Fitting the spare under the battery cowl
Bajaj's have rather ugly spare wheel carriers and unless you want to shell out good money for a 4 in 1 rear rack there isn't much else you can do.
And whilst those racks look good, they are in fact quite heavy and also create a fair bit of drag on the move and I have found that on wet and windy days can make the back end very skittish and all it takes then is a wet drain cover or patch of diesel at the wrong moment and you are earning your self some road striping and a new paint job if you are lucky, I won't need to emphasis on the prizes for being unlucky...
Also it surprisingly allows the bike to be a bit more balanced, Bajaj's are very much like the old 1960's Vespa's with a habit of being a little heavy on one side, whilst the wheel is bigger it does have a slightly bigger centre of gravity and will take a bit of the wobble out of the ride.
Now for this project and again this is only my own way of doing this, you will need the Vespa Cosa spare wheel holder assy which bolts on under the Cosa cowl snug against the inner panel, the battery and rectifier bolt into the Cosa's built in battery tray and you have a little area behind with a bit of creativity would give you a place say to keep a roll of tools or a can of tyreweld.
You will need to modify the Cosa mount a little using a dremil and on the body of the Bajaj you will see a lip or hump at the bottom of the inner panel, that too has to go because it won't let you put a wheel there.
Alternatively instead of a Cosa mount if you have a spot weld drill bit, you can take the spare wheel mount off a PX and simply bolt that on in the right place, TSR do sell chromed wheel mount sub assemblies for approx 40 pounds.
Tools needed:
Drill
Selection of metal drilling bits
Dremil cutting kit or angle grinder with fine cutting wheel
Metal file for removing burrs and sharp edges (Or use the Dremil with appropriate stone wheel)
Gloves and goggles
Selection of spanners and sockets to remove old battery tray and fit new nuts and bolts.
Items needed:
Vespa Cosa wheel mounting bracket
Selection of bolts, nyloc nuts, washers, reinforcing washers
Rust protector
Touch up paint
Brush
Preparing the Cosa wheel assy:
Preparing the bike before installation:
Remove tank
Remove battery tray
Disconnect regulator
Disconnect starter relay and battery connections
Cut the lip off bottom inner panel.
Measuring and marking the mount:
Fitting the mount:
Setting the battery and other ancillaries up:
Testing and finishing off:
And whilst those racks look good, they are in fact quite heavy and also create a fair bit of drag on the move and I have found that on wet and windy days can make the back end very skittish and all it takes then is a wet drain cover or patch of diesel at the wrong moment and you are earning your self some road striping and a new paint job if you are lucky, I won't need to emphasis on the prizes for being unlucky...
Also it surprisingly allows the bike to be a bit more balanced, Bajaj's are very much like the old 1960's Vespa's with a habit of being a little heavy on one side, whilst the wheel is bigger it does have a slightly bigger centre of gravity and will take a bit of the wobble out of the ride.
Now for this project and again this is only my own way of doing this, you will need the Vespa Cosa spare wheel holder assy which bolts on under the Cosa cowl snug against the inner panel, the battery and rectifier bolt into the Cosa's built in battery tray and you have a little area behind with a bit of creativity would give you a place say to keep a roll of tools or a can of tyreweld.
You will need to modify the Cosa mount a little using a dremil and on the body of the Bajaj you will see a lip or hump at the bottom of the inner panel, that too has to go because it won't let you put a wheel there.
Alternatively instead of a Cosa mount if you have a spot weld drill bit, you can take the spare wheel mount off a PX and simply bolt that on in the right place, TSR do sell chromed wheel mount sub assemblies for approx 40 pounds.
Tools needed:
Drill
Selection of metal drilling bits
Dremil cutting kit or angle grinder with fine cutting wheel
Metal file for removing burrs and sharp edges (Or use the Dremil with appropriate stone wheel)
Gloves and goggles
Selection of spanners and sockets to remove old battery tray and fit new nuts and bolts.
Items needed:
Vespa Cosa wheel mounting bracket
Selection of bolts, nyloc nuts, washers, reinforcing washers
Rust protector
Touch up paint
Brush
Preparing the Cosa wheel assy:
Preparing the bike before installation:
Remove tank
Remove battery tray
Disconnect regulator
Disconnect starter relay and battery connections
Cut the lip off bottom inner panel.
Measuring and marking the mount:
Fitting the mount:
Setting the battery and other ancillaries up:
Testing and finishing off: