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Post by ot2020 on Jan 31, 2021 14:59:44 GMT -5
Hey all, I am new here. Also I am putting disc brakes on my Yamaha C3. It’s going to be wild. And I will post the progress and parts needed here. As I get some photos I will put them here. Essentially this project requires changing the forks, wheel, axle, speedometer gear and cable, brake line and brake lever. Plus you need to buy a disc and caliper. Obviously I have chosen the largest rotor and caliper I could find. Hopefully you guys are interested More to come OT2020 This is a before pic of my scooter
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Post by aeroxbud on Jan 31, 2021 16:14:37 GMT -5
Welcome to the forum. Sounds like an interesting project.
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Post by jbjhillbilly on Feb 1, 2021 0:55:47 GMT -5
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Post by ot2020 on Feb 1, 2021 13:29:05 GMT -5
So here we go. The first thing you need is the forks. The forks for the 2012-20 zuma50 seem like they should work, mine are from a 2014 and they work nice 1CD-F3126-10-00 and 1CD-F3103-10-00. I bought them on ebay for 100 USD for the set. The next thing I bought was the caliper, now I am a fool so I bought a front left caliper from a 2013 BMW F800GT. I figured since the BMW needs 2 at the front 1 should be approprate for my scooter. Anyway, this brake is way bigger than I expected, but will still fit. I also bought this on ebay for 40 USD. For a wheel I wanted a 12" wheel from a ZUMA/BWS 125 (100-150 USD on ebay 5ML-F5168-20-33) but they were too expensive so I bought a very similar looking wheel from a Yamaha Cygnus for 20 GBP (which is like 30 USD). I think this wheel is pretty much the same but silver instead of black. I went to Ali Express for the rotor and bolts and got a 260mm rotor for the BWS/Cygnus/Zuma for ~50 USD. This thing is big and fills up most of the space inside the wheel but the caliper will still fit. Ali Express is also the source for the axle, I need a 12mm axle for the wheel and it needs to be really long to fit on the C3. The one I bought was 360mm long and cost ~30 USD. The stock axle is not long enough to be used with the Zuma50 forks as they are a little wider, if you are considering a 10mm axle set up. Next I bought a speedometer gear for a 2013 Zuma125 (32S-F5190-00-00) off ebay for 15USD and a speedo cable (32S-H3550-10-00, also for a 2013 Zuma125) from Partzilla for 7 USD. I also bought a "collar" on Partzilla that goes on the axle to hold the bearing in place (90387-125J1-00) for 7 USD.
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Post by ot2020 on Feb 2, 2021 0:03:23 GMT -5
Photos of all the parts on the axle To assemble it this far, I first needed to drill out the axle hole in the forks from 10 to 12mm. After that I put the forks on the C3 and started lining things up to determine how big the spacers should be to centre the wheel. In the end I figured out that I needed one spacer that was 18mm and another that was 24mm, I made them out of 1 inch diameter aluminum round bar.
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Post by ot2020 on Feb 3, 2021 0:21:25 GMT -5
Ok now I have made an adapter for the caliper out of plywood to get things lined up before making one out of aluminum. This took a few tries to get right but I am pretty happy with the look. Also the caliper only fits over the rotor with the pads out. After bolting up the caliper the pads can be installed I have ordered a new tire that should be a little bigger than this one, but I am worried that the fender gap may still be too high. Does anyone have experience lowering the forks. Can I cut the springs? Let me know if there is a way to drop this down even as little as a half inch would likely be enough
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Post by aeroxbud on Feb 3, 2021 4:56:56 GMT -5
That is going to stop like hitting a wall!👍 You could cut the springs, but often they have spacer tubes fitted in the fork. It's better to fit smaller spacers. Then you don't compromise fork travel.
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Post by ot2020 on Feb 11, 2021 0:00:36 GMT -5
Alright since I am waiting on some things I have thought about lowering the front end. I have the zuma springs and the C3 springs The zuma springs are the longer ones. So I figured I would try the c3 springs in the zuma forks to get that 1/2 inch of lowering I am after. I measured the fork length with the zuma spring to be 15 inches exactly. After adding the c3 springs the forks were still exactly 15 inches. Both measurements were taken on the bike with the centre stand engaged and the same amount of weight on the front wheel. So it looks like this difference between the springs wasn’t enough to give me any sort of drop. Oh well. I noticed something different between the forks today. Despite being the same part with the same part number the inner tubes of the zuma forks have a groove at the top but the C3 are smooth. I also swapped the dust cover from the c3 forks to the zuma forks and removed the accordion ones.
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Post by captincvmn on Feb 11, 2021 6:42:51 GMT -5
That rotor looks too small. Corvette rotor?
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Post by aeroxbud on Feb 11, 2021 10:46:16 GMT -5
Most of the Yamaha forks have that recess in them. There is a circlip that's located in it. Normally on both tubes. Are they pattern parts? You are not getting a true gauge of the forks. Most of the weight will be taken by the centre stand. Try it as you would ride it.
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Post by Happypancake! on Feb 11, 2021 11:30:15 GMT -5
Alright since I am waiting on some things I have thought about lowering the front end. I have the zuma springs and the C3 springs The zuma springs are the longer ones. So I figured I would try the c3 springs in the zuma forks to get that 1/2 inch of lowering I am after. I measured the fork length with the zuma spring to be 15 inches exactly. After adding the c3 springs the forks were still exactly 15 inches. Both measurements were taken on the bike with the centre stand engaged and the same amount of weight on the front wheel. So it looks like this difference between the springs wasn’t enough to give me any sort of drop. Oh well. I noticed something different between the forks today. Despite being the same part with the same part number the inner tubes of the zuma forks have a groove at the top but the C3 are smooth. I also swapped the dust cover from the c3 forks to the zuma forks and removed the accordion ones. Just loosen the top bolt holding the top of the shock, open the yoke, and slide the shock up.
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Post by ot2020 on Feb 11, 2021 12:00:12 GMT -5
Most of the Yamaha forks have that recess in them. There is a circlip that's located in it. Normally on both tubes. Are they pattern parts? You are not getting a true gauge of the forks. Most of the weight will be taken by the centre stand. Try it as you would ride it. Good point about the forks not being fully compressed due to the stand. I think I will leave the c3 springs in for now mainly because they are so much easier to install. The threaded plug that goes into the top of the fork, while mounted on the bike, goes in with minimal effort. The same action with the zuma springs is so tough. With respect to the groove on the tubes, I don’t think I have to worry about it, the c3 tubes didn’t have it and I am putting it in a c3 so the triple tree should not have any features to interact with this groove. I bought these forks on eBay and my c3 was bought used so the authenticity of these parts is not certain, but they both seem to match the exploded drawings on Yamaha OEM parts websites. There is a clip shown in the drawing but I don’t think it goes around the outside of the tube. www.partzilla.com/catalog/yamaha/scooter/2010/c3-xf50zb/front-fork www.partzilla.com/catalog/yamaha/scooter/2014/zuma-50f-yw50fegy/front-fork
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Post by ot2020 on Feb 11, 2021 12:14:14 GMT -5
Just loosen the top bolt holding the top of the shock, open the yoke, and slide the shock up. There seems to be a hard stop at the top of the yoke that keeps the forks from going up any higher. If I remove the bolt I might be able to get the top of the fork through but if I tighten I back down it seems like it would just be contacting the tube at that hard stop. I might be misunderstanding, but any advice you have is greatly appreciated. Thanks
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Post by ot2020 on Feb 11, 2021 16:26:07 GMT -5
That rotor looks too small. Corvette rotor? Lol if you look up c3 rotor in google most of what you get is C3 corvette hits. The C3 corvette has 295mm rotors, mine is only 260mm. I looked for bigger but this was as good as I could do.
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Post by ot2020 on Feb 14, 2021 22:06:31 GMT -5
Painting the Cygnus wheel black. First primer then black then clear.
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