Modern Vespa

Fist post here:

I'm doing a rebuild and EV conversion of a beaten-down 2004 Bajaj Chetak 4S. $200 Will be a mechanical rebuild only, the 'patina' will remain mostly as-is. Done a few EV conversions before so that side I have under control. This is my first 'vespa' so that's a new adventure. Done a bit of research and found that parts interchangeability between Chetak and other Vespas is hit-or-miss, so I may need to draw on the hive mind here from time to time. So I thought I'd just post up and say hello!

Here's the beauty:

Fast forward:
Bike doesn't run. Mostly complete but some parts are missing and some are just so thrashed it's not worth saving.

To start...
-Bonded title - paperwork has been sent in.
-All new cables (will still be used with the EV conversion, a-la a retrospective scooters setup).
-New headset. Technically the old headset is usable but it's got no headlight, the grips are disintegrated, and the instrument cluster design is awful. I found *finger's crossed* a complete headset that lists as fitting the Chetak 4 Stroke, from India, which had a different speedo. (The Chetak's sold in the US seem to have a speedo from the 'Bajaj Bravo' according to my searching around).
-New tail-light

First part has arrived. It was actually one of the few parts I found that seemed pretty straight-forward, as it's commonly available and lists as a direct fit the Bajaj Chetak 4 Stroke.

Surprise surprise, doesn't fit. Too curved for this flat rear fender.
Per this old website a Stella one may fit with some modification:
https://orphanbajajusa.weebly.com/parts/taillight-replacement-with-stella-taillight
It does appear much flatter...

I've sourced one from India. Hopefully it fits.

The Bajaj is a strange beast. They are around - there seems to always be one up for sale on the Marketplace. I never owned one because of the uniqueness of the scooter and the problems thereof, specifically finding parts. Something like the Stella 4T - probably not a bad ride, but tough to get parts for. It also seems that any rubber bits disintegrate rather quickly. This ranges through all Indian made scoots, be it Bajaj, Stella, Royal Enfield, etc.... Good luck with the scoot, sorry I could not help any.

I bought a Bajaj 4t 2002, in 2002. I put over 13,000 miles on it. I feel silly for selling it, now that I look back.

My experience was the rubber was of quality, whereas the Stella brethren were disintegrating before our very eyes.

Lots of funkiness to be had. I loved the loaf of bread seat and endless glove box

And I forgot to say - I'm happy to see and I think it's a great choice for an electric conversion!

I loved mine and I've had the thought that all the 4t Bajaj's should be converted....

At least they'd still be on the road.

I'll be following along and rooting for you! My latest project (Bajaj LML 🇮🇳 hybrid w/ autolube & electric start) was also repowering a Bajaj 4T, but I used a Stella 2T motor. And small world, here you are using a Stella tail light and I had similar issues using a random Bajaj tail light on my Bajaj. The curve didn't match but not as bad as yours, so I settled for good enough and am just pretending it's 'proper'.

This project went on the backburner for a while, but it's back on the front burner!

As you would expect, this thing had no title. Bonded title is usually pretty simple but the tax office couldn't find a 'presumptive value' for this strange off-brand Indian scooter, which put me in the position of having to load up the scooter and find a shop which would do an 'appraisal' on a box of parts. Got that taken care of and now the paperwork should be sorted shortly.

Got the motor, controller and battery and some metal tubing and bushings for the swingarm. Everything looks like it will fit with room to spare so far....

HV Battery fitment will be tricky, but I think I'll be able to fit it with a little massaging. 88V40ah pack. Threw together a rough battery tray mockup today, it's 3D printing currently and I'll be able to see how close I am. Shouldn't have to drill any holes... not in the pursuit of originality really, just out of laziness.

Got the Indian 'sprint/bajaj headset in. Looks like it will fit and looks a lot better than the plastic thing that was on there before.

I will be completely redoing the low-voltage harness as well... no point in adapting the old one or sourcing a new one with all the custom stuff I'll be doing. Two things I haven't been able to google, as I'm sure it's one of those questions that's so basic nobody would ever ask it.

First: I can't figure out the RH handlebar switch. It has a 2 position toggle, I assume that's headlights on/off. There's a button on the side, I assume that's flash. But then there's a 3 position toggle... is that for brights/parking? The old sprint user manual doesn't say what the buttons do, and I'd like to retain the stock functionality.

Second, how does the OEM wiring connect to the back of the switches? Is it a male bullet connector, or soldered on? Is this what I'd need?
https://www.scooterwest.com/bullet-connector-for-vintage-vespa.html?srsltid=AfmBOopAdaWKRtEDUlKli-pMJmp2Ad-g76ctkB3r38p_9a0GoyKg-RhK

Looks correct in the switch pictures except the toggle is off/pilot and tail light on/ everything on, and the rocker switch is high and low beam. The button on the side is the kill button. The wires go in those holes and have screws on the flip side to secure them. Make sure the tips are tinned so you get a good connection.

Getting closer...

All goes well I'll just hand those 8 laser-cut pieces to my local tig welder, it all slots together and he'll hand me back a finished swingarm. In theory anyway...