Bajaj Auto Legend 00300728, Service Station Manual

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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 arm shaft
l
Take out both the rocker arms.
l
Take out camshaft.
l
Using valve spring compressor and adaptor press
down the valve spring retainer.
l
Remove the collets.
Removal of valve
l
Loosen valve spring compressor and take out
valve spring retainer, valve spring and spring seat.
l
Push out one valve.
l
Repeat same procedure for the other valve.
Kick Shaft Dismantling :
l
Remove circlip holding the spring guide.
l
Remove spring guide by nose plier.
l
Remove spring by taking it out from the hole
provided on the kick shaft.
l
Remove the circlip alongwith the washer.
l
Take out gear kick alongwith washer on other side
of gear. Remove circlip and take out ratchet gear.
l
Remove spring coil and cup kick shaft.
l
Remove circlip.
Kick Shaft Dismantling
ENGINE ASSEMBLY
REASSEMBLING OF SUB-ASSEMBLIES :
Kick Shaft Assembly :
l
Fix circlip for the gear kick on kick shaft and assemble
washer on it.
l
Assemble gear kick on kick shaft.
l
Put one washer on gear kick & fix circlip on it.
l
Assemble ratchet gear on the serrations of kick
shaft in such a way that the dot mark punched on
the beginning of serrations on kick shaft matches
with the dot mark on the ratchet gear.
l
Fix coil spring on shaft and put cup kick shaft.
l
Fix circlip over the cup kick shaft.
l
Assemble kick return spring on the shaft in such a
way that hook on inner diameter of spring is located
in hole on kick shaft.
l
Put nylon spring guide on the kick shaft and fix
circlip.
Cylinder Head Assembly :
l
Smear slight amount of grease on valve.
l
Push inlet valve into the valve guide from combustion
chamber side.
l
Put spring seat, valve spring and valve spring
retainer from the other side. The loose coil ends of
the spring should be facing downwards.