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Post by gy6rocket on Feb 25, 2009 18:20:01 GMT -5
Hey shook, The ID of the intake does not match exactly, there is a little bit of difference, but its actually bigger ID not smaller so performance should not be hurt. What I am planning is custom fabricating a solid 1 piece neck and flange that will mount the carb right where I want it. That way there is no worries of intake track fluctuations. That will be later on though after I get the bike back together. Will probably make a few of them since its cheaper that way, and I'm sure I could sell a few to defray the cost of manufacturing them. OK, so I bought a few more parts today, I'm working on the engine mount some more, on a axle locking mechanism. Basically once the engine is mounted I can torque down a couple "J" bolts and lock the hinge axle in place. Its still in the works but it seems feasible to add at this point for the $2 investment in hardware This way, even if the nut somehow rattled loose the bolt would still be held in place for safety purposes. Also picked up the sweetest find yet, a $5.99 briggs and stratton 5-8 HP muffler with a 1" OD, 3/4" ID inlet, which matches my header near perfect. It's not a straight through design so it should be even quieter than the KM racing, however I blew through it and it flows really well. I'm assuming it's going to sound like a lawnmower, which I suppose is not too bad since lawnmowers are generally bearable. I'm not expecting it to be QUIET, as I'm not seeking that, I am going to gamble that this new muffler is about the same noise level as the straight through KM style. The header is going to be modified and shortened a bit, I don't want the exhaust to interfere with the rear wheel removal at all. It should look pretty sweet once its welded up, them I'm considering wrapping the entire thing in header wrap, black color. Looking at this picture you can probably imagine the weight savings here, I would estimate about 20 lbs or so. Best part is the new exhaust will be so small and light only the 2 manifold bolts will be required to hold it in place. I'm aiming to have the dump exit right after the oil filler neck under the engine. No reason to have an exhaust suited for a 600cc sportbike for a 150cc engine.
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Post by stradarx150te on Feb 25, 2009 19:02:53 GMT -5
Will probably make a few of them since its cheaper that way, and I'm sure I could sell a few to defray the cost of manufacturing them
Sold i'll buy one for sure!!
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Post by shookupart on Feb 26, 2009 9:25:12 GMT -5
Im with ya' on that note strada...gotta have that exhaust too
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Post by owenbrau on Feb 26, 2009 11:13:49 GMT -5
I don't think you can ad air knowing its nitrogen filled thats why its adjustable so you can set it where you want? Maybe what I read meant adjusting it to increase the pressure, not actually add air. There's a knob between the bottom mounts, I assume it does something, but no idea what.
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Post by stradarx150te on Feb 26, 2009 15:06:32 GMT -5
That knob should be to adjust the pressure. i think there's a small spring inside the shock and moving the knob will move that spring up and down. Then you can also adjust the outside spring as well for ride height. At least thats how my shocks work.
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Post by owenbrau on Feb 26, 2009 17:25:50 GMT -5
Would it be turn it in (clockwise) to increase pressure/damping, and out (counterclockwise) to decrease?
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Post by stradarx150te on Feb 26, 2009 17:33:45 GMT -5
Yeah
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Post by gy6rocket on Mar 2, 2009 1:30:58 GMT -5
Well after a few idle days catching up on work and life, and forfeiting watching the simpsons, I got a few hours in on the bike. The new shock showed up Sat, pretty fast shipping from Hawaii. As soon as I opened it I saw something was off. The new shock is shorter than the old one. Here is a pic, keep in mind the new shock (black & orange) is adjusted to about as short as it goes. Still even with about 1" out as I set it, it was still way shorter. I was bumed until I realized my GY6 has 2 mounting holes for a shock, and using the closer hole, the shock fit perfect. Using the forward mount point also keep my planned geometry correct, an important factor when fabricating suspension. The engine mount also worked out great, The engine has no movement at all except straight up and down.. like it should be. The old mount allowed for play left and right, not much but enough I could feel it while riding, esp. at higher speeds. The two mount points, I chose #1, seems stronger with more material around it, and not "hanging" off the back. **Also the small "knob" on the bottom of the shock is an air hose fitting. The shock is pumped full of nitrogen, same stuff the local tire guys put into tires. So nitrogen can be added or vented to change dampening characteristics** Moving on, here is the completed tie bar to keep the frame from flexing: Another mod completed, shaved the big plastic fender away from my LED tail: Just some more of assembly and a proposed gas tank mounting location. Good shot of the engine mount in use. The mount works as good as expected, I added some large thick hose around the bolt that sits in the cradle on the bottom. This keep the majority of the weight on the rubber busing and not the aluminum. Now I need to polish the mount a bit, looks crusty next to the shiny engine
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Post by jrinlv315 on Mar 2, 2009 2:31:58 GMT -5
Looks awsome, keep the pics comin and thanks JR
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Post by owenbrau on Mar 2, 2009 11:52:55 GMT -5
Is the gearbox vent just stuck in the other shock mount hole?
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Post by gy6rocket on Mar 2, 2009 12:31:04 GMT -5
Yep. I have to say I like the short shock / new mounting better. The old setup put the shocks at a strange angle when compressed, and this new way seems to further tighten up the rear suspension. I've decided since I went this far to go ahead and get the NCY front forks too. My next 2 big items are the wire harness and the new handle bar mod. Once those are done I just have the tire mounting left and she'll be getting close to street legal. What do you guys think about the gas tank being mounted to the tie bar, motorcycle style? It would be so easy to plumb, like 1 foot of line to the carb, plus have gravity and forward motion pushing it into the carb.
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Post by kuzikood on Mar 2, 2009 13:30:13 GMT -5
i bought one of those mufflers a few days ago before reading this thread, and reversed it and welded it to the pipe ..... it only sounds like a lawnmower at idle....... few lawnmowers hit 5 or 6k rpms .... however it actually quite restrictive .well not compared to stock but still ....... however if you start small and enlarge as nescacary , you can drill the center baffle out and tune the mufflers back preassure and tone ..hence for 6 bucks you have a tunable muffler ..... now that is awesome and it doesent take up much space so you can actually hide it along the frame for that stealth look .... but .... the coating on it will burn off the first time you ride it so i would suggest burning the coating off with a torch in a well ventalated area......... then clean it scuff it and paint or polish it
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Post by stradarx150te on Mar 2, 2009 13:55:09 GMT -5
Yeah i forgot about the nitrogen scam that all the dealers and tire places are doing. I think there's like 98% of nitrogen in the air already. The dealers charge money to fill up your tires with free air. So yeah with the shock just go to a car dealer and fill it up. Or just use normal air its the same thing.
The scooter is looking sweet, I like the gas tank where it is. So next winter your going to be bored so you can do mine next LOL
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Post by gy6rocket on Mar 2, 2009 14:21:20 GMT -5
The atmosphere is a mixture of gases, it is composed of Nitrogen (78%), Oxygen (21%), and other gases (1%).
So the dealers are putting in 100% nitrogen, which actually does have some benefits, improvements in a vehicle's handling, fuel efficiency and tire life through better tire pressure retention, improved fuel economy and cooler running tire temperatures. I'm sure the pressure retention and cooler running temp benefit the shock also.
We'll see though, I have yet to ride report the new shock so time will tell.
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Post by stradarx150te on Mar 2, 2009 14:25:47 GMT -5
Yeah thats it 78%
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Post by gy6rocket on Mar 2, 2009 14:37:32 GMT -5
Oh No. ... .
Just found a killer deal on a flatslide. . .
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Post by gy6rocket on Mar 2, 2009 14:41:13 GMT -5
The scooter is looking sweet, I like the gas tank where it is. So next winter your going to be bored so you can do mine next LOL Hehe, well I have actually reserved next winter to do the engine. Big Bore stroker For now though the engine still has a lot of life left, I'll probably put about 3k more miles on her before I open it up.
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Post by Kaos on Mar 2, 2009 14:56:54 GMT -5
I plan to build a shop this summer and just go wild doing......whatever....after all...one could have worse habits.
Great thread!!!
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Post by kliff on Mar 2, 2009 15:07:58 GMT -5
Looooking Goooooood!
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Post by kink on Mar 2, 2009 20:00:32 GMT -5
aww, man... see this is why i haven't been checking the forums over the winter.
man i can't wait to get my scoot out of storage!
looking good so far. can't wait to see the finished product.
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Post by usfmarine on Mar 2, 2009 22:20:51 GMT -5
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Post by gy6rocket on Mar 3, 2009 17:18:24 GMT -5
Something long that line, I am somewhat partial to Mikuni carbs though. I had a TM24, wish I would have held on to it.
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Post by stradarx150te on Mar 3, 2009 17:34:19 GMT -5
Hey GY6ROCKET are you going to run with out the swing arm Also let me know how it rides with one shock i kinda like the look of that
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Post by stradarx150te on Mar 3, 2009 17:44:41 GMT -5
Oh yeah where are you going to put your registration sticker at now
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Post by gy6rocket on Mar 3, 2009 18:09:59 GMT -5
That is correct, no more right side swing arm. That part alone is like 20 lbs. The engine casting + the CVT cover bolted on, that swingarm is SOLID! Without the CVT cover I would have doubts, but with it in place, good to go.
I fabricated a small black triangular aluminum plate and put my sticker on that when I first got it, so I will fasten that part probably to the remaining rear plastic, there is still 2 holes there.
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Post by shookupart on Mar 4, 2009 18:13:31 GMT -5
good job rocket... I am not crazy about the gas tank position though. The motor looks soooo sweet all polished like that!!! Ive been busy makin' the new seat. Lots of trial and error and money. I do have a working solution now. just wanted to let you know I have not forgot about your project. lookin really good!!
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Post by stradarx150te on Mar 6, 2009 8:25:40 GMT -5
Hey gy6rocket If your looking for a flat slide carb there's a guy thats from Oxford Michigan, He is on ebay, NAME PARTSMAN888 But i talked to him and he told me its cheaper if i just go to there warehouse, and pick it up.
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Post by gy6rocket on Mar 6, 2009 22:30:10 GMT -5
Thanks for the heads up strada, I will go check out his warehouse, hopefully get myself a deal! SO the update for today is I tackled the wire harness. WHEW! I worked on it for about a total of 6 hours, went through the entire thing, took it completely apart. Removed a few circuits I'm not using anymore, like the horn and fuel level wiring. Cleaned everything up, added some quick disconnects, hid all wiring in the frame brackets. Rewrapped the harness in new sheathing I bought at Radio Shack. Overall it came out really nice, and best part was it all worked perfect when I was done! The turn signals blink like normal, however if I want to use the hazards I just flick L and R switch up and they both blink I left the starter circuit as-is, meaning the brake needs to be depressed before the start button will crank the engine. I'll take some more pics of the wiring and how it's concealed, for now here is a pic of the dashboard, took it with my phone. I labeled the switches as to what they do.
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Post by stradarx150te on Mar 7, 2009 8:29:01 GMT -5
heres the phone number 1-248-628-4638
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Post by jackthefuzz on Mar 7, 2009 12:49:11 GMT -5
Yeah i forgot about the nitrogen scam that all the dealers and tire places are doing. I think there's like 98% of nitrogen in the air already. The dealers charge money to fill up your tires with free air. So yeah with the shock just go to a car dealer and fill it up. Or just use normal air its the same thing. The scooter is looking sweet, I like the gas tank where it is. So next winter your going to be bored so you can do mine next LOL actually its not a scam. filling your tires with nitrogen means no variation in tire pressure between hot and cold, it also means all the molecules inside the tire are uniform in size and cannot escape the tire. I have been running only nitrogen in my vehicle tires ( not the scooter) for years. its really good insurance if you tend to drive fast. Nitrogen is also dry and wont absord water or moisture so corrosion is no longer an issue.
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