Checking -ATiT< r mi[ T r Procedure -b[ T r)-kri[ / ni kri[ • Starter Motor b[ T r) ciJ< > g k> D )Sn •...
  • Page 218 BATTERY Battery Technical Specification : • Type & Capacity Pulsar 150 - 12V - 7 AH Pulsar 180 - 12V - 9 AH • Specific gravity of electrolyte 1.24 for use above 10 C for initial filling of new battery •...
  • Page 219 BATTERY • Top up level with distilled water to max level and results in loss of capacity. Mostly the causes of when the electrolyte level is less than half of min sulphation are as under : & max level. a. Undercharging. •...
  • Page 220 BATTERY 6 Channel Battery Charger 6- c[ n l b[ T r) cij< r • Make Teknikraft T[ k n)k\ i fT m[ e k • Model 12M6, with stand m[ i Dl Suitable for charging 6 batteries (2.5Ah/5Ah/7Ah/9Ah) Constant current type having 0.25 Amp. /0.5 Amp./0.7 Amp./0.9 Amp.
  • Page 221 BATTERY Checking Condition of Battery For checking condition of battery, load tester as per following specifications is to be used : Make Midtronics Model PBT50 Procedure for checking battery condition • Disconnect battery +ve & -ve terminals. • Confirm battery type & reference no. •...
  • Page 222 ELECTRICAL CHECKING PROCEDURES Switches : Front Brake Light Switch Inspection : • Turn ON the ignition switch. • The brake Light LED Blank should get on when the front brake (Lever is pressed) is applied. • If it does not, check the Front brake switch. Brown Blue Lever Pressed...
  • Page 223 ELECTRICAL CHECKING PROCEDURES Stator Plate Coils Inspection : • Disconnect stator plate coupler • Set multi meter on ohm range. (Ohm Meter) Pickup Coil Resistance : Range Connections Reading Meter +ve Meter -ve White/Red Black/Yellow Battery Charging Coil : Range Reading Meter +ve Meter -ve...
  • Page 224 ELECTRICAL CHECKING PROCEDURES Fuse : Main Fuse Inspection (Capacity = 15 Amp) / Secondary Fuse Inspection (Capacity = 10 Amp) • Inspect the fuse element • If it is blown out, replace the fuse. • If a fuse fails during operation, the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
  • Page 225 ELECTRICAL CHECKING PROCEDURES Starter Relay Coil Resistance Checking Measuring & Testing Equipment : Multimeter Meter Range Connections Standard Value Meter +ve Meter -ve 200 Ohms Starter Relay Starter 3.9 Ohms Coil Red - Relay Coil Yellow Wire Black Wire SOP : •...
  • Page 226 ELECTRICAL CHECKING PROCEDURES DC Charging Voltage Measurement : (Use fully REGULATOR CAPACITOR WITH CAPACITOR charged battery while measuring) To measure the DC voltage; set the meter at 20VDC range. Connect the meter +ve lead to white from RR unit and meter -ve lead to ground. Start the engine and set it at 4000 25 RPM.
  • Page 227 ELECTRICAL CHECKING PROCEDURES Fuel Gauge - Tank Unit Empty Tank Measuring & Testing Equipment : Multimeter Meter Range Connections Standard Value Meter +ve Meter -ve As per chart 200 Ohms White / Yellow Black / Yellow given below Standard Value : (For 150 CC & 180 CC) Full Tank Fuel Level Fuel Quantity...
  • Page 228 ELECTRICAL CHECKING PROCEDURES Speedometer Console : The speedometer has a wide Digital LCD screen with a orange backlit display mode for superb visibility of display during night riding condition. This entire speedo console houses following : • A large analogue tachometer with self check mechanism. •...
  • Page 229 ELECTRICAL CHECKING PROCEDURES Tail LED Lamp : The illumination for Tail lamp and Brake lamp are done through 2 rows of LED’s each. These are high intensity LED’s. The main advantage of these LED’s is that; • They consume very less power. i.e LED consumes 3W power against 21 W power of a conventional brake lamp.
  • Page 230 ELECTRICAL CHECKING PROCEDURES CDI Assembly Identification : • Case colour - Black for Pulsar 150 • Coupler - White 2 coupler with sealed type. • Case colour - Brown for Pulsar 180 • Coupler - Black 2 coupler with sealed type.
  • Page 231 ELECTRICAL CHECKING PROCEDURES Light Control Module Location : Mounted on bracket above high beam projector lamp. This unit is a combination of head light controller & flasher unit. Function : The flasher circuit controls the flashing rate & operation of side indicators. The light control module switches ON head light (Low beam &...
  • Page 232 ELECTRICAL CHECKING PROCEDURES Vehicle Speed Sensor • Non contact Wheel Sensor - In LCD speedo console there are no moving parts as wheel speed is sensed through a non contact hall effect sensor. The hall sensor is an electronic switch which operates due to magnetic field.
  • Page 233 ELECTRICAL CHECKING PROCEDURES Starter Motor - Current Drawn Measuring & Testing Equipment : DC Clamp Meter Meter Range Connections Standard Value 30 ~ 38 Amps Spark Encircle clamp meter Plug Caps removed 200 DC A transformer jaws around (Measured at 27 ) thick Red wire of starter motor SOP : •...
  • Page 234 STARTER MOTOR DE Bracket Assly. (Cover Front) Yoke Assembly ‘O’ Ring for 1 Fiber & 1 Plain Washer DE Bracket Armature Assembly “O’ Ring (2 nos.) Positive Brush Tie Bolt (2 nos.) Holder Assly CE Bracket Assembly Sealing Ring (Cover Rear) (2 nos.) Negative Brush Holder Assly...
  • Page 235 STARTER MOTOR Shaft Permanent Magnets Brush Holder Commutator Bush Brush Holder Carbon Brushes Armature Winding • Remove carbon particles from commutator slots by sharp blade / knife. • Clean commutator segments by soft cloth. • Lubricate brass bush by 2~3 drops of Servo 32 oil & NR Bearing by high temperature-high speed OKS410 grease .
  • Page 236 DOS AND DON’TS Battery Don’ts • Apply petroleum jelly to • Do not apply grease to poles / terminals. poles / terminals. • Use proper tools. • Do not hammer battery terminals. • Use only distilled water • Do not use mineral water, to top up battery.
  • Page 237 DOS AND DON’TS Battery Don’ts • C h e c k o p e n c i r c u i t • Do not short circuits the voltage by multi meter. poles. • Always maintain battery • Do not fit extra electrical top cover clean and dry.
  • Page 238 SOP FOR CHECKING CHARGE CONDITION OF BATTERY - b[ T r)n) cij< k> D )Sn c[ k )> g - b[ T r)n) cij< k> D )Sn c[ k )> g SOP for Checking Charge Condition of Battery • Ensure Ignition switch of the vehicle is in OFF position. 'OFF' vihnn) e³n)Sn Av)c pi[ z )Snmi>...
  • Page 239 SOP FOR CHECKING CHARGE CONDITION OF BATTERY • Confirm display indication on LCD. • Clamps connection is not firm, remove dirt, dust, rust if any from battery terminals. LCD D)A¼l[ cil& C[ k[ nh) t[ c[ k kri[ b[ T r) Tm)< n ln[ sif kr) kn[ k Sn n kri[ •...
  • Page 240 SOP FOR CHECKING CHARGE CONDITION OF BATTERY • Voltage indication and green & yellow LED's are glowing-Battery is partially charged. Charge the battery using Metafab make VRLA battery charger • Voltage Indication & yellow LED is glowing-Battery is discharged. Charge the battery using Metafab make VRLA battery charger •...
  • Page 241 DOS AND DON’TS HORN Don'ts Ensure that horn is firmly fitted Never remove resonator on frame cap as it could result in water entry & subsequent malfunctioning of horn Ensure that horn is free from Do not apply pressurised dust and mud accumulation. water jet directly on horn resonator.
  • Page 242 DOS AND DON’TS IGNITION SYSTEM • Always install recommended capacity of battery on the bike. • Always replace spark plug by correct heat range plug. • Check & adjust spark plug gap periodically. Adjust it to 0.7~0.8mm by feeler gauge. •...
  • Page 243 DOS AND DON’TS LIGHTS • Check that all bulbs are firmly fitted in bulb holder. • Ensure that all fixing screw of bulb housing are intact. • Ensure that Reflector / Glass of Head Lamp, Tail Lamp, Side indicator is intact. •...
  • Page 244 ELECTRICAL CIRCUIT DIAGRAMS Starter Motor Circuit START SWITCH ENGINE OFF KILL SWITCH ATiT< r mi[ T r srk)T Br/L IGNITION SWITCH CABLE ASSY. RELAY TO STARTER MOTOR STARTER FUSE 1 MOTOR (15 Amps.) STARTER RELAY BATTERY MF 9Ah CABLE NEUTRAL ASSY SWITCH EARTH...
  • Page 245 ELECTRICAL CIRCUIT DIAGRAMS Brake Light Circuit REAR BRAKE FRONT BRAKE SWITCH SWITCH b\ [ k lieT srk)T TAIL LAMP ASSLY. (Stop LED) Br/L IGNITION SWITCH TWIN BOX ASSY FUSE 1 FUSE 2 (15 Amps.) (10 Amps.) BATTERY MF 9Ah CAPACITOR Battery Charging Circuit b[ T r) ciJ<...
  • Page 246 ELECTRICAL CIRCUIT DIAGRAMS Neutral Lamp Circuit PIN NO. 1 INSTRUMENT CLUSTER + INPUT Gr/R Gr/R ENG OFF KILL ºy& T ^ l l[ À p srk)T SWITCH PIN NO. 6 COMMON GROUND PIN NO. 7 COMMON GROUND PIN NO. 9 TALE-TELL NEUTRAL INDICATOR PIN NO.
  • Page 247 ELECTRICAL CIRCUIT DIAGRAMS Fuel Gauge Circuit PIN NO. 1 INSTRUMENT CLUSTER + INPUT Gr/R fy& a l g[ j srk)T KILL SWITCH TANK UNIT ENG OFF PIN NO. 6 ENG ON COMMON GROUND PIN NO. 7 COMMON GROUND PIN NO. 13 FUEL GAUGE INDICATOR PIN NO.
  • Page 248 ELECTRICAL CIRCUIT DIAGRAMS Gr/R Tachometer Circuit PIN NO. 1 KILL SWITCH INSTRUMENT CLUSTER + INPUT ENG OFF T[ k i[ m )Tr srk)T ENG ON DC C.D.I. ASSY. PIN NO. 6 COMMON GROUND PIN NO. 7 COMMON GROUND PIN NO. 8 TACHOMETER Gr/R PIN NO.
  • Page 249 ELECTRICAL CIRCUIT DIAGRAMS el[ k T^ ) kl srk)T Diyig\ i m LIGHT SWITCH LED CONTROL KILL SWITCH Lighting Circuit LIGHT CONTROL MODULE Gr/R ENG OFF Kill Switch ON ENG ON lieTn)> g srk)T DC REGULATOR ASSLY WITH CAPACITOR CAPACITOR BACK LIGHT GROUND HIGH BEAM INDICATOR...
  • Page 250 Notes Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 251 p\ [ i blm Si[ F vi an[ t[ n & (nrikrN Diagnosis & Troubleshooting...
  • Page 252 DIAGNOSIS AND TROUBLESHOOTING For Diagnosis & trouble shooting refer trouble shooting encyclopedia uploaded on portal. Pulsar 150/180 DTS-i Dealer Development Center Service Station Manual Akurdi Pune...
  • Page 253 Bajaj Auto Limited bÔj ai[ T i[ l)m)T[ D Akurdi Pune 411 035 India aik& D )< p& n i 4110 035, Birt Tel +91 20 2 7472851 Fax +91 20 2 7407385...

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