TnG Venice Project - My first project scoot

[AtariGuy]

Update - done tore into the powerhouse. I have a bone stock engine, 12mm wrist pin, 15 spline 16mm crankshaft build.

However, the stator is jacked up, it rotates below the flywheel (puller tool should arrive tomorrow with the post) and appears some wires have torn free under it. Need a new one, will find which style it is when i get there. Plus, the flywheel nut is missing and it doesn't have the cooling fan or shroud...

I need to get a top end kit, the cylinder is scored, the rings are busted, and the piston is ruined. I suspect that the PO kept trying to use the oil injector not knowing it was busted and that burned up the cylinder. Good news is, i already planned to go 70cc anyway. PO tried to use black silicone on the spark plug, i would need to chase the head threads, but otherwise the head is usable to anyone who wants it.

The previously mentioned busted kickstart blew the fins off the fixed face on the variator and those busted pieces scored the pulley faces. So i will need a replacement variator, belt, and cvt cover with kickstart stuff.

I still need to split the case and inspect the crankshaft, but from what i see through the jug port, its quite heat stressed. My right case half arrived yesterday so the old, busted one can be stripped and recycled. I'm going to replace the crank bearings and seals whether they need it or not, so thats on my list.

I think that about covers what i've seen so far, so if anybody has gently used replacements that you don't use, i'd be glad to buy them from you (and i'll pay shipping too) - please PM me.

[AtariGuy]

So I took a mental step back to look at the project. I realized I may be overthinking all this and detailing stuff that every scoot builder already sees on a normal day. Perhaps I've been writing this as some kind of journal on my first build, and hoping to provide depth and story to something more than "well, i bought this and this, put it together, now it's a 60mph scoot" - at least to keep some kind of entertainment value or to provide some kind of thought process for new builders as well.

Update on the engine, I do have it all but split now that my flywheel tool came in. Realized I'm short one case splitting tool and all my local parts stores are closed now, so I'll complete that tomorrow and bring it to the DIY car wash and put their pressure washer onto "engine degreaser" mode. I took some pictures, but they're nothing amazing, more or less just some kind of reference pictures for myself to make sure I get the right parts - like which plugs i have on my stator, the wire colors, etc...

Side note, seems I have a slightly different version of the chinarelli unlike that which most other pictures here show. my final gearbox has a five bolt cover completely underneath the clutch/rear pulley. QJ1E40QMB - I'll attempt to get some pictures of the rear gearbox area for some clarity...

[oldgeek]

Jan 31, 2017 1:47:12 GMT -5 AtariGuy said:

So I took a mental step back to look at the project. I realized I may be overthinking all this and detailing stuff that every scoot builder already sees on a normal day. Perhaps I've been writing this as some kind of journal on my first build, and hoping to provide depth and story to something more than "well, i bought this and this, put it together, now it's a 60mph scoot" - at least to keep some kind of entertainment value or to provide some kind of thought process for new builders as well.

Update on the engine, I do have it all but split now that my flywheel tool came in. Realized I'm short one case splitting tool and all my local parts stores are closed now, so I'll complete that tomorrow and bring it to the DIY car wash and put their pressure washer onto "engine degreaser" mode. I took some pictures, but they're nothing amazing, more or less just some kind of reference pictures for myself to make sure I get the right parts - like which plugs i have on my stator, the wire colors, etc...

Side note, seems I have a slightly different version of the chinarelli unlike that which most other pictures here show. my final gearbox has a five bolt cover completely underneath the clutch/rear pulley. QJ1E40QMB - I'll attempt to get some pictures of the rear gearbox area for some clarity...

You have shortcase horizontal minarelli there. Very common in the retro scooters like the venice and yamaha vino and some small ATV. More info here.

49ccscoot.proboards.com/thread/999 Have fun!

[AtariGuy]

I see what you mean! I had just assumed before that the long case was just stretched to be proportional to frames. Didn't realize the rear clutch shaft and the axle were staggered that far apart. Is there a side by side comparison to how the short and long case gear housings differ? Cuz curiosity just bit this cat lol

[niz76]

The shortcase gearbox is pretty compact and the main shaft to the tire comes out one side of the case the same place the input shaft of the clutch goes in. The longcase is almost like the gearbox is 'hanging off the back of the engine'.
The output shaft to the rear tire is about 5"-6" further back than the input shaft of the clutch.

For this reason the gearboxes are totally different and gears aren't interchangeable.

Here's some real good info from the Tech Library here that Brent has put together. (Almost anything you'd want to know about Longcase or shortcase or any variation of our Minarelli 2t's can be found in the tech library!)

49ccscoot.proboards.com/thread/6145/minarelli-clone-bearings-seals-torque

[AtariGuy]

Tore into my gearbox, primary 13-48, secondary 12-36. Comes out to 11.077 gears. Everything is stamped with QJ so i assume my gears are pretty picky, but i'd like to figure out how to bring the gears down to about 10.3 eventually. And tomorrow looks like better weather for the power sprayer, so some clean cases will be coming up soon. Thanks again to everyone whos chipping in on parts to this. All worth the 20 bucks i donated to the cause!

[AtariGuy]

Speed list update, it can do zero to 12mph in 30 feet... thrown... lol i am having problems trying to get the bearings, bushings, and seals off the left carter. I have a scheduled case dip and bake friday at the local cycle shop and would like to get the case down there with no hitch hikers still attached. Any tips?

[90GTVert]

Seals should be easy enough if you can get the bearings out. Then you can use a socket or something with a mallet to tap them out from the back. If you have a heat gun, heat the cases before trying to remove the bearings.

youtu.be/MxIW7Pj_NEI?t=4m46s

www.youtube.com/watch?v=lt7GCyDsVpo

[niz76]

During assembly and disassembly keep the Hot/Cold rule in mind; "Cold shrinks stuff and Heat expands it". Many of these parts are a very very tight fit and almost impossible to remove/install without heating/cooling.

So for example you could try to use a heatgun or torch or whatever to heat the case area and expand it and use some freeze spray to shrink the bearings and hopefully they'll pop out. I have regularly used cans of electronics duster flipped upside down for instant super freezing of parts. Good Luck!

[AtariGuy]

(Previously posted in "what i did to my scooter today" thread)
I have spent most of the day with my wife doing valentines stuff. Earned me a go-ahead on a naraku sport 70cc kit! Also spent the last 3 hours uncorking PO's corked up black silicone air leak sealing job - at least the bit of mess involving a seriously gummed up carb. Wife swears i must've swapped to a brand new mikuni i had stashed somewhere. Definitely need jets though...

To detail more, the dude who owned this scooter before me claimed he attempted fixing some kind of leak that caused the scooter to run like hell if at all. I swear he used zero finesse trying to seal this that and everything else from the airbox to the cylinder. Anywho, tonight was "detail the carb night" and i am still astounded by the lack of aptitude he had. There was black soup inside the bowl, silicone up and down the slide (no wonder the throttle cable broke) and so much gummy crap everywhere. I did get it all cleaned out and polished up, it looks like a brand new mikuni! Its been jetted at 22.5 pilot, 70 main.

So on my order list is a set of jets, oil seals, complete gasket set, and a carb seal kit. And the naraku cylinder kit - but thats gonna wait til we have a little more disposable cash after the bills are done.

180ºoff sent me the first half of a big pile of parts - and i spent some time sifting through a lot of it. Theres a pretty decent stock iron jug i gave a 2 day vinegar soak to and coated, a nice movable variator face that i refaced, and a nice backup pile of bits. Looking forward to the cvt cover in the next box. Ryan_ott and niz76 also have parts flying out my way, and i'm starting to feel like a kid at christmas! Theres so much love here, i can't even express how awesome it is that ya'll are chipping in with parts and advice and info and just so much brotherly love, its awesome! I chipped in 20 bucks last week to the forum, but i almost feel its not enough for what ya'll have already given me! If i could afford it, i'd send brent a grand. I need to win the lottery, rc-ones for everybody!

[niz76]

 Awesome to hear Atariguy! Stator should be to you on Thursday! Pm'd tracking info

[AtariGuy]

Well heres my breakdown currently, kinda like it! I'd love if it were all together. Thats the old piston by the way, so yea it looks like garbage. New small case half, 180's jug, and the carb i cleaned last night. I figured i'd get some pics anyway just so you can see what i've been up to

[niz76]

You're right, that carb does look brand new!

[AtariGuy]

I noticed on my way out the door to work today that my display was all jacked up lol has anyone spotted "whats wrong with this picture" yet?

[niz76]

I noticed that the cylinder was on the studs upside down right away, but ya know- didn't want to be that guy to point it out lol.