the mates pk

[tzsteve]

a few very simple jobs on a mates PK

these are all simple things that just needed to be put right



the throttle stop needs to be filed a little.
a PK only has 27mm of movement on the throttle cable.
this scoot has a nice engine built by another member a while ago and is getting a 32mm carb obviously 27mm is not going to help a 32mm carb.
so a little metal is removed from the throttle stop giving about 33mm cable movement.

this scoot also has a slightly bent throttle tube. this made the trottle progressively stiffer as the throttle was wound open.
so a couple of hours were spent with some emery cloth easing the throttle
tube a little.
..................................

checking the connectors over showed a very common bodge,
a wire in the headset had obviously lost a couple of inches over the years.
the common bodge is to crimp an extra piece of wire on to the end to extend
it enough to reach the terminal on the head lamp bowl.
this often works but also leaves potential problems in the future.

solution is simple,
cut the crimp off, solder a piece of fresh wire of the "correct colour" to the remaining end and pull it through the sleave to the switch unit,
remove the old wire and solder the new piece in place.
then fit a new connector and insulating cover to the business end of the wire

( crimp and solder ) job done

................................



this scoot has a nice reed valve fitted.
however the manifold is one of those "race" ones with no groove to help the
carb rubber stay on.
simple solution put the manifold on the lathe and cut a groove to fit a
32mm dellorto rubber, this could have been done by the maker.
i suppose the makers could argue that not cutting the groove allows the
end user to decide where to cut the groove after the customer has bought
a carb ( perhaps ).
.............................

start on the lighting and ignition

this is all new to me as for the last 35 years i have always made my own looms and gone 12vdc.
12v ac with vespatronic on a pk is going to be a learning game
any tips would be "VERY WELCOME" gents
........................



i had a quick look at the case bolts and found one that was still loose,
to be honest i have missed a nut or two myself in the past.
so there is no shame in this sort of oversight.
having a mate check your work is always a good idea.

i was told that the fan retaining bolts needed some loctite so while doing that i spotted a low strength nyloc had been used for the flywheel nut so that was soon swapped for a high tensile jobbie (M12x1.25 grade 8.8)

the owner of this scoot needs to buy a flywheel holding tool and a flywheel puller
for this scoot as the vespa ones do not fit.
once i have my hands on the holding tool i will be able to check the torque on the flywheel nut

so more expense for the owner of this PK
..................

i had been told there was a problem of some sort with the horn
so i removed the top screw from the cover and then spotted this



thinks me

removing the cover needs the buttie box to be removed as there are two home made brackets holding both the horn cover and the buttie box to the frame.



these brackets are actually quite nice but i have replaced the rivets with a couple of button head socket screws ( Allen screws ) this looks neater and makes any future work a little easier for the owner.



and this is why the horn is not working.



so when the owner is buying his flywheel tools he could also get a new horn


.......................


a few other little jobs also done,
but just the simple stuff of fitting cables,
trimming the carb cable outer,
making a suitable choke cable,
then the fun job of fitting a new fuel tap which was not too difficult
once i had got the nut onto the tap inside the tank.

still a few simple jobs left but these will keep for a few days

currently scratching my head on the electrics.

i know that the black and blue on the frame are for the lighting

and the green is only connected to the cut out on the steering lock,

however the lighting only works when the stator is connected to the blue and green

so i suspect that the wiring has had a couple of connectors swapped at sometime in the past

the job now is hunting the mistake.

[tzsteve]

continuing to try to solve the problems of the lighting

THIS IS GETTING INSANE


so i decided to check the regulator, relay and all other connections including all the lights.

and this is the standard of workmanship that i found

this is a close up of one connector showing the lack of care
from whoever made the loom.



waiting on a few petrol pipe clips once they arrive i will be able to check the voltages supplied to the lights.
rather than just watching to see that lights come on

another look at this tomorrow before i start my afternoon shift

[henri]

there not even crimped , reckon somebody had been told off an thought a bit of "revenge sabotage" was in order . H

[tzsteve]

a couple of hours this morning just doing simple jobs

tidying up the connectors on the indicators and back light.

made a small bracket to hold the CDI.

checked the flywheel torque it`s at about 35ftLb or about 50Nm which is spot on.

then put my meter on the stator and finally realized what i had been doing wrong.


just waiting for a couple of meters of wire to arrive, i`ve used up all the common colours on other jobs.
i also need a couple of connectors mine are all straight crimps i need a couple of 90deg "flag" connectors for the CDI as the CDI is close to the pipe, if i used straight connectors here there is a chance of the wires coming into contact with the pipe ( not good ).

this might be useful to others,
even if you are not doing an ac PK it gives an indication of how a vespatronic is wired.

[terjee]

the manual to vespatronic is for PX, it was the same on pk.

[tzsteve]

Aug 17, 2018 18:45:29 GMT terjee said:

the manual to vespatronic is for PX, it was the same on pk.

handy to know