ASSEMBLY - ENGINE
Pulsar 150/180 DTS-i
Service Station Manual
137
Dealer Development Center
Akurdi Pune
Assembly Balancer Idler Gear Bearing
Fit :
Using Bearing Driver set (P. No.: 37 1030 61)
• Needle roller bearings in crankcase RH and Cover
Note :
Apply oil on bearing OD before pressing bearings for smooth bearing fitment.
Fit :
• Springs
• Scissor Gears
• Circlip
Thrust washer
(D)
(C)
(B)
•
Similarly carry out the same procedure on other side of the gear to
assemble the Balancer Idler Gear completely.
Note :
Ensure that one spring end butts against spring dowel in Balancer Idler Gear and
the other end of spring should but against the lug on Scissor Gear.
AC
BD
E
CB A
D
Loading the assembly Balancer Idler Gear
Using Sp. Tool : Balancer Gear Holder
3710DJ63
Using Special Tool
• Slide the Assembly Balancer Idler
Gear in special tool (A)
• Rotate the Scissor Gear anti-
clockwise till the lug contacts the
torsion spring.
• Using a marker, mark the Balancer
Idler Gear & Scissor Gear Tooth
• Turn the Scissor Gear anticlockwise
such that 2 teeth pre-load is
achieved. This can be confirmed by
the markings done previously.
• Holding the Scissor Gear pre-loaded
in the above position slide the
Scissor Gear into the special tool
completely.
Repeat the same procedure for loading
the other Scissor Gear.
Note :
Keep this Assembly balancer idler gear in loaded
condition with special tool.
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