[sushil_n79]

Some more pictures:



Thanks and Regards

Sushil Narayanan

[sushil_n79]

Hi All

Its been sometime since I have updated the current status of the thread After the HCSC meet on the 18th May 2012, Since the rainy season was approaching I had cleaned up my scooter and covered and kept it in Hibernation to ensure that I di not use it in the rainy season to prevent underbody rust.

Two weeks ago lifted the cover and cleaned up the scooter as some dust had accumulated

However on one of the days because of heavyrains there was water which was logged in our parking area and the scooter was standing in water which was like 2inches deep but did check the bottom of the engine it was not submerged or near the water level.

Yesterday , Since the rainy season was over I wanted to start the scooter and wake it up by moving my scooter a bit to clean it and to my horror the following has happened.

1. The gear Lever is stuck on 1 st gear cannot get it to neutral.
2 . The Kick lever does not operate seemed to be jammed.

The vehicle had covered 850 kms after the engine rebuild.
My question is If the vehicle is kept idle for 3 - 4 months will the engine cease. as I have been really cautious on the useage of @T oil and have been only using Shell 2T Advance Oil

As advised by my friend and fellow team bhpian ,Rahul
the startup process which is also mentioned in the owners manual of both bajaj150 and vespa 150

I will try the following.tomorrow:
1. remove the spark plug the wire of which is currently disconnected.
2. Open the carburrettor case and remove the air filter.
3. Get a shell 40 ML 2T pouch and pour half of it in the cylender and the
shutter inside the engine.
4. Get some fresh grease and ensure that the gearbox is properly
lubricated and not dry .
5. The above ensures that if at all there is any moisture inside it will not
cause much harm.
6. Once in neutral I ll try to engage the kick lever a couple of times to
ensure that its working properly.
7. Clean the sparkplug, fit it properly ensure that the wire is connected
8. Fill up petrol in the tank, with 3% oil mix. I have been adhering to 3%
mix as the engine was newly rebuilt. after first service will decide
what to do next.
9 Try to start the vehicle to see if things are fine.
10. Maybe will take her for a small ride to ensure that Its back in motion.

Hope I have not missed any step in there. Experts please advise.
As of now I have not spoken to my mechanic as some of the logical resoning that they put up are really not understandable.

Getting really worried about the same Hope there is no major damage .

Has anyone else faced a similar kind of issue , If yes please share the inputs on what was done to resolve the same.

Anjan Sir, looking forward to your assistence.

Thanks and Regards

Sushil Narayanan

[Scarlet_Rider]

Originally Posted by sushil_n79

The gear Lever is stuck on 1 st gear cannot get it to neutral. The Kick lever does not operate seemed to be jammed.

This usually happens when a scooter is laid off for a long period. I had also faced this issue with my Bajaj Super which was not used for more than a year. Pouring some 2T oil in the spark plug hole and the carburetor shutter should resolve the issue. Get the scooter thoroughly serviced once you use it for a few days, probably after the 1000 km mark.

Originally Posted by sushil_n79

Get some fresh grease and ensure that the gearbox is properly lubricated and not dry.

I hope you are referring to the gear shifter box and NOT the gearbox. Can't imaging grease being filled in the gearbox!! By the way also check the oil level in the gearbox and top up with good quality SAE 30 oil if required.

Regards and Keep Revving,

Rahul Waghmare.

[ilangop]

Originally Posted by sushil_n79

Yesterday , Since the rainy season was over I wanted to start the scooter and wake it up by moving my scooter a bit to clean it and to my horror the following has happened.

1. The gear Lever is stuck on 1 st gear cannot get it to neutral.
2 . The Kick lever does not operate seemed to be jammed.

The vehicle had covered 850 kms after the engine rebuild.
My question is If the vehicle is kept idle for 3 - 4 months will the engine cease. as I have been really cautious on the useage of @T oil and have been only using Shell 2T Advance Oil

As advised by my friend and fellow team bhpian ,Rahul
the startup process which is also mentioned in the owners manual of both bajaj150 and vespa 150

I will try the following.tomorrow:
1. remove the spark plug the wire of which is currently disconnected.
2. Open the carburrettor case and remove the air filter.
3. Get a shell 40 ML 2T pouch and pour half of it in the cylender and the
shutter inside the engine.
4. Get some fresh grease and ensure that the gearbox is properly
lubricated and not dry .
5. The above ensures that if at all there is any moisture inside it will not
cause much harm.
6. Once in neutral I ll try to engage the kick lever a couple of times to
ensure that its working properly.
7. Clean the sparkplug, fit it properly ensure that the wire is connected
8. Fill up petrol in the tank, with 3% oil mix. I have been adhering to 3%
mix as the engine was newly rebuilt. after first service will decide
what to do next.
9 Try to start the vehicle to see if things are fine.
10. Maybe will take her for a small ride to ensure that Its back in motion.

Hi Sushil,
Hope the stuck gear lever is due to cables getting jammed due to the rains. Not a big problem though.
The Lambretta procedure is to open the spark plug and add few drops of 2T oil inside the cylinder. Half a packet sounds too lavish, you might have trouble starting the scooter.
Though the manual asks you to run in for 500 Kms, it is better to adhere to running in precautions for 1000 Kms. For my Vijai Super I used 5% oil till 1000 Kms and then 4% on every fuel filling. The above data are for a Lambretta. I assume they are the same for the Vespa as well, because they all have the similar Cast Iron bore. The recommendations could be different though, you and Rahul might be knowing them better.

[sushil_n79]

hope you are referring to the gear shifter box and NOT the gearbox. Can't imaging grease being filled in the gearbox!! By the way also check the oil level in the gearbox and top up with good quality SAE 30 oil if required.

Regards and Keep Revving,

Rahul Waghmare.

Hi Rahul bhai

thanks for the updates. will sure do check the oil in the gear box. however can you please elaborate whats the difference beween gear shifter box and gear box? Getting a little confused.

Regards

Sushil Narayanan

[Scarlet_Rider]

Originally Posted by ilangop

Though the manual asks you to run in for 500 Kms, it is better to adhere to running in precautions for 1000 Kms. For my Vijai Super I used 5% oil till 1000 Kms and then 4% on every fuel filling.

I have owner's manuals for both Bajaj 150 and Bajaj Super. Both give the running in periods as 2000 kms (1200 miles). However the best practice is to extend this further till 2500 to 3500 kms since quality of the bore and piston used may not be on par with the one that comes with a new scooter. Though the manuals give the fuel mixture as 2% for pure mineral oil and 3% for self mixing oil, it is safer to stick to a 4% to 5% mixture as you rightly said.

Originally Posted by sushil_n79

Can you please elaborate whats the difference beween gear shifter box and gear box?

In simple words, you can see the gear shifter box from outside whereas to see the gearbox you need to open the engine. The following pictures from my Bajaj Super manual will help you.

Regards and Keep Revving,

Rahul Waghmare.


The highlighted part is the gear shifter box which is usually lubricated with grease. The two gear cables are connected from the handle bar to this box.



The highlighted areas show the insides of the gearbox which are lubricated by the SAE 30 gearbox oil.

[sushil_n79]

Hi all

First of all a big thanks to ilangpop and rahul for quick response to the query and apt solution for my issue
I was on weekend today so thought of working on the scooter.
Did the following
1. tried to move the vehicle with the clutch depressd. after 2 tries back and forth without much effort got the scooter to neutral.
2. Removed the spark plug and cleaned it.
3. Opened the carburrettor case and removed the air filter. since it was getting stuck had to remove the RPM screw as well. ensured that its rotations are counted while opening and while fitting it back to ensure opti,u, tuning.
4. Since my regular brand shell 40 ML 2T pouch was not available opted to Mak T Oil as of now and poured half of it in the shutter and half of it in the spark plug fixing area.
5..Since the packs of Grease were not available left the gear shifter box as it is.
6. Once in neutral and with 2T oil poured in tried to engage the kick lever a couple of times while the cluch was depressed initially and then after leaving the clutch lever to ensure that the oil is properly circulated.
7. Fixed the spark plug carefully ensuring that the thread is not damaged
8. Fixed the airfilter inside the carbuttor first and then the idle screw which was later set to optimum levels.
8. Fill up petrol in the tank, with 3% oil mix.i.e around 81ML oil for 2.65 litres of petrol
9. Turned the Petrol ON
10. Attempt 1 to start the vehicle with 2 kicks ,without Choke= Failed
11.. Attempt 2 to start the vehicle with 1 kick , with choke= Vehicle started but on leavingthe choke lever it shut down
12. Attempt 3 to start the vehice with 1/2 kick and choke = vehicle started. held the choke pulled out for 5 seconds and then gradually increased accelaration. wow it was realy smooth
13 when was idling there was so much smoke coming out of the vehivle while idling that someone might have though this is the muncipality vehicle which normally sprays mosquitto replillent spray in the colony.
after some time the amount of smoke went down and was not visible I hope this was because of the additional oil put in the shutter and the piston. Hope this will not do much harm (Experts please advise on the same)
Took the scooter out for a small ride and ensured that Its back in motion. although as smooth as before I felt the idling rpm needs to be increased a bit as on slowdowns and sudden brakes on cold engine the vhicle was switching off which was resolved once the engine was warm. Experts need assitance on this one as well.

Also just wanted to share the details of the MAK 2T Oil used.

Courtsey : www.maklubes.com

MAK 2T



Description
It is a new generation semi-synthetic, extremely low smoke, environmentally friendly two stroke engine oil. Blended from highly refined mineral base oil & a special synthetic component, and fortified with finely balanced low ash additives. A specially selected diluent is added to ensure instantaneous self-mixing of oil with fuel.
Applications
It is used for all types of 2 or 3 wheeler vehicles and outboard boats fitted with 2 stroke petrol engines / CNG gas.
For gear box application of 2 wheelers, use MAK MULTIGRADE 20W-40.
This oil received On-file status from JASO (Japanese Automotive Standards Organisation) 2-Cycle Oil Standards Implementation Panel for Gasoline Engine Performance Classification (JASO M 345).
Performance Benefits

• Extremely low visible exhaust smoke levels
• Reduced spark plug fouling and exhaust system deposits
• Excellent lubrication under all working conditions, thereby, leading to longer engine life, increased fuel economy, reduced maintenance cost, and above all, reduced environmental pollution

Performance Level

• JASO FC
• API TC
• ISO GC
• T-SL4 Category of IS 14234 (part 1) : 2002

<img id="ImgProd" class="indprdmain" width="160" align="right">


Characteristics IS 1448 Typical Figures Appearance ---- Clear & Bright Colour, Visual Observation ----OrangeDensity @15°CP:160.8797 K.V at 40° C, cSt P:25 8.4 Copper Corrosion @ 100° C for 3 hrs P:15 1a Flash Point, (PMCC), °C P:69 94


Health and Safety
This oil is not hazardous under normal conditions of use. For further guidance appropriate Material Safety Data Sheet may be referred.

Thanks once again for the asstance. I am relaxed and relieved now of the tension.

Regards

Sushil Narayanan

[Scarlet_Rider]

Glad to hear that your scooter is back in action!

Originally Posted by sushil_n79

after some time the amount of smoke went down and was not visible I hope this was because of the additional oil put in the shutter and the piston. Hope this will not do much harm

Whenever the scooter is started after pouring additional oil through the spark plug hole and / or the shutter, it will smoke a lot for some time. This is normal. There is no harm since you have done this as your scooter was not in use for a long time. The only thing that you will have to do is ride the scooter for a few more kilometers and then clean the spark plug. The additional oil poured would have fouled the plug.

Originally Posted by sushil_n79

I felt the idling rpm needs to be increased a bit as on slowdowns and sudden brakes on cold engine the vhicle was switching off which was resolved once the engine was warm.

The engine must be stalling due to the additional oil that was poured. When you clean the spark plug, adjust the idling RPM accordingly.

The only thing that your scooter needs now is good footwear. I have two 3.50 x 8 Ceat Secura tyres lying idle at home. They still have about 70-80 % tread left. You can come and collect them. Remember the line from the movie, The Godfather : "I'm going to make him an offer he can't refuse." Well, if you want the Hyderabadi version : "Aisa offer detu, Nakko nahi bol sakte!"

Regards and Keep Revving,

Rahul Waghmare.

[CAC444]

Originally Posted by sushil_n79

An Appeal to All
This thread is not only a medium for me to present to you all the details of the restoration project but also to tell my story and experiences with the bajaj150.

Hi Sushil,

A really touching story indeed. Quite similar to another one I read of a Morris Minor. I will mention the same thing as I did in the other thread.... "Glad to see that the scooter is still with the family."

Will read the rest of your posts now!

Cheers,
Praveen

[sushil_n79]

Originally Posted by Scarlet_Rider

Remember the line from the movie, The Godfather : "I'm going to make him an offer he can't refuse." Well, if you want the Hyderabadi version : "Aisa offer detu, Nakko nahi bol sakte!"

Regards and Keep Revving,

Rahul Waghmare.

HI Rahul,
Well said, The English version is awesome, The Angrez..(Hyderabadi).version is hillarious
.
Thanks for the Offer though, Yes Indeed I canot refuse this offer can I. Shall try to meet you on one of the weekends and Accept the Offer. Yippie, my sweethert will finally have new set of foorwear, I am excited and waiting to see her in the same.

Regards
Sushil Narayanan

[sushil_n79]

Originally Posted by CAC444

Hi Sushil,
Will read the rest of your posts now!
Cheers,
Praveen

Hi Praveen,

First of all welcome to the thread and Thanks for the compliments.
Yes , it has been a nice experience right from owning the scooter and of course now restoring it and to see it in the former glory.

I shall be keeping you al updates so that anyone who wants to start a project for their scooter, can seek guidence from the same. Though this is my first project, and I am a novice at the same and still learning. But I am sure right now after restoring my scooter,I have Learnt a lot about many of the aspects.

Please feel free fo share your inputs on the same which can be implemented by others in their projects.

Thanks Again

Regards

Sushil Narayanan

[sushil_n79]

Hi All

I am really sorry for being away from the thread for a long time but has been busy restoring my brother in law;s fiat UNo. I will be sharing the link with you all soon.

Just to let you all know had taken my scooter to work today and was really feeling great. I have clocked 920kms as of now on it and very soon I ll be getting the first service done after overhaul at 1000kms. but I must say that even at a speed of 70 it was steady... once again thanks to Rahul bhai for tuning her to this stage. many more rides to come.I shall update the pictures shortly.

Regards

Sushil Narayanan

[Scarlet_Rider]

Sushil, good to hear that the Bajaj 150 is back in action. You took the scooter to work? Great!! Hope you have a safe/covered parking space at office. This is the distance that your scooter needs to do frequently in order to run-in the engine better. By the way, the two 3.50 x 8 Ceat Secura tyres that I had mentioned are still waiting for you.

Regards and Keep Revving,

Rahul Waghmare.

[sushil_n79]

Originally Posted by Scarlet_Rider

Sushil, good to hear that the Bajaj 150 is back in action. You took the scooter to work? Great!! Hope you have a safe/covered parking space at office. This is the distance that your scooter needs to do frequently in order to run-in the engine better. By the way, the two 3.50 x 8 Ceat Secura tyres that I had mentioned are still waiting for you.

Regards and Keep Revving,

Rahul Waghmare.

Hi Bhai

Thanks for the wishes though, yes there was a covered and dedicated parking for me at the jublee hills office since I am working from there at the moment, Yes well said feels good to cover a long distence on the scooter at my own pace especially when time is not a restriction. Yes I still remember the two 3.50 x 8 Ceat Secura tyres that You had mentioned, will definitely pick them up soon.

Regards

Sushil Narayanan

[sushil_n79]

Hi folks

I am back with the updates the updates. a week after the last post I had got the new tyres from Scarlet rider theceat secura 3.50.8 tyres and YES the scooter rides and feels better especially while cornering its more confident now. I will upload the pictres soon

Regards

Sushil Narayanan