BAJAJ CHETAK 2002 & LEGEND 2003 PASSIVE EMISSION CONTROL HOO

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🏷️ Basic Information Identification Make: Bajaj Model: Chetak Model Variant: Legend Year: 2002 Year Variant: 2003 Codes Emission Control Type: Passive Emission Control 👋 Introduction Market Position Vehicle Segment: Classic...

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Type: Motorcycle

Vendor:

Sku: 194037

Tags: 2002 2003 Bajaj Chetak CHETAK 2002 LEGEND 2003 Motorcycle Motorcycles

Product variants

Description

🏷️ Basic Information

Identification

Make:

Bajaj

Model:

Chetak

Model Variant:

Legend

Year:

Year Variant:

Codes

Emission Control Type:

Passive Emission Control

👋 Introduction

Market Position

Vehicle Segment:

Classic Indian Scooter

Target Audience:

Owners and technicians maintaining Bajaj Chetak scooters

Competitive Analysis

Competitors Era:

Lambretta, Vespa (historical context)

Key Features

Engine Type:

2-stroke, air-cooled

Design Philosophy:

Robust, reliable, user-friendly urban commuter

Emission Control Significance:

Adaptation to evolving environmental regulations

📋 Manual Details

Coverage Areas

Primary Focus:

Passive Emission Control System Hookup

Related Systems:

Engine, Fuel System, Exhaust System, Electrical

Page Count

Estimated Pages:

Manual Type

Type:

Technical Service Bulletin / Schematic

Language

Language:

English

Format

Format:

Digital (likely PDF or image file)

📖 Manual Coverage

Systems Covered

Emission Control Components:

Air injection system, reed valve, air filter, exhaust manifold routing, vacuum lines (if applicable)

Engine Ancillaries:

Component connections related to emission control

Procedures Included

Hookup Diagrams:

Detailed visual representation of component connections

Wiring Schematics:

Electrical routing for emission control components (if applicable)

Troubleshooting Guidance:

Implied guidance based on correct hookup

Technical Depth

Depth:

Specific component routing and connection for emission control

Application:

Installation, repair, and verification of passive emission control system

📊 Manual Specifications

File Format

Format:

PDF (assumed, for digital delivery)

Searchability:

Likely searchable if digitally created PDF

Print Quality

Quality:

N/A (digital)

Binding Type

Type:

N/A (digital)

Paper Type

Type:

N/A (digital)

⚙️ Engine Specifications

Primary Engine

Type:

Two-stroke, forced air-cooled

Displacement:

145.5 cc (approximate for this era)

Bore X Stroke:

54 mm x 63.5 mm (typical for this displacement)

Carburetor Type:

VM20 (typical Dell'Orto or similar)

Performance

Horsepower:

Approx. 7-8 HP @ 5000 RPM (estimated for this generation)

Torque:

Approx. 10-12 Nm @ 3500 RPM (estimated)

Fuel System

Fuel Delivery:

Carburetor

Fuel Type:

Unleaded Petrol with 2-stroke oil mixture (e.g., 1:20 or 1:30 ratio, refer to specific Bajaj guidelines)

Emission Control System

System Type:

Passive Emission Control (likely air injection into exhaust port)

Key Components:

Reed valve, air injection nozzle, vacuum pulse secondary air injection (if fitted)

🔧 Transmission

Standard

Type:

Manual, 4-speed

Gear Selection:

Hand-operated gear shift lever

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 1770 mm

Width:

Approx. 670 mm

Height:

Approx. 1030 mm

Wheelbase:

Approx. 1230 mm

Weights

Kerb Weight:

Approx. 115-120 kg

Payload Capacity:

Approx. 150 kg (including rider)

🛡️ Safety Features

Passive Features

Frame Type:

Monocoque Steel Body

Lighting:

Headlight, Taillight, Turn Signals

Active Features

Braking System:

Front: Drum Brake, Rear: Drum Brake

Suspension Front:

Trailing link with coil spring and hydraulic damper

Suspension Rear:

Swing arm with coil springs and hydraulic dampers (twin shock absorbers)

💡 Technology Features

Infotainment

Features:

Basic analog speedometer, fuel gauge (if applicable), indicator lights

Driver Assistance

Features:

N/A (mechanical controls)

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Engine:

Refer to owner's manual; typically after initial break-in and then as per usage (2-stroke requires oil in fuel)

Spark Plug Replacement:

Approx. every 5,000-8,000 km

Air Filter Cleaning Replacement:

Clean every 2,000 km, replace as needed

Fluid Specifications

Gearbox Oil:

SAE 30 or SAE 10W-30 API GL-3 (refer to Bajaj's specific recommendation, often a small quantity)

Brake Fluid:

DOT 3 or DOT 4 (for drum brake actuation fluid if any)

Known Issues

Common Problems:

Carburetor clogging, ignition issues (spark plug, coil), clutch wear, brake adjustments, exhaust port carbon buildup

Emission Control Specific:

Blocked air injection ports, damaged reed valve, vacuum leaks in the air supply line

Part Numbers

Spark Plug Example:

Bosch W7AC or Champion L82C (typical for the era, verify)

Air Filter Example:

Bajaj Part No. varies, often a felt or foam element

📚 Vehicle History

Brand Heritage

Manufacturer:

Bajaj Auto Ltd.

Origin:

India

Model Evolution

Introduction Year:

1972 (original Chetak)

Design Basis:

Licensed from Vespa (Italian)

Legend Variant Context:

Later iterations with styling and mechanical updates

Production

Production Period:

1972 - 2009 (original platform)

Manufacturing Location:

India

🏆 Awards & Recognition

Recognitions

Market Impact:

Widely popular and iconic Indian scooter, known for affordability and reliability

Ratings

Durability:

High (for its class and era)