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Have all the listed items ready.
Remove the air hose.
Remove the tappet plate spring.
Unscrew the screw securing the tappet plate.
Remove the tappet plate.
Remove the nozzle.
Gently unscrew the solenoid valves – be careful with the very delicate O-rings on the valve.
Using the dedicated wrench included in the kit or Seger-type safety pliers, unscrew the nozzle guide. The first engine release may not have had them included, but they are available in our store.
Using tweezers or a screwdriver, gently remove the poppet from inside the body.
Remove the tappet plate piston (you can use tweezers or a sharp knife for this, paying attention not to damage the piston).
Remove all the O-rings from the engine components except the solenoid valve (it is best to use plastic tools for this so as not to damage the aluminum surfaces of the engine – this is not covered by the warranty).
If the o-rings are not damaged, you can reuse them after cleaning them with a paper towel – it is best to avoid washing the o-rings with detergents.
If the o-rings are damaged or show signs of wear, replace them with new ones – included in the kit.
Place the engine components in a dish with petroleum ether (NOTE – does not apply to the solenoid valves. Avoid immersing them in cleaning agents).
Using a thicker brush and tweezers, thoroughly clean the engine components.
For solenoid valves, gently wipe the O-ring surfaces and remove visible dirt with a dry brush.
Set the washed parts aside on a paper towel to dry completely (you can speed up the process by blowing the parts with compressed air).
Reinstall the o-rings (you can lightly grease them before installation):
Install the o-rings according to the diagram below:
1 o-ring 16x1.5 mm and 1 o-ring 6x1 mm in the nozzle guide.
2 o-rings 8x1 mm for the poppet.
1 o-ring 4x1 mm for the tappet plate piston.
Prepare all parts with the O-rings installed, as well as grease and a smaller brush.
grease two places in the rear of the engine body:
The cylinder where the piston moves (take care not to grease the bottom of the cylinder).
Then the vertical surfaces of the cylinder where the poppet moves. Try not to grease the bottom of the cylinder. This can have a negative effect on engine performance.
Grease the o-ring on the piston and the piston.
Place the piston in its cylinder and collect excess grease.
Grease well the two o-rings in the nozzle guide (you can remove the excess with a paper towel).
In the poppet, also grease two places:
Both O-rings. As with the rear of the engine, be careful not to leave grease on the flat rear surface of the nozzle.
And the narrowed poppet surface.
Place the greased poppet in the inner part of the nozzle guide.
Then screw the nozzle guide into the engine body using a wrench or the aforementioned pliers.
Grease the nozzle guide.
Grease the nozzle from the inside in the o-ring area.
Install the nozzle on the guide.
Gently grease the thread and O-rings of the valve with a flat brush. Avoid getting grease into the moving parts of the valve.
Gently, while taking care of the solenoid valve's o-rings, screw it into the valve socket. Just do it with your bare hand, do not use tools for this.
Grease the surface over which the tappet plate moves.
Install the tappet plate. Press it well against the nozzle.
Secure the tappet plate with the screw. Tighten the screw until you feel resistance in the operation of the tappet plate and then loosen the screw so that the tappet plate can move freely and without resistance.
Install the tappet plate spring.
Screw on the air hose.
The engine is once again ready for use.
Poppet Replacement
What poppets are available?
There are three variants of poppets with different flow diameters:
ø2 mm
ø3 mm
ø4 mm
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How does a reduced-flow poppet work, and when should it be replaced?
A reduced-flow poppet limits the amount of air propelling the BB while maintaining the proper operating pressure of the PULSAR D engine. These poppets are ideal for replicas used in CQB games and in regions with very low FPS limits, even as low as 0.5 J.
Replacing the poppet is necessary when you need to reduce the replica's muzzle velocity but cannot do so because you have reached the lower operating pressure limit of the PULSAR D engine. Using a reduced-flow poppet allows you to increase the operating pressure while maintaining a lower power limit for the replica.
Which poppet should you choose?
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Poppet replacement and list of required components:
Selected poppet with the appropriate flow
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The PULSAR D engine comes with a ø4 mm poppet pre-installed. Available variants include:
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Clean, fine brush for applying grease
Tool for unscrewing the nozzle guide
Balystik Premium Grease – Pneumatic or Gun Sav by TechT
Optional tools and materials:
Paper towels
Clean, thicker brush for cleaning components
Container for cleaning parts
Plastic tweezers for removing and installing o-rings
Degreasing agent for all parts, e.g., extraction gasoline (must not damage o-rings)
Disassemble the PULSAR D engine from the replica.
Prepare the components shown in the photo.
Remove the tappet plate spring.
Unscrew the screw securing the tappet plate.
Remove the tappet plate.
Remove the nozzle.
Use the tool attached to the PULSAR D to unscrew the nozzle guide. If you don't have the tool, use circlip pliers or needle-nose pliers.
Using tweezers or the back end of a brush, gently remove the poppet from inside the body. Set the poppet aside.
Check if there is any debris on the engine and ensure it is properly lubricated. This is a good time to perform maintenance and lubricate the engine if necessary.
Check the visual condition of all seals and o-rings. If necessary, replace them with the ones included in the repair kit.
Prepare the new poppet for installation by applying a thin, even layer of grease. The areas to grease on the poppet are:
Both o-rings. Be careful not to leave any grease on the flat rear surface of the poppet.
The tapered surface of the poppet.
Lubricate the nozzle guide.
Place the lubricated poppet inside the inner part of the nozzle guide.
Screw the nozzle guide into the engine body using the tool.
Lubricate the inside of the nozzle where the o-ring is located.
Install the nozzle onto the nozzle guide.
Lubricate the surface where the tappet plate moves.
Install the tappet plate. Press it firmly against the nozzle.
Secure the tappet plate with the screw. Tighten the screw until you feel resistance from the tappet plate, then loosen the screw slightly so that the tappet plate can move freely without any obstruction.
Check if the tappet plate can move freely forward and backward. If necessary, tighten or loosen the screw to ensure smooth movement.
Install the tappet plate spring.
Screw in the air hose.
The engine is ready for reuse.
Repair Kit
Use the repair kit if any of the o-rings are damaged/worn.
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