It's all about the spark

Every Bajaj owner should not only carry a spare spark plug with them at all times (they need to be replaced every 3-5K miles), but should also replace the spark plug resistor cap. Even if your bike is running great it's bad economy not to make the replacement. A spark plug resistor cap will cost you $2.50 and a pack of 4 Iridium upgrade spark plugs costs $9 or a stock spark plug for $2 from Amazon. For part numbers reference Retro Bajaj Forum's part list. Do not buy the 90 degree spark plug resistor cap. It does not fit as it should. Buy the 120 degree one.

If your scooter is sputtering or not running this is the first thing you should do. If your bike is running perfectly, you should still do this $4.50 upgrade, because at some point your stock resistor cap will go bad and it will be a bummer if it's when you are out a long epic ride in the middle of no where or in a rush to work.

Here's a quick install video.

This job will take you no longer than 10 minutes and what a difference it will make in how your scooter starts and runs.

Upgrade your spark plug resistor

One of the most common things to go wrong on your Bajaj is a sputtering loss of power. Eventually, at some point, your spark plug resistor cap will go bad, so why not replace it now? It only cost $2.50. Furthermore, while you are at it, replace or upgrade your spark plug. Seriously, why do wait until we hit 10,000 miles on the odo? We're talking $5.

Buy:

Resistor cap: VB05 (NGK stock replacement 120 degree bend - this is important so that it fits using your stock set-up. The 90 degree one will require you to cut away plastic from the engine cover to get a tight fit).

Spark plug upgrade: BPR7HIX/NGK5944 (NGK Iridium upgrade - your bike will idle smoother and create more power at higher RPMs with this plug. It costs $7 as opposed to $2.50 for the stock one).

Remember, when installing the spark plug resistor cap to twist the old one counter clockwise out of the wire and it will come off pretty easily. Then cut just the tip of the wire so the new spark plug resistor cap will have good contact.

Also, keep in mind you need the screw on the spark plug cap that comes with your brand new spark plug. The stock spark plug resistor from Bajaj did not use it.

Call your local motorcycle/scooter shop and ask them to order the parts. Autozone can get the spark plug, but not the cap.

For a list of parts visit RetroBajaj and you can also read discussions on why people upgraded.

I just replaced only the spark plug resistor cap and rode up a San Francisco hill and my bike was pulling/jumping in 2nd gear wanting to give me more. It runs as strong as the day I first bought it - maybe stronger. It tacked hills in 3rd gear too!

Spark plug changed and finished

As some of you may remember I had a NGK style upgrade on my spark plug with the nice tight ball bearing connection, but was warned by a reader that it stood too tall and would dent the underside of the cowl when my wife rode over a big bump. You can see a photo and read the comments about my modified spark plug clip here. I didn't take any chances and changed it back to stock, which is a good thing.It takes very little work to remove the spark plug clip. No need to cut the wire and chance the wire being too short -- mine was in danger of being too short. I used pliers and gently walked it around the clip's end and listened for a small "cracking" sound. It did and I was able to pull the wire out with no effort at all.As you can see it was a clean break. I am no expert, but logic tells me the fact that the modified NGK spark plug clip has a sharp nail like pin going into the cables inside the wire produce both a superior connection and a better water/weather proof protection than the stock one did.In an effort to increase the connection "area" between the wire and the spark plug clip, I recommend trimming the rubber on the wire back and folding the wire back over itself so it literally rests against the clip when you tighten it down. That way you have two connections: the spike in the clip, which goes through the wire, and the folded over wire you created. Click to enlarge the photo to see what I did. Thanks to David at First Kick, who taught me this trick.

Parts Purchase

Using Ted W.'s 20% discount, on Saturday he picked up the following items from B & B Yamaha:

1) Light bulbs for front & rear tail lights

2) 2 Qrts of Yamalube 2cycle oil

3) A variety of nuts and bolts (metric). The smaller n/b will be purchased at the local hardware store.

4) Spark plug NGK B6ES (2 more are on order)

5) Gas line tubing

TOTAL (about): $25

That's it for now. I am still working on finding non-Indian grommets. I have two leads.