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Post by Raizer on Feb 10, 2016 19:50:57 GMT -5
I'm actually tempted to split one of my other spare Suzuki engines to compare them.
This one is the "Suzuki Morini" designed in collaboration by Suzuki and Minarelli and it seems the only thing Morini about it is the cylinder stud pattern, stroke and name!
I've got one of the much more common Franco Morini AD engines that Suzuki built under license for 20+ years sitting under my bench, I think that it will be a lot closer to the TGB's Morini AL engine.
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Post by Raizer on Feb 11, 2016 23:21:38 GMT -5
Nothing too exciting, I have started cleaning up the casings with needle files and sand paper, not going to take much more out but it's looking a bit better to me! Before:  After rough shaping, still a few little bits to shape up and a bit of sanding to go:  Stripped the gearbox, think one or 2 of the bearing could do with replacement, so I'll most likely just change the lot.  Speaking of bearings, the old owner of the AZ Tom aka VG has hooked me up with a great deal on the crank bearings, seals and a nice 1/4" torque wrench to put the engine back together with! Pulled the flywheel and stator off the UZ50 Let's 4 engine I've got here, the 8 pole stator has the same 2 wires as my stock 7 pole and fits right in my case, it's only one more pole but it all counts right?  And I managed to get the small case half that clean yesterday it stood out like anything compared to the large case, so much to the Mrs's dismay I've got it soaking in a tub of hot water and cleaners in our washhouse haha  Have gotten a lot deeper into this project than ever intended!! Edit: It's 11pm and I have spent most of my Friday night scrubbing my engine with a toothbrush... Dawned on me after a while that it was clean and that Suzuki had painted/coated the engine in an alloy colour when it was made, the dirty spots I was trying to scrub off are clean raw alloy that looks dirty in comparison to the coating lol I see some high temp pain in this engines future!  |
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Post by Raizer on Feb 12, 2016 15:48:40 GMT -5
As much as I hate getting woken up by a courier pounding on the door first thing on a Saturday morning, I love getting new goodies lol  And where I've stopped on the cases, just going to clean up my sanding marks. I didn't take as much off the large case, there far from symmetrical and I didn't feel like it needed much taken off   |
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Post by Lucass2T on Feb 12, 2016 19:20:36 GMT -5
Looks nice!
The suzuki engine has a better design than the minarelli engine. Nice stuffer in the reed block, nice reed angle and semi trenched cases. Strange it never became that popular in scooterracing in Europe (dunno about asia?).
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Post by niz76 on Feb 12, 2016 19:28:25 GMT -5
That should flow mo better!
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Post by Raizer on Feb 12, 2016 22:46:55 GMT -5
Had a play with the carb to see how much of a mission it will be to fit, looks like it should be fairly easy really. Need to drill it and press in a fitting for a vacuum port  Stock throttle cable inner is way too short!  Easy enough to sort out though, I cut the end off the stock inner and also from the long green cable I had brought from Aliexpress and slipped it into the stock outer  Just need to figure out the right length of cable to for the PHVA then cut it and add a knarp. Also removed all the bearings and seals from the gear box, this one was an absolute prick to get out!!  Forgot to take pics, but I used an m12 125mm Dynabolt like this  And made a blind bearing puller slide hammer contraption out of it, bit of heat + a bit of brute force and out it came! |
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Post by Lucass2T on Feb 13, 2016 4:13:37 GMT -5
I'd put that vacuum port on the intake, not the carb. I'd rather leave the carb and make changes to a part thats less expensive...
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Post by Raizer on Feb 13, 2016 6:44:09 GMT -5
You might just have a very good point there Lucass2TThe inlet does have a spot at the flange that should be perfect too  Lol never realized that these Dellortos came with plastic slides! |
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Post by Lucass2T on Feb 13, 2016 6:50:29 GMT -5
Lol never realized that these Dellortos came with plastic slides! Yeah PHVA's have plastic slides  they wear like hell and nearly all of them get damaged and get deep scratches from sand and other contaminations. I guess from all the tinkering they get subjected to. |
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Post by Raizer on Feb 15, 2016 2:06:47 GMT -5
So yesterday I' pressed the engine mount and shock bushings out of my cases, cleaned up, tested and fitted an electric choke to the PHVA and late last night I scrubbed another pile of parts! Also test fitted the carb to my manifold and found that the manifold inlet was a tiny bit smaller than the carbs throat  Today I spent an hour with the dremal and ported out the manifold, then turned a bolt into a cable end 49ccscoot.proboards.com/thread/14967/diy-throttle-cable-modWhich resulted in being able to open the throttle on the PHVA Attacked my manifold with a drill  And used a 2T oil fitting from the ZZ engine to add a vacuum port  Going to need a smear of retaining compound to seal it up, the hole ended up a hair too big so the fitting is snug but not a press fit   That's 1.5mm, the hole in the factory Keihin carb is 1mm, but my chuck won't hold a bit any smaller than 1.5mm, I'm sure it'll be fine! Didn't take any pics, but I combined my lightest clutch shoes with the best backing plate and bell I've got and swapped them in, much better take off! And of course because I'm changing carbs soon I've almost got the tune nailed  , think it could be a touch richer mid throttle, but low and WOT are pretty well sorted IMO! Just a pity I'm changing carbs haha Oh and I ordered in new engine mount bushings, Suzuki wanted NZ$25e ex Japan, I cross-referenced the size and found there used on a lot of Honda scoots, $12e and will be in store in the morning! Fingers crossed I can find one for the rear shock too! |
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Post by niz76 on Feb 15, 2016 5:41:36 GMT -5
Nicely done Raizer! Loving this thread!
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Post by Raizer on Feb 17, 2016 1:57:32 GMT -5
Cheers niz76! Again I've got nothing too exciting to report, picked up my new engine mount bushings from Honda, no luck finding a shock bush though, but the Let's 4 engine I've got came through again with a like new one which I swapped into my case when I fitted the other bushings.  Last night I spent much longer than expected masking off all the gasket surfaces and bearing seats etc.  Hung the cases up and gave them a good scrub with wax and grease remover  And then hit them with a few coats of paint   Struggled to get a good pic of the colour in the shed lighting, but it's a charcoal metallic and I think it looks pretty sweet!  Just waiting on my bearings and torque wrench to get here and I can start assembly. |
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Post by tsimi on Feb 17, 2016 2:32:48 GMT -5
How did you close those little screw holes? Hot glue?
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Post by Raizer on Feb 17, 2016 2:50:59 GMT -5
Rolled up masking tape so it was just thick enough to thread in for the threaded holes.
I decided I didn't want paint where the heads of the 6 screws that hold the halves together go, just so there's nothing under the screws when I torque them, so I wrapped insulation tape around the thread of some shorter screws with the same heads until they were a tight fit and pushed them into the holes.
Hot glue would no doubt work well too though, I considered it last night, but my glue gun is in my workshop and I couldn't be bothered going to go get it lol
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Post by Clank on Feb 17, 2016 6:33:21 GMT -5
Rolled up masking tape so it was just thick enough to thread in for the threaded holes. I decided I didn't want paint where the heads of the 6 screws that hold the halves together go, just so there's nothing under the screws when I torque them, so I wrapped insulation tape around the thread of some shorter screws with the same heads until they were a tight fit and pushed them into the holes. Hot glue would no doubt work well too though, I considered it last night, but my glue gun is in my workshop and I couldn't be bothered going to go get it lol Ear plugs |
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they wear like hell and nearly all of them get damaged and get deep scratches from sand and other contaminations. I guess from all the tinkering they get subjected to.
, think it could be a touch richer mid throttle, but low and WOT are pretty well sorted IMO!
