Bajaj Discover 100M, Service Station Manual

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ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
Discover DTS-Si
Service Station Manual
126
Dealer Development Center
Akurdi Pune
Fitment of Damper on Crankcase LH
Ensure fitment of Damper Rubber washer in magneto
side crankcase on bearing seat before joining two
crankcase halves.
Crankshaft Oil Passage
Confirm oil supply to crank big end pin by pumping engine oil through its
passage hole by oil can.
Crankshaft Fitment
SOP :
Before assembling crankshaft, heat crankcase main ball bearing seats to 150 c
by electric heater to facilitate easy insertion of
main bearing into their
crankcase seats.
0
• Keep heater on crankcase main ball bearing setting area & switch ON heater.
• LED will glow till temp. reaches to 150 C.
• Remove the heater when LED becomes off, & insert crankshaft in crankcase.
0
Output Shaft Assembly
Ensure that 1st, 2nd, 3rd gear
output are freely rotating on Shaft
Output. Assemble washers & circlip
locks as shown in exploded view.
8 : Shaft Output
9 : Gear 2nd Driven
10 : Washer Gear 2nd Driven
11 : Gear 3rd Driven
12 : Gear 4th Driven
13 : Bush 1st Driven
14 : Gear 1st Driven
15 : Washer Thrust
16 : Collar Sprocket Drive
17 : ‘O’ Ring
18 : Sprocket Output
19 : Plate Lock-sprocket output
20 : Bolt Flanged