The Matrix: Rebuilding By runningslow (Read 26,529 times)

[runningslow]

As promised, some pictures. I don't have any of it with the motor mounted, since it was way too dark by the time I was done. I was expecting to see in some robust packaging, but for the most part it looks like it arrived in good shape.

I'm not a fan of the chrome CVT cover. I'll probably swap it out for my original UM branded one.

It has a drum brake, which I may or may not use. For now, I'm going to try to use my disc brake, but I may try to use the drum, since I've had issues with that rear caliper before. All I would need would be a new left brake lever and the cable for it.

When I mounted it, I just left the brake shoes in place. The wheel slipped right over it.

Motor in the box:


Oil cooler that got banged up during the shipping:




Speedo Cable:

[runningslow]

Technical Difficulties:

Ok, so I'm going to reconnect all the wiring and I stumble into this. The wires coming from the flywheel on the new motor do not match the wires on the old motor. I'm guessing this means the new motor doesn't have the same stator as the old one? I don't want to tear it apart to find out, yet. I had an 11 pole on the old one.

The new motor, the main connector has a green, yellow and white wires:


The old motor, that same connector has 3 yellow wires and a green:


So, of course the mating end on the bike matches the old motor:
(I assure you it has three yellow wires, but I had to double check after seeing this pic)


Is there a way to splice these wires to make it work?

[Bashan]

Your new motor has an eight pole stator, that's the problem. I think it would be easier to put the eleven pole in the new motor if it was working OK, then you can just plug it in without rewiring. You know how to pull the flywheel, is there some reason you're hesitant to do that again? You probably have a seven pin rectifier while an eight pole has four pins. You can see the three yellows on that diagram so you're not crazy. I'm sure it could be rewired but it would be really problematic. Also, I'd put a dab of grease on both the front and rear axle but not too much. Rich

[runningslow]

As excited as I am to have my new motor and I want to get it running ASAP, I've just been so busy this past week and its still so bloody hot in my garage. My reluctance is tearing into a brand new motor, even if I'm just pulling the flywheel.

I'm not convinced the old 11 pole was working right. I thought I was having some charging issues before all my problems. We'll see, since it looks like I'll be making the swap tomorrow.

Other issues: I've already completely stripped a bolt on the new one, too. I'm trying to swap out the oil cooler hoses for those from the old motor. The lines that came with the new one were too short to reach to the original mounting position. I stripped one of the heads trying to remove it.

[runningslow]

Now that I've had some time to digest everything and I've calmed down from stripping a bolt head.... I have one thing to say: Thanks, Rich!

I'll swap the old 11 pole stator onto the new motor this evening. If it is in fact bad, it looks like I can replace it for around $45 (shipped) from ebay.

I'm still not sure what to do about the stripped bolt... stupid Chinese hardware. I've already tried vice grips... that only made it worse. Its also not like its your average run of the mill of the bolt. A little bit of googling I come to find it called a "banjo bolt". A hollow bolt, with a hole near the head. Hopefully, once I've got it out I can go down to AutoZone and find a replacement.

Question: Taking into consideration that these oil hoses have banjo fittings on both ends, does anyone have a thought as to how I may be able flush the hoses? Since I'm going to be using the original hoses, I want to make sure they're free and clear of any of any little metal shavings. Or, am I just being too cautious and I should not worry about it and just frequently change the oil for the break-in period?

Checklist to a running scoot:
1) Remove and replace stripped banjo bolt
2) Install oil cooler with original longer oil lines
3) Swap 11 pole stator from old motor
4) Replace fuel filter
5) Clean carb
6) Fresh tank of gas
7) Double check all the Wiring
8) ....
9) Profit! ;D

[jake aka:ventoscoot]

Sounds like your list is good. hafe you tried some "liquid wrench" on the bolt? The bolt should be easy to replace once you get it off. just a thought, is it a left handed bolt? (probably not, but you never know).

[runningslow]

Sept 13, 2010 13:47:03 GMT -6 jake aka:ventoscoot said:

Sounds like your list is good. hafe you tried some "liquid wrench" on the bolt? The bolt should be easy to replace once you get it off. just a thought, is it a left handed bolt? (probably not, but you never know).

I used some PB Blaster on it last night. Let it soak for a few minutes, but still nothing. I thought about trying to heat it up, but I don't own a torch of any kind. Actually, would a camping lighter get it hot enough?

I know its a normal right hand thread, because the other banjo bolt came out just fine. It took some effort to break loose, but it did break loose.

[runningslow]

Stubborn frigging bolt!! Still not coming out.... I did however get the 11 pole stator installed.

[runningslow]

QUESTION: Is it common for two wires to go into a bullet connector, but be different colors?

Unless I've been smoking something that's making me see pretty colors, this appears to be happening all over my bike. I've been sitting on this question since last night, but I thought I should ask.

I, like an idiot, didn't label any wires or hoses as I disconnected them. I assumed the colors would all match up as I went to reassemble it.

[Bashan]

Well where are the wires coming from and going to? What color are they? Yeah, on my Bashan they ran two different colors into one bullet and a different color off the other side, it was a helluva mess. Half off the wires I discovered went NOWHERE! They just ended in a blind connector. I figured the harness was meant for a myriad of scooters and whoever was putting it together knew that bike and what to do. I've got pictures somewhere, I'll see if I can dig them up. Anyway, can you kinda figure out what area they run to? Rich

[Bashan]

I deleted most of them, trying to clean house a while ago, you know how it goes. But I did find this example of their idiodic methods. Here was this multi wire connector that plugged into another connector, that had one jumper in it. Now, was there not an easier way to do this? I unraveled all of those wires and got rid of them except the two that were jumped, I put a bullet between them.

[runningslow]

I give up. I surrender. That bolt is NOT coming out. I think I'm going to leave the banjo bolt in place and just cut the hose, buy a nice brass coupler and splice the old hose and the new hose to fit.

If anyone thinks that's a bad idea, let me know. I'm not going to have any more garage time until Thursday.

Thanks for the info, Rich. I'll look into my wiring deeper later.

[Bashan]

I think it's a great idea and I was going to suggest it but chickened out . Rich

[runningslow]

Thanks, so I'm not completely crazy! ;D

I see a stop at Home Depot (maybe ACE) on my way home for that coupler and a new fuel filter.

[jake aka:ventoscoot]

sounds like a plan!! probably what I sould have done n teh first place instead of trying to use the old hoses.
(wow, must have been really tired when I wrote that)
I meant, "probably what I would have done in the first place"