suggestions on my overrange setup zuma horizontal bbk

[airbats801]

I'd like to pick your brains on my variator setup for my malossi overrange.

my current setup is a top perfromance variator kit with the bando belt and stock gearing, the bike was pretty fast on takeoff at first, would pop the wheel off the ground then later it just had maybe belt slip, but seemed to do low 50s. It's a malossi sport cast, yasuni r, phva or phbn 17.5 electric choke, new crank seals, and 6.5g sliders. I think I have white or yellow clutch springs, and im running a 2001 driven as mine was bad when I got it. My biggest issues were a slipping at takeoff, coulda been clutch, maybe belt, who knows but it ran good and fast otherwise. I could run the guts out of it downhill just waiting for my crank to explode.

So the belt decides to die a very violent death at about 500 to 700 miles, toasted everything. I had to clean for hours to get all the belt residue off. At this point im like well shit, lets try the multivar, so I bought the multivar and a malossi belt. This was a nightmare. I couldnt actually get the belt loose enough no matter the shimming as the belt was too tight. I ran it, and it was a bit quicker to speed, but would hit 44gps and just get this weird jerking like something in the variator wasnt right. I fought this for days and even shaved the boss trying to see if there was a way to get more slack. At that point I figured it was the belt. I talked with swap shop and brandon actually gave me a bando out of a top perormance kit. granted this was all with 6.5g sliders. This instantly bumped my speed up to 49gps with the multivar, but I still get this weird thing at the top like its rubberbanding. I gotta let off at about 48 because it will get this bad weird slowdown if I go faster. I still cant get tmultivar to run all the way up either as it seems short. So now comes fuck it, buying overrange, dont wanna deal with this crap

So running the steel pulley overrange. I have a white spring, but also bought a yellow contra. I bought 7g rollers, and I also bought 13/44 gearing. This hasnt been installed, but I'd like your opinions on this setup for the sport bbk with yasuni r.. I'm also curious if I should look at a better clutch. I'm trying not to buy a ton of more parts, but if I need a clutch looking for recomendations. Im also curious if my contra spring and weights are ballpark. this engine is going in a ruckus as soon as I get it sorted, and im about 250lbs

[Zino]

You have a great set up I have run that exact same set up on a bug eye zuma .
Yasuni R Malossi sport 17.5 phva carb malossi multi var I ran lighter sliders 5 to 6 gram and malossi yellow contra and stiffer clutch springs .

What size belt is the bando ?
What size is the malossi ?
The best way to measure them is like this to compare sizes .
www.youtube.com/watch?v=K7oGuQLrGzs&ab_channel=PartsForScooters

Have you done the sharpie test to see how much travel you are getting ?
If you had belt slip that would be a good reason why your belt exploded .

A stiffer contra would clean that belt slip up .
I typically upgrade from the stock clutch to a aftermarket clutch.


.

[airbats801]

Aug 22, 2021 6:45:22 GMT -5 Zino said:

You have a great set up I have run that exact same set up on a bug eye zuma .
Yasuni R Malossi sport 17.5 phva carb malossi multi var I ran lighter sliders 5 to 6 gram and malossi yellow contra and stiffer clutch springs .

What size belt is the bando ?
What size is the malossi ?
The best way to measure them is like this to compare sizes .
www.youtube.com/watch?v=K7oGuQLrGzs&ab_channel=PartsForScooters

Have you done the sharpie test to see how much travel you are getting ?
If you had belt slip that would be a good reason why your belt exploded .

A stiffer contra would clean that belt slip up .
I typically upgrade from the stock clutch to a aftermarket clutch.


.

Yeah, I did, the bando was a tad bit narrower and i'd say a tiny bit longer. I cant recall the polini belt part number off hand. I think I typoed when I said malossi belt. They were both from scoot swap shop which is local for me. Either way, that setup is going in the parts bin as I picked up the malossi overrange. as we do a lot of riding up mountains and hills on passes, trying to build the best out of my ruckus. I spent enough money on a get and while I do enjoy the engine,f or bigger people and loaded with camping gear for scooter trips they just dont go up hills fast enough. I wanted to stay stockish looking and stock ride height so the zuma swap seems like the right choice minus the fuel economy lol.

I think I will try the yellow contra, and maybe pick up a clutch. I'm thinking the malossi clutch unless you have other recommendations?

I'm still running the stock crank, but I know the pipe falls off around 10k. Maybe I will order some lighter sliders and see how they perform.

[Zino]

Malossi Fly clutch is very easy to set up
with the yasuni R yellow springs or stiffer is what I like to use .

The overrange belts are quite a bit longer
If you have the regular multivar paited with the overrange rear pulley 122mm or better you can upsize the belts to the bws 100 sizes .
Here is a thread about this budget overrange .
49ccscoot.proboards.com/thread/24543/top-performance-td-belt-length

[airbats801]

Aug 22, 2021 16:07:16 GMT -5 Zino said:

Malossi Fly clutch is very easy to set up
with the yasuni R yellow springs or stiffer is what I like to use .

The overrange belts are quite a bit longer
If you have the regular multivar paited with the overrange rear pulley 122mm or better you can upsize the belts to the bws 100 sizes .
Here is a thread about this budget overrange .
49ccscoot.proboards.com/thread/24543/top-performance-td-belt-length

Thanks for the link. I was wondering how much difference the multivar is vs the complete overrange package. I already have a entire overrange package right now though.

[Zino]

You have the better setup that is is designed to work together just a little case grinding so the rear pulley spins freely and you have to remove the estart to make it fit

The overrange uses larger and wider belts than the multi var the face of the variator is 99mm to 97 mm for the multivar the rear pulley is 125 mm on the overrange compared to 122 for the budget overrange or 115 mm for stock

[dcdirtrider]

For anybody who runs across this thread in the future, here is what you need for a budget "overrange" setup on a long-case Minarelli

1) Oversized variator, (S6-5616634 or ‎MS-5112800)- $100(ish)
2) BWS 100, Jog 90 122mm torque driver- $30(ish)
3) Yamaha 4VP-17641-00 774x17.7mm CVT Drive Belt- $10(ish)

*The cheapest place to get the Stage6 variator is usually Brixiamoto ($100), since their US shipping is about $15. Just expect a month in processing/shipping time. Don't know about Malossi. 

*The cheapest place to get the BWS 100 driver is AliEx, but expect it to be unbalanced (wobbly) if you get the cheap one from "Glixal" ($25). AliEx now has fairly easy returns, compared to the ol' "negotiate with seller" style, so it might be worth a shot if you're in the US. You can get a used OEM driver from Europe using eBay, or spend a bit more for the TWH/JISO (Taiwan) options. I have not tried the Taiwan drivers to see if they're any better, so this will be at your own risk. 

*And the cheapest place to get a belt is also AliEx, several belts options can be found for well under $10. I'm using one from the "CQZY&CY" store, and no issues so far after about 100 miles. If you're looking for name-brand belts, you can use the models Scarabeo 100 2T, BWS 100, and Aerox 100 to find belts. I also bought one that's meant for a Peugeot Speedfight 50 that's 770x18mm, which is another model that has a similar belt size. Stage6's oversized/overrange belt is almost the same exact dimensions to the AliEx belts, but usually runs about $50-100 for a single belt in the US. 

I am not a scooter/motorcycle tech, so try at your own risk. Hope this helps!