2004 Zuma 56 mph Daily Driver
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Author:  zino18 [ Sat Sep 08, 2018 9:44 pm ]
Post subject:  2004 Zuma 56 mph Daily Driver

More Top end 45+ and then shoot for 50 currently at 41 Mph
Acceleration Who doesn't want more .
Close to Stock Exhaust sound . Keep the performance under wraps .
Use as rest as much stock as possible .

Parts installed
Dual headlight .

To hit 45
Parts ordered
Malossi Wild Lion Stealthy exhaust.
Roller kit to balance the engine RPM's to the pipes power band.
46 pilot jet for stock Tk carb 82 main jet and 84 main Jet The pipe and the eventual BBk will need a richer set up
84 main part #14T-14343-42-00 82 main part #14T-14343-41-00 5BM-14353-23-00 - 46 Vino pilot
Next decision
Cast iron is decided Model is up for grabs
Polini ,Malossi ,Top Performance

To Hit 50
I figure i will have to upgrade gears and the clutch to either a 2008+ version or one of the performance clutch's and bells

The Upgrade Journey begins

Author:  zino18 [ Tue Oct 02, 2018 6:00 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Stage 1
Status on exhaust and carb upgrades .
Upgraded the exhaust to malossi wild lion .
Sounded a little lean and zingy after warm up and 1 mile test ride .
Upjetted the carb to a Tk 84 main jet and the 46 pilot jet .
The pilot jet seemed about a perfect swap the idle smoothed right out when warm as soon as i swapped.
it is 50 degrees today so the scoots plug chop looked very good with the 84 .
tommorrow it is 70 degrees so i will look at the plug chop again .
I left the clip in the middle notch that chop looks real close also .

Now the pipe pushes acceleration harder from 5-30 mph .
I have done multiple speed runs in stock form racing from the same 3 mailboxes with all my scooters.
My neighbors just love it .
I used hit the first mailbox under 20 mph now i am over and the 2nd mailbox i would be under 29 mph now i am over 31 mph .
the initial take off to 5 mph seems to lag and then it pulls harder after 5 mph to 30 mph .

Top end
+2 mph to 43 mph on multiple flat runs.
The pipe is very similar to stock sound .
It helps the most in the mid range in my opinion with current set up.

My next move will be continue to dial in carbs and see if i can dial up the acceleration and still hold the top end with adjusting the variator weights .

Author:  zino18 [ Mon Nov 26, 2018 7:34 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Carharts rock
Wife calls me crazy .
I ride all the way to 35 degrees
winter jet is 84 tk pushes me to 44 -45
The cold air leans me out a little bit chop still looks good.
I might be a tad rich for above 70 degrees .

I am installing the bbk over spring break so i can get that rocking for summer i will re plug chop then .

I plan on enjoying for a month or so until i swap i the athena 14/42 gears that should put me at 11-1 final ratio .
Probably upgrade the whole back end then have the polini 3 shoe clutch already just have to get a better rear sheave .

I am running Low 40s with this pipe.
Looking forward to the bbk results .

Author:  zino18 [ Mon Jan 07, 2019 6:59 am ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Santa was good to me
Technigas next R for zuma so much for stealthy
Wild lion will go on the vino's now .
Polini 3 shoe clutch
polini hi speed variator
Spring project will now be bbk and exhaust for zuma.
vinos with wild lions
Also picked up a Eton beamer that a airsal bbk to bolt on in spring

Author:  zino18 [ Mon Apr 08, 2019 7:02 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Top speed 45 Mph acceleration is down from the wild lion
Technigas next r exhaust with a new variator
Still tuning the transmisison may pick up a mile or two ans some aceeleration .
BBk is next step .

Eton Beamer
Airsal Sport BBk 70 cc still breaking in currently at 40 mph but acceleration is way up over stock .
This is BBk peaks out art 9200 rpm so far so top end by rpm's are limited.
Still tuning the transmission may pick up a little .
Overall A $90 upgrade .
And a good scooter for my son and I to wake up .

Author:  zino18 [ Mon Apr 08, 2019 7:10 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Goals for Zuma accomplished
Hit 45 with pipe, variator and carb upjet .

New Goal
Breaking 50
Malossi bbk and Athena gears to get me at a 11 to 1 ratio.

Touch 40 now with jetting carb derestrict and tuning transmission.
Breaking 45 with bbk and upgrading transmision .

Author:  zino18 [ Sun Apr 14, 2019 11:19 am ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Cleaning up the malosssi bbk for install

Spent some time chamfering all the ports with some hobby files.

Hand Polished the exhaust port to ,Started with 60 grit finished it with 400 grit near mirror finish .

The rest of transfers left rough .

Author:  zino18 [ Thu Apr 18, 2019 7:54 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Just stripped the zuma down to naked .
malossi Bbk and trail tech temp gauge gets installed tomorrow.
In the morning i will finish washing up the bbk in the sink with dish soap and water to get rid of metal dust.
Remove the shrouds and old bbk .
Clean up the gasket surfaces .
Test fit the the kit to make sure it seats .
Install base gasket with copper spray.
Install one f-in wrist pin at my kitchen table first.
Install piston rings on piston
install piston on connecting rod with new bearing swear 70 times putting in the other wrist clip
Lube the bbk and cylinder and piston
Ease the bbk over the piston .
Copper spray the head gasket
Torque down the head in a star pattern .
put back the shrouds without messing with the oil line .
Installl the exhaust with a good seal .
take her for a warm up run watch temp .
take the shrouds off retorque heads .
that is part 1

Author:  zino18 [ Sat Apr 20, 2019 7:09 am ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Started in the morning on the the tear down .
Got my 11 year old son to get his hands dirty he is getting sharp at this stuff I quiz him at each step of the rebuild .
Torque questions ,proper gaskets,carbs ,dry fitting ,spining the fan wheel to check for binding,

The c clips are a pain in the butt The g clips are so much easier to snap in .
Usually i struggle with these on the floor the second one snapped right in to place at 2nd try the other one i did at the kitchen table.

The fan shrouds had some rounded bolts so i had to make a hardware store run to get some allan heads after getting the off with channel locks .

First impression the kit is solid .
I popped the stock exhaust back on left the 84 jet in for initial break in .
The plug is on the rich side and throttle response at all positions is good .
I ran a 80 with stock exhaust before so i probaly can drop to that or the 82
I am in the warm it up and ride it like you stole it camp for break in just vary the speed a lot .
The stock exhaust limits the rpms about 9000 rpm on my scoot so top speed is 40-41 so that is where i am that but she gets to the top fast .
The wild lion exhaust gets to low 9000 rpms so it runs at 42-43
The next r pushes mid 9000 rpms so it runs at 44-55
Conventional wisdom the stock crank doesnt want to cruise above 10 k.
So i chose reliability over speed with the pipes and kit .
Still planning for tuning for breaking 50
Dialing in the jet to day and then i will work on the cvt .
The easter bunny brought me a malossi variator

The vinos go high 8000s on the stock exhaust

Author:  zino18 [ Sat Apr 20, 2019 9:51 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Took the air box off this morning checked for leaks .
The cylinder base and head are good copper color coming through on gasket no dark spots .
installed the malossi reeds buttoned up tight with permatex copper gold .
waiting for that to cure till tomorrow .
84 jet was a little on rich side running the 82 tomorrow .
Will see if the jet is right the clip is up one notch rich and i have the 46 pilot jet
and then on to the cvt the easter bunny brought me a malossi variator .
I was running 4.9 grams withe the tecnigas pipe hitting 45 mph on the polini variator and the green springs with the polini clutch.
I was going to raise the clutch engagement one notch more for better take off but the bbk needed to get done first and i was going to break in with stock pipe .
With the malossi i used the stock variator with 6.5 grams and kept the clutch springs stock .

Author:  zino18 [ Sun Apr 21, 2019 4:11 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

It is a 78 degree day
The jetting is settled the malossi likes 82 main needle 1 clip rich .
it revs to low 9s at peak .
runs to 43-44 has more to go but i am still breakin in varying speed so i havent really got all the way on it .
Stock motor pipe and variator I ran 39-40 so te malossi spins up just a little higher .
The variator needs to be tuned the polini with 4.7 jumps it to 8500 rpms .
and then she overrevs to low 9s
I didnt bother dialing it farther The Easter Bunny brought me the malossi variator the ramp angle is different and the variator is larger .
The polini added a little bit maybe a mile or 2 and it shifted way better.

So this wednesday i have time to dial that in.

Author:  zino18 [ Tue Apr 23, 2019 5:33 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Had time this afternoon tuned the variator and put on 20 miles after dialing it in
4.7 grams Is too light without a pipe the rpms spun up to 8500 ish when I mashed the throttle and seemed to be the top end of power band .
5.2 grams works is as light as I can be with good belt travel and great acceleration jumps the rpms right to 8000
5.7 grams works and is about as heavy as I would want to be rpms are at 7800.
6.1 and above started to get worse below 6500 rpms was doggy
Around low 7s to mid 8s rpms is about peak power for the stock pipe and The Malossi.

I leaned on it a lilttle harder after a few miles 45-46 is the top .
Rpms low 9's 9100-9200
Runs High 30's effortlesly..

The Polini Variator is a very good upgrade for shifting and a little top end after this run the Malossi Variator is going to end up on the Vino when I kit it .

Author:  zino18 [ Tue Apr 23, 2019 5:55 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Current set up and costs and current results
Malossi bbk
150 bucks with g clips instead of c clips they are easier to put in

Stock carb
82 main 46 pilot jet needle raised one notch rich cost 10 bucks

Polini High Speed Variator
5.2 grams 120 bucks I bought 4.7 5.2 5.9 6.9 grams for dialing in.

Polini 3 shoe clutch and bell 107 mm
80 bucks green clutch springs ,polini blue contra plus 10 %

350 bucks or so
Power Band for this stock pipe and bbk is low 7's to mid 8's is where i will target to stay between for trans tuning.
At break in goes 45-46 over revs to 9100-9200 rpm and runs in low 300's for temps at peak .

Author:  zino18 [ Wed Apr 24, 2019 8:29 pm ]
Post subject:  Re: 2004 Zuma Daily Driver Stock with Stealthy Upgrades

Next stage after a few more hundred miles of breakin

If the kit doesnt loosen up and get me over 50 the athena gears that will take me from a 14.4 ratio to a 11 to 1 ratio I am adding next should put me in the mid 50's.

Ordered rear sheeve/torque driver to clean up the 2005 shift from the weird shift angle .

For those that wonder about gas mileage before pipes and bbk was running 70 ish mpg now running around 60.

Author:  zino18 [ Mon Apr 29, 2019 6:32 pm ]
Post subject:  Re: 2004 Zuma 50 mph Daily Driver Stock with Stealthy Upgrad

Time for tires for the zuma .
Michelin Reggaes or Boppers are what I am homing in on .

If i buy the tires from them on there tire sale .
Dealer says 250 installed if I bring in the rims .
375 if they take them off the scoot .

Well a set of goes for about a hundred bucks if i buy them shipped to my door.
If they install tires they don't sell 125 bucks .

So I guess i will teach my son how to do it in our garage .

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