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Post by joshua864 on Dec 17, 2016 3:10:34 GMT -5
Patent pending... Great job! Maybe. LOL Nahh, I sorta stole the idea from the those that make the "Ankle Biter" setups for the Ruckus. They use a 2 plate system where mine is just one. The Kymco's belt runs on the inside of the trans and not the cover. The Ruckus's belt runs in the cover hence the 2 plate setup. Kymco Trans.  Ruckus setup.  That bottom pick is of gy6 150cc. Not the ruckus GET engine |
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Post by gsx600racer on Jan 11, 2017 3:54:53 GMT -5
More updates. After taking a few weeks off from scooter stuff,(holidays and ect) I'm back to messing with this project. I had a few set backs which were anticipated. In the vid, seems the cover worked with the 2003 ZX50. When I tried fitting on the 2005, the starter bendix bound up. I'm not sure why, the stock CVT covers were swapped between the two.  So after many trial and error fittings, shifting holes, modding the bendix support bracket, I got it to the point it worked. Unfortunately if I removed it and put it back on I had to tweak the cover so the bendix would spin freely again. I was relaying on the small cover holes to locate the cover. That idea didn't work. I ended up opening up two of holes where the stock alignment pin locate the cover. To make the align with the case I opened up the holes slightly with a drill, the modded a dremel bit that would follow the case hole while open up the cover hole to match. Sorta like a zip bit for cutting holes in sheet rock for electrical boxes(highlighted in green) Next issue was the belt, I thought the belt would be fine but I was wrong. I fired off the scooter and it ran up a bit and a couple seconds later I smelled burnt rubber(not the tire type. lol) I forgot to take in account as the belt rides up the pulley, it shifts to one side, the cover side.  So the belt hits the cover(highlighted in red)  I am toying with a couple options, machining the cover half the thickness(red area)and shimming the cover out some or a combination both. I will have to go back and re-machine the bendix bracket to compensate the difference from shimming.  |
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Post by gsx600racer on Aug 27, 2017 22:51:08 GMT -5
I had a chance to revisit this project again and finish it. In previous post I wanted to machine slots in the plate to fix the belt interference at full speed, but decided on spacers instead. I didn't want to weaken the what little metal I had to work with. So this is what I ended up with.  
Center stand lever looks a little out of place without the full cover.  
Showing spacer(s) gap 
Spacers and Alignment pins  
A short vid in action. Iv taken a few rides with this setup and no issues. There is a slight bendix singing noise at higher rpms, but chances are this noise existed before and was muted by the full cover. Nothing is hitting or grinding. |
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So after many trial and error fittings, shifting holes, modding the bendix support bracket, I got it to the point it worked. Unfortunately if I removed it and put it back on I had to tweak the cover so the bendix would spin freely again. I was relaying on the small cover holes to locate the cover. That idea didn't work. I ended up opening up two of holes where the stock alignment pin locate the cover. To make the align with the case I opened up the holes slightly with a drill, the modded a dremel bit that would follow the case hole while open up the cover hole to match. Sorta like a zip bit for cutting holes in sheet rock for electrical boxes(highlighted in green)
So the belt hits the cover(highlighted in red) 