Dealer Development Center
56
Dealer Development Center
55
Remove :
•
While removing engine foundation bolts, first remove the topmost bolt
and then go down progressively.
Note :
Bolts (A) holding the engine to the chassis. (4 bolts of 12 mm
and 1 bolt needs deep socket for removing it).
• Lift up the engine off the chassis and place it on engine stand.
Note :
After disconnecting all the sub assemblies and control cables
from the engine lift up the engine and remove it from RHS of the
vehicle.
Pulsar DTS-i UG-III-180cc
Training Notes
Pulsar DTS-i UG-III-180cc
Training Notes
Engine Top End Dismantling :
Remove :
• Pull out the cover on the spark plug cap RH and the spark
plug cap itself
• Using a plug spanner, loosen and remove the spark plug RH
• Loosen and unscrew the allen head grub screw of the sleeve
spark plug
Remove :
• Loosen bolt
(A)
and unscrew chain tensioner plunger
• Cam chain tensioner assembly 2 bolts
(B)
• Cam chain tensioner assembly
Remove :
•
Both tappet caps
•
Magneto cover cap seal and rotate crankshaft to get piston at
TDC.
•
Ensure both tappets are at free state (i.e. at the end of
compression stroke)
Remove :
• 2 dummy plug
• 2 gaskets
Note :
Wrap a piece of cloth around the protruding edge of the
sleeve spark plug and using a plier, pull out the sleeve.
Note :
Remove these only if the ‘O’ ring protrusim in the bore is
non-existant (which means that the ‘O’ ring has set and it has lost its
compression or sealing ability.)
Remove :
• There are 2 ‘O’ rings fitted in the cylinder head, one on the
cam chain wall and the other near the spark plug threading
• Using a thin, sharp pointed tool pierce the ‘O’ rings and
remove them. (If required)
A
B
Removal of Engine from Frame
Dismantling Engine
