My Mostly Suzuki AZ50 Based build... ... Is now a Let's II

[Raizer]

Got the stand mounted, need to tweak it a bit so the scoot sits level but that's no biggie, it's just a case of bending the foot piece a touch so the scoot stands on the stand rather than that bit.
Edit: might make more sense wit this pic



Today I made a mess of my plastics trying to make a mount for the CHT display, it's pretty ugly but I think a bit of shaping and it will do the job


Still dizzy from the fumes from welding that!

Then I went to hook the CHT itself up, figured I should test it before putting all the plastics back on yet again...

Engine was much warmer than 25c! And if you look closely you will see the earth wire isn't hooked up at all, if I hooked the earth up the display would come up with E1.
The thermocouple is faulty!
In the pic it was earthing out, giving the cord a wriggle where it joins to the ring stopped it earthing out so I hooked the earth wire up, at first it seemed ok showing 63.2c which seemed ok.
But when I started the engine it shot up to 375c, gave the lead another wriggle and suddenly my temp dropped to -40 then up to 80, so yeah have emailed procon-products, hopefully they will replace it!

The new facelift fuel and oil tanks arrived, just waiting on the matching seat bucket to get here then I'll swap them over.

[Raizer]

Procon-Products never replied to my email about the faulty thermocouple, so I ordered one a few dollars cheaper from sensors_factory on eBay, turns out sensors_factory IS procon-products just under a different name and listed as in China rather than Canada!
Either way the tracking info shows the new one has already left China, so fingers crossed it will be here soon and will be made properly!

Have figured out that the actual thermocouple wasn't fully seated into it's pocket in the ring/washer when it was crimped, that's what is letting it move and earth out etc.


Volt meters arrived today

Can't complain for under $1.20e!
Just have no idea where I'm going to mount one now lol

Hopefully my jets will be here in the next day or 2 too.

[Raizer]

Jets and thermocouple should be here Tuesday morning, found the tracking number for the jets the other day, looks like they attempted delivery last Wednesday but didn't leave a card!

Bent the stand into shape the other day, little more tweaking and it should be sweet.

Finished cleaning up the plastics today, plastic welded a couple bits back together and smoothed out what I could around the gauge mount.
Then sprayed them with bed liner, what weird stuff to spray!!




Not sure I'm going to end up using one of those volt meters on this now, can't find anywhere easy to mount one!

[Raizer]

Still no thermocouple though!
Bed liner has set nice, I like the finish too although it's fairly matte.

[spaz12]

Mar 28, 2016 23:53:25 GMT -5 Raizer said:

Still no thermocouple though!
Bed liner has set nice, I like the finish too although it's fairly matte.

And that's to way to order jets!

[Raizer]

Just need to find a few more pilot jets and I think I'm be sorted for tuning supplies!

I've got 70 to 108 going up in 2s, then 108 right through to 122 main jets now!

Only thing I don't really like with the Aliexpress 6mm jets is that they have no markings on them, think I might engrave them myself if I can be bothered lol
Other than that they look just as well made as a genuine Dellorto jet, and at $10 for 12-15 of them there great value.

[Jwhood]

Mar 29, 2016 0:41:08 GMT -5 Raizer said:

Just need to find a few more pilot jets and I think I'm be sorted for tuning supplies!

I've got 70 to 108 going up in 2s, then 108 right through to 122 main jets now!

Only thing I don't really like with the Aliexpress 6mm jets is that they have no markings on them, think I might engrave them myself if I can be bothered lol
Other than that they look just as well made as a genuine Dellorto jet, and at $10 for 12-15 of them there great value.

Only thing I hate is there not stamped with jet size,I ordered same ones a year ago and got them all mixed up now I don't know what is what!!errrrr

[Raizer]

Yeah I can imagine that would be a pain!!
One seller there does them with the size stamped, think it's only bigger sizes (110-180 or something) and you get a few less for the money.
I sat down last night and cut the numbers into the heads of the jets lol


Facelift tanks, seat bucket, seat and replacement thermocouple!
Going to go see if I can scrounge a cheap off cut of vinyl and attempt recovering the seat.

[Raizer]

I'm giving up on CHT for now, my display now reads 48.5°c even without the thermocouple connected and goes up to 86.3°c with it connected, and something in it is getting really hot.

Possibly going to order one more from a different seller, otherwise I'm just going to stick a volt meter in the hole and stick with plug chops.

[Raizer]

Ordered a CHT display from sensors_factory/Procon-Products, same as tsimi 's but with a green LCD display, should be here anyday now, fingers crossed it solves the problem!


Finally got off my ass and did something on the scoot today!
Tried to fit the facelift seat bucket, it fouls pretty hard on the latch that locks the seat down.


Think a bit of time in the company of Mr. A Grinder might persuade the latch to let the seat bucket to pass!

Remember when I chopped up the little carb mudguard thing when I built the engine?

Feb 25, 2016 3:17:09 GMT -5 Raizer said:

The carb cover/mudguard was pretty haggard, and rubbed on the tyre all the time


Didn't really want to try to refit that!
So I chopped it down

Well as it's coming into winter now and it's already raining a lot I decided I really didn't want to subject my carb to all the crap that would be sprayed up off the wheel!
So using the end of the rear mudguard that came with the facelift fuel set up, one pop rivet and maybe 20minutes "plastic welding" I came up with this



Notice the wheel is off?
Yeah there's a funny story about that...

So when I was considering what size to make the guard I noticed that my rear wheel was loose, loose enough to move 2+mm on its spline!
So I figured I'd just pinch the nut up and keep an eye on it in future, well what do ya know, that nut was as tight as ever!!
Washer was tight against the end of the spline, but wasn't even touching the wheel if I pushed the wheel on.

So I pulled the wheel off the scooter to find it had been sliding in far enough for the brake drum to rub on the engine case and for the brake shoes to wear a slight groove on the inside face of the drum!

Tried all three wheels I've got here, one was a little bit worse and the other one fitted perfect, but the one that fits isn't mine!
Measured the splined centre bits and they were all different lengths, so I dug through my bits and pieces and found a spacer that fits the axle perfectly and also pushed the wheel out far enough to clear the case/brakes.


Much better!

Has given some much needed clearance from the carb's guard too


Cleaned up all the excess 2t oil from my pipe, scraped the messed up exhaust gasket off and refitted the pipe with some magic exhaust goo

Have used it in place of a gasket on many a scooters exhaust over the years!



Getting a bit pic heavy, so time for a new post

[Raizer]

When I last attempted tuning I left it with a 108MJ, 40SJ with airscrew 3.5ish turns out, A21 needle fully lifted.
Warmed it up with this combo fitted.

After warming it up I went to remove the airbox so I could change jets, managed to tear the rubber joiner elbow when taking it off the carb
Don't have anything to replace it with either so I PIG 'd up the foam filter that's been kicking about the shed unused.


Pulled the carb


Fitted a 112MJ and the about 37SJ I drilled a while ago, left the needle fully lifted as it had been, fired it up and I adjusted the air screw, ended up about 2 turns out.
Result:


Hmmm could say that's a little rich!!

So instead of going down a couple sizes in MJ like I would have in the past I thought for a sec then decided to try lowering the needle.
Here it is with the same jets, only difference is I lowered the needle 2 slots so the clip is in the centre slot:


Much better, but not 100% yet, not sure what to tweak next, almost thinking it's a hair lean now with how the revs stay up a sec?

Edit: the more I listen to it the more I'm thinking it's a bit rich still?
Not used to the sound difference with the foam filter yet either.

[Raizer]

Getting somewhere?



Had no time today to go chop some plugs, but adjusted the air screw and got it going pretty well I think!
Although I think I could use a smaller SJ again (probably shouldn't have drilled my 35...) but it's much better than it was with the 40sj!
It's nuts on grass/loose surfaces!!
My boy took a photo instead of hitting record on the run down the driveway where it went fully sideways then hit the hard surface and stood up on the rear just about throwing me right off the back hahaha
Probably should have put a couple of the seat bolts in before riding it lol

[tsimi]

You crashed it?

You are trying too hard to get a wheelie, no need for such crazyness.
But if you keep trying at least cut the rear fender otherwise you'll crash it for sure.

Your Scoot sound awesome! Nice power too considering that you "only" run a 17.5mm carb.

[Raizer]

tsimi I probably should have worded my last post a bit better .
Didn't quite crash it, came close to coming off the back though, was just caught a bit off guard when it went from sliding on the grass to suddenly hooking traction and popping the front way up while still somewhat sideways
Wouldn't have been anywhere near as sketchy if the seat was bolted on and the floor wasn't still hanging up in the workshop
I had to avoid standing on my CDI and battery!

When it's on a solid surface with traction it wants to lift up the front all the time when the clutch bites now
Have been thinking of trimming the rear fender, but for looks rather than wheelies as the end of the fender is pretty messed up.
I'm not planning on doing too many wheelies TBH, but well it's nice to know I've got the power there if I ever want to

I'm loving the sound from the foam filter!!
It's loud, but not to the point of being obnoxious (well to me at least, the neighbours may not agree ) and with PIG 's tape mod it really isn't as hard to tune as I expected!


Have kinda been having bad thoughts about cutting the flange off and having a boss welded onto my other inlet manifold to run a 19mm or 21mm carb, but the 17.5mm really seems to be working very nicely for my set up!

Still got the Stage6 ProRep sitting there waiting to be welded up to fit yet... 



Can't wait to try it out on the road now for some real testing!!

[Raizer]

Been concentrating on my attempt at launching my own small business lately, which has meant lots of workshop time but sadly not much of it spent on the scooter

Although today I did manage to finally road test it with the 112mj and foam filter etc, OMG it's starting to go very well indeed!!
Massive (to me) low and mid end pull right from the clutch engaging until close to WOT, wants to pull the front up whenever I open the throttle at low RPM.
Still feels a little flat/like it has more to give at WOT, think the jet is still a touch small, will swap in maybe a 114 or 115 main next time I get a chance then finally do some plug chops.

Ordered a couple more plugs in today too, fingers crossed with 4 new plugs I'll have enough to get the tune sorted and still have a new plug to run after.


Going to give the SJ50 a good check up over the weekend too, have ordered a range of jets as it's 4 stroking a tiny bit with the drilled jet that's in it, need to drop the needle back to the centre slot as I lifted it one when I rebuilt the carb and it's too rich, I just have to be careful not to break the plastic linkage joint thing.
Will likely need to order rollers and a belt etc for it, probably put the "racing CDI" in as well.
Have decided to try to cut a bracket to fit the Chinese scooter caliper to the Sepia front end, I just can't track down a piston to suit the Sepia caliper and the tiny drum on the SJ just isn't cutting it anymore now we're getting rain etc!