ZX50 Build,,, Again!!!

[sidthesloth]

G'day all, I have been at it again. Have managed to get some money together and buy some more bits for the scoot. I am still going to keep my exhaust, for now, but I have just fitted a new variator as the slides in the old one were worn. I have bought a new cylinder kit, 47mm and a 44mm crankshaft. Once I make up a crank puller I will strip the engine and see how this new gear goes together. Unfortunately I bought a cylinder kit that was made in China, so I may have made a mistake already, but will remain optimistic. With my previous crankcase work it should be ok. Hopefully.
cheers,
sid.

[Shaka]

Awesome Sid!  I just finished up mine last night, initial impressions are great!  Keep us posted, lots of pics!

[sidthesloth]

Hey, that's cool, how did you go with the engine mount bushes? I have the crank puller sussed, just got to cut, weld, drill and hope for the best, after all, two spark plugs were sacrificed for it. When I get a chance, I will do a port map, the trans ports look rather small. Might be that I am used to the big ones of the 50mm kit.

[Shaka]

Haven't gotten to the bushings yet.  I have to make a call and see about some bearings.  It will probably be a project for next week.  I can't wait to see this contraption your making!  I'm not visualizing how you're using spark plugs to pull a crank.  I'm sure it will be interesting.  Send me your portmap and I'll run some #'s for you.  I'm always curious to see different cylinders!

[sidthesloth]

Will do. I thought the spark plug reference would spark some interest. I don't kow if what I have in mind will be strong enough, but the crank is not in that tight, so it should be good enough.

[thebatman]

Sid, whats up man?  good to see you. Hadnt heard from you in a bit.. Well, you have my interest already. 1 ? tho, why go down in size?... suppose to keep going up.. ...That shoulda made it close to a 99cc with the 50mm.....i THINK...
Cant wait to see this build. 

oh yeah, pics...pics..pics...

[sidthesloth]

G'day thebatman, yeah, coming back into the fold. I guess I was getting sick of banging my head on a wall, so I was looking for a kit I could afford, turns out it wasn't so cheap after all, seller wanted more than the quoted price for shipping, cost a little over $160. If it turns out to be no good, I can always go back to my 50mm kit with the 44mm crank. I will try to take lots of pics where I can.
Question for you batman, on each side of the engine, how far does the crankshaft protrude from the cases From memory, I think they are about flush, but would like to make sure before I make a tool that won't fit.
cheers,
sid.

[thebatman]

Good morning sid...well...here..  
Do you mean from the seals? or looking "down" on the engine?.. YEah, looking "down" from top view, It protrudes approx. 1 inch.. I believe the right side is more "flush"(looking from the top) than the var side
I can measure for you if need be. I still have the var side open..
Can i ask where you ordered from?..carlos?

[sidthesloth]

G'day thebatman, the kit is from scrappydog scooters, only way to find out if any good is try it.
Carlos has a new batch of 50mm kits coming in, from the Honda/Sym OEM, $100.
 No need to measure, I just couldn't remember if the shaft protrudes past the case or not, but if it is not too much I should be ok. I have made the tool, very crude but if it does the job, then all is well. Just have to drill the holes and cut the slots, will include a pic of it.
Shaka, will try to get a port map in the morning, will post on here and email a copy.
cheers,
sid.

[sidthesloth]

Oops, that pic was a bit bigger than I thought.

[sidthesloth]

Here is the port map of the 47mm cylinder.
The square window is the boost port inlet, the piston does not have a window in the skirt so I figure that window is below the piston skirt. With the 44mm stroke, the piston should clear the lowest point of the boost port. I forgot to write on the paper, the exhaust port is 25mm, left transfer 35mm, boost 34mm, right transfer 34mm.

[sidthesloth]

Ok, so I have stripped the engine, and see that the new variator is not using the full potential, there is a ring of about 2-3mm wide at the outer edge of the variator, this will be something to look at when running again. I have taken some pics as requested and will post them in the next couple of posts. Here is a pic of the variator.

[sidthesloth]

Using the homemade universal holder to remove the flywheel nut.

[sidthesloth]

Removing the flywheel, this tool was only $11 from scooter assassins.

[sidthesloth]

Splitting the crankcase with the rough as guts homemade puller.