Bajaj Discover 100M, Service Station Manual

Page: 158 / 319

LH Crankcase Assembly
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•
Assemble Crankshaft, Gear Shift Drum & Transmission Shafts with Gears,
Kick return spring into Crankcase LH.
Ensure that Gear Shift Drum rotates freely in Bushing.
Important : Fit “Fork shift input” such that mark (QK) faces upward & ‘JD’
mark faces downward.
Bush (Roller) Fork Shift
Always assemble ‘Bush Fork Shift’ (roller)
on fork shift pin such that chamfer (taper)
side of bush faces towards ‘Shaft Fork
Shift’ (that is towards ID of ‘ Fork Shift’).
A : Special Bolt
B : Cam Gear
C : Pin Dowel
D : Drum Gear Change
E : Fork Shift-Input
F : Shaft Fork
G : Fork Shift-Output
H : Bush (Roller)
Assembly of I/P & O/P shaft thrust
washers
Ensure fitment of one ‘washer Thrust’
Part no. JA551008 on top face of 1st
Gear output.
One ‘washer thrust’ JA551004 below
2nd Gear Input. Missing washer would
lead to excessive shaft end play &
gear slippage.
Assembly sequence of fork shift
output
Important :
This means mark on lower & upper
“Fork Shift Output” must face to
each other.
First assemble lower “Fork
Shift Output” such that mark (QC)
faces upward & then upper “Fork Shift
Output” such that mark (QC) faces
downward.
Up Side
Down
Side
ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
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Service Station Manual
127
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4
2
2
3
1
6
5
7
Upper
Fork
Shift
Lower
Fork
Shift