Pulsar DTS-i 180 UG III - Cylinder Head Cover, Camshaft, and Cylinder Head Assembly Removal; Crankcase Components Removal

Dealer Development Center
57
Dealer Development Center
58
Remove :
• Cylinder head securing head cover 2 bolts (A)
• Cylinder head securing head cover 4 bolts (B)
• Cylinder head securing head cover 4 domed cap nuts (C)
• 4 copper plated steel washers
Remove :
• Cylinder head cover complete
• Cam shaft cap
Note : Improper tightening sequence may cause warpage in cylinder
head cover and it can be damaged permanently.
A
B
C
Sprcoket Catcher
Using Sp. Tool : Sprocket
Catcher - 3710 DH 36
Remove :
• Allen bolt
• Spacer
• Cam sprocket
• Collar
• Cam shaft assly
Using Special Tool : Sprocket Catcher - 3710 DH 36
Note : Hold the cam chain up right using soft copper wire or thread.
Do not use cotton waste for holding the cam chain.
Remove :
• Cylinder head assembly
• 2 dowels
• Gasket cylinder head
Remove :
• Non tensioner side chain guide
• Cylinder block assembly
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
Engine LH (Magneto Side) :
Remove :
• 5 bolts (A)
Remove :
• Piston pin lock LH & RH side
Note : Tie the cam chain firmly using soft copper wire/thread firmly to
avoid slipping down into crankcase.
Note : Place a piece of clean cloth above hallow portion of crankcase
to arrest piston pin circlip if it falls during fitment.
Using Special Tool :
Drift 74 9309 89
Remove :
• Remove piston pin
• Piston assembly
Caution : When tapping the drift for removal of piston pin, confirm that
the connecting rod is held firmly against the direction of tapping to
avoid damage to big end bearing connecting rod of crankshaft.
Remove :
• Block gasket
• 2 dowels (A)
Remove :
• Cover magneto.
A
A
Dismantling EngineDismantling Engine