Bajaj Discover 100M Service Station Manual page 165

ENGINE ASSEMBLING - IMPORTANT SKILL TIPS
Spacer -
'JD'
mark
B
A
D
C
A
Discover DTS-Si
Service Station Manual
Clutch Washer Sequence
Place one plain Spacer (JD551400) on 'Input shaft
Bearing' before assembling 'Collar Clutch' (Ja551406).
Place one plain washer (39260011) between 'Clutch
Housing' & Clutch Stack.
Collar
Clutch
Clutch Spl. Nut Washers
A : Special Nut
B : Belleville washer
C : Plain Washer
D : Clutch Plate Assly
Before tightening clutch Special nut, place one Plain washer followed by
Belleville washer on the clutch plate assembly.
Clutch Nut Tightening
• Input shaft & clutch special nut is having LH
threading. Ensure fitment of a plain & Belleville
washer before special nut. Belleville washer's bigger
contactcircle diameter must face towards clutch &
smaller contact circle diameter touching with special
nut. Apply loctite 243 to special nut threads &
tighten it to specified torque 5 ~ 5.5 Kgm.
Crankshaft Oil Plunger
Ensure fitment of spring (A), lock pin (B) & oil plunger (C) on RH side end of
crankshaft. Ensure proper springing action of plunger.
Missing oil plunger would affect lubrication of crankshaft & cylinder piston
B C
resulting into sever damage to these components due to lack of lubrication.
Clutch Cover Oil Passage
Before assembling clutch cover, ensure that its oil passage are clear. This is to
be checked & confirmed by pumping engine oil into the passages.
CAUTION
134
Plain Washer
Dealer Development Center
Akurdi Pune