Bajaj pulsar DTS-i, Service Station Manual

Page: 143 / 253

ASSEMBLY - ENGINE
Pulsar 150/180 DTS-i
Service Station Manual
139
Dealer Development Center
Akurdi Pune
Input Shaft Assembly
Fit :
• (I)
• (G)
(F)
(D)
• (C)
From LH side of shaft (A)
Splined washer
Gear 3rd drive
Circlip
Gear 5th drive
Gear 2nd drive
• Thrust washer
Gear 4th
Circlip
• Splined washer
Thrust washer
(K)
(J)
(H)
(E)
(B)
•
•
•
•
•
Output Shaft Assembly
Fit :
• (N)
(L)
• (K)
Fit :
(H)
(G)
• (F).
(E)
(D)
• (C)
(B)
(A)
from LH side of shaft
Bush with shoulder ring
Gear 2 driven
Washer
from RH side of shaft
Thrust washer behind the 3 gear on output shaft
• Gear 3 driven
Spline washer
Circlip
Gear 4th driven
Steel bush with shoulder ring
• Gear1st driven
Thrust washer
•
•
•
•
•
•
•
(M)
(J)
Gear 5th driven
Circlip
nd
rd
rd
B C
D
E F
G H J
I K
A
A B C
D
E F
G
H
I J K
L M
N
Engine Assembling
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’.