Super 9 Makeover

[scootertrog]

Here are the results of my winter project, I'm sure most of you are not used to seeing Super 9's re-painted. I have a handful of decals to apply next. Here are a few particulairs about my scoot:

2004 Kymco Super 9
Airsal T6 73cc
Tecnigas RS 70 pipe
Top Boy 100cc intake (tuned by me)
Arreche 19mm w/manual choke
Arreche "Porcupine" air filter
Malossi Variator
Malossi Torque Drive Pulley
Polini 2g clutch
Polini Speed Bell

What it used to look like:

Setting up a paint booth in my garage:

All parts primed and sealed:

Color applied and ready to buff:

And what it looks like now:

scootertrog

 

[Astrolopitec]

Very, very nice !

 

[rydah]

very nice, i think your bike would look even better if you got rid of that lic plate holder, thats killing the sport look of your tail section and get rid of those round reflectors and turn signals under your handlebars. that would really clean up the nice looks of your bike. maybe even some open bars would really make your bike look sweet, some polished ones to match your pipe.

 

[Powellyboi]

looks good mate, love the front panels look

 

[Mekai]

What kind of exhaust is it?

/Mekai

 

[scootertrog]

very nice, i think your bike would look even better if you got rid of that lic plate holder, thats killing the sport look of your tail section and get rid of those round reflectors and turn signals under your handlebars. that would really clean up the nice looks of your bike. maybe even some open bars would really make your bike look sweet, some polished ones to match your pipe.

Thanks Rydah.
Yea, Getting rid of the plate holder is high on my list, but I will need to leave some provision for a light and plate bracket for future licenseing.
The reflectors are DOT required. Although most cops don't care, there's always the one, and I'm afraid I'll find him.
I'm contemplating hooking up the lower signal indicators and losing the stalk-mounted ones, also illegal. I like the looks of the "downhill" bars, but find the OEM ones have a lot more comfortable riding position.

scootertrog

 

[scootertrog]

What kind of exhaust is it?

/Mekai

It's a Tecnigas RS 70.

scootertrog

 

[scatscoot]

Winter Paint Project

Oh ! most excellent man, metallic teal, no?
I really like the white as contrast.

Gregg

 

[scootertrog]

Hey Gregg,
Surprised you've just found this site. It's the best non-brand-specific one on the web. These guys are very helpful, and some serious tuners lurk here.
Yes, It's Auto Air's Sparklescent Real Teal. Lots of metallic, and the hue goes from blue to green depending on the light, but not a total color change like a chameleon color.

scootertrog

 

[scootertrog]

And now let's do something about those ugly OEM blinkers! Here is a picture of one:

Here is a picture of what I will be using next to the OEM version:

And here we have the the new set installed:

That's more like it!

More to come......

 

[scootertrog]

Now we have to do something about that nasty intake manifold. The OEM manifold for the Super 9 has an I.D. of 18mm. It is fairly thin walled, so you can't ream it out any. I found out that the manifold from a Top Boy 100cc was a direct bolt-on, but had an I.D. of 20mm, as well as thick walls. Here is a side-by-side view, with the 49cc version on the left side.

I marked in red the area to be removed to match the reed cage and ground it out (photo shows just a little red left for this picture)

The entire I.D. was opened to approximately 24mm with a home-made "flap bit":

And the carb-mating end was opened:

The torque has been improved very noticably across the entire powerband! And to my surprise, I am getting improved fuel mileage, up from about 50 mpg to nearly 60! A performance upgrade that was cheap and does not break.

 

[scootertrog]

And now for the mud flap/license plate bracket. This took quite a bit of thought, as the S9 tail light assy and mud flap interlock with each other. First, I modeled everything in Autodesk Inventor to get a workable idea and make a cardboard prototype:

The metal was laser cut out of 14 ga steel. I had to use screws to temporarily hold it in place and get everything lined up. The screws would be removed after welding.

Welded, screw holes filled and painted to match the scooter:

And mounted complete with LED light that faces the plate:

No more crappy plastic scoop-looking thing!

scootertrog

 

[rydah]

cool, now get rid of those america only front signals and use the real ones in the front panel and your bike will look way way better.

 

[ryaquinn]

Nice job. I might be getting a LC Super 9 in a week or two.

 

[scootertrog]

Ryaquinn, I went from a kitted Mz RX 50 (same as your CPI) to a S9. BIG difference in ride quality. The l/c models may never come back into the US, so if you get a chance to get one, go for it.

scootertrog

 

[ryaquinn]

Ryaquinn, I went from a kitted Mz RX 50 (same as your CPI) to a S9. BIG difference in ride quality. The l/c models may never come back into the US, so if you get a chance to get one, go for it.

scootertrog

Yea, I work at a Kymco dealer. So I always get harrased by my boss for not having one. They are alright, I just found one for cheap. I was going to get a Zuma, but I will just daily drive the S9.

Oh, and the CPI I got for my sister. That way she has something to ride.

 

[scootertrog]

and now to install a Malossi Torque Drive pulley, here is the Malossi next to the OEM unit:

and as you can see, the seal collar will not go all the way down - not good

here is the problem - a lip that needs to be machined down

machined lip

also removed a little off the top of the seal collar. Total removed from the Malossi lip - .09", removed .03 from the seal collar.

IMO, Malossi dropped the ball on this one - obviously this pulley was a one-size-fits-many (with some work). One should not have to pay top dollar only to have to do machine work to get it to really fit . The good news is that the scooter now holds rpm's much better under load and up hills.

scootertrog

 

[Mexicano]

Very nice and clean job you did on that license plate!...very nice!

So, in your opinion, the Malossi or Polini torque driver, worths the money???

I have been fooling around to buy one, but my problem is I don't know which one to pick, there is not one for Vento's!!!!...may I use a Yamaha?..33 or 34 m.m.??..this is the main problem I'm facing on this issue.

Regards,

 

[scootertrog]

Mexicano,
I've only been able to ride a few times since installing the aftermarket torque driver, but I'd definately say yes, it is worth it. In fact, I think if I was starting out fresh with a 49cc scoot, I'd install the variator/torque driver immediately after changing the pipe, and before installing a bore kit.
About the best way I can describe it is that you will have access to your most horsepower at any speed, so the scooter responds better to the throttle. Maybe others here can describe it better or more accurately.
There's got to be one available for your engine, maybe not Malossi or Polini. I bet NCY, Koso or one of the other Asian companies have what you need. I do believe you should probably use both the variator and torque driver from the same manufacturer. Make sure the driver has the straight grooves.

scootertrog

 

[Mexicano]

Thanks scootertrog!!

I know my Vento Triton R4i is a clone from CPI Hussar, Polini web page says I can use the same Torque Driver as Yamaha Aerox 100, P/N 244.541, this is a 34 m.m. torque driver also used on Yamaha Aerox 50 c.c.!!!!.....I will check mine and verify it is a 34 m.m. before ordering a 80.00 Euros part.

Regards,