beating a dead horse- she lives again!

[drizzle]

my '85 Aero 50 build
so far- ruckus variator, leovince sp3.


got my polini bore today. that was pretty sweet.
disassembled everything. getting ready to dive into the unknown.


the bare block, ready for it's heart transplant


what's this? looks like some previous owner tried to do a bit of "porting" in the past?



comparison. oh lawdy lawd


had everything re-assembled when i realized...




anyhow. put everything back together, and the plastic/metal shroud assembly doesnt fit. had to do a bit of hammering to the metal part to make ends meet, but even so, it's not fitting so well. looks like a job for duct tape? i think so.

put the stock exhaust back on, left the 88 jet in the carb with stock airbox, and 9g weights in variator, and put a splash of oil in the gas tank. better to have a few dirty plugs than to have a seized piston.

started after a few minutes of trying, and on the stand, it ran like it was going WOT. nothing a bit of fiddling with the carb couldn't fix. took a ride around the block (exactly 1 mile), and it ran... pretty much the same as before. what gives? granted, i was going very easy on the throttle... but still.

more to come.

[Wheelman-111]

Greetings:

You're not the only person here to assemble everything, then realize the base gasket was sitting under the tool box.

Nice work so far. Fix the shroud with autoparts store Muffler Repair Tape, as it will easily withstand the temperatures. Duct Tape not so much...

[edgargonz]

my '85 Aero 50 build
so far- ruckus variator, leovince sp3.


got my polini bore today. that was pretty sweet.
disassembled everything. getting ready to dive into the unknown.


the bare block, ready for it's heart transplant


what's this? looks like some previous owner tried to do a bit of "porting" in the past?



comparison. oh lawdy lawd


had everything re-assembled when i realized...




anyhow. put everything back together, and the plastic/metal shroud assembly doesnt fit. had to do a bit of hammering to the metal part to make ends meet, but even so, it's not fitting so well. looks like a job for duct tape? i think so.

put the stock exhaust back on, left the 88 jet in the carb with stock airbox, and 9g weights in variator, and put a splash of oil in the gas tank. better to have a few dirty plugs than to have a seized piston.

started after a few minutes of trying, and on the stand, it ran like it was going WOT. nothing a bit of fiddling with the carb couldn't fix. took a ride around the block (exactly 1 mile), and it ran... pretty much the same as before. what gives? granted, i was going very easy on the throttle... but still.

more to come.

just use a few bolts between the fan shroud, at each mounting location, and the mounting screw and this will give you the clearance you need easy.....

[drizzle]

thanks for the advice guys. i think i'll go with the muffler wrap, that seems... less complex for my feeble mind.

i took it out for a few more heat cycles earlier (even though it began raining...)
wheelies were definitely there at half throttle, * yeah. meeting and beating my expectations. TONS of smoke coming from the engine area... i don't know if it's smoke though, or just because i've been riding in water...

10 inches expected for tonight


plans for after break in-
reinstall SP3, get ahold of malossi gears and ZX trans, and, i pray to god, a kickstart conversion. and of course all the odds and ends of fine tuning.

[novs86]

Harbor Freight sells a real inexpensive rivet applicator for under $10.

I used it to extend my shroud with some flashing.

You definitely want to make sure it is a tight fit to make sure your engine will stay as cool as possible with little to no air leaks.

[bigluelok]

nice are you going to rejet?
there are alot of aero projects lately

[drizzle]

rejetting is all part of the "fun" of tuning.

ive changed my mind about the gears though. i'm going to find some '87 elite 10:1's, even if it kills me.

[drizzle]

somewhat of an update

40 miles on the new bore in 30 degree weather, no troubles so far, except for an extremely annoyin rattle from the kickstand, and the variator nut keeps falling off, always after the ride's done... lucky.

one thing ive noticed though-

there seems to be some sort of moisture on the exhaust side of the bore and on the top of the fan cover every time i'm done riding. not riding through any snow or puddles, whats this all about? too rich and its leaking out? soiling myself and not noticing while riding? 88 jet, stock exhaust and airbox with 3 7/16 holes drilled in it.... im pretty sure it's the rich theory.

for your viewing pleasure-

[Dakine]

Are you running an exhaust gasket? Did you make sure exhaust is tightened and your bore and head? What type of bore gasket are you using metal or the other material lol its like almost cardboard in a way. If your using the metal only its probably going to leak.

[drizzle]

i'm using metal gaskets that came with the bore. i've never really used an exhaust gasket, it didn't come with one when i bought the scooter, i just assumed it was only the O ring. everything seems tightened down nice and proper.

...should i be using an exhaust gasket?

[Dakine]

Yes thats honestly probably why Those o Ring exhaust gaskets suck in my opinion lol. You can actually use both though since the o ring fits flush and the other gasket mounts onto the exhaust bolts and then you pur your pipe on.

Try see if your bike will shut off with you holding the end of the pipe while its on. If it doesnt that means your have an exhaust leak.

[drizzle]

went ahead and tried that. it barely ran, struggling, but barely, barely running for a good 10 seconds before dying.

guess i got a leak.

[Dakine]

If you dont want to spend money and buy the exhaust gasket i think its only a couple bucks you could make 1 outta cardboard or any other material like it. Just make a cut out that has a circle big enough for the pipe and bore and put the handmade gasket on top of the studs that are on the bore then put ur pipe back on.

Hope this helps

[novs86]

The Polini exhauast gasket that came with your bore.... Throw it right into the trash!

It leaked for me as well.

Buy a nice new stock exhaust ring gasket and the issue goes away.

Now, that was my issue since I'm using the stock exhaust, not leovince.

BUT.... try it anyway to see if it helps.

The stock gasket is thicker and sealed better for me.

BTW...You have a better chance finding the Malossi primary gears than the 87 Elite 50S gears.

My scoot runs great with the Malossi gears!

[drizzle]

i've found some already from a dude on the islands, i just wouldn't want the whole super-slow acceleration thing. i want absurd amounts of take off!

how do you find them to perform? i know wheelman had them and described the take-off as "second gear start", and he went all-out on those set ups, from what i scavenged and understood from old threads.