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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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 Bajaj Chetak power loss and now does not run |
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Howdy folks,
Have 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.
Suggestions? Questions?
Jeremy
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces)
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Mon Apr 04, 2011 4:36 am |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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I should note that when the bike broke down I suspected it was an electrical issue. The bike had a tune-up not terribly long ago and the spark plug looks good, but I wonder if the spark plug cap is bad. Is that a possibility?
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Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Tue Apr 05, 2011 4:43 am |
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dirkhunt
Joined: 15 Oct 2009
Posts: 153
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VERY possible. Make sure it is all the way in to the coil if someone was a little ham fisted they may have yanked it out some.
Another thing to check is the bolt that holds the coil on (it also functions as a ground for the coil)
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See now, this is why mad scientists are generally less desirable than your common or garden variety scientist. |
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| Tue Apr 05, 2011 9:41 pm |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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VERY possible. Make sure it is all the way in to the coil if someone was a little ham fisted they may have yanked it out some.
Another thing to check is the bolt that holds the coil on (it also functions as a ground for the coil) |
Will check it out. Though the flywheel side makes a weird air sound when I kick it over. That concerns me. I'm not sure what that can be.
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Apr 06, 2011 5:04 am |
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Grover
Joined: 02 Aug 2007
Posts: 195
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In the middle of the elbow-bend of your carb manifold there's a rubber hose that comes into it. Make sure that hose is not split, and that it's sitting on the nipple thing it attatches to tightly. I had one split and it made a hissing/sucking sound. Phil POC told me that having a vacuum leak there was potentially a big deal as it would heavily lean out your mix, might be bad for your top end. I ended up plugging that hole up on that bike rather than trust that little hose.
My grey-market Chetak doesn't even have that hose, and the manifold is solid with no opening there.
can you move your ear down to ground level and try to pinpoint the source of the sound?
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| Wed Apr 06, 2011 8:14 am |
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dirkhunt
Joined: 15 Oct 2009
Posts: 153
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good call GROVER
_________________
See now, this is why mad scientists are generally less desirable than your common or garden variety scientist. |
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| Wed Apr 06, 2011 1:39 pm |
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rufusswan
Joined: 29 Sep 2007
Posts: 1732
Location: Taneyville, Missouri |
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The sound of a motor sucking in air even when nothing is wrong, is actually quite loud, and when you think things are wrong your hearing gets hyper-sensitive too  If the motor is not firing you can also hear odd sounds coming out the exhaust.
So you can also check the exhaust connection at the heads, the valve covers, make sure the carb and intake are secure, and the airbox connection to the carb.
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"The trick to thinking is the ability to be able to stop thinking." - actual wisdom found on the web !!
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| Wed Apr 06, 2011 1:49 pm |
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Ronin
Joined: 25 Mar 2008
Posts: 117
Location: Royal Oak, Michigan, USA |
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If all else fails, throw your spare CDI on it and see what happens. When I bought mine, it had an 'intermittent' CDI that was a bastard to track down. Finally swapped a know-good one and bang, it started right up.
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Ronin
Rovers SC
1981 Vespa P200e
2002 Bajaj Legend
2011 Genuine Blur
Examiner column: http://www.examiner.com/x-3223-Detroit-Scooter-Examiner
IMS blog: http://bit.ly/maAW9D |
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| Tue Apr 12, 2011 9:18 pm |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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Guys, repaired one scooter and am finally getting back to this one. A while back I looked for the tech (in the correct forum) info on which spark plug cap to replace the stock one with. I think I should start there. Would one you point to the link with the list of replacement option spark plug caps so I can hit the auto store and replace my stock one?
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Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jun 29, 2011 2:12 pm |
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rufusswan
Joined: 29 Sep 2007
Posts: 1732
Location: Taneyville, Missouri |
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Under "Maint and Service" forum look in the 'Parts List' for details.
_________________
"The trick to thinking is the ability to be able to stop thinking." - actual wisdom found on the web !!
http://zenhuckfinn.wordpress.com |
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| Wed Jun 29, 2011 4:07 pm |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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Under "Maint and Service" forum look in the 'Parts List' for details. |
Thx found it. Which one, do you prefer? 120 degree?
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Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jun 29, 2011 5:26 pm |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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Update:
I just replaced the spark plug resistor cap with the NGK one. No help. I pulled the spark plug. The threaded tip smells of gas and is a little damp. The spark plug is not terribly old. Maybe less than 150 miles. It's still whitish and has not run enough to develop into the chocolate brown or worse the black. That terribly weird scraping sound is still there. Fly wheel maybe.
I recorded a video of it here for your reference:
http://www.youtube.com/watch?v=iixungFqC4s
I am not sure if you can really hear the sound I am talking about, but the video should give you a much better idea. I kick started my running Chetak with the key out / kill switch on "off" and it sounded like a big breath and powerful too. My wife's Chetak (the one in the video) does not sound like that at all.
From here, what are the steps of trouble shooting you recommend I take?
Thanks in advance,
Jeremy
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 12:14 am |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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In the middle of the elbow-bend of your carb manifold there's a rubber hose that comes into it. Make sure that hose is not split, and that it's sitting on the nipple thing it attatches to tightly. I had one split and it made a hissing/sucking sound. Phil POC told me that having a vacuum leak there was potentially a big deal as it would heavily lean out your mix, might be bad for your top end. I ended up plugging that hole up on that bike rather than trust that little hose.
My grey-market Chetak doesn't even have that hose, and the manifold is solid with no opening there.
can you move your ear down to ground level and try to pinpoint the source of the sound? |
Elbow-bend is in good shape.
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 3:14 am |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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VERY possible. Make sure it is all the way in to the coil if someone was a little ham fisted they may have yanked it out some.
Another thing to check is the bolt that holds the coil on (it also functions as a ground for the coil) |
Coil is tightly secured to the frame and appears tha wires are securely connected.
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 3:15 am |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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Could the issue be CDI? How much does a replacement one cost?
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 3:28 am |
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Grover
Joined: 02 Aug 2007
Posts: 195
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Just watched your video. Are You missing some flywheel rivets, like most of them maybe? Failing flywheel rivets was a common problem for '02's, though I've never had it happen to me. Could easily explain a grinding sound if your flywheel is no longer properly moored on it's central axis. I'm not talking about the 4 bolts, but the 6 or 8 little nubs in a ring inside that.
Also I thought your engine wasn't spinning as far as it should after the kick-starts, even not running the flywheel seemed to stop short quite quickly. An off-center or eccentrically placed flywheel rubbing on something could easily explain a lot of this.
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| Wed Jul 13, 2011 8:51 am |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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Just watched your video. Are You missing some flywheel rivets, like most of them maybe? Failing flywheel rivets was a common problem for '02's, though I've never had it happen to me. Could easily explain a grinding sound if your flywheel is no longer properly moored on it's central axis. I'm not talking about the 4 bolts, but the 6 or 8 little nubs in a ring inside that.
Also I thought your engine wasn't spinning as far as it should after the kick-starts, even not running the flywheel seemed to stop short quite quickly. An off-center or eccentrically placed flywheel rubbing on something could easily explain a lot of this. |
Oh my gosh! grover you are correct. All the rivets are missing on the flywheel. Only two are missing the heads, the other six must have fell back inside the flywheel. That would explain why it does not run, correct?
Is there a better quality aftermarket flywheel available?
_________________
Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 3:01 pm |
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rufusswan
Joined: 29 Sep 2007
Posts: 1732
Location: Taneyville, Missouri |
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When the flywheel comes loose, the stator will not work so all electrics are lost. There are some threads around here about fixing the issue. It just needs re-riveted back together and all will be well.
_________________
"The trick to thinking is the ability to be able to stop thinking." - actual wisdom found on the web !!
http://zenhuckfinn.wordpress.com |
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| Wed Jul 13, 2011 4:05 pm |
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JeremyJSutton
Joined: 10 Oct 2010
Posts: 53
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When the flywheel comes loose, the stator will not work so all electrics are lost. There are some threads around here about fixing the issue. It just needs re-riveted back together and all will be well. |
Thank you I will do a search for the threads.
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Jeremy J. Sutton
2004 Bajaj Chetak
1962 Lambretta TV175 (in pieces) |
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| Wed Jul 13, 2011 4:14 pm |
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