My PDI experiences. We can start with the 550 pound delivery of the scooter in a metal frame on a wooden pallet. The delivery driver delivered it to my house and transported into the garage to where I wanted it. We looked down into the top of the cardboard part and saw no damage so I signed the release.
Then I removed the cardboard and the metal frame and got the scoot lifted off the packaging down to the floor. Wish my adult kids had been here as I nearly did not get the 300 pound scoot out of the frame base. I survived and the scoot lives.
Then I started to fiddle with getting it started, but that was no problem at all. A few tries and it started to run. Had some good help from the forum on how to set the idle speed. Some days passed and I kept smelling a sour odor and seeing spots on the garage floor. At first I though it was a water leak and asked for ideas about finding the leak with the covers on. Advice was to remove the covers. So that became a project for the next day.
I took off the aluminum foot panels. I took the screws out of the right and left side panels. Then I took the screws out of the floor panels. The final thing I did was to unscrew the three bolts on each side of the floor panel. I did not take out the two plastic retainers on each side so the side panels remained attached to the floor panel. Then I took two screws off the upper side panels near the front end and also had to remove the seat to finish that job.
With all attaching screws and bolts removed I then began the tedious job of flexing panels, pulling tabs out, helping the floor board to come loose. I had to remove the gas cap and radiator overflow bottle caps to get the front of the floor panel loose. Finally it was all released and then the task of lifting it up and out without scratching the body panels. I got it out by lifting the rear of the floor panel from one side then the other until finally it cleared and the front portion finally followed up and out from under the handle bar area.
Later I decided that putting it all back on in one piece would be next to impossible to do and likely would scratch or break something, so I separated the side panels from the floor panel by pulling the plastic retainers out. There is a near match at the Car Quest auto stores with the part ID of AP20349. It looks very close and I bought some but did not have to use them as the old ones were not damaged when I pulled them out. I have them for the next time, just in case.
Now we begin the search for the water leaks. It turns out to be the gas level sensor gasket is shot.
I tried AutoZone for gasket material, none. Then I drove out to a Honda place and they sold me a Oring that did not work on the scoot. Finally to the Car Quest where they had some 1/8” rubberized cork for fuel systems. They sold me a two inch wide piece off of the roll. I then measured inside and outside from the sensor and drew it on the cork and cut it with razor knife and scissors. A little trim and it fit perfectly. Replaced the sensor, filled the tank, tiny tighter on the nuts and it quite leaking.
Then I went to the coolant change out. It was very dark and had some gritty looking stuff that settled out. Don't know what that might have been but it is gone. I did not have a hose outside as it was way too cold. I did the best I could with a bucket and funnel and burped the best I could. Then I refilled with the proper aluminum friendly coolant. Ran the engine and burped some more.
Next was the oil change. Removed the drain hole on the side and found two Styrofoam balls and some fuzzy stuff on the filter. Then I took the bottom plug out and finished the last bit of drain. Reinstalled the bottom bolt first then the regular drain plug with the filter and spring attached. Put in some oil till it reached the fill mark. No leaking so far.
Finally I did the gear oil. Extra work as the guard needs removed and replaced. There I had a bottle of Honda gear oil and the neck just fit in the fill hole so all I had to do was squeeze the bottle till it was overflowing. Wipe up the overflow and put the bolt back in.
Front tire was flat and the back tire was low. I inflated both to approximately 30 pounds. Two days later the front was flat again and the back had lost a few pounds. Tightened the cores and refilled. Still some lose over time, but not much. I think I will replace those cores one of these days and see if that will help.
Now we put the covers back on. I started by draping a blanket over the rear covers to prevent any scratching of the panels. Then I put the floor panel over the center, with the front going down and in first. Then I pulled the upper corner of the rear panels out so I could get the floor panel inside. This took a couple efforts from one side to the other till the floor panel was finally in place in the rear. Then I worked at the front of the floor panel till I got its tabs in place. Once it seemed to be settled in I started to put some screws in to hold it in place.
My first big mistake at reassembling. I put the left lower panel on before I screwed the three bolts into the floor side parts, foot rest area. As a result I could only get two bolts to take thread and tighten. So for that one bolt I put a glob of silicon on it to keep it from rattling and the next time I am in the mood I will take the side panel off so I can push up from underneath till the bolt takes some threads and tightens.
On the right side I put the bolts in with no problems and set a couple screws too. Then I put the lower right side panel on. Slip the tabs on the lower side panel into the slots first. It may take a bit of help to get the tabs to line up. I used a flat screw driver from above down into the path of the tab to make it ride up and into the slot. The old plastic retainers worked but not sure if pried out again so I do have the new ones that look close. May need to put a drill through the holes to open just a tad first. Not too big though or the retainer won't have enough to grab on.
At last, I put the seat back on and tightened that up real good. Now with all the internal panels and all the side panels in place it looks just like the scooter I had bought. But now it has all fresh liquids to take me around the town and elsewhere.
Lots of help to make this happen. Enjoyed all the help I got. Will probably be more times I get confused and maybe some times I might be able to help some one else as new as I have been.
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..BAD TO THE BONE..
in the last 2 months I have taken it out 4 times only. Here in Chi it has been raining and raining and windy.