Bajaj pulsar DTS-i, Service Station Manual

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PARTS INSPECTION PARAMETERS
• No Teeth breakage or crack
• No Wear pattern on teeth
• No Wear of dog teeth & dog holes on gear
• No Seizure mark on gear seat.
• Free movement of gears on the shaft (1 Output, 2 Output, 3
Output, 4 Input and 5 input gears are free on the respective
shaft)
• Free movement of Fork shift on the fork shaft
• Gear shift drum groove profile - Ok / No damage - Wear
• Free movement of Fork shift guide roller in the drum groove
st nd rd
th th
• Presence of Neutral rivet on the Drum
• Free rotation of Drum in LH crankcase parent hole.
• Inner hollow portion must be free from casting dust / burr
• Groove profile width as per Service Data
• Hole available for parallel pin
• Drum profile free from Hi-Spot for free sliding of bush
• Presence of locating washer
• Free rotation of bearing
• Lobe height - as per Service Data
• No cut / wear marks on cam
Transmission :
Drum :
Camshaft :
• Nylon scissor gears worn out
• Circlip on either side
• Torsion spring sustaining adequate tension
• Torsion spring locking groove / hole oblonged or damaged.
Assembly Balancer Idler Gear :
Pulsar 150/180 DTS-i
Service Station Manual
130
Dealer Development Center
Akurdi Pune