It has been a while since the last update, life gets in the way along with 1000 other projects.
My boy has graduated High School and started working while waiting to leave for the Navy, so in the end I worked on this whole project by myself, it has been a learning and very interesting experience.
As I imagined, the part sourcing was the hardest. I ended up buying most of the parts from Scooter Lounge Online and some generic ones from eBay. The OEM parts from SLO are pretty expensive considering how much the scooter is actually worth and they also take about three weeks to arrive, so waiting for parts has been tough as well.
Here is what happened in the last couple of months:
Ok, so, I started with this pile of parts:
Rebuilt the final drive with new OEM bearings, gasket and seals:
...then moved to the front and installed the timing chain and crankshaft:
The GY6 gasket is slightly different, so I had to order an OEM gasket:
I then realized that the piston pin hole in the rod was way smaller than the oem, bummer! This was labeled "Genuine Blur 150", and it was OEM but I'm afraid it was mislabeled and it's the 50cc version:
The two different crankshafts: the clutch side is different as well as the rod:
...so I ended up ordering a new OEM crankshaft. Looks like the rod is heat-treated, the old one was the same way
The stator bolts stripped right away, thankfully I have a 6mm time-sert set, the best money I have ever spent!
I used the Chinese piston that came with the HP kit, it's the same size as the OEM:
I feel like the Chinese head is very well made, at least at par with the rest of the scooter:
I used the Chinese cylinder that came with the kit as well:
I used the camshaft that came with the kit, seems well made, the lobes are much more round than the oem:
The rockers and holder are the oem:
I matched the intake spacer to the head:
The oem starter was $200!!! I bought a $25 Chinese repro and it didn't fit, I ended up buying a $70 from Taiwan (oem manufacturer but sold through eBay thank goodness) and it fit perfectly.
The oem chain tensioner fit perfectly with the Chinese gasket
variator and clutch back in:
Time to get kinky!
The engine is back in at last!
It was tricky to sort out this hose maze, I also eliminated the AIAC system:
I changed the oil filter ( this scooter has a sweet oil cooler/filter up front),filled up with Rotella 15w-40 heavy duty diesel oil, weird but that's what it calls for.
The final drive takes 140w gear oil.
I installed a new battery and then took some time to fill up the booster gas tank, but once it was filled the scooter started right up! The exhaust gasket was junk and leaked, so I replaced it with a flange type, hand-filed the exhaust flange to flatten it and there are no leaks!
The scooter is running great! I am currently breaking it in but I love riding this thing, it's very smooth and capable.
As it sits today:
![Image](http://i286.photobucket.com/albums/ll97/acuyano/Mobile%20Uploads/IMG_20150626_120505732_HDR.jpg)
Cheers!
-Marco.