My Mostly Suzuki AZ50 Based build... ... Is now a Let's II

[triesandluth]

That pipe sounds nice, and I really dig that instrument cluster. I thought you said this was a budget build? I've seen those clusters for 300+ dollars!! That's not much of a budget speedo to me! Lol.
If you found it super cheap, please share. I would so get one...

[Raizer]

It's still very much a budget build in my mind, I paid under US$100 each for the AZ and Let's, under US$70 for the pipe and that's the 3 biggest individual purchases.
Registration is going to be the next big expense as the Let's has been deregistered so it needs a new plate as well as a license/rego, that's NZ$130/US79 for the plate and 6 months of rego.
The AZ has a live plate, but it's not worth swapping it over as I want to keep my driver's license haha!

My gauge set was well under US$50, it's not a genuine Koso, but it fitted my budget and seems to work well so far
www.aliexpress.com/item/KOSO-RX2N-style-motorcycle-meter-backlight-adjustable-wheel-size-adjustable/1851881648.html

There's a reason it started as the Aliexpress special haha


I paid more for the SJ50 and the Sepia ZZ, but I don't really count them as part of the AZ/Let's build, more of a stepping stone towards the AZ/Let's

[triesandluth]

That's a good deal on that speedo! Thanks for the link!
Sure is turning into a fine ride for the prices you've paid. Great job!

[Raizer]

Just tried to ride it, as we all know by now the clutch is engaging too soon.
But I'm now also firmly in agreement that the rollers are too heavy!
Sounds like it's quickly changing ratio after about 10 meters lol

About to go rego it, put the stock pipe, main jet and tail lights on then go for a ride I think!
Will order some lighter rollers later this week, it's got 5.5g ones now so I'm thinking a set of 4g?

[triesandluth]

If 4 is lower than you like then you could always mix your 5.5s with the 4s, maybe find a happy medium.
49ccscoot.proboards.com/thread/1199/ or this to find your desired weight, maybe?

[Raizer]

I was thinking of using the lathe at work to take a couple grams out of the rollers cores, but I didn't want to risk stuffing them up when I don't have any spares!

Went and got a new plate and 6 months license on the scooter today, so as I said in my last post I tried to ride it.
This is with the Stage6, 78ish jet and the 5.5g rollers in the Chameleon Factory variator


Speedo is a bit choppy as it's only got one magnet at the moment, once I can get hold of another I'll run 3 magnets which should make it a lot more steady.
Also the tach keeps shooting way up then settling down to a more believable RPM, I think I've read somewhere this can be smoother out with a resistor or something in the signal wire??

So after that video and getting teased by the wife and father in law about her having the faster scooter, I refitted the factory main jet and exhaust, which is pretty well stuffed!

Looks even worse in person!
But the results speak for themselves!

As said needs more magnets for the speedometer!!
It is pretty accurate though...      Not bad for a stock CDI!

Turns out my rear tire wasn't seated on the bead on one side, let it down, soaped the rim and it popped right into place when I pumped it up, so much nicer to ride now!
Then I plastic welded the big crack in the helmet tub (that is too dang small to close with my helmet in ) and started putting it back together.

Swapped the seat skin over from the AZ, I can't stretch it tight enough to get rid of the wrinkles so I think I'll take a box of beer to a friendly upholsterer on Friday and see if I can persuade him to stretch and staple it for me.
Thinking of installing the LED spotlight I was going to use on the AZ on the front for a super high beam.

Need to tidy up a few rough edges, finalize the dash install and sort out a replacement tail light/indicator set and I am kinda considering a paint job, but that can wait until after summer as I want to ride it as much as possible!!

Have been offered a Daytona CDI for a good price, so if it's still around on pay day I'll nab it!

Also picked up an offcut of 3mm plate that's big enough to give me 2 or 3 attempts at another exhaust mount.

[90GTVert]

A 10KΩ 1/2W resistor seems to be the most common recommendation to smooth out a tach signal. Some wire them different ways, but inline with the tach signal is what I saw in a couple of places using a Chinese tach. Google will bring up quite a few results if you wanna look over the idea more.

[Raizer]

Soldered a 10KΩ 1/2W resistor in the RPM signal wire up close to the gauge.
Works perfectly now!
Adding a couple more magnets to my brake rotor tomorrow, will hopefully sort the speedometer out.

[Raizer]

Forgot to post this earlier


That's 45mp/h.
Didn't think that was bad for an almost mechanically stock 50cc, just variator and bigger tyres and squashed header pipe lol.

Thinking of saving up for either some kind of Leo Vince pipe or more likely a Tecnigas Next R, the more I read and think about it, the more I'm realizing the Stage6 is just too much pipe for my stock 50cc and crank, the lower peak and wider power band of a Leo or Tecnigas should suit my goals much better.

[Raizer]

Nothing too exciting to report, just been tweaking a few little bits, trying to find a tail light/at least right rear indicator lens and riding it a lot!!
Oh and this:

Dec 8, 2015 22:07:33 GMT -5 Raizer said:

Adding a couple more magnets to my brake rotor tomorrow, will hopefully sort the speedometer out.

Didn't happen the next day, but today we made another magnet at work for my speedometer pick up, drilled 2 holes in my brake rotor to suit/so I've now got 3 magnets which is meant to be a lot more accurate and steady, just need to grab an E clip tomorrow to fit them.


Looks rough, but it's just picked up steel dust!





The eagle eyed among you may notice there's no drill in the mill, I remembered to take a photo after it was away.
The super eagle eyed will notice the new holes don't quite line up with the 3 mounting bolts, that's because the first speedometer I brought only took one magnet so I drilled the first hole freehand with my cordless drill at home lol

Going to turn up a spacer at some point to take the place of the manual speedometer drive, I was somewhat surprised at the amount of resistance it provides! 

Have decided I'm going to order a Next R pipe, hopefully next payday, also considering a cheap 70cc kit and 17.5mm Arreche carb (only because they do a direct bolt on replacement carb for the flanged Suzuki manifold)

[Raizer]

Have ordered a Next R pipe and a top end gasket kit, supposedly 6-10 days from Racing Planet in Germany, we'll see...
(Would have ordered from scootertuning.ca or one of several US sites but either no one came close to matching RP in price OR they wouldn't ship outside of US territories)

Today I measured the squish (1.79mm) then pulled the head/bore off my spare engine from the AZ, it looks to be in very good clean condition, so I'm planning to mill a skim off the head, clean up and chamfer the ports a touch and swap it into my Let's II when my pipe gets here.
Exhaust port looks like it can be opened up a LOT as it's oval right to the pipe!

Plan then is to build up my Let's engine with a 70cc kit and some other goodies as $$ allows and swap it back when it's built.

Also looking at possibly using the stator from the 4t UZ50 engine I picked up, as it's got a lot more coils on it and is well under a year old.


Also I started cleaning up the front end off the Sepia ZZ I stripped, to get it ready to swap over onto the wife's SJ50.
The brakes look like someone tried using mud instead of brake fluid (puke)
Other than a patch of rusted through chrome on the caliper piston all the bits look to be in perfect order, just filthy.
I'm going to turn a new SS piston for the caliper at work I think, rather than try to track down a factory replacement.
Looks like it uses the same pads as many scooters and dirt bikes etc so there cheap and easy to find even for decent ones.

Got distracted by my phone ringing and moved my hand at the worst moment, caught the end of my finger between the body of the calliper and the piston popping out with 110psi of pressure behind it!!
After a bit of swearing I called it quits on the scooters for the day and went to work!

[Raizer]

It's been much longer between updates than I would have liked!!

After ordering the new pipe I did another attempt at getting a top speed GPS run accomplished for a comparison

That's 48mph, I don't think thats bad for a nearly stock 50!
I think I could have hit 80k if I hadn't run out of road.

I ordered some jets and clutch springs from Aliexpress, less than 2 weeks after I ordered they arrived from China

Need to get hold of a 34mm socket to change the clutch springs, I've got up to 32mm and Suzuki saw fit to recess the nut so you can't get a spanner onto it!
Still need to get a heavier contra too most likely.

As with last time I ordered the seller included a couple extra jets for free, so I've now got 72 through to 105 main jets so I should have the one I need.

Dec 16, 2015 0:34:39 GMT -5 Raizer said:

Have ordered a Next R pipe and a top end gasket kit, supposedly 6-10 days from Racing Planet in Germany, we'll see...

So yeah, 44 odd days later...

It finally arrived today, looks like it's been on a bit of an adventure along the way!*


The inner box wasn't as bad thanks to a few layers of brown paper, but you can see where the pipe has tried to escape through the bottom of the box



Was surprised to see no form of restriction in the head pipe or silencer


At this stage it looked mint to me though, so I fitted the silencer to the chamber and then had to go back to work rather than install it like I'd have rather done


It didn't come with the variator rollers that racing planet and Technigas both said come packaged with it though*


So after work I pulled the beast out of the shed and removed the stock exhaust

Still can't believe it ran so well with this mess!!

Looks the part!


But it's sitting in too far, it's close to the wheel and there's no room to get the bracket in between the pipe and the engine (and that's pretending the bracket even fitted my engine haha)


Not the best pic, but you can kinda see how far in the pipe is

Am thinking I might be able to get away with heating the head pipe and giving the whole pipe a bit of a tweak out to gain some clearance since there's meant to be spacer between the pipe and the mount too.

Little bit of hacking precision trimming with my trusty angle grinder tomorrow should sort the bracket out


Then it's time to tune


*Please note that I can not and do not blame Racing Planet at all for the delay or the missing variator rollers!!
I ordered on the 15th and I had tracking info showing the pipe left Germany on the 16th and the box was still factory sealed so RP shipped it super fast and it was Tecnigas that didn't include the rollers.

I knew it might be a little bit longer since the holidays were coming, but DHL really haven't impressed me with this!!

[Raizer]

/\ That came out a bit longer than planned haha!

One day I hope to build an engine that will suit the Pro Rep pipe, but I think the Next-R should suit this Let's just fine


In other news I think I have decided to go with a Malossi Sport 70cc kit and 17.5mm PHVA, looks like I can get either a genuine Dellorto or a Naraku clone with a flange to fit directly to my stock manifold.


Thinking it'd be better to get a bolt on rather than trying to modify the inlet to take a rubber coupler carb like most other scoots have.
Just trying to confirm that they have the oil inlet line and a vac line as I can't find any pics of them showing the fittings.

[Raizer]

Bit of cutting and bending later


Then it was time to swap the clutch springs, so I pulled the cover off and removed the clutch assembly, got it apart (turns out 34mm sockets are a lot cheaper than I'd thought lol) and screwed it to the bench to hold it solid while I pry the springs off...

Notice the fact there is 2 clutches and 2 totally different sized springs in this pic?
The lower clutch that's screwed to the bench is the SJ50 clutch I have been running, the smaller spring is one from it, the yellow spring is a "1500 RPM Jog" spring which I was about to install in the SJ50 clutch when I realized that it wasn't going to work!

So yeah I'm now running the 2 arm Let's II clutch assembly with the yellow 1500rpm springs, plan to swap them back as soon as I can find some better springs for the 3 armed clutch!!
Took a fair bit of time to clean up the Let's clutch and torque driver  assemblies as they had both pretty much seized, even without the springs it took a LOT of effort to move the clutch arms!

Tried to test ride it at this point, was a little lean, clutch engaged at about 5000rpm, accelerated very slowly and never really seemed to get on pipe, maxed about 7500rpm.

Figured it was time for lighter rollers!
Pulled the variator and checked what weight was in it


Ran a 12mm drill bit through them in my drill press


Tried riding again, after an age it seemed to start sounding like it wanted to pick up and get on pipe but was being held back, hitting about 7750rpm.
So decided they needed to be lighter again, this time I took them to work


Got them all down to 4.39g, again time to test ride


Ignore the spike to 10,000rpm+ at the beginning, the tach still mucks around a bit once in a while and sorry it's all mainly wind noise!! 
Thinking I need to go to about 4g with the rollers?
I will order a new set of decent rollers once I find the best weight, can't find much in the way of cheap rollers for testing in 17x12mm!

Good to see all the marker is gone too


So yeah, getting there I think, but your thoughts/tips are welcomed!

[Senna1Rossi]

huh, a Suzuki scooter... whadaya know.


p.s.
Such a nice looking exhaust system.  Where do you order your performance items from?