New Day, New Progress!!! By Gti (Read 1,197 times)

[Gti]

Well Alley today I did not get the chance to write those boring papers I wanted to write but what I did do was go work on the scoot and the progress was astounding.


I was about to get the scooter running and it ran pretty damn good. It took a few minutes before it would idle on its own but it eventually did. I was able to ride it BUT there were gremlins in the scooter. The problem was when I get the throttle to about 1/4 to 1/2 way open. The engine sputtered as if the coil was cutting out. It would run, cut back, pick up, cut back. It did this for a for the afternoon. The scooter would not charge the battery either. This is a brand new stator and everything and I am a little baffled about that. Oh and before I closed shop for the evening the clutch assembly came apart. But I fixed that issue and now tomorrow I have to work on the sputtering issue. For a coil I am using the NCY direct ignition thingy.

Thanks Alley!!!!

[Alleyoop]

Tomorrow if it won't start with a few hits Take the Spark Plug Out and see if it is WET OR DRY. Need to know if to much fuel or not enough to make the right adjustments.
That will tell a lot. Did you tape off some of the AIR FILTER to cut some air off?

Now the no charging could be the Stator or the Regulator/Rectifier, when you put in the Stator was it a PLUG AND PLAY or did you have to splice in wires etc..
Alleyoop

[Gti]

I had to splice the wires, I wished it was a plug and play thing. I went to Harbor Freight tonight and got new connecters and some heat shrink so I can make sure all the connections are right and pretty. I was smelling some fuel so I think it is getting fuel. I did not try the tape route but I did go by the K&N oil for the filter and that helped quite a bit. Oh and BTW I did get the stock CDI and it did not stop the kick back.

[Alleyoop]

Damn OEM CDI did not stop the kickback! do you remember when the piston is at TOP DEAD CENTER and the came aligned DO YOU KNOW where the POINTER on the CASE is pointing on the FLYWHEEL? How Far away from the "T" or on the "T" mark 1/4 of an inch from the "T" Mark or 1/2 inch or 1 inch or 2 inchs etc.. Or better yet take a picture when the cam sprocket is aligned, it could be off 1 link on the Cam Sprocket and that is quite a bit.

Does it start right away or do you have to play with it for a bit before it will start?


Since you put on the OIL on the filter and it help quite a bit DO CHECK the plug when you try to start it and it doesn't start. That will tell if to much fuel or not enough.
Alleyoop

[Gti]

Will handle those things this morning Alley. I am so pumped to have this project close to being finished!!!

[Alleyoop]

Well you are close now that AT LEAST it will start and run.
Alleyoop

[justbuggin]

way did you change the stator ? the stator and R/R need to match as not all stators are the same some have floating grounds and others dont we need more info on the stator and R/R to be able to help with the charging issues

[sprocket]

Sound to me like you are a link out on the timing chain...

[Gti]

Today I took two steps forward and one step back. I went in and started the engine but it sounded horrible. I decided to take the engine down and see what the problem was and to double check the timing yet again. After a complete tear down and rebuild there is ZERO evidence of kick back or any other noises that were out of place. Now the engine sounds great BUT I have lost spark. I have traced wires, changed out the trigger and I am lost. I keep hear something about a R/R on this bike from others. What is it and where do I find it? OH I figured I had a spark issue and where the woodruff key mated with the flywheel, broke and left the crank spinning and flywheel stationary. I am confused.

[tvnacman]

Oct 19, 2012 13:42:26 GMT -6 sprocket said:

Sound to me like you are a link out on the timing chain...

pointed in the correct direction .

John

[Alleyoop]

The kickbacks could of been caused by the woodruff key out of position and then your timeing would have been off. But the R/R is your Regulator/Rectifier it feeds the lights and charges your battery.

You have the worst luck I have ever heard someone having.

When you put the Stator and Flywheel on you must be sure the woodruff key is in the grove in the shaft and when you push the Flywheel on it does not move out. What you shoud do is put the Woodruff Key in the grove and give it a few taps to seat it in the grove good then slide the flywheel on.

Since the woodruff key broke Check the Flywheel slot to see if it wasn't also damaged.

Alleyoop

This is what your R/R looks like it has COOLING FINs. Could be mounted anywhere on the frame or in front behind the cowl.

[Gti]

The flywheel was toast and I put on a new one that I had been saving. I think the scooter is not working because my family thinks that I am placing my life i danger by riding this and they are not willing to help me do anything to fix it. I have been doing this project on my own and trying to learn as much as I could along the way. I am determined though and it will run and I will ride.

I bought some wood ruff keys from parts4scootes and they fit a little loose in the groove. Even with a little tap. I bought a woodruff key set from Harbor Freight and none of those will fit at all. As far as the reftitier goes will that keep the engine from producing spark or should I price a new stator, flywheel and R/R?

[tvnacman]

if the flywheel was wobling it may have damaged the pick up coil .

John

[Alleyoop]

Gti,
How does the Stator look and the Pick Up Coil did the Flywheel happen to hit them and damage them or not. Can you take a picture of the stator with the Flywheel off to see if it looks damaged. Right now from how your talking you put on another flywheel is that correct?
Did you also put on a new PICKUP COIL that is the black square right above the Flywheel and that is the one that tells the CDI to release the voltage to the COIL to fire the Plug.
Alleyoop

[Gti]

Yeah I did put on a new (Different) flywheel and tried a different pick up coil. I will take pics in the morning. This is so odd. I thought I had this all figured out. Neither of those worked but it had gotten late and I did not have time to finish up properly. But will post pics a.s.a.p.

Thanks Guys!!