Running video

 Small video of it running, lights etc

The fuel gauge itself does work when I short the fuel sender plug, but not when plugged into the sender, I will look into this post MOT..he states confidently...

New ignition barrel

 I had ordered a new aftermarket ignition barrel and 2 keys..as I never had any keys when my mate gave me the scooter.

It was a different length so not a straight fit..Hopefully the pics explain the process to swap the pins over to the original barrel with a bit of dremel skimming to a working lock..

I now have a proper ignition switch 

Petrol tank cleaning

 Like the carburetor, the petrol tank had a layer of brown rust\sediment that i could seen - i did not take a pic - but as a reminder the carb is pictured below:

I have filled the tank with caustic soda (100g) and cold water - will check over 48 hours on the results.

A few minor jobs left - and hopefully booked for a MOT before Sept end.

24 hours later..

Will leave for another 24 hours..these were the deposit removals..

 

Rear wheel

 That will do for me..

Hub and wheel

 Cleaned up the wheel and loosely assembled back on..looking better..

Hoping to do the same to the rear soon 

Front wheel disassembled..

 Finally got the front wheel apart - was contemplating getting it shot blasted etc - but decided this project should be home brewed as mush as possible..

Its a given the tyres should be replaced due to age etc, guess that will be true of the inner tube as well.

It lives!!

 After playing with the air screw and idle screw..relatively smooth idle

Carburetor diagnostic

I managed to get the scooter running by pouring some petrol directly into the carb only.

So I suspect petrol from the tank was not being drawn into the bowl..

Bit mucky in there...quick carb clean and wooden toothpick.

The main fuel tube was blocked..so using some welding wire and carb cleaner finally allowed fuel through.

With the carb back on the engine I managed to get fuel drawn into the bowl from a makeshift tank..The vacuum drawn fuel meant all was well...but the engine was not smooth ,often idle falling ,rising and stalling. It seemed to prefer running with full choke..so base settings will be researched for the carb once I have identified it..

The carb has the following ID on it

M72 PDOC

I found this on the net for PD carbs - but i suspect mine was built by Bajaj under license??

PD carb

The  main jet is #108

The slow jet is #42

Front end - fitting is reversal of removal...

 The lower bearing carrier cleaned up and placed back on  the painted front hub arm, i wanted to remove the suspension swing arm bearings - but could not make them budge, so i inspected the bearings and replaced the two outer seals (pics later)

The front brake cable and speedometer cables were fed through the steering column without too much effort..

 

bit more done...

 

 more progress..at a leisurely pace..

Got the front swing arm installed 

 Getting there...

  Getting this back on the road - having stood unloved for many years

The teardown has begun - front first, i finally got to the front spindle - first obstacle is to remove the two bearing carriers ..i think i will pass this job to the local garage - as i will just use a big hammer!

i have disassembled to just the leg - shock absorber, mount , speed and brake cables all removed

Front hub