My PDI - Tank 250DE VOG XY260T-4

[Ixty]

Hi All.

Based on the wonderful write ups regarding a proper PDI and how to remove the body parts for the Tank 250DE / VOG XY260T-4, I thought I would share a few thoughts and observations.

Background - Purchased from Evo Sales in September 2009 for $1899 on sale. Purchasing online was fast and easy. Used a credit card for the purchase. My Tank 250DE arrived drop-shipped from Evo Sales a week later. Came via Old Dominion Freight lines in a shipping truck (not a semi) so it fit in my driveway.

After uncrating, noticed a broken passenger armrest (it is a connecting point for the crate cables). everything was attached (including front wheel) except for windscreen mirrors and battery (they were under seat). General nicks and such on the paint, but I am not too worried about superficials.

Certificate of origin was under the seat along with a small tool kit. The Certificate of origin was very handy so that I could send the VIN to Evo Sales to get the MCO and Bill of Sale from them - the VIN plate on the body is nearly illegible. MCO arrived in two days via snail mail.

Getting the bike a title at the DMV was a breeze (in Oregon). Did not need to have the bike there to look at VIN. YMMV.

[Ixty]

First step: Body panel removal

There are some great posts about body panel removal on the dawg forums, so I will let you go find those yourself if you want. The main thing is be careful about what you remove and make sure all the screws are out. I also screwed the screws back in to their respective locations / anchors so that I could reassemble without confusing myself later. It took about six hours and a six-pack of tall boys to undress the bike.

Now some walk though guides go back to front, some front to back. It really doesn't matter.

Here's a nekkid Tank 250DE:




A garage full of body parts:

[allworld]

Hello Ixty:
Congratulations on your new ride, doing a complete PDI will eliminate 90% or more of any potential problems, and make for a better and safer ridding experience.
This scooter under the hood looks very much like one I helped work on with a friend of mine. The big difference this one looks like it has been thought out a little more.
Radiator in front of gas tank. Also on his the frame support in the rear was bolted in place so which had to be unfastened in order to remove the under-seat tub.
Good luck with your PDI

[Ixty]

Hi Allworld,

Thanks man, there is no way I could ride this bike by just throwing gas in it and going. A PDI has to be mandatory for any drop-shipped bike in my book.

Here's from the TANK warranty registration page:

"IMPORTANT NOTE TO DEALERS AND CONSUMERS:
During assembly you must drain all shipping fluids and replace them with a quality US branded fluids. This includes engine oil, gear oil and coolant. Screws, nuts and bolts should be checked before each ride. It is advisable to use a product such as “Loctite” on screws that tend to back out."


I have a lot more to post to this thread, I hope you enjoy the pics and information to come.

[christoforous]

Great show and tell. i never saw a vog unveiled like that, interestiing. I did notice the front forks appear to be large unlike some of the other 250cc class scoots

[Ixty]

Here's my list of items that need work:

If anyone has any suggestions in addition to what is below, please PM it to me and you'll get the credit- thanks!

Completed items are strikethrough

[/size][/b]
[li]Reconnect coolant line retaining strap
[/li][li]Replace missing coolant line retaining strap Tie-wrapped it!

[/li][li]Realign misaligned seat tub/top
[/li][li]Realign misaligned front body panel
[/li][li]Replace missing fuel filter line clamp
[/li][li]Realign misaligned fuel filter line clamp

[/li][li]Replace split rebreather hose cut off the tip and put back on

[/li][li]Repair bent brake line holder on fork

[/li][li]Realign misaligned front brake line holder on front body

[/li][li]Investigate possible broken intake manifold further It appears that they all come this way. Bobby at Evo Sales looked at their floor models and they all have this. Makes sense because of the clearance over the top of the allen bolt but still suspicious...

[/li][li]Connect disconnected coolant radiator cap retaining chain

[/li][li]Tighten loose bar end weights
[/li][li]Investigate fuel tank mounting bracket twisted out of way It doesn't appear to be used.
[/li][li]Replace passenger backrest seat latch mounting allen bolts
[*]Tighten loose rear clip (body) bolts at passenger backrest
[/li][li]Inspect CVT


Bigger Stuff:
[/li][li]Replace all fuel lines - 1/8" ID
[/li][li]Replace all coolant lines (Props to electric57)
[/li][li]Replace fuel filter Ha! there were two of them! I only reinstalled the one between the fuel pump and the carb, and ditched the other one. Is the other one there to filter the fuel before it gets to the fuel pump and possibly protect it? Seems silly to me.
[/li][li]Replace all vacuum lines - 3/32" ID
[/li][li]Replace all hose clips with band clamps I did it on fuel lines and main vacuum lines
[/li][li]Replace 4-way vacuum connector with brass or SS one Couldn't find one
[/li][li]Replace spark plug with iridium plug
[/li][li]Replace engine oil - Shell Rotella T 15-40 for Diesel The oil from the factory is really scary and toxic
[/li][li]Replace gear oil - Synthetic 70W140 Done, but may switch to 80/90 in the future..
[/li][li]Replace coolant - Zerex G-05
[/li][li]Check air filter Air intake hose not connected to bottom of air filter box. Is this how they keep you buying new motors?
[/li][li]Move fuel breather and rubber shield away from radiator cooling fan When the fan does kick in, it really draws a lot of heat out of the radiator. With the rubber moved back I can see how the original design could really hamper the effectiveness of the fan.
[/li][li]Replace tire valve stems Finally done!
[/li][li]Inspect/pack fork headset bearings
[/li][li]Inspect/pack wheel bearings
[/li][li]Replace and lubricate broken throttle cable - Received the warranty replacement part from Evo Sales in about 2 weeks. It is slightly different, but could work, we will see...
[/li][li]Adjust valves
[/li][li]Install electric fuel pump
[/li][li]Adjust carb/idle
[/li][li]Lube speedo cable
[/li][li]Replace headlight bulbs
[/li][li]Treat fuel tank with Seafoam Fuel tank was clean inside, but i did inspect first in case I had to vacuum. Interesting note: The fuel gauge does not read in a "Linear" fashion, it slowly goes up and then "jumps" up at the end. Therefore, 1/2 way down on the fuel gauge does not mean you have ridden 1/2 way through the ride!
[*]Remove/reassemble exhaust manifold/pipe hardware
[/li][li]Deal with frame rust
[/li][li]Diagnose and repair mono shock adjustment knob/cylinder Was turned all the way to "hard" twisted it back and it came loose.
[/li][li]Reinstall all sheet screws with "fixed" clips and silicone
[/li][li]Remove and reinstall all bolts/nuts with blue Loctite. Make sure you shake the bottle often.
[/li][li]Use a silver paint pen on all secured bolts and screws for reference My own special touch. Call it the "Ixty"! Couldn't do this without it. There are hundreds of screws and bolts! How else do you know which ones you tightened and put Loctite on after you've had a few?
[/li][li]Bypass stand kill switch Not going to do this as it is a safety feature - you could be thrown from the bike during a left hand turn if the kickstand is accidentally left down. (credit to Allworld)
[/li][li]Silicone all wiring harness connectors - cap unused and silicone
[/li][li]Silicone spray motor bay and rubber
[/li][li]Clean brake rotor surface with brake cleaner
[/li][li]Change brake fluid
[/li][li]Reroute overflow tubes as needed


Fun Stuff!
[/li][li]Install brake light modulator
[/li][li]Install front light modulator
[/li][li]install float charger
[/li][li]Upgrade horn
[/li][li]Install 12VDC convenience outlets/lights
[/li][li]Install blinker piezo
[/li][li]Put together tool kit
[/li][li]Install Mixedspecies
[/li][li]Wash and wax
[/li][li]Name her! I think she likes to be called "Melinda"
[/li][/ul]

[allworld]

Well you are doing a bang up job, and will most likely have prevented many hours or down time, not to mention the safety factor. I would caution about disconnecting the kill switch on the side stand, but that is your decision.

[Ixty]

Oct 1, 2009 15:32:31 GMT -5 allworld said:

Well you are doing a bang up job, and will most likely have prevented many hours or down time, not to mention the safety factor. I would caution about disconnecting the kill switch on the side stand, but that is your decision.

Thanks and good point as always Allworld

I learned tonight in the motorcycle safety course that if a kickstand is accidentally left down a left turn could potentially be dangerous. I will heed the advice and leave it connected.

[leo]

the best things ive done to my scoot was to replace the radiator with a larger one, replace the valve stems, and replace the the stock plug with an iridium plug.

i just got through with repacking the wheel bearings after about 4000 miles.
the steering head bearings are still tight and full of grease.
other than than the above i've replaced the roller weights and intake.

the only plastic i've had to remove was the tail light lens to replace a bulb and the front cowl to add coolant to the radiator.
why anyone would want to take all the panels off their scoot is a mystery to me.

BTW, can anyone tell me where to get a band clamp for a 3/8" vacuum hose?

[gmoney]

Great job on the PDI, I'm sure you will enjoy many miles on your new ride. Congradulations to ya!

Gary

[Ixty]

Oct 1, 2009 18:00:56 GMT -5 @leo said:

the best things ive done to my scoot was to replace the radiator with a larger one, replace the valve stems, and replace the the stock plug with an iridium plug.

i just got through with repacking the wheel bearings after about 4000 miles.
the steering head bearings are still tight and full of grease.
other than than the above i've replaced the roller weights and intake.

the only plastic i've had to remove was the tail light lens to replace a bulb and the front cowl to add coolant to the radiator.
why anyone would want to take all the panels off their scoot is a mystery to me.

BTW, can anyone tell me where to get a band clamp for a 3/8" vacuum hose?

Ooh - thanks for the plug replacement reminder! ;D

My decision to remove all of the panels is because:

(1) The price point and reputation of the bike. As you can see, I have plenty to fix that is not in a normal PDI. I would have never have seen the other issues without stripping it. If I spent 6k at a Suzuki dealer I wouldn't even be writing this.

(2) Getting to know my bike. This bike is the only thing between me and the pavement at highway speed and we are going to get to know and trust each other REAL well.

(3) Securing the body screws. I needed to remove the screws, crimp the speed nut/plates, silicone and replace the screws anyhow. It keeps a vibrating machine together.

[Ixty]

Thanks mathclub and Gary!

mathclub: Are you hot for my girlfriend? Oh wait, she is nekkid. Enjoy

Gary: Thanks! Wait until I post more pics and all the fun stuff here, it should be interesting!

-Brent

[chaz12]

Ixty, can you help my friend on scootdawg. He owns a xy260-4 scooter and is having difficulty. I think you are the pro at this. I own a Bali 250, but I can't help him with his problems. Scoots are sort of different. Thank.. He is writing for help all over scootdawg forum( 250cc scoots).

[Righteous Brother]

Ixty, I am starting to think you have waaayyy too much time on your hands. Slap that thing together and get to scootin'.

RB

[Ixty]

Thanks Chaz, I checked his post and it sounds like he is doing ok now!

Hey Rightous Bro! Wow this PDI is taking a looong time! Last weekend was spent taking my motorcycle safety course, and I have been working all week nights on the scoot! I want to be back together for a ride this weekend!

["Big Guy"]

Oct 7, 2009 22:50:35 GMT -5 Righteous Brother said:

Ixty, I am starting to think you have waaayyy too much time on your hands. Slap that thing together and get to scootin'.

What... are you kidding? A proper PDI is absolutely mandatory on crate scooters!

Carry on Ixty... you will be one of the few here NOT crying for help stranded on the road....


-Rich

[Ixty]

Don't forget I have a ton of pics of the "before" (closeups of what the insides of my bike looks like off the truck) You will see these after I am done.

If you buy a bike from the internet and not from a local dealer you are on your own. If you can buy it local that is great! I went the crate/internet version...

UPDATE:

With all of the fuel / vacuum lines replaced (and the fuel filter, and adding Seafoam) replaced, and I replaced all of the oil, gear oil, and antifreeze, my bike fueled up on it's own and fired up GREAT!

I did not have to prime the carb or anything, I could see the filter getting the fuel easily from the pump, and it wants to ride.


-Ixty

[Blayne Mathieu]

Keep at it Ixty! The "non-riding" time you are putting in now will be saved 10-fold in downtime later on!

Super job!

And, yes, it does look sexy naked...

-Blayne

[JR]

Oct 8, 2009 19:58:12 GMT -5 "Big Guy" said:

Oct 7, 2009 22:50:35 GMT -5 Righteous Brother said:

Ixty, I am starting to think you have waaayyy too much time on your hands. Slap that thing together and get to scootin'.

What... are you kidding? A proper PDI is absolutely mandatory on crate scooters!

Carry on Ixty... you will be one of the few here NOT crying for help stranded on the road....




-Rich

Gonna have to get on the band wagon with BIG GUY here!! Oh the joy of riding and not being on the side of the road to a loose dang wire!! JRR

[anhoa]

This is what happen when you don't do PDI.

www.topix.com/forum/motorcycles/scooters/TGN2OVN3E4MVRTC42

Anhoa
71xx miles and counting...diapers.

[electric57]

I found the radiator hoses to be OK when visually checking them on my xy260t-4, during the PDI, but after a year of riding with premium anti-freeze, that I installed during the PDI, I found the inside of the radiator and the water pump was covered with a black gunk that had to have come off of the inside of the hoses and had nearly gummed up everything. You should replace all of the hoses on the cooling system.

[Ixty]

Oct 14, 2009 16:42:30 GMT -5 electric57 said:

I found the radiator hoses to be OK when visually checking them on my xy260t-4, during the PDI, but after a year of riding with premium anti-freeze, that I installed during the PDI, I found the inside of the radiator and the water pump was covered with a black gunk that had to have come off of the inside of the hoses and had nearly gummed up everything. You should replace all of the hoses on the cooling system.

Great advice electric57, duly noted and will include in my winter teardown/rebuild. I am saving the un-done items above for the cold cold winter months.

Otherwise, she has 120 miles on her so far - just took her out for a spin in the rain to practice my wet-weather stopping...

[Ixty]

650 Miles! Finally got to the tire valve stem replacement.

[xy260t4]

IXTY "Would luv to see some of the pics of the bike(modication u put on )etc.
Aslo what's the size of our radiator hose? and where did u get it????what's the size of the fuel line? thanks

[Ixty]

Thanks XY, I haven't taken any pics recently - I don't know the size of the radiator and fuel / vacuum line hoses, best bet is to take them off and take them to the auto parts store for sizing. Good Luck!

[carlosbm94]

i need scoteers parts

[carlosbm94]

I need to buy parts for my scotter,bms 260 call me at 559 2754845.

[Ixty]

Hi Carlos, try out tank-sports.com, evosales.com, pacificscootersonline.com!

Thanks,

Brent

[Ixty]

Time to revive this one so I can finish up my valve adjustments etc.

[trailheadmike]

Ixty - I just finished my Vog pdi. what i found was that the things that look like fuel filters aren't fuel filters at all, but "check valves" to keep gas from backing up. In fact, mine had only check valves and no filter. I put a good filter between the tank and the fuel pump.

Do you know what the 3" plastic cylinder on the back, right side of the scooter (attached to the outside of the frame) is for? This does look like it has a filter part in it, but I can't figure out what it would be filtering. Thanks in advance.