Bajaj Discover 100M, Service Station Manual

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Intake & Exhaust Rocker Shaft
•
•
Intake Rocker Shaft is short in length as compared to Exhaust Rocker Shaft.
Length of Intake Rocker Shaft = 48 mm,
Length of exhaust Rocker Shaft = 48 mm
Exhaust Rocker Shaft - 48 mm
Cam Sprocket Assembly
• Ensure fitment of collar behind cam sprocket. Collar must be freely rotating
on cam shaft.
• Apply loctite 243 to threads of cam sprocket special bolt with integral washer
& tighten it to specified torque (1.6 ~ 1.8 Kgm).
Routing of Stator Plate Wiring Harness
•
•
While assembling stator plate on crankcase LH, guide (route) wiring harness
of stator through the groove formed by two small ribs provided on the
crankcase & fit the lock plate. Apply loctite 243 to screw securing lock plate.
Apply three bond gasket to grommet of stator plate wiring harness before
assembling.
Piston Ring Fitment
•
•
•
•
•
•
•
Piston rings must always be fitted with respect to exhaust mark on the piston
First place the bottom oil rail ring with end
gap 30
towards left of the exhaust mark in
the last groove.
Place oil expander ring with butting end
downward & end gap facing opposite to the
exhaust mark.
Now fit top oil rail ring on the expander ring
with end gap 30
towards right of the
exhaust mark.
Fit the second piston ring with ‘Top 2’ mark facing upward and end gap
facing opposite to the exhaust mark.
Finally fit the first ring with ‘Top 1’ mark upward and end gap facing towards
the exhaust mark.
Remember fitment of 2nd ring upside down may lead to passing of oil above
the piston and ultimately leading to smoky exhaust.
0
0
Exhaust
Arrow
Front
1
2
3
3
4
Top 1 Mark
Top
ring
Top 2 Mark
2nd
ring
ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
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Intake - 48 mm Rocker Shaft