Periodic Maintenance & Lubrication Chart
Dealer Development Center
14
PDI SOP
Dealer Development Center
13
Description
Position
SMM
GP Tools
Special
Tools
PNR & its
Attachment
Consumables
M & T / Service
Shop Equipments
Sr.
No.
20
Check all important nut bolts for
torque and tightness,
• Handle bar mounting bolt
• Stem lower & upper bracket bolts
• Stem of bolts
• Front axle nut
• Cylinder head nuts
• Engine foundation bolts
• Trailing arm bolts
• Silencer cover shield bolts
• Both LH/RH engine mtg. bolts
LH/RH
4.00
12-13, 14-15,
16-17, 20-22
Ring Spanner,
22 mm Box
Spanner with
Handle Ratchet
Pistol Grip
PNR
21
Check the following and
lubricate if necessary
• Rear brake lever
• Rear brake pedal / cam
• Pillion foot rest
• Center stand
• Side stand
• Kick lever boss
• Clutch lever
RH/LH
FRONT
REAR
1.00
Oil Can
SAE
20W40 Oil
22
OE accessories fitment -
Mirrors RH & LH
LH/RH
1.15
17mm
OE Spanner
23
OE accessories fitment -
Leg guard
LH/RH
3.25
10-12 No.
OE Spanner
and 12 No.
Box Spanner
Pistol Grip
PNR
24
Start vehicle, Check operation of
electrical like- Head light, Tail light,
Brake light, Side stand indicator,
Horn, Speedometer, Odometer,
Side indicators, Parking and
Pass light working.
LH/RH
0.35
25
Check Idling and CO%.
LH/RH
0.60
Small
Screw driver
CO-HC Analyzer;
Tachometer,
Proper Exhaust
Sealing
Arrangement
of Silencer
26
Trip meter working
LH/RH
0.10
27
Check all locks for proper operation
LH/RH
0.50
28
Test drive the vehicle, check digital
speedometer working. Study the
job card and verify work done.
Take vehicle out and park.
1.30
29
Clean/Wash the veh. before delivery
1.00
17.75
Total SMM
30
Repair for any other defects seen
or observed during test drive.
Expected Output in 480 Minutes / Man / 27 Vehicles
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
1. Servicing llll l
2. Idle speed / CO% C,A llll l
3. Valve tappet clearance A l Every 5000 kms
4. Engine oil (SAE 20W50 of API SG+JASO MA) R ll Every 5000 kms
5. Oil strainer / Centrifugal filter CL Every 10000 kms
6. Air cleaner element V CL llll l
7. Air cleaner element R Every 10000 kms
8. Carburettor CL,A llll l
9. Fuel system leakages C,R llll l
10. Fuel pipes R Every Year
11. Spark plug / gap CL,A llll l
12. Spark plugs (2 Nos.) R Every 10000 kms
13. Battery electrolyte level C,A llll Every Year
14. Brake light switch C,A llll l
15. Clutch play C,A llll l
16. Throttle play C,A llll l
17. Rear brake pedal play C,A llll l
18. Brake lining or pad wear C,R llll l
19. Brake fluid level / top up C 1 Month llll l
20. Brake fluid change R Every 10,000 kms.
21. Steering play C,A llll l
22. All fasteners tightness C,T llll l
23. Engine mounting silent blocks R Every 20,000 kms.
24. Tyre tread wear C,R lll l
25. General lubrication L llll l
26. Steering stem bearing L,R 1 year Every 10000kms
27. Wheel bearing C,L 1 year Every 10000kms
28. Master cylinder cup and Dust seal R Every 2 years
29. Caliper piston seal and Dust seal R Every 2 years
30. Swing arm pivot pin L l Every 5000kms.
31. Front fork C,L ll l
32. Front fork oil R Every 10000kms
33. Front brake hose C,R 2 years
2
34. Rr. Shock Absorber- Check gas pressure 7.0+0.5 Kg/cm Every 10000kms
35. Drive chain L Every 500 kms.
36. Drive chain slack A l Every 2500 kms.
37. Drive chain wear / Remove & Lubricate C,R l Every 5000kms.
38. Engine compression pressure C Every 10000kms
39. Cylinder head de-carbonising & valve lapping CL Every 30000kms
40. Valve oil seals R Every 30000kms
Sr.
No.
Operation
Whichever
comes first
750 2,500
RECOMMENDED FREQUENCY
Initial
Subsequent
5,000 7,500 Every 2,500km
Kms.
Days
OR
30~45
105~120
195~210
285~300
Every 90 days
l : Indicates operation to be performed.
« : More frequent cleaning may be required when driving in dusty condition.
Note: Parts / Lubricants to be replaced as per Periodic Maintenance and
Lubrication Chart are mandatory and the same are chargeable to customer.
A - Adjust
CL - Clean
C - Check
L - Lubricate
T - Tighten
R - Replace
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