🏷️ Basic Information Identification Make: Bajaj Model: Chetak & Legend Year: 2003 Engine Type: 2-Stroke Scooter Engine Product Focus: Cam Timing Marks Alignment 👋 Introduction Market Position Vehicle Segment: Entry-level to mid-range scooters. Competitive Analysis Competitors: Other Indian and international scooter manufacturers of the era (e.g., Honda Activa, TVS Scooty). Key Features Vehicle Reputation: Known for robust build, practicality, and iconic design (Chetak). Manual Importance: Critical for maintaining engine health and performance, especially after engine work. 📋 Manual Details Coverage Areas Primary Focus: Camshaft timing synchronization and alignment procedures. Related Systems: Engine mechanics, valve train operation, ignition timing prerequisites. Page Count Estimated Pages: 1-5 Pages (Technical Note) Manual Type Type: Technical Service Bulletin / Special Instruction Language Language: English Format Format: Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Camshaft, crankshaft, piston, cylinder, valve train (valves, springs, rockers). Ignition System: Indirectly, as correct timing is crucial for ignition. Procedures Included Timing Alignment: Step-by-step instructions for aligning camshaft timing marks with crankshaft marks. Verification: Methods to confirm correct timing has been achieved. Technical Depth Detail Level: Specific visual indicators and positional references for critical timing components. Diagnostic Focus: Addressing symptoms of incorrect valve timing (e.g., poor performance, rough idle). 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if digitally created and optimized. Print Quality Quality: Dependent on source scan or creation, typically clear for diagrams. Binding Type Binding: N/A (Digital File) Paper Type Paper: N/A (Digital File) ⚙️ Engine Specifications Primary Engine Model Designation: Likely derived from Bajaj’s established 2-stroke scooter engine lineage. Configuration: Single-cylinder, 2-stroke, air-cooled. Displacement: Approximately 145cc (Chetak) or 110cc (Legend variant, though often refers to Chetak). Exact displacement for specific Legend models should be cross-referenced. Performance Horsepower: Typically in the range of 7-10 HP, depending on exact model and tuning. Torque: Approx. 10-13 Nm. Fuel System Carburetor: PZ20 or similar Mikuni/Dellorto type carburetor. Fuel Type: Unleaded Petrol (Gasoline) with 2-stroke oil mixture. 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with clutch. Features Drive Type: Belt drive to rear wheel. Fluid Specifications Gear Oil: SAE 90 API GL-4 hypoid gear oil (for gearbox, separate from engine oil). 📐 Dimensions Exterior Length: Approx. 1780 mm Width: Approx. 690 mm Height: Approx. 1070 mm Weights Kerb Weight: Approx. 115-120 kg Payload Capacity: Approx. 150 kg (including rider and pillion). 🛡️ Safety Features Ratings Crash Safety: Not formally rated by modern automotive safety standards (e.g., NHTSA, Euro NCAP) as it predates widespread standardization for scooters in this segment. Active Features Brakes: Front: Drum brake; Rear: Drum brake. Passive Features Frame Type: Monocoque chassis. 💡 Technology Features Infotainment Features: Basic analog speedometer, fuel gauge (if equipped), turn signal indicators, headlight, taillight. Driver Assistance Features: None (This is a 2003 era scooter; no electronic driver assistance systems). Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change: 2-stroke: Oil level check should be frequent, top-up as needed. Engine oil for gearbox: Check every 5,000-7,000 km. Spark Plug Replacement: Recommended every 3,000-5,000 km or as per manufacturer's schedule for optimal combustion. Air Filter Cleaning: Check and clean every 1,500-2,500 km; replace as needed. Fluid Specifications 2 Stroke Oil Grade: API TC, JASO FD rated 2-stroke engine oil (e.g., Castrol Activ, Motul 2T). Gear Oil Grade: SAE 90 API GL-4 (refer to owner's manual for precise specification). Known Issues Engine Performance: Incorrect valve timing can lead to loss of power, rough idling, difficult starting, and increased fuel consumption. Carburetor Issues: Clogged jets, worn needle valve, improper air-fuel mixture adjustments are common for carbureted engines. Ignition System: Worn spark plugs, faulty ignition coil, or stator issues can affect spark delivery. 2 Stroke Specific: Carbon buildup in exhaust ports and cylinder head, spark plug fouling, correct oil-fuel premix ratio. 📚 Vehicle History Brand Heritage Bajaj Auto: Bajaj Auto Ltd. is a major Indian manufacturer of motorcycles, scooters, and auto rickshaws, established in 1945. Known for its iconic 'Chetak' scooter. Model Evolution Chetak Legacy: The Bajaj Chetak is a legendary scooter model in India, produced for decades and highly influential in Indian personal transportation. It has seen various iterations and engine updates over its long production run. Production Production Years: Chetak production spanned from the 1970s into the early 2000s. The 'Legend' variant likely refers to a specific late-model iteration or trim of the Chetak. Manufacturing Location: India 🏆 Awards & Recognition Recognitions Brand Recognition: Bajaj Chetak is widely recognized as an icon of Indian scooter history and a symbol of affordable personal mobility. Ratings Customer Satisfaction: Historically high due to reliability and low maintenance costs for its era. Certifications Emissions Standards: Compliant with Indian emission norms applicable at the time of manufacture (e.g., Bharat Stage II).