P200e - this time for real!
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Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Oct 15, 2018 8:31 pm quote
nomadinsiam wrote:
I just replaced a worn out lever (ovalized pivot hole) on my PX. I did something similar. The objective is to unbolt the lever and replace it without disconnecting the pinch bolt at the clutch cable arm. I taped the existing lever closed against the grip and then wrapped a piece of baling wire around the clutch arm and rear brake cable housing. Then I took the tape off the lever. Without any cable tension, it's a simple unbolt and swap out of the old lever and replace with the new lever. Remove the wire and it snaps back into place.
Great way to replace a lever - easier than what I did! Thanks for sharing it. Looks like a good addition for this thread: Random tricks, share your best little tips & shortcuts.
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Oct 15, 2018 8:41 pm quote
Boneheaded Maneuver
Man oh man, I can be thick sometimes. Here is the skinny. I put the carb back together after a thorough cleaning and replacing all the pertinent bits, but something felt "off". So I checked the slide opening and it was only opening up 1/2 way - maybe a little more. So I pulled the carb and removed the slide and the piece of metal rod that connects to the throttle cable and the slide was bent?!? Say whaaaattt? I put the thing back together with the rod going inside the spring, not below it. Dooohhhh!

So I straightened the rod and put it back together properly and readjusted the throttle cable. This is after I had to push and coast home because the cable popped out of it's holder because of lack of tension. Fortunately it happened at almost the top of the hill by the house. I must have stretched the cable when the slide connector was installed improperly.

What this means is I'm starting from scratch in the jetting department. Thanks for the info Jack and I'll post back here when I get it sorted.

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Don't put the slide puller inside the spring! Man, that was lame....

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Attach the slide to the puller, then put the spring in place.

Molto Verboso
1979 P150X, 1983 P200E, 1987 T5, 1996 PX200E, 2011 Yamaha Fazer 600 S2
Joined: 02 Aug 2015
Posts: 1431
Location: Veria, Greece
Tue Oct 16, 2018 1:18 am quote
The spring should have a bent tip that goes into the slot and keeps the rod in place. Either get a new one or bend the tip on yours...

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Molto Verboso
1979 P150X, 1983 P200E, 1987 T5, 1996 PX200E, 2011 Yamaha Fazer 600 S2
Joined: 02 Aug 2015
Posts: 1431
Location: Veria, Greece
Tue Oct 16, 2018 1:19 am quote
But, you have an older type slide, so scratch my previous comment...
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Sun Oct 28, 2018 8:26 pm quote
CHT Install
So I finally got a Trailtech CHT gauge. Here is the blow-by-blow up to this point.

1) I took out the tank and removed the horncast.
2) Then snaked an electricians tape from the bottom of the horncast area to the tank area.
3) I then taped a 4' thermistor extension wire, a green wire, and two lengths of weed whacker string, and pulled this back through the body of the scooter. The green wire and two lengths of string are for future use. I figure if I'm putting the tape through, I might as well make it easy if there is a next time.
4) feed the thermistor wire through the space between the headset and leg shield.
5) Attach the TrailTech to a mirror mount - I haven't gotten to this part yet.
6) Reinstall the tank and headset.

So I managed to get 1 through 4 done so far. OK, ok, on with the pictures!

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The extension wire, weed whacker string, and green wire are taped to the end of the fishtape.

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I've pulled the fishtape out with the wires still attached - yea!

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Now I'm fishing the extension wire up using a piece of weed whacker string.

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This is where the extension wire is going to come out, after I loosen up the headset and lift it up slightly.

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I pulled the 13mm bolt out of the hole. Make sure the wheel and bars are all the way to the left or the bolt won't come out.

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I cleaned things up, greased the cowl latches, and put some dielectric grease on the electrical connectors.

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Ready to put the tank back in. I coiled up the extra stuff. Not too bad in there for 39 years old.

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Yes - it works! Now to put everything back together and mount this baby.

Molto Verboso
Joined: 26 Oct 2015
Posts: 1380

Sun Oct 28, 2018 8:46 pm quote
Hi Scott, good job on fishing those wires through. It's never a fun task. One thing I would caution you about is where the CHT wire is run. Between the neck of the frame and the headset is a notorious place for wires to break (because the handlebars are always turning back and forth). A safer place to run that wire is though one of the small holes (that are inside the glovebox) that the front turn signal wires poke though. But that's only if you're planning on mounting the gauge on the top of your glovebox.
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Oct 29, 2018 8:57 am quote
whodatschrome wrote:
One thing I would caution you about is where the CHT wire is run. Between the neck of the frame and the headset is a notorious place for wires to break (because the handlebars are always turning back and forth). A safer place to run that wire is though one of the small holes (that are inside the glovebox) that the front turn signal wires poke though. But that's only if you're planning on mounting the gauge on the top of your glovebox.
Thanks for this Whodat. I'm going to mount it on a mirror mount so I think I'm going to beef up the wire insulation - maybe heat shrink, maybe some sort of sheath so the sheath can get trashed but the wire can move and not rub as much. Hmmm - I'll definitely address this before I put it all together. Thanks again!
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Oct 29, 2018 6:32 pm quote
It's complete - I cleaned everything up and put it all back together and mounted the CHT on a backwards mirror mount. I put heat shrink tubing on both sides of the connector, and the tubing is down the bend at the headset so hopefully that'll protect the wire from getting rubbed in half.

I may move it on top of the storage compartment down the line, but first I'll run it where it is.

Y'all will love this. I showed a picture to my wife and she says: "That's just there temporary right?". I replied, "uhhhhh, why?". "Because it totally blows the whole look!". Doohhh! I think it'll be very functional and easy to read where it is, but she does have a point.

I haven't gone for a ride yet, but did start the scooter in the driveway to make sure I didn't pinch a fuel line or anything, and watched the temp of the engine climb - Wooohooo!

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The CHT mounted - pretty easy to read!

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The heat shrink tubing on the wires, going over the connectors ever so slightly.

Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Thu Nov 01, 2018 6:59 pm quote
New shoes! I changed the front brake shoes today and I only took one picture. I haven't gone for a ride yet to check them out. I did clean everything up and sanded the drum with some 80 grit to remove any glaze. Maybe this will help the weak front brake.

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Ossessionato
2 matching N.Z. '69 VBC Super, 177cc Racer, VespaCross Bodge, Puch SRA150, Piaggio Zip 100! & others
Joined: 26 May 2013
Posts: 3755
Location: Millbin, Ostrayleea, mate
Sat Nov 03, 2018 3:16 pm quote
Finally, someone else who adds wires for future use!
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Sun Nov 04, 2018 6:32 pm quote
SubEtherBASS wrote:
Finally, someone else who adds wires for future use!
Thanks Sub! If you're going to do it once, might as well make it count! I almost got a TrailTech Vapor but couldn't figure out where to mount it without removing the speedo and fitting it in there, so I didn't get one. But a tach would be nice, so maybe I'll add one in the future. And now, it'll be fairly painless now that a stringer is already pulled through!
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Sun Nov 18, 2018 8:12 pm quote
Low Beam Blues
The low beam finally gave up - it would sporadically come on - then shut off. So I peek under the headset and the wire from the hibeam/lowbeam switch was flattened where the headset screws down. Ah-ha, that's the problem, or so I thought...

I proceeded to open up the headset and got the meter out and checked continuity between the switch and headlight...and...all was good! Hmmm?!?!?

I took a good look at the switch and even had to break out Luckybears reading glasses to get an up close look. After starting the scooter, and playing with the switch for a while, I noticed that the main pin with the brown wire going into the back was a little loose. Then I noticed that the plate that goes under the rocker switch isn't connected to the pin, but just behind the pin, so if I pushed the pin tight against the rocker plate, the low beam comes on.

The pin is held in by just mushrooming out the back of the pin - so I took the pliers and a screwdriver to the back of the switch and now the light is working again! YESYESYES!!!! And here I thought I was going to be splicing wires...

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See how the wire is pancaked from being pinched when the headset was tightened down? This wasn't the problem though.

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The square base under the rocker switch sits on top on the metal band connection to the rocker switch. This square base is the culprit because it wasn't making contact with that metal band.

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Here is the back side of the switch. Notice the pins are just held in by mushrooming out the holes.

Addicted
P125X, P200E
Joined: 02 Apr 2011
Posts: 566
Location: Fresno, CA
Mon Nov 19, 2018 9:58 am quote
Yeah, I've had similar problems with wires in that highbeam/lowbeam switch. I understand that all those wires are supposed to be soldered into those holes but my soldering skills are substandard and I wasn't able to do the job. I wound up holding the wires in place by jamming a toothpick into the hole next to the wire. My Mickey Mouse fix has held up for more than 3 years so I guess I'm ok but I'd sure welcome instructions as to how to do a better job than I have done.
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Nov 19, 2018 1:38 pm quote
Reflection
So I striped Ruby with black reflective vinyl. It's black stripes during the day, but when the light hits it, it reflects quite bright!

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Cool black stripes - I like them anyway!

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A little reflective going on in this pic..

Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Tue Nov 20, 2018 2:08 pm quote
It's Official
It's officially a grocery getter now!

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There are three bags in the crate!

Hooked
64 V90 survivor
Joined: 30 May 2018
Posts: 149
Location: Madison WI
Tue Nov 20, 2018 3:40 pm quote
Very nice crate. Fitting for Ruby
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Sat Nov 24, 2018 6:45 pm quote
I went for a ride with this windsail and my homemade mounts were a bit lacking. Lots of vibration. So I made a new set of mounts and am in the process of cutting about 6 inches off the windscreen. I did the same for the GTS 250.

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This thing is super tall. I'm going to cut it down so I can see over it.

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The new bracket - I kept the angle on the angle iron to give it rigidity or stiffness - yeah, stiffness. :-)

Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Nov 26, 2018 6:04 pm quote
Lemonade
So I barely started cutting the huge windscreen and it splintered - splintered bad. I was about to play frisbee with it and decided, what the hell, make lemonade out of this lemon and cut it down to the top of the splinter. It came out pretty cool and works really well. I think so anyway.

Now it's more like a midscreen verses a flyscreen or a sail. And it covers my hands. I went for a ride in the rain yesterday and my hands stayed dry. Then again, it could be the waterproof gloves I had on but you get the idea...

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Dangit - I didn't even get a 1/2" inch until it split. Better find a dull metal blade...

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Here is what I cut off. Over 10".

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And here is the end result. After sanding the edge and giving it a quick polish.

Veni, Vidi, Posti
a herd of easy shifty rats
Joined: 22 Nov 2010
Posts: 6793
Location: seattle/athens
Mon Nov 26, 2018 9:18 pm quote

Nice clean job, I thought that was a 'before' pic at first. Had to put this up again to compare. It's much better now but still so huge . And that's fine if it keeps you riding
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Mon Nov 26, 2018 10:02 pm quote
V oodoo wrote:
Nice clean job, I thought that was a 'before' pic at first. Had to put this up again to compare. It's much better now but still so huge . And that's fine if it keeps you riding
Thanks man! Cut 10 inches off that big mamoo. Used a sharpie and bungie cord to draw the arc, then finished it up with the orbital to smoothen the arc, then a quick hand sanding. And I'm happy with how the mounts came out - so much so I even mounted the right hand mirror too.
Addicted
P125X, P200E
Joined: 02 Apr 2011
Posts: 566
Location: Fresno, CA
Tue Nov 27, 2018 3:38 pm quote
That looks SO much better! Good job on the cutdown!
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1049
Location: Florence, OR
Tue Jan 29, 2019 10:46 am quote
Haven't done much on Ruby, except ride almost daily into town! I did change the gear oil and JBWelded these magnets onto the oil drain and oil filler plugs. We'll see if they catch anything floating around in there.

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The plugs with the magnets on the end.

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Bag-o-magnets

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