you can't handle the truth

The handling issues became more and more apparent. I added the 'engine mount stabilisers' from 'hot rod scooters' that I had lying around. I thought the engine mount area was the problem. This didn't help, so I put in new rubber engine mounts, removing the uprated urethane ones. This didn't help either but it did reduce vibrations by a lot. This is a rlief and was something I intended sooner or later anyway.
I went to see Klaus (scooter expert and collector) and he went around the block, instantly blaming the steering bearings for the wierd handling..... so below is the final post on th ebbs forum explaining how I dealt with it.


Another problem solved... and here's what happened (for future searches).
I bought all new post 63 bearings and races.(apparently they are all the same from then on ... but I find it hard to believe).

I pulled out the fork and had a look at the upper and lower bearing races. Both seemed to be deeper than the new ones. Seeing as I was committed to the PK lower lower cone, I decided to try and remove the lower frame race from the GL frame. Fortunately it was a later style without the sleeve going up the tube.
I made a tool (handy owning a metal shop , albeit wrought iron) to extract the race and it worked fine. Before I could measure the old race to see if the new one would go in, I dropped it into the frame channel (forever).
Two hours of fiddling, sanding, making tools and hammering saw the new bottom frame race go in. Everything else was a doddle.
Before reassembling I had to clean up and rush out to a wedding (congrat's Dave and Kerrie), so I didn't have that magic feeling of a well handling old vespa until this morning.
Cruising at 60 kmh, I took my hands off the bars no probs, then applied the rear brake. It tracked straight and true. Now the project is complete, and thanks to this bearing issue, I changed back to rubber engine mounts, killing the vibrations and proving the old mazz crank to be useable in the future (I blamed it for the vibrations and ordered a new balanced LS crank).

testing 1-....ooh

Probably done a hundred k's so far, and last night thought i'd let the revs do their thing.
Then it died. Here's the BBS transcripts...
Finally had the courage to test the new motor at high revs (in 3rd) and it stopped dead.
Not a seize
Not the fuel
compresion is fine
Spark has no bits on it, looks in good shape and is chocolatty brown.
No spark
Isolated engine (pulled green wire)

question.... After I find out it is not the spark, cap or lead, what is the most likely electronic thing to shit itself at high revs? CDI or stator?

cheers
derek

derek
63 GL 220
port matched malossi kitted px200 lump

I'd check in order-
Compression (just feeling it by kicking it over)
Spark
Fuel
Timing (sheared key?)

Thanks E. so far.....
compression- OK
fuel - OK
spark - no
spark with two other cdi's - no
spark from end of lead - NO
does a sheared woodruff prevent spark? Logically it would create a spark, but just at the wrong time to start the bike.

I am stranded at home 15 km from my workshop. i have a junior member of staff bringing half my tools in the truck.
What I want ... to remove the flywheel and solder a loose wire back onto the stator.

derek
63 GL 220
port matched malossi kitted px200 lump

>junior member of staff bringing half my tools in the truck.
>What I want ... to remove the flywheel and solder a loose
>wire back onto the stator.

yep. happened to me just like that. 140 miles from home.

white wire has been rubbing on flywheel near the stator. The insulation has worn off but the wire is intact.
Is if the white wire is rubbing on the inside of the flywheel, will this kill my spark?

jUnior forgot the multimeter, so I'll stitch it back together with some tape and see what happens.

derek
derek
63 GL 220
port matched malossi kitted px200 lump
... now I have found the desired resistance from the stator...

Here are the #'s to test the sparking coil and pick-up.

resistance between white and green 500 +/- 20 - ME-spot on
"" white and red 110 +/- 5 - ME - 37,000 ohms

I have ordered a new stator from GPS imports in Abbotsford, and booked an express courier to bring them to me in my home. I am determined to get to work ON MY DIRTY ROCKET at some stage today.

'

gordon's alive

It works. today the inaugural ride to the servo for fuel went without too much trouble. (naturally it revealed a leak in the fuel tank lid ).
Gear changes are a bit iffy and the clutch, while engaging quite far out on the lever action, still grabs.
things to do...
-fix fuel tank lid
-attach bike speedo
-attach cht guage
-sort out mirror
-get chrome toggle for spotties (by the way the spotlight kit was great and came with all the wires, junctions and even chrome coil cable covers). The switch they came with is plastic and doesn't suit my look.

note - did 10km today an dall seems good. The motor is very responsive. Handling is a bit strange, but I assume that it is a matter of getting used to a new bike. The front brake is no good at all so I must decide whather to get a new PK drum, or go ahead and install a disc kit.

one drop of essence of terror, two drops of sinister sauce....

well it runs.
Problems...

Gear change cables don't work too good
Throttle control doesn't open it out all the way
No bolt for old sito plus
clutch cable jumps out of position (therefore front brake may do the same)
no holding clip on gear change shaft
carb floods (probably due the upward angle of the malossi reed block intake manifold).

Solutions....

Gear change cables don't work too good- fiddle around and make sure it is not just incorrect tension
Throttle control doesn't open it out all the way - I can dremel off part of the stopper in the headset
No bolt for old sito plus- buy one
clutch cable jumps out of position (therefore front brake may do the same) - dunno, fiddle a bit and see what's what
no holding clip on gear change shaft - tgry to make something or buy something - research availability of spring steel
carb floods (probably due the upward angle of the malossi reed block intake manifold).- change the float position and hope it doesnt cause fual starvation.


.... mor eto come I'm sure.....

feeling cranky

well today the crank and head arrived, but the wait saw loads of gardening get done.
They were packed badly with the crank exposed to any impact during transit. we will only really know if it has been knocked out of true when I start it.
I installed the crank, eventually got the flyside inner race on and closed up the cases.
The crank spins ok, and I put the cylinder on. As it is a long stroke crank and I am using the deepened head rather than a thick base gasket, I must be careful to align the head so the piston doesn't hit the head on the way to top dead centre.
Oh, and also I had to dremel off soem of the malossi reed block to get the cases to close up.
Tomorrow night the engine goes in the bike... yikes!

ah, ups

Location	Date	Local Time	Description
ASCOT VALE, VIC, AU	16/10/2006	2:15	IN-TRANSIT SCAN
ASCOT VALE, VIC, AU	14/10/2006	10:53	IMPORT SCAN
ASCOT VALE, VIC, AU	13/10/2006	22:11	PACKAGE DATA PROCESSED BY BROKERAGE. WAITING FOR CLEARANCE;RELEASED BY CLEARING AGENCY. NOW IN-TRANSIT FOR DELIVERY
	13/10/2006	21:21	PACKAGE DATA PROCESSED BY BROKERAGE. WAITING FOR CLEARANCE
	13/10/2006	21:21	REGISTERED WITH CLEARING AGENCY;SHIPMENT SUBMITTED TO CLEARING AGENCY
	13/10/2006	21:21	REGISTERED WITH CLEARING AGENCY;RELEASED BY CLR AGENCY. NOW IN-TRANSIT
CHANGI, SG	13/10/2006	6:45	ARRIVAL SCAN
KOELN (COLOGNE), DE	10/10/2006	23:30	ORIGIN SCAN
	10/10/2006	23:29	EXPORT SCAN
	10/10/2006	23:17	EXPORT SCAN
	10/10/2006	21:06	ARRIVAL SCAN
	10/10/2006	16:49	ARRIVAL SCAN
HERNE-BOERNIG, DE	10/10/2006	15:39	DEPARTURE SCAN
	10/10/2006	14:49	DEPARTURE SCAN
	10/10/2006	11:23	ARRIVAL SCAN
FRANKFURT, DE	10/10/2006	7:30	DEPARTURE SCAN
	10/10/2006	6:15	ARRIVAL SCAN
DITZINGEN, DE	10/10/2006	3:08	DEPARTURE SCAN
WENDLINGEN, DE	09/10/2006	23:11	DEPARTURE SCAN
	09/10/2006	20:44	ARRIVAL SCAN
GERSTHOFEN, DE	09/10/2006	19:25	ORIGIN SCAN
DE	09/10/2006	11:24	BILLING INFORMATION RECEIVED

Tracking results provided by UPS: 15/10/2006 5:31 Eastern Time (EST)/New York Time (USA)

seeing red .... tape

Today saw the start of the registration process. It won't be easy as the frame sat in the desert for years and the Vin doesn't show up on the rego computers. I have written a letter to Canberra and I'll keep you posted.

zzzzzzzz

...so after waiting a week for my cank, reed block and head I rang SIP and re-ordered (as they seemed to be waiting for the reed), cancelling the reed block and was told it would be posted that day. Next day I get an email (the usual one saying that postage will be much more than anticipated) and I reply saying "yes ok please go ahead with the order... I am in a hurry".
To back this up I rang that night (morning in Germany) and was told yes, it has been sent.
A week later I rang again and was assure the items were posted 8 days before.
A week later I rang and was told 'do you want to go ahead with the order?'
I am so frustrated as this is the finish line.

New wack a wheel squeeze

Unfortunately my history of disappointment didn't let me down today when the postie arrived.
The rack (bought off ebay pictured on a 10 inch bike) turned out to be for an 8 inch spare wheel.
The rack fitted the scooter alright, and was just the delicate looking one I wanted..... so........
......





Sorted. Sometimes it's handy having a steelworking factory.
I could have put it back on ebay then started again but I'm not that kind of guy.


Also, by coincidence the scooter owned by the rack seller (ebay) had these strange mirrors(below). I had heard of the clamp things to go onto the VNA split headset, but when this pic arrived I decided to get them. I ordered them from scooterworks in the USA.
Now it is a matter of waiting for the crank and head.

I can't stand it anymore

It's the 11th hour of this project and I'm waiting for engine parts. Tonight I couldn't wait anymore and made a 'placebo' engine so I could get the bloody thing off the stand and see what it feels like to sit on.
I welded some tube together in the appropriate places, attached an old front hub... and bingo ...off the stand.
... so I sat on it...

... bring on the new crank Mr Postman

reedy to roll

ok the reeds are in, the glove box is in and I am now deciding whether it is naff to put the vapor enduro computer on the headset or down near the glovebox. I have a standard 2 inch round temp guage with a chrome holder, but (as the speedo will not be connected) I will also have to install a bicycle computer. I would then have to wire up lights in order to see the guages at night. If I decide for the vapor ( http://www.trailtech.net/vapor.htm ) on the headset I will do it right away and start with that. If I decide on a vapor for behind the legshield I will make do with the round gauge then buy a vapor later. Here's a computer mockup of what it may look like... (note the new glovebox)



Arguments for and against the headset mounting....

for - I built this scooter for a purpose, and on the headset i can easily see speed, temp, rpm, distence etc. (internal light)

against - It will look blatantly unoriginal

for - It is the VNA split headset, so I can get another in the future and get it back to oldy worldy.

for - I am getting to like the idea of having something unique. The scooter is made up of so many different parts anyway.

against - It could look ugly, but I don't think I'll really know until I do it. I will get one sooner or later so there's no harm in sitting it there to see how it looks.

reed and weep

Today was one of those Santa days. First my glove box arrived, then my reed block. At 5pm (start of workday German time) I rang SIP and apparently the head and crank have been in transit for 5 days and are due this week.

I had to grind the glove box a fair bit to make it fit, but all was well in the end and I have painted it already.


I got straight into dremeling the cases as soon as I had the glove box painted. my first go on the dremel and I think I did alright. There could be another couple of hours of perfecting the inlet porting but I want to see how it goes with mild work done. The inlet has already been heavily dremeled, so it was already pretty smooth. I removed the rotary pad an opened the inlet to match the malossi reed block. The crank I ordered has some kind of 'special lip' (worb5) so probably reduces the need to heavily dremel out the case.

Great Racks drive me spare - they wheely do

I just won an ebay auction for a rear 2-in-1 chrome rack. Buying one was on the agenda, so I've no doubt saved a few bob. Hopefully it will fit.

Also the glove box arrived today (scootrs) . It looks pretty crappy and will have to be cut and ground to fit properly. It was cheap and was bought so I didn't feel bad cutting holes for guages in a collectable GS one.

Still no word from SIP or Beedspeed on the engine parts. They seem to know when you are extremely desperate, and refuse to answer any emails for a week. I will ring them all tonight and see what's what.