Genuine Roughhouse Back In Black built by Zino

[Zino]

Wiscootsin hooked me up with a Roughouse engine from a salvaged scoot
I will up load pictures of the trans and engine tear down .

[Zino]

There is No locking tool for the roughhouse variator .
So I use a dewalt impact with a 14 mm socket.
On the variator nut I could also use it for the clutch nut
For the clutch I like the buzetti 39mm wrench BU5476 part number for taking off and putting on the clutch bell nut and the larger 39mm clutch nut .





Clutch bell Locked in place for taking off or putting on with a torque wrench .

With a couple taps on the cement floor this works for getting off the clutch nut and tightening it back to proper torque .

[Zino]

torque wrench work around
before the first time you take the clutch nuts and variator nuts make a mark with a permanent marker from inside to the outside like this
This way at a glance you can tighten to the proper torque

[Zino]

behind the variator
There is the starter gear then a spacer and then a crankshaft oil seal this seal has a slight leak of oil residue and needs to be replaced otherwise the cylinder would eventually burn up.

[Zino]

After taking out the 6 bolts it took a couple light taps on the cover with a rubber mallet to loosen it so I could pull off the cover

The primary gear shaft and cover

Too get the secondary gears out.
Take the back tire off and I use a block of wood against the drive axle on the tire side and tap lightly to gently push loose of the oil seal in the gear case .

[Zino]

new gears to pres on
stock gears 52/13 primary and 44/13 secondary
13.53 final gear ratio
Malossi Secondary part # M6714744 42/15 tooth count
11.2 final gear ratio
This will put me close to the 11 to 1 ratio ,
I shoot for on the Yamaha Zuma to maximize top end performance with still having good take off .
On the Zuma it typically added 5-10 mph top end With a similar 20% increase in Gear Ratio .
Added benefit is the engine works less hard at cruising speeds.




Malossi Gears on the right in both pictures will need to be pressed on .

[islandscrub]

Any idea what makes the RH gearbox different from a chinarelli? At a glance it looks similar, but I guess they all would anyway..

[Zino]

Island They look similar to me

I installed 17.5 dellorto with the flange L-DEL1438 ordered from TreatLand 
It hooks right to the roughhouse flange ,You also can bolt the stock autochoke to it .
It does work with the stock throttle cable .
I pulled the snorkle out of the air box .
With the colder dryer weather
The jets I settle on for now might be a notch rich for summer
90 main jet was a little rich
88 main sounds like mad hornets and feels close to right and had better speed then the 90.
Temps are lower than the stock carb I am peaking around 280 degrees .
Worked down from top of the needle 2nd from the bottom clip was the richest setting with the best throttle response.
The 35 pilot is a little big
I have it at 3 3/4 turns out to get the fastest and smoothest idle .
Cruising at part throttle tempatures are 240-270

Treatland has a 15% off sale
So I ordered some odds and end parts along with a 33 and 34 pilot.

[Zino]

My Treatland order came in
This knock off Naraku other guys have used .
www.scootertuning.ca/en/carburettors-sport-midrace/99005-carburetor-naraku-175mm-genuine-pgo-kymco.html

I used treatland to buy my dellorto stuff every other month they tend to have a 15% off sale
So I got a genuine dellorto with flange for the price of a Naraku.
www.treatland.tv/ProductDetails.asp?ProductCode=dellorto%2DPHVA%2D17%2E5%2DUS%2D1438&CartID=1

This bolts right up with stock cables and stock auto choke just like the naraku.

To adjust the throttle slack tighter I swapped on this top

www.treatland.tv/dellorto-top-for-PHVA-carburetors-p/dellorto-phva-top-1368300.htm
used one of these adaptors screwed in the top
www.treatland.tv/straight-cable-guide-p/dellorto-guide-0110400.htm

Grabbed a smaller pilot # 33
I was running a tad rich on stock 35 and could not lean it out in under 3 1/2 turns
I am now at 2 1/2 turns out with the 33 snorkle out of stock carb

Bought the polini jets 6mm 80-98
I ended up with snorkle in/out in the high 80's to low 90s for jetting with a pipe to get in that safe slightly rich daily rider style of jetting

I have a bunch of delloro stuff from past builds that I swapped on different fittings .
The ones I listed worked best.
The straight adjustable fitting worked best the bent ones did not .

[Zino]

Once you get the seat off the carb is easy to work on
At the top of the picture the tube covered with the spring is the oil feed .
It feed the mainfold directly so when swapping to a aftermarket carb .
You can leave just like stock if you want to continue to use oil pump


The throttle cable take a little patience to work through the cap on the top of the carb


The auto choke is easy to swap over from the stock carb to the dellorto 17.5
Just 2 screws to take off pop the choke off press it in new carb and tighten down the 2 screws.

[Zino]

When swapped to the bigger carb .
Better Temps more RPMS .

Stock Carb
Temps drop dramatically .
I was touching 320-330 with stock carb at wide open Long runs .
Mid throttle was 280-300
Peak rpms 9000-9100

With Dellorto 17.5
I am running at 280-290 degrees on long wide open runs and Mid throttle 240-260
Peak Rpms
9300

Both Carbs are set for a tad rich at all throttle positions for daily driving .
The Snorkle is removed from the Air box .

Stock Carb with snorkle in
Wild Lion Exhaust Stock Bore
I settled on 82 main 38 pilot without shimming needle

Dellorto
Wild Lion exhaust with stock bore
I have settled on 88 Main 33 pilot 2 1/2 turns out 2nd richest needle position.

These are my colder weather under 50 degrees settings for the carbs so they will be richer in the summer temps.

[aeroxbud]

That's a coincidence. I have just fitted a Dellorto 17.5 to the aerox. I found like you the 38 stock pilot jet was way too rich.
Even a 36 had quite a bit of stuttering at 8th throttle. Runs great with a 34 though.

[Zino]

The Stock 35
I could not get any real control over the air screw , I was closer to 4 turns out.
I like being a little fat on the bottom but that jet was way to rich even with snorkle out of stock airbox .

Swapped in the 33 and 2-3 turns is where the idle smoothed out .

These were all Genuine Dellorto Pilot Jets .

[yambw’s]

I have not long installed the 17.5 dellorto and I have the snorkel out with the hole opened up a notch, stock 38pilot that came with the 17.5 carb 97 main jet and the air/fuel screw 3 and a quarter turns out guess that means the idle jet is a bit fat but no spluttering, plug looking good after that 80mile ride

[Zino]

The 35 was functional just a notch rich.
I have been fine tuning the main and pilot before I swap cylinders .


Fine tuning the pilot .

By blipping it on a well warmed up engine .
The idle either hangs and then drops down which is a tad lean
The idle Drops below and then cleans up and rises back to idle speed which is a tad rich
the idle drops right back to idle speed.

The 35 pilot at 3 1/2-4 turns out was dropping the idle speed
the 33 pilot at 2 1/2 - 3 turns out the Idle falls right back with no hang.
I then dial it in by 1/8's for best transition to needle.

Fine Tuning the Main
When I get to the richest jet that gives best Top speed .
For a Daily driver I would be done .

A race day trick is run wide open and then close the throttle by 1/4 to 1/8 so you just go slightly on needle this richens you up temporarily .

3 things happen
Your Speed rises You are a notch lean on The Main
Your Speed drops quick you are a notch rich on the Main
If your speed drops slow or holds for a second You are close to perfect for that days temps and humidity .