Custom Clutch Spring

Actually this has to be written about 5 month ago. But sadly at that time I don't have much time to spare.

The story begin when I change my scooter clutch with the brand new one. Bought a set of clutch and the clutch bell (clutch house or whatever it call). I must change the clutch because the old one had damaged when I tried to climb up a bridge. The bridge is not high, but I had to stop my scooter on the foot of the bridge because the traffic is stuck; my scooter incline position is about 35 degree with full of bagage and tandem with my wife. When the car in front of me is moving, I tried to open the throttle, but its to heavy for my scooter, and I open it a little wide; my scooter is moving and pass the bridge.

But there is something wrong after it, there is a vibration when it come on a stop and go traffic. Oh no, I think the clutch is burning. The vibration getting worse and worse, and I have to get used to it after the parts that I ordered is ready stock.

After the clutch is ready, I switch the old clutch with the brand new. Nah, it's done. Clean up the tools, and take some break.

Now, time to test the new clutch performance. I know that the new one is a stock, so I don't expect any increase on the performance. Turn on my scooter engine, and run it on the street.

First impression is, the brand new clutch is very poor on the performance. it need very high RPM to start the scooter to engage. This is very bad for the fuel consumption. But let us make an exception for this because it is a brand new clutch and it must be the clutch shoes didn't sit properly on the inner clutch bell. Let's test it for a two week, if there is no change on the performance, then I would do something about it.

1st week is very bad, fuel consumption become doubled than regular. I hate it so much, the scooter performance is very poor indeed. It take lot of time for my scooter to engage, the exact RPM is about 4800. And on the 60kmh, it need 8000RPM; regular is 6000RPM. Hope next week will be better.

2nd week is good, but not good enough. still my scooter engage in a high RPM about 4500. Usually my scooter engage on 4000 RPM.

I can't wait any longer, I must do something to make it good or better than before.

I think the brand new clutch had a problem on the friction point that make the clutch can not stick tightly on the clutch bell. So how come can I fix this problem. I think the best way to solve this is to change the clutch spring with the softer one.

I need a softer spring than the one on the after market. The solution is, I must make a custom clutch spring.

I search on the market any spring that softer than the stock and it must be steel not iron, and the length quite similar. Got it! Time to change the clutch spring with this one.

Prepare some tools:
1. 8mm socket
2. 17mm socket
3. Clutch special tool
4. Big sized minus (-) screw driver

- Open the CVT cover with 8mm socket and remove it.
- Open the front pulley with a special tools and 17mm socket, or if you has an impact wrench then open with it.
- Remove the front pulley.
- Open the clutch bell with a special tools and 17mm socket and remove it.
- Pull the clutch from the engine.


As you can see the clutch isn't touched the bell inner surfaces properly, about 60%, signed with the black surface on the shoe.

- Remove the clutch from the sheave with clutch special tool opener.
- After that, we must remove the three pieces steel ring with a big sized minus screw driver and remove the plate.






- Separate the clutch shoe from where it sit with the screw driver


- Now you can see the clutch clearly and remove it


This is the stock clutch spring:


This is the stock and the custom spring:

- Plug the custom spring on the clutch shoe, and stick everything together backward.

Done with that, lets test it right away.

Turn on the engine until it hot enough, and open the throttle while I see the RPM meter closely. I feel the scooter is engage, and you know what; the scooter engage on the 3500 RPM.

Scooter Auto Detailing

Saturday, October 10, 2008, I decided to migrating from my old wax into the new one. And I want it to move not only the wax, but something beyond from it. It is auto detailing; I choose Meguiar's.

I prepare my scooter and go to the Meguiar's shop and buy three of their product:
- Smooth Surface® Clay Kit
- NXT Generation® Tech Wax™ Paste
- Supreme Shine® Microfibre Towel

I know that three of these product is not enough if I really want to concentrate on auto detailing for my scooter. The answer is money. My spend money is only enough for three of these product, and based on my knowledge this is enough for the basic auto detailing.

Clay is useful to remove the contaminants that wash process can not clean it. The inside clay package is:
- 16oz Quik Detailer
- 2 clay bars
- Supreme Shine® Microfibre Towel
- 4oz Cleaner Wax

I don't use the Cleaner Wax, because I already buy NXT Tech Wax 2.0

Now let's prepare the scooter first with wash. After that, I open the clay bar and flatten it on my palm. I spray small amount of the Quik Detailer onto the clay, and I spray it either to the paint surface. I buff the paint surface with the clay, after that I clean it with the Microfibre Towel included in the package.

Done with that, now it is time to move on to the wax to protect the paint system of my scooter.

NXT Tech Wax™ Paste package contains:
- Wax Paste
- Application Pad

Hold the pad on my palm and touch the wax. Buff lightly onto the paint surface.

Wait until it dry and use the Supreme Shine™ Microfibre Towel to remove the residue. Almost forgot, the Supreme Shine™ Microfibre Towel contains three pieces of towel. With this towel, cleaning the wax residue become more easier and faster. I note the previous differences with my past wax is, this NXT doesn't leaves a white residue if it touch the plastic parts.

Here is the result:

Front:

Rear:

Bottom Plastic:


As you can see, the result is amazing, especially on the black paint; the result is like a mirror. You can see the reflection on the black paint clearly.

Now I must spend more money if I want more deep gloss and darker result.

Go Green with Asbestos Free

After a long search, I found such a good product to replace my brake pad. Asbestos free made from a carbon, make this pad very special. It claims that this pad is work great on a wet and dry condition, and stands the heat better than the stock. And something that makes me so curious about this pad is; it cost far lower than the stock, about half the price.

Let us prepare the tools needed to plug the pad into the braking system.

1. Big sized minus (-) screwdriver
2. 12mm socket
3. 5mm hex socket

Remove the two bolts that stick the caliper onto the shock absorber with 12mm socket.

Now remove the two bolts that hold the pad with 5mm hex.

After that, remove the pad. Now I tried to clean the pad and compare with the carbon pad. This is the original pad:

This is the carbon pad:

And this is the surface of both pad:

Left one is the stock and the right one is the carbon pad. As you can see the quality of the carbon pad is good enough.

The distributor offer a replacement if the pad washed-up before six month or 15,000km. And he claims that this pad is not abrasive.

After everything is setup, on later day I try it performance. Oh no, I can stop my scooter properly, my scooter can not stop! What happen, did this pad is bad or what? I check my disc brake, and I saw something weird. The pad isn’t full contacting with the disc; signed with a dark Grey mark on the disc surface.

OK, lets wait a couple of day and see it performance, is it going better or not. After a week, my braking system is improving, but it still lacks of braking power, I need more. I check again the disc surface, now I’m so amaze that this pad still isn’t full contacting!

I should wait a little longer and be patient with the road condition.

After a long wait (almost 3 weeks), the pad indicate its true performance. The braking system is good enough, better than the stock. I can use late braking without worries. And it’s true that after using 5 month, the disc is still in good shape and smooth condition. But the side effect of this pad is, it make the disc become a dark Grey not shiny.

Hybrid System

After successful migrating into full DC system, theres is something wrong with my scooter. The battery loosing its power slowly! I must do something quick to make the battery work like before.

I tried to count electricity consume by the lighting system.
6 bulb 3.4W
1 bulb 12W/12W (brake lamp)
2 bulb 18W/18W (head lamp)
The total when it on is 80.4W = 80.4W / 12V = 6.7Ampere

Ups, this is to much for the battery, I must migrating some of it back into AC system. The Head light is the biggest battery consume, so I must migrating it as soon as possible. But only the head light not the other, because the brake lamp and the rest is sharing one switch.

Cut on there and plug in here, etc. Finished with that, I turn the key on and switch on the light. First is the twilight lamp. Yes, it turn on without the engine have to turn on, and now the head lamp. Move the switch slider again, to make the head lamp turn on, but it won’t turn on. Now I turn the engine on, and yeah, the head lamp is on.

Horay… the hybrid system is worked…!!!

This is the result, after I’m using 6 luxeon on my scooter:

And this is the speed indicator:

Testing Pulsar 180 Dts-i

I don’t know exactly when I tested this motorcycle, may be at end year 2007; quite long indeed. This motorcycle is owned by my brother. He pick this motorcycle because this is the best motorcycle based on his criteria.
1. Fuel economic about 1:50
2. Low engine vibration compared to local Japanese brand in this country
3. Best value for his money compared to the others brand that has lower capacity engine.

Based on those criteria, he was chose this motorcycle (the back one)..

Ok, I don’t want to discuss much further about this. Let me test this motorcycle performance.

1. Handling, Steering and Stability
Pulsar 180 Dts-i handling is very good, its stability and accurate handling is just the answer if you like a touring bike. If we look on the wheel based then you will know that this bike is design for stability not for a fast cornering. But with a right handling skill, it shouldn’t be any problem.
The thank is big enough (15L), but the design is not good. It should be bigger near my leg, so my leg is more comfort.
Front shock absorber is soft and the rear too soft, I should adjust it based on my criteria.

I test it on a medium ‘till high RPM on the cornering; the bike is very good, I can push the bike until I touch the curb and get out as fast as I can. But there is something that bugs me; the tire grip isn’t good enough on cornering. I should be more careful on this tire performance.

2. Riding Position
Riding position on Pulsar is like a semi sport touring bike with a medium steering (not too low and not too high). Pulsar is offer enjoy of city ride. I can not sit on the seat a little backward, because it’s not comfort on there, I should sit forward near the thank. That’s the most comfort riding position.
The seat foam is thin, I can not sit a little bit longer with it.

3. Torque and Power
Turn the engine on, and I’m ready to roll. Shifting to gear one and open the throttle. Engine power distributing to the rear wheel is very smooth, and I think this 180cc engine torque shouldn’t be like this, it should serving me with more torque on first acceleration.
I almost forget, shifting to the gear one from the second gear is a little bit difficult if I compared to the other gear.
Open the throttle minimum 5000 RPM on every gear giving me the right power on the track. Fortunately I can only go about 60kmh; the track isn’t support for a top speed. But I’m pretty satisfied with the engine test result

4. Braking System
Front and rear braking system is good; I don’t need more effort to stop this motorcycle while I’m on fast mode. The bike stop just as I want.

That is my test result on Pulsar 180. I know this is quite late, because I’m kinda busy to start writing these days.

Oh, the pulsar engine vibration is increased on medium RPM, it seem that Bajaj should fix this a soon as possible because it disturbing me. I always using medium until high RPM, and I can feel it on the seat. But I think the vibration is not as high as Japanese brand.

Rubber steering is hurting my palm, the rubber design is like a 0.5mm needle on its surfaces; should wearing my glove.

Luxeon

Saturday, July 19, 2008, at 10:35AM, I start to migrating my scooter lighting system from AC system into DC system. Because Luxeon need a DC System from 10V-15V. If this is not fulfill, then the Luxeon will damage in a short term.

It takes about 1 hour to migrating the whole system. Checking the cabling with Ohm Meter to figure out which one is the DC. After I found the cable, I attach the cable that connect to the lighting system onto the DC socket cable.

Finished with that, I turn on my scooter without ignited the engine and move the light switch on. Horay, my scooter had successfuly migrating to the DC system.

This is the picture of my scooter after migrating to the DC system taken at 04.00PM


At 04:05PM, I loosen the screw that hold the mica and remove it. Now I can see the bulb. The original bulb was 3.4W triple, so the total is 3.4W * 3 = 10.2W

I only have 2 pieces Luxeon @1W. Now the total is (1W * 2) + 3.4W = 5.4W

As you can see, I can save 4.8 Wattage if I use this Luxeon. And if all of the lamp is Luxeon, I can save 7.2W. This will help the battery from light consuming.

Here is the picture after I change the light with Luxeon taken at 05:30PM


Next project is, I want to change the last bulb and the speed indicator bulb with Luxeon. My speed indicator uses 2 bulb 3.4W too, if I change whole of it, the total Wattage before migrating to Luxeon is 3.4W * 5 = 17W. And after migrating to Luxeon is 1W * 5 = 5W ONLY!!!

I can save 12W!

1W Luxeon produce about 120 lumens, the minimum standard for headlight is 900 lumens. So if I want to use this Luxeon for my headlight, I need 900/120 = 7.2 pieces.

8000km with Amsoil and Migrating to AMO

Wednesday, March 18, 2008, Amsoil MCF 10W-40 has reached 8000 kilometer. It's time to drainage the oil and change it with the new one.

8000 kilometer for Amsoil it seem ok, I don't sense any minor failure about this oil. Run very great for my scooter.

1. Engine Noise
The engine noise is still low as before.

2. Engine vibration
This what I like about this oil, the engine vibration almost reduced if I using this oil. And 8000km is no problemo at all. Good bye vibration.

3. Power and Torque
The power and torque had been drop on 7000km, but that is not Amsoil failure. That is my fault, cleaning the air filter with the wrong way. But amsoil can make the whole system work great even when the air is not flown with the correct way. 7000-8000km the power and torque isn't change at all.

Let's change the oil. Prepare 17" rachet, tray and beaker.

First put the tray below the scooter and open the oil drainage nut with 17" rachet. Drain the oil until the last drop.


I touch the oil with my finger and feel it. This oil is still slick. I think this oil can go further, may be about 10,000 kilometer, don't know for sure.

Next is I put two drop of oil on a plastic and see the oil, if it still clean or dark or none of those.

As you can see, the oil is very dark color. I tried to flatten it again and see if there is still gold color. Yes, there is.

That convince me that this oil is great for my engine. I recommend it for anyone who would like to try this oil.


Pour the Amsoil AMO 10W-40 into the beaker about 800mL. And fill it into the engine after tighten the drainage nut. Finished; check the dip stick gauge if it correct.

Job done. Time to test this oil performance.

I turn on my engine and warm it until the RPM steady about 1700RPM. Open the garage and run my scooter to the office.

On a heavy traffic there is no difference on the torque and power, so the engine vibration. On a light traffic, I open the throttle wide, and fell it. Nope, nothing change at all. But wait when my scooter speed reached 80kmh, the engine vibration is differ than before. The engine vibration is getting down and down. Even when I force my scooter until 100kmh, still the engine vibration is low than the old one.

I think the second Amsoil change work better than before, because the first one, is still contaminated with the old one.

Now my engine lubrication, pure with Amsoil. And it work very great. Thank you Amsoil.

Pirelli SL 26

Wednesday, February 20, 2008, I change my scooter tire with a pair of Pirelli SL26 100/80-10 53J TL and 110/80-10 58J TL

According to the official website, it say that this tire give a good wet performance. But when I look at it, it has only a small amount of grooves. How can it give a good wet performance? Don't know for sure. I should test it to prove it.

As you can see on the left picture it turn backward for the front tire. You are wonder right, why it turn on the opposite?

The answer is, it help on the handling and helping you out from the mud if you cross on it. Its not digging the mud, instead floating onto the mud. Weirdo isn't it? But thats the fact! If you go to the farmer that has a tractor, you will see that the front tire is opposite from the rear. Tractor use that combination to help them get out from the mud.

Let see this tire rotation direction:

Pirelli recommend for the front tire is opposite from the rear. Obviously Pirelli support tire installation this way.


After I put the tire into the rim, I inflated it with a Nitrogen (sign with the green nipple cap) 25psi on the front and 33psi on the rear. After that, I plug it into my scooter.

This is some picture of it after I install it.

This is the ground clearance on the rear when swith the stand. Almost same as the old one. The old stock use 100/90-10 on both of the tires, about 1.5cm to the ground.

Lets test this tire performance.

I turn on my scooter run it. Who ho, the handling is so light. Far more light than the old stock, seems like it flying. Almost forgot, the old stock id heavier than this one, I don't know for sure how much gram the differences. But I sense something weird about the handling, sometime I can not control it. What happen? I park my scooter and check it.

Can you see this, it has a rubber on the middle of the tire. I should do a break in period for the new tires about first 50-100km. That will increase the lean angle until the mold release compound is worn off the tread. And I should avoid sudden brake or panic stops. After the break in period, the tire should be free from any shine.

At 5.00pm, I try my scooter again to break in the tire. I want to try it about >50km, so I pick the path that accomodate my will. I choose a light traffic to break in this tires. The handling is still the same, very crappy. After a long ride, I check the tire. Some of the mold compound is still there but not much as before. I it run again and again. Hey wait, I sense something different about it, I can sense that this tires is gripping on the street. Horai, The tire is getting better and better. Now its light and very stable, there isn't any wrong movement from the tire. Even when I'm doing fast cornering without braking, this tire is gripping!

Cornering with this tire is great, very improved from the stock. No slippery on a very low cornering.

Thursday, February 21, 2008, I run my scooter again. This time the weather is differ than yesterday. It rainy.

Time to test wet performance of this tire. I prepare my jacket and my boots and turn the engine on. I used the yesterday path, because its the best place to test tire performance. I run it on the street and figure out that this tire is great even on a wet track. No Slippery fault!

Let us test the braking system with this tire. I'm waiting for a heavy traffic ahead. When I see it, I hit the brake, not hard, because I don't want to hurt this new tires. Hey, my scooter is stop pretty fast without any leftover movement on the front or rear. It steady!!!

2008 Resolution

Another year has lapsed, a new year is coming. Year 2008 is coming and it warming my heart to encourage me to take a step forward. Before that, I want to step back to review my past resolution.

- New book of journey

This is the best part of my resolution. The most wonderful day when He has made this book of journey fill with two ink. I am so thankful to Him. Rejoice in my heart.

- New Scooter Techno GT 150

I can not fulfill this one. Because the scooter is not sell in my country, and I don't have enough money either if this scooter is coming. I have to use my money for another purpose. But even I can not buy this scooter, I buy another type.

- Building my house

I don't want to fulfill this resolution, I change my mind. Because the house that I buy, is not good enough based on my criteria. So I buy another one that good enough, but it takes my money alot. Almost doubled from the first one.
What about the first one? I'm gonna sell it to the someone who love it.

- March 17-18th, Yogyakarta Touring

Travel with some of my best friend to the Yogyakarta is so amazing. I already write this one, but I can not finish it, because of one two thing that bothers me.

- Activating Jakarta-Yogyakarta Mediavisi

I have to apologize to someone who work so hard so that Mediavisi is still alive until now. I'm so sorry, I can not focusing my mind. I am disappoint you.


In 2008, I only has one resolution based on my life experiences. That is:

- Zero Accident

I had enough accident in the past, and I don't want to it happen again and again. I hate it so much. A lot of people say this and that. But I don't know which one is true and which one is not. I'm so confused.

Right now I can only blame my selves to all what happened to me. I know that He want to tell me something, but I closed my ear and closed my heart. Such a selfish man I am.

Now I want to change my self, but I can't do it alone.

"Dear Father, please put a coals in my tongue and thorn in my flesh."

IRC Tire is Suck!!!

As you can see in the title, I'm trying to write my upset to this tire manufacturer. I'm using IRC MB-520-m on my scooter, because this is the only IRC tubeless tire sole option for my scooter in Indonesia.

Lets track back my experiences with this tire.

1. Tire Lump
I don't know exactly what time it was. What I know is, I change my rear tire with this tire. I don't have to wait too long before lump appear, about 6000km after I change it.

2. Tire Ripped
Friday, October 12, 2007, me and my wife was riding to a friend house. Suddenly my scooter become unsteady after I heard an explosion. Fortunately I can handle my scooter so we aren't fall down to the grown. I run my scooter to the left side of the street and see what happen.

When I see my rear tire, it had flattened. Whats going on? I check my tire and found out, It Ripped! Whereas I fill the rear tire with 32psi appropriate to the owner manual.

3. Tire Slippery
Saturday, December 22, 2007, about 10pm I rode my scooter alone to home. I know its very late, but I don't have any choice. With no street light at all, I can only count on my scooter head light. Suddenly it happened. In front of me not far about 5 meter, there is a huge hole on the ground. I can't avoid it, it half the street. And on the right side, there is a huge mud truck.

I must slow down my scooter. I hit the brake not too hard and my scooter is slowing down. But suddenly I sense something wrong with the rear. It shaky! I'm loosing a grip on my rear tire. I tried to control it, but it didn't work. I hit the ground!

That is what happen to me, three is just enough for me to judge that this tire is suck.

Lets analyze this tire.

According to the official website, there is MB-520. But when I see it deeply, that is differ from what they sold in Indonesia
And this is the one that IRC sold in Indonesia

These two pattern are different! What is wrong with IRC? Do they change the specification pattern on each country?

Now I'm going to test this tire with a simple test. I spray water on the tire surface to see the water drainage.

As you can see as point the arrow, water drainage is so bad. It block the water on the center of the tire. That will make water floating on the tire.

How about if we use this tire for cornering on a wet surface?

Again, this tire drainage is really bad. It blocking the water while it use on cornering. Dangerous indeed if we keep using this tire on a wet surface.

So, my conclusion for this tire is: IRC MB-520 for my country IS SUCK !!!