96' Zuma Build

[yahnos]

I recently moved closer to the beach here in Sydney, Australia and decided that I need a scooter to make it easier to get around. settled on a prebug which seem to be quiet rare in Australia but eventually found one in another state and bought it site unseen. It  arrived about two weeks later in mostly original condition but unfortunately somone had taken to the wheels and forks with black spray paint. It had been sitting for a while so i charged the battery, cleaned out the carb, put fresh fuel in and it start pretty much straight away. 

Keen to get started on the build and have ordered the following parts, thoughts advice anyone?

• Exhaust Yasuni R Minarelli Vertical - Choose : Aluminium Black
• Cylinder kit Stage6 SPORT 70cc MKII 10mm Minarelli Vertical
• Air filter insert Malossi red sponge (Bwsr/Zuma 1996-2001)
• Clutch Malossi Fly 105mm Minarelli
• Variator Malossi MULTIVAR Minarelli
• Main Jet Set Stage6 Dellorto 5mm - Jet Size : 5mm 10 pieces 88- 110
• Carburetor Stage6 Dellorto RACING Black Edition MKII 19mm
• Reed valve Polini Evolution Minarelli Vertical

Suspension and brakes are horrible so upgrading these will be next. trying to source the front end from a later model in Australia is pretty much impossible so wondering if anyone has any recommendations for a wheels to fit NCY forks?

[aeroxbud]

I fitted aerox forks to my later 2002 model. They fit straight into the triple trees. I'm not sure what size fork stanchions you have.
You could then use a BWS or Zuma front wheel and disc setup.

[Timmer]

I just love a Zuma (of Booster Spirit as they're called here). Maybe my next project will be one of these

[yahnos]

Sept 8, 2024 3:54:41 GMT -5 aeroxbud said:

I fitted aerox forks to my later 2002 model. They fit straight into the triple trees. I'm not sure what size fork stanchions you have.
You could then use a BWS or Zuma front wheel and disc setup.

Sounds like an idea but even they seem to be scarce here in Australia. I can get the tree and the forks online but a later model wheel with the disc is the problem.

[yahnos]

Just wondering who has experience installing Stage 6 MK2 70cc kits on Zuma's? i noticed that the itake ports are much larger than the original cylinder head. Is it a necessity to dowl out the cases to match the size of the gasket?

[aeroxbud]

I've fitted the racing one in my Aerox. You don't really need too . But it won't get the peak performance without.
I did do it on my bike. But I had the cases apart to fit a crank at the same time. Unless you are splitting the cases already, its a lot of work for not a massive gain.
Is it the racing kit, or sport pro? I wouldn't run the racing on a standard crank.

[Timmer]

Pretty much what aeroxbud said. I used to run Polini 70 kit on standard carters, it worked fine, my mate portmatched his case, and although he was faster in top end and a bit faster of the line, i couldn’t be bothered with all the work for those gains, we were already running 90km/h+.
Is it needed, no. Is it recommended, depends. Will it be better, yes.

[yahnos]

Its the sport kit not the racing so i won't be splitting the cases for now. Thanks guys, I won't bother with the port matching.

[Timmer]

Get a decent kit, vario, clutch and exhaust, and match that with like a 17.5 or 19mm carb. It’ll get you to around 80 or 90km/h without much hassle.
Zuma’s are easy to work on, don’t have a liquid cooled setup, and everything is pretty well accessible (maybe with the reeds being an exception).

And most of all, i loooooved to drive one, it was just fun.

[yambw’s]

Very cool. Love the tyres.

[yahnos]

Oct 7, 2024 1:18:44 GMT -5 Timmer said:

Get a decent kit, vario, clutch and exhaust, and match that with like a 17.5 or 19mm carb. It’ll get you to around 80 or 90km/h without much hassle.
Zuma’s are easy to work on, don’t have a liquid cooled setup, and everything is pretty well accessible (maybe with the reeds being an exception).

And most of all, i loooooved to drive one, it was just fun.

Yep, thats the plan. I spent a bit of time today putting the engine back together with all the following parts.

• Stage 6 70cc sport kit
• Yasuni R exhaust
• Malossi Fly 105mm clutch
  
• Malossi multivar variator, white spring and 7g rollers
• Polini Evolution Reed valve
• Stage 6 19mm Dellorto Carb
• Standard airbox with Malossi filter however I don't think this will fit with the 19mm carb

Any thoughts on the above? the engine looks dirty in the photos below, i cleaned it up as much as i could be bothered with. i'm not too concerned with how the scooter looks, If it sticks out too much it will probably disappear one night.

I'm very new to tuning so just wondering if anyone has any feedback on best jet to start with, rollers to use, clutch springs, contra spring? 

I had issues trying to connect the throttle cables to the carb, it didn't come with the 90degree cable adaptors. Will i need to purchase these for the throttle cable to work properly?

[aeroxbud]

The street race and Yasuni R is one of my favourite combinations. 👌
Whether you need the 90 degree bend will depend on where the carb sits. Most carbs sit under the seat bucket. So the carb can't come out straight from the carb.
You might find the 7g rollers too heavy for the pipe.

[Timmer]

The 90 degree would be practical, as aeroxbud pointed out, you’ll find it sits underneath the gastank (if my memory serves me right, i haven’t tinkered with a Zuma for over 20 years). I remember i had rollers in the vario in the 5,5grams, and i ran giannelli / bidalot and a few leovinci exhausts back in the day. The Yasuni’s were awesome too, i just never used one. As for a contraspring, malossi white might be too light, id’d go the yellow one. Again, this is all from memory, i don’t remember the values for them.

As for the mentioned setup, it’ll go pretty decent imo. You should probably get a nice speed, i just never cared much for top speed, but more for acceleration (hence the 5g rollers).

Tip: if you intend to run the standard airbox, remove the small tube on the inside, get a foam that’s a bit coarser (like a malossi for more airflow compared to stock).
We got those fitted on the 19’s back in the day, but if i’m correct we blasted with a heatgun (without the airbox) as to get it to fit.

Also: the engine for me should be clean, not spotless. Stains and chips are normal, these things aren’t brand new. Yours looks good to me, i’d use it like it is.

[yahnos]

I bought the Malossi red ait filter for the standard air box but this Stage 6 carb is proving to be a bit of a pain in the arse. I think it sticks out too far to be able to fit to the standard air box so I'll have to order a pod filter, anyone have any recommendations?

I'm more interested in the acceleration too, I'll see how it goes with the 7g rollers and then drop back the weight if need be.

Mounted the engine to the frame today along with the exhaust, starting to come back together.






The engine never had a cooling shroud over the cylinder, is it an issue with cooling if I don't install one?

[aeroxbud]

It will heat seize without the cover on the cylinder. The cover forms a channel for the air blown by the fan.