ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Jul 31, 2020 13:05:49 GMT -5
Hey Guys, I just purchased a 2005 Yamaha Zuma bone stock with 500 miles on it. This is my first scooter and I have been riding it around my neighborhood and really enjoying everything about it. But, like most people on these forums, I like working on things and modding them to much greater potential than stock. Currently I am getting around 38mph top speed and would like to get 50-55mph as there is a feeder road right outside my neighborhood with a 50mph speed limit that would allow me to access many more places to ride my scooter and even run errands with it. Since I live in a suburban neighborhood I don't want a screaming loud exhaust which is why I currently have an order on the Tecnigas Silent Pro exhaust which has still not showed up unfortunately so it is holding me up from putting most of my parts on. I started ordering a few parts from different places I found online and then stumbled upon Zino's excellent build thread for his Zuma which led me to ordering more parts. Parts from ScooterPartsCo.com: Parts from Scooterswapshop.com: Parts from Zumasrus.com: Parts from Scootertronics.com: Parts from eBay.com: Parts from Amazon.com: "Budget" overrange as discussed here and the links for the parts on dynoscooter are below:       |
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Post by geoffh on Jul 31, 2020 15:03:18 GMT -5
That,s a good looking scoot,I am going to sound like your grandad,if it,s your first rodeo take your time it,s not a good idea to throw all those new parts on in one go,you might end up dazed and confused as to what went wrong,Zino has a talent and loads of experience tuning scoots his list is a great guide but that's what it is a guide not a cert for your build.
Geoff
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Post by Zino on Jul 31, 2020 17:30:23 GMT -5
Nice looking scoot .
You got quite a pile of nice parts there .
Geoff is right go slow so you can enjoy the parts .
If you want to get started instead of waiting for the pipe
With each change go 3-4 tanks of gas so you can feel and apreciate your work .
You could swap on the malossi kit and break it in with the stock pipe
That combo alone would push you to mid 40's .
You would have to up jet the carb the mikuni jets 95,90 ,85 is the order
I would look to use and richen up the needle Because you spend alot more time on part throttle.
The Stock pipe and Malossi is actually a popular build and some guys just stop there .
Next swap on the Variator you will notice it shifts just a little better and you pick up some top end .
Save the clutch springs torsion control contra belt for after you add the new pipe .
So you can apreciate and feel the difference those parts make with the new pipe they really dont add much with the stock pipe .
Uni filter add this last you most likely will have to up jet slightly with this .
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Post by Zino on Jul 31, 2020 17:42:28 GMT -5
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ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Jul 31, 2020 19:57:01 GMT -5
Thanks for all the advice! I hadn’t seen those BBK install instructions yet and they are great after reading through.
Definitely gonna be taking this slowly so I can get it properly dialed in and not try to install everything at once.
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Post by Zino on Jul 31, 2020 20:37:30 GMT -5
If you go slow you apreciate it more and when you build your next one or help buddy build his you will have a better understanding of troubleshooting and best bang for the buck mods .
Swapping to many things at once is one of the biggest errors we see people do over and over again .
Other big errors are underjetted carbs and unbalanced cvts .
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ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Aug 1, 2020 23:25:24 GMT -5
Ok guys I have to admit that right before I started this build thread I installed the Malossi variator and outer variator pulley as I figured the variator was an easy and safe first change while I was waiting on my exhaust. The 41mm clutch tool hasn't showed up yet so I decided to try it without the white contra spring that came with the multivar and the stock belt.
As I started off things seemed alright but as soon as i started getting around 15 mph my revs were really high and I decided to stop there and put the bike up.
I was at Lowes today and spotted a crescent wrench that maxed out at 1 5/8in so I purchased it and it worked to get the clutch nut off so I put the white contra spring in to see if things were better and it helped a little but still not right.
At this point I am tempted to put the stock variator and contra spring back on but there has to be some reason it doesn't just go on and work with a stock bike?
I followed the instructions and used the 2mm adapter behind the variator and did not use the 5mm. I made sure to put the belt limiter spacer on and everything went together but is that the proper way to install it on the Zuma?
Do I need a longer belt for the new variator size? I have the Malossi Kevlar one that I was going to wait to put on after my stock belt gets more miles.
Do I need to put lighter weights than the 7gr ones it came with even though I don't have any other performance upgrades?
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Post by Zino on Aug 2, 2020 7:12:35 GMT -5
Stock belt works fine with the variator lot of us prefer stock belts until we go to overrange set ups . The malossi Variators do spin up faster than a stock variator . I am not using a 2mm spacer behind the variator with my set up. It would not give me enough travel from top to bottom on the variator shimmed like that . Tuning Tip Take a permanent marker and make a mark from the inner to out edge of the variator and run down the road full blast. Measure that you should have less thn 2 mm left. I am down to 1 mm currently . I am running less than 1 mm total shims on both ends of variator  |
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Post by aeroxbud on Aug 2, 2020 7:23:56 GMT -5
Every brand of variator is slightly different. So might need different weights. If you put lighter rollers on, it will rev higher.
When you say " I made sure to put the belt limiter spacer on and everything. " d
Do you mean the stock restriction ring? This would make it rev higher as it stops the variator closing. In effect making it stuck in a low gear.
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ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Aug 2, 2020 8:27:56 GMT -5
Every brand of variator is slightly different. So might need different weights. If you put lighter rollers on, it will rev higher. When you say " I made sure to put the belt limiter spacer on and everything. " d Do you mean the stock restriction ring? This would make it rev higher as it stops the variator closing. In effect making it stuck in a low gear. It came with the multivar and looks like it keeps the belt from going all the way down to the hub. The small stock restrictor was not put back on with the multivar. I used this install video as a guide to exactly how I installed everything and you can see at around 3:23 the limiter goes on over the variator hub right after the variator is put in but before the outer pulley. youtu.be/JBywYzPiXg8 |
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Post by aeroxbud on Aug 2, 2020 9:54:04 GMT -5
That's why it's not working right. That is a restriction. Remove it and it will work as designed.
The variator can't close and give you high gear.
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Post by Zino on Aug 2, 2020 9:55:13 GMT -5
That wedding band is not installed by anyone that wants full performance .
It is a restriction to keep you below 40 mph.
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ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Aug 2, 2020 10:57:54 GMT -5
Ah ok I will definitely be removing it today then and will report back!
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ingram
Scoot Enthusiast
Posts: 100
Location: Houston, TX
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Post by ingram on Aug 2, 2020 19:12:04 GMT -5
Ok the wedding band was definitely the problem. I removed it and was able to hit top speed again. I don’t have additional weights or shims yet to dial it in so I’ll probably go back to stock now and get ready for the BBK or maybe exhaust if it shows up before next weekend.
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Post by aeroxbud on Aug 3, 2020 5:20:42 GMT -5
That's good then. At least you know when you go back to it.
It might be worth getting a tuning set of rollers. Then when you change things you will be able to work out the ideal weight.
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