My Super 9 AC Build

[2strokd]

I dunno? That one is for a different style engine altogether, vertical mill. The mounting bolt pattern looks the same though. Im sure fitment would be an issue.

[Reign]

The Dio mounting pattern for the intake won't fit a Minarelli. Trust me That is to say... without modification. It might be the same bolt pattern, per say, but the intake won't fit in the area because of the angle. You'd end up having to trim at least 1 edge of the intake away.

[2strokd]

He is shopping for a Kymco SF10 engine i believe.?.

[lbo]

Alright, I got the carb on. I think 100% but I am still uncertain if I got the slide/spring/back plate in correctly. It was a lot of trial and error getting it together properly but I have a couple concerns.

Not sure if the backplate inside the slide (holding the spring down) is aligned properly, it has that notch on it and can't see if it slid into the grove properly. I am assuming I wouldn't be able to get the cap on if it weren't in correctly. Is this a safe assumption?

There is no play what so ever with the throttle, not even a wiggle. It is also tight. It will twist from the 12:00 position to about 10:00 or 9:30 to WOT. I was thinking there should be a little more range of movement.

This is what the slide looks closed;


Thinking that gap is too big and should close more.

At WOT, I adjusted the nut on top of the cap to get it open all the way;



On a side note the main jet was a 60, came with a 90 spare. Thinking that a 60 is way too small I put the 90 in. The needle was in the middle notch so I moved it up 1 to the top. Doing some research I have read I am better off with a S1 needle or to move it up one (little more lean) so hope I got it close.

What it looks like on the scooter. The cap removal of the Keihin carb was a little challanging too, I just cut it off.




Do you think the slide assembly is assembled correctly? Back plate has me concerned and only get about, maybe, 60 degrees of rotation from the throttle. I have a feeling I am going to have to open it back up.

[2strokd]

yeah, you need some play in the throttle. Just a lil will do... When you think you have it right, start the scoot and turn the bars (steering) lock to lock and make sure the engine dosnt rev on its own.
Can you adjust some slack into the cable with the adjusters?

Almost looks like the slide is in 180 degrees out? Can it be turned around?

[lbo]

Nah, the slide is in right, I am pretty sure. There is a groove is fits into and only one way it can go. There aren't any real adjustments for the cable except the nut on the top. I have adjusted it so that it now opens fully whereas before it wouldn't open all the way.

When I broke that head bolt I applied oil to help loosen it up before I extracted it out. As a result oil got all on the gasket, soaked part of it, so I dediced to replace it with a new one. Can't do much more of anything until that gasket arrives and then I can finish with the build.


I am not feeling 100% comfortable with the carb assembly, I think I need to open it up again and make sure all is correct. I can hear the spring making noises when I open it up so I am thinking it's not in correctly.

[lbo]

Upon further review it appears as though it's set up properly. There is a notch at the bottom of the carb the slide fits in when all the way closed so thats ok. At WOT the slide still goes all the way up. I guess the lack of play in the grip and the fact the grip only turns about 60 degrees around threw me off. I adjusted the nut on top of the carb and still no play in it, I guess thats normal?

Getting ancy waiting on other parts. (Gasket and RSII pipe) Thinking about modifying the airbox some. The ID of the tube going to the carb is 1", the size of the tube at the airbox end is only 3/4". Maybe that too is a restriction or the way it is suppossed to be, thinking an automotive hose with a consistent diameter might be in order. I don't know though, just getting bored and thinking of other stuff to mess with LOL

[lbo]

I fixed the carb, realized I put the backplate on top of the spring instead of below it. It moves much smoother now but still no play in the grip.


I modded the airbox today. The free flow air filters are just way too loud from what I understand. The hose going from the airbox to the carb is tiny, figured it would be good to give it more air. Bought a 1 1/2 inch hose at the auto store.

Old hose and a noticable difference with the new one;



Changed out the snorokel as well.





I also gutted the inside of the cover to get rid of some un-neccessary plastic blocking flow.

Finished product;

[90GTVert]

Nice work on the airbox.

[lbo]

Thanks!


Well..................










SHE'S ALIVE!!!!!!!!!!!!!!!!! Woo Hoo!

Gave it a few kicks and it fired right up! I drove it around the neighborhood and wow, just wow. Why I didn't upgrade years ago I don't know. This thing is a beast now.

I still need to fine tune, do my plug chops and make sure all else is good. Still waiting on my Technigas RSII pipe, currently using my old Technigas Next R. The acceleration is silly and can easily top out at my old top end at just half 3/4 throttle.......... and do so much much sooner. I am also happy it's not very loud, wasn't sure what to expect noise wise with the modified airbox, now I can't wait to get that RSII pipe and hope it's not obnoxiously loud either.


A couple concerns off the bat. The idle is high, fiddled with it some but nothing seemed to bring it down. It's fine if I am sitting on it or if I hold the rear brake. Once I let it go it will just climb, I am thinking a possible air leak maybe somewhere.

Another thing that I found odd was the condensation covering the carb. Granted the humidity is high today but what would cause all this moisture all over the carb?

[byte]

Are you using the stock cable and throttle? That's the cause of that.

[kglazer]

are you premixing?

[lbo]

Stock cable, pretty much a direct bolt on.

Not pre-mixing either, I did adjust the cable for the oil pump to open as soon as I twist the throttle and opens all the way just before it's at WOT.

I am thinking the condensation was from a combination of high humidity and the fact I didn't run it long enough for the carb to get hot. It gets up to around 50-52MPH, (speedo hits the P in MPH, well past 50) feels like it wants to go faster though. It might need more room to top out but I don't want to run at WOT for a long time while breaking it in. I think the Next R pipe is restricting it, and maybe the CDI. I do have a no-rev limit CDI to install and the RSII pipe should make a differnece.

I have never seen a carb collect so much moisture like that but was told elsewhere not to be concerned.

[90GTVert]

It's pretty natural for a carb to sweat on a humid day. The carb is usually fairly cold until it soaks up heat from being close to the engine or from the manifold. Atomization and evaporation of gas causes a drop in temperature as does air passing through the venturi. The cold carb will condense water vapor from the air and so you see it sweating. Take a cold soda out of the fridge and you'll see it do the same thing. In extreme cases/conditions you can even have carb icing.

You can try setting the idle mixture a little richer to see if the RPM at idle will straighten out. Check for intake leaks as well.

[lbo]

Yeah thanks, makes sense about the carb sweating like that.

I just did a 1/8 throttle plug chop this AM. (Excited to get it dialed in LOL) I need a better cell phone camera but this gives you an idea what I am looking at. I wonder if it's possible that the choke isn't working properly, it worked fine on the old stock set up but could be another avenue to explore. It's as though the A/F and stop screw don't make much difference. I have some jets coming and maybe I should step up the PJ when they arrive. Currently at idle on center stand the RPM's just start to climb too much.