Pulsar DTS-i 180 UG III - Centrifugal Oil Filter and Input Shaft Removal; Balancer Gear Removal

Dealer Development Center
62
Dealer Development Center
61
Dia. = 25.9+0.1
Using Special Tool :
Special Nut Puller 37 10DJ43
Primary Gear Holder 3710 DJ28
Remove :
• Centrifugal oil filter special
nut
• Belleville washer
• Body centrifugal oil filter
assly
Remove :
• Bearing with plunger
Using Special Tool : Special
Nut Puller 37 10DJ 43
Primary Gear Holder 3710DJ28
Remove :
• Input shaft special nut
• Belleville washer
• Clutch assly comp
• Spacer
Note : The existing Special Nut Puller 37 10DJ 43 can be used by
grinding the tool OD to 25.9 + 0.1 mm
Using Special Tool : Primary
Gear Holder 37 10DJ 28
Remove :
• 3 phillips head screws (A)
• Centrifugal oil filter cover
• Gasket
Warning : These parts may be hot, if removed from a hot engine. Use
gloves for protection.
Note : Some amount of oil is trapped in cover and body of centrifugal
oil filter, this oil should be drained into the oil tray.
A
Pulsar DTS-i UG-III-180cc Training NotesPulsar DTS-i UG-III-180cc Training Notes
Remove :
• Assly Bal. idler gear
• 2 Washer
Note : Take case that square key does not fall inside the crankcase
hollow portion while removing.
Remove :
• Bolt (A)
• Locking plate
• Body balancer gear assly
Remove :
• Primary gear
• Square key
Remove :
• Cam chain
• Cam chain sprocket
• Parallel Pin
A
Remove :
• 3 Assly balancer Idler gear cover bolts (A)
• Cover
• Washer
• 2 Dowel
Remove :
• Clutch housing
A
Note : For ease in removal of clutch house insert special tool
(P. No.-37 10DJ 63) in Assly Balancer Idler Gear.
Dismantling EngineDismantling Engine