Dealer Development Center
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Dealer Development Center
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Customer Eductaion Tips :
• While starting the engine in any case throttle should not be rotated more. Even if this happens,
engine will start, but the engine rpm will shoot uo too much (due to too high throttle opening)
• Whenever there is a sudden subtantial drop in mileage, customer should report to Bajaj Auto’s
Authorised Service Centres.
CO % Checking and Tune Up (To ensure betten mileage) :
Check following before CO % checking / Tune up -
• Air filter connections, intake manifold, insulator fitment, connecting tube fitment.
• Spark Plug gap (0.7 to 0.8 mm)
• All pipes and connections of fuel system for any cracks, leakage, plucking, pinching and loose
connections.
• Ensure Tappet Clearance :
Inlet : 0.05 mm
Exhaust : 0.1 mm
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• Ensure compression pressure inside the cylinder (6 to 10 Kg/cm )
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• Check the ignition timing (10 BTDC at 1500 rpm and 28 BTDC at 3500 rpm)
CO % checking and carburettor VC screw setting
• Start and warm up the engine
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• The oil temperature should be above 60 C. This can be achieved by running vehicle in top gear
at the speed of minimum 40 Kmph for 5 ~ 6 Kms.
• Adjust the engine speed to 1400 + 100 rpm with idling adjustment screw of carburettor.
• Adjust the CO with the VC screw. It should be in between 1.75 to 2.25 %
• Confirm the engine speed whether it is within 1400 + 100 rpm or not. When setting Idle CO %,
idle rpm and VCS have to be adjusted together to achieve 2 % CO and 1400 + 100 engine
rpm.
Item Pulsar 180cc
Make Ucal-Mikuni BS 26
Identification No DJ - U3
Type CV Type
Idling Speed 1400+100
VC Screw Setting 2.5+2 turns out
Main Jet 117.5
Jet needle mark 4DHL42
Needle jet mark 922MP-1
Jet needle clip position 2 from top
Pilot Jet 17.5
Starter Jet Fixed type
Throttle valve Fixed type
Chock lever 2 stage with push
pull type mechanism
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
• Remove the ‘Allen Head Grub Screw’ before removing the ‘Sleeve Spark Plug’.
• Before fitting the ‘Sleeve Spark Plug’ apply thin layer of molybdenum disulphite
grease on the entry chamfers for the ‘O’ rings for smooth sliding inside.
• ‘Inlet Rocker Arm Shaft’ is longer in length.
• Rocker arm has 20 Rollers inside the outer cage.
• Doesn't have inner cage.
• Take utmost care while dismantling. Rollers should not fall inside engine.
• Apply grease for fixing needle rollers inside rocker arm.
• While removing / refitting of piston pin circlip, cover the crankcase chamber
with clean cotton cloth to avoid falling of circlip inside the engine.
• Blow pressurised air to oil passages in reverse direction to that of oil flow.
• Do not apply liquid gasket at location (A) which may block the lubrication
passage.
A
• Secure the ‘Cam Chain Sprocket’ in the special tool firmly and then tighten the
sprocket allen bolt (A).
• Ensure that the ‘O’ mark on washer always faces outwards when tightening the
allen bolt.
A
Valve timing
• Ensure the sprocket marks (A) are aligned horizontally with cylinder head top
machined face and the piston is at TDC.
A
A
Digital Twin Spark Plug Ignition (DTS-i)
Important Points to Remember
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