Pulsar DTSi UG III Workshop Manual 3

Dismantling - Engine Sub Assemblies Dismantling - Engine Sub Assemblies
Dismantling of Oil Seals and Bearings : Remove :

• Bolt (A)
Crankcase Clutch Side : • Bearing stopper
Using Special Tool : Using Special Tool : Bearing
Bearing Driver set - 37 1030 61 Driver Set - 37 10BA 61
Remove : Remove:
• Bearing (A) for input shaft A
• Bearing for gear drum from
assembly from crankcase RH RH crankcase
A Dismantling of Subassemblies :
B Using Special Tool : Bearing C Magneto Cover
Extractor - 37 10DJ 77 B
A Remove :
Remove: • 2 Phillips head screws (A) of pulsar coil (E) mounting.
• Bearing (B) for output shaft E • Bolts (B) of stator assembly.
assembly from crankcase RH • 1 Phillips head screw (C) of stopper.
D
• Stator coil assembly (D) along with pulsar coil.
Cylinder Head Cover

Crankcase Magneto Side :
Using Sp. Tool Rocker Pin
Remove : remover 37 10DH 35
B
• Oil seal A
Remove :
A Using Special Tool : Bearing • Rocker shaft (A)
Extractor - 37 10DJ 77 • Rocker arm
C
Remove : • Set of washers (1 wave and
• Bearing (A) for output shaft 2 plane) (B)
assembly from crankcase LH • Rollers 20 nos. (C)
Note : Similarly remove the other Rocker shaft & Rocker Arm from
head over
Using Special Tool : Bearing
Extractor - 37 10DJ 77
A Top End :
Remove : B
A
• Bearing (A) for body balancer Cylinder Head
D
gear bearing from crankcase Using Sp. Tool Valve Spring Compressor 37 1031 07 & Adapter
LH 37 10DJ 78
C
Remove :
• 2 Cotter valve (A)
F
• Valve spring retainer (B)
Using Special Tool : Bearing • Springs inner (D)
Extractor - 37 10DJ 76 E
• Spring outer (C)
Remove :
A • Valve from below (E)
• Bearing (A) for input shaft
assembly from crankcase LH • Washer (F)
• Valve steam seal (G)
Similarly carry out the same
procedure to dismantle the other
valve from the cylinder head
assembly.
65 66
Pulsar DTS-i UG-III-180cc Training Notes Dealer Development Center Dealer Development Center Pulsar DTS-i UG-III-180cc Training Notes
Dismantling - Engine Sub Assemblies Dismantling - Engine Sub Assemblies
A Chain Tensioner Assembly Bearing Removal from Assly Balancer Idler Gear Cover and
B
Remove : Crankcase RH
C
D • Circlip (A) from the body (I) Using Sp. Tool : Bearing Extractor - 37 10CD 30
E • Cap (B) along with screw internal and screw external (C) Remove :
F
• Spring (D) • Needle roller bearing from RH crankcase.
I • Thrust washer (E)
H
G • ‘O' ring (F)
• Bolt (G) and ‘O’ ring (H)
Assembly Balancer Idler Gear
6
Clutch Assembly A C D Remove :
2
7
4 Remove : • Thrust washers (A)
6
6
• 4 bolts (A) • Circlip (B) from any one side of the gear
7 8
12 • Holder clutch (B) • Scissor gear (C)
10
5 9 • 4 springs (C) • Torsion Spring (D)

1
14
6 16 • Clutch center (D) Similarly carry out the same procedure on other side of the gear
3 17 13 B D E CB A
11
15
• Plain washer to dismantle the idler gear completely.
• Bellivellie washer
• Disc clutch friction (E) (Qty. 6 for 180cc / Qty. 5 for 150 cc)
• Plate clutch (F) Gear Complete Starter Counter Assembly
• Plate clutch pressure (G) (Wheel clutch) • Place the gear comp. starter counter assly on the arbor press
as shown in the figure.
• Clutch housing
• Using Bearing driver set (P. No. 37 1030 61)
• Thrust washer - conical from inner ID
Remove :
• Needle roller bearing
Oil Pump
Remove :
• Clip (A) Input Shaft Assembly
C
• Oil strainer element (B) with • 1st gear is integral with the shaft (A)
B C EF I K
B ‘O’ ring (C)
• Remove thrust washer (B) and slide out gear 2nd drive (C)
A
• Remove gear 5th drive (D) and collect the splined washer (E)
behind it.
• Remove circlip (F) and remove gear 3rd drive (G)
Kick Shaft Assembly
• Remove circlip (H) and collect the splined washer (I)
H Remove : D G H J A • Remove gear 4th (J) and collect the thrust washer (K) behind it.
A E G B • Thrust washer (A)
• Washer thrust (B) L M H FE CB A Output Shaft Assembly
• Circlip (C) & thrust washer (D) • There are no integral gears on output shaft.
• Spring kick starter ratchet (E) • Remove thrust washer (A) and slide off the gear1st driven (B) and
I • Ratchet kick starter (F) collect the steel bush (1st driven gear is mounted on steel bush (C)
with shoulder ring
C D F • Circlip (G)
• Slide off the gear 4th driven (D).
• Washer (H)
• Remove circlip (E) and spline washer (F). Remove the gear 3rd
• Pinion complete kick starter (I)
driven (G).
rd
• Collect the thrust washer (H) behind the 3 gear on output shaft (I)
JK N I G D
• Remove circlip (J) and collect the washer (K)
• Remove gear 2nd driven (L) mounted on bush (N) with shoulder ring
• Slide out gear 5th driven (M)
67 68
Dismantling - Engine Sub Assemblies
Crankcase Magneto Side
Remove :
• 3 Screws (A)
• Guide starter assembly (B) on which oil seal is mounted.
C
• Oil seal (C)
A D
• Damper (D)
B
Clutch Cover
G A Remove :
B
• Parallel Pin (A)
• Clutch shaft release completely (B) by slightly rotating it so,
• Rack (C)
H • Plunger oil (D)
• Plate plunger oil (E)
• Spring joint ‘A’ (F)
C
• Oil filler plug (G)
• Oil seal kick shaft (H)
K • Wire clip (I)
F • Oil inspection window
J E
L D • Flanged bolt (8 Nos.) (J)
• Set of damper (K)
• Set of plate (L)
• Grommet (M)
Camshaft Dismantling
Using Special Tool :
Bearing Pullers :
3710DJ 74 for Bearing 39227020
A
B 3710DJ75 for Bearing 39148520
C Remove :
F
• Bigger Bearing using sp. tool
from camshaft assembly(A)
E
• Collar de-comp (B)
D
• Decompression unit (C)
• Small Bearing (E)
• Lock washer (D)
• Parallel pin (F)
Gear Starter Clutch

Remove :
• Place the gear starter clutch on arbor press as shown in photo
• Using Bearing Driver Set (P. No.: 37 1030 61)
Remove :
• Needle roller bearing
69 70
Parts Inspection Parameters Parts Inspection Parameters
Spark Plug : Crankshaft :
• Type / Heat value - RG 4 HC/Bosh UR3DC (Resistive) • Big end axial/radial play : As per Service data.
• Gap between electrodes - 0.7 to 0.8 mm • Runout : As per Service data.
• Electrode condition - No errosion • Threading condition : Ok / No damages.
• Colour at the electrodes tip - Brownish • Key way condition : Ok / No damages.
• Threads of reach portion - Ok / No damage • Big end bearing : Free rotation / Jam
• Con-rod : No bending / twisting
• Oil passage : No blockage.
Cylinder Head : • Square slot key way for primary gear
• Mating surface : No warpage / No scratches (Service limit for
warpage: 0.05mm) Crankcase :
• Identification mark - DJ mark embossed on casting • Mating surface : Smooth / No scratches.
• No fins breakage • No Cracks, damages, breakage.
• Spark plug hole threads - Ok / No damage • Bearing seat, oil seal seat & proper pressing / positioning of oil
• Carbon built up in combustion chamber cavity- Clean it seals, needle roller, ball bearings freely rotating
• Valve seat : No pitting / No carbon deposition • No Blow holes in casting
• Proper fitment of Dampers (4 Nos)
• Breather pipe / hole : No clogging
• Proper fitment of ‘O’rings
• Proper fitment of valve stem oil seals on valve guide • Oil passage : Clean / No clogging
• Valve guide for crack if any • Threads of holes & studs : Ok / No damages
• Silencer mounting studs threads - Ok / No damage • Visible number punching on LH Crank Case
Cylinder Block :
• No fins breakage Bearings :
• No Scoring marks • Axial play : Ok / Not excessive
• No Seizure marks • Radial play : Ok / Not excessive
• Ok Seating – mating surfaces • Bearing Seat : No sign of high spot on seating area.
• Smooth Honing pattern
• Bearing class & code : As per specification numbers
• Correct / Same grouping mark w.r.t. piston (A & B group)
• Inner diameter of block as mentioned in service data. • Bearing Rotation : Free Rotation
• Ovality - Not more then 0.05 mm.
• 3 Nos. of damper rubbers Properly fitted on fins
• Proper fitment of ‘O’ ring on bottom side Clutch :
• Clutch plates / Steel plates - Thickness as per service data
Piston : • Warpage as per service data
• Grouping mark with respect to cylinder block must be same. • No Seizure / Damaged bonding of friction material
• Diameter of the piston - As mentioned in service data
• Tangs (Lugs) / Teeth - No wearing
• No scoring marks on the skirt
• Thrust plate cracked
• No blow by marks
• No Foreign material embedded
• No seizure marks.
• Manufacturing / Identification code and date code • Colour change / Signs of overheating if any
• Piston pin - scratches dent marks • No uneven wear pattern
• Steel plates planishing
Rings : • Conical face machining for spacer clutch
• No uneven wear around circumference / breakage.
• Discoloration at working face. Clutch Housing :
• Carbon built up on inner face if any. • No Wear marks on slots.
• Piston ring end gap - As per Service data • Clearance between clutch plate tangs and slot in the clutch
housing should not be excessive
• Piston ring width (thickness) - As per Service data
• Free movement of plates in clutch housing slots.
• Free rotation of Rings in Piston grooves - No stickyness.
• Rivets of clutch housing should not be loose.
• Piton ring identification mark
Top Ring : TOP 1, Second Ring : TOP 2 • Free rotation of housing on Input shaft
71 72
Parts Inspection Parameters Parts Inspection Parameters
Clutch Hub / Clutch Wheel : Guide Kick :
• Contact surface for friction plates-should not be worn out • No presence of any burr & flashes
excessively • Face to face fitment on Crankcase after tightening.
• Pressure Plate free movement in clutch hub splines • Application of loctite 638 to securing allen bolts
• Holes for lubrication
• Clutch hub height
• Smoothness in ID of clutch wheel
• Spacer free movement on clutch wheel
Camshaft :
• Presence of plain and wave washer in 1st clutch plate
• Presence of locating washer
• Free rotation of bearing
Transmission :
• Lobe height - as per Service Data
• No Teeth breakage or crack
• No cut / wear marks on cam
• No Wear pattern on teeth
• De-comp mechanism stickyness
• No Wear of dog teeth & dog holes on gear
• No Seizure mark on gear seat.
• Free movement of gears on the shaft (1st Output, 2nd Output, 3rd
Notes :
Output, 4th Input and 5th input gears are free on the respective
shaft)
• Free movement of Fork shift on the fork shaft
• Gear shift drum groove profile - Ok / No damage - Wear
• Free movement of Fork shift guide roller in the drum groove
Drum :
• Presence of Neutral rivet on the Drum
• Free rotation of Drum in LH crankcase parent hole.
• Inner hollow portion must be free from casting dust / burr
• Groove profile width as per Service Data
• Hole available for parallel pin
• Drum profile free from Hi-Spot for free sliding of bush
Carburettor :
• Float
- No puncture
- Alignment w.r.t float pin - Ok
- Not touching to bowl walls
• Needle Valve
- No groove formation on the tip
- Smooth action of spring loaded pin,
- Smooth movement in its seat.
• Volume Control Screw
- Not bent / Threads OK. / Not jammed / Presence of Spring
Washer and ‘O’ ring.
• Jets
- Correct size, No wear of jet hole, No clogging
• Piston Valve
- Smooth free sliding, clearance in its seat, no excess wear mark.
• Choke Operation - Smooth (Push and pull type)
73 74
Service Data - Engine Service Data - Engine
Compression Pressure Valve Clearance Rocker Arm Shaft Dia. Piston Diameter Piston / Cylinder Clearance Piston Ring / Groove Clearn.
7mm
Std. Limit 6.0 ~ 10.0 Kg/cm2 Inlet Exhaust Std. Limit 7.994 ~ 8.0 Std. Limit 63.478 ~ 63.488 Std. Limit 0.012 ~ 0.030 TOP SECOND
Std. Limit 0.05 0.10 Std. Limit 0.02~0.06 0.01~0.05
2
Serv. Limit 5.0 ~ 10.0 Kg/cm Serv. Limit 0.05 0.15 Serv. Limit 7.98 Serv. Limit 63.488 ~ 63.498 Serv. Limit —
Serv. Limit 0.16 0.15
Cam Sprocket Diameter Cam Height Valve Spring Free Length Piston Ring End Gap Clutch Spring Free Length Friction Plate Thickness
Std. Limit 61.48 ~ 61.36 Inlet Exhaust Inner Outer TOP SECOND Std. Limit 30.0 Std. Limit 2.9 ~ 3.1
Std. Limit 31.0 30.4 Std. Limit 39.10 43.6 Std. Limit 0.15~0.30 0.30~0.45
Serv. Limit 61.30 Serv. Limit 29.0 Serv. Limit 2.75
Serv. Limit 30.8 30.2 Serv. Limit 39.00 42.6 Serv. Limit 0.55 0.70
Valve Stem Diameter Valve Stem Bend Valve Head Thickness Pressure Plate Warp Shift Fork Guide Pin Dia. Shift Drum Groove Width
Inlet Exhaust Inlet Exhaust Std. Limit 7.15

Std. Limit TIR 0.01 Std. Limit 0.2 Std. Limit 4.4
Std. Limit 4.48 4.46 Std. Limit 0.5 0.8
Serv. Limit TIR 0.03 Serv. Limit 0.3 0.6 Serv. Limit 0.3 Serv. Limit 4.2 Serv. Limit 7.0
Serv. Limit 4.40 4.41
Cylinder Head Warp Camshaft Chain Lth. 20 Links Cylinder Inside Diameter Crankshaft Run Out
20-link length
10mm
20mm
40mm
1st 2nd 21st

MEASURE THIS LENGTH
Std. Limit 127.00 ~ 127.20 Std. Limit 63.50 ~ 63.508 Std. Limit 0.02 Max.
Serv. Limit 0.05
Serv. Limit 128.0 Serv. Limit 63.508 ~ 63.515 Serv. Limit 0.05
75 76
Service Data - Frame Service Data - Frame
Brake Panel Cam Hole Dia. Brake Cam Diameter Front Brake Pad Thickness Front Fork Spring Free Length Front Fork Oil
Free Length
Fork Oil Level

218 + 2.0 mm.
Grade : SAE 10W20
Std. Limit 12.00 ~ 12.03 Std. Limit 11.95 ~ 11.98 Std. Limit 7.4 Std. Limit 398.50 Quantity :165 ml / Fork Pipe
(Drain & Refill)
Serv. Limit 12.15 Serv. Limit 11.88 Serv. Limit 3.8 Serv. Limit 391.00
Brake Shoe Lining Thickness Brake Drum Inside Diameter Axle Run Out
Notes :
100 mm
Std. Limit 3.85 ~ 4.15 Std. Limit 130 .0 ~ 130.16 Std. Limit TIR 0.1 or Less
Serv. Limit 2.0 Serv. Limit 130.75 Serv. Limit TIR 0.2
Axial Wheel Run Out Radial Wheel Run Out Drive Chain Slack
Std. Limit TIR 1.0 or Less Std. Limit TIR 0.8 or Less Std. Limit 25 ~ 35
Serv. Limit TIR 2.0 Serv. Limit TIR 2.0 Serv. Limit 40 ~ 50
Drive Chain Length Rear Sprocket Warp Tyre Tread Depth
20-link length
1st 2nd 21st

MEASURE THIS LENGTH
Std. Limit 254.0 ~ 254.6 Std. Limit 0.4 or Less Std. Limit Front: 5.0 Rear: 6.8
Serv. Limit 259.0 Serv. Limit 0.5 Serv. Limit Front: 1.0 Rear: 1.5
77 78
Parts Identification Parts Identification
Parts Identification - Engine UG-III Parts Identification - Engine UG-II
Part Name Shaft Input Transmission Part Name Shaft Input Transmission
Part No. DK 1011 25 Part No. DH 1015 19
Better clamping of clutch assly is ensured on Effective clamping of clutch assembly is ensured on
Description Input Shaft for effective torque transmission with Description Input Shaft by using guide plate clutch in between
this new clutch mechanism. shaft & clutch assembly.
No Taper provided on shaft near clutch

Identification Mark Taper provided on shaft near clutch mounting end. Identification Mark mounting end.
Part Name Guide Gear Shift Part Name Guide Gear Shift
Part No. DK 1011 58 Part No. DJ 1011 48
Guide Gear with 6 pins is meshed with gear Guide Gear with 4 pins is meshed with gear change
Description change lever & transmits reciprocating motion into Description lever & transmits reciprocating motion into rotary
rotary motion & thus rotates drum change. motion & thus rotates drum change.
Identification Mark Guide Gear is having 6 pins. Identification Mark Guide Gear is having 4 pins.
Part Name Fork Gear Shift (Input & Output) Part Name Fork Gear Shift (Input & Output)
Part No. Input : DK 1011 33 Output : DK 1011 34 Part No. DH 1011 30 - Input DH 1011 32 - Output
The roller in fork gear shift roll in the drum profile smoothly The fork gear shift pin slides in the drum profile as
Description as & when drum rotates & guides to transmit To & Fro Description & when drum rotates & guides to transmit To & Fro
motion to fork gear shift for matching respective gears. motion to fork gear shift for matching respective gear.
Ø 5 mm
4
Ø 4. Pin dia. = 5 mm. I/P shaft fork mark = S 32.
Identification Mark • Pin diameter is 4.4 mm • ‘U’ mark on fork shift. Identification Mark O/P shaft fork mark = S 95 & S 92 respectively.
Part Name Gear Drum Change Assembly Part Name Gear Drum Change Assembly

5 mm
It has a wide profile (groove) for smooth rolling of It has a wide profile (groove) for smooth sliding of
Description fork gear shift roller in drum profile for smooth Description fork gear shift pin in drum profile for
7.15 shifting of gear. shifting of gears.
mm
Profile width is 7.15 mm. It has a square window Profile width is 5 mm. It has a odd shape window
Identification Mark parallel to neutral stopper locater. Identification Mark parallel to neutral stopper locater.
Part Name Lever Comp Gear Shift Part Name Lever Comp Gear Shift
Part No. DH 1017 05 Part No. DH 1011 34

Lever comp. gear shift is meshed with guide gear Lever comp. gear shift is meshed with guide gear
Description shift constantly. Thus helps in transmitting Description shift constantly. Thus helps in transmitting
reciprocating motion to guide gear. reciprocating motion to guide gear.
Selector lever operates radially. Selector lever is Selector lever operates To & Fro. Selector lever
Identification Mark short in length. Identification Mark is more in length.
79 80
Part Name Clutch Cover Part Name Clutch Cover
Part No. DJ 1012 41 Part No. DH 1011 49
Description It houses the entrire clutch side assemblies. Description It houses the entire clutch side assemblies.
Clutch cover does not have Engine oil

Identification Mark Clutch cover has Engine oil inspection window. Identification Mark inspection window.
Part Name Holder Clutch (Thrust Plate) Part Name Holder Clutch (Thrust Plate)
Description Holder clutch holds the clutch bearing & plunger. Description Holder clutch holds the clutch bearing & plunger.
Identification Mark Holder clutch has 4 holes for mounting. Identification Mark Holder clutch has 6 holes for mounting.
Part Name Clutch Spring Part Name Clutch Spring
Clutch spring helps smooth engaging & disengaging Clutch spring helps smooth engaging & disengaging
Description Description the clutch mechanism.
the clutch mechanism.
Identification Mark Clutch spring height is 30.8 mm. Identification Mark Clutch spring height is 29.3 mm.
Part Name Clutch Center Part Name Clutch Center

H H
Clutch center holds the set of clutch plate & Clutch center holds the set of clutch plate &
Description Description
pressure plate. pressure plate.
26 mm
Step for spacer is provided. Clutch center 30 mm No step for guide plate provided. Clutch center
Identification Mark height is 26 mm. Identification Mark height is 30 mm.
Part Name Clutch Wheel Part Name Clutch Wheel
Clutch wheel holds the set of clutch plate & Clutch wheel holds the set of clutch plate &
pressure plate. pressure plate.
Clutch wheel has 4 legs for mounting Clutch wheel has 6 legs for mounting
Identification Mark clutch springs. Identification Mark clutch springs.
81 82
Part Name Clutch Plain Washer Part Name NA
Part No. 39 2161 11 Part No. NA
Description New part added for preventing clutch judder. Description NA
Identification Mark Plain washer with no Identification Mark. Identification Mark NA
Part Name Clutch Belleville Washer Part Name NA
Part No. 39 2167 12 Part No. NA
Description New part added for preventing clutch judder. Description NA
Identification Mark Clutch Belleville Washer is concave in shape. Identification Mark NA
Part Name Disc Clutch Friction Plate Part Name NA
Part No. DK 1011 49 Part No. NA
Clutch plate ID is smaller than regular clutch plate because to

Description accommodate the plain washer & wave washer of anti judder Description NA
mechanism. This plate is fitted facing the clutch hub side.
• Internal diameter is 109.5 mm.

Identification Mark Identification Mark NA
• Friction material cubs are 48 nos.
Part Name Clutch Plate Pressure Part Name Clutch Plate Pressure (6 Clutch Plates)
New part added. This plate is fitted facing the Total 6 clutch plates of same specifications are
clutch wheel side. housed in clutch assembly for torque transmission.
Friction material cubs = 40 nos. Clutch plate

Identification Mark appears to be in Brownish colour. Identification Mark All clutch plates are Brown in colour.
Part Name Clutch Plate (4 Nos.) Part Name NA
Part No. DK 1011 51 Part No. NA
New part added. 4 clutch plates of same

Description specifications are sandwiched in between LH & RH Description NA
clutch plates for torque transmission.
Friction material cubs 36 nos. Clutch plate appears

Identification Mark to be in Greenish colour. Identification Mark NA
83 84
Part Name Plate Clutch (Pressure Plate) Part Name Plate Clutch (Pressure Plate)
Description Pressure plate are housed in between clutch plates. Description Pressure plate are housed in between clutch plates.
Pressure plate is more wide. Pressure plate Pressure plate is not wide as compared with regular.
Identification Mark width = 17 mm. Identification Mark Width = 14 mm.
Part Name Spacer Part Name Guide Plate Clutch

ID
New part added for adding is better face clamping Guide plate clutch helps in better clamping of
of clutch assembly on Input Shaft. clutch assly. on Input shaft.
Guide Plate clutch has a stainless steel finish with

Identification Mark Internal diameter (ID) is in conical shape. Identification Mark
internal splines.
Part Name Clutch Housing Part Name Clutch Housing
Clutch housing holds the entire clutch assembly &

Description Description Clutch housing holds the entire clutch assembly.
the slots helps for effective lubrication.
Identification Mark Slots provided in clutch housing. Identification Mark No slots in clutch housing.
Part Name Head Cover Part Name Head Cover
Part No. Cylinder head cover is a part of Cylinder Head Comp Part No. Cylinder head cover is a part of Cylinder Head Comp
Description Head cover houses the complete OHC system. Description Head cover houses the complete OHC system.
Identification Mark ‘U’ mark embossed in casting. Identification Mark ‘DJ’ mark embossed in casting.
Part Name Cylinder Head Comp Part Name Cylinder Head Comp
Cylinder head comp houses the complete OHC Cylinder head comp houses the complete
system with valve train. OHC system with valve train.
‘DJ’ mark along with ‘U’ mark embossed in casting. ‘DJ’ mark embossed in casting. Valve springs
Identification Mark Valve springs fitment groove is deep. Identification Mark fitment groove is not deep.
85 86
Part Name Camshaft Assembly Part Name Camshaft Assembly
Camshaft assly is housed in between cylinder head Camshaft assly is housed in between cylinder head
Description cover & cyl. head comp. It drives the entire valve Description cover & cyl. head comp. It drives the entire
train assly as per enhanced valve timing. valve train assly.
9.6 mm 12.6 mm
Identification Mark Cam (track) width is less. Track width = 9.6 mm. Identification Mark Cam (track) width is more. Track width = 12.6 mm.
Part Name Valve Spring Outer Part Name Valve Spring Outer
Part No. DH 1017 30 Part No. DS 1011 11
Valve spring helps in smooth closing of valves Valve spring helps in smooth closing of valves
without any noise as per enhanced valve timing. without any noise.
It is more in length. Length = 43.6 mm. Spring is It is short in length. Length = 42 mm. Spring is
Identification Mark Identification Mark
marked with White oil paint. marked with Blue oil paint.
Part Name Valve Spring Inner Part Name Valve Spring Inner
Part No. DH 1017 31 Part No. DS 1011 10
Valve spring helps in smooth closing of valves Valve spring helps in smooth closing of valves
without any noise as per enhanced valve timing. without any noise.
It is more in length. Length = 39.1 mm. Spring is It is short in length. Length = 38 mm. Spring is
marked with White oil paint. marked with Blue oil paint.
Part Name Stator Plate Part Name Stator Plate
Part No. DJ 1110 21 Part No. DJ 1110 04
All Electrical coils like Pick-up, Exciter, Lighting,

All Electrical coils like Pick-up, Exciter, Lighting,
Description Battery charging coils with enhanced ignition timing Description
Battery charging coils are fitted on this plate.
values are fitted on this plate.
Stator plate harness neutral coupler is having Stator plate harness neutral coupler is having bullet
Identification Mark square shape. Identification Mark type terminal.
Part Name Magneto Assembly (Rotor) Part Name Magneto Assembly (Rotor)
Magneto assembly rotor is having analog ignition Magneto assly rotor is having only Digital Ignition
timing for initial starting for avoiding back kicking. Timing.
UG-3 mark embossed on the body viewed ‘E’ & ‘M’ mark embossed on the body viewed from
from tail side. tail side.
87 88
Part Name Centrifugal Oil Filter Part Name Centrifugal Oil Filter
The centrifugal oil filter body wall thickness has

The centrifugal oil filter body internal diameter is
Description been increased by reducing the internal diameter Description
more as compared to UG-III filter.
for getting better strength.
The centrifugal oil filter does not have cut mark

Identification Mark The centrifugal oil filter has a cut mark on tail end. Identification Mark
on tail end.
89 90
Parts Identification - Chassis UG-III Parts Identification - Chassis UG-II
Part Name Carburettor Assembly Part Name Carburettor Assembly
With enhanced valve timing & to achieve better To meet the requirement of UG-II engine
Description engine performance the carburettor assembly Description specifications the carburettor is tuned.
is retuned.
On RH side of Carburettor body BS-29, DJ-U3 On RH side of Carburettor body BS-29, DJ-U2
Identification Mark Identification Mark mark is embossed.
mark is embossed.
Part Name Air Filter Assembly Part Name Air Filter Assembly
The new large volume air filter with fine & corse
A large volume air filter is introduced to provide
Description filter foam is incorporated to provide torque on Description
torque on demand with optimised intake system.
Drain demand with optimised intake system.
Tube
Drain tube is provided on bottom side to discharge No drain tube is provided on bottom side to
the condensed engine oil. discharge the condensed eng. oil.
Part Name Silencer Assembly Part Name Silencer Assembly
The silencer has been further optimised to match The silencer has been optimised to meet the
Description the changes done incorporating the new camshaft Description performance of Pulsar UG-II with ExhausTEC
& air filter assembly. introduction.
Flanged bolt on ExhausTEC for measuring CO% is

Identification Mark Flanged bolt on ExhausTEC is facing on LH side. Identification Mark facing perpendicular to steering.
Part Name Head Light Assembly Part Name Head Light Assembly
The parking lamps are projected out with a new aggressive The parking lamps are in line with the head light
Description look & together with the mask that gives a real ‘Phantom’ Description
look. H/L facing has been lowered to give balanced looks.
body line.
Parking lamps are projected out. Provision for Parking lamps are inline with head light body.
Identification Mark mask fitment. Identification Mark No provision for mask fitment.
Part Name Handle Holder Assembly Part Name Handle Holder Assembly
Part No. DH 1810 53 Part No. DJ 1810 38
Handle holder assembly height has been increased Handle holder assembly height is been designed
to accommodate new speedo console. H low to accommodate twin pod speedo console.
H
Identification Mark Height of handle holder is more i.e. 31.5 mm. Identification Mark Height of handle holder is less i.e. 18.5 mm.
91 92
Part Name Holder Fork Upper Part Name Holder Fork Upper
Description Holder fork upper cover clamps the fork pipes & Description Holder fork upper cover clamps the fork pipes,
handle holder. handle holder & twin pod speedometer assembly.
To mount the twin pod speedo console there is a

Identification Mark No bracket for holding speedo console. Identification Mark bracket provided.
Part Name Brace Fender Part Name Brace Fender
Brace fender gives reinforcement to mud guard & Brace fender gives reinforcement to mud guard &
Description also guides the wire / hose going to wheel sensor Description also guides the brake hose going towards
& caliper assembly respectively. caliper assembly.
2 nos. of brackets provided for No bracket provided for disc brake hose /
Identification Mark a) Speedometer wire. b) For disc brake hose. Identification Mark speedo cable.
Part Name Front Number Plate Bracket Part Name Front Number Plate Bracket
The front number plate bracket holds the number The front number plate bracket holds the number
plate & for firm fitment 3 point mounting is given. plate & is mounted with 2 point mounting.
• 3 holes for mounting on lower ‘T’.

Identification Mark • 1 hole is oblong. Identification Mark • 2 holes for mounting on lower ‘T’.
Part Name Speedometer Assembly Part Name Speedometer Assembly
Easy to read digital speedometer displaying speed in Twin pod analogue type speedometer displaying
Description kmph, odometer displaying distance covered & trip meter Description vehicle speed, engine rpm, odometer & trip meter.
displaying distance covered per trip with resetting facility. With trip meter adjustment facility.
Identification Mark Digital speedometer with analogue type tachometer. Identification Mark Twin pod analogue type speedometer.
Part Name Wheel Sensor Unit Part Name Case Meter
New part added. It is a sensor sensing the vehicle Case meter assly houses the speedometer worm
speed and is a non contact type wheel sensor. gear & the pinion gear assly to drive speedometer.
Provision for mounting pinion gear &

Identification Mark NIL Identification Mark speedometer gear.
93 94
Part Name Control Switch LH Part Name Control Switch LH

The switches operate without any physical contact & These are conventional switches & operate on
thus has no wear & tear of parts. Also these have physical make & brake mechanism causing more
Description illumination of tell-tale icons through LED's which Description
wear & tear of parts.
glows Bluish-White during night driving.
Identification Mark Coupler colour is White. Identification Mark Coupler colour is Red.
Part Name Control Switch RH Part Name Control Switch RH
The switches operate without any physical contact &

These are conventional switches & operate on
Description thus has no wear & tear of parts. Also these have Description
illumination of tell-tale icons through LED's which physical make & brake type mechanism causing
glows Bluish-White during night driving. more wear & tear of parts.
Identification Mark Provision of engine kill switch. Identification Mark No engine kill switch available.
Part Name Battery Part Name Battery
A low maintenance battery with a unique vent Conventional type of battery with overflow tube
mechanism that allows only gas / vapours to
Description Description mechanism. Electrolyte level inspection interval is
escape & not the electrolyte. Hence electrolyte level
inspection interval is less. more as compared to low maintenance battery.
Battery top side mould has orange colour. Battery top side mould has black colour.
Battery has vent valve on RH side. Battery have a vent plug on RH side.
Part Name CDI Unit Part Name CDI Unit
For easy kick starting the ignition timing has been

Description optimised by introducing analogue signaling to CDI Description CDI unit has only digital signaling.
unit till 3000 rpm & thereafter digital signaling.
Identification Mark Two green colour dot marks on CDI unit. Identification Mark One green colour dot marks on CDI unit.
Part Name Side Stand Switch Part Name Side Stand Switch
Side stand switch assembly coupler mounting

Description Description NIL
position shifted hence cable is longer in length.
Identification Mark Side stand switch cable length is more. Identification Mark Side stand switch cable length is less.
95 96
Part Name Side Stand Magnet Part Name Side Stand Magnet
Part No. Part No.
Description NIL Description NIL
Identification Mark Side stand magnet body has green passivation. Identification Mark Side stand magnet body is black in colour.
Part Name Seat Assembly Part Name Seat Assembly
For proper locking & proper fitment of tool kit the

Description Description NIL
seat assembly is redesigned.
No rib at tool kit mounting area. Seat locking stud Rib at tool kit mounting area. Seat locking stud is
Identification Mark Identification Mark located in central part of seat assly.
is located at extreme tail end.
Part Name Seat Lock Assembly Part Name Seat Lock Assembly
Description Since seat lock is shifted to tail end of the seat. Description The seat lock is located at center of the seat.
Seat lock cable length is short as compared to

Identification Mark Seat lock cable length is more. Identification Mark
UG-III cable.
Part Name Gear Change Pedal Part Name Gear Change Pedal
The gear change pedal has more curved shape for

Description proper placing of foot & to avoid foot fouling Description NIL
with step holder.
Identification Mark Gear pedal has more curved shape. Identification Mark Gear pedal has less curved shape.
Part Name Holder RH Step & LH Step Part Name Holder RH Step & LH Step
Part No. DJ 1612 57 & DJ 1612 56 Part No. DJ 1611 12 & DJ 1611 11
Description Holder step provided for resting pillion rider's foot. Description Holder step provided for resting pillion rider's foot.
Additional projected step is provided for better

Identification Mark aesthetic look. Identification Mark No additional projected step is provided.
97 98
Part Name Rear Fender Part Name Rear Fender
The rear fender is located below the rider seat for The rear fender is located below the rider seat for
arresting dust / dirt & water splashing on. arresting dust / dirt & washer splashing on.
On rear fender a step is provided at

Identification Mark rear end RH side. Identification Mark On rear fender no step is provided.
Part Name Saree Guard Part Name Saree Guard
Saree guard is mounted on chassis as a safety Saree guard is mounted on chassis as a safety
Description feature for arresting the possibility of saree getting Description feature for arresting the possibility of saree getting
entangled into rear wheel while riding the bike. entangled into rear wheel while riding the bike.
Saree guard has a less curve shape near ladies Saree guard has more curve shape near ladies foot
foot step as compared to UG-II. Saree guard step as compared with Pulsar UG-III. Saree guard
mounting allen bolt is short in length. mounting allen bolt is more in length.
99 100

Pulsar DTSi UG III Workshop Manual 3

Uploaded by

Copyright:

Available Formats

Pulsar DTSi UG III Workshop Manual 3

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pulsar DTSi UG III Workshop Manual 3

Uploaded by

Copyright:

Available Formats

Dismantling - Engine Sub Assemblies Dismantling - Engine Sub Assemblies

Dismantling of Oil Seals and Bearings : Remove :

Cylinder Head Cover

5 9 • 4 springs (C) • Torsion Spring (D)

Gear Starter Clutch

Inlet Exhaust Inlet Exhaust Std. Limit 7.15

1st 2nd 21st

Fork Oil Level

Drive Chain Length Rear Sprocket Warp Tyre Tread Depth

1st 2nd 21st

Part No. DK 1011 25 Part No. DH 1015 19

No Taper provided on shaft near clutch

Part No. DK 1011 58 Part No. DJ 1011 48

Part No. DK 1011 32 Part No. DJ 1011 46

Part No. DH 1017 05 Part No. DH 1011 34

Part Name Clutch Cover Part Name Clutch Cover

Part No. DJ 1012 41 Part No. DH 1011 49

Clutch cover does not have Engine oil

Part No. DK 1010 78 Part No. DH 1014 84

Part Name Clutch Spring Part Name Clutch Spring

Part No. DH 1017 43 Part No. DH 1014 83

Part Name Clutch Center Part Name Clutch Center

Part No. DK 1010 01 Part No. DJ 1011 79

Part Name Clutch Wheel Part Name Clutch Wheel

Part No. DK 1011 63 Part No. DH 1013 44

Part Name Clutch Plain Washer Part Name NA

Part No. 39 2161 11 Part No. NA

Description New part added for preventing clutch judder. Description NA

Identification Mark Plain washer with no Identification Mark. Identification Mark NA

Part Name Clutch Belleville Washer Part Name NA

Part No. 39 2167 12 Part No. NA

Description New part added for preventing clutch judder. Description NA

Identification Mark Clutch Belleville Washer is concave in shape. Identification Mark NA

Part Name Disc Clutch Friction Plate Part Name NA

Part No. DK 1011 49 Part No. NA

Clutch plate ID is smaller than regular clutch plate because to

• Internal diameter is 109.5 mm.

Part No. DK 1011 63 Part No. DH 1013 44

Friction material cubs = 40 nos. Clutch plate

Part Name Clutch Plate (4 Nos.) Part Name NA

Part No. DK 1011 51 Part No. NA

New part added. 4 clutch plates of same

Friction material cubs 36 nos. Clutch plate appears

Part No. DK 1011 63 Part No. DH 1015 57

Part Name Spacer Part Name Guide Plate Clutch

Part No. DK 1011 26 Part No. DH 1013 74

Guide Plate clutch has a stainless steel finish with

Part Name Clutch Housing Part Name Clutch Housing

Part No. DK 1010 74 Part No. DH 1015 58

Clutch housing holds the entire clutch assembly &

Part Name Head Cover Part Name Head Cover

Part No. DJ 1012 69 Part No. DH 1016 00

Part Name Camshaft Assembly Part Name Camshaft Assembly

Part No. DH 1017 03 Part No. DH 1016 17

Part No. DH 1017 30 Part No. DS 1011 11

Part No. DH 1017 31 Part No. DS 1011 10

Part Name Stator Plate Part Name Stator Plate

Part No. DJ 1110 21 Part No. DJ 1110 04

All Electrical coils like Pick-up, Exciter, Lighting,

Part No. DJ 1110 20 Part No. DJ 1110 57