Pulsar 150/180 DTS-i
Service Station Manual
43
Dealer Development Center
Akurdi Pune
Speedo cable Standard routine
Drive Chain
Slackness standard - 25 ~ 35 mm
Drive chain lock position & standard fitment
Equal marking of chain adjuster on both side
No touching to chain case
SUSPENSION
Front Fork No leakage. Smooth working
Rear Shock Absorber
Spring adjuster notch position : 1st notch (Standard)
Steering Smooth operation (No play / No Sticky movement)
Lock Operation
Steering cum Ignition lock, Seat lock, LH side cover lock,
Petrol tank cap lock
Fasteners
(Check torque)
Front axle nut (150cc - 4~5 Kgm, 180cc - 8~10 Kgm)
Rear axle nut (150cc - 8~10 Kgm, 180cc - 8~10 Kgm)
Torque rod nut (150 cc & 180cc - 3~4 Kgm)
Steering cap bolt (150cc - 3.5 Kgm, 180cc - 5 Kgm)
Handle bar bolts (150cc - 2~2.2 Kgm, 180cc - 2~2.2 Kgm)
Caliper install bolts (150 cc & 180cc - 2.2~2.8 Kgm)
RSA mounting dome nut (150 cc & 180cc - 3.5~4.0 Kgm)
Swing arm pivot nut (150 cc & 180cc - 8~10 Kgm)
Brake disc allen bolts (150 cc & 180cc - 2.6~3.2 Kgm)
Pinch clamp bolt (180cc - 2.0~2.2 Kgm)
ELECTRICAL
Battery
Terminal voltage 12.4 V DC & Charge status using load tester.
Electrolyte level.
Tightness of battery terminals / cables/ petroleum jelly application
Proper routine of overflow pipe
Fuse Position of fuse box
All Bulbs Working
Head light, Tail / stop lamp, Side indicators, Speedo bulb,
Number plate lamp
Switch Operation
RH & LH control switch, Ignition switch & Brake switch
(Front & Rear)
Starter Motor
Working / Engagement in gear & neutral
No abnormal noise
Speedometer
Working of Speedometer, Odometer
Working of all signal indicators icons (Neutral, Turn signal High beam,
& Bajaj logo)
Headlamp assembly No excess gap & Uneven gap
Horn Ensure no distorted sound
Visual inspection
No dent / damages / scratches
TEST DRIVE
Starting
Cold start & Warm start
Idling speed (Warm condition) (1400 + 100 RPM)
Drive ability
Throttle response
Brakes effectiveness - Front & Rear
CO % Check
CO should b RPMe 1.5 ~ 2.5 % in engine warm condition at idling
Cleaning Wash & Clean vehicle.
PRE-DELIVERY INSPECTION CHECKLIST
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