HELP!! 70cc problems

[mak_lok]

I have attempted to install a Polini 70cc kit onto my 2003 vino but have run into a major problem. After following all of the directions on the "How to" link correctly my scooter won't start.

The engine turns over, but doesn't start with either the electric start or manual. I have checked the spark plug and it works fine. I tried putting some gas directly into the carb and the cylinder to see if either of those dried out during my installation and still no luck. My battery is completely charged and I have even tried running it off a car battery.

In addition, there is a wining sound emitting from a connection that appears to have to do with the starter. This sound is only audible when the throttle is engaged. I have included pictures of the connection, image 1 and 2.

Other problems that it might be: The kit came with an O-ring, which I never used. Not sure if I need this or where it should be placed. Between the base gasket and head gasket? Or below the base gasket? Also the thin metal sheet that goes between the gaskets is not a circle like the stock (see image 3). Perhaps this is supposed to be on a specific way. Any help is appreciated. Thanks.
Mak

[XPS1210]

the "plastic box" is a relay for the starter... it shouldn't whine... maybe with the car battery you pushed to much power through it and screwed it up...

It should make a ticking noise when you press the starter button and have the brake lever pulled in.


anyway the important part...

that little "o ring" is your gasket that goes between the cylinder and the head... without it you will have a huge compression leak and probably not be able to start it!

The metal gasket goes between the case and the cylinder... it'll only fit correctly one direction. and it MUST be installed to keep your compression...

Which "HOW TO's" did you use? Mine (Jered's how to's) or a different one for the polini cylinder?

With a new cylinder, you need to make sure you use all the new parts that come with your cylinder... IE: the new gaskets, "C" clips etc... DO NOT use the old stuff...

I think that once you get the gaskets installed like they are supposed to be, then you'll fire right up...

Oh yeah... for the "O RING" gasket, unbolt the head and remove (just the head) there is a circle cut into the head that the gasket sits inside of. Place it in the ring and reinstall the head.

If you didn't use the new metal gasket, then swap that out as well...

You didn't way what kind of polini cylinder you got... Is it the Corsa, Corsa/R? or the other one, I can't remember the name...?

[shayandaman]

what o-ring are you talking about? I had one on my airsal that I never installed. Any pictures?

[mak_lok]

Jared, thanks for the quick response. First off, the kit I have is the Polini 70cc Contesta cylinder kit number Kit #166.0076, according to the eBay seller I purchased this from it should work with the 2003 vino.

I have tried all the suggestions you made and I am still unable to get the scooter running. I put the O-ring between the two gaskets as you said, and I have tried the metal gasket in every possible direction. All the parts that I have been using were included in the kit.

As for the “how to” instructions I used the ones that are linked from the provoscooter main page.

If you have any more suggestions that would be fan-tastic.

Thanks,
Mak

PS King, I apologize if I placed this thread in the wrong post. At the time I was very frustrated with my situation and posted it in here b/c the subheading said 70cc.

[XPS1210]

okay... The contesta is the polini's basic 70cc cast cylinder... so it's not gonna be a beast but will be much better than the stock 49cc kit...

here is the order of parts for the cylinder install...

to start you should have 4 studs sticking out of the case and have the connecting rod sticking out...

connect the piston onto the connecting rod (and clips etc.)

next slide the metal gasket onto the cylinder with the "square cut out" facing out to the sides of the cylinder (for the transfer ports to be open)....

next is the cylinder, compress the rings and slide it all the way to the engine case...

now you take the "O" ring and place it into the groove in the head and slide the head onto the studs...

There should be nothing else in there... So you kinda lost me with the "o ring between the 2 gaskets" comment...

http://uk.catalogo.polini.it/image/immArt/mini/166,0076.gif

okay... http://uk.catalogo.polini.it/image/immKitEspl/maxi/166,0076.jpg this shows the order of how these go onto the engine...

Let us know if this is how you have them installed...

[Little D]

Not to interupt, but do you have the piston facing the right way?

[XPS1210]

good point... if it's upside down (spun a 180) then it will keep the fuel from transfering as well... the solid part of the piston should be towards the exhaust hole... like in the pic...

[mak_lok]

Update:

thanks for the help, my problem was that I had put the metal gasket in the wrong place. Now that I have moved that it seems to want to run, but the spark plug isn't sparking. The piston moves freely when the spark plug isn't in. I ordered a new plug from erich a day or two ago so I expect that in the near future. I will keep you all posted on any new developements. Thanks again.

[XPS1210]

did you have it above the cylinder instead of below?

After a little while of cranking and not firing I could see how the plug could be bad...

Try this though...

take the plug cap off and place new plug wire near metal and turn the engine... do you see a spark?

If so then the plug is the issue... if not then you have other issues....

Be careful not to get your hands to close to the spark or you'll get a little tickle!!!

[mak_lok]

the spark plug is still sparking.... good news?

[XPS1210]

so did you get it to fire? or is the wire sparking but the plug not?

[mak_lok]

If i remove the spark plug from the cylinder but still have it connected to the plug cap and ground the threads then the spark plug will spark.

I am not sure exactly what you mean about using a "new spark wire" to check the spark. please explain.

[XPS1210]

I just said to take the plug wire off of the plug and place it near the frame...

if you have spark with it removed from the scooter... what makes you think it's not sparking in the cylinder? It's obviously sparking...

I think you have a fuel issue or something else... not a spark problem...

what other upgrades did you do when you installed the cylinder?

[mak_lok]

The cylinder was the only upgrade i made. I had figured that the spark plug was the problem because everyone suggests upgrading to the 70cc spark plug when you do your upgrade. It appears that the fuel and oil are going into the cylinder correctly. Thanks for the help.

[mak_lok]

got it going... once i had the new spark plug from provo the scooter turned after a few good cranks on the kick starter. thanks everyone for all the help!