Bajaj Auto Legend 00300728 Service Station Manual Download

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Assemble Front brake cable adjuster into Front
brake panel.

Assemble Brake links on Actuating lever by Split
pin.

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 greasing.

Assembly of Brake links (a)

DISMANTLING OF FRONT SHOCK ABSORBER

Remove two nuts (c) holding Front shock absorber
upper mounting bracket .

Remove the Shock pads & Pad locators.

Remove nut holding spring and then remove front
suspension spring .

FRONT SHOCK ABSORBER ASSEMBLY:

Assemble front suspension spring on front shock
absorber such that its lower pitch side face down-
wards and then tighten the nut.

Assemble shock pads & pad locators on front shock
absorber and then tighten with the nuts.

Assembly of Front shock absorber

REMOVAL OF ENGINE FROM VEHICLE :

Put the vehicle on the stand , open seat lock & lift
seat and remove both LH and RH bonnets.

Drain Engine oil completely by removing drain plug.

Disconnect lower ends of rear brake & clutch cable.

Remove gear shifter cover and release lower ends
of gear cables by unscrewing screw terminals.

Disconnect magneto harness coupler from main
harness. Also remove body earthing screw on fan
cover & remove earthing cable.

Disconnect choke and throttle cable from carburettor.

Disconnect duct from carburettor. Disconnect
carburettor from intake manifold. Disconnect fuel
pipe and sensing pipe.

Remove bolt fixing lower end of rear shock
absorber to the engine.

Hold engine carefully & remove the bolt fixing
c,case arm with engine mounting link on chassis.

Take out the engine carefully from the chassis.

CHASSIS ASSEMBLY

Assemble various grommets on chassis in respective
holes i.e. grommets for petrol pipes, tail lamp,
control cables etc.

Fix plug for bonnet on LH and RH side of chassis.

Insert 2 bolts alongwith plain washer from front side
of shield in the holes for L. box Fit plain washer,
spring washer and on each bolt and tighten it.

Pre-fit shield beading on shield on the shield by light
hammering by rubber mallet

Press fit the beading by using special tool.

Insert 4 bolts for stand mounting and Position stand
on chassis and insert stand clip LH and RH on the
bolts. Prefix 4 nuts spring washers and tighten
them.

Assemble hook plate on chassis and assemble
stand spring.

Insert wiring harness into the chassis from front side
(Near steering hsg. side)

Take out the harness branches for LH and RH
control switches, head lamp and instrument panel
from the cavity of the chassis.

Take out harness branch for brake switch from the
hole on chassis near brake pedal mounting.

Insert tail lamp wiring harness through diaphragm
hole. Route the harness along LH side of diaphragm
and take it out from hole on rear end of chassis.

Take out harness branch for regulator and CDI unit
through hole on LH side of chassis.

Take out harness branch for stator from hole on RH
side of chassis.

Align hook with chassis holes and fix it with 2 Nos of
screws alongwith plain, spring washers and nuts.

Insert control cables i.e. Accelerator cable, Gear
cables and choke cables from upper terminal in
proper position.

Fix cap for upper terminal.

Assemble handle for Engine bonnet and LH bonnet
with spring, plain washer and nylock nut on LH and
RH side of chassis.

Shock pad

Pad locator

Nut 'C'