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 We have liftoff.....AZU 250 rebuild thread 
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Firing on two.
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Joined: October 22nd, 2014, 10:59 pm
Posts: 1397
Location: South-Limburg
Post Re: We have liftoff.....AZU 250 rebuild thread
you have a wiring loom with one or 2 fuseboxes?


August 15th, 2020, 2:26 pm
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Firing on two.

Joined: May 23rd, 2011, 7:14 pm
Posts: 262
Location: ecosse
Post Re: We have liftoff.....AZU 250 rebuild thread
Just one fusebox.......4 fuses


August 15th, 2020, 10:10 pm
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Firing on two.

Joined: May 23rd, 2011, 7:14 pm
Posts: 262
Location: ecosse
Post Re: We have liftoff.....AZU 250 rebuild thread
Moving to 602 means cable accelerator rather than rod.....so new hole needed. Why so complicated at the bulkhead ..... ;) Unreasonably strong spring, complicated locking......grrrrrrr

Took ages.....to fit a single cable !!


August 15th, 2020, 10:21 pm
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Firing on two.
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Joined: October 22nd, 2014, 10:59 pm
Posts: 1397
Location: South-Limburg
Post Re: We have liftoff.....AZU 250 rebuild thread
OK will have look in the factory manuals. P.s. It is not that difficult. If you lay out the wiring loom as it should go. You see the couloured plugs of all items to hook up near the loom. Just connect colour to colour... :mrgreen:


August 15th, 2020, 10:24 pm
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Firing on two.

Joined: May 23rd, 2011, 7:14 pm
Posts: 262
Location: ecosse
Post Re: We have liftoff.....AZU 250 rebuild thread
yeah......I understand the concept but I think I must be colour blind :D I can't find any mauve or Violet terminations and I see a number of shades of brown !!

My bulbs arrived yesterday so I'll get them installed and work on trial and error basis. Thank goodness my van does not have the electric window/air-con/ABS/traction control optional extras..... :lol: :lol:


August 16th, 2020, 10:10 am
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Firing on two.
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Joined: July 10th, 2010, 12:35 pm
Posts: 945
Location: Magyar
Post Re: We have liftoff.....AZU 250 rebuild thread
The colours of the wiringloom starts to fade after some years . I had the same problem.
I did it like you now, working on trial and error basis .
Good luck !

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August 16th, 2020, 10:41 am
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Firing on two.
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Joined: October 22nd, 2014, 10:59 pm
Posts: 1397
Location: South-Limburg
Post Re: We have liftoff.....AZU 250 rebuild thread
Well i did fin these triple schemes. Could this be the right ones?


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August 16th, 2020, 4:23 pm
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Firing on two.

Joined: May 23rd, 2011, 7:14 pm
Posts: 262
Location: ecosse
Post Re: We have liftoff.....AZU 250 rebuild thread
Cheers, thanks for the diagrams !

Through an elimination process, I managed to get most of it sorted. Still missing fuel gauge an oil warning light but im still looking :)

Todays progress....

https://youtu.be/HTRgds6zg1o

Image

Image

Exhaust blowing everywhere but some other issues to tackle first....

Image

Fairly decent oil leak from right hand bank....seems to be higher up than oil tube seals.....Perforated pushrod tube??? Some inestigation needed.

Also got the brakes bled :)

Still getting there...

Cheers
Gerry


August 16th, 2020, 10:34 pm
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Firing on two.
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Joined: October 22nd, 2014, 10:59 pm
Posts: 1397
Location: South-Limburg
Post Re: We have liftoff.....AZU 250 rebuild thread
fuel gauge is a small yellow connector on the meter there should be a yellow dot of paint And the same for the purple one. On the tank there must also be a mass wire otherwise it 'won't work. There is also an mass wire on the complete speedo cluster.


August 16th, 2020, 10:45 pm
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Firing on two.

Joined: May 23rd, 2011, 7:14 pm
Posts: 262
Location: ecosse
Post Re: We have liftoff.....AZU 250 rebuild thread
Well.......stripped a million fixings from all of the front shroud and the bottom cylinder cowling so I could check the oil feed and the pushrod tubes.....

Oil feeds all dry if a little rusty. Cleaned up all of the residual mess and fired the engine up. The problem was immediately apparent, a holed pushrod tube :(

Image

Some reading in the forums suggest a number of options:
1 replacement
2 aluminium welding/brazing rods
3 Chemical metal
4 Rubber patch and jubilee clip

Since first two options involve head removal, I think I'm going to go with either 3 or 4 for the moment so that I can get the van on the road for the remainder of the summer and tackle the head in the winter.....

Any preferences for option 3 or 4 ??


August 17th, 2020, 11:31 pm
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