Pulsar - DTSi - UG - III - Workshop Manual 1 PDF

7.
ExhausTEC
8. Tail Light LED display
3. Control Switch LH
4. Body Control Unit
6. Vehicle Speed Sensor
Pulsar DTS-i UG-III-180cc Training Notes
(Placed inside Head Light fairing)
5. Hall Sensor for Indicator
2. LCD Speedo Console
The Engine and Frame serial numbers are used

to register the vehicles. They are the only
means of identifying your particular vehicle
from the other of the same model and type.
These serial numbers may be needed by your
dealer when ordering the parts. In the event of
theft, the investigating authorities will require
both these numbers in addition to the model,
type and any special features of your vehicle
that can help identifications.
1. Control Switch RH
Location of Parts
Identification Data
Dealer Development Center
Salient Features
Ergonomically designed self-letting switches
Louver type LH & RH covers with wire mesh gives sturdy look.
New seat cowl to match stylish LED tail lamp.
New age, sharp and attractive 2 Row Tail lamp with LED lights
Clear lens indicator with amber bulbs.
adds to aesthetics.
Self check provision for Tachometer for its functioning
glows continuously till the petrol filled to main level.
Engine oil level window for easy to monitor level.

Maintenance free battery once a year electrolyte top up.
In addition to Fuel gauge, Reserve indicator bulb is provided that
will be switched off automatically.
Self-canceling indicators After completion of turn, the indicator
provision.
LCD Speedo Console with digital fuel gauge (12 level indicator)
Digital speed display, odometer and two trip meter with resetting
Convenience and Comfort
Stylish fairing and head lamp assembly with owleye

A new black mask that separates headlamp from parking lights
Style :
function for the life of the bike. Absolutely no maintenance in

absence of mechanical contacts.
Stainless steel silencer that overcomes rusting problem

All sensor type electrical switches that enables switches to
maintenance
LED tail lamp that consumes negligible power & require zero
friction reduction that improves drivability.
Optimized valve timing and Roller rocker with NR bearing for
provide better torque
New Bigger twin foam filter with an optimized intake system to
& revamped gear shifting mechanism that gives

smooth, positive, virtually friction-free gear shift feel
New clutch
location and revised ignition timing with intelligent CDI
Refined engine power delivery by optimization of Exhaus TEC
Performance :
Salient Features
LED illumination for tell-tale icons on electrical switches that glows in

the night for positive access of individual functions.
to bring down the engines RPM for safety.
Engine cut-off at 10000 RPM Spark gets cut-off at 10000 RPM
when engine reaches to 9000 RPM

automatically Red LED bulb starts blinking. This enables the rider to
control the speed to avoid damages if any that may take place to
engine components.
High RPM warning lamp
glow brightly in the day for clarity, and Intensity reduces during night to
reduce irritance to the rider's eye
Day night mode of Speedo console

The turn Indicator, neutral, high beam, and side stand Indicator bulb
Safety :
1st
2nd
3rd
4th
5th
gear
gear
gear
gear
gear
:
:
:
:
:
:
:
:
:
:
:
Spark Plug Gap

Lubrication
Starting
Clutch
Transmission
Primary Reduction
Gear Ratios:
Rear
Rims (Alloy Wheels)
Tyre Pressure
Front
Rear
Front
Rear Solo
Rear Pillion
:
:
:
:
:
:
:
Front
Brakes
Front
Rear
:
:
Suspension
Tyres
:
Front
Rear
Frame Type
CHASSIS & BODY
Spark Plug
Final drive ratio
Carburettor
280 BTDC at 3500 rpm.

:
:
Fuel
100 BTDC at 1500 rpm.

:
Ignition Timing
:
:
:
:
:
1
1
1
1
1
(36/13)
(32/17)
(29/21)
(26/24)
(24/26)
1.60 x 17
2.15 x 17
1.75 kg/cm2 (24.5 Psi)

2.00 kg/cm2 (28.0 Psi)
2
2.25 kg/cm (32.0 Psi)
2.75 x 17, 41 P
100/90 x 17, 55 P
Mechanically expanding shoe and drum type.

Hydraulically operated disc type.
Mechanically expanding shoe and drum type.
Telescopic front fork with DU bush (Stroke 135mm)

Trailing arm with coaxial hydraulic cum gas filled
adjustable shock absorbers, and triple rate coil springs.
Double cradle.
2.80 : 1 (43/15)
26.93
18.31
13.43
10.54
8.98
3.47 : 1 (66/19)
5 speed constant mesh.
Wet, Multidisc type.
Kick start / Electric start.
Wet sump, Forced.
0.7 to 0.8 mm.
2 Nos. Champion RG4HC, Bosch UR3DC (Resistive)
UCAl-MIKUNI BS29, Side Drought, CV Type.
Unleaded petrol
Microprocessor controlled digital C.D.I.
Ignition System
15.22 Nm at 6000 rpm.
12.15 kW (16.51 Ps) at 8000 rpm.
1400 + 100 rpm.
9.5 + 0.5:1
178.60 cc.
56.40 mm.
63.50 mm.
Four stroke DTS-i, Natural air cooled.

One
Max. net torque
Max. net power
:
:
Compression ratio
Idling Speed
Engine displacement
Bore
:
No. of cylinders
Stroke
:
:
Type
Engine and Transmission
Technical Specifications
mm.
mm.
mm.
mm.
mm. (Minimum)
mm. (Minimum)
Specifications are subject to change without notice.
Definitions of terminologies wherever applicable are as per relevant IS/ISO standards.
All dimensions are under UNLADEN condition.
125 km/h with single rider (68kg)

28% (160 Maximum)
143 kg.
273 Kg.
1990
750
1090
1320
2180
165
Values given babove are nominal and for guidance only, 15% variations is allowed to cater for
production and measurement variation.
:
:
:
:
:
:
:
:
:
:
12 V (AC+DC)
12V 9Ah
35/35 W-HS1
5W - 2 Nos.
LED
10 W (2 Nos.)
LED
LED
LED
LED
LED display
5 W
12V DC
Pedal operated by right foot
Lever operated on RH side of handle bar
Lever operated on LH side of handle bar
Left foot pedal operated
Twist grip type on RH side of handle bar
Handle Bar
Notes:
Maximum speed
Climbing ability
PERFORMANCE
Vehicle kerb weight

Gross vehicle weight
WEIGHTS
Length
Width
Height
Wheel base
Turning circle radius
Ground clearance
DIMENSIONS
System
Battery
Head Lamp
Pilot Lamp
Tail/Stop lamp
Turn signal lamp
Turn signal pilot lamp
Side stand indicator lamp
Hi beam indicator lamp
Neutral indicator lamp
Speedometer lamp
Rear number plate lamp
Horn
:
:
:
:
:
:
:
:
:
:
:
:
:
Rear
ELECTRICALS
Front
Gears
Brakes
Clutch
2.0 liters Usable reserve
Accelerator
15 liters Full
3.2 liters Reserve
Steering
CONTROLS
Fuel Tank Capacity
Technical Specifications
The major changes / features are
Front wheel of the bike has a sensor & magnet unit. The sensor counts no. of pulses w.r.t.
wheel rotation & logically calculates number of wheel rotation & gives input to the display
unit in the speedo console and the LCD display indicates accurate speed, odo reading &
trip meter readings.
How does the digital Speedo work?
Day night mode of Speedo console, LED illumination for tell-tale icons on electrical
switches that glows in the night for positive access.
High RPM warning lamp when engine reaches to 9000 RPM automatically Red LED
bulb starts blinking.
Engine cut-off at 10000 RPM Spark gets cut-off at 10000 RPM
Enhanced Safety
Oil level inspection window that indicates oils level at a glance.
Self check provision for tachometer to ensure proper functioning.
Apart from digital fuel meter, warning light for low fuel level is provided.
Car like self canceling indicator switches that keeps rider free from switching off the
indicators after turn.
Loaded with Digital Technology like LCD Speed/Odo display, digital fuel meter, Digital
trip meter that enables to count two trips.
Enhanced Comfort & Convenience
Absolutely no maintenance in absence of mechanical contacts.
Ergonomically designed self-letting switches
Louver type LH & RH covers with wire mesh gives sturdy look.
New age, sharp & attractive 2 Row Tail lamp with LED lights
Stylish fairing & Headlamp assembly with owl eye, new black mask to separate
headlamp from parking lights
Enhanced Style
All sensor type electrical switches that function for the life of the bike. Absolutely no
maintenance in absence of mechanical contacts.
Stainless steel silencer that lasts long & overcomes rusting.
Refined engine power delivery by optimization of ExhausTEC location, bigger & twin
Air Filter element, optimized valve timing, reduced engine friction etc.
Enhanced Performance
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.
Pulsar UGIII is next version of Pulsar breed. It is loaded with lots of unique &
contemporary features and that distinguishes the Pulsar not only in the category of Power,
Performance & Style but also for Comfort, Convenience & Safety from the competition.
What is so special in this 'PULSAR DTS-i 180 UG III '?
What are the special features of 'PULSAR DTS-i 180 UG III '? OR
Frequently Asked Questions (FAQs)
When the digital fuel meter is available, why the red warning light is provided?
While the LCD graphical bar segments indicates the petrol level in the fuel tank, the red
warning light continuously reminds the rider to fill the petrol.
Why two trip meter reading option is given? How is it useful?
It is just to enable the rider to count reading for two different trips unlike only single trip in
case of conventional type.
It is like this - on selecting 'Trip1' its will indicate the distance covered in first trip that is
set for. In continuation, on selecting 'Trip2', it will indicate the distance covered in the
second trip. Then if one wants to know the cumulative distance covered in first & second
trip, it can be found in 'Trip1' mode. For this one has to just press/select 'Trip1' mode.
This is an added advantage taken from digital technology!
What do Self-canceling Indicators switches means?
In conventional type of switches, the rider has to manually depress or turn knob of
indicator switch for putting 'OFF' the indicator bulbs. In case of this Self-canceling'
switches the indicator goes off automatically after the rider takes a turn & brings the
handle bar straight. This feature is similar to cars. That means, rider do not have to press
or turn the switch to cancel the indicators.
What if one switches ON the indicator and do not physically take a turn? Will it work
in such situation?
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 after pre-set time.
For this a timer function is incorporated in the system. And the timing for this timer is set
around 80 seconds.
Apart from LCD graph bar, a red warning light also has been provided in the console that
glows continuously when the petrol level falls down to reserve. And it will be 'ON' till petrol
is filled above reserve level.
When the petrol level comes down to below four liters, all the segments of the bar will
vanish.
As the float gauge in the tank starts lowering down due fuel level coming down, the
segments of the bar graph starts diminishing with corresponding drop in fuel level.
Yes. The tail lamp is unique on this vehicle and no other competitor's vehicle has this
feature. It consists of 16 (8) nos. of LED bulbs with bi-filaments.
The specialties of LED bulbs are
So, in all it is almost maintenance free battery. Moreover, the LED bulbs, & disable
function of cranking after 3 successive self starts attempts, will further only enhance the
life of the battery.
- No drainpipe unlike in conventional type battery. So no chances of spillage of electrolyte.
- The unique vent mechanism that do not allow loss of electrolyte
The battery is new development in DC system on two wheelers (in fact, such batteries are
introduced in cars earlier than bikes) it is different than the conventional one in the material
composition it is made up of. The main features of this new battery are
- Electrolyte level checking is required at every one year instead of every fortnight
What is this maintenance free Battery?
Absolutely not. In fact, all the bulbs & backlit bulbs in the Speedo console (except Head
Lamp bulb & pilot bulbs) are of LED type. Few of them works on AC & few are on DC i.e.
battery. So there is hardly any drain on the battery as compared to conventional type of
bulbs.
Moreover, the Battery of this new Pulsar 180 is special & maintenance free.
If so much so electrical /electronic appliances are loaded, it may affect on Battery?
Bi-filament bulb means these LED bulbs have two filaments in each bulb. One filament of
lower wattage for parking lights & another for brake lighting, which is of little higher
wattage.
What is this bi-filament bulb?
So, the LED tail lamp apart from delivering fantastic performance, it adds to aesthetics.
- Totally maintenance free
- Last far long
- Glow brightly
- Consume very low current
The tail lamp assembly seems to be too special. What is so in that?
The other feature, in these switches is the Illumination of the tell-tale icons that is lit up
with LEDs inside the switch body. This gives the icons a pleasant bluish white glow that
can be seen in the night clearly & coolly.
Graphic bar with 12-segment display is provided in the speedo console for indicating fuel
level in the tank. If the all the 12 segments of a bar graph are 'ON', that indicates that the
fuel tank is full.
This feature will have any wear and tear & hence its life would be more than the life of the
bike. These are absolutely maintenance free as far as wear & tear is concerned.
How the digital fuel indicator meter works? OR How one can understand the available
fuel level in the fuel tank? OR How to read the graphical bar of the fuel meter?
The control switches on both sides of the handlebar are conventional to look at, in terms
of switch operations & knob position etc. But the key & distinguishing difference is the
principle of functioning that means these switches do not function on the basis of physical
contact for ON & OFF. These are on non-contact sensor based.
This system is totally contact less & no mechanical transmission of drive from wheel to
speedometer is available. Thus this system is totally maintenance free & lasts for the life of
the bike.
What does non-contact Handlebar switches mean?
What are the advantages / Benefits of the digital speedometer apart from giving
accurate reading?
A protective device has been incorporated in the system that allows rider to attempt selfstart option (pressing of self-start button) for starting only three times at times. After third
attempt the battery power supply gets cut-off to the self-starter motor, thus avoid rider
from further cranking of engine by self-start.
This is mainly to protect the battery from over draining by excess attempts of pressing of
self-start button to start the engine.
However, one can again use the self-start option after 15 seconds after third attempt.
How come so many features are managed accurately & what is the guarantee of no
malfunctioning of these features?
It is needless to say that the digital technology that works with sensors & chips works
accurately. To control all the functions of these electronics features, an intelligent device
has been installed in the electrical system. This is called BCU (Body Control Unit)
What exactly is BCU (Body Control Unit)? How it controls all these functioning?
BCU (Body Control Unit) is a device that integrates & controls major of all electrical /
electronic functions on the vehicle. It is an intelligent device that works on microchip base.
In the eventuality of electrical overloads or short circuits, the built in intelligent protection
circuit takes the control of the situation & prevent future damages on other electronic
parts. For example:- During night, suppose 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 beam automatically
without manual shifting of any switches.
It also checks & inspects the fused circuit religiously for any corrections and thus riders'
safety is ensured.
Are these type of product features available in Pulsar150cc also?
Presently not. But as in all sphere of life, technology also proliferates. When that happens
you may find similar features in Pulsar 150cc also.
Can one alter the current Pulsar model & incorporate these features?
B` No. It is not possible. Physically lot of changes are there that are not easily
accommodated in the existing Pulsar.
What is that disabling of cranking after 3 successive attempts?
FRONT / REAR WHEEL OFFSET

WHEEL
5
6
Speedo :
LED functioning - Speedounit - Both side indication,

Side stand, Neutral, Hi beam, RES ind lamp
Head light / tail light illumination after 3 seconds
Auto-switch off of Ind lamps(H bar straight for > 2 sec)
Red lamp blinking after crossing Engine RPM 9000
Reserve indication (by red lamp)
Fuel level indication
Auto - Calibration of RPM meter
Odometer working
Tripmeter - 1/2 working -Resetting
SPEEDO Needle flickering.
SPEEDO NOT SENSING.
HORN :- DISTORTED/WEAK SOUND(DO NOT SET)

11
TAIL/BRAKE LED
HEAD LIGHT
Side indicator blinking.
LIGHTS:-
IGNITION SWITCH SHORT
LH Switch operations
10
SWITCHES
RH switch operations
SILENCER -BAFFLE NOISE
REAR WHEEL RUN OUT (SPECIFY)
FRONT WHEEL RUNOUT (SPECIFY)
FR. WHEEL TYRE -Free rotation.
FUEL COCK OPERATION - HARD / LEAKAGE
OTHERS
RUSTY
BLISTERS
(Specify)
FUEL TANK DEFECTS

LEAKAGE
PAINT FINISH - OVER FLOW (Samples / photographs)
SIDE COVER LOCK NOT WORKING
STEERING LOCK NOT WORKING/JAM
LOCK OPERATION
Check Points for PDI
Sl.
Pre Delivery Inspection Checklist

Check
PDI Done by
Dealer
PDI done by BAL/

Service Engg.
10
14
11
TRANSIT DAMAGES (Send photographs)
MINOR ADJUSTMENTS
OTHER DEFECTS :
(Give chassis no & reason for chassis opening)
FRAME OPENING DURING PDI (If any)
(Give engine no & reason for engine opening)
ENGINE OPENING DURING PDI (If any)
HANDLE BAR
PLATING DEFECTS
CLUTCH JUDDERING
HARD
CLUTCH OPERATION
OIL FILTER COVER
OIL LEVEL INDICATOR WINDOW
CHAIN TENSIONER 'O' RING
BENJO BOLT
TAPPET COVER
OHC COVER
OIL FILLING PLUG
CRANKCASE JOINT
MAGNETO COVER
DRAIN BOLT
ENGINE OIL LEAKAGE
CHAIN TENSIONER / TIMING CHAIN
TAPPET NOISE
ENGINE NOISE
ENGINE MOUNTING BOLT
KICK BOSS BOLT
LOOSE PARTS
CHECK POINTS FOR PDI
GAP AT THE REED SWITCH AND MAGNETO.
BRAKE LIGHT REMAINING ON CONTINUOUSLY.
REAR BRAKE EFFECTIVENESS
Marked if the ok observed
24
23
22
21
20
19
18
17
16
15
BRAKE OPERATION - FRONT/REAR
13
FRONT BRAKE
DRIVE CHAIN slack (mention amont of play)
12
Check Points for PDI
FLAT SPOT (GIVE CO %)
Sl.
Pre Delivery Inspection Checklist

Check
PDI Done by
Dealer
PDI done by BAL/

Service Engg.
Front
Check front mudguard alignment

wrt Front Wheel
19
RH /
Front
LH
LH
LH
LH
LH
Rear
Rear
RH/LH
LH
Front
Front
/ RH
Check & Adjust steering and

Handle bar for free movement.
Check gear shifter lever operation
Check & Adjust TPS
Check Accelerator cable free play
Check Choke lever operation
Lubricate chain and Check /

Adjust chain slackness if required.
Check and Correct tyre inflation

pressure - Rear Wheel.
Check Rear brakes for efficient

working & adjust if required.
Inspect Rear Shock Absorber

setting & correct if necessary.
Check Battery voltage, fill /

top-up electrolyte, apply
petroleum jelly, connect
terminals properly.
Check and correct tyre inflation

pressure - Front Wheel
Check front brakes for efficient

working & Adjust if required.
RH
Check clutch cable operation &

Adjust if required.
18
17
16
15
14
13
12
11
10
RH
Check & top up engine oil level,

if required.
Check for smooth operation of

fuel cock lever
4
5
Open Petrol tank cap

& pour petrol
0.05
0.20
0.05
0.10
0.05
0.05
0.40
0.20
0.10
0.10
0.60
0.20
0.10
0.10
0.30
0.10
0.50
0.50
Remove the Thermocol and

additional packing if any. Study
PDI card and Work content.
SMM
0.80
Position
Identify & Park Vehicle on

Work Bay
Description
Sr.
No.
PDI SOP
12-13, 16-17
Ring Spanner
8 No.
T Spanner
10-11 No.
OE Spanner
8 & 10 No.
OE Spanner
10-11 No.
OE Spanner
Fork Spanner
12
Air gun
Cloth,
Graphite Grease,
Fine Polish Paper
Hydrometer,
Battery Charger,
Battery Tester
Analogous/Digital
type Pressure
gauge, Air filling
Valve
Air Gun
20-22, 24-27
Ring Spanner,
10-11 No. OE
Spanner,
Torque Wrench,
Socket Set,
Oil Can
Cloth,
SAE 90 Oil
Cloth, Fine
Polish Paper,
Petroleum
Jelly,
Distilled Water
Petrol, Waste
Cloth
Lifter Bay
M & T / Service
PNR & its
Consumables Shop Equipments
Attachment
Analogous/Digital
Type Pressure
Gauge, Air Filling
Valve
Special
Tools
Pencil Type
Pressure Gauge
14-15 No.
O.E. Spanner
Screw Driver,
Distilled water
Filler, 10mm
T Spanner
Pencil Type
Pressure Gauge
12-13 Ring
Spanner
12-13 OE
Spanner
Measuring Jar,
Funnel
GP Tools
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
13
1.30
Small
Screw driver
10-12 No.
OE Spanner
and 12 No.
Box Spanner
17mm
OE Spanner
Oil Can
12-13, 14-15,
16-17, 20-22
Ring Spanner,
22 mm Box
Spanner with
Handle Ratchet
GP Tools
Expected Output in 480 Minutes / Man / 27 Vehicles
Repair for any other defects seen

or observed during test drive.
Total SMM
30
1.00
17.75
Clean/Wash the veh. before delivery
29
0.10
0.50
28
LH/RH
Test drive the vehicle, check digital

speedometer working. Study the
job card and verify work done.
Take vehicle out and park.
LH/RH
0.60
Trip meter working
25
0.35
Check all locks for proper operation
LH/RH
Check Idling and CO%.
24
3.25
26
LH/RH
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.
23
1.15
1.00
4.00
SMM
27
LH/RH
OE accessories fitment Leg guard
REAR
FRONT
RH/LH
LH/RH
Rear brake lever

Rear brake pedal / cam
Pillion foot rest
Center stand
Side stand
Kick lever boss
Clutch lever
LH/RH
Position
22
Check the following and

lubricate if necessary
Check all important nut bolts for

torque and tightness,
Description
OE accessories fitment Mirrors RH & LH
21
20
Sr.
No.
PDI SOP
Special
Tools
Pistol Grip
PNR
Pistol Grip
PNR
CO-HC Analyzer;
Tachometer,
Proper Exhaust
Sealing
Arrangement
of Silencer
SAE
20W40 Oil
M & T / Service
PNR & its
Consumables Shop Equipments
Attachment
Engine compression pressure
38.
CL
C,R
C,R
C,L
C,L
L,R
C,R
C,T
C,A
C,R
C,A
C,A
C,A
C,A
C,A
CL,A
C,R
CL,A
CL
CL
C,A
Days
2 years
1 year
1 year
Note: Parts / Lubricants to be replaced as per Periodic Maintenance and

Lubrication Chart are mandatory and the same are chargeable to customer.
Initial
CL -
Every 10000kms
Every 10000kms
Adjust
Check
Replace
Tighten
14
Lubricate
Every 30000kms
Every 30000kms
Every 10000kms
Every 5000kms.
Every 2500 kms.
Clean
Every 5000kms.
Every 2 years
Every 2 years
Every 10000kms
Every 10000kms
Every 20,000 kms.
Every 10,000 kms.
Every Year
Every 10000 kms
Every Year
Every 10000 kms
Every 10000 kms
Every 5000 kms
Every 5000 kms
Every 90 days
Every 500 kms.
30~45 105~120 195~210 285~300
Every 2,500km
Subsequent
RECOMMENDED FREQUENCY
Kms. 750 2,500 5,000 7,500
1 Month
OR
l : Indicates operation to be performed.

: More frequent cleaning may be required when driving in dusty condition.
Valve oil seals
Drive chain wear / Remove & Lubricate
Cylinder head de-carbonising & valve lapping
Drive chain slack
36.
37.
40.
Drive chain
35.
39.
Rr. Shock Absorber- Check gas pressure 7.0+0.5 Kg/cm2
Front brake hose
33.
34.
Front fork
Front fork oil
31.
32.
Swing arm pivot pin
Master cylinder cup and Dust seal
28.
30.
Wheel bearing
27.
Caliper piston seal and Dust seal
Steering stem bearing
26.
29.
Tyre tread wear

General lubrication
25.
Engine mounting silent blocks
23.
24.
Steering play
All fasteners tightness
21.
22.
Brake fluid change
20.
Brake lining or pad wear

Brake fluid level / top up
18.
19.
Throttle play
16.
Rear brake pedal play
Clutch play
15.
17.
Battery electrolyte level

Brake light switch
13.
Spark plugs (2 Nos.)
Spark plug / gap
14.
12.
11.
Fuel pipes
Carburettor
Fuel system leakages
8.
9.
10.
Air cleaner element V

Air cleaner element
6.
7.
Engine oil (SAE 20W50 of API SG+JASO MA)

Oil strainer / Centrifugal filter
4.
5.
Valve tappet clearance
Idle speed / CO%
2.
3.
Servicing
1.
Sr. Operation
No.
Whichever
comes first
Periodic Maintenance & Lubrication Chart
RH
LH
LH
LH
LH
LH/RH
LH /
Rear
Rear
Clean Air filter.

(Replace - if necessary)
Drain Carburetor.
(Overhaul - if required)
Check Accelerator and adjust
Clean, Check & Adjust

(Replace - if necessary)
Check & Adjust tappet

clearance. (if required) During
4th Servicing or after 5000 Km
whichever is later.
Check
Side bolts of Front fork
Side stand
RSA top and bottom nuts
Adjust chain slackness &

Lubricate. Remove and Clean,
If required.
Check/ Adjust
10
11
12
13
14
LH
Drain Engine Oil
15
0.70
Start veh. & Warm up. Remove

RH/LH side covers, Seat,
Petrol Tank & keep properly.
LH/RH
0.30
Raise the lift
0.50
3.90
0.60
2.40
0.40
1.30
3.00
1.30
0.50
Identify the Vehicle
Bring vehicle & position on bay
0.30
SMM
Both
LH/RH
Side
Wash vehicle thoroughly.
Sr. Description
No.
Periodic Service SOP
Filler
Gauge
0.01~1mm
Tappet
Holder
8-9 No. Ring

Spanner, 24-27
OE Spanner,
14 mm Box
Spanner with
Handle Ratchet,
Spark Plug
Spanner
Air Gun
Cloth, Graphite
Grease, Fine
Polish Paper
20-22, 24-27 Ring

Spanner, 10-11,
14-15 OE Spanner
Air gun
Spark Plug
Cleaner and
Tester, Air Gun
Air gun
Cloth,
SAE 90 Oil
Pistol Grip
PNR
Cloth
Cloth, Fine
Polish Paper,
Spark Plug
Cloth, Diesel
10mm T
Spanner, 20-22,
24-27 Ring
Spanner, 10-11
OE Spanner
14-15, 16-17,
20-22 Ring
Spanner, 12 mm
Box Spanner with
Handle Ratchet,
12-13 No.
OE Spanner
Filler
Gauge
0.01~1mm
Spark Plug
Spanner, Plug
Cleaner,
Wire Brush
8-9, 10-11
OE spanner
Phillips Screw
Driver, Screw
Driver, 10mm
Nylon Brush,
Plastic Tray,
10-11 & 14-15mm
OE Spanner
Filter Cleaning
Stand, Air Gun
Cloth,
20W40 Oil,
Diesel, Air
Filter Element
M & T / Service
Shop Equipments
8mm
T Spanner
Consumables
Oil Draining
Equipment
Pistol Grip
PNR
PNR
Cloth
Float
Gauge
Special
Tools
16mm Socket,
Extension,
Tommy
& Plastic Tray
12-13 No.
Ring Spanner,
12mm Socket
To be done by
washing boy
GP Tools
Check
Front axle nut
Side bolts of Front fork
Handle bar bolts
RSA top and bottom nuts
Swing arm axle nut
Silencer protective cover
screws / bolts
Rear view mirror
Check and Adjust steering.
Check & Adjust front tyre

air pressure.
Check/ Adjust
Check and Top-up

brake fluid level.
Clean, Check & Adjust

RH spark plug.
Fill engine oil.
Check clutch and Adjust.
Clean oil strainer.

(Replace - if required) After
1 Year or 10000 Km
whichever is later.
Check Battery, Top-up distilled

water. Clean terminals & apply
petroleum jelly. Route cables
properly and fit terminal caps
properly. Recharge battery if
required.
Check & Adjust

Rear tyre air pressure.
25
24
23
22
21
20
19
18
17
16
15
Sr.
Description
No.
RH
Front
Front
Front
Front
RH
RH
RH
RH
LH
Rear
LH/RH
Side
1.30
0.80
0.40
0.50
1.00
2.40
1.35
0.30
1.80
0.40
SMM
10-11, 12-13,
14-15, 16-17,
20-22 No.
Ring Spanner,
22 mm Box
Spanner with
Handle Ratchet
16-17 No.
Ring Spanner
Pencil Type
Pressure Gauge
12-13
Ring Spanner,
5 & 10 mm
Allen Key
Phillips
Screw Driver
Spark Plug
Spanner,
Plug Cleaner,
Wire Brush
6 Combination
Pliers, Measuring
Jar 1Liter, Funnel
12-13 OE
Spanner, Small
Screw Driver
8 No. Box
Spanner, 12-13
OE Spanner,
12-13 Ring
Spanner, 8mm T
Spanner. Plastic
Tray, Phillips
Screw Driver
Screw Driver,
Distilled Water
Filler, 10mm
T Spanner
Pencil Type
Pressure Gauge
GP Tools
Fork
Spanner
Filler
Gauge
0.01~1mm
Special
Tools
Cloth, Fine
Polish Paper
Cloth,
Oil Dot-4
Cloth, Fine
Polish Paper,
Spark Plug
Cloth, Oil 20W50

of API SG +
JASO MA grade
Diesel, cloth,
Clutch Cover
Gasket,
Oil Strainer
Cloth, Fine
Polish Paper,
Petroleum Jelly
Distilled Water
Consumables
Analogous /
Digital Type
Pressure Gauge,
Air filling Valve
Air Gun
Spark Plug
Cleaner and
Tester, Air Gun
Oil Dispenser
Hydrometer,
Battery Charger,
Battery Tester
Analogous /
Digital Type
Pressure Gauge,
Air Filling Valve
16
M & T / Service
Shop Equipments
Pistol Grip
PNR
Pistol Grip
PNR
PNR
Lower the Lift
Take vehicle out and park
32
33
Clean the vehicle at the

time of delivery.
17
PNR = Pneumatic Nut Runner
Will be done
by Delivery boy
27000~27500
36
975~990
8th Paid
To be Carried
out by Expert
1.5
Test Ride of the Vehicle

if required and park.
35
42.50
24500~25000
Total SMM
885~900
19500~20000
7th Paid
705~720
Expected Production / 480 minutes / Man / 11
5th Paid
17000~17500
14500~15000
22000~22500
10.00
32.50
0.50
0.30
1.00
Small
Screw Driver
615~630
555~570
795~810
Carry out any additional work

as indicated by the Customer
or as required.
LH
4th Paid
4th Free
6th Paid
34
Study Job Card. Verify work.
31
Sub Total
Tune Engine & Carburetor.
30
2.00
1
NIL
1
1
Brake shoes (if worn out)

Front disc pad inspect / replace (If worn out)
NIL
Chain sprocket kit
Carburettor insulator
NIL
NIL
NIL
Drive chain lock & link set
Rear brake damper
Clutch plate
330 ml.
Spark plug
Fork oil
1
1
Air filter foam element
1000 ml.
NIL
Clutch cover gasket
Engine oil
NIL
1000 ml.
NIL
12000~12500
Steering cone kit
CO-HC
Analyzer,
Tachometer,
Proper Exhaust
Sealing
Arrangement
of Silencer
465~480
2
Cylinder head gasket (If required)
1
Fork oil seal
1
Starter clutch bush
1
Brake shoes (if worn out)
330 ml.
Fork oil
Spark plug
1000 ml.
NIL
1000 ml.
NIL
Clutch cover gasket
Engine oil
NIL
Engine oil
NIL
1000 ml.
Engine oil
Clutch cover gasket
Quantity
Part Name
3rd Paid
9500~10000
7000~7500
285~300
375~390
4500~5000
195~210
3rd Free
1st Paid
2nd Paid
2000~2500
500~750
Kms. Limit
105~120
30~45
Days
2nd Free
1st Free
Type of Service
Periodic Part Replacement Kit for Free Services
Engine oil
Phillips
Screw Driver
Air Gun
Grease Gun
M & T / Service
Shop Equipments
Both
RH/Rear
Brake light.
0.95
Screw Driver
20W40 Oil,
Graphite
Grease, Cloth
Consumables
Front
Rear
Tail light.
Pistol Grip
PNR
PNR
Side Indicators - Front & Rear
Front
Head light.
30
0.50
Special
Tools
Speedo, Pass, Parking light
RH
Start vehicle, Check & Adjust

the following.
29
0.50
12-13 No.
Ring Spanner,
12mm Socket
Oil Can
GP Tools
Front
Front
Check all Meters for proper

functioning & Correct, if reqd.
28
0.50
0.80
SMM
Service Wise Part Kit
Horn
LH
Check and Clean fuel line &

Clean petrol tank.
(Replace fuel pipe - if required)
LH/RH
LH/RH
Refit RH, LH side covers,

Seat, Petrol tank
Clutch lever
Rear Brake pedal
Rear Brake Cam
Pillion Foot Rest
Center Stand
Side Stand
Kick lever boss pin
LH/RH
Side
27
26
Lubricate
Sr. Description
No.
18
Kms. Limit
29500~30000
Days
1065~1080
1
1

Steering cone kit
19
Notes :
330 ml.
Brake shoes (If worn out)
Fork oil
1
4
Valve oil kit
Cylinder head stud copper washer
Spark plug
Cylinder head gasket
1
1
1000 ml.
Engine oil
Clutch cover gasket
Quantity
Part Name
Use always Genuine Bajaj Auto parts & recommended lubricants.

(Engine oil: SAE 20W50 API SG + JASO MA grade)
9th Paid
Type of Service
Periodic Part Replacement Kit for Free Services
Service Wise Part Kit
Lower
Level Mark
Upper
Level Mark
Quantity
Remove :
Drain engine oil.
Clutch cover
Oil pump mounting bolts (A)
(3 Nos.)
Pump with strainer.
Clip (B) and take out Oil
Strainer from oil pump.
Oil Strainer Cleaning
Note : It is most vital to adhere to recommended frequency of oil change

for the purpose of long life of critical engine components for details refer
Periodic Maintenance Chart.
SAE 20W50 of API SG + JASO MA

Drain & Refill 1000 ml.
Engine Overhaul 1100 ml.
Grade
Recommended Oil Grade and Qty
Top up if required
It should be in between upper and lower mark
Inspect the oil level through oil inspection window
20
Park the vehicle on level surface on center stand to check the oil
level.
Engine Oil Level Checking
Periodic maintenance (in accordance with the periodic maintenance

chart) of a vehicle is most important to prolong vehicle life, trouble
free running and ensure your safety while driving.
Periodic Maintenance
Caution : Water may enter on the brake liners during washing & brake
slippage may occur. Ensure that brake liners are dry before driving the
vehicle.
After washing, dry the vehicle with compressed air and carry out the
lubrication as recommended
Brushing with kerosene and wiping dry with clean rag is advisable for
external cleaning of the engine. All painted surfaces should be washed
with water. Do not use kerosene or hard detergent soap on painted
surfaces as it damages the paint and turns it dull.
The vehicle must be cleaned periodically using pressurized water.

Before cleaning the vehicle cover the important parts like Ignition
switch, Silencer Tail end, CDI unit, H.T. coil with plastic bags. Dont
apply the jet of water directly on electrical parts such as Switches,
Ignition unit, Coils etc. otherwise they may get damaged.
Cleaning
Schedule Maintenance
21
Note :
No need of removing flame arrestor
White colour filter portion towards carburettor side
Ensure beading placed properly when fitting cover
Seperate foam filter from the catrej
Air filter element assembly along with catrej
Remove :
Air filter cover (B).
2 bolts (A).
Remove :
RH side panel by unlocking it with key
Remove :
Air Cleaner Element Removal
Air Filter
Remove :
Centrifugal oil filter cover mounting
screws (C) 3 Nos.
The cover with gasket
Replace gasket if damaged
Clean centrifugal oil filter using
Nylon brush/kerosene or Diesel
Centrifugal Oil Filter Cleaning:
Clean oil strainer with Kerosene / Diesel blow compressed air and
then refit it.
Replace oil strainer if found damaged.
Remove :
Dry with Cotton Cloth
Squeeze and Remove

Excess Oil
Dip into
Engine Oil (20W40)
3rd Stage:
Warning : Clean the element in a well-ventilated area, and make sure

that there are no sparks or flames anywhere near the working area.
Because of the danger of highly flammable liquid, do not use
gasoline/petrol or a low-flash point solvent to clean the element.
Note : In dusty areas, the element should be cleaned more frequently

than the recommended interval.
After riding through rain or on muddy roads, the element should be
cleaned immediately.
Since repeated cleaning opens the pores of the foam element replace it
with a new one in accordance with the Periodic Maintenance Chart.
Also if there is a brakage in the element material or any other damage
to the element replace the element with a new one.
Air Filter Element Cleaning and Inspection
Blow Low Pressure

Compressed Air
Clean with
Kerosene Again
2nd Stage:
Squeeze
Clean with Kerosene
1st Stage:
Clean Air filter element adhering to standard SOP
Air Filter Cleaning
22
23
0.7 ~ 0.8 mm
After every 10000 Kms.
Electrode Gap
Replace Spark Plug
Check to see that both sleeves are turned to the same relative
position.
Turn the adjusting sleeve on each shock absorber to the desired

position. The higher the adjuster sleeve is positioned, the stronger
the spring tension, and the harder the ride.
To adjust the Rear Shock Absorbers
Shock Absorbers adjusted either too soft or too hard adversely affect
riding comfort and stability.
The rear shock absorbers can be adjusted to one of five positions to

suit riding conditions. Using special tool adjust the required position
you desire. They can be left soft for average road riding condition
but should be adjusted harder for rough road condition.
Rear Shock Absorber
in a year.
Note : It is advisable that brake fluid should be replenished once
Use only DOT-3 or DOT-4 brake fluid (from sealed container) to

top up if required.
Always ensure that brake fluid level is above MIN mark given on
inspection window.
To check oil level, park the vehicle on Main / Center stand with
handle bar in straight position.
Front brake fluid master cylinder reservior is located near RH

switch on handle bar.
Front Brake Fluid Level
Apply petroleum jelly on to the terminals
Note : Add only distilled water to the battery. Tap water is not a
substitute for distilled water and will shorten the life of the
battery.
Remove the battery filler caps and fill with distilled water until the
electrolyte level in each cell reaches the upper level line if
required.
Check the electrolyte level in each cell and ensure that the level is
between the upper and lower level lines.
Battery is located inside LH cover
Battery - 12V - 9 Ah
Champion RG4HC / Bosch UR3DC
Recommended Spark Plug
Spark Plug
3
Stronger
Service Limit 35 ~ 45 mm
Drive Chain Slackness : 25 ~ 30 mm
Check drive chain slackness at every 1000 kms.
24
If the drive chain is too tight or too loose, adjust it so that the
chain slack will be within the standard value.
Rotate the rear wheel to find the position where the chain is
tightest & measure the vertical movement midway between the
sprockets.
Set the motorcycle upon its center stand.
Drive Chain Slack / Lubrication
Finally fix the phillips headed screw with O ring.
Pull out the air pump along with needle carefully and take out the
guide clamp
Keep on pumping the air unless you get 7.5 kg/cm2 on the gauge
To fill the air into the canister, apply full stroke of pump as
shown; otherwise air will not get inflated into the pump.
Read the gas pressure on the dial gauge. If the gas pressure is
below 6.5 Kg/cm2 refill the air by pumping, keeping the needle in
as it is condition without removal. As the natural air consists of
71% of nitrogen it will serve the purpose.
The molded needle adaptor will rest into the clamped cylindrical
guide
Hold the pump as shown and pierce the syringe needle into the
center of rubber plug.
Clamp the cylindrical guide clamp on to the canister keeping the

rubber plug in the center to support the syringe needle insertion
and keeping in position.
Remove the Phillips-headed small screw and O ring.
Procedure for gas checking and Refilling
Nitrox Air Filling
Note : Std setting is done in 2nd notch
If the Shock Absorber sleeves on both sides are not adjusted

to the same position, an unsafe riding condition may result.
Spring Action
Position
25
Hook Chain for

dripping of excess oil
Final Stage:
Soak into SAE 90 Oil
Dip into SAE 90 Oil
3rd Stage:
Blow Compressed Air
Clean with Cleaner

Kerosene again
2nd Stage:
Clean with Kerosene
1st Stage:
Drive Chain Cleaning / Lubrication
2.00 Kg/cm2 (28 PSI)

2.25 Kg/cm2 (32 PSI)
Rear - with Solo

Rear - with Pillion
26
Again check the tappet clearance with gauge. The gauge should
slide with slight resistance between tappet and valve stem head
feeler and tighten the check nut with a spanner.
Inlet Valve : 0.05 mm
Exhaust Valve : 0.1 mm
Special Tools : Feeler Gauge - 69 7502 51
: Valve Adjusting Screw Holder - 37 1031 53
Lock the nut holding screw with special tool after getting desired
clearance.
Put the feeler gauge, measure and adjust the clearance.
Holding tappet screw firmly with

special tool loosen the tappet
screw nut.
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 are free.
Ensure that the engine is cold.
Tappet Clearance Setting
Idling Sped : 1400 + 100 rpm
Do not attempt to compensate for faults in other systems by

adjusting the idle speed.
Rotate the throttle a few times to make sure that the idling speed
does not change. Readjust if necessary.
For the precise adjustment of idling speed, use of tachometer is

recommended.
Then set the engine idling r.p.m. by rotating the idle adjustment
screw clockwise or anticlockwise by hand.
Connect the probe of CO analyser. Set the CO between

1.75 ~ 2.25% by adjusting volume control screw.
Remove the Bolt/Plug near Exhaus TEC
Start engine & drive it for at least

5 kms. or warm the engine till
the oil temp reaches 600C.
Whenever the idling adjustment is

disturbed follow the procedure
given below for setting proper
engine idling.
Idling Speed Adjustment
Important Adjustments and

Checking Procedures
1.75 Kg/cm2 (25 PSI)
Front
Keep appropriate tyre pressure as mentioned below to increase

life of this tyre and for better fuel consumption.
Tyre Air Pressure
27
Accelerator Grip Free Play : 2 ~ 3 mm
Tighten both the lock nuts on bracket by holding one nut and
tightening the other, after ensuring the required free play.
Loosen the 2 lock nuts (C) on accelerator cable bracket end

adjust by adjuster (D) provided on the cable.
If the accelerator free play can not be adjusted with the adjuster
at the handle bar end, use the adjuster at the lower ends of the
Accelerator cable situated on carburettor.
Tighten the lock nut (B) against the adjuster.
Turn the adjuster (A) until the proper amount of free play can be
obtained.
Accelerator Free Play Adjustment
Clutch Lever Free Play : 2 ~ 3 mm
Loosen the 2 lock nuts (C) on clutch cable bracket and adjust
threading in the adjuster provided on the clutch cover. Tighten
both the lock nuts on clutch cable bracket by holding one nut and
tightening the other, after the required free play.
Tighten the lock nut (B) against the adjuster. If the clutch free play
cannot be adjusted with the adjuster at the handle bar end, use
the adjuster at the lower ends of the clutch cable situated on
clutch cover.
Turn the adjuster (A) until the proper amount of free play can be
obtained.
Check that the clutch cable outer end is fully seated in the
adjuster.
Slide the dust cover at lever yoke end.
Clutch Lever Free Play Adjustment
Remember the T marked line is a reference line for TDC

position of the piston and is not for Ignition timing.
This indicates the advance timing is functioning correctly.
As the engine rpm is increased the A marked on the rotor

coincide with the line mark on magneto side ccase. (280 BTDC
@ 3500 rpm).
At idling speed the F marked line on the rotor coincide with

the line mark on magneto side ccase. (100 BTDC @ 1500 rpm).
Aim the stroboscope light at Magneto cover glass window.
Start the engine.
0.00
0.00
Gap
2.5mm max.
28
On De-acceleration, when of Reed Switch magnet re-coinsides with

straight edge of fix bracket of Reed Switch Multimeter should show
continuity.
When throttle is open and Reed Switch magnet crosses to straight

edge of fix bracket of Reed Switch multimeter should show
discontinuity.
On connecting multimeter to Reed Switch coupler it should show

continuity.
Keep throttle at zero position.
Reed Switch : Checking
Protude stopper of the throttle lever bracket must on idling screw tip.
Accelerator cable play: 2-3 mm by adjusting the Adjuster
Reed Switch : Setting
Movement of throttle lever with magnet assembly and Reed Switch

fitted should be free.
Gap between Magnet & Reed Switch should not be more than 2.5mm.
Magnet should not touch with reed switch.
Reed Switch Setting and 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.
Ignition Timing Inspection
Connect cable of stroboscope to one of the H. T. Coil carrying

current to spark plug.
29
Loosen the bearing carrier nut (D).
30
Warning : Misalignment of the wheel will result in abnormal wear, and

may result in unsafe riding condition.
Turn both chain adjusting nuts evenly until the drive chain has the
correct amount of slack. To keep the chain and wheel properly
aligned, the notch (E) on the left chain adjuster should align with
the same swing arm mark that the right chain adjuster notch (E)
aligns with.
If the chain is too tight, back out the left & right chain adjusting
nuts evenly & kick the wheel forward until the chain is too loose.
Loosen the axle nut (C).
When either the front or rear brake is applied, the brake light glows on.
The front brake light switch requires no adjustment but the rear brake light
switch should be adjusted in accordance with the periodic maintenance
chart.
Inspection :
Turn on the ignition switch. The brake light should go on wheel the front
brake is applied.
If it does not, then inspect the front brake light switch.
Check the operation of the rear brake light switch by depressing the
brake pedal. The brake light should glow after about 15 mm of pedal
travel.
If it does not, adjust the rear brake light switch.
Adjustment :
Adjust the rear brake light switch (A) by rotating the switch nut to create
adequate tension in spring to operate the switch.
Loosen the left and right chain adjuster lock nuts (B).
Loosen the rear torque link nut (A) & rear brake adjusting nut (F).
If the drive chain is too tight or too loose, adjust it so that the
chain slack will be within the standard value i.e. 25-30 mm.
Rotate the rear wheel to find the position where the chain is
tightest and measure the vertical movement midway between the
sprockets.
Set the motorcycle upon its centre stand.
Chain Slack Adjustment :
Caution : If wet compression is done, remove second spark plug and

clean thoroughly to avoid oil fouling before fitment.
If compression pressure remains the same, then the cause for low
compression pressure lies in Cylinder / Head assembly.
If you find considerable increase this time, then cause for the low
compression pressure lies in Cylinder / Piston assembly.
If the compression pressure is found below lower limit than

specified, put few drops of engine oil through the spark plug hole
and again check compression pressure.
Wet Compression Test :
Confirm the compression pressure is between 6 to 10 Kg/cm
Take average of 3 such readings for noting actual compression

pressure.
Rear Brake Light Switch Adjustment
Note : After pedal position adjustment, it is necessary to set the free play.
Ensure free play by turning the adjuster clockwise or anticlockwise to

achieve specified free play. Fix the rubber sleeve on the bolt.
To suit rider foot comfort / operating style the angle of the rear
brake pedal can be adjusted by loosening the lock nut (A) and
adjusting the bolt (B).
Rear Brake Pedal Position Adjustment
Rear Brake Pedal Play : 25 ~ 30 mm.
Turn the adjuster until the rear brake pedal have the correct
amount of play.
If there is any doubt as to the conditions of the brake, check the

brake parts for wear or damage.
Check braking effectiveness.
Rotate rear wheels to check for brake drag.
Operate the pedal (B) for few times to see that it returns to its
rest position immediately upon release.
If the rear brake pedal free play is incorrect, adjusting the rear
brake shoe adjuster nut (A).
Depress the rear brake pedal lightly by hand. This is free play.
Release the pressure by pressing the release valve on hose pipe.
Check the rear brake pedal play as stated below. If it is more or

less than the standard, adjust the rear brake.
Open the throttle fully then kick 5 times instantaneously.

Note the reading in the compression gauge.
Disconnect H. T. lead cable from second spark plug i.e. RH
Fit the compression gauge with adapter in the Spark plug hole.
Caution :
side.
Rear Brake Pedal Adjustment
Front Brake Lever Play : 2 ~ 3 mm.
Remove the spark plug. LH side.
Compression Pressure Testing

For testing the compression pressure first warm up the engine.
Front Brake Free Play Adjustment
Standard Checking Procedure
There is no need for free play adjustment, since the pistons in

caliper assembly will move towards the pads and take new positions
in order to automatically compensate for pad wear. The free play will
be approximately 2 ~ 3 mm.
31
Remember fitment of 2nd ring upside down may lead to passing of oil
above the piston and ultimately leading to smoky exhaust.
Finally fit the first ring with Top 1 mark upward and end gap facing
towards the exhaust mark.
Fit the second piston ring with Top 2 mark facing upward and end gap
facing opposite to the exhaust mark.
Now fit top oil rail ring on the expander ring with end gap 300 towards
right of the exhaust mark.
Place oil expander ring with butting end downward and end gap facing
opposite to the exhaust mark.
First place the bottom oil rail ring with end gap 280 towards left of the
exhaust mark in the last groove.
Piston rings must always be fitted with respect to exhaust mark on the
piston.
Piston Ring Fitment :
Note : This procedure can prevent a soft or spongy feeling brake.
Center the brake panel assembly in the brake drum. This is done by
tightening the axle nut lightly, spinning the wheel, and depressing the
brake pedal forcefully. The partially tightened axle nut allows the
brake panel assembly to center itself within the brake drum.
Tighten the Axle Nut
Tighten the torque link nut
Fix the snap ring
Adjust the correct brake play
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.
This may cause misalingment of the
wheels and result in loss of control.
Tighten the sleeve nuts securely.
Tighten both chain adjuster lock

nuts.
- Vehicle sensor speed.

- Hall sensor.
- Starter relay.
Through this harness the following testing can be carried out :
Connect wiring harness to C1 connector.
Manual Testing
32
The Jig should carry out a self test, where first all Red LED; glow
sequentially and then all Green LED; flash twice.
Power Up the Jig
Fit the Phillips head screw & small O ring fitted on air valve of
Nitrox RSA.
Once the pressure reaches upto 7.5 Kg/cm2, take out the needle
slowly from canister.
Note the pressure indicated by pressure gauge of Nitrox air pump.

Refill the pressure.
Insert the Nitrox air filling pumps needle end into the guide &
carefully pierce the rubber pin fitted inside the air valve of Nitrox
RSA.
Fix the guide to canister of Nitrox shocker in such a way that

guide hole is concentric with air filling valve.
Remove the Phillips head screw & small O ring fitted on air valve
of Nitrox RSA.
Nitrox Air Filling
After completing the bleeding, top up the master cylinder up to the

maximum level mark.
Once the air escapes out from the hose pipe the brake lever meets
resistance, which indicates completion of air bleeding
Keep on operating the brake lever till the air bubble escape out
completely through bleeder screw, and top up the master cylinder
if required.
Operate the brake lever and keeping in pressed position loosens

the bleeder screw so that some oil escapes with the air bubbles.
Connect transparent tube to the bleeder screw at caliper
Operate the brake lever slowly in order to get filled the oil in the
circuit.
For air bleeding from front Hydraulic brake system first top up the
master cylinder with hydraulic oil.
Air Bleeding of Disc Brake System :

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Pulsar - DTSi - UG - III - Workshop Manual 1 PDF

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7.

8. Tail Light LED display

4. Body Control Unit

6. Vehicle Speed Sensor

Pulsar DTS-i UG-III-180cc Training Notes

(Placed inside Head Light fairing)

5. Hall Sensor for Indicator

2. LCD Speedo Console

The Engine and Frame serial numbers are used

Dealer Development Center

Dealer Development Center

Ergonomically designed self-letting switches

New seat cowl to match stylish LED tail lamp.

Clear lens indicator with amber bulbs.

Pulsar DTS-i UG-III-180cc Training Notes

Self check provision for Tachometer for its functioning

glows continuously till the petrol filled to main level.

Engine oil level window for easy to monitor level.

will be switched off automatically.

Self-canceling indicators After completion of turn, the indicator

Convenience and Comfort

Stylish fairing and head lamp assembly with owleye

function for the life of the bike. Absolutely no maintenance in

Stainless steel silencer that overcomes rusting problem

friction reduction that improves drivability.

Optimized valve timing and Roller rocker with NR bearing for

provide better torque

New Bigger twin foam filter with an optimized intake system to

& revamped gear shifting mechanism that gives

location and revised ignition timing with intelligent CDI

Refined engine power delivery by optimization of Exhaus TEC

Pulsar DTS-i UG-III-180cc Training Notes

Dealer Development Center

LED illumination for tell-tale icons on electrical switches that glows in

to bring down the engines RPM for safety.

Engine cut-off at 10000 RPM Spark gets cut-off at 10000 RPM

when engine reaches to 9000 RPM

High RPM warning lamp

Day night mode of Speedo console

Spark Plug Gap

Dealer Development Center

Rims (Alloy Wheels)

CHASSIS & BODY

Final drive ratio

280 BTDC at 3500 rpm.

100 BTDC at 1500 rpm.

Pulsar DTS-i UG-III-180cc Training Notes

1.75 kg/cm2 (24.5 Psi)

Mechanically expanding shoe and drum type.

Telescopic front fork with DU bush (Stroke 135mm)

5 speed constant mesh.

Wet, Multidisc type.

Kick start / Electric start.

Wet sump, Forced.

0.7 to 0.8 mm.

2 Nos. Champion RG4HC, Bosch UR3DC (Resistive)

UCAl-MIKUNI BS29, Side Drought, CV Type.

Microprocessor controlled digital C.D.I.

15.22 Nm at 6000 rpm.