R50x restoration - questions

[dnbosiris]

Hi all
I have just acquired a 2006 R50X which had been sitting in the previous owners shed for up to 3 years.
i'm going through the process of restoring it to its former glory.
I have got it running & idling for 30 seconds but then it dies (working through this issue - pretty sure its carb related). Auto choke seems to work fine (did the test).

Aside from that issue I have a couple questions:

1. The headlights do not turn on with the key. I've checked the two main bulbs and they work fine. Indicators work fine. Any ideas?
2. What is this wire for? it doesn't seem to have been connected to anything. Can I ignore?
https://i.ibb.co/bHsD1c5/20190917-150331-2016x1512.jpg

I'll probably have more questions as I go along!

thanks!

[harry]

you have to hold in the brake lever in when starting the scooter .. there is a electrical (grounding)
lockout to keep scooter from starting unless lever is pulled in..however kick is always good.

2 types of scoot electrical systems .. ones that headlights come on with key on (battery)
and ones that come on when motor is started.

as for the other loose wire  picture   please post it here

 

[dnbosiris]

you have to hold in the brake lever in when starting the scooter .. there is a electrical (grounding)
lockout to keep scooter from starting unless lever is pulled in..however kick is always good.

2 types of scoot electrical systems .. ones that headlights come on with key on (battery)
and ones that come on when motor is started.

as for the other loose wire  picture   please post it here

thanks... you are too quick for me. I modified my post to remove the question about the kick starter because I read the user manual and it stated the brake had to be held in for it to start. Woops.

I have tried to attach to this post.

[harry]

so that looks like the fuse holder,,,, usually its attached to the positive
battery post .
see if there is  matching connectors

[dnbosiris]

Ok this scooter is starting to drive me a little crazy
It just will not start at all.
Things I have done so far:
Cleaned the carby with carby cleaner and compressed air (multiple times)
Cleaned out the fuel lines
Cleaned air filter
Replaced fuel filter
Replaced spark plug
Checked the auto choke (ok)
Tested ignition coil with a multimeter (seems ok)

Things I know for certain:
It is getting fuel
The battery is charged
I can't see any spark in the spark plug when I pull it out and ground it against the body and crank it over with the starter. I should, right?

Since I'm not seeing spark... Could it be the Stator?

Please help!

[harry]

if you do not have the fuse connected it will not start.
if the fuse has blown it will not start.

 it is possible that the stator is bad but  but seeing the picture  of the
fuse holder not connected i suspect that is your issue

also since i do not know your skill level , so bear with me.
since you cleaned the carb did you set all the adjustment screws back correctly?
these scooters are a bit touchy when it comes to carb settings

 oilyhans

[dnbosiris]

if you do not have the fuse connected it will not start.
if the fuse has blown it will not start.

 it is possible that the stator is bad but  but seeing the picture  of the
fuse holder not connected i suspect that is your issue

also since i do not know your skill level , so bear with me.
since you cleaned the carb did you set all the adjustment screws back correctly?
these scooters are a bit touchy when it comes to carb settings

 oilyhans

Hi oilyhans
the main fuse is connected
the picture that I showed before was not the main fuse
see attached pic
the red cable is the main fuse and the other one i don't know what that is but it wasnt connected to anything when i bought the bike


and I am 100% not seeing spark so i'm going to replace the stator given its a 2006 and the stator was known to be defective for this model year

[dnbosiris]

oilyhans,

How do I get the flywheel off? Which removal tool do I need?
thanks

[harry]

yes, they were known to go bad .
there is a special tool to remove the flywheel
look for a
27mm X 1mm FLYWHEEL/ROTOR REMOVAL TOOL
 i think thats the one but just make sure its for morini

oilyhans

[dnbosiris]

yes, they were known to go bad .
there is a special tool to remove the flywheel
look for a
27mm X 1mm FLYWHEEL/ROTOR REMOVAL TOOL
 i think thats the one but just make sure its for morini

oilyhans

thanks will order one now
any tips on where to find a replacement 8 coil stator for this model?
peaking through my flywheel i can see it’s got 8 coils however i can only find 4 coil replacement stators online.

[harry]

i'll see what i can find

[dnbosiris]

oilyhans - or anyone

i'm desperate now with trying to get this flywheel removed.
i've tried two different "flywheel removal" tools , one of them being the size you described, and one being a 6 way tool
however neither of them fit

i'm a bit stuck here - how on earth do you get the flywheel off ??

the thread is M10 and it's about 10mm long from the flywheel

what am i missing??

[harry]

perhaps there is a circlip on the output shaft that has to come off first.
but i've never seen one on a tgb morini but the suzuki morini (AD50) has
some real weird ways of doing things.
if the flywheel itself has threads the removal tool should do the job
if the tool will thread on and you tighten the inner bolt so you know
its under compression-  wack the flywheel with a hammer/mallet
sometimes you need to do that to get flywheels off

also the 2 threaded holes are for a different type of puller but
you could try them

oilyhans

[dnbosiris]

oilyhans
I ended up getting the flywheel off and I replaced the stator - but still not getting spark

I'm at a bit of a loss as what to do next. So far I have

Replaced Battery with new one
Replaced Spark plug with new one
Replaced Stator with new one
Tested ignition coil - I get <1 ohm resistance between primary and ground, and 11k ohms between end of connector and ground.

It's still got the original CDI - should I replace this next?

Any other ideas are most welcome !?

[harry]

you did try holding in left brake lever and then try right lever
to make sure the brake switch is not faulty
they are  the electrical lockout of the cdi  so unless it is pulled in no spark.

just with key on:
tract the power/grd to the cdi double check ones that
seems dead - make sure you hold in the brake.

 from cdi to coil:
check continuity in your harness
and in the coil spark wire &cap

crank it over:
check that power is being produced by the stator
be careful it can be up to 75vac *this scooter has a rectifier!* perhaps more 
make sure it is getting power and it is coming out (dc)

check the wiring diagram (pg13) for what is connected to what
http://www.peirspeed.com/Cobrasales/docs/TGB%20Service%20Manual%20-%20101S%20(BH1)%20-%20303R-50%20(BR1)%20-%20Delivery%2050%20(BK1).pdf