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Post by tk3000 on Sept 19, 2010 22:14:19 GMT -6
Sorry about the absence of response. I was away and did not check the forum for a while. That bike has been victimized with electrical grimilins that seemed difficult to sort out, and sometime they can be intermitent but for now are more likely constant and permanent. I checked the voltage going to the enricher in AC mode and fount out about 8 Volts, so I went to the voltage regulator and the output from the yellow wire seems to be around 8 Volts sometimes. Below are some measurements taken from the Voltage Regulator: AC Voltage Output: Yellow: 10 (rough idle) , 11 (higher rpm) White: 28 (rough idel), 44 (higher rpm) DC Voltage Output: Red: 15 (rough idel), 15.5 (higher rpm) Note: there is no light on the headlights. I then replaced the voltage regulator with another one (a new black one I bought off ebay). Once I did that I noticed smoke coming from the dashboard: one of the bulb that illuminates the inside of the dashboard (instrument cluster panel) was smoking like craze (the bulb rubber socket was melting down and the bulb producing a very strong light for its nominal capacity) so it seemed that the new voltage regulator wasn't doing it job of regulating and reconditioning the voltage (once measured at the regulator itselt I found out that the AC output was too high which then confirmed the suspicion). I already replace the stator, and last time I checked it was ok. I also soldered all the connectors of the stator and created a secondary ground connecting the engine to the frame as shown below. My suspicion was then: bad connection and thus high resistance somewhere, bad ground somewhere, some small short somewhere. Maybe the electrical issue is originated inside the instrument cluster since I checked most of main harness for resistance (all seems ok) and for any short (found none). Secondary path to Ground (the primary one at the stator housing does not inspire much confidence): Harness reconditioned: When I checked the white wire coming from the stator (not connected to the voltage regulator) the readout is about 45 AC volts (Idle) and 65 (high rmp). Apart from the electrical issues and absence of headlight the bike starts and run fine Any insight would be appreciated
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Post by tk3000 on Sept 5, 2010 17:07:35 GMT -6
Hello Folks,
I tested the auto-chock/enricher circuit in my 150cc and obtained the following:
1) Resistance of the enricher itself => 8 ohms 2) There is no voltage when the key is in the ON position, the voltage only starts to go to the enricher circuit when the engine is running and is measurable as DC voltage (thus it should come from the voltage regulator) and the voltage is around 5.6 Volts
Are the data above sound/correct?
Thanks, tk3000
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Post by tk3000 on Aug 14, 2010 11:39:14 GMT -6
Unfortunately I haven't had much time to work on the 250cc lately, sorry for the absence of response. Well, I have to admit that I really like the looks, size, and color of the your scooter DR. JR., and jonway should build a decent bike; I am even considering buying one too. The thing about the confusion with GY6 and 250cc displacement engine is that it seems that all of a sudden too many sellers start to follow suit and associated the GY6 with a 250cc displacement engine, as if there were such a variant of the GY6 (which I was pretty sure wasn't the case); but there were such a massive amount of sellers doing so that I decided to ask.
I cleaned the carb with carb cleaner and an air-compressor, since the bike was hesitating too much specially under acceleration, and found out that I also had a fuel delivery issue: fuel starvation which then seems to be associated with the fuel vacuum activated valve (petcock); for instance, if I create vacumm with my mouth I can barely have some droplet of fuel coming through (so I ordered a new petcock). But in the meantime I bypassed the petcock altogether and installed new fuel hoses, filter, etc; and the fuel starvation issue is gone for good. Also the orientation of the old petcock does not seem help since it is gravity fed.
I follow phils adviced and ordered a slightly smaller belt (gates power link belt): a 906 x 22 x 30.
Cruiser, in the past I used a wrench from harborfreight but was a flimsy and light one, the one from Husky is much better; but I certainly could give yours a try. But the tool I have is very hand one and is appropriate for the job, the problem is that there is no holes in the variator to hook up the tool.
Overall the bike is more responsive and working better, but I found out that after taking the bike for a spin (to test it for about 2 minutes) when I park it I notice some oil leaking underneath the engine case, not one single spot of the under the engine case but almost the whole area. The good thing is that it only leak just after having ridden it, and then it spots leaking. I hope it is not the crankcase gasket, and maybe something as simple as the crankcase breather tube . Any insights would be appreciated.
Thanks, tk
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Post by tk3000 on Jul 30, 2010 11:44:39 GMT -6
chyder, I, like you, only have good things to tell about bargaintory; they offered several options to take care of the issues with the bike: they offered to pick up the bike and send me a new one (well in spite of all the problems I grew attached to that bike, and besides I already registered, insured it, and have done lots of work on it), they also offered to pay for the repair in a local shop (I do all the repair myself, don't like shops), so they refund me some of money paid for the bike in order to pay for parts needed. All in all, I am very satisfied with bargaintory and would recommend them for anyone. Jrryan interesting tool to hold variator in order to apply the proper torque. So back to the bike issues, I have not been working on the bike lately. Zug, I have used a wrench strap in the past unsuccessfully but it was a cheap made one and it was on a stator's magneto; the ones you showed seems much better and heavy duty; so I got excited, went to Homedepot and bought the following: But yesterday I tried using it; having some success with the clutch since it has more surface area for the tool to grip on, but not much success with the variator. At end of the end day I got the hang of using my old holding too with variator: the trick is to stabilize the tool and use the soil as a base and then from a 30 degrees angle rotates the tool clockwise more 20 degrees, and then repeat the same process until one obtains the proper torque. If I don't use such method (30 degree angle, turning clockwise in increments of 20 degrees) the bike would tip over or move (but if you have a friend who could seat on the bike...). Below is an image of the setup mentioned: The pulley is not much of a problem since it turn is engaged in the rear wheel and would only turn in synchrony with the wheel which then can be locked with the bike's rear brake combined with the bike weight seating on its side stand. At the end of the day I was able to apply the proper torque to the clutch and variator. But it seems that I will order a new clutch to replace that one since it seems to be the weakest link responsible for the issues with speed. Also measure the distances between the variator pulley faces with a micrometer; the distances seems to be constant ‑‑ around 39 mm – with a margin of error in the order a fraction of a mm And finally some pics of the plumbing underneath the bike: A spare radiator cap attached to the frame: Spark plug also has been replaced for a ngk Another issue I am having is backfiring (more like a sequence of loud coughs rather than a gun shot) during desacceleration. I sort of rooted the problem to some possible causes: carburetor lean condition (pilot circuit, cut-off valve), vacuum leak, muffler not properly sealed/insulated or missing gasket (I will check that out), or something else.
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Post by tk3000 on Jul 25, 2010 14:08:24 GMT -6
Thanks for all the insights on how to insert and install the belt, I guest after some time I got the hang of it: first I installed the bent in the variator and clutch, leaving the variator open since there was enough threads protruding from the engine shaft in order to thread the nut in and then slowly I started to pull the belt inside the clutch and thus stretching, pulling, and straighten it torwards the variator. After having some threads protruding was able to slightly thread the nut in, and from that point on I used the impact wrench which (about four hits) and stretched and straighten the variator inbetween each hit. Previously I also tried to use a large slotted screwdriver, but I was wondering if the scratches caused a screwdriver on the polished surfaces of the clutch would not somewhat compromise? Anyhow I am still stuck with speeds of about 25mph, and whenever I try to go any faster the engine roars, bike trembles and goes nowhere beyond 25mph... I measured the belt size with a tape and obtained around 37 inches. Besides the variator, clutch and belt, what else could be the responsible for such issue; engine transmission gear maybe? Valves? Below are some pics: Belt reinstalled, I could not use my holding tool to install the variator since the variator is missing the holes necessary to use the holding tool. Holding tool (can be used for the magneto to remove stator, and variator): I would rather have used the holding too together with my torque wrench so that I could measure and apply the proper torque. As far as dimensions for the variator and clutch I could not take all measurements as of now since they are already installed but based on the dimensions of the outside diameter they seem to be ones showed in the following links: www.partsforscooters.com/Complete-front-variator-assembly-180-3www.partsforscooters.com/180-108_Clutch_Assembly?sc=9&category=73532
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Post by tk3000 on Jul 23, 2010 17:31:44 GMT -6
Hi TK, Assemble the variator without the belt. Torque the nut to 70 foot pounds. You might want to apply some blue locktite first. Here's how I mount my belt. Get a large standard screwdriver or small pry bar (tire iron) and carefully insert into the open side (left side) of the clutch pulley. While twisting the pry bar I squeeze the right side of the clutch pulley with my right hand. Keep turning and prying as needed to open up the clutch. When this is done, you should have no problem mounting the belt. Hello Cruiser, Sorry but I am not sure about what you mean by left side, and I don't see any slot where I could insert a large screwdriver to try to pry it open. I have tried using something similar to a screwdriver covered by a rag to avoid any scratch in the surface but I could not do it safely (without scratching the of walls whereon the belt is located). Would you insert the screwdriver between the polished surfaces where the belt is inserted? thanks! tk
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Post by tk3000 on Jul 23, 2010 11:58:18 GMT -6
That looks like a beeper or a siren. Perhaps your scoot has an alarm (mostly bad news from what I've seen on this and other forums). Runs the battery down. Perhaps your scoot is plug and play like in you go thru the scoot and plug everything back in where it's suppose to go and then you'll be able to play..... You'll get there and have the peace of mind that you know the scoot like the inside of your hand. kiwiscoot, that is part of the reason I have and enjoy scooters; to work on them and make improvements, and so on. But that one has had more than its fair fare of issues (structural bolts breaking inside the sub-frame parts, cvt issues, hopefully the engine bushings are ok...). Trivial things such as carburetors adjustments, etc, are to be expected when buying such type of scooters though. But I also wan to ride it! As of now I am kind of struggling to install the belt back (in my other scooters such task was much easier...), apparently I can not stretch and open the belt enough in the variators end to fully insert the variator assembling and then be able to have the threads protruding up enough to then thread the nut in, as shown in the following pic (yeah in the clutch side I try to open the clutch to insert the belt in as much as possible, but it is very difficult by hand): Not enough threaded are protruding off the drive shaft in order to install the bolt Clutch bearing view: Maybe the belt it too short, I will measure it. I also measure the engine compression (with a cold engine) and obtained around 120 PSI, does it sound ok for that type of engine? Any insights would be great.
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Post by tk3000 on Jul 20, 2010 23:04:36 GMT -6
Thanks for the insights about the belt and cvt issue, phil54 and kiwiscoo. I removed the variator and clutch with my almighty impact wrench and apparently it seems fine, but I will further investigate it tomorrow. Another thing I found out was the source of slow down and noise on my front wheel, after having removed the front wheel mud cover, I found an electrical component locked inside the mudguard making contact with the tire; so whenever the tire was rotating it would hit such thing (would anyone know what such component is?): Also the engine was vibrating and shaking unusually, after further investigation I found out that the main bolt in the engine mount was not properly torqued; torqued it and solved the annoying vibration and noise problem. That bike definitely is not plug-and-play...
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Post by tk3000 on Jul 20, 2010 23:00:24 GMT -6
828-22.5-30 is standard for the 244cc with a 10" wheel. With a 13" wheel I guess we have a long case 244. The belt on my M3 is unmarked. Using the nominal and actual dimensions of a gy6 835 belt and the OD of the M3 belt, I come out with 918-22.5-30 as the belt size, there is a 906 belt that might also work. I also found there are 2 possible variators for the 244cc, 128mm and 138mm. Keeping in mind my limited experience with scooters, the first thing that comes to my mind is a clutch bearing. It will work fine on the center stand but under a load you get serious belt slippage and low speeds - had that experience with my Carino. I don't know if that could cause the belt slap you spoke of - I haven't had that problem. Thanks for the insights, I will contact the seller tomorrow and ask to have such parts replaced. That scooter has had lots of other issues, all such issues in conjunction makes it difficult to isolate and diagnose the main issue. What would be the best way to test the bearing into the clutch assembly?
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Post by tk3000 on Jul 19, 2010 20:48:38 GMT -6
Zug :
I took the CVT cover off some time ago, actually in my very first post there is a link to video where the cvt is showed in action. One thing I noticed is that the with CVT cover on the belt seems to hit the CVT cover, and with the CVT cover off there is not such hitting noise. Also at first the belt seems to be too big (I found out inscribed on the belt itself: 915 22 30) it seems too large for that type of engine (I am not sure if there are variations of the engine case and engine itself for the CF-Motor 250cc, as is the case with gy6?). At first 915 22 30 seems too large, wouldn't a 828.22.30 belt size be more appropriate for such engine? If it uses the same belt used on a gy6 150cc (vento clone) I could take the belt off my 150cc and install it in the 250cc to see what happens. Of course I am assuming that there are weights inside the Dr. Pulley,etc, and none of the mechanisms have collapsed or failed.
The feeling that I have when I try to accelerate above 25 mph is as if I was trying to accelerate an engine with the clutch pulled in (makes noise but goes nowhere faster)
Thanks!
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Post by tk3000 on Jul 19, 2010 19:52:46 GMT -6
Some is wrong, maybe the related to the transmission: whenever I take it to a test ride and try to accelerate above 25 mph the engine roars, the bikes sort of trembles, but the bike does not take off (stays at the same speed: 25mph). Any enlightment?
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Post by tk3000 on Jul 19, 2010 19:45:58 GMT -6
Welcome to the shoehorn club ;D Thanks! I saw your thread, very instructive and insightful!
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Post by tk3000 on Jul 17, 2010 13:59:03 GMT -6
Now glitches and beyond... Turned out that when test riding it the front column (handlebar + stem + shocks) would tend to sink when under some stress (stopping quickly from mild speed [30 mphs], so I had to investigate: at first it seemed that one shock was slightly (maybe 4 mm higher) higher than the other,and apparently one of the bolts (or maybe two) holding one of the shocks abs were not properly torqued and thus was undertaken unusual stress and probably was compromised. Anyway I tried to apply the proper torque (around 35/40 foot/pounds) and the bolt simply broke inside. Bolt Extraction Phase: Bolt replace by a slightly different bolt, but with the same basic specs (pitch, size, strength/grade, etc): Next step is to take a look at the steering column nuts, castle nuts, bolts, fasteners, washers, and bearings. Some more pics of the disassembling process: The front handlebar and instrument cover is hold by many tabs and few screws: To be continued..
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Post by tk3000 on Jul 17, 2010 13:46:36 GMT -6
That's awesome that you got all those radiators. It ain't gonna overheat. Sounds like the belt's too big, maybe an 872 22 30 would work. Thanks, I will contact them about the belt issue. It really seems that the belt is hitting the CVT cover.
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Post by tk3000 on Jul 17, 2010 13:45:16 GMT -6
Sorry cant help with the CVT issue. Wow they really pack 20 lbs of crap in a 10 lbs bag on them things. You got some more pictures of that. Would love to see some over all pictures and some over all Nudes of that. Would love to see how they are running the hoses for the second radiator. Looks like it is running the 244cc Honda Clone that I have. Sure I will be posting pics of the radiators and their links and connections. Yeah, it is impressive how such a bigger engine and so many parts were put together in a such a nice and nifty way.
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