Ingram's 2005 Yamaha Zuma Build

[Zino]

That sucks that it doesnt fit .
The polini and malossi bell do work I have used both
The good news is that the clutch nut is made of a softer grade of metal then the gear shaft and crank shaft .
So they fail instead of the bigger repair .
So you will be down for A little till you get the right nut.

[ingram]

Found a regular M10 X 1.0 nut at AutoZone yesterday so I am back in business! Also ordered the OEM replacement nut along with a few other parts on Partzilla like final drive bearings as I do plan on putting 14/42 gears in eventually.

The Malossi multivar and top performance rear pulley are a really nice combo! Using the recommended Polini belt the travel on the variator is spot on. I will play with shims a little as the belt might be able to reach closer to the bottom of the variator but it definitely is reaching within 1-2mm from the top.

The included 7gr weights were alright and I tried 6gr which definitely got things moving faster from stop but top speed was not as high. Will try 6.5gr next but I also want to play with the clutch springs as I am getting a little rolling at first before things kick in now with the BBK installed.

[Zino]

Good to hear your back on the road .
Both sides of the malossi variator when properly shimmed will get to 2mm or less on top and bottom left from the sharpie test.
When you get your pipe be prepared for even stiffer clutch springs and lighter weights The extra power from the pipe will fling the weights out sooner

[ingram]

Ok I got the Malossi MHR Bell in the mail today and it works great without clearance issues, also higher quality in my opinion than the Stage 6 Bell so I am all smiles now. Dynoscooter also is accepting a return of the Stage 6 bell without a hassle so major props to their customer service.


Here is my latest sharpie results after running down the road. I am happy with the top but the bottom looks like I need to add another shim to the drive boss?

[Zino]

You have a little room even less than a 1/2 mm more shim can clean that up .

[ingram]

My cheap temp gauge didn’t work out so I was looking at the trail tech gauges and ended up going with the Vapor as it isn’t a whole lot more than buying the temp and tach gauges separately and gives me a full speedometer now which will be nice.

So over the past few days I have been deciding where to mount it and ended up putting it just below where the stock gauge goes. I had to carefully measure where to drill the mounting holes and I think it came out real nice. Next up is getting all the sensors installed on the zuma.

I got the Vapor from treatland.tv and they actually have quite a few other parts including 16X13 roller weights for $5 per set so I got me some 4.5, 5.5, and 6.5 weights now.

[Zino]

Some guys just center the vapor over the stock gauges.
THey Balck out the plastic and discontinue the stock gauges .

[ingram]

Aug 21, 2020 7:15:33 GMT -5 Zino said:

Some guys just center the vapor over the stock gauges.
THey Balck out the plastic and discontinue the stock gauges .

Yes I have seen that but decided I wanted to keep the stock gauges for now to maintain the fuel gauge and signal/oil indicators. The holes I created to mount would be simple enough to cover back up if I ever decide to remove the stock gauges in the future.

I have been watching the 49ccScoot videos on Youtube which are a great resource for the Vapor. Part 2 specifically shows different installation and mounting tips: www.youtube.com/watch?v=9A5oq70SG_w

[aeroxbud]

You can see how inaccurate the stock Speedo is now 😉

[ingram]

Ok got the Vapor fully installed and took some pictures of the plug when I removed it to put the temp sensor in. This was a brand new plug that I put in at the same time as the BBK so this is what it looks like after only a couple runs around the neighborhood.



Speed sensor installed. I used the bolt magnet to replace one of the rotor bolts and then used the mount available on Treatland that I purchased with the Vapor to mount the sensor to one of the caliper bolts.


I found a nice spot in the ignition wiring for 12V battery source that I wired the Vapor to.


All mounted and turned on!



I added another 1/2mm shim to the variator boss and now my sharpie marks look great. So in the end I don't have any shims behind the variator and have just a hair under 1.5mm in total shims on the drive boss to get the belt all the way down.

[ingram]

Ok I got my 14/42 gears installed today and will post pictures later but I am getting a slight grinding/rubbing noise from the gears at low speed or when I let off the throttle. I only left my driveway and then turned around because I wasn’t comfortable with the noise to continue. 

here is a video so you know what I mean: photos.app.goo.gl/necZzr3Y5y4gUx7T9

I refilled with about 120ml of Bel Ray 80w90 hypoid gear saver oil that I bought from scooter swap shop. So, is the gear oil I used and the amount correct for the Zuma? Is this noise normal at first and goes away after a while? Or is this normal for these straight gears as opposed to the helical ones that came stock?

[aeroxbud]

My straight cut gears never sounded like that. It was more of a whine.

[ingram]

Aug 29, 2020 19:18:29 GMT -5 aeroxbud said:

My straight cut gears never sounded like that. It was more of a whine.

I pulled the gears out and re-pressed as well as put a brand new bearing on the drive shaft and the grinding noise really isn’t present anymore but definitely a loud whine while going down the road. It’s actually pretty loud so I’m not sure if that is normal? I took a video of the whine:
photos.app.goo.gl/SLUUXB9vZnEC7dHM9

[aeroxbud]

I had the stage 6 ready pressed gears. That does sound quite loud. But it's hard to tell from a video.
I would give it a while to bed in properly, then see what they are like.

[Zino]

My gears were really loud they sound like a turbo spinning up they do get quieter over time but I still hear them thousands of miles later.