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Post by leon on Jul 24, 2016 16:27:51 GMT
Just dropped the engine and got it on the bench. I took the barrel off and it's clear the worst leak was at the base to the front. Think the biggest issue was I'd used Loctite blue to hold the studs, but there was residue round each stud which had set hard and prevented the gasket and barrel from making a seal. Schoolboy error.
There was evidence of a much smaller leak at the head and at the base of the exhaust manifold.
Just gonna clean it all up and rebuild with new gaskets and sealant as above. The piston and barrel are both fine which was what I was worried about.
I'm gonna have to sort out the throttle tube which I'm not sure about but I'll post in technical if I can't find what I need. The tube had jammed into the headset but I free it with a tap or two with a wooden drift. Will need refurbing before I can use it again. The steering stop on the fork is knackered now too - with the bike falling on its right side and putting the bars into full lock left, it's forced the fork tube past the stop and bent it so the left grip almost touches the seat.
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Post by dazzz on Jul 24, 2016 16:43:13 GMT
Not sure mine really counts as a project as such as all I'm intending to do is change the carb and fit a new speedo (plus put the badges and legshield trim on) but might as well stick a few pics up for the hell of it eh? Makes me smile when I look on your thread 11 pages later. lol
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Post by leon on Jul 24, 2016 17:45:53 GMT
Haha I know. Famous last words eh?
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Post by leon on Aug 4, 2016 8:41:16 GMT
Brief update - as I have non matching cases thats a suspect for the poor sealing of the barrel so theyre off to the machine shop to get the gasket face milled. Seeing as I'll need to split the casings to get the crank out I'm gonna see if I can scrape enough together to get a new gear dog. Looking at the throttle tube I think I need a new one as the welded on washer that keeps it in place is mashed to buggery.
And I'm off to see my dad next week who is giving me a compressor and spray gun so at this rate I might even be tempted to go the whole hog and do a paint job on it seeing as the engine door is all scraped now....
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Post by tzsteve on Aug 4, 2016 15:35:32 GMT
compressors are great next thing you will be after is a die grinder with a few collets and a handful of rotary burrs
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Post by leon on Oct 17, 2016 20:51:16 GMT
After a near three month break I finally got back in my shed today. I had to build another shed in the meantime to move all the junk that was in my way in my scoot shed, and have been skint so was no point going any further. But I now have a a small scooter kitty and a clean and tidy workbench again, and today I drained the oil and removed the barrel studs ready to split the casings again, hopefully tomorrow. Felt good.
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Post by leon on Oct 18, 2016 15:52:02 GMT
Split and stripped the casings today, and managed to remove the old gear selector without losing my balls. Just ordered a DRT gear selector, new Malossi air filter and a new throttle tube from SIP. Taking the cases to be decked on Thursday.
I also noticed that one of the wires on the stator has come away so I'll have to solder that when I'm sticking it all back together. It was from Beedspeed, aren't they a bit variable on quality? Anyway, I'm back in the game.
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Post by leon on Oct 27, 2016 15:46:10 GMT
Fitted the DRT selector on the shaft today. I struggled as expected but then after googling for tips on how to do it I spotted that SIP sell a plastic tool with a little indentation in it to stop the bearing slipping as you press it into place. A quick rummage round the shed and I found some plastic bicycle tyre irons. I hacksawed off the end, and drilled a little indent in them, hey presto its a piece of piss!! I also soldered (after a fashion) the stator and fitted the Malossi air filter
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Post by henri on Oct 27, 2016 16:55:07 GMT
plastic bike tyre levers , but thats cheating , i for one am goin to remember that one .much more satisfying to make ya own tool , cheat sip out of the euro's an not wait 5 days for it to arrive . puter screens fixed itself with the help of some rude words from me ,so i can say from what i see that solder joint dont look "dry" ,its a tricky one that needs a 80-90watt iron to get enough heat into laminates to "take" . as for filter ,some call it "brute force n ignorance" , but amongst us who know better its " the scientific appliance of extreme violence" ,a recognised skill/method of the scooter mechanic . H
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Post by leon on Oct 27, 2016 17:53:46 GMT
Cheers H. On the solder are you saying it looks ok or needs redoing? Forgive my numptiness, my iron is 40 watt, is that hot enough you reckon?
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Post by henri on Oct 28, 2016 6:42:20 GMT
looks ok , a "dry" joint is what you dont want , it looks dry n dusty an happens when theres not enough heat used to get solder to flow proper . that joint looks shiny an ok .H
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Post by leon on Oct 28, 2016 21:54:43 GMT
looks ok , a "dry" joint is what you dont want , it looks dry n dusty an happens when theres not enough heat used to get solder to flow proper . that joint looks shiny an ok .H Cheers H.
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Post by davet on Oct 29, 2016 9:59:09 GMT
Keep up the good work Leon. H keep drinking the fishtank water
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Post by henri on Oct 29, 2016 11:51:37 GMT
water , i dont touch the stuff ,you do know fish do "unnatural" things in it dont you . unless purified with hops or coffee i wont touch the stuff .H
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Post by leon on Nov 8, 2016 23:49:59 GMT
I bought this scooter a year ago this week. So far I've ridden it three times. Still love it though.
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Post by cluelessfromkent on Nov 9, 2016 0:14:38 GMT
I bought this scooter a year ago this week. So far I've ridden it three times. Still love it though. Your patience and tenacity is admirable Leon. Top work mate.
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Post by leon on Nov 9, 2016 11:39:37 GMT
Cheers mate, I'll get there in the end.
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Post by kev on Nov 9, 2016 22:51:45 GMT
I bought this scooter a year ago this week. So far I've ridden it three times. Still love it though. I know that feeling when I was doing my Pk
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Post by leon on Nov 20, 2016 23:06:21 GMT
Got the casings back together this weekend. Planned to dry fit the barrel and check squish today but a poorly nephew meant a trip to A&E instead. Nephew is fine though luckily, so will crack on later this week.
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Post by leon on Dec 22, 2016 10:57:56 GMT
Been slow to work on this and update the thread, but I've checked squish and with one ali gasket its 1.1mm which I believe is good for a Polini. Had some issues checking the compression with air blowing out of the exhaust manifold, so have some stuff to make a gasket for the exhaust recommended by Tzsteve and need to plane the manifold flat as the ears had bent from over tightening as suggested by Potatopl. Had loads of uni work on so couldn't get in the shed but thats all submitted now so I hope to get the engine running over christmas and back in the frame as soon as possible after that.
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