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Post by Zino on Jun 9, 2020 23:47:11 GMT -5
There is a formula for a safe starting point that should ave you pig rich unless you are open filter for a dellorto 21 mm carb x .9 x 5 = 94.5 for the main jet Round up to the next size jet you have above that You should be gurgly rich at wide open and then work your way down till it cleans up . If you are not gurgly go up a couple jets and then work your way down . High speed runs wide open are agoo way to get you in range I like to take the richest jet that gives me the highest speed and then do a WOT plug chop with that jet and look for a smoke ring I beleive 90GTVert and ryan_ott are currrently running 21 mm dellorto they will probably chime in. Here is the discussion www.tuningmatters.com/how-tos/how-to-quickly-determine-the-carburetor-main-jet-size/I b
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Post by hippo008 on Jun 11, 2020 10:55:40 GMT -5
Zino I saw that article a little while ago. Since I have a racing exhaust and pod filter that means I should add the .05 to the modifier. 21 x 1 x 5 = 105 main jet which seems big for my scooter.
I'd rather be on the large side than the small side though. Ill start there.
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Post by hippo008 on Jun 12, 2020 13:35:07 GMT -5
Another update video today. Let me know what you guys prefer. The videos let me cram in a lot more information than a write-up but I tend to ramble. Whatever works!
The TrailTech Vapor came in last night and I got that installed today. I also got some miscellaneous wiring and cleanup done. The pump is installed, the switches are installed correctly, everything works and no shorts anywhere.
Im not sure what to do about the nest of wires beneath the handlebars. If you guys have any ideas let me know.
No updates for a little while im heading out on vacation. It will be nice to get away from COVID, work and to step away from my project for a bit.
More to come (eventually)
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Post by hippo008 on Jun 30, 2020 18:56:30 GMT -5
Ok everybody. After some time away from this project I am back at it and have really made some progress.
Ill start with the bad news. I was doing some heat cycles on the new Stage6 Streetrace cylinder with the radiator hooked up temporarily in the new unfinished cowling. The exhaust flange cracked around one of the studs during the very first break-in ride. Stage6 is unwilling to replace it and ScooterTuning understandably wont take a return on the item. Thankfully they offered me a site credit to use in replacement which is good enough for me. As a replacement I ordered up a Polini Corsa and a Top Preformance PGO Race Crank to handle the horsepower. I may do some porting on the Corsa but I am not sure. If anybody has any pointers on porting I would really like to hear them. I have been reading this blog and have found it really useful.
Today I broke down the engine cases completely. I used a Tusk brand case splitter and couldnt be happier with the results. Made a very scary PING when the cases separated but that was just the crank being freed of its bearing.
I also got around to flowing the case halfs. I did not want to go crazy so I just used some small files and a rotary cutter on a very low speed. I also used some different abrasive paper to blend the surface. Here are some pics, let me know how I did!
Lastly I am almost finished with the new cowling and the fit is perfect *italian kiss fingers* couldnt be happier. Ill take some pics after some more sanding.
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Post by hippo008 on Jul 4, 2020 20:16:58 GMT -5
Does anybody know if the Genuine motors have gear kits? I know one user on here whoaabuddy put one in his buddy. Im not sure what gears they are and where he got them though.
Anybody know what I should do? Any ideas for gear ratios?
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Post by hippo008 on Jul 14, 2020 19:32:27 GMT -5
Got some work done today on my day off.
I got a bunch of parts in from ScooterLounge and Racing Planet including the crank and bearings. I stripped the cases down for degreasing and more cleaning. I used the heat method to install the bearings onto the crank however no matter what I did the crank wouldnt install into the cases straight. I ended up using a bearing splitter and a two arm puller to take the bearings off the crank. I used a race installer and a torch to seat the bearings into the cases. Using the same heat method I installed the crank into the large case half and applied the Hondabond around the sealing areas. I tried using heat to get the small case half on but that didnt work. I ended up using my Tusk crank installer to get everything installed and centered up. The case bolts were tightened to 10ft/lbs per PGO specs. I replaced all the bearings and seals with brand new stuff. Pretty much everything in this engine will be totally fresh.
I also got around to building the transmission. I replaced essentially every component in the CVT with brand new stuff. All new washers, spacers, bendix, electric starter gear, nuts and drive face direct from PGO. The variator is a Malossi Multivar PGO New Motor model w/ Stage6 4.5g rollers. The clutch is a brand new PGO clutch with Polini green springs from a tuning kit and a NCY performance clutch bell. The primary pully is new from PGO with a NCY secondary slider and a yellow Malossi contra spring. The belt was replaced with a Dayco Kevlar belt for strength. I am hoping this will be a good setup.
CVT tuning is really out of my realm of understanding. Are there any good resources I can look at to help better understand the CVT and how to tune it?
I decided now would be a good time to do some "best practices" stuff while the motor was out. I broke out my tap set and chased all the threads all over the cases. An air gun was used to blow out all the threads and clean everything up. Some of the casting defects on exterior of the cases I took some files to and cleaned up.
I was hoping to assemble the bottom end but the stator had other plans for me. I am not sure what happened but the stator bolt hole in the cases just blew out when I put a bolt in. I was using a torque wrench set to 10ft/lbs per PGO specs. I mixed up some JB weld and with the cracked off pieces I roughly assembled the broken cases and filled the old bolt hole. Ill use my M6x1 tap and cut a new thread tomorrow.
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Post by Mech Warrior on Jul 15, 2020 12:57:30 GMT -5
General rule of thumb anything over 10k you want a performance crank Ive been reading through lots of dyno numbers. PedParts seems to have a lot of the best information available. What is the hypothetical limit of the stock crank? Ive been told 11k is about the limit of any stock Minarelli crank, lower if a china clone. However I have also been told stock cranks do just fine into high rpm builds up into 14k. Ive been looking around online and there are seemingly only two "race" cranks available for PGO engines. Im not sure if they are rated to the RPM required. Lastly, I am always a bit nervous with aluminum single ring cylinders. Can I expect the same reliability from an Aluminum bore as a two ring cast iron?
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Post by hippo008 on Jul 15, 2020 17:20:18 GMT -5
General rule of thumb anything over 10k you want a performance crank Ive been reading through lots of dyno numbers. PedParts seems to have a lot of the best information available. What is the hypothetical limit of the stock crank? Ive been told 11k is about the limit of any stock Minarelli crank, lower if a china clone. However I have also been told stock cranks do just fine into high rpm builds up into 14k. Ive been looking around online and there are seemingly only two "race" cranks available for PGO engines. Im not sure if they are rated to the RPM required. Lastly, I am always a bit nervous with aluminum single ring cylinders. Can I expect the same reliability from an Aluminum bore as a two ring cast iron? I ended up with a Jasil Full Circle PGO crank which is rated for 14,000RPM according to manufacturer. I think the full circle crank should also bring up my primary compression and aid in filling. Im not sure what kind of RPM the Corsa lives at, I have been told its something like 10k. I think the Yasuni R + stock Corsa should be fine on the Jasil crank.
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Post by Zino on Jul 15, 2020 17:39:29 GMT -5
You will be in good shape . The yasuni r runs out of steam below 11k rpms .
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Post by hippo008 on Jul 15, 2020 19:12:02 GMT -5
You will be in good shape . The yasuni r runs out of steam below 11k rpms . Zino, I was looking through some PedParts dyno charts for the Yasuni pipes. Is the R a good fit on the Corsa? I was stuck between the C16 and the R.
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Post by Zino on Jul 15, 2020 19:33:57 GMT -5
The R and C16 both overlap well with the Corsa . You have the Crank to handle either How Racy do you want your build ? C16 11000 plus rpms better top end more acceleration But it needs to rev higher to get on the pipe . So it may be more annoying in street light to street light driving .
R Less than 11,000 rpms peak Still plenty fast . Easier for Stop n Go traffic .
The Corsa is a good cylinder and pairs well with Mid race pipes like the c16 and pipes that stretch to mid race like the r you can even run street pipes that rev up to low 9s for rpms .
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Post by hippo008 on Jul 15, 2020 20:03:25 GMT -5
The aim was a reliable street scooter that I can enjoy light to light but also on longer rides too. I chose to go LC with a two-ring cast bore for those reasons. I fugure the lower revving R with its wider powerband will not only prolong engine life but also be easier to ride.
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Post by Zino on Jul 15, 2020 22:48:19 GMT -5
I fly to work 12 miles going 55 most of the way. The last 2 miles is under 35 mph . With my Yasuni R . Its Loud and Proud . Actually very easy to set up
I have run 5 gram all the way to 6 grams and it runs real well with full belt travel. I could run probably all the way down to 4.5 grams but that is running on the outer edge of the power band . It is real snappy with a rpm range of mid 8s to mid 9s for setting the variator . Most other expansion pipes you need to be within a half gram or so and 500 rpms of range Get some stiffer clutch springs you want to take off above 5000 rpms so you get a good launch .
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Post by hippo008 on Jul 16, 2020 8:37:37 GMT -5
What cylinder and CVT setup are you running Zino?
I just saw your build thread. A Malossi sport. I hope the more powerful Corsa and Liquid Cooling gets me to 60MPH top speed!
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Post by Mech Warrior on Jul 16, 2020 9:00:12 GMT -5
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