Bajaj Auto Legend 00300728 Service Station Manual Download

Page: 12 / 66

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 :

Open seat lock & lift the seat. Remove LH bonnet.

Remove spare wheel.

Pull 'Cover air filter slot' from slot provided on chassis
for inserting air filter assly.

Take out air filter assly carefully from slot.

Remove air filter element.

Removal of air filter

Air filter cleaning :

Soak the element for about 1/2 minute in high flash
point stoddard solvent or equivalent.

Squeeze the element, blow the air so that it dries.

Dip the element in 20 W 40 oil. Soak the element for
about 1/2 minute.

Squeeze the element hard, manually so that excess
oil is removed.

Assemble the air filter assly. insert it inside slot.

Fix the 'Cover air filter slot' on chassis.

DO NOT USE PETROL OR LOW FLASH POINT SOLVENT
FOR CLEANING. THIS MAY CAUSE BACK FIRE.

Air filter element should be cleaned as per periodic
maintenance chart. If vehicle is operating in dusty roads
/ area the element should be checked and cleaned more
frequently.

Recommended Spark Plugs :

Champion PL 7 YC

Spark Plug Cap : Resistance

Electrode gap : 0.6 to 0.7 mm

Wash

Squeeze Out

Oil

Squeeze Out

And Dry

Excess oil

SPARK PLUG

The condition of the spark plug indicates how the engine
is operating. A defective spark plug will lead to difficult
starting and poor performance. Engine heat and
combustion chamber deposits will cause any spark plug
to slowly break down and erode over a period of use. The
spark plug should be removed periodically and inspected
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 :

Greyish yellow to light brown : Correct running
of engine. Spark plug is perfectly matched for
optimum engine performance.

Shining black or wet carbon deposits : Presence
of oil in fuel.

Burnt white/pearly deposits of metallic enamel
beads: Overheated engine, too lean air fuel mixture,
spark plug not fully tight, use of hotter plug.

Dull black velvety carbon deposits : Too rich fuel
air mixture, electrode gap too wide, plug too cold,
clogged air cleaner, insufficient high tension voltage,
continuous slow speed driving.

Clean the spark plug preferably in a sand blasting device
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.

Connect the H.T. lead to spark plug, ground the plug and
check the current jumping across the plug electrode.
The bright blue spark should jump across the electrodes.

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