PARTS INSPECTION PARAMETERS
• Grouping mark with respect to cylinder block must be same.
• Diameter of the piston - As mentioned in service data
• No scoring marks on the skirt
• No blow by marks
• No seizure marks.
• Manufacturing / Identification code and date code
• Piston pin - scratches dent marks
• Groove for piston pin lock
Piston :
• No uneven wear around circumference / breakage.
• Discoloration at working face.
• Carbon built up on inner face if any.
• Piston ring end gap - As per Service data
• Piston ring width (thickness) - As per Service data
• Free rotation of Rings in Piston grooves - No stickyness.
• Piton ring identification mark
Top Ring : TOP 1, Second Ring : TOP 2
• Big end axial/radial play : As per Service data.
• Run out : As per Service data.
• Threading condition : Ok / No damages.
• Key way condition : Ok / No damages.
• Big end bearing : Free rotation / Jam
• Con-rod : No bending / twisting
• Oil passage : No blockage.
• Square slot key way for primary gear
• Identification mark 'DK' on connecting rod
• Mating surface:Smooth / No scratches.
• No Cracks, damages, breakage.
• Bearing seat, oil seal seat and proper pressing/positioning of oil
seals, needle roller, ball bearings freely rotating
• No Blow holes in casting
• Breather pipe / hole:No clogging
• Oil passage:Clean / No clogging
• Threads of holes & studs:Ok / No damages
• Visible number punching on LH Crank Case
Rings :
Crankshaft :
Crankcase :
Pulsar 150/180 DTS-i
Service Station Manual
128
Dealer Development Center
Akurdi Pune
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