Rick, manager of Geronimo, left Japan recently and left behind his 50cc 2001 Yamaha Vino moped (actually Victoria’s moped which she hasn’t learned how to ride yet). I have been wanting to learn a bit about how to work on bikes, so I have taken over the moped and will work on it during the summer.
In general the bike seems to be in decent shape mechanically — the clutch is smooth, whereas the clutches on 50cc mopeds tend to go gravelly after a while. Also, the bike has no problem getting up to 60 km/h which suggests to me that the drive belt hasn’t worn down (or has been replaced). There may be a bit of a problem with the choke, since it’s hard to start when it’s cold.
There are a couple of “roadworthiness” issues that I need to address — the tail light is not firmly attached to the bike, the horn does not work, and the lenses are missing from the turn signals. After that, I can get cracking on the cosmetic issues, where I will learn how to repair body work and paint plastic motorcycle panels.
So, here is Part 1, where I reattached the tail light to the moped.

Here’s what we’re starting with.

I must say that the rear fairing made of duct tape is not very attractive, and it may be a bit of a safety issue, as the tail light is not secured to the bike and is moving freely.

I took off the duct tape and found that some of the plastic from the rear fairing is missing entirely. It seems to have been kicked in at some point.

Here is the bike with the side fairings and rear fairing removed. Scooters are not very attractive without fairings; I guess that’s why they’re so expensive.

I took as many of the pieces of plastic as I had and cleaned them off, and then held the jigsaw puzzle together with masking tape. It’s still missing a lot.

I used a fiberglass repair kit (which consists of some sheets of fiberglass cloth, some resin, and some hardener) to build up some fiberglass from the inside of the panel to give it some structural integrity and hold all of the existing plastic in place.

Here is the repaired panel from the outside. The panel still doesn’t look very good, but it is strong enough that it can hold the brake light in place. I have put about 100km on the bike since then and it seems to be holding up well. The next step, once I take care of more roadworthiness issues, will be to fill in the cracks and missing areas with Bondo, then sand and repaint the panel.

Big sister and little brother together in the parking lot!
Stay tuned for Part 2 of the project, where I will address the issue that the bike is insufficiently horny.