Bajaj Auto Legend 00300728 Service Station Manual
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Bajaj Auto Legend 00300728 Service Station Manual

Bajaj Auto Legend 00300728 Service Station Manual

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Service Station Manual
Service Station Manual
USA
MODEL NO.: 00300728

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Summary of Contents for Bajaj Auto Legend 00300728

  • Page 1 Service Station Manual Service Station Manual MODEL NO.: 00300728...
  • Page 2 NOTICE All information contained in this manual is based on the latest product information at the time of publication. Bajaj Auto Ltd. accepts no liability for any inaccuracies or omissions in this publication , although every possible care has been taken to make it as complete and accurate as possible.
  • Page 3 We have pleasure in presenting this Service Manual for Bajaj LEGEND This manual is designed by bajaj auto ltd., primarily for use by authorised bajaj dealers and their qualified mechanics. However, it contains enough details and basic information to make it useful to the vehicle owner who desires to carry out his own basic maintenance and repair work.

  • Page 4: Table Of Contents

    INDEX Sr.No. Description Page No. Identification Data Technical Specification General Information Periodic Maintenance Chart Check and Adjustments during P.D.I. and 1st, 2nd, 3rd, 4th & 5th Servicing Scheduled Maintenance 7-13 General Precautions (Dismantling / assembly ) 14-15 Tightening Torques 16-17 Special Tools 18-21 Engine Exploded View...

  • Page 5: Identification Data

    IDENTIFICATION DATA The chassis and engine serial numbers are used to register the vehicles. They are the only means of identifying your particular vehicle from the other of the same model and type. These serial numbers may be needed by your dealer when ordering the parts.

  • Page 6: Technical Specification

    TECHNICAL SPECIFICATIONS ENGINE & TRANSMISSION CONTROLS : Type : Four stroke, Forced Air cooled. Steering : Handle bar No. of cylinders : One. Accelerator : Twist grip type on right hand Bore : 57.00 mm of handle bar Stroke : 57.00 mm Gears : Twist grip type on left hand of Engine displacement : 145.45 cc...

  • Page 7: General Information

    GENERAL INFORMATION l Confirm that the turn indicator switch is “OFF” and RUNNING IN : supplementary engine stop switch in “RUN” position. In the process of manufacturing the best possible materials l Press the Start Button to start the engine. are used and all machined parts are finished to a very high l Release start button as soon as engine starts.
  • Page 8 l Don’t overload the vehicle above the specified pay Stopping the engine : load. l Close the throttle. l For stopping the engine, turn the key to 'OFF' position l Use the accelerator judiciously. Think of the of ignition switch. accelerator barrel as fuel cock.

  • Page 9: Periodic Maintenance Chart

    The maintenance and adjustments outlined in this section are easily carried out and must be done in accordance with the periodic maintenance chart to keep the vehicle in good running condition. The initial maintenance is vitally important and must not be neglected. PERIODIC MAINTENANCE CHART FREQUENCY WHICHEVER COMES FIRST...
  • Page 10 CHECK & ADJUSTMENTS TO BE CARRIED OUT DURING P.D.I., 1st, 2nd, 3rd , 4th & 5th SERVICING Sr. No. Operation to be carried out P.D.I. 3rd. Wash and clean the vehicle on receipt Check and correct tyre inflation pressure including that of spare wheel Check all nuts and bolts for tightness especially handle bar bolt, engine foundation bolt, shock absorber...

  • Page 11: Scheduled Maintenance

    SCHEDULED MAINTENANCE l Fit back the dipstick and tighten it securely. CLEANING l Ensure that there is no oil leakage. The vehicle must be cleaned periodically by using pressurised water. Before cleaning the vehicle cover the important parts like ignition switch, silencer, ignition unit, H.T.
  • Page 12 SPARK PLUG AIR FILTER : The condition of the spark plug indicates how the engine Bigger PU foam air filter is provided for better breathing. is operating. A defective spark plug will lead to difficult If the air filter is clogged, intake air flow will be restricted starting and poor performance.
  • Page 13 l Open and close the throttle a few times to make sure ACCELERATOR GRIP that the idling speed does not change. Readjust if The accelerator grip controls the movement of carburettor necessary. throttle valve and ignition timing (For TRICS). If the l With the engine idling, turn the handle bar to either accelerator grip has excessive play due to cable stretch, side.
  • Page 14 Rear wheel : brakes which can lead to loss of control, an upset, or a serious accident with subsequent serious injury or even l Remove LH cover. death. l Remove spare wheel l Rotate wheel cover cap in anticlockwise direction Front Brake Lever Play 3 to 5 mm and take out.
  • Page 15 TIRES When exchanging the bulbs, always replace the bulbs with that of the specified type and rating. This is important For better road-holding and longer tire life always maintain to prevent the electrical lighting circuit from malfunctioning. correct air pressure. Overinflation will cause bumpy ride and faster wear of the tire at the centre.
  • Page 16 Brake/Tail light, rear blinkers bulb replacement : For replacing Tail/stop bulb or rear blinkers bulb, remove 2 screws for lens, take out lens & replace bulb. 15° 2M/6.56 FT 2M/6.56 FT Hi Beam pattern Low Beam pattern Removal of screws for lens Front blinker bulb replacement : l Remove 2 mounting screws for nose grill and take out nose grill.
  • Page 17 l Tighten the upper lock ring nut to a specified torque. LUBRICATION OF FRONT SUSPENSION l Check the steering again. If the steering is still tight The locations of Grease nipples and recommended or loose repeat the adjustment. If the proper condition intervals for lubrication of Front suspension by grease (HP cannot be obtained inspite of correct adjustment, multipurpose or equivalent) are as under.

  • Page 18: General Precautions (Dismantling / Assembly )

    GENERAL PRECAUTIONS (Dismantling / assembly) Before Servicing High Flash-point Solvent Before starting to service a vehicle, careful reading of the A high flash-point solvent is recommended to applicable section is recommended to eliminate reduce fire danger. Always follow manufacturer unnecessary work. Photographs, diagrams, notes, and container directions regarding the use of any cautions, warnings, and detailed descriptions have been solvent.
  • Page 19 (14 ) Lubrication (16 ) Replacement Parts Engine wear is generally at its maximum while the When there is a replacement instruction, replace engine is warming up and before all the rubbing these parts with new ones every time they are surfaces have an adequate lubricative film.

  • Page 20: Tightening Torques

    TIGHTENING TORQUES ENGINE SR. NO. PART NAME TORQUE - Kgm. NUTS FOR : Crankcase to Crankcase (Qty. 5)................... 1.5 to 1.8 Gear shifter housing (Qty. 2) ..................1.3 to 1.5 Cylinder Head (Qty. 4) ....................2.0 to 2.2 Crankshaft clutch side (Gear primary spur) ..............9.0 to 9.5 Crankshaft magneto side (Rotor nut) ................
  • Page 21 TIGHTENING TORQUES CHASSIS SR. NO. PART NAME TORQUE - Kgm. NUTS FOR : Front shock absorber ..................... 3.0 to 3.5 Fuel cock assly on Fuel tank ..................3.0 Engine link mounting on chassis..................3.0 to 4.0 Engine mounting on link ....................3.5 to 4.0 Pivot securing wheel hub ....................

  • Page 22: Special Tools

    SPECIAL TOOLS The special tools recommended for carrying out repairs / overhauls are illustrated below. These tools are designed to facilitate quick and safe repairs. Use of these special tools is recommended to carry out repairs efficiently and for avoiding costly mistakes such as damages to parts, injuries etc. The following list contains for each tool the description, tool application and an illustrative sketch.
  • Page 23 37-1028-32 37-1030-61 : Spur gear holder : Bearing driver set Tool for holding primary gear while removing nut. Inner Driver f f f f f 20 - used with Bearing Driver set for installing main shaft bearing & magneto side oil seal. 37-1030-34 : Rotor puller Inner Driver...
  • Page 24 37-1031-53 37-1801-06 : Valve adjusting screw driver : Bearing races assembly tool Used for holding screw while adjusting valve clearance. To be used for installing the upper and lower bearing race on chassis tube. 37-1519-03 : Bearing driver 37-1805-08 : Bearing driver for fork assembly To be used with bearing driver set (37-1030-61) for assembling needle roller bearing in front brake drum.
  • Page 25 37-10BA-56 : Bearing extractor To remove main shaft ball bearing from crankcase cover. 37-1030-79 : Crankshaft alignment fixture To be used for mounting crankshaft while checking its run out. 67-7505-51 : Compression Tester To be used for checking compression pressure in the cylinder.

  • Page 27: Engine Dismantling

    ENGINE DISMANTLING l Take out the engine carefully from the chassis. REMOVAL OF ENGINE FROM VEHICLE : l Take out rear wheel and mount the engine on l Remove both LH and RH bonnets. support stand P.No. 37 1030 01. l Drain Engine oil completely by removing drain plug.
  • Page 28 l Remove rear brake drum by following method :- on camshaft. Slide out timing chain from sprocket - Straighten bent edges of split pin and pull it out and take out sprocket. l Remove 4 nuts and 2 bolts mounting cylinder head on with the help of plier.
  • Page 29 l Remove rotor nut by holding rotor with the help of CYLINDER BLOCK PISTON REMOVAL : rotor holder (37 1030 54). l Take out cylinder head as explained above. l Remove the cylinder head gasket and dowel pins. l Pry up the cylinder with a suitable tool to free the cylinder from crankcase.
  • Page 30 l Hold the wheel clutch with the help of clutch holder GEAR SHIFTER REMOVAL : (37 1031 52). Remove clutch hub nut. l Remove 2 nuts mounting gear shifter on crankcase. NOTE : HUB NUT HAS LEFT HAND THREADING . l Engage 4th gear &...
  • Page 31 l Remove guide chain (tension) by removing the special bolt. l Take out timing chain. l Remove oil pump assembly by removing 3 screws. Take out dowel pin and two 'O' rings carefully and store them alongwith oil pump. l Take out screw pan cross and take out oil tube alongwith oil seal.
  • Page 32 l Take out oil seal for crankshaft magneto side. l Remove the plunger. l Remove the spring for clutch spindle assembly. l Take out clutch spindle assembly alongwith internal lever and plain washer. l Remove 'O' ring. Main Shaft : Removal of crankshaft magneto side oil seal l Take out guide kick by removing 2 screws.
  • Page 33 l Loosen valve spring compressor and take out Clutch Dismantling : valve spring retainer, valve spring and spring seat. l Take out hub clutch. l Push out one valve. l Take out plate friction and plate clutch one by one. l Repeat same procedure for the other valve.
  • Page 34 l Use the valve spring compressor to press down the Main shaft Assembly : valve spring retainer. l Install the collets, and slowly remove the spring compressor. Ensure that the collets are seated properly holding the retainer down. l Repeat same procedure for exhaust valve. l Assemble cam shaft.
  • Page 35 l Assemble 'O' ring into the bore for clutch lever. l Assemble spring & plain washer on clutch lever spindle. l Smear light coat of grease on clutch lever spindle and assemble it into the clutch cover alongwith internal lever. l Lock the spring on the clutch cover lug.
  • Page 36 l Assemble 2 no. of dowels on crankcase. ENGINE ASSEMBLY : l Assemble the centre gasket on to the crankcase. l Take crankcase magneto side subassembly. l Assemble crankcase clutch side on magneto side l Assemble the rubberised damper ring around the taking studs as guide.
  • Page 37 l Put the spring inside the hole on crankshaft. l Assemble springs on the hub clutch & plate the l Assemble parallel pin in the through hole provided holding plate on it. Assemble bolts on the holding on the crankshaft arm. plate and tighten it in criss-cross pattern.
  • Page 38 l Prefix nut, plain washer & spring washer and tighten l Assemble 2 dowels on crankcase. (One on clutch them. side and the other on magneto side ) block sitting l Assemble larger O' ring for back plate and also area.
  • Page 39 l Put timing chain through tunnel on cylinder head and l Assemble fan cover and cowling into the slots of hold on holder camshaft on cam shaft. each other. Fix the fan cover and cowling screws. l Fix cylinder head with the help of special copper l Assemble H.T.

  • Page 40: Service Data : Engine

    SERVICE DATA (ENGINE) SR.NO. DESCRIPTION STANDARD REMARK CARBURETTOR : Make & Type Keihin PB20 Main jet Main air jet Pilot jet Jet needle OB 4 Jet needle clip position from top Float height 10.7 mm Air screw setting 2.25 ± 0.25 turns (From fully closed position) CYLINDER HEAD : Cylinder head warp...
  • Page 41 SERVICE DATA (ENGINE) SR.NO. DESCRIPTION STANDARD REMARK CYLINDER / PISTON GROUPING Cylinder bore 57.000 - 57.015 mm Piston diameter. 56.979 - 56.995 mm Measure at 7 mm from bottom. Cylinder / Piston clearance 0.010 - 0.029 mm Use Cylinder & Piston of same group .

  • Page 42: Dismantling And Assembly : Chassis

    DISMANTLING AND ASSEMBLY : CHASSIS REMOVAL OF 'T' NOSE REMOVAL OF LUGGAGE BOX Open Luggage box door. A) Removal of 'T' Nose assly. from chassis : Remove 2 screws provided on the topmost portion Open Luggage box door. of Luggage box. Remove 2 square grommets on the side walls of Remove 2 Nuts from the door opening.
  • Page 43 Carefully disengage the locking lugs of handle bar front cover by prying with the help of a small screw driver. Take out Handle bar front cover. Disconnect Head lamp harness coupler and remove handle bar front cover. Remove both mirror by removing packing and hex socket bolts.
  • Page 44 Remove spring clip holding gas control pulley and Remove 2 nuts mounting hook for seat lock alongwith take out gas control pulley. Pull out gas control tube. spring washers. Remove spring clip holding gear control link and take out gear control link. Remove plain and special washer.
  • Page 45 REMOVAL OF PETROL TANK a) Removal of petrol tank from chassis Removal of seat hinge with dual seat & carrier plate with seat lock: Disconnect coupler joining fuel gauge tank unit with main wiring harness. Lift the fuel tank and remove vaccum pipe & fuel pipe alongwith clips from fuel cock assly.
  • Page 46 REMOVAL OF AIR FILTER BOX Remove spare wheel. Take out Air Filter element. Remove Dual seat hinge, carrier plate. Take out fuel tank. Remove flange bolts of Air filter from engine bonnet side. Slide out outlet of air filter from the hole on chassis and take out Air Filter box.
  • Page 47 Remove circlip holding front brake panel on front axle and then remove front brake panel . Removal of Lock plate (a) Tilt the scooter on one side and take out the steering Removal of Circlip for removing Front brake panel column carefully from the bottom side.
  • Page 48 Remove the needle roller bearing from the Brake While fitting Speedometer gear and Spacer on drum by using Extractor (P. No. 371703 05) without Front brake drum use Special Tool - Outer driver (P. its cup but with the tool (P. No. 371819 04). No.
  • Page 49 Using suitable punch from bearing driver set punch Grease seal into Front brake panel. Removal of Big bushes (a) of Antidive kink ANTIDIVE LINK ASSEMBLY: Assembly of Grease seal Assemble ‘L’ type grease nipple at one end of link Assemble Grease nipple on Front brake panel. and other type of grease nipple at other end of link Insert Front brake Actuating shaft assly into Front as shown in sketch.
  • Page 50 Assemble Front brake cable adjuster into Front REMOVAL OF ENGINE FROM VEHICLE : brake panel. l Put the vehicle on the stand , open seat lock & lift Assemble Brake links on Actuating lever by Split seat and remove both LH and RH bonnets. pin.

  • Page 51: Service Data : Chassis

    SERVICE DATA (CHASSIS) SR.NO. DESCRIPTION STANDARD REMARK WHEEL RIM RUN-OUT: Axial 0.5 mm Service limit : 2.0 mm Radial 0.5 mm Service limit : 2.0 mm BRAKE DRUM INSIDE DIAMETER: Front 150.16 mm Service limit : 151.00 mm Rear 130.16 mm Service limit : 131.00 mm BRAKE SHOE LINING THICKNESS Front...

  • Page 52: Electricals

    ELECTRICALS : MAINTENANCE & CHECKING GENERAL PRECAUTIONS : THROTTLE REGULATED IGNITION CONTROL SYSTEM (TRICS) There are some important precautions to be taken while servicing electrical system. Please follow them. In 'TRICS', Ignition timing varies as per throttle opening. l Do not reverse the battery lead connections. This will Below half throttle, ignition timing changes from 16 to 30 burn out the diodes in the electrical parts.
  • Page 53 B) FRONT & REAR BRAKE SWITCHES : CHECKING PROCEDURES Disconnect the two terminals of the front or rear brake switch and connect an ohmmeter between the two terminals A) CONTROL SWITCHES setting it on x 10 ohms range. When the switch is pressed the ohmmeter should show infinity ( ) and when switch Control switch LH is released the ohmmeter should show 0 ohms.
  • Page 54 2) Charging Coil G) BATTERY CHARGING SYSTEM l Ensure that battery is fully charged. First connect the + ve meter lead to Violet cable and l Set meter range at 20 A DC - ve meter lead to Black (earth). The resistance value l Remove fuse &...
  • Page 55 the signals from sender into the movement of needle. Checking of Fuel Tank Unit: Connection Tank (float) Reading White/Black Fuel(Full) 1.0 to 5.0 (Highest position) ohms Meter x10 ohms Black Fuel(Empty) 103 to 117 (Lowest position) ohms J) DC Voltage Measurement : l Connect +ve lead of meter to Orange wire and -ve lead of meter to Orange/Brown wire from AC/DC unit.
  • Page 56 M) C.D.I. UNIT (With 'TRICS' ) METER METER NEGATIVE (-VE) LEAD CONNECTION RANGE X 10 W × × 40 ~ 60 W × × × 250 ~ 400 W 40 ~ 60 W × × × × 250 ~ 400 W 40 ~ 60 W ×...
  • Page 57 CHECKING PROCEDURE FOR SELF STARTER On vehicles with button start, a 12V motor is used to Thus with ignition switch in ON position, vehicle in crank the engine instead of a kick, when button is neutral gear; the current flows through relay when pressed.

  • Page 58: Technical Specification

    BATTERY Hydrometer TECHNICAL SPECIFICATION : Make, voltage & type : Exide,12V MX 9-B Read here Capacity : 9 AH Specific gravity of electrolyte : 1.24 for use above for initial filling of new battery 10°C Specific gravity of electrolyte : 1.28 for use below for initial filling of new battery 10°C Electrolyte volume...
  • Page 59 BATTERY MAINTENANCE : exposed surfaces will harden and will become sulphated. For the optimum performance and longer battery life d) Adding acid:if acid is added to-a cell in which the maintenance of battery is important. The condition sulphation exists the condition will be aggravated. of the battery should be checked at least once in a e) High specific gravity:if specific gravity is higher than month as follows :-...
  • Page 60 TROUBLE SHOOTING FOR STARTER MOTOR : COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION Starter Motor not A) Ensure that the battery is fully working. charged. Check Specific gravity of electrolyte in each cell. It should be as specified B) Fuse (10A) to be intact. C) All terminal screws/nuts at the starter motor.
  • Page 61 COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION 1.3 Relay operation not present (click 1.3.1 Check for 12 V.D.C. supply at the Relay noise of Relay operation not heard) coil terminals (Soldered points C1 and C2 : Ref circuit diagram). If the supply is indicated on the V.M.
  • Page 62 COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION 1.4 Neutral switch checking. 1.4.1 Adjust continuity range on a multimeter. Connect the multimeter across the neutral switch with one probe on the switch terminal (black wire) and the other probe on the gear shifter. If continuity is not observed then it indicates that the neutral switch may be faulty.

  • Page 64: Trouble Shooting Guide

    TROUBLE SHOOTING GUIDE This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the trouble shooting for some of the more common difficulties. For details of Electrical Component Checking , please refer "Electricals : Maintenance & Checking" . STARTING TROUBLE B) Fuel air mixture improper l Pilot jet clogged...
  • Page 65 GEAR SHIFTING NOT PROPER ELECTRICAL l Clutch not disengaging properly A. Fuel Gauge not working l Clutch / Gear cable play improper l Tank unit defective / loose contact at resistor coil l Gear shifter stem worn out l Fuel meter in instrument panel defective l Cross worn out l No supply to tank unit.
  • Page 66 For effective overhaul and optimum performance : Get fully familiarised with dismantling / assembly procedures as given in this manual Always use genuine Bajaj Spares for replacement. Use special tools developed for disassembling and assembly procedures.

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