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Licensed Joined: 08 May 2005 Posts: 352

Hello,

The old Bajaj engine is running fine. However, I am getting no electrics with or without the battery and with or without the engine running (and all iterations therein). I've removed every bulb on the thing and still get nothing. I've tried three separate fuses and still get nothing. When I look at the wiring, there does not appear to be anything obvious out of whack.

Any constructive advice?

Thanks.

Licensed Joined: 05 May 2005 Posts: 293

Are you running the original regulator/rectifier? We've needed to replace most of the 2002 units eventually.

Licensed Joined: 08 May 2005 Posts: 352

Hey Bob,

I replaced something back in 2005 or 2006 over at Scooterville - I believe it was the rectifier. It was located just behind the battery. I read at a Bajaj use-group site that it might be the voltage regulator or another thing that I can't recall right now (that isn't the rectifier - coil?).

Joe.

Training Joined: 01 Dec 2005 Posts: 28

those old style regulator/rectifiers usually need to be replaced with the newer unit. Is your battery dead? Im pretty sure all the lights run off your battery, but its been awile so i forget.

Licensed Joined: 08 May 2005 Posts: 352

Thanks for the info.

I spoke with another Minnescootarer who mentioned to me that his Bajaj goes total dead without a battery - I'm heading over to SV tomorrow night to get a new battery to figure out if that's the problem.

Licensed Joined: 19 Jan 2005 Posts: 576 Location: St. Paul

A few years ago, I broke a battery (broke the internal plates I assume) on a ride down a very rough gravel road near stillwater. It ran, but basically had no lights.

If the recifier is broke, the battery will not charge and it eventually will not run when the battery dies down.

My guess is the battery. See an Al Kovites battery post below.

Brad

> Subject: Re: [bajajscooter] Is battery necessary?
>
>
> The CDI ignition is completely independent from the battery charging
> circuit. The magneto ignition system does not require a battery to work
> properly.
>
> The major down side of not having a battery is that you have very weak
> lights at idle and too much voltage to the bulbs at higher engine
> speeds. The DOT requires that you have your headlight on all the time,
> and they also specify a minimum illumination level, so without a
> battery and dim headlight, you are illegal.
>
> The battery acts as a buffer to charging voltage variations as well as
> providing correct voltage to your lights when at idle.
> Is the battery really bad or just not charging? Is the charging circuit
> functioning? The manual on our web site will give you instructions on
> how to check it.
>
> I do not recommend running without a battery.
>
> Al Kolvites

Licensed Joined: 08 May 2005 Posts: 352

Hey Brad,

It was very pleasant seeing you the other day. You and Jonathon at Scooterville were exactly correct. The issue was a dead, non-recoverable battery. I put a new battery in at SV at the damn thing started right up.

Cheers,

Joe.

Licensed Joined: 19 Jan 2005 Posts: 576 Location: St. Paul

Glad your's is running. Mine has been down most of the summer, first the clutch, now no spark.

Was cutting out at high rpm, barely got home from the clutch repair, now nothing. Replaced the plug wire, nothing. Checked the service manual and it suggests the HT Coil might be the issue. If not that, then onto the CDI.

Rats.

Brad

Licensed Joined: 19 Jan 2005 Posts: 576 Location: St. Paul

Ann it lives again. Got a new coil, when I was installing it I notice that one of the electrical plugs under the coil appeared to be plugged, but was really loose. Secured the conection and now it runs fine again. The plug was near the choke, must have been rubbing and working loose slowly over time.

Training Joined: 01 Dec 2005 Posts: 28

how many mechanics are over there now when i worked there it was just me n steven.

Licensed Joined: 19 Jan 2005 Posts: 576 Location: St. Paul

It's dead again. I took it up to Rice Lake Wisonsin last weekend and it started cutting out above 50 mph. On the way home tuesday, the electrics cut out at a lower rpm so I could only go 30-45 depending on the hills. By the time I was coming through White Bear, I got a whopping 28 mph out of it on a flat.

Gas is flowing well, re-checked the TRICS, changed the coil, no difference. Did hear a rattle under the flywheel, maybe something is broken loose under there, didn't have the tool to pull the flywheel. It also seems to run better when cold. For a brief ride, it actually hit 65 on a flat. goofy.

It's back in the shop at scooterville and they are looking at it again. Gotta get this sorted before we run to duluth.

Licensed Joined: 19 Jan 2005 Posts: 576 Location: St. Paul

There were about 4 mechanics the last I checked. Stephen, Stephen, Brooke and a new kid.

Licensed Joined: 06 May 2005 Posts: 215