Broken flywheel results in power loss

My wife has a 2002 Bajaj Chetak, which ran well and was maintained per manufacturer schedule. Rode streets and a 5 mile stretch of high way daily. Felt a power loss on the highway as if I ran out of gas. Went 100 feet with power sputtering. Clutch in . . . engine died. Would not kick over. Has compression. Flywheel side might be the source of the funky air release sound when I kick the kick start.

Trouble shooting with the help of the Retro Bajaj Forum.

Replaced the spark plug resistor cap. Spark plug appears decent, but will replace as it's only a $2.00 test.

The big concern is the scraping sound the flywheel makes and the fact that bike will not fire up, as you will note in this video:



It appears that almost all of the flywheel rivets are missing from my wife's scooter as you can see in the video or the photos. I have been told I all I need to do is have the flywheel re-riveted. I suppose I could also have it welded so that never happens again.


The steps I will follow to repair the flywheel can be found here with pictures included.

For a list of other common issues for the 2002 Bajaj Chetak visit the Retro Bajaj forum.

Scooter Rider Magazine review of Bajaj 2003

Before reading there are two things to note:
(1) There are many typos in this article that I commented about to the editor/publisher, but I was never responded to. I do race to get info up on my blogs and have limited time, but as a journalism major when it comes to print I want my words to best represent me. I assure this article did that, but was cut down and revised by the editor without my approval. For an example in the 3rd paragraph it should NOT be "Asians or Indians," but rather should be "Asian-Indians". The meaning was completely misconstrued, likely because the editor did not know that a Bajaj is Asian-Indian made.
(2) After owning two Bajaj's in our family for 9 and 8 years I can say that they have required nothing more than the normal maintenance; hence without a doubt the Bajaj Chetak is a perfect first scooter for those that love the vintage look and feel. I now own a 1962 Lambretta TV175, because the Chetak made me comfortable enough . . . .

Scoot Quarterly's review of the Bajaj Chetak & Legend 2002

Click on picture to enlarge.

Battery

I have used Yusa and Interstate batteries. They a good batteries. I scored Interstate for $19.99 and Yuasa for $36 from a battery supply store back in Harrisburg, PA. They cost near $50 where I am now, so I opted for the $25 Walmart battery. Note: for the battery kits (where you charge them) that you need a battery charger. I own a Battery Tender Junior.

The secret to maintaining and extending the life of your battery is to ride frequently and often or use a "float" charger, because float charger turn off and do not over charge.

The batteries which work for your Bajaj are:

Generic battery: 12N9-4B-1 9Ah

Yuasa: Yb9b

Parts Unlimited: rcb-9b

Exide: 12MX9-B

For more information visit Retro Bajaj.

I've heard many times the starter eats up a lot of battery juice; hence it is recommended you use the kick start instead.

If you are not riding at least three times per week, you will find the battery is not being recharged quickly enough, which will result in a short life. To combat this it is wise for you to invest in a "float" charger (shuts off automatically and does not overcharge like a "trickle" charger does, which could also destroy your battery). I have owned three and am the most happy with the "Battery Tender Jr.", which I bought via Amazon for the best price I could find.

If you are riding often, it's a good idea to plug into the charger once per month and fully recharge your battery. A quality $50 battery should last 3-5 years and with a float charger used properly, definitely 5 years.

Headlight upgrade

A while back I rode my buddies P200 with the upgraded halogen headlight at night time. I could see so well. I wanted it on my Bajaj. It costs me $11 at Autozone. I also applied some bulb grease to the conductors to expand its life. I was careful not to touch the bulb at all as oils from our skin will also shorten the life of the bulb. What a difference this bulb makes in terms of our safety.

It should be noted that this bulb pulls more from your battery than the stock bulb. So make sure you ride frequently or use a float charger to protect your battery.

The bulb you want is H-4 60/55 watt halogen. While I at Autozone I also replaced a blinker light and the tail light again applying the light bulb grease.

For a list of parts or any help you need with your Bajaj visit Retro Bajaj. These guys are knowledgeable and friendly - it's a wonderful community that has been around for a while.

Upgrade your spark plug resistor

One of the most common things to go wrong on your Bajaj is a sputtering loss of power. Eventually, at some point, your spark plug resistor cap will go bad, so why not replace it now? It only cost $2.50. Furthermore, while you are at it, replace or upgrade your spark plug. Seriously, why do wait until we hit 10,000 miles on the odo? We're talking $5.

Buy:

Resistor cap: VB05 (NGK stock replacement 120 degree bend - this is important so that it fits using your stock set-up. The 90 degree one will require you to cut away plastic from the engine cover to get a tight fit).

Spark plug upgrade: BPR7HIX/NGK5944 (NGK Iridium upgrade - your bike will idle smoother and create more power at higher RPMs with this plug. It costs $7 as opposed to $2.50 for the stock one).

Remember, when installing the spark plug resistor cap to twist the old one counter clockwise out of the wire and it will come off pretty easily. Then cut just the tip of the wire so the new spark plug resistor cap will have good contact.

Also, keep in mind you need the screw on the spark plug cap that comes with your brand new spark plug. The stock spark plug resistor from Bajaj did not use it.

Call your local motorcycle/scooter shop and ask them to order the parts. Autozone can get the spark plug, but not the cap.

For a list of parts visit RetroBajaj and you can also read discussions on why people upgraded.

I just replaced only the spark plug resistor cap and rode up a San Francisco hill and my bike was pulling/jumping in 2nd gear wanting to give me more. It runs as strong as the day I first bought it - maybe stronger. It tacked hills in 3rd gear too!

3rd, 4th or what ever hand tool it is helps

Your local bike or scooter shop sell 3rd hand tools or your friendly internet store. Mine is a Hazzo. Pedro is another good brand. Expect to pay $25. Note: using a Dremel or another device for the certain thick cables on some bikes you will need make a grind line where the cable runs and gets pinched (see photo: it's the right arm only). I understand hardcore cyclist don't use this tool and mock it, but hey we're scooterists. Ain't no shame! With a ratchet and a 3rd hand tool I was done in 3 minutes as opposed to being clumsy with pliers and having my wife hold the brake in while I tighten.