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Post by roger32849 on Nov 10, 2013 20:56:22 GMT
 I just got the calipers back from the powder coating guy down the street. He has a small business and gives personalized service. If anybody needs his business information I will be more than happy to provide it. ANYWAY..... I am about ready to add some brake fluid, bleed the air, adjust the parking brake and do the last minute stuff that needs to be done....... I am very happy with the progress so far. Thanks for suggesting the RED Erik. It does look very nice...... Roger Worcester, MA |
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Post by roger32849 on Nov 10, 2013 21:02:11 GMT
  Just a quick couple of pictures of the progress. I finally painted the radiator black. It looks better in person than with a flash photo... I am also dealing with the rigors of electrical rewiring. I have the turn signals all installed. The rears are connected, but the front ones are not yet. The Engine control module and fuse box are located on the left side beneath the black panel. It keeps the "VISUAL" wiring clutter down to a manageable tolerance. |
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Post by roger32849 on Nov 10, 2013 21:08:00 GMT
  The turn signal brackets are almost finished. I need to install a small gusset to hold it steady. The signals are visible from the front and side. The bracket is not what I wanted for a permanent mount, but given the circumstances and the choices of lighting that is DOT approved, I am somewhat limited to my choices. None the less the brackets will be finished tomorrow and they will look a little better than the bare metal that you see. This morning I added the gusset so the bracket wouldn't vibrate so much. I might eventually install smaller diameter headlights and will reduce the size of the brackets or make new ones. They are simple enough to do. I finally got a new welder last month and "WHAT A DIFFERENCE"..... Roger Worcester, MA |
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Post by roger32849 on Nov 12, 2013 11:20:28 GMT
link Here is how the turn indicators will look mounted with the "L" bracket behind the headlight bucket.
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Post by roger32849 on Nov 12, 2013 11:57:20 GMT
link The radiator is all mounted after the paint job. Next is the antifreeze for it and it will be a done deal.
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Post by roger32849 on Nov 12, 2013 12:03:58 GMT
link link The overflow bottle and radiator filling tube are securely mounted as well as the rear turn signal wiring. So far everything is going well with the final assembly. I am trying NOT to get caught up in the details. Everything gets looked at and wrenched and looked at and wrenched again..... So OKAY.. Maybe I am getting caught up a bit.
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Post by roger32849 on Nov 19, 2013 20:52:10 GMT
link ROLL OUT AND FIRST START UP VIDEO. (Double click on picture for video)
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Post by roger32849 on Nov 19, 2013 21:16:00 GMT
I finally got the Exo-Exo-R off the assembly table and on the floor. I did the test ride without the benefit of the right front fender in place. The hood and the tank cover were in place. I ran it afterward until the cooling fan came on. I found I had not sufficiently tightened a radiator hose and it started to drip. I tightened the clamp and problem resolved. I also have a small oil leak from the filter area. Not much I am going to do about that until I change out the oil. Dry Weight on the front tires was within a pound of each other, weighing in at 110 for the left and 111 for the right. The brakes felt a bit unresponsive but solid. I imagine it was in part due to new pads, and the rotors not being absolutely wiped dry of any lubricant. All things considered they worked good and I had to bring the pedal up about an inch and a half. I am considering ordering the aftermarket clock set. I am not to pleased with the stock unit. I will have to see though.
Anyway, the handling was light, not wobbly at all, not the least bit sensitive nor did I notice any tendency to pull left or right.... for the record, the head lights, and controls function as they should. The turn indicators including the emergency flashers all work. The horn even blows. I have a "Lucas" style tail light assembly ordered. I will see if that will work on the back as my brake, and tail light.
I started cleaning up the garage and stowing the lesser used tools. The assembly table has found a resting place in the back garden. It will be my new potting table....
Best regards to Scott in England for doing a great job on the frame and GRP pieces.... and for sending all the odd bits and pieces. Also my hat is off to Kevin at Exomotive for allowing a visit this summer. I owe a special thanks to Edward Van Belkom, without his expertise and our 3 to 4 hour phone calls, I wouldn't be at this point.
The assembly was not overly difficult, I kept it as simple as the modifications would allow. This will be a fun time this summer.
Roger
Worcester, Massachusetts
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Post by erik on Nov 20, 2013 17:01:51 GMT
Nice progress! Just an other step forward to street legal  |
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Post by edvb on Nov 21, 2013 1:29:03 GMT
You did a great job Roger. Thanks for the kind words and having a new friend along the way.
The great thing with the builds we are doing is that the frame is sound and we now have the data for any new builders that decide to put a later year engine it or like mine having a front radiator.
Most of the engineering in making it work is done so all they need is the measurements that we came up with and along they go.
Working with you and those short 3-4 hour phone call are of great joy and am always picking up something that you said in my build.
I hope you fly through the inspection as I cannot see anything in your build that we did not cover in great detail during our calls.
Best of luck
Ed
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Post by roger32849 on Nov 21, 2013 11:08:49 GMT
link When I get the wheel sensor for the speedometer I will install the gauge console and start to work on the tail light mount. Everything considered I am about finished.
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Post by roger32849 on Nov 21, 2013 11:21:48 GMT
link I had a wiring issue concerning the temperature gauge. As you can see, the gauge set is from an older Burgman and as such is completely analog, no electronics, just plain old fashioned electrics... (Good stuff). The stock wiring routes everything through the Engine Control module, but the wiring diagrams do not give a clue to which wire is connected to the temperature gauge. I rerouted the gauge wiring to bypass the Control Module and connects it straight to the sensor. The sensor still provides feedback to the control module, but also allows the gauge to read properly as well.
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Post by roger32849 on Nov 21, 2013 11:34:30 GMT
 lin I bought this Lucas Style tail light. It takes the 1157 bulb, and has a chrome housing. It is from Emgo which probably means it is from China. It isn't bad quality but it isn't as good as OEM either. I am going to restyle my back end a little and then make a decision on what to use for lighting. To be honest, the Light shown above is a bit small, but it is bright. More to come. |
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Post by roger32849 on Nov 21, 2013 12:33:34 GMT
It has been an interesting time with this build., I had a major kitchen renovation to do, floors sanded, walls painted and so on. On top of that, my daughter got married in Georgia and I took a couple of vacations to get away from it all. There is more to building an Eco-Exo than just taking parts off of a scooter and bolting them to the kit... But not that much more. Welding mounting tabs, and modifying the wiring bundle were the difficult parts. If I had an older donor scooter to start with, it wouldn't have taken from June until now to get to my current stage of completion.
There are three kits in the US that I am aware of, Jim Cox in Texas, Edward Van Belkom in Oshkosh Wisconsin, and me (Roger Baker) in Worcester Massachusetts. While we all have the same kit, all three are different. Jim Cox used part of the scooter plastics to make a custom bonnet and side rail covers... Edward van Belkom fabricated his own bonnet much on the same theme as Jim Cox and both moved the radiator to the front. I kept the basic design.. I like the way the bonnet is shaped, but might incorporate a housing made of carbon fiber or GRP to house the gauge set and also mount the windshield. It is like the old saying, "no one of us is as smart as all of us" and I learned a lot from Ed, Jim and Erik in the Netherlands. I always felt I had a friend I could ask if I had a problem. So, thanks to all the Eco-mev owners that are active on the blog.... And again, thanks Ed you blazed a lot of trails in your build and you never hesitated to offer assistance... Great wiring diagrams, engineering methods, and ergonomics in the seating area. If ANYONE needs assistance, the experience and expertise offered on this forum is extremely valuable..... From Scott Turner, Stuart Mills on down to the actual owners. Thank you EVERYONE!!!
Roger Baker
Worcester Massachusetts
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Post by roger32849 on Nov 24, 2013 20:13:41 GMT
link The purpose of this video is to demonstrate the ability to cross platform years when it comes to the Suzuki Burgman/Skyway scooter. I have a pre-2003 speedometer that I got from Scott Turner with my kit. I bought a 2006 speedometer wheel sensor and I have a 2008 wiring harness. As you will note, the wiring color codes are the same, just the plug and receptical are different. In the end, I extended the wiring harness from the wheel sensor, removed the 2006 plug from the sensor harness and installed the 2008 plug to mate with the 2008 wiring harness. Everything was completely interchangeable. When I removed the spacer from my left from wheel and installed the sensor, the axle bolt snugged up and tightened down. I am off to the parts store to buy some 1/4" wiring loom. The above is a Video, double click and it will play. Roger Worcester, Massachusetts
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