2008 Zuma - The Keeper, Always Evolving

[oldgeek]

Chop it up! You know you will do it eventually anyway

[ryan_ott]

May 29, 2019 16:03:10 GMT -5 oldgeek said:

Chop it up! You know you will do it eventually anyway:P

But all those nice new parts... your right!

[ryan_ott]

I guess there’s no going back now. Rear caliper mount cut into case and the bracket was beefed up and welded. I cut a tad deeper this time to get some extra clearance around the wheel. The transfers also got matched up and blended, bearings are pressed in. The next break I get I’ll get the crank in and squish set, maybe tonight if I get motivated. Grinding on cases when it’s humid out really sucks, it sticks to everything.

[ryan_ott]

Bearings and crank are in, I figured out which gasket I need for .7mm squish. (Psst... it’s the .22mm base) I’m impressed by the factory chamfer on the ports. Now I’m debating whether or not to drill the piston for extra lube to the exhaust bridge. Wiesco recommends it on their pistons, is it needed?

[oldgeek]

It's been working good for you so far, if Wiseco recommends it must be right.

[190mech]

How do you cool a "butterfly"(as the Europeans say) port??Thats a tough question!Honda tried a water jacket in their roadrace motors,,All us local boys can do is keep it as cool as possible..Piston bleed holes are the only option,then hope for the best,,The hot Ex gasses flowing thru the port cause the bridge to expand and bites the piston,,soo we undercut the bridge to clear the piston when hot and keep the piston rings from snagging the port..I'd drill those holes and hope the bridge stays cool!!

[ryan_ott]

It’s been drilled and got a 2000 grit oily polish. Tomorrow when I’ve got less beers in me I’ll button it up.

[ryan_ott]

The bottom end is assembled with the reeds and intake, leak checked and it passed first try. The ring gap was right on no filing needed. Compression feels good turning it over by hand. Tomorrow I’m hoping to have time to swap it in and at least start it. I still have the gears, cvt and ignition to swap over. I think I was running a 88 with the 21mm on the Polini cast so I think I’ll bump it up to a 95 and see how that feels. I have a feeling I’ll need to find a new needle setup. By the weekend I should be up and running. Fingers crossed!

[mattyslimz]

Sweet build. I like the rear disc brake mod. I haven’t gone through the pages of your build yet but were you able to source Aerox parts i.e. wheels, brake parts from the U.K. or the like?

[ryan_ott]

The original wheels I got from a member here but I also sourced a replacement rear from eBay.uk, the front caliper is from a prebug Zuma which is the same as an Aerox. Rear you could probably make something else work but mine is Aerox, the mount was fabbed up and works really well if you don’t mind trimming the case to fit it... you also need the wheel mount. This has really turned into a fun ride and has been a good adventure get it to where it is and I love it!

[ryan_ott]

I finished up work early and got a head start swapping everything over. I kind of just wanted to get it back on it’s own 2 feet again so CVT is the same with a new TD spring and belt, I’ll adjust rollers later it needed. The water pump still needs to get setup and I didn’t want to rush that so I just put water in the motor and looped the hoses for the first start. Only took 5 kicks. Quick video below, nothing special I just wanted to hear it run. I’ve got work tonight so I’ll get it buttoned up tomorrow.
For my reference: 40/95 W9 2nd from top.

[tsimi]

I said it once and say it again. Those bronze wheels man...

Those bronze wheels look really great. Super envious.

[aeroxbud]

Yeah it lives 😁 sounds good too 👍

[ryan_ott]

I spent some time getting the water pump and direct drive adapter that 90GTVert made for me setup. To my surprise not because of his work more my measurements it fits purfect. No shims under the pump cover it under the adapter were needed. I might have 1/16” clearance between the adapter and pump casing. I decided to put a washer under the pin to keep it from getting pushed into the pump too far. A quick test it seems to work. The CVT needs work so that will be tomorrow.

[ryan_ott]

Yesterday I started it up to work on the CVT and noticed a drip of coolant under it. Wiped everything up and no drips with it off. When it runs it’s leaking through one of the cylinder studs. I guess I’ll drain coolant and see if I can get the o-rings to seal.