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Post by danlmvac on Apr 18, 2012 9:37:17 GMT -6
Oh yeah, I had drained all the old gas and put fresh in. For future reference, you can prime the carb simply by sucking on the VACUUM line to the petcock. Make SURE you are sucking on the vacuum line, NOT the fuel line. I still had to briefly put my hand over the carb throat while cranking to get that first bit of gas in the carb passages.
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Post by danlmvac on Apr 18, 2012 9:20:59 GMT -6
The scooters runs and drives! Thanks guys! Changed the stator, no spark. Took that all apart again, found no errors in my installation. Checked wires for continuity, found all okay. Began tracing other wires. Found the spade terminals for the coil where apparently manufactured from some kind of tin foil/lead alloy and had self-destructed when I slipped the protective boot over the coil. Repaired coil wires, had spark. The scooter had sat for over a year without use and many had told me to remove and clean carb. Went to remove electric choke and it broke off with very little provocation. Must have been cracked during storage and moving from place to place. Contacted a guy I know who assembles scooters for local dealer who sells them and he had a spare choke. Went and got it and it was too big to fit in the hole. So, I ordered one from partforscooters.com. It was the same size as the other one that didn't fit. So, I carefully sanded down the first one (it was only about 1 mm too big) till it fit in the hole then ever so slightly deepened to groove for the O-ring with a moto-tool and used a very small amount of RTV in reassembly. It works and doesn't leak. Scoots starts right up, idles nicely, power output seems fine, and everything except the fuel guage seems to work just fine. I put three miles on it going up and down my gravel driveway. (My motorcycle license expired long ago.) My driveway is half-mile long. Being on gravel, 30mph was as fast as I felt comfortable piloting this thing but it seems to work just fine. Took me 3 weeks, but I got 'er done! Thanks again and keep up the good work.
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Post by danlmvac on Apr 7, 2012 21:17:18 GMT -6
Thanks sprocket, I found that diagram earlier. I am pretty confident I hooked everything up correctly. The machine sat for at least a year and I had the carb upsidedown at one point te get it out of the way while installing the new engine. So, pretty sure there is no fuel in float bowl. My question is, if there is no fuel in the float bowl, it won't start and create vacuum to open the fuel valve. So how does it get the initial fuel to start? Or, does it create enough vacuum to open the valve just with cranking? I will check for spark tomorrow. Yes, i have the kill switch in the "on" position.
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Post by danlmvac on Apr 7, 2012 18:37:14 GMT -6
D'OH!!!! It cranks just fine WHEN I APPLY THE BRAKE!! Yes, another benefit of the nanny-state. Still didn't start. I'll have to check for fuel later. If the fuel valve is vacuum operated, how does it open when you're cranking and the carb is dry?
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Post by danlmvac on Apr 7, 2012 17:50:25 GMT -6
Thanks again guys! I think I have all the lines hooked up correctly. I sure hope I didn't bend the flywheel. D'oh! So, I got it the machine to the point where I felt I could do a test-start. No seat, sidepanels, or air cleaner, but enough for it to run. The machine I have is not equipped with a PAIR system, although the new engine has the S tube., which I blocked off as you suggested, Rich. So, I go for the start up, and I got nothin". The lights, horn, turn signals all work but no crank and no start. I hit the kick starter and I can hear compression, but she doesn't offer. I squirt a tiny bit of carb spray in the carb and no pop. I see the starter relay up on the left side and jump across it with a screwdriver and it cranks but no spark. I checked for some kind of interlock device to keep the scoot from starting if the seat is open but found none. I did try starting with the seat latch flipped to the closed position with a screwdriver. Nope, that aint it. So, if my mind is gonna play "scooter detective" I imagine the lady who owned it flyin' down the highway at WOT when the engine makes the 70 mph maraca sound. She costs to a stop and, despite having just heard a sound that could only be from catastrohic engine failure, she hits the starter button. She hears a clunk but no start, so she hits the button again, this time longer and harder---and fries the fuse for the starter ignition. So, that's my next step--I assume it's behind the cowl under the handle bars?
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Post by danlmvac on Apr 7, 2012 14:11:54 GMT -6
Thanks! Yup, I needed a flywheel puller. I live rural and the nearest town is 500 people, so I didn't even bother makin' a trip to Tom's Hardware and I didn't want to wait for a shipment to come in. So, I took my Wonderbar, marked the location of two of the holes for the fan mounting holes in the flywheel using the fan and proceeded to attempt to drill two holes in the Wonderbar---which is spring steel. After discovering I only had one drill bit hard enough to drill through it (and dulling numerous others mercilessly) I was successful. I put the nut back on the end of the crank to protect the threads, then used two 8mm bolts slightly longer than the fan-mounting bolts to tighten the bar up against the end of the crank, effectively pulling the flywheel toward me. Things got very, very tight and the Wonderbar started to bend slightly when the flywheel popped off with a very loud POINK! While this worked, I don't think it's a viable bit of advice for others as one could easily run the bolts into the stator windings, among other things. It also took me 90 minutes of messin' around drillin' holes in something I shouldn't have been drilling holes in. On the hose routing, oh boy. I need to search the site, but from what you say, Bashan, are you telling me they inject air into the exhaust like cars did in the late 70's with the Air Injection Reactor Pump? I see nothing on the Baron for such a provision. The old head and cylinder have no such ports of fittings. So, If I put a piece of hose on it and vent it, what I will have is another exhaust pipe. So, I'm just gonna plug that. Thanks again. As soon as I finish this cheap pizza, I'm back on it. Oh, do you have a link to a hose routing schematic? Yes, I was worng this morning, the fuel valve hose goes to intake manifold vacuum. Does the crankcase breather end up at the evaportive emissions canister?
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Post by danlmvac on Apr 7, 2012 6:31:02 GMT -6
Thanks! I'll be on it here shortly. Do I need a flywheel puller? Also, the new engine has a fairly large steel tube (about 1/2" OD) coming up and out of the head right next to the valve cover and angling back past the carb that the original engine did not have. I assume this is cranckase ventilation. In a car, I would guess that would go to the PCV system and/or the air cleaner. I had planned to just attach a piece of hose and let it vent below the scoot. There is another smaller hose on the valve cover, but it looks like that goes to what appears to be fuel pump on the rear corner of the gas tank. AND, (man, I'm getting annoying) there's a hose right above the gear box that appears to vent the gear box. I figured that one just vents to atmosphere also. Did I mention the machien came to me as a basket case? Partially disassembled in boxes? Always a joy with that. Thanks again
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Post by danlmvac on Apr 7, 2012 2:17:47 GMT -6
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Post by danlmvac on Apr 6, 2012 14:27:15 GMT -6
The folks at partsforscooters.com told me to swap in the stator from the old machine. Swell.
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Post by danlmvac on Apr 6, 2012 11:55:54 GMT -6
Hello, my name is Dan and I run a donated vehicle program in Minnesota. We're about the only one not funded by tax dollars, so we don't have huge piles of your tax dollars to throw around. Anyway, A lady donated a 2007 Baron 150cc scooter to us with a bad motor. I decided to work on it myself to save bucks. I drop the motor, remove the cylinder head and the head of the intake valve falls on the ground. The head of the exhaust valve is completely gone and there's a hole in the piston I can put two gloved fingers through. Wow. Epic fail. The lady admitted to sustained WOT. The scoot's only got 501 miles on it and still looks nice, so I shop around and find a very reasonably priced engine and transmission assembly from an outfit in Florida. They send it, and the output shaft is short and I need long, so I tear all that apart and swap shafts. I proceed with installation and find that there is a group of wires coming out of the fan shroud near the right engine mount that terminates in a plug different than on the machine I have. I assume these come from the stator. The original machine had a white plug with four wires. One wire is green and the other three are all yellow. The engine they sent has a much smaller green plug with only three wires. They are green, white, and yellow. (There were two other wires also coming out of the same notch on the case, but those did fairly closely match what I have on the scoot.) So, I know how to run a soldering iron, but kinda clueless on how to proceed. I've looked at several wiring diagrams on this site, and it appears green is ground but still clueless on the rest.
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