How to swap Malossi primary set into a zx50 & 13k run video on full MHR

[LoveMyKymco]

Heres a few pics to show the swap done easily, it is a drop in swap.
Malossi gear about to go onto the zx counter after pressing off old one.


This is what the case side looks like stock after trans final drive housing is removed.


Housing side with the C clip on the final drive out put shaft, Im sure thats not the technical term but back off it is what it is.


You take the case with the primary gear over to the press and press it out, you can use a torch for a little heat if you plan on replacing the oil seal.



Try not to let gears hit the floor ever, I have a bunch of soft stuff under it also including the bag.

Side by side kind of shot from on top.

Press Malossi back in with some grease after freezing for at least 30- 60 minutes, I do over night.


Press malossi big gear onto counter shaft after freezing the shaft for at least 30-60 minutes, I do over night when I can.


Put them back in the case to make sure they line up. For final installation I swapped location of the blue trans washer and the metal washer on the counter shaft, other wise it binds, but after swapping its always perfect. The blue will go towards the clam shell side and metal will go towards case side.

Dont forget to put the larger inner diameter washer under the final drive gear against the case so when you push the trans clam-shell closed it will be pushed against the gear and the bearing opposite of the C clip. the gear will ride against the C clip and the washer to gear combo.
Use this diagram from kymcopartsonline for reference if you get confused on location of anything.
http://kymcopartsonline.com/catalog/search_diagram_detail.php?s_fk_manufacturers_id=21&s_fk_model_year_id=1&s_fk_scooter_model_id=12&s_parts_diagram_id=275
I hope any of this helps in an easy swap and you dont get stuck like this guy did in front of my house. I think hes on the crack.

Id like to thank my neighbor for letting me use his press and his help with this.

[LoveMyKymco]

Final gear ratio is extremely low for most builds, I run a ported corsa with an extremely ported case, 2k rear spring very tight spring, polini variator, Sef ramp, Naruku high speed pulley with 7.2 g polini weights and a malossi delta clutch with 2k over stock launch springs. I dont really notice bad take off but you might without a lot of trans work.
the final ratio comes in at under 7 to 1, more like 6.9 : 1, not drag racing gearing.

[thebatman]

Great Post..........

I should have taken more pics and uploaded something to that effect myself...
Great job on the tutorial.....

[thebatman]

That lil dam blue washer is what caused my rear-end to fail....
I am pretty sure anyway, nothing else could have...lol

Again......great post

[LoveMyKymco]

I did some routing to the bearing oiling hole, Had some relining of the boost area after this one.

Not the best quality shot, but shows the intake tract ramp decent, its near straight down, no stepping. I also angled the intake port window downward some in hope of reducing turbulence.

You can see the area removed going towards the boost port area.
These are a few of them before final clean up, had to bring them out of the bat cave to see them in natural light. Also had a couple nostrils full of port so it felt good to breath the fresh air. These were all cleaned up and made straight before anyone comments lol.

[LoveMyKymco]

Exhaust port on the MHR, seems I dont have any pics of the transfers. Ill have to take the cylinder off and do them at a later time. I re inspect a cylinder after a few hours of running.

This is my Motorio exhaust I run on the MHR, formerly on the Polini Corsa, now the corsa has the leo vince for now.

Even with mallosi primary gears at 6.9:1 gearing this thing pulls hard all around still, malossi multi var, mallosi 7g rollers, naraku high speed light weight drive face, Mallosi white "reinforced" contra spring, Malossi spring saver, Polini evo2 clutch, Polini 2k "triple" springs (only 2 on the evo) with a stage 6 bell helps keep it nice and swift, not sure of the top speed but I got concerned I was double the posted speed limit at half throttle.

[LoveMyKymco]

A video of it running rich due to weather conditions and whoreyness. Couldnt floor it or it would run way to rich, so most throttle used was around 3/4. Yesterday all sunny and gorgeous no problem lol. Im getting a 25mm Mallosi carb and intake next week so Ill be retuning again anyways. Down with the CT!

[LoveMyKymco]

Not the zx engine its a kx65 about to be 82cc with an athena single ring race kit, but so you see how the tusk crank puller works

[Peters]

How did I miss this thread?

Nice build dude 

[LoveMyKymco]

Malossi intake, 25mm dellorto PHBL carb, malossi air filter

Malossi intake for dios

Malossi air filter for 25mm PHBL Dellorto

Malossi Reed block for dio

Intake

Intake

72cc scorpion drag race pipe

72cc scorp cone sections

72cc scorp cone union

72cc scorp barrel

50mm cast iron bore for fun on something

25mm phbl

Assorted parts

Malossi Wing bell with extra cooling fins

Malossi Wing bell with extra cooling fins

Assorted parts for minas and a 72cc PH short pipe for dios, engine is a 1e50qmf(90cc jog clone)


I have an arrow pipe, Motorio C16 for dio, pg long, PG v8, YMS V8, and an old PG Yoshimura pipe, Ill get pics eventually of them all together and comparisons. My neighbor has a "wind jammer" pipe that he paid close to 700 for that I can use also.

[LoveMyKymco]

Malossi CDI


Malossi Kevlar belt

Malossi Delta Clutch and Yellow torque/contra spring which I dont run

[Peters]

 

[LoveMyKymco]

New Burial pipe

and Nology hot wire

[LoveMyKymco]

I forgot about these super light weight valve stem caps, they add an extra 21.85 mph on the cool factor.

[LoveMyKymco]

Going to build another sc10as begining with a few fabrizi and malossi parts, still awaiting the gears, vario, drive face, clutch, bell, and overdrive sheave.
I feel the MHR 72cc is amazing and killer power band and want to race it vs a Fabrizi 82cc race cylinder. Ill put the MHR on a heavily modified lighter spree chassis and use the fabrizi on a semi heavier heavily modified 89 elite sa50 LX frame.