2006 TGB R50X "Bat outta Hell"

[Elektrey]

Might as well do a write up.

First thing I did was take a sharpie (silver to write on the black plastic) and make a rough sketch of where I wanted to the hole to be. You can use isopropyl alcohol to remove the sharpie and alter the lines.

Do this until you are happy with it. Make sure to measure the size you need for the cutout, and draw about 80% of that size with the sharpie.

Then take a boxcutter and a torch and heat it up real good, get the tip to glow orange. I shook it/blew on it after heating it up so it wasn't on fire, and then start cutting the sharpie outline with the knife. Push the knife in and it should cut the plastic like butter. Make sure you know what is behind the plastic before you start cutting! don't want to cut wires or melt anything with the blade.

After you cut all over the outline, it should pop out pretty easily.

From here I used a file and filed down the rough edges, but I don't think this is absolutely neccesary.

After I got the rough shape cut out with the knife I used the knife to make each edge straight by sort of "carving" out each side. After each side was pretty straight and I was satisfied I took the display and put it in the hole and saw how much I needed on each side for it to fit.

I did top to bottom fitment first. Look at it from a few feet back and see which way would be better to expand the hole (up or down). I cut mine out down. I took a small (0.5-1.5mm) carving from the bottom line and then put the display in to see if it would fit. Eventually I got the hole big enough to fit height-wise.

I did the same steps for the length and then once both fit I tried pushing the panel into the hole. It might help to examine the corners and open them up a little to get the whole thing to fit in.

It eventually just pushed in and looks great! Real tight fit too. It has tabs on the sides to keep it locked in, but It would have stayed put with just the tolerance fit I gave it anyways.


Heres the initial cut


final cut


Here it is fit in the hole


and from the back


Just need to hook up the connector that I wired yesterday:

EDIT: I put it in upside down lol, going to go fix it.

[Elektrey]

Trying to prep the BBK installation.

Installed a circlip in the piston.

Noticed these two circular recesses in the cylinder, should I see if they will replace it or will this cause any problems?



Also checked ring end gap and virtually nothing so I will have to gap them myself. (not even 0.04mm would fit in the gap)

[Elektrey]

Any help with those nicks in the cylinder?

Should I return it?

[iwiketuddlz]

Mm? Is that a new Cylinder?? Certainly shouldn't be thee if it's brand new id say., I don't think that will hurt anything though , I have ran muuuuch worse lol

[Elektrey]

Yes it's new, haven't done anything except opened up the box so far.

[190mech]

Those dings wont hurt anything,maybe even hold a bit of oil there to lube the piston..How is the port layout compared to your last cylinder?

[Jwhood]

Didn't look back what cylinder did you get,the malossi or the hoca??edit: never mind I see now!!!

[Elektrey]

190mech

I sent scooterpartco an email about the dings but if it's no problem then I'll just use it.

I tried doing a port map onto paper with a pencil but it didn't work out.

I will check tommorow and see if I can't visually compare the durations/timing

Jwhood

yes the malossi sport cylinder kit.

[Elektrey]

scooterpartsco replied and said its fine to install because they are below the ports. I'm not exactly sure what they mean by that but aren't they "above" the ports?

[90GTVert]

They're above the ports... unless you're like a bat and hang from your feet. Regardless, 190mech won't steer you wrong.

[Elektrey]

thanks I'll just use it.

I'm thinking I'll put off the BBK until it gets cooler out.

There's nothing worse than working on a scooter and driving it around the block then taking it back to adjust something and getting back on etc. etc. in 100 degree weather.

Maybe October

Oh and I insterted a circlip in the piston and tried to get it to be straight up-down but It's off maybe 10-15 degrees should I reinsert it so it's up/down or will that be fine?

And still not sure what to do about the rings. Instructions say nothing about the end gap but they nearly completely close and leave no gap when I sat them inside the cylinder (yes I put the piston in to level the rings)

Also something interesting from the intsructions, it claims it has a 13.5:1 compression ratio, which seems awfully high.

[90GTVert]

The gap in the circlip should face the top or bottom of the bore.

You'll probably want about 0.008" end gap if it's a 47mm bore. If I'm wrong on the bore size, go to the calculators link in the sidebar and plug in your bore size into the end gap calc. You don't want them butting up to each other with no gap.

The stated compression ratio would be uncorrected. Even a stock Zuma claims 12:1 IIRC. Corrected (taking port openings into account) will be much lower, 7:1 for the Zuma for example.

[Elektrey]

Filed down the piston rings and got approx 0.009" - 0.010" is that close enough or should I order new rings?

EDIT: well I just shattered a ring trying to get it in the second slot, didn't realize these things were so brittle.

Ordered a pair from treatland (thanks for the code Brent!) $14 shipped so pretty happy it wasn't too costly.

[90GTVert]

You definitely can't put a lot of force on rings. Pretty much everyone says they're unnecessary, and it's true that rings can be done fine by hand, but I have never regretted spending $10 on piston ring tool years ago. I find it easier to remove and install them with one.

9 or 10 thou should work. They'll work fine for a bit beyond that, but I'd still shoot for 0.008" next time. Thousandths come off quick, so you gotta take your time filing.

[Raizer]

Good looking scoot!



Hey is that one of those tachometer/speedo/fuel gauge etc combos you can get from aliexpress?
If so how well does it work?
Am looking at one for mine.