Bajaj Auto Legend 00300728 Guide

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

NOTICE
All information contained in this manual is based on the latest product
informationatthetimeofpublication. BajajAutoLtd.acceptsnoliabilityfor
any inaccuracies or omissions in this publication , although every possible
care has been taken to make it as complete and accurate as possible.
All procedures and specifications subject to change without prior notice.
The right is reserved to make changes at any time without prior notice and
without incurring an obligation to make such changes to product
manufactured previously. Contact your authorised bajaj dealer for the
latest information on product improvements incorporated after this manual
was issued.
DOC. NO. 36 02 0147

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 desires to carry out his own basic maintenance and repair work.
Since a certain basic knowledge of mechanics, the proper use of tools, and workshop procedures
must be understood in order to carry out maintenance and repair satisfactorily; the adjustments,
maintenance,andrepairsshouldbecarriedoutonlybyqualifiedmechanic. Ifproperadjustmentcan
not be obtained by following the procedures in this manual, find out the cause and correct as
necessary.
In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the
text thoroughly,familiarisinghimselfwiththeproceduresbeforestartingwork,andthendothework
carefullyinaclean area. Wherever special toolorequipmentis specified, make surethatsameare
used. Precision measurements can only be made if proper instruments are used and the use of
substitute tools may adversely affect safe operation of the vehicle.
Thesafetyprecautionandspecialinstructionshavebeenprintedinboldtypetodrawyourattention.
These instructions indicates points of particular interest for more efficient, convenient and safe
operation. It is essential that you do not neglect these instructions while carrying out repairs so as
to avoid any personnel injury and damage to or destruction of equipments and vehicle.
As the technique of repair/maintenance procedure develops and as the manufacturing process
changes, it is likely that this Service Station Manual will be subject to modifications as necessary.
The manual is therefore, to be taken valid for operation on the date of its print. For subsequent
modifications and informations always refer to Service Information Circulars.
This manual has been divided into various sections for convenience of presenting the contents in
a useful manner. Please refer to the detailed Index for locating the section/information you want.
WARNING : This manual is intended for use by experienced mechanics, and is not intended
for use by the general public. Therefore, please refer to the appropriate Owner's Manual for
warnings applicable to this scooter. Mechanical repair can be hazardous, and is very
dangerous if you are inexperienced or unknowledgeable. We strongly urge you to never
undertakerepairoperationswithwhichyouarenotcompletelyfamiliar.Therepairoperations
described in this book must be carried out exactly as described, in order to ensure that the
scooter is returned to safe condition after you have worked on it. Failure to observe this
warning can lead to a dangerous condition which could lead to an upset, accident, serious
injury, or even death.

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 60-61
18. Trouble Shooting Guide 62-63
INDEX

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 below :
Chassis number
Engine number
Thechassisandenginenumbersserialnumbersareusedbythefactorytoidentifyyourparticularvehicle.Alwaysquote
thesenumberswhenorderingpartsorwhenmakinginquirywithregardtoserviceoperations.Thevehicleisidentifiedby
theDepartmentof MotorVehiclesinyourstate by theVehicleIdentificationNumber.It isacrimeinall statestoalterany
of these numbers.
Location of VIN Number
VIN Number VIN Number

2
ENGINE & TRANSMISSION
Type : Four stroke, Forced Air cooled.
No. of cylinders : One.
Bore : 57.00mm
Stroke : 57.00mm
Enginedisplacement : 145.45 cc
Maximumnetpower : 9.00 HP / 6.71 kw at 6000 rpm.
Maximumnet torque : 1.15 kgf.m.at 4000 rpm
Compression Pressure : 12 ± 1 kg/cm2
CompressionRatio : 9.3 : 1
Idlingspeed : 1200 ± 150 rpm
Ignition system : C. D. I.
Fuel : 87 octane petrol.
Carburettor : Keihin PB 20
SparkPlug : ChampionPL 7YC
Sparkpluggap : 0.6 to 0.7 mm
Lubrication : Wet sump, forced lubrication.
Starting : Kick start / Electric start
Clutch : Wet, multidisc type.
Transmission : 4 speed constant mesh.
Overallgearratios
Firstgear : 17.33 : 1
Secondgear : 10.81 : 1
Thirdgear : 7.96 : 1
Fourthgear : 6.11 : 1
Primarygearratio : 2.75 : 1
CHASSISANDBODY:
Frametype : Monocoqueconstruction
Suspension
Front : Leadinglink Anti-dive,variable
rate coil spring & double
actingshock absorber
Rear : Variable rate coil spring &
doubleactingshockabsorber
Brake type
Front& Rear : Mechanicalexpanding
shoe friction type.
Brake size
Front : 150 mm dia / 5.91"
Rear : 130 mm dia / 5.12"
Tires Front : 3.50 X 10, 4 P.R.
Rear : 3.50 X 10, 4 P.R.
Tirepressure-
FRONT : 1.25 kg/cm2 (18 Psi)
REAR(withoutpillion) : 1.75 kg/cm2(25 Psi)
REAR(withpillion) : 2.50 kg/cm2(36 Psi)
Fuel tank capacity : 1.32 Gal. (5 litres)
CONTROLS:
Steering : Handlebar
Accelerator : Twist grip type on right hand
ofhandlebar
Gears : Twist grip type on left hand of
handlebar
Clutch : Lever operated on left side of
handlebar
Brakes
Front : Lever operated on right side of
handlebar
Rear : Pedal operated by right foot.
ELECTRICALS:
System : 12 Volts, DC
Battery : 12V-9Ah
Headlamp : 35/35W
Tail/stop lamp : 5 / 10 W
Sideindicator lamp : 10W
Horn : 12V,DC
DIMENSIONS:
Length : 1825 mm / 71.85"
Width : 685 mm / 26.97"
Wheelbase : 1275 mm / 50.20"
Height : 1150 mm / 45.28"
Saddleheight : 805 mm / 31.69"
WEIGHTS:
Curb weight : 115 kg / 253 lbs
Max.totalweight : 256 kg / 564 lbs
(includingdriver)
PERFORMANCE:
Maximumspeed : 90 km/h / 55 mph
with 68 kg/150 lbs
(singlerider)payload
Climbingability : 25.0 % max.
NOTES :
lAll dimensions are under unladen condition.
lAbove information is subject to change, for the
latest information please contact Service dept. .
TECHNICAL SPECIFICATIONS

3
RUNNINGIN:
Intheprocessofmanufacturingthebestpossiblematerials
are usedandallmachinedpartsarefinishedtoaveryhigh
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
reliability of the engine depends upon the care and
restraint exercised during its early life. The general
running in rules are :
lAlways keep to the specified running-in speed.
lDo not ride the vehicle at high speed.
lDo not race the engine.
lDo not run the engine under constant speed for
prolongedperiod, pleasevary the speedfor better
bedding in of the mating parts.
lDonot startmovingorrace theengine immediately
after starting. Run the engine for a few minutes at
idle speed to give the oil a chance to workup into all
engineparts.
The table given below shows the maximum permissible
speedduring running in:
Distance Max. vehicle speed in
in miles gears(mph)
Ist IInd IIIrd IVth
0-1200 10 20 30 40
STARTING :(Kick start)
lTurn the Ignition switch to 'ON' position.
lConfirmthat thevehicleisin neutralgear,turn indica-
tor switch is “OFF” and supplementary engine stop
switch in “RUN”position.
How to operate kick:
Move the kick slowly.
Ensure that ratchet is engaged, then kick.
When engine is cold :
Use‘CHOKE’only forcoldstarting. Donotopenthrottle.
Pull the choke lever and operate kick for starting.
Release the Choke lever to‘ OFF’ position immediately
once the engine starts.
When engine is warm :
Do not open throttle while kick starting. If the engine
fails to start with 2-3 kicks, slightly open the throttle (not
more than 1/4 th turn) before kicking.
STARTING:(With Self Start)
lTurn the Ignition switch to 'ON' position.
lConfirm that the vehicle is in neutral gear otherwise
engine will not start.
(Neutral switch is fitted on gear shifter assly for this
purpose as a safety feature.)
GENERAL INFORMATION
lConfirm that the turn indicator switch is “OFF” and
supplementary enginestopswitchin“RUN”position.
lPress the Start Button to start the engine.
lRelease start button as soon as engine starts.
When engine is cold :
lPull the choke lever in 'ON' position.
lPress the Start Button with accelerator in completely
closedposition.
lOnce the engine warms up, release choke lever to
'OFF'position.
When engine is warm :
lWhilestartingwarmengine,opentheaccelerator1/8th
to 1/4th and press the Start Button.
NEVER REV UP THE ENGINE TO HIGHER RPMs
IMMEDIATELY AFTER STARTING OR IN NEUTRAL
GEAR. If the engine is raved to higher RPMs immedi-
ately after starting it may lead to severe engine
damagesas lubricatingoil takesome timetoreach allth
components.
Moving from ‘Stand still position’
Pull the clutch lever and twist the gear control tube
upwards in one smooth motion to put the vehicle in 1st
gear.Release clutchgraduallyand simultaneously open
the throttle gradually to move away from stand still
position.
Don’t run vehicle with clutch lever partially depressed or
don’t slip the clutch to overtake or to climb a gradient.
This will damage the clutch.
Downshifting of gears i.e.. Shifting from 4th to 3rd to
2nd to 1st gear :- Reduce the speed of the vehicle.
Depress the clutch lever completely and twist the gear
leverupwards andreleasethe clutchlevergradually and
increasethrottle. Forfurther easeofgear shiftingslightly
openthethrottle momentarilywhiledepressingthe clutch
lever and then twist the gear lever upwards.
Donot tilt thevehicle towardsspare wheelside. Engine
oil may drain out from the crankcase breather tube and
hence there will be a drop in oil level in the crankcase.
Accidentlyif thevehiclesfalls downonspare wheelside,
ensure correct oil level after lifting and placing the ve-
hicle on stand.
Braking:
For stopping the vehicle smoothly and safely first close
the accelerator and then apply front and rear brake
simultaneously. Using only the front or rear brake is
dangerous and cause skidding and loss of control.
Anticipateyourstopwellinadvancefor avoidingsudden
brakingwhichmaybedangerous.

4
Stopping the engine :
lClose the throttle.
lForstoppingtheengine,turnthekeyto'OFF' position
of ignition switch.
lSupplementary 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 :
lAlwaysprefertoparkthevehicleonlevelgroundand
on the centre stand.
lLock the steering-cum-ignition lock.
DAILY SAFETY CHECKS :
Check the following items each day before you ride.
These checks hardly require any time and habitual
performance of these checks will help to ensure a safe,
reliableride.
Ifanyirregularitiesarefoundduringthesechecksreferto
the maintenance chapter or contact an authorised bajaj
dealer for the action required to return your vehicle to a
safeoperatingcondition.
Fuel :
Enough fuel for the planned distance of travel & check
leakage if any.
Electrical:
Operation of switches, lighting of head, tail /brake lamp,
hornsound,batteryelectrolytelevelandbatterycondition.
Brakes:
Front and rear brake effectiveness, lever play.
Tires :
Inflation pressure, cracks, cuts and foreign material
embeddedintread.
FUEL SAVING TIPS :
Awellmaintainedvehiclecancontributealottothesaving
ofpetrol. Followingareafewsimpletipsforkeepingyour
vehicle healthy and your pocket wealthy.
Good riding habits :
lRide smoothly and steadily at an optimum driving
speed of 18 to 25 mph.
lDon’t waste petrol by stop and go riding and by
sudden starts and stops.
lAvoid harsh braking. Do not brake unless it is very
essential,anticipateyourstops,turnswellinadvance
andslowdown bydeceleration.
lChoose a proper route to ride especially in peak
hours.
lDon’t overload the vehicle above the specified pay
load.
lUse the accelerator judiciously. Think of the
accelerator barrel as fuel cock. The more you will
turn it, the more petrol will be consumed.
lFor better fuel economy,change the gear as given
below:
Change 1st to 2nd gear at 6 mph.
Change 2nd to 3rd gear at 12 mph.
Change 3rd to 4th gear at 18 mph.
Drive at 18 to 30 mph in 4th gear.
lCut off the engine if you want to stop more than for
two minutes. Remember, idling costs fuel.
Vehicle condition :
lCheckall fuellinesand connectionswheneveryour
vehiclesmells ofpetrol. Never fillthe petrolright up
to the filler cap.
lAlways maintain the recommended tyre pressure
and check it every week. Under-inflated tyres
increases rollingresistanceandthuscostsbothfuel
and tyre life.
lEnsurethat thebrakesarenot dragging/binding.
lFor keeping the engine healthy :
qInspect and clean the spark plug, adjust the
gap.
qClean the air filter.
qService carburettor and adjust idling speed.
qIf there is a power loss, then contact an
authorisedbajaj dealerand getthe vehicle
properly tuned.
Regular maintenance will save fuel and money
assuringyoutroublefree,enjoyableandsafe riding.

5
The maintenance and adjustments outlined in this section are easily carried out and must be done in accordance with
theperiodicmaintenancecharttokeepthevehicle ingoodrunningcondition. Theinitialmaintenanceisvitallyimportant
and must not be neglected.
PERIODIC MAINTENANCE CHART
SR.
FREQUENCY WHICHEVER COMES FIRST ODOMETER READING
(MILES)
NO. OPERATION EVERY 300 1200 3000 6000 9000 12000 15000
lIndicates operation to be performed.
nIndicates lubrication by SAE 20W40 of API SC/CC grade oil.
oIndicates lubrication by Lithium-calcium soap base grease.
jTo be cleaned more frequently in dusty area.
** Must be performed to maintain emissions warranty.
1 Servicing lllllll
2 Engine oil: Replacement lllllll
3 Oil strainer cleaning lll
4 Air filter element cleaning j ** 3000 MILES lllll
5 Spark plug : Cleaning/gap setting ** lll l l
: Replace 6000 MILES ll
6 Carburettor cleaning /overhaul ** lllll
7 Fuel line / Fuel Filter element cleaning ll l l
Fuel Filter replacement if required 6000 MILES ll
8 Check & adjust valve clearance ** lllllll
9 Control cables adjustment lllllll
10 Tightening nuts/bolts/fasteners Month lllllll
11
Checkfunctioningofallelectricalcomponents Day lllllll
12 Head lamp alignments- check & adjust lllllll
13 Tire rotation 6000 MILES
14 Tire pressure Week lllllll
15 Steering column : check and adjust ll
16 Front/rear brake : inspection/adjustment lllllll
: Overhaul ll
17 Check battery electrolyte level Month lllllll
Apply petroleum jelly on battery terminals Month lllllll
18 Lubricate
a) Front and rear brake levers ooooooo
b) Control cables , gear shifter nn
c) Speedo pinion/gears/cable oo
d) Brake cam shafts After oooooo
e) Stand pivot washing ooooooo
f) Front fork bearing races/balls the vehicle oo
g) Wheel bearings oo
h) Front suspension Refer Page No. 15
EVERY 3000 MILES
EVERY 3000 MILES

6
1 Wash and clean the vehicle on receipt lll ll
2 Check and correct tyre inflation pressure llll ll
including that of spare wheel
3 Check all nuts and bolts for llll ll
tightness especially handle bar bolt,
enginefoundationbolt,shockabsorber
nuts and wheel nuts etc.
4 Check Engine oil level and top l
up, if necessary.
5 Flush and refill Engine oil lll ll
6 Remove and clean air cleaner filter element lll ll
7 Clean spark plug , adjust the gap and refit lll ll
8 Clean the carburettor / adjust idling speed lll
9 Check & adjust valve clearance lll ll
10 Carry out lubrication as per lubrication chart lll ll
11 Check steering-cum-ignition lock & other lock l
forproperoperation.
12 Check for smooth operation of choke lever l
andaccelerator.
13 Check front & rear brakes for efficient working. llll ll
14 Check and adjust steering. ll
15 Check all lights, horn, switches, speedometer llll ll
for satisfactory working.
16 Initial charging of battery. Install & apply l
Petroleum Jelly on Terminals.
17 Check battery electrolyte level & apply lll ll
petroleum jelly on terminals
18 Test drive the vehicle. llll ll
19 Repair for any other defects seen or l
observedduring testdrive
20 Clean the vehicle before delivery. llll ll
Sr. No. Operation to be carried out P.D.I. 1st 2nd 3rd. 4th 5th
CHECK & ADJUSTMENTS TO BE CARRIED OUT DURING
P.D.I., 1st, 2nd, 3rd , 4th & 5th SERVICING

7
CLEANING
The vehicle must be cleaned periodically by using
pressurisedwater. Beforecleaningthevehiclecoverthe
importantpartslikeignitionswitch,silencer,ignitionunit,
H.T.coil,startermotorbyplasticbags. Don’tapplythejet
ofwaterdirectlytowardselectricalpartssuchasswitches,
ignitionunit, coilsetc.otherwise theymay getdamaged.
Brushing with parafin and wiping dry with clean rag is
advisableforexternalcleaningoftheengine. Allpainted
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.
Ifnecessary,blowwithcompresseddryair,theheadlamp
reflector, clean or wipe off dust with a very soft feather
brush. After washing, dry the vehicle and carry out the
lubrication.
WARNING:Washingyourscooterwillallowthebrakesto
becomewet,withthesameeffectasridingonawetroad.
Whenever the brakes become wet, always dry them by
gently applying the brakes, repeatedly, until the heat
causes the brakes to dry and full brake function is
restored.Failuretofollowthisprocedurecanleadtoloss
of brake effectiveness and a serious accident.
PERIODICMAINTENANCE
Periodic maintenance (in accordance with the periodic
maintenance chart) of a vehicle is most important to
prolongitslife,troublefreerunningandensureyoursafety
whiledriving.
LUBRICATION
Toreducethefrictionbetweentwomovingpartslubricate
themperiodically. Insufficientlubricationwillcauserapid
wear,damagingthepartsprematurely. Lubricateeverytime
after washing the vehicle and whenever the vehicle is
operatedunderwet,rainyconditions. Beforelubricating,
cleanoffanyrustypartsandwipeoffoldgrease,oilordirt.
Afewdropsofoilareeffectivetokeepboltsandnutsaway
from rusting and sticking. This makes removal easier.
Please refer lubrication chart, for details of lubrication.
ENGINE OIL : Check engine oil level daily.
Forproperfunctioningof cylinderblock/piston,crankshaft,
tappets, clutch and transmission, the oil should be
maintainedatanappropriatelevel.
Oil level inspection :
lPlacethevehicle oncentre stand,onalevelground.
lCleanthe surfacearea aroundthe oilfiller opening.
lUnscrew the dipstick from oil filler opening hole and
wipe it dry.
lPutthedipstick,onoilfilleropening,takeoutthedip
stick and observe the oil level on it.
lThere are two marks engraved on it. If the level is
below the lower level mark, top up with the
appropriatequantityofrecommendedoiluptoupper
level mark. If the oil level is too high i.e. above
the upper level mark, drain some oil from drain hole.
lFit back the dipstick and tighten it securely.
lEnsure that there is no oil leakage.
A) Oilfillerhole B) Oil level gauge
C) Upper level D) Lower level
Oilreplacement:
If the oil is used for a longer duration its lubricating
performance deteriorates. So it is necessary to replace
the oil in accordance with periodic maintenance chart.
For replacing the oil follow the procedure given below :
lRun the vehicle for few minutes.
lPlace the vehicle on main stand. Let the oil settle.
lRemove the oil drain bolt with its aluminium washer.
Also take out dip stick. Let the oil drain completely.
Tighten the drain bolt with new aluminium washer
securely. (Tightening torque 2.6 - 3.0 kg.m.)
lByusingafunnelpourtherecommendedoilfrom the
oilfilleropeningholeoropenInlettappetcover&pour
oil.
lFit back the dip stick and tighten it securely.
lEnsure that there is no oil leakage.
Do not use inferior grade of oil as a replacement for
the recommended oil, otherwise it will lead towards
enginetroubles.
Oil capacity: 1100 ml (For newly assembled engine)
: 1000 ml (For drain & refill)
Recommended oil : SAE 20 W40 of API SC/SF grade
Replace oil after every 5000 kms / 3000 miles.
Drain bolt
SCHEDULED MAINTENANCE
C
A
B
D

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 :
lOpen seat lock & lift the seat. Remove LH bonnet.
lRemovesparewheel.
lPull 'Coverairfilterslot'fromslotprovidedonchassis
for inserting air filter assly.
lTake out air filter assly carefully from slot.
lRemove air filter element.
Removal of air filter
Air filter cleaning :
lSoak the element for about 1/2 minute in high flash
point stoddard solvent or equivalent.
lSqueeze the element, blow the air so that it dries.
lDip the element in 20 W 40 oil. Soak the element for
about 1/2 minute.
lSqueeze theelementhard,manuallyso that excess
oil is removed.
lAssemble the air filter assly. insert it inside slot.
lFix the 'Cover air filter slot' on chassis.
DONOTUSEPETROLORLOWFLASHPOINTSOLVENT
FOR CLEANING.THIS MAYCAUSEBACK FIRE.
Air filter element should be cleaned as per periodic
maintenancechart.If vehicleisoperatingin dustyroads
/areatheelementshouldbecheckedandcleaned more
frequently.
Recommended Spark Plugs :
Champion PL 7 YC
SparkPlug Cap : Resistance
Electrode gap : 0.6 to 0.7 mm Wash Squeeze Out Oil Squeeze Out
And Dry Excess oil
SPARK PLUG
Theconditionofthespark plugindicateshowtheengine
is operating. A defective spark plug will lead to difficult
starting and poor performance. Engine heat and
combustionchamber depositswill causeany sparkplug
toslowlybreakdownanderodeoveraperiodofuse. The
sparkplugshouldberemovedperiodicallyandinspected
for electrode gap and the colour at the tips, at regular
intervals as specified in periodic maintenance chart.
If the engine is operating correctly and the machine is
being ridden properly, the colour at the electrode tip will
be greyish yellow to light brown. The centre electrode
will not have pitting and the side electrode will have
constant thickness. The combustion chamber residues
left on the tip gives an indication of engine performance
as follows :
lGreyish yellow to light brown : Correct running
of engine. Spark plug is perfectly matched for
optimum engine performance.
lShiningblack or wetcarbondeposits : Presence
of oil in fuel.
lBurnt white/pearly deposits of metallic enamel
beads: Overheatedengine,tooleanairfuelmixture,
spark plug not fully tight, use of hotter plug.
lDull black velvety carbon deposits : Too richfuel
air mixture, electrode gap too wide, plug too cold,
cloggedaircleaner,insufficienthightensionvoltage,
continuous slow speed driving.
Cleanthesparkplugpreferablyinasandblastingdevice
and thoroughly clean off abrasive material left on it .
Measure the gap between the electrodes with the wire
type thickness gauge, adjust the gap if incorrect by
bending the outer electrode carefully. The gap at the
electrode for optimum performance is 0.6 to 0.7 mm.
ConnecttheH.T.leadtosparkplug,groundtheplugand
check the current jumping across the plug electrode.
Thebrightbluesparkshouldjumpacrosstheelectrodes.
Replace the spark plug in case of following conditions:
1. Excessive electrode wear 2. Cracked insulator.
3. Chipped off insulator 4. Shorted plug.
While installing back the spark plug, check for ;
1. The condition of sealing washer.
2. Cleanliness of contact surfaces of spark plug seat
and cylinder head seat.
When installing the plug, first screw it in with finger
and then use the spanner for the final tightening
only. This will prevent chances of stripping of the
cylinder head threads.
Spark Plug gap

9
lOpenandclosethethrottleafewtimestomakesure
that the idling speed does not change. Readjust if
necessary.
lWith the engine idling, turn the handle bar to either
side. Ifthehandlebarmovementchangestheidling
speed, the accelerator cable may be improperly
adjusted, damaged or improperly routed. Rectify
any of these conditions before riding.
lDo 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.Increasespeed D. Air screw
REMOVALOF WHEELS
Forremovalofwheelsincaseofpuncture orTirerotation,
followthe proceduregiven below:
Front wheel :
lRotate wheel cover cap in anticlockwise direction
and take out.
lPull wheel cover.
lRemove 5 nuts (3 special & 2 regular) and take out
front wheel assly.
lAfter mounting wheel, check the sequence of 5
mountingnuts.
Front wheel nuts
ACCELERATORGRIP
Theacceleratorgripcontrolsthemovementof carburettor
throttle valve and ignition timing (For TRICS). If the
acceleratorgrip hasexcessiveplaydue tocablestretch,
itwillcause adelayincarburettorresponseespecially at
lowengine rpmandcause improperignitiontiming. Also
throttle valve will not open completely in full throttle
condition.Ontheotherhand,iftheacceleratorgriphasno
play,controlofcarburettorthrottlevalvewillbedifficult. If
theinnercableisoverstretched,idlingrpmwillbetoohigh
andcause improperignitiontiming.
ACCELERATORPLAYADJUSTMENT:
lChecktheaccelerator playby lightlyturningthegrip
back and forth.
lAccelerator play can be adjusted by cable
adjuster (a) provided on carburettor. Loosen the
adjusterlocknutandturntheadjuster untilspecified
free play is obtained. Retighten lock nut after
adjustment is over.
ACCELERATOR GRIP PLAY : 4 - 5 MM.
Adjusters(A) onCarburettor.
CAUTION:Alwaysmaintaincorrectacceleratorplay.
Itis very importantforvehicles fitted with'TRICS'as
the ignition timing is regulated by throttle opening.
IDLINGSPEEDADJUSTMENT
Whenever the idling adjustment is disturbed follow the
proceduregivenbelowforsettingproperengineidling.
lOpen seat lock & lift the seat. Remove engine.
lStart engine & drive it for atleast 5 kms.or warm the
engine till the oil temp. reaches 800C.
lThen set the engine idling r.p.m. by rotating the idle
adjustment screw clockwise or anticlockwise with
the help of a screw driver.
lFor the precise adjustment of idling speed, use of
tachometerisrecommended.
BC
A
A
D

10
anti dive
brakes which can lead to loss of control, an upset, or a
serious accident with subsequent serious injury or even
death.
FrontBrakeLeverPlay 3 to 5 mm
Frontbrakeadjuster
REARBRAKEADJUSTMENT
Check the rear brake pedal play as shown in figure. If it
is more or less than the standard, adjust the rear brake.
lThe adjusting nut for rear brake is located on rear
brake inner cable at the end.
lDepending upon the adjustment required, turn the
adjuster back or forth as follows :
- Turning the adjusting nut in (clockwise direction)
increases the play at the brake pedal.
- Turningtheadjustingnutout(anticlockwise direction)
reduces the play at the brake pedal.
lAfter adjustment, check the wheel for free rotation
and for braking effectiveness.
lRearbrakeshoe,linerwearcanbecheckedthrough
the inspection window on rear brake drum, after
unscrewingtheplug.
"If the brake remain ineffective despite above
adjustments,checkbrakeshoes,brakedrum&brake
cable."
RearBrakepedalPlay 10 to 15 mm
Rearbrakeadjustingnut
Rearwheel:
lRemoveLH cover.
lRemovesparewheel
lRotate wheel cover cap in anticlockwise direction
and take out.
lPull wheel cover.
lTilt the vehicle on engine side.
lRemove 5 nuts (3 special & 2 regular) and take out
front wheel assly.
lAfter mounting wheel, check the sequence of 5
mountingnuts.
Rear wheel nuts Inspection window
Installation:
lInstall the rear wheel on brake drum studs.
lInstall the plain and spring washers.
lInstallthenutsandtightenthemsecurely(Tightening
torque - 2 to 2.5 kg.m.)
BRAKES
Brakesshouldalwaysbemaintainedinperfectcondition
forsafety. Brakedrumwear,brakeliningwearandbrake
cable stretch causes the brakes to go out of adjustment.
Thisincreasesthefreeplayatthebrakeleverandreduces
the braking efficiency.
FRONTBRAKEADJUSTMENT
Checkthefront brakeleverplay. Ifitismore orlessthan
the standard, adjust the front brake.
lThe adjusting nut for front brake is located on front
brake inner cable at the end.
lDepending upon the adjustment required, turn the
adjuster back or forth as follows :
- Turning the adjusting nut in (clockwise direction)
increases the play at the brake lever.
- Turningtheadjustingnutout(anticlockwise direction)
reduces the play at the brake lever.
lAfter adjustment, check the wheel for free rotation
and for braking effectiveness.
"If the brake remain ineffective despite above
adjustments,checkbrakeshoes,brakedrum&brake
cable."
WARNING:Neverpermittheoperationof ascooterwith
abrakecableinanythingbutabsolutelyperfectcondition.
Anywearingorfrayingofthecablecanleadtoineffective

11
FLASH
TIRES
Forbetterroad-holdingandlongertirelifealwaysmaintain
correctairpressure. Overinflationwill causebumpy ride
andfasterwearofthetireatthecentre. Under-inflationwill
cause poor steering and faster wear at the sides.
RecommendedTirePressure
Front 1.25 Kg/cm2 (18 PSI)
Rear Solo 1.75 Kg/cm2 (25 PSI)
With Pillion 2.50 Kg/cm2 (36 PSI)
Tirewear/damage:
Wornout tireisunsafe. Replace thetyrewhen thetread
depth reaches to less than 3 mm.
Tiretreaddepth :
Measurethetiretreaddepthbyusingthedepthgauge. If
treadpattern isnot visible,replace thetire. Also replace
the tire when the tire tread depth is found to be less than
the service limit.
Standard Service limit
5 to 6 mm 3 mm
Tire rotation :
Toevenouttreadwearitisnecessarytochangetheface
of tire and to rotate it position wise every 10000 kms.
Change the face of the tire in relation with the wheel rim
and inflate tire to the specified pressure. The good tire
should be kept at the rear, which is a driving wheel.
CONTROLCABLES:
Duetocontinuousoperationofcablesbythebrakelevers
and throttle the inner cables are subjected to wear and
tear. Cable maintenance is primarily concerned with
preventingdeteriorationduetorustandweatheraswellas
providing proper lubrication for free movement of inner
cablesintheoutercasing. Forcheckinganyofthecontrol
cables follow the procedure given below :
lDisconnect the inner cable.
lCheckfree movementof thecablewithin itscasing.
If movement is obstructed, check for fraying or
kinkingof cablestrands. Ifsuch damageisnoticed,
replace the inner cable or cable assembly as
necessary.
lTo lubricate cable, hold it in vertical position. Apply
necessary oil to uppermost end of cable and move
theinnercabletoandfro. Leaveitinverticalposition
untiltheoilflowsdowntothelowerend. Allowexcess
oil to drain and reinstall the cable.
Note:Frictionfreecablesdo not require lubrication.
BULBREPLACEMENT:
When exchanging the bulbs, always replace the bulbs
withthatofthespecifiedtypeandrating. Thisisimportant
topreventtheelectricallightingcircuitfrommalfunctioning.
Head light bulb replacement :
For replacing head light bulb follow the procedure given
below:
lRemove2 screwsonHandle barrearcover holding
Handlebar frontcover.
Handlebarcover(Rear) mountingscrews.
lRemove one screw provided on H. Bar front cover
just below H. Light adjustment screw.
lCarefully disengage the locking lugs of handle bar
front cover by prying with the help of a small screw
driver.
lDisconnect Head Lamp harness coupler . Take out
Handle bar front cover with head lamp assly.
lSlidebellow fromheadlamp bulbholder.
Head light bulb holder
lRemovebulb holder&replacebulb.

12
Screw for head lamp adjustment
STEERING :
Steering play :
If the steering is too tight, it will be difficult to turn the
handlebarquickly,thevehiclemaypulltoonesideandthe
steering stem bearings may become damaged. If the
steering is too loose, the handlebar will vibrate and the
vehicle will be unstable and difficult to steer in a straight
line.
Inspection:
lRaise the front wheel off the ground.
lFrom the straight forward position of the handle bar
slowly push the handlebar to either side.
lIf the handle bar to turn by the action of gravity and
continues moving until its stopper on L.H.and R.H.
side, the steering is not too tight.
lIfthehandlebardoesnotbegintoturnby theaction
of gravity, the steering is too tight necessitating
adjustment.
lSquat infrontofthevehicleandgraspthelowerends
ofthefrontfork. Pushandpulltheforkendbackand
forth.
lIf the play is felt the steering is loose, necessitating
adjustment.
Adjustment:
lRemovehandlebarcovers.
lLoosen Handle bar bolt & lift up slightly.
lLoosen the upper lock ring nut.
lIf the steering is too tight, loosen the lock nut a
fractionofturn;ifthesteeringistooloose,tightenthe
locknut a fraction of turn.
Brake/Tail light, rear blinkers bulb replacement :
ForreplacingTail/stopbulborrearblinkersbulb,remove
2 screws for lens, take out lens & replace bulb.
Removal of screws for lens
Front blinker bulb replacement :
lRemove2mountingscrewsfornosegrillandtakeout
nose grill.
lRemove 2 mounting screws for blinker and take out
blinker assly.
lTake out holder & replace the bulb.
HEADLIGHTBEAMALIGNMENT
The headlight beam can be adjusted vertically and
horizontally. Ifadjustedtoolow,neitherlownor highbeam
will illuminate the road adequately. If adjusted too high,
the high beam will fail to illuminate the road.
lKeep the vehicle off the stand facing a wall.
lInflate both front and rear tyres to specified inflation
pressure.
lThere should be sufficient darkness.
lKeep the vehicle at a distance of 5 meter/16.4 ft from
a wall as shown in figure.
lStartthevehicle. SwitchONthe Headlighthighbeam
andthen lowerbeam.
lCheck the beam pattern on the wall.
lForcorrectpattern ofHighbeam& lowbeam,ascrew
isprovided belowHead lampassly. Loosethisscrew
before carrying out adjustment. Pressing Head light
assly at the top shifts the pattern up and pressing
Headlightassly atthebottom,shiftsthepattern down.
lThe High beam pattern should be as shown in figure
and it should be 1 meter/3.28 ft. above the ground.
lTheLow beampattern shouldbe set 5cm belowthe
HV point as shown in the figure.
SCREEN
1M/3.28 FT
5 M/16.4 FT VEHICLE OFF THE STAND
1M/3.28FT
HV
H
V
Hi Beam pattern
HV
2M/6.56FT
5CM
15°
V
Low Beam pattern
HV
2M/6.56FT

13
LUBRICATIONOFFRONTSUSPENSION
The locations of Grease nipples and recommended
intervalsforlubricationofFrontsuspensionbygrease(HP
multipurposeor equivalent)are as under.
Antidive link bushes & 'O' rings.
LubricateatEvery 2000miles.
NeedlerollerbearingsofFront
brakepanel.
LubricateatEvery 4000miles.
Bushes & 'O' rings of Antidive
link & hub pin.
LubricateatEvery 2000miles.
NON-USEMAINTENANCE
Non-use maintenance is necessary if a vehicle remains
offroadforalongerduration. Thecorrectandcarefulnon-
usemaintenancecarriedoutbeforestoringthevehiclewill
preventthevehiclefromrustingandfromsuchothernon-
operationaldamageslike firehazards.
lCleanthe entirevehiclethoroughly.
lEmptythefuelfromthefueltankandcarburettorfloat
bowl (if fuel is left in for a longer time, the fuel will
breakand couldclog thecarburettor.)
lRemove the spark plug and put several drops of 2T
oilintothecylinder. Kicktheengineoverslowlyafew
timestocoatthecylinderwallwithoilandinstallback
the spark plug.
lSet the vehicle on a box or a stand so that both the
wheels are raised off the ground.
lSprayoil onall unpaintedmetal surfacesto prevent
rusting. Avoid getting oil on rubber parts or brake
shoes.
lLubricate the control cables.
lCover the entire vehicle neatly. Make sure that the
storage area is well ventilated and free from any
source of flames or spark.
lRemove battery from vehicle.
lMaintain electrolyte level at 'Upper Level'.
lEnsure that battery is fully charged. Charge the
battery once in a month.
lKeep the battery away from rain, dew, moisture &
direct sunlight. Store battery in cool & dry place.
lTightentheupperlockringnuttoaspecifiedtorque.
lCheck the steering again. If the steering is still tight
orlooserepeattheadjustment.Ifthepropercondition
cannot be obtained inspite of correct adjustment,
inspect the steering parts.
lInstall handle bar covers.
OIL STRAINER CLEANING
lOilstrainer issituatedin sidethebolt as shownin fig.
lRemove the bolt and take out oil strainer.
lCleanitwithpetrol.Applyairjettodryoilstrainerand
assembled back.
lOil strainer should be cleaned in accordance with
periodic maintenance chart ( i.e. at every 3000
miles.)
Oil strainer bolt
BATTERYMAINTENANCE
lFor checking / topping up electrolyte level :
- Remove LH bonnet.
-Remove rubberstrapholding batteryandslide out
battery slightly for easy topping up.
lRemove battery filler cap & fill distilled water until
the electrolyte level in each cell reaches the upper
level line.
CAUTION: Addonlydistilledwatertothebattery.Do
notuseordinary waterfortopping up,it willshorten
life of battery.
lApply petroleum jelly to the terminals & assembled
back battery on the vehicle .
Locationofbattery

14
(6) High Flash-point Solvent
A high flash-point solvent is recommended to
reduce fire danger. Always follow manufacturer
andcontainerdirections regarding theuseofany
solvent.
(7 ) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been
inservice.Thematingsurfacesaroundthegasket
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
wheelbearing,shouldfirstbecoatedwithoilonits
outer or inner circumference so that it will go into
place smoothly.
(9 ) Ball Bearing
When installing a ball bearing, the bearing race
which is affected by friction should be pushed by
a suitable driver. This prevents severe stress on
the balls and races, and prevents races and balls
from being dented. Press a ball bearing until it
stops at the stop in the hole or on the shaft.
(l0 ) Oil Seal and Grease Seal
Replaceanyoilorgreasesealsthatwereremoved
with new ones, as removal generally damages
seals.
Whenpressinginasealwhichhasmanufacturer’s
marks,pressitinwith themarks facingout. Seals
should be pressed into place using a suitable
driver,whichcontactsevenlywiththesideofseal,
untilthefaceofthesealisevenwiththeendofthe
hole.
(11 ) Seal Guide
A seal guide is required for certain oil or grease
seals during installation to avoid damage to the
seal lips. Before a shaft passes through a seal,
applyalittleoil,preferablyhightemperature grease
on the lips to reduce rubber to metal friction.
(12 ) Circlip, Retaining Ring
Replace any circlips and retaining rings that were
removedwithnewones,asremovalweakensand
deforms them. When installing circlips and
retaining rings, take care to compress or expand
them only enough to install them and no more.
(13 ) Cotter Pin
Replace any cotter pins that were removed with
new ones, as removal deforms and breaks them.
GENERAL PRECAUTIONS (Dismantling / assembly)
Before Servicing
Beforestartingtoserviceavehicle,carefulreadingofthe
applicable section is recommended to eliminate
unnecessary work. Photographs, diagrams, notes,
cautions,warnings,anddetaileddescriptionshavebeen
included wherever necessary. Nevertheless, even a
detailed account has limitations, a certain amount of
basic knowledge is also required for successful work.
Especially note the following:
(1 ) Dirt
Before removal and disassembly, clean the
vehicle.Anydirtenteringtheengineorotherparts
willwork asanabrasive andshortenthelife ofthe
vehicle. For the same reason, before installing a
new part, clean off any dust or metal filings.
(2 ) Tightening Sequence
Generally, when installing a part with several
bolts,nuts,or screws,they shouldallbestartedin
their holes and tightened to a snug fit. Then
tighten them evenly in a cross pattern. This is to
avoid distortion of the part and/or causing gas or
oilleakage.Converselywhenlooseningthebolts,
nuts, or screws, first loosen all of them by about a
quarter of turn and then remove them.
Wherethereisatighteningsequenceindicationin
this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method
indicated.
(3 ) Torque
The torque values given in this Service Manual
shouldalwaysbeadheredto.Eithertoolittleortoo
much torque may lead to serious damage. Use a
good quality, reliable torque wrench.
(4 ) Force
Common sense should dictate how much force is
necessary in assembly and disassembly. If a part
seemsespeciallydifficulttoremoveorinstall,stop
and examine what may be causing the problem.
Whenever tapping is necessary, tap lightly using
a wooden or plastic faced mallet. Use an impact
driver for screws (particularly for the removal of
screws held by a locking agent) in order to avoid
damaging the screw heads.
(5 ) Edges
Watch for sharp edges, especially during major
engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when
lifting the engine or turning it over.

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 for the following conditions or
other damage If there is any doubt as to the
condition of them, replace them with new ones.
Abrasion Crack
Hardening Warp
Bent Dent
Scratch Wear
Colour change Deterioration
Seizure
(18 ) Service Data
Numbersofservicedatainthistexthavefollowing
meanings:
“Standards”: Showdimensionsorperformances
which brand-new parts or systems have.
“Servicelimits”: Indicatetheusablelimits.If the
measurement shows excessive wear or
deteriorated performance, replace the damaged
parts.
(14 ) Lubrication
Enginewearisgenerallyatitsmaximumwhilethe
engine is warming up and before all the rubbing
surfaceshaveanadequatelubricativefilm.During
assembly, oil or grease (whichever is more
suitable)shouldbeappliedtoanyrubbingsurface
which has lost its lubricative film. Old grease and
dirtyoilshouldbecleanedoff.Deterioratedgrease
has lost its lubricative quality and may contain
abrasive foreign particles.
Don’t use just any oil or grease. Some oils and
greasesinparticularshouldbeusedonlyincertain
applications and may be harmful if used in an
application for which they are not intended. This
manualmakesreferencetomolybdenumdisulfide
grease (MoS2) in the assembly of certain engine
and chassis parts. Always check manufacturer
recommendations before using such special
lubricants.
(15 ) Electrical Wires
All the electrical wires are either single-colour or
two-colour and, with only a few exceptions, must
beconnected towiresof thesame colour.Onany
of the two-colour wires there is a greater amount
of one colour and a lesser amount of a second
colour,soatwo-colourwireisidentifiedbyfirstthe
primarycolourandthenthesecondarycolour.For
example, a yellow wire with thin red stripes is
referred to as a “yellow/red” wire; it would be a
‘’red/yellow” wire if the colours were reversed to
make red the main colour.
Wire (cross-section) Name of Wire Color
Red
Wire strands Yellow/red
Yellow
Red

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).......................................................................................... 1.3 to 1.5
3 Cylinder Head (Qty. 4) ................................................................................................... 2.0 to 2.2
4 Crankshaft clutch side (Gear primary spur) ...................................................................9.0 to 9.5
5 Crankshaft magneto side (Rotor nut)............................................................................. 5.5 to 6.0
6 Intermediate shaft (For clutch assly).............................................................................. 9.0 to 9.5
7 Tappet ............................................................................................................................0.8 to 1.0
8 Main shaft....................................................................................................................... 5.0 to 5.5
9 Cover to Crankcase ....................................................................................................... 1.3 to 1.5
10 Silencer to Cylinder head............................................................................................... 2.0 to 2.5
11 Crankcase to Crankcase (Qty. 2)................................................................................... 1.3 to 1.5
12 Kick lever........................................................................................................................ 2.0 to 2.5
BOLTS FOR :
13 Cylinder head to Cylinder Block (Qty. 2)........................................................................ 0.9 to 1.1
14 Silencer to Crankcase (Qty.1) ........................................................................................3.0 to 3.5
15 Cam shaft sprocket ........................................................................................................1.1 to 1.3
16 Cam chain tensioner adjuster ........................................................................................ 0.8 to 1.0
17 Manifold to Cylinder head ..............................................................................................0.6 to 0.8
18 Chain tensioner body ..................................................................................................... 0.6 to 0.8
19 Cover to Crankcase ....................................................................................................... 1.3 to 1.5
20 Oil drain bolt ...................................................................................................................2.6 to 3.0
SCREWS FOR :
21 Stator plate .....................................................................................................................0.6 to 0.8
22 Screw for oil tube assly .................................................................................................. 0.3 to 0.4
23 Stopper plate (Cylinder head) ........................................................................................ 0.6 to 0.8
24 Gear shifter cover........................................................................................................... 0.6 to 0.8
25 Guide kick (Qty. 2) .........................................................................................................0.6 to 0.8
GENERAL :
26 Spark plug ...................................................................................................................... 2.5 to 3.0
27 Cap (Cylinder head) ....................................................................................................... 0.8 to 1.0
28 Oil plug ........................................................................................................................... 2.6 to 3.0
ENGINE