Bajaj Auto Legend 00300728, Service Station Manual

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 cable and - ve
meter lead to Black (earth). The resistance value should
be as tabulated below.:

Range

Connection

     Reading

Meter +ve

  Meter -ve

   x10 ohms

   Grey                      Black

  108 to 132ohms

4) Battery Charging Coil

First connect the + ve meter lead to Orange cable and -
ve meter lead to Blue/Red. The resistance value should
be as tabulated below.:

Range

     Connection

       Reading

   Meter +ve

   Meter -ve

   x10ohms         Yellow   Yellow/Red                       0.65 to 0.95 ohms

5) Insulation Check (ForLighting,Horn,Battery
Charging coils & Charging coils)

 : To check

whether coil is body short

Note : Disconnect wire connected to earth for lighting &
charging coil before conducting insulation check.

  Range

     Connection

            Reading

Meter +ve

Meter -ve

x1 K

Core

Either one        >200 K

ohms

ohms

(Remove varnish

of terminal

from core to have
proper contact

F) DC VOLTAGE REGULATOR

DC Voltage Measurement :

l

Cve lead of meter to +ve terminal of Battery
and - ve terminal of meter to - ve terminal of Battery.

l

Ensure that all lights are off.

l

Start the Engine, set it at 3500 RPM .

l

Measure the Battery terminal voltage.

LOAD

METER

READING AT 4500 RPM

OFF

DC 25 V

14.7 ±1V

Note : Use fully charged Battery ( specific gravity of
electrolyte = 1.24)

G) BATTERY CHARGING SYSTEM

l

Ensure that battery is fully charged.

l

Set meter range at 20 A DC

l

Remove fuse & connect  meter +ve lead to other
terminal of fuse i.e. Red / White wire coming from
DC Regulator and meter - ve lead to Red wire coming
from bve terminal.

l

All DC load viz.  Brake lights and Side indicator bulbs
are to be  switched OFF.

l

Start the Engine. Set the Engine RPM at 3500 RPM.

l

Measure  Battery charging current. It should be 1.0 to
3.0 amps i.e. current must flow into the Battery.

   Range

           Connection

         Reading

 Meter +ve

Meter -ve

20A DC

Red/White

Red

1.0 to 3.0A

l

Stop the Engine. Disconnect the meter and reconnect
the fuse.

l

As a further check, set meter range at 25 V DC.

l

Cve lead of meter to +ve terminals of Battery
and - ve terminal of meter to - ve terminal of Battery.

l

Ensure that all lights are off.

l

Start the Engine.

l

As the RPM of engine increases, voltage will also
increase. Measure the Battery terminal voltage at
3500 RPM.

   Range

           Connection

         Reading

 Meter +ve

Meter -ve

25V DC

Bve

Bve

14.7±1 V

Note : Use fully charged Battery ( specific gravity of
electrolyte = 1.24)

H) TURN SIGNAL RELAY

Remove the flasher unit which is to be checked and
connect it to another vehicle whose flasher unit and side
indicators are working properly.  Check that the terminals
are connected correctly.  Start the vehicle and put ON the
indicator switch and see if the flasher unit functions or not.
If flasher unit works properly then there may be some
problem with the switch  or regulator or with the wiring of
the vehicle whose flasher unit is being checked.

Also check flash rate (No.of flashes/min). If flash rate is
not within the specified limit i.e.90 ±30 flashes / min,
replace it as it is faulty.

If right or left signal gets ON, check that the blinker bulbs
are Ok.

I) FUEL LEVEL GAUGE (TANK UNIT)

For knowing the quantity of fuel inside the fuel tank at a
glance, fuel gauge is provided on an instrument panel. The
fuel gauge works on the principle of 'variable resistance'.
The fuel gauge works on A.C. supply.
The fuel gauge consists of a float for level sensing, a
sender for sending the signal and the gauge for converting