Sym dd50 build!!

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Wheelman-111
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Re: Sym dd50 build!!

Post by Wheelman-111 »

Greetings:

The bearings aren't all that tight a fit on the crankshaft or the cases. If you really don't care about the crank. thread on a couple of nuts to the end of the crank. Then make sure you SUPPORT the crankcase on a work surface like my WorkMate with the nutty end of the crankshaft pointing up, the case pointing down. Then use a proper Metal hammer to strike the nut - attached to the crank and tap it out. The nut will get dented, but the crank should be fine unless you fail to catch it before it hits the floor.

Sometimes the bearings stay stuck in the case. Put the biggest socket you can fit on it and tap it out the same way. A bearing puller slide-hammer is more elegant, but since you will be replacing the bearings anyway (Won't You??) it doesn't really matter. If you put the case+crank in the freezer for an hour, then use a Propane torch to warm the case, sometimes the bearing just falls out.

If the bearing is stuck to the shaft, you'll need this Large Bearing Separator and/or This kit. The smaller separators didn't work on mine, and I had to modify - sharpen the edges with a grinder - of the big separator to get it to dissect my bearing off a used - and overheated - crank. Any bearing subjected to this tool must be replaced. $40 from Honda for the real NTK stuff is well worth it.

Yes a press is nice to have, but costly. Also in my opinion there is a greater risk of cracking the case. Working on Iron Surfaces with a machine with that much power, things happen all at once. You really have to know what you're doing to use it safely. Tap-tapping with the case on wood is safer.

Reassembly with the TUSK tool is a MUST. Remember that. Tusk is a Must! Honda-san's tool is even better, because you can use it to press in the seal to the prescribed depth. But it'll cost over $150 if your dealer can even find it. I just use Mighty Wheel-Thumbs. :wink:
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
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Madman
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Sym dd50 build!!

Post by Madman »

Thanks wheelman that gives me a whole bunch of different options and of course I'm replacing the bearings.
SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

Bit of elbow grease and boo yaaah.
Image

Image

Image
SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

The sym block has almost no boost port.
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

And the intake is really small, put a cigarette there for comparison.
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

Started the boost port!! Using a hacksaw blade to start and will finish with a file.
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ImageUploadedByTapatalk1335614508.599435.jpg (60.89 KiB) Viewed 6817 times
SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

Big difference!!
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

Almost done with file!
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

Not the best job on the intake but it will do as I don't really have the right tools for this part!
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Downsouthdio
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Re: Sym dd50 build!!

Post by Downsouthdio »

Dude.. Looks good!
Honda super dio
Corsa
26mm
Sparrow
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Madman
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Sym dd50 build!!

Post by Madman »

And my 50mm kit arrived again!! This time it is 50 mm and its like night and day. Correct gaskets and it's not damaged
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SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Madman
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Sym dd50 build!!

Post by Madman »

And some shots of my work done today!

Image

Image

Image
SYM dd
50mm 82cc KABOOOOOMMM
Strengthend crank
V8 typhoon
Malossi clutch springs yellow
Datona +20% center spring
kitako type x variator
Oko28mm
CT intake
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Downsouthdio
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Re: Sym dd50 build!!

Post by Downsouthdio »

Wow huge boost port..! Nice work bro.. Looks really good
Honda super dio
Corsa
26mm
Sparrow
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paulpauly7
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Re: Sym dd50 build!!

Post by paulpauly7 »

yip looking good

that is the kit ive got are you gonna try it out or use your other kit you have
86 Nifty Fifty (spree)
ZX disk brake
Kitico 120kmh speedo
AF18 ZX ported
Polini corsa
Malossi crank
CTmani
24mmOKO
40pilot118main
Scorpion pipe
8.44 to 1
Michelin s1
71.3mph
92 yz125, 94 crm250
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kingkamehameha
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Re: Sym dd50 build!!

Post by kingkamehameha »

Good work! i suggest buying a dremel and bits and doing the intake ports right
ua mau ke 'ea o ka aina i ka pono o hawaii
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