878Evo project. AC to LC. COMPLETE
Aug 18, 2015 0:29:31 GMT -5
90GTVert, derbiman, and 7 more like this
Post by sai on Aug 18, 2015 0:29:31 GMT -5
url=http://postimg.org/image/etklr7y6d/]
[/url] 
First of all, thank you to Brent, 190mech, spaz21 and Niz for continuously helping me this past month with my project, specially 190Mech
who actually built me my S6 pro rep exhaust with passion. And of course my kind mechanic who helps me tirelessly .
Also thank you to the people I haven't mentioned who has pitched in with ideas and knowledge in this project.
This is the original thread: 49ccscoot.proboards.com/thread/13016/kymco-super-50cc-conversion-thread
This thread is just to show you all the result of it.
GOAL: I have burnt 2 Malossi BBK AC in the past year and so I thought using an LC system would minimize that tremendously.
While I'm at it, I figured might as well try to get the bike running at 60-65mph at least. I have always been able to hit 50mph+ with the old AC system.
===============================================================
1. This bike is no longer a Taiwaneese Kymco at this point, it has mostly Italian parts and some German.
2. We had to take off the bottom front panel to be able to fit a radiator and created a custom bracket which we attached to the frame. The BBK LC has a hose opening that has to be plugged somehow so we machined an aluminum block to seal it and attach an L shaped pipe so we can attach the hose. Filling the radiator is a problem too, I'm in the process of figuring out how... I'm thinking of just drilling a hole so I could fit a hose and funnel to the radiator, rather than cutting a hole big enough to reach in with my hand to open the radiator cap, as I can do that from the front side.
3. All the hose, hose clamps and other little hoses are taken off a dirtbike.
4. You can see above that I'm painting the bike without taking the panels off.
I went to sherman williams to have custom paint mixed for me. So I used a primer, paint then semi matte coating.
It's not perfect if you look really close, but I have a friend who is a professional painter to fix the imperfections and bulges.
5. Now I need a temp gauge and tach. At first I was going to bolt an extra gauge on top of my original speedo, but I then decided might as well do it right. So I got a TRAIL TECH VAPOR. Mine came with a Speedo, Tach and cylinder head screw in temp gauge. NO CHT. Now the problem is the cable for the temp gauge is way too short.
I'm also getting the PDA so I can have turn signal, oil light and high beam light. Now all that's left is the Fuel gauge.
The original Fuel gauge has 3 wires apparently, so I need to figure out which cheap and small gauge I can get to be compatible.
5b. Bigger problem... I have to cover the hole where the original speedometer was and install the Vapor... right now I'm using a cardboard -_- . Tried using metal and it was no luck. The metal refuses to bend correctly.
6. Water pump is electric and to prevent it from running 24/7, we connect it to the ignition switch, so it starts when I turn the key once. I always check if the pump works by listening to it before kick starting the engine.
7. SO you all know, the headlights of a Kymco will remain dim when you ride unless you use the original speedometer. I dismantelled the speedo and took the electronic parts off and installed them with zip tied under the VAPOR. Now everything is working again as it should.
8. The original fabric for the seat is pretty thin and cheap, I replaced it with ARCTIC VINYL. This is the type of vinyl that'll last against UV, rain and snow. 1/2 yard is more than enough. cost? $8/yard . Beats $180 + installation from an upholstery shop. Check out the photo below, it looks like leather and it's jet black gloss.
NOTE: There are quite a few things that broke with this bike, such as the plastic parts, rear wheel bracket etc. All these things are fixed by modifying and drilling the plastic panels and securing them with steel (the original plastic are cracked / broken).
====================================
Below is where I'll post final photos:
==========Parts========
Malossi:
70cc BBK LC
Variator
9gram rollers
Delta Clutch + yellow racing clutch spring
Forged wing bell
Red Contra spring
Torsion controller
Electric water pump
Dellorto 19mm PHBG
W9 Needle <--- Waiting for a richer W6 once the port timing and squish are modified.
93 Main jet
40 Idle jet
Trail Tech Vapor 752-1050
Trail Tech PDA<--- Don't waste your money on this you can use your own stock bulbs and be creative.
(Mine was free)
Jasil Crank shaft
Naraku Bearings & Oil seal
Stage 6 Pro Replica - Chrome & Black silencer
Motobatt battery 12v 8.5a
Results: (so far with stock speedo that maxes out at 50mph)
55mph (the needle keeps going beyond 50, so I'll update once my Vapor is setup correctly)
9000 RPM - 9500rpm
Port timing: Stock (will be modified later by adding 1mm to the base gasket)
Squish: 1.75mm
[/url] First of all, thank you to Brent, 190mech, spaz21 and Niz for continuously helping me this past month with my project, specially 190Mechwho actually built me my S6 pro rep exhaust with passion. And of course my kind mechanic who helps me tirelessly .
Also thank you to the people I haven't mentioned who has pitched in with ideas and knowledge in this project.
This is the original thread: 49ccscoot.proboards.com/thread/13016/kymco-super-50cc-conversion-thread
This thread is just to show you all the result of it.
GOAL: I have burnt 2 Malossi BBK AC in the past year and so I thought using an LC system would minimize that tremendously.
While I'm at it, I figured might as well try to get the bike running at 60-65mph at least. I have always been able to hit 50mph+ with the old AC system.
===============================================================
1. This bike is no longer a Taiwaneese Kymco at this point, it has mostly Italian parts and some German.
2. We had to take off the bottom front panel to be able to fit a radiator and created a custom bracket which we attached to the frame. The BBK LC has a hose opening that has to be plugged somehow so we machined an aluminum block to seal it and attach an L shaped pipe so we can attach the hose. Filling the radiator is a problem too, I'm in the process of figuring out how... I'm thinking of just drilling a hole so I could fit a hose and funnel to the radiator, rather than cutting a hole big enough to reach in with my hand to open the radiator cap, as I can do that from the front side.
3. All the hose, hose clamps and other little hoses are taken off a dirtbike.
4. You can see above that I'm painting the bike without taking the panels off.
I went to sherman williams to have custom paint mixed for me. So I used a primer, paint then semi matte coating.
It's not perfect if you look really close, but I have a friend who is a professional painter to fix the imperfections and bulges.
5. Now I need a temp gauge and tach. At first I was going to bolt an extra gauge on top of my original speedo, but I then decided might as well do it right. So I got a TRAIL TECH VAPOR. Mine came with a Speedo, Tach and cylinder head screw in temp gauge. NO CHT. Now the problem is the cable for the temp gauge is way too short.
I'm also getting the PDA so I can have turn signal, oil light and high beam light. Now all that's left is the Fuel gauge.
The original Fuel gauge has 3 wires apparently, so I need to figure out which cheap and small gauge I can get to be compatible.
5b. Bigger problem... I have to cover the hole where the original speedometer was and install the Vapor... right now I'm using a cardboard -_- . Tried using metal and it was no luck. The metal refuses to bend correctly.
6. Water pump is electric and to prevent it from running 24/7, we connect it to the ignition switch, so it starts when I turn the key once. I always check if the pump works by listening to it before kick starting the engine.
7. SO you all know, the headlights of a Kymco will remain dim when you ride unless you use the original speedometer. I dismantelled the speedo and took the electronic parts off and installed them with zip tied under the VAPOR. Now everything is working again as it should.
8. The original fabric for the seat is pretty thin and cheap, I replaced it with ARCTIC VINYL. This is the type of vinyl that'll last against UV, rain and snow. 1/2 yard is more than enough. cost? $8/yard . Beats $180 + installation from an upholstery shop. Check out the photo below, it looks like leather and it's jet black gloss.
NOTE: There are quite a few things that broke with this bike, such as the plastic parts, rear wheel bracket etc. All these things are fixed by modifying and drilling the plastic panels and securing them with steel (the original plastic are cracked / broken).
====================================
Below is where I'll post final photos:
==========Parts========
Malossi:
70cc BBK LC
Variator
9gram rollers
Delta Clutch + yellow racing clutch spring
Forged wing bell
Red Contra spring
Torsion controller
Electric water pump
Dellorto 19mm PHBG
W9 Needle <--- Waiting for a richer W6 once the port timing and squish are modified.
93 Main jet
40 Idle jet
Trail Tech Vapor 752-1050
Trail Tech PDA<--- Don't waste your money on this you can use your own stock bulbs and be creative.
(Mine was free)
Jasil Crank shaft
Naraku Bearings & Oil seal
Stage 6 Pro Replica - Chrome & Black silencer
Motobatt battery 12v 8.5a
Results: (so far with stock speedo that maxes out at 50mph)
55mph (the needle keeps going beyond 50, so I'll update once my Vapor is setup correctly)
9000 RPM - 9500rpm
Port timing: Stock (will be modified later by adding 1mm to the base gasket)
Squish: 1.75mm
