Post by ronnie on Jun 24, 2018 13:45:50 GMT -5
Dear Friends,
regarding to Raizer-s idea to make separate thread, i would like to introduce you my work. Because of some unexpected "situations" in adult/family life, the whole project was 3months delayed... so is still in progress. I was hesitating to let the Scoot in stock look and only renew the bad parts, but because of low possiblities to get new parts (written lower also...) and daily use, i prefer to make the bike more usefull. Also, the Let's II wasn't exceptional or cult masterpiece, which would be worth to let as it was. Most of them are already dead because of age, Morini engine etc...
Introducing :
Suzuki Let's II (rare low light model), year 98, from first hand (family). The Scoot was in 90% stock/factory and "running" condition, but there was minimal inspected parts (i mean inspection/service parts like belt, clutch, vario,suspension, etc...) changed. So i need to change maybe everything, because of the age of the Scoot. If this should happen, then i had "dream bigger" and make some mods, to become more modern look, power, fun... My budget is (specially here in Slovakia) bit more limited, also some parts are impossible to get, or they have enormous costs. So therefore i need to let some parts construct, modify. They are no 100%, but i hope they will work !
Picture from web (i don't have the old photos, but except the colour, it was the same...
The main troubles for me for today driving was the small 10" wheels (for our roads), basic suspension (one part from suspension is directly soldered to steering oculars, joke...), AC powered CDi which was factory blocked and the unlocked version is maybe the most expensive part to get for this bike, (sometimes dangerous on the roads that you cannot reach the unlocked +10KM/h), AC powered lights (cannot use modern, efficient and high powered light source as xenon or LED. The factory old "candles" wasn't in sunny shiny days safe anymore, regarding to high traffic), very very low quantity/possiblity to get new parts (or maybe just here in Slovakia, but it is very difficult or expensive to get some Let's II or Moto Morini parts...) and as i write upper, the whole Scoot needs inspection (carb leaks/low power, belt damaged, vario weights brushed, front/rear suspension without function, damaged seals on crankshaft etc...).
If you see/read the new parts list below, maybe you ask "why you didn't buy something else in great condition or maybe whole new chinese Scooter ?".
Two reasons : 1. (less important...) Because we everybody need some time to chill. In my situation is now "my lounge to chill - the garage". 2. (most important!!!) Based on our country laws/regulations for vehicles (motorcycle - 49ccm - age/year 1998 - max.construct speed 45KM/h) doesn't need any registration ! So i don't need to have registration number plates, technical controls, mandatory equipment for vehicles (first aid, reserve bulbs, etc...). It is classified almost as bicycle. So every newer, bigger, factory faster Scooter needs registration and "everything" around as for example 1200ccm motorcycle, car or truck... Having a "fast bicycle" is a great thing and i love lo live with this option in regulations.
Main mod parts are from Yamaha Jog special RR edition :
12" white alloy wheels, front + rear Paioli suspension, Brembo brake calipper, oculars, electro wiring... all other parts was bought step by step, and completed in garage, waiting for fitting.
The (maybe) complete list of new parts are next :
Custom front mask with Suzuki GSR headlight
12" white alloy FRONT + REAR wheels
100/60/R12 Duro FRONT + REAT tyres
FRONT steering oculars for 26mm suspension
FRONT disc brake
FRONT Brembo brake calipper
Digital speedometer signal directly mounted to front wheel holder shaft (factory Jog RR)
FRONT Paioli suspension
Fully digital speedometer
LEFT + RIGHT side hadlebars with switches/controllers
Koso mirrors
Malossi kevlar intake valves
All seals new + NEW drive bearing
Custom 19mm intake manifold with separate oil injector
Arreche 19mm carb
Fuel + oil hoses + filters (of course...)
Kartbox air filter housing
Malossi vario belt
Vario weight wheels
Brake light flash strobe controller
REAR light
REAR Paioli suspension
REAR LED sidelights + LED flash regulator
Yamaha JOG RR factory unrestricted DC CDi
Yamaha JOG RR factory DC wiring
12ah Exxide battery
USB/dual USB port 4.2A with voltmeter
The procedure :
The first step was the front mask. It is still in progress. The final step would be painting to black color (to become "one" piece and cover the weldings). The plastic "bridge" under (the factory light bottom holder) would be removed. It looks like "street transformer"
It is very slow and heavy job, because we want to let the circuit and the mounting points to other pieces of bikes body. Everything needs to fit as the factory front. The light source would be LED-s. I had also idea to use LED tubes and use them as position/parking lights at night. But, i wont let them uncovered in mask, and i didn't find anybody near, who can make some shape from plexi to cover the LED tubes. The next idea is, to mount them inside the headlight. I'm hesitating, it depends on possibility to open the light.
The next step was the front oculars/suspension holders/both wheels. Because of Let's "funny" front suspension and oculars, i cannot replace them with others. Like this (as you see, the upper part from suspension os directly soldered to oculars) :
No problem ! I bought from JOG RR also this front part ! The bar was disassembled front factory front, and mounted to JOG RR oculars
BUT.... the seller has "forgot" to tolda me, that JOG had an accident. After mounting the front together (wheel, brake, tacho, suspension, bar) i saw, that oculars have cca 1cm difference in one side. So if you take a look at mounted front, suspension on one side was cca 2cm behind to next side. This damage wasn't visible without mounting.
I would not buy everything again, and other (is not so hard to buy a complete front). I had HQ suspension (front and back), wheels, brakes, but no oculars to mount them. There wasn't on the market other JOG RR with same config. There was a fight to find oculars with 26mm mounting holes for my suspension. I can get 28mm-30mm-31mm, but no other. I found one piece, which should be OK for me, cca 20KM away. LUCK !! Was there ! Bit rusted, thinner material, from some chinese scooter. Because the factory bar from Let's was already pressed and soldered to damaged JOG oculars, i decided to let the "new" oculars as they are. Two times soldering, pressing - not so healthy and safe. This would be task for future, because the steering handlebar mounting point are different. Everything would fit, and it fit's, but the Suzuki handlebar need some mod to fit as it should. I was happy, to put everything together,but..again. The seller has again forget to say, that theads in suspension holders and completely crap because of rust. Impossible... Impossible... This wasn't so big fault, but it takes time and also nerves. The material of oculars doesn't tolerate fault by thread cutting, but it is done. Im also happy with this forced mod, the suspension holds now like hell !!! Front ready, come on to rear wheel. The JOG RR wheels is (compared to Let's wheel) lot bigger, wider and with other drive/gear toothed wheel in the middle.
(Speech is about rear wheels, on the picture the fronts to compare. I don't have any photos)
The main problem was the mentioned toothed wheel in rear wheel. Suprisly the JOG RR wheel have smaller toothed wheel as Let's ! So the was some CNC and maschine work to make the hole bigger, and cutting the right "teeth".Wheel bigger - looks OK with the right tyre dimension, wider - looks also OK, rear drum brakes fits perfectly. The wheel is directly in the "middle", in range with front wheel, geometry is flawless, cca 1mm from the transmission housing, we see... The drive bearing is also new, this parts should not move. Living on the edge !
Next stop, carburetor. The factory Keihin was great carb for 20years. But today, with huge leaks, fueling/Jet/choke problems was impossible to renew it. Was time for new one. My choose was Arreche 19mm with auto choke option. If i needed to buy whole new carb, i choose one size bigger. BUT... i didn't know, that intake manifold in this (or any) size for Morini is today impossible to get, and also the carb doesn't have an option to connect the oil pump. Yes, it was misunderstanding with the dealer, my fault, but i let the carb. Why ? Because it's absolutely classic and modern carb. To the future, it is better to make custom bigger intake manifold with oil jet and using standard carburetors, as searching always for something special - expensive - nonexistent. The alu flanges from factory manifold was cutted and welded to Keeway Hurricane alu manifold knee (min. diameter 19mm). I also made a jet directly to manifold for connecting the oil hose from oil pump. Finally painted to black to cover the welding (not finally)
to be continued...
SORRY FOR MY VOCABULARY AND ENGLISH.
Greetings from Slovakia
Ronnie
regarding to Raizer-s idea to make separate thread, i would like to introduce you my work. Because of some unexpected "situations" in adult/family life, the whole project was 3months delayed... so is still in progress. I was hesitating to let the Scoot in stock look and only renew the bad parts, but because of low possiblities to get new parts (written lower also...) and daily use, i prefer to make the bike more usefull. Also, the Let's II wasn't exceptional or cult masterpiece, which would be worth to let as it was. Most of them are already dead because of age, Morini engine etc...
Introducing :
Suzuki Let's II (rare low light model), year 98, from first hand (family). The Scoot was in 90% stock/factory and "running" condition, but there was minimal inspected parts (i mean inspection/service parts like belt, clutch, vario,suspension, etc...) changed. So i need to change maybe everything, because of the age of the Scoot. If this should happen, then i had "dream bigger" and make some mods, to become more modern look, power, fun... My budget is (specially here in Slovakia) bit more limited, also some parts are impossible to get, or they have enormous costs. So therefore i need to let some parts construct, modify. They are no 100%, but i hope they will work !
Picture from web (i don't have the old photos, but except the colour, it was the same...
The main troubles for me for today driving was the small 10" wheels (for our roads), basic suspension (one part from suspension is directly soldered to steering oculars, joke...), AC powered CDi which was factory blocked and the unlocked version is maybe the most expensive part to get for this bike, (sometimes dangerous on the roads that you cannot reach the unlocked +10KM/h), AC powered lights (cannot use modern, efficient and high powered light source as xenon or LED. The factory old "candles" wasn't in sunny shiny days safe anymore, regarding to high traffic), very very low quantity/possiblity to get new parts (or maybe just here in Slovakia, but it is very difficult or expensive to get some Let's II or Moto Morini parts...) and as i write upper, the whole Scoot needs inspection (carb leaks/low power, belt damaged, vario weights brushed, front/rear suspension without function, damaged seals on crankshaft etc...).
If you see/read the new parts list below, maybe you ask "why you didn't buy something else in great condition or maybe whole new chinese Scooter ?".
Two reasons : 1. (less important...) Because we everybody need some time to chill. In my situation is now "my lounge to chill - the garage". 2. (most important!!!) Based on our country laws/regulations for vehicles (motorcycle - 49ccm - age/year 1998 - max.construct speed 45KM/h) doesn't need any registration ! So i don't need to have registration number plates, technical controls, mandatory equipment for vehicles (first aid, reserve bulbs, etc...). It is classified almost as bicycle. So every newer, bigger, factory faster Scooter needs registration and "everything" around as for example 1200ccm motorcycle, car or truck... Having a "fast bicycle" is a great thing and i love lo live with this option in regulations.
Main mod parts are from Yamaha Jog special RR edition :
12" white alloy wheels, front + rear Paioli suspension, Brembo brake calipper, oculars, electro wiring... all other parts was bought step by step, and completed in garage, waiting for fitting.
The (maybe) complete list of new parts are next :
Custom front mask with Suzuki GSR headlight
12" white alloy FRONT + REAR wheels
100/60/R12 Duro FRONT + REAT tyres
FRONT steering oculars for 26mm suspension
FRONT disc brake
FRONT Brembo brake calipper
Digital speedometer signal directly mounted to front wheel holder shaft (factory Jog RR)
FRONT Paioli suspension
Fully digital speedometer
LEFT + RIGHT side hadlebars with switches/controllers
Koso mirrors
Malossi kevlar intake valves
All seals new + NEW drive bearing
Custom 19mm intake manifold with separate oil injector
Arreche 19mm carb
Fuel + oil hoses + filters (of course...)
Kartbox air filter housing
Malossi vario belt
Vario weight wheels
Brake light flash strobe controller
REAR light
REAR Paioli suspension
REAR LED sidelights + LED flash regulator
Yamaha JOG RR factory unrestricted DC CDi
Yamaha JOG RR factory DC wiring
12ah Exxide battery
USB/dual USB port 4.2A with voltmeter
The procedure :
The first step was the front mask. It is still in progress. The final step would be painting to black color (to become "one" piece and cover the weldings). The plastic "bridge" under (the factory light bottom holder) would be removed. It looks like "street transformer"
It is very slow and heavy job, because we want to let the circuit and the mounting points to other pieces of bikes body. Everything needs to fit as the factory front. The light source would be LED-s. I had also idea to use LED tubes and use them as position/parking lights at night. But, i wont let them uncovered in mask, and i didn't find anybody near, who can make some shape from plexi to cover the LED tubes. The next idea is, to mount them inside the headlight. I'm hesitating, it depends on possibility to open the light.The next step was the front oculars/suspension holders/both wheels. Because of Let's "funny" front suspension and oculars, i cannot replace them with others. Like this (as you see, the upper part from suspension os directly soldered to oculars) :
No problem ! I bought from JOG RR also this front part ! The bar was disassembled front factory front, and mounted to JOG RR oculars
BUT.... the seller has "forgot" to tolda me, that JOG had an accident. After mounting the front together (wheel, brake, tacho, suspension, bar) i saw, that oculars have cca 1cm difference in one side. So if you take a look at mounted front, suspension on one side was cca 2cm behind to next side. This damage wasn't visible without mounting.I would not buy everything again, and other (is not so hard to buy a complete front). I had HQ suspension (front and back), wheels, brakes, but no oculars to mount them. There wasn't on the market other JOG RR with same config. There was a fight to find oculars with 26mm mounting holes for my suspension. I can get 28mm-30mm-31mm, but no other. I found one piece, which should be OK for me, cca 20KM away. LUCK !! Was there ! Bit rusted, thinner material, from some chinese scooter. Because the factory bar from Let's was already pressed and soldered to damaged JOG oculars, i decided to let the "new" oculars as they are. Two times soldering, pressing - not so healthy and safe. This would be task for future, because the steering handlebar mounting point are different. Everything would fit, and it fit's, but the Suzuki handlebar need some mod to fit as it should. I was happy, to put everything together,but..again. The seller has again forget to say, that theads in suspension holders and completely crap because of rust. Impossible... Impossible... This wasn't so big fault, but it takes time and also nerves. The material of oculars doesn't tolerate fault by thread cutting, but it is done. Im also happy with this forced mod, the suspension holds now like hell !!! Front ready, come on to rear wheel. The JOG RR wheels is (compared to Let's wheel) lot bigger, wider and with other drive/gear toothed wheel in the middle.
(Speech is about rear wheels, on the picture the fronts to compare. I don't have any photos)
The main problem was the mentioned toothed wheel in rear wheel. Suprisly the JOG RR wheel have smaller toothed wheel as Let's ! So the was some CNC and maschine work to make the hole bigger, and cutting the right "teeth".Wheel bigger - looks OK with the right tyre dimension, wider - looks also OK, rear drum brakes fits perfectly. The wheel is directly in the "middle", in range with front wheel, geometry is flawless, cca 1mm from the transmission housing, we see... The drive bearing is also new, this parts should not move. Living on the edge !
Next stop, carburetor. The factory Keihin was great carb for 20years. But today, with huge leaks, fueling/Jet/choke problems was impossible to renew it. Was time for new one. My choose was Arreche 19mm with auto choke option. If i needed to buy whole new carb, i choose one size bigger. BUT... i didn't know, that intake manifold in this (or any) size for Morini is today impossible to get, and also the carb doesn't have an option to connect the oil pump. Yes, it was misunderstanding with the dealer, my fault, but i let the carb. Why ? Because it's absolutely classic and modern carb. To the future, it is better to make custom bigger intake manifold with oil jet and using standard carburetors, as searching always for something special - expensive - nonexistent. The alu flanges from factory manifold was cutted and welded to Keeway Hurricane alu manifold knee (min. diameter 19mm). I also made a jet directly to manifold for connecting the oil hose from oil pump. Finally painted to black to cover the welding (not finally)
to be continued...
SORRY FOR MY VOCABULARY AND ENGLISH.
Greetings from Slovakia
Ronnie