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Old 12-10-2013, 08:07 PM   #46
Yellow Jacket
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Location: Moutains of North Carolina
Oddometer: 136
OK!!, we have reversed the ratchet, Blowfly is going back together. As often happens in a case like this, we had to do a little improvising. Shade tree engineering ring compressor. A hose clamp of the right size and a piece of feeler stock.


Ready to compress the oil ring.


Worked like a charm. In this case I decided I would start the piston into the bore on the bench. Installed piston just far enough that I could still get the pin in.


Going back together.




A little bit like Humpty Dumpty going back together but for every part going back on that's one less part on the bench.
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Old 12-10-2013, 08:40 PM   #47
Yellow Jacket
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A side note, the after market exhaust is 4 1/2 pounds lighter than the stock one.
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Old 12-10-2013, 11:18 PM   #48
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Piaggio must make these mufflers out of cast iron. The muffler by itself on my Leader 125 engine Sportcity One weighed in at 6kg!
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Old 12-13-2013, 03:39 PM   #49
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It's Alive!

All buttoned up and it runs!
Stay tuned for a preliminary report.
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Old 12-14-2013, 01:57 PM   #50
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10 miles so far...

Got about 10 miles on it before time and weather closed us out. Bike runs smoothly and accelerates well. Lot of pop/backfire on decel from 20mph down, off throttle. Did not occur with just the pipe.
Not really enough miles to test and have an opinion or timed runs to see what has been gained.
Thinking the plug will need to be checked after a little more riding to see if re jetting is called for.
Main jet ?
Idle jet?
Idle mixture?
Any thoughts appreciated.
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2005 Vespa GT200
2011 PCX 125
2006 Fly 150 "BlowFly 200"
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Old 12-14-2013, 04:46 PM   #51
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Start with the main as most riding will be done at wot.

Find the number of turns the mixture screw needs to be turned in or out with the highest and best idle with a fully warmed bike off of choke.

If the idle mixture screw is over three turns out from seated you can go up on the pilot jet.

Keep in mind that adding power will require tranny adjustments. Heavier rollers, taller gearing, possibly a more heavy duty clutch.
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Old 12-14-2013, 10:36 PM   #52
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Find out the stock jetting for the Liberty 200 and go from there would be a good start I rekn.
Same for roller weights, clutch springs, etc.
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Old 12-15-2013, 08:32 AM   #53
Yellow Jacket
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Warming trend moving into our area. I plan on getting out for a few more break-in miles tomorrow. Tue. is our best day here but I have other obligations for that day. By Wed. I won't be able to stand it any more, hope to do a little testing.
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Old 12-15-2013, 02:08 PM   #54
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Moving Forward

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Originally Posted by MODNROD View Post
Find out the stock jetting for the Liberty 200 and go from there would be a good start I rekn.
Same for roller weights, clutch springs, etc.
From what I could find, the Liberty 200 has a 26mm CVEK Kehein carb.
Main is 80 and pilot is 35. Idle screw out 2 turns.
Thought it interesting that for the Liberty 125 the main is listed as 82 and pilot 42 with 2.5 turns on idle screw. Don't think I got the numbers reversed.

The Fly is listed as having a 26mm CVEK Kehein carb.
Main 82 and pilot 35 with 1.75 turns on idle screw.
Pretty sure the head and valve size are the same on both bikes.
Guess we will go up some on the main first after checking the plug (perfect on stock set up) and idle screw adjustment.

Roller weights were listed as 11 gm on one site and 11.5gm on another for the Liberty 200. We went back to the mix of 3x9.5 and 3x14gm rollers in the Malossi variator. New spring that came with the kit installed. This should have it close if on the heavy side by 4gm..
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2011 PCX 125
2006 Fly 150 "BlowFly 200"

driller screwed with this post 12-15-2013 at 05:03 PM
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Old 12-16-2013, 06:04 AM   #55
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Jetting

The wife's Malossi has main up one, pilot up one, and idle at 2.25 turns with PM pipe on our Fly 150. Tried up two main and up one/two on pilot. Plugs were darker. Good luck.

Jim
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Old 12-16-2013, 06:42 PM   #56
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Thanks, Jim. Testing Wednesday. Jets on the way.
The pipe is getting discolored. Probably from being lean.
Any discoloration on yours?
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Why did I wait so long to do this?
Now "Certified Scooter Trash"
2005 Vespa GT200
2011 PCX 125
2006 Fly 150 "BlowFly 200"
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Old 12-17-2013, 06:59 PM   #57
Yellow Jacket
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I really hate it when something rather simple turns out to be much more difficult than it needs to be. I've put about 75 miles on the Fly since the 200 cc kit installed. Right from the beginning I had concerns that something just wasn't right with it. For unknown reasons the power just isn't there, not even up to what it was before any mod's. This morning I took the slide out of the carb to check the diaphragm for any leaks. While I had it apart I decided to shim the needle. Buttoned it up and went for a test ride. Very doggie. Went home and removed the shim and tried again. Still no good. Did an top end run and could barely get an indicated 60 MPH. Pulled the carb and tried to push the slide up by hand. It would only go about half way. Found the slide spring was all wadded up under the cap. I very carefully assembled the slide and made sure the slide worked free. Installed carb & went for a ride, sort of. Could only get it up to about 30 MPH. Removed carb again, slide would barely open by hand. Removed slide, found nothing wrong. I duct taped my shop vac to the carb to check slide action. Done this in the past with problem carbs. Slide should go up when you open the throttle. With this carb the slide just sits there doing nothing.
That is where I'm at now, totally lost. Any suggestion would be welcomed. BTW, does anyone know what the free length of the slide spring is? This one is 4 3/8 or about 11 CM long. Wondering if someone may have stretched it for some unknown reason. Driller and I will scratch our heads more tomorrow, sure hope we can come up with something before I go off the deep end with this thing.
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Old 12-17-2013, 07:16 PM   #58
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If it was fine before removal and now it isn't, look to what you have changed and reverse it.
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Old 12-19-2013, 09:01 PM   #59
Yellow Jacket
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Wow, what a pain!! But I think now I might have a handle on the problem. I would be embarrassed to reveal how many hours Driller and I have put in on that stupid carb over the last couple days. The cap on the vacuum chamber is poorly designed. Instead of sitting down on the diaphragm the cap just barely catches the very outside edge of that diaphragm. The diaphragm comes out of the little groove on the top of the carb and there goes your seal. Who would think you could put that cap on 15-20 times and never once get it on right. If the diaphragm comes out of the groove the cap still fits down normally, you can't tell that the dia. isn't seated correctly. Finally after connecting the carb to my shop vac to test the slide, it worked just like it should. I've worked of dozens of this type carb but never had this kind of problems. Once in a while while working too fast I have pinched a dia. Usually just looking how the cap sits on the carb body will tell you what is wrong.
So, tomorrow we should have decent weather so I'm off to my test location with high hopes for some very positive results.
On a side note, Driller also has a Vespa 200 with nearly the same motor as the Fly, just more CC's. The bike had a very rough idle ever since he owned it. He left it here with me to see if I could find the problem. After fooling with it, I finally found an air leak where the intake manifold mounts to the head. Problem solved!! Idles fine, but now it seems to be down on power. I'm guessing that diaphragm may also be a problem. We did take the diaphragm out yesterday because I wanted to look at the spring. This time I may have done a better job on reassembly because he called me today to say it seemed to run better on his way home.
That's all for now, wish me luck tomorrow. Hope I don't get hurt if it wheelie's over backwards.
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Old 12-20-2013, 07:51 AM   #60
Yellow Jacket
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Starting to warm up here in the moutains of North Carolina so I'll get out later today on the BlowFly.
I like your little story abut the rag in the air filter. Similar story. I went to look at a bike that was for sale. Ad says it starts and runs but wouldn't take throttle. I got the bike for $400. Found a mouse nest in the air box. Sold it a month later for $1200.
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