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 kayakbuilder's '99 budget (re-)build 
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Post Re: kayakbuilder's '99 budget (re-)build
You should give them a call. They have a toll free number.


Wed Aug 15, 2012 4:06 am
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Post Re: kayakbuilder's '99 budget (re-)build
daex wrote:
You should give them a call. They have a toll free number.


Dan responded to my e-mail this morning, saying he would look into it.

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Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
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Wed Aug 15, 2012 9:27 am
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Post Re: kayakbuilder's '99 budget (re-)build
It just came in the mail today. Not sure when I will be able to work on it, as I have a lot going on right now.

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Vivid Red Candy '99 Zuma II Athena Sport BBK, Motoforce FG Reed (Re)Build Thread
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Wed Aug 15, 2012 10:58 am
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Post Re: kayakbuilder's '99 budget (re-)build
Here is the new PHBN 17.5 carb on the left, and the original PHBN 12 on the right.

Image

The original had an A21 needle and a metal slide. The new has an A12 needle and a plastic slide. The new needle came with the clip one notch down from the top. Should I move it down one more to the exact middle for the initial start up, or leave it where it is? I would think I should move it as it is better to start too rich instead of too lean.

Image

Installation should be straight forward. The throttle tube on the 17.5 is shorter, but the carb is taller with a longer slide, so it needs to be shorter.

The float bowl on the original has a drain, and the new one does not. I may switch the bowls out, if the original is in good enough condition.

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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 Aug 21, 2012 10:34 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Is the choke jet in the bowl? Some did, not sure. I could not tell from Photo. {In case you swap bowls}
I just looked its the bowl vent. Not the choke jet. :doh:

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Wed Aug 22, 2012 2:25 am
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Post Re: kayakbuilder's '99 budget (re-)build
It runs!!! :toot: :toot: :toot:

Problem is, I think the throttle cable (and possibly the choke cable) is too short.

After installing the new carb, I could see the throttle was still more open than it should have been, it started up easy, and idled okay even after shutting the choke off, then the rpms started climbing the clutch engaged and the rear wheel started spinning fast. I shut it down and tried it again with the same results.

I used the shortest elbow and adjusted the cable for the most slack, but it is still too tight. I need to examin the length of the cable to see if there is any more room for adjustment.

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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 25, 2012 2:12 pm
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Post Re: kayakbuilder's '99 budget (re-)build
How long is the outside bend on the elbow. Its so hard to buy this cable stuff the pics suck.
You got two choices.... Make inner longer. Or shorten outer casing.
Treatland, has a good assortment on the bends. But the pics don,t tell you length. You need to Call them.
I replaced the whole cabel & throttle, when I did mine for I had the dual cable OE carb.

If you have enough Casing you can slide the casing end cover off, unravel the metal casing. Cut it with side cutters of a cut off wheel. Remove some of the vinyl cover, slide the end cover back on. You now have more free cable.

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MHR Hyper Race, 70cc #318440 / Yasuni C-16 pipe, Stage 6 HPC 12mm Crank, Polini C-3 Race Brg. MVT premium, IGGY, TNT- Adj- Inj Pump / Y-Plate, Motul 710, Malossi Over-Range Var-6.0 rollers,Torque Boost Rear Pulley & Stage 6 k-belt, Orange, Contra / 1 spacer, DR HIT Clutch,red malossi race / no pillows+ STG 6 433 Bell, 15-50 Up Gear, Moto Tassinari VF3 Reed's & 4mm spacer, Clone-Blk 21mm, MJ #-94,PJ#42, W-7 2nd , 45*Slide, OEM Airbox , Snorkle out, 5 vents, Side Stand, Daytona Style Alloy Wheels,WD Torsion Arm, Stage 6 R/T Multimeter, Strt-8-HD Fan Trimmed + Air Scoop 50cc Fan Housing, Frt - Pirelli - SL 26 - 120/90/10, Rear- Shinko - 160/70/12, Frando Racing / 5DV-001 Ceramic Rear Shoes - Sigma BC-8 Speedometer-


Sat Aug 25, 2012 8:53 pm
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Post Re: kayakbuilder's '99 budget (re-)build
corrosion wrote:
How long is the outside bend on the elbow. Its so hard to buy this cable stuff the pics suck.
You got two choices.... Make inner longer. Or shorten outer casing.
Treatland, has a good assortment on the bends. But the pics don,t tell you length. You need to Call them.

The carb came with two elbows, a shot and a long, both are shorter than the stocker, and I used the shortest. It should be working. It could be that things did not seat correctly. The inner sleeve for the elbow caused me a lot of grief on the install. I will double check that.

corrosion wrote:
If you have enough Casing you can slide the casing end cover off, unravel the metal casing. Cut it with side cutters of a cut off wheel. Remove some of the vinyl cover, slide the end cover back on. You now have more free cable.

If everything is seated correctly, I was going to look into shortening the casing.

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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 25, 2012 9:30 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Can you adjust the cable from the throttle side too? That would give you some more slack in the cable.

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Sat Aug 25, 2012 10:44 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Did that early on.

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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


Sun Aug 26, 2012 1:03 am
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Post Re: kayakbuilder's '99 budget (re-)build
kayakbuilder wrote:
It runs!!! :toot: :toot: :toot:

Problem is, I think the throttle cable (and possibly the choke cable) is too short.

After installing the new carb, I could see the throttle was still more open than it should have been, it started up easy, and idled okay even after shutting the choke off, then the rpms started climbing the clutch engaged and the rear wheel started spinning fast. I shut it down and tried it again with the same results.

I used the shortest elbow and adjusted the cable for the most slack, but it is still too tight. I need to examin the length of the cable to see if there is any more room for adjustment.



Same issue with mine. What i did was cut the thin gray plastic wrap at near the end of the cable. Use the PBHN12 old elbow with the adjustment cranked it ALL the way in, yes the last few threads can be turned in. Now at the throttle grip, turn your adjustment in as much as you can.

With all this, your slide should be able to completely close if you turn your idle screw all the way out.

:cheers:

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Prebug- sold


Sun Aug 26, 2012 1:17 am
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Post Re: kayakbuilder's '99 budget (re-)build
x10BWS,

Thanks for the tip. :cheers:

I had already adjusted everything for max slack from both ends. The Old elbow looked longer than the new one, but it actually gave me just enough slack for it to idle right. It idles great, and had to just barely bump up the idle. I have done the first heat cycle now.

:toot: :toot: :toot:

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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


Tue Aug 28, 2012 4:33 pm
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Post Re: kayakbuilder's '99 budget (re-)build
Glad it worked out for you :)

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2004 Yamaha BWS/Zuma YW50
Top Performance Trophy 70cc, LeoVince ZX (Aerox) exhaust, Dellorto 17.5mm PHBN carb, Malossi MHR small end bearing, Malossi Yellow contra, Doppler 15/50 12.22 final ratio, MXT Racing Variator, MXT Evolution Racing clutch, Hebo Club bell, Carbon fibre reeds, Stage6 choke cable, Style Pro single throttle cable, Motion Pro throttle sleeve, MXT "carbon fibre" stem, Cafe Racer handlebars, Buzzetti side KICKSTAND

Dual headlight mod, Integrated rear indicators, Vented CVT cover, DIY footrest bar

Prebug- sold


Wed Aug 29, 2012 10:29 pm
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Post Re: kayakbuilder's '99 budget (re-)build
After the heat cycles, I rode it for about a block to check it out. It has a VERY light front end 1/4 throttle lifts the front wheel. Taking off quick will require leaning forward. Now I get to tune the carb. I wish the spark plugs were easier to change on this, plug chops will be more difficult.

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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


Mon Sep 03, 2012 2:45 pm
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Post Re: kayakbuilder's '99 budget (re-)build
just read all 12 pages of your build, good deal man! Glad to see you putting in the time on a budget for a new life on the scoot.
Im in a similar position myself with rebuilding a '90 prebug, good job on the body panels too, got me thinkn about a couple of mine.
Do you have a pic by chance of the choke controls by the handle grip? mine is broken and have no idea what im lookin for to find another...
Awesome build so far, wheres it at now?


Tue Dec 18, 2012 4:42 pm
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