GEOCOCCYX BLOG 2020.

Thursday 20-2-2020.  New helmet arrived, but it is a medium size.  Tight to wear, but did not give me a headache after 30 minutes of wearing.

Saturday 22-2-2020.  Charged batteries, and started car.  It ran fine for 30 seconds, then cut out.  It did not want to run properly, and sounded like starving for fuel.  I took off the fuel filter, and replaced it with a new one, but there was no change.  It sawed off the tube of the old fuel filter, and used it to put into the line – no filter at all – but there was no change.  So I replaced the new filter into the line.  It starts, but does not want to accept any throttle.

Tuesday 254-2-2020.  Motorcycle Mad advised to drain old fuel, replace with new fuel, and try again.  I made a drain hose, and connected it, ran fuel pump till tank empty.  Put 1 litre of new fuel in.  It started perfectly when cold, but as soon as it started to warm up would not accept throttle, stumbled, ran rough, and stalled again.

Tuesday 3-3-2020.  Picked up Geo from Motorcycle Mad.  They said that it was running perfectly yesterday.  My spare starter solenoid had been fitted, and the TPS adjusted.  I paid the bill of $165.00 and when they decided to help put the trailer on the back of the car, they started Geo, and it was exactly as it was when I took it to them.  They played around with throttle settings, unplugged individual fuel injector wires, plugged in the dashboard, unplugged the dashboard, and there was no change.  I noticed that they were using the ignition switch brutally, and it started to malfunction.  Then the battery started to run down.  They then said that the fuel cap was on too tightly, and the return line was aerating the fuel in the tank, and could be causing it to not run properly.  Then the speedo suddenly started to register, and they said that was caused by a loose earth somewhere.

In disgust I simply loaded it up and drove home.

Wednesday 4-3-2020.  Finished making fuel fitting, bought new 8 ID fuel line, and fitted it to inside of tank.  Reassembled tank and return line to outside, and put fuel into tank.  Started engine, and it ran just OK till it started to get warm, then it did not want to accept throttle. When it stalled it would not start again.  Found that the O2 sensor wire was close to the exhaust, so took it apart at the joiner, where there was a piece of SS spring wire jammed into it.  Removed it, and re-routed the cable.  Tested the engine, and it was unchanged.  Took the plug off the water temperature sensor, and it would not fire up.  Ordered a replacement water temperature sensor from Shepparton, with the cost of  $30 + postage.

Tuesday 10-3-2020.  Replacement water temperature sensor arrived.

Saturday 14-3-2020.  Finally built up enough courage to try out the replacement water temperature sensor.  Started car, and it ran perfectly while warming up, and continued to run perfectly when warm.  It picked up without stumbling on the opening if the throttle, and revved out well.  Turned it off, and after 5 minutes tried again.  It started first go, and ran perfectly.  Built an aluminium bracket to sit on the water manifold and hold the temperature sender above it.

Sunday 5-4-2020.  Charged battery, but it needed only 10 minutes.  Started it perfectly, revved cleanly, warmed up evenly, ran it for 3 minutes or so.

Sunday 3-5-2020.  Started engine, and it ran perfectly.  Charged battery.

Wednesday 29-7-2020.  Charged jump battery and car battery.  Started first kick.

Sunday 2-8-2020.  HSCCQ Khanacross / Motorkhana.  Willowbank Raceway.  Fine, warm.  10 psi fronts, 18 psi rears, 80 psi in reservoir. Did 4 runs at Cloverleaf, one run at Khanacross, and one run at Hopscotch.  Engine running really well, but still a bit ON/OFF in the throttle.  Cloverleaf test.

Run 1               21.97

Run 2               22.02

Run 3               21.56               Fastest Outright

Run 4               21.93

Khanacross                  80.26               4^th fastest.

Hopscotch Test.

Run 1.              29.73

Run 2.              28.28               Fastest Outright

Tuesday 4-8-2020. Reinstalled original starter solenoid, sprayed all electricals to clean off coolant.  Painted blue triangle.  Zip tied hose clamps where they came apart.

Saturday 8-8-2020.  Built pull line warm up throttle.

Monday 10-8-2020.  Installed new coolant sender in manifold.

Wednesday 12-8-2020.  Got coolant drain pipe back from Bushell Engineering, and fitted it with M6 bolt and neoprene washer.  Added coolant and ran car without any leaks.

On Sunday 16-8-2020 I tried to replace the existing seat with the one out of Casper, but after lots of problems, reverted to the existing seat.

Thursday 17-9-2020.  Drove car at Willowbank, engine revs right out, no overheating, no fluid leaks.

Sunday 4-10-2020.  Interclub Khanacross, Willowbank.  In first run at first test the bolts stripped the threads of the right rear VW Golf ball joint, and the suspension collapsed.

Monday 26-10-2000.  New wheel bearings into trailer.

Sunday 15-11-2020.  QMC Willowbank.  Fine, very hot.  At start of third test, there was suddenly no power to the ignition.  I checked the battery terminals, main fuse, wires to main switch, and still nothing.  Connected up jumper battery, and still nothing.  Took insulation tape off main switch, and checked terminals, no change.  Jiggled wires at starter solenoid, and suddenly everything worked.  The TPS seems to be set incorrectly, because there is no progressive power – just an on-off switch with the power.  Very difficult to drive.  Reversing box was very slow to change back into forward.  RH Turning brake not working properly, and left hand one only intermittently.

I decided that the car needs a complete rebuild back to the bare chassis, so on Monday 23-11-2020, and started taking car apart.  Photographed details for re-assembly.

Tuesday 8-12-2020.  Cut the four intake pipes off, stole the air filters off Kwakakart, and screwed them onto the intakes of Geo.  Now I have room to reposition the fuel pump and filter, and have saved 0.7 kg of weight in the intakes.

Friday 11-12-2020.  Modified fuel pump mount, painted it, and fitted it.

Tuesday 15-12-2020.  Took little used tools out of toolbox, and weight went from 26 kg to 15 kg.  Painted box.

Sunday 27-12-2020.  Removed R/V mirror, and made wooden tapped blocks to experiment with curving the mirror.  It does so quite well, so drew modified mirror to be larger and adjustable in its curvature.  Designed new coolant pressure equalising pipe.

Monday 28-12-2020.  Shifted bare chassis to driveway, and water blasted it.  Back onto trestles, and rolled it over to weld skid blocks on.  Touched up welds and grinding.  Welded on two earth blocks.

Tuesday 29-12-2020.  Picked up paint, wire brushed exhausts and repainted them.  Sprayed number panels & dashboard.  Found some ¼” dia brass rod for coolant equaliser pipe.

Wednesday 30-12-2020.  Cut out 12 thick ralloy mirror mounts.

Thursday 31-12-2020.  Made jig and drilled & tapped holes in R/V mirror mounts.

GEOCOCCYX VELOX BLOG 2019

The first event for 2019 was the HSCCQ Come and Try Motorkhana / Khanacross at Willowbank on 24^th February. The car would not start – battery flat.  Jumper battery also flat.  Brought it home, charged battery, and it started first touch.  Brake master cylinder caps all breaking apart at layers in the threads.  Next day I bought 4 new brake master cylinder caps from Supercheap, and fitted them.  Butchy revealed he had the same problem, so I gave one of my new brake master cylinder caps to him, and bought a replacement for Geo.

Sunday 14-4-2019.  Interclub Motorkhana, Willowbank.  Scrappy run in Star. but 22.49 fastest first run.  24.19 +5 second run.  2^nd outright. The engine was surging in first run at Eccentric, (37.15), back to pits, top up with fuel, then it would not start.  Battery flat.  Connected jump start battery at home, and it started first go. On Sunday 19-5-2019 I tried to start car, but battery is flat.  Charged battery and jump start battery, and next day it started first click.

Sunday 16-6-2019.  HSCCQ Khanacross / Motorkhana at Willowbank. Ran slicks on the puddles in the Motorkhana, and did 3 runs at Straight Slalom.  Best time 21.22 (fastest outright).Then battery went flat, and the jumper battery also.  Did one run at Knitting in Terry’s Skyline, recording 44.59, 0.59 slower than Terry, but faster than Noel.

Sunday 14-7-2019.  Installed new labels on dashboard.

Sunday 28-7-2019.  Both batteries flat and do not start car.  Charged them both, and car battery started engine OK.  Sunday 4-8-2019.  Batteries will not start car.  Charged them, and it started on car battery.

Tuesday 6-8-2019.  New battery from Battery World, $110.  Charged it, fitted it, and it started first go.

Sunday 11-8-2019.  Geo started first pop on its own battery.

Wednesday 14-8-2019.  Installed new starter solenoid, and started engine OK.

Sunday 18-8-2019.  HSCCQ Khanacross / Motorkhana at Willowbank. The engine overheated after the second run in the motorkhana, and the fan would not work.  In the second run at the top khanacross, at full revs in second gear over some giant bumps, the left rear suspension pushrod broke, and the suspension collapsed.  Top Khanacross Run 1.     51.21 seconds (2^nd to Stuart Bell)  Open Slalom Run 1.   22.10 (2^nd to Brant).

Sunday 22-9-2019.  QMC at Willowbank Raceway.  Engine not running well, seemed to be starving of fuel sometimes.  I took the fuel pump off, and blew through it backwards, and it seemed to improve for 1 test.

1.                   22.21               second to Brant.
2. Pine Tree. 60
3. 41.34               trouble with gears.
4. 49.41               trouble with gears.
5. Gate Slalom mirror. 53               5th

Monday 7-10-2019.  Took fuel pump and its mounting tray off, shifted them to beside the gearbox, rewired it, and re-routed the fuel lines.

Friday 11-10-2019.  Pick up radiator from Valley Radiator Works, there was a groove in the outlet pipe that was causing the leak.  $50.  Fitted it, and filled with coolant.  Fitted new fuel filter.

Friday 18-10-2019.  Ordered replacement TPS from South Australia.

Monday 21-10-2019.  Ordered a brand new TPS from DH gate.com.

Saturday 26-10-2019.  Tested spare (original) TPS with multimeter, and it “seems” to be OK.  Sunday 27-10-2019.  HSCCQ Interclub Khanacross.  Willowbank Raceway.  Problems with intermittent cutting out, and starter seemed to occasionally jamb on

Monday 28-10-2019.  TPS arrived from South Australia.  Typical !!!!!

Tuesday 29-10-2019.  Installed new TPS, and started car.  All seemed OK till the engine warmed up, then it stalled when on the over-run.  Then it would not run at a steady throttle.  I adjusted the TPS throughout its whole range, and it kept doing the same thing.

Thursday 31-10-2019.  Tyres on trailer wheels swapped at Jax, Michelton.  $50.  Fitted them onto trailer.

Friday 1-11-2019.  Moved cutoff master switch to be accessible from outside of vehicle.  Started OK.

Saturday 2-11-2019.  Removed padding from steering rack, and built an aluminium shield for it.  Painted and fitted it.

Wednesday 6-11-2019.  To Team Moto, Alderley.  Asked them about the Diagnosis plug.  They are only on bikes after 2003, and before that the diagnosis was done through the dashboard.  They did not seem to be helpful, so I chased alternative motorcycle mechanics.

Tuesday 12-11-2019.  Bought new multimeter, and tested TPS that is fitted to car.  Problems with calculating operating range, so fitted it in central position.  Wednesday 13-11-2019.  Started engine, but it cut out straight away.  Repositioned TPS, and it started well, and warmed up normally.

Friday 15-11-2019.  TPS from DH Gate, USA arrived in mail.  It does not look brand new.

Sunday 17-11-2019.  HSCCQ Motorkhaha / Khanacross, Willowbank.  Fine, very hot.  Started car on jumper battery, and warmed it up.  It then simply cut out.  Noel came to investigate, and reset TPS, but it still cutout when warm.  Then the starter motor jammed, and was working as soon as the master switch was turned on.  Brought it home, and took all the panels off.  Took off new starter solenoid, and put the original one back on.  Found that the live terminal was oversize, and was possibly shorting out on the mounting plate.  Insulated it with tape, and re-installed it.  All now works perfectly.  However the motor cuts out when warm.  Found the coolant temperature sensor, and tested engine with the temp sensor unplugged.  Engine ran fine, so connected the sensor, and it stalled.  Repeated the procedure and got the same results.  Removed the water temperature sender, and cleaned it.  Tested it again connected and it stalled, but stalled with the sensor unplugged.  My diagnosis of a bad sensor is destroyed.  Battery went flat, so charged it.

Monday 18-11-2019.  Took Geo to Motorcycle Mad at Brendale.  They diagnosed a crack in the exhaust system, which is causing the O2 sensor to shut down the ECU.

Tuesday 19-11-2019.  Electronic dashboard arrived.

Wednesday 20-11-2019.  Ordered exhaust mandrels and expanders from Mac’s Mufflers, Enoggera.  Draw exhaust headers and jig.  Started making exhaust headers jig.

Thursday 21-11-19.  Picked up 4mandrel bends 38 OD x 180 degrees, and 2 x 1.5 metres of 38 OD pipe with expanded ends from Mac’s Mufflers, Enoggera. $125.  Worked on drawings of headers.

Friday 22-11-2019.  To Alltype to pick up header connectors.  Work on headers drawing and jig.  Then I started manufacturing the new headers, and after lots of problems final finished them on 15^th of December.

I got a larger replacement radiator from a Ninja 650, and built new brackets for it, and it was complete on 17^th December.

Thursday 19-12-2019.  Took car back to Brendale, and noticed that the LR suspension had been broken again.  Engine started perfectly, and ran quietly and smoothly. Injectors balanced, coolant “O” rings replaced, tune up etc.  $220.