Pulsar DTSi UG III Workshop Manual 4

Tightening Torque - Engine Tightening Torque - Frame
Clutch Nut (LH Threads) Cylinder Head Cover Bolts Cylinder Head Cover Nuts Front Axle Nut Rear Axle Nut Torque Rod Nut
5.0 Kg.m 3.5 Kg.m 1.0 ~ 1.5 Kg.m 4.0 ~ 5.0 Kg.m 8.0 ~ 10.0 Kg.m 3.0 ~ 4.0 Kg.m
Camshaft Sprocket Allen Bolt Starter Motor Mounting Bolts Rotor Mounting Bolt Sleeve Nut Rear Sprocket Mtg. Nut Handle Bar Holder Bolts
1.4 Kg.m (Loctite 243) 1.1 Kg.m 4.5 Kg.m 7.0 ~ 8.0 Kg.m 1.8 ~ 2.5 Kg.m (Loctite 243) 2.0 ~ 2.2 Kg.m
Kick Guide Allen Bolts Spark Plugs (2 Nos.) Drain Bolt Steering Top Cap Bolt Stg. Stem Nut (slotted) Upper Clamp Allen Bolt
1.2 Kg.m 1.4 Kg.m 2.5 Kg.m 3.5 Kg.m 0.5 Kg.m 1.8 ~ 2.0 Kg.m
Lower Clamp Bolt RSA Mounting Dome Nut Swing Arm Pivot Nut
2.5 ~ 3.5 Kg.m 3.5 ~ 4.0 Kg.m 8.0 ~ 10.0 Kg.m
Caliper Install Bolts Brake Disc Allen Bolts Banjo Bolt Caliper
2.2 ~ 2.8 Kg.m 0.9 ~ 1.1 (Loctite 243) 2.2 ~ 2.8 Kg.m
103 104
Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Assembly - Engine Assembly - Engine
Fitting of Oil Seals and Bearings : Fit :

• Oil seal for ‘Output Shaft’
Crankcase RH (Clutch Side)
Use Bearing Driver set (P. No. 37 1030 61)
Fit :
• Bearing for ‘Input Shaft Assembly’
Use Bearing Driver set (P. No. 37 1030 61) Fit :

Fit : • Oil seal for ‘Gear Changer Lever’
• Bearing for ‘Output Shaft Assembly’
Crankcase LH (Magneto Side) Clutch Cover

Fit : • Oil seal for ‘Kick Shaft Assembly’
• Bearing for ‘Output Shaft’

Fit : • Oil seal for ‘Clutch Lever’ on ‘Clutch Cover’
• Bearing for ‘Input Shaft’
Note : Do not use inner guide while fitting the bearing for ‘Input Shaft’
in ‘Crankcase LH’ as this will damage the protruding lug of crankcase
casting. Shield of brg. must be on crankcase side/protruding lug side.
Use Bearing Driver set (P. No. 37 1030 61) Assembly of Sub assemblies :
Fit :
Magneto Cover
• Bearing for ‘Body Balancer gear Assembly’
Fit :
• ‘Harness’ in the ‘Cover’
• ‘Stopper’ and tighten the ‘Screw’ (Use Loctite 243)
• ‘Pulsar Coil’ and tighten 2 ‘Screws’ (Use Loctite 243)
• ‘Stator Assembly’ and tighten 2 ‘Bolts’ (Use Loctite 243)
• 2 ‘Dowel Pins’
Use Bearing Driver set (P. No. 37 1030 61)
Camshaft Assembly
Fit : F Fit :
• Oil seal on ‘Guide Starter Assembly’ C
B • Parallel Pin (A)
• ‘O’ ring on ‘Guide Starter Assembly’.
A • De-compression Mechanism (B)
• Damper
• ‘Washer’ (C)
D
• Washer (D)
E
105 106
• Using Arbour Press Similarly carry out the same procedure to assemble the other
Fit : ‘Valve’ in the ‘Cylinder Head’.
• ‘Bigger Bearing’ (E)
• ‘Small Bearing’ (F) Note : Ensure that there is no valve leakage. If required pour
the petrol in intake and Exhaust manifold and observe leakage
at valve head.
Note : Apply thin layer of oil on sliding surfaces of parts for smooth
fitting.
Head Cover A Chain Tensioner Assembly

B
Fit : C
Fit :
• Roller rocker arm D • ‘O’ ring (F) in the body (I)
• Tappet Screw E • ‘Thrust Washer’ (E)
F
• Tappet Nut • ‘Spring’ (D)
• 20 Rollers in cage outer I • ‘Cap’ (B) along with ‘Screw Internal’ and ‘Screw External’ (C)
H
G (Keep the ‘Spring’ and ‘Screw Terminal’ fully compressed inside)
Note :
• There are 2 cages in roller rocker arm each cage holds 20 rollers
• ‘Circlip’ (A)
• Inner cage in Absent
• Multipurpose grease is to be applied in outer cage to hold the roller 6
Clutch Assembly
2
7
firmly while assembling 4 Assemble the clutch plates and friction plates in clutch center /
6
7 clutch hub.
6
7 8 Fit :
Assembling Head Cover 12
10
Fit : 5
• ‘Plain Washer’ in ‘Clutch Center’ / ‘Clutch Hub’
9
1
14
• Roller Rocker Arm 16
• ‘Bellivelli Washer’
B 6
17
A
3 13
11
• Set of Plan and Wave Washer 15
• ‘Clutch Plate’(A) 1 Nos
• Rocker arm shaft • ‘Pressure Plate’ 5 Nos
C • Gaskets • ‘Clutch Plate’ (B) 4 Nos
• Dummy Plugs • ‘Clutch Plate’ (C) 1 Nos
• ‘Wheel Clutch’
Note : Repeat the same procedure for fitment of other roller rocker arm • ‘Springs’ 4 Nos.
• ‘Thrust Plate’
• ‘Bolt’
A
Cylinder Head
B Fit : Using Special Tool T1011168
D • Valve steam seals Align the clutch assly into the clutch housing.
• Slide the ‘Valve’ from below. Fit :
C • Place the ‘Valve Springs’ • ‘Spacer’
(C&D) (Inner and outer • ‘Clutch Assly’
closed coiled ends placed
F at the bottom side)
• Valve Spring Retainer’ (B)
E Using the sp. tool Valve
Spring Compressor 37 Note :
1031 07 & Adaptor 37 • Ensure concentrity of ‘Thrust Plate’ w.r.to ‘Clutch Wheel’, ‘Clutch
10DJ 78 Center’, ‘Clutch Housing’. Using Special Tool -
• Press the valve springs • The Special Tool can also helps in preventing the cracking /
• Fit the cotter valves (A) & Bending of ‘Thrust Plate’ while removing and refilling the thrust
release the special tool plate.
107 108
Oil Pump Loading the assembly Balancer
Fit : Idler Gear
• ‘O’ ring (A) on the ‘Oil Strainer’ (B) Using Special Tool - Balancer
A • ‘Clip’ (C) Gear Holder 37 10DJ 63
• Slide the ‘Assembly Balancer
B
Idler Gear’ in special tool (A)
C • Rotate the ‘Scissor Gear’
anticlockwise till the lug contacts
the torsion spring.
Kick Shaft Assembly • Using a marker, mark the ‘Balancer Idler Gear’ and ‘Scissor
Fit : Gear Tooth’
H
A E G B • ‘Pinion Complete Kick Starter’ (I) Using Special Tool
• ‘Washer’ (H) • Turn the ‘Scissor Gear’ anticlockwise such that 2 teeth pre-load
is achieved. This can be confirmed by the markings done
• ‘Circlip’ (G)
previously.
• ‘Ratchet Kick Starter’ (F)
• Holding the ‘Scissor Gear’ pre-loaded in the above position
I slide the ‘Scissor Gear’ into the special tool completely.
Note : Match the dot mark of ‘Ratchet Kick Start’ with respect to
C D F ‘Spindle Kick Start Assembly’ and then slide ‘Ratchet Kick Starter’ (F) Repeat the same procedure for loading the other ‘Scissor Gear’.
on ‘Spindle Kick Start’
Note : Keep this Assembly balancer idler gear in loaded condition with
special tool.
• ‘Spring Kick Starter Ratchet’ (E)
• ‘Washer Thrust’ (D)
• ‘Circlip’ (C) Gear Complete Starter Counter Assembly
• ‘Washer Thrust’ (B) Using Arbour Press
• ‘Thrust Washer’ (A) Fit :
• ‘Needle Roller Bearing’
Assembly Balancer Idler Gear Bearing
Using Bearing Driver set (P. No.: 37 1030 61)
Fit :
• Needle roller bearings in crankcase RH and Cover
Crankcase LH (Magneto Side)
Note : Apply oil on bearing OD before pressing bearings for smooth Fit :
bearing • ‘Guide Starter Assembly’
• 3 ‘Screws’ (A) (Use loctite 243)
Fit :
A C D • ‘Springs’ (D) A
• ‘Scissor Gears’ (C)
• ‘Circlip’ (B)
Clutch Cover
• Thrust washer
G A Fit :
Similarly carry out the same procedure on other side of the gear B
• Kick shaft oil seal (H)
to assemble the ‘Balancer Idler Gear’ completely.
• Oil inspection window
B D E CB A
• Wire clip (I)
Note : Ensure that one spring end butts against spring dowel in H
• Set dampers (K)
‘Balancer Idler Gear’ & the other end of spring should butt • Set of plates (L)
against the lug on ‘Scissor Gear’
C • Bolts (J)
• ‘Rack’ (C)
• ‘Shaft Clutch Release’ (B) in ‘Clutch Cover’ by rotating it slightly
K to match the teeth.
F
J E • ‘Parallel Pin’ (A) to lock the ‘Shaft Clutch Release’
L D
• Washer
109 110
• ‘Spring’ torsion clutch lever Engine Assembling
• External lever
• ‘Bolt’ Engine Central Part
• Spring joint ‘A’ (F)
Fit : (In Magneto side Crankcase)
• ‘Plunger Plate’ (E)
• ‘Input and Output Shaft Assembly’ simultaneously.
• ‘Plunger oil (D)
• ‘Fork shifts’ along with rollers on ‘Input and Output Shaft
• 2 ‘Dowel Pins’
Assembly’ (2 bigger fork shifts on output shaft and 1 smaller on
• ‘Grommet (M) input shaft).
• Oil feeler plug (G)
Apply loctite 243 to all damper fitment bolts. Note : For ease of assembly of gears, remove gear 1st driven and
insert both the input and output shaft assemblies with gears in mesh
into their respective bearings. The gear box should be in neutral gear
Note : Ensure fitment of set of dampers and plate before fitting the before ‘RH Crankcase’ is assembled on to ‘LH Crankcase’.
above.
Fit :
A
• ‘Drum Change’
Input Shaft Assembly
• ‘Shaft Gear Shift’
B C EF I K Fit : From LH side of shaft (A)
• ‘Kick Spring’ (A)
• Thrust washer (K)
• 2 Dowels
• Gear 4th (J)
• ‘Gasket’
• Splined washer (I)
• Circlip (H)
• Gear 3rd drive (G) Caution : Use a sharp blade or knife to cut off any protruding
D G H J A
• Circlip (F) ‘Gasket’. This is very important for preventing any oil leakage from
‘Crankcase’ and ‘Cylinder Block Joint’. Don't apply grease / any
• Splined washer (E)
adhesive to ‘Crankcase Gasket’ as these ‘Gasket’ when comes in
• Gear 5th drive (D) contact with oil expands and seals hidden cavities.
• Gear 2nd drive (C)
• Thrust washer (B) Fit :
• Crankshaft
L M H FE CB A Output Shaft Assembly
Fit : from LH side of shaft Caution : Check oil supply to big end bearing by pumping oil in the
clutch side end of crankshaft and lets oil dribble out of con-rod big
• Gear 5th driven (M)
end sides.
• Bush (N) with shoulder ring
nd
• Gear 2 driven (L)
• washer (K)
Fit :
• Circlip (J)
• Crankcase RH
Fit : from RH side of shaft
rd
• Bolts (LH & RH Side)
JK N I G D • Thrust washer (H) behind the 3 gear on output shaft
rd
• Gear 3 driven (G)
• Spline washer (F).
• Circlip (E)
• Gear 4th driven (D) Clutch Side
• Steel bush (C) with shoulder ring Fit :
• Gear1st driven (B) • ‘Parallel Pin’.
• Thrust washer (A) • ‘Sprocket Cam Drive’
• ‘Cam Chain’
Note : Hold the cam chain upright using a soft copper wire or a
thread.
111 112
Fit : Fit :
• ‘Square Key • Washer
• ‘Primary Gear’. • ‘Kick Shaft Assembly’
• Washer
Note :
Note : Ensure fitment of 2 ‘Plain Washers’ on either side of ‘Kick Shaft
Assembly’. 1. Ensure fitment of 2 ‘Plain Washers’ on either side of ‘Kick Shaft
Assembly’
2. Refer Skill tip for fitment procedure on page no....
Fit :
• ‘Body Balancer Gear’. Fit :
A • ‘Lock’. • ‘Thrust Washer’
• ‘Bolt’ (A) (Use Loctite 243) • ‘Assly Balancer Idler Gear’ with Special Tool
• Thrust washer
Fit :
Fit :
• ‘Parallel Pin’.
Align gear timing marks of ..
• ‘Spacer’
A • ‘Guide gear shifter’ • Primary gear mark w.r.t
crankcase mark
• ‘Allen Bolt’ (A)
• Body balancer assly mark
w.r.t crankcase mark
Fit :
Fit :
• ‘Spring’ (A)
• Clutch housing
A
Note : Note :
a. Apply Loctite 638 at ‘Bolt Shift Change’ (B) if removed. 1. Ensure perfect matching of gear alignment marks w.r.to crankcase
b. Ensure free movement on ‘Stopper Gear Shift’ in ‘Bolt Shift marks.
B Change’. 2. Refer the skill tips section for understanding procedure for gear
alignment marks given on page no 52.
Fit : Fit :
• ‘Gear change lever assly’ • 2 ‘Dowels’
• ‘Assly Balancer Idler Gear Cover’
• 3 ‘Bolt’
Using Special Tool - Primary

Fit :
gear holder 37 10DJ 28 &
• ‘Gear kick Idler’ Special Nut 37 10DJ 43
• Stopper Fit :
A • Stopper bolt (A) (Use loctite 243) • ‘Spacer’.
• ‘Clutch Assembly Complete’
• 'Washer’
Note : Ensure loctite 638 on ‘Kick Guide’ allen bolts, if removed
• ‘Special Nut’
113 114
Note : Special nut for input shaft has LH threads. Fit :

• ‘Clutch Cover’
• 10 ‘Bolts’
Fit :
• ‘Bracket clutch cable’
• ‘Bearing with plunger’.
• ‘Starter Motor Cap’
• ‘Screw’
• ‘Kick starter lever’
Note : When assembling the ‘Clutch Cover’ always remember

that the entry of ‘Kick Shaft’ into the ‘Clutch Cover’ is the tightest
as the tolerances are tightly controlled. One should concentrate
Using Special Tool : Primary
on aligning the kick shaft bore and kick shaft first, rather than
Gear Holder - 37 10DJ 28
concentrating on the possibility of the plunger falling down. When
Using Sp. Tool : Centrifugal working on vehicle It is advisable to loosen the ‘RH Rider
Oil Filter Nut - 37 10DJ 43 Footrest’ which helps in the above and helps also in loosening
Fit : and tightening of the 2 M6 bolts partially masked by the
‘Footrest’.
• ‘Centrifugal Oil Filter’.
• Washer
• ‘Special Nut’.
Magneto Side
Using Special tool : Primary Fit :
gear holder 37 10DJ 28 • ‘Shaft Starter Counter’.
Fit : • ‘Gear complete starter counter assly’.
• ‘Gasket’ • ‘Collar’
• 3 screws
• Cover Note : Always apply a thin layer of grease on to the roller bearing of
starter counter gear.
Fit :
Fit :
• 2 Dowels
• ‘Woodruff key’
• ‘Oil Pump Assembly’
• ‘Magnet along with gear starter clutch’.
• 3 ‘Bolts’
Note :
• Always apply a thin layer of grease to the roller bearing of gear
starter clutch.
• Add few drops of oil on OD of gear starter clutch for lubrication.
Fit :
Fit :
• ‘Starter Motor’
• ‘Plate starter clutch return (A)
• Clutch cover gasket’
• ‘Bolt’ (Use loctite 243) (B)
• ‘2 Dowels’
A
B
Note : Do not apply any grease to stick ‘Gaskets’ to the
‘Clutch Cover / Magneto Cover’ or ‘Crankcase’. As grease
deteriorates the gasket material and reduces sealing
effeciency.
115 116
Using Special Tool : Rotor Note : Place clean piece of cloth on the ‘Crankcase’ bottom end
Holder H6 0721 00 because their is chance of ring snap falling down while fitment.
Fit :
• ‘Washer’
• ‘Bolt’
Using Special Tool : Piston

Fit :
Ring Holder 37 10DJ 30
• ‘2 Dowel’
Fit :
• ‘Gasket’
• Slide the ‘Cam Chain’
upright with soft copper
wire / Thread into cylinder
• Slide the piston assly into
cylinder
Fit : Note : Apply thin layer of oil in cylinder bore and piston assly
when sliding inside for ease in fitment.
• ‘Magneto Cover’
• 5 ‘Bolts’
Fit :
• Neutral switch coupler
• Head gasket
• 2 ‘Dowels (A)
A
• ‘Chain Guide’ (Non tensioner side)
Using Special Tool : Output Note : Holding the chain firmly bring the piston assly to TDC position
and Ensure ‘T’ mark on the rotor is matching with generator cover
sprocket holder 37 1030 53
mark.
Fit :
• ‘Bush’. Fit :
• ‘Sprocket’. • ‘Cylinder Head Assly’.
• 2 Dowels
• ‘Plate drive Sprocket’.
• 2 ‘Bolts’ (Use loctite 243).
Top End
Fit :
• 2 ‘Dowels’
• Block Base Gasket Fit :
• ‘Spark Plug Sleeve’.
• ‘Grub Screw’.
• ‘Spark Plug’
Using Special Tool : Drift Note : Before fitting the sleeve spark plug apply thin layer of
74 9309 89 molybdenum disulphide grease on the entry chambers for the ‘O’ rings.
Fit :
• ‘Piston’
• ‘Piston Pin’
• ‘Circlip’
117 118
Fit : Fit :
• ‘Cam Shaft’. • ‘Cam Chain Tensioner’
• ‘Collar’. • 2 ‘Bolt’
• Release the tensioner plunger bolt
• ‘Dust cap’ and ‘O’ ring’
Adjust :
Using Sp. Tool - 37 10DH 36
• Check and adjust the tappet
Fit :
clearance
• ‘Cam Sprocket’.
• ‘Special Washer’.
• ‘Allen Bolt’ Inlet Valve : 0.05 mm
Exhaust Valve : 0.1 mm
Note : Always ensure that the piston is at the end of compression

Note : stroke and ‘T’ is seen from ‘Timing Inspection Window’ at generator
• Ensure the sprocket marks are aligned horizontally with cylinder cover. When adjusting tappet clearance.
head top machined face and the piston is at TDC.
• Secure the ‘Cam Chain Sprocket’ in the special tool firmly and then
tighten the sprocket allen bolt.
A
A • Ensure that the ‘O’ mark on washer always faces outwards when
tightening the allen bolt.
Fit :
Fit :
• Tappet cap with ‘O’ ring
• ‘Cam Shaft Cap’. • Cap magneto cover
• 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.
• Refer Skill Tip for more details
II Fit :
• ‘Copper Plated Washer’
• Tighten bolts as per sequence
Ist : 4 Domed cap nut
III
I IInd : 4 Long bolts of Head Cover
IIIrd : 2 Longest bolts of Head cover
II
Note : Improper tightening sequence of bolts may cause permanent
warpage in cylinder head cover and it can get damaged permanently.
119 120
Dismantling Front Fork Dismantling Front Fork
Remove : C Remove :
• Speedometer sensor cable from wheel (A) and from fender • Bellow clamp (A)
B clamp (B) • Bellow (B)
Skill Tip : Keep it aside safely
• Bolt fork (C) from the top of front fork assembly along with the ‘O’
ring
A
A B
Remove : Remove :
• Caliper assembly front mounting bolt (A) • Seat fork spring (8 Allen bolt)
• Spacer tube
A • Washer
Skill Tip : Place wedge between pads. Remove front brake lever.
• Spring
• Fork oil in a container
• The dust seal and the snap ring over the oil seal
Recommended Oil Capacity per fork tube

Remove :
Approx 145 + 2.5 ml. (Drain and refill)
• Front axle self locking nut(A)
• Front axle (B)
Using Special Tool : Fork for
• Distance piece (C) A
Cylinder Holder Handle -
• Wheel sensor (D) 37 1830 06 & Adapter for Fork
• Pull out front wheel assly A C D B - 37 1830 11
Remove :
• Allen screw that is located at
bottom with the help of allen B
Remove :
key (A) by holding the fork
• 2 allen bolts (A) (on either side) piston with the help of a
• Front mudguard assembly adapter (B) and holder
• Piston assembly
Skill Tip : Painted parts should be handled with utmost care to avoid
scratches
A Using Special Tool : Front Fork Tube Extractor - 74 9310 15
Remove :
• The inner tube assembly will not come itself because of two DU
bushes fitted. One bush is fitted on inner tube and other bush is
Remove : fitted in outer tube.
• Rubber grommet (A) A
• Fit the front fork tube on the vehicle by assembling the special
• 2 Allen bolts (B) tool (A) and lock it at number plate mounting screw.
A
B • Rotate the special tool handle to seperate the inner tube from
outer tube as shown in the fig.
Skill Tip :
• Fit the fork tube without touching head light fairing
• Rotate special tool without hitting number plate.
Remove :
C D Remove :
• Loosen bolt (C)
• Inner tube (B) of front fork with DU bush
• Pull down fork leg assembly by slowly rotating it
• Oil seal (C) for outer tube
• Similarly carry out the same procedure to take out other side
fork leg • Guide bush washer (D)
• Spacer
C • Bushing
B
121 122
Assembling Front Fork Front Disc Brake
Using Sp. Tool : Fork for cylinder holder adapter - 37 1830 08/11 Master Cylinder
Fit :
Working:
• Place Fork cylinder set in the inner tube, cylinder base & place
it in outer tube. Hold the piston with the help of special tool. When the brake lever is in idle condition, there is no pressure inside
the cylinder. The feed & compensation aperture are open & connect
• Bolt it from lower side of outer tube with Allen key. the pressure chamber & compensation chamber to reservoir.
• Guide bush, washer When the brake lever is operated, the push rod pushes the piston
• Oil seal using special tool (A) inside the cylinder. A small quantity of fluid returns from pressure
• Snap Ring chamber to reservoir before primary seal completely blocks the feed
aperture. Once this condition is achieved, any force exerted on the
• Dust seal lever is transformed into pressure in the brake circuit.
Air Vent
A • Spring and fill oil. Cover
Feed aperature Diaphragm When the brake lever is released, the piston is pressed back quickly
Compensation operature Reservoir
• Seat fork spring and Collar fork. Secondary seal Master cylinder by the return spring to its idle position. Due to this, a vacuum is
body
• Bolt generated in the pressure chamber & the fluid in the compensation
Piston Outlet Port
chamber flows to pressure chamber through the primary seal, the
Similarly carry out the same procedure to assemble the other fork. Brake Lever
Compensattion Pressure external edges of which flex approximately to allow fluid to pass to
Chamber Chamber
Skill Tip : The Part Name & No written on oil seal should face up side Primary seal
pressure chamber. After return of the master cyl. piston, the caliper
i.e. towards technician while fitting. Spring retracts (after some relative time delay). This causes the fluid in the
pressure chamber to return to the reservoir through feed aperture.
Fit : Master Cylinder Dismantling and Assembling
• Slide the front fork assly in the fork holder Dismantling :
• Allen bolts • Remove front brake switch and its connection (A)
• Bolt fork at the top end
Similarly carry out the same procedure for fitment of the other
shock absorber.
Fit :
• Remove front brake lever by removing the nut and pivot bolt (B)
• Front fender
• The push rod boot (One end of the boot is held in a groove in
• 2 Allen bolts (A) (2 on either side) the push rod and its other (larger) end is held in a groove in the
cylinder body).
A B
Fit :
• Top cover by removing 2 screws (C)
• Front wheel assembly.
• Front axle (A)
• Tighten self lock nut
A • Calliper assembly and
tighten 2 bolts
• Speedometer sensor cable C
connection.
• Nylon Cap (D)
Caution : Don’t apply excess grease or any other lubricant on the
wheel sensor case. • Rubber diaphragm (E)
D E
123 124
Front Disc Brake Front Disc Brake
• Brake fluid from the reservoir with the help of syringe/syphon Caliper Assembly
pump
Working :
In the brake released condition, the brake fluid inside the caliper is at
atmospheric pressure and the disc rotates freely as the pads do not
press against it.
When the brake lever is operated, the pressure generated in the
hydraulic circuit acts on the caliper pistons. The caliper in turn push
the friction pad on the side of the caliper body against the rotating
disc. The friction pad on the other side of the disc also presses against
• Master cylinder along with hose assembly from handle bar by the disc due to reaction force on caliper body. Thus both the friction
removing the 2 flanged 8 bolts (F) on the clamp. Hose pads press against the disc, thereby generating braking torque.
• Brake hose from master cylinder outer by removing banjo bolt (G)
When the lever is released, the pressure in the hydraulic circuit return
• Wipe out clearly the outer surface of master cylinder. Bleeder to atmospheric level. The friction pads return to idle position due to
F Screw
return of the caliper pistons which is due to the spring action of the
Banjo seals.
G Skill Tip : Bolt
• Ensure that there should not be any spillage of brake fluid on When the pads wear, the pistons move further towards the Disc during
painted parts brake application, but after release of pressure they retract only to the
extent allowed by the spring action of the seal. The pistons therefore
take up new positions in idle condition, and thus provide automatic
adjustment to compensate for pad wear. Due to this reason, there is
Safety Tip :
no need for free play adjustment in the Brake Lever in Master Cylinder.
• Take care of your eyes while working with brake fluid. Pin
Piston
Disc
• Hold the master cylinder in a soft jaw vice. Pad
Disc
• Remove circlip with the help of a plier, by pressing the piston Pad
slightly inside the bore, with a nylon or wooden rod. Piston
Seal
• Take out the piston assembly along with the Return spring by
pulling it out. Caliper
Body
If transparent window in the cylinder body for level indication
needs replacement (due to damage, etc.) proceed as follows:- Carrier
Disc Bracket
• Remove Lock Ring on the window with screw driver
Dust Seal
• Remove window and ‘O’ ring.
Master Cylinder Assembly : Dismantling of Caliper

• Never allow mineral oil to come in contact with seal or other
Dismantling the Assembly
rubber parts of disc brake, since it will cause damage to these
parts. A • Remove caliper mounting bolts (A)
B • Remove banjo bolt (B)
• Free play at the end of the lever is provided to ensure that in the
free condition, the piston does not remain in the pushed • Remove caliper from fork
condition, This ensures that there is no pressure in the system Removal of Pads :
when the brake is not applied.
• Remove the pad retaining body’s Allen bolt
• Remove the pads
• Remove the pad spring from the caliper body with a screw driver
Piston and Piston Seal Removal :
• Wipe out cleanly, the outer surface of the caliper.
• Remove LH pad retaining case by removing allen bolts
• Put a wooden wedge in between the piston and caliper.
• Blow compressed air into cylinder through benzo bolt hole where
the brake hose was fitted, with the air pressure, the piston will be
pushed out of cylinder.
125 126
Front Disc Brake Front Disc Brake
Warning : Do not apply high pressure compressed air, which will cause Inspection and Maintenance Frequency
the piston to jump out of the cylinder. The piston should be taken out
gradually with moderately compressed air. Care to be taken not to Check Points Frequency
damage the sealing surface of the inlet port while applying air pressure.
Brake Fluid Level / Leakage Inspect during every service /
• Do not place your finger in front of the piston while applying every 2500 Km refil up to upper
compressed air to push it out. limit (till step on the inner side of
the reservoir) if level is low.
• Remove piston seal using a thin part like a thickness gauge, etc.
Replace brake fluid every two years.
Caution : Be careful not to damage inside (bore side) of the cylinder. (In severe operating conditions,
replace in a year.)
Skill Tip : While assembling use loctite paste 243 on allen bolt for
mounting LH pad retainer case. Brake Lever Operation Inspect during every service/every
2500 Km
• Assemble the caliper assly in reverse order of dismantling
Air Bleeding of Disc Brake System :

For air bleeding from front Hydraulic brake system first top up the
master cylinder with hydraulic oil.
Operate the brake lever slowly in order to get filled the oil in the
circuit. Brake Pads lInspect during every 2500 Km
Connect transparent tube to the bleeder screw at caliper or thereafter for wear and condition
syphon pump of linings.
Operate the brake lever and keeping in pressed position loosens
the bleeder screw so that some oil escapes with the air bubbles.
Keep on operating the brake lever till the air bubble escape out
completely through bleeder screw, and top up the master cylinder
if required.
Once the air escapes out from the hose pipe the brake lever
Brake Disc Inspect during every 5000 Km.
meets resistance, which indicates completion of air bleeding
and every 2500 Km thereafter.
After completing the bleeding, top up the master cylinder up to
the maximum level mark. Check for excessive scoring
• Also syphon pump can be used for air bleeding marks on friction surface of disc,
and run out.
Brake Fluid for Disc Brakes
Always use only recommended brake fluid from sealed container to ensure durability of the system. Never
reuse brake fluid removed from a system.
Important points on 2 wheeler disc brake system : Master Cylinder & Caliper Inspect every 5000 Km for
leakage.
1. Since front disc brake is more powerful than drum brake, apply front and rear brake together gradually.
Avoid braking during turning.
2. Use only DOT 3 or DOT 4 brake fluid from a sealed container from recommended makes.
3. Do not apply mineral oil for cleaning any brake parts. Use only brake fluid for cleaning the seals.
4. Do not apply mineral based grease on bore, pistons and seals of master cylinder and caliper. Apply
only recommended assembly fluid.
5. Do not use cotton cloth to wipe cylinder bore, fibres of cloth will remain in cylinder bore surface.
6. Ensure dust free condition during assembly. Brake Hose Inspect for leakage & damage
during every service / every 2500
7. Do not polish friction disc with sand paper, as hard particles deposited in the lining may damage steel Km.
disc.
8. While filling the reservoir after bleeding, ensure that drops or splashes do not remain on the painted
surface or plastic surface, since brake fluid is corrosive.
127 128
Maintenance - Electricals Maintenance - Electricals
Battery • Remove vent plug strip happens, the chemical reactions within the battery
• Top up level with distilled water in between are affected and results in loss of capacity. Mostly
Technical Specification : the causes of sulphation are as under :
Min and Max. level
• Type & Capacity 12V - 9 AH • Connect battery to charge and ensure a. Undercharging.
respective terminal are connected properly
0 b. Standing in a partially or completely discharge
• Specific gravity of electrolyte 1.24 for use above 10 C • Set charging current at 0.9 A DC condition for long time.
for initial filling of new battery
• Charge battery for 3/4 hrs., then check c. Low electrolyte level : If electrolyte level is
• Specific gravity of electrolyte 1.28 for use above 100C voltage and special gravity. permitted to fall below the top of the battery
for initial filling of new battery • Voltage should be 12.5 volts and special plates, then the exposed surfaces will harden
gravity in all 6 cells should be 1.240. This is a and will become sulphated.
• Initial charging duration 10 ~ 15 hrs
confirmation check for a fully charged battery.
d. Adding acid : If acid is added to a cell in which
• Initial charging current 0.9 to 1 Amp • Disconnect the battery from the changer. sulphation exists the condition will be
• Fit vent plug strip firmly. aggravated.
Initial Charging Procedure
Hydrometer • Connect battery on to vehicle. e. High specific gravity : If specific gravity is higher
1. Fill each cell with battery grade sulfuric acid • Apply petroleum jelly on to the battery than the recommended value, then sulphation
of the correct Sp. gravity (1.24 at room temp. terminal. may occur.
0
for use above 10 C and 1.28 at room temp. Read f. High temp.: High temperature accelerates
0
for use below10 C). Here Battery Maintenance sulphation, particularly of an idle, partially
2. Allow the battery to stand for 30 min. after discharged battery.
For the optimum performance and longer battery
filling. life the maintenance of battery is important. Voltage of the sulphated battery : -
3. Keep vent plugs open. Connect battery to a. Always keep the battery clean and dry. Cells of the sulphated battery will show low
charger and charge at 0.9 Amp.
specific gravity. Follow the procedure given below.
b. Visually inspect the surface of the battery
4. Charge continuously for 10~15 hours taking container. If there are any signs of cracking or • Check voltage before charging.
Sp. gravity readings every hour. Fully charged electrolyte leakage from battery, replace the
condition is indicated when all cells are • Charge for 2 hours
battery inside the box provided on floor board. battery.
gassing freely and evenly and show no rise in • Check voltage every 1 hour. If voltage increases
Fasten the battery firmly with bracket & allied
specific gravity over 3 successive readings. Never add acid or ordinary tap water for then continue charging. But if voltage does not
fasteners.
topping up since this will shorten Battery life. increase, discontinue charging. Otherwise
5. After charging push vent plugs strip firmly into
place and wash off acid spillage with water c. Connect cables to the positive and negative battery charger will get permanently damaged. If
and dry the battery. terminals properly. Reverse connections will Non Use Maintenance battery is not badly sulphated (i.e. voltage more
damage the charging system permanently. than 9 volts), then battery can be revived by
Checking the Specific Gravity When the vehicle is likely to remain off-road for special treatment. In such case it is advisable to
d. Always connect the “negative (earthling) longer, time (say more than a month) then Non give sulphated battery to authorised dealer of
The charge condition of the individual cell can be terminal” at Iast. Use Maintenance should be carried out as battery manufacturer for necessary special
checked by measuring Sp. gravity of electrolyte in e. Clean the battery terminals and cable follows otherwise the battery may get sulphated treatment.
that cell. The specific gravity of electrolyte can be connections. Smear them with petroleum jelly and permanently damaged.
checked by using Hydrometer having small to avoid corrosion How to Determine Condition of Battery
a. Remove the battery from vehicle.
diameter spout.
g. Check that the battery cable connections are b. Maintain electrolyte at ‘Upper Level’. Specific gravity check: - Whether battery is fully
For measuring the Sp. gravity bring the electrolyte firm and cables do not rub against any metal charged or partially charged, it will always show
in the Hydrometer to eye level, and read the components. c. During off service period, battery should be same “no load voltage” of 12 volts or more
graduations on the float scale bordering on the charged once a month. (unless battery cells are damaged due to
lower meniscus (i.e. curved down portion of sulphation etc). But specific gravity of the fully
electrolyte surface) as shown in the figure. After Battery Charging Procedure : d. Keep the battery fully charged.
charged battery and partially charged battery will
charging is over, fit the filling caps strip, wash This is a M.F (Maintenance Free) battery. This e. Store the battery in cool, dry place. be different. Fully charged battery will show Sp.
acid spillage with water. Dry the battery. Ensure battery is not having any exhaust tube instead it gravity of 1.240 while partially charged battery
terminals are clean. f. Keep the battery away from rain, dew,
has a unique vent mechanism. will show less specific gravity. Therefore, specific
moisture and direct sunlight.
gravity check is very important to know condition
Battery Installation: The electrolyte level in this M.F. battery needs to
of the battery.
be topped up with distilled water once in a year. Battery Sulphation
Install the battery on vehicle as described below In case battery in discharged and needs to be
charged using battery changed procedure is as A sulphated battery is one which has been left
a. Ensure that in all six cells the level of standing in a discharged condition or
follows :
electrolyte is near the maximum level mark. undercharged to the point where abnormal lead
• Remove battery from vehicle
b. To clean and dry the surface wipe the top of sulphate has formed on the plates (Sulphate cells
• Clean battery throughly looks like white crystal like sugar). Where this
the battery with a clean cloth. Install the
129 130
Switches : Brown Blue CDI Unit and H. T. Coil Inspection :

a. Front Brake Light Switch Inspection : • CDI unit can be checked using OK H.T. coil on Electronic Test
‘ON’ (Vehicle in neutral)
i. Turn ON the ignition switch. jig
ii. The brake Light LED Blank should get on ‘OFF’ (Vehicle in gear) • Similarly H.T. Coil can be checked using OK CDI unit on
when the front brake (Lever is pressed) is electronic Test jig
applied.
e. Ignition Switch : H.T. Coils : (Inspection Using Multimeter)
iii. If it does not, check the Front brake switch.
• Measure the primary winding resistance as follows
Brown Blue Brown White Black / White Black / Yellow • Connect the hand tester between the coil terminals.
Lever Pressed ‘OFF’ • Measure the secondary winding resistance as follows
Lever Released ‘ON’ • Remove the plug cap by turning it counter clockwise.
• Connect the tester between the spark plug leads.
g. Stator Plate Coils Inspection : • Measure primary winding resistance.
b. Rear Brake Light Timing Inspection :
i. Disconnect stator plate coupler • Measure secondary winding resistance.
i. Turn ON the ignition switch.
ii. Set multimeter on ohm range. (Ohm Meter)
ii. Check the operation of the rear brake • If the valve does not match as per, replace the coil.
coils light switch by depressing the
brake pedal
• Pickup Coil Resistance :
Primary Winding 0.40 to 0.49 Ohms
iii. If it does not operate as specified, adjust
the brake light switch or check Rear Range Connections Reading Secondary Winding 4.23 to 5.17 K Ohms
brake switch Meter +ve Meter -ve 200+22
2 K W
Brown Blue White/Red Black/Yellow ohm • If the meter reads as specified, the ignition coil windings are
probably good. However, if the ignition system still does not
Pedal Pressed perform as it should after all other components have been
• Excitor Coil :
Pedal Released checked test replace the coil with one known.
Range Meter +ve Meter -ve Reading • Visually inspect the secondary winding lead.
c. Fuel Level Indicator : 200 W Red Black/Yellow 14+1.4 W • If it shows any damage, replace the coil.
i. For knowing then quantity of fuel inside
the fuel tank at a glance, is provided on • Battery Charging Coil :
Speedo consle. The fuel gauge works on
the principle of ‘variable resistance’. The Range Meter +ve Meter -ve Reading Fuse Inspection (Capacity = 10 Amp)
fuel gauge works on D.C supply.
200 W Blue/White Blue/White 1.3+0.13 W • Inspect the fuse element
ii. For checking the resistance across the
sender and across the gauge, make the • If it is blown out, replace the fuse.
connections verify the readings, make • Lighting Coil : • If a fuse fails during operation, the electrical system to
the connections verify the readings as determine the cause, and then replace it with a new fuse of
tabulated below Range Meter +ve Meter -ve Reading proper amperage.
200 W Yellow/Red Black/Yellow 0.7+0.07W
Connection Tank (Float) Resistance Caution : When replacing a fuse be sure the new fuse matches the
specified fuse rating for that circuit. Installing of a fuse with a higher
White / Yellow Full 4 - 10 W rating may cause damage to wiring and components.
Meter (Highest position)
10 W
Empty 95~105 W Relay (Inspection Using Multimeter) :
Black / Yellow
(Lowest position)
Coil Resistance Meter +ve Meter -ve Reading
d. Neutral Switch : X 200 Ohm Brown Green/White 55+5.5 Ohm

i. The neutral switch will be in ON position
only when the engine is in neutral • Also this relay can be checked on electronic Test jig.
position.
ii. The neutral light will not glow when
vehicle is in geared position
131 132
REGULATOR RECTIFIER UNIT DC Charging Voltage Measurement :
Rectifier & Regulator Assembly :
(Use fully charged battery while
AC Voltage Measurement : measuring)
To measure AC voltage, open the headlight housing. Start the engine and set it at 4000+25 RPM. Ensure To measure the DC voltage; set the meter at
that the headlight, tail light, Speedometer light are ‘ON’ and the dipper switch is at ‘Hi beam’ position. 20VDC range. Connect the meter +ve lead to
L/W
L/W
Connect AC voltmeter in parallel across the AC circuit load by connecting the +ve meter lead to white from RR unit and meter -ve lead to
red/black lead from the dipper switch and the -ve meter lead to ground. ground. Start the engine and set it at 4000+25
RPM. Measure the voltage with and without
Measure AC lighting voltage at 4000+25 RPM. The voltage should be 13.5+0.5 V. Stop the engine. headlight switch to the ON position. Stop the
Disconnect the meter leads. Reassemble the headlight housing. engine disconnect the meter leads.
Meter Range Specification at 4000+25 RPM Multimeter connected in
Parrallel with Battery for Meter Range Specification at 4000+25 RPM
AC 2o Volt 13.7 + 0.3 V
W
checking DC charging
L/W
L/W
DC 20 Volt 14 ~ 15 V
voltage
AC Lighting Circuit : 14.2
FUSE
(10 Amps.)
W/B
B
L/W
L/W
CONTROL
SWITCH RH R
PIN NO.3 R/B R/B
HIGH BEAM INDICATOR BATTERY
PIN NO.2 Br Br 12V-9Ah
INSTRUMENT CLUSTER + INPUT REGULATOR STARTER RELAY
PIN NO.11 RECTIFIER WITH DAMPER
B/Y B/Y BODY CONTROL UNIT
COMMON GROUND UNIT
PIN NO.13 R R AC INPUT MAGNETO

POSITION LAMP ON- INPUT & OUTPUT
INSTRUMENT CLUSTER
Y/R
PIN NO.20 W
20 PIN COUPLER WITH DUST COVER

PERMANENT BATTERY + INPUT
R/B
REGULATOR RECTIFIER UNIT Battery DC Charging current : (Use fully
Y
R
R/Y
O charged battery while measuring)
Y
O
Y/R
F
N
F
Br Br To measure the DC charging current, set the
IGNITION
SWITCH meter at 20ADC. Connect meter+ve lead to
13.5
W W
TAIL/
White/black lead from RR Unit and meter -ve
R R STOP lead to battery +ve lead.
W
LED
L/W
L/W
ASSLY
+
W
- R Start the engine and set it at 4000+25 RPM.
NO.
R
PLATE Measure the DC charging current. The DC
FUSE LAMP Multimeter connected
10 Amps 5 W
R/B R/B in Series with Battery charging current should be 2 A max stop the
W/B
HEAD LAMP engine and disconnect meter leads. Connect
Y/R
ASSY/LAMP LIGHTING for checking DC
B/Y B/Y COIL the RR unit and battery
12V-35/35W HS1 B
R/Y R/Y R
charging Current
POSITION LAMP
12V-5W- 2 NOS. BATTERY 0.9 Meter Range Connection Specification
STARTER RELAY 12V-9Ah
70A RATING
W
L/W
L/W
DC10A Meter +ve Meter -ve 2 A max at

R
White/Black Battery (+) 4000+25 RPM
MAGNETO
terminal of lead (White)
R/R
FUSE
(10 Amps.)
W/B
B
L/W
L/W
BATTERY
12V-9Ah
STARTER RELAY
WITH DAMPER
MAGNETO
133 134
Speedometer/Tachometer Console mind and wants to continue straight ahead.

• Back-lit, Non-contact Handlebar switches : The rider has only to re-select the opposite
The speedometer has a wide Digital LCD screen with a orange The control switches on both sides of the side indicator again to cancel the previously
backlit display mode for superb visibility of display during night riding handlebar are conventional to look as, in terms of selected indication. (There is no depress to
condition. switch positioning. The main features of these are cancel function)
This entire speedo console houses following : ... The other feature which has been incorporated in
• Operation is based on non-contact the switches is the illumination of the tell-tale icons.
• A large analogue tachometer with self testing mechanism. The illumination is backlit by LED’s which again are
• A red LED indicator showing low fuel level inside the fuel tank. • Switching is done without physical contact long-life and have a pleasant bluish-white glow to
And also indicates a flashing signal when engine RPM exceeds • There is no wear and tear them. All the icons like the turn indicators, low
above 9000 RPM. Thus ensuring safety of rider and engine. • Life would be equal to that of the bike beam, high beam, horn, starter etc. glow when the
itself. Parking or Headlight switches are put ON.
• Digital Displays for • The operational force required for the
switches has been kept as low as possible Checking of switches on handle bar : As like in
- Odometer
to give a light feel and reduce fatigue for conventional switches, since switch is not having
- Trip meter (Unique facility of resting the trip meter 1 & 2 respectively) any electrical contact, We can’t check the switch
the rider.
- Fuel level indicator functioning (Continuity) by multimeter. But it can be
• A row of indication LED displaying functioning of Working of Switches : These are non-contact type checked on electronic test jig.
switches, so instead of contact set it consists of
- Neutral Light hall sensor and magnet combination. • Clutch Switch : The clutch switch has 3 wires
Whenever any handlebar switches is pressed the and it has contact configration of
- High beam
hall sensor gets operated and its output signal is This vehicle is not having interlock relay
- Turn signal gives to a BCU (Body Control Unit) and BCU Instead its working is taken care of by clutch
- Side stand ON further calculates and gives precise signal to the
respective unit for functioning. e.g.
with a unique Day-Night mode functioning feature for riders Light Green Yellow/GreenBlack/Yellow
convenience and safety.
Horn Switch BCU Horn OFF Clutch
Lever
Released
Head Light
Note : The speedometer console has a unique builtin memory logic function which stores all the data like Pass Switch BCU High Beam ON Clutch
distance covered etc. in its memory even if DC supply is disconnected. Lever
Released
• Self Indicator Switch : In the conventional
type of switches the rider has to manually • Body Control Unit (BCU) : This is a sealed
Vehicle Speed Sensor
depress the Turn Indicator knob or return the Electric Control Unit located inside head light
• Non Contact Wheel Sensor : In LCD speedo console there are Turn indicator knob to its non-signalling assly.
no physical moving parts as sensing of wheel speed is through position.
- In case of overload or short circuit, BCU
a Non Contact hall effect Sensor. In UG III there is no separate press to off
has a short circuit/overload prevention
The hall sensor is a electronic switch which operates due to buttons for cancelling side indicator signal. This
facility.
magnetic field. The sensor has 3 wires supply, earth and output feature is achieved by providing a self cancelling
- This vehicle does not have a flasher. The
hall sensor and magnet fitted on steering column
whenever during rotations of wheel magnet passes through flasher operation is carried out by BCU
assembly.
sensor. A signal is given to speedometer through a wire to only.
This cancellation signal is processed through
speedometer which displays speed of vehicle in km/hr. - In case of failure of one of the filaments
BCU and then side indicators are switched off.
of head lamp. The BCU will automatically
The self cancelling feature automatically turns of
changeover to IInd filament. This is
the indicator of the indicator under 3 conditions.
provided for safety rider during night
• Tail Lamp : The illumination for Tail lamp and Brake lamp are • The first indication is when after the turn has
driving conditions.
been completed and the handlebar comes
done through 2 rows of LED’s each. These are high intensity - If customer operated starter switch
to a straight ahead position, the indicators
LED’s the main advantage of these LED’s is they consume very contunuously 3 times in a go for 4 th
switch off by themselves.
less power. i.e LED consumes 3W power against 21 W power of cranking BCU will disable cranking
• The second condition is when the rider has
a conventional brake lamp. When you operate light control operation and next cranking would be
selected a right or left turn but not
switch to glow but intensity will be very low. As soon as you possible after 20 second only. This
physically done the turn and is continuing to
feature is added which gives better
operate brake switch the brightness of LED increases to size go straight ahead and may be unaware of
battery life.
you bright light. the enabled turn signal too. A timer function
Maintenance :
This changeover of intensity is maintained with the help of gets enabled which switches off the
• Ensure no direct high pressure water
indicators after a pre-set time.
electronic circuit placed inside Tail Lamp Console assly and is a water is applied on Speedo console and
• The third condition is when the rider has
totally sealed unit. wheel sensor.
selected for eg. a left turn, but changes his
135 136
137
Notes :
Maintenance - Electricals
Pulsar DTS-i UG-III-180cc Training Notes
•
•
•
apply any grease or lubricant.
Do not open control switches and don’t
between the rotating parts.
Do not apply in grease or lubricant in
Ensure sensor cable is intact.
problems.
working on front brake drum relating
Handle wheel sensor carefully while
rubber cover.
mating coupler is always covered by
Ensure speedo console and harness
circumstances.
side of speedo under any under any
Don’t open rubber pins located on back
on console cover
Ensure there are no scratches/breakage
inverted
Speedo console should not be kept
Dealer Development Center
Dealer Development Center
Main Electrical Wiring Diagram

POSITIVE SUPPLY
CONTROL
Gr Gr KIL SWITCH SWITCH CONTROL LH SIDE IND. OUTPUT
SIGNAL LAMP MAGNET ASSLY
SWITCH LH
FRONT RH B/Y B/ Y RH RH SIDE IND. OUTPUT (S.C.B. UNIT)
LAMP 12V-10W GROUND
NOT USED
PIN NO.1 R/W R/W R/W

VEHICLE SPEED SENSOR + INPUT
PIN NO.2 Br Br VEHICLE FROM FROM FROM B/R
INSTRUMENT CLUSTER + INPUT SPEED RH SWITCH LH SWITCH S.C.B. UNIT
SENSOR
PIN NO.3 R/B R/B
SWITCH- BODY CONTROL UNIT
B
Br
HIGH BEAM INDICATOR

O/Br O/Br SWITCH ASSY.
PIN NO.4
L/W
HALL SENSOR ASSLY

B/Y
TALE-TELL SIDE STAND INDICATOR AC INPUT DC INPUT C.D.I. ASSY.

W/Y W/Y (S.C.B. UNIT)

PIN NO.5 & OUTPUT & OUTPUT
FUEL GAUGE INDICATOR
INSTRUMENT CLUSTER
W/R
B/Y
PIN NO.6 L/W L/W

Br/B
Br
B/Y
R/W
Gr
R/Y
R/B
VEHICLE SPEED SENSOR OUTPUT

R
Y
PIN NO.7 Gr Gr
REAR BRAKE
TALE-TELL BLINKER- RH INPUT FRONT BRAKE SWITCH SWITCH
G G
W/R
B/W
H.T. SPARK
B/Y
PIN NO.8
B/R
R
B
TALE-TELL BLINKER- LH INPUT COIL PLUG

PIN NO.9 Lg Lg FUEL LEVEL B
B/Y
TALE-TELL NEUTRAL INDICATOR GAUGE

PIN NO.10 B B REGULATOR
Br
L
TACHOMETER
Br
L
PIN NO.11 B/Y B/Y

COMMON GROUND
PIN NO.13 R R
L/W
L/W
B/ Y
Y/R
W
Y
POSITION LAMP ON- INPUT

W/Y
B/Y
PIN NO.20 W
Br

L
B/Y
Br
L
L/W
L/W
B/ Y
Y/R
H.T. SPARK
W
Gr Gr SIGNAL
Y
B/Y
COIL PLUG LAMP

B /Y B/ Y
REAR RH
O
O
F
N
F
Br Br
IGNITION TAIL
W W
SWITCH LAMP
B/W B/W L L ASSY
B/Y B/Y B/ Y B/ Y
R/W R /W R TAIL/
STOP
LED
R
B/Y
B/ Y SIGNAL
LAMP
O/Br
G G
B/Y
R/B R/B REAR LH

B/Y
Pulsar DTS-i UG-III-180cc Training Notes
HEAD LAMP B/Y B/Y

ASSY/LAMP
B/ Y ASSY.
12V-35/35W HS1 R/Y R/Y EARTH-FRAME LIGHT
R R NO.
W/ R
L/W
L/W
Y/R
B/Y PLATE
B/Y
O/Br
B/Y
POSITION LAMP
Lg
12V-5W- 2 Nos. R
R STARTER
MOTOR
W
SIDE STAND
Lg
Br/B
Br/B
B/Y SWITCH
R/W
B/Y
B/Y
Y/G
W/R
FUSE
L/W
L/W
Y/R
B/Y
SIGNAL LAMP 10 Amps

R
B
W/B
FRONT LH
G G CABLE
ASSEMBLY
Lg EARTH
R
Lg BATTERY
B/Y 12V-9Ah
B/Y HORN (LH) HORN (RH)
CLUTCH STARTER RELAY
SWITCH 70A RATING
ING
PU OIL
Y/G NEUTRAL
C
LS
SWITCH MAGNETO CABLE ASSY. RED

Y/G
138
Individual Circuit Diagrams Individual Circuit Diagrams
Ignition Circuit : Brake Light Circuit :
B/R
REED SWITCH FRONT BRAKE REAR BRAKE
ASSY. (TPS) SWITCH SWITCH
H.T. COIL
No. 2 SPARK C.D.I. ASSY.
(For PLUG
Secondary
Spark Plug)
L
L
Br
Br
G
B
B/Y
B/W
B/R
W/R
Y
H.T. COIL
L
L
Br
Br
No. 1 SPARK
B/Y
B/W
W/R
(For PLUG O
Primary O F
O Spark Plug)
N F
O
F
N Br
F
IGNITION B/W B/W IGNITION
SWITCH SWITCH
B/Y B/Y L STOP
W
LAMP
LED
R
BANK
W/R B/Y
B/Y
Kill Switch
W
FUSE
R
10 Amps
B/Y
W/R
W/B
EXCITER COIL
R
STARTER RELAY
ING
EARTH-FRAME 70A RATING
C
BATTERY
LS
12V-9Ah
PU OIL
MAGNETO
Battery Charging Circuit : Horn Circuit :
CONTROL
REGULATOR SWITCH LH
RECTIFIER UNIT
BODY CONTROL UNIT
B/Y
L/W
L/W
Br
B/Y
O
Br/B
O
F
N
F
Br Br
IGNITION
B/Y SWITCH
W W
B/Y
W
W
Br/B
B/Y
FUSE EARTH-FRAME
10 Amps
L/W
L/W
W/B
FUSE
10 Amps
B
R
W/B
BATTERY
CHARGING COIL
B/Y
B/Y
Br/B
Br/B
R
BATTERY B
STARTER RELAY 12V-9Ah
70A RATING
STARTER RELAY BATTERY
70A RATING 12V-9Ah
MAGNETO HORN (LH) HORN (RH)
139 140
AC Lighting Circuit : Side Indicator Circuit :
CONTROL
POSITIVE SUPPLY
SWITCH RH Gr Gr
SIGNAL LAMP LH SIDE IND. OUTPUT
PIN NO.3 R/B R/B CONTROL
FRONT RH
HIGH BEAM INDICATOR SWITCH LH RH SIDE IND. OUTPUT
B/Y
PIN NO.2 Br Br GROUND
INSTRUMENT CLUSTER + INPUT REGULATOR PIN NO.2 Br Br
PIN NO.11 RECTIFIER INSTRUMENT CLUSTER- INPUT BODY CONTROL UNIT
B/Y B/Y
B/Y
BODY CONTROL UNIT UNIT
COMMON GROUND
PIN NO.7 Gr Gr
PIN NO.13 R R AC INPUT
& OUTPUT TALE-TELL BLINKER- RH INPUT Gr
POSITION LAMP ON- INPUT
TURN SIGNAL
INSTRUMENT CLUSTER
Y/R
PIN NO.20 W G G G
PIN NO.8

PERMANENT BATTERY + INPUT TALE-TELL BLINKER- LH INPUT
R/B
SELF CANCELLATION DEVICE
PIN NO.11 B/Y B/Y
Y
R
Br
B/Y
R/Y
O COMMON GROUND
Y
O
Y/R
F
N
F
Br Br PIN NO.20 W
Br
IGNITION PERMANENT BATTERY + INPUT
Gr
SWITCH
TAIL/
W W
W
STOP SIGNAL
B/Y
LED Gr Gr
O O LAMP
Assly
R R N F REAR
F B/Y
Br Br RH
IGNITION
W
R NO. W W
B/Y
SWITCH
R
PLATE
FUSE LAMP B/Y B/Y
10 Amps 5 W
R/B R/B B/Y
W
W/B
HEAD LAMP SIGNAL
Y/R
ASSY/LAMP LIGHTING SIGNAL LAMP LAMP
B/Y B/Y COIL FRONT LH REAR
12V-35/35W HS1 B
G G G G LH
R/Y R/Y R
POSITION LAMP FUSE
B/Y
12V-5W- 2 NOS. BATTERY 10 Amps

STARTER RELAY 12V-9Ah BATTERY
W/B
70A RATING
12V-9Ah
R
STARTER B
R RELAY
EARTH-FRAME 70A RATING
MAGNETO
Speedometer and Tachometer Circuit : Fuel Indicator Circuit :
PIN NO.1 R/W R/W PIN NO.5 W/Y W/Y

VEHICLE SPEED SENSOR + INPUT FUEL GAUGE INDICATOR
VEHICLE
PIN NO.2 Br Br SPEED FUEL LEVEL GAUGE
INSTRUMENT CLUSTER + INPUT SENSOR PIN NO.2 Br Br
INSTRUMENT CLUSTER + INPUT
PIN NO.6 L/W L/W
VEHICLE SPEED SENSOR OUTPUT
B/Y
PIN NO.11 B/Y B/Y
W/Y
PIN NO.10 B B COMMON GROUND

INSTRUMENT CLUSTER
C.D.I. ASSY.
SPEEDOMETER COUPLER
TACHOMETER
INSTRUMENT CLUSTER
B/Y B/Y PIN NO.20 W
W/Y
B/Y
PIN NO.11
COMMON GROUND PERMANENT BATTERY + INPUT

B
B/Y
B/Y
PIN NO.20 W
O
O F
N F
O O B Br Br
N F IGNITION
F
Br Br SWITCH W W
IGNITION
W
SWITCH
B/Y
W W FUSE
W
10 Amps
W/B
FUSE
10 Amps
R
B
W/B
BATTERY
12V-9Ah
B EARTH-FRAME
R STARTER BATTERY
RELAY 12V-9Ah
70A RATING
STARTER RELAY
70A RATING
141 142
Stator Motor Circuit : Side Stand Indication Circuit :
PIN NO.9 Lg Lg CONTROL O/Br

SWITCH RH PIN NO.4
TALE-TELL NEUTRAL INDICATOR
TALE-TELL SIDE STAND INDICATOR
PIN NO.2 Br Br
PIN NO.2 Br Br
PIN NO.11 Please note that INSTRUMENT CLUSTER + INPUT
COMMON GROUND BODY CONTROL UNIT Starter Switch is enable only
if Kill Switch is in
DC INPUT ‘OFF’ condition.
W
INSTRUMENT CLUSTER
PIN NO.20 & OUTPUT
PERMANENT BATTERY + INPUT B/Y B/Y
O/Br
PIN NO.11
COMMON GROUND
INSTRUMENT CLUSTER
SPEEDOMETER COUPLER
B/Y
O O
N F
F
Br
Br Br PIN NO.20 W
IGNITION
SWITCH PERMANANT BATTERY + INPUT
W W
Y/G
W
O O
N F
F
R Br Br
IGNITION
STARTER SWITCH
B/Y
W W
R/W
MOTOR
W
FUSE
10 Amps
B/Y
B/Y
EARTH-FRAME
FUSE
W/B
10 Amps
Lg Lg
Lg
R
B
W/B
R/W
B/Y B/Y
B
R
EARTH-FRAME
B/Y
STARTER
O/Br
BATTERY
RELAY 12V-9Ah
70A RATING
Y/G Y/G STARTER RELAY BATTERY
NEUTRAL SIDE STAND SWITCH 70A RATING 12V-9Ah
SWITCH
Neutral Light Circuit :
PIN NO.9 Lg Lg
TALE-TELL NEUTRAL INDICATOR
PIN NO.2 Br Br
PIN NO.11 B/Y B/Y

COMMON GROUND
INSTRUMENT CLUSTER
W
PIN NO.20
Br
Lg
O
W
O F
N F
Br Br
IGNITION
SWITCH W W
W
FUSE
Lg
10 Amps
W/B
B
R
STARTER
RELAY
NEUTRAL SWITCH 70A RATING BATTERY
12V-9Ah
143 144
DTSi Trouble Shooting DTSi Trouble Shooting
High Fuel Consumption

OK
4th Step : TPS Related
1st Step : Idling RPM Related
Not Adjust accelerator cable free play
Check idling RPM Not Adjust idling to specified idling rpm Check accelerator OK
as per specification OK by idling adjusting screw cable free play for
TPS function
If OK
Idling RPM 1400 + 100
Accelerator Replace accelerator cable

Cable Free Play if sticky / jam
OK
OK
2~3 mm
2nd Step : Air Induction Related 5th Step : Front Wheel Rotation Related
Check air filter foam Not Clean air filter foam element (fine & corse) as per Not Adjust front brake lever free play
element for OK SOP if clogged / excess oil soaked OK if less than specified
Check front wheel
no clogging / for free rotation
correct oil soaking
If OK Front Brake Lever Free Play
Clean air intake duct 2~3 mm

if blocked / clogged
If OK
OK
3rd Step : Choke Related Check disc for run out
Not Lubricate / Replace choke plunger

Check free movement OK if sticky / jam If OK
of choke knob
If OK
Check proper fitment of wheel bearing Disc side
Clean choke plunger if sticky / jam
OK
If OK
Using following sequence Tighten the fasteners as

Axle Nut, Mudgaurd Mounting Bolts,
Lower ‘T’, Upper ‘T’, Cap nut
OK
Continued.....
Continued.....
145 146
OK
OK
6th Step : Rear Wheel Rotation Related 8th Step : Spark Plug Related
Not Adjust rear brake free play if Check spark plug Not Clean & adjust spark plug gap
Check rear wheel OK less than specified for no fouling / OK as per specification
for free rotation correct heat range
& gap. Check both
Rear Brake Pedal Free Play If OK
spark plug for
If OK DTS-i engine
25 ~ 30 mm Replace spark plug by recommended
one if incorrect heat range
Lubricate rear brake pedal

shaft if dry / sticky If OK
If OK OK Replace spark plug if fouled

OK
Lubricate rear brake cam if sticky / jam

9th Step : Carburettor Related
Check carburettor Not Adjust VC screw as

7th Step : Clutch Cable Related for correct air fuel OK per specification & CO limit
mixture with
Not the help of ‘CO’
Adjust clutch lever free play if
Check clutch cable gas analyser If OK
OK less / more than specified
for free play &
smooth operation Correct ‘e’ clip position
If OK as per specification
Standard CO % = 1.75 to 2.25%
Std. VC Screw Settings = 2.5+2 Turns
Clutch Cable Correct clutch cable routing If OK
Free Play
2~3 mm Clean carburettor body air passages

If OK if clogged
Replace clutch cable complete

if sticky / jam If OK
Replace carburettor jets if worn out

OK
If OK
Replace needle valve & its seat

if worn out
Continued..... Continued.....
147 148
OK
OK
10th Step : TPS Related 12th Step: Engine Compression Pressure Related
Check
Check TPS for Not Adjust gap between magnet & reed compression
correct gap / free OK switch as per specification if found more pressure.
movement / magnet Perform dry If compression pressure If compression pressure
presence / continuity & wet in wet test is NOT OK in wet test is OK
If OK compression
Check & Rectify Check & Rectify
test cylinder head cylinder block
Clean TPS switch related reasons related reasons
Standard Gap
Between Magnet & if stuck up / sticky operation
Reed Switch
2.5 mm If OK
Correct valve timing Clean compression
if mark on cam ring & piston groove
Replace magnet if missing sprocket not aligning if sticky / jam
with cyl. head when
OK rotor ‘T’ mark is
If OK aligned with
crankcase L.H. mark
Replace TPS switch if reed switch Replace piston ring set

short / open circuited if compression ring
worn out
* Reset valve tappet

11th Step : Ignition Timing Related clearance as per
specs. if found less
Not
Replace CDI if timing is incorrect Replace cylinder block
OK piston assembly
Check
ignition timing if worn out /
If OK excessive clearance
Clean valve guide &
Replace rotor if cam position wrong valve stem if gummy
leading to incorrect ignition timing substance deposited
Replace cylinder
If OK piston assembly
if partially seized
Replace H.T. coil for malfunctioning Rectify valve seat and valve
face by lapping if pitted /
OK worn out / excess carbon
deposition Inspect De-comp *Standard Inlet Exhaust
mechanism for stickness Tappet
Clearance 0.05 mm 0.10 mm
Replace inlet & exhaust

valve if bent
Continued.....
149 150
Poor Pick-up & Poor Acceleration OK

4th Step: Engine Compression Pressure Related
1st Step : Fuel Related
Check
Check fuel compression
Not Replace fuel from petrol tank, cock pressure.
for no adulteration / If compression pressure If compression pressure
contamination OK & carburettor bowl Perform dry in wet test is NOT OK in wet test is OK
& wet
compression Check & Rectify Check & Rectify
OK test cylinder head cylinder block
2nd Step : Air Induction Related related reasons related reasons
Check air induction Not
Clean air intake duct if blocked
system for OK Skill Tip :
no choke-up / no •Do not scribe.
If OK
clogging i.e. correct Correct valve timing •Clean by
quantity & smooth if not OK Acetone/CCL4.
supply of air Clean air filter foam element as per
SOP if clogged / excess oil soaked
Clean compression
OK ring & piston ring
Reset valve tappet
3rd Step : Carburettor Related if sticky / jam
clearance if not
Not as per specifications
Check carburettor Re-adjust V.C. screw as per specifications
for correct OK
air fuel mixture
with the help of If OK Replace piston ring set
CO gas analyser if compression
Tighten cylinder head
Correct ‘e’ clip position ring worn out
bolts if loose
as per specification
Standard Settings = 2.5+2.0 turns If OK

‘e’ Clip position = 2nd from top Replace cyl. hd. gasket Replace cylinder block
Clean main jet, pilot jet if clogged if torn / cut / pressed piston assly if worn out
/ excessive clearance
If OK
Skill Tip :
Clean carburettor air & Ensure cylinder &
Replace cylinder head
mixture passages if clogged piston are of the
if spark plug mtg. hole
threads washed out same group while
If OK replacing.
Correct diaphragm position if wrong

Replace cylinder
Carry out surface facing
If OK piston assembly
/ Replace cylinder head
if partially seized
if warpage is equal to
Replace carburettor piston valve assly or more than 0.05 mm
OK if diaphragm punctured
Continued..... Continued.....
151 152
OK Vehicle pulling to one side

Continued.....
1st Step : Steering Related
Check
compression Check steering for If stg. jam, loosen front fork side bolts,
pressure. If compression pressure If compression pressure free movement Not top bolts, steering ring nut & adjust
Perform dry in wet test is NOT OK in wet test is OK by rotating handle the steering for free movement.
& wet OK
on either side Retighten the bolts as per SOP sequence.
compression
test Continued from Continued from
back page back page
Piston ring to groove clearance

Std Limit Service Limit OK
Clean valve guide &
valve stem if Top Ring : 0.06 mm 0.16 mm
deposited with
gummy substance
Compression Ring End Gap 2nd Step : Chain Adjuster Related
Std Limit Service Limit
Check rear wheel
alignment w.r.t. Not Set both side
0.15 ~ 0.30 mm 0.50 mm
drive chain adjusters OK drive chain adjusters equally
Rectify valve seat
& valve face by
lapping if pitted /
worn out / excess
OK 3rd Step : Handle Bar Related
carbon depostion
Not
Replace handle bar if bent
OK
Check handle bar &
upper holder bkt. If OK
Replace inlet / exhaust for alignment
valve if bent Replace fork upper holder bracket
if misaligned
OK
Inspect De-compression
4th Step : Fork Inner Pipe Related
mechanism for stickyness
Not
Replace fork inner pipes if bent
OK
Check fork inner pipe
Piston Standard Diameter Cylinder Standard Diameter & under holder If OK
bracket for alignment
‘A’ Group ‘B’ Group ‘A’ Group ‘B’ Group
63.478~63.488 63.488~63.498 63.50~63.508 63.508~63.515 Replace fork under holder bracket ‘T’ if bent
OK
Continued.....
153 154
Kick lever not returning

OK
5th Step : Swing Arm Related
1st Step : Kick Lever Assembly Related
Check swing arm Not Check kick lever Not Replace kick boss if kick lever
for alignment Replace swing arm if bent
OK assembly for no OK resting area worn out / not flat
fouling with silencer,
for intact condition
If OK
OK 6th Step : Frame Alignment Related Replace kick lever if bent / kick boss
Not resting area worn out / not flat
Replace frame if misaligned at
OK steering tube area
Check frame for If OK
alignment
If OK
OK Replace kick boss if splines /
serrations worn out
Replace frame if mounting hole of
swing arm is oblonged
2nd Step : Kick Shaft Related
Dismantle clutch Not Match the dot mark on ratchet gear

cover & check kick w.r.t. dot mark on
shaft assembly for OK kick shaft end if timing incorrect
• Correct timing of
ratchet gear w.r.t. If OK
kick shaft
• Return spring Engine O/H and Replace kick shaft return
tension O.K. spring if weak
OK 3rd Step : Kick Guide Related

Not Tighten kick guide allen bolts by applying
OK loctite 638 if loose
Check kick guide
screws for tightness If OK
and intact condition
Replace kick guide allen bolts if sheared off
OK
4th Step : Crankcase L.H. Related
Check crankcase RH
Not Replace crankcase RH if cracked at
kick boss area
for intact condition OK kick boss area
155 156
Clutch slippage
OK 5th Step : Clutch Assembly Related
1st Step : Clutch Lever Free Play Related Not
Replace clutch springs if free length
OK is less than standard
Check clutch lever Not Set clutch lever free play Dismantle clutch &
free play OK as per specifications
check all
components for If OK
Std. Free Play correct dimensions
for Clutch Lever & no abnormal wear Replace friction plates
if worn out /
2~3 mm OK 2nd Step : Clutch Cable Related
burnt / friction bonding given away
Not Dismantle, rectify & refit
OK clutch lever if sticky
If OK
Check clutch lever
operation for If OK
Replace steel plates
smooth working if worn out / burnt / glazy
Replace clutch cable if sticky / jam
If OK
OK Replace clutch center (clutch hub)

3rd Step : Engine Oil Related if worn out
Not Top up engine oil level
OK if less than specified If OK
Check engine
oil level
and viscosity If OK Replace clutch wheel if worn out
Replace engine oil if viscosity not OK
OK
4th Step : Clutch Release Mech. Related
Not
Replace clutch release lever
OK if bent / O.D. oversize
Check clutch release
mechanism for
smooth operation If OK
Replace clutch cover if release lever’s

parent hole undersize / oval
If OK
OK
Replace rack & ‘Clutch Release Shaft’
if teeth worn out / damaged
Continued.....
157 158
Drive chain noise OK

5th Step : Rear Damper Rubber Related
1st Step : Chain Adjustment Related Check damper
rubbers of Not
Check drive chain rear wheel sprocket Replace damper rubbers if worn out
Not Adjust slackness as per specification & OK
for slackness for no abnormal wear
OK lubricate the chain by SAE 90 oil
& lubrication
Chain Slackness = 30 ~ 35 mm OK 6th Step : Chain Sprocket Related

Not
OK OK Align engine sprocket & rear wheel sprockets
2nd Step : Chain Cover Related Dismantle chain -
Not sprocket assly. &
Refit chain covers properly If OK
OK check for wear
& alignment
If OK Replace drive chain if 20 link length
Check chain cover is more than service limit
for correct fitment
& alignment Fit PVC strips if missing
Drive Chain 20 Link Length If OK
Std. Limit Ser. Limit
If OK
254 ~ 254.6 mm 260 mm Replace chain sprocket kit if worn out
Replace chain cover bolts & washers
by O.E. ones if touching to chain
If OK
OK
Correct alignment of swing arm
brackets if bent
3rd Step : Sprocket Mtg. Bolt Related

Check rear wheel Not
sprocket bolts Tighten bolts to specified torque if loose
OK
for tightness
OK
4th Step : Engine Sprocket Collar Related
Check output Carry out sanding operation of collar I.D.

Not
sprocket collar & apply SAE 90 oil if collar jam
for free rotation OK on O/P shaft O.D.
OK
Continued.....
159 160
Silencer noise OK
5th Step : Muffler Related
1st Step : Mounting Nuts Related
Check silencer for Not Replace silencer if baffle plate /
Check silencer intact baffle plates OK plates are loose
Not
mouth securing nuts Tighten silencer mouth nuts if loose
for tightness OK
OK
Tightening Torque = 1.4~1.9 Kgm 6th Step : Torque Expansion chamber Related
Check silencer Not Tighten ‘CO’ nozzle bolt if loose / replace

ExhausTEC chamber
OK OK silencer if nozzle given away
for no noise
If OK
2nd Step : Gasket Related
Check silencer Replace silencer mouth gasket Replace silencer if noise in ExhausTEC
Not chamber due to paint solidified from inside
mouth gasket (gasket exhaust) if pressed
for intact condition OK
OK
3rd Step : Silencer Guard Related
Check silencer guard Tighten silencer guard screws / allen bolts

securing screws / Not if loose. Apply loctite 243.
allen bolts OK
for tightness
OK
4th Step : Footrest Fouling Related
Check silencer for

bend pipe not Not Correct silencer fitment if fouling
fouling with OK with rider’s foot rest
rider’s foot rest
OK
Continued.....
161 162
Steering sticky / Jam movement Poor braking - Disc brake system
1st Step : Steering Ring Nut Related 1st Step : Master Cylinder Related
Not Top-up master cylinder by using
Check steering ring Loosen steering center nut / bolt,
nut & center fork side clamp bolts and OK DOT-3/DOT-4 brake fluid if fluid
nut / bolt for Not fork top bolts, steering ring nut Check brake fluid level is below minimum mark
correct tightness OK & tighten them in sequence as per S.O.P. in master cylinder
(No over tightening) to specified torque for correct level
If OK
Identify source of leakage, rectify

& top-up leakage if any,
Tightening Torques in Kgm if brake fluid level is low prematurely
OK
Description Torque
Steering center 2nd Step : Brake Disc Pad Related

special nut / 3.5 Kgm
bolt Check disc pads for Not Clean disc pads by emery paper if found
surface condition OK water soaked, oil / grease soaked, glazed
OK Fork side bolts 2.5~3.5 Kgm
Fork top bolts 2.5~3.5 Kgm

OK
Steering
ring nut 0.5 Kgm
Check disc pads Not Replace disc pads if worn
for thickness OK out beyond service limit
2nd Step: Steering Races Fitment Related Disc Pad Lining Thickness
Standard Limit Service Limit
Not 7.4 mm 3.8 mm
Check steering races Refit steering races as per S.O.P. OK
for correct fitment OK if fitted in tilted condition 7.4 mm 3.8 mm
3rd Step : Caliper Related
OK Check oil seal of

Caliper piston for Not Replace Caliper seals if - seal lips worn
3rd Step: Stg. Races Condition Related
intact lip condition OK out, deformed, became hard.
Check condition of
steering races for
no pitting marks Not Replace steering races & balls OK
& steering balls for OK if pitted / rusty respectively
4th Step : Brake Disc Related
no rusting / breakage
Not
Check brake disc for Replace brake disc if worn out,
thickness & alignment OK run out exceeds service limit.
Note : Lubricate steering races and balls by Servo
Gem RR-3 grease at every 10,000 Kms. Disc Disc Runout
Standard Limit Service Limit
Less than 0.2 mm 0.2 mm
163 164
DTSi Trouble Shooting
Spongy brakes - Disc brake system
1st Step : Master Cylinder Related

Check brake fluid Top up master cylinder by DOT-3/DOT-4
level in Not
brake fluid only if fluid level
master cylinder OK is below minimum mark.
OK
2nd Step : Brake Fluid leakage Related
Check brake hose,
Caliper and Identify source of leakage, rectify &
Not
Master cylinder top-up if brake fluid level is below
OK minimum mark
for no leakages.
OK
3rd Step : Air Trapping Related
Check Disc Brake
system free Not Carry out air bleeding of
from air trapping. OK disc brake system as per SOP
OK
4th Step : Master Cylinder Related
Check master Clean master cylinder cover &
cylinder vent holes Not
vent holes if clogged
for no clogging. OK due to oxidation / dust.
OK
Check master cylinder Not Replace diaphragm by new one

diaphragm for no
OK if deformed / torn.
deformation teared off
OK
Check master
Not Replace primary seal of
cylinder primary seal
OK master cylinder if worn out.
for no wear.
OK
4th Step : Caliper Related
Check for free
floating movement Not Clean & Lubricate caliper pins by
of Caliper. OK silicon grease / brake fluid if jam.
165
Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center

Pulsar DTSi UG III Workshop Manual 4

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Tightening Torque - Engine Tightening Torque - Frame

2.5 ~ 3.5 Kg.m 3.5 ~ 4.0 Kg.m 8.0 ~ 10.0 Kg.m

Fitting of Oil Seals and Bearings : Fit :

Use Bearing Driver set (P. No. 37 1030 61) Fit :

Crankcase LH (Magneto Side) Clutch Cover

Use Bearing Driver set (P. No. 37 1030 61) Fit :

Head Cover A Chain Tensioner Assembly

Using Special Tool - Primary

Note : Special nut for input shaft has LH threads. Fit :

Note : When assembling the ‘Clutch Cover’ always remember

Using Special Tool : Piston

Note : Always ensure that the piston is at the end of compression

Recommended Oil Capacity per fork tube

Master Cylinder Assembly : Dismantling of Caliper

Air Bleeding of Disc Brake System :

Switches : Brown Blue CDI Unit and H. T. Coil Inspection :

d. Neutral Switch : X 200 Ohm Brown Green/White 55+5.5 Ohm

PIN NO.13 R R AC INPUT MAGNETO

20 PIN COUPLER WITH DUST COVER

DC10A Meter +ve Meter -ve 2 A max at

Speedometer/Tachometer Console mind and wants to continue straight ahead.

Main Electrical Wiring Diagram

PIN NO.1 R/W R/W R/W

HIGH BEAM INDICATOR

HALL SENSOR ASSLY

TALE-TELL SIDE STAND INDICATOR AC INPUT DC INPUT C.D.I. ASSY.

W/Y W/Y (S.C.B. UNIT)

PIN NO.6 L/W L/W

VEHICLE SPEED SENSOR OUTPUT

TALE-TELL BLINKER- LH INPUT COIL PLUG

TALE-TELL NEUTRAL INDICATOR GAUGE

PIN NO.11 B/Y B/Y

POSITION LAMP ON- INPUT

PERMANENT BATTERY + INPUT

COIL PLUG LAMP

R/B R/B REAR LH

HEAD LAMP B/Y B/Y

SIGNAL LAMP 10 Amps

SWITCH MAGNETO CABLE ASSY. RED

Battery Charging Circuit : Horn Circuit :

BODY CONTROL UNIT

MAGNETO HORN (LH) HORN (RH)

20 PIN COUPLER WITH DUST COVER

PIN NO.11 B/Y B/Y

12V-5W- 2 NOS. BATTERY 10 Amps

Speedometer and Tachometer Circuit : Fuel Indicator Circuit :

PIN NO.1 R/W R/W PIN NO.5 W/Y W/Y

PIN NO.10 B B COMMON GROUND

20 PIN COUPLER WITH DUST COVER

PIN NO.9 Lg Lg CONTROL O/Br

Neutral Light Circuit :

PIN NO.11 B/Y B/Y

High Fuel Consumption

Accelerator Replace accelerator cable

Clean air intake duct 2~3 mm

3rd Step : Choke Related Check disc for run out

Not Lubricate / Replace choke plunger

Using following sequence Tighten the fasteners as

Lubricate rear brake pedal

If OK OK Replace spark plug if fouled

Lubricate rear brake cam if sticky / jam

Check carburettor Not Adjust VC screw as

2~3 mm Clean carburettor body air passages

Replace clutch cable complete