KymcoForum.com

3 restrictions on this bike.

Variator boss, carb jet, and muffler.  Easiest thing to do is buy a new variator because they usually come with a new drive boss.  You will need an electric impact wrench or figure out a way to hold the variator while you unscrew the variator nut.  Upgrade the carb jet (search this forum for size).  The muffler can be left alone but to de-ristrict it you can cut off the extra emissions tubes and weld the hole shut.

New Carb.

Still was having heat problems (350ish) in hilly areas and i noticed that at wot the temperature was fine.  As I backed off the throttle it heated up quickly and also at 1/2-3/4 throttle it was running hotter than wot.  Started thinking about the needle.  Since the needle clip is not adjustable in the original carb (no room for shims either) I bought a 19mm $25 chinese carb on amazon.  Still ran hot with needle clip in #3.  Tested and moved it down, again down and ended in position #5.  Same hilly area and the temperature hasn't gone above 300 degrees.  Still want to get rid of the air restrictor but I am happy with the performance.

Main jet 92, Idle jet 38, needle clip in position 5 (closest to the point).

I am mixing 50:1 (2.6 ounces/gallon) now in addition to the oil pump.  The engine sounds different when I premix and I am sticking with it.

My two-year saga of my bbk seems to finally be over.   My first try was the Naraku which seized up and scratched/pitted the cylinder head.  Malossi was next which resulted in the piston and rings toasted (head still salvageable with only 1 small scratch in it.   After going through 2 bbk kits ($$$$$) I decided to put the original back in which led to soft siezes and me pushing the bike home several times.  Gave up on it last fall and started thinking (and watching youtube videos) about pressure testing.  Finally pressure tested it 2 weeks ago and found my problem was the reed cage gaskets were leaking (which I replaced during the 1st BBK) causing the extreme lean/heat conditions.

I got a new Malossi piston (why do they make their pistons a little shorter than the standard size? and wtf with their circlips?) and reassembled the head using hondabond (in addition to base gasket, no hondabond on o-ring gasket).  In addition I used hondabond on the reed cage.  Pressure tested and it held 5 lbs for 40 minutes so I was confident the problem was solved.  Next was an install of temperature/tachometer gauge to monitor the cylinder head temperature.  Used 245Luigi’s posts (ty) for jetting the original carb, added 2 capfuls of oil to gas tank and turned up the oil pump to maximum and I was ready to go

The engine was running a little hot  (350-375making me nervous) so I switched to heavier rollers (6.5 slider to 8.5 roller I had laying around).  Still a little too hot so I had to reinstall the black plastic air flow restriction (that came with the bike) in the air intake and that makes the bike a little slower with less rpms so it runs a little cooler (300-325 with one time today at 350 in a hilly area.   

Have a 92 main jet right now and when I upjetted to 95 it just ran hotter so I stayed at 92.  I hope I can find a solution to the heat so I can get rid of the air flow restriction.  Top speed without the air flow restriction was mid 40’s, 41 with it.  I think that speed is the bike’s maximum because of the gearing.

My advice to anyone doing the bbk, pressure test, Honda Bond, temperature gauge, tachometer.  Hope this helps someone the same way I have been helped by this forum.

This bike has 2 oil injection nipples.  One on the carb and one of the intake manifold.

I was planning on doing a big bore on my Like 50 but I was able to purchase a low mileage semi wrecked 200i.  Beside the engine, I believe they are exactly the same bike.  I want to do an engine swap (complete lower swing arm) to keep this bike in the lower registration class.  Both engines are completely intact.  So far I see the only see different:

• 2 shocks on 200i (I think I am OK with only the one on my 50)
  remove 2t oil reservoir
  swap gas tanks (fuel injection)

Any thoughts?

Thanks in advance.

When I opened up the variator cover it was just as I suspected.  A couple rodents got in through the vent hole and nested.  Cleaned it out, lubed it and all is fine now with the electric start.

25 mph    1500 spring, 6 gram sliders and smooth boss

30 mph  oem spring, 6 gram sliders and smooth boss

35 mph   oem spring, oem rollers, and smooth boss.

39 mph   oem spring, oem rollers, smooth boss, muffler restrictions removed (from http://www.kymcoforum.com/index.php?topic=11962.0), 88 jet, air restriction removed from air box.

Hesitates a little on acceleration which on my gy6 indicated it was running rich.