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Hello All,

Well it has been about a month or so since I was last here. My scoot is still acting funky!!

When last we spoke, it was running very fairly well (but rich) after installing a new kei-hin carb. Fast forward a bit; I rode it to work for about a week or more with no real problems it was running fast passing cars while slabbing it on the freeway.

One day after work decided to go for a little longer trip about one hour out of town in the boonies to enjoy cali spring weather. Ended up coming back on a tow truck!

(It could be battery leach, while sitting at work overnight, considering putting on batt kill switch). I always kept it on a little batt tender while at home.

Had plenty of fuel but fuel pump stopped running. (even after charging batt again) Little aftermarket one, all oem stuff cut off by po. Took fuel tank out of floor and mounted above carb added filter and now have a nice gravity fed fuel system. It gets plenty of fuel now.

Charged it and it ran good again, rode to mom’s house in the country by way of highway and good roads. No problem; left moms house because it was late and dark, so I took short cut (rough country roads pot holes etc. Muffler fell off!!!!

When I got to my exit and could hear over roar of wind that muffler was disconnected (still hanging on by a thread). Bike would not stay running at idle.

Re connected muffler with better clamp (one of the nuts was stripped). Now it will run under throttle but cuts out and feels like dying at just above ide to 1900 rpm. Hesitates/ dies under low power, roars at WOT.

Now! Bike is completely pulled apart again on the garage floor. Since apart I just re did the valve clearance; set to 004 top and 006 bottom after finding tdc. Bottom was 005 when I re adjusted (still ok I think but website said set at 006) .001 is not a very large gap difference.

The instrument cluster plastic housing (plastic box) was crumbling from heat of cdi or rectifier or both or just age (IDK?). Since apart I fabricated a new housing box out of tin flashing.
Now all gages are secured and cluster looks much better.

Gages all seem to work (no actual connections or fusible links touching metal to short out) Lights are all now in the proper places instruments light up properly.

Wrapped new box in duct tape to try to waterproof seams a little. (I can buy a new one but I am hesitant to spend any more big money on this thing until sure it is going to run).

Pulled plug: Bike is running rich as hell. I have tried adjusting A/F mix and idle. I cannot get it to smooth out.

Must be vacuum/ fuel (but seriously po has cut almost everything off and there is really no vac lines running to anything any longer).

One vac from intake maniforld to egr. I plugged egr where it comes out of larger port. With a hose and a large bolt. No leaks there.

One big hose comes off of timing chain cover (round bowl shaped thing covering small bicycle chain). Where does this go? Should this be a vent or connected to something? Steam/ heat comes out when running. No noticeable change in running when hose is plugged by thumb. Should I leave open or plug as well?

Carb bowl has little L shapped vent hose. That’s about it.
No air box any longer so vac lines running to it. No charcoal smog crap any longer either.

Radiator has leak, while apart going to have that fixed as well. Just found leak behind water pump. Going to take off and see if damaged or gasket bad or something.

I cannot believe all this is because of the muffler falling off. Sorry about the long post. I tried to break it up into manageable sections so you all can digest it all.

Thanks again

Dave

P.S. cooling system is still apart so I cannot start bike yet to see if valve job fixed or not. Any ideas at all fellas?

Hi Richard,
Thanks for the link and the help.
Unfortunately that is the one in my kit that I returned. if you look at the photo in the top right portion (the hard plastic portions shape is completely round.) On mine the rear (lower towards the needle) portion is round and the front is a cut out square shape. This one (photo) goes to the vertical engine. I have the horizontal version.

Thank you again for your help
Dave

Thank you alleyoop. I guess it's back to the drawing board again

I got to go away for training for work this week to the Bay. I'll write this weekend when I get back.

Thanks for trying to take one apart for me. If I did it It would either cost me the 30 bux for the kit I have or the 200 for the new carb!!!!

Sorry you broke one of yours on my account.
Dave

Sorry about the little delay in responding, my job shift was changed yesterday (I'm trying to get acclimated.

Tomorrow (Saturday after I get off work, I'll snap a few photos).

everything in the kit looks fairly similar ( I did not open up the carb all the way). Guy on the phone from the shop said that the jets probably will not work. Needle looked close. It is adjustable with the clip.

diaphragm looks about the same except for the lower hard plastic end. the one in the kit is basically a circle. The one on my scoot has a half semi circle on one side and a flat squarish section. Ill photograph it to show what I mean.
thanks again for the help.
dave

do you think there is a way to remove the soft diaphragm plastic and install it on the hard plastic section of my old one?

Mucho Thanks Alleyoop

Dave

edit: I just bought that kit, thank you.

Thank you for all the info, and places to begin.

The previous owner removed the “airbox” as well.

There is the original duct-work and what looks like a 45 degree elbow at end. Connected to this elbow is a regular old fashioned Specter round air filter cone. It is about 6 inches round.

I’ll plug up that egr valve this weekend. And close all the open lines I find. This weekend I’ll try to snap a few photos so you can see what I am looking at.

The vacuum line from the intake runs down to that valve. I presume that the nipple that should go to the air box is the one I plugged with a bolt and a little piece of hose. It probably is leaking around the bolt.
I'll plug it with Jb. I never thought about using that as a plug. Thankx

Thank you again for your help. It is much appreciated.
Dave