Service Manual Bajaj Pulsar 220
Service Manual Bajaj Pulsar 220
Service Manual Bajaj Pulsar 220
Identification Salient Features Technical Specifications FAQs PDI Checklist PDI SOP Periodic Maintenance and Lubrication Chart Periodic Service SOP Service Wise Part Kit
All information contained in this Note is based on the latest product information at the time of publication. Bajaj Auto Limited accepts no liability for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. All procedures and specifications subject to change without prior notice. The right is reserved to make such changes at any time without prior notice.
Scheduled Maintenance Standard Checking Procedure Special Tools Carburettor and Fuel System Digital Twin Spark Ignition System Important Points to Remember Removal of Engine from Frame Removal of Engine from Frame Dismantling
Dismantling Engine Sub Assembly Parts Inspection Parameters Service Data - Engine/Frame Parts Identification Tightening Torque - Engine/Chassis Assembling Engine Dismantling Front Fork Front Disc Brake Maintenance Electricals Main Electrical Diagram & Individual Circuit Diagrams DTS-i Trouble Shooting
Identification Data
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 when ordering the parts. In the event of theft, the investigating authorities will require both these numbers in addition to the model, type and any special features of your vehicle that can help identifications.
Salient Features
Performance :
New clutch
& revamped gear shifting mechanism that gives smooth, positive, virtually friction-free gear shift feel
Location of Parts
LED tail lamp that consumes negligible power & require zero
maintenance
3 2
Stainless steel silencer that overcomes rusting problem All sensor type electrical switches that enables switches to
function for the life of the bike. Absolutely no maintenance in absence of mechanical contacts.
Style :
1
Stylish fairing and head lamp assembly with owleye A new black mask that separates headlamp from parking lights
4
adds to aesthetics.
Clear lens indicator with amber bulbs. New age, sharp and attractive 2 Row Tail lamp with LED lights New seat cowl to match stylish LED tail lamp. Louver type LH & RH covers with wire mesh gives sturdy look. Ergonomically designed self-letting switches
LCD Speedo Console with digital fuel gauge (12 level indicator) Digital speed display, odometer and two trip meter with resetting
provision.
1. Control Switch RH 2. LCD Speedo Console 3. Control Switch LH 4. Body Control Unit
(Placed inside Head Light fairing)
5. Hall Sensor for Indicator 6. Vehicle Speed Sensor 7. ExhausTEC 8. Tail Light LED display
Engine oil level window for easy to monitor level. Maintenance free battery once a year electrolyte top up. In addition to Fuel gauge, Reserve indicator bulb is provided that
glows continuously till the petrol filled to main level.
Salient Features
Safety :
Technical Specifications
Engine and Transmission
Type No. of cylinders Bore Stroke Engine displacement Compression ratio Idling Speed Max. net power Max. net torque Ignition System Ignition Timing Fuel Carburettor Spark Plug Spark Plug Gap Lubrication Starting Clutch Transmission Primary Reduction Gear Ratios: 1st 2nd 3rd 4th 5th gear gear gear gear gear : : : : : : : : : : : : : : : : : : : : : : : : : : : : Front Rear Front Rear Tyres Tyre Pressure Front Rear Front Rear Solo Rear Pillion Front Rear : : : : : : : : : : : Four stroke DTS-i, Natural air cooled. One 63.50 mm. 56.40 mm. 178.60 cc. 9.5 + 0.5:1 1400 + 100 rpm. 12.15 kW (16.51 Ps) at 8000 rpm. 15.22 Nm at 6000 rpm. Microprocessor controlled digital C.D.I. 100 BTDC at 1500 rpm. 280 BTDC at 3500 rpm. Unleaded petrol UCAl-MIKUNI BS29, Side Drought, CV Type. 2 Nos. Champion RG4HC, Bosch UR3DC (Resistive) 0.7 to 0.8 mm. Wet sump, Forced. Kick start / Electric start. Wet, Multidisc type. 5 speed constant mesh. 3.47 : 1 (66/19) 26.93 18.31 13.43 10.54 8.98 : : : : : 1 1 1 1 1 (36/13) (32/17) (29/21) (26/24) (24/26)
Day night mode of Speedo console The turn Indicator, neutral, high beam, and side stand Indicator bulb
glow brightly in the day for clarity, and Intensity reduces during night to reduce irritance to the rider's eye
when engine reaches to 9000 RPM automatically Red LED bulb starts blinking. This enables the rider to control the speed to avoid damages if any that may take place to engine components.
2.80 : 1 (43/15) Double cradle. Telescopic front fork with DU bush (Stroke 135mm) Trailing arm with coaxial hydraulic cum gas filled adjustable shock absorbers, and triple rate coil springs. Mechanically expanding shoe and drum type. Hydraulically operated disc type. Mechanically expanding shoe and drum type. 2.75 x 17, 41 P 100/90 x 17, 55 P 1.75 kg/cm2 (24.5 Psi) 2.00 kg/cm2 (28.0 Psi) 2.25 kg/cm2 (32.0 Psi) 1.60 x 17 2.15 x 17
Brakes
Technical Specifications
Fuel Tank Capacity : : : 15 liters Full 3.2 liters Reserve 2.0 liters Usable reserve Handle Bar Twist grip type on RH side of handle bar Left foot pedal operated Lever operated on LH side of handle bar Lever operated on RH side of handle bar Pedal operated by right foot 12 V (AC+DC) 12V 9Ah 35/35 W-HS1 5W - 2 Nos. LED 10 W (2 Nos.) LED LED LED LED LED display 5 W 12V DC
CONTROLS
Steering Accelerator Gears Clutch Brakes Front Rear : : : : : : : : : : : : : : : : : : :
ELECTRICALS
System Battery Head Lamp Pilot Lamp Tail/Stop lamp Turn signal lamp Turn signal pilot lamp Side stand indicator lamp Hi beam indicator lamp Neutral indicator lamp Speedometer lamp Rear number plate lamp Horn
DIMENSIONS
Length Width Height Wheel base Turning circle radius Ground clearance
Loaded with Digital Technology like LCD Speed/Odo display, digital fuel meter, Digital trip meter that enables to count two trips. Car like self canceling indicator switches that keeps rider free from switching off the indicators after turn. Apart from digital fuel meter, warning light for low fuel level is provided. Self check provision for tachometer to ensure proper functioning. Oil level inspection window that indicates oils level at a glance. Enhanced Safety Engine cut-off at 10000 RPM Spark gets cut-off at 10000 RPM High RPM warning lamp when engine reaches to 9000 RPM automatically Red LED bulb starts blinking. Day night mode of Speedo console, LED illumination for tell-tale icons on electrical switches that glows in the night for positive access. B How does the digital Speedo work? Front wheel of the bike has a sensor & magnet unit. The sensor counts no. of pulses w.r.t. wheel rotation & logically calculates number of wheel rotation & gives input to the display unit in the speedo console and the LCD display indicates accurate speed, odo reading & trip meter readings.
WEIGHTS
Vehicle kerb weight Gross vehicle weight : : 143 kg. 273 Kg.
PERFORMANCE
Maximum speed Climbing ability : : 125 km/h with single rider (68kg) 28% (160 Maximum)
Notes:
Values given babove are nominal and for guidance only, 15% variations is allowed to cater for production and measurement variation. All dimensions are under UNLADEN condition. Definitions of terminologies wherever applicable are as per relevant IS/ISO standards. Specifications are subject to change without notice.
B B
B B B
B B
B B B
B B
B B
B B B
B B
B B
B` No. It is not possible. Physically lot of changes are there that are not easily accommodated in the existing Pulsar.
10
PDI SOP
Sr. No. 1 Description Identify & Park Vehicle on Work Bay Remove the Thermocol and additional packing if any. Study PDI card and Work content. Open Petrol tank cap & pour petrol Check for smooth operation of fuel cock lever Check & top up engine oil level, if required. Check clutch cable operation & Adjust if required. Check front brakes for efficient working & Adjust if required. Check and correct tyre inflation pressure - Front Wheel RH RH Front / RH Position SMM 0.80 GP Tools Special Tools M & T / Service PNR & its Consumables Shop Equipments Attachment Lifter Bay
3 4 5 6 7
12-13 OE Spanner 12-13 Ring Spanner Pencil Type Pressure Gauge Cloth, Fine Polish Paper, Petroleum Jelly, Distilled Water Air Gun Analogous/Digital type Pressure gauge, Air filling Valve Hydrometer, Battery Charger, Battery Tester
Front
0.20
Check Battery voltage, fill / top-up electrolyte, apply petroleum jelly, connect terminals properly. Inspect Rear Shock Absorber setting & correct if necessary. Check Rear brakes for efficient working & adjust if required.
LH
0.60
10
RH/LH
0.10 14-15 No. O.E. Spanner Cloth, Graphite Grease, Fine Polish Paper Analogous/Digital Type Pressure Gauge, Air Filling Valve
11
Rear
0.10
12
Rear
0.20
Pencil Type Pressure Gauge 20-22, 24-27 Ring Spanner, 10-11 No. OE Spanner, Torque Wrench, Socket Set, Oil Can 10-11 No. OE Spanner 8 & 10 No. OE Spanner 10-11 No. OE Spanner 8 No. T Spanner 12-13, 16-17 Ring Spanner
13
LH
0.40
Air gun
14 15 16 17 18 19
Check Choke lever operation Check Accelerator cable free play Check & Adjust TPS Check gear shifter lever operation Check & Adjust steering and Handle bar for free movement. Check front mudguard alignment wrt Front Wheel
LH LH LH LH RH / Front Front
Fork Spanner
11
12
PDI SOP
Sr. No. Description 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 12-13, 14-15, 16-17, 20-22 Ring Spanner, 22 mm Box Spanner with Handle Ratchet Position SMM GP Tools Special Tools M & T / Service PNR & its Consumables Shop Equipments Attachment
l l
l l
l l l l
l l
20
LH/RH
4.00
2. 3. 4. 5. 6. 7. 8. 9. 10.
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
21
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
22
OE accessories fitment Mirrors RH & LH OE accessories fitment Leg guard 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
1.15
17mm OE Spanner 10-12 No. OE Spanner and 12 No. Box Spanner Pistol Grip PNR
23
LH/RH
3.25
24
LH/RH
0.35
25
LH/RH
0.60
26 27
Trip meter working Check all locks for proper operation Test drive the vehicle, check digital speedometer working. Study the job card and verify work done. Take vehicle out and park. Clean/Wash the veh. before delivery
LH/RH LH/RH
0.10 0.50
28
1.30
29
1.00
Total SMM
30 Repair for any other defects seen or observed during test drive.
17.75
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.
L T R
CL C -
13
14
15
Rear
0.40
16
Check Battery, Top-up distilled water. Clean terminals & apply petroleum jelly. Route cables properly and fit terminal caps properly. Recharge battery if required.
LH
1.80
Screw Driver, Distilled Water Filler, 10mm T Spanner 8 No. Box Spanner, 12-13 OE Spanner, 12-13 Ring Spanner, 8mm T Spanner. Plastic Tray, Phillips Screw Driver
LH
1.30
Cloth
RH
3.00
Clean oil strainer. (Replace - if required) After 1 Year or 10000 Km whichever is later.
RH
RH
0.30
12-13 OE Spanner, Small Screw Driver 6 Combination Pliers, Measuring Jar 1Liter, Funnel Spark Plug Spanner, Plug Cleaner, Wire Brush Phillips Screw Driver 12-13 Ring Spanner, 5 & 10 mm Allen Key Pencil Type Pressure Gauge 16-17 No. Ring Spanner Fork Spanner Filler Gauge 0.01~1mm Cloth, Oil 20W50 of API SG + JASO MA grade Cloth, Fine Polish Paper, Spark Plug Cloth, Oil Dot-4 Cloth, Fine Polish Paper Oil Dispenser
LH
1.30
RH
1.35
LH
0.40
20
Clean, Check & Adjust RH spark plug. Check and Top-up brake fluid level.
RH
2.40
10
LH
2.40
21
Front
1.00
11
Check & Adjust tappet clearance. (if required) During 4th Servicing or after 5000 Km whichever is later.
LH
22 Cloth 23
Check/ Adjust
Front
0.50
Air Gun
Front
0.40
12
Check Side bolts of Front fork Engine foundation bolts Side stand RSA top and bottom nuts
Check and Adjust steering. Check Engine foundation bolts Front axle nut Side bolts of Front fork Handle bar bolts RSA top and bottom nuts Swing arm axle nut Silencer protective cover screws / bolts Rear view mirror
Front
0.80
LH/RH
0.60
RH
1.30
13
LH / Rear
3.90
10-11, 12-13, 14-15, 16-17, 20-22 No. Ring Spanner, 22 mm Box Spanner with Handle Ratchet
14
Check/ Adjust
Rear
0.50
Air Gun
15
16
26
LH/RH
0.80
Oil Can
Grease Gun
27
Refit RH, LH side covers, Seat, Petrol tank Check and Clean fuel line & Clean petrol tank. (Replace fuel pipe - if required) Check all Meters for proper functioning & Correct, if reqd. Start vehicle, Check & Adjust the following. Head light. Tail light. Brake light. Horn Speedo, Pass, Parking light Side Indicators - Front & Rear
LH/RH
0.50
28
LH
0.50
Air Gun
2nd Paid 375~390 9500~10000
29 30
0.50
Drive chain lock & link set Brake shoes (if worn out) Starter clutch bush
Fork oil seal Cylinder head gasket (If required) Front disc pad inspect / replace (If worn out) NIL Engine oil 4th Free 555~570 14500~15000 Drive chain lock & link set Steering cone kit 4th Paid 615~630 17000~17500 NIL Engine oil Clutch cover gasket Air filter foam element Spark plug 5th Paid 705~720 19500~20000 Brake shoes (if worn out) Front disc pad inspect / replace (If worn out) Fork oil Clutch plate Rear brake damper
30
LH
2.00
31 32 33
Study Job Card. Verify work. Lower the Lift Take vehicle out and park
Sub Total
34 Carry out any additional work as indicated by the Customer or as required.
32.50
10.00
Drive chain lock & link set 6th Paid 7th Paid 8th Paid 795~810 885~900 975~990 22000~22500 24500~25000 27000~27500 NIL Carburettor insulator Chain sprocket kit NIL
Total SMM
42.50
17
18
Schedule Maintenance
Cleaning
The vehicle must be cleaned periodically using pressurized water. Before cleaning the vehicle cover the important parts like Ignition switch, Silencer Tail end, CDI unit, H.T. coil with plastic bags. Dont apply the jet of water directly on electrical parts such as Switches, Ignition unit, Coils etc. otherwise they may get damaged. Brushing with kerosene and wiping dry with clean rag is advisable for external cleaning of the engine. All painted surfaces should be washed with water. Do not use kerosene or hard detergent soap on painted surfaces as it damages the paint and turns it dull. After washing, dry the vehicle with compressed air and carry out the lubrication as recommended
Caution : Water may enter on the brake liners during washing & brake slippage may occur. Ensure that brake liners are dry before driving the vehicle.
Periodic Maintenance
Periodic maintenance (in accordance with the periodic maintenance chart) of a vehicle is most important to prolong vehicle life, trouble free running and ensure your safety while driving.
Use always Genuine Bajaj Auto parts & recommended lubricants. (Engine oil: SAE 20W50 API SG + JASO MA grade)
Notes :
Note : It is most vital to adhere to recommended frequency of oil change for the purpose of long life of critical engine components for details refer Periodic Maintenance Chart.
19
20
Schedule Maintenance
Remove : Clean oil strainer with Kerosene / Diesel blow compressed air and then refit it. Replace oil strainer if found damaged.
Schedule Maintenance
Air Filter Cleaning Clean Air filter element adhering to standard SOP
1st Stage:
Centrifugal Oil Filter Cleaning:
Remove : Centrifugal oil filter cover mounting screws (C) 3 Nos. The cover with gasket Replace gasket if damaged Clean centrifugal oil filter using Nylon brush/kerosene or Diesel
Squeeze
Air Filter
Air Cleaner Element Removal Remove : RH side panel by unlocking it with key
2nd Stage: Clean with Kerosene Again Dry with Cotton Cloth
Remove : Air filter element assembly along with catrej Seperate foam filter from the catrej Air Filter Element Cleaning and Inspection
Note : In dusty areas, the element should be cleaned more frequently than the recommended interval. After 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 with a new one in accordance with the Periodic Maintenance Chart. Also if there is a brakage in the element material or any other damage to the element replace the element with a new one.
Note : No need of removing flame arrestor White colour filter portion towards carburettor side Ensure beading placed properly when fitting cover
Warning : Clean the element in a well-ventilated area, and make sure that there are no sparks or flames anywhere near the working area. Because of the danger of highly flammable liquid, do not use gasoline/petrol or a low-flash point solvent to clean the element.
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22
Schedule Maintenance
Spark Plug
Recommended Spark Plug Electrode Gap Replace Spark Plug Champion RG4HC / Bosch UR3DC 0.7 ~ 0.8 mm After every 10000 Kms.
Schedule Maintenance
Position Spring Action 1 2 3 Stronger 4 5
If the Shock Absorber sleeves on both sides are not adjusted to the same position, an unsafe riding condition may result.
Note : Std setting is done in 2nd notch
Battery - 12V - 9 Ah
Battery is located inside LH cover Check the electrolyte level in each cell and ensure that the level is between the upper and lower level lines. Remove the battery filler caps and fill with distilled water until the electrolyte level in each cell reaches the upper level line if required.
Note : Add only distilled water to the battery. Tap water is not a substitute for distilled water and will shorten the life of the battery.
23
24
Schedule Maintenance
Drive Chain Cleaning / Lubrication 1st Stage: Clean with Kerosene
Schedule Maintenance
Tyre Air Pressure
Keep appropriate tyre pressure as mentioned below to increase life of this tyre and for better fuel consumption. Front Rear - with Solo Rear - with Pillion 1.75 Kg/cm2 (25 PSI) 2.00 Kg/cm2 (28 PSI) 2.25 Kg/cm2 (32 PSI)
2nd Stage: Clean with Cleaner Kerosene again Important Adjustments and Checking Procedures
Idling Speed Adjustment Whenever the idling adjustment is disturbed follow the procedure given below for setting proper engine idling. Start engine & drive it for at least 5 kms. or warm the engine till the oil temp reaches 600C. Remove the Bolt/Plug near Exhaus TEC Connect the probe of CO analyser. Set the CO between 1.75 ~ 2.25% by adjusting volume control screw.
Then set the engine idling r.p.m. by rotating the idle adjustment screw clockwise or anticlockwise by hand. For the precise adjustment of idling speed, use of tachometer is recommended. Rotate the throttle a few times to make sure that the idling speed does not change. Readjust if necessary. Do not attempt to compensate for faults in other systems by adjusting the idle speed. Idling Sped : 1400 + 100 rpm
Put the feeler gauge, measure and adjust the clearance. Lock the nut holding screw with special tool after getting desired clearance. Again check the tappet clearance with gauge. The gauge should slide with slight resistance between tappet and valve stem head feeler and tighten the check nut with a spanner. Inlet Valve : 0.05 mm Exhaust Valve : 0.1 mm Special Tools : Feeler Gauge - 69 7502 51 : Valve Adjusting Screw Holder - 37 1031 53
25
26
Schedule Maintenance
Ignition Timing Inspection
Connect cable of stroboscope to one of the H. T. Coil carrying current to spark plug. Start the engine. Aim the stroboscope light at Magneto cover glass window. At idling speed the F marked line on the rotor coincide with the line mark on magneto side ccase. (100 BTDC @ 1500 rpm). As the engine rpm is increased the A marked on the rotor coincide with the line mark on magneto side ccase. (280 BTDC @ 3500 rpm). This indicates the advance timing is functioning correctly. Remember the T marked line is a reference line for TDC position of the piston and is not for Ignition timing.
Schedule Maintenance
Reed Switch Setting and Checking
Check throttle lever movement by rotating it with hand. It should not be sticky in operation and should return back it self on releasing. bracket Multimeter should show continuity.
Gap 2.5mm max.
Magnet should not touch with reed switch. Gap between Magnet & Reed Switch should not be more than 2.5mm. Movement of throttle lever with magnet assembly and Reed Switch fitted should be free.
Loosen the 2 lock nuts (C) on clutch cable bracket and adjust threading in the adjuster provided on the clutch cover. Tighten both the lock nuts on clutch cable bracket by holding one nut and tightening the other, after the required free play. Clutch Lever Free Play : 2 ~ 3 mm
When throttle is open and Reed Switch magnet crosses to straight edge of fix bracket of Reed Switch multimeter should show discontinuity.
0.00
On De-acceleration, when of Reed Switch magnet re-coinsides with straight edge of fix bracket of Reed Switch Multimeter should show continuity.
27
28
Schedule Maintenance
Front Brake Free Play Adjustment
There is no need for free play adjustment, since the pistons in caliper assembly will move towards the pads and take new positions in order to automatically compensate for pad wear. The free play will be approximately 2 ~ 3 mm. Front Brake Lever Play : 2 ~ 3 mm.
Fit the compression gauge with adapter in the Spark plug hole. Open the throttle fully then kick 5 times instantaneously.
Note the reading in the compression gauge. Release the pressure by pressing the release valve on hose pipe. Take average of 3 such readings for noting actual compression pressure. Confirm the compression pressure is between 6 to 10 Kg/cm2 Wet Compression Test : If the compression pressure is found below lower limit than specified, put few drops of engine oil through the spark plug hole and again check compression pressure. If you find considerable increase this time, then cause for the low compression pressure lies in Cylinder / Piston assembly. If compression pressure remains the same, then the cause for low compression pressure lies in Cylinder / Head assembly.
Caution : If wet compression is done, remove second spark plug and clean thoroughly to avoid oil fouling before fitment.
29
30
Connect transparent tube to the bleeder screw at caliper Operate the brake lever and keeping in pressed position loosens the bleeder screw so that some oil escapes with the air bubbles. Keep on operating the brake lever till the air bubble escape out completely through bleeder screw, and top up the master cylinder if required. Once the air escapes out from the hose pipe the brake lever meets resistance, which indicates completion of air bleeding After completing the bleeding, top up the master cylinder up to the maximum level mark.
Center the brake panel assembly in the brake drum. This is done by tightening the axle nut lightly, spinning the wheel, and depressing the brake pedal forcefully. The partially tightened axle nut allows the brake panel assembly to center itself within the brake drum. Tighten the Axle Nut Tighten the torque link nut Fix the snap ring Adjust the correct brake play
Note : This procedure can prevent a soft or spongy feeling brake.
Manual Testing
Connect wiring harness to C1 connector. Through this harness the following testing can be carried out : - Vehicle sensor speed. - Hall sensor. - Starter relay.
31
32
Special Tools
Details of Exclusive Special Tool For carrying out repairs / overhauls, 1 new special tools for Pulsar DTS-i UG III have been developed. Rest of the special tools required remains the same which were earlier required for Pulsar and Pulsar DTSi
Engine
Sprocket Catcher
Drawing No.: 37 10DH 36 Application : For holding sprocket during removal / refitting of Cam sprocket allen bolt. Camshaft Big Bearing Puller Drawing No.: 37 10DH 32 Application : To remove bearing (Decompression assembly side) of camshaft.
Camshaft Small Bearing Puller Drawing No.: 37 10DH 31 Application : To remove small bearing of camshaft.
Rocker Pin Remover Drawing No.: 37 10DH 35 Application : To remove rocker pin from cylinder head.
Silent Bush Puller Drawing No.: 37 10DH 33 Application : To remove silent bush from cylinder head cover.
33
34
Special Tools
Rotor Puller with Butt Pin Drawing No.: 37 10DJ 32 Application : Used to pull out the rotor from crankshaft assembly.
Special Tools
Bearing Extractor Drawing No.: 37 10DJ 76 Application : Used to extract the input shaft bearing from crankcase LH.
Primary Gear Holder Drawing No.: 37 10DJ 28 Application : Use to hold primary gear while loosening / tightening the clutch nut.
Bearing Puller Drawing No.: 37 10DJ 77 Application : Used to pull out the bearing for body balancer from crankcase LH.
Balancer Gear Holder Drawing No.: 37 10DJ 63 Application : Used to load the pre-tensioned scissor gears of Assly balancer Idler gear. Special Nut Drawing No.: 37 10DJ 43 Application : Used to remove / fit of centrifugal oil filter nut.
Dia. = 25.9+0.1
Adaptor & Valve Spring compressor Adaptor - Drawing No.: 37 10DJ 78 Valve Spring Compressor - Drawing No.: 37 1031 07 Application : Used for assembling / dismantling inlet, exhaust valves by compressing spring in cylinder head. Rotor Holder Drawing No.: H6 0721 00 Application : To hold rotor while loosening bolt.
Piston Ring Holder Drawing No.: 37 10DJ 30 Application : Used for compressing the piston rings when assembly piston in the cylinder block. Bearing Race Extractor Drawing No.: 37 00DJ 01 Application : Used for removing the lower bearing race from T
Thrust plate aligner/holder Drawing No.: T-1011168 Application : To align the clutch hub concentricity w.r.to clutch wheel, clutch housing and thrust plate
35
36
Special Tools
Crankshaft Bearing Extractor Drawing No.: 37 1001 14 Application : To remove bearing from crankshaft
Special Tools
Chassis
Fork oil seal fitment punch Drawing No.: 37 0040 03 Application : To fit fork oil seal on outer pipe
Output Sprocket Holder Drawing No.: 37 1030 53 Application : To hold the output sprocket while removing sprocket bolt Rear Shock absorber adjuster Drawing No.: 37 00DH 14 Application : For adjusting the notch position of RSA to achieve hard or soft rear suspension Fork Inner & Outer Tube Extractor Drawing No.: 74 9310 15 Application : Used for removing front fork inner tube from outer tube.
Bearing Driver Set Drawing No.: 37 1030 61 Application : Common bearing driver set for fitting and removing bearings from crankcase.
37
38
Remove : Pull the cable from the cover LH to unlock the seat lock Seat assembly
Note : To remove the seat assembly hold the seat assembly and lift it from the rear end and pull it back.
Remove : 1 bolt (A). Fuel gauge wiring connection. Drain pipe connection. Fuel pipe connection. Fuel tank assembly
Note : To remove the fuel tank assembly from the chassis lift the fuel tank assembly by holding it at the rear end and pull it back.
Fuel Tank Inspection Remove the hoses from the fuel tank, and open the tank cap. Check to see if the breather pipe and water drain pipe in the tank for clogging. If they are clogged, remove the tank and drain it, and then blow pipes free with compressed air. Fuel Tank Cleaning
Warning : Clean the tank in well ventilated area, and take care that there are no smokes or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or lowflash point solvents to clean the tank.
39
40
Note : While installing the fuel tank on chassis make sure that the dampers (A) on petrol tank are mounted on the chassis.
Notes :
Fuel Tank Cap Dismantling To unlock the Fuel tank cap, insert the key in the key slot and turn it anticlockwise direction and lift open the tank cap. A Now remove the anti theft screw and then remove the allen and remove the fuel tank cap assembly from the fuel tank. the reverse procedure of dismantling. But take care that hole is free from any foreign particles that may clog the lock the fuel tank cap, just press the cap without key. Fuel Cock Removal Remove : 2 bolts (A) Fuel cock assembly from the fuel tank. A bolts (A) Fitting is the vent hole. To
Note : Always loosen the bowl of the fuel cock on vehicle itself
Check the fuel cock strainer for any breaks or deterioration. If the fuel cock strainer have any breaks or are deteriorated, they may allow dirt to reach the carburettor, causing poor running. Replace the strainer.
Clean the fuel cock strainer in a high-flash point solvent. Pour high flash point solvent through the cock in all lever positions. Dry the tank and the fuel cock with compressed air. Install the cock in the tank.
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42
Working of Carburettor
Starter Circuit : Constant Velocity Carburettor
Cut Section View of Mixing Chamber
Working of Carburettor
Pilot Circuit : Constant Velocity Carburettor
1. Pilot Jet 2. Pilot Outlet Hole 3. Butterfly Valve 4. Volume Control Screw 5. Idling Adjustment Screw 6. Fuel Inlet
Towards Engine
Towards Engine
1. Plunger Cap 2. Diaphragm Cap 3. Diaphragm Piston Valve 4. Piston Valve with Jet Needle 5. Float Chamber
Towards Engine
Function
Function
The pilot circuit provides the air fuel mixture at idling when not enough air is being drawn through the carburettor to cause the main circuit to operate.
The function of starter circuit is to provide rich air fuel mixture on starting / cold starting. At cold engine condition the air is dense also the engine parts are cold enough this does not allow the petrol to vaporize properly this leads to starting trouble.
Construction
Construction
The Starter Circuit consists of a starter jet and a plunger. The starter jet is used to meter the fuel and a plunger that opens an air passage from the inlet of the carburettor (underneath the diaphragm) which passes the mixture to the mainfold.
The pilot circuit consists of pilot jet, pilot air jet and volume control screw. The pilot jet meters the fuel and the pilot air jet meters the air quantity. The volume control (VC) screw controls the amount of air fuel mixture flowing through the pilot outlet.
Working
Working
On pulling the choke lever the plunger is lifted by a cable. This uncovers the fuel passage that leads to the starter jet, air inlet passage and the outlet passage towards the manifold. This creates enough suction to draw fuel up from the bowl into the mixing chamber (below the plunger). Here the fuel is mixed with the air and the mixture is drawn into the engine through the outlet passage.
As the air enters the pilot air inlet the fuel is metered by pilot jet and air quantity is metered by pilot air jet. The atomized / vaporized mixture 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 mixture is supplied mainly by pilot outlet only. Air fuel mixture volume is adjusted by volume control (VC) screw and mixture becomes lean when volume control (VC) screw turned clockwise and rich when it is turned Anticlockwise direction.
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44
Working of Carburettor
Progression Circuit : Constant Velocity Carburettor
1. Pilot Jet 2. Pilot Outlet Hole 3. Bypass / Progression Holes 4. Butterfly Valve 5. Volume Control Screw 6. Throttle Lever
Working of Carburettor
Main Circuit : Constant Velocity Carburettor
1. Piston Valve 2. Piston Valve Diaphragm 3. Jet Needle 4. Needle Jet 5. Jet Holder 6. Main Jet
Towards Engine
Function
Towards Engine Air Inlet for pilot jet
The Main Circuit provides air fuel mixture by lifting up the piston valve in direct proportion to the engine demand. This assures the correct venture size & air velocity throughout the mid range operation of the engine.
Construction
This circuit consists of jet needle, needle jet and main jet. To assist in atomization an air bleed circuit is incorporated in the main metering system and it aids fuel vaporization by introducing the air into the fuel before it enters the main air stream.
Function
The progression circuit provides the air / fuel mixture at small throttle opening when pilot circuit is still working but unable to meet the engine demands on small throttle opening.
The piston valve movement is controlled by spring and carburettor venture vacuum which is generated below the piston valve diaphragm.
Construction
Working
The progression circuit follows the path of pilot circuit and the construction is same as that of pilot circuit.
When the butterfly valve is opened and air flow through the venturi increases, the air pressure in the venturi (and the upper chamber) decreases. As the atmospheric pressure in the bottom chamber is greater than the venturi pressure above the diaphragm, the piston valve along with jet needle is pushed up and more air fuel mixture is drawn into the engine from main jet through needle jet into the main air stream. When the butterfly valve is closed, air flow through the venturi decreases; air pressure in the venturi increases and approaches atmospheric pressure, & the spring pushes the piston valve along with jet needle down.
Working
As like pilot circuit the fuel is metered by pilot jet and air volume is metered by pilot air jet. This mixture in vaporized / atomized form is discharged through the bypass ports when the butterfly valve is opened from idling further.
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46
Working of Carburettor
Dos
Handling
Use appropriate screw drivers.
Donts
Never use oversize screw drivers. Do not over tighten the jets and screws. These will damage the jets and their seats.
Pulsar DTSi is the first bike in the world (In small cc engine) to have twin spark ignition system. 1. The most obvious feature is the Twin Spark Plug configuration o f the Engine. The cylinder head has 2 spark plugs one on either side. The spark plugs are of the smae Heat range (Champion RG4HC/Bosh UR3DC (Resistive) and have similar electrode gaps. These also spark simultaneuosly, This has been done to improve the combustion process by reducing the time of combustion. The end results are low emissions, good fuel economy and good driveability To enable the sparking of the 2 spark plugs, a intelligent CDI capable of handling this was developed. Further more, the ignition timing has been optimised to give the best output from engine (100 BTDC @ 1500 rpm, 280 BTDC @ 3500 rpm). To enable optimum igntion timing for part throttle loads and full throttle loads, there are separate igntion maps stored in the memory of the CDI. These are activated depending on the throttle opening and engine speed. The Digital CDI has a bit Microprocessor which handles all these inputs and gives out the required and correct spark advance. The intelligent CDI can be easily indentified by 2 green dots marked on CDI case. To enable switching the required igntion maps, a magnetically operated need switch is incorporated on the carburettor throttle shaft and carburettor body. This is known as TRICS. Throttle Responsive Igntion Control System. These engines are capable of of reviving very high, quite easily. To keep them mechanically safe, a engine rpm limiter has been incorporated in the Digital CDI. This curtails the sparks to the spark plugs thereby limiting the engine rpm Max upto 9000 and thus keeps the engine mechanically safe. There are 2 spark plugs. LH spark plug fires at 350 rpm and then continues to give spark till at 9000 rpm of engine. The spark is cut off from LH plug 9000 rpm to protect engine from excessively high speed. RH spark plug gives spark at 750 rpm and then continues to give till 6000 rpm of engine. If engine rpm exceeds 6000 rpm then RH plug is cut off. This is done to reduce combustion noise created in engine. This engine has been extensively tuned for more Power and Torque. The DTSi technology has enabled the Pulsar to meet 2006 norms without any Secondary air injection devices.
2.
Cleaning
For cleaning always use carburettor cleaner like - Acetone - Carbon Tetra chloride - Aerosol - CVC spray Never clean the carburettor with water. Jets & air passages will get clogged due to sediments if cleaned by water. 3. Ensure Jets - Holes are clean. - Holes are not worn out. - Size as per specification. Float is in good condition. Replace Jets - Worn out jet. - Incorrect size jet.
Maintenance
4.
Float Pin - Tip having no wear mark. - Spring loaded pin is free in movement.
5. 6.
Troubleshooting : Malfunctioning of the Reed switch assly will not harm the engine, neither it will give any physical indicators like starting trouble or misfiring. However checking of proper functioning of Reed Switch Assly at PDI and at every service is essential. Following symptoms may indicate as malfunctioning of Reed Switch Assly as one of the cause. Symptom Cause Remedy
Sudden drop in mileage & power The igntion systems is working only Replacement of Reed Switch Assly lack in mid range rpm in 2nd map due to reed switch is stuck in open circuit
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48
Do not apply liquid gasket at location (A) which may block the lubrication passage.
A
Valve timing Ensure the sprocket marks (A) are aligned horizontally with cylinder head top machined face and the piston is at TDC.
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
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.
Jet needle clip position 2 from top Pilot Jet Starter Jet Throttle valve Chock lever 17.5 Fixed type Fixed type 2 stage with push pull type mechanism
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.
49
50
Ensure While assembling hub clutch place plain washer first and then place belleville washer. Concave face should be upwards i.e. toward technician.
2 7
4 6 7 6 7 12 10 5 1 14 6 17 11 15 16 13 8
After placing Belleville, fit clutch plate with 48 friction material cubs (A) with more I.D. 4 Nos. of clutch plates with 36 friction material cubs (B) alternatively along with steel plates. Fit top clutch plate with 40 friction material cubs (C). Input shaft has special nut. Thick spacer washer tapered I.D. it should be placed on tapped portion of Input Shaft. Input Shaft has left hand threads.
Take the Assembly Balancer Idler Gear along with Thrust Washer which is preloaded and is held in special tool, Slide down the special tool with Gear to engage the bottom half of the Assembly Balalncer Idler Gear with the Body Balancer Gear Assembly Fit Thrust washer on the other side. On assembly of Assembly Balancer Idler Gear the itched/Dot mark of ;Body Balancer Gear Assembly should match with the line mark on the Crankcase. Holding the Assembly Balancer Gear in special tool now slide inside the Clutch Housing so that the Clutch Housing smoothly engages with the top half of Assembly Balancer Idler Gear. Remove the special tool gently. Fit 2 dowels and Assly Balancer Idler Gear Cover Ensure perfect marking of gear marks with respect to crankcase mark.
When splitting crankcase always remove 1 long bolt fitted from clutch side first.
Remove long bolt immediately after removal of long bolt clutch side. Ensure proper fitment of bolt with copper washer to avoid oil leakage.
Shifter fork is having a roller. These roller are one side tappered inner dia. Taper portion of roller should face towards fork gear shift.
Fit primary gear drive (A). The mark teeth of the primary gear should match with the line mark on the ccase. This indicated that the piston is at TDC position. This procedure should be carried before fitting the Clutch Housing & this position should not be disturbed while fitting the Clutch Housing.
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52
B
Note : Always remove the flange mounting first and then rear mounting to avoid misalignment of studs.
Remove : Seat assembly by pulling the cable for seat lock release located on RH side. Disconnect the negative terminal of the battery. Disconnect the wiring harness socket for fuel level Indicator. Fuel pipe connections and moisture drain pipe from fuel tank. Disconnect stator plate harness Disconnect neutral switch coupler Remove : Drain bolt (A) and drain out the oil from engine. Refit the drain bolt with gasket & tighten it.
Recommended Oil Grade and Qty Grade SAE 20W50 of API SG + JASO MA Drain & Refill 1000 ml. Engine Overhaul 1100 ml. Quantity
Remove : Bolt (A) of silencer bracket mounted on pillion RH side footstep. Silencer assembly.
A
Remove : PCV pipe from breather
Remove : Bolts (A) B A Gear shift pedal bolt (B) Drive sprocket cover LH.
Using Special Tool : Sprocket Holder - 37 1030 53 A Remove : Bolts (A) Plate drive sprocket Drive sprocket along with the chain. Neutral switch coupler (B).
Remove : Air filter mounting bolts to facilitate the removal of carburettor with reed switch. Clamps of carburettor and disconnect carburettor along with insulator and dismantle cables from it. Bracket bolts securing clutch cable on clutch cover. Spark plug cap RH
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54
Dismantling Engine
Engine Top End Dismantling :
Remove : Pull out the cover on the spark plug cap RH and the spark plug cap itself Using a plug spanner, loosen and remove the spark plug RH Loosen and unscrew the allen head grub screw of the sleeve spark plug
Note : Wrap a piece of cloth around the protruding edge of the sleeve spark plug and using a plier, pull out the sleeve.
Note : Bolts (A) holding the engine to the chassis. (4 bolts of 12 mm and 1 bolt needs deep socket for removing it).
Remove : There are 2 O rings fitted in the cylinder head, one on the cam chain wall and the other near the spark plug threading Using a thin, sharp pointed tool pierce the O rings and remove them. (If required)
Note : Remove these only if the O ring protrusim in the bore is non-existant (which means that the O ring has set and it has lost its compression or sealing ability.)
Lift up the engine off the chassis and place it on engine stand.
Remove : Loosen bolt (A) and unscrew chain tensioner plunger Cam chain tensioner assembly 2 bolts (B) Cam chain tensioner assembly A B Remove : Both tappet caps Magneto cover cap seal and rotate crankshaft to get piston at TDC. Ensure both tappets are at free state (i.e. at the end of compression stroke)
Note : After disconnecting all the sub assemblies and control cables from the engine lift up the engine and remove it from RHS of the vehicle.
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Dismantling Engine
Remove : Cylinder head securing head cover 2 bolts (A) Cylinder head securing head cover 4 bolts (B) B C Cylinder head securing head cover 4 domed cap nuts (C) 4 copper plated steel washers
Note : Improper tightening sequence may cause warpage in cylinder head cover and it can be damaged permanently.
Dismantling Engine
Remove : Piston pin lock LH & RH side
Note : Place a piece of clean cloth above hallow portion of crankcase to arrest piston pin circlip if it falls during fitment.
Using Special Tool : Drift 74 9309 89 Remove : Remove piston pin Piston assembly
Using Special Tool : Sprocket Catcher - 3710 DH 36 Using Sp. Tool : Sprocket Catcher - 3710 DH 36 Remove : Allen bolt Spacer Cam sprocket Collar Cam shaft assly
Sprcoket Catcher
Caution : When 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 crankshaft.
Note : Hold the cam chain up right using soft copper wire or thread. Do not use cotton waste for holding the cam chain.
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Dismantling Engine
Using Special Tool : Holder - H6 0721 00 Remove : Rotor bolt (A) Washer Rotor
Dismantling Engine
Remove : A 3 Screw (A) Guide starter assembly along with oil seal.
Caution : Ensure that the woodruff key of rotor is removed prior to the removal of guide starter assembly. The lips of magneto oil seal housed in guide starter assembly will get damaged if not done so.
Using Special Tool - Rotor Puller with butt pin : 37 10DJ 32 Remove : Rotor assembly Woodruff key.
Note : Holding the gear complete starter clutch rotate the rotor and pull it out in Anticlockwise direction to prevent rollers and springs coming out. Rotor puller has left hand threads.
Warning : These components remain hot for a long time especially if removed from a hot engine. Wear suitable hand protection to prevent burns. Rotor puller has left hand threads
Remove : Gasket Bolt (A) Plate starter clutch gear return (B) A B Remove : Collar (A) Shaft Gear comp. starter counter assly A Gear starter clutch
C B
Remove 12 Clutch cover bolts (B) Bracket clutch cable (C) Clutch cover
Note : The rod clutch lifter, plunger oil, plate plunger oil and spring joint may fall out of their respective places into the oil collection tray. If so, ensure that these are collected & accounted for before proceeding.
Remove :
B
3 bolts (A) Oil pump assembly 2 Dowels Clutch cover gasket Starter Motor (B)
Warning : The oil pump may be hot, hence use suitable hand protection. Also, since the oil pump houses the oil strainer / mesh also, it may retain some quantity of oil. This oil may be hot. Hence proper care should be taken to drain it. Note : The oil which is in the oil pump housing should also be drained out into the oil drain tray for measuring drained oil.
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60
Dismantling Engine
Using Special Tool : Primary Gear Holder 37 10DJ 28 A
Dismantling Engine
Remove : A 3 Assly balancer Idler gear cover bolts (A) Cover Washer 2 Dowel
Remove : 3 phillips head screws (A) Centrifugal oil filter cover Gasket
Warning : These parts may be hot, if removed from a hot engine. Use gloves for protection. Note : Some amount of oil is trapped in cover and body of centrifugal oil filter, this oil should be drained into the oil tray.
Using Special Tool : Special Nut Puller 37 10DJ43 Primary Gear Holder 3710 DJ28
Remove : Centrifugal oil filter special nut Belleville washer Body centrifugal oil filter assly Remove : Bearing with plunger
Using Special Tool : Special Nut Puller 37 10DJ 43 Primary Gear Holder 3710DJ28 Remove : Input shaft special nut Belleville washer Clutch assly comp Spacer
Note : Take case that square key does not fall inside the crankcase hollow portion while removing.
Note : The existing Special Nut Puller 37 10DJ 43 can be used by grinding the tool OD to 25.9 + 0.1 mm
Dia. = 25.9+0.1
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Dismantling Engine
Remove : Gear change lever
Dismantling Engine
Remove : Bolt (B) on LH side crankcase (Magneto side)
Remove : Spring Allen bolt (A) Guide gear Spacer Parallel Pin
Note : Check and inspect the drum change arm stopper for free movement always.
Remove : Kick spring 2 Shafts (A) & (B) of gear shifter fork. 3 fork shifts (1 small for input 2 big for output shaft. 3 Rollers A Drum change
Using Kick starter lever Remove : Washer Kick shaft assly comp
Note : Rotate the kick starter lever in Anticlockwise direction for removing the kick shaft assly.
Remove : Remove : Bolt (A) A Locking Plate Kick idler gear The entire gear box assembly together
Remove :
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Using Special Tool : Bearing Extractor - 37 10DJ 77 Remove: Bearing (B) for output shaft assembly from crankcase RH
Dismantling of Subassemblies :
C B A
E D
Magneto Cover Remove : 2 Phillips head screws (A) of pulsar coil (E) mounting. Bolts (B) of stator assembly. 1 Phillips head screw (C) of stopper. Stator coil assembly (D) along with pulsar coil. Cylinder Head Cover
Remove : Rocker shaft (A) Rocker arm Set of washers (1 wave and 2 plane) (B) Rollers 20 nos. (C)
Note : Similarly remove the other Rocker shaft & Rocker Arm from head over
Using Special Tool : Bearing Extractor - 37 10DJ 77 Remove : Bearing (A) for output shaft assembly from crankcase LH
Remove : Bearing (A) for body balancer gear bearing from crankcase LH
A B D C
Top End :
Cylinder Head Using Sp. Tool Valve Spring Compressor 37 1031 07 & Adapter 37 10DJ 78 Remove :
F
Springs inner (D) Spring outer (C) Valve from below (E) Washer (F) Valve steam seal (G) Similarly carry out the same procedure to dismantle the other valve from the cylinder head assembly.
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Chain Tensioner Assembly Remove : Circlip (A) from the body (I) Cap (B) along with screw internal and screw external (C) Spring (D) Thrust washer (E) O' ring (F) Bolt (G) and O ring (H)
Remove : Thrust washers (A) Circlip (B) from any one side of the gear Scissor gear (C) Torsion Spring (D)
Remove : 4 bolts (A) Holder clutch (B) 4 springs (C) Clutch center (D) Plain washer Bellivellie washer Disc clutch friction (E) (Qty. 6 for 180cc / Qty. 5 for 150 cc) Plate clutch (F) Plate clutch pressure (G) (Wheel clutch) Clutch housing Thrust washer - conical from inner ID Oil Pump Remove : Clip (A)
B D E CB A
Similarly carry out the same procedure on other side of the gear to dismantle the idler gear completely.
Gear Complete Starter Counter Assembly Place the gear comp. starter counter assly on the arbor press as shown in the figure. Using Bearing driver set (P. No. 37 1030 61) Remove : Needle roller bearing
C B A
1st gear is integral with the shaft (A) Remove thrust washer (B) and slide out gear 2nd drive (C) Remove gear 5th drive (D) and collect the splined washer (E) behind it.
Remove circlip (F) and remove gear 3rd drive (G) Remove circlip (H) and collect the splined washer (I)
D G H J A
Remove : Thrust washer (A) Washer thrust (B) Circlip (C) & thrust washer (D) Spring kick starter ratchet (E)
I
Remove gear 4th (J) and collect the thrust washer (K) behind it.
A
FE
CB
Output Shaft Assembly There are no integral gears on output shaft. Remove thrust washer (A) and slide off the gear1st driven (B) and collect the steel bush (1st driven gear is mounted on steel bush (C) with shoulder ring Slide off the gear 4th driven (D). Remove circlip (E) and spline washer (F). Remove the gear 3rd driven (G).
Ratchet kick starter (F) Circlip (G) Washer (H) Pinion complete kick starter (I)
JK N I G D
C D
Collect the thrust washer (H) behind the 3rd gear on output shaft (I) 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)
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C A B D
K J L D E F
Clutch Cover Remove : Parallel Pin (A) Clutch shaft release completely (B) by slightly rotating it so, Rack (C) Plunger oil (D) Plate plunger oil (E) Spring joint A (F) Oil filler plug (G) Oil seal kick shaft (H) Wire clip (I) Oil inspection window 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 3710DJ75 for Bearing 39148520 Remove : Bigger Bearing using sp. tool from camshaft assembly(A) Collar de-comp (B) 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
B F C
E D
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Cylinder Head : Mating surface : No warpage / No scratches (Service limit for warpage: 0.05mm) Identification mark - DJ mark embossed on casting No fins breakage Spark plug hole threads - Ok / No damage Carbon built up in combustion chamber cavity- Clean it Valve seat : No pitting / No carbon deposition Proper fitment of Dampers (4 Nos) Proper fitment of Orings Proper fitment of valve stem oil seals on valve guide Valve guide for crack if any Silencer mounting studs threads - Ok / No damage Cylinder Block : No fins breakage No Scoring marks No Seizure marks Ok Seating mating surfaces Smooth Honing pattern Correct / Same grouping mark w.r.t. piston (A & B group) Inner diameter of block as mentioned in service data. Ovality - Not more then 0.05 mm. 3 Nos. of damper rubbers Properly fitted on fins Proper fitment of O ring on bottom side Piston : Grouping mark with respect to cylinder block must be same. Diameter of the piston - As mentioned in service data No scoring marks on the skirt No blow by marks No seizure marks. Manufacturing / Identification code and date code Piston pin - scratches dent marks Rings : No uneven wear around circumference / breakage. Discoloration at working face. Carbon built up on inner face if any. Piston ring end gap - As per Service data Piston ring width (thickness) - As per Service data Free rotation of Rings in Piston grooves - No stickyness. Piton ring identification mark Top Ring : TOP 1, Second Ring : TOP 2
Visible number punching on LH Crank Case Bearings : Axial play Radial play Bearing Seat Bearing class & code Bearing Rotation : : : : : Ok / Not excessive Ok / Not excessive No sign of high spot on seating area. As per specification numbers Free Rotation
Clutch : Clutch plates / Steel plates - Thickness as per service data Warpage as per service data No Seizure / Damaged bonding of friction material Tangs (Lugs) / Teeth - No wearing Thrust plate cracked No Foreign material embedded Colour change / Signs of overheating if any No uneven wear pattern Steel plates planishing Conical face machining for spacer clutch Clutch Housing : No Wear marks on slots. Clearance between clutch plate tangs and slot in the clutch housing should not be excessive Free movement of plates in clutch housing slots. Rivets of clutch housing should not be loose. Free rotation of housing on Input shaft
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72
Camshaft : Presence of locating washer Free rotation of bearing Lobe height - as per Service Data No cut / wear marks on cam De-comp mechanism stickyness
Notes :
73
74
7mm
Std. Limit Serv. Limit 6.0 ~ 10.0 Kg/cm2 Std. Limit 5.0 ~ 10.0 Kg/cm2 Serv. Limit Inlet 0.05 0.05 Exhaust 0.10 0.15 Serv. Limit 7.98 Serv. Limit 63.488 ~ 63.498 Serv. Limit Std. Limit 7.994 ~ 8.0 Std. Limit 63.478 ~ 63.488 Std. Limit 0.012 ~ 0.030 Std. Limit Serv. Limit TOP 0.02~0.06 0.16 SECOND 0.01~0.05 0.15
Cam Height
30.0 29.0
0.2 0.3
4.4 4.2
7.15 7.0
1st
2nd
21st
75
76
Free Length
100 mm
25 ~ 35 40 ~ 50
1st 2nd
21st
77
78
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Shaft Input Transmission DK 1011 25 Better clamping of clutch assly is ensured on Input Shaft for effective torque transmission with this new clutch mechanism. Taper provided on shaft near clutch mounting end.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description Shaft Input Transmission DH 1015 19 Effective clamping of clutch assembly is ensured on Input Shaft by using guide plate clutch in between shaft & clutch assembly. No Taper provided on shaft near clutch mounting end. Guide Gear Shift DJ 1011 48 Guide Gear with 4 pins is meshed with gear change lever & transmits reciprocating motion into rotary motion & thus rotates drum change. Guide Gear is having 4 pins. Fork Gear Shift (Input & Output) DH 1011 30 - Input DH 1011 32 - Output
UG-II
Guide Gear Shift DK 1011 58 Guide Gear with 6 pins is meshed with gear change lever & transmits reciprocating motion into rotary motion & thus rotates drum change. Guide Gear is having 6 pins. Fork Gear Shift (Input & Output) Input : DK 1011 33 Output : DK 1011 34
The roller in fork gear shift roll in the drum profile smoothly as & when drum rotates & guides to transmit To & Fro motion to fork gear shift for matching respective gears.
4 4.
5 mm
Identification Mark Part Name
The fork gear shift pin slides in the drum profile as & when drum rotates & guides to transmit To & Fro motion to fork gear shift for matching respective gear. Pin dia. = 5 mm. I/P shaft fork mark = S 32. O/P shaft fork mark = S 95 & S 92 respectively. Gear Drum Change Assembly DJ 1011 46 It has a wide profile (groove) for smooth sliding of fork gear shift pin in drum profile for shifting of gears. Profile width is 5 mm. It has a odd shape window parallel to neutral stopper locater. Lever Comp Gear Shift DH 1011 34 Lever comp. gear shift is meshed with guide gear shift constantly. Thus helps in transmitting reciprocating motion to guide gear. Selector lever operates To & Fro. Selector lever is more in length.
Pin diameter is 4.4 mm U mark on fork shift. Gear Drum Change Assembly DK 1011 32 It has a wide profile (groove) for smooth rolling of fork gear shift roller in drum profile for smooth shifting of gear. Profile width is 7.15 mm. It has a square window parallel to neutral stopper locater. Lever Comp Gear Shift DH 1017 05 Lever comp. gear shift is meshed with guide gear shift constantly. Thus helps in transmitting reciprocating motion to guide gear. Selector lever operates radially. Selector lever is short in length.
5 mm
7.15 mm
Identification Mark
Identification Mark
79
80
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Clutch Cover DJ 1012 41 It houses the entrire clutch side assemblies.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description Clutch Cover DH 1011 49 It houses the entire clutch side assemblies. Clutch cover does not have Engine oil inspection window. Holder Clutch (Thrust Plate) DH 1014 84 Holder clutch holds the clutch bearing & plunger.
UG-II
Holder Clutch (Thrust Plate) DK 1010 78 Holder clutch holds the clutch bearing & plunger.
Holder clutch has 4 holes for mounting. Clutch Spring DH 1017 43 Clutch spring helps smooth engaging & disengaging the clutch mechanism. Clutch spring height is 30.8 mm. Clutch Center DK 1010 01
Holder clutch has 6 holes for mounting. Clutch Spring DH 1014 83 Clutch spring helps smooth engaging & disengaging the clutch mechanism. Clutch spring height is 29.3 mm. Clutch Center DJ 1011 79 Clutch center holds the set of clutch plate & pressure plate. No step for guide plate provided. Clutch center height is 30 mm. Clutch Wheel DH 1013 44 Clutch wheel holds the set of clutch plate & pressure plate. Clutch wheel has 6 legs for mounting clutch springs.
H 26 mm
H
Clutch center holds the set of clutch plate & pressure plate. Step for spacer is provided. Clutch center height is 26 mm. Clutch Wheel DK 1011 63 Clutch wheel holds the set of clutch plate & pressure plate. Clutch wheel has 4 legs for mounting clutch springs. Description
30 mm
Identification Mark
Identification Mark
81
82
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Clutch Plain Washer 39 2161 11 New part added for preventing clutch judder.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description NA NA NA
UG-II
Plain washer with no Identification Mark. Clutch Belleville Washer 39 2167 12 New part added for preventing clutch judder.
NA NA NA NA
Clutch Belleville Washer is concave in shape. Disc Clutch Friction Plate DK 1011 49
Clutch plate ID is smaller than regular clutch plate because to accommodate the plain washer & wave washer of anti judder mechanism. This plate is fitted facing the clutch hub side.
NA NA NA NA
Internal diameter is 109.5 mm. Friction material cubs are 48 nos. Clutch Plate Pressure DK 1011 63 New part added. This plate is fitted facing the clutch wheel side. Friction material cubs = 40 nos. Clutch plate appears to be in Brownish colour. Clutch Plate (4 Nos.) DK 1011 51 New part added. 4 clutch plates of same specifications are sandwiched in between LH & RH clutch plates for torque transmission. Friction material cubs 36 nos. Clutch plate appears to be in Greenish colour.
NA Clutch Plate Pressure (6 Clutch Plates) DH 1013 44 Total 6 clutch plates of same specifications are housed in clutch assembly for torque transmission. All clutch plates are Brown in colour. NA NA NA
Identification Mark
Identification Mark
NA
83
84
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Plate Clutch (Pressure Plate) DK 1011 63 Pressure plate are housed in between clutch plates. Pressure plate is more wide. Pressure plate width = 17 mm. Spacer DK 1011 26 New part added for adding is better face clamping of clutch assembly on Input Shaft. Internal diameter (ID) is in conical shape. Clutch Housing DK 1010 74 Clutch housing holds the entire clutch assembly & the slots helps for effective lubrication. Slots provided in clutch housing. Head Cover Cylinder head cover is a part of Cylinder Head Comp Head cover houses the complete OHC system.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description Plate Clutch (Pressure Plate) DH 1015 57 Pressure plate are housed in between clutch plates. Pressure plate is not wide as compared with regular. Width = 14 mm. Guide Plate Clutch DH 1013 74 Guide plate clutch helps in better clamping of clutch assly. on Input shaft. Guide Plate clutch has a stainless steel finish with internal splines. Clutch Housing DH 1015 58 Clutch housing holds the entire clutch assembly.
UG-II
ID
Description
No slots in clutch housing. Head Cover Cylinder head cover is a part of Cylinder Head Comp Head cover houses the complete OHC system.
U mark embossed in casting. Cylinder Head Comp DJ 1012 69 Cylinder head comp houses the complete OHC system with valve train. DJ mark along with U mark embossed in casting. Valve springs fitment groove is deep.
DJ mark embossed in casting. Cylinder Head Comp DH 1016 00 Cylinder head comp houses the complete OHC system with valve train. DJ mark embossed in casting. Valve springs fitment groove is not deep.
Identification Mark
Identification Mark
85
86
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Camshaft Assembly DH 1017 03 Camshaft assly is housed in between cylinder head cover & cyl. head comp. It drives the entire valve train assly as per enhanced valve timing. Cam (track) width is less. Track width = 9.6 mm. Valve Spring Outer DH 1017 30 Valve spring helps in smooth closing of valves without any noise as per enhanced valve timing. It is more in length. Length = 43.6 mm. Spring is marked with White oil paint. Valve Spring Inner DH 1017 31 Valve spring helps in smooth closing of valves without any noise as per enhanced valve timing. It is more in length. Length = 39.1 mm. Spring is marked with White oil paint. Stator Plate DJ 1110 21 All Electrical coils like Pick-up, Exciter, Lighting, Battery charging coils with enhanced ignition timing values are fitted on this plate. Stator plate harness neutral coupler is having square shape. Magneto Assembly (Rotor) DJ 1110 20 Magneto assembly rotor is having analog ignition timing for initial starting for avoiding back kicking. UG-3 mark embossed on the body viewed from tail side.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description Camshaft Assembly DH 1016 17 Camshaft assly is housed in between cylinder head cover & cyl. head comp. It drives the entire valve train assly. Cam (track) width is more. Track width = 12.6 mm. Valve Spring Outer DS 1011 11 Valve spring helps in smooth closing of valves without any noise. It is short in length. Length = 42 mm. Spring is marked with Blue oil paint. Valve Spring Inner DS 1011 10 Valve spring helps in smooth closing of valves without any noise. It is short in length. Length = 38 mm. Spring is marked with Blue oil paint. Stator Plate DJ 1110 04 All Electrical coils like Pick-up, Exciter, Lighting, Battery charging coils are fitted on this plate. Stator plate harness neutral coupler is having bullet type terminal. Magneto Assembly (Rotor) DJ 1110 57 Magneto assly rotor is having only Digital Ignition Timing. E & M mark embossed on the body viewed from tail side.
UG-II
9.6 mm
12.6 mm
Identification Mark
Identification Mark
87
88
Parts Identification
Parts Identification - Engine
Part Name Part No. Description Centrifugal Oil Filter DH 1010 64 The centrifugal oil filter body wall thickness has been increased by reducing the internal diameter for getting better strength. The centrifugal oil filter has a cut mark on tail end.
Parts Identification
UG-III Parts Identification - Engine
Part Name Part No. Description Centrifugal Oil Filter DH 1010 64 The centrifugal oil filter body internal diameter is more as compared to UG-III filter. The centrifugal oil filter does not have cut mark on tail end.
UG-II
Identification Mark
Identification Mark
89
90
Parts Identification
Parts Identification - Chassis
Part Name Part No. Description Carburettor Assembly DJ 1012 32 With enhanced valve timing & to achieve better engine performance the carburettor assembly is retuned. On RH side of Carburettor body BS-29, DJ-U3 mark is embossed. Air Filter Assembly DJ 1210 40 The new large volume air filter with fine & corse filter foam is incorporated to provide torque on demand with optimised intake system. Drain tube is provided on bottom side to discharge the condensed engine oil. Silencer Assembly DJ 1012 43 The silencer has been further optimised to match the changes done incorporating the new camshaft & air filter assembly. Flanged bolt on ExhausTEC is facing on LH side. Head Light Assembly DJ 2011 32
The parking lamps are projected out with a new aggressive look & together with the mask that gives a real Phantom look. H/L facing has been lowered to give balanced looks.
Parts Identification
UG-III Parts Identification - Chassis
Part Name Part No. Description Carburettor Assembly DJ 1210 20 To meet the requirement of UG-II engine specifications the carburettor is tuned. On RH side of Carburettor body BS-29, DJ-U2 mark is embossed. Air Filter Assembly DJ 1211 05 A large volume air filter is introduced to provide torque on demand with optimised intake system. No drain tube is provided on bottom side to discharge the condensed eng. oil. Silencer Assembly DJ 1011 61 The silencer has been optimised to meet the performance of Pulsar UG-II with ExhausTEC introduction. Flanged bolt on ExhausTEC for measuring CO% is facing perpendicular to steering. Head Light Assembly DJ 2011 04 The parking lamps are in line with the head light body line. Parking lamps are inline with head light body. No provision for mask fitment. Handle Holder Assembly DJ 1810 38 Handle holder assembly height is been designed low to accommodate twin pod speedo console. Height of handle holder is less i.e. 18.5 mm.
UG-II
Drain Tube
Parking lamps are projected out. Provision for mask fitment. Handle Holder Assembly DH 1810 53 Handle holder assembly height has been increased to accommodate new speedo console. Height of handle holder is more i.e. 31.5 mm.
H
Identification Mark
Identification Mark
91
92
Parts Identification
Parts Identification - Chassis
Part Name Part No. Description Holder Fork Upper DH 1810 56 Holder fork upper cover clamps the fork pipes & handle holder. No bracket for holding speedo console. Brace Fender DH 1613 04 Brace fender gives reinforcement to mud guard & also guides the wire / hose going to wheel sensor & caliper assembly respectively. 2 nos. of brackets provided for a) Speedometer wire. b) For disc brake hose. Front Number Plate Bracket DH 1612 92 The front number plate bracket holds the number plate & for firm fitment 3 point mounting is given. 3 holes for mounting on lower T. 1 hole is oblong. Speedometer Assembly DJ 2011 44
Easy to read digital speedometer displaying speed in kmph, odometer displaying distance covered & trip meter displaying distance covered per trip with resetting facility.
Parts Identification
UG-III Parts Identification - Chassis
Part Name Part No. Description Holder Fork Upper DJ 1810 17 Holder fork upper cover clamps the fork pipes, handle holder & twin pod speedometer assembly. To mount the twin pod speedo console there is a bracket provided. Brace Fender DH 1612 58 Brace fender gives reinforcement to mud guard & also guides the brake hose going towards caliper assembly. No bracket provided for disc brake hose / speedo cable. Front Number Plate Bracket DJ 1811 11 The front number plate bracket holds the number plate & is mounted with 2 point mounting. 2 holes for mounting on lower T. Speedometer Assembly DJ 1910 48 Twin pod analogue type speedometer displaying vehicle speed, engine rpm, odometer & trip meter. With trip meter adjustment facility. Twin pod analogue type speedometer. Case Meter DJ 1510 57 Case meter assly houses the speedometer worm gear & the pinion gear assly to drive speedometer. Provision for mounting pinion gear & speedometer gear.
UG-II
Digital speedometer with analogue type tachometer. Wheel Sensor Unit DK 1011 63 New part added. It is a sensor sensing the vehicle speed and is a non contact type wheel sensor. NIL
Identification Mark
Identification Mark
93
94
Parts Identification
Parts Identification - Chassis
Part Name Part No. Description Control Switch LH DH 2010 48 The switches operate without any physical contact & thus has no wear & tear of parts. Also these have illumination of tell-tale icons through LED's which glows Bluish-White during night driving. Coupler colour is White. Control Switch RH DH 2010 49 The switches operate without any physical contact & thus has no wear & tear of parts. Also these have illumination of tell-tale icons through LED's which glows Bluish-White during night driving. Provision of engine kill switch. Battery DJ 2011 25 A low maintenance battery with a unique vent mechanism that allows only gas / vapours to escape & not the electrolyte. Hence electrolyte level inspection interval is less. Battery top side mould has orange colour. Battery has vent valve on RH side. CDI Unit DJ 1110 23 For easy kick starting the ignition timing has been optimised by introducing analogue signaling to CDI unit till 3000 rpm & thereafter digital signaling. Two green colour dot marks on CDI unit. Side Stand Switch DH 2010 55 Side stand switch assembly coupler mounting position shifted hence cable is longer in length. Side stand switch cable length is more.
Parts Identification
UG-III Parts Identification - Chassis
Part Name Part No. Description Control Switch LH DJ 2010 24 These are conventional switches & operate on physical make & brake mechanism causing more wear & tear of parts. Coupler colour is Red. Control Switch RH DJ 2010 12 These are conventional switches & operate on physical make & brake type mechanism causing more wear & tear of parts. No engine kill switch available. Battery DJ 2010 36 Conventional type of battery with overflow tube mechanism. Electrolyte level inspection interval is more as compared to low maintenance battery. Battery top side mould has black colour. Battery have a vent plug on RH side. CDI Unit DJ 1110 17 CDI unit has only digital signaling.
UG-II
One green colour dot marks on CDI unit. Side Stand Switch DJ 2011 05 NIL
Identification Mark
Identification Mark
95
96
Parts Identification
Parts Identification - Chassis
Part Name Part No. Description NIL Side Stand Magnet
Parts Identification
UG-III Parts Identification - Chassis
Part Name Part No. Description NIL Side Stand Magnet
UG-II
Side stand magnet body has green passivation. Seat Assembly DJ 2110 03 For proper locking & proper fitment of tool kit the seat assembly is redesigned. No rib at tool kit mounting area. Seat locking stud is located at extreme tail end. Seat Lock Assembly DJ 2110 06 Since seat lock is shifted to tail end of the seat.
Side stand magnet body is black in colour. Seat Assembly DJ 2110 01 NIL Rib at tool kit mounting area. Seat locking stud is located in central part of seat assly. Seat Lock Assembly DH 1610 46 The seat lock is located at center of the seat. Seat lock cable length is short as compared to UG-III cable. Gear Change Pedal DH 1011 49 NIL
Seat lock cable length is more. Gear Change Pedal DJ 1011 49 The gear change pedal has more curved shape for proper placing of foot & to avoid foot fouling with step holder. Gear pedal has more curved shape. Holder RH Step & LH Step DJ 1612 57 & DJ 1612 56 Holder step provided for resting pillion rider's foot. Additional projected step is provided for better aesthetic look.
Gear pedal has less curved shape. Holder RH Step & LH Step DJ 1611 12 & DJ 1611 11 Holder step provided for resting pillion rider's foot.
Identification Mark
Identification Mark
97
98
Parts Identification
Parts Identification - Chassis
Part Name Part No. Description Rear Fender DJ 1612 54 The rear fender is located below the rider seat for arresting dust / dirt & water splashing on. On rear fender a step is provided at rear end RH side. Saree Guard DH 1612 94 Saree guard is mounted on chassis as a safety feature for arresting the possibility of saree getting entangled into rear wheel while riding the bike. Saree guard has a less curve shape near ladies foot step as compared to UG-II. Saree guard mounting allen bolt is short in length.
Parts Identification
UG-III Parts Identification - Chassis
Part Name Part No. Description Rear Fender DJ 1610 51 The rear fender is located below the rider seat for arresting dust / dirt & washer splashing on. On rear fender no step is provided. Saree Guard DJ 1612 15 Saree guard is mounted on chassis as a safety feature for arresting the possibility of saree getting entangled into rear wheel while riding the bike. Saree guard has more curve shape near ladies foot step as compared with Pulsar UG-III. Saree guard mounting allen bolt is more in length.
UG-II
Identification Mark
Identification Mark
99
100
1.1 Kg.m
1.1 Kg.m
5.5 Kg.m
1.1 Kg.m
101
102
5.0 Kg.m
3.5 Kg.m
Sleeve Nut
1.1 Kg.m
4.5 Kg.m
Drain Bolt
1.2 Kg.m
1.4 Kg.m
2.5 Kg.m
3.5 Kg.m
0.5 Kg.m
103
104
Assembly - Engine
Fitting of Oil Seals and Bearings :
Crankcase RH (Clutch Side) Use Bearing Driver set (P. No. 37 1030 61) Fit : Bearing for Input Shaft Assembly
Assembly - Engine
Fit : Oil seal for Output Shaft
Use Bearing Driver set (P. No. 37 1030 61) Fit : Bearing for Output Shaft Assembly
Crankcase LH (Magneto Side) Use Bearing Driver set (P. No. 37 1030 61) Fit : Bearing for Output Shaft
Use Bearing Driver set (P. No. 37 1030 61) Fit : Bearing for Input Shaft
Note : Do not use inner guide while fitting the bearing for Input Shaft in Crankcase LH as this will damage the protruding lug of crankcase casting. Shield of brg. must be on crankcase side/protruding lug side.
Use Bearing Driver set (P. No. 37 1030 61) Fit : Bearing for Body Balancer gear Assembly
Use Bearing Driver set (P. No. 37 1030 61) Fit : Oil seal on Guide Starter Assembly O ring on Guide Starter Assembly. Damper
Camshaft Assembly Fit : Parallel Pin (A) De-compression Mechanism (B) Washer (C) Washer (D)
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Assembly - Engine
Using Arbour Press Fit : Bigger Bearing (E) Small Bearing (F)
Note : Apply thin layer of oil on sliding surfaces of parts for smooth fitting.
Assembly - Engine
Similarly carry out the same procedure to assemble the other Valve in the Cylinder Head. Note : Ensure that there is no valve leakage. If required pour the petrol in intake and Exhaust manifold and observe leakage at valve head.
Head Cover Fit : Roller rocker arm Tappet Screw Tappet Nut 20 Rollers in cage outer
Note : There are 2 cages in roller rocker arm each cage holds 20 rollers Inner cage in Absent Multipurpose grease is to be applied in outer cage to hold the roller firmly while assembling
I
B C D E F H
Chain Tensioner Assembly Fit : O ring (F) in the body (I) Thrust Washer (E) Spring (D)
G
Cap (B) along with Screw Internal and Screw External (C) (Keep the Spring and Screw Terminal fully compressed inside) Circlip (A) Clutch Assembly
2 7
4 6 7
Assemble the clutch plates and friction plates in clutch center / clutch hub. Fit : Plain Washer in Clutch Center / Clutch Hub Bellivelli Washer Clutch Plate(A) 1 Nos Pressure Plate 5 Nos Clutch Plate (B) 4 Nos Clutch Plate (C) 1 Nos Wheel Clutch Springs 4 Nos. Thrust Plate Bolt
6 7 12 10 8
Roller Rocker Arm Set of Plan and Wave Washer Rocker arm shaft Gaskets Dummy Plugs
Note : Repeat the same procedure for fitment of other roller rocker arm
1 14 6 17 11 15
16 13
A B D C
Cylinder Head Fit : Valve steam seals Slide the Valve from below. Place the Valve Springs (C&D) (Inner and outer closed coiled ends placed at the bottom side) Valve Spring Retainer (B)
E
Using Special Tool T1011168 Align the clutch assly into the clutch housing. Fit : Spacer Clutch Assly
Using the sp. tool Valve Spring Compressor 37 1031 07 & Adaptor 37 10DJ 78 Press the valve springs Fit the cotter valves (A) & release the special tool
Note : Ensure concentrity of Thrust Plate w.r.to Clutch Wheel, Clutch Center, Clutch Housing. Using Special Tool The Special Tool can also helps in preventing the cracking / Bending of Thrust Plate while removing and refilling the thrust plate.
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Assembly - Engine
Oil Pump Fit : O ring (A) on the Oil Strainer (B) Clip (C)
Assembly - Engine
Loading the assembly Balancer Idler Gear Using Special Tool - Balancer Gear Holder 37 10DJ 63 Slide the Assembly Balancer Idler Gear in special tool (A) Rotate the Scissor Gear anticlockwise till the lug contacts the torsion spring. Kick Shaft Assembly Fit : Pinion Complete Kick Starter (I) Washer (H) Circlip (G) Ratchet Kick Starter (F)
Note : Match the dot mark of Ratchet Kick Start with respect to Spindle Kick Start Assembly and then slide Ratchet Kick Starter (F) on Spindle Kick Start
A B C
H A E G B
Using a marker, mark the Balancer Idler Gear and Scissor Gear Tooth Using Special Tool Turn the Scissor Gear anticlockwise such that 2 teeth pre-load is achieved. This can be confirmed by the markings done previously. Holding the Scissor Gear pre-loaded in the above position slide the Scissor Gear into the special tool completely. Repeat the same procedure for loading the other Scissor Gear.
Note : Keep this Assembly balancer idler gear in loaded condition with special tool.
I C D F
Spring Kick Starter Ratchet (E) Washer Thrust (D) Circlip (C) Washer Thrust (B) Thrust Washer (A)
Gear Complete Starter Counter Assembly Using Arbour Press Fit : Needle Roller Bearing
Assembly Balancer Idler Gear Bearing Using Bearing Driver set (P. No.: 37 1030 61) Fit : Needle roller bearings in crankcase RH and Cover
Note : Apply oil on bearing OD before pressing bearings for smooth bearing
Crankcase LH (Magneto Side) Fit : Guide Starter Assembly 3 Screws (A) (Use loctite 243)
A C D
Fit : Springs (D) Scissor Gears (C) Circlip (B) Thrust washer Similarly carry out the same procedure on other side of the gear to assemble the Balancer Idler Gear completely.
CB A
Note : Ensure that one spring end butts against spring dowel in Balancer Idler Gear & the other end of spring should butt against the lug on Scissor Gear
K J L
D E F
Clutch Cover Fit : Kick shaft oil seal (H) Oil inspection window Wire clip (I) Set dampers (K) Set of plates (L) Bolts (J) Rack (C) Shaft Clutch Release (B) in Clutch Cover by rotating it slightly to match the teeth. Parallel Pin (A) to lock the Shaft Clutch Release Washer
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110
Assembly - Engine
Spring torsion clutch lever External lever Bolt Spring joint A (F) Plunger Plate (E) Plunger oil (D) 2 Dowel Pins Grommet (M) Oil feeler plug (G) Apply loctite 243 to all damper fitment bolts.
Note : Ensure fitment of set of dampers and plate before fitting the above.
Assembly - Engine
Engine Assembling
Engine Central Part Fit : (In Magneto side Crankcase) Input and Output Shaft Assembly simultaneously. Fork shifts along with rollers on Input and Output Shaft Assembly (2 bigger fork shifts on output shaft and 1 smaller on input shaft).
Note : For ease of assembly of gears, remove gear 1st driven and insert both the input and output shaft assemblies with gears in mesh into their respective bearings. The gear box should be in neutral gear before RH Crankcase is assembled on to LH Crankcase.
Fit : Drum Change Shaft Gear Shift Kick Spring (A) 2 Dowels Gasket
Fit : From LH side of shaft (A) Thrust washer (K) Gear 4th (J) Splined washer (I) Circlip (H) Gear 3rd drive (G)
G H
Circlip (F) Splined washer (E) Gear 5th drive (D) Gear 2nd drive (C) Thrust washer (B)
Caution : Use a sharp blade or knife to cut off any protruding Gasket. This is very important for preventing any oil leakage from Crankcase and Cylinder Block Joint. Don't apply grease / any adhesive to Crankcase Gasket as these Gasket when comes in contact with oil expands and seals hidden cavities.
Fit : Crankshaft
FE
CB
Output Shaft Assembly Fit : from LH side of shaft Gear 5th driven (M) Bush (N) with shoulder ring Gear 2nd driven (L) washer (K) Circlip (J) Fit : from RH side of shaft Fit : Crankcase RH Bolts (LH & RH Side)
Caution : Check oil supply to big end bearing by pumping oil in the clutch side end of crankshaft and lets oil dribble out of con-rod big end sides.
JK
Thrust washer (H) behind the 3rd gear on output shaft Gear 3rd driven (G) Spline washer (F). Circlip (E) Gear 4th driven (D) Steel bush (C) with shoulder ring Gear1st driven (B) Thrust washer (A)
Clutch Side Fit : Parallel Pin. Sprocket Cam Drive Cam Chain
Note : Hold the cam chain upright using a soft copper wire or a thread.
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112
Assembly - Engine
Fit : Square Key Primary Gear.
Assembly - Engine
Fit : Washer Kick Shaft Assembly Washer
Note : Ensure fitment of 2 Plain Washers on either side of Kick Shaft Assembly. Note : 1. Ensure fitment of 2 Plain Washers on either side of Kick Shaft Assembly 2. Refer Skill tip for fitment procedure on page no....
Fit : Body Balancer Gear. A Lock. Bolt (A) (Use Loctite 243) Fit : Thrust Washer Assly Balancer Idler Gear with Special Tool Thrust washer
Fit : Parallel Pin. Spacer A Guide gear shifter Allen Bolt (A)
Fit : Align gear timing marks of .. Primary gear mark w.r.t crankcase mark Body balancer assly mark w.r.t crankcase mark
Fit : Gear kick Idler Stopper A Stopper bolt (A) (Use loctite 243)
Note : Ensure loctite 638 on Kick Guide allen bolts, if removed
Using Special Tool - Primary gear holder 37 10DJ 28 & Special Nut 37 10DJ 43 Fit : Spacer. Clutch Assembly Complete 'Washer Special Nut
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Assembly - Engine
Note : Special nut for input shaft has LH threads.
Assembly - Engine
Fit : Clutch Cover Fit : Bearing with plunger. 10 Bolts Bracket clutch cable Starter Motor Cap Screw Kick starter lever Note : When assembling the Clutch Cover always remember that the entry of Kick Shaft into the Clutch Cover is the tightest as the tolerances are tightly controlled. One should concentrate on aligning the kick shaft bore and kick shaft first, rather than concentrating on the possibility of the plunger falling down. When working on vehicle It is advisable to loosen the RH Rider Footrest which helps in the above and helps also in loosening and tightening of the 2 M6 bolts partially masked by the Footrest.
Using Special Tool : Primary Gear Holder - 37 10DJ 28 Using Sp. Tool : Centrifugal Oil Filter Nut - 37 10DJ 43 Fit : Centrifugal Oil Filter. Washer Special Nut. Using Special tool : Primary gear holder 37 10DJ 28 Fit : Gasket 3 screws Cover
Magneto Side Fit : Shaft Starter Counter. Gear complete starter counter assly. Collar
Note : Always apply a thin layer of grease on to the roller bearing of starter counter gear.
Fit : Starter Motor Clutch cover gasket 2 Dowels A B Note : Do not apply any grease to stick Gaskets to the Clutch Cover / Magneto Cover or Crankcase. As grease deteriorates the gasket material and reduces sealing effeciency.
Fit : Plate starter clutch return (A) Bolt (Use loctite 243) (B)
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Assembly - Engine
Using Special Tool : Rotor Holder H6 0721 00 Fit : Washer Bolt
Assembly - Engine
Note : Place clean piece of cloth on the Crankcase bottom end because their is chance of ring snap falling down while fitment.
Using Special Tool : Piston Ring Holder 37 10DJ 30 Fit : Slide the Cam Chain upright with soft copper wire / Thread into cylinder Slide the piston assly into cylinder
Note : Apply thin layer of oil in cylinder bore and piston assly when sliding inside for ease in fitment. Fit : Head gasket 2 Dowels (A) Chain Guide (Non tensioner side)
Note : Holding the chain firmly bring the piston assly to TDC position and Ensure T mark on the rotor is matching with generator cover mark.
Using Special Tool : Output sprocket holder 37 1030 53 Fit : Bush. Sprocket. Plate drive Sprocket. 2 Bolts (Use loctite 243). Top End Fit : 2 Dowels Block Base Gasket
Using Special Tool : Drift 74 9309 89 Fit : Piston Piston Pin Circlip
Note : Before fitting the sleeve spark plug apply thin layer of molybdenum disulphide grease on the entry chambers for the O rings.
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Assembly - Engine
Fit : Cam Shaft. Collar.
Assembly - Engine
Fit : Cam Chain Tensioner 2 Bolt Release the tensioner plunger bolt Dust cap and O ring
Using Sp. Tool - 37 10DH 36 Fit : Cam Sprocket. Special Washer. Allen Bolt
Adjust : Check and adjust the tappet clearance Inlet Valve : 0.05 mm Exhaust Valve : 0.1 mm
Note : Ensure the sprocket marks are aligned horizontally with cylinder head top machined face and the piston is at TDC. Secure the Cam Chain Sprocket in the special tool firmly and then tighten the sprocket allen bolt. Ensure that the O mark on washer always faces outwards when tightening the allen bolt.
Note : Always ensure that the piston is at the end of compression stroke and T is seen from Timing Inspection Window at generator cover. When adjusting tappet clearance.
Fit : Cam Shaft Cap. Apply thin layer of liquid gasket to head cover Head Cover
Note : Do not apply liquid gasket on to the cam shaft cap and other inside mounting areas. Refer Skill Tip for more details
II
III
I II
Fit : Copper Plated Washer Tighten bolts as per sequence Ist : 4 Domed cap nut IInd : 4 Long bolts of Head Cover IIIrd : 2 Longest bolts of Head cover
Note : Improper tightening sequence of bolts may cause permanent warpage in cylinder head cover and it can get damaged permanently.
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Remove : Seat fork spring (8 Allen bolt) Spacer tube Washer Spring Fork oil in a container The dust seal and the snap ring over the oil seal Recommended Oil Capacity per fork tube Approx 145 + 2.5 ml. (Drain and refill) Using Special Tool : Fork for Cylinder Holder Handle 37 1830 06 & Adapter for Fork - 37 1830 11 Remove : Allen screw that is located at bottom with the help of allen key (A) by holding the fork piston with the help of a adapter (B) and holder Piston assembly Using Special Tool : Front Fork Tube Extractor - 74 9310 15 Remove : The inner tube assembly will not come itself because of two DU bushes fitted. One bush is fitted on inner tube and other bush is fitted in outer tube. Fit the front fork tube on the vehicle by assembling the special tool (A) and lock it at number plate mounting screw. Rotate the special tool handle to seperate the inner tube from outer tube as shown in the fig. Skill Tip : Fit the fork tube without touching head light fairing Rotate special tool without hitting number plate. A
Remove : Front axle self locking nut(A) Front axle (B) Distance piece (C) Wheel sensor (D) Pull out front wheel assly A C D B
Remove : 2 allen bolts (A) (on either side) Front mudguard assembly
Skill Tip : Painted parts should be handled with utmost care to avoid scratches
Remove : Loosen bolt (C) Pull down fork leg assembly by slowly rotating it Similarly carry out the same procedure to take out other side fork leg C
Remove : Inner tube (B) of front fork with DU bush Oil seal (C) for outer tube Guide bush washer (D) Spacer B Bushing
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Brake Lever
When the brake lever is released, the piston is pressed back quickly by the return spring to its idle position. Due to this, a vacuum is generated in the pressure chamber & the fluid in the compensation chamber flows to pressure chamber through the primary seal, the external edges of which flex approximately to allow fluid to pass to pressure chamber. After return of the master cyl. piston, the caliper retracts (after some relative time delay). This causes the fluid in the pressure chamber to return to the reservoir through feed aperture. Master Cylinder Dismantling and Assembling Dismantling : Remove front brake switch and its connection (A)
Fit : Slide the front fork assly in the fork holder Allen bolts Bolt fork at the top end Similarly carry out the same procedure for fitment of the other shock absorber. A Fit : Front fender 2 Allen bolts (A) (2 on either side)
Remove front brake lever by removing the nut and pivot bolt (B) The push rod boot (One end of the boot is held in a groove in the push rod and its other (larger) end is held in a groove in the cylinder body). B
Fit : Front wheel assembly. Front axle (A) Tighten self lock nut A Calliper assembly and tighten 2 bolts Speedometer sensor cable connection.
Caution : Dont apply excess grease or any other lubricant on the wheel sensor case.
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Master cylinder along with hose assembly from handle bar by removing the 2 flanged 8 bolts (F) on the clamp. Brake hose from master cylinder outer by removing banjo bolt (G) Wipe out clearly the outer surface of master cylinder. F G
Skill Tip : Ensure that there should not be any spillage of brake fluid on painted parts
Safety Tip : Take care of your eyes while working with brake fluid.
Hold the master cylinder in a soft jaw vice. Remove circlip with the help of a plier, by pressing the piston slightly inside the bore, with a nylon or wooden rod. Take out the piston assembly along with the Return spring by pulling it out. If transparent window in the cylinder body for level indication needs replacement (due to damage, etc.) proceed as follows: Remove Lock Ring on the window with screw driver Remove window and O ring. Master Cylinder Assembly : Never allow mineral oil to come in contact with seal or other rubber parts of disc brake, since it will cause damage to these parts. Free play at the end of the lever is provided to ensure that in the free condition, the piston does not remain in the pushed condition, This ensures that there is no pressure in the system when the brake is not applied.
Disc
Dismantling of Caliper Dismantling the Assembly B A Remove caliper mounting bolts (A) Remove banjo bolt (B) Remove caliper from fork Removal of Pads : Remove the pad retaining bodys Allen bolt Remove the pads Remove the pad spring from the caliper body with a screw driver Piston and Piston Seal Removal : Wipe out cleanly, the outer surface of the caliper. Remove LH pad retaining case by removing allen bolts Put a wooden wedge in between the piston and caliper. Blow compressed air into cylinder through benzo bolt hole where the brake hose was fitted, with the air pressure, the piston will be pushed out of cylinder.
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Frequency Inspect during every service / every 2500 Km refil up to upper limit (till step on the inner side of the reservoir) if level is low. Replace brake fluid every two years. (In severe operating conditions, replace in a year.)
Skill Tip : While assembling use loctite paste 243 on allen bolt for mounting LH pad retainer case.
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Maintenance - Electricals
Battery
Technical Specification : Type & Capacity Specific gravity of electrolyte for initial filling of new battery Specific gravity of electrolyte for initial filling of new battery Initial charging duration Initial charging current 12V - 9 AH 1.24 for use above 100C 1.28 for use above 100C 10 ~ 15 hrs 0.9 to 1 Amp Hydrometer
Maintenance - Electricals
Remove vent plug strip Top up level with distilled water in between Min and Max. level Connect battery to charge and ensure respective terminal are connected properly Set charging current at 0.9 A DC Charge battery for 3/4 hrs., then check voltage and special gravity. Voltage should be 12.5 volts and special gravity in all 6 cells should be 1.240. This is a confirmation check for a fully charged battery. Disconnect the battery from the changer. Fit vent plug strip firmly. Connect battery on to vehicle. Apply petroleum jelly on to the battery terminal. 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 long time. c. Low electrolyte permitted to fall plates, then the and will become level : If electrolyte level is below the top of the battery exposed surfaces will harden sulphated.
d. Adding acid : If acid is added to a cell in which sulphation exists the condition will be aggravated. e. High specific gravity : If specific gravity is higher than the recommended value, then sulphation may occur. f. High temp.: High temperature accelerates sulphation, particularly of an idle, partially discharged battery.
Read Here
Battery Maintenance
For the optimum performance and longer battery life the maintenance of battery is important. a. Always keep the battery clean and dry. b. Visually inspect the surface of the battery container. If there are any signs of cracking or electrolyte leakage from battery, replace the battery. Never add acid or ordinary tap water for topping up since this will shorten Battery life.
Voltage of the sulphated battery : Cells of the sulphated battery will show low specific gravity. Follow the procedure given below. Check voltage before charging. Charge for 2 hours Check voltage every 1 hour. If voltage increases then continue charging. But if voltage does not increase, discontinue charging. Otherwise battery charger will get permanently damaged. If battery is not badly sulphated (i.e. voltage more than 9 volts), then battery can be revived by special treatment. In such case it is advisable to give sulphated battery to authorised dealer of battery manufacturer for necessary special treatment.
battery inside the box provided on floor board. Fasten the battery firmly with bracket & allied fasteners. c. Connect cables to the positive and negative terminals properly. Reverse connections will damage the charging system permanently. d. Always connect the negative (earthling) terminal at Iast. e. Clean the battery terminals and cable connections. Smear them with petroleum jelly to avoid corrosion g. Check that the battery cable connections are firm and cables do not rub against any metal components.
Battery Installation:
Install the battery on vehicle as described below a. Ensure that in all six cells the level of electrolyte is near the maximum level mark. b. To clean and dry the surface wipe the top of the battery with a clean cloth. Install the
Battery Sulphation
A sulphated battery is one which has been left standing in a discharged condition or undercharged to the point where abnormal lead sulphate has formed on the plates (Sulphate cells looks like white crystal like sugar). Where this
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Maintenance - Electricals
Switches : a. Front Brake Light Switch Inspection :
i. ii. iii. Turn ON the ignition switch. The brake Light LED Blank should get on when the front brake (Lever is pressed) is applied. If it does not, check the Front brake switch. Brown Lever Pressed Lever Released Blue OFF ON ON (Vehicle in neutral) OFF (Vehicle in gear) Brown Blue
Maintenance - Electricals
CDI Unit and H. T. Coil Inspection : CDI unit can be checked using OK H.T. coil on Electronic Test jig Similarly H.T. Coil can be checked using OK CDI unit on electronic Test jig Measure the primary winding resistance as follows Connect the hand tester between the coil terminals. Measure the secondary winding resistance as follows Remove the plug cap by turning it counter clockwise. Connect the tester between the spark plug leads. Measure primary winding resistance. Measure secondary winding resistance. If the valve does not match as per, replace the coil. Primary Winding
Reading 200+22 ohm
e. Ignition Switch :
Brown White Black / White Black / Yellow
Disconnect stator plate coupler Set multimeter on ohm range. (Ohm Meter)
Secondary Winding
Excitor Coil :
Range 200 Meter +ve Red Meter -ve Black/Yellow Reading 14+1.4
If the meter reads as specified, the ignition coil windings are probably good. However, if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known. Visually inspect the secondary winding lead. If it shows any damage, replace the coil.
ii.
For knowing then quantity of fuel inside the fuel tank at a glance, is provided on Speedo consle. The fuel gauge works on the principle of variable resistance. The fuel gauge works on D.C supply. For checking the resistance across the sender and across the gauge, make the connections verify the readings, make the connections verify the readings as tabulated below Tank (Float) Resistance
Fuse Inspection (Capacity = 10 Amp) Inspect the fuse element If it is blown out, replace the fuse. If a fuse fails during operation, the electrical system to determine the cause, and then replace it with a new fuse of proper amperage.
Caution : When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit. Installing of a fuse with a higher rating may cause damage to wiring and components.
Lighting Coil :
Range 200 Meter +ve Yellow/Red Meter -ve Reading
Black/Yellow 0.7+0.07W
Black / Yellow
95~105 W
Relay (Inspection Using Multimeter) : Coil Resistance Meter +ve Brown Meter -ve Green/White Reading 55+5.5 Ohm
d. Neutral Switch :
i.
ii.
The neutral switch will be in ON position only when the engine is in neutral position. The neutral light will not glow when vehicle is in geared position
X 200 Ohm
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Maintenance - Electricals
Rectifier & Regulator Assembly : AC Voltage Measurement :
To measure AC voltage, open the headlight housing. Start the engine and set it at 4000+25 RPM. Ensure that the headlight, tail light, Speedometer light are ON and the dipper switch is at Hi beam position.
Maintenance - Electricals
REGULATOR RECTIFIER UNIT
L/W
L/W
Connect AC voltmeter in parallel across the AC circuit load by connecting the +ve meter lead to red/black lead from the dipper switch and the -ve meter lead to ground. Measure AC lighting voltage at 4000+25 RPM. The voltage should be 13.5+0.5 V. Stop the engine. Disconnect the meter leads. Reassemble the headlight housing. Meter Range AC 2o Volt Specification at 4000+25 RPM
L/W
L/W
AC Lighting Circuit :
13.7 + 0.3 V
L/W
L/W
W/B
INSTRUMENT CLUSTER
PIN NO.3 HIGH BEAM INDICATOR PIN NO.2 INSTRUMENT CLUSTER + INPUT PIN NO.11 COMMON GROUND PIN NO.13 POSITION LAMP ON- INPUT PIN NO.20 PERMANENT BATTERY + INPUT
R/B Br B/Y R W
R/B Br B/Y R
CONTROL SWITCH RH
R BATTERY 12V-9Ah
Y/R
O O F N F
13.5
IGNITION SWITCH
Br W
Br W R R W
R/Y
L/W
L/W
R R
Y/R
B/Y R/Y
B/Y R/Y
W/B
R/B
R/B
FUSE 10 Amps
Start the engine and set it at 4000+25 RPM. Measure the DC charging current. The DC charging current should be 2 A max stop the engine and disconnect meter leads. Connect the RR unit and battery
Meter Range DC10A Connection Specification
L/W
L/W
R MAGNETO
Meter +ve Meter -ve 2 A max at White/Black Battery (+) 4000+25 RPM terminal of lead (White) R/R
L/W
L/W
W/B
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Maintenance - Electricals
Speedometer/Tachometer Console
The speedometer has a wide Digital LCD screen with a orange backlit display mode for superb visibility of display during night riding condition. This entire speedo console houses following : A large analogue tachometer with self testing mechanism. A red LED indicator showing low fuel level inside the fuel tank. And also indicates a flashing signal when engine RPM exceeds above 9000 RPM. Thus ensuring safety of rider and engine. Digital Displays for - Odometer - Trip meter (Unique facility of resting the trip meter 1 & 2 respectively) - Fuel level indicator A row of indication LED displaying functioning of - Neutral Light - High beam - Turn signal - Side stand ON with a unique Day-Night mode functioning feature for riders convenience and safety.
Maintenance - Electricals
Back-lit, Non-contact Handlebar switches : The control switches on both sides of the handlebar are conventional to look as, in terms of switch positioning. The main features of these are ... Operation is based on non-contact Switching is done without physical contact There is no wear and tear Life would be equal to that of the bike itself. The operational force required for the switches has been kept as low as possible to give a light feel and reduce fatigue for the rider. mind and wants to continue straight ahead. The rider has only to re-select the opposite side indicator again to cancel the previously selected indication. (There is no depress to cancel function) The other feature which has been incorporated in the switches is the illumination of the tell-tale icons. The illumination is backlit by LEDs which again are long-life and have a pleasant bluish-white glow to them. All the icons like the turn indicators, low beam, high beam, horn, starter etc. glow when the Parking or Headlight switches are put ON. Checking of switches on handle bar : As like in conventional switches, since switch is not having any electrical contact, We cant check the switch functioning (Continuity) by multimeter. But it can be checked on electronic test jig. Clutch Switch : The clutch switch has 3 wires and it has contact configration of This vehicle is not having interlock relay Instead its working is taken care of by clutch
Light Green Yellow/GreenBlack/Yellow
Working of Switches : These are non-contact type switches, so instead of contact set it consists of hall sensor and magnet combination. Whenever any handlebar switches is pressed the hall sensor gets operated and its output signal is gives to a BCU (Body Control Unit) and BCU further calculates and gives precise signal to the respective unit for functioning. e.g.
Horn Switch
BCU
OFF Clutch Lever Released ON Clutch Lever Released Body Control Unit (BCU) : This is a sealed Electric Control Unit located inside head light assly. -
Note : The speedometer console has a unique builtin memory logic function which stores all the data like distance covered etc. in its memory even if DC supply is disconnected.
Pass Switch
BCU
Tail Lamp : The illumination for Tail lamp and Brake lamp are done through 2 rows of LEDs each. These are high intensity LEDs the main advantage of these LEDs is they consume very less power. i.e LED consumes 3W power against 21 W power of a conventional brake lamp. When you operate light control switch to glow but intensity will be very low. As soon as you operate brake switch the brightness of LED increases to size you bright light. This changeover of intensity is maintained with the help of electronic circuit placed inside Tail Lamp Console assly and is a totally sealed unit.
Self Indicator Switch : In the conventional type of switches the rider has to manually depress the Turn Indicator knob or return the Turn indicator knob to its non-signalling position. In UG III there is no separate press to off buttons for cancelling side indicator signal. This feature is achieved by providing a self cancelling hall sensor and magnet fitted on steering column assembly. This cancellation signal is processed through BCU and then side indicators are switched off. The self cancelling feature automatically turns of the indicator of the indicator under 3 conditions. The first indication is when after the turn has been completed and the handlebar comes to a straight ahead position, the indicators switch off by themselves. The second condition is when the rider has selected a right or left turn but not physically done the turn and is continuing to go straight ahead and may be unaware of the enabled turn signal too. A timer function gets enabled which switches off the indicators after a pre-set time. The third condition is when the rider has selected for eg. a left turn, but changes his
In case of overload or short circuit, BCU has a short circuit/overload prevention facility. This vehicle does not have a flasher. The flasher operation is carried out by BCU only. In case of failure of one of the filaments of head lamp. The BCU will automatically changeover to IInd filament. This is provided for safety rider during night driving conditions. If customer operated starter switch contunuously 3 times in a go for 4 th cranking BCU will disable cranking operation and next cranking would be possible after 20 second only. This feature is added which gives better battery life. Maintenance : Ensure no direct high pressure water water is applied on Speedo console and wheel sensor.
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PIN NO.3 HIGH BEAM INDICATOR PIN NO.4 TALE-TELL SIDE STAND INDICATOR PIN NO.5 FUEL GAUGE INDICATOR PIN NO.6 VEHICLE SPEED SENSOR OUTPUT PIN NO.7 TALE-TELL BLINKER- RH INPUT PIN NO.8 TALE-TELL BLINKER- LH INPUT PIN NO.9 TALE-TELL NEUTRAL INDICATOR PIN NO.10 TACHOMETER PIN NO.11 COMMON GROUND PIN NO.13 POSITION LAMP ON- INPUT PIN NO.20 PERMANENT BATTERY + INPUT
Br
L/W
B/Y
B/Y
W/R
B/Y
R/Y
Gr G Lg B B/Y R W
Gr G Lg B B/Y
R/B
R/W
Br/B
Gr
L/W
L/W
Br
INSTRUMENT CLUSTER
SPARK PLUG B
W/Y
B/Y
Br
B/Y
Br
Br
B/Y
B/Y
O/Br
B/Y
B/Y R/Y R EARTH-FRAME R L/W L/W Y/R / R W O/Br B/Y Lg B/Y B/ Y R R STARTER MOTOR B/Y Br/B B/Y Br/B Y/G R L/W L/W Y/R W/R R/W B/Y SIGNAL LAMP FRONT LH G Lg B/Y CLUTCH SWITCH Lg B/Y Y/G Y/G G SIDE STAND SWITCH Lg W ASSY. LIGHT NO. PLATE
B/Y
B/Y
W/B
FUSE 10 Amps
C PU OIL LS ING
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Notes :
Maintenance - Electricals
Speedo console should not be kept inverted Ensure there are no scratches/breakage on console cover Dont open rubber pins located on back side of speedo under any under any circumstances. Ensure speedo console and harness mating coupler is always covered by rubber cover. Handle wheel sensor carefully while working on front brake drum relating problems. Ensure sensor cable is intact. Do not apply in grease or lubricant in between the rotating parts. Do not open control switches and dont apply any grease or lubricant.
CONTROL SWITCH LH NOT USED R/W Br R/B O/Br W/Y R/W Br R/B O/Br W/Y AC INPUT & OUTPUT DC INPUT & OUTPUT R/W VEHICLE SPEED SENSOR FROM RH SWITCH FROM LH SWITCH SWITCH- BODY CONTROL UNIT
PIN NO.1 VEHICLE SPEED SENSOR + INPUT PIN NO.2 INSTRUMENT CLUSTER + INPUT
B/R
H.T. COIL
SPARK PLUG
Gr B /Y
Gr B/ Y
IGNITION SWITCH
Br W B/W B/Y
Br W B/W B/Y
TAIL LAMP ASSY R/W L B/ Y R /W L B/ Y R TAIL/ STOP LED R B/ Y R/B R/B G G SIGNAL LAMP REAR LH
R HORN (LH) HORN (RH) BATTERY 12V-9Ah STARTER RELAY 70A RATING NEUTRAL SWITCH MAGNETO
138
Br
B/W
W/R
B/R
B/Y
G Y
Br
IGNITION SWITCH
O O F N F
H.T. COIL No. 1 (For Primary Spark Plug) B/W B/Y B/W B/Y
Br
Br
SPARK PLUG
B/W
W/R
B/Y
O O F N F IGNITION SWITCH
W
R W/R
W/R
B/Y
EXCITER COIL
Kill Switch
B/Y
B/Y
B BATTERY 12V-9Ah
C PU OIL LS IN G
EARTH-FRAME
MAGNETO
Horn Circuit :
CONTROL SWITCH LH
Br
Br
B/Y
B/Y
Br
B/Y
L/W
L/W
EARTH-FRAME
Br/B
Br/B
B/Y
B/Y
R BATTERY 12V-9Ah
W/B
FUSE 10 Amps
B BATTERY 12V-9Ah
MAGNETO
HORN (LH)
HORN (RH)
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140
INSTRUMENT CLUSTER
PIN NO.3 HIGH BEAM INDICATOR PIN NO.2 INSTRUMENT CLUSTER + INPUT PIN NO.11 COMMON GROUND PIN NO.13 POSITION LAMP ON- INPUT PIN NO.20 PERMANENT BATTERY + INPUT
R/B Br B/Y R W
R/B Br B/Y R
SIGNAL LAMP FRONT RH REGULATOR RECTIFIER UNIT PIN NO.2 INSTRUMENT CLUSTER- INPUT PIN NO.7 TALE-TELL BLINKER- RH INPUT Y/R Y PIN NO.8 TALE-TELL BLINKER- LH INPUT PIN NO.11 COMMON GROUND PIN NO.20 PERMANENT BATTERY + INPUT O O N F F IGNITION SWITCH R/B
R/Y
O O F N F IGNITION SWITCH
Br
Br W
Y/R
B/Y
Gr
B/Y
Br
Gr Br W B/Y W
Br W B/Y
Y/R
B/Y R/Y
B/Y R/Y
W/B
R/B
R/B
FUSE 10 Amps
G B/Y
FUSE 10 Amps
R MAGNETO
EARTH-FRAME
L/W
L/W B/Y
Br
SPEEDOMETER COUPLER
Br
Br
Br
C.D.I. ASSY.
B/Y
B/Y
W/Y
B/Y
B/Y
O O N F F IGNITION SWITCH
B Br Br
O N IGNITION SWITCH
O F F
Br W
Br W B/Y
FUSE 10 Amps
BATTERY 12V-9Ah
141
B/Y
B/Y
B/Y
W/Y
142
O/Br
Br
Br
Please note that Starter Switch is enable only if Kill Switch is in OFF condition.
Br
SPEEDOMETER COUPLER
INSTRUMENT CLUSTER
Br
B/Y
B/Y
IGNITION SWITCH
O O N F F
Br W
Br
Y/G
Br
O O N F F IGNITION SWITCH
Br W
Br W W
B/Y
B/Y
W/B
Lg
Lg
Lg
W/B
EARTH-FRAME
FUSE 10 Amps
B/Y
O/Br
B/Y
FUSE 10 Amps
B/Y
Y/G
Y/G
BATTERY 12V-9Ah
EARTH-FRAME
O/Br
B BATTERY 12V-9Ah
NEUTRAL SWITCH
PIN NO.9 TALE-TELL NEUTRAL INDICATOR INSTRUMENT CLUSTER PIN NO.2 INSTRUMENT CLUSTER + INPUT PIN NO.11 COMMON GROUND PIN NO.20 PERMANENT BATTERY + INPUT
Br
Br
B/Y
B/Y
O O F N F IGNITION SWITCH
NEUTRAL SWITCH
B BATTERY 12V-9Ah
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OK
2nd Step : Air Induction Related Check air filter foam element for no clogging / correct oil soaking Not OK Clean air filter foam element (fine & corse) as per SOP if clogged / excess oil soaked If OK Clean air intake duct if blocked / clogged OK 3rd Step : Choke Related Check free movement of choke knob Not OK Lubricate / Replace choke plunger if sticky / jam If OK Clean choke plunger if sticky / jam
OK Not OK
5th Step : Front Wheel Rotation Related Adjust front brake lever free play if less than specified
Front Brake Lever Free Play 2~3 mm If OK Check disc for run out
If OK Using following sequence Tighten the fasteners as Axle Nut, Mudgaurd Mounting Bolts, Lower T, Upper T, Cap nut
OK
Continued.....
Continued.....
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146
OK Not OK
Lubricate rear brake pedal shaft if dry / sticky If OK Lubricate rear brake cam if sticky / jam OK
OK
9th Step : Carburettor Related Check carburettor for correct air fuel mixture with the help of CO gas analyser Not OK Adjust VC screw as per specification & CO limit If OK Correct e clip position as per specification If OK Clean carburettor body air passages if clogged If OK Replace carburettor jets if worn out OK If OK Replace needle valve & its seat if worn out Continued..... Continued.....
7th Step : Clutch Cable Related Check clutch cable for free play & smooth operation Not OK Adjust clutch lever free play if less / more than specified If OK Clutch Cable Free Play 2~3 mm Correct clutch cable routing
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If compression pressure in wet test is NOT OK Check & Rectify cylinder head related reasons
If compression pressure in wet test is OK Check & Rectify cylinder block related reasons
Correct valve timing if mark on cam sprocket not aligning with cyl. head when rotor T mark is aligned with crankcase L.H. mark
Replace piston ring set if compression ring worn out * Reset valve tappet clearance as per specs. if found less Replace cylinder block piston assembly if worn out / excessive clearance Clean valve guide & valve stem if gummy substance deposited Replace cylinder piston assembly if partially seized Rectify valve seat and valve face by lapping if pitted / worn out / excess carbon deposition Inspect De-comp mechanism for stickness
11th Step : Ignition Timing Related Not OK Replace CDI if timing is incorrect
If OK
Inlet
Exhaust
0.05 mm 0.10 mm
Continued.....
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If compression pressure in wet test is NOT OK Check & Rectify cylinder head related reasons
If compression pressure in wet test is OK Check & Rectify cylinder block related reasons
Skill Tip : Do not scribe. Clean by Acetone/CCL4.
2nd Step : Air Induction Related Clean air intake duct if blocked If OK Clean air filter foam element as per SOP if clogged / excess oil soaked
OK Check carburettor for correct air fuel mixture with the help of CO gas analyser Not OK
3rd Step : Carburettor Related Re-adjust V.C. screw as per specifications If OK Correct e clip position as per specification
If OK Clean main jet, pilot jet if clogged If OK Clean carburettor air & mixture passages if clogged If OK Correct diaphragm position if wrong If OK Replace carburettor piston valve assly if diaphragm punctured Continued.....
Replace cylinder head if spark plug mtg. hole threads washed out
Carry out surface facing / Replace cylinder head if warpage is equal to or more than 0.05 mm
OK
Continued.....
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Not OK
If stg. jam, loosen front fork side bolts, top bolts, steering ring nut & adjust the steering for free movement. Retighten the bolts as per SOP sequence.
Clean valve guide & valve stem if deposited with gummy substance
Std Limit
Top Ring : 0.06 mm
Service Limit
0.16 mm
OK
2nd Step : Chain Adjuster Related Check rear wheel alignment w.r.t. drive chain adjusters Not OK Set both side drive chain adjusters equally
Service Limit
0.50 mm
Rectify valve seat & valve face by lapping if pitted / worn out / excess carbon depostion
OK Not OK Check handle bar & upper holder bkt. for alignment
3rd Step : Handle Bar Related Replace handle bar if bent If OK Replace fork upper holder bracket if misaligned
OK 4th Step : Fork Inner Pipe Related Not OK Replace fork inner pipes if bent If OK Replace fork under holder bracket T if bent OK Continued.....
Check fork inner pipe & under holder bracket for alignment
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6th Step : Frame Alignment Related Replace frame if misaligned at steering tube area
Dismantle clutch cover & check kick shaft assembly for Correct timing of ratchet gear w.r.t. kick shaft Return spring tension O.K.
Not OK
Match the dot mark on ratchet gear w.r.t. dot mark on kick shaft end if timing incorrect If OK Engine O/H and Replace kick shaft return spring if weak
OK Not OK Check kick guide screws for tightness and intact condition
3rd Step : Kick Guide Related Tighten kick guide allen bolts by applying loctite 638 if loose If OK Replace kick guide allen bolts if sheared off
OK 4th Step : Crankcase L.H. Related Check crankcase RH kick boss area for intact condition Not OK Replace crankcase RH if cracked at kick boss area
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OK 1st Step : Clutch Lever Free Play Related Check clutch lever free play
Std. Free Play for Clutch Lever 2~3 mm
5th Step : Clutch Assembly Related Not OK Replace clutch springs if free length is less than standard If OK Replace friction plates if worn out / burnt / friction bonding given away If OK Replace steel plates if worn out / burnt / glazy If OK
Not OK
Dismantle clutch & check all components for correct dimensions & no abnormal wear
OK Not OK
2nd Step : Clutch Cable Related Dismantle, rectify & refit clutch lever if sticky If OK Replace clutch cable if sticky / jam
OK 3rd Step : Engine Oil Related Not OK Top up engine oil level if less than specified If OK Replace engine oil if viscosity not OK OK 4th Step : Clutch Release Mech. Related Not OK Check clutch release mechanism for smooth operation Replace clutch release lever if bent / O.D. oversize If OK Replace clutch cover if release levers parent hole undersize / oval If OK OK Replace rack & Clutch Release Shaft if teeth worn out / damaged Continued.....
Replace clutch center (clutch hub) if worn out If OK Replace clutch wheel if worn out
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Chain Slackness = 30 ~ 35 mm OK Not OK Check chain cover for correct fitment & alignment 2nd Step : Chain Cover Related Refit chain covers properly If OK Fit PVC strips if missing If OK Replace chain cover bolts & washers by O.E. ones if touching to chain If OK OK Correct alignment of swing arm brackets if bent
OK Not OK Dismantle chain sprocket assly. & check for wear & alignment
6th Step : Chain Sprocket Related Align engine sprocket & rear wheel sprockets If OK Replace drive chain if 20 link length is more than service limit If OK Replace chain sprocket kit if worn out
Drive Chain 20 Link Length Std. Limit 254 ~ 254.6 mm Ser. Limit 260 mm
3rd Step : Sprocket Mtg. Bolt Related Check rear wheel sprocket bolts for tightness Not OK Tighten bolts to specified torque if loose
4th Step : Engine Sprocket Collar Related Not OK Carry out sanding operation of collar I.D. & apply SAE 90 oil if collar jam on O/P shaft O.D.
OK Continued.....
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160
5th Step : Muffler Related Replace silencer if baffle plate / plates are loose
6th Step : Torque Expansion chamber Related Tighten CO nozzle bolt if loose / replace silencer if nozzle given away
OK
If OK
2nd Step : Gasket Related Check silencer mouth gasket for intact condition Not OK Replace silencer mouth gasket (gasket exhaust) if pressed
Replace silencer if noise in ExhausTEC chamber due to paint solidified from inside
3rd Step : Silencer Guard Related Tighten silencer guard screws / allen bolts if loose. Apply loctite 243.
Not OK
OK Check silencer for bend pipe not fouling with riders foot rest
OK
Continued.....
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Not OK
Tightening Torques in Kgm Description Steering center special nut / bolt OK Fork side bolts Fork top bolts Steering ring nut Torque
2nd Step: Steering Races Fitment Related Check steering races for correct fitment Not OK Refit steering races as per S.O.P. if fitted in tilted condition OK
OK 3rd Step: Stg. Races Condition Related Check condition of steering races for no pitting marks & steering balls for no rusting / breakage
Not OK
Replace Caliper seals if - seal lips worn out, deformed, became hard.
Not OK
OK 4th Step : Brake Disc Related Check brake disc for thickness & alignment Not OK Replace brake disc if worn out, run out exceeds service limit.
Note : Lubricate steering races and balls by Servo Gem RR-3 grease at every 10,000 Kms.
Disc Disc Runout Standard Limit Service Limit Less than 0.2 mm 0.2 mm
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2nd Step : Brake Fluid leakage Related Not OK Identify source of leakage, rectify & top-up if brake fluid level is below minimum mark
OK Check Disc Brake system free from air trapping. OK Check master cylinder vent holes for no clogging. OK Check master cylinder diaphragm for no deformation teared off OK Check master cylinder primary seal for no wear. OK Check for free floating movement of Caliper. Not OK Not OK Not OK Not OK Not OK
3rd Step : Air Trapping Related Carry out air bleeding of disc brake system as per SOP
4th Step : Master Cylinder Related Clean master cylinder cover & vent holes if clogged due to oxidation / dust.
4th Step : Caliper Related Clean & Lubricate caliper pins by silicon grease / brake fluid if jam.
165