Hi all I thought I'd share my build of my 2010 Yamaha Zuma. This is it current set up Converted to L/C TPR 86cc TPR 44mm stroke crank with 85mm conrod MVT DD19 Inner rotor Vforce3 reed block 28mm PWK Keihin carb Bosch electric water pump Malossi overrange Dr.Pulley HIT clutch S6 433g clutch bell S6 forks Doppler rear shock S6 280mm rotor S6 brake calliper 13inch gyronetics wheels Naked bar conversion with S6 gauges All the case work was done by hand with simple everyday tools. First off you'll need to fill the back of the cases with JB weld where you plan to grind/file. Its very thin here so your going to put holes in the cases if you don't do this step first The idea here is to make a smooth flow path from the intake to the transfers/boost ports You can see the darker spots in the "trench" that's where I broke through the cases and into the JB weld
Now to fit the crank and cylinder. All this was done with simple hand tools. A dremel with a selection of cutters, files, flap wheels and sand paper. This kit calls for the cases to be opened up to 76.5mm to fit the crank. To mark the cases and to check fitment as you go you'll want to turn down an old crank bearing so it slip fits in and out, on and off the cases/crank. Before Cases marked and ready to cut Small case half cut and the crank now fits that side Now on the the big case half. You'll have to do this in three cuts This 3 inch flap wheel worked perfect to clean everything up Close enough for this guy Now to match up the transfers and cut cases bigger to fit the cylinder. These cases had been transfer matched previously to a S6 MKII race so there wasn't much material to remove for the TPR 86cc. Marked Cut and cleaned up It's fits
nice work, although im not sure about the jbweld...... thats some steady hand you have to do that machining with a dremel!
i would weld it. i was unsure as to if jb weld would last over time. but ive never tried it, only used it for a quick fix here and there
JB weld is what everyone uses over here. Never had a problem with it. Do you have a build thread here? I'd love to check it out. It dosent seem like many guys are building any off the high end stuff on this forum anymore. A few years ago there was some pretty crazy builds here.
ive done countless builds, but all at work, i work for a main dealer well did before bad health got the better of me. anyway no build threads from me.... i will do a build thread when i do my first supercub custom thing, but thats a while off yet.
