Rode another 1 hour or so, just 23 hours to complete break-in? Running nice, I really like the Malossi BBK. Starts easy, sounds awesome (even with stock muffler). I can tell going to be loud with the cool chrome Tecnigas Next-R pipe I have to install.
Just cruising around neighborhood, 30mph top speed. Has stock muffler, pod air filter, carb jetted 108 main, 45 slow jets, CVT 100% oem, except for Malossi torsion controller (yellow plastic bit). Have oil pump hooked up, set to pump a little more oil, and adding approx 1 oz extra oil per fill-up of approx 1 gallon gas.
Backup to install: Took the good advice and didn't flexhone the cylinder. Cleaned with diesel oil and compressed air, then wiped down with clean cloth. Put some 2 cycle oil in squirt bottle and gave the cranks bearings, and big rod bearing a shot of oil. Put some grease on the end of the oil pump gear. Installed the piston, the side with the hole goes up, let's in air/ fuel mixture from intake manifold, or the arrow on top of piston goes down toward exhaust.
Still hard to get piston circlips in, there is a trick to doing this, but I haven't figured it out yet. Sometimes they go in easy, sometimes difficult, easy to take out. I have very nice needle nose pliers to do the job, couldn't do it without really good needle nose pliers.
Read somewhere nice to install cylinder studs, with the BBK the cylinder bolts are a little too long and will sometimes have trouble blowing head gaskets. I measured, and sure enough the Malossi BBK cylinder/ head is just a touch shorter than the oem Kymco cylinder/ head. I thought about studs, decided might be in the way removing/ installing the piston, so I bought some nice 7mm washers to space out the bolts just a little. I think they needed it, I used one washer per bolt.
Another issue is the sparkplug connector, it doesn't fully engage the sparkplug now. I read somewhere the BBK kit head changes the location of the sparkplug and so the blower housing sparkplug hole isn't centered, that's what causes the trouble. I couldn't tell it wasn't centered, but already experienced this issue. I removed the rubber boot fitting around the connector the 1st and 2nd times, and planned to do something about it later. Upon close inspection, realized the BBK sparkplug is farther away from the blower housing and doesn't fully engage the plug. But, THE RUBBER BOOT FITTING HAS ANOTHER SETTING THAT PUTS THE CONNECTOR CLOSER TO THE PLUG. Not easy to move the connector farther into the boot, but once I got it relocated, worked like a charm. I had to put the hard plastic connector in the vise to hold it, being careful not to crack it, while I manipulated the rubber boot. So, before you start grinding on the blower housing, try moving the sparkplug connector a little farther into the rubber boot.
If you want to use the oil pump, be sure and bleed it. Easy to do, just put some oil in the tank with the oil line from the tank to the pump disconnected. Pretty soon oil will come out the oil line, so quickly connect it to the pump and you are good there. Then zip tie the oil pump full open and start the engine. Should be OK for awhile, just put a load of oil into the engine lubing the bearings, piston, cylinder. Plus, added some oil premix to the gas. Let it run awhile, then pull the oil line from the oil pump to the intake manifold and check for oil flow. If working properly, there will be a little pulse of oil coming out the oil line, so you know it's working. Put the oil line back, remove the zip tie holding the oil pump full open, and you are good.
Cheers
