Need some Kymco help, DIO engine/ build thread

danmdevries · Post by **danmdevries** » Mon Apr 28, 2008 9:23 pm

What kind of tach do you guys run, and where can I get one? I've found a couple, but they stop at 10krpm, don't our motors spin a bit higher than that?

Same with the temp gauge, what's a good budget temp gauge to pick up?

And if anyone has their stock elite gears after changing out for a gear kit, let me know, I want a set of stockers.

danmdevries · Post by **danmdevries** » Wed Apr 30, 2008 1:23 am

Bump anybody? No answers...

Post by **noiseguy** » Wed Apr 30, 2008 1:51 pm

I'd suggest running what VT Cycles is telling you to run. They have experience with these bikes, and a good reputation. I guess what I'm trying to say is that I don't think they're trying to rip you off. Make sure to get some sort of matched intake filter to work with it.

So you're using the 19mm carb with the stock intake? That sounds like a potential issue. Put it on Ebay to offset the cost of the 28mm intake/carb.

As for the tach; most engines actually don't run over 10K RPM unless they're been tweaked. Tweaked engines can hit 14K reportedly. Ask VT Cycles what to run.

Best of luck.

danmdevries · Post by **danmdevries** » Fri May 09, 2008 10:22 pm

More progress has been made. I missed one photo that I wish I had taken, I'll get to that later.

VTCycles is much more on top of things than who I was dealing with before, and I spoke over the phone and through email for about two weeks before settling on a course of action, I was very happy with their knowledge and customer service.

I bought a new variator and ramp plate. It allows me to actually hit the lowest ratio on the pulley, the other one did not. After just adding that, the front end pops up effortlessly with my 230lb self on there. That wasn't enough though. I also bought myself a larger carb, intake, and reed valves.

This was my first step up if you didn't recall:

And here's where I am going right now:

I also ditched the factory intake manifold in favor of a much larger one:

And along with that, the reed valve assy had to be switched out, the stock was all too restrictive:

Now in doing all this I forgot something: behind the reed valves, where the charge actually enters the crankcase is now the only restriction on the intake side short of the internal ports. I'll tear into the engine if it's noticeable. I'm installing the carb set right now, we'll see how it works out once I tune it.

I may be switching out my exhaust with a PG long pipe, it makes a more usable powerband than what I've got, and is much easier to tune compared with my large chambered exhaust according to VT.

I am interested in anyone's broken/non running DIO engine. I've done all I can with mine, there's slight differences that prevent me from going further with this build like the elites are able to do. Gearing being the main one.

Dac · Post by **Dac** » Fri May 09, 2008 11:32 pm

nice looking stuff.
Cant wait to hear the results.

What are you going to do with your old pipe? if i were to buy any aftermarket pipe i would get a PG long. But i am kinda looking for something cheap for now.

danmdevries · Post by **danmdevries** » Sat May 10, 2008 12:49 am

I'm going with a PG long when I have the money for it. I have to change out my cyl kit as well, basically I'm starting all over. Just not doing it any time soon, I've spent waaaay too much money on this scooter, especially considering I can't change out the gears and am limited to 40mph forever. Just now I get there in about 3-4 seconds

That pipe was $175, not exactly a cheap pipe... just not a great one. Personally I haven't had a bad time tuning it, but VT says they have. I'll sell it for the right price though. PM me if you're interested, I may be willing to work something out.

My 19m Amal/Arreche carb is FS too

maddog · Post by **maddog** » Thu May 15, 2008 3:25 am

your oil pump should be fine, if it smokes real bad on a cold start then its time to change it, did you take the restrictor ring off the front pulley? also up to 19mm carbs the stock intake is used, your main jet should be a#85 or #87 i can find a set of stock set of honda gears from the shop i deal with, you also need to change the center spring & clutch springs, remember when you install a bore kit everything needs to be changed you only did half of it.

danmdevries · Post by **danmdevries** » Thu May 15, 2008 7:27 am

maddog wrote:your oil pump should be fine, if it smokes real bad on a cold start then its time to change it, did you take the restrictor ring off the front pulley? also up to 19mm carbs the stock intake is used, your main jet should be a#85 or #87 i can find a set of stock set of honda gears from the shop i deal with, you also need to change the center spring & clutch springs, remember when you install a bore kit everything needs to be changed you only did half of it.

No, I did all of it.

High speed variator with the ring removed from the shaft
New clutch springs
1500rpm center spring

Oil pump is shot, does not pump any oil, I have been premixing for the last 500 miles.

28mm carb setup and the rest of my setup didn't play well together, my cyl kit sucks so the carb and intake is up for sale. I also can not change out the gearing due to the way the final drive is installed (clip in vs pressed on)

maddog · Post by **maddog** » Thu May 15, 2008 11:12 pm

I called several shops and it turns out kymco has a different spline than the honda so you are out of luck, the best thing you can do is low profile tires and a high speed pulley.

happyman · Post by **happyman** » Sat May 17, 2008 10:47 am

danmdevries wrote:Bump anybody? No answers...

i have a super 9 kymco with a 73 cc airsal kit. it has the 19 mm arrache carb and ported intake and few other things . ported most everything just a little and port matched it spools 11300 rpm and i run a 100 main jet and its none too rich .. this is also a water cooled motoer which yours is not but that scooter should run much better.. you may want to up the jet to at least a 85. asx far as a plug i would call someone who is in the know.. that bike should go 50 mph i would say.
get the oil pump replaced and, then you can get rid of that hassle.. just make sure you adjust it too open as far as it will go under full throttle. good luck
Happy

danmdevries · Post by **danmdevries** » Sun May 18, 2008 12:39 am

Everything's running fine, and has been for 600 miles now. I top out at 44 on flatland with no wind, 40 with a crosswind, 38 up hills. I'm 6'3" 230 lbs so I can't complain.

I'm premixing, I had other issues causign the fouling, it's all sorted out. I'm not using the 28mm carb mainly because I don't need it. It's for sale if anyone wants it, barely ran a full floatbowl of fuel through it.

I've also not used two full tanks of premix (5 gal gas tank) yet in my scooter, so I'm doing better than 60mpg.

stillspeeding · Post by **stillspeeding** » Thu May 22, 2008 3:58 am

you did something wrong on that setup, my stock italjet dragster does 50mph, sell your scoot to someone in michigan if they can afford it....

danmdevries · Post by **danmdevries** » Thu May 22, 2008 6:29 pm

stillspeeding wrote:you did something wrong on that setup, my stock italjet dragster does 50mph, sell your scoot to someone in michigan if they can afford it....

Did you not read the post above this? I'm also not going to sell my scooter, why would I? It's doing great.

Everything's working fine. I'm sure if I was smaller it would go faster, but I'm 6'3" and 230 lbs.

It's getting somewhere in the high 60/low70 mpg so I'm perfectly happy with what I've got.