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Post by kindarowdy on Jul 24, 2022 19:29:38 GMT -5
Aloha, I have a PGO Big Max 50 that was given to me in running but poor condition. I have since brought her back to life. I have been working on the Genuine Roughhouse, Buddy 50, and other Genuine models for the last few years so the PGO Big Max has been a breeze to repair My current build is: Polini sport 70 166.0076 Athena HPC Crank 075314 21mm Stage6 PWK Carb S6-31RT-PWK21 Yasuni r TUB902 Style Pro reed cage(carbon fiber) BM311510 Polini Hi-Speed variator with 6.65 weights 241.490 Malossi kevlar piaggio long 4 stroke belt 6116424 NCY secondary slider (scooterworks PN: 1200-1057) A Polini torque spring (unknown stiffness)(maybe 243.101) Polini 3g clutch w/green springs 249.049 Polini evo 2 bell 250.025 Polini 15/42 secondary gears 202.1346 Other cool items include NCY front and rear suspension, Michelin Boppers, trail tech vapor, NCY 220 caliper, and NCY steel braided brake line. I'm not finished with the build quite yet though... I'll upload a better picture in the future.  |
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Post by Zino on Jul 24, 2022 21:23:21 GMT -5
Following your thread for ideas for build ideas for my roughhouse .
Thanks for including the part numbers .
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Post by Lucass2T on Jul 25, 2022 2:51:36 GMT -5
Nice build and parts list!
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Post by aeroxbud on Jul 25, 2022 5:26:51 GMT -5
Nice build so far.
And a bar conversation too. 😉
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Post by kindarowdy on Jul 25, 2022 17:15:49 GMT -5
Following your thread for ideas for build ideas for my roughhouse . Thanks for including the part numbers . You are a huge inspiration to this post, Zino. I really appreciate all the information you've brought to this site. |
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Post by kindarowdy on Jul 25, 2022 17:17:54 GMT -5
Nice build so far. And a bar conversation too. 😉 Thanks, the bar conversion was made so I could use the vapor and NCY throttle kit more easily. I just have to figure out how to mount the front turn signals. |
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Post by kindarowdy on Jul 25, 2022 17:27:39 GMT -5
Something interesting I tested yesterday was the fitment of a Malossi overrange torque driver 619733 turns out that it fits pretty well. Stock the torque driver is 117mm, and Malossi's is 128mm. I was planning on ordering Malossi's overrange kevlar belt 6115822 to see how well it all fits together. Im assuming this kit: speed-line.com/pgo-big-max-50-2t-10/variator-4/variomatics-malossi-mhr-overrange-system-12 includes the same belt, torque drive, and Malossi varriator 518852.  |
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Post by Lucass2T on Jul 26, 2022 9:56:54 GMT -5
It's nice you don't have to trim the structural fins on the inside. With non zuma long case minarelli motors you must grind some of it away otherwise the belt will rub against them.
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Post by Zino on Jul 26, 2022 17:14:48 GMT -5
Something interesting I tested yesterday was the fitment of a Malossi overrange torque driver 619733 turns out that it fits pretty well. Stock the torque driver is 117mm, and Malossi's is 128mm. I was planning on ordering Malossi's overrange kevlar belt 6115822 to see how well it all fits together. Im assuming this kit: speed-line.com/pgo-big-max-50-2t-10/variator-4/variomatics-malossi-mhr-overrange-system-12 includes the same belt, torque drive, and Malossi varriator 518852. Nice find This could be a game changer . |
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Post by kindarowdy on Jul 30, 2022 1:20:12 GMT -5
Alright, Got the Malossi overrange belt in today 6115822. Fit well after shimming the varriator to 1.02mm  The Polini torque spring installed on the NCY slider was too large for the torque driver, so I replaced it with a white Malossi spring 298360.w0 The main issue I ran into was the weld on the back of the Malossi torque driver.    When I first installed the bell, I noticed a lot of friction on the torque driver. I chose to ignore the warning and decided to bolt everything up and start the scooter. After noticing the damage to the rear seal, I ground the weld down. Next, I tested the clearance by applying white paint to the weld, reinstalling the rear drive with the bell, and spinning it by hand. There was a small amount of contact with the case from the belt, so I did have to remove some material.  |
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Post by 808ministroke on Jul 30, 2022 4:03:29 GMT -5
Melosi actually sells a spacer specifically for their overrange rear torque assembly you should look into that.
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Post by Zino on Jul 30, 2022 7:22:06 GMT -5
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Post by kindarowdy on Jul 30, 2022 21:57:41 GMT -5
Today I swapped to the malossi variator kit (518852). The kit comes with a yellow center spring and 7g weights. It feels higher quality and fits well together. Unlike the polini variator which has more play.
I currently have the 6.6g weights inside the malossi kit. I will be changing them out for the 7g weights.
The belt is still making contact on the top of the transmission so I will need to remove more material.
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Post by bm50adz on Jul 31, 2022 6:22:49 GMT -5
Today I swapped to the malossi variator kit (518852). The kit comes with a yellow center spring and 7g weights. It feels higher quality and fits well together. Unlike the polini variator which has more play. I currently have the 6.6g weights inside the malossi kit. I will be changing them out for the 7g weights. The belt is still making contact on the top of the transmission so I will need to remove more material. Keep us informed buddy. I don't think I ever have the money to get the kit. But will like to no what gain it gives 👍🏻 |
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Post by kindarowdy on Aug 2, 2022 0:14:01 GMT -5
Done a lot today. Started with a simple CVT transmission that morphed into a top-end job. The main takeaway is that I installed a Stage6 Sport Pro MK2 S6-7416603. I didn't inspect the head thoroughly until everything was ready to go on. Also, I was sent a 12mm wrist pin instead of a 10mm pin. Thankfully, I had another Sport Pro kit I could take from until I get a replacement.   The cylinder head has a recessed area for the sparkplug to interface with. Which made me believe it would be impossible to mount my CHT gauge. I would love for someone to jump in and tell me this was all a waste of time and there is another option. Here was my solution    I hated doing this and will try anything not to do it again. It was able to pass the leak test with some copper sealant. After installing the kit I installed the white contra spring and 5.6-gram weights which put my RPMs at a mild 9500rpm which feels great with the sport pro.  Unfortunately, something bad happened on the way home. I felt something slip it happened suddenly and I had been riding for at least 20 minutes with plenty of stops and go. During all that time there was no other slipping. I'm hoping it was the belt or clutch. But I'm afraid that the gears are slipping on the secondary kit. One of the gears went on way too easily. |
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