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Handlebar/FrontWheel Alignment

 
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Handlebar/FrontWheel Alignment
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rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Handlebar/FrontWheel Alignment Reply with quote
All,

Have an '02 Chetak, and when underway I can tell that the handlebars are off center by a few degrees. I can see it, which is disconcerting, and the headlight also points a few degrees too far to the right. I assume that this condition is not normal.

I have the manuals downloaded and it appears as though I can dismantle some stuff and get to a large nut to make a minor adjustment.

Is there any real trick to this? Will I see any fork/HB alignment marks?

Any help will be appreciated.

Paz

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Thu Oct 04, 2007 10:45 pm View user's profile Send private message Send e-mail MSN Messenger
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
There is a bolt directly below the speedometer, slightly to the right.

Loosen this bolt up... but not too much. It has a nut on the other side. If the nut comes loose, you have to take the whole headset apart to get everything back together again.

Now head around to the front of your scooter, put the fender between your legs, and adjust the handlebars until they're straight.

Don't worry if you're off by one or two degrees... It's not really easy to get everything to jive perfectly. Just get it to where you feel comfortable with it and then tighten up the bolt again.

Hope this helps.

-Matt
Thu Oct 04, 2007 11:32 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
Matt,

I was adjusting the mirrors yesterday and saw that bolt, I forgot to mention it in my post. Cool, that you can adjust after all things are bolted, or if somehow you wack the front end. I'll have it adjusted in a few minutes and in a while it'll be dark enough to finish adjusting headlamp.

Thanks and have a beer on me.

Paz

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Thu Oct 04, 2007 11:41 pm View user's profile Send private message Send e-mail MSN Messenger
scootermike



Joined: 25 Mar 2007
Posts: 525
Location: portland,oregon

Post Reply with quote
its easier if you have a friend help one to alighn the wheel the other to tighten.
Mike
Fri Oct 05, 2007 12:31 am View user's profile Send private message Visit poster's website
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
Friends are nice, but I got'er in about 2 minutes. Just loosened the nut and tapped the bars a few degrees. Now my headlamp is pointing down the road not looking over at the ditch for deer.

I notice yur from Portland. My scoot originally came from Columbia scooters. Still has their round logo sticker on right cowl. Still has the barcode labels, wiring diagram, and instructions for correct operation of petcock. This puppy is 4 years old and still thinks it's on the showroom floor in Oregon!

Paz

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Fri Oct 05, 2007 1:36 am View user's profile Send private message Send e-mail MSN Messenger
scootermike



Joined: 25 Mar 2007
Posts: 525
Location: portland,oregon

Post Reply with quote
Mine came from the same shop, they are about the biggest scooter dealer in portland we have 6 or 7 not counting the motorcycle shops your bike has gone a long way.if you ever have problems finding parts Tim at columbia takes phone orders all the time, he knows bajaj scooters I have never had to wait more than a day or two for parts, only when he had to special order something. thats not to often he keeps quite a bit in stock.
Mike
Sat Oct 06, 2007 3:43 pm View user's profile Send private message Visit poster's website
inkdog



Joined: 03 Aug 2007
Posts: 27
Location: Seattle area

Post Reply with quote
Quote:
There is a bolt directly below the speedometer, slightly to the right.

Loosen this bolt up... but not too much. It has a nut on the other side. If the nut comes loose, you have to take the whole headset apart to get everything back together again.


Guess what I did Embarassed Can anyone walk me through the process of of getting to that nut and putting it back together? I can't believe I did that Mad
Sat Apr 26, 2008 4:17 am View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
inkdog,

Surely someone who has done this will respond.

Download the repair manual and the parts list so you can get some view of how the front steering assembly is put together. I've never done it, but it's not as complicated as rebuilding a tranny, so don't despair. Plate and page #'s below are from the parts manual.

Plate 40, page 57 shows the full headset assembly, including the nut (item #3) that dropped off. Plate 38, page 55 shows the steering column assembly that drops out the bottom of the frame once the nuts and bearing are removed from above.

I think you have the handlebars ready to pop right off Wink since you lost the nut that holds it on. Pop off the top of the headset and disconnect all the cables. Remove the nut, bearings, etc. at the top of the steering column, then it should drop out of the frame. The nut your are seeking should fall right to the ground.

While you have it apart, you might grease the bearings. I don't know if there is any way to attach that damned nut so it doesn't fall off, but one might think that the engineering team would have given this some sort of consideration. Maybe superglue or permatite might do it.

It will appear like you are messing with lots of parts, yea, but it is not as complex as it looks. It will all come apart easier than it goes back in. You will have to learn how much tension to put nuts and bearing races. Reassemble slowly, step by step. You can always redo the steering assembly install until you get it right. The upper bearing race (plate #38,#10) should thread on. Finger tighten until it starts to bind, then back it off a little. You'll get the hang of it. Then you can install the last washer and locking nut (#11 & #12). Test again, as tightening the last nut can over-tension the entire assembly.

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Sat Apr 26, 2008 6:13 am View user's profile Send private message Send e-mail MSN Messenger
inkdog



Joined: 03 Aug 2007
Posts: 27
Location: Seattle area

Post Reply with quote
Well it wasn't as difficult as I imagined it to be! Had to take off the mirrors and the 5 screws underneath the headset. Once you get the headset off it is quite clear what nut needs to be pushed back in place. I tightened it up most of the way with the headset off and finished it off after reassembling everything. Really no big deal, just a pain in the #**!
Sat Apr 26, 2008 6:40 am View user's profile Send private message
chetakinator



Joined: 29 May 2014
Posts: 15
Location: Oakland CA

Post Reply with quote
im attempting to look for a short in my wiring since i keep blowing fuses, and im looking at the wires that go up through the steering mechanism. can anyone tell me how the heck to remove the final bolt ("M" in the service manual exploded view, with the captive square nut "L") holding the bottom of the assembly on the fork? im stymied...

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Sun Jun 29, 2014 3:43 am View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
I'm guessing that is the 'pinch' bolt that is loosened to allow you to get the headset square to the wheel. It should come right out. Just loosen and the headset should come off the top of the fork if that is what you are attempting.

If not, some more explanations are in order.

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Mon Jun 30, 2014 12:35 am View user's profile Send private message Send e-mail MSN Messenger
chetakinator



Joined: 29 May 2014
Posts: 15
Location: Oakland CA

Post Reply with quote
that sounds like the one, closes the clamp at the bottom of the head assembly around the steering column? cant get the bugger out of there and it needs to be removed to take the top off.

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Mon Jun 30, 2014 12:51 am View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
Since you know that turning a bolt counter clockwise will remove it from it's nut, you have this old guy confused. Or is it that you cannot loosen the pinch bolt/nut assembly?

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Mon Jun 30, 2014 1:41 am View user's profile Send private message Send e-mail MSN Messenger
chetakinator



Joined: 29 May 2014
Posts: 15
Location: Oakland CA

Post Reply with quote
it was loosened ok, just that now my handlebars dont hold a strict center and the bolt wont shimmy out unless it has a straight path through two concentrically swiveling metal apparati. i held the wheel with my knees and turned the handles straight and voila, got the bolt. still dont see a short, but i seem to have gained access to narnia. Very Happy

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