Genuine Black Cat Polini sport

[jackmisanthrope]

Spring is on the way, temps will be in the 50s next week, and I believe I have collected all the pieces (for now). It's time to get going on this build. I'm starting with a stock 2006 Genuine Black Cat. It has just over 1000 miles. 


Parts List
47mm Polini Sport
Yasuni R with Z mounting bracket
17.5mm Dellorto PHVA
Malossi Carbon Reeds
Malossi Multivar with Stylepro pulley
Malossi Fly clutch and bell with yellow springs and white contra
Misc accoutrement (shims, jets, rollers, belts, fluids, plugs)

Have the pipe derestricted, the new cylinder and piston cleaned up, and most of the body panels out of the way.

 


My goal isn't top speed, just looking for something fun to ride around town that accelerates quickly. I think once tuned this will be exactly that. Zino and Hippo sharing their threads were a tremendous help. They answered pretty much all my questions without needing to ask. I'm hoping to get a jump on it next week as the temps rise.

[aeroxbud]

Should be a nice build.
I had a Minarelli vertical engine with the Polini sport, 17.5 Dellorto, and a Yasuni R. Was a lot of fun round the city.

[Timmer]

This is fun, and like aeroxbud i too had a mina vertical AC when i was a teenager, and if memory serves me correctly i ran;
70cc polini
19 dellorto
Polini 2G clutch
Polini hi speed vario
Bidalot S2 racing exhaust
Original airfilter (modified)
And probably some other stuff (malossi vl12 membrane, carbon valves,…)
It did around 90-95kph (so like +-55mph?) and popped wheelie’s whenever i wanted it too. That thing was a blast to drive!

[jackmisanthrope]

Making some room today, got everything stripped out of the way and the exhaust is off. Probably not going to stop here just had a couple of questions.





What do I do with this hose that came from the old exhaust and all the shtuff attached to it?




I was ordering some secondary gears today and was thinking about getting the Malossi torque driver Does it make any noticeable improvements? Is it it worth getting. TIA

[aeroxbud]

On my bikes I have always just ditched the emissions system once I don't have a standard pipe.
The straight torque drives give you much more linear acceleration. The standard ones shift into a higher gear earlier when they hit the point the ramp plate becomes less vertical.
You get a much more continuous acceleration. With something like the Malossi. Not as good if you do lots of cruising. But if you love racing from stop light, to stop light. 👌

[Zino]

on the exhaust pipe side
just get rid of that extra hose and stuff you wont use it with new exhaust.

on the cvt side
You could leave some of the hose that connects to the cvt and plug it so water does not get in to the transmission

I put gears in mine it adds a few miles to the top end you
I use the ncy torque driver the stock torque driver has a dog leg in it that causes it to shift abruptly the malossi and ncy have a smoother shifting as the torque driver opens

[jackmisanthrope]

Thanks for the responses. That was my plan for the emissions junk. I removed everything but the little hose on the cvt side for ease of plugging.

I think I'll add the torque driver to the list. Sounds like it does what I want it to do.

Zino, what belt did you settle on? 


This is where I stopped. I loathe cleaning gasket surfaces but a little elbow grease and acetone should do it. 

[Zino]

I use the standard Bando with a ncy variator 
If you use the malossi variator
I would use the malossi belt 6116424 or 6112735  that actual creates a budget overrange and gives you better take off and more top end
Jpskamp1 just installed the malossi combo 

I have a malossi belt that I just used for testing that I could sell you to build the budget overrange with

[jackmisanthrope]

Got everything cleaned up and the top end on.








Unfortunately I didn't have the same luck as others with using the yasuni z bracket. I'm going to have to make something work. I'll probably just make one. In the mean time I'll start on the carb and cvt.

Zino I have one of the 6116424 but once I make sure that's the one I'm going to run I'll probably take you up on that. 

[TheScooterJesus]

Awesome build! I just put a big bore kit on my roughhouse (same engine as your scooter) and did a tiny bit of CVT tuning and i can go almost 60.
Id suggest using honda bond on all your gaskets when doing the cylinder, these gaskets are known to leak easily

[jackmisanthrope]

Thank you, I'm pretty excited to get it on the road. I've never liked the metal base gaskets. Ive had better luck cutting my own out of thin felpro paper and spraying them with copper spray. 

I recieved my carb top from Treats today. They were sold out when I ordered my carb. Got lucky and caught them with one last week. Just have to decide what angle cable adjuster I want to use and I should be able to get the carb on today.

[jackmisanthrope]

Haven't made much progress, ran into a couple of set backs.


I'm not sure it it was already cracked or if I just don't know my own strength. I was just using my hands to try to free it from the intake and that happened.

Also discovered a leaky CVT side crank seal. So just waiting on parts at this point.

I did get the malossi torque driver installed with the white spring and torsion controller.

[Timmer]

If that’s the OEM valve-thingy, those break easy when they have some age.

As for gaskets, i try to avoid the metal ones, unless i’m running a 50cc with the original specs. For a fast 50 or higher, i use the paperlike gaskets.

[broyager]

I found the yellow torsion controller didn't let the white contra spring I had compress all the way, there were too many turns in it

I think I bought the wrong white contra (298360.w0) though, it does work by itself.

The yellow one (297042.y0) works best for me in the Buddy / Ligero, but the correct white with torsion controller may have worked too.

[jackmisanthrope]

Put the new cvt side crank seal in today and adjusted the bracket so I could mount the pipe.




I also apparently ordered the wrong white malossi spring, it's almost 2 coils longer.  So I think I'll run the stock spring with the torsion controller to start and see how that feels. I also have the yellow spring that came with the multivar I can try if need be. Should be able to start it up tomorrow after my reed cage arrives