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Dealer Development Center
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Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
Do’s
Do’s
Don’ts
Don’ts
• Use appropriate screw
drivers.
Handling
Cleaning
• For cleaning always use
carburettor cleaner like
- Acetone
- Carbon Tetra chloride
- Aerosol
- CVC spray
Maintenance
Ensure
• Jets
- Holes are clean.
- Holes are not worn out.
- Size as per specification.
• Float is in good condition.
• Float Pin
- Tip having no wear mark.
- Spring loaded pin is free
in movement.
• Needle Jet
- No wear at taper portion.
- Circlip position is in
specified groove.
• Piston valve
- No wear mark.
- Diaphragm condition.
• Never use oversize screw
drivers.
• Do not over tighten the jets
and screws.
• These will damage the jets
and their seats.
• Never clean the carburettor
with water.
• Jets & air passages will get
clogged due to sediments if
cleaned by water.
Replace
• Jets
- Worn out jet.
- Incorrect size jet.
- Punctured, Squeezed and
distorted float.
- Worn out tip.
- If spring loaded pin is
sticky.
- Needle worn out at taper
portion.
- Piston valve worn out.
Scoring marks.
- Diaphragm punctured.
Overhaul carburettor at every 10,000 kms. and insepct the parts.
Pulsar DTSi is the first bike in the world (In small cc engine) to have twin spark ignition system.
1. The most obvious feature is the Twin Spark Plug configuration o f
the Engine. The cylinder head has 2 spark plugs one on either
side. The spark plugs are of the smae Heat range (Champion
RG4HC/Bosh UR3DC (Resistive) and have similar electrode gaps.
These also spark simultaneuosly, This has been done to improve
the combustion process by reducing the time of combustion.
The end results are low emissions, good fuel economy and good
driveability
2. To enable the sparking of the 2 spark plugs, a intelligent CDI
capable of handling this was developed. Further more, the
ignition timing has been optimised to give the best output from
00
engine (10 BTDC @ 1500 rpm, 28 BTDC @ 3500 rpm). To
enable optimum igntion timing for part throttle loads and full
throttle loads, there are separate igntion maps stored in the
memory of the CDI. These are activated depending on the
throttle opening and engine speed. The Digital CDI has a bit
Microprocessor which handles all these inputs and gives out the
required and correct spark advance. The intelligent CDI can be
easily indentified by 2 green dots marked on CDI case.
3. To enable switching the required igntion maps, a magnetically
operated need switch is incorporated on the carburettor throttle
shaft and carburettor body. This is known as TRICS. Throttle
Responsive Igntion Control System.
4. These engines are capable of of reviving very high, quite easily.
To keep them mechanically safe, a engine rpm limiter has been
incorporated in the Digital CDI. This curtails the sparks to the
spark plugs thereby limiting the engine rpm Max upto 9000 and
thus keeps the engine mechanically safe. There are 2 spark
plugs. LH spark plug fires at 350 rpm and then continues to
give spark till at 9000 rpm of engine. The spark is cut off from
LH plug 9000 rpm to protect engine from excessively high
speed.
RH spark plug gives spark at 750 rpm and then continues to
give till 6000 rpm of engine. If engine rpm exceeds 6000 rpm
then RH plug is cut off. This is done to reduce combustion
noise created in engine.
5. This engine has been extensively tuned for more Power and
Torque.
6. The DTSi technology has enabled the Pulsar to meet 2006
norms without any Secondary air injection devices.
Troubleshooting :
• Malfunctioning of the Reed switch assly will not harm the engine, neither it will give any physical
indicators like starting trouble or misfiring.
However checking of proper functioning of Reed Switch Assly at PDI and at every service
is essential.
• Following symptoms may indicate as malfunctioning of Reed Switch Assly as one of the cause.
Cause
Symptom
Remedy
Sudden drop in mileage & power
lack in mid range rpm
Replacement of Reed Switch AsslyThe igntion systems is working only
in 2nd map due to reed switch is
stuck in open circuit
Working of Carburettor
Digital Twin Spark Plug Ignition (DTS-i)
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