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Post by oldgeek on Apr 20, 2024 8:45:45 GMT -5
Malossi 6113501 has been working well for me 731.9x18.2x30x8.74 Scooter parts co has them and all Malossi parts pretty cheap ($29).
I believe a true 738 will be too long.
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Post by dexameth on Apr 20, 2024 13:05:44 GMT -5
Good info oldgeek, thanks!!!
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Post by dexameth on Apr 20, 2024 13:06:28 GMT -5
I did just realize I'll need the NCY drive face as I'm pushing past the ramp surface of my current drive face
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Post by dexameth on Apr 21, 2024 6:41:07 GMT -5
All together, and running!  Engine bay mostly cleaned up  I had to modify the mount on the radiator, one to fit the bolt pattern of the ZX and then again to fit the overflow tube. I believe this is where they proposed the overflow tank to go, as the rubber mount fits oh so good. But, it left no room for the hose! I drilled a quick hole and it seemed to work just fine. Recycled a PCV breather from a 4 poke air box to get the nice tight bend from the radiator.   |
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Post by dexameth on Apr 21, 2024 6:43:50 GMT -5
Alright guys, I didn't document enough but the engine is in, fired right up 3rd kick, and I've taken it around the block a few times. Didn't even get the temps past 95°c at the spark plug. Felt great! 24mm carb, 48/120 jets seemed a bit rich but good enough to not hurt anything.
I did a couple laps around the trailer park then parked it and went for a good ride about an hour later. I got one mile down the road and my overflow to the radiator was spewing coolant out. Literally spraying like a stream out of the overflow tank breather! Pulled over and killed the engine, dumped the overflow out and all seemed well. Got halfway back home and it started doing it again. Pulled over and parked for a minute, then started walking on the sidewalk... then figured I'd start it up and limp it home. Temps were showing 130°c at the spark plug head, the radiator temp only showed 40°. I thought it had bled all the coolant out so I was worried. I have a little hose pushed into the breather cap of the overflow, and that hose it directed to the side of the scoot so luckily when this happened it mostly just sprayed around me.
I drove about 10mph on the sidewalk all the way home, until about a quarter mile from my place then got it up to about 30mph. Temp went from 130 to 112! weird...
So why the heck is this thing continuously spewing coolant? It's literally a stream, like a water fountain. At first I suspected blown head gasket, but it starts first kick and doesn't blow excessive smoke out the exhaust, typical 2t oil smoke is all.
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Post by 90GTVert on Apr 21, 2024 7:21:06 GMT -5
Mine would fill up the overflow and then actually overflow (pressurized spray from the tank cap) when I had head sealing issues. Could be combustion pressure finding it's way into the coolant passages. It would usually run fine. I wound up getting a ride in a truck a few times, but generally because my coolant temps were high (measured at the head) and it just kept going through water/coolant. Most of the time for me, this was poor design of the cylinder head setup. Had it with both of the Taiwan 54mm bores and my TPR 86cc for Minarelli. The Taiwan kits were setup for equal clamping force on the coolant to outer seal while many appear to have a slightly larger gap out there to allow more clamping force around the bore/stud section. The 86cc just had super thin dividers around the studs and bore that could crack or break, especially if over-torqued at all.
I noticed the temp gauge on the radiator cap. Is that the only gauge for coolant temp? Never used one, but curious if it would be effective with lower coolant levels.
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Post by dexameth on Apr 21, 2024 18:54:03 GMT -5
I installed a Koso clone inline water temp sensor tonight, as that cap was the only water temp sensor. It has a probe that would feel the water coming in from the tube, so even at low level it would sense the temp... but I suspected that cap from not sealing against the lower point as the gaskets were not like the OEM cap. They are much closer together, making me think the "reach" of the fancy cap wasn't enough, allowing the pressure to push by easily. Well after installing the OEM style cap it was still spewing coolant.
I have been going back and forth in my mind about a blown head gasket so I thought, why not try to re torque the head bolts and OMG THEY WERE ALL LOOSE. Like, a good half turn on each to get tight. Why wouldn't I be "burning" coolant, or running rough? Idk. I torqued them all down and fired it up. No pressure. No spraying. Rode around the trailer park a few times. Saw 155°F at the spark plug and 120°f water temp after idling for a while. No time for a test drive but I think I found the problem. Base gaskets are compressing! Now I should recheck the squish haha but it's Sunday night and I'm tossing in the towel after the positive progress.
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Post by dexameth on Apr 21, 2024 18:55:31 GMT -5
See how the fancy cap has the gaskets close together? I didn't think the lower gasket would reach the radiator to seal. I've been using the OEM style cap to verify a good seal. After tonight's progress I'll probably try the fancy one again.  |
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Post by dexameth on Apr 22, 2024 8:19:42 GMT -5
Oh hey, just found the NCY drive face for Ruckus which is 26 splined just like my Kymco... and it's 93mm outer diameter should pair up nicely with my 95mm vari. Amazon had it next day for $33! Score! This engine will be kickstart only so I like the idea of no bendix teeth on the outer rim, which also allows the belt surface to go all the way to the edge. Overrange!
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Post by dexameth on Apr 22, 2024 19:09:45 GMT -5
...I'm gonna need a bigger fuel tank...
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Post by oldgeek on Apr 23, 2024 18:09:26 GMT -5
All together, and running! Engine bay mostly cleaned up I had to modify the mount on the radiator, one to fit the bolt pattern of the ZX and then again to fit the overflow tube. I believe this is where they proposed the overflow tank to go, as the rubber mount fits oh so good. But, it left no room for the hose! I drilled a quick hole and it seemed to work just fine. Recycled a PCV breather from a 4 poke air box to get the nice tight bend from the radiator. Hard to tell for sure in the 2nd picture, but I think the pump/water plumbing is not right? Pump should be pumping cooled water from the radiator into the base of the cylinder, looks like inlet of pump may be connected to the base of cylinder? |
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Post by dexameth on May 2, 2024 6:05:33 GMT -5
All together, and running! Engine bay mostly cleaned up I had to modify the mount on the radiator, one to fit the bolt pattern of the ZX and then again to fit the overflow tube. I believe this is where they proposed the overflow tank to go, as the rubber mount fits oh so good. But, it left no room for the hose! I drilled a quick hole and it seemed to work just fine. Recycled a PCV breather from a 4 poke air box to get the nice tight bend from the radiator. Hard to tell for sure in the 2nd picture, but I think the pump/water plumbing is not right? Pump should be pumping cooled water from the radiator into the base of the cylinder, looks like inlet of pump may be connected to the base of cylinder? I have the pump sucking the water from the cylinder spigot, it flows the hot water up to the top of the radiator. It cools, comes out the bottom of the radiator and flows to the head. |
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Post by dexameth on May 2, 2024 6:18:53 GMT -5
So I got the AliExpress spacers in. Coulnd't believe it, took just over a week to get two 1mm spacers and a set of colorful handlebar switches. Last time I ordered the switches it took almost a month! The spacers won't work. Check out how the boost port is MUCH too big. The transfers are the same size, but like "wider" in the middle causing it to make contact with the intake manifold. If I file it down so the bolt holes line up, I'll literally file the spacer away to make it fit.   We have some aluminum supply houses around here. I may try to fabricate my own, I just don't have very good tools so wish me luck!! Or, if anyone knows of any spacers that just bolt up... please let me know! |
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Post by oldgeek on May 2, 2024 15:56:54 GMT -5
Hard to tell for sure in the 2nd picture, but I think the pump/water plumbing is not right? Pump should be pumping cooled water from the radiator into the base of the cylinder, looks like inlet of pump may be connected to the base of cylinder? I have the pump sucking the water from the cylinder spigot, it flows the hot water up to the top of the radiator. It cools, comes out the bottom of the radiator and flows to the head. I think hot water through the pump is no good, it will shorten the life of the pump.  Try and set it up like I mentioned in my previous post. |
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Post by dexameth on May 9, 2024 14:54:05 GMT -5
I have the pump sucking the water from the cylinder spigot, it flows the hot water up to the top of the radiator. It cools, comes out the bottom of the radiator and flows to the head. I think hot water through the pump is no good, it will shorten the life of the pump. Try and set it up like I mentioned in my previous post. Strange... as this is how I've noticed many cooling systems operate... be it aftermarket electronic pumps or factory mechanical pumps, they all seem to pull the heat away from the cylinder, allowing cool water to enter the head. |
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Try and set it up like I mentioned in my previous post.