Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

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Please do share pics of your ride ..

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

You have surely invested a good amount of money. Would like to see the result. Please post some pics.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

where are the pictures man.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Please post the details, as well, through which it was rebuilt.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

My father does have one 1983 Bajaj Super which needs refurbishing therefore I am too interested. It has lost much of compression an has run 46000 kms.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Hello again friends,
Sorry for the late post as I was out of city, all the pics I have of Scooter are on my desktop. So, updating my post now.

First a brief history of this scooter. My Dad's office colleague had this scooter since the year 1999 and I had seen him riding it since I was a small child. He had ridden this scooter up to the year 2010 and then he made it stand in the open yard of his home under a tree!! It was kept there unmoved till the end of year 2013. In November 2013 I just casually told Dad that we must buy an old Scooter for him (since I watched movie D-Company) and also that I like scooter so much (I already have Pulsar 150). So Dad suggested about this friend of him. The very next day Dad contacted his friend and he told Dad to take the scooter whenever we feel comfortable!!! (he told later that due to its unattended condition many auto-scrap dealers contacted him for selling it to them).

So the very next day we went to his home with a Bajaj Scooter expert mechanic and picked it up. He totally rejected to accept any money in return of his scooter!! Anyways, we picked it up and brought it home. Now, the condition of scooter, because of being under a tree for 3 and half years, was so damn pathetic that it wasn't even moving a bit. It's gears were totally jammed, clutch wasn't working, had rusted rims. But the only good thing, as told by the mechanic, was that its engine was in good condition, also Dad's friend told that during 1993 to 2010 his scooter's engine was never opened a bit. Hence, we took it to my home in a loading-rickshaw!!

Now, once home, the mechanic removed engine cover, and filled its carb with the petrol and kicked-start it and on the fourth kick it started (though with lot of smoke and rumbling noise)!!!! I told mechanic that I want it to be in the brand new condition as much as possible that too with all the original Bajaj parts. The main concern was getting the required parts that too original. As this mechanic is from the Bajaj dealership at my place he suggested me to contact them. I visited them the very next day and asked about the parts. They told me that I can get all the required parts but can't guarantee anything in a particular time-frame. I just given them the parts-list made by the mechanic and told them to enquire.

They took almost 3 months for it and at last told me that better I buy all these parts from a dealer (other than my city) from whom even they buy the parts for outdated models. He ensured me that the parts sold by that dealer are original Bajaj parts with original packing too. Next day I contacted the dealer (80 KMs from my place) and gave him the complete list of required parts. He said everything is available with him (only the minor parts like rubber-linings etc of other manufacturers).

I visited the dealer after a week and really got all the required parts. As such, during the rebuild, I needed to visit this dealer a total of 6 times to get all what I needed!! Also, the mechanic which I hired could work on my scooter only on Sundays as he has a job at Bajaj dealership, so it took total 6 months to rebuild it.

I am going to post the pics of my scooter with their individual description. And yes, very sorry that I don't have any pics of the initial condition of my scooter as that time I was not sure that this scooter could ever be rebuilt successfully!! But just for the info, scooter was in the stock Grey color, with almost everything rusted, jammed wheels, jammed gear-box and all. Now, the pics,

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This is the initial pic of my scooter. I got it painted Midnight Black (stock color of my Pulsar 150, same with the blue and green stars visible in direct sunlight)

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This is the front view of my scooter, all the accessories are original Swastik brand. Those who know about the scooters would definitely know about this accessories-brand.

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View from the rear, with the long and single seat of Bajaj Classic.

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I didn't got original Bajaj monos so I got them made with Radium. Needed to give the soft copy of older Bajaj mono to radium artist!!

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Got new speedometer too. Since the rebuild since 3 months ridden it for 1200 KMs. Every single electical and electronic part is working perfectly.

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Got my complete engine painted black too (heat resistive color). The insides of scooter are painted with black rubber paint to prevent rusting and the engine is painted with Satin Black shade.

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Both the rims and stepny and all three tyres with tubes are brand new and got them painted with Satin Grey to prevent rusting.

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I covered all the accessory brand-logos with the older Bajaj logo made out of radium. I think this adds to the looks of my scooter.

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Original Swastik accessory brand logo on accessory.

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Black engine in all its glory.

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Fuel switch, with radium wordings.

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Brand new Ignition switch too.

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Front fork (new) and suspension (new) are too painted Satin Grey.

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Front fork (new) and suspension (new) are too painted Satin Grey.

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Silencer is also coated in heat resistive Satin Black.

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Attached a side-stand too along with the main-stand.

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Attached a grab-rail under the seat, very helpful while removing from stand or reversing or for the lady pillion.

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Black light-dimming sticker on headlight, to give my scooter a real classic look and also not to trouble people coming from front side at nights.

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Grab-rail for small children too under the neck of scooter.

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Now waiting anxiously for your replies, comments and suggestions. Please don't hesitate to give any negative or reformative suggestions for the scooter, thank you.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Astonishing achievement man, you have done a splendid job, in a world where normally people don't even care there cars you have resurrected a dying two wheeler and that too a scooter, just take good care of the vehicle use good quality 2t oil and transmission oil i would suggest Motul, keep it clean, purchase a body cover for the scooter, and ride safely.
cheerz......

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Amazing feet! Salutes to your passion for this old workhorse.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Actually forgot to mention that each and every electrical part is made to be in working condition. Changed the complete wiring of the scooter. Had got complete denting and welding job too on the floor of scooter from below. Also, i live in a city of population only 3-4 lakhs so it was a real pain in ass to get everything done perfectly.

First of all after disassembling everything the chassis and all the parts I took to to the welder. He took 10 days to weld it throughly and then removed the dents and furnished it. From there i again took it to the painter, showed him the color and pics of what I want to be done. He took a week to complete it. The shade I wanted is not readily available so got it made from the Dupont Paints Color Machine. Added the glitter paint to it. Then the painter applied 3 coats of putty, then 2 coats of grey base-paint then 3 coats of my desired color then 2 coats of PU Clear Paint. All this while the parts were totally in the disassembled state. But the job done by the welder and painter is too perfect. The result is this that even when a drop of water falls on the scooter then it doesn't stop anywhere, it directly moves and drips down. Means the finishing is superb with not a single ups or downs on the body. Then after the assembling completed then I again took it to the painter and he completely did a work of Rubbing and polishing on it. The painter is a real wizard I must say.

Apart from all this, I completed its legal papers too i.e. renewed its insurance, got the scooter transferred to my dad's name and now in November its RTO registration is getting expired so I need to renew it, but that's nothing as it needs only Rs.360.

Right now the scooter is giving an average of 48 KMpL and I am really satisfied with it. I had also driven it to 500 KMS in the longest stretch but there wasn't even a single issue.

All the pain and cumbersome work I done has been repaid by this wonderful scooter.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Nice job buddy

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Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

My mechanic did the complete work at my home compound. The pics of scooter I posted are of the same compound where all the disassembling and reassembling was done.

I shelled-out Rs.1500 for the welding and denting.

Had to pay Rs.2500 for painter's labor plus I spent Rs. 3800 for the paints and all the stuff.

Made total 6 visits (80 KMs away) to the parts-dealer and got the parts of total Rs.26000.

Apart from this the freight and tempo charges are additional to it. The train-tickets (for going to parts-dealer) and documents procedure is of almost Rs.3000.

Had almost completely rebuilt the engine with genuine Bajaj parts. Silencer is also from Bajaj.

And the most important thing is that it needed the complete dedication and cumbersome efforts to make it all happen. I struggled all through this just because I wanted this scooter to be perfectly like a stock build. And I think I had achieved it. Still a lot of people stop me midway and enquire about the scooter. Or if I park it somewhere in the market then people snap its pics. This is the greatest joy I feel when people ask me about it. Most of the people ask whether Bajaj relaunched the Scooter series again!!!

I dared to do all this only after watching the first season of 'Counting Cars'on The History Channel. I wish to give the credit of the idea of restoring this scooter to 'Danny-The Count' of the 'Count Customs' from this great show.

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

Amazing job buddy! Nice to see your love for the golden era of bajaj super. My dad has owned two such scooters during 1985 - 2002. Reminds me of family rides within city and joyrides to ice-cream parlours..

Re: 1999 Bajaj Super Scooter rebuilt in 2014!!!

OMG, you spent more than the actual cost of the scooter. Amazing stuffs bro. Your uncle's expression on seeing this beauty would have been priceless