Bajaj Discover 100M Service Station Manual page 161

ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
Primary Gear Washers Sequence
Ensure fitment of one plain washer
part no. 59110008 & one Belleville
washer part no 59120003 on primary
Gear face & then secure it by flange
nut (19mm A/F)
A : Primary Gear
B : Plain Washer
C : Belleville Washer
D : Flange Nut (19 mm A/F)
Kick Shaft Assembly
Always match punched dot mark on
'Kick Ratchet' with respect to the dot
mark on 'Shaft Kick'. Assemble kick
shaft washers as shown in the
exploded view.
1 :Kick Shaft
2 : Washer Thrust
3 : Circlip
4 : Spring Kick Starter Ratchet
5 : Ratchet
6 : Washer Plain
7 : Assly Gear Starter Pinion
8 : External Circlip
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Aligning TDC Position marks for Valve Timing
Align 'T' mark on Magneto Rotor with the mark on
LH Crankcase to bring piston to TDC position at
the end of compression stroke. Then align two
marks (horizontal lines) on Cam Sprocket parallel
to cylinder head top face and cam Sprocket's 'T'
mark at top position. In this position rocker arms
must be in free dancing position.
D
7
8
6
6
6
130
C
3
3
4
5
A
B
1
2
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