I'm not sure if this qualifies as a "custom" Build, but it will be a pretty complete rebuild/restoration/upgrade type build. I've got alot of time on my hands and a scoot, so I'll record it here. You are welcome to come along for the ride!
This is my scoot the morning after I bought it. It is 2008 Baja SC150, 150cc.
After having it about 2 weeks, it looked like this for awhile.....
After a good tear down and inspection, I saw that the entire electrical system was toast. There had been a small fire in the headlight section and all of the wires were melted into one piece in several areas. The headlight/running light switch also had the plugs melted into it. Sorry, no pics of that part. Obviously the electrical system on this scoot was not to be trusted. Big surprise, huh? Digging deeper I found this.....
Somewhere down the line the the stator shorted out and was obviously not going to work... This will be a good time to update to an 11 pole stator, go to full wave charging, and change out the rectifier.
I'm in the process of completing a much better main wiring harness. I'll do different upgrades or changes after I get it running. I'll update after I get the stator and we see if it will start with the stock CDI and coil. I've already changed out the fuel system and cleaned the carb.
I got my first repair completed... While I complete the wiring and wait for parts I decided to attempt a repair on my rear tail light/mud flap section before I lost my license plate.
I decided to try sandwiching 2+ layers of fiberglass tape (Drywall tape) between layers of epoxy and hope for the best. I figure I will have to replace it at some point, but I'll worry about that later. It does seem pretty strong, for now. We'll see how it fairs after the test of time.
No matter how careful you're being, no matter what your routine is... Murphy has an ability to show up when you have to pee. Somehow while I was gone 30 seconds to relieve myself... My soldering iron jumped out of it's holder and landed on the nose piece of my scoot.... Man!... whaddyado? I am very thankful that it only hurt this piece... I should be able to fix it. Maybe I'll mount a dash cam there....lol
The good news is, I've got the 4 main auxiliary harnesses complete, tail lights, dash, front turn signals, and headlights. All I need to do now is obtain a stock headlight switch and a couple diodes... Then make the main harness... But that has to wait until I get my new stator and rectifier. I can safely predict that I should NEVER have a grounding issue.... Ever!
No pics today, but BIG news! It runs!!!!.... Well, kinda. It'll start and idle for a few seconds than die. This was expected because I haven't adjusted the carb at all, the intake manifold is ripped (it's in the mail).... AND I forgot to hook up the enricher/choke. I'm going to pull it back off tomorrow and clean/rebuild it again just for good measure. I'll also hopefully remember to check the jet sizes. All of the electrical repair is complete, except tying in the headlight relay/harness I've created and adding diodes/flasher to the emergency flasher assembly. I got too excited when I realized that the starting/charging wires were finished..... I just HAD TO push the go button! I'm actually embarrassed with the look of my main wiring harness.... so we'll call this one a prototype. It's solid, soldered everywhere, and correct, but alot of the wires are the wrong color.... Close, but wrong. Remember, I started with a jumbled molten mess. I'm super proud that it fired up right away
I pulled off the carb for the 2nd time and cleaned it. I soaked it in vinegar for about 18 hours, then rinsed it in HOT water... then scrubbed it with soapy water. I really need to get a compressor so I can blow out the passages next time! By the looks of the vinegar I didn't get it very clean the first time! This time there was actual chunks of grease and other gunk at the bottom of the bowl. I discarded the old intake manifold in anticipation of a new one showing up in the mailbox "any day"... You know how that goes. I'll hopefully end up getting a better intake at some point, but for now I'm not changing anything I don't need to until it makes noise consistently. Also, the stock headlight switch just won't work for my application. The one I ordered broke right away, so I'm going to go a different route. I'll install a heavier duty switch in a different location and possibly add a charging port to the original area.
For anyone that was curious.... The carb is a PD24j. The jets that were in it when I got it were idle-35s, Main 110. I'm getting a tuning set of jets, but expect I'll need a 125-130 main jet... I am not sure if it'll need an idle jet. We'll see!
I hadn't thought of that! I'm sure I have some laying around somewhere.
GREAT NEWS!!! I finally got my intake manifold and decided to try and see if it ran with the old jets and stock air box.... It did! And it ran great! I got to ride it up and down my hill a few times without any issues. It was so funny! I've never ridden a scooter before, and it has been several years since I had anything with 2 wheels..... So I was stiff! Really stiff! On a side note, I'm glad I started with a 150cc (although I still want a 50cc) It has a bit more oomph than I expected, but not so much that it isn't forgiving.
I haven't done much to the scoot in the last couple of weeks or so. We had a snow/ice storm that kept my shop too cold to work on it... So I spent most of the last couple weeks insulating my shop and setting it up to work on scooters. In the last few days I replaced my rear tire valve stem (front will be done soon)(I had it stuck in my mind that I already did them), changed my gear oil, adjusted the carb, and replaced the nuts on the exhaust. The big news is that I finally got it out on the road! It was plenty fast, Speedometer said over 60mph (YEAH RIGHT... lol) ... but there's a catch! This thing wobbles like crazy! I'll spend my next free time checking the front end out and trying to diagnose that issue. No pics this time either, everything I've done is documented 100's of times on the web. All That I need to do to it now is put loom on the wires, fix the hole I put in the front fairing, replace the rear brake switch, mount the headlight switch, and clean the whole scooter up... Then on to the fun stuff! Paint and lighting! I am leaning toward orange, silver, and black... and of course LED's all around, a flashing brake light, and low mount fog lights. I want to thank everyone on this forum, and on youtube as well for all of the help and knowledge I've gained. A couple of months ago I knew nothing about scoots, except that I wanted one. Now I feel that I know my scoot very well and have confidence in my repair/maintenance/upgrade ability. I am starting my own youtube channel TheScooterHole, I hope to upload a walk around today.
EDIT: Everything on the front looks fine.... But the back tire is either very out of balance, or out of round. I also noticed that my frame stand is going too far forward....
On the many forums I've seen posts about egg shaped tires,,,,that very well could be the problem,,,another problem that crops up from time to time is the motor mount bushings may be getting or are bad
Thanks Cyborg, I'll be sure to look into my motor mounts. I sure hope that's not it because the scoot only has 782 miles (Km?) on it, and everything else seems nearly unused. I plan on ordering a tire soon, the sidewall on the one that's on it isn't in the best shape... Better safe than sorry!
Do yourself a favor if one is going the other isn't too far behind,,,change both,,,,they be cheap and easy enough to change them yourself,,,,
I most certainly will replace both before I do more than a test ride, but it'll take awhile for this busted up old dude to squeeze $80 for 2 tires out of the wife. I can't work and don't get disability.