Bajaj Discover 100M Service Station Manual page 159

ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
OD = 25.7 mm OD = 25.1 mm
ID = 13.3 mm ID = 12.3 mm
Washer of
2nd Gear Input 1st Gear Output
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Washer Fitment
• Washer of 2nd Gear Input is thin & having more diameter. (OD = 25.7 mm,
ID = 13.3 mm, Thickness = 0.4mm).
• Washer for 1st Gear Output is thick & having less diameter (OD = 25.1mm,
ID = 12.3 mm, Thickness = 1.00 mm).
Washer of
Output shaft washer will not get fitted on Input Shaft because of less ID.
Input shaft washer can get fitted on Output shaft but this could lead to
excessive end play in the shaft.
Transmission Neutral Position
Before joining crankcase LH & RH halves, ensure that transmission gears are
in neutral position
Crankcase Joining
Before joining crankcase LH & RH, apply 3 bond liquid gasket on RH side
crankcase surface evenly.
Loctite L 5702
BAL part no.: 36 0010 51
Crankshaft Centering
After joining crankcase LH & RH halves, check & confirm Free Rotation of
crankshaft Perfect centering of crankshaft.
Rocker Arm Fitment
Ensure that rockers are intact. Apply molybdenum disulphide grease to rollers
so that they will not come out during assembling.
Missing rollers would cause noise in cylinder head.
CAUTION
128
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