Dealer Development Center, Pune
34
Pulsar DTS-i 150/180 Training Notes
Tightening Torque (For 150 cc & 180 cc)
Clutch Nut (LH Threads)
7.0 Kg.m
Camshaft Sprocket Allen Bolt
1.4 Kg.m (Loctite 243)
4.5 Kg.m
Rotor Mounting Bolt
Starter Motor Mtg. Bolts
1.1 Kg.m
Kick Guide Allen Bolts
1.2 Kg.m
Drain Bolt
2.5 Kg.m
Cylinder Head Cover Bolts
3.5 Kg.m
Cylinder Head Cover Nuts
1.0 ~ 1.5 Kg.m
Spark Plugs (2 Nos.)
1.4 Kg.m
Dos & Don’ts
Dealer Development Center, Pune
35
Pulsar DTS-i 150/180 Training Notes
• Always set / adjust valve tappet clearance in engine cold condition.
Intake : 0.0 5mm Exhaust : 0.10mm
• Always blow compressed air into clutch cover oil passage inner
gallery in opposite to the direction of flow of oil
• Always tighten engine foundation bolts as per recommended
sequence.
• Always replace engine oil by recommended quantity & quality of oil.
Recommended grade : 20W40 (for Pulsar 150cc) & 20W50 (for
Pulsar 180cc) API ‘SJ’ or ‘SL’ + JASO ‘MA’ grade.
• Always keep breather passage in clean condition & confirm it is
clear by blowing compressed air. This will facilitate oil fumes to
escape from engine crankcase otherwise clogged breather passage
would lead to oozing out of oil through oil seals, 'O' Rings, Gaskets
& Breather pipe.
• Whenever installing Spark Plugs, first screw by hand & then tighten
to specified torque. This is to ensure proper fitment & avoid thread
damage.
• Always use wire gauge for setting spark plug electrode gap.
• Use feeler gauge for setting valve clearance.
• Always follow loosening / tightening sequence of cylinder head
bolts otherwise its surface may get warped.
• Always fit piston ring as per standard SOP & ensure their end
position.
• Always use Loctite to bolts, screws & nuts wherever recommend.
• Always rotate ‘Gear Starter Clutch’ in clockwise direction & pull it
out immediately.
place plastic cap into one way clutch rollers for securing them their
position.
• Tighten nut-bolts in criss-cross pattern for matching of mating
surfaces to avoid distortion otherwise it leads to oil leakage.
• Ensure crankcase / clutch cover oil passages are clear by pumping
oil using a ‘Oil Can’.
• Always replace circlips & locks of transmission gears, kick shaft
assembly if removed. Circlips / locks tend to loose their spring
tension once removed.
• While assembling cylinder block, always apply thin layer of engine
oil to cylinder walls & piston rings for ease of fitment & to prevent
dry running.
• Blow dust free / moisture free air in all the orifices, passages of
the engine components & confirm that the oil passages are clear.
• Always apply oil during assembling engine components, particularly
at friction prone area to avoid dry running.
• Confirm seating of circlip locks by rotating on their seat to avoid
further consequences.
• While installing engine bearings always tap / pressed on the race
which is taking seat to avoid damage to the bearing otherwise axial
/ radial clearance may increase.
Dos
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