Post by wildbill84 on May 28, 2008 5:29:55 GMT -5
Vog 260 Body Panel Disassembly By- WildBill84, aka RacerX
Part 1: Gathering tools you’ll need
1 Phillips Screwdriver
Ratchet with 10mm socket
some pliers ( regular & needlenose if you have some)
Part 2: the disassembly
--------------------------------------
Edit 9/25/2009
I left out how to remove the "Y" shaped plastic panel that is between the headlights
The first screw is a phillips and is right under the nose of the scooter, after removing it, next remove the 2 more phillips screws, one from each side, pictured here the top red arrow points to where the two screws are (1 on each side)
After removing this piece look for a huge phillips screw near the bottom of the panel underneath the "Y" shaped panel you just removed . This is the only screw holding this Panel on.
Front Fairing (nose piece)
We’ll start by taking off the front fairing (nose piece) of the scooter.
Here’s is a pic showing which screws will need 2 be removed along the sides of the scooter.
In order to access the 2 screws at the bottom of the pic you'll need to remove the rubber footmat. It just pulls off, just start at the top and work your way down.
Go ahead and remove these same screws from the right side of the fairing while your at it.
When you're done with the side screws, we'll move on the the screws located behind the front wheel, on each side of the radiator.
The two RED arrows point to the 2 push tabs that will need to be pulled out or pushed from the inside, I was only able to reach the top one from reaching inside.
The GREEN arrow points to the last bolts holding the front fairing on, when you begin to unscrew these 2, make sure you or your helper is supporting the fairing from falling off and being scratched or damaged.
IMPORTANT- Remove the fairing slowly, because before you pull it all the way off the Lighting wire harness needs to be UNplugged, so you don't damage it.
---------------------------------------------
**SkidPlate/Under Belly
Next we'll start removing the underbelly of the scooter.
It is held in place entirely by push tabs,
here's a pic of them to get a better understanding of how they come apart.
The blue circles indicate where the push tabs are located.
As the push tabs are removed the bottom should start to fall down.
This tab is on the Right side of the underbelly of the Vog.
With the underside completely removed, we'll move on to the sides of the scooter.
---------------------------------------------
Panels underneath Floorboard area
With the front rubber floormats removed already we'll begin there.
This pic shows the screws nedded to be removed circled in blue.
The red arrows illustrate how the panel goes back on.
Now begin by removing the rear floorboard. Its longer than the front one but is held in the same way, so start in the front and work your way to the end.
Now you'll see something like this.
This shows how the front of the side panels look
---------------------------------------
Radiator guard
At this point the radiator guard isn't held on by much, Just 4 spots.
This pic shows the 2 tabs holding the guard on at the bottom.
And this pic shows the two tabs holding it up top on each side.
----------------------------------------
Removing - Radiator Fill Cover
I feel these pics explain themselves.
----------------------------------------
Speedometer, its wire harness & speedo cable
Its not necessary to remove the speedometer. If u don't you still MUST remove the speedometer cable from the back of the speedometer. And unplug the Speedometer's wire harness
----------------------------------------
Removing - Speedometer Housing Part
Now we'll remove the part that houses/housed the speedometer
This part isn't very hard to take off. Just 6 screws. 3 on each side, like ducks in a row! ;D
3 on the left (facing the scoot)
3 on the right (facing the scoot)
----------------------------------------
Engine Vent (piece under the front of the seat)
Another easy one!
After you take out these 3 screws the part should pull backwards and up.
----------------------------------------
Front Floorboard/Body Shield
Here we start by removing 4 screws with the RED arrows (2 on each side)
Then remove the two screws with the GREEN arrow (1 on each side)
If you didn't remove this screw earlier now would be a good time to.
-----------------------------------------
Floorboards (entire length) The home stretch!!!
We start with removing 8, 10mm bolts, 4 on each side, holding the floorboards down. This pic points them out.
Now remove 2 push tabs, 1 on each side, at the very back of the floorboards.
This pic shows their location
CAUTION- don't be rough with the next step, easy does it!!, Or you WILL break locking tabs, and the part won't go back on as flush as it come off. BE GENTLE on the locking tabs.
With all the bolts and push tabs removed the floorboard is ready to be removed! This picture shows the tabs holding this part in place, Now slide the floorboard FORWARDS to release it from the licking tabs. When ALL tabs release it drop the part down and remove it.
---------------------------------------------
Relocation of Fuel tank breather & its hose
I really feel that this step is very beneficial to the Vog 260's cooling system.
The Problem-
To me, the fuel tank breather is located in the worst spot possible.
It forces the rubber spark guard sheet right up against the back of the cooling fan, not allowing the fan to pull much air at all through the radiator. When you cut the zip ties holding the rubber sheet in place and remove it you'll immediately see the problem, putting this filter in a spot that is super cramped. (see below)
To free the breather filter, and make room, you must cut the rubber ring off of it, in the above pic i had already cut the ring off, but you'll see it on your vog, its the major cause the rubber sheet was butted right against the back of the cooling fan, CUT IT OFF!, but BE CAREFUL that you don't cut off so much that you make a hole in the gasoline cap spill guard!!
Once you free the filter and its hose you'll see you have enough slack to relocate it to several different places.
This pic shows that slack.
Now, The FUN part! Deciding where to put it.
Here's where I put mine, which isn't the best way.
Mine's vertical and it may allow contaminants down into the fuel tank, So I'm going to be removing it and re-ziptying it horizontally.
Here's how mine looks as of now.
You can see in this pic how much better the fan can move air now that there's a reasonable amount of space between it and the rubber spark guard sheet!
You'll see it the 2 above pics that I used a belt to draw the rubber sheet a little further away from the radiator fan, If you use this method don't draw the belt, or whatever u use, too tight or it will tear the rubber sheet on the gas tank seam over time, tighten it up only tight enough to draw the rubber sheet back clear and out of the way, but not super tight.
----------------------------------------------
GOOD LUCK WITH YOUR PDI!, -WildBill84
Part 1: Gathering tools you’ll need
1 Phillips Screwdriver
Ratchet with 10mm socket
some pliers ( regular & needlenose if you have some)
Part 2: the disassembly
--------------------------------------
Edit 9/25/2009
I left out how to remove the "Y" shaped plastic panel that is between the headlights
The first screw is a phillips and is right under the nose of the scooter, after removing it, next remove the 2 more phillips screws, one from each side, pictured here the top red arrow points to where the two screws are (1 on each side)
After removing this piece look for a huge phillips screw near the bottom of the panel underneath the "Y" shaped panel you just removed . This is the only screw holding this Panel on.
Front Fairing (nose piece)
We’ll start by taking off the front fairing (nose piece) of the scooter.
Here’s is a pic showing which screws will need 2 be removed along the sides of the scooter.
In order to access the 2 screws at the bottom of the pic you'll need to remove the rubber footmat. It just pulls off, just start at the top and work your way down.
Go ahead and remove these same screws from the right side of the fairing while your at it.
When you're done with the side screws, we'll move on the the screws located behind the front wheel, on each side of the radiator.
The two RED arrows point to the 2 push tabs that will need to be pulled out or pushed from the inside, I was only able to reach the top one from reaching inside.
The GREEN arrow points to the last bolts holding the front fairing on, when you begin to unscrew these 2, make sure you or your helper is supporting the fairing from falling off and being scratched or damaged.
IMPORTANT- Remove the fairing slowly, because before you pull it all the way off the Lighting wire harness needs to be UNplugged, so you don't damage it.
---------------------------------------------
**SkidPlate/Under Belly
Next we'll start removing the underbelly of the scooter.
It is held in place entirely by push tabs,
here's a pic of them to get a better understanding of how they come apart.
The blue circles indicate where the push tabs are located.
As the push tabs are removed the bottom should start to fall down.
This tab is on the Right side of the underbelly of the Vog.
With the underside completely removed, we'll move on to the sides of the scooter.
---------------------------------------------
Panels underneath Floorboard area
With the front rubber floormats removed already we'll begin there.
This pic shows the screws nedded to be removed circled in blue.
The red arrows illustrate how the panel goes back on.
Now begin by removing the rear floorboard. Its longer than the front one but is held in the same way, so start in the front and work your way to the end.
Now you'll see something like this.
This shows how the front of the side panels look
---------------------------------------
Radiator guard
At this point the radiator guard isn't held on by much, Just 4 spots.
This pic shows the 2 tabs holding the guard on at the bottom.
And this pic shows the two tabs holding it up top on each side.
----------------------------------------
Removing - Radiator Fill Cover
I feel these pics explain themselves.
----------------------------------------
Speedometer, its wire harness & speedo cable
Its not necessary to remove the speedometer. If u don't you still MUST remove the speedometer cable from the back of the speedometer. And unplug the Speedometer's wire harness
----------------------------------------
Removing - Speedometer Housing Part
Now we'll remove the part that houses/housed the speedometer
This part isn't very hard to take off. Just 6 screws. 3 on each side, like ducks in a row! ;D
3 on the left (facing the scoot)
3 on the right (facing the scoot)
----------------------------------------
Engine Vent (piece under the front of the seat)
Another easy one!
After you take out these 3 screws the part should pull backwards and up.
----------------------------------------
Front Floorboard/Body Shield
Here we start by removing 4 screws with the RED arrows (2 on each side)
Then remove the two screws with the GREEN arrow (1 on each side)
If you didn't remove this screw earlier now would be a good time to.
-----------------------------------------
Floorboards (entire length) The home stretch!!!
We start with removing 8, 10mm bolts, 4 on each side, holding the floorboards down. This pic points them out.
Now remove 2 push tabs, 1 on each side, at the very back of the floorboards.
This pic shows their location
CAUTION- don't be rough with the next step, easy does it!!, Or you WILL break locking tabs, and the part won't go back on as flush as it come off. BE GENTLE on the locking tabs.
With all the bolts and push tabs removed the floorboard is ready to be removed! This picture shows the tabs holding this part in place, Now slide the floorboard FORWARDS to release it from the licking tabs. When ALL tabs release it drop the part down and remove it.
---------------------------------------------
Relocation of Fuel tank breather & its hose
I really feel that this step is very beneficial to the Vog 260's cooling system.
The Problem-
To me, the fuel tank breather is located in the worst spot possible.
It forces the rubber spark guard sheet right up against the back of the cooling fan, not allowing the fan to pull much air at all through the radiator. When you cut the zip ties holding the rubber sheet in place and remove it you'll immediately see the problem, putting this filter in a spot that is super cramped. (see below)
To free the breather filter, and make room, you must cut the rubber ring off of it, in the above pic i had already cut the ring off, but you'll see it on your vog, its the major cause the rubber sheet was butted right against the back of the cooling fan, CUT IT OFF!, but BE CAREFUL that you don't cut off so much that you make a hole in the gasoline cap spill guard!!
Once you free the filter and its hose you'll see you have enough slack to relocate it to several different places.
This pic shows that slack.
Now, The FUN part! Deciding where to put it.
Here's where I put mine, which isn't the best way.
Mine's vertical and it may allow contaminants down into the fuel tank, So I'm going to be removing it and re-ziptying it horizontally.
Here's how mine looks as of now.
You can see in this pic how much better the fan can move air now that there's a reasonable amount of space between it and the rubber spark guard sheet!
You'll see it the 2 above pics that I used a belt to draw the rubber sheet a little further away from the radiator fan, If you use this method don't draw the belt, or whatever u use, too tight or it will tear the rubber sheet on the gas tank seam over time, tighten it up only tight enough to draw the rubber sheet back clear and out of the way, but not super tight.
----------------------------------------------
GOOD LUCK WITH YOUR PDI!, -WildBill84