Electrical Systems — Taking the Indian out of the Bajaj Chetak Classic

12 Янв 2015 | Author: | Комментарии к записи Electrical Systems — Taking the Indian out of the Bajaj Chetak Classic отключены
Bajaj Chetak
Bajaj Chetak

Bajaj Vs Vespa — comparison

The Bajaj Chetak SL and Vespa are VERY similar in but have annoying differences can drive you bonkers unless you sit and think about how electrics

The biggest difference IS going to be the the later Vespa’s used an type horn whereas the uses the older SHUTTER horn which means you to buy the right switch otherwise horn will simply not

That aside, it is literally a of identifying which circuits do identifying which of those are where in your Chetak and the new switches and bulbs onto circuits.

I used the PX200 diagram above for pretty everything except the horn and light switch.

The Speedo

Pictured above is the pre printed EFL speedo that I used, because it looked good, had directional indicators and was marginally than a MK1 surprisingly which a different headset top or the later type with the printed and car type bulb holders.

It a communal earth for all circuits, the are T5 — 286 which I have everything BUT the indicator bulbs LED’s of the same fitting, you can cut too such as wiring the speedo AND the lights on light from one with a spur feed from the full beam to power the full beam which is a requirement of law here in the UK to working.

It also uses the older type speedo cable isn’t going to snap off the third or fourth attempt to get it

However it is a BIG unit and Bajaj have a lot more free in their headsets than EFL’s do and Bajaj use a lot of wiring in the take that into as I realised after that I have taken all the wiring to behind the horncast instead of the conditions inside the speedo


The Bajaj uses a three wire system is basically a feed which is into the left or right there are plentiful supplies of 3 wire out there, using the diagram above you can identify the green and blue wires are and them in easily.

The indicators I have used are cheap pod LED’s I found on simply find which is and positive on each and it is a simple of swapping the wires from one to the making sure the earth and are properly connected.

I would EVEN if the unit is working to invest in a electronic LED capable two flasher relay which about 4 pounds at time of They use less current regulate the system even if a blows and last 100 times than the old relay clicker

You can if you fit a Vespa PX toolbox actually use the PX but you will have to mark make a template and using a cut out the apertures needed for these units, you cannot fit them the Bajaj toolbox which is an inch slimmer on the width and the toolbox actually fouls the where the lights would sit. This is important the profile of the light units is and is designed to fit snugly onto the beading as well as the legshield without leaving a gap. If you put it in the place they will awful and crooked.

If you are looking to remove the cowl then read the below

The hardest and most difficult of this conversion is reaching the frame to get the wires off the panel you will need to remove the tank completely and under the drip tray are two spring the individual wires that are on each are your indicator feeds. A simple matter of a nice long bit of wire each and running them the top wiring grommet in the petrol area to outside and wiring your existing lights.

you have the petrol tank out now is a time to replace your hose, Bajaj are very in the hose that you have and you hardly any room to get your out, I added an extra to my new fuel line and can balance the on the lip of the aperture without straining the

That is if you wish to remove pug ugly Bajaj panel on the cowls like I did, it does tidy up the scooter but each to their own, ignore this section if you are with some of the looks.

Bajaj Chetak


Again Vespa and followed much the same here, the difference being on a EFL switch there is no option for lights whereas the Bajaj has a only switch which powers all the basic light such as speedo illumination and lights.

I used a LML Star 2T 5 switch for the lights with the light enabled with the on function.

Be very careful of the terminals on these switches, thread out REALLY EASILY. Be be very gentle.

The wiring is straight forward and you will you can strip one defunct circuit if not two out you have worked up your setup as you are wiring directly to as opposed to passing from one to another as the Bajaj way does.

For the lights I used a double Eye light unit which back light, plate brake and indicators all in one, its LED and will use virtually no current at I have had my unit on two years and in time I would have at two, three sets of maybe, LED conversion is not only as they are more reliable and can up to 24v before they really problems but over the long run are cheaper too and won’t leave you lights on a dark night as a failure will.

Starter system

This is the part of a Bajaj — conversion as they both use the type plunger switch two wires, it is a simple case of off the old switch and wiring in the new and your will work just the

Fitting the switch will some drilling under the or indicator switches where should be a flat area, you need some slender and bolts, make three two for the bolts and one for the wires and I would sealing it all with some silicon sealant to keep wet and from getting into the or causing the throttle tube to

You must also ensure the throttle tube isn’t to foul the wires or break You will need to mark out a area in the tube for where wires will go through, to your other cutouts to get an of how big that cutout needs to be as the is just for the wires to pass the height of the cutout is the max travel of the throttle cable and work out accordingly.

This write up into account that the is a bit scooter and mechanically savvy, attempt things beyond means or understanding and give me an for further clarification on the contact

Bajaj Chetak
Bajaj Chetak
Bajaj Chetak
Bajaj Chetak

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