Tech Notes, provided in .pdf format, answer technical/mechanical issues of interest.  If we see a problem we can address, a Tech Note will be produced. 

TECH NOTES LIBRARY

 Automatic Timing Chain Tensioner

 Cam Timing Marks, Legend & Chetak

 Charging Failures & Battery Maintenance

 Chetak CDI Diagnostics  P/N CL111022

 Evaporative Emission Control System Hookup Schematic

 Legend CDI Diagnostics P/N 28111058

 Legend CDI Diagnostics P/N 28111072

 Oil Change Procedure Chetak & Legend

 Legend & Chetak Main Shaft Gear Assembly Axial Clearance

REPAIR, PARTS CATALOGS &  OWNER'S MANUALS

These manuals are not meant to be training manuals for the novice mechanic. You will not find step by step instructions for many commonly performed services.  These manual are written for trained and experienced mechanics.  The posting of these manuals does not constitute or imply encouragement or consent from us to perform your own maintenance or repairs.

Legend Owner's Manual

Legend Parts Catalog

Legend Service Manual

Chetak Owner's Manual

Chetak Parts Catalog

Chetak Service Manual

The Chetak Service Manual is smaller than the Legend manual because they share the same engine and the bulk of engine information will be found in the Legend Service Manual.  If you have a Chetak, download both service manuals.

Exploded view, Chetak/Legend engine

WIRING DIAGRAMS

Wiring diagrams for Legend and Chetak in .pdf format. The paper size is 24 X 36.  Tile it if you can, the printing is very small if printed on an 8.5 X 11" sheet.

Wiring diagrams for older Bajaj 2 stroke scooters

Bajaj Super - contact breaker ignition

Bajaj Super Excel - electronic ignition

Bajaj Classic - with electric start

BAJAJ SCOOTER EXHAUST EMISSIONS

If you are concerned, or just interested, about the amount of pollutants gasoline powered Bajaj scooters produce, take a look at this chart comparing Bajaj scooters, motorcycles, autos and SUV's/trucks, and (gasp-cough-cough) two stroke scooters... click here

DRIVING SAFELY

Even if you don't live in California, you'll find the California Motorcycle Handbook full of good information on two wheel safety.  Available in .PDF format at:  

http://www.dmv.ca.gov/pubs/pubs.htm

Check out the Motorcycle Safety Foundation.  They provide information on motorcycle rider training, operator licensing & government relations. It includes information on rider courses, riding gear, and motorcycle safety for riders of all ages. You can also download motorcycle publications, contact listings, and news.  http://www.msf-usa.org

TOUCH UP PAINTS

All the colors used for the Bajaj scooters are DuPont paints identified by DuPont paint codes.  We did this so that wherever you may be, the local automotive paint supplier can mix up an exact duplicate using the DuPont codes.  Even non-DuPont paint suppliers can cross reference the codes and match the colors.

We have used matched colors in 16oz. spray paint cans from NMB Paints Sales in Miami Beach, Florida.  Their prices are about 1/2 of other touch-up sprays we have seen.  Their web site:  www.nmbpaint.com

2002 Bajaj scooters DuPont color codes:

2003/2004 Bajaj Scooter DuPont color codes:

SPARK PLUG SUBSTITUTION 

The Champion spark plug, PL7YC, that's in your Legend/Chetak engine is difficult to find in U.S. auto parts stores, but it is available from your Bajaj dealer.  The equivalent, readily available, Champion plug is L87YC.  We always recommend the original equipment, but here are 3 possible substitutes: Bosch W5BC or W5BP and NGK BP7HS.

3 wheeler spark plugs substitutions: 
NGK BP8HS
Mico WR7BC4

Other Sources of Information

Another good source of  information can be found on the Bajaj Scooter Forum.  There are many helpful members that take the time to discuss and exchange information and ideas about their scootering experiences.