Bashan 150cc Modifications By Bashan (Read 45,031 times)

[Bashan]

Mar 6, 2011 9:48:51 GMT -6 benellibob said:

I would find a better horn button you can mount on the handlebar.

I agree that's not the most accessible spot for the horn. I was going more for looks to have a big garish button right in the middle of everything. In retrospect, safety should have trumped appearance.

Mar 6, 2011 9:48:51 GMT -6 benellibob said:

did you mean horn button AS a starter button? that would make more sense, since i only see the one button...

You're right, I didn't make that clear. The starter button is right on top of the "dashbord" and is energized by the big ignition swithch at the bottom after it's turned on. Theoretically you could accidentally bump the starter button and engage it while you're riding. However, you'd have to reach way forward over the top to activate it plus it's one of those industrial strength buttons that's hard to push; I think the chances of engaging it are very small. I screwed up and didn't get a clear picture of it, here's one with an arrow pointing to it:

My heartfelt thanks to Madcollie for sending me a bunch of nice soft velcro ties as a goof. Actually they came in very handy and I put them to good use. I decided I couldn't live without a a blinker system so I got a pair of trailer side marker lights from Wally World ($6) that I mounted on the front. Here's a picture of them:

They tie into the back lights of course and I mounted the relay down by the foot rest bar:

It's kind of hard to see but it's there. Then I wanted to be able to charge my Tom Tom without taking it off, it's pretty much permanently attached with zip ties and mounting pads. So I took the cigarette lighter charger and zip tied it behing the headlight. Then I used a lighted switch I found to run the power from the battery to the charger. It lights up when it's turned on charge so there's no danger of me forgetting it and leaving it on. Here's a picture of the charging system off; the arrow points to the switch with the light off:

Here it is on and sending juice to the Tom Tom charger; you can see it's not something you'd miss and leave on:

You can even see the green light on the Tom Tom charger when the circuit is energized, the starter button is clearly visible also:

And Madcollie's gift made short work of snuggly tucking the new circuits into place. The arrows show just a few spots I used them around the bike:

Well maybe I'm done posting on this thread now, we'll just have to see. Rich

[jhbietz]

You can't be done! I have bean following this thread for months. You can just quit now.

[benellibob]

boooo cmon you can do better! keep modding!! start making a few holes in the frame and re-run those wires!!!

[Bashan]

Well, it's just very odd that you would lament the end of the Frankenscoot mods. We're going up to Toledo over Memorial Day and it's the only scoot that will fit easily on the trailer with my wife's scooter. So the modding begins! I'm putting floorboards on so it's narrower and probably going to install a oil cooler if I have time. They are actually the same scooter so I'll have tie off points that are situated at exactly the same heighths. I'm using Canyon Dancer Handlebar Harnesses so I'll get some pics of how all that works on the scooters. The creature lives! Actually I ride the thing all the time, it is a absolute blast. Pretty fast too, it'll do 55 on a flat road, the accelleration is really strong, pulls a hill like a champ. Rich

[benellibob]

dont forget to check out my moto-scooteR, i did a small update. going to be on the road soon and that means making body panels

[tvnacman]

rich , you should have upgraded to 11pole stator for more juice

[zugzug]

What did ya do with that sweet exhaust you were sporting when you first started this hack job..er I mean beautiful custom scoot?

[Bashan]

I didn't get any love with this oil cooler project on the 50 to 200cc board so I thought I'd give it a go over here. Of course I did flame out on that thread due to our trip to the Dragon's Tail. My thanks to Cruiser for turning me on to Sliconeintakes.com where I got the radiator and fan. Thanks to Sprocket, Cruiser, and 13lky2 for bouncing some ideas back and forth on PMs. Here's a picture of what I've been working with:

Front L to R: oil cooler & fan, Carter fuel/oil pump, Top: oil temp gauges

Here's a closer look at the radiator and fan. I found 1/2 NPT to 3/8" barb reducers at Lowes for the radiator connections. The fan feels industrial but is only supposed to draw 2 amps:

I was a bit worried about the Carter pump because the instructions say to use a 10 amp fuse. However, after running it a few times it just doesn't seem to pull enough to cause any problems:

The oil temp gauges have an electric sending unit and were on sale from Harbor freight for $12.00! I put one at the beginning of the system and one at the end so I'll be able to see if the system is working. I don't have them wired in yet but they're supposed to draw less than an amp.

I had originally planned to mount the radiator on the front to simulate the look of an old '30's auto:

But it had also crossed my mind to set it on the back rack running horizontal and mount the fan on top:

Here it is with the fan sitting on top:

That looks pretty cool but for now I decided to mount it on the frame for experimentation's sake, I can always move it later:

Are you laughing at my tupperware air cleaner? That's not very nice! Actually that's a testing device in that I have different covers with different amounts of openings. That way I can switch jets with different airflows and see what works best. I'll continue this thread with a new post.

[Bashan]

I decided to use the left side oil drain as the intake for the system. I wasn't comfortable with drawing from the bottom of the oil screen next to the scooter's oil pump feed. I used a metric 12mm X 1.5 to 1/8 NPT and a 1/8 NPT to 3/8" barb for a hook up to the 3/8" fuel hose I bought for the system. I used a little black permatex around all the fittings for some added sealing power. I don't know if it did anything but nothing leaks.

Here is a shot showing the drain plug (red arrow), a ball valve to aid in filling the system (yellow arrow), and the first temp sensor (green arrow).

Here's the inlet to the radiator on the left side. Are you laughing at my air cleaner again!?

Here's the outlet on the right side of the radiator and the path through the pump. The red arrow is from the radiator to the pump. The yellow shows the pump inlet, and the green shows the path out of the pump. The light blue arrow points to a 3/8" barb with a ball valve under it. I used that to put a funnel on and fill the system.

The yellow and red arrows show another ball valve and the cool side temp sensor.

Here the cool side hose does a 180 around the frame and goes underneath.

I used a 3/8" barb to 1/4 NPT with a nut through a drilled hole in an oil screen plug for going into the engine. I used some JB Weld in the bottom of the plug to seal things up. This is hanging a bit low but only about an inch below the frame. If this works out I'll redo the hoses, this is all an experiment anyway.

Here I am set up outside on the lift for a little testing. I thought I could get some decent pics with the camera of the oil moving through the filter but it wouldn't show much.

So I did a Youtube. I can see the oil moving at all temperatures with the pump on but it's most evident when the oil gets hot and thin. I was surprised at how frothy the oil got with some RPMs. Luckily, this pump doesn't seem to mind.

I've ran the scoot on the lift three times and let it get completely warmed up. The oil temp hasn't got over 180 so far using the oven thermometer right after I shut it off. The radiator gets a little too hot to touch but not burn your skin hot. I'm going to rig up some lights and take it out on the road this weekend, wish me luck. Rich

[13lky2]

Let me know how it works out!

[tvnacman]

take off the handle bars and put on a steering wheel

John

[jhbietz]

Looking forward to seeing temp readings before and after the cooler. This is a very interesting experiment.

[Bashan]

Well no pre and post system readings yet, I have to wire the thing from bottom to top to incorporate the temp gauges and everything else. However, I did take it out on the road for the first time today since installing the cooler. I spent about 10 minutes getting it really warmed up and then turned on the oil pump and rode another 10 minutes. I did get some significant information compiled. First, this was the temp reading immediately after I got back using the Martha Stewart method:

Pretty good huh? The second thing was that the bike started right up after I got back so the pump didn't drain the battery. Third, I didn't have any oil leaks so apparently I got things sealed up pretty well. I'll try to do some wiring Tuesday but that's going to take a while. Oh, and my Tupperware air cleaner worked great. Rich

[Bashan]

[Alleyoop]

Very nice Demo Rich, and I bet when moving it would drop even further as it gets some air.
No to just get it to Charge up and it would be a winner.
Alleyoop