VICTORY!
After about 6 hours work on it yesterday, I finally got everything put together. Some kind person was nice enough to post a much better instruction set than came with my engine.
http://www.zoombicycles.com/downloads/usermanual.pdf. The instruction sheet and even the DVD that BikeBerry sends out are inadequate at best. There is SO much more detail that they don't even begin to cover, that the Zoom Bikes manual does. I think I would buy from them in a heartbeat if they weren't in Canada.
Anyway, I went over everything twice just to make sure everything was connected using their manual. Put about a cup of gas in the system and started petaling like mad. After about 6 tries it finally fired up and I let out on the clutch to go. I gave the engine a little gas and it revved but I was still just coasting. Come to find out the master link on my chain had popped off and my chain was lying on the ground about 15 feet in back of me! I picked up the chain and found everything but the clip for the master link. DOH!
Today, when I looked, I was unable to find the clip. I went to my local Lowe's Home Depot and Sears but no one had any masterlinks. So I went back to Home Depot and bought a couple of C clips as a TEMPORARY solution.
I took it out again, and it took a good 10 times before it would start. Though it doesn't seem to want to idle at all. I took it for a short ride around the block and tried adjusting the idle without any luck so far. Then I took it out again and laughed all the way, this is the coolest thing I have ever done...
I am very happy with the progress so far and thrilled that it actually started up. I know that I have a lot more work to do before everything is close to done but I have a good place to start from.
Here is what I am going to be researching in the forums today:
1) Idle. Still not sure why it isn't, I adjusted the idle quite a bit without luck. Perhaps it needs be be run a little more before adjustment will work?
2) Chain. I need a new master link for starters. Perhaps a couple of spares also. I have also read a few threads on opinions of #41 chain vs the 415 chain that comes with it. Still not decided yet.
3) Chain tension. I removed as many loose links as I could and it still quite floppy, the chain tensioner helps but I don't want it to take up as much slack as it is. I forget which post I read it in but it was suggested to put a small shim between the frame and back engine mount to move the engine forward just enough to take up some slack. I like that idea as it would also give my air filter (missing in the pictures) a bit more room to breathe (pardon the pun).
4)Vibration. Do all these things vibrate this bad? I am sure I have to tighten things down a bit more but the way it is now I am sure my wife would get more enjoyment out of the movement then I do. We'll see if that clears up as things come together more.
5)Clutch arm(at least I think that is what it's called the thing that the clutch cable connects to). I tried to pull it off the rod that it's connected to but it would not budge, even with a hammer. Though it is not part of it, there is NO way that thing is coming off. I am thinking about bending it in just a little so it is not sticking out too far and so that the movement is smoother.
6) Noise. This thing is quite noisy too. Mine sounds like a line trimmer or maybe even a little louder. I thought with the exhaust pipes they would be quiter. Before I ever installed the engine I was looking at some stuff you put in the pipe itself like fiberglass that helps quiet it. Also saw a post about plastidip on the gear cover too.
Like I said, I know things are a bit sloppy right now, but it's running! That was my first goal, now to get it into shape...
Also, my van still sits outside, we still haven't found someone to help us look into it. If it's something serious we are just going to sell it as a parts car and get a different vehicle. Even in great shape running Bluebook on it is under 2K.
