I thought I would start my blog a day earlier than planned. I need to get the information from Kevin to get my kit on order. I have a basic donor bike. It is a 2008 Suzuki Burgman 400. I got it as a salvage bike, but the motor runs great. I also need the speedometer and the housings. I figure Ebay will be the source that will provide what I need. As you might have guessed by the motorcycle in the background, I am a rider. Also on a personal note, I did thoroughly clean the garage after I stripped the Burgman of all user parts.
This is why I couldn't get it started. Both relays were no good. One obviously the other just wouldn't "click" when power was applied. I managed to get a pair plus the tip over relay for short money on ebay.
I removed the engine and started corrosion control mesures. Note the wire brushes and swirl marks on the engine. Here is what I was getting rid of. There was a lot of this sort of corrosion on the engine but with the help of a dremel tool and some elbow grease, it all came off and cleaned up very nicely.
The engine looks pretty good considering the build up or corrosion on the case. If you look at the engine itself, you will see there is a great deal of difference between the older 400 engines and the newer models. The cylinder head appears to be thicker, and longer. The mount points are pretty much the same. The oil filter was moved to the left side. If you compare this picture with the photo of the "BIG BROTHER BUILD" you will get a better idea of the differences. I cannot rotate the throttle body without major rework. It isn't going to deterant to the build though. It will be a modification.
Note the absence of the Brake Caliper mount. The Mag/Stator leads have been relocated and naturally the oil filter cover is on the left.
I have been ordering what I need and trying to second guess what might come up. The items I bought are necessary to have a reliable scooter. Among the items was a new Rectifier. The 2008 models had a recall on that, so I just bought a new one. Most Motorcycle rectifiers act the same way, some have higher amp ratings that others, but they all are there to convert electricity to DC (or so I am told) I just received the speedometer (an ebay purchase) I connected all the wiring and verified that it works. I also checked the starting circuit and ran a fault code through it for the O2 sensor. It returned an F1 code which cleared when I reconnected the sensor. It gave me a good feeling to see the gauge light up, and function properly.
You will also notice the radiator has the top and bottom tanks placed on the "LONG" side. The radiator measures about 12 inches X 9.5 inches. It is less than 3.5 inches thick including the cooling fan, and it is upside down in this picture.
The throttle body intake to the airfilter is routed to the left of the engine. It probably will not clear the radiator. If the radiator can be mounted to the right, then It may fit. There is a lot going on perched on top of this little motor. Seven sensors including the head temp. The throttle body has six connections.
Note the spark plug location. It dead center of the head, waaay down in the well. To do a tune up, I will have to modify the rear panel with an access point of some sort.
I put my Eco-Exo "R" on order today through Exomotive in Roswell Georgia. Thanks to Kevin Patrick I will be receiving my kit in 10 to 12 weeks. I took my donor bike paperwork to the inspection station to see if it was sufficient to proceed with my order. I had to order the insurance companies appraisal and the rest was ok. The appraisal is on the way. Another thing I didn't count on was that Massachusetts doesn't accept a receipt from eBay as proof of purchase. They want hard receipts with addresses and amounts and so on. Good to know stuff. I have a few receipts on the way, so if you use eBay for parts you must request a hard copy of the receipt. If it is a major purchase, they want the VIN of the vehicle it came from. That's about it. The inspectors want to make sure everything you do is documented and you have receipts to prove what you bought. The bulk of the inspection centers around documentation and proof of ownership. The roadworthy inspection is easy in comparison.
I will be waiting to buy anything more. I need to have the kit in my possession, then buy what it needs for completion. I will be posting the issues if any, I have during this project. More pictures to follow later.
I was sent my Ecopy of the assembly plans today. Thanks Kevin!!! I read through it twice already. I believe I am going to have a great time during the assembly process. I would imagine it gets easier after the 3rd or 4th build. I am prepping the wheels for blasting and powder coating. I removed the bearings (what was left of them) and ordered two new sets and the seals, along with a new set of Bridgestone tires for the front. The rear tire is new, so I figure a little scrubbing with soap and water along with an Armor-All wipedown will improve the looks.
Thank you Erik for the link. That is a CLEAN build. I really like the interior work, also the attention to detail to the entire trike is a testament to your skill. Outstanding!!!!!
Last Edit: Mar 29, 2013 20:28:10 GMT by roger32849
The electric scooters and motorcycles are not known for their overall performance, when you combine aerodynamic looks, range, and top speed. The rear car tire on the scooter isn't a "bad" idea. While it isn't OEM it isn't a hazard either. My dad ran car ties on his old Harley way back in the early 50's, and a lot of guys install them on Heavy haulers still. I took a 10,000 mile cross country trip last summer on my Kawasaki VN1700. It took me across some very isolated landscape where the only thing between me and the next fuel stop was rattle snakes and sage brush. Before I left home I found information in the Vulcan Owners Association forum on which car tire will fit. I kept the information handy and would not hesitate to install a car tire in an emergency. I am going to look into the possibility of using a narrow set of radials for the front of the Eco-Exo after It passes the state inspection with the Bridgestone Hoops in place. I also might install one for the rear, but it isn't high on my build list right now. The main area of concentration will be to do a clean build while using an engine not within the design of the kit. It will require some modifications and rework, but I do not believe it will look much different than the display models on the Eco-Exo web site. I will be powder coating the frame after the dry fit. I will clean up and polish/paint all donor parts before they are installed There isn't much extra room to work with on the kit but there is enough, so I am tasked with making the best use it and making it look as neat as I can. Perhaps after I ride a few thousand miles in trike, I may do a few serious modifications. My primary goal: pass the inspection, then drive it!! There is a lot of FUN that follows.
Perhaps after I ride a few thousand miles in trike, I may do a few serious modifications. My primary goal: pass the inspection, then drive it!! There is a lot of FUN that follows.
Hehe, my philofophy is "buy cheap, buy twice". All parts on my project have street legal markings so there isn't really any need to upgrade your project after is has been approved. Building it in a rush may show many things you would change the next time you build one but it isn't likely this will happen
One thing to reconsider is a towing ring. I forgot to weld one on mine, just in case...
Erik: The state of Massachusetts uses the SEMA guidelines to inspect kit built vehicles. Often times guys will do a project only to have their efforts and hopes dashed by failing the inspection. Having only DOT approved equipment does not automatically garner a passed inspection result. EVERYTHING I buy for this project MUST be accompanied by a receipt. ALL used donor parts MUST have the Vehicle Identification Number of the donor vehicle. It is a given that the parts must meet DOT (Department of Transportation) standards where applicable. Bottom line: No receipts, No registration. The safety inspection and having the vehicle pass the emission control standards are very important. Since I am using all DOT approved brakes, lights, horn and steering systems, I do not believe there will be an issue if installed correctly. This holds true for the 2008 donor Suzuki Burgman 400 emission system. It is complete and unaltered. My focus during this build will be to pass all phases of the inspection, to fail on a simple correctable item such as an undetected bulb being out isn't a big deal, but not having a receipt for a new working muffler is a "hard fail" to deal with. They do not accept eBay receipts of any kind. If I buy using eBay, I must contact the seller to insure they enclose a receipt from their store. Here is how the bottom line affects me: When and where possible I buy new parts, OEM quality. If I need used such as the extra front wheel, I get a written receipt from the business that sold it to me along with the VIN of the donor. What it all comes down to, nothing about this project is easy, or cheap. The inspector is not in the favor granting department by passing your kit built vehicle. If it passes here, it means it has been done right and not on the cheap. Buying cheap here doesn't just mean buying it twice, it's definition goes beyond that by a stretch. I am All in favor of a good bargain, I love a good sale, but cheap isn't The same as a bargain. My project will be finished to a very high degree both in appearance, quality of parts and safety. My background is rebuilding the old Honda GL1000 & GL1100 Goldwings.
I know I have gone on a bit, but it appeared I may have given you the impression I was going to do a cheap build using bottom of the line parts. I can assure you, this isn't the case. There is enough money in the budget for upgrades from entry level equipment and parts. My focus still remains to pass the inspection to obtain my registration. From all accounts that I have read, the Eco-Exo trike kit is top quality. It deserves the same in parts. As time permits, after the big inspection I may alter some of the work I have done. It doesn't mean anything was done poorly, but I might find a way to save space, or make the engine conform to emission standards by installing a more compact system. Things that come to mind are a stereo system, custom color matched upholerstry and upgraded tires. They are not high on my list, but only things to consider.
I will bear the towing ring in mind, perhaps two of them to be used as possible tie down points. Good suggestion!!
Having seen the bike build offs by USA companys on tv wonders if there is any regulations over there... Lucky to see you need to make good effort to make it roadworthy.I don't think the Eco-exo is ugly with stock parts at all and there is a minimum of accesoiries needed to make it look great. Just paying a little attention on those makes a lot of difference in appearance.
I agree with you, more is not always better, attention to detail will always be better. I personally think like you about the bike build off programs. Full of canned drama, the bike is never ridden because it is a show bike, there never has been a program where they show cased an inspection by the state. I can see why you would wonder about it. The reality is, they build a nice custom bike. The illusion is, they want you to believe everything they build is rideable. NOT!!!! TV is for entertainment value and anymore bears no resemblance to fact once you look past the characters. All of them are staged, from Pawn Stars, to Counting Cars, and OCC. Junk programming. Good observation on your end Erik! I always enjoy your comments and observations. Happy Easter!!
It's all in the details. I have read many threads over here and many projects look complex due to average wiring/tubing/hosing/routing etc. If you build without a deadline the over all qty will be so much better. If you managed to build her clean and straightforward it might please approval as well, in fact, I think it will raise the value of your project more as invested. Making a spachetti incident will easely reduce value.
Build slow, take your time chosing accesoiries, colors and materials like high temp resistant wiring, spiral hoses,T-wraps, shrinking tube with inner layer of hotglue , water resistant switches, lighting etc. make choices why some materials fail or approve for your liking. Feel free to make shameless copies of other contributions of this forum. that's what a forum is for
Here we are waiting, I managed to get a few things ready. My wheels are alll ready for a hot bath, then some media blasting and off to the powder coating booth. I am not going to alter tradition, the wheels will be metallic silver. That little space on the brake rotor between the mounting holes and braking surface will be painted epoxy black then hardened chrome bolts installed. New skins are on the way... Bridgestone Hoop OEM tires!!