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PostPosted: Fri Jan 05, 2018 8:06 pm 
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Wait...


Dremel with a smaller wheel than pictured.

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Now

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Next, hammer time.

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    2013 Honda PCX 150, NCY Variator kit, Dr Pulley 12g Roller weights
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PostPosted: Sun Jan 07, 2018 6:02 pm 
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Here are a couple pictures of my progress. Will do a How to guide later.


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PostPosted: Sun Jan 07, 2018 7:30 pm 
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View of brackets that where cut, my shoddy new brackets and paint. :)

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PostPosted: Sun Jan 07, 2018 7:39 pm 
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Intriguing puzzle. . ..

Amazing! :geek:


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PostPosted: Mon Jan 08, 2018 8:14 am 
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The tank is in and it looks like everything else will bolt on with no issue, we will see.

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Gil

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PostPosted: Mon Jan 08, 2018 8:40 am 
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PCX150Rider wrote:
Intriguing puzzle. . ..

Amazing! :geek:


The plastic panels might be the most difficult post of the puzzle. :D

Gil :lol:

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PostPosted: Mon Jan 08, 2018 6:16 pm 
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Hopefully it works. Awesome job.


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PostPosted: Tue Jan 09, 2018 6:34 am 
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Is the fuel cap going to be at a steeper angle than usual (will the pastics fit around that) - trying to make sense from the pics :)

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PostPosted: Wed Jan 10, 2018 2:28 am 
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iceman wrote:
Is the fuel cap going to be at a steeper angle than usual (will the pastics fit around that) - trying to make sense from the pics :)


It doesn't look like it, but I won't know until I start putting those panels back on. There are little details like extending the fuel pumps wire harness, so that it's slack is like stock, that come up as I continue assembling it. I'm cleaning up some wiring I added to the scoot at the moment, so assembly has slowed for now. I'm wiring up the LED drivers for the headlights and the arduino controlled daytime running lights. It's much easier to do electrical wiring now that all the panels are off.


Here is the stock fuel pump harness. It's stretched a bit too much, so I extended it to avoid future problems. The picture is of the stock harness.

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pcx888 wrote:
Hopefully it works. Awesome job.


Thanks 8)

Gil

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PostPosted: Wed Jan 10, 2018 1:06 pm 
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Kudo's to you Gil! By the Way....You Crack Me Up!
"Hammer Time!"
I like that :D

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PostPosted: Wed Jan 10, 2018 1:17 pm 
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I have to say, that was an amazing job you did! Even if the panels don't fit, just being able to get everything working is a feat in itself. I hope everything connects together. Keep us informed.

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PostPosted: Wed Jan 10, 2018 2:56 pm 
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Perhaps there is some truth to the old saying "Smash to fit. . .Grind to match". :lol:


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PostPosted: Thu Jan 11, 2018 3:53 am 
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Thanks everyone, I'm happy with the results so far.
The end is near. :)


PCX150Rider wrote:
Perhaps there is some truth to the old saying "Smash to fit. . .Grind to match". :lol:


That saying definitely fits. :lol:

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PostPosted: Thu Jan 11, 2018 8:48 am 
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Fuel pumps


The fuel pumps are only different on how the fuel sender is arranged and the pickup screen. Here is a picture of them side by side.


Gil


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PostPosted: Fri Jan 19, 2018 1:26 am 
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The scoot is back together


It took me a while to get it back together, as I was working on cleaning up some electrical wiring that I did.
I had assembled most of the panels onto the scoot at the beginning of the week, but soon found out that I needed to shave more plastic from the side panels that come in contact with the tank. I also over loosened the intake valve, so I had to redo that.

Side Panels


In the following pictures you will see the final look of the side panels. I needed a couple of millimeters shaved of both sides.
All the panels bolted back up like OEM. I was planning to add some electrical tape between the panels and the tank so that the paint on the tank wouldn't be rubbed off, but forgot to.

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On the right side, I had to shave some of the plastic where the wire harness passes by.

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Fuel line


When I plugged in the original fuel line, it stretched a bit too much for my liking. I added a bit of slack by bolting the fuel line mounting bracket, close to the gas tank, more towards the inside and twisted it a bit. I believed that it helped, but I'm still concerned.
I did buy the fuel line from the 2015 model year, but it was a bit too long. It turns out that not only is the spout from the fuel pump assembly different, the fuel injector is too, the fuel injectors spout points back towards the rear tire. I left the original fuel line installed. I'll be checking the fuel line for defects on future maintenance checks.
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I need to wash my scoot, it's dirty. :)
Gil

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PostPosted: Fri Jan 19, 2018 12:59 pm 
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Is it fully assembled and running yet? I am amazed that you were able to reassemble the bike after all of the modifications done in order to get the gas tank to fit. Have you started it to make sure it runs now? You have definitely done something that most of us would not/could not do.

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PostPosted: Fri Jan 19, 2018 2:18 pm 
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Mel46 wrote:
Is it fully assembled and running yet? I am amazed that you were able to reassemble the bike after all of the modifications done in order to get the gas tank to fit. Have you started it to make sure it runs now? You have definitely done something that most of us would not/could not do.


It idles Mel46. Everything that plugged into the stock tank also plugged into the newer tank. The fuel pump harness was a bit short along with the fuel line that was a bit too short , but those two issues where addressed.I will go on Test ride today and fill the tank, as it's close to empty. I'm hoping that I don't have any squeaking from the modified plastic panels. :D

Gil

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PostPosted: Fri Jan 19, 2018 6:39 pm 
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Went on a 50 mile ride and all is good except for the fuel gauge that meters the fuel level differently, i'll have to keep an eye on it too learn it's patterns.


Filled up 1.7 Gal

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PostPosted: Fri Jan 19, 2018 7:45 pm 
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Did you end up installing the 2015 fuel line and just cutting it to fit?

Nice job! 8)


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PostPosted: Fri Jan 19, 2018 7:54 pm 
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PCX150Rider wrote:
Did you end up installing the 2015 fuel line and just cutting it to fit?

Nice job! 8)



I left the original one on, I just added more slack by adding spacers to one of the fuel line mounting brackets.
I think it will be OK.

I mounted the bracket circled in purple to the inside of the chassis mounting point and added a spacer. I also twisted it counter clockwise a bit. I don't have a before and after unfortunately.

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Gil :geek:

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