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Easy-X |
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Easy-X Super Spammer
Joined: 08 Mar 2019 Karma :
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Posted: 00:56 - 30 Dec 2019 Post subject: |
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Rebuilt the seat/helmet lock:
https://i.imgur.com/k7UBav6.jpg?1
Haven't seen one of these turn up yet on eBay etc. so a bought a cheap copy of the ignition with the intention of stealing the barrel. That didn't work as the tab at the bottom is at a different angle. Bah! Okay so I'll just steal the levers. Nope! The copy is a mirror image (key-wise) of the seat lock I got my local key cutter to hack something off this mirror and then put it back together with the new lock's levers. Needed some small adjustments with a file but now you only need to jiggle the key occasionally to get it to turn
Rebuilt the forks:
https://i.imgur.com/3ywxsyM.jpg?1
Pretty straightforward considering this guy basically has the same bike:
https://www.youtube.com/watch?v=ZEAPFhdjaW0
My tips are: pay careful attention to the damper rod assembly order
Things I have realised...
Yamaha DT forks have quite some variance across engine sizes and years. From what I've seen the fork bottoms are similar - a 30mm DT125 fork bottom from one year is probably interchangeable with 30mm DT175 from a another year. The same might not be said about stanchions and dampers, I've seen a good few variations. What I'm saying is: don't lose any bits as you'll not likely find individual parts
Having said that oil seals and dust caps seem easy enough to get hold of and that's the main thing
Oh yeah, the silver paint! The tops of the stanchions are fucked but hidden behind the headlamp brackets so unimportant. I might get them rechromed at some point though. ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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Easy-X |
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Easy-X Super Spammer
Joined: 08 Mar 2019 Karma :
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Posted: 01:01 - 30 Dec 2019 Post subject: |
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Oh yeah, no longer pissing out oil when compressed ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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Sister Sledge |
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Sister Sledge World Chat Champion
Joined: 17 Aug 2018 Karma :
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Easy-X |
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Easy-X Super Spammer
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Easy-X |
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Easy-X Super Spammer
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Posted: 18:13 - 04 Jan 2020 Post subject: |
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I got up at the crack of midday to work on the bike...
https://i.imgur.com/MMxGThV.jpg?1
Threw the handlebars on and realised nothing was straight so went round loosening everything up and took well over an hour to sort it out. Mainly as a friend came round and started regaling me of tales of his Bonneville
Got the clutch and brake levers at the angle I like - the cheap seat doing a fine job - and then hooked up both cables. I dunno about you but I instinctively grab the front brake on a bike (even without an engine!) and it's a source of comfort to get it working if a little unnecessary at this stage.
Time for a relaxing cup of tea and squinting at cable routing diagrams. ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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WD Forte |
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WD Forte World Chat Champion
Joined: 17 Jun 2010 Karma :
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Easy-X |
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Easy-X Super Spammer
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Easy-X |
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Easy-X Super Spammer
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Posted: 18:17 - 11 Jan 2020 Post subject: |
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Started routing the cables:
https://i.imgur.com/LMAuBpb.jpg?1
https://i.imgur.com/KB4jROf.jpg?1
Not quite happy with it but then I can't say I think much of the original layout.
So I have tacho, speedo, clutch, brakes all in:
https://i.imgur.com/oRbBYOc.jpg?1
Had some fun and games getting the throttle hooked up but mostly a case of stupidity
https://i.imgur.com/9FdPnSq.jpg?1
I've left a lot of pipes hanging out for testing. Fresh oil added to the gearbox.
https://i.imgur.com/yPcbBT6.jpg?1
Problems? I'm glad you asked...
I think I had about three attempts at routing the cables and wiring. The main thing I focused on is not getting things like the brake, clutch and throttle trapped on full lock. Wiring doesn't have quite the same issue but it does need to avoid hot areas where possible.
Of course I tested for spark at the earliest opportunity... yes, there is spark but only when the ignition is off I had to strip the switch out and reverse the internals. Glad I took the time to map out the original switch's function now
"Didn't you sort the ignition out way, way back?" Well yes, but I missed the fact the original had ~30cm of wire and the copy had ~10cm so I did a bit of a mash up. Badly as it turns out.
Anyhoo, all good now; if the weather's okay tomorrow I might get it started up ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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Sister Sledge |
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Sister Sledge World Chat Champion
Joined: 17 Aug 2018 Karma :
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piazza |
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piazza Brolly Dolly
Joined: 23 Aug 2008 Karma :
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Posted: 19:52 - 11 Jan 2020 Post subject: |
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Bleed that 2 stroke pump |
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Easy-X |
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Easy-X Super Spammer
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WD Forte |
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WD Forte World Chat Champion
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Easy-X |
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Easy-X Super Spammer
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Posted: 01:00 - 12 Jan 2020 Post subject: |
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Good point
The carb drain is a clear pipe (so it can double as a float height checker.) Maybe replace the pump to carb pipe with an oil resistant clear one? ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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WD Forte |
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WD Forte World Chat Champion
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Easy-X |
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Easy-X Super Spammer
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Posted: 17:53 - 12 Jan 2020 Post subject: |
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Rigged up a temporary tank:
https://i.imgur.com/BZUyVxZ.jpg?1
Premix fuel plus some oil in automix tank to see if the pump works...
Bled the system fine. Took a fair few kicks to get the engine going again but then I had dripped a little extra 2-stroke oil in the cylinder just to be on the safe side
So far I've got it idling consistently with the choke on but as there's effectively an air leak where the oil feed should come into the carb I didn't get seriously into it.
Regarding the oil pump. It initially spluttered out a little oil but then stopped. I'll probably take a quick look at it (easy to take off and dismantle without popping the whole case side off) before weighing up blanking it off - annoying as I have to dump all the gearbox oil I just put in ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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WD Forte |
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WD Forte World Chat Champion
Joined: 17 Jun 2010 Karma :
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Posted: 20:58 - 12 Jan 2020 Post subject: |
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Be interested to see how they work
I'll guess it will be a LPLV rotor type thing with a metering valve
that opens up with the throttle.
Maybe it's more sophisticated than that, dunno
EDIT:
It is, found this
A load of balls pistons plungers and valves
https://dansmc.com/oil_pump2stroke1.JPG ____________________ bikers smell of wee |
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WD Forte |
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WD Forte World Chat Champion
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Easy-X |
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Easy-X Super Spammer
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Posted: 21:33 - 12 Jan 2020 Post subject: |
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Great link! Many thanks ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Easy-X Super Spammer
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A100man |
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A100man World Chat Champion
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Posted: 12:58 - 13 Jan 2020 Post subject: |
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Easy-X wrote: | stinkwheel wrote: | With regard to the current project. With the engine idling on premix, pull on the oil pump branch of the throttle cable. This will move the pump to the fully on position to prime the hose more quickly. |
Lol... good shout! I was thinking I'd be super-annoying revving the engine just to see if any oil is being pumped |
This is what I did with my GT250.. This has a number of branches form the pump output that feed the main bearings and also the intake ports. you can actually watch the air bubbles 'pulse' up through the transparent feed tubes when bleeding.. ____________________ Now: A100, GT250A, XJ598, FZ750
Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600 |
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Easy-X Super Spammer
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Posted: 18:43 - 18 Jan 2020 Post subject: |
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Day 1 of "Operation: Haven't You Fecking Finished This Yet?"
I'll start off with a shocking revelation:
Sometimes, just sometimes Chinese carb copies aren't worth a w*nk
I know that might kick off a riot but there, I've said it now!
It did work, briefly, and then it just decided to stop working. And then it decided to start pissing fuel from the overflow - completely spontaneously - and, after some pissing about with it, I did the sensible thing and gave up and put the old one on. Yes, it's a bit beat up but at least I knew it did work.
Or so I thought.
After the bowl filled it took 2 kicks to start. (First I forgot the choke.) I let it sit while I looked for a socket extension for the exhaust nuts (more on that later.) And then it started revving like f*ck! Eeeeek! Thankfully the kill switch was wired Kicked over again and just the slightest touch of throttle sounded like a Space X test flight... not one of the good ones
"WTF is going on here? Massive air-leak?" No, always K.I.S.S.
I tried again but this time with a hand ready over the airbox snorkel. Yup, start blocking it and the engine dies. So far so good. Touch of revs to start it off and starving it of air calmed things down. "Feck! There's a surprising amount of suction..." Hmm
With the engine off I checked the carb slide was moving freely. "No problems there... hang on a moment!"
The carb spring on the left is the original and the one on the right is from the new (but rubbish) copy:
https://i.imgur.com/J1KZCxd.jpg?1
Compress the new one and you'll send it pinging across the garden. The old one, not so much
Yes, folks, just that simple! The engine catches and the suction holds the carb slide open spontaneously. Swapped in the better spring and normal service was resumed:
https://img.youtube.com/vi/8fkdIMI4qB8/0.jpg
https://youtu.be/8fkdIMI4qB8
With the engine running calmly again I could look at the exhaust leak. I went with "finger tight + half turn" and then "quarter turn till the leak disappears" classic but it works
https://img.youtube.com/vi/v7gyo8pd-Jo/0.jpg
https://youtu.be/v7gyo8pd-Jo
Exhaust sorted but what about the oil pump? I pissed about some more:
https://img.youtube.com/vi/VVLySH6mAwI/0.jpg
https://youtu.be/VVLySH6mAwI
So it does seem to work. Doesn't seem very dramatic though I know two revelations in one post might be a bit much but... I have no idea what I'm doing here
Is a dribble on full throttle and barely a drip on idle the right amount?
Other than that I've spent the last few evenings squinting at the circuit diagram. The right one this time! Only the 1G1 specific diagram in the Haynes manual is 100% correct - there are slight variations (unsurprisingly) between the years but also between markets (US vs Europe.)
Anyhoo, I realised the connectors for the indicators I so carefully repaired need to be double bullet sockets:
https://i.imgur.com/tLn5o3h.jpg?1
Fingers crossed for the weather tomorrow for Part 2.
<addendum> Oh yeah, the tacho was off 'cos it didn't seem to do anything. I have the old tacho cable kicking about so I'm going to test it, off the bike, with the old "electric drill" trick ____________________ Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter |
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stinkwheel |
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stinkwheel Bovine Proctologist
Joined: 12 Jul 2004 Karma :
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Posted: 20:07 - 18 Jan 2020 Post subject: |
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Used to check the operation of some oil pumps by counting drips with them set to a certain position. It would ba a drip every so many seconds.
Remember, it's probably delivering somewhere in the ball-park of 40:1 oil to fuel so roughly 1ml for every float-bowl full. ____________________ “Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles. |
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Easy-X |
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Easy-X Super Spammer
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Posted: 21:36 - 18 Jan 2020 Post subject: |
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Old Thread Alert!
The last post was made 4 years, 100 days ago. Instead of replying here, would creating a new thread be more useful? |
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