Pulsar DTS-i 180 UG III User Manual

Dealer Development Center
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Dealer Development Center
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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.
Location of Parts
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3
4
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Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
1. Control Switch RH
2. LCD Speedo Console
3. Control Switch LH
4. Body Control Unit
(Placed inside Head Light fairing)
5. Hall Sensor for Indicator
6. Vehicle Speed Sensor
7. ExhausTEC
8. Tail Light LED display
 Refined engine power delivery by optimization of Exhaus TEC
location and revised ignition timing with intelligent CDI
 New clutch & revamped gear shifting mechanism that gives
smooth, positive, virtually friction-free gear shift feel
 New Bigger twin foam filter with an optimized intake system to
provide better torque
 Optimized valve timing and Roller rocker with NR bearing for
friction reduction that improves drivability.
 LED tail lamp that consumes negligible power & require zero
maintenance
 Stainless steel silencer that overcomes rusting problem
 All sensor type electrical switches that enables switches to
function for the life of the bike. Absolutely no maintenance in
absence of mechanical contacts.
Performance :
Style :
 Stylish fairing and head lamp assembly with owleye
 A new black mask that separates headlamp from parking lights
adds to aesthetics.
 Clear lens indicator with amber bulbs.
 New age, sharp and attractive 2 Row Tail lamp with LED lights
 New seat cowl to match stylish LED tail lamp.
 Louver type LH & RH covers with wire mesh gives sturdy look.
 Ergonomically designed self-letting switches
Convenience and Comfort
 LCD Speedo Console with digital fuel gauge (12 level indicator)
 Digital speed display, odometer and two trip meter with resetting
provision.
 Self-canceling indicators After completion of turn, the indicator
will be switched off automatically.
 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
glows continuously till the petrol filled to main level.
 Self check provision for Tachometer for its functioning
Identification Data
Salient Features

Pulsar DTS-i 180 UG III Specifications

General

Displacement	178.6 cc
Fuel System	Carburetor
Transmission	5-speed
Fuel Tank Capacity	15 liters
Ground Clearance	165 mm
Engine Type	4-stroke, air-cooled, DTS-i
Ignition System	Digital
Starting	Electric Start and Kick Start
Front Brake	Disc
Rear Brake	Drum
Front Suspension	Telescopic
Rear Suspension	5-step adjustable Nitrox shock absorbers

Summary

Technical Specifications

Engine and Transmission

Details engine and drivetrain specifications.

Chassis and Body

Pre Delivery Inspection Checklist

PDI SOP

Periodic Maintenance & Lubrication Chart

Periodic Service SOP

Schedule Maintenance

Spark Plug, Battery, and Brake Fluid Maintenance

Drive Chain Cleaning and Lubrication

Ignition Timing and Clutch/Accelerator Free Play

Brake Adjustments and Light Switch

Idling Speed and Tappet Clearance Adjustment

Procedures for idling speed and tappet clearance.

Standard Checking Procedure

Compression Pressure Testing

Procedure for compression pressure testing.

Disc Brake System Air Bleeding

Procedure for bleeding the disc brake system.

LCD Speedo Console and BCU Test

Chain Slack Adjustment

Procedure for chain slack adjustment.

Special Tools

Engine Special Tools

Lists special tools for engine work.

Chassis Special Tools

Lists special tools for chassis work.

Sprocket Catcher and Camshaft Bearing Pullers

Tools for sprocket and camshaft bearing removal.

Rotor Puller, Primary Gear Holder, and Balancer Gear Holder

Tools for rotor, primary gear, and balancer gear.

Fork Oil Seal Fitment Punch

Tool for fork oil seal fitting.

Rocker Pin Remover and Silent Bush Puller

Tools for rocker pin and silent bush removal.

Special Nut, Piston Ring Holder, and Bearing Race Extractor

Tools for filter nut, piston rings, and bearing race.

Rear Shock Absorber Adjuster

Tool for shock absorber adjustment.

Fork Inner & Outer Tube Extractor

Tool for fork tube extraction.

Bearing Extractor, Bearing Puller, and Valve Spring Compressor

Tools for bearing and valve spring work.

Rotor Holder, Drift, and Thrust Plate Aligner/Holder

Tools for rotor, piston pin, and clutch alignment.

Carburettor and Fuel System

Carburettor Specifications

Specifications of the carburettor.

Fuel Tank Procedures

Working of Carburettor

Starter Circuit Operation

Describes the starter circuit of the carburettor.

Progression Circuit Operation

Describes the progression circuit of the carburettor.

Main Circuit Operation

Describes the main circuit of the carburettor.

Digital Twin Spark Plug Ignition (DTS-i)

DTS-i Troubleshooting

Removal of Engine from Frame

Initial Removal and Disconnection Steps

Engine Mountings and Sub-assembly Removal

Dismantling Engine

Engine Top End Dismantling

Covers top end components removal.

Cylinder Head Cover, Camshaft, and Cylinder Head Assembly Removal

Covers cylinder head cover, camshaft, and assembly removal.

Rotor and Starter Assembly Removal

Covers rotor and starter assembly removal.

Centrifugal Oil Filter and Input Shaft Removal

Gear Change Lever and Kick Starter Removal

Crankcase Components Removal

Engine RH (Clutch Side) Dismantling

Balancer Gear Removal

Crankcase Splitting and Gear Box Assembly Removal