IMPORTANT POINTS TO REMEMBER
• Remove long bolt immediately after removal of long bolt clutch side.
• Ensure proper fitment of bolt with copper washer to avoid oil leakage.
• When splitting crankcase always remove 1 long bolt fitted from clutch side
first.
• Load the assly balancer idler gear with 2 teeths from either side using the
special tool.
• Input shaft has special nut.
• Thick spacer tapered I.D. should be placed on tapered portion of Input
Shaft.
• Input Shaft has left hand threads.
• Fit primary gear drive (A).
• The mark teeth of the primary gear should match with the line mark on the
crankcase. This indicated that the piston is at TDC position.
This procedure should be carried before fitting the ‘Clutch Housing’ and this
position should not be disturbed while fitting the ‘Clutch Housing’.
Pulsar 150/180 DTS-i
Service Station Manual
96
Dealer Development Center
Akurdi Pune
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