Bajaj Discover 100M, Service Station Manual

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GENERAL INFORMATION
Discover 100 M
Service Station Manual
13
Dealer Development Center
Akurdi Pune
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To avoid damage to head of fasteners do not use over size or worn out tools.
To avoid damage to painted parts, prevent spillage of battery acid & brake fluid.
To avoid damage of machined face & color of the components store the parts in a clean plastic bin having
compartments to avoid components touching to each other.
To avoid warpage of mating / sealing faces, mounting bolts should be tightened in a criss-cross pattern.
To avoid slippage of threads leading to components damage, do not over torque bolts, nuts or screws.
Always install new gasket & O rings when reassembling.
Always apply grease to the lip of seal before installing.
Always replace circlips / cotter pins & radiator hose clamps with new ones.
Take care not to excessively spread open circlips with tool during installing to prevent deformation.
Always use appropriate special tool for opening & assembling parts to avoid damages.
To avoid dust / muck entry inside the engine wash vehicle throughly before executing any repair work related to
engine or otherwise this may lead to early failure of parts.
Always use lint free cloth while handling engine parts.
Always apply few oil drops between two moving parts to avoid dry run.
Always blow high pressure compressed air through oil passage holes in reverse direction of flow of oil & ensure that
the passages are clear.
Always apply loctite to bolts, screws or nuts wherever recommended to avoid loosening & subsequent break down.
Confirm proper seating of circlips by rotating them to avoid it from coming out.
Do not tap engine components by hammer in order to avoid damage. Engine components are precisely machined.
Do not fit extra electrical accessories otherwise wiring would get short & battery would get discharged.
General Precautions