New Parts

In a previous update I described how I found that the starter relay was bad. I really didn't want to walk into the Yamaha dealership and ask how much a new one cost. I couldn't find one on the internet. After I lost an eBay auction for a used starter relay that went to $30, I began looking for an alternative. I started looking for 12 volt relays on DigiKey. The closest looking one was the Z785-ND. The data sheet looked pretty good, as did the specification sheet. So I ordered one for $11 including shipping.

When the relay arrived, it looked like a good match. It was about the same size as the old one, and I could see that the coil and contacts were similar between the two. The original relay was made to fit a Yamaha connector on the scooter, so I had to add four wires with spade connectors to fit into the Yamaha connector. I had expected to do that anyway. The new relay fit right into place on the scooter. I hooked up the batter charger, and pressed the starter button. The relay clicked and the starter spun! Well, it sort of spun. I could hear it speeding and slowing as it turned the motor through each compression stroke. Hopefully some of that was due to the corroded battery cables and the dead battery. I should see some improvement after I clean and/or replace the batter cables.

I put some shrinkwrap tubing over the spade connectors to try and make the relay a little more waterproof. Then I wrapped electrical tape around the whole thing. Jeez, I can't believe somebody would actually be reading this. I mean, what did Donald Trump do today? "I brokered three multi-million dollar deals and appeared on a hit television show. How about you?" "Oh, I put tape on a relay and wrote about it on the internet". I guess that's not as bad as reading about how some guy put tape on a relay.

Okay, back to the scooter. It obviously needs a new battery. I sure don't want to kick the thing into life every time. I looked on eBay for a while, and finally found one for $23 delivered. I still have to buy acid for it, though. And I found a guy who was parting out a Razz who still had the front brake cable. The one that came on this scooter is frozen solid. I've been soaking it with penetrating oil, and hanging it up, but after a week it has not come free. So this guy sold me a used front brake cable for $7.50 delivered. I don't want to think Yamaha would have charged. When the battery and cable get here I'll put them on, and I should be able to spin the starter motor at any time.

The next step is to clean out the carburetor and look into the oil injection. And some internet research has told me that I'll probably have to clean out the muffler as well. But after that there's a good chance I can get this thing started.