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| Enviromoto |
 Posted: Sun Dec 20, 2009 12:26 am |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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Hi,
My current project is a 05 Zuma engine, front end, wiring, and controls bolted to a 06 Honda Ruckus. The reason I am doing the swap is the motor on the Ruckus was bad and the body on the Zuma was beat. Not only that but I always wanted a Ruckus but hated the limited power that can be made with the motor.
Right now its a little past mock up as I have the motor mocked in and the front end swapped over.
All you have to do is take a little off of the Zuma motor mount and it will bolt right up.
Ziiiiiiip
I went with a NCY extension bracket to keep it from looking to squaty.
Then I swapped out the Ruckus front end for the Zuma one. All I had to do is swap over the bottom bearing race and everything lined right up. Even the steering stem threads were they exact same pitch and everything. If it was much easier it would'nt have been any fun at all. The Zuma stem is a little longer but that wont be much of a issue.
Its extremely fugly right now but its all broke down and in boxes waiting for me to order parts. I am on a pretty tight deadline and this will be my first "real" 2 stroke build. So I would like to get some input from you guys before I get much deeper. Im just going to rattle off my parts and upgrade list and you guys give me the thumbs up or down.. ok ?
I want to keep it stock looking but you can tell right away something is different about it.
List:
NCY Zuma handlebar mount and MX Style Handlebars
Stock Zuma wiring and controls
Strip engine and powdercoat black
Paint front fender black
Doppler air shock black
Polini crank bearings
Crank undecided
70cc kit undecided
Athena Gears
Stage 6 intake spacer
19mm Del Orto Stage 6 black
Stage 6 choke cable
Stage 6 free flow air filter
Polini speed kit
Polini clutch and bell
Stage 6 Pro or Pro rep exhaust
OEM style tires
LED lighting conversion (except the headlights)
Mikuni fuel pump
HP Coil and CDI
Stock Stator
Aftermarket Speedo undecided but I like the Koso ones
I need to have this completed before the first week of February. I would like to learn a little bit more about porting so this will be my first official shot at it. All of my previous experience has been 4 stroke tuning and not much with the 2 stroke.
Thanks in advance.  |
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| StepVino |
| Posted: Sun Dec 20, 2009 1:39 am |
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Joined: 05 Feb 2008
Posts: 1655
Location: Houston, TX
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Looks like it's going to come out great.
Maybe you can call it a Yonda Zuckus! |
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01 Vino, ported Polini sport
05 Vento BKM Jazz stock |
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| Timmy |
| Posted: Sun Dec 20, 2009 10:55 am |
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Joined: 02 Sep 2008
Posts: 144
Location: Dearborn Heights MI
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| Me too stepvino i think this hybrid is going to work. I like to see photos after its done. |
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2003 Aprilia sr 50 ditech
Mods
Pionner head unit
Red neons and leds
Malossi 6.5 gram rollers
Malossi yellow contra spring
Malossi delta clutch
Dragon custom air intake
Leo vince rr pipe
Gates power belt
Triple chrome rims |
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| Enviromoto |
| Posted: Sun Dec 20, 2009 11:34 am |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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Any thoughts on a 70cc kit? I like Polini and was thinking of going with the 70cc sport kit and crank..thoughts?
I do like the price point on the Stage 6 stuff as well. |
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| StepVino |
| Posted: Sun Dec 20, 2009 1:14 pm |
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Joined: 05 Feb 2008
Posts: 1655
Location: Houston, TX
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I've had a Polini sport cylinder and it's been great. It has
suffered through a lot as far as experimenting and just
keeps going. I even got it used after it was seized, and
that was at least 2k miles ago. A great kit.
If you replace the crank, I would go for a 12mm pin.
I like the Stage 6 stuff as well, but never tried it. |
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01 Vino, ported Polini sport
05 Vento BKM Jazz stock |
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| Enviromoto |
| Posted: Sun Dec 20, 2009 9:44 pm |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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I have a Polini sport 12mm 70cc kit
Still debating on the crank, not looking to spend a lot of coin but since it has so many miles I am definitely replacing it.
Here is the pipe I like, I know its not super fancy but I plan on riding the snot out of this thing.
Anyone heard any results with this pipe?
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| StepVino |
| Posted: Mon Dec 21, 2009 10:51 am |
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Joined: 05 Feb 2008
Posts: 1655
Location: Houston, TX
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Never seen that pipe, but it doesn't look like an expansion
chamber pipe. Depends on what kind of riding you are going
to do. If you want something quiet that performs better than
the stock pipe, the one in the pic might be ok. Otherwise I
would get a Yasuni C16, maybe skimp on the other parts
(except engine) if you need to, the pipe is more important. |
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01 Vino, ported Polini sport
05 Vento BKM Jazz stock |
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| Enviromoto |
| Posted: Mon Dec 21, 2009 11:42 am |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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The expansion chamber is hidden inside the pipe.
From my friend brent over at 49ccscoot.com
From Leo's site...
Quote: SCOOT Handmade GP Exhaust
Ultimate performance and look for 50cc 2-stroke scooters
MotoGP style sectionalized hand welded 304 stainless steel with brush finish
Individually engineered for broad power across RPM range
Handmade expansion chamber for maximum performance
Performance clutch weights and springs included when needed
CAD/CAM designed for precise fit
I'm guessing it's soemthing like D. Even though it looks like a flat end so it's just the header, diffuser, and belly, the stinger and convergent cone are probably still inside.
The C16 isint out of the question as I am a Yasuni dealer, but I would like to keep it as stock looking as possible. |
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| StepVino |
| Posted: Mon Dec 21, 2009 7:07 pm |
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Joined: 05 Feb 2008
Posts: 1655
Location: Houston, TX
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The key phrase is "broad power across rpm range". If it were a tuned
pipe it would not have a broad rpm range. However, it is starting
to sound good. Since I had never seen one, it could have been from
China, a regular exhaust with sheet steel wrapped around for looks.
Why does being a Yasuni dealer stop you from using one on your
scooter? |
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01 Vino, ported Polini sport
05 Vento BKM Jazz stock |
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| Enviromoto |
| Posted: Mon Dec 21, 2009 7:59 pm |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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| Being a Yasuni dealer dosent stop me but I am going for a certain look. A 2t pipe like that is a dead give away. However I may just suck it up and go with one anyways. |
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| StepVino |
| Posted: Mon Dec 21, 2009 9:20 pm |
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Joined: 05 Feb 2008
Posts: 1655
Location: Houston, TX
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Don't let me talk you out of anything  . If you are going for
a specific look, then get your first choice. From the description
you should be able to get over 50mph with it, and still be able
to engage the clutch at lower rpm.
Can I ask how much it is, and who make it? |
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01 Vino, ported Polini sport
05 Vento BKM Jazz stock |
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| Enviromoto |
| Posted: Tue Dec 22, 2009 10:18 am |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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| Enviromoto |
| Posted: Wed Dec 23, 2009 9:19 pm |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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Today I finally got to tear into the motor. Wanted to get it torn down and ready to go to powder coat asap. I still need to clean and media blast the cases and wheels. Then I can start putting this thing together. The clock is ticking.. tick tock.
The spark plug was finger tight. Remember this Zuma had almost 14k on it and she fired first kick every time.
Went its whole life with the stock metal reeds.
I have never seen a clutch worn down all the way down like this before.
Wore down so far that it cut into the bell.
Variator looked stock and has held up well.
The rollers have to have been replace they look almost new.
Look at the grove in the backing plate.
Remember this picture and what a mess this thing was when you see the finished product.
Im pretty sure this thing was never rebuilt
I cant believe it was still running.
Bought the puller at Autozone. Then I just bought some longer bolts for the variator side and split the case.
I messed up this seal later in the evening as I was removing all the oil seals. I think I screwed up as it wont come out for nothing. How do you remove this little devil?
The crank itself looked ok but the bearings are shot. I plan on replacing the whole thing out with maybe a motoforce one.
How do you remove this little guy?
Removed a couple small brackets
Time for powdercoat and paint. |
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| zombie |
| Posted: Thu Dec 24, 2009 12:18 am |
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Joined: 08 Oct 2009
Posts: 397
Location: N.W. Florida
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| Whats Up Doc? That seal is just a standard oil seal with a rubber coating. You can use a small screwdriver to deform it, and it will fall right out. I have also used a torch to burn the rubber, it just leaves a little extra clean up. Looks Like this will be one super cool Hybred! |
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| Enviromoto |
| Posted: Thu Dec 24, 2009 10:05 am |
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Joined: 23 Feb 2009
Posts: 187
Location: Camby, IN.
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| Thanks I was wondering why it wouldnt come out like a oil seal. Like I said this is my first 2t teardown so things that may seem obvious to some is all new to me. Im a 4t guy and those crank seals just pop out from my experience. |
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