Post by JohnnyC on Sept 4, 2011 6:48:30 GMT -5
After buying and riding my 2010 Jonway YY250T for a while, I found myself needing to adjust the idle adjustment screw often. On this model, to adjust the idle one must open the seat, remove two screws, remove the battery cover, adjust the idle screw, replace the battery cover, put the two screws back in, then close the seat. That's simply too many things to adjust the idle... very annoying. Oh... it also requires that I carry two sets of keys and generally a small screwdriver in my pocket to do the adjustment.
So I decided a modification was in order... and here it is:
First I went to Home Depot. After searching around the store, I found the following items that I thought would do the trick.
1. Ryobi Flexible Shaft Bit Extension
2. Two Liberty Cabinet Door handles (only used one)
3. DeWalt #2 Phillips head bit.
4. Two Milford Hangers (the copper hanger thingies... only used one)
5. Door weather stripping (had some extra around the house)
6. Some 1cm thick semi-hard foam (not shown)
Here's a close up of the Ryobi Flexible Shaft:
I didn't take pictures of the entire process... but here is how I ended up installing it on the inside:
This is a picture of the knob on the outside of the bike before I painted it.
This is a picture of the knob after I painted it (notice the locking screw on the top side of the knob):
And here is what it looks like from a wider shot (blends in pretty nicely):
From the idle screw outward it goes like this:
1. The DeWalt Bit
2. The Flexible Shaft
3. A bent up portion of one Milford Hanger with foam attached screwed into the top of the air intake roundabout (figured it wouldn't hurt it too much to have a couple screws going down into it.
4. A little chunk of the hard foam with a hole drilled in it.
5. The hole where the end of the shaft sticks out.
6. A wooden knob with a screw in the side to hold it on more securely.
The metal portion of the shaft does not turn, only the inside. The tension on the shaft between the hole and the screw keeps the bit firmly in place on the screw. The hard foam gives a little bit of a buffer between the end of the shaft and the body panel. The bracket keeps the shaft up and away from the throttle cable and keeps it from moving around too much. The foam around the shaft stabilizes it but allows it to move a bit (since the engine will move somewhat independently from the body panel it needs some 'give').
I had bought two knobs as I mentioned earlier but only used one. A small round wooden knob. I drilled the hole in the back of the knob out to slightly smaller than the phillips bit size. Then I lightly hammered another bit down into the hole and pulled it back out to create the hex shape for the end of the shaft. I drilled a tiny hole in the side for a short/small screw to be inserted. Then all I had to do was put it on the end of the shaft sticking out and tighten the locking screw to secure it in place.
The knob turns the shaft, the shaft turns the bit, the bit turns the screw. Now all I have to do to adjust the idle is reach down and turn the knob. Unfortunately I had to install it so the knob is on the right side. Due to the length of the shaft assembly, there just wasn't a good way to make it go to the left side of the bike. So to adjust I do have to let go of the throttle if I'm sitting on the bike since my left hand won't really be able to reach it. Not too big a deal. All in all I'm very happy with the way it turned out.
I haven't had a chance to take it out and ride since the modification, so I'm not 100% sure it'll hold all in place how I have it set up, but it should. I will let you guys know if I run into any problems with it. As it stands... it easily turns the idle adjustment screw without any problems.
Hope this helps out... It cost me $20 for parts to cobble it together and I bought too many hangers and an extra knob). Final cost is probably about $17 without the extra parts.
This same technique could be applied to other scooters as well, but would need tailor made for the scooter.
So I decided a modification was in order... and here it is:
First I went to Home Depot. After searching around the store, I found the following items that I thought would do the trick.
1. Ryobi Flexible Shaft Bit Extension
2. Two Liberty Cabinet Door handles (only used one)
3. DeWalt #2 Phillips head bit.
4. Two Milford Hangers (the copper hanger thingies... only used one)
5. Door weather stripping (had some extra around the house)
6. Some 1cm thick semi-hard foam (not shown)
Here's a close up of the Ryobi Flexible Shaft:
I didn't take pictures of the entire process... but here is how I ended up installing it on the inside:
This is a picture of the knob on the outside of the bike before I painted it.
This is a picture of the knob after I painted it (notice the locking screw on the top side of the knob):
And here is what it looks like from a wider shot (blends in pretty nicely):
From the idle screw outward it goes like this:
1. The DeWalt Bit
2. The Flexible Shaft
3. A bent up portion of one Milford Hanger with foam attached screwed into the top of the air intake roundabout (figured it wouldn't hurt it too much to have a couple screws going down into it.
4. A little chunk of the hard foam with a hole drilled in it.
5. The hole where the end of the shaft sticks out.
6. A wooden knob with a screw in the side to hold it on more securely.
The metal portion of the shaft does not turn, only the inside. The tension on the shaft between the hole and the screw keeps the bit firmly in place on the screw. The hard foam gives a little bit of a buffer between the end of the shaft and the body panel. The bracket keeps the shaft up and away from the throttle cable and keeps it from moving around too much. The foam around the shaft stabilizes it but allows it to move a bit (since the engine will move somewhat independently from the body panel it needs some 'give').
I had bought two knobs as I mentioned earlier but only used one. A small round wooden knob. I drilled the hole in the back of the knob out to slightly smaller than the phillips bit size. Then I lightly hammered another bit down into the hole and pulled it back out to create the hex shape for the end of the shaft. I drilled a tiny hole in the side for a short/small screw to be inserted. Then all I had to do was put it on the end of the shaft sticking out and tighten the locking screw to secure it in place.
The knob turns the shaft, the shaft turns the bit, the bit turns the screw. Now all I have to do to adjust the idle is reach down and turn the knob. Unfortunately I had to install it so the knob is on the right side. Due to the length of the shaft assembly, there just wasn't a good way to make it go to the left side of the bike. So to adjust I do have to let go of the throttle if I'm sitting on the bike since my left hand won't really be able to reach it. Not too big a deal. All in all I'm very happy with the way it turned out.
I haven't had a chance to take it out and ride since the modification, so I'm not 100% sure it'll hold all in place how I have it set up, but it should. I will let you guys know if I run into any problems with it. As it stands... it easily turns the idle adjustment screw without any problems.
Hope this helps out... It cost me $20 for parts to cobble it together and I bought too many hangers and an extra knob). Final cost is probably about $17 without the extra parts.
This same technique could be applied to other scooters as well, but would need tailor made for the scooter.
