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

[Raizer]

Got the ZZ's stator mounted, $25 to have a new slot broached into the flywheel to retard it 28° to match the stators position, which I'm getting done on Monday.

[Raizer]

Almost ready to burn this project!*

Today saw next to no progress.
AC stator gives an awesome pulse signal, but both the lighting/main and charging coils are putting out 0v.
The guy i brought the CDI from claimed with DC ignition scooters you can take the pulse from the charging coil, so chucked the factory DC stator back in.
7VAC from the lighting coil and only 4 or 5VAC from the charging one, pulse light on CDI box flashing less excitedly than with the proper pulse coil on AC stator.
No output from the CDI box to coil.

Also now I can't seem to get spark out of any of the 3 coils I've got when bench testing.

May have just brought another engine to rob bits from though. It's a TGB which is meant to share it's design with my Suzuki edging, it's supposedly a great runner, has AC stator and comes with CDI so might just attempt making it fit.


In more positive news the ZZ starter and Bendix fitted sweet, the Chinese scooter had a brand new battery fitted so I've now got electric no start.

*Welder was dropped off today, so time to melt some metal.

[190mech]

Quite a few pages on failed TGB CDI parts in this thread;
49ccscoot.proboards.com/thread/10231/2006-tgb-r50x-bat-outta?page=25

The DC CDI cant be made to work?Its the best of the iggy systems...

[Raizer]

It looks like it would need another stator as well as a DC CDI box to get it going, 7VAC isn't enough to run it, or I wouldn't have thought so?
That's 7VAC with the engine cranking over fast from my car battery with no plug in, it was giving about 3VAC cranking off the scooter battery, couldn't get a reading using the kick starter.




Also I put the ZZ expansion type exhaust onto the SJ50 today, Suzuki must have got something right in it's design as it's enough of an improvement for the carb to now need to be up jetted!

[Raizer]

Almost too embarrassed to post this...

Was just trying to go to sleep when something dawned on me, I've been trying to use the exciter coil for the pulse signal while attempting to power the CDI from the lighting circuit...
Yup I'm an idiot with a capital ID!

I dunno why it came to me, but for some reason I remembered changing the exciter coil and setting the points on my old A50 when I was a teenager and a light came on in my head and I very nearly face palmed.


To think I've installed several stand alone car ECUs, wired many car audio installs not to mention all sorts of gizmos like boost controllers and custom ignition systems in cars without a hitch, only to be caught out by something as stupid as this




Off topic, but man I'd love another A50 or AC50 one day

[aeroxbud]

Great read

[Raizer]

Did I mention I am an idiot?
Just a small puff of either.



Hot glue gun, extreme edition.

[Raizer]

Hope I'm not being a pain updating so much, it's just good to be among other scooter people!

Mixed up a couple of litres of fresh 32:1 fuel and attempted having the thing run more than 3 seconds, it looks like my fuel tank is only around 2L at most, so will need to do something about that ASAP.

Lighting circuit makes power


As does the charging circuit!

Whacked on the Chinese 4 stroke exhaust on just to shut it up for the neighbours



It won't rev, obviously very lean, blocked off 90% of the carb inlet but it still didn't choke it enough.
Also I wasn't sure if it was getting fuel, so whipped the carb off, bit of crud in it from sitting around, think there's some in the jets too, so will strip it down tonight and hopefully give it a bath in the ultrasonic cleaner at work tomorrow.


Any thoughts on where to start jet size wise?
My eyes are struggling to read it, but it looks like the jet it has now is a 72.

Edit: just pulled the main jet out, 100% blocked...

[190mech]

Pull the pilot jet too,its likely clogged,also the choke(enricher) pickup tube that leads into its own chamber in the float bowl has a tiny jet in the bottom of the bowl that clogs easily too.Guess what I'm saying is take everything apart and clean the heck out of it..A wire brush hair is good for unclogging tiny holes..

[Raizer]

Yeah every thing below the top of the floats was gummed up solid with sticky old 2T oil, it had sat for a few years after being stripped down, I'd say it still had a bowl full of premix when it was left.
I don't know how it even ran as well as it did today it was that blocked up!
I have got it pretty clean now, but will still stick it in the ultrasonic I think.

[Raizer]

So yesterday I put the carb back on, fired it up and it runs much much better!
Took it for a quick lap of the yard and other than desperately needing a much bigger main jet it goes damn well!

Then I stripped the makeshift wiring, seat, 4 stroke exhaust and rear shock off it.
Cut a piece of tube and hard tailed it at just above the point where the rear spring bottoms out.

Now to enlarge the fuel tank to fill the gap up, then once it's back on it's shock I know it won't have the tank hit the carb if it ever bottoms out.
Also trying to find a comfortable seat position for me.


Tons of room to take the top of the tank up!

Been scavenging metal to make bits out of, for some reason the idea of steel mesh foot boards is appealing to me.



Also just brought this off a local auction site, only $100NZ! (about $62USD at the moment)


Hope to have the pipe in the next few days.

[Clank]

Nice. Can't wait to see it finished.

[Raizer]

Neither can I!!


Ordered some jets this morning from Aliexpress www.aliexpress.com/item/4MM-whorl-DIO-Two-stroke-Motorcycle-Keihin-carburetor-CVK24-26-GY6-50-80-PZ19-main-injectors/32366833009.html
Specified 90, 92, 95, 98, 100, 102 jets, and asked how much it would be for 2 to 3 more added to the order.

Just got a reply from the seller:

Hello friend,

As you didn't tell me what other size you want I have just now sent you 88.90, 92, 95, 98, 100, 102,105.108 jet.

No extra payment is required.

Thanking you for your patronage

So can't complain at that!


Only got to spend an hour on it tonight, started chopping up the fuel tank, then quickly remembered why I gave up trying to weld years ago!

Half my problem is that the steel I was using is a bit too thin, going to buy a bit of 1mm sheet tomorrow, cut that mess off and start over!

[Raizer]

Tank, take 2. And yes I am well aware my welding sucks!!
Plan is to bribe a friendly plumber I know with beer to solder over all the seems to seal it.

Cut along the top and folded it down, cut a couple triangles to fill the sides


Filled in the back with a strip of steel.


Chopped the top out


Finished up here

It's just over 4L now, have an idea to gain another litre too.
Amazingly I only found 4 leaks!  And only set myself on fire twice

Spaced the front of the seat up for clearance and because the front was down a little bit lower than it's meant to and it felt like I was going to slip off the front of the seat haha.  Might still bring it back an inch, undecided as yet.
Still plenty of room on top of the tank for my CDI box, reg/rect, small battery and flasher unit if I decide to put them there.

[90GTVert]

Good work!