Bajaj Discover 100M, Service Station Manual

Page: 155 / 319

Bearing Fitment
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Always fit ball bearing of input shaft in crankcase RH from clutch cover side
& ensure that bearing is ‘Face-to-Face’ with crankcase surface. Apply loctite
243 to Phillips screw securing ‘Bearing Stopper Plate’.
Fit needle roller bearing of input shaft in crankcase LH such that bearing
surface is 0.5 mm below crankcase surface.
Always fit ball bearing of output shaft in crankcase LH from inner side of
crankcase & ensure that bearing is ‘Face-to-Face’ with crankcase surface.
Fit needle roller bearing of output shaft in crankcase RH such that bearing
surface is 0.5 mm below crankcase surface.
Crankcase Oil Passages
Always blow high pressure compressed air through the oil passage holes (of
crankcase & clutch cover) in reserve direction of flow of oil & ensure that the
Passages are clear.
Bushing for Gear Shift Drum
Use special tool no E6101100TE to fit ‘Bushing for Gear shift Drum’ into
crankcase RH. Ensure intact condition of PTFE coating on ID of Bushing.
Always fit Bushing in crankcase RH such that its slit
is at Top Position (facing towards crankcase wall).
After fitment Bushing must be 0.5 mm below the
crankcase surface. Ensure that ‘Gear Shift Drum’
rotates freely in the bushing.
ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
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Service Station Manual
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