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Bajaj Pulsar 150 DTS-i Maintenance Manual

Summary of Pulsar 150 DTS-i

  • Page 1

    Dealer development center, pune pulsar dts-i 150/180 training notes contents i read ..... I learn 1 identification salient features 3 technical specifications frequently asked questions (faq’s) read before your ride 5 9 11 2 i check ..... I maintain 15 pdi sop** pdi checklist 16 periodic maintenance...

  • Page 2

    Dealer development center, pune pulsar dts-i 150/180 training notes dealer development center, pune 1 pulsar dts-i 150/180 training notes • identification • silent features • technical specifications • frequently asked questions (faq’s) • read before you ride i read ..... I learn frame & suspension ...

  • Page 3

    Identification data dealer development center, pune 2 pulsar dts-i 150/180 training notes dealer development center, pune 3 pulsar dts-i 150/180 training notes the engine and frame serial numbers are used to register the vehicles. They are the only means of identifying your particular vehicle from t...

  • Page 4

    Dealer development center, pune 4 pulsar dts-i 150/180 training notes dealer development center, pune 5 pulsar dts-i 150/180 training notes technical specifications (pulsar 150cc) salient features features : • lcd speedo console • self cancelling indicators • thicker front fork & swing arm with need...

  • Page 5

    Dealer development center, pune 6 pulsar dts-i 150/180 training notes dealer development center, pune 7 pulsar dts-i 150/180 training notes technical specifications (pulsar 180cc) technical specifications (pulsar 150cc) engine and transmission type : four stroke dts-i, natural air cooled. No. Of cyl...

  • Page 6

    Features pulsar dts-i 180 cc pulsar dts-i 150 cc cubic capacity 178.60 cc 149.01 cc horse power 17.02 ps 14.09 ps torque 14.22 nm 12.76 dc ignition yes yes starting mechanism self start only self & kick start tubeless tyre yes no intelligent digital cdi yes yes exhaustec yes yes controlled lubricati...

  • Page 7

    Dealer development center, pune 10 pulsar dts-i 150/180 training notes frequently asked questions (faq’s) dealer development center, pune 11 pulsar dts-i 150/180 training notes read before you ride function to show display & analogue display of..... • warning indicators : a digital display through i...

  • Page 8

    Tyre pressure - 150 cc 2 front : 1.75 kg/cm (25.0 psi) 2 rear solo : 2.00 kg/cm (28.4 psi) 2 rear pillion : 2.25 kg/cm (32.0 psi) dealer development center, pune 12 pulsar dts-i 150/180 training notes dealer development center, pune 13 pulsar dts-i 150/180 training notes read before you ride read be...

  • Page 9

    Dealer development center, pune 14 pulsar dts-i 150/180 training notes dealer development center, pune 15 pulsar dts-i 150/180 training notes • pdi sop** • pdi checklist • periodic maintenance & lubrication • periodic service sop** • service wise part kit • scheduled maintenance** • standard checkin...

  • Page 10

    Suspension pdi check list pdi check list dealer’s name dealer’s code date of pdi please ensure that following checks are carried out during pdi before delivery of vehicle. Pdi done by frame no. Engine no. Dealer development center, pune 16 pulsar dts-i 150/180 training notes dealer development cente...

  • Page 11

    Periodic maintenance & lubrication chart periodic maintenance & lubrication chart dealer development center, pune 18 pulsar dts-i 150/180 training notes dealer development center, pune 19 pulsar dts-i 150/180 training notes 1. Servicing 3 3 3 3 3 2. Engine idling speed / co% c,a c,a c,a c,a check & ...

  • Page 12

    Service wise part kit service wise part kit dealer development center, pune 20 pulsar dts-i 150/180 training notes dealer development center, pune 21 pulsar dts-i 150/180 training notes notes : 1000 ml nd 2 free rd 3 free type of service qty nil 1000 ml 1 th 4 free st 1 paid 240 days 75 days from th...

  • Page 13

    Special tools special tools dealer development center, pune 22 pulsar dts-i 150/180 training notes dealer development center, pune 23 pulsar dts-i 150/180 training notes details of exclusive special tool for carrying out repairs / overhauls, 5 new special tools are identified for pulsar 180 cc. Thes...

  • Page 14

    Dealer development center, pune 24 pulsar dts-i 150/180 training notes dealer development center, pune 25 pulsar dts-i 150/180 training notes • fuel supply system** • dismantling/assembling fuel cock** • working of various cv carburettor circuits** • dos & don’ts** • carburettor specifications • tun...

  • Page 15

    Carburettor specifications dealer development center, pune 26 pulsar dts-i 150/180 training notes dealer development center, pune 27 pulsar dts-i 150/180 training notes carburettor specifications of pulsar 150 cc : make and type ucal-mikuni bs26, cv type identification no. Dh - u3 idling speed 1400 ...

  • Page 16

    Dealer development center, pune 28 pulsar dts-i 150/180 training notes dealer development center, pune 29 pulsar dts-i 150/180 training notes • importance points to remember during engine overhauling** • removal of engine from frame** • dismantling of engine** • dismantling engine sub assembly** • p...

  • Page 17

    Service data (for 150 cc & 180 cc) dealer development center, pune 30 pulsar dts-i 150/180 training notes dealer development center, pune 31 pulsar dts-i 150/180 training notes service data (for 150 cc & 180 cc) compression pressure 6.0~10.0 2 kg/cm 11.0~13.0 2 kg/cm standard limit 5.0~10.0 2 kg/cm ...

  • Page 18

    Dealer development center, pune 32 pulsar dts-i 150/180 training notes dealer development center, pune 33 pulsar dts-i 150/180 training notes shift drum groove width 7.5 7.5 standard limit 7.65 7.35 service limit pulsar 150 cc pulsar 180 cc crankshaft run out 0.02 max 0.02 max standard limit 0.05 0....

  • Page 19

    Dealer development center, pune 34 pulsar dts-i 150/180 training notes tightening torque (for 150 cc & 180 cc) clutch nut (lh threads) 7.0 kg.M camshaft sprocket allen bolt 1.4 kg.M (loctite 243) 4.5 kg.M rotor mounting bolt starter motor mtg. Bolts 1.1 kg.M kick guide allen bolts 1.2 kg.M drain bol...

  • Page 20

    Dealer development center, pune 36 pulsar dts-i 150/180 training notes dos & don’ts • don't reuse 'o' rings, gaskets, oil seals, circlip locks as they use their strength & properties, once they are opened. • don't adjust spark plug electrode gap by hacksaw blade or with judgement of eye otherwise it...

  • Page 21

    Dealer development center, pune 38 pulsar dts-i 150/180 training notes controlled lubrication system the key changes for controlled lubrication with closed clutch are as mentioned below - • separate oil passage in cylinder block & crankcase. Both passages are connected by banjo & pipe. - passage in ...

  • Page 22

    Service data (for 150 cc & 180 cc) dealer development center, pune 40 pulsar dts-i 150/180 training notes dealer development center, pune 41 pulsar dts-i 150/180 training notes service data (for 150 cc & 180 cc) brake panel cam hole diameter 12.0~12.03 14.0~14.03 standard limit 12.15 14.15 service l...

  • Page 23

    2.0 ~ 2.2 (150 cc photo not illustrated) 3.5 5.0 torque value in kg.M pulsar 150 cc pulsar 180 cc 8.0 ~ 10.0 8.0 ~ 10.0 torque value in kg.M pulsar 150 cc pulsar 180 cc 0.5 0.5 torque value in kg.M pulsar 150 cc pulsar 180 cc 3.0 ~ 4.0 3.0 ~ 4.0 torque value in kg.M pulsar 150 cc pulsar 180 cc 1.8 ~...

  • Page 24

    Dealer development center, pune 44 pulsar dts-i 150/180 training notes dealer development center, pune 45 pulsar dts-i 150/180 training notes tubeless tyre & its puncture repair procedure (applicable for pulsar dts-i 180 cc only) function 1. Supporting vehicle weight. 2. Transferring traction and br...

  • Page 25

    Dealer development center, pune 46 pulsar dts-i 150/180 training notes dealer development center, pune 47 pulsar dts-i 150/180 training notes tubeless tyre & its puncture repair procedure (applicable for pulsar dts-i 180 cc only) tubeless tyre & its puncture repair procedure (applicable for pulsar d...

  • Page 26

    Dealer development center, pune 48 pulsar dts-i 150/180 training notes dealer development center, pune 49 pulsar dts-i 150/180 training notes tubeless tyre & its puncture repair procedure (applicable for pulsar dts-i 180 cc only) why inflation pressure is important? 1. Air inside the tyre sustains t...

  • Page 27

    Dealer development center, pune 50 pulsar dts-i 150/180 training notes dealer development center, pune 51 pulsar dts-i 150/180 training notes sop for tubeless tyre removal (applicable for pulsar dts-i 180 cc only) sop for fitment of tyre : • place the tyre on any used old tyre and apply soap water o...

  • Page 28

    Dealer development center, pune 52 pulsar dts-i 150/180 training notes dealer development center, pune 53 pulsar dts-i 150/180 training notes dismantling & assembling front fork (applicable for pulsar dts-i 180 cc only) dismantling & assembling front fork (applicable for pulsar dts-i 180 cc only) lo...

  • Page 29

    Dealer development center, pune 54 pulsar dts-i 150/180 training notes dealer development center, pune 55 pulsar dts-i 150/180 training notes dismantling & assembling front fork (applicable for pulsar dts-i 180 cc only) dismantling & assembling front fork (applicable for pulsar dts-i 180 cc only) fi...

  • Page 30

    Dealer development center, pune 56 pulsar dts-i 150/180 training notes dealer development center, pune 57 pulsar dts-i 150/180 training notes • digital twin spark ignition (dts-i) • dc ignition system • maintenance electrical • dos & don’ts • electrical checking procedure electricals information on ...

  • Page 31

    Dealer development center, pune 58 pulsar dts-i 150/180 training notes dts-i ignition & dc ignition system 1. The most obvious feature is the twin spark plug configuration of the engine. The cylinder head has 2 spark plugs one on either side. The spark plugs are of the same heat range (champion rg4h...

  • Page 32

    Dealer development center, pune 60 pulsar dts-i 150/180 training notes happens, the chemical reactions within the battery are affected and results in loss of capacity. Mostly the causes of sulphation are as under : a. Undercharging. B. Standing in a partially or completely discharge condition for lo...

  • Page 33

    Dealer development center, pune 62 pulsar dts-i 150/180 training notes maintenance - electrical pickup coil resistance : meter +ve meter -ve reading range connections 2 k w white/red black/yellow 215 + 20 ohm battery charging coil : meter +ve meter -ve reading range 200 w blue/white blue/white 0.9~1...

  • Page 34

    Dealer development center, pune 64 pulsar dts-i 150/180 training notes maintenance - electrical battery dc charging current : (use fully charged battery ensuring battery voltage = 12.5 + 0.3 v before measuring) to measure the dc charging current, set the meter at 20adc. Connect meter+ve lead to whit...

  • Page 35

    Dealer development center, pune 66 pulsar dts-i 150/180 training notes measuring & testing equipment : dc clamp meter horn 200 dc a meter range 2.2 amps encircle clamp meter jaws around brown wire of horn connections standard value sop : • encircle clamp meter jaws around brown wire of horn. • press...

  • Page 36

    Dealer development center, pune 68 pulsar dts-i 150/180 training notes dos & don’ts battery dos 3 • always install recommended capacity of battery on the bike. • secure battery firmly in its box / cage. • always keep battery terminals clean & in firmly tightened condition • connect red colour wire o...

  • Page 37

    Dealer development center, pune 70 pulsar dts-i 150/180 training notes dos & don’ts switches • after washing the vehicle ensure to apply dry air on switches before operation. • always ensure that grommets provided on clutch switch, front brake switch and rear brake switch are intact. • always apply ...

  • Page 38

    Dealer development center, pune 72 pulsar dts-i 150/180 training notes electrical circuit diagrams battery charging circuit dealer development center, pune 73 pulsar dts-i 150/180 training notes electrical circuit diagrams lighting circuit in st ru me nt c lu st er r w/r w w/r co il pu ls in g m a g...

  • Page 39

    Dealer development center, pune 74 pulsar dts-i 150/180 training notes electrical circuit diagrams starter motor circuit w/r d c c .D .I. A s s y. Lg lg o f f o n b/y w w b r n e u t r a l s w it c h ig nit io n sw it ch e a r t h f r a m e le v e r a s s y c lu t c h s w it c h y /g b /y y /g b/y l...

  • Page 40

    O brake shoe cleaning - don’t inhale brake shoe lining dust. The dust could be cancerous. O battery acid handling - use hand gloves. - wear apron. - wear safety goggle - avoid contact of battery acid with skin - use plastic trays for keeping batteries while charging. - avoid spillage of battery acid...

  • Page 41

    Dealer development center, pune 78 pulsar dts-i 150/180 training notes workshop safety o hand tools - do not use worn out hand tools. O calibration of workshop equipment - calibrate all workshop and m & t equipment once in a year. O avoid direct body contact with petrol, kerosene. Caution : prolonge...