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Post by sevenninesandtens on Aug 31, 2020 17:10:39 GMT -5
new base gasket should be here this week so I should be able to get it reassembled soon. Carb is all clean. Just waiting on the gasket to put it back together. I still gotta hook up that dyi ultrasonic cleaner and run the piston through that to try and get the gummed up oil from under the piston rings.
slow progress.
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Post by 190mech on Aug 31, 2020 17:57:59 GMT -5
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Post by sevenninesandtens on Sept 18, 2020 21:52:05 GMT -5
So I got the gasket finally. Put her on and torqued it all up. Did a leak down test and have leaks around the intake and top of the cylinder where it meets the case. No issues there I can seal them up.
Next I was looking at the variator and it's definitely sealed. Read in the book that you can only replace the whole unit. Boring. So I gotta look for a new one, but the crank shaft is bigger than on my Vino. Do variators come in other sizes for the mounting hole?
Other thing is the belt. The lowest it sits is still quite a bit high up in the vari. Was thinking of trying a smaller width belt to try to get it to seat lower. Current one says yamaha 17M-17641-10 anyone know what length that is? 641mm seems WAY too short and I'm not finding anything online yet.
Another thing I noticed was the oil line from the pump to the carb is cracked. So I'm probably just gonna go premix.
All this in about an hour of working on her.
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Post by 190mech on Sept 19, 2020 4:45:27 GMT -5
Jog 90,Polaris Sportsman 90,and BWS 100 all have the big spline Yamaha variator shaft,yours is likely the same,,
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Post by sevenninesandtens on Sept 19, 2020 8:18:12 GMT -5
Jog 90,Polaris Sportsman 90,and BWS 100 all have the big spline Yamaha variator shaft,yours is likely the same,, Thank you!
trying to find any info on this scooter has been like using a brick as a web browser...
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Post by geoffh on Sept 19, 2020 9:03:50 GMT -5
I have a few Yamaha belts on hand 4VP-17641-00 752mm,3AA-17641-00 738mm,the 17641 seems to say drive belt,I use a piece of tape on the bench and roll the belt along it to get a true length.
Geoff
Also worth a mention ,there is a service manual in the tech section ,to the left on this screen .
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Post by sevenninesandtens on Sept 22, 2020 12:10:17 GMT -5
I have a few Yamaha belts on hand 4VP-17641-00 752mm,3AA-17641-00 738mm,the 17641 seems to say drive belt,I use a piece of tape on the bench and roll the belt along it to get a true length. Geoff Also worth a mention ,there is a service manual in the tech section ,to the left on this screen . I have a manual, came with the bike thankfully. It's not the most informative though...
Got the gasket and put the cylinder back together and on the case. My leakdown tester doesn't seal in the intake fully. Different size intake than my Vino by just a little bit. Next chance I get I'll try gluing some old bicycle tube to the pvc to seal it up better.
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Post by sevenninesandtens on Sept 22, 2020 12:14:41 GMT -5
Kick starting your scoot is the norm here,not sure what you mean by cracked ignition coil,photos help Geoff second photo I posted originally shows the crack. It's that white round part on the CVT cover. No clue if it's an issue yet or not. It's still all in pieces. Got the cylinder done though. working on the Carb and cvt next. The carb's float needle lost the little rubber end that seals it so I gotta try to find a replacement for that one.
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Post by geoffh on Sept 22, 2020 15:24:19 GMT -5
Your ignition looks like an old version of the current one a £15 "service" part.float needle is a 17L 14190 00 00 Unazom.com list one available £3.75 check the numbers and take a punt at that price.
Geoff
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Post by Steve B on Sept 23, 2020 17:30:26 GMT -5
Sevenninesandtens, I like you're build progress.
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Post by sevenninesandtens on Sept 23, 2020 20:54:13 GMT -5
Sevenninesandtens, I like you're build progress. Thanks! I gotta upload some more pics of the progress, even know it's been kinda slow going.
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Post by sevenninesandtens on Sept 23, 2020 21:01:44 GMT -5
Decided after looking at Brent's Malossi Overrange install thread to measure the variator and pulley and the rear pulley and torque driver.
Variator measures 109mm Fr Pulley 111mm R Pulley/TD 132mm
So rather than needing the whole overrange set up I could get by with a 16mm spline Malossi variator even know that measures 10mm smaller. Maybe that would work since I can't swap rollers to deal with the belt travel (or lack there of). I'll try and post pics of the wear lines on both. there's a good 10mm or so of travel available on the variator and about that much on the rear pulley.
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Post by sevenninesandtens on Oct 7, 2020 17:28:18 GMT -5
GD-it
Crank seal is shot. Got the cylinder back on and went to do a pressure test and didn't hold any air. Took the variator and the starter and all that nonsense out and sprayed the crank with soapy water and hello air bubbles!
Sigh.
I did remove the oil pump (had a cracked hose so I just removed the whole pump) and blocked off the hole with a part I got off ebay. Now I gotta order an oil seal for the crank and try again.
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