Vintage Grumble Posted February 8, 2016 Share Posted February 8, 2016 Yeh, I found having the temp sensor under the plug very helpful, as heat is the devil to two strokes. And yeh man, just PM me the part numbers and i'll see what I can find. Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 8, 2016 Author Share Posted February 8, 2016 Mint will confirm the numbers and get back to you! Looks like I'm going to give Total hi-perf semi synthetic oil a go. Elf place won't order anything less than a 20l for me. Quote Link to comment Share on other sites More sharing options...
kyteler Posted February 8, 2016 Share Posted February 8, 2016 Wot. Useless. Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 8, 2016 Author Share Posted February 8, 2016 Yeah! It's a hydraulic supply store and while they use to carry Elf engine oil they found no demand so now will only add a 20l to a bulk hydro order. But have just been told pit stop here carry Elf and the owner is into motox and gokarts so will try them, failing that total semi seems to get good reviews and since they sell so much of it he gets a good rate so prices it cheaper than I've been getting the Castrol! Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 10, 2016 Author Share Posted February 10, 2016 Smells awesome at the very least! Starting to do a thing Fuck it's hard to get these things clean!! Going to split it tonight I think, plan to clean up some of the case porting, new bearings and seals (will text/pm you some numbers later today Mr. Grumble) and I've got a few other ideas kicking about in my noggin that should work out interesting... 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 10, 2016 Author Share Posted February 10, 2016 Did more of things Hunted around a few shops in town this morning for case sealant, only thing I could really get easily was Yamabond 4 ($25) or Threebond 1211 ($90)...Then I did thisBit gummy, funnily though the other case half is spotless!Feels well made to me, no rough edges etc Big end feels perfect, no excessive play.Gave it a clean with brake cleaner, blew it out, poured 2t oil all over the bearing and spun the rod to work it in to the bearing to keep it protected from rust.Intake should benefit from having all the casting seems cleaned out of it.Tapers from 19mm at the carb to 25mm at the reed block.Plan at the moment is to not go overboard on porting the cases, just to take out all the casting marks and smooth out any sharp edges along the intake path.New C3 bearings and good quality seals from the fabulous Mr. Grumble and yeah doort.Bearings in it for reference are a 6006 and a 6204.Seals measure at 22x40x7mm and 17x27x7mm. 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 11, 2016 Author Share Posted February 11, 2016 Just realized I didn't take any pics of the small case after I had taken the crank out.Took a few nowIt's in my washhouse soaking in a bucket of hot soapy water to try to loosen more grime lol Shouldn't be too bad to clean up rough bits with the dremal. 1 Quote Link to comment Share on other sites More sharing options...
10Speed Posted February 11, 2016 Share Posted February 11, 2016 I put a set of cases through the dishwasher once... ymmv 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 11, 2016 Author Share Posted February 11, 2016 Very good idea, but my dishwasher is 11 years old, struggles with getting cutlery clean and would likely expect pocket money if I asked him to scrub these haha 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 12, 2016 Author Share Posted February 12, 2016 Nothing too exciting, I have started cleaning up the casings with needle files and sand paper, not going to take much more out but it's looking a bit better to me!Before:After rough shaping, still a few little bits to shape up and a bit of sanding to go:Stripped the gearbox, think one or 2 of the bearings could do with replacement, so I'll most likely just change the lot.Speaking of bearings, VG has hooked me up with a great deal on the crank bearings, seals and a nice 1/4" torque wrench to put the engine back together with, think I'll need to shout him a couple 3L juices in return Pulled the flywheel and stator off the UZ50 Let's 4 engine I've got here, the 8 pole stator has the same 2 wires as my stock 7 pole and fits right in my case, it's only one more pole but it all counts right?And I managed to get the small case half that clean yesterday it stood out like anything compared to the large case, so much to the Mrs's dismay I've got it soaking in a tub of hot water and cleaners in our washhouse hahaHave gotten a lot deeper into this project than ever intended!! Edit: It's now 11pm and I have spent most of my Friday night scrubbing my engine with a toothbrush...Dawned on me after a while that it was clean and that Suzuki had painted/coated the engine in an alloy colour when it was made, the dirty spots I was trying to scrub off are clean raw alloy that looks dirty in comparison to the coating lolI see some high temp paint in this engines future! 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 12, 2016 Author Share Posted February 12, 2016 As much as I hate getting woken up by a courier pounding on the door first thing on a Saturday morning, I love getting new goodies lol Those jets are apparently worth there weight in gold! And where I've stopped on the cases, just going to clean up my sanding marks. I didn't take as much off the large case, there far from symmetrical and I didn't feel like it needed much taken off 1 Quote Link to comment Share on other sites More sharing options...
Shakotom Posted February 12, 2016 Share Posted February 12, 2016 Okay I'm looking on aliexpress for scooter parts now 93kmh! Wowzers Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 13, 2016 Author Share Posted February 13, 2016 Sadly it's got a MUCH lower Aliexpress part and a much higher wallet raping part content than I had originally planned, turns out if you want to build a scoot from Ali bits you really need to start with a Yamaha! Had a play with the carb and a spare throttle cable, throttle etc to see how much of a mission it will be to fit, looks like it should be fairly easy really.Need to drill it and press in a fitting for a vacuum portStock throttle cable inner is way too short!Easy enough to sort out though, I cut the end off the stock inner and also from the long green cable I had brought from Aliexpress and slipped it into the stock outerJust need to figure out the right length of cable to for the carb then cut it and add a knarp/find where to buy a knarp.Also removed all the bearings and seals from the gear box, this one wanted to be an absolute cunt to get out!!Forgot to take pics, but I used an m12 125mm Dynabolt and made a blind bearing puller/slide hammer contraption out of it, bit of heat + a bit of brute force and out it came! So need 3 more bearings, 2 more seals, maybe some paint and 90ml of good 75w-90 or 80w-90 gear oil and I should be able to start putting this bottom end back together. Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 17, 2016 Author Share Posted February 17, 2016 The other day I pressed the engine mount and shock bushings out of my case halves, cleaned up, tested and fitted an electric choke to the PHVA and I've scrubbed up all the plastics and other parts for this engine.Test fitted the carb to my manifold and found that the manifold inlet was a tiny bit smaller than the carbs throat Spent some time with the trusty dremal and ported the manifold to suit. Couldn't find a source for cable knarps and wasn't keen on payin $35 to have an end put on my accelerator cable, so I found a bolt with a 6mm shank and drilled a hole in it Stuck my cable through and added an electrical crimp Bit of solder Then after a bit of grinding I had a fully functioning cable Attacked the inlet with the drill too And now it has a vacuum port Combined my lightest clutch shoes with the best backing plate and bell I've got and swapped them in, much better take off!And of course just because I'm changing carbs soon I've almost got the tune nailed on the Keihin Ordered in new engine mount bushings, I cross-referenced the size and found there used on a lot of Honda scoots and unlike Suzuki, Honda had them in stock in NZ and got them for me overnight for less than the price of one bush from Suzuki. Couldn't get a shock bushing though, but the Let's 4 parts engine I've got sitting around came through for me again with a like new bush, so I pressed it out and fitted it to my engine. Spent way longer than anticipated masking off all the gasket faces and bearing seats etc last night Then a good wipe over with wax and grease remover followed by a few coats of paint tonight Struggled to get a good pic of the colour in the shed lighting, but it's a charcoal metallic and I think it looks pretty sweet! Just waiting on my bearings and torque wrench to get here from VG then I can start assembly 1 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 17, 2016 Author Share Posted February 17, 2016 Chur VG! Was a little concerned when I popped the shields off and found a nylon cage in one of them, but after asking uncle Google I now know it's sweet as to use in a 2 stroke lol. Quote Link to comment Share on other sites More sharing options...
Vintage Grumble Posted February 17, 2016 Share Posted February 17, 2016 No shit, I didn't even know that had poly cages, haha. I can send you a steel cage one with the next lot of bearings if you want, as i'm not sure poly likes going over 70deg for long periods of time, though things probably don't get that hot in the guts of a scooter. Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 17, 2016 Author Share Posted February 17, 2016 Yeah the "energy efficient" 6006 has a poly cage, I'm unsure if I should run it or go for a steel cage now? Steel might be safest in the long run, it seems some kart guys run these bearings, but they are rebuilding there engines a hell of a lot more often than I ever plan to! Also I kinda destroyed the steel covers when I pried them off haha Edit: Malossi rebranded bearings for Yamaha engines reckon "phenolic resin cages with material based reinforcement" Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 21, 2016 Author Share Posted February 21, 2016 Spending a bit of time on the masking payed off After a LOT of searching I managed to find a Street Magic workshop manual online, so now I've got all the torque settings for the engine. Good thing I didn't just go with Yamaha settings as the Suzuki ones are a fair bit lower. Today has been another clean and paint day. Fought the urge to paint my carb!! I'd noticed that both my engines came with after market variators and that both had not had the CVT fan refitted, well yet again the 4stroke came through for me with a good fan and like new kick starter crown etc! Also cleaned up the fixed pulley. Decided that scrubbing it with a brush or even sandpaper just wasn't going to cut it, I needed something a bit more hardcore! I needed a way of both cleaning the pulley AND gambling with death/imminent lose of digits... Can't argue with the results and I only needed one small plaster! The rest of my bearings and seals should be sent tomorrow (cheers again VG!!), so all going well I'll be able to start assembly on Tuesday! Fingers crossed my next update will be more exciting 3 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 21, 2016 Author Share Posted February 21, 2016 Quote Link to comment Share on other sites More sharing options...
Raizer Posted February 21, 2016 Author Share Posted February 21, 2016 Now what could be in there?? :grin: All the jets and needles I should ever need! Contras Rollers, small end bearing, oil line and some gaskets etc. Then there was this little cooler box Mmmm special bologna... This is why I've been putting together a decent bottom end with good bearings etc! 47mm bore "70cc kit", with the short Suzuki stroke it works out at just on 68cc. Dunno why the reeds are different colours?? And the most important item of the lot A new box for Dewey haha 2 Quote Link to comment Share on other sites More sharing options...
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