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 YAMAHA ZUMA - Over range tech info / case grinding / setup. 
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 YAMAHA ZUMA - Over range tech info / case grinding / setup.
Hey, just got a steal on a Malossi MHR overrange kit. I'm really impressed with the quality, and the driven pulley is hugeeee!!! The instructions are for the horizontal minarelli and they call for shaving down a little bit of case material. Well turns out in my prebug, it looks like i have to shave off a ton to make it work. Anyone here do the overrange on a prebug?


https://www.scootertuning.ca/en/80-variators
Variator Malossi MHR Overrange 2005 Minarelli
Model: 5112800
Variator kit Stage6 R/T Oversize Minarelli
Model: S6-5616634
Variator Polini Hi-speed Evolution 2016 (13mm)
Model: 241.727
Variator Malossi MHR Overrange 2013 Minarelli
Model: 5115823
Oversize CVT Malossi MHR Overrange 2005 Minarelli Long
Model: 6112811
Oversize CVT kit Stage6 R/T Minarelli Long
Model: S6-5616601
Rear Pulley Speed Drive Polini Evo 3 Iron Minarelli
Model: 244.0582
Rear pulley MHR Overrange Aluminium 2013
Model: 6114590
Oversize CVT Polini Evolution 3 (Ceramic)
Model: PACKPOLCER
Oversize CVT Malossi MHR Overrange La Furia Rossa 2013 Minarelli Long
Model: 6115821
Rear Pulley Polini Speed Drive Evo 3 Ceramic
Model: 244.0579
Oversize CVT Polini Evolution 3 (Iron)
Model: PACKPOLIRO
Rear pulley 2Fast GP aluminium
Model: TRT8000

_________________
2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Mon Nov 10, 2014 9:58 pm
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Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
To anyone that is thinking about the MHR Overrange, it's 100% worth it. My bike is nearly stock for the moment, waiting tel after December to order top and bottom end guts. Before the Overrange My bike would start winding out around 35mph with the spacer out, and have pretty poor off the line performance. With the Overrange I have Lightning fast gearing off the line, and the variator starts to wrap out around 40mph and downhill 9000rpm is well over 45mph. There was a fair amount of clearancing needed to fit the driven pulley, unlike the horizontal Minarelli with more room around the clutch. I had to flatten the top and bottom case reinforcement like the bugeye case. The bottom part by the clutch even after grinding aluminum away was still pretty close to the belt so I polished that area in case the belt makes slight contact every once and a while. I could not find ANY other Prebug Overrange reviews/ instructions or pictures for the prebug so I'll add a few more pictures. BTW anyone ordering the Overrange for a non-race engine should get 6.5g or heavier 19x15.5mm weights, the kit comes with like 3g and 4g weights and it SCREAMS past the prebug powerband.


Got the overrange in after a bunch of grinding with the Dremel.
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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sat Nov 15, 2014 6:03 pm
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scooters and mods: 05 Z50 4200 miles, 70cc Polini, 84 jet, Leo Vince zx, Athena Variator, stock clutch w/LV yellow springs and Athena contr
Post Re: MHR overrange on prebug help
The OR is freaking great, i'nit. That's a tight fit! Did you get the right one? They make one for the Bugeye
(6112811) and a different one for the Prebug (6112812).

Look at www.scootertuning.ca that is where I get all my parts from and Jean and Eric are the best. The scooter turd shop is ok but the selection is small and prices are to high.

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'05 Zuma 50, Athena sport 70cc (12mm piston) with Polini head (.9 squish), B9ES spark plug; timing advanced about 2˚; Yasuni C16 exhaust, Buzzetti kick stand to make room for it (and Stage6 paddock stand after dropping the freaking bike because of the kick stand); stock airbox no snorkel, 5 x 1/2" holes; Stage6 21mm racing PHBG, 45/95/W7 1 lean/40 slide; Polini/Power One 12mm HPC crank; Athena 15/50 gears (also have 14/42s pressed into a gearbox cover, just switched back and like the 15/50s so far); 107mm Malossi Delta clutch, "racing" red springs/lighter "racing" counterweights ± 6800 RPM engagement, Stage6 Kupplungsglocke (bell - the light one); Malossi 6112811 Overrange kit, red contra and 28.2G rollers; VForce 3 reeds; Michelin Bopper tires; back to the stock shock; dual headlight wiring; C3 mirrors; Trailtech TTO tachometer and temp gauge.


Sat Nov 15, 2014 6:39 pm
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Joined: Sun Jun 15, 2014 9:17 pm
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Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
Hmmm didn't know that I had multiple sites list M6112811 for the prebug, and it works great! Do you know the difference between the two?

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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sat Nov 15, 2014 6:52 pm
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Joined: Sun Jun 15, 2014 9:17 pm
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Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
I just checked pulley alignment and it's spot on, now you got me wondering if maybe they made the prebug driven pulley smaller? Either way I couldn't be happier, best buy for the zuma by far. I can't wait to see what it'll do kitted up now!

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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sat Nov 15, 2014 7:06 pm
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Joined: Sun Jun 15, 2014 9:17 pm
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Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
http://scooterpartsco.com/index.php?main_page=product_info&products_id=756

They list the M6112812 other minarelli scoots but not the zuma or mbk booster.
They list the M6112811 for the booster and zuma. Idk haha it works I'm happy

Also check out:
https://www.scootertuning.ca/en/80-variators

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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sat Nov 15, 2014 7:23 pm
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Post Re: MHR overrange on prebug help
That belt hitting the case where it comes off the pulley at the bottom? Could sharpie it to find out, I spose.

_________________
08 Zuma "The Fly" 50: Stage6 Racing Mk.1 (0.7 squish), Athena Race exhaust (S6 Pro), Malossi RHQ crank, Doppler 15/50s, Dellorto 21mm PHBG DS (60/42/90), Top Perf. Vforce3 reed valve, Malossi Multivar w/drive face, Malossi Delta Clutch & Wing bell (Yellow contra, yellow clutch springs on stiffest), Stage 6 R/T forks, Stage6 R/T 4 pot brake, S6 280mm big brake, Aerox 100 rims, S6 CNC'd controls, Brembo master cylinder, Hoca/Bando ignition, naked bars, manual petcock, Pirelli SL26s, dual light mod, re-profiled seat, LED signals, doodads and gizmos (TT Vapor, Harris Project R1 grips, silly stuff) and always running Amsoil Dominator.


Sat Nov 15, 2014 10:16 pm
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Joined: Tue Jul 08, 2008 9:16 pm
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scooters and mods: 05 Z50 4200 miles, 70cc Polini, 84 jet, Leo Vince zx, Athena Variator, stock clutch w/LV yellow springs and Athena contr
Post Re: MHR overrange on prebug help
[size=200]I don't know what the difference is, but as long as it's working who cares. My guess is that the belt is the main difference, but who knows. It's hard to imagine how the pulley alignment could be off, actually, because the variator is going to be pulled by the belt to the point of least resistance. But I don't understand the things people say about alignment anyway. I just put as little shimming as possible behind the variator back plate to stop it from hitting the case, and only enough behind the variator front plate to tighten the variator nut (which is no shims with the OR, but I did need one when I was using the Athena variator before this). It makes zero sense to me to shim the variator open, because the belt is going to force the back plate as far back as it needs to go when you're taking off. And shimming it closed (behind the back plate) isn't going to make it close any tighter, so you're not going to get more top speed! Anyway, congratulations on the OR. It really is freaking awesome.[/size]

_________________
'05 Zuma 50, Athena sport 70cc (12mm piston) with Polini head (.9 squish), B9ES spark plug; timing advanced about 2˚; Yasuni C16 exhaust, Buzzetti kick stand to make room for it (and Stage6 paddock stand after dropping the freaking bike because of the kick stand); stock airbox no snorkel, 5 x 1/2" holes; Stage6 21mm racing PHBG, 45/95/W7 1 lean/40 slide; Polini/Power One 12mm HPC crank; Athena 15/50 gears (also have 14/42s pressed into a gearbox cover, just switched back and like the 15/50s so far); 107mm Malossi Delta clutch, "racing" red springs/lighter "racing" counterweights ± 6800 RPM engagement, Stage6 Kupplungsglocke (bell - the light one); Malossi 6112811 Overrange kit, red contra and 28.2G rollers; VForce 3 reeds; Michelin Bopper tires; back to the stock shock; dual headlight wiring; C3 mirrors; Trailtech TTO tachometer and temp gauge.


Sat Nov 15, 2014 10:57 pm
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Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
FScott wrote:
That belt hitting the case where it comes off the pulley at the bottom? Could sharpie it to find out, I spose.

I think it might be ever so slightly, a little belt dust when u opened it back up after a 7 or so mile ride. No obvious hard scrape marks on the belt surface so i think it just slaps it a little, that's where I polished it but I think I might grind it more there.

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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sun Nov 16, 2014 12:31 am
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Posts: 287
Location: Portland, OR.
scooters and mods: 2003 Kymco Bet&Win 250; MRP 300cc kit FAST!!! *NEW* 2001 Yamaha ZUMA, mods to come!!!!
Post Re: MHR overrange on prebug help
Nick Batzdorf wrote:
I don't know what the difference is, but as long as it's working who cares. My guess is that the belt is the main difference, but who knows.
Anyway, congratulations on the OR. It really is freaking awesome.


The prebug has the exact same belt as the bugeye, same part number n everything. But yeah it is one fine piece of engineering!

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2001 "Yamaha" Zuma PreBug. MXS Race .55 squish, Polini Evo crank and evo bearings, Malossi Overrange 5.5g rollers, Stage 6 MKII Clutch, malossi 14/42 primary Polini 14/41 secondary 8.9:1, MXS Hyperhace exhaust, Stage 6 intake, VForce 3 reeds, Stage 6 VHST 26mm flat slide (125mj/35sj/50 slide/d44 needle), Malossi MHR inner rotor 28° advance, Nolgy Hotwire, Mallosi RS3 shock.


Sun Nov 16, 2014 1:22 am
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Post Re: YAMAHA ZUMA - Over range tech info / case grinding / set
This is the machine work I've done so far. I've not setup a belt to see if it makes contact anywhere.


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MY 2000 PREBUG PHOTOS -----> viewtopic.php?f=50&t=25587
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