Pulsar DTS-i 180 UG III - Removal of Engine from Frame; Engine Mountings and Sub-assembly Removal; Engine Top End Dismantling

Dealer Development Center
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Dealer Development Center
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Remove :
• While removing engine foundation bolts, first remove the topmost bolt
and then go down progressively.
Note : Bolts (A) holding the engine to the chassis. (4 bolts of 12 mm
and 1 bolt needs deep socket for removing it).
• Lift up the engine off the chassis and place it on engine stand.
Note : After disconnecting all the sub assemblies and control cables
from the engine lift up the engine and remove it from RHS of the
vehicle.
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
Engine Top End Dismantling :
Remove :
• Pull out the cover on the spark plug cap RH and the spark
plug cap itself
• Using a plug spanner, loosen and remove the spark plug RH
• Loosen and unscrew the allen head grub screw of the sleeve
spark plug
Remove :
• Loosen bolt (A) and unscrew chain tensioner plunger
• Cam chain tensioner assembly 2 bolts (B)
• Cam chain tensioner assembly
Remove :
• Both tappet caps
• Magneto cover cap seal and rotate crankshaft to get piston at
TDC.
• Ensure both tappets are at free state (i.e. at the end of
compression stroke)
Remove :
• 2 dummy plug
• 2 gaskets
Note : Wrap a piece of cloth around the protruding edge of the
sleeve spark plug and using a plier, pull out the sleeve.
Note : Remove these only if the ‘O’ ring protrusim in the bore is
non-existant (which means that the ‘O’ ring has set and it has lost its
compression or sealing ability.)
Remove :
• There are 2 ‘O’ rings fitted in the cylinder head, one on the
cam chain wall and the other near the spark plug threading
• Using a thin, sharp pointed tool pierce the ‘O’ rings and
remove them. (If required)
A
B
Removal of Engine from Frame Dismantling Engine