2001 Honda Elite 50 (wife's scoot)

[gsx600racer]

May 4, 2017 5:41:19 GMT -5 oldgeek said:

Thats pretty darn good for a cylinder that's just under 65cc! With the same kit on my naked Kymco I have only seen 48 in perfect flat conditions but usually it will stay around 43 all day long.

As you know from my thread I had a hell of a time getting a good tune on this kit. I took your recommendations and put the V8 pipe on, and a 19mm PHBG but I still had a really hard time getting the tune right. It is my first aluminium kit and I would have certainly destroyed it without a temp gauge to help me. As a matter of fact the tune is off a bit again due to the hot weather arriving, it seems to be slightly lean in a spot, I would have thought it would have gotten richer if anything. Cylinder temps are around 270 WOT with the occasional jump to 300 - 310 when I come off of WOT and I forget to pulse the throttle a bit to cool it off. It hangs between 225 - 260 in heavy stop and go traffic.

I may have to try a stock Kymco exhaust since you are having great results with yours. If you do try your V8 pipe, I ended up needing one of the S6 flat exhaust gaskets to finally get a leak free seal. The flange on the airsal is milled really big for a donut style gasket, but the donut style gasket just would not seal with the V8 pipe I have.

I hear ya, keep in mind this is the Honda engine, the intake opening into the case is larger than the Kymco is stock. Second I think the gearing is a factor, although the Honda cvt pulleys are smaller stock, the DIO ZX trans is like putting a piggy front and rear pulley(which are much larger) vs the kymco's stock pulleys. 

I was a believer that bigger was not necessarily better when it comes to carbs, but when I swapped from a 21mm to a 28mm, a lot of my cooling issues want away, but now its a guzzler when it comes to fuel. They say the Polini carbs are much better on fuel, but at $100+ a whack I'm not going to buy several of them till I get on e that works the best. 

I really want to put a few more miles on it with its current setup(other then needle and jet change) before I get more involved in tuning. Getting a good baseline feel I think will better idea for more/better tune. 

Its summer, we will get you into the 50's, just going to take some trial and error. I will try to help you the best I can with what I know. 

I was blown away with the 53 mph top speed, I was expecting less. I plan on replicating with vid to support it. Just waiting for the smartphone mount goodies to arrive. I got a beater Galaxy Nexus I found a few year ago on the side of the road that I had added to my plan that I want to use for the HUD speed app. In the end I want to run the same cam setup you got, I looked at it before I bought my cheapie one, plus I wanted to see how the overly stuff worked before I got one. Just looking for a deal now. lol

My Kymco with the Polini, PG short, 28mm carb and gears gave me this a couple weeks ago.

[gsx600racer]

Time to switch gears, figuratively and literally. Took the ZX off the bench and put the Elite on. I wanted to do this last year but waiting to find a deal on a set of gears. Then I found this.

www.scootertuning.ca/en/gears-secondary/1710000-gear-kit-taida-15-32-dio.html?search_query=dio&results=196



Seems they went up in price, I paid less.





I do have set of 9:1 gears I got from ryan_ott, but I think this Airsail kit a tad mild to pull them. 

[ryan_ott]

Try both and see how they both perform. Have you made any changes to the port timing from what you had listed on the first page? 172/125 Maybe it’ll make decent power lower in the rpm range and surprise you.

[gsx600racer]

Jan 24, 2019 20:28:38 GMT -5 ryan_ott said:

Try both and see how they both perform. Have you made any changes to the port timing from what you had listed on the first page? 172/125 Maybe it’ll make decent power lower in the rpm range and surprise you.

I have not touched the port timing, but when riding it a few times last year, I think I heard detonation when backing out of the throttle. I want to do a compression check, recheck the squish, and if questionable, raise the head to bump things down. Going to look into upping the jetting too.

Being more cautious with this setup seeing its a aluminum cyl kit. That and my goto source for this kit no longer has them.

[gsx600racer]

I was bored so I figured id get a head start and pulled the rear transmission cover off. Came apart pretty easy.



Then this showed up this afternoon.



This is the second time Iv used www.scootertuning.ca, and both times iv got parts within 2 days.

[gsx600racer]

So the question is, how much force do you think it takes to remove/install the gear from the final drive shaft ?

Was curious because this is the second time Iv had to do this and maybe see a 3rd and 4th time down the read and was considering getting a small hydraulic bench press or maybe a hydraulic gear puller.





I also looked for used final drive shafts(so I could just press on the new gear and leave it on), and they might as well be attached to unicorns.

[190mech]

The only set Ive done were Chinarelli long case ,they were super tough to press on!Others have used bench vices..The last press pic is the one I have now(modified,with China tools,you are buying a "kit"..)have used it on lots of projects,many crank rebuilds too...

[ryan_ott]

My AF16 gears I used a press, my Zuma I just used a 3 jaw puller. Ok I did break it but I still got it done. I’d get the bench press, it’ll come in handy in the future.

[gsx600racer]

Jan 25, 2019 19:16:07 GMT -5 190mech said:

The only set Ive done were Chinarelli long case ,they were super tough to press on!Others have used bench vices..The last press pic is the one I have now(modified,with China tools,you are buying a "kit"..)have used it on lots of projects,many crank rebuilds too...

The ones I did for the Kymco were tough too. Did them at my friends shop.

I tried this and got scared. I didn't like how the end of the tool wanted to "walk" off the end of the shaft the tighter I turned it.

[gsx600racer]

Harbor Freight has the bench version for 78 bucks

With the 20% off coupon gets its down to 63 bucks.

[oldgeek]

Get yourself a press. I got a crazy deal on the HF 20 ton press a couple years back $120 I think. Its overkill, i think the benchtop model would be better. Also works great with a short piece of 2x4 to break the bead on tires.

[gsx600racer]

Jan 25, 2019 20:41:15 GMT -5 oldgeek said:

Get yourself a press. I got a crazy deal on the HF 20 ton press a couple years back $120 I think. Its overkill, i think the benchtop model would be better. Also works great with a short piece of 2x4 to break the bead on tires.

Yeah, that's what I am leaning towards.

[gsx600racer]

Well I went to Harbor Freight and came home with nothing.

I looked at the 6 ton and figured Id grow out of that in a minute. Was going to get the 12 ton instead, out of stock. 20 ton was on sale for 10 bucks more, out of stock too. So it was a de-pressing trip.

[gsx600racer]

Well back to the scooter, did compression test last night, and it was a healthy 175 psi. A little too healthy for pump gas. Haven't rechecked the squish yet.

I did take a little peak inside and things looked decent.



I started to take the shrounds off to get to the head bolts then seen this mess.





So I went ahead and pulled the engine. Going to clean things up and pressure test it first. Still going to shim the head some to bump the compression down a tad.

I think its mostly from the exhaust, it's definitely not hurting for oil.

[gsx600racer]

So its all cleaned up.(I hate working on greasy/dirty stuff)

Did a leak test, and the only leak was around the spark plug. Swapped plug and pressurized it to 7 psi and it didn't budge for several hours. So it was just the exhaust leaking around the flange and covering everything.

Cleaned up the dome of the piston(pretty much wiped off, only had to wire brush where it was engraved)





So here are some numbers.

Head shims and squish: .037"(what are the odds that they are the same)
Compression: 175 psi

Head shim and squish: .o61"
Compression 150 psi

and what I ended up going with
Head shim and squish: .048"
Compression 160 psi

I went this route because I thought the .061 squish was on the high side.