My Super 9 AC Build

[lbo]

After 16,000+ KM of driving on the 50cc I decided an upgrade was due. Sounds simple; 70cc Malossi, 19mm arreche carb, and a Technigas RSII pipe.


This is her before the tear down;





First thing was the intake manifold, had one laying around for a couple years and going to put it to use. Have an upgraded space and manifold (going from 14mm to 19mm) so that will work, I ported out some of the rough edges on this manifold.

I did manage to over torque a head bold but got that out, waiting on replacement bolts as I type (and the pipe.)

My current hiccup is the carb install. Tring to figure out how to get this cap off without cutting it off. I have heard there are tabs within that can help remove it but haven't figured it out. So how do install this??

Cap:



This is where I need help, not sure what order and how to with these parts.



On a side note I also bought the HOCA variator but the backplace didn't fit. No worries I drilled it out so it would then realized it's too big and rubs where the starter is located.



Meh, I will use what I had and the new Dr. Pulley weights. I also got a new belt and is much tighter, the other was worn. Got an original BANDO belt as a kevlar I had before was shredded quickly.

Another concern is that the malossi reeds that came with the cylinder didn't seem to match up, so I went back to stock. Is it a big deal to use stock?



Lastly, while I am waiting on parts, is there anything I can do to restore or clean the plastic? You can see what was covered and what was exposed. Any good cleaners or method to restore it?




In summary right now is help with the carb. How do I remove the old cap and what order does the Arreche parts get installed?

[90GTVert]

Aug 31, 2011 19:25:54 GMT -5 lbo said:

This is where I need help, not sure what order and how to with these parts.

Is #4 the spring compressed? Put #2 through #3 in the center hole. Get the cable through the cap (should be no diff in the two) and then put #1 on. I use 1 to compress and hold the spring up against the cap. Maneuver the cable through the slot in #3 and move it sideways where it should sit. Then you just have to get #1 properly situated in #3. It might take some getting used to, but it's not that hard.

Aug 31, 2011 19:25:54 GMT -5 lbo said:

Another concern is that the malossi reeds that came with the cylinder didn't seem to match up, so I went back to stock. Is it a big deal to use stock?

You made the right choice there. Looks like the reeds aren't made for your app. The last thing you want are reeds that don't seal.

[lbo]

Thanks.


First thing is deciding to get the cap to the stock carb off the throttle cable. Any ideas???

I have seen videos of taking a demel to cut it off and heard of a way to release it using picks and it releases from the L_bend piece. Not sure if I should remove that stock L too and replace with part in kit.

[90GTVert]

I'm not familiar with your carb so the best advice I can give you is to wait for more help and to examine it closely with plenty of light to see if there is anything that could be released in there. On most minarellis the cable just pulls out. The elbows on ours usually unscrew or there's a lip under the cap that can be ground or cut off to remove the whole elbow.

[jmkjr72]

i dont know how to get your cap off but you should use your existing l
yeah i have noticed from time to time reeds dont match up but if i can i normaly use the old ones as a tempalte and trim the new ones to fit with a hobby knife and clear nail polish on the edges

[lbo]

Thanks. Yeah those malossi reed just aren't wide enough to trim so I guess I will go with stock. They seem to be of the same thin carbon fiber material. The cap to the carb has me perplexed.

[Thebatman]

n, Yeah i went thru the EXACT same thing with a set of reeds. On the s9 i have YET to find any other reeds except for the oem. NO aftermarkets... There is only 1 intake made aftermarket also...
Here is a link to show you haow to do your carb set up....
f1.grp.yahoofs.com/v1/QANfTn6BL3cf8x4a9MsudBv5lyTBRv_vUqmbMskSGB9pYbAuKwcKRFA0O-ChzEQrtBmaQq4oG-n6wpWKNXiZNJ9fNUd42RxV44E/How%20To%20-%20Install%20an%20Arreche%20Carb.doc

[90GTVert]

May be of interest... 1st 2 show how to remove the cap w/o cutting.

[2strokd]

Nice! Can you post some pics of the intake you are using? Can i ask were you got it?
Everyone i know that gets a Malossi BBK for a Kymco SF10 ends up with a set of Minarelli reeds.. They are a direct fir to a hori Mina but wont fit your S9 . I had to cut my own for an SF10 build out of a carbon sheet.

As far as the plastic goes... Just spray it down real good (soak it) with any ArmorAll type product and let it sit for awhile. At least an hour IMO. Then wipe away to decent plastic again. If that dosnt work for you, you might decide you want to paint it? In that case, its just normal paint prep. Make sure you use a paint good for plastic. But honestly ive seem plastic that was almost white from fading still come back to shiny black after a good soaking. UV rays and weather have beaten the color right out of it. Mine was the same when i got it.
Nice scoot!

[lbo]

I got the intake from someone over at the Super 9 yahoo group a while back, he explained it was one that comes with the Super 9's in Canada. Apparently in the US it's a smaller intake, had it sitting around for a couple years.

Here you can see the difference in the spacer alone;


Here is the new spacer with the new intake on the old carb, quite a noticable difference;


The manifold had a port for the oil injection, I sealed it up and will hook up the oil to the carb. A picture of the manifold after some dremel work and as it sits now. It looks like the stock manifold, just 5mm larger on the inside;

[lbo]

Back to the cap on the throttle cable. I do see two notches on the top of the cap, I have stuck all kinds of things in those tiny notches hoping to release it. No luck.

I looked at those videos (thanks for posting) before and it never really showed how he got them off. I think cutting it off might be best but I know there is some way to get it off without destroying it. I saw somewhere else there is a C-Clip and stuff but still don't know how to access that.

I got my head bolts, only other thing I am waiting on now is a new gasket. The old one was oily from the oil applied to get the broken bolt out. I had used a little gasket maker to seal it well and why I didn't remove it sooner. Anyway the RSII pipe and this gasket is all I am waiting for. The gasket should be here soon and can use the old pipe until it arrives.


Thanks for the help, any ideas on this cap removal before it sees a dremel is appreciated.

[2strokd]

Not sure about the throttle? Ive never messed with mine on my Kymco yet. Thanks for sharing the info and pics of that intake! I had no idea and never heard of there being different sizes. Can you give me a measurement of the two? Just the spacer is fine!

[lbo]

The one, stock, measure 14mm and the new one is 3/4" or about 19mm. Same with the intake.

With a standard tape measure..........stock manifold;


Upgraded one;






My understanding is that this is a point of restriction on my '07 and the CDI was is not restricted. The tube from the airbox to the carb I have heard is also a restriction for the AC US models........ looks like it's smaller too. Not sure how true this is or if different from previous LC models but no doubt the 19mm intake is bigger then the stock 14mm intake on my '07.



Back to the reeds, here is another picture showing the difference;

[2strokd]

I agree... My 03 model has a 19mm tho, as well as the 01 my Uncle owned. I guess its the newer models with this type restriction.

You can probably sell those reeds to a Minarelli owner? They will fit the horizontal mina...

[reveeen]

That manifold..... it looks to me like the Honda Dio one would fit, or I should say: the aftermarket one:

www.treatland.tv/OKO-26mm-reed-block-intake-p/oko-dio-reed-block.htm

Measurements are there (I'm really hoping to get some Honda scans up in the gasket area soon)