Pulsar DTS-i 180 UG III - Rotor and Starter Assembly Removal; Engine RH (Clutch Side) Dismantling

Dealer Development Center
60
Dealer Development Center
59
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
Using Special Tool : Rotor
Holder - H6 0721 00
• Hold the rotor assembly
Remove :
• Rotor bolt (A)
• Washer
Using Special Tool - Rotor
Puller with butt pin : 37 10DJ 32
Remove :
• Rotor assembly
• Woodruff key.
A
Note : Holding the gear complete starter clutch rotate the rotor
and pull it out in Anticlockwise direction to prevent rollers and
springs coming out. Rotor puller has left hand threads.
Warning :
• These components remain hot for a long time especially if removed
from a hot engine. Wear suitable hand protection to prevent burns.
• Rotor puller has left hand threads
Remove :
• Gasket
• Bolt (A)
• Plate starter clutch gear return (B)
• Gear starter clutch
Remove :
• Collar (A)
• Shaft
• Gear comp. starter counter assly
A
A
B
Remove :
• 1 screw - (A)
• Starter motor cover
Remove :
• 3 Screw (A)
• Guide starter assembly along with oil seal.
Engine RH : (Clutch Side)
Remove :
• Kick starter bolt
• Kick starter
Warning : The oil pump may be hot, hence use suitable hand
protection. Also, since the oil pump houses the oil strainer / mesh also,
it may retain some quantity of oil. This oil may be hot. Hence proper
care should be taken to drain it.
Note : The oil which is in the oil pump housing should also be drained
out into the oil drain tray for measuring drained oil.
Note : The rod clutch lifter, plunger oil, plate plunger oil and spring
joint may fall out of their respective places into the oil collection tray. If
so, ensure that these are collected & accounted for before proceeding.
Remove
• 12 Clutch cover bolts (B)
• Bracket clutch cable (C)
• Clutch cover
Caution : Ensure that the woodruff key of rotor is removed prior to the
removal of guide starter assembly. The lips of magneto oil seal housed
in guide starter assembly will get damaged if not done so.
A
B
A
Remove :
• 3 bolts (A)
• Oil pump assembly
• 2 Dowels
• Clutch cover gasket
• Starter Motor (B)
A
B
C
Dismantling EngineDismantling Engine