OMG!!! Ponies!!!

Discussion in 'Battle Scooters' started by GotMojo, May 21, 2019.

  1. Fiftygrit

    Fiftygrit Been here awhile

    Joined:
    Jun 30, 2014
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    972
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    Git her done guys, looking good so far.
  2. GotMojo

    GotMojo Been here awhile

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    Jan 10, 2016
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    Orange County, CA
    Well, we had a major incident in the garage. Not sure if things can continue.

    Major blowout.

    IMG_20190901_194616289.jpg

    Full delamination on the passenger side. Only 3 years old!

    I suffered through part of the day with that thing flopping around and finally had enough.

    So much so that I found myself at Nordstrom Rack.

    Say what??? :dunno

    IMG_20190901_194734290.jpg

    Sometimes you gotta grab the bull by the horns and solve the problem.
  3. GotMojo

    GotMojo Been here awhile

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    After a quick reshodding side trip, I ventured to Harbor Freight and picked up a few items.

    Specifically this:

    image_25272.jpg

    No, not 'yet another crappy set of poor quality bits to go with the other 15 mismatched sets in the drawer.

    This is a left handed crappy set of poor quality bits!

    My hunch was that if I could get a good bite, the screw would crack and come right out.

    IMG_20190901_193357040.jpg

    I do so love it when a plan comes together!

    :happay

    Ever think about how it always looks like a scene from the inquisition whenever a bolt extraction operation is in progress?

    IMG_20190901_193443894.jpg
  4. villageidiot

    villageidiot Long timer Supporter

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    Good job, that.

    I spent 6hours in the garage this morning getting the transmission/primary back in my sportster, and swapping out drive sprockets. Only had to go from Tustin to Costa Mesa twice for tools.
  5. Wentwest

    Wentwest How's that work?

    Joined:
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    2,808
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    Northern California
    That's a job for Shoe-Goo! If you don't have some, you should. Keep the unused left over in a glass jar and it will last.
  6. GotMojo

    GotMojo Been here awhile

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    On flip flops? I don't think so.

    Besides, you missed the fact that they're 3 years old. Time for some new ones anyway. I've got 3 pairs plus the Chacos I picked up today. I'm good for another 5+!
  7. GotMojo

    GotMojo Been here awhile

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    Defeat has once again been snatched away by the jaws of victory.

    New engine is a fail. :(

    Cranks about 1 turn and stops unceremoniously.

    Tried all the usual suspects.

    Topped off battery. Same result.
    Tried second battery. Same result.
    Swapped out starter for the one on the old engine. Same result.
    Removed plug. Slightly more turns. And I felt *some* air getting pushed.

    Ok, so there's compression but it ain't turning right.

    Hmm...

    Took off variator cover (again) and tried turning by hand.

    Aha!

    Loads of resistance every other turn.

    So, 3 possibilities that I can think of:
    1. Crank is toast (worst case)
    2. Top end is toast
    3. Exhaust valves not opening
    All 3 will require removal of the head.
    I JUST replaced the water pump and refilled all of the fluids. :becca

    I decide to do something else with my time otherwise the scooter is getting tossed into the pool.

    How about some of that long-promised engine forensics porn?

    From the top end:

    IMG_20190907_213423536_BURST000_COVER_TOP.jpg

    And the lower bits

    IMG_20190907_213430868_BURST000_COVER_TOP.jpg

    God, I shoud have gotten a parts washer a LONG time ago!
  8. GotMojo

    GotMojo Been here awhile

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    Cylinder looks ok. Some light marks but nothing too deep. I can still see crosshatching underneath them. I think we're good here!

    IMG_20190907_213136283.jpg
    IMG_20190907_213234626.jpg
    IMG_20190907_212759019.jpg
    IMG_20190907_212809850.jpg
  9. GotMojo

    GotMojo Been here awhile

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    Had a scare with the rockers. Looked like there was some galling on the lower part of one (8G)

    IMG_20190907_212557377.jpg

    IMG_20190907_212524688_BURST000_COVER_TOP.jpg

    IMG_20190907_212529938_BURST000_COVER_TOP.jpg

    Turns out, it was just crud.

    IMG_20190907_212723744.jpg

    Surfaces are still shiny with no visible galling.

    :happay
  10. GotMojo

    GotMojo Been here awhile

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    Oddometer:
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    The Cam also wasn't quite as as bad as expected.

    IMG_20190907_212403440.jpg
    IMG_20190907_212441295_BURST000_COVER_TOP.jpg
    IMG_20190907_212447680_BURST000_COVER_TOP.jpg
    IMG_20190907_212450647_BURST000_COVER_TOP.jpg

    Signs of galling on all lobes. Can't tell for sure but there also appears to be some other type of damage on the two middle ones around the edges.

    Status: Questionable.

    Damn shame as this part alone is over $200.
  11. GotMojo

    GotMojo Been here awhile

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    From the no-shit-sherlock files:



    The crank bearings are no more.

    Totally expected that. Hopefully it didn't tear up the case bearings. I'm hopeful since there hasn't been *that* much metal in the bottom of the case (so far) and there's very little damage to the top end.

    I didn't get any further because I tried to save a few bucks and ordered a QUALITY BEST VESPRA PGGIO FLYWHEEL TOOL TO EXTRACT 100% item off of eBay.

    Needless to say, it was less than useful for extracting the flywheel. :baldy

    I'll never learn.
  12. GotMojo

    GotMojo Been here awhile

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    Tomorrow I'll revisit #2 engine that's currently mounted. Hopefully I just screwed something up when assembling it.

    I'm not hopeful.

    I might have another concurrent 52 engine part pickup game on my hands before high noon.
    Wentwest and villageidiot like this.
  13. sro99

    sro99 one odd owl

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    Could it be cam chain off by one tooth? I'm glad there's no pic of the bottom of the pool... yet :D
  14. GotMojo

    GotMojo Been here awhile

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    Engine #2 has unknown history and unknown miles.

    It could be filled with velociraptor eggs for all I know. Cross fingers that crank is ok.

    That will be my 'abandon all hope' indicator.
    villageidiot and sro99 like this.
  15. GotMojo

    GotMojo Been here awhile

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    Ever wonder what 1000 miles on a malossi head looks like?

    Wonder no more.

    IMG_20190908_105712788.jpg

    IMG_20190908_105721324.jpg

    IMG_20190908_105716602.jpg

    Overall, not bad.
  16. Bueller

    Bueller Cashin? Super Supporter

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    I can’t quite tell which way you are moving the rod in the video. I cannot speak to that specific crank, but in this type of design it is often quite normal to have lots of side to side movement. Where there can be no movement is pulling out and pushing in on the rod.
  17. GotMojo

    GotMojo Been here awhile

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    Oddometer:
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    Found a couple of issues.

    #1 one of the coolant hoses was rubbing.

    IMG_20190908_114727318.jpg

    Zoikes! This would have been catastrophic on the cannonball!

    The OEM hose is reinforced at this point and that's where all the damage occured. I think the shape of the Malossi head is different and has a sharp edge somewhere that's tearing the hose up. Need to take a closer look and figure out how to fix it.

    #2 I found the source of the chriping cricket.

    IMG_20190908_113551663.jpg
    IMG_20190908_113555920.jpg

    I now believe that the crank was on its way out already and I merely accelerated the process by starving it of oil. This *could* explain why it failed so quickly. It ran for 30 seconds, tops after I discovered the oil loss.

    I didn't check the stator but I imagine that if it was the problem I'd see a scratch all around the flywheel and not just in one section, no?
  18. GotMojo

    GotMojo Been here awhile

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    Enough damage porn, on to Engine #2 teardown.

    I bought this for $200. The bike 'ran, but needed a new water pump'.

    Oh, it needed more than a water pump.

    IMG_20190908_144546681.jpg

    See the problem?

    Hint: I didn't feed this thing viagra. It should be NOT be maintaining an erection.

    The oil sludge in the head/cylinder tells the story.

    IMG_20190908_144553374.jpg
    IMG_20190908_144549699.jpg

    PO asshat ran this thing for a LONG time with low oil. He then filled it up with new oil to hide the evidence. I was able to turn the crank a bit when removing the variator so I didn't think there was anything wrong. I should have tried to turn a few full rotations before I went any further.

    Let that be a lesson. Don't trust what anybody says. I got excited and went for the easy kill and I got burned. See why I didn't want to go with a 'donor engine' solution? :thwak

    3 weekends down and we're back to square one.

    *sigh*

    I need a new hobby.
  19. GotMojo

    GotMojo Been here awhile

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    Sorry the video was so short. I was tired last night. The play is excessive. There is some back and forth play as well. I don't think the bearing has completely disintegrated like the one in Robot's video.



    It's possible that the problem is in the case bearings. See the photos of the flywheel damage.

    Unfortunately I can't take it apart right now as I don't have a flywheel puller.
  20. Bueller

    Bueller Cashin? Super Supporter

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    Wow. I’m frustrated for you, that really sucks. Maybe it’s just best to buy a crank and rebuild the original. What’s a few hundred more after all of this?