PULSAR Service Guide

Identification Data Salient Features
Location of Parts
8
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 hen ordering the parts. In the event of
theft! the investigating authorities ill re"uire
both these numbers in addition to the model!
type and any special features of your vehicle
that can help identifications.
#
$
Performance %
&efined engine poer delivery by optimi'ation of E(haus TE)
location and revised ignition timing ith intelligent )DI
*e clutch + revamped gear shifting mechanism that gives
smooth! positive! virtually friction,free gear shift feel
*e -igger tin foam filter ith an optimi'ed inta.e system to
provide better tor"ue
/ptimi'ed valve timing and &oller roc.er ith *& bearing for
friction reduction that improves drivability.
LED tail lamp that consumes negligible poer + re"uire 'ero
maintenance
Stainless steel silencer that overcomes rusting problem
0ll sensor type electrical sitches that enables sitches to
function for the life of the bi.e. 0bsolutely no maintenance in
absence of mechanical contacts.
Style %
1
Stylish fairing and head lamp assembly ith oleye
0 ne blac. mas. that separates headlamp from par.ing lights
adds to aesthetics.
2
)lear lens indicator ith amber bulbs.
*e age! sharp and attractive $ &o Tail lamp ith LED lights
*e seat col to match stylish LED tail lamp.
Louver type L3 + &3 covers ith ire mesh gives sturdy loo..
4
Ergonomically designed self,letting sitches
1. )ontrol Sitch &3
$. L)D Speedo )onsole
#. )ontrol Sitch L3
2. -ody )ontrol 5nit
6Placed inside 3ead Light fairing7
8
9
4. 3all Sensor for Indicator
8. :ehicle Speed Sensor
9. E(hausTE)
8. Tail Light LED display
)onvenience and )omfort
L)D Speedo )onsole ith digital fuel gauge 61$ level indicator7
Digital speed display! odometer and to trip meter ith resetting
provision.
Self,canceling indicators 0fter completion of turn! the indicator
ill be sitched off automatically.
Engine oil level indo for easy to monitor level.
;aintenance free battery once a year electrolyte top up.
In addition to Fuel gauge! &eserve indicator bulb is provided that
glos continuously till the petrol filled to main level.
Self chec. provision for Tachometer for its functioning
1 $
Pulsar DTS,i 5<,III,18=cc Training *otes Dealer Development )enter Dealer Development )enter Pulsar DTS,i 5<,III,18=cc Training *otes
Technical Specifications
Salient
Features
Safety %
Engine and Transmission
Day night mode of Speedo console
The turn Indicator! neutral! high beam! and side stand Indicator bulb
glo brightly in the day for clarity! and Intensity reduces during night
to reduce irritance to the rider>s eye
3igh &P; arning lamp hen engine reaches to ?=== &P;
automatically &ed LED bulb starts blin.ing. This enables the rider to
control the speed to avoid damages if any that may ta.e place to
engine components.
Engine cut,off at 1==== &P; Spar. gets cut,off at 1==== &P;
to bring don the engines &P; for safety.
LED illumination for tell,tale icons on electrical sitches that glos in
the night for positive access of individual functions.
Type % Four stro.e DTS,i! *atural air cooled.
*o. of cylinders % /ne
-ore % 8#.4= mm.
Stro.e % 48.2= mm.
Engine displacement % 198.8= cc.
)ompression ratio % ?.4 @ =.4%1
Idling Speed % 12== @ 1== rpm.
;a(. net poer % 1$.14 .A 618.41 Ps7 at 8=== rpm.
;a(. net tor"ue % 14.$$ *m at 8=== rpm.
Ignition System % ;icroprocessor controlled digital ).D.I.
Ignition Timing % 1=
=
-TD) at 14== rpm.
% $8
=
-TD) at #4== rpm.
Fuel % 5nleaded petrol
)arburettor % 5)0l,;IB5*I -S$?! Side Drought! ): Type.
Spar. Plug % $ *os. )hampion &<23)! -osch 5&#D) 6&esistive7
Spar. Plug <ap % =.9 to =.8 mm.
Lubrication % Aet sump! Forced.
Starting % Bic. start C Electric start.
)lutch % Aet! ;ultidisc type.
Transmission % 4 speed constant mesh.
Primary &eduction % #.29 % 1 688C1?7
<ear &atios% 1st gear %
$nd gear %
#rd gear %
2th gear %
4th gear %
$8.?# % 1 6#8C1#7
18.#1 % 1 6#$C197
1#.2# % 1 6$?C$17
1=.42 % 1 6$8C$27
8.?8 % 1 6$2C$87
Final drive ratio % $.8= % 1 62#C147
)30SSIS + -/DD
Frame Type % Double cradle.
Suspension Front % Telescopic front for. ith D5 bush 6Stro.e 1#4mm7
&ear % Trailing arm ith coa(ial hydraulic cum gas filled
adEustable shoc. absorbers! and triple rate coil springs.
-ra.es Front % ;echanically e(panding shoe and drum type.
3ydraulically operated disc type.
&ear % ;echanically e(panding shoe and drum type.
Tyres Front % $.94 ( 19! 21 P
&ear % 1==C?= ( 19! 44 P
Tyre Pressure Front % 1.94 .gCcm
$
6$2.4 Psi7
&ear Solo % $.== .gCcm
$
6$8.= Psi7
&ear Pillion % $.$4 .gCcm
$
6#$.= Psi7
&ims 60lloy Aheels7 Front % 1.8= ( 19
&ear % $.14 ( 19
# 2
Technical Specifications Fre"uently 0s.ed Fuestions 6F0FGs7
Fuel Tan. )apacity % 14 liters Full
% #.$ liters &eserve
% $.= liters 5sable reserve
)/*T&/LS
Steering % 3andle -ar
0ccelerator % Tist grip type on &3 side of handle bar
<ears % Left foot pedal operated
)lutch % Lever operated on L3 side of handle bar
-ra.es Front % Lever operated on &3 side of handle bar
&ear % Pedal operated by right foot
ELE)T&I)0LS
System % 1$ : 60)@D)7
-attery % 1$: ?0h
3ead Lamp % #4C#4 A,3S1
Pilot Lamp % 4A , $ *os.
TailCStop lamp % LED
Turn signal lamp % 1= A 6$ *os.7
Turn signal pilot lamp % LED
Side stand indicator lamp % LED
3i beam indicator lamp % LED
*eutral indicator lamp % LED
Speedometer lamp % LED display
&ear number plate lamp % 4 A
3orn % 1$: D)
DI;E*SI/*S
Length % 1??= mm.
Aidth % 94= mm.
3eight % 1=?= mm.
Aheel base % 1#$= mm.
Turning circle radius % $18= mm. 6;inimum7
<round clearance % 184 mm. 6;inimum7
AEI<3TS
:ehicle .erb eight % 12# .g.
<ross vehicle eight % $9# Bg.
PE&F/&;0*)E
;a(imum speed % 1$4 .mCh ith single rider 688.g7
)limbing ability % $8H 618
=
;a(imum7
*otes%
I :alues given babove are nominal and for guidance only! 14H variations is alloed to cater for
production and measurement variation.
I 0ll dimensions are under 5*L0DE* condition.
I Definitions of terminologies herever applicable are as per relevant ISCIS/ standards.
I Specifications are subEect to change ithout notice.
Ahat are the special features of >P5LS0& DTS,i 18= 5< III >J /&
Ahat is so special in this >P5LS0& DTS,i 18= 5< III >J
B Pulsar 5<III is ne(t version of Pulsar breed. It is loaded ith lots of uni"ue +
contemporary features and that distinguishes the Pulsar not only in the category of Poer!
Performance + Style but also for )omfort! )onvenience + Safety from the competition.
B 0part from refining the poer delivery! it is loaded ith the features that are meant for
cars. So! here is the )omfort! )onvenience + Safety of the 2 heels 6cars7 available on $
heels.
B The maEor changes C features are
Enhanced Performance
I &efined engine poer delivery by optimi'ation of E(hausTE) location! bigger + tin
0ir Filter element! optimi'ed valve timing! reduced engine friction etc.
I Stainless steel silencer that lasts long + overcomes rusting.
I 0ll sensor type electrical sitches that function for the life of the bi.e. 0bsolutely no
maintenance in absence of mechanical contacts.
Enhanced Style
I Stylish fairing + 3eadlamp assembly ith ol eye! ne blac. mas. to separate
headlamp from par.ing lights
I *e age! sharp + attractive $ &o Tail lamp ith LED lights
I Louver type L3 + &3 covers ith ire mesh gives sturdy loo..
I Ergonomically designed self,letting sitches
I 0bsolutely no maintenance in absence of mechanical contacts.
Enhanced )omfort + )onvenience
I Loaded ith Digital Technology li.e L)D SpeedC/do display! digital fuel meter! Digital
trip meter that enables to count to trips.
I )ar li.e self canceling indicator sitches that .eeps rider free from sitching off the
indicators after turn.
I 0part from digital fuel meter! arning light for lo fuel level is provided.
I Self chec. provision for tachometer to ensure proper functioning.
I /il level inspection indo that indicates oils level at a glance.
Enhanced Safety
I Engine cut,off at 1==== &P; Spar. gets cut,off at 1==== &P;
I 3igh &P; arning lamp hen engine reaches to ?=== &P; automatically &ed LED
bulb starts blin.ing.
I Day night mode of Speedo console! LED illumination for tell,tale icons on electrical
sitches that glos in the night for positive access.
3o does the digital Speedo or.J
B Front heel of the bi.e has a sensor + magnet unit. The sensor counts no. of pulses .r.t.
heel rotation + logically calculates number of heel rotation + gives input to the display
unit in the speedo console and the L)D display indicates accurate speed! odo reading +
trip meter readings.
4 8
Fre"uently 0s.ed Fuestions 6F0FGs7 Fre"uently 0s.ed Fuestions 6F0FGs7
Ahat are the advantages C -enefits of the digital speedometer apart from giving
accurate readingJ
B This system is totally contact less + no mechanical transmission of drive from heel to
speedometer is available. Thus this system is totally maintenance free + lasts for the life of
the bi.e.
3o the digital fuel indicator meter or.sJ /& 3o one can understand the available
fuel level in the fuel tan.J /& 3o to read the graphical bar of the fuel meterJ
B <raphic bar ith 1$,segment display is provided in the speedo console for indicating fuel
level in the tan.. If the all the 1$ segments of a bar graph are >/*>! that indicates that the
fuel tan. is full.
B 0s the float gauge in the tan. starts loering don due fuel level coming don! the
segments of the bar graph starts diminishing ith corresponding drop in fuel level.
B Ahen the petrol level comes don to belo four liters! all the segments of the bar ill
vanish.
B 0part from L)D graph bar! a red arning light also has been provided in the console that
glos continuously hen the petrol level falls don to reserve. 0nd it ill be >/*> till petrol
is filled above reserve level.
Ahen the digital fuel meter is available! hy the red arning light is providedJ
B Ahile the L)D graphical bar segments indicates the petrol level in the fuel tan.! the red
arning light continuously reminds the rider to fill the petrol.
Ahy to trip meter reading option is givenJ 3o is it usefulJ
B It is Eust to enable the rider to count reading for to different trips unli.e only single trip in
case of conventional type.
B It is li.e this , on selecting >Trip1> its ill indicate the distance covered in first trip that is
set for. In continuation! on selecting >Trip$>! it ill indicate the distance covered in the
second trip. Then if one ants to .no the cumulative distance covered in first + second
trip! it can be found in >Trip1> mode. For this one has to Eust pressCselect >Trip1> mode.
B This is an added advantage ta.en from digital technologyK
Ahat do Self,canceling Indicators sitches meansJ
B In conventional type of sitches! the rider has to manually depress or turn .nob of
indicator sitch for putting >/FF> the indicator bulbs. In case of this Self,canceling>
sitches the indicator goes off automatically after the rider ta.es a turn + brings the
handle bar straight. This feature is similar to cars. That means! rider do not have to press
or turn the sitch to cancel the indicators.
Ahat if one sitches /* the indicator and do not physically ta.e a turnJ Aill it or.
in such situationJ
B Des. /f course. Ahen the rider selects a right or left turn indicator! but changes his mind
and physically do not ta.e a turn! the indicators turn >/FF> automatically after pre,set time.
For this a timer function is incorporated in the system. 0nd the timing for this timer is set
around 8= seconds.
Ahat does non,contact 3andlebar sitches meanJ
B The control sitches on both sides of the handlebar are conventional to loo. at! in terms
of sitch operations + .nob position etc. -ut the .ey + distinguishing difference is the
principle of functioning that means these sitches do not function on the basis of physical
contact for /* + /FF. These are on non,contact sensor based.
B This feature ill have any ear and tear + hence its life ould be more than the life of the
bi.e. These are absolutely maintenance free as far as ear + tear is concerned.
B The other feature! in these sitches is the Illumination of the tell,tale icons that is lit up
ith LEDs inside the sitch body. This gives the icons a pleasant bluish hite glo that
can be seen in the night clearly + coolly.
The tail lamp assembly seems to be too special. Ahat is so in thatJ
B Des. The tail lamp is uni"ue on this vehicle and no other competitor>s vehicle has this
feature. It consists of 18 687 nos. of LED bulbs ith bi,filaments.
B The specialties of LED bulbs are
, )onsume very lo current
, <lo brightly
, Last far long
, Totally maintenance free
B So! the LED tail lamp apart from delivering fantastic performance! it adds to aesthetics.
Ahat is this bi,filament bulbJ
B -i,filament bulb means these LED bulbs have to filaments in each bulb. /ne filament of
loer attage for par.ing lights + another for bra.e lighting! hich is of little higher
attage.
If so much so electrical Celectronic appliances are loaded! it may affect on -atteryJ
B 0bsolutely not. In fact! all the bulbs + bac.lit bulbs in the Speedo console 6e(cept 3ead
Lamp bulb + pilot bulbs7 are of LED type. Fe of them or.s on 0) + fe are on D) i.e.
battery. So there is hardly any drain on the battery as compared to conventional type of
bulbs.
B ;oreover! the -attery of this ne Pulsar 18= is special + maintenance free.
Ahat is this maintenance free -atteryJ
B The battery is ne development in D) system on to heelers 6in fact! such batteries are
introduced in cars earlier than bi.es7 it is different than the conventional one in the material
composition it is made up of. The main features of this ne battery are
, Electrolyte level chec.ing is re"uired at every one year instead of every fortnight
, The uni"ue vent mechanism that do not allo loss of electrolyte
, *o drainpipe unli.e in conventional type battery. So no chances of spillage of electrolyte.
B So! in all it is almost maintenance free battery. ;oreover! the LED bulbs! + disable
function of cran.ing after # successive self starts attempts! ill further only enhance the
life of the battery.
9 8
Pre Delivery Inspection )hec.list Fre"uently 0s.ed Fuestions 6F0FGs7
Sl. )hec. Points for PDI )hec.
PDI done by -0LC
Service Engg.
PDI Done by
Dealer
1 L/)B /PE&0TI/*
STEE&I*< L/)B */T A/&BI*<CL0;
SIDE )/:E& L/)B */T A/&BI*<
$ P0I*T FI*IS3 , /:E& FL/A 6Samples C photograp s7
# F5EL T0*B DEFE)TS
LE0B0<E
-LISTE&S
&5STD
/T3E&S 6Specify7
2 F5EL )/)B /PE&0TI/* , 30&D C LE0B0<E
4 F&/*T C &E0& A3EEL /FFSET
8 A3EEL
F&. A3EEL TD&E ,Free rotation.
F&/*T A3EEL &5*/5T 6SPE)IFD7
&E0& A3EEL &5* /5T 6SPE)IFD7
9 SILE*)E& ,-0FFLE */ISE
8 SAIT)3ES
&3 sitch operations
L3 Sitch operations
I<*ITI/* SAIT)3 S3/&T
? LI<3TS%,
Side indicator blin.ing.
3E0D LI<3T
T0ILC-&0BE LED
1= 3/&* %, DIST/&TEDCAE0B S/5*D6D/ */T SET7
11 Speedo %
SPEED/ */T SE*SI*<.
SPEED/ *eedle flic.ering.
Tripmeter , 1C$ or.ing ,&esetting
/dometer or.ing
0uto , )alibration of &P; meter
Fuel level indication
&eserve indication 6by red lamp7
&ed lamp blin.ing after crossing Engine &P; ?===
0uto,sitch off of Ind lamps63 bar straight for M $ sec7
3ead light C tail light illumination after # seconds
LED functioning , Speedounit , -oth side indication!
Side stand! *eutral! 3i beam! &ES ind lamp
Ahat is that disabling of cran.ing after # successive attemptsJ
B 0 protective device has been incorporated in the system that allos rider to attempt self,
start option 6pressing of self,start button7 for starting only three times at times. 0fter third
attempt the battery poer supply gets cut,off to the self,starter motor! thus avoid rider
from further cran.ing of engine by self,start.
B This is mainly to protect the battery from over draining by e(cess attempts of pressing of
self,start button to start the engine.
B 3oever! one can again use the self,start option after 14 seconds after third attempt.
3o come so many features are managed accurately + hat is the guarantee of no
malfunctioning of these featuresJ
B It is needless to say that the digital technology that or.s ith sensors + chips or.s
accurately. To control all the functions of these electronics features! an intelligent device
has been installed in the electrical system. This is called -)5 6-ody )ontrol 5nit7
Ahat e(actly is -)5 6-ody )ontrol 5nit7J 3o it controls all these functioningJ
B -)5 6-ody )ontrol 5nit7 is a device that integrates + controls maEor of all electrical C
electronic functions on the vehicle. It is an intelligent device that or.s on microchip base.
B In the eventuality of electrical overloads or short circuits! the built in intelligent protection
circuit ta.es the control of the situation + prevent future damages on other electronic
parts. For e(ample%, During night! suppose one of the 3ead light filament blos /FF then
there is a possibility of an accident due to sudden dar.ness.. To rescue! here the -S5
plays an important role. It sitches over the 3eadlight to the other beam automatically
ithout manual shifting of any sitches.
B It also chec.s + inspects the fused circuit religiously for any corrections and thus riders>
safety is ensured.
0re these type of product features available in Pulsar14=cc alsoJ
B Presently not. -ut as in all sphere of life! technology also proliferates. Ahen that happens
you may find similar features in Pulsar 14=cc also.
)an one alter the current Pulsar model + incorporate these featuresJ
BN *o. It is not possible. Physically lot of changes are there that are not easily
accommodated in the e(isting Pulsar.
? 1=
Pre Delivery Inspection )hec.list PDI S/P
Sr.
No.
Description Position SMM GP Tools
Special
Tools
PNR & its
Attachment
Consumables
M & T / Service
Shop Euipments
1
Identify & Park Vehicle on
Work Bay
0.80 Lifter Bay
2
Remoe the !hermocol and
additional "ackin# if any. $t%dy
P&I card and Work content.
0.'0
(
)"en Petrol tank ca"
& "o%r "etrol
0.'0
*ea+%rin# ,ar-
.%nnel
Petrol- Wa+te
/loth
0
/heck for +mooth o"eration of
f%el cock leer
0.10
'
/heck & to" %" en#ine oil
leel- if re1%ired.
R2 0.(0
3
/heck cl%tch ca4le o"eration &
5d6%+t if re1%ired.
R2 0.10
1271( )8
$"anner
9
/heck front 4rake+ for efficient
:orkin# & 5d6%+t if re1%ired.
.ront
; R2
0.10
1271( Rin#
$"anner
5ir <%n
8
/heck and correct tyre inflation
"re++%re 7 .ront Wheel
.ront 0.20
Pencil !y"e
Pre++%re <a%#e
5nalo#o%+;&i#ital
ty"e Pre++%re
#a%#e- 5ir fillin#
Vale
=
/heck Battery olta#e- fill ;
to"7%" electrolyte- a""ly
"etrole%m 6elly- connect
terminal+ "ro"erly.
L2 0.30
$cre: &rier-
&i+tilled :ater
.iller- 10mm
>!? $"anner
/loth- .ine
Poli+h Pa"er-
Petrole%m
,elly-
&i+tilled Water
2ydrometer-
Battery /har#er-
Battery !e+ter
10
In+"ect Rear $hock 54+or4er
+ettin# & correct if nece++ary.
R2;L2 0.10
11
/heck Rear 4rake+ for efficient
:orkin# & ad6%+t if re1%ired.
Rear 0.10
1071' @o.
).8. $"anner
/loth- <ra"hite
<rea+e- .ine
Poli+h Pa"er
12
/heck and /orrect tyre inflation
"re++%re 7 Rear Wheel.
Rear 0.20
Pencil !y"e
Pre++%re <a%#e
5nalo#o%+;&i#ital
!y"e Pre++%re
<a%#e- 5ir .illin#
Vale
1(
L%4ricate chain and /heck ;
5d6%+t chain +lackne++ if re1%ired.
L2 0.00
20722- 20729
Rin# $"anner-
10711 @o. )8
$"anner-
!or1%e Wrench-
$ocket $et- )il
/an
/loth-
$58 =0 )il
5ir #%n
10 /heck /hoke leer o"eration L2 0.0'
10711 @o.
)8 $"anner
1' /heck 5ccelerator ca4le free "lay L2 0.0'
8 & 10 @o.
)8 $"anner
13 /heck & 5d6%+t !P$ L2 0.10
10711 @o.
)8 $"anner
19 /heck #ear +hifter leer o"eration L2 0.0'
8 @o.
>!? $"anner
18
/heck & 5d6%+t +teerin# and
2andle 4ar for free moement.
R2 ;
.ront
0.20
1271(- 13719
Rin# $"anner
.ork $"anner
1=
/heck front m%d#%ard ali#nment
:rt .ront Wheel
.ront 0.0'
Sl. )hec. Points for PDI )hec.
PDI done by -0LC
Service Engg.
PDI Done by
Dealer
1$ FL0T SP/T 6<I:E )/ H7
1# D&I:E )30I* slac. 6mention amont of play7
12 -&0BE /PE&0TI/* , F&/*TC&E0&
F&/*T -&0BE
&E0& -&0BE EFFE)TI:E*ESS
-&0BE LI<3T &E;0I*I*< /* )/*TI*5/5SLD.
14 <0P 0T T3E &EED SAIT)3 0*D ;0<*ET/.
)3E)B P/I*TS F/& PDI
18 L//SE P0&TS
BI)B -/SS -/LT
E*<I*E ;/5*TI*< -/LT
19 E*<I*E */ISE
T0PPET */ISE
)30I* TE*SI/*E& C TI;I*< )30I*
18 E*<I*E /IL LE0B0<E
D&0I* -/LT
;0<*ET/ )/:E&
)&0*B)0SE L/I*T
/IL FILLI*< PL5<
/3) )/:E&
T0PPET )/:E&
-E*L/ -/LT
)30I* TE*SI/*E& >/> &I*<
/IL LE:EL I*DI)0T/& AI*D/A
/IL FILTE& )/:E&
1? )L5T)3 /PE&0TI/*
30&D
)L5T)3 L5DDE&I*<
$= PL0TI*< DEFE)TS
30*DLE -0&
$1 E*<I*E /PE*I*< D5&I*< PDI 6If any7
6<ive engine no + reason for engine opening7
$$ F&0;E /PE*I*< D5&I*< PDI 6If any7
6<ive chassis no + reason for chassis opening7
$# /T3E& DEFE)TS %
;I*/& 0DL5ST;E*TS
$2 T&0*SIT D0;0<ES 6Send photographs7
;ar.ed if the o. observed
11 1$
Periodic ;aintenance + Lubrication )hart
PDI S/P
Sr.
No.
Description Position SMM GP Tools
Special
Tools
PNR & its
Attachment
Consumables
M & T / Service
Shop Euipments
20
/heck all im"ortant n%t 4olt+ for
tor1%e and ti#htne++-
A 2andle 4ar mo%ntin# 4olt
A $tem lo:er & %""er 4racket 4olt+
A $tem of 4olt+
A .ront aBle n%t
A /ylinder head n%t+
A 8n#ine fo%ndation 4olt+
A !railin# arm 4olt+
A $ilencer coer +hield 4olt+
A Both L2;R2 en#ine mt#. 4olt+
L2;R2 0.00
1271(- 1071'-
13719- 20722
Rin# $"anner-
22 mm BoB
$"anner :ith
2andle Ratchet
Pi+tol <ri"
P@R
21
/heck the follo:in# and
l%4ricate if nece++ary
A Rear 4rake leer
A Rear 4rake "edal ; cam
A Pillion foot re+t
A /enter +tand
A $ide +tand
A Cick leer 4o++
A /l%tch leer
R2;L2
.R)@!
R85R
1.00 )il /an
$58
20W00 )il
22
)8 acce++orie+ fitment 7
*irror+ R2 & L2
L2;R2 1.1'
19mm
2(
)8 acce++orie+ fitment 7
Le# #%ard
L2;R2 (.2'
1=,1$ *o.
/E Spanner
and 1$ *o.
-o( Spanner
Pi+tol <ri"
P@R
20
$tart ehicle- /heck o"eration of
electrical like7 2ead li#ht- !ail li#ht-
Brake li#ht- $ide +tand indicator-
2orn- $"eedometer- )dometer-
$ide indicator+- Parkin# and
Pa++ li#ht :orkin#.
L2;R2 0.('
2' /heck Idlin# and /)D. L2;R2 0.30
$mall
$cre: drier
/)72/ 5nalyEerF
!achometer-
Pro"er 8Bha%+t
$ealin#
5rran#ement
of $ilencer
23 !ri" meter :orkin# L2;R2 0.10
29 /heck all lock+ for "ro"er o"eration L2;R2 0.'0
28
!e+t drie the ehicle- check di#ital
+"eedometer :orkin#. $t%dy the
6o4 card and erify :ork done.
!ake ehicle o%t and "ark.
1.(0
2= /lean;Wa+h the eh. 4efore deliery 1.00
Total SMM !"."#
(0
Re"air for any other defect+ +een
or o4+ered d%rin# te+t drie.
E$pecte% &utput in '() Minutes / Man / *" +ehicles
Sr.
*o.
/peration
Ahichever
comes first
&E)/;;E*DED F&EF5E*)D
Initial Subse"uent
/&
Bms. 94= $!4== 4!=== 9!4== Every $!4==.m
Days #=O24 1=4O1$= 1?4O$1= $84O#== Every ?= days
1. Servicing l l l l l
$. Idle speed C )/H )!0 l l l l l
#. :alve tappet clearance 0 l Every 4=== .ms
2. Engine oil 6S0E $=A4= of 0PI S<@L0S/ ;07 & l l Every 4=== .ms
4. /il strainer C )entrifugal filter )L Every 1==== .ms
8. 0ir cleaner element : )L l l l l l
9. 0ir cleaner element & Every 1==== .ms
8. )arburettor )L!0 l l l l l
?. Fuel system lea.ages )!& l l l l l
1=. Fuel pipes & Every Dear
11. Spar. plug C gap )L!0 l l l l l
1$. Spar. plugs 6$ *os.7 & Every 1==== .ms
1#. -attery electrolyte level )!0 l l l l Every Dear
12. -ra.e light sitch )!0 l l l l l
14. )lutch play )!0 l l l l l
18. Throttle play )!0 l l l l l
19. &ear bra.e pedal play )!0 l l l l l
18. -ra.e lining or pad ear )!& l l l l l
1?. -ra.e fluid level C top up ) 1 ;onth l l l l l
$=. -ra.e fluid change & Every 1=!=== .ms.
$1. Steering play )!0 l l l l l
$$. 0ll fasteners tightness )!T l l l l l
$#. Engine mounting silent bloc.s & Every $=!=== .ms.
$2. Tyre tread ear )!& l l l l
$4. <eneral lubrication L l l l l l
$8. Steering stem bearing L!& 1 year Every 1====.ms
$9. Aheel bearing )!L 1 year Every 1====.ms
$8. ;aster cylinder cup and Dust seal & Every $ years
$?. )aliper piston seal and Dust seal & Every $ years
#=. Sing arm pivot pin L l Every 4===.ms.
#1. Front for. )!L l l l
#$. Front for. oil & Every 1====.ms
##. Front bra.e hose )!& $ years
#2. &r. Shoc. 0bsorber, )hec. gas pressure 9.=@=.4 BgCcm
$
Every 1====.ms
#4. Drive chain L Every 4== .ms.
#8. Drive chain slac. 0 l Every $4== .ms.
#9. Drive chain ear C &emove + Lubricate )!& l Every 4===.ms.
#8. Engine compression pressure ) Every 1====.ms
#?. )ylinder head de,carbonising + valve lapping )L Every #====.ms
2=. :alve oil seals & Every #====.ms
)8 $"anner
l Indicates operation to be performed.
G More frequent cleaning may be required when driving in dusty condition.
Parts / Lubricants to be replaced as per Periodic Maintenance and
Lubrication Chart are mandatory and the same are chargeable to customer.
1# 12
Periodic Service S/P
Sr.
No.
Description
,-/R-
Si%e
SMM GP Tools
Special
Tools
PNR Consumables
M & T / Service
Shop Euipments
1 Wa+h ehicle thoro%#hly. Both
!o 4e done 4y
:a+hin# 4oy
2 Identify the Vehicle 0.(0
( Brin# ehicle & "o+ition on 4ay 0.'0
0 Rai+e the lift 0.(0
'
$tart eh. & Warm %". Remoe
R2;L2 +ide coer+- $eat-
Petrol !ank & kee" "ro"erly.
L2;R2 0.90
1271( @o.
Rin# $"anner-
12mm $ocket
Pi+tol <ri"
P@R
3 &rain 8n#ine )il L2 1.(0
13mm $ocket-
8Bten+ion-
!ommy
& Pla+tic !ray
/loth
)il &rainin#
81%i"ment
9
/lean 5ir filter.
HRe"lace 7 if nece++aryI
R2 (.00
8mm
>!? $"anner
/loth-
20W00 )il-
&ie+el- 5ir
.ilter 8lement
.ilter /leanin#
$tand- 5ir <%n
8
&rain /ar4%retor.
H)erha%l 7 if re1%iredI
L2 1.(0
Philli"+ $cre:
&rier- $cre:
&rier- 10mm
@ylon Br%+h-
Pla+tic !ray-
10711 & 1071'mm
)8 $"anner
.loat
<a%#e
/loth- &ie+el 5ir #%n
= /heck 5ccelerator and ad6%+t L2 0.00
87=- 10711
)8 +"anner
10
/lean- /heck & 5d6%+t
HRe"lace 7 if nece++aryI
L2 2.00
$"ark Pl%#
$"anner- Pl%#
/leaner-
Wire Br%+h
.iller
<a%#e
0.01J1mm
/loth- .ine
Poli+h Pa"er-
$"ark Pl%#
$"ark Pl%#
/leaner and
11
/heck & 5d6%+t ta""et
clearance. Hif re1%iredI &%rin#
0th $ericin# or after '000 Cm
:hicheer i+ later.
L2
87= @o. Rin#
$"anner- 20729
)8 $"anner-
10 mm BoB
$"anner :ith
2andle Ratchet-
$"ark Pl%#
$"anner
.iller
<a%#e
0.01J1mm
!a""et
2older
/loth
12
/heck
A $ide 4olt+ of .ront fork
A $ide +tand
A R$5 to" and 4ottom n%t+
L2;R2 0.30
1071'- 13719-
20722 Rin#
$"anner- 12 mm
BoB $"anner :ith
2andle Ratchet-
1271( @o.
)8 $"anner
Pi+tol <ri"
P@R
1(
5d6%+t chain +lackne++ &
L%4ricate. Remoe and /lean-
If re1%ired.
L2 ;
Rear
(.=0
10mm >!?
$"anner- 20722-
20729 Rin#
$"anner- 10711
)8 $"anner
/loth-
$58 =0 )il
5ir #%n
10 /heck; 5d6%+t Rear 0.'0
20722- 20729 Rin#
$"anner- 10711-
1071' )8 $"anner
/loth- <ra"hite
<rea+e- .ine
Poli+h Pa"er
5ir <%n
Sr.
No.
Description
,-/R-
Si%e
SMM GP Tools
Special
Tools
PNR Consumables
M & T / Service
Shop Euipments
1'
/heck & 5d6%+t
Rear tyre air "re++%re.
Rear 0.00
Pencil !y"e
Pre++%re <a%#e
5nalo#o%+ ;
&i#ital !y"e
Pre++%re <a%#e-
5ir .illin# Vale
13
/heck Battery- !o"7%" di+tilled
:ater. /lean terminal+ & a""ly
"etrole%m 6elly. Ro%te ca4le+
"ro"erly and fit terminal ca"+
"ro"erly. Rechar#e 4attery if
re1%ired.
L2 1.80
$cre: &rier-
&i+tilled Water
.iller- 10mm
>!? $"anner
/loth- .ine
Poli+h Pa"er-
Petrole%m ,elly
&i+tilled Water
2ydrometer-
Battery /har#er-
Battery !e+ter
19
/lean oil +trainer.
HRe"lace 7 if re1%iredI 5fter
1 Kear or 10000 Cm
:hicheer i+ later.
R2
8 @o. BoB
$"anner- 1271(
)8 $"anner-
1271( Rin#
$"anner- 8mm >!?
$"anner. Pla+tic
!ray- Philli"+
$cre: &rier
Pi+tol <ri"
P@R
&ie+el- cloth-
/l%tch /oer
<a+ket-
)il $trainer
18 /heck cl%tch and 5d6%+t. R2 0.(0
1271( )8
$"anner- $mall
$cre: &rier
1= .ill en#ine oil. R2 1.('
3L /om4ination
Plier+- *ea+%rin#
,ar 1Liter- .%nnel
/loth- )il 20W'0
of 5PI $< M
,5$) *5 #rade
)il &i+"en+er
20
/lean- /heck & 5d6%+t
R2 +"ark "l%#.
R2 2.00
$"ark Pl%#
$"anner- Pl%#
/leaner- Wire
Br%+h
.iller
<a%#e
0.01J1mm
/loth- .ine
Poli+h Pa"er-
$"ark Pl%#
$"ark Pl%#
/leaner and
!e+ter- 5ir <%n
21
/heck and !o"7%"
4rake fl%id leel.
.ront 1.00
Philli"+
$cre: &rier
/loth-
)il &ot70
22 /heck; 5d6%+t .ront 0.'0
1271(
Rin# $"anner-
' & 10 mm
5llen Cey
/loth- .ine
Poli+h Pa"er
5ir <%n
2(
/heck & 5d6%+t front tyre
air "re++%re.
.ront 0.00
Pencil !y"e
Pre++%re <a%#e
5nalo#o%+ ;
&i#ital !y"e
Pre++%re <a%#e-
5ir fillin# Vale
20 /heck and 5d6%+t +teerin#. .ront 0.80
13719 @o.
Rin# $"anner
.ork
$"anner
2'
/heck
A .ront aBle n%t
A $ide 4olt+ of .ront fork
A 2andle 4ar 4olt+
A R$5 to" and 4ottom n%t+
A $:in# arm aBle n%t
A $ilencer "rotectie coer
+cre:+ ; 4olt+
A Rear ie: mirror
R2 1.(0
10711- 1271(-
1071'- 13719-
20722 @o.
Rin# $"anner-
22 mm BoB
$"anner :ith
2andle Ratchet
Pi+tol <ri"
P@R
!e+ter- 5ir <%n
14 18
Service Aise Part Bit
Sr.
No.
Description
,-/R-
Si%e
SMM GP Tools
Special
Tools
PNR Consumables
M & T / Service
Shop Euipments
23
L%4ricate
A /l%tch leer
A Rear Brake "edal
A Rear Brake /am
A Pillion .oot Re+t
A /enter $tand
A $ide $tand
A Cick leer 4o++ "in
L2;R2 0.80 )il /an
20W00 )il-
<ra"hite
<rea+e- /loth
<rea+e <%n
29
Refit R2- L2 +ide coer+-
$eat- Petrol tank
L2;R2 0.'0
1271( @o.
Rin# $"anner-
12mm $ocket
Pi+tol <ri"
P@R
28
/heck and /lean f%el line &
/lean "etrol tank.
HRe"lace f%el "i"e 7 if re1%iredI
L2 0.'0 5ir <%n
2=
/heck all *eter+ for "ro"er
f%nctionin# & /orrect- if re1d.
.ront 0.'0
(0
$tart ehicle- /heck & 5d6%+t
the follo:in#.
R2
0.='
2ead li#ht. .ront $cre: &rier
!ail li#ht. Rear
Philli"+
$cre: &rier
Brake li#ht. R2;Rear
2orn .ront
$"eedo- Pa++- Parkin# li#ht .ront
$ide Indicator+ 7 .ront & Rear Both
(0 !%ne 8n#ine & /ar4%retor. L2 2.00
$mall
$cre: &rier
/)72/
5nalyEer-
!achometer-
$ealin#
5rran#ement
of $ilencer
(1 $t%dy ,o4 /ard. Verify :ork. 1.00
(2 Lo:er the Lift 0.(0
(( !ake ehicle o%t and "ark 0.'0
Sub Total .*.#)
(0
/arry o%t any additional :ork
a+ indicated 4y the /%+tomer
or a+ re1%ired.
10.00
Total SMM '*.#)
E$pecte% Pro%uction / '() minutes / Man / !!
('
!e+t Ride of the Vehicle
if re1%ired and "ark.
1.'
!o 4e /arried
o%t 4y 8B"ert
(3
/lean the ehicle at the
time of deliery.
1
Will 4e done
4y &eliery 4oy
Periodic Part &eplacement Bit for Free Services
Type of Service Days Bms. Limit Part *ame Fuantity
1st Free #=O24 4==O94=
Engine oil 1=== ml.
)lutch cover gas.et 1
$nd Free 1=4O1$= $===O$4== *IL *IL
#rd Free 1?4O$1= 24==O4=== Engine oil 1=== ml.
1st Paid $84O#== 9===O94== *IL *IL
$nd Paid #94O#?= ?4==O1====
Engine oil 1=== ml.
0ir filter foam element 1
Spar. plug $
For. oil ##= ml.
Drive chain loc. + lin. set 1
-ra.e shoes 6if orn out7 1
Starter clutch bush 1
For. oil seal $
)ylinder head gas.et 6If re"uired7 1
Front disc pad inspect C replace 6If orn out7 1
#rd Paid 284O28= 1$===O1$4== *IL *IL
2th Free 444O49= 124==O14===
Engine oil 1=== ml.
Steering cone .it 1
2th Paid 814O8#= 19===O194== *IL *IL
4th Paid 9=4O9$= 1?4==O$====
Engine oil 1=== ml.
Spar. plug $
-ra.e shoes 6if orn out7 1
For. oil ##= ml.
)lutch plate 1
&ear bra.e damper 1
8th Paid 9?4O81= $$===O$$4== *IL *IL
9th Paid 884O?== $24==O$4===
)arburettor insulator 1
)hain sproc.et .it 1
8th Paid ?94O??= $9===O$94== *IL *IL
Pro"er 8Bha%+t
PNR / Pneumatic Nut Runner
19 18
Schedule ;aintenance
Service Aise Part Bit
Periodic Part &eplacement Bit for Free Services
Type of Service Days Bms. Limit Part *ame Fuantity
?th Paid 1=84O1=8= $?4==O#====
Engine oil 1=== ml.
Spar. plug $
:alve oil .it 1
)ylinder head gas.et 1
)ylinder head stud copper asher 2
-ra.e shoes 6If orn out7 1
Steering cone .it 1
For. oil ##= ml.
)leaning
The vehicle must be cleaned periodically using pressuri'ed ater.
-efore cleaning the vehicle cover the important parts li.e Ignition
sitch! Silencer Tail end! )DI unit! 3.T. coil ith plastic bags. DonGt
apply the Eet of ater directly on electrical parts such as Sitches!
Ignition unit! )oils etc. otherise they may get damaged.
-rushing ith .erosene and iping dry ith clean rag is advisable for
e(ternal cleaning of the engine. 0ll painted surfaces should be ashed
ith ater. Do not use .erosene or hard detergent soap on painted
surfaces as it damages the paint and turns it dull.
0fter ashing! dry the vehicle ith compressed air and carry out the
lubrication as recommended
)aution % Aater may enter on the bra.e liners during ashing + bra.e
slippage may occur. Ensure that bra.e liners are dry before driving the
vehicle.
5se alays <enuine -aEaE 0uto parts + recommended lubricants.
6Engine oil% S0E $=A4= 0PI PS<G @ L0S/ P;0G grade7
Periodic ;aintenance
Periodic maintenance 6in accordance ith the periodic maintenance
chart7 of a vehicle is most important to prolong vehicle life! trouble
free running and ensure your safety hile driving.
*otes %
5pper
Level ;ar.
Loer
Level ;ar.
Engine /il Level )hec.ing
I Par. the vehicle on level surface on center stand to chec. the oil
level.
I Inspect the oil level through oil inspection indo
I It should be in beteen upper and loer mar.
I Top up if re"uired
&ecommended /il <rade and Fty
<rade S0E $=A4= of 0PI PS<G @ L0S/ P;0G
Fuantity Drain + &efill 1=== ml.
Engine /verhaul 11== ml.
*ote % It is most vital to adhere to recommended fre"uency of oil change
for the purpose of long life of critical engine components for details refer
Periodic ;aintenance )hart.
/il Strainer )leaning
&emove %
I Drain engine oil.
I )lutch cover
I /il pump mounting bolts 607
0 6# *os.7
I Pump ith strainer.
I )l i p 6 -7 and t a.e out P /i l
StrainerG from oil pump.
-
1? $=
Schedule ;aintenance Schedule ;aintenance
&emove %
I )lean oil strainer ith Berosene C Diesel blo compressed air and
then refit it.
I &eplace oil strainer if found damaged.
0ir Filter )leaning
)lean 0ir filter element adhering to standard S/P
)entrifugal /il Filter )leaning%
&emove %
I )entrifugal oil filter cover mounting
scres 6)7 # *os.
I The cover ith gas.et
I &eplace gas.et if damaged
I )lean centrifugal oil filter using
*ylon brushC.erosene or Diesel
1st Stage%
)lean ith Berosene
S"uee'e
#rd Stage%
Dip into
Engine /il 6$=A2=7
S"uee'e and &emove
E(cess /il
0ir Filter
0ir )leaner Element &emoval
&emove %
I &3 side panel by unloc.ing it ith .ey
$nd Stage%
)lean ith
Berosene 0gain
Dry ith )otton )loth
&emove %
I $ bolts 607.
I 0ir filter cover 6-7.
-lo Lo Pressure
)ompressed 0ir
&emove %
I 0ir filter element assembly along ith catreE
I Seperate foam filter from the catreE 0ir Filter Element )leaning and Inspection
*ote %
I *o need of removing flame arrestor
I Ahite colour filter portion toards carburettor side
I Ensure beading placed properly hen fitting cover
*ote % In dusty areas! the element should be cleaned more fre"uently
than the recommended interval.
0fter 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
ith a ne one in accordance ith the Periodic ;aintenance )hart.
0lso if there is a bra.age in the element material or any other damage
to the element replace the element ith a ne one.
Aarning % )lean the element in a ell,ventilated area! and ma.e sure
that there are no spar.s or flames anyhere near the or.ing area.
-ecause of the danger of highly flammable li"uid! do not use
gasolineCpetrol or a lo,flash point solvent to clean the element.
$1 $$
Position 1 $ # 2 4
Spring 0ction Stronger
&ecommended Spar. Plug )hampion &<23) C -osch 5&#D)
Electrode <ap =.9 O =.8 mm
&eplace Spar. Plug 0fter every 1==== Bms.
Spar. Plug
If the Shoc. 0bsorber sleeves on both sides are not adEusted
to the same position! an unsafe riding condition may result.
*ote % Std setting is done in $nd notch
-attery , 1$: , ? 0h
I -attery is located inside L3 cover
I )hec. the electrolyte level in each cell and ensure that the level is
beteen the upper and loer level lines.
I &emove the battery filler caps and fill ith distilled ater until the
electrolyte level in each cell reaches the upper level line if
re"uired.
*ote % 0dd only distilled ater to the battery. Tap ater is not a
substitute for distilled ater and ill shorten the life of the
battery.
I 0pply petroleum Eelly on to the terminals
Front -ra.e Fluid Level
I Front bra.e fluid master cylinder reservior is located near &3
sitch on handle bar.
I To chec. oil level! par. the vehicle on ;ain C )enter stand ith
handle bar in straight position.
I 0lays ensure that bra.e fluid level is above P;I*G mar. given on
inspection indo.
I 5se only D/T,# or D/T,2 bra.e fluid 6from sealed container7 to
top up if re"uired.
*itro( 0ir Filling
Procedure for gas chec.ing and &efilling
I &emove the Phillips,headed small scre and P/G ring.
I )lamp the cylindrical guide clamp on to the canister .eeping the
rubber plug in the center to support the syringe needle insertion
and .eeping in position.
I 3old the pump as shon and pierce the syringe needle into the
center of rubber plug.
I The molded needle adaptor ill rest into the clamped cylindrical
guide
I &ead the gas pressure on the dial gauge. If the gas pressure is
belo 8.4 BgCcm$ refill the air by pumping! .eeping the needle in
as it is condition ithout removal. 0s the natural air consists of
91H of nitrogen it ill serve the purpose.
I To fill the air into the canister! apply full stro.e of pump as
shonQ otherise air ill not get inflated into the pump.
I Beep on pumping the air unless you get 9.4 .gCcm$ on the gauge
I Pull out the air pump along ith needle carefully and ta.e out the
guide clamp
I Finally fi( the phillips headed scre ith P/G ring.
*ote % It is advisable that bra.e fluid should be replenished once
in a year.
&ear Shoc. 0bsorber
The rear shoc. absorbers can be adEusted to one of five positions to
suit riding conditions. 5sing special tool adEust the re"uired position
you desire. They can be left soft for average road riding condition
but should be adEusted harder for rough road condition.
Shoc. 0bsorbers adEusted either too soft or too hard adversely affect
riding comfort and stability.
To adEust the &ear Shoc. 0bsorbers
Turn the adEusting sleeve on each shoc. absorber to the desired
position. The higher the adEuster sleeve is positioned! the stronger
the spring tension! and the harder the ride.
)hec. to see that both sleeves are turned to the same relative
position.
Drive )hain Slac. C Lubrication
I Set the motorcycle upon its center stand.
I &otate the rear heel to find the position here the chain is
tightest + measure the vertical movement miday beteen the
sproc.ets.
I If the drive chain is too tight or too loose! adEust it so that the
chain slac. ill be ithin the standard value.
I )hec. drive chain slac.ness at every 1=== .ms.
Drive )hain Slac.ness % $4 O #= mm
Service Limit #4 O 24 mm
$# $2
#rd Stage%
Dip into S0E
Soa. into S0E
he
n
ge
th
th
et
Drive )hain )leaning C Lubrication
1st Stage%
)lean ith Berosene
Tyre 0ir Pressure
I Beep appropriate tyre pressure as mentioned belo to increase
life of this tyre and for better fuel consumption.
Front 1.94 BgCcm
$
6$4 PSI7
&ear , ith Solo $.== BgCcm
$
6$8 PSI7
&ear , ith Pillion $.$4 BgCcm
$
6#$ PSI7
$nd Stage%
)lean ith )leaner
Berosene again
-lo )ompressed 0ir
?= /il
Important 0dEustments and
)hec.ing Procedures
Idling Speed 0dEustment
Ahenever the idling adEustment is
disturbed follo the procedure
given belo for setting proper
engine idling.
I Start engine + drive it for at least
4 .ms. or arm the engine till
the oil temp reaches 8=
=
).
I &emove the -oltCPlug near E(haus TE)
I )onnect the probe of )/ analyser. Set the )/ beteen
1.94 O $.$4H by adEusting volume control scre.
I Then set the engine idling r.p.m. by rotating the idle adEustment
scre cloc.ise or anticloc.ise by hand.
I For the precise adEustment of idling speed! use of tachometer is
recommended.
I &otate the throttle a fe times to ma.e sure that the idling speed
does not change. &eadEust if necessary.
I Do not attempt to compensate for faults in other systems by
adEusting the idle speed.
Idling Sped % 12== @ 1== rpm
Final Stage%
3oo. )hain for
?= /il
Tappet )learance Setting
I Ensure that the engine is cold.
I Ensure the PTG mar. on t
P&otorG match ith the mar.
o the P)ran.case L3G. 0t this
sta the PPistonG is at TD) and
bo the PTappetsG are free.
I 3olding tappet scre firmly i
special tool loosen the tapp
scre nut.
I Put the feeler gauge! measure and adEust the clearance.
I Loc. the nut holding scre ith special tool after getting desired
dripping of e(cess oil
clearance.
I 0gain chec. the tappet clearance ith gauge. The gauge should
slide ith slight resistance beteen tappet and valve stem head
feeler and tighten the chec. nut ith a spanner.
I Inlet :alve % =.=4 mm I E(haust :alve % =.1 mm
Special Tools % Feeler <auge , 8? 94=$ 41
% :alve 0dEusting Scre 3older , #9 1=#1 4#
$4 $8
<ap
$.4mm ma(.
Ignition Timing Inspection
N )onnect cable of stroboscope to one of the 3. T. )oil carrying
current to spar. plug.
N Start the engine.
N 0im the stroboscope light at ;agneto cover glass indo.
O 0t idling speed the PFG mar.ed line on the rotor coincide ith
the line mar. on magneto side cGcase. 61=
=
-TD) R 14== rpm7.
O 0s the engine rpm is increased the P0G mar.ed on the rotor
coincide ith the line mar. on magneto side cGcase. 6$8
=
-TD)
R #4== rpm7.
O This indicates the advance timing is functioning correctly.
O &emember the PTG mar.ed line is a reference line for TD)
position of the piston and is not for Ignition timing.
&eed Sitch Setting and )hec.ing
)hec. throttle lever movement by rotating it ith hand. It should not
be stic.y in operation and should return bac. it self on releasing.
brac.et ;ultimeter should sho continuity.
I ;agnet should not touch ith reed sitch.
I <ap beteen ;agnet + &eed Sitch should not be more than $.4mm.
I ;ovement of throttle lever ith magnet assembly and &eed Sitch
fitted should be free.
&eed Sitch % Setting
I 0ccelerator cable play% $,# mm by adEusting the 0dEuster
I Protude stopper of the throttle lever brac.et must on idling scre tip.
)lutch Lever Free Play 0dEustment
-
I Slide the dust cover at lever yo.e end.
I )hec. that the clutch cable outer end is fully seated in the
0
adEuster.
I Turn the adEuster 607 until the proper amount of free play can be
obtained.
I Tighten the loc. nut 6-7 against the adEuster. If the clutch free play
cannot be adEusted ith the adEuster at the handle bar end! use
the adEuster at the loer ends of the clutch cable situated on
clutch cover.
I Loosen the $ loc. nuts 6)7 on clutch cable brac.et and adEust
threading in the adEuster provided on the clutch cover. Tighten
)
both the loc. nuts on clutch cable brac.et by holding one nut and
tightening the other! after the re"uired free play.
)lutch Lever Free Play % $ O # mm
&eed Sitch % )hec.ing
I Beep throttle at 'ero position.
I /n connecting multimeter to &eed Sitch coupler it should sho
continuity.
1
I Ahen throttle is open and &eed Sitch magnet crosses to straight
edge of fi( brac.et of &eed Sitch multimeter should sho
discontinuity.
0ccelerator Free Play 0dEustment
I Turn the adEuster 607 until the proper amount of free play can be
obtained.
I Tighten the loc. nut 6-7 against the adEuster.
I If the accelerator free play can not be adEusted ith the adEuster
at the handle bar end! use the adEuster at the loer ends of the
0ccelerator cable situated on carburettor.
I Loosen the $ loc. nuts 6)7 on accelerator cable brac.et end
D
adEust by adEuster 6D7 provided on the cable.
I Tighten both the loc. nuts on brac.et by holding one nut and
tightening the other! after ensuring the re"uired free play.
)
0ccelerator <rip Free Play % $ O # mm
=.==
I /n De,acceleration! hen of &eed Sitch magnet re,coinsides ith
straight edge of fi( brac.et of &eed Sitch ;ultimeter should sho
continuity.
$9 $8
Standard )hec.ing Procedure
Schedule ;aintenance
Front -ra.e Free Play 0dEustment
There is no need for free play adEustment! since the pistons in
caliper assembly ill move toards the pads and ta.e ne positions
in order to automatically compensate for pad ear. The free play ill
be appro(imately $ O # mm.
Front -ra.e Lever Play % $ O # mm.
&ear -ra.e Pedal 0dEustment
)hec. the rear bra.e pedal play as stated belo. If it is more or
less than the standard! adEust the rear bra.e.
I Depress the rear bra.e pedal lightly by hand. This is free play.
I If the rear bra.e pedal free play is incorrect! adEusting the rear
bra.e shoe adEuster nut 607.
- I /perate the pedal 6-7 for fe times to see that it returns to its
rest position immediately upon release.
I &otate rear heels to chec. for bra.e drag.
I )hec. bra.ing effectiveness.
I If there is any doubt as to the conditions of the bra.e! chec. the
bra.e parts for ear or damage.
I Turn the adEuster until the rear bra.e pedal have the correct
amount of play.
0 &ear -ra.e Pedal Play % $4 O #= mm.
)ompression Pressure Testing
N For testing the compression pressure first arm up the engine.
N &emove the spar. plug. L3 side.
)aution % Disconnect 3. T. lead cable from second spar. plug i.e. &3
side.
N Fit the compression gauge ith adapter in the Spar. plug hole.
N /pen the throttle fully S then .ic. 4 times instantaneously.
N *ote the reading in the compression gauge.
N &elease the pressure by pressing the release valve on hose pipe.
N Ta.e average of # such readings for noting actual compression
pressure.
N )onfirm the compression pressure is beteen 8 to 1= BgCcm
$
Aet )ompression Test %
N If the compression pressure is found belo loer limit than
specified! put fe drops of engine oil through the spar. plug hole
and again chec. compression pressure.
N If you find considerable increase this time! then cause for the lo
compression pressure lies in )ylinder C Piston assembly.
N If compression pressure remains the same! then the cause for lo
compression pressure lies in )ylinder C 3ead assembly.
)aution % If et compression is done! remove second spar. plug and
clean thoroughly to avoid oil fouling before fitment.
&ear -ra.e Pedal Position 0dEustment
-
To suit rider foot comfort C operating style the angle of the rear
bra.e pedal can be adEusted by loosening the loc. nut 607 and
adEusting the bolt 6-7.
Ensure free play by turning the adEuster cloc.ise or anticloc.ise to
achieve specified free play. Fi( the rubber sleeve on the bolt.
*ote % 0fter pedal position adEustment! it is necessary to set the free play.
&ear -ra.e Light Sitch 0dEustment
Ahen either the front or rear bra.e is applied! the bra.e light glos on.
The front bra.e light sitch re"uires no adEustment but the rear bra.e
light
0 sitch should be adEusted in accordance ith the periodic maintenance
chart.
Inspection %
I Turn on the ignition sitch. The bra.e light should go on heel the
front bra.e is applied.
I If it does not! then inspect the front bra.e light sitch.
I )hec. the operation of the rear bra.e light sitch by depressing the
bra.e pedal. The bra.e light should glo after about 14 mm of pedal
travel.
I If it does not! adEust the rear bra.e light sitch.
0dEustment %
I 0dEust the rear bra.e light sitch 607 by rotating the sitch nut to create
ade"uate tension in spring to operate the sitch.
)hain Slac. 0dEustment %
I Set the motorcycle upon its centre stand.
I &otate the rear heel to find the position here the chain is
tightest and measure the vertical movement miday beteen the
sproc.ets.
I If the drive chain is too tight or too loose! adEust it so that the
chain slac. ill be ithin the standard value i.e. $4,#= mm.
I Loosen the rear tor"ue lin. nut 607 + rear bra.e adEusting nut 6F7.
I Loosen the left and right chain adEuster loc. nuts 6-7.
I Loosen the a(le nut 6)7.
I Loosen the bearing carrier nut 6D7.
I If the chain is too tight! bac. out the left + right chain adEusting
nuts evenly + .ic. the heel forard until the chain is too loose.
I Turn both chain adEusting nuts evenly until the drive chain has the
F 0
correct amount of slac.. To .eep the chain and heel properly
aligned! the notch 6E7 on the left chain adEuster should align ith
the same sing arm mar. that the right chain adEuster notch 6E7
aligns ith.
Aarning % ;isalignment of the heel ill result in abnormal ear! and
may result in unsafe riding condition.
E
$? #=
Standard )hec.ing Procedure Standard )hec.ing Procedure
I Tighten both chain adEuster loc.
nuts.
I Tighten the sleeve nuts securely.
Aarning % Tighten the beari ng
) carrier nut before tightening the a(le
nut. If the nut tightening order is D
reversed! the rear a(le ill not be
securely mounted on the sing arm.
This may cause misalingment of the
heels and result in loss of control.
0ir -leeding of Disc -ra.e System %
N For air bleeding from front 3ydraulic bra.e system first top up the
master cylinder ith hydraulic oil.
N /perate the bra.e lever sloly in order to get filled the oil in the
circuit.
N )onnect transparent tube to the bleeder scre at caliper
N /perate the bra.e lever and .eeping in pressed position loosens
the bleeder scre so that some oil escapes ith the air bubbles.
N Beep on operating the bra.e lever till the air bubble escape out
completely through bleeder scre! and top up the master cylinder
if re"uired.
N /nce the air escapes out from the hose pipe the bra.e lever meets
resistance! hich indicates completion of air bleeding
N 0fter completing the bleeding! top up the master cylinder up to the
ma(imum level mar..
I )enter the bra.e panel assembly in the bra.e drum. This is done by
tightening the a(le nut lightly! spinning the heel! and depressing the
bra.e pedal forcefully. The partially tightened a(le nut allos the
bra.e panel assembly to center itself ithin the bra.e drum.
I Tighten the 0(le *ut
I Tighten the tor"ue lin. nut
I Fi( the snap ring
I 0dEust the correct bra.e play
*ote % This procedure can prevent a soft or spongy feeling bra.e.
Piston &ing Fitment %
I Piston rings must alays be fitted ith respect to e(haust mar. on the
piston.
I First place the bottom oil rail ring ith end gap $8
=
toards left of the
e(haust mar. in the last groove.
I Place oil e(pander ring ith butting end donard and end gap facing
opposite to the e(haust mar..
I *o fit top oil rail ring on the e(pander ring ith end gap #=
=
toards
right of the e(haust mar..
I Fit the second piston ring ith PTop $G mar. facing upard and end gap
facing opposite to the e(haust mar..
I Finally fit the first ring ith PTop 1G mar. upard and end gap facing
toards the e(haust mar..
I &emember fitment of $nd ring upside don may lead to passing of oil
above the piston and ultimately leading to smo.y e(haust.
*itro( 0ir Filling
I &emove the Phillips head scre + small P/G ring fitted on air valve
of *itro( &S0.
I Fi( the guide to canister of *itro( shoc.er in such a ay that
guide hole is concentric ith air filling valve.
I Insert the *itro( air filling pumps needle end into the guide +
carefully pierce the rubber pin fitted inside the air valve of *itro(
&S0.
I *ote the pressure indicated by pressure gauge of *itro( air pump.
&efill the pressure.
I /nce the pressure reaches upto 9.4 BgCcm
$
! ta.e out the needle
sloly from canister.
I Fit the Phillips head scre + small P/G ring fitted on air valve of
*itro( &S0.
Poer 5p the Lig
The Lig should carry out a self test! here first all &ed LEDQ glo
se"uentially and then all <reen LEDQ flash tice.
;anual Testing
I )onnect iring harness to )1 connector.
I Through this harness the folloing testing can be carried out %
, :ehicle sensor speed.
, 3all sensor.
, Starter relay.
#1 #$
Special Tools
Standard )hec.ing Procedure
L)D Speedo )onsole Test
I )onnect iring harness number $ to )$ connector.
I 0fter connecting speedo console ait unitl console L)D goes
blan..
I *o press speedo console test sitch to start the test.
I /bserve for or.ing of speedo console till test ends.
Details of E(clusive Special Tool
For carrying out repairs C overhauls! 1 ne special tools for Pulsar DTS,i 5< III have been
developed. &est of the special tools re"uired remains the same hich ere earlier re"uired for
Pulsar and Pulsar DTSi
Engine
-ody )ontrol 5nit 6-)57 Test
I )onnect iring harness number # to )#! )2 and )4 connectors
respectively.
I Press the -)5 test sitch.
I 0t the end of complete test! <reen colour gloing of P&esultG LED
indicates -)5 test passed.
I 0t the end of complete test! &ed gloing of P&esultG LED indicates
-)5 test failed at respective &ed indications.
Sproc.et )atcher
Draing *o.%
#9 1=D3 #8
0pplication %
For holding sproc.et during removal
C refitting of )am sproc.et allen
bolt.
)amshaft -ig -earing Puller
Draing *o.%
#9 1=D3 #$
0pplication %
To remove bearing 6Decompression
assembly side7 of camshaft.
)amshaft Small -earing Puller
Draing *o.%
#9 1=D3 #1
0pplication %
To r emove smal l bear i ng of
camshaft.
&oc.er Pin &emover
Draing *o.%
#9 1=D3 #4
0pplication %
To remove roc.er pin from cylinder
head.
Silent -ush Puller
Draing *o.%
#9 1=D3 ##
0pplication %
To remove silent bush from cylinder
head cover.
## #2
Special Tools Special Tools
&otor Puller ith -utt Pin
Draing *o.%
#9 1=DL #$
0pplication %
5sed to pull out the rotor from
cran.shaft assembly.
-earing E(tractor
Draing *o.%
#9 1=DL 98
0pplication %
5sed to e(tract the input shaft
bearing from cran.case L3.
Primary <ear 3older
Draing *o.%
#9 1=DL $8
0pplication %
5se to hold primary gear hile
loosening C tightening the clutch nut.
-earing Puller
Draing *o.%
#9 1=DL 99
0pplication %
5sed to pull out the bearing for
body balancer from cran.case L3.
-alancer <ear 3older
Draing *o.%
#9 1=DL 8#
0pplication %
5sed to load the pre,tensioned
scissor gears of 0ssly balancer Idler
gear.
0daptor + :alve Spring compressor
0daptor , Draing *o.% #9 1=DL 98
:alve Spring )ompressor , Draing
*o.% #9 1=#1 =9
0pplication %
5sed for assembling C dismantling
inlet! e(haust valves by compressing
spring in cylinder head.
Dia. T $4.?@=.1
Special *ut
Draing *o.%
#9 1=DL 2#
0pplication %
5sed to remove C fit of centrifugal
oil filter nut.
*ote % E(isting tool can be used by reducing diameter to $4.? @ =.1 mm
&otor 3older
Draing *o.%
38 =9$1 ==
0pplication %
To hold rotor hile loosening bolt.
Piston &ing 3older
Draing *o.%
#9 1=DL #=
0pplication %
5sed for compressing the piston
rings hen assembly piston in the
cylinder bloc..
Drift
Draing *o.%
92 ?#=? 8?
0pplication %
To remove piston pin.
-earing &ace E(tractor
Draing *o.%
#9 ==DL =1
0pplication %
5sed for removing the loer bearing
race from PTG
Thrust plate alignerCholder
Draing *o.%
T,1=11188
0pplication %
To align the clutch hub concentricity
.r.to clutch heel! clutch housing
and thrust plate
#4 #8
)ran.shaft -earing E(tractor
Draing *o.%
#9 1==1 12
0pplication %
To remove bearing from cran.shaft
/utput Sproc.et 3older
Draing *o.%
#9 1=#= 4#
0pplication %
To hold the output sproc.et hile
removing sproc.et bolt
-earing Driver Set
Draing *o.%
#9 1=#= 81
0pplication %
)ommon bearing driver set for fitting
and r emovi ng bear i ngs f r om
cran.case.
)hassis
For. oil seal fitment punch
Draing *o.%
#9 ==2= =#
0pplication %
To fit for. oil seal on outer pipe
&ear Shoc. absorber adEuster
Draing *o.%
#9 ==D3 12
0pplication %
For adEusting the notch position of
&S0 to achieve hard or soft rear
suspension
For. Inner + /uter Tube E(tractor
Draing *o.%
92 ?#1= 14
0pplication %
5sed for removing front for. inner
tube from outer tube.
#9 #8
)arburettor and Fuel System )arburettor and Fuel System
Item Pulsar 18=cc
;a.e and Type 5cal,;i.uni -S$?
Identification *o. DL , 5#
Idling Speed 12== @1==
:) Scre setting $.4 @$ turns out
;ain Let 119.4
Let needle mar. 2D3L2$
*eedle Eet mar. ?$$;P,1
Let needle clip $nd from top
position
Pilot Let 19.4
Starter Eet Fi(ed type
Throttle valve Fi(ed type
)hoc. Lever $ stage ith push pull type mechanism
)arburettor
Specifications %
Fuel Tan.
I Turn the fuel tap to the off position.
I Disconnect the fuel pipe connections from the petrol coc..
I Disconnect the fuel indicator iring harness connection.
&emove %
I Side cover L3 and &3 by unloc.ing it ith .ey.
*ote % To remove the side covers L3 and &3! unloc. ith the .ey then
hold the front end of the cover and pull the front end out then pull the
cover in forard direction to remove it from the lug.
*otes %
&emove %
I Pull the cable from the cover L3 to unloc. the seat loc.
I Seat assembly
*ote % To remove the seat assembly hold the seat assembly and lift it
from the rear end and pull it bac..
&emove %
I 1 bolt 607.
I Fuel gauge iring connection.
I Drain pipe connection.
I Fuel pipe connection.
I Fuel tan. assembly
*ote % To remove the fuel tan. assembly from the chassis lift the fuel
tan. assembly by holding it at the rear end and pull it bac..
Fuel Tan. Inspection
&emove the hoses from the fuel tan.! and open the tan. cap. )hec.
to see if the breather pipe and ater drain pipe in the tan. for
clogging. If they are clogged! remove the tan. and drain it! and then
blo pipes free ith compressed air.
Fuel Tan. )leaning
Aarning % )lean the tan. in ell ventilated area! and ta.e care that
there are no smo.es or flame anyhere near the or.ing area. -ecause
of the danger of highly flammable li"uids! do not use gasoline or lo,
flash point solvents to clean the tan..
#? 2=
I &emove the fuel tan. and drain it.
I Pour some high,flash point solvent into the fuel tan. and sha.e
the tan. to remove dirt and fuel deposits.
I Pour the solvent out of the tan..
I Dry the tan. and the fuel tap ith compresses air.
I Install the fuel tan..
I -ol
I Strainer
I <as.et
I Selector -ody
I $ hole subber seal
*ote % Ahile installing the fuel tan. on chassis ma.e sure that the
dampers 607 on petrol tan. are mounted on the chassis.
Fuel Tan. )ap Dismantling
To unloc. the Fuel tan. cap! insert the .ey in the .ey slot and turn
it anticloc.ise direction and lift open the tan. cap.
0
*o remove the anti theft scre and then remove the allen bolts 607
and remove the fuel tan. cap assembly from the fuel tan.. Fitting is
the reverse procedure of dismantling. -ut ta.e care that the vent
hole is free from any foreign particles that may clog the hole. To
loc. the fuel tan. cap! Eust press the cap ithout .ey.
*otes %
Fuel )oc. &emoval
&emove %
I $ bolts 607
I Fuel coc. assembly from the fuel tan..
0
*ote %
I 0lays loosen the bol of the fuel coc. on vehicle itself
I )hec. the fuel coc. strainer for any brea.s or deterioration.
I If the fuel coc. strainer have any brea.s or are deteriorated!
they may allo dirt to reach the carburettor! causing poor
running. &eplace the strainer.
I )lean the fuel coc. strainer in a high,flash point solvent.
I Pour high flash point solvent through the coc. in all lever positions.
I Dry the tan. and the fuel coc. ith compressed air.
I Install the coc. in the tan..
21 2$
Aor.ing of )arburettor Aor.ing of )arburettor
Scre
4. Idling 0dEu
Scre
8. Fuel Inlet
unction
Starter )ircuit % )onstant :elocity )arburettor
)ut Section :ie
of ;i(ing )hamber
Pilot )ircuit % )onstant :elocity )arburettor
1. Pilot Let
$. Pilot /utlet 3ole
#. -utterfly :alve
2. :olume )ontrol
stment
0ir inlet
for cho.e
Toards
Engine Toards
Engine
1. Plunger )ap
$. Diaphragm )ap
#. Diaphragm Piston :alve
2. Piston :alve ith Let *eedle
4. Float )hamber
1. Plunger
$. ;i(ing )hamber
#. Starter Let
Toards
Engine
0ir Inlet
for pilot Eet
Function
The function of starter circuit is to provide rich air fuel mi(ture on starting C cold starting. 0t cold engine
condition the air is dense also the engine parts are cold enough this does not allo the petrol to
vapori'e properly this leads to starting trouble.
)onstruction
The Starter )ircuit consists of a starter Eet and a plunger. The starter Eet is used to meter the fuel and a
plunger that opens an air passage from the inlet of the carburettor 6underneath the diaphragm7 hich
passes the mi(ture to the mainfold.
Aor.ing
/n pulling the cho.e lever the plunger is lifted by a cable. This uncovers the fuel passage that leads to
the starter Eet! air inlet passage and the outlet passage toards the manifold. This creates enough
suction to dra fuel up from the bol into the mi(ing chamber 6belo the plunger7. 3ere the fuel is
mi(ed ith the air and the mi(ture is dran into the engine through the outlet passage.
F
The pilot circuit provides the air fuel mi(ture at idling hen not enough air is being dran through the
carburettor to cause the main circuit to operate.
)onstruction
The pilot circuit consists of pilot Eet! pilot air Eet and volume control scre. The pilot Eet meters the fuel
and the pilot air Eet meters the air "uantity. The volume control 6:)7 scre controls the amount of air fuel
mi(ture floing through the pilot outlet.
Aor.ing
0s the air enters the pilot air inlet the fuel is metered by pilot Eet and air "uantity is metered by pilot air
Eet. The atomi'ed C vapori'ed mi(ture is discharged through the pilot outlet. The pilot outlet is located on
the manifold side of the carburettor. Since the throttle valve is almost at fully closed position! air fuel
mi(ture is supplied mainly by pilot outlet only. 0ir fuel mi(ture volume is adEusted by volume control 6:)7
scre and mi(ture becomes lean hen volume control 6:)7 scre turned cloc.ise and rich hen it is
turned 0nticloc.ise direction.
2# 22
8. Throt
iaphragm
provides air fuel mi(ture by
on valve in direct proportion
emand. This assures the
'e + air velocity throughout
eration of the engine.
sts of Eet needle! needle Eet
assist in atomi'ation an air
Progression )ircuit % )onstant :elocity )arburettor
1. Pilot Let
$. Pilot /utlet 3ole
#. -ypass C
Progression 3oles
2. -utterfly :alve
4. :olume )ontrol
Scre
tle Lever
;ain )ircuit % )onstant :elocity )arburettor
1. Piston :alve
$. Piston :alve D
#. Let *eedle
2. *eedle Let
4. Let 3older
8. ;ain Let
Toards
Engine
0ir Inlet
for pilot Eet
Function
The ;ain )ircuit
lifting up the pist
to the engine
d correct venture
si
the mid range op
Toards
Engine
0ir Inlet
for main Eet
Function
The progression circuit provides the air C fuel mi(ture at small throttle opening hen pilot circuit is still
or.ing but unable to meet the engine demands on small throttle opening.
)onstruction
The progression circuit follos the path of pilot circuit and the construction is same as that of pilot
circuit.
Aor.ing
0s li.e pilot circuit the fuel is metered by pilot Eet and air volume is metered by pilot air Eet. This mi(ture
in vapori'ed C atomi'ed form is discharged through the bypass ports hen the butterfly valve is opened
from idling further.
)onstruction
This circuit consi
and main Eet. To
bleed circuit is incorporated in the main
metering system and it aids fuel vapori'ation
by introducing the air into the fuel before it
enters the main air stream.
The piston valve movement is controlled by spring and carburettor venture vacuum hich is generated
belo the piston valve diaphragm.
Aor.ing
Ahen the butterfly valve is opened and air flo through the venturi increases! the air pressure in the
venturi 6and the upper chamber7 decreases.
0s the atmospheric pressure in the bottom chamber is greater than the venturi pressure above the
diaphragm! the piston valve along ith Eet needle is pushed up and more air fuel mi(ture is dran into
the engine from main Eet through needle Eet into the main air stream.
Ahen the butterfly valve is closed! air flo through the venturi decreasesQ air pressure in the venturi
increases and approaches atmospheric pressure! + the spring pushes the piston valve along ith Eet
needle don.
24 28
Aor.ing of )arburettor Digital Tin Spar. Plug Ignition 6DTS,i7
, ):) spray
;aintenance
Ensure
I Lets
, 3oles are
, 3oles are
, Si'e as pe
in
cleaned by
&eplace
I Lets
lean. , Aorn out Eet
ot orn out. , Incorrect si'
specification.
ood condition.
Symptom )ause &emedy
Sudden drop in mileage + poer
lac. in mid range rpm
The igntion systems is or.ing only
in $nd map due to reed sitch is
stuc. in open circuit
&eplacement of &eed Sitch 0ssly
&o?+ &o?+ &on?t+ &on?t+
3andling
I 5se appr opr i at e scr e
drivers.
)leaning
I *ever use oversi'e scre
drivers.
I Do not over tighten the Eets
and scres.
I These ill damage the Eets
and their seats.
Pulsar DTSi is the first bi.e in the orld 6In small cc engine7 to have tin spar. ignition system.
1. The most obvious feature is the Tin Spar. Plug configuration o f
the Engine. The cylinder head has $ spar. plugs one on either
side. The spar. plugs are of the smae 3eat range 6)hampion
&<23)C-osh 5&#D) 6&esistive7 and have similar electrode gaps.
These also spar. simultaneuosly! This has been done to improve
the combustion process by reducing the time of combustion.
The end results are lo emissions! good fuel economy and good
driveability
$. To enable the spar.ing of the $ spar. plugs! a intelligent )DI
capable of handling this as developed. Further more! the
ignition timing has been optimised to give the best output from
engine 61=
=
-TD) R 14== rpm! $8
=
-TD) R #4== rpm7. To
I For cleaning alays use
carburettor cleaner li.e
, 0cetone
, )arbon Tetra chloride
, 0erosol
c
n
r
I Float is in g
I Float Pin
, Tip having no ear mar..
, Spring loaded pin is free
movement.
I *eedle Let
, *o ear at taper portion.
, )i rcl i p posi t i on i s i n
I *ever clean the carburettor
ith ater.
I Lets + air passages ill get
clogged due to sediments if
ater.
.
e Eet.
, Punctured! S"uee'ed and
distorted float.
, Aorn out tip.
, If spring loaded pin is
stic.y.
, *eedle orn out at taper
portion.
Troubleshooting %
enable optimum igntion timing for part throttle loads and full
throttle loads! there are separate igntion maps stored in the
memory of the )DI. These are activated depending on the
throttle opening and engine speed. The Digital )DI has a bit
;icroprocessor hich handles all these inputs and gives out the
re"uired and correct spar. advance. The intelligent )DI can be
easily indentified by $ green dots mar.ed on )DI case.
#. To enable sitching the re"uired igntion maps! a magnetically
operated need sitch is incorporated on the carburettor throttle
shaft and carburettor body. This is .non as T&I)S. Throttle
&esponsive Igntion )ontrol System.
2. These engines are capable of of reviving very high! "uite easily.
To .eep them mechanically safe! a engine rpm limiter has been
incorporated in the Digital )DI. This curtails the spar.s to the
spar. plugs thereby limiting the engine rpm ;a( upto ?=== and
thus .eeps the engine mechanically safe. There are $ spar.
plugs. L3 spar. plug fires at #4= rpm and then continues to
give spar. till at ?=== rpm of engine. The spar. is cut off from
L3 plug ?=== rpm to protect engine from e(cessively high
speed.
&3 spar. plug gives spar. at 94= rpm and then continues to
give till 8=== rpm of engine. If engine rpm e(ceeds 8=== rpm
then &3 plug is cut off. This is done to reduce combustion
noise created in engine.
4. This engine has been e(tensively tuned for more Poer and
Tor"ue.
8. The DTSi technology has enabled the Pulsar to meet $==8
norms ithout any Secondary air inEection devices.
specified groove.
I Piston valve
, *o ear mar..
, Diaphragm condition.
, Piston valve orn out.
Scoring mar.s.
, Diaphragm punctured.
I ;alfunctioning of the &eed sitch assly ill not harm the engine! neither it ill give any physical
indicators li.e starting trouble or misfiring.
3oever chec.ing of proper functioning of &eed Sitch 0ssly at PDI and at every service
is essential.
I Folloing symptoms may indicate as malfunctioning of &eed Sitch 0ssly as one of the cause.
/verhaul carburettor at every 1=!=== .ms. and insepct the parts.
29 28
Digital Tin Spar. Plug Ignition 6DTS,i7 Important Points to &emember
rpm.
I
I
I -lo pressuris
I
I
Item Pulsar 18=cc
;a.e
Identification *o
Type
Idling Speed
:) Scre Setting
;ain Let
Let needle mar.
*eedle Eet mar.
Let needle clip position
Pilot Let
Starter Let
Throttle valve
)hoc. lever
5cal,;i.uni -S $8
DL , 5#
): Type
12==@1==
$.4@$ turns out
119.4
2D3L2$
?$$;P,1
$ from top
19.4
Fi(ed type
Fi(ed type
$ stage ith push
pull type mechanism
)ustomer Eductaion Tips %
I Ahile starting the engine in any case throttle should not be rotated more. Even if this happens!
engine ill start! but the engine rpm ill shoot uo too much 6due to too high throttle opening7
I Ahenever there is a sudden subtantial drop in mileage! customer should report to -aEaE 0utoGs
0uthorised Service )entres.
)/ H )hec.ing and Tune 5p 6To ensure betten mileage7 %
)hec. folloing before )/ H chec.ing C Tune up ,
I 0ir filter connections! inta.e manifold! insulator fitment! connecting tube fitment.
I Spar. Plug gap 6=.9 to =.8 mm7
I 0ll pipes and connections of fuel system for any crac.s! lea.age! pluc.ing! pinching and loose
connections.
I Ensure Tappet )learance %
Inlet % =.=4 mm
E(haust % =.1 mm
I Ensure compression pressure inside the cylinder 68 to 1= BgCcm
$
7
I )hec. the ignition timing 61=
=
-TD) at 14== rpm and $8
=
-TD) at #4== rpm7
)/ H chec.ing and carburettor :) scre setting
I Start and arm up the engine
I The oil temperature should be above 8=
=
). This can be achieved by running vehicle in top gear
at the speed of minimum 2= Bmph for 4 O 8 Bms.
I 0dEust the engine speed to 12== @ 1== rpm ith idling adEustment scre of carburettor.
I 0dEust the )/ ith the :) scre. It should be in beteen 1.94 to $.$4 H
I )onfirm the engine speed hether it is ithin 12== @ 1== rpm or not. Ahen setting Idle )/ H!
idle rpm and :)S have to be adEusted together to achieve $ H )/ and 12== @ 1== engine
I &emove the P0llen 3ead <rub ScreG before removing the PSleeve Spar. PlugG.
I -efore fitting the PSleeve Spar. PlugG apply thin layer of molybdenum disulphite
grease on the entry chamfers for the P/G rings for smooth sliding inside.
I Do not apply li"uid gas.et at location 607 hich may bloc. the lubrication
passage.
A
:alve timing
I Ensure the sproc.et mar.s 607 are aligned hori'ontally ith cylinder head top
machined face and the piston is at TD).
A
A
Secure the P)am )hain Sproc.etG in the special tool firmly and then tighten the
sproc.et allen bolt 607.
Ensure that the P/G mar. on asher alays faces outards hen tightening the
allen bolt.
A
PInlet &oc.er 0rm ShaftG is longer in length.
I &oc.er arm has $= &ollers inside the outer cage.
I Doesn>t have inner cage.
I Ta.e utmost care hile dismantling. &ollers should not fall inside engine.
I 0pply grease for fi(ing needle rollers inside roc.er arm.
Ahile removing C refitting of piston pin circlip! cover the cran.case chamber
ith clean cotton cloth to avoid falling of circlip inside the engine.
ed air to oil passages in reverse direction to that of oil flo.
2? 4=
Important Points to &emember Important Points to &emember
I Ahen splitting cr
first.
I &emove long bolt
I Ensure proper fit
I S
I T
I E
8
2
8
9 8
1=
0elleville
1asher
Plain
1asher
Clutch
-ub
Ensure
I Ahile assembling hub clutch place plain asher first and then place belleville
asher. )oncave face should be upards i.e. toard technician.
I Load the assly balancer idler gear ith $ teeths from either side using the
special tool.
I 0fter placing -elleville! fit clutch plate ith 28 friction material cubs 607 ith
$
9 more I.D.
9
8 I 2 *os. of clutch plates ith #8 friction material cubs 6-7 alternatively along ith
1$
steel plates.
I Ta.e the P0ssembly -alancer Idler <earG along ith Thrust Aasher hich is pre,
loaded and is held in special tool! Slide don the special tool ith P<earG to engage
the bottom half of the P0ssembly -alalncer Idler <earG ith the P-ody -alancer <ear
0ssemblyG
4 ? 1
12
8 18
# 19 1#
11
14
I Fit top clutch plate ith 2= friction material cubs 6)7.
I Input shaft has special nut.
I Thic. spacer asher tapered I.D. it should be placed on tapped portion of
Input Shaft.
I Input Shaft has left hand threads.
I Fit PThrust asherG on the other side.
I /n assembly of P0ssembly -alancer Idler <earG the itchedCDot mar. of Q-ody
-alancer <ear 0ssemblyG should match ith the line mar. on the P)ran.caseG.
3olding the P0ssembly -alancer <earG in special tool no slide inside the P)lutch
3ousingG so that the P)lutch 3ousingG smoothly engages ith the top half of
P0ssembly -alancer Idler <earG.
I &emove the special tool gently.
I Fit $ doels and 0ssly -alancer Idler <ear )over
I Ensure perfect mar.ing of gear mar.s ith respect to cran.case mar..
an.case alays remove 1 long bolt fitted from clutch side
immediately after removal of long bolt clutch side.
ment of bolt ith copper asher to avoid oil lea.age.
hifter for. is having a roller. These roller are one side tappered inner dia.
aper portion of roller should face toards for. gear shift.
nsure damper rubber fitment on magneto side guide plate.
I Fit primary gear drive 607.
I The mar. teeth of the primary gear should match ith the line mar. on the cGcase.
This indicated that the piston is at TD) position. This procedure should be carried
before fitting the P)lutch 3ousingG + this position should not be disturbed hile
fitting the P)lutch 3ousingG.
41 4$
&emoval of Engine from
Frame
Frame
4#
&ecommended /il <rade and Fty
<rade S0E $=A4= of 0PI PS<G @ L0S/ P;0G
Fuantity Drain + &efill 1=== ml.
Engine /verhaul 11== ml.
&emoval of Engine from Frame %
&emove %
I Put /FF the fuel coc.
I Side panel L3
I Side panel &3
&emove %
I $ nuts 6-7 for silencer flange
*ote % 0lays remove the flange mounting first and then rear mounting
to avoid misalignment of studs.
&emove %
I Seat assembly by pulling the cable for seat loc. release located
on &3 side.
I Disconnect the negative terminal of the battery.
I Disconnect the iring harness soc.et for fuel level Indicator.
I Fuel pipe connections and moisture drain pipe from fuel tan..
I Disconnect stator plate harness
I Disconnect neutral sitch coupler
&emove %
I Drain bolt 607 and drain out the oil from engine.
I &efit the drain bolt ith gas.et + tighten it.
&emove %
I -olt 607 of silencer brac.et mounted on pillion &3 side footstep.
I Silencer assembly.
&emove %
I Starter motor connection 607
0
&emove %
0
I -olt 607
I Petrol tan. assembly.
&emove %
I -olts 607
I <ear shift pedal bolt 6-7
-
0
I Drive sproc.et cover L3.
5sing Special Tool % Sproc.et
3older , #9 1=#= 4#
0
&emove %
I -olts 607
I Plate drive sproc.et
I Drive sproc.et along ith
- the chain.
I *eutral sitch coupler 6-7.
&emove %
I P): pipe from breather
&emove %
I Disconnect the reed sitch coupler.
I Spar. plug cap L3
&emove %
I 0ir filter mounting bolts to facilitate the removal of carburettor
ith reed sitch.
I )lamps of carburettor and disconnect carburettor along ith
insulator and dismantle cables from it.
I -rac.et bolts securing clutch cable on clutch cover.
I Spar. plug cap &3
42
Frame
Dismantling
Engine
&emove %
I Ahile removing engine foundation bolts! first remove the topmost bolt
and then go don progressively.
*ote % -olts 607 holding the engine to the chassis. 62 bolts of 1$ mm
and 1 bolt needs deep soc.et for removing it7.
Engine Top End Dismantling %
&emove %
I Pull out the cover on the spar. plug cap &3 and the spar.
plug cap itself
I 5sing a plug spanner! loosen and remove the spar. plug &3
I Loosen and unscre the allen head grub scre of the sleeve
spar. plug
*ote % Arap a piece of cloth around the protruding edge of the
sleeve spar. plug and using a plier! pull out the sleeve.
&emove %
I There are $ P/G rings fitted in the cylinder head! one on the
cam chain all and the other near the spar. plug threading
I 5sing a thin! sharp pointed tool pierce the P/G rings and
remove them. 6If re"uired7
*ote % &emove these only if the P/G ring protrusim in the bore is
non,e(istant 6hich means that the P/G ring has set and it has lost its
compression or sealing ability.7
I Lift up the engine off the chassis and place it on engine stand.
0
*ote % 0fter disconnecting all the sub assemblies and control cables
from the engine lift up the engine and remove it from &3S of the -
vehicle.
&emove %
I Loosen bolt 607 and unscre chain tensioner plunger
I )am chain tensioner assembly $ bolts 6-7
I )am chain tensioner assembly
&emove %
I -oth tappet caps
I ;agneto cover cap seal and rotate cran.shaft to get piston at
TD).
I Ensure both tappets are at free state 6i.e. at the end of
compression stro.e7
&emove %
I $ dummy plug
I $ gas.ets
44 48
Dismantling
Engine
Dismantling
Engine
&emove %
I )ylinder head securing head cover $ bolts 607
I )ylinder head securing head cover 2 bolts 6-7
-
)
I )ylinder head securing head cover 2 domed cap nuts 6)7
I 2 copper plated steel ashers
0 *ote % Improper tightening se"uence may cause arpage in cylinder
head cover and it can be damaged permanently.
&emove %
I Piston pin loc. L3 + &3 side
*ote % Place a piece of clean cloth above hallo portion of cran.case
to arrest piston pin circlip if it falls during fitment.
&emove %
I )ylinder head cover complete
I )am shaft cap
5sing Special Tool %
Drift 92 ?#=? 8?
&emove %
I &emove piston pin
I Piston assembly
5sing Special Tool % Sproc.et )atcher , #91= D3 #8
5sing Sp. Tool % Sproc.et
)atcher , #91= D3 #8
&emove %
I 0llen bolt
I Spacer
I )am sproc.et
I )ollar
)aution % Ahen tapping the drift for removal of piston pin! confirm that
the connecting rod is held firmly against the direction of tapping to
avoid damage to big end bearing connecting rod of cran.shaft.
&emove %
I -loc. gas.et
I $ doels 607
0
I )am shaft assly
Sprco.et )atcher
*ote % Tie the cam chain firmly using soft copper ireCthread firmly to
*ote % 3old the cam chain up right using soft copper ire or thread.
Do not use cotton aste for holding the cam chain.
avoid slipping don into cran.case.
&emove %
I )ylinder head assembly
I $ doels
I <as.et cylinder head
&emove %
I *on tensioner side chain guide
I )ylinder bloc. assembly
Engine L3 6;agneto Side7 %
0
&emove %
I 4 bolts 607
&emove %
I )over magneto.
49 48
5sing Special Tool % &otor
3older , 38 =9$1 ==
I 3old the rotor assembly
0
&emove %
I &otor bolt 607
I Aasher
&emove %
0
I # Scre 607
I <uide starter assembly along ith oil seal.
)aution % Ensure that the oodruff .ey of rotor is removed prior to the
removal of guide starter assembly. The lips of magneto oil seal housed
in guide starter assembly ill get damaged if not done so.
5sing Special Tool , &otor
Puller ith butt pin % #9 1=DL #$
&emove %
I &otor assembly
I Aoodruff .ey.
Engine &3 % 6)lutch Side7
&emove %
I Bic. starter bolt
I Bic. starter
*ote % 3olding the gear complete starter clutch rotate the rotor
and pull it out in 0nticloc.ise direction to prevent rollers and
springs coming out. &otor puller has left hand threads.
Aarning %
I These components remain hot for a long time especially if removed
from a hot engine. Aear suitable hand protection to prevent burns.
I &otor puller has left hand threads
&emove %
I <as.et
I -olt 607
I Plate starter clutch gear return 6-7
0
I <ear starter clutch
-
&emove %
I 1 scre , 607
I Starter motor cover
0
&emove
)
I 1$ )lutch cover bolts 6-7
I -rac.et clutch cable 6)7
-
I )lutch cover
*ote % The rod clutch lifter! plunger oil! plate plunger oil and spring
Eoint may fall out of their respective places into the oil collection tray. If
so! ensure that these are collected + accounted for before proceeding.
&emove %
I )ollar 607
I Shaft
I <ear comp. starter counter assly
0
&emove %
I # bolts 607
-
I /il pump assembly
I $ Doels
I )lutch cover gas.et
I Starter ;otor 6-7
0
Aarning % The oil pump may be hot! hence use suitable hand
protection. 0lso! since the oil pump houses the oil strainer C mesh also!
it may retain some "uantity of oil. This oil may be hot. 3ence proper
care should be ta.en to drain it.
*ote % The oil hich is in the oil pump housing should also be drained
out into the oil drain tray for measuring drained oil.
4? 8=
5sing Special Tool % Primary
<ear 3older #9 1=DL $8
0 &emove %
I # phillips head scres 607
I )entrifugal oil filter cover
I <as.et
Aarning % These parts may be hot! if removed from a hot engine. 5se
gloves for protection.
&emove %
0
I # 0ssly balancer Idler gear cover bolts 607
I )over
I Aasher
I $ Doel
&emove %
I )lutch housing
*ote % Some amount of oil is trapped in cover and body of centrifugal
oil filter! this oil should be drained into the oil tray. *ote % For ease in removal of clutch house insert special tool
6P. *o.,#9 1=DL 8#7 in 0ssly -alancer Idler <ear.
5sing Special Tool %
Special *ut Puller #9 1=DL2#
Primary <ear 3older #91= DL$8
&emove %
I )entrifugal oil filter special
nut
I -elleville asher
I -ody centrifugal oil filter
assly
&emove %
I 0ssly -al. idler gear
I $ Aasher
&emove %
I -earing ith plunger
0
5sing Special Tool % Special
*ut Puller #9 1=DL 2#
Primary <ear 3older #91=DL$8
&emove %
I Input shaft special nut
I -elleville asher
I )lutch assly comp
I Spacer
*ote % The e(isting Special *ut Puller #9 1=DL 2# can be used by
grinding the tool /D to $4.? @ =.1 mm
&emove %
I -olt 607
I Loc.ing plate
I -ody balancer gear assly
&emove %
I Primary gear
I S"uare .ey
*ote % Ta.e case that s"uare .ey does not fall inside the cran.case
hollo portion hile removing.
&emove %
I )am chain
I )am chain sproc.et
I Parallel Pin
Dia. T $4.?@=.1
81 8$
&emove %
I <ear change lever
&emove %
I -olt 6-7 on L3 side cran.case 6;agneto side7
-
&emove %
I Spring
I 0llen bolt 607
I <uide gear
I Spacer
I Parallel Pin
&emove %
I 8 bolts on L3 side cran.case
I Split the )ran.case halves.
*ote % -efore separating cran.case halves confirm that all the
cran.case Eoining bolts are removed and the sproc.et cam drive ith
parallel pin on cran.shaft assembly is removed.
*ote % )hec. and inspect the drum change arm stopper for free
movement alays.
5sing Bic. starter lever
&emove %
I Aasher
I Bic. shaft assly comp
*ote % &otate the .ic. starter lever in 0nticloc.ise direction for
removing the .ic. shaft assly.
&emove %
I -olt 607
I Loc.ing Plate
0
I Bic. idler gear
&emove %
I Bic. spring
I $ Shafts 607 + 6-7 of gear shifter for..
I # for. shifts 61 small for input $ big for output shaft.
I # &ollers
I Drum change
0
&emove %
I The entire gear bo( assembly together
Engine )entral Part %
&emove %
I -olt 607 on &3 side cran.case 6)lutch side7
&emove %
I )ran.case gas.et
I $ doels
I )ran.shaft assly
0
8# 82

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