Bajaj pulsar DTS-i, Service Station Manual

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STARTER MOTOR
• Do not drop down the motor.
• Don not Clean Commutator segments by polish paper.
• Do not wash or clean the armature and carbon with kerosene or petrol.
• Do not hit the motor body by hammer or screw driver as it will lead to magnet
breakage.
• Do not use worn out / broken sealing rings of Yoke assly as this would lead to water
entry.
• Do not direct pressurized water jet on motor body during washing.
• Do not crank the engine continuously in case the engine does not start. Analyze the
cause and correct. Otherwise battery will get drained and the starter motor will get
damaged.
• Do not energize the starter motor when the engine is running. Serious damages will
occur to the drive mechanism.
• Don’t press starter switch more than 3 seconds. After 3 successive cranking, if engine
doesn’t start, wait 15 ~ 20 seconds for battery to recover & then crank for next cycle.
Shaft
Permanent
Magnets
Carbon Brushes
Commutator
Brush Holder
Armature Winding
Bush
Brush Holder
• Remove carbon particles from commutator slots by sharp
blade / knife.
• Clean commutator segments by soft cloth.
• Lubricate brass bush by 2~3 drops of Servo 32 oil & NR
Bearing by high temperature-high speed OKS410 grease .
• Clean the carbon particles deposited inside the rear end
cover.
• Remove all accumulated rust particles by paper.
• Ensure firm connection of Red wire of starter motor
• Replace the Yoke sealing Rings if worn out / broken.
• Ensure the +ve brush holder assly securing nut is fully tight.
• Use correct capacity and fully charged battery.
• Starter switch should be released immediately once the engine starts.
• Assemble Starter Motor front cover such that the mark on it matches with 2 marks on
body. Assemble rear cover such that mark on it matches
w i t h 1 m a r k o n b o d y.
Otherwise motor will rotate in reverse direction due to reverse polarity of magnets. This
will give cranking trouble.
• Replace Yoke Sealing Rings & tie bolt ‘O’ Rings whenever starter motor is dismantled.
• Put few drops of oil on starter motor front cover ‘O’ ring before assembling starter
motor.
Dos 3
7
Don’ts
Pulsar 150/180 DTS-i
Service Station Manual
231
Dealer Development Center
Akurdi Pune