Piaggio hyper race on rexy frame, the true sexy rexy.

[808ministroke]

So i found A working boot and a big enough hose clamp to atatch my filter runs pretty good now, not as good as it has ran before with a smaller carb but The carb has yet to be properly tuned. this carb is a hell of alot different than a 28mm pwk, havent tried a kehin but polini, Oko(real and fake), and other chinese cloned pwks and the genuine 33mm Kehin is alot different so far. It doesnt seem to have all its power at aroubd half throttle and nothing much behond that like 28's seems to do. It feels alot more like a round slide to me in that respect, you can realy control the speed and reacts as ypu would expect in variuos throttle positions i.e. you can cruise slowly below 1/4 throttle and when you 3/4 s open and yougo to WOT there is a difference. Plus the quality of the slide and everything really can't be beat. I doubt Stage 6 PWKS even come anywere close.
I do wanna try and optimize the flow becasue now their is a lip on the intake going from the boot to the mount. Maybe some tapered donut for a gradual dsecrease in diameter?












I tried a little CVT tuning however should try original belt as i switched to the malossi one b4 i got carb squared away, A new carb shouldn't mess with the cvt tune, or am i wrong here? I went for Malossi belt simply because it sits higher in the rear pulley, but its thickiness may cause it to not sit as low in front so maybe its better to back to original which so far has always felt the best....




have yet to find suitable conector for the OEM Volkswagen pump so went back to Amazon one still pumping strong...



polished my exhaust port and outside of cylinder a bit, there is some scuffing on walls but it is below where combustion takes place and dont think it will matter.
I swithced my entire front brake caliper and master cylinder/lever which was needed ant im happy with it.

[billwill]

Dec 19, 2023 5:30:16 GMT -5 808ministroke said:

A new carb shouldn't mess with the cvt tune, or am i wrong here?

Dealing with some of the same issues, tuning trans and carb at the same time. oldgeek put it pretty eloquently in that, its something that can come together in unison and making a change to one may require a change to the other, and that its usually something the comes together at the same time. 

I'm dealing with this right now as I get my overrange and carb tuned. I'm using a Polini PWK 24 which is new to me so that makes it even more fun LOL.

Just this week I took the bike out and had it running pretty well. Came back and changed only the roller weights and it seems like the carb is either too lean or too rick on the main. 

Keep at it!

[808ministroke]

I ain t stopped yet .. ..
don't plan on it....
1st time tuning a pwk is a great experience, super sensitive and when done right amazingly responsive !

[808ministroke]

So I got in a little Christmas package From my girlfriend, Just to be clear I had to pick the parts out she is not a unicorn she's a real live person of the female variety.
Anyways II have been I've open box part on scooter tuning.ca for a while and it was a Mallosi torque driver for Piaggio (it didn't say it was but after comparing measurements and ones from a European parts site I was sure enough) .

I also got a open box set of new goggles and some stage 6 racing break shoes (which were desperately needed)
Have yet to put them on but I have compared the piazzio ones and the melosi ones that I also have brand new in the stage 6 ones with the Grooves in the pad at least seem like they would be very effective which as we all know rear drum breaks are usually not Something you can count on to avoid an accident if Your life depended on it.

Well my girlfriend went on a random trip to Washington so lucky me I have time to actually rebuild and finish up my bike.
I spent the last week just trying to remove a stripped cylinder nut that I assume was damaged from running a stock stud with a not chromed nut and not using coolant but water It was bound to happen and I'm never gonna simply put water in for a test and forget it ever again this was the last failure due to not having coolant in my system that I'm going to allow myself to see.
So after spending a week with a dream of trying to saw A slot in the nut or simply double nutting the end and removing the stud I finally was able to get that stripped not off yesterday it Was only accomplished by vigorous hours of hand filing...
Afterwards I was unable to remove the cylinder more than a few millimeters at a time by tapping one end of it was wood I got it about half of the way off and had already checked and nothing was binding as far as the piston or ring, It had to be the studs somehow.
Side note the 2 studs on the staterside have been replaced with malosi M6 cylinder studs that I compared to the stock ones that came with the bike and we're almost an entire millimeter wider than the thin on threaded parts of the stock studs, My plan already was to switch out the other 2 on the CVT side for the stronger melosi studs because I believe this bike needs to be completely after market except for the engine case in the rear wheel.
It literally2 2 men 2 hrs to remove, I think it cane down to a taper on the mallosi studs that i installed on case side and should have been other way round.

Today I was able to change out the rear torque driver which I thought was the last stock component I opted for the most straight of the three angles offered.

then I realized that the vell wasn't a mallosii just the clutch so I got one more component to upgrade atleast.

[808ministroke]

Initial quick test ride with the malossi rear torque converter was awesome!
what a difference compared to stock.
added a small transmission cooler to the liquid cooling loop, it sits right behind the front radiator, don't think it will cool that much better and would be mire useful if it was placed underneath the floor panel or somewhere else but since both connectio s are on same side I went this route.

Have to re wire in the toggle switch for the pump and changerear break pads still.

[808ministroke]

Did a overhaul On the rear brakes That couldn't stop a 6 pounds school bus Traveling slower than a one-legged centipede Through an obstacle course on a dry day, No joke, I mean literally I did the calculations And the scientific evidence points to The exact rate of speed through space-time Equal to that of the aneadopt listed above.📐📈✒️📖🔄 If you're really curiousThis is equal toOr greater than 0.0000021900 Miles per hour squared( times by ♑️ on your CIA issued calculator from 2099) Or3.2 inches per year cubed Divided by it's rate of decay...

With all that technical jargon out of the wayLet's get back to the humanTransport vehicle 👽I mean My build!

I initially installed these really nice looking stage 6 racing shoes that had grooves in the friction material which I'm guessing allowed for better cooling and possibly a method for dust to not collect on suwhatever the Science ha ha behind that it seems that the shoes I ordered were for minerally brownie as they fit on the bike almost perfect except the circular part At the top of each shoe was cut out to fit a smaller pin which upon inspection of my other bike realized it's exactly how the minerals are made same measurement shoes just smaller lever luckily I had a set of melosi sport shoes that were brand new that I managed to fit on so we're looking really goover the shiny obsidian Glazed shoes that I removed....

[808ministroke]

so I tracked down the nasty gremlin in my engine turns out what I thought was overheating or something related to air fuel mixture  was actually just a loose spark plug boot,  ordered the mallosi one this time instead of the NGK. BEST PURCHASE EVER. sits soo tight on the plug I cam barely get it off....

when I managed to here's what my plug looked Liked. I have noticed that one side of my plug is always darker then the other I'm assuming it could be a sign of exhaust leak, does that make sense?

I have noticed some oil residue by the exhaust header so that's what I'm thinking but other than that plug looks good yah?

[808ministroke]

well something was bound to give eventually...

[190mech]

OUCH! I'd say that case is too dangerous to drive..

[808ministroke]

I always thought that it would be pa rod holding the custom mount to the frame that would give first as it wasn't any special alloy just threaded rod probably stainless. I knew that the stretch mount, the added bracketry to connect it and the custom rear shock mount on frame were SOLID af thanks to my good freind nate.

a little shocked the case was the first thing to crack, actually the c9rner of the kicker case went awhile ago but it only put me out one bolt and one dowel from undamaged cover, could maybe have contributed to the crack in the case but I'm not too sure.
I feel that if I had gotten the rear torsen arm that are mythical status at this point this wouldn't have even happened.
but it did happen I have seen
this ocur on vertical minarellis but apparently this happens on piaggio cases as well, bummer.

Ofcoarse I'm gunna work tooth and nail to try and "weld" the crack the question is *WHAT METHOD AND WHAT SORT OF MATERIAL WOULD HAVE THE HIGHEST CHAMCE OF SUCCESS?
My buddy who did the fabing on the frame suggested to get alumaloy rods that can be brazed with just a map gas torch and apparently has a good tensial strength.

Does anyone have any other suggestions?

[808ministroke]

Mar 17, 2024 16:43:00 GMT -5 190mech said:

OUCH! I'd say that case is too dangerous to drive. 190 you were the exact person I was hoping to get a response from thank you for replying so quickly as you are basically the designated welder in this forum, I understand completely that it is not safe to ride thank God I didn't make it complease engine failure while I was going 70 miles an hour  And I wouldn't dare write it anywhere to possibly make the crack worse, But I'm glad I have you here right now cause you're the person I wanted to ask about this welding I know aluminum is a pain in the ass And someone with my skill levels or someone that isn't well versed in welding aluminum warping/melting the case.
 That's why the aluminum oil that my body recommended sounds to me like it might be the answer because it doesn't need to be at a super high temperature to be Liquified and bonded as far as I know also also since it's sort of easy to add I could add much more like a good inch thick bead To hopefully reinforce this damaged area.  I know that JB Wells won't do the trick this time there may be an alternative method like I don't know something that is a powder that maybe hardens in the something I think the bees method would be the best because I can't get away with adding a lot of extra material too.

[190mech]

The only way to do a strong repair would be TIG welding, even then it may not work out as cast aluminum tends to have poor alloys added in, have seen very high quality Honda castings impossible to get a clean weld!
Best choice would be to source another case and not waste time and money trying to fix that one..

[oldgeek]

808ministroke I have a mint set of Piaggio cases I would be willing to gift to you for the cost of shipping, which may be astronomical since I am in South Carolina and you are in Hawaii. PM me if you are interested.

[808ministroke]

ladies and gentlemen we have a angel amongst us, what a guy! If old geek does what he offered, and I believe he will then the scooter gods really are on my side.
not that I hadn't known that already....
MAN THIS FORUM IS LIKE A FAMILY where else do you Get a group of individuals that are Genuinely trying to help people reach and pursue their goals as long as their goals are Related to a moped most of mine are... If it wasn't for this form I would have never been able to build this in the first place and it's looking like because of this form my labor of love will continue I can't think everybody enough special thanks to Brent who keeps it going.

[Timmer]

Hi, how is that Fireyou master cilinder and rpm caliper holding up? I’ve read many things on them, going all over the place when it comes to either good or bad.
nk they look a lot like the Stage 6 calipers, but i don’t know if they are the same. Got any info/feedback you.re willing to shed on this? I need to replace both my master cilinders and the fireyou ones have popped up on amazon, but again, i have no experience with them.

That engine case is toast, might wanna replace that