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That may be my lean condition then, as I think I have about 4 oz per my tank right now... so, am I safe to run 40:1?  I think if I do that, its less oil, but should be a richer mixture, just want to make sure its safe to ride at that ratio.

Ok, Peters, I follows the instructions on that link you sent me, the only difference in my test, was that I ran it at full throttle for about 30 to 40 seconds, which may have been too short of a run.  Either way, I pulled the plug, ran home on the old plug, and chopped it, and here is what I found (its hard to get a good pic of the ring, but hopefully you can see it):







So, it looks a little light, and almost 2mm thick.  I think the ring is smaller because of how short the full throttle run was.  Also, I think that the jetting is actually ok though, because I did a couple runs and it really runs strong from idle to full speed.  I got it up to just under 50mph tonight.  So, my stock airbox has 4 holes drilled in the lid.  One on the bottom, and 3 along the outer part of the lid.  All holes are about 7/16" in diameter.  So, since looking at the ring, I figured it might be a tad lean, I went ahead and put black tape over the three holes in the lid, leaving just the one in the bottom (besides the factory opening). I figured this would richen the mixture a bit, and I could see how it ran.  I made the same trip down the road, and it burbled a bit on acceleration from idle, and at speed, when I rolled into it, it would have to clear out a bit then would do ok.  I removed the tape from one hole, so now two were covered, and two open.  Still burbled a bit, but a bit better.  Took the tape off, and bam, back to great acceleration from idle to full speed.  It definitely feels the best with 4 holes open in the stock airbox.

I don't get any stumble at full speed, indicating a lean condition.  The pipe looks good, not overheated close to the cylinder, so I am hoping that I got lucky, and it is jetted ok on the main jet.

The only area I noticed  it a bit rough, is when you are just cruising, not really giving any throttle, or decelerating... the motor kind of does this fast bup bup bup bup sound.  Not smooth, but also it just kind of sounds like a 2 stroke.  It might be totally normal, just thought I would see what you guys thought about it.

Ok, so here is the exhaust install... I have to say that the hardware and instructions (or lack thereof) were pretty lame.  I know its an easy install, and have done similar, so no big deal, but man, I ended up using half of my own hardware to mount it, and the nuts holding the silencer to the header are super tender, I worried I might strip them or pull the studs at any moment while tightening them.

To get the exhaust gasket to stay in the head, I put a couple small dabs of this grease on the gasket and pressed it into the head:


Picture of the hardware that came with the pipe, you can see one of the allen bolts was super long:


Good news, the clear coat on the pipe was nice, so I didn't have to paint it at all.

And on to the jetting... I installed the 110 main jet, and took it out for a ride.  It felt good, a little bobble in the middle (probably needle setting), but that is just if I ease through to high speed.  If I goose it from an idle, it accelerates great.  When I got back, I checked the plug, and here is what it looks like:





Looks greyish brown, so maybe a tad lean, but I think it looks ok... any thoughts?

Finally, a couple pics of the Scooter, it was silver, and I had the front cowl painted black, along with the headlight surround piece.  Turned out pretty good I think.

Sounds good, I'll start at 110... I'll report back tomorrow.  I have all the pics to post of the BBK and carb install as well.

Yep, I have used that stuff as well, and it works well.

Do you have a good starting point on the main jet with a stock air cleaner, the 19mm Malossi carb, and the 72cc BBK?  The stock jet was 80, I bought the jet kity that ranges from 90 to 110, and I went all over the place while trying to figure out the exhaust issue, so I think I have it at 94, but am thinking it will probably need to start around 100.

Peters, I know you are running the Technigas as well, so you and I have almost identical setups now.  Maybe you remember what main jet you are running.

I finally got confirmation on the CDI's from a couple sources.  For the 2 Stroke Kymco People 50's, the CDI is in fact the larger DC unit.  If your CDI has a green wire coming out of it, then it is the restricted version (that is, if you plug the green wire in).  The earlier CDI's (like the one in my 2001 People 50), do not have a green wire visible on the outside, and are not restricted (according to the Kymco dealer).

I have asked about coils as well, and I know the aftermarket ones are supposed to have a hotter spark, and I don't think there is any difference between a 2 stroke or 4 stroke coil, as long as you get the one with 2 spade connectors on the end, and the same mount style as our bikes take.  Someone correct me if I am wrong. 

I opted to run the original CDI on my BBK, and it works great.  Then again, I haven't tried the aftermarket CDI to know the difference.  Not sure if I will be doing a lot of riding above 9K rpm anyway.

Ok, so I went with the Technigas Next R:
http://www.racingplanetusa.com/exhaust-tecnigas-nextr-kymco-horizontal-p-108-1.html?cPath=2_18_110&sessID=0b7a6bfa6ae6650a1fc6b723da4d6e62

I opted for this because the price was right, $158, and it was in stock in the US, so I can actually have it by next week.  I was going to spend more for the chrome versions and even for the RS2, but all were in Europe, and I am too impatient for now, I want to get to riding this thing before I run out of nice weather.  The exhaust from my wife's 2005 sounded like the core was rattling around when I was carrying the system over to my 2001, so I am guessing that I will be buying another exhaust for her in the coming months... I'll try the Next R on my BBK scooter for now, then move it to hers, and see how the RS2 does on mine later on.

So, I am guessing that my main jet is going to be much higher.... in the order of 100 or so.  I am guessing that it was stuttering so bad due to the fact that the muffler was so plugged.  I guess I could have left the whole bike stock, and it probably would have run fine with the 125psi of compression, had I known that the exhaust was prone to plugging.  Oh well, can always use more power

I called the local Kymco shop, and when I told him what I found, he was like, "Oh, you had the dreaded carboned up muffler, eh?", like it was a known thing amongst 2 stroke Kymco owners... how was it that this never came up in the 5 conversations I had with them.  I've owned Banshee's, YZ250's and a bunch of other 2 stroke bikes, and have never had a pipe carbon up.  I understand with the oil in the exhaust, how it could happen, but have never had it happen, or heard of friends that have had it happen.  I mean even on old Banshee's from 1989 with stock pipes still. 

Oh well, its these experiences that make us better techs... I still love the small wins like this, especially when they feel huge.

Awe yea!!!!!!!! Jeeemoneeee crisssmassss it worked!!!!!!

I swapped out the exhaust this morning and oh my goodness, what a powerhouse!  I honestly would never have guessed that the muffler would have been the issue, but it was totally the problem.

Ok, so now I need an exhaust really quickly. Any suggestions?  I think that I saw the technigas R exhaust for $158, but also the NCY exhaust is like $260, and looks super sweet, but looks like it could be super loud too.

Thoughts?