Fuel vacuum issues, please help

[zombie]

Way cool.

No rush Bro. Just try to get it right.
If you want to Mod the bike down the road I can set you up w/ everything you need for anything from a 55MPH daily to a once a month 80MPH screamer. Anywhere from 400.00 ish to 3,000.00 ish

[super50zx]

hey quick question looks like the bike is holding six pounds for six minutes like the vid, when i ordered my new gaskets i forgot to order an exhaust gasket.....what can i use or do? do i just need to order another one? try to re-use the accordion type one? also I am wanting to put everything back together and try to fire it up, does the exhaust have to be hooked up for that? just anxious to see if what i did worked, thanks

[zombie]

You can run it for a few moments without the pipe but I would not recommend it for a newly reassembled bike. If something is off or mis aligned you won't be able to hear it.

The second problem w/ that is the fuel charge will blow right out the manifold, and you will be running very lean.

What I have done for emergency exhaust gaskets is wrap the old one in five or six layers of teflon plumbers tape. That can take the heat until you can replace it.

I KNOW you are stoked to run it but it is better to wait till you have it properly sealed up (exhaust)

[super50zx]

cool man thanks alot, I will try the old gasket thing until the new one comes in and another question if I am having a carb issue and want to replace it I am fine with one that is not oem, but could not find any on line to fit my bike, do you know of any? thanks.

[zombie]

Polini makes a 19mm that is a direct swap. SPI has them, and I am guessing around 40-60 bucks with an account.

The other option is to replace the intake manifold, and reed cage w/ a CT set. Then you can use any carb you like

http://www.ebay.com/itm/Honda-DIO-Racing-Intake-Power-intake-kit-4-valves-/231104867975?pt=Motors_ATV_Parts_Accessories&hash=item35ceec6e87&vxp=mtr

Here is an OEM type direct swap carb as well...

http://www.ebay.com/itm/NEW-17mm-Carb-Carburetor-Honda-2-Stroke-50cc-Dio-50-SP-ZX34-35-SYM-Kymco-Scooter-/360662197721?pt=Motorcycles_Parts_Accessories&hash=item53f92465d9&vxp=mtr

The Polini carb will direct swap (for the Dio engines) BUT if you swap the intake, and go to a different type of carb you will also need to swap out the throttle cable, get rid of the oil injection pump, and get a new throttle cable.

Zx's are a PAIN in the ASS to get started modifying. But once you get it all converted they are fast as F_ck!

[super50zx]

cool man thanks so much...okay here is the deal, the exhaust fit in with the old gasket. I made it fit in the head first then the pipe came to really nice and even....(im very impatient...lol.)  put it all back together minus the plastic farings or shrouds body panels ( hate dealing with those.  after a few cranks on the starter with fresh battery from the 40.00 scoot.... it fired up ....... success.....! thanks to you all. I have to put the air box on yet and the body to go ride it and make sure all is good and assuming i will need to play some with the carb adjustment. So far on the carb the air screw was from all the way in position one and a quarter turn out and not sure where the gas one is yet as it is running pretty decent not under a load yet but ran some rpms through it and it started to idle on its own. thanks alot zombie and I will be packing up the test kit this week, make sure you open the kit before you return it or store it as something in there is for you, thanks again

[zombie]

Love ya already Super50.
I have you on my Xmas card list. Stick around for some of this late night posting crap, and trollin fun. It's like shooting monkeys in a barrel.

[super50zx]

okay....i knew i spoke to soon, so put the air box back on all the panels, the engine shrouds etc. now it wont start....? and when i pull the brake handle in to for the starter to work the brake light does not come on but the instrument cluster lights come on.......wtf....... was all looking forward to a light night neighborhood ride, any ideas on what might have happened? 

[super50zx]

another quick post before i get killed for f-ing with scooter when there is going to be a party here soon..... i think the light issue was from a battery that was a bit to big group size, put the original battery back in it today after charging it. lights worked fine and it started third try. ran around a little and all seemed good but then just shut down on me, would not restart at all had to push about 1/2 mile. let it sit for a little bit and cool some, not as much as I should have and it started and ran for about 10 seconds, then another no start.....ideas? thanks

[zombie]

It sounds like a wiring issue. The brake light gets 12V off the battery/key switch. The ground wire is what gets switched at the lever. When you pull the lever it grounds making the light come on. That ground is also the ground for the starter relay. The starter will not crank unless the brake light is ON.

My GUESS is you either forgot to hook up the ground wire that attaches to the engine/frame or the ground is simply loose. I would look for that ground or run a new ground from the engine to the battery, and te frame.

The second MAYBE is the CDI/Stator. When either of them start going bad they usually will run for a short while until the heat generated causes a Fail. When they cool it will run again for a short time, and so on...

If it is a no crank issue when it wont start I suspect the ground. If it cranks but wont start it could be the ground wire to the engine OR the cdi stator.

Try re grounding everything first.

[super50zx]

ground seems to be fine, starting procedures are fine, the tail light operates as it should the starter cranks etc., when it is cold it starts and seems to run fine, when i get running for a while and assumably it is getting hot the bike then shuts down. I will double check the ground wires, what does the cdi look like etc, is that easy to fix? what is the stator? thanks 

[zombie]

the cdi is mounted under the seat pan/pet carrier. It is a cigarette pack size black plastic box.
These replace it with some easy re-wiring. They unlock the rev limiter, and add around 5MPH.

http://www.ebay.com/itm/Performance-Racing-Ignition-CDI-SCOOTER-Race-5-Pin-KYMCO-ZX-50-SA50-SR50-NB50-/161086185438?hash=item25817c1fde&vxp=mtr

The stator is this...

http://www.ebay.com/itm/NEW-STATOR-KYMCO-ZX-50-FEVER-/251423734922?pt=Motorcycles_Parts_Accessories&hash=item3a8a05bc8a&vxp=mtr

You can get one from Stadium Yamaha, and get 15% off as a forum member.

They both act exactly the same when they fail so I always replace both as a set.

That may be why the bike was laid up to begin with. I went thru 6 CDI's in two years before I started posting here.

[super50zx]

well i know for sure the crankshaft seals where bad as i was doing leak down testing they were bubbling soapy water, replaced them and the engine held pressure.  before that i had to keep pumping the bulb to make any air come through as it would not even hold 2 psi. so that was my not getting fuel to carb issue and i would guess no start issue as it had that much of an air leak , once that was fixed and carb was semi tuned the scoot would run.  today throughout the day a few times went into the garage and when the bike was cold hit the starter button and fired up each time with the first attempt. but when running down the road and i guess when it gets hot is when it shuts down. and it did that to me today this morning but have not ran it again since as i have not had time, but cold starts seem to be not an issue so far.  and the goofy thing with the light last night i have no idea but the starter was working it was just the instrument cluster lights would come on instead of the brake light as normal....weird. but have not had that problem since i put the standard group size battery in it. It will kick start as well. again thanks for all of your help i would not have gotten this far! 

[zombie]

That thing with the Inst. lights coming on screams bad ground to me. Like the bike is using the resistance of the lights as the ground.  The cold/no hot running is always electronic (cdi/stator) but I think you still have a bad ground. There should be a heavy wire (8 gauge) hooked up from the starter mounting bolt to the frame, and a second one from the frame to the battery. There is also a third thinner wire that is the harness itself.

Also check right next to the battery... There is a rubber cover that has a gang plug, and a few bullet connectors in side that cover. Make sure all those are clean, and tight. The bullet connectors quite often seem tight but are not. You may have to squeeze down the contacts before putting them together.

I don't mind helping at all. It's a 800-900 dollar bike when you get it running right.

[super50zx]

dude you have been a huge help...... I will check for all the grounds and everything sometime this week i hate messing with anything electrical as I am quite intimidated by it as i just dont really get it....but hey i think i will be good to go with your advice as i was intimidated at first to break open this scooter to start with but now i am feeling quite good about the work on it so far! So if i order that cdi box it is pretty simple to wire it into the old connections, I am a big fan of the plug and play as it makes it easy for electrical morons like me... but your saying if i need a new cdi box to get the amped up one right.