Bajaj Discover 100M, Service Station Manual

Page: 163 / 319

ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
Discover DTS-Si
Service Station Manual
132
Dealer Development Center
Akurdi Pune
Cam / Guide Gear & Special Bolt
Insert 5 no. of pin dowels into the holes of Gear Shift
Drum. One hole is provided extra on the Drum. One pin
is press fitted on the drum (which is less in height) for
neutral position.
This hole must be kept blank & pin must not be inserted
otherwise assly. of Cam/Gear Guide would not be
possible. ‘Cut portion’ of Cam must be in line of neutral
pin.
Blank hole
Press fit pin
for neutral position
Cam guide
cut portion
Guide Gear (Cam) Fitment
While assembling Guide Gear on the drum pins, ensure that its plain side
(integral collar washer side) faces towards pins & other side (5 Star side) to
Special Bolt. Cut portion of cam should be aligned with neutral pin press fitted
on ‘Gear Shift Drum’ for correct assembly.
Cam Gear Special Bolt
Apply loctite 243 to special bolt with integral collar securing cam gear change
drum.