Post by phssthpok on Aug 10, 2014 20:11:29 GMT -5
So I decided to do something about the random loss of spark, and replace the stator/pick-up unit (not realizing at the time that it is possible to buy just the pick-up). And, of course, since I can never seem to do anything the simple way I decided "What the heck.. let's upgrade to an 11 pole stator! And since I'm tearing stuff apart, I'll get a 115mm variator, some 12 gram sliders, and a new gasket for that danged leaking header-flange!"
Ordered everything I needed, including the 7 pin regulator and the 'special tool' for pulling the flywheel. Since I'm working nigh 60 hours a week, I had to wait for Sunday to have the time to work on the scoot, but today was the day! Sunny. Warm (almost hot, but not quite). Light Breeze.
Perfection.
Get the scoot rolled into position for working on. Get the parts-n-tools all laid out on my wrenching table. Pull up all the bookmarked wiring diagrams and helpful how-to's I had found...aaaaaaand promptly discovered that my scoot's wires only matched about 40% of the colors called out in the diagrams.
After several hours of multi-metering things, and cross referencing information sources, I finally have a wiring arrangement that I'm confident will, if not work, at least NOT fry anything. Part of my issue was that I was bound and determined to do this project without cutting anything on the factory harness. I achieved my goal (I think).
Since I got the hard part done I was pretty amped up to get the 'easy' part done.. pull the flywheel, replace the stator, plug in the rest of the wires, button it up and (hopefully) go for a test ride.
Yeah...not so fast, buck-o. first you need to dig out the compressor for the impact wrench, then you need to find the accessory kit you bought with all the quick couplers so you can attach the new hose to the tank and to the impact.
<sigh>
Get that all done, zip the nut off the flywheel, and commence to threading on the 'tool' to pull it. <Spin...spin..spin>... Da-faq? <Jiggle-spin...jiggle-spin...> "Why wont this thing thread in? I'm turning counter clockwise like I'm supposed to."
<try the 'small' side> Nope.. too small.. I need the fat side. <Examine the threads to make sure it's not a buggered thread preventing engagement> Looks fine. <mindlessly run a fingernail through the groove to make sure the threads are clean> DA-FAQ?? "There's no taper on these threads!"
Message sent to merchant who sent the parts, but I doubt I'll hear back before tomorrow, since today is Sunday and IIRC they are closed today. So I put the scoot more-or-less back together (mainly to keep from losing anything) and decided to move on to replacing that danged header flange gasket since I was already flat dirty.
Aaaaand now it looks like I'm going to be replacing the head. I stripped out one of the header studs!
(I WASN'T EVEN PUTTING THAT MUCH EFFORT INTO TURNING THE NUT!! 
).
I know that I could always helicoil it, but to be honest..a helicoil kit would probably cost about as much as a new head, and I'd still have to R-n-R the head in order to work on it. I can drill and re-tap the old head for larger studs at work (once things slow down a bit) and have a spare on-hand. Heck I may even take it to a weld-shop and have them fill the stripped hole with aluminum, and just re-tap it for the stock stud.
Regardless... the fastest fix will be a new head. Ordering it tonight it should arrive about the same time as the replacement flywheel tool. With any luck I'll actually be able to finish this project NEXT Sunday.
Of course this now has me thinking even harder about the exhaust modifications I wanted to do (making a new header pipe that's a true 1" diameter). I have to remove the muffler for the head work anyway, and it wouldn't be hard to cut the stock pipe off the flange and weld on a larger diameter pipe. I am a welder after all..
Le Sigh....
Nothing's ever simple...
Ordered everything I needed, including the 7 pin regulator and the 'special tool' for pulling the flywheel. Since I'm working nigh 60 hours a week, I had to wait for Sunday to have the time to work on the scoot, but today was the day! Sunny. Warm (almost hot, but not quite). Light Breeze.
Perfection.
Get the scoot rolled into position for working on. Get the parts-n-tools all laid out on my wrenching table. Pull up all the bookmarked wiring diagrams and helpful how-to's I had found...aaaaaaand promptly discovered that my scoot's wires only matched about 40% of the colors called out in the diagrams.
After several hours of multi-metering things, and cross referencing information sources, I finally have a wiring arrangement that I'm confident will, if not work, at least NOT fry anything. Part of my issue was that I was bound and determined to do this project without cutting anything on the factory harness. I achieved my goal (I think).
Since I got the hard part done I was pretty amped up to get the 'easy' part done.. pull the flywheel, replace the stator, plug in the rest of the wires, button it up and (hopefully) go for a test ride.
Yeah...not so fast, buck-o. first you need to dig out the compressor for the impact wrench, then you need to find the accessory kit you bought with all the quick couplers so you can attach the new hose to the tank and to the impact.
<sigh>
Get that all done, zip the nut off the flywheel, and commence to threading on the 'tool' to pull it. <Spin...spin..spin>... Da-faq? <Jiggle-spin...jiggle-spin...> "Why wont this thing thread in? I'm turning counter clockwise like I'm supposed to."
<try the 'small' side> Nope.. too small.. I need the fat side. <Examine the threads to make sure it's not a buggered thread preventing engagement> Looks fine. <mindlessly run a fingernail through the groove to make sure the threads are clean> DA-FAQ?? "There's no taper on these threads!"
Message sent to merchant who sent the parts, but I doubt I'll hear back before tomorrow, since today is Sunday and IIRC they are closed today. So I put the scoot more-or-less back together (mainly to keep from losing anything) and decided to move on to replacing that danged header flange gasket since I was already flat dirty.
Aaaaand now it looks like I'm going to be replacing the head. I stripped out one of the header studs!
(I WASN'T EVEN PUTTING THAT MUCH EFFORT INTO TURNING THE NUT!! ). I know that I could always helicoil it, but to be honest..a helicoil kit would probably cost about as much as a new head, and I'd still have to R-n-R the head in order to work on it. I can drill and re-tap the old head for larger studs at work (once things slow down a bit) and have a spare on-hand. Heck I may even take it to a weld-shop and have them fill the stripped hole with aluminum, and just re-tap it for the stock stud.
Regardless... the fastest fix will be a new head. Ordering it tonight it should arrive about the same time as the replacement flywheel tool. With any luck I'll actually be able to finish this project NEXT Sunday.
Of course this now has me thinking even harder about the exhaust modifications I wanted to do (making a new header pipe that's a true 1" diameter). I have to remove the muffler for the head work anyway, and it wouldn't be hard to cut the stock pipe off the flange and weld on a larger diameter pipe. I am a welder after all..
Le Sigh....
Nothing's ever simple...
(oddly enough it seemed to idle nicely at a mere 1000 RPM 
)