[funkykar]

Ye zameen yeh aasman,
Ye zameen yeh aasman,
Hamhara kal hamhara aaj,
Hamhara kal hamhara aaj,
Bulandh Bharat ki buland tasveer,
Hamhara Bajaj hamhara Bajaj,
Bulandh Bharat ki buland tasveer,
Hamhara Bajaj hamhara Bajaj.

Who wouldn't get goosebumps and drown in nostalgia when this advertisement is seen (we all saw it on Doordarshan):

https://www.youtube.com/watch?v=scltYH13uEY

If you are in your late 20's or 30 and above, chances are you or your family member has owned a Bajaj Scooter. For majority of us, our parents ferried us on the Scooter. 'Hum Do, Hamhare Do' was popular and so it was common to see a family of Father, Mother, Son and Daughter on a Chetak up to late 90's. Most of us learnt riding on scooters. We had our first fall on scooter and had the best times with a scooter in our childhood or early adulthood days.

I always associated Nostalgia with my childhood, especially with objects/vehicles I thought I may never be able to own. Incidentally, I had a 1991 Bajaj Super FE in college around 1998. I simply loved riding it. More than the love for scooter, it was love for it as an automobile. The Super FE was super special to me because I happened to own it by chance. A relative of my dad owed some money. After a long time, he offered this scoot instead. My dad took it with open arms as the relative returning money looked too bleak. Dad's idea was to resell and cut his losses. The scoot came all the way from Anantapur. As it was AP registration, selling wasn't a breeze. He needed some time to figure the formalities. By then, I started using it casually. By time my Dad could figure how to liquidate, I had made him look at the scoot as a necessity to me. Slowly, he let go of the idea and the scoot was all for me. I was worried about riding an AP registered scoot in Bangalore. When asked what to do if cops caught, he always said follow the rules, nothing will happen. Worst case, leave it and come, we will look into it later (he meant leave it, and let's forget we had a scooter). Enjoyed it for few years and then started working and bought a RX 135 and interest on scooter died down. Priorities changed and my dad's scooter went bust in 2005 and he used mine for few years until I got him a Activa in 2008. Sadly, in 2010 we had to scrap both the scooters during my wedding as mom very insistent on cleaning up lot of old stuff for a new beginning in my life. There it went!!

[funkykar]

This thread is not about the scooter I owned in the past. It really is about the present. Few months ago, I got an itch towards geared scooter. There was a period of few weeks where I started feeling I need to ride and own a scooter. A sweet co-incidence was this thought came exactly 20 years after my first scooter. I looked around Olx for days together. I couldn't find any good ad nor did I understand how to spot a good scooter ad. I was very rusty, confused and what not. Then I remembered my friend Arun (Arun1100) had one at his home. His dad got it in 1997 and used for around 10 years and then it was lying idle. It had a lot of cement on it that fell when they had some renovation work going on. Arun was wanting to restore this scooter since long. With his busy schedule and family commitments, he just couldn't. I causally asked him to give his scooter. Without any hesitation, he simply parted it to me for free! He said, I will get it fixed nearby and give you in running condition which he did.

The scoot wouldn't start and kicker was getting jammed. Arun was kind enough to identify a FNG and get it fixed. I preferred Arun's scooter because of the fact it was a known good scoot and genuinely low run (just 24k kms).

This is how it looked like at Aruns backyard:

First look after removing the cover after many years:


The original key:


The rusty meter:


Look at all the rusty extra fittings and cement spots all over the scooter:




A the FNG:





Initially, we thought just cleaning carburetor, tank and pouring fresh petrol would suffice. It wasn't the case and mechanic had to work on unjamming the kicker(We weren't present when that work was done).

[funkykar]

With the scooter being able to run, we noticed that there was a very harsh noise from the engine bearings. Though it rode perfectly, the irritating and harsh noise was killing all the fun. Also, noticed that the fitness of the scooter had lapsed as they were not using it since few years. Now, I had to find a good mechanic to set the scooter right. I had no clue where to start. All I knew was car mechanics. I asked all my mechanics who couldn't refer me to any good scooter mechanics. They did refer me to some places but those garages were least interested in old vehicles like this scooter and preferred only Activa/Deo.

While researching, I needed some spares like mat and other things. Some how found the spares shop nearby. The shop owner was a nice chap and referred me to a mechanic nearby. He said he has the shop since 35 years and only this one mechanic is best when it comes to Bajaj Scooters. There was no 2nd best also in say 3-4 km radius. He vouched for him fully.

I took the scooter to Sunil. He immediately said this is bearing noise and engine has to be opened. He was reluctant in doing so. He was saying this is expensive work. Once engine is opened there are something we proactively need to change and we may unearth few other things to change and all. He said why you want to spend so much look for another Chetak you will get at same price of the work needed. He was seeing me from same perspective of his many other customers who are rightly reluctant to spend more on scooters. Then he understood I am passionate about this and not worried about petty expenses, he agreed. I told him upfront I very curious and want to watch him do the work. He was elated and said it will be my pleasure. He said he will start work any time in next 2 days where he gets a dedicated 3-4 hours time at a stretch and he would call me. He liked the interest I was showing and some how he made it happen the very next day morning 9AM! I was elated and was with him all day watching him remove the engine apart. The was he executed I could understand how knowledgeable he was and organized. Some pics while he downed the engine:

Mechanic starts work to remove the engine, starting from side cover going off and carburetor removal




Other side of scooter, he removed the wheel and drum and also noticed brake shoes were quite worn



The Scoot without engine



The Engine and further dismantling the engine














The gears




The faulty bearings (marked in blue) that was causing such a noise:

[funkykar]

Mechanic after thoroughly checking noticed the Connecting Rod to have a lot of play and for some strange reason it was full of rust. He asked if the vehicle was submerged any time. I said never! He too said it was strange that only connecting rod was rusted badly and said may be poor quality control of factory. He replaced the bearings, connecting rod, clutch and few other minor things.

The meticulous process of assembling the engine. He always prefers to do it after hours so he is not disturbed by walk in customers






The packing set:



The new Connecting Rod visible here:

[funkykar]

Once all work was completed, the scooter rode like a charm. It surpassed all my expectations and really rode better than a new Bajaj Scooter when it was available new. I felt I was very lucky to identify the mechanic who made this happen! Here are some pics after the engine work.

[funkykar]

Now that the Scooter ran beautifully, it was time to set the papers in order. To my shock, to fix the paper work or mean renew fitness was a super expensive thing. Just penalty of 300rs * 25 months was to be paid long with the fees for FC and smart card!! Refer to an earlier thread I had created on this RTO penalties(https://www.team-bhp.com/forum/stree...-services.html (Multi-fold fee hike for various RTO services)). I felt a bit devastated. It was freaking costing more than price of a used Bajaj Chetak! It did not deter me and I made up the courage to pay it and update to make it road legal and also renewed insurance.

When I went for the Fitness Test by myself, the inspector failed the Fitness. He was a very nice guy who checked every aspect of the scooter. He actually liked the fact that everything worked well. He just said the front bumper is too very faded and so is the handle. Just get this over coated and your scoot will be through. I felt fair enough and returned. Pictures taken on morning of day of inspection:

Added the new leather covers for the side shield and front dickey to enhance its looks. Of course, I gave it a generous bath with a good car detergent.










The odd looking and badly faded bumper very visible here(Even after I applied some rubbing compound and polishing):






I visited my mechanic who introduced me to next door tinker and nearby painter. I wasn't interested in just repainting handle and mudguard. I inquired the costs for full overcoat. I got a quote and painter too saw some passion in me and asked why not go for a full paint job and he gave a quote for that as well. He showed many vehicles he had painted and his work spoke a lot. He was absolutely good with it.

I left the scooter there and thought about it for 2 days. In fact I was thinking which color to repaint to lol. Spoke to the tinker (very little tinkering was needed) and painter and chose a different color.

[funkykar]

Now that I got the engine work done, paid hefty penalty and FC fees and decided to do a full paint job, it only meant my budget was going unreasonably north. This also meant, I would have to go for new fittings, new rims and new tyres to make it a full package and end to end restoration and make it brand new. I thought and thought several times and very hard. Finally, listened to my heart that really said it wants the best possible scooter.

The work began super quick, starting with the tinkering



The only main place where tinkering was needed on left side of the floor, rest was minor










Mechanic had already removed all the fittings before tinker guys work









Under the seat, surprisingly less rust

[funkykar]

The shade card was shown to me and I had the most difficult task of selecting a color









I finally selected the VW Carbon Steel (Grey)


\
The work by paint team started in full swing












The petrol tank being worked upon



The floor is ready!



The side panels and front dickey ready to be painted






The rest of the Scoot looks ready to be painted

[funkykar]

After the base coat was applied, I took pictures of the Scooter from all possible angles.






















Sadly, I wasn't present on the day the painting happened. I couldn't capture the pictures of the work being done.

[funkykar]

After the paint work was completed, it was back to the mechanic for the fittings.









The gloor looked so neat and level now!



I chose to install new leather for the side shields and front dickey!

[funkykar]

I also chose to install new rims and new tires. After all the apprehensions of how the chosen color would look like, my nerves calmed after seeing the final outcome. I was totally ecstatic and simply loved the way it appeared. I fell in love with the scooter again and again. By this time, it was not only love but I was OBSESSED! I simply couldn't wait for the work to get completed and go for a spin.

the Final Product After Completing The Full Restoration







Arun1100 on the Scooter:


Me on the Scooter:



My 1.5 year old daughter with my niece:



Finally, a selfie with my mechanic:



Every now and then I receive a smile acknowledging the brand new looking scooter from fellow motorists. That apart, most motorists in traffic ask me what I mileage I get

In last few weeks at least 2 of them asked me if it was brand new and if Bajaj started making Chetak again

[funkykar]

Though my mechanic said a running in is not needed as bore wasn't touched, I still chose to be gentle with the Scoot for the first couple hundred kilometers. In my earlier Scooter in late 90's, the long rides for us used to be to ride up to some dhaba's around Yelahanka (15-20kms range) and occasional ride up to Nandi Hills. It used to be quite a task as the roads werent as good as now.

One fine afternoon, I got reminded of a ride I did to Nandi hills may be in 1998 and quickly decided to do it again and solo. As the scooter was as good as brand new, it needed no preparation. I just checked if spanner to remove wheel in case of puncture was there and if I had plug spanner. Had both. Thats it. I started in the afternoon and was such a pleasant and beautiful ride reliving my first ride 20 years ago. Here are a host of pictures I captured.

On elevated road to Airport



Stopped for a mandatory photo shoot near Devanahalli





Stopped for a snack. At the parking of hotel Nandi Upachar





The Sambar for the idli was piping hot and yummy!!



Stopped for another photo shoot while ascending:








At one of the curves enroute:



A beautiful view:



Time for a Selfie!



After passing a curve



After finishing all the hairpins, at the entrance on top of Nandi:



Captured the sun set while returning



An app I was running to capture average speeds



During the entire process of restoration, I was questioning and doubting all my decisions especially as it involved many thousand rupees. I have now completed close to 1500kms on this Scooter. 500-700 kms after engine work, before complete restoration and around 800kms post full restoration. My heart was always satisfied, now my mind also is in line with heart and is satisfied completely. Whoever said money cant buy happiness should have put a conditions apply *

[funkykar]

When it comes to the engine and bore, its simply doing fantastic. Even in city I can get to higher gears damn quickly! I ride in 3rd and 4th gear literally 40-50% of the times even though I live in heart of city in Bangalore and experience extremely high traffic. My Access 125 gives around 25-26, Deo and Active deliver about 29-30.

This Scooter surprised me with its mileage figures. Its been giving me around 32kmpl with ease. On the Nandi Hills ride, it surely has given me 55+ kmpl.



Above is a data sheet I maintained to arrive at the mileages. The one that reads 48kmpl includes Nandi Hills ride + city riding and still was 48kmpl.

[SmartCat]

Moving thread from Assembly line to Motorbikes forum. Thanks for sharing, Karthik!

[Lalvaz]

Congratulations on having the passion to restore a real classic like the Chetak. It’s a simple vehicle which has surprisingly high torque. I used to ride one for a few years and boy, do I have some fun memories with the ride!

Interesting that you point out the higher mileage figures as compared to the current crop of scooters. Shows how even the old 2 stroke engines could give better mileage and yet are condemned for being more polluting. No one thinks about the pollution and environmental consequences of scrapping perfectly running vehicles and swapping them with new ones.

Wish you many kilometers of safe riding on her. Be very careful during the rains- I have managed to skid on a wet road and it wasn’t something I’d like to revisit.