Help Please! Scooter Dies & Looks Like It's Not Ge By gebe (Read 768 times)

[gebe]

I have a 2004 Diamo Classic 150cc GY6 scooter that I bought last summer. After I bought it I adjusted the valves, put in a new spark plug, adjusted the carb and installed a new fuel filter.

It ran great all summer until I put it up for winter. I pulled it out a few weeks ago after winter and it started right up and ran great.

Yesterday I took it on the highway for a ride to the next town 10 miles away. It ran perfect at a steady 60 mph all the way. On the trip back and about 2 miles from home it sputtered and just died.

I coasted to the shoulder of the road and waited for a little while and tried starting it with no luck. A friend came with his pickup and we brought it home.

After I got it home, I checked the spark plug which was fairly new and it was in great shape. I then installed a new fuel filter. I tried starting it again and still no luck.

I did find a good amount of crud in the old filter and thought the new filter would help start it. After I installed the new filter and tried starting it again I noticed there was hardly any gas in the new filter and this was after pumping it many times and running the electric start.

I think the new filter should at least be 3/4 full after much pumping and starting but there was just a tiny amount of gas in it.

Any ideas? Also, what is the thing that screws into the bottom of the gas tank that the fuel line connects to?

Any help would be much appreciated and thanks much!

[cruiser]

Welcome to the forum, gebe. The unit on the bottom of the tank is the vacuum operated gas petcock. Here is a video about it which also explains how to check it for gas flow:

s499.photobucket.com/user/jrryan2008/media/Scoot%20Prof/vacuumswitchtest.mp4.html

Check the vacuum lines for cracking and dry rot. They should be soft and hopefully a good quality American line. These lines are normally replaced as part of a PDI which is performed when you first get the scoot.

[gebe]

Thank you cruiser and thanks for the link.

Today I replaced ALL fuel and vacuum lines with brand new line. I took the carb float bowl off and it looked good as did the inside of the carb and the floats were moving fine. I took the jets out and cleaned them thoroughly along with the float bowl.

I tried starting it but still no luck. However, this time I could see fuel coming into the fuel filter and it sounded like it almost wanted to start.

Any other ideas? Thanks much!

[gebe]

Success!!! I thought for sure I had checked for spark but decided to check it again, just in case.

I pulled the plug out, pushed the boot back on, held the plug about 1/4" from the valve cover and NO SPARK!

I didn't know what to do so I thought I'd check the wires going to the coil. I pulled the rubber boot off of the coil and guess what? The green wire's connector to the coil was snapped in half and the wire wasn't connected to the coil.

Evidently, whoever had worked on the scoot in the past had just bunched the wires up and stuffed them back into the boot and shoved it back on the coil causing a crack in the connector. On my last ride, the bumps and vibration must have caused it to snap off.

I cut the wire from the old connector, stripped the wire, and installed a new connector and pushed it back on the coil.

I then did the spark check again and this time I had spark! Put the plug back in and hit the starter and it started instantly. Yippie!

It was a hassle to replace the fuel and vacuum lines but I'm glad I did it as I won't have to worry about them.

Again, thanks for the replies folks!