Bajaj pulsar DTS-i, Service Station Manual

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DISMANTLING ENGINE SUB ASSEMBLIES
B
C
A
Oil Pump :
Remove :
• Clip
• Oil strainer element with 'O' ring
(A)
(B)
(C)
Bearing Removal from Assly Balancer Idler Gear Cover and Crankcase
RH
Using Sp. Tool : Bearing Extractor - 37 10CD 30
Remove :
• Needle roller bearing from RH crankcase.
Assembly Balancer Idler Gear
Remove :
•
•
•
(A)
(B)
(C)
(D)
Thrust washers
Circlip from any one side of the gear
Scissor gear
• Torsion Spring
Similarly carry out the same procedure on other side of the gear to
dismantle the idler gear completely.
A C
B D E C B A
D
Gear Complete Starter Counter Assembly
Remove :
• 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)
• Needle roller bearing.
B C
D
E F
G H J
I K
A
Input Shaft Assembly
• 1st gear is integral with the shaft
• Remove thrust washer and slide out gear 2nd drive
• Remove gear 5th drive and collect the splined washer
behind it.
• Remove circlip and remove gear 3rd drive
• Remove circlip and collect the splined washer
• Remove gear 4th and collect the thrust washer behind it.
(A)
(B) (C)
(D) (E)
(F) (G)
(H) (I)
(J) (K)
Pulsar 150/180 DTS-i
Service Station Manual
124
Dealer Development Center
Akurdi Pune