Big Bore and Valve Cover Questions

[bhead12000]

Hi All!

I am new here and have found a great resource with you guys! I am installing some performance items to my new Chinese scooter (read: 47mm big bore, larger head, new exhaust, foam filter, oil catch, slides, ignition, carb etc.) and have a few questions. Here goes:

1.) Successfully installed new cylinder and piston. Installed new head. I need to remove the intake and exhaust manifold studs from old head and am getting no where. They seem to be locked in place. Does anyone know how to do this? If not, can I get new ones?[code[/code]

2.) When adjusting the valves to the new head, I am using almost all of the the adjustment available to get .004 for the exhaust and .003 for the intake. I am afraid to to tighten the lock nut too tight because I do not feel it is getting enough of a "bite" on the adjuster pin. Am I missing something?

3.) The valve cover has more than just a breather hose. It also has a bent chrome tube that is fashioned to the side of the valve cover. The new head has a mount for this but it is plugged. Should I leave it that way?[img src="http://i1008.photobucket.com/albums/af208/bhead12000/Scooter/IMG_0558.jpg"]/code]

4.)  I am going to a foam air filter.  What do I do with the old box that has tubes running to it?

5.)  The new intake manifold that was provided with the carb only has one hose connection as compared to the stock that has two.  What do I do with the extra hose?[code][img src="http://i1008.photobucket.com/albums/af208/bhead12000/Scooter/IMG_0545.jpg"]/code]

I hope these questions make sense.  I will try to attach pictures but am not certain I know how.

Thank you all very much.

Ben

[Fox]

Put two nuts on the studs and lock them together tightly with two wrenches then you can turn the stud out of the head counterclockwise.

Get 4 feet of 1/4 in. fuel line from the auto parts store and run it from the valve cover up the frame with a few zip ties and out the back of the scooter at the rear splash guard. Drill two holes about 3/4 in. apart near the bottom of the splash guard and run a zip tie through there to hold the end of the tube.

There's probably a black cannister on your scooter with a vacuum line and a larger tube. You can remove that all together. One side goes to the fuel tank vent. just leave the vent open to the atmosphere. You should plug off the large port on the bottom of the valve cover with a piece of the tubing that once connected there. Cut a 3 inch piece, stuff a short fat bolt in one end to create a plug and put it on the valve cover.

Or, you can remove the U-shaped tube from the head and valve cover and make a plug for the port on the head out of some 3/16 steel plate like the sketch below. All you need is a piece of 1 inch wide flat steel, a hack saw, a grinder and a drill.