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 HONDA RUCKUS 2t zuma watercooled build 
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Silver Member
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Joined: Thu May 01, 2014 8:29 pm
Posts: 777
Location: Orlando, FL
Post Re: Honda Ruckus- water cooled and air cooled
I'm attempting to install a Malossi Overrange, and noticed a similar issue. Did your kit come with any spacers or shims that go between the clutch and clutch bell? I was having problems similar to yours, and the spacers that came with my kit cleared that up pretty well.

_________________
2003 Zuma
(tuning)
Top Performances Trophy Black Edition 70cc
Stage6 19mm PHBG (38pj/84mj/W7 1 lean)
Motoforce derestricted intake
Stock airbox, UNI filter, snorkel removed
Stage6 HPC 10mm crank
Stage6 Pro Replica, derestricted
Malossi MHR Overrange (24.3g)
Malossi 107mm Delta Clutch (yellow Malossi springs)
Malossi 107mm MHR Wing Bell
Malossi Yellow Contra Spring
Malossi Torsion Controller
Top Performance Reed Block and CF Reeds
RFY Shock
Stage 6 F1 Mirrors
Stage 6 14/42s
NGK BR9HS
Michelin Boppers
Trail Tech Vapor
LEDGlow Underglow Kit


Mon May 04, 2015 3:14 pm
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
ill check the box the over range pulley came in again. but if i remember correctly it just had a spare O rings. ill check though and report back. i talked with Scooterswapshop last night he suggested a spacer in between the clutch and bell. so i tried a couple different ways. smaller spacer sitting inside the clutch on the splines pushing the bell out did nothing. i also tried a larger washer that sits pancaked between the clutch and bell. i was able to get the horrible high pitched grinding noise to dismiss but if im past finger tight the wheel is still locked. "heavy sign"

Image
larger spacer pictured...

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Tue May 05, 2015 7:21 am
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
at work right now. but i pulled up the stock photo. looks like it has this black washer to sit on the splines i hope its still in the box where it should be. ill give it a go on my lunch.

Image

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Tue May 05, 2015 7:25 am
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
that moment when you put on the supplied spacer that came with your over range, and everything works as it should


moving along.

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Tue May 05, 2015 11:40 am
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
:doh: silly me lol

pretty excited!! just got to time it with the help of a buddy and tune it. ignition timing is by far my weakest link. im clueless.

snapped some pics of her goods. :2bong:
Image
Image
Image

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Tue May 05, 2015 3:02 pm
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Silver Member
Silver Member

Joined: Thu May 01, 2014 8:29 pm
Posts: 777
Location: Orlando, FL
Post Re: Honda Ruckus- water cooled and air cooled
Haha glad you got that sorted out (and that the spacer was still in the box)! It's funny how such small parts can make such a big difference!

_________________
2003 Zuma
(tuning)
Top Performances Trophy Black Edition 70cc
Stage6 19mm PHBG (38pj/84mj/W7 1 lean)
Motoforce derestricted intake
Stock airbox, UNI filter, snorkel removed
Stage6 HPC 10mm crank
Stage6 Pro Replica, derestricted
Malossi MHR Overrange (24.3g)
Malossi 107mm Delta Clutch (yellow Malossi springs)
Malossi 107mm MHR Wing Bell
Malossi Yellow Contra Spring
Malossi Torsion Controller
Top Performance Reed Block and CF Reeds
RFY Shock
Stage 6 F1 Mirrors
Stage 6 14/42s
NGK BR9HS
Michelin Boppers
Trail Tech Vapor
LEDGlow Underglow Kit


Tue May 05, 2015 6:39 pm
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Joined: Wed Mar 25, 2015 11:44 pm
Posts: 126
Location: East Bay CA
Post Re: Honda Ruckus- water cooled and air cooled
Hey there hothatch! Good to see you here too!

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1990 Yamaha Jog CG50-CW50 swap
1992 Yamaha Jog CY50-stock
2000 Honda Elite SR50-72cc Corsa, Arrow, OKO24, Polini vari, 8.4:1
PocketChangeScooterClub
1995 Suzuki Intruder VS800
2014 Yamaha FZ-09


Wed May 06, 2015 2:44 am
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
soooo i got the bike started last night and it does this weird thing where each time the bike is shut off the power switches from forward to reverse. literally the wheel changes directions each time. could my gears have been installed backwards??
Image

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Wed May 06, 2015 7:15 am
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Silver Member
Silver Member

Joined: Thu May 01, 2014 8:29 pm
Posts: 777
Location: Orlando, FL
Post Re: Honda Ruckus- water cooled and air cooled
Never heard of that before. Is your CVT spinning backwards too or just the wheel?

_________________
2003 Zuma
(tuning)
Top Performances Trophy Black Edition 70cc
Stage6 19mm PHBG (38pj/84mj/W7 1 lean)
Motoforce derestricted intake
Stock airbox, UNI filter, snorkel removed
Stage6 HPC 10mm crank
Stage6 Pro Replica, derestricted
Malossi MHR Overrange (24.3g)
Malossi 107mm Delta Clutch (yellow Malossi springs)
Malossi 107mm MHR Wing Bell
Malossi Yellow Contra Spring
Malossi Torsion Controller
Top Performance Reed Block and CF Reeds
RFY Shock
Stage 6 F1 Mirrors
Stage 6 14/42s
NGK BR9HS
Michelin Boppers
Trail Tech Vapor
LEDGlow Underglow Kit


Wed May 06, 2015 8:02 am
Profile
Gold Member
Gold Member
User avatar

Joined: Fri Jun 25, 2010 6:56 am
Posts: 14281
Location: San Diego, CA
scooters and mods: FA$T Zuma 155cc
Post Re: Honda Ruckus- water cooled and air cooled
I know small diesel engines can run in reverse when starting them

could your timing be too far over causing some weird kickback from the magnetism when shutting off
and the key, or kill switch isnt cutting off the cdi properly maybe a ground issue because of the paintjob too thick not tying the frame together

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2010 Zuma 155cc
BWS X Digital Gauges<>Clear Smoke BWS 125 Turn Signal Covers<>Billet Bar Ends<>Front Brake Rotor 260mm<>Razor Cam Covers<>NCY Breather Assembly<>Polini EVO Clutch Bell<>Anodized Orange Dipstick<>RRGS Front and Rear Shocks<>Dual 5000K HID's 35w High/Low Beam<>Black Adjustable Brake levers<>Halo Led's<>TST 2 Stage Variator 9gL 10gS <>NCY Oil Cooler<>Yamaha Skid Plate<>NCY Contra Spring Bearing<>1000 Rpm RRGS Contra Spring<>Yoshimura Exhaust<>NCY Direct Ignition Coil<>Lightweight Cooling Fan<>Koso Cable Clamps<>High Lift Cam+Lightened Cam Sprocket<>Underseat Storage Bag<>Stage 6 (Koso) Clutch<>Accel Handlebars<>Koso Brake Light<>Lightweight Swingarm<>RRGS 4 Pot Caliper (PH80)<>Stainless Braided Brake Line<>Lightened F|ywheel<>OEM Headlight Screens<>Zubiku Wing<>Air Horn<>9 inch stretch<>Koso High Flow Filter/Cover<>RPM 10 Spoke Wheels<>Digital Camo Vinyl Wrap<>SEP Cvt Covers





Image Image Image


Wed May 06, 2015 9:03 am
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Scooterologist
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Joined: Mon Apr 20, 2015 5:49 pm
Posts: 69
Post Re: Honda Ruckus- water cooled and air cooled
If your timing is too close to TDC, a 2 stroke motor can run backwards....

Pete

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05 Zuma:
Stage6 70cc Sport Pro MKII,Stage6 12mmHPC crank,Stage6 MKII intake, MKII 21mm Dellorto;95mj-45pj,Stock airbox; snorkel out(2) 3/4 holes,Adj-Inj pump;yellow cover,Stage6 Choke cable w/my own aluminum lever(plastic one broke before I even rode the scoot),YMS pipe ,Stock variator;4.0 rollers,Stock belt, NCY TD ; pins in 40 degree slots, Stage6 medium contra,Stage6 MKII 107mm clutch; orange springs adjusted-tight,all weights in each shoe,Stage6 R/T 433 Bell,15/50 up- gears , Aerox wheels and forks,Aerox front fender, Stage6 280mm front brake....


Thu May 07, 2015 5:55 pm
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
got the timing corrected. was 180 off and firing after tdc. with the timing set correctly i now dont have a spark. coil reads good but not getting much of a reading from the stator. very small ac pulse when kicked and thats it. frustrated and tired. just want to enjoy it.

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Wed Jun 03, 2015 1:58 pm
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Silver Member
Silver Member

Joined: Sat Jul 14, 2012 9:14 am
Posts: 981
Post Re: Honda Ruckus- water cooled and air cooled
The MVT DD is easy to start backward. Give it a good, stiff kick to start it every time.

I can make my Jog start in reverse very easily by giving it a soft kick.

This is because the MVT DD double sparks at lower RPMs. If the starting kick isn't strong enough to put the crank into a decent motion, the secondary fire can make it fire backward. At least that's my own theory, which would be explained bymost MVT DDs doing this.

Re-do the timing and double-check the wiring for your current no-spark issue.

_________________
'94 Yamaha Jog - MHR BigBore 77cc, Yasuni C30, Stage6 HPC 12mm, MHR Digital Direct + EPROM 3 CDI, Dell'Orto VHST 28mm BS, Stage6 Big Valve intake, Stage6 NBR reeds, Malossi MHR Overrange 2005, Stage6 Torque Control + Stage6 CNC 450g bell, 14/46 primary gears


Wed Jun 03, 2015 2:41 pm
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Joined: Fri Feb 15, 2013 7:55 pm
Posts: 1509
Location: Las Vegas, NV
Post Re: Honda Ruckus- water cooled and air cooled
I accidentally started one of my rc helicopters in reverse one time. Didn't know that it was possible for a 2 stroke to do that :doh:

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(Unfinished)2005 Zuma 50 W/ Aerox LC motor
Malossi MHR Big Bore 77 LC, Malossi RHQ crank, Roost 86 pipe, 28mm Keihin PWK Carb, Stage6 reverse intake manifold, Custom Subframe, Stage6 Vforce3 reed valve, Polini open air Filter, Malossi 2010 Over Range, Polini 2G clutch, Dr Pulley clutch bell, Malossi yellow contra. Aerox wheels. ProTaper bars. Buzzeti side stand. Many more upgrades to come...

2008 Zuma 50
2012 Zuma 50 (sold)
2006 Metropolitan selling/parting out!
2003 Derbi Red Bullet


Wed Jun 03, 2015 11:01 pm
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Scooterologist

Joined: Wed Mar 25, 2015 9:02 am
Posts: 42
Post Re: Honda Ruckus- water cooled and air cooled
Update. It's fast. Really fast.
Image

_________________
Honda Ruckus- stage6 RT 72cc watercooled cylinder. stage6 RT exhaust. Stage6 race crankshaft. Polini Superspeed variator. MVT Digital Ignition. Polini 28mm carb. Polini 2 shoe race clutch. Polini Evo clutch bell. Stage6 RT oversize rear pulley. Polini primary and secondary gears. Tadia water pump and radiator kit. Air ride. 2pc FLP wheels. Polini Reed valve and Polini 360 degree manifold


Honda Ruckus- Minarelli Clone, Polini Corsa 72cc air cooled, MHR Crank. Koso manifold and reed valve. Polini variator. Polini clutch and bell. MHR exhaust. Polini CP 21mm carb. Unlimited CDI from ebay.


Fri Aug 28, 2015 12:49 pm
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