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Sp
ecia
l T
oo
ls
LC
D S
pe
ed
o C
on
so
le T
est
•C
on
nect
wirin
g h
arn
ess n
um
ber
2 t
o C
2 c
on
necto
r.
•A
fter
co
nn
ectin
g
sp
eed
o
co
nso
le
wait
un
itl
co
nso
le
LC
D
go
es
bla
nk.
•N
ow
pre
ss s
peed
o c
on
so
le t
est
sw
itch
to
sta
rt t
he t
est.
•O
bserv
e f
or
wo
rkin
g o
f sp
eed
o c
on
so
le t
ill t
est
en
ds.
Bo
dy C
on
tro
l U
nit
(B
CU
) T
est
•C
on
nect
wirin
g
harn
ess
nu
mb
er
3
to
C3
, C
4
an
d
C5
co
nn
ecto
rs
resp
ectively
.
•P
ress t
he B
CU
test
sw
itch
.
•A
t th
e en
d o
f co
mp
lete
te
st,
G
reen
co
lou
r g
low
ing
o
f ‘R
esu
lt’
LE
D
ind
icate
s B
CU
test
passed
.
•A
t th
e e
nd
of
co
mp
lete
test,
Red
glo
win
g o
f ‘R
esu
lt’
LE
D i
nd
icate
s
BC
U t
est
faile
d a
t re
sp
ective R
ed
in
dic
atio
ns.
Deale
r D
eve
lop
ment
Cente
r34
Deale
r D
eve
lop
ment
Cente
r33
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ca
msh
aft
Big
Be
ari
ng
Pu
lle
r
Dra
win
g N
o.:
37
10
DH
32
Ap
plic
ati
on
:
To
re
mo
ve
bearin
g
(Deco
mp
ressio
n
assem
bly
sid
e)
of
cam
sh
aft
.
Ca
msh
aft
Sm
all B
ea
rin
g P
ulle
r
Dra
win
g N
o.:
37
10
DH
31
Ap
plic
ati
on
:
To
re
mo
ve
s
ma
ll
be
arin
g
of
cam
sh
aft
.
Ro
ck
er
Pin
Re
mo
ve
r
Dra
win
g N
o.:
37
10
DH
35
Ap
plic
ati
on
:
To
re
mo
ve
rocker
pin
fr
om
cylin
der
head
.
Sile
nt
Bu
sh
Pu
lle
r
Dra
win
g N
o.:
37
10
DH
33
Ap
plic
ati
on
:
To
re
mo
ve sile
nt
bu
sh
fr
om
cylin
der
head
co
ver.
De
tails o
f E
xc
lusiv
e S
pe
cia
l T
oo
l
Fo
r carr
yin
g
ou
t re
pairs
/ o
verh
au
ls,
1
new
sp
ecia
l to
ols
fo
r P
uls
ar
DT
S-i
U
G
III
have
been
d
evelo
ped
. R
est
of
the sp
ecia
l to
ols
re
qu
ired
re
main
s th
e sam
e w
hic
h w
ere
earlie
r re
qu
ired
fo
r P
uls
ar
an
d P
uls
ar
DT
Si
En
gin
e
Sp
roc
ke
t C
atc
he
r
Dra
win
g N
o.:
37
10
DH
36
Ap
plic
ati
on
:
Fo
r h
old
ing
sp
rocket
du
rin
g re
mo
val
/ re
fitt
ing
o
f C
am
sp
rocket
allen
b
olt.
Sta
nd
ard
Checkin
g P
roced
ure
Deale
r D
eve
lop
ment
Cente
r36
Deale
r D
eve
lop
ment
Cente
r35
Ro
tor
Pu
lle
r w
ith
Bu
tt P
in
Dra
win
g N
o.:
37
10
DJ 3
2
Ap
plic
ati
on
:
Used
to
p
ull
ou
t th
e
roto
r fr
om
cra
nksh
aft
assem
bly
.
Pri
ma
ry G
ea
r H
old
er
Dra
win
g N
o.:
37
10
DJ 2
8
Ap
plic
ati
on
:
Use
to
h
old
p
rim
ary
g
ea
r w
hile
lo
osen
ing
/ t
igh
ten
ing
th
e c
lutc
h n
ut.
Ba
lan
ce
r G
ea
r H
old
er
Dra
win
g N
o.:
37
10
DJ 6
3
Ap
plic
ati
on
:
Use
d
to
loa
d
the
p
re-t
en
sio
ne
d
scis
so
r g
ears
o
f A
ssly
b
ala
ncer
Idle
r g
ear.
Sp
ec
ial
Nu
t
Dra
win
g N
o.:
37
10
DJ 4
3
Ap
plic
ati
on
:
Used
to
re
mo
ve
/ fit
of
cen
trifu
gal
oil
filter
nu
t.
Pis
ton
Rin
g H
old
er
Dra
win
g N
o.:
37
10
DJ 3
0
Ap
plic
ati
on
:
Used
fo
r co
mp
ressin
g
the
pis
ton
rin
gs
wh
en
assem
bly
p
isto
n
in
the
cylin
der
blo
ck.
Be
ari
ng
Ra
ce
Extr
ac
tor
Dra
win
g N
o.:
37
00
DJ 0
1
Ap
plic
ati
on
:
Used
fo
r re
mo
vin
g th
e lo
wer
bearin
g
race f
rom
‘T
’
No
te :
Exis
ting
to
ol
can b
e u
sed
by r
ed
ucin
g d
iam
ete
r to
25.9
+ 0
.1 m
mD
ia. =
25.9
+0.1
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Be
ari
ng
Extr
ac
tor
Dra
win
g N
o.:
37
10
DJ 7
6
Ap
plic
ati
on
:
Use
d
to
extr
ac
t th
e
inp
ut
sh
aft
b
earin
g f
rom
cra
nkcase L
H.
Be
ari
ng
Pu
lle
r
Dra
win
g N
o.:
37
10
DJ 7
7
Ap
plic
ati
on
:
Used
to
p
ull
ou
t th
e
beari
ng
fo
r b
od
y b
ala
ncer
fro
m c
ran
kcase L
H.
Ad
ap
tor
& V
alv
e S
pri
ng
co
mp
resso
r
Ad
ap
tor
- D
raw
ing
No
.: 3
7 1
0D
J 7
8
Va
lve
S
pri
ng
C
om
pre
sso
r -
Dra
win
g
No
.: 3
7 1
03
1 0
7
Ap
plic
ati
on
:
Used
fo
r assem
blin
g
/ d
ism
an
tlin
g
inle
t, exh
au
st
valv
es b
y co
mp
ressin
g
sp
rin
g i
n c
ylin
der
head
.
Ro
tor
Ho
lde
r
Dra
win
g N
o.:
H6
07
21
00
Ap
plic
ati
on
:
To
ho
ld r
oto
r w
hile
lo
osen
ing
bo
lt.
Dri
ft
Dra
win
g N
o.:
74
93
09
89
Ap
plic
ati
on
:
To
rem
ove p
isto
n p
in.
Th
rust
pla
te a
lig
ne
r/h
old
er
Dra
win
g N
o.:
T-1
01
11
68
Ap
plic
ati
on
:
To
alig
n th
e clu
tch
h
ub
co
ncen
tric
ity
w.r
.to
clu
tch
w
heel,
clu
tch
h
ou
sin
g
an
d t
hru
st
pla
te
Sp
ecia
l T
oo
lsS
pecia
l T
oo
ls
Deale
r D
eve
lop
ment
Cente
r38
Deale
r D
eve
lop
ment
Cente
r37
Cra
nk
sh
aft
Be
ari
ng
Extr
ac
tor
Dra
win
g N
o.:
37
10
01
14
Ap
plic
ati
on
:
To
rem
ove b
earin
g f
rom
cra
nksh
aft
Ou
tpu
t S
pro
ck
et
Ho
lde
r
Dra
win
g N
o.:
37
10
30
53
Ap
plic
ati
on
:
To
h
old
th
e
ou
tpu
t sp
rocket
wh
ile
rem
ovin
g s
pro
cket
bo
lt
Be
ari
ng
Dri
ve
r S
et
Dra
win
g N
o.:
Ap
plic
ati
on
:
Co
mm
on
bearin
g d
river
set
for
fitt
ing
a
nd
re
mo
vin
g
be
arin
gs
fr
om
cra
nkcase.
37
10
30
61
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ch
assis
Fo
rk o
il s
ea
l fi
tme
nt
pu
nc
h
Dra
win
g N
o.:
37
00
40
03
Ap
plic
ati
on
:
To
fit f
ork
oil
seal
on
ou
ter
pip
e
Re
ar
Sh
oc
k a
bso
rbe
r a
dju
ste
r
Dra
win
g N
o.:
37
00
DH
14
Ap
plic
ati
on
:
Fo
r ad
justin
g
the
no
tch
p
ositio
n
of
RS
A
to
ach
ieve
hard
o
r so
ft
rear
su
sp
en
sio
n
Fo
rk I
nn
er
& O
ute
r T
ub
e E
xtr
ac
tor
Dra
win
g N
o.:
74
93
10
15
Ap
plic
ati
on
:
Used
fo
r re
mo
vin
g
fro
nt
fork
in
ner
tub
e f
rom
ou
ter
tub
e.
Sp
ecia
l T
oo
lsS
pecia
l T
oo
ls
Carb
ure
tto
r and
Fuel
Sys
tem
Deale
r D
eve
lop
ment
Cente
r40
Deale
r D
eve
lop
ment
Cente
r39
Ca
rbu
rett
or
Sp
ec
ific
ati
on
s :
Ite
mP
uls
ar
18
0c
c
Ma
ke
an
d T
yp
eU
cal-
Mik
un
i B
S2
9
Ide
nti
fic
ati
on
No
.D
J -
U3
Idlin
g S
pe
ed
14
00
+1
00
VC
Sc
rew
se
ttin
g2
.5 +
2 t
urn
s o
ut
Ma
in J
et
11
7.5
Je
t n
ee
dle
ma
rk4
DH
L4
2
Ne
ed
le j
et
ma
rk9
22
MP
-1
Je
t n
ee
dle
clip
2n
d f
rom
to
p
po
sit
ion
Pilo
t Je
t1
7.5
Sta
rte
r je
tF
ixed
typ
e
Th
rott
le v
alv
eF
ixed
typ
e
Ch
oc
k L
eve
r2
sta
ge w
ith
pu
sh
pu
ll ty
pe m
ech
an
ism
No
tes :
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Fu
el
Ta
nk
•T
urn
th
e f
uel
tap
to
th
e o
ff p
ositio
n.
•D
isco
nn
ect
the f
uel
pip
e c
on
nectio
ns f
rom
th
e p
etr
ol
co
ck.
•D
isco
nn
ect
the f
uel
ind
icato
r w
irin
g h
arn
ess c
on
nectio
n.
No
te :
To
re
mo
ve th
e sid
e co
vers
LH
and
R
H,
unlo
ck w
ith th
e key th
en
ho
ld th
e fr
ont
end
o
f th
e co
ver
and
p
ull
the fr
ont
end
o
ut
then p
ull
the
co
ver
in f
orw
ard
directio
n t
o r
em
ove i
t fr
om
the l
ug
.
Re
mo
ve
:
•S
ide c
over
LH
an
d R
H b
y u
nlo
ckin
g i
t w
ith
key.
Re
mo
ve
:
•P
ull t
he
ca
ble
fro
m t
he
co
ve
r L
H t
o u
nlo
ck t
he
se
at
loc
k
•S
eat
assem
bly
No
te
: T
o
rem
ove
the
seat
assem
bly
ho
ld
the
seat
assem
bly
and
lif
t it
fro
m t
he r
ear
end
and
pull
it b
ack.
Re
mo
ve
:
•1
bo
lt (
A).
•F
uel
gau
ge w
irin
g c
on
nectio
n.
•D
rain
pip
e c
on
nectio
n.
•F
uel
pip
e c
on
nectio
n.
•F
uel
tan
k a
ssem
bly
No
te
: T
o
rem
ove
the
fuel
tank
assem
bly
fr
om
th
e
chassis
lif
t th
e
fuel
tank a
ssem
bly
by h
old
ing
it
at
the r
ear
end
and
pull
it b
ack.
Fu
el
Ta
nk
In
sp
ec
tio
n
Rem
ove t
he h
oses f
rom
th
e f
uel
tan
k,
an
d o
pen
th
e t
an
k c
ap
. C
heck
to
see
if
the
bre
ath
er
pip
e
an
d
wate
r d
rain
p
ipe
in
the
tan
k
for
clo
gg
ing
. If th
ey are
clo
gg
ed
, re
mo
ve th
e ta
nk an
d d
rain
it,
an
d th
en
b
low
pip
es f
ree w
ith
co
mp
ressed
air.
Fu
el
Ta
nk C
lea
nin
g
Wa
rnin
g
:
Cle
an
the
tank
in
well
ventila
ted
are
a,
and
ta
ke
care
th
at
there
are
no
sm
okes o
r flam
e anyw
here
near
the w
ork
ing
are
a.
Because
of
the
dang
er
of
hig
hly
flam
mab
le
liquid
s,
do
no
t use
gaso
line
or
low
-flash p
oin
t so
lvents
to
cle
an t
he t
ank.
Carb
ure
tto
r and
Fuel
Sys
tem
Deale
r D
eve
lop
ment
Cente
r42
Deale
r D
eve
lop
ment
Cente
r41
•R
em
ove t
he f
uel
tan
k a
nd
dra
in i
t.
•P
ou
r so
me
hig
h-f
lash
p
oin
t so
lven
t in
to
the
fuel
tan
k
an
d
sh
ake
the t
an
k t
o r
em
ove d
irt
an
d f
uel
dep
osits.
•P
ou
r th
e s
olv
en
t o
ut
of
the t
an
k.
•D
ry t
he t
an
k a
nd
th
e f
uel
tap
with
co
mp
resses a
ir.
•In
sta
ll th
e f
uel
tan
k.
No
te
: W
hile
in
sta
lling
th
e
fuel
tank
on
chassis
m
ake
sure
th
at
the
dam
pers
(A
) o
n p
etr
ol
tank a
re m
ounte
d o
n t
he c
hassis
.
Fu
el
Ta
nk
Ca
p D
ism
an
tlin
g
To
u
nlo
ck th
e F
uel
tan
k cap
, in
sert
th
e key in
th
e key slo
t an
d tu
rn
it a
nticlo
ckw
ise d
irectio
n a
nd
lift
op
en
th
e t
an
k c
ap
.
No
w re
mo
ve th
e an
ti th
eft
scre
w an
d th
en
re
mo
ve th
e alle
n b
olts (A
) an
d re
mo
ve th
e fu
el
tan
k cap
assem
bly
fr
om
th
e fu
el
tan
k.
Fittin
g is
th
e
revers
e
pro
ced
ure
o
f d
ism
an
tlin
g.
Bu
t ta
ke
care
th
at
the
ven
t h
ole
is
fr
ee
fro
m
an
y
fore
ign
p
art
icle
s
that
may
clo
g
the
ho
le.
To
lo
ck t
he f
uel
tan
k c
ap
, ju
st
pre
ss t
he c
ap
with
ou
t key.
Fu
el
Co
ck
Re
mo
va
l
Re
mo
ve
:
•2
bo
lts (
A)
•F
uel
co
ck a
ssem
bly
fro
m t
he f
uel
tan
k.
•C
lean
th
e f
uel
co
ck s
train
er
in a
hig
h-f
lash
po
int
so
lven
t.
•P
ou
r h
igh
fla
sh
po
int
so
lven
t th
rou
gh
th
e c
ock i
n a
ll le
ver
po
sitio
ns.
•D
ry t
he t
an
k a
nd
th
e f
uel
co
ck w
ith
co
mp
ressed
air.
•In
sta
ll th
e c
ock i
n t
he t
an
k.
A
No
te :
•A
lways l
oo
sen t
he b
ow
l o
f th
e f
uel
co
ck o
n v
ehic
le i
tself
•C
heck t
he f
uel
co
ck s
train
er
for
an
y b
reaks o
r d
ete
rio
ratio
n.
•If
the
fuel
co
ck
str
ain
er
have
an
y
bre
aks
or
are
d
ete
rio
rate
d,
they
may
allo
w
dirt
to
reach
th
e
carb
ure
tto
r,
cau
sin
g
po
or
run
nin
g.
Rep
lace t
he s
train
er.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
A
•B
ow
l
•S
train
er
•G
asket
•S
ele
cto
r B
od
y
•2
ho
le s
ub
ber
seal
No
tes :
Carb
ure
tto
r and
Fuel
Sys
tem
Carb
ure
tto
r and
Fuel
Sys
tem
Deale
r D
eve
lop
ment
Cente
r44
Deale
r D
eve
lop
ment
Cente
r43S
tart
er
Cir
cu
it :
Co
nsta
nt
Velo
city C
arb
ure
tto
r
1.
Plu
ng
er
Ca
p
2.
Dia
ph
rag
m C
ap
3.
Dia
ph
rag
m P
isto
n V
alv
e
4.
Pis
ton
Va
lve
wit
h J
et
Ne
ed
le
5.
Flo
at
Ch
am
be
r
Air
in
let
for
ch
oke
To
wa
rds
En
gin
e
Fu
nc
tio
nT
he fu
nctio
n o
f sta
rter
circu
it is
to
p
rovid
e rich
air fu
el
mix
ture
o
n sta
rtin
g /
co
ld sta
rtin
g.
At
co
ld en
gin
e
co
nd
itio
n
the
air
is
den
se
als
o
the
en
gin
e
part
s
are
co
ld
en
ou
gh
th
is
do
es
no
t allo
w
the
petr
ol
to
vap
orize p
rop
erly t
his
lead
s t
o s
tart
ing
tro
ub
le.
Co
nstr
uc
tio
nT
he S
tart
er
Circu
it c
on
sis
ts o
f a s
tart
er
jet
an
d a
plu
ng
er.
Th
e s
tart
er
jet
is u
sed
to
mete
r th
e f
uel
an
d a
plu
ng
er
that
op
en
s
an
air
passag
e
fro
m
the
inle
t o
f th
e
carb
ure
tto
r (u
nd
ern
eath
th
e
dia
ph
rag
m)
wh
ich
passes t
he m
ixtu
re t
o t
he m
ain
fold
.
Wo
rkin
gO
n p
ulli
ng
th
e ch
oke le
ver
the p
lun
ger
is lif
ted
b
y a cab
le.
Th
is u
nco
vers
th
e fu
el
passag
e th
at
lead
s to
the
sta
rter
jet,
air
inle
t p
assag
e
an
d
the
ou
tlet
passag
e
tow
ard
s
the
man
ifo
ld.
Th
is
cre
ate
s
en
ou
gh
su
ctio
n
to
dra
w
fuel
up
fr
om
th
e
bo
wl
into
th
e
mix
ing
ch
am
ber
(belo
w
the
plu
ng
er)
. H
ere
th
e
fuel
is
mix
ed
with
th
e a
ir a
nd
th
e m
ixtu
re i
s d
raw
n i
nto
th
e e
ng
ine t
hro
ug
h t
he o
utlet
passag
e.
Cu
t S
ec
tio
n V
iew
of
Mix
ing
Ch
am
be
r
To
wa
rds
En
gin
e
1.
Plu
ng
er
2.
Mix
ing
Ch
am
be
r
3.
Sta
rte
r Je
t
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
1.
Pilo
t Je
t
2.
Pilo
t O
utl
et
Ho
le
3.
Bu
tte
rfly
Va
lve
4.
Vo
lum
e C
on
tro
l
Sc
rew
5.
Idlin
g A
dju
stm
en
t
Sc
rew
6.
Fu
el
Inle
t
Fu
nc
tio
nT
he p
ilot
circu
it p
rovid
es th
e air fu
el
mix
ture
at
idlin
g w
hen
n
ot
en
ou
gh
air is
b
ein
g d
raw
n th
rou
gh
th
e
carb
ure
tto
r to
cau
se t
he m
ain
circu
it t
o o
pera
te.
Co
nstr
uc
tio
nT
he p
ilot
circu
it co
nsis
ts o
f p
ilot
jet,
p
ilot
air je
t an
d vo
lum
e co
ntr
ol
scre
w.
Th
e p
ilot
jet
mete
rs th
e fu
el
an
d t
he p
ilot
air j
et
mete
rs t
he a
ir q
uan
tity
. T
he v
olu
me c
on
tro
l (V
C)
scre
w c
on
tro
ls t
he a
mo
un
t o
f air f
uel
mix
ture
flo
win
g t
hro
ug
h t
he p
ilot
ou
tlet.
Wo
rkin
gA
s th
e air en
ters
th
e p
ilot
air in
let
the fu
el
is m
ete
red
b
y p
ilot
jet
an
d air q
uan
tity
is
m
ete
red
b
y p
ilot
air
jet.
Th
e a
tom
ized
/ v
ap
orized
mix
ture
is d
isch
arg
ed
th
rou
gh
th
e p
ilot
ou
tlet.
Th
e p
ilot
ou
tlet
is l
ocate
d o
n
the
man
ifo
ld
sid
e
of
the
carb
ure
tto
r.
Sin
ce
the
thro
ttle
valv
e
is
alm
ost
at
fully
clo
sed
p
ositio
n,
air
fuel
mix
ture
is s
up
plie
d m
ain
ly b
y p
ilot
ou
tlet
on
ly.
Air f
uel
mix
ture
vo
lum
e i
s a
dju
ste
d b
y v
olu
me c
on
tro
l (V
C)
scre
w an
d m
ixtu
re b
eco
mes le
an
w
hen
vo
lum
e co
ntr
ol
(VC
) scre
w tu
rned
clo
ckw
ise an
d rich
w
hen
it is
turn
ed
An
ticlo
ckw
ise d
irectio
n.
Pilo
t C
irc
uit
: C
on
sta
nt
Velo
city C
arb
ure
tto
r
To
ward
s
En
gin
e
Air
In
let
for
pilo
t je
t
Wo
rkin
g o
f C
arb
ure
tto
rW
ork
ing
of
Carb
ure
tto
r
Deale
r D
eve
lop
ment
Cente
r46
Deale
r D
eve
lop
ment
Cente
r45
1.
Pilo
t Je
t
2.
Pilo
t O
utl
et
Ho
le
3.
Byp
ass /
Pro
gre
ssio
n H
ole
s
4.
Bu
tte
rfly
Va
lve
5.
Vo
lum
e C
on
tro
l
Sc
rew
6.
Th
rott
le L
eve
r
Fu
nc
tio
nT
he p
rog
ressio
n circu
it p
rovid
es th
e air /
fuel
mix
ture
at
sm
all
thro
ttle
o
pen
ing
w
hen
p
ilot
circu
it is
still
wo
rkin
g b
ut
un
ab
le t
o m
eet
the e
ng
ine d
em
an
ds o
n s
mall
thro
ttle
op
en
ing
.
Co
nstr
uc
tio
nT
he
pro
gre
ssio
n
circu
it
follo
ws
the
path
o
f p
ilot
circu
it
an
d
the
co
nstr
uctio
n
is
sam
e
as
that
of
pilo
t
circu
it.
Wo
rkin
gA
s l
ike p
ilot
circu
it t
he f
uel
is m
ete
red
by p
ilot
jet
an
d a
ir v
olu
me i
s m
ete
red
by p
ilot
air j
et.
Th
is m
ixtu
re
in vap
orized
/
ato
miz
ed
fo
rm is
d
isch
arg
ed
th
rou
gh
th
e b
yp
ass p
ort
s w
hen
th
e b
utt
erf
ly valv
e is
o
pen
ed
fro
m i
dlin
g f
urt
her.
To
ward
s
En
gin
e
Air
In
let
for
pilo
t je
t
Pro
gre
ssio
n C
irc
uit
: C
on
sta
nt
Velo
city C
arb
ure
tto
r
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Ma
in C
irc
uit
: C
on
sta
nt
Velo
city C
arb
ure
tto
r
1.
Pis
ton
Va
lve
2.
Pis
ton
Va
lve
Dia
ph
rag
m
3.
Je
t N
ee
dle
4.
Ne
ed
le J
et
5.
Je
t H
old
er
6.
Ma
in J
et
Fu
nc
tio
nT
he
Main
C
ircu
it
pro
vid
es
air
fuel
mix
ture
b
y
liftin
g u
p th
e p
isto
n valv
e in
d
irect
pro
po
rtio
n
to
the
e
ng
ine
d
em
an
d.
Th
is
assu
res
the
co
rrect
ven
ture
siz
e
&
air
velo
city
thro
ug
ho
ut
the m
id r
an
ge o
pera
tio
n o
f th
e e
ng
ine.
Co
nstr
uc
tio
nT
his
circu
it
co
nsis
ts
of
jet
need
le,
need
le
jet
an
d
main
je
t.
To
assis
t in
ato
miz
atio
n
an
air
ble
ed
c
irc
uit
is
in
co
rpo
rate
d
in
the
m
ain
mete
rin
g
syste
m
an
d
it
aid
s
fuel
vap
orizatio
n
by
intr
od
ucin
g
the
air
into
th
e
fuel
befo
re
it
en
ters
th
e m
ain
air s
tream
.
To
wa
rds
En
gin
eA
ir I
nle
t
for
ma
in j
et
Th
e p
isto
n valv
e m
ovem
en
t is
co
ntr
olle
d b
y sp
rin
g an
d carb
ure
tto
r ven
ture
vacu
um
w
hic
h is
g
en
era
ted
belo
w t
he p
isto
n v
alv
e d
iap
hra
gm
.
Wo
rkin
gW
hen
th
e
bu
tterf
ly
valv
e
is
op
en
ed
an
d
air
flo
w
thro
ug
h
the
ven
turi
incre
ases,
the
air
pre
ssu
re
in
the
ven
turi (
an
d t
he u
pp
er
ch
am
ber)
decre
ases.
As
the
atm
osp
heric
pre
ssu
re
in
the
bo
tto
m
ch
am
ber
is
gre
ate
r th
an
th
e
ven
turi
pre
ssu
re
ab
ove
the
dia
ph
rag
m,
the p
isto
n valv
e alo
ng
w
ith
je
t n
eed
le is
p
ush
ed
u
p an
d m
ore
air fu
el
mix
ture
is
d
raw
n in
to
the e
ng
ine f
rom
main
jet
thro
ug
h n
eed
le j
et
into
th
e m
ain
air s
tream
.
Wh
en
th
e
bu
tterf
ly
valv
e
is
clo
sed
, air
flo
w
thro
ug
h
the
ven
turi
decre
ases;
air
pre
ssu
re
in
the
ven
turi
incre
ases
an
d
ap
pro
ach
es
atm
osp
heric
pre
ssu
re,
&
the
sp
rin
g
pu
sh
es
the
pis
ton
valv
e
alo
ng
w
ith
je
t
need
le d
ow
n.
Wo
rkin
g o
f C
arb
ure
tto
rW
ork
ing
of
Carb
ure
tto
r
Deale
r D
eve
lop
ment
Cente
r48
Deale
r D
eve
lop
ment
Cente
r47
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Do’s
Do’s
Don
’ts
Don
’ts
•U
se
a
pp
ro
pria
te
sc
re
w
dri
ve
rs.
Han
dlin
g
Cle
an
ing
•F
or
cle
an
ing
a
lwa
ys
u
se
ca
rbu
rett
or
cle
an
er
like
-A
ce
ton
e
-C
arb
on
Te
tra
ch
lori
de
-A
ero
so
l
-C
VC
sp
ray
Main
ten
an
ce
En
su
re
•Je
ts
-H
ole
s a
re c
lea
n.
-H
ole
s a
re n
ot
wo
rn o
ut.
-S
ize
as p
er
sp
ec
ific
ati
on
.
•F
loa
t is
in
go
od
co
nd
itio
n.
•F
loa
t P
in
-T
ip h
avin
g n
o w
ea
r m
ark
.
-S
pri
ng
lo
ad
ed
p
in
is
fre
e
in m
ove
me
nt.
•N
ee
dle
Je
t
-N
o w
ea
r a
t ta
pe
r p
ort
ion
.
-C
irc
lip
p
os
itio
n
is
in
sp
ec
ifie
d g
roo
ve
.
•P
isto
n v
alv
e
-N
o w
ea
r m
ark
.
-D
iap
hra
gm
co
nd
itio
n.
•N
eve
r u
se
o
ve
rsiz
e
sc
rew
dri
ve
rs.
•D
o n
ot
ove
r ti
gh
ten
th
e je
ts
an
d s
cre
ws.
•T
he
se
w
ill
da
ma
ge
th
e
jets
an
d t
he
ir s
ea
ts.
•N
eve
r c
lea
n
the
c
arb
ure
tto
r
wit
h w
ate
r.
•Je
ts &
a
ir p
assa
ge
s w
ill
ge
t
clo
gg
ed
d
ue
to
se
dim
en
ts if
cle
an
ed
by w
ate
r.
Re
pla
ce
•Je
ts
-W
orn
ou
t je
t.
-In
co
rre
ct
siz
e j
et.
-P
un
ctu
red
, S
qu
ee
ze
d
an
d
dis
tort
ed
flo
at.
-W
orn
ou
t ti
p.
-If
s
pri
ng
lo
ad
ed
p
in
is
sti
cky.
-N
ee
dle
w
orn
o
ut
at
tap
er
po
rtio
n.
-P
isto
n v
alv
e w
orn
ou
t.
Sc
ori
ng
ma
rks.
-D
iap
hra
gm
pu
nc
ture
d.
Overh
au
l carb
ure
tto
r at
every
1
0,0
00
km
s.
an
d
insep
ct
the
part
s.
Pu
lsar
DT
Si
is t
he f
irst
bik
e i
n t
he w
orld
(In
sm
all
cc e
ng
ine)
to h
ave t
win
sp
ark
ig
nitio
n s
yste
m.
1.
Th
e m
ost
ob
vio
us f
eatu
re i
s t
he T
win
Sp
ark
Plu
g c
on
fig
ura
tio
n o
f
the E
ng
ine.
Th
e cylin
der
head
h
as 2
sp
ark
p
lug
s o
ne o
n eith
er
sid
e.
Th
e
sp
ark
p
lug
s
are
o
f th
e
sm
ae
Heat
ran
ge
(Ch
am
pio
n
RG
4H
C/B
osh
UR
3D
C (
Resis
tive)
an
d h
ave s
imila
r ele
ctr
od
e g
ap
s.
Th
ese als
o sp
ark
sim
ultan
eu
osly
, T
his
h
as b
een
d
on
e to
im
pro
ve
the
co
mb
ustio
n
pro
cess
by
red
ucin
g
the
tim
e
of
co
mb
ustio
n.
Th
e e
nd
resu
lts a
re l
ow
em
issio
ns,
go
od
fu
el
eco
no
my a
nd
go
od
d
riveab
ility
2.
To
en
ab
le
the
sp
ark
ing
o
f th
e
2
sp
ark
p
lug
s,
a
inte
llig
en
t C
DI
cap
ab
le
of
han
dlin
g
this
w
as
develo
ped
. F
urt
her
mo
re,
the
ign
itio
n tim
ing
h
as b
een
o
ptim
ised
to
g
ive th
e b
est
ou
tpu
t fr
om
0
0en
gin
e
(10
B
TD
C
@
15
00
rp
m,
28
B
TD
C
@
35
00
rp
m).
To
en
ab
le
op
tim
um
ig
ntio
n
tim
ing
fo
r p
art
th
rott
le
load
s
an
d
full
thro
ttle
lo
ad
s,
there
are
sep
ara
te
ign
tio
n
map
s
sto
red
in
th
e
mem
ory
o
f th
e
CD
I.
Th
ese
are
activate
d
dep
en
din
g
on
th
e
thro
ttle
o
pen
ing
an
d
en
gin
e
sp
eed
. T
he
Dig
ital
CD
I h
as
a
bit
Mic
rop
rocesso
r w
hic
h h
an
dle
s all
these in
pu
ts an
d g
ives o
ut
the
req
uired
an
d
co
rrect
sp
ark
ad
van
ce.
Th
e
inte
llig
en
t C
DI
can
b
e
easily
in
den
tified
by 2
gre
en
do
ts m
ark
ed
on
CD
I case.
3.
To
en
ab
le
sw
itch
ing
th
e
req
uired
ig
ntio
n
map
s,
a
mag
netically
o
pera
ted
n
eed
sw
itch
is
in
co
rpo
rate
d o
n th
e carb
ure
tto
r th
rott
le
sh
aft
an
d
carb
ure
tto
r b
od
y.
Th
is
is
kn
ow
n
as
TR
ICS
. T
hro
ttle
R
esp
on
siv
e I
gn
tio
n C
on
tro
l S
yste
m.
4.
Th
ese en
gin
es are
cap
ab
le o
f o
f re
viv
ing
very
h
igh
, q
uite easily
. T
o keep
th
em
m
ech
an
ically
safe
, a en
gin
e rp
m lim
iter
has b
een
in
co
rpo
rate
d
in
the
Dig
ital
CD
I.
Th
is
cu
rtails
th
e
sp
ark
s
to
the
sp
ark
p
lug
s th
ere
by lim
itin
g th
e en
gin
e rp
m M
ax u
pto
9
00
0 an
d
thu
s
keep
s
the
en
gin
e
mech
an
ically
safe
. T
here
are
2
sp
ark
p
lug
s.
LH
sp
ark
p
lug
fire
s
at
35
0
rpm
an
d
then
co
ntin
ues
to
giv
e sp
ark
till
at
90
00
rp
m o
f en
gin
e.
Th
e sp
ark
is
cu
t o
ff fr
om
L
H
plu
g
90
00
rp
m
to
pro
tect
en
gin
e
fro
m
excessiv
ely
h
igh
sp
eed
.R
H
sp
ark
p
lug
g
ives
sp
ark
at
75
0
rpm
an
d
then
co
ntin
ues
to
giv
e
till
60
00
rp
m
of
en
gin
e.
If
en
gin
e
rpm
exceed
s
60
00
rp
m
then
R
H
plu
g
is
cu
t o
ff.
Th
is
is
do
ne
to
red
uce
co
mb
ustio
n
no
ise c
reate
d i
n e
ng
ine.
5.
Th
is
en
gin
e
has
been
exte
nsiv
ely
tu
ned
fo
r m
ore
P
ow
er
an
d
To
rqu
e.
6.
Th
e
DT
Si
tech
no
log
y
has
en
ab
led
th
e
Pu
lsar
to
meet
20
06
n
orm
s w
ith
ou
t an
y S
eco
nd
ary
air i
nje
ctio
n d
evic
es.
Tro
ub
lesh
oo
tin
g :
•M
alfu
nctio
nin
g o
f th
e R
eed
sw
itch
assly
will
no
t h
arm
th
e e
ng
ine,
neith
er
it w
ill g
ive an
y p
hysic
al
ind
icato
rs l
ike s
tart
ing
tro
ub
le o
r m
isfirin
g.
Ho
we
ve
r c
he
ck
ing
o
f p
rop
er
fun
cti
on
ing
o
f R
ee
d S
wit
ch
A
ssly
a
t P
DI
an
d a
t e
ve
ry se
rvic
e
is e
sse
nti
al.
•F
ollo
win
g s
ym
pto
ms m
ay i
nd
icate
as m
alfu
nctio
nin
g o
f R
ee
d S
wit
ch
Assly
as o
ne o
f th
e c
au
se.
Ca
use
Sym
pto
mR
em
ed
y
Su
dd
en
dro
p i
n m
ile
ag
e &
po
we
r
lac
k i
n m
id r
an
ge
rp
m
Re
pla
ce
me
nt o
f R
ee
d S
wit
ch
Assly
Th
e ig
nti
on
syste
ms is
wo
rkin
g o
nly
in 2
nd
ma
p d
ue
to
re
ed
sw
itc
h i
s
stu
ck in
op
en
cir
cu
it
Wo
rkin
g o
f C
arb
ure
tto
rD
igital
Tw
in S
park
Plu
g I
gnitio
n (
DT
S-i)
Deale
r D
eve
lop
ment
Cente
r50
Deale
r D
eve
lop
ment
Cente
r49C
usto
me
r E
du
cta
ion
Tip
s :
•W
hile
sta
rtin
g th
e en
gin
e in
an
y case th
rott
le sh
ou
ld n
ot
be ro
tate
d m
ore
. E
ven
if th
is h
ap
pen
s,
en
gin
e w
ill s
tart
, b
ut
the e
ng
ine r
pm
will
sh
oo
t u
o t
oo
mu
ch
(d
ue t
o t
oo
hig
h t
hro
ttle
op
en
ing
)•
Wh
en
ever
there
is
a su
dd
en
su
bta
ntial
dro
p in
m
ileag
e,
cu
sto
mer
sh
ou
ld re
po
rt to
B
aja
j A
uto
’s
Au
tho
rised
Serv
ice C
en
tres.
CO
% C
he
ck
ing
an
d T
un
e U
p (
To
en
su
re b
ett
en
mile
ag
e)
:
Ch
ec
k f
ollo
win
g b
efo
re C
O %
ch
ec
kin
g /
Tu
ne
up
-
•A
ir f
ilter
co
nn
ectio
ns,
inta
ke m
an
ifo
ld,
insu
lato
r fitm
en
t, c
on
nectin
g t
ub
e f
itm
en
t.•
Sp
ark
Plu
g g
ap
(0
.7 t
o 0
.8 m
m)
•A
ll p
ipes an
d co
nn
ectio
ns o
f fu
el
syste
m fo
r an
y cra
cks,
leakag
e,
plu
ckin
g,
pin
ch
ing
an
d lo
ose
co
nn
ectio
ns.
•E
nsu
re T
ap
pet
Cle
ara
nce :
Inle
t :
0.0
5 m
mE
xh
au
st
: 0
.1 m
m2
•E
nsu
re c
om
pre
ssio
n p
ressu
re i
nsid
e t
he c
ylin
der
(6 t
o 1
0 K
g/c
m)
00
•C
heck t
he i
gn
itio
n t
imin
g (
10
BT
DC
at
15
00
rp
m a
nd
28
BT
DC
at
35
00
rp
m)
CO
% c
he
ck
ing
an
d c
arb
ure
tto
r V
C s
cre
w s
ett
ing
•S
tart
an
d w
arm
up
th
e e
ng
ine
0•
Th
e o
il te
mp
era
ture
sh
ou
ld b
e a
bo
ve 6
0 C
. T
his
can
be a
ch
ieved
by r
un
nin
g v
eh
icle
in
to
p g
ear
at
the s
peed
of
min
imu
m 4
0 K
mp
h f
or
5 ~
6 K
ms.
•A
dju
st
the e
ng
ine s
peed
to
14
00
+ 1
00
rp
m w
ith
id
ling
ad
justm
en
t scre
w o
f carb
ure
tto
r.•
Ad
just
the C
O w
ith
th
e V
C s
cre
w.
It s
ho
uld
be i
n b
etw
een
1.7
5 t
o 2
.25
%•
Co
nfirm
th
e en
gin
e sp
eed
w
heth
er
it is
w
ith
in 1
40
0 +
1
00
rp
m o
r n
ot.
W
hen
sett
ing
Id
le C
O %
, id
le
rpm
an
d
VC
S
have
to
be
ad
juste
d
tog
eth
er
to
ach
ieve
2
%
CO
an
d
14
00
+
1
00
en
gin
e
rpm
.
Ite
mP
uls
ar
18
0c
c
Make
Ucal-
Mik
un
i B
S 2
6
Iden
tificatio
n N
oD
J -
U3
Typ
eC
V T
yp
e
Idlin
g S
peed
14
00
+1
00
VC
Scre
w S
ett
ing
2.5
+2
tu
rns o
ut
Main
Jet
11
7.5
Jet n
eed
le m
ark
4D
HL
42
Need
le je
t m
ark
92
2M
P-1
Jet n
eed
le c
lip p
ositio
n2
fro
m to
p
Pilo
t Jet
17
.5
Sta
rter
Jet
Fix
ed
typ
e
Th
rott
le v
alv
eF
ixed
typ
e
Ch
ock lever
2 s
tag
e w
ith
pu
sh
p
ull
typ
e m
ech
an
ism
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
•R
em
ove t
he ‘
Alle
n H
ead
Gru
b S
cre
w’
befo
re r
em
ovin
g t
he ‘
Sle
eve S
park
Plu
g’.
•B
efo
re f
ittin
g t
he ‘
Sle
eve S
park
Plu
g’
ap
ply
th
in l
ayer
of
mo
lyb
den
um
dis
ulp
hite
gre
ase o
n t
he e
ntr
y c
ham
fers
fo
r th
e ‘
O’
rin
gs f
or
sm
oo
th s
lidin
g i
nsid
e.
•‘In
let
Ro
cker
Arm
Sh
aft
’ is
lo
ng
er
in l
en
gth
.
•R
ocker
arm
has 2
0 R
olle
rs i
nsid
e t
he o
ute
r cag
e.
•D
oesn
't h
ave i
nn
er
cag
e.
•T
ake u
tmo
st
care
wh
ile d
ism
an
tlin
g.
Ro
llers
sh
ou
ld n
ot
fall
insid
e e
ng
ine.
•A
pp
ly g
rease f
or
fixin
g n
eed
le r
olle
rs i
nsid
e r
ocker
arm
.
•W
hile
re
mo
vin
g
/ re
fitt
ing
o
f p
isto
n
pin
circlip
, co
ver
the
cra
nkcase
ch
am
ber
with
cle
an
co
tto
n c
loth
to
avo
id f
alli
ng
of
circlip
in
sid
e t
he e
ng
ine.
•B
low
pre
ssu
rised
air t
o o
il p
assag
es i
n r
evers
e d
irectio
n t
o t
hat
of
oil
flo
w.
•D
o
no
t ap
ply
liq
uid
g
asket
at
locatio
n
(A)
wh
ich
m
ay
blo
ck
the
lub
ricatio
n
passag
e.
A
•S
ecu
re t
he ‘
Cam
Ch
ain
Sp
rocket’
in
th
e s
pecia
l to
ol
firm
ly a
nd
th
en
tig
hte
n t
he
sp
rocket
alle
n b
olt (
A).
•E
nsu
re t
hat
the ‘
O’
mark
on
wash
er
alw
ays f
aces o
utw
ard
s w
hen
tig
hte
nin
g t
he
alle
n b
olt.
A
Va
lve
tim
ing
•E
nsu
re
the
sp
rocket
mark
s
(A)
are
alig
ned
h
orizo
nta
lly
with
cylin
der
head
to
p
mach
ined
face a
nd
th
e p
isto
n i
s a
t T
DC
.
AA
Dig
ital
Tw
in S
park
Plu
g I
gnitio
n (
DT
S-i)
Imp
ort
ant
Po
ints
to
Rem
em
ber
Deale
r D
eve
lop
ment
Cente
r52
Deale
r D
eve
lop
ment
Cente
r51
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
•E
nsu
re d
am
per
rub
ber
fitm
en
t o
n m
ag
neto
sid
e g
uid
e p
late
.
•W
hen
sp
littin
g
cra
nkcase
alw
ays
rem
ove
1
lon
g
bo
lt
fitt
ed
fr
om
clu
tch
sid
e
firs
t.
•R
em
ove l
on
g b
olt i
mm
ed
iate
ly a
fter
rem
oval
of
lon
g b
olt c
lutc
h s
ide.
•E
nsu
re p
rop
er
fitm
en
t o
f b
olt w
ith
co
pp
er
wash
er
to a
vo
id o
il le
akag
e.
•S
hifte
r fo
rk i
s h
avin
g a
ro
ller.
Th
ese r
olle
r are
on
e s
ide t
ap
pere
d i
nn
er
dia
.
•T
ap
er
po
rtio
n o
f ro
ller
sh
ou
ld f
ace t
ow
ard
s f
ork
gear
sh
ift.
•In
pu
t sh
aft
has s
pecia
l n
ut.
•T
hic
k
sp
acer
wash
er
tap
ere
d
I.D
. it
sh
ou
ld
be
pla
ced
o
n
tap
ped
p
ort
ion
o
f In
pu
t S
haft
.
•In
pu
t S
haft
has l
eft
han
d t
hre
ad
s.
•A
fter
pla
cin
g
Belle
vill
e,
fit
clu
tch
p
late
w
ith
4
8
fric
tio
n
mate
rial
cu
bs
(A)
with
m
ore
I.D
.
•4
No
s.
of
clu
tch
pla
tes w
ith
36
frictio
n m
ate
rial
cu
bs (
B)
altern
atively
alo
ng
with
ste
el
pla
tes.
•F
it t
op
clu
tch
pla
te w
ith
40
frictio
n m
ate
rial
cu
bs (
C).
En
su
re
•W
hile
assem
blin
g h
ub
clu
tch
p
lace p
lain
w
ash
er
firs
t an
d th
en
p
lace b
elle
vill
e
wash
er.
Co
ncave f
ace s
ho
uld
be u
pw
ard
s i
.e.
tow
ard
tech
nic
ian
.
Bell
evil
le
Wash
er
Pla
in
Wash
er
Clu
tch
Hu
b
•F
it p
rim
ary
gear
drive (A
).•
Th
e m
ark
teeth
of
the p
rim
ary
gear
sh
ou
ld m
atc
h w
ith
th
e lin
e m
ark
on
th
e c
’case.
Th
is in
dic
ate
d t
hat
the p
isto
n is a
t T
DC
po
sitio
n.
Th
is p
roced
ure
sh
ou
ld b
e c
arr
ied
b
efo
re f
ittin
g t
he ‘
Clu
tch
Ho
usin
g’
& t
his
po
sitio
n s
ho
uld
no
t b
e d
istu
rbed
wh
ile
fitt
ing
th
e ‘
Clu
tch
Ho
usin
g’.
2
14
17
1
16
9
8
12
10
5
7
6
7
6
7
6
4
6
15
11
13
3
•L
oad
th
e
assly
b
ala
ncer
idle
r g
ear
with
2
te
eth
s
fro
m
eith
er
sid
e
usin
g
the
sp
ecia
l to
ol.
•T
ake t
he ‘
Assem
bly
Bala
ncer
Idle
r G
ear’
alo
ng
with
Th
rust
Wash
er
wh
ich
is p
re-
load
ed
an
d is h
eld
in
sp
ecia
l to
ol, S
lide d
ow
n t
he s
pecia
l to
ol w
ith
‘G
ear’
to
en
gag
e
the b
ott
om
half o
f th
e ‘
Assem
bly
Bala
lncer
Idle
r G
ear’
with
th
e ‘
Bo
dy B
ala
ncer
Gear
Assem
bly
’•
Fit ‘T
hru
st w
ash
er’
on
th
e o
ther sid
e.
•O
n
assem
bly
o
f ‘A
ssem
bly
B
ala
ncer
Idle
r G
ear’
th
e
itch
ed
/Do
t m
ark
o
f ;B
od
y
Bala
ncer G
ear A
ssem
bly
’ sh
ou
ld m
atc
h w
ith
th
e li
ne m
ark
on
th
e ‘C
ran
kcase’.
Ho
ldin
g t
he ‘
Assem
bly
Bala
ncer
Gear’
in
sp
ecia
l to
ol
no
w s
lide i
nsid
e t
he ‘
Clu
tch
H
ou
sin
g’
so
th
at
the
‘Clu
tch
H
ou
sin
g’
sm
oo
thly
en
gag
es
with
th
e
top
h
alf
of
‘Assem
bly
Bala
ncer
Idle
r G
ear’
.
•R
em
ove t
he s
pecia
l to
ol
gen
tly.
•F
it 2
do
wels
an
d A
ssly
Bala
ncer
Idle
r G
ear
Co
ver
•E
nsu
re p
erf
ect
mark
ing
of
gear
mark
s w
ith
resp
ect
to c
ran
kcase m
ark
.
Imp
ort
ant
Po
ints
to
Rem
em
ber
Imp
ort
ant
Po
ints
to
Rem
em
ber
Rem
ova
l o
f E
ng
ine f
rom
Fra
me
Deale
r D
eve
lop
ment
Cente
r54
Deale
r D
eve
lop
ment
Cente
r53
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Re
mo
va
l o
f E
ng
ine
fro
m F
ram
e :
Re
mo
ve
:
•P
ut
OF
F t
he f
uel
co
ck
•S
ide p
an
el
LH
•S
ide p
an
el
RH
Re
mo
ve
:
•S
eat
assem
bly
by p
ulli
ng
th
e c
ab
le f
or
seat
lock r
ele
ase l
ocate
d
on
RH
sid
e.
•D
isco
nn
ect
the n
eg
ative t
erm
inal
of
the b
att
ery
.
•D
isco
nn
ect
the w
irin
g h
arn
ess s
ocket
for
fuel
level
Ind
icato
r.
•F
uel
pip
e c
on
nectio
ns a
nd
m
ois
ture
dra
in p
ipe f
rom
fu
el
tan
k.
•D
isco
nn
ect
sta
tor
pla
te h
arn
ess
•D
isco
nn
ect
neu
tral
sw
itch
co
up
ler
Re
mo
ve
:
•D
rain
bo
lt (
A)
an
d d
rain
ou
t th
e o
il fr
om
en
gin
e.
•R
efit
the d
rain
bo
lt w
ith
gasket
& t
igh
ten
it.
Re
mo
ve
:
•B
olt (
A)
•P
etr
ol
tan
k a
ssem
bly
.
Re
mo
ve
:
•B
olts (
A)
•G
ear
sh
ift
ped
al
bo
lt (
B)
•D
rive s
pro
cket
co
ver
LH
.
Usin
g S
pe
cia
l T
oo
l :
Sp
roc
ke
t
Ho
lde
r -
37
10
30
53
Re
mo
ve
:
•B
olts (
A)
•P
late
drive s
pro
cket
•D
rive
sp
roc
ke
t a
lon
g
wit
h
the c
hain
.
•N
eu
tral
sw
itch
co
up
ler
(B).
A
A
BA
R
ec
om
me
nd
ed
Oil G
rad
e a
nd
Qty
Gra
de
SA
E 2
0W
50 o
f A
PI
‘SG
’ +
JA
SO
‘M
A’
Qu
an
tity
Dra
in &
Refill
1000 m
l.E
ng
ine O
verh
aul
1100 m
l.
A B
Re
mo
ve
:
•2
nu
ts (
B)
for
sile
ncer
flan
ge
Re
mo
ve
:
•B
olt (
A)
of
sile
ncer
bra
cket
mo
un
ted
on
pill
ion
RH
sid
e f
oo
tste
p.
•S
ilen
cer
assem
bly
.
Re
mo
ve
:
•S
tart
er
mo
tor
co
nn
ectio
n (
A)
Re
mo
ve
:
•P
CV
pip
e f
rom
bre
ath
er
Re
mo
ve
:
•D
isco
nn
ect
the r
eed
sw
itch
co
up
ler.
•S
park
plu
g c
ap
LH
Re
mo
ve
:
•A
ir
filter
mo
un
tin
g
bo
lts
to
facili
tate
th
e
rem
oval
of
carb
ure
tto
r w
ith
reed
sw
itch
.
•C
lam
ps
of
carb
ure
tto
r an
d
dis
co
nn
ect
carb
ure
tto
r alo
ng
w
ith
in
su
lato
r an
d d
ism
an
tle c
ab
les f
rom
it.
•B
racket
bo
lts s
ecu
rin
g c
lutc
h c
ab
le o
n c
lutc
h c
over.
•S
park
plu
g c
ap
RH
No
te :
Alw
ays re
mo
ve th
e flang
e m
ounting
firs
t and
th
en re
ar
mo
unting
to
avo
id m
isalig
nm
ent
of
stu
ds.
B
B
A
Rem
ova
l o
f E
ng
ine f
rom
Fra
me
Deale
r D
eve
lop
ment
Cente
r56
Deale
r D
eve
lop
ment
Cente
r55
Re
mo
ve
:
•W
hile
re
mo
vin
g eng
ine fo
und
atio
n b
olts,
firs
t re
mo
ve th
e to
pm
ost
bo
lt
and
then g
o d
ow
n p
rog
ressiv
ely
.
No
te :
Bo
lts (A
) ho
ldin
g th
e eng
ine to
th
e chassis
. (4
b
olts o
f 12 m
m
and
1 b
olt n
eed
s d
eep
so
cket
for
rem
ovin
g i
t).
•L
ift
up
th
e e
ng
ine o
ff t
he c
hassis
an
d p
lace i
t o
n e
ng
ine s
tan
d.
No
te
: A
fter
dis
co
nnecting
all
the
sub
assem
blie
s
and
co
ntr
ol
cab
les
fro
m
the
eng
ine
lift
up
th
e
eng
ine
and
re
mo
ve
it
fro
m
RH
S
of
the
vehic
le.
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
En
gin
e T
op
En
d D
ism
an
tlin
g :
Re
mo
ve
:
•P
ull
ou
t th
e
co
ver
on
th
e
sp
ark
p
lug
cap
R
H
an
d
the
sp
ark
p
lug
cap
its
elf
•U
sin
g a
plu
g s
pan
ner,
lo
osen
an
d r
em
ove t
he s
park
plu
g R
H
•L
oo
sen
an
d
un
scre
w
the
alle
n
head
g
rub
scre
w
of
the
sle
eve
sp
ark
plu
g
Re
mo
ve
:
•L
oo
sen
bo
lt (
A)
an
d u
nscre
w c
hain
ten
sio
ner
plu
ng
er
•C
am
ch
ain
ten
sio
ner
assem
bly
2 b
olts (
B)
•C
am
ch
ain
ten
sio
ner
assem
bly
Re
mo
ve
:
•B
oth
tap
pet
cap
s
•M
ag
neto
co
ver
cap
seal
an
d ro
tate
cra
nksh
aft
to
g
et
pis
ton
at
TD
C.
•E
nsu
re
bo
th
tap
pets
are
at
free
sta
te
(i.e
. at
the
en
d
of
co
mp
ressio
n s
tro
ke)
Re
mo
ve
:
•2
du
mm
y p
lug
•2
gaskets
No
te
: W
rap
a
pie
ce
of
clo
th
aro
und
th
e
pro
trud
ing
ed
ge
of
the
sle
eve s
park
plu
g a
nd
usin
g a
plie
r, p
ull
out
the s
leeve.
No
te
: R
em
ove
these
only
if
the
‘O’
ring
p
rotr
usim
in
th
e
bo
re
is
no
n-e
xis
tant
(whic
h m
eans th
at
the ‘O
’ ring
has set
and
it has lo
st
its
co
mp
ressio
n o
r sealin
g a
bili
ty.)
Re
mo
ve
:
•T
here
are
2
‘O
’ rin
gs
fitt
ed
in
th
e
cylin
der
head
, o
ne
on
th
e
cam
ch
ain
wall
an
d t
he o
ther
near
the s
park
plu
g t
hre
ad
ing
•U
sin
g
a
thin
, sh
arp
p
oin
ted
to
ol
pie
rce
the
‘O’
rin
gs
an
d
rem
ove t
hem
. (If
req
uired
)
A B
Rem
ova
l o
f E
ng
ine f
rom
Fra
me
Dis
mantlin
g E
ng
ine
Deale
r D
eve
lop
ment
Cente
r57
Deale
r D
eve
lop
ment
Cente
r58
Re
mo
ve
:
•C
ylin
der
head
secu
rin
g h
ead
co
ver
2 b
olts (
A)
•C
ylin
der
head
secu
rin
g h
ead
co
ver
4 b
olts (
B)
•C
ylin
der
head
secu
rin
g h
ead
co
ver
4 d
om
ed
cap
nu
ts (
C)
•4
co
pp
er
pla
ted
ste
el
wash
ers
Re
mo
ve
:
•C
ylin
der
head
co
ver
co
mp
lete
•C
am
sh
aft
cap
No
te
: Im
pro
per
tig
hte
nin
g
seq
uence
may
cause
warp
ag
e
in
cylin
der
head
co
ver
and
it
can b
e d
am
ag
ed
perm
anently.
ABC
Sp
rco
ke
t C
atc
he
r
Usin
g
Sp
. T
oo
l :
Sp
roc
ke
t
Ca
tch
er
- 3
71
0 D
H 3
6
Re
mo
ve
:
•A
llen
bo
lt
•S
pacer
•C
am
sp
rocket
•C
olla
r
•C
am
sh
aft
assly
Usin
g S
pe
cia
l T
oo
l :
Sp
roc
ke
t C
atc
he
r -
37
10
DH
36
No
te :
Ho
ld th
e cam
chain
up
rig
ht
usin
g so
ft co
pp
er
wire o
r th
read
. D
o n
ot
use c
ott
on w
aste
fo
r ho
ldin
g t
he c
am
chain
.
Re
mo
ve
:
•C
ylin
der
head
assem
bly
•2
do
wels
•G
asket
cylin
der
head
Re
mo
ve
:
•N
on
ten
sio
ner
sid
e c
hain
gu
ide
•C
ylin
der
blo
ck a
ssem
bly
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
En
gin
e L
H (
Ma
gn
eto
Sid
e)
:
Re
mo
ve
:
•5
bo
lts (
A)
Re
mo
ve
:
•P
isto
n p
in l
ock L
H &
RH
sid
e
No
te :
Tie
th
e cam
chain
firm
ly usin
g so
ft co
pp
er
wire/t
hre
ad
firm
ly to
avo
id s
lipp
ing
do
wn i
nto
cra
nkcase.
No
te :
Pla
ce a
pie
ce o
f cle
an c
loth
ab
ove h
allo
w p
ort
ion o
f cra
nkcase
to a
rrest
pis
ton p
in c
irclip
if
it f
alls
during
fitm
ent.
Usin
g S
pe
cia
l T
oo
l :
Dri
ft 7
4 9
30
9 8
9
Re
mo
ve
:
•R
em
ove p
isto
n p
in
•P
isto
n a
ssem
bly
Ca
uti
on
:
When t
ap
pin
g t
he d
rift
fo
r re
mo
val
of
pis
ton p
in,
co
nfirm
that
the
co
nnecting
ro
d
is
held
firm
ly
ag
ain
st
the
directio
n
of
tap
pin
g
to
avo
id d
am
ag
e t
o b
ig e
nd
bearing
co
nnecting
ro
d
of
cra
nkshaft
.
Re
mo
ve
:
•B
lock g
asket
•2
do
wels
(A
)
Re
mo
ve
:
•C
over
mag
neto
.
A
A
Dis
mantlin
g E
ng
ine
Dis
mantlin
g E
ng
ine
Deale
r D
eve
lop
ment
Cente
r60
Deale
r D
eve
lop
ment
Cente
r59
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Usin
g
Sp
ec
ial
To
ol
:
Ro
tor
Ho
lde
r -
H6
07
21
00
•H
old
th
e r
oto
r assem
bly
Re
mo
ve
:
•R
oto
r b
olt (
A)
•W
ash
er
Usin
g
Sp
ec
ial
To
ol
- R
oto
r
Pu
lle
r w
ith
bu
tt p
in : 3
7 1
0D
J 3
2
Re
mo
ve
:
•R
oto
r assem
bly
•W
oo
dru
ff k
ey.
A
No
te
: H
old
ing
th
e g
ear
co
mp
lete
sta
rter
clu
tch
ro
tate
th
e ro
tor
an
d
pu
ll it
ou
t in
A
nticlo
ckw
ise
directio
n
to
pre
ven
t ro
llers
an
d
sp
rin
gs c
om
ing
ou
t. R
oto
r p
ulle
r h
as l
eft
han
d t
hre
ad
s.
Wa
rnin
g :
•
These co
mp
onents
re
main
ho
t fo
r a lo
ng
tim
e esp
ecia
lly if re
mo
ved
fr
om
a h
ot
eng
ine.
Wear
suitab
le h
and
pro
tectio
n t
o p
revent
burn
s.
•R
oto
r p
ulle
r has l
eft
hand
thre
ad
s
Re
mo
ve
:
•G
aske
t
•B
olt (
A)
•P
late
sta
rter
clu
tch
gear
retu
rn (
B)
•G
ear
sta
rter
clu
tch
Re
mo
ve
:
•C
olla
r (A
)
•S
haft
•G
ear
co
mp
. sta
rter
co
un
ter
assly
A
A B
Re
mo
ve
:
•1
scre
w -
(A
)
•S
tart
er
mo
tor
co
ver
Re
mo
ve
:
•3
Scre
w (
A)
•G
uid
e s
tart
er
assem
bly
alo
ng
with
oil
seal.
En
gin
e R
H :
(C
lutc
h S
ide
)
Re
mo
ve
:
•K
ick s
tart
er
bo
lt
•K
ick s
tart
er
Wa
rnin
g
: T
he
oil
pu
mp
m
ay
be
ho
t,
hen
ce
use
su
itab
le
han
d
pro
tectio
n.
Als
o,
sin
ce t
he o
il p
um
p h
ouses t
he o
il str
ain
er
/ m
esh a
lso
, it
may
reta
in
so
me
quantity
o
f o
il.
This
o
il m
ay
be
ho
t.
Hence
pro
per
care
sho
uld
be t
aken t
o d
rain
it.
No
te :
The o
il w
hic
h is
in
th
e o
il p
um
p ho
usin
g sho
uld
als
o b
e d
rain
ed
o
ut
into
the o
il d
rain
tra
y f
or
measuring
dra
ined
oil.
No
te
: T
he
rod
clu
tch
lifte
r,
plu
ng
er
oil,
p
late
p
lung
er
oil
and
sp
ring
jo
int
may f
all
out
of
their r
esp
ective p
laces i
nto
the o
il co
llectio
n t
ray.
If
so
, ensure
that
these a
re c
olle
cte
d &
acco
unte
d f
or
befo
re p
roceed
ing
.
Re
mo
ve
•1
2 C
lutc
h c
over
bo
lts (
B)
•B
racket
clu
tch
cab
le (
C)
•C
lutc
h c
over
Ca
uti
on
:
Ensure
that
the w
oo
dru
ff k
ey o
f ro
tor
is r
em
oved
prio
r to
the
rem
oval
of
guid
e sta
rter
assem
bly
. T
he lip
s o
f m
ag
neto
o
il seal
ho
used
in
guid
e s
tart
er
assem
bly
will
get
dam
ag
ed
if
no
t d
one s
o.
A
B
A
Re
mo
ve
:
•3
bo
lts (
A)
•O
il p
um
p a
ssem
bly
•2
Do
wels
•C
lutc
h c
over
gasket
•S
tart
er
Mo
tor
(B)
A
B
C
Dis
mantlin
g E
ng
ine
Dis
mantlin
g E
ng
ine
Deale
r D
eve
lop
ment
Cente
r62
Deale
r D
eve
lop
ment
Cente
r61
Dia
. =
25
.9+
0.1
Usin
g S
pe
cia
l T
oo
l :
Sp
ec
ial N
ut
Pu
lle
r 3
7 1
0D
J4
3
Pri
ma
ry G
ea
r H
old
er
37
10
DJ2
8
Re
mo
ve
:
•C
en
trifu
gal
oil
filter
sp
ecia
l n
ut
•B
elle
vill
e w
ash
er
•B
od
y
cen
trifu
gal
oil
filter
assly
Re
mo
ve
:
•B
earin
g w
ith
plu
ng
er
Usin
g
Sp
ec
ial
To
ol
: S
pe
cia
l
Nu
t P
ulle
r 3
7 1
0D
J 4
3
Pri
ma
ry G
ea
r H
old
er
37
10
DJ2
8
Re
mo
ve
:
•In
pu
t sh
aft
sp
ecia
l n
ut
•B
elle
vill
e w
ash
er
•C
lutc
h a
ssly
co
mp
•S
pacer
No
te
: T
he
exis
ting
S
pecia
l N
ut
Pulle
r 37
10D
J
43
can
be
used
b
y
grind
ing
the t
oo
l O
D t
o 2
5.9
+ 0
.1 m
m
Usin
g
Sp
ec
ial
To
ol
: P
rim
ary
Ge
ar
Ho
lde
r 3
7 1
0D
J 2
8
Re
mo
ve
:
•3
ph
illip
s h
ead
scre
ws (A
)
•C
en
trifu
gal
oil
filter
co
ver
•G
asket
Wa
rnin
g :
These p
art
s m
ay b
e ho
t, if re
mo
ved
fr
om
a ho
t eng
ine.
Use
glo
ves f
or
pro
tectio
n.
No
te :
So
me am
ount
of
oil
is tr
ap
ped
in
co
ver
and
b
od
y o
f centr
ifug
al
oil
filter,
this
oil
sho
uld
be d
rain
ed
into
the o
il tr
ay.
A
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Re
mo
ve
:
•A
ssly
Bal. i
dle
r g
ear
•2
Wash
er
No
te
: T
ake
case
that
sq
uare
key
do
es
no
t fa
ll in
sid
e
the
cra
nkcase
ho
llow
po
rtio
n w
hile
rem
ovin
g.
Re
mo
ve
:
•B
olt (
A)
•L
ockin
g p
late
•B
od
y b
ala
ncer
gear
assly
Re
mo
ve
:
•P
rim
ary
gear
•S
qu
are
key
Re
mo
ve
:
•C
am
ch
ain
•C
am
ch
ain
sp
rocket
•P
ara
llel
Pin
A
Re
mo
ve
:
•3
Assly
bala
ncer
Idle
r g
ear
co
ver
bo
lts (
A)
•C
over
•W
ash
er
•2
Do
wel
Re
mo
ve
:
•C
lutc
h h
ou
sin
g
A
No
te
: F
or
ease
in
rem
oval
of
clu
tch
h
ou
se
insert
sp
ecia
l to
ol
(P
. N
o.-
37 1
0D
J 6
3)
in A
ssly
Bala
ncer
Idle
r G
ear.
Dis
mantlin
g E
ng
ine
Dis
mantlin
g E
ng
ine
Deale
r D
eve
lop
ment
Cente
r64
Deale
r D
eve
lop
ment
Cente
r63
Usin
g K
ick s
tart
er
leve
r
Re
mo
ve
:
•W
ash
er
•K
ick s
haft
assly
co
mp
Re
mo
ve
:
•B
olt (
A)
•L
ockin
g P
late
•K
ick i
dle
r g
ear
No
te
: C
heck
and
in
sp
ect
the
dru
m
chang
e
arm
sto
pp
er
for
free
mo
vem
ent
alw
ays.
No
te
: R
ota
te
the
kic
k
sta
rter
lever
in
Anticlo
ckw
ise
directio
n
for
rem
ovin
g t
he k
ick s
haft
assly
.
Re
mo
ve
:
•S
prin
g
•A
llen
bo
lt (
A)
•G
uid
e g
ear
•S
pacer
•P
ara
llel
Pin
En
gin
e C
en
tra
l P
art
:
Re
mo
ve
:
•B
olt (
A)
on
RH
sid
e c
ran
kcase (
Clu
tch
sid
e)
Re
mo
ve
:
•G
ear
ch
an
ge l
ever
A
A
Puls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
sP
uls
ar
DT
S-i
U
G-I
II-1
80cc Tra
inin
g N
ote
s
Re
mo
ve
:
•B
olt (
B)
on
LH
sid
e c
ran
kcase (
Mag
neto
sid
e)
Re
mo
ve
:
•K
ick s
prin
g
•2
Sh
aft
s (
A)
& (
B)
of
gear
sh
ifte
r fo
rk.
•3
fo
rk s
hifts
(1
sm
all
for
inp
ut
2 b
ig f
or
ou
tpu
t sh
aft
.
•3
Ro
llers
•D
rum
ch
an
ge
Re
mo
ve
:
•T
he e
ntire
gear
bo
x a
ssem
bly
to
geth
er
Re
mo
ve
:
•C
ran
kcase g
asket
•2
do
wels
•C
ran
ksh
aft
assly
Re
mo
ve
:
•8
bo
lts o
n L
H s
ide c
ran
kcase
•S
plit
th
e C
ran
kcase h
alv
es.
No
te
: B
efo
re
se
pa
rati
ng
c
ran
kc
ase
h
alv
es
co
nfi
rm
tha
t a
ll
the
cra
nkcase
join
ing
b
olts
are
re
mo
ved
and
th
e
sp
rocket
cam
d
rive
with
para
llel
pin
on c
rankshaft
assem
bly
is r
em
oved
.
B
A
Dis
mantlin
g E
ng
ine
Dis
mantlin
g E
ng
ine
