1. DL manuals
  2. Bajaj Auto
  3. Scooter
  4. Legend 00300728
  5. Service Station Manual

Bajaj Auto Legend 00300728 Service Station Manual

Summary of Legend 00300728

  • Page 1

    Service station manual service station manual usa model no.: 00300728.

  • Page 2: Notice

    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 possi...

  • Page 3: Foreword

    Foreword 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 d...

  • Page 4: Index

    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 ) ...

  • Page 5: Identification  Data

    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, t...

  • Page 6: Technical Specifications

    2 engine & transmission type : four stroke, forced air cooled. No. Of cylinders : one. Bore : 57.00 mm stroke : 57.00 mm engine displacement : 145.45 cc maximum net power : 9.00 hp / 6.71 kw at 6000 rpm. Maximum net torque : 1.15 kgf.M.At 4000 rpm compression pressure : 12 ± 1 kg/cm 2 compression ra...

  • Page 7: General Information

    3 running in : in the process of manufacturing the best possible materials are used and all machined parts are finished to a very high degree of accuracy. But it is still necessary to allow the moving parts to break in before subjecting the engine to maximum stresses. The future performance and reli...

  • Page 8

    4 stopping the engine : l close the throttle. L for stopping the engine, turn the key to 'off' position of ignition switch. L supplementary engine stop switch on rh control switch can also be used to stop the engine when ignition switch is not to be put off. Parking : l always prefer to park the veh...

  • Page 9: Periodic Maintenance Chart

    5 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 sr. F...

  • Page 10

    6 1 wash and clean the vehicle on receipt l l l l l 2 check and correct tyre inflation pressure l l l l l l including that of spare wheel 3 check all nuts and bolts for l l l l l l tightness especially handle bar bolt, engine foundation bolt, shock absorber nuts and wheel nuts etc. 4 check engine oi...

  • Page 11: Scheduled Maintenance

    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 switche...

  • Page 12

    8 air filter : bigger pu foam air filter is provided for better breathing. If the air filter is clogged, intake air flow will be restricted which results in low engine power ,increase in fuel consumption & spark plug fouling. Air filter removal : l open seat lock & lift the seat. Remove lh bonnet. L...

  • Page 13

    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 impro...

  • Page 14

    10 anti dive brakes which can lead to loss of control, an upset, or a serious accident with subsequent serious injury or even death. Front brake lever play 3 to 5 mm front brake adjuster rear brake adjustment check the rear brake pedal play as shown in figure. If it is more or less than the standard...

  • Page 15

    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...

  • Page 16

    12 screw for head lamp adjustment steering : steering play : if the steering is too tight, it will be difficult to turn the handlebar quickly, the vehicle may pull to one side and the steering stem bearings may become damaged. If the steering is too loose, the handlebar will vibrate and the vehicle ...

  • Page 17

    13 lubrication of front suspension the locations of grease nipples and recommended intervals for lubrication of front suspension by grease (hp multipurpose or equivalent) are as under. Antidive link bushes & 'o' rings. Lubricate at every 2000 miles. Needle roller bearings of front brake panel. Lubri...

  • Page 18

    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 gaske...

  • Page 19

    15 (16 ) replacement parts when there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lost their original function once removed. (17 ) inspection when parts have been disassembled, visually inspect these parts fo...

  • Page 20: Tightening Torques

    16 tightening torques sr. No. Part name torque - kgm. Nuts for : 1 crankcase to crankcase (qty. 5) ................................................................................... 1.5 to 1.8 2 gear shifter housing (qty. 2) .............................................................................

  • Page 21: Tightening Torques

    17 tightening torques sr. No. Part name torque - kgm. Nuts for : 1 front shock absorber ..................................................................................................... 3.0 to 3.5 2 fuel cock assly on fuel tank .......................................................................

  • Page 22: Special Tools

    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 : extract...

  • Page 23

    19 11. 37-1030-61 : bearing driver set inner driver f f f f f 20 - used with bearing driver set for installing main shaft bearing & magneto side oil seal. Inner driver f f f f f 25 - used with bearing driver set for installing main shaft oil seal 12. 37-1031-07 & 37-1031-08 : valve spring compressor...

  • Page 24

    20 14. 37-1031-53 : valve adjusting screw driver used for holding screw while adjusting valve clearance. 15. 37-1519-03 : bearing driver to be used with bearing driver set (37-1030-61) for assembling needle roller bearing in front brake drum. 16. 37-1519-04 : driver for assembling speedometer gear &...

  • Page 25

    21 22. 37-10ba-56 : bearing extractor to remove main shaft ball bearing from crankcase cover. 23. 37-1030-79 : crankshaft alignment fixture to be used for mounting crankshaft while checking its run out. 24. 67-7505-51 : compression tester to be used for checking compression pressure in the cylinder....

  • Page 26

    22.

  • Page 27: Engine Dismantling

    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...

  • Page 28

    24 l remove rear brake drum by following method :- - straighten bent edges of split pin and pull it out with the help of plier. Remove the cap. - remove castle nut and washer. - pull out the brake drum. A) castle nut for removal of rear brake drum. L removal of rear brake drum back plate - - hold th...

  • Page 29

    25 cylinder block piston removal : 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. L lift the cylinder off and guide the cam chain through the tunnel in the cylinder. L take...

  • Page 30

    26 gear shifter removal : l remove 2 nuts mounting gear shifter on crankcase. L engage 4th gear & pull out gear shifter complete. Nuts for gear shifter assly. Removal of clutch cover (c'case cover): l loosen 6 flanged bolts and remove them. L remove 4 nuts alongwith plain and spring washers. A) bolt...

  • Page 31

    27 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. L take out ...

  • Page 32

    28 l take out oil seal for crankshaft magneto side. Removal of crankshaft magneto side oil seal l take out guide kick by removing 2 screws. Crankcase clutch side : l remove ball bearing from crankcase clutch side. Removal of ball bearing crankcase cover (clutch cover) : l remove circlip for mainshaf...

  • Page 33: Engine Assembly

    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 ...

  • Page 34

    30 l use the valve spring compressor to press down the 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. L assemble both rocker...

  • Page 35

    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 plun...

  • Page 36

    32 engine assembly : l take crankcase magneto side subassembly. L assemble the rubberised damper ring around the crankshaft bearing seat area in crankcase magneto side. Damper ring for crankshaft l assemble the crankshaft assembly into the bearing seat of crankcase. Note : crankshaft assembly is sli...

  • Page 37

    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 ...

  • Page 38

    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 rea...

  • Page 39

    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 ...

  • Page 40: Service  Data (Engine)

    36 service data (engine) sr.No. Description standard remark 1 carburettor : make & type keihin pb20 main jet 108 main air jet 90 pilot jet 42 jet needle ob 4 jet needle clip position 3 rd from top float height 10.7 mm air screw setting 2.25 ± 0.25 turns (from fully closed position) 2 cylinder head :...

  • Page 41: Service  Data (Engine)

    37 7 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 . 8 piston ring piston ring groove thickness a) top ring 1.0 mm b) second ring 1.0 mm c) ...

  • Page 42

    38 removal of 't' nose a) removal of 't' nose assly. From chassis : l open luggage box door. L remove 2 square grommets on the side walls of the luggage box and 2 round grommets on the front face of luggage box. L remove 2 screws each from both side attaching nose with chassis from square holes prov...

  • Page 43

    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 disconnec...

  • Page 44

    40 l remove spring clip holding gas control pulley and take out gas control pulley. Pull out gas control tube. L remove spring clip holding gear control link and take out gear control link. Remove plain and special washer. Pull out gear control tube assly. L take out silent bushes from handle bar lh...

  • Page 45

    41 removal of petrol tank a) removal of petrol tank from chassis l removal of seat hinge with dual seat & carrier plate with seat lock: l disconnect coupler joining fuel gauge tank unit with main wiring harness. L lift the fuel tank and remove vaccum pipe & fuel pipe alongwith clips from fuel cock a...

  • Page 46

    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...

  • Page 47

    43 l remove circlip holding front brake panel on front axle and then remove front brake panel . Removal of circlip for removing front brake panel a) circlip b) washer l remove front shock absorber upper mounting bracket by removing 2 nuts . Removal of upper bracket (a) for fr. Shock absorber l remov...

  • Page 48

    44 l remove the needle roller bearing from the brake drum by using extractor (p. No. 371703 05) without its cup but with the tool (p. No. 371819 04). Removal of needle roller bearing l remove the circlip locking ball bearing from front brake drum. Tap out ball bearing with the help of suitable punch...

  • Page 49

    45 removal of big bushes (a) of antidive kink antidive link assembly: l assemble ‘l’ type grease nipple at one end of link and other type of grease nipple at other end of link as shown in sketch. Link assly. L press big bushes using suitable punch from bearing driver set (p.No. 37103061) and then as...

  • Page 50

    46 l assemble front brake cable adjuster into front brake panel. L assemble brake links on actuating lever by split pin. L assemble antidive link end having ‘l’ type grease nipple on brake panel by bolt alongwith flexible washer . It should be assembled such that it should have easy access while gre...

  • Page 51: Service  Data (Chassis)

    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 fr...

  • Page 52

    48 throttle regulated ignition control system (trics) in 'trics', ignition timing varies as per throttle opening. Below half throttle, ignition timing changes from 16 0 to 30 0 in proportion to engine rpm. Refer graph1. 40 30 20 16 10 1000 2000 3000 4000 rpm k ignition timing below half throttle aft...

  • Page 53: Checking Procedures

    49 control switch lh a) dipper switch (when head light is on) position colour brown/ blue yellow/red violet hi l l low l l b) horn switch position colour black white on (pressed) l l off l l control switch rh a) side indicator switch position colour green/white grey/red blue/white rh l l l n l l l l...

  • Page 54

    50 2) charging coil first connect the + ve meter lead to violet cable and - ve meter lead to black (earth). The resistance value should be as tabulated below.: range connection reading meter +ve meter -ve x10ohms violet black 245 to 295ohms 3) pulser coil first connect the + ve meter lead to grey ca...

  • Page 55

    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 ...

  • Page 56

    52 meter meter negative (-ve) lead connection range x 10 w 1 2 3 4 6 7 8 9 1 × × 40 ~ 60 w × × × 0 2 250 ~ 400 w 40 ~ 60 w × × × × 250 ~ 400 w 3 40 ~ 60 w × 250 ~ 400 w × × × 40 ~ 60 w 4 × × × × × × × 6 × × × × × × × 7 × × × × × × × 8 × × × × × × × 9 0 × × 40 ~ 60 w × × × m) c.D.I. Unit (with 'trics...

  • Page 57

    54 thus with ignition switch in on position, vehicle in neutral gear; the current flows through relay when starter button is pressed. Starter motor is energised which engages the pinion to ring gear on flywheel and the starting shock is absorbed by spring. Upon engaging the ring gear rotates with ma...

  • Page 58

    55 battery technical specification : make, voltage & type : exide,12v mx 9-b 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

    56 battery maintenance : for the optimum performance and longer battery life the maintenance of battery is important. The condition of the battery should be checked at least once in a month as follows :- a) always keep the battery clean and dry. B) visually inspect the surface of the battery contain...

  • Page 60

    57 trouble shooting for starter motor : complaint steps for checking cause and corrective action starter motor not working. A) ensure that the battery is fully charged. Check specific gravity of electrolyte in each cell. It should be as specified b) fuse (10a) to be intact. C) all terminal screws/nu...

  • Page 61

    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 start...

  • Page 62

    59 complaint steps for checking cause and corrective action 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...

  • Page 63

    60

  • Page 64: Trouble Shooting  Guide

    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 diaphr...

  • Page 65

    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 / l...

  • Page 66: Assembly Procedures.

    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.