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Post by jhobe6678 on Sept 9, 2014 4:49:16 GMT -5
Since you removed the intake and reused the gasket w/o sealer there is a good chance you have a leak at the intake. Even with new gaskets and sealer they leak. A 2t will not run right with an air leak. Ok, so looks like I'm ordering some new intake gaskets then. Yay, more blind guessing.
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Post by 2TDave on Sept 9, 2014 4:59:59 GMT -5
I've got some if you want to come pick a couple up after work. Get some permatex Ultra Grey also.
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Post by jhobe6678 on Sept 9, 2014 5:50:27 GMT -5
I've got some if you want to come pick a couple up after work. Get some permatex Ultra Grey also. Hah. I ordered two of them just in case, and a rebuild kit for the carb. Honestly I don't have the time to run around after work, if I don't get to work on it I lose light and gain mosquitoes. Maybe this weekend though? Let me see how quick the stuff arrives. I also have to consider that I stripped one of the holes for the intake so I may have to re-tap it or put a helicoil in it. So that's another PITA thing I have to try and do without dumping shavings into the engine. I'm also thinking of ordering a choke, also considering that may be part of the problem. I don't know. Without someone else there I'm really lost and it's frustrating because the GF doesn't have a ride. So not only do I have to try and fix it, I have to drive her around too.
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Post by 2TDave on Sept 9, 2014 6:14:49 GMT -5
I've got some helicoils also. I had to use a couple on my cvt cover on this engine. I'm not sure how hard it would be to get to and drill out and tap with the motor in.
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Post by jhobe6678 on Sept 9, 2014 6:21:09 GMT -5
I've got some helicoils also. I had to use a couple on my cvt cover on this engine. I'm not sure how hard it would be to get to and drill out and tap with the motor in. Well I figure worse case I can hold a rag under the hole if I have to drill. Otherwise I may just try to drive a slightly larger bolt into the head. I don't know, I have a friend here at work who knows more about that. He's also working on his own project so getting him over would be next to impossible. But yeah, the list is adding up. I'm going to take the carb off tonight, take it apart and bring it to work for an ultra sonic cleaning. Today I have to go to the post office right after work to pick up a package then I have to pick the GF up from work by 5. So I won't be able to do squat till then. But I'm going to take the entire intake system off, plug the hole and slowly work my way to putting it back together. No sense in rushing to do a half ass fix if it won't work or hold. No? Just a bummer that it was running and this all started with me wanting to change a fuel line and filter. *sigh* I'm thinking something shoot loose and got stuck somewhere. I'm hoping that's it anyways.
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Post by 2TDave on Sept 9, 2014 6:26:46 GMT -5
I wouldn't put a larger bolt in there. It will just be an issue later if it actually worked. We are talking about one if the four bolts holding the rubber intake to the block right? The carb is easy to clean at home.
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Post by jhobe6678 on Sept 9, 2014 6:30:17 GMT -5
I wouldn't put a larger bolt in there. It will just be an issue later if it actually worked. We are talking about one if the four bolts holding the rubber intake to the block right? The carb is easy to clean at home. Yeah, one of those bolts. The one closest to the piston head. I'm not worried about cleaning the carb at home, I'd just feel better putting it in the ultra sonic here at work. My friend that works here has been doing the same thing with his bike. He's re-building an Enduro and he had the carb here to clean the other day. He told me to bring mine in and we can clean it. To be honest, I'm kind of glad this is all happening because I wanted to rebuild the scoot anyways, I just wish it could have waited till I got her another one. *sigh* lol.
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Post by jhobe6678 on Sept 9, 2014 9:13:32 GMT -5
Well the good news is I found out where Partsforscooters.com is and it looks like I'll have the carb rebuild kit and gasket in a couple days! YAY! I'm going to remove the carb tonight and clean it tomorrow. I'm also looking into either tapping the holes for the air intake all to 1/4x20 since I have TONS of it here and it's close to M8 size. Now to just get my tap & die set back from my cousin.
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Post by jhobe6678 on Sept 9, 2014 20:53:07 GMT -5
Update 3:
So I think I figured it out. First off, thanks 2TDave for your input and a super HUGE thank you to 90GTvert for his awesome picture step by step on the carb. Totally what I have on my scoot and it helped me tons!
So I took the carb apart for cleaning, I have a repair kit on the way so when that comes in, I'll put it together and hope all is well. Anyways, here's what I'm pretty sure I found.
When taking it all apart, I was going mostly by memory from 90GTvert's post, when it came to the throttle assembly I thought something was funny. So I went back to check and AH HAH! The throttle valve assembly was all wrong. When I took it out of the carb, the throttle cable was wound around the spring for some reason. I also noticed that the needle came right out. When I got the throttle cable off of it and got the carb inside for the dis-assembly, I noticed the "E" clip and the spring clip that hold the needle in place were just laying on the bottom of the throttle valve assembly! I kept thinking and saying to myself that it all sounded like choke issues! So the kit looks to have a whole new needle and clips, I'll be using those. The jet did look a little clogged, not sure if I should upjet the carb just yet but at least now I see it's not that difficult at all. I could do it with it still in the scoot even, just detached from the intake assembly.
So this is where I am now. The scoot is without a heart, the intake is plugged up with a rag and I'm crossing my fingers that I've found the problem and will have the solution soon. PartsforScooters already shipped my stuff today so I'm hoping to have it before the weekend and have the scoot running!
My only concern is that if this happened form hitting a bump, who's to say it won't happen again? That makes me nervous I suppose. Who knows, maybe I'll surround the carb in foam or nerf or something lol.
The other project I will try this weekend will also be to vent my CVT cover. I'm going to keep it simple, just make some holes and grind out a few "vents" on top and maybe some holes on the bottom. I want to find some screen material though and JB Weld it in place so debris doesn't make its way in. Plus I think it will kind of look cool that way too. Home Depot maybe? Who knows.
Anyways, this is where I am now I suppose.
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Post by jhobe6678 on Sept 13, 2014 13:03:11 GMT -5
Update 3.1:
I cleaned the carb and put it back together. The rebuild kit I ordered was for a stock Minarelli carb, which I found out after that the carb I have is a Mikuni. Not sure if that's good or bad. But I got it back together, put the carb & intake back on, put the new fuel pump/petcock on and prayed to everything I could think of. She runs now, and yes she throttles up. So I was right, the needle fell and wasn't moving when giving it throttle.
I also took a chance and threaded a 1/4x20 bold into the hole that I stripped on the intake, had to add a lock washer because the bolt I put in was a hair longer and I figured the lock washer would help hold it together. It's on and quite secure.
So now I'm back to where I was before. Not sure if she sounds right or not. I have to give it a little throttle on a cold start but once she's up she stays idle quite steady. I adjusted the throttle cable so there wasn't so much slack in it too. I adjusted the idle to about 2,000 rpm give or take and adjusted the mixture screw to about where it was before I took it apart. Going by eye on that one.
So now here's the thing. The needle for the throttle is now sitting a notch higher (richer?) than it was before. I moved the "E" clip to a lower notch since the one it was on looked more worn down. I thought if switching the needle from the one of the rebuild kit, but I'd rather have someone else take a look and tell me. I should have taken a side by side pic, stupid me.
It still sounds a little louder than it was before and I can't figure out what to attribute it to. Keep in mind, the GF said it got louder as she was driving it and that's about when we put the higher octane (93) gas in it. I didn't do a mix yet, but I did suspect the oil wasn't flowing right. That's why I figured the heck with it and go mix. That's when I changed the fuel filter and lines for the last time and that's when I ran into hell.
So.. Even watching the videos, I'm not sure what she should be tuned to. I'm not sure if the change in noise is from octane or now that I'm mixing and the carb just isn't jetted right for it. But she runs. If the weather clears up a little, I may take it for a test run. I'm letting it cool off along with myself right now before I go back out.
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Post by 2TDave on Sept 13, 2014 13:44:26 GMT -5
Sounds promising. Try spraying soapy water around the exhaust flange with it running to check for exhaust leaks.
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Post by 90GTVert on Sept 13, 2014 13:49:51 GMT -5
Moving the clip up/needle down leans. Moving the clip down/needle up richens. Easy way to remember is that the farther the needle goes down the more fuel it blocks off. You might be able to use the needle from the rebuild kit. Put them side by side and check length and positions and diameter. If it looks like a close match, you can try it. Thinner or shorter needles (clip to lower tip) block off less fuel so they're more rich. Thicker or longer needles block off more fuel, so they make it leaner.
There are all sorts of things that can make a noise, but one thing I would not attribute noise to is using premium fuel.
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Post by jhobe6678 on Sept 13, 2014 16:17:39 GMT -5
Moving the clip up/needle down leans. Moving the clip down/needle up richens. Easy way to remember is that the farther the needle goes down the more fuel it blocks off. You might be able to use the needle from the rebuild kit. Put them side by side and check length and positions and diameter. If it looks like a close match, you can try it. Thinner or shorter needles (clip to lower tip) block off less fuel so they're more rich. Thicker or longer needles block off more fuel, so they make it leaner. There are all sorts of things that can make a noise, but one thing I would not attribute noise to is using premium fuel. I was on the same page as just what you said. The only part of the needle that was really different was down the shaft towards the tip, it had a more constant thickness VS the needle in there now goes from a very fine point and graduates less dramatically. I was afraid you would say that about the noise. *sigh* The thing is, short of taking the whole thing apart trial by error, I have no way of finding out on my own and I don't have the luxury of taking it all apart. So, that being said. I decided to buy a compression tester from Harbor Freight. Now I'm not sure if my tester is crap or if my scoot is running by some miracle. I did what Bret showed, I did it with the electric start then kick start a few times. It showed 30psi... WTF?!?!?! HOW IS IT RUNNING?!?!?! I put the plug back in and decided to take it for a test ride just now. Short, so I wouldn't risk too long of a walk in the thunderstorm that's about to come over me. Well, it rode ok? Didn't pick up the top speed I had the other day, but then again it was a short ride AND the wind is kicking outside. Plus I didn't have my super duper slick Daft Punk looking helmet on. (Oh, yeah, I need to post pics of that haha.) So. It runs and drives, throttle responds well as it should (At least I think so...) and when I went to start it up after the compression test, it started within less than a second of holding the e-start. So I think my compression gauge is crap or something?
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Post by 2TDave on Sept 13, 2014 16:24:50 GMT -5
The tester may of not sealed well. Make sure you hold the throttle open while testing.
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Post by jhobe6678 on Sept 13, 2014 16:31:13 GMT -5
The tester may of not sealed well. Make sure you hold the throttle open while testing. Oh... I might have missed the throttle part... I'll let it cool a bit first and maybe check again in a few if it's still calm out. I just put all the tools away. I live in a 1 bedroom apartment and my laundry room is my "garage" too. So having everything out means it's either on the patio or in the living room and well, no lol.
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