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Post by lshigham on Oct 17, 2010 11:53:37 GMT -5
The 22mm hole I drilled. Attachments:
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Post by lshigham on Oct 17, 2010 11:54:46 GMT -5
Where the snorkel used to be. Attachments:
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Post by lshigham on Oct 17, 2010 12:04:24 GMT -5
I forgot to photograph it, but I also made some big holes in the partition between the back of the box and the filter, which is attached to the front that also holds the filter in. There was originally just two small holes, 8 and 6mm in diameter. I removed as much material as I could get away with, the resultant gap is now about 5cm2. I upjetted from a 78 to 82 and went for a test run, not good. It would bog over 3/4 throttle. I had to go up to a 95 to eliminate that and a 100 to get it to my liking. That's one restrictive airbox The rather bad pic shows the completely white plug after a 82 run. On the upside, it makes a lovely deep sound and I've gained 800 RPM, from 9600 to 10400. Attachments:
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Post by 90GTVert on Oct 18, 2010 10:03:35 GMT -5
Nice work.
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Post by lshigham on Oct 18, 2010 16:22:00 GMT -5
Thanks. I told a lie about the jetting, still as lean as they come with a 100 main! 110, here I come...
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Post by lshigham on Oct 18, 2010 16:22:46 GMT -5
Oh, and the exhaust should be with me Tuesday (tomorrow).
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Post by 90GTVert on Oct 18, 2010 18:46:24 GMT -5
You might get to go bigger still when the pipe is installed.
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Post by lshigham on Oct 19, 2010 1:29:05 GMT -5
You might get to go bigger still when the pipe is installed. Don't say that! - I ran out of jets at 85 I've a set of HSS drill bits that go up in increments of 0.05mm, but only up to 1mm, after that it's in 0.1mm.
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Post by lshigham on Oct 22, 2010 3:24:37 GMT -5
Crap, I've melted my piston .
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Post by lshigham on Oct 22, 2010 3:30:04 GMT -5
The spark plug indicates that it was in fact running rich at the time of death. I'm thinking possibly an oil injector problem.
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Post by 90GTVert on Oct 22, 2010 8:18:34 GMT -5
Ouch. Might wanna check your squish clearance to see if that's really tight. When you pull it apart, the piston might give you more clues.
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Post by lshigham on Oct 22, 2010 10:42:10 GMT -5
Ouch. Might wanna check your squish clearance to see if that's really tight. When you pull it apart, the piston might give you more clues. It was the complete lack of carbon on the head and piston that gave it away. I knew something was up when I noticed that it was only using about 1/2 as much oil as I would have expected, I should have investigated at the time. It looks a lot like your melted piston, but with a smaller hole right on the ring guide. Lesson learned, it's premix time I've removed the oil pump and associated gubbins and will run 33:1 in future. The damage done was to the piston and barrel, the crank is fine. I'm replacing the small end bearing for a Polini one, just in case. Parts ordered, for delivery tomorrow: www.adrenalin-pedstop.co.uk/p/Doppler_S7R_cylinder_kit_for_Piaggio_engines_%E2%80%93_Runner_NRG_etc-3441.aspxwww.adrenalin-pedstop.co.uk/p-Polini_small_end_bearing_12mm_pin-3565.aspxI've got everything stripped down and ready for installation tomorrow, I think it'll take about 1hr to complete. The differences between the Doppler cylinder I am about to fit and the PM Tuning one I killed are: - the Doppler has a stepped combustion chamber
- the squish can be set on the Doppler with the supplied gaskets
- the Doppler has a larger, bridged exhaust port
- it's £20 cheaper, but is usually sold for £60 more
- apparently it's better than the Stage6, which is comparable to the one I killed
I'll post a pic of the old cylinder and piston.
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Post by lshigham on Oct 24, 2010 10:23:14 GMT -5
Well, I've got it all installed. The problem now is overheating, it's getting into the red just idling. I flushed the coolant through using a hosepipe, but it's still doing it. I cant help but think that this may have been the cause of the engine failure on Friday. I've verified that it is indeed the pump, which leaves the question of how to fix it. I'm tempted to buy a 12v pump like this: www.mackengineering.co.uk/products/GP1392-WHALE-12V-IN%252dLINE-PREMIUM-PUMP-13.2LPM.html and leave everything else as it is. There are water pump repair kits available, but I don't have a flywheel puller so can't see what the problem is without purchasing one, probably to find that it's something not fixable with the kit contents.
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Post by 90GTVert on Oct 24, 2010 13:38:14 GMT -5
Beyond a sport kit, pretty much everyone says ditch the oil injection.
A flywheel puller is money well spent IMO. Dunno what to tell you on the pump. I've never had the pleasure of messing with an LC scoot.
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Post by lshigham on Oct 24, 2010 13:49:54 GMT -5
Beyond a sport kit, pretty much everyone says ditch the oil injection. A flywheel puller is money well spent IMO. Dunno what to tell you on the pump. I've never had the pleasure of messing with an LC scoot. I may put in an adjustable oil pump that can do 33:1. I've settled on a flywheel puller, pump repair kit and a few other goodies like some 100ml measuring cylinders with caps (premix purposes). Not realising that I had a malfunctioning pump I went for a spin and very nearly killed the new kit - minor scuffing around the exhaust bridge is present, but nothing serious. I will replace the cylinder and barrel once everything is set up, for reliabilities sake. The flywheel puller and pump repair kit (shaft, impeller, bearings and gaskets) were $20.
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Post by lshigham on Oct 25, 2010 9:43:50 GMT -5
I've found my problem - the drive belt for the oil pump had fallen off. What I didn't realise was that it also powers the water pump on the other side. Lesson learned. I also discovered the reason for the unusually high jetting, a pretty hefty exhaust leak. I need to down jet a lot now, even an 80 was too high. On order, for delivery tomorrow is: - New Doppler cylinder kit
- Two jet packs, covering 50-98 in divisions of 2
- Flywheel puller and variator locker (for future use)
- A new temp sensor, I snapped the top off mine. Oops
- Two 100ml cylinders with caps, for 2T oil
Hopefully I can get the bloody thing working properly sometime soon.
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Post by 90GTVert on Oct 25, 2010 10:27:49 GMT -5
Very nice. Just make sure you see investigate anything out of the ordinary that could cause the belt to pop off. The expansion chamber pipe might wake up even more without a leak! ;D
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Post by lshigham on Oct 25, 2010 11:18:22 GMT -5
Very nice. Just make sure you see investigate anything out of the ordinary that could cause the belt to pop off. The expansion chamber pipe might wake up even more without a leak! ;D I would assume so, but it was pretty scary with a buggered up exhaust, dying cylinder and dodgy jetting! I've looked, and everything seemed normal. I took it for a test ride (if you can call spluttering down the road at 30 mph a test ride!) and returned with a fouled plug and a belt still attached. For all I know the cylinder could have seized because of dirt/dodgy jetting and the resultant force (I was doing 55 at the time) knocked the belt off.
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Post by lshigham on Oct 25, 2010 13:37:54 GMT -5
The correct jetting seems to be in the 90 range. 100 and 110 are too rich and both 70 and 80 are too lean.
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Post by lshigham on Oct 26, 2010 9:28:50 GMT -5
Found why the jetting is so off - I've bugger all compression. I expect when I get the cylinder off to replace tomorrow I will find a distinct lack of NiCaSil plating.
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Post by lshigham on Oct 27, 2010 1:21:58 GMT -5
Today's jobs, assuming everything arrives on time are to: - Install new cylinder, piston and head
- Replace the water with antifreeze
- Stronger clutch springs, to move the take off point up to about 6000RPM. At the moment it bogs in the low range because the load is too high
- Rejet for a cylinder with something vaguely resembling compression (hopefully!)
- Try not to remove any more skin from the back of my hand
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Post by 90GTVert on Oct 27, 2010 7:26:51 GMT -5
Good luck with all of your objectives. ;D
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Post by lshigham on Oct 27, 2010 12:10:46 GMT -5
Well, I managed everything. Even keeping my skin!
All is working well with a 105 main. I took it for a test ride, I'm still not happy with the top RPM of 9400, I was hoping for something closer to 10500. I'm going to drop the roller weight from 6.3g to 5.3 and see where that takes me.
The cylinder was quite badly scarred with two lines across the cylinder, probably causing the problems at low revs.
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Post by lshigham on Oct 28, 2010 10:17:53 GMT -5
Aaah, that's better. Revs now at 11000 and a top speed in excess of 65 (I'm taking it easy for now, don't want to seize it again).
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Post by 90GTVert on Oct 28, 2010 12:00:41 GMT -5
Sweet. ;D Just make sure you keep an eye on the temp and tune and make sure it's still getting oil till you know you can trust that belt driving the pumps.
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Post by lshigham on Oct 28, 2010 16:32:03 GMT -5
Sweet. ;D Just make sure you keep an eye on the temp and tune and make sure it's still getting oil till you know you can trust that belt driving the pumps. I've found the problem with the pump, the sprocket that is driven by the belt is able to slide forward so a made up a steel bracket to hold it in place. I never did re-install the oil injection, I'm going to leave it off and run 40:1 premix. I took it for a 70 mile round trip at 50-60MPH, everything seems to be working fine. I love riding (when it all works ). Hit 68MPH on a slight uphill stretch whilst overtaking. It was a 60 zone, so ;D I'm still having some take off problems (the cylinder is designed to be revved at 12000 RPM, so sacrifices some bottom end power). I'm going to go a 1/2 gram lighter rollers and install the stronger clutch springs, which should hopefully rectify that. I'm also considering putting in a 21mm carb instead of the stock 17.5, what sizes do you use, Brent? Thanks ;D
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Post by 90GTVert on Oct 29, 2010 10:18:07 GMT -5
68 on an incline. Ridiculous. lol ;D
I'd definitely think a 21mm would be a good upgrage at those revs. I use stock carbs a lot on my 70s, but they are all sport stuff and don't rev like this. 2strokd has been messing with a big 18mm carb on his 12,000+RPM 70cc, but I don't think he's ever got good enough results to warrant using it vs the 21mm Dello he was using for the street. Gas mileage usually drops off with those big carbs. I know with a 25mm on one of my bigger minarellis I was getting 40MPG.
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Post by lshigham on Oct 29, 2010 10:23:04 GMT -5
Malossi air filter and Dellorto PHBG 21mm carb ordered, thanks for the advice 40 MPG! I'm getting 60 plus with my scoot!
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Post by lshigham on Oct 30, 2010 7:24:39 GMT -5
Malossi filter arrived today, it's threaded like the PHBG, so I can't use it yet. I removed the intake manifold and reed block to check the reeds, unfortunately I forgot to block the hole and dropped a screw down there. I panicked, thinking I'd have to remove crank to get it out. Fortunately, a strong magnet, copper brazing rod and some duct tape saved the day
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Post by 90GTVert on Oct 30, 2010 11:28:48 GMT -5
The "tink tink" of a screw falling into the crankcase and the feeling you get afterward usually serves as a good reminder to stuff a rag in there on future endeavors. lol
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