Bajaj Pulsar 150 DTS-i, Руководство по обслуживанию

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Special Tools Special Tools
Dealer Development Center, Pune
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Pulsar DTS-i 150/180 Training Notes Dealer Development Center, Pune
23
Pulsar DTS-i 150/180 Training Notes
Details of Exclusive Special Tool
For carrying out repairs / overhauls, 5 new special tools are identified for Pulsar 180 cc. These
5 new special tools were developed earlier exclusively for Pulsar DTS-i 200cc & Pulsar DTS-Fi
220cc. Rest of the special tools required remains the same which were earlier used for Pulsar,
Pulsar DTSi UG-II, Pulsar DTSi UG III.
Drawing No : 37 1740 05
Application :
Used for holding the fork piston
from inside.
Fork Holder :
Drawing No : 37 1740 03
Application :
To fit fork oil seal on outer pipe.
Fork oil seal fitment punch :
Drawing No : 37 1740 04
Application :
Used for removing front fork
inner tube from outer tube.
Fork Inner & Outer Tube
Extractor :
Drawing No :
Application :
To remove the bearing from
crankshaft.
JC1010 01
Crankshaft Bearing
Extractor :
Drawing No : 74 9309 93
Application :
To remove & refit needle roller
bearing from swing arm.
Needle Bearing Puller :
Details of Other Common Special Tool
Special Tool Name
Sprocket Catcher
Camshaft Big Bearing Puller
Camshaft Small Bearing Puller
Rocker Shaft Remover
Silent Bush Puller
Rotor Puller with Butt Pin
Primary Gear Holder
Balancer Gear Holder
Special Nut
Bearing Race Extractor
Bearing Extractor
Bearing Puller
Adaptor & Valve Spring
Compressor
Rotor Holder
Drift
Thrust Plate Aligner / Holder
Output Sprocket Holder
Bearing Driver Set
Rear Shock Absorber Adjuster
Piston Ring Holder
37 10DH 36
37 10DH 32
37 10DH 31
37 10DH 35
37 10DH 33
37 10DJ 32
37 10DJ 28
37 10DJ 63
37 10DJ 43
37 00DJ 01
37 10DJ 76
37 10DJ 77
37 10DJ 78 / 37103107
H6 0721 00
74 9309 89
T 10111 68
37 1030 53
37 1030 61
37 00DH 14
37 10DJ 30
Special Tool No.
For holding sprocket during removal / refitting of Cam sprocket allen bolt.
To remove bigger bearing
To remove small bearing of camshaft.
To remove rocker shaft from cylinder head cover.
To remove & refit silent bush from cylinder head cover.
Used to pull out the rotor from crankshaft assembly.
Use to hold primary gear while loosening / tightening the clutch nut.
Used to load pre-tensioned scissor gears of Assly balancer Idler gear.
Used to remove / fit of centrifugal oil filter nut.
Used for removing the lower bearing race from ‘T’
Used to extract the input shaft bearing from crankcase LH.
Used to pull out the bearing for body balancer from crankcase LH.
Used for assembling / dismantling inlet, exhaust valves by compressing
spring in cylinder head.
To hold rotor while loosening bolt.
To remove piston pin.
To align the clutch hub concentric w.r.t clutch wheel, clutch housing and
thrust plate for assembly of clutch.
To hold the output sprocket while removing sprocket bolt
Common bearing driver set for fitting and removing bearings from
crankcase.
For adjusting the notch position of RSA to achieve hard or soft rear
suspension.
Used for compressing the piston rings when assembling piston in the
cylinder block.
Application