Hey all! Get ready for a long single paragraph rambling post! OK~Here it is. The Malossi 47mm jug ran up 67mph new. 64 after 2 years. 60 from the third on... The whole set up was a 28mm Delorto (48 pilot/150ish main), K&N style air filter, Malossi reed block w/ Boysen .30 carbon reeds, Technigas r2 pipe, Suatai re-programed cdi, Malossi Delta clutch (2000 rpm fly springs, and Yellow Contra spring), Malossi Var. w/ 5.5 malossi rollers. All of these bits were tweaked a bit to get more out of them.
The new setup is Oko 24mm pwk carb (47 pilot/115 main) K&N style filter, CT intake, and fiber glass reeds, Ruima 50mm jug, Ruima "capped" 44mm stroker crank, Jiangwayne stainless pipe, Same Suatai cdi, Malossi delta (2000 fly/Red Contra) Malossi 6gr rollers.
First the crank. The bearings are a BIT*H!!! Use the hot/cold method, and use the case bolts to get it together. Check the clearence of the Con. Rod big end after the crank is in. It may get too tight, and you will need to re set this. (I used a fiberglass wedge to adjust this)You have all seen Bat's Picts. of the case porting soooo. I added a few things to the cases. Remove the tabs left after the boost port is cut, Remove the large support opposite the boost port. Drill the crank oilers to 5/16", and chamfer top and bottom of these holes. Remove all the material in the intake passage. Match the cases to the jug. Match the cylinder skirts to the cases. Chamfer all the port edges inside the jug. Polish the exhaust port w/o changing the shape of the port roof. Mirror polish the top 1/2 of the cases. (intake thru transfers). This step will allow the oil to slide down the cases to the crank where it is needed. Also Scotch brite the bottom of the cases to make the oil "stick".
The Ruima jugwill plug, and play alone, but needs attention w/ the stroker crank. (1) gasket top, and bottom results in 13.7:1 compression. Can you say hand grenade? You need to bring the jug up 2.4mm., and for breakin use an extra head gasket to keep the compression low (10.2:1). There are no locater pins in this jug/head so you will want to add a pair to the stud holes. The jug timing is very good for the exhaust duration, and the Intake is just a little low. (188* exh/127*int) but is is good for everyday.
Now the piston... The piston SUCKS!!! Cast alum, and not very well finished, Drill (2) 2mm oilers for the wrist pin (chamfered inside, and out) Dimple the exh side of the dome 1.5mm from the edge I used a 1mm wire bit to drill 8 dimples. These will attract heat away from the edge, and prevent melt over on the rings. The skirt also needs to be beveled to a negative 22* to push oil onto the cyl. wall vs the stock removal. Chamfer all the piston edges when done.
This kit MUST be run on Pre-mix. I tried the pump. and adding 2t to the tank but it just is not efficient enough, and you will get 4 corner scoring on the piston.
Run 7-8gr rollers for break in
Run 1 clip rich on the needle for break in
Run 1 turn rich on the idle mix screw for break in
Use a BR9HSA NOT the BR8HSA
Now for some fun stuff... Use a Ruckus Variator. They start at 94mm, and go to 104mm over range. I have a Prodigy Ruk. at 97mm, and love it. You need to remove the electric start motor to use this, but it is worth it. The Var. will not fit the cases unless you remove material from the starter housing, and you will need a NEW zx/50 drive boss. I say new cause the Ruk uses a 15mm crank, and its drive boss won't work. Your old zx boss will but it will be worn, and for 15 bucks why blow a case up? You will need a longer belt now... 735x18.5x30 is the new size. I had to shim my boss .3mm to get a good bite at full stop. I forgot to say use your orig ramp plate. you want the belt to be running ON the boss at full stop.
More fun... I "glassed" all of the rear body pannels into one piece. I remove two bolts from the seat pan, and two nuts from the tail light, and the whole saction comes off for easy access.
Now the fan has sort of a screen in front of it. Remove it!
Same w/ the cvt cover. There is a circle over the clutch that says Kymco cut this out to cool the clutch.
Here is the bottom line... The scoot now does 143mph in the power band, and 127 cruise. It will run on Vodka/gin/ whiskey, but I'm not sure about beer (Slinger) Maybe a fatter jet?.?
Nawwwwww Really is MUCH quicker at take off, and hits my old top speed at 3/4 throttle. I haven't opened it up yet as it takes too long to get pistons. My guess is approx. 73-74mph. I have a few picts. to post, and I'm sure I missed a few fine points so I will stick around to answer any ?'s.
I love my Bro's here, and think this set-up will be one for the books~ CHEAP (yes)/FAST (hell yeah)/DURABLE (?) My camera is at the shop but I will get some more Picts. Mass Iridium to all~
