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 kayakbuilder's '99 budget (re-)build 
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Post kayakbuilder's '99 budget (re-)build
The scooter had been wrecked and was given to me.
Image

I traded a damaged horizontal Stage6 StreetRace BBK for a new vertical Athena Sport Pro.

I finally spent money ($30) on it today, and ordered a Motoforce FG reed, Stage6 small end bearing, and two (95 & 98) 6mm Dellorto jets.

Next is a new front fender.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 1:11 pm
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Post Re: kayakbuilder's '99 budget (re-)build
kayakbuilder wrote:
Next is a new front fender.


Whats wrong with the one thats on it? :D


Fri Aug 26, 2011 1:14 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Here is the kit. The ports had already been chamfered. Initially I plan on keeping the stock Dellorto PHBN 12 carb and upjetting as needed.
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 1:27 pm
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Post Re: kayakbuilder's '99 budget (re-)build
PiNk wrote:
kayakbuilder wrote:
Next is a new front fender.


Whats wrong with the one thats on it? :D



It is just a minor scratch. Should I try to repair it, or should I replace it? All of the mounting tabs are broken, and it is in two pieces.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 1:34 pm
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Post Re: kayakbuilder's '99 budget (re-)build
It will buff out.


Fri Aug 26, 2011 1:58 pm
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Post Re: kayakbuilder's '99 budget (re-)build
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Destickered! They were in bad shape.

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 4:41 pm
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Post Re: kayakbuilder's '99 budget (re-)build
buguy wrote:
It will buff out.


Outside
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Inside
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 4:59 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Any ideas on how to fasten an access panel with three out of four fasteners tabs broken off?
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IMAG0924.jpg
IMAG0924.jpg [ 906.82 KiB | Viewed 6944 times ]

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Fri Aug 26, 2011 5:03 pm
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Post Re: kayakbuilder's '99 budget (re-)build
kayakbuilder wrote:
Any ideas on how to fasten an access panel with three out of four fasteners tabs broken off?
Attachment:
IMAG0924.jpg



Glue on new tabs. :awesome:

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2001 ZUMAII - Tires TBD
Motor #1(2008) R.I.P this listed configuration, for it breaths new life under the rule of a new King...ENJOY NICK B!!!: Athena Sport BBK, Ported case, Power 1 HPC crank, Yasuni City16 (fully derestricted), Stage 6/Mototassinari V-Force 3 reed cage, OKO 24mm flatslide carb, S6 R/T rear facing manifold, running pre-mix, S6 BIG filter,Malossi drive face, lightened flywheel, Lightened Athena vario - (22.5g), S6 R/T WingCooler Bell, NCY TD, Malossi Delta clutch 107mm- 8K engagement, Malossi red Contra w/Malossi Torsion Controller.

Motor #2(2005): To be built.....ported cast iron 48mm bore, 41.4mm stroker crank, Ported case..(the rest of the following I don't have 2 of each...this stuff is coming off the 2008 motor) Yasuni City16 (fully derestricted), Stage 6/Mototassinari V-Force 3 reed cage, OKO 21mm flatslide carb, S6 R/T rear facing manifold, running pre-mix, S6 BIG filter, lightened flywheel, Lightened Athena vario, S6 R/T WingCooler Bell, NCY TD, Malossi Delta clutch 107mm- 8K engagement, Malossi red Contra w/Malossi Torsion Controller, Athena 15/50's for 12:1 ratio


Fri Aug 26, 2011 5:15 pm
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Post Re: kayakbuilder's '99 budget (re-)build
You "could" fix those panels with some fiberglass and a little filler. Also gluing new tabs works fine. I use wooden dowls from Lowes or whatever. Cut whatever length I need them, then just glue them on. Be sure to pre drill the screw holes though.


Sat Aug 27, 2011 7:25 am
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Post Re: kayakbuilder's '99 budget (re-)build
buguy wrote:
You "could" fix those panels with some fiberglass and a little filler. Also gluing new tabs works fine. I use wooden dowls from Lowes or whatever. Cut whatever length I need them, then just glue them on. Be sure to pre drill the screw holes though.


What glue sticks to these panels? :confused:

I don't plan a permanent repair to the fender. Do you use Polyester resin for fiberglassing stuff like this? I always use epoxy, and found it doesn't hold very well on most plastics. 3M 5200 might do the job, but it expensive enough that I am better off getting new panels. :doh:

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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sat Aug 27, 2011 8:29 am
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Post Re: kayakbuilder's '99 budget (re-)build
you could also try using zip ties as a filler and plastic welding it
http://chinesescoots.forumwise.com/chin ... d3986.html

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Sat Aug 27, 2011 8:40 am
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Post Re: kayakbuilder's '99 budget (re-)build
Yeah I got a 3500 PSI plastic glue at Auto Zone that works well. And yes I use Polyester resin with the glass. Just rough the surface with some 180 grit paper first and clean it well. I think Wal Mart has a glass kit for $13 or something.

Plastic welding works pretty good too. I use black plastic hangers for my plastic welding.


Sat Aug 27, 2011 8:56 am
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Post Re: kayakbuilder's '99 budget (re-)build
I've got loads of sandparer, plenty of dowels for pegs. I'll check out the plastic glue, and see if I can fab up some new tabs.

The tires need to be replaced, as they are badly checked. I am guessing they are originals. I may swap out my old bugeye tires onto this, as they still have a year or so of like left. If I like the thing, then I will buy new tires.
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2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Sat Aug 27, 2011 10:56 am
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Post Re: kayakbuilder's '99 budget (re-)build
Got the new Motoforce fg reed, S6 small end bearing, and Dellorto main jets (95 & 98), so now I can install the Athena Sport bbk.
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IMAG1086.jpg
IMAG1086.jpg [ 1.36 MiB | Viewed 6882 times ]

_________________
2013 Kymco Downtown 300i, pearl white
Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
Raven '08 Zuma S6 SportPro, LV ZX, Keli Variator, SL26 Tires, Canadian OEM Short Windshield, Fiamm Low Note Horn, LED Stobe Brake Lights, Triple Brake light Mod, Dual Headlight Mod - SOLD


Tue Sep 06, 2011 5:39 pm
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