got my ZipR3 parts but...

[Malformed]

i dont feel comfortable swapping the carbs.

i just dont know if the 19mm carb is plug and play on my zip r3i, i dont have a clue what id have to do with the cables, and the new carb is so alien looking.
i allready swapped the jets as directed so i dont have to worry about the shop neglecting that part.
and id rather have the shop handle the actual install.

since im doing that, im going to have them do the 70cc upgrade for me at the same time.

the exhaust will be done after the rest is done.
i have it set up and ready for the guy at the shop to just bolt it on.

im also going to go ahead and replace the variator, and fan (broken fin)
and clutch springs, and whatever that red spring is that came in the box.
going to do that before i have the shop come pick up the scooter, that way i can ride it home instead of paying extra for them to return it to me.


anyway... the but part...
i set up the exhaust, was going to bolt it on before sending it to the shop.

got it on fine, but whats going to hold the plastic fender off the rear tire?
there is no mount for it on the new exhaust, the old bracket had a place to screw the fender to.
did provoscooter forget to send me something that would solve that problem?
anyone have a way to fix that without removing the fender?

[Lennox]

I took that lower fender off my ZIP. You can either take it off or custom fabricate something to hold it.

[Malformed]

that seems easy enough, i was just hoping that something was allready made and for sale, save me some time.

ok now i looked closer at the old and new carbs and realy they arent that different. it looks like all the hoses and the cable hook up into the same general locations.

if i can get the carb and cable planned out, the only hurdle in my way is actualy removing the body pannels. i assume i need to do this for both the carb and the 70cc upgrade.

once i have everything figured out i may do all the work myself to save money.

top view of the carb, after i took off the black cap that was held by 2 screws.
http://www.makeitstop.org/scooter/zipr3i-upgrade/19mm-1.jpg

pulled out everything (actualy, it fell out into my hand)
i imagine thats the hole the cable goes through.
http://www.makeitstop.org/scooter/zipr3i-upgrade/19mm-2.jpg

and out the other side there are two holes side by side.
one appears to have a ledge that the end of the cable sits in, pretty standard i suppose.
i shouldnt have to clip off the current end of the cable if its set up the same way. just slide it out, and into the new carb.
http://www.makeitstop.org/scooter/zipr3i-upgrade/19mm-3.jpg

[Malformed]

oi

so many screws.

i got the seat and underseat compartment out.
undid every screw i could find.
couldnt get the pannels off!

i look inside and there are more screws, i could see them but hah! reaching them is a totaly different story.
i put it all back together, once i get the variator fan, and install the new variator & rollers, clutch spring, torque spring, i will install the new exhaust and fabricate a brace for the fender since the new exhaust doesnt have anywhere for the fender to attatch to.

i will let the shop do the rest of the work.

you all can just ignore everything i previously posted, for a second there i thought i could actualy do the work myself and got a little excited.
im going to get raped on labor cost, i can see the numbers hitting triple digits allready. :eek:

any of you in the florida panhandle area? and want to lend a semi mechanicly inclined person a hand with scooter work?
70cc upgrade and carb.
i can pay, i just cant afford the $30 an hour for labor at the shop.
feel free to pm me.

[XPS1210]

that seems easy enough, i was just hoping that something was allready made and for sale, save me some time.

ok now i looked closer at the old and new carbs and realy they arent that different. it looks like all the hoses and the cable hook up into the same general locations.

if i can get the carb and cable planned out, the only hurdle in my way is actualy removing the body pannels. i assume i need to do this for both the carb and the 70cc upgrade.

once i have everything figured out i may do all the work myself to save money.

top view of the carb, after i took off the black cap that was held by 2 screws.


pulled out everything (actualy, it fell out into my hand)
i imagine thats the hole the cable goes through.


and out the other side there are two holes side by side.
one appears to have a ledge that the end of the cable sits in, pretty standard i suppose.
i shouldnt have to clip off the current end of the cable if its set up the same way. just slide it out, and into the new carb.



The stock throttle cable will need to be "shaved" not clipped... I used a dremmel... a sanding tip and sanded away...

See my scootergarage for a pic of the before and after of the cable... Also, be very careful if you are shaving the cable end so you don't take to much of the end off... I did on my 1st one and then had to shave the second one and make that work...

To make the new cable sit into the carb slide correctly (with out taking to much off) I ended up drilling the hole out on the little brass washed piece as well to make the cable end fit in there... As I said the 1st cable I used I made to small and it popped out of the carb slide... Making me walk the 30 minute walk from where it happened home...

[XPS1210]

any of you in the florida panhandle area? and want to lend a semi mechanicly inclined person a hand with scooter work?
70cc upgrade and carb.
i can pay, i just cant afford the $30 an hour for labor at the shop.
feel free to pm me.


Try PM or emailing lennox... He might be able to help out a little... Not saying he will but I know he is in Florida somewhere and might be willing to assist you...

[Lennox]

Unfortunatly, the Panhandle is in a different time zone, about 9-10 hours away. I am in the bottom of Florida.

You are more than welcome to take a road trip here, and I would gladly put you up, and make your scoot fast...... Has anyone read my post about a Keys run?? http://www.provoscooter.com/vbull/showthread.php?t=421

[Malformed]

i would love to but i cant, the scooter IS my only transportation, which is why im realy pressing to get this done.
i need to either find someone localy to help me out, or im stuck having the shop come pick it up.
i just figured it would be a chance for one of you to make some cash and teach a newbie.
id rather spend the cash & learn how to do the stuff myself, than to spend cash for a mechanic to do it and i dont learn anything.

feel like taking a drive any time soon? :D
anyone?

Unfortunatly, the Panhandle is in a different time zone, about 9-10 hours away. I am in the bottom of Florida.

You are more than welcome to take a road trip here, and I would gladly put you up, and make your scoot fast...... Has anyone read my post about a Keys run?? http://www.provoscooter.com/vbull/showthread.php?t=421

[Malformed]

well i did the carb, it wasnt so hard.
the end of the cable fit nicely through all the holes, but it ended up being about an inch too long because of the change in hardware.

im sort of stuck at this point because i wasnt prepared for this.

any advice? :confused: i tried to find the small pinch screws but there realy isnt a place around here that sells them.
i duno where to even look for the end caps that you crimp on but i suppose thats the next logical step.

apparently im inept, should i just give up and let the shop pick up where i left off? lol

id still like to do the 70cc myself, there isnt much to that just sort of hard to get to.

[XPS1210]

eblieve it or not... The carb is the hardest to do...

The rest is just swapping exact parts for exact parts...

For the throttle cable, you left the 2nd stock cable on? If so then you can pull that cable till the new one is tight... Then crimp it so that it uses that location as the idle point...

[Malformed]

theres only one throttle cable, so yea i left it on.

i put it all back together, if i had an end cap for the cable i would have crimped it on and been done.
but since i dont, i will have the shop do it, since they have to take some of those body pannels off to get to the cylinder anyway.

hopefully in addition to me putting the carb on, i can do the variator, clutch springs, torque spring, and variator fan myself.
that will leave the 70cc cylinder, throttle cable, and some fine tuning, up to the mechanic at the shop. hopefully it wont cost much for that.

[XPS1210]

If you have a 13mm socket, needle nose pliers, large phillips screw driver...

That's all you need for the 70cc cylinder install... It litterally is SO, SO simple... if you did the carb... you should give the cylinder a try... you'll be shocked at how easy it is... It's just a matter of making sure you put the new stuff on as you took the old stuff off...

a quick break down... there are 4 screw on the right side of the scooter that hold the plastic shroud on over the cylinder... unscrew them... the plastic will slide right off... (make sure you took teh plug wire off)...

Then move up top the foot rest area... take the 13mm socket and remove the 4 nuts... The head will slide off easily... gentally tap the cylinder... it will loose the seal with the crank case... gentally pull it off...

There are 2 little clips that hold the piston on, one on each side of the piston... use the needle nose to get them both off... Then use the screw driver to push the pivot piece out... catch the piston as it'll fall... Then you install the new parts in the same order... (make sure all gasket materials are removed)...

Place ring on piston, Install the new piston, slide the new pivot pin in and then install the new clips (one on each side)... slide the new gasket in place... Then slide the cylinder on... Notice the there is a little place on the piston where the ring space needs to be for it to compress correctly... Since ther eis only one ring you can easily do it with your fingers... Slid piston into the cylinder (I used a little oil on the parts as your gonna crank it in a few minuites... why crank it dry!)... Install the new head gasket... place head onto the 4 studs... and finger tighten the nuts... Evenly apply a "moderate" amount of pressure on each bolt... I didn't torque mine to "spec"... you can but I didn't...

Install new spark plug...

Place plastic shroud back in place... return 4 screws and your done...

That's it.. maybe an hour later and your done...

[Lennox]

tell me exactly what you cannot remove from your Zip body and I will talk you through it.

[Malformed]

i dont know for sure what panels i need to remove for the cylinder & piston.

in the picture attatched i have the panels i think i have to remove outlined in green.
the one that gave me trouble before was the black one that wraps around under the seat.
and i cant get the bottom off because of the bolts that hold the pegs on.
i dont have an allen wrench large enough for it.

[Lennox]

buy the allen wrench and take off the foot pegs. Did you get the seat out? once the seat is out, and the gray bottom skid plate is off, you should have no trouble, if so I'll pm you my phone#.

[Malformed]

wouldnt know offhand what size i need for that do you?
id like to avoid buying the wrong one.

so all i need to remove is the seat/seat compartment and bottom grey one?

i figured i would have to remove the foot pannel, and the other black one just under the seat, the one im allways hitting my heals on.

maybe im confused, wouldnt be the first time.

[Lennox]

I think 8mm im not sure. Can let you know for sure tommorow.

For only a couple bucks more, you can buy the whole set (metric), they come in handy;)

[Malformed]

well ****, i allready have 2 sets of both kinds. i just dont have the larger ones.
:(

im still confused about what pannels to remove, see above post. ;)

[Lennox]

everything you have outlined needs to be removed, I was just saying that oncce the seat and grey piece are off you should be able to see all the screws for the heel clicker piece, foot well can stay.

[Malformed]

i was able to use the extra metal piece from the throttle cable as an allen wrench. i plugged it into a socket, and used a ratchet to remove the pegs.

i took off the bottom body pannel, but still couldnt get to the bolts and screws to remove the cover for the fan and etc.
it was the frame itself that was in my way on the left side.
im sure i could have figured out a way to get them all out but set it aside untill after i tried to change the variator, clutch springs, and torque spring.

i got the kickstarter and cover off, grabbed my strap wrench and socket set and went to work.
couldnt even get the bugger to budge!
so i figured, oh well... have the shop do it with an impact setup.
so i moved onto the clutch. i didnt have a socket big enough!

oh well. i put it all back together, having the shop come pick it up monday morning or afternoon hopefully.
i will eventuly need to buy the tools i need to do this work and other routine maintenence, but right now i need my scooter in 100% running order.
so i will bite the bullet and let the shop finish up and get it road ready for me.
i wish i could have done it all myself.

thanks for all the help guys, i learned quiet a bit that will come in handy next time i need to work on my scooter. hopefully i will have the proper tools by then. :)

[Malformed]

found a piece of aluminum after huricane ivan, duno where it came form but it was thick.

i cut a strip off an inch wide and folded it over width wise for strength, drilled a hole into it to mount it to the allen bolt on the exhaust.
bent the end towards the tire and drilled a hole into it.
bolted the fender through the hole.

the aluminum looks nice, and i still have the protection of the fender.