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Post by gummybody on Apr 2, 2018 10:28:03 GMT
Hi, I've got a 63 Douglas 150 GL with a 1991 125 EFL engine. It has been running great for 18 months but it started losing power in 3rd and 4th when coming home from work in October. Managed to get home and since then have cleaned carb ( Dellorto si 20/20 d ), blown jets and carb, replaced mainjet stack 160/be5/96 but problem still exists. It will start ok and sit ticking over all day but as soon as I set off in 1st it feels "boggy" and stalls before I have gone 100 yards. Emptied tank and re-filled with new juice, tested fuel flow which looks ok, new float chamber , still same. Tried with fuel cap off, same, new CDI, same. Thinking now maybee exhaust? Is there anything I can do to prove this or just try a new one or any other ideas please?
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Post by henri on Apr 2, 2018 20:23:29 GMT
right ,its in a 63 so am guessing the your pre-mixing , jetting to my mind should be 140/be5/98 , your larger air jet is covering the lean autolube 96 main jet .but that aint ya problem . my moneys on low feed from the green wire off stator to cdi , meter between green an white earth wire , should get around 500 ohms ,with some indian stators showing 460-ish . the green dye in the insulation piaggio used is acidic an a known problem ,it corrodes the copper an breaks down the insulation .also suspect will be the low tension coil on the stator the green wire comes from ,the paper wrapped coil next to black box the pick up .whilst ya got the meter out measure on lowest scale between the red wire an white ,thats the pick up ,any reading outside 100 to 110 ohms an ya got a dodgy pick up.
but my best bet is broken insulation on green wire , fine at low voltage/tickover ,soon as volts rise its arcing out , an my moneys on were wires come thru stator plate .seen it so often it appears in my dreams .H
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Post by gummybody on Apr 3, 2018 21:02:47 GMT
Thanks Henri, correct I am pre-mixing. I will try your jetting suggestion when I’m running again. Meter showing 500 ohms between Green n White and 112 ohms between Red n White. Will check for damaged insulation on green wire in Stator at the weekend. Thanks again for the info, measurements with CDI disconnected btw.
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Post by gummybody05 on Apr 9, 2018 12:23:25 GMT
Update on this :- I removed the flywheel and checked that the wires were ok around the stator plate ( They were all ok ) I cleaned the Flywheel and re-fitted it. Connected CDi wiring again and had a short test run. Hey presto, it was running ok. Fingers crossed and I will ( weather permitting ) try a longer run this week. Now, bearing in mind I had already changed the CDi for a new one then re-fitted original so I am almost sure the connections / CDi were not the problem, that only leaves the removal / re-fitting of the flywheel as a cure? Any thoughts on this?
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Post by gummybody on Apr 24, 2018 19:22:20 GMT
Ok so a couple of short rides where it was not quite right but rideable until Iit came back again last week. Couldn’t go 100 yards without cutting out. Flywheel off again and torch / magnifying glass and all looked ok. Bearing in mind Henry’s earlier comments Making me think electrical rather than fuel problem, I nipped the spade connectors with pliers and reconnected to CDI. Started it up and it ran like new. Still need a couple more rides when rain stops but fingers crossed, will update later.
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Post by gummybody on May 1, 2018 15:57:39 GMT
Hopefully the last update on this. I have had a few rides and it is running like new. Big thanks to Henri for pointing toward an Electrical rather than fuel based problem. I will try the suggested change to the Mainjet later.
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wink
2nd Class Ticket
Posts: 33 
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Post by wink on May 3, 2018 18:08:54 GMT
Well done Gummybody for persevering with solving the problem (hopefully it’s all sorted now) and as always well done to Henri, your posts of advice and help on the forum are invaluable, i’ve Used them to solve countless problems. Thanks mate....
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