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Hey Rudolf / MrBios, thanks for all that good info you posted about this fix. I ordered a few of those EL inverters from ebay, really cheap at about $2 each, and they work perfectly! A few years ago I had originally ripped out the centre foil on the dash (there are 3 foils on the B&W dash) and installed 2 brite LED's 'cos I had no idea what the problem was and needed to see the speedo at night. Anyhow, I thought it would be cool to see the remaining parts of the dash lit up again, so I removed the existing inverter from the circuit board and ran the wires thru the main wire cork stopper. Installed the new inverter out the back of the casing and that dash is now super sweet! Cheers

Hey Dan, just saw this post, it will be great to get info on the exact parts replaced.
I'm in new Zealand, but it seems many owners have similar probs. Enjoy your vacation, Nigel

I've always had reliable service from stadiumyamaha. Last time I contacted them was Nov 2013, but it looks like they took down their Kymco page. Try emailing them on parts@stadiumyamaha.com. All the best.

Sorry I can't help you with your question, but can I ask you about the 300cc kit. What else is reqd to upgrade to this kit? I would have thought it is just a bigger cylinder and piston and therefore nothing else is needed and that the carb would handle the extra load. Cheers and good luck. Let us know what it rides like !

Hi all
Just an update on this issue - I sent everything back to J Costa. I still believe there is something wrong in the kit that was sent to me. Just waiting for my refund now......

In the meantime my Dr Pulley weights are just awesome! I installed 26g weights which I think is really the highest the scoot can handle on my weight. The rpms have dropped by about 2000rpm at 105kph !!! Currently it is 6000, used to be almost 8000. High speed cruising is now virtually effortless....

I also installed a new rear tyre and drive belt.

cheers

OK, if anybody's interested, the dashboard backlight is NOT fixable.

It appears that the "backlight" is actually an illumination strip - i guess it is some or other type of flourescence activated by electricity.

Getting the unit apart is another beast, which presented a nice challenge. The front cover is glued tightly shut so cannot be lifted out. So I drilled it out, using a small bit and about 300 holes (just a guess). After that it was plain sailing. I took everything apart except the needle because i was afraid that once the needle comes off it might not fit properly again. The strip was then almost accessible - just had to cut it so that I could slip it out around the needle.

My plan is to use 5 or 6 hi-bright green LED replacements. Now that the illumination strip is out I can get the LEDS right up against the perspex reflector lens - at least I'll be able to see my speedo now at night! The front cover will be reglued / resealed into place with some good silicone.

cheers

Yes, I tested with both the new and stock belts, so yes, I have become quite good at changing the belts and variators....

As a follow up to this (and  in case anyone is vaguely interested) I contacted J Costa directly and they emailed me an installation manual, different to and much better than the one supplied in the kit. However, the new instructions verified I was installing everything correctly - it is a very basic installation anyway.

I also took their advice and ordered and installed heavier 14g weights.

** Even with heavier weights, the J Costa variator still DOES NOT WORK **

OEM variator = 105kph (65mph) at 7000rpm
J Costa variator = 70kph (43mph) at 7000rpm

Both J Costa and my scooter shop have now gone quiet on me.

I can only assume that there must be an incorrect part in the kit, but J Costa is not forthcoming at all about any information. Very frustrating

In the meantime I have ordered some Dr Pulley weights to get me back on the road again......