A moped blog

Mopeds at Dawn is a collection of photos, videos and information on mine, and other peoples classic mopeds.

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Thursday, 22 November 2012

Tomos A3 engine swap (part5)

After discovering that the conrod was just touching the case i split the cases again and using a heatgun removed the crankshaft. When i inspected the cases there was a slight mark where the conrod was making contact. So i used my rotary tool to remove a tiny amount of material from the case.
I then installed the crankshaft and bolted the cases together and it now spins freely!
Next i installed the gears and clutch mechanism and bolted on the right engine cover. I then attached the kickstart mechanism to make sure the engine turned over as it should. It did, so i added the correct amount of engine oil.
Next i removed the flywheel and stator from the A3 engine as i will use this stator until i can figure out which electronic ignition to get.

Wednesday, 21 November 2012

Tomos A3 engine swap (part 4)

I spent a few hours on my last day off re-assembling the A35 motor. I rebuilt the clutches and installed the gears only to find out it would get stuck when i tried to turn it over. Long story short the base of the conrod is just catching the side of the case @#%&#!!!!!

Monday, 12 November 2012

Tomos A3 engine swap (part3)

Today I thought id do a bit more on my A35 Build. Once I had made sure that both cases were clean and free from metal shavings from the case matching I pushed in the new crank seals.

The next thing to do was install the new bearings on the Top Racing crank. I used a heat gun to get the bearings really hot so they expanded then I used a some pliers to drop them onto the crank.

Below is a shot of the crank with the bearings installed.

Next I needed to heat up the cases so the crank with bearings would fit. I then realised that I would have to remove the seals as I didn't want them to melt.

Above is a shot of the crank installed in one case with the gasket in place.

After heating up the other case I fitted them together and bolted them up. Once the cases had cooled I pushed in the crank seals from the outside.

The next thing to do was to install the gasket and then the piston on a new roller bearing.

More to follow soon!

Saturday, 10 November 2012

Friday, 9 November 2012

Passola fuel system

I thought id spend some time on the second Passola and get it ready for MOT. With fresh fuel it started up and ok but wouldn't run very well.

I decided to install an inline fuel filter and fuel tap. The fuel tap is because the fuel in the tank drains out slowly over time.

I installed the tap so it would line up along the side of the bike.

So then I used a hole saw on the plastic panel so the fuel tap can be accessed from the outside.

After cleaning out the carb i cant get the bike to run. Ive tried adjusting the air and idle screw and also the needle height. I guess ill keep at it.