27/04/2018 - I've started archiving the project on an external page, to help me keep it better organised; chronological updates will of course still be provided here! http://deliverscoot.com/kymcolike200iHi!
I've needed somewhere to write a minor project thread, and this seems to be the most appropriate forum; please move the topic if I've got that wrong!
Last time I did an overhaul on a scooter, I didn't provide enough information, take enough pictures or record enough videos, and that's something I'm very keen to rectify this time around.
My Like 200i is back from the MOT (UK safety check) shop, with a reasonable bill of health. However, I'm off on a 2500 mile tour in June and want the bike sorted and ready to go. Unlike my previous ride, as this one didn't cost much, I'm not too worried about drilling holes in it and the like. So, with that in mind, here's the to-do list;
Mechanical/Frame/Suspension- Valve adjustment, inspect tappets and valves for undue wear
- Check clutch condition (currently a bit "snaggy") and re-set idle which is currently too high
- Replace rollers with the slider pieces type (generic) and new variator bushes (do you call them sliders?) from Dr. Pulley
- Change gear oil
- Centrestand and mounts - remove, clean, paint, grease, reassemble
- Front wheel - remove, replace front bearings, regrease and reassemble
Speedo drive - remove, clean, grease, check cable condition In progress - all a bit rusty inside so stripped out and awaiting new grease and reassembly- Remove forks to check and grease head bearings if required (I hate head bearings)
- Forks - check and clean seals, change oil, install gaitors if possible
- Exhaust mount (axle) bracket - remove, clean, replace bearing, paint, reassemble Deemed unnecessary for now - may remove anyway to see if shock can be greased
- Exhaust - remove, de-rust, remove and copper grease LAMBDA sensor threads, paint with VHT paint, reinstall In progress - LAMBDA sensor came free (hooray) but require other steps to be completed before I can reassemble, as the exhaust has been patched up with repair putty, sanded and repainted.
- Rear shocks - remove, clean, grease (they squeak like nothing else!)
Electrical/Accessories- Install mini fuse box under front panel and aux loom so everying can be easily removed and returned to standard.
- Horn - swap for two-tone ones that sound like a van so I can scare anybody I desire to
- Install USB charger into glove box
- Install direct-to-battery marine 12v socket near battery tray so I can trickle charge from the 12v socket from my shed's solar panel when it's parked up. Need a much bigger drill bit!
- Install 12v marine power socket outside of glove box, higher up.
- Install modified hand guards with integrated LED indicators to supplement standard turn signals In progress - handguards are being modified but need to be fitted and wired in.
- Install elderly heated grips pinched from my old bike, installing the controller in the glove box to help it live longer
- Add LED tail/turn lamp to underside of luggage rack in addition to standard tail/stop lamp In progress - need to make up a bracket and install cable gland above rear light for it to be permanently connected in
- Install additional DRL side lights on the front, switched seperately from standard lights In progress - foam pads have been located to front panel but I can't work out how to get the big panel off - sunny day job for wiring everything up.
- Make a bracket for a front flood and spot lights, install it without making everything look terrible
Pictures of the bike in it's current state (which isn't bad by any means) to follow, with additional pictures added for each task completed as I go along, with write ups.