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Post by strgazr27 on Oct 9, 2015 8:29:30 GMT -5
My Mother In Law bought this for my Father In Law back in 2006. He wanted a motorcycle, she said fat chance and bought him this instead lol. He rode it for 13.7 miles at which point he proceeded to lose control one day and drove it into the garage door. He parked it and there it sat for the last 6 years. He never drained the tank, or removed the battery  . He pulled off the cracked front panel, floor mat and started piling shit on top of it. I couldn't stand it anymore and after years of hearing him tell me he was going to ride it someday I told him no you're not. You're 80 and those days are over so let me have it as a project. He looked at me and said I was right, have fun with it! This is it the morning I went to dig it out and pick it up.  Threw it in the back of my Tahoe and brought it home. Here it is IMBY ready for teardown.   It doesn't look that bad in the pictures but it had tons of scratches and scuffs from sitting under a pile for the last 6 years. The front fender was cracked from the hit, mirrors were loose, front plastic is missing which I am trying to find in the garage but may need to order online if I can find one and front and back tires were barely full of air. And so it begins..... |
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Post by strgazr27 on Oct 9, 2015 8:40:14 GMT -5
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Post by strgazr27 on Oct 9, 2015 8:45:40 GMT -5
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Post by 90GTVert on Oct 9, 2015 8:53:35 GMT -5
Excellent paint work. Sounds like it may be a good thing your father-in-law didn't get a big bike.
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Post by strgazr27 on Oct 9, 2015 8:56:06 GMT -5
At this point I began pulling the scoot apart to find out what was wrong with it, what needed to be replaced and or upgraded and what the electrical system looked like as I had found several scary issues while removing body panels. The carb was shot. There was no way in hell I would ever get the thing clean and useable, even with the ultrasonic cleaner we have at work. The gum and rust had taken to big a toll. The fuel valve was leaking rust colored gas through the vacuum side so I knew that needed to be replaced. Off came the tank for a thorough cleaning and a new petcock. the tank was emptied, brought into work and allowed to sit for several hours in the parts washer. Followed that up with a complete wash out with alcohol and blow out with compressed air. The tank was in decent shape after this. A new fuel valve was installed and the tank bolted back up. I replaced all the fuel and vauum lines with fresh silicone lines.   |
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Post by strgazr27 on Oct 9, 2015 9:06:16 GMT -5
Pulling the head off revealed the damage sitting had done. It was VERY stiff to try and kick start and with a fresh battery it sounded horrible cranking over with the electric starter. It looks like the rings had started to corrode to the cylinder wall. The connecting rod was covered in surface rust and draining the oil revealed it was almost empty. Barely enough to provide lubrication. So the next order of business was to order a BBK kit, new Kei-Hin Carb, A9 cam, high flow muffler, jet kit and oil pump assembly. I was able to clean up the connecting rod, flush the block and ditch the exhaust while I waited for parts to arrive.   |
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Post by strgazr27 on Oct 9, 2015 9:24:14 GMT -5
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Post by strgazr27 on Oct 9, 2015 9:37:02 GMT -5
  After the install I couldnt get it to start. Checking the plug found it was in bad shape. Installed an NGK and still had no spark. Checking out the plug wire I found it brittle and cracked in several spots. Testing the coil found no output. Looking at the condition of the CDI box and the coil I decided to order a new coil, wire and CDI. At this point it didn't pay to use any of the old stuff. Once they were installed I discovered an intermittant no crank condition. Manually jumping the starter relay confirmed a bad relay. I pulled it apart but found the contacts beyond help so I ordered a new relay. THANK GOD parts are relatively cheap for these scoots lol. |
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Post by katastroff on Oct 9, 2015 10:05:33 GMT -5
Would be a lot less typing to list the part you kept.  That's gonna be one sweet ride!!!! |
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Post by strgazr27 on Oct 9, 2015 10:17:39 GMT -5
At this point it was time to tackle the electric issues that the scoot had which were MANY! The horn didn't work, the front turn signals didn't work, the scoot would not shut off with the key, the headlight suffered from intermittent issues and I discovered to open connections and one rogue wire flying in the breeze lol. as it turns out a lot of the issues came down to bad bulbs, bad/loose grounds and or poor connections. I replaced all the bulbs in the scoot with LED's except for the rear turn signals. These I think need a resistor inline as they will not flash. The fronts work fine but the rears stay on solid. Any thoughts on this? The headlight came down to a corroded connector. I CANNOT STAND the stock headlight and would love to swap it with a higher wattage bulb or LED but cannot figure out how to replace it, It is the old H4 style with the 2 solder bumps on the bottom for a connection into a bayonet style mount. What could this be swapped for? Thanks to spaz12 the no shut off with key issue was merely finding the correct position for the alarm jumper. THANKS spaz for the help with that! Than found several wires melted from laying up against the ballast resistors. UGH. Lots of splicing, heat shrink and dielectric grease fixed those issues. At this point I have fixed every electrical issue. I than took apart every plug I could find cleaned the terminals, filled with dielectric grease and plugged them back together.      |
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Post by strgazr27 on Oct 9, 2015 10:19:00 GMT -5
Would be a lot less typing to list the part you kept. That's gonna be one sweet ride!!!! LMAO I know right. If I didn't get the thing for nothing I would have sold it for parts and bought new. |
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Post by strgazr27 on Oct 9, 2015 11:23:14 GMT -5
Turned my attention to the CVT. I replaced the belt as it looked real dry. Im waiting for my new compressor to show up so I can run my impact tools again so until than the stock clutch springs, ciontra spring and rollers are staying. I did take some time with a caliper and uni-bit to vent the CVT cover.   I also added a cool scoop I picked up on Ebay. I don't know if it really helps with cooling but it looks pretty good lol. I removed the stock plastic grating from the original cover. I than cleaned, scuffed up and epoxied the scoop tio the stock cover. After this was dry I took a little filler and smoothed the gap where the 2 met. A couple coats of black dip had it looking pretty good.  |
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Post by strgazr27 on Oct 9, 2015 11:29:23 GMT -5
This is how it sits right now. I would love to keep the front end open like this but it would require a custom moulded piece to hide all the wiring etc. Hoping to add the front fairing tonight. See how it looks with just that in place. If it looks like I think I may just leave the front fender off. Any thoughts?   |
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Post by strgazr27 on Oct 9, 2015 11:47:42 GMT -5
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Post by ams417 on Oct 9, 2015 12:03:23 GMT -5
Awesome build documentation. When I get started working I always get so focused I forget to take pics. These bikes are a lot of cheap fun.
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. He pulled off the cracked front panel, floor mat and started piling shit on top of it. I couldn't stand it anymore and after years of hearing him tell me he was going to ride it someday I told him no you're not. You're 80 and those days are over so let me have it as a project. He looked at me and said I was right, have fun with it!
