Bajaj pulsar DTS-i - Page 129

DISMANTLING ENGINE SUB ASSEMBLIES
Pulsar 150/180 DTS-i
Service Station Manual
125
Dealer Development Center
Akurdi Pune
Output Shaft Assembly
• There are no integral gears on output shaft.
• Remove thrust washer and slide off the gear 1st driven
and collect the steel bush (1 driven gear is mounted on steel
bush with shoulder ring
• Slide off the gear 4th driven
• Remove circlip and spline washer Remove the gear 3
driven
• Collect the thrust washer behind the 3 gear on output shaft
• Remove circlip and collect the washer
• Remove gear 2 driven mounted on bush with shoulder
ring
• Slide out gear 5th driven
(A) (B)
(C)
(D).
(E) (F).
(G).
(H) (I)
(J) (K)
(L) (N)
(M)
st
rd
rd
nd
ABC
D
EF
G
H
I
J
K
LM
N
A
B
C
D
Crankcase Magneto Side
• (D)
Remove :
• 3 Screws
• Guide starter assembly on which oil seal is mounted.
• Oil seal
(A)
(B)
(C)
Damper
Clutch Cover
Remove :
• Parallel Pin
Clutch shaft release completely by slightly rotating it so,
Rack
Plunger oil
Plate plunger oil
Spring joint ‘A’
Oil filler plug
• Wire clip
• Oil inspection window
• Flanged bolt (8 Nos.)
• Set of damper
• Set of plate
• Grommet
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
(K)
(L)
(M)
•
•
•
•
•
•
• Circlip & Valve assembly
B
G
F
E
D
A
J
L
K
C
H