How to install a new engine step by step By Doug in San Diego (Read 483 times)

[Doug in San Diego]

Hello All

The new engine finally arrived, so I thought I would document the installation process.

The new engine looks great. It is a 1p57QMJ so I’m hoping it will produce a little more power.

1) Remove old engine – This is actually very easy. Then engine is only held on by the shocks, one long bolt, and the swing arm. Disconnect a few wires ,remove the starter, remove the carburetor , the brake line and the engine comes right out.

I have a video from a previous removal on youtube





Stupid alert – It’s easier to remove the fluid while it is still attached (forgot this)

2) Before I put the new engine onto my scooter I had to swap out the stator. This was very simple. I used an impact wrench and a flywheel puller and the swap was easy. The only reason I did this was that my old wires did not match up with my new wires.

3) I also took the opportunity to adjust my valves (much easier to do on a bench)

4) I put my nice prodigy variator, clutch, 1500 contra spring, and clutch bell onto the new engine. (also easier to do on a bench)

My next step is to install the motor, replace the old fluids, and start connecting parts

I will keep you posted

Doug

[JR]

Great Doug and for sure we'll keep this one for future reference!! Good work!

JR

[Doug in San Diego]

Day 2

Make sure you get an engine whose brake system matches your original. better yet, it has the brakes installed already

My new engine was set up for Disc brakes, not drum. I had to remove the "pegs" that hold the disk brakes on the new engine and replace them with the ones to hold drum brakes from my old engine.

The only problem........ you have to remove the final gear cover and assembly to access the nut holding those on

Time consuming, but not too difficult. At least it gave me a chance to finally see what is in there.

So after 2 hours I'm back on track

[Doug in San Diego]

It's ALIVE..... IT'S ALIVE!!!!

New engine is in!

Carb and all electrics hooked up.

Basically just put it all back together.

Put in all new fluids

Charged the battery, and she fired right up

Next step is to put the seat on, and begin the Motoman Break-in

Now if can just not mess this one up (12,000 miles here I come)

For $250 this is a nice way to get a fresh start.

Doug

[Doug in San Diego]

Possible new thread but what is your opinion on break in?

I respect your opinion

[JR]

I personally like the varied speed break in and while I don't baby it, at the same time I don't try to run a drag race either! LOL So vary your speeds say 2 miles at 40 MPH and then little by little raise the speed and do this for abvout 50 miles and then ride her like you want.

JR

[sprocket]

I do the break-in like JR...and city traffic 'stop and go' driving is excellent.... however you need to run the scooter for say 30 minutes and then let it cool down. The hot/cool cycles is very important to tighten the case seams and set the gaskets...it also allows parts in the engine to expand and contract...

Use regular oil 10W30 for the first 500 miles but change it at 50 miles, 250 miles and 500 miles...
after 500 miles go to 10W40.

I only switch to synthetics after 1000 miles... but others differ...

[Doug in San Diego]

So far so good

Ran it around town for 30 minutes. Did not gun it off the line, up to 35 or 40 then slow down. Variety of speeds but nothing over 42 . (back roads so it was easy to slow down and get some engine braking.

Then let it cool down. (put 13 miles on it) The only oil was a little excess from the UNI Filter oil.

I'll keep it up. I'm trying to find an alternative route from work, so I don't have to go up the monster hill.

If I can't find one, I'll take Sprocket's advice and wait till I get 100 miles on it.

Thanks for the advice JR and Sprocket

[sprocket]

Sounds good Doug.. ya that hill will kill a new engine...even at 100 miles break-in, take it really easy...

Hills stress the engine more than ANY other thing...even running at WOT for hours...

[Doug in San Diego]

Yikes!

I took the car today. Using the odometer, that hill is 2 MILES LONG!

I had no idea it was so long.

I also checked out other routes. Sadly, in San Diego, there a no roads that don't have giant hills

Guess I'll have to break it in good, and just baby it up my hill (let those bastards behind me honk all they want)

[Doug in San Diego]

It's running like a top

So far I have done 3 30 minute sessions. Varied speed. Only up to about 40 miles on the odometer so far.

The 122 seems a tiny bit rich, as the exhaust has a slight gasoline smell. But I would rather run rich than lean.

[JR]

Might drop it back to 120 and hit the sweet spot?

JR