Bajaj Auto Legend 00300728 Service Station Manual

Text of Bajaj Auto Legend 00300728 User Guide:

• Bajaj Auto Legend 00300728, 47 SERVICE DATA (CHASSIS) SR.NO. DESCRIPTION STANDARD REMARK 1 WHEEL RIM RUN-OUT: Axial 0.5 mm Service limit : 2.0 mm Radial 0.5 mm Service limit : 2.0 mm 2 BRAKE DRUM INSIDE DIAMETER: Front 150.16 mm Service limit : 151.00 mm Rear 130.16 mm Service limit : 131.00 mm 3 BRAKE SHOE LINING THICKNESS Front 4.03 mm Service limit : 2.5 mm Rear 4.03 mm Service limit : 2.5 mm 4 BRAKE ACTUATING SHAFT DIAMETER : Front 12.925-12.968 mm Rear 11.957-11.984 mm 5 BRAKE ACTUATING SHAFT HOLE DIAMETER : Front 13.043 mm Rear 12.027 mm 6 BRAKE SHOE SPRING FREE LENGTH : Front 44.00 - 46.0

• Bajaj Auto Legend 00300728, 23 REMOVAL OF ENGINE FROM VEHICLE : l Remove both LH and RH bonnets. l Drain Engine oil completely by removing drain plug. A) Drain Plug B) Nut for rear brake cable C) Nut for gear shifter assly. l Disconnect lower ends of rear brake & clutch cable. l Remove gear shifter cover and release lower ends of gear cables by unscrewing screw terminals. l Remove H.T. Coil by removing 2 screws on crankcase side. A) Screws for removal of H.T. coil l Disconnect magneto harness coupler from main harness. l Disconnect choke and throttle cable from carburettor. l Disconnect duct from carburettor. Disconnect carburettor from intake

• Bajaj Auto Legend 00300728, 19 11. 37-1030-61 : Bearing driver set Inner Driver ff ff f 20 - used with Bearing Driver set for installing main shaft bearing & magneto side oil seal. Inner Driver ff ff f 25 - used with Bearing Driver set for installing main shaft oil seal 12. 37-1031-07 & 37-1031-08 : Valve spring compressor assembly with adopter. Used for taking out inlet & exhaust valves by compressing valve spring in cylinder head. 13. 37-1031-52 : Clutch holder. Used for hold the clutch housing stationary while loosening & tightening the clutch hub nut. 7. 37-1028-32 : Spur gear holder Tool for hold

• Bajaj Auto Legend 00300728, 31 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. l Apply some grease on plunger and assemble it on the internal lever. Crankcase Clutch Side : l Press ball bearing for intermediate shaft. Fitment of bearing Assemble of oil pump l Assemble 2 'O' rings for oil pump on the crankcase. l Assemble hallow dowel pin. l Assemble oil

• Bajaj Auto Legend 00300728, 9 l Open and close the throttle a few times to make sure that the idling speed does not change. Readjust if necessary. l With the engine idling, turn the handle bar to either side. If the handle bar movement changes the idling speed, the accelerator cable may be improperly adjusted, damaged or improperly routed. Rectify any of these conditions before riding. l Do not attempt to compensate for faults in other systems by adjusting the idle speed. Normal idling speed : 1200 ± 150 rpm A. Idling adjustment screw B. Decrease speed C. Increase speed

• Bajaj Auto Legend 00300728, 35 l Put timing chain through tunnel on cylinder head and hold on holder camshaft on cam shaft. l Fix cylinder head with the help of special copper plated washers and dome cap nut. Apply torque of 2.0 to 2.2 Kg.m. to dome cap nuts. l Assemble two flanged bolts on cylinder head joining cylinder head and cylinder block with crankcase. l Assemble chain on timing sprocket and fix it with the help of two bolts. Keep piston at TDC position with the help of rotor and marking provided on crankcase magneto side. Check that the marking on timing chain sprocket matches with marking provided on cylinde

• 62 STARTING TROUBLE A) No fuel supply l No Fuel in fuel tank l Clogged fuel filter in fuel cock l Vacuum line disconnected l Leakage from vacuum side of Fuel cock l Fuel cock fitment not at 45 0 angle with respect to fuel tank centre line B) Flooding l Float valve stuck / Worn out l Fuel cock diaphragm damaged / remains open l Tank cap air vent obstructed C) No. Spark / Weak spark l Spark

• Bajaj Auto Legend 00300728, 14 (6) High Flash-point Solvent A high flash-point solvent is recommended to reduce fire danger. Always follow manufacturer and container directions regarding the use of any solvent. (7 ) Gasket, O-ring Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (8 ) Press A part installed using a press or driver, such as a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (9 ) Ball Bearing When installing a ball bearing, the b

• 11 FLASH TIRES For better road-holding and longer tire life always maintain correct air pressure. Overinflation will cause bumpy ride and faster wear of the tire at the centre. Under-inflation will cause poor steering and faster wear at the sides. Recommended Tire Pressure Front 1.25 Kg/cm 2 (18 PSI) Rear Solo 1.75 Kg/cm 2 (25 PSI) With Pillion 2.50 Kg/cm

• TM 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. l l l

• Bajaj Auto Legend 00300728, 18 1. 37-0030-01 : Engine support stand For supporting engine, crankcase while assembly / dismantling. 2. 37-1003-02 : Extracter Extractor for needle bearing in crankcase magneto side. 3. 37-1005-04 : Bearing Driver Driver for fitting needle bearing in crankcase magneto side. 4. 37-1014-10 : Extractor for input shaft bearing. To be used for removing input shaft bearing from crankcase clutch side. 5. 37-1014-13 : Inner driver To be used with holder and outer bearing driver for installing front brake drum bearing. 6. 37-1014-14 : Inner driver To be used with holder & outer bearing driver for installing input shaft bearing in crankcase (clutch side) & needle bearin

• Bajaj Auto Legend 00300728, 29 Clutch Dismantling : l Take out hub clutch. l Take out plate friction and plate clutch one by one. Clutch dismantling Cylinder Head : l Remove stopper plate by removing screw . l Take out inlet rocker arm shaft by using a bolt. l Take out exhaust rocker arm shaft by nose plier. Removal of rocker arm shaft l Take out both the rocker arms. l Take out camshaft. l Using valve spring compressor and adaptor press down the valve spring retainer. l Remove the collets. Removal of valve l Loosen valve spring compressor and take out valve spring retainer, valve spring and spring seat. l Push out one valve. l Repeat same procedure for the other valve. Kick Shaft Dismantling : l Remove circlip ho

• Bajaj Auto Legend 00300728, 7 CLEANING 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. coil,starter motor by plastic bags. Don’t apply the jet of water directly towards electrical parts such as switches, ignition unit, coils etc. otherwise they may get damaged. Brushing with parafin and wiping dry with clean rag is advisable for external cleaning of the engine. All painted surfaces should be washed with water. Do not use kerosene or detergent soap on painted surfaces as it damages the paint and turns it dull. If necessary, blow with comp

• Bajaj Auto Legend 00300728, 33 l Put the spring inside the hole on crankshaft. l Assemble parallel pin in the through hole provided on the crankshaft arm. l Assemble key (parallel) on the crankshaft key way and fix primary spur gear (I/P) on it. l Prefix the special nut on the crankshaft. l Hold the primary spur gear with the help of special tool P. No. 37 1028 17 and tighten the special nut to 9 to 9.5 kgm torque. Fitment of primary spur gear l Assemble timing chain on crankshaft sprocket. l Assemble the plunger in such a way that it fits into the parallel pin fitted in the crankshaft arm.

• Bajaj Auto Legend 00300728, 1 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. In the event of theft, the investigating authorities will require both these numbers in addition to the model, type and any special features of your vehicle that can help identification. Serial numbers with prefix 28 C and 28 E are stamped on chassis and engine of the vehicle in the position indicated in the figures

• Bajaj Auto Legend 00300728, 39 l Carefully disengage the locking lugs of handle bar front cover by prying with the help of a small screw driver. l Take out Handle bar front cover. l Disconnect Head lamp harness coupler and remove handle bar front cover. l Remove both mirror by removing packing and hex socket bolts. l Disconnect L.H. and R.H. Switch couplers near steering column lower mounting race. l Remove 2 screws mounting Handle bar rear cover on handle bar (from front side) l Remove 1 screw mounting handle bar rear cover from back side. l Remove speedometer cable connection and harness conne

• 58 COMPLAINT STEPS FOR CHECKING CAUSE AND CORRECTIVE ACTION 1.3 Relay operation not present (click noise of Relay operation not heard) 1.3.1 Check for 12 V.D.C. supply at the Relay coil terminals (Soldered points C1 and C2 : Ref circuit diagram). If the supply is indicated on the V.M. then the Starter Relay is faulty. Replace the same. 1.3.2 If the 12 V.D.C.sup

• Bajaj Auto Legend 00300728, Sr.No. Description Page No. 1. Identification Data 1 2. Technical Specification 2 3. General Information 3-4 4. Periodic Maintenance Chart 5 5. Check and Adjustments during P.D.I. and 1st, 2nd, 3rd, 4th & 5th Servicing 6 7. Scheduled Maintenance 7-13 8. General Precautions (Dismantling / assembly ) 14-15 9. Tightening Torques 16-17 10. Special Tools 18-21 11. Engine Exploded View 22 12. Dismantling and Assembly : Engine 23-35 13. Service Data : Engine 36-37 14. Dismantling and Assembly : Chassis 38-46 15. Service Data : Chassis 47 16. Electricals 48-59 17. Electrical Wiring Diagram

• 42 REMOVAL OF AIR FILTER BOX l Remove spare wheel. l Take out Air Filter element. l Remove Dual seat hinge, carrier plate. l Take out fuel tank. l Remove flange bolts of Air filter from engine bonnet side. l Slide out outlet of air filter from the hole on chassis and take out Air Filter box. REMOVAL OF STEERING LOCK l Remove 'T' nose. l Remove screw for igniti

• Bajaj Auto Legend 00300728, 63 GEAR SHIFTING NOT PROPER l Clutch not disengaging properly l Clutch / Gear cable play improper l Gear shifter stem worn out l Cross worn out l Gear shifter slider jam KICK SLIP l Clutch plates burnt l Gear kick and ratchet kick teeth chipped off l Spring for gear kick weak l Guide kick broken / loose STEERING COLUMN A. Becomes tight l Bearing races pitted. l Balls pitted. l Race fitment improper B. Excessive play l Bearing races not fitted properly or lock ring nut loose. POOR BRAKING l Control pedal or lever play not adjusted properly. l Brake shoes lining worn o

• Bajaj Auto Legend 00300728, 51 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. - Start the engine and set it at 3500 rpm. - Press the Horn button. - Measure the DC Voltage at 3500 rpm. Range Connection Reading Meter +ve Meter -ve 25V DC Orange Orange/Brown 9 to1

• Bajaj Auto Legend 00300728, 34 l Prefix nut, plain washer & spring washer and tighten them. l Assemble larger O' ring for back plate and also assemble 2 nos. of smaller rubber gaskets on crankcase. l Assemble back plate and fix 3 screws alongwith spring washer. l Assemble cam brake and 'O' ring on the crankcase. l Assemble rear brake lever along with rear brake links on cam brake. l Fix the rear brake lever on cam brake with the help of flanged bolt. l Assemble brake shoes alongwith spring on the cam brake and pivot pins. l Assemble cam brake retur

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