Triton # 1 (T1) : Liquid Cooled Conversion & Updates

[90GTVert]

It does somehow feel better building your own... I mean after the feeling comes back in your arms. I'm not promising tire smoking videos, I do like my Boppers. Hmmmm. That little bent wheel from the Venus would fit. Might get rough with the bent rim though.

[90GTVert]

I stuck the engine together with a base gasket on each side of the spacer. I got 1.3mm of squish clearance, using just the o-ring in the head. I think I was using the Airsal's thinner base gasket before, so I might have to shave off a fraction of a mm more from the spacer. I got 180psi when I did a compression test, even with a wide squish clearance. The gauge shows 176 or so psi because it leaked for a second. It does that sometimes.



None of the fittings I had want to seal the big exhaust port, but I hooked up the rest of my leakdown tester. I decided to pump it to see if I heard the intake leaking or anything like that. I heard air coming from the stator side of the engine. I thought the reeds must not be sealed there or a base gasket has a small leak. Felt around and determined it was behind the stator, so maybe a bolt or the crank seal or something? I pulled the flywheel and stator off and pumped the leakdown tester again, only to feel air hitting me in the face as I looked around at all the bolts and the crank seal. After a moment, I noticed this...



I small cut in the case, just above my finger. I think I can seal that up with JB Weld, but it does make me wonder just how thin my case is all around there. I just looked back and you can actually see the hole in this picture from just after I got my cases back.



I'm not sure how neither the machinist or I noticed that. It looks pl;ain as day once you know what you're looking for in that pic. Apparently to do a proper clearancing job you need to make no contact with those outer walls.

[2strokd]

Very nice! Great work guys! Both of you..
Thanks for all the help!

[190mech]

J-B weld time!!

[2strokd]

Mix some aluminum dust in the JB...Itle be fine bud

[190mech]

I'm sure he's got a lot of aluninum dust around there!

[stepthrutuner]

Apr 1, 2010 21:08:36 GMT -5 90GTVert said:

It does somehow feel better building your own... I mean after the feeling comes back in your arms. I'm not promising tire smoking videos, I do like my Boppers. Hmmmm. That little bent wheel from the Venus would fit. Might get rough with the bent rim though.

That rim didn't look too bad. Should hammer out pretty good using soft metal or hard wood intervening.

[90GTVert]

I mixed some aluminum dust in with the JB Weld and sealed the case.



I pulled the cylinder back off and knocked .2-.3mm off of the spacer and got it back together. I'll let the JB Weld set up overnight and try to do squish, compression, and leakdown tests tomorrow.

[90GTVert]

I knocked a bit off of the spacer and got the squish down to 0.95mm. Cylinder pressure jumped up more than 10psi to about 192psi. According to the manual, I need 6 more psi just to be in spec with stock.



It passed a leakdown test after having to put some sealant on my reed gaskets. I'm 2 for 2 on those, makes me wonder if I've ever had 'em seal just right. Got the engine all tied up. It's not pretty, but I taped the seam of the air shrouds to make sure they seal. 90cc shroud works fine for the stroker.



I pulled T1 out from under it's cover and out from behind everything. Poor scoot is dusty and dirty and skinned up from being stepped around and stored for so long.



Slapped the engine in. Still needs all the connections made, a new throttle, carb installed, etc... etc...



This is gonna sound really dumb, but I can't wait to try my air horn. I installed the big air horn right before it went off the road. I used it 1 time. lol

[90GTVert]

I had bought this Motion Pro throttle cable, thinking it would work with my DellOrto since it said it works with DellOrto carbs.

www.provoscooter.com/throttle-cable.html

Not so much. This is all the slack I could get in the cable.



Had to cut the end off to make enough slack to let the throttle close all the way. It would probably work well with the 19mm Arreche or smaller DellOrtos, but don't get this cable if you have a big carb and want something plug'n'play.

[2strokd]

Wow, i almost forgot what that thing looked like! J/k
Cant wait to hear her rip! Im sure the airhorn is still loud as hell

[90GTVert]

Fired it up! I cheated and sprayed a very small whiff of carb cleaner in the exhaust port to get it to fire instantly, I hoped, and start picking up fuel from the carb. As you can see, my ignition and kill switches don't work since the new CDI so I had to pull the plug to kill it. The idle screw and cable were set a little off at first, but it calmed down pretty well once I got them adjusted right.



I gotta figure out how to wire the CDI in. It's got 1 wire my other didn't which is apparently for killing the ignition.

[stepthrutuner]

Great to hear it run. Wish I had a head's up on that CDI for ya.

[90GTVert]

I got the CDI issue straight. It was a dumb mistake on my part. The wire that needed to be plugged in was tucked into the wiring harness and I never noticed it last night. I fixed it in 1 minute or less when I looked at it this morning. lol

[2strokd]

ITS ALIVE ! Sounds like... goood? Well the engine sounds good, but i dont like that exhaust at all ! When they start making invisible pipes? 190mech, what you up to now? lol.
J/k, no really. You dont fire em up at first with an exhaust? Or no pipe to put on it yet? Sounds good tho, really! Glad you found your wire.
A nights sleep is priceless some nights I was a zombie when i hit the sack last night . Think i fell asleep in the shop sometime and slept walked to bed lol.