[sushil_n79]

Originally Posted by anjan_c2007

sushiln79
Sushil, you are welcome.So the restoration job is progressing. Monsoon creates some problems of course.

The figure is for illustration as not much had changed from the Bajaj 150 to the Bajaj Cub as far as the front suspension is concerned:
Attachment 584702
pic source connect.in.com

Thanks again Anjan sir,
I am always amazed at how well you are able to explain things.
regards
Sushil

[sushil_n79]

. It would be great if you can upload the scanned service manual since we don't have that any more.

Here is my second attempt at uploading the photo.
Attachment 584690[/quote]

hi again mate

i have the vespa manual in pdf form but its pretty similar to all vintage bajaj models as the design was same i can mail it to you if you want.

wow it looks great in its present avatar.... please don't part with it

my fathers 1984 Bajaj Chetak failed to start. He has been using it almost everyday to go to the market. The mechanic who usually takes care of it said the carburetor was faulty and has to be changed. He said there is still no guarantee about other parts even if he changes the carburetor. He also suggested that he could 'take it off of our hands' while not mentioning any particular amount (guess he wants it for free)

If a mechanic is truely confident of his skills he will never give up no matter how big the challenge is. In this case since I have not seen the vehicle I may not be able to comment on the same but i am sure that since its a daily runner a good clean of the spark plug and change of magneto points should make it a drool maal for now even my scooter had the same problem. one thing i did is to change the points,clean the spark plug once in 2 months and to stop using 2t oil available at the petrol pump. i only use shell2t pouch 1 pouch for 2 litres petrol and even when I start my scooter after 20 days it starts in 2nd kick after tilting it to 45 deg

thats nice if you are planning to get her restored ..all the best. i can already see her done up like this



please pm me your e mail address so that I can mail you the manual.

Take care and keep smiling always

Regards
Sushil Narayanan

[anjan_c2007]

Originally Posted by sushil_n79

Thanks again Anjan sir,
I am always amazed at how well you are able to explain things.
regards
Sushil

Welcome again Sushil. Do ask anything where I can help with whatever little I know.
I also hope you know that the wheel discs were of body colour those days. It was only in the early 1980's after the launch of the Bajaj Super (1978), that they followed the silver grey and later light grey paint for the wheel discs.The light grey wheel discs lasted till the last Chetaks and Supers were made.

[sushil_n79]

Originally Posted by anjan_c2007

Welcome again Sushil. Do ask anything where I can help with whatever little I know.
I also hope you know that the wheel discs were of body colour those days. It was only in the early 1980's after the launch of the Bajaj Super (1978), that they followed the silver grey and later light grey paint for the wheel discs.The light grey wheel discs lasted till the last Chetaks and Supers were made.

Hi again Anjan Sir,

Thanks for reminding me on this , yes the Wheel Rims were of body colour only. I have already told my painter that I want him to do it that way and will re-instate the same once the painting work starts.

Take care and keep smiling always.

Regards

Sushil Narayanan

[plain.vanilla]

Sushil, I got the scooter repaired. It was indeed a problem with the carburetor. Initially I was looking for a new carburetor which would have cost anything from Rs.550 - Rs.950 but a local auto shop salesperson suggested that we try the carburetor repair kit which basically consists of a float, nozzle and a rubber gasket for Rs.150. That worked for us. Also cleaned the spark plug.

Originally Posted by sushil_n79

. it starts in 2nd kick after tilting it to 45 deg
Reminds me of a Sardar joke where he takes a cue from his Bajaj scooter and helps to launch a NASA rocket by first tilting it to 45 degs

thats nice if you are planning to get her restored ..all the best. i can already see her done up like this
Thanks. The scooter in the picture looks very similar to the original look of the one we have except for the orange turning lights and the box up front. We have an open basket instead. Still making inquiries to find someone who can do the work

please pm me your e mail address so that I can mail you the manual.
I don't have pm privileges right now. Please send the manual to fascin8ing {at} msn {.com}

[sushil_n79]

Originally Posted by plain.vanilla

Sushil, I got the scooter repaired. It was indeed a problem with the carburetor. Initially I was looking for a new carburetor which would have cost anything from Rs.550 - Rs.950 but a local auto shop salesperson suggested that we try the carburetor repair kit which basically consists of a float, nozzle and a rubber gasket for Rs.150. That worked for us. Also cleaned the spark plug.

He brother

Congratulations on bringing her back to life....really happy for you.


Wish you were in hyderabad...We have some really good mechanics here who still work only on vespas nad vintage scooters , they do not work on the newer activas or bikes.

all the best with the restoration

takecare and keep smiling always


regards

Sushil Narayanan

[sushil_n79]

HI all

I am back with loads of updates for you all Sorry for the delay as was real busy with work at office.

My denting guy has worked on the middle flooring and has smoothened it up he has got the floor board which looks like steel really thick gauge without the holes , I am planning to go this time without the holes.

The next step is to completely examining the body inch by inch to see any visible traces of rust /corrosion and replace the metal with new ones wherever required to get a totally rust free body .Even the rear mudguard needs attention as is corroded with holes so he will be changing that corroded section .Some pictures for you all.















The rear number plate and tail light section mudguard as seen from inside













More Updates to follow soon

Take care and Keep smiling always

Sushil Narayanan

[sushil_n79]

Hi All

I am back with some surprising updates

In the meantime my mechanic called me to show the reason why the Fuel knob when left in ON/RES state even for 5 minutes used to lead to starting problems (He figured this issue out even without me telling him about it). Seems the petrol chamber near in the crankshaft had gone for a toss because of which the petrol used to seep into the chamber before the process of combustion started which lead an engine overflow and to prevent this switching off the petrol knob even in short stoppages was becoming a habit. Apart from this he noticed certain other problems like the engine oil clogging the rear wheel break drum, and flowing out thereby making the rear wheel rim totally black and sooty, the kick-shaft slipping, and most importantly the crank shaft rubbing inside the engine casing due to faulty main bearing.. Therefore had to go for a complete engine overhaul which I .after riding one of the scooters completely done up by my mechanic 10 months ago. And I can tell you all that it was smoother than my bike and the best thing was its sweet whistling sound as if it was a brand new scooter some pictures for you all.

























More Pictures follow soon.....

[sushil_n79]

More Pictures follow soon.....[/quote]

























More Pictures follow soon.....

[sushil_n79]

More Pictures follow soon.....[/quote]

























So for the engine side the following is in store:
1. Dismantling the engine completely(already done)
2. Removing the vital parts like crank shaft , bore and sending the same for lathe work.
3.There was hole in the engine foundation bar ()
to accomodate the silencer and the orginal nut on which the silencer is broken, so to correct my mistake that i had done 10 years ago , my mechanic is going to seal that hole and weld a new nut to the foundation bar
4.Zinc plating the engine compartment to give that aluminium shine.outside
5. New set of 6 bearings (Sealed ones from TATA to prolong bearing life)
6. New set of piston and Rings
7. New kick-shaft
8. New clutch plates.
9.New gear changer in the gear box.
10. New set of all rubber parts like oil seals ,kick shaft rubber etc.
11. New packing kit
12. New silencer
13.Complete reassembling the engine.

Hope the final outcome is as expected.

That is all for now.
I will be back with the updates on the body soon.
Take Care and Keep smiling always
Regards
Sushil Narayanan

[sushil_n79]

5. New set of 6 bearings (Sealed ones from TATA to prolong bearing life) the difference between the normal bearing and sealed bearing can be illustrated as under:
Normal bearing :




Sealed bearing :



More updates on the body front to follow soon.

Take care and keep smiling always

Regards

Sushil Narayanan

[Scarlet_Rider]

Hey Sushil,

Good to see that you and your mechanic are leaving no stone unturned in the restoration of the Bajaj 150. One suggestion: Please get hold of a decent digicam to capture the wonderful restoration of your scooter. Will try to drop down one of these days to check out the work.

Regards and Keep Revving,

Rahul Waghmare.

[sushil_n79]

Originally Posted by Scarlet_Rider

Hey Sushil,

Good to see that you and your mechanic are leaving no stone unturned in the restoration of the Bajaj 150. One suggestion: Please get hold of a decent digicam to capture the wonderful restoration of your scooter. Will try to drop down one of these days to check out the work.

Regards and Keep Revving,

Rahul Waghmare.

Hi Rahul bhai,

Thanks for the encouragement., i ll surely try to source a decent camera to capture these precious moments. Tll the tie i get it tried to increase the resolution of my existing camera on the mobile phone to see if it makes any difference.
Hey , It would be my pleasure if you drop in one of these days to check out the work, just give me a call whenever you want to check out the progress.

Since work is going on at a regular pace will keep updating the thread .

Keep watching this space.

Regards

Sushil Narayanan

[sushil_n79]

Hi all

Good day...

On the body front the next step is to apply the primer[Red Oxide] on the middle flooring and to fix the flooring board on the same.(done as of now) Some pictures for you all….

























This completes the preparation of the complete body for denting

Regards

Sushil Narayanan

[sushil_n79]

Hi All

Need help to get this tail lamp assembly in hyd attached image below for reference..Someone please help me Ram bhai, Bala, Rahul and everyone else please help me in getting the same




Thanks and Regards

Sushil Narayanan