IMPORTANT POINTS TO REMEMBER
• Take ‘Assembly Balancer Idler Gear’ along with Thrust Washer which is
pre-loaded and is held in special tool, Slide down the special tool with
‘Gear’ to engage the bottom half of the ‘Assembly Balancer Idler Gear’ with
the ‘Body Balancer Gear Assembly’
• Fit ‘Thrust washer’ on the other side.
• On assembly of ‘Assembly Balancer Idler Gear’ the itched / Dot mark of
Body Balancer Gear Assembly’ should match with the line mark on the
‘Crankcase’.
• Holding the ‘Assembly Balancer Gear’ in special tool now slide inside the
‘Clutch Housing’ so that the ‘Clutch Housing’ smoothly engages with the
top half of ‘Assembly Balancer Idler Gear’.
• Remove Spl. tool gently.
• Fit 2 dowels and Assly Balancer Idler Gear Cover
• Ensure perfect marking of gear marks with respect to crankcase mark.
• Do not dismantle the cam chain tensioner assembly.
The existing special nut puller for Pulsar can be use for Pulsar UG-III and
Pulsar 200 cc by reducing its diameter to 25.9 0.1 mm.+
Pulsar 150/180 DTS-i
Service Station Manual
97
Dealer Development Center
Akurdi Pune
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