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 PREBUG OVERHAUL 
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Newb
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Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post PREBUG OVERHAUL
hello all, this is my prebug overhaul, any advice is appreciated, i plan on doing a bbk install since my cylinder recently seized, more info/pics to come.


Sun Aug 10, 2014 2:53 pm
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Newb
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Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
this is how it looked before the tear down, i will get more pics up soon.


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Sun Aug 10, 2014 3:01 pm
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Joined: Mon Sep 23, 2013 8:29 pm
Posts: 1062
Location: Lansing, MI
Post Re: PREBUG OVERHAUL
Clean scoot.

Let us know what you're plans are!

_________________
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.


Sun Aug 10, 2014 10:11 pm
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Newb
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Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
my plans since it seized last week are bbk, 17.5 carb, wrist pin, crank bearings and seals. i will post pics later on today, i got the engine off the frame yesterday. it really needs alot of cleaning up, my stock carb was leaking everywhere. when i got the scooter it looked like it had been sitting outside for years without being run, i got it running without spending much money and i spray painted the body white to clean it up a little. it ran pretty good for about 500 miles it has about 3000 on it. the engine always made this weird rattle noise at idle or when i let off the gas, i could never really figure out what it was.


Mon Aug 11, 2014 7:39 am
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Newb
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Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
just pulled the cylinder off, lets just say it wasn't very pretty. looks like the little circle clip that holds the pin popped out. also upon further inspection i noticed the rod had alot of free play on the crank side, im not sure if that's normal or not.


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Mon Aug 11, 2014 9:21 am
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Post Re: PREBUG OVERHAUL
this is just a shot of what my garage looks like right now with the scooter apart


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Mon Aug 11, 2014 9:31 am
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Joined: Mon Sep 23, 2013 8:29 pm
Posts: 1062
Location: Lansing, MI
Post Re: PREBUG OVERHAUL
Circlip failures seem to be the order of the day lately. It's important they be oriented correctly when installed.

_________________
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.


Mon Aug 11, 2014 1:49 pm
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Newb
Newb

Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
could it have something to do with the rod having play on the crank? or is that normal for it to wobble around? :confused:


Mon Aug 11, 2014 3:21 pm
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Newb
Newb

Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
update! if anyone is actually following this post.... any ways i ordered a bunch of new stuff for the zuma. for precautionary reasons i ordered a new athena crank along with a polini cast iron 70cc cylinder kit, 17.5 dellorto carb and a malossi intake manifold, since my other variator flywheel got destroyed with the circle clip incident i ordered a polini flywheel and some new clutch springs. :cheers:


Thu Aug 14, 2014 11:37 pm
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Joined: Mon Sep 23, 2013 8:29 pm
Posts: 1062
Location: Lansing, MI
Post Re: PREBUG OVERHAUL
Yeah, following! Let us know exactly what you got and we can offer some advice!

_________________
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.


Fri Aug 15, 2014 12:12 pm
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Newb
Newb

Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
everything i ordered is listed in the update, any advice is appreciated. :cheers:


Sat Aug 16, 2014 12:39 pm
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Newb
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Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
just got my order in from drowsports


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Fri Aug 22, 2014 6:53 pm
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Joined: Mon Sep 23, 2013 8:29 pm
Posts: 1062
Location: Lansing, MI
Post Re: PREBUG OVERHAUL
So it looks like you got a Polini Sport, Polini drive face, 17.5mm PHBG, and the Athena OE replacement crank?

Should be a reliable runner. Hope you know what you got yourself into with the crank, IMO it would've been good to spend a few more shekels for a HPC crank if you're going to the trouble of splitting the cases.

Do you have jets for the carb?

_________________
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.


Fri Aug 22, 2014 10:47 pm
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Newb
Newb

Joined: Sun Aug 10, 2014 2:36 pm
Posts: 22
Post Re: PREBUG OVERHAUL
yah i have the jet polini sent, i would have liked to get the better crank but financially i couldnt do it, splitting the case shouldnt be to bad ive replaced clutches on cars i assume it will be some what the same amount of work maybe less, anyways im gonna start on it today. i already have the rear end on my bench with the cylinder off, im shooting to try and get the crank in today. i will take more pictures and update yall later on what i get done. :cheers:


Sat Aug 23, 2014 7:00 am
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Joined: Mon Sep 23, 2013 8:29 pm
Posts: 1062
Location: Lansing, MI
Post Re: PREBUG OVERHAUL
Excellent! It's not a bad crank by any means, it's just not HPC. But with a Polini Sport you won't notice. It'd only be if you get addicted and want to squeeze every ounce of performance out later down the road that you'd address that.

Any questions let us know!

Do you have a starting point with your jets you want to run by us?

_________________
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 Aug 23, 2014 3:08 pm
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