SOP FOR DISMANTLING ENGINE
Remove :
• Both tappet caps
Remove :
• Magneto cover 5 bolts
• Disconnect neutral switch coupler
• Magneto cover
• Rotate crankshaft to get piston at
TDC.
Ensure both tappets are at free state
(i.e. at the end of compression
stroke)
•
Remove :
• Loosen 2 dummy plug (A)
Remove :
• Cylinder head securing head cover 2 bolts (A)
(B)
(C)
• Cylinder head securing head cover 4 bolts
• Cylinder head securing head cover 4 domed cap nuts
• 4 copper plated steel washers
Note : Improper tightening sequence may cause warpage in cylinder head cover and
it can be damaged permanently.
Remove :
• Cylinder head cover complete
• Cam shaft cap
• 2 Dummy plugs
• Dummy plug gasket
A
C
B
A
Pulsar 150/180 DTS-i
Service Station Manual
108
Dealer Development Center
Akurdi Pune
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