new pulsar 125 Workshop-manual : Page 160

          17. STARTING SYSTEM                                                      Pulsar   CK   125


 Check if the bearing in the rear cover turns                                     Rear Cover
 freely and has no excessive play.
 Replace if necessary.




                                                  Bearing

                                                                  Washers         Rear Cover
 ASSEMBLY
 First remove the brush springs and then
 install the brushes onto the brush holders.
 Insert the commutator into the starter motor
 housing.
 Be careful not to damage the brush and
    commutator contacting surfaces.
 Apply a thin coat of grease to the rear cover
 bearing and then install the washers and rear
 cover.
                                                            O-rings

                                                                      Brush
 Install the brush springs.

 Make sure that the brushes move freely
    after installation.




 Apply a thin coat of grease to the front cover                       Spring
 oil seal and bearing.
 Install the O-ring and front cover onto the                                   Punch Marks
 motor body.
 · Be careful not to damage the oil seal.
    · The punch marks on the front and rear
      covers must be aligned with that on the
      housing.
 Tighten the starter motor case bolts.
 Torque: 0.30.4kg-m
 After assembly, check the starter motor for
 proper operation.
                                                  Punch Marks                     O-ring

                                                                                       17-4