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Post by Raizer on Nov 29, 2015 17:41:33 GMT -5
Been a little longer between updates than I would have liked!!
I got sick of waiting for the custom tank to be made, so I've told him this morning not to worry about it.
So this project is starting to get back on track, although it's now going to be going in a rather different direction!!
Last night this was posted on a NZ car forum I'm a member of:
So yeah I've snapped it up!!
It's the same model as my Frankenscooter (AZ50), but the JDM version "Let's II" badged variant.
Hopefully it's going to be shipped up to me this week!
Going to fit my Stage6 pipe and ride it for a bit, then will swap my forks etc over.
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Post by Raizer on Dec 4, 2015 1:58:46 GMT -5
Picked it up today!!  Wish I'd taken my trailer instead of my father inlaws plywood special that was 4cm to narrow! Guy on the forklift tried to put it on long ways, found it didn't fit, turned around and put it down like this and left.  Shhhhh it's sleeping! Stood it up, tipped in some Castrol Active 2T and hit the starter, fired straight up and runs pretty well mint! Opened it up on the grass strip up the middle of my workshops driveway and as Ben (who I brought it from) had warned it's pretty quick! I just wish that I had 1: remembered he said it had stuff all brakes and 2: known that the front and rear brakes had been reversed! Speedo said 40k when I ripped on what I thought was the back brake to pull a skid on the grass outside my workshop and the front wheel locked up and nearly threw me off! haha Took it for a sly no rego test ride to the servo and around town to make sure all the majors worked, tomorrow I plan to take all the good bits from the other one and swap it all over  Not 100% sure which of the 2 engines I'm going to run with as yet, going to have a nosey inside the new one in the morning to see if there's any fancy bits as Pro's Goes off the clock (60km/h+) with ease 2 stroke Is there any other kind  Electric Start Has a plate Everything works except headlight (suspect blown bulb) yup good smile to mile ratio. Has a key. Suave black colour scheme with HD sticker Separate Oil tank so don't have to mix dem fuels. Starts really easily and runs perfect. Still quiet enough. Really does, not staying quiet for long though... Con's Brakes are designed for slow scooter which this isn't Brakes are terrifying!! Disk swap ASAP! Something's going on in the rear suspension dept which means the whole power train shifts forward under heavy acceleration. Mount is stuffed, other one is mint. Kick starter is removed completely. Other engine has one Rough around the edges. Meh Deregistered Easy to sort Missing rear indicator lens Need to find a right hand lens/swap to my LEDs So yeah the project is heading in a much different direction that I'd imagined a few weeks back! The remains of the other one is going to go back to the old owners OG plan of a trail/motoX scooter, for my boy to play on. So yeah again watch this space! |
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Post by Raizer on Dec 4, 2015 21:11:09 GMT -5
Progress is being made! First thing I did was strip it down a bit to change the engine mount  While testing to make sure it was the mount, I managed to get the engine to come so far forwards it smashed the sparkplug to pieces against the frame!! Can see how stuffed the old one was!  Am going to straighten the old one had get a couple gussets welded in and swap it back in future. Quick degrease  With a bit of shaping with my trusty angle grinder I made one of the Chinese side stands I scored amongst a pile of parts fit  Remembered that Tom had said he had put a new drive belt in the AZ50 when I brought it, so decided I might as well swap it over when I put the kick starter on  Discovered why it's got no kick starter! Also it turns out both scooters have after market variators!! The new one/Let's II has an old Kitaco with flat spotter rollers  And I was very pleasantly surprised to find this in the old scoot/AZ50  A brand new Chameleon Factory variator with new rollers!! It's a good bit bigger diameter than the Kitaco one which is factory sized so should give a bit extra top end  The new scoot does have a new looking SJ50QT (according to the markings) clutch fitted with red springs (flaked off the contra mostly, ends are still red), think I'm going to lighten the arms a bit for a more aggressive engagement and use it  The clutch pads are shorter but way wider than stock?? So that's where I'm at as of this minute. Thoughts? |
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Post by spaz12 on Dec 4, 2015 21:38:31 GMT -5
Looks cool so far and can't wait to see what you do with it!  |
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Post by Raizer on Dec 5, 2015 2:27:07 GMT -5
Fitted my pipe, going to have to rework the silencer bracket a bit as it's going to foul the bodywork.  Also whacked my air filter on  Stock Stage6 and filter As you can probably hear it was running rather lean (I think?), that was with a 95 jet (stock was 68), idle mixture screw did nothing at all until it was removed so a bigger pilot jet is in order I think? Also it would rev to the point the clutch engaged but not have the guts to move. Ended up putting a 100 jet in the other engines carb and swapping it over, improved things a lot but still way too lean I think, would max out at 50k after taking ages to get there. Might have a go at repacking the silencer too as it's a bit too loud! Need to attempt swapping my 3.50 rear tyre onto another rim, turns out the one it's on is rather buckled!! My phone's battery died at around this point so no more pics for now, but got the front forks swapped over, front brake bled up (syringe bleeding FTW) so yeah progress! Had a bit of a play with my dash, am having a bit of trouble getting the tach to work properly, taking it's signal from the pick up it's smooth but slow to react to the throttle, taking the signal from the coils trigger wire it's erratic. |
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Post by 190mech on Dec 5, 2015 6:53:47 GMT -5
You'll likely need some lighter rollers and heavier clutch shoe springs to get that pipe revving quickly.An open element air filter causes a lot of noise and tuning problems,,may try the stock airbox with a few mods to help it breath a bit better also..
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Post by Raizer on Dec 5, 2015 7:12:54 GMT -5
I was starting to think the same thing with the air box, I just need to find one in better condition, the rubber pipe that joins it to the carb has a big split in it.
I weighed the rollers in the chameleon variator before I refitted it, there all 5.5g, will order a few lighter weights to test.
Another bonus with the chameleon vari is that it takes 16x13 rollers which seem a LOT easier to find and cheaper than the 17x12 ones Suzuki use from factory.
Am planning on lightening the clutch arms as soon as I can borrow a 34mm socket.
When I've got the clutch apart I'll be able to measure the springs, I can't find anything Suzuki specific, but have read a few times Jog ones should fit, just want to be sure before I order them.
Plan for today is to go up a size on the pilot jet, raise the needle one notch and go up another main jet size or 2.
/after I figure out putting the front end back together anyway lol
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Post by triesandluth on Dec 5, 2015 9:21:14 GMT -5
youtu.be/aEDdglsl9PMThis is how I have gotten off many seemingly impossible clutch nuts. It shows it after a few filler video bits. Also, might want to wear gloves if you take this route. The torque drive is able to do some slicing of the palms!
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Post by Raizer on Dec 6, 2015 1:50:29 GMT -5
youtu.be/aEDdglsl9PMThis is how I have gotten off many seemingly impossible clutch nuts. It shows it after a few filler video bits. Also, might want to wear gloves if you take this route. The torque drive is able to do some slicing of the palms! Thanks for the tip, looks like it works well! Unfortunately Suzuki decided to have the nut sunk into the clutch so you can't get a spanner on it, just a socket! Today has been interesting, but I'll start with where it was left off yesterday. So this is pretty much how it sat when I got to my shed this AM   Fork fitted, brake bled, bars fitted. First thing I did was to make a spacer out of a piece of old BMX handle bars as we'd bored my master to suit 22mm bars and I've gone back to the smaller stock size. Then I drilled out some alloy round to make steering limiters  Did a rough trim of the headlight panel to suit the hydo brakes  Just a quick dremal cut job, I do plan to tidy it up a bit! Time to install the new dash! Ground down a pop rivet to make a depinning tool and depined a factory gauge plug/think I actually pinched the plug from the Sepia ZZ ignition switch.  I love these crimping pliers!  Ran a RPM wire to the coil, hooked up the indicators and high beam etc and then... All seems to be working well! Think I'm going to wire the low oil switch up to the water temp light. Started mocking up the mount, going to make a panel to tidy it all up!  *it's missing most of the screws at this point lol So now here is where I'm finding it getting interesting/confusing! I was starting to think the same thing with the air box, I just need to find one in better condition, the rubber pipe that joins it to the carb has a big split in it. Plan for today is to go up a size on the pilot jet, raise the needle one notch and go up another main jet size or 2. So I drilled a pilot jet out to 45 from the factory 40 that was in the Let's carb, when I swapped it in I also changed the 100 main jet out for a 105 and raised the needle. If any thing this made it a fair bit worse all through the rev range! Swapped the pilot out for the 38 that came in the AZ and lowered the needle back to the center notch. With this setting I could get a decent idle but it just wasn't running well at all. So I tried the factory air box, with it on the scoot just wouldn't idle or rev, it was soo rich it's crazy!! Dropped the main jet down to a 90 and it seems to rev a better on the stand, still a lot of hesitation to pick up revs and it still won't really move under it's own power*. I may be wrong, but I think I may need to go a lot leaner with my jetting? The stock AZ main is 68, the Let's came with a 72 in it and I have seen several people say you should go up about 20% with a pipe, so that would be about an 86 main right? Will try drilling one of the stock jets out to 85 tomorrow, if that helps I'll order some more to suit. *I'm hoping it's not wanting to move under it's own power thing is just down to the jetting + the clutch engaging way to early and not me stuffing up the drive system! Sorry for the massive post, if you've made it this far you deserve a cookie  |
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Post by Raizer on Dec 6, 2015 3:41:31 GMT -5
Been thinking about it, the tune pipe looses low end power so the pilot jet wouldn't have needed to be much richer right? Wasn't expecting to loose so much low end that the scooter wouldn't move when the clutch engaged though haha I think the clutch is engaging around 3500 RPM, should have paid more attention to the tach. Just ordered 3 sets of springs www.aliexpress.com/item/Cluch-Spring-For-YAMAHA-JOG-50-90-100-MIO-BWS100-Hi-performance-motorcycle-scooter-parts-made/32455284006.htmlAs well as 72, 75, 78, 80, 82, 85, 87 main jets. Plan in my head now is to swap the stock 72 main back in and refit the factory pipe so it's at least rideable until the springs and jets get here. Might see if the AZ50 clutch with it's longer/narrower contact surfaces works any better too. Also in the video I posted up there of the stage6 pipe with foam filter, was that "4 stroking" when I tried to rev it? |
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Post by 190mech on Dec 6, 2015 5:49:52 GMT -5
Yeah it was 4 stroking,but thats normal at such low RPM's..
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Post by Raizer on Dec 6, 2015 6:07:42 GMT -5
That was the highest it would rev at that point!!
Have been doing a lot of reading tonight about jetting these carbs and came across a post by the old owner of my AZ, from when he was jetting his street magic (same engine/carb just bigger jet/better exhaust from factory).
He had the same overfueling problem I'm having when he was tunning for a tecnigas pipe, after running several jets in the 95-105 range he ended up getting it spot on with a 78, stock was 75.
Turns out that like me, he'd been told by several people to run a main around #100.
After a bit of research it sounds like everyone recommending the #100 jet were used to Dellorto carbs not Keihins.
A Keihin 100 jet is apparently much bigger than a Dell 100 as the Keihin number is the physical size of the hole in the jet and Dellorto jets are marked by flow rate?
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Post by Raizer on Dec 6, 2015 6:12:15 GMT -5
Also I just want to say thanks for putting up with my noob posting, I've got a bad habit of over thinking things and rambling when excited about a subject haha
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Post by 90GTVert on Dec 6, 2015 8:23:01 GMT -5
You shouldn't use anyone's jet recommendation as anything more than a starting point. If it's a rich starting point, that's good. Much safer to work your way down in jet size if it sputters than to go out and seize it on the first run. Jets from different manufacturers are rated in different ways, but usually not to the point that something around and 80 and 100 will be equal. It could also be a difference in the design of the carb. At any rate, once you get those jets you should be able to do a proper tuning process and find the main jet that works best at WOT and then work on the other throttle positions. www.49ccscoot.com/faq/carbtune.htmlwww.49ccscoot.com/faq/symptoms.htmlYou don't have to thank us for putting up with your posts. There have been some interesting ideas here and it's fun to watch a project come together. Thank you for sharing. |
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Post by Raizer on Dec 7, 2015 3:33:48 GMT -5
Drilled the 68 main from the AZ out to about 78, sounds a LOT better than the 90!! Will move under it's own power now too, but hoping it will pick up a LOT with the heavier clutch springs. Bit of a rough shaky video just to show the difference in sound Clutch is engaging at about 3000, sitting on the scoot I can feel it starting to catch at about 2750. I then had a look at stopping the silencer mount from hitting the body work/oil tank cover. Managed to swing it out a little bit to give enough clearance.  You can see where it's been gouging a bit. Then I realized that the pipe won't line up with the bracket I'd made any more and that there is also a fairly remote chance that over a really big bump the bracket may hit the bottom of the oil tank. So I'm going to scavenge a bit of 3mm mild steal and make a new mount bracket as I'm not keen to try to work with that saw blade steel again!!  Then I decided to tackle the super stiff steering, didn't take any pics but long story short I had to remove all the bits from the bars, then take the bars and forks off the scooter. It turned out the bottom bearing cup was too tight for my forks steerer tube and was jamming it up! Swapped to the cup from the AZ, which is visually identical and the problem was solved, nice smooth steering! |
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