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Post by gsx600racer on Mar 26, 2016 1:26:13 GMT -5
Well the scooter I told myself Id leave stock other than some cvt tweeks is on the bench. Will share pics as I go along. Base parts list. Polini Corsa 70cc OKO 21mm Carb w/o power jet OKO 26mm reed block CT intake UNI Air Filter Tecnigas Next-R chrome Malossi gears 16/32 Oil pump delete plug Iv deleted the "droopy" US turn signals and wired/connected the existing European signals. Pulled engine and started stripping down. Now the fun stuff, cylinder to block matching. This is what Iv got to work with.  I am disappointed in the case halves where the boost port is. My 2002 ZX was at least cast-ed evenly. So the first question, do I go crazy getting rid of all the "red" and blend into the neighboring surfaces? I really do not want to split the case if I don't have to, but I have a feeling before I am done the case will come apart. |
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Post by 90GTVert on Mar 26, 2016 6:52:35 GMT -5
If you can get it sealed off enough that you can blend that in without getting debris into the rest of the crankcase, I'd go for it. Still flush it afterward, even if you don't think anything made it's way in. If you split the cases, definitely do it. You don't really have to. You should still get nice gains as-is.
That "I'm gonna leave something stock for once in my life" resolution is nice, but pretty short-lived for most of us here.
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Post by oldgeek on Mar 26, 2016 7:06:51 GMT -5
Definitely open up the intake windows if you do anything. You should also consider deleting the oil pump and going premix. Here is a link to my build, there are pictures scattered around in it. Kymco SC10 buildEDIT: I see the delete plug in your parts list now. Also what malossi Part # are your gears? I doubt they are going to fit, at least the ones I have will not work. Also I see this is not your first rodeo with this motor.  |
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Post by gsx600racer on Mar 26, 2016 20:47:34 GMT -5
Definitely open up the intake windows if you do anything. You should also consider deleting the oil pump and going premix. Here is a link to my build, there are pictures scattered around in it. Kymco SC10 buildEDIT: I see the delete plug in your parts list now. Also what malossi Part # are your gears? I doubt they are going to fit, at least the ones I have will not work. Also I see this is not your first rodeo with this motor. Iv played with a few Elites and have 2 Kymco's and 1 Elite here. I like the fact most parts crossover. This is my 3rd bbk build(mine) Iv done/working on. Iv seen your builds here as well as on a the "spree" forum. Nice seeing other ZX50 peeps here I got my gears from Treatland. Confirmed fit thru Racingplanet site. www.treatland.tv/peugeot-fox-malossi-race-gears-many-more-p/fox-malossi-race-gears-676458.htmwww.racingplanetusa.com/transmission-gear-malossi-kymco-kb50-fever-p-1302-1.html?backcPathco=3&cPath=2_622#.VvcCFfkrKHsPulled transmission apart to confirm they fit. There might be issues with gear widths. Working on the math. Pressed on gear width(large) Malossi/.417" Stock/.393" Input shaft gear width(small) Malossi/.558" Stock/.617" Will let you know what my game plan is for the gears after talking to someone.(shim and/or surface grind gears) Got pics for ya. Stock on left/Malossi on right  Left to right. Malossi gear(front)/stock gear(rear). Malossi input shaft gear. Stock input shaft.  To make my life easier, I am just going to order another 6203 bearing vs pressing the old one off. Hope this helps. |
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Post by ryan_ott on Mar 26, 2016 20:56:03 GMT -5
Seems to be a lot of these zx50 around lately, not here though. Should be a nice motor when your done.
DONT FORGET THE GEAR OIL!!!!!!
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Post by oldgeek on Mar 26, 2016 21:03:44 GMT -5
Seems to be a lot of these zx50 around lately, not here though. Should be a nice motor when your done. DONT FORGET THE GEAR OIL!!!!!! Like I did? Lol! |
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Post by ryan_ott on Mar 26, 2016 21:04:54 GMT -5
Just a friendly reminder...
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Post by gsx600racer on Mar 26, 2016 21:12:08 GMT -5
If you can get it sealed off enough that you can blend that in without getting debris into the rest of the crankcase, I'd go for it. Still flush it afterward, even if you don't think anything made it's way in. If you split the cases, definitely do it. You don't really have to. You should still get nice gains as-is. That "I'm gonna leave something stock for once in my life" resolution is nice, but pretty short-lived for most of us here. I am not going to go too crazy on the clean up. Have seen some builds where people gone nuts with material removal. I will be cleaning up the intake as well, seem the Kymco's and Honda's are famous for bottle-necks in that area. Iv spent a few weeks contemplating doing this or not. The fact that this scooter has less than 1000 miles on the stock crank was sorta a no brainier to do it. That and $240 for the kit, $90 for the gears, $150 in carb, intake, needles and jets. Seeing that stuff sitting on the shelf doing nothing was a motivator too. lol |
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Post by oldgeek on Mar 26, 2016 21:13:17 GMT -5
Definitely open up the intake windows if you do anything. You should also consider deleting the oil pump and going premix. Here is a link to my build, there are pictures scattered around in it. Kymco SC10 buildEDIT: I see the delete plug in your parts list now. Also what malossi Part # are your gears? I doubt they are going to fit, at least the ones I have will not work. Also I see this is not your first rodeo with this motor. Iv played with a few Elites and have 2 Kymco's and 1 Elite here. I like the fact most parts crossover. This is my 3rd bbk build(mine) Iv done/working on. Iv seen your builds here as well as on a the "spree" forum. Nice seeing other ZX50 peeps here I got my gears from Treatland. Confirmed fit thru Racingplanet site. www.treatland.tv/peugeot-fox-malossi-race-gears-many-more-p/fox-malossi-race-gears-676458.htmwww.racingplanetusa.com/transmission-gear-malossi-kymco-kb50-fever-p-1302-1.html?backcPathco=3&cPath=2_622#.VvcCFfkrKHsPulled transmission apart to confirm they fit. There might be issues with gear widths. Working on the math. Pressed on gear width(large) Malossi/.417" Stock/.393" Input shaft gear width(small) Malossi/.558" Stock/.617" Will let you know what my game plan is for the gears after talking to someone.(shim and/or surface grind gears) Got pics for ya. Stock on left/Malossi on right  Left to right. Malossi gear(front)/stock gear(rear). Malossi input shaft gear. Stock input shaft.  To make my life easier, I am just going to order another 6203 bearing vs pressing the old one off. Hope this helps. Those gears are different from mine. I saw the ones you have on Treatland also, they looked like would fit, but I. Think they will take you from stock 10.65 to 6.92 and it will be hard to pull that gear! By the way I am looking for a stock primary gear set. Do you have a good source for them or do you have a set that you want to sell? |
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Post by gsx600racer on Mar 26, 2016 21:16:13 GMT -5
Seems to be a lot of these zx50 around lately, not here though. Should be a nice motor when your done. DONT FORGET THE GEAR OIL!!!!!! Like I did? Lol! I know, I know. LOL. Once the transmission is bolted back together, that will be the next to do on the list. Thanks everyone so far. |
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Post by gsx600racer on Mar 26, 2016 21:34:20 GMT -5
Iv played with a few Elites and have 2 Kymco's and 1 Elite here. I like the fact most parts crossover. This is my 3rd bbk build(mine) Iv done/working on. Iv seen your builds here as well as on a the "spree" forum. Nice seeing other ZX50 peeps here I got my gears from Treatland. Confirmed fit thru Racingplanet site. www.treatland.tv/peugeot-fox-malossi-race-gears-many-more-p/fox-malossi-race-gears-676458.htmwww.racingplanetusa.com/transmission-gear-malossi-kymco-kb50-fever-p-1302-1.html?backcPathco=3&cPath=2_622#.VvcCFfkrKHsPulled transmission apart to confirm they fit. There might be issues with gear widths. Working on the math. Pressed on gear width(large) Malossi/.417" Stock/.393" Input shaft gear width(small) Malossi/.558" Stock/.617" Will let you know what my game plan is for the gears after talking to someone.(shim and/or surface grind gears) Got pics for ya. Stock on left/Malossi on right Left to right. Malossi gear(front)/stock gear(rear). Malossi input shaft gear. Stock input shaft. To make my life easier, I am just going to order another 6203 bearing vs pressing the old one off. Hope this helps. Those gears are different from mine. I saw the ones you have on Treatland also, they looked like would fit, but I. Think they will take you from stock 10.65 to 6.92 and it will be hard to pull that gear! By the way I am looking for a stock primary gear set. Do you have a good source for them or do you have a set that you want to sell? Sorry, I am hanging on to mine in case I don't like the Malossi set. I am hoping the Corsa makes enough low end torque so it will balance out the "tall-ness" of the new gears. As for sources, Iv used Racing Planet for OEM(but pricey), I did check out the local Honda shop(sells Kymco too) about a new crank, they quoted me $125 w/o outer bearings. Thought that was too good to be true price for OE, going to double check when I am out again with this PN/13000-GR1-9600.(see if the were quoting OE or aftermarket) I am always looking on CL for part ZX's, will let you know if I find anything. I am trying to find a CVT cover I can mod for venting. |
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Post by gsx600racer on Mar 27, 2016 19:51:41 GMT -5
Let the case clean up begin. The debate to split/not split the case ended in splitting. The more I thought about it, I wanted to do this right and hopefully once. It actually came apart easier than I thought would. So I started with the intake. It's scary to see how the factory cleans up things before assembly.   Small preview of how much I am cleaning up.  Finished results. I didn't go crazy with the height of the opening or remove the center "web". Iv seen/read some builds where they made it too thin and removed the web and had issues with leaks/sealing. My guess is Iv made the opening a 1/3 larger.   Well that was the easy part. So much for slapping on cylinder, more problems.  I think I am going to knock off the corners that are hitting first to get the cylinder to sit properly on the engine case. So much for making opening up the intake and making it purdy.  Once I get the cylinder fitment, then I can see how much I have to remove to open intake window up. I dont think I will have to do the same to the opposite half of case seeing there is no intake window. Comment/feedback welcomed. More to come but need to take a break, The Walking Dead is coming on shortly. lol |
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Post by oldgeek on Mar 27, 2016 20:31:53 GMT -5
Looks good to me. I agree with you about the center and not getting it to thin. If you desire you could cut some more from the outer right and left side of the windows. Every little bit helps in this bottleneck area, I cant wait to get a ported one running again!
I also had a problem with the cylinder skirt hitting on one of my case sets, but not on the other two, so there must be slight differences in cases from year to year. I trimmed the skirt corners to remedy mine.
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Post by gsx600racer on Apr 1, 2016 23:34:23 GMT -5
Oldgeek, I am going to make ya proud again. I got the CT intake manifold out and was pre-fitting and checking things out and I didn't like the step at the top of the intake window, so out came the dremel again. So I went from this.  To this   All thats left is matching the manifold to the intake.  Also trued all the surfaces on the CT manifold and reed cage with my surface plate and sandpaper. Id like to hear your thoughts as well as from others here on this. I mentioned in a previous post that I was doing the oil pump delete, premixing and installing pump plug. Wellllll I was thinking of keeping the pump. Here's why. With premix all your oil is in the gas. Which is great if your running wide open getting the most fuel and oil when wide open. When you back out the throttle(especially from wide open), the needle drops and less fuel/oil as well as air is passing thru the engine but you engine is still spinning at a high rpm due the the clutch has not disengaged and your still moving at a pretty good clip. So my thought was to leave the pump, and unhook the cable so its only supplying oil at idle rate. In doing this the engine is getting that little extra oil it would be loosing from the throttle being closed. I still will be premixing as well. Kinda like a off throttle insurance policy. It might smoke a little more and maybe foul plugs quicker. lol |
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Post by Lucass2T on Apr 2, 2016 2:24:50 GMT -5
Looks good! A lot of pics is also nice!  |
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