Assessment Type 1 PART A: PROPOSAL
Contents
1. Rrchased OEM den Chewihe Switch Was faulty further inspection Cevealed hro ken wines E rt of prob len EAU Sng no spark Attempt to start the moped Page 20 of 29 Research Project Clarifying Forum SACE Board of South Australia 2011 PROBLEM NO Spark had followed all steps in service manual of how to start and test components for function First attempt to start showed nothing Concern have no experience in electronics and diagnosing this problem was going to be trial and error based on other people s experience in forum GOOGLE SEARCH FOR SOLUTION TO NO SPARK Showing results for yamaha QT 50 no spark Search instead for yamata QT 50 no spark Search Results Moped Army yamaha QT50 no spark 14 Jul 2008 Just bought a 1982 QT50 No spark Replaced the plug still nothing Replaced spark coil and boot Still would not fire www mopedarmy com forums discuss 6 135744 1 35 744 LOTS of Yamaha QT50 QT60 Performance Parts JEMCO 17 Jan 2010 Help Yamaha QT50 18mph max amp Slow off the m 24 Oct 2009 1980 Yamaha QT50 25 May 2005 More results from mopedarmy com Yamaha QT50 Wikipedia the free Encyclopedia The Yamahopper is not really a scooter as the QT50 has no fairing sports footpegs ignition supplies a stronger than normal spark for initial starting en wikipedia org wiki Yamaha_QT50 Motorcycle Questions have a Yamaha QT50 cant get a spark to 172. Preparation the more effort you put in determines whether it is a quality or poor finish When rims are painted make sure they are dry use steel wool to bring out the chrome finish in the rims Research Project Clarifying Forum Page 16 of 29 SACE Board of South Australia 2011 W A a ih Wy bi A on Ne Y A K Hen i MN i i a gt i 4 The rims a and ae Followed WH s s process on this Even though they are 30 years old they look amazing restored and new Next step was restoring the throttle Was a bit rusty and tarnished didn t know anything about polishing skills used the knowledge got from doing the wheels Again WH was really helpful in giving me expert advice on this This is the process followed e Light sandpaper all over the parts e Wash with kerosene e When dry use a product called Autosol to rub down the throttle and its parts Looked up how to polish metal using Autosol on YouTube http www youtube com watch v rvY2SBlFewg The Polish Guy 2008 very helpful These are the important tips from that video e Wear Nitro gloves Squeeze a bit out of the tube and rub into surface with finger tip of your glove Can use micro fibre cloth but is more wasteful Rub the Autosol onto the surface and when complete leave for a few moments Then take a microfiber cloth and start to rub it off Then buff with a microfiber cloth used a microfiber cloth and
3. 2 0 Research Parts Needed for 1979 Yamaha QT50 2 0 1 2 0 2 2 03 2 04 Purchase service manual research specifications assess moped list parts needed Purchased Yamaha QT50 manual from eBay cost 25 will be guide to removing and rep fitting parts and components e after studying service manual and analysing my moped my first thoughts are that will need the following parts that are broken or need to be replaced o Gasket kit o Tyres by 2 sizes 225 14 o Seat cover Research Project Clarifying Forum Page 6 of 29 SACE Board of South Australia 2011 Brake light lens Research Process Yamaha sticker set book based Tubes for tyres research e g Handle bar grips studying service Ignition barrel and key set up manual Battery part no 6n4 2na observation of Brake cables moped Throttle cables Speedo cables O O O 0 0 Oe Oe oor 3 2 0 5 Therefore have made up budget to see if manageable within my budget Re chrome components 100 A Workshop consumables 500 S O Tyres tube removed fitted 8 SS Research Processes Research Parts o Online stores a parts available locally Experts e 29 4 Email to Yamaha Pitmans no luck gave me a mobile number to call b e 7 5 Called no answer tried again one month later number disconnected Consultation e Ring Scooter World none locally Suggested online eBay with local experts b Research eBay c Research web based Robert Liv
4. This is a task that will risk further damage to the wheels due to their rusted components Recommended to paint and polish the wheels Will need to have old tyres professionally removed and buy new tyres think otherwise will risk damaging the rims Research Project Clarifying Forum Page 15 of 29 SACE Board of South Australia 2011 4 0 3 WHEELS AND TYRES Things to do e Investigate legal requirements re tyre specifications for these bikes in SA Research in phone book for local motor cycle tyre shops Get tyres stripped from rims Get advice from WH re polishing techniques for chrome rims Do paint and polish of rims Legal Requirements Quote From Transport SA website Motorcycle tyres which are marked not for highway use or have a marking meaning the same must not be fitted to motorcycles used on public roads It is recommended that only tyres of the size and speed rating specified by the motorcycle manufacturer are fitted to the motorbike Tyre specifications from QT50 Service Manual e Front 225 14 Yokahama brand e Rear 225 14 PROBLEM After checking out shops in Adelaide NO tyres available in SA for my moped Very frustrating One old man with his own motorcycle business gave me a list of every contact he knows that deals in tyres no one had them due to the vintage age of the moped Will have to research on line again Was quite difficult to find but did so eventually at a reasonable cost from Tiaro Motorcy
5. 50mm Outcome Cylinder bore is OK to reuse This was a very time consuming process but worth it in the long run continued replacing all the gaskets and completed maintenance cleaning as recommended in the service manual which was a fantastic reference for this exercise When had trouble reassembling any part of the engine simply followed the step by step guide for fitment and tensioning requirements Research Project Clarifying Forum Page 11 of 29 SACE Board of South Australia 2011 Measuring the piston with the Vernier Calipers Process for Rear driveshaft Luckily there was no damage here when took it apart It was just dry dirty and required cleaning The service manual said to grease it every two years using a lithium based grease followed the diagram in the service manual to position grease for reassembly All parts of the rear driveshaft were re greased cleaned and painted Weren t any drama s here Engine was then reassembled using the Service Manual as my guide New Skills learnt during the dismantling and rebuilding of the engine How to pull apart engines How to measure engine components for proper function Importance of taking photos during disassembly Checking head for warpage using surface plate Honing cylinder bore techniques to remove wear marks Cleaning techniques for rear drive axle How to check rear drive axle for run out Applying grease to moving parts Engine maintenance Tension requi
6. Aug 2008 have a Yamaha QT50 can t get a spark to the plug have checked the plug gap 24 to 28 on a new plug no spark checked the cdi www justanswer con 1d5hc yamaha qt50 can t spark plug html Research Processes Web based research Re yamaha QT50 no spark Checking online forums Author peterg ri ri cox net Verified User peterg Date Posted 07 14 08 23 16 seem to remember something about grounding also discovered from research forums that it was likely that electrical components were missing Followed advice to check clean all connections one at a time Found one plug not connected properlyChecked the wiring diagram with the and confirmed likelihood of missing components but still not confident Join Date Mar 2010 Location Rock Island Illinois bwdbrnl Q Posts 97 Registered 1 Take E Thanked 40 Times in 32 Posts Yamaha moped electrics l ve tried other forums so l Il try this one too picked up a little 50cc Yamaha QT50 moped It s a very clean little machine and doesn t look to have been abused but can t get spark to the plug It s got a 6v system I ve put in a new battery as the old one was toast New rectifier as the original was missing completely and a new fuse and fuse holder as they were missing too used a spade type fuse and it calls for a 10amp Somewhere along the line somebody before me evidently replaced the charging coil The stator te
7. South Australia 2011 Some pieces of the moped after dismantling also shows some of the parts that needed to be repainted by a professional have decided to clean in stages as dismantle and rebuild each section 4 0 Rebuild 4 0 1 WORKING ON THE ENGINE Original state of the engine After consultation with WH about some things to particularly look out for when dismantling and rebuilding the engine e learned that would need to use a high pressure wash machine to clean and remove the oil luckily we already have one of these and have used it before e pull apart required components and inspect for damage e Measure engine tolerances e Sandblast cylinder head e Purchase new sparkplug port Research Project Clarifying Forum Page 9 of 29 SACE Board of South Australia 201 1 ETHICAL ISSUES Before dismantling the engine knew that there would be some oil to drain and dispose of looked in the Yellow Pages and found a company that will pick up waste oil free of charge as they will reuse it Mulhern Waste Company Great news They suggested putting it in a large strong plastic bucket was really pleased 18 6 10 viewed YouTube video rebuild a moped http www youtube com watch v ylt1 ricqQ1g This was helpful to me because gained knowledge about e how to inspect engine components e clean and remove gaskets e where parts could be purchased although this was in the USA it did give me some ide
8. dust will damage engine Research Project Clarifying Forum Page 10 of 29 SACE Board of South Australia 201 1 Cylinder head i i a A i As you can see the engine components of the cylinder head were rusted and had corrosion followed instructions from the Service Manual e g to remove warpage have to resurface by rubbing on 400 grit sandpaper using a figure 8 sanding pattern thought about purchasing a new cylinder head as these are really important parts but decided to persist WH was very helpful again in a short phone call He suggested that the parts be sandblasted acid cleaned sanded and polished Components were painted in Kill Rust to prevent further damage Reflection Getting great deal of knowledge about engines Did not have much experience in pulling apart an engine Worried about forgetting how to reassemble the motor so used the photographs in the service manual The engine condition was overall very clean Having never seen it work run it was a big unknown All measurements of engine parts were taken using the Vernier Calipers as the service manual suggested and they were within tolerance by the manufacturers which meant could reuse them Measurements of the piston and the cylinder bore were taken as seen below Test Results of measurement Piston Size 40 20 mm Wear Limit 40 10mm Outcome Piston is OK to reuse Test Results of measurement Cylinder bore size 40 30mm Wear Limit 40
9. many employability skills have been learned All the skills mentioned above Budgeting OHSW practices Talking to people don t know working independently Problem solving My question at the discussion was about my new idea for my Outcome found that there was a real need for detailed accurate information about all stages of the restoring and rebuilding process of the moped ideally in one location such as a website or a link on a Forum looking over individual forum entries had been helpful for me to find information needed thinking about preparing the information for a website bringing together all the things had learned about the process for others Teacher said it was a great idea BIBLIOGRAPHY bikebandit com Yamaha at Bikebandit com Accessed numerous times throughout 2010 http www bikebandit com Diospeed Demon Sept 14 2008 1983 YAMAHA QT50 MJ50 TOWNY MOPED 2 Accessed 25 4 2010 http www youtube com watch v ylti ricqQig Research Project Clarifying Forum Page 28 of 29 SACE Board of South Australia 2011 eBay Accessed numerous times throughout 2010 lt www ebay com gt Livesay R How to restore a motorcycle Accessed 3 3 2010 lt http www helium com knowledge 88371 how to restore a motorcycle gt McKay I 2009 Cheap Mopeds com Your Guide to finding Cheap Mopeds and Scooters on the Internet Accessed February 2010 lt http www cheap mopeds com gt Moped Army Forum viewed nu
10. ting varie for iter chipped from an intarnatianst ua re Other tem into eBay Buyer Protection Q eBay will cover your purchase price plus original shipping Item number 360285679039 Paes Item location pasadena ca United States Ships to Worldwide Enlarge Payments PayPal See details Share Print Report tem Description Shipping and payment Buying tips i l ETE Seller assumes all responsibility for this listing po rig inal Companen Condition Used An item that has been used previously The item may have some signs of Warranty No cosmetic wear but is fully Read more item Specifics This is an ON OFF only ignition switch and comes with factory original Yamaha key This fits on the Yamahopper QT50 model Some models have a 3 clicks including one for starting or neutral but this switch is models with just ON OFF T a s avallable SPARE HAAT ALAA AAEN EES A rr Es rem Es brand new quarene ef Lo work ase e cardan d Unable to test whether mM Werks or Not Ec a ia Ne ect to ey Seer p fern oben al Er e ohh Lost ond l ong dl el very Erme s AVI OINAS a unsure of I Detect Fit to i rag daora EN g dash assemb y ds _ Winn c wd Plua a drect wo keys Spplied ao O E X lostralra which Would meca only 2 doy E Wabia for post md ch ECD Erreak COLT e CH fa dash assem a wel Need mo gt a un rye Na x E Ce
11. with 18 to 22 gauge metal which would have needed a cutting and welding torch have never used one of those although would like to learn This cleaning really took the most time Imagine how long it would take if you were doing a car Then we had to prime the surface using even strokes to apply a urethane primer This is then sanded down to even it out using a method called blocking use a 400 grit sandpaper around a rigid block He used two coats of paint which took 90 minutes each to dry followed by three coats of paint that each took 15 minutes to dry Seems like the best 250 spent the paint job was so professional with no imperfections According to WH and the manual with Rebuilding one of main activities is test fitting the components to make sure they fit RUSTY PARTS NEEDING RE CHROMING Research in Phone book in Yellow pages Load all parts in car Visit business and obtain quotes Compare prices for quality v cost book in job pick up parts HANS ole Comparison of quotes for re chroming Windsor Electroplaters Klemzig Platers Quote 70 for front headlight surround Quote 45 for front headlight surround 90 for rear basket including polishing 45 for rear basket including polishing Wait time 3 weeks Wait time 2 weeks TOTAL 160 TOTAL 90 Winner Klemzig Platers After visiting both businesses also learned that cant chrome the wheels unless they are completely pulled apart
12. without a paint reaction trial and error NOTE will not clean the rear mudguard with kerosene consultation with experts observation web based consultation with Research Paint colour experts Google search to discover the name of the original paint colour Majolica Blue testing http www jacksscootershop com Yamaha_VIN html sourcing and comparing quotes Research observation action research The tradesperson from Pro Finish allowed me to enter his workshop and showed me through stages of preparing the frame for painting He said it would get a much better finish due to the rust eating into the metal if used a bare metal preparation This involved removing all the original paint Research Project Clarifying Forum Page 14 of 29 SACE Board of South Australia 201 1 Consumed many hours of time using different methods Learnt many new skills from taking part use sand paper e g 320 grit sandpaper or a power sander or a sandblaster clean the entire surface using a grease and wax remover Best not to use paint thinner or mineral spirits as can leave a residue Wipe surface dry with a tack cloth Also have to be careful to drag the cloth across the surface and not rub or you will get bits of the tack cloth stuck on the surface e And even though it added 250 to cost think it was worth it as can be seen in the photo below Luckily didn t have to cut away any parts that were so damaged or rusted and patch them up
13. Assessment Type 1 PART A PROPOSAL BROAD AREA OF RESEARCH How to rebuild a moped Background to choice have a real interest in mechanics and have done so since was a kid grew up taking things apart and putting them back together again Luckily we have a really large workshop at our place and a lot of tools as my father and brother are also keen on working with cars started an apprenticeship in electrical engineering but have returned to school as would really like to complete my SACE and have the option to go on to tertiary study I m not sure if want to just rebuild things as a hobby or if would like it to be my future career and own my own business or if want to go to university and study engineering there When heard about the Research Project at the end of last year got the idea of restoring a moped had been thinking about doing for a long time as wanted a cheap environmentally friendly set of wheels During the holidays after doing some research on the internet decided on the model to buy based on availability and cost Six days after putting an online advertisement got a call and was able to buy a vintage Yamaha QT50 moped for 50 PERFECT This led me to a Refined topic Rebuild a Yamaha QT50 to vintage specifications Planned research processes a Web based research e Information about different types of bikes to inform my decision on what sort to buy eBay for bike parts components onlin
14. Put a new one in and it started after three kicks It s got other issues that need to be looked into leaky case seal can t get the mixture right and it s becoming one of those man vs machine things now but it runs and that s a good thing di researchin ts Brum ft brou _ home name F or th electrical Sy SFEM ae A we totally over looked A lo mo pect WAS hat require Spt OUs ele Pi al Tm 3N ets T missing Vari one S emp down Y USIing Research Project Clarifying Forum Page 23 of 29 SACE Board of South Australia 2011 Le yO EMA DE CABLAGE mD A poe Re H Qy 7 wt MELAD MALLAS 7 7 3 WIRING DIAGRA M a cee a 2 pe AA TN A Eau en used this and a book from Dick Smith that bought called Basic Electronics and learnt how to Page 24 of 29 Research Project Clarifying Forum SACE Board of South Australia 2011 Research e read wiring diagram E e All wiring has a colour code and needs to be matched Web based e Need to have earth connected to ground Looking on e How to test for electricity YouTube for e How to diagnose a problem information to solve e Soldering wires the electrical problem Further research is required Found a YouTube where a guy was having a similar problem to me and there was a lot of helpful comments under the YouTube http www youtube com watch v NX4rRTh5fFY See below e this guy is
15. aha QT50 Honda Express e putadon local website http adelaide gumtree com au for a 1979 Yamaha QT50 e looked at ads on ebay for the ones recommended by cheap mopeds com Honda NC50 Yamaha QT50 Honda Express 1 bikes available 2 bikes available Very rare 705 parts available internationally 498 parts available internationally Limited parts available Discarded Honda Express as too expensive and rare 1 0 2 Continue to Investigate parts availability to narrow search WIKIPEDIA re the Yamaha QT50 hittp en wikipedia org wiki Yamaha_QT50 Research Project Clarifying Forum Page 5 of 29 SACE Board of South Australia 2011 1 0 3 After assessing all information Yamaha QT50 seems like the best option lis simple maintenance free shaft drive contained in the single sided swingarm eliminates chain maintenance safety and wear concerns as well as weather wear factors and contributes to the durability and ease of use of these tiny motorbikes The drive unit also incorporates a traditional centrifugal clutch but only a single speed gearing unlike most mopeds which have two speeds The simplified driveshaft setup makes wheel changes easy 1 05 Purchase transport home 26 4 10 Recvd call purchased Yamaha QT50 for 50 Body is in poor condition requiring full restoration Engine OK as the motor turns over Perfect TOPIC REFINEMENT How to rebuild a 1979 Yamaha QT50 to vintage specifications Moped purchased
16. as about the sort of places might look in Australia e reassembly modifications maintenance areas that will help in the future e g things that can go wrong over time e how to remove carbon buildup with solvents kerosene steel brushes white spirits sandpaper steel wool e spark plug cleaning with petrol this sounds a bit unsafe to me Using information from this YouTube clip and the service manual pulled apart the engine cylinder components and inspected for damage PROBLEM While dismantling the cylinder discovered an oil leak which investigated was determined source of oil leak Decided new gaskets needed so did my research online SOLUTION Discovered great site for parts www bikebandit online Ordered gasket parts PROBLEM realised there is a flat rate of US 110 for postage which was more than the parts SOLUTION Research other options for gaskets Online searching MotorcycleRecyclers com au Found a full kit for a Yamaha PW50 which looked like my engine so sent an email to ask if this was the same as the QT50 kit Parts were ordered and was very happy with the outcome Gasket kit arrived test fitted components Called WH and he told me that the important things to consider when replacing the gaskets were e check piston rings for scoring e hone cylinder bore using a hone with fine stones Hone no more than required to remove wear marks e apply kerosene and clean all components properly as metal
17. cc 2 A o 4 ee 0 Research Project Clarifying Forum Page 4 of 29 SACE Board of South Australia 2011 1 0Sourcing moped Factors in decision of which type of bike moped to buy e Price of unit don t want to spend more than 200 e Proximity needs to be close to Adelaide so can inspect pick up or delivery costs not too much e Parts need to be readily available and affordable 1 01 Internet Search of different manufacturers of bikes mopeds Research Processes e Internet search Google on mopeds e talked to people know Advice stay clear of vehicles build in China due to poor build quality with metal imperfections which lead to breakages e cheap mopeds com advised noped type as cheapest available on Ebay Suzuki FA50 Yamaha QT50 Honda Express because they are big brands See quote below DEFINITION Nopeds Are a clever combination of moped and scooter They usually have a minimal chassis design and larger wheels like a moped with a modern enclosed engine transmission that moves in unit with the rear suspension like a scooter Nopeds have no pedals so hills and acceleration can be a problem but as we re talking about cheap mopeds http www cheap mopeds com This looks like the best way to go these models and parts will fit into my budget and meet my criteria for affordability and parts availability 1 01 1Research availability and affordability of Suzuki FA50 Yam
18. cle wreckers in Qld 83 delivered Delivered the wheels to Total Motorcycles to have the old tyres removed Also ordered two new tubes as old tubes were damaged due to age THE RIMS Need to gather knowledge about how to restore my very rusty old rims to the original Will interview WH Research Processes Interview with expert Most important is preparation preparation preparation Interview with WH Re Rust removal painting and polishing techniques for wheels and rims 1 Where do you recommend to start when faced with such poor condition rims Lightly remove all heavy rust with coarse sandpaper also using wire brush Gradually change to less coarse sandpaper to remove scratches then finish with steel wool Do not concentrate on one area constantly move around rim 2 What products do need to purchase to aid with cleaning rims and dust removal Steel wool 100 grade sandpaper 800 grade sandpaper water bucket scourer wire brush thinner solvent For paint use Kill Rust spray paint as this prevents rust from coming back 3 Any tips regarding painting for a beginner Preparation is important Make sure all oils and dust has been cleaned with thinners solvent Purchase Kill Rust spray cans and shake well before use Wear a mask for breathing and lay down paper on the ground to avoid painting the ground 4 Further comments you would like to add Paint components on warm day as end result will improve with heat
19. d be helpful Research Project Clarifying Forum Page 2 of 29 SACE Board of South Australia 2011 WORK BREAKDOWN STRUCTURE Source amp rebuild vintage moped Source moped Research parts Dismantle source Rebuild Register and Ride 1 0 needed 2 0 parts 3 0 4 0 5 0 Internet search diff Purchase online manual Dismantle Take Engine Test drive make manufacturers 2 0 1 photographs of all 4 01 adjustments 1 0 1 parts 3 0 1 5 0 1 Investigate parts Research manual Parts dealers online Clean components Reg requirements availability specifications 3 0 2 4 01 1 5 0 2 1 0 2 2 0 2 Decide on type of moped Legal requirements Local Yamaha Replace damaged Inspection to buy rebuilding mopeds motorcycle dealers 4 01 2 5 0 3 1 0 3 2 0 3 3 0 3 Advertise online local Assess current state of Source painting and Resurface Pay registration newspapers 1 0 4 moped 2 0 4 polishing 3 0 4 4 01 3 5 0 4 Purchase amp transport Draw up list of parts Motor trimmers home 1 0 5 needed 3 0 5 2 0 4 Prepare budget Research tyres 2 0 5 3 0 6 Framework Hit the road 4 0 2 5 0 5 Strip 4 0 2 1 Trade Study Repaint polish Compare prices etc 4 0 2 2 3 0 7 3 0 8 Wheels tyres 4 0 3 3 0 9 Seat 4 0 4 Ignition switch wiring 4 0 5 Research Project Clarifying Forum Page 3 of 29 SACE Board of South Australia 2011 a I a E E 1 ha T p 1 a o T o PT T pat iy D mi Ei T ay ps any Ds Ti JD T ET 2 1 ia e a qe Ta k j qe pas T a Jk Ti g
20. e new cover Learnt the value of getting more than one quote This upholstery business Massoud Upholstery quoted me 50 for the refit so saved myself 40 Even though the owner instructed me on how to remove the old seat cover by removing the staples thought it was worth getting it done professionally Research Project Clarifying Forum Page 18 of 29 SACE Board of South Australia 201 1 4 0 5 IGNITION SWITCH WIRING When rebutlaina Moped Lo howe Slowlg been Pie Cin together abl ComponetS s The dash Cono le dl y Nake Mpeg Torn operate Fler esearch ont ne oe Tuna Pio Sp CS PS Was masing the lantion lt itch Ee A UE pat fo Hi me page Who we are and How to Contact Us Contact Model Identification Find Parts and Accessories CEDATE Sfiermadees Ports Eta Repitta Parts Ignition Switch Assembly Universal Enter a Bike Moder or New Lgnition Switch Assemkly Universal Part Name or Part Number Aftermarket Replacement Ignition Switch Assembly Universal A Universal two wire On Off Ignition switch Two keys supplied Advanced search Genuine amp Aftermarket Parts Yamaha Parts Honda rene Numbered tag attached Suzuki Parts y Kawasaki Parts Orange cover over key hole to protect against dust rain and make it easy to find KTM Parts the correct hole Classic Replica Parts Detail view Dimensions How to Information Pages Links to useful friends Diameter 19mm Trips White L
21. e stores for parts components YouTube advice from experts re various stages of the re build Online Forums solutions to problems that may arise Transport SA site for official legal requirements b Technical Book based studying service manual c Consultation with Experts advice on how to do some of the tasks problem diagnosis solutions d Observation painting and polishing techniques in a trade workshop e Trial and Error f Testing of parts g Interview s with expert have already asked WH vehicle restorer Ethical Issues e need to find out about safe work practices for the mechanical tasks e environmental issues observe safe practice when disposing of chemical wastes from engine cleaning agents painting e provide information about the project to people wish to work with and obtain their permission Capability have chosen work as the most relevant capability My reasons for this are that will be developing employability skills relevant to the work place e g e Time management e Responsibility e Specific mechanical skills e g painting polishing sanding measuring Research Project Clarifying Forum Page 1 of 29 SACE Board of South Australia 2011 e Working independently and with others e Learning about responsible participation in work finding out about environmental issues and OHSW practices e Problem solving also hope that by undertaking this research project will he
22. esay s website http www helium com items 507127 how to restore a motorcycle Complete motorcycle restoration almost always requires a It also requires If your budget doesn t allow for this go round your area and ask the mechanics at the larger Japanese motorcycle dealers if they know a specialist restoration mechanic in your area The nature of motorcycle restoration is that there are always surprises and usually those surprises require more time and work and not less Even though it requires a lot of time and quite a bit of money Research Project Clarifying Forum Page 7 of 29 SACE Board of South Australia 2011 Rebuilding sequence according to this short but good article 1 Dismantle 2 Clean 3 Rebuild or replace parts 4 Re chrome 5 Professional body work and painting hope to do this myself to save money Parts book Be prepared for surprises Useful article outlining areas to complete a restoration on motorcycle It suggests the need to pay particular attention to professional painting new seat cover and engine overhaul Also how important it is to have a manual Luckily had already thought of that from previous experiences Studying the manual to carefully dismantle the moped Note wearing safety glasses covered in shoes and well covered clothes Service manual suggested this was necessary Research Project Clarifying Forum Page 8 of 29 SACE Board of
23. experimentation research processes Have learned and have followed practices recommended by WH the expert vehicle restorer to wear covered shoes long sleeved trousers shirts safety glasses gloves with some coverings 2 This research has also meant take care of my safety while undertaking this practical research Are the research processes producing the information required to investigate the research topic Yes Yamaha QT50 service manual this is absolutely essential Don t know what would do without it Has such detailed drawings and step by step instructions normally for a mechanic servicing a moped but they are gold me even though don t have all the technical knowledge of a specialist bike mechanic WH was really helpful with information on techniques and skills for restoring even though he is a motor vehicle restorer and has never done a moped His knowledge is able to be applied to my research on mopeds Online research processes have on the whole been the most successful processes have used to locate the information needed e YouTube and Online Forums really helpful particularly as there doesn t seem to be any books published about mopeds so have to rely on experts Some of them ordinary people like me who just have a bit of a hobby and enthusiasts But it is amazing how other people have had similar problems to me like the fuel problem and just like me they have worked out a solution by trail and err
24. fic to this topic that have developed either through observation advice from experts realtime or online trial and error studying the service manual e Disassembling an engine Measuring engine components for proper function using Vernier Clips Honing the cylinder bore to remove wear marks using a hone with fine stones Checking head for warpage using surface plate Cleaning techniques for rear axle drive Applying grease to moving parts Tension requirements of engine parts Polishing metal components Preparation of metal for painting Soldering wires How to test for electricity What challenges have you faced and how have you overcome them lack of local expert knowledge or availability of parts on vintage Yamaha mopeds in Adelaide early research really good model to buy because parts would be available locally every step along the way were no parts available locally in Adelaide had to show lot more initiative look for alternative sources through research Thank God for the internet found a number of overseas and Australian sites who had the parts needed usually in vintage specifications Everything has in fact been purchased interstate or internationally couldn t even get a globe for the moped as the one required is an old style that is no longer used having to my topic to just rebuild it not necessarily to vintage specifications What are your thoughts about your chosen capability work Still most relevant so
25. ine Fever Length from base to binnacle 45mm N Motorcycle Calculator Tool Total length 50mm Shopping basket k No mount plate supplied but alty plate is good requires 20mm hole Your shopping basket is empty Lock nut with zinc lock washer to keep it ati together Lock nut 21mm Sign in ae xs Wires are 120mm long to top of plastic lock housing Some bikes may need to have alternate fittings attached P f K assword X SA Sii Signin O Forgot your password t Register Two mate pin connectors in a plastic tock housing O B Product is in stock Delivery period 3 day s 3 Shop miri PayPal AUS 5S 47 wring ot Dash control assembly MUSSA q anidan con ry re mA ES Page 19 of 29 Research Project Clarifying Forum g SACE Board of South Australia 2011 a ee gs E ON E e Cars amp Trucks Parts amp Accessories Motorcycles Powersports Beats Other Vehictes e Back to My eBay f Listed in category eBay Motors gt Parts amp Accessories Other Vehicle Parts gt Scooter Parts You bought this item View order details Yamaha QT50 Yamahopper Key Ignition Switch QT 50 Sellerinfo ltem condition Used papamikesbikes 11073 27 100 Positive feedback Sold For US 59 00 Ask a question Save this seller See other lems Retums 7 day money back Read details El Visit store Papa Mike s Bikes Shipping 9 55 USPS First Class Mail Internationa i See all datatis a Costes debvery
26. it worked really well as didn t have Nitro gloves The throttle came up like new Even though it was time consuming it worked well The only other option could have used was to pay a professional But this would have been too expensive and as it was learnt more new skills and gained knowledge didn t have before PROBLEM MORE BROKEN PARTS as rebuilding the front hub parts realized that more ports were broken e g Speedo gear Speedo cable rusted seized front brake cable Frustrating as many damaged components were overlooked at the beginning but when focusing on rebuilding a particular area this becomes apparent Then need to investigate parts online to solve the latest issue Research on eBay for these cables Tail light lens replacement purchased on eBay Research Project Clarifying Forum Page 17 of 29 SACE Board of South Australia 201 1 4 0 4 SEAT RESTORATION Photograph of my seat Needed to find a seat cover and a motor trimmer to fit it Purchased a replica seat on eBay 1 3 the price of an original Still need to find someone to refit it Google search for Motor Trimmers turned up 7 businesses telephoned the first three Only one who was able to do the work quoted 90 minimum Decided to visit one of the businesses close to home only to find out that business had moved As was leaving the industrial area noticed a furniture upholstery business and decided to drop in and see if they would refit th
27. lendar Events Today s Posts AE Ne Join Date Mar 2010 a bwdbrnl e Someone exa l l a j Location Rock Island Illinois Registered II A i Thanks 4 Si ni lo P O em e Thanked 19 Times in 16 Posts pamana onthe forum with s Posts 56 Yamaha moped electrics I ve tried other forums so I ll try this one too I picked up a little 50cc Yamaha QT50 moped It s a very clean little machine and doesn t look to have been abused but I can t get spark to the plug It s got a 6v system I ve put in a new battery as the old one was toast New rectifier as the original was missing completely and a new fuse and fuse holder as they were missing too I used a spade type fuse and it calls for a 10amp Somewhere along the line somebody before me evidently replaced the charging coil The stator tested O K on a multimeter on the bench but the ignition coil tested bad Installed a new ignition coil but I m still not getting spark I can let the coil dangle from the input lead and I get a flash on a circuit tester out at the plug end but not with a spark plug and as soon as I attach the coil to the bike I don t get anything So question is where do I begin to start checking now 09 12 2010 06 56 AM 6 Join Date Mar 2010 e Location Rock Isiand Illinois bwdbrni Se Posts 56 Registered 11 Thanks 1 Thanked 19 Times in 16 Posts y Re Yamaha moped electrics Turned out to be the charging coil
28. list of parts that need repainting and re chroming frame plastic components foot rests headlight surround number plate bracket rims rear basket front basket engine components cylinder head engine side covers rear drive shaft and hub set up Research Processes observation and analysis of information Some of the parts and components that need repainting and re chroming PROBLEM think the moped s paint condition is too damaged for me to do a good job It s rusty faded flaking off in places Needs an expert to do job or will look very amateurish Advice from WH put me on to another professional Pro Finish custom painting Contacted Pro Finish Got quote 250 Will compare with another quote Contacted tradesperson knew from school visited workshop his quote came in at 700 This person insisted the components had to be dipped in acid first to prevent rust which made it more expensive probably worth it but just too pricey for me Another painting problem mudguards and brackets Plastic was sun damaged and metal rusted cleaned this was kerosene as the YouTube clip said but after first coat of paint some sort of reaction had occurred Consulted WH explained Due to cleaning with kerosene the paint reacted to the oil in the kerosene base product Suggested to re sand mudguard clean with thinners and repaint Research Processes Followed this advice and it worked
29. lp me make up my mind about my future career e g setting up my own business specialising in restoring vintage bikes or whether should try to go on to University Research Outcome A restored moped and a written report explaining how the research drove the decisions to restore it in the way did Part B Research Development 1 0 Sourcing Vehicle this was completed in the holidays am interested in rebuilding some sort of bike moped but don t want to have to get a special drivers licence Task Investigate Legal requirements for riding a moped e g licence at TransportSA website Here is what they said Riding a moped The holder of any class of South Australian driver s licence can ride a moped as long as the moped is registered insured and compliant with Australian design rules The holder of a learner s permit cannot ride a moped unless the permit is for R DATE or R class What is a moped A moped is defined as a two or three wheeled motor vehicle other than a power assisted bicycle that is propelled by an internal combustion engine with a capacity not exceeding 50 millilitres or a motor other than an internal combustion engine and is capable of a speed not exceeding 50 kilometres per hour http www sa gov au subject Transport travel and motoring Motoring Motorcycling Motorcycles Ridi ng a moped THIS IS PERFECT FOR ME Task Will brainstorm all aspects of my topic Work Breakdown Structure woul
30. merous times throughout 2010 lt http mopedarmy com gt SA Govt Motor cycle legal requirements Accessed Jan 2010 and June 2010 lt http www sa gov au subject Transport travel and motoring Motoring Motorcycling Motorcycles Ridin g a moped gt Smith Dick 1998 Electronic Basics Smokstak 2009 Forum Accessed numerous times throughout 2010 lt http www smokstak com forum showthread php t 79909 gt Taro Motor Cycle Wreckers New Old Stock Genuine New Yamaha Parts Accessed 2 6 10 lt http www tiaromotorcyclewreckers com Nos 20Yamaha htm gt Radical Harmony July13 2009 QT50 Starting issues Accessed June 2010 lt http www youtube com watch v NX4rRTh5tFY gt Yamaha 1979 Yamaha QT50 Service Repair Manual Yamaha Corporation Japan Yuba Community College District Codes of Practices for Mechanics http www yccd edu Mechanics paf provides detailed advice on safe practices for mechanics even though American based Research Project Clarifying Forum Page 29 of 29 SACE Board of South Australia 2011
31. or e eBay research for parts Trial and error e g used kerosene to clean the sun damage and rust off the paint of mudguard brackets After the first coat of paint reaction occurred Expert Phil Hoffman said the oil in the oil based kerosene reacted with paint so told me to re sand it clean with thinners and repaint Did this and worked and followed this process with the other mudguard and worked well Research Project Clarifying Forum Page 27 of 29 SACE Board of South Australia 2011 What important ideas and findings emerging from the research so far and how they have developed directly or indirectly from the research processes Necessity for a manual when rebuilding a moped from Robert Livesay s website What skills and knowledge specific to your topic have you been developing Which of these are new and which already existed had some skills from apprenticeship e g skills in precision work in putting metal parts together checking the accuracy of finished parts was comfortable with machinery but these had not been applied before in the area of motor vehicle engines particularly moped engines Many of the other skills already had were not relevant e g using the designing tools such as CAD and CNC machines robotics Probably already had problem solving skills that have needed and developed further in this research project Didn t have any knowledge or skills about moped or motor vehicle engines Skills speci
32. rements for reassembly ENGINE IS COMPLETED It looks fantastic Research Project Clarifying Forum SACE Board of South Australia 2011 Skills and Knowledge gained and applied Page 12 of 29 Response to Challenge change of direction originally set out to rebuild moped using original components Due to research findings project is becoming too expensive E g genuine scooter seat cover 64 US whereas replica called an aftermarket copy is 24 90 Is a pity feel really let down but don t think the average person would know the difference Have decided will only buy the original if no other option e g no other parts available REFINEMENT OF TOPIC Rebuild a Yamaha QT50 only using genuine parts if no other parts are available 4 0 2 FRAMEWORK To do list completely strip all components load parts into car that require painting ring pro finish custom painting and organize time for quotation polish forks and handle bars order Yamaha emblems When pulling apart moped framework some parts were rusted and seized together 1 Had phone conversation with W H advised an anti seize lubricant which releases rusted threads used this and was able to loosen and remove the rust so that could dismantle this part of the bodywork without damaging it Research Project Clarifying Forum Page 13 of 29 SACE Board of South Australia 2011 After dismantling this part of the moped here is the
33. right 1 have owned a couple of those exact mopeds and the problem with mine was the fuel filter was clogged cjmotorsified 11 months ago galactophore 1 year ago Followed advice from this realized one area had overlooked while rebuilding was the fuel tank It was full of rust dirt and was blocking the fuel filter Cleaned the filter and moped runs properly 5 0 Register and Ride 5 0 1 TEST DRIVE It s alive throughout the test ride the moped felt good Engine operated smoothly without a misfire got a lot of attention from pedestrians and motorists After test ride performed a full soanner check as per tension requirements in service manual 5 0 2 REGISTRATION Phone call to Transport SA re how to get it registered e Discovered that needed previous owner s name e Research to solve this problem Looking at photos on a Yamaha QT50 webpage came across photos of able to contact him and got necessary details Got it registered Fully able to ride it legally What a rush NEW IDEA for Research Outcome All through the project it has been very time consuming to get information have come up with the idea for my outcome to be a Google Site It will have a main page of advice for people who want to restore a moped Then will put all the photos and specific details from this folio into other pages that can be accessed from the main page This would have been really helpful to me and hopefully will be great for others Re
34. search Project Clarifying Forum Page 25 of 29 SACE Board of South Australia 2011 Research Project Clarifying Forum Page 26 of 29 SACE Board of South Australia 2011 ASSESSMENT TYPE 1 The Folio PART C The Discussion The formal discussion took place near the end of the research project We were given a list of questions and prepared some answers After the discussion added some reflections on what said and the feedback got in the discussion How have you refined your research topic if at all lt was pretty specific to start with e g rebuilding a Yamaha QT50 to vintage specifications The demands of cost and time have meant that have had to refine this just to rebuilding a Yamaha QT50 Reflection In a way this topic is more general and less specific than it was to start with but it is just necessary How effective and manageable are the research processes that you originally planned 1 Work Breakdown Structure and Gantt chart incredibly detailed and covered everything could think of at the time 2 The sequence and the time allocation turned out differently 3 found that some things took longer than others and that actually often had a number of processes on the go at the same time while was waiting for parts to arrive or while was waiting for the parts to be painted needed to be going on with something else so started another part of the rebuilding If hadn t done this then would be way behind
35. sted O K on a multimeter on the bench but the ignition coil tested bad Installed a new ignition Research Project Clarifying Forum Page 21 of 29 SACE Board of South Australia 2011 coil but I m still not getting spark can let the coil dangle from the input lead and get a flash on a circuit tester out at the plug end but not with a spark plug and as soon as attach the coil to the bike don t get anything So question is where do begin to start checking now Join Date Mar 2010 Location Rock Island Illinois Posts 97 Thanks 5 Thanked 40 Times in 32 Posts bwdbrn1 Y Registered Re Yamaha moped electrics Turned out to be the charging coil Put a new one in and it started after three kicks It s got other issues that need to be looked into leaky case seal can t get the mixture right and it s becoming one of those man vs machine things now but it runs and that s a good thing http www smokstak com forum showthread php t 79909 Learnt new skills ability to make up two wires and joining them together result complete electrical circuit that created spark Research Project Clarifying Forum Page 22 of 29 SACE Board of South Australia 2011 Home HELP Forums Articles Photo Gallery fence ts i aa q ae sa Links Books Sponsors User Name User Name Remember Me g Password Log in i Yamaha moped electrics Forgot Password Jain Us Register Gallery EAN Ca
36. t gt gt gt cl mi AR E E AO O AO ARI IIS IE IE II IL IR Je MIES it 1 soolsourcemopes Y So S o H lt pH tt Hp pp Internal search manufacturers Investigate parts availability 10S Decide on typemodel 1 OM Advertise for moped Purchasedranspod home aodlresarenparsnectea TT CT CT O O IO IO E IO O O IO A Research Specifications a E Oo E OO J J E Assess mopadlist parts needed US O ie o i o IO M o T tT M D5iPrepare budget Pm i o T J ia ef I Ao M Dismantlefsource parts MAA E J T E pp J BO Tr E Cismantle photograph sections O El O E o o E Pats dealers online T E E E O E ah a ah Parts dealers Local Yamaha a oe Source painting palishing Source motor timmers si en TRA S Y pop E sehen E jo ft 5 AS OS O IO E IU III IS IO O IS O O O OS O O OS OS O O OS OS T gees _ a A A AAA ee AAA AA AAA cciesrcenponants A do YY A o Emm ERE akee ff Ay E premem OS T T E S S OO O O O ES a S s S ee epe II o ME Eee ee 022 Jrepamrapots QA eee A _ om MEM sose YY po Mo Mo PB BM ee O ee eee ee 2 UR gsr aon Hoquiremernts Roadworthiness Inspector alPay registration MV PU A O O O IS O O NS O O IS SS too pt A 10 S S A S l OH el peo e A 0 Ap 0 4 Atl
37. time 4 had originally planned to repaint the bodywork myself After a bit of research into the process of doing this to the professional standards was hoping to achieve through consulting an expert on body work and reading this up on Forums and a bit of experimentation realized that couldn t do it to the standard wanted so then had to do more research like a trade study to get quotes from paint places to do it for me So that meant didn t get to personally undertake that research process of implementing the techniques l d found out about Even thought it ate into my budget it was worth it in the end 5 Also while it was dismantling moped realized that there were some things would have to do that had not planned for originally didn t realize for example that the rust would be so severe it was too difficult to get the parts apart without damaging them so had to research how to do this 6 Also sometimes discovered that more parts needed repairing than had planned such as when was rebuilding the front hub realized that there was a broken Speedo gear broken Speedo cable and rusted seized front brake and cable SO needed to purchase those parts 7 didn t anticipate everything in my original plan or all the research processes How are you showing consideration of safe and ethical research processes 1 have learned a lot mostly about OHSW and safe work practices when doing trial and error observation and
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