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Author Topic: 125 engine swap, Wont fire up. Need help confirming connections  (Read 902 times)

Stag

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125 engine swap, Wont fire up. Need help confirming connections
« on: September 19, 2018, 07:22:17 PM »

Bit of backstory.

The bike started off as a gt125r, Engine sized. Replaced the 125cc engine with the 250cc engine, Did a thousand or so miles on it. Valve went through the position. Moved from the UK to France for 7 months. The bike was dry stored in my garage for 9 or so months. Bought a 125cc engine for the bike so I could just wack it in and sell it. Saw vids of the engine running. Arrived to collect the engine and I realized they had made a right mess of removing the old exhaust manifold.

 

When it should look like this



As I already had 4 other heads, I swapped out the head and redid the timing in the process, I'm confident it's correct.

I reinstalled the new engine into the bike, But as I had not planned on ever buying a new engine for the bike and reinstalling it I did not have any pictures to go off for which pipe goes to what If that makes sense. From what I could find on the internet I think I have the set up correct, But when I try to start the bike she turns over but won't fire. Both of the spark plugs are sparking, There is back pressure as both exhausts manifolds are sealed. She is compressing. Not quite sure why she won't start. Does anyone have any ideas?

Below are images of how I have the bike setup







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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #1 on: September 19, 2018, 10:36:58 PM »

Is the magneto rotor the same year model as the CDI? Perhaps replace the magneto rotor with one that you know has the correct timing magnet spacing.

I suspect that the bike is sparking at the wrong times.
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Stag

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #2 on: September 19, 2018, 11:07:19 PM »

The magneto rotor thats currently in the bike, Is the one that came with the engine, You reckon swap it over with the one that was in the 125/250 ?

The one that I had in the last engine was from 2009 the one thats in it right now is 2016. I will try this tomorrow
« Last Edit: September 19, 2018, 11:13:40 PM by Stag »
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Cloud

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #3 on: September 19, 2018, 11:43:05 PM »


The magneto rotor thats currently in the bike, Is the one that came with the engine, You reckon swap it over with the one that was in the 125/250 ?

The one that I had in the last engine was from 2009 the one thats in it right now is 2016. I will try this tomorrow

Not gonna make a difference as far as I'm aware.

EFI spark systems need EFI rotor, but a carb spark TCI will run on either.
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Stag

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #4 on: September 20, 2018, 01:17:47 AM »

what would you suggest I try bro ?
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Joss

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #5 on: September 20, 2018, 01:14:34 PM »

From that photo you have a vacuum pipe not connected. Are you saying its not starting with the petrol tank on or off the bike?
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Stag

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #6 on: September 20, 2018, 02:28:50 PM »

Its not starting with the airbox and tank both connected to the bike, And fuel is being pulled from the tank
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Cloud

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #7 on: September 20, 2018, 07:22:04 PM »


Connect your blue pipe here to the tank directly, and give that go.

Haha a great reminder why I've chucked out all this complex garbage. I've got no vac petcock, no pump, no EGR, no PCV to airbox...

All useless.

I have a pipe from the tank to the carbs. That's it.

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Stag

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #8 on: September 21, 2018, 01:11:50 AM »

I tried that, Fuel is not being pulled from the tank.  How does fuel get pulled from your tank  if you dont have a pump? Just gravity fed ?
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Stag

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Re: 125 engine swap, Wont fire up. Need help confirming connections
« Reply #9 on: September 21, 2018, 01:17:32 AM »


Connect your blue pipe here to the tank directly, and give that go.

Haha a great reminder why I've chucked out all this complex garbage. I've got no vac petcock, no pump, no EGR, no PCV to airbox...

All useless.

I have a pipe from the tank to the carbs. That's it.

Ive even tried removing the tank completely, And using a syringe to inject fuel directly in to the carb, And Im still not getting anything.

Thing thats stumping me is that this is not anything new to me, Ive done a hyosung engine swap before, and Im no stranger to getting my hands dirty in the garage
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